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Home My WebLink About26 05 00-2 Arthaus Kohler Generator Product Data and shop drawings_CORRECTIONS NOTED PROCEEDVecino Construction, LLC (Contractor Review) Recommend Approval Recommend Approval as Noted Revise and Resubmit Reviewed for general conformance with the Contract Documents. Subcontractor or material supplier is responsible for: confirming and correlating all quantities and dimensions; selecting fabrication processes and techniques of construction; coordinating his work with that of all other trades; and performing his work in a safe and satisfactory manner. Project: Reviewed by: Date: Corey Olmstead 18260 Ithaca Arthaus 9/3/2020 AEL 9/9/2020 Submittal for Approval ITHACA ARTHAUS NY KPS QUOTE # J-20-1854 Kohler SAP # 26673162 Generator & Automatic Transfer Switch Package September 1, 2020 TO: Demco NY Electric FROM: Dave Lavender Sales Engineer 6701 Manlius Center Rd Kinsley Power Systems 60 Loudonville Road East Syracuse, NY 13057 Albany, NY 12204 Office: 518-292-6659 Fax: 518-458-1738 Cell: 518-369-0272 ATTN: John Orr E-mail: dlavender@kinsleypower.com NOTE: This submittal is contingent upon receipt of written approval to release for production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ill of Materials The Energy Solutions Company 60 Loudonville Road Albany, NY 12204 800.255.3503 www.kinsleypower.com V 1.03A.3 Quote Number Project Name Project Location Q-20-4580 Ithaca Arthaus NY From: David Lavender 60 Loudonville Road Albany, NY 12204 Phone: 518.292.6659 Fax: 518.458.1738 Email: DLavender@KinsleyPower.com Cell: 518.369.0272 Qty Bill of Material Summary 1 Kohler 50REOZK Generator Output- 52.0kW, 65 KVA, 120/208 Volt, 180 Amps,60 Hz , Three Phase Fuel Type - Diesel Tank - 24 Hours / 133 Gallons Enclosure - Sound Attenuated Warranty - 1 Year Standard Estimated Leadtime - 10 Weeks, ARO 1 Kohler KSS-ACTA-0100S Transfer Switch Type - Specific Breaker Rated, Open Transition, 208 Volts/60Hz, 100 Amps Poles - 3-Pole, 4-Wire, Solid Neutral Enclosure - NEMA 1 Enclosure Warranty - 1 Year Standard Estimated Leadtime - 8 Weeks, ARO 1 Distributor Start-Up Start-up Service with Connected Load Test Should be 150A per SI-05 Bill of Materials The Energy Solutions Company 60 Loudonville Road Albany, NY 12204 800.255.3503 www.kinsleypower.com V 1.03A.3 Generator Qty Description 50REOZK Generator System 1 50REOZK Generator Set Includes the following: Literature Languages English Approvals and Listings UL2200 Listing Engine 50REOZK, 12V, 60Hz, KDI3404TM Nameplate Rating Standby 130C Rise Voltage 60Hz, 120/208V, Wye, 3Ph, 4W Alternator 4P10X Cooling System Unit Mounted Radiator, 50C Skid and Mounting Skid/Tank Air Intake Heavy Duty Controller APM402 Enclosure Type Sound Enclosure Material Steel Enclosure Silencer Internal Silencer Fuel Tank Type Standard Fuel Runtime (Approx.) 24 Hours Subbase Fuel Tank Capacity 133 Gallons Starting Aids, Installed 1000W,110-120V Electrical Accy.,Installed Battery, 1/12V, Wet Electrical Accy.,Installed Battery Charger, 6A Electrical Accy.,Installed Run Relay Electrical Accy.,Installed Governor, Electronic Rating, LCB 1 80% Rated Amps, LCB 1 100 Trip Type, LCB 1 Thermal Magnetic Interrupt Rating LCB 1 18kA at 480V Fuel Lines, Installed Flexible Fuel Lines Miscellaneous Accy,Installed Air Cleaner Restriction Ind. Miscellaneous Accy,Installed Coolant in Genset Miscellaneous Accy,Installed Oil in Genset Warranty Standard Bill of Materials The Energy Solutions Company 60 Loudonville Road Albany, NY 12204 800.255.3503 www.kinsleypower.com V 1.03A.3 Automatic Transfer Switch Qty Description ATS 1200 Transfer Switch System 1 KSS-ACTA-0100S Includes the following: Literature Languages English Mechanism Specific Breaker Transition Standard Logic 1200 Voltage 208 V / 60 Hz Poles & Wires 3 Pole/4 Wire, Solid Neutral Enclosure Nema 1 Amps 100 Amps Connection Standard Warranty 1-YR STANDARD 6SHF6KHHWV 6WDQGDUG)HDWXUHV ವ.RKOHU&RSURYLGHVRQHVRXUFHUHVSRQVLELOLW\IRUWKHJHQHUDWLQJV\VWHPDQGDFFHVVRULHV ವ7KHJHQHUDWRUVHWDQGLWVFRPSRQHQWVDUHSURWRW\SHWHVWHGIDFWRU\EXLOWDQGSURGXFWLRQWHVWHGವ7KH+]JHQHUDWRUVHWRIIHUVD8/OLVWLQJವ7KHJHQHUDWRUVHWDFFHSWVUDWHGORDGLQRQHVWHSವ7KH+]JHQHUDWRUVHWPHHWV1)3$/HYHOZKHQHTXLSSHG ZLWKWKHQHFHVVDU\DFFHVVRULHVDQGLQVWDOOHGSHU1)3$VWDQGDUGVವ7KHJHQHUDWRUVHWHQJLQHLVFHUWLILHGWRPHHWWKH(QYLURQPHQWDO3URWHFWLRQ$JHQF\(3$HPHUJHQF\VWDWLRQDU\HPLVVLRQVUHTXLUHPHQWVವ7LHU(3$&HUWLILHGIRU6WDWLRQDU\(PHUJHQF\$SSOLFDWLRQV1RWIRU VDOHLQ&DOLIRUQLDವ$RQH\HDUOLPLWHGZDUUDQW\FRYHUVDOOJHQHUDWRUVHWV\VWHPVDQGFRPSRQHQWV7ZRDQGILYH\HDUH[WHQGHGOLPLWHGZDUUDQWLHVDUHDOVRDYDLODEOHವ$LU&OHDQHU+HDY\'XW\ ವ$OWHUQDWRU3URWHFWLRQವ%DWWHU\5DFNDQG&DEOHVವ2SHQ&UDQNFDVH9HQWLODWLRQ $OWHUQDWRU)HDWXUHV ವ2LO'UDLQDQG&RRODQW'UDLQZLWK+RVH%DUEವ2LO'UDLQ([WHQVLRQZLWKQDUURZVNLGDQGHQFORVXUHPRGHOVRQO\ ವ2SHUDWLRQDQG,QVWDOODWLRQ/LWHUDWXUHವ5DGLDWRU'UDLQ([WHQVLRQZLWKHQFORVXUHPRGHOVRQO\ವ6WDLQOHVV6WHHO)DVWHQHUVRQ(QFORVXUHZLWKHQFORVXUHPRGHOVRQO\ವ7KHXQLTXH)DVW5HVSRQVH;H[FLWDWLRQV\VWHPGHOLYHUVH[FHOOHQWYROWDJHUHVSRQVHDQGVKRUWFLUFXLWFDSDELOLW\XVLQJDUDUHHDUWK SHUPDQHQWPDJQHW30H[FLWHGDOWHUQDWRU 2WKHU)HDWXUHV ವ.RKOHUGHVLJQHGFRQWUROOHUVIRUJXDUDQWHHGV\VWHPLQWHJUDWLRQDQGUHPRWHFRPPXQLFDWLRQ6HH&RQWUROOHUVRQSDJHವ7KHORZFRRODQWOHYHOVKXWGRZQSUHYHQWVRYHUKHDWLQJVWDQGDUGRQUDGLDWRUPRGHOVRQO\ ವ,QWHJUDOYLEUDWLRQLVRODWLRQHOLPLQDWHVWKHQHHGIRUXQGHUXQLWYLEUDWLRQVSULQJLVRODWRUV *HQHUDWRU6HW5DWLQJV 6WDQGE\&5DWLQJV $OWHUQDWRU 9ROWDJH 3K +] 3HDNN9$ N:N9$ $PSV 3; 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The APM402 controller meets NFPA 110, Level 1 whenequipped with the necessary accessories and installed per NFPA standards. The APM402 controller uses a patented hybrid voltage regulatorand unique software logic to manage alternator thermal overloadprotection features normally requiring additional hardware.Additional features include: D A digital display and pushbutton/rotary selector dial provide easy local access to data. D Measurements selectable in metric or English units. D The controller can communicate directly with a personalcomputer via a network or serial configuration usingSiteTechtor Monitor III software. D The controller supports Modbusr protocol. Use with serial bus or Ethernet networks. (Ethernet requires an externalModbusr/Ethernet converter module.) D Scrolling display shows critical data at a glance. D Digital display of power metering (kW and kVA). D Integrated hybrid voltage regulator providing r0.5% regulation. D Built-in alternator thermal overload protection. Modbusris a registered trademark of Schneider Electric. Industrial Generator Set Accessories APM402 G6-161 4/18b Page 1 G6-161 4/18b Page 2 FAULT OFF/RESET AUTO RUN ALARM SILENCE/LAMP TEST Volts L1ŞL2: 480.0 VEmergency Stop Switch Digital Display Master Control Buttons Off-Reset/Auto/Run with Lights Pushbutton/Rotary Selector Dial Alarm Silence/Lamp TestButtonwithLight Annunciator Fault Light Red-Shutdown, Yellow-Warning USB Communication Connection Alarm Horn (located inside the controller) User Interface Controls and Components D Emergency stop switch D Backlit LCD digital display with two lines of 12 characters(see User Interface Displays for menus) D Alarm horn indicates generator set shutdown and warning faults D Environmentally sealed membrane keypad with three master controlbuttons with lights d Off/Reset (red) d Auto (green) d Run (yellow) D Pushbutton/rotary selector dial for menu navigation d Rotate dial to access main menus d Push dial and rotate to access sub menus d Press dial for 3 seconds to return to top of main menu D Annunciator fault light d System shutdown (red) d System warning (yellow) D Alarm silence/lamp test button d Alarm silence d Lamp test D USB and RS-485 connections d Allows software upgrades d Provides access for diagnostics d PC communication using SiteTecht or Monitor III software D Dedicated user inputs d Remote emergency stop switch d Remote 2-wire start for transfer switch d Auxiliary shutdown D Integrated hybrid voltage regulator D Auto-resettable circuit protection mounted on circuit board. D One relay output standard. Optional five relay output available. D One analog and three digital inputs standard. Optional two inputsavailable.NFPA 110 Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine/generator functions/faults shown below. D Engine functions: d Overcrank d Low coolant temperature warning d High coolant temperature warning d High coolant temperature shutdown d Low oil pressure shutdown d Low oil pressure warning d High engine speed d Lowfuel(levelorpressure)* d Low coolant level d EPS supplying load d High battery voltage d Low battery voltage D General functions: d Master switch not in auto d Battery charger fault * d Lamp test d Contacts for local and remote common alarm d Audible alarm silence button d Remote emergency stop * * Functionrequiresoptionalinputsensorsorkitsandisenginedependent,see Controller Displays as Provided by the Engine ECM. User Interface Displays The listing below has D denoting main menus and ddenoting sub-menus. D Overview d Software version d Active shutdowns and warnings (if any are present) d Engine run time, total hours d Average voltage line-to-line d Frequency d Average current d Coolant temperature d Fuel level or pressure * d Oil pressure d Battery voltage D Engine Metering d Engine speed d Oil pressure d Coolant temperature d Battery voltage D Generator Metering d Total power, VA d Total power, W d Rated power, % d Voltage, L-L and L-N for all phases d Current, L1, L2, L3 d Frequency D GenSet Information d Generator set model number d Generator set serial number d Controller serial number D GenSet Run Time d Engine run time, total hours d Engine loaded, hours d Number of engine starts d Total energy, kWh D GenSet System d System voltage d System frequency, 50 or 60 Hz d System phase, single or three (wye or delta) d Power rating, kW d Amp rating d Power type, standby or prime d Measurement units, metric or English (user selectable) d Alarm silence, always or auto only (NFPA 110) d Manual speed adjust * D GenSet Calibration d Voltage, L-L and L-N for all phases d Current, L1, L2, L3 d Reset calibration D Voltage Regulation d Adjust voltage,r10% D Digital Inputs d Input settings and status D Digital Outputs d Output settings and status D Analog Inputs d Input settings and status D Event Log d Event history (stores up to 1000 system events) D Selector Switch (requires initial activation by SiteTecht) G6-161 4/18b Page 3 Controller Features D AC Output Voltage Regulator Adjustment. The voltage adjustment provides a maximum of r10% of the system voltage. D Alarm Silence.The controller can be set up to silence the alarm horn only when in the AUTO mode for NFPA-110 application orAlways for user convenience. D Alternator Protection. The controller provides generator setoverload and short circuit protection matched to each alternator forthe particular voltage/phase configuration. D Automatic Restart. The controller automatic restart feature initiates the start routine and recrank after a failed start attempt. D Common Failure Relay.This relay is integrated on the controller circuit board. Contacts are rated 2 amps at 32 VDC or 0.5 amp at120 VAC. D Communication.Controller communication is available. D Cyclic Cranking.The controller has programmable cyclic cranking. D ECM Diagnostics.The controller displays engine ECM fault codedescriptions to help in engine troubleshooting. D Engine Start Aid. The starting aid feature provides control for anoptional engine starting aid. D 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. D Historical Data Logging. Total number of generator set successfulstarts is recorded and displayed. D Integrated Hybrid Voltage Regulator. The voltage regulatorprovidesr0.5% no-load to full-load regulation with three-phasesensing. D Lamp Test. Press the alarm silence/lamp test button to verify functionality of the indicator lights. D LCD Display.Adjustable contrast for improving visibility. D Measurement Units.The controller provides selection of English or metric displays. D Power Metering. Controller digital display provides kW and kVA. D Programming Access (USB). Provides software upgrades anddiagnostics. D Remote Reset. The remote reset function resets faults and allowsrestarting of the generator set without going to the master control switch off/reset position. D Remote Monitoring Panel.The controller is compatible with the Kohlerr Remote Serial Annunciator. D Run Time Hourmeter. The generator set run time is displayed. D Time Delay Engine Cooldown (TDEC). The TDEC provides a timedelay before the generator set shuts down. D Time Delay Engine Start (TDES). The TDES provides a time delaybefore the generator set starts. D Voltage Selection Menu.This menu provides the capability ofquickly switching controller voltage calibrations. Requires initial