Kohler 20--2800 kW Industrial Generator Sets Operation Manual

Operation

Industrial Generator Sets

Models:

20--2800 kW

Controllers:

Decision-Maker t 550

Software (Code) Version 2.10 or higher

TP-6200 3/06e

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts.

Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference.

Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

Record the product identification numbers from the generator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

Controller Identification

Record the controller description from the generator set operation manual, spec sheet, or sales invoice. Record the Controller Serial Number from the controller nameplate.

Controller Description

Controller Serial Number

Decision-Maker t 550

Firmware/Software Version Numbers

Record the version and reference numbers as shipped from the manufacturer.

Determine the Application

Program Version Number as shown in Menu 20.

Determine the Personality Profile Reference Number from the disk supplied with the literature packet.

Application Program Version Number

Personality Profile Reference Number

User Parameter File Reference Number

Version Number Upgrades/Updates

Record the version number upgrade/updates when installed.

Version No./Date Installed

Version No./Date Installed

Version No./Date Installed

Version No./Date Installed

Version No./Date Installed

Version No./Date Installed

Version No./Date Installed

Version No./Date Installed

Software Options

Record the software options.

Number and Description

Number and Description

Number and Description

2 TP-6200 3/06

Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

13

13

13

14

Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2

Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1

Annunciator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2

Digital Display and Keypad

1.2.3

Switches and Controls

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

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

1.2.4

Controller Circuit Boards

1.2.5

Fuses

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

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

1.2.6

Terminal Strips and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.7

Circuit Board Interconnections for Calibration Procedure . . . . . . . . . . . .

1.2.8

Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.1

Status Event and Fault Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3.2

Voltage Regulator and Calibration Specifications . . . . . . . . . . . . . . . . . .

1.3.3

Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

15

21

22

22

22

28

28

15

16

17

19

20

20

20

Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

Exercising Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

Controller Operation

2.3.1

Starting

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

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

2.3.2

Stopping (User Stopping and Fault Shutdown) . . . . . . . . . . . . . . . . . . . .

2.3.3

Emergency Stop Switch Resetting

2.3.4

Status Lamp

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

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

2.3.5

System Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.6

System Shutdown Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.7

Controller Resetting (Following System Shutdown or Warning) . . . . . .

2.4

Menu List Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Digital Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Reviewing the Digital Display

2.6.1

Keypad Operation

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

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

2.6.2

Auto-Scroll Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3

Request and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1

PC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2

Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8

Reviewing the Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.1

Menu 1—Generator Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.2

Menu 2—Engine Monitoring

2.8.3

Menu 3—Analog Monitoring

2.8.4

Menu 4—Operational Records

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

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

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

2.8.5

Menu 5—Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.6

Menu 6—Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.7

Menu 7—Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.8

Menu 8—Time Delays

2.8.9

Menu 9—Input Setup

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

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

2.8.10

Menu 10—Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.11

Menu 11—Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31

31

55

57

58

59

59

59

61

62

64

66

50

52

52

53

45

47

47

48

48

50

33

33

33

35

38

39

31

31

31

33

TP-6200 3/06 Table of Contents 3

Table of Contents, continued

2.8.12

Menu 12—Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.13

Menu 13—Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.14

Menu 14—Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.15

Menu 15—Paralleling Relays (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.16

Menu 20—Factory Setup (Version 2.10)

2.8.17

Menu 20—Factory Setup (Version 2.21)

2.9

Local Programming Mode On

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

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

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

2.9.1

Menu 1—Generator Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.2

Menu 2—Engine Monitoring

2.9.3

Menu 3—Analog Monitoring

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

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

2.9.4

Menu 4—Operational Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.5

Menu 5—Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.6

Menu 6—Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.7

Menu 7—Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.8

Menu 8—Time Delays

2.9.9

Menu 9—Input Setup

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

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

2.9.11

Menu 11—Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

93

95

2.9.10

Menu 10—Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101

111

74

78

81

83

85

86

87

67

68

69

70

71

72

73

2.9.12

Menu 12—Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.13

Menu 13—Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

122

2.9.14

Menu 14—Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.15

Menu 15—Paralleling Relays (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

126

128

2.9.16

Menu 20—Factory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

133

Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

135

3.1

Alternator Service

3.2

Engine Service

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

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

135

135

3.3

Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

136

3.4

Alternator Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

3.4.1

20--300 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

3.5

3.4.2

350--2000 kW Models with Single-Bearing Alternator

3.4.3

1250--2800 kW Models with Two-Bearing Alternator

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

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

138

138

Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

3.5.1

Bleeding Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2

Subbase Fuel Day Tank Electronic Control Module (ECM) . . . . . . . . . .

138

139

3.5.3

Subbase Inner Fuel Tank Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

3.6

Gas/Gasoline Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

140

3.6.1

Gaseous Fuel System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.2

LP Liquid Withdrawal Fuel System Concept . . . . . . . . . . . . . . . . . . . . . . .

3.6.3

LP Gas/Natural Gas Conversion for Straight Gas Fuel System . . . . . . .

140

141

141

3.6.4

Fuel System Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.5

Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6.6

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

142

142

142

3.7

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.1

Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.2

Cooling System Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .

143

143

143

3.7.3

Procedure to Drain Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7.4

Procedure to Flush and Clean Cooling System . . . . . . . . . . . . . . . . . . . .

3.7.5

Procedure to Refill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Radiator Expansion Joint Loosening—Initial Setup Only . . . . . . . . . . . . . . . . . . . .

144

144

144

145

3.9

Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

145

3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.1

Clean Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

146

147

3.10.2

Electrolyte Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10.3

Specific Gravity Check

3.10.4

Charge Battery

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

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

147

148

148

4 Table of Contents TP-6200 3/06

Table of Contents, continued

3.11 Detroit Diesel Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

149

3.11.1

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11.2

DDEC Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

149

149

3.12 Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150

3.13 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.1

Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.2

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

150

150

151

3.13.3

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.13.4

Internal Engine Components (Gas/Gasoline-Fueled Engines) . . . . . . .

3.13.5

Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

151

151

3.13.6

Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

151

Section 4 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

153

4.1

General Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

154

4.2

Controller Display and Voltage Regulation Troubleshooting Chart . . . . . . . . . . . .

157

Section 5 Generator Set Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

159

5.1

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

Voltage Reconnection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

159

160

Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165

6.1

Accessories and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1

Audiovisual Alarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.2

Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165

165

166

6.1.3

Controller (Customer) Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.4

Float/Equalize Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . .

166

166

6.1.5

Idle (Speed) Mode Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168

6.1.6

Low Fuel (Level/Pressure) Switch

6.1.7

Prime Power Switch Kit

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

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

168

168

6.1.8

Remote Annunciator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.9

Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

169

171

6.1.10

Remote Reset Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.11

Remote Serial Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

172

6.1.12

Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) . . . .

174

6.1.13

Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.14

Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.15

Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

175

175

6.1.16

Twenty-Relay Dry Contact Kit (450--2000 kW Models Only)

6.1.17

Wireless Monitor

. . . . . . . . .

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

177

178

6.2

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

179

Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183

Appendix B User-Defined Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

185

Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190

Appendix D Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196

Appendix E Inputs and System Events by Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

197

TP-6200 3/06 Table of Contents 5

Notes

6 Table of Contents TP-6200 3/06

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.

This manual has several types of safety precautions and instructions: Danger,

Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely.

The decals are shown throughout this publication to improve operator recognition.

Replace missing or damaged decals.

Safety Precautions and Instructions

Accidental Starting

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

WARNING

Explosion.

Can cause severe injury or death.

Relays in the battery charger cause arcs or sparks.

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin.

Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water.

Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

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.

TP-6200 3/06 Safety Precautions and Instructions 7

Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging.

Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.

Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections.

Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits.

Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage.

Disconnect the battery before generator set installation or maintenance.

Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash

Fire

Fire.

WARNING

Can cause severe injury or death.

Do not smoke or permit flames or sparks near fuels or the fuel system.

Servicing the fuel system. A flash fire can cause severe injury or death.

Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.

Catch fuels in an approved container when removing the fuel line or carburetor.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive.

Handle these materials carefully to minimize the risk of fire or explosion.

Equip the compartment or nearby area with a fully charged fire extinguisher.

Select a fire extinguisher rated ABC or

BC for electrical fires or as recommended by the local fire code or an authorized agency.

Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Generator set operation.

Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.

8 Safety Precautions and Instructions

Carbon monoxide symptoms.

Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases.

Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness

D Physical fatigue, weakness in joints and muscles

D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep.

Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

Copper tubing exhaust systems.

Carbon monoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems.

Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust leakage.

Fuel System

WARNING

Explosive fuel vapors.

Can cause severe injury or death.

Use extreme care when handling, storing, and using fuels.

The fuel system.

Explosive fuel vapors can cause severe injury or death.

Vaporized fuels are highly explosive.

Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the 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 lines and connections tight and in good

TP-6200 3/06

condition. Do not replace flexible fuel lines with rigid lines.

Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.

Repair fuel systems before resuming generator set operation.

Explosive fuel vapors can cause severe injury or death.

Take additional precautions when using the following fuels:

Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.

Propane (LP)—Adequate ventilation is mandatory.

Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturer’s instructions.

Natural Gas—Adequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturer’s instructions.

Fuel tanks. Explosive fuel vapors can cause severe injury or death.

Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

Gas fuel leaks.

Explosive fuel vapors can cause severe injury or death.

Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to

6--8 ounces per square inch

(10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

LP liquid withdrawal fuel leaks.

Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi

(621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

Hazardous Noise

CAUTION

Hazardous noise.

Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than

105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/

Electrical Shock

DANGER

Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

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

Hazardous voltage.

Backfeed to the utility system can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

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. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards.

Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

High voltage test.

Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator.

An improper test procedure can damage equipment or lead to generator set failure.

TP-6200 3/06 Safety Precautions and Instructions 9

Testing the photo transistor circuit board.

Hazardous voltage can cause severe injury or death. When the end cover is removed, do not expose the photo transistor circuit board mounted on the generator set end bracket to any external light source, as exposure to light causes high voltage. Keep foreign sources of light away from the photo transistor circuit board during testing.

Place black electrical tape over the LED on the circuit board before starting the generator set.

Installing the photo transistor circuit board.

Hazardous voltage can cause severe injury or death. Ensure that the foil side of the photo transistor circuit board, the end of the shaft, and the threaded holes are clean and free of metal particles and chips. Metal debris may short-circuit the photo transistor circuit board and cause hazardous voltage in the generator set. Do not reconnect the generator set to the load until the AC voltmeter shows the correct output.

Installing the battery charger.

Hazardous voltage can cause severe injury or death.

An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies).

Have a qualified electrician install the battery(ies).

Servicing the day tank. Hazardous voltage can cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing.

Press the day tank ECM OFF pushbutton to disconnect the power.

Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set

10 Safety Precautions and Instructions and day tank are electrically grounded.

Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution.

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.

Engine block heater.

Hazardous voltage can cause severe injury or death. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.

Handling the capacitor. Hazardous voltage can cause severe injury or death.

Electrical shock results from touching the charged capacitor terminals. Discharge the capacitor by shorting the terminals together.

(Capacitor-excited models only)

Electrical backfeed to the utility.

Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power.

Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

Testing live electrical circuits.

Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits.

Use adequately rated test equipment 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) Remove all jewelry.

(2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure.

(4) Be prepared for the system to operate automatically.

(600 volts and under)

Heavy Equipment

damage.

the skid.

WARNING

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment

Do not use lifting eyes.

Lift the generator set using lifting bars inserted through the lifting holes on

Hot Parts

WARNING

Hot coolant and steam.

Can cause severe injury or death.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

Servicing the alternator. Hot parts can cause severe injury or death.

Avoid touching the alternator field or exciter armature.

When shorted, the alternator field and exciter armature become hot enough to cause severe burns.

TP-6200 3/06

Checking the coolant level.

Hot coolant can cause severe injury or death.

Allow the engine to cool.

Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after pressure has been completely released and the engine has cooled.

Check the coolant level at the tank if the generator set has a coolant recovery tank.

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.

WARNING

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

Airborne particles.

Can cause severe injury or blindness.

Wear protective goggles and clothing when using power tools, hand tools, or compressed air.

Tightening the hardware.

Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury.

Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware.

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

246242

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate.

Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE

Hardware damage. The engine and generator set may use both American

Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.

NOTICE

When replacing hardware, do not substitute with inferior grade hardware.

Screws and nuts are available in different hardness ratings.

To indicate hardness, American

Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.

NOTICE

Canadian installations only.

For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with

Canadian Electrical Code, Part 1.

TP-6200 3/06 Safety Precautions and Instructions 11

Notes

12 Safety Precautions and Instructions TP-6200 3/06

This manual provides operation instructions for

20--2800 kW generator sets equipped with the following controller:

D

Decision-Maker t 550, Software (Code) Version 2.10

or higher

Version 2.10 refers to the controller application software.

To determine the generator set controller software version, go to Menu 20—Factory Setup and scroll down to Code Version. The code version is the controller software version.

Wiring diagram manuals are available separately. Refer to the engine operation manual for generator set engine scheduled maintenance information.

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.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the

Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals.

Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service.

The disk supplied with this generator set is a backup copy of the generator set personality program containing data specific to the engine and alternator.

The engine and alternator data was preprogrammed in the controller at the factory and no further use of the disk should be necessary.

Typically, your authorized distributor stores this disk for possible future use such as controller replacement or other circumstances requiring a backup.

Introduction

Abbreviations

This publication makes use of numerous abbreviations.

Typically, the word(s) are spelled out along with the abbreviation in parentheses when shown for the first time in a section.

Appendix A, Abbreviations, also includes many abbreviation definitions.

List of Related Materials

Separate literature contains communication and software information not provided in this manual.

Figure 1 lists the available literature part numbers.

Communication and Software

Manual Description

550 Controller Spec Sheet

Generator Set/Controller

Wiring Diagram Manual

550 Communications Spec Sheet

Monitor II Software Spec Sheet

Monitor II Software

Operation/Installation Manual

Monitor III Converters, Connections, and Controller Setup

Monitor III Software Spec Sheet

Monitor III Converter,

Modbus r/Ethernet Spec Sheet

Monitor III Software Operation Manual

Modbus r Communications Protocol

Operation Manual

Setup and Application Manual

Service Parts Controllers

Communication Kits Installation

Program Loader Software Installation

Remote Serial Annunciator (RSA)

Controller Service Replacement

Figure 1 Related Literature

Literature Part No.

G6-46

Multiple Part Numbers

Contact your

Distributor/Dealer

G6-50

G6-38

TP-6194

TT-1405

G6-76

G6-79

TP-6347

TP-6113

TP-6140

TP-6009

TT-847

TT-1285

TT-1377

TT-1310

Modbus r is a registered trademark of Schneider Electric.

TP-6200 3/06 Introduction 13

Several engine manufacturers provide engines with electronic controls. These electronic controls indicate engine fault codes in addition to the generator set controller.

Use Figure 2 for literature part numbers relating to the identifying engine fault codes. For the latest literature part numbers, see the respective Parts

Catalog.

Model

30 kW and 80--125 kW GM

80--200 kW John Deere 4045/6068

275--500 kW Kohler Branded Engines

135--275 kW DDC Series 50/60 Gas

230--450 kW DDC Series 60

230--450 kW DDC Series 60

230--450 kW DDC Series 60

450/500 kW DDC Series 2000

650--1000 kW DDC Series 2000

1350--2000 kW DDC/MTU Series 4000

2500/2800 kW DDC/MTU Series 4000

Figure 2 Related Engine Literature

Literature Part No.

Description

TP-6215 Engine ECM Service Manual

TP-6285

TP-6218

TP-5830

Engine Operation Manual

Engine Operation Manual

Natural Gas Generator Set Engine Operator’s Manual

TP-6056

TP-6422

TP-5611

TP-6361

TP-6375

TP-6237

TP-6248

DDEC IV Application and Installation Manual

DDEC V ECM Troubleshooting Guide

Engine Operator’s Guide

DDEC IV ECM Troubleshooting Guide

Engine Operating Instructions (MDEC)

Engine Operating Instructions (MDEC)

Engine Operating Instructions (MDEC)

Service Assistance

For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D

Consult the Yellow Pages under the heading

Generators—Electric

D

Visit the Kohler Power Systems website at

KohlerPowerSystems.com

D

Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product

D

Call toll free in the US and Canada 1-800-544-2444

D

Outside the US and Canada, call the nearest regional office

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems

ZI Senia 122

12, rue des Hauts Flouviers

94517 Thiais Cedex

France

Phone: (33) 1 41 735500

Fax: (33) 1 41 735501

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

14 Service Assistance TP-6200 3/06

1.1 Introduction

The spec sheets for each generator set provide modelspecific generator and engine information.

The controller spec sheet provides specifications for this controller. Refer to the respective spec sheet for data not supplied in this manual. Consult the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications.

1.2 Controller Features

The controller features include the annunciator lamps, digital display and keypad, switches and controls, and fuses and terminal strip.

The following paragraphs detail the features by general topics.

Section 1 Specifications and Features

The controller features, accessories, and menu displays depend upon the engine electronic control module

(ECM) setup and features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted.

Note: Press any key on the keypad to turn on the controller lights and display.

The lights and display turn off 5 minutes after the last keypad entry.

Note: Measurements display in metric or English. Use

Menu 7—Generator System to change the measurement display.

See Figure 1-1 for an illustration of the controller front panel.

1 2 3 4 5 6

8

1. Emergency stop switch

2. Alarm horn (see keypad for alarm silence)

3. Annunciator lamps (see keypad for lamp test)

4. Generator set master switch, run/off-reset/auto positions

Figure 1-1 550 Controller

7

5. Digital display

6. Keypad

7. Operating guide

8. Controller terminal strips (on circuit board)

TP-6083-2

TP-6200 3/06 Section 1 Specifications and Features 15

1.2.1

Annunciator Lamps

Five annunciator lamps provide visual generator set status. See Figure 1-2.

TP-6083-2

Figure 1-2 Annunciator Lamps

System Ready.

Green lamp illuminates when the generator set master switch is in the AUTO (automatic start) position and the system senses no faults. The unit is ready to start.

Not in Auto (NIA). Yellow lamp illuminates when the generator set master switch is not in the AUTO

(automatic start) position.

Programming Mode.

Yellow programming lamp indicates the user selected programming mode. See

Figure 1-3.

Programming Lamp

Lamp Flashing

Lamp Steady On

Lamp Off

Programming Mode Selection

Local Programming

Remote Programming

Programming Disabled

Figure 1-3 Programming Lamp Mode

Note: Find additional information for the programming mode lamp function and access to the local or remote programming modes in Section 2.9, Local

Programming Mode On, Menu 14—Programming

Mode.

System Warning. Yellow lamp identifies an existing fault condition that does not shut down the generator set. A continuing system warning fault condition may cause a system shutdown. Correct all system warnings as soon as practical.

See Section 2.3.5, System Warning Lamp, for definitions of the items listed.

The following conditions cause a system warning:

D

Engine functions: d d d d d d d d d

High battery voltage

High coolant temperature

Low battery voltage

Low coolant temperature

Low fuel (level or pressure)*

Low oil pressure

Speed sensor fault

Starting aid (system status)

Weak battery

D d d d d d d d

General functions: d

Auxiliary—Analog up to 7 user selectable inputs each with a high and low programmable warning d level.

Auxiliary—Digital up to 21 user selectable warnings

Battery charger fault*

Emergency power system (EPS) supplying load

Engine cooldown delay

Engine start delay

Load shed kW overload

Load shed underfrequency

Master switch not in AUTO (automatic start) position d d

NFPA 110 fault (National Fire Protection

Association)

System ready (system status)

D

Alternator functions: d d d

AC sensing loss

Ground fault*

Overcurrent

* Requires optional input sensors.

Note: See Figure 2-9 in User Inputs for factoryreserved analog and digital inputs that are not user-selectable.

System Shutdown.

Red lamp indicates that the generator set has shut down because of a fault condition. The unit will not start without resetting the controller, see Section 2.3.7, Controller Reset

Procedure.

See Section 2.3.6, System Shutdown Lamp, for definitions of the items listed.

16 Section 1 Specifications and Features TP-6200 3/06

The following conditions cause a system shutdown:

D

Engine functions: d d d d d d d d d

Air damper closed (status), if equipped

Coolant temperature signal loss

High coolant temperature

High oil temperature

Low coolant level

Low oil pressure

Oil pressure signal loss

Overcrank

Overspeed

D d d d d d d d

General functions: d

Auxiliary—Analog up to 7 user selectable inputs each with a high and low programmable shutdown level d

Auxiliary—Digital up to 21 user selectable shutdowns

ECM communications loss (ECM models only)

Emergency stop

Internal fault

Master switch in OFF/RESET position

Master switch error

Master switch open

NFPA 110 fault

D d d d d

Alternator functions: d d d

AC output overvoltage

AC output undervoltage

Alternator protection against overload and short circuits

Field overvoltage (M4, M5, or M7 alternator only)

Locked rotor (failed to crank)

Overfrequency

Underfrequency

Note: See Figure 2-9 in User Inputs for factoryreserved analog and digital inputs which are not user selectable.

1.2.2

Digital Display and Keypad

Figure 1-4 illustrates the digital display and keypad.

Note: Press any key on the keypad to turn on the controller lights and display.

The lights and display turn off 5 minutes after the last keypad entry.

The 2-line vacuum fluorescent display provides generator set and engine condition information.

The 16-button keypad gives the user information access and local programming capability.

Keypad Functions

Alarm (Horn) Off key silences the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. See Section 2.3.7, Controller Reset Procedure, and Section 1.2.3, Switches and Controls.

AM/PM key provides time of day data entries when programming.

Enter

↵ key provides confirmation entry when selecting menu or programming.

Lamp Test key tests the controller indicator lamps, horn, and digital display. See Section 1.2.3, Switches and Controls.

Menu down

↓ key provides navigation within menus when necessary.

Menu right

→ key provides navigation within menus when necessary.

Numeric 0--9 keys provide numeric data entries when selecting menus or programming.

Reset Menu key exits a menu, clears incorrect entries, and cancels the auto-scroll feature.

Stop Prog (Program) Run key allows the user to stop any previously programmed generator set run sequence. See Section 1.2.3, Switches and Controls.

Yes/No keys provides data answer entries when programming.

TP-5829-2

Figure 1-4 Digital Display and Keypad

TP-6200 3/06 Section 1 Specifications and Features 17

Alternator Output Displays

AC Amps displays the alternator output current. The display shows each line of 3-phase models.

AC Volts displays the alternator output voltages. The display shows all line-to-neutral and line-to-line voltage combinations.

Alternator Duty Level displays the actual load kW divided by the nameplate kW rating as a percentage.

Frequency displays the frequency (Hz) of alternator output voltage.

Hourmeter displays the generator set operating hours loaded and unloaded for reference in scheduling maintenance.

KVA displays the total and individual L1, L2, and L3 kVA.

KVAR displays the total and individual L1, L2, and L3 kVAR.

Power Factor displays the kW/kVA and the individual line power factor values.

Watts displays the total and individual L1, L2, and L3 kilowatts.

Engine Displays

Some engine displays are available with selected generator set engines using engine ECMs only. The controller display shows N/A (not available) for items that are unavailable. See the controller spec sheet for applicable generator set models.

Ambient Temperature displays the generator set area ambient temperature.

Coolant Level displays the engine coolant level.

Coolant Pressure displays the engine coolant pressure.

Coolant Temperature displays the engine coolant temperature.

Crankcase Pressure displays the engine crankcase pressure.

DC Volts displays the voltage of starting battery(ies).

Fuel Pressure displays the fuel supply pressure.

Fuel Rate displays the calculated fuel consumption rate based on fuel injector outputs.

Fuel Temperature displays the fuel supply temperature.

Oil Level displays the engine oil level as a percent of full capacity.

Oil Pressure displays the engine oil pressure.

Oil Temperature displays the engine oil temperature.

RPM (Tachometer) displays the engine speed.

Used Last Run displays the accumulated amount of fuel used since last reset by the engine DDEC reader.

Operational Record Displays

The operational record displays events since last reset.

See Section 2.9.4, Menu 4—Operational Records, for resetting procedure.

Engine Start Countdown displays the time remaining before the next generator set startup.

Event History displays up to 100 stored system events including status, warnings, and shutdowns.

Last Start Date displays the date when the generator set last operated.

Number of Starts displays the total number of generator set startup events.

Number of Starts (Since) Last Maintenance displays the total number of generator set startup events since the last maintenance date.

Operating Days (Since) Last Maintenance displays the total number of days of operation since the last maintenance date. A counted day of operation can be

1--24 hours.

Run Time displays the total loaded hours, total unloaded hours, and total kW hours.

Run Time Since Maintenance displays the total loaded hours, total unloaded hours, and total kW hours.

Time Delay Displays

The time delays are user adjustable. See Section 2.9.8,

Menu 8—TIme Delays, for time delay adjustments. See

Section 1.3.1, Status Event and Fault Specifications, for range and default settings.

Crank On/Crank Pause displays the time allocated for generator set crank on and crank pause in minutes:seconds.

18 Section 1 Specifications and Features TP-6200 3/06

Engine Cooldown displays the time delay for engine cooldown while the master switch is in the AUTO or RUN positions and not in the idle mode.

Engine Start displays the time delay before the generator set starts while the master switch is in AUTO or RUN positions.

Overcrank Shutdown (Number of) Crank Cycles displays the number of unsuccessful crank cycles

(crank on/crank pause) before the generator set shuts down on an overcrank fault.

Overvoltage displays the time delay before the generator set shuts down because of an overvoltage condition.

Starting Aid displays the engine starting aid activation time.

