SHOP DRAWING REVIEW - MKC Associates, Inc. CSD/09-ED1-045… · 1 MTG, LCB2, H-FR TO H/J, 100-150A,...

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Architecture - Engineering - Planning www.mkcinc.com

Mansfield, Ohio New Philadelphia, Ohio Powell, Ohio 419-525-1102 - phone 330-364-8871 - phone 740-657-3202 - phone 419-525-1428 - fax 330-343-3075 - fax 740-657-1717 - fax

SHOP DRAWING REVIEW

REVIEWEDFURNISH AS CORRECTEDREVISE AND RESUBMITREJECTEDSUBMIT SPECIFIED ITEM

Date:Todd Moore / DLayBy: Feb 6, 2012

Comments:

This review is only for general conformance with (1) the design concept and (2) the informationgiven in the construction documents. Corrections or comments made on a shop drawing duringthis review do not relieve the contractor from compliance with the requirements of the plans andspecifications. Approval of a specific item does not include approval of an assembly of whichthe item is a component. The contractor remains responsible for: dimensions to be confirmed andcorrelated at the job site; information that pertains solely to the fabrication process or to themeans, methods, techniques, sequences and procedures of construction; coordination of theWork with that of all other trades; and performing all Work in a safe and satisfactory manner.

1. The block engine coolant heater shall be 2000 watt, 208 volt single phase. The contractor shall provide 15A-2P breakerinstalled in available space in lieu of 120 volt circuit, new homerun shall be 2#12 & 1#12 GND-3/4”C from same panel. Thespecified 120 volt breaker shall become spare.

2. A remote pushbutton type Emergency stop for the generator shall be located adjacent to the remote annunciator.

3. The smaller breaker shall be an 80 amp 80% rated breaker in lieu of 100 amp submitted.

4. The maintenance kit shall include all applicable items per specification section 26 32 13, 1.10.

File Name:

263213-1 Generator

Westlake City Schools Submittal Cover Sheet

(To be filled out and submitted with each submittal)

School ___MIDDLE______ Contractor: _Turner Logistics Date __1/24/12___ Item:____Generator_& ATS________________

Specification Section: __263213 _ Sub Specification Section: ____263600____________ Contractor’s Submittal # __263213-01__Revision # __0____ Submittal Type ___PDF__________ Lead Time After Approval (wks) _10__ Manufacturer/Supplier: _Kohler/Buckeye Power Sales_ Intended Area of Use, Drawing # and Detail Reference: _____________________________________

Contractor Stamp

APPROVED Buckeye Power Sales

_____________________________ Mark Cronin

_____________________________ 1-24-12

CM Stamp

TURNER/RESOURCE

Reviewed for general acceptance only. This review does not relieve the Contractor of the responsibility for making the work conform to the requirements of the contract. The Contractor is responsible for all dimensions, correct fabrication and accurate fit with the work of other trades. SUBJECT TO ARCHITECT’S APPROVAL Signed: ____________________ Date: _____________ CM Submittal #: ________________________________

Architect Stamp Engineer Stamp

PROJECT SUBMITTAL

MARK PEPERA OFFICE OF THE TREASURER

BOARD OF EDUCATION OF THE WESTLAKE CITY

150REOZJF

PROJECT: LEE BURNESON MIDDLE SCHOOL

LOCATION: WESTLAKE, OH

B U C K E Y E P O W E R S A L E S C O M P A N Y, I N C .

TABLE OF

CONTENTS

Bill of Material…………………………………………Pages 3-6 Spec Sheets……………………………………………..Pages Generator Data Sheet, pages Alternator Data Sheet, pages Controller Data Sheet, pages Enclosure Data Sheet, pages Battery Charger Data Sheet, pages Line Circuit Breaker Data Sheet, pages Transfer Switch Data Sheet, pages Emissions Data…………………………………………Pages Dimensional Drawings………………………………....Pages Generator Drawing, pages Enclosure Drawing, pages Fuel Tank Drawing, page Transfer Switch Drawing, pages Wiring Schematics ……………………………………..Pages Controller Schematic, pages Controller Wiring Diagram, pages Remote Serial Annunciator Diagram, pages

Transfer Switch Schematic, pages Transfer Switch Wiring Diagram, pages Miscellaneous…………………………………………..Pages Battery Charger Drawing, pages Block Heater Drawing, pages Line Circuit Breaker Drawings, page Warranty………………………………………………...Pages Prototype Test Certifications. ……………………….….Pages Prestartup Checklist………..……………………………Pages

TABLE OF CONTENTSSection Sub-Section LiteratureQuoteModel 150REOZJF Spec SheetsModel KCP-DMTD-0150B Spec SheetsAlternator Data

Alternator Data Sheet 4R13XEmissions Data

Emissions Data Emissions DataEPA Certificate EPA CertificateSCAQMD Permit SCAQMD Permit

Dimensional DrawingsGenerator ADV8183Accessories ADV-7841Controller ADV-7935Enclosure ADV-7825Subbase Tank ADV-7881Transfer Switch ADV-7184

Wiring Schematic DiagramsController Schematic Diagram ADV-8043Controller Wiring Diagram GM79693Controller Wiring Diagram GM78246Interconnection Diagram GM78246Remote Serial Annunciator ADV-6990Remote Serial Annunciator GM62554Transfer Switch GM51950Transfer Switch GM51952

MiscBattery Charger ADV-5971Battery Charger Assembly 233967Block Heater 326220Block Heater GM75555Circuit Breaker GM47475Circuit Breaker GM47476Circuit Breaker Mounting ADV-7371

WarrantyWarranty TP-5373Warranty TP-5374Warranty TP-5561Warranty TP-6087

CertificationISO9001 Certificate G15-152Prototype Test Certificate G18-56

Pre-Startup ChecklistPre-Startup Checklist PreStartUpCheckList

Job Name: Westlake City Schools –Lee Burneson Middle School

Offer:T110211WL-003672Version 3.0

11/2/2011Page 1

DID YOU KNOW BUCKEYE POWER HAS RENTAL GENERATORS To: Mark Pepera

Office of the Treasurer Board of Education of the Westlake City School District 27200 Hilliard Blvd. Westlake, OH 44145

Mark Cronin Power System Sales Buckeye Power Sales 8465 Tower Park Drive Twinsburg, Ohio 44087 P: 330-425-9165 F:330-487-0229 mcronin@buckeyepowersales.com

GENERATOR SET

Model: 150REOZJF This generator set equipped with a 4R13X alternator operating at 277/480 volts is rated for 150 kW/188 kVA. Output amperage: 226

Configuration Qty Description 1 150REOZJF Generator Set, 12V, 60Hz, 6068HF 1 Block Heater, 240V, 2000W 1 Run Relay, 12V 1 DEC3000 2Input/5Output 1 Flexible Fuel Lines 1 Battery Charger,Float w/Alarms,12V-10A 1 Nameplate Rating, Standby 130 Degree 1 Warranty, 5 Year Comprehensive 1 RSA II, ATS Annunciator 1 Power Factor Test,0.8,3Ph Only 1 Certified Test Report 1 Air Cleaner Restriction Ind 1 Skid, Extension 1 Coolant in Genset 6 gals. 2 Lit Kit, 150REOZJF,General Maintenance 1 LCB, 200A, JDL, Therm Mag, 80% 1 Mtg, LCB, J-Frame, 200-250A, 4S

Job Name: Westlake City Schools - Lee BurnesoOffer:T110211WL-003672

Version 3.011/2/2011

1 Decal, UL2200 Listing (Diesel) 1 Neutral, 600A 4S 1 LCB, 100A, HDL, Therm Mag, 80% 1 MTG, LCB2, H-FR TO H/J, 100-150A, 4S/4UA 1 Covers, 4S J-Box H/J-Frame With H/J LCB 1 Voltage,60Hz,277/480V,3Ph,4W,0.8PF 1 Alternator & Mtg. 4R13X 1 Unit, Mtd. Radiator Cooling 1 Skid & Plant Mtg. 1 Air Intake, Standard Duty 1 Controller, DEC3000 800A , 3Ph 1 Control & Harness, 150 JD 4RX/4TX D3K 1 Accessory Inner Panel 1 Enclosure, Sound Steel 1 316 Gallon (24 Hour) , Double Wall, Subbase Diesel Fuel Tank

5 Gallon Spill Containment Leak Detector Alarm Panel Fuel Level Switches – One (1) Low Level and One (1) High Level Tank Equipped with accessories to comply with State of Ohio Requirements

NOTE: On Site Fuel Tank Pressure Testing As Required By The State of Ohio Fire Marshall To Be Performed By Others

NOTE: DIESEL FUEL BY OTHERS

Dimensions – Enclosure & Subbase Tank : 173.8” L x 45.4” W x 88” H Weight – Enclosure & Tank (without fuel): 5,712 lbs

AUTOMATIC TRANSFER SWITCH

ATS-1 ATS-2 Model: KCP-DMTD-0150B 3 Pole, 4 Wire, Solid Neutral, 0150 Amps, Kohler Standard rated automatic transfer switch, Model KCP-DMTD-0150B, rated 480V, 60 Hz, complete with all standard equipment and housed in a NEMA 4 enclosure.

Configuration Qty Description 2 KCP-DMTD-0150B 2 Warranty - ATS, 5 Year Comprehensive

Job Name: Westlake City Schools –Lee Burneson Middle School

Offer:T110211WL-003672Version 3.0

11/2/2011Page 3

1 Start-up including – antifreeze, lube oil, batteries, preparation (single visit during normal business hours) 1 Warranty – five (5) year comprehensive 1 Load bank test – two (2) hours performed during start-up 1 Annual maintenance agreement 1 Maintenance kit 1 Certified test reports – 0.8 pF 2 Operation and maintenance manual

Spec Sheets

150REOZJFDiesel

Standard Features• Kohler Co. provides one-source responsibility for the

generating system and accessories.• The generator set and its components are prototype-

tested, factory-built, and production-tested.• The 60 Hz generator set offers a UL 2200 listing.• The generator set accepts rated load in one step.• The 60 Hz generator set meets NFPA 110, Level 1,

when equipped with the necessary accessories andinstalled per NFPA standards.

• A one-year limited warranty covers all systems andcomponents. Two-, five-, and ten-year extendedwarranties are also available.

• Alternator Features:o The unique Fast-Response X excitation system

delivers excellent voltage response and short circuitcapability using a rare-earth, permanent magnet(PM)-excited alternator.

o The brushless, rotating-field alternator has broadrange reconnectability.

• Other Features:o Controllers are available for all applications. See

controller features inside.o The low coolant level shutdown prevents overheating

(standard on radiator models only).o Integral vibration isolation eliminates the need for

under-unit vibration spring isolators.o Multiple circuit breaker configurations.

Generator Set RatingsStandby130C

RatingsAlternator Voltage Ph Hz kW/kVA Amps4R13X 277/480 3 60 150/188 226RATINGS: All three-phase units are rated at 0.8 power factor. All single-phase units are rated at 1.0 power factor. Standby Ratings: The standby rating is applicable to varying loads for the duration of a poweroutage. There is no overload capability for this rating. Prime Power Ratings: At varying load, the number of generator set operating hours is unlimited. A 10%overload capacity is available for one hour in twelve.Ratings are in accordance with ISO-8528-1 and ISO-3046-1. For limited running time and continuous ratings, consult the factory. Obtain technical information bulletin (TIB-101) for ratings guidelines, completeratings definitions, and site condition derates. The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever.

Model: 150REOZJF, continued

Alternator Specifications

Specifications Alternator

Alternator manufacturer KohlerType 4-Pole, Rotating-FieldExciter type Brushless, Rare-Earth Permanent-MagnetLeads, quantity 12, ReconnectableVoltage regulator Solid State, Volts/HzInsulation NEMA MG1Insulation: Material Class HInsulation: Temperature Rise 130°C, StandbyBearing: quantity, type 1, SealedCoupling Flexible discAmortisseur windings FullVoltage regulation, no-load to full-load RMS Controller DependentOne-Step Load Acceptance 100% of ratingUnbalanced load capability 100% of Rated Standby Current

• Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds.• Sustained short-circuit current enabling down stream circuit breakers to trip without collapsing the alternator field.• Self-ventilated and dripproof construction.• Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long life.• Superior voltage waveform from a two-thirds pitch stator and skewed rotor.

