Kohler 40-150EOZDJ Installation Manual
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Kohler 40-150EOZDJ Installation Manual

Kohler 40-150EOZDJ Installation Manual

Marine generator sets
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Installation
Marine Generator Sets
Pleasure Craft Models:
40- -150EOZDJ
33- -125EFOZDJ
Commercial Models:
40- -150EOZCJ
33- -125EFOZCJ
Decision-Makerr 3500
Controller:
TP-6862
6/14a

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Summary of Contents for Kohler 40-150EOZDJ

  • Page 1 Installation Marine Generator Sets Pleasure Craft Models: 40- -150EOZDJ 33- -125EFOZDJ Commercial Models: 40- -150EOZCJ 33- -125EFOZCJ Controller: Decision-Makerr 3500 TP-6862 6/14a...
  • Page 2 TP-6862 6/14...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Section 1 Introduction .
  • Page 4 Paralleling Set Up ........... . . 9.3.1 PGEN Communication Wiring .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting Engine Backfire/Flash IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, Fire including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose WARNING life-threatening danger when improperly installed, operated, maintained. To prevent accidents be aware of potential dangers and act safely.

  • Page 6: Fuel System

    Exhaust System Fuel System Hazardous Voltage/ Moving Parts WARNING WARNING WARNING Carbon monoxide. cause severe nausea, Explosive fuel vapors. Hazardous voltage. Moving parts. fainting, or death. Can cause severe injury or death. Can cause severe injury or death. exhaust system must Use extreme care when handling, Operate the generator set only when...

  • Page 7: Hot Parts

    Notice Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can NOTICE cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while This generator set has been making adjustments repairs. rewired from its nameplate voltage Remove all jewelry before servicing the equipment.
  • Page 8 Notes Safety Precautions and Instructions TP-6862 6/14...

  • Page 9: Section 1 Introduction

    Information in this publication represents data available Note: Only qualified persons should install the generator set. at the time of print. Kohler Co. reserves the right to change this publication and the products represented Marine generator set installations must comply with all without notice and without any obligation or liability applicable regulations and standards.
  • Page 10 Notes Section 1 Introduction TP-6862 6/14...

  • Page 11: Section 2 Location And Mounting

    Section 7 of this manual for generator set dimensions and weights. See Figure 1-1 for a typical installation. Kohler Co. recommends mounting the generator set on a flat board attached to the craft stringers. Craft stringers generally provide the best generator set 2.2 Location...
  • Page 12 Notes Section 2 Location and Mounting TP-6862 6/14...

  • Page 13: Section 3 Cooling System

    Section 3 Cooling System 3.1 Ventilation Engine combustion, generator cooling, and expulsion of flammable and lethal fumes require ventilation. Provide ventilation compliant with USCG regulations governing the sizing of vents and other considerations. As a rule, size each inlet- and outlet-vent area to a minimum of 13 sq.

  • Page 14: Seacock

    Do not use a speed scoop or cup design intake Mount the seawater strainer to the seacock or through-hull strainer because it can cause a ramming permanent structure at a point not higher than the effect and force water upward, past the seawater pump, seawater pump.
  • Page 15 Seawater Freshwater (Coolant/Antifreeze) TP-5592-6 1. Oil cooler 8. Silencer (customer-supplied) 2. Engine block 9. Exhaust outlet 3. Thermostat 10. Intake strainer 4. Water-cooled manifold 11. Seacock 5. Heat exchanger 12. Seawater strainer 6. Exhaust mixer elbow 13. Engine-driven seawater pump 7.
  • Page 16 1 1/4 in. (31.75 mm) ID fill/vent line with a slope not less than 30 degrees * Overflow bottle or tank with cap Bypass Engine Block & Inlet Line Exhaust Manifold Outlet Line Return Line Water pump Keel Cooler Hull * 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 the tank.

  • Page 17: Section 4 Exhaust System

    D Physical fatigue, weakness in end of the flexible exhaust hose connections. joints and muscles Kohler Co. requires a downward pitch of at least 13 mm D Sleepiness, mental fatigue, per 30.5 cm (1/2 in. per running foot). Use a flexible...

  • Page 18: Sound Shielded Units With Dry Exhaust

    4.3 Sound Shielded Units with Dry Alternator-End View Exhaust For units equipped with a dry exhaust and sound shield, insulate the exhaust system inside of the sound shield to the turbocharger/manifold. Use fiberglass exhaust tape/wrap (or equivalent) and secure with stainless wire (or material suitable for use in a marine environment).

