Installation Marine Generator Sets Models: 3.5EFOZ/4EOZ, 4EFOZ/5EOZ 6.5EFOZ/8EOZ, 8.5EFOZ, 9EFOZ/10EOZ 11EFOZ/13EOZ, 11.5EFOZ/14EOZ 13EFOZ/15.5EOZ, 16EFOZ/20EOZ 17.
Table of Contents Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Section 2 Location and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1 General Considerations .
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of the craft’s occupants, install a carbon monoxide detector. Consult the boat builder or dealer for approved detector location and installation. Inspect the detector before each generator set use. In addition to routine exhaust system inspection, test the carbon monoxide detector per the manufacturer’s instructions and keep the detector operational at all times. Operating the generator set.
CAUTION Welding the generator set. Can cause severe electrical equipment damage. Never weld components of the generator set without first disconnecting the battery, controller wiring harness, and engine electronic control module (ECM). Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment.
Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation. Moving Parts WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place.
Notes VI Safety Precautions and Instructions TP-6069 6/03
Section 1 Introduction Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. marine generator set. For operating instructions, refer to the operation manual. x:in:001:002:a Use the specification sheets as a guide in planning your installation. Use current dimension drawings and wiring diagrams.
Notes 2 Section 1 Introduction TP-6069 6/03
Section 2 Location and Mounting 2.1 General Considerations The key to installation is location. Before making final plans for locating a generator set, consider the following. Installation Location Considerations Allow clearance for vibration and cooling during operation. Allow a minimum of 38 mm (1.5 in.) clearance on all sides (top, front, rear, and sides) of a generator set without an optional sound shield. Refer to the instruction sheet for minimum clearances for sound-shielded units.
Notes 4 Section 2 Location and Mounting TP-6069 6/03
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 sizing of vents and other considerations. 1 As a rule, size each inlet- and outlet-vent area to a minimum of 13 sq. cm/30.5 cm (2 sq. in. per ft.) of the craft’s beam. Should this rule conflict with USCG Regulations, follow USCG Regulations. For applications with screened inlets, double the size (4 sq.
Do not use a speed scoop or cup design intake through-hull strainer because it can cause a ramming effect and force water upward, past the seawater pump, and into the engine cylinders when the vessel is moving and the generator set is shut down. Do not use hulls incorporating sea chests or other designs that provide a positive pressure to the raw water pump for the intake through-hull strainers. Positive pressure forces water past the raw water pump and into the engine.
2 1 3 4 6 8 5 7 14 9 Arrow Description Direction of Flow 10 Seawater Freshwater (Coolant/Antifreeze) 11 12 13 TP-5586-6 1. 2. 3. 4. 5. 6. 7. Engine block Exhaust manifold Exhaust mixer elbow Outlet flapper (exhaust/water discharge) Silencer (customer supplied) Thermostat open Thermostat Figure 3-6 TP-6069 6/03 8. 9. 10. 11. 12. 13. 14.
1 2 3 4 5 7 6 8 9 14 13 12 11 Seawater Freshwater (Coolant/Antifreeze) 10 TP-5592-6 1. 2. 3. 4. 5. 6. 7. Oil cooler Engine block Thermostat Water-cooled manifold Heat exchanger Exhaust mixer elbow Water-cooled turbocharger Figure 3-7 8 8. 9. 10. 11. 12. 13. 14.
7 6 8 9 10 3 5 4 2 1 TP-6134- 1. 2. 3. 4. 5. Intake strainer Seacock Seawater strainer Engine-driven seawater pump Oil exchanger Figure 3-8 TP-6069 6/03 6. 7. 8. 9. 10. Zinc plug Exhaust manifold elbow Exhaust hose Silencer (customer supplied) Outlet flapper (exhaust/water discharge) Direct Water-Cooled Cooling System (3.
Notes 10 Section 3 Cooling System TP-6069 6/03
Section 4 Exhaust System WARNING Carbon monoxide. Can cause severe fainting, or death. nausea, The exhaust system must be leakproof and routinely inspected. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.
4.3 Exhaust System Location, Mounting, and Installation Mount the silencer independently to eliminate stress on the exhaust system and the exhaust manifold/mixer elbow. See Section 7 for the mixer elbow water line hose size. See Figure 4-1 for the exhaust connection to the mixer elbow. Provide an adequate hose length from the exhaust mixer to the silencer to allow for generator set movement. Locate the exhaust outlet at least 10 cm (4 in.) above the waterline when the craft is loaded to maximum capacity.
4 5 6 3 2 1 7 8 13 9 15 Waterline 12 16 10 14 11 1. Slight lift improves silencing and prevents water backwash into the silencer (keep below the level of the exhaust manifold outlet) 2. Silencer (customer-supplied) 3. Exhaust manifold outlet 4. Exhaust mixer elbow 5. Heat exchanger (locations vary by model) 6. Coolant recovery tank (located on the unit on some models) 7. Locate the coolant recovery tank at the same height as the heat exchanger 8. Maximum seawater pump lift of 1 m (3 ft.) 9.
