S02 261219-Engine-Generator-Re-Submittal-Review_2018-09-06 (COR).pdf

PREVIOUS EDITION IS OBSOLETE.

MATERIAL APPROVAL SUBMITTAL

(See Instructions on Reverse)

TO: (Contracting Officer)

PROJECT NUMBER

FOR GOVERNMENT USE ONLY

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Please DO NOT RETURN your form to either of these addresses. Send your completed form to: SAF/AQCO, Pentagon, Washington DC 20330-1000.

FROM: (Contractor)

DATE

For Evaluation and Action

TO: (Base Civil Engineering Officer/ COR)

TYPE OR PRINT NAME AND GRADE SIGNATURE

TO: (AF Contracting Office)

RECOMMEND APPROVAL DISAPPROVAL AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE

APPROVED

DISAPROVED AS INDICATED ABOVE AND SUBJECT TO ANY APPLICABLE COMMENTS ON THE REVERSE SIDE. REQUEST

TO: (Contractor)

DATE TYPE OR PRINT NAME AND GRADE SIGNATURE

DATE

DATE TYPE OR PRINT NAME AND GRADE SIGNATURE

MODIFIED AF FORM 3000, SEP 91 (EF)

SUBMITTALSUBMISSION NUMBERCONTRACT NUMBER

NEW RESUBMITTAL

PREVIOUS SUBMISSION NUMBER

ITEM

NO.

SPECIFICATION SECTION/

PARA NO./DRAWING NO.

DESCRIPTION OF MATERIAL

(Include Type, Model Number, Mfg., etc. & file name of attachments)

SEE

REVERSE INITIAL

BY COMPLETING THIS FORM, THE UNDERSIGNED CONTRACTOR CERTIFIES THAT

THE MATERIAL COMPLIES WITH ALL SPECIFICATIONS OF SUBJECT CONTRACT.

AP-

PROVED

DISAP-

PROVED

TO BE COMPLETED BY CONTRACTOR

DATE TYPE OR PRINT NAME AND TITLE

SIGNATURE

FOR GOVERNMENT USE ONLY

Form Approved OMB No 9000-0062 Expires Apr 30, 1993

RESUBMITTAL ON DISAPPROVED ITEMS WITHIN DAYS OF DATE SHOWN BELOW.

marcel.cartier Text Box marcel.cartier Text Box marcel.cartier Text Box marcel.cartier Text Box marcel.cartier Text Box A-E marcel.cartier Text Box VA Engineer/COTR marcel.cartier Text Box Contracting

COMMENTS

(Number to correspond with applicable Item Number on reverse)

INSTRUCTIONS TO CONTRACTORS

1. The term "material" is defined as articles, supplies, raw materials, equipment, parts, components, and end items that are to be incorporated into the work required by the contract.

2. This form is to be used by contractors for submitting Shop Drawings (*.DWG or *.PDF format), Manufacturer's Literature and Certificates (scanned as *.PDF) to the Government for approval in accordance with the provisions of this contract. Unless otherwise specified, it is to be prepared, signed, and E-mailed to the contracting officer with appropriate attachments. One paper format copy is to be submitted also.

3. Item(s) to be approved will be clearly tabbed or identified. Data pertaining to item(s) to be approved will be clearly identified or tabbed, particularly where documents are voluminous, in order to properly evaluate the materials or articles to be incorporated in the work. Each attachment will be numbered to correspond with the item number shown on the face of this form.

4. Requests submitted shall be numbered consecutively, by contract, in the space entitled "Submission No.". This number, in addition to the Contract No., will be used to identify each Material Approval Submittal. Resubmissions will be indicated in the appropriate block and the insertion of previous submission number and data in addition to a new submission number. A single submission should be used for all work of a section of the specifications, but in NO instance should the submission include work for more than one (1) contract. Submittals requiring priority handling will be submitted by separate submittal using the form and so marked across the face of the form.

5. This Material Approval Submittal is not valid unless it is signed by the contracting officer. This approval is required as called for by the contracting officer under the terms of this contract. One paper copy of the submittal is to be hand signed for Contracting Officers records.

MODIFIED AF FORM 3000, SEP 91 (E-MAIL FORMAT) (EF) (REVERSE)

marcel.cartier Text Box

Submittal for Approval

CT/MRI FACILITY

MA

KPS QUOTE # P‐18‐0416

Kohler SAP # 26453336

Generator Submittal Package

August 15, 2018

TO: Powers Generator Services FROM: Sean Hall Sales Engineer

265 Homestead Highway Kinsley Power Systems 14 Connecticut South Drive

Swanzey, NH 03446 East Granby, CT 06026 Office: 860‐844‐2233 Cell: 802‐359‐2579 Fax: 860‐844‐6136

ATTN: Al Powers _ E‐mail: shall@kinsleypower.com

NOTE: This submittal is contingent upon receipt of written approval to release for production.

TABLE OF CONTENTS

Sub-Section

Controller Circuit Breaker Circuit Breaker Circuit Breaker Circuit Breaker Circuit Breaker

Literature

G6-46 G6-88 Circuit Breaker Trip Curves Circuit Breaker Trip Curves Circuit Breaker Trip Curves P_R Frame Breaker G6-146

Exhaust Voltage Regulator G6-139

4UA13

Emissions Data EPA Certificate

ADV-7645

ADV-7900

ADV-8629

ADV-78900

ADV-7932

GM75953

GM78247

ADV-6990

GM62554

S4001S1R

Section Summary Model 300REOZJ Spec Sheets Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet Specification Sheet

Alternator Data

Emissions Data

Dimensional Drawings

Wiring Schematic Diagrams

Misc

ADV-7372

TP-5700

Battery Charger

Exhaust Voltage Regulator Remote Serial Annunciator Day Tank Controller

Alternator Data Sheet

Emissions Data Emissions Data

State Tank Day Tank Controller Generator Accessories Seismic Instruction

Controller Schematic Diagram Controller Wiring Diagram Interconnection Diagram Remote Serial Annunciator Remote Serial Annunciator Day Tank Controller

Flexible Exhaust

Circuit Breaker Mounting Rigging and Installation

GM32384

smurphy Rectangle

Warranty tp-5374

Certification G18-206

Pre-Startup Checklist

Warranty

IBC Seismic ISO9001 Certificate Prototype Test Certificate Prototype Test Report

Pre-Startup Checklist

G15-152 G18-56

PreStartUpCheckList

14 Connecticu

East Granby, C

Tel: 860.844.6

Fax: 860.844.6

T

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Submit

1.

