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AST APPL 6/30/2004 (COPY)
~ JUlt 28 2004 12:56 BKSFLD FIRE PREVEMTIOM (661)852-2172 p.1 omcE OF ~o~~ SERmCES el~ CA (~1) 32~3979 APPLICATION TO INSTALL AND/OR REMOVE ABOVE GROUND STORAGE TANK(S) Name of~y Address subject to the provisions and/or limitations as provided. Violation of pertinent ordimnc~ code~ and/or Ai~toved by:. Applicant Name (print) licam Sigmt~ THIS APPLICATION BECOMES A PERRflT WHEN APPROVED '~', ',% ~,,...,; ~.,, ,,.,,,./. ,. ,:,...'.. , ,h., ,. "J3~45 ~.EMINOII: DR.S' "" ' ..... ' ''~ "" ' "'""~ ' "' ' ' ' ., 909-627-,3651' ..: ~', . '" ' "' ,/' '" ' ' "' "" ":~':";"'" '~' '"' " ~...:.,-.~.~ ~'_ ~-~z~_,~4 '.,. PAY., - ' ' '" ' '"- , '.:~....'., ,,,,;.~. ," .,'i D. AT ' ', 441 -'":"';'"": ............... -. ,,, ,,.,.,, CAR. S . .. ,oo;.~u. ,~,~o,,o '"' ....... . . "' .... ' ,::.,,-~',,'.:.; ::: ;:"-.,~1989;.':..::; : '" i",L;,_-, ir "' ·. :-:.,; , . ' "_;_,,,:',::.~. '..' ...... ..., . Power Services Company SERVING THE SOUTHEAST SINCE 1945 Toll Free Phone: 866-766-4966 OPRO~ ~~ Thi~ ~u~i~;al has been re~ewod ~r general con~rm~nc~ Ro:ponsibi~ty,for ~zo, Con~imanco, and Cot: ::'., of all items to $pech'ic~ons and Drawlnss Supplier er Sub-Contractor S ~ g Controctors, Inc. {907, 627-~651 I TABLE OF CONTENTS I DRAWING NUMBER DESCRIPTION SYSTEM START-UP SHEET I TP-5561 WARRANTY SHEET BILL OF MATERIAL G5-219 KOHLER MODEL 350REOZV SPEC. SHEET I .ADV-6791 DIMENSION PRINT - ENGINE/GENERATOR ADV-6791 DIMENSION PRINT - ACCESSORIES ADV-6791 CIRCUIT BREAKER-600 AMPS I ADV-6799 DIMENSION PRINT- HOUSING SN-27200 DRAWING ASSEMBLY ES-38259 CIRCUIT BREAKER-150 AMPS I ADV-5912 DIMENSION PRINT - CIRCU IT BREAKER X-6304 CIRCUIT BREAKER SPECIFICATION G6-46 DECISION-MAKER 550 CONTROLLER ADV-5849 DIMENSION PRINT- DEC-550 CONTROLLER I C24-6463 SUBBASE FUEL TANK 50236 SUBBASE FUEL TANK G6-15 BATTERY CHARGER FLOAT/EQUALIZER I 233968 WIRING DIAGRAM FLOAT/EQUALIZER TT-700 RUN RELAY TT-1300 SINGLE LIGHT ALARM I G11-52 ZCS 600 AMP AUTOMATIC TRANSFER SWITCH G11-56 K SERIES M340 LOGIC - 600 AMP ATS 321287 SCHEMATIC DIAGRAM - 600 AMP ATS I 321288 LOGIC INTERCONNECTION ADV-5936 DIMENSION PRINT -600 AMP ATS ADV-6089 INTERCONNECT DIAGRAM I G11-73 GLS 150 AMP AUTOMATIC TRANSFER SWITCH G11-75 GLS SERIES M340 LOGIC- 150 AMP ATS 362114 SCHEMATIC DIAGRAM - 150 AMP ATS i -'"' '" D'~7~I~-'tO~PRINT- 150 AMP ATS SYSTEM IN'I ERCONNECTION DRAWING DATE RECEIVED:. GENERATOR SYSTEM INFORMATION START-UP GUIDELINES This guideline will ensure that your generator set start-up is completed smoothly and correctly. Failure to follow this start-up guideline can cause delays and unnecessary expense on your behalf. Please read the following information carefully as it is provided for your benefit: 1. -START-UP SERVICE: Contact Hunter Johnson 704-588-1043 ext. 224 at least 1-2 weeks prior fo required start-up date to allow for scheduling. 2. All wiring is the responsibility of the installer. Our service technicians are not allowed to make these connections. Ensure that all interconnect wiring ('AC and control) is mn in separate conduit and connected prior to start,up (see Kohler drawing ADV-5795.) 3. Commercial AC power must be available and connected to the transfer switch line side terminals prior to start-up. 4. Fuel lines must be connected and fuel available to the generator set prior to start-up. 5. Diesel generator sets are designed to operate on fuels with sulfur content below 0.5% (by weight). Contact Nixon Power Services Co before using fuels with high sulfur content. 6. Exhaust piping must be Complete prior to start-up. 7. Information regarding the installation of wiring, fuel lines, exhaust pipes, ventilation, etc is contained in the submittal package' or available from Nixon Power Services Co. 8. · The generator will have batteries, oil, and system coolant installed prior to shipment. The service technician will test the system for proper operation and inform your personnel of any discrepancies. 9. Start-up service includes one visit. Waiting time after the first 30 minutes and any additional site visits due to improper or incomplete installation will be invoiced at standard rates. 10. Manufacturer's warranty period will begin upon completion of initial start-up. If you have any questions concerning the above information, please contact Hunter Johnson with Nixon Power Services Co at 704-588-1043 for further clarification. I Extended Five-Year or Three Thousand'(3000)-Hour ! Comprehensive Stationary Standby Limited Warranty This Kohler Standby Generator System has been manufactured and inspected with care by experienced craftsmen. If you are the original purchaser, Kohler Co. warrants for five years or three thousand (3000) hours, whichever occurs first, that the system will be free I from defects in material and workmanship if properly installed, maintained, and operated in accordance with Kohler Co.'s instruction manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty 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. I During the warranty period, repair or replacement at Kohler Co.'s option will be furnished free of charge for parts, provided an inspection to Kohler Co.'s satisfaction discloses a defect in material and workmanship, and provided that the part or parts are returned to Kohler Co. or an authorized service staff on, if requested. This extended warranty expires five full years after date of startup or after 3000 hours of operation, whichever occurs first. I This warranty does not apply to malfunctions caused by damage, unreasonable use, misuse, or normal wear and tear while in your possession.. The following will not be covered by this warranty: 1. Normal engine wear, routine tuneups, tuneup parts, 7. Engine coolant heaters, heater controls, and circulating adjustments, and periodic service, pumps after the first year. 2. Damage caused by accidents, improper installation or 8. Rental of equipment during performance of warranty handling, faulty repairs not performed by an authorized repairs. service representative, or improper storage. 9. Non-Kohler-authorized repair ~hop labor without prior 3. Damage caused by operation with improper fuel or at approval from the Kohler Co. Warranty Department. speeds, loads, conditions, modifications, or installation 10. Parts purchased from sources other than Kohler. contrary to published specifications.or recommendations. Replacement of a failed Kohler part with a non-Kohler part 4. Damage caused by negligent maintenance such.as: voids warranty on that part. a. Failure to provide the specified type and sufficient lubricating oil. 11. Radiators replaced rather than repaired. b. Failure to keep the air intake and cooling fin areas 12. Fue['injection pumps not repaired Iocally by an authorized clean, servicing dealer. c. Failure to service the air cleaner. 13. Engine fluids such as fuel, oil, or coolant/antifreeze. d. Failure to provide sufficient coolant and/or cooling air. 14. Shop supplies such as adhesives, cleaning solvents, and e. Failure to perform scheduled maintenance as prescribed in supplied manuals, rags. f. Failure to exercise with load regularly. 15. Expenses incurred investigating performance complaints 5. Original installation charges and startup costs, unless the problem is caused by defective Kohler 6. Starting batteries and the following related expenses: materials or workmanship. a. Labor charges related to battery service. 16. Maintenance items such as fuses, filters, spark plugs, b. Travel expense related to battery service, loose/leaking clamps, and adjustments. A Startup Notification form must be on file at Kohler Co. A Startup Notification form must be completed by Seller and received at Kohler Co. within 60 days after the date of initial startup. Standby systems not registered within 60 days of startup will automatically be registered by Kohler Co. using the Kohler Co. ship date as the stadup date. To obtain Warranty service, call 1-800-544-2444 for your nearest authorized Kohler service representative, or write Kohler Co., Generator Service Department, Kohler, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIN D including, I~ut not limited to, incidental consequential labor costs, installation charges, telephone charges, or transportation charges in connection with the replacement or repair of defective parts. This is our exclusive written warranty. We make no other express warranty, nor is anyone authorized to make any in our behalf. ANY IMPLIED OR STATUTORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS OF PURCHASE, is expressly limited to the duration of this warranty. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. KOHLER ' KOHLER CO. Kohler, Wisconsin 53044 ® Phone 920-565-338!, Fax 920-459-1646 POWER SYSTEMS For the nearest saleslservice outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com TP-5561 12/99c . SERVING THE SOUTHEAST Power Services Company Toll Free Phone: 866-766-4966 ext. 231 Fax: 704-588,8373 the generator people... I Date: 12/01/03 i Quote Number: 4780 Re: Lowe's - South Bakersfield, CA I As Lowe's National Account supplier for generator systems, we are pleased to offer the following Bill of Material per the Agreement: I Qty: 1 Kohler Model 350REOZV Engine Driven Generator System Rated 350 KW, 438 KVA, ~ 0.8 PF, 277/480 VAC, 3 Phase, 60 Hz I ENGINE FUEL SYSTEM I · Diesel COOLING SYSTEM ACCESSORIES I · Mounted radiator Low coolant level shutdown · I · Engine block heater i FUEL SYSTEM ACCESSORIES · Flexible fuel lines I · Sub base fuel tank - 1500 gallons · Double wall construction with leak detection monitor · U.L. 1.42 Listed I · Fuel level gauge · Four (4) seismic zone 4 vibration isolators · Low fuel level alarm I · High fuel level alarm I Page 1 of 4 I Quote # 4780_REV1 Bill of Material_REV1 I I UNIT ACCESSORIES · Weather housing - Standard with hinged, lockable doors · Silencer mounting kit I · Critical grade exhaust silencer with tail pipe and rain cap ENGINE ELECTRICAL ACCESSORIES I · Battery rack, cables and starting battery system - lead acid type · Battery charging alternator I Automatic float/equalize, 10 output with Alarm Kit Battery charger alllp iGOVERNOR AND ACCESSORIES · Electronic/Isochronous governor I GENERATOR ACCESSORIES I · Main line circuit breaker - 3 pole, 600 amps with shunt trip, installed on generator · Main line circuit breaker - 3 pole, 150 amps, installed on generator · Voltage regulator +/- 2% I KOHLER DEC 550 CONTROL CONSOLE INCLUDING: I · A/C meters (volts, hertz) amps, · Voltage adjusting rheostat · Alarm horn & silencing switch I · System ready light · Not in auto light I · High engine temperature light · Low oil pressure light · Overspeed light I · Overcrank light' · Auxiliary safety shutdown light · Run-off/reset-auto switch I · Wattmeter · Programmable control I · Running time meter · A/C meter panel · Engine gauges I I i Page 2 of 4 ..~ Quote # 4780_KEV1 Bill of Material_REV1 I ! OPTIONAL CONTROLLER ACCESSORIES I · Pre-High Engine Temperature Alarm Sender · Pre-Low Engine Oil Pressure Alarm Sender I · Low Engine Temperature Alarm Sender · Engine Run Relay I ADDITIONAL ACCESSORIES · 14 relay kit, installed I · Terminal strip for Building Management connection, installed · Remote annunciator with silencer, single light alarm Vibration isolators - standard between engine/generator and skid base I · Oil. drain extension with valve · Skid end caps I · 3 Set of owners/operators manuals · 5 Year Kohler Comprehensive Warranty I AUTOMATI~C TRANSFER SWITCH Qty: 1 Kohler Model: ZCS-566641-0600 I Rated 277/480 volts, 600 amps, 3 phase, 4 pole, NEMA 1 enclosure All standard features and accessories are included as well as the following optional accessories: I · Extended time delay group · Plant exerciser with load/no load selector i · Inphase monitor · Under/over voltage sensing · Single phase/phase rotation I · Auxiliary contacts for monitoring · AUTOMATIC TRANSFER SWITCH 'l Qty: 1 Kohler Model: GLS-566641-0150 Rated 277/480 volts, 150 amps, 3 phase, 4 pole, NEMA 1 enclosure I All standard features and accessories are included as well as the following optional accessories: · Extended time delay group · Plant exerciser with load/no load selector · Inphase monitor i i · Under/over voltage sensing · Single phase/phase rotation · Auxiliary contacts for monitoring I i ~ Page 3 of 4 Quote # 4780_REV1 Bill of Material_REV1 DISTRIBUTOR SITE WORK · Engine oil and antifreeze provided at upfit · System checkout and start up service after installation is complete · System load testing with available facility load · System training provided at start up service Page 4 of 4 Quote # 4780_REV1 Bill of Material_REV1 ...... ........... Mode :'350REOZV 4-Cycle KOHLER2©WER SYSTEMS 190-600 V Diesel 'O9001 Standard Features ¢~SYSTEMS · Kohler Co, provides one-source responsibility for the ' NATIONAI.!.Y REGISTERED generating system and accessories, · The generator set and its components are prototype-tested, Ratings Range factory-built, and production-tested. 60 Hz 50 Hz · The 60 Hz generator set offers a UL-2200 I!sting. Standby: kW 305-355 288-328 · The generator set accepts rated load in one step. kVA 381-444 . 360-410 · The generator set complies with ISO 8528-5, Class G3 Prime: kW 275-320 260-296 requi.rements for transient performance. kVA 344-400 325-370 · The 60 Hz generator set engine is certified by the Environmental Protection Agency (EPA) to conform to Tier 2 Generator Ratings nonroad emissions regulations. Standby Rating Prime Rating · A one-year limited warranty covers all systems and 150oc 130oc 125oc 105oc components. Two-, five-, and ten-year extended warranties Rise Rise Rise Rise are also available. Generator Voltage Ph Hz kW'kVA kW/kVA kW/kVA kW/kVA-· Generator features: 120/208 3 60 350'438 350/.438 320/400 320/400 o Kohler's unique Fast-IResponse'" excitation system 127/220 3 60 350'.438 350/438 320/400 320/400 139/240 3 60 350'438. 350/438 320/400 320/400 delivers the fastest voltage response in the industry. 220/380 3 60 305'381 305/381 275/344 275/344 o The brushless, rotating-field generator has broadrange 240/416 3 60 350~438 350/438 320/400 320/400 reconnectability. 4M4019 277/480 3 60 350~438 350/438 320/400 320/400 o Kohler's permanent magnet-excited generator (PMG) 110/190 3 50 324~405 300/375 292/365 272/340 provides superiorshort-circuitcapability. 115/200 3 50 324~405 292/365 292/365 264/330 · Other features: 120/208 3 50 312/390 288/360 284/355 260/325 220/380 3 50 324/405 300/375 292/365 272/340 o Controllers are available for all applications. See 230/400 3 50 324~405 292/365 292/365 264/330 controller features inside. 240/416 3 50 3121390 288/360 284/355 260/325 o The Iow coolant level shutdown prevents overheating. 120/208 3 60 35¢/438 350/438 320/400 320/400 (Standard on radiator models only.) 127/220 3 60 350/438 350/438 320/400 320/400 o Integral vibration isolation eliminates the need for 139/240 . 3 60 355/444 355/464 320/400 320/400 under-unitvibration spring isolators. 220/380 3 60 315/394 315/394 285/356 285/356 240/416 3 60 350/438 350/438 320/400 320/400 0 An electronic, isochronous governor delivers precise 277/480 3 60 355/444 355/444 320/400 320/400 frequency regulation. 4M4021 110/190 3 50 328/410 320/400 296/370 288/360 o Electronic engine controls and a generator 115/200 3 50 328/410 324/405 296/370 292/365 microprocessor controller combine to deliver one of the 120/208 3 50 328/410 320/400 296/370 288/360 most advanced control systems in today's generator 220/380 3 50 328 410 320/400 296/370 288/360 market. 230/400 3 50 32~ 410 324/405 296/370 292/365 240/416 3 50 328 410 320/400 296/370 288/360 120/208 3 60 355'444 355/444 320/400 320/400 127/220 3 60 '355444 355/444 320/400 320/400 ~----~-- 139/240 3 60 355444 355/444 320/400 320/400 220/380 3 60 355'444 355/444 320/400 320/400 240/416 3 60 355'444 355/444 320/400 320/400 ~ 5M4027 277/480 3 60 355~444 355/444 320/400 320/400 110/190 3 50 328 '410 328/410 296/370 296/370 115/200 3 50 328'410 328/410 296/370 296/370 120/208 3 50 328~410 328/410 296/370 296/370 220/380 3 50 328'410 328/410 296/370 296/370 230/400 3 50 328/410 328/410 296/370 296/370 240/416 3 50 328/410 328/410 296/370 296/370 4M4158 220/380 3' 60 355/444 355/444 320/400 320/400 ' 5M4162 220/380 3 60 355/444 355/444 320/400 320/400 · ~ ~ : 4M4266 347/600 3 60 355/444 355/444 320/400 320/400 5M4272 347/600 3 60 355/444 355/444 320/400 320/400 RATINGS: Ail three-phase units are rated at 0.8 power factor. S~andby Ratings: Standby ratings apply to installations served by a reliable utility source. Tn· standby rating is ap~licebte to varying toscis for the duration of a power outage. There is no ovedoad capability for this rating. Ratings are in accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271. Prime Power Ratings: Pdme power ratings apply to installations where utility power is unavailable or unraliab~e. At varying load, the number of generator set operating hours is unlimited. A 10% overload capacity is ava/labia for one hour in twa/ye. Ratings are in accordance with ISO-8528/1, ovedoad power in accordance with ISO-3C,46/1, BS 5514, AS 2789, and DIN 6271. For limited running.time and base load ratings, consult the ~ctory, Obtain the technical information buliatin (TIB-101 ) on ratings guidelines for the complete ratings definitions. The generator set rnanLdacturer reserves the tight to cha~ge the design or specifications without notice and without any obligation or liability whatsoever. GENERAL GUIDELINES FOR DERATION: Altitude: Derate 0.8% per 100 m (328 ft.) elevation above 1000 m (3280 ft.). Temperature: Derate 5.0% per 10°C (18°F} temperature above 40°C (104°F). For radiator cooling system capacity, derate 0.5°C (0.9°F) per 100 m (328 ft.) elevation above 150 m (492 '~.). G5-219 (350REOZV) 12/02b Alternator Specifications Specifications Generator · NEMA MG1, IEEE, and ANSI stand~rd~ compliance for temperature rise and motor starting. Type 4-Pole, Rotating-Field Exciter type Brushless, Permanent- · Sustained short-circuit current of up to 300% of the Magnet, Fast-Response~ rated current for up to 10 seconds. Leads: quantity, type 12, Reconnectable · Sustained short-circuit current enabling downstream Voltage regulator Solid State, Volts/Hz circuit breakers to trip without collapsing the generator insulation: NEMA MG1 field. Material .......................... Class H · Self-ventilated and dripproof construction. Temperature rise .................. 