  • Page 19: Above-Waterline Installation

    19. Maximum silencer vertical lift of 1.2 m (4 ft.) 8. Coolant recovery tank (located on the unit on some models) 20. Kohler recommends locating the generator set at elevation 9. Locate the coolant recovery tank at the same height as the...

  • Page 20: Mid/Below-Waterline Installation

    4.4.2 Mid/Below-Waterline Installation Non-Service Side View Follow USCG regulations for installing an antisiphon provision to prevent raw water entry into the engine. Use the siphon break if the exhaust manifold outlet is located less than 23 cm (9 in.) above the waterline when the craft is loaded to maximum capacity.
  • Page 21 Waterline 1. Cap 21. Maximum distance between exhaust outlet and generator of 2. Reed valve 4.6 m (15 ft.) 22. Minimum exhaust outlet distance above waterline of 10 cm 3. Mounting base (4 in.) 4. Maximum silencer vertical lift of 1.2 m (4 ft.) 23.
  • Page 22 23. Silencer (customer-supplied) 9. Siphon break 24. Waterline 10. Cap 25. Kohler recommends locating the generator set at elevation 11. Reed valve that exhaust mixer is above the highest point of the exhaust 12. Mounting base 13. Heat exchanger (locations vary by model) outlet hose.
  • Page 23 24. Height of internal lift tube to be below generator exhaust 12. Seawater strainer manifold 13. Seacock 25. Kohler recommends generator be located at elevation that 14. Intake strainer exhaust mixer elbow is above silencer exhaust outlet 15. Engine-driven seawater pump 26.
  • Page 24 Satisfactory generator set performance requires proper Ensure that there is a means to periodically drain exhaust system installation. Figure 4-10 condensation in exhaust, such as a silencer equipped Figure 4-11 show typical arrangements for commercial with a drain plug (see Figure 4-12), or a wye- or tee-type marine exhaust systems.

  • Page 25: Section 5 Fuel System

    Section 5 Fuel System WARNING Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. Do not modify the tank or the propulsion engine fuel system. Equip the craft with a tank that allows one of the two pickup arrangements.

  • Page 26: Fuel Lines

    5.2 Fuel Lines 5.3 Fuel Filters Return the generator set fuel return line to the fuel tank. Conform to USCG regulations regarding inline fuel Locate the fuel return line as far as practical from the fuel filters or strainers. pickup to allow the tank fuel to cool the return fuel before delivery back to the fuel injectors.
  • Page 27 1. Electric fuel or mechanical check valve 5. Fuel return line (diesels only) 10. Clamp 2. Permanent supports for fuel system 6. Carburetor or injection pump 11. Support clamp components 7. Secondary filter 12. Metallic line 3. Fuel lift pump 8.
  • Page 28 Notes Section 5 Fuel System TP-6862 6/14...

  • Page 29: Section 6 Electrical System

    Section 6 Electrical System 6.2.1 Circuit Breaker Considerations WARNING Mounting location. Mount the circuit breakers in the generator set’s junction box. See Section 6.2.2. Sizing. Use the generator set voltage/frequency configuration determine circuit breaker Hazardous voltage. Moving parts. Can cause severe injury or death. amperage.

  • Page 30: Circuit Breaker Installation

    Grounding electrical equipment. Hazardous voltage can Amps Model(s) cause severe injury or death. Electrocution is possible 33EFOZD(C)J whenever electricity is present. Ensure you comply with all 40EOZD(C)J, 33EFOZD(C)J, 40EFOZD(C)J, applicable codes and standards. Electrically ground the 45EFOZD(C)J generator set, transfer switch, and related equipment and electrical circuits.
  • Page 31 9. Check that the generator set master switch is in the OFF position. Reconnect the generator set engine starting battery, negative (--) lead last. JW250000 1. Circuit breaker 4. Bus 2. Circuit breaker mounting panel 5. Hardware 3. Load lead access panel 6.

  • Page 32: Installation In Steel Or Aluminum Vessels

    6.3 Installation In Steel or 6.5 Battery Aluminum Vessels Batteries and their installation must conform to USCG Regulations 183.420 (a) through (g). Provide generator Installation of a generator set in a vessel constructed of sets with batteries separate from the propulsion a material capable of conducting current (e.g., steel or engine’s whenever possible.