activation using SiteTecht software.NOTE:Generator set outputleads require voltage reconnection. Controller Functions The following chart shows which functions cause a warning or shutdown. All functions are available as relay outputs. Warning causes the fault 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. WarningFunction ShutdownFunction Engine Functions Critically high fuel level *d ECM communication loss D ECM diagnostics D D Engine over speed D[ Engine start aid active Engine under speed D Fuel tank leak *d d High battery voltage D High coolant temperature D D[ High fuel level *d Low battery voltage D Low coolant level D Low coolant temperature D Low cranking voltage D Low engine oil level *d d Low fuel level (diesel models) *d d Low fuel pressure (gas models) *d Low oil pressure D D[ No coolant temperature signal D No oil pressure signal D Overcrank D[ Speed sensor fault D General Functions Alarm horn silenced Analog inputs d d Battery charger fault *D Chicago code active * Common fault (includes [)D Common warning D Digital inputs d d Emergency stop D[ Engine cooldown (delay) active Engine start delay active Engine started Engine stopped EPS supplying load Generator running Input/output communication loss D Internal failure D Master switch not in auto D NFPA 110 alarm active Remote start System ready Generator Functions AC sensing loss D D Alternator protection D Ground fault input *D kW overload D Locked rotor D Overfrequency D Overvoltage (each phase)D Underfrequency D Undervoltage (each phase)D D Standard function d Available user function * Functionrequiresoptionalinputsensorsorkitsandisenginedependent; see Controller Displays as Provided by the Engine ECM. [Items included with common fault shutdown ¤2018 by Kohler Co., All rights reserved. DISTRIBUTED BY: G6-161 4/18b Page 4 Controller Displaysas Provided by the Engine ECM Engine Manufacturer and Model Kohler Diesel (KDI M, TM*) Kohler Diesel (KDI TCR) Kohler Gas(KG2204, KG2204T) GM/PSI andKohler Gas(KG6208,KG6208T)DD/MTU Doosan JohnDeere Volvo Intake air pressure S/D D Intake air Temperature D D S/D D D D Coolant level D D D D D D Coolant temperature D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D Crankcase pressure D ECM battery voltage S S/D S S S Engine model number S S S S S S S Engine serial number S S S S S S S Engine speed C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D Fuel pressure D C/S/D C/S C/S/D C/S[C/S/D Fuel rate S S S S S Fuel temperature D S S/D S Oil level S[S/D[S[S[S[ Oil pressure C/S/D D C/S/D C/S/D C/S/D C/S/D C/S/D Oil temperature S D SD C = Value displayed on controller, S = Value displayed in Site Tech, D = ECU diagnostic is supported * Electronic governor and ECM are optional on KDI M and TM engines. [Controller uses local analog input to obtain this information. NOTE:REOZMD/ROZMC (Mitsubishi engines) have an ECM but do not send signals to the generator set controller. NOTE:See the generator set specification sheet for engine model identification. Controller Specifications D Power source with circuit protection: 12- or 24-volt DC D Power drain: 200 milliamps at 12 VDC or 100 milliamps at 24 VDC D Humidity range: 5% to 95% noncondensing D Operating temperature range: -40qCto+70qC(-40qF to +158qF) D Storage temperature range: -40qCto+85qC(-40qF to +185qF) D Standards: d CE Directive d NFPA 99 d NFPA 110, Level 1 d CSA 282-09 d UL 508 d ASTM B117 (salt spray test) D Panel dimensions—W x H, 229 x 160 mm (9.0 x 6.3 in.) Communication and PC Software Available Options Refer to G6-76 Monitor III Software and the communication literature foradditional communication and PC software information includingModbusrcommunication. -Monitor III Software for Monitoring and Control(Windowsr-based user interface) -Converter, Modbusr/Ethernet.Supports a power system usingcontrollers accessed via the Ethernet. Converter is supplied with anIP address by the site administrator. Refer to G6-79 for converter details. -Converter, RS-232/RS-485.Supports a power system usingcontrollers accessed via a serial (RS-232) connection. APM402 Available Options -Float/Equalize Battery Charger available with 6 or 10 amp output for 12 or 24V DC voltage output. The 10 amp model providesNFPA 110 charging and alarming capability. -Manual Speed Adjust available for applications using closedtransition ATS. Adjustment range for 60 Hz: 1751-1849 rpm(58.2-61.8 Hz) and for 50 Hz: 1451-1549 rpm (48.2-51.8 Hz). -Prime Power Switch prevents battery drain during generator setnon-operation periods and when the generator set battery cannot bemaintained by an AC battery charger. -Remote Emergency Stop Switch available as a wall mountedpanel to remotely shut down the generator set. -Remote Monitoring Panel.The Kohlerr Remote SerialAnnunciator (RSA) enables the operator to monitor the status of thegenerator set from a remote location, which may be required forNFPA 99 and NFPA 110 installations, and up to four Automatic transfer switches. -Run Relay provides a relay indicating that the generator set isrunning. -Shunt Trip Wiring provides relay outputs to trip a shunt trip circuitbreaker and to signal the common fault shutdowns. Contacts ratedat 10 amps at 28 VDC or 120 VAC. -Two Input/Five Output Module provides a generator set mountedpanel with two inputs and five relay outputs. Modbusris a registered trademark of Schneider Electric. Windowsris a registered trademark of Microsoft Corporation. Availability is subject to change without notice. Kohler Co. reserves the righttochangethedesignorspecificationswithoutnoticeandwithoutany obligation or liability whatsoever. Contact your local Kohlerr generatorset distributor for availability. KOHLER CO., Kohler, Wisconsin 53044 USAPhone 920-457-4441, Fax 920-459-1646For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444KOHLERPower.com Kohler Diesel (KDI M,TM*) - - KINSLEY POWER SYSTEMS 14 CONNECTICUT SOUTH DRIVE EAST GRANBY, CT 06026 860-844-6100 www.KinsleyPower.com Industrial Generator Set Accessories Standard Features D The line circuit breaker interrupts the generator set output during a short circuit and protects the wiring when an overload occurs. Use the circuit breaker to manually disconnect the generator set from the load during generator set service. D Circuit breaker kits are mounted to the generator set and are provided with load-side lugs and neutral bus bar. D Kohler Co. offers a wide selection of molded-case line circuit breaker kits including single, dual, and multiple configurations for each generator set. D Four types of line circuit breakers are available: (see page 2 for definitions and pages 3 and 4 for application details) d Magnetic trip d Thermal magnetic trip d Electronic trip d Electronic with ground fault (LSIG) trip D In addition, line circuit breakers are offered with 80% and 100% ratings. D Single line circuit breaker kits allow circuit protection of the entire electrical system load. D Dual line circuit breaker kits allow circuit protection of selected priority loads from the remaining electrical system load. D Multiple line circuit breaker kits with field connection barrier allow circuit protection for special applications (350-2500 kW models and selected 80-300 kW models). D Up to four line circuit breakers can be used on 350-2500 kW models. D Line circuit breakers comply with the following codes and standards unless otherwise stated. d UL 489 Molded Case Circuit Breakers d UL 1077 Supplementary Protectors d UL 2200 Stationary Engine Generator Assemblies Line Circuit Breakers 15-3250 kW Multiple Circuit Breaker Kit with Neutral Bus Bar180-300 kW Model Shown Single Circuit Breaker Kit with Neutral Bus Bar15-300 kW Model Shown Multiple Circuit Breaker Kits with Neutral Bus Bar350-2250 kW Model Shown(also applies to some 300 kW models) Circuit Breaker Kits with Neutral Bus Bar 800-2500 kW KD Model Shown G6-88 6/19p Page 1 Single Circuit Breaker Kit with Neutral Bus Bar15-300 kW Model Shown Thermal magnetictrip G6-88 6/19p Page 2 Line Circuit Breaker Types Magnetic Trip Themagnetictripfeaturesanelectromagnetinserieswiththeloadcontactsandamoveablearmaturetoactivatethetripmechanism.When a sudden and excessive current such as a short circuitoccurs, the electromagnet attracts the armature resulting in aninstantaneous trip. Thermal Magnetic Trip Thermal magnetic trip contains a thermal portion with a bimetallicstrip that reacts to the heat produced from the load current.Excessive current causes it to bend sufficiently to trip themechanism. The trip delay is dependent on the duration andexcess of the overload current. Elements are factory- calibrated.A combination of both thermal and magnetic features allows adelayed trip on an overload and an instantaneous trip on a short circuit condition. Electronic Trip These line circuit breakers use electronic controls and miniaturecurrent transformers to monitor electrical currents and trip whenpreset limits are exceeded. LIbreakersareacombinationofadjustabletripfunctionsincludinglong-time ampere rating, long-time delay, and instantaneouspickup. LSI breakers have all of the LI breaker features plusshort-timepickup,short-timedelay,anddefeatableinstantaneouspickup. LSIG breakers have all of the LSI breaker features plusground-fault pickup and delay. Electronic with Ground Fault Trip The ground fault trip feature is referred to as LSIG in thisdocument. Models with LSIG compare current flow in phase andneutral lines, and trip when current unbalance exists. Ground fault trip units are an integral part of the circuit breakerand are not available as field-installable kits. The ground faultpickup switch sets the current level at which the circuit breakerwill trip after the ground fault delay. Ground fault pickup valuesare based on circuit breaker sensor plug only and not on therating plug multiplier. Changing the rating plug multiplier hasno effect on the ground fault pickup values. 80% Rated Circuit Breaker Most molded-case circuit breakers are 80% rated devices. An 80% rated circuit breaker can only be applied at 80% of itsrating for continuous loads as defined by NFPA 70. Circuitconductors used with 80% rated circuit breakers are requiredto be rated for 100% of the circuit breaker’s rating. The 80% rated circuit breakers are typically at a lower costthan the 100% rated circuit breaker but load growth is limited. 100% Rated Circuit Breaker Applications where all UL and NEC restrictions are met can use100% rated circuit breakers where 100% rated circuits can carry100% of the circuit breaker and conductor current rating. The 100% rated circuit breakers are typically at a higher costthan the 80% rated circuit breaker but have load growthpossibilities. When applying 100% rated circuit breakers, comply with thevarious restrictions including UL Standard 489 and NECSection 210. If any of the 100% rated circuit breaker restrictionsare not met, the circuit breaker becomes an 80% rated circuitbreaker. Line Circuit Breaker Options -Alarm Switch The alarm switch indicates that the circuit breaker is in a trippedposition caused by an overload, short circuit, ground fault, theoperation of the shunt trip, an undervoltage trip, or the push-to- trip pushbutton. The alarm resets when the circuit breaker is reset. -Auxiliary Contacts These switches send a signal indicating whether the main circuit breaker contacts are in the open or closed position. -Breaker Separators (350-2500 kW) Provides adequate clearance between breaker circuits. -Bus Bars Bus bar kits offer a convenient way to connect load leads to thegenerator set when a circuit breaker is not present.15-300 kW.Bus bar kits are available on alternators with leadsfor connection to the generator set when circuit breakers are not ordered. 