130°C, Standby · Superior voltage waveform from a two-thirds pitch Bearing: quantity, type 1, Sealed ' stator and skewed rotor. Coupling Flexible Disc · Digital solid-state, volts-per-hertz ~/oltage regulator with Amortisseur windings Full ___0.25% no-load to full-load regulation. Voltage regulation, no-load to full-load 3-Phase Sensing, 0.25% load acceptance 100% of Rating · Brushless alternator with brushless pilot exciter for One-step Unbalanced load capability 100% of Rated Standby excellent load response. Current Peak motor starting kVA: (35% dip for voltages below) 480 V, 380 V 4M4019 (12 lead) .... 1350 (60Hz), 875 (50Hz) 460 V, 380 V 4M4021 (12 lead) .... 1350 (60Hz), 825 (50Hz) 460 V, 360 V 5M4027 (12 lead) .... 1575 (60Hz), 1100 (50Hz) 380 V 4M4158 (4 lead) ..... 1000 (60Hz) 380 V 5M4162 (4 lea.d) ..... 2100 (60Hz) 600 V 4M4266 (4 lead) ..... 1300 (60Hz) 600 V 5M4272 (4 lead) ..... 1750 (60Hz) Application Data Engine ' Engine Electrical Engine SPecifications 60 Hz 50 Hz Engine Electrical System 60 Hz 50 Hz Engine model D350 12.1A65 Battery charging alternator: Engine type 4-Cycle, Turbocharged, Ground (negative/positive) ....... Negative Charge Air Cooled Volts (DC) ..................... 24 Cylinder arrangement 6, Inline Ampere'rating ................. 60 Displacement, L (cu. in.) 12.13 (740) Starter motor rated voltage (DC) 24 Bore and stroke, mm (in.) 131 x 150 (5.16 x 5.91 ) Battery, recommended cold cranking Compression ratio 17.5:1 amps (CCA): Piston speed, m/min. (ft./min.) 540 (1772) 450 (1476) Qty., CCA rating ............... 2, 950 Main bearings: quantity, type 7, Precision Half-Shell Battery voltage (DC) -12 Rated rpm 1600 1500 Max. power at rated rpm, kWm (BHP) 393 (527) 363 (486) Fuel Cylinder head material Cast Iron Fuel System 60 Hz 50 Hz Piston: type, material Swirl Chamber, Fuel supply line, min. ID, mm (in.) 10 (0.39) Graphite-Coated Aluminum Fuel return line, min.' ID, mm (in.) 10 (0.39) Crankshaft material Forged Steel Max. lift, engine-driven fuel pump, m (ft.) 2.0 (6.6) Valve material Nimonic Max. fuel flow, Lph (gph) 550 (145.3) 500 (132.1) .Governor: type, make/model EDC III Fuel prime pump Manual Frequency regulation, no-load to full-load Isochronous Fuel filter: quantity, type 2, Primary; 30 Microns/ Frequency regulati(~n, steady state . ~-0.25% Secondary w/Water Frequency Field-Convertible Separator, 5 Microns Air cleaner type, all models Dry Recommended fuel #2 Diesel Exhaust Lubrication Exhaust System 60 Hz 50 Hz Lubricating System 60 Hz 50 Hz Exhaust flow at rated kW, m3/min. (cfm) 71.9 (2540) 62.9 (2220) Type Full Pressure Exhaust temperature at rated kW, dry Oil pan capacity, L (qt.) 31 (33) exhaust, °C (°F) 490 (914) 504 (940) Oil pan capacity with filter, L (qt.) 35 (37) Maximum allowable back pressure, Oil filter: quantity, type 3, Cartridge kPa (in. Hg) 10.2 (3.0) Oil cooler Water-Cooled Engine exhaust outlet size, mm (in.) See ADV Drawing G5-219 (350REOZV) 12/02b Application Data Controllers Cooling (standard Radi'a{*0r) Cooling System Ambient temperature, °C (°F)* 50 (122) Engine jacket water capacity, L (gal.) 20 (5.28) Radiator system capacity, including engine, L (gal.) 44.0 (11.62) Engine jacket water flow, Lpm (gpm) 360 (95) 288 (76) Available ContrOllers Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 148 (8420) 132 (7500) Decision-MakerTM 550 Controller Audiovisual annunciation with NFPA 110 Level I capability. Heat rejected to charge air cooler at rated kW, dry exhaust, kW (Btu/min.) 84 (4780) 73 (4140) Programmable microprocessor logic and digital display features. Generator safeguard cirCuit protection. Water pump type Centrifugal 12- or 24-volt engine electrical system capability. Fan diameter, including blades, mm (in.) 890 (35) Remote start, remote annunciation, and remote communication options. Fan, kWm (HP) 15 (20) 9 (12) Refer to G6-46 for additional controller features and accessories. Max. restriction of cooling air, intake and discharge side of radiator, kPa (in. H20) 0.125 (0.5) Decision-MakerTM 3+, 16-Light Controller · Audiovisual annunciation with NFPA 110 Level I capability. * Weather and sound enclosures with internal silencer reduce ambient Microprocessor logic, AC meters, and engine gauge features. temperature capability by 5°C (9°F). 12- or 24-volt engine electrical system capability. Remote start, prime power, and remote annunciation options. Operation Requirements Refer to G6-30 for additional controller features and accessories. Air Requirements 60 Hz 50 Hz Radiator-cooled cooling air, m3/min. (scfm)?_ 561 (19812) 462 (16315) Combustion air, m3/min. (cfm) 29 (1030) 25 (880) _ Heat rejected to ambient air: Engine, kW (Btu/rain.) .......... 75.6 (4300) 72.8 (4140) Generator, kW (Btu/min.) ........ 22.7 (1290) 24.8 (1410) ~' Air density = 1.20 kg/m3 (0.075 Ibm/ft3) Fuel Consumption 60 Hz 50 Hz Diesel, Lph (gph) at % load Standby Rating 100% 93.6 (2z~.7) 84.7 (22.4) 75% 70.0 (18.5) 62.7 (16.6) 50% 48.4 (12.8) 42.8 (11.3) 25% 28.3 (7.5) 24.3 (6.4) Diesel, Lph (gph) at % load Prime Rating 100% 84.2 (22.2) 76.1 (20.1) 75% 63.5 (16.8) 56.8 (15.0) 50% 44.2 (11.7) 39.4 (10.4) 25% 26.4 (7.0) 22.4 .(5.9) ! I G5-219 (350REOZV)12/02b KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381 Fax 9_20-459-1646 . Asia Pacific Headquarters For the ne~res'~'sales and service outlet in the ......... ' 7 Jur0ng'Pie'r Road US and Canada, phone 1-800-544-2444 Singapore 619159 KohlerPowerSystems.com Phone (65)264-6422, Fax (65)264-6455 Standard Features and Accessories Standard Features Maintenance and Literature · Battery Rack and Cables [] General Maintenance Literature Kit · Electronic, Isochronous Governor [] Maintenance Kit (includes air, oil, and fuel filters) · Oil Drain Extension ~) NFPA 110 Literature · Operation and Installation Literature [] Overhaul Literature Kit · Alternator Protection (standard with Decision-MakerTM 550) [] Production Literature Kit Accessories Controller Enclosed Unit ' [] Common Failure Relay Kit Sound Enclosure and Subbase Fuel Tank Packages [] Communications Products and PC Software (Decision-MakerTM 550 controller only) [] Weather Enclosu~ and Subbase Fuel Tank Packages ~ Customer Connection Kit [] Weather Housing (with skid end caps and roof-mounted silencer) [] Dry Contact Kit (isolated alarm) Open Unit [] Engine Prealarm Sender Kit [] Exhaust Silencer, Hospital (kits: PA-354903, PA-354905) [] Prime Power Switch Kit (Decision-Maker'" 550 controller only) [] Exhaust Silencer, Critical (kits: PA-354880, PA-354881) [] Remote Annunciator Panel [] Flexible Exhaust Connector, Stainless Steel [] Remote Audiovisual Alarm Panel Cooling System [] Remote Emergency Stop Kit [] Block Heater; recommended for ambient temperatures below [] Remote Mounting Cable 4oc (40OF) ~ Run. Relay Kit ~] Radiator Duct Flange Miscellaneous Accessories Fuel System [] [] Flexible Fuel Lines [] ' [] Fuel Pressure Gauge [~ [] Subbase Fuel Tanks [] [] Subbase Fuel Tank with Day Tank [] Electrical System [--I Battery [] J~ Battery Charger, Equalize/Float Type [] Battery Heater Dimensions and Weights Engine and Generator Overall Size, L x W x H, mm (in.): 3300 x 1250 x 1922 [] Air Cleaner, Heavy Duty (129.92 x 49.21 x 75.67) [] Air Cleaner Restriction Indicator Weight (radiator model ~, wet,__kg (lb.): 3175 (7000) [] Crankcase Emission Canister [] CSA Certification [~ Generator Strip Heater ~ Line Circuit Breaker (NEMA1 enclosure) [] Line Circuit Breaker with Shunt Trip (NEMA1 enclosure) []. Rated Power Factor Testing [] [] - - I~1 Rodent Guards - [] Safeguard Breaker (not available with Decision-MakerTM 550) [] Skid End Caps NOTE: This drawing is provided for reference only and should not be usec~ for Planning ir~stallation, Contact your loc. al distributor for more detailed ir~formetion. Paralleli.ng System [] Load-Sharing Modute DISTRIBUTED BY: [] Reactive Droop Compensator [] Remote Speed Adjusting Control [] Remote Voltage Adjustment Control [] Voltage Regulator Relocation Kit © 2002 by Kohler Co. All rights reserved. G5-219 (350R~OZV) 12/02b § [ 7 I 6 I 5 ~ 4 3 I 2 I 1 ~ I ~o RETURN SlUg-UP AR~, ~ ~ 75 [2 95] ~ 24V BAKERY LOCAIION ~~~ ~. ~ 3/8~18 N~ ~E) · 742 [2g.21] / - ~ g65 [37.gl] . LOAD L~DS REMOTE ANNU~CIATO~ ~ SUBBASE TANK A~ I ~ ~ ~ rap.iroN ....... y .~..~ I = ~ I ] I ~ ~ SCALE ,75X CHARCER ' ~. t II~N330 [12.gui I ~ I I X R ~--I ~75 [2.g5] II I SUCGESTED BLOCK H~TER ' ,__ 1) DIMENSIONS I' [ ] ARE ~ EXTEND BEYOUND THE SKID ~ SEE SUB'SE ~ANK ADV · 2) WHEN A HOUSING IS USED TH~ FUEL LINE FOR ADD~IONAL DIMENSIONS MUST BE STUBBED UP FROM blRECILY I ~ 1560 [61.42] --J OP~ONAL 455 [17.91]--I MUST BE LOCAIED OUTSIDE OF 'rANK AR~ ~J 2845 [112.01] J ~ AIR CL~NER --~312 [12.28] OR IN STUB-UP AR~ FOR SUB,SE TANK. CON].O~, FAcE ~ (o~os.[ s~o~) ~ ~ EX~UST (SEE FUEL INLET o ('~ENS[T~T~.HOLE~)~ ~ ['g'~g] I*T,c CAD FI.LEt 6X e17.50 [,688] 1247 [4g.og] , [49.21]- GENS~ MT~. HOLES) 1680 [66.14] NOTE: DANCE )~X WEIGHT (W~) 3175Kg [70OOIbs] m, * ~ . I ......... ~ ...... I 3300 [12g.g2] ~50/400 MODELS 8 I 7 I 6 I 5 ? I 3 I 2 '~' 330 [13.00] ---67 [2,64] ~ ' CONDUIT ENJRY AREA ~..-...:¢-SEE CIIART FOR 1200 AMP & BELOW "A" EXT. BOX , NOIE: 'DIMENSIONS IN [ ] AREENGLI$1I INCH EOU~ALE~S, MERLIN GERIN LINE CIRCUIT BREAKER KITS ~" I KOHLER CG (4M SHOWN) :~I~ 4 I 3 I 2 333~ 029 [32.63] 1067 [42.01] ~ OPENING WITH ~~Dii~O R[£41~~OPENING WlIH ~~MIO.e~7'5OHoLES DOOR REMOVED (, P~CES) -,~ 2632 [103,63~ OPENING WITH 40 [1,573 369 [14.51] R~O~S]DE ONLY, : = ' 550 [2~:ss]-- ~40 [~25] - 5300 [129.92]. NOE['. DIMENSIOHS IN [ ] MODEL GENS~ WEIGHT (W~) HOUSING ONLY AND W~HER HOUSING [ ] 30O (4UA13 ALT) 2803 Kg [6180 LSS] 499 Kg [1100 LBS3 3302 Kg [7280 LBS~ 350 (4u4019,21,4158,4266 AL~) 2839 Kg [6260 LBS] 499 ~g [1100 LBS] 3338 Kg [7360 LBS] ~HLER 400 (4M4019,21.4266 ALT) 2839 Kg [6260 LBS] 489 Kg [1100 LBS] 3338 Kg [7360 LBS] 275-400 MODELS 400 (5M4024,27,4160,62,4272 ALT) 3175 Kg [7000 LBS] 4gg Kg [1100 LBS]3674 Kg [8100 LaS] D300 ~2, tA65/D350 12.1A65/D400Wi311 EXTENSION12'1A65~OX ~'~f PR~NT WIIH ~oor ~OUNTED SILENCER J~' ~" [,-.-o~[ ADV-6799 I D I 7 I 5 I 5 ? 4 I 3 I 2 I ...... I · ,. TO ~AINS1' SIO~ P~EL. USL' U ~ll~m~L ~ 1~1( HOLES 01.1 J-~o~ R~t VIEW 'OF SIIOWII W/, C(~R $OU~IE p (UL'I t~P-I-RAU£.£1RCUll BnE4~Efl SlOE VIEW DF J-BOX I I I I I I I I I I I I I I I I I I I 8 SUPPLIER sQUARE D GEN. ELECTRIC WESTINGHOUSE C MERLIN GERIN (U.L.) MERUN GERIN (LE.C.) t OF BRrd~ER-7 HANDLE CUTOUT A J ~ [ OF BREAKERHANDLE ~ ( OFH~NDLE M t, OF HANDLE HANDLE ~ ~ sw~£ 2 swLE 3 ~ 4 ~m[ s I ,"~-_.~ I KOHLER CO ~ SQUARE-D UL ...... ~'~'"~ NUMBER REV. AMPS RATiNGVOLT POLES FRAME TRIP · FEATURES NUMBER OFsHuNTSERV' TRipONLY OFsHuNTSERV* TRipONLY REMARKS [~~ -,~-6.1 ~,~(cb'li)~./'-3#~- t u~'/. x-~4-t l?z ~[~ X-6504-110DM~ ~ 24V DC NONE ~-56600-1027 ~1-1027 - LO~ SIDE lUGS ~LY X-6504-170D~ ~ 24V ~ ~RM SW. ~L-56SO0-2205 ~1-~027 - X-6304-111DF , ~ NONE NONE ~P-367~ - - LOAD SIOE LUGS ~LY X-6304-113DM 7~ 600 3 ~ 2~V DC NONE ~-367~-1027 ~1-1027 - LOAD SIDE LUGS ONLY X-6304-173OT ~ 24V ~ ~M SW. ~L-36700-2203 ~1-1027 - X-6504-116DF ~ NONE NONE ~P-568~ - LOAD SIDE LUGS ONLY X-6304-117EG 8~ 600 3 ~ 24V ~ NONE ~-3~-1027 ~1-1027 LO~ SIDE LUGS ONLY X-6304-118DM ~ 2~V ~ AUX. SW. ~-368~-1386 ~1-1027 LO~ SIDE LUGS ONLY X-6304-119DF ~ NONE NONE ~P-56900 - LO~ SIDE LUGS ONLY X-6304-120DM ~ 24V DC NONE ~-36g~-I027 ~I-1027 LOAD SIDE LUGS X-5304-~74DT ~ 24V ~ A~M SW, ~-36g00-2203 ~1-1027 - X-6504-12~DF ~ NONE NONE ~--361000 LOAD SIDE LUGS ONLY X-6304-122DM 1000 600 5 ~P 24V ~ NONE ~-361~-1027 ~1-1027 LO~ SIDE LUGS ~LY X-630~-125DF ~ NONE NONE ~-3612~ LO~ SIDE LUGS ~LY X-6304-126DM ~ 24V DC NONE ~-36f2~-~027 ~1-1027 LO~ SIDE LUGS ONLY X-~-129 DG - PE12~2 NE~ S~SOR ONLY, FOR 12~ PX BRIERS .. X-6304-147DR I400-~OC _ - - - HR-PA REP~EMENT ~DLE. FOR PA/~ BRIERS X-6~04-130~ P~ NONE NONE P~363~ - X-6304-131~ 1400 600 3 P~ 24V ~ NONE P~561400-1027 PA1-1027 335325 - X-6504-~32~ ~ PXF NONE GROUND FAULT PXF361~OG USE ~ X-~-34 X-63~-32 DE 1600 600 3 PXF NONE GROUND F~LT PXF361600G USE ~TH X-~LS~ X-65~-33 DE PXF 24V ~ GROUND FAULT PXF561600G-1027 PAl-lO27 335325 USE ~TH X-6~4-~ OK - PE16~2 - N~ SENSOR ONLY. FOR 1~-1600A BR~ X-6504-145DP P~ 24~ AUX7 SW. P~5616~-1386 PA1~027 ~35525 - X-6~-35 DL p~ NONE NONE P~361800 - - - X-63~-36 DL P~ 24V ~ NONE P~56 ~8~- 1027 PA1-~027 335525 - X-6~-37 DL 1800 600 3 PXF NONE GROUND F~LT PXF361800G - - USE ~TH X-~-~ X-63~-58 DL PXF 24V ~ GROUND F~LT PXF561800~-1027 PAl-1027 335325 USE ~TM X-6~-~ x-~-~0 ~. .~ ~.~ ~.~ .~ooo - - X-6304~41 DH P~ 24V ~ NONE P~362~-1027 PAl-t027 335325 - X-63~-42 ~ 2000 600 3 PXF NONE GRO~N~ ~T PX~S2000G- - - = USE ~T~ X-6~-~ X-6~-45 DH PXF 24V ~ GROUND F~LT PXF562~-1027 PA1-~027 335325 USE ~H X-~-~ X-63~-44 DK - P~O~2 - - N~ SENSOR ONLY, FOR 18~-2~0A X-65~-45 DR PCF NONE NONE PCF362500-691~ - USE ~ X-6304-146 NO~: X-63~-46 DZ ~F 24V ~ NONE PCF362500-6919 PA1-1027 335325 USE ~H X-6304-146 UN,SS OTH~ISE ~[CIRED, X-6~-47 DR PXF NONE 'GROUND FAULTPX~6250~ - - U~ ~H X-~-49 ~ X-6304-1~ ALL BR~KERS TO BE SUPPLIED X-6304-48 DR ~ 2~0 6~0 5 PXF 24V ~ GROUND F~LT PXF362500G-1027 PAI-1027 335325 USE ~H X-~-49 & X-63~-1~ ~TH LO~ ~D UNE TERMI~ - P~5~2 - - N~ SENSOR ONLY, FOR 2500A BRIERS SUIT~LE FOR CURRE~ RATING X-6~0~49 DH - 1/2 x (B024~272-50) - - LO~ SiDE B~ Kff. ~R 2~ BR~E~ OF ~[ BRIER. X-6304-146OR, FOR BRIER DIMS SEE ~V-5912 ALL 3 PO~ BR~KE~ MU~ BE ~KEO: 'UL LISTED FOR USE ON ~D ~0 P~E ~PUCATIONS'. I ~ X- 6504 8 I 7 6 I ~ · · I 3 I 2 I I GENERATOR ACCESSORIES ! KOHLER POWER SYSTEMS GeneratOrcontrollerSet I _9om Kohler® DeciSion-Maker TM 550 ,~,,oNA,LY,G,~,,~ Controller (VersiOn 2.10 or higher) i ~ General DescriPtion and Function The Decision-Maker TM 550 generator set controller provides Iadvanced control, additional system monitoring, and system diagnostics for optimum performance. ~ ~-~ The Decision-Maker'" 550 generator set controller provides I complete compatibility with selected engine Electronic Control ~ .. ~ ~ [ ] Module (ECM) and non-ECM equipped generator set engines. (,,._) ~¢~ o(~ (~(~(~) The Decision-Maker TM 550 generator set controller interfaces · i,~ '~=o ,.~.~o (~)(~ between the generator set and Kohler switchgear for paralleling .... ,.---_--_o --"o ,-~=o ~)~)~) applications between generator sets and/or the utility. o,..,.,G~. . ECM models only: The Decision-Maker'" 550 controller directly =~ .... communicates with the ECM to monitor engine parameters and .~_ .~-~__.~.._~ -~ == r--.--------- diagnose engine problems. (See Engine Data Displays for details.) I Standard Features · The controller meets the National Fire Protection Association requirements of NFPA~ 99 and NFPA 110. I · The controller is listedl under Underwriter's Laboratories UL-508. · A digital display and keypad provide access to data. A two-line vacuum fluorescent display provides complete and I understandable information. · The controller can communicate with a personal computer individually or on a network when equipped with optional I communications prodUcts. See spec sheets G6-38 Generator System Monitoring and Control for Windows® and G6-50 Decision-MakerTM550~Controller Communications for more information. I · An optional menu-driven, Windows®-based PC'software monitors engine and alternator parameters and also provides control capability. i · An operator with a PC can control and monitor the generator set from a remote site 'over telephone lines. · The co~troller supports Modbus® RTU (Remote Terminal Unit)--an i'ndustry standard open communication protocol. I · The 230-300REOZDi generator set models with the Decision-Maker'" 5501 controller comply with ISO 8528-5, Class G3, for transieht response. I · The Optional parallelihg feature provides user-defined paralleling relay functions and time delays. I Modbus® is a registered trademark of Schneider Electric. Windows® is a registered trademark Of Microsoft Corporation. I G6-46 10/02b Decision-MakerTM550 Controller ' I f I EMERGENCY RESET RUN AUTO I ' Programming Mode 0 0 Shutctown ~ Operating Guide1 I l~., v~aee~ · O~l~-~...~l.~,.~I/. . 12 CaDl~l~ea · Control Features Specifications Engine Data Displays I · Power source with circuit protection: 12- or 24-volt DC Some of the engine data available is dependent on the engine family. · Current drain: 700 milliamps (or 400 milliamps without panel lamps) As a result, some monitoring displays may not be available with a given · Humidity range: 5% to 95% noncondensing Detroit Diesel engine. Note: All Detroit Diesel Series 60, 2000, and · · Operating temperature range: -40°C to +70°C 4000 engines are engine ECM equipped. The following table indicates · Storage temperature range: -40°C to +85°C '- controller displays that each engine family provides. · Standards: o NFPA 99 135- 230- 450- 1250- o NFPA110, Level 1 275kW 400kW 1000kW 2000kW I DDC DDC DDC DDC o UL-508 Series Series 60 Series Series · Display 50/60 Gas Diesel 2000 4000 Hardware Features Ambient Temperature x x I x x I Coolant Level 1' ~ I ? t i · Alarm horn I Coolant Pressure ? -{- t 1` x · Battery circuits are fuse protected · Controller mounts in four orientations locally or remotely up to a Coolant Temperature x x I x x distance of 12 m (40 ff. ) Crankcase Pres~;ure t' 1' I i' x · Dimensions--W x H x D, ECM Battery Voltage x x I x x · 460 x 275 x 291 mm (18.15 x 10.8 x 11.47 in.) ECM Serial Number x x Environmentally sealed 1 6-button membrane keypad Engine Model No. x x I x x · Five LED status indicating lights [ Engine Serial No. x x I x x · Latch-typeElectromechanicalemergenCYcommissionStOp switch(iEG)Withyellowlnternationalring identification I Engine Speed x x I Fuel Consumption Rate x x I x x · Vacuum fluorescent display '· Three-position (run, off/reset, auto) selector switch Fuel Pressure 1` ? I x x · Two-position terminal strip for'remote start Fue Temperature x x I x x · Two-position terminal stri~3 for remote emergency stop I Fuel Used Last Run* x x ! x x · · Terminal strip for auxiliary analog inputs Oil Level · Terminal strip for auxmary'"- digital inputs Oil Pressure x x I x x · Terminal s[np-' for remote annunciator Oil Temperature x x I x x · Terminal strip for remote dry contact kit Unit Number x x I x x · x1` Available display feature Value must be reset using the DDEC reader Not available at this time G6-46 10/02b ! I Contro! FUn.cfi.q. ns The control functions apply to both the ECM and non~ECM equipped · Generator' Set Master Switch Faul~ I models unless noted otherwise. The generator set master switch position or failure provides fault detection at four levels: 1) master switch to off, 2) master switch · AC Output Voltage Adjustment open, 3) master switch error, and 4) master switch not in auto. Each The voltage adjustment provides a numeric keypad adjustment of of these faults/warnings provides local display, alarm horn on, and 0.5% resolution of the average line-to-line AC output voltage, + 10%. RDO on. I · Alternator Protection · Idle Speed Function The controller firmware provides generator set overload and short Idle speed function provides the ability to start and run the engine at circuit protection