Kohler 30REZG Generator Set

⚠ Copying personality profiles from one controller to another can overwrite calibration coefficients and requires re-calibration.

Tools: Calibrated multimeter with recent calibration verification

1. Use a calibrated multimeter to measure the generator voltage and enter the correct value in the CONTROLLER CONFIG -> CALIBRATION screen.
2. Use a calibrated multimeter to measure the bus voltage and enter the correct value in the CONTROLLER CONFIG -> CALIBRATION screen.

⚠ Never use compressed air to clean brake components; some components may contain asbestos.

Tools: Adjustment tool or large slotted screwdriver, Jack stands

1. Raise the trailer with wheels off the ground and block safely with jack stands; remove the wheel.
2. Remove the rubber plug from the backing plate slot.
3. Insert an adjustment tool or large slotted screwdriver in the slot and rotate the star wheel to expand the shoe against the drum.
4. Expand the shoe until the drum can't be turned by hand to center each shoe.
5. Back off the adjustment in the other direction until the drum turns freely with slight resistance.
6. Replace the rubber plug in the backing plate slot.
7. Repeat procedure for remaining wheels.

⚠ Generators must all operate at the same frequency, voltage, and phase connection in order to parallel.

Tools: SiteTech software

1. Ensure the load is not connected or is drawing less power than a single generator can provide.
2. Navigate to CONTROLLER CONFIG -> COMMUNICATION SETUP and verify PGEN Nodes Online indicates the correct number of nodes.
3. Verify alternator connection (voltage selector switch position), system voltage, and voltage regulator target on each generator.
4. Start a single generator by pressing the Run button; the paralleling box contactor should close and the Generator Connected to Bus indicator should light.
5. Verify bus and generator voltages match and generator to bus phase angle is between -10 and 10 degrees.
6. Verify the load bus is energized and available at the load.
7. Stop the generator by pressing the OFF button; the contactor should open.
8. Repeat for each generator in the paralleling system.

Tools: Load bank (optional)

1. Place all generators in automatic mode by pressing the Auto button; verify the red shutdown indicator is not illuminated.
2. Provide a local start request by holding AUTO, pressing RUN, releasing RUN, then releasing AUTO.
3. Verify all generators start, one generator closes its contactor, and the others synchronize and close their contactors.
4. Verify that the % of rated power of the generators matches, showing the generators are sharing load equally.
5. If a load bank is available, test the system under load.

1. Determine entry hole type: round or slotted.
2. Determine exit hole type: fixed female thread (weld nut), round, or slotted.
3. For round and slotted exit holes, determine if hardware is greater than 1/2 inch in diameter.
4. Hardware greater than 1/2 inch in diameter uses a standard nut and SAE washer.
5. Hardware 1/2 inch or less in diameter can use a properly torqued whiz nut or spiralock nut.
6. Always use a washer between hardware and a slot.
7. Always use a washer under a nut.
8. Use a washer under a bolt when the female thread is fixed (weld nut).

⚠ The control harness connections for GEN 1 and GEN 2 must correspond to the source camlock cable connections.

1. Connect the control harness from the generator set connected to the GEN 1 camlock connectors to GEN 1 CONTROL.
2. Connect the control harness from the generator set connected to the GEN 2 camlock connectors to GEN 2 CONTROL.
3. When not used, store the control harnesses on the storage rack inside the enclosure.

⚠ Grounding electrical equipment: hazardous voltage can cause severe injury or death. Turn off the main circuit breakers of all power sources before servicing.

1. Connect the ground lug on the paralleling box to earth ground according to applicable state and local codes.
2. Follow NEC guidelines for grounding electrical equipment.
3. The neutral is bonded to ground inside the paralleling box; if required, remove the bonding bus to disconnect neutral from ground.

⚠ Multiple power sources can automatically energize the distribution bus. Disconnect all power sources before connecting to the distribution bus.

1. Remove the camlock security guard from one row of connectors for each generator and store the guard.
2. Connect the load side ground (green) camlock cables to the distribution bus and then to the paralleling box.
3. Connect the load side neutral (white) camlock cables to the distribution bus and then to the paralleling box.
4. Connect the load side L1 (black), L2 (red), and L3 (blue) camlock cables to the distribution bus and then to the paralleling box.

1. Connect one or two generators to each paralleling box.
2. Use Belden cable #9841 (or equivalent) shielded twisted-pair communication cable to connect the PGEN terminal blocks on the paralleling boxes.
3. Tighten the connections to 0.5 Nm (4.4 in. lbs.).

⚠ Generator management must be disabled manually at each generator set controller.

Tools: Personal computer with SiteTech software

1. Check that the voltage selector switch and/or alternator wiring matches the building voltage configuration for all generator sets.
2. Set the digital output to Contactor (SiteTech Programmable Digital Output 116).
3. Set reactive droop to 0.5-2% (default 1%), using the same reactive droop setting on all generators.
4. Set the target voltage on all paralleled generators to the same value.
5. Set engine speed adjustment to 50 on all generators (default 50; range 40-60).
6. Verify metering; if voltage is incorrect, use the calibration procedure.
7. Set Sync Mode in AUTO to ACTIVE and Sync Mode in Run to CHECK on all generators.
8. Set Generator Management Enabled to OFF at each generator unless generator management is requested.
9. Set up load management (load shed priorities) for non-critical loads.
10. Stop all generators by pressing the OFF button on each controller.

⚠ Hazardous voltage. This equipment must be installed and serviced by qualified electrical personnel. Do not connect or disconnect cables under load.

1. Remove the camlock security guard from one row of connectors for each generator and store the guard.
2. Generator 2 connects to the upper set of camlocks; generator 1 connects to the lower set.
3. Connect the source side ground (green) camlock cables to the paralleling box first and then to each generator.
4. Connect the source side neutral (white) camlock cables to the paralleling box first and then to each generator.
5. Connect the source side L1 (black), L2 (red), and L3 (blue) camlock cables to the paralleling box first and then to each generator.

⚠ Do not move the voltage selector switch while the generator set is running.

⚠ Affix voltage reconnection decal 246242 after reconnecting to a different voltage.

Tools: User-supplied load lug wrench

1. Press the generator set master control OFF/RESET button.
2. Open the main line circuit breaker.
3. Navigate to Generator Info then Voltage Selector Switch menu; press the selector dial.
4. Select Present Position and change to the desired selection (Three Phase Wye 480 V, Three Phase Wye 208 V, or Single Phase Dogleg).
5. Rotate the voltage selector switch on the junction box to match the desired voltage shown on the controller.
6. Disconnect the engine starting battery, negative lead first; disconnect battery charger power.
7. Make lead connections between load devices and the load lugs or camlocks.
8. Make a ground connection to earth ground per NEC guidelines.
9. Replace all electrical guards, barriers, and covers.
10. Reconnect the battery, negative lead last; reconnect battery charger power.
11. Press RUN to start and check voltages on the display.
12. Press OFF/RESET to stop.
13. Close the main line circuit breaker and any downstream circuit breakers.