4.3.2 Mid/Below-Waterline Installation 1 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. Install the siphon break at least 31 cm (1 ft.) above the waterline using the instructions provided with the siphon break kit.
2 7 3 8 9 10 1 6 21 5 Waterline 11 4 19 20 16 12 18 15 13 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Mounting base Retaining cap Reed valve assembly Maximum silencer vertical lift of 1.2 m (4 ft.) Exhaust mixer elbow distance above waterline; if less than 23 cm (9 in.), a siphon break is required Minimum siphon break distance above waterline of 30.5 cm (1 ft.
Notes 16 Section 4 Exhaust System TP-6069 6/03
Section 5 Fuel System 2 WARNING 1 Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels. Installing the fuel system. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. 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 described in the installation section. The tank and installation must conform to USCG Regulations.
5.2 Fuel Lines 5.3 Fuel Filters Locate the fuel return line as far as practical from the fuel pickup to allow the tank fuel to cool the return fuel before delivery back to the fuel injectors. Incoming fuel cools the injectors to achieve maximum engine efficiency. Conform to USCG Regulations regarding inline fuel filters or strainers. Note: Do not tee into the main propulsion engine’s fuel line.
Section 6 Electrical System 6.1 AC Voltage Connections WARNING Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Connect the generator set to the building/marina electrical system only through an approved device and after the building/marina main switch is opened.
Amps 20 Max. Voltage 250 Number of Poles 1 Model(s) 4EFOZ Number of Poles Type Model(s) 60 600 3 UL/IEC 33EFOZ, 40EOZ 70 600 3 UL/IEC 40EFOZ, 40EOZ 80 480 3 UL/IEC 40EFOZ, 50EOZ 100 480 3 UL/IEC 55EFOZ, 50/65EOZ 600 3 8.5/11.5EFOZ, 14EOZ 22 250 2 4EFOZ, 5EOZ 25 250 2 5EOZ 1 6.5EFOZ 2 6.5EFOZ 100--125 600 3 IEC 33/55EFOZ, 40/65EOZ 600 3 11.5/17.
Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Place the generator set start/stop switch in the STOP position. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery.
10. Connect the side of the circuit breaker marked LOAD to the ship-to-shore switch or craft wiring. Attach insulation boots to the black leads if the kit includes insulation boots. With a single-pole circuit breaker use one black lead (L1). With a two-pole circuit breaker use two black leads, L1 and L2. Connect the neutral (white) lead to the L0 stud. Connect the equipment ground (green) lead to GRD stud. Note: Wire material. Use stranded copper for all wiring.
8 9 1 2 3 4 5 6 ASSEMBLY VIEW C-C 6 7 ASSEMBLY VIEW A 1 5 ASSEMBLY VIEW B DX-250000-B 1. 2. 3. 4. 5. Existing mounting hardware Load lead access panel Screw Hang tag Circuit breaker Figure 6-4 6. 7. 8. 9. Circuit breaker panel Extension leads, if equipped Rear connection used on 125-250 amp circuit breaker Spacer used on 125-250 amp circuit breaker Circuit Breaker Mounting 6.
6.5 Battery Batteries and their installation must conform to USCG Regulations 183.420 (a) through (g). Provide generator sets with batteries separate from the propulsion engine’s whenever possible. The starting/charging systems of both the generator set and the engine must have a common negative (--) ground. USCG Regulation 183.415, Grounding, requires connection of a common conductor to each grounded cranking-motor circuit. Size the conductor to match the larger of the engine’s two battery cables.
6.7 Remote Start Switch Connection Kohler Co. offers several remote panels for connection to the generator set. Contact your local Kohlerr distributor/dealer for detailed descriptions. See Figure 6-8 for remote start panel connection to the generator set controller. Kohler Co. also offers a wiring harness with a connector keyed to the controller box connector.
ADV--6115A-A Figure 6-9 26 Remote Controller and Harness Options (33--150 kW Models) Section 6 Electrical System TP-6069 6/03
Figure 6-10 Remote Controller and Harness Options (33--150 kW Models) TP-6069 6/03 Section 6 Electrical System 27
Notes 28 Section 6 Electrical System TP-6069 6/03
Section 7 Installation Drawings Use the drawings in this section for installation purposes. Consult the supplier and verify that the drawings are the most current for your specifications. Installation drawings show exhaust outlet locations, fuel inlet and return connections, siphon break locations, and battery connections. See Figure 7-1 for installation drawing identification. Model No. 3.5EFOZ and 4EOZ with remote options Drawing ADV-6652A-B ADV-6652B-B Page 30 31 4EFOZ and 5EOZ with sound shield 6.
NOTE: Dimensions in [ ] are inch equivalents. Figure 7-2 30 ADV-6652A-B Dimension Drawing, 3.
ADV-6652B-B Figure 7-3 TP-6069 6/03 Remote Options, 3.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents. Figure 7-6 34 ADV-6284A-J Dimension Drawing, 6.