matched to each alternator for the particular idle speed for a selectable time period. The engine will go to normal i voltage/phase configuration, speed should the temperature reach warm-up before the time delay is complete. · Automatic Restart The controller automatic restart feature initiates the start routine and · Load Shed recrank if the generator slows to less than 390 rpm after exceeding The load shed function provides a load control output (RDO) with I crank disconnect speed, user selectable load shed level. · Battleswitch (Fault Shutdown Override Switch) · Modbuse Interface The battleswitch input provides the ability to override the normal fault The Modbus® interfa? provides industry standard open protocol for shutdowns except emergency stop and overspeed shutdown in communication between the generator set controller and other I emergency situations and during generator set troubleshooting, control and monitoring devices· · Clockand Calendar · Programming Access Real-time clock and calendar functions time stamp shutdowns for The setup access and programming information is password I local display and remote monitor. Also, use these functions as an protected. When locally accessing programming information, the actual and resettable record to determine the generator start date PM (programming mode) LED flashes. When remotely acc'essing and days of operation, programming information, the PM LED is steady. · Cooldown Temperature Override · Programmed Run I Tills feature provides the ability to bypass (override) the generator The programmed run function provides user-selectable time for set's smart cooldown temperature shutdown and force the generator exercising the generptor set. · set to run for the full engine cooldown time delay. Also see.Time Delay Engine Cooldown (-I'DEC). · Remote Reset I The remote reset function resets faults and allows restarting of the · Cyclic Cranking generator without going to the master switch off/reset position. The The controller has programmable cyclic cranking. The customer remote reset functiora is initiated via the remote reset input. selects the number of crank cycles 1-6 and the crank time from 1-60 seconds. The crank disconnect depends upon the speed · Running Time Houimeter I sensor input information or the generator frequency information. The The running time hourmeter function is available on the local display default cyclic crank setting is 15 seconds on, 15 seconds off for and remote monitor. The information displayed uses real time three cycles, loaded and unloaded run time as an actual and resettable record. I · Digital Voltage Regulator · Self-Test The digital voltage regulator provides 4-0.25% load regulation for the The controller has memory protection and microprocessor self-test. single- or three-phase loads. · Starting Aid · Display Power Shutdown ~ The starting aid feature provides for function of an ether injection I The controller automa, tically conserves engine battery'power. The system. This setup has adjustable on time before engine crank from display turns off after 5 minutes of inactivity and instant on by 0-10 seconds. This feature is also part of the remote communication pressing any keypad button, option. I. · ECM Communication · Time Delay EnginelCooldown (TDEC) The controller monitors ECM communication links and provides fault The TDEC provides,a user selectable time delay before the detection for oil pressure signal loss, coolant temperature signal generator set shuts down. loss, and ECM communication loss. Each of these faults provides If the engine is above the preset temperature and the unit is local display, alarm horn ON, and relay driver output (RDO) on (ECM signalled to shut doWn, the unit will continue to run for the duration of I models only), the TDEC. If the engine is at orlbelow the preset temperature and the unit is · Generator Number of Starts signalled to shut doWn or the TDES is running, the unit will shut Total number of generator successful starts is recorded and down without ~aiting for the time delay to expire. I displayed on the local display and remote monitor. This information is a resettable and total record· · Time Delay Engine Start ('I'DES) The TDES providesla user selectable time delay before the generator set starts: I Modbus® is a registered trademark of Schneider Electric. I G6-46 10/02b .... Diagnostics I The controller features shutdowns and warnings as text messages on the User-Defined Common Faults and Status vacuum fluorescent display. 1) Shutdowns show red LED and stop the generator set. The user customizes outputs through a menu of status conditions, lib 2) Warnings show yellow LED and signal an impending problem, shutdowns, and warnings. User defines up to 21 RDOs (relays not Note: The available user inputs are dependant on factory reserved inputs included) from the following list of functions: for specific engine types, engine controls, and paralleling applications. · Engine functions: Shutdown Functions o Air damper fault, if equipped o Air/fuel module engine start delay § · Engine functions: o Air/fuel module remote start § o Air damper fault, if equipped o Coolant temperature signal loss o High coolant temperature o Fuel valve relay-§ o High oil temperature o High battery voltage o Low coolant level o High coolant temperature Shutdown ! o Low fuel pressure (standard on 125RZG) * o High coolant temperature warning o Low oil pressure o High intake air temperature shutdown § o Overcrank o High intake air temperature warning § o Overspeed o High oil temperature shutdown (ECM models only) · · General functions: . o High oil temperature warning § 0 Auxitiary--(up to 7 analog inputs each with a high and Iow ~ Low battery voltage programmable shutdown level), o Low coolant level o Auxiliary--digital (up to 21 programmable shutdowns) o Low coolant [emperature warning o ECM communications loss (ECM models only) o Low fuel (level or pressure) warning * · o Emergency stop o Low oil pressure shutdown ~' o internal fault o Low oil pressure Warning o Master switch in off/reset position o NO intake air temperature signal § o Master switch error o No oil temperature signal § o Master switch open o Oil pressure signal loss · o NFPA 110 fault o Overcrank ? · o Serial number mismatch o Overspeed ? · Generator functions: o Prelube relay § o Alternator protection against overload and shod circuits o Speed sensor fault · o Critical overvoltage o Starling-aid o Generator set parameter fault o Weak battery o Locked rotor (failed to crank) · General functions: o Over AC output voltage o Battery charger fault * o Overfrequency o ECM communications loss (ECM models only) · o Under AC output voltage o EEPROM write failure o Underfrequency o Emergency stop ? o Engine cooldown delay · Paralleling functions (Menu 15): o Loss of field o Engine start delay o Overcurrent o EPS supplying load · o internal fault · o Overpower o Load shed kW overload o Reverse power o Load shed under[requency Warning Functions o Master switch error · 0 Master switch not in auto · Engine functions: o Master switch open o Coolant temperature signal loss o Master switch to off o High battery voltage o NFPA 110 common alarm fault o High coolant temperature o SCRDOs 1-4 (software controlled RDOs) · o Low battery voltage o System ready o Low coolant temperature · Generator functions: o Low fuel (level or pressure) * o AC sensing loss o Low oil pressure o Alternator protection against overload and shod circuits o Oil pressure signal loss o Generator running · o Speed sensor fault o Ground fault o Weak battery o Locked rotor (failed to crank) · General functions: . o Overcurrent o Auxiliary--(up to 7 analog inputs each with a high and Iow o Overfrequency programmable warning level), o Overvoltage o Auxiliary--Digital (up to 21 programmable warnings) o Underfrequency o Batterybharger fault* o Undervoltage o Emergency power system (EPS) supplying load · Paralleling applications with Kohler switchgear o Load shed kW overload o Breaker trip · o Load shed underfrequency o Loss of field shutdown o Master switch not id auto o Overcurrent shutdown paralleling relay o NFPA 110 fault o Overpower shutdown o Serial number mismatch o Reverse power shutdown · Generator functions: o Loss of synchronization · o AC sensing loss o Generator set parameter fault * Requires optional input sensors on some models i' Factory default settings for defined common faults o Ground fault * +-' Standard on Detroit Diesel DDEC o Overcurrent I o Underfrequency § Standard on Waukesha engine only · Paralleling functions: o Common protection relay output G6~6 10/02b NFPA-110 Alarms · Operational records: ...... o Event history (stores up to 100 system events) Additional annunciated alarms including NFPA 110 alarms, c Last start date ' · Engine functions: o Number of starts o Air damper indicator o Number of starts since last maintenance o EPS supplying load o Operating days since last maintenance o High battery voltage o Operating mode--standby or prime power o High coolant temperature shutdown o Run time (total, loaded and unloaded hours, and total kW hours) o High coolant temperature warning o Run time since maintenance (total, loaded, and unloaded hours o Low battery voltage and total kW hours) o Low coolant level c System shutdowns o Low coolant temperature warning o System warnings o Low fuel (level or pressure) * o Time, date, and day of week o Low oil pressure shutdown · Time delays--general: o Low oil pressure warning o Crank cycles for on/pause o Overcrank o Crank cycles for overcrank shutdown o Overspeed o Engine cooldown · General functions: o Engine start c Battery charger fault* o Load shed o Master switch not in auto o Voltage, over- and iunder- o Starting aid MonitOring · Time Delays--paralleling relays (PR) for optional switchgear Standard Equipment and Features applications: o Current--over (PR) · Alarm horn o Current--over shutdown and under- · Indicators: o Frequency--over-, (PR and shutdown) o Not in auto (yellow) o Loss of field (PR and shutdown) o Program mode (yellow) o Loss of field shutdown (PR) o System ready (green) o Power--over (PR), o System shutdown (red) o Power--over shutdown o System warning (yellow) o Reverse power (PR) · Switches and standard features: o Reverse power shutdown o Keypad, 16-button multi-function soft-membrane environmentally o Synch matching--frequency, phase, voltage sealed o Voltage---over- and under- (PR and shutdown) o Lamp test · System parameters: o Switch, auto, off/reset, run (engine start) o Current, rated o Switch, emergency stop (normally closed contacts) o ECU serial number · Vacuum fluorescent display with two lines of 20 characters o Engine model number o Engine serial number Displays o Frequency o Generator set model number Some engine displays are dependent upon enhanced electronic engine o Generator set serial number control availability. . o Generator set spec number · Engine monitoring data (metric or English units): o kW Rating o Battery voltage o Phase, single andithree (wye or delta) o Coolant--pressure and level -~ o Unit number -~ o Coolant--temperature o Voltage, AC o Engine start countdown o Voltage configuration, wye or delta o Fuel--pressure temperature, and fuel rate. Inputs The fuel rate L/hr. (gal./hr.) display is the accumulated amount of fuel used since last reset by the DDC engine DDEC reader $ · Customer and remote inputs: o Fuel--used last run ~ o Analog inputs 0-51VDC (up to 7 user-defined analog inputs with c Oil--level and crankcase ~ multiple shutdowh and warning levels). pressure o Oil--pressure o Digital contact (uprto 21 user-defined digital inputs with shutdown o Oil--temperature +§ or warning levels).; o RPM o Ground fault detector* o Temperature--ambient ~ o RemOte emergency stop o Temperature---intake air § o Remote reset · Engine setpoints o Remote 2-wire start o Coolant-- high temperature shutdown and warning setpoints · Digital inputs: o Oil--low pressure shutdown and warning setpoints o Air damper fault, if equipped o Temperature--engine cooled down setpoint ~. o Air/fuel module shutdown § o Temperature--engine warmed up setpoint .~ o Battery charger fault* · Generator monitoring data: o Battleswitch o Current (L1, L2, L3), ±0.25% accuracy o Detonation shutdown § o Frequency, ±0.5% accuracy o Detonation warning § o Kilowatts, total per phase (L1, L2, L3), ±0.5% accuracy o Emergency stop o KVA, total per phase (L1, 1_2, L3), ±0.5% accuracy o Field overvoltage o KVAR, {otal absorbing/generating per phase (L1, L2., L3), ±0.5% ' o High oil temperatUre accuracy o Idle mode active (ECU models only) o Percent alternator duty level (actual load kW/standby kW rating) o Knock shutdown § o Power factor per phase, leading/absorbing o Low coolant level' o Voltage (line-to-line, line-to-neutral for all phases), ±0.25% o Low coolant temperature accuracy o Low fuel warning · Requires optional input sensors on some models o Low fuel shutdown (standard on 125RZG) Standard Detroit Diesel DDEC § Standard on Waukesha engines i G6~6 10~2b KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Syster~s Phone 920-565-3381, Fax 920-459-1646 Asia Pacific Headqua, rters For the nearest sales and servif;e outlet in the .... '7 Jureng Pier Road ';: .... ' ' - ......... US and Canada, phone 1-800-544-2444 Singapore 619159 KohlerPowerSystems.com Phone (65)264-6422,! Fax (65)264-6455 Inputs, continued Other Accessories · Switchgear inputs (to interface with switchgear system): [] Common Failure Relay remotely signals auxiliary fault, emergency o Circuit breaker closed stop, high engine temperature, iow oil pressure, o.'vercrank, and o Enable synch overspeed via one single-pole, double-throw relay with 10 amp o Lockout shutdown contacts at 120 VAC or 28 VDC maximum. o Remote reset o Remote shutdown [] Controller Cable enables remote mounting ofthe~ controller with o Run--no Icad/Icad distances of up to 12 m (40 ft.) from the generator set. o VAR/PF mode selection o Voltage--raise/lower (or VAR/Pr raise/lower in VAR/Pr mode.) [~ Controller Connection Kit provides a cable conhecting the controller output terminals to a terminal strip in thb junction box. Specify the controller corm®chon k~t ~f s~ngle-strand sol~d conductors Outputs ..... ' · See the Diagnostics section for a breakdown of the available shutdown connect the controller to remote devices. and warning functions. [] Dry Contact Kit interfaces between the controllei signals and · Controller outputs: customer-supplied accessories providing contact iclosure to activate o Fifteen NFPA 110 relay output drivers (relays not included) warning devices such as lamps or horns. Kits are available with o Thirty-one user-defined relay output drivers (relays not included) either one or ten single-pole, double-throw relayslwith 10 amp o User-defined common fa, FI! drivers (relays not included) contacts at 120 VAC or 28 VDC maximum. Communication Q Engine Sensors detect Iow water temperature, approaching Iow oil pressure, and approaching high water temperature. Note: · Modbus® RTU communication port Standard on DDEC controlled Detroit Diesel ehgihes. · RS-232 connector for a PC or modem (software required) . · SAE J1939 connector for the engine ECM (engine control module) [] Float/Equalize Battery Charger with Alarm Feature signals (ECM models only) controller of battery charger fault. Decision-MakerTM550 Accessories [] Key-Controlled, Generator Set Master Switch ~vith three positions for run, off/reset, and auto functions. Communication and PC Software Accessories [] Prime Power Switch prevents battery drain durir~g generator set Refer to spec sheets G6-38 and G6-50 for additional communication non-operation periods and when the generator set battery cannot and PC software information including KBUS and Modbus® be maintained by an AC battery charger. , communication. , [] Paralleling Relay functions and switchgear comrhunications via · Local Single Connection. A PC is connected directly to the device Modbus®. communication module with an RS-232 cable for applications where the PC is within 15 m (50 ft.) of the device or RS-485 cable for [] Remote Annunciator Panel enables the operator to monitor the applications where the PC is up to 1220 m (4000 ft.) from the device, status of the generator from a remote location. May be required for NFPA 99 and NFPA 110 installations, includes 14,-relay dry contact · Local Area Network (LAN). A PC is connected directly to the box for connection between controller terminal strip and remote device's local area network. A LAN is a system of connecting more annunciator panel. Remote annunciator panel ha's surface or flush than one device to a single PC. mounting capability. · Remote Single Connection. The PC and device are connected by [] Remote AudioVisual Panel warns the operator o,f fault shutdowns modems. The PC communicates with the device via a telephone and warning conditions. Kit includes common fault lamp and horn network and the PC can be located anywhere a telephone line can with silence switch. be accessed. [] Remote Emergency Stop Panel immediately shbts the generator · Remote Area Network. A PC is connected to a modem. The set down from a remote station. devices are connected as a LAN network. The PC communicates with the devices via a telephone network that interfaces to the LAN [] Run Relay provides a three-pole, double-throw relay with 10 amp network. The PC can be located anywhere a telephone line can be contacts at 120 VAC or 28 VDC maximum for indicating that the accessed, generator set is running. Modbuse is a registered trademark of Schneider Electric. [] Windows® Software for Monitoring and Control Windows® is e registered trademark of Microsoft Corporation. ~1 RS-232 to RS-488 Port Converters [] Cable for direct connection to a PC [] External Modems DISTRIBUTED BY: ! Availability is Subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any · obligation or liability whatsoever. Contact your local Kohler® generator distributor for availability. © 2000, 2002 by Kohler Co., All rights reserved. G6-46 10/02b ~ I 7 I s I" 5 ~, 4 I =o ...... eeee ~ ............. o ~ . ~ 0 0 DECISION-MAKER 550 20-2000 KW PART ND. I)ESCRIPTIDN 07311 /2' PIPE PLUG 196 OVERALL 16676 1/2-3/8 DBL TAP ]~OSHING 134-1/2 GENSET I 18757 IN. GALV, MUSHRDDM VENT/SCREEN J-. -- 95-3/16 I J ~ ISOLATOR CENTER ~ ~14-5/16 '/" T - - 1691013397 2'2' PIPEpiPE PLuGNIPPLE 4' LONG / 40197 3/8' PIPE PLUG ~J'lJl 1,1 . \"U II II Frei Iq u u n i 5022318089 6' EMER. VENTBusHING 4 IN - 2 IN 13399 DOUBLE TAPPED BUSHING 2IN - 1/2IN 16909 FILL CAP (HINGED) I II II II I II II II , I 49,56 FUEL GAUGE 'J Jl : ~iE'~JJlmJ Ii .i Ii mi j~ Jlml I1', mi Ii : i 49378 HI/LDV LEVEL 3.75 ND, 17.37S NC (~) : ======================================== ( ~ I(_ll~ Id " /" " . JlJ Id" " II ~ I 18453 LEAK DET. SWTCH 49878 RAIL 49884 SIDE SUPPORT ~REMDVABLE 50233 STUB-UP PANEL ASSY. TING HOLES. 