350-2500 kW.A bus bar kit is provided when no circuit breaker is ordered. Bus bars are also available in combination withcircuit breakers or other bus bars on the opposite side of thejunction box. On medium voltage (3.3 kV and above) units, abus bar kit is standard (not applicable to KD models). -Field Connection Barrier Provides installer wiring isolation from factory connections. -Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. -Lockout Device (padlock attachment) This field-installable handle padlock attachment is available formanually operated circuit breakers. The attachment canaccommodate three padlocks and will lock the circuit breaker in the OFF position only. -Lugs Various lug sizes are available to accommodate multiple cable sizes for connection to the neutral or bus bar. -Overcurrent Trip Switch The overcurrent trip switch indicates that the circuit breaker hastripped due to overload, ground fault, or short circuit and returnsto the deenergized state when the circuit breaker is reset. -Shunt Trip, 12 VDC or 24 VDC A shunt trip option provides a solenoid within the circuit breakercase 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 overmanual or motor operator closing. -Shunt Trip Wiring Connects the shunt trip to the generator set controller. (standard on KD models with the APM802 controller) -Undervoltage Trip, 12 VDC or 24 VDC The undervoltage trips the circuit breaker when the controlvoltage drops below the preset threshold of 35%-70% of the rated voltage. ThermalMagnetic Trip 80%Rated Circuit Breaker G6-88 6/19p Page 3 15-300 kW Line Circuit Breaker Specifications 80% Rating Circuit Breaker Alt. Model AmpereRange Trip Type C. B.FrameSize 4D/4E 15-150 Thermal magnetic HD60-150 Electronic LI Electronic LSI Electronic LSIG 60-150 Electronic LI HGElectronic LSI Electronic LSIG 4P/4PX/ 4Q/4QX 30-100 Magnetic, UL 1077 E(480 Vmax.) Magnetic, UL 1077 with 12V shunt trip Magnetic, UL 1077 with 24V shunt trip 15-150 Thermal magnetic HD60-150 Electronic LI Electronic LSI Electronic LSIG 60-150 Electronic LI HGElectronic LSI Electronic LSIG 30 Magnetic 9-325 HJ50Magnetic 84-546 100 Magnetic 180-1040 150 Magnetic 348-1690 175-250 Thermal magnetic JD250 Electronic LI Electronic LSI Electronic LSIG 250 Electronic LI JGElectronic LSI Electronic LSIG 250 Magnetic only 684-2500 JJ 300-400 Thermal magnetic LA 400 Magnetic 500-1000 LA Magnetic 750-1600 Magnetic 1000-2000 Magnetic 1125-2250 Magnetic 1250-2500 Magnetic1500-3000 Magnetic 1750-3500 Magnetic 2000-4000 400 Electronic LI LGElectronic LSI Electronic LSIG 4RX4S/4SX4TX4V 30-100 Magnetic, UL 1077 E(480 Vmax.) Magnetic, UL 1077 with 12V shunt trip Magnetic, UL 1077 with 24V shunt trip Alt. Model AmpereRange Trip Type C. B.FrameSize 4RX4S/4SX4TX/4V 4UA 4M6226 15-150 Thermal magnetic HD60-150 Electronic LI Electronic LSI Electronic LSIG 60-150 Electronic LI HGElectronic LSI Electronic LSIG 30 Magnetic 9-325 HJ50Magnetic 84-546 100 Magnetic 180-1040 150 Magnetic 348-1690 175-250 Thermal magnetic JD250 Electronic LI Electronic LSI Electronic LSIG 250 Electronic LI JGElectronic LSI Electronic LSIG 250 Magnetic only 684-2500 JJ 300-400 Thermal magnetic LA 400 Magnetic 500-1000 LA Magnetic 750-1600 Magnetic 1000-2000 Magnetic 1125-2250 Magnetic 1250-2500 Magnetic1500-3000 Magnetic 1750-3500 Magnetic 2000-4000 400-600 Electronic LI LGElectronic LSI Electronic LSIG 800 Electronic LSI PGElectronic LSIG 700-800 Thermal magnetic MG 4UA4M6226 1000-1200 Thermal magnetic PGElectronic LSI Electronic LSIG 1200 Thermal Magnetic PJElectronic LSI Electronic LSIG 4P/4PX/ 4Q/4QX HD 15-150 Thermal magnetic G6-88 6/19p Page 4 15-300 kW Line Circuit Breaker Specifications 100% Rating Circuit Breaker Alt. Model Ampere Range Trip Type C. B.FrameSize 4D/4E 15-150 Thermal magnetic HD60-150 Electronic LI Electronic LSI Electronic LSIG 60-150 Electronic LI HGElectronic LSI Electronic LSIG 4P/4PX 4Q/4QX 15-150 Thermal magnetic HD60-150 Electronic LI Electronic LSI Electronic LSIG 60-150 Electronic LI HGElectronic LSI Electronic LSIG 175-250 Thermal magnetic JD 250 Electronic LI JDElectronic LSI Electronic LSIG 250 Electronic LI JGElectronic LSI Electronic LSIG 400 Electronic LI LGElectronic LSI Electronic LSIG 4RX4S/4SX4TX4V 4UA4M6226 15-150 Thermal magnetic HD60-150 Electronic LI Electronic LSI Electronic LSIG 60-150 Electronic LI HGElectronic LSI Electronic LSIG 175-250 Thermal magnetic JD250 Electronic LI Electronic LSI Electronic LSIG 250 Electronic LI JGElectronic LSI Electronic LSIG 400 Electronic LI LGElectronic LSI Electronic LSIG 600-800 Electronic LSI PGElectronic LSIG 4UA 4M6226 1000-1200 Electronic LSI PGElectronic LSIG 1200 Electronic LSI PJElectronic LSIG 100% Rating Electrically Operated Breakers For use as paralleling breakers with the APM603 controller. Generator-Mounted P-Frame, 24VDC Electrically Operated Alt. Model Amps Trip Unit Frame 4RX 4S/4SX4TX4V 250 400600800 3.0 LI PJ 5.0 LSI PJ 3.0 LI PL 5.0 LSI PL 4UA4M6226 250400 600 80010001200 3.0 LI PJ 5.0 LSI PJ 3.0 LI PL 5.0 LSI PL All circuit breakers listed in this table include line side bus and load side lugs, 24VDC motor operators, 2 type C auxiliary contacts, and 1 type CSDE overcurrent switch contact. No second breakers are allowed incombination with these breakers. Interrupting Ratings Circuit BreakerFrame Size 240 Volt,kA 480 Volt,kA 600 Volt,kA HD 25 18 14 HG 65 35 18 HJ 100 65 25 JD 25 18 14 JG 65 35 18 JJ 100 65 25 LA 42 30 22 LG 65 35 18MG PG PJ 100 65 25 PL 125 100 25 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 J 175 One 1/0 to 4/0 200-250 One 3/0 to 350 kcmil LA 300-400 One#1to600kcmilor Two#1to250kcmil LG 400-600 Two 2/0 to 500 kcmil AL/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 Mechanical Load Lugs Included with H, J, and LG LSIG Neutrals H 60-150 One #14 to 3/0 AL/CU J 250 One 3/0 to 350 kcmil AL/CU LG 400-600 Two 4/0 to 500 kcmil AL/CU HD 25 H 15-150 One #14 to 3/0 G6-88 6/19p Page 5 15-300 kW Line Circuit Breaker Applications Single Circuit Breaker Installations A generator set with a single circuit breaker installed typicallyfeeds a single transfer switch and then a distribution panel.This allows protection of the entire system. To Remaining Building Loads To Priority Load(s) Line C.B. Single line circuit breaker configuration where circuit breaker can trip causing all power to building loads including priority load tobe disrupted. ATS DistributionPanel DistributionPanel Multiple Circuit Breaker Installations A generator set with dual circuit breakers installed is used toseparate 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 orpriority loads. Multiple circuit breakers allow circuit protectionfor special applications. To RemainingBuilding Loads To Priority Load(s) FirstLine C.B. SecondLine C.B. Dual line circuit breaker configuration where first circuit breakercan trip allowing second circuit breaker to continue supplying power to priority load(s). ATS ATS DistributionPanel DistributionPanel Circuit Breaker Combinations AlternatorModel FirstC. B.Frame SecondC. B.Frame ThirdC. B.Frame Trip Type ALLexcept 4D/4E H —— AllJ—— LA —— LG —— 4D/4E H ——Standard or LSIG H H —No LSIG 4P/4PX4Q/4QX H HorJ — No LSIG J — LA — LG H, J or LG — 4RX4S/4SX 4TX 4V M ——All P ——All HorJ HorJ — No LSIG LA H, J, or LA — LG H, J, LA,or LG —M P HorJ HorJ HorJ 4UA4M6226 MorP ——All HorJ HorJ — All LA H, J, orLA — LG H, J, LA,or LG — MorP H, J, LA,or LG — P P — No LSIG HorJ HorJ HorJ LA HorJ HorJ LA H, J, orLA LG HorJ HorJ LA H, J, orLA LG H, J, LA, or LG MorP HorJ HorJ LA H, J, orLA LG H, J, or LG Single Circuit Breaker Installations 1.5700150200300400600800900200030004000500070008000900010000.5.6.7.8.912345678910152030405060708090100600015001000500.005 .006 .007 .008 .009 .01 .015 .02 .03 .04 .05 .06 .07 .08 .09 .1 .15 .2 .3 .4 .5 .6 .7 .8 .91 1.5 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 15 200 300 400 500 600 700 800 900 1000 1500 2000 3000 4000 6000 7000 8000 9000 5000 100001.5.6.7.8.91.52345678910152030405060708090100MULTIPLES OF RATED CURRENT TIME IN SECONDS.005 .006 .007 .008 .009 .01 .015 .02 .03 .04 .05 .06 .07 .08 .09.1 .15 .2 .3 .4 .5 .6 .7 .8 .9 1 1.5 2 3 4 5 6 7 8 9 10 15 20 30 40 50 60 70 80 90 100 150 200 300 400 500 600 700 800 9001000 1500 2000 3000 4000 5000 6000 7000 8000 9000 10000 TIME IN SECONDS1/2 CYCLE (60 Hz) 1/2 CYCLE (50 Hz)150200300400500600700800900100015002000300040005000600070008000900010000150 MULTIPLES OF RATED CURRENT 1 CYCLE (60 Hz) 1 CYCLE (50 Hz) MAXIMUM CLEARING TIME (AT 50 Hz)(AT 60 Hz) 70 80100 90 MAXIMUM SINGLE-POLE TRIP TIMESAT 25°C BASED ON NEMA AB-4 2003 90 A, 100 A 70 A, 80 A HD, HG, HJ, HL MOLDED CASE CIRCUIT BREAKERS CHARACTERISTIC TRIP CURVE NO. 50-3 CIRCUIT BREAKER INFORMATION Circuit Breaker Continuous Maximum Number Prefix Ampere Rating AC Voltage of Poles HD, HG, HJ, HL 70–100 600 2, 3 This curve is to be used for application and coordination purposes only. The EZ-AMP overlay feature at the bottom of the page should be used during coordination studies. All time/current characteristic curve data is based on 40°C ambient cold start. Terminations are made with conductors of appropriate length and ratings. Curve No. 0050TC0403June 2004Drawing No. 48095-050-03 TM © 2004 Schneider Electric All Rights Reserved 7\SLFDO2YHUDOO'LPHQVLRQV 6WDQGDUG)HDWXUHV ವ .RKOHU&RVHOHFWVEDWWHULHVWRPHHWWKHHQJLQHPDQXIDFWXUHU V VSHFLILFDWLRQVDQGWRFRPSO\ZLWK1)3$UHTXLUHPHQWVIRUHQJLQH FUDQNLQJF\FOHV ವ +HDY\GXW\VWDUWLQJEDWWHULHVDUHWKHPRVWFRVWHIIHFWLYHPHDQVRI HQJLQHFUDQNLQJDQGSURYLGHH[FHOOHQWUHOLDELOLW\LQJHQHUDWRUVHW DSSOLFDWLRQV ವ 7RXJKSRO\SURS\OHQHFDVHVSURWHFWDJDLQVWOLIHVKRUWHQLQJYLEUDWLRQ DQGLPSDFWGDPDJH ವ %DWWHULHVDUHUDWHGDFFRUGLQJWR6$(VWDQGDUG- ವ $OOEDWWHULHVDUHYROWV.LWVWKDWFRQWDLQWZRRUIRXUEDWWHULHVDUH DYDLODEHIRUYROWV\VWHPVDQGRUV\VWHPVZLWKUHGXQGDQW VWDUWHUV ವ :HWDQGGU\FKDUJHGEDWWHULHVKDYHOHDGFDOFLXPRUOHDG DQWLPRQ\SODWHVDQGXVHVXOIHULFDFLGHHOHFWURO\WH5HPRYDEOHFHOO FRYHUVDOORZFKHFNLQJRIHOHFWURO\WHVSHFLILFJUDYLW\ ವ $EVRUEDQWJODVVPDW$*0EDWWHULHVDUHVHDOHGDQGPDLQWHQDQFH IUHH ವ %DWWHULHVDUHIRUDSSOLFDWLRQVEHORZDQGDERYHr&r) &KDUJH 7\SH %DWWHU\ 3DUW 1XPEHU %DWWHU\ 4W\SHU 6L]H %&, *URXS 6L]H %DWWHU\6$('LPHQVLRQ PPLQ &ROG&UDQNLQJ $PSVDW|& |)0LQ 5HVHUYH&DSDFLW\ 0LQXWHVDW ||)0LQ %DWWHU\3RVW /D\RXWDQG6W\OH /:+ :HW ' %DWWHU\6SHFLILFDWLRQV ,QGXVWULDO*HQHUDWRU6HW$FFHVVRULHV 6\VWHP%DWWHULHV 12 Volt (24 Volt*), 6 Amp Float/Equalize Battery Charger Industrial Generator Set Accessories Standard Features D 12 VDC output. * Use two battery chargers for 24-voltelectrical systems D Automatic 3-stage float/equalize battery charger D Charges both lead-acid and gel-cell type batteries D Indicator lamps: red and green LEDs indicate bulkcharge, absorption, and float charge stages D Durable potted assembly for full waterproofing andshockproofing D Reverse-polarity protection D Short-circuit protection D UL 1236 listed D UL 2200 compliant D UL 991 compliant for vibration and shock D UL listed to Canadian safety standards D UL rated inline fuse D FCC Class B-compliant for EMI/RFI(Date code 8/26/04 or later) D One-year warranty D Easy installation: d Integral mounting flanges d Ring terminals for battery connection d Standard US style 3-prong AC plug G6-60 2/16f Specifications Input Voltage 90--135 VAC Input Frequency 50/60 Hz DC Output: Bulk Absorption Float 11.8--14.0 VDC @ 5.0--6.0 amps 14.0--14.5 VDC @ 1.5--5.0 amps 13.3--14.5 VDC @ 0.1--1.5 amps Steady Full-Load Output Current 6amps Current Limit 7amps Output Power Limit 70 +2/--5 watts Line Regulation Across Input Voltage Range 1% Isolation, Input to Output 2500 V Dimensions (L x W x D)164x87x53mm(6.4x3.5x2.1in) Weight 1.6kg(3.5lb.) Temperature Range, Operating and Storage -- 40q to 70qC(--40qto 158qF) Humidity 0 to 100% (condensing) ¤2003, 2004, 2011, 2014, 2016 by Kohler Co. All rights reserved. DISTRIBUTED BY: G6-60 2/16f Dimensions are in mm. Output lead length 1.2 m (4 ft.) ACinputleadlength1.8m(6ft.) 4X¡6.00 164.0 143.5 52.210.3 86.637.024.8Fuse Battery Connections Lead Length 1.2 m (4 ft.) Battery Connections 9.5 mm (3/8 in.) ring terminals AC Power Connections Lead Length 1.8 m (6 ft.) Connection Standard US style 3-prong AC plug Charging Curves 5.5 5 4.5 4 3.5 3 2.5 2 1.5 1 0.5 0.16 12 13 14 15 11Output Voltage to Battery, VDC DC Amps AbsorptionBulk Float KOHLER CO., Kohler, Wisconsin 53044 USAPhone 920-457-4441, Fax 920-459-1646For the nearest sales and service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455 Availability is subject to change without notice. Kohler Co. reserves therighttochangethedesignorspecificationswithoutnoticeandwithoutanyobligation or liability whatsoever. Contact your local Kohlerr generatorset distributor for availability. 