2.

3.

4.

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CT 06026

6100 · 800.255.3503

To:

Project Name

Date:

Subject:

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60 Loudonville Roa

Albany, NY 12204

Tel: 518.458.8614 · 8

Fax: 518.458.1738

P

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8.15.18

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Kohler 300RE tion to 375kV ed on the rec

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300kW/375

Engine Lubri ater required

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VA Brockton M

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• Resubmittal includes 120V thermostatically controlled oil heater.

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Maker ® cont gh this screen rm features a nunciator RSA additional sp

605 Cambridge Avenue

Syracuse, NY 13208

Tel: 315.455.8440 · 315.4

Fax: 315.455.8069 rator Service

MRI/CT Facilit bmittal Comm d the generat d for record o

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2205 Kenmore Avenue, S

Tonawanda, NY 14207

Tel: 716.876.2324

Fax: 716.876.2326 nse bove referenc nerator must the following nce with draw er specificatio and 2.10.

individual fau e individual fa um florescent DEC‐550 contr heet compre ze alarms and

Suite 104 310 Guin

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6 32 13 2.4 F a ights for 11 li r lights for 7 l y faults or wa provide a com of NFPA 110 fa ty to group co

76 Willie Hill Road, U

Wells, ME 04090

Tel. 800-255-3503 nce our respo maximum ser ed and 2.9. Jacke sted fault isted fault rnings will be mprehensive l ault alarms. I ommon alarm

Unit 1 onse vice et e ist n ms to

14 Connecticu

East Granby, C

Tel: 860.844.6

Fax: 860.844.6

5.

ut South Drive

CT 06026

6100 · 800.255.3503

261219‐2.1 Study.

All b curv

Elec

60 Loudonville Roa

Albany, NY 12204

Tel: 518.458.8614 · 8

Fax: 518.458.1738

Line Breaker breakers prov ve.

ctric System P ad

877.790.9961 rs: Generator vided have an

Protective De

605 Cambridge Avenue

Syracuse, NY 13208

Tel: 315.455.8440 · 315.4

Fax: 315.455.8069 circuit break n Interrupt Ra evice Study by

T

455.8069 T

F ers must be c ating of 35kA y others.

2205 Kenmore Avenue, S

Tonawanda, NY 14207

Tel: 716.876.2324

Fax: 716.876.2326 coordinated w at 480V. Refe

Suite 104 310 Guin

Brewster

Tel. 914.2

Fax. 914.

with Electric S erence respe nea Road r, NY 10509

218.9940

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System Prote ctive data sh

76 Willie Hill Road, U

Wells, ME 04090

Tel. 800-255-3503 ctive Device eet and trip

Unit 1

Proposal

The Energy Solutions Company 14 Connecticut South Drive Page 1 of 5 East Granby, CT 06026 800.255.3503 www.kinsleypower.com

Quote Number Project Name Project Location Date

Q‐18‐2491 Generator Only CT/MRI Facility 6/15/2018

From: Sean Hall

14 Connecticut South Drive

East Granby, CT 06026

Phone: 860.844.2233

Fax: 860.844.6136

Email: shall@KinsleyPower.com

Cell: 802.359.2579

Generator

Qty Description

300REOZJ Generator System

1 300REOZJ Generator Set

Includes the following:

Literature Languages English

Approvals and Listings UL2200 Listing

Approvals and Listings IBC Seismic Certification

Engine 300REOZJ, 24V, 60Hz

Nameplate Rating Standby 130C Rise

Voltage 60Hz, 277/480V, Wye, 3Ph, 4W

Alternator 4UA13

Cooling System Unit Mounted Radiator, 50C

Skid and Mounting Skid

Air Intake Standard Duty

Controller DEC550

Controller Accy, Installed Controller Connection Kit

Fuel Tank Type State

Fuel Runtime (Approx.) 24 Hours

Qty Bill of Material Summary

1 Kohler 300REOZJ Generator Output‐ 300.0kW, 375 KVA, 277/480 Volt, 451 Amps,60 Hz , Three Phase Fuel Type ‐ Diesel Tank ‐ 24 Hours / 555 Gallons Configuration ‐ Open Unit Warranty ‐ 1 Year Standard

Proposal

The Energy Solutions Company 14 Connecticut South Drive Page 2 of 5 East Granby, CT 06026 800.255.3503 www.kinsleypower.com

555 Gallons

5 Gal Spill Cont w/95% Shutoff

Emergency Vent, 4", IBC

2500W,90‐120V,1Ph,w/Valves

Radiator Duct Flange

Battery Charger, 10A

Run Relay

Failure Relay w/Harness,1Fault

Generator Heater

100% Rated

Electronic, LSI

35kA at 480V

Shunt Trip

100% Rated

Electronic, LI

35kA at 480V

Shunt Trip

100% Rated

Electronic, LI

35kA at 480V

Shunt Trip

Shunt Trip Wiring

Ground Fault Relay Indication

Flexible Fuel Lines

Coolant in Genset

Standard

Power Factor Test,0.8,3Ph Only

Subbase Fuel Tank Capacity

Fill Pipe/Spill Fill Options

Fuel Tank Vent

Starting Aids, Installed

Cooling System Acc.,Installed

Electrical Accy.,Installed

Electrical Accy.,Installed

Electrical Accy.,Installed

Electrical Accy.,Installed

Rating, LCB 1

Amps, LCB 1

Trip Type, LCB 1

Interrupt Rating LCB 1

Aux Trip, LCB 1

Rating, LCB 2

Amps, LCB 2

Trip Type, LCB 2

Interrupt Rating LCB 2

Aux Trip, LCB 2

Rating, LCB 3

Amps, LCB 3

Trip Type, LCB 3

Interrupt Rating LCB 3

Aux Trip, LCB 3

LCB Accy. Installed

Ground Fault Relay Indication

Fuel Lines, Installed

Miscellaneous Accy,Installed

Warranty

Testing, Factory

Flexible Exhaust, 6" Flange Lit

Kit, Gen Maint, 300REOZJ RSA

III, Mult. ATS Annunciator

W/ Duplex Pumps

Spec Sheets

Standard Features

• Kohler Co. provides one-source responsibility for the generating system and accessories.