Engine

Engine Specifications

Engine Manufacturer John DeereEngine Model 6068HF285Engine: type 4-Cycle, Turbocharged, Charge Air-CooledCylinder arrangement 6 InlineDisplacement, L (cu. in.) 6.8 (415)Bore and stroke, mm (in.) 106 x 127 (4.19 x 5.00)Compression ratio 17.0:1Piston speed, m/min. (ft./min.) 457 (1500)Main bearings: quantity, type 7, Replaceable InsertRated rpm 1800Max. power at rated rpm, kWm (BHP) 177 (237)Cylinder head material Cast IronCrankshaft material Forged SteelValve (exhaust) material Intake Chromium-Silicon SteelValve (exhaust) material Exhaust Stainless SteelGovernor: type, make/model JDEC Electronic L16 Denso HP3Frequency regulation, no-load to-full load IsochronousFrequency regulation, steady state ±0.25%Frequency FixedAir cleaner type, all models Dry

Exhaust

Exhaust System

Exhaust Manifold Type DryExhaust flow at rated kW, m³/min. (cfm) 33.9 (1197)Exhaust temperature at rated kW, dry exhaust, °C(°F)

510 (950)

Maximum allowable back pressure, kPa (in. Hg) 7.5 (2.2)Exh. outlet size at eng. hookup, mm (in.) 98 (3.86)

Engine Electrical

Engine Electrical System

Battery charging alternator 12 Volt/24 VoltBattery charging alternator: Ground (negative/positive) Negative Volts (DC) 12/24 Ampere rating 65/45Starter motor rated voltage (DC) 12/24Battery, recommended cold cranking amps (CCA): Qty., CCA rating each One, 640/Two, 570Battery voltage (DC) 12

Fuel System

Fuel type DieselFuel supply line, min. ID, mm (in.) 11.0 (0.44)Fuel return line, min. ID, mm (in.) 6.0 (0.25)Max. lift, fuel pump: type, m (ft.) Electronic, 1.8 (6.0)Max. fuel flow, Lph (gph) 96.9 (25.6)Fuel prime pump ManualFuel Filter Secondary 2 Microns@ 98% EfficiencyFuel Filter Primary 30 MicronsFuel Filter Water Separator YesRecommended fuel #2 Diesel

Lubrication

Lubrication System

Type Full PressureOil pan capacity, L (qt.) 27.0 (28.5)Oil pan capacity with filter, L (qt.) 27.9 (29.5)Oil filter: quantity, type 1, CartridgeOil cooler Water-Cooled

Cooling

Radiator System

Ambient temperature, °C (°F) 50 (122)Engine jacket water capacity, L (gal.) 11.3 (3.0)Radiator system capacity, including engine, L (gal.) 25.7 (6.8)Engine jacket water flow, Lpm (gpm) 174 (46)Heat rejected to cooling water at rated kW, dryexhaust, kW (Btu/min.)

76.3 (4340)

Heat rejected to air charge cooler at rated kW, dryexhaust, kW (Btu/min.)

31.8 (1810)

Water pump type CentrifugalFan diameter, including blades, mm (in.) 660 (26)Fan, kWm (HP) 7.7 (10.3)Max. restriction of cooling air, intake and dischargeside of radiator, kPA (in. H20)

0.125 (0.5)

* Enclosure with internal silencer reduces ambient temperature capability by 5°C (9°F). Operation Requirements

Air Requirements

Radiator-cooled cooling air, m³/min. (scfm) * 226.5 (8000)Combustion air, m³/min. (cfm) 13.6 (480)Heat rejected to ambient air: Engine, kW (Btu/min.) 35.9 (2040)Heat rejected to ambient air: Alternator, kW (Btu/min.)

12.3 (700)

*Air density = 1.20 kg/m³ (0.075 lbm/ft³) Fuel Consumption

Diesel, Lph (gph), at % load Rating

Standby Fuel Consumption at 100% load 44.3 Lph (11.7 gph)Standby Fuel Consumption at 75% load 35.1 Lph (9.3 gph)Standby Fuel Consumption at 50% load 26.3 Lph (6.9 gph)Standby Fuel Consumption at 25% load 16.2 Lph (4.3 gph)Prime Fuel Consumption at 100% load 40.6 Lph (10.7 gph)Prime Fuel Consumption at 75% load 32.3 Lph (8.5 gph)Prime Fuel Consumption at 50% load 24.0 Lph (6.3 gph)Prime Fuel Consumption at 25% load 14.4 Lph (3.8 gph)

Dimensions and Weights

Overall Size, L x W x H, mm (in.): 2950 x 1120 x 1527 (116.1 x 44.1 x 60.1)Weight (radiator model), wet, kg (lb.): 1295-1402 (2855-3090)

NOTE: This drawing is provided for reference only and should not be used for planning installation. Contact your local distributorfor more detailed information.

Alternator Data

1TIB-102 4R13X 60 Hz 5/11n

TIB-102

TECHNICAL INFORMATION BULLETIN

Alternator Data SheetAlternator Model: 4R13X

Frequency: 60 HzSpeed: 1800 RPMLeads: 12 (6 Lead, 600 Volt)

kW* (kVA)

Class B Class F Class H

Voltage Power 80°C 90°C 95°C 105°C 130°C 125°C 150°C

L--N/L--L Phase Factor Connection Continuous Lloyds ABS Continuous Standby Continuous Standby

139/2403 0.8 Wye

120.5 127.0 130.0 136.5 150.0 147.0 157.0

277/480 (150.5) (158.5) (162.5) (170.5) (187.5) (183.5) (196.0)

127/2203 0.8 Wye

117.0 123.0 125.5 132.0 143.0 140.5 150.0

254/440 (146.0) (153.5) (156.5) (165.0) (178.5) (175.5) (187.5)

120/2083 0.8 Wye

114.0 119.5 122.0 128.0 137.0 134.5 144.0

240/416 (142.5) (149.0) (152.5) (160.0) (171.0) (168.0) (180.0)

110/1903 0.8 Wye

103.5 108.5 111.0 116.0 124.5 122.0 131.0

220/380 (129.0) (135.5) (138.5) (145.0) (155.5) (152.5) (163.5)

120/240 3 0.8 Delta114.0 119.5 122.0 128.0 137.0 134.5 144.0

(142.5) (149.0) (152.5) (160.0) (171.0) (168.0) (180.0)

120/240 1 1.0 Dogleg91.5 94.5 96.0 99.5 107.0 105.5 109.0

(91.5) (94.5) (96.0) (99.5) (107.0) (105.5) (109.0)

347/600 3 0.8 Wye120.0 126.5 129.5 136.0 149.5 146.5 156.5

(150.0) (158.0) (161.5) (170.0) (186.5) (183.0) (195.5)

* All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without noticeand without any obligation or liability whatsoever.

Submittal Data: 139/240 Volts, 0.8 PF, 1800 RPM, 60 Hz, 3 Phase, 130°C Rise

Symbol PerUnit Ohms Symbol Value

Typical Cold Resistances Typical Time Constants

Phase Resistance 0.107 0.033 Armature Short Circuit Ta 0.008 sec.

Rotor Resistance 20.96 6.436 Transient Short Circuit T’d 0.072 sec.

Typical Reactances Transient Open Circuit T’do 0.885 sec.

Synchronous Typical Field Current

Direct Xd 2.872 0.882 Full Load IfFL 18.5 amps

Quadrature Xq 1.467 0.451 No Load IfNL 5.2 amps

Transient Typical Short Circuit Ratio 0.348

Unsaturated X’du 0.265 0.082 Harmonic Distortion

Saturated X’d 0.234 0.072 RMS Total Harmonic Distortion 3.22%

Subtransient Max. Single Harmonic 5th

Direct X’’d 0.103 0.032 Deviation Factor (No Load, L--L) <5%

Quadrature X’’q 0.098 0.030 Telephone Influence Factor <50

Negative Sequence X2 0.101 0.031 Insulation Class

Zero Sequence X0 0.009 0.003 per NEMA MG1--1.66 H

Phase Rotation ABC

TIB-1022 4R13X 60 Hz 5/11n

* All data tested in accordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or specifications without noticeand without any obligation or liability whatsoever.

4R13X, 60 Hz, 139/240, 277/480 Volts, WyeTYPICAL MOTOR STARTING CHARACTERISTICS*

��E

Output (KW)

4R13X, 60 Hz, 139/240, 277/480 Volts, WyeTYPICAL ALTERNATOR EFFICIENCY*

0.8 PF

Locked Rotor KVA

4R13X, 60 Hz, 139/240, 277/480 Volts, WyeTYPICAL MOTOR STARTING CHARACTERISTICS*

��E

Output (KW)

4R13X, 60 Hz, 139/240, 277/480 Volts, WyeTYPICAL ALTERNATOR EFFICIENCY*

0.8 PF

0 25 50 75 100 125 150 175

0 100 200 300 400 500 600 700

TIB-1024 4R13X 60 Hz 5/11n

10 100 1000 10000Armature Current (A)*

Alternator damage curve 3 phase symmetrical

Line to Line 1ph Line to Neutral 1ph

*Instantaneous current (t=0) is asymmetric. Divide by 1.73 for symmetric.

4R13X, 60 Hz, High Wye ConnectionSHORT CIRCUIT DECREMENT CURVE

Generator Set Controller

Kohler� Decision-Maker� 3000 Controller

General Description and Function

The Decision-Maker� 3000 generator set controller providesadvanced control, system monitoring, and system diagnosticsfor optimum performance.

The Decision-Maker� 3000 controller meets NFPA 110, Level 1when equipped with the necessary accessories and installedper NFPA standards.

The Decision-Maker� 3000 controller uses patented softwarelogic to manage sophisticated functions, such as voltageregulation and alternator thermal overload protection, normallyrequiring additional hardware. Additional features include:

� A digital display and pushbutton/rotary selector dial provideeasy local access to data.

� Measurements selectable in metric or English units.

� Scrolling display shows critical data at a glance.

� Digital display of power metering (kW and kVA).

� Integrated hybrid voltage regulator providing ±0.5%regulation.

� Built-in alternator thermal overload protection.

Industrial Generator Set Accessories

Decision-Maker� 3000

Volts L1--L2:

480.0 V

G6-100 10/10a Page 1

G6-100 10/10a Page 2

OFF/RESET AUTO RUN ALARM SILENCE/

LAMP TEST

Volts L1-L2:

480.0 V

Emergency Stop Switch

Digital Display

Master Control Buttons

Off--Reset/Auto/Run

with Lights

Pushbutton/Rotary

Selector Dial

Alarm Silence/Lamp

Test Button with Light

Annunciator Fault Light

Red--Shutdown,

Yellow--Warning

USB Connection

Alarm Horn (located

inside the controller)

User Interface Controls and Components� Emergency stop switch

� Backlit LCD digital display with two lines of 12 characters(see User Interface Displays for menus)

� Alarm horn indicates generator set shutdown and warning faults

� Environmentally sealed membrane keypad with three master controlbuttons with lights� Off/Reset (red)� Auto (green)� Run (yellow)

� Pushbutton/rotary selector dial for menu navigation� Rotate dial to access main menus� Push dial and rotate to access sub menus� Press dial for 3 seconds to return to top of main menu

� Annunciator fault light� System shutdown (red)� System warning (yellow)

� Alarm silence/lamp test button� Alarm silence� Lamp test

� USB connection� Allows software upgrades� Provides access for diagnostics

� Dedicated user inputs� Remote emergency stop switch� Remote 2-wire start for transfer switch� Auxiliary shutdown

� Integrated hybrid voltage regulator

� Auto-resettable circuit protection mounted on circuit board

� One relay output standard. Optional five relay output available.

� One analog and three digital inputs standard. Optional two inputsavailable.

NFPA 110 RequirementsIn order to meet NFPA 110, Level 1 requirements, the generator set

controller monitors the engine/generator functions and faults shown

below.