49894 SUCTION/RETURN TUBES STUB UP PANEL 50236 UL 142 SCGBT 1500 GALLON- CALIFORN! k'~ (~) /~ FOR ISOLATOR MOUNTING, , '~ i-~- -~- --/ ....-~- - - i~ U i~ ii I ii I 4~-~/~6 Ii' '~./, 1] ' ' -lib ,m II'lil I'III'I' I ,' 117': ~'_'~11 ' ~ ~-- "!" . ,~ _ ,~__]i]]_ L__iJZ ~__I_~L] _ 76-1/2 NOMINAL CAPACITY DF 15DB GALLONS AND ES TI] BE TESTED @ 3.5 PSI. TANK P~RT ]]ESCRiPT[ON I~ 19~ OVERALL NPT J~ 134-1/P GENSET ITEM SIZE PORT I)ESCRIPTION 95-3/16 (A) 2' HIGH COMBO/LOS/ LEVEL --8-1/4 (]~) 2' GAUGE PORT + SPARE TYP 7 TYP, ISOLATOR CENTERS · . 14-5/16 (C) 2' FILL PORT / SPARE J . (])) 2' NORMAL VENT / I I il jl Jl ---'~l'--- il ~-il I ® Iue' I SUCTION-RETURN , _11[ Ii Ii I, I, I, 21 m(r) I 6. I PRIMARY VENI ..... _1 .... · IL_ JJ___ U J J (G) Jl/2' J LEAK DETECTION m II Im Im I <H> I ~'I SECONDARY VENT I Ii _iL ii_ I<J) I l/e' I BASIN ~RAIN 72 64 =1= = = _~ ......... ....... I <K) I 4' I 4' FILL PORT " I il il J il il il il ' _I_==_IL_ -- ___IL_ ~_~ __~1 ...... ~- I II II ~ II II II II II 4)LIFTING (8) ¢ 11/16 73 LUGS RAIL MOUNT HOLES 78 _ 78-13/32 ii ii ii ii ii ii ij ii J I 34 [ [ J iI [[ ii ii il . ,] ], I ii I ii I J _ ],__ _iL_ _ ~___ iL ....i,] _ L _iL _ 1 _ U _ J_[_ · J' 120-3/16 190 25 GENERATOR* ACCESSORIES KOHLER PC)WER SYSTEMSBatteryFI°at/EqualiZecharger 9001 ~ · Kohler automatic battery chargers feature two ,~'~'~~ charging modes to keep lead-acid and nickel-cadmium batteries fully charged without overcharging. The battery charger automatic float-to-equalize operation maintains battery voltage with no manual intervention.. · Temperature compensation feature prevents C overcharginlg or undercharging battery at high/Iow ambient temperatures. · Current-limiting circuitry prevents battery charger from overload at Iow battery voltage ~ w~N,~ I and during a short circuit. Ten amp DC current ~=-,~,~-~m'~?"-~ limit eliminates crank disconnect during I ............... generator set exercise period. OUTPUT INPUT 5 0 0 Specifications Number of Cells Model No. Output Voltage Output Amps Lead Acid I Ni-Cd Voltage Regulation I PAD-292862 12 10 6 I 9 +_1 % PAD-292863* 12 10 6 . 9 -+1% " PAD-292864 24 10' 12 18 +-1%. I PAD-292865* 24 10 12 18 -+1% Weight 26 lbs. (11.8 kg) Dimensions 10.67 x 5.63 x 16.63 in. I D x H) (271-x 143 x 422 mm) (L X * Includes optional alarm ;ircuit board. NOTE: Complies with NFPA 110 code requirements when equipped with optional alarm cimuit board. Alarm board features Iow battery I voltage, high battery voltage, and battery charger malfunction alarm contacts. I G6-15 1/95g Automatic Float to Equalize ~-- ~ Equalize Voltage When the battery loses its charge, the battery charger ' .4o~~ ; ! ~ Fioat Voltage operates in the High Rate Constant Current Mode until the = , battery voltage rises to the preset equalize level. ,, .L , .50 ye of High Rate At the preset equalize level, the battery charger switches to~i lOO% output Current ~'~ ,~/ the constant voltage Equalize Mode until the current ~.' Float Curm. nt required to maintain this voltage drops to 50% of the battery Time charger's high rate current. [] High Rate Constant Current Mode [] Equalize Mode The battery charger then switches to the lower constant [] Float Mode voltage Float Mode when the battery nears full charge. The battery charger continues to operate in this mode until AC Figure 1 input power disconnects or the current required to maintain the battery at the float voltage setting exceeds 6 amps. Temperature Compensation · ~ 60 I The battery charger compensates for battery temperature o using a negative temperature coefficient. The battery ~ 40 charger provides temperature compensation of -2mv/°C ~ . , per cell over the ambient temperature range of -40°C up to~ 20 ................. 60°C. The temperature compensation automatically ~ ' , adjusts the float and equalize voltage settings to prevent ~ _ ,' ,' : the battery from overcharging at high ambient ~ o , , temperatures and undercharging at Iow ambient ~ ........... _, ....... : _ [] temperatures. -2o I I I ' t I I ,I I I 92 94 96 98 100 102 104 106 % of Nominal Charging Voltage Figure 2 I ! G6-15 1/95g Standard"FeatUi;es -- ~ ........ e'"'~-UL ,is~dTCSA ce ifi d. · Ammeter and voltmeter indicate battery charging rate · Wall-mount, slotted enclosure with knockouts for with 5% full-scale accuracy. POWER ON lamp customer conduit installation. indicates battery charger is operating. · Reconnection blocks allow operation at 120 or 240 · AC input and DC output fuses prevent battery volts AC, single phase, 50 or 60 hertz. charger damage from abnormal overload and short-circuit conditions. · Battery charger~circuitry protected from AC line and DC load voltage spikes and transients. · Operational temperature range is from -40°F (-40°C) to 140°F (60°C). Battery charger float and · Terminal block for remote battery sensing leads, equalize voltage automatically adjust throughout the temperature range. · Automatic flOat-to-equalize operation with individual potentiometer adjustments. Charge up to 12 · Reverse polarity protection circuitry prevents lead-acid or 18 nickel-cadmium battery cells. battery charger from energizing if improperly connected. · No adjustment's are necessary for lead-acid or · Internal terminal blocks for AC input and DC output/ nickel-cadmium batteries. sensing lead connections. · Oversized transformer and SCR heatsink allow · DC voltage regulation of_+1% from no load to full load constant current Charging at 10 amps up to the equalize and AC input :line voltage variations of ___10%. voltage setting for fastest battery charging. G6-15 1/95g m KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Kohlere Power Systems · ,~Phone 920~565-338_!, Web site www. kohlergenerators.cgm ......... Asi_a Pacific Headquarters ........... Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) 7 Jurong Pier Road For the nearest sales and service outlet in U.S.A. and Canada Singapore 619159 Phone 1-800-544-2~ __ _ __ Phone (65)264-6422, Fax (65)264-645~. ~~-- 10.67 [271] ---------------~ I m .500 DIA. X .219 DIA. ~-~ 5.63 [143] · m / ~---~//,~...~ ~ L~A CUSTOMER CONNECTIONS · // ~ ,v-,.o. co,~^~Ts, C,OSE O. / // ~ LOW BA'FrER¥ VOLTAGE / t" z.oo[~?~] '1 ' HV-N.O. CONTAcTs, C~OS~ON /_ .~ r~ ~ CM -".0. CONTACTS, C'OSE ON / . tel . LOSS OF AC INPUT OR LOSS ! (2 HOLES) OF DC OUTPUT ~ ~ VIEW A~A I m OUSTO~IER IN pLrr CONNECTIONS ~ OPTIO~OARD SENSE LEADS TO BATTERY. ' CHANGED T0 AGREE AS SHOWN HVADJ LV~ ~ m m Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler Co. generator distributor for availability. © Kohler Co., 1992, 1993, 1994, 1995, 1999. All figh~ reserved. G6-15 1/95g __ ' ~] ~0 , ~ ~ 'r ................ ~ ............ ~ ..................... ~-~u~ ....................... r ..... , _ , ~ ~ ~, , .......... ,, ~ ~ 20 VAC-7A 2~ r ~ I AC FUSE DC FUSE ) -2 --Ac2 ----- ) ~ T~NSFOR~ER AC, ~,2 ~, ' I J ' ~ I ~ (R~O)~--- , ~~ ~ J ~ POWER , '1 B~CK~-~ B:' - ~ ~ ' ~ I , ~2 I I I TERMImL , ~ ~ ~6 AC INPUT FUSE MUST BE C~NGED 10 AGREE ~ I ~ LU~ ~ ~ ~ LUO I I I I I I ]7~2 ' ~HLER~ AUtO-FLOAT ~ ~_~._ DIAORAM,j WIRING 24 VOLT -- ~ BATTERY CHARGER ~ ~ 8 I 7 I 6 t 5 ? 4 I 3 I 2 TT-700 2/95a INSTALLATION INSTRUCTIONS ~ Original Issue Date: 3/94 I Model: 6-2000 kW Market: Industrial Subject: Run Relay Kits PA-273743, PA-273743-SD, PA-273744, and PA-273744-SD I I ntrod uction battery. Follow these precautions to prevent starting of the generator set by an'automatic transfer switch, remote I The run relay kit may control air intake and/or radiator start/stop switch, or engine start command 'from a remote louvers and is energized only when the generator set is computer. running. Alarms, lights, and other signalling devices can also be connected to the 3PDT relay. See Figurel. The 1. Move. the generator master switch to the I contacts are rated for a maximum of 10 amps at 28 VDC, OFF-RESET position. Disconnect the generator 10 amps at 120 VAC, and 6 2/3 amps at 250 VAC. Read set engine starting battery(les), negative (-) lead the instructions completely before mounting the run first. ' I relay kit. 2. Install the run relay (273705 or 273706) in the Read the entire installation procedure and compare the junction box. It is connected to the controller kit parts with the parts list at the end of this publication safeguard terminal strip by the wiring harness " provided. Use insulated 18-ga. stranded wire to before beginning installation. Perform the steps in the connect the relay to the controller safeguard order shown. terminal strip if the relay kit is mounted in a location remote from the generator set. Do not mount the I run relay kit more than 61.5 m (200 ft.) from the Safety Precautions generator set. Observe the follov~ing safety precautions while installing I the kit. 3. Mark positions for drilling two holes 63.5 mm (2.5 in.) apart center to center. ~ 4. Drill'two 4.0 mm (0.156 in.) holes. Install the relay · ' ~~~/~ hardware.in the desired location using the enclosed Can cause severe injury or death. I' 4, t 5[~ / 6r~ II I Disconnect the battery cables before working on the generator set. Remove the negative (-) lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the 273705 I OFF position. (2) Disconnectthe powertothe battery charger. (3) Remove the battery cables, negative (-) lead first. Figure 1 Run Relay Reconnect the negative (-) lead last when reconnecting the ! 5. Locate the safeguard terminal strip in junction box. See Figure 2. Connect the red wire ofthe run relay Safeguard Terminal Strip to terminal 70 (+) and the black lead to terminal 7N / (-) of the safeguard terminal strip. Connect the -- ~ I I relay kit according to the diagram in Figure 3. . ? ~' i ~..// Note: Do not reverse the leads to the safeguard ~'~ terminal strip because this will damage the diode and/or blow the controller fuse. 6. Mount the run relay using 2 screws (X-49-26), 2 washers (X-25-9), and 2 nuts (X-6210-3). o An adequate electrical supply is required to connect the customer-provided devices to the run relay for necessary operation. Check the electrical requirements of the customer-provided accessories prior to installation. The customer- . provided accessories should comply with applicable national, state, and local electrical ~ 3-~oo-m71-5 codes. Figure 2 Location of Safeguard Termihal Strip, 7. Reconnect the generator set engine starting Typical I battery, negative (-) lead last. Relay Sc ~hematic Safeguard Terminal A RED+ /Strip O I I A-273936-E l Figure 3 Connections for Run Relay Kit , ! Parts List Kits: PA-273743/PA-273743-SD and PA-273744/PA-273744-SD QTY.2 Washer,Descripti°nplain t PA'273743'X-25-9 PA-273743-SD I PA-273744,X_25.9 PA-273744-SD I 2 Screw, RHM, 6-32 x 1/2 X-49-26 X-49-26 2 Nut, whiz, 6-32 X-6210-3 X-6210-3 B 1 Relay, run 273705 273706 -, 2 TT-700 2~95 TT-1300 4/01b INSTALLATION INSTRUCTIONS Original Issue Date: 4/01 Model: 20-2000 kW Market: Industrial Generator Sets with the 550 Controller Subject: Audiovisual Alarm Kits: GM17070-KP1, GM17070-KP2, and GM17070-KP3 Introduction Read the entire installation procedure and compare the kit parts with the parts list in this publication before -I:he audiovisual alarm signals fault conditions to the beginning installation. Perform the steps in the order operator at a remote location. The audiovisual alarm kit shown. includes an alarm horn, an alarm silence switch, and a single fault lamp. See Figure 1. if a fault (shutdown or Observe applicable national and local electrical codes warning) ~ondition occurs, the alarm horn sounds and when installing the Wiring system. the fault lamp lights. Quiet the alarm horn by moving the alarm switch to SILENCE; the lamp remains lit until the Safety Precautions fault is corrected. See Resetting section following.' Mount the audiovisual alarm(s) in a location easily Observe the following safety precautions while installing observable by the operating personnel at their work the kit. station. Typically, .the audiovisual alarm annunciates the ~- WARNING NFPA-110 common alarm and connects to terminal 32. Alternatively, the user can select a single fault by connecting the signal lead (white) to any fault terminal. 117 (4 19/32) ~ 46 (1 13/16)~ Accidental starting. Can cause severe injury or death, -- © © Disconnect the battery cables before ' ~1 working on the generator set. O~ Remove the negative (-) lead first ~- ~ when disConnecting the battery. ~ ~ ~ ~2 Reconnect. the negative (-) lead last ~ ~ when reconnecting the battery. ~ ~m ALARM-----~---- 3 ~ NORMALS) SILENCE Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the --O O generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. Dimension are in mm (in.) A-292887-H (3) Remove the battery cables, negative (-) lead first. 1. Fault lamp Reconnect the negative (-) lead last when reconnecting the 2. Alarm horn battery. Follow these precautions to prevent starting of the 3. Alarm silenceswitch automatic transfer switch, remote generator set by an Figure 1 Audiovisual Alarm Panel start/stop switch, or epgine start command from a remote computer. Installation Procedure 2.2 GM17070-KP2 kit (350/400 kW) 2.2.1 Remove the junction box rear panel and 1. Remove the generator 'set from service, hardware. 1.1 Place the generator set master switch in the OFF 2.2.2 Remove the four screws attaching the position, controller to the junction box. See 1.2 Disconnect the power to the battery charger, if Fioure 3. equipped. 2.2.3 Mark the drill hole locations where the terminal block bracket (347292) mounts to 1.3 Disconnect the generator set engine starting the junction box top panel using the battery(les), negative (-) lead first, dimensions given in Figure 3. 2. Mount and connect the controller 2.2.4 Move the controller away from the rear of connection assembly, · the junction box in order to provide enough clearance to drill two 9 mm (0.344 in.) dia. 2.1 GM17070-KP1 kit (20-300 kW) holes in the top of the junction box. 2.1.1 Remove the junction box rear panel and 2.2.5 Remove burrs from the d~illed holes and hardware. "' cleanup all metal chips in the junction box. 2.1.2 Attach the controller connection assembly 2.2.6 Place the terminal block biacket (347292) (GM13984) to the junction box using six on the underside of the junction box top screws (X-~51-3), spacers (X-712-9), arid panel with the bracket mounting holes nuts (X-6210-4). Place the spacers visiblefromtherearofthejunctionboxand between the controller connection mount using two screws', (X-125-3) and assembly and the junction box bracket, nuts (X-6210-7). See FigUre 3. See Figure 2 for the mounting location. 2.2.7 Reposition the controller over the junction 2.1.3 Plug the wiring connection harness box holes and install the f(~ur screws. (GM17033) into the controller connection assembly's P25 connector. + ----- + 51 mm (29 b) ~ INJUNC-rlONI~OX 2.1.4 Proceed to step 2.4. i ' t (~-"- ! , . View A A GM17032- ~'~'~ , [ 1. Controller connection assembly (GM13984) ~ GMl¢028-A Figure '2 Controller Connection Assembly Mounting 1. Terminal block bracket screws 0(-125-3) and nuts (X-6210-7) Locations in Junction Box (20-300 kVV) 2. Terminal block bracket (347292) 3. Controller connection assembly (GM13984) 4. Detail A, mounting hole dimensions (top view) Figure 3 Terminal Block Bracket and Controller Connection Assembly Mouflting (350/400 kVV) 2 TT-1300 4/01 b I 2.2.8 Attach the controller connection assembly 2.4 Remove the controller cover and hardware. (GM13984) to the termir~al block bracket using six screws (X-51-3), spacers 2.5 Route the other end of the wiring connection (X-712-9), and nuts (X-70-12). Place the harness (GMl17029, GM17033, or GM16753) I betweenthe controller connection through the junction box port to the controller spacers assembly and the mounting bracket, interconnection circuit board. I 2.2.9 Plug the wiring connection harness 2.6 Plug the wiri0g harness connector into the (GM17029) into the controller connection interconnection circuit board's P23 connector. assembly's P25 connector. Connect lead ES3 to TB-1 terminal 3 and connect lead ES4 to TB-1 terminal 4. See Figure 5. If I 2.2.10 Proceed to step 2.4. access to the: interconnection circuit beard is difficult, remove the two controller panel top 2.3 GM17070-KP3 kit (450-2000 kW) screws, centerlbottom screw, and then loosen the bottom screws to swing the rear controller panel I 2.3.1 Remove the junction box upper rear panel down. and hardware. 2.7 Swing the rear Controller panel up and replace the i 2.3.2 Remove the inner panel access door screws, if previously removed. Replace the screws and swing open the access door. controller cover and hardware. Tighten all controller screws. 2.3.3 Attach the controller connection assembly I (GM 13984) to the junction box inner panel - studs using six spacers (X-712-9) and nuts ,~ ~ (X-70-12). Place the spacers between the ////~ ~ controller connection assembly and the~' ,_~,, ~ mounting bracket. See Figure 4 for the ~ ..~.OO.NEO~O, "1 mounting location. ',. I 2.3.4 Plug the wiring connection harness ,~ (GM16753) into the controller connection ,,, ~ , assembly's P25 connector. ;-,, ,, ~ ~ I 2.3.5 Proceedtostep2.4. 1,~ ~ .... ~ , , . A-365487-NGM10193B · · 1. Interconnection circuit board (top view) 2. P23 connector 3, Interconnection circuit board mounted on the controller rear panel 365569A-G/GM 16780-A 1. Inner panel access door 4. Connect lead ES3~to TB-1 terminal 3 and connect lead I 2. inner panel access door screws (6) ES4 to TB-1 terminal 4 3. Controller connection assembly (GM13984) Figure 5 Attaching Wiring Connection Harness to . Figure 4 Terminal Block Bracket Mounting in' ControlLer Circuit Board I Junction Box (450-2000 kVV) I q-['-1300 4/01 b 3 3. Mount and connect the audiovisual 3.4 Attach the audiovisual panel to the electrical box alarm panel-assembly, with four machine screws (292828). 3.1 Mount atwo-gang electrical box (not supplied) in a 3.5 Route the three leads to the contrOller connection location selected for the audiovisual alarm(s), assembly in the generator set junction box. Cut Mount the electrical box(es) flush with the leads to length, strip wire ends, crimp-on spade surrounding wall surface. See Figure 6. terminals (not supplied), and connect the leads to the screw terminals shown in Figure 7. Keep the 3.2 Supply three lengths of 18 gauge (minimum) audiovisual alarm leads away from the generator stranded wire to make the audiovisual leads long set output leads. enough to reach the controller connection assembly in the junction box (or to reach the controller terminal Typically, the audiovisual alarm connects to the strip if the fault terminal is not available at the NFPA-110 common alarm iterminal 32. controller connection assembly). Use color-coded Alternatively, the user can select a single fault by wirefor easy identification. Make leads long enough connecting the signal lead (white) to any fault to allow for walls, ductwork, and other obstructions, terminal. See Figure 8 and Figure 9 for alternate Use separate conduit for the audiovisual alarm terminal connections. leads. 