• The generator set and its components are prototype-tested, factory-built, and production-tested.

• The 60 Hz generator set offers a UL 2200 listing.

• The generator set accepts rated load in one step.

• The 60 Hz generator set meets NFPA 110, Level 1, when equipped with the necessary accessories and installed per NFPA standards.

• A one-year limited warranty covers all systems and components.

Two- and five-year extended warranties are also available.

• Tier 3 EPA-certified for Stationary Emergency Applications

Alternator Features

• The unique Fast-Response II excitation system delivers excellent voltage response and short circuit capability using a permanent magnet (PM)-excited alternator.

• The brushless, rotating-field alternator has broad range reconnectability.

Other Features

• Controllers are available for all applications. See controller features inside.

• The low coolant level shutdown prevents overheating (standard on radiator models only).Integral vibration isolation eliminates the need for under-unit vibration spring isolators.

• An electronic, isochronous governor delivers precise frequency regulation.

• Multiple circuit breaker configurations.

Generator Set Ratings Standby130C Ratings

Alternator Voltage Ph Hz kW/kVA Amps

4UA13 277/480 3 60 300 / 375 451

RATINGS: All three-phase units are rated at 0.8 power factor.

Standby Ratings: Standby ratings apply to installations served by a reliable utility source. The standby rating is applicable to varying loads for the duration of a power outage.

There is no overload capability for this rating. Ratings are in accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271.

Prime Power Ratings: Prime power ratings apply to installations where utility power is unavailable or unreliable. At varying load, the number of generator set operating hours is unlimited.

A 10% overload capacity is available for one hour in twelve. Ratings are in accordance with ISO-8528/1, overload power in accordance with ISO-3046/1, BS 5514, AS 2789, and DIN 6271. For limited running time and base load ratings, consult the factory.

Obtain the technical information bulletin (TIB-101) on ratings guidelines for the complete ratings definitions.

The generator set manufacturer reserves the right to change the design or specifications without notice and without any obligation or liability whatsoever.

GENERAL GUIDELINES FOR DERATION: Altitude: Derate 1.3% per 100 m (328 ft.) elevation above 762 m (2500 ft.). Temperature: Derate 1.0% per 10?C (18?F) temperature above 25?C (77?F).

300REOZJ

Diesel

Alternator Specifications Specifications Alternator Alternator manufacturer Kohler Type 4-Pole, Rotating-Field Exciter type Brushless,Permanent-Magnet Leads, quantity 12, Reconnectable Voltage regulator Solid State, Volts/Hz Insulation NEMA MG1 Insulation: Material Class H Insulation: Temperature Rise 130°C, Standby Bearing: quantity, type 1, Sealed Coupling Flexible disc Amortisseur windings Full Voltage regulation, no-load to full-load (with <0.5% drift due to temp.

variation)

Controller Dependent

One-Step Load Acceptance 100% of rating Unbalanced load capability 100% of Rated Standby Current

• NEMA MG1, IEEE, and ANSI standards compliance for temperature rise and motor starting.

• Sustained short-circuit current of up to 300% of the rated current for up to 10 seconds.

• Sustained short-circuit current enabling down stream circuit breakers to trip without collapsing the alternator field.

• Self-ventilated and dripproof construction.

• Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability and long life.

• Superior voltage waveform from a two-thirds pitch stator and skewed rotor.

• Fast-Response™ II brushless alternator with brushless exciter for excellent load response.

Engine Engine Specification Engine Manufacturer John Deere Engine Model 6090HFG86 Engine: type 4-Cycle, Turbocharged, Charge Air Cooled Cylinder arrangement 6, Inline Displacement, L (cu. in.) 9.0 (548) Bore and stroke, mm (in.) 118.4 x 136 (4.65 x 5.35) Compression ratio 16.0:1 Piston speed, m/min. (ft./min.) 457 (1500) Main bearings: quantity, type 7, Replaceable Insert Rated rpm 1800 Max. power at rated rpm, kWm (BHP) 345 (463) Cylinder head material Cast Iron Crankshaft material Forged Steel Valve (exhaust) material Intake Chromium-Silicon Steel Valve (exhaust) material Exhaust Stainless Steel Governor: type, make/model JDEC Electronic L14 Denso HP4 Frequency regulation, no-load to-full load Isochronous Frequency regulation, steady state ±0.25% Frequency Fixed Air cleaner type, all models Dry

Model: 300REOZJ, continued

Exhaust Exhaust System Exhaust Manifold Type Dry Exhaust flow at rated kW, m3/min. (cfm) 63.6 (2246) Exhaust temperature at rated kW, dry exhaust, °C (°F) 497 (927) Maximum allowable back pressure, kPa (in. Hg) Min. 0 (0) Max. 7.5 (2.2) Exh. outlet size at eng. hookup, mm (in.) 98 (3.86)

Engine Electrical Engine Electrical System Battery charging alternator: Ground (negative/positive) Negative Battery charging alternator: Volts (DC) 24 Battery charging alternator: Ampere rating 45 Starter motor rated voltage (DC) 24 Battery, recommended cold cranking amps (CCA): Qty., CCA rating each

Two, 950

Battery voltage (DC) 12

Fuel Fuel System Fuel type Diesel Fuel supply line, min. ID, mm (in.) 11.0 (0.44) Fuel return line, min. ID, mm (in.) 6.0 (0.25) Max. lift, fuel pump: type, m (ft.) Electronic, 3 (10) Max. fuel flow, Lph (gph) 240 (63.4) Fuel prime pump Electronic Fuel Filter Secondary 2 Microns@ 98% Efficiency Fuel Filter Primary 10 Microns Fuel Filter Water Separator Yes Recommended fuel #2 Diesel

Lubrication Lubrication System Type Full Pressure Oil pan capacity, L (qt.) 32.5 (34.4) Oil pan capacity with filter, L (qt.) 33.4 (35.3) Oil filter: quantity, type 1, Cartridge Oil cooler Water-Cooled

Cooling Radiator System Ambient temperature, °C (°F) 50 (122) Engine jacket water capacity, L (gal.) 16 (4.25) Radiator system capacity, including engine, L (gal.) 36 (9.5) Engine jacket water flow, Lpm (gpm) 265 (70) Heat rejected to cooling water at rated kW, dry exhaust, kW (Btu/min.) 114 (6489) Heat rejected to air charge cooler at rated kW, dry exhaust, kW (Btu/ min.)

