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HomeMy WebLinkAboutABOVEGROUND STORAGE TANK #1(ABOVEGROUND STORAGE TANK) FILE #l ;FMC DIALYSIS SRVCS OF BKFLD ~ 8625 LIBERTY PARK DRIVE I _ -T- --- --- ----~-- 0 .v ,. .,. .. .~.. _- m- .,- ~ ~^ s J ..- _, «~ ~~ 4 IRE PREV~WTION INSPECTION B 8 R S P I D P/IRE ARTM T i ( -~. ~ , . _ ~') ., r.. _~ BAKERSFIELD FIRE DEPT. Prevention Services 900 Truxtun Ave., Ste. 210 ~~ Bakersfield, CA 93301 ~~ Tel.: (661) 326-3979 ^ Fax: (661) 52-2171 /.~ DISTRICT t `~ %'. ` - {~ ' i _ ' , ~° BLOCK NO. ~ ~ ; i DATE ..- EE FACILITY ADDRESS ~ ~ /O CITY, STATE, IP FACILITY NAME ~ MANAGE 'S NAME FACILI P NE N t7 BUSINESS OWNER'S NAME AND ADDRE S CITY, STATE, ZIP O NER'S PHONE N BILL TO: (IF DIFFERENT FROM ABOVE) NAME, ADDRESS CITY, STATE, ZIP, B LI G HONE NO. OCC TYPE OCC LOAD NO. OF FLOORS HIGH RISE BLDG RISER DATE ~'j -~~~~ / ( ^ YES Q NO CORRECT ALL VIOLATIONS wourww REQUIREMENTS CHECKED BELOW No. COMBUSTIBL WASTE /DRY 1 Remove and safely dispose of all hazardous refuse and dry vegetation on the above premises (U.F.C.) E VEGETATION 2 Provide non-combustible containers with tight fitting lids for the storage of combustible waste and rubbish pending its safe disposal. (U.F.C.) COMBUSTIBLE STORAGE 3 Relocate combustible storage to provide at least 3 feet clearance around motor fuse box/fire door (N. E.C.) (U.F.C.) 4 Relocate fire extinguisher(s) so that they will be in a conspicuous location, hanging on brackets with the top to the extinguisher not more than 5 feet above the floor. (N.F.P.A. No. 10) EXTINGUISHERS 5 Provide and install (amount) _____ approved (type 8 size) __ _ o b xtinguisher to be ~ ~ immediately accessible for use in (area) _______________~~~_y~l~.~. ~ ~ ` g Re-charge all fire extinguishers. Fire extinguishers shall be serviced at least once each year, and~or after each use, by a person having a valid license or certificate. (U.F.C.) 7 Provide and maintain "EXIT" sign(s) with letters 5 or more inches in height over each required exit (door/window) to SIGNS ~ fire escape. (U.F.C.) g Provide and maintain appropriate numbers on a contrasting background and visible from the street to indicate the correct address of the building. (B. M.C.) (U.F.C.) g Repair all (cracks/holes/openings) in plaster in (location) ______________________________________. Plastering FIRE DOORS/ FIRE SEPARATIONS shall return the surface to its originalfire resistive condition. (U.B.C.) 10 Remove/repair (item & location) _________________________________________________________. Self-closing doors shall be designed to close by gravity, or by the action of a mechanical device, or by an approved smoke and heat sensitive device. Self-closing doors shall have no attachments capable of preventing the operation of the closing device. (U.F.C.) Exrrs ~ 11 Remove all obstruction from hallways. Maintain all means of egress free of any storage. (U.F.C.) ,; 12 Provide a contrasting colored and permanently installed electric light over or near required exit (location) ______________________________ to clearly indicate it as an exit. (U.F.C.) STORAGE 13 Remove all storage and/or other obstructions from fire escape landings and stairways stair shafts. (Fire escapes/stair shafts are to be maintained free from obstructions at all times.) (U.F.C.) 14 Extension cords shall not be used in lieu of permanent approved wiring. Install additional approved electrical outlets ~~ELECTRICALAPPLIANCES where needed. (N.E.C.) (U.F.C.) 15 Remove multiple attachment cords from specific electrical convenience outlet (one plug per outlet) (N.E.C.) (U.F.C.) OUTDOOR BURNING 16 Violation of Section 1102 dealin with recreational fires or o en burnin U.F.C. FIREWORKS 17 Violations of Section 7802 U.F.C. or 8.49.040 of the Bakersfield Munici al Cod .C. ar fireworks. OTHER 1g j~ I ~ t ~ n 1 ~ ~ ~ f l 1 1 ~ f ~ l cr rt r" ` ` • _ ~~j j~ r~~y .~,,5 . ` / f ~ CUSTOMER: ~ LEGEND: ,. , , C.F.C. CALIFORNIA FIRE CODE SI net re Please Print Name Le I ( g ( g~ lX, Title) U.B.C. UNIFORM BUILDING CODE ~ B.M.C. BAKERSFIELD MUNICIPAL CODE INSPECTOR: ~ - ~ AP.NO.: N.F.P.A. NATIONAL FIRE PROTECTION _ ( Cl (Signature) ASSOCIATION N.E.C. NATIONAL ELECTRIC CODE Y '^"r ~ ~~ White -Customer/Original Yellow -Station Copy Pink -Prevention Services FD 2022 (Rev. 09/05) SEP-1 - ~ '-~.8~ 45 DHS L 'AND C SBDO .~ `~ 8Tl-71~cOFGLIPORk. FIRE SAFE 11NSPECTIQN REQUEST sm.e~ocroAr_,a.aa) 909 8SS 2315 P. 02 See i»sfrueffor~son ~vterse. AA~1[.YCONRACTBNAA~ TELB~lSONt:NWMBBi REOU65TflATE FRO@iAM ~ 909 383-4777 08-03-Q6 ~, dt C EVALLIA70R8NA4@ REd.IEr$iINOA6ENCYFACLfTrNUM9ER I~QUESTCOL>E IA CODES ~It~t 3 ~ t. oaGINAL a FIRE CLEARANCE t 1N3 Califor~lia eIIt Of 8ealti~ S ervices /IGENCY Llicensing & Carti~atttiOII 2 RENEWAL B. LIFE SAFETY NAB ~~ $AO BemSTdiIIO District OBiCB 3- CAPACfiY CHANGE ~~~ 964 Wast4$~ $teeef, Sldte 529 4. OWNERSHIP CFMNGE Sbn Bernardino, CA 92401 5. ADDRESS CHANGE 6. NAME CiIANOE 7. OTHER CAPACITY FAC~JfYNA1E - Freaeniue; Modirai Care ofBakersfield s~rAn4REaelAe~.+~,p 8623 Liberty Park, Suite 102 aTY B®ka:e8eld. t.',A 9331 I rAalmaoNTAT:rPeReolreRAr~ ~ _ Sbeai>f tianma (sas}49a-9s2z j ,;- 6pE;Li~LCaltarloNe --- Imtlal of an ~d Stage Renal Disease Center. '~s~~~~ ~BalTessfield ~Y Flee #9 wur~pRrrrY 7912 Westwood Alive NAIAE /1ND Bakersfield, CA. 93309 AOtbgEBS 1___ CFtRB Nl1M~ER 1 1 O i ES1ZD IA1A®ERdFBU1LDIfN 1 RES1RAp0T wolriae 6 AM to 6 pM 1. FI CLFJIRANCE GRANTID t FRE cLEARANL"E DENIED A. E%iT'B 6- CoNBTitUCTI4N C. FIRE ALJ~[~lyl O. SPRINKLERS E. HOU3EI~INO F. SPECWL HAZARD Q- OTHER d ~~-Y ~ ~~~ n ~ }~.~~ '~ SEP-11~-2006 08 45 DHS L RND C SBDO 464 West 4~' Street, Suite 529 San Bernardino, CA 92401 (909) 383-4777 FAX (909) 888-2315 909 888 2315 P.01 L-_ prom: /~ 1 '! ~g ~r Faa~ ~ ~~ ~/ / ~ Pages: Phanac ~ ~ d~ ~ ~ ~ ~~ I~tee ~ r~ ^ Urgent ^ por Review ^ Please Comn~~ ^ Please Reply ^ please Reayde ~ . ~1~1~5( ~// ovr ~. z . m4i/ ~'iyi~i/ .siyrruf~irC ropy ~o ~n~ ~- Qc~~SS ~i° 3 - ~, sr~n~d r~1°y ~~s u yam' ~y, ~~ 7 X6,/7 Cd ~ ****** HP MFP Digital Sending: Delivery Confirmation ****** The following job has been successfully delivered to the specified recipient(s) and/or intermediate server. ---------------- Original message header ------------------ From: BFD HazMat 900 Truxtun - 10.1.17.55 Date: Monday, September 25, 2006 4:12:30 PM Subject ---------------------.Recipient List ---------------------- 19098882315 [successful transmission] _ ~. ****** HP MFP Digital Sending: Delivery Confirmation ****** The following job has been successfully delivered to the specified recipient(s) and/or intermediate server. ---------------- Original message header ------------------ From: BFD HazMat 900 Truxtun - 10.1.17.55 Dater Monday, September 25, 2006 4:16:12 PM Subject:. ------------------=-- Recipient List ---------------------- 6647168 [successful transmission] 1 • ' ABOVEGROUND STORAGE TANKS ~~~~ ~,~ APPLICATION FO~tM ~ Tel.. (661) 326-3979 FOR INSTALLATION !REMOVAL OF AN AST Fax (661) 852-2171 Page 1 of 2 INSTALL u REMOVE P~IVIIT: ~ '~ 1- O So FACILITY ~ *~ C 1,J ~ ~ L~S `S S ~1` ~ ~,S O~ ~ ~' ~SI~~ ,-J ADDRESS ~ S L-FSF~Z `Pa.R-~~i~~~E ~j~l<c~g~~~] CIS. 93311 OPERATORS NAME PERMiT TO OPERATE NO. OYtlNERS NAME , B~ w1,~ (~PPl.ict~.olJS 6F CA,.t~ocl.~+ta I ~ c NUMBER OF TANKS TO BE INSTALLE ~ /REMOVED ~ ......... :: .~~~~ _~ay..Y y_` 3 %(k'i'i.'. ~`: ivy -';l ?..S'.,-~tP ~~. '1. w.`s_. ,'?i:~ry'.' .s~ ~7 m?nt~.~'• .~~G•.., ..1 .. M:~v. J v ~. .~...>.-.~ ~~ .+'r .,,..,: ;.'," ,a~t.~.i}f`e.'i .¢Ys~:•." ~~ a.. ..:•:.t ~:. < ti ....~ ~~. .:~ 1 ~ 2 ~ ~ ~SEL ~-C,D1J NAME OF COMPAIiY INSTALLING 3 ! OR REMOVING TANK(S) - MAILING ADDRESS 3805 l 2 ~ . L.Ils~j ~ ~-~ --- ~~f=~~~-~-..i~.k Z.. ~~ ~~ NAPE A PCNO'NE NUMBER OF CONTACT PERSON /,1 ~b~ ? G ~J - ~ j G O ~ ~ f~ ~M, 1.-~. (`-`C J C (O DATE ~ TIME T 18 TO BE INSTALLED OR REMOVED ~ ~ o _~- 9 :od ~ ~ SIGNATURE OF APPLI DATE ~~ Q APPROVED BY DATE FD 2081 (Rev. o91os) BAIfERSFIELD FIYtE D~P'~. } >, Prev~entioa Serves ~~~ 9001~-uxttui Ave., Ste. 210 ~~>r~ Bakersfield, CA 93301 .zan.zaS x~.3 £00/ZOO 3J~'d 05 ~ OT 9002/LZ/~ x~,~~q~i}l ~ ~ Lb~Oti 900ZiLZibO :~ . ABOVEGROUND STORAGE TANK BAKERBFIELD FaZL DELnT. Preveatioa Services 900 nttxtun Ave., Suitie 210 GUIDELINES FOR PERMIT TO INSTALL/REMOyB ~~t Bakersfield, CA 93301 AST FOR DrSPENSING OF FLAMMABLE OR COMBUSTIBLE AiiRT/ Tel.: (661) 326-3979 LIQUIDS AND CONDITIONS FOR CLOSURE, EXCAVATIQM, ~ Fax: (661) $52-2171 REMOVAL 8 DISPOSAL. SOIL SAMPLING, PRELIMINAF(~f ~. SITE ASSESSMENTS Page 2 oft GUIDELINES FOR PERMIT TO INSTALL AN AST FOR DISPENSING OF FLAMMABLE OR COMBUSTIBLE LIt~UIDS 1. Any above ground storage tank irrsffired wilhir the City of IxPkersfiek! for the purpose of dispensing motor vehfde fuels must meet the requiremerAs of section 5202.3.7 of the Cafifomia Foe Codts, 2001 Ediiorr and Bakersfield Municipal Code. 2 The tank sores shelf not exceed a capaady of t-vo thousand (x,000) gaions individual or four thousand (4,000) galbns aggnagate. Any above ground storage Of peboleum with a cumulaflve Y of more than 1,320 galbn must complete a Spill Prevention, Control and Counterrrreasure (SPCC) Plan, per Cafifnmia Health & Sall Code Division 20 Chapter 6.67. A copy of this plan must be submr7led ~ the Bakersfield Fire Department OfTice of Prevention Services l4ot~d at 900 Tnactun Avenue, Suite 210, Bakersfield, CA 933oi and can be reached at t361 -326-3979. 1. Provide tvw sets of a pbt plan for the faality. This plan must Indude bcatiorr of properq± lines, all fauidings and openings ffi Bch build'mg (such as windows. doors. . etc.), nearest road or iirttetsec6on, all tAr>ks piping, any fiared source of ignllion (i.e., water heaters, forced air, AC units, etc.), aQ foundations, and equipment io be s~ffiyed. 2. Caistn,ction detects of tank pad seismic straps or fodures, and sash posts. 3. Certification by the manufacture than the tank meets the appQOabte codes. 4. ktentification of the maffiriafs b be stored in the above grid storage tartlc. 5_ Buid"mg permits for all reinforced corraete and elec~ical vrgrK must be obtained at the Bakersfield City Build'mg Department located at 1715 Trurdrm Avenue, Bakersfield, CA 661 -326-372x. Construction cancel begin without their approved permit. 6. Complete arty rreoessary application for the Air Polution Cgnpol D"rstri[3 for any storage or dispensing of gasd'ne or aviation fuel. 7. Appfa:atiorrs must be fully completed or they will be retunted: Iro earoeptiorrs. S. Pemrit fee must be submr~ted with the application or the apptieation will not be processed. 9. A final inspection must be completed before AST system is qpp fatiortal. This is to insure oomplbnce with the UFC regard'mg placement of placards, and where applicable, the testing of emergency shuts device, and overfi9/overspill. GUIDELINES FOR PERMIT TO REMOVE AN AST Tanks may not tye removed without an inspector present. 301E SAMPLINGlPRELIMINARY SITE ASSESSMENT i _ Sol samples shall be abffiired under the diecilon of a protessi0nal engineer, geobgist, or aWrorimed nrpreset~ve of a state-approved faboratoty. 2. Samples shall be ooeected, at a mir~rrum, from depths of 2 and 6 feet bebw the tank bottom, dispensers, and product foes and from the talawing locations (carless waived by 1'he Ibrraf agierxy>»spedtliran syl`e): A From the oerrtar of the tank B. Betovv ore dispensers. C. Pipatg - every 20 feet andlor at oonrtections, joints, bends, etc. 3. Arty area of obvious cortffimirration of liceh/ areas of carrharni-~jon may tae requtied to be sampled. 4. Aft samples shay tae analyzed by a state certified laboratory. 5. Sol samples shag be anatyned for a• known and suspec6~d subslanoes to have been stoned in the tank Methyl Tertiary Butyl Caher (M'rBE) shag addEarraly tae arralyded in ai sot samples taken from berms ttlrllc systems which contained any motor vehide fuel. 6. At samples wi tae aooompanied by a Chain-Of~Cr~tody sf~t. 7. A soil serrnpfe reportlpreJ~rrinary asse.~srrrerrt sha0 be submits ip the Office of Prevention Services wrltrirt Eve days after tesr~ls have been received and shall contain at a mirririum the toitowing irrWmiation. A Name and bcation of where the ffinks were disposed of_ B. Name and lora6ori of where the rinseale wart disposed of. C. A signed copy of the Ha¢ardous Was6e Marti test D. A tank disposal receipt from the scraping faGlll~. E Copies of all lab data sheets and Chain~OF (`,ystody docaanentalion. F. A plot plan SFiowrg the locations of the biclldit~gs, tanks, pQaiig runs, dispensers, and ALL SAMPLE LOCATiON.S WITH CORRESPONDING I.D. NUMBERS AND ~PTHS. FD 2081 (Rev. os/o5) .zanaaS X~3 £00/£00 3JVd 05~OT 9002/LZ/~ ~~3~~~z33 ~ Zl Lb=Oi 900ZiLZibO .I MORTAR GAP rig ~ D ~ 2-#5 IN 8" D~f ~ ,~ GROUTED SONG f SEAM ~ ~ SOLID GROUT 8 x 8 x I6 GMU STEM TD FIN. 51NGLE SCORE MATCH BUILDING GRADE I , ~ WALLS. ~ 2-#5 GOVT. IN DOWI=L.S TO MA " EXISTING GONG. - 8 DEEP AND LAP ALL y~ALK ~ ~ 0 GROUTED VERT. WALL REI ;q BOND BEAM GONG. SLAB ~ A5 REQUIRED TO CLEAR EXISTING BUILDING FOOTING I ~I . GONG. fi FOOTING ~p~ ~' H4 ~ ., -o -o ,~ 2-#5 ~ ~ GONT a ~ , a,. 4 4 ~? ~! I~ ! ~ sa ,I ~ , L I II -I ~II VII I~~ - ~ ~ I I I I I 2'-4° i~ l) ~ . _.,.,. ~z ~ i __. W_ ~.. ~ ~ H4 ~CMU-ENCLOSURE-VVALL W G~~ UJ ~ ~ . ~tn ~•~~. b y v~ , ~~ I ' ° ' u i -0 -O GENERATOR I ~ PER GUT SH~T~ FIN. I ~~ GRADE L d- ! ~ ~ ~~t . I~I i I mom / , 8'-0" I, I 4'-0" ~ I [ \ #5 ~ 12" O.G. EACH WAY TOP AND BOTTOM AS SHOWN - GLR. ' LAP = 30' A5 OCCURS REMOVE AND RELOCATE i' EXISTING LANDSCAPING AND jj I IRRIGATION SYSTEM AS j REQUIRED TD CLEAR II I `- 12'-0" x 5'-5" GENERATOR ENCLOSURE I VERIFY W/ 6c~NERATOR Mfg. CONNECT GENERATOR TO SLAB/ f ~~ I L FOUNDATION W/ BOLTS PER MFR. RECOMMENDATIONS: EMERGENCY ~5 GENERAT®R ENCL®SU fc' = 3000 PSI Fy =60K51 GENERAT®R H5 SLa4BIF0UNDATI®N ~i { L I n VICINITY MAP 475 GALLON ABOVE GROUND STORAGE TANK FOR FMC -Dialysis 8625 LIBERTY PARK DRIVE BAKERSFIELD, CA ~e~ ~c , E~ SN?:. MRR/ ~ t U~ 6 APRI~C~~ED BAKERSFlELD FIRE DEPART~ENf OFFICE OF ENVIRONMENTAL SERVICES NOTE: Acceptance allies to plans as submitted and for constru tfon and;or ~stailat?on thereon, sub;~ct to final ion and,@cceptance. SIB ~, ~~ ~~~~ ~~ tiE~ 18d ~f - kp u~ 'nl ~S~l A6o~2 C~~p, ~~. ~R~1~~1 ~~ N -~ 475 GALLON ABOVE GROUND STORAGE TANK FOR FMC -Dialysis 8625 LIBERTY PARK DRIVE BAKERSFIELD, CA ~..-~~;.[.1=i/~_'~'~FJr=, ~i?::l f i"~ (~;_:NS'?"NUC7It~Pd ~_ _ ~ ; tom. (~~~ POWER SYSTEMS ~1 c+Gs~~rc~•a171t Ley aapzrating personnel ;~a n nrsamai ~rark statir,n. Na<.3T~ ~n~, c+~n~'ai:~~,tiar, of ?x.,'41' aitirzais andJc: x~rrc-te a~t3:~.ur!.cs~ttrars talaiin~ tl~.a-e~; may lie cr~r~nrcted tc cir~: ~eneraicr see ~:corDtrolier.. t;~r~dby ~~~~lr~~~r ~~1~~ '~~ 'lie ~:udio--•Visual lA/~~} ala,nzt tivarrts the c~p~;rntor of taulr shutdrw-n anfl pre-ralann ccrnciitions (except batteb~,r Nh~inrC t"aalt snd law battery vc~.t:agc) #'ro~, a location rn3oCs: of th;, gerserator set. 'Tl~e pre•--alarms are aTraila~lc o:~ly ~vitla lea-3 cony©llers. lnclutiecl i.n the ~!V dlarna l;it is a chirue alaarrn, an alarm aileae;; s~vit.ch, ar~d a eommor~ fault lamp. See p'ioure 1. Flgttre ]. A1V ~larnn Pastel ,.,,,, Tr a ~~atatt s11ut~vrrx or pre-alarm oarrditican occurs, tkte chime alarrra r~riil saaJtt:l aaa.~?. the corrtrrron iav.lt Iarsap will light. fila4 chinYC ~tipar(n i.s defea,~:ed ly rn4vin~ the AlU alarn~ su~itcla to 51~,~A1~;L. Wish ;~ee~~ satin#t•trilers, the fault lamp will rerna.iiz lit. until tl~e fault c~arditio~rl is corrected ar,d the ccratroller is reset, Weth R~'atataal( IiLela.~~ c~eatroilexs, the fain? l~rnp will gw 4~.1t where zhc gertexatar RLTA/STtJIr switch is raa~~arcd tc~ il~e S"ftJP pasiti.on: See "~.esPtting" swetian lol!c~wirrg. ~'o prol-erly rrtorrit~: the cand;'tioi~ rsf the gunera.t~~r, rile AIV ala.t~trt(s) should. h: rr:ou,raierl. era a lacatior~ readily ~'~-:~ "~ ~r~~ T'!se auclic-~~i,aet4al alarr9- l;it a}t~Mald ra~~t be directly ~o9in.~:.cted to a L1Eac, 3 cor~trnller. A r!a^y votttuct icit mta~~r l~~s used wl~eaa anstallirag era ludic-••visttktl al~°tn kit ~ a gener•at~r set •with aDec-3 coiztrolle:. 7"he r1/V alarirr 1~:it car; tlr.e;r~ be rala:uected to the dry cr(rit~ct lcit zllo+~iaag~ bettI• access to elccu•icai sQrurectioxis and }~rc~vidtr~~ protcrti~rn t:~r the eontr~~Ilea_ '~'6'.~-f~ihlil'~C; accidental starti~~. dart caress se~erQ itaju~ry or death. ~isceuircr:t baxtey~ cables before working on ~ealtr~rtc~r set ~negat:ve lead first and recaniyect it l:asi}. ~rcisl(ental st~rtiar$ care c~a.rase severe injtary nr death. 'T'u'rn ~(;etz4rator "vlaster Swiich tti ®PF }~sxtiorr, di{,cannwct. po+a~cr t~ ha?tc6;~ charger, an~f rcrtat,ue batt~ay cables ,rctnsa+~~c n~grltive lead first art~~~ rECOi~ect it last) tc, ~'isabl~e ~Zexleratc~r set before worlcirag on a;iv equipla2ent corttu~*ctecl I:u generator. Tl:e neRZril,tC+A' SCt C@13a ~~ Star'terl t~;+ automatic aaalsler switch or rcasc~te stast:'stop swiCWla unless rlaese prec;rirtit~rrs are fc~llni~~ed. ~=„~p.~:. ?~~r~6 i~~: a? ~ r`{i: ~:::~PJS~rR4 ~:"i Ir~;rJ J N::~. 2~r'~' ~a11 l~Q'F~ ,A~.pg~iicable lu~:a.i and. r•:atic~n;rl ~:ic;ctrical cofi.es .oust: be ulascrved wh;,n inst-a.llizzb the A,'~/ ~~iarrt- ;~~iri~ig _- ~ sx~stem. t~lzJ' :#larnn .€n4t~il~tian ,x` ~ ~~' Dove cont~~aller roaster s,xjzteFt tQ ~~~~'!I~.CS~.~' p+~siticazz.. ?~isc~nnrzect gc~zrerato! se: l~trttez~~, negative lrYad first., Mfluz-t a suital:-ie tiw~o--g$ng elect-;.ca1 box (zz~st supplied} in lor.:atinn selected far ear.}D 1~1'J a1~.rxtt. ,!~!W alt~z7tz par.-ei requires a mie-itt-um !r_ourft~ng dr;pth of ~I~ iz~. (l9 rr~}. Bc st:~x~ t~~ itnt;lucie suf~rcient rovrzr far ~vwring. The electz~ical ladx.(~s} shoulr3 I~€: rna~reci,l7uslz +~ritl'~ the suYraaeiYding wvall st7,rfac~y culz.er~: pnssiblc. Sep; pigul•e `. ~~a ~s, CSQ'iE 4~~F ,..~~ }~lgure 7~, l~lew~'ical $tex Pa~Tc~z~rttlzag 3, Use three cazzdt~,cto~rs ~~f to nr `t~ ~aCUpe scrrn3tfed wire 1010 ~. E3~~ rn} rs~x. ?~Rr ~.~;nzaect ?~N alarm ro ~~Dez~<,tc7r set. C7se a; role-:~--:o~~lkd. 54'Dre I~ flu""C1111JA'ltrrl.c~G1~. ~C.Y' 4°e'l~~r ~.~lWrltl'~iCf-L.lrJl'3. lie sore lerz~t:ns a.r~: ade~ua.tu to all.os~r rtz~4:tr--~ tl~,~ou~h galls, ducte~oric, and aa'~F.u~d ~absrructions. 7 Slrila orre ez^.d of eac3: r~~~ire ieay~th :u1d ccDranec:t to ~fV panel leads. 5rcure wire cn-7nections cx~it~ ~z%ire i-uts ~itot supplied}. Attach A~'~' ~sazcel tc~ elccuricai ba:r with fsrur zztachiri:: sCre~,vs (192t~? 8}. ~a. C:attrzcctiaze to dry Contact 1Cit anc4 l~ec--3 Cc~tatrnll:;r: kzma~re c:antrrller cnvc.r to acreMs tern'li;tli~al 4t7~ an cnvtro:ii~;r circuit board. I.orvGr cUZ-t~olle:; circuit beard pas,sal to hc~rzca~ntal gositiaza..l~.a~.zte ~-lii`rzr~ leads ,}i.ro~zgh c=ci~troller a~+enin~ to circ-.lit l;os~rri terrnir-ai strip. strip tea~j er-ds ,~zYd rri:~~p ort sp~r~c terroiria;s (mc~t s~irpiied;l. fee l«i,~-esre .~. Aaisc ;,~srltrc;ller r.ircuit li-aard panel tb a vertical nctsitiarz ansl replace ccintr:~ilez~ c;avwr Use tha iza.struatic.n:- included ~w'i~th the rir,~ ca-st;3ct kit fcDr specific ins~3llatiarz and Wlc-:tt~cal cannectian int-,rraatic~r±. ~?~. C'ax~nes:ti~7n to i3.elay l:azttt'c~ller: Upeza ~;c~ner~ttor set junr:tian bcsx lianei to gain accz:ss to tshrrninai strip. Strip lead erz~ls a~nnd crimp oa:- 3pacie tezxtDirzals ;ra.ot supplia~}, ~.nute lc.acis t$-rotzgh concii:it ia-ta ius-ction nax. Canned red lead to totxz-iza;~-l 3~, GaWc~t hla~~k ie~u~ and white leads tr: termirtai 7I'+i. 5~ Fi,;ure =1a. lZeplare jttrsctian bax pazlel. ~`ee Fii,~?are eta if a c[ry caxtr$ct kit is used.. ~I~'lI: ~ '~dlzen used a,~•;ith tk~ rnar-eaaiirelay uontrolltr, the Al'~'~ al~~ ~~itl rzot si,~na~: (audibiW al~srn) t.iaat all 1'rtuitr- lza.:~~e been t~'.ea.rec~ wtzile in the ~Tt IJIVC~ po,tition. Aet~u~ swi±cls 6c- Atb~h'fAl~ far both. au,dif~le a:zd visual ala.rirt::. l'lacitrg switch iu SYY,~ICly lDOSitiar'~, will only n11cw ~li:;~a€-l alarrtz tc~ signal should F- fault p~'Cl3T. ~. T+.ecozDZZect get-cretc~r s~~t hattt^ry, negative l,ercd. fast. h'lc>~~c; cor-trodler rx-a+ster switch to AU'Tt~ fhz-taztw,.~p by rt~nate ux~•es#er stiE~tolt or remote ~;~.rc%s.~op s+rditch. ~~~:`E~4:`~k~C~E: C'q: ~7 ~~ {'C:ldSr~;1Ji~~T IGPd `•,..J ~, ~~ `~: -JJ !•.10.:4 ;' D 12 ~.~~ ~' f ~t2a~cr~ ice-~ ~ -- .._,..~.._~._.._.~.~_.,.....~.._ G~eatri~t4or ~~ 'T'ertrtingt sr~~~ ~.. -_~~T~ -~.__ _ ._ ~- ~ ~ ~ cy ~ a~ era er c~ n~ crs rn ~ ~+ ca c~ ~- ~v ~ -- cu ua r. ~ ~ ~t r- rs c~ r~ cn c~C ~ ~ c~ t~ co cra a~ ~~~' ..,.._._.,......____. ~~a_~._._,_...~.._._.~.....~.,.r...~. ~`9gu.re 3. A/~' ~darm Cannecdl~srws ~~ sec-3 S~ant~~oitcx casing; ~3ry 4:'nrarta+~t ~#t ~~ ~,~ Cotlt~CC Ad~ri17 Kit iCit .......~.._.._-..,,_...~,...~.._.._ ttFi~ C ~LA.CK ~ $r ~ C7 ~+ GAiy iV l') a ~' - ~ ~'ALlL:Y' ~~~~ ----•---~ 9~'d±i 1'i'E AiV .4laxrn ! ~~,~ Kit. ~.r~o..r~. ~.J" i }, WlrLY'T~ 'd'erarainul Six#~ is ~re&lex8C~1r Sit Jae~ctiats lax f ~i~ ~~~~~ 32 4 3 ?~ 70 FPt f P 6~' di$ F`igua~e 4a. ~/4Y Alarm ~ona~cctinrs to ?~.aalual~e&ay ~~n~asllet IC'e-atact Alarm Kit , R.~(3 it Li~A.CK C A A+ ~+ ~~4d ~ ~J~9.G17 ,~++~~gg pp'yp 4T,i 40 ~' ~ ~~ r F:'&V~~ y 8 544 ~ -- ~..et ~esm~nal Strip Y~ Gea~,r;~tnr Set 4 laflctdon ~~x ~~~~~~~~ 32 a 3 7th 7a ~~ ~~ s~ se ~'i~aare 4t,.. 41~' Agar~xa ~t~xane~~i~Tts to l~~A.r-nabt~Ca~ C~n~rc~1[cr zssi~~ (otiptrmn~l} dry Cunt~-et ~.ft (~;~;'©F~/21~G~6 49:=4'i hiC: i=~i~ISTRU"TIJFJ , . ,.~,~ G. Move Ar~% al~rrn switch to "dURa~3:A.1:,, Tt c~im,; a,larna sounc!s or lamp renrcains lit, ref: r f.o "1~esetting" sectioa~ following. resetting Ar`~ A~;rrrrt with Iles-3 te~ntrcltex Ltse the fc~llowin.g procedure to reset the cttttl'allur and AEI als~rm a.l~er a fault alarrc~ under normal eitc~unnstances. 5hc~uld ay4 act?~al 4:~aergency exiwt, appropriate action sha>r;l,d be taken. ~ t-~d~~ ~. M~+ve cantrrsller chime ttlttrm switch t,c; khe h'UI~MAL position far standard ~aperaticn. ~esettimg .~,rV Alarm with MantY~i/l~~lay Controllas' l.~~e the following procedure to reset the coattroiier anal A"~ alarm cl~:Gr a fault alarnn under normal c.ira:uta7st.~i~ccs. Shaul~i an actual etnerg~ncy exist., tlpprolariate acric~.n sita~;.lu he tall:en. 1. 11~1uve ~v xlarrn switch to SfLEI\'CL to sso'ta 1. Move a..~1' a.tam, switch io ~1Z.:~NCE to stop chime ai.s'~rlll, t31V lamp relnainQ lit, Ma~,~e ci~ir~e a1~,.rrn. A.'~' lamp rerrlains lit. controller nlann scvit;.h to the S1LL1~1CIr pasition {if 3o equipped). 2. la~scoeiur;wt generator set frora~ lase with lir~c; eircxiit. t~realcer ur ~:utaxnatac trAnsfcr s~ti~itcFS. 2. 15iscannect geaa.erator set fxorn toad ~'itl; liz~e< ci.rcu.it breaker ar ~I-1to131~.tiC transfer switch. ~ , Mane generator set ir.aster s'~,•itc}; tc~ the Uf'h latasitton. 'I'Yie 1-1/'~' alarm fault lamp vv~!ti g~ ~~ut. ~y 3• ~~~~ rv ~~t~4evt V'~~.u°3`~' I)~ 1'~u1t a,larr:Y, {~.7~e LJ~~ii~:rattsr Uperatian ltaartunl. aytd/ar Ser'aiae'~Tan~~al.,r ~• correct cause Qf iati.lt alts {~~C Servn~ce MaI,)ual,) ~Y, Mov;: ~enerat~r rziaster suYitcit to L~~l~i1~FSl"'~' ~,,: a~)d then to the p.L~l position rot start-up. 5. Mnue generator .waster swite~h to 'he RL~d pusrtion- far start ~ul:. 5. Ueri3y~ that cause cif aiarrn h;~s been carrect;:w. Af'-1 tat;lt tamp should ga rut anal chime ~~l~gsan G. V'a,,i'fy that c-atitse of alarn; leas beelx :.arrected. st,ou,lcl sound. The controller alatan IArbrn ~i'y fxui! .lamp sl).awld bc~ out. shc+utd soLtrad (if sa ecluipped~. „„~yr l~ytJ R 6. Keco:~nect generator tci load r•ia tine circuit 4•Vith manu;i,i~relay conaroller5 tlzc ,~/'v' alarm i~t°4alcc~' ar autorn;etic transfer swit:;h. class sot scu.nd with switch iir SII.EtVCI~ f+asatia~7 even at'ter faults are cleaz'ed. 7'he ~1/V ? Move tenea'ator r,~tsy,cr switcta to ;A.l,S3't~+ switch must br; rcturtte~l to the ?~1UFtMAL pasi~aon for ctazr: up by autama.tiu transfer pc~sitiar.. switch or remote starv'stt~p switch. Move. A/V clairrle alf~rrn switcl, to NCIRl'Vt.t~L. i, I~.ecUnne;.t ge`±erator to load via Iine Circ~art Pd®1'lE brtiah.er nr a~rt4;natic tra.risf't;r switch. Until the alarm sac~itch is moved to 1~1f'31~1~.L, the alarm will caotinue to sound. ?lCi. sigrlaly ~. Mt-ve AIV alani~ switch to NURM~L '!w'o that the fault has been cleared bt~t the ai~rm a~rdia o.r Y%is;~al alarrxr s;~attld occur. switch is not i» its proper operatiz,g {n~•+:rral) pvsiiion, Tl?is al.sa praviclss audible protection li'AI~~I; ~.I~'1~'lil~1~ +_,~~ a;~ainst i:~Iadveilent switching to gll:Ll~£far, ldescriptian ~~ p"art 140. which vratald cth rw-ise deactivate the Al~~ parrel.Assy. l A-•~~2497 alsrne system. Screws; molentin~ 4 ?9~~2$ '- ~KRAE~P®INs'Ei~ ,~ ~~ ~~~~~~~ Su~~~~~~' g g For: 1=1~~S~NIUS M~DICAIL CAI~~ 1 ~OR~OZJC ~3AKERS~'IEL® • Distributor: Kraft Power Corp. 199 Wildwood Ave Woburn, MA 01801 USA Phone: '781-93&9100 Fax: 781-933=7812 Customer: Nardone Electric 100 Winchester St. Medford, Ma 02151 USA Phone: 781-391-2727 Fax: 781-395-7530 Jay Nardone 10/24/05 ~®Kf~i~~~l~l it ~~ ~17~ ~: ~~ ensors~~ ~ ~ - s ~~ s ~ ~~ Each of these series offers unique features. Choose from this selection when all-plastic material is desirable and tank space is not restricted. LS-30 Series- Polysulfone ;-p,., _ ~~ , i 7 t ~ ~.~ ~~ ' ~~ CE For water-based liquids, with limited use in oils and chemicals. Cost is suited for high volume OEM use. Polysulfone material of construction complies with FDA food contact regulations. • ?,~-7IF.i, ta,,.iida; LS-74780 - A11 CPVC ,,y~yiCE Particularly well suited for rough service. Ideal for use in chemical and plating applications. LS-1900TFE rr~ ~~ CE Resists build-up of foreign material or sticky media. Float travel remains uninhibited in viscous or corrosive liquids. SPDT switch. LS-1700TFE `,' ., CE A medium-size solution for ultra-pure liquid level sensing. Made of corrosion resistant PTFE for low particle generation. ~ ~~~ S ~~ ~, P~tdF~ LS-30 Series LS-74780 LS-1900TFE LS-17007 ~~ POLYMERIC PVC JACKETED TEFLON69JACKETED f LEADWIRES WIRE. 22AWG. ~ TEF24NT026ETED -JACKETED i' LEAD WIRES 1/4' NPi 21/32" 5/8"HEX (16.7 mm) (15.9 mm) 1.1/~ - ~/ LEAD WIRES 1/4-NPT 21/32 5/8"HEX (16.7 mm) 15.9 mm) ( 3/4- 3/16" (20.6 mm) 92- (22.3 mm)~ 1/4-NPT ~ ~ 21/32"HEX (16.7 mm) (610 mm la 660 mm) EXTENDED LENGTH { 1~ /' 1/B" NPT REI 518-REF. 15.9 mm) 1/2- HEX. RI ( K ~ (12.1 mm' ACTUATION " (31.8 mm)~ ~ 3-318- (B5.7mm) -~ 1-7/8" 2-23/32" (47.6 mm) 1 69 3-7/1fi" (19.1 mm)' (87.3 mm) ~ 2-25/37 ~ 1-13/16" m) (4 3-15132" ~ (88.tmm) 21 32' 2 ~'[" I 1-15/16" 49 2 2-1/2 REF. LEVEL (63.5 mm) i '--- _ ~- `~t114105 FLOAT 1.31132' REF. mm) ~ ~ ( . (70.6 mm) ~ - 1 (67.5 mm) . mm) ( ~ (50.0 mm) ~~ I C~ I 1174106. " I I- RETAININ CLIP I I ft-7/8" DIR. ~ (47.6 mm) ~t-7/2 DlA. (38.1 mm) .. 