Tp6862!33!125efozdj Installation Manual

Marine Generator Sets

TP-6862 6/14a

Installation

Pleasure Craft Models:

40--150EOZDJ33--125EFOZDJ

Commercial Models:

40--150EOZCJ33--125EFOZCJ

Controller:Decision-Makerr 3500

TP-6862 6/142

TP-6862 6/14 Table of Contents 3

Table of Contents

Safety Precautions and Instructions 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Introduction 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Location and Mounting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 General Considerations 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Location 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Mounting 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Cooling System 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Ventilation 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Cooling System Components 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.1 Intake Through-Hull Strainer (Seacock Cover) 13. . . . . . . . . . . . . . . . . . . . .3.2.2 Seacock 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.3 Seawater Strainer 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.4 Water Lines 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2.5 Closed Heat Exchanger 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Exhaust System 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Types 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Exhaust Lines 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Sound Shielded Units with Dry Exhaust 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Exhaust System Location, Mounting, and Installation 18. . . . . . . . . . . . . . . . . . . . . . .

4.4.1 Above-Waterline Installation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4.2 Mid/Below-Waterline Installation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Fuel System 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Fuel Tank 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Fuel Lines 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Fuel Filters 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4 Fuel/Water Separator 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5 Fuel Pump Lift 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6 Fuel Consumption 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 6 Electrical System 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 AC Voltage Connections 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2 Circuit Protection 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.1 Circuit Breaker Considerations 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.2.2 Circuit Breaker Installation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3 Installation In Steel or Aluminum Vessels 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4 Installation Regulations 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5 Battery 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6 Wiring 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7 Remote Connection 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8 Paralleling Generator Sets 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 7 Installation Drawings 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 8 Reconnection/Adjustments 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.1 Twelve-Lead Reconnection 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 9 Paralleling Generator Sets 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Introduction 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1 Paralleling Basics 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.1.1 Why Parallel Generator Sets 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.1.2 Paralleling Functions 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.2 Paralleling Considerations 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2.1 Generator Requirements 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.2.2 Paralleling Controller—PGEN 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6862 6/14Table of Contents4

9.3 Paralleling Set Up 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.1 PGEN Communication Wiring 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.3.2 Decision-Makerr 3500 Paralleling Sequence of Operation 63. . . . . . . . . . .

9.4 Troubleshooting When Breaker Does Not Close to Bus 64. . . . . . . . . . . . . . . . . . . . .9.4.1 Faults Not Shown 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.4.2 Faults Shown 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.5 Troubleshooting When Breaker Does Close to Bus 67. . . . . . . . . . . . . . . . . . . . . . . . .9.5.1 Faults Shown 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.6 Troubleshooting When Running in AUTO 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.6.1 Faults Shown 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.7 Generator Management Setup 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7.1 Manual Order Selection Setup: 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7.2 Run Time Order Selection Setup 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7.3 Fuel Level Selection Setup 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.7.4 Paralleling Parameters 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9.8 Load Add/Shed Configuration 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.8.1 Load Add/Shed Setup 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Generator Selection and Wattage Requirements 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Abbreviations 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6862 6/14 5Safety Precautions and Instructions

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

Engine Backfire/FlashFire

Fire.Can cause severe injury or death.

Do not smoke or permit flames orsparks near fuels or the fuel system.

WARNING

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the fuel injection system,fuel line, fuel filter, fuel pump, or otherpotential sources of spilled fuels or fuelvapors. Catch fuels in an approvedcontainer when removing the fuel lineor fuel system.

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner/silencerremoved.

Combustible materials. A suddenflash fire can cause severe injury ordeath. Do not smoke or permit flamesor sparks near the generator set. Keepthe compartment and the generator setclean and free of debris to minimize therisk of fire. Catch fuels in an approvedcontainer. Wipe up spilled fuels andengine oil.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

TP-6862 6/146 Safety Precautions and Instructions

Exhaust System

Carbon monoxide.Can cause severe nausea,fainting, or death.

The exhaust system must beleakproof and routinely inspected.

WARNING

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

Inspecting the exhaust system.Carbon monoxide can cause severenausea, fainting, or death. For thesafety of the craft’s occupants, install acarbon monoxide detector. Neveroperate the generator set without afunctioning carbon monoxide detector.Inspect the detector before eachgenerator set use.

Operating thegenerator set. Carbonmonoxide can cause severe nausea,fainting, or death. Be especiallycareful if operating the generator setwhen moored or anchored under calmconditions because gases mayaccumulate. If operating the generatorset dockside, moor the craft so that theexhaust discharges on the lee side (theside sheltered from the wind). Alwaysbe aware of others, making sure yourexhaust is directed away from otherboats and buildings.

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

Use extreme care when handling,storing, and using fuels.

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

Draining the fuel system. Explosivefuel vapors can cause severe injuryor death. Spilled fuel can cause anexplosion. Usea container to catch fuelwhendraining the fuel system. Wipeupspilled fuel after draining the system.

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Hazardous Voltage/Moving Parts

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Servicing the generator set when itis operating. Exposedmoving partscan cause severe injury or death.Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcovers before operating the generatorset.

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

Disconnecting the electrical load.Hazardous voltage can causesevere injury or death. Disconnectthe generator set from the load byturning off the line circuit breaker or bydisconnecting the generator set outputleads from the transfer switch andheavily taping the ends of the leads.High voltage transferred to the loadduring testing may cause personalinjury and equipment damage. Do notuse the safeguard circuit breaker inplace of the line circuit breaker. Thesafeguard circuit breaker does notdisconnect the generator set from theload.

TP-6862 6/14 7Safety Precautions and Instructions

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death.Connect the generator set to thebuilding/marina electrical system onlythrough an approved device and afterthe building/marina main switch isturned off. Backfeed connections cancause severe injury or death to utilitypersonnel working on power linesand/or personnel near the work area.Some states and localities prohibitunauthorized connection to the utilityelectrical system. Install aship-to-shore transfer switch to preventinterconnection of the generator setpower and shore power.

Testing live electrical circuits.Hazardous voltage or current cancause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of thetest equipment manufacturer whenperforming voltage tests. Observe thefollowing precautions when performingvoltage tests: (1) Remove all jewelry.(2) Standonadry, approvedelectricallyinsulated mat. (3) Do not touch theenclosure or components inside theenclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Hot Parts

Hot coolant and steam.Can cause severe injury or death.

Before removing the pressure cap,stop the generator set and allow it tocool. Then loosen the pressure capto relieve pressure.

WARNING

Notice

NOTICE

This generator set has beenrewired from its nameplate voltageto

246242

NOTICEVoltage reconnection. Affix a noticeto the generator set after reconnectingthe set to a voltage different from thevoltage on the nameplate. Ordervoltage reconnection decal 246242from an authorized servicedistributor/dealer.

NOTICEFuse replacement. Replace fuseswith fuses of the same ampere ratingand type (for example: 3AB or 314,ceramic). Do not substitute clearglass-type fuses for ceramic fuses.Refer to the wiring diagram when theampere rating is unknown orquestionable.

NOTICESaltwater damage. Saltwater quicklydeteriorates metals. Wipe up saltwateron and around the generator set andremove salt deposits from metalsurfaces.

TP-6862 6/148 Safety Precautions and Instructions

Notes

TP-6862 6/14 9Section 1 Introduction

Section 1 Introduction

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

The safe and successful operation of a marine powersystem depends primarily on the installation. SeeFigure 1-1. Use this manual as a guide to install themarine generator set. For operating instructions, referto the operation manual.

Note: Only qualified persons should install thegenerator set.

Marine generator set installations must comply with allapplicable regulations and standards.

Use the specification sheets as a guide in planning yourinstallation. Use current dimension drawings andwiringdiagrams.

1 3

7

8

6

10

11

12

13

1415

16

17

18

19

20

21

ADV8500-

1. Exhaust mixer elbow (exhaust/water outlet)2. Fuel return connection3. Heat exchanger (not shown)4. Fuel feed pump *5. Fuel inlet connection6. Seawater pump (seawater inlet)7. Coolant recovery tank (located on the unit on somemodels)8. Seawater strainer *9. Seawater inlet connection10. Seawater line *11. Seacock *

12. Craft stringers13. Fuel/water separator (see Section 5 for more information)14. Fuel supply line *15. Hose clamps16. Fuel return line *17. Mounting skid18. Battery/battery storage box19. Battery cables20. Exhaust hose or exhaust line *21. Electrical leads (AC output leads/remote start panel leads)

* Indicated components must conform to USCG regulations.

2 5

9

4

Figure 1-1 Typical Generator Set Location and Mounting (40EOZDJ Model Shown Without Sound Shield)

Note: See text for complete explanation of installationrequirements.

Note: Use two hose clamps on each end of all flexibleexhaust hose connections.

TP-6862 6/1410 Section 1 Introduction

Notes

TP-6862 6/14 11Section 2 Location and Mounting

Section 2 Location and Mounting

2.1 General Considerations

The key to installation is location. Before making finalplans for locating a generator set, consider thefollowing.

Installation Location Considerations

1. Choose a location that allows adequate space forcooling and exhaust system installation, fuelsystem installation, ventilation, and service accessto the generator set (engine and generator).

2. Use craft stringers or other available structuralmemberscapableof supporting thegenerator set’sweight.

3. Seal the generator set’s engine room from thecabin to prevent exhaust gases and fuel vaporsfrom entering the cabin.

See the current generator set specification sheet orSection 7 of this manual for generator set dimensionsand weights. See Figure 1-1 for a typical installation.

2.2 Location

Locate the generator set to allow easy service access tothe generator set’s engine, controller, cooling, and fuelsystem components. The engine compartment is oftenthe ideal location for the generator set if the propulsionengine(s) does not obstruct access to the generator setand controller.

Marine Generator Set Installations inEuropean Union Member Countries

This generator set is specifically intended and approvedfor installation below the deck in the enginecompartment. Installation above the deck and/oroutdoorswould constitute a violation of EuropeanUnionDirective 2000/14/EC noise emission standard.

Allow clearance for vibration and cooling duringoperation. Allow a minimum of 38 mm (1.5 in.)clearance on all sides (top, front, rear, and sides) of agenerator set without an optional sound shield. Forsound-shielded units, allow 305 mm (12 inches)minimum clearance for the left-rear door and front door(intake and discharge openings). Also, allow space forthe power takeoff (PTO) option, if equipped.

Kohler ignition-protected generator sets carry aUL1500marinemark (decal). Check for this mark to ensure thatyour specific model is ignition protected. USCGRegulation 183.410 requires ignition-protected devicesonly in gasoline/gaseous-fueled environments.

2.3 Mounting

Mount the generator set as high as possible to avoidcontact with bilge splash and lower-lying vapors and toallow for downward pitch of the exhaust line toward theexhaust outlet.

Kohler Co. recommends mounting the generator set ona flat board attached to the craft stringers. Craftstringers generally provide the best generator setsupport. Ensure that the structural members cansupport the generator set’s weight and withstand itsvibration.

The generator set includes vibration mounts and amounting tray or skid. If desired, install additionalvibration isolating pads underneath the generator set’sbase. Use the four mounting holes in the mounting trayto mount the generator set securely to the craft.

For angular operating limits, consult the operationmanual.

TP-6862 6/1412 Section 2 Location and Mounting

Notes

TP-6862 6/14 13Section 3 Cooling System

Section 3 Cooling System

3.1 Ventilation

Engine combustion, generator cooling, and expulsion offlammable and lethal fumes require ventilation. Provideventilation compliant with USCG regulations governingthe sizing of vents and other considerations.

As a rule, size each inlet- and outlet-vent area to aminimum of 13 sq. cm/30.5 cm (2 sq. in. per ft.) of thecraft’s beam. Should this rule conflict with USCGregulations, follow USCG regulations. For applicationswith screened inlets, double the size (4 sq. in. per ft.) ofthe hull/deck openings. Extend the vent ducts to bilges toexpel heavier-than-air fumes.

For generator setsmounted in the engine compartment,increase the air flow to allow for the generator set’srequirements. Install optional detection devices tocause alarm, warning, or engine shutdown shoulddangerous fumes accumulate in the compartment.

See the generator set specification sheet that shippedwith the generator set for air requirements. The air intakesilencer/cleaner provides combustion air to the engine.Do not compromise the recommended minimumclearance (shown in Section 2) between a duct openingand enclosure wall. The engine/generator performancewill decline if you compromise these guidelines. SeeFigure 3-1 for allowable intake restriction.

Note: ISO 3046 derates apply. See Appendix C.

ModelAllowable

Intake Restriction

40--150EOZDJ/EOZCJ33--125EFOZDJ/EFOZCJ

25 in. H2O(6.25 kPa) or less

Figure 3-1 Combustion Air Intake Restriction

3.2 Cooling System Components

Design the marine generator set’s cooling system toinclude the following features.

3.2.1 Intake Through-Hull Strainer(Seacock Cover)

Install a screened-intake, through-hull strainer toprevent entry of foreign objects. Use perforated,slotted-hole, or unrestricted-hole design strainers. SeeFigure 3-2 for examples of typical strainers. The innerdiameter of the strainer opening must be equal to orgreater than the inner diameter of the water line hose tothe seawater pump.

1

2

34

55982--3.1

1. Inside packing2. Outside packing3. Seacock cover4. Direction of vessel movement5. Typical intake through-hull strainers

Figure 3-2 Seacock Installation

Do not align the strainer (in relation to the direction oftravel) with any other through-hull intakes. SeeFigure 3-3. Flush mount the recommended through-hullstrainer. Install slotted-hole-design strainers with theslots parallel to the direction of the vessel’s movement.

Note: Position the intakes in relation to the vessel’stravel so neither is in the wake of the other.