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Controller G11-127 (MPAC 1200) 3/14 Page 1 Applicable Models Model Description KCS Standard-Transition Any Breaker ATS ] KCP Programmed-Transition Any Breaker ATS ] KCC Closed-Transition Any Breaker ATS w KSS Standard-Transition Specific Breaker ATS ] KSP Programmed-Transition Specific Breaker ATS ] ]Available with automatic or non-automatic controller w Available with automatic controller only Decision-Makerr MPAC 1200 Controller Standard Features D Microprocessor-based controller D Environmentally sealed user interface D LCD display, 4 lines x 20 characters, backlit D Dynamic function keypad with tactile feedback pushbuttonsallows complete programming and viewing capability at thedoor D LED indicators: Source available, transfer switch position,service required (fault), and not in auto D Broadrange voltage sensing (208--600 VAC) on all phases D Phase-to-phase sensing and monitoring with 0.5% accuracy on both sources D Frequency sensing with 0.5% accuracy on both sources D Anti-single phasing protection D Phase rotation sensing for three-phase systems D Real-time clock with automatic adjust for daylight saving time andleapyear D Run time clock and operation counter D Time-stamped event log D Fail-safe transfer for loaded test and exercise functions D DIP switches: password disable and maintenance D Isolated RS-485 ports for Modbus connections (9.6, 19.2, and 57.6 kbps) D Modbusr RTU protocol (Modbus register map available) D USB port. Connect a personal computer and use Kohlerr SiteTecht software to view events and adjust settings. * D Available in automatic and non-automatic versions; seesupervised transfer control switch on page 5 Programmable Features D Programming and monitoring methods: d Monitoring and password-protected programming at the door using the keypad and display d Program using a PC with Kohlerr SiteTecht software(available to Kohler-authorized distributors and dealers) D Over/undervoltage for all phases of the normal and emergency sources D Over/underfrequency for the emergency source D Adjustable time delays D Load/no load/auto-load test and load/no-load exercise functions D Programmable inputs and outputs D Load bank control for exercise or test D Time-based load control, nine individual time delays forselected loads D In-phase monitor (3-phase only) D Password protection, three security levels D See pages 2 and 3 for additional programmable features * SiteTech software is available to Kohler-authorized distributors and dealers. Modbus is a registered trademark of Schneider Electric. KSS G11-127 (MPAC 1200) 3/14 Page 2 Decision-Makerr MPAC 1200 Controller Features User Interface LED Indicators D Contactor position: source N and source E D Source available: source N and source E D Service required (fault indication) D Not in automatic mode LCD Display D System status D Line-to-line voltage D Line-to-neutral voltage D Active time delays D Source frequency D Preferred source selection D System settings D Common alarms D Load current, each phase (current sensing kit required) D Inputs and outputs D Faults D Time/date D Address D Event history D Maintenance records D Exerciser schedule D Exerciser mode D Time remaining on active exercise Dynamic Function Tactile Keypad Operations D Scroll up/down/forward/back D Increase/decrease/save settings D End time delay D Start/end test or exercise D Reset fault D Lamp test DIP Switches D Maintenance mode D Password disable Event History D View time and date-stamped events on the display or on apersonal computer equipped with Kohlerr SiteTechtsoftware. * D Download complete event history files using Kohler SiteTechsoftware and a PC connected to the USB port. * Main Logic Board Inputs and Outputs D Two (2) programmable inputs D Two (2) programmable outputs Communications D Optional Ethernet communications with RJ45 connector for 10/100 Ethernet connection D Isolated RS-485 ports for Modbus communications D Modbusr RTU and Modbusr TCP/IP protocols(Modbusr register map available) D USB Port. Use SiteTech software to upload or download files and adjust transfer switch settings * d Application software d Event history files d Language files d Parameter settings d Usage reports d Feature configuration Programmable Features D System voltage, 208--600 VAC [ D System frequency, 50/60 Hz [ D Single/three-phase operation [ D Standard/programmed/closed-transition operation [ D Preferred source selection allows the normal or emergency source to be used when both sources are available (alarm module required) D Phase rotation: ABC/BAC/none selection with errordetection D Overvoltage and undervoltage pickup and dropout settings, both sources D Overfrequency and underfrequency pickup and dropout settings, Emergency source D Voltage unbalance, enable/disable D In-phase monitor: enable/disable and phase angle D Transfer commit/no commit D Passwords, system and test D Time, date, automatic daylight saving time enable/disable D Time delays (see table) D Exerciser: calendar mode, loaded/unloaded up to 21 events D Test: loaded/unloaded/auto load (1--60 minutes) D Remote test: loaded/unloaded D Automatic override on generator failure (loaded test and exercise) D Peak shave delay enable/disable D Current monitoring (current sensing kit required) D Load control pre/post-transfer delays, 9 individual time delays for selected loads D Resettable historical data * SiteTech software is available to Kohler-authorized distributors and dealers. [System parameters are factory-set per order. Modbus is a registered trademark of Schneider Electric. G11-127 (MPAC 1200) 3/14 Page 3 Decision-Makerr MPAC 1200 Controller Features, Continued Programmable Inputs D Forced transfer to OFF (programmed-transition models only; requires load shed accessory) D Inhibit transfer D Low battery voltage (external battery supply module required) D Peak shave/area protection input D Remote common fault D Remote test D Remote end time delay D Remotely monitored inputs, four (4) available Programmable Outputs D Alarm silenced D Audible alarm D Chicago alarm control D Common alarm events D Contactor position D Exercise active D Failure to acquire standby source D Failure to transfer D Generator engine start, source E D I/O module faults D In-phase monitor synch D Load bank control D Load control active (pre/post transfer delay, up to 9 outputs) D Loss of phase fault, source N and E D Low battery fault (external battery supply module required) D Maintenance mode D Non-emergency transfer D Not in automatic mode D Over/undervoltage faults, source N and E D Peak shave/area protection active D Phase rotation error, source N and E D Preferred source supplying load D Software-controlled relay outputs (four maximum) D Source available, preferred and standby D Standby source supplying load D Test active D Transfer switch auxiliary contact fault D Transfer switch auxiliary contact open D Voltage unbalance, source N and E Voltage and Frequency Sensing Parameter Default AdjustmentRange Undervoltage dropout 90% of pickup 75%--98% Undervoltage pickup 90% of nominal 85%--100% Overvoltage dropout *115% of nominal*106%--135% Overvoltage pickup 95% of dropout 95%--100% Unbalance enable Disable Enable/Disable Unbalance dropout 20%5%--20% Unbalance pickup 10%3%--18% Voltage dropout time 0.5 sec.0.1--9.9 sec. Underfrequency dropout [99% of pickup 95%--99% Underfrequency pickup [90% of nominal 80%--95% Overfrequency dropout [101% of pickup 101%--115% Overfrequency pickup [110% of nominal 105%--120% Frequency dropout time [3 sec.0.1--15 sec. * 690 volts, maximum. Default = 110% for 600 volt applications. [Emergency source only Adjustable Time Delays Time Delay Default Adjustment Range Engine start 3 sec.0--6 sec.[ Engine cooldown 5min. 0--60 min. Fail to acquire standby source 1min. Transfer, preferred to standby 3 sec. Transfer, standby to preferred 15 min. Transfer, off to standby 1 sec.1sec.--60min.Transfer, off to preferred 1 sec. Fail to synchronize 60 sec.10 sec -- 15 min. Auto load test termination after transfer 1 sec.1 sec.--60 min. Load Control Time Delays: Pretransfer to preferred 0 sec. 0--60 min. Post-transfer to preferred 0 sec. Pretransfer to standby 0 sec. Post-transfer to standby 0 sec. Note:Time delays are adjustable in 1 second increments, except asnoted. [Enginestarttimedelaycanbeextendedto60 minuteswithanExternal Battery Supply Module Kit. DISTRIBUTED BY: Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone(65)6264-6422,Fax(65)6264-6455 KOHLER CO., Kohler, Wisconsin 53044 USAPhone 920-457-4441, Fax 920-459-1646For the nearest sales and service outlet in theUS and Canada, phone 1-800-544-2444 KOHLERPower.com Availability is subject to change without notice. Kohler Co. reserves theright to change the design or specifications without notice and withoutany obligation or liability whatsoever. Contact your local Kohlerr PowerSystems distributor for availability.¤2014 by Kohler Co. All rights reserved. G11-127 (MPAC 1200) 3/14 Page 6 Environmental Specifications Operating Temperature -- 20 qCto70qC(--4qF to 158qF) Storage Temperature -- 40 qCto85qC(--40qF to 185qF) Humidity 5% to 95% noncondensing Main Board I/O Specifications Output contact type Isolated form C (SPDT) Output contact rating 1 amp @ 30 VDC, 500 mA @120 VAC I/O terminals wire size #12--24 AWG KINSLEY POWER SYSTEMS 14 CONNECTICUT SOUTH DRIVE EAST GRANBY, CT 06026 860-844-6100 www.KinsleyPower.com $OWHUQDWRU'DWD 1TIB-102 4P10X 60 Hz 5/11n TIB-102 TECHNICAL INFORMATION BULLETIN Alternator Data Sheet Alternator Model: 4P10X Frequency: 60 Hz Speed: 1800 RPM Leads: 12 (6 Lead, 600 Volt) kW* (kVA) Class B Class F Class H Voltage Power 80qC 90qC95qC 105qC130qC 125qC 150qC L--N/L--L Phase Factor Connection Continuous Lloyds ABS Continuous Standby Continuous Standby 139/240 30.8 Wye 66.0 69.5 71.0 74.5 82.0 80.5 87.5 277/480 (82.5) (86.5) (88.5) (93.0) (102.5) (100.5) (109.0) 127/220 30.8 Wye 66.5 69.5 71.5 74.5 81.0 80.0 86.5 254/440 (83.0) (86.5) (89.0) (93.0) (101.0) (100.0) (108.0) 120/208 30.8 Wye 65.0 67.5 68.5 71.5 77.5 76.0 82.0 240/416 (81.0) (84.0) (85.5) (89.0) (96.5) (95.0) (102.5) 110/190 30.8 Wye 59.0 61.5 62.5 65.0 70.5 69.0 74.5 220/380 (73.5) (76.5) (78.0) (81.0) (88.0) (86.0) (93.0) 120/240 3 0.8 Delta 65.0 67.5 68.5 71.5 77.5 76.0 82.0 (81.0) (84.0) (85.5) (89.0) (96.5) (95.0) (102.5) 120/240 1 1.0 Dogleg 53.0 54.5 55.0 58.5 63.0 62.0 66.5 (53.0) (54.5) (55.0) (58.5) (63.0) (62.0) (66.5) 120/240 1 0.8 Dogleg 38.0 40.0 41.0 43.0 46.5 46.0 49.0 (47.5) (50.0) (51.0) (53.5) (58.0) (57.5) (61.0) 347/600 3 0.8 Wye 65.5 69.0 70.5 74.0 81.5 80.0 87.0 (81.5) (86.0) (88.0) (92.5) (101.5) (100.0) (108.5) * 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, 130qCRise Symbol PerUnit Ohms Symbol Value Typical Cold Resistances Typical Time Constants Phase Resistance 0.028 0.016 Armature Short Circuit Ta 0.009 sec. Rotor Resistance 12.75 7.169 Transient Short Circuit T’d 0.074 sec. Typical Reactances Transient Open Circuit T’do 0.809 sec. Synchronous Typical Field Current Direct Xd 3.137 1.763 Full Load IfFL 15.9 amps Quadrature Xq 1.517 0.853 No Load IfNL 4.1 amps Transient Typical Short Circuit Ratio 0.319 Unsaturated X’du 0.327 0.184 Harmonic Distortion Saturated X’d 0.288 0.162 RMS Total Harmonic Distortion 2.57% Subtransient Max. Single Harmonic 5th Direct X’’d 0.126 0.071 Deviation Factor (No Load, L--L) <5% Quadrature X’’q 0.118 0.067 Telephone Influence Factor <50 Negative Sequence X2 0.122 0.069 Insulation Class Zero Sequence X0 0.009 0.005 per NEMA MG1--1.66 H Phase Rotation ABC 120/208 3TIB-102 4P10X 60 Hz 5/11n 1 10 100 1000 Time (s) 410, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 0.01 0.1 1 10 100 1000 Time (s) Armature Current (A)* 3 phase symmetrical 10 100 1000 10000 Alternator damage curve Line to Line 1 ph Line to Neutral 1 ph * Instantaneous current (t=0) is asymmetric. Divide by 1.73 for symmetric. 4P10X, 60 Hz, Low Wye or Delta Connection SHORT CIRCUIT DECREMENT CURVE 6RXQG'DWD TIB-114 150REOZK 60 Hz 8/15j TIB-114 TECHNICAL INFORMATION BULLETIN TIB-114 TECHNICAL INFORMATION BULLETIN TIB-114 TECHNICAL INFORMATION BULLETIN Generator Set Sound Data Sheet Sound Pressure Data in dB(A) Generator Set Model Hz Load Raw Exhaust Open Unit, Isolated Exhaust Weather Enclosure Sound Enclosure 50REOZK 60 100% Load 103.1 81.6 79.7 64.6 No Load 95.4 80.9 79.0 62.7 Note: Sound pressure data is the logarithmic average of eight perimeter measurement points at a distance of 7 m (23 ft.), except Raw Exhaust data which is a single measurement point at 1 m (3.3 ft.) from the mouth of a straight pipe exhaust. 50REOZK 60 Hz Sound Pressure Levels, dB(A) Load Distance,m (ft) Enclosure MeasurementClock Position Octave Band Center Frequency (Hz)OverallLevel631252505001000200040008000 100%Load 7 (23) Sound 3:00 49.2 54.3 58.6 56.1 54.7 57.5 52.0 49.1 64.1 1:30 47.7 51.8 56.9 56.6 55.4 57.6 51.3 47.5 63.6 12:00--Engine 47.4 51.3 60.4 59.2 57.1 57.6 51.9 48.5 65.4 10:30 46.2 54.6 60.1 59.9 58.0 59.9 52.3 47.7 66.2 9:00 48.5 53.9 58.7 57.6 54.9 56.4 50.4 48.2 64.1 7:30 44.6 52.3 58.7 57.3 57.2 58.5 50.9 44.8 64.6 6:00--Alternator 41.7 54.0 57.0 56.9 53.5 56.8 48.9 41.4 63.1 4:30 42.4 52.9 59.1 57.5 56.2 60.4 52.2 46.9 65.2 8--pos. log avg. 46.7 53.3 58.8 57.8 56.1 58.3 51.4 47.3 64.6 The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever.¤2015 by Kohler Co.All rights reserved. ([KDXVW6\VWHP'DWD 1 50REOZK 3/20 TIB-119 TIB-119 TECHNICAL INFORMATION BULLETIN Enclosed Generator Set Exhaust System Data Sheet Model Enclosure Type Consumed Back Pressure (in H20) Consumed Back Pressure (in Hg) Back Pressure Limit(s) (in H20) Back Pressure Limit(s) (in Hg) Flex Exhaust Tube(s) Silencer Drawing All Weather & Sound Enclosures 20.1 1.5 24-36 1.7-2.6 GM94612 GM95578 ADV-8740 50REOZK All AQMD Weather & Sound Enclosures 23.2 1.7 32-54 2.3-4.0 GM102366 - Flex 483.002180.092.00.0 - Lombardini CAT GM95578 ADV-8740 1. Total system exhaust back pressure is applicable to generator sets equipped with Kohler standard enclosure packages. 