Undervoltage displays the time delay before the generator set shuts down because of an undervoltage condition.

1.2.3

Switches and Controls

See Figure 1-5 and Figure 1-6 for switches and controls.

1 2 3

Alarm (Horn) Off.

The keypad switch silences the alarm horn at the operator’s discretion.

Place the generator set master switch in the AUTO position before silencing the alarm horn. Restore alarm horn switches at all locations including those on remote annunciator and audiovisual alarm kits to the normal position after correcting the fault shutdown to avoid reactivating the alarm horn.

See Section 2.3.7, Controller Reset

Procedure.

AM/PM. This keypad switch provides time of day data entries when programming.

Emergency Stop. The operator-activated pushbutton immediately shuts down the generator set in emergency situations.

Reset the emergency stop switch after shutdown by pulling the switch knob outward. Use the emergency stop switch for emergency shutdowns only.

Use the generator set master switch for normal shutdowns.

Generator Set Master Switch (Run/Off-Reset/Auto).

This switch resets the controller fault lamps and start/stops the generator set. Refer to Section 2.3.1,

Starting, Section 2.3.2, Stopping, and Section 2.3.3,

Emergency Stop Switch Reset Procedure.

Lamp Test.

The keypad switch tests the controller indicator lamps, horn, and digital display. Press the reset menu key before pressing the lamp test key.

Stop Prog (Program) Run. Keypad switch allows the user to stop any previously programmed generator set run sequence.

TP-6083-2

1. Emergency stop switch

2. Alarm horn

3. Generator set master switch

Figure 1-5 Switches and Alarm Horn

Note: Find additional switches and controls in

Section 2.6.1, Keypad Operation.

Alarm Horn. The alarm horn alerts the operator or other attendants that a shutdown or warning condition exists.

See Section 1.3, Controller Logic Specifications, for conditions. Place the generator set master switch in the

AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the generator set master switch is in the AUTO position.

See

Section 2.3.7, Controller Reset Procedure.

1

2

3

1. Lamp test

2. Alarm horn silence

3. Stop program run

Figure 1-6 Keypad Switches

TP-6200 3/06

TP-5829-2

Section 1 Specifications and Features 19

1.2.4

Controller Circuit Boards

The controller has five circuit boards—indicator, interconnection, keypad, digital display, and main logic/communication. See Figure 1-7 for circuit board locations.

1 2

5 4 3

GM10193B-A

1. AC fuse block (TB5)

2. Interconnection circuit board TB1, TB2, TB3, and TB4 terminal strips and F1, F2, and F3 fuses

3. Main logic (microprocessor)/communication circuit board

4. Keypad and digital display circuit boards

5. Indicator circuit board (LED and alarm horn)

Figure 1-7 Controller Circuit Boards and Fuses

(Controller Top View)

Indicator (Status) Circuit Board includes the LED status lamps, alarm horn, and generator set master switch.

Interconnection Circuit Board provides the terminal strips to connect the controller (customer) connection board and/or dry contact kits and three DC fuses (F1,

F2, and F3). See 6.1.3 for more information.

Keypad (Switch Membrane) Circuit Board provides the keypad to navigate the generator set displays and enter data.

Digital Display Circuit Board provides the vacuum fluorescent display (VFD) for monitoring the generator set functions and output values.

Main Logic (Microprocessor)/Communication

Circuit Board provides the controller operation logic and provides PC communication locally (direct) or remotely (via modem) using RS-232 or RS-485 connectors.

1.2.5

Fuses

AC Circuit Fuses (TB5). Fuses are located inside the controller. See Figure 1-7.

D

1.5-Amp (V7) fuse protects L1 sensing input to interconnection circuit board.

D

1.5-Amp (V8) fuse protects L2 sensing input to interconnection circuit board.

D

1.5-Amp (V9) fuse protects L3 sensing input to interconnection circuit board.

DC Circuit Fuses fuses are located on the controller interconnection circuit board.

D

5-Amp Remote Annunciator (F1) fuse protects the dry contact kit if equipped and the controller panel lamps.

D

5-Amp Controller (F2) fuse protects the controller circuitry.

D

15-Amp Engine and Accessories (F3) fuse protects the engine/starting circuitry and accessories.

1.2.6

Terminal Strips and Connectors

Terminal strips and connectors for inputs and outputs are located on the interconnection circuit board. See

Section 6, Accessories.

TB1 Input Connection Terminal Strip provides input connections for remote start and emergency stop

(E-Stop).

TB2 Analog Input Connection Terminal Strip provides analog input connections, including non-ECM sensor connections.

TB3 Accessory Power Output Connection Terminal

Strips provides a generator set power supply for factory use.

TB4 Digital Input Connection Terminal Strips connect external devices (engine ECM and user supplied) to the generator set digital inputs.

P23 Connector connects the interconnection circuit board to the controller (customer) connection terminal strip (connector P25) inside the junction box. See 6.1.3

for more information.

20 Section 1 Specifications and Features TP-6200 3/06

Figure 1-8 shows locations of the terminal strips on the controller interconnection circuit board. See Section 6.2,

Accessory and Connections, for specific terminal identification information. Refer to the wiring diagrams for additional information on connecting accessories to the terminal strips.

1.2.7

Circuit Board Interconnections for

Calibration Procedure

The interconnection circuit board shown in Figure 1-9 contains a ribbon connector that requires disconnection during the calibration procedure in Menu 12—

Calibration. Disconnect ribbon connector P2 prior to zeroing out (resetting) the auxiliary analog inputs.

1 2

3

4 5

1

2

ADV-6533-A

1. TB1 terminal strip

2. TB2 terminal strip

3. P23 Connector

4. TB3 terminal strip

5. TB4 terminal strip

Figure 1-8 Interconnection Circuit Board Terminal

Strips and Connectors

3

4

ADV-6533-A

1. Interconnection circuit board

2. P2 ribbon connector

3. P12 ribbon connector

4. Main logic circuit board

Figure 1-9 Interconnection Circuit Board Ribbon

Connector P2 (Top View of Circuit Board)

TP-6200 3/06 Section 1 Specifications and Features 21

1.2.8

Communication Ports

The main logic circuit board contains several communication ports for Modbus r and KBUS connections.

See Figure 1-10.

Refer to the List of

Related Materials in the Introduction for corresponding communication installation information.

1.3 Controller Logic Specifications

The controller logic specifications section is an overview of the various features and functions of the controller.

Certain features function only when optional accessories are connected. See Section 2, Operation, for details.

The default selection time delays and relay driver outputs (RDOs) are factory set and adjustable with the programming mode on (Menu 14). Some data entries require using a PC in the Remote Programming mode.

See the Monitor Software Operation Manual for details.

Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect a fault or status event. Select the desired inhibit time delay from 0 to 60 seconds.

TIme Delay (Shutdown or Warning). The time delay follows the inhibit time delay. The time delay is the time period between when the controller first detects a fault or status event and the controller warning or shutdown lamp illuminates.

The delay prevents any nuisance alarms.

Select the desired time delay from 0 to

60 seconds.

1.3.1

Status Event and Fault

Specifications

The table starting on the next page contains all status events and faults with ranges and time delays including items that do not have adjustments.

Note: The engine ECM may limit the crank cycle even if the controller is set to a longer time period.

6

1 2 3 4 5

ADV-6533-A

1. P19—unused isolated connection (ISO2), RS-485 port

2. P21—KBUS isolated connection (ISO1), RS-485 port

3. P18—KBUS or Modbus r, RS-232 port

4. P20—Modbus, RS-485 port

5. P22—ECM connector

6. Main logic circuit board

Figure 1-10 Main Logic Circuit Board Communication

Ports (Top View of Circuit Board)

Modbus r is a registered trademark of Schneider Electric.

22 Section 1 Specifications and Features TP-6200 3/06

Factory-Defined Settings

Status Event or Fault

Access Code

(password)

AC Sensing Loss

Refer to

Menu

14

Digital

Display

10 AC Sensing

Loss

Air Damper Control

(if used) **

Air Damper Indicator

(if used) Digital Aux.

Input D20 **

Air/Fuel Module

(AFM) Engine Start

Delay

]

Air/Fuel Module

(AFM) Remote Start

]

Air/Fuel Module

(AFM) Shutdown

]

Alternator Protection

Shutdown

Analog Aux. Inputs

A01--A07

10

9, 10 Air Damper

D20

10 AFM Eng

Start Delay

10 AFM Remote

Start

9, 10 AFM

Shutdown

10

9

Alternator

Protection

User-Defined

A01--A07

Relay

Driver

Output

(RDO)

RDO-25*

RDO-23*

(lead 56)

Alarm

Horn

On

On

RDO-25

]

Off

On

On

Lamp

Warning

Shutdown

Shutdown

Shutdown

Analog Aux. Input

A01 (non-ECM only)

Analog Aux. Input

A02 (non-ECM only)

Analog Aux. Input

A03

]

Analog Aux. Input

A04

]

Analog Aux. Input

A07 w

9

9

9

9

9

A01 Coolant

Temp

A02 Oil

Pressure

A03 Intake

Air

Temperature

A04 Oil

Temperature

A07 Voltage

Adjust

Range Setting

User Selectable

Fixed

Fixed

Fixed

Default

Selection

0 (zero)

0 sec.

inhibit,

0 sec. delay

On Shutdown or

Warning

On Shutdown or

Warning

On Shutdown or

Warning

On

On

Off

Shutdown or

Warning

Warning

Warning

Warning

Default Values with

Warning Enabled:

HI warning 90%

LO warning 10%

HI shutdown 100%

LO shutdown 1%

Default Values with

Warning Enabled:

HI/LO warning and HI/LO shutdown are all engine dependent

Default Values with

Warning Enabled:

HI/LO warning and HI/LO shutdown are all engine dependent

(255 psi max.)

Default Values with

Warning Enabled:

HI/LO warning and HI/LO shutdown are all engine dependent

Default Values with

Warning Enabled:

HI/LO warning are engine dependent

±10% of system voltage over the range of

0.5--4.5 VDC

Fixed

30 sec.

inhibit,

5 sec. delay

30 sec.

inhibit,

0 sec. delay warning,

5 sec. delay shutdown

30 sec.

inhibit,

0 sec. delay warning,

5 sec. delay shutdown

30 sec.

inhibit,

0 sec. delay warning

30 sec.

inhibit,

0 sec. delay warning

0 sec.

inhibit,

0 sec. delay

Fixed

Battery Charger Fault,

Digital Aux. Input

D01 **

Battle Switch

(Fault Shutdown

Override Switch)

Block Heater Control

[[

Breaker Trip w

Common Paralleling

Relay Output w

Critical Overvoltage

Shutdown

9, 10

9

Battery

Charger

Fault

Battle Switch

10 Block Heater

Control

RDO-11

(lead 61)

RDO only

10 Breaker Trip RDO-30

10 Common PR

Output

RDO-31

10 Critical

Overvoltage

Off

Off

On

Warning

Warning

Shutdown Fixed 275 volts

(L1--L2)

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

Inhibit

Time

Delay

(sec.)

0--60

Time

Delay

(sec.)

0--60

TP-6200 3/06 Section 1 Specifications and Features 23

Factory-Defined Settings

Status Event or Fault

Cyclic Cranking

Defined Common

Faults

(each input value is set separately)

Refer to

Menu

8

10

Digital

Display

Defined

Common

Fault

Detonation Shutdown

]

Digital Aux. Input

D01--D21

9, 10

Detonation Warning

] 9, 10

Deton

Shutdown

Deton

Warning

9, 10 User-Defined

D01--D21

Relay

Driver

Output

(RDO)

RDO-18

(lead 32A)

Alarm

Horn

Off

Lamp Range Setting

1--6 crank cycles

10--30 sec. crank on

1--60 sec. pause

Default

Selection

3

15 sec.

15 sec.

On Shutdown or

Warning

Default shutdowns include:

Emergency stop

High coolant temp

Low oil pressure

Overcrank

Overspeed

30 sec.

inhibit,

5 sec. delay

On Shutdown Fixed

On

On

Warning

Shutdown or

Warning

Fixed

30 sec.

inhibit,

5 sec. delay

Digital Aux. Input

D05 w

Digital Aux. Input

D06 w

Digital Aux. Input

D11

]

Digital Aux. Input

D12

]

Digital Aux. Input D13

Detonation Sensing

Module (DSM)

]

Digital Aux. Input D13

Knock Detection

Module (KDM)

]

EEPROM Write

Failure

Emergency Stop

Shutdown

Engine Cooldown

(see Time Delay--)

9, 10 D05 Breaker

Closed

9, 10 D06 Enable

Synch

9, 10 D11 AFM

Shutdown

9, 10 D12 Deton

Warning

9, 10 D13 Deton

Shutdown

9, 10 D13 Knock

Shutdown

10

10

EEPROM

Write Failure

Emergency

Stop

RDO-14

(lead 48)

On Shutdown

On Warning

On Shutdown

On Shutdown

On Shutdown

On Shutdown

0 sec.

inhibit,

0 sec. delay

2 sec.

inhibit,

0 sec. delay

0 sec.

inhibit,

0 sec. delay

0 sec.

inhibit,

0 sec. delay

Engine Start

(see Time Delay--)

EPS (Emergency

Power System)

Supplying Load

Field Overvoltage

Digital Aux. Input D04

(M4, M5, or M7 alternator only)

Fuel Valve Relay

]

10

9, 10

10

EPS

Supplying

Load

Field

Overvoltage

Fuel Valve

Relay

RDO-22

RDO-23

]

Off Warning

On Shutdown

Fixed

Fixed

1% of rated line current

1 sec.

inhibit,

15 sec.

delay

Generator Set

Running

Ground Fault

Detected

High Battery Voltage

10

10 Ground Fault

10 High Battery

Voltage

RDO-15

(lead 70R)

RDO-13

Off

On

Off

Warning

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

Warning 14.5--16.5 V (12 V)

29--33 V (24 V) w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

16 V (12 V)

32 V (24 V)

Inhibit

Time

Delay

(sec.)

0--60

0--60

Time

Delay

(sec.)

0--60

0--60

10

24 Section 1 Specifications and Features TP-6200 3/06

Factory-Defined Settings

Status Event or Fault

High Coolant

Temperature

Shutdown

High Coolant

Temperature Warning

High Oil Temperature

Shutdown

High Oil Temperature

Warning

] [[

Idle (speed) Mode

Function Digital Aux.

Input D21

Refer to

Menu

10

10

10

10

Digital

Display

Hi Cool

Temp

Shutdown

Hi Cool

Temp

Warning

Hi Oil Temp

Shutdown

Hi Oil Temp

Warning

9, 10 Idle Mode

Active

Relay

Driver

Output

(RDO)

RDO-03

(lead 36)

RDO-06

(lead 40)

RDO-21

Alarm

Horn

Lamp

On Shutdown

On

On

On

Off

Warning

Shutdown

Warning

Warning

Range Setting

Default

Selection

Inhibit

Time

Delay

(sec.)

30

Time

Delay

(sec.)

5

30

30

30

5

Fixed inhibit time 0 sec.

inhibit,

60 sec.

delay

0--600

Intake Air

Temperature

Shutdown

] [[

Intake Air

Temperature Warning

] [[

Internal Fault

Shutdown

Knock Shutdown

] kW Overload

(see Load Shed)

Load Shed kW Overload

10

10

10

10

Intake Air

Temp Sdwn

Intake Air

Temp Warn

Internal Fault

Knock

Shutdown

On

On

On

On

Shutdown

Warning

Shutdown

Shutdown Fixed

30

30

10 Load Shed

KW Over

RDO-30

]]

Off Warning 80%--120% 100% of kW rating with

5 sec. delay

2--10

Load Shed Over

Temperature

[[

Load Shed

Underfrequency

10

10

Load Shed

Over

Temperature

Load Shed

Under

Frequency

RDO only

RDO-31

[

Off Warning 59 Hz with

(60 Hz)

49 Hz with

(50 Hz)

5

Locked Rotor

Shutdown

Loss of ECM

Communication

(ECM only)

Loss of Field

Shutdown w

Low Battery Voltage

Low Coolant Level

Low Coolant Level,

Digital Aux. Input

D14

(with LCL switch) **

Low Coolant

Temperature

10

10

10

Locked

Rotor

10 Loss of ECM

Comm

SD Loss of

Field

Low Battery

Voltage

10 Low Coolant

Level

9, 10 Low Coolant

Level

RDO-26*

RDO-12

(lead 62)

RDO-19

10 Low Coolant

Temp

RDO-05

(lead 35)

Low Coolant

Temperature, Digital

Aux. Input D03 **

9, 10 Low Coolant

Temp

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

TP-6200 3/06

On Shutdown

On Shutdown

On

Off

On

On

On

On

Shutdown

Warning

Shutdown

Warning

Warning

Warning

10--12.5 V (12 V)

]] FAA only

20--25 V (24 V) w Paralleling applications

[[ DDC/MTU engine with MDEC

12 V (12 V)

24 V (24 V)

0 sec.

inhibit,

0 sec. delay

30

Section 1 Specifications and Features

4

10

5

25

Factory-Defined Settings

Status Event or Fault

Low Coolant

Temperature

Shutdown

[[

Low Fuel Warning,

Digital Aux. Input D02

Refer to

Menu

Digital

Display

10 Low Coolant

Temperature

Shutdown

9, 10 Low Fuel

Relay

Driver

Output

(RDO)

RDO-08

(lead 63)

Alarm

Horn

Lamp

On Shutdown

On Warning

On Warning Low Fuel (Level or

Pressure) Warning,

Digital Aux. Input

D02 **

Low Fuel Pressure

Shutdown, Digital

Aux. Input D09

(125RZG only)

(Low) Oil Pressure

Shutdown

(Low) Oil Pressure

Warning

Master Not In Auto

(Generator Set

Switch)

Master Switch Error

Master Switch to Off

Master Switch Open

MDEC Yellow Alarm

[[

MDEC Red Alarm

[[

NFPA 110 Fault

9, 10

9, 10

Low Fuel

Warning

Low Fuel

Shutdown

10 Oil Pressure

Shutdown

10 Oil Pressure

Warning

10 Not In Auto

RDO-04

(lead 38)

RDO-07

(lead 41)

RDO-09

(lead 80)

10

10

10

10

10

10

Master

Switch Error

Master

Switch to Off

Master

Switch Open

MDEC

Yellow Alarm

MDEC Red

Alarm

NFPA 110

Fault

RDO-10

(lead 32)

No Air Temperature

Signal Warning w

No Coolant

Temperature Signal

No Oil Pressure

Signal

10

10

10

No Air Temp

Signal

No Cool

Temp Signal

No Oil

Pressure

Signal

No Oil Temperature

Signal Warning w

10 No Oil Temp

Signal

Overcrank Shutdown 8, 10 Over Crank RDO-02

(lead 12)

Overcurrent

Over Current Voltage

Regulator Shutdown

Overfrequency

Shutdown w

10 Over Current

10 SD Over

Current VR

7, 10 Over

Frequency

RDO-28

Over Power

Shutdown w

10 SD Over

Power

Overspeed Shutdown 7, 10 Over Speed RDO-01

(lead 39)

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

On Shutdown

On Shutdown

On

On

Warning

Not In

Auto

On Shutdown

On Shutdown

On Shutdown

On Warning

On Shutdown

On Shutdown or

Warning

On Warning

On Shutdown

On Shutdown

On Warning

On Shutdown

On Warning

On Shutdown

Range Setting

Fixed

0--6 Cycles

Default

Selection

Inhibit

Time

Delay

(sec.)

Time

Delay

(sec.)

0 sec.

inhibit,

0 sec. delay

3 Cycles

110%

On

On

Shutdown

Shutdown

102%--140%

On Shutdown 65--70 Hz (60 Hz)

55--70 Hz (50 Hz) w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

140% Std.

103% FAA

102% Stdby

112% Prime

70 (60 Hz)

70 (50 Hz)

30

30

30

30

30

5

4

4

4

10

10

0.25

26 Section 1 Specifications and Features TP-6200 3/06

Factory-Defined Settings

Status Event or Fault

Overvoltage

Shutdown

Refer to

Menu

7, 8,

10

Digital

Display

Relay

Driver

Output

(RDO)

Over Voltage RDO-20

(lead 26)

Alarm

Horn

Lamp

On Shutdown

Range Setting

105%--135% of nominal

Default

Selection

115%

2-sec time delay

[

135%

10-sec time delay w

Inhibit

Time

Delay

(sec.)

Time

Delay

(sec.)

2--10

Password

(see Access Code)

Pre Lube Relay

]

Reverse Power

Shutdown w

Speed Sensor Fault

10

10

10

Pre Lube

Relay

SD Reverse

Power

Speed

Sensor Fault

RDO-26

RDO-24

On

On

Shutdown

Warning

Starting Aid (see Time

Delay Starting Aid)

Synchronized

System Ready

Time Delay Engine

Cooldown (TDEC)

Time Delay Engine

Start (TDES)

Time Delay Starting

Aid

Underfrequency

10

10

In Synch

8, 10 Delay Eng

Cooldown

8, 10 Delay Eng

Start

8, 10

RDO-29 w

RDO-17

(lead 60)

RDO-16

(lead 70C)

7, 10 Under

Frequency

Off

Off

Off

System

Ready

Off

RDO-29

]

On Shutdown

Undervoltage

Shutdown

7, 8,

10

Under

Voltage

RDO-27 On Shutdown

Weak Battery 10 Weak

Battery

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

Off

00:00--10:00 min:sec

00:00--5:00 min:sec

0--10 sec.

80%--97%

5:00

00:01

70%--95%

Warning w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

97% FAA

90%

[

80% w

85%

10-sec time delay

[

70%

30-sec time delay w

60% of nominal

4

10

5--30

2

Calibration

Voltage Adjustment

Underfrequency Unload

Frequency Setpoint

Underfrequency Unload

Slope

Reactive Droop

VAR Control

Power FActor (PF) Adjust

Control

Regulator Gain or Stability

VAR/PF Gain or Utility

Stability

Refer to

Menu

11

11

11

11

11

11

11

11

Digital Display

Volt Adj

Frequency

Setpoint

Slope

Voltage Droop kVAR Adj

PF Adj

Regulator Gain

VAR/PF Gain

Range Setting

±10% of system voltage—

Version 2.10

±20% of system voltage—

Version 2.11 or higher

40 to 70 Hz

Default Selection

System voltage

0--10% of rated voltage volts per cycle

0--10% of system voltage

0 to rated kVAR generating

0 to 35% of rated kVAR absorbing

0.7 to 1.0 leading

0.6 to 1.0 lagging

1--10000

1--10000

1 Hz below system frequency (ECM)

2 Hz below system frequency (non-ECM)

3.1% of system voltage

4% of system voltage

0

0.8 lagging

100

100

Figure 1-11 Calibration Specifications for 550 Controller Internal Voltage Regulation

TP-6200 3/06 Section 1 Specifications and Features 27

1.3.2

Voltage Regulator and Calibration

Specifications

The 550 controller has a voltage regulation function that is internal to the processor. This means that no external voltage regulator is necessary. The voltage regulation of the controller uses root mean square (rms) sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy

(

±0.25% rms compared to 5% of AVR).

RMS voltage regulation is available for both paralleling and utility application to control changes in the reactive loads due to load changes, prime mover speed variation, thermal drift, and other variations.

See

Figure 1-11 for data on the 550 controller voltage regulation.

Refer to Appendix C to customize adjustments for specific applications.

1.3.3

Voltage Regulator Adjustments

The descriptions of the voltage regulator adjustments and features follow. See Appendix C, Voltage Regulator

Definitions and Adjustments, for additional information.

Voltage Adjustment. The voltage adjustment allows the user to enter the desired generator set output level.

This regulated level setting is the average of the three line-to-line voltages in three-phase configurations or

L1-to-L2 in single phase configurations.

Submenus display the individual line-to-line voltages.

These voltages are for reference only and are relevant in unbalanced load conditions.

The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system.

Underfrequency Unload Frequency Setpoint. This adjustment affects the voltage droop (volts per Hz) when load is applied and underfrequency occurs.

The underfrequency unload setting defines the setpoint where underfrequency starts. Any frequency below the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the underfrequency unload slope setting.

Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions.

The underfrequency unload setting should match the engine speed recovery characteristics for the application.

Underfrequency Unload Slope.

This setting determines how much the voltage drops during an underfrequency condition. Typically, applying a large electrical load causes a dip in engine speed and frequency.

The voltage regulator reduces voltage, allowing engine speed recovery.

The volts-per-Hz setting determines the amount of voltage drop.

Reactive Droop.

Reactive droop compensation provides reactive current flow adjustment in the generator set during generator set-to-generator set paralleling applications.

Reactive droop reduces excitation levels with increasing reactive current.

A reduced excitation level reduces generator set reactive current or generated VARs, improving reactive load sharing.

Enter the gain setting as a percentage of system voltage when full-rated load with 0.8 power factor is applied.

Any loads less than full load force the voltage to drop by the ratio of reactive volt-amps (VARs) to rated VARs.

VAR Control.

VAR control is used in some utility paralleling applications. The excitation is regulated to maintain the reactive load rather than output voltage.

The VAR adjust setting determines what reactive load is maintained at the generator set output. The VAR adjust is the total reactive load (sum of three phases).

VAR control allows the user to define the direction of the reactive current out of the generator set (generating) or into the generator set (absorbing).

The utility supply, not the controller, determines terminal voltage.

Engine fueling determines real power, measured in watts, using load sharing module control.

Power Factor (PF) Adjust Control.