� Engine functions:� Overcrank� Low coolant temperature warning� High coolant temperature warning� High coolant temperature shutdown� Low oil pressure shutdown� Low oil pressure warning� High engine speed� Low fuel (level or pressure) *� Low coolant level� EPS supplying load� High battery voltage� Low battery voltage

� General functions:� Master switch not in auto� Battery charger fault *� Lamp test� Contacts for local and remote common alarm� Audible alarm silence button� Remote emergency stop *

* Functions require optional input sensors or kits

User Interface DisplaysThe listing below has � denoting main menus and � denoting sub-menus.

� Overview� Software version� Active shutdowns and warnings (if any are present)� Engine run time, total hours� Average voltage line-to-line� Frequency� Average current� Coolant temperature� Fuel level or pressure *� Oil pressure� Battery voltage

� Engine Metering� Engine speed� Oil pressure� Coolant temperature� Battery voltage

� Generator Metering� Total power, VA� Total power, W� Rated power, %� Voltage, L--L and L--N for all phases� Current, L1, L2, L3� Frequency

� GenSet Information� Generator set model number� Generator set serial number� Controller serial number

� GenSet Run Time� Engine run time, total hours� Engine loaded, hours� Number of engine starts� Total energy, kWh

� GenSet System� System voltage� System frequency, 50 or 60 Hz� System phase, single or three (wye or delta)� Power rating, kW� Amp rating� Power type, standby or prime� Measurement units, metric or English (user selectable)� Alarm silence, always or auto only (NFPA 110)

� GenSet Calibration� Voltage, L--L and L--N for all phases� Current, L1, L2, L3� Reset calibration

� Voltage Regulation� Adjust voltage, ±10%

� Digital Inputs� Input settings and status

� Digital Outputs� Output settings and status

� Analog Inputs� Input settings and status

� Event Log� Event history (stores up to 1000 system events)

* Function requires optional input sensors or kits

G6-100 10/10a Page 3

Controller Features

� AC Output Voltage Regulator Adjustment. The voltageadjustment provides a maximum of ±10% of the system voltage.

� Alarm Silence. The controller can be set up to silence the alarmhorn only when in the AUTO mode for NFPA-110 application orAlways for user convenience.

� Alternator Protection. The controller provides generator setoverload and short circuit protection matched to each alternator forthe particular voltage/phase configuration.

� Automatic Restart. The controller automatic restart featureinitiates the start routine and recrank after a failed start attempt.

� Common Failure Relay. This relay is integrated on the controllercircuit board. Contacts are rated 2 amps at 32 VDC or 0.5 amp at120 VAC.

� Cyclic Cranking. The controller has programmable cyclic cranking.

� ECM Diagnostics. The controller displays engine ECM fault codedescriptions to help in engine troubleshooting.

� Engine Start Aid. The starting aid feature provides control for anoptional engine starting aid.

� Event Logging. The controller keeps a record (up to 1000 entries)for warning and shutdown faults. This fault information becomes astored record of system events and can be reset.

� Historical Data Logging. Total number of generator set successfulstarts is recorded and displayed.

� Integrated Hybrid Voltage Regulator. The voltage regulatorprovides ±0.5% no-load to full-load regulation with three-phasesensing.

� Lamp Test. Press the alarm silence/lamp test button to verifyfunctionality of the indicator lights.

� Measurement Units. The controller provides selection of Englishor metric displays.

� Power Metering. Controller digital display provides kW and kVA.

� Programming Access (USB). Provides software upgrades anddiagnostics.

� Remote Reset. The remote reset function resets faults and allowsrestarting of the generator set without going to the master controlswitch off/reset position.

� RSA II Remote Monitoring Panel. The controller is compatiblewith the Kohler� Remote Serial Annunciator (RSA II).

� Run Time Hourmeter. The generator set run time is displayed.

� Time Delay Engine Cooldown (TDEC). The TDEC provides a timedelay before the generator set shuts down.

� Time Delay Engine Start (TDES). The TDES provides a time delaybefore the generator set starts.

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 * �

ECM communication loss �

ECM diagnostics � �

Engine over speed ��

Engine start aid active

Engine under speed �

Fuel tank leak * � �

High battery voltage �

High coolant temperature � ��

High fuel level * �

Low battery voltage �

Low coolant level �

Low coolant temperature �

Low cranking voltage �

Low engine oil level * � �

Low fuel level (diesel models) * � �

Low fuel pressure (gas models) * �

Low oil pressure � ��

No coolant temperature signal �

No oil pressure signal �

Overcrank ��

Speed sensor fault �

General Functions

Alarm horn silenced

Analog inputs � �

Battery charger fault * �

Chicago code active *

Common fault (includes �) �

Common warning �

Digital inputs � �

Emergency stop ��

Engine cooldown (delay) active

Engine start delay active

Engine started

Engine stopped

EPS supplying load

Generator running

Input/output communication loss �

Internal failure �

Master switch not in auto �

NFPA 110 alarm active

Remote start

System ready

Generator Functions

AC sensing loss � �

Alternator protection �

Ground fault input * �

kW overload �

Locked rotor �

Overfrequency �

Overvoltage (each phase) �

Underfrequency �

Undervoltage (each phase) �

� Standard functions

� Available user functions

* Functions require optional input sensors or kits� Items included with common fault shutdown

DISTRIBUTED BY:

G6-100 10/10a Page 4

Controller SpecificationsDecision-Maker� 3000—Software Version 1.00 or higher

� Power source with circuit protection: 12- or 24-volt DC� Power drain: 200 milliamps� Humidity range: 5% to 95% noncondensing� Operating temperature range: --40°C to +70°C (--40°F to +158°F)� Storage temperature range: --40°C to +85°C (--40°F to +185°F)� Standards:

� CE Directive� NFPA 99� NFPA 110, Level 1� UL 508� ASTM B117 (salt spray test)

� Panel dimensions—W x H, 229 x 160 mm (9.0 x 6.3 in.)

Decision-Maker� 3000 Available Options

� Float/Equalize Battery Charger available with 6 or 10 amp DC voltoutput. The 10 amp models are available with and without NFPAalarm to signal a battery charger fault.

� Prime Power Switch prevents battery drain during generator setnon-operation periods and when the generator set battery cannotbe maintained 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 Kohler� Remote SerialAnnunciator (RSA II) enables the operator to monitor the status ofthe generator set from a remote location, which may be required forNFPA 99 and NFPA 110 installations.

� 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 120VAC.

� Two Input/Five Output Module provides a generator set mountedpanel with two inputs and five relay outputs.

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 1-800-544-2444KohlerPower.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 Kohler�generator set distributor for availability.

Industrial Generator Set AccessoriesSound Enclosure

with Lift BasePackage

Sound Enclosure Standard Features• Internal-mounted critical silencer and flexible exhaust

connector.• Lift base-mounted or tank mounted steel construction

with hinged doors.• Fade-, scratch-, and corrosion-resistant Kohler®

cream beige and black powder-baked finish.• Lockable, flush-mounted door latches.• Vertical air inlet and outlet discharge to redirect air and

reduce noise.• Lift base or tank-mounted, steel construction with

hinged doors.• Accoustic insulation that meets UL 94 HF1

flammability classification and repels moistureabsorption.

• Sound attentuated enclosure that uses up to 51 mm(2 in.) of acoustic insulation.

Subbase Fuel Tank Features• The above-ground rectangular secondary

containment tank mounts directly to the generator set,below the generator set skid (subbase).

• Both the inner and outer tanks have emergency reliefvents.

• Flexible fuel lines are provided with subbase fuel tankselection.

• The secondary containment generator set base tankmeets UL 142 tank requirements. The inner (primary)tank is sealed inside the outer (secondary) tank. Theouter tank contains the fuel if the inner tank leaks orruptures.

Sound Enclosure with Lift Base Package, continued

Sound Enclosure Features• Available in steel (14 gauge) formed panel, solid construction. Preassembled package offering dent resilient structure

mounting directly to lift base or fuel tank.• Powder-baked paint. Superior finish, durability, and appearance.• Internal critical exhaust silencer offering maximum component life and operator safety.• Interchangeable modular panel construction. Allows complete serviceability or replacement without compromising

enclosure design.• Cooling/combustion air intake with a horizontal air inlet. Sized for maximum cooling airflow.• Service access. Multi-personnel doors for easy access to generator set control and servicing of the fuel fill, fuel gauge, oil

fill and battery.• Cooling air discharge. Weather protective design featuring vertical air discharge. Exhausts air through a punched air outlet

grille.• Attenuated design. Acoustic insulation UL 94 HF1 listed for flame resistance offering up to 51 mm (2 in.) mechanically

restrained acoustic insulation.• Cooling air discharge. The sound enclosures include acoustic insulation with urethane film.Fuel TankCapacity, L

(gal.)

Est. FuelSupply

Hours at60 Hz

with FullLoad

Max.Length,mm (in.)

Max.Width,

mm (in.)

Enclosureand Fuel

TankLength,mm (in.)

Enclosureand Fuel

TankWidth, mm

Enclosureand Fuel

TankWeight, kg

Enclosureand Fuel

TankHeight, mm

FuelTank

Height(H),mm(in.)

SoundPressure

at 7m(23ft.),dB(A)

Max.Height,

mm(in.)

Weight,kg (lb.)

Lift base 0 3532(139.0)

1153(45.4)

1860(4101)

1753 (69) 73

1198 (316) 24/27 4414(173.8)

1153(45.4)

2591(5712)

2236 (88) 73

Industrial Generator Set AccessoriesFloat/Equalize

Battery Charger

Standard Features• Kohler automatic battery chargers feature two

charging modes to keep lead-acid and nickel-cadmium batteries fully charged without overcharging.The battery charger automatic float-to-equalizeoperation maintains battery voltage with no manualintervention.

• Temperature compensation feature preventsovercharging or undercharging battery at high/lowambient temperatures.

• Current-limiting circuitry prevents battery charger fromoverload at low battery voltage and during a shortcircuit. The ten amp DC current limit allows the batterycharger to remain connected to the battery duringengine cranking.

• Battery charger complies with NFPA 110 coderequirements when equipped with optional alarmcircuit board. Alarm board features low batteryvoltage, high battery voltage, and battery chargermalfunction alarm contacts.

SpecificationsInstalled Battery NFPA 110 Alarm Outputs Output Number of Cells

Voltage Amps Lead Acid Ni-CdPAD-292863 Yes 12 10 6 9

Battery Charger Kit PAD-292863Input Voltage 120/240 VACInput Frequency 120/240VAC, 50/60 HzDC Voltage Regulation ±1%Dimensions (L x W x D) 271 x 143 x 422 mm (10.67 x 5.63 x 16.63 in.)Weight 11.8 kg (26 lb.)

Float/Equalize Battery Charger, continued

Automatic Float to Equalize When the battery loses its charge, the battery chargeroperates in the High Rate Constant Current Mode until thebattery voltage rises to the preset equalize level.At thepreset equalize level, the battery charger switches to theconstant voltage Equalize Mode until the current requiredto maintain this voltage drops to 50% of the batterycharger's high rate current.The battery charger thenswitches to the lower constant voltage Float Mode whenthe battery nears full charge. The battery chargercontinues to operate in this mode until AC input powerdisconnects or the current required to maintain the batteryat the float voltage setting exceeds 6 amps.

Temperature Compensation The battery charger compensates for battery temperatureusing a negative temperature coefficient. The batterycharger provides temperature compensation of -2mv/°Cper cell over the ambient temperature range of -40°C upto 60°C. The temperature compensation automaticallyadjusts the float and equalize voltage settings to preventthe battery from overcharging at high ambienttemperatures and undercharging at low ambienttemperatures.

Standard Features

• Ammeter and voltmeter indicate battery charging rate with 5% full-scale accuracy. POWER ON lamp indicates batterycharger is operating.

• AC input and DC output fuses prevent battery charger damage from abnormal overload and short-circuit conditions.

• Operational temperature range is from 40°C (--40°F) to 60°C (140°F). Battery charger float equalize voltageautomatically adjust throughout the temperature range.

• Reverse polarity protection circuitry prevents battery charger from energizing if improperly connected.

• Internal terminal blocks for AC input and DC output/ sensing lead connections.

• DC voltage regulation of ±1% from no load to full load and AC input line voltage variations of ±10%.

• UL listed/CSA certified.

