Kohler GM88594-KP1-QS Installation Manual
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Kohler GM88594-KP1-QS Installation Manual

Kohler GM88594-KP1-QS Installation Manual

Paralleling box 30-175 kw mobile generator sets equipped with the decision-maker 3500 controller
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Installation
Mobile Generator Sets
Model:
Paralleling Box
GM88594-KP1-QS
Applicable Generator Set Models:
30--175 kW Mobile Generator Sets
equipped with the Decision-Makerr 3500 Controller
TT-1672 10/16a

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Summary of Contents for Kohler GM88594-KP1-QS

  • Page 1 Installation Mobile Generator Sets Model: Paralleling Box GM88594-KP1-QS Applicable Generator Set Models: 30--175 kW Mobile Generator Sets equipped with the Decision-Makerr 3500 Controller TT-1672 10/16a...

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............Introduction .
  • Page 4 Table of Contents, continued Section 6 Maintenance ..............Scheduled Maintenance .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. DANGER Electromechanical equipment, including generator sets WARNING accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Hazardous voltage. aware of potential dangers and act Will cause severe injury or death.
  • Page 6 Heavy Equipment Grounding electrical equipment. WARNING Hazardous voltage cause severe injury or death. Electrocution WARNING is possible whenever electricity is present. Ensure you comply with all applicable codes standards. Electrically ground the generator set Hazardous voltage. and related equipment and electrical Backfeed to the utility system can circuits.

  • Page 7: Introduction

    Information in this publication represents data available information and instructions. The following list shows at the time of print. Kohler Co. reserves the right to additional literature relevant to the paralleling system. change this literature and the products represented...

  • Page 8: Service Assistance

    Phone: (86) 10 6518 7950 KOHLERPower.com. (86) 10 6518 7951 (86) 10 6518 7952 Look at the labels and decals on your Kohler product Fax: (86) 10 6518 7955 or review the appropriate literature or documents included with the product.

  • Page 9: Section 1 Specifications And Features

    Section 1 Specifications and Features 1.1 Introduction Connection of 1 -- 3 priorities to each generator provides better redundancy than connecting all priorities to a Different operation modes are possible with paralleled single generator. generator sets. Review the brief descriptions below and refer to the generator set Operation Manual for 1.2 Paralleling Box Features complete operation information.

  • Page 10: Requirements

    1.3 Requirements 1.4 Specifications Paralleled generator sets: Paralleling Box Specifications Source Input Voltage Range 120--600 VAC Must be mobile models REOZT4 or REZGT equipped Load Output voltage Range 120--600 VAC with the Decision-Makerr 3500 controller, voltage Source Current Limit 1000 amps each (max.) * selector switch, and camlock connectors.
  • Page 11 If the generator sets are not equipped with the control See Section 1.3 and follow the instructions harness connector shown in Figure 1-1, install the retrofit provided with the harness. harness. * Follow the instructions provided in the Install generator sets and place the paralleling box within 20 generator set manuals.
  • Page 12 CONTROL HARNESS (SUPPLIED WITH PRODUCT, QTY. 2) PGEN CABLE FOR MULTIPLE BOXES (CUSTOMER SUPPLIED BELDEN #9841 OR EQUIVALENT) NOTE: N = NUMBER OF PARALLELING BOXES. MAXIMUM NUMBER OF PARALLELING BOXES IS 4. MAXIMUM NUMBER OF GENERATOR SETS IS 8. Figure 1-7 System Interconnection Diagram Section 1 Specifications and Features TT-1672 10/16...

  • Page 13: Section 2 Transportation And Location

    Section 2 Transportation and Location 2.1 Introduction guideline when selecting a location for the paralleling box. Be aware of potential detrimental conditions and Read and follow the safety precautions included in this use common sense when determining a location. The manual.
  • Page 14 Notes Section 2 Transportation and Location TT-1672 10/16...