  • Page 33: Wiring

    Kohler Co. recommends using one 12-volt battery (or Note: Gauge senders. Gauge senders are available for most generator sets. If using customer- two for 24-volt systems, as the spec requires) to start the supplied gauges, be sure they are compatible generator.
  • Page 34 Notes Section 6 Electrical System TP-6862 6/14...

  • Page 35: Section 7 Installation Drawings

    Section 7 Installation Drawings Use the drawings in this section for installation Model No. Drawing Page purposes. Consult the supplier and verify that the 40EOZD(C)J and 33EFOZD(C)J drawings are the most current for your specifications. open unit (sheet 1 of 2) ADV-8500A-A Installation drawings show exhaust outlet locations, fuel open unit (sheet 2 of 2)
  • Page 36 NOTE: Dimensions in [ ] are inch equivalents. ADV-8500A-A Figure 7-2 Dimension Drawing, 40EOZD(C)J & 33EFOZD(C)J (Open Unit Sheet 1 of 2) Section 7 Installation Drawings TP-6862 6/14...
  • Page 37 NOTE: Dimensions in [ ] are inch equivalents. ADV-8500B-A Figure 7-3 Dimension Drawing, 40EOZD(C)J & 33EFOZD(C)J (Open Unit Sheet 2 of 2) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 38 NOTE: Dimensions in [ ] are inch equivalents. ADV-8503- Figure 7-4 Dimension Drawing, 40EOZDJ & 33EFOZDJ (with Sound Shield) Section 7 Installation Drawings TP-6862 6/14...
  • Page 39 NOTE: Dimensions in [ ] are inch equivalents. ADV-8501A-A Figure 7-5 Dimension Drawing, 40/50EFOZD(C)J & 55/65EOZD(C)J & 45/55EFOZD(C)J (Open Unit Sheet 1 of 2) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 40 NOTE: Dimensions in [ ] are inch equivalents. ADV-8501B-A Figure 7-6 Dimension Drawing, 40/50EFOZD(C)J & 55/65EOZD(C)J & 45/55EFOZD(C)J (Open Unit Sheet 2 of 2) Section 7 Installation Drawings TP-6862 6/14...
  • Page 41 NOTE: Dimensions in [ ] are inch equivalents. ADV-8504- Figure 7-7 Dimension Drawing, 40/50EFOZDJ & 55/65EOZDJ & 45/55EFOZDJ (with Sound Shield) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 42 NOTE: Dimensions in [ ] are inch equivalents. ADV-8506A-B Figure 7-8 Dimension Drawing, 80/99EOZD(C)J & 70/80EFOZD(C)J (Open Unit Sheet 1 of 2) Section 7 Installation Drawings TP-6862 6/14...
  • Page 43 NOTE: Dimensions in [ ] are inch equivalents. ADV-8506B-B Figure 7-9 Dimension Drawing, 80/99EOZD(C)J & 70/80EFOZD(C)J (Open Unit Sheet 2 of 2) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 44 NOTE: Dimensions in [ ] are inch equivalents. ADV-8507-A Figure 7-10 Dimension Drawing, 80/99EOZDJ & 70/80EFOZDJ (with Sound Shield) Section 7 Installation Drawings TP-6862 6/14...
  • Page 45 NOTE: Dimensions in [ ] are inch equivalents. ADV-8508A- Figure 7-11 Dimension Drawing, 125/150EOZD(C)J & 100/125EFOZD(C)J (Open Unit Sheet 1 of 2) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 46 NOTE: Dimensions in [ ] are inch equivalents. ADV-8508B- Figure 7-12 Dimension Drawing, 125/150EOZD(C)J & 100/125EFOZD(C)J (Open Unit Sheet 2 of 2) Section 7 Installation Drawings TP-6862 6/14...
  • Page 47 NOTE: Dimensions in [ ] are inch equivalents. ADV-8509- Figure 7-13 Dimension Drawing, 125/150EOZD(C)J & 100/125EFOZD(C)J (with Sound Shield) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 48 NOTE: Dimensions in [ ] are inch equivalents. ADV-8505A-A Figure 7-14 Dimension Drawing, 40--150EOZD(C)J & 33--125EFOZD(C)J (with Unit-Mounted Radiator) Section 7 Installation Drawings TP-6862 6/14...
  • Page 49 NOTE: Dimensions in [ ] are inch equivalents. ADV-8505B-A Figure 7-15 Dimension Drawing, 40--150EOZD(C)J & 33--125EFOZD(C)J (with Electric Clutch PTO) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 50 NOTE: Dimensions in [ ] are inch equivalents. ADV-8505C-A Figure 7-16 Dimension Drawing, 40--99EOZD(C)J & 33--80EFOZD(C)J (with Keel Cooling & Dry Exhaust) Section 7 Installation Drawings TP-6862 6/14...
  • Page 51 NOTE: Dimensions in [ ] are inch equivalents. ADV-8505D-A Figure 7-17 Dimension Drawing, 125/150EOZD(C)J & 100/125EFOZD(C)J (with Keel Cooling & Dry Exhaust) TP-6862 6/14 Section 7 Installation Drawings...
  • Page 52 Notes Section 7 Installation Drawings TP-6862 6/14...