3.6 GM17070-KP3 kit only (450-2000 kW). Swing 3.3 Strip each end of the leads and connect to the the access door closed and install the screws. audiovisual panel leads 2 (black), 32 (white), and 42A (red). Secure the wire connections with wire 3.7 Replace the junction box panel any hardware. nuts (not supplied). 4. Restore the generator set to service. [ sions are in mm (in.) 4.1 Check that the generator set master switch is in the OFF position. 4.2 Reconnect the generator set engine starting ~i~ battery, negative (-) lead last. 4.3 RecOnnect power to the battery charger, if equipped. " 4.4 Move the generator master switch to AUTO for startup'by remote transfer switch or remote l start/stop switch. ; wa~ 4.5 Move the audiovisual alarm switci~ to NORMAL. The audiovisual alarm lamp should not be lit. If the -"t (5) 7/32 A-292887-H alarm horn s'ounds or the lamp remains lit, refer to section 5, Resetting the audio/visual alarm. Figure 6 Electrical Box Mounting OPTIONAL ~ [~ COMMONA/V ~ t o°o°o°o° o°o°o°t _ ALARM CONNECTIONS TB8 ll ll ll®ll®t®ll®Jl®ll l ll®ll CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX I ' GM13984- Figure 7 Audiovisual Alarm Connections to the 550 Controller (Connection to Common Fault Terminal 32 Shown) 4 : TT-1300 4/0lb 3 23 -- TB1 43' 4 ENGINE START TB4 24 __ 25 5 1 & E-STOP DIGITAL INPUT 26 6 I -- CONNECTIONS CONNECTIONS ;27 7 , g ~30 ~ CONTROLLER , 10 32 ,'T~21 INTERCONNECTIO" [. 111~ ~ ~ ANALOG INPUT TB3 ~ ,~ CONNECTIONS OUTPUT 3 I 7 21 ' CONNECTIONS 2 8 41 2.._? I OUTPU~ CONNECTION,( 3 7 11 15 19 23 27 31 35 4 8 12 16 20 24 :2832 36 TB7 tROO8 IRDO9 I RDOI~RDO111 FID012~ RDO13{ RDOI 4{ RDOI~ RD01E~ RDO17 I 119131721252933 CUSTOMER CONNECTION P25 2 6 l0 14 22 ES4 ~ 34 BOARD 3 11 15 19 23 27 31 35 4 12 16 20 24 28 32 36 GM16088A-A i Figure 8 Controller Connection Kit TB6 Terminal Strip--RDOs 1-7 TB9 Terminal Strip~RDOs 24-31 Term. Description Term. Description I 42A, Battery (+) RDO24 Speed sensor, fault GND Battery (-) RDO25 Loss of AC sensing N/C RDO26 ECM loss of communication RDO1 Overspeed (lead 39) RDO27 Undervoltage' RDO2 Overcrank (lead 12) RDO28 Overfreguency I RDO3 High coolant temperature shutdown (lead 36) RDO29 Undeffrequency RDO4 Low oil pressure shutdown (lead 38) RDO30 Load shed kW overload RDO5 Low coolant temperature (lead 35) RDO31 Load shed under[requency RDO6 High coolant temperature warning (lead 40) 3 Remote start RDO7 Low oil pressure warning (lead 41) 4 Remote start I TB7 Terminal Strip~RDOs 8-17 Term. Description Note: Lead numbers~ shown in parentheses are the factory RDO8 Low fuel (lead 63) default wire designations. RDO9 Master switch not in auto ( lead 80) I RDO10 NFPA 110 common alarm (lead 32)* Note: RDO-1 though RDO-31 are customer definable with RDO11 Battery charger fault (lead 61) the following factory defaults: emergency stop, high coolant RDO12 Low battery voltage (lead 62) temperature, Iow oil pressure, overcrank, and overspeed RDO13 High battery voltage RDO14 Emergency stop (lead 48) *NFPA-110 commonlalarm faults include: I RDO15 Generator running (lead 70R) RDO16 Time delay engine cooldown (TDEC) (lead 70C) Air damper indicator (RDO-23) RDO17 System ready (lead 60) Battery charger fault (RDO-11) EPS supplying Icad (RDO-22) TB8 Terminal Strip---RDOs 18-23 High battery voltage (RDO-13) I Term. Description High coolant temperatu[e, warning (RDO-06) 42A Battery (+) High coolant temperature shutdown (RDO-03) 42A Battery (+) Low battery voltage (RDO-012) 2 Battery (-) Low coolant level (RDO-19) 2 Battery (-) Low coolant temperature warning (RDO~05) I RDO18 Defined common fault (lead 32A) Low fuel (level or pressUre) (RDO-08) RDO19 Low coolant level Low oil pressure warning (RDO-07) RDO20 Overvoltage (lead 26) Low oil pressure shutdown (RDO-04) RDO21 Idle mode Master switch not in auto (RDO-09) RDO22 EPS supplying Icad Overcrank (RDO-02) I RDO23 Air damper indicator (lead 56) Overspeed (RDO-01) Figure 9 Controller Connection Kit Terminal Strip identification with Relay Driver Outputs (RDOs) I TT-1300 4/01b 5 5. Resetting the audiovisual alarm. Parts List Use the following procedure to reset the controller Audiovisual Alarm Kits and the audiovisual alarm after a fault alarm. Kit: GM17070-KP1 (20-300 kW) !Description I Part Number 5.1 Press the ALARM OFF key on the controller Qty. keypad to silence the controller alarm horn. 4 i Screw, mounting 292828 1 Panel assembly, audiovisual alarm A-292887 5.2 Move the audiovisual alarm horn switch to I i Connectionassembly, controller GM13984 SILENCE to stop the alarm horn. The audiovisual I i Harness, wiring controller connection GM17033 lamp remains lit. 6 Screw, mount'lng X-51-3 5.3 DiscOnnectthe generator setfromthe system Icad 6 Spacer, 0.25 in OD x 0.5 in. ×-712-9 with the line circuit breaker or automatic transfer 6 Nut, 8-32 whiz X-6210-4 switch. Kit: GM17070-KP2 (350/400 kW) 5.4 Correct the cause of the fault alarm (refer to the Qty. !Description i;Part Number generator set service manual). 4 Screw, mounting 292828 1 Panel assembly, audiovisual alarm A-292887 5.5 Move the generator set master switch' to OFF/RESET position and then to the RUN 1 Bracket, terminal block 347292 position for startup. The audiovisual alarm horn 1 Connection assembly, controller GM13984 and the controller alarm horn sound because the 1 Harness, wiring controller connection iGM17029 unit is not in the AUTO position. 6 Screw, mounting ,X-51-3 2 Screw, 5/16-18 x 3/4 in. X-125-3 5.6 Verify that the cause of the alarm has been 6 Nut, 8-32hex 'X-70-12 corrected. 2 Nut, 5/16-18 spiralock X-6210-7 5.7 Reconnect the generator set to the system Icad 6 Spacer, 0.25 in OD x 0.5 in. ,X-712-9 via the line circuit breaker or automatic transfer switch. Kit: GM17070-KP3 (450-2000 kW) ~ Qty. I Description iPart Number 5.8 Move the generator set master switch to the 4 Screw, mounting ,292828 AUTO position for startup by remote transfer 1 Panel assembly, audiovisual alarm :A-292887 switch or the remote start/stop switch. 1 Connection assembly, controller GM13984 5.9 Move the audiovisual alarm horn switch to the 1 Harness, wiring controller connection GM16753 NORMAL position. 6 Nut, 8-32 hex X-70-12 6 Spacer, 0.25 in OD x 0.5 in. iX-712-9 ! 6 TT-1300 4/01 b I I ', Model: ZCS Contactor Automatic I KOHLER POWER SYSTEMS Transfer Switches 9001 Standard Features .... · Underwriter's Laboratories UL 1008 listed at 480 VAC and Canadian Standards Association CSA certified at 600 VAC TRANSFER SWITCH · Equipped with M340+ microprocessor electrical controls. See ~ specification sheet Gll-56 for electrical control features and available options · Available in 2-, 3-, or 4-pole configurations · National Electrical ManufactUrers Association NEMA type 1 i~r '~- or as open units · ~'" ~ · Available to 600 VAC, 50 or 60 Hz · Suitable for emergency and standby applications on all classes of Icad, 100% tungsten rated through 400 amps · Exceeds UL 1008 requirements for temperature rise after · mat~. overload and endurance tests in unventilated enclosure PO~/ER SYSTEMS · Auxiliary position contacts: 2 closed on normal switch position, 2 closed on emergency switCh position Model ZCS Standard Transition Model ZCS Programmed Transition · Ratings from 600 to 4000 amps · Ratings from 40 to 4000 amps · Transfer time less than 100 milliseconds · Adjustable center-off time: 2-40 seconds with solid-state (6 cycles @ 60 Hz) controls; 0:00-99:00 min.:sec, with microprocessor controls Contactor Ratings* Withstand and Closing Current Ratings Maximum current in RMS symmetrical amperes when coordinated with customer-supplied fuses or circuit breakers. Current-Limiting Fuses Molded;Case Circuit Breakers Specific Manufacturers Switch Any Manufacturer (3 cycles) (See the following tables) Rating @ 480 VAC @ 600 VAC Max. Size @ 480 VAC @ 600 VAC Max. Size @ 480 VAC @ 600 VAC (amps) Max. Max. (amps) Class Max. Max. (amps) Max. Max. Programmed Transition Models: 40 80 200 22,000 18,000 150 22,000 18,000 100 150 200,000 150,000 J, RK5, RK1 225 400 30,000 25,000 400 42,000 35,000 26O 400 600 35,000 30,000 : 800 50,000 '42,000 Standard and Programmed Transition Models: --~ 600 750 L, J, RK5, RK1 800 ? 65,000 50,000 800 ** 1200 1200 50,000 42,000 1000 3000 1600 85,000 65,000 1200 1600 200,000 150,000 2000 2500 L 2500 2500 100,000 85,000 100,000 85,000 4000 3000t 4000 4000 · UL 1008 listed at 480 VAC and CSA listed at 600 VAC. · *For an 800 A, 600 V rating, order a 1000 A, 600 V transfer switch. . Gll-52 (Model ZCS Contactor) 3/01d Contactor Ratings with Coordinated Circuit Breakers, 480 V Maximum, UL Listed and CSA Certified chart lists contactor withstand and closing ratings (WCR) for each circuit breaker manufacturer. Circuit supplied by the customer. I Molded-Case Circuit Breakers WCR, RMS Maximum Switch Symmetrical Size Rating150 I Amperes, Manufacturer~CK400HType or Class (amps) 40 80 22,000 All 150 Ampe~res Maximum 150 100 i ABB JHB ! General Electric TB4, TJL, TLB4, THLC4 · i Merlin Gerin CJ400L, 225 42,000 i ITE/Siemens CJD6, SCJD6, HJD6, SHJD6 400 260 ! Square D IL il C~ler-Hammer HKD, KDC, LCL, LATRI-PAC TB4, TLB4, THLCA 400 General Electric TB6, TJL I 600 TB8, TKH, TKL, TP, THP, TC, THC 800 CJ400L, CK400H 400 Merlin Gerin CK800H 600i CJD6, SCJD6, HJD6, SHJD6 400 , 400 50,000 ITE/Siemens CLD6, SCLD6, HLD6, SHLD6, HHJD6, HHLD6 600 MD6, MXD6, SMD6, CMD6, SCMD6, HMD6, 800 HMXD6, SHMD6 IL 400 Square D MH, ME, SE 600 HKD, KDC, LCL, ~TRI-PAC . 400 Cutler-Hammer HLD, LDC 600 HMC, NB TRt-PAC 800 General Electric TB8, TKL, TP, THP, TC, THC ITE/Siemens CMD6, SCMD6, HMD6, SHMD6 600 65,000 Square D ME, MH, MX 800 Cutler-Hammer NB TRI-PAC, DSI P06, HMDL, CHMDL General Electric TKL12S, SKP12, SKL12 800 65,000 ITE/Siemens CND6, SCND6, HND6, SHND6 1200 Square D NC, NE, NX C~ler-Hammer HND, NDC, CHND, CNDC General Electric TP, THP, TC, THC 1600 CK 1000L 1200 Merlin Gerin CM 1600 1600 1200 1000 CND6, SCND6 1200 85,000 ITE/Siemens CPD6 1600 '. 1200 NC, NE Square D PH, PE, SE 1600 Cutler-Hammer PC, PCC, PB TRI~PAC 1600' ~ 600 2000 4000 2500 100,000 All 4000 Ampere Maximum 3000 4000 Gll-52 (Model ZCS Conta~or) 3/01d Contactor Ratings with Coordinated Circuit Breakers, 600 V Maximum, CSA Certified The following chart lists contactor withstand and closing ratings (VVCR) for each circuit breaker manufacturer. Circuit breakers are supplied by the customer. Molded-Case Circuit Breakers Switch WCR, RMS Maximum Rating Symmetrical Size (amps) Amperes Manufacturer Type or Class .(amps) 40 80 18,000 All 150 Amperes Maximum 150 100 ABB JHB, MHB 400 TB4, SGH4, TJJ 400 150 General Electric TB6, SGH6 600 225 35,000 260 Merlin Gerin CK400H, CK400L, CK400N, CK400NN ITE/Siemens C J, SKM 400 Cutler-Hammer HKD, KDC, HLD, LATF~I-PAC SCL4, SGP4 400 General Electric SCL6, SGP6 600 CJ400L, SK400N, SK400H 400 Merlin Gerin SKS00N 600 400 42,000 CJD6, SCJD6, SHP, SHK, CED6, CFD6 400 ITE/Siemens CLD6, SCLD6, HLD6, SHLD6 600 HKD, KDC, LA TRI-PAC 400 Cutler*Hammer NB TRI-PAC 800 General Electric TBS, TKL, TP, THP, TC, THC, TKH, TBC8 \ ITE/Siemens CP, CN ~ 600 50,000 800 J Square D SE, SES, SEH, MA, MH Cutler-Hammer NB TRI-PAC, DSL206 General Electric TKMA, THKMA, TPMM, THMM, TPSS, TJS, TJSS, TKS, THKS, THKSS, THSS 1600 Merlin Gerin MP16H1, MP16H2, MC16H1 CND6 1200 1000 65,000 ITE/Siemens 1200 CPD6, HPD6, HRD6 1600 N C 1200 Square D PHF, PCF 1600 Cutler-Hammer PC, PCC, PB TRI-PAC 1600 1600 2000 2500 85,000 All 4000 Ampere Maximum 4000 3000 4000 Note: For an 800 A, 600 V rating, order a 1000 A, 600 V transfer switch. Gll-52 (Model ZCS Contactor) 3/01d Features Automatic Transfer Switches All ZCS Models Programmed Application Information Feature Standard Transition A high contact pressure and positive mechanical lock allow Switches are factory-wired, I for withstand and closing ratings that far exceed UL interconnected, and tested prier to · · shipment, requirements. Units are listed with UL 3-cycle, coordinated The contactor is electrically operated breaker, and current-limiting fuse ratings. and mechanically held by a simple, . · over-center mechanism. Neutral Switching i The transfer switch has segmented silver tungsten alloy contactswith Switches are available in true lo.ur-pole designs for separate arcing contacts on all sizes multi-source power systems with ground fault protection of switches. Transfer switcheshave that may require switching the neutral.' The neutral arc quenching grids, enclosed arc · · chambers, and a wide contact air contacts are identical to the main contacts and have the gap toensuresuperior same current-carrying and high withstan,d and closing source-to-source isolation on all ratings. They are designed to break last and make first to units, reduce the possibility of transients while, switching the The transfer switch components are neutral. accessible for inspection and · · maintenance without removal of the switch or the power conductors. Manual Operation A mechanicalindicator and A manual operator is a large, easy-to-use 'handle for transparent chamber cover aid · · inspection, improve safety, and ease manual operation during installation and maintenance or in position designation, an emergency. The manual operator is removable and can The transfer switch has a ' be conveniently stored within the transfer switch. double-throw, interlocked operation. ' · A disconnect switch inhibits transfer. · · Standard ZCS Models The programmed transition function allows the load's magnetic field to collapse before transferring to either · Application Information source. The drive mechanism features a unidirectibnal stroke and Switching is accomplished by a dual fully electrically energized drive mechanism that prevents DC solenoid drive for rapid operation · and long life. an accidental neutral position and ensures contact transfer The time delay after the opening of in 6 cycles or less. the closed contacts and before the closing of the open contacts is · A simple, over-the-center design achieves a mechanically adjustable, locked position in either the normal or emergency position. The transfer switch is suited for : applications where the Icad consists · Operation of large motors and/or transformers. When the normal source fails and the emergency source is available, the transfer switch energizes a solenoid that drives the main contacts out of the normal position and locks them mechanically into the emergency position. The emergency power source then supplies power to the Icad. When the normal source is restored for a! predetermined time period, the transfer switch energizes la solenOid that drives the main contacts from the emergen~cy position and locks them mechanically into the normal! position. The normal power source then. supplies power Gll-52 (Model ZCS Contactor) 3/01d Features, Continued Application Information Operation When designing a system to transfer large motors, UPS When the normal source fails and the emergency source is systems, or transformers between two sources of power available, the transfer switch energizes a solenoid that that may not be synchronous, consider the elimination or drives the main contacts out of the normal position and reduction of voltage and current transients that may occur mechanically locks them into the off position. After a preset when these loads disconnected from the first time delay, the transfer switch energizes a solenoid that are power source and immediately connected to the second source, drives the main Contacts out of the off position and Transient currents may trip circuit breakers or cause mechanically locks them into the emergency position. The damage to motor shafts, couplings, and other machinery, emergency power source then supplies power to the load. Transient voltages may corrupt or damage sensitive When the normal source is restored for a predetermined electronic equipment such as computer and time period, the transfer switch energizes a solenoid that communication systems, even in circuits that are not drives the main contacts from the emergency position and directly connected, mechanically locks them into the off position. After a preset A programmed transition transfer switch provides an off time delay, the transfer switch energizes a solenoid that period between disconnecting the load and transferring itto drives the main contact.s out of the open position and the other power source. The adjustable time off period mechanically locks them into the normal position. The allows residual voltages in the load circuits to decay before normal power source then supplies power to the load. connecting to the second source. During the off period, the ATS main contacts are open and neither source powers the load. Using a programmed transition transfer switch to transfer loads offers the following advantages: · Operation that is totally independent of the synchronism of the power sources. · Easy application. Gll-52 (ModeIZCS Contactor) 3/01d Weights and Dimensions I Complete NEMA Type I Unit Weight lbs. (kg) Dimensions, in. (mm) Number Programmed of Poles Amperes Standard .. Transition Height Width Depth 40, 80, 100 -- I 237 (108) 51.00 (1295) 27.00 (686) 19.00 '(483) 150, 225, 260 -- I 242 (110) 51.00 (1295) 27.00 (686) · 19.00 "(483) 2 400 -- 524 (238) 68.00 (1727) 27.00 (686) 21.00 (533) 600 618 (280) 638 (289) 76.00 (1930) 31.00 (787) 23.00 (584) 800 642 (291) 678 (308) 76.00 (1930) 31.00 (787) 23.00 i(584) 40, 80, 100 -- 237 (108) 51.00 (1295) 27.00 (686) 19.00 ~(483) 150,225, 260 -- 242 (110) 51.00 (1295) 27.00 (686) 19.00 :(483) 400 -- 524 (238) 68.00 (1727) 27.00 (686) 21.00 (533) 600 618 (280) 638 (289) 76.00 (1930) 31.00 (787) 23.00 (584) 3 800, 1000, 1200 642 (291) 678 (308) 76.00 (1930) 31.00 (787) 23.00 :(584) 1600, 2000 975 (442) 975 (442) 90.00 (2286) 36.00 (914) 54.00 (1372) 2500,3000 1155 (524) 1155 (524) 90.00 (2286) 36.00 (914) 54.00 (!372) 4000 2150 (975) 2150 (975) 90.00 (2286) 42.00 (1067) 60.00 (1524) 40, 80,100 -- 242 (110) 51.00 (1295) 27.00 (686). 19.00 .