  • Page 15: Section 3 Prestart Checks And Paralleling Setup

    Section 3 Prestart Checks and Paralleling Setup 3.1 Prestart Checklist 3.3 Paralleling System Setup Perform the prestart checks listed in the generator set Use a personal computer with SiteTecht software operation manual. In addition to those generator set connected to the generator set controller to configure items, check the following on the paralleling box before each generator in the paralleled system.
  • Page 16 On the Decision-Makerr 3500 controller, go to 8. Set Generator Management Enabled to OFF at GENERATOR INFO > CONFIGURATION > each generator set unless generator management GENERATOR CONFIG. is requested for the application. See the generator operation manual for detailed information about Note: 50 is the default setting, which sets the generator management.
  • Page 17 Parameter Recommended Setting DEC 3500 Menu SiteTech Menu Digital Output Contactor I/O > DIGITAL OUTPUT > Programmable Digital Output DIGITAL OUTPUT 1:2 116 Menu (verification only) Digital Output Event Reactive Droop Default setting = 1%. GENERATOR INFO > Reactive Power Sharing VOLTAGE REGULATION Menu Range 0.5 -- 2%.
  • Page 18 Sync Mode Setting Description Sync Mode in Auto Sync Mode in Auto is the synchronization mode that the controller uses when the engine control switch is in AUTO, as indicated by the blue indicator over the AUTO button. This Sync Mode defaults to Active, which will work for almost all applications.

  • Page 19: Calibration

    3.4 Calibration incorrect bus voltage. If the measured bus voltage is either higher or lower than the actual bus voltage, it will Note: Copying personality profiles from one controller result in reactive power transfer when the breaker to another can overwrite the calibration closes, potentially causing a generator to disconnect coefficients.
  • Page 20 Notes Section 3 Prestart Checks and Paralleling Setup TT-1672 10/16...

  • Page 21: Section 4 Electrical Connection And Test

    Section 4 Electrical Connection and Test 4.1 Introduction 4.2 Electrical Panel Cover Read and follow the safety precautions included in this DANGER manual. Pay attention to the decals on the equipment and follow the instructions below. All personnel involved in handling, site preparation, installation, testing, operation, and maintenance should be thoroughly familiar with the information in Hazard...

  • Page 22: Cable Specifications

    4.3 Cable Specifications Wire Number of Model Gauge, Cables per Number Min. Phase Output Voltage Two 7.6-meter (25-foot) long control harnesses are 120/208 wye 30REZGT provided with each paralleling box. Grounding and 277/480 wye power cables are customer-provided. If multiple 120/240 dog-leg paralleling boxes are used, the PGEN cable connecting 35REOZT4...

  • Page 23: Disable The Generator Sets

    4.4 Disable the Generator Sets Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Ensure you comply with all WARNING applicable codes and standards. Electrically ground the generator set and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment.

  • Page 24: Source Connections

    4.6 Source Connections 1. Connect the source side ground (green) camlock cables to the paralleling box first and then to each generator. DANGER 2. Connect the source side neutral (white) camlock cables to the paralleling box first and then to each generator.

  • Page 25: Load Connections

    4.7 Load Connections 1. Connect the load side ground (green) camlock cables to the distribution bus and then to the paralleling box. DANGER 2. Connect the load side neutral (white) camlock cables to the distribution bus and then to the paralleling box.

  • Page 26: Control Harness Connections

    4.8 Control Harness Connections Two control harnesses (GM97197) are included with the paralleling box. Each harness includes: Power leads to supply power for the contactors, lights, and fans in the relay box. GEN 1 CAMLOCKS Communication leads from the generator controller to the paralleling box.

  • Page 27: Multiple Paralleling Boxes (Pgen Connections)

    4.9 Multiple Paralleling Boxes (PGEN Connections) Up to four paralleling boxes with eight generator sets can be connected together. Connect one or two generators to each paralleling box as described in the previous sections. Connect the paralleling boxes together using the PGEN terminal blocks as described below.

  • Page 28: Re-Enable The Generator Sets

    4.10 Re-enable the Generator Sets online. This parameter is also viewable in SiteTech under Synchronization Control. See Figure 4-15. DANGER Hazardous voltage. Will cause severe injury or death. This equipment must be installed and serviced qualified electrical personnel. Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.
  • Page 29 5. With the contactor in the paralleling box closed, verify the following metered values in SiteTech under Generator Metering and Bus Metering, or under GENERATOR INFO -> PARALLELING OPERATION -> SYNCHRONIZING SETUP on the DEC3500 controller. See Figure 4-16. Bus Voltage L1-L2 should match Generator Voltage L1-L2 (not necessary to check if not using SiteTecht) Bus Voltage L2-L3 should match Generator...