  • Page 53: Section 8 Reconnection/Adjustments

    Section 8 Reconnection/Adjustments WARNING WARNING Hazardous voltage. Moving parts. Accidental starting. Can cause severe injury or death. Can cause severe injury or death. Operate the generator set only when Disconnect the battery cables before all guards and electrical enclosures working generator set.
  • Page 54 Electroswitch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load...

  • Page 55: Twelve-Lead Reconnection

    NOTICE Kraus Naimler/American Solenoid Voltage reconnection. Affix a notice to the generator set after 4-Wire, 3-Phase Generator Sets reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer. Twelve-Lead Reconnection Procedure 1.
  • Page 56 Figure 8-3 Generator Reconnection (ADV-5875F-R) Section 8 Reconnection/Adjustments TP-6862 6/14...

  • Page 57: Section 9 Paralleling Generator Sets

    Section 9 Paralleling Generator Sets Introduction WARNING Read and follow the safety precautions included in this manual. Pay attention to the decals on the equipment and follow the instructions below. All personnel involved in handling, site preparation, Accidental starting. installation, testing, operation, and maintenance Can cause severe injury or death.

  • Page 58: Paralleling Basics

    9.1.2 Paralleling Functions Decision-Makerr 3500 Controller Features Include: There are two methods of paralleling: Isochronous (real and reactive) load sharing with other Decision-Makerr 3500 equipped generator sets. 1. PGEN. Decision-Makerr 3500 full-featured paralleling controller. It offers Random first-on logic to prevent two or more integrated control for synchronizing, load sharing, generator sets from closing to a dead bus.
  • Page 59 Generator Info -> Voltage Regulation Menu and Generator Info -> Paralleling Operation -> Sharing Setup Menus. Note: Non-ECM engines will require an electronic governor (Woodward APECs) and an appropriate Kohler governor calibration in Range: -100.00% – 100.00% order to permit speed adjustment. Default: 0.00% **Not Writable**...
  • Page 60 Voltage Bias is the amount that the controller is Synchronizing attempting to adjust the output voltage (100% bias Before a generator set can operate in parallel with = +10% on the output voltage, --100% = --10% on another generator set, its electrical output must be the output voltage).

  • Page 61: Paralleling Considerations

    CAN gauge On the generator set, pre-wired from the factory. Modbusr Kohler SiteTecht software Remotely mounted. Customer needs to wire to status, trip, close, charge motor, and bus sensing. AUTO--RUN/AUTO--OFF button...

  • Page 62: Paralleling Set Up

    9.3 Paralleling Set Up Voltage and Reactive (kVAR) Power The Decision-Makerr 3500 controls the generator set’s 9.3.1 PGEN Communication Wiring output voltage. In order to parallel two or more generator sets using The generator set response to the signal varies PGEN, a communication wire is required.

  • Page 63: Decision-Makerr 3500 Paralleling Sequence Of Operation

    9.3.2 Decision-Makerr 3500 Paralleling Sequence of Operation Follow the instructions provided Install generators earlier in this manual. Note: Sequence of operation Connect circuit Consult the wiring diagrams breaker control and is for unit-mounted breakers. Additional provided in the operation manual. status wiring steps for remote-mounted breakers are shown in:...

  • Page 64: Troubleshooting When Breaker Does Not Close To Bus

    PGEN and assert it, or set Standalone mode in communication. The controller supports this Kohler SiteTecht. Note, Standalone mode scenario if the controller is configured in should only be asserted if there is only one Standalone mode.

  • Page 65: Faults Shown

    9.4.2 Faults Shown Step Potential Cause Explanation Troubleshooting Fault: System Voltage Mismatch Between Generators System voltage is not One of the controllers on the network is Verify the system voltage of all the equivalent configured differently than the other generators match the requirements of the controllers.
  • Page 66 Step Potential Cause Explanation Troubleshooting Fault: Close Attempt Fault: Fail to Close (Continued) Breaker is not powered The 24V electronics on the circuit breaker Verify the 24V input which exists on require an external 24V source on a 12V paralleling generators is receiving 24VDC generator.