99.1 (5641)

Water pump type Centrifugal Fan diameter, including blades, mm (in.) 863.6 (34.0) Fan, kWm (HP) 9 (12.1) Max. restriction of cooling air, intake and discharge side of radiator, kPA (in. H20)

0.125 (0.5)

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

Operation Requirements Air Requirements Radiator-cooled cooling air, m3/min. (scfm) * 396.4 (14000) Combustion air, m3/min. (cfm) 26.5 (936) Heat rejected to ambient air: Engine, kW (Btu/min.) 60.8 (3460) Heat rejected to ambient air: Alternator, kW (Btu/min.) 23.9 (1360)

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

Fuel Consumption Diesel, Lph (gph), at % load Rating

84.1 Lph (22.2 gph)

67.7 Lph (17.9 gph)

49.7 Lph (13.1 gph)

26.3 Lph (7.0 gph)

Standby Fuel Consumption at 100% load Standby Fuel Consumption at 75% load Standby Fuel Consumption at 50% load Standby Fuel Consumption at 25% load

Generator Set Controller

Kohlerr Decision-Makerr 550 Controller

General Description and Function

The Decision-Makerr 550 generator set controller provides advanced control, system monitoring, and system diagnostics for optimum performance and compatibility with selected engine Electronic Control Modules (ECM).

ECM models only: The Decision-Makerr 550 controller directly communicates with the ECM to monitor engine parameters and diagnose engine problems (see Controller Diagnostics for details).

Standard Features

D A digital display and keypad provide access to data. The display provides complete and understandable information, and the keypad allows easy local access.

D Measurements selectable in metric or English units.

D The controller can communicate directly with a personal computer via a network or via a modem configuration.

D The controller supports Modbusr protocol. Use with serial bus or Ethernet networks. (Ethernet requires an external Modbusr/Ethernet converter module.)

D Integrated voltage regulator providing 0.25% regulation.

D Built-in alternator thermal overload protection.

D A lockout keyswitch meets appropriate local code requirements.

Optional Features

D Monitor III, an optional menu-driven Windowsr-based PC software, monitors engine and alternator parameters and also provides control capability. See G6-76 spec sheet for more information.

D Menu 15 (Protective Relays) is required for optional protective functions and is only available with the Kohler PD-Series switchgear.

Modbusr is a registered trademark of Schneider Electric.

Windowsr is a registered trademark of Microsoft Corporation.

Industrial Generator Set Accessories

Decision-Makerr 550

G6-46 12/15o Page 113

G6-46 12/15o Page 2

Decision-Makerr 550 Controller

15 Protective Relays

Controller Features Decision-Makerr 550—Software Version 2.70 or higher

Specifications D Power source with circuit protection: 12- or 24-volt DC D Power drain: 700 milliamps (or 400 milliamps without panel lamps) D Humidity range: 5% to 95% noncondensing D Operating temperature range: --40C to +70C (--40F to +158F) D Storage temperature range: --40C to +85C (--40F to +185F) D Standards:

d NFPA 99 d NFPA 110, Level 1 d CSA 282-09 d UL 508

Hardware Features D Vacuum fluorescent display D Environmentally sealed 16-button membrane keypad D LED status indicating lights D Three-position (run, off/reset, auto) keyswitch D Latch-type emergency stop switch with International

Electromechanical Commission (IEC) yellow ring identification D Alarm horn D Fuse-protected battery circuits D Controller mounts locally or remotely up to a distance of 12 m (40 ft.)

and viewed from one of four positions D Dimensions—W x H x D, 460 x 275 x 291 mm (18.15 x 10.8 x 11.47 in.)

NFPA Requirements

In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine/generator functions and faults shown below.

NFPA 110 Common Alarm

D Engine functions:

d Overcrank d Low coolant temperature warning d High coolant temperature warning d High coolant temperature shutdown d Low oil pressure shutdown d Low oil pressure warning d Overspeed d Low fuel (level or pressure) * d Low coolant level d EPS supplying load d High battery voltage * d Low battery voltage * d Air damper indicator

D General functions:

d Master switch not in auto d Battery charger fault * d Lamp test d Contacts for local and remote common alarm d Audible alarm silence switch d Remote emergency stop

* Function requiresoptional input sensors or kits and is enginedependent, see Controller Displays as Provided by the Engine ECM.

G6-46 12/15o Page 3

Controller Functions

The control functions apply to both the ECM and non-ECM equipped models unless noted otherwise.

D AC Output Voltage Adjustment The voltage adjustment provides keypad adjustment in 0.1 volt increments of the average line-to-line AC output voltage with a maximum adjustment of 10% of the system voltage.

D Alternator Protection The controller firmware provides generator set overload and short circuit protection matched to each alternator for the particular voltage/phase configuration.

D Automatic Restart The controller automatic restart feature initiates the start routine and recrank when the generator set slows to less than 390 rpm after a failed start attempt.

D Battleswitch (Fault Shutdown Override Switch) The battleswitch input provides the ability to override the fault shutdowns except emergency stop and overspeed shutdown in emergency situations and during generator set troubleshooting.

D Clock and Calendar Real-time clock and calendar functions time stamp shutdowns for local display and remote monitor. Also use these functions to determine the generator set start date and days of operation.

D Cooldown Temperature Override This feature provides the ability to bypass (override) the cooldown temperature shutdown and force the generator set to run for the full engine cooldown time delay. Also see Time Delay Engine Cooldown

(TDEC).