2-1/ 8" DIR. ~ i ~` , DIA~REF. 5/16" Ir--- (28.5 mm) DIR. REF. 7 9 (54 mm) . ( mm) fL~=Switch actuation level, nominal (based on a liquid specific gravity of 1.0 and N.O. dry circuit-dimension will vary for N.C. circuit). ~.,f:lia3Tl~g <. w Electrical Termination: No. 18 AWG, 24"' L., Lead Wires (Jacket material is indicated on dimensional drawings, above). Approvals: LS-30 Series switches are U.L. Recognized -File No. E45168. Materials Li Pressure, Pa', Numher Series Numbe Slem, Mounting Min. quid Gr S 0 eratin Te p 9 mperature PSI, Switch* Moe :Ling Size r and Other Wetted Floai . p. Maz. 1/4"" NP i 1/8"'NPT SPST, 20 VA _ 46201' ' - LS-30 Polysulfone with 316 S.S. Cli R tai i .55 -40°F to +225°F (-40°C to +107.2°C) 50 SPST, 100 VA 46202*` 4 - p ng e n SPDT, 20 VA 46203 - LS-74780 CPVC .85 -40°F to +180°F (-40°C to +82.2°C) 15 SPST, 20 VA 74780"* i - LS-1900TFE Teflon® .80 -40°F to +300°F (-40°C to +148.9°C) 30 SPDT, 20 VA 133299 ¢ - ° ° ° ° SPST, 20 VA, N.O. - 174100 LS-1700TFE PTFE .86 F to +212 F(0 Cto +100 C) +32 25 SPST, 20 VA, N.C. - 174200 ' See "Electrical Data" on Page X-5 for more information. '* Switch operation is selectable, N.O. or N.C., by inverting the float on the unit stem. Units are shipped N.O. unless otherwise specified. ft 100 VA switches are not U.L. Recognized. f -Stock Items. F. www.gemssensors.com Electrical Data Standard reed s in GEMS level switch units are hermeti- cally-sealed, tically actuated, make-and-break type. Switches are SPST or SPDT and are rated in Volt-Amps (VA). See the chart below for maximum load characteristics of GEMS level switches. CAUTION: Contact protection is required for tran- sient orhigh in-rush current. Refer to GEMS Bulletin #133702 or call your GEMS representative. VA Volts Amps AC Amps DC 10 0-SD .2 .13 General Use 120 .08 N.A. 100 N.A. .10 20 0-30 .4 .3 Pilot Duty 120 .17 .13 240 .08 .06 0-50 0.5 0.5 50 General Use 120 .4 .4 240 .2 .2 120 .8** N.A. Typical Wiring Diagrams (Circuit Condition Dry) SPST. Normally Ooen or Closed Red • Red SPST. With Thermostat option Black -'-~ Red ---~ Green PDT Orange, Yellow or COM N.O. White N.C. Red Black 100* 240 .4 N.A. Thermostat switches open or close when ambient temperature reaches Not U.L. Recognized ** Limited to 50,000 operations specified setpoint. Thermostat units not CE approved. Euro-peon Pressure Directive Addendum The product is designed and manufactured in accordance with Sound Engineering Practice as defined by the Pressure Equipment Directive 97123lEC. This product must not be used as a "safety accessory° as defined by the Pressure Equip- ment Directive, Article 1, Paragraph 2.1.3. The presence of a CE Mark on the unit does not relate to the Pressure Equipment Directive. C ~ This product is suitable for Class I and Class II applications only, per the requirements of standard EN60730 and any additional specific requirements for a particular application or medium being sensed. Class I compliance of metal bodied units requires a ground connection between the metal body and the earthing system of the installation. Class I compliance of plastic bodied units in contact with a conductive medium requires that the medium be effectively earthed so as to provide an earthed barrier between the unit and accessible areas. For Class III compliance, a supply at safety extra-low voltage (SEEN) must be provided. Please consult the Factory for compliance information on specific part numbers. Important Points! Product must be maintained and installed in strict accordance care in the proper selection of materials of construction; particu- with the National Electrical Code and GEMS product catalog and lady wetted materials. instruction bulletin. Failure to observe this warning could result Life expectancy of switch contacts varies with applica- in serious injuries or damages. tions. Contact GEMS if life cycle testing is required. An appropdate explosion-proof enclosure or intrinsically safe Ambient temperature changes do affect switch set points, interface device must be used for hazardous area applications since the specific gravity of a liquid can vary with tempera- involving such things as (but not limited to) ignitable mixtures, lure. combustible dust andflammable matedals. Level switches have been designed to resist shock and •' Warning: To prevent ignition of flammable or combus- vibration; however, shock and vibration should be minimized. tibia atmospheres, disconnect power before servicing. Liquid media containing particulate and/or debris should Pressure and temperature limitations shown on indi- be filtered to ensure proper operation of GEMS products. victual catalog pages and drawings for the specified level Electrical entries and mounting points may require liq- switches must not be exceeded. These pressures and tam- uidlvapor seating if located in an enclosed tank. peratures take into consideration possible system surge Level switches must not be field repaired. pressures/temperatures and their frequencies. Physical damaged sustained by the product may render it un- Selection of materials for compatibility with the media serviceable. is critical to the life and operation of GEMS level switches. Take ~_ Gems Sensors Inc. /~~ One Cowles Road ~/ ~~-~ Plainville, CT P/N 72947 06062.1196 Rev. Y ~ Sensors fel 860.747.3000 i `• rax 860.747.4244 \_.._ ~" `,i,~ n~~s I\`~ Sensors UVt,l~t-t~t_ ...~yvfr~t.~w of Single-Station Level tches Instruction Bulletin No. 72947 Series Mounting HEX Size Float Diameter LS-1700** 1/8" NPT 1/2" 1" (Slosh Shield Version 1-13/32" LS-1700TFE* 1!8" NPT 1!2" 1-118" LS-1750** 1/8" NPT 112" 1-1/2" (Slosh Shield Version 1-13/16") LS-1755** 1/8" NPT 1/2" 1-1/32" LS-1800*' 1/8" NPT 1/2" 1-114" LS-1850** 1/2" NPT 3/4" Wrench Flat 3-1/2" LS-1900"`' 1!4" NPT 5/8" 1-7/8" LS-1900TFE* 1/4" NPT 21/32" 2-1/8" LS-1950*" 1/4" NPT 5/8" 2-1/16" LS-19735* 1/4" NPT 5/8" 1-1/2" 1/8" NPT 1/2" 1" 3/8" - 16 Str. Thd. 1/2" 1" LS-3* 1/8" NPT 1/2" 1-1/4" Slosh Shield Version 1/8" NPT 1/2" 1-7/8" (P/N 76707) 1l8" NPT 1/2" 3/4" (P/N 201540) LS-30* 1/4" NPT 5/8" 1-7/8" LS-38760"* 1/4" NPT 9/16" Wrench Flat 1-7/8" LS-74780* 1/4" NPT 5/8" 1-1 /2" LS-77700** 1/8" NPT 1J2" 1" 3/8" - 24 Str. Thd. 3/4" 1-1/2" TH 800-A**` Level Temp 1/4" NPT 5!8" 1-1/4" * Plastics *` Alloys *** S ecialty_ Switches: Please use caution when handling these units, as shock may damage the thermostat temperature setting. Thermostat units not CE approved. Installation A standard ~emale boss in tank tap, bot- tom or side Is I that is required. Units oper- ate in any attitude -from the vertical to a 30° inclination -with lead wires up or down. Stan- dard IPS pipe extends units to any intermedi- ate level in the tank. (Figure 1) Moisture Protection: When moisture exists in conduit and extension pipes, the potential for this moisture to "wick" down the wire leads and into the switch assembly exists. Should this happen, the switch will appear to be closed due to a high resistance path through the moisture. The following suggestions may help to prevent this from happening: 1. Pitch conduit away from the level switch when possible, so that condensation will drip away from the level switch assembly. (Figure 2) 2. When a vertical run of extension pipe is used to extend a level switch down -from the top of the tank, anon-conductive silicone oil should be used to fill the vertical run. Alternatively, an appropriate potting may be used to fill the ver- tical run to occupy the space in which conden- sation will normally form. (Figure 3) CAUTION Most of GEMS level products incorporate a pot- ting cap or are fully potted. Due to the bonding characteristics of the potting to the wire leads, there is no way of assuring awater-tight seal at the potting joint. Our potting cap will resist moisture to some degree, but the precautions mentioned above should be used to assure moisture doesn't enter the switch and cause a short. --- -~ 30° Max. - Figure 1 - Conduit - Figure 2 - Silicone oil - Figure 3 - Consult your GEMS representative for more suggestions on how to lessen the effects of moisture. ~- - - - - - - - - - - - - - - - - - - J Thread Treatment 1. Sealin When threading metal threads into a metal coupling, pipe sealant or Teflon® tape is recommended. Due to potential compatibility problems, when sealing plastic threaded units, a compatible pipe sealant such as No More LeaksT"^ from Permatex~ is recommended. 2. Tightening: When threading a plastic level switch into a metal coupling, the installer should use a suitable wrench and tighten the threads one to one and one- half additional turns past hand-tight. Over-torquing of the threads will result in damage to the plastic mounting plu~. No More Leaks is a trademark of ermatex®Industrial Corp., a subsidiary of Loctite Corporation. Teflon is a registered trademark of DuPont Corporation 3. The Effect of Thread Engagement on Actuation Points ~~oF The length of mounting threads engaged at installation is important Iculating switch actuation points and the actual length of stem extending into the tank. .Use the chart below to find the thread engagement length (T) for a given NPT size. Factor the dimension into any calculation of switch actuation levels (L) and overall length (Lo). NPT T Dim. 1/8" 1/4" 1/2" 3/4" 1" 1-114" 2" 3" .27" .39" .53" .55" 68" .71" .76" 1.20" - See Examples Below - Definition of Variables Used in Examples Below A =Mounting Length T =Thread Engagement P =Distance from coupling (bung) top to inside surface of tank or bracket Lo =Overall length from bottom of mounting L =Switch actuation level as measured from inside surface of tank or bracket to fluid surface L~ =Switch actuation level, nominal, as measured from bottom of mounting (based on a liquid specific gravity of 1.0) 114° NPT Internally Mounted LS-1900 (Standard Length) - A T LS-1900 Series internally mounted 21/32" through a 1/4" NPT hole. To 1-3/16 L Actual calculate "L" dimension: Tank L = L1 + (A-T) Lo Fluid Intrusion L = 1-3/16" + (21/32" - .39") Level L = 1.46" ~, 1/8" NPT Internally Mounted LS-170011750 ~ _~ (Standard Length) T A - _-~ LS-1700/1750 internally mounted 9/16" through a 1/8" NPT hole. To T L calculate "L" dimension: L,=s/a° Actual Tank L = L1 + (A-T) Fluid Lo _~ Intrusion Level (Jl C.~L- ~~ ~ o B #. I ( STANDARD SPILL CONTAINMENT ASSAY (5.1 gal ACTUAL CAPACITY) L PR( PART #: 8205 1`' ( ~ u MATERIAL: 14GA STEEL TH15 AUTOCAD DRAWING IS THE PROPERTY OF GL08AL POWER CONK NENTS AND MAY NOT BE USED IN ANY NAY DETRIMENTAL TO THE WTERESTS OF CPC. ANY MANUAL CHANCES N0.1. VOID TH6 ORAWINC. SPECIFlCATIONS YAY CHANGE YITTFIOUf NOTICE. 1 -1 X oaa~• ~ r~s: a anre: t as/ac x nwc /: oPr eme-vne orum~ er: ru ORMES VIEW trv LID u i/s WRAP I iHrs nuroalo ow~wu+c Is rF+E atoP~Rrr of aoeK POWER awaaaErrts AND wr tror 8E uSEO IN ~wr rr~r DETRdIENru To THE a~rtERESrS of cpC. iwv w~l. QUNf~S wlu. Moro rH5 ORAW9IC. SPEaFlGTIONS wr MIITHOUr ~ • 2~3 PART #: 8205 x oer eared-cvt rorsarr~ er: a~a ~ ~„~- ~ N~7~-i ~l ~"t~,~ ~ P 3 ~3 JOB # PART #: BILtI SPILL BOX INSTALLATION ITE PART# QTY DEC'. 1 - 1 SPILU 2 - 1 NIPP' I '~ 3 - 1 NIPP' I 4 - 1 TEE, I S - 1 UNIC I 6 - i BUSH I 7 - 1 HOST I I I 8 - 1 HOSI I ~ _,~ 9 - 1 TUBII I 10 - 1 FLAM ~~ I 11 - i COUI I 12 1 RANI 13 1 HASH u 14 - 1 HINC a _ ,. ,,,. ,~ ~. ~. ,~ ~. ,o TOCAD DRAWING 6 THE PROPERTY OF KLEIN CORPORATION AND MAY NOT BE USED M ANY WAY DETRIMENTAL TO THE INTERESTS OF KLEIN. ANY NANUAI. CHANGES WILL VOID THIS DRAWING. SPE REVISIONS REVISIONS REVISIONS REV DATE: CHANGE MADE BY REV DATE: CHANGE MADE BY REV DATE: CHANGE MADE BY 1 T 21 01 FITTINGS ALT TOMER ID % DRANANG REP: - JOB REF; X OWG /: NtTON fNUrn ~~~a~s~®~~~a • TA~I.~~ ®~ C®1®T'TEI~IITS G~N~RA~oR s~~M~~~rA~, Generator Data Sheet Paee# 7 Enclosure Paee# 15 Sub-base Fuel Tank Paee# 20 Sueeested Pad Layout Paee# 22 Circuit Breaker Pase# 25 • Block Heater Pase# 39 Control Panel Pase# 40 Battery Chareer Paee# 56 RSA-100 Remote Annunciator Paee# 61 Simplified Annunciator Wirins Diaerams Pase# 65-67 Transfer Switches Pase# 89 Warranty Paee# 98 ~~~~®®CC ~~ ,Th ~~~~~® r~IG~ BILL OF MATERL4L 1~OK~'SOUSED DIESEL FUELED EMERGENCY GENERATOR SET FRESINIUS MEDICAL CARE BAgERSFlELD BAgERSFIELD, CA # 4173 The following represents the equipment, materials and services being proposed by KRAFT POWER CORP. for the subject job. One (1) Diesel Fueled Generator Set, Kohler Mode1180REOZJC (Diesel, Tier 2), Standby, 180 KW, 225KVA, 3-Phase, 60 Hertz, 120(208 Volts, 0.8 Power Factor, 1800 RPM, comprised of the following: ENGINE: John Deere, Mode16068HF275, 4-Cycle, 6-Cylinder, 4.19'" Bore, S.QO" Stroke, 414 Cubic Inch Displacement, Turbocharged, Diesel Fueled, Rated 282 HP maximum at 1800 RPM with: - Unit Injection Fuel System with Fuel Transfer Pump and Fuel Filters - Full-Pressure Lubrication System with Oil Cooler and Full Flow Filter System with Bypass Filter Arrangement -Governor: Electronic, tsochronous-JDEC BOSCH/VP44.25% steady state -Flywheel and Flywheel Housing - Dry Type Heavy Duty Air Cleaner - 12 Volt Run Solenoid - Flexible Fuel Lines - Oil Drain Extension with Valve -Closed Loop Crankcase Ventilation System COOLING SYSTEM: Unit Mounted Radiator with Engine Driven Jacket Water Pump with Thermostatic Control Radiator is designed to cool the engine at full rated load in a maximum ambient temperature of 122°F, using a 50% solution of glycol and water. ENGINE HEATER: A 1500-watt, 240 volts, single phase Jacket Water Heater with Thermostatic Control is mounted and piped to the unit. ENGINE GENERATOR MOUNTING: The engine and generator are close coupled, mounted and aligned on a common structural steel sub-base designed to maintain proper alignment. Unit can be mounted on any level surface, "vibration isolation" is provided between engine/generator and the base. ~ri[6~A~~"P®11~~~r' 2 GENERATOR: Alternator is Single Bearing, brushless, 12-lead reconnectable, Kohler Mode14S9W, self-ventilated of drip-proof construction with amortisseur rotor windings and skewed stator for smooth voltage waveform The insulation meets NEMA standard (MGl-22.40 and 16.40) for Class "H" and is insulated with epoxy varnish to be fungus resistant Pr°r MIL 1-24092. Temperature rise is 130 degree C over 40 Degree Ambient.. The Permanent Magnet excitation system is of brushless construction controlled by a solid-state voltage regulator capable of maintaining voltage within.+/-2% at any constant load from 0% to 100% of rating. The regulator is isolated to prevent tracking when connected to SCR loads, and provided with individual adjustments for voltage range, stability and volts-per-hertz operation; and is protected from the environment by conformal coating. The generator is capable of sustaining 300% of rated current for at least 10 seconds under a three-phase symmetrical short by inherent design. ~,INE CIRCUIT BREAKERS: FOUR (4) Resetable Line Current sensing circuit breakers with inverse time verses current response will be mounted within generator enclosure. One rated at 40 amp, three rated at 150-amp. SAFETY SWITCHES: The Generator Set is equipped with Safety Switches for: - Low Coolant Level Shutdown -Low Oil Pressure Shutdown and Prewarn - High Water Temperature Shutdown and Prewarn - Low Water Temperature Prewarn - Overspeed -separate device to shut the engine down on overspeed - Overvoltage Protection and Shutdown - Overcrank - The Safety Switches activate the shutdown circuits in the Auto-Start Control described herein ENGINE GENERATOR CONTROL PANEL: A combination Analog Engine-Generator Control Panel is shock-mounted at the generator end of the unit. The panel is the dead front type with removable top panel as described in the attached brochure; model DEC3+. MUFFLER: A Super Critical Silencer from Kohler is included as described in the enclosed brochure. A stainless steel flex exhaust connection is also included. Silencer is mounted within the Generator Enclosure. REMOTE ANNUNCIATOR: A Digital Remote Annunciator, surface and/or flush mounted, as manufactured by Kohler Model # RSA-1000 is provided as described in the enclosed brochure. A Communication Module for the 16 light controller is provided and installed. ~T~~r~~~i~® r~~~ 3 SOUND ATTENUATED WEATHERPROTECTIVEHOUSING: AKohler Sound Attenuated Enclosure constructed of Powder Painted Galvanized Steel is included with the following features: -14 Gauge Construction. -Five (5) Hinged & Removable Doors for Servicing the Generator, Keyed Alike -Stainless Steel Latches -Automatic Door Holders -Air inlet Louvers and Ba.ffies to minimi~.e rain and snow entry -Pitched Roof to prevent standing Water -Critical Grade Silencer mounted within the Housing -Vertical outlet hoods w/ 90-degree angles to redirect air and reduce noise, -Housing is lined w/ Acoustic insulation material Meeting UL 94 HFI Flammability classification. -75 DBA @ 23 Ft. STARTING SYSTEM: A complete 12 Volt D.C. Starting System is included with: - One (1)12 Volt Starting Battery rated at 950 CCA - One (1) Battery Rack and Cable - Belt-Driven Battery Charging Alternator, 12 Volt D.C. Rated 55 Ampere - 12-Volt Automotive Type Starting Motor - Starting Solenoid -Starting System is controlled by Start Control described herein BATTERY CHARGER: A Kohler, Model GM28569-KAI,.~s uichided as described in the enclosed brochure & Installed in the Generator Enclosure. RODENT GUARDS: Roderrt guards are installed to prevent the entry of rodents LUBE OIL & ANTIFREEZE: Initial charges of Lubricating oil and 50/50 solution of glycol antifreeze and water are included. FIELD TEST AND START UP: The services of qualified field service technician to perform initial start-up, adjustment and TWO (2) -Hour connected building load tests are included, per the specification. FACTORY TESTING: A ONE (1) -Hour Factory Power Factor Test will be completed and a Certified Test Report will be provided. LOAD BANK TESTING: A TWO (2) -Hour load bank test will be performed at our Woburn location and a report will be sent to Nazdone Electric after the test. RUN RELAY: An additional relay is included for customer use. WARRANTY: Two (2) year from date of final field test or first beneficial use to the owner, whichever comes first. // T~~i~~/f ~0 r~~~6 4 EMISSIONS: Emissions Data is attached FUEL TANK: We are providing a 300 Gallon Sub Base Fuel Tank, built to California standards, with the. following features: -Double Wall Construction -UL Listed UL 142 ~ -Fuel Level Gauge -ST 5 Gallon Lockable Fill. port with spill containment -Fill pipe within 6 inches of tank bottom -Low fuel alarm Switch -Leak Alarm Switch -Extended Atmospheric Vent to 12 inches above grade (122 inches above tank top) -4 inch NPT emergency pressure relief vent cap -Stub up azea -Inner Tank Leak alarm panel shipped loose for mounting by others. ~~ -36 hours of fuel (Fuel provided by others) -Dimensions= 22.0"H X 40.94"W X 138.00"L AUTOMATIC TRANSFER SWITCHES: FOUR (4) Kohler Automatic Transfer Switch Model KCT-ACVC-02005, UL 1008 Listed, Rated 200 Amps, 120/208 Volt, 4 Wire, 4 Pole, 60 Hertz, Mounted in a Nema 1 Enclosure with the Following Features: -Time Delay Engine Start . -Time Delay Transfer to Emergency -Time Delay Emergency to Normal -Awdliary Contacts-2 Programmable N.Q. & 2 N.C. contacts aze provided -Pilot Lights -Plant Exerciser -In phase Monitor -Engine Start Contacts COMMENTS A- If this Penerator is placed within 1000 F~ of a school a SOOT FILTER may be required which will add additional cost Maaao 780REOZJ~ ~ KONLERPOWER S15TEMS :oe-ems v °oiY~si Standard 6=eatures Beatings Range 60 Flz Standby: kW 145-180 kVA 181-225 Prime: kW 130-165 kVA 163-206 ~~1 LJ • Kohler Co. provides one-source responsibility for the generating system and accessories. • The generator set and its components are prototype-tested, factory-built, and production-tested. • The 60 Hz generator set offers a UL 2200 listing. • The generator set accepts rated load in one step. • The 60 Hz generator set engine is certified by the Environmental Protection Agency (EPA) to conform to Tier 2 nonroad emissions regulations. • A one-year limited warranty covers all systems and components. Two-, five-, and ten-year extended warranties are also available. • Altemator features: o Kohler's Fast-Response"" III wound field (WF) design alternator provides excellent voltage response and short-circuit capability.using an auxiliary power brushtess exciter. o Kohler's unique Fast-Response'" II excitation system delivers excellent voltage response and short circuit capability using a permanent magnet (PM)-excited altemator. o The brushtess, rotating-field alternator has broadrange reconnectability. • Other features: o Controllers are available for all applications. See controller features inside. o The low coolant level shutdown prevents overheating (standard on radiator models only). o integral vibration isolation eliminates the need for under-unit vibration spring isolators. Generator Set Ratings 130°G Rise 105°C Rise Standby Rating Prime Rating Alternator Ph F~ kW/kVA A kWlkVA Amps 120/208 3 60 180/225 625 165/206 573 12 0 3 5 165/206 54t 120/240 3 60 180/2'25 541 165/206 496 4S15W/ 139/240 3 60 180(225 541 165(206 496 220/380 3 60 145/181 275 130/163 247 277/480 3 60 1801225 271 165/206 248 347!600 3 60 180(225 2i7 1651206 198 RAnNGS: Aunvee-phese~naserere~ede~o.e~rerie~r. were-pheseunroserereredect.opowerteaor. raear~ sr~,deymm~BsnppNm~r~emaenonsee~veduyareeaeieumnr. me ~Y~InSiaep~a~6letovety[n8~edefarC~edure4Ona~apcwercu~age. The~eisnoouerloedcepeb6ltyta'ttLLsretlng. Radc~ereiner~ordanoawUhl50304Q(1.8555t4.PS2788,andDM18'Mt. Prune PoworRe6rrgar Prune power re5rtgs apply m butallationa where talrsy power is urtflveBede a unraltede. At vetyrrg load. the number of generator set oparetlng hags's unfunded. A 11196 overoad capadly is available for one hour in twelve. Ratlnps ere In aocordar~e with IS0~521f/1, overload power in etxortlenoawitln IS0~06~i, BS 5514. AS 2788, erW DIN 8271. Far fanned nrnnmg time and base leer ratngs, catsup the festory. obtem the technical nfanu0lon bddin {ns-to1) an r gWdel~s tflr 1ha mmplece rsHn~ daMlnons. S1re ganermor aet tnenufae4,rer reeeivea me dgrn to d,mtge lfte dasipn or apeoifimuone wdhout notloe antl wtlhoui arty obligallan w 6eDilily vrhatsoever. GENERAL GllIDEUN6 FOR DEAATION: AR~de: Derate 0.5% per 100 m (328 ft.) elevation above 1000 m (330D ft.). Temperature: Perate t.0% per 10°C (16°~ tatnperewre attove 40°C (104° F). Ci5.252 (180REOZJLy 4/04c Altere~ator Specifications Speclflcatfons Attemator Manufacturer Kohler Type 4-Pole, Rotating-Field Excter type Wound field (WF) ................. Wound Exciter Field with Separate Excltation Power Winding Permanent magnet (PM) ........... Brushiess, Permanent- . Magnet Leads: quantity, type 12, Reconnectable Voltage regulator Solid State, Volts/Hz Insulation: NEMA MG1 Mffierial .......................... Class N Temperature rfse ............:..... 130°C, Standby Bearing: quantity, type 1, Seefed Coupling Flexible Disc Amortisseur windings Full Voltage regulation, no-load to full-load Wound field (WF7 alternator ........ x0.25% Average Permanent magnet (PM) alternator .. r2% Average 550 controller (with 0.5°~ drift due to temperature variation) ....... 3-Phase Sensing, x.25% Unbalanced load capability 100% of Rated Standby Current One-step load acceptance 100% of Rating Peak motor stoning kVA: (35% dip for voltages below) 480 V 4S75W14S15 (12 lead) ..... 620 (60 Hz) • NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting. • Sustained short-circuit curzent of up to 300% of the rated current for up to 10 seconds. • Sustained short-circuit current enabling downstream circuit breakers to trip without collapsing the altemator field. • Self-ventilated and dripproof construction. • Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long life. • Superior voltage waveform from atwo-thirds pitch stator and skewed rotor. • Solid=state, volts-per-hertz voltage regulator with s2% no-load to full-load regulation. • Fast-Response'" III wound field (WF) brushless atemator with auxiliary power brushless exciter for excellent load response. • Fast-Response"" II brushless alternator with brushless exciter for excellent load response. Application ®ata En ine Engine Specifications 60 Hz Manufacturer J re Engine model 6068HF275 Engine type 4-Cycle, Turbocharged Cylinder arrangement 6 Inline Displacement, L (cu. in.) 6.79 (414) Bore and stroke, mm (in.) 106 x t 27 (4.19 x 5.00) Compression ratio 17.0:1 Piston speed, Mmin. (ft./min.) 457 (1500) Main bearings: quantity, type 7, Replaceable Insert Rated rpm 1800 Max. power ffi rated rpm, kWm (BHP) 210 (262) Cylinder head material Cast iron Crankshaft material Forged Steel Valve material: Intake ........................ Chromium-Silicon Steel Exhaust ...................... Stainless Steel Governor: type, make/model JDEC Electronic, Bosct~lP44 Frequency regulation, no-load to full-load Isochronous Frequency regulation, steady state x0.25% Frequency Fixed Air cleaner type, all models Dry Exhaust Exhaust System ~,~0 Hz ~ Exhaust manifcid type Dry Exhaust flow at rated kW, m3/min. (cfm) 39.1 (1380) Exhaust temperature ffi rated kW, dry exhaust, °C (°F) 543 (1010) Maximum allowable back pressure, kPa (in. Hg) 7.5 (2.2) Exhaust outlet size ffi engine hookup, mm (in.) 98 (3.88) Engine Electrical Engine ElectNcai System (12124 Volt) \$~„J~/F Battery charging attemffior: 12 Volt/24 Volt Ground (negative/positive) ....... Negative Volts (DC) ..................... 12/24 Ampere rating ................. 65!45 Starter motor rated voltage (DC) 12/24 Battery, recommended cold cranking amps (CCA): 12 Volt/24 Volt Quantity, CCA rating each ....... One, 640/Two, 570 Battery voltage (DC) 12 *12-volt or 24-volt engine electrical systems are available. GS-252 (r80REOZ.IC) 4JO9c Appiicatioin Data • Fuel Fuel System 60 Hz Fuel supply line, min. ID, mm (in.) 11.0 0. ) Fuel return line, min. ID, mm (in.) 6.0 (0.25) Max. lift, electron(c fuel pump, m (ft.) 0.9 (3.0) Max. fuel flow, Lph (gph) 187.7 (49.6) Fuel prime pump Electronic Fuel filter Secondary, 5 Microns Q 98% Efficiency Primary, 30 Microns w/Wffier Separator, Recommended fuel #2 Diesel Lubrication Lubricating System HBO Hz} Type Full ressure Oil pan capacity, L (qt.) 27.0 (28.5) Oll pan capacity with finer, L (qt.)' 27.9 (29.5) Oil fltter: quantity, type 1, Cartridge Oil cooler Water-Cooled vvvr n r Radiator System 0 Hz Ambient temperature, °C (°F)* 5 Engine jacket water capacity, L (gel.) 11.3 (3.0) Radiator system capacity, including engine, L (gal.) 25.7 (6.8) Engine jacket water flow, Lpm (gpm) 174 (46) Heat:rejected to cooling water ffi rated kW, dry exhaust, kW (Btu/min.) 85 (4830) Heffi rejected to charge cooler ffi rated kW, dry exhaust, kW (Btu/min.) 29 (1630) Water pump type Centrifugal Fan~diameter, including blades, mm (In.) 660 (26) Fan,lcWm (HP) 10.8 (14.5) Max, restriction of coaling air, intake and discharge side of radiffior, kPa (in. H2O) 0.125 (0.5) * Enclosure with enclosed silencer reduces ambient temperature capability by 10°C (18°F). Oaeration Requirements Air Requirements {, 60 Ham] Radifficr-cooled cooling air, m3/min. (scfm)'+ 278 (9800) Combustion air, m3/min. (cfm) 14.7 (520) Heat rejected to emblem air: Engine, kW (Btu/min.) .......... 40.4 (2300) Alternator, kW (Btu/min.) ........ 14.4 (820) $ Air density = 1.20 kglm3 (0.075 Ibm/fts) Fuel Consumption 60 Hz Diesel, Lph (gph) at % load Standby Rating 100% 49.9 (13.2) 75% 37.7 (10.0) 50% 26.0 (6.9) 25% 14.2 (3.8) Diesel, Lph (ttahl at % load Prime I~at~no 100% 45.4 (12.0) 75% 34.8 (9.2) 50°~ 24.0 (6.3) 25°~6 13.3 (3.5) Controll O -. Decision-Maker'" ontroller Audiovisual ennunc' ion wtth NFPA 110 Level 1 capability. Programmable opracessor logic and digital display features. Attemffior saf and circuit protection. 12- or 24-v ngine electrical system capability. Remote ,remote annunciation, and remote communication options. Refer 6-48 for additional controller features end accessories. `~ ®~ O ~* 4 Decision-Maker"' 3+, 1&LIgM Controller Audiovisual annunciation with NFPA 110 Level 1 capability. Microprocessor logic, AC meters, and engine gauge features. 12- or 24-vott engine electrical system capability. Remote start, prime power, end remote annunciation options. Refer to G6-30 for additional controller features and accessories. ~~~ 0 °~ Decision-Maker"' t Controll Single-light annunciation asic controls with NFPA capability. Relay logic, AC meters, engine gauge features. 12-volt engine electri system capability only. Remote or autom start options. Refer to G6-29 additional controller features and accessories. aszs2 i~eoREOZaccy aloac KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-585-3381, Fax 920-459-1646 Asia Pacific Headquarters • For the nearest sales and service outlet in the 7 Jurong Pier 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 Additional Standard Features • Alternator Protection (standard wfth 550 controller) • Battery Rack and Cables. • Emission Compliant Engine • Integrel Vibrffiion Isolation • 011 Drain Extension • Operation and Installation Literature . Accessories Endossd Unlt Sound Enclosure (with enclosed crttical silencer) ^ Weather Enclosure (wfth enclosed critical silencer) ^ Weather Housing (with roof-mounted critical silencer) Open Unlt ^ Exhaust Silencer, Critical (kft: PA-354809) ^ Exhaust Silencer, Hospital (kit: PA-365349) ^ Fexfble Exhaust Connector, Stainless Steel Cooling System Block Heater ^ Radiator Duct Flange Fuel System ^ Auxiyary Fuel :Pump . ,~" Flexible Fuel tines ^ Fuel Pressure Gauge ~` Subbase Fuel Tanks ^ Subbase Fuel Tank with Day Tank Elsftrical System Battery Battery Charger, EquelizeJFioffi Type ^ f3ettery Heater Engine and Alternator Aftemffior, Wound Feld (WF) Aftemator, Permanent Magnet (PM) ^ Air Cleaner, Heavy Duty ^ Air teener Restriction Indicator ^ Aftemator Strip Heater ^ Bus Bar Tats ^ Closed Crankcase Canister ^ CSA Certfflcatian ^ Current Transformer tat ^ Electronic Isochronous Govemor (:0.25% freq. reg. steady state) tine Circuit Breaker (NEMA type 1 enclosure) tine Circuit Breaker with Shunt Trip (NEMA type 1 enclosure) Rated Power Factor Testing ^ Rodent Guards ' ^ Safeguard Breaker (not available wfth 550 controller) Skid End Caps ^ Voltage Regulation, 1 % ^ Voltage Regu!ffior Sensing, 3-Phase • Parafieling System ^ Reactive Droop Compensator ^ Rarnote Speed Adjust Control/Electronic Govemor ^ Volleys Adjust Control ^ Voltage Regulator Relocation tat Maintenance ^ General Maintenance Literature Kit ^ Meirtenence fat (includes standard air, oil, end fuel fitters) ^ NFPA 110 Lfterffiure ^ Overhaul Literature Ktt ^ Production Literature Kit Controller (550 and 16-tight) Common Failure Relay Iat ^ Communication Products end PC Software (550 controller only) ^ Customer Connection Iat ^ Dry Contact Kft (isolated alarm) Engine Prealarm Sender let Prime Power Switch (550 controller only) ,~ Remote Annunciator Panel ^ Remote Audiovisual Alarm Panel ^ Remote Emergency Stop Ktt ^ Remote Mourting Cable ~, Run Relay fat IAiscellaneous Accessories Dimensions and Weights Overall Size, L x W x H, mm (in.): Weight (radiator model), wet, kg (Ib.) ~r 1 ~.