  • Page 67: Troubleshooting When Breaker Does Close To Bus

    9.5 Troubleshooting When Breaker Does Close to Bus 9.5.1 Faults Shown Step Potential Cause Explanation Troubleshooting Fault: Close Attempt Fault: Fail to Close Breaker status feedback The breaker closes but the controller does Verify the wiring on the circuit breaker to is not valid, no bus not see a change in status.
  • Page 68 Step Potential Cause Explanation Troubleshooting Fault: Bus Voltage Amplitude Mismatch- -Phase A The phase A voltage of The voltage measured on the bus sensing Verify the bus sensing wire for phase A is the bus does not match for phase A does not match the voltage connected to phase A of the load side of the generator measured on phase A of the generator.
  • Page 69 Step Potential Cause Explanation Troubleshooting Fault: Bus Sensing Phases A and B are Reversed The bus sensing for Phase angle from generator to bus is about Verify wiring between bus sensing inputs phase A is connected to 180_ and bus rotation is backwards. and load side of paralleling breaker.
  • Page 70 Step Potential Cause Explanation Troubleshooting Fault: Bus Sensing Connected to Generator Side of Breaker Bus metering is The controller sees the bus voltage always Verify the bus metering is connected on the connected to the wrong matches the generator voltage, even when load side of the paralleling breaker.

  • Page 71: Troubleshooting When Running In Auto

    9.6 Troubleshooting When Running in AUTO 9.6.1 Faults Shown Step Potential Cause Explanation Troubleshooting Fault: Generator Phase Rotation Mismatch This generator is wired The controller has validated that the bus Verify wiring between this generator and with the opposite phase metering is accurate relative to this the paralleling breaker.
  • Page 72 Step Potential Cause Explanation Troubleshooting Fault: Bus Frequency Out of Spec The generators which When the generators which are supplying a Verify the load requirements are met by a are connected to the load are overloaded, their engine speed will single generator.
  • Page 73 Step Potential Cause Explanation Troubleshooting Fault: Generator Disabled Due to High Frequency Attempting to operate a The speed bias and voltage bias control Install contacts in series with the base-load generator in base-load real and reactive load in base-load mode mode input to the controller which are mode while it is against a source with a nearly constant...
  • Page 74 Step Potential Cause Explanation Troubleshooting Fault: Generator Disabled Due to Reverse VARs Different sized units The reactive power may overshoot when in It may be necessary to adjust the kVAR a power control situation such as a load load sharing gains. ramp or a quickly changing customer load.

  • Page 75: Generator Management Setup

    9.7 Generator Management Setup Typical Applications for Fuel Level Order Selection Mode: Generator Management starts and stops generators Prime power applications where the generators have based on the requirements of the load. The order in individual fuel tanks and have level indication on the which the generators are started or stopped is fuel tanks.

  • Page 76: Paralleling Parameters

    all the generators are stopped. The generator with the Generator Start Percentage most fuel will be started first. The Generator Start Percentage is the percent load on the running generators above which this generator will Because a generator will not be consuming fuel when it begin timing for the Generator Start Delay.

  • Page 77: Load Add/Shed Configuration

    9.8 Load Add/Shed Configuration The Load Add/Shed configuration (also known as load control) is intended to remove non-critical loads from the generator in the event of a condition where the generator capacity is insufficient to support the load. This allows the critical loads to receive power until the load decreases or the capacity increases.
  • Page 78 Notes Section 9 Paralleling Generator Sets TP-6862 6/14...

  • Page 79: Appendix A Generator Selection And Wattage Requirements

    Appendix A Generator Selection and Wattage Requirements Consider total wattage requirements (lights, motors, are DC powered by a 12-volt battery. Make sure the appliances) when selecting a generator set or when calculated total wattage includes only lights actually on sizing wattage usage in which available space and the generator set AC circuit.

  • Page 80: Appendix B Abbreviations

    (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour 80 Appendix TP-6862...
  • Page 81 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
  • Page 82 TP-6862 6/14...
  • Page 83 TP-6862 6/14...
  • Page 84 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com Kohler Power Systems Asia Pacific Headquarters TP-6862 6/14a 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 E 2013 and 2014 by Kohler Co. All rights reserved.

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