1

3 2

5982--3.2

1. Generator set intake2. Aft (rearward)3. Fore (forward)

or or

Figure 3-3 Intake Strainer

TP-6862 6/1414 Section 3 Cooling System

Do not use a speed scoop or cup design intakethrough-hull strainer because it can cause a rammingeffect and force water upward, past the seawater pump,and into the engine cylinders when the vessel is movingand the generator set is shut down.

Do not use hull designs incorporating sea chests orother designs that provide a positive pressure to the rawwater pump for the intake through-hull strainers.Positive pressure forces water past the rawwater pumpand into the engine. A sea chest is a concavemolded-in-the-hull chamber that aligns to the directionof travel. A sea chest configuration applies a positivepressure similar to a scoop-type through-hull strainer.

3.2.2 Seacock

Mount the seacock to the hull, assemble it to the intake,andensure that it is accessible for operation. Figure 3-2shows a typical installation.

Avoid overcaulking the seacock. Excess caulk reduceswater flow and, in some cases, develops a barrier thatcan force water upward, past the seawater pump, andinto the engine cylinders when the vessel is moving andthe generator set is shut down.

3.2.3 Seawater Strainer

123

5982--3.3

1. Seawater pump2. Seawater strainer3. Seacock

Figure 3-4 Seawater Strainer

Mount the seawater strainer to the seacock orpermanent structure at a point not higher than theseawater pump. Ensure that the strainer is accessiblefor service. See Figure 3-4 for a typical installation.

Some seawater strainers include a seacock and anintake through-hull strainer.

Maximumseawater inlet pressureat the seawater pumpis 34.5 kPa (5 psi). Excessive pressurewill causewateringestion.

3.2.4 Water Lines

Water lines from the seacock to the engine-drivenseawater pump are usually constructed of flexible hose.Connect a flexible section of hose to the seawater pumpto allow for vibrationalmotion of the generator set duringoperation. Support a nonflexible water line within102 mm (4 in.) of its connection to the flexible section.

Keep the seawater hose as straight and short aspossible. If the hose is too long, usually over 4.6 m(15 ft.), water suction problems may occur. SeeSection 7 for the inlet water line hose size and theseawater connection to the seawater pump inlet. Avoidrunning the inlet pipe above the generator. SeeFigure 3-5 for the seawater inlet connection.

1

ADV8500A-1. Seawater pump2. Seawater inlet (opposite side)

2

Figure 3-5 Seawater Inlet Connection (Located onnon-service side), Typical

3.2.5 Closed Heat Exchanger

A closed heat exchanger is the best cooling method formost applications. See Figure 3-6 for a typicalinstallation. Provide space to access the water-cooledexhaust manifold pressure cap.

TP-6862 6/14 15Section 3 Cooling System

Seawater

Freshwater (Coolant/Antifreeze)

TP-5592-6

1 23

4 5

67

8

9

10

11

12

13

14

1. Oil cooler2. Engine block3. Thermostat4. Water-cooled manifold5. Heat exchanger6. Exhaust mixer elbow7. Water-cooled turbocharger

8. Silencer (customer-supplied)9. Exhaust outlet10. Intake strainer11. Seacock12. Seawater strainer13. Engine-driven seawater pump14. Engine-driven water pump

Figure 3-6 Typical Closed/Heat Exchanger Cooling System (40--99EOZD(C)J/33--80EFOZD(C)J Models)

TP-6862 6/1416 Section 3 Cooling System

* If a single fill/vent line between the expansion tank and the engine cannot be used, separate lines must be used for filling and venting thetank. A 1/4 in. (6mm) vent line is routed from the engine top tank to theexpansion tank. Theexpansion tank fill line goes from the bottomofthe expansion tank to the top of the keel cooler return line. A separate line, dedicated to filling the system,must be sized tomeet the fill raterequirements published by the engine manufacturer.

Overflow bottle ortank with cap

Keel CoolerHull

1 1/4 in. (31.75 mm) ID fill/vent line witha slope not less than 30 degrees *

Bypass

Water pump

Return LineOutlet Line

Inlet Line Engine Block &Exhaust Manifold

Figure 3-7 Keel Cooling System Installation (Single Fill/Vent Line)

3/4” min. fill lineto water pump inlet.(Tee in as close to the enginepump inlet as practical incustomer-supplied piping).

1/4” max. vent linesfrom high points insystem to top of tank.

Figure 3-8 Keel Cooling System Installation (Multiple Vent Lines)

TP-6862 6/14 17Section 4 Exhaust System

Section 4 Exhaust System

Carbon monoxide.Can cause severe nausea,fainting, or death.

The exhaust system must beleakproof and routinely inspected.

WARNING

Carbon monoxide symptoms. Carbon monoxide cancause severe nausea, fainting, or death. Carbonmonoxideis a poisonous gas present in exhaust gases. Carbonmonoxide is an odorless, colorless, tasteless, nonirritating gasthat can cause death if inhaled for even a short time. Carbonmonoxide poisoning symptoms include but are not limited tothe following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptoms and carbon monoxidepoisoning is possible, seek fresh air immediately and remainactive. Do not sit, lie down, or fall asleep. Alert others to thepossibility of carbon monoxide poisoning. Seek medicalattention if the condition of affected persons does not improvewithin minutes of breathing fresh air.

Inspecting the exhaust system. Carbon monoxide cancause severe nausea, fainting, or death. For the safety ofthe craft’s occupants, install a carbon monoxide detector.Never operate the generator set without a functioning carbonmonoxide detector. Inspect the detector before eachgenerator set use.

Operating thegenerator set. Carbonmonoxide cancausesevere nausea, fainting, or death. Be especially careful ifoperating the generator set when moored or anchored undercalm conditions because gases may accumulate. If operatingthe generator set dockside, moor the craft so that the exhaustdischarges on the lee side (the side sheltered from the wind).Always be aware of others, making sure your exhaust isdirected away from other boats and buildings.

4.1 Types

Kohlerr generator sets covered in this manual useeitherwet or dry exhaust systems. Dryexhaust systemsare common in commercial applications. See theengine manual for specifications.

Note: Silencer selection is the responsibility of theinstaller butmustmeet theparameters outlined inthis manual.

4.2 Exhaust Lines

Use water-cooled exhaust lines in all marineinstallations. Keep the lines as short and straight aspossible. NFPA 302 Fire Protection Standard forPleasure and Commercial Motor Craft, Clause 4-3,recommends using two corrosion-resistant hoseclampswith aminimumwidth of 13mm (1/2 in.) on eachend of the flexible exhaust hose connections.Kohler Co. requires a downward pitch of at least 13mmper 30.5 cm (1/2 in. per running foot). Use a flexibleexhaust hose that conforms toULStandard 1129 for theengine’s wet exhaust components between the mixerelbow and the exhaust outlet.

SeeFigure 4-1 forminimumrecommendedexhaust linehose selection. See Section 7 for exhaust outlet sizeand location.

Models

Min.Wet Exhaust

HoseDiametermm (in.)

Min.Dry Exhaust

HoseDiametermm (in.)

40EOZD(C)J33EFOZD(C)J 89 (3.5) 89 (3.5)

40/50EFOZD(C)J 102 (4.0) 102 (4.0)

55/65EOZD(C)J45/55EFOZD(C)J 102 (4.0) 102 (4.0)

80/99EOZD(C)J70/80EFOZD(C)J 127 (5.0) 102 (4.0)

125/150EOZD(C)J100/125EFOZD(C)J 127 (5.0) 102 (4.0)

Figure 4-1 Exhaust Hose Sizes (Minimum)

TP-6862 6/1418 Section 4 Exhaust System

4.3 Sound Shielded Units with DryExhaust

For units equippedwith a dry exhaust and sound shield,insulate theexhaust system insideof the sound shield tothe turbocharger/manifold. Use fiberglass exhausttape/wrap (or equivalent) and securewith stainlesswire(or material suitable for use in a marine environment).The exhaust system around the elbow inside of thesound shield must be insulated so that temperatures donot exceed 88_C (190_F). See Figure 4-2.

1

1. Dry exhaust elbow2. Turbocharger

2

Figure 4-2 Dry Exhaust/Turbocharger Location(Shown with Sound Shield removed)

4.4 Exhaust System Location,Mounting, and Installation

Note: Should any information regarding installationconflict with USCG regulations, follow USCGregulations.

Mount the silencer independently to eliminate stress onthe exhaust system and the exhaust manifold/mixerelbow. SeeSection7 for themixer elbowwater linehosesize. See Figure 4-3 for the exhaust connection to themixer elbow. Provide an adequate hose length from theexhaust mixer to the silencer to allow for generator setmovement.

1

ADV8501B-1. Exhaust outlet

Alternator-End View

Figure 4-3 Mixer Elbow/Exhaust Connection,Typical

Locate the exhaust outlet at least 10 cm (4 in.) above thewaterlinewhen the craft is loaded tomaximumcapacity.Install an exhaust port with the flap at the exhaust(transom) outlet to prevent water backup in followingseas or when moving astern (backward). A lift in theexhaust piping before the piping exits the craft preventsbackwash. SeeFigure 4-5, item2. Support the exhaustlines to prevent the formation of water pockets.

Exhaust system installation guidelines for variousgenerator set locations follow. Information andillustrations of stern- (rear) exhaust installations alsoapply to side-exhaust installations. Whereexhaust linesrequire passage through bulkheads, use port (left)- orstarboard (right)- side exhaust outlets, also inapplications in which long exhaust lines to the transom(rear) could cause excessive back pressure. SeeFigure 4-4 for allowable back pressures.

Model

MaximumAllowable

Exhaust BackPressure,≤kPa

(in. H2O)

40--150EOZDJ/EOZCJ33--125EFOZDJ/EFOZCJ 7.5 (30) *

* Under ALL engine loading conditions.

Figure 4-4 Allowable Exhaust Back Pressures


4.4.1 Above-Waterline Installation

Install a customer-supplied silencer with the silencer’soutlet at a maximum of 3 m (10 horizontal ft.) from thecenter of the engine’s exhaust outlet. See Figure 4-5.Mount a typical silencer with the inlet and outlethorizontal andwith thedrain plugdown. Useanexhaust

hose pitch of at least 13 mm per 30.5 cm (0.5 in. perrunning foot). Some silencers require two supportbrackets or hanger straps for installation to stringers orother suitable structure. Follow the instructionsprovided with the silencer. Install any lift (seeFigure 4-5, item 2) in the exhaust line below the engineexhaust manifold outlet.

12 3

4

6 78

9

10

11

12

13

14

15

17

18

Note: Data applies to both rear- and side-exhaust installations.

Note: Numbers in illustration refer to callouts below and not todimensions.

Note: Read the text for complete explanation of dimensions andother installation considerations.

Note: Use twohoseclampsoneachendof all flexible exhaust hoseconnections.

Note: Damagecausedbywater ingestionwill not becoveredby thegenerator warranty.

1. Minimum exhaust outlet distance above waterline of 10 cm(4 in.). Note: Vessel fully loaded

2. Slight lift improves silencing and prevents water backwashinto the silencer (keep below the level of the exhaustmanifold outlet)

3. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.per ft.)

4. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.per ft.)

5. Exhaust manifold outlet6. Exhaust mixer elbow7. Heat exchanger (locations vary by model)8. Coolant recovery tank (located on the unit on some models)9. Locate the coolant recovery tank at the same height as the

heat exchanger

10. Maximum seawater pump lift of 3 m (10 ft.)11. Seawater strainer12. Intake strainer13. Seacock14. Engine-driven seawater pump15. Maximum distance between silencer and exhaust mixer

elbow of 3 m (10 ft.)16. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)17. Silencer (customer-supplied)18. Waterline19. Maximum silencer vertical lift of 1.2 m (4 ft.)20. Kohler recommends locating the generator set at elevation

that exhaust mixer is above the highest point of the exhaustoutlet hose.

20

16

19

5

Figure 4-5 Typical Above-Waterline Installation


4.4.2 Mid/Below-Waterline Installation

Follow USCG regulations for installing an antisiphonprovision to prevent raw water entry into the engine.Use the siphon break if the exhaust manifold outlet islocated less than 23 cm (9 in.) above thewaterlinewhenthe craft is loaded to maximum capacity. Install thesiphon break at least 31 cm (1 ft.) above the waterlineusing the instructions providedwith the siphon break kit.

Note: An improperly installed siphon break will causeengine damage and may void the warranty.

Install the siphon break above the highest point in theexhaust line between the heat exchanger and theexhaust mixer. See Figure 4-6 for the siphon breakconnection. Support the siphon break and hoses tomaintain their position and function. Allow a slight offsetto clear the stringers or other permanent structures.Protect the siphon break air inlet from dirt and debris.

Note: Topreventwater leakageon thegenerator set, donot mount the siphon break directly over thegenerator set.

Note: Ensure that the siphon break’s cap is tight beforeoperating the generator set.

1

ADV8501B-

1. Cut hose and connect siphon break and hardware

Non-Service Side View

Figure 4-6 Siphon Break Connection (Typical forNon-Sound Shielded Units)

Mount a typical silencer’s basenomore than1.2m (4 ft.)below the highest point in the exhaust line. Attach aseparate wood mounting base to the hull stringers orother suitable structures. Use the silencermanufacturer’s recommendation for securing thesilencer to the hull. Mount the silencerwith the outlet notmore than 3 m (10 horizontal ft.) from the engine’sexhaust manifold outlet. Use a USCG-type certifiedmarine exhaust hose.