Power factor control is used in some utility paralleling applications.

The excitation is regulated to maintain PF rather than output voltage. The PF adjustment setting determines what PF is maintained at the generator set output. PF adjustment is the average of three phases.

Power factor is defined as the ratio of real power (watts) over the volt-amps. Power factor can be calculated as the cosine of the electrical angle between current and voltage.

The cosine function is positive for angles between --90 degrees and +90 degrees including zero; and is negative for angles between --90 and +90 including 180 degrees. This adjustment requires the user to determine whether the current leads or lags the voltage.

28 Section 1 Specifications and Features TP-6200 3/06

Regulator Gain. Regulator gain refers to the gain of the control system. Generally, the higher the gain the faster the system responds to changes. The lower the gain, the more stable the system.

If the voltage is slow the recover when loads are applied or removed, increase the regulator gain. If the voltage is unstable, decrease the regulator gain. Regulator gain is active only while not in the VAR/PF mode.

VAR/PF Gain. The VAR/PF gain also refers to the gain of the control system. Unlike the regulator gain, the response and stability of the system refers to the reactive current, or more specifically the VARs and/or power factor.

If the system is slow to recover to the desired VAR or PF setting, increase the VAR/PF gain. If the VARs or PF of the system is unstable, decrease the VAR/PF gain.

Because VAR/PF stability can be effected by the prime mover (engine), VAR/PF gain adjustments should be coordinated with the load sharing adjustment.

TP-6200 3/06 Section 1 Specifications and Features 29

Notes

30 Section 1 Specifications and Features TP-6200 3/06

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and maintenance.

Controller.

After reconnecting the battery, set the controller time and date. See Section 2, Menu 14—

Programming Mode On and Menu 6—Time and Date.

Coolant Level. Check the coolant level according to the cooling system maintenance information.

Note: Block Heater Damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater.

Drive Belts. Check the belt condition and tension of the radiator fan, water pump, and battery charging alternator belt(s).

Exhaust System.

Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

Inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks, leaks, and corrosion.

D

Check for corroded or broken metal parts and replace them as needed.

D

Check for loose, corroded, or missing clamps and hangers.

Tighten or replace the exhaust clamps and/or hangers as needed.

D

Check that the exhaust outlet is unobstructed.

D

Visually inspect for exhaust leaks (blowby). Check for carbon or soot residue on exhaust components.

Carbon and soot residue indicates an exhaust leak.

Seal leaks as needed.

TP-6200 3/06

Section 2 Operation

Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.

Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.

Operating Area.

Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.

2.2 Exercising Generator Set

Operate the generator set under load once each week for one hour. Perform the exercise in the presence of an operator when the generator set does not have a programmed exercise mode or an automatic transfer switch with an exercise option.

During the exercise period apply a minimum of 35% load based on the nameplate standby rating, unless otherwise instructed in the engine operation manual.

The operator should perform all of the prestart checks before starting the manual exercise procedure. Start the generator set according to the starting procedure in

Section 2.3, Controller Operation. While the generator set is operating, listen for a smooth-running engine and visually inspect generator set for fluid or exhaust leaks.

The generator set exercise time can be programmed for a one-time exercise period. See Menu 4—Operational

Records. The generator set controller does not provide weekly scheduled exercise periods.

For scheduled exercise periods, refer to the automatic transfer switch

(if equipped) literature.

2.3 Controller Operation

2.3.1

Starting

Local Starting

Move the generator set master switch to the RUN position to start the generator set at the controller.

Note: The alarm horn sounds and the Not-In-Auto lamp lights whenever the generator set master switch is not in the AUTO position.

Note: The transient start/stop function of the controller prevents accidental cranking of the rotating engine.

The generator set stops and recranks when the generator set master switch is momentarily placed in OFF/RESET position and then returned to RUN.

Section 2 Operation 31

Auto Starting

Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or remote start/stop switch (connected to controller terminals 3 and 4).

Terminals 3 and 4 connect to a circuit that automatically starts the generator set crank cycle when an external source closes the circuit.

Note: The controller provides up to 60 seconds of programmable cyclic cranking and up to

60 seconds rest with up to 6 cycles. The default setting is 15 seconds cranking and 15 seconds rest for 3 cycles.

Make cyclic cranking adjustments using the keypad. See Section 2.9.14,

Menu 14—Programming Mode, and Section 2.9.8,

Menu 8—Time Delays.

Idle (Speed) Mode Warmup and Cooldown

Function

The idle (speed) mode function provides the ability to start and run the engine at reduced speed for a selectable time period (0--10 minutes) during warmup.

See Section 6.1.5, Idle (Speed) Mode Feature, for installation information.

The controller will override the idle speed mode when the engine reaches the preprogrammed engine warm-up temperature before the idle mode times out.

The idle function also provides engine cooldown at idle speed. The controller overrides the idle speed mode when the engine reaches the preprogrammed engine cooldown temperature before the idle mode times out.

During the idle (speed) mode the controller continues to monitor critical engine parameters such as oil pressure, coolant temperature, and engine speed. The voltage regulator, thermal protection feature, and AC metering are disabled in the idle speed mode.

The controller overrides the idle speed function when the generator set is signaled to start while in the AUTO position. This override provides emergency generator set power in the event of a utility power failure. When the utility power returns and the generator set is signalled to stop, the generator set continues to run for the duration of the idle mode period when the idle mode is active.

When the idle mode is not active, the generator set will shut down in the normal stopping mode including time delays.

See Menu 9—Input Setup to activate the idle speed function as a user-defined digital input. The idle speed feature requires an ECM-equipped engine with the idle speed function.

32 Section 2 Operation

Run Time Feature

The run time feature allows the user to set up the generator set to run unassisted and automatically return to the standby mode. The user does not need to wait for the exercise period (run time) to conclude in order to place the unit back in the standby mode.

See

Menu 4—Operational Records for setup of this feature.

With the run time enabled, the generator set will begin to crank and run based on the run time period and all previously established time delays from Menu 8—Time

Delays.

Generator Set Connected to an Automatic Transfer

Switch. Should a utility power failure occur while the unit is in the run time mode, the controller will bypass the run time mode and function in the standby (backup) mode. When the utility power returns, the generator set continues to run for the duration of the run time period when not timed out.

Note: Press the STOP PROG RUN key, when necessary, to stop the generator set when it is in the run time mode.

Prime Power Switch

The digital controller has an optional prime power mode of operation.

The prime power mode requires installation of an optional prime power switch kit. See

Section 6, Accessories, for instructions on how to install the optional prime power switch kit. The prime power switch kit prevents engine starting battery drain when the generator set is shut down and no external battery charging is available.

Move the prime power switch located on the back of the controller to the CONTROLLER ON position and set the controller time and date before attempting to start the generator set. When the prime power mode is off, all controller functions including the digital display, LEDs, and alarm horn are operative.

Note: After energizing the controller using the prime power switch, set the controller time and date.

See Section 2.9.6, Menu 6—TIme and Date.

Stop the generator set using the stopping procedures in

Section 2.3.2 before placing the generator set in the prime power mode.

Move the prime power switch located on the back of the controller to the

CONTROLLER OFF position. When the generator set is is the prime power mode, all controller functions including the digital display, LEDs, alarm horn, and communications are inoperative.

TP-6200 3/06

2.3.2

Stopping (User Stopping and

Fault Shutdown)

Normal Stopping

Run the generator set without load for 5 minutes to ensure adequate engine cooldown.

The controller has a programmable cooldown timer that functions only when the master switch is in the AUTO position. To stop the generator set, place the generator set master switch in the OFF/RESET position and wait until the generator set comes to a complete stop.

Note: The cooldown cycle times out before the generator set stops when a remote switch or automatic transfer switch initiates the generator set start/stop sequence.

Emergency Stopping

Use the controller emergency stop switch or optional remote emergency stop for immediate shutdown.

The emergency stop switch bypasses the time delay engine cooldown and immediately shuts down the generator set.

Note: Use the emergency stop switch(es) for emergency shutdowns only. Use the generator set master switch for normal shutdowns.

The controller system shutdown lamp lights and the unit shuts down when the local or remote emergency stop switch activates.

Battle Switch/Fault Shutdown Override

Switch

The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown.

When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/alternator damage can occur.

When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5— Event History.

See Section 2.9.9, Menu 9—Input Setup, for information on how to enable the battle switch feature.

Cooldown Temperature Override Function.

This feature provides the ability to bypass (override) the generator set’s smart cooldown temperature shutdown and force the generator set to run for the full engine cooldown time delay.

TP-6200 3/06

See Section 2.9.8, Menu 8—Time Delays, for information on how to enable the cooldown temperature override feature.

2.3.3

Emergency Stop Switch Resetting

Use the following procedure to reset the generator set after shutdown by a local or remote emergency stop switch.

Refer to Section 2.3.7, Controller Reset

Procedure, to restart the generator set following a fault shutdown.

1. Place the generator set master switch in the

OFF/RESET position.

2. Investigate and correct the cause of the emergency stop.

3. Reset the optional remote emergency stop switch by replacing the glass piece, when equipped. Additional glass rods are available as a service part. Reset the controller emergency stop switch by pulling the switch knob outward.

4. After resetting all faults using the controller reset procedure in Section 2.3.7, toggle the generator set master switch to RUN or AUTO to restart the generator set. The generator set will not crank until the reset procedure completes.

2.3.4

Status Lamp

System Ready. The green lamp illuminates when the generator set master switch is in the AUTO position and the system has no fault conditions.

2.3.5

System Warning Lamp

The yellow warning lamp illuminates indicating a fault or status event but does not shut down the generator set under the following conditions. In some cases the alarm horn also sounds. See Section 2.3.7, Controller Reset

Procedure, for instructions on resetting a system warning.

When the system warning lamp is on and no message displays, press the Reset Menu and the menu down

↓ key to view messages.

When the system warning continues, it may lead to a fault and cause a system shutdown.

Use the Alarm Off keypad switch to silence the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the master switch is in the AUTO position.

Note: Text shown in italics in this manual represents digital display messages.

Section 2 Operation 33

AC Sensing Loss.

The lamp illuminates when the controller does not detect nominal generator set AC output voltage after crank disconnect. The local display shows AC sensing loss.

Battery Charger Fault. The lamp illuminates when the battery charger malfunctions. This fault feature requires an optional battery charger with a malfunction output for the lamp to function. Local display shows bat chgr fault.

Common Paralleling Relay Output.

The lamp illuminates and the alarm horn sounds when a common paralleling relay fault occurs. The local display shows common pr output. (Paralleling applications only.)

Customer Auxiliary (Warning). The lamp illuminates and the alarm horn sounds when an auxiliary digital or analog inputs signals the controller. The user can define inputs as shutdowns or warnings. The local display shows digital input D01-D21 or analog input A01-A07.

Using the remote communications package, the user can label the auxiliary functions. The controller displays the selected name instead of digital input D01-D21 or analog input A01-A07.

Detonation Warning.

The lamp illuminates and the alarm horn sounds when the engine detects combustion system detonation.

The local display shows deton warning. (Waukesha-powered models only.)

Emergency Power System (EPS) Supplying Load.

The lamp illuminates when the generator set supplies more than 1% of the rated standby output current. The local display shows EPS supplying load.

Generator Switch Not in Auto. The lamp illuminates and the alarm horn sounds when the generator set master switch is in the RUN or OFF/RESET position.

The local display shows master not in auto.

Ground Fault Detected. The lamp illuminates and the alarm horn sounds when a user-supplied ground fault detector signals the controller. The local display shows ground fault.

High Battery Voltage. The lamp illuminates when the battery voltage rises above the preset level for more than 10 seconds. The local display shows high battery voltage.

Figure 2-1 shows high battery voltage specifications.

The high battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes.

Engine Electrical

System Voltage

12

24

High Battery

Voltage Range

14.5--16.5

29--33

High Battery Voltage

Default Setting

16

32

Figure 2-1 High Battery Voltage Specs

34 Section 2 Operation

High Coolant Temperature Warning.

The lamp illuminates and the alarm horn sounds when the engine coolant temperature approaches the shutdown range.

The local display shows hi cool temp warning.

High Oil Temperature Warning. The lamp illuminates and the alarm horn sounds when the engine high oil temperatuare approaches the shutdown range. The local display shows hi oil temp warning (DDC/MTU models with

MDEC and Waukesha-powered models only).

Intake Air Temperature Warning. The lamp illuminates and the alarm horn sounds when the engine intake air temperature approaches the shutdown range. The local display shows intake air temp warn (DDC/MTU models with MDEC and Waukesha-powered models only).

Load Shed. The lamp illuminates when the generator set’s total kW load exceeds the programmed level for more than the load shed time. When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp circuit latches and remains on until the generator set shuts down. The local display shows load shed kW over.

When the generator set frequency drops to less than

59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system for more than 5 seconds, the local display shows load shed under freq. When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp latches and remains on until the generator set shuts down.

Low Battery Voltage. The lamp illuminates when the battery voltage drops below a preset level for more than

10 seconds.

The local display shows low battery voltage.

See Figure 2-2 for low battery voltage specifications.

Engine Electrical

System Voltage

12

24

Low Battery

Voltage Range

10--12.5

20--25

Low Battery Voltage

Default Setting

12

24

Figure 2-2 Low Battery Voltage Specs

The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes.

The controller logic inhibits the low battery voltage warning during the crank cycle.

Low Coolant Level.

The lamp illuminates and the alarm horn sounds when the engine coolant level is low.

The local display shows Low Coolant Level. See NFPA

110 Fault following.

Low Coolant Temperature. The lamp illuminates and the alarm horn sounds when the engine coolant temperature is low. The local display shows low coolant temp.

TP-6200 3/06

Low Fuel (Level or Pressure) Warning. The lamp illuminates and the alarm horn sounds when the fuel tank level on gasoline or diesel models approaches empty or low fuel pressure on gaseous fueled models occurs. This fault requires an optional low fuel switch for the lamp to function. The local display shows low fuel warning.

(Low) Oil Pressure Warning. The lamp illuminates and the alarm horn sounds when the engine oil pressure approaches the shutdown range.

The local display shows oil press warning.

Master Switch in OFF/RESET Position. The lamp illuminates and the alarm horn sounds when the master switch is placed in the OFF/RESET position. The local display shows master not in auto.

MDEC Yellow Alarm. The lamp illuminates and the alarm horn sounds when MDEC yellow alarm signals the controller. The local display shows MDEC yellow alarm. This fault only relates to the DDC/MTU engine with MDEC. The user can navigate the menus to access the fault code. The Engine Operation Manual provides the fault code descriptions.

NFPA 110 Fault. The lamp illuminates and the alarm horn sounds when NFPA 110 faults signal the controller.

The local display shows the respective fault message.

The NFPA 110 faults include:

D

D

D

D

D

D

D

D

D

D

D

D

D

D

D

Air damper indicator (Factory Reserved D20)

Battery charger fault (Factory Reserved D01)

EPS supplying load

High battery voltage

High coolant temperature warning

High coolant temperature shutdown

Low battery voltage

Low coolant level (Factory Reserved D14)

Low coolant temperature warning

(Factory Reserved D03)

Low fuel (level or pressure) (Factory Reserved D02)

Low oil pressure warning

Low oil pressure shutdown

Master switch not in auto

Overcrank

Overspeed

Overcurrent. The lamp illuminates and the alarm horn sounds when the generator set supplies more than

110% of the rated standby output current for more than

10 seconds. The local display shows overcurrent.

Speed Sensor Fault. The lamp illuminates and the alarm horn sounds when the speed signal is absent for one second while the generator set runs. The local display shows speed sensor fault. This warning lamp remains on until the operator places the master switch in the OFF/RESET position.

Underfrequency. The lamp illuminates and the alarm horn sounds when the frequency falls below the underfrequency setting.

The local display shows underfrequency. See Figure 2-3.

Underfrequency

Setting Range

80%--95% of nominal

Time Delay

Range

10 sec.

Figure 2-3 Underfrequency Specs

Underfrequency

Default Setting

90% of nominal

Weak Battery. The lamp illuminates when the battery voltage falls below 60% of the nominal voltage (12 VDC or 24 VDC) for more than 2 seconds during the crank cycle. The local display shows weak battery.

2.3.6

System Shutdown Lamp

The red lamp illuminates, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the following conditions. See Section 2.3.7, Controller

Reset Procedure, for information on resetting a system shutdown.

Use the Alarm Off keypad switch to silence the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn will not stop sounding unless the master switch is in the AUTO position.

Note: The text shown in italics represents digital display messages.

Air Damper Indicator. The lamp illuminates and the unit shuts down when signaled by a closed air damper circuit. The local display shows air damper indicator.

Air/Fuel Module. The lamp illuminates and the unit shuts down when the controller detects a fault with the air/fuel module. The local display shows afm shutdown.

(Waukesha-powered models only.)

Alternator Protection. The lamp illuminates and the unit shuts down because of an alternator overload or short circuit. The local display shows altrntr protect sdwn. See Appendix D, Alternator Protection for more information.

TP-6200 3/06 Section 2 Operation 35

Critical Overvoltage. The lamp illuminates and the unit shuts down when the voltage exceeds 275 volts. The local display shows critical overvoltage.

For voltages configurations of 240 volts and less, the critical voltage shutdown monitors nominal voltage line-to-line. For voltage configurations greater than

240 volts and less than 600 volts, the critical voltage shutdown monitors nominal voltage line-to-line with a center tap connection. For voltage configurations of

600 volts and above, the critical voltage shutdown monitors nominal voltage with a stepdown transformer in the 208--240 voltage range.

Customer Auxiliary (Shutdown).

The lamp illuminates and the unit shuts down when an auxiliary digital or analog input signals the controller. The user can define inputs as shutdowns or warnings. The local display shows digital input D01-D21 or analog input

A01-A07 when activated.

Using the remote communications package, the user can label the auxiliary functions. The controller displays the selected name instead of digital input D01-D21 or analog input A01-A07.

Detonation Shutdown. The lamp illuminates and the unit shuts down when the controller detects combustion system detonation.

The local display shows deton shutdown. (Waukesha-powered models only.)

EEPROM Write Failure. The lamp illuminates and the unit shuts down when the control logic detects a data save error. The local display shows EEPROM write failure.

Emergency Stop. The lamp illuminates and the unit shuts down when the local or optional remote emergency stop switch activates.

The local display shows emergency stop.

Field Overvoltage. The lamp illuminates and the unit shuts down when the controller detects field overvoltage. The local display shows field over volts.

(350--2000 kW generator sets only)

High Coolant Temperature Shutdown.

The lamp illuminates and the unit shuts down because of high engine coolant temperature.

The shutdown occurs

5 seconds after the engine reaches the temperature shutdown range.

The high engine temperature shutdown does not function during the first 30 seconds after startup.

The local display shows hi cool temp shutdwn.

Note: The high engine temperature shutdown function and the low coolant level shutdown function are independent. A low coolant level condition may not activate the high engine temperature switch.

High Oil Temperature. The lamp illuminates and the unit shuts down because of high engine oil temperature.

The shutdown occurs 5 seconds after the engine oil reaches the temperature shutdown range. The high engine oil temperature shutdown does not function during the first 30 seconds after startup.

The local display shows high oil temp sdwn.

Intake Air Temperature. The lamp illuminates and the unit shuts down because of high intake air temperature.

The shutdown occurs 5 seconds after the engine intake air reaches the temperature shutdown range.

The engine intake air temperature shutdown does not function during the first 30 seconds after startup. The local display shows intake air temperature. (DDC/MTU models with MDEC and Waukesha-powered models only.)

Internal Fault. The lamp illuminates and the unit shuts down when the internal diagnostics detect a controller malfunction. The local display shows internal fault.

Knock Shutdown. The lamp illuminates and the unit shuts down when the controller detects a detonation fault.

The local display shows knock shutdown.

(Waukesha-powered models only.)

Locked Rotor. If none of the speed sensing inputs show engine rotation within 5 seconds of initiating engine cranking, the ignition and crank circuits turn off for 5 seconds and the cycle repeats. The unit shuts down after the second cycle of 5 seconds of cranking.

The local display shows locked rotor.

Loss of ECM Communications. The lamp illuminates and the unit shuts down when the ECM communication link is disrupted. The local display shows loss of ECM comm.

Loss of Field (Reverse VARs). The lamp illuminates and the unit shuts down when the reactive current into the alternator (absorbing) exceeds the shutdown level.

This could be caused by a disruption of the field signal.

The local display shows sd loss of field. (Paralleling applications only.)

Low Coolant Level. The lamp illuminates and the unit shuts down because of low low coolant level. Shutdown occurs 5 seconds after low coolant level is detected.

Low coolant level shutdown is inhibited during the first

30 seconds after startup.

Local display shows low coolant level.

Low Fuel (Pressure) Shutdown. The lamp illuminates and the unit shuts down when the controller detects a low fuel condition. The local display shows low fuel shdown. (125RZG only.)

36 Section 2 Operation TP-6200 3/06

(Low) Oil Pressure Shutdown. The lamp illuminates when the unit shuts down because of low oil pressure.

The shutdown occurs 5 seconds after the low pressure condition is detected. The low oil pressure shutdown does not function during first the 30 seconds after startup. The local display shows (low) oil press shutdown.

Master Switch Error. The lamp illuminates and the unit shuts down when the controller detects a fault in the master switch position or circuit.

The local display shows master switch error.

Master Switch Open. The lamp illuminates and the unit shuts down when the controller detects an open circuit in the master switch circuit.

The local display shows master switch open.

MDEC Red Alarm. The lamp illuminates and the unit shuts down when the controller receives a signal from the engine. The local display shows MDEC red alarm.

This fault only relates to the DDC/MTU engine with

MDEC. The user can navigate the menus to access the fault code. The Engine Operation Manual provides the fault code descriptions.

NFPA 110 Fault. The lamp illuminates and the unit shuts down when NFPA 110 faults signal the controller.

The local display shows the respective fault message.

See Section 2.4, Menu List Summary, Menu 10—Output

Setup, for the NFPA 110 list.

No Air Temperature Signal. The lamp illuminates and the unit shuts down when the air temperature sender circuit is open. The local display shows no air temp signal. (Waukesha-powered models only.)

No Coolant Temperature Signal.

The lamp illuminates and the unit shuts down when the engine coolant temperature sender circuit is open. The local display shows no cool temp signal.

No Oil Pressure Signal. The lamp illuminates and the unit shuts down when the engine oil pressure sender circuit is open. The local display shows no oil press signal.

No Oil Temperature Signal. The lamp illuminates and the unit shuts down when the oil temperature sender circuit is open. The local display shows no oil temp signal. (Waukesha-powered models only.)

Overcrank. The lamp illuminates and cranking stops when the unit does not start within the defined cranking period.

The local display shows overcrank.

See

Section 2.3.1, Auto Starting, and Section 1,

Specifications and Features, for cyclic crank specifications.

Note: The controller is equipped with an automatic restart function. When speed drops below 13 Hz

(390 rpm) while the engine is running, the unit attempts to recrank. The unit then follows the cyclic cranking cycle and, when the engine fails to start, will shut down on an overcrank fault condition.

Overcurrent Shutdown Paralleling Relay. The lamp illuminates and the unit shuts down when the controller detects an overcurrent fault with the paralleling relays.

The local display shows sd over current vr. (Paralleling applications only.)

Overfrequency.

The lamp illuminates and the unit shuts down when the frequency is above the overfrequency setting.

The local display shows overfrequency. See Figure 2-4.

Overfrequency

Setting Range

102%--140% of nominal

Time Delay

10 sec.

Figure 2-4 Overfrequency Specs

Overfrequency

Default Setting

140% of nominal

Overpower. The lamp illuminates and the unit shuts down when the controller detects a fault in the paralleling system. The shutdown is set at 102% for standby and 112% for prime power applications. The local display shows applications only.) over power.

(Paralleling

Overspeed. The lamp illuminates and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models exceeds the overspeed setting for

0.25 seconds. The local display shows overspeed. See

Figure 2-5 for overspeed specs.

Generator Set

Frequency Hz Time Delay

60 0.25 sec.

Overspeed

Range Hz

65--70

50 0.25 sec.

55--70

Overspeed Default

Setting Hz

70

70

Figure 2-5 Overspeed Specs

TP-6200 3/06 Section 2 Operation 37

Overvoltage. The lamp illuminates and the unit shuts down when the voltage exceeds the overvoltage setting for the time delay period.

The local display shows overvoltage. Overvoltage specifications follow. See

Figure 2-6.

Note: Overvoltage can damage sensitive equipment in less than one second.

Install separate overvoltage protection on online equipment requiring faster than 2-second shutdown.

Overvoltage

Setting

Range

105%--135% of nominal

Time

Delay

Range

2--10 sec.

Overvoltage

Default Setting without Paralleling

115% at 2 sec.

Overvoltage

Default Setting with Paralleling

135% at 10 sec.

Figure 2-6 Overvoltage Specs

Reverse Power.

The lamp illuminates and the unit shuts down when the controller detects a reverse power condition. The reverse power relay senses AC power flow into the generator set. If the generator set is being feed power or being ”motored” by another generator set or the utility, the reverse power relay senses this AC power flow and opens the generator set circuit breaker.

The local display shows sd reverse power. (Paralleling applications only.)

Underfrequency.

The lamp illuminates and the unit shuts down when the frequency falls below the underfrequency setting.

The local display shows underfrequency. See Figure 2-7.

Underfreq.

Setting

Ranger

80%--95% of nominal

Time

Delay

Underfrequency

Default Setting without Paralleling

Underfrequency

Default Setting with Paralleling

10 sec.