2. For generator sets with multiple exhaust outlets, total system exhaust back pressure value represents each outlet. 3. The total system back pressure should not exceed the manufacturer’s recommended limit. 4. The total back pressure only includes exhaust components installed inside the Kohler enclosure. Customers must calculate any additional back pressure caused by piping, extensions, or components added after the silencer outlet. Refer to the installation manual for additional details. All Weather & yp Sound 20.1 1.5 24-36 1.7-2.6 GM94612 GM95578 ADV-8740 Enclosures (PLVVLRQV'DWD Model: KDI 3404 TM Bore, mm (in.) 96 (3.28) Nameplate BHP @ 1800 RPM: 86 Stroke, mm (in.) 116 (4.57) Type: 4-Cycle, 4 Cyl., Inline Displacement, L (cu. In.) 3.4 (207) Aspiration: Turbocharged Compression Ratio: 18.5:1 EPA Family: LKHXL3.36EST EPA Certificate: LKHXL3.36EST-005 PERFORMANCE DATA: Engine bkW @ 1800 RPM Fuel Consumption (Lph) @ 100% Load (Standby) Exhaust Gas Flow (m3/min) Exhaust Temperature (°C) EXHAUST EMISSION DATA: NMHC CO2 NOx (Oxides of Nitrogen as NO2) CO (Carbon Monoxide) PM (Particular Matter) 50REOZK 60 HZ. DIESEL INDUSTRIAL GENERATOR SET EMISSION DATA SHEET ENGINE INFORMATION 64 17.4 8.8 490 49-State Values are in g/kWh unless otherwise noted 0.11 881.70 3.55 0.9 0.31 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY2020 MODEL YEARCERTIFICATE OF CONFORMITYWITH THE CLEAN AIR ACTOFFICE OF TRANSPORTATIONAND AIR QUALITYANN ARBOR, MICHIGAN 48105Certificate Issued To: Kohler Co.(U.S. Manufacturer or Importer)Certificate Number: LKHXL3.36EST-005Effective Date:12/03/2019Expiration Date:12/31/2020_________________________Byron J. Bunker, Division DirectorCompliance DivisionIssue Date:12/03/2019Revision Date:N/AModel Year: 2020Manufacturer Type: Original Engine ManufacturerEngine Family: LKHXL3.36ESTMobile/Stationary Indicator: StationaryEmissions Power Category: 56<=kW<75Fuel Type: DieselAfter Treatment Devices: No After Treatment Devices InstalledNon-after Treatment Devices: Engine Design ModificationPursuant to Section 111 and Section 213 of the Clean Air Act (42 U.S.C. sections 7411 and 7547) and 40 CFR Part 60, and subject to the terms and conditions prescribed in those provisions, this certificate ofconformity is hereby issued with respect to the test engines which have been found to conform to applicable requirements and which represent the following engines, by engine family, more fully described inthe documentation required by 40 CFR Part 60 and produced in the stated model year.This certificate of conformity covers only those new compression-ignition engines which conform in all material respects to the design specifications that applied to those engines described in thedocumentation required by 40 CFR Part 60 and which are produced during the model year stated on this certificate of the said manufacturer, as defined in 40 CFR Part 60.It is a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 1068 and authorized in a warrant or court order. Failure to comply with the requirements of such awarrant or court order may lead to revocation or suspension of this certificate for reasons specified in 40 CFR Part 60. It is also a term of this certificate that this certificate may be revoked or suspended orrendered void ab initio for other reasons specified in 40 CFR Part 60.This certificate does not cover 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.The actual engine power may lie outside the limits of the Emissions Power Category shown above. See the certificate application for details. a~a~ pi_cj~~ of~~ f~a~W d~ ^qp A 12345678 B C D 12345678 A B C D TITLE SCALE DWG NO. CAD NO.SHEETDRAWN CHECKED APPROVED MAX. THIRD ANGLEPROJECTION POWER SYSTEMS, KOHLER, WI 53044 U.S.A. THIS DRAWING IN DESIGN AND DETAIL IS KOHLER CO.PROPERTY AND MUST NOT BE USED EXCEPT INCONNECTION WITH KOHLER CO. WORK. ALL RIGHTS OF DESIGN OR INVENTION ARE RESERVED. SEE SHEET 2 [CT168590] 2300 [90.6]110[4.3]274 [10.8] 1656 [65.2]1131[44.5]1098[43.2]383 [15.1] 75[3.0]325[12.8] 812 [32.0] 75 [3.0] 327 [12.9] 152 [6.0] 75[3.0] 480 [18.9] 75 [3.0] 924 [36.4]75[3.0]150[5.9]216[8.5]50[2.0]50[2.0]679 [26.8] 337[13.3] 1040 [40.9] 970 [38.2] 520 [20.5]232 [9.1]FUEL INLET628 [24.7]FUEL INLET 884 [34.8]EXHAUST OUTLET923 [36.3] EXHAUST OUTLET CENTER OF BALANCE (SEE CHART) 120° 63,5 [2.50] R47,0[1.85] R12,5 [0.49] 3X 8,7 [0.34] 104,0 [ 4.09] B.C. PRO-EMETRIC DIMENSION PRINT 40-60 KW KDI 0.14 1 of 6 ADV-8739 D UNLESS OTHERWISE SPECIFIED -1) DIMENSIONS ARE IN MILLIMETERS2) TOLERANCES ARE: SURFACE FINISH APPROVALS DATE KNN 1-30-15 KNN 1-30-15 BMK 1-30-15 REV DATE ON COMPOSITE DWGS, SEE PART NO. FOR REVISION LEVEL BY - 1-30-15 NEW DRAWING [CT105282] KNN A 9-29-15 SEE SHEET 2 [CT126143] CEK B 4-22-16 SEE SHEET 3 [CT144988] RRT C 10-4-16 (C-2) DIM. 104,0 [4.09] ADDED [CT161121] ADP D 12-22-16 ADP E 10-20-17 SHEETS 4, 5 & 6 ADDED [CT180516] CEK F 2-2-18 SEE SHEETS 4 & 5 [CT184126] CEK INSTALLATION NOTE: IF A SUBBASE FUEL TANK AND/OR ENCLOSURE IS USED, REFER TO SUBBASE FUEL TANK ADV TO DETERMINE MOUNTING LOCATIONS. NOTES:1. WHEN SUBBASE TANK IS USED, CONDUIT MUST BE LOCATED OUTSIDE OF TANK AREA OR IN STUB-UP AREA FOR SUBBASE TANK. REFER TO SUBBASE ADV. 2. DIMENSIONS IN [] ARE ENGLISH EQUIVALENTS. 3. IF AN ENCLOSURE IS USED, THE FUEL LINE MUST BE STUBBED UP FROM DIRECTLY UNDER THE UNITOR BROUGHT IN FROM THE END OF THE SKID. REFER TO ENCLOSURE ADV. 40,50,60KW KOHLER DIESEL RECON. 600V ALTERNATORS 4Q8X, 4P10X, 4Q10X, 4P7BX, 4Q7BX, 4P8X,60HZ 4P5X, 4Q5X, 49 STATE 4X 17.50 [0.688] GENSET MTG HOLES 1/2 NPTF OIL DRAIN FUEL INLET FITTING FOR 8[0.312] I.D. HOSE FUEL RETURN FITTING FOR6.35 [.25] I.D. HOSE DEC 3000 CONTROLLEROIL FILL PORT 1/2 NPTF COOLANT DRAIN SUGGESTED LOCATION FOR FUEL RETURN FLEXIBLE FUEL LINE 3/8 NPT (FEMALE) BATTERY RACK LOCATION SUGGESTED LOCATION FOR FUEL INLET FLEXIBLE FUEL LINE 3/8 NPT (MALE) OPTIONAL BLOCK HEATER CONDUCT LOCATION CONDUCT ENTRY AREA FOR GENERATOR LOAD LEADS (BOTTOM ENTRY) CIRCUIT BREAKER OPTION, REMOTE SWITCH AND REMOTE ANNUNCIATOR EXHAUST OUTLET MODEL COB OPEN GENSET WEIGHT (WET) KG [LBS] 40 4P/Q5X 52.6" 750 [1654] 40/50 4P/Q78X 53.6" 787 [1735] 50/60 4P/Q8X 54" 802 [1769] 60 4P/Q10X 55" 841 [1855] FOR OVERALL DIMENSIONS, SEE TANK DRAWING A 12345678 B C D 12345678 A B C D TITLE SCALE DWG NO. CAD NO.SHEETDRAWN CHECKED APPROVED MAX. THIRD ANGLEPROJECTION POWER SYSTEMS, KOHLER, WI 53044 U.S.A. THIS DRAWING IN DESIGN AND DETAIL IS KOHLER CO.PROPERTY AND MUST NOT BE USED EXCEPT INCONNECTION WITH KOHLER CO. WORK. ALL RIGHTS OF DESIGN OR INVENTION ARE RESERVED.150[5.9]317 [12.5] 1126 [44.3] 1670 [65.7] 780 [30.7]242[9.5]629 [24.8]695[27.4]1055[41.5]356 [14.0]120[4.7]325 [12.8] 53[2.1]1080[42.5] 201 [7.9] 769 [30.3] 75 [3.0]50[2.0]1022[40.2]392 [15.5]62[2.4]166[6.5]75 [3.0]50[2.0]836 [32.9]EXHAUST OUTLET541 [21.3] EXHAUST OUTLET CENTER OF BALANCE (SEE CHART) 330 [13.0] 57 [2.3] 718 [28.3]1259 [49.6]OPTIONAL FLEX EXHAUSTPRO-EMETRIC DIMENSION PRINT 40-60 KW KDI 0.16 2 of 6 ADV-8739 D UNLESS OTHERWISE SPECIFIED -1) DIMENSIONS ARE IN MILLIMETERS2) TOLERANCES ARE: SURFACE FINISH APPROVALS DATE KNN 1-30-15 KNN 1-30-15 BMK 1-30-15 REV DATE ON COMPOSITE DWGS, SEE PART NO. FOR REVISION LEVEL BY - 1-30-15 NEW DRAWING [CT105282] KNN A 9-29-15 (C-3) DIMS 330.0 & 57.4 ADDED [CT126143] CEK B 4-22-16 SEE SHEET 3 [CT144988] RRT C 10-4-16 SEE SHEET 1 [CT161121] ADP D 12-22-16 (A-8) DIM. 718 [28.3] ADDED [CT168590] ADP E 10-20-17 SHEETS 4, 5 & 6 ADDED [CT180516] CEK F 2-2-18 SEE SHEETS 4 & 5 [CT184126] CEK NOTES:1. WHEN SUBBASE TANK IS USED, CONDUIT MUST BE LOCATED OUTSIDE OF TANK AREA OR IN STUB-UP AREA FOR SUBBASE TANK. REFER TO SUBBASE ADV. 2. DIMENSIONS IN [] ARE ENGLISH EQUIVALENTS. 3. IF AN ENCLOSURE IS USED, THE FUEL LINE MUST BE STUBBED UP FROM DIRECTLY UNDER THE UNITOR BROUGHT IN FROM THE END OF THE SKID. REFER TO ENCLOSURE ADV. 40,50,60KW KOHLER DIESELRECON. 600V ALTERNATORS 4Q8X, 4P10X, 4Q10X, 4P7BX, 4Q7BX, 4P8X, 60HZ 4P5X, 4Q5X, 49 STATE 4X 17.50 [0.688] GENSET MTG HOLES DEC 3000 CONTROLLER FUEL RETURN FITTING FOR 6.35 [.25] I.D. HOSE COOLANT DRAIN OIL DRAIN BATTERY RACK LOCATION SUGGESTED LOCATION FOR FUEL RETURN FLEXIBLE FUEL LINE 3/8 NPT FEMALE. SUGGESTED LOCATION FOR FUEL INLET FLEXIBLE FUEL LINE 3/8 NPT (MALE) OPTIONAL BLOCK HEATER CONDUCT LOCATION CONDUCT ENTRY AREA FORGENERATOR LOAD LEADS (BOTTOM ENTRY) CIRCUITBREAKER OPTION, REMOTE SWITCH AND REMOTE ANNUNCIATOR OPTIONAL BLOCK HEATER CONDUCT LOCATION OPTIONAL FLEX EXHAUST :LULQJ6FKHPDWLFV 47< 1 120 1000 1 90-135 1.6 1 100 Three120/208 0LVFHOODQHRXV :DUUDQW\ Stationary Standby and Prime Power Industrial Generator Set One-Year or Two Thousand (2000)-Hour Limited Warranty Your Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original end user,Kohler Co.warrants,fortheperiodindicatedbelow,eachproducttobefreefromdefectsinmaterialsandworkmanship. Intheeventofadefect in materials or workmanship, Kohler Co. will repair, replace, or make appropriate adjustment at Kohler Co.’s option if the product,upon Kohler Co.’s inspection, is found to be properly installed, maintained, and operated in accordance with Kohler Co.’s instructionmanuals. A Kohler distributor, dealer, or authorized service representative must perform startup. Kohler Product Warranty Coverage Stationary Standby Generator Set & Accessories One (1) year from registered startup or two thousand (2000) hours(whichever occurs first). In any event, the warranty period will expire notlater than thirty (30) months from the date of shipment from Kohler Co.’sfactory.Stationary Prime Power Generator Set & Accessories One (1) year from registered startup or two thousand (2000) hours(whichever occurs first). In any event, the warranty period will expire notlater than thirty (30) months from the date of shipment from Kohler Co.’sfactory. TP-5374 12/15f To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., ServiceDepartment, MS072, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, AND/OR CONSEQUENTIAL DAMAGES OF ANY KINDincluding, but not limited to, incidental and/or 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 FOR APARTICULAR PURPOSE, IS EXPRESSLY LIMITED TO THE DURATION OF THIS WARRANTY. Some states do not allowlimitations on how long an implied warranty lasts, or the exclusion or limitation of incidental and/or consequential damages,so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444 KOHLERPower.com The following will not be covered by the warranty: 1. Normal wear, routine tuneups, tuneup parts, adjustments, and periodic service. 2. Damage, including but not limited to damage caused byaccidents, improper installation or handling, faulty repairs not performed by an authorized Kohler service representative, improper storage, or acts of God. 3. Damage caused by operation at speeds, or with fuel, loads,conditions,modificationsorinstallationcontrarytopublished specifications. 4. Damage caused by negligent maintenance such as: a. Failure to provide the specified type and sufficientquantity of lubricating oil.b. Failuretokeeptheairintakeandcoolingfinareasclean.c. Failure to service the air cleaner.d. Failure to provide sufficient coolant and/or cooling air.e. Failure to perform scheduled maintenance asprescribed in supplied manuals. f. Failuretoregularlyexercisethegeneratorsetunderload(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 expenses related to battery service. 7. Additional expenses for repairs performed after normalbusiness hours, i.e. overtime or holiday labor rates. 8. Rental of equipment during the performance of warrantyrepairs. 9. Removal and replacement of non-Kohler-supplied options and equipment. 10. Non-Kohler replacement parts. Replacement of a failed Kohler part with a non-Kohler part voids the warranty on that part. 11. Radiators replaced rather than repaired. 12. Fuel injection pumps not repaired by an authorizedKohler service representative. 13. Non-Kohler-authorized repair shop labor without prior approval from Kohler Co. Warranty Department. 14. Engine fluids such as fuel, oil, or coolant/antifreeze. 15. Shop supplies such as adhesives, cleaning solvents,and rags. 16. Expenses incurred investigating performancecomplaints unless the problem is caused by defectiveKohler materials or workmanship. 17. Maintenance items such as fuses, lamps, filters, sparkplugs, loose or leaking clamps, and adjustments. 