Waterline

7

14

13

1215

109

8

19

1120

6

17

45

22 16

23

1. Cap2. Reed valve3. Mounting base4. Maximum silencer vertical lift of 1.2 m (4 ft.)5. Exhaust mixer elbow distance above waterline; if less than

23 cm (9 in.), a siphon break is required6. Minimum siphon break distance above waterline of 30.5 cm

(1 ft.)7. Siphon break8. Exhaust mixer elbow9. Heat exchanger (locations vary by model)10. Coolant recovery tank (located on the unit on some models)11. Indicates the coolant recovery tank is at the sameheight as the

heat exchanger12. Seawater strainer13. Seacock14. Intake strainer15. Engine-driven seawater pump16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in. per ft.)17. Maximumdistance between silencer and exhaustmixer elbow

of 3 m (10 ft.)18. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)19. Silencer (customer-supplied)20. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm

(0.5 in. per ft.)

21. Maximum distance between exhaust outlet and generator of4.6 m (15 ft.)

22. Minimum exhaust outlet distance above waterline of 10 cm(4 in.)

23. Exhaust hose, exhaust gas outlet hose after separator. SeeFigure 4-1 for hose sizes.

24. Gas/water separator (optional). Install directly above thecanister muffler.

25. Distance abovewaterline for drain outlet from silencermust beequal to or greater than water drain (item 26) to be greaterthan 30.5 cm (1 ft.)

26. Water drain distance below waterline27. Water drain (separated water from item 24)28. System installer is responsible for designing enough capacity

into the lift muffler and plumbing to prevent engine wateringestion upon shutdown. Otherwise, water will drain backinto item 19 on generator set shutdown.



Note: Use two hose clamps on each end of all flexible exhausthose connections.

Note: Data applies to both rear- and side-exhaust installations.Note: Damage caused by water ingestion will not be covered by

the generator warranty.

21

24

2

1

3

18

25

26

28

27

Figure 4-7 Typical Mid- and Below-Waterline Installation with Optional Gas/Water Separator







1

4

57

89

13

14

15

16

1718

19

21

20

23

24


2. Exhaust hose (see Figure 4-1 for hose sizes)3. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.

per ft.)4. Maximum silencer vertical lift of 1.2 m (4 ft.)5. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.

per ft.)6. Exhaust mixer elbow distance above waterline; if less than


(1 ft.)8. Exhaust mixer elbow9. Siphon break10. Cap11. Reed valve12. Mounting base13. Heat exchanger (locations vary by model)

14. Coolant recovery tank (located on the unit on some models)15. Indicates the coolant recovery tank is at the same height as

the heat exchanger16. Seawater strainer17. Seacock18. Intake strainer19. Engine-driven seawater pump20. Install optional water lock here21. Maximum distance between silencer and exhaust mixer

elbow of 3 m (10 ft.)22. Maximum distance between silencer and exhaust outlet of

1.5 m (5 ft.)23. Silencer (customer-supplied)24. Waterline25. Kohler recommends locating the generator set at elevation

that exhaust mixer is above the highest point of the exhaustoutlet hose.

25

22

2

6

3

10

1112

Figure 4-8 Typical Mid- and Below-Waterline Installation


1

1. Cap2. Reed valve3. Mounting base4. Maximum silencer internal vertical lift of 1.2 m (4 ft.)5. Exhaust mixer elbow distance above waterline; if less than


(1 ft.)7. Siphon break8. Exhaust mixer9. Heat exchanger10. Coolant recovery bottle11. Indicates the coolant recovery tank is at the same height as

the heat exchanger12. Seawater strainer13. Seacock14. Intake strainer15. Engine-driven seawater pump16. Minimum exhaust hose pitch of 1.3 cm per 30.5 cm (0.5 in.

per ft.)

17. Maximum distance between silencer and exhaust mixer elbowof 3 m (10 ft.)

18. Water drain distance below waterline19. Combination silencer that contains lift muffler and gas water

separating sections in single component (customer-supplied)20. Distance above waterline for drain outlet from silencer must

be equal to or greater than water drain (item 18) to be greaterthan 30.5 cm (1 ft.)

21. Exhaust outlet to be diameter appropriate so exhaust backpressure does not exceed limit at engine exhaust manifold


23. Exhaust hose24. Height of internal lift tube to be below generator exhaust

manifold25. Kohler recommends generator be located at elevation that

exhaust mixer elbow is above silencer exhaust outlet26. Seawater pump lift27. Waterline

23

4

5

6

7

8

9

10

11

12

13

14

15

16

1718

19

20

21

22

2425

26

23

16

16

27






Figure 4-9 Exhaust System


Satisfactory generator set performance requires properexhaust system installation. Figure 4-10 andFigure 4-11 show typical arrangements for commercialmarine exhaust systems.

1

3 24

56

7 8

TP-5700-51. Supports2. Pitch line downward3. Silencer4. Water trap

5. Drain petcock6. Flexible section7. Solid section 152--203 mm (6--8 in.)8. Manifold

NOTE: Horizontalsilencer shown.

Figure 4-10 Exhaust System, End Inlet Silencer

2

65

1

8

71. Silencer2. 45 Y fitting3. Water trap4. Drain petcock

3

4

5. Outer diameter adapter and clamp6. Flexible section7. Manifold8. 45 elbow


Figure 4-11 Exhaust System, Side Inlet Silencer

Ensure that there is a means to periodically draincondensation in exhaust, such as a silencer equippedwith a drain plug (see Figure 4-12), or awye- or tee-typecondensation trap with a drain plug, or petcock installedbetween the engine and silencer (see Figure 4-13).

1

TP-5700-51. Pipe Plug


Figure 4-12 Silencer Condensation Drain Plug

1

TP-5700-51. Condensation trap


Figure 4-13 Condensation Trap

TP-6862 6/14 25Section 5 Fuel System

Section 5 Fuel System

Explosive fuel vapors.Can cause severe injury or death.

Use extreme care when handling,storing, and using fuels.

WARNING

Do not modify the tank or the propulsion engine fuelsystem. Equip the craft with a tank that allows one of thetwo pickup arrangements.

Note: Fuel system installations must conform to USCGregulations.

5.1 Fuel Tank

Mostmarinegenerator sets draw fuel from the same fueltank as the craft’s propulsion engine(s). If the tank’s fuelpickup opening allows amultiple dip tube, use amultipledip tube arrangement. See Figure 5-1. Themultiple diptubearrangement incorporates a shorter dip tube for thegenerator set and a longer dip tube for the propulsionengine. With this arrangement, the generator set runsout of fuel before the propulsion engine during a low fuelsupply situation. Equip the fuel systemwith a fuel/waterseparator to remove any accumulated dirt and water.

2

1-788

1

1. Fuel line to propulsion engine2. Fuel line to generator set

Figure 5-1 Multiple Dip Tube Arrangementm:is:102:001

TP-6862 6/1426 Section 5 Fuel System

5.2 Fuel Lines

Return the generator set fuel return line to the fuel tank.Locate the fuel return line as far as practical from the fuelpickup to allow the tank fuel to cool the return fuel beforedelivery back to the fuel injectors. Incoming fuel coolsthe injectors to achieve maximum engine efficiency.

Note: Do not tee into the main propulsion engine’s fuelline.

Under no circumstances should the propulsion engineandgenerator set sharepickupor return lines (throughatee arrangement) that would allow the larger engine tostarve fuel from the smaller engine. It is possible that theoperation of either engine could completely drain thefuel line of the other engine and make starting difficult.

Use a flexible hose section to connect the metallic linefrom the fuel tank to the engine’s fuel pump inletconnection point. Also, use a flexible hose section toconnect the metallic line from the fuel tank to the fuelreturn connection point. The flexible section allowsvibrational motion of the generator set during operation.

Model

Fuel LineID Sizemm (in.)

40--150EOZDJ/EOZCJ40--125EFOZDJ/EFOCJ 9.7 (3/8)

Figure 5-2 Fuel Line ID Size

See Figure 5-2 for the ID size of the customer-suppliedfuel line that connects to the fuel pump and fuel return.Route the fuel lines from the fuel tank in a gradual inclineto the engine. Do not exceed the height of the generatorset and do not route fuel lines above the generator set.Comply with USCG regulation 46CFR182.20 regardingfuel lines and supports.

See Section 7 for fuel feed pump inlet connection andfuel return line connection.

5.3 Fuel Filters

Conform to USCG regulations regarding inline fuelfilters or strainers.

5.4 Fuel/Water Separator

A fuel/water separator is standard on 33--150 kWmodels. Consult the engine operation manual forservice procedure.

5.5 Fuel Pump Lift

See Figure 5-3 for fuel pump lift capabilities.

ModelFuel Pump Lift

m (ft.)

Pleasure Craft:40EOZDJ/33EFOZDJ40EFOZDJ50EFOZDJCommercial Craft:40EOZCJ/33EFOZCJ40EFOZCJ50EFOZCJ

3 (10)

Pleasure Craft:55EOZDJ/45EFOZDJ65EOZDJ/55EFOZDJ80EOZDJ/70EFOZDJ99EOZDJ/80EFOZDJ125EOZDJ/100EFOZDJ150EOZDJ/125EFOZDJCommercial Craft:55EOZCJ/45EFOZCJ65EOZCJ/55EFOZCJ80EOZCJ/70EFOZCJ99EOZCJ/80EFOZCJ125EOZCJ/100EFOZCJ150EOZCJ/125EFOZCJ

2.4 (7.9)

Figure 5-3 Fuel Pump Lift

5.6 Fuel Consumption

Consult the current generator set specification sheetsfor generator set fuel consumption rates.

TP-6862 6/14 27Section 5 Fuel System

1 23

4

5

6

7

9

1011

12

13

14

1. Electric fuel or mechanical check valve2. Permanent supports for fuel system

components3. Fuel lift pump4. Flexible line

5. Fuel return line (diesels only)6. Carburetor or injection pump7. Secondary filter8. Primary filter9. Flexible fuel line

10. Clamp11. Support clamp12. Metallic line13. Dip tube14. Fuel tank

2

8

Figure 5-4 Fuel System, Typical

* Anti-siphon protection is required for gasoline-powered units if diptube opening is below the waterline.

Fuel Return (Diesel Only)(Below Fluid Level)

Fuel Supply

Check Valve(Optional) *

12 in.min.

Baffles

Main Fuel TankDrain Valve

Fuel Lift

Figure 5-5 Fuel System, Typical

TP-6862 6/1428 Section 5 Fuel System

Notes

TP-6862 6/14 29Section 6 Electrical System

Section 6 Electrical System



Moving parts.

WARNING

Electrical backfeed to the utility. Hazardous backfeedvoltage can cause severe injury or death. Connect thegenerator set to the building/marina electrical system onlythrough an approved device and after the building/marinamain switch is turned off. Backfeed connections can causesevere injury or death to utility personnel working on powerlines and/or personnel near the work area. Some states andlocalities prohibit unauthorized connection to the utilityelectrical system. Install a ship-to-shore transfer switch toprevent interconnection of the generator set power and shorepower.

6.1 AC Voltage Connections

Make AC connections to the generator set inside thejunction box. Typically, the generator set connects to aship-to-shore transfer switch that allows the use ofshore/utility power when docked or generator set powerwhen docked or at sea. The wiring then connects to amain circuit breaker box (panel board) that distributesbranch circuits throughout the craft. See Section 8 forreconnection of the generator set.

6.2 Circuit Protection

The AC circuit breakers (optional) protect the wiringfrom the AC circuit breakers to the vessel’s distributionpanel. ACcircuit breakers tripwhen theydetect a fault inthe output circuit.

After correcting the fault, reset the AC circuit breaker(s) byplacing them in the ON position. Restart the unit. Do notstart the unit under load. See Figure 6-1 and Figure 6-2for AC circuit breaker ratings. The unit’s voltageconfiguration determines the circuit breaker selection.

Note: Circuit breaker ampere rating and availability aresubject to change.

6.2.1 Circuit Breaker Considerations

Mounting location. Mount the circuit breakers in thegenerator set’s junction box. See Section 6.2.2.

Sizing. Use the generator set voltage/frequencyconfiguration to determine the circuit breakeramperage. If the generator set voltage configurationchanges, change the circuit breaker to provide optimumprotection.

For circuit breaker application and selectioninformation, contact an authorized distributor/dealer.

Have a qualified electrician or technician install circuitbreakers and reconnect the generator set. Comply withall governing standards and codes.

AmpsMax.

Voltage Model(s)

70 600 40EOZD(C)DJ, 33EFOZD(C)J

80 600 40EFOZD(C)J, 45EFOZD(C)J

90 480 40EFOZD(C)J, 45EFOZD(C)J

100 480 55EOZD(C)J, 45EFOZD(C)J, 50EFOZD(C)J

125 480 50EFOZD(C)J, 65EOZD(C)J, 55EFOZD(C)J

125 600 33EFOZD(C)J

150 480 80EOZD(C)J, 70EFOZD(C)J

150 600 40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J

175 480 99EOZD(C)J, 70EFOZD(C)J 80EFOZD(C)J

175 600 40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J,45EFOZD(C)J

200 600 40EFOZD(C)J, 50EFOZD(C)J, 55EOZD(C)J

250 60050EFOZD(C)J, 55EOZD(C)J, 45EFOZD(C)J,65EOZD(C)J, 55EFOZD(C)J, 125EOZD(C)J,

100EFOZDJ(C)J

400 60080EOZD(C)J, 70EFOZD(C)J, 99EOZD(C)J,

80EFOZD(C)J, 150EOZD(C)J,100EFOZD(C)J, 125EFOZD(C)J

600 600 125EOZD(C)J 150EOZD(C)J,100EFOZD(C)J, 125EFOZD(C)J

Figure 6-1 3-Pole AC Circuit Breaker Ratings(33--150 kW Models), Listed By Amps

TP-6862 6/1430 Section 6 Electrical System

Amps Model(s)

63 33EFOZD(C)J

80 40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J,45EFOZD(C)J

100 40EFOZD(C)J, 50EFOZD(C)J, 55EOZD(C)J,45EFOZD(C)J

125 33EFOZD(C)J, 50EFOZD(C)J, 65EOZD(C)J,55EFOZD(C)J

160 40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J,80EOZD(C)J, 70EFOZD(C)J

200 40EOZD(C)J. 40EFOZD(C)J, 50EFOZD(C)J,55EOZD(C)J, 45EFOZD(C)J

25050EFOZD(C)J, 55EOZD(C)J, 45EFOZD(C)J,65EOZD(C)J, 55EFOZD(C)J, 125EOZD(C)J,

100EFOZD(C)J

400 80EOZD(C)J, 70EFOZD(C)J, 100EFOZD(C)J,150EOZD(C)J, 125EFOZD(C)J

630 125EOZD(C)J, 100EFOZD(C)J, 150EOZD(C)J,125EFOZD(C)J

Figure 6-2 4-Pole AC Circuit Breaker Ratings(33--150 kW Models), Listed By Amps



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.