90% of nominal 80% of nominal

Figure 2-7 Underfrequency Specs

Undervoltage. The lamp illuminates and the unit shuts down when the voltage falls below the undervoltage setting for the time delay period.

The local display shows undervoltage.

Undervoltage specifications follow. See Figure 2-8.

Undervoltage

Setting

Range

70%--95% of nominal

Time Delay

Range

Undervoltage

Default Setting w-o/Paralleling

Undervoltage

Default Setting w/Paralleling

5--30 sec.

85% of nominal at 10 sec.

70% of nominal at 30 sec.

Figure 2-8 Undervoltage Specs

2.3.7

Controller Resetting (Following

System Shutdown or Warning)

Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition. This procedure includes the resetting of the optional remote annunciator and the audiovisual alarm.

Refer to Section 2.3.3, Emergency Stop Switch Reset

Procedure, to reset the generator set after an emergency stop.

1. Move the generator set master switch to the AUTO position, if not already done.

2. Silence the controller alarm horn by pressing the alarm off key.

When equipped, the optional remote annunciator and/or audiovisual alarm horn and lamp activate.

Move the alarm switch to the SILENCE position to stop the alarm horn. The lamp stays lit.

3. Disconnect the generator set load using the line circuit breaker or automatic transfer switch.

4. Correct the cause of the fault shutdown or warning.

See the Safety Precautions and Instructions section of this manual before proceeding.

5. Start the generator set by moving the generator set master switch to the OFF/RESET position and then to the RUN position.

When equipped, the remote annunciator and/or audiovisual alarm horn sounds when the alarm switch is in the NORMAL position.

When necessary, move the alarm switch to the SILENCE position to stop the alarm horn. The lamp turns off.

6. Test operate the generator set to verify correction of the shutdown cause.

7. Move the generator set master switch to the

OFF/RESET position to stop the generator set.

8. Move the generator set master switch to the AUTO position.

9. Silence the controller alarm horn by pressing the alarm off key.

10. Reconnect the generator set load via the line circuit breaker or automatic transfer switch.

38 Section 2 Operation TP-6200 3/06

11. Move the generator set master switch to the AUTO position for startup by the remote transfer switch or the remote start/stop switch.

When equipped, move the remote annunciator and/or audiovisual alarm switch to the NORMAL position.

2.4 Menu List Summary

Use the Menu List Summary section on the following pages after reading and understanding the features of the keypad.

See Section 1.2.2, Digital Display and

Keypad.

The Menu List Summary provides a quick reference to the digital display data. Some digital display data may not be identical to your display due to generator set application differences.

The closed bullet items represent main level data and the open bullet items are sub-level data.

Section 2.8, Reviewing the Menu Displays, provides a digital display menu overview and explains the navigation using the down and right arrow keys.

Section 2.9, Local Programming Mode On, contains the keystroke details of each menu when programming.

User Inputs. Available user inputs are dependent on factory reserved inputs for specific engine types, engine controls, and paralleling applications. See Figure 2-9 for analog and digital inputs which are not user selectable.

TP-6200 3/06 Section 2 Operation 39

Specific Applications

Input

Type

ECM Engine

Analog Inputs

Non-ECM

Engine NFPA 110

Waukesha-

Powered Engine

550 with Menu

15 (Paralleling

Application)

A1

A2

A3

A4

A5

A6

A7

Digital Inputs

X

X

X

D1

D2

D3

D4

D5

D6

D7

D8

D9

D10

D11

D12

D13

X

X

X

X

X

X

Low Coolant

Temp.*

X

X

X

X

X

X

X

X

X

X

Coolant

Temp.*

Oil Pressure*

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Battery Charger Fault*

Low Fuel Warning*

Low Coolant Temp.*

X

X

X

X

X

X

X

X

X

X

Coolant

Temperature*

Oil Pressure*

Intake Air Temp.

Warning*

Oil Temperature

Warning*

X

X

X

X

X

X

X

X

X

X

X

X

X

AFM Shutdown*

Deton Warning*

Deton/Knock

Shutdown*

D14

D15

D16

D17

D18

D19

D20

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Low Coolant Level

(with LCL

Switch)*

X

X

X

X

X

Air Damper*

X

X

X

X

X

X

X

D21

Idle Mode

Active

X X X

(1) D4 is preassigned as Field Overvolts when using a Marathon alternator.

(2) D9 is preassigned as Low Fuel Shutdown when using 125 kW GM-powered engine.

(3) D15 is preassigned as Remote Shutdown.

(4) D16 is preassigned as Remote Reset.

(5) D17 is preassigned as VAR/PF mode.

(6) D18 is preassigned as Voltage Lower.

(7) D19 is preassigned as Voltage Raise.

* Factory reserved inputs that are fixed and not user changeable.

X

X

X

X

X

X

Voltage Adjust

X

X

X

X

Breaker Closed*

Enable Synch*

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

Figure 2-9 User Inputs (X) and Factory Reserved Inputs (as shown)

DDC/MTU

Engine with

MDEC

Other

Specialized

Application

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X (1) *

X

X

X

X

X (2) *

X

X

X

X

X

X (3) *

X (4) *

X (5) *

X (6) *

X (7) *

X

X

40 Section 2 Operation TP-6200 3/06

Menu 1

Generator Monitoring

Volts & Amps

D L1-L2 Volts

L1 Amps

D L2-L3 Volts

L2 Amps (3 phase)

D L3-L1 Volts

L3 Amps (3 phase)

D L1-L2 Volts

L2 Amps (1 phase)

D L1-L0 Volts

L1 Amps

D L2-L0 Volts

L2 Amps

D L3-L0 Volts

L3 Amps (3 phase)

D Frequency

V & A Summary

D V L1-L2, L2-L3, L3-L1

(3 phase)

D V L1-L0, L2-L0, L3-L0

(3 phase)

D A L1, L2, L3 (3 phase)

D V L1-L2, L1-L0, L2-L0

(1 phase)

D A L1, L2 (1 phase)

Power kW

D Total kW

Power Factor

D L1 kW

Power Factor

D L2 kW

Power Factor

D L3 kW

Power Factor (3 phase)

D Total kW

% of Rated kW

Power kVAR

D Total kVAR

Absorbing/Generating

D L1 kVAR

Absorbing/Generating

D L2 kVAR

Absorbing/Generating

D L3 kVAR

Absorbing/Generating

(3 phase)

Power kVA

D Total kVA

D L1 kVA

D L2 kVA

D L3 kVA (3 phase)

Menu List Summary

(Legend:

D First level submenu, d second level submenu)

Menu 2

Engine Monitoring

Engine Monitoring Basic

D Oil Pressure

Coolant Temperature

D Intake Air Temperature

Oil Temperature

(DDC/MTU engine with

MDEC and Waukesha engine only)

D Engine RPM

Local Battery VDC

D High Coolant

Temperature Shutdown and Warning Setpoints

D Low Oil Pressure

Shutdown and Warning

Setpoints

D Engine Warmup

Temperature Setpoint

D Engine Cooldown

Temperature Setpoint

Engine Monitoring

Detailed (DDEC equipped engines only)

Engine Fuel

D Fuel Pressure

Fuel Temperature

D Fuel Rate

D Used Last Run

Engine Coolant

D Coolant Pressure

Coolant Temperature

D Coolant Level

Engine Oil

D Oil Pressure

Oil Temperature

D Oil Level

D Crackcase Pressure

Engine Misc

D ECM Battery VDC

Ambient Temperature

D Engine Model No.

D Engine Serial No.

D Unit No.

ECM S/N

Menu 2

Engine Monitoring, cont.

Engine Monitoring

Detailed (MDEC equipped engines only)

Engine Fuel

D Fuel Pressure

Fuel Temperature

D Charge Air Pressure

Charge Air Temperature

D Fuel Rate

D Daily Fuel Used

D Total Fuel Used

Engine Oil

D Oil Pressure

Oil Temperature

Engine Misc

D ECU Supply VDC

Ambient Temperature

D ECU Hours

D ECU Fault Codes

Menu 3

Analog Monitoring

D Local Batt VDC

D Analog 01 to 07 (userdefined descriptions)

(Scroll through 7 userdefined descriptions. See

Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.)

Menu 4

Operational Records

D Factory Test Date

D Total Run Time

D Total Run Time

Loaded Hours

D Total Run Time

Unloaded Hours

D Total Run Time kW Hours

D No. of Starts

D Engine Start Countdown d Run Time

D Records-Maintenance d Reset Records

D Run Time Since Maintenanc

Total Hours

D Run Time Since Maintenanc

Loaded Hours

D Run Time Since Maintenanc

Unloaded Hours

D Run Time Since Maintenanc kW Hours

D Operating Days

Last Maintenance

D No. of Starts

Last Maintenance

D Last Start

Date

D Length of Run

(Un)loaded Hours

Menu 5

Event History

D (Message Text)

D (Scroll through up to 100 stored events)

Menu 6

Time and Date

D Time 00:00 AM/PM

D Date

TP-6200 3/06 Section 2 Operation 41

Menu List Summary, continued

(Legend:

D First level submenu, d second level submenu)

Menu 7

Generator System

D Operating Mode d Standby Y/N d Prime Power N/Y

D System Voltage

Line-Line

D System Frequency

D Phase d 3-Phase Delta Y/N d 3-Phase WYE N/Y d 1-Phase N/Y

D kW Rating

D Rated Current

D Load Shed Output d Time Delay

D Overvoltage d Time Delay

D Undervoltage d Time Delay

D Overfrequency

D Underfrequency

D Overspeed

D Battery Voltage d 12 VDC Y/N d 24 VDC N/Y

D Low Battery Voltage

D High Battery Voltage

D Block Heater ON

[

D Block Heater OFF

[

D Enable VSG Y/N

[

D Enable DSC

[

D Metric Units Y/N

D Set NFPA110 Defaults Y/N

[ DDC/MTU MDEC engine only

Menu 8

Time Delays

D Time Delay

Engine Start

D Time Delay

Starting Aid

D Time Delay

Crank On

D Time Delay

Crank Pause

D Time Delay

Eng. Cooldown

D Cooldown Temperature

Override Y/N

D Overcrank Shutdown

Crank Cycles

D Time Delay

Overvoltage

D Time Delay

Undervoltage

D Time Delay

Load Shed kW

Menu 9

Input Setup

Setup Digital

Auxiliary Inputs

D Digital Input

(Scroll through up to 21 user-defined descriptions. See

Figure 2-9 in User Inputs for factory-reserved inputs which are not user selectable.)

D Digital Input

Message Text Y/N, see Group A

Group A

The preprogrammed selections include the following:

Warning

Shutdown Type A

Shutdown Type B

Voltage Raise

Voltage Lower

VAR PF Mode

Remote Shutdown

Remote Reset

Air Damper

Low Fuel

Field Overvoltage

Idle Mode Active

(ECM engines only)

Battle Switch

Ground Fault

Bat Chgr Fault

High Oil Temperature

(non-ECM only)

Low Coolant Level

Low Coolant Temperature

(Not user selectable)

Breaker Closed, (Paralleling non-selectable)

Enable Synchronizer,

(Paralleling non-selectable)

Air/Fuel Module Shutdown*

Knock Shutdown*

Detonation Warning*

Detonation Shutdown*

Low Fuel Shutdown

D Digital Input

Enable Y/N

D Digital Input

Inhibit TIme

D Digital Input

Delay Time

*Waukesha engine only

Menu 9

Input Setup, cont.

Setup Analog

Auxiliary Inputs

D Analog Input

(Scroll through up to 7 user-defined descriptions.

See Figure 2-9 in User

Inputs for factory reserved inputs which are not user selectable.)

D Analog Input

Warning Enabled Y/N

D Analog Input

Shutdown Enabled Y/N

D Analog Input

Inhibit Time 0--60 Sec.

D Analog Input

Warning Delay Time

0--60 Sec.

D Analog Input

Shutdown Delay Time

0--60 Sec.

D Analog Input

Low Shutdown Value

D Analog Input

Low Warning Value

D Analog Input

High Warning Value

D Analog Input

High Shutdown Value

Menu 10

Output Setup

Defined Common Fault

D Defined Common Fault

(Y/N for a single defined common fault)

Scroll through status and fault choices from: d System events, see Group B (except

Defined Common Fault) d 21 digital inputs

D01-D21 d 7 analog inputs

A01--A07

Menu 10

Output Setup, cont.

Relay Driver Outputs

(RDOs)

D RDOs (Y/N)

(Scroll through up to

31 status and fault choices from: d System events, see Group B d 21 digital inputs

D01-D21 d 7 analog inputs

A01--A07

Group B

The system events include the following:

Emergency Stop

Over Speed

Overcrank

High Cool Temp Shutdown

Oil Pressure Shutdown

Low Coolant Temperature

(non-ECM engines)

Low Fuel Warning

Hi Cool Temp Warning

Oil Pressure Warning

Master Not in Auto

NFPA 110 Fault

[

[

The 15 NFPA 110 Common

Fault Alarms include the following:

Over Speed

Overcrank

High Coolant Temperature

Shutdown

Oil Pressure Shutdown

Low Coolant Temperature

High Coolant Temperature

Warning

Oil Pressure Warning

Low Fuel

Master Not In Auto

Battery Charger Fault

Low Battery Voltage

HIgh Battery Voltage

Low Coolant Level

EPS Supplying Load

Air Damper Indicator

42 Section 2 Operation TP-6200 3/06

Menu List Summary, continued

(Legend:

D First level submenu, d second level submenu)

Menu 10

Output Setup, cont.

Group B, continued

Low Battery Voltage

High Battery Voltage

Battery Charger Fault

System Ready

Loss of ECM Comm

(ECM engines)

No Oil Pressure Signal

High Oil Temperature

Shutdown

No Temperature Signal

Low Coolant Level

Speed Sensor Fault

Locked Rotor

Master Switch Error

Master Switch Open

Master Switch to Off

AC Sensing Loss

Over Voltage

Under Voltage

Weak Battery

Over Frequency

Under Frequency

Load Shed kW Over

Load Shed Under Freq

Over Current

EPS Supplying Load

Internal Fault

Delay Engine Cooldown

Delay Engine Start

Starting Aid

Generator Set Running

Air Damper Control

Ground Fault

EEPROM Write Failure

Critical Overvoltage

Alternator Protection

Air Damper Indicator

Defined Common Fault

(RDO only)

SCRDOs 1--4 (Software-

Controlled RDOs)

Menu 10

Output Setup, cont.

Group B, continued

Reverse Power Shutdown

[

Over Power Shutdown

[

Loss of Field Shutdown

[

Paralleling Relay

Overcurrent Shutdown

[

Common Paralleling Relay

Output

[

In Synchronization

[

Breaker Trip

[

Fuel Valve Relay*

Prelube Relay*

Air/Fuel Module Remote

Start*

No Oil Temperature Signal*

High Oil Temperature

Warning*

]

No Air Temperature Signal*

Intake Air Temperature

Warning*

]

Intake Air Temperature

Shutdown*

]

Air/Fuel Module Engine

Start Delay*

MDEC Yellow Alarm

]

MDEC Red Alarm

]

Block Heater Control

]

Low Coolant Temperature

Shutdown

]

Load Shed

Overtemperature

]

*Waukesha engine

[Paralleling applications

]DDC/MTU engine with MDEC

Menu 11

Voltage Regulator

AVG L-L V

Volt ADJ

D L1-L2 Volts

D L2-L3 Volts (3 phase)

D L3-L1 Volts (3 phase)

Under Freq. Unload

Enabled N/Y

D Frequency

Setpoint (Cut-In Point)

D Slope

Volts-Per-Cycle

Reactive Droop

Enabled N/Y

D Voltage Droop at 0.8 PF

Rated Load

VAR Control

Enabled N/Y

D Total kVAR (Running) kVAR Adj

D Generating/Absorbing Y/N

PF Control

Enabled N/Y

D Average PF

PF Adjustment

D Lagging/Leading Y/N

Regulator Gain Adj.

D Gain

Utility Gain Adj.

D Gain

Reset Regulator Defaults?

Menu 12

Calibration

Scale AC Analog

Inputs

Generator Set Voltage LN

D Gen L1-L0 V

Calibration Reference

D Gen L2-L0 V

Calibration Reference

D Gen L3-L0 V (3 phase)

Calibration Reference

Generator Set Voltage LL

D Gen L1-L2 V

Calibration Reference

D Gen L2-L3 V (3 phase)

Calibration Reference

D Gen L3-L1 V (3 phase)

Calibration Reference

D Calibrate Regulator Y/N

Generator Set Amps

D Gen L1 Amps

Calibration Reference

D Gen L2 Amps

Calibration Reference

D Gen L3 Amps (3 phase)

Calibration Reference

Load Voltage LN

(Paralleling Applications only)

D Load L1--L0 V

Calibration Reference

D Load L3--L0 V

Calibration Reference

Restore Defaults? Y/N

Scale Aux. Analog

Inputs

D Zero Aux. Analog Inputs?

(Scroll through up to 7 user-defined descriptions. See

Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.)

D Analog 01

Scale Value 1 d Scale 1 V

Scale 2 V

D Analog 01

Scale Value 2 d Scale 1 V

Scale 2 V

TP-6200 3/06 Section 2 Operation 43

Menu 13

Communications

Protocol

KBUS

D KBUS Online Y/N

D Connection Type

(User-defined) d Local Single Y/N d Local LAN Y/N d Local LAN Conv Y/N d Remote Single Y/N d Remote LAN Y/N d Remote LAN Conv

Y/N

D Primary Port

(User-defined) d RS-232 Y/N d RS-485 ISO1 Y/N

D Address

(LAN Connections)

D System ID

(Remote Connections)

D BAUD Rate

(User-defined) d BAUD Rate

1200

2400

9600

Protocol

Modbus

D Modbus Online N/Y

D Connection Type

(User-defined) d Single Y/N d Convertor Y/N

D Primary Port d RS-485 d RS-232

D Address

D BAUD Rate

(User-defined) d 9600 d 19200

Menu List Summary, continued

(Legend:

D First level submenu, d second level submenu)

Menu 14

Programming Mode

D Programming Mode d Local? Y/N d Remote? Y/N d Off? Y/N

D Programming Mode

Change, Access Code d Enter Old Code d Enter New Code

Menu 15

Paralleling Relays (PR)

D PR Overvoltage VAC d Time Delay Seconds

D PR Undervoltage VAC d Time Delay Seconds

D PR Overfrequency Hz d Time Delay Seconds

D PR Underfrequency Hz d Time Delay Seconds

D PR Reverse Power kW d Time Delay Seconds

D SD Reverse Power kW d Time Delay Seconds

D PR Over Power kW d Time Delay Seconds

D SD Over Power kW d Time Delay Seconds

D PR Loss of Field kVAR d Time Delay Seconds

D SD Loss of Field kVAR d Time Delay Seconds

D PR Overcurrent Amps d Time Delay Seconds

D SD Overcurrent Amps d Time Delay Seconds

D Synchronization d Synch Voltage Match

VAC d Synch Freq. Match

Hz d Synch Phase Match

Degrees d Time Delay Seconds

Menu 20

Factory Setup Menu

D Final Assembly Date

DD/MM/YY

D Final Assembly Clock No.

D Operating Days

D Model No.

D Spec No.

D Generator Set Serial No.

D Alternator Part No.

D Engine Part No.

D Temp Sensor d GM31045-X d GM16787 d GM17362

D Serial No.

D Controller Serial No.

D Code Version

D Setup Locked

Menu 55

Load Factor

D 100%--125% Load Factor

Hours

D 126%--150% Load Factor

Hours

D 151%--200% Load Factor

Hours

D 201%+ Load Factor

Hours

44 Section 2 Operation TP-6200 3/06

2.5 Digital Display Messages

Throughout this manual there are examples of the display text. In some cases, the message words and phrases are abbreviated or shortened to accommodate the 40-character display. See the following table for a full description of the system event display messages.

System Events Display Message List

Display Message

A01 through A07

AC SENSING LOSS

AFM ENG START DELAY

AFM REMOTE START

AFM SHUTDOWN

AIR DAMPER CONTROL

AIR DAMPER INDICATOR

ALTRNTR PROTECT SDWN

BATTERY CHGR FAULT

BATTLESWITCH

BLOCK HEATER CONTROL

BREAKER CLOSED

BREAKER TRIP

COMMON PR OUTPUT

CONTROLLER SETUP ERR

CRITICAL OVERVOLTAGE

D01 through D21

DATE CHANGED FROM

DEFINED COMMON FAULT

DELAY ENG COOLDOWN

DELAY ENG START

DETON SHUTDOWN

DETON WARNING

EEPROM INITIALIZED

EEPROM WRITE FAILURE

EMERGENCY STOP

ENABLE SYNCH

EPS SUPPLYING LOAD

FIELD OVER VOLTS

FREQ SELECTION ERR

FUEL VALVE RELAY

GENERATOR SET RUNNING

GENSET PARAM WARNING

GENSET S/N WARNING

GENSET S/N SHUTDOWN

GROUND FAULT

HI COOL TEMP WARNING

HI COOL TEMP SHUTDWN

HIGH OIL TEMP

HI OIL TEMP WARNING

HIGH OIL TEMP SDWN

HIGH BATTERY VOLTAGE

IDLE MODE ACTIVE

IN SYNCH

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

Description

Analog auxiliary input A01 through A07

AC sensing loss

Air/fuel module engine start delay (Waukesha powered models only)

Air/fuel module remote start (Waukesha powered models only)

Air/fuel module shutdown (Waukesha powered models only)

Air damper control

Air damper indicator

Alternator protection shutdown

Battery charger fault

Battle switch (fault shutdown override switch)

Block heater control (DDC/MTU engine with MDEC only)

Circuit breaker closed

Circuit breaker trip

Common paralleling relay output

Controller setup error

Critical overvoltage shutdown

Digital auxiliary input D01 through D21

Date changed from

Defined common fault (do not use for common fault)

Time delay engine cooldown (TDEC) timing

Time delay engine start (TDES) timing

Detonation shutdown (Waukesha powered models only)

Detonation warning (Waukesha powered models only)

EEPROM initialized

EEPROM write failure

Emergency stop

Enable synchronization

Emergency power system supplying load

Field over volts

Frequency selection error

Fuel valve relay

Generator running

Generator set parameter warning

Generator set serial number warning

Generator set serial number shutdown

Ground fault detected

High coolant temperature warning

High coolant temperature shutdown

High oil temperature

High oil temperature warning (DDC/MTU engine with MDEC and Waukesha powered models only)

High oil temperature shutdown

High battery voltage

Idle mode active

In synchronization (paralleling application)

Intake air temp. warning (DDC/MTU engine with MDEC and Waukesha powered models only)

Intake air temp. shutdown (DDC/MTU engine with MDEC and Waukesha powered models only)

TP-6200 3/06 Section 2 Operation 45

System Events Display Message List, continued

Display Message

INTERNAL FAULT

KNOCK SHUTDOWN

KW SELECTION ERR

LOAD SHED KW OVER

LOAD SHED OVER TEMP

LOAD SHED UNDER FREQ

LOCKED ROTOR

LOSS OF ECM COMM

LOW BATTERY VOLTAGE

LOW COOLANT LEVEL

LOW COOLANT TEMP

LOW COOL TEMP SDWN

LOW FUEL SHUTDOWN

LOW FUEL WARNING

MASTER SWITCH ERROR

MASTER SWITCH TO OFF

MASTER NOT IN AUTO

MASTER SWITCH OPEN

MDEC RED ALARM

MDEC YELLOW ALARM

NFPA 110 FAULT

NO AIR TEMP SIGNAL

NO COOL TEMP SIGNAL

NO OIL PRESS SIGNAL

NO OIL TEMP SIGNAL

OIL PRESS SHUTDOWN

OIL PRESS WARNING

OVER CRANK

OVER CURRENT

OVER FREQUENCY

OVER SPEED

OVER VOLTAGE

PHASE SELECTION ERR

PRE LUBE RELAY

PR LOSS OF FIELD

PR OVER CURRENT VR

PR OVER FREQUENCY

PR OVER POWER

PR OVER VOLTAGE

PR REVERSE POWER

PR UNDER FREQUENCY

PR UNDER VOLTAGE

REMOTE RESET

REMOTE SHUTDOWN

SD LOSS OF FIELD

SD OVER CURRENT VR

SD OVER POWER

SD REVERSE POWER

SHUTDOWN TYPE A

SHUTDOWN TYPE B

SPEED SENSOR FAULT

STARTING AID

Description

Internal fault shutdown

Knock shutdown kW selection error

Load shed kW overload

Load shed over temperature (DDC/MTU engine with MDEC only)

Load shed underfrequency

Locked rotor

Engine control module communications loss (ECM models only)

Low battery voltage

Low coolant level

Low coolant temperature warning

Low coolant temperature shutdown (DDC/MTU engine with MDEC only)

Low fuel pressure shutdown (125 kW GM powered model only)

Low fuel level (gasoline or diesel) or pressure (gas) warning

Master switch error (invalid sequence or transition)

Master switch in the OFF position (user must move master switch to OFF position)

Master switch not in the AUTO position

Master switch open

MDEC red alarm (DDC/MTU engine with MDEC only)

MDEC yellow alarm (DDC/MTU engine with MDEC only)

NFPA 110 common fault

No air temperature signal (Waukesha powered models only)

Coolant temperature signal loss

Oil pressure signal loss

Oil temperature signal loss (Waukesha powered models only)

Oil pressure shutdown

Oil pressure warning

Overcrank shutdown

Overcurrent warning

Overfrequency shutdown

Overspeed shutdown

Overvoltage shutdown

Phase selection error

Prelubrication relay (Waukesha powered models only)

Protective relay loss of field (paralleling application)

Protective relay overcurrent voltage regulator (paralleling application)

Protective relay over frequency (paralleling application)

Protective relay over power (paralleling application)

Protective relay over voltage (paralleling application)

Protective relay reverse power (paralleling application)

Protective relay under frequency (paralleling application)

Protective relay under voltage (paralleling application)

Remote reset

Remote shutdown

Loss of field shutdown (paralleling application)

Over current with voltage restraint voltage regulator shutdown

Over power shutdown (paralleling application)

Reverse power shutdown (paralleling application)

Shutdown type A

Shutdown type B

Speed sensor fault

Starting aid status

46 Section 2 Operation TP-6200 3/06

System Events Display Message List, continued

Display Message

STATE INITIALIZED

Description

State initialized

S’WARE CONTROLLED #1 through #4 Software-controlled relay driver outputs #1 through #4 (RDO only)

SYSTEM READY System ready

UNDER FREQUENCY

UNDER VOLTAGE

VAR PF MODE

VOLTAGE LOWER

Underfrequency shutdown

Undervoltage

VAR power factor mode

Voltage lower

VOLTAGE RAISE

VOLT SELECTION ERR

WARNING

Voltage raise

Voltage selection error

Warning

WEAK BATTERY Weak battery warning

2.6 Reviewing the Digital Display

The user interacts with the controller with a keypad and digital display. Use the keypad to access the generator set informational data and preset settings. This review section shows how to access the data. See Section 2.9,

Local Programming Mode On, for instructions on how to change the information.