18. Travel time and mileage exceeding 300 miles round trip. Your Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original end user,Kohler Co.warrants,fortheperiodindicatedbelow,eachproducttobefreefromdefectsinmaterialsandworkmanship. Intheeventofadefectinmaterialsorworkmanship,KohlerCo.willrepair,replace,ormakeappropriateadjustmentatKohler Co.’soptioniftheproduct,upon Kohler Co.’s inspection, is found to be properly installed, maintained, and operated in accordance with Kohler Co.’s instructionmanuals. A Kohler distributor, dealer, or authorized service representative must perform startup. Kohler Product Warranty Coverage Transfer switch and factory-supplied One (1) year from the registered startup date. In any event, thetransfer switch accessories warranty period will expire not later than thirty (30) months from thedate of shipment from Kohler Co.’s factory. Transfer switch main contacts Ten (10) years from the registered startup date. In any event, thewarrantyperiodwillexpirenotlaterthaneleven(11)yearsandsix(6)monthsfrom the date of shipment from Kohler Co.’s factory. TP-5373 4/15f Transfer Switch One-Year Limited Warranty To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co., KohlerPower Systems Service Department, MS072, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, AND/OR CONSEQUENTIAL DAMAGES OF ANY KINDincluding, but not limited to, incidental and/or 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 FOR APARTICULAR PURPOSE, IS EXPRESSLY LIMITED TO THE DURATION OF THIS WARRANTY. Some states do not allowlimitations on how long an implied warranty lasts, or the exclusion or limitation of incidental and/or consequential damages,so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. The following will not be covered by the warranty: 1. Normal wear, periodic service, and routine adjustments. 2. Damage, including but not limited to damage caused by accidents, improper installation or handling, faulty repairs not performed by an authorized Kohler service representative, improper storage, or acts of God. 3. Damage caused by: a. Operation above or below ratedcapacity, voltage,orfrequency. b. Modifications. c. Installation contrary to published specifications andcodes. 4. 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 asprescribed in supplied manuals. d. Use of parts and/or procedures other thanfactory-supplied or -approved replacement partsand/or procedures. 5. Non-Kohler replacement parts. Replacement of a failed Kohler part with a non-Kohler part voids the warranty on that part. 6. Original installation charges and startup costs. 7. Additional expenses for repair after normal business hours, i.e. overtime or holiday labor rates. 8. Rental of equipment during performance of warranty repairs. 9. Removal and replacement of non-Kohler-suppliedoptions and equipment. 10. Non-Kohler-authorized repair shop labor without priorapproval from Kohler Co. Warranty Department. 11. Expenses incurred investigating performance complaints unless the problem is caused by defectiveKohler materials or workmanship. 12. Maintenance items such as fuses, lamps, and adjustments. 13. Labor and travel charges after the first year of thetransfer switch main contacts warranty period. 14. Travel time and mileage exceeding 300 miles round trip. KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com .2+/(5&2.2+/(5:,6&216,1)281'(',13+21()$; February 5, 2010 Letter Number 10-01 To: All Kohler Power Systems North American Distributors Attn: Service and Sales Managers Long Term Storage Due to the current economic climate, many customers are delaying the startup of their products and storing them for extended periods of time. Also, distributors and dealers may have product in their inventory for an extended period of time. This bulletin is to highlight key storage requirements and remind customers that it is necessary to properly prepare units for long term storage as well as to perform the proper procedures when the product is removed from storage. This bulletin should be used in conjunction with the information in the equipment manuals to provide adequate and proper product storage. For Generator Sets: Long term storage is defined differently depending on the engine manufacture and other unit specific factors. Generally, long term storage is defined as any non operation for 3 months or more. The owner’s manual for both the generator set and engine should be consulted as to the unit’s storage requirements. If a unit is serviced and placed into long term storage the Generator Field Service department should be notified when that procedure is performed so we can record the that the unit was placed into storage and take steps to ensure that the warranty remains in effect. In some cases, especially with diesel powered product above 200kW, specific instructions may be needed to be followed to properly prepare the engine for long term storage and take the engine out of long term storage. These procedures may also require the engine manufacturer’s authorized representatives perform the procedure to keep the warranty intact. Special consideration should also be given to the AC alternator service when being stored. For units up to and including 600V (considered low voltage) a megaohm test should be performed on the AC alternator rotor and stator windings before placing into storage and also when the product is removed from storage. This information will need to be provided to the Generator Service Department when this procedure is performed. For medium voltage product, the units should be stored with the generator heater operational. This should also be checked periodically throughout the storage period to confirm operation. It is necessary to maintain an AC alternator temperature above the ambient dew point to eliminate the formation of condensation in the alternator winding. An appropriate megaohm test is necessary to confirm the winding condition both when the unit is placed into storage and when the product is removed from storage for service. For units that for some reason were not properly prepared for long term storage, specific procedures need to be performed at the time of commissioning before the engine is turned over. Please contact the factory for these procedures. For Automatic Transfer Switches: Transfer switches should be stored in-doors and in an environment that will prevent the formation of condensation in and on the unit. Please see the appropriate owner’s manuals for guidelines on storage procedures. Please note that power components, lugs and bus work will corrode if subject to moisture or condensation. Units that are being stored on a jobsite for an extended period of time should have a supplemental heat source that will keep the unit above the ambient dew point. Product that is stored for a period of time longer than 6 months should have a physically inspection and thermal temperature rise inspection. Inspections should be done on all power carrying components including transfer switch contacts, power connections, and bus bar connections and joints. For Switchgear: In general, the same guidelines as indicated above for ATS’s should be used for switchgear. In addition, each subassembly manufacturer has particular requirements based on their system and the voltage and/or amperage rating of the switchgear assembly. The appropriate manuals as shipped with the unit should be consulted to determine the requirements for storage. In each case, the factory should be notified that the switchgear is being placed or removed from storage so that any required procedures and/or inspections are completed. The requirements listed in the warranty policy for each particular unit do not supersede the storage requirements. As an example, units placed into service within 24 months from the ship date are not exempt from the storage requirement. If you have any questions, please feel free to contact the generator field service department. Sincerely, Dennis Christian Manager – Field Service Kohler Power Systems &HUWLILFDWLRQ ! "# $%& '%$(% ) *+ , - .$ / /' /0 (1&%23 # 4*&5% 5 / 6/ -7/ 0 --- /0 !" # 8 / / $1 &6/ 0 $!$(966 0 8 $!!&6/0 1%$:0 (%$ #0 (%$ 6*0 * 8 $!!& 1%$ 6/0 :0 (%$ #0 (%$ 6*0 ! 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Inkeepingwithouruncompromisingcommitmenttoquality,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 destructivetests necessary to verify design, proper function of protective devices and safety features, and reliability expectations. Kohler’s prototype testing includes thefollowing: D Alternator temperature rise test per NEMA MG1-32.6. Standby and prime ratings of the alternator are established during this test. D Maximum power test to assure that the primemover and alternator have sufficient capacity tooperate within specifications. D Alternator overload test per NEMA MG1-32.8. D Steady-stateloadtesttoensurevoltageregulationmeets or exceeds ANSI C84.1, NEMA MG1-32.17 requirementsandtoverifycompliancewithsteady- state speed control specifications. D Transient test to verify speed controls meets or exceeds specifications. D Transient load tests per NEMA MG1-32.18, and ISO 8528 to verify specifications of transientvoltage regulation, voltage dip, voltage overshoot, recovery voltage, and recovery time. D Motor starting tests per NEMA MG1-32.18.5 to evaluate capabilities of generator, exciter, and regulator system. D Three-phase symmetrical short-circuit test per NEMA MG1-32.13 to demonstrate short circuitperformance, mechanical integrity, ability to sustain short-circuit current. D Harmonic analysis, voltage waveform deviation per NEMA MG1-32.10 to confirm that the generator set is producing clean voltage withinacceptable limits. D Generator set cooling and air flow tests to verifymaximum operating ambient temperature. D Reliability tests to demonstrate product durability,followed by root cause analysis of discovered failures and defects. Corrective action is taken to improvethedesign,workmanship,orcomponents. D Acoustical noise intensity and sound attenuation effects tests. Production Testing In production, Kohler Standby/Prime generator sets are built to the stringent standards established by the prototypeprogram. EveryKohlergeneratorsetisfullytested prior to leaving the factory. Production testing includes the following: D Statorandexciter windinghigh-potentialtest onall generators. Surge transient tests on stators for generators 180 kW or larger. Continuity andbalance tests on all rotors. D One-step, full-load pickup tests to verify that theperformance of each generator set, regulator, and governor meets published specifications. D Regulation and stability of voltage and frequency aretestedandverifiedatnoload,1/4load,1/2load, 3/4 load, and full-rated load. D Voltage, amperage, frequency and power output ratings verified by full-load test. D The proper operation of controller logic circuitry, prealarm warnings, and shutdown functions is tested and verified. D Any defect or variation from specification discoveredduringtestingiscorrectedandretestedprior to approval for shipment to the customer. Torsional analysis data, to verify torsional effects are not detrimental and that the generator set will providedependable service as specified, is available upon request. Kohler offers other testing at the customer’s request at an additional charge. These optional tests include power factor testing, customized load testing for specific application, witness testing, and a broad range of MIL-STD-705c testing. A certified test report is also available at an additional charge. KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KohlerPowerSystemscom G18-414 2/20 Kohler Automatic Transfer Switch Test Program Non-Bypass Models Testing is an integral part of quality assurance. In keeping with our uncompromising commitment to quality, safety, and reliability, every Kohler Automatic Transfer Switch (ATS) undergoes an extensive series of performance and production testing. Performance Testing All Kohler ATSs are UL1008 listed, which includes the following performance tests: D General – Normal Operation D Overvoltage D Undervoltage D Overload D Temperature Rise D Endurance D Dielectric Voltage – Withstand D Short Circuit Withstand D Short Circuit Close-On D Dielectric Voltage – Withstand (repeated) D Strength of insulating base and support EMC/EMI Immunity Verification Controls and printed circuit board assemblies areevaluated to IEC and IEEE tests, including: D EN61000-4-4 Fast Transient Immunity SeverityLevel 4 D EN61000-4-5 Surge Immunity Class 4 (voltage sensing and programmable inputs only) D IEC Specifications for EMI/EMC Immunity: d CISPR 11, Radiated Emissions d IEC 1000-4-2, Electrostatic Discharge d IEC 1000-4-3, Radiated Electromagnetic Fields d IEC 1000-4-4, Electrical Fast Transients (Bursts) d IEC 1000-4-5, Surge Voltage d IEC 1000-4-6, Conducted RF Disturbances d IEC 1000-4-8, Magnetic Fields d IEC 1000-4-11, Voltage Dips and Interruptions D IEEE 472 (ANSI C37.90A) Ring Wave Test Production Testing Every Kohler ATS is fully tested prior to leaving thefactory. Visual inspections are also performed by the mechanism manufacturer as well as Kohler personnel during assembly and final test.Production testing includes the following: D Electrical operation testing on all ATSs D Verification of controller communication D Verification of controller settings D Voltage calibration D Automatic transfer switch operation when Normalsource is lost d Verify engine start signal d Verify transfer to Emergency position when Emergency source is available D Automatic Transfer switch operation when Normal source returns d Verify transfer to Normal position d Verify engine start signal is removed CSA Certification CSA Certification is also available upon request.CSA certification includes the following additional test: D Dielectric test at 1000V plus twice the maximum rated voltage Options Testing The operation of all installed options is verified. Tested options include: D Input/Output Modules D Supervised Transfer Control Switch D Preferred Source Switch D Load Shed, Normal and Emergency D Line-to- Neutral Monitoring D Digital Meter setup and operation Kohler offers other testing at the customer’s request at an additional charge. These optional testsinclude customized load testing for specific application, witness testing, and contact resistance testing. A certified test report is also available at anadditional charge. KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com EXAMPLE ONLY: Certified Test Record Are Unit Specific 3UHVWDUWXS&KHFNOLVW 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 Yes DoesNotApply 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. Is there emergency lighting available at the equipment room or weather housing? 