D Cyclic Cranking The controller has programmable cyclic cranking. The customer selects the number of crank cycles (1--6) and the crank time from 10 to 30 seconds. The crank disconnect depends upon the speed sensor input information or the generator frequency information.

The default cyclic crank setting is 15 seconds on, 15 seconds off for three cycles.

D Digital Voltage Regulator The digital voltage regulator provides0.25% no-load to full-load regulation.

D Display Power Shutdown To conserve battery power, the display turns off after 5 minutes of inactivity. Pressing any keypad button activates the display.

D ECM Communication The controller monitors ECM communication links and provides fault detection for oil pressure signal loss, coolant temperature signal loss, and ECM communication loss. Each of these faults provides local display, alarm horn ON, and relay driver output (RDO) on ECM models only. See Controller Diagnostics following for additional information.

D Idle Speed Function Idle speed function provides the ability to start and run the engine at idle speed for a selectable time period. The engine will go to normal speed should the temperature reach warm-up before the time delay is complete.

D Lamp Test Keypad switch verifies functionality of the indicator LEDs, alarm horn, and digital display.

D Load Shed The load shed function provides a load control output (RDO) with user-selectable load shed level.

D Master Switch Fault The generator set master switch has fault detection at four levels:

1) master switch to off, 2) master switch open, 3) master switch error, and 4) master switch not in auto. Each of these faults/ warnings provides local display, alarm horn on, and activates a relay driver output (RDO). By placing the master switch to the off/reset position, all generator set faults can be reset.

D Modbusr Interface The Modbusr interface provides industry standard open protocol for communication between the generator set controller and other devices or for network communications.

D Number of Starts Total number of generator set successful starts is recorded and displayed on the local display and remote PC monitor. This information is a resettable and total record.

D Programming Access The setup access and programming information is password protected. When locally accessing programming information, the PM (programming mode) LED flashes. When remotely accessing programming information, the PM LED is steady.

D Programmed Run The programmed run function provides user-selectable time for a one-time exercising of the generator set. The controller does not provide weekly scheduled exercise periods.

D Remote Reset The remote reset function resets faults and allows restarting of the generator set without going to the master switch off/reset position.

The remote reset function is initiated via the remote reset digital input.

D Running Time Hourmeter The running time hourmeter function is available on the local display and remote monitor. The information displayed uses real time loaded and unloaded run time as an actual and resettable record.

D Self-Test The controller has memory protection and a microprocessor self-test.

D Starting Aid The starting aid feature provides control for an ether injection system. This setup has adjustable on time before engine crank from 0 to 10 seconds. This feature is also part of the remote communication option.

D Time Delay Engine Cooldown (TDEC) The TDEC provides a user-selectable time delay before the generator set shuts down. If the engine is above the preset temperature and unit is signalled to shut down, unit will continue to run for the duration of the TDEC. If the engine is at or below the preset temperature and unit is signalled to shut down or the TDEC is running, unit will shut down without waiting for the time delay to expire. Also see Cooldown Temperature Override.

D Time Delay Engine Start (TDES) The TDES provides a user-selectable time delay before the generator set starts.

Modbusr is a registered trademark of Schneider Electric.

G6-46 12/15o Page 4

Controller Diagnostics The controller features warnings and shutdowns as text messages on the vacuum fluorescent display. See the table below.

Warnings show yellow LED and signal an impending problem.

Shutdowns show red LED and stop the generator set.

Note: Menu 15 features are available by purchasing the paralleling switchgear option.

Note: The available user inputs are dependent on factory reserved inputs for specific engine types, engine controls, and paralleling applications.

User-Defined Common Fault and Status. The user customizes outputs through a menu of warnings, shutdowns, and status conditions.

User defines up to 31 relay driver outputs (RDOs) (relays not included).

Warning Function

Shutdown Function

User- Defined

User RDOs

Engine Protection Air damper control, if equipped X X

Air damper indicator, if equipped X X X

Coolant temp. signal loss X X X High battery voltage X X X High coolant temperature X X X X High oil temp. shutdown X X X Low battery voltage X X X Low coolant level X X X Low coolant temperature X X X Low fuel level (diesel) * X X X Low fuel pressure (gas) * X X X Low oil pressure X X X X Oil pressure signal loss X X X Overcrank X X X Overspeed X X X Speed sensor fault X X X Starting aid X X Weak battery X X X General Protection Auxiliary inputs 0--5 VDC— up to 7 analog X X X X

Auxiliary inputs— up to 21 digital X X X X

Battery charger fault * X X X Defined common fault [ X X EEPROM write failure X X X Emergency stop X X X Engine cooldown delay X X Engine start delay X X EPS supplying load X X X Internal fault X X X Load shed kW overload X X X

Warning Function

Shutdown Function

User- Defined

User RDOs

Load shed underfrequency X X X Master switch error X X X Master switch not in auto X X X Master switch open X X X Master switch to off X X X NFPA 110 common alarm X X SCRDO’s 1--4 (software controlled RDOs) X X

System ready (status) X X Alternator Protection AC sensing loss X X X X Critical overvoltage X X X Generator running X X Ground fault * X X X Locked rotor X X X AC Protection (includes Menu 15 Enabled Enhancements) Alternator protection (short circuit and overload)

X X X

Breaker trip ] X Common protective relay output X X

In synchronization ] X Loss of field (reverse VAR) X X X Overcurrent X X X X Overfrequency X X X Overpower X X X Overvoltage X X X Reverse power X X X Underfrequency X X X Undervoltage X X X

* Function requires optional input sensors or kits and is engine dependent, see

Controller Displays as Provided by the Engine ECM.

[ Factory default settings for the defined common fault are emergency stop, high coolant temperature shutdown, low oil pressure shutdown, overcrank, and overspeed.

] Factory set inputs that are fixed and not user changeable.

