Kohler 33-125EFOZCJ Installation Manual Download Page 3

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TP-6862 6/14

Table of Contents

Table of Contents

Safety Precautions and Instructions

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Section 1 Introduction

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Section 2 Location and Mounting

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2.1

General Considerations

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2.2

Location

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2.3

Mounting

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Section 3 Cooling System

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3.1

Ventilation

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3.2

Cooling System Components

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3.2.1

Intake Through-Hull Strainer (Seacock Cover)

. . . . . . . . . . . . . . . . . . . . .

3.2.2

Seacock

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2.3

Seawater Strainer

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3.2.4

Water Lines

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3.2.5

Closed Heat Exchanger

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Section 4 Exhaust System

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4.1

Types

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4.2

Exhaust Lines

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4.3

Sound Shielded Units with Dry Exhaust

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4.4

Exhaust System Location, Mounting, and Installation

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4.4.1

Above-Waterline Installation

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4.4.2

Mid/Below-Waterline Installation

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Section 5 Fuel System

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5.1

Fuel Tank

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5.2

Fuel Lines

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5.3

Fuel Filters

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5.4

Fuel/Water Separator

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5.5

Fuel Pump Lift

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5.6

Fuel Consumption

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Section 6 Electrical System

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6.1

AC Voltage Connections

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6.2

Circuit Protection

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6.2.1

Circuit Breaker Considerations

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6.2.2

Circuit Breaker Installation

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6.3

Installation In Steel or Aluminum Vessels

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6.4

Installation Regulations

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6.5

Battery

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6.6

Wiring

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6.7

Remote Connection

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6.8

Paralleling Generator Sets

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Section 7 Installation Drawings

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Section 8 Reconnection/Adjustments

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8.1

Twelve-Lead Reconnection

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Section 9 Paralleling Generator Sets

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Introduction

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9.1

Paralleling Basics

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9.1.1

Why Parallel Generator Sets

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9.1.2

Paralleling Functions

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9.2

Paralleling Considerations

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9.2.1

Generator Requirements

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9.2.2

Paralleling Controller—PGEN

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Summary of Contents for 33-125EFOZCJ

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

Page 2: ...TP 6862 6 14 2...

Page 3: ...ne 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...

Page 4: ...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...

Page 5: ...r death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnec...

Page 6: ...he engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel...

Page 7: ...with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remov...

Page 8: ...TP 6862 6 14 8 Safety Precautions and Instructions Notes...

Page 9: ...gs and wiring diagrams 1 3 7 8 6 10 11 12 13 14 15 16 17 18 19 20 21 ADV8500 1 Exhaust mixer elbow exhaust water outlet 2 Fuel return connection 3 Heat exchanger not shown 4 Fuel feed pump 5 Fuel inle...

Page 10: ...TP 6862 6 14 10 Section 1 Introduction Notes...

Page 11: ...ve the deck and or outdoors would constitute a violation of European Union Directive 2000 14 EC noise emission standard Allow clearance for vibration and cooling during operation Allow a minimum of 38...

Page 12: ...TP 6862 6 14 12 Section 2 Location and Mounting Notes...

Page 13: ...if you compromise these guidelines See Figure 3 1 for allowable intake restriction Note ISO 3046 derates apply See Appendix C Model Allowable Intake Restriction 40 150EOZDJ EOZCJ 33 125EFOZDJ EFOZCJ 2...

Page 14: ...unt the seawater strainer to the seacock or permanent structure at a point not higher than the seawater pump Ensure that the strainer is accessible for service See Figure 3 4 for a typical installatio...

Page 15: ...3 Thermostat 4 Water cooled manifold 5 Heat exchanger 6 Exhaust mixer elbow 7 Water cooled turbocharger 8 Silencer customer supplied 9 Exhaust outlet 10 Intake strainer 11 Seacock 12 Seawater strainer...

Page 16: ...g the system must be sized to meet the fill rate requirements published by the engine manufacturer Overflow bottle or tank with cap Keel Cooler Hull 1 1 4 in 31 75 mm ID fill vent line with a slope no...

Page 17: ...rating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee sid...