Moving parts.

WARNING

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or appliances when standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Short circuits. Hazardous voltage/current can causesevere injury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while making adjustments orrepairs. Remove all jewelry before servicing the equipment.

Electrical backfeed to the utility. Hazardous backfeedvoltage can cause severe injury or death. Connect thegenerator set to the building/marina electrical system onlythrough an approved device and after the building/marinamain switch is turned off. Backfeed connections can causesevere injury or death to utility personnel working on powerlines and/or personnel near the work area. Some states andlocalities prohibit unauthorized connection to the utilityelectrical system. Install a ship-to-shore transfer switch toprevent interconnection of the generator set power and shorepower.

6.2.2 Circuit Breaker Installation

1. Place the generator set master switch in the OFFposition.

2. Disconnect the generator set engine startingbattery, negative (--) lead first.

3. Remove the six screws from the right side junctionbox panel and remove the panel.

4. Install the circuit breaker on the new panel with thescrews and washers. Position the ON side of thecircuit breaker toward the rear of the junction box.See Figure 6-3.

5. Attach stator leads L1, L2, and L3 to the extensionleads (if supplied) or to the line side of the circuitbreaker. See Figure 8-3.

Note: Insulate leads with electrical tape afterconnecting extension leads to stator leads.

6. Connect the neutral connection stator leads to theL0 stud.

Note: Verify that terminal positions and previouslymade line lead connections allow room forload connections to load studs.

7. Connect the load side of the circuit breaker tocustomer-supplied craft wiring. Connect theneutral lead to the L0 stud. See Figure 8-3.

8. Attach the new panel to the junction box using theoriginal six screws. See Figure 6-3.


9. Check that the generator setmaster switch is in theOFF position. Reconnect the generator set enginestarting battery, negative (--) lead last.

JW250000

1. Circuit breaker2. Circuit breaker mounting panel3. Load lead access panel

4. Bus5. Hardware6. Bus line

Figure 6-3 Circuit Breaker Mounting, Typical


6.3 Installation In Steel orAluminum Vessels

Installation of a generator set in a vessel constructed ofa material capable of conducting current (e.g., steel oraluminum) is subject to considerations not normallyencountered in fiberglass or wood vessels. Thesedifferences include equipment grounding, grounding ofneutral conductors, ground-fault protection, andisolation of galvanic currents.

Note: Isolated ground kits are available as options forsteel- or aluminum-hulled vessels. Consult yourlocal dealer/distributor for more information.

The scope of these topics is too extensive to be fullydiscussed here. Consult your local marine authority formore information.

Before installing the generator set, check the availablewiring diagrams in the operation manual to becomefamiliar with the electrical system.

6.4 Installation Regulations

The U.S. Coast Guard governs generator setinstallation in U.S. pleasurecraft and commercialvessels. Refer to the applicable regulations below:

U.S. Pleasurecraft InstallationRegulations

Title 33CFR, Chapter I, U.S. Coast Guard, Part 183

1. Subpart I—Electrical Equipment

2. Subpart J—Fuel Systems

U.S. Commercial Vessel InstallationRegulations

Title 46CFR, Chapter I, U.S. Coast Guard

1. Part 111—Electrical Systems

2. Part 182—Machinery Installationm:sc:001:001

6.5 Battery

Batteries and their installation must conform to USCGRegulations 183.420 (a) through (g). Provide generatorsets with batteries separate from the propulsionengine’s whenever possible. The starting/chargingsystems of both the generator set and the engine musthave a common negative (--) ground.

USCG Regulation 183.415, Grounding, requiresconnection of a common conductor to each groundedcranking-motor circuit. Size the conductor to match thelarger of theengine’s twobattery cables. Figure 6-4 listsrecommended minimum cable sizes for generator setbattery connections at various generator set-to-batterydistances. Connecting a common conductor to eachgrounded cranking motor circuit prevents the startingmotor current from using alternative electrical pathsshould the crankingmotor ground circuit be restricted oropen because of oxidation or loose hardware.Alternative electrical paths include metallic fuel linesthat can pose a hazard. See Section 7 for locations ofthe battery connections to the generator set.

Required Battery Cable(Minimum)

Distance (from battery togenerator set) 2.5 m (8.3 ft.) 5 m (16.4 ft.)

Battery Voltage 12V 24V 12V 24V

40--65EOZDJ/EOZCJ33--50EFOZDJ/EFOZCJ # 0 # 4 # 3/0 # 2

80--99EOZDJ/EOZCJ70--80EFOZDJ/EFOZCJ # 2/0 # 2 # 4/0 # 1/0

125--150EOZDJ/EOZCJ100--125EFOZDJ/EFOZCJ # 2/0 # 2 # 4/0 # 1/0

Figure 6-4 Battery Cable Sizing Recommendations


Kohler Co. recommends using one 12-volt battery (ortwo for 24-volt systems, as the spec requires) to start thegenerator. See Figure 6-5 for minimum cold crankingamps (CCA) recommendations.

12-Volt Starting Battery Size CCAat --18C (0F) or 100 Amp. Hr.

Models CCA

40EOZDJ and 33EFOZDJ40EOZCJ and 33EFOZCJ 640

40EFOZDJ40EFOZCJ50EFOZDJ50EFOZCJ55EOZDJ and 45EFOZDJ55EOZCJ and 45EFOZCJ65EOZDJ and 55EFOZDJ65EOZCJ and 55EFOZCJ

625

80EOZDJ and 70EFOZDJ80EOZCJ and 70EFOZCJ99EOZDJ and 80EFOZDJ99EOZCJ and 80EFOZCJ125EOZDJ and 100EFOZDJ125EOZCJ and 100EFOZCJ150EOZDJ and 125EFOZDJ150EOZCJ and 125EFOZCJ

925

Figure 6-5 Battery Recommendations

6.6 Wiring

Use only stranded copper wire. Conform to USCGRegulations 183.425 through 183.460 for wire gaugesand insulation, conductor temperature ratings, sheathstripping, conductor support and protection, conductorterminals and splices, and over-current protection(circuit breakers, fuses). Use rubber grommets andcable ties as necessary to protect and secure the wirefrom sharp objects, the exhaust system, and movingparts.

6.7 Remote Connection

Kohler Co. offers several remote panels for connectionto the generator set. Contact your local Kohlerrdistributor/dealer for detailed descriptions. Kohler Co.also offers wiring harnesses in various lengths with aconnector keyed to the controller box connector. A“pigtail” harness is also offered which includes theappropriate connector on one end and has pigtails thatthe installer can use to connect to a customer-suppliedstart/stop switch or separate lights and hourmeter.Consult wiring diagrams, ADVs, and instruction sheetsfor connection information/details.

Note: Gauge senders. Gauge senders are availablefor most generator sets. If using customer-supplied gauges, be sure they are compatiblewith generator set senders. Contact anauthorized Kohlerr service distributor/dealer.Gauges and senders are available as serviceitems from an authorized Kohlerr servicedistributor/dealer.

Various wiring harnesses, Y-connectors, pigtailharnesses, remote control panels, and remoteannunciator panels are available.

6.8 Paralleling Generator Sets

See Section 9 for information on paralleling generatorsets.


Notes

TP-6862 6/14 35Section 7 Installation Drawings

Section 7 Installation Drawings

Use the drawings in this section for installationpurposes. Consult the supplier and verify that thedrawings are the most current for your specifications.Installation drawings showexhaust outlet locations, fuelinlet and return connections, siphon break locations,and battery connections. See Figure 7-1 for installationdrawing identification.

Model No. Drawing Page

40EOZD(C)J and 33EFOZD(C)J

open unit (sheet 1 of 2) ADV-8500A-A 36

open unit (sheet 2 of 2) ADV-8500B-A 37

with sound shield(not available on EOZCJ/EFOZCJ models)

ADV-8503- 38

with radiator ADV-8505A-A 48

with electric clutch ADV-8505B-A 49

with keel cooling & dry exhaust ADV-8505C-A 50

40EFOZD(C)J50EFOZD(C)J55EOZD(C)J and 45EFOZD(C)J65EOZD(C)J and 55EFOZD(C)J

open unit (sheet 1 of 2) ADV-8501A-A 39

open unit (sheet 2 of 2) ADV-8501B-A 40


ADV-8504- 41




80EOZD(C)J and 70EFOZD(C)J99EOZD(C)J and 80EFOZD(C)J

open unit (sheet 1 of 2) ADV-8506A-B 42

open unit (sheet 2 of 2) ADV-8506B-B 43


ADV-8507-A 44




125EOZD(C)J and 150EFOZD(C)J100EOZD(C)J and 125EFOZD(C)J

open unit (sheet 1 of 2) ADV-8508A- 45

open unit (sheet 2 of 2) ADV-8508B- 46


ADV-8509- 47



with keel cooling & dry exhaust ADV-8505D-A 51

Figure 7-1 Installation Drawings(33--150 kW Models)

TP-6862 6/1436 Section 7 Installation Drawings

ADV-8500A-ANOTE: Dimensions in [ ] are inch equivalents.

Figure 7-2 Dimension Drawing, 40EOZD(C)J & 33EFOZD(C)J (Open Unit Sheet 1 of 2)


ADV-8500B-ANOTE: Dimensions in [ ] are inch equivalents.

Figure 7-3 Dimension Drawing, 40EOZD(C)J & 33EFOZD(C)J (Open Unit Sheet 2 of 2)


ADV-8503-NOTE: Dimensions in [ ] are inch equivalents.

Figure 7-4 Dimension Drawing, 40EOZDJ & 33EFOZDJ (with Sound Shield)



Figure 7-5 Dimension Drawing, 40/50EFOZD(C)J & 55/65EOZD(C)J & 45/55EFOZD(C)J (Open Unit Sheet 1 of 2)



Figure 7-6 Dimension Drawing, 40/50EFOZD(C)J & 55/65EOZD(C)J & 45/55EFOZD(C)J (Open Unit Sheet 2 of 2)



Figure 7-7 Dimension Drawing, 40/50EFOZDJ & 55/65EOZDJ & 45/55EFOZDJ (with Sound Shield)


ADV-8506A-BNOTE: Dimensions in [ ] are inch equivalents.

Figure 7-8 Dimension Drawing, 80/99EOZD(C)J & 70/80EFOZD(C)J (Open Unit Sheet 1 of 2)


ADV-8506B-BNOTE: Dimensions in [ ] are inch equivalents.



ADV-8507-ANOTE: Dimensions in [ ] are inch equivalents.

Figure 7-10 Dimension Drawing, 80/99EOZDJ & 70/80EFOZDJ (with Sound Shield)


ADV-8508A-NOTE: Dimensions in [ ] are inch equivalents.



ADV-8508B-NOTE: Dimensions in [ ] are inch equivalents.




Figure 7-13 Dimension Drawing, 125/150EOZD(C)J & 100/125EFOZD(C)J (with Sound Shield)



Figure 7-14 Dimension Drawing, 40--150EOZD(C)J & 33--125EFOZD(C)J (with Unit-Mounted Radiator)



Figure 7-15 Dimension Drawing, 40--150EOZD(C)J & 33--125EFOZD(C)J (with Electric Clutch PTO)


ADV-8505C-ANOTE: Dimensions in [ ] are inch equivalents.

Figure 7-16 Dimension Drawing, 40--99EOZD(C)J & 33--80EFOZD(C)J (with Keel Cooling & Dry Exhaust)


ADV-8505D-ANOTE: Dimensions in [ ] are inch equivalents.

Figure 7-17 Dimension Drawing, 125/150EOZD(C)J & 100/125EFOZD(C)J (with Keel Cooling & Dry Exhaust)


Notes

TP-6862 6/14 53Section 8 Reconnection/Adjustments

Section 8 Reconnection/Adjustments



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.



Moving parts.

WARNING


TP-6862 6/1454 Section 8 Reconnection/Adjustments

Electroswitch

L1

L2

To GeneratorSet

To ShorePower

To Load

2-Wire Generator Sets

L1

L2

To GeneratorSet

To ShorePower

To Load



Kraus Naimler/American Solenoid(Early Rectangular Design)

Kraus Naimler/American Solenoid(Newer Round Design)

2 1 3 4

6 5 7 8

1 2 6 5

3 4 8 7

L1

L2

To GeneratorSet

To ShorePower

To Load

3 2 4 1

7 6 8 5

L1

L2

To GeneratorSet

To ShorePower

To Load


2 1 3 4

6 5 7 8

L010 9 11 12

1 2 6 5

3 4 8 7

9 10 14 13

L1

L2

To GeneratorSet

To ShorePower

To Load


L0

3 2 4 1

7 6 8 5

11 10 12 9

L1

L2

To GeneratorSet

To ShorePower

To Load


L0

TP-5399-5

Figure 8-1 Marine Manual (Ship-to-Shore) Transfer Switch

TP-6862 6/14 55Section 8 Reconnection/Adjustments

7 6 8 5

11 10 12 9

15 14 16 13

L2

L3

To GeneratorSet

To ShorePower

To Load

4-Wire, 3-Phase Generator Sets

L0

3 2 4 1L1

L2

L3

L0

L1

L2 L3 L0L1

Kraus Naimler/American Solenoid

I-940

Figure 8-2 Marine Manual (Ship-to-Shore) TransferSwitch, continued

8.1 Twelve-Lead Reconnection

The reconnection procedure details voltagereconnections only. If the generator set requiresfrequency changes, adjust the governor and voltageregulator. See the generator set service manual forinformation regarding frequency adjustment.