Controller Displays as Provided by the Engine ECM (availability subject to change by the engine manufacturer) Display GM/PSI Doosan John Deere (JDEC) Volvo (EMS II) Volvo (EDC III) DD/MTU (ADEC)

Ambient temperature X Charge air pressure X X X X X Charge air temperature X X X X X Coolant level X X X Coolant pressure X X Coolant temperature X X X X X X Crankcase pressure X X ECM battery voltage X X X ECM fault codes X X X X X X ECM serial number X Engine model number X X Engine serial number X X Engine speed X X X X X X Fuel pressure X X Fuel rate X X X X X X Fuel temperature X X X X Oil level X Oil pressure X X X X X X Oil temperature X X X Trip fuel X X X

NOTE: 40--60REOZK (KohlerKDI engines) donot includeanECMas standard equipment. REOZMD/ROZMC(Mitsubishi engines) have anECMbut do not send signals to the generator set controller.

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G6-46 12/15o Page 5

Controller Monitoring Standard Equipment and Features

D Alarm horn D Indicators:

d Not in auto (yellow) d Program mode (yellow) d System ready (green) d System shutdown (red) d System warning (yellow)

D Switches and standard features:

d Keypad, 16-button multi-function sealed membrane d Lamp test d Keyswitch, auto, off/reset, run (engine start) d Switch, emergency stop (normally closed contacts)

D Vacuum fluorescent display with two lines of 20 characters

Displays Some engine displays are dependent upon enhanced electronic engine control availability.

D Engine monitoring data (metric or English units):

d Battery voltage d Engine model number [ d Engine serial number [ d Engine speed d Engine start countdown d ECM—battery voltage [ d ECM—fault codes d ECM—serial number [ d Fuel rate d Level—coolant [ d Level—oil [ d Pressure—crankcase [ d Pressure—charge air [ d Pressure—coolant [ d Pressure—fuel d Pressure—oil d Rpm d Temperature—ambient [ d Temperature—charge air [ d Temperature—coolant d Temperature—fuel [ d Temperature—oil [ d Trip fuel [

D Engine setpoints d Coolant—high temperature shutdown and warning setpoints d Oil—low pressure shutdown and warning setpoints d Temperature—engine cooled down setpoint d Temperature—engine warmed up setpoint

D Generator monitoring data:

d Current (L1, L2, L3),0.25% accuracy d Frequency,0.5% accuracy d Kilowatts, total per phase (L1, L2, L3),0.5% accuracy d KVA, total per phase (L1, L2, L3),0.5% accuracy d KVAR, total absorbing/generating per phase (L1, L2, L3), 0.5% accuracy d Percent alternator duty level (actual load kW/standby kW rating) d Power factor per phase, leading/lagging d Voltage (line-to-line, line-to-neutral for all phases),0.25% accuracy D Operational records:

d Event history (stores up to 100 system events) d Last start date d Number of starts d Number of starts since last maintenance d Operating days since last maintenance d Operating mode—standby or prime power d Run time (total, loaded and unloaded hours, and total kW hours) d Run time since maintenance (total, loaded, and unloaded hours and total kW hours) d System shutdowns d System warnings d Time, date, and day of week

D Time delays—general:

d Crank cycles for on/pause d Crank cycles for overcrank shutdown d Engine cooldown d Engine start d Load shed d Voltage, over- and under-d Starting aid

D Time delays—paralleling relays (PR) for optional switchgear applications:

d Current—over (PR) d Current—over shutdown d Frequency—over- and under- (PR and shutdown) d Loss of field (PR and shutdown) d Loss of field shutdown (PR) d Power—over (PR) d Power—over shutdown d Reverse power (PR) d Reverse power shutdown d Synch matching—frequency, phase, voltage d Voltage—over- and under- (PR and shutdown)

D System parameters:

d Alternator number d Current, rated (based on kW, voltage, connection settings) d Frequency d Generator set model number d Generator set serial number d Generator set spec number d Rating, kW d Phase, single and three (wye or delta) d Voltage, AC d Voltage configuration, wye or delta

Inputs D Customer and remote inputs:

d Analog inputs 0--5 VDC (up to 7 user-defined analog inputs with multiple shutdown and warning levels) d Digital contact inputs (up to 21 user-defined digital inputs with shutdown or warning levels) d Ground fault detector * d Remote emergency stop d Remote reset d Remote 2-wire start

D Digital inputs (standard):

d Air damper fault, if equipped d Battery charger fault * d Battleswitch d Emergency stop d Field overvoltage (350 kW and higher) d High oil temperature d Idle mode active (ECM models only) * d Low coolant level d Low coolant temperature d Low fuel warning * d Low fuel shutdown *

D Switchgear inputs in Menu 15 (to interface with switchgear system):

d Circuit breaker closed d Enable synch d Lockout shutdown d Remote reset d Remote shutdown d VAR/PF mode selection d Voltage—raise/lower (or VAR/PF raise/lower in VAR/PF mode)

Outputs See the Fault Diagnostics section for a breakdown of the available shutdown and warning functions.

D Thirty-one user-defined relay driver outputs (relays not included) d Fifteen NFPA 110 faults d Defined common faults

Communication D RS-485 connector for Modbusr RTU communication port D RS-232 connector for a PC or modem (optional software required) D SAE J1939 connector for the engine ECM (engine control module)

* Function requires optional input sensors or kits and is engine dependent; see Controller Displays as Provided by the Engine ECM on page 4.

[ See Controller Displays as Provided by the Engine ECM on page 4 for display availability.

Modbusr is a registered trademark of Schneider Electric.

2003, 2005, 2006, 2007, 2008, 2011, 2012, 2013, 2015 by Kohler Co., All rights reserved.

DISTRIBUTED BY:

G6-46 12/15o Page 6

Decision-Makerr 550 Controller Available Options Communication and PC Software Available Options

Refer to spec sheet G6-76, Monitor III Software for additional communication and PC software information including Modbusr communication.

- Local Single Connection. A PC is connected directly to the device communication module with an RS-232 cable for applications where the PC is within 15 m (50 ft.) of the device or RS-485 cable for applications where the PC is up to 1220 m (4000 ft.) from the device.

- Local Area Network (LAN). A PC is connected directly to the device’s local area network. A LAN is a system of connecting more than one device to a single PC.