See Figure 2-10 for an illustration of the digital display and keypad.

TP-5829-2

Figure 2-10 Digital Display and Keypad

Note: After energizing the controller by reconnecting the battery, set the controller time and date. See

Section 2.9.6, Local Programming Mode On,

Menu 6—Time and Date.

Pressing any key on the keypad activates the controller panel display. The panel lamps and display turn off

5 minutes after the last keypad entry.

2.6.1

Keypad Operation

Use the keypad to enter information into the controller.

Some of the keys have two functions. The following gives keypad definitions and functions.

Alarm (Horn) Off Key.

Press the alarm off key to silence the horn at the user’s discretion.

Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the master switch is in the AUTO position.

See Section 2.3.7, Controller Reset

Procedure, for more information on turning the alarm horn off.

AM/PM Key. When the controller displays a question during programming requiring a nonnumeric answer (am or pm), the controller accepts the secondary key function and ignores the alarm off function of the key.

Enter

↵ Key. Press the enter ↵ key to confirm the entered information on the display when selecting menus or programming.

Lamp Test Key. Press the lamp test key to check that the status and fault lamps illuminate, the horn sounds, and the digital display clears. Press the reset menu key before pressing the lamp test key.

Menu Down

↓ Key. The controller displays consist of menus with various data levels or programming steps.

Use the menu down

↓ key to navigate through the menu levels.

Note: Pressing the menu down

↓ key in some menus locks the user into that level structure of the menu where the display will not change. Press the reset menu key to access other main menus.

TP-6200 3/06 Section 2 Operation 47

Menu Right

→ Key. Press the menu right → key to scroll through sub-levels of each main menu.

The display contains an arrow in the right-hand corner when there is a sub-level. Pressing the menu right

→ key when no arrow is present moves to the next submenu header. Press the menu right

→ key prior to entering decimal values when required.

Note: Pressing the menu right

→ key in some menus locks the user into that level structure of the menu where the display will not change. Press the reset menu key to access other main menus.

Numeric 0--9 Keys.

Press the numeric keys when selecting menus or entering numeric values during programming.

The controller ignores the secondary function of the key (yes, no, etc.) when only numeric values are valid.

Reset Menu Key. The reset menu key exits a menu, clears incorrect entries, and cancels the auto-scroll function. Press the reset menu key to exit a menu or any layer within that menu.

Stop Prog Run Key. Press the stop prog run key to end the generator set programmed exercise run created in

Menu 4—Operational Records.

The generator set shuts down after the time delay for engine cooldown expires. The stop prog run key does not affect the programmed transfer switch exercise function.

Yes/No Keys. When the controller displays a question during programming requiring a nonnumeric answer (yes or no), the controller accepts the secondary key function and ignores the numeric value of the key. Press the

ENTER key to confirm the response.

2.6.2

Auto-Scroll Function

The auto-scroll function continuously shows voltage and current data from Menu 1—Generator Monitoring,

V & A Summary without the need to press the down arrow for each display.

For auto-scroll function press ENTER at the V & A

Summary menu. Press the Reset Menu key or Menu

Right

→ key to stop the auto-scroll function.

2.6.3

Request and Error Messages

Note: When EEPROM errors occur or initializing the

EEPROM is required, contact an authorized distributor/dealer.

Request and Status Messages

Display messages require the user to enter additional data, confirm the previous entry or require time to process as described below.

Entry Accepted appears for several seconds after pressing the Enter key during the programming mode.

The display then shows the new data.

Initialize EEPROM? Menu will not accept changes when a system shutdown exists.

Clear the system shutdown before initializing the EEPROM.

Reset Complete indicates the user has successfully:

D

D

Reset the maintenance records or

Restored the AC analog inputs to the default settings.

Right Arrow

→ directs the user to the next menu. The menus loop; press the right arrow key to move to the next menu.

Setup Complete indicates the completion of the analog input setup.

Setup Locked appears when user attempts to change a value or perform a function available only when the system is unlocked.

Setup Unlocked appears when user has unlocked the system for maintenance or troubleshooting.

(Question) ? asked by the control firmware; answer the question by pressing the yes/no, numeric digit, or am/pm key.

Wait for System Reset (6 Sec) appears while the

EEPROM initializes.

Error Messages

When an error message appears, the entered information is not within the allowable parameters set by the control firmware or is not permitted as described below.

In cases where the data was outside the parameters, press the Reset Menu key and enter the corrected information.

Access Denied appears when the user attempts to:

D

D

D

Enter data prohibited by the master switch position,

Enter data prohibited by the generator set state, or

Enable the LDD (load disturbance detection).

48 Section 2 Operation TP-6200 3/06

Access Denied Idle Mode Active appears when the user attempts to modify the voltage regulator setup while the idle mode is active.

Alarm Active appears when the user attempts to modify a digital input that is active. See Menu 9—Input

Setup.

Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify an RDO setting that is a NFPA 110 default requirement.

Cannot Change Preset appears when the user attempts to change the factory preset digital input or input parameter.

EEPROM Write Error appears when a component failure, lightning strike, or voltage spike occurs. Contact an authorized distributor/ dealer.

Entry Unacceptable appears when the user attempts an invalid input to the voltage regulator setup.

Fixed Frequency when entry is beyond the range of limited entries for the respective alternator. Updated parameter files may be available by contacting an authorized service dealer/distributor.

Fixed Phase when entry is beyond the range of limited entries for the respective alternator. Updated parameter files may be available by contacting an authorized service dealer/distributor.

Fixed Voltage when entry is beyond the range of limited entries for the respective alternator. Updated parameter files may be available by contacting an authorized service dealer/distributor.

Func (Function) Used by (RDO) XX Reassign?

appears when the user attempts to assign an RDO to a function already assigned.

Note: This function is not user selectable. Contact an authorized Distributor/Dealer.

Internal Error appears when controller logic detects a functional sequence error.

Invalid Code appears when the user attempts to enter:

D

D

An invalid access code for programming mode setup, or

An invalid access code for setup unlock.

Invalid Menu ID appears when the user attempts to enter a menu number which is unavailable or non-functional.

N/A appears when the controller logic does not support the engine parameters.

No Input Assigned appears when the user attempts to assign any of the following system faults to an RDO where the digital input is not defined. See digital input scale requirements in Menu 12—Calibration.

D

D

D

D

D

D

Air damper indicator

Battery charger fault

Ground fault

High oil temperature shutdown

Low coolant level

Low fuel

Not in Local Program Mode appears when the user attempts to program using the keypad when the programming mode is set for remote or off.

Not User Selectable appears when the user attempts to change an analog or digital input which is factory reserved. Items identified as not user selectable are included for specific applications.

(Example: AFM

SHUTDOWN is enabled with a Waukesha-powered model.) The user can not disable a analog or digital input when identified as not user selectable.

See

Figure 2-9 in User Inputs for factory reserved digital and analog inputs which are not user selectable.

Output in Use appears when the user attempts to modify or reassign an active RDO.

Port in Use appears when the user attempts to use an already assigned communications port.

Range Error appears when the user attempts to enter:

D

A numeric input that is not within the acceptable range of the system settings, time delays, addresses, etc.

D

D

D

An invalid analog or digital input number.

An invalid date/time.

Some operating condition that precludes changing the parameter.

Remove Load appears when trying to calibrate the voltage regulator in menu 12 with load connection. The voltage regulation calibration must be performed during a no load condition.

Setpoint Values Cannot be Equal appears when the user attempts to enter the same value for both setpoints during the analog input calibration.

TP-6200 3/06 Section 2 Operation 49

2.7 Monitoring and Programming

Setup

The user can access the controller data with the controller keypad and display or a personal computer

(PC) with optional software to monitor and/or program.

Access the controller system with a PC using local

(direct) or remote (modem) systems.

Refer to the

Introduction, List of Related Materials for related software literature. See Menu 13—Communications.

The user can access the controller data while in the programming mode off or programming mode on. See

Menu 14—Programming Mode.

While this manual focuses on data access and programming through the controller keypad and display, some data entries require input using a PC for initial setup. The PC entries typically include alpha characters such as digital input descriptions. The individual menus in Section 2.9, Local Programming Mode On, indicate where data requires entry using a PC.

There are six basic configurations for data monitoring and programming using access source options. See

Figure 2-13.

Other combinations of data monitoring and programming are possible but require programming from a single location.

Figure 2-13, Monitoring and

Programming Configurations, briefly describes the settings of Menu 13—Communications and Menu 14—

Programming Mode based on user selected operating mode.

Use the keypad and digital display to setup the access configurations the first time. Go to Section 2.9, Local

Programming Mode On, and set the desired selection in Menu 13—Communication and Menu 14—

Programming Mode before accessing data.

2.7.1

PC Communications

There are four ways to communicate between a PC and the generator set and/or transfer switch devices using

KBUS communication protocol. The PC connections require optional software and possibly other hardware, communication modules in the generator set controller and/or transfer switch.

See the Monitor Software operation manual for details. Contact your authorized distributor/dealer for availability.

Local Single Connection

A PC connects to the COM port of the controller module using an RS-232 cable when the PC is within 15 m

(50 ft.) of the device or an RS-485 cable when the PC is within 1220 m (4000 ft.) of the device. See Figure 2-11 or Figure 2-12.

Personal

Computer

RS-232 up to

15 m (50 ft.)

Figure 2-11 Local Single Connection, up to 15 m (50 ft.)

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Personal

Computer

RS-232 to RS-485 port converter

RS-485 up to

1220 m

(4000 ft.)

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Figure 2-12 Local Single Connection, up to

1220 m (4000 ft.)

User Operating Mode Selection Menu 13—Communications Settings

User

Activity Access Source

M it

Controller

Direct PC and

PC via Telephone Lines

Controller

Direct PC

PC via Telephone Lines

On

Line?

No

Yes

Yes

No

Yes

Yes

Local

LAN?

No

Yes

No

No

Yes

No

Remote Single or LAN?

No

No

Yes

No

No

Yes

Programming

Mode Off?

Yes

Yes

Yes

No

No

No

Menu 14—Programming Mode

Local Programming

Mode?

No

No

No

Yes

No

No

Remote

Programming Mode?

No

No

No

No

Yes

Yes

Figure 2-13 Monitoring and Programming Configurations

50 Section 2 Operation TP-6200 3/06

Local Area Network (LAN)

A PC connects to the device’s LAN. A LAN is a system that connects more than one device to a single PC.

Acceptable devices include the Decision-Maker

™ 550 controller, Decision-Maker

™ 340 controller, M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor. See Figure 2-14.

Personal

Computer

RS-232 to RS-485 port converter

RS-485 up to

1220 m

(4000 ft.)

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Figure 2-14 Local Area Network

The 550 controller can be used as an RS-232 to RS-485 port converter in a LAN network if the 550 controller is located within 15 m (50 ft.) of the PC. This configuration is the Local LAN Conv option.

Remote Single Connection

A modem connects a PC to a single device. The PC communicates with the device via a telephone network.

Locate the PC anywhere a telephone line is available.

See Figure 2-15.

Remote Area Network

A PC connects to a modem. The devices connect to a

LAN network. The PC communicates to the devices via a telephone network that is interfaced to the LAN network. Acceptable devices include the Decision-

Maker

™ 550 controller, Decision-Maker™ 340 controller,

M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor.

Locate the PC anywhere a telephone line is available.

See

Figure 2-16.

The 550 controller can be used as an RS-232 to RS-485 port converter in a LAN network if the 550 controller is located within 15 m (50 ft.) of the device modem. This configuration is the Remote LAN Conv option.

Modem

Personal

Computer

RS-232 up to

15 m (50 ft.)

Figure 2-15 Remote Single Connection

Telephone

Lines

Modem

RS-232 up to

15 m (50 ft.)

Generator Set

Controller or

Transfer Switch

Control

Modem

Personal

Computer

Telephone

Lines

Figure 2-16 Remote Area Network

TP-6200 3/06

Modem

RS-232 to RS-485 port converter

RS-485 up to 1220 m

(4000 ft.)

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Section 2 Operation 51

2.7.2

Modbus r Communications

The controller communicates using Modbus r as a slave connection with the Modbus r master initiating the communication. The controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus r master. In addition, the controller accepts information to alter controller parameters including generator set starting and stopping. See Figure 2-17. Refer to the List of Related

Materials for available Modbus r literature.

Note: Only one Modbus r master can be connected to the 550 controller. Examples include the remote serial annunciator, Monitor III, and switchgear applications.

Generator Set

Controller

RS-485 up to 1220 m (4000 ft.)

Modbus r

Master

RS-232 up to 15 m (50 ft.)

Figure 2-17 Modbus r Connections

2.8 Reviewing the Menu Displays

Use this section to review generator set controller data while in the programming off mode.

Press the Reset key, enter the desired menu number key(s), and then press the Enter key. Use the down arrow and right arrow keys for navigation.

See Section 1, Specifications and Features, to review set point ranges and default settings for comparison to the actual setup.

The user must enable the programming mode to edit the display.

See Menu 14—Programming Mode and

Section 2.9, Local Programming Mode On, for more information.

Note: Press any key on the keypad to activate the controller panel display. The panel display turns off 5 minutes after the last keypad entry.

Note: Press the Reset Menu key to clear error messages.

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Menus displaying the # symbol represent one of the following data types:

D

D

D

System-calculated data

System-measured data

User-entered data

Menus displaying the ? symbol require the user to enter data.

Menus displaying the * symbol represent access code or password type entries. The actual key entry does not display.

See Section 2.6.3, Request and Error Messages, for error display messages and explanations while navigating the menus.

Legend:

Menu Down Key

Menu Right Key

Modbus r is a registered trademark of Schneider Electric.

52 Section 2 Operation TP-6200 3/06

2.8.1

Menu 1—Generator Monitoring

Menu 1 displays generator output data including line-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent of maximum kW, total kVA, and total kVAR.

Menu 1 displays three-phase voltage and current readings when applicable.

All menu displays apply to both single-phase and threephase voltages unless otherwise noted as (1 PH) or (3

PH) on the menu overview. The phase designation does not appear in the controller menu displays.

Menu 1 Overview (Three-Phase Connections)

MENU 1

GENERATOR MONITORING

VOLTS & AMPS

→

V & A SUMMARY

→

POWER KW

Note: For the auto-scroll function, press ENTER at V &

A Summary menu. Press the Reset Menu key or

Menu Right

→ key to stop the auto-scroll function.

Note: Pressing a right arrow key from any submenu moves to the next submenu header.

→

POWER KVAR

→

POWER KVA

→

# L1-L2 VOLTS

L1 AMPS

L2-L3 VOLTS

L2 AMPS

L3-L1 VOLTS

L3 AMPS

L1-L0 VOLTS

L1 AMPS

L2-L0 VOLTS

L2 AMPS

L3-L0 VOLTS

L3 AMPS

FREQUENCY

#

#

V L1-L2 L2-L3 L3-L1

# # #

TOTAL KW #

PF # LEADING/LAGGING

TOTAL KVAR #

ABSORBING/GENERATING

TOTAL KVA

#

#

V L1-L0 L2-L0 L3-L0

# # #

L1 KW #

PF # LEADING/LAGGING

L1 KVAR #

ABSORBING/GENERATING

L1 KVA

#

#

A L1

#

L2

#

L3

#

L2 KW #

PF # LEADING/LAGGING

L2 KVAR #

ABSORBING/GENERATING

L2 KVA

#

#

For the auto-scroll function, press ENTER at

V & A SUMMARY menu.

L3 KW (3 PH) #

PF # LEADING/LAGGING

L3 KVAR (3 PH) #

ABSORBING/GENERATING

L3 KVA

#

#

#

#

Use the MENU

→ key to stop the auto-scroll function.

TOTAL KW

% OF RATED KW

#

#

# HZ

#

#

#

TP-6200 3/06 Section 2 Operation 53

Menu 1—Generator Monitoring, continued

Menu 1 Overview (Single-Phase Connections)

MENU 1

GENERATOR MONITORING

VOLTS & AMPS

→

V & A SUMMARY

→

POWER KW

→

POWER KVAR

→

POWER KVA

L1-L2 VOLTS

L1 AMPS

L1-L2 VOLTS

L2 AMPS

L1-L0 VOLTS

L1 AMPS

L2-L0 VOLTS

L2 AMPS

FREQUENCY

#

#

V L1-L2 L1-L0 L2-L0

# # #

TOTAL KW #

PF # LEADING/LAGGING

TOTAL KVAR #

ABSORBING/GENERATING

TOTAL KVA

#

#

A L1

#

L2

#

L1 KW #

PF # LEADING/LAGGING

L1 KVAR #

ABSORBING/GENERATING

L1 KVA

#

#

#

#

For the auto-scroll function, press ENTER at

V & A SUMMARY menu.

L2 KW #

PF # LEADING/LAGGING

L2 KVAR #

ABSORBING/GENERATING

L2 KVA

# HZ

Use the MENU

→ key to stop the auto-scroll function.

TOTAL KW

% OF RATED KW

#

#

#

#

→

#

54 Section 2 Operation TP-6200 3/06

2.8.2

Menu 2—Engine Monitoring

Menu 2 displays engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooled-down temperature setpoints.

The detailed engine monitoring feature functions show

DDEC-equipped engine and MDEC-equipped engine versions.

Note: A right arrow from any submenu moves to the next submenu header.

Menu 2 Overview

MENU 2

ENGINE MONITORING

(DDEC-Equipped Engines only)

ENGINE MONITORING

BASIC

→

ENGINE MONITORING

DETAILED

→

OIL PRESSURE

COOLANT TEMP

# PSI

# F

ENGINE FUEL

→

ENGINE COOLANT

→

ENGINE OIL

→

ENGINE MISC

→

INTAKE AIR # F

OIL TEMP (Waukesha) # F

FUEL PRES

FUEL TEMP

# PSI

# F

COOLANT PRES

COOLANT TEMP

# PSI

# F

OIL PRES

OIL TEMP

# PSI

# F

ECM BATT VDC

AMBIENT TEMP

#

# F

ENGINE RPM

LOCAL BATT VDC

HCT WARNING

HCT SHUTDOWN

#

#

FUEL RATE

# F

# F

USED LAST RUN

# GAL

# GPH COOLANT LEVEL #% OIL LEVEL #%

CRANKCASE PRES # PSI

ENGINE MODEL NO.

#

ENGINE SERIAL NO.

#

LOP WARNING

LOP SHUTDOWN

# PSI

# PSI

UNIT NO.

ECM S/N

#

#

ENGINE WARMED UP

# F

ENGINE COOLED DOWN

# F

TP-6200 3/06 Section 2 Operation 55

Menu 2 Overview

MENU 2

ENGINE MONITORING

(MDEC-Equipped Engines only)

ENGINE MONITORING

BASIC

→

ENGINE MONITORING

DETAILED

→

OIL PRESSURE

COOLANT TEMP

# PSI

# F

ENGINE FUEL

→

ENGINE OIL

→

ENGINE MISC

→

INTAKE AIR # F

OIL TEMP (Waukesha) # F

FUEL PRES

FUEL TEMP

# PSI

# F

ENGINE RPM

LOCAL BATT VDC

HCT WARNING

HCT SHUTDOWN

#

#

CHG AIR PRES

CHG AIR TEMP

# F

# F

FUEL RATE *

# PSI

# F

# GPH

LOP WARNING

LOP SHUTDOWN

# PSI

# PSI

DAILY FUEL USED * # GAL

ENGINE WARMED UP

# F

ENGINE COOLED DOWN

# F

TOTAL FUEL USED * # GAL

OIL PRES

OIL TEMP

# PSI

# F

ECU SUPPLY VDC

AMBIENT TEMP

#

# F

ECU HOURS #

ECU FAULTS CODES #

* While these menu displays do appear on the 550 controller, the engine ECM is not currently set up to provide this data.

56 Section 2 Operation TP-6200 3/06

2.8.3

Menu 3—Analog Monitoring

Menu 3 displays battery voltage and up to 7 userdefined analog items dependent upon the generator system.

The User Defined Desc display refers to a description entered into the controller using the PC software. This description remains as the display for future review until changed by the PC software user. The display has

20 characters maximum.

Menu 3 Overview (ECM Engines)

MENU 3

ANALOG MONITORING

Note: If the analog display shows O/R (out of range), no input is connected.

Note: See Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.

Menu 3 Overview (Non-ECM Engines)

MENU 3

ANALOG MONITORING

LOCAL BATT VDC #

LOCAL BATT VDC #

ANALOG 01

(USER DEFINED DESC)

#

ANALOG 02

(USER DEFINED DESC)

#

ANALOG 03

(USER DEFINED DESC)

#

ANALOG 04

(USER DEFINED DESC)

#

ANALOG 05

(USER DEFINED DESC)

#

ANALOG 06

(USER DEFINED DESC)

#

ANALOG 07

(USER DEFINED DESC)

#

ANALOG 01

COOLANT TEMPERATURE

#

ANALOG 02

OIL PRESSURE

#

ANALOG 03

(USER DEFINED DESC)

#

ANALOG 04

(USER DEFINED DESC)

#

ANALOG 05

(USER DEFINED DESC)

#

ANALOG 06

(USER DEFINED DESC)

#

ANALOG 07

(USER DEFINED DESC)

#

TP-6200 3/06 Section 2 Operation 57

2.8.4

Menu 4—Operational Records

Menu 4 displays the generator set’s operating record including operating start date, last logged maintenance, total run time loaded and unloaded, run time since last maintenance, number of starts, and number of days the unit ran.

Menu 4 Overview

MENU 4

OPERATIONAL RECORDS

After performing maintenance, enter YES to reset records reflecting the current day. The user must enable the programming mode to edit the display.

NO. OF STARTS

LAST MAINT

#

##-###-##

FACTORY TEST DATE

##-###-##

TOTAL RUN TIME

HRS #

LAST START

DATE

##:## AM/PM

##-###-##

LENGTH OF RUN

(UN)LOADED HRS #

TOTAL RUN TIME

LOADED HRS

TOTAL RUN TIME

UNLOADED HRS

TOTAL RUN TIME

KW HRS

NO. OF STARTS

#

#

#

#

ENGINE START?

COUNTDOWN

RECORDS-MAINT

Y/N

→

##:##

RUN TIME HR:MN

→

??:??

→

RESET RECORDS?

Y/N

→

RUN TIME SINCE MAINT

TOTAL HRS #

RUN TIME SINCE MAINT

LOADED HRS #

RUN TIME SINCE MAINT

UNLOADED HRS #

RUN TIME SINCE MAINT

KW HRS #

OPERATING DAYS

LAST MAINT

#

##-###-##

58 Section 2 Operation TP-6200 3/06

2.8.5

Menu 5—Event History

Menu 5 stores and displays the times and dates of up to

100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events.

Menu 5 Overview

MENU 5

EVENT HISTORY

(MESSAGE TEXT)

##-###-## ##:## AM/PM

SCROLL THROUGH 100 (max.)

STORED EVENTS

2.8.6

Menu 6—Time and Date

Menu 6 sets the clock time and date and internal calendar.

The controller uses the set clock time to determine exercise run time and event records. The time and date are valid as long as the controller power

(starting battery) remains connected.

The user must enable the programming mode to edit the display.

2.8.7

Menu 7—Generator System

Menu 7 displays factory-preset generator set voltage and frequency data.

Enter the new voltage and/or frequency data when the generator set requires voltage reconnection and/or frequency adjustment.

It is imperative that the user enter the correct data because these settings trigger all related shutdowns.

The user must enable the programming mode to edit the display.

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Note: The user defines the data shown in Menu 7. It is

NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control.

Note: Some alternators are designed to operate at limited voltage, frequency, or phase connections.

Settings outside of these parameters may cause a range error message.

Items marked * apply to DDC/MTU engines using

MDEC engine controls.

Note: Menus include variable speed governor (VSG) and digital speed control (DSC).