(483) 150, 225, 260 -- 247 (112) 51.00 (1295) 27;00 (686) 19.00 i(483). ~ 400 -- 524 (238) 68.00 (1727) 27.00 (686) 20.00 ',(508) ~')600, 800 638 (289) 658 (298) 76.00 (1930) 31.00 (787) 23.00 '(584) 4 ,1000, 1200 725 (329) 761 (345) 76.00 (1930) 41.00 (1041) 23.00 (584) 1600, 2000 1100 (499) 1100 (499) 90.00 (2286) 42.00 (1067) 54.00 (i372) 2500,3000 1295 (587) 1295 (587) 90.00 (2286) 42.00 (1067) 54.00 (!372) 4000 2300 (1043) 2300 (1043) 90.00 (2286) 48.25 (1226) 48.60 (~524) Application Data AI/Cu UL-Listed'Solderless Screw-Type Terminals for External Power Connections Switch Normal, Emergency, and Load Terminals Rating (amps) Cables per Pole Range of Wire Sizes 40 1 #14 AWG to #2 AWG 80-100 1 #14 AWG to 1/0 AWG 150 1 #8 AWG to 3/0 AWG 225 1 #6 AWG to 250 MCM 260 1 #6 AWG to 350 MCM 400 1 #4 AWG to 600 MCM · ~ 600 2 #2 AWG to 600 MCM 800-1200 4 #2 AWG to 600 MCM 1600-4000 Bus Bar Connection I Gll-52 (Model ZCS Contactor) 3/01d ATS Model Numbers Specs M340+ Controls Programmed Poles Amps Standard TransitionSwitch Transition Switch 40 -- ZCS-6xx231-0040 80 -- ZCS-6xx231-0080 100 -- ZCS-6xx231-0100 150 -- zcS-6xx231-0150 2 225 -- ZCS-6xx231-0225 260 -- ZCS-6x~231-0260 400 -- ZCS-6xx231-0400 600 ZCS-5xx231-0600 ZCS-6xx231-0600 800 ZCS-5xx231-0800 ZCS-6xx231-0800 40 -- ZCS-6xx341-0040 80 -- ZCS-6xx341-0080 100 -- ZCS-6xx341-0100 150 -- ZCS-6xx341-0150 225 -- ZCS-6xx341-0225 260 -- ZCS-6xx341-0260 400 -- ZCS-6xx341-0400 3 600 ZCS-5xx341-0600 ZCS-6xx341-0600 800 ZCS-5xx341-0800 ZCS-6xx341-0800 1000 ZCS-5xx341-1000 ZCS-6xx341-1000 1200 ZCS-5xx341-1200 ZCS-6xx341-1200 1600 ZCS-5xx341-1600 ZCS-6xx341-1600 2000 ZCS-5xx341-2000 ZCS-6xx341-2000 2500 ZCS-5xx341-2500. ZCS-6xx341-2500 3000 ZCS-5xx341-3000 ZCS-6xx341-3000 4000 ZCS-5xx341-4000 ZCS-6xx341-4000 40 -- ZCS-6xx641-0040 80 -- ZCS-6xx641-0080 100 -- ZCS-6xx641-0100 150 -- ZCS-6xx641-0150 225 -- ZCS-6xx641-0225 260 -- ZCS-6xx641-0260 400 -- ZCS-6xx641-0400 '~00 ~,ZCS-5xx641-0600 ZCS-6xx641-0600 4 00 ZCS-5xx641-0800 ZCS-6xx641-0800 1000 ZCS-5xx641-1000 ZCS-6xx641-1000 1200 ZCS-5xx641-1200 ZCS-6xx641 -1200 1600 ZCS-5xx641-1600 ZCS-6xx641-1600 2000 ZCS-5xx641-2000 ZCS-6xx641-2000 2500 ZCS-5xx641-2500 ZCS-6xx641-2500 3000 ZCS-5xx641-3000 ZCS-6xx641-3000 4000 ZCS-5xx641-4000 ZCS-6xx641-4000 KEY xx = Voltage, Frequency: 53=220 V, 60 Hz, 60=600 V, 60 Hz, 63=220 V, 50 Hz 64=240 V, 60 Hz, 66:480 V, 60 Hz, 68=208 V, 60 Hz, 71=380 V, 50 Hz, 72=380 V, 60 Hz, 73:416 V, 50 Hz Note: Models listed in this table are UL 1008 listed at 480 V and below, CSA certified at 600 V. Note: Models listed in this table have NEMA type 1 enclosures. The model number changes from xxx-xxxxxl to xxx-xxxxx0 for open units, xxx-xxxxx2 for NEMA type 12 enclosures, or · xxx-xxxxx3 for NEMA type 3R enclosures. Only models with NEMA type I enclosures and open units are CSA certified. Models with NEMA type 12 enclosures are available only as engineering specials. Note: Some voltage and frequency combinations are not available. Gll-52 (Model ZCS Contactor) 3/01d m KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Kohler Power Systems · Phone 920-565-3381, Web site www. kohlergenerators.com Asia Pacific Headquaders Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) 7 Jurong Pier Road For the nearest sales and service outlet in U.S.A. and Canada Singapore 619159 Phone 1-800-544-2444 Phone (65)264-6422, Fax (65)264-6455 m Record the transfer switch model number in the boxes below. The transfer switch model number defines characteristics and ratings as explained in the accompanying chart. Model Controls Voltage and Frequency Poles Wires Enclosure Current Rating m Kohler® Tranefer Switch ~odel Designation This chad explains the Kohler® transfer switch model numbering system. The sample model Sample Model Number · number shown is for a Model ZCS automatic transfer switch that uses a standard contactor power switching device with M340+ microprocessor electrical controls rated at 600 volts, ZCS-56034 1 ':1000 60 hertz, 3 phase, 3 poles, and 4 wires in a NEMA type 1 enclosure with a current rating of b___ ___1 L J 1000 amperes. Not all possible combinations are available. ] · / Transfer Switch Model ZCS: Model ZCS 600 volt maximum contactor automatic transfer switch Electrical Controls I 5: M340+ microprocessor 6: M340+ microprocessor with programmed transition Voltage Code (other codes possible) m 53:220 VOltS, 60 Hz 60:600 Volts, 60 Hz 63:220 Volts, '50 Hz 64:240 Volts, 60 Hz 66:480 Volts, 60 Hz 68:208 Volts, 60 Hz 71: 380 Volts, 50 Hz 72:380 Volts, 60 Hz 73:416 Volts, 50 Hz m Number of Poles and Phases 2:2 pole, 1 phase 3:3 pole, 3 phase 4:3 pole, 1 phase 6:4 pole, 3 phase m Number Of Wires 3:3 wire 4:4 wire Enclosure I 0: Open unit* 1: NEMA type 1' 2: NEMA type 12i' 3: NEMA type 3R * CSA certified · i' Available only as an engineering special. Current Rating Numbers indicate the current rating of the switch in amperes · m DISTRIBUTED BY: m m m Availability is subject to change without notice. Kohler Co. reserves the · right to change the design or specifications without notice and without · any obligation or liability whatsoever. Contact your local Kohler® generator distributor for availability. © 1994, 1995, 1996, 1997, 1998, 1999, 2001, 2003 by Kohler Co. All rights reserved. Gll-52 (Model ZCS Contactor) 3/01d I ! I M340+ Controls Automatic I KOHLER, PC)WEP-. SYSTEMS Transfer Switches O 9001 .... Standard Features I · M3'40+ microprocessor-based electrical controls for ~. ~ ==-~ .... o-°°"ta~"°'~°"o-- ~T'm"D"'"Y~___J JrC-------~ Model M and Z automatic transfer switches. o-- o...., o o-----.-. · CMOS microprocessor and nonvolatile memory for · System Status 0 0'-~,'~.~ , .... o-.~ o--- o o~ [~[~D[~(~ retention of stor'ed settings and setpoints. ^ .... ~ (~(~(~) · Digital accuracy of time delays, load transfer, and i o--- o-- o--.-- o-~ (~)[~)~)(~) generator set exerciser intervals. i ~-'=:' ;-'~ .......... ....... · Circuitry protected against EMI, voltage transients, -~- -~-, .___ . .... .,o~,~..~.,.~e ESD, shock, vibration, and other hostile '~"'""~'~'~ ...... :'E-.-.'E-_ "-__"_'--' :--'-'--::--~~ environments per U.S.A., Canadian, and IEC · : E..=_.-__ :.~- ........ ~ standards· · Conformal coating on all printed circuit boards for I Typical M340+ control panel shown without optional environmental protection· accessories · Area protection capability with override. · Normal source monitored across live lines of I single-phase switches· Normal source monitored line-line on all Phases on three-phase switches. Emergency source monitored across one phase for i voltage and frequency· · User-adjustable time delays: engine start (TDES), normal-to-emergency (TDNE), emergency-to- normal O-DEN), engine cooldown O-DEC), I off-to-emergency O-DOE), and off-to-normal (TDON). · LCD display, touch key pad, and LED indicators for I user access to system information and settings. · Generator set exerciser: choice of automatic 7-day, 14-day, calendar-based, or manual one-time" I exercise modes. · Test pushbutton to simulate a normal power source failure. I · Provision for oPtional communication with a PC. · Program transi{ion available, individual time adjustment of 2 to 40 seconds off-to-emergency I (TDOE) and off-to-normal (TDON). I ' · Gll-56 (M340+ COntTOIS) .11/99C · Additional Standard Features · LED Indicators · LCD Displays o Voltage, frequency, running time, and transfer o Contactor in normal position (green). count. o Contactor in emergency position (red). · Programming Mode Switch o Local position allows monitoring and control from o Contactor in OFF position programmed transition the local display and keypad. ATS only. o Remote position allows monitoring and control by a personal computer. o Normal power source available (green). o Off position allows system monitoring only. o Emergency power source available (green). · Other Switches o Lamp test. o System status (yellow)--not in automatic, system o Stop exerciser mode. alert, and programming mode. o Main shaft auxiliary contacts--one closed on o Accessory active (yellow)--plant exerciser, load normal, one closed on emergency. shed, inphase monitor, and area protection. · Engine-Start Contacts Specifications Sensing Ranges and Factory Settings Communication Adjustable under- and overvoltage and adjustable under- A personal computer can communicate with tl~e M340+ and overfrequency normal source sensing (all phases) and controls using Kohler-designed, menu-driven software with emergency source (one phase), installed communication accessories and additional communication products. Communication funbtions include: Voltage and Frequency Sensing Ranges and Factory Settings · Monitoring of system parameters Pickup Factory Dropout Factory Setpoint Range Setting Range Setting · Alteration of timers and setpoints Overvoltage 100-130% 110% 105-135% 115% · Star/lng/stopping the generator and transfe.rnng the load Undervoltage 75-100% 90% 70-95% 85% See Communication Products for Monitoring a'nd Control Overfrequency 100-130% 110% 105-135% 115% under Accessories for available products. Underfrequency 85-100% 90% 80-95% 85% Time Delay Ranges and Factory Settings Shunt/Jumper-Controlled AccesSories Time delay ranges are adjustable in one-second intervals. Shunt/Jumper-Controlled Accessories Factory-installed shunts enable the following accessories. Time delays are extendable to 99 minutes with option Specify these accessories by accessory number. All shunt/ DD- 100-B. A customer-supplied 12/24 VDC battery source jumper-controlled accessories are UL listed. is required to maintain controller power when using ~DD-100-B Extended timedelay, adjustable from0to extended time delays. 99 minutes. Affects TDES, TDNE, TDEN, TDEC, TDON, TDOE and load shed settings (load shedding requires accessory DD-35-N). A 12 ',or 24 volt battery 'rime Delay Ranges and Factory Settings source is required to maintain contr(~ller power when Factory using extended time delays. ,; · Time Delay Range Setting ~ DD-23-C No-load plant exerciser with overridb. Choice of 7-day, 14-day, or calendar-based ex~rcise modes. Engine Start (-DDES) 0-6 sec. 5 sec. , Normal-to-Emergency (TDNE) 0-5 min. 5 sec. .~ DD-34-A Inphase monitor, both directions. Emergency-to-Normal (TDEN) 0-30 min. 5 min./~DD-34-J Overvoltage sensing on all normal sburce phases, over- and underfrequency sensing on one phase of Engine Cooldown (TDEC) 0-30 min. 5 min. the normal source, and overvoltage and Off-to-Normal (TDON) 0-2 min. 1 sec. overfrequency sensing on one phase of the Off-to-Emergency (TDOE) 0-2 min. 1 sec. emergenc_y source. ,DD-34-Z Phase rotation and phase loss moniioring including Environmental Ranges anti-single-phasing_protection for three-phase applications. Require~ accessory DD-5-K for emergency source sensing. · Ambient temperature range '. Operation -20° to 150°F (-29° to 66°C) Storage -60° to 220°F (-51 o to 104°C) · Humidity: 5% to 95% noncondensing during operation and storage. Gll-56 (M340+ Controls) 11/99c Accesso ri es TestSwitches,3-Position This accessory replaces ithe standard pushbutton test switch. A three-position test switch permits three modes of operation. The All accessories are UL listed and CSA certified unless TEST WITH LOAD position simulates a normal power source failure. ENGINE START position closes engine start circuit. The AUTO otherwise specified. All DD- accessories are installed on (automatic) position returns the switch to automatic operation. switches with NEMA type 1 enclosures unless otherwise Momentary TEST WITH LOAD position, maintained AUTO specified and all PA- accessories are loose accessories. (automatic) and ENGINE START positions. Some DD- accessories may have additional suffixes that [] DD-6-N Momentary TEST/AUTO/ENGINE START. specify such things as the transfer switch voltage, O DD-6-P Momentary TEST/AUTO/ENGINESTART, frequency, phase, amperage, or enclosure types, key-°perated' Test Switch, 4-Position Installed Accessories Th~s accessory replaces.'the standard pushbutton test switch. A four-position selector switch permits four modes of switch operation: TEST, AUTO, OFF, and ENGINE START. The OFF position Plant Exerciser deenergizes the control circuitry and opens the engine-start circuit. Plant exerciser accessories provide a choice of 7-day, 14-day, The transfer switch does not operate nor does the engine start on calendar-based, or manual one-time exercise modes and an override 3ower source failure. The TEST position simulates a normal power function that allows the user to terminate the exercise at any time. failure. The AUTO position returns the transfer switch to automatic The generator set run time is adjustable from 0-72 hours in operation. The ENGINE' START position closes the engine-start one-minute increments, Manual one-time exerciser allows the option circuit. The switch transfers only if the normal power source fails. to exercise the generator set loaded or unloaded. Momentary TEST, maintained AUTO, OFF, and ENGINE START positions. [~ DD-23-C Plant exerciser runs the generator set unloaded. DD-23-D Plant exerciser runs the generator set loaded. [] DD-7-D Momentary TEST/AUTO/OFF/ENGINE START. ,J~DD-23-G Plant exerciser includes a two-position selector , Time Delay Override Switches switch that determines if the generator set runs [] DD-8-C Pushbutton bypasses time delay emergency to unloaded or loaded, normal (TDEN) and allows manual transfer at any time after the normal power source is restored. Auxiliary Contacts, Relay Isolated form C auxiliary relay contacts operate when controller [] DD-8-D Pushbutton bypasses time delay normal to 3ower is available. Accessory DD-14-G is a ten-relay kit. emergency ('rDNE) and allows manual transfer at Accessories DD-14-H, J, K, L, M, N, P, and R are single-relay kits. any time after the emergency power source is Each contact is rated: restored. 10 A @ 120 VAC resistive; 10 A @ 28 VDC maximum; Meters 10 milliamperes @ 28 VDC minimum. Meters are mounted on the enclosure door. Meters are not available NOTE: The transfer switch can have a maximum of one DD-14-G on models with NEMA type 3R or 12 enclosures. Meters used on and two DD-14-H through DD-14-R accessories in any open units are for NEMA type I applications only. combination. [] DD-18-G Frequency meter, analog, one phase of emergency /~DD-14-G Indicates contactor in the normal position, contactor only. in the emergency position, normal source available [] DD-18-J Voltmeter and ammeter, analog. Displays line-line (2c0ntacts), emergency source available voltages for the emergency and normal sources. (2contacts), programming mode not in OFF, and Displays line currents for the load. system alert (2 contacts). Load-Shedding Contacts [] DD-14-H Indicates contactor in the normal position. [] DD-35-N Load sequencer operates up to nine sets of isolated [] DD-14-J Indicates contactor in the emergency position, form C contacts before (adi. 0-60 sec.) and after [] DD-14-K Indicates normal source available. (adj. 0-5 sec.) switch transfer in either direction to control loads. All nine sets of contacts operate to [] DD-14-L Indicates emergency source available, shed loads in a block before transfer. From one to [~ DD-14-M Indicates ATS not in automatic mode. nine sets of contacts operate in a block or sequentially to restore loads after transfer. The [] '~)D-14~N Indicates'programming mode not in OFF. sequence interval time delay is adjustable from · [] DD-14-P indicates system alert condition. 0-5 sec. (use option DD-100-B to extend time [] DD-14-R Indicates load bank control is active, delays),. Each contact is rated: 10A @ 120 VAC resistive; 10 A @ 28 VDC max; Battery Chargers 10 milliamperes @ 28 VDC min, 2-amp maximum charge rate with automatic adjustable float. Manual Operation Switches With Override [] DD-24-xxA 12 VDC battery charger. Manual operation switches have a maintained two-position [] DD-24-xxB 24 VDC battery charger, auto/manual selector switch that permits pushbutton manual transfer to an available source when in the MANUAL position and automatic xx Voltage- and frequency-dependent code. operation when in the AUTO position. An override feature seeks an Source Monitor, Emergency available source if a connected source fails during manual operation. [] DD-5-K Overfrequency sensing 1-phase, over/under voltage- [] DD-29-X Maintained key-operated auto/manual selector sensing 3-phase, phase rotation and anti-single switch enables manual pushbutton operation from phasing protection, emergency to normal. Test Switch, 2-Position [] DD-29-Y Necessary when DD-29-X is specified and This accessory replaces the standard pushbutton te~t switch, programmed transition is supplied. DD-29-Y initiates a manual transfer to the OFF position. [] DD-6-F Momentary AUTO/TEST simulates normal power failure, key-operated. I Gll-56 (M340+ Controls) 11/99c KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Kohler® Power Systems Phone 920-565-3381, Web site www. kohlergenerators.com Asia Pacific Headquarters Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) 7 Jurong Pier Road For the nearest sales and service outtet in U.S.A. and Canada Singapore 619159 Phone 1-800-544-2444 Phone (65)264-6422, Fax (65)264-6455 Communication Accessories Loose Accessories (Cont'd.) Communication Products for Monitoring and Control Accessory Shunts Communication accessories allow monitoring or control of the [] PA-294869 Shunts to enable shunt/jumper-controlled transfer switch using a personal computer (PC) and software, accessories--quantity 10. Monitor and control an ATS locally through a local single connection or a local area network connection of transfer switch controllers, Literature and Technical'-Literature Kits generator set controllers, or power monitors; or remotely using modems and telephone lines with single or network connections. [] Gll-50 Model MMS/MNS spec sheet. See spec sheet for Generator System Monitoring and Control, G6-38 [] G11-52 Model ZCS spec sheet. (VVin 95/98/NT) for more information. [] Gll-56 M340+ Controls spec sheet. [] DD-51 -A RS-485 communication module for ATS controller. [] Gll-71 Model MMT/MNT spec sheet. [] DD-51-B RS-232 communi'cation module for ATS [] TP~5658 Model MMS/MNS Circuit Brealler/Switch controller. Operation and Installation manual. [] PA-352249 External RS-232 to RS-485 port converter for [] TP-5660 Model ZCS Controls Operation ~and Installation controller. Add cable kit PA-294992 for manual. ; connection to a PC. 120 VAC, 60 Hz. r-i TP-5664 M340+ Controls Operation and :Installation [] PA-294992 RS-232 cable and adapters to connect a PC manual. directly to an RS-232 communication module or I~ TP-5665 Model ZCB Bypass isolation Ol~eration and RS-232 to RS-485 port converter. installation manual. [] PA-294864 External modem kit for PC*. Includes 10 ft. RS-232 cable. 120 VAC, 60 Hz. [] TP-5672 M340+ Service and Parts manu;al. [] PA-294865 External modem kit for controller*. Includes 10 ft. [] TP-5678 Model MMS/MNS Operation an, d Installation RS-232 cable. 