NOTE: Dimensions in [ ] are inch equivalents. Figure 7-7 TP-6069 6/03 ADV-6284B-J Dimension Drawing, 6.
NOTE: Dimensions in [ ] are inch equivalents. Figure 7-8 36 ADV-6026A-K Dimension Drawing, 8.
NOTE: Dimensions in [ ] are inch equivalents. Figure 7-9 TP-6069 6/03 ADV-6026B-K Dimension Drawing, 8.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents. ADV-6513A-C Figure 7-12 Dimension Drawing, 11.5/13EFOZ and 14/15.
NOTE: Dimensions in [ ] are inch equivalents. ADV-6513B-C Figure 7-13 Dimension Drawing, 11.5/13EFOZ and 14/15.
NOTE: Dimensions in [ ] are inch equivalents. ADV-6481A-D Figure 7-14 Dimension Drawing, 16/17.
NOTE: Dimensions in [ ] are inch equivalents. ADV-6481B-D Figure 7-15 Dimension Drawing, 16/17.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
NOTE: Dimensions in [ ] are inch equivalents.
Section 8 Reconnection/Adjustments 8.1 Four-Lead Reconnection The following information illustrates the reconnection of four-lead generator sets. In all cases, conform to the National Electrical Code (NEC). breaker. Application of two single-pole circuit breakers does not conform to NEC requirements for supplying a 200--240-volt load, even if the breakers are mechanically attached together. Leads L1 and L2 are for different phases; never connect them together. NOTICE L0 (Neutral) Voltage reconnection.
8.1.3 200--240-Volt Configurations The 200--240-volt configuration does not use a jumper lead. If the unit was originally wired for straight 100--120 volt, 3-wire, remove the jumper lead (see Figure 8-1 for location). L0 (Neutral) L0 GRD. Ground L1 Load Side Line Side Single-Pole Circuit Breaker Tape to insulate from ground regulator. See the generator set service manual for information regarding frequency adjustment.
Note: Position the current transformers with the dot or HI side CT marking toward the generator set. Note: Only generator sets equipped with AC meter controllers and/or safeguard circuit breakers require CTs. 5. If the controller has meters, remove the controller cover and reposition the meter scale lamp jumper (see Figure 8-6) matching the position of the desired voltage (shown in Figure 8-5). 1 Note: Equipment damage.
Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment. Figure 8-8. The generator set should shut down on an overvoltage fault in approximately 2 seconds. 1 2 Overvoltage Shutdown Adjustment Procedure 1.
Electroswitch 2-Wire Generator Sets 3-Wire Generator Sets L1 To Generator Set L1 2 1 3 4 7 8 To Shore Power L2 2 1 6 5 3 4 L2 6 5 To Generator Set 7 8 11 12 To Shore Power L0 10 9 To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets L1 L1 To Generator Set 1 2 3 4 6 5 To Shore Power 1 2 6 3 4 8 9 10 14 5 L2 L2 8 7 To Generator Set 7 To Shore Power L0 13 To Load To Load Kraus Naimler/Ameri
Note: Broadrange generator sets. The following adjustment procedure is for readjustment of the voltage regulator and governor for broadrange generator sets with mechanical governors. Kraus Naimler/American Solenoid 4-Wire, 3-Phase Generator Sets L1 L1 3 2 4 1 L2 To Generator 7 Set 6 8 5 10 12 9 L3 Note: Special tool. Frequency meter 50/60 Hz. L2 To Shore Power L3 11 Note: Rheostat connection.
Stabilizer Potentiometer (Pot) fine tunes the regulator circuitry to reduce light flicker. Voltage Adjustment Pot adjusts the generator voltage output within the range of approximately 100 to 130 volts. Volts/Hz Pot determines the engine speed (Hz) at which the generator output voltage begins to drop. Note: The volts/Hz adjustment does not apply to the following models: Model 4/6.5/8/8.5/9EFOZ 5/8/9/10EOZ Note: On these models, turn the volts/Hz adjustment pot full counterclockwise to stop and seal.
Notes 74 Section 8 Reconnection/Adjustments TP-6069 6/03
Appendix A Generator Selection and Wattage Requirements are DC powered by a 12-volt battery. Make sure the calculated total wattage includes only lights actually on the generator set AC circuit. Consider total wattage requirements (lights, motors, appliances) when selecting a generator set or when sizing wattage usage in which available space and construction limit the size of the generator set.
Appendix B Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw.
kg kg/cm2 kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd.
Appendix C Generator Set Output Ratings Procedure Kohler Co. develops the kilowatt output rating of a Kohlerr marine generator set based upon the calculations specified in ISO 3046 and ISO 8528-1. The calculations correct for environmental variables encountered in a generator set installation. Figure 1 outlines the calculations. Figure 2 contains examples of how heat variables affect generator set ratings.
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com TP-6069 6/03d E 2000, 2001, 2002, and 2003 by Kohler Co. All rights reserved.