4. Is there adequate heating for the equipment room or outdoor weather housing? 5. 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? Yes Does Not 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 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? * 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. Generator Set/Transfer Switch Startup Checklist Thisdocumenthasgenericcontentandsomeitemsmaynotapplytosomeapplications. Checkonlytheitemsthatapplytothespecificapplication. 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. Yes DoesNot 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. Open all water and fuel valves. Temporarily remove the radiator cap to eliminate air in the cooling system. Replace radiator cap in step 21. 4. 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 oil pressure and high coolant temperature shutdowns.* 24. Check the overcrank shutdown.* 25. Place the generator set master switch in the OFF/RESET position. 26. Open the normal source circuit breaker or remove fuses to the transfer switch. 27. Disconnect the power switching device and logic controller wire harness at the inline disconnect plug at the transfer switch. 28. Manually transfer the load to the emergency source. Yes DoesNot Apply 29. Close the normal source circuit breaker or replace fuses to the transfer switch. 30. Check the normal source voltage, frequency, and phase sequence on three-phase models. The normal source must match the load. 31. Open the normal source circuit breaker or remove fuses to the transfer switch. 32. Manually transfer the load to the normal source. 33. Close the generator set main line circuit breakers, close the safeguard breaker, and/or replace the fuses connected to the transfer switch. 34. Place the generator set master switch in the RUN position. 35. Check the generator set voltage, frequency, and phase sequence on three-phase models. The generator set must match normal source and load. 36. Place the generator set master switch in the OFF/RESET position. 37. Open the generator set main line circuit breakers, open the safeguard breaker, and/or remove the fuses connected to the transfer switch. 38. Reconnect the power switching device and logic controller wire harness at the inline disconnect plug at the transfer switch. 39. Close the normal source circuit breaker or replace fuses to the transfer switch. Place the generator set master switch to the AUTO position. 40. Close the generator set main line circuit breakers, close the safeguard breaker, and/or replace the fuses connected to the transfer switch. 41. 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. 42. Readjust frequency to 50 or 60 Hz with total building loads.* 43. Verify that the current phase is balanced for three phase systems. 44. 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). 45. Allow the generator set to run and shut down automatically after the appropriate cool down time delay(s). 46. Set the plant exerciser to the customer’s required exercise period, if equipped. 47. Verify that all options on the transfer switch are adjusted and functional for the customer’s requirements. 48. If possible, run the building loads on the generator set for several hours or perform the load bank test if required. 49. Verify that all the wire connections from the generator set to the transfer switch and optional accessories are tight and secure. 50. 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. 51. Fill out the startup notification at this time and send the white copy to the Generator Warranty Dept. Include the warranty form if applicable. ϬϯͬϮϬϮϬ– KPS Start Up Check List 1 'EZ>/E&KZDd/KEͲW>^Zs/t͗ CONTRACTOR NAME & PHONE # FOR SCHEDULING PURPOSES: Company: Phone: Contact: Jobsite Superintendent: Jobsite Phone: Contact Email: State: Zip: END USER INFORMATION;ZYh/Z/EKZZdK^,h>Ϳ: End User Name: End User Contact Name: End User Contact Phone: Equipment Address: City: Contact Email: KPS GENERATOR SET INSTALLATION CHECK LIST ϭ͘ThŝƐ form ƐŚŽƵůĚďĞ completed ŝŶŝƚƐĞŶƚŝƌĞƚǇand returned to͗ &Ăǆ͗;ϴϲϬͿϯϵϮͲϬϮϮϮŽƌŵĂŝů͗^ƚĂƌƚƵƉΛŬŝŶƐůĞǇƉŽǁĞƌ͘ĐŽŵ Ϯ͘ WůĞĂƐĞĞŶƐƵƌĞƚŚĂƚKinsley Power Systems has received payment in full for the projectnoted below;ŵƵƐƚďĞƉĂŝĚƉƌŝŽƌƚŽƌĞƋƵĞƐƚĞĚ^ƚĂƌƚƵƉĂƚĞͿ. W>^EKd͗ϮͲϯt<^ΖEKd//^ZYh/ZWZ/KZdK^,h>/E'͘ ΎhŶůĞƐƐŽƚŚĞƌǁŝƐĞƐƉĞĐŝĨŝĞĚ͕ŽŶĞďƵƐŝŶĞƐƐĚĂǇ͛ƐůĂďŽƌŝƐƉƌŽǀŝĚĞĚĨŽƌƐƚĂƌƚͲƵƉƵƉĂŶĚƚƌĂŝŶŝŶŐ͘/ĨũŽďƐŝƚĞŝƐŶŽƚƌĞĂĚǇ͕ ĐŚĞĐŬůŝƐƚŝƚĞŵƐĂƌĞŝŶĐŽŵƉůĞƚĞŽƌŵĂƌŬĞĚŝŶĐŽƌƌĞĐƚůǇ͕ĂƐƵďƐĞƋƵĞŶƚƚƌŝƉŵĂǇďĞŶĞĐĞƐƐĂƌǇ͘/ĨĂƐƵďƐĞƋƵĞŶƚƚƌŝƉŝƐ ŶĞĞĚĞĚ͕ĂĚĚŝƚŝŽŶĂůĨĞĞƐŵĂǇĂƉƉůǇ͘ ZYh^d^dZdͲhWd͗BBBBBBBBBBBBBBBBBB JOB NAME: KINSLEY JOB#: GENERATOR MODEL #: ATS MODEL #: GENERATOR SERIAL #: ATS SERIAL #: Mailing Address, if different than equipment location: ĚĚƌĞƐƐ͗ͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺŝƚǇ͗ͺͺͺͺͺͺͺͺͺͺͺͺͺͺ^ƚĂƚĞ͗ͺͺͺŝƉ͗ͺͺͺͺͺͺͺͺͺͺ DĂŝŶŽŶƚĂĐƚWŚŽŶĞη;ŝĨĚŝĨĨĞƌĞŶƚƚŚĂŶĂďŽǀĞͿ͗ͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺ ^>^E'/EZ͗ͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺͺ ϬϯͬϮϬϮϬʹ<W^^ƚĂƌƚhƉŚĞĐŬ>ŝƐƚ2 DIESEL ϵ͘( ) FUEL LINES: Fuel lines from day tank to main tank and engine should be complete. Supply line from main tank to pump on day tank should be connected to the pickup tube on main tank. Run return line from engine to day tank and run return from day tank to main tank. Day tank and main tank should be vented. Black pipe or copper should be used for fuel lines. (NEVER USE GALVANIZED PIPE) ϭϬ͘( ) MAIN FUEL TANK: Be sure fuel tank is ĨŝůůĞĚϴϬͲϵϬйƌĂƚĞĚĐĂƉĂĐŝƚǇ͘WůĞĂƐĞĚŽŶŽƚĨŝůůŽǀĞƌϵϬйZĂƚĞĚĂƉĂĐŝƚǇ͘ ϭϭ͘( ) DAY TANK: AC motor should be wired to an emergency panel that will be hot during a power failure. Day tank motor should be tested before start up and insure proper fuel line connections. Day tank should be installed on same level as the engine. Day tank pump supply line should be primed if pump does not pick up fuel in approximately (2) minutes. NOTE: REMOVE SHIPPING BRACKET FROM FLOAT SWITCH ADJUSTING DIAL OR TANK WILL OVERFILL. NATURAL GAS/PROPANE 12.( ) GAS LINES: Verify correct gas pressure is available. Gas pressure MUST be a minimum of 7” water column and a maximum of 11” water column to the unit mounted gas solenoid valve. The gas volume required for this unit are located on the specification sheets provided in cubic feet per hour @ 100% rated load. Fuel lines and any additional regulators required must be sized to handle this volume. IMPORTANT NOTE: Many natural gas utility companies supply either 6” water column or 14” water column supply pressure. In both cases a change in the supply configuration is required. CONTRACTOR - GENERAL ϭϯ͘( ) MUFFLER: Muffler and exhaust lines should be installed, including condensation trap and weather protection. Be sureƚŚĞĞǆŚĂƵƐƚ ƐƚĂĐŬ͕ŝĨĂƉƉůŝĐĂďůĞ͕ŝƐŝŶƐƚĂůůĞĚĂŶĚall exhaust linefittings and flanges are tightened. Insulation (if required) should be complete before start-up. ϭϰ͘( ) ISOLATORS: Isolators should be installed under engine base. Isolators should be installed and adjusted as per manufacturer’s recommendations. Kohler generator sets below 400KW have factory isolators between engine/generator assemble and frame. Kohler Company does not require isolators between frame and pad. ϭϱ͘( ) RADIATOR DUCT: Radiator exhaust duct should be complete. NOTES ϭϲ͘( ) CLEANING: Area under and around generator set should be cleaned before start-up. This will prevent damage to radiator by debris being drawn into it and personal injury by the flying debris. ϭϳ͘( ) INSTRUCTING OWNERS PERSONNEL: Electrical contractor should notify owner’s personnel that operation and maintenance instructions will be given at time of start-up. ft. ϭϴ͘( ) IF LOAD BANK TESTING IS REQUIRED: How close can we get to the unit with trailer mounted test equipment? If unit is located indoors is there access for cables and how close can we get? ft. Is unit on top of bldg? ϭϵ͘( ) IF UNIT HAS REMOTE RADIATOR, we need capacities of system. Kinsley Power will provide only coolant as specified on unitŵŽƵŶƚĞĚ radiators unless quoted before sale. If capacity is not known, give pipe sizes and length. DATE: Print Name: COMPLETION VERIFIED & SIGNED BY: **By completing and signing this start up checklist you are verifying that all items have been completed per this checklist; authorizing any additional charges that may apply if additional work is required and confirming that all Kinsley Power Systems’ terms and conditions have been met. ** KINSLEY POWER SYSTEMS GENERATOR SET INSTALLATION CHECK LIST ELECTRICAL ϭ͘( ) CONTROL WIRING: Insure wires are run terminated between DC junction box and transfer switches, annunciator, etc. WARNING!! Do not run any control wires in same conduit with any AC wiring. Doing so will cause failure and damage to the control logic in generator and transfer switch. Ϯ͘( ) AC CONDUCTORS (Normal and Emergency): Insure AC conductors are run and terminated between generator and normal and transfer switches. NOTE: Neutral and equipment earth ground shall be run as per codes. ϯ͘( ) EMERGENCY PANEL: If generator feeds an emergency panel before going to the transfer switches, proper-sized fuses should be installed before start-up. ϰ͘( ) TURN MAIN GENERATOR CONTROL SWITCH OFF. ϱ͘( ) BATTERIES: Kinsley Power Systems at start-up will provide Batteries. NOTE: DO NOT ATTEMPT TO START ENGINE!!!!! ϲ͘( ) BATTERY CHARGERS: Charger should be connected to AC power. DC leads should be connected to proper terminals on starter terminals on Kohler generator sets. ϳ͘( ) ENGINE HEATERS: Wiring to water heater and lube oil heaters should be terminated. Kohler generators are shipped with radiators and oil pans dry, therefore, power breakers should be left off until unit is filled on start-up, or oil and water levels are checked. ϴ͘( ) LOUVERS: Louvers on air intake or radiator exhaust should be complete. Control wiring run to DC junction box to terminal block which is used for such accessories. ϬϯͬϮϬϮϬʹ<W^^ƚĂƌƚhƉŚĞĐŬ>ŝƐƚ3 CUSTOMER OR CUSTOMER REPRESENTATIVE MUST BE PRESENT AT TIME OF START UP TO SIGN OFF ON ALL PAPERWORK For scheduling assistance, or if any problems arise in installation of generator system, no matter how minor, please contact: (800) 255-3503 SPECIAL DIRECTIONS TO JOBSITE: KPS USE ONLY: START UP DATE ASSIGNED BY KPS: Start Up Miles RT: Service Miles RT: Customer ID#: Warranty: Extended Warranty: Service Contract: KOHLER GENERATORS This instruction set should be visibly displayed in the Emergency Power Supply System, generator set room. Safety Precautions: Safety is built into every engine driven generator, however, like any other electro-mechanical device it can present serious threat to life and limb if imprudently operated and maintained. Remember that the best safeguards against accidents are to keep ever mindful of the potential dangers and to always use good common sense. In the interest of safety, some general precautions are presented below-keep these in mind! WARNING-Do not operate with panels or covers removed. WARNING-HIGH VOLTAGE-Remember that the function of a generator set is to produce electricity and wherever electrical energy is present, there is the potential danger of electrocution. Keep everyone, especially children, away from the set while it is running and take precautions to prevent unqualified personnel from tampering with or attempting to operate your generator set. Have the set and electrical circuits serviced only by qualified technicians. Wiring should be inspected frequently-replace leads that are frayed or in poor condition. Be especially careful not to come in contact with electrical equipment when standing in water or on wet ground or when your hands are wet. WARNING-LETHAL EXHAUST GAS-The engine powering your generator discharges deadly carbon monoxide as part of the exhaust gas when operating. Carbon monoxide is particularly dangerous in that it is odorless but keep in mind that it can cause death if inhaled for even a short period of time. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate in any area where exhaust gas could accumulate and seep back inside an occupied building. Avoid breathing exhaust fumes when working on or near the generator set. WARNING-DANGEROUS FUELS-Use extreme caution when handling, storing, and using fuels-they are highly volatile and explosive in vapor state. Store gasoline only in approved red containers clearly marked GASOLINE. Store in well ventilated areas out of reach of children and away from any flame or spark producing equipment. Do not store gasoline inside home or any occupied building. Never add fuel to tank while engine is running to prevent spilled fuel from igniting on contact with hot parts or from ignition spark. Adequate ventilation for LP gas and natural gas is mandatory. Detectors should be installed. Propane is heavier than air-install detectors low in room. Natural gas rises-install detectors high in room. Inspect detectors often. WARNING-AUTOMATIC TRANSFER SWITCH-Units with automatic transfer switches start automatically. Before working on equipment connected to generator, the generator must be disabled. Use line circuit breaker or remove generator leads from transfer switch (tape the ends). The generator safeguard breaker is not a line circuit breaker. Starting Procedure Two-Position Switches-On generator sets with a two-position stop-start switch and an automatic transfer switch, leave the switch in STOP position. The transfer switch will operate the generator set. To manually start the generator move the switch to START position. Three-Position Switches-If the switch has AUTO-OFF/RESET-RUN positions, the set will not start until the toggle switch is moved out of the center OFF position. The NOT-IN-AUTO lamp will continue flashing whenever the toggle switch is in the OFF/RESET or RUN positions. The battery draw of this flashing lamp is very light and will not cause depletion of battery even under extended periods. The other two switch positons are RUN and AUTO. RUN: Switching to this positon will initiate starting of the generator set. If the set is connected to an automatic transfer switch, the set will start and run but the electrical load will not be transferred to the generator set. Use this positon for starting sets not equipped with transfer switches. AUTO: Use this positon on generator sets equipped with automatic transfer switches. On these, the set will not start when the switch is moved to this position but will ready the set for automatic startup by the automatic transfer switch. Reset Procedure Your generator set may be equipped with protective devices which will automatically shut down the set if specific fault conditions occur while the set is in operation. The conditions are high water temperature, low coolant level, over-speed, over-voltage, and low oil pressure. The appropriate indicator lamp on the controller (if equipped) will light to tell you why the shutdown occurred. First move the starting mode switch to OFF/RESET or STOP positon. The cause must then be located and eliminated. To clear the fault shutdown circuit and prepare the set for restarting, the following steps must be taken-this procedure also applies if the set has shutdown due to overcranking or after it has been stopped using the emergency stop button. Some earlier model generator sets have an automatic 20 second delay before the set can be restarted. Later model generator sets require only about 5 seconds. For test runs, use the TEST switch on the transfer switch (if equipped). Leave generator switch in STOP or AUTO positon. Step 1: Move the starting mode switch to the center OFF/RESET or STOP positon. Step 2: Locate and eliminate the cause of shutdown. Step 3: Return the generator switch to the desired starting mode positon. Stopping Procedure Manual Stop-To stop, move the generator switch to the OFF/RESET position or, in an emergency, use the remote emergency stop switch. Automatic Transfer Switch-With three-position switches, the switch must be in AUTO position for the transfer switch to stop the generator set. The set will shut down after a cooling-off period when the transfer switch transfers the load back to commercial supply. With two-position switches, the transfer switch will stop the set when the switch is in STOP position. Item System-Component Frequency F=Follow procedures and frequencies indicated in manufacturer's manual. If not indicated, follow this schedule. X=Action. R=Replace as required. Visually Inspect Check Change Clean Test 1. a FUEL-Main tank supply level XWeekly b Day tank level X XWeekly c Fuel level switch X XWeekly d Transfer pump operation X XWeekly e Solenoid valve operation X XWeekly f Filter(s)FQuarterly g Water in system, remove FFWeekly h Flexible lines and connectors R Weekly i Tank vents and return lines for obstructions XYearly j Fuel piping X Yearly k Gasoline supply R Six Months 2. a LUBRICATION-Oil level F FWeekly b Change oil F 50 hours or yearly c Replace filter(s)F 50 hours or yearly d Crankcase breather F FQuarterly 3. a COOLING-Coolant level F FWeekly b Antifreeze protection level F Six Months c Coolant FYearly d Water supply to heat exchanger XYearly e Clean heat exchanger XYearly f Air inlet to room/enclosure XWeekly g Clean radiator exterior XYearly h Fan and alternator belts F F F Monthly i Water pump(s) F Weekly j Flexible hoses and connectors X XWeekly k Block heater operation XWeekly l Air ducts, louvers XXYearly m Louver motors and controls X XXYearly 4. a EXHAUST LINE-Leakage X XWeekly b Drain condensate trap XWeekly c Insulation, fire hazards X Quarterly d Excessive back pressure XYearly e Hangers and supports X Yearly f Flexible connectors X Six Months Scheduled Maintenance Procedure 5. a BATTERY SYSTEM-Electrolyte level XMonthly b Terminals clean and tight X XQuarterly c Remove corrosion, case exterior clean, dry X XMonthly d Specific gravity, charge state XMonthly e Charger operation, charge rate X Monthly f Recharge after engine start XMonthly 6. a AC ELECTRICAL SYSTEM-General Inspection X Weekly b Tighten control and power wiring connections XYearly c Wire abrasion where subject to motion X XQuarterly d Safety and alarm operation X X Six Months e Controller lamp test R RWeekly f Circuit breakers, fuses. CAUTION: Do not break manufacturer's seals or internally inspect these devices. X X R X X Monthly g Transfer switch main contacts X XYearly h Voltage-sensing device/relay adjustment FFYearly i Wire-cable insulation breakdown X 3 years or 500 hours 7. a ENGINE-General Inspection F Weekly b Air clearer service F F Six Months c Governor Operation, lubrication F FMonthly d Governor oil FYearly e Ignition components F FYearly f Choke, carburetor adjustment F Six Months g jpp j p py pattern XYearly h Valve clearance X 3 years or 500 hours i Bolt torque F F 3 years or 500 hours 8. a GENERATOR-General Inspection X Weekly b Rotor and stator X XYearly c Bearing condition and lubrication X XR Yearly d Exciter X XXYearly e Voltage regulator X XXYearly f with insulation tester (Megger, with FR-Activator or rectifier disconnected)XYearly 9. a GENERAL CONDITION OF EQUIPMENT-Any condition of vibration, leakage, noise, temperature, or deterioration X XWeekly b qp housing X XWeekly 10. a Ensure that system is set for automatic operation X Weekly Item No.Frequency System-Component Performed By Date 1. a Weekly FUEL-Main tank supply level bWeekly Day tank level cWeekly Fuel level switch dWeekly Transfer pump operation eWeekly Solenoid valve operation fQuarterly Filter(s) gWeekly Water in system, remove hWeekly Flexible lines and connectors iYearly Tank vents and return lines for obstructions jYearly Fuel piping k Six Months Gasoline supply 2. a Weekly LUBRICATION-Oil level b 50 hours or yearly Change oil c 50 hours or yearly Replace filter(s) dQuarterly Crankcase breather 3. a Weekly COOLING-Coolant level b Six Months Antifreeze protection level cYearly Coolant dYearly Water supply to heat exchanger eYearly Clean heat exchanger fWeekly Air inlet to room/enclosure gYearly Clean radiator exterior hMonthly Fan and alternator belts iWeekly Water pump(s) jWeekly Flexible hoses and connectors kWeekly Block heater operation lYearly Air ducts, louvers mYearly Louver motors and controls 4. a Weekly EXHAUST LINE-Leakage bWeekly Drain condensate trap cQuarterly Insulation, fire hazards dYearly Excessive back pressure eYearly Hangers and supports f Six Months Flexible connectors 5. a Monthly BATTERY SYSTEM-Electrolyte level bQuarterly Terminals clean and tight cMonthly Remove corrosion, case exterior clean, dry dMonthly Specific gravity, charge state eMonthly Charger operation, charge rate fMonthly Recharge after engine start Scheduled Maintenance Record Copy this blank form, and enter information on copies, in order to keep ongoing, permanent records. See scheduled maintenance. 6. a Weekly AC ELECTRICAL SYSTEM-General Inspection bYearly Tighten control and power wiring connections cQuarterly Wire abrasion where subject to motion d Six Months Safety and alarm operation eWeekly Controller lamp test fMonthly Circuit breakers, fuses. CAUTION: Do not break manufacturer's seals or internally inspect these devices. gYearly Transfer switch main contacts hYearly Voltage-sensing device/relay adjustment i 3 years or 500 hours Wire-cable insulation breakdown 7. a Weekly ENGINE-General Inspection b Six Months Air clearer service cMonthly Governor Operation, lubrication dYearly Governor oil eYearly Ignition components f Six Months Choke, carburetor adjustment gYearly Injector pump and injector flow rate, pressure, spray pattern h 3 years or 500 hours Valve clearance i 3 years or 500 hours Bolt torque 8. a Weekly GENERATOR-General Inspection bYearly Rotor and stator cYearly Bearing condition and lubrication dYearly Exciter eYearly Voltage regulator fYearly Measure and record resistance readings of windings with insulation tester (Megger, with FR-Activator or rectifier disconnected) 9. a Weekly GENERAL CONDITION OF EQUIPMENT-Any condition of vibration, leakage, noise, temperature, or deterioration bWeekly Clean interior of equipment room or outdoor weather housing 10. a Weekly Ensure that system is set for automatic operation 11 Note any conditions found, requiring repair or correction, and action taken: Monthly Operational Test-Exercise Log x Check mark lines 1, 3, 10, and 14. Enter date and performed by to record completion of scheduled test-exercise. x For other lines, enter necessary numbers at time of routine system exercising. Note: Load connected to generator set during exercising should be at least 50% of total system load and at least 30% of generator set’s nameplate rating. Exercise period should last for 30 minutes. Exercising should be done at least every 30 days. Copy this blank form, and enter information on copies in order to keep ongoing, permanent records. Date: ______________________________ Performed By:_______________________ Record of: 1. Scheduled maintenance 2. Generator set hours at start and end of test:_____________________________________ 3. Power failure simulation 4. Time delay before engine cranks:__________________________________________sec 5. Cranking time before engine starts:_________________________________________sec 6. Time before load transfers:_______________________________________________sec 7. AC Volts, Hz, Amps after transfer:___________________________________________ 8. Oil pressure, DC Volts/Amps after startup:_____________________________________ 9. Oil pressure, DC Volts/Amps, water temperature after 15 minutes:__________________ 10. Restore normal power 11. Before system retransfers to normal power, record: x Oil pressure:________________________ x DC Amps:__________________________ x Water temperature:___________________ x AC Voltage:________________________ x Hz: _______________________________ x AC Amps:__________________________ 12. Time from normal power restoration to load transfer:__________________________min 13. Time from load transfer to generator set shutdown:____________________________min 14. Be sure that generator set master switch is in AUTO position 15. Note any conditions found, requiring repair or correction, and action taken: ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________ ________________________________________________________________________