  • Page 30: Verify Paralleling And Load Sharing

    4.11.2 Verify Paralleling and Load generators should start, one generator should close the contactor that it controls in the Sharing appropriate paralleling box, and the other When all generators in the paralleling system have been generators should synchronize to it (often undergoing audible changes in speed) and close verified, perform the following tests.

  • Page 31: Section 5 Tear-Down/Disassembly

    Section 5 Tear-Down/Disassembly 5.1 Turn OFF all Power Sources DANGER WARNING Hazardous voltage. Will cause severe injury or death. This equipment must be installed and Accidental starting. serviced qualified electrical Can cause severe injury or death. personnel. Disconnect the battery cables before working generator set.

  • Page 32: Control Harnesses

    See Figure 5-1. Note: Do not open the electrical compartment on the opposite side enclosure. That compartment should be opened only by Kohler authorized distributors dealers maintenance and service purposes. ADV--8713 1. PGEN terminal block Figure 5-2 PGEN Cable Connection 1.

  • Page 33: Disconnect Load Cables

    5.4 Disconnect Load Cables 5. Connect the load side ground GND (green) camlock cable from the distribution bus. Then disconnect the GND cable from the paralleling box. DANGER Remove the camlock security guards from their storage locations and install over the camlock connectors on the box.

  • Page 34: Disconnect Source Cables

    5.5 Disconnect Source Cables 3. Disconnect the source side neutral (white) camlock cables at the generator set first and then at the paralleling box. WARNING 4. Disconnect the source side ground (green) camlock cables at the generator set first and then at the paralleling box.
  • Page 35 Preventive maintenance includes periodic testing, DANGER cleaning, inspection, and replacement of worn or missing components. A Kohler authorized distributor/dealer can provide complete preventive maintenance and service to keep the equipment in top condition. Unless otherwise Hazardous voltage.
  • Page 36 6.2 Inspection CAUTION Contact a Kohler authorized distributor/dealer to inspect and service the paralleling box annually and also when any wear, damage, deterioration, or malfunction of the paralleling box or its components is evident or Hot surfaces. suspected. 6.2.1 External Inspection...
  • Page 37 6.3 Storage Procedure Filter A filter is located in the air duct at the bottom of the Store control harnesses on the storage rack inside the enclosure. See Figure 6-1. Check the condition of the box when not in use. Lock the cabinet door with the key filter before operation.
  • Page 38 Notes Section 6 Maintenance TT-1672 10/16...
  • Page 39 Section 7 Drawings and Diagrams Refer to the drawings as needed during installation. Drawing Description Drawing Number Page ADV-8713 Dimension Drawing Sheet 1 Sheet 2 Sheet 3 Sheet 4 Schematic Diagram ADV-8769 Wiring Diagram GM95768 TT-1672 10/16 Section 7 Drawings and Diagrams...
  • Page 40 Figure 7-1 Dimension Drawing ADV-8713, Sheet 1 of 4 Section 7 Drawings and Diagrams TT-1672 10/16...
  • Page 41 Figure 7-2 Dimension Drawing ADV-8713, Sheet 2 of 4 TT-1672 10/16 Section 7 Drawings and Diagrams...
  • Page 42 Figure 7-3 Dimension Drawing ADV-8713, Sheet 3 of 4 Section 7 Drawings and Diagrams TT-1672 10/16...
  • Page 43 Figure 7-4 Dimension Drawing ADV-8713, Sheet 4 of 4 TT-1672 10/16 Section 7 Drawings and Diagrams...
  • Page 44 Figure 7-5 Schematic Diagram ADV-8769 Section 7 Drawings and Diagrams TT-1672 10/16...
  • Page 45 Figure 7-6 Wiring Diagram GM95768 TT-1672 10/16 Section 7 Drawings and Diagrams...
  • Page 46 Notes Section 7 Drawings and Diagrams TT-1672 10/16...
  • Page 47 (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 TT-1672 10/16 Appendix 47...
  • Page 48 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 49 Notes TT-1672 10/16...
  • Page 50 Notes TT-1672 10/16...
  • Page 52 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com Kohler Power Systems Asia Pacific Headquarters TT-1672 10/16a 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455 E 2015, 2016 by Kohler Co. All rights reserved.

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