• Wall-mount, slotted enclosure with knockouts for customer conduit installation. Reconnection blocks allowoperation at 120 or 240 volts AC, single phase, 50 or 60 hertz.

• Battery charger circuitry protected from AC line and DC load voltage spikes and transients.

• Terminal block for remote battery sensing leads.

• Automatic float-to-equalize operation with individual potentiometer adjustments. Charge up to 12 lead-acid or 18nickel-cadmium battery cells.

• No adjustments are necessary for lead-acid or nickel-cadmium batteries.

• Oversized transformer and SCR heatsink allow constant current charging at 10 amps up to the equalize voltagesetting for fastest battery charging. Note: The battery charger will discharge the engine starting battery(ies) when the battery charger is connected to thebattery(ies) and is not connected to an AC power supply. To prevent engine starting battery(ies) discharge, install batterycharger relay kit GM39659.

Standard Features

� The line circuit breaker interrupts the generator setoutput during a short circuit and protects the wiring

when an overload occurs. Use the circuit breaker to

manually disconnect the generator set from the load

during generator set service.

� Circuit breaker kits are mounted to the generator setand are available standard with load-side lugs or

bus bars and neutral bus bar.

� Kohler Co. offers a wide selection of molded-case

line circuit breaker kits including single and dual

configurations for each generator set.

� Four types of line circuit breakers are available:

� Magnetic trip

� Thermal magnetic trip

� Electronic trip

� Electronic with Ground Fault Circuit Interruption

(GFCI) trip

� In addition, line circuit breakers are offered with 80%

and 100% ratings (thermal magnetic available only

in 80% rating).

� Single line circuit breaker kits allow circuit protection

of the entire electrical system load.

� Dual line circuit breaker kits allow circuit protection

of selected priority loads from the remaining

electrical system load.

� Line circuit breakers comply with the following codes

and standards unless otherwise stated.

� UL 489 Molded Case Circuit Breakers

� UL 1077 Supplementary Protectors

� UL 2200 Stationary Engine Generator Assemblies

Line Circuit Breakers 20--2250 kW

Dual Circuit Breaker Kit with Neutral Bus Bar20--300 kW Model Shown

Single Circuit Breaker Kit with Neutral Bus Bar20--300 kW Model Shown

G6-88 9/10d

Line Circuit Breaker Types

Magnetic Trip

The magnetic trip features an electromagnet in series with theload contacts and a moveable armature to activate the tripmechanism. When a sudden and excessive current such as ashort circuit occurs, the electromagnet attracts the armatureresulting in an instantaneous trip (UL 1077 circuit breakers).

Thermal Magnetic Trip

Thermal magnetic trip contains a thermal portion with abimetallic strip that reacts to the heat produced from the loadcurrent. Excessive current causes it to bend sufficiently to tripthe mechanism. The trip delay is dependant on the durationand excess of the overload current. Elements are factory-calibrated. A combination of both thermal and magneticfeatures allows a delayed trip on an overload and aninstantaneous 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.

Electronic with Ground Fault Trip

The ground fault trip feature is commonly referred to as GroundFault Circuit Interruption (GFCI). Models with GFCI comparecurrent flow in phase and neutral lines, and trip when currentunbalance 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 has noeffect on the ground fault pickup values.

80% Rated Circuit Breaker

Most molded-case circuit breakers are 80% rated devices. An80% 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 required tobe rated for 100% of the circuit breaker’s rating.

The 80% rated circuit breakers are typically at a lower cost thanthe 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.

Accessories

� 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 isreset.

� Auxiliary Contacts

These switches send a signal indicating whether the maincircuit breaker contacts are in the open or closed position.

� Bus Bars (units without circuit breakers installed)

Bus bar kits are available on alternators with leads forconnection to the generator set when circuit breakers are notordered. Bus bar kits offer a convenient way to connect loadleads to the generator set when a circuit breaker is not present.

� Ground Fault Annunciation

A relay contact for customer connection indicates a ground faultcondition 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 inthe OFF position only.

� Neutral Lugs

Various neutral lug sizes are available to accommodate multiplecable sizes for connection to the bus bar only.

� 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.

� 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 therated voltage.

� 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 circuitbreaker to be tripped by customer-selected faults such asalternator overload or overspeed. The circuit breaker must bereset locally after being tripped. Tripping has priority overmanual or motor operator closing.

� Shunt Trip Wiring

Connects the shunt trip to the generator set controller.

G6-88 9/10d

Line Circuit Breaker Specifications

80% Rating Circuit Breaker

Gen. SetkW

Alt.Model

AmpereRange Trip Type

C. B.FrameSize

20--60 4P/4Q

30--100

Magnetic, UL 1077

E(480 Vmax.)

Magnetic, UL 1077with 12 V shunt trip

15--150 Thermal magnetic H

175--250 Thermal magnetic J

60--180 4S/4V

30--100

Magnetic, UL 1077

E(480 Vmax.)

300--400 Thermal magnetic L

600Electronic

DElectronic GFCI

700--800 Thermal magnetic M

800 ElectronicP

800 Electronic GFCI

200--300 4UA

600Electronic

DElectronic GFCI

1000--1200 Thermal magnetic P

800--1200 ElectronicP

800--1200 Electronic GFCI

350--900(small ext.

box)(no 5M4044)

4M/5Mw/leads

600Electronic

DElectronic GFCI

1000--1200 Thermal magnetic P

800--1200Electronic

PElectronic GFCI

350--900(large ext.box) (no

5M4044) *�

4M/5Mw/leads

1600--2500

Thermal magnetic

RElectronic

Electronic GFCI

1000-- 2250and 900 kWwith 5M4044

(largeext. box) *�

5M/7Mw/busbars

1200--2500

Thermal magnetic

RElectronic

Electronic GFCI

* Available as front or rear facing circuit breaker on junction box.Front facing circuit breakers are not available on the600--2000REOZM, 600--2000REOZMB, and 400--800RZW models

� Front facing circuit breakers for 450/500REOZVB models are availablefor units with standard air cleaner and not with heavy-duty air cleaner.

� The 5M4044 is a 4-bus alternator and has bus-type mounting.

� Contact the factory for this rating.

100% Rating Circuit Breaker

Gen. Set kWAlt.

ModelAmpereRange Trip Type

C. B.FrameSize

20--60 4P/4Q 150--400Electronic

DElectronic GFCI

60-180 4S/4V

150--400Electronic

DElectronic GFCI

600--800Electronic

PElectronic GFCI

200--300 4UA

150--400Electronic

DElectronic GFCI

600--1200Electronic

PElectronic GFCI

350--900(small ext. box)(no 5M4044)

4M/5Mw/leads

150--400Electronic

DElectronic GFCI

600--1200Electronic

PElectronic GFCI

350--900(large ext. box)(no 5M4044) *�

4M/5Mw/leads

1600--2500Electronic

RElectronic GFCI

3000Electronic

NWElectronic GFCI

1000-- 2250 and900 kW with5M4044 (largeext. box) *�

5M/7Mw/busbars

1200--2500Electronic

RElectronic GFCI

3000Electronic

NWElectronic GFCI

Circuit Breaker Lugs Per Phase (Al/Cu)Frame Size Ampere Range Wire Range

E(480 V max.)

30--100Up to two wire terminals fitting

10-32 or 1/4-20 stud

H 15--150 One #14 to 3/0

J175 One 1/0 to 4/0

200--250 One 3/0 to 350 kcmil

L 300--400 One #1 to 600 kcmil Al

150--400One #2 to 500 kcmil Al

One #2 to 600 kcmil Cu

600Two 2/0 to 500 kcmil Al

Two 2/0 to 350 kcmil Cu

M 700-800 Three 3/0 to 500 kcmil

P600-800 Three 3/0 to 500 kcmil

1000-1200 Four 3/0 to 500 kcmil

R 1600-2500 (8) lugs per phase rated for(1) #4--600 kcmil or(2) 1/0--250 kcmilNW 2500/3000

Interrupting RatingsInterrupting Rating

Code240 Volt,

kA480 Volt,

kA600 Volt,

B 10 — —

D 25 18 14

G 65 35 18

J 100 65 25

K (except P Frame) 65 � 65 � 65 �

K (P Frame) 65 � 50 � 50 �

L (except NW Frame) 125 � 100 � 50 �

H (NW Frame) 100 � 100 � 85 �

L (NW Frame) 200 � 150 � 100 �

DISTRIBUTED BY:

G6-88 9/10d

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 RemainingBuilding Loads

To Priority Load(s)

Line C.B.

Single line circuit breaker configuration where circuit breaker tripcan trip causing all power to building loads including priority loadto be disrupted.

DistributionPanel

Dual Circuit Breaker Installations

A generator set with dual circuit breakers installed is used tosegregate critical loads. Typically, one circuit breaker will feed amain transfer switch with noncritical loads and the other circuitbreaker will feed a second transfer switch that feeds criticalloads.

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 supplyingpower to priority load(s).

ATS ATS

DistributionPanel

Dual Circuit Breaker Combinations

AlternatorModel

FirstC. B. Frame

SecondC. B. Frame

Size Comments

4P/4Q/4S/4V/4UA

4S/4V/4UA L —

4P/4Q/4S/4V/4UA

D —100% rating, standard orGFCI

4S/4V/4UA

P —100% rating, standard orGFCI

4P/4Q/4S/4V/4UA

J H or J

4S/4V/4UA L H, J, or L

4P/4Q/4S/4V

D H, J, L, or D 100% rating, no GFCI

4UA D H, J, L, or DPrimary or sec. available as100% rating, std. or GFCI

AlternatorModel

FirstC. B. Frame

SecondC. B. Frame

Size Comments

4S/4V M H, J, L, or D 100% rating, no GFCI

4UA M H, J, L, or D D available as GFCI

4S/4V P H, J, L, or D 100% rating, no GFCI

4UAP H, J, L, or D

P and/or D available asGFCI

P P 100% rating, no GFCI

4M/5M/7M All —Dual circuit breakerconfigurations available asEngineered Specials

Availability is subject to change without notice. Kohler Co. reserves theright to change the design or specifications without notice and without anyobligation or liability whatsoever. Contact your local Kohler� generator setdistributor for availability.

Powerpact® H- and J-Frame 15A to 250AMolded Case Circuit Breakers

Delivering unmatched application flexibility

Well-suited to a wide range of applications, the Powerpact H- andJ-Frame Molded Case Circuit Breakers feature a full complement offield installable accessories, field installable trip units and improvedinterrupting ratings. These Molded Case Circuit Breakers deliverunmatched design flexibility for 15A to 250A applications and shareidentical mounting holes, handle locations, trim dimensions andaccessories, allowing customers to standardize equipment designsfor 15A to 250A applications.

Full-Featured Performance

� H-Frame – 150A available in both standard and 100% ratingswith standard amperage ratings from 15 to 150A. Interruptingratings (AIR) include D-18kA, G-35kA, J-65kA and L-100kA at480VAC

� J-Frame – 250A available in both standard and 100% ratings with standard amperage ratings from 150A to 250A. Interruptingratings (AIR) include D-18kA, G-35kA, J-65kA, and L-100kAat 480VAC

� Field installable accessories are common for H- and J-FrameCircuit Breakers to make stocking and installation easy

� Unique snap-in terminals make converting bus bar and lugconfigurations simple and easy

� Field-installable trip units lower inventory costs and reducestocking space by configuring products at point of use

� Allows design standardization for 15A to 250A applications withcommon mounting holes, handle locations, and trim dimensionsfor both H- and J-Frame Circuit Breakers

� Many configuration options provide application flexibility, withI-Line®, plug-in, drawout, rear connected, distribution lug, crimplug and din-rail configurations

� Motor operators, rotary handles and cable operators provideoptions for integrating into a variety of applications

� Certified to global standards, including UL, IEC, CSA and NOM

H-Frame 150A

HD and HG 2-Pole

J-Frame 250A

PowerpactH-J-Mhandouts 4/8/04 3:44 PM Page 1

Consolidate Inventory

Reduce inventory costs with thePowerpact H- and J-Frame Molded CaseCircuit Breakers. These circuit breakersare designed to work with commoncomponents like operating handles,auxiliary switches, shunt trips and manyother accessories. They also offer savingsin the form of rationalized mounting pans,door trims and enclosures.