~ 2600 x 1040 x 1538 (110.24 x 40.94 x 60.55) 1429-1497 (3150-3300) NOTE This drawing fs provided for reference only and should not be used for plenninp irtstarelian. Cortt&t your local disbiDutor for more detailed IMortnadon. DISTRIBUTED BY: ® 2lxM by Kohter Co. All riphta reserved. G5-252 (180REOZ,IC) 4~04C ~-~ • • L_ 0 CONDOR ENTRY AREA FOR CENERIOR LOAD LEAt% (BOTTOM ENTRY), CBtCUIT BREAI(E!t OPTION. REMOTE CONNEC110N TO 1RANSFER STRTCN AND RFAf01E ANNUNCNTOR. I s 1840 75 [2.a5] S0. 400 [15.75] 12v BAiniTlr LaatwN 0 SUGCESIID BATTERY HEATER /CHARGER CONDlBi LOCATON (~~U ~ sLiccESrED eLOac HEATER CONDOR LoraT1DN (om1DNAL) 4 3 4aB [3.88] n L• ~i12 [4.4T] [48.83] °; n ^ o ~_ a ' o f DETAIL A ,~ (411,'8'9: EXHAUST OUREf INSTA 10 OTE IF SUBBASE FUEL TANK AND/OR 7 [295] S0.- SOUND HOUSING IS USED, REFER Boy [231 TO SUBBASE FUEL TANK ADV TO DETERMINE MOUNTING LOCATIONS. 24V BATTERY uocAnaN ~ ~ IB [40.54] 0 ^~ 7S [2.95] SO. ~ o © ~ °, ~ 890 [35.04] ~ RI SUGGESTED BATTERY ~ C u ~ .r 350 [13.7e] 1220 [48.03] ~ cGN~wr uuAUCanoria ~ C $ soo [Ig.6a] ~ 2OSa [el.ot] 889 [28.34] (0~0~ 1878 [88.07] HDAC - J3S [13.17] SUGGESTED LOCATION FOR FUEL INLET AND RETURN 228 [8.88] (FLEXIBLE FUEL INLET UNE 3/8 NPT MALE) 1320 [51.96] FUEL RETURN (OPPOSITE SR1E) (FLEwtLLE Futi TiEfURN La1E 3/B HFT ~) 1199 [48.80] FUEL INLET 52 2.OS] FUEL aJLET FITTING 823 [32.41] 2HT[.91] [ FOR 8.0 [J12) I.D. NOSE EX1iAUST OURET 40 1.58 - ~ EXNAUSr ourLET ° FUEL RETUfOT FRIING SEE DETAIL A I FOR 8.4 [.25] O.D. TU~NG _I__~ / .. I FACE ~ ~ Tl I ~ FUEL INLET B CONTROLLER ~ ` ~ 3 •• _ ~ o $ ~ .• ~ w~ a ul ~ ~ ~ ~ ~ ~i ~ .. 7' ~ A r, n d ~ ~~ _ ~ ~•o r O \~ 128 [4.97] 1401A11Sf ounEr Yy- I ~0- ~ "' MODEL ALT GENSET WEICFiT WEf I 13S 15 4511,45 14 0 Kg 150 LBS I50 4515 S00 K 3300 LBS 8 ~ ~ ~0t~. m Y/HEN SUBBASE T/WK 15 USED, CONDUIT n MUST BE LOCATED OUTSIDE OF TIWK ARG OR IN STUB-UP AREA FOR SUB[TASE TANK. REFER 10 SUBBASE ADV. 2) OINENSIONS IN [ ]ARE f44GUSH EgUNALEMS. "! 3) IF AN ENCLOSURE IS USED 7HE FUEL LINE °_' MUST BE STUfiBED UP FROM DIRECRY " UNDER THE UNIT OR BROUGHT IN FROM ~ E ~. REFER TO ENCIASUFIE ADV METRIC CAD FILE 4x m.50 [e.sea] a DRAIN LoanoN 4B3 [19.00] A A a1p4 (DENSET AND SUI~ASE I B88 [J4.89] OIL ORNN ~ 965 [37.99] . y TANK NOLINIINC HOLES) 520 [20.47] 2185 [85.24] 430 [16.93] 1040 [40.94] I 1412 [35.S7J 4575 ~"--1388 [53.77] 4511 g 4513 1~ N0~1.((TIRTI 4513, 4513 ~ 1;« ~` ~~ • ~ ~~ (~~ ~ ~~) RE~CONNECGBIE DIMENSION PRINT 2800 [11024] WPROVED MOTOR STARTING (INS) RECQNNECTABLE ¢a r-n-m ~ V A1.TERNATQR3 a n-Vf-ot.. •u ~ rawawtao ~-x 808@NF JOHN DEERE s~ uc-ai' ADV-6645 D R 7 6 4 2 i-'°'" • • D~ B I BLOCK FiEA1FR"s 149 [5.88]~i L//'BLOCK 120 AND BATTERY CHARGER A~ 12 [.47] 320 [12.60] BS [2.58] O O _L M6-1 . e . • (10 PLACES) u, •a •o ~ n• 0 •o •o n ° .. ., I~~ 90-135V AC POWER R°y . 1829 [72.0] -BATTERY CHARGER 1 CONNECT 70 BATTERY 2 RADIATOR OUCf FIANGE BAl7TRY CHARGER 24V ~- [8.35] to 823 [32.41) C ex rz2a e' EQUALLY SPACED ON x241.3 [9.S] B.C. • v + g® 8' AN51 FLANGE (BIBS CLASS 150) •_ _•O •' B FLETQBIE E%HAUSf (.75 SCALE) METRIC CAD FILE A 135 NODEL (PIER 11) 451t,4S13 150 YODEL (TIER I) 1515, 4515 CONNECTA@LE IMPROYED MOTOR STARTING (IYS) RECONNECTABLE 3 800V ALTERt1ATOR3 BOTRINF JOHN DEERE 3 • PG ERAS Ti I B-~ 02 J/03~ TECI°ONICAI. INFORMATION ~UI.LETIN Alternat®r ®eta Sheet • • Alternator Model: 4Si5 Frequency: 60 Hz Speed: 1800 RPM Leads: i2 (6 Lead, 600 Volt) ktlV'~ (kVA) Voltage Power 90°C 95°C i05°C 130°C L~N/L-L Phase Factor Connection 80°C Lloyds ABS Pdme 125°C Stsndby 139!240 3 0.8 WYe 164.0 172.0 176.0 180.0 180.0 180.0 2771480 (205.0) (215.0) (220.0) (225.0) (225.0) (225.0} 127/220 3 0.8 WYe 155.0 163.0 166.0 174.0 180.0 180.0 2541440 (193.8) (203.8) (207.5) (217.5) (225.0) (225.0) 120/208 3 0.8 WYe 150.0 156.0 161.0 166.0 180.0 180.0 240/416 (187.5) (197.5) (201.3) (210.0) (225.0) (225.0) 1101190 3 0.8 WYe 135.0 136.0 137.0 140.0 147.0 149.0 22080 (168.8) (170.0) (171.3) (175.0) (183.8) (186.3} 1201240 3 0.8 Delta 150.0 158,0 161.0 168.0 180.0 182.0 (187.5) (197.5) {201.3) (210.0) {225.0) (227.5) 1201240 1 1.0 Dogleg 104.0 105,0 106.0 107.0 109.0 110.0 (104.0) (105.0) (106.0) (107.0) (109.0) (110.0) 347/600 3 0.8 Wye 150.0 158.0 161.0 168.0 180.0 182.0 187.5) 197,5 (201.3) (210.0) {225.0 (227.5 * Ap data tested in arxordance with IEEE Standard 115. Kohler Co. reserves the right to change the design or speolfications without notlce and without any oWigatlon or liability whatsoever. Submittal Dana: 139/240 Volts, O.8 PF,1800 RPM, 80. Ht, 3-Phase,130°C Rise Symbol Per Unit Ohms Symbol Value ly/pfcsl Resistances Typical Time Constants Phase Resistance 0.001 0.004 Armature Short Circuit Ta 0.009 sec. Rotor Resistance 8.2 2.10 Transient Short Circuit T'd 0.148 sec. Typical Reactances Transient Open Circuit T'do 1.740 sec. Synchronous Typical Fleld Current Direct Xd 2.990 0.766 Fuil Load H~ 30.5 amps Quadrature x4 1.470 0.376 No Load ~NL 12.6 amps Transient Typical Short Circuit Ratio 0.39 Unsaturated X'd„ 0.288 0.074 Harmonic Distortion Saturated X'd 0.253 0.065 RMS Total Harmonic Distortion <5% Subtransient Max. Single Harmonic 5a' Duect X°d 0.079 0.020 Deviation Factor (No Load, L-L) 3.7% Cauadrature X°y 0.080 0.020 Telephone Influence Factor <50 Negative Sequence X2 0.079 0.020 Zero Sequence Xo 0.007 0.002 Insulation Material Class per NEMA MG1-1.66 H Phase Rotation ABC TI&102 8/03 • TYPICAL GENERATOR EFFICIENCY* 139/240, 277/480 Volts, Wye • 35 30 E W is p 20 • m 15 10 4S75 60 Hz Typical Generator Efficiency Data Unavailable at This Time Output (kVY) TYPICAL MOTOR STARTING CHARACTERRSTICS* 110/190, 220/380 Volts, Wye 25 5 • 0 ,r ~ ~ ~ i 0 150 250 350 X50 550 650 Locked Rotor kVA • AA data tested in accccdence with IEEE Standard 115. iCohier Co. reserves the right to changethe design or specifications without notice and vrittrout arty obUgation a liability whatsoever. TIB-102 9/03 • • Industrial Generator het Accessories ~~~E~®POWER SYSTEMS so~,nd nciosu ~s ~9®®1 ~~~~ Appll®c~ble to the following: NATIONALLY REGISTERED 20E-'10ZJ~ I I I I i I I I I I i I I I I I I I I I I O O Weather Enclosure 20-230REOZJ~ 80-200REOZJc Kohler® enclosures protect stationary generator sets from the elements, animal intrusion, and unwanted entry. The enclosure design allows ample air flow ensuring optimum generator set performance. Kohler Co. prototype-tests the generator set inside the enclosure for performance. See the generator set specification sheet for generator set ratings and temperature and attitude Berates. Weather Enclosure Standard Features • Enclosed insulated critical silencer with tailpipe and rain cap. • Skid-mounted, fully corrosion-resistant material construction with hinged and removable doors. • Fade-, scratch-, and corrosion-resistant Kohler® cream beige and black powder-baked finish. o Available steel construction enclosure. o Available aluminum construction enclosure (20-125 kW models only). • Hinged and removable doors. • Lockable, flush-mounted door latches. • Automatic door holders. O O Sound Enclosure • Air inlet louvers and baffles to minimize rain and snow entry. • Pitched enclosure roof to minimize water accumul 'on. Sound Enclosure Standard Features • Includes all of the weather enclosure features. • Vertical outlet hoods with 90° angles to redirect air and reduce noise. • Acoustic insulation meeting UL 94 HF1 flammability classification. • Gff-551JOSf Pagel • Sound Enclosure Data Sound Data for Generator Sets Operating Inside a Sound Enclosure /~, ~`~ ~ Measurement Positions ~ I ~ Generator Radiator and Distances for Data End \ / \ I / / End \ I / \ ~ \ / I Microphone Positions: Microphone Distance: (1-8) as shown 7 m (23 ft.) (from surface of enclosure) 3 - - - - \ / ~~ _ _ _ _ 7 Microphone Height: 1 m (3.28 ft.) / \ Data Measured in: dB(A), sound pressure \ / I \ / 7 Mater Radius // I \\ / Note: Measurements taken with the generffior set 4 I operating at full load. ~ \ I ~ - ~ . v -~ Sound Data in dB(A) Microphone Positions Models Hz 1 2 3 4 5 B 7 8 20ROZJB * 60 77 75 79 77 77 77 79 77 50 72 73 74 74 73 75 76 74 20REOZJB 60 69 71 74 73 70 71 73 71 50 67 69 70 69 68 70 71 69 30REOZJB 60 69 71 74 73 70 71 73 71 50 67 69 70 69 68 70 71 69 40REOZIB 60 69 71 74 73 70 li 73 71 50 67 69 70 69 68 70 71 69 50REOZJ6 60 74 73 75 75 73 73 73 72 50 73 71 72 72 71 72 72 71 BOREOZ,lB 60 75 74 76 76 75 74 74 74 50 74 71 72 72 71 72 72 72 80REOZJB 60 73 75 75 75 74 75 77 74 50 71 71 71 71 72 72 72 72 100REOZ,16 60 73 74 75 75 73 72 74 73 50 72 72 73 73 72 70 71 71 125REOZJB 60 73 75 76 76 74 73 74 73 50 73 73 74 74 73 71 71 72 150REOZJB 60 74 75 76 74 74 75 73 76 50 71 71 73 72 72 73 73 73 180REOZJ6 60 76 76 76 78 76 76 76 76 50 72 72 74 74 72 73 73 73 200REOZJB 60 75 75 75 77 74 75 75 76 50 71 71 71 71 71 72.' 72 72 230REOZJB 60 76 75 76 77 75 75 75 76 50 73 73 71 72 72 73 72 72 80REOZJC 60 74 74 76 75 75 76 75 75 tOOREOZJC 60 74 75 76 76 74 T5 75 75 135REOZJC * 60 74 73 76 73 73 73 73 73 C 180REOZJC 60 75 75 76 . 74 74 74 74 75 * 75 * Estimated values cs-ss Brost ~ z r i• AIR WTAKE r--- 1888 (14'26( O O 0 d O N "rye ~a~ a 0 I I I ~ I i I I I ~ I i ~ ~ 712128.05] 712128.05] 712 (28.06f OPENWO WITt1 OPENWG WITH OPENING WRH DOORREMOVED ODOR REMOVED ~OOOR REMOVED 21e51852a] -~igg0I18881 2800 11024 12 ENGINE EXHAUST AIR INTAI(E . \ ~- 1888 p425] ~. AIR s, /DISCHARGE • ENGWE EXHAUST 14841 •~ , ^ - - - - ~ DISCHARGE ° ~ ~ 1 I I 1 b-i ~ 11 ~ I _' C7 ~al ~ ~ ~ ~ ~ `Oz ~ ~ ~ a 0 - - - - q .eel 8 let [30.>) I I let 130.7) 6 ~,p3f AiR o~scD rwRGE ~ DOOR I-- -~I DOOR ~ OPENWO REMOVAL 914,1 [92,05) REMOVAL " CLEARANCE OPENING ~~~ ~' ls/~e1 ~ ~ WITH PANEL 1 ] 1040 [40.94 11.48) REMOVED 4X 017.50 (.888] MTG. HOLES Dlmerreiltna in [ ]ere loch equhrelerOS. 135-180REOZJC Weather Enclosure ADV-8882&F ~1 I ~ I ~ I ~ I g~ ~~ I ~ I ~ ~ I n N~ _~_ ~ ~ N~ w ~ i ~ ~ O ~ ~ a I I I i ~+ 761 190.71 DOOR ~ 444~~~--- -- 17e1 [30.7[ I DOOR r1 712 [ZBABJ OPENWG VRT 712 [28.05) PENWG 712 (ZB.OSJ PENINO WITH -_ ~ REAAOVAL 814.1 (3205) REMOVAL DOOR REMOVED DOOR REMOVED DOOR REMOVED `~ CLEARANCE g CLEARANCE ~3 2185 [8524] --~i 430 (18.83 789131A7J g WITH PANEL REMOVED 20001110.24] o+ 08 (t.4e] Dlmanaiorls in [Jere Inch equivalents. ADV•8G82GF 48-55 7/05f Papa 8 380174.94) KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565.381, Fax 920.459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US end Canada, phone 1-800-544-2444 Singapore 619159 KohlerPowerSystems.com Phone (65) 6264-6422, Fax (55) 6264-6455 Sound Enclosure Weight • Steel Construct ion Enclosure Aluminum Cortstructic enclosure ltilodei ARemator Generator Set (Wet) with Enclosure, kg (Ib.) Sound Enclosure, Oniy, kg (Ib.) Generator Set (Wet) wlth Enclosure, kg (Ib.) "sound ^losure, C °, kg (Ib.) 20REOZJB 4P4W, 404W, 4P4, 404. 1016 (2240) 336 (740) 855 (1885) (385) 30REOZJB 404W, 404 1016 (2240) 336 (740) 855 (1885) (385) 30REOZJ6 4P5W, 4P5 1032 (2275) 336 (740) 871 (1920) (385) 40REOZJB 4P7W, 4P8W, 4Q10W, 4P7, 4P8, 4Q70 1093 (2410) 336 (740) 932 (2055) (3^5) 50REOZJ6 4PBW, 4P8 1317 (2903) 367 (810) 1142 (2518) (425) 50REOZJB 4010W, 4010 1360 (2998) 367 (810) 1185 (2613) (425) 80REOZJB 4P10W, 4P10 1360 (2998) 367 (810) 1185 (2613) (425) 80REOZJB 4S7W, 4V7W, 4S7, 4V7 1422 (3136) 367 (810) , 1248 (2751) (425) BOREOZ.IB 4S7W, 4S7 1422 (3136) 367 (810) 1248 (2751) (425) 80REOZJB 4S9W, 4V9W, 4S9, 4V9 1492 (3290) 367 (810) 1318 (2905) ~ (425) 100REOZJB 4S9W, 4S9 t 674 (3690) 467 (1030) 1558. (3435) (525) 100RE02JB 4V11W, 4V11 1783 {3930) 467 (1030) 1558 (3435) (525) 125REOZJB 4S11W, 4S11 1783 (3930) 467 (1030) 1578 (3479) (525) 125REOZJ6 4S13W, 4S13 1805 (3980) 467 (1030) 1578 (3479) (525) 150REOZJB 4S13W, 4S73 1996 (4400) 567 (1250) - - 150REOZJB 4S15W, 4S15 2064 (4550) 567 (1250) - - 180REOZJB 4S15W, 4S15 2427 (5350) 567 (1250) - - 200REOZJB 4UA9W, 4UA9 2712 (5980) 653 (1440) - - 230REOZJ6 4UA10W, 4UAt3W, 4UA10, 4UA73 2903 (6400) 653 (1440) - - 80REOZJC 4S7W, 4S7 1468 (3236) 413 (910) - - 80REOZJC 4S9W, 4V9W, 4S9, 4V9 1538 (3390) 413 (910) - - t00RE0ZJC 4S9W, 4S9 1538 (3390) 413 (910) - - 100REOZJC 4S11W, 4V11W, 4S11, 4V11 1647 (3630) 413 (910) - - 135RE02JC 4S11W, 4S13W, 4S71, 4S13 1996 (4400) 567 (1250) - - 150REOZJC 4S13W, 4S13 1996 (4400) 567 (1250) - - 180REOZJC 4S15W, 4S15 50 2427 (5350) 567 (1250) - - - - t ,4U - - Availability is subject to change without notice. Kohler Co. reserves the rlghtto change the design or speciffcaticns without notice and withoutany obligation or liability whatsoever. Contact your local Kohler® generator set distributor for aveilebllity. DISTRIBUTED BY: ® 2D02, 2003.2004, 2005 by Koller Co. All rights reserved 05-55 1/054 Page 12 • ~ EIICINE EwlwsT . AIR INTAKE 1888 (74.25] p _ _ O o m uni I I ~ 1 I I ~ ~ I 1 ~ ~ I 1 I 1 1 ~ I ~ ~ j ~ ~ ~ ~ a i i ~ ~ 1 I ~ 1 a I I 1 ; i i 1 i O 1 I I 1 1 ; i I I I ~ I - -- --------------- _ - -J ' -------------- ------------- -------------- . , .. r 7eI [30.7] ~ ~ 791 [30.7] ~ 7IZ [2a.os] 7IZ [za.os] 71z [za.ols] 6 ~ DOOR DOOR OPENING a1TH OPENING wffH OPENING 1aiF1 REMOVAL 814.1 [32.OS] REMOVAL DOOR REMOVED DOOR REMOVED DOOR REMOVED ~ CIFARlwCE YII11~Pw~ rJ.FnRAncE ~ 2185 [86.24] - ~ 430 (18.93] Tae RDJOVEO 2800 [Iloz4] ~+~- wElcx+r (wET) sounD MooEL w SOUND ENCLOSIRIE ENCLOSURE ONLY 13s/TSo 150 4S1 160 (TIER IQ 4515 2064 Ke [4550 l8S 987 Kg [1250 l9S] 180 4515 1!S YODEL (TIER IQ 4511. 4513 ISO YODEL (TIER I ~ TIER 11 4513, 4513 180 MODEL ERR 4S1S E A61.E IMPROVED MOTOR STARIINC (IYS) RECONNECTAaIE k 800Y AL7ERNAi0R5 6O6BHF/AF JOHN DEERE ~o 94] ~~ nzso [.a6e] I8 HOLES le] METRIC CAD FILE A Industrial Generator Set Accessor6e~ ~ ICO~ILE~L.POWER SYSTEMS D;ege, F e; ~a~k~ NATIONAIIV REGISTERED • ---r-~-----~- .~ II~~ I~ ~, ~ Double-Wall Subba~e"Tank with Optional Weather Enclos A Double-Wall Subbase Fuel Tanks (UL Listed) Applicable to the following: 20ROZJB 20-230REOZJB 80-180REOZJC Secondary Containment (SC) Tank • The above-ground rectangular secondary containment tank mounts directly to the generator set. The secondary containment fuel tank mounts below the generator set skid (subbase}. • Both the inner and outer UL-listed tanks have emergency relief vents. • The containment tank's double-layer construction protects against fuel leaks and ruptures. The inner tank is sealed inside the outer tank. The outer tank contains the fuel if the inner tank leaks or ruptures. • ,The subbase fuel tank is compatible with a weather housing, weather enclosure, or sound enclosure. Standard Features. • Heavy-gauge construction • Integral stub-up area • Removable end channel for easy access to stub-up area • Emergency pressure-relief vent outer tank • Lockable fill cap and riser, 2 in. NPT • Low fuel level switch for controller alarm (optional with Decision-Maker'" 1 controller) • Mechanical fuel gauge • Normal vent with riser and mushroom cap • Emergency pressure-relief vent inner tank • Fuel supply and fuel return openings • Basin drain • Overflow opening Ca6-87 7f04b Double-wall Subbase Tank • Fuel 'Dank Features nov-se,~n-A ~ 4 • Figure 1 Double-Wall Subbase Fuel Tanks (Secondary Containment) 1. Emergency vent per NFPA 30 2 in. NPT 227-382 L (60-101 gal.) 3 in. NPT 450-973 L (119-257 gal.) 4 in. NPT 1124-1874 L (297-495 gal.) up to 180 kW 9 1 ~ 8 5 6 4 in. NPT 1609-2347 L (425-620 gal.) 200/230 kW 5 in. NPT 2249-3944 L (594-1042 gal.) up to 180 kW 5 in. NPT 3096-4614 L (818-1219 gal.) 200)230 kW ' 2. 2 in. NPT raised manual fill cep wkh 51 mm (2 in.) riser 3. 21n. NPT level gauge 4. 1 1/4 in. NPT norrnal vent w(th 127 mm (5 in.) riser and mushroom cap 5. 3/8 in. diptube with check valve, (female) customer fuel supply connection 3/e in. NPT 20-180 kW 1/2 in. NPT 200/230 kW 7 3 2 4 1 6. 3/B in. diptube with check valve, 3/8 in. NPT (female) customer fuel return connection 7. 2 in. NPT with low level switch 8. 2 in. NPT for sensor/pump control float noveerzA-n 9. 1 in. NPT for overflow, 7.6 L (2 gpm) pump maximum 10. 1 in. NPT for tank fill 3. Emergency pressure relief vent inner tank 2 for details) 4. 1/2 In. NPT for leek detection switch Figure 2 Fuel Tank Fittings Top Vew (Figure 1, Item 3) Fuel Tank Accessories • Inner tank leak alarm kit • Low fuel alarm (Decision-Maker"' 1 controller only) oe-e7 ~mab KOFLERPOWER SYSTEMS TO: Kraft Power Corporation PO Box 2989 Woburn, MA 09888-0389 ATTN: Dan Little REF: 25024190 Quotation #ST00006527 November 1, 2004 PLEASE ACCEPT OUR QUOTATION FOR THE FOLLONRNG (16,) USTSC-475 475 E~allon Seoondaoy containment Sub-base Tank's - UL #142 Listed ENGINE/GENERATOR MODEL AND TANK DIMENSIONS Genset model =Kohler 180REOZJB or C Gensetfootprint = 40.94"W x 110.24"L Sub-base dimensions = 36.0"H x 40.94°W x 120.00°L Shipping weight = 1,875 lbs. (each) NOTE.• Sub-base tank extends beyond genset by 9.76" on the radiator end. STANDARD EQUIPMENT The Sauk Technologies UL #142 listed secondary cantainmentsub-base diesel fuel tank has an inner tank that is manufactured fiom 10 gauge steel, and an outer tank which is comprised of 7 gauge steel side and end d-annels, akxrg with a !0 gauge steel bottom, and 7 gauge thick steel top. The tank Domes standard with (n 2°NPT fittings (removable engine supply dlp tuba, removable fuel return dip tube, fill, nom-a! vent (bushed down to 1-i/4° NPT), gauge, and two additional fittings for optional level alamr switches). (2) Required size emergency Trent fittings are provided, one for the inner fast tank, and a second for the outer containment area. (!) ~4°NPT besfn drain is also provided. A direct reading mechanics! leveel gauge and lining provisions ere also standard equipment. SPECIAL OPTIONS ON EACH TANK (1) PICKUP Pickup of Genset of Kohler Facbry (1) MOUNT -Mount Genset to ST Supplied Tank (1) 3190 Electrical Stub-Up Area (10. i2' (1) 3200 Removable End Channel (1) 3000 2" NPT Lackable.Fflf Cap with 8' Pipe Riser (i) 2000 1-1/4"NPT Screened Atmospheric Vent Cap (2) 2140 4°NPT Emergency Pressure Relief Vent Cap (1) 1000 Low Fue/ Level Switch -Standard (1) 1200 Fuel In Basin Switch -Side Mounted, Standard (1) PAINT Tank Is Painted Standard Black TERMS AND CONDITIONS OF SALE Alf Items shipped F.O.B. SaukvUle, VI/i our dodo. Payment terms are net 30 days (subject to credit approval) from date of shipment Thls product requires drawing approval befor9 manufacturing may begin. Current lead-time fs 30.45 woridng days from Saukville, h/I. Quotation is valid fur 90 calendar days from time of quote. This quote fs based upon the Information given to us at the time of quotation. Changes, additions and/or additional requirements may change the stated amount and wfll require a re-quote. For more fnfomratfon, or to place art order, contact Tim Thomas at 888-688- 9500 or Trm Mintner at 800-320-9447. Fax requests to (262) 268-3900. We appredeta the opportunity to provide this quotation. Rev A Confrrm 'cin still valid. TTT- 2/1ti/05 Rev B Add C as a valid o Lion TTT -3/2/05 300 N. Dakota Woods Blvd. f~0 Sox 80300 ~ Saukville, Wisconsin ~ 530811 Tell Frra~ 1-Rnn-~~n-4447 ~. TPL~ ~f,7-7FR-~Rnn ~ FaY~ ~~~ar,~-~4nn ~ cniktPrhrnintpcla~-a~~kFPrh.rnm ~ www.c+iikta~h_mm nna s<rrrlr~ A B" NPT NORMAL VENT Ff1Til~ri_G ((bnetied dawa to i-1/4' NPT) B 4" NPT 1i1~ENCY YEIiT lT1TING PER NFPA 90 (4b R) C 8' NPT FUEL FILL FTI'TII~iG D 2" NPT FOB REMOYABI= FIJBL SUPPLY DIP TUBE - !/2" NPP E E" NPT FOB RSIIOYABLIS FIJffi. RETURN DIP TUBE - 1/8" NPT F 2" NPT FUEL LBVEL GAUGE FTTTDRG G R" NPT FOR OPTIONAL LOIf FUEL LEVEL SIIITCH J 1/8" NPT~FORPOPTIONAL FUEL~IN HASDQ SIffPCB s i/a' NrT Fos i~-sitrr nIlAn~r .n nor _ •.n n~• Genset ~' ~f Geneet 9.78` TANH CAN9TRUCTION 1) SIDE AND END CHANNELS ARE 7 GA. 6fEEL. MAIDIIJM GENS6P ^SIGHT IB (6.000 Lam.: NUMBER OF TOP 0 G POIN3'f . 8OUTER CO ON TOP D3 7 GA. 8 0 TANS BOTTOM Di 10 GAUGE. 4 DiNEB TANS ffi 10 GAITGE BTEEL. 5 RiTERNAL BAFFI.B TO SEPARATE COOL SUPPLY FUEL FROM HOT RETURN FI)EL. e) DvTERIOR COATED t1TrH RvsT iNSIDTfOR. 7 BSfSRLOR PRa® AND FINISH PAINTED. TANS 3P8CIFiCATI0N3: i} GENSBT TYPE $ehler 160-1@ORSOZJB '} GSNBSf 11E[GHT - 9 SUB-RASE 11S[GHT 4 DOUBLE 1fALL SPECIFICATION ~_ SECONDARY CONTALNIIDNT 6) TANY HEIGHT RANGE FROM 8" TO 98". B) SUH-BASE TANS OPTIONS ~ LG~BUSI. LSVBL SIITTCH BiGH FUEL LEVEL SRTfCH Z N~RMAL PENT CAP ICY VENT CAPS 2" NPT LOCSABLE FILL CAP R fltJ. PIPE TO 1lTTHIIi 8" OFT BOTTOM REMOYABiE END CHANPiffi. 7) TANS COMES STANDARD 11TFH A DIRECT READING MECHANICAL FUEL LEVEL GAUGE. cvsTO1~R APPROVAL NAME s DATE SIDE_ VIER RADIATOR END Ylislf ~~~® IQNIIN TOLBRANCB3 Sauk T e c hn o 1 o ie s ~ usTSC-475 ~/ $a8~ ~ s/v : _ +/- o.a• ~ Referea~ce (quote •5700008827 9-10-06 START FROM 79-09087 G71f i~ s~+~ 00 ~m b~ ~ I~i'aft I'o~er Cug Qr~t3Q~ ~~zE DItSCRIPTtON coo BY Date: s-to-o6 SI~~~'~ 1 OF 1 °~~ A2`~Q0.00 r~ Hountitos Holes TOP VIEIf FUEL TANK 180F2EOZJB BASED ON QUOTE ST~6827 DRAINING #73-03067 180REOZJB SUGGESTED :CONCRETE PAD LAYOUT 144.00" X 65.D0" INCLUDES 12"LIP ON ALL SIDES 3.40" 35.D0" 120AQ" ~e.oe° x ss.es~~ snBam ,~~~. 2.00 10.00 GENERATOR END 6.00" .144.00 11.00" 15.00" 10.00" CONDUIT STUB-UP M LOCATION .~~, (BELOW _` ~.; ~ BREAKER} :41.00•'. 65.D0" RADIATOR END RADIATOR END KRAFT POWER CURP. WOBURN, MA FOUNDATION LAY01lT 180REOZJB FRESENIUS MEDICAL CARE • 1°P-1137 2/~5~ INSTALLATION INSTRUCTIONS Original Issue Date: 4196 Model: 20-2000 kW Generator Sets Market: Industrial Subject: Inner Tank Leak Alarm Kits PA-226203, PA-226203-SD, PA-226204, PA-226204-SD • • Introduction The inner tank leak alarm indicates the inner tank has Peaked into the outer tank and the double-wall subbase fuel tank needs.replacement. See Figure 1. Inner Tank O FualLeak Alarm ®° Alem~ Normal ® Silence HP-273000A-F Figure 1 Inner Tank Leak Alarm Panel Toois Required • Electric drill • Drill bit 3/16 in. • 3/8 in. hex driver Leak Alarm Panel Function Use the Figure 2 table to identify leak alarm conditions. Alarm Float Switch Switch Position Position Horn/Lamp Functions Normal Open The alarm hom and the lamp are not energized. Norn-al Closed The alarm hom and lamp activate when a fuel leak occurs. If the alarm switch is moved to the silence position, the lamp stays on until the fuel leak fault is corrected. Silence Open The alam- horn sounds to alert the user that the alarm hom switch is not in the normal position and that the alarm horn will not sound should a fuel leak occur. Figure 2 Leak Alarm Function Safety Precautions Observe the following safety precautions while installing the kit. ® WARNING ~ ~~ Accidental starting. Can cause severe InJury or death. Disconnect the battery cables before working on the generator set. Remove the negative (-).lead first when disconnecting the battery. Reconnect the negative (-) lead last when reconnecting the battery. Disabling the generator set. Acclderttal starting can cause severe InJury yr death. Before working on the generator set or connected equipment, disable the generator setasfollows: (1) Movethegeneratorsetmasterswitchtothe OFF position. (2) Disconnectthe powertothe batterycharger. (3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. A WARNING L Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. Read the entire installation procedure and compare the kit parts with the parts list in this publication before beginning installation. Perform the steps in the order shown. Installation Procedure This installation instruction provides recommended locations. Select the location and position of the leak alarm front panel where access and visibility is optimum for the application and within the limits of the wiring harness. Refer to Figure 3 with kit PA-226203/PA-226203-SD and Figure 4 with kit PA-226204/PA-226204-SD. 1. Removing the generator set from service. 1.1 Place the generator set master switch in the OFF/RESET position, 1.2 Disconnect the power to the battery charger. 1.3 Disconnect the generator set engine starting battery(ies), negative (-) lead first. 1:4 Remove the junction box doors: 2. Mounting the leak alarm kit components. 2.1 Remove the pipe plug from the fuel tank for the leak alarm sensor. See Figure 3 or Figure 4 for pipe plug location. 2.2 . Remove.any tape or banding from the leak alarm sensor. Apply pipe sealant to the threads of the leak alarm sensor (A-226201) and install in the fuel tank. See Figure 3 or Figure 4, Detail D, for leak alarm sensor position. 2.3 Kit PA-22fi204/PA-226204-SD only. Use bracket (336505) as a template and drill two 3/16 in. dia. holes in junction box. See corresponding illustration in Figure 4 for location. Deburr the holes and clean up any metal chips. Attach leak alarm bracket (336505) to the junction box (J-box) using two drill screws (X-794-1). 2.4 Kit PA-226203/PA-226203-SD only. Attach leak alarm bracket (336505) to the junction box (J-box) using two screws (X-51-11) and nuts (X-6210-4) in the predrilled holes. 2.5 Place the annunciator box assembly (A-224861) on the alarm bracket and secure with three nuts (X-6210-4). See Figure 3 or Figure 4. Position the leak alarm front panel where access and visibility is optimum,for the application. 3. Wiring the leak alarm kit. 3.1 Connect the leak alarm wiring harness (226207 or 226208) to the annunciator box assembly and the leak alarm sensor. See Figure 3 or Figure 4. 3.2 Connect the wiring harness positive (+) lead to either the engine starting battery(ies) or starter solenoid battery positive terminal, See illustrations in Figure 3 or Figure 4. 3.3 Connect the wiring harness negative (-) lead to either the engine starting battery(ies) negative terminal or the engine block ground. See illustrations in Figure 3 or Figure 4. Kit PA-226204/PA-226204-SD only. Replace N terminal with ring terminal i;X-283-21) as needed. 4. Restoring the generator set to service. 4.1 Replace the junction box doors. 4.2 Check that the generator set master switch is in the OFF position. 4.3 Reconnect the generator set engine starting battery, negative (-) lead last. 4.4 Reconnect power to the battery charger and block heater as required. 