The following information illustrates the reconnection oftwelve-lead generator sets. In all cases, conform to theNational Electrical Code (NEC).

Reconnect the stator leads of the generator set tochange output phase or voltage. Refer to the followingprocedureandconnection schematics. Followall safetyprecautions at the front of this manual and in the textduring the reconnection procedure.

NOTICEVoltage reconnection. Affix a notice to thegenerator set afterreconnecting the set to a voltage different from the voltage onthe nameplate. Order voltage reconnection decal 246242from an authorized service distributor/dealer.

Twelve-Lead Reconnection Procedure

1. Place the generator start/stop switch in the STOPposition.

2. Disconnect generator set engine starting battery,negative (--) lead first.

3. Disconnect power to battery charger, if equipped.

4. Use Figure 8-3 to determine the generator setvoltage configuration. Note the original voltageand reconnect the generator set as needed. Forunits with current transformers, route leadsthrough current transformers (CTs) and connectthe leads according to the diagram for the desiredphase and voltage.

TP-6862 6/1456 Section 8 Reconnection/Adjustments

Figure 8-3 Generator Reconnection (ADV-5875F-R)

TP-6862 6/14 57Section 9 Paralleling Generator Sets

Section 9 Paralleling Generator Sets



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or connected equipment, disable the generatorset as follows: (1) Move the generator setmaster switch to theOFFposition. (2) Disconnect the power to the battery charger.(3) Remove the battery cables, negative (--) lead first.Reconnect the negative (--) lead last when reconnecting thebattery. Follow these precautions to prevent starting of thegenerator set by an automatic transfer switch, remotestart/stop switch, or engine start command from a remotecomputer.



Moving parts.

WARNING


Introduction

Read and follow the safety precautions included in thismanual. Pay attention to the decals on the equipmentand follow the instructions below.

D All personnel involved in handling, site preparation,installation, testing, operation, and maintenanceshould be thoroughly familiar with the information inthis manual and the customer drawings providedbefore working on this equipment.

D Never make interlocks inoperative or operate theequipment with any safety barriers removed.

D Always assume that all high-voltage parts areenergized until it is certain that they arede-energized.

D Use only test equipment rated for the serviceintended.

D Check interconnection diagrams and make surethere are no potential backfeed sources.

D Never disconnect the main trip source of energizedequipment.

D Use out-of-service tags and padlocks when workingon equipment. Leave tags in place until the work iscompleted and the equipment is ready to be put backinto service.

D The complete assembly arrangement determines ifthe top or bottom contacts are the line side; both canbe energized when the circuit breaker is removedfrom the compartment.

D Do not use liquid fire extinguishers or water onelectrical fires. Before extinguishing fires within theassembly, be absolutely certain that the main powersource is disconnected and the main and all feederbreakers are tripped.

The Decision-Makerr 3500 generator set controllerprovides generator set advanced control, systemmonitoring, and system diagnostics for parallelingmultiple generator sets.

The Decision-Makerr 3500 interfaces the generator setto other power system equipment and other networkmanagement systems using standard industry networkcommunications.

The controller uses unique software logic to managesophisticated functions, such as voltage regulation,synchronizing and load-sharing controls, and protectiverelays for paralleling up to eight generator sets.

TP-6862 6/1458 Section 9 Paralleling Generator Sets

Decision-Makerr 3500 Controller FeaturesInclude:

D Isochronous (real and reactive) loadsharingwithotherDecision-Makerr 3500 equipped generator sets.

D Random first-on logic to prevent two or moregenerator sets from closing to a dead bus.

D Automatic synchronizer with dead bus closing.

D Soft loading and unloading.

D Protective relay functions include:

D Loss of fieldD Over currentD Over frequencyD Over powerD Over voltageD Reverse powerD Under frequencyD Under voltage

D Generator management allows unneededgenerators to be stopped to conserve fuel.

D Load control logic permits prioritization of suppliedloads, allowing critical load to retain power in a failurescenario.

A generator set needs to be configured and set upcorrectly towork in paralleling applications. This sectioncovers:

D Paralleling Basics (see Section 9.1)D Paralleling Considerations (see Section 9.2)D Paralleling Set Up (see Section 9.3)D Paralleling Troubleshooting (see Section 9.4,Section 9.5, and Section 9.6)

D Generator Management Setup (see Section 9.7)D Load Add/Shed Configuration (see Section 9.8)

9.1 Paralleling Basics

9.1.1 Why Parallel Generator Sets

Some reasons to parallel generator sets are:

D RedundancyD Increased power capacityD Decreased fuel consumptionD Reduced chance of wet stacking/fuel on waterD Increased reliabilityD Greater flexibilityD Individual generators can be serviced in prime powerapplications

9.1.2 Paralleling Functions

There are two methods of paralleling:

1. PGEN. The Decision-Makerr 3500 is afull-featured paralleling controller. It offersintegrated control for synchronizing, load sharing,protective relays, generator management, andload add/shed. This functionality is performedautomatically by the Decision-Makerr 3500controller. PGEN requires an RS-485 betweeneach of the paralleling generators for parallelingoperation.

Note: If the controller loses PGENcommunications while the generator setsare operating, the Decision-Makerr 3500controller will enter droop mode where theoutput frequency varies with the real load.

2. Remote Speed and Voltage Bias. TheDecision-Makerr 3500 controller is also capable ofaccepting a speed and voltage bias from anexternal paralleling control. In these applications,the external paralleling control performs all of therequired functionality and the Decision-Makerr3500 controller merely provides a control interfaceand protective functions for the generator set.

Note: For external speed and voltage bias, thePGEN communication’s cable shouldnot be connected between generators.

TB13 is located inside the junction box andcontains the connection points for external speedand voltage bias control and accommodates 0--5volt input for active control. See the table belowand the wiring diagrams in the Operation Manualfor more information.

Connection

Speed Bias Negative (--) TB13-SBN

Speed Bias Positive (+) TB13-SBP

Voltage Bias Negative (--) TB13-VBN

Voltage Bias Positive (+) TB13-VBP

Simple paralleling requires the external speed andvoltage bias inputs to be enabled. UsingSiteTecht, under the Synchronization Controlparameter change the setting to the following:

External Bias Inputs: True

Note: For more information on SiteTecht, seeTP-6701tSiteTech Software OperationManual.


With the external bias enabled, the engine speed isset based on the voltage between SBP and SBN:

D Voltage < 0.5V: Engine Run Speed

D Voltage = 0.5V: 95% of Engine Run Speed

D Voltage = 2.5V: Engine Run Speed

D Voltage = 4.5V: 105% of Engine Run Speed

D Voltage > 4.5V: Engine Run Speed

With the external bias enabled, the output voltageis set based on the voltage betweenVBPandVBN:

D Voltage < 0.5V: Voltage Regulator AverageVoltage Adjustment

D Voltage = 0.5V: 90% of Voltage RegulatorAverage Voltage Adjustment

D Voltage = 2.5V: Voltage Regulator AverageVoltage Adjustment

D Voltage = 4.5V: 110% of Voltage RegulatorAverage Voltage Adjustment

D Voltage > 4.5V: Voltage Regulator AverageVoltage Adjustment

The Decision-Makerr 3500 controller reads thevoltage on the speed and voltage bias inputs every50 ms (20 times per second) and passes the newtarget to the voltage regulator and the ECM.

Reactive droop should be enabled on theDecision-Makerr 3500 when paralleling withanother generator set (either in simple or intelligentparalleling). The slope should be identical on allgenerators in the paralleling system (the default is1.0%). Reactive droop can be configured usingeither SiteTecht or the User Interface (UI) at thecontroller:Using SiteTecht, under the Reactive PowerLoad Sharing parameter.Using the UI , under theGenerator Info -> Voltage Regulation Menu andGenerator Info -> Paralleling Operation ->Sharing Setup Menus.

Note: Non-ECM engines will require an electronicgovernor (Woodward APECs) and anappropriate Kohler governor calibration inorder to permit speed adjustment.

Speed Bias is the amount that the controller isattempting to adjust the output frequency of thegenerator (100% bias = +5% on the engine speed,--100%= --5%on the engine speed). The controlleradjusts the Speed Bias to match frequency andphase with the paralleling bus.

Note: TheSpeedBias canalso be controlled byanexternal device if the External Bias InputsEnabled parameter is true, the Stand AloneOperation parameter is false, no generatorsare visible on the PGEN communicationschannel, and the voltage applied to thespeed bias input is between 0.5V and 4.5V.

The External Speed Bias Input (SBP and SBN) is avoltage measuring channel capable of readingfrom --10V to 30V DC. The input is normally pulleddown to --3.3V, but can be overridden by applying avoltage to the input.

The voltage that the controller sees on the voltagemeasuring channels is visible in the AnalogVoltage Input Metered Relative Value under theProgrammable Analog Voltage Input 108parameter heading. The input is polarity sensitive.

The Speed Bias is interpreted by the controller asshown in Figure 9-1.

Range: -100.00% – 100.00%Default: 0.00% **Not Writable**

Figure 9-1 Speed Bias


Voltage Bias is the amount that the controller isattempting to adjust the output voltage (100% bias= +10% on the output voltage, --100% = --10% onthe output voltage). The controller adjusts thevoltage bias to match the generator voltage to thebus voltage.

Note: The Voltage Bias can also be controlled byanexternal device if theExternal Bias InputsEnabled parameter is true, the Stand AloneOperation parameter is false, no generatorsare visible on the PGEN communicationschannel, and the voltage applied to thevoltage bias input is between 0.5V and 4.5V.

The External Voltage Bias Input (VBP and VBN) isa voltage measuring channel capable of readingfrom --10V to 30V DC. The input is normally pulleddown to --3.3V, but can be overridden by applying avoltage to the input.

The voltage that the controller sees on the voltagemeasuring channels is visible in the AnalogVoltage Input Metered Relative Value under theProgrammable Analog Voltage Input 107parameter heading. The input is polarity sensitive.

The Voltage Bias is interpreted by the controller asshown in Figure 9-2

Range: -100.00% – 100.00%Default: 0.00% **Not Writable**

Figure 9-2 Voltage Bias

Synchronizing

Before a generator set can operate in parallel withanother generator set, its electrical output must besynchronized (matched) to the power source it willparallel. The parameters that must be matched are:

D FrequencyD Phase AngleD VoltageD Phase Rotation

The synchronizer will issue a breaker close commandwhen the frequency difference, phase angle, andvoltage difference are within an acceptable range andthe phase rotation matches.

For PGEN paralleling, the synchronizing is handledwithin the Decision-Makerr 3500 controller.

For Remote Speed and Voltage Bias paralleling, thesynchronizing is handled by an external controller,typically supplied on switchgear.

Real (kW) Load Control

When generator sets are running in parallel (electricallyconnected), the load controller controls the generatorsets so each generator set is supplying its proportionalshare of power to the load while maintaining ratedfrequency. This is isochronous load sharing.

The load controller communicates (analog or digital) tothe other load controllers and determines how muchpower each generator set should supply.

For PGEN paralleling, the load controller is within theDecision-Makerr 3500 controller.

For Remote Speed and Voltage Bias paralleling, theload controller is performed by an external controller,typically supplied on switchgear.

Reactive (kVAR) Control (Isolated Bus)

When generator sets are paralleled, the voltage outputof each generator set must be equal. Reactive powercontrol is needed between the generator sets to ensurethat each is supplying its share of the reactive load andtominimizecirculating currents. This canbedone inoneof two ways:

1. Active Control (Used in PGEN Paralleling andRemote Speed and Voltage Bias Paralleling).The reactive load controller communicates(analog or digital) to the other reactive loadcontrollers tomaintain thesameproportional kVARoutput while maintaining the system’s nominalvoltage.


2. Passive Control (Used in Droop Paralleling).The voltage regulators are connected in droop orcross current compensation. There is no activecontrol from the controller.

9.2 Paralleling Considerations

9.2.1 Generator Requirements

Alternator and Connections

Units to be paralleled must have the same frequency,the same number of phases, the same voltage, and thesame phase rotation. The latter merely means that thevoltages across the terminals must reach theirmaximum and minimum values in the same order.Otherwise, the magnetic forces would try to turn therotors in opposite directions.

The pitch of the paralleled alternators needs to be thesame or excessive circulating currents may occur.

Motorized Paralleling Circuit Breaker

The Decision-Makerr 3500 controller provides controlof a single motor-operator breaker to selectively closeon or off the bus. For motorized paralleling breakers,there are two options:

D On the generator set, pre-wired from the factory.

D Remotely mounted. Customer needs to wire tostatus, trip, close, charge motor, and bus sensing.See the wiring diagram in the operation manual formore information.

Speed Control (Required for Paralleling Done ViaRemote Speed and Voltage Bias Method)

The Decision-Makerr 3500 controller will accept aninput from the paralleling controller. This is the way theparalleling controller adjusts the frequency and controlsthe power output of the generator set.

The Decision-Makerr 3500 controller has the ability toaccept a remote speed adjust input of:

D 0.5 -- 4.5 volts±5% (values supplied outside of thisrange will default the setting to nominal)

Note: Some engines may limit this speed adjust to nomore than approx. +3.5%.