Page 18: ...ngth from the exhaust mixer to the silencer to allow for generator set movement 1 ADV8501B 1 Exhaust outlet Alternator End View Figure 4 3 Mixer Elbow Exhaust Connection Typical Locate the exhaust out...

Page 19: ...onnections Note Damage caused by wateringestion willnot be covered by the generator warranty 1 Minimum exhaust outlet distance above waterline of 10 cm 4 in Note Vessel fully loaded 2 Slight lift impr...

Page 20: ...to maintain their position and function Allow a slight offset to clear the stringers or other permanent structures Protect the siphon break air inlet from dirt and debris Note To preventwater leakage...

Page 21: ...tor of 4 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 See Figure 4 1 for hose sizes 24 Gas water separator optiona...

Page 22: ...5 in per ft 6 Exhaust mixer elbow distance above waterline if less than 23 cm 9 in a siphon break is required 7 Minimum siphon break distance above waterline of 30 5 cm 1 ft 8 Exhaust mixer elbow 9 S...

Page 23: ...ce above waterline for drain outlet from silencer must be equal to or greater than water drain item 18 to be greater than 30 5 cm 1 ft 21 Exhaust outlet to be diameter appropriate so exhaust back pres...

Page 24: ...1 Silencer 2 45 Y fitting 3 Water trap 4 Drain petcock 3 4 5 Outer diameter adapter and clamp 6 Flexible section 7 Manifold 8 45 elbow NOTE Horizontal silencer shown Figure 4 11 Exhaust System Side In...

Page 25: ...ame fuel tank as the craft s propulsion engine s If the tank s fuel pickup opening allows a multiple dip tube use a multiple dip tube arrangement See Figure 5 1 The multiple dip tube arrangement incor...

Page 26: ...125EFOZDJ EFOCJ 9 7 3 8 Figure 5 2 Fuel Line ID Size See Figure 5 2 for the ID size of the customer supplied fuel line that connects to the fuel pump and fuel return Route the fuel lines from the fuel...

Page 27: ...injection pump 7 Secondary filter 8 Primary filter 9 Flexible fuel line 10 Clamp 11 Support clamp 12 Metallic line 13 Dip tube 14 Fuel tank 2 8 Figure 5 4 Fuel System Typical Anti siphon protection is...

Page 28: ...TP 6862 6 14 28 Section 5 Fuel System Notes...

Page 29: ...e fault reset the AC circuit breaker s by placing them in the ON position Restart the unit Do not start the unit under load See Figure 6 1 and Figure 6 2 for AC circuit breaker ratings The unit s volt...

Page 30: ...l power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Short ci...

Page 31: ...set master switch is in the OFF position Reconnect the generator set engine starting battery negative lead last JW250000 1 Circuit breaker 2 Circuit breaker mounting panel 3 Load lead access panel 4...

Page 32: ...Coast Guard 1 Part 111 Electrical Systems 2 Part 182 Machinery Installation m sc 001 001 6 5 Battery Batteries and their installation must conform to USCG Regulations 183 420 a through g Provide gene...

Page 33: ...cessary to protect and secure the wire from sharp objects the exhaust system and moving parts 6 7 Remote Connection Kohler Co offers several remote panels for connection to the generator set Contact y...

Page 34: ...TP 6862 6 14 34 Section 6 Electrical System Notes...

Page 35: ...nd 45EFOZD C J 65EOZD 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 with sound shield not available on EOZCJ EFOZCJ models ADV 8504 41 with radiator A...

Page 36: ...TP 6862 6 14 36 Section 7 Installation Drawings ADV 8500A A NOTE Dimensions in are inch equivalents Figure 7 2 Dimension Drawing 40EOZD C J 33EFOZD C J Open Unit Sheet 1 of 2...

Page 37: ...TP 6862 6 14 37 Section 7 Installation Drawings ADV 8500B A NOTE Dimensions in are inch equivalents Figure 7 3 Dimension Drawing 40EOZD C J 33EFOZD C J Open Unit Sheet 2 of 2...

Page 38: ...TP 6862 6 14 38 Section 7 Installation Drawings ADV 8503 NOTE Dimensions in are inch equivalents Figure 7 4 Dimension Drawing 40EOZDJ 33EFOZDJ with Sound Shield...

