Kohler Power Systems is launching a new Mobile Paralleling Box, which delivers flexibility by allowing users to combine different sized generators with different fuel types. The new paralleling box, specifically designed for use with Kohler’s gaseous and diesel mobile generator line, was officially introduced during the recent 2015 PGA Championship at Whistling Straits.

“We’re excited to introduce this new technology and proud to have launched it during the PGA Championship,” said Anne Feudner, product manager for Kohler Power Systems. “This new product will bring unmatched flexibility and a new level of customization to a wide variety of applications — including large scale, world-renowned events like the PGA golf tournament.”

Mix and Match

The new Mobile Paralleling Box, along with a fleet of Kohler generators, allows users to mix and match different size generators to meet job requirements.  Four of the new boxes can be used to parallel as many as eight generators. The Kohler Decision-Maker 3500 digital controller, which is standard on all Kohler gaseous and Tier 4 Final diesel mobile generators, provides the paralleling intelligence and network communications for remote monitoring.

“Any Kohler mobile generator with the Decision-Maker 3500 digital controller will work with the Mobile Paralleling Box,” Feudner said.  

The digital controller along with the new Mobile Paralleling Box makes it possible to parallel generators for applications such as using multiple smaller units to replace a larger generator, providing redundancy to a primary generator in support of critical loads, meeting system capacity demands when one generator is inadequate, or managing generators to be sequenced on or off in a predetermined order based on system output.

One Size Fits All

The new system uses contactors to connect to the bus and eliminates the need for installing or investing in motorized breakers on generators that may never be used in a parallel application. Each contactor is rated at 1,000 amps — different sized generators can parallel as long as each unit’s output is less than 1,000 amps.

“The advantage of the new paralleling system is that it removes the need to size circuit breakers to specific generator output,” Feudner said. 

Color-coded camlocks for input and output feeds make the new box easy to setup and maintain while unused camlock connectors are protected with lockable security bars. The system also includes two 25-in. control cables as well as lockable storage for control cables.  During the PGA Championship, the Mobile Paralleling Box from Kohler Power Systems was used to provide power redundancy for Kohler Co. hospitality tents. A Kohler 175REOZT4 Tier 4 Final diesel unit was used as the primary power source and a Kohler 125REZGT — an EPA-certified gaseous unit that runs on LP — served as a secondary power source.

Advanced Digital Controller

Paralleling intelligence is incorporated into the Kohler Decision-Maker 3500 digital controller, which provides system monitoring and diagnostics while also offering a user-friendly display. The advanced digital controller uses a patented hybrid voltage regulator and unique software logic to manage alternator thermal overload protection features that normally require additional hardware. Paralleling functions featured on the controller include:

  • Bus sensing for accurate metering and control
  • First-on logic – starts all generators to allow the first generator to reach rated voltage to close to the bus
  • Synchronizing adjusts other generators’ engine speed and voltage to allow them to connect to the bus
  • External-controlled load sharing via analog bias signals
  • Load management to ensure the generators are not overloaded