4.5 Place the inner tank leak alarm panel switch to the NORMAL position. Parts List Inner Tank Leak Alarm Klts Parts List Ktts: PA-226203, PA-226203SD, PA 226204, PA-226204 -SD Qty. Description Common Parts PA226203, PA226203SD PA-226204, PA-226204-SD 2' Screw, drill X-794-1 2 Screw, 8-32 x 3/4 X-51-11 5 Nut, 8-32 whiz X-6210-4 3 Nut, 8-32 whiz X-6210-4 1 Terminal, ring X-283-21 1 Box, annunciator A-224861 1 Sensor, leak alarm A-226201 1 Hemess, leak alarm wiring 226207 226208 1 Bracket, leak alarm 336505 2 TT 1137 2/05b u I 1 /- A-224861 / LEAK ALARM / PANEL (~ X-6210-4 R STARTER ALARM PANEL ~~ ue SEE VIEW C) (BRAG X-51-/1 J® ®e XB210d~ ° o c® c ~ ®~ 0 ~ 0 0 ~ F1 . _ _ - ' 6~ ~ a ~ O (~ + u voc RYA LEAK ALARM N BATTE ~ 2~ ~ ~ 6 07 N GND N / // 4OaO +®aO E K ' L A EN R II II I I I I I I II I I SO 'S II II II ~ ~ ~ ~ II i I V VIEW B LEAK ALARM WIRINd DIAGRAM II II A-228201 GENERATOR SETS WITH 4P AND 4S ALTER NATORS LEAKALARM SENSOR (SEE VIEW B FOR WIRING DIAGRAM) (SEE DETAIL D FOR SENSOR POSITION) X-51-11 (2) X-62104 (2) NOTE REMOVE ANY TAPE OR BANDING FROM FLOAT BEFORE INSTALLATION INTO TANK BASIN. NO 1 NC ORIENT SWRCH AS SHOWN (3) AIL D ANNUNCIATOR BOX MOUNT GENERATOR SETS WITH 4P AND 4S ALTERNATORS r- BatTt_RY BATTERY CONNECTIONS Note: Dimensions shown are in inches; 1 in. equals 25.4 mm. HP-273000AB-F Figure 3 20-180 kW Generator Sets Using Inner Tank Leak Alarm Kit PA-226203/PA-226203-SD TT-1137 2/05b 0 BATTERY ALTERNATE HOOKUP TO STARTER 3 x-e21 lY ALARI ?R PANE dL B) WIRING DIAGRAM 228 NOTE: REMOVE ANY TAPE OR BANDING FROM FLOAT BEFORE INSTALLATION INTO TANK BASIN. NO a NC ORIENT SWITCHAS SHOWN DETAIL D X-7B4-1 (2) VIEW A-A zo-aoo ew J-Box ANNUNCIATOR BOX MOUNTING DRILL (2) (b.188 HOLES USE BRACKETAS TEMPLATE T 0 d 1.0 X-784-1 (2) VIEW A-A 350-2000 kW J-BOX ANNUNCIATOR BOX MOUNTING HOLE LOCATIONS DRILL(2) Sb.198HOLES USE BRACKET AS TEMPLATE BATTERY STARTER RELAY LOCATED IN J-BOX ON DDC SERIES 60 DIESEL BATTERY CONNECTIONS :] Note: Dimensions shown ere in inches; 1 In. equals 25.4 mm. AB Figure 4 200-2000 kW Generator Sets Using Inner Tank Leak Alarm Kit PA-226204/PA-226204-SD a X-784-' I.0 VIEW A-A 950-2000 kW J-BOX ANNUNCIATOR BOX MOUNTING HOLE LOCATK)N3 WHEN J-BOX IS EQUIPPED WITH CIRCUR BREAKER EXTENSION BOX DRILL (2) Q).198HOLE3 USE BRACKEfAS TEMPLATE } BATTERY (REPLACE'N' TERMINAL Wmi X-283-21 WHEN NECESSARY) ALTERNATE HOOKUP TO STARTER TT-1137 2/05b (SEE WIRING DIAGRAM) (SEE DETAIL D FOR SWfTCH POSRION) T'IiERW1AL-IiAAONETIC/1U0A+~NEYIC ONLY sEPTeMBER,,9s, MOI~E® CASE CIRCUIY BREAKERS 100A FRAME SELECTION DATA UNIT MOUNT CIRCUIT BREAKERS ~R ~ Ma9n~ One Pole Trro Pole Three Pole LS~tend~rd Retlnp rp p~ Cataog No. Catalog Na Catalog No. WireAanlle FCL Erse En~w 1ulcEaauar~Mla FlL TWD 8 THREE POLE 20-100 AMPERES 100 AMP'eRE FRAME FAL srsNnnRn ~RRtmnaG Mold Trip 120VaC 2aovao 240Vao i6 275 600 FAL12015 FAL22015 FAL32015 AL60FA 20 275 600 FAL12020 FAL22020 FAL32020 ~~~ ~ 25 275 600 FAL12025 FAL22025 FAL32025 #12-#4 AI 30 275 B00 FALt2030 FAL22030 FAL32030 35 400 950 FAL12035 FAL22035 FAL32035 40 400 850 FAL12040 FAL22040 FAL32040 45 400 850 FAL12045 FAt.22045 FAL32045 50 400 850 FAL12060 FAL22p60 FAL32050 AL100FA 80 830 1450 FAL12080 FAL22080 FAL92060 #14-tt1 /0 Cu or 70 B00 1450 FAL72670 FAL22070 FAL32070 #1241110 AI 80 800 1450 FAL12080 FAL22080 FAL32080 90 900 1700 FAL12090 FAL22090 FAL32090 100 900 1700 FA112100 FAL22100 FAL32100 FOL lrerimarm rrurErrarraTrnr~ Hold Trlp 277Vec, 125Vdc 480Vec, 250VdC 4BOV8C, 250Vdc 15 275 800 FAL14015 FAL24015 FAL340t5 AL50FA 20 275 600 FAL1402D FAt.?rW20 FAL34020 #t4~ Cu or 26 27b 800 FAL1402b FAL24025 FAL34026 #i2~t4 AI 30 275 800 FAL14030 FAL24030 FAL34030 35 400 850 FAL1403S FAL24035 FAL34035 40 400 B50 FA114040 FAL24040 FAL34040 45 400 850 FAL14045 FAL24045 FAL34045 SO 400 850 FAL14050 FAL24050 FAL34050 ALi00FA BO 800 1450 FAL1406D FAL24060 FAL94060 #14-#110 Cu or 70 800 1450 FAL74070 FAL24070 FAL34070 1112-#1/0 AI 80' 800 1450 FAL14080 FAL24080 FAL34080 90 900 1700 FAL14090 FAL24090 FAL34080 100 900 1700 FAL14100 FAL24/00 FAL34100 FAL sTaNnaan errERnuanNG Hold Trip ~~~ 250Vdc fi00Vac, 250Vdc 15 275 B00 ...... FAL260i5 FAL36015 AL50FA 20 25 275 276 600 800 ...... FAL2602D FAL28025 FAL36020 814-#4 Cu or FAL36l52b 30 275 600 ...... FAL26030 #12-114 AI FAL36030 ...... FAL26035 ...... FAL2B040 AL36040 b0 400 850 ...... FAL28045 FAL28050 FAL38050 AL100FA 60 80D 1450 ...... FAL28060 FA13606 1114-111 /0 Cu or 70 800 1450 ...... FAL28070 FAL360 #12-#110 AI 80 800 1450 ...... FAL26090 FAL36080 90 900 1700 ...... FAL2609D FAL36080 100 900 1700 FAL26100 FAL36100 FF11. HIGN IN TERRU PTING Hokl Trip 125~Vd~c ~OVd~c 15 275 BOp FHL18015 FHL26015 FHL360i5 ALSOFA 20 275 600 FHL1 BD20 FHL28D20 FWL36020 #14-#4 Cu or 25 275 BOD FHL78025 FHL26025 FHL38025 11'12-#4 AI 30 275 B00 FH118030 FHL26030 FHL36030 3b 400 850 FHL1B035 FHL26035 FHL36035 40 400 850 FNL1B040 FHL26040 FHL38040 45 400 850 FHL16045 FHL28045 FHL36045 50 400 850 FH118050 FH128050 FHL86050 AL100FA 80 B00 1450 FHL1B060 FHL28080 FH136060 #14-p1/0 Qior 70 800 1450 FHL1B070 FHL28070 FHL98070 1N2-#1/0AI 80 800 1450 FHL18080 FHL28080 FHL38080 90 900 1700 FHL16090 FHL26090 FHL38090 100 900 170D FHL18100 FHL2:8400 FHL36f00 Hold Trip 496VacG 4BOVac Standard Lug K1t Wire Range 15 275 60D ...... FCL24015' FCL94016 20 275 600 ... FCL24020 FC134020 CU30FA 25 276 BOD ...... FCL24025 FGL34025 #14#10 Cu ~ 275 600 FCL24030 FCL34030 35 40D 85D ...... FCL24035 FCL34035 40 400 850 ...... FCL24040 FCL34040 46 400 85D ...... FCL24045 FCL34045 50 400 850 ...... FCL24050 FCL34050 ALI0DFA4 60 800 1450 ...... FCL24080 FCL34080 #14-#3 Cu or 70 80D 1450 ...... FCL24070 FCL34070 #12-iti AI 80 800 1450 ...... FCL24080 FCL34080 90 900 170D ...... FCL24D90 FCL34090 100 900 1700 FCL24100 FCL34100 o FCL 2-pde o1n:Wt breaker bulN using 3-pole module. FAL OtiE POLE 15-16D AMPERES _':':: cfn _.~.:.~) ,;,CIi~. ti' N c FAL/FFIL FAL/Flil./FCL 1~100AMP~ERES iS100~AMP RERE R AC Magri Two Pyle Three Po19 ~gd ~~ Tr Sip -eUi Clog No. Catalog Na Wlre Range 100 A MPERE FRA ME FIL FLI NATER® CURRE NT Lp~ARING Hotel 'ITip 600VaC 6DOVac 20 275 B00 FIL26020 FIL381120 AL50FA 1"k14-iW Cu or 30 275 600 FIL26030 FIL36030 1-#12-#4 AI 40 40D ' 860 FIL26040 FlL36040 50 400 850 FIL28050 FIL36050 6D B00 1700 F1L26080 FlL3606D AL100FA , 70 800 1700 FIL26070 FIL38D70 1-#14-111 /O Cu or 80 800 1700 F028D80 FIL36080 i -0112-111 /0 AI 90 800 1700 FtL28090 FlL36090 100 800 1700 FIL28100 FlL36100 soLIA-Ae a con~~r 17 SEPTEMBER. 1991 '~~IERf~I~-L-AAI40NETIC/IUI~-ONETi IC ONLY VIOL®E® CASE CIRC!!IY BREAKERS 100A FRAME FAl., FHL, FCL* DIIIAEKSIOkS .se .as ~o io O~ O O -~- O O O -~- ~ ~-, 2~ s.~ ,~ 2~8 2~ 2~ OR ~ OR ~ OR O O v O O O® O I ie ~ a ~e ~1 ~ ii I t ~. ~98 111"""___ ~ 3,~0 ~ n~ sr / 1 U 7~8 ?~ Je 159 .7~3 t~ 4 a81~ .708 t ~ ~ t.gq o~ o o~ o 0 0 1.18 t.16 191oB --mot- ~ _t # FCL 2-pose clrcuR breaker tlimenslon la same as 3•pole circuit breaker. oua orue„aorr~ INCHES uislmeters • 0 SGIUAREe a cONP.~NY ~u~i ~ci ass ,, ~6 ~,0 ~ ~~~~I ~3 ~' ~ ~~ ~ ~ ' TIAE IN SECOMCS Y $ §~ia 3 a 9 ~ p ~ 9Y9- - ~ . « . ~.._ t ...s _ r r a a e y>,ae a 0 ~ f B i ~~LD i ~ ~ 1 ! ~8@B~ ,._.. :..: :, . _ _._!_, . . ~.. 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B@IOD39 NI9WLL L a N N • • • s~~B~,,s~, YHERIi~AL-AAAGNEYIC/MAB;fVEYIC 4Nl.Y M®~E.D CASE C163CdJl'P ~REAI6EH~S 100A FRAME nrc~ cuavEs • 6R7LTIPLBa OP RATED CURRENT ~~ ~ ~~~ ..~~.. w, . w w,....1 ...Q.. 5...-_il. _ Y- 0_E.RG.II l~ Moe ... •.;.'.. F~UPIUFC 7HEgAEAL.111AOME'iIC ~ ~ . , ~ ; _ 1l~ C/i8E CRtCUR BREall~p6 •~. :.' ~:: ctarmciewsnc ~ cx~RVe xo. Eso.s C81CI8~ BREAREA Bp7galRTpN w-~ + Clrcuk araeker Cominuan Maximum Number a-:- ~ .... i. P-Itl[ Ampero RatmO AC Yhka0e d Pales FA T40 ti, Z,9 -~ ~ FC ~ t ~ a ~ ~ i 90 d 100 a9 0 : ~: FA 600 29 FH 600 t~, Z,9 i 120Vaa r7N[sreaa ~:.... .. •~ • 2T7vac rrokKem . . ... , :. . ; .... o ....... ....:. ,. - .. i. i; Ole ...--:... . ~ o._:. i ~. i..: .: i .... ; i ' •~l"tA+lriiWY1IN8Y[.~L81i1~nYE6 aT ae'C'?' s-.. ,IAaPO.ONk16pA MEkt~O. .~.. .. ~.. ...._. . - ....._......~... w .. ... ........ ...: ........ .. : .._. _. p. .. _ _I ..., _ i,~ .• ~• , ... r .. . .._ ~ s -- ~ i ; , ~ p .....; ..... ...r ~~ ~ l..n. .~... t -. I . 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P 8 8 8 8 P~R98~ ~ ' MULTiPI.!'6 OF RATED CUAAENT O 8 MULTPLEB OF RATED CURRENT a~, :6 01, ,.,w . r ....5 0 8 8 !,8 8lBBA a ... .. _ Fl H,11EfERO CURREWT LAiUTErK~ Tnenc T~ippinp cunrea for Coordfnatlon ahtdea ere available upon reque~.t. D~ SQUARE D CONF~i4NY 2~ MULTMLIB OR RATED CURRENT ~~~ YHERAAA6.-NiAGNETIC/MA~NEYiC C~Nl.1( SEPTEMBER, 493'8 ~~i l~ M®!.®E® C~E,SE CIi~CUiY BRE/AKEi~.S 225l250A FLAME • • SE~TI®N 2 225/2SOA FRAME This section provides specific infomtation on Square D 225! 250A frame thermal-magnetic molded case circuit breakers. For mare information, see Part 1, "Introduction to Thermal- Magnetic and Magnetic Only Molded Case Circuit Breakers' DESCRIPTION CiIRSI~t t~eelCef D98Crlptbn D2 100-225A, 240Vac. 50/80 Hz, 2• end 3-pde KA/KFI ~o-25oA, soovec, 5a~ Hz, z5ovdc, 2- and 3~pole Kc ~1o-zson, 4eova~. 5oreo HZ, 2- and 3-pola KI 110-250A, 600VaC, 50/60 Hz, 2-end 3-pole current Ifmitirg APPLICATIONS • KI current limiting circuit breakers are used for electrical systems where high fault currents can occur. • KA/Kli, KC and HI circuit breakers are used in industrial enclosures, panelboards, switchboards, busway plug-in amts, combination starters a~ motor control centers. Q2 circuit breakers are used in individual enclosures, metering devices, panelboards and switchboards. ACCESSORIES See Part 3, "Accessories," for a complete list of available accessories. See "Catalog Numbers" for an explanation of the the catalog numbering system 'The following pages provide catalog numbers, selection data, dimensions, characteristic tripping curves and let-thmugh curves relating to 225/250A frame Square Dthermal- magnetic molded case circuit breakers. Catalog N C M UL Elated Interruptlng Ratin g rel F d IEC 157-1 P7 Rating Number Prefix a Cf o . Ampere AC W1le-F~IutS Syrrcnetr rfr~ll Amperes DC Wits e 9 SpeCS. ~ Poles Ra11ng W-C-375B/GEN KAL KA 2,3 70-250 42K 42K 42K 25K 25K 22K 10K tOK 10a,20a 25K 25K KHLO KHO KHL-DCir ... 3 ... ... ... ... .. ... ... ... ... 20K ... ... ... KCL KC 2,3 110-250 100K 100K t00K 86K 85K ... ... ... ... 23a 85K 85K KIL Kt 2, 3 110-260 200K 200K 200K 2tXA( 2001( 100K ... ... ... 18a 200K 200K Q2L Q2 3' i00~225 10K tOK 10K ... ... ... ... ... ... 12b t]2L-H ~_I.f 2 9 100-226 100-22b 22K 22K 22K 2210 22K 22K ... ... ... ... ... ... ... ... ... ... ... ... 12b,14b Q2LH Q2H $ 100-225 42K 42K 42K ... ... ... ... ... ... 12b,14b ~ UL~Lis d 600V~ ratVrrNig~for u e 2a4i0ungroun~d s~stemg~. Must bge ca n~ecbd 3 p~oleBs Iren sees uC~orrst~ilt ~ I~al ~5uare b sales otflce tar addittonel Formation 28 svuAae a con~Y 0 SEPTEMBER, 1991 TI-IEI~MAL-MAGNETi IC/MAGNETi iC ONLY MOL®E® CASE CIRCIJIY BREAICE6~.S I ~ 2251250A FRAME SELECTION DATA O • • uNrr MouNr clRCUrr BREAKERs A~ I ~~_ gee ~ Two Pole Three Pole tsnda!d Rat C A S~tie. Catalog Na Catalog No. WlreLugRaKrU~e_ 250 AMPERE FRAME KAL STANDARb INTE'FIRUPTMG ' Low High 600Vac,250Vdc 600Vao.250Vdc 70 350 700' KAL28070 KAL3t~70 80 400 000 KALZ8080 KAL38060 90 450 900 KAL28090 KAL380B0 100 500 1000 KAL28100 KAL38100 ~ 1 1100 . KAL28110 KAL38110 ~ AL250KA 150 750 1500 KAL281 0 KAL38160 1-p6-350 kcmll KAL28175 200 1000 2000 KAL26200 225 1126 2250 KAL28225 KAL86725 250 1250 2500 KAL28250 KAL36250 tCNL -ttGGt INTERRUt~T~tG Low High BOOVac,250Vdc 600Vec,250Vdc 70 350 700 KHL26070 KHL3fi070 ~ 400 800 KHL28080 KHL38080 90 450 900 KHL28080 KHL3fi090 too 500 iaoo KHL261oo KHL3fi1oo 110 650 1100 KHL281i0 KHL36t10 AL250KA 125 625 1250 KH128125 KHL36125 1-tt8-350 kcmll 150 750 1500 KHL26150 KHL36150 175 675 t750 KHL2fi175 KHL3$17S 200 100D 2000 KHL282D0 KHL36200 225 1125 2250 KHL28725 KHL98225 250 1250 2500 KH128250 KHL36260 KGL EXTRA HIGH ItiTFARUPTING LOw High 480V8C 480Vac 110 550 1100 KCL24110 KCL34110 125 625 1250 KCL24125 KCL3412b AL250KA 150 760 1500 KCL24750 KCL34160 1-it8-350kcmil t75 875 1750 KCL2417b KCL34175 200 1000 2000 KCL24200 KCL34200 A1 250K1 225 1126 2250 KCL24225 KCL3422b . 1-1/0.350 kcmU 250 1250 250D KCL24250 KCL34250 KIL 4LOUItTEA® CIIRREM LIM17tNG Low High BOOVac 600Vac i10 550 1100 KIL28110 KIL38110 125 625 1250 KIL28125 KIL38125 AL250KA 150 750 1500 KIL26150 KIL36150 1-i1fi-350 kcmil 176 675 1750 IOL26175 IQL3fi175 20D 10D0 2000 K1L26200. KIL38200 AL250K1 225 1125 2250 KIL2822S KIL3l;'125 1-110-360 komU 250 1250 2500 KIL28250 KiL36250 FRAME Two Pole 'Three Pole Two Pole ThreB Pole Two Pole ~ 9 Catalog No. Catalog No. Catalog Na Catalog N0. Catalog N0. C~2Ldr 10,000 A1C 22,000 AIC 42,000 A[C 12A/240Vac 240Vflc 240Vac 240Vac 240Vac 100 p2L2100 p2L3100 p2L2100H Q2L3100H p2L,1i2100 110 Q2L2110 p2L3110 Q2L2110H p2L3110H Q2L4i2110 125 p2L2126 ~p2L3725 p2L2125H Q2L3126H Q2LH2126 150 p2L2150 p2L3i60 p2L21601i Q2L3150H p2LH2160 175 p2L2t75 p2L3175 p212176H p2L3175H p2LH2175 200 p2t2200 Q21.3200 Q2L2200H p2L3200H p2LH2200 225 p2L2225 p2L3225 p2L2226H p2L3225H p2LH2225 ~ UL magnetic trip aeWng tolerences ere t25% Low) end t20% (HIghI from the nominel values shown. yt Accessories and replacement lugs are not ava table on the Q2 circuH breaker. Lugs for the p2 circuit txeakers accept 1-tt4300 kcmtL tGAUfOiL tctl TWO & THREE POLE TWO & THREE POLE 70-250 /lMPERE$ t t0-260 AMPERES O2 BOLT-0N CIRCUIT BREAKERS Meter Center Short ClrcuU Currant Raring 10,000 RMS Symms- 22,000 R M S Symms- 42,000 R M S Symma- Amp. trEcal Ampex p r S tr m p n$ A Ratlng Listed Bd ClrcuU Listed BoR-On Circus BOa-0 f~rCUft LSted Breakers Installed Breakers Installed Breakerslnatailed Catalog Number Catalog Number Catalog Number 100 p2M2700 p2M2100VH p2MH2100 125 p2M2125 p2M2125VH Q2MH2725 150 p2M2150 42M2'150VH p2MH2150 175 p21JML175 p2M2175VH p2MH2175 200 Q2M2200 p2M2200VH Q2AAH2200 sr~uaRe a con~+-nnr 2~ YHERINI/~L-NIA~aNEYIC/M/QfaNEYIC ONLY SEPTEMBER,1931 IIII®L®E® CkSE CIRCUiY BREAKERS 250A FRAME KAL, KHL, KCL AND KIL DgIAEldSiONS lJ 4 748 1~7a •~ •~~~. ~ "'~ V-111 o°o°o z.ss 2~8 o~ ', ~nOnO 2.24e,Typ. i~---I' ~~~1 4~~ {.._igBO 1~ .7g3 If~ .082T-0yp. 2.58 ss 1.09 Re Dual Dlmetgbnx ll9lUmie6~e a 4.14 1 32 sauAaE a con~~r 0 • • • S~ ~_~ ~~ e~ ~~ ~~ ~I.._...i _ ............ .. ` .. .. ,... Ji..... :..~ l_........i .. ..... .... .:.. ..: :. .:. a:.. ~..t.. .. ~... .. ... .. ... tl'......._iw ~. i ~... .. ~. . ..f... ...{.i .... . { ~ j ~ : i ,. r :.: ..~ r~. ~.. ,~ r., t ~.... _.... .... .__ ~..:: .:. ..., ,:~. ,.~ ...: y ~~ ~~~ ,..... ;~.~ a . =; u; ,: ~:.~. ~ .~ $; ~,- ,: ~' P s 3~f ro n ~ ~ .:. .. .;j .. .. ...............~..._.._.._. _. , r _ .:.' 1 i .: ;:: , ..: i :.. ... ~., ~~: .._ _ .... .. ......... ....... ... .. . ~ t .. _ .... .j. . 4 l.i . _..... i...:..... c.:.;1......._..:.i. . .. ,.. ...i ...., x i... .... ... , .'.. .... .l.... ~ i.}C... .. ~....~.. ~..... ... .. ..... _ 'I " _t. e r a e e 8~4at t~ t t ~itt~, :;'. ~..r i . ~ .. ~ .. .: .:. ...~._... 1 ..I i .: _ .' .,. ..~ ~gQ ~i ....... ,;. :. ~'. •: ~.~__....u. ~.~..:.. :.. _ ~ ... ~ ~ i : '. .. r ~t... . t - ,.:. ... . . . .. .: • C ~ :• :. -~ ~ ~ s..~ ~ :s ~ ~ ~ ,~ ~ y ~~ ~ g oS ~ s 2 ~ ?s p •w gY {Ed .°° 8 :a ~~ jro SA a ~w ~s ®~ N ~A~p/~~ V/ y~/ ~ ~ mm ga n~ ~~ ~' e m W~ ~~ ~~ m® ~z m • • • Small Tank Beaters 1~6igh lainpect Plastic Sia>fgle Phase 500-2000 Watts t20V & 240V • View of a Kim Hotstart TPS tank heater. This durable heater is assembled with abuilt-in thermostatand 4-foot power cord. n„r, rT "^°`°"RB.625I.D. 'Off temperature -adjustable 90-130°F (On differential - 20° F) .25 (4X) Holes Far Mounting Brackets ~ O • • Molded. from Polyphenylene Sulfide (PPS). • Rust-free, resists corrosion, exceptional tensile strength. • Vibration and shock tested to extreme limits to guarantee durability. • Greatly reduced heat loss for more efficient operation. • Compatible with all chemicals. • Incoloy element for longer service life. • Thermostatically controlled. • All parts are field replaceable - not a throw away heater. • Compact design requires minimal mounting space. Ambient Ambient Kim Hotstart Thermostat Range Above ° Below ° Model Number Uolts Phase Watts Amps On Off •20 F -20 F TPS051GT8-000 120 1 500 4.2 80°F 100°F TPS051GT10-000 120 1 500 42 100°F 120°F 150 150 TPS051GT12-000 120 1 500 4.2 120°F 140°F ° Cubie Ineh Cubic Inch TPS051GT12-A00 120 1 500 4.2 ADIUSTABLE ° ° or Less or Less TPS052GT8-000 240 1 500 2.1 F 100 F 80 ° ° TPS052GT10-000 240 1 500 2.1 F 120 F 100 TPS052GT12-000 240 1 500 2.1 120°F 140°F TPS052GT12-A00 240 1 500 2.1 ADJUSTABLE' TPS101GT8-000 120 .1 1000 8.4 80°F 100°F TPS101GT10-000 120 1 1000 8,4 100°F 120°F 350 200 TPS101GT12-000 120 1 1000 8.4 120°F 140°F Cubic Inch Cubic Irtclt TPS101GT12-A00 120 1 1000 8.4 ADJUSTABLE` or Less or less TPS102GT8-000 240 1 1000 4.2 80°F 100°F TPS102GT10-000 240 1 1000 4.2 100°F 120°F TPS102GT12-000 240 1 1000 4.2 120°F 140°F • TPS102GT12-A00 240 1 1000 4.2 ADIUSTABLE` TPS151Gi8-000 120 1 1500 12.5 80°F 100°F TPS151GT10-000 120 1 1500 12.5 100°F 120°F 350 - 500 200 -300 TPS151GT12-000 120 1 1500 12.5 120°F 140°F Cubic Inch Cubic Inch TPS152GT8-000 240 1 1500 6 3 80°F 100°F or Less ar Less . TPS152GT12-000 240 1 1500 6.3 120°F 140°F TPS152GT12-A00 240 1 1500 6.3 ADJUSTABLE' TPS181GT8-000 120 1 1800 15 80°F 100°F TPS181GT10-000 120 1 1800 15 100°F 120°F 500 - 700 300 -4:00 TPS181GT12-000 120 1 1800 15 120°F 140°F Cubic Inch Cubie Ineh TPS181GT12-A00 120 1 1800 15 ADJUSTABLE" or Less or Less TPSZ02GT8-000 240 1 2000 8.3 80°F 100°F TPS202GT10.000 240 1 2000 8.3 100°F 120°F TPS202GT12.000 240 1 2000 8.3 120°F 140°F TPS202GT12-A00 240 1 2000 8.3 ADJUSTABLE" INLET HOSEBARB .625 I.D. 4.6 6 Kim Hotstart Manufacturing Company, Inc. P.O. Box 11245 Spokane, WA 99211-0245 46' 16-3 HPN G~N~E3~iTi0~ ACC~SSORI~S ~ IQOFILER.POWER SYSTEMS ce~e~no~ se, co~o-an3. ~9U~1 Kohler® ®ecision-Maker' 3+ -~^~ ~ Controller NAiIONALIY 0.EGISTERED General Description and Function • • wW~wu6yyy Wkalw4hLyyp~ ,yl~wudu.YeW,ypy~ ~~ • ~® ® ®SL o~ o-° o~•~- oar ~ ~__ °`~ °°°_ o~ T b i ~.~ --0- The generator set controller provides system control, monitoring, arid diagnostics for optimum performance. The generator set controller provides both analog AC meters and engine gauges and 16-light annunciation of warnings and shutdowns. Standard Features • Supports Modbus® RTU (Remote Terminal Unit) communication protocol. • Supports specific ECM engines using CANbus communication protocol. • Contains microcomputer-based logic with a ROM (read-only memory)-based control algorithm. • Features upgradeable software for new engine functionality. . • Compatible with 12- or 24-volt engine electrical systems. • Meets Underwriter's Laboratories UL 508 requirements for use on a stationary generator set. • Meets the National Fire Protection Association requirements of NFPA 99 and NFPA 110 with additional accessories. NFPA 110, Level 1 .- requirements typically apply to health care facilities; NFPA 110, Level 2 requirements apply to less-critical applications. • Contains internal protection ftom electrical noise. • Vibration isolated for mounting on the generator set. • Conformal coated circuit boards for environmental durability. Modbuam is a rep~tetetl hadamerk of Schneldar Electric OB-30 8/09h Decision-I~akerTM 3+, 16-Light Controller Ihli~iltlddlldp~/~/~/ NERrz A-C AMPERES O UPPER METER SCALES o~ ~ u ~, Lu, uit ~ uL.is uL-iz AMPS Lzia O LowER UETEA SCALES bldtllbll~Il~hG/d A.C voLTs VOLTAGE EMERGENC ® STOP aalusr ONLY OIL WATER O T~E1~EN0MIURE O TBAFFAATURfi OAU~mrRV O VOLTAGE O O PREBS°RURE O 17WiGER FAULT O °WPER O TENPEIMTthiE O srOF °°'~ O ALT "°''' O ~T (~ LOW KIEL (~ OVERBPEED O OVEACPANN O NOT~AUTO RUN OFRREEEr AUTO - ~~O ~~L ~~ IC~Hl.ER UWO TEEf Controller Features • Specifications - ~ - • Power source with circuit protection: 12- or 24-volt DC • Powerdraw: 220 milliamps in system ready mode (or 200 milliamps without panel lamps) • Humidity range: 596 to 9596 noncondensirig • Operating temperature range: -40°C to +70°C (-40°F to +158°F) • Storage temperature range: -40°C to +85°C (-40°F to +185°Fj • Standards: o NFPA 99 o NFPA 110 o UL 508 Hardware Features • AC interlock to prevent starter reengagement with engine . running • Battery (DC) circuits are fuse protected • Controller mounts locally or remotely up to a distance of 12 m (40 ft.) and viewed from one of four positions • Dimensions-W x H x D, 461 x 247 x 297 mm (18.15 x 9.71 x 11.68 in.) • Wiring harness specfc for electrical connections • RS-485 Modbus® port • CANbus port Communicaion Features • The controller supports Modbus® RTU (Remote Terminal Unit)-an industry standard open communication protocol. • Supports ECM engines specific to CANbus communication protocol. NFPA Requirements • In order to meet NFPA 110, Level 1 requirements the generator set controller must monitor and display specific engine/generator safety indications and shutdowns. Engine functions: o Overcrank o High coolant temperature shutdown o High coolant temperature waming o Low coolant temperature waming o Low oil pressure waming o Low oil pressure shutdown o Overspeed o Low fuel (level or pressure) o Low coolant level (auxiliary fault) o High battery voltage o Low battery voltage * o Air damper indicator • General functions: o Battery charger fault o Master switch not in auto o Lamp test o Audible alarm silence * Requires optional input sensors on some generator set models G&30 8103h r~ LJ • Standard Features • Sixteen LED indicating lights for status, warnings, and shutdowns • Status indicators: o Air damper (red) (if equipped)* o Generator switch not-in-auto (red) o System ready (green) • blaming indicators: o Auxiliary (multiple function)(red) o Battery charger (red)* o Fuel, low-level or pressure (red)* o Pressure, low oil (yellow)* o Temperature, low engine (red)* o Temperature, high engine (yellow)* o Voltage, high battery (yellow)* o Voltage, low battery (red)* • Shutdown indicators: o Auxiliary (multiple function)(red) o Emergency stop (red)* o Low fuel (utilizes auxiliary indicator); 125RZG model only o Level, low coolant (utilizes auxiliary indicator) (available with radiator-mounted generator set models only) o ~Overcrank (red) o Overspeed (red) o Temperature, high engine (red) o Pressure, low oil (red) • Panel illumination lamps (2) • Analog gauges; 51 mm (2 in.). o Pressure gauge, oil o Temperature gauge, engine cooling system o Voltmeter, DC battery • Analog meters, 89 mm (3.5 in.): o AC ammeter, 2% of full-scale accuracy o AC voltmeter, 2% of full-scale accuracy o Frequency meter, 0.5% of ful{-scale accuracy • Running time meter • Switches and standard features: o Hom, alarm (with silencing switch) o Mode, prime power o Potentiometer, generator output voltage-adjusting (front panel mounted, .5% of nominal voltage) (350-2 kW models have adjustment on voltage regulator in junction box) o Shutdown, overvoltage protection . o Switch, latch-type emergency stop (standard on most 200-2000 kW generator set models) o Switch, tamp test o Switch, meter range selector o Switch, run, off/reset, auto (engine start) generator se' master o Timer, engine cooldown, (5-minute fixed) • Eight DIP switches for control and communication: o Cooldown disable o Crank mode select for continuous or cyclic cranking. cranking provides up to 45 seconds of continuous crag or 75 seconds of cyclic cranking (crank 15 seconds, r 15 seconds, crank 15 seconds, etc.). The crank disconnect speed is 750 rpm (25 Hz). o Engine communication setting (2) o Modbus® addresses (bit 0, bit 1, bit 2) o Overspeed protection selection of 60 Hz for 50 Hz m: or 70 Hz for 60 Hz models • Terminal strips: o Terminal strip connections for 2-wire remote start o Terminal sMp connections for 2-wire (series connectic remote emergency stop o Terminal strip connections for remote annunciator o Temiana! strip connections for remote dry contact kit • LEDs on circult board for troubleshooting diagnosis o Crank fault o Emergency stop . o Overvottage fault o Run operation * Requires optional kit or user-provided device to enable function and lamp indication. i l .g ~. ti6-30 8/03h KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381, Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada, phone 1-800-544-2444 Singapore 619159 KohlerPowerSystems.com Phone (65)264-6422, Fax (fi5)264-6455 Selected ®ecision-I~iaker'~ 3+ Accessories Common Failure Relay remotely signals auxiliary ~ Controller-Mounted Emergency Stop Switch shuts fault, emergency stop, high engine temperature, low down generator set immediately in emergency oil pressure, overcrank, and overspeed via one single-. situations. Use the generator set master switch for pole, double-throw relay with 10 amp a~ 120 VAC, normal shutdowns. Standard on most 200-2000 kW 10 amp at 28 VDC contacts. generator set models (see respective generator set specification sheet for details). ^ Controller Cable, 12 m (40 ft.), enables remote mounting of the controller. ^ Controller Connection Kit provides a cable connecting the controller to a terminal strip in the . junction box. Specify the controller connection kit for junction box remote device connections. ^ Dry Contact Kits interface between the controller signals and customer-supplied accessories providing contact ciasure to activate warning devices such as lamps or horns. Kits are available in either one or ten single-pole, double-throw relays with 3 amp at 250 VAC contacts. A kit with twenty single-pole, double- throw relays with 3 amp at 250 VAC contacts is available on 450-2000 kW models. •o Prealarms warn of low water temperature, approaching low oil pressure, and approaching high engine temperature. Kits for gas-fueled models include a low fuel pressure switch. Remote Annunciator Panel enables the operator to monitor the status of the generator from a remote location. May be required for NFPA 99 and NFPA 110 installations. ^ Remote Audiovisual Panel warns the operator of fault shutdowns and prealarm conditions. Common fault lamp and horn with silence switch. ^ Remote Emergency Stop Panel immediately shuts the generator set down from a remote station. FASTCHECK® hand-held diagnostic fault detector ° activates controller circuits without operating engine/ ~ Run Relay provides athree-pole, double-throw relay generator. Helps service or~maintenance personnel with 10 amp at 250 VAC contacts for indicating that quickly identify faults in controller and engine circuits.. the generator set is running or shut down. ^ 10 Amp. Float/Equalfae Battery Charger with Alarm Feature warns controller of battery charger fault, high battery voltage, and low battery voltage. 6 Amp Float/Equalize Battery Charger has automatic 3-stage charging with indicator LEDs. Durable potted assembly for full waterproofing and shockproofing. UL 1236 fisted. Availability Is subject to change wfthout notice. Kohler Co. reserves the right to changathe design or specificffiions without notice and without any obligation or liability whffisoever. Contact your local Kohlera generator set distributor for availability. DISTRIBUTED BY: ® 1885,1888, 1887,1888, 2000, 2002, 2003 by Kohler Co. All rights reserved. 68.30 8/03h ~ m ~~ V 1 V ., C 4 N m o fu N O O u 1.25 [32] B.~S [217J u l ~ ~ [s] 4 ± ~ 1 m ~ N • ~ y ~~ ~s~ ~o <~ e~ J I O V V G Y H ~ ~ 0 0 0 u F ~R~ ~ y .~ ;li~~ ~~ ~ boo o sqo ~y/9y~ fA MMM 9 ~ a ~~ 9 8 ~~ ~io~~ ~~ ®' ~ O 1 2 ~_ 0~ E z~"' C vj zL ~ . ~.., > m f7 ~ O I~~ • •i • i. i• p ~ y b m ~ s ~ ~ ~~ ~ ~~ a N ~ ~ - ~~~ ~ ~ ~~ ~~ ~ ~ ~ ~~ ~~~ ~~~~ ~ ~ ~~FZj~ ~ i 0 0 0 W 4 tl S~ Y J i L 6 6 ~. ~~ J W~ 3~~a~~~~~8~g~~~x~5§~~3~~`~~o~~a~~~~~~~~~~3 ~+ n WBBR:~~-OpZ^ m _- SSR=RWA S ~ .. n _ a ~~ s ~. r h w ite w~ee~e~ a a m l - 8~A~5 v ~_ a a--~ z fd A ~.~.e.~e.e-_: e - ~ R ~ ~^ + n ------- - ---------------- -------------------Ij i ~ ~~~ I I R (st-t.0 pf ~~i I I ~ ~~ >~,~ s ~~ ~~~~~ ~ ~ Y ~ i--- ~~ u S R R N R~~~4W w rn.~oe !~ E _N- J ~ t ~ E-i ~ $ a B u + 8 $ ~ I I ~ - ~ys-t~ u ~ .. ° ~' ~ s s a~$ N ~~o F~n G~M @r O ~x 1-~ ~ ~a ~m~~ F 10-~ ggyAj ~ gg~ I 1- ~~ 5~ g fi~ I ~~~ ~_ ~6y ~~~6{{ ~3~~yy ~~ Oi ~ q IX I ~ and ~ ~ ~ , ~ ~ ~ ~~~~ ~~ g~ ~¢ u~ 3 ~ ~ B~tl ~ S 6 v I ~ € r• & ~~ ~^ ` b 0 ww ~ m u - OyhO I ~ e $ & ~& I o v m • • ENGINE swz ~ilt00m1cP srn ~san°Fal 4 OIC (P27-IQ 4 m ~nl 1P77-P) s9rroart( ~ (~w PoK~ t ~ ~ ~~^ 25 '5 ~ fS ~ ~ 150-180 KW (N1LY I80-175 KW ONLY i I i I O~ 0 0 I 0 0 0 0 I I x s a o o TB12 / z s 4 a o TB12 I I ~ ~~~ I ~ ~~~~ I I ~ a s S I~ S S S S I TO SHEET 1 7N (R111-7N) INI tPl-e) ~ .~ (tee) e e lclc-s) ]{ 74 (PI-21) LCT 13 17 (PI-7!) I tCP11elU1) -7C (CPC-S) _~ ~"--' HCT/LRS OPS LOP r~-~ 1 `" EBG "' (P1-74) 41A (Pl-2]) N ~7 ss 9almr a --- salon ~ sw 4Y OIl1T ~ 12 VOLT ~ 24 VOLT Di D4 04 f"~N ~N nl Ti -~ Ti -I ~ ~ r ~ , I rr, I I M0 I (r K2D I I I I g K2D I I I = ~ ~ ~~ I, J I1 1, 11 11 P2 7 CANNECilONS Pm M We . C (1(11-]D) I ~ D WC '2 P WC . 