- Remote Network (Ethernet): A PC with a NIC card uses an Ethernet connection to access a remotely located converter (Modbusr/Ethernet) serving a controller. Refer to G6-79 for system details.

- Remote Network (Modem): A PC uses a modem to connect to a remotely located device modem serving a controller. Monitoring software (Monitor III) runs on the PC to view system operation.

- Monitor III Software for Monitoring and Control (Windowsr-based user interface)

- Converter, Modbusr/Ethernet. Supports a power system using a controller accessed via the Ethernet. Converter is supplied with an IP address by the site administrator. Refer to G6-79 for converter details.

- RS-232 to RS-485 Port Converters

Other Available Options

- Common Failure Relay remotely signals auxiliary fault, emergency stop, high engine temperature, low oil pressure, overcrank, and overspeed via one single-pole, double-throw relay with 10-amp contacts at 120 VAC or 28 VDC maximum.

- Run Relay provides a three-pole, double-throw relay with 10-amp contacts at 120 VAC or 28 VDC maximum for indicating that the generator set is running.

- Controller Cable enables remote mounting of the controller with distances of up to 12 m (40 ft.) from the generator set.

- Controller Connection Kit provides a cable connecting the controller output terminals to a terminal strip in the junction box.

- Dry Contact Kit interfaces between the controller signals and customer-supplied accessories providing contact closure to activate warning devices such as lamps or horns. Kits are available with either one or ten single-pole, double-throw (form-C) relays with 10-amp contacts at 120 VAC or 28 VDC maximum.

- Float/Equalize Battery Charger with Alarm Feature signals controller of battery charger fault.

- Prealarm Kit for NFPA 110 (gas fuel models only) warns the operator of low fuel pressure. Select the kit based on LP vapor or natural gas, combination dual fuel, or LP liquid withdrawal.

- Prime Power Switch prevents battery drain during generator set non-operation periods and when the generator set battery cannot be maintained by an AC battery charger.

- Remote Audiovisual Alarm Panel warns the operator of fault shutdowns and warning conditions. Kit includes common fault lamp and horn with silence switch.

- Remote Emergency Stop Panel immediately shuts the generator set down from a remote station.

- Remote Serial Annunciator (RSA) Panel enables the operator to monitor the status of the generator set from a remote location, which may be required for NFPA 99 and NFPA 110 installations. Uses Modbusr protocol, an industry standard.

Modbusr is a registered trademark of Schneider Electric.

Windowsr is a registered trademark of Microsoft Corporation.

Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455

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

Availability is subject to change without notice. Kohler Co. reserves the right to change the design or specificationswithout notice andwithout any obligation or liability whatsoever. Contact your local Kohlerr generator set distributor for availability.

Device modem

External PC modem

Personal computer Telephone lines

Generator Set with the Decision-Makerr 550 controller

RS-232 to RS-485 port converter or rpiquette Kinsley rpiquette Highlight rpiquette Highlight rpiquette Highlight rpiquette Highlight

Industrial Generator Set Accessories

Standard Features D The line circuit breaker interrupts the generator set output during a short circuit and protects the wiring when an overload occurs. Use the circuit breaker to manually disconnect the generator set from the load during generator set service.

D Circuit breaker kits are mounted to the generator set and are provided with load-side lugs and neutral bus bar.

D Kohler Co. offers a wide selection of molded-case line circuit breaker kits including single, dual, and multiple configurations for each generator set.

D Four types of line circuit breakers are available:

(see page 2 for definitions and pages 3 and 4 for application details) d Magnetic trip d Thermal magnetic trip d Electronic trip d Electronic with ground fault (LSIG) trip

D In addition, line circuit breakers are offered with 80% and 100% ratings.

D Single line circuit breaker kits allow circuit protection of the entire electrical system load.

D Dual line circuit breaker kits allow circuit protection of selected priority loads from the remaining electrical system load.

D Multiple line circuit breaker kits with field connection barrier allow circuit protection for special applications (350--2500 kW models and selected 80--300 kW models).

D Up to four line circuit breakers can be used on 350--2500 kW models.

D Line circuit breakers comply with the following codes and standards unless otherwise stated.

d UL 489 Molded Case Circuit Breakers d UL 1077 Supplementary Protectors d UL 2200 Stationary Engine Generator Assemblies

Line Circuit Breakers 15--2500 kW

Multiple Circuit Breaker Kit with Neutral Bus Bar 180--300 kW Model Shown

Single Circuit Breaker Kit with Neutral Bus Bar 15--300 kW Model Shown

Multiple Circuit Breaker Kits with Neutral Bus Bar 350--2250 kW Model Shown

(also applies to some 300 kW models)

Circuit Breaker Kits with Neutral Bus Bar 800--2500 kW KD Model Shown

G6-88 7/17n Page 119 rpiquette Highlight rpiquette

G6-88 7/17n Page 2

Line Circuit Breaker Types Magnetic Trip Themagnetic trip features an electromagnet in serieswith the load contacts and amoveable armature to activate the tripmechanism.

When a sudden and excessive current such as a short circuit occurs, the electromagnet attracts the armature resulting in an instantaneous trip.

Thermal Magnetic Trip Thermal magnetic trip contains a thermal portion with a bimetallic strip that reacts to the heat produced from the load current.

Excessive current causes it to bend sufficiently to trip the mechanism. The trip delay is dependent on the duration and excess of the overload current. Elements are factory- calibrated.

A combination of both thermal and magnetic features allows a delayed trip on an overload and an instantaneous trip on a short circuit condition.

Electronic Trip These line circuit breakers use electronic controls and miniature current transformers to monitor electrical currents and trip when preset limits are exceeded.

LI breakers are a combination of adjustable trip functions including long-time ampere rating, long-time delay, and instantaneous pickup. LSI breakers have all of the LI breaker features plus short-time pickup, short-time delay, and defeatable instantaneous pickup. LSIG breakers have all of the LSI breaker features plus ground-fault pickup and delay.

Electronic with Ground Fault Trip The ground fault trip feature is referred to as LSIG in this document. Models with LSIG compare current flow in phase and neutral lines, and trip when current unbalance exists.