120 VAC, 60 Hz. manual. ~ [] PA-2948'66 ATS RS-485 Port communication module for [] TP-5972 Monitoring and Control Softwar~ Operation and direct or LAN connection Installation manual (Win 95/98/NT). [] PA-294867 ATS RS-232 Port communication module for [] TP-5973 Model MMT/MNT Circuit Break~r/Switch direct or modem connection Operation and installation manu, al. [] PA-353073 External modem kit for PC*. Includes 10 ft. [] PA-353647 Model MMS/MNS Transfer Swi}ch tech. lit. kit. RS-232 cable. 220 VAC, 50 Hz. [] PA-353659 Model ZCS Transfer Switch tech. lit. kit. [] PA-353074 External modem kit for controller*. Includes 10 ft. RS-232 cable. 220 VAC, 50 Hz. [] PA-353665 Model ZCB Transfer Switch tech. lit. kit. [] PA-361725 Software kit for monitoring and control, PC compatible, Win 95/98/NT version.' Other Options , *__ Uinimum~operating temperature o~f th___ese accessories 32°F (0°C). Export Boxing Available only on models with NEMA type 1 enclost~res. Loose Accessories []362186 Export boxing, 40-400A. The following accessories are provided as kits that may [] 362187 Export boxing, 600-1250A. require installation: [] 362188 Export boxing, 1600A and abov'e. Other Enclosures Neutral Lug Assembly (for Model Z only) Model ZCS transfer switches are also available in NEMA type 12 or [] PA-362151 For 40-100 amp switches. 3R enclosures. Additional enclosures may be available. The transfer [] PA-362152 For 150-200 amp switches, switch model number is changed from NEMA 1 to NEMA 3R or to an open unit enclosure as follows: Zxx-xxxxxl become, s Zxx-xxxxx3 or [] GMIO4OO-KP1 For 225-260 amp switches. Zxx-xxxxxO, respectively, I [] GM10401-KP1 For 400 amp switches. [] NEMA type 12 enclosure. Transient Voltage Suppression [] NEMA type 3R enclosure. ANSI C62.41-1980 protection from transient voltage surges produced by lightning and other sources. Protection module features metal [] Open type enclosure. oxide varistor (MOV) design and is typically connected to the normal power source terminals. [] PA-294538 For 40 amp switches. [] PA-294530 For 80-100 amp switches. DISTRIBUTED BY: ID PA-294531 For 150 amp switches. [] PA~294532 For 225-4000 amp sw tches. Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler Co. generator distributor for availability. © Kahler Co. 1994, 1999. All rights reserved. Gll-56 (M340+ Controls) 11/99c 2 I ~ B 5-5-g8 (A-2) 600-1200 AMP. WAS 800-1200 AMP. [53924J C 4-27-98 (C-t) DS - BISCONNECT SWITCH ADDED TO LEGEND. [53942]JLRHm J LOGIC m%¢~;~?TMt KOHLER CQ . . MODEL ZCS-5 .... ~*[s SCHEMATIC DIAGRAM 3 & 4 POLE c~=m AH I 14 94 ~ NONE Im~ 321287.DWC m~ 1-1 FOR INTERCONNECTION DIAGRAM SEE DWG. 321288 CH ,-,,-~ 321287 2 R_ELAY DETAIL__S 1 :EC WAS NC [5971]] VIEW[O FROM TOP AS ASSEMBLED CN1, CCE WAS C£1 [64149] d- ~.,[, ~ C INTERCONNECTIO ~ ~o7~ ~6 MODEL ZCS-5 ~PR~ALS - ~R~I~L BLUE 36 PiN CON.[CTOR 3~ ~a C0~C30~ ~ / / / ~ ~' 321208,dwg J~ 1-1 FOR SCHEMATIC DIAGRAM SEE DWG. 321287 ~ AH ,[,e]** ~ ~'"' 321288 4 I ~ I ~ I 1000--1200A (STD) 3 30.00 [762] 30.89 [785] 27.00 [SBOJ ¢ 1-1~ol ~-5) ~ c~l~l~ ~ ~T~ (~ ~m 1000-1200A PROG~MMED T~NSITION 2 · 5 50.00 [762~ 50.89 [785] 27.00 686] 1000-1200A (STD) & 4 40.00 [1016) 40.89 [1039] 57.~ [940] D (zoP ~ ~ COmROL j ~ HINGE SIDE OF O00R B ~ ......... ~ / - g J P~ING: LE~ TO RIGHT CONNECIION FOR NOR~L, ~ ~1j AT INST~TION ~.so ~3~] ~ ~ ~ ' uo~[: FLOOR MOUNTING HOLES ~ ~ ~ 1, DIMENSIONS IN [ ] ARE MILLIMETERS, (4 HOLES) .81 [21]~ ~22.1g [564]~ ~*~*w ~m ~m ~ CABLE LUG SIZE A.B.C.N WHEN PR[SEro [ ~ PRO,RAiNED ~OOELTRANSiTioNZCS ~ I~,~ DIMENSION_. PRINT AMPERE SiZE USA) SIZE (METRIC) I 800-1200) [4) t28 - 5~0 MGM [4)) 53.0 - 504.0 ~M~7. m 6 m 5 ~ 4 I 3 I 2m 4 I ~ ~ ~ I COMMERCIAL OR NORMAL S;Ot)RCE L, L2 L~ LO I I D D IS,NOLE ~HASE) L~ L~ LO 30~~ ~ ¢~~ (SINGLE PHASE) L1 ~ I EB EC ENI / ERATOR SINGLE PHASE) COMMERCIAL OR , NORMAL SOURCE L1 L2 L3 LO L2 .xxx± ANG[-ES± I GENE~TOR DNISION, KOHLER, WI 53044 U,S.A. xx S A [ FINISHTHIS D~NG tN OESICN AND D~AIL. IS KOHLER CO. PROPER~ ~D CHECXED / / ~ .O. ADV6089.DWG 1-1 ZCS, ..... [~" ADV-6089 I B ~ · 4 I 3 t 2 ~ Model' GLN/GLS/GTN/GTS Contactor Automatic KOHLER POWER SYSTEMS Transfer Switches 9001 Standard Features · UL 1008 listed and CSA certified. -- · Complies with transient tests in accordance with NEMA and IEEE standards. · Current ratings from 40 to 400 amps (250 volt maximum switches only though 200 amps) · 100% equipment rated and can be applied at the rated current without derating in open or enclosed configurations. · Rated for all classes of load, both inductive and noninductive. · Available in 2-, 3-, or 4-pole configurations. B31II.E~ · Available in NEMA types 1 12, or 3R enclosures or as open units. POWER SYSTEM ' · Model GLN, GLS, GTN, and GTS switches are available with S340 solid-state controls. Model GLS switches are available with M340 TRANSFER SWITCH microprocessor electrical controls. See specification sheets Gll-74 or Gll-75 for electrical control features and available options. · Model GTN and GTS switches have 250-volt maximum contactor power switching devices which are UL listed ,and CSA certified at 240 VAC. Shown with S340 controls and optional accessories · Model GUN and GLS switches have 600-volt maximum contactor power switching devices which are UL listed at 480 VAC and CSA certified at 600 VAC. · Transfer time less than 50 milliseconds. · Auxiliary position contacts: one closed on normal switch position and one closed on emergency switch position (mode[ GLN and GLS switches only; model GTN and GTS switches do not:have auxiliary contacts as a standard feature). · Ambient operating temperature range -4° to 167°F (-20° to 75°0). · Ambient storage temperature range -22° to 185°F (-30° to 85°C). Contactor Ratings* · Humidity range 5% to 95% nonconder~sing. Withstand and Closing Current Ratings 0NCR), Maximum Current in RMS Symmetrical iAmperes When Coordinated With Specifications Current-Limiting Fuses Molded-Case Circuit Breakers (CB) Any Specific Manufacturer's - Max, Manufacturer's (See the Following Tables) Max, Fuse Max, C'B Switch Rating Max, .Application Size Size Cycles (Amps) Voltage Voltage WCR (Amps) Class WCR (Amps) WCR @60 Hz ..~ 40, 80, 100,200 250 240 22,000 480 200,000 400 J, RK1, or 40, 80, 100,~.1~ 600 600 RK5 10,000 400 30,000 1.5 22,000 200,000 J ; 480 50,000 225, 260, 400 600 100,000 600 RK1 or RK5 35,000 800 3.0 600 200,000 J 42,000 · Current ratings listed are based on UL 1008 standards. 250-volt maximum switches are UL 1008 listed at 240 VAC maximum. 600-volt maximum switches are UL 1008 listed at 480 VAC maximum and CSA certified at 600 VAC maximum. Gll-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b Contactor Ratings With Coordinated Circuit Breakers Withstand and Closing Current Ratings (WCR) for Model GTN and GTS Switches (250 V Maximum Contactors) Rated 40-200 Amps at 240 VAC Maximum Application Voltage when Coordinated with Specific Manufacturer's Circuit Breakers as Applicable to UL and CSA Standards Specifications I Specific Manufacturer's Molded-Case Circuit Breakers Switch Max. WCR (RMS Maximum Rating Max. Application Symmetrical Size (Amps) Voltage Voltage Amps) Manufacturer Type or Class (Amps) FCL, FB Tripac 100 Cutler-Hammer/ FD, FDC, HFD 150 .Westinghouse HJD, JD, JDB, JDC · 250 Fc,HKD'FH,KD'F[ KDB' KDC, LA Tripac, LCL, DK 400100 Square D KA, KC, KH, KI 250 LA, LC, LE, LH, LI, LX, LXI 400 CED6, ED6, HED4, HED6, ED4 125 40-200 250 240 22,000 CFD6, FD6, FXD6, HFD6 250 ITE/Siemens SHJD6,CJD6' HJD6,sJD6HHJD6, HHJXD6, JD6, JXD6, SCJD6, 400 TB1 100 SEL, SEP, TEL, THED, THLC1 150 General Electric TFK,sFL, SFp,TFL' TFjTHFK' THLC2 250225 SGL4, SGP4, TB4, THJK4, THLC4, T J J, TJK4, ' 400 TLB4 Gll-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b I Contactor Ratings With Coordinated Circuit Breakers, cont'd. Withstand and Closing Current Ratings (WCR) for Model GLN and GLS Switches (600 V Maximum Contactors) Rated 40-400 Amps at 480 VAC Maximum Application VOltage when Coordinated with Specific Manufacturer's Circuit Breakers as Applicable to UL and CSA Standards Specifications Specific Manufacturer's Molded-Case Circuit Breakers Switch Max. WCR (RMS !Maximum Rating Max. Application Symmetrical Size (Amps) Voltage Voltage Amps) Manufacturer Type or Class (Amps) FDC, HFD 150 r Cutler-Hammer/ HJD, JDC 250 Westinghouse HKD, KD, KDB, KDC, LATdpac, LCL 400 FC, FI 100 Square D KC, KH, KI 250 LA, LC, LE, LH, L[, LX, LXl 400 CED6, HED4, HED6 125 40-150 30,000 tTE/Siemens CFD6, FD6, FXD6, HFD6 250 CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, 400 SHJD6, SJD6 TB1 100 SEL, SEP, TEL, THLC1 150 General Electric TFL, THLC2 225 SFL, SFP 250 SGL4, SGP4, TB4, THJK4, THLC4, T J J, TJK4, 400 TLB4 JDC, HJD 250 Cutler-Hammer/ CHKD, HKD, KDC, LCL, LA Tripac 400 600 480 Westinghouse CHLD, CLDC, HLD, LDC 300-600 NB Tripac 300-800 KC, 250 KI Square D LC, LE, LI, LX, LXl 600 ME, MH, MX 800 CFD6, HFD6 250 CJD6, HHJD6, HHJXD6, HJD6, SCJD6, SHJD6 400 ITE/Siemens ! CLD6, HHLD6, HHLXD6, HLD6, SCLD6, SHLD6. 600 225-400 50,000 ~ CMD6, HMD6, HMXD6, MD6, MXD6, SCMD6, 800 i SHMD6, SMD6 SFL, SFP, TFL, THLC2 250 i SGL4, SGP4, TB4, THLC4, TLB4 400 General Electric SGL6, SGP6, TB6, TJL4V, TKL4V, TJL1S-6S 600 i SKL8, SKPS, SKH8, TB8 800 CF250L, CF250H 250 CJ400L, CK400H, CJ400H, CK400N 400 Merlin Gerin CJ600H 600 CK800H, CK800N 800 I Gll-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b Contactor Ratings With Coordinated Circuit Breakers, cont'd. Withstand and Closing Current Ratings (WCR) for Model GLN and GLS Switches (600 V. Maximum Contactors) Rated 40-400 Amps at 600 V Maximum Application Voltage when Coordinated with Specific Manufacturer's Circuit Breakers as Applicable to CSA Standards Specifications I Specific Manufacturer's Molded-Case Circuit Breakers Switch Max. WCR (RM$ Maximum Rating Max. Application Symmetrical Size (Amps) Voltage Voltage Amps) Manufacturer Type or Class (Amps) FDC, HFD 150 Cutler-Hammer/ HJD, JDC 250 Westinghouse HKD, KD, KDB, KDC, LATripac, LCL 400 FI 100 Square D KA, KH, Kl 250 LA, LC, LE, LH, LI, LX, LXI 400 CED6 125 ITE/Siemens CFD6, HFD6 250 40-150 22,000 CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, 400 SHJD6, SJD6 TB 1 100 SEL, SEP, TEL, THLC1 150 General Electric TFL, THLC2 225 SFL, SFP 250 SGL4, SGP4, TB4, THJK4, THLC4, TJJ, TJK4 400 600 600 KDC, LA Tripac, LCL 400 Cutler-Hammer/ CLDC, LDC 300-600 Westinghouse NB Tripac 300-800 KI 250 Square D LI, LXl 600 CFD6 250 CJD6, HHJD6, HHJXD6, SCJD6 400 ITE/Siemens CLD6, HHLD6, HHLXD6, SCLD6 600 225-400 42,000 CMD6, HMD6, HMXD6, SCMD6, SHMD6 ' 800 THLC2 250 SGL4, SGP4, TB4, THLC4 400 General Electric SGL6, SGP6, TB6 600 SKLS, SKP8, TBS 800 CF250L 250 Merlin Gerin CJ400L, CK400H 400 CK800H 800 ! Gl1-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b I m Design Features Application Data Transfer Switch Design UL-Listed Solderless Screw-Type Terminals m · All switches are factory~wired, interconnected, and tested for External Power Connections prior to shipment. Switch Normal, Emergency, and Load Terminals · Switches use front-connecting lugs. Rating Cables per Range of Wire Sizes ' m contactor Design (Amps) Pole (Copper or Aluminum) 40 I #14 to #6 AWG · · Contactors offer high-speed transfer, 50 milliseconds or less, including relay operating time for all ampacities 80 I #14to #1/0 AWG exclusive of controller time delays. 100 1 #14 to #2/0 AWG I · are 150 1 #8 to #3/0 AWG Contactors of double-throw, inherently interlocked J design. 200 I #8 to #3/0 AWG (copper only) · Contacts are readily accessible from the front for easy I inspection. 1 #4 AWG to 600 MCM · Main shaft auxiliary contacts operate only with the main 225-400 2 #1/0 AWG to 250 MCM contacts and provide a positive indication of the switch position. · · Current-carrying parts are silver plated or are of a silverWeights alloy. Alloy contacts, which provide resistance to welding, sticking, and voltage drop, are shaped to give concentrated contact pressure for positive circuit continuity. Specifications Nominal Weight lbs. (kg) I · The single coil is momentarily energized during transfer, Amps r Poles NEMAType 1 Enclosed . providing long, dependable life. 2 129 (58.5) · Switching mechanisms are lubricated for life. ~ ~ 40-200 3 132 (59.9) · All switches have self-wiping contacts. / 4 135 (61.2) I · 4-pole switches use break last make first neutral switching. 213 2 (96.6) Ratings 225-400 3 218 (98,9) 4 225 (102) ' mm · All models are 100% equipment rated and can be applied at im the rated current without derating. · All switches are rated for a maximum of 30% tungsten load..D irna nsio ns However, 40 to 225-amp, 600-volt maximum switches m applied at 240 VAC or less are acceptable for up to 100% I tungsten load. Complete ATS ~ Enclosed Unit Dimensions*, in. (mm) · Switched neutral contact ratings correspond to the Specifications line-switching contacts. Amps !Height I Width I Depth I · Auxiliary contacts rated 20 amps, 250 VAC. NEMA Type 1, 5340 or M340 Controls Standards ~40-200 I 35.75 (908) 25.72 (653) 14.15 (359) · All models are UL 1008 listed. 225-400I 47.09 (1196) 26.02 (661) 15.41 (391) I · All switches meet transient overvoltage impulse withstand NEMA Type 12, S340 or M340 Controls tests and voltage surge withstand capability in accordance 40-200 I 38.50 (978) 30.00 (762) 17.15 (436) with ANSI/IEEE C37.90-1978. 225-400I 50.50 (1283) 36.00 (914) 21.41 (544) i · Switches are suitable for emergency and standby NEMAType3R, S340Controls applications without modification. · All NEMA enclosure types meet the requirements of NEMA 40-200 37.96 (964) 25.72 (653) 15.48 (393) standard publication number ICS6, and ULstandards 1008, 225-400 47.09 (1196) 26.02 (661) 15.41 (391) i 508 (ANSI C33.76), and 50. NEMA Type 3R, M340 Controls 40-200 37.96 (964) 25.72 (653) 15.48 (393) 225-400 50.50 (1283) 36.00 (914) 21.41 (544) I Open Unit Contactor Only Specifications Dimensions, in. (mm), Amps ;Height Width Depth I 40~200 11.00 (279) 9.00 (229) 4.86 (123) 225-400 (2 pole) 12.03 (306) 225-400(3pole) 15.63 (37) 13.93 (354) 7.13 (181) i 225-400 (4 pole) 15.83 (402) Dimensions for units with NEMA type 12 and 3R enclosures include permanent mounting tabs or lifting eyes. See the submittal drawings for more information, m Gll-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b Model Numbers 250 Volt Maximum Transfer Switch with 600 Volt Maximum Transfer Switch with · Solid-State Controls*~' Solid-State Controls*'~ Specifications S340 Electrical Controls Specifications S340 Electrical Controls Poles I Amps Automatic I Nonautomatic Poles I Amps Automatic I Nonautomatic 2 40 GTS-1xx231-0040 GTN-1xx231-0040 2 40 GLS-1xx231-0040 GLN-1xx231-0040 · 80 GTS-1xx231-0080 GTN-1xx231-0080 80 GLS-1xx231-0080 GLN-1xx231-0080 100 GTS-1xx231-0100 GTN-1xx231-0100 100 GLS-1xx2.31-0100 GLN-1xx231-0100 200 GTS-lxx231-0200 GTN-1xx231-0200 150 GLS-lxx231-0150 GLN-lxx231-0150 3 40 GTS-1xx341-0040 GTN-1xx341-0040 225 GLS-1xx231-0225 GLN-1xx231-0225 · · 80 GTS-1xx341-0080 GTN-1xx341-0080 260 GLS-1xx231-0260 GLN-1xx231-0260 100 GTS-1xx341-0100 GTN-1xx341-0100 400 GLS-1xx231-0400 GLN-1xx231-0400 200 GTS-1xx341-0200 GTN-1xx341-0200 3 40 GLS-1xx341-0040 GLN-1xx341-0040 x~ Voltage and Frequency Code 80 GLS-1xx341-0080 GLN-1xx34~-0080 · 61:110 Volt, 50 Hz 100 GLS-1xx341-0100 GLN-1xx341-0100 62:120 Volt, 60 Hz 63:220 Volt, 50 Hz 150 GLS-1xx341-0150 GLN-1xx341-0150 64:240 Volt, 60 Hz 225 GLS-1xx341-0225 GLN-1xx341-0225 · 67:190 Volt, 50 Hz 260 GLS-1xx341-0260 GLN-1xx341-0260 68:208 Volt, 60 Hz 400 GLS-1x~341-0400 GLN-1xx341-0400 * Models listed in this table are UL listed and CSA certified at 240 volts 4 40 GLS-1x~641-0040 GLN-1xx641-0040 and below. 80 GLS-1xx641-0080 GLN-1xx641-0080 · ~' Models listed in this table have NEMA type 1 enclosures. The model 100 GLS-1xx641-0100 GLN-1xx641-0100 number changes from xxx-xxxxxl to x~x-x~ooo(0, xxx-xxxxx2, or xxx-xxxxx3 for open units, NEMA type 12, or NEMA type 3R 150 GLS-1xx641-0150 GLN-1xx641-0150 enclosures respectively. 225 GLS-1 )o<641-0225 GLN-1 xx641-0225 260 G~.S-1xx641-0260 GLN-1xx641-0260 · 400 GLS-lxx641-0400 GLN-lxx641-0400 · xx Voltage and Frequency Code 53:220 Volt, 60 Hz 60:600 Volt, 60 Hz · 62:120 Volt, 60 Hz[] 63:220 Volt, 50 Hz 64:240 Volt, 60 Hz ' 65:550 Volt, 60 Hz 66:480 Volt, 60 Hz 68:208 Volt, 60 Hz 71: 380 Volt, 50 Hz 72:380 Volt, 60 Hz 73:416 Volt, 50 Hz · Models listed in this table are UL listed at 480 volts and below, CSA certified at 600 volts and below. ? Models listed in this table have NEMA type I enclosures. The model number changes from xxx-xxxxxl to xxx-xxx)o(0, xxx-x~oo(2, or x-xx-xxxxx3 for open units, NEMA type 12, or NEMA type 3R enclosures respectively. 1 Gll-73 (Model GLN/GLS/GTNIGTS Cont~ctor) 5/99b ~ 600 Volt Maximum Transfer Switch with Microprocessor Controls~ Specifications M340 Electrical Controls Poles Amps Automatic 2 40 GLS-5xx231-0040 80 GLS-5xx231-0080 100 GLS-5xx231-0100 150 GLS-5xx231-0150 _ 225 GLS-5xx2.31-0225 260 GLS-5xx231-0260 400 GLS-5xx231-0400 3 40 GLS-5xx341-0040 80 GLS-5xx341-0080 100 GLS-5xx341-0100 150 GLS-5xx341-0150 150 GLS-5xx341-0150 -- 225 GLS-5xx341-0225 260 GLS-5xx341-0260 400 GLS-5xx341-0400 '4 40 GLS-5xx641-0040 80 GLS-5xx641-0080 ~00 GLS-5xx641-0100 . 150 GLS-5xx641-0150 _ 225 GLS-5xx641-0225 260 GLS-5xx641-0260 400 GLS-5xx641-0400 xx Voltage and Frequency Code 53:220 Volt, 60 Hz 60:600 Volt, 60 Hz 62:120 Volt, 60 Hz 63:220 Volt, 50 Hz 64:240 Volt, 60 Hz 65:550 Volt, 60 Hz 66:480 Volt, 60 Hz 68:208 Volt, 60 Hz 71:380 Volt, 50 Hz 72:380 Volt, 60 Hz 73:416 Volt, 50 Hz Models listed in this table are UL listed at 480 volts and below, CSA certified at 600 volts and below. t' Models listed in this table have NEMA type 1 enclosures. The model number changes from xxx-x~ooo(1 to xxx-xxxxx0, xxx-xxxxx2, or xxx-xxxxx3 for open units, NEMA type 12, or NEMA type 3R enclosures respectively. ! I Gll-73 (Model GLN/GLS/GTN/GTS Contactor) 5/99b KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Kohier~ Power Systems Phone 920-565-3381, Web site www. kohlergenerators.com Asia Pacific Headquarters Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (international) 7 Jurong Pier Road For the nearest sales and service outlet in U.S.A. and Canada Singapore 619159 Phone 1-800-544-2444 Phone (65)264-6422, Fax (65)264-6455 Record the transfer switch model number in the boxes below. The transfer switch model number defines characteristics and ratings as explained in the accompanying chart. Model Controls Voltage and Frequency Poles Wires Enclosure Current Rating · · Kohlere Part Number Key SAMPLE MODEL NUMBER This chart explains the Kohler® transfer switch model numbering system. The sample model number shown is for a Model GTS automatic transfer switch that uses a 250-volt maximum contactor power switching device with S340 solid-state electrical controls rated at 240 volts, GTS-1 6423 1 '0200 60 hertz, 1 phase, 2 poles, and 3 wires in a NEMA type I enclosure with a current rating of 200 amperes. Not all possible combinations are available. Switch Classifi~n or Family G: Model GLN~_LS~TN/GTS cbntactor-type transfer switch Power Switching Device Characteristics ..T~: 250-volt maximum contactor, 40-200 amperes Lf,~. 