1 o m: (Nn-e7) O mf OII R 47] (d10) J 112 (cell-74) ~ ~~, R ele (sss-4) ~ P 911 1]ITJ-» R N/C S WC T N/C u N/C rWC. • We . x N/C P2B CANNECDDNS rr1 M nl (mts-s) 12 I e ols tress-1) teals Iw CH.tl C 014 11e17i) J~ P 91] ITB17->) o~'~cJ' °W°. N We . n.ne L WC ~ We . N I1/C o We . P es4 (1917-1) o We . R N/C T WC uWC. ^Wc. x We . • • • °~a QQ ~~g ~ ~QQ ~ ~~$ ~~ 6 9 !1~ ~ ~99 ~ g~~F~~~~9 ~ ~~g~~~~~,~~~~~;~~~~~~~ ~9 ~ l~gg~~ ~~~~ ~B~l~~~~@A~f~19g6~~~~~~~ 91~Ek~~~99 ~~~~ ~3wn••i>:RRA ~ RRRS:cRt~~a RYSC~assao SRRa c d~ bt~ ~~~ ~ ~~~ ~ N ~ r ~~. ~ ~- oos ~- !!oo>w j ~ ~ i i i 1 --' ~' 'Y-~-J i 1 ----- _ Y~_~_ - ------ 31 e - s o ~~ ~~~~ ~ ~~ ~~ ~ ~~ 4~~E ~e A ~~ ~f ,~ ~ =_ ~` ~' T N t e : m~ o~ ~m ~~ ~~ ss u v u as g u u u u u ^ ~ J a i i 7 v u u u o .1i 7 f ~T u u v v 7 u u v u u u u u u u u u u u u v ~n.nn m~^°^°«"~ ~~~ ~~ ~~~ ~~~`` a!Y? ' ~ i a• mn on •n oo a• ' Jy V 37 V 37 V V V ~? U 37 V V 37 V V 7~ o u u 37 v v ~jF U U V' "`JJJ V V 3 V V V ~~ v 73 7 u 37 ~ v ~ a~ v v v v u ~~ V ~~~ ~~b -n nn a~ ~~ ~~ n ~~~~ OEC190N-MAKER 3+ CONTROLLER 80-180 Kid JOHN DEERE 71EN II ECM SPLLi ACTIVATOR lA. 31 NdD @OOV 7 Y _~ 0 ~m~ ~ ~ '~~~ ~~p~p 1 ~til~~y 1jd~ 1 1 1 K 1 1 w 1 1 ~~~ta~~~~~~3 ~ c ~~3 !J ~~r~ ~ o ¢~~~~~~~ ~F~~ ~.. v ~+ V~ d V V ~V 7 3~ ~~gg ~ ~~ti~~~~o~a~F~~ ii~ I I 1 1 1 j 1 1 1 1 1 1~~ I. B u xx.°~~~ss~ooa 4 as ~~ ~g 3 g~~ ~~~ (r~f+ K W~¢3ETj ~F~~V ~O~W~jO ~~ ~ $ a= 1 ~ I ~~ 1 1 1 1~1 1 1 1 1 1 1 1 ~ A ~~m~~~~~~~_~_ • 1-T-700 2195 INSTi4LLATION INSTRUCTIONS v.,~~ Original Issue Date: 3/94 Model: 6-1600 kW Market: Standby Subject: Run Relay Kits PA-273743, PA-273743-SD,. PA-273744, and PA-273744-SD The run relay kit may control air intake and/or radiator louvers, and is energized only when the generator set is running. Alarms, lights, and other signalling devices can also be connected to the 3PDT relay. See Figure 1. The contacts are rated for a maximum of 10 amps at 28 vdc, 10 amps at 120 vac, and 6 2/3 amps at 250 vac. Read the instructions completely before mounting the run relay kit. ® W~4RNING ~"e"= o ;~ Accidental starting. Can cause severe injury or death. Disconnect battery cables before working on generator set (negative lead first and reconnect it last). Accidental starting can cause severe injury or death.. Turn generator set master switch to OFF position, disconnect power to battery charger, -and remove battery cables (remove negative lead first and reconnect it last) to disable generator set before working on any equipment connected to generator set. The generator set can be started by automatic transfer switch or remote start/stop switch unless these precautions are followed. 273705 Figure 1. Run Relay 2. Install the run relay (273705 or 2~ "J6) in the junction box.. It is connected tot controller safeguard terminal strip by the wi l harness provided. Use insulated 18-ga. str ~d wire to connect the relay to the controll-. safeguard terminal strip if the relay kit is mounte, a location remote from the generator set. Do ~ mount the run relay kit more than 200 ft. (61. )from the generator set. 3. Mark positions for drilling two holes : in. (a;:..:0 mm) apart center to center. 4. Drill two 0.156 in. (4.0 mm) holes. In:: I the relay in the desired location using tF enclosed hardware. 1. Move the generator master switch to the OFF-RESET position. Disconnect the battery cables, negative lead first. 5. Locate the safeguard terminal strip in .:action box. See Figure 2. Connect the red wir: of the run relay to terminal 70 (+) and the b;:.~k lead to terminal 7N (-) of the safeguard to -urinal strip. Connect the relay kit according to the diagram in Figure 3. • NOTE Do not reverse the leads to the safeguard terminal strip because this will damage the diode andlor 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). 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 codes. 7. Reconnect the battery, negative lead last. .7 U (°,) Relay Schematic 2 3 7 .8 9. A B rJ L~ I I----~----1 A-273936-E Figure 3. Connections for Run Relay Kit • Parts List KITS: PA-273743/PA-273743-SD and PA-273744/PA-273744SD Part Number Qty. Description PA-273743, PA-273743-SD PA-273744, PA-273744-SD 2 Washer, plain X-25-9 X-25-9 2 Screw, r.h.m. 6-32 x 1/2 X-49-26 X-49-26 2 Nut, whiz 6-32 X-6210-3 X-6210-3 1 Relay, run 273705 273706 2 Safeguard Terminal /Strip TT 700 2/95 Figure 2. Location of Safeguard Terminal Strip (Typical) -~--~ os~ ~ ~~~ • INSTALLATION INSTRUCTIONS Original Issue Date: 5/95 Model: 20-2000 kW Market: Industrial Subject: Failure Relay Kits PA-347274, PA-347274-SD, PA-361548, PA-361548-5® The failure relay kit allows remote monitoring of the standby system by using one set of contacts to trigger customer-provided signaling devices if a fault condition occurs. The kit typically connects to terminal 32A on terminal strip TB1. Connection to 32A on the controller circuit board part number A-336415 monitors emergency stop, auxiliary, overspeed, high engine temp, and low oil pressure. Connection to 32A on the controller circuit board A-352160 monitors emergency stop, overspeed, low oil pressure, high engine temperature, and overcrank: Typically, lamps, audible alarms, or other devices are connected to signal the conditions. Figure 1 shows the failure relay kit. I `~' I Accidental starting. ~(~ ~ Can cause severe Injury or death. =0 ~- ~-~- ~. G294301 Figure 1. Failure Relay Kit Customer-provided accessories require their own electrical source and must not exceed the relay contact ratings following. Connect customer-supplied 12 volt DC accessories to battery positive (+} at the starter solenoid and to the battery negative (-) at the engine ground. Do not use terminals 42A and N of the controller or the connection kit terminal strip to supply the voltage to the relay contacts. Use separate leads directly from the battery for the supply voltage leads. Size leads according to local, state, and national electrical codes. Observe the following safety precautions while installing the kit. NOTE Observe applicable local, state, and national electrical codes when installing the failure relay kit and related accessories. NOTE Monitor single faults by connecting to the appropriate terminal. A WARNING ~~ X Disconnect the battery cables before working on the generator set. Remove the negative. (-) lead first when disconnecting the battery. Reconnect the negative (-) lead fast when reconnecting the battery. Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (-) lead first. Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer. Relay Contact Rating Maximum Switching Voltage ......120 Volts AC Maximum Switching Current ....: 10 Amps Minimum Switching Power ....... 10 Milliamps at 28 Volts DC or equivalent InstaOlati®n • • 1. Place the generator set master switch in the OFF position. 2, Disconnect the power to the battery charger, if equipped. 3. Disconnect the generator set engine starting battery(ies), negative (-) lead first. 4. Remove the generator set controller cover. 5. Mount the failure relay inside the junction box. Drill four 3/16 in. (5 mm) diameter holes in the generator panel using the relay board as a template. See Figure 3. . 6. Attach the relay to the junction box. See Figure 3 for mounting styles and locations. 7. Use the supplied wiring harness and 18-gauge stranded wire to extend the failure relay wiring harness 'rf mounting the kit in a location remote from the generator set. NOTE Do not mount the kit more than 200 ft. (61 m) from the generator set. 8. Connect the failure relay kit wiring harness (347275) according to one of the wiring diagrams listed in Figure 2. Use a customer connection kit (terminal strip) for easier connection and disconnection of generator set accessories. Controller/connection kit terminals 2 (ground) and 42A (battery voltage) must be connected to the failure relay terminal strip providing an electrical source to operate the Ki relay. Determine which accessory connection wiring diagram to use by identifying the type of generator set controller by the circuit board part number on the controller circuit board. The letter in the circuit board part number may be different from the letter A shown. See Figure 2. Circuit Board Wiring Part Number Terminal Strip f1ty. Diagram A-336415 TBi and TB2 Figure 4 A-352160 TB1, T62, T63, and T64 Figure 5 Figure 2. Generator Set Controller Identification Select normally open or normally closed contacts, depending upon the application. The relay contact closure corresponds to the selected controller light being activated. 9. Customer-provided devices connected to the failure relay kit must have an adequate electrical supply to operate the device. Check the electrical requirements of the customer-provided accessories prior, to installation. Use 18-gauge stranded wire to connect customer-provided accessories to the failure relay terminal strip. 10. Use cable tie (X-468-1) to bundle and secure the wiring harness. 11. Reinstall the generator set controller cover. 12. Reconnect the generator set engine starting battery, negative (-) lead last. 13. Reconnect the power to the battery charger, if equipped. Ti esting Test the failure relay operation by connecting an ohmmeter across the NO and C terminals on the relay terminal strip. Start the generator set and ground the connected shutdown switch on the controller terminal strip T61. During generator set shutdown, the relay contacts should close and the ohmmeter should display a low resistance reading (continuity). After the test is completed, place the generator controller master switch in the OFF position. TT-1068 t /99 • • 1. Circuit board 2. Relay panel 3. Circuit board standoff (360459) 4. Wiring harness 5. Screw (X-51-3) 6. Spacer (X-712-9) 7. Nut (X-6210-4) Figure 3. Failure Relay Kit Installation rr-lose ~~ss E-a-~ 350-1600 kW Controller Terminal Identification TB7 Terminal Strip 1 Ground-emergency stop ray (K4)-Conned emergency stop across ferrnlnels T81-1 end tAt f A F-mergency Stop Relay (K4) coil; negative side-Conned emergency slap ticoss tertnlrtels TBt-1 end 1 At 2 Ground terminal 12 Overctenk (OC) signal" 26 Auxiliary (AUX) signaM 32 Failure Relay/Preffiarm Une 1~/V alerts or failure relay activated by QC, 12; AUX, 28; tlNl; 35; HET, 3B; LOP, 3Q OS, 39; AHET, 40; ALOP, 41; and LF, fXi fauns 32A Failure Reiay/Prealann Une 2-A/V alartTt ar failure relay activated try AUX, 28; HET, 38; LOP, 38; OS, 39; end ES, 48 faults 35 Law water temperature (ENVY) signal 35 Hlgh engine temperature M~ signal' 38 l~wail pressure (LOP) signal' 38 Overspeed (OS) signet' 40 Antldpffiory tdgh engine temperature (AHET) signaM 41 Ardidpffiary low oil pressure (ALOP) signal" 42A Battery voltage (fuse kt protected)-accessory porrer supply, Customer may also provide separate acoessory power source 48 Emergency stop (ES) signal' 58 Air damper (AD) swttch, 'rf equipped. Standard an all 200.2000 kW Detroit Diesel powered models BO System reedy signal' B1 Battery chargerfault---Canned hffitary charger alarm tooted to TBt-B1 fA activate fault lamp (active law) H used 02 Lawbatteryvolts-Conned battery charger alarm tooted to T81.82 to activate fault lamp (active low) H used 63 Low fuel (LF) fault-Conned fuel level sensor ro TBl-83 to activate fault lamp (active love it used 70C Generetar in cad down made signal 70R Generator in running mode signal SO Not in auto signaM NOTE: Not ell tertninels are used for ell generetor sets (sae appropriate wiring diagrams for specific generffior sal mods 1' Connect jumper across terminals 1 and tA'rf emergency stop switch is not used. " Use a remote annunciator and/or Af V alerts kit as an Indicfficr with a dry cooled kit connected to oomrdler Terminal strip TB1. TB2 Terminal Strip 1P Prime power operation 2P PNme power operation 3 Remote start ground--Conned transfer swkch c remote start switch to TB2-3 end T82-4 3P Prime power operation 4 Remote start-Conned trensfer switch or remote start switdt to TB2.3 end TB2-4 4P Prime power operation 9 Crank mode selection (open-cydic sank; ground-continuous tank). Conned TB2.9 to Tt32-9A for continuous conking; leave T82-9 open cydic cranking-see Starting 9A Crank mode ground NOTE: To use prirtre power mode--place (umpers acoss T82-1 P to T62-2P, T82-3Pto T82.4P, end TB2-3 m T82-4. To deactivate prime power mode--remove jumpers across T62-iP to TB2-2P, TB2-3P to T82.4P, end T82-3 ro Tffi-4. , • Note: tMring harness leads connected to comrdler/connectian kit terminals 2 end 42A conned to failure relay terminals 2 end 42A respectivey. The remaining wiring hemess lead connects to selected generator output on the comroller/connection kit terminal strip end to failure relay Kl tertninel. H wiring harness is connected to tertninel dher than 32A mark lead according to new terminal Cannedion. 328912• 8. Circuit board part ntunber locffiion Figure 4. Controller Circuit Board A-336415 Wiring Diagram Tf-1068 1 X99 r r: TB1 Terminal Strip-Output Connections 1 Engine ground 18 42A battery voltage--accessory power suppy 2 Engine ground 19 42A battery voltage-accessory power supply 3 Engine ground 20 42A battery voltage-accessory power supply 4 Engine ground 21 Digital voltage regulator (DVR) adjustment down 5 Panel lamp layout 22 Digital voltage regulator (DVR) adjustment common 6 Relay driver output (RDO)-10 high battery voltage 23 Digital voltage regulator (DVR) adjustment up 7 Relay driver output (RDO)-9 speed sensor faun 24 Relay driver output (RDO}--8 EPS supplying load 8 Relay driver output (RDO)-7 low coolant level 25 Relay driver output (RDO)-6 overvoltage 9 Relay driver output (RDO)-5 air damper (56) 26 Relay driver output (RDO)--4 engine cooldown (70C) 10 Not in auto relay output (BO) 27 Relay driver output (RDO)~ generator running (70R) 11 Overcrank relay output (12) 28 Relay driver output (RDO)-2 defined comm. fault (32A) 12 Low battery voltage relay output (62) 29 Relay driver output (RDO)-1 NFPA comm. faun: (32) 13 Low coolant temperature relay output (35) 30 System ready output (60) 14 Low ail pressure relay output (38) 31 Emergency stop relay output (48) 15 High coolant temperature relay output (36) 32 Battery charger fauh relay output (61) 16 Low oil pressure warning relay output (41) 33 Low fuel relay output (63) 17 High coolam temperature warning relay output (40) 34 Overspeed relay output (39) NOTE: Nat ail terminals are used for all generator sets (see appropriate wiring diagrams for specific generator set madeq Use a remote annunciatorand/or AN alarm kit as an indicator with a dry contact kft connected to controller terminal strip T81. RDO outputs are active low (-). TB2 Termina! Strip-Input Connections RMT RST Remote reset* GND FLT Ground fauh* SP1 Not used SP2 Not used BCF Battery Charger fauh* LF Low fuel* PP Prime power mode* GND Engine ground GND Engine ground GND Engine ground * Connect to ground to activate T83 Temt[nal Strip--Input Connections 1 Emergency stop ground 1A Emergency stop 3 Remote start 4 Remote start AX1 Auxiliary 1 * AX2 Auxiliary 2* AX3 Auxiliary 3* AX4 Auxiliary 4* 7C Oil pressure 5 Coolant temperature * Connect to ground to activate T84 Terminal Strip-AC Input Ce =rt~ations LO LO (VO) Li L1 (V7). L2 L2 (V8) L3 L3 (V9) - Not used C3 C3 C2 C2 C1 C1 CO CO * Connect to ground to acctivvate TBl n~iri "~~uSP1 SP2 BCF LF PP GNDGND o RST FLT GND ~ 17 P5 1 2 3 4 5 6 7 8 9 10 ~ 16 32 T82 14 31 30 TB3 17 18 19 20 1 2 1 1A 13 29 13 14 16 3 3 12 28 9 10 12 4 4 10 28 5 g 8 INTERCONNECTION 5 AX' 9 25 1 2 3 4 6 '~` 8 24 7 AX; 7 P3 6 P18 8 ~~ 22 5 21 9 7C 4 20 10 5 3 19 TB4 2 1 18 1 2 3 4 5 6 7 8 9 Pt2 10 O LO Li L2 L3 C3 CO C2 CO C1 CO .a+ 2 aaa OPTIONAL ONE ISOLATES ALARM CONTACT ~ ~ x a KIT CONNECTIONS OUT Ki I I~ I NO NC C 354246A- Figure 5. Controller Circuit Board A-352160 Wiring Diagram • TT-1068 1/99 • w • Failure Relay ICR Parts List Kits: PA-347274, PA-347274-SD, PA-361548, PA-361548-SD Unique Parts PA-347274 PA-361548 Qty. Descri ion Common Parts PA-347274SD PA-361548-SD 1 Circuit board assembly, failure relay C-294301 4 Screw, r.h.m., 8-32 x 1.0 in. X-51-3 . 1 Tie, cable X-468-1 4 Spacer, 1!2 in. X-712-9 4 Nut, 8-32 X-6210-4 1 Harness; wiring 347275 4 Standoff, circuit board 360459 TT 1068 1/99 lndustria! Generator Set Accessories • 12 Volt (24 Volt*), 6 Amy ~\~~~~~®POWE~ SYSTEMS Float/Equalize Battery Charger • NATIONALLY standard Features • 12 VDC output. ' Use two battery chargers for 24-volt electrical systems • Automatic 3-stage float/equalize battery charger • Charges both lead-acid and gel-cell type batteries • Indicator lamps; red and green LEDs indicate bulk charge, absorption, and float charge stages • Durable potted assembly for full waterproofing and shockproofing • Reverse-polarity protection • Short-circuit protection • UL 1236 listed • UL 2200 compliant • UL 991 compliant for vibration and shock • UL listed to Canadian safety standards • UL rated inline fuse • FCC Class B-compliant for EMI/RFIt • 1-year warranty - - - -- --- -- --- - - - - - - • Easy installation: - - - - - - - - ,- - - - -. _- _ o Irrtegral mounting flanges ~ - o Ring terminals for battery connection o Standard US style 3-prong AC plug Specifications # Date code BJ26/04 or later Battery Charger Kits GM28688-KA1/KP1, KA2/KP2 GM28569-KA1/KP1, KA2/KP2, KA3/KP3 Input Voltage 90-135 VAC Input Frequency 50/60 Hz DC Output: Bulk Absorption Float 11.8-14.0 VDC @ 5.0-6.0 amps 14.0-14.5 VDC @ 1.5-5.0 amps 13.3-14.5 VDC @ 0.1-1.5 amps Steady Full-Load Output Current 6 amps Current Limit 7 amps Output Power Limit 70 +2/-5 watts Une Regulation Across Input Voltage Range 1 °k Isolation, Input to Output 2500 V Dimensions (L x W x D) 164 x 87 x 53 mm (6.4 x 3.5 x 2.1 in) Wei ht 1.6 kg (3.5 Ib.) Tem erature Range, Operating and Storage -40° to 70°C (-40° to 158° F) Humid' 0 to 10086 (condensing) c3s-ao eroaa KOHLER CO., Kohler, Wisconsin 53044 USA Phone 920-565-3381, Fax 920-459-1646 • For the nearest sales and service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65} 6264-6422, Fax (65} 6264-6455 164.0 143.5 10.3 52.2 4 X (116.00 N _ I~~l a-~~ ~siF~ns Q co r~ we d~.~ ~, ~ cc w, ,~.rvwe.e.a.. M ao -~- wmrt:uwooa.mw ~xr:iowm M.w.. v c Output lead length 1.2 m (4 ft.) Fuse _~ Dimensions are in mm. At~ put lead length 1.8 m (6 ft.) I - - IIWU'- -- ..-- -- Battery Connections Lead Length 1.2 m (4 ft.) Battery Connections 9.5 mm (3/8 in.) ring terminals AC Power Connections Lead Length 1.8 m (6 ft.) Connection Standard US style 3-prong AC plug Shipping Information Carton Size 254 x 152 x 89 mm (10 x 6 x 3.5 in.~ Shipping Weight 1.8 kg (4 Ib.) w~- ----=-- - ^---- -- - 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 Kohlere generator distributor for availability. ®2oos, 2ooa ey xoMer co. ai r~pnrs reserved. as-eo aloes • '• • 8 ~ 7 ~ 6 ~ 5 ovERVIEw: THE AUTOMATIC MULTI-LEVEL FLOAT/ EOUALI2E CHARGER SPECIFIED BELOW IS INTENDED TO CHARGE ENGINE STARTING BATTERIES EITHER INDEPENDENT OR IN CONJUNCTION W17H AN ENGINE DRIVEN CHARGING SYSTEM. BATTERY TYPES TO BE CHARGED: LEAD ACID GEL CELL INPUT: U INPUT VOLTAGE: 90-i35 VOLTS AC INPUT FR EOUENCT: 50/60 Hz INPUT LEAD: APPROXIMATELY 1.8M 172'1 IREFI TYPE SJTOW -10°C TO 105°C Ul RATED WIRE. TERMINATED IN PRE-MOLDED US STYLE 120 V 3 PRONG AC PLUG. DC OUTPUT: AUTOMATIC FLOAT EDUALIIE STEADY FULL LOAD CURRENT: 6 AMPS BULK 11.8-14.D VOLTS 0 5.0-6.0 AMPS ABSORPTION VOLTAGE: 11.0-14.5 MOLTS 0 I.S-5.0 AMPS FLOAT VOLTAGE: 13.3-14.5 VOLTS 8 0.1-I.S AMPS BULK TO ABSORPTION TRANSITION: 14.0 VOLTS ABSORPTION TO FLOAT TRANSITION: 1.5 AMPS CURRENT LIMIT 1 AMPS OUTPUT POWER LIMITS: 70 r2/-5 WATTS FLOAT TO ABSORPTION TRANSITION: 2.06 VOLTS PER CELL LINE REGULATION ACROSS INPUT VOLTAGE RANGE: IX SPARK PROTECTION CONNECTION AND OPERATION ~ OUTPUT LEAD: APPROX. 1.2M l48") IREFI TYPE SJTOOW -50'C TO IOSC UL RATED WIRE WITH RED AHD BLACK WIRE INSULATION. TERMINATED 1N 9.5 mm IREFI RING STYLE TERMINALS. ' FUSES: THE FUSE MUST BE LOCATED APPROXIMATELY 5' FROM RING TERMINAL ON RED OUTPUT LEAD. DC OUTPUT: RATED PER UL 1125X RATED OUTPUTI ISOLATION: INPUT i0 OUTPUT: 2500V ENVIRONMENTAL: STORAGE TEMPERATURE RANGE: -40 TO +70"C f-40 TO +158'FI OPERATING TEMPERATURE RANGE: -40 TO +70°C 1-40 TO +ISB'F) HUMIDITY: 0 TO 1001 1CONDENSINGI VIBRATION AND SHOCK: UL991 R EYERSE POLARITY PROTECTION: THE CHARGER SHALL SUSTAtN NO DAMAGE WHEN INCORRECTLY CONNECTED TO THE BATTERY IN REVERSE ORIENTATION. MOUNTING: SHALL HAVE INTERGRAL MTG. FLANGES. B ENCLOSURE: SHALL PROTECT THE CHARGER COMPONETS FROM RAIN, SNOW. DUST AND ORtPPING WATER. ALL INTERNAL COMPONENTS PROTECTED FROM WATER DROPLETS. INDICATORS: .SHALL HAVE CHARGE INDICATOR LAMP TO INDICATE BULK CHARGE AND FLOAT CHARGE CYCLES. OPERATIONAL: CAPABLE OF WITHSTANDING AN INDEFINITE OUTPUT SHORT CIRCUIT WITHOUT DAMAGE TO THE CHARGER. SHALL OPERATE PROPERLY AND SUSTAIN NO DAMAGE WHEN CONNECTED TO INPUT POWER WHILE CONNECTED TO THE BATTERY AND CHARGING SYSTEM OF ENGINE WHILE ENGINE IS CRANKED, RUNNING OR SHUTDOWN. DOCUMENTATION: THERE SHALL BE AN INSTALLATION / OPERATIONAL MANUAL SUPPLIED KITH EACH CHARGER. PER KOHLER SUPPLIED ARTWORK. CERTIFICATIONS IUS AND CANADA): - MUST COMPLY WITH UL2200 UL1236 MUST MEET CSA REQUIREMENTS EMI / RFI FCC CLASS D COMPLIANT AFTER CHARGER DATE CODE 8/26/04 A PRODUCT LABELING: THE LABEL ATTACHED~TO THE CHARGER SHALL HAVE THE FOLLOWING INFORMATION: UL LISTING KONLER PART NUMBER ' DESCRIPTION OF All INDICATOR ALLOWABLE RANGE OF BATTERY UNIT CAPACITY ALLOWABLE BATTERY TYPES OUTPUT CURRENT AND VOLTAGE INPUT VOLTAGE AND FREQUENCY 8 ~ ~ ~ 6 ~ 5 4 3 2 PACKAGING: 'KITH ANAAPPROPRIATESLABELDATTACNED. zAN50PERATeONAL /I/NSTALLATIONSMANUALFSNAZ~TON iBE SUPPLIED WITH EACH INDIVIDUAL PACKAGE. PACKAGING LABEL: ' THE PACKAGING LABEL SHALL CONTAIN THE FOLLOWING INFORMATION: KOHLER P!N . DESCRIPTION - BATTERY CHARGER MFG. MODEL N0. MFG. PART NUMBER DATE CODE WARRANTY: i2 TEAR FROM DATE OF PURCHASE FROM.NANUFACTURE. i ' OUTPi i ISEE SPECIFII i ISEE SPECIFICATI t r INPUT LEADS (SEE SPECIFICATIONS) D C IB A i I i I 4 ~ 3 ~ 2 x1 Kea x.t~z. is rr~sxi`.Ltti ~idrr N POW~B S~SSNPAS WITIpIx...1 .. 11. rirl .1 .I.r lrlal rl.rl. .u.a ..Ir r. rrq.ru r•u«x .u pl. IMi; 11f xK Yr11411.U amrr. Iz ra s x rn cf~! n uzrza xr1. LLf.: IN N xr. M.. e.a: Industrial Generator Set Accessories ~~~.E~.POWER SYSTEMS System Batteri • ~9®(~1 ~~~ • Kohler Co. selects batteries to meet f NnrioNnur RE~,STEREO engine manufacturer's specrfications and to comply with NFPA requiremer . for engine-cranking cycles. Tiypical Overail Dimensions ~. ~- Battery Specifications • Neavy-duty starting batteries are the most cost-effective means of engine cranking and provide excellent reliab' in generator set applications. • Batteries are rated according to SAE standard J-537. All batteries are 12- and have lead-calcium or lead-antim~_ plates with sulfuric acid electrolyte. • Most generator set battery kits offer dry-charged orwet-charged batteries • lough polypropylene cases protect against Iffe-shortening vibration and impact damage. • Removable cell covers allow checkin :f electrolyte specific gravity. Battery Post Layouts A-D and Style 1 4D ® A 8D p 1 C ® 31 0 PosiWe, 17.48 dia. B ® D . 24/24F N5.88 height~88 dia. ®Ui o Post 1:9 taper Notes: Dimensions are in mm; 25.4 mm equals 1 inch. BCI group numbers shown in italics. GB•18 8(04k KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381, Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales end service outlet in the 7 Jurong Pier Road US end Canada, phone 1-800-5442444 Singapore 619159 KohlerPowerSystems.cam Phone (65) 6264-6422, Fax (65) 6264-6455 Diesel Models with 12-Volt Engine Electrical Systems Cold Reaerve Battery Battery Crenldng Capactty Post Battery Battery City. BCI Battery SAE Dlmenslons, mm pn.) Amps Mlnutee r. ~ d~ Charge * Ktt Pert par Group L W at -1a°C ° ° 27°C (80 : atl Models 7ype Number Number Idt Size H (0 F) Mtn. Mlnimurr Style Dry PA-225280 225289 1 I 20ROZJ8 24F 270.0 (10.8) 171.5 (8.8) 225.6 (8.9) 650 130 D/1 Wet PA-258885 256984 1 Dry PA-225290 225289 1 20-BOREOZJB 24F 270.0 (10.8) 171.5 (6.6) 225.6 (8.8) 650 130 D/1 Wet PA-258985 258984 1 ..._ 80/100REOZJC Wet PA-256985 258984 1 24F 270.0 (10.8) 171.5 (6.8) 225.6 (8.8) 850 130 ._. i t)J1 Dry PA-338693 324587 1 ~ . 100-180REOZJB 31 333.2 (13.1) 173.0 (6.8) 239.8 (9.4) 950 20D = C/1 Wet PA-338892 4586 .,;~ 1 i80REOZJC Wet PA-338692 324586 1 31 333.2 13.1) 173.0 (6.8) 239.8 (9.4) 950 200 I C/1 * Charge type: Dry-charged batteries do not contain electrolyte. Suppy and add electrolyte per instructions enclosed with each kit. Wet-charged batteries contain electrolyte and have removable covers. Note: Ali models have a single starter motor. Batteries are for applications below end above 0°C (32°F). • 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 Kohlerm generator set distributor for availability. DISTRIBUTED BY: O 1988, 1987, 1 889,1999, 200D, 2001,2002, 2003, 2004 by Kahler Co. All fights reserved. GB-18 BIONt G~N~~Afo~ ACC~sso~i~~ ~~V67~~~®PC~WER SYSTEMS Rerv>I®te Serial Annunciator o J®~1 ~ Srsrenns . NAr10NAtLY NEGISTEREO Remote Serial Annunciator RSA 1000 for Kohler® Controller • Annunciator panel monitors the condition of a generator set equipped with one of the following controllers: Decision-Maker"" 550 version 2.10 and higher Decision-Maker'" 3+ version 1.13* I`I\~ lh Surface Mounted ~\ W H ~p~ Wi ~" ~D Flush Mounted • Meets the National Fire Protection Association Standard NFPA 110 for critical facilities. • Surface- or flush-mount box provided. Also fits in a standard 203 mm x 203 mm (8 in. x 8 in.) Hoffman box. • Uses Modbus® RTU (Remote Terminal Unit), an industry standard open communication protocol. • Controller connections: RS-485 network communications 12-/24-volt DC power supply • One remote serial annunciator (master) can support additional remote serial annunciators (slaves). The RSA 1000 is a Modbus® master device to the generator set controller. • RSA panel includes writable surfaces (four white boxes in illustration) for user data. • Dimensions-W x H x D, mm (in.) Surface Mounted: 203x203x51.5 (8.Ox8.Ox2.0) Flush Mounted: 203x203x53.0 (8.Ox8.Ox2.1) Flush mounting plate Wi: 229 (9.0) Flush Mounted:' 203x203x 103 (8.Ox8.Ox4.1) Flush mounting plate Wi: 229 (9.0) • Requires cbntroUer main clrcuk hoard GM28725 and communication nrodule kR GM32844-1~7 t Requires user-supplied Hoffman box 203 x 203 x 102 mm (B x 8 x 4 In,) Modbus® is a registered trademark of Schneider ElecMc. Ge-88 4/04a • Fault and Status Conditions Fault LEDs Fault Horn System Rea LED Generator Running LED Communfcation Status LED Overcrank Shutdown Red On Red Off Green High fan ine Temperature Warning * Yellow On Red Green Green Hi h En ine Temperature Shutdown Red On Red Off Green Low Oil Pressure Warning * Yellow On Red Green Green Low Oil Pressure Shutdown Red On Red Off Green Overepeed Shutdown Red On Red Off Green Erne nc Stop * Red On Red Off Green Low Content Level Red On Red Off Green Low Coolant Temperature * Yellow On Aed Off Green Low Fuel-Level or Pressure * Yellow On Red Green or Off Green Not-In-Auto Red On Red Green or Off Green Common Faun Red On Green Green or Off Green Battery Charger Fault (550 controller) * Yellow On Red Green or Off Green Bette Charger Fault (16-light controller) * Yellow On Green Green or Off Green Hf h Battery Voltage * Yellow Off Green Green or Off Green Low Bette Voltage * Yellow Off Green Green or Off Green User In ut #1 Red On Green Green or Off Green User Input #2 Red On Green Green or Off Green User Input #3 (550 controller) Red On Green Green or Off Green EPS Suppl ing Load Yellow Off Green Green Green Green LEDs appear as steady on when activated. Yellow LEDs slow flash when activated except steady on with EPS supplying load and high battery voltage. Red LEDs slow flesh when activated except fast flash with loss of communication and not-in-auto. Sp~e~ificatiores • Power source with circuit protection; 12- or 24-volt DC • Power draw: 200 mA • Humidify range: 0% to 95% noncondensing • Operating temperature range: -20°C to +70°C (-4°F to +158°F) • Storage temperature range: -40°C to +85°C (-40°F to +185°F) • Standards: o CE Directive o EN61000-4-4 Fast Transient Immunity o NFPA 99 o NFPA 110, Level 1 o UL 508 Recognized • RS-485 Modbus® isolated port • 19200 baud rate Standard features • Up to twenty-froe LED indicating lights for status, warning, and/or shutdown. See the above chart for details. • DIP Switches: 0 1-Local or Remote ATS (EPS Supplying Load) # 0 2-User input #1 0 3-User input #2 0 4-Master or slave 0 5-Future use NFPA Requirements • To meet NFPA 110 requires the RSA 1000 must comply with Section 5.6:6. • Engine functions: o High battery voltage warning o High engine temperature shutdown o High engine temperature warning o Low battery voltage warning o Low coolant level shutdown o Low coolant temperature warning o Low fuel warning (level or pressure) o Low oil pressure shutdown o Low oil pressure warning o Overcrank shutdown o Overspeed shutdown • General functions: o Audible alarm silence o Battery charger fault o Lamp test o Master switch not-in-auto Accessories ^ Additional remote serial annunciators can report to one RSA master. ^ Communication module GM32644-KP1 is required with Decision-Maker"" 3+ controllers. • * May require optional kit or user-provided device to enable function and LED indication. 