Menu 6 Overview

MENU 6

TIME AND DATE

DAY OF WEEK ##-###-##

##:##AM/PM

TIME ??:?? AM/PM

DATE ??-???-??

TP-6200 3/06 Section 2 Operation 59

Menu 7 Overview

MENU 7

GENERATOR SYSTEM

OPERATING MODE

STANDBY

SYSTEM VOLTAGE

LINE-LINE

SYSTEM FREQ

→

Y/N

?

# HZ

OPERATING MODE

PRIME POWER

→

Y/N

→

N/Y

PHASE

SINGLE PHASE

PHASE

3 PHASE DELTA

KW RATING

RATED CURRENT

→

Y/N

PHASE

3 PHASE WYE

?

#

LOAD SHED OUTPUT

?%

→

# KW

TIME DELAY

OVERVOLTAGE

?%

→

# VAC

TIME DELAY

UNDERVOLTAGE

?%

→

# VAC

TIME DELAY

OVERFREQUENCY

?% # HZ

UNDERFREQUENCY

?% # HZ

OVERSPEED

? HZ

BATTERY VOLTAGE

12 VDC

# RPM

→

Y/N

BATTERY VOLTAGE

24 VDC

LOW BATTERY VOLTAGE

?.? VDC

MIN:SEC

→

??:??

MIN:SEC

→

??:??

MIN:SEC

→

??:??

→

Y/N

HIGH BATTERY VOLTAGE

?.? VDC

BLOCK HEATER ON * # F

→

N/Y

BLOCK HEATER OFF * # F

ENABLE VSG *

ENABLE DSC *

METRIC UNITS

SET NFPA 110

DEFAULTS

Y/N

Y/N

Y/N

Y/N

*DDC/MTU MDEC engine only

60 Section 2 Operation TP-6200 3/06

2.8.8

Menu 8—Time Delays

Menu 8 displays the cyclic cranking cycles, various engine related starting and shutdown features, and auxiliary shutdown and inhibit time delays.

The user must enable the programming mode to edit the display.

Cooldown Temperature Override.

This feature provides the ability to bypass (override) the generator set’s smart cooldown temperature shutdown and force the generator set to run for the full engine cooldown time delay.

Menu 8 Overview

MENU 8

TIME DELAYS

If the engine is above the preset temperature and the unit is signalled to shut down, the unit will continue to run for the duration of the TDEC.

If the engine is at or below the preset temperature and the unit is signalled to shut down or the TDEC is running, the unit will shut down without waiting for the time delay to expire.

TIME DELAY

ENGINE START

MIN:SEC

??:??

TIME DELAY

STARTING AID

TIME DELAY

CRANK ON

MIN:SEC

??:??

MIN:SEC

??:??

TIME DELAY

CRANK PAUSE

MIN:SEC

??:??

TIME DELAY

ENG COOLDOWN

MIN:SEC

??:??

COOLDOWN TEMPERATURE

OVERRIDE Y/N

OVERCRANK SHUTDOWN

CRANK CYCLES ?

TIME DELAY

OVERVOLTAGE

MIN:SEC

??:??

TIME DELAY

UNDERVOLTAGE

MIN:SEC

??:??

TIME DELAY

LOAD SHED KW

MIN:SEC

??:??

TP-6200 3/06 Section 2 Operation 61

2.8.9

Menu 9—Input Setup

Menu 9 displays the setup of user-defined digital and analog warning and shutdown inputs.

These inputs provide a multitude of choices for configuring customized auxiliary inputs.

The user must enable the programming mode to edit the display.

Note: Press the down arrow to move to the start of the next input setup.

Digital and Analog Inputs. After the user selects input, enter the following choices or values—enabled

(yes/no), inhibit time (min.:sec.), and delay time

(min.:sec.).

Note: See Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.

D

Enabled. This menu entry enables the input. The previous yes/no selection does not activate the input.

Analog inputs have separate warning and shutdown enabled choices.

D

Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect the fault or status event. The inhibit time delay range is from 0 to 60 seconds.

D

Time Delay (shutdown or warning). The time delay follows the inhibit time delay. The time delay is the time period between when the controller first detects the fault or status event and the controller warning or shutdown lamp illuminates. The delay prevents any nuisance alarms. The time delay range is from 0 to

60 seconds.

Additional Analog Input Entries. The analog input selection typically requires entering four values—low warning, high warning, low shutdown, and high shutdown.

Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature.

The battle switch does not override the emergency stop and overspeed shutdown.

When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/generator damage can occur.

When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5— Event History.

Shutdown Type A and Shutdown Type B. Choose shutdown type A for standard shutdown where red lamp illuminates and alarm horn sounds.

Choose shutdown type B for shutdown where air damper indicator RDO-23 energizes for two seconds, red lamp illuminates, and alarm horn sounds.

Analog Input A07—Voltage Adjust. Analog input A07 is the voltage adjustment for paralleling applications only. This input adjusts the input up or down from the value entered in Menu 11, Voltage Regulator.

The paralleling option predefines analog input A07 as the remote adjustment. If the user chooses to use this input for another function, change the description using the Monitor II software accessory.

Note: If the analog input A07 description does not match analog volt adjust, input A07 will not function as the voltage adjust.

Identification and Descriptions. Descriptions for user inputs (auxiliary analog or auxiliary digital) may be entered using the Monitor II software accessory where the user determines the descriptions in upper and lower case.

62 Section 2 Operation TP-6200 3/06

Menu 9 Overview

MENU 9

INPUT SETUP

SETUP DIGITAL

AUXILIARY INPUTS

→

TO ANALOG INPUT

SETUP (NEXT)

DIGITAL INPUT 01

(USER DEFINED DESC)

→

DIGITAL INPUT 01

(see Group A)

→

YES/NO

DIGITAL INPUT 01

ENABLED

→

YES/NO

DIGITAL INPUT 01

INHIBIT TIME

→

?:??

DIGITAL INPUT 01

DELAY TIME

→

?:??

Press the down arrow to scroll through additional

DIGITAL auxiliary inputs

1--21 or enter the input number.

Group A

The preprogrammed selections include the following list. See

Appendix E for application and restrictions with specific engines.

WARNING Y/N

SHUTDOWN TYPE A Y/N

SHUTDOWN TYPE B Y/N

VOLTAGE RAISE

VOLTAGE LOWER

Y/N

Y/N

Group A, continued

VAR PF MODE Y/N

REMOTE SHUTDOWN Y/N

REMOTE RESET

AIR DAMPER

LOW FUEL

Y/N

Y/N

Y/N

FIELD OVERVOLTAGE Y/N

IDLE MODE ACTIVE Y/N

BATTLE SWITCH

GROUND FAULT

Y/N

Y/N

BAT CHGR FAULT

HIGH OIL TEMP

Y/N

Y/N

Group A, continued

LOW COOLANT LEVEL Y/N

LOW COOLANT TEMP Y/N

BREAKER CLOSED

ENABLE SYNCH

AFM SHUTDOWN

Y/N

Y/N

Y/N

KNOCK SHUTDOWN Y/N

DETON WARNING Y/N

DETON SHUTDOWN Y/N

LOW FUEL SHUTDOWN Y/N

SETUP ANALOG

AUXILIARY INPUTS

→

ANALOG INPUT XX

(USER DEFINED DESC)

→

ANALOG INPUT XX

→

WARNING ENABLED Y/N

ANALOG INPUT XX

→

SHUTDOWN ENABLED Y/N

ANALOG INPUT XX

INHIBIT TIME

→

?:??

TO DIGITAL INPUT

SETUP (PREVIOUS)

ANALOG INPUT XX

WARN DELAY TIME

→

?:??

ANALOG INPUT XX

SDWN DELAY TIME

→

?:??

ANALOG INPUT XX

LO SDWN VALUE

→

??

ANALOG INPUT XX

LO WARN VALUE

→

??

ANALOG INPUT XX

HI WARN VALUE

→

??

ANALOG INPUT XX

HI SDWN VALUE

→

??

TP-6200 3/06 Section 2 Operation 63

2.8.10 Menu 10—Output Setup

Menu 10 displays the setup of user-defined system, digital, and analog status and fault outputs and relay driver outputs (RDO) 1--31. These RDO outputs provide a multitude of choices for configuring customized auxiliary outputs.

Additional individual outputs are available for monitoring, diagnostics, and control functions.

The user must enable the programming mode to edit the display.

Note: Some data require entry using a PC in the

Remote Programming mode. See the Monitor

Software Operation Manual for details.

Note: See Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.

Common Faults

The user can program a single fault comprised of faults from 3 common fault programs—system, digital, and analog faults.

Up to 62 user-defined system status events and faults are available. See Group B on the following pages for specific descriptions. The NFPA 110 faults are part of

Menu 10 Overview

MENU 10

OUTPUT SETUP the system fault program and are comprised of

15 individual faults shown on the next page.

The user can select up to 21 user-defined digital status events and faults designated as D01 to D21. Each of the

21 status events and faults are assignable as shutdowns or warnings.

The user can select up to 7 user-defined analog status events and faults designated as A01 to A07. Each of the

7 status events and faults are assignable as shutdowns or warnings with high or low settings for a total of up to

7 status events and fault functions.

Relay Driver Outputs (RDOs)

Up to 31 RDOs are available using the system, digital, and analog status events and faults. RDOs provide only the driver. The contact relays that interface with other equipment are optional.

Note: Func(tion) Used By (RDO) XX Reassign? error message appears when the user attempts to duplicate an existing RDO selection.

Note: Cannot Change NFPA is Enabled. error message appears when the user attempts to modify RDO setting defaulted as NFPA 110 requirement.

DEFINE COMMON

FAULTS

→

SYSTEM EVENTS

→

DIGITAL INPUTS

→

ANALOG INPUTS

→

COMMON FAULT

(see Group B)

Y/N COMMON FAULT

(see Group C)

Y/N COMMON FAULT Y/N

(see Group D)LO WARNING→

COMMON FAULT Y/N

HI WARNING

→

Press down arrow to scroll through available faults.

Press down arrow to scroll through digital auxiliary inputs.

Press down arrow to scroll through analog auxiliary inputs.

COMMON FAULT Y/N

LO SHUTDOWN

→

COMMON FAULT Y/N

HI SHUTDOWN

→

RELAY DRV OUT XX

(see Group E)

→

SYSTEM EVENTS

→

DIGITAL INPUTS

→

ANALOG INPUTS

→

Press down arrow to scroll through RDO’s 1--31 or enter

RDO number.

RELAY DRV OUT XX Y/N

(see Group B)

RELAY DRV OUT XX

(see Group C)

Y/N RELAY DRV OUT XX Y/N

(see Group D)LO WARNING→

RELAY DRV OUT Y/N

HI WARNING

→

Press down arrow to scroll through available RDO faults.

Press down arrow to scroll through RDO digital auxiliary inputs.

Press down arrow to scroll through RDO analog auxiliary inputs.

RELAY DRV OUT Y/N

LO SHUTDOWN

→

RELAY DRV OUT Y/N

HI SHUTDOWN

→

64 Section 2 Operation TP-6200 3/06

Menu 10 Overview, continued

Group B

For defined system events, choose from the following

62 status events and faults by changing selection to

YES. See Appendix E for application and restrictions with specific engines.

EMERGENCY STOP

OVER SPEED

OVER CRANK

HI COOL TEMP SHUTDWN

OIL PRESS SHUTDOWN

LOW COOLANT TEMP

(non-ECM engines)

LOW FUEL

HI COOL TEMP WARNING

OIL PRES WARNING

MASTER NOT IN AUTO

NFPA 110 FAULT*

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

BATTERY CHARGE FAULT

SYSTEM READY

LOSS OF ECM COMM

(ECM engines)

NO OIL PRESS SIGNAL

HI OIL TEMP

NO COOL TEMP SIGNAL

LOW COOLANT LEVEL

SPEED SENSOR FAULT

LOCKED ROTOR

MASTER SWITCH ERROR

MASTER SWITCH OPEN

MASTER SWITCH TO OFF

AC SENSING LOSS

OVER VOLTAGE

UNDER VOLTAGE

WEAK BATTERY

OVER FREQUENCY

UNDER FREQUENCY

LOAD SHED KW OVER

LOAD SHED UNDER FREQ

OVER CURRENT

EPS SUPPLYING LOAD

INTERNAL FAULT

DELAY ENG COOLDOWN

DELAY ENG START

STARTING AID

GENERATOR RUNNING

AIR DAMPER CONTROL

GROUND FAULT

EEPROM WRITE FAILURE

CRITICAL OVERVOLTAGE

ALTERNATOR PROTECTION

SHUTDOWN

AIR DAMPER INDICATOR

DEFINED COMMON FAULT

(RDO only)

[

SCRDOs 1--4 (software controlled RDOs)

*NFPA 110 FAULT

The 15 NFPA 110 Fault

Alarms include the following:

OVERSPEED

OVERCRANK

HIGH COOLANT TEMP

SHUTDOWN

OIL PRESSURE

SHUTDOWN

LOW COOLANT

TEMPERATURE

HIGH COOLANT TEMP

WARNING

OIL PRESSURE

WARNING

LOW FUEL

MASTER NOT IN AUTO

BATTERY CHARGER

FAULT

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

LOW COOLANT LEVEL

EPS SUPPLYING LOAD

AIR DAMPER INDICATOR

[DEFINED COMMON

FAULT

The 5 defined common faults include the following:

EMERGENCY STOP

HI COOL TEMP

SHUTDOWN

OIL PRESS SHUTDOWN

OVERCRANK

OVERSPEED

TP-6200 3/06

Group B, continued

Paralleling applicatons:

SD REVERSE POWER

SD OVER POWER

SD LOSS OF FIELD

SD OVERCURRENT PR

COMMON PR OUTPUT

IN SYNCH

BREAKER TRIP

Waukesha-powered models:

FUEL VALVE RELAY

PRELUBE RELAY

AFM REMOTE START

NO OIL TEMP SIGNAL

HI OIL TEMP WARNING

NO AIR TEMP SIGNAL

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

AFM ENG START DELAY

DDC/MTU engine with MDEC:

HI OIL TEMP WARNING

INTAKE AIR/TEMP WARN

INTAKE AIR TEMP SDWN

MDEC YELLOW ALARM

MDEC RED ALARM

BLOCK HEATER CONTROL

LOW COOL TEMP SDOWN

LOAD SHED OVER TEMP

Group C

Up to 21 user-defined digital status events and fault inputs designated as D01 to D21 can result in a digital input common fault.

Group D

Up to 7 analog inputs, userdefined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high or low settings.

Group E

Choose up to 31 status event and fault RDOs from the following:

SYSTEM FAULTS

(see Group B, 46 Items)

DIGITAL INPUTS

(see Group C, 21 Items)

ANALOG INPUTS

(see Group D, 7 Items)

Section 2 Operation 65

2.8.11 Menu 11—Voltage Regulator

Menu 11 displays setup of the voltage regulator functions including line-to-line voltages, underfrequency unloading

(volts per Hz), reactive droop, power factor, and kVAR adjustments.

Adjust the frequency at the generator set’s governor before making voltage regulator adjustments.

The user must enable the programming mode to edit the display.

Menu 11 Overview

MENU 11

VOLTAGE REGULATOR

Note: The individual line-to-line voltages are displayed for review purposes only.

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Note: Voltage regulator gain is used for adjusting voltage stability and/or response.

Note: Utility gain is used for VAR or PF stability adjust while paralleling to a utility.

AVG L-L V

VOLT ADJ

#

?.?

→

L1-L2 VOLTS

#

UNDER FREQ UNLOAD

ENABLED

→

Y/N

FREQUENCY

SETPOINT

REACTIVE DROOP

ENABLED

VAR CONTROL

ENABLED

PF CONTROL

ENABLED

→

Y/N

.8 PF RATED LOAD

VOLTAGE DROOP

→

Y/N

TOTAL KVAR

KVAR ADJ

→

Y/N

AVERAGE PF

PF ADJ

→

L2-L3 VOLTS (3 PHASE)

#

→

L3-L1 VOLTS (3 PHASE)

#

→

# HZ

→

?.? HZ

SLOPE

?.? VOLTS-PER-CYCLE

→

→

?.?%

#

→

?.?

#

→

?.?

GENERATING/

ABSORBING

LAGGING/

LEADING

Y/N

→

Y/N

Y/N

→

Y/N

REGULATOR GAIN ADJ

GAIN #

UTILITY GAIN ADJUST

GAIN #

RESET REGULATOR

DEFAULTS?

Y/N

66 Section 2 Operation TP-6200 3/06

2.8.12 Menu 12—Calibration

Menu 12 provides calibration of the voltage sensing logic and displays. Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment.

The user must enable the programming mode to edit the display.

Connect a meter with a minimum accuracy of

±1% to the output leads to calibrate the voltage-sensing logic.

Configure the generator set controller for the system operating configuration using Menu 7—Generator

System.

If the generator set has a digital voltage regulator, adjust the generator set voltage using

Menu 11—Voltage Regulator. Adjust the frequency at the generator set governor before making calibration adjustments.

Menu 12 Overview

MENU 12

CALIBRATION

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Note: View up to 7 user-defined analog inputs

A01--A07.

See Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.

Note: Analog input 7 is predefined as voltage adjust when the paralleling option is included and no calibration is required.

SCALE AC ANALOG

INPUTS

GEN VOLTAGE LN GEN VOLTAGE LL GEN AMPS LOAD VOLTAGE LN

TO SCALE AUX. ANALOG

INPUTS SETUP (NEXT)

RESTORE DEFAULTS Y/N

GEN L1--L0 V

CALIB REF

#

?

GEN L1--L2 V

CALIB REF

#

?

GEN L1 AMPS

CALIB REF

#

?

LOAD L1--L0 V #

CALIB REF (PARALLEL) ?

GEN L2--L0 V

CALIB REF

#

?

GEN L2--L3 V

CALIB REF

(3 PHASE)

#

?

GEN L2 AMPS

(3 PHASE)

#

CALIB REF ?

GEN L3--L0 V

CALIB REF

(3 PHASE)

#

?

GEN L3--L1 V

CALIB REF

(3 PHASE)

#

?

GEN L3 AMPS

CALIB REF

(3 PHASE)

#

?

LOAD L3--L0 V #

CALIB REF (PARALLEL) ?

CALIBRATE REGULATOR?

Y/N

SCALE AUX. ANALOG

INPUTS

ZERO AUX. ANALOG

INPUTS?

Y/N

ANALOG XX

SCALE VALUE 1

#

?

Press YES or NO. Text appears on display lower line.

Pressing ENTER confirms

YES or NO selection.

SCAL 1

SCAL 2

# V

# V

ANALOG XX

SCALE VALUE 2

#

?

SCAL 1

SCAL 2

# V

# V

TP-6200 3/06

TO AC ANALOG INPUTS

SETUP (PREVIOUS)

Section 2 Operation 67

2.8.13 Menu 13—Communications

Menu 13 provides local or remote access to the control logic.

Use the LAN (local area network) to gain remote access to multiple devices/addresses.

Enable the local programming mode to edit the display using the keypad and digital display or the remote programming mode to edit the display using a PC. Use the Monitor Software

Operation Manual when accessing this menu, programming from a remote location, and determining address and system identification information.

See the Modbus r Communications Protocol Operation

Manual for a list of Modbus r registers for the 550

Controller.

Menu 13 Overview

MENU 13

COMMUNICATIONS

PROTOCOL

KBUS

→

PROTOCOL

MODBUS

KBUS ONLINE Y/N

MODBUS ONLINE

→

Y/N

CONNECTION TYPE

(USER DEFINED)

PRIMARY PORT

(USER DEFINED)

ADDRESS

(LAN Connections)

→

Y/N

CONNECTION TYPES

LOCAL SINGLE

LOCAL LAN

LOCAL LAN CONV

REMOTE SINGLE

REMOTE LAN

REMOTE LAN CONV

Y/N

Y/N

Y/N

Y/N

Y/N

Y/N

→

PRIMARY PORTS

RS-232

RS-485 ISO 1

?

Y/N

Y/N

CONNECTION TYPE

(USER DEFINED)

PRIMARY PORT

(USER DEFINED)

ADDRESS

BAUD RATE

(USER DEFINED)

→

Y/N

→

Y/N

CONNECTION TYPES

SINGLE

CONVERTOR

PRIMARY PORTS

RS-232

RS-485

Y/N

Y/N

Y/N

Y/N

?

→

Y/N

BAUD RATES

9600

19200

Y/N

Y/N

SYSTEM ID

(Remote Connections)

?

BAUD RATE

(USER DEFINED)

→

Y/N

BAUD RATES

1200

2400

9600

Y/N

Y/N

Y/N

Modbus r is a registered trademark of Schneider Electric.

68 Section 2 Operation TP-6200 3/06

2.8.14 Menu 14—Programming Mode

Menu 14 provides local or remote access to the programming function. The user enters a password to access the programming mode.

Note: Log into the local programming mode to edit the programming access code. The factory default access code is the number 0.

Use Menu 14 to change the access code. Record the new number and give the access code only to authorized individuals. Should the controller logic not accept the access code or if the new code number is lost, contact your local authorized distributor/dealer for password information.

The user chooses one of three programming modes:

D

D

D

Local—using the controller keypad

Remote—using a PC

Off—no programming is permitted

Note: Use the generator set controller to initially set up remote programming.

Remote programming cannot be accessed from a PC unless the controller is first set for remote programming using Menu 14.

Menu 14 Overview

MENU 14

PROGRAMMING MODE

PROGRAMMING MODE

LOCAL

→

Y/N

PROGRAMMING MODE

REMOTE

→

Y/N

PROGRAMMING MODE

CHANGE ACCESS CODE

→

PROGRAMMING MODE

ENTER OLD CODE

→

#

PROGRAMMING MODE

OFF

→

Y/N

PROGRAMMING MODE

ENTER NEW CODE

→

#

TP-6200 3/06 Section 2 Operation 69

2.8.15 Menu 15—Paralleling Relays (PR)

Menu 15 provides paralleling relay setup and time delays for units with the paralleling protection option.

This menu will only be visible and accessible if this option is included. The shutdown (SD) settings override those in menu 7 and/or menu 8.

Menu 15 Overview

MENU 15

PARALLELING RELAYS

→

PR OVERVOLTAGE

?%

→

# VAC

TIME DELAY

? SEC

PR UNDERVOLTAGE

?%

→

# VAC

TIME DELAY

? SEC

PR OVERFREQUENCY

?%

→

# HZ

TIME DELAY

? SEC

PR UNDERFREQUENCY

?%

→

# HZ

TIME DELAY

? SEC

→

→

→

→

PR REVERSE POWER

?%

→

# KW

TIME DELAY

? SEC

SD REVERSE POWER

?%

→

# KW

TIME DELAY

? SEC

PR OVER POWER

?%

→

# KW

TIME DELAY

? SEC

→

# KW

TIME DELAY

? SEC

SD OVER POWER

?%

PR LOSS OF FIELD

?%

→

# KVAR

TIME DELAY

? SEC

→

→

→

→

SD LOSS OF FIELD

?%

→

# KVAR

TIME DELAY

? SEC

PR OVER CURRENT VR

?%

→

# AMPS

TIME DELAY

? SEC

SD OVER CURRENT VR

?%

→

# AMPS

TIME DELAY

? SEC

SYNC VOLTAGE MATCH

? VAC

→

SYNC FREQ MATCH

? HZ

→

→

→

→

SYNC PHASE MATCH

? DEG

→

TIME DELAY

? SEC

→

70 Section 2 Operation TP-6200 3/06

2.8.16 Menu 20—Factory Setup

(Version 2.10)

Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software

(code) version.

Menu 20 Overview

MENU 20

FACTORY SETUP

FINAL ASSEMBLY DATE

DD/MM/YY

FINAL ASSEMBLY

CLOCK NO ?

OPERATING DAYS #

MODEL NO #

SPEC NO #

GENSET SERIAL NO #

ALTERNATOR PART NO #

ENGINE PART NO #

SERIAL NO #

CONTROLLER SERIAL NO

CODE VERSION

COPYRIGHT

SETUP LOCKED

#

XXXX

YES

TP-6200 3/06 Section 2 Operation 71

2.8.17 Menu 20—Factory Setup

(Version 2.21)

Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software

(code) version. The temperature sensor setup applies to non-ECM engines only.

Menu 20 Overview

MENU 20

FACTORY SETUP

FINAL ASSEMBLY DATE

DD/MM/YY

FINAL ASSEMBLY

CLOCK NO ?

OPERATING DAYS #

MODEL NO #

SPEC NO #

GENSET SERIAL NO #

ALTERNATOR PART NO #

ENGINE PART NO

TEMP SENSOR

GM31045--X

SERIAL NO

#

YES

#

TEMP SENSOR

GM16787

NO TEMP SENSOR

GM17362

CONTROLLER SERIAL NO

CODE VERSION

COPYRIGHT

SETUP LOCKED

#

XXXX

YES

NO

72 Section 2 Operation TP-6200 3/06

2.9 Local Programming Mode On

The Local Programming Mode On section explains how to program the generator set controller logic.

Each menu contains a step-by-step procedure for programming the various logic groups. See Section 1,

Specifications, for setting ranges and default settings.

Please read and understand the entire Local

Programming Mode On section before attempting any programming. The factory settings are adjustable and programming without full understanding of the logic features and functions can cause inadvertent changes.

Refer to Menu 14—Programming Mode for information regarding menu programming activation.

After completing the programming always place the controller back in the Programming Mode Off position to prevent inadvertent program changes.