Voltage Regulator

The voltage regulator is integral to the Decision-Makerr3500 controller and is capable of accepting remote inputfor voltage adjustment. It adjusts to:

D 0.5 -- 4.5 volts±10% (values supplied outside of thisrange will default the setting to nominal)

Generator Set Protection

A reverse power relay senses the direction of powerflow. Each generator’s Decision-Makerr 3500controller contains a reverse power relay. If any unit inthe system has a malfunction such as a loss of fuelcausing current to flow into the generator, the reversepower relay will sense the reverse power anddisconnect the unit from the system. If reverse powerrelays are not used, units still running will drive the unitthat has stopped as a motor.

9.2.2 Paralleling Controller—PGEN

Starting and Stopping Generator Set

The Decision-Makerr 3500 controller has supervisorycontrol over paralleling. There are several methods thatcan be used to start and stop the generator set (consultthe operation manual for more detail):

D CAN gauge

D Modbusr

D Kohler SiteTecht software

D AUTO--RUN/AUTO--OFF button

D RUN button

D Contacts 3 and 4 for remote signal

Frequency and Real (kW) Power

Depending on the state of the paralleling motorizedbreaker, the Decision-Makerr 3500 controls thefrequencyor kWoutputof thegenerator setbysendingasignal to the engine governor over J1939 (CAN).

D Motorized Paralleling Breaker Open. Thegenerator set speed (frequency) will vary with thissignal. This would be the case while synchronizing.

D Motorized Paralleling Breaker Closed. If thegenerator set parallel motorized breaker is closedand the generator set is operating in parallel withanother power source, this signal will control the kWload provided by the generator.

Modbusr is a registered trademark of Schneider Electric.


Voltage and Reactive (kVAR) Power

The Decision-Makerr 3500 controls the generator set’soutput voltage.

The generator set response to the signal variesdepending on the state of its paralleling motorizedbreaker.

D Motorized Paralleling Circuit Breaker Open. If themotorized circuit breaker is open, the output voltagewill change. This would be the case whilesynchronizing.

D Motorized Paralleling Circuit Breaker Closed. Ifthe motorized circuit breaker is closed and thegenerator set is operating in parallel with anotherpower source, this signal will control the kVAR loadprovided by the generator.

9.3 Paralleling Set Up

9.3.1 PGEN Communication Wiring

In order to parallel two or more generator sets usingPGEN, a communicationwire is required. Use aBeldencable #9841 (or equivalent) shielded twisted-paircommunication cable. Connect the shield to ground atone end only. Tighten the connections to 0.5 Nm(4.4 in. lbs.). The PGEN connection between thegenerator sets is always required when the generatorsets connect to a common bus. See Figure 9-3.

TB12 TB12 TB12 TB12

Figure 9-3 Paralleling System Interconnection Diagram

PGEN connections are made on terminal block TB12.TB12 is located in the generator set junction box. SeeFigure 9-5 for TB12 location. See Figure 9-4 for PGENconnection locations. A small portion of the wiringdiagram is shown in Figure 9-4. See the operationmanual for the complete wiring diagram.

1

ADV-8535-A

1. PGEN (+) connection on TB122. PGEN (--) connection on TB12

2

Figure 9-4 Terminal Block TB12 PGEN Connections

1

GM86968-

1. TB12 location

Figure 9-5 TB12 Terminal Block Location


9.3.2 Decision-Makerr 3500 Paralleling Sequence of Operation

Generator operateswithout any faults or

warnings

Generatorautomatically closesto bus. The breakercloses, reopens, and

closes again.

All generators in OFFConfirm dead bus

Start generator 1using RUN button

Generator 1 in OFF

Repeat for eachgenerator individually

If breaker does not close or reopen,see Section 9.4.

If faults or warnings are displayedon the Decision-Makerr 3500controller, see Section 9.5.

Install generatorsFollow the instructions providedearlier in this manual.

Connect output leadsto the paralleling bus

Consult the wiring diagramsprovided in the operation manual.

Connect PGENcommunication wiring See Section 9.3.1 in this manual.

If the engine does not start, consult theoperation manual for troubleshootinginformation.

Generator 1 in OFF

Place all generatorsin AUTO and give

start signal

If faults or warnings are displayedon the Decision-Makerr 3500controller or if the generator setdoes not function correctly, seeSection 9.6.

Note: Sequence of operationis for unit-mounted breakers. Additionalsteps for remote-mounted breakers areshown in:

Connect circuitbreaker control and

status wiring

Connect bus sensingConsult the wiring diagramsprovided in the operation manual.

Consult the wiring diagramsprovided in the operation manual.

Figure 9-6 Sequence of Operation


9.4 Troubleshooting When Breaker Does Not Close to Bus9.4.1 Faults Not Shown

Step Potential Cause Explanation Troubleshooting

1 PGENcommunication notoperational

The controller must have seen PGENcommunication with at least one other nodeat some time since the last power cycle eventbefore it will close the breaker.

In Controller Config --> Communication Setup,verify the PGEN Nodes Online is at least 2. Ifso, continue troubleshooting at Step 8otherwise, continue on to Step 2.

2 Single generatorapplication

There is only one generator on site, but thecontroller is expecting to see PGENcommunication. The controller supports thisscenario if the controller is configured inStandalone mode. Standalone mode can beset using the standalone input to thecontroller or in Kohler SiteTecht.

Configure a digital input to Standalone modeand assert it, or set Standalone mode inKohler SiteTecht. Note, Standalone modeshould only be asserted if there is only onegenerator set at the site.

3 PGEN wiring notconnected correctly

PGEN communicates over an RS-485connection. RS-485 requires that thenetwork be connected in a daisy-chainconfiguration, terminated at 120 Ohms ateither end of the network and that positive (B)and negative (A) polarity be maintained.

Verify wiring, all PGEN + connections shouldbe connected with daisy-chain wire (Belden#9841 or equivalent). Verify terminations areat the end of the network. Verify that thereare no unintentional or loose connections.

4 Baud ratemisconfigured

One of the controllers on the network isattempting to communicate at a differentbaud rate than the other controllers. Thisresults in collisions on the communicationbus and incorrect interpretation of the data.

In Controller Config --> Communication Setup,verify that the baud rate of all generators onthe network matches. Default is 57,600baud.

5 Interference The PGEN network is seeing noise whichmakes it difficult for the generator controllersto communicate.

Verify that PGEN network uses Belden #9841or equivalent. Verify that the shield drain forthe cable is grounded at only one end.

6 Short circuit incommunicationwiring

The RS-485 communication wires areshort-circuited together.

In Controller Config --> Communication Setup,verify the PGEN Node ID is less than 16. Ifnot, check the PGEN wiring for short circuits.Otherwise, continue troubleshooting to Step 7.

7 Intermittentconnection in PGENwiring

Although the generator controllers canoccasionally communicate, the connection isunreliable. This can be caused by a short oropen circuit.

It is not uncommon for small communicationswire to not connect directly to a terminal blockwell. Verify there are no loose wiringconnections or “whiskers” at the PGENterminal blocks. “Fork”, “ring”, or “crow’s feet”connectors are preferred for terminal blockconnections.

8 Unable to establishfirst-on lock

The generator is trying to close to a dead busbut it is not receiving permission from one ofthe other nodes to allow it to do so. This canoccur if one of the other nodes has seen anode removed from the network.

Cycle power on all generators.


9.4.2 Faults Shown


Fault: System Voltage Mismatch Between Generators

1 System voltage is notequivalent

One of the controllers on the network isconfigured differently than the othercontrollers. This will inhibit any of thegenerators from closing to the bus.

Verify the system voltage of all thegenerators match the requirements of thesite.

Fault: System Frequency Mismatch Between Generators

1 System frequency is notequivalent


Verify the system frequency of all thegenerators match the requirements of thesite.

Fault: Phase Connection Mismatch Between Generators

1 Phase connection is notequivalent


Verify the phase connection of all thegenerators match the requirements of thesite.

Fault: Live Bus Sensed When Dead Bus Expected

1 Bus is considered to belive

The controller is measuring voltage on theparalleling bus. This will inhibit the breakerfrom closing.

Check bus for residual voltage (sometimesinduced by large transformers or motors).Possibly, adjust the Dead Bus Threshold toaccommodate the residual voltage.

2 Bus sensing is notconnected

The controller may see voltage on theparalleling bus when the generator isoperating and the bus sensing isdisconnected.

Verify the bus sensing wiring is connectedto the load side of the motor-operatedbreaker for this generator.

Fault: Close AttemptFault: Fail to Close

1 Breaker is unable toclose

The controller is attempting to close thecircuit breaker but the breaker is notclosing.

Watch the ready flag on the motor operatorof the circuit breaker. If it indicates notready when the engine is stopped andtoggles to the ready state when thegenerator is trying to close the breaker, thetrip coil is acting correctly. Continue atStep 5 otherwise, continue on to Step 2.

2 Trip is not removed fromthe circuit breaker

The controller is attempting to close thecircuit breaker but the breaker is notclosing because the trip coil is stillenergized.

If the ready flag of the motor operatorindicates ready when the engine isstopped, continue at Step 3 otherwise,continue on to Step 4.

3 CB trip relay is wired asnormally open

The controller is expecting that the trip onthe circuit breaker is a normally-closedcontact. This is intentional as it holds a tripon the breaker if the controller is removed.

Verify the CB trip relay is wired to hold atrip on the breaker when the relay is notenergized.

4 Incorrect wiring betweenthe CB trip relay and thetrip coil on the breaker

The CB trip relay is operating correctly butthe trip coil on the breaker is remainingenergized. This could be due to incorrectwiring between the generator controller andthe circuit breaker.

Verify the wiring to the circuit breaker.

5 Close is not applied tothe circuit breaker

The breaker trip is removed but thecontroller is not able to close the breaker.

Verify the wiring between the generatorcontroller and the circuit breaker close coil.Check the close coil to ensure that it is notdefective.

6 Breaker is not charged The breaker is receiving the signal to closebut the energizing spring is not charged.

Verify the motor operator is receivingvoltage at the appropriate contacts to allowit to wind the spring.



Fault: Close AttemptFault: Fail to Close(Continued)

7 Breaker is not powered The 24V electronics on the circuit breakerrequire an external 24V source on a 12Vgenerator.

Verify the 24V input which exists onparalleling generators is receiving 24VDCin the correct polarity.

8 Wiring to power is notcomplete

There is no voltage to the CB close relayon this circuit breaker.

Connect the supply to the CB close relay toeither 24V from wire #70 or an external24VDC supply (with battery storage).

9 Breaker status feedbackis not valid, no bussensing

The breaker closes but the controller doesnot see a change in status. The controllercannot see the bus is energized as the bussensing is not connected correctly on anygenerators on the network.

Verify the wiring on the circuit breaker toensure that it is connected correctly. Verifybus wiring for all nodes. Verify thegenerator output is connected to the lineside of the generator breaker.

Fault: CB StatusWarning: Bus Sensing Not Connected


The breaker closes but the controller doesnot see a change in status. The controllercannot see the bus is energized as the bussensing is not connected correctly on thisgenerator, but another generator isconnected.

Verify the wiring on the circuit breaker toensure that it is connected correctly. Verifybus wiring for this generator.

Fault: CB Status

1 Breaker status feedbackis not valid

The breaker closes but the controller doesnot see a change in status. The controllersees the bus is now live.

Verify the wiring on the circuit breaker toensure that it is connected correctly.


9.5 Troubleshooting When Breaker Does Close to Bus9.5.1 Faults Shown


Fault: Close AttemptFault: Fail to Close


The breaker closes but the controller doesnot see a change in status. The controllercannot see the bus is energized as the bussensing is not connected correctly on anygenerators on the network.

Verify the wiring on the circuit breaker toensure that it is connected correctly. Verifybus wiring for all nodes. Verify thegenerator output is connected to the lineside of the generator breaker.

Fault: CB Status

1 Breaker status feedbackis not connected

The breaker closes but the controller doesnot see a change in status. The controllersees the bus is now live.

Verify the wiring on the circuit breaker toensure that it is connected correctly.

2 Breaker status is shortcircuited

The controller sees the breaker is closedeven when it is not trying to open it.

Verify connection of the breaker statuswiring at the circuit breaker.

3 Breaker status feedbackis connected to thewrong contacts

The controller sees open status for thebreaker after telling it to close, closedstatus after telling it to open.

The controller is expecting the breakerstatus to be an “A” contact. Verify thecircuit breaker auxiliary contacts are either:11 and 1421 and 2431 and 34 or41 and 44.

4 Breaker status feedbackis connected to alatching contact

The breaker status indicated that it closedwhen it was triggered to close but it did notindicate that it was open when the breakeropened. This fault will only occur if the bussensing is connected correctly (thecontroller sees the voltage go to 0 whenthe breaker is triggered to open).

Verify the breaker status input to thecontroller is connected directly to anauxiliary contact on the circuit breaker.

Fault: Bus Phase Rotation Mismatch

1 All of the bus sensingwires are incorrectlyconnected

The bus sensing wires must be connectedto phase A, phase B, and phase C of thebus. If any two connections are reversed,the controller can detect the reversedconnections. This fault will only occur if allthree wires are incorrectly connected.

Verify the bus metering connections.

2 The phase connectionson the parallelingbreaker are inconsistentwith the generator

The power leads from the generator to theparalleling circuit breaker must beconnected consistently. Phase A from thegenerator must go to phase A of the lineside of the paralleling (motor operated)breaker, phase B from the generator tophase B of the breaker and phase C of thegenerator to phase C of the breaker.

Verify the output cable connections.

3 Generator sensing isconnected incorrectly

The controller measurement leads are notconnected to the appropriate output phasesor the phases are incorrectly labeled.

Verify the sensing leads from the controllerare connected to the appropriate outputleads from the generator. L1 shouldconnect to phase A, L2 to phase B, L3 tophase C, L0 to neutral.