1' User may connect the ATS (EPS Supplying Load) signal wiring at either the controller (remote) or at the RSA master (local). Modbus® Is a registered trademark of Schneider Electric. as-ea a~oae Fault and Status LEDs and Lamp Test Switch Alarm Horn. Hom sounds when a warning or shutdawn faun Lamp Test Switch. Switch tests alt the annunciator indicator condition exists except on high/low battery voltage or EPS LEDs and hom. supplying load. Low Coolant Level. LED lights when engine coolant level is Alarm Silenced. Red LED lights when alarm ham is below acceptable range on radiator•mounted generator sets de-activated by alarm silence switch. only. Alarm Silence Switch. Switch quiets the alarm during servicing. The hom will reactivate upon additional faults. Battery Charger Fault. LED lights 'rf battery charger malfunctions. Requires battery charger with alarm contact. Battery Voltage. LED flashes 'rf battery or charging voltage drops below preset level. LED lights steady 'rf battery voltage exceeds preset level. Common Fault. LED lights when a single or multiple common faults occur. Communication Status. Green LED {fights indicating annunciator communications functional. Red LED indicates communication fault. Emergency Power System (EPS) Supplying Load. LED lights when the generator set is supplying output current (550 controller) or when transfer switch is in the emergency position (16-light controller). Low Coolant Temperature. LED lightsrf optional engine block heater malfunctions and/or engine coolant temperature is too low. Requires prealarm sender on some models. Low Fuel. LED lights if fuel level in tank approaches empty. Requires customer-supplied level switch. Low OII Pressure. Red LED lights if generator set shuts down because of insufficient oil pressure. Yellow LED lights if engine oil pressure approaches shutdown range. Requires warning sender on some models. Overcrank. LED lights and cranking stops if engine does not start in either continuous cranking or cyclic cranking modes. Overspeed. LED lights if generator set shuts down because of overspeed condition. System Ready. Green LED lights when generator set master switch is in AUTO position and the system senses no faults. Red LED indicates system fault. Emergency Stop. LED lights and engine stops when emergency stop is made. May require a local emergency stop switch on some 16-light controllers. Generatnr:Aunning. LED lights when generator set is in operation. (Generator Switch) Not In Auto. LED lights when generator set master switch is in RUN or OFF/RESET position. High Engine Temperature. Red LED lights if engine has shut down because of high engine coolant temperature. Yellow LED lights if engine coolant temperature approaches shutdown range. Requires warning sender on some models. User-Defined Dlgttal inputs #1, #2, and #3. Monitors three digital auxiliary inputs (status, warnings, and/or shutdowns). Individual red LEDs flash when a fault occurs or the status changes. User-defined digital input #1 and #2 are selected via the RSA master DIP switches for local or remote. 16-tight Controller. When remote, digital input #1 and #2 are tied to the communication module. When local, they are tied directly to the RSA master. Digital input #3 is factory-set for. high battery voltage. 550 Controller. When remote, digital inputs #1, #2, and #3 are tied to controller digital inputs (D7, DB, and D10). When local, user-defined digital inputs #1 and #2 are tied directly to the RSA master. Input #3 is remote only. Communications Local Single (Master) Connection A single RSA connects directly to the controller's communication port with an RS-485 cable for applications up to 1220 m (4000 ft.) from the device. Communication Module 1 Eli M onl Remote serial Generator set annunciator r controller (master) RS-485 ~ up to 1220 m ~ (4000 ft.) ~ RS-485 r_____, ~ ' up to1220m (4000 ft ) . I - ~ PC L _ _ _ _ _ J Available on 550 controller with ~ (user supplied) ~ ~ ~ KBus only L_-___J Local Multiple (Master/Slave) Connections A single RSA master connects directly to the controller's communication port with an RS-485 cable for applications up to 1220 m (4000 ft.) from the controller. Additional RSAs (slaves) can connect to the single master RSA up to 1220 m (4000 ft.) from the controller. Status of the RSA (master) is annunciated on the RSA (slave) panel. Communication Module 1 Eli M onl Remote serial Generator set annunciator ~ controller (master) RS-485 up to 1220 m (4000 ft.) RS-485 up to 1220 m (4000 ft.) from controller Remote serial Remote serial annunciator annunciator (SIflVe) (SIBV@) x8-88 4/048 KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381, Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada, phone 1-800-544-2444 Singapore 619159 KohlerPowerSystems.com Phone (65)264-6422, Fax (fi5)264-6455 Comrnuinication Connections Generator Set Decision-Maker'" 3+ Controller RS-485 Port The remote serial annunciator connects to the controller circuit board. • • 1 f-_"_~' T3 ~„pp,A _ C1 - C J LJvR, ~ a@~~~ ~ r 2 K1 O CG ~ ~ ~, ~E ®' ® ~m ®~ / ®7 ® ~ u oe ~ ~ aL; 0 ® ® 7l~ " Mf~=,~ 1 3 ®' 12 T a T4 a N1 1. SW1 DIP switches 1-5 for digital inputs and master/slave optior 2. P27 RS-485 communication connection 3. T612 input/outputs and DC power supply connections Generator Set 550 Controller RS-455 Port The remote serial annunciator connects to the controller circuit board. „ ie en na P10 axo o n to as ~ ~ P21 Q OLI •~ ba ~ P18 MAIN LOGIC p20 P/1 P78 ~ r ~ s Piz Pis ° ~ Pty P13 P14 P18 0 0 1 2 3 g 0 a -- TT-1310 1. Main circuit board (top view) 2. P21 for KBus RS-485 communication connection 3. P20 for RSA 1000 RS-485 communication connection 4. Main logic (microprocessor)/communication circuit board Availability is subject to change without notice. Kohler Co. reserves the rightto chengethe design or specifications without notice and without any obligation or liability whatsoever.. Contact your local Kohler® generator sat distributor for availability. DISTRIBUTED BY: ® 2004 by Kohler Co. All righm reserved. GB-86 4N4a Remote Serial Annunciator Connections I ~~~ ®The power of performance. iZSA-1000 Wiring #1: Connect Belden# 9841 (or equivalent): In the DEC3+, Red circuit board: Terminal Strip# P21 1 Negative 2=Positive 3=Shield In the annunciator: Terminal Strip # F27: 1 Negative 2=Positive 3=Shield NOTE: If only one annunciator is being used: Move 1-4 dip switches to the "On" position (up} #2: Connect battery power: At Generator: Connect two wires directly to battery (Positive @ starter, Negative @ engine block connection) At Annunciator: Terminal Strip# TB 12: #5 Negative #6=Positive #3: Connect ATS Position: Connect two wires @ the ATS position contacts. Connect these in the remote annunciator on terminal strip# TB 12, terminal #'s 3 & 9, NOTE: If you have more than one ATS, connect the others to terminal #'s 18z 7 and #Z & 8 respectively. #4: NOTE: Once all connections are made, you must REMOVE FUSE # FZ IN THE DEC3+ AND THEN RE-INSTALL. This "resets" the controller to recognize the dip switch settings. • 4 3 2 D - - - - - - - - ~ - - - - - 12-/24 VOLT, 200mA DC POWER 0-450 FT. [0-138 m], 2 WIRES, 22 GA. pC p BATTERY POSITIVE 450-700 FT. [138-214 m], 20 GA. VOLTAGE -"'~~ CONNECTION I 700-1125 F1'. [214-344 m], 18 GA. FROM 1125-1800 FT. [344-550 m], 16 GA. GENERATOR I 1800-2800 FT. [550-856 m], 14 GA. BATTERY N ~ CONNECT OANIVE (--- ---- I ON 16 LIGHT CONTROLLER CONNECT TO P21, I ON 550 CONTROLLER CONNECT TO P20 2 WIRES 10 GA. MINIMUM I CONTROL PANEL 1 s-ucHr, 4 WIRES 18-20 GA. BATTERY 550, 2 WIRES 18-2o cA. CHARGER I I BATTERY CHARGER ALARMS yy FAULT C I I r- -- RS-485 ---- ~ --------- A/L.ARMS I I BELDEN 9841 OR EQUIVALENT, I MAX. DISTANCE 4000 FT. [1223 m] i I I alveu~ ~ rwc (7xaa5] ~ wu~ES u-xD cti• nmE AENSTD (tie-3) CDtAn COMM. MODULE BOHtD ~ AU10YA71C iRANSFFI TOED (73777] i90 RffIIENCfS CHANGED 10 550. ALL DEC 3t --~ BLOCK HEA C I COMM. I I I MODULE I I I I I I I BOARD . , I I I I I I I i I I I I 16-LIGHT ONLY i I REQUIRES I AIN LOGIC ( I 3 WIRES (INCLUDING I GROUND} 51ZED AS I I BOARD GM28725) I I ~ I I REQUIRED I ~ GENERATOR SET OUTLINE - ~ I - - _ - - - - - _ 9 - ~ B I i 2 WIRES 18-20 GA. J ' I I ` 2 WIRES 18-20 GA. I I `- AS REQUIRED I ENGINE START WIRES ~ TO CUSTOMER'S OVERCURRENT I I OPTIONAL I REMOTE I I AUTOMATIC TO CUSTOMER'S 15-AMP OVERCURRENT PROTECTIVE/DISCONNECT DEVICE. VOLTAGE AND CURRENT RATING TO I I ( E-STOP I L TRANSFER PROTECTIVE/DISCONNECT DEVICE. BATTERY CHARGER VOLTAGE IS 120VAC BE DETERMINED FROM BLOCK HEATER NAMEPLATE. SOURCE TO I SWITCH 240VACR(SEE ORAWINGWADVD597R). BE INDEPENDENT OF GENERATOR. RSA 1000 I SOURCE TO BE INDEPENDENT OF REMOTE SERIAL _ _ _ _ _ _ 1-- ro PosmoN CONTACTS GENERATOR. ANNUNCIATOR 2 WIRES 14-20 GA. ~~ (CLOSED IN EP5 SUPPLYING LOAD INDICATION (16-LIGHT ONLY) ~ , EMERGENCY) CONNECT TO COMM. MODULE BOARD REFER TO WIRING DIAGRAM GM34474 FOR OR RSA 1000. ! ( CONNECTION DETAIL. A EPS SUPPLYING LOAD INDICATION VIA RS-485 ON (550) ~ DIMENSIONS IN [ ]ARE METRIC EQUIVALENTS. NOTES: 1. TYPICAL CUSTOMER WIRING SHOWN DASHED. 2. CUSTOMER RESPONSIBLE FOR ADDITIONAL WIRING SHOWN IF COMPONENTS ARE SHIPPED LOOSE (BATTERY CHARGER, DRY-CONTACT BOX, ETC.) 3. IF BATTERY CHARGER IS SHIPPED LOOSE ADDITIONAL WIRES MAY BE REQUIRED FOR PROPER VOLTAGE SENSING. REFERENCE DRAWING ADV-5971 FOR INTERCONNECT. 4. DC VOLTAGE FOR RSA REMOTE ANNUNCIATOR MAY ALSO BE SUPPLIED BY A LOCALLY MOUNTED 12 OR 24 VDC AC AD!+_~'TFR. 4 3 INTERCONNECTION DIAGRAM CONTROLLER WITH RSA ANNUNCIATOR 2 ~oit ao nwu! 4+ POlflt 9Y7IO1t. KOHlfl1. M 77DM Y.E.A. n ~~ ~ ~w ~° a'~°m x ao ~ cs ~a°roim * ~ u is ~ ~ ca or """'°°* ""` DIAGRAM ~°""' °"" RSA INTERCONNECTION ~ as 7-xs-at _- ' as 7-an-aa ,LL..-• I•'.•• l1DV-I;bQQ i i _ A r~nslDNs REY Igli olfn wTE NOTE 1: BATTERY SENSING CONNECTIONS: If charger output leods are longer than 15 ft., ALARM REMOTE disconnect terminal block jumpere and run ~ EMERGENCY separate sense leads to battery. Usa minimal STEP 2 WIRES ~ 16 GA. Wire. 18-20 GA ------------------- ------------- ------- NOTE 2: r GENERATOR TERMINAL BOX ~ ~ GENERATOR SKID ~ Uae solid or stranded 12-22 gauge wire. To Es I ~ I I I determine the wire gouge, measure the cable I GA I I I distance between the controller and master I i GENERATOR I ~TT~' I RSA. For example, it the Coble distance U5E (t) BELDEN 9847 HEATER KR HEATER KR I SNIELDEO PAIR OR EQUAL I I I between the controller and the master RSA is I SEE NOTE 2/FlGURE 19 8 WIRES I I I 122 m (400 ft.), then the total wire length GENERATOR to-zo cA ___ _ ~ for each conductor Is 122 m (400 ft.). I CONTROL SEE NOTE 2.10 I ~ ~~ - i----- I I 2 WIRES I ~ I I According to the chart in Figuro 15, this I PANEL 18-2o G4 I f I BLOCK ( example requires 22-gauge wire. I I j ~ __~_~~ HEATER ~ ( Throughout step 4, refer to the following I I ~/ I 1 illustrotiona. See Figure 16 for RSA circuit I I ~ ~ _ _ _ _ _ - - - ~ board terninol strips. See Figuro 17 for RSA I COMMON RUN RELAY I circuit boord terminal connections and DIP I FAULT RELAY 10 RELAY I switch eeleetiona. See Figuro 18 for the RSA CONTACT KIT i - wiring diogrom. ~ ~~ ~~ ~~ j ~ NOTE 2.10: L___ ___________ _____ ____ _ _________J Connect wiring from the user-supplied 2 WIRE 18-20 CA - CUSTDIAER'S V' bottery ehorger high and low battery votage ENGINE START INPUT ~ii ~ and fault contacts to the remaining terminal TERMINALS AC POWER on harness GM35318 and TBS-6 for RSA 5EE NOTE 3 - j ~ ~ annuneiotion of (high) Buttery Voltage. See Figuro 10 for wiring sizes. RSA 1000 TRANSFER DAY TANK ~~~ ~---~~ DIGRAL REMOTE SWITtYi LOW FUEL- CHARGER `i NOTE 2.11: - ANNUNCIATOR 3 WIRES SWRCH I EPS SUPPLYING LOAD: Connect wiring from the 18-20 GA ( user-supplied transfer switch (ATS) emerrggency SEE NOTE 2.Tr Cusr. arc. _ CEN SEr 8ATIERY POSTIIVE position ouxillary contorts to terminals TB5-3 30 WIRES MA7r ~~-~~ ,ENGINE CONNECTKIN AT ~ and 7135-9 for RSA annunciation of EPS _ _ _ _ _ _ _ _ _t s a^ _ _ _ 1_ ~ ~ST~~ _ _ ^ _ _ _ _ _ ~ Supplying Lood. See Figure 1 O for wire sizes. GEN SET BATTERY NEGATNE~ Z WIRES 10 GA POWER TO RSA ANNUNCIATOR ~ ~GI~NE~CONNECTKIN AT SEE NOTE 1. ~ NOTE 3: FROM flATT + $ - (STARTER If DEC 550 controller is supplied start terminals SOLENOID $ ENGINE GROUND) - - ~ 3 do 4 aro located in generator terminal box, SEE NOTE 4.4 interconnect board T89. LENGTH. m (fL) Wire Gauge 0-137 (0-450) 22 137-213 (450-700) 20 213-343 (700-1125) 18 343-549 (1125-1800) 16 549-853 (1800-2800) 14 853-1219 (Z13UU--i'v~r/ Fire 10 Wire Specifications for the Communication Module Connections LENGTH, m (ft.) Wire Gauge 0-137 (0-450) 22 137-213 (450-700) 20 213-343 (700-1125) 18 343-549 (1125-1800) 16 549-853 (1800-2800) 14 i - i i ~jgure 15 Wire Specifications between RSA and Generator Set Controller NOTE 4.4: Each RSA requires o 12-/24-volt, 200 rr1A DC power source. The RSA voltage should match the generator set alerting system. This power source can be from the generator set battery ar an AC adapter. When RSA slaves are connected, the installer must determine whether AC odapten, or a single AC adapter sized for oil RSAs to moat proeticol. When the power source is the starting battery(ies), attach to the battery posl8ve (+) connection of the starter solenoid and the battery negative (-) connection at the engine ground. Do not use terminals 42A and 2 on the controller connection kit terminal strip. iii LJ~ i ..,..,, <.tsij.)UI~tJ1iUi1 ' ' "`antD AYENUE W08Ui;S!, E111 U1i301 1M9 DItUCRi'J I.N n1E C67CLS 1 DWN BY: MFB SfFTFM CCr$A44tllTFQN fC't MC O4T'7 CrSSr£"'~'R tm""'! mrn:lar ~ n eru F rrsrerm, DATE: JUL '04 . r>;rr ^IYI.° rL"~t ^'! C^T 1 rRwr lY -P _rtrL:l Kann Fc--n c ~ - ~4,~Pan Bn MJL rce -~ '=m =~€i ~'~ sT'] ~ Arm r_r r:m::ur i - '7~tlEnr~;/a{ cn1 t _ 1 ; i 'U? ~n PFANI~'Or Dr YJbB-1 !'L ~c~"+.~. r3 ^.c n_ r rarE . „cr, r , C • 0 U g 3 W O O U m 1 w yw ~~1 n ~~ ~~~ N `N O"s _N^~~ D I I :N ...r7 e~ DO e ~ 's d. ~~ 1 I I I ~ ~ nn I g ~~ I $~ ! $ ~ w ,~ I d I i p~G~~"~ ~~4~~11 yy~3g3g n_i ~ n n I ( J~~~~~~`J J7 ~~ I ~ _ - h I I N_ _N _N ~_ q ~_ q N_ N C N_ n n I 1 - _ _ .._ _ _ _ I _ I ~_'~~_ I ~$(~tx~ I ~v6 I A p =anvee I 88801'SRR^n2°~ I V ~. I L J~^ ~~ ~_ O O N b n V~ l I sstisattgx s ~~ n^nn ~^nnvne m i 0 w 0 d + a n x - v N ~ n LC n LL m I YY •ry ro ~ Ta Yi +~ e _ t0 W 7s t 9 a3 pQ w yg ~ G 6f ^ e N ° ~ ' zt ~x tl e_ sc ~ tn __ c_ w w m a __ oc ~ R •Y. n s s n D m ~~ ~~ i; ~~~ ~~s a ~~ VI ~~~ ~~ S #W O h a v ~~ ~ onvnr~- Ym ~~ `~--. ~~ ~ ~^~...^~ ~~~~ ~^nn ~~~ ~~~~ ^wnvnnweeR^~ ~. '.^ v ~ii~ ne• R 1 1 1 ~~~~ ~03~~ t I I I ~~ I I R$ I ` ~9'Y ~~ ~ T ~ '" - N nV n b ~ - $ I 5 l I I I~ I to ~ ~ ~ ^~~r~ n ^i ~~~~ I ~ ~ I A~$~~~~t I ~ i3 =nneno Ti 1'-1377 10/04b • INSTALLATION INSTRUCTIONS Original Issue Date: 4/04 Model: 20-2800 kW Generator Sets with 550 Controller or 16-Light Microprocessor Controller Market: Industrial Subject: Remote Serial Annunciator (RSA 1000) Kits GM34474-KA1/-KA1S; GM34474-KP1/-KP1S, and GM34474-KP2/-KP2S and Communication Module Kit GM32644-KP1 Intr®duction The remote serial annunciator (Figure 1) monitors the condition of the generator set from a location remote from the generator set. If a generator alarm condition occurs, the remote annunciator alerts the operator through visual and audible signals. The RSA 1000 is offered in three kit configurations. See Figure 2. • The remote serial annunciator kit includes components for flush and surface mounting. One RSA (master) can support up to a maximum of three additional RSAs (slaves). The RSA will function as master or slave by changing the DIP switch position on the RSA board. If a generator set fault occurs, the RSA 1000 horn activates and the corresponding LED illuminates. The following paragraphs describe specific features of the RSA 1000. RSA Kits GM34474KP1 GM34474KP7 GM34474KP2 GM34474-KP1S GM34474KP1S GNi34474KP2S Installed Shipped Loose Shipped Loose 16-Light 550 or 16-Light 16-Light Includes: Indudes: Indudes: RSA 1000 RSA 1000 RSA 1000 Comm. module Order comm. module Communication factory-installed GM32644-KP1J-KP1S module when ordered with when selecting a (shipped loose) a 16-light controller 16-light controller Figure 2 RSA 1000 Kit Components s Modbus® is a registered trademark of Schneider Electric. Figure 1 Remote Serial Annunciator (RSA 1000) • • • The RSA 1000 is compatible with the following controllers: • 550 Controller software code version 2.10 and higher • .16-Light Controller software code version 1.13 and higher The RSA requires connection to the controller Modbus® RS-485 port. If the RS-485 port is needed for swltchgear monitoring or a wireless monitor, the RSA cannot be connected to the controller. If the RS-485 port is unavailable, please select an alternate annunciator kit. See Figure 3 for kit numbers. t~Ligfit Controller 20-400 kW GM25955-KP1, -KP1S 450-2000 kW GM27526-KPt, -KP1S 5S0 Controller 20-300 kW GM27558-KPi, -KPiS 3501400 kW GM27558-KP2, -KP2S 450-2800 kW GM27558-KP3, •KP3S Figure 3 16-Light Remote Annunciators If connecting the RSA 1000 to a generator set with a 16-light controller, the communication module board must be used. See Figure 4 for the location of communication module board. The communication module is .included with RSA 1000 kits GM34474-KP2/ -KP2S. The communication module is also available as a separate kit GM32644-KP1/-KP1S. ~~ ~; 1. Communication Module GM3284M6 Figure 4 16-Light Controller with Installed Communication Module (controller top view) FSa~UPeS Horn Alarm Horn. The alarm horn sounds when a warning or shutdown fault condition exists except on high/low battery voltage or EPS supplying load. Horn sounds when user inputs 1-3 are activated with a 550 controller. Horn sounds when user inputs 1-2 are activated with a 16-light controller. Switches Alarm Silence. Press the Alarm Silence/Lamp Test switch to quiet the alarm during servicing. The horn will reactivate upon additional faults. Lamp Test. Press the Alarm Silence/Lamp Test switch to test the RSA indicator LEDs and horn, LEDs There are up to 25 LED indicating lights for status, warning, and/or shutdown. Some items have two LEDs: • Communication status (green functional, red fault} • High engine temperature (yellow warning and red shutdown) • Low oif pressure (yellow warning and red shutdown) • System ready (green functional, red fault) Alarm Silenced. Red LED is steady on when alarm horn is deactivated by the Alarm Silence/Lamp Test switch. Battery Charger Fault. Yellow LED flashes slow when battery charger malfunctions. Requires battery charger with alarm contact with 16-light controllers. Battery Voltage. 16-Light controller requires battery charger with alarm contacts. See Figure 37 relating to battery charger for additional information. • Yellow LED flashes blinks) slow when battery or charging voltage drops below preset level. • Yellow LED is s n 'rf battery voltage exceeds preset level. Common Fault. Red LED flashes slow when a single or multiple common fault occurs. Common faults are selectable on the 550 controller using the respective controller menu choices. The 16-light controller offers two choices for common faults using terminal 32 or 32A. TT-1377 10/04 i~ Terminal 32 provides the following 9 common faults • Auxiliary Warning • High Engine Temperature Shutdown • High Engine Temperature Warning • Low Water Temperature Warning . Low Fuel Warning • Low Oil Pressure Shutdown • Low Oil Pressure Warning • Overcrank Shutdown • Overspeed Shutdown Terminal 32A provides the following 5 common faults: • Auxiliary Warning • Emergency Stop • High Engine Temperature Shutdown • Low Oil Pressure Shutdown • Overspeed Shutdown Communication Status. The RSA is shipped from the factory preset as a master device. The generator set controller is a slave device. Additional RSA devices on the same network must be reset in the field as slave devices. • Green .LED is steady on when communications is okay. • Red LED flashes slow when no device is found on master and slave. High Engine Temperature. • Red LED flashes slow when engine has shut down because of high engine coolant temperature. • Yellow LED flashes slow when engine coolant temperature approaches shutdown range. Requires warning sender on some generator set models. Low Coolant Level. Red LED flashes slow when engine coolant level is below acceptable range on radiator-mounted generator sets only. Low Coolant Temperature. Yellow LED flashes slow when optional engine block heater malfunctions and/or engine coolant temperature is too low. Requires prealarm sender on some generator set models. Low Fuel. Yellow LED flashes slow when level in diesel fuel tank approaches empty or low pressure occurs with gas fuels. Requires customer-supplied level or pressure switch on some generator set models. Low OII Pressure. • Red LED flashes slow when set shuts down because of insufficient oil pressure. • Yellow LED flashes slow when engine oil pressure approaches shutdown range. Requires warning sender on some generator set models. Overcrank. Red LED flashes slow and cranking stops when engine does not start in either continuous cranking or cyclic cranking modes. - .--- • Red LED flashes fast on master and slow on slave 'rf--Overspeed-Red LED flashes slow when engine shut"s communication is lost with generator set controller____.dnwn because of an overspeed condition. ----- . after communication was initially established. • Red LED on the slave flashes slow when System Ready. communication is lost between master and slave. • The master does not change. Emergency Power System (EPS) Supplying Load. Yellow LED is s o when the generator set is supplying more than 5% of standby output current (550 controller) or when transfer switch is in the emergency position (16-light controller).- Emergency Stop. Red LED flashes slow and engine stops when emergency stop is made. May require an (optional) local emergency stop switch on some 16-light controllers. Generator Running. Green LED is steady on when generator set is in operation. See System Ready note. • (Generator Switch) Not-In-Auto. Red LED flashes fit when generator set master switch is in the RUN or OFF/RESET position. Green LED is steady on when generator set master switch is in AUTO position and the system senses no faults. • Red LED flashes slow when a system fault occurs. Note: A System Ready red LED and/or a Generator Running LED off, without an associated LED shutdown indication on the RSA, may represent a generator set fault initiated by the engine ECM fault detection. User Digital Inputs #1, #2, and #3. Monitors three digital inputs (status, warnings, and/or shutdowns). A separate red LED flashes slow for each input when a fault occurs or the status changes. Note: User-defined digital inputs #1 and #2 are selected at the RSA master only and annunciated to the RSA slave(s). Nouser-defined digital input selection is available at the RSA slave(s). TT-1377 10/04 L_J 16-Light Controller. User-defined digital input #1 and #2 are selected via the RSA master DIP switches for local or remote. User-defined digital inputs #1 and #2 tied directly to the RSA master are considered local. User-defined digital inputs #1 and #2 connected to the controller communication module board are considered remote. Digital input #3 is factory-set for high battery voltage. 550 Controller. User-defined digital inputs #1 and #2 are selected via the RSA master DIP switches for local or remote. Input #3 is remote use only. When local, user- defined digita! inputs #1 and #2 are tied directly to the RSA master. When remote, they are tied to controller digital inputs (D7, D8, and D10). Figure 5 (16-light controller) and Figure 6 (550 controller) show the status of the system ready LED, generator running LED, communication status LED, common fault LED, common fault output, and horn for each fault or status condition. Mounting Flush- or Surface-Mounting CapabiliE This instruction includes installation information i~or both flush- and surface-mount models. Fault and Status Condition Fault LEDs System Monitoring LEDs and Functions System Generator Comm. Common Comma' Ready LED Running LED Status LED Fault LED Fault Out; Hom Overcrank Shutdown Red Red SF Off Green Red SF On On High Engine Temperature Warning * Yellow Red SF Green Green Red SF On On High Engine Temperature Shutdown Red Red SF Off Green Red SF On On Low Oil Pressure Warning * Yellow Red SF Green Green Red SF On On Low Oil Pressure Shutdown Red Red SF Off Green Red SF On On Overspeed Shutdown Red Red SF Off Green Red SF _ _ On On Emergency Stop * Red Red SF Off Green Off On On Low Coolant Level * Red Red SF Off Green Red SF On On Low Coolant Temperature * Yellow Red SF Off Green Red SF On On Low Fuel-Level or Pressure " Yellow Red SF Off Green .Red SF _ On On EPS Supplying Load (RSA) Yellow Green Green or Off Green Off Off Off System Ready ~ ~ ~ ~ Green `- Green "- ~ Green or Off ` -Green -- - `Off-" ~''Off"~` '-Off" System Not Ready -Red -Red SF'- "Green or Off " ~ Green"`- !Off"`" "' " On _"` ` On~- No Device at Powerup Red Off Off Red SF Off On On Loss of Controller Comm. (Master RSA) Red Off Off Red FF Off On On Loss of Controller Comm. (Slave RSA) Red Off Off Red SF Off On On Not-In-Auto Red Red SF Green or Off Green Red SF __ On On Battery Charger Fauk * Yellow Green Green or Off Green Off On On High Battery Voltage (HBV) * Yellow Green Green or Off Green Off _ Off Off . Low Battery Voltage * Yellow Green Green or Off Green Off Off Off User Input #1 (RSA) Red Green Green or Off Green Off On On User Input #2 (RSA) Red Green Green ar Off Green -Off On On User Input #3 (factory set for HBV) - - - - - - - User Input #1 (16-Light Controller Communication Module) Red Green Green ar Off Green Off On On User Input #2 (16-Light Controller Communication Module) Red Green Green or Otf Green Off On On Common Fault Red Green Green or Off Green Red SF On On SF =Slow Flash, FF =Fast Flash * May require optional kit or user-provided device to enable function and LED indication. i ~__ • Figure 5 System Monitoring LEDs and Functions (16-Light Controller} 4 TT-1377 10/04 • • • System Monitoring LEDs and Functions Fault and Status Condition Fault LEDs System Ready LED Generator Running LED Comm. Status LED Common Fault LED Common Fault Output Horn Overcrank Shutdown Red Red SF O(f Green Off On On High Engine Temperature Warning Yetiow Red SF Green Green Off On On High Engine Temperature Shutdown Red Red SF Off Green Off On On Low Oil Pressure Weming Yellow Red SF Green Green Off On On Low OII Pressure Shutdown Red Red SF Off Green Off On On Overspeed Shutdown Red Red SF Off Green Off On On Emergency Stop Red Red SF Off Green Off On On Low Coolant Level Red Red 5F Off Green Off On On Low Coalent Temperature Yellow Red SF Off Green Off On On Low Fuel-Level or Pressure * Yellow Red SF Green Green Off On On EPS Supplying Load (550 Controller) Yellow Green Green Green Off Off Off EPS Supplying Load (RSA) Yellow Green Green or Off Green Off Off Off System Ready Green Green Green or Off Green Off Off Off System Not Ready Red Red SF Green or Off Green Off On On No Device at Powerup Red Off Off Red SF Off On On Loss of Controller Comm. (Master RSA) Red .Off Off Red FF Off On On Loss of Controller Comm. (Slave RSA) Red Off Otf Red SF Off On On Not-In-Auto Red Red SF Green or Off . Green Off On On Battery Charger Fauk * Yellow Red SF Green or Off Green Off On On High Battery Vokage Yellow Green Green or Off Green Off Off Off Low Battery Vokage Yellow Green Green or Off Green Off Off Off User Input.