Standardize Designs

Designed to help simplify the design process, the Powerpact H- andJ-Frame Molded Case Circuit Breakers feature common mountingholes, handle locations and trim dimensions.

H-Frame J-Frame H-Frame J-Frame

Simplify Installation

Field-installable accessories provide flexibilityfor late specification changes or installationat point of use. Auxiliary switches, shunt tripand undervoltage release are easy to install,reliable and common to many PowerpactCircuit Breakers.

Streamline Design Integration

Comprehensive technical literature, CADdrawings and 3D models are available onlineto support the Powerpact H- and J-FrameCircuit Breaker line. In addition, 3D modelscan be downloaded in most CAD formats.

Easy to Convert

Unique snap-in lugs makeconverting between busbar and lug optionssimple and easy. Whetherthe application calls forlugs on the line side, loadside or both, conversionsare simple, making thePowerpact H- andJ-Frame Molded CaseCircuit Breakers ideal forapplications that requireconfiguring products atthe point of use. Theterminal nut or mechan-ical lug is set on a plasticretainer that slides andsnaps into place, withoutthe use of tools.

Bus Bar Option

Lug Option

Auxiliary switch(OF1)

Auxiliary switch(OF2)

Alarm switch(SD)

Overcurrent tripswitch (SDE)

Shunt trip (MX)or undervoltagetrip (MN)

Ordering Flexibility for Various Applications

� Purchase Standard Circuit BreakerFeatures fixed trip unit capable of reverse connection.

� Circuit Breaker and Separate Trip Units*

Save valuable inventory costs by configuring products at point of use. Only three

frame sizes are needed to cover the entire range from 15A to 250A (shown below

with H-Frame Circuit Breaker).

� Purchase the Complete Circuit Breaker with Field-Interchangeable Trip Unit*

Respond to last minute specification changes with the flexibility of a field

interchangeable trip unit.

Powerpact® H- and J-Frame 15A to 250AMolded Case Circuit Breakers

Contact your Square D salesrepresentative for additional information.Or, visit www.us.SquareD.com.

03-04Order Number 0611HO0401

Schneider Electric - North American Operating Division

1415 S. Roselle RoadPalatine, IL 60067Tel: 847-397-2600Fax: 847-925-7500

Multiple Configurations

Cradle Plug-in Base I-Line Rear Connected

*Marked line and load and not suitable for reverse connection

0.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 9 10 15 20 30 40 50 60 70 80 90 100

1000500

8090100

8009001000

80009000

1.5 .6 .7 .8 .9 1.5

2 3 4 5 6 7 8 9 10 15 20 30 40 50 60 70 80 90 100

MULTIPLES OF RATED CURRENT

.009.01

800900

80009000

1/2 CYCLE(60 Hz)

1/2 CYCLE(50 Hz)

1 CYCLE(60 Hz)

1 CYCLE(50 Hz)

MAXIMUM CLEARING TIME(AT 50 Hz) (AT 60 Hz)

7080100

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 BREAKERSCHARACTERISTIC TRIP CURVE NO. 50-3

CIRCUIT BREAKER INFORMATION

Circuit Breaker Continuous Maximum NumberPrefix 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. TheEZ-AMP overlay feature at the bottom of the page should be used duringcoordination 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 2004

Drawing No. 48095-050-03

0.5 .6 .7 .8 .9 1 2 3 4 5 6 7 8 9 10 15 20 30 40 50 60 70 80 90 100

1000500

8090100

8009001000

80009000

1.5 .6 .7 .8 .9 1.5

2 3 4 5 6 7 8 9 10 15 20 30 40 50 60 70 80 90 100

.009.01

800900

80009000

1/2 CYCLE(60 Hz)

1/2 CYCLE(50 Hz)

1 CYCLE(60 Hz)

1 CYCLE(50 Hz)

LIMITS HIGHSETTING

LIMITS LOWSETTING

MAGNETIC TRIPADJUSTMENT RANGE

MAXIMUM CLEARING TIME(AT 50 Hz) (AT 60 Hz)

250 17

MAXIMUM SINGLE-POLE TRIP TIMESAT 25°C BASED ON NEMA AB-4 2003

JD, JG, JJ, JL MOLDED CASE CIRCUIT BREAKERSCHARACTERISTIC TRIP CURVE NO. 50-5

CIRCUIT BREAKER INFORMATION

Circuit Breaker Continuous Maximum NumberPrefix Ampere Rating AC Voltage of Poles

JD, JG, JJ, JL 150–250 600 2, 3

This curve is to be used for application and coordination purposes only. TheEZ-AMP overlay feature at the bottom of the page should be used duringcoordination 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. 0050TC0405June 2004

Drawing No. 48095-050-05

Remote Annunciator RSA IIfor Kohler� Controllers� Monitors the generator set equipped with one of the following

controllers:

Decision-Maker� 550 Software Version 2.10 and higher

Decision-Maker� 3+ Software Version 1.13 and higher

KPC 1000 Version 1.37 and higher

� Allows monitoring of the common alarm, remote testing of theautomatic transfer switch, and monitoring of the normal/emergency source with one of the following controllers:

MPAC� 1000 Version 1.27 and higher

MPAC� 1500 Version 1.00 and higher

� Configuration via a personal computer (PC) software.

� RSA II panel includes writable surfaces (four white boxes inillustration) for user-defined selections.

� Uses Modbus� protocol, an industry standard.

� Controller connections:

RS-485 for serial bus network

USB device port for PC

12-/24-volt DC power supply

120/208 VAC power supply (available accessory)

� Meets the National Fire Protection Association StandardNFPA 110, Level 1.

Dimensions

� Dimensions—W x H x D, mm (in.). Also fits in a standard203 mm x 203 mm (8 in. x 8 in.) Hoffman box.

Surface Mounted:203 x 203 x 56 (8.0 x 8.0 x 2.2)

Flush Mounted:203 x 203 x 58 (8.0 x 8.0 x 2.3)Flush mounting plate W1: 229 (9.0)

Modbus� is a registered trademark of Schneider Electric.

Remote Annunciator (RSA II)

Surface Mounted Flush Mounted

RSA II

RSA II with ATS Controls

Failure

G6-95 2/09b

Fault and Status Conditions Fault LEDs Fault HornSystem

Ready LEDGenerator

Running LEDCommunication

Status LED

Overcrank Shutdown Red On Red Off Green

High Engine Temperature Warning * Yellow On Red Green Green

High Engine Temperature Shutdown Red On Red Off Green

Low Oil Pressure Warning * Yellow On Red Green Green

Low Oil Pressure Shutdown Red On Red Off Green

Overspeed Shutdown Red On Red Off Green

Emergency Stop * Red On Red Off Green

Low Coolant Level/Aux. Shutdown Red On Red Off Green

Low Coolant Temperature * Yellow On Red Off Green

Low Cranking Voltage Yellow On Red Off Green

Low Fuel—Level or Pressure * Yellow On Red Green or Off Green

Not-In-Auto Red On Red Green or Off Green

Common Fault Red On Green Green or Off Green

Battery Charger Failure (550 controller) * Yellow On Red Green or Off Green

Battery Charger Failure (16-light controller) * Yellow On Green Green or Off Green

High Battery Voltage * Yellow Off Green Green or Off Green

Low Battery Voltage * Yellow Off Green Green or Off Green

User Input #1 (Warning) Yellow Off Green Green or Off Green

User Input #1 (Shutdown) Red On Green Off Green

User Input #2 (Warning) Yellow Off Green Green or Off Green

User Input #2 (Shutdown) Red On Green Off Green

User Input #3 (Warning) (550 controller) � Yellow Off Green Green or Off Green

User Input #3 (Shutdown) (550 controller) � Red On Green Off Green

EPS Supplying Load Yellow Off Green Green Green

Communications Status (Fault mode) — Off Green or Red Green or Off Red

ATS Fault (RSA II with ATS Controls only) Red On Red or Yellow Green or Off Green

Green LEDs appear as steady on when activated.Yellow LEDs slow flash when activated except steady on with EPS supplying load and high battery voltage.Red LEDs slow flash when activated except fast flash with loss of communication and not-in-auto.

Specifications

� LED indicating lights for status, warning, and/or shutdown.See the above chart for details.

� Power source with circuit protection: 12- or 24-volt DC

� Power source with120/208 VAC, 50/60 Hz adapter (option)

� Power draw: 200 mA

� Humidity range: 0% to 95% noncondensing

� Operating temperature range: --20°C to +70°C(--4°F to +158°F)

� Storage temperature range: --40°C to +85°C(--40°F to +185°F)

� Standards:

� NFPA 110, level 1

� UL 508 recognized

� CE directive

� NFPA 99

� EN6II-4-4 fast transient immunity

� RS-485 Modbus� isolated port @ 9.6/19.2/38.4/57.6 kbps(default is 19.2 kbps)

� USB device port

� NEMA 2 enclosure

ATS Controls (RSA II with ATS controls only)

� ATS position LED (normal or emergency)

� Power source indicator LED (normal or emergency)

� ATS fault LED

� Key-operated spring-loaded test switch(Re-Transfer/Auto/Test)

NFPA Requirements

� NFPA 110 compliant

� Engine functions:

� High battery voltage warning *

� High engine temperature shutdown

� High engine temperature warning *

� Low battery voltage warning *

� Low coolant level/aux. shutdown

� Low coolant temperature warning *

� Low cranking voltage

� Low fuel warning (level or pressure) *

� Low oil pressure shutdown

� Low oil pressure warning *

� Overcrank shutdown

� Overspeed shutdown

� General functions:

� Audible alarm silence

� Battery charger fault *

� Lamp test

� Master switch not-in-auto

* May require optional kit or user-provided device to enable function andLED indication.

� Digital input #3 is factory-set for high battery voltage on the 16-lightcontroller.

G6-95 2/09b

Fault and Status LEDs and Lamp Test SwitchAlarm Horn. Horn sounds giving a minimum 90 dB at0.1 m (0.3 ft.) audible alarm when a warning or shutdownfault condition exists except on high/low battery voltage or EPSsupplying load.

Alarm Silenced. Red LED lights when alarm horn isdeactivated by alarm silence switch (lamp test switch).

Alarm Silence Switch. Switch quiets the alarm duringservicing. The horn will reactivate upon additional faults.

ATS Fault. Red LED lights when ATS fails to transfer.

Aux. See Low Coolant Level/Aux.

Battery Charger Failure. LED lights if battery chargermalfunctions. Requires battery charger with alarm contact.

(High/Low) Battery Voltage. LED flashes if battery orcharging voltage drops below preset level. LED lights steadyif battery voltage exceeds preset level.

Common Fault. LED lights when a single or multiplecommon faults occur.

Communication Status. Green LED lights indicatingannunciator communications functional. Red LED indicatescommunication fault.

Emergency Power System (EPS) Supplying Load. LEDlights when the generator set is supplying output current (550controller) or when transfer switch is in the emergency position(16-light controller).

Emergency Stop. LED lights and engine stops whenemergency stop is made. May require a local emergencystop switch on some 16-light controllers.

Generator Running. LED lights when generator set is inoperation.

(Generator Switch) Not In Auto. LED lights when generatorset master switch is in RUN or OFF/RESET position.

High Engine Temperature. Red LED lights if engine has shutdown because of high engine coolant temperature. YellowLED lights if engine coolant temperature approaches shutdownrange. Requires warning sender on some models.

Lamp Test Switch. Switch tests all the annunciator indicatorLEDs and horn.

Low Coolant Level. LED lights when engine coolant level isbelow acceptable range on radiator-mounted generator setsonly. When used with a 16-light controller, the LED indicateslow coolant level or an auxiliary fault shutdown. Requires user-supplied low coolant level switch on remote radiator models.

Low Coolant Temperature. LED lights if optional engine blockheater malfunctions and/or engine coolant temperature is toolow. Requires prealarm sender on some models.

Low Cranking Voltage. LED lights if battery voltage dropsbelow preset level during engine cranking.

Low Fuel (Level or Pressure). LED lights if fuel level in tankapproaches empty with diesel models or fuel pressure is low ongas models. Requires customer-supplied switch.

Low Oil Pressure. Red LED lights if generator set shuts downbecause of insufficient oil pressure. Yellow LED lights if engineoil pressure approaches shutdown range. Requires warningsender on some models.

