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Marine Generator Sets

TP-6862 6/14a

Installation

Pleasure Craft Models:

40--150EOZDJ

33--125EFOZDJ

Commercial Models:

40--150EOZCJ

33--125EFOZCJ

Controller:

Decision-Maker

3500

Содержание 33-125EFOZCJ

Страница 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...

Страница 2: ...TP 6862 6 14 2...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 82: ...TP 6862 6 14 82...

Страница 83: ...TP 6862 6 14 83...

Страница 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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