#1 (RSA) Red Green Green or Off Green Off On On User Jnput~2 (fiSA) Red Green Green or Off Green Off On On User Input~#t (550 ControAer) Red Red SF Green or Off Green Off On On User input #2 (550 Controller) Red Red SF Green or Off Green Off On On User Input:#3 (550 Controller) - Red- ~- Red SF-- - Green or Off- -Green--- -Off--- ---- On -~»- - On- Common Fautt -Red - -- Green -- -Green or Off- -Green-~- -Red SF- ---~-- On - On- SF = Sfow Flash, FF =Fast Flasfi * May require optional kit or user-provided device to enable function and LED indication. Figure 6 System Monitoring LEDs and Functions (550 Controller) Tr-~ sn ~ o~oa Safety Precautions 1.3 Disconnect the generator set engine starting battery(ies), negative (-) lead first. Observe the following safety precautions while installing the kit. 1.4 Remove the controller cover and hardware. ® WARNING 2. Mount and wire the communication module board in the 16-light controlier. Note: Requires 16-light controller logic board GM28725. Perform step 2 with GM34474-KP1/ Accidental starting. -KPiS kit when ordered shipped loose, Can cause. severe Injury or death. GM34474-KP2/-KP2S kit, and GM32644-KP1 kit only. If GM34474-KP1/-KP1S kit was ordered Disconnect the battery cables before insfalled, skip step 2 and go to step 3. working .on the generator set. Remove the negative (-) lead first Note: Perform step 2 with GM34474-KP2/-KP2S and when disconnecting the battery. GM32644-KP1 kits only. When installing Reconnect the negative (-) lead last when reconnecting the battery. GM34474-KP1/-KPiS kits, skip step 2 and go to step 3. Dlsabiing the generator set. Accidental starting can 2.1 Connect new 24-position ribbon cable GM32632 cause severe Injury or death. Before working on the. to the indicator panel circuit board. See Figure 7. generator set or connected equipment, disable the generator The new ribbon cable has three connectors-one set as follows: (1) Move thegeneratorsetmasterswitchtothe at each end and an inline connector. Attach the OFF position. (2) Disconnectthepowertothe batterycharger. end connector (nearest to the inline connector) to (3) Remove the battery cables, negative (-) lead first. the indicator panel circuit board. The connectors Reconnect the negative (-) lead last when reconnecting the battery. Follow these precautions to prevent starting of the are polarized and attach in one position only. All generator set by an automatic transfer switch, remote ribbon connectors shown in Figure 7 are included start/stop switch, or engine start command from a remote 'tn the Communication module kit. computer. ~~~ Read the entire installation procedure and compare the ~ ,- - .. ae.n°c::°°°v°: TM '° / 1 kit parts with the parts lisf in this publication before ~" " ~ "' " beginning installation: -Perform the steps in the order - - .~=®/ - ° °° , - ; 2 _ _ shown. .,,..~, tiY°G=0:p9P0 Note: Observe applicable local and national electrical g~ '°~"~' codes when installing the wiring system. ~° _ ~ 4 NOTICE I Electrostatic discharge damage. Electrostatic discharge '°°"°'°' ^ (ESD) damages electronic circuit boards. Prevent cue--a`~M~e~a ~r electrostatic discharge damage by wearing an approved ~P~~ via r g ~~. , ~ 5 ~q-rwg ~' grounding wrist strap when handling electronic circuit boards ~~ eo a era, or integrated circuits. An approved grounding wrist strap ~• provides a high resistance (about 1 megohm), not adirect / "~ short, to ground. ~ \ Installation Procedure oM s4a a ~ 1.164igM controller mein circuft board 2. 24-position ribbon cable GM32632 to main circuit board 1. Remove the generator set from service. 3. Communication module board GM31070 4. 24-position ribbon cable GM32632 to comm. module board 1.1 Place the generator Set master switch in the 5. Lead GM35318 connecting T27 on indicator panel to user OFF/RESET pOSltlOn. input 3 on comm. module board for high.battery voltage 6. 24-position ribbon cable GM32632 to indicator panel 7. Corrtroller Indicator panel circuit board on the RSA 1.2 Disconnect the power to the battery charger, if 8. 10-position ribbon cable GM21340 to comm. module board equipped. 9. 10-position ribbon cable GM21340 to main circuit board • Figure 7 Communication Module Electrical Connections, 16-Light Controller 6 TT-1377 10/04 2.2 Remove the existing three nuts attaching the indicator panel circuit board. Leave the existing • washers in place. The nuts will be reused. 2.3 Attach the three spacers to the indicator panel circuit board studs. See Figure 8. 2.4 Remove the existing 24-position ribbon cable 336428 between the indicator panel circuit board and the main circuit board. See Figure 8. This ribbon cable will not be reused. 2.5 Position. the communication module board GM31070 on the spacers. 2:6 Install three lock washers X-22-7 and the existing three nuts on the spacers to secure the communication module board. Do not overtighten the nuts. 2.7 Attach the 24-position ribbon cable GM32632 inline connector to the communication module board. Attach the remaining end connector to the main circuit board. The connectors are polarized and attach in one position only. 1 2 i~ 9 8 1. Ribbon cable, 10 position GM21340 I 2. Controller main circuit board '~ 3. Ribbon cable, 24 position GM32632 , GM32644-B 4. Existing nuts (3) 5. lock washers (3) X-22-7 6. Spacers (3) GM32633 7. Existing washers (3) 8. Existing indicator panel circuit board 9. Communication module board GM31070 Figure 8 Mounting Communication Module in 16-Light Controller • 2.8 Attach the 10-position ribbon cable GM21340 to the communication module board and the main circuit board. 2.9 High battery Voltage. Locate T27 lead on the indicator panel assembly and connect the communication board HBV harness GM35318. Use the terminal connector on GM353i8 with the two leads together. Verify that the stripped end of the harness is securely connected to communication module board terminal TB5-12. See Figure 7 for an illustration of the wiring connection. See Figure 9 and Figure 10 for the communication module board terminal strip location and terminal designations. CIB TB5 USERS RETURN 12 USER @iPUrJ 11 USER INPUT2 USER2 RETURN USER 7 RETURN 1 O USER wPUr 1 ATS POSRION 9 ATS POSITION RETURN P9 Pe I GM32644- re 9,....Communication. Connector Deslgnatlon Clrcult Board Deslgnatlo 1 Not used 2 Not used 3 ATS Position Input Retum 4 User 1 Input Retum 5 User 2 Input Retum 6 User 3 Input Retum 7 Not used 8 Not used 8 ATS Position Input 10 User 1 Input 11 User 2 Input t2 User 3 Input Figure 10 Communication Module TB5 Terminal Strip Connections TT-1377 10/04 7 2.10 Connect wiring from the user-supplied battery 3.2 charger high battery voltage contacts to the remaining terminal on harness GM35318 and TB5-6 for RSA annunciation of (high) Battery 1/oltage. See Figure 11 for wire sizes. 2.11 EPS Supplying Load. Connect wiring from the user-supplied transfer switch (ATS) emergency position auxiliary contacts to terminals TB5-3 and TB5-9 for RSA annunciation of EPS Supplying Load. See Figure 11 for wire sizes. 2.12 User Input 1 and User Input 2. Make additional user-selected connections to the communication module board TB5 terminal block. See Figure 11 for wire sizes. The user-selected connections are defined in Figure 10 and include: • User Input 1 (remote) • User Input 2 (remote) Note: User input 3 is factory-set for high battery voltage as outlined in step 2.9. Document the user-selected inputs for future reference. If user selected inputs 1-2 (remote) are used, the user may add the identification on the RSAfront panel strip. This procedure isfurther explained in step 4.11 of this instruction. i! • Length, m (ft.) Wire Gauge 0-137 (0-450) 22 137-213 -- (450-700)--.-- --.--20-..-.._.....- ___-._ 213-343__ (700-1125)___ 18 343-549 (1125-1800) 16 549-853 (1800-2800) 14 Figure 11 Wire Specfications for the Communication Module Connections 3. Select a mounting location for the RSA. GM34474-KPi/-KP1S and GM34474-KP2/-KP2S kits only. Note: Use step 3 for mounting the RSA master and the RSA slaves as needed. The recommended maximum total is three RSA slaves. The RSA wiring information is covered in step 4. 3.1 Select a visible location for mounting the RSA up to 853 m (2800 ft.) firom the controller. Install the RSA, either surface- or flush-mounted, in a location easily observable by operating personnel at their work stations. See Figure 12 for RSA overall dimensions. Note: Locate all RSAs up to 853 m (2800 ft.) from the controller. Remove four screws X-67-154 from the RSAfront panel assembly GM34433-i or GM34433-2. Detach the RSA front panel from the box by removing whiz nut X-6210-1, flat washer X-25-36, and ground wire LK-1212-1414 at the front panel cover; see Figure 13. See Figure 14 for RSA supplied box mounting hole information. The installation instructions describe three RSA mounting scenarios: • Surface-mount with supplied box (step 3.3) • Flush-mount. using supplied box (step 3.4) • Flush-mount using auser-supplied Hoffman box (step 3.5) 3.3 Surface-mount RSA initial installation. 3.3.1 Prepare the mounting site by drilling pilot holes for anchors, if used. Note: Mount the RSA box to a standard 10 cm (4 in.) square electrical box installed in the wall. 3.3.2 Create an opening in the wall for the electrical wiring from the master RSA to the controller communications and power supply. The wall opening must allow for the wiring of the RSA slave 'rf used. Protect the RSA front panel assembly from dust and debris when drilling the holes. ~W~ -- =W • H H ® ,~` • \p~ W1~~D p Surface Mounted Flush Mounted nov-se3~,-e Dimensions-W x H x D, mm (n.) Surface Mounted: 203x203x51.5 (8.Ox8.Ox2.0) Flush Mounted: 203 x 203 x 53.0 (8.0 x 8.0 x 2.1) Flush mounting plate W1: 229 (9.0) Flush Mountefi*: 203x203x103 (8.Ox8.Ox4.1) Flush mounting plate Wt: 229 (9.0) 'Requires user-supplied Hoffman hox 203 x 203 x 102 mm (0 x 8 x 4 in.) Figure 12 RSA Box Dimensions rr-1377 1 oioa 1 2 0 ~ o O a a® 3 4' o ~ o o GM34433 1. White identification strips (text inserts) 2. Nameplate 3. Bar code decal 4. Whiz nut X-6210.1, flat washer X-25-36, ground lead LK-1212-1414, and lock washer X-22-13 Figure 13 RSA Front Panel Assembly Ground Connection (back view) 188.93 mm (7.438 in.) i• 140 mm (5.5 in.) a o o ~ Grommet I.D. 110 mm 25 mm 4.4 mm (4.3 in.) (1 in.) (0.17 inJ . 4tX.4_ ~ _ ___ .`• . o 0 5.6 mm (0.22 in.) atv. 4 5mm (0.2 in.) 47.6 mm (1.t37 in.) __, GM34433 3.4 Flush-mount RSA initial installation with supplied box GIV131884. 3.4.1 Prepare mounting site by creating an opening in wall for flush mounting RSA box. 3.4.2 Remove bushing X-634-15 from box GM31884 if a user-supplied conduit connector is required. Install the user- supplied connector. Size the flexible conduit for the electrical wiring from master RSA to the controller communications and power supply. The flexible conduit size must allow for the wiring of a RSA slave if used. 3.4.3 Attach the RSA box to the wall with user-supplied hardware. Protect the RSA front panel assembly from dust and debris when drilling the mounting holes. 3.4.4 Repeat step 3 for the RSA slaves, as needed. 3.4.5 Proceed to step 4, Wire the RSA. 3.5 Flush-mount RSA initial installation with a user-supplied Hoffman box. 3.5.1 Prepare the mounting site by creating an opening in the wail for flush mounting the RSA using a user-supplied 203 x 203 x ~` 102 mm (8 x 8 x 4 in.) Hoffman box (part - ------~- ~ no. A-SG8X8X4) or equivalent. - -~ ~- -~ Figure 14 RSA Mounting Hole Dimensions in Supplied Box GM31884 3.3.3 Remove bushing X-634-15 from box GM31884 if a user-supplied conduit connector is required. install the user- supplied connector. 3.3.4 Temporarily mount the RSA box to the wall or to the electrical box in the wall and check for proper hole alignment. Adjust as needed. Remove RSA box. Note: Use mounting hardware suitable for the wall composition and thickness. 3.3.5 Repeat step 3 for the RSA slaves, as needed. 3.3.6 Proceed to step 4, Wire the RSA. rT 1377 ,aoa 3.5.2 Use wall mounting plate GM33031 as a template and drill four 4.4 mm (0.17 in.) diameter holes in the Hoffman box front edge for mounting the RSA front panel assembly if not already done. See Figure 15. s Figure 15 Dril{ing Mounting Holes in Hoffman Boxfor RSA Front Panel Assembly 3.5.3 Remove the ground wire and hardware from box GM31884 and install the ground wire and hardware in the Hoffman 'box. See Figure 14 for recommended location. Substitute user-supplied ground wire and hardware as needed. Temporarily install the RSA front panel assembly to be sure the ground wire location does not interfere with attaching the RSA front panel assembly. 3.5.4 Select a location on the box and install a user-supplied conduit connector or bushing. Temporarily install the RSA front panel assembly to be sure the hole location with bushing or conduit connector does not interfere with attaching the RSA front panel assembly. Size the flexible conduit for the electrical wiring from the master RSA to the controller communications and .power supply. The flexible conduit size must allow for the wiring of the RSA slaverf used. ~~ 3.5.5 Attach the RSA box to the wall with user-supplied hardware. Protect the RSA front panel assembly from dust and debris when drilling the mounting holes. 3.5.6 Repeat step 3 for the RSA slaves, as needed. 3.5.7 Proceed to step 4, Wiring the RSA. 4. Wiring the RSA. GM34474-KP1/-KP1 S and GM34474-KP2/-KP2S kits only. The installer must supply all leads. Observe the following guidelines during installation: • Ground the RSA box to the building electrical system. • Isolate the RSA leads from all other voltages. • Use separate conduit. • Use grounded metallic conduit for leads or use shielded cable in nonmetallic conduit. • Use color-coded wire for easy identification. • Make leads long enough to allow for walls, ductwork, and obstructions. Use solid or stranded 14-22 gauge wire. To determine the wire gauge, measure the cable distance between the controller and master RSA. For example, if the cable distance between the controller and the master RSA is 122 m (400 ft.), then the total wire length for each conductor is 122 m (400 ft.). According to the chart in Figure 16, this example requires 22-gauge wire. Throughout step 4, refer to the following illustrations. See Figure 17 for RSA circuit board terminal strips. See Figure i8 for RSA circuit board terminal connections and DlP switch selections. See Figure 36 for the ~ 3A wiring diagram and Figure 37 for the~3A Interconnection diagram. The RSA has the following wiring and selections: • Ground wire (see step 4.3) • DC power supply (see step 4.4) • P27 RS-485 communication between controll end •RSA master (see step 4.5) • P27 RS-485 communication between RSA r .;ter and RSA slaves (see step 4.6) • T612 user input/output selections (see step 4. • SWi DIP switch positions (see step 4.9) • T3 isolated or non-isolated RS-485 (see step 7) L®ngth, m (it.) Wire Gau :~ 0-137 (0-450) 22 137-213 (450-700) 20 213-343 (700-1125) 18 _ 343-549 (1125-1800) 16 549-853 (1800-2800) 14 Figure 16 ire Specifications between RSA an'~ Generator Set Controller 1 2 3 4 - ra e, ~ e' U g~~' "PZ7 a -' J `~", `rrr` 0 Kto ~ ~L~ ~ ~ i ® ® ~, ®~ ®' ~~ ®~ ® ® o~aJ woe ®~ 12 T n :, ra ~ Nt Gf '1211- 1. TB12 user input/outputs and DC power supply conned :..^.s 2. SW1 DIP swftches 3. T3 isolation jumper 4. P27 RS-485 communication connections Figure 17 RSA Circuit Board 10 TT-1377 10/04 • •_ • TB72 Input/output Connections TB12-1 User Input 2 return TB72-2 User Input 1 return TB12-3 Local ATS emergency an input return T612-4 Local common fault input return TB12-5 Battery/DC power supply negative input TB12-6 Battery/DC power supply positive input T612-7 User input 2 TB12-8 User input 1 T612-9 Local ATS emergency on input TB12-10 Local common fault input TB12-11 Annunciator common fault relay normally open output TB12-12 Annunciator common fault relay common output SW1 DIP Switches (on =closed and oft =open SW1-1 Local ATS (Ori is local) SW1-2 User input 1 (On is local) SWt-3 User input 2 (On is local) SWi-4 Master/Slave (On is master) SW1-5 Not used T3' Isolation Jumper Connections T3 to T1 Isolated RS-485 (default setting) T3 to T2 Non-isolated RS-485 P27 RSr1 85 Connections (master) P27-1 (-) Black (from controller) P27-2 (+) White (from controller) P27~ Shield (from controller) P27-4 (-) Black (to slave or terminating resistor) P27-5--- (+) White (to slave or terminating resistor)-~---------- P27-6.-.- Shfeld (to slave or open) t~2T RS~485 Connections (slave) P27-1 (-) Black (from master or previous slave) P27-2 (+) White (from master or previous slave) P27-3 Shield (from master or previous slave) P27-4 (-) Black (to next slave or terminating resistor) P27-5 (+) White (to next slave or terminating resistor) P27-6 Shield (to next slave or open) Figure 18 RSA Circuit Board Terminal Connections and DIP Switch Selections 4.1 Deenergize the RSA{s) 12-/24-volt DC power source, if not already done. 4.2 Flush-mount RSA only. When using aflush- mountRSA box with a bushing, it is recommended to run all wiring to the RSA box and then mount itto the wall or to the electrical box in the wall. Check that box is square to the wall; adjust as needed. After the RSA box in mounted, make the individual electrical connections to the RSA circuit board as described in the following steps. Tr-1377 1 o~oa Position the wall mounting plate GM33031 against RSA front panel assembly GM34433-1 or GM34433-2 prior to attaching the wiring. 4.3 Attach the mounting box ground wire to the RSA front panel assembly stud by installing lock washer X-22-13, ground wire, flat washer X-25-38, and whiz nut X-6210-1. See Figure 19. 4.4 Each RSA requires a 12-/24-volt, 200 mA DC power source. The RSA voltage should match the generator set starting system. This power source can be from the generator set battery or an AC adapter. When RSA slaves are connected, the installer must determine whether generator set battery power, individual AC adapters, or a single AC adapter sized for all RSAs is most practical. When the power source is the starting battery(ies), attach to the battery positive (+) connection at the starter solenoid and the battery negative (-) connection at the engine ground. Do not use terminals 42A and 2 on the controller connection kit terminal strip. After determining the type of power supply, select and connect the wiring to each RSA. The circuit must include fuse or circuit breaker protection and an independent circuit disconnect. Keep the power source deenergized at this time. Connect DC positive lead to T612-6 and DC negative lead to T612-5. r3M34433 1. Whiz nut X-6210-1, flat washer X-25-36; ground lead LK-1212-1414, and lode washer X-22-13 Figure 19 RSA Front Panel Assembly Ground Connection (back view of front panel) 11 4.5 Select and connect the RS-485 wiring from the controller to the RSA master using Belden #9841 or equivalent. If there is only one RSA it is the master. If several RSAs are installed, choose either the RSA closest to the generator set or determine which RSA is more practical for use as a master and use a daisy chain wiring configuration for the remaining RSAs. The RSA connected to the controller MUST be assigned as the RSA master. Connect RS-485 wiring to the included 6-position Euroblock plug 294619 and attach to the 'RSA circuit board. The Euroblock connector is polarized and attaches in one position only. See Figure 20 for a typical RS-485 connection. i6-Light Controlier. Figure 21 shows the 16-light controller with P21 location and Figure 22 shows the RS-485 connections. 550 Controller. Figure 23 shows the 16-light controller with P20 location and Figure 24 shows the RS-485 connections. RSA Master. Figure 25 shows the master/slave RS-485 connections and Figure 26 shows the RSA with P27 location. Generator Set P20 (550 ) Controller P21 (16-light) i __ Connect + to + -to- GND toshield between devices ~ ( X-6058-27 resistor ~ J (121 ohms) connect + RSA 0000 to - on last device in network (resistor is Belden #9841 included with each or equivalent RSA kit) n2es Figure 20 RS-485 Connector Details • 4.6 Select and connect the RS-485 wiring from the RSA master to the RSA slave(s) in a daisy chain wiring configuration using Belden #9841 or equivalent.. Figure 25 shows the master/slave RS-485 connections and Figure 26 shows the RSA with P27 location. See Figure 36 for additional information regarding master/slave RSAs. Connect the RS-485 wiring to the included 6-position Euroblock plug 294619 and plug into the RSA circuit board. The Euroblock connector is polarized and attaches in one position only. Each RSA is shipped with a terminating 121 ohm resistor connected to P27 terminals 4 and 5. Determine the need of the resistor based on the following three applications. Circuit Board Designation Connector Designation Wire Designation - 1 Black + 2 White GND 3 Shield Figure 22 16-Light Controller P21 RS-485 Connections t2 n-~sn ~o/oa Figure 21 16-Light Controller'RS-485 Connections • • +a +e RR I1R Gl3 P1O ow p n GID mro~1L..ll~ pR GlS P21 R GLt P22 ~ a MAIN LOCK: P/9 ' IL JI P2O P71 P18 a 0 P72 P15 t II s P77 P73 P74 a P18 l~ ~ 2 3 4 0 ~1~,, i~~P' 1. Mein circuit board (top view) Tr-13n 2. P21 inr KBus RS-485 communication connection 3. P20 for RSA;RS-485 communication connection 4. Main logic (microprocessor)/communication circuit board Figure 23 550 Controller RS-485 Connections ~Clrcult Board Destgnstlon Connector Designation :Wire Designation GND 1 Shield + 2 White - 3 Black Figure 24 550 Controller P20 RS-485 Connections Master/Slave Terminals Ctrcult Board Designation Connector Designation Wire Designation - 1 Black Master + 2 Whte GND 3 Shield - 4 Btack Slave + 5 White GND 6 Shield Figure 25 P27 Connection on RSA via RS-485 TT-13n ~ 0/04 1 2 3 4 ;~ C L8 ~~~ ~ ~, ~ T3 _ _ P27 f u~ J $O R R>o R a Kt O C[3 CG W ®] ® II O1 {J L ® ® a~ mue ~~ a ^^x ® G7 "E ®7 ®ot3 r°,e °; ~ s ®7 ® at4 ' /2 a~8 ,~' a 8 r . T4 1 ll7 N1 f3M31211- 1. TB12 user input/outputs and DC power supply connections 2. SW1 DIP switches 3. T3 isolation jumper 4. P27 RS-485 communication connections Figure 26 RSA Circuit Board RSA Master only. Verify that the terminating 121 ohm resistor is connected to P27 terminals 4 and 5 on the RSA master. RSA Masterwlth up to three RSA Slaves. Verify that the terminating 121 ohm resistor is connected to P27 terminals 4 and 5 on the ~ RSA slave in the daisy chain connection. Remove the 121 ohm resistor connected to P27 terminals 4 and 5 on the RSA master and atl RSA slaves except the last RSA slave. RSA Master with more than three RSA Slaves. Connecttheterminating 121 ohm resistorin series with a 0.1 MFD, . 50-volt capacitor, part no. GM28875-1 (not supplied) to P27 terminals 4 and 5 on the limit RSA slave in the daisy chain connection. Remove the 121 ohm resistor connected to P27 terminals 4 and 5 on the RSA master and all RSA slaves except the last RSA slave. 13 4.7 Make any additional local. user-selected connections to the RSA TB12 terminal block. User-defined inputs can be used for any status, warning, or shutdown including open circuit breaker, air damper, etc. The user-selections connections are defined in Figure 29 and include: • User Input 1 (local). • User Input 2 (local). • ATS emergency input (local). Connect wiring from the user-supplied transfer switch (ATS) emergency position auxiliary contacts 10-11. See Figure 27. • Local common fault input. • Annunciator common fault relay output. Note: User-defined digital inputs #1 and #2 are selected at the RSA master only and annunciated to the RSA slave(s). No user-defined digital input selection is available at the RSA slave(s). 4.8 550 Controller only. The RSA user inputs 1-3, when in the remote connection, are tied to the 550 controller digital inputs. See Figure 28. If required, the user-input selection tied to digital inputs D7, D8, and/or D10 can be changed using the 550 controller Menu 9, Input Setup. Refer to the .550 controller operation manual TP-6200 or MP-6200 for instructions. Document the user-selected. inputs .for future reference. If user selected inputs 1-3 (remote) are used, the user may add the identification on the RSAfront panel strip. This procedure is further explained in step 4.11 of this instruction. 31 29 13 11 J~ ...L T T 32 30 12 10 c,~nzosoi Figure 27 Auxiliary Contacts 10-13 and 29-32 (shown with contactor contacts in normal position) • RSA User Inputs (Remote) Tied to 550 Controller Digital Inputs 1 D7 2 D8 3 D10 Figure 28 RSA Remote User Inputs with 550 Controller Optional Connartions RSA 550 16-Light Function RSA (Local) (Remote) (Remote) T812-8 T64-7 (D7) T85-10 on user- user-selectable communication selectable using Menu 9 module. User input 1 user-selectable T612-2 TBa-28 TB5-4 (ground) (ground) (ground) T612-7 TBa-8 (D8) T65-11 on user- user-selectable communication selectable using Menu 9 module. User input 2 user-selectable TB72-1 T64-29 TB5-5 (ground) (ground) (ground) Remote only T64-10 (D10) Factory-set for user-selectable high battery User input 3 using Menu 9 voltage on TBa-31 communication (ground) module ATS auxiliary via RSA/550 ATS auxiliary contact 10 to comm. link contact 10 to TB12-9 T65-9 on Local ATS comm. module emergency on input ATS auxiliary via RSA/550 ATS auxiliary contact 11 to comm. link contact 11 to TB72-3 TB5-3 on (ground) comm. module TB12-10 TB&RDO18 TB1-32 or Local T'Bi -32A common fault input T812-4 TB8-GND TBt-2 (ground) (ground) (ground) T612-11 AN alarm kit or A/V alarm kR or Annunciator (N.O, user-supplied user-supplied common contact) device device fault relay TB12-12 AJV alarm kit or A/V alarm kit or °~P~ (common user-supplied user-supplied contact) device device Figure 29 RSA Local TB12 Input/output Connections 1 a TT-13n 1 o/oa • • • 4.9 Setthe SWi DIP switches on the RSA master and subsequent RSA slave ('rf used). See Figure 30. RSA connected to controller MUST be assigned as the RSA master. See Figure 31 for a summary of the EPS Supplying Load (ATS) annunciation sources depending upon DIP switch position. When SW1-1 is OFF, the generator set controller activates the. EPS Supplying Load LED. When SWi-1 is ON (local), transfer switch activates LED. Note: When SW1-4 is in the slave position, DIP switches SWi-1, SW1-2, and SWi-3 are not functional as the RSA master annunciates the RSA slaves. SW1 DIP Switches (on =closed and oft =open SW7-1 . Local ATS (On is loran SW1-2 User input 1 (On Is loran SW1-3 User input 2 (On is local) SW1-4 Master/Slave (On is master) SW1-5 Not used Figure 30 RSA DIP Switch Selections Rsa swt Position 16-Light Controller 550 Controller Local RSA connection to the RSA connection to the (hard wired) ATS ATS Remote Comm. module board 550 controller (RS-485) connection to the ATS connection to the ATS Figure 31 EPS Supplying Load (ATS) Annunciation Sources 4.10 In most situations the T3 isolation jumper should " be connected to T3 and T1 (isolated position) on the RSA master and slave. This configuration provides the generator set controller with the best protection against damage from stray voltage without using additional devices. If the generator set controller has an isolation kit installed, the RSA master should have the T3 isolation jumper connected to T3 and T2 (non-isolated position). The RSA slaves, ff installed, should have the T3 isolation ,jumper connected to T3 and T1 (isolated position). 4.11 Document any local and remote user-selected inputs for future reference. If user selected inputs 1-3 (local or remote) are used, the user may add the identification on the RSA front panel. Remove the white identification strip and print with black non-permanent marker. See Figure 32. The user can also fill in the Generator ID Location informationrf needed. Allow the marker ink to dry before replacing the white identification strip. TT-~ sn ~ o/oa Another method to add the information to the identification strip would be to use a PC and print the. information on an adhesive label. The print font on the RSA front pane(is Myriad bold 10 point. Attach the printed label(s) to the white identification strip and then insert it in the RSA front panel. 