The programming feature alters stored settings and changes characteristics of the logic. Do not operate the controller with the program mode on unless there is a need to edit program logic or clear stored data. Limit programming responsibilities to individuals with training and authority.

The product application requires expertise in the design and programming of control systems. Only qualified personnel should program, install, alter, and apply this product.

Use Section 2.8, Reviewing the Menu Displays, to view the generator set operation data and review previously programmed information and to review the data when no programming is necessary.

D

D

D

Menus displaying the # symbol represent one of the following data types:

System-calculated data

System-measured data

User-entered data

Menus displaying the ? symbol require the user to enter data.

Menus displaying the * symbol represent access code or password type entries. Actual key entry does not display.

See Section 2.6.3, Request and Error Messages, for error display messages and explanations should they appear while navigating through the menus.

All menu displays apply to both single-phase and three-phase voltages unless otherwise noted as (1 PH) or (3 PH) on the menu overview. The phase designation does not appear in the actual menu displays.

Note: Place the generator set master switch in the

OFF/RESET position when using the programming mode on.

Note: Use the generator set controller to initially set up the remote programming. Set the controller for remote programming using Menu 14 and remote communication using Menu 13 before attempting remote programming.

Note: Press any key on the keypad to activate the controller panel display. The panel display turns off 5 minutes after the last keypad entry.

Note: Press the Reset Menu key to clear the Error display.

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Refer to Figure 2-18 for a quick reference to the menu number and description.

12

13

14

15

9

10

7

8

11

20

Menu No.

Menu Description

1 Generator Monitoring (Three-Phase Connections)

1

2

Generator Monitoring (Single-Phase Connections)

Engine Monitoring

5

6

3

4

Analog Monitoring

Operational Records

Event History

Time and Date

Generator System

Time Delays

Input Setup

Output Setup

Voltage Regulator

Calibration

Communication

Programming Mode

Paralleling Relays

Factory Setup Menu

Figure 2-18 Menu Number and Description

TP-6200 3/06 Local Programming Mode On Section 2 Operation 73

2.9.1

Menu 1—Generator Monitoring

Menu 1 provides generator output data including line-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent of maximum kW, total kVA and total kVAR displays.

Menu 1 displays three-phase and single-phase connections separately.

Note: For the auto-scroll function, press ENTER at the

V & A Summary menu. Press the Reset Menu key or Menu Right

→ key to stop the auto-scroll function.

Note: A right arrow from any submenu moves to the next submenu header.

Menu 1—Generator Monitoring (Three-Phase Connections)

Menu 1 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 1

Press the Enter key.

MENU 1

GENERATOR MONITORING

VOLTS & AMPS

→

Displays the menu number and name.

Displays the volts and amps heading.

L1-L2 VOLTS

L1 AMPS

L2-L3 VOLTS

L2 AMPS

L3-L1 VOLTS

L3 AMPS

L1-L0 VOLTS

L1 AMPS

L2-L0 VOLTS

L2 AMPS

L3-L0 VOLTS

L3 AMPS

#

#

#

#

#

#

#

#

#

#

#

#

Displays L1 and L2 volts and L1 amps.

Displays L2 and L3 volts and L2 amps.

Displays L3 and L1 volts and L3 amps.

Displays L1-L0 volts and L1 amps.

Displays L2 and L0 volts and L2 amps.

Displays L3-L0 volts and L3 amps.

FREQUENCY # HZ

MENU 1

GENERATOR MONITORING

VOLTS & AMPS

→

Displays the frequency.

Returns the user to the menu number and name.

Returns the user to volts and amps heading.

V & A SUMMARY

→

V

V

L1-L2 L2-L3 L3-L1

# # #

L1-L0 L2-L0 L3-L0

# # #

Displays the volts and amps summary heading.

Displays L1-L2, L2-L3, and L3-L1 volts.

Displays L1-L0, L2-L0, and L3-L0 volts. (3 ph. only)

74 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 1—Generator Monitoring (Three-Phase Connections), continued

Menu 1 Displays with Key Entries

Key

Entry Display Description

A L1

#

V & A SUMMARY

L2

#

L3

#

→

Displays L1, L2, and L3 amps.

Returns the user to the volts and amps summary heading.

POWER KW

→

Displays the power kilowatt heading.

TOTAL KW

PF #

#

LEADING/LAGGING

L1 KW

PF #

L2 KW

PF #

#

LEADING/LAGGING

#

LEADING/LAGGING

L3 KW

PF #

#

LEADING/LAGGING

TOTAL KW

% OF RATED KW

POWER KW

#

#

→

Displays total kilowatts and leading or lagging power factor.

Displays total L1 kilowatts and leading or lagging power factor.

Displays total L2 kilowatts and leading or lagging power factor.

Displays total L3 kilowatts and leading or lagging power factor.

Displays the total kW and percent of rated kilowatts.

Returns the user to the power kilowatt heading.

POWER KVAR

→

Displays the power kVAR heading.

TOTAL KVAR

ABSORBING/GENERATING

#

L1 KVAR

ABSORBING/GENERATING

#

L2 KVAR

ABSORBING/GENERATING

#

L3 KVAR

ABSORBING/GENERATING

#

POWER KVAR

→

Displays total kVAR, absorbing or generating.

Displays L1 kVAR, absorbing or generating.

Displays L2 kVAR, absorbing or generating.

Displays L3 kVAR, absorbing or generating. (3 ph. only)

Returns the user to power kVAR heading.

POWER KVA

→

Displays the power kVA heading.

TOTAL KVA #

Displays total kVA.

L1 KVA #

Displays L1 kVA.

L2 KVA #

Displays L2 kVA.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 75

Menu 1—Generator Monitoring (Three-Phase Connections), continued

Menu 1 Displays with Key Entries

Key

Entry Display Description

L3 KVA #

Displays L3 kVA.

POWER kVA

→

Returns the user to power kVA heading.

Menu 1—Generator Monitoring (Single-Phase Connections)

Menu 1 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 1

Press the Enter key.

MENU 1

GENERATOR MONITORING

VOLTS & AMPS

→

Displays the menu number and name.

Displays the volts and amps heading.

L1-L2 VOLTS

L1 AMPS

L1-L2 VOLTS

L2 AMPS

L1-L0 VOLTS

L1 AMPS

L2-L0 VOLTS

L2 AMPS

#

#

#

#

#

#

#

#

Displays L1 and L2 volts and L1 amps.

Displays L1 and L2 volts and L2 amps.

Displays L1-L0 volts and L1 amps.

Displays L2 and L0 volts and L2 amps.

Displays the frequency.

FREQUENCY # HZ

MENU 1

GENERATOR MONITORING

VOLTS & AMPS

→

Returns the user to the menu number and name.

Returns the user to volts and amps heading.

V & A SUMMARY

→

Displays the volts and amps summary heading.

V L1-L2 L1-L0 L2-L0

# # #

A L1

#

V & A SUMMARY

L2

#

→

Displays L1-L2, L1-L0, and L2-L0 volts.

Displays L1 and L2 amps.

Returns the user to the volts and amps summary heading.

76 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 1—Generator Monitoring (Single-Phase Connections), continued

Menu 1 Displays with Key Entries

Key

Entry Display Description

POWER KW

→

Displays the power kilowatt heading.

TOTAL KW

PF #

#

LEADING/LAGGING

L1 KW

PF #

L2 KW

PF #

#

LEADING/LAGGING

#

LEADING/LAGGING

TOTAL KW

% OF RATED KW

POWER KW

#

#

→

Displays total kilowatts and leading or lagging power factor.

Displays total L1 kilowatts and leading or lagging power factor.

Displays total L2 kilowatts and leading or lagging power factor.

Displays the total kW and percent of rated kilowatts.

Returns the user to the power kilowatt heading.

POWER KVAR

→

Displays the power kVAR heading.

TOTAL KVAR

ABSORBING/GENERATING

#

L1 KVAR

ABSORBING/GENERATING

#

L2 KVAR

ABSORBING/GENERATING

#

POWER KVAR

→

Displays total kVAR, absorbing or generating.

Displays L1 kVAR, absorbing or generating.

Displays L2 kVAR, absorbing or generating.

Returns the user to power kVAR heading.

POWER KVA

→

Displays the power kVA heading.

TOTAL KVA #

Displays total kVA.

L1 KVA #

Displays L1 kVA.

L2 KVA #

Displays L2 kVA.

POWER kVA

→

Returns the user to power kVA heading.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 77

2.9.2

Menu 2—Engine Monitoring

Menu 2 provides engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooled-down temperature setpoints.

Menu 2—Engine Monitoring

Menu 2 Displays with Key Entries

Key

Entry Display Description

The detailed engine monitoring feature requires an DDC

DDEC-equipped engine or DDC/MTU MDEC-equipped engine.

Note: A right arrow from any submenu moves to the next submenu header.

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 2

Press the Enter key.

MENU 2

ENGINE MONITORING

ENGINE MONITORING

BASIC

→

OIL PRESSURE

COOLANT TEMP

# PSI

# F

INTAKE AIR

OIL TEMP (Waukesha)

ENGINE RPM

LOCAL BATT VDC

# F

# F

#

#

HCT WARN

HCT SDOWN

# F

# F

LOP WARN

LOP SDOWN

ENGINE WARMED UP

# F

# PSI

# PSI

ENGINE COOLED DOWN

# F

MENU 2

ENGINE MONITORING

ENGINE MONITORING

BASIC

→

(DDEC-Equipped Engines only)

ENGINE MONITORING

DETAILED

ENGINE FUEL

→

→

Displays the menu number and name.

Displays the basic engine monitoring heading.

Displays the oil pressure and coolant temperature.

Displays the intake air and oil temperature

(Waukesha-powered models only)

Displays the engine rpm and local battery VDC.

Displays the high coolant temperature warning and shutdown setpoints.

Displays the low oil pressure warning and shutdown setpoints.

Displays the engine warmed up temperature setpoint.

Displays the engine cooled down temperature setpoint.

Returns the user to the menu number and name.

Returns the user to basic engine monitoring heading.

Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature requires an DDC DDEC-equipped engine.

Displays the engine fuel subheading.

78 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 2—Engine Monitoring (DDEC-Equipped Engines), continued

Menu 2 Displays with Key Entries

Key

Entry Display Description

FUEL PRES

FUEL TEMP

# PSI

# F

Displays the fuel pressure and fuel temperature.

FUEL RATE # GPH

Displays the fuel rate per hour.

TP-6200 3/06

USED LAST RUN

# GAL

ENGINE MONITORING

DETAILED

ENGINE FUEL

→

→

Displays the amount of fuel used during the last run.

Returns the user to the detailed engine monitoring heading.

Displays the engine fuel subheading.

ENGINE COOLANT

→

Displays the engine coolant subheading.

Displays the coolant pressure and coolant temperature.

COOLANT PRES

COOLANT TEMP

COOLANT LEVEL

ENGINE COOLANT

# PSI

# F

#%

→

Displays the coolant level as a percent of full capacity.

Returns the user to engine coolant subheading.

ENGINE OIL

→

OIL PRES

OIL TEMP

OIL LEVEL

CRANKCASE PRES

ENGINE OIL

# PSI

# F

#%

# PSI

→

ENGINE MISC

ECM BATT VDC

AMBIENT TEMP

ENGINE MODEL NO.

#

ENGINE SERIAL NO.

#

UNIT NO.

ECM S/N

ENGINE MISC

→

#

# F

Displays the engine oil subheading.

Displays the oil pressure and oil temperature.

Displays the oil level as a percent of full capacity and crankcase pressure.

Returns the user to engine oil subheading.

Displays the miscellaneous engine subheading.

Displays the engine ECM battery VDC and ambient temperature.

Displays the engine model number.

Displays the engine serial number.

#

#

→

Displays the unit number and ECM serial number.

Returns the user to the miscellaneous engine subheading.

Local Programming Mode On Section 2 Operation 79

Key

Entry Display

(MDEC-Equipped Engines only)

ENGINE MONITORING

DETAILED

ENGINE FUEL

→

→

FUEL PRES

FUEL TEMP

# PSI

# F

CHG AIR PRESSURE

CHG AIR TEMP

# PSI

# F

FUEL RATE * # GPH

DAILY FUEL USED * # GAL

TOTAL FUEL USED * # GAL

ENGINE MONITORING

DETAILED

ENGINE FUEL

→

→

ENGINE OIL

→

OIL PRES

OIL TEMP

ENGINE OIL

ENGINE MISC

ECU SUPPLY VDC

AMBIENT TEMP

ECU HOURS

# PSI

# F

→

→

#

# F

#

ECU FAULT CODES

ENGINE MISC

#

→

Description

Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature requires a DDC/MTU MDEC-equipped engine.

Displays the engine fuel subheading.

Displays the fuel pressure and fuel temperature.

Displays the charge air pressure and temperature.

Displays the fuel rate per hour.

Displays the amount of fuel used during the last 24 hours.

Displays the amount of fuel used since the last reset.

Returns the user to the detailed engine monitoring heading.

Displays the engine fuel subheading.

Displays the engine oil subheading.

Displays the oil pressure and oil temperature.

Returns the user to engine oil subheading.

Displays the miscellaneous engine subheading.

Displays the engine ECU supply VDC and ambient temperature.

Displays the ECU operating hours.

Displays the ECU fault codes.

Returns the user to the miscellaneous engine subheading.

* While these menu displays do appear on the 550 controller, the engine ECM is not currently set up to provide this data.

80 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.3

Menu 3—Analog Monitoring

Menu 3 provides the battery voltage and up to 7 userdefined analog monitoring items dependent upon the generator system.

The User Defined Desc display refers to a description entered into the controller using the PC software. This description remains as the display for future review until changed by the PC software user. The display has

20 characters maximum.

Paralleling Option.

When the paralleling option is selected, analog input 7 is predefined as voltage adjust.

The voltage of this input will define the adjustment from the setting in Menu 11, Voltage Regulator. The normal

Menu 3—Analog Monitoring (ECM Engines)

Menu 3 Displays with Key Entries

Key

Entry Display Description analog input range of 0.5 to 4.5 corresponds to a

±10% of system voltage. The midpoint 2.5 volts corresponds to 0 volts offset. If there is no connection at analog input

7, no voltage adjust is recognized.

Note: If the analog display shows O/R (out of range), no input is connected.

Note: Some data require entry using a PC in the

Remote Programming mode. See the Monitor

Software Operation Manual for details.

Note: See Figure 2-9 in User Inputs for factory reserved inputs which are not user selectable.

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 3

Press the Enter key.

MENU 3

ANALOG MONITORING

LOCAL BATT VDC #

Displays the menu number and name.

Displays the local battery VDC.

Displays analog 01 and the user-defined description.

ANALOG 01

(USER DEFINED DESC)

ANALOG 02

(USER DEFINED DESC)

ANALOG 03

(USER DEFINED DESC)

ANALOG 04

(USER DEFINED DESC)

ANALOG 05

(USER DEFINED DESC)

ANALOG 06

(USER DEFINED DESC)

ANALOG 07

(USER DEFINED DESC)

OR

ANALOG 07

VOLTAGE ADJUST

ANALOG MONITORING

MENU 3

#

#

#

#

#

#

#

#

Displays analog 02 and the user defined description.

Displays analog 03 and the user-defined description.

Displays analog 04 and the user-defined description.

Displays analog 05 and the user-defined description.

Displays analog 06 end the user-defined description.

Displays analog 07 and the user-defined description.

Displays analog 07 voltage adjustment VDC value for paralleling applications only.

Returns user to analog monitoring heading.

Note: Enter data using a PC in the Remote Programming Mode.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 81

Menu 3—Analog Monitoring (Non-ECM Engines), continued

Menu 3 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 3

Press the Enter key.

MENU 3

ANALOG MONITORING

LOCAL BATT VDC #

Displays the menu number and name.

Displays the local battery VDC.

Displays analog 01 coolant temperature.

ANALOG 01

(USER DEFINED DESC)

ANALOG 02

(USER DEFINED DESC)

#

#

ANALOG 03

(USER DEFINED DESC)

OR

ANALOG 03

INTAKE AIR TEMP WARN

#

#

ANALOG 04

(USER DEFINED DESC)

OR

ANALOG 04

OIL TEMP WARN

ANALOG 05

(USER DEFINED DESC)

ANALOG 06

(USER DEFINED DESC)

ANALOG 07

(USER DEFINED DESC)

OR

ANALOG 07

VOLTAGE ADJUST

#

#

#

#

#

#

ANALOG MONITORING

MENU 3

Displays analog 02 oil pressure.

Displays analog 03 and the user-defined description.

Displays analog 03 intake air temperature warning value for

Waukesha-powered models only.

Displays analog 04 and the user-defined description.

Displays analog 04 oil temperature warning value for Waukeshapowered models only.

Displays analog 05 and the user-defined description.

Displays analog 06 end the user-defined description.

Displays analog 07 and the user-defined description.

Displays analog 07 voltage adjustment VDC value for paralleling applications only. Note: This function may be overridden by changing the description using the optional Monitor II software.

Returns user to analog monitoring heading.

Note: Enter data using a PC in the Remote Programming Mode.

82 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.4

Menu 4—Operational Records

Menu 4 provides the generator set operational records including the operating start date, last logged maintenance, total run time loaded and unloaded, run time since the last maintenance, number of starts, and number of running days.

Run Time Feature. This menu provides the ability to run the generator set for a designated time. After the run time elapses. the generator set shuts down and functions in the standby mode. The generator set controller does not provide weekly scheduled exercise periods.

Generator set connected to an automatic transfer switch. Should a utility power failure occur while the unit is in the run time mode, the controller bypasses the run time mode and functions in the standby (backup) mode. If the utility power returns, the generator set continues to run for the duration of the run time period if not timed out.

Note: Press the STOP PROG RUN key to stop the generator set when in the run time mode, if necessary.

After performing maintenance, enter yes to reset records reflecting the current day. The user must enable the programming mode to edit the display.

Menu 4—Operational Records

Menu 4 Displays with Key Entries

Key

Entry Display

TP-6200 3/06

ENTER MENU NO. 1--15

MAIN MENU NUMBER 4

Description

Input a menu number.

Press the Enter key.

MENU 4

OPERATIONAL RECORDS

FACTORY TEST DATE

##-###-##

Displays the menu number and name.

Displays the factory test date (day-month-year).

TOTAL RUN TIME

HRS

TOTAL RUN TIME

LOADED HRS

TOTAL RUN TIME

UNLOADED HRS

TOTAL RUN TIME

KW HRS

NO. OF STARTS

ENGINE START?

COUNTDOWN

RUN TIME

RUN TIME

ENGINE START?

COUNTDOWN

#

#

#

Displays the total run time (hours:minutes).

Displays the total run time for loaded hours.

Displays the total run time for unloaded hours.

#

#

Displays the total run time in kW hours.

Displays the number of engine starts.

Y/N

→

##:##

HR:MN

→

??:??

HR:MN

→

##:##

Y/N

→

##:##

Displays the start and countdown subheading.

Displays the run time (hours:minutes) feature. When required, use the numeric keys to enter the selected run time (hours:minutes) and press the Enter key.

Confirms entry and displays the selected run time (hours:minutes). The generator set will start after activation. Note: Activate the generator set run time feature by pressing the Yes and Enter keys. See the following steps.

Returns the user to the start and countdown subheading. Enter Yes to start the generator set.

Local Programming Mode On Section 2 Operation 83

Menu 4—Operational Records, continued

Menu 4 Displays with Key Entries

Key

Entry Display Description

ENGINE START?

COUNTDOWN

YES

→

##:##

Press the Enter key.

RUN TIME HR:MN

→

##:##

RECORDS MAINT

→

Confirms the entry. The generator set will begin cranking and run based on the run time (hours:minutes) period and all previously established time (hours:minutes) delays from Menu 8—Time Delays. Note: Press the STOP PROG RUN key to stop the generator set when in the run time mode, if necessary.

Displays the records maintenance subheading.

RESET RECORDS?

→

RESET RECORDS?

YES

→

RESET RECORDS?

YES

→

Displays the reset records option. After performing maintenance or when required, enter Yes to reset.

Enter Yes to reset to the current date and press the Enter key.

Confirms the entry.

RECORDS MAINT

→

Returns the user to records maintenance subheading.

RUN TIME SINCE MAINT

TOTAL HRS #

RUN TIME SINCE MAINT

LOADED HRS

RUN TIME SINCE MAINT

UNLOADED HRS

RUN TIME SINCE MAINT

KW HRS

#

#

#

OPERATING DAYS

LAST MAINT

#

##-###-##

NO. OF STARTS

LAST MAINT

#

##-###-##

LAST START

DATE

LENGTH OF RUN

(UN)LOADED HRS

##:## AM/PM

##-###-##

#

MENU 4

OPERATIONAL RECORDS

Displays the run time since the last maintenance with total hours.

Displays the run time since last the maintenance with loaded hours.

Displays the run time since the last maintenance with unloaded hours.

Displays the run time since the last maintenance in kW hours.

Displays the operating days since the last maintenance.

Displays the number of starts since the last maintenance date

(day-month-year).

Displays last the start time (hours:minutes) and date (day-month-year).

Displays the length of last run in (un)loaded hours.

Returns the user to the operational records heading.

84 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.5

Menu 5—Event History

Menu 5 stores and displays the times and dates of up to

100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events.

Menu 5—Event History

Menu 5 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 5

Press the Enter key.

MENU 5

EVENT HISTORY

(MESSAGE TEXT)

##-###-## ##:## AM/PM

MENU 5

EVENT HISTORY

Displays the menu number and name.

Displays the message text, date (day-month-year) and time

(hours:minutes).

Scroll through up to 100 stored events.

See

Section 2.3.5, System Warning Lamp, for fault descriptions.

Returns the user to event history heading.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 85

2.9.6

Menu 6—Time and Date

Menu 6 sets the clock time and date and internal calendar. The controller uses set time for determining the exercise run time and event records. The time and date are valid only if the controller power (starting battery) remains connected.

The user must enable the programming mode to edit the display.

Menu 6—Time and Date

Menu 6 Displays with Key Entries

Key

Entry Display Description

Note: A change to the time/date is recorded as a system event. The time/date reset and other events are viewable (up to 100 events). For events that occurred prior to a date change, use the previous date as the reference point for determining the event’s actual date.

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 6

Press the Enter key.

MENU 6

TIME AND DATE

DAY OF WEEK ##-###-##

##:## AM/PM

TIME ??:?? AM/PM

Displays the menu number and name.

DAY OF WEEK ##-###-##

##:## AM/PM

DATE ??-???-??

DATE

AND

??-???-??

DATE

AND

??-???-??

AND

DAY OF WEEK ##-###-##

##:## AM/PM

Displays the day of the week, date (day-month-year), and time

(hours:minutes).

Displays the time (hours:minutes) of day entry. When required, use the numeric and am/pm keys to set the time (hours:minutes) of day and press the Enter key.

Displays the corrected time (hours:minutes) of day.

Displays the date (day-month-year) entry.

When required, use the numeric keys to set the day of the month.

Use the Menu Right

→ key to select the month.

Use the numeric keys to set the two-digit year and press the Enter key.

Displays the corrected date (day- month-year).

86 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.7

Menu 7—Generator System

Menu 7 contains the factory-preset generator set voltage and frequency data. Enter the corresponding data if the generator set requires voltage reconnection and/or frequency adjustment. It is imperative that the user enter the correct data because these settings trigger all related shutdowns.

See Section 2.6.3, Request and Error Messages, for error display messages and explanations while navigating the menus.

The user must enable the programming mode to edit the display.

Note A:Some alternators have limited voltage and frequency configurations.

Inappropriate voltage or frequency entries will cause a

RANGE ERROR message.

Note: The user defines the data shown in Menu 7. It is

NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control.

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Note: The variable speed governor (VSG) display provides the ability to parallel the generator set.

Menu 7—Generator System

Menu 7 Displays with Key Entries

Key

Entry Display

TP-6200 3/06

ENTER MENU NO. 1--15

MAIN MENU NUMBER 7

Description

Input a menu number.

Press the Enter key.

MENU 7

GENERATOR SYSTEM

OPERATING MODE

(see note)

→

YES

OPERATING MODE

STANDBY

OPERATING MODE

STANDBY

OPERATING MODE

STANDBY

OR

OPERATING MODE

PRIME POWER

OPERATING MODE

PRIME POWER

OPERATING MODE

PRIME POWER

SYSTEM VOLTAGE

LINE-LINE

SYSTEM VOLTAGE

LINE-LINE

SYSTEM FREQ

→

NO

→

YES

→

YES

?

→

NO

→

YES

→

YES

Displays the menu number and name.

Displays the operating mode selection. Note: The display sample may differ depending upon previous entries.

The previously selected operating mode appears first, either standby or prime power.

Displays the optional operating mode selection. When required, enter

YES for standby operating mode. Note: This display indicates the generator set application.

Enter YES to change the operating mode selection to standby and press the Enter key.

Confirms the entry.

Displays the optional operating mode selection. When required, enter

YES for the prime power operating mode. Note: This display indicates the generator set application.

Enter YES to change the operating mode selection to prime power and press the Enter key.

Confirms the entry.

Displays the line-to-line system voltage as entered data. When required, use the numeric keys to set new value. Press the Enter key.

Displays the corrected line-to-line system voltage. See NOTE A.

#

# HZ

Displays the system frequency as entered data. When required, use the numeric keys to set the new value. Press the Enter key.