4 Breaker to bus wiring isinconsistent

In applications where the bus sensing istaken from a location other than the loadside of the paralleling breaker, it is possibleto connect the wiring incorrectly betweenthe load side of the output breaker and theparalleling bus.

Verify the cable connections from theparalleling breaker to the paralleling bus.



Fault: Bus Voltage Amplitude Mismatch--Phase A

1 The phase A voltage ofthe bus does not matchthe generator

The voltage measured on the bus sensingfor phase A does not match the voltagemeasured on phase A of the generator.

Verify the bus sensing wire for phase A isconnected to phase A of the load side ofthe paralleling breaker and there are nobreaks in the wire.

Fault: Bus Voltage Amplitude Mismatch--Phase B

1 The phase B voltage ofthe bus does not matchthe generator

The voltage measured on the bus sensingfor phase B does not match the voltagemeasured on phase B of the generator.

Verify the bus sensing wire for phase B isconnected to phase B of the load side ofthe paralleling breaker and there are nobreaks in the wire.

Fault: Bus Voltage Amplitude Mismatch--Phase C

1 The phase C voltage ofthe bus does not matchthe generator

The voltage measured on the bus sensingfor phase C does not match the voltagemeasured on phase C of the generator.

Verify the bus sensing wire for phase C isconnected to phase C of the load side ofthe paralleling breaker and there are nobreaks in the wire.

Fault: Bus Voltage Amplitude Mismatch

1 The bus metering is notconnected correctly

The bus metering is not connected to theappropriate lugs of the load side of theparalleling breaker (but there is somevoltage present).

Verify the bus sensing wire for all threephases is connected to the appropriatelugs on the load side of the parallelingbreaker and there are no breaks in any ofthe wires.

2 The generator meteringis not connectedcorrectly

The generator metering is not connected tothe output of the generator.

Verify the generator metering is sensed atthe output of the generators. A commonmistake is to connect the metering to thecenter tap voltages V7, V8, V9.

Fault: Phase Angle Mismatch

1 All of the bus sensingwires are incorrectlyconnected

The bus sensing wires must be connectedto phase A, phase B and phase C of thebus. If any two connections are reversed,the controller can detect the reversedconnections. This fault will only occur if allthree wires are incorrectly connected.

Verify the bus metering connections.

2 The phase connectionson the parallelingbreaker are inconsistentwith the generator

The power leads from the generator to theparalleling circuit breaker must beconnected consistently. Phase A from thegenerator must go to phase A of the lineside of the paralleling (motor operated)breaker, phase B from the generator tophase B of the breaker, and phase C of thegenerator to phase C of the breaker.

Verify the output cable connections.

3 Generator sensing isconnected incorrectly

The controller measurement leads are notconnected to the appropriate output phasesor the phases are incorrectly labeled.

Verify sensing leads from the controller areconnected to the appropriate output leadsfrom the generator. L1 should connect tophase A, L2 to phase B, L3 to phase C, L0to neutral.

4 Breaker to bus wiring isinconsistent

In applications where the bus sensing istaken from a location other than the loadside of the paralleling breaker, it is possibleto connect the wiring incorrectly betweenthe load side of the output breaker and theparalleling bus.

Verify cable connections from theparalleling breaker to the paralleling bus.

Fault: Bus Frequency Mismatch

1 Abnormal condition Bus frequency is not similar to generatorfrequency with breaker closed.

Verify bus metering is connected correctly.Reset the controller.



Fault: Bus Sensing Phases A and B are Reversed

1 The bus sensing forphase A is connected tophase B of theparalleling bus and viceversa

Phase angle from generator to bus is about180_ and bus rotation is backwards.

Verify wiring between bus sensing inputsand load side of paralleling breaker.

2 The wiring between thegenerator and theparalleling breaker isincorrect


Verify wiring between generator andparalleling breaker.



Verify metering connections on thegenerator. L1 should connect to thephase A output lead. L2 to phase B, L3 tophase C, L0 to neutral.

Fault: Bus Sensing Phases B and C are Reversed

1 The bus sensing forphase B is connected tophase C of theparalleling bus and viceversa

Phase angle from generator to bus is about--120_ and bus rotation is backwards.








Fault: Bus Sensing Phases C and A are Reversed

1 The bus sensing forphase A is connected tophase C of theparalleling bus and viceversa









Fault: Bus Sensing Not Connected

1 No wires connect thebus sensing on thegenerator to the loadside of the parallelingbreaker

Wiring not connected between load side ofthe paralleling breaker and the busmetering.

Verify that the bus sensing is connected.

2 No leads connect thegenerator output to theline side of theparalleling breaker

The leads connecting the output of thegenerator to the paralleling breaker are notconnected.

Verify that the leads connecting thegenerator to the paralleling breaker areconnected.

3 The line circuit breaker isopen

The line circuit breaker (at the generator) isopen, disconnecting the output from thegenerator from the line side of theparalleling breaker.

Verify that the line circuit breaker is closed.



Fault: Bus Sensing Connected to Generator Side of Breaker

1 Bus metering isconnected to the wrongside of the parallelingbreaker

The controller sees the bus voltage alwaysmatches the generator voltage, even whenthe breaker contacts indicate that thebreaker is open.

Verify the bus metering is connected on theload side of the paralleling breaker.

2 Breaker is closed andstatus feedback is notconnected

The controller sees that the bus voltagealways matches the generator voltage,even when the breaker contacts indicatethat the breaker is open.

Verify the paralleling breaker control wiringis connected correctly and the statusfeedback is connected to an “A” contact.

Fault: Failure to Open

1 Wiring between CB triprelay and trip coil is notconnected

The CB trip relay is releasing, but the coil inthe breaker is not energizing, hence thebreaker is not opening.

Verify wiring to the trip coil (A4) isconnected correctly.

2 CB trip relay is notreceiving 24V power

The CB trip relay is releasing, but there isno voltage to apply to the trip coil. This ismost likely to occur when the generator hasa 12V battery and there is an externalbattery bank to operate the circuit breaker.

Verify the CB trip relay has a 24VDCsupply which is common to the CB closerelay and charge motor.


9.6 Troubleshooting When Running in AUTO9.6.1 Faults Shown


Fault: Generator Phase Rotation Mismatch

1 This generator is wiredwith the opposite phaserotation of all the othergenerators on theparalleling bus

The controller has validated that the busmetering is accurate relative to thisgenerator, if the bus phase rotation isbackwards to the generator, the phaserotation must really be different.

Verify wiring between this generator andthe paralleling breaker. It may benecessary to reverse two phases betweenthe generator and the paralleling breakerand then to reverse the sensing at the busto match. This generator should be startedand closed to a dead bus again to validatethe changes.

2 The wiring between theparalleling breaker andthe paralleling bus isincorrectly connected(two phases arereversed)

Voltage from other generators comes intothis generator as incorrect phase rotationbecause the wiring connections to theparalleling bus are reversed, even thoughthe rotation of the other generators isidentical to the rotation of this generator.

Verify wiring between the parallelingbreaker and the paralleling bus. It may benecessary to reverse the connection of twoof the leads. This generator should bestarted and closed to a dead bus again tovalidate the changes.

3 The generator which isconnected to theparalleling bus has theopposite phase rotationof this generator and allothers

Voltage from the other generator comesinto this generator as incorrect phaserotation because the wiring connectionsfrom the other generator to the parallelingbus are reversed, even though the rotationof the other generators is identical to therotation of this generator.

Verify wiring between the parallelingbreaker and the paralleling bus of the othergenerator. It may be necessary to reversetwo phases between the paralleling breakerand the paralleling bus on the othergenerator. The other generator should bestarted and closed to a dead bus again tovalidate the changes.

Fault: Dead Bus Sensed When Live Bus Expected

1 The wiring was notconnected between theload side of theparalleling breaker forthis generator and theparalleling bus

This generator controller observedaccurate bus voltage when it closed thebreaker, the other generator controller didthe same, but the bus of this generator isnot connected to the bus of the othergenerator. The other generator isenergizing the load, this generator cannotenergize the load as there is adisconnected wiring between this generatorand the paralleling bus.

Verify wiring between the parallelingbreaker and the paralleling bus of thisgenerator.

2 The wiring was notconnected between theload side of theparalleling breaker forthe other generator andthe paralleling bus

This generator controller observedaccurate bus voltage when it closed thebreaker, the other generator controller didthe same, but the bus of this generator isnot connected to the bus of the othergenerator. The other generator is notenergizing the load because it is notconnected to it—this generator may beable to energize the load, but there is nosimple way of telling this withoutconnecting the output of the othergenerator.

Verify wiring between the parallelingbreaker and the paralleling bus of the othergenerator.

Fault: Bus Voltage Out of Spec

1 The generators whichare connected to theparalleling bus areoverloaded

When the generators which are supplying aload are overloaded, their engine speed willdecrease, resulting in a decrease in outputvoltage. Sometimes this decrease in outputvoltage is sufficient to allow the generatorsto recover.

Verify the load requirements are met by asingle generator. If not, it may benecessary to connect several low priorityloads to load shed outputs from theparalleling generators to avoid overloadinga single generator.

2 Excessive cable lengthsfrom generators toparalleling bus

Although a single generator can handle theload, the cables which connect thegenerator to the paralleling bus are toolong or too small of gauge, resulting ininsufficient bus voltage.

Increase wire size on the generatorconnection leads.



Fault: Bus Frequency Out of Spec

1 The generators whichare connected to theparalleling bus areoverloaded

When the generators which are supplying aload are overloaded, their engine speed willdecrease, resulting in a decrease in outputvoltage. Sometimes this decrease in outputvoltage is sufficient to allow the generatorsto recover.

Verify the load requirements are met by asingle generator. If not, it may benecessary to connect several low priorityloads to load shed outputs from theparalleling generators to avoid overloadinga single generator.

Fault: Failure to Synchronize

1 Varying loadrequirements drivegenerator frequencyunstable

Heavy variations in the load on a generatorwill cause the speed of the generator tovary significantly. It can be difficult tosynchronize with a generator withcontinuously changing frequency.

Adjustment of synchronizing dwell time orsynchronizing gains may improve ability tosynchronize.

2 Fuel variations or otherenvironmental factorscause the generatorfrequency regulation tosuffer

When the frequency regulation is impededby atmospheric conditions or fuel quality,the ability to synchronize may be affected.Not only is the bus varying more thannormal, but it is more difficult for thegenerator to control speed while synching.

It may be necessary to adjust thesynchronizing gains.

3 Different sized units orunits of different fueltypes

The factory synchronizing gains werecalibrated for equal-sized units. Theresponse of a large unit to a small one isslightly different than two small units. A dieselgenerator has significantly better frequencyregulation than a natural gas generator.

It may be necessary to adjust thesynchronizing gains.

Fault: Generator Disabled Due to High Voltage

1 Metering calibrationissue

All the generators on the paralleling busattempt to control to the same voltage. Ifone has incorrect calibration, it may seethis voltage as a much higher level than theother generators, resulting in a protectiverelay trip.

Verify the controller is measuring voltageaccurately. If not, re-calibrate it.

2 Voltage drop ongenerator connectionleads

If the generator is sourcing high currentthrough too small of output leads, thevoltage drop in these cables may requirethe generator to run at an increasedvoltage to supply the necessary current tothe paralleling bus.

Install oversized connecting leads for thegenerator to minimize voltage dropbetween the generator and the parallelingbus.

3 Attempting to operate agenerator in base-loadmode while it isconnected to a variableload

The speed bias and voltage bias controlreal and reactive load in base-load modeagainst a source with a nearly constantfrequency and voltage (such as a utilitysource). If the generator is disconnectedfrom the utility source, the speed andvoltage will deviate to either extreme of thebias range, depending on the target loadand the actual load.

Install contacts in series with the base-loadmode input to the controller which aredisconnected when the utility source isdisconnected from the paralleling bus.

Fault: Generator Disabled Due to Low Voltage

1 Metering calibrationissue

All the generators on the paralleling busattempt to control to the same voltage. If onehas incorrect calibration, it may see thisvoltage as a much lower level than the othergenerators, resulting in a protective relay trip.

Verify the controller is measuring voltageaccurately. If not, re-calibrate it.






Fault: Generator Disabled Due to High Frequency




Fault: Generator Disabled Due to Low Frequency




Fault: Generator Disabled Due to Over Power

1 Continuous overload The generator breaker will trip to protectthe generator from damage due toexcessive loads.

Ensure that the load is low enough for asingle generator to support it.

Fault: Generator Disabled Due to Reverse Power

1 Loss of fuel pressure The generator breaker will trip to preventgenerator operation. Otherwise, powercould be absorbed from other generatorscausing potential damage to the fuelsystem by operating without lubrication.

Ensure that the generator has sufficientfuel to support load. Connect a fuel levelsensor and place Generator Managementin Fuel Level Equalization mode.

2 Quick ramp rate settings The real power may overshoot when in areal power control situation such as baseload or system control.

It may be necessary to adjust the loadcontrol gains.

3 Different sized units orunits of different fueltypes.

The real power may overshoot when in areal power control situation such as a loadramp or a quickly changing customer load.

It may be necessary to adjust the kW loadsharing gains.

4 Different engine speedadjust settings

Setting the Engine Speed Adjust parameterhigh on a generator will result in thatgenerator providing more real power thanthe other generators. It is possible to drivethe other generators offline in light loadingconditions.

Set the engine speed adjustment similarlyon all generators.

Fault: Generator Disabled Due to Over Current

1 Excessive reactive load The generator breaker will trip to preventthe generator from damage due toexcessive stator current. Note, thecontroller also has a heat-model-basedalternator protection algorithm (which willshut the generator down).

Ensure that the load is low enough for asingle generator to support it.