Ground fault trip units are an integral part of the circuit breaker and are not available as field-installable kits. The ground fault pickup switch sets the current level at which the circuit breaker will trip after the ground fault delay. Ground fault pickup values are based on circuit breaker sensor plug only and not on the rating plug multiplier. Changing the rating plug multiplier has no effect on the ground fault pickup values.

80% Rated Circuit Breaker Most molded-case circuit breakers are 80% rated devices.

An 80% rated circuit breaker can only be applied at 80% of its rating for continuous loads as defined by NFPA 70. Circuit conductors used with 80% rated circuit breakers are required to be rated for 100% of the circuit breaker’s rating.

The 80% rated circuit breakers are typically at a lower cost than the 100% rated circuit breaker but load growth is limited.

100% Rated Circuit Breaker Applications where all UL and NEC restrictions are met can use 100% rated circuit breakers where 100% rated circuits can carry 100% of the circuit breaker and conductor current rating.

The 100% rated circuit breakers are typically at a higher cost than the 80% rated circuit breaker but have load growth possibilities.

When applying 100% rated circuit breakers, comply with the various restrictions including UL Standard 489 and NEC Section 210. If any of the 100% rated circuit breaker restrictions are not met, the circuit breaker becomes an 80% rated circuit breaker.

Line Circuit Breaker Options

- Alarm Switch The alarm switch indicates that the circuit breaker is in a tripped position caused by an overload, short circuit, ground fault, the operation of the shunt trip, an undervoltage trip, or the push-to-trip pushbutton. The alarm resets when the circuit breaker is reset.

- Auxiliary Contacts These switches send a signal indicating whether the main circuit breaker contacts are in the open or closed position.

- Breaker Separators (350--2500 kW) Provides adequate clearance between breaker circuits.

- Bus Bars Bus bar kits offer a convenient way to connect load leads to the generator set when a circuit breaker is not present.

15--300 kW. Bus bar kits are available on alternators with leads for connection to the generator set when circuit breakers are not ordered.

350--2500 kW. A bus bar kit is provided when no circuit breaker is ordered. Bus bars are also available in combination with circuit breakers or other bus bars on the opposite side of the junction box. On medium voltage (3.3 kV and above) units, a bus bar kit is standard (not applicable to KD models).

- Field Connection Barrier Provides installer wiring isolation from factory connections.

- Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm.

- Lockout Device (padlock attachment) This field-installable handle padlock attachment is available for manually operated circuit breakers. The attachment can accommodate three padlocks and will lock the circuit breaker in the OFF position only.

- Lugs Various lug sizes are available to accommodate multiple cable sizes for connection to the neutral or bus bar.

- Overcurrent Trip Switch The overcurrent trip switch indicates that the circuit breaker has tripped due to overload, ground fault, or short circuit and returns to the deenergized state when the circuit breaker is reset.

- Shunt Trip, 12 VDC or 24 VDC A shunt trip option provides a solenoid within the circuit breaker case that, when momentarily energized from a remote source, activates the trip mechanism. This feature allows the circuit breaker to be tripped by customer-selected faults such as alternator overload or overspeed. The circuit breaker must be reset locally after being tripped. Tripping has priority over manual or motor operator closing.

- Shunt Trip Wiring Connects the shunt trip to the generator set controller.

(standard on KD models with the APM802 controller)

- Undervoltage Trip, 12 VDC or 24 VDC The undervoltage trips the circuit breaker when the control voltage drops below the preset threshold of 35%--70% of the rated voltage.

smurphy Highlight smurphy Highlight smurphy Highlight

G6-88 7/17n Page 4

100% Rating Circuit Breaker

Alt. Model Ampere Range Trip Type

C. B.

Frame Size

4D/4E

15--150 Thermal magnetic

HD

60--150

Electronic LI

Electronic LSI

Electronic LSIG

60--150

Electronic LI

HGElectronic LSI

Electronic LSIG

4P/4PX

4Q/4QX

15--150 Thermal magnetic

HD

60--150

Electronic LI

Electronic LSI

Electronic LSIG

60--150

Electronic LI

HGElectronic LSI

Electronic LSIG

175--250 Thermal magnetic JD

Electronic LI

JDElectronic LSI

Electronic LSIG

Electronic LI

JGElectronic LSI

Electronic LSIG

Electronic LI

LGElectronic LSI

Electronic LSIG

4RX

4S/4SX

4TX

4V

4UA

4M6226

15--150 Thermal magnetic

HD

60--150

Electronic LI

Electronic LSI

Electronic LSIG

60--150

Electronic LI

HGElectronic LSI

Electronic LSIG

175--250 Thermal magnetic

JD

Electronic LI

Electronic LSI

Electronic LSIG

Electronic LI

JGElectronic LSI

Electronic LSIG

Electronic LI

LGElectronic LSI

Electronic LSIG

600--800 Electronic LSI

PG

Electronic LSIG

4UA

4M6226

1000--1200 Electronic LSI

PG

Electronic LSIG

Electronic LSI

PJ

Electronic LSIG

Interrupting Ratings Circuit Breaker Frame Size

240 Volt, kA

480 Volt, kA

600 Volt, kA

HD 25 18 14

HG 65 35 18

HJ 100 65 25

JD 25 18 14

JG 65 35 18

JJ 100 65 25

LA 42 30 22

LG

65 35 18MG

PG

PJ 100 65 25

PL 125 100 25

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

E (480 V max.) 30--100

Up to two wire terminals fitting 10-32 or 1/4-20 stud

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

J 175 One 1/0 to 4/0

200--250 One 3/0 to 350 kcmil

LA 300--400

One #1 to 600 kcmil or Two #1 to 250 kcmil

LG 400--600 Two 2/0 to 500 kcmil AL/CU M 700-800 Three 3/0 to 500 kcmil

P 600-800 Three 3/0 to 500 kcmil 1000-1200 Four 3/0 to 500 kcmil

Mechanical Load Lugs Included with H, J, and LG LSIG Neutrals H 60--150 One #14 to 3/0 AL/CU J 250 One 3/0 to 350 kcmil AL/CU LG 400--600 Two 4/0 to 500 kcmil AL/CU rpiquette Highlight rpiquette Highlight rpiquette…