Overcrank. LED lights and cranking stops if engine does notstart in either continuous cranking or cyclic cranking modes.

Overspeed. LED lights if generator set shuts down because ofoverspeed condition.

System Ready. Green LED lights when generator set masterswitch is in AUTO position and the system senses no faults.Red LED indicates system fault.

User-Defined Digital Inputs #1, #2, and #3. Monitors threedigital auxiliary inputs (status, warnings, and/or shutdowns).Individual red LEDs flash when a fault occurs or the statuschanges. User-defined digital input #1 and #2 are selected viathe RSA II master for local or remote (generator set or ATS).The user-defined digital input can be assigned at the controlleror via PC software.

16-Light Controller. When remote, digital input #1 and #2are tied to the communication module. When local, they aretied directly to the RSA II master. Digital input #3 is factory-setfor high battery voltage.

550 Controller. When remote, digital inputs #1, #2, and #3are tied to controller digital inputs (D7, D8, and D10). Whenlocal, user-defined digital inputs #1 and #2 are tied directly tothe RSA II master. Input #3 can only be configured for local orremote (generator set).

Communications (Shown with RSA II with ATS Controls)Local Single (Master) Connection

A single RSA II connects directly to the controller’scommunication port with an RS-485 cable.

Generator setcontroller

Remoteannunciator(master)

PC(user-supplied)

Use RS-485, see Note*Available on 550 controller

with KBus only

CommunicationModule

(16-light only)Transfer Switch

Use RS-485,see Note*

Local Multiple (Master/Slave) Connections

A single RSA II master connects directly to the controller’scommunication port with an RS-485 cable. Additional RSA IIs(slaves) can connect to the single master RSA II. Status of theRSA II (master) is annunciated on the RSA II (slave) panel.

CommunicationModule

(16-light only)

Generator setcontroller

Remoteannunciator(master)

Remoteannunciator

(slave)

Remoteannunciator

(slave)

Transfer Switch

Note*: Use RS-485 for a total of up to 1220 m (4000 ft.) maximum from the first device to the last device.

DISTRIBUTED BY:

G6-95 2/09b

Modbus�/Ethernet, Single Master or Multiple Master/Slave Connections(Shown with RSA II with ATS Controls)

An RSA II master communicates with a controller and RSA IIslaves through an Ethernet network. A Modbus�/Ethernetconverter is required for each RSA II and controller. RS-485cable connects the RSA II to the converter. Category 5e (Cat5e) network cable connects the Modbus�/Ethernet converter tothe Ethernet.

Note: When combining RSA II remote annunciators with theRSA 1000 it is permissible provided that the masterremote annunciator is a RSA II remote annunciator.

Note*: UseRS-485 for a total of up to 1220 m (4000 ft.) maximum

from the first device to the last device.

Generator setController

Remote Annunciator(Master)

CommunicationModule

(16-light only)

Ethernet

Remote Annunciator(Slave)

Modbus�/EthernetConverter

Remote Annunciator(Slave)

TransferSwitch

Accessories

� Power source adapter kit 120/208 VAC, 50/60 Hz.

� Modbus�/Ethernet converter GM41143-KP2 for serial toEthernet communication.

� Communication module GM32644-KA1 or GM32644-KP1 isrequired with Decision-Maker� 3+ controllers.

Availability is subject to change without notice. Kohler Co. reserves theright to change the designor specificationswithout noticeandwithoutanyobligation or liability whatsoever. Contact your local Kohler� generatorset distributor for availability.

Model KCP-DMTD-0150B

Transfer Switch Standard Features• UL 1008 listed at 480 VAC file #E58962 (automatic), #E86894

(nonautomatic)• CSA certification available• IBC seismic certification available• Standard-transition or programmed-transition modes of

operation with either automatic or non-automatic control• Available in 2, 3, or 4 pole configurations• Electrically operated, mechanically held mechanism• Double-throw, mechanically interlocked design (break-before-

make power contacts)• Solid, switched, or overlapping neutral (make-before-break)• High withstand and close-on ratings• Design suitable for emergency and standby applications on all

classes of load, 100% tungsten rated through 400 amps• Standard-transition transfer time less than 100 milliseconds (6

cycles @ 60 Hz)• Silver alloy main contacts• Gold-flashed engine start contacts rated 2 amps @ 30 VDC/250

VAC• Front-accessible contacts for easy inspection• Front-replaceable main and arcing contacts (800-4000 amps)• Reliable, field-proven solenoid mechanism• Switching mechanisms lubricated for life• Internal manual operating handle• Main shaft auxiliary position-indicating contacts (rated 10 amps

@ 32 VDC/250 VAC)• NEMA type 1, 12, 3R, 4, and 4X enclosures available

MPAC® 1500 Controller Standard Features• Microprocessor-based controller• Environmentally sealed user interface• LCD display, 4 lines x 20 characters, backlit• Dynamic function keypad with tactile feedback pushbuttons

allows complete programming and viewing capability at the door• LED indicators: Source available, transfer switch position,

service required (fault), and “not in auto"• Broadrange voltage sensing (208-600 VAC) on all phases• Phase-to-phase sensing and monitoring with 0.5% accuracy on

both sources• Frequency sensing with 0.5% accuracy on both sources• Anti-single phasing protection• Phase rotation sensing for three-phase systems• Real-time clock with battery backup and automatic adjust for

daylight saving time and leap year• Time-stamped event log• Fail-safe transfer for loaded test and exercise functions• DIP switches: password disable and maintenance• Modbus® RTU and Modbus® TCP/IP protocols• (Modbus® register map available)• RJ45 connector for 10/100 ethernet connection• USB port with read/write compatibility• Isolated RS-485 ports• One-year limited warranty Programmable Features• Programming and monitoring methods:

o Monitoring and password-protected programming atthe door using the keypad and display

o Program and monitor using a PC with Monitor IIIintegrated generator set and ATS monitoring software

o Transfer files through the USB port• System voltage and frequency• Voltage unbalance• Over/undervoltage and over/underfrequency for all phases of the

normal and emergency sources• Time delays• Load/no load/auto-load test and load/no-load exercise functions• Programmable inputs and outputs• Load control outputs (load stepping)• Selectable operating modes: utility-generator, generator-

generator, or utility-utility• Load bank control for exercise or test• Pre/post-transfer, 9 individual time delays for selected loads• ABC/BAC/none phase rotation selection with error detection• Resettable historical data• In-phase monitor• Password protection, 3 security levels

KCP-DMTD-0150B, continued

User Interface LED Indicators• Contactor position: source N and source E• Source available: source N and source E• Service required (fault indication)• Not in automatic mode LCD Display• System status• Line-to-line voltage• Line-to-neutral voltage• Active time delays• Source frequency• Preferred source selection• System settings• Common alarms• Load current, each phase (requires optional current

transformers)• Inputs and outputs• Faults• Time/date• Address• Event history• Maintenance records• Exerciser schedule• Exerciser mode• Time remaining on active exercise

Dynamic Function Tactile Keypad Operations• Scroll up/down/forward/back• Increase/decrease/save settings• End time delay• Start/end test• Reset fault• Lamp test DIP Switches• Maintenance mode• Password disable Event History

View up to 99 time and date-stamped events on the display or ona personal computer equipped with optional Monitor III software.

Download up to 2000 events with Monitor III software or downloadcomplete event history file to a PC or a memory device connectedto the USB port. Main Logic Board Inputs and Outputs• Two (2) programmable inputs• Two (2) programmable outputs, isolated form C (SPDT) contacts

rated 1 amp @ 30 VDC, 500 mA @120 VAC

Main Board I/O Specifications Output contact type Isolated form C (SPDT) Output contact rating 1 amp @ 30 VDC, 500 mA

@120 VAC I/O terminals wire size range #12-24 AWG

Communications• USB port with read/write capability• Isolated RS-485 ports• RJ-45 connector for 10/100 ethernet connection• Modbus® RTU and Modbus® TCP/IP protocols (Modbus®

register map available)• USB Port. Upload or download files from a PC or a memory

device through the USB port.

o Application software o Event history files o Language files o Parameter settings o Usage reports o Feature configuration

USB Data Logger• Time-stamped voltage and frequency readings• Minimum and maximum current and voltage readings for a

selected time period Programmable Features• System voltage, 208 600 VAC *• System frequency, 50/60 Hz *• Single/three-phase operation *• Standard/programmed-transition operation *• Preferred source selection• Phase rotation: ABC/BAC/none selection with error detection• Voltage and frequency pickup and dropout settings• Voltage unbalance, enable/disable• In-phase monitor: enable/disable and phase angle• Transfer commit/no commit• Source/source mode: utility/gen, gen/gen, utility/utility, or utility/

gen/gen for 3-source systems• Passwords, system and test• Time, date, automatic daylight saving time enable/disable• Time delays (see table)• Exerciser: calendar mode, loaded/unloaded up to 21 events• Test: loaded/unloaded/auto load (1-60 minutes)• Remote test: loaded/unloaded• Automatic override on generator failure (loaded test and

exercise)• Peak shave delay enable/disable• Current monitoring †• Pre/post-transfer, 9 individual time delays for selected loads• Current-based load control settings: high/low current levels and

load add/remove priority for 9 separate loads †• Prime power sequence alternates between two generator sets• Resettable historical data

* System parameters factory-set per order.

† Requires optional current sensing kit

Modus® is a registered trademark of Schneider Electric.

Programmable Inputs• External time delay input• External battery fault• External common fault• Inhibit transfer• Load shed to force transfer to OFF (programmed-transition

models only; requires accessory)• Peak shave/area protection input• External test• Three-source system disable Programmable Outputs• Chicago alarm control• Common alarm events• Contactor position• Exercise active• Failure to acquire standby source• Failure to transfer• Generator engine start, source N and E• I/O module faults• Load bank control• Load control active (pre/post transfer delay, up to 9 outputs)• Loss of phase fault, source N and E• External battery fault• Non-emergency transfer• Not in automatic mode• Over/underfrequency faults, source N and E (generator)• Over/undervoltage faults, source N and E• Peak shave/area protection active• Phase rotation error, source N and E• Preferred source supplying load• Software-controlled relay outputs (4 maximum)• Source available, preferred and standby• Standby source supplying load• Synchronizing output• Test active• Transfer switch auxiliary contact fault• Transfer switch auxiliary contact open• Voltage unbalance

Voltage and Frequency Sensing Parameter Default Adjustment Range Undervoltage dropout 90% of pickup 75%-98% Undervoltage pickup 90% of nominal 85%-100% Overvoltage dropout * 115% of nominal* 106%-135% Overvoltage pickup 95% of dropout 95%-100% Unbalance enable Disable Enable/Disable Unbalance dropout 20% 5%-20% Unbalance pickup 10% 3%-18% Voltage dropout time 0.5 sec. 0.1-9.9 sec. Underfrequency dropout 99% of pickup 95%-99% Underfrequency pickup 90% of nominal 80%-95% Overfrequency dropout 101% of pickup 101%-115% Overfrequency pickup 110% of nominal 105%-120% Frequency dropout time 3 sec. 0.1-15 sec. * 690 volts, maximum. Default = 110% for 600 volt applications.

Adjustable Time DelaysTime Delays Default Adjustment Range

Engine start, Source S2 3 sec. 0-60 sec. † Engine start, Source S1 (gen/gen)3 sec.

Engine cooldown, Source S2 5 sec.

0-60 min.

Engine cooldown, S1 (gen/gen) 2 sec.Fail to acquire standby source 1 min.Fail to acquire preferred source 1 min.Transfer, preferred to standby 3 sec.Transfer, standby to preferred 15 min.Transfer,off to standby 1 sec.Transfer, off to preferred 1 sec.Fail to synchronize 30 sec. Auto load test duration 30 min. 1-60 min.

(1 min. increments)Prime power run duration 0 min. 6 min. - 100 days.

(6 min. increments)Load control Time Delays:Pretransfer to preferred 0 sec.

0-60 min.

Post-transfer to preferred 0 sec.Pretransfer to standby 0 sec.Post-transfer to standby 0 sec.Load add Source1/Source2 0 sec.Load remove Source1/Source2 0 sec.Note: Time delays are adjustable in 1 second increments, exceptas noted.