4.12 Replace the controller cover and hardware on the 550 controller only. 6M39433 I t . Carefully pull out the white identification strip and write with black non-permanent marker or attached printed label Figure 32 RSA Front Panel Assembly Identification Strips 5. Complete the RSA final installation. GM34474-KP1/-KP1S and GIV134474-KP2/ -KP2S kits only. Proceed to either Step 5.1, Surface-mount RSA final installation or Step 5.2, Flush-mount RSA final installation. 5.1 Surface-mount RSA final installation. Note: Wall mounting plate GM33031 is not used with the surface-mounted RSA. 5.1.1 Mount the RSA box to the wall or to the electrical box in the wall if not already done. Check that the box is square to the wall; adjust as needed. 5.1.2 Position the RSA front panel assembly to the surface-mount box and install the four self-tapping screws (X-67-154).' Do not tighten the screws. 5.1.3 Center the remote annunciator in the box and square with the wall. Tighten the screws. 5.1.4 Proceed to step 6. is 5.2 Flush-mount RSA final installation. 5.2.1 Place the wall mounting plate GM33031 behind the RSA front panel assembly flange if not already done. See Figure 33. Note: The wall mounting plate can be installed behind the RSAftont panel assembly flange even 'rf RSA front panel assembly is already wired. 5.2.2 Align the holes of the wall mounting plate with the RSA front panel assembly to the surface-mount box and install the four self-tapping screws (X-67-154). Do not tighten the screws.- 5.2.3 Center the remote annunciator in the box and position wall mounting plate square with the wall. Tighten the screws. 5.2.4 Proceed to step 6. 6. Configure. the 16-light controller to the remote serial annunciator. The- RSA requires a controller with a MODBUS® address #1 and a baud rate of 19200. Note: After setting DIP switches to the generator set application, be sure to power down and then power up the controller. Either disconnect the battery and then reconnect the battery of the generator set, use the prime power switch ('rf equipped), or remove and then replace the F2 controller fuse. The controller will NOT acknowledge the DIP switch change until after generator set controller is powered up. 6.1 Set the controller MODBUS® address to #1 by placing DIP switches 6, 7, and 8 to the open position. See Figure 34. 6.2 The 16-light controller baud rate is fixed at 19200. No change is required. • 6.3 Replace the controller cover and hardware. 7. Restore the generator set to service. 7.1 Check that the generator set master switch is in the OFF position. 7.2 Reconnect the generator set engine starting battery, negative (-) lead last. 7.3 Reconnect power to the battery charger, 'rf equipped. 7.4 Energize the RSAs. 7.5 Move the generator set master switch to the AUTO position for startup by a remote transfer switch or remote start/stop switch. 7.6 Reset alarm horns as needed. 1 1. wall mounting plate QM33031 anv$easa-a- ~ Figure 33 RSA Wall Mounting Plate 1 2 3 4 5 6 7 8 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 OPEN to open circuit. 8128 Figure 34 16-Light Controller DIP Switches ~ s rr-i 3n t o~oa • • • w c V ~ J w J 4Q ~r^ M IA tD n O 7 7 D) O 7 v to v m O a~ ~ F e~co'ns xmu~eoiwoewraunc mu+gea 6VATCNMOED V~nl OF8 D --~ -- -- -- -- -- -- -- -- -- -- -- -- 12-/24 VOLT, 200mA OC POWER BATTERY POSITIVE 2 G0. FT D . [0-138 m], 2 0-450 DC r I 450-700 FT. [138-214 m], 20 GA. VOLTAGE CONNECTION I I 700-1725 FT, [214-344 m], 18 GA. FROM ~ I 1125-1800 FT. [344-550 m],18 GA. 1800-2800 FT. [556-858 mj, 14 GA GENERATOR N BATTERY NEGATIVE BATTERY CONNECTION - - - - - - - - - - - - - - - I- oN 18-LIGHT CONTROLL6i, CoNNf~T TO P21, C I I I ON 55 CONTROLLffT, CONN~T TO Pt0 fl I I 2 WIRE310(iA MIWMUM I I CONTROL PANEL ` 1s.uGHT, a wRES 1e~o GA BATTERY CHARGER BLOCK HEATER ~vHCH RG G L I 5 ~ PAMS I B 4TT P W/FAULT I I C C I i RS-485 - ALARMS r- ---------- -------- I i saDea seal oR EDUIVaLesr i I / MAX DISTANCE 4000 FT. [1223 m] I I I I ~ ~ COMM. i ~ ~ I I I ~ MODULE I I ~ BOARD I I I I 1 I I I I 18-LIGHT I I ~ I 3 WIRES (INCLUDING I I I CONlAOLL6t ONLYI I ~ ~ ( (REQUIRES I ~ I GROUND) SIZED AS I A OGIC I B ~ M IN L REQUIRED I - - - I GENERATOR SET OUTLJNE BOARD GM28725] + I _ I --~-- ~-- - I ~-- -- -- I-- -- - ~ ` I B AS REQUIRED ' I 2 WIRES 18-20 GA. 20 GA I I 2 WIRES 18 . I - ENGINE START WIRES I TO CUSTOMER'S OVERCURRENT I I I PROTECTIVE/DISCONNECTDEVICE. OPTIONAL I I REMOTE I ~ TO CUSTOMER'S 15-AMP OVERCURRENT yOLTAGE ANO CURRENT RATING TO AUTOMATIC pROTECTIVE/DISCONNECT OEVICE . BE DETERMINED FROM BLOCK i E-STOP I L TRANSFER BATTERY CHARGER VOLTAGE IS 120VAC HEATER NAMEPLATE. SOURCE TO I SWITCH STANDARD. CAN BE REWIRED FOR gE INDEPENDENT OF GENERATOR. 240VAC (SEE DRAWING ADV-5971). - RSA 1000 I SOURCE TO BE INDEPENDENT OF - - - - - _ - - - - _ - J - ~ GENERATOR. REMOTE SERIAL - ~ ANNUNCIATOR 2 WIRES 14-20 GA. ATS POSITION INDICATIO CONNECT TO COMM. MODULE BOARD REFER TO WIRING DIAGRAM GM34474 FOR OR RSA 1000. CONNECTION DETAIL. (1B-LIGHT CONTROLLE~i ONLl9 DIMENSIONS IN [ ]ARE METRIC EQUIVALENTS. A A NOTES: ~ ~ ~m;~; 1. TYPICAL CUSTOMER WIRING SHOWN DASHED. m' . ~ ...a : ~ s :... 2. CUSTOMER RESPONSIBLE FOR ADDITIONAL WIRING SHOWN 1F COMPONEN79 ~ ARE SHIPPED LOOSE (BATTERY CHARGER, DRY-CONTACT BOX, ETC.) ^""°- ` ~ «~ `"' DIAGRAM } 9. IF BATTERY CHARGER IS SHIPPED LOOSE ADDITIONAL WIRES MAYBE REQUIRED FOR "PP"0YN' °~'~ ONNEGITION E INT RC PROPER VOLTAGESENSING. REFERENCE ORAVVING ADV-5971 FOR INTERCONNECT. INTERCONNECTION DIAGRAM ,e ~-xe.w 4. DC VOLTAGE FOR RSA REMOTE ANNUNCIATOR MAY ALSO BE SUPPLIED BY A CONTAOLL61 A ,..p.o, ~~~~ ~ovamnowo '-' LOCALLY MOUNTED 12 OR 24 VDC AC ADAPTER. WTTH RSA ANNUNCIATOR ^'^°® xa ,~.a. ADV-6990 C o . 4 3 2 1 • • • Parts List Remote Serial Annunciator Kits and Communication Module Kit Remote Serial Annunciator Kits Communication Module Kit aty. ..Description GM34474-KPt/-KP1S GM34474-KP2/-KP2S GM32644-KP7 1 Plate, wall mounting GM33031 ~ GM33031 1 Ribbon cable, 10-position GM21340 GM21340 1 Communication module board GM31070 GM31070 1 Ribbon cable, 24-portion GM32632 GM32632 3 Spacer, 8-32 x 5/8 male-female GM32633 GM32633 3 Washer, #8 lock X-22-7 X-22-7 1 Harness, comm. HBV wiring GM35318 GM35318 1 Annunciator assembly, remote serial Includes:) GM34433-1 (kit GM34474KP1) GM34433-2 (kit GM34474KP1S) GM34433-t (kit GM34474KP2) GM34433-2 (kit GM34474KP2S) 1 Decal, ground 344295 344295 1 Decal, bar code GMt3213 GM132t3 1 Circuit board, RSA GM31211 GM31211 1 Resistor, 121 ohm X-6058-27 X-6058-27 1 Euroblock plug, 6-posftlon 294619 294619 1 Box GM31884 GM31884 1 Cover GM344341 {kH GM34474KP1) GM344341 (kit GM34474KP2) 1 Cover GM344342 (kft GM34474-KP1S) GM344342 (kit GM34474-KP2S) 1 Nameplate GM34618 GM34618 1 Lead L.K-1212-1414 1JG1212-1414 2 Washer, #10 lock X-22-13 X-22-13 1 .Bushing, 1.0 in. x 1.375 in. X-634-15 X-634-15 4 Screw, self-tapping X-67-154 X-67-154 1 Nut, 10-32 hex X-70-3 X-70-3 1 Washer, #10 flat X-25-36 X-25-36 1 Identification sVips (white) GM34477 GM34477 20 '1'T-1377 10/04 Model KDYJKi1~~i ~l~l~~P~WE~ SYSTEMS Transfer sWitcn~~ ~~~~~ MPAC 1000 ~' Controller ~~~ Standard Features lUTIWIAll1' REGISTERED • Microprocessor controller • • Ratings Voltage 208-480 VAC 50/60 Hz Current 40-600 amps Standard Contactor Features • Open-transition operation • Available with either automatic or non-automatic control • UL 1008 listed at 480 VAC • Underwriters Laboratories Inc., listed to Canadian Safety Standards (cUL) • 2, 3, or 4 poles • Electrically operated, mechanically held mechanism • Arc-quenching grids with enclosed arc chambers • Double.throw, mechanically interlocked contactor mechanism • Real-time clock with battery backup • Broadrange voltage sensing wdh 2% accuracy on both sources • Frequency sensing with 1°k accuracy on both sources • Environmentally sealed user interface • Keypad witit tactile feedback pushbuttons • LED indicators • Selectable operating modes • Programmable inputs and outputs • Load/no load exeroise function • Anti-single phasing protection • Load control inputs and outputs • Phase rotation sensing • Time-stamped event log • Gold-flashed engine start contacts • Modbus® communication with network and setup connections MPAC 1000' Controller Programmable Features • System voltage and frequency. • Adjustable over/undervoltage and over/underfrequencyfnr the normal and emergency sources • Adjustable time delays • Commit/no commft transfer • ABCBAC phase rotation selection with error detection • Resettable historical data • In-phase monitor • Password protection Accessories • Programmable input/output (I/O) modules with two inputs and sbc outputs (output rating 2 amps @ 30 VDC/250 VAC); four I/O module maximum • Three-stage charging, dual-output battery charger (6 amps @ 12 VDC/3 amps @ 24 VDC) • Padlockable user interface cover • Preferred source switch • Silver tungsten alloy contacts on 400-600 amp models • Supervised transfer control switch • Suitable for emergency and standby applications • Setup software • Au~aliary position-indicating contacts, one set Normal and •Line-to-neutral monitoring one set Emergency, rated 15 amps @250 VAC • External battery supply module (allows extended engine time delays) Modbus® is a registered trademark of Schneider Electric. • Chicago alaml module Git-89(ModelFmT/IO~ATTrar~sferSrr~ch) 8/04b MP~4C 1000' Controller Features Standard Controller Features User Intertace Keypad • Start/end system test • Set/end exercise • End time delay • Lamp test/service reset • • User irrtertace Indicators • Contactor position: Normal, Off, Emergency • Source available: Normal, Emergency • Service required: immediate, maintenance • Not in automatic mode • Four-stage time delay remaining • Exercise: load, no load, set/disabled • Test: load, no load • Load control active: peak shave, pre/post-transfer signal • In-phase monitor active Selectable Operating Modes* • 1 week/2 week manually set exercise (1 week) • Disable%nable exercise (enable) • Load/no load exercise (no load) • Load/no load test (load) • Enable/disable transfer (enable) Programmable Inputs (factory settings) • End time delay • Peak shave/area protection Outputs • Generator engine start gold-flashed contact rated 2 amps @ 30 VDC/250 VAC • Pre-transfer load control, one normally open contact rated 10 amps @ 30 VDC/250 VAC • One programmable output, factory-set to load bank control rated 2 amps @ 30 VDC/250 VAC Software Event MonRoring Use a personal computer with the optional setup software or a Modbus® link to view historical data and system events. • Historical data (total and resettable) • System everrts (time and date-stamped) • System faults (time and date-stamped) • Line-to-line voltage • System frequency • Time delay active • Time delay remaining • System status • Source available • Contactor position • Exerciser schedule, mode, and time remaining on active exercise Communications ~ Serial port for PC connection • Modbus® network interface Programmable Features Use a personal computer with the optional setup software or a Modbus® link to view, select, or adjust programmable features. Programmable Features* • System voltage# • System ftequency# • Single/three-phase operation# • ABC or CBA phase rotation (ABC) • In-phase monitor (disabled) • Commitino commit switch (no commit) • User-defined password • Calendar mode exerciser (up to 21 events) Programmable Inputs and Outputs Use a personal computer with the optional setup software or a Modbus• link to define inputs and outputs. Programmable Inputs • End time delay input (defauR) • Inhibit transfer • Low battery fault • Peak shave/area protection input (default) • Remote common fault • Remote test Programmable Outputs . • Au~dliary switch fault • Common fault • Contactor position • Exercise active • Failure to acquire standby source • Failure to transfer fault • Generator engine start • Load bank control (defauR) • Load control (pre/post transfer, up to 9 outputs) • Loss of phase fault • Low backup battery • Modbus®-controlled relay outputs (4 maximum) • Not in automatic mode • Non-emergency transfer • Over and undervoltage faults • Over and underfrequency faults • Peak shave/area protection active • Phase rotation error • Source available • Test active ~ Factory defauk settings are shown in parentheses. All settings ere stored in non-volatile memory. # System parameters set per order. Git-BB(ModellmTlIGATTrensferSwltch) 8/04b NiPi4C i 000 ~" Controller Features ~4pplia:ation Data • Voltage and Frequency Sensing Parameter Defauh Ad)ustment Range Undenroltage pickup 90°k of nominal 85°~-100°~G of nominal Undenrottage dropout 90% of pickup 75%-98% of pickup Ovenroftage dropout 115% of nominal 105°,6-135% of nominal* Overvoftage pickup 85% of dropout 95%-100°6 of dropout Voltage dropout time 0.5 sec. 0.1-9.9 sec. Undetfrequency pickup 90% of nominal 85%-95% of nominal dUn~rirequency 99% of pickup 95%-99% of pickup Overfrequency dropout 101% of pickup 101%-105% of pickup OverUequency pickup 110% of nominal 105%-120% of nominal Frequency dropout time 3 sec. 0.1-15 sec. " 680 volts, matamum UL-Listed Solderless Screw Type Terminals for Externs{ Power Connections Normal, Emergency, and Load Terminals Switch Rating (Amps) Cables per Pole Range of Wlre Sizes, Copper or Aluminum 40-150 1 #B to 3/0 AWG 200-225 20 1 1 #6 AWG to 25 1 ff4 AWG to 600 MCM 400 2 #6 AWG to 250 MCM 600 2 #2 AWG to 600 MCM • Adjustable Time Delays Time Daisy Default Ad)ustment Range Engine start 3 sec. 0-fi sec.# Preferred to standby 1 sec. S"teutdby to preferred 15 min. Engine trooldown 0 min. Failure to acquire standby source 1 min. Pretransferto preferred signal 3 sec. Pretransfer to standby signal 3 sec. 0-60 mina Post-transfer to preferred signal 0 sec. Post-transfer to standby signet 0 sec. Off to standby (progremmed-transition only) 1 sac. Off to preferred (programmed-transition only) 1 sec. ~ Adjustable fn 1 second incremerrts Input and Output Connection Specifications Component Number of Wires Wire Size Range Terminal strip I/O terminals 1 #12-24 AWG 1/O module terminals 1 #14-24 AWG Environmental Specifications Operating Temperature -20°C to 70°C (-4°Fto-158°F) Storage Temperature -40°C to 70°C (-40°F to 158°F) Humidity 5% to 95% noncondensing ARitude 0 to 3050 m (10000 it.) without Berating Weights anal Dimensions Weights and dimensions are shown for transfer switches in NEMA type 1 and type 3R endosures. Consult the factory for NEMA type 12, 4, and 4X enclosures. Weight kg (Ib.) Amps 2-Pole 3-Pole 4-Pole - 28 (62) 30 (65) 66 260-400 52 (115) 56 (123) 59 (131) 600 179 (395) 183 (403) 186 (410) Dimensions mrn (In.) Amps Hei ht Width Depth - 791 (31.1 450 (f 7. 260-400 1223 (48.1) 560 (22.0) (14.3) 600 1702 (67.0) 610 (24.0) 514 (20.2) " Allow enough room to. fully open the door for inspection and service per NEC and local codes. The NEMA type 3R enclosures have a security cover on the corrtrolier that extends 54 mm (2.1 in.) beyond the door. G11.88 (Model ImT/IOutT Transfer Slwhch) 8/04b Codes and Standards r The ATS meets or exceeds the requirements of the following specifications: • Underwriters Laboratories UL 508, Standard for industrial Control Equipment • Underwriters Laboratories UL 1008, Standard for Automatic Transfer Switches for Use in Emergency Standby Systems • Underwriters Laboratories inc., Listed to Canadian Safety Standards (cUL) • NFPA 70, National Electrical Code • NFPA 99, Essential Electrical Systems for Health Care Faciifties • NFPA 110, Emergency and Standby Power Systems • IEEE Standard 446, IEEE Recommended Practice for Emergency and Standby Power Systems for Commercial and industrial Applications e NEMA Standard ICS10-1993 (formerly ICS2-447), Electromechanical AC Automatic Transfer Swtch Equipment • EN61000-4-5 Surge Immunity Class 4 (voRage sensing and programmable inputs only) • EN61000-4-4 Fast Transient Immunity Severity Level 4 e IEC Specifications for EMI/EMC Immunity: o CISPR 11, Radiated Emissions o IEC 1000-4-2, Eiectrostaiic Discharge o IEC 1000-43, Radiated Electromagnetic Fields o IEC 1000-4-4, Electrical Fast Transients (Burs:) o IEC 1000-4-5, Surge Voltage o IEC 1000-4-6, Conducted RF Disturbances o IEC 1000-4-8, Magnetic Fields o SEC 1000-4-i1, Voltage Variations and IMerrup ia~ns Withstand and Closing- Ratings (WCR} The transfer switch is rated for use on a circuit capable of delivering not more than the RMS symmetrical amperes listed at t . ~ specified maximum voltage below, but no greater than the interrupting capacity of the selected circuit breakerorfuse. Circuit breake: ~ and fuses are supplied by the customer. Ratings Summary • Certified Withstand and Closing Current Ratings in RMS Symmetrical Amperes With Current-Umiting Fuses Specltic Coordinated Breaker Rating Switch Rating, Amps Maximum Fuse Size, Amps Fuse Class Amps Maximum Voltage Maximum Circuit Breaker Size, Amps ~~mps 40 50 80 100 100 125 r 200 J 200,000 480 V/60 Hi 400 J,000 a 2 0 300 300 260 N/A N/A N/A 480 VJ6D Hz 400 35,000 J 200,000 400 640 RK5, RK7 100,000 480 V/60 Hz 800 50,000 600 N/A N/A N/A * All values are available s metrical RMS am res and tested in accordance with the withstand end dose-on r uiremerrts of UL 1009. Ratings with Specific Manufacturers' Circuit i3reakers Power switching devicewithstand and closing ratings (WCR) in RMS symmetrical amperesfor specific manufacturers' circuit breakers. Molded-Case Circuit Breakere Swltch Rating, Am s WCR, Amps RMS Voltage, Max. Manufacturer Type R"ar,. Size, lam FDC,HFD 150 Cutler-Hemmer HJD, JDC 250 HKD, KD, KDB, KDC, LAIR{-PAC, LCL 400 FC, FI 100 ~ Squere D KC, KH, KI 250 BO LA, LC, LE, LH, LI, L)G LXI 400 100 30 000 460 CEDE, HED4, HEDB 125 , Siemens CFD6, FD6, FXD6, HFD6 250 200 CJD6, HJD6, HHJD6, HHJXD6, JD6, JXD6, SCJD6, SHJD6, SJDB 400 TBi 700 SEL,SEP,TEL,THLC1 t50 GE TFL,THLC2 225 SFL, SFP 250 SGL4 SGP4 T84 THJK4 THLC4 TJJ TJK4 TL84 400 G17-88(ModellmT/IQ,ATTrensfer3wkch) 8J04b KOHLER CO., Kohler, Wisconsin 53044 USA Kohler Power Systems Phone 920-565-3381, Fax 920-459-1646 Asia Pacific Headquarters For the nearest sales and service outlet in the 7 Jurong Pier Road US and Canada, phone 1-800-544-2444 Singapore 619159 KohlerPowerSystems.com Phone (65}264-6422, Fax (65)264-6455 • Record the transfer switch model designation in the boxes below. The transfer switch model designation defines characteristics and ratings as explained in the accompanying chart. Model Mechanism Transition Controls Voltage Poles Enclosure Current Rating Connections ® ®. Kohler Model Designation Key This chart explains the Kohler transfer switch model designation system. The sample model designation shown is for a Model K automatic transfer switch thffi uses an open-transition contactor with MPAC 1000'" electrical controls rated ffi 480 volts/60 Hz, 3 poles, 4 wires, end solid neutral in a NEMA 1 enclosure with a current rating of 225 amperes. Not all possible combinations are available. SAMPLE MODEL DESIGNATION ~c~~--an~-~a-o22~s Model K: Model K Transfer Switch Mechanism D: Automatic M: Non-Automatic Transkion L T: Open-Transition Electrical Controls A: MPAC 1000" (Microprocessor ATS Controls) Voltage/Frequency C: 208 Volts/60 Hz H: 400 Volts/50 Hz M: 460 Votts(60 Hz D: 220 Volts/50 Hz J: 416 Volts/50 Hz P: 360 Volts/60 Hz F: 240 VoRs/60 Hz K: 440 Volts/60 Hz S: 220 Volts/60 Hz G; 380 Volts/50 Hz Number of Poles~res N: 2-pole, 3-wire, solid neutral T: 3-pole, 4-wire, solid neutral V: 4-pole, 4-wire, switched neutral Enclosure A: NEMA 1* C; NEMA 3R F: NEMA 4X !3: NEMA 12 D: NEMA 4 G: Open unit * Standard Current Rating: Numbers indicffie the cunent rating of the switch in amperes: 0040 0150 0225 0400 0080 0200 0260 0600 0100 Power Connections S: Standard Availability is subject to change without notice. Kohler Co. reserves the right to change the design or spec~cffiions without notice and without any obligation or liability whatsoever. Contact your local Kohier® generator set distributor for availability. DISTRIBUTED BY o zone, z~a br f(ohier co, ai riphb reserved. 011-69 (Model tmT/IGAT Transfer Switch) 6/04b ~ • 8 7 6 5 4 3 2 I A~ ~ D 0 p a o_o I LOAp -a N I NORNAL = O - AUXILIARY CONTACTS ® 0 0 o I I C ~ 0 0 0 _ I I I I 0 0 ~ ° Q ~° o ®~ O I I EMERGENCY ENGINE START iERNINALS O I ,n - ro s 8 8 I w~ 10 1 11 p ~J 5EC71ON A A -4 73 305 A A Rcr R9r[ nuivo. -)-0! NEST DRAl11 YG [6x/94] Rr wtuww~~a ww~lu~ /r/~ SD riio~anw[[a:~" ~rM ~' SCREW TYPE TERMINALS FOR EXTERNAL POWER CONNECTION ! A e-Il-o! fA-n /o-9slA YA3 i2!•260A• [A-RI ID-200A DATA DDCD tce9 n r n*trs, RRNItR. ro s![u RtA R RR rpn[q tp, s '"oki9".""~ f4['RO'F .i ~fF6' ac:1 E ~Y ~" ~ w ~ 03 U-RI WIRC CHART UROATED fT021 )1 8 T •AII A[aR1s2 iT i BONIER (0. R <9RRP~o ~n[ ~n[S~aRw iR CRtiRR AlI[R[ttrr[D. R T RANGE OF WIRE SIZES G - - B D T:FY A I SWITCH (AMPS) N ~ C d-2l-0! SCE SM Ei 1 [69e117 E~.9~ s [[ CONTACTOR NEUTRAL GROUND WEIGHTS KG lLBS) MODEL B MvnovA C wsD !-)-o! ,, ° ~ 40- 150 ONE i8 TO 3/0 R4 TO GOOMCM Rld TO I/O 2 POLE 3 POLE 4 POLE ~ 40-225A NEMA 1 d 3R ,, [ou z a t ~ " TN! !-)-D3 ADV-6826 0 "'~° 200.225 ONE R6 TO 250MCM 28 (62) 30 (65f 31 1681 ANN !-)-D! g 7 6 5 4 3 2 I • • g ~ g 5 4 3 2 I O 0 _ C D ® -- ~° a.o o a SECURITY COVER OPTIONAL ON NEMA I ' REQUIRED FOR NEMA 3R ' PROGRAMMABLE I/O B SEt:T1W C'-C A -BATTERY CHARGED (OPTIONAII (OPTIONAL) . C c 9 I I ° c - C ° ® ® PREFERRED SOURCE 8 f SUPERVISORY TRANSFER ° $WITC HES (OPTIONALI I -L ----- I p e O II I 10 ® NEUTRAL ' (2 S 3 POLE UNIT$ ONLY) I I I I ® ® B 8 I 1 ° ~ PADLOCH HASP I I _ ° (SECURITY OPTION ONLY) 1 I 1 I DIMENSIONS IN C I ARE INCHES. ° FINISH: ANSI d9 GRAY. ENT ° REf ER TO OPERATOR'S MANUAL PRIOR TO GROUND ® I I INSTALLATION AND OPERATION OF UNIT. POWER CABLES AND CONTROL WIRING MUST BE RUN IN METAL CONDUIT. - SECTION A-A B A >DYCTION 6@ - A A 4SO 17- 7] DLY DI r[ }[YI r t0} 3-1-°3 NEW DRAxrIND [BD/931 Br amnam B/~~ ^SD i'1 wlx~°tlllRlBr lv:ll~a°u Yt AO}[xtlDI~1l6~ ORLF}, 11 BIBAA Y.B.A. h 6-13-03 IA-AI ~0-z25h DAS 72S-2BDh [09091) }BO D A} [a lD+ MD pFrA IL [ +ORL[x W. n w ~ B e-1-03 BfE SHEET Z [l0 I J W~ Xa Or eE uB }[DW,sR~~ I+ SD T ~~ x AID+ry a i [ i L [~ r ~r' ~ C 8-Z6-03 IA-11 CON IT p07 UPDATED [ 9 AI gl i [B[AY[E . [ M 01 Ix Kxf SD J D[SI ti~A[a Yx DArc DIIIAET790M PWNT ' MODEL B 40-225A D rsD 1HS 3-]-03 3-i-o3 ""' DoxF ~~ .I t I Y NEMA I 8 3R ""PO hJN 9•i-03 ~y'88Z6 0 g 1 6 S 4 3 2 I • o V m ~.. ~ ~~ ~~ ~ ~ ~ _ _ i~ii~~~~ai~ ~~~~ N~,j ~~~~ • ~I~~~Z~~trN~MM a ®4n~~ - • a ~ ~ ~.,~ir~lrlr~~,.Jr;r I ~J ~en~meneae~~ I ~ I v I I ., • L__J d • • ~ V V V ~ 'yew' /y~~~'yo~, e g7V_)VV ~ V ~~ ~ Y ~~ \% ~ ®~ ® ~ ~~~ .. I I: ~ ... sl ~ I~ ~:: ~I ~ I ~'~~ I ~ I ......... I ~ ~ ~ ~T~ ~~ 7gbT ~T~ ~~ ~ gu3~ '~u~1 gu$ guY I~ t~ t~ i~ 9 a 3 3 g~~-l~fl • I II k m~ o ~ m t q Y d 7 m es o a ~ m ~ s ~ s t t swt aT 4 (06NILT P05111M19 SFIO1~gM) y 2 Y+ 4 N- i O V -+ i O O e "~ O p• Y N -~ m w nR3g r ~ Y ~ oe ~c Pt-E s }~Q~{ Q$q 4gq ~ ~ O ~ ~ Y o FI hi R ~ ~ ~ Pt-9 0 Pt-to 0 ~ ~ ~ S 6 to ~ Pt-ts ,_ ~~ _ o a v a ~~ ~~ ~ e v ~ P to o x{ ~ ~ w a '~ +' i ~. a. ~ V r ~ Pt-t as a ~~ D ~~1 .+~ a a a a ~ ~ a p N AI °~ ~`L-_ J~. V u ; ~ ~ .~. n ~ Y ~ ~ ~ r ~ u Y e ~ ~ ~ ~ ~ . ~ ~ ~ ~ m.,yg~yfs $N= a0 t~yn~~~ N OZ9J[ p , tt~,,,,,tt,~; ~~~d p_. s ~ ~ ~ ~ ~ ~ ~ ~~~~ ~ ~ ~ ~ g ~ ;, ~ ~ ~ ~ [@i N i~ ~ V ~~ s i~n ~~ ° ~ ~~ ~ 9 ~ r~ -- a : 1~ > tto n • • Mended Tvvo-Year or Two ~i housand (2®®~)-Hour Stati®nary Standby Limited 1lVarranty This Kohler Standby Generetor System has been menufadarred and inspected with care by experienced craftsmen. ff you ere the original purchaser, Kohler Co. wanarrts for two years or two thousand (2000) hours, whichever occurs first, thffithe system wily befrse from dsfeffis in material and workmanship ff properly installed, maintained, and operated in accordance with Kohler Co. instru.^tion manuals. A Kohler distributor, dealer, or authorized representative must perform startup. This warranty is not eNective unless a proper extentled warranty registration form and warramy fee have been sent to tlfotthr Co. within one year of supervised startup. Duringthewarrentyperiod, repairarreplacementffiKohler Co.'s optionwill befumishedfreeotchargeforparls,Provided enirrspedion to Kohler Co.'s satisfaction discloses a defect in material end workmanship, and provided thffi the part or parts are returned to Kotler Co. or an authorized service station, 'd requested. This eudended warrenly expires two years after dffie of startup or sitar 2000 hours of operation, whichever ocarrs first.* This warranty does not apply to meliunctions caused by damage, unreasonable use, misuse, or rrorrtal wear end tear while in your possession. come resMr~ions may apply. Contact your Katrler distributor/dealer for full details. The fdiowir~ will not be covered by this werartty: ~~ ~J 1. Nortnel engine wear, routine tuneups, tuneup parts, adjustmens, and periodic service. 2. Damage caused by aociderrts, improper installation or handling, faulty repairs not performed by en authorized service representative, or improper.storage. 3. Dammge caused by operation with improper fuel or ffi speeds, loads, conditions, modifications, or installation contrerytopublishedspedfications orrecommendatiarrs. 4. Damage caused by ne¢igent maintenarxe such es: a Failure to provide the specified type and sufficdent lubricating oil. b. Failure to keep the air intake end cooling fin areas clean. c. Failure to service the air leaner. d. FailuretoprovidesuffideMcoalentand/orcooiingair. e. Failure to perform scheduled maintenance as presrxitred in supplied manuals. f. Failure to exerlse with load regularly. 5. Ori¢rral Irrstatiffiion charges end startup costs. 8. Starting batteries and the fdlowing related expenses: a Lobar charges related to battery service. b. Travel expense related to battery service. 7. Engine wolant heaters, heater controls, and dreulffiing pumps after the first year. 8. Rental of equipment during perfom-ence of warranty repairs. 9. Parts purchased from sources other than f(otiler ReplacementoFafailed Kohlerpertwithanon-Kohlerpart voids warranty on that pert. 10. Radiators replaced rather than repaired. 11. Fuel ir~edion pumps not repaired locally by an authorized servicing dealer. 12. Nan-Kohler-authorized repair shop labor without prior approval from the Koller Co. Warranty Departmerrt. 13. En¢ne fluids such as fuel, oil, or coolard/antifreeze. 14. Shop supplies such as adhesives, leaning solverls, and rags. 15. Expensesincurredirnestigffiingperfortnancecomplaints unless the problem is caused by defective Kohler materials or workmanship. 16. Maintenance items such as fuses, filters, spark plugs, loose/leaking clamps, end adjustments. A Startup NotiScffifon form must be on file ffi Kohler Co. A Startup Notification form must be completed by Seiler and received ffi Kotler Co. witiln 80 days afterthe dffie of initial startup. Standby systems not registered within 60 days of startup will automatically be re¢ffiered by Kohler Co. using the Kohler Co. ship dffie as the startup dffie. To obtain werrarrty service, call 1-800544-2444 for your nearest authorized Kohler service representative, ~ write Kohler Co., Generator Service Department, Kahier, WI 53044 USA. KOHLER CO. SHALL NOT BE LIABLE FOR SPECIAL, INCIDENTAL, OR CONSEQUENTIALDAMAGES OFANYKIND including, but notiirrlbedt~, irtldwttelcortsequerdiffi laborcosts, instefiation charges,telephone charges, ortrarrsportation chargesin connectionwith the replacement or repair of defective parts. This is our exdusive written warranty. We make no other express warranty nor is erryone authorized to make any in our behaff. ANY IMPLIED OR STAMORY WARRANTY, INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FlTNESS OF PURCHASE, ~ expressly limited to the duration of this warranty. Some states do rrot allow limitations on haw long an implied warranty lasts, or the exclusion or limitation of incidental or consequential damages, so the shwa firrltation or exclusion may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from stffie to stffie. lil~~® KOHLER CO. Kohler. Wisconsin 53044 Phone 920{65-3391, Fax 920-459~184a E~ SYSTEMS K~~ P ~ ~y~~; ~N$ ~`2 TP-5487 12(98c