Fault: Generator Disabled Due to Reverse VARs

1 Different sized units The reactive power may overshoot when ina power control situation such as a loadramp or a quickly changing customer load.

It may be necessary to adjust the kVARload sharing gains.

2 Different automaticvoltage regulator settings

Setting the Engine Speed Adjust parameterhigh on a generator will result in thatgenerator providing more real power thanthe other generators. It is possible to drivethe other generators offline in light loadingconditions.

Set the voltage regulator average voltageadjustment to the same value on allconnected generators.

3 Different voltagecalibrations

Because each generator will attempt tomatch the target output voltage, generatorswith incorrect calibration may be targeting adifferent output voltage, thus generating orabsorbing VARs.

Verify the controller is measuring voltageaccurately, If not, re-calibrate.

4 Failure in voltageregulator or activatorboard

The generator breaker will trip to preventthe generator from absorbing VARs fromthe other generators. Providing power whileabsorbing VARs may cause that alternatorto slip a pole—potentially damaging therotor or crankshaft.

Verify the voltage regulator and activatorare ok. Perform load tests to verify.

Fault: Generator Management Config Mismatch

1 Two generators that arecommunicating on thenetwork have differentOrder Selection modes

Generator management will not operate ifany generators on the PGEN network havedifferent Order Selection modes.

Adjust the Order Selection mode on anygenerator on the network to set the OrderSelection mode in all controllers.

2 Two generators that arecommunicating on thenetwork have differentStability delays

Generator management will not operate ifany generators on the PGEN network havedifferent Stability delays.

Adjust the Order Selection mode on anygenerator on the network to set the Stabilitydelay in all controllers.

3 Two generators that arecommunicating on thenetwork have differentRedundancyRequirements

Generator management will not operate ifany generators on the PGEN network havedifferent Redundancy Requirements.

Adjust the Order Selection mode on anygenerator on the network to set theRedundancy Requirements in allcontrollers.

4 Two generators that arecommunicating on thenetwork have differentMaximum Run TimeHour DifferenceThresholds

Generator management will not operate ifany generators on the PGEN network havedifferent Maximum Run Time HourDifference Thresholds.

Adjust the Order Selection mode on anygenerator on the network to set theMaximum Run Time Hour DifferenceThreshold in all controllers.

5 Two generators that arecommunicating on thenetwork have differentMaximum Fuel LevelDifference Thresholds

Generator management will not operate ifany generators on the PGEN network havedifferent Maximum Fuel Level DifferenceThresholds.

Adjust the Order Selection mode on anygenerator on the network to set theMaximum Fuel Level Difference Thresholdin all controllers.


9.7 Generator Management Setup

Generator Management starts and stops generatorsbased on the requirements of the load. The order inwhich the generators are started or stopped isdetermined according to one of the following:

D Manual/Fixed—The starting order of the generatorsis determined at the time of configuration (It isadjustable at a later time through the menu on thecontroller display). The controllers automaticallynegotiate to ensure that no two units have the sameorder number -- setting the order number on onecontroller which conflicts with the order of anothercontroller will cause the two controllers to exchangeorder numbers.

D Run Time—The starting order of the generators isdetermined based on the run time hours on thegenerators. The generator with the most run timehourswill stop first and start last.Generatorswhich arealready running are allowed to continue to run untiltheir run timehours exceed stopped the run timehoursof a stopped generator by an adjustable threshold.

D Fuel Level—The starting order of the generators isdetermined based on the fuel level remaining in thesupply tanks for the generators. This option is onlyvalid if the generators have indication of fuel.

Typical Applications for Manual Order SelectionMode:

D Units of various sizes are operated in a prime powerapplication and the generator management settingsare optimized for minimal fuel consumption.

D An older unit is intended to accumulate most of therun time hours because it is scheduled forreplacement soon.

D Someunits are quieter or locatedmore remotely thanother units, making them more desirable to operate.

D A unit is in need of maintenance but is stilloperational—this unit can be used if necessary, butshould not operate more than is necessary.

Typical Applications for Run Time Order SelectionMode:

D Normal Standby Power systems without specialrequirements.

D Multiple generator systemwhere all generators areofidentical size and age, where the generator run timeshould remain essentially identical.

D Prime power applications where the generators areall of similar size.

Typical Applications for Fuel Level OrderSelection Mode:

D Prime power applicationswhere the generators haveindividual fuel tanks and have level indication on thefuel tanks.

D Standby applications where the generators haveindividual fuel tanks and have level indication on thefuel tanks.

9.7.1 Manual Order Selection Setup:

The Generator Management order should be configuredso that the generator which is preferred to run has thelowest order. If the controllers are communicating overPGEN, changing the order on one generator will causethe order of the other generators to rearrange toaccommodate the changed order of the one generator.

The Manual Start order can be changed through themenu on the controller display at any time after thecommissioning of the site is complete.

9.7.2 Run Time Order Selection Setup

When Run Time Order Selection Mode is selected,Generator Management will automatically adjust theorder of the connected generators based on their runtime hours. The order of each should reflect the relativerun time of that generator if all the generators arerunningor all thegenerators are stopped.Thegeneratorwith the lowest run time will be started first.

Because a generator will not be accumulating run timewhen it is stopped, it is necessary to add a stabilitythreshold to each generator which is not running or thegenerators will start 12 minutes after they stop(0.2 hours). This threshold is called the GeneratorManagement Run Time Threshold.

Configure the threshold to allow the generators toequalize run time without starting and stopping eachgenerator unnecessarily. The factory default is 12.0hours—one of the running generators will have to have12.0 fewer hours than the generator that is stoppedbefore the generator will start. Once that generator isonline, the generator with the most run time hours willstop.

9.7.3 Fuel Level Selection Setup

When Run Time Order Selection Mode is selected,Generator Management will automatically adjust theorder of the connected generators based on their fuellevel. The order of each should reflect the relative fuellevel of that generator if all the generators are running or


all the generators are stopped. The generator with themost fuel will be started first.

Because a generator will not be consuming fuel when itis stopped, it is necessary to add a stability threshold toeach generator which is not running or the generatorswill start as soon as 1%of the running generator’s fuel isconsumed. This threshold is called the GeneratorManagement Fuel Level Threshold.

Configure the threshold to allow the generators toequalize run time without starting and stopping eachgenerator unnecessarily. The factory default is 10% offuel level—one of the running generators will have tohave 10% less fuel than the generator that is stoppedbefore the generator will start. Once that generator isonline, the generator with the least fuel will stop.

9.7.4 Paralleling Parameters

Generator Management Enabled

Set this to true if Generator Management is desired forthis application

Generator Management Stability Delay

The Stability Delay is intended to ensure that all loadshave returned to their normal demand beforeGeneratorManagement considers stopping a generator.

All generators will be told to run until the Stability Delayhas expired.

Generator Management Minimum Gens Online

The Minimum Gens Online parameter will allow thesystem tobeconfigured to requireat least 1 generator orto require at least 2 generators. If set to 2 Generators,the system will always keep one more generator onlinethan is required.

Note: The default setting is 2.

Generator Management Min Load Shed Priority

The Minimum Load Shed Priority is the priority whichhas to be online to allow Generator management tobecome active (start the stability timer). This parametershould match the maximum load shed priority that isconnected to an actual load.

The default setting is 6 (load priority 6 must be onlinebefore generator management becomes active).

Generator Start Percentage

The Generator Start Percentage is the percent load onthe running generators above which this generator willbegin timing for the Generator Start Delay.

The default setting is 80%, this means that the othergeneratorswill havemore than80%loadon thembeforethis generator will begin timing for the Generator StartDelay.

Generator Stop Percentage

The Generator Stop Percentage is the percent load onthe other running generators belowwhich this generatorwill begin timing for the Generator Stop Delay. The Stoppercentage is calculated as if this generator was notrunning (the percent load on the remaining generators).

The default setting is 60%, thismeans that the total loadon all the running generators is low enough that all therunning generators other than this one will have lessthan 60% load on them if they were supporting the load.The order 1 generator does not stop.

Generator Start kW

TheGenerator Start kW is calculated based on theStartkWsof eachof thegeneratorswith a lower order numberand the Start percentage for this generator. The StartkW is the total load on the bus above which thisgeneratorwill begin timing for theGeneratorStartDelay.

Generator Stop kW

TheGenerator Stop kW is calculated based on the StopkWsofeachof thegeneratorswith a lower order numberand theStoppercentage for this generator. TheStopkWis the total load on the bus below which this generatorwill begin timing for the Generator Stop Delay.

Generator Start Delay

The Generator Start Delay is the time delay in secondsfor this generator to start. Because the start delay isactually a curve based on the difference between theactual kW and the start kW of this generator, the startdelay is actually the time for the generator to start with a10% overload.

Generator Stop Delay

The Generator Stop Delay is the time delay in secondsfor this generator to stop. Because the stop delay isactually a curve based on the difference between theactual kW and the stop kW of this generator, the startdelay is actually the time for the generator to start with10% less load than the stop kW.


9.8 Load Add/Shed ConfigurationThe Load Add/Shed configuration (also known as loadcontrol) is intended to removenon-critical loads from thegenerator in the event of a condition where thegenerator capacity is insufficient to support the load.This allows the critical loads to receive power until theload decreases or the capacity increases.

9.8.1 Load Add/Shed Setup

Generator Maximum Percent Capacity

This is the maximum load on the generator which theLoad Add/Shed will automatically allow. If the loadexceeds this level, no additional loadswill be addeduntilthe load decreases below this level. The time to add aload increases as the load approaches this level.

Generator Overloaded Percent

This is themaximum load that the generator will supportbefore it begins to shed load. The time to shed a loaddecreases as the load on the generator increases.

Load Priority Configuration

The Load Shed priorities are events which can beassigned to programmable IO. Priorities 1 and 2 aredefaulted to RDO outputs 3 and 4. The priorities can beconfigured to outputs on the 14 relay dry contact kit oreach controller on thenetwork canbegivenconsecutiveassignments to the existing IO.

For Example:Generator #1—Load Shed Priority 1 and Load Shed Priority 2Generator #2—Load Shed Priority 3 and Load Shed Priority 4Generator #3—Load Shed Priority 5 and Load Shed Priority 6

Note: The load control outputs behave similarly oneach of the generators. If an output is configuredfor Load Shed Priority 1 on all generators, theywill all shed and add at the same time.

Note: The advantage of setting a few load shed outputson each controller is that if one generator has thebattery removed for service, the load controloutputs on the other controllers are still able toshed loads (allowing the system to shednon-critical loads and continue supplying criticalloads with power). The priorities that are shedmay bemore important than the priorities that arecontrolled by the disconnected generator but atleast the critical loads will not lose power due toan overload condition.


Notes

TP-6862 6/14 79Appendix

Appendix A Generator Selection and Wattage Requirements

Consider total wattage requirements (lights, motors,appliances) when selecting a generator set or whensizing wattage usage in which available space andconstruction limit the size of the generator set.

Motors

When figuring generator set capacity requirements forloads that include electric motors, consider the highcurrent demanded by the motors during startup. Theinrush or starting current is typically 2--3 times higherthan that required when the motor reaches normaloperating speed. Allow reserve for inrush demands plusother loads which could be on the line as the electricmotor starts. Use Figure 1 as a guide when selectinggenerator set capacity requirements involving motorloads.

MotorHP

Starting (Inrush)Watts

RunningWatts

1/4 750 330

1/3 1000 400

1/2 1500 600

3/4 2000 750

1 3300 1100

2 4000 2000

3 5000 3000

Figure 1 Motor Requirements

Lighting

To calculate lighting load, add the wattage of eachgenerator set-operated lamp. Note that not all of thelights or lamps are on the generator set AC circuit; some

are DC powered by a 12-volt battery. Make sure thecalculated total wattage includes only lights actually onthe generator set AC circuit.

Air Conditioners

The starting characteristics of air conditioners varygreatly; one 12,000 Btu unit has, for example, lowerstarting requirements than a 10,000 Btu unit of anothervariety. When using only one unit, there is usually nostarting problem, provided the lighting and applianceload is not too high when starting the unit.

Simultaneous starting of two air conditioning units,however, can present problems if the generator setcapacity ismarginal. Becauseof the variation in startingcharacteristics among air conditioners, this publicationmakes no statements regarding multiple-motor startingcapabilities of the generator set covered. Considerdelayed starting or use of easy-starting devices on airconditioner units whenever simultaneously startingmore than one motor.

See Figure 2 for typical air conditioner requirements.Information will vary with manufacturer.

Appliances

Generator sets often furnish AC for appliances such asTV, stereo, electricwater heater, etc. With the exceptionof the resistance-type loads such as the water heater,requirements for appliances are usually low. Do notoverlook such loads when figuring total requirements.Allow reservecapacity for anticipatedappliance loads toavoid overloading a generator set.

Air Conditioner Size (Btu/Hr.)

7,000 9,000 12,000 16,000 24,000

Voltage 115 230 115 230 115 230 115 230 230

Full load amps 9.3 4.8 9.9 5.0 11.8 6.3 16.3 8.0 11.6

Rated load amps 7.7 4.0 7.0 3.5 8.9 4.8 13.0 6.2 10.2

Locked rotor amps 34.0 20.0 40.0 20.0 50.0 31.0 75.0 36.0 56.0

Starting (inrush) watts 3910 4600 4600 4600 5750 7130 8630 8280 12,900

Running watts 886 920 805 805 1020 1100 1500 1430 2350

Figure 2 Typical Marine Air Conditioner Requirements, 60 Hz

TP-6862 6/1480 Appendix

Appendix B Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6862 6/14 Appendix 81

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gas

NBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

TP-6862 6/1482

TP-6862 6/14 83

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455E 2013 and 2014 by Kohler Co. All rights reserved.

TP-6862 6/14a

Documents

Tp6862!33!125efozdj Installation Manual