† Engine start can be extended to 60 minutes with an ExternalBattery Supply Module Kit.

Environmental Specifications Operating Temperature -20°C to 70°C (-4°F to 158°F) Storage Temperature -40°C to 85°C (-40°F to 185°F) Humidity 5% to 95% noncondensing

Input and Output Connection Specifications Component Wire Size Range Main board I/O terminals #12-24 AWG I/O module terminals #14-24 AWG

Auxiliary Position Indicating Contacts

(rated 10 Amps @ 32 VDC/250 VAC)

Switch Rating(Amps)

Number of Contacts IndicatingNormal, Emergency

Transition0150 8, 8

UL-Listed Solderless Screw-Type Terminals forExternal Power Connections

Normal, Emergency, and Load Terminals

SwitchRating,Amps

Normal,Emergency and

Load (perphase)

Neutral (3-pole)

Ground

0150 (1) #4 AWG to600 KCMIL OR(2) 1/0- TO 250

(3) #4 AWG to600KCMIL OR(6) 1/0- TO 250

(3) #4 AWGto 600

KCMIL or (6)1/0- to 250

KCMILUse 75 degree C minimum Cu/AL wire for power connections

Ground Bus, Mechanical Lugs (Optional)

Switch Rating, amps Range of Wire Sizes0150 #14 to 1/0 AWG

Codes and Standards

• The ATS meets or exceeds the requirements of the following

specifications:• Underwriters Laboratories UL 508, Standard for Industrial

Control Equipment• Underwriters Laboratories UL 1008, Standard for Automatic

Transfer Switches for Use in Emergency Standby Systems file# E58962 (automatic), # E86894 (nonautomatic)

• CSA C22.2 No. 178 certification at 600 VAC available, file#LR58301

• NFPA 70, National Electrical Code• NFPA 99, Essential Electrical Systems for Health Care Facilities• NFPA 110, Emergency and Standby Power Systems• IEEE Standard 446, IEEE Recommended Practice for

Emergency and Standby Power Systems for Commercial andIndustrial Applications

• NEMA Standard ICS 10-2005, Electromechanical AC AutomaticTransfer Switch Equipment

• EN61000-4-4 Fast Transient Immunity Severity Level 4• IEC 60947-6-1, Low Voltage Switchgear and Control Gear;

Multifunction Equipment; Automatic Transfer SwitchingEquipment

• EN61000-4-5 Surge Immunity Class 4 (voltage sensing andprogrammale inputs only)

• EIC Spedifications for EMI/EMC Immunity:o CISPR 11, Radiated Emissionso IEC 1000-4-2, Electrostatic Dischargeo IEC 1000-4-3, Radiated Electromagnetic Fieldso IEC 1000-4-4, Electrical Fast Transients (Bursts)o IEC 1000-4-5, Surge Voltageo IEC 1000-4-6, Conducted RF Disturbanceso IEC 1000-4-8, Magnetic Fieldso IEC 1000-4-11, Voltage Dips and Interruptions

• IEEE 472 (ANSI C37.90A) Ring Wave Test• Seismic certification in accordance with the International Building

Code availableo IBC 2000, referencing ASCE 7-98 and ICC AC-156 o IBC 2003, referencing ASCE 7-02 and ICC AC-156o IBC 2006, referencing ASCE 7-05 and ICC AC-156

Accessory kit is required for seismic certification

Weights and Dimensions See ADV drawings for weights and dimensions. Allow 15% additional weight for packing materials.

NEMA Type Amps Poles Height Width Depth Weight

Withstand and Close-On Ratings (WCR)

Programmed Transition Model

Maximum current in RMS symmetrical amperes when coordinated with customer-supplied fuses or circuit breakers.

Withstand Current Ratings in RMS Symmetrical Amperes Any Circuit Breaker Current-Limiting Fuses

CurrentLimiting Fuse

Rating

Max. FuseAmps

Max. FuseType

SpecificBreakerRating

Any BreakerRating

Short TimeWithstand

Ratings

Short TimeDuration,

Cycles

TestedVoltages,

VAC200000 600 J 42000 35000 N/A - 600

200000 800 L 42000 35000 N/A - 600

200000 600 J 50000 35000 N/A - 480

200000 800 L 50000 35000 N/A - 480

200000 600 J 65000 65000 N/A - 240

200000 800 L 65000 65000 N/A - 240? All values are available symmetrical RMS amperes and tested in accordance with the withstnad and close-on requiements of UL 1008. Applicationrequirements may permit higher withstand ratings for certain size switches. Contact Kohler Co. for assistance.* Short time ratings are provided for applications involving breakers that do not have instantaneous trips for systems coordination.** Any breaker ratings are based on 1.5 cycles for 30-230 amps. Applicable to breakers with instantaneous trip elements.

Ratings with Specific Manufacturer's Circuit Breaker

The following chart list power switching device withstand and close-on ratings (WCR) in RMS symmetrical amperes forspecific manufacturers' circuit breakers. Circuit breakers are supplied by the customer.

Molded-Case Circuit Breaker

WCR Voltage Manufacture Type Max Size Amps22000 480 GE TEL, THED, THLC1 150

22000 480 GE TFL, THFK, THLC2 225

22000 480 GE SFL, SFP, TFJ, TFK 250

22000 480 GE SGL4, SGP4, TLB4 400

22000 480 ITE CFD6, FD6, FXD6, HFD6 250

22000 480 ITE CJD6, HHJD6, HHJXD6,HJD6, JD6, JXD6,

SCJD6, SHJD6, SJD6

22000 480 Square D KA, KC, KH, KI 250

22000 480 Square D LC, LI 0300

22000 480 Square D LA, LH 400

22000 480 Cutler-Hammer FD, FDC, HFD 150

22000 480 Cutler-Hammer HJD, JD, JDB, JDC 250

22000 480 Cutler-Hammer LCL, Tri-Pac LA, HKD,KD, KDB, KDC

22000 480 ABB S3 150

22000 480 Merlin Gerin CF250 250

22000 480 Merlin Gerin CJ400 400

50000 480 Cutler-Hammer HJD, JDC, JGH, JGC 250 Programmed-

transitionmodels

KCS only.

50000 480 Cutler-Hammer HKD, CHKD, KDC 400 Programmed-

transition

modelsKCS only.

50000 480 Cutler-Hammer HLD,CHLD, LDC, CLDC 600 Programmed-

transitionmodels

KCS only.

50000 480 GE SFL, SFP 250 Programmed-

transitionmodels

KCS only.

50000 480 GE TJL4V, TJL1S-6S 600 Programmed-

transitionmodels

KCS only.

50000 480 GE SG1L, SG4L, SG1P,SG4P

600 Programmed-

transitionmodels

KCS only.

50000 480 Siemens HFD, HFXD 250 Programmed-

transitionmodels

KCS only.

50000 480 Siemens HJD, HJXD, SHJD 400 Programmed-

transitionmodels

KCS only.

50000 480 Square D KC 250 Programmed-

transitionmodels

KCS only.

50000 480 Square D CK400N, CK400NN,CM1250HH

400 Programmed-

transitionmodels

KCS only.

42000 600 Cutler-Hammer JGC 250 Programmed-

transitionmodels

KCS only.

42000 600 Cutler-Hammer KDC 400 Programmed-

transitionmodels

KCS only.

42000 600 Cutler-Hammer LDC, CLDC 600 Programmed-

transition

Emissions Data

Model: John Deere, 6068HF285K Bore: 106mm (4.19 in.)Nameplate BPH @ 1800 RPM: 237 Stroke: 127mm (5.00 in.)Type: 4-Cycle, 6 Cylinder, Inline Displacement: 6.79 L (414 cu. in.)Aspiration: Turbocharged, Charge Air-cooledCompression Ratio 17.0:1 EPA Family: BJDXL06.8120

EPA Certificate: JDX-NRCI-11-29

PERFORMANCE DATA:

1/4Standby

1/2Standby

3/4Standby

FullStandby

Engine bkW @ Stated Load 74.67 99.56 132.75 177.00Fuel Consupumtion (g/kWh) 249.60 243.50 222.00 214.40Exhaust Gas Flow (m3/s) 1674.00Exhaust Temperature (°C) 528.00

EXHAUST EMISSION DATA:

HC (Total Unburned Hydrocarbons) 0.250 0.140 0.070 0.060NOx (Oxides of Nitrogen as NO2) 3.350 2.950 4.030 5.080CO (Carbon Monoxide) 1.760 1.110 0.700 0.540PM (Particular Matter) 0.239 0.129 0.109 0.080Smoke (Pierburg)

Data and specifications subject to change without noticeFor further information, please contact Todd Loes at John Deere Power Systems, 319-292-6050

TEST METHODS AND CONDITIONS

ISO 8528 D2

150REOZJF60 HZ. DIESEL INDUSTRIAL GENERATOR SET

EMISSION DATA SHEETENGINE INFORMATION

Values are in g/kWh

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY OFFICE OF TRANSPORTATION AND AIR QUALITY WASHINGTON, DC 20460

CERTIFICATE OF CONFORMITY

Pursuant to Section 111 and Section 213 of the Clean Air Act (42 U.S.C. sections 7411 and 7547) and 40 CFR Part 60 andPart 89, and subject to the terms and conditions prescribed in those provisions, this certificate of conformity is herebyissued with respect to the test engines which have been found to conform to applicable requirements and which representthe following stationary engines, by engine family, more fully described in the documentation required by 40 CFR Part 60and 89, and produced in the stated model year.

This certificate of conformity covers only those new stationary compression-ignition engines which conform in all material respects to the design specifications that applied to those engines described in the documentation required by 40CFR Part 60 and 89 and which are produced during the model year stated on this certificate of the said manufacturer, asdefined in 40 CFR Part 60.

It is a term of this certificate that the manufacturer shall consent to all inspections described in 40 CFR 89.129-96 and89.506-96 and authorized in a warrant or court order. Failure to comply with the requirements of such a warrant or courtorder may lead to a revocation or suspension of this certificate for reasons specified in 40 CFR Part 89. It is also a term ofthis certificate that this certificate may be revoked or suspended or rendered void ab initio for other reasons specified in 40CFR Part 89.

This certificate does not cover stationary engines sold, offered for sale, or introduced, or delivered for introduction, intocommerce in the U.S. prior to the effective date of the certificate

2011 MODEL YEAR

Manufacturer:Engine Family:

JASON GUMBS

g/kW-hr EphraimStephenR@JohnDeere.

NR (130-560)Intended Service Class:DIESEL (LOW OR ULTRA LOW SULFUR)Fuel Type:NMHC + NOx: N/ANOx: N/APM:

Certificate Number:

JOHN DEERE POWER SYSTEMSBJDXL06.8120JDX-NRCI-11-29

N/AEffective Date:

Karl J. Simon, DirectorCompliance and Innovative Strategies DivisionOffice of Transportation and Air Quality

10/7/2010Date Issued: 10/7/2010

Large CI

Dimensional Drawings

Wiring Schematics

Miscellaneous

Warranty

A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received atKohler Co. within 60 days after the date of initial startup. Standby systems not registered within 60 days of startupwill automatically beregistered by Kohler Co. using the Kohler Co. ship date as the startup date.

To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative, or write Kohler Co.,Generator Service Department, Kohler, WI 53044 USA.

KOHLERCO.SHALLNOTBELIABLEFORSPECIAL, INCIDENTAL,ORCONSEQUENTIALDAMAGESOFANYKIND including,butnot limited to, incidental consequential laborcosts, installationcharges, telephonecharges,or transportationcharges inconnectionwiththe replacement or repair of defective parts.

This is our exclusive written warranty. We make no other express warranty, nor is anyone authorized to make any in our behalf.

ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OFPURCHASE, is expressly limited to the duration of this warranty.

Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequentialdamages, 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.

TP-5561 12/99c

Extended Five-Year or Three Thousand (3000)-HourComprehensive Stationary Standby Limited WarrantyThis Kohler Standby Generator System has been manufactured and inspected with care by experienced craftsmen. If you are theoriginal purchaser, Kohler Co.warrants for five years or three thousand (3000) hours,whichever occurs first, that the systemwill be freefrom defects in material and workmanship if properly installed, maintained, and operated in accordance with Kohler Co.’s instructionmanuals. A Kohler distributor, dealer, or authorized representative must perform startup.