Page 39: ...TP 6862 6 14 39 Section 7 Installation Drawings ADV 8501A A NOTE Dimensions in are inch equivalents Figure 7 5 Dimension Drawing 40 50EFOZD C J 55 65EOZD C J 45 55EFOZD C J Open Unit Sheet 1 of 2...

Page 40: ...TP 6862 6 14 40 Section 7 Installation Drawings ADV 8501B A NOTE Dimensions in are inch equivalents Figure 7 6 Dimension Drawing 40 50EFOZD C J 55 65EOZD C J 45 55EFOZD C J Open Unit Sheet 2 of 2...

Page 41: ...TP 6862 6 14 41 Section 7 Installation Drawings ADV 8504 NOTE Dimensions in are inch equivalents Figure 7 7 Dimension Drawing 40 50EFOZDJ 55 65EOZDJ 45 55EFOZDJ with Sound Shield...

Page 42: ...TP 6862 6 14 42 Section 7 Installation Drawings ADV 8506A B NOTE Dimensions in are inch equivalents Figure 7 8 Dimension Drawing 80 99EOZD C J 70 80EFOZD C J Open Unit Sheet 1 of 2...

Page 43: ...TP 6862 6 14 43 Section 7 Installation Drawings ADV 8506B B NOTE Dimensions in are inch equivalents Figure 7 9 Dimension Drawing 80 99EOZD C J 70 80EFOZD C J Open Unit Sheet 2 of 2...

Page 44: ...TP 6862 6 14 44 Section 7 Installation Drawings ADV 8507 A NOTE Dimensions in are inch equivalents Figure 7 10 Dimension Drawing 80 99EOZDJ 70 80EFOZDJ with Sound Shield...

Page 45: ...TP 6862 6 14 45 Section 7 Installation Drawings ADV 8508A NOTE Dimensions in are inch equivalents Figure 7 11 Dimension Drawing 125 150EOZD C J 100 125EFOZD C J Open Unit Sheet 1 of 2...

Page 46: ...TP 6862 6 14 46 Section 7 Installation Drawings ADV 8508B NOTE Dimensions in are inch equivalents Figure 7 12 Dimension Drawing 125 150EOZD C J 100 125EFOZD C J Open Unit Sheet 2 of 2...

Page 47: ...TP 6862 6 14 47 Section 7 Installation Drawings ADV 8509 NOTE Dimensions in are inch equivalents Figure 7 13 Dimension Drawing 125 150EOZD C J 100 125EFOZD C J with Sound Shield...

Page 48: ...TP 6862 6 14 48 Section 7 Installation Drawings ADV 8505A A NOTE Dimensions in are inch equivalents Figure 7 14 Dimension Drawing 40 150EOZD C J 33 125EFOZD C J with Unit Mounted Radiator...

Page 49: ...TP 6862 6 14 49 Section 7 Installation Drawings ADV 8505B A NOTE Dimensions in are inch equivalents Figure 7 15 Dimension Drawing 40 150EOZD C J 33 125EFOZD C J with Electric Clutch PTO...

Page 50: ...TP 6862 6 14 50 Section 7 Installation Drawings ADV 8505C A NOTE Dimensions in are inch equivalents Figure 7 16 Dimension Drawing 40 99EOZD C J 33 80EFOZD C J with Keel Cooling Dry Exhaust...

Page 51: ...TP 6862 6 14 51 Section 7 Installation Drawings ADV 8505D A NOTE Dimensions in are inch equivalents Figure 7 17 Dimension Drawing 125 150EOZD C J 100 125EFOZD C J with Keel Cooling Dry Exhaust...

Page 52: ...TP 6862 6 14 52 Section 7 Installation Drawings Notes...

Page 53: ...cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Hazardou...

Page 54: ...r American Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets...

Page 55: ...t to change output phase or voltage Refer to the following procedure and connection schematics Follow allsafety precautions at the front of this manual and in the text during the reconnection procedur...

Page 56: ...TP 6862 6 14 56 Section 8 Reconnection Adjustments Figure 8 3 Generator Reconnection ADV 5875F R...

Page 57: ...in this manual Pay attention to the decals on the equipment and follow the instructions below D All personnel involved in handling site preparation installation testing operation and maintenance shoul...