00-volt maximum contactor, 40-400 amperes .~oeration Classification (..~ Automatic N: Nonautomatic Electrical Controls (Lo. Controller) 1: S340 solid state . f~,5;)M340 microprocessor Voltage and Frequency (other codes possible) 53:220 Volts, 60 Hz 60:600 Volts, 60 Hz 62:120 Volts, 60 Hz 63:220 Volts, 50 Hz 64:240 Volts, 60 Hz 65:550 Volts, 60 Hz 480 Volts, 60 Hz 68:208 Volts, 60 Hz 71: 380 Volts, 50 Hz 7~2:380 Volts, 60 Hz 73:416 Volts, 50 Hz Poles and Phase Number of 2:2 pole, 1 phase 3:3 pole, 3 phase 4:3 pole, I phase (~)4 pole, 3 phase NumberwireOf Wires ~j Wire 3:3 (_,,/4 Enclosure 0: Open unit 4~ NEMA type 1 2: NEMA type 12 3: NEMA type 3R Current Rating Numbers indicate the current rating of the switch in amperes DISTRIBUTED BY: Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specifications without notice and without- any obligation or liability whatsoever. Contact your local Kohler Co. generator distributor for availability. © Kohler Co. 1998, 1999. All rights reserved. Gll-73 {Mode~ GLN/GLS/GTN/GTS Cont~,ctor) 5/99b I I Model: GLS M340 Controls Automatic I' KOHLER POWER SYSTEMSTransfer Switches I cD 9001 .... Standard Features I · Microprocessor-based electrical controls for Model GLS automatic transfer switches. I __ __ --"~f,~"~=~ Contactor Position 'l~me Delay ~ ~ o-- o~ -- · CMOS microprocessor and nonvolatile memory for o-- o---. o o .... retention of stored settings and setpoints. System Status O ~ ~ o-.m o--- o o-.~ [~)(~)~ · Digital accuracy of time delays, Icad transfer, and i ^=,,o~^~ (~(~)(~)(~ generator set exerciser intervals. o__ o__ o__ o__ ~ --~ 'o..~..__~ .... ---. . ....~)~)~ · Circuitry protected against EMI, voltage transients, ! i ~-=-" -~-- !F_~: ESD, shock, vibration, and other hostile I i -=-='- '-%----'-- i?~-~'.'- environments per U.S.A., Canadian, and IEC i , ::'--;2'-.~-- "'-'--'~=' !'----':----'--"?-~-=' ~(i~ standards. :-'-E*.'--- --_ ....... .----- · Conformal coating on all printed circuit boards for I ...... environmental !protection. M340 control panel shown without optional accessories · Area protection capability with override. · Normal source monitored across live lines of I single-phase switches. Normal source monitored line-line on all phases on three-phase switches. ~ ~ Contactor Position TJmeDelay Emergency source monitored across one phase. I o-- .o-.-, o o .... · User-adjustable time delays: engine start (TDES), ~ .. o-.m o~-- o o..-~ normal to emergency (TDNE), emergency to normal O ^~*=~. (~(~)[~)(~ (TDEN), and engine cooldown. (TDEC). o-~ o-~ o~ o-~ ~[~(~) · LCD display, touch key pad, and LED indicators for I ~ user access to system information and settings. :,--~-,-~.-~. Programming,~e · Generator set exerciser: choice of automatic 7-day, I ....... -.'_.--.-.=. :'_=~:.-,.-'_ ,~, 14-day, calendar-based, or manual one-time i ~.----~7-' ........ ==-'"'"'"-' "'-~ ~' exercise modes. · Test pushbutton to simulate a normal power source M340 control panel shown with optional accessories failure, I · Provision for Optional communication with a PC. I Gll-75 (Model GLS, M340 Controls) 5/99b Additional Standard Features · LED Indicators · Programming Mode Switch controls access mode o Contactor in normal position/green), o Local position allows monitoring and control from o Contactor ir~ emergency position (red). the local display and keypad. o Normal power source available (green). o Remote position allows monitoring and control by a personal computer. o Emergency power source available (green). o Off position allows system monitoring only. o System status (yellow)--not in automatic, system alert, and programming mode. · Other Switches o Accessory active (yellow)--plant exerciser, Icad o Lamp test. shed, inphase monitor, and area protection, o Stop exerciser mode. · LCD Displays o Main shaft auxiliary contacts--one closed on o Voltage, frequency, running time, and transfer normal, one closed on emergency. count. · Engine-Start Contacts Specifications Sensing Ranges and Factory Settings Environmental Ranges Adjustable under- and overvoltage and adjustable under- · Ambient temperature range · and overfrequency normal source sensing (all phases) and Operation -20° to 150°F (-29° to 66°C) emergency source (one phase). Storage -60° to 220°F (-51 ° to 104°C) · Humidity: 5% to 95% noncondensing during operation and Voltage and Frequency Sensing Ranges and Factory Settings storage. Pickup Factory Dropout Factory Setpoint Range Setting Range Setting Shunt/Jumper-Controlled Accessories Overvoltage 100~130% 110% 105-135% 115% Undervoltage 75-100% 90% 70-95% 85% Shunt/Jumper-Controlled Accessories Overfrequency 100~130% 110% 105-135% 115% The following accessories are enabled by factory-installed Underfrequency 85-100% 90% 80-95% 85% shunts. Specify these accessories by accessory number. There is no charge for shunt/jumper-controlled accessories if ordered with the transfer switch. All shunt/jumper-controlled Time Delay Ranges and Factory Settings accessories are UL listed. Time delay ranges are adjustable in one-second intervals. [] KD-100-B Extended time delay, adjustable from 0 to 99 minutes. Affects TDES, TDNE, TDEN, TDEC, and Time delays are extendable to 99 minutes with option Icad shed settings (Icad shedding requires accessory KD-100-B. A customer-supplied 12/24 VDC battery source KD-35-N). A 12 or 24 volt battery source is required to maintain controller power when using extended is required to maintain controller power when using time delays. extended time delays. [] KD-23~C No-load plant exerciser with override. Choice of 7-day, 14-day, or calendar-based exercise modes. Time Delay Ranges and Factory Settings I~1 KD-34-A Inphase monitor, both directions, Factory [] KD-34-J Overvoltage sensing on all normal source 'phases, Time Delay Range Setting over-and underfrequency sensing on one phase of the normal source, and overvoltage and Engine Start ('I'DES) 0-6 sec. 5 sec, , overfrequency sensing on one phase, of the Normal to Emergency (TDNE) 0-5 min. 5 sec. emergency source. Emergency to Normal ('rDEN) 0-30 min. 5 Tin, [] KD-34-Z Phase rotation and phase loss monitoring including Engine Cooldown (TDEC) 0-30 min. 5 min. anti-single-phasing protection for three-phase applications. Requires accessory KD-5-K for Communication emergency source sensing. A personal computer can communicate with the M340 controls using Kohler-designed menu-driven software with installbd communication accessories and additional communication products. Communication functions include ~ Monitoring of system parameters · Alteration of timersand setpoints See Communication Products for Monitoring and Control under Accessories for available products. Gl1~75 (Model GLS, M340 Controls) 5/99b Accessories All accessories are UL listed and CSA certified unless Test Switches, 2-Position otherwise specified.. All KD- accessories are installed on This accessory replaces the standard pushbutton test switch. I switches with NEMA type 1 enclosuresr unless otherwise [] KD-6-F Two-position key-operated test switch interrupts normal power source sensing to simulate a. normal specified and all PA- accessories are loose accessories, power source failure when the switch is in the TEST Some KD- accessories .may have additional suffixes that position. Momentary TEST position, maintained specify such things as the transfer switch voltage, AUTO (automatic)position. I frequency, phase, amperage, or other enclosure types. Test Switches, 3-Position This accessory replaces the standard pushbutton test switch. A three-position test switch permits three modes of operation. The '1 nstalled Accessories TEST WITH LOAD position simulates a normal power source failure. i ENGINE START position closes engine start circuit. The AUTO automatic) position returns the switch to automatic operation. Plant Exerciser Momentary TEST WITH LOAD position, maintained AUTO Plant exerciser accessories provide a choice of 7-day, 14-day, automatic) and ENGINE START positions. calendar-based, or manual one-time exercise modes and an override [] KD-6-N Test switch. I function that allows the user to terminate the exercise at any time. The generator set run time is adjustable from 0-72 hours in [] KD-6-P Test switch, key-operated. one-minute increments. Manual one-time exerciser allows the option Test Switches, 4-Positi0n to exercise the generator set loaded or unloaded. This accessory replaces'the standard pushbutton test switch. A [] KD-23-C Plant exerciser runs the generator set unloaded, four-position selector switch permits four modes of switch operation: I TEST, AUTO, OFF, and ENGINE START. The OFF position [] KD-23-D Plant exerciser runs the generator set loaded, deenergizes the control Circuitry and opens the eng ne-start c fruit. [] KD-23-G Plant exerciser includes a two-position selector The transfer switch does not operate nor does the engine start on switch that determines if the generator set runs )ower source failure. The TEST position simulates a normal power unloaded or leaded, failure. The AUTO position returns the transfer switch to automatic I operation. The ENGINE START position closes the engine-start Auxiliary Contacts, Relay circuit. The switch transfers only if the' normal power source fails. Isolated form C auxiliary relay contacts operate when controller Momentary TEST, maintained AUTO, OFF, and ENGINE START 2ower is available. Accessory KD-14-G is a ten-relay kit. )ositions. Accessories KD-H, J, K, L, M, N, P, and R are single-relay kits. Each I contact is rated [] KD-7-D Test switch. 10 A @ 120 VAC resistive or 10 A @ 28 VDC maximum, [] KD-7-F Test switch, key-operated. 10 milliamperes @ 28 VDC minimum. Time Delay Override Switches NOTE: The transfer switch can have a maximum of one KD-14-G I and two KD-14-H through KD-14-R accessories in any [] KD-8-C Pushbutton bypasses time delay emergency to combination, normal (TDEN) and allows manual transfer at any time after the normal power source is restored. [] KD-14-G Indicates contactor in the normal position, contactor in the emergency position, normal source available [] KD-8-D Pushbutton bypasses time delay normal to (2 contacts), emergency source available (2 emergency (TDNE) and allows manual transfer at I contacts), programming mode not in Off, and system any time after the emergency power source is alert (2 contacts), restored. [~ KD-14-H indicates contactor in the normal position. Meters Meters are mounted on ,the enclosure door. Meters are not available [] KD-14-J Indicates contactor in the emergency position, on models with NEMA type 3R or 12 enclosures. Meters used on I KD-14-K Indicates normal source available, open units are for NEMA type I applications only. [] [] KD-14-L indicates emergency source available. [] KD-18-G Frequency meter, analog, one phase of emergency [] KD-14-M Indicates ATS not in automatic mode. only. I []KD-14-N Indicates programming mode not in Off. [] KD-18-J Voltmeter and ammeter, analog. Displays line-line voltages for the emergency and normal sources. · [] KD-14-P Indicates system alert condition. DisplaYs line currents for the Icad. [] KD-14-R Indicates Icad bank control is active. Load-Shedding Contacts I Auxiliary Contacts, Main Shaft, Contactor Position [] KD-35-N Load sequencer operates up to nine Sets of isolated form C, contacts before (adj. 0-60 sec.) and after [] KD-15-N Main shaft auxiliary contacts operate with the (adj. 0-5 sec.) switch transfer in either direction to transfer switch main contacts and provide positive control,' loads. All nine sets of contacts ope[ate to indication of Contactor position. One additional shed loads in a block before transfer. From one to contact closed on normal, one additional contact I closed on emergency. Order one addi[ional nine sets of contacts operate in a block or sequentially to restore loads after transfer. The KD-15-N with 600-volt maximum contactors. Each sequence interval time delay is adjustable from contact is rated 20 amps, 125/250 VAC. 0-5 sec. (use option KD-100-B to extend time Battery Chargers delays). Each contact rated 10 A @ 120 VAC I 2-amp maximum charge rate with automatic adjustable float resistive or 10 A @ 28 VDC maximum, 10 milliamperes @ 28 VDC minimum. [] KD-24-xxA 12 VDC battery charger. · Manual Operation Switches With Override [] KD-24-xxB 24 VDC battery charger. Manual operation switches have a maintained two-position xx Voltage- and frequency-dependent code. auto/manual selector switch that permits.pushbutton manual transfer I to an available source when in the MANUAL position and automatic Source Monitors, Emergency operation when in the AUTO position. An override feature seeks an [] KD-5-K Emergency source 3-phase sensing capability, if a connected source fails during manual operation. I available source [] KD-29-X Maintained key-operated ~uto/manuai selector I switch enables manual pushbutton operation from emergency to normal. · Gli-75 (ModeIGLS, M340 Controls) 5/CJgb · KOHLER CO., Kohler, Wisconsin 53044 U.S.A. Kohler® Power Systems Phone 920-565-3381, Web site www. kohiergenerators.com Asia Pacific Headquarters Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) 7 Jurong Pier Road For the nearest sales and service outlet in U.S.A. and Canada Singapore 619159 Phone 1-800-544-2444 Phone (65)264-6422, Fax (65)264-6455 Communication AccesSOries Loose Accessories (Continued) Communication Products for Monitoring and Control Transient Voltage Suppression Communication accessories allow monitoring or control of the ANSi C62.41-1980 protection from transient voltage surges produced transfer switch using a personal computer (PC) and software, by lightning and other sources. Protection module features metal Monitor and control an ATS locally through a local single connection oxide varistor (MOV) design and is typically connected to the normal ~ or a local area network connection of transfer switch controllers, power source terminals. generator set controllers, or power monitors; or remotely using modems and telephone lines with single or network connections. ~ PA-294538 For 40 amp switches. See one of the spec sheets for Generator System Monitoring and ~1 PA-294530 For 80-100 amp switches. Control, G6-35 (DOS) or G6-38 (Win 95/NT) for more information. ~ PA-294531 For 150 amp switches. t~ KD-51-A RS-485 communication module for ATS controller. [] PA-294532 For 200-400 amp switches. [] KD-51-B RS-232 communication module for ATS Accessory Shunts controller. ~l PA-294869 Shunts to enable shunt/jumper-controlled [] PA-352249 External RS-232 to RS-485 port converter for accessories--quantity 10. controller. Add cable kit PA-294992 for Literature connection to a PC. 120 VAC, 60 Hz. {~ Gll-73 Model GLN/GLS/GTN/GTS transfer switch spec ~) PA-294992 RS-232 cable and adapters to connect a PC sheet.' directly to an RS-232 communication module or RS-232 to RS-485 port converter. [] Gll-75 Model GLS, M340 controls spec sheet. [] PA-294864 External modem kit for PC*. Includes 10 f. [] TP-5991 Model GLN/GLS/GTN/GTS transfer switch RS-232 cable. 120 VAC, 60 Hz. operation and installation manual. ~ PA-294865 External modem kit for controller*. Includes 10 ft. [] TP-5994 Model GLS, M340 controls operation and RS-232 cable. 120 VAC, 60 Hz. installation manual. [~1 PA-353073 External modem kit for PC*. Includes 10 ft. [] TP-5604 M340 controls service manual. RS-232 cable. 220 VAC, 50 Hz. [] TP-5823 Monitoring and control software operation and [] PA-353074 External modem kit for controller*. Includes 10 ft. installation manual (DOS). RS-232 cable. 220 VAC, 50 Hz. [] TP-5972 Monitoring and control software operation and [] PA-354235 Software kit for monitoring and control, PC installation manual (VVin 95/NT). compatible, DOS version [~ PA-361725 Software kit for monitoring and control, PC compatible, Win 95/.T version. OtherOptions '¢ Minimum operating temperature of these accessories 32°F (0°C). Export Boxing Loose Accessories Ava, able only on models with NEMA type 1 enclosures. [] Export boxing. Other Enclosures The following accessories are provided as kits that may Model GLS transfer switches are also available in NEMA type 12 or require installation. 3R enclosures. The transfer switch model number is changed as follows: GLS-xxxxxl becomes GLS-xxxxx2 or GLS-x~o(xx3 Neutral Lug Assembly respectively. [] PA-362151 For 40-100 amp switches. [] NEMA type 12 enclosure. [] PA-362152 For 150-200 amp switches. ~ NEMA type 3R enclosure. ~ GM10400-KP1 For225-260 amp switches. · [~ GM10401-KP1 For 400 amp switches. DISTRIBUTED BY: I Availability is subject to change without notice· Kohler Co. reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever. Contact your local Kohler Co~ generator distributor for availability. © Kohler Co. 1998, 1999. mi rights reserved. Gll-75 (Model GLS, M340 Controls) 5/99b 6 ~NSFORM~R ASSY, TERM~L ~L~K DIAGRAM, SCHEMATIC 5~ 5 POLE 5 OR 4 WIRE 562114 - .40B (10.31 ~ , (10.3) WIDTH OF SLO~~3'74 TYP. - : 18.25 DIA, HOLE (NEMA 1 ONLY) R5) (NEMA 3R ONLY) ' Il I ; [~.EB.EC) ~ SIZES OF UL LISTED SOLDERLESS ~ SCR~ ~PE TERMINALS FOR I ~ ~ EXTERNAL POWER CONNECTIONS I ~ ~ TERMINAL BLOCK m ~J 40 ONE ~14 ~0 ~6 AWG so ONE ~4 TO ~/0 AW~ .58 15 ~P.~ - 4.1 [105]n~'531 (13.5 150 ONE ~8 TO ~3/0 AWG HOLE 200 ONE J8 ~0 ~5/0 AWG (COPPER ONLY) 14.15 (~59) [315] [25] · 15.48 (393) 25.72 (653) NOT~: (NEMA 3R ONLY) 1. NUMBERS IN ~ ] ARE MILLIMETERS ~-~40 (NEMA 1 ONLY ~ ~-~m-, ~ --' ADV-6424 Dc -- 8 { 7 I 6 { 5 ? 4 I 3 I 2 B I 7 I 6 I 5 ,~ 4 I ~ i 2 I A/V ALARM EMERGENCY DEC 3 CONT STOP 2 WIRE~GA.~ / BATTERY GENERATOR TERMINAL HEATER KIT HEATER KIT MUST BE MOUNTED I STRIP REMOTE [ ....... ANNUNCIATOR 10 OR 14 RELAY / CUSTOMER DRY CONTACT I ~ I HEATER KIT J COMMOM FAULT ~,m,/ j RELAY i AC CONNECTION ~4 WIRES TS - 20 GA.J KIT ~ 2 WIRE J GEN JB ,~ /18 -20GA. NEGATNE ENGINE CONNECTION. 18 - 20 GA. 5 WIRES~ FOR REMOTE ANNUC)ATOR "C" '~ 18 - 20 DA. TERMINALS OF THE REMOTE 1 RELAY 200 FT. MAX. ANNUNCIATOR 10 OR 14 RELAY DRY CONTACT RELAY(S) MOST BE HARDW)RED TO CONTACT .......................... THE DEN SET BATTERY NEGATIVE KIT BA~rERY ENGINE CONNECTION. "P" TERMINAL CHARGER J OF REMOTE ANNUNCIATOR 10 RELAY, SWITCH ~ jli OF CENSET REMOTE ANNUCIATOR TRANSFER 10 RELAY LOW FUEL __ ___ SWITCH CONTACT / KIT ~ C~_ DEN SET BAITERY NEOATNE t ' ' DEN SET SEE NOTE 1 30 WIRES M~J(. BATTERY POSITIVE & POSITIVE CONNECTION lB GA. ENGINE CONNECTION I~.~,'~ 2 WIRES - 14 GA. SEE NOTE 2 - O ~.ER',' NEO^T~ ~'J I'~'~ I "1-5DIMENSION PRINT -- SYSTEM CONFIGURATION I= FOR ACCESSORY CONMECllOMS ~ B I 7 I $ I 5 ? 4 I 3 I 2