This warranty is not effective unless a proper extended warranty registration form and warranty fee have been sent to

Kohler Co. within one year of supervised startup.

During thewarranty period, repair or replacement atKohler Co.’s optionwill be furnished freeof charge for parts, provided an inspectionto Kohler Co.’s satisfaction discloses a defect in material and workmanship, and provided that the part or parts are returned toKohler Co. or anauthorizedservicestation, if requested. This extendedwarrantyexpires five full yearsafter dateof startupor after3000hours of operation, whichever occurs first.

This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, or normal wear and tear while in yourpossession.

The following will not be covered by this warranty:

1. Normal engine wear, routine tuneups, tuneup parts,adjustments, and periodic service.

2. Damage caused by accidents, improper installation orhandling, faulty repairs not performed by an authorizedservice representative, or improper storage.

3. Damage caused by operation with improper fuel or atspeeds, loads, conditions, modifications, or installationcontrary topublishedspecificationsor recommendations.

4. Damage caused by negligent maintenance such as:

a. Failure to provide the specified type and sufficientlubricating oil.

b. Failure to keep the air intake and cooling fin areasclean.

c. Failure to service the air cleaner.d. Failure to provide sufficient coolant and/or cooling air.e. Failure to perform scheduled maintenance as

prescribed in supplied manuals.f. Failure to exercise with load regularly.

5. Original installation charges and startup costs.

6. Starting batteries and the following related expenses:

a. Labor charges related to battery service.b. Travel expense related to battery service.

7. Engine coolant heaters, heater controls, and circulatingpumps after the first year.

8. Rental of equipment during performance of warrantyrepairs.

9. Non-Kohler-authorized repair shop labor without priorapproval from the Kohler Co. Warranty Department.

10. Parts purchased from sources other than Kohler.Replacement of a failedKohler part with a non-Kohler partvoids warranty on that part.

11. Radiators replaced rather than repaired.

12. Fuel injection pumpsnot repaired locally by an authorizedservicing dealer.

13. Engine fluids such as fuel, oil, or coolant/antifreeze.

14. Shop supplies such as adhesives, cleaning solvents, andrags.

15. Expenses incurred investigating performancecomplaintsunless the problem is caused by defective Kohlermaterials or workmanship.

16. Maintenance items such as fuses, filters, spark plugs,loose/leaking clamps, and adjustments.

KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KohlerPowerSystems.com

Extended Five-Year ComprehensiveTransfer Switch Limited Warranty

This Kohler product has been manufactured and inspected with care by experienced craftsmen. If you are the original purchaser,Kohler Co.warrants for five years that thesystemwill be free fromdefects inmaterial andworkmanship if properly installed,maintained,andoperated inaccordancewithKohler Co. instructionmanuals. AKohlerdistributor, dealer,orauthorizedrepresentativemustperformstartup.

This warranty is not effective unless a proper extended warranty registration form and warranty fee have been sent to

Kohler Co. within one year of supervised startup.

During thewarranty period, repair or replacement atKohler Co.’s optionwill be furnished freeof charge for parts, provided an inspectionto Kohler Co.’s satisfaction discloses a defect in material and workmanship, and provided that the part or parts are returned toKohler Co. or an authorized service station, if requested. This extended warranty expires five full years after date of startup.

This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, or normal wear and tear while in yourpossession.

A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received atKohler Co.within 60 days after the date of initial startup. Product not registeredwithin 60days of startupwill automatically be registeredby Kohler Co. using the Kohler Co. ship date as the startup date.

To obtain warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative or write Kohler Co.,Generator Service Department, Kohler, WI 53044 USA.

KOHLERCO.SHALLNOTBELIABLEFORSPECIAL, INCIDENTAL,ORCONSEQUENTIALDAMAGESOFANYKIND including,butnot limited to, incidental consequential laborcosts, installationcharges, telephonecharges,or transportationcharges inconnectionwiththe 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 IMPLIEDORSTATUTORYWARRANTY, INCLUDINGANYWARRANTYOFMERCHANTABILITYORFITNESSOFPURPOSE,is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts, or theexclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

This warranty gives you specific legal rights, and you may also have other rights that vary from state to state.

The following will not be covered by the warranty:

1. Normal wear, periodic service, and routine adjustments.

2. Damage caused by accidents, improper installation orhandling, faulty repairs not performed by an authorizedservice representative, or improper storage.

3. Damage caused by operation above or below ratedcapacity, voltage, or frequency; modifications; orinstallation contrary to published specifications, codes,recommendations, and accepted industry practices.

4. Original installation charges and startup costs.

5. Damage caused by negligent maintenance such as:

a. Failure to provide a clean, dry environment.b. Failure to perform recommended exercising.c. Failure to perform scheduled maintenance as

prescribed in supplied manuals.d. Useof other than factory-suppliedor -approved repair

parts and/or procedures.

6. Rental of equipment during performance of warrantyrepairs.

7. Non-Kohler-authorized repair shop labor without priorapproval from the Kohler Co. Warranty Department.

8. Expenses incurred investigating performancecomplaintsunless the problem is caused by defective Kohlermaterials or workmanship.

9. Maintenance items such as fuses, lamps, andadjustments.

10. Transfer switch main contacts.

TP-6087 2/00b

KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KohlerPowerSystems.com

Certification

G18-56 12/05a

Kohler Standby/Prime Generator Set Test Program

Testing is an integral part of quality assurance. In keepingwith ouruncompromising commitment to quality, safety,and reliability, every Kohler Standby/Prime power generator set undergoes an extensive series of prototype andproduction testing.

Prototype Testing

Prototype testing includes the potentially destructivetests necessary to verify design, proper function ofprotective devices and safety features, and reliabilityexpectations. Kohler’s prototype testing includes thefollowing:

� Alternator temperature rise test per NEMAMG1-32.6. Standby and prime ratings of thealternator are established during this test.

� Maximum power test to assure that the primemover and alternator have sufficient capacity tooperate within specifications.

� Alternator overload test per NEMA MG1-32.8.

� Steady-state load test to ensure voltage regulationmeets or exceeds ANSI C84.1, NEMAMG1-32.17requirementsand toverifycompliancewithsteady-state speed control specifications.

� Transient test to verify speed controls meets orexceeds specifications.

� Transient load tests per NEMA MG1-32.18, andISO 8528 to verify specifications of transientvoltage regulation, voltage dip, voltage overshoot,recovery voltage, and recovery time.

� Motor starting tests per NEMA MG1-32.18.5 toevaluate capabilities of generator, exciter, andregulator system.

� Three-phase symmetrical short-circuit test perNEMA MG1-32.13 to demonstrate short circuitperformance, mechanical integrity, ability tosustain short-circuit current.

� Harmonic analysis, voltage waveform deviationper NEMA MG1-32.10 to confirm that thegenerator set is producing clean voltage withinacceptable limits.

� Generator set cooling and air flow tests to verifymaximum operating ambient temperature.

� Reliability tests to demonstrate product durability,followed by root cause analysis of discoveredfailures and defects. Corrective action is taken toimprove thedesign,workmanship, or components.

� Acoustical noise intensity and sound attenuationeffects tests.

Production Testing

In production, Kohler Standby/Prime generator setsare built to the stringent standards established by theprototype program. Every Kohler Generator set isfully tested prior to leaving the factory. Productiontesting includes the following:

� Stator and exciterwinding high-potential test onallgenerators. Surge transient tests on stators forgenerators 180 kW or larger. Continuity andbalance tests on all rotors.

� One-step, full-load pickup tests to verify that theperformance of each generator set, regulator, andgovernor meets published specifications.

� Regulation and stability of voltage and frequencyare testedandverifiedatno load, 1/4 load, 1/2 load,3/4 load, and full-rated load.

� Voltage, amperage, frequency and power outputratings verified by full-load test.

� The proper operation of controller logic circuitry,prealarm warnings, and shutdown functions istested and verified.

� Any defect or variation from specificationdiscoveredduring testing is correctedand retestedprior 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 powerfactor testing, customized load testing for specific application, witness testing, and a broad range ofMIL-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

Prestartup Checklist

Columbus, Ohio Cincinnati, Ohio Cleveland, Ohio Indianapolis, Indiana 6850 Commerce Court Drive 7782 Service Center Drive 8465 Tower Drive 1229 Indy Place P.O. Box 489 West Chester, Ohio 45069 P.O. Box 394 Indianapolis, Indiana 46214 Blacklick, Ohio 43004-0489 Telephone (800) 368-7422 Twinsburg, Ohio 44087-0394 Telephone (800) 632-0339 Telephone (800) 523-3587 Telephone (800) 966-2825 __________________________________________________________________________________________________________________________________________

Pre Start-Up Checklist

Attn: ___________________________ Fax/email: ____________________ Company: ______________________ Project: _____________________ Included with your generator package is a complete start-up service. Before this service can be scheduled the following checklist must be completed, signed and returned to the service department for the appropriate branch listed above. Check

1. _____Generator must be bolted to the concrete pad which has been engineered to meet code. 2._____Exhaust System

Indoor units must have the exhaust completely installed. The flexible connector must not be used as an offset of 90 degree. An engineered thimble MUST be used were the exhaust penetrates the roof or wall. At the termination there must a rain cap on vertical discharge and on horizontal discharge there must be either a rain cap or the pipe cut off at a 45 degree with bird screen installed.

Outdoor units require the exhaust to be completely installed including the rain cap which must be able to open and close freely. Rain caps may be secured for shipping.

3. _____ Load Conductors Generator load conductors must be connected to the generator output breaker and the transfer switch. If different size lugs are needed contact your sales representative and note they may take 3 weeks to deliver. Generators generally have the neutral bonded to ground from the factory. If the system requires a solid neutral then the jumper on the generator must be removed. It is usually from the ground stud on the main alternator to the neutral bar.

4. _____ Control Wiring Control wiring should be in a conduit separate from the load conductors. Start wires need to be a minimum of number 18 and labeled #3&#4. They need to be pulled up into the generator controller and to the connection point in the transfer switch. The service technician can land these. If start wires are in the same conduit as the load conductors they should be shielded.

5. _____ Remote Annunciator Remote annunciator panel requires 2 number 14awg minimum from the generator to the annunciator. A Belden 9841 cable is also required. 3 number 14’s are required from

the transfer switch to the annunciator. If using with a building network contact the service department for proper installation requirements.

6. _____ Utility Power

Utility power must be connected and available to the transfer switch. Don’t plug the controller in! Building loads must be available. Transfer switch must be allowed to be tested. Transfer Switch must be powered down to plug in controller. Power outages will occur during testing.

7. _____ Radiator Ductwork Cooling system duct at radiator must be installed. Intake and exhaust louvers must be operational.

8. _____ Diesel Fuel System Fuel tank must have pressure test completed before scheduling start up. The tank should be at least 75% full with #2 off highway diesel supreme.

9. _____ Spark Ignited Engines Fuel system must be installed per the Kohler installation manual, TP-5700, pages 21-24 and 32. Gas pressure MUST be 4-6 oz or 7-11 inches of water column at the generator fuel inlet at all times. Supply volume must be sized for 100% rated load. Volume requirement is supplied on the generator data sheet.

10. ____ Block Heater Block heater must be wired for the appropriate voltage. Do Not Energize! 11. ____ Battery Charger

Battery charger must be installed and wired. Check installation instructions. If charger is more than 15 feet from batteries, additional sensing wires may be required. If this is a NFPA 110 installation 3 additional wires must be pulled from the charger to the generator controller for alarms.

Start-up dates are reserved on a first come first serve basis and require at least 1-2 week notice. Starts up are to be performed during normal business hours and generally can be completed in 1-2 business days. If after hours testing is required there will be additional charges. If there is anything on this list that is marked as being ready and it is not, requiring a second trip, the contractor will be held responsible for the additional trip charges. __________________________________ __________________________ ________ Name (print) Signature Date

SHOP DRAWING REVIEW - MKC Associates, Inc. CSD/09-ED1-045… · 1 MTG, LCB2, H-FR TO H/J, 100-150A,...

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