Page 58: ...he Decision Makerr 3500 is a full featured paralleling controller It offers integrated control for synchronizing load sharing protective relays generator management and load add shed This functionalit...

Page 59: ...teTecht under the Reactive Power Load Sharing parameter Using the UI under the Generator Info Voltage Regulation Menu and Generator Info Paralleling Operation Sharing Setup Menus Note Non ECM engines...

Page 60: ...The synchronizer will issue a breaker close command when the frequency difference phase angle and voltage difference are within an acceptable range and the phase rotation matches For PGEN paralleling...

Page 61: ...ote Some engines may limit this speed adjust to no more than approx 3 5 Voltage Regulator The voltage regulator is integral to the Decision Makerr 3500 controller and is capable of accepting remote in...

Page 62: ...el two or more generator sets using PGEN a communication wire is required Use a Belden cable 9841 or equivalent shielded twisted pair communication cable Connect the shield to ground at one end only T...

Page 63: ...utput leads to the paralleling bus Consult the wiring diagrams provided in the operation manual Connect PGEN communication wiring See Section 9 3 1 in this manual If the engine does not start consult...

Page 64: ...that there are no unintentional or loose connections 4 Baud rate misconfigured One of the controllers on the network is attempting to communicate at a different baud rate than the other controllers Th...

Page 65: ...this generator Fault Close Attempt Fault Fail to Close 1 Breaker is unable to close The controller is attempting to close the circuit breaker but the breaker is not closing Watch the ready flag on the...

Page 66: ...as the bus sensing is not connected correctly on any generators on the network Verify the wiring on the circuit breaker to ensure that it is connected correctly Verify bus wiring for all nodes Verify...

Page 67: ...was open when the breaker opened This fault will only occur if the bus sensing is connected correctly the controller sees the voltage go to 0 when the breaker is triggered to open Verify the breaker s...

Page 68: ...not connected to the output of the generator Verify the generator metering is sensed at the output of the generators A common mistake is to connect the metering to the center tap voltages V7 V8 V9 Fau...

Page 69: ...and bus rotation is backwards Verify metering connections on the generator L1 should connect to the phase A output lead L2 to phase B L3 to phase C L0 to neutral Fault Bus Sensing Phases C and A are R...

Page 70: ...when the breaker contacts indicate that the breaker is open Verify the paralleling breaker control wiring is connected correctly and the status feedback is connected to an A contact Fault Failure to O...

Page 71: ...enerator should be started and closed to a dead bus again to validate the changes Fault Dead Bus Sensed When Live Bus Expected 1 The wiring was not connected between the load side of the paralleling b...

Page 72: ...ct calibration it may see this voltage as a much higher level than the other generators resulting in a protective relay trip Verify the controller is measuring voltage accurately If not re calibrate i...

Page 73: ...or breaker will trip to protect the generator from damage due to excessive loads Ensure that the load is low enough for a single generator to support it Fault Generator Disabled Due to Reverse Power 1...

Page 74: ...twork have different Order Selection modes Generator management will not operate if any generators on the PGEN network have different Order Selection modes Adjust the Order Selection mode on any gener...

Page 75: ...main essentially identical D Prime power applications where the generators are all of similar size Typical Applications for Fuel Level Order Selection Mode D Prime power applications where the generat...

Page 76: ...rator Start Percentage The Generator Start Percentage is the percent load on the running generators above which this generator will begin timing for the Generator Start Delay The default setting is 80...

Page 77: ...es are events which can be assigned to programmable IO Priorities 1 and 2 are defaulted to RDO outputs 3 and 4 The priorities can be configured to outputs on the 14 relay dry contact kit or each contr...

Page 78: ...TP 6862 6 14 78 Section 9 Paralleling Generator Sets Notes...

Page 79: ...requirements than a 10 000 Btu unit of another variety When using only one unit there is usually no starting problem provided the lighting and appliance load is not too high when starting the unit Si...

Page 80: ...s cu in cubic inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dB A decibel A weighted DC direct current DCR direct current resista...

Page 81: ...hillipsr head Crimptiter screw PHH Phillipsr hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per million P...

Page 82: ...TP 6862 6 14 82...

Page 83: ...TP 6862 6 14 83...

Page 84: ...the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65...

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