Local Programming Mode On Section 2 Operation 87

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key

Entry Display Description

SYSTEM FREQ # HZ

PHASE

(see note)

PHASE

3 PHASE DELTA

PHASE

3 PHASE DELTA

PHASE

3 PHASE DELTA

PHASE

3 PHASE WYE

OR

PHASE

3 PHASE WYE

PHASE

3 PHASE WYE

OR

PHASE

SINGLE-PHASE

PHASE

SINGLE-PHASE

PHASE

SINGLE-PHASE

→

NO

→

YES

→

YES

→

NO

→

YES

→

YES

→

YES

→

NO

→

YES

→

YES

Displays the corrected system frequency. See NOTE A.

Displays the phase configuration selection. Note: The display sample may differ depending upon previous entries. The user-selected phase appears first, either wye, delta, or single phase.

Displays the optional phase configuration selection. When required, use the YES key to choose the delta phase configuration.

Enter YES to change the phase configuration to a delta phase configuration and press the Enter key.

Confirms the entry. See NOTE A.

Displays the optional phase configuration selection. When required, use the YES key to choose the wye phase configuration.

Enter YES to change the phase configuration to a wye phase configuration and press the Enter key.

Confirms the entry. See NOTE A.

Displays the optional phase configuration selection. When required, use the YES key to choose the single-phase configuration.

Enter YES to change the phase configuration to a single-phase configuration and press the Enter key.

Confirms the entry. See NOTE A.

KW RATING ?

Displays the generator set kW rating as entered data. When required, use the numeric keys to set the new value. Press the Enter key.

KW RATING #

Displays the corrected system kilowatt rating.

RATED CURRENT #

LOAD SHED OUTPUT

?%

LOAD SHED OUTPUT

#%

→

# KW

→

# KW

TIME DELAY MIN:SEC

→

??:??

TIME DELAY MIN:SEC

→

##:##

LOAD SHED OUTPUT

#%

→

# KW

88 Section 2 Operation

Displays the generator set rated current as entered data. Note: This is a read-only display.

Displays the load shed output setting. When required, use the numeric keys to set the new value. Press the Enter key. See Menu 10, Output

Setup for Group B User-Defined Systems Events

Displays the corrected load shed output setting.

Displays the load shed time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected load shed time (minutes:seconds) delay setting.

Returns the user to the load shed output setting.

Local Programming Mode On TP-6200 3/06

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key

Entry Display Description

OVERVOLTAGE

?%

→

# VAC

Displays the overvoltage setting. When required, use the numeric keys to set the new value. Press the Enter key.

OVERVOLTAGE

#%

TIME DELAY

→

# VAC

MIN:SEC

→

??:??

Displays the corrected overvoltage setting.

Displays the overvoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.

TIME DELAY

OVERVOLTAGE

#%

MIN:SEC

→

##:##

→

# VAC

Displays the corrected overvoltage time (minutes:seconds) delay setting.

Returns the user to the overvoltage setting.

UNDERVOLTAGE

?%

→

# VAC

UNDERVOLTAGE

#%

TIME DELAY

→

# VAC

MIN:SEC

→

??:??

TIME DELAY

UNDERVOLTAGE

#%

MIN:SEC

→

##:##

→

# VAC

Displays the undervoltage setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected undervoltage setting.

Displays the undervoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overvoltage time (minutes:seconds) delay setting.

Returns the user to the undervoltage setting.

OVERFREQUENCY

?%

OVERFREQUENCY

#%

# HZ

# HZ

UNDERFREQUENCY

?% # HZ

UNDERFREQUENCY

#% # HZ

OVERSPEED

? HZ

OVERSPEED

# HZ

# RPM

# RPM

Displays the overfrequency setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overfrequency setting.

Displays the underfrequency setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected underfrequency setting.

Displays the overspeed setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overspeed setting.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 89

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key

Entry Display Description

BATTERY VOLTAGE

(see note)

BATTERY VOLTAGE

12 VDC

→

YES

→

NO

Displays the battery voltage selection. Note: The display sample may differ depending upon previous entries.

The user-selected battery voltage appears first, either 12 VDC or 24 VDC.

Displays the 12 VDC battery voltage selection. When required, use the

YES key to choose the 12 VDC battery voltage.

BATTERY VOLTAGE

12 VDC

BATTERY VOLTAGE

12 VDC

OR

BATTERY VOLTAGE

24 VDC

BATTERY VOLTAGE

24 VDC

BATTERY VOLTAGE

24 VDC

→

YES

→

YES

→

NO

→

YES

→

YES

Enter YES to change the battery voltage to 12 VDC and press the Enter key.

Confirms the entry.

Displays the 24 VDC battery voltage selection. When required, use the

YES key to choose the 24 VDC battery voltage.

Enter YES to change the battery voltage to 24 VDC and press the Enter key.

Confirms the entry.

Displays the low battery voltage setting. When required, use the numeric keys to set the new value. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

LOW BATTERY VOLTAGE

?.? VDC

AND

LOW BATTERY VOLTAGE

?.

? VDC

LOW BATTERY VOLTAGE

#.# VDC

HIGH BATTERY VOLTAGE

?.? VDC

AND

HIGH BATTERY VOLTAGE

?.

? VDC

HIGH BATTERY VOLTAGE

#.# VDC

BLOCK HEATER ON # F

AND

BLOCK HEATER ON ? F

Displays the corrected low battery voltage setting.

Displays the high battery voltage setting.

When required, use the numeric keys to set the new value. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Displays the corrected high battery voltage setting.

Displays the block heater energize temperature setting. When required, use the numeric keys to set the new value. Applies to Detroit Diesel engines with MDEC engine controls only.

Use the numeric keys to enter the decimal value. Press the Enter key.

BLOCK HEATER ON # F

BLOCK HEATER OFF

AND

BLOCK HEATER OFF

# F

? F

Displays the corrected block heater energize temperature setting.

Displays the block heater deenergize temperature setting.

When required, use the numeric keys to set the new value. Applies to Detroit

Diesel engines with MDEC engine controls only.

Use the numeric keys to enter the decimal value. Press the Enter key.

BLOCK HEATER OFF # F

Displays the corrected block heater deenergize temperature setting.

90 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key

Entry Display Description

ENABLE VSG YES/NO

Displays the variable speed governor (VSG) yes or no selection for paralleling applications. When required, use the numeric keys to set the new value. Applies to DDC/MTU MDEC engine only.

ENABLE VSG NO

ENABLE VSG YES Entering YES enables the VSG function.

ENABLE VSG YES

Confirms the entry..

ENABLE VSG

OR

ENABLE VSG

YES

NO Entering NO disables the VSG function.

ENABLE VSG NO

ENABLE DSC YES/NO

Confirms the entry..

Displays the digital speed control (DSC) yes or no selection for paralleling applications. When required, use the numeric keys to set the new value. Applies to DDC/MTU MDEC engine only.

ENABLE DSC

ENABLE DSC

ENABLE DSC

ENABLE DSC

OR

ENABLE DSC

NO

YES

YES

YES

NO

Entering YES enables the DSC function.

Confirms the entry..

Entering NO disables the DSC function.

ENABLE DSC NO

Confirms the entry..

TP-6200 3/06 Local Programming Mode On Section 2 Operation 91

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key

Entry Display Description

METRIC UNITS

METRIC UNITS

METRIC UNITS

METRIC UNITS

OR

METRIC UNITS

METRIC UNITS

METRIC UNITS

SET NFPA-110

DEFAULTS

SET NFPA-110

DEFAULTS

SET NFPA-110

DEFAULTS

SET NFPA-110

DEFAULTS

OR

SET NFPA-110

DEFAULTS

SET NFPA-110

DEFAULTS

SET NFPA-110

DEFAULTS

MENU 7

GENERATOR SYSTEM

Y/N

NO

YES

YES

YES

NO

NO

YES

NO

NO

Y/N

NO

YES

YES

Displays the metric units selection.

Enter YES to change to metric displays and press the Enter key.

Confirms the entry.

Enter NO to change to English displays and press the Enter key.

Confirms the entry.

Displays the NFPA 110 default yes or no selection.

Note: See

Menu 10—Output Setup, Overview for a list of the NFPA-110 faults.

Enter YES to select the NFPA 110 default selection and press the Enter key.

Confirms the entry.

Enter NO to deselect the NFPA 110 default selection and press the Enter key.

Confirms the entry.

Returns the user to the generator system heading.

92 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.8

Menu 8—Time Delays

Menu 8 displays the various time delays for cyclic cranking and other engine-related starting and shutdown features.

The user must enable the programming mode to edit the display.

Cooldown Temperature Override.

This feature provides the ability to bypass (override) the generator set’s smart cooldown temperature shutdown and force the generator set to run for the full engine cooldown time delay.

If the engine is above the preset temperature and the unit is signalled to shut down, the unit will continue to run for the duration of the TDEC.

If the engine is at or below the preset temperature and the unit is signalled to shut down or the TDES is running, the unit will shut down without waiting for the time delay to expire.

Menu 8—Time Delays

Menu 8 Displays with Key Entries

Key

Entry Display

ENTER MENU NO. 1--15

MAIN MENU NUMBER 8

MENU 8

TIME DELAYS

TIME DELAY

ENGINE START

MIN:SEC

??:??

TIME DELAY

ENGINE START

TIME DELAY

STARTING AID

TIME DELAY

STARTING AID

TIME DELAY

CRANK ON

TIME DELAY

CRANK ON

MIN:SEC

##:##

MIN:SEC

??:??

MIN:SEC

##:##

MIN:SEC

??:??

MIN:SEC

##:##

TIME DELAY

CRANK PAUSE

TIME DELAY

CRANK PAUSE

MIN:SEC

??:??

MIN:SEC

##:##

TIME DELAY

ENG COOLDOWN

MIN:SEC

??:??

TIME DELAY

ENG COOLDOWN

MIN:SEC

##:##

COOLDOWN TEMPERATURE

OVERRIDE Y/N

Description

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the engine start time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected engine start time (minutes:seconds) delay setting.

Displays the starting aid time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected starting aid time (minutes:seconds) delay setting.

Displays the crank on time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected crank on time (minutes:seconds) delay setting.

Displays the crank pause time delay in minutes:seconds.

When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected crank pause time (minutes:seconds) delay setting.

Displays the engine cooldown time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected engine cooldown time (minutes:seconds) delay setting.

Displays the cooldown temperature override. When required, use the

Yes key to override the cooldown temperature time delay.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 93

Menu 8—Time Delays, continued

Menu 8 Displays with Key Entries

Key

Entry Display

COOLDOWN TEMPERATURE

OVERRIDE YES

COOLDOWN TEMPERATURE

OVERRIDE Y/N

OVERCRANK SHUTDOWN

CRANK CYCLES ?

OVERCRANK SHUTDOWN

CRANK CYCLES #

TIME DELAY

OVERVOLTAGE

MIN:SEC

??:??

TIME DELAY

OVERVOLTAGE

MIN:SEC

##:##

TIME DELAY

UNDERVOLTAGE

MIN:SEC

??:??

TIME DELAY

UNDERVOLTAGE

TIME DELAY

LOAD SHED KW

MIN:SEC

##:##

MIN:SEC

??:??

TIME DELAY

LOAD SHED KW

MENU 8

TIME DELAYS

MIN:SEC

##:##

Description

Enter YES to select cooldown temperature override time delay and press the Enter key.

Confirms the entry.

Displays the engine crank cycles before overcrank shutdown. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected engine crank cycles before overcrank shutdown setting.

Displays the overvoltage time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overvoltage time (minutes:seconds) delay setting.

Displays the undervoltage time delay in minutes:seconds.

When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected undervoltage time (minutes:seconds) delay setting.

Displays the load shed time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected load shed time (minutes:seconds) delay setting.

Returns the user to the time delays heading.

94 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.9

Menu 9—Input Setup

Menu 9 provides the setup of user-defined digital and analog warning and shutdown inputs.

These inputs provide a multitude of choices for configuring customized auxiliary inputs.

The user must enable the programming mode to edit the display.

Note: Press the down arrow to move to the start of the next input setup.

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown analog values based on a 0--5 VDC scale. See Menu 12, Calibration.

Note: If the ALARM ACTIVE message appears, the selected input has an active fault disabling the input. This prevents the enabled choice change from yes to no.

The LED display indicates whether the fault is a warning or shutdown.

Correct the fault condition before attempting the keypad entry.

Note: Some data requires entry by a PC in the Remote

Programming mode. See the Monitor Software

Operation Manual for details.

Digital and Analog Inputs. After the user selects the input, the setup requires entering the following choices or values: enabled (yes/no), inhibit time, and delay time.

Note: See Figure 2-9 in User Inputs for factory reserved digital and analog inputs which are not user selectable.

D

Enabled. This menu entry enables the input. The previous yes/no selection does not activate the input.

Digital inputs have three tier groups: the selection group (25 total), the chosen group (up to 21 total), and the enabled group (up to 21 total based on the chosen group). Analog inputs have separate warning and shutdown enabled choices.

D

Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect fault or status events. The inhibit time delay range is from 0 to 60 seconds.

D

TIme Delay (Shutdown or Warning).

The time delay follows the inhibit time delay. The time delay is the time period between the controller fault or status event detection and the controller warning or shutdown lamp illumination. The delay prevents any nuisance alarms. The time delay range is from 0 to

60 seconds.

Digital Inputs. Items identified as not user selectable are included for specific applications. (Example: AFM

SHUTDOWN is enabled with a Waukesha-powered model.) The user can not disable a digital input when identified as not user selectable.

Analog Inputs. View up to 7 user-defined analog inputs

A01--A07.

Analog Input A07—Voltage Adjust. Analog input A07 is the voltage adjustment for paralleling applications only. This input adjusts the input up or down from the value entered in Menu 11, Voltage Regulator.

The paralleling option predefines analog input A07 as the remote adjustment. If the user chooses to use this input for another function, change the description using the Monitor II software accessory.

Note: If the analog input A07 description does not match analog volt adjust, input A07 will not function as the voltage adjust.

Identification and Descriptions. Descriptions for user inputs (auxiliary analog or auxiliary digital) may be entered using the Monitor II software accessory where the user determines the descriptions in upper and lower case.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 95

Analog Input Values.

The analog input selection typically requires entering four values: low warning, high warning, low shutdown, and high shutdown. The analog values and time delays affect how and when the controller reacts. See Figure 2-19. The user must set both the high and low levels so the unit will not inadvertently trigger the adjacent high or low value to cause a warning or shutdown fault.

Each analog input has the following nine features:

D

D

D

D

D

One warning enabled and one shutdown enabled

One inhibit time period

One warning delay and one shutdown delay

Two warning levels (high and low)

Two shutdown levels (high and low)

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale.

See Menu 12—Calibration.

Analog

Values

High shutdown value is above the high warning value

Time after Crank Disconnect

Inhibit

Time

Period

!

Time

Delay

Period

!

Time

Delay

Complete

High shutdown function

The controller

High warning function

High warning value is above the acceptable value

The

Acceptable analog value does not view the

Low warning value is below the acceptable value input signal value

Low shutdown value is below the low warning value the analog input signal the time delay

System ready status

Low warning function

Low shutdown function

Figure 2-19 Analog Input Logistics

Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature.

The battle switch does not override the emergency stop and overspeed shutdown.

When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/generator damage can occur.

When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5— Event History.

Shutdown Type A and Shutdown Type B. Choose shutdown type A for standard shutdowns where the red lamp illuminates and the alarm horn sounds.

Choose shutdown type B for shutdowns where air damper indicator RDO-23 energizes for two seconds, the red lamp illuminates, and the alarm horn sounds.

96 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 9—Input Setup

Menu 9 Displays with Key Entries

Key

Entry Display

ENTER MENU NO. 1--15

MAIN MENU NUMBER 9

Description

Input a menu number.

Press the Enter key.

MENU 9

INPUT SETUP

SETUP DIGITAL

AUXILIARY INPUTS

→

DIGITAL INPUT 01

(USER DEFINED DESC)

→

Displays the menu number and name.

Displays the setup of digital auxiliary inputs heading.

DIGITAL INPUT 01

ENABLED

→

YES/NO

DIGITAL INPUT 01

ENABLED

DIGITAL INPUT 01

ENABLED

→

NO

→

YES

DIGITAL INPUT 01

ENABLED

OR

DIGITAL INPUT 01

ENABLED

→

YES

DIGITAL INPUT 01

ENABLED

→

YES

→

NO

DIGITAL INPUT 01

ENABLED

→

NO

Displays the digital input 01 with the user-defined description.

Note: Press the down arrow to move to the start of the next input setup.

DIGITAL INPUT 01

(see Group A)

→

YES/NO

Group A

The preprogrammed selections include the following list. See

Appendix E for application and restrictions with specific engines.

WARNING Y/N

SHUTDOWN TYPE A Y/N

SHUTDOWN TYPE B Y/N

VOLTAGE RAISE

VOLTAGE LOWER

Y/N

Y/N

Identifies the signal source for digital input 01. Use the menu down

↓ key to select the digital input.

Group A, continued

VAR PF MODE Y/N

REMOTE SHUTDOWN Y/N

REMOTE RESET

AIR DAMPER

Y/N

Y/N

LOW FUEL Y/N

FIELD OVERVOLTAGE Y/N

IDLE MODE ACTIVE

BATTLE SWITCH

Y/N

Y/N

GROUND FAULT

BAT CHGR FAULT

HIGH OIL TEMP

Y/N

Y/N

Y/N

Group A, continued

LOW COOLANT LEVEL Y/N

LOW COOLANT TEMP Y/N

BREAKER CLOSED

ENABLE SYNCH

Y/N

Y/N

AFM SHUTDOWN Y/N

KNOCK SHUTDOWN Y/N

DETON WARNING Y/N

DETON SHUTDOWN Y/N

LOW FUEL SHUTDOWN Y/N

Displays the digital input 01, enabled yes or no selection.

Entering YES enables digital input 01.

Press the Enter key.

Confirms the entry.

Entering NO disables digital input 01.

Press the Enter key.

Confirms the entry.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 97

Menu 9—Input Setup, continued

Menu 9 Displays with Key Entries

Key

Entry Display

DIGITAL INPUT 01

INHIBIT TIME

→

?:??

DIGITAL INPUT 01

INHIBIT TIME #:##

DIGITAL INPUT 01

DELAY TIME

→

?:??

DIGITAL INPUT 01

DELAY TIME

DIGITAL INPUT 01

(USER DEFINED DESC)

→

#:##

→

DIGITAL INPUT XX

(USER DEFINED DESC)

→

MENU 9

INPUT SETUP

SETUP DIGITAL

AUXILIARY INPUTS

→

SETUP ANALOG

AUXILIARY INPUTS

ANALOG INPUT 01

(USER DEFINED DESC)

→

→

ANALOG INPUT 01

WARNING ENABLED

ANALOG INPUT 01

WARNING ENABLED

ANALOG INPUT 01

WARNING ENABLED

AND

ANALOG INPUT 01

WARNING ENABLED

OR

ANALOG INPUT 01

WARNING ENABLED

ANALOG INPUT 01

WARNING ENABLED

AND

ANALOG INPUT 01

WARNING ENABLED

→

Y/N

→

NO

→

YES

→

YES

→

YES

→

NO

→

NO

Description

Displays the digital input 01 inhibit time (minutes:seconds) setting. When required, use the numeric keys to set the new values. Press the Enter key.

Displays the corrected inhibit time (minutes:seconds) setting.

Displays the digital input 01 delay time (minutes:seconds) setting. When required, use the numeric keys to set the new values. Press the Enter key.

Displays the corrected delay time (minutes:seconds) setting.

Returns the user to digital input 01.

Displays digital inputs 02 to 21. Note: Press the down arrow to scroll through additional digital auxiliary inputs or enter the input number.

Note: Press the right arrow at each digital auxiliary input to enable the selection, inhibit time setting, and delay time setting. See Digital Input 01 instructions for complete procedure and Group A selections.See

Figure 2-9 in User Inputs for factory reserved digital and analog inputs which are not user selectable.

Returns the user to the menu number and name.

Returns the user to setup digital auxiliary inputs.

Displays the setup of analog auxiliary inputs heading.

Displays the analog input 01 with user-defined description.

Note: ECM engines have inputs 01--07 and non-ECM engines have inputs 03--07. Note: Press the down arrow to move to the start of the next input setup.

Displays the analog input 01, warning enabled yes or no selection.

Entering YES enables the warning analog input 01.

Press the Enter key.

Confirms the entry.

Entering NO disables the warning analog input 01.

Press the Enter key.

Confirms the entry.

98 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 9—Input Setup, continued

Menu 9 Displays with Key Entries

Key

Entry Display

ANALOG INPUT 01

SHUTDOWN ENABLED

→

Y/N

ANALOG INPUT 01

SHUTDOWN ENABLED

→

NO

ANALOG INPUT 01

→

SHUTDOWN ENABLED YES

AND

ANALOG INPUT 01

→

SHUTDOWN ENABLED YES

OR

ANALOG INPUT 01

→

SHUTDOWN ENABLED YES

ANALOG INPUT 01

SHUTDOWN ENABLED

AND

ANALOG INPUT 01

SHUTDOWN ENABLED

→

NO

→

NO

ANALOG INPUT 01

INHIBIT TIME

→

?:??

ANALOG INPUT 01

INHIBIT TIME

→

#:##

TP-6200 3/06

ANALOG INPUT 01

WARN DELAY TIME

ANALOG INPUT 01

WARN DELAY TIME

ANALOG INPUT 01

SDWN DELAY TIME

ANALOG INPUT 01

SDWN DELAY TIME

ANALOG INPUT 01

LO SDWN VALUE

ANALOG INPUT 01

LO SDWN VALUE

ANALOG INPUT 01

LO WARN VALUE

ANALOG INPUT 01

LO WARN VALUE

Description

Displays the analog input 01, shutdown enabled selection.

Entering YES enables the shutdown analog input 01.

Press the Enter key.

Confirms the entry.

Entering NO disables the shutdown analog input 01.

Press the Enter key.

Confirms the entry.

Displays the analog input 01, inhibit time (minutes:seconds) setting.

When required, use the numeric keys to set the new values. Press the

Enter key.

Displays the corrected inhibit time (minutes:seconds) setting.

→

?:??

→

#:##

Displays the analog input 01, warning time (minutes:seconds) delay setting. When required, use the numeric keys to set the new values.

Press the Enter key.

Displays the corrected warning time (minutes:seconds) delay setting.

→

?:??

→

#:##

→

?

Displays the analog input 01, shutdown time (minutes:seconds) delay setting. When required, use the numeric keys to set the new values.

Press the Enter key.

Displays the corrected shutdown time (minutes:seconds) delay setting.

Displays the analog input 01, low shutdown value. When required, use the numeric keys to set the new values.

Press the Enter key.

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See

Menu 12—Calibration.

Displays the corrected low shutdown value.

→

#

→

?

→

#

Displays the analog input 01, low warning value. When required, use the numeric keys to set the new values.

Press the Enter key.

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See

Menu 12—Calibration.

Displays the corrected low warning value.

Local Programming Mode On Section 2 Operation 99

Menu 9—Input Setup, continued

Menu 9 Displays with Key Entries

Key

Entry Display

ANALOG INPUT 01

HI WARN VALUE

ANALOG INPUT 01

HI WARN VALUE

ANALOG INPUT 01

HI SDWN VALUE

→

?

ANALOG INPUT 01

HI SDWN VALUE

ANALOG INPUT 01

(USER DEFINED DESC)

ANALOG INPUT XX

(USER DEFINED DESC)

→

→

#

→

SETUP ANALOG

AUXILIARY INPUTS

SETUP DIGITAL

AUXILIARY INPUTS

→

→

→

#

→

?

Description

Displays the analog input 01, high warning value. When required, use the numeric keys to set the new values.

Press the Enter key.

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See

Menu 12—Calibration.

Displays the corrected high warning value.

Displays the analog input 01, high shutdown value. When required, use the numeric keys to set the new values.

Press the Enter key.

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See

Menu 12—Calibration.

Displays the corrected high shutdown value.

Returns the user to analog input 01.

Displays analog inputs A02 to A07. Note: Press the down arrow to scroll through additional analog auxiliary inputs or enter the input number.

Note: ECM engines have inputs A01--A07 and non-ECM engines have inputs A03--A07.

Note: Press the right arrow at each analog auxiliary input for the following selections and settings:

Warning enabled

Shutdown enabled

Inhibit time

Warning delay time

Shutdown delay time

Low shutdown value

Low warning value

High warning value

High shutdown value

See the Analog Input 01 instructions for the complete procedure.

Returns the user to the setup analog auxiliary input heading.

Returns the user to the setup digital auxiliary input heading.

100 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.10 Menu 10—Output Setup

Menu 10 provides setup of the user-defined system, digital and analog status and fault outputs, and relay driver outputs (RDO) 1--31. These outputs provide a multitude of choices for configuring customized auxiliary outputs. Additional individual outputs are available for monitoring, diagnostic, and control functions.

The user must enable the programming mode to edit the display.

Note: Some data require entry using a PC in the

Remote Programming mode. See the Monitor

Software Operation Manual for details.

Common Faults

The user can program a single fault comprised of status and fault events from 3 common fault programs— system, digital, and analog faults.

Up to 62 user-defined system events are available, which provide status and fault information. See Group B on the following pages for specific descriptions. The

NFPA-110 faults are part of the system fault program and are comprised of 15 individual faults shown on this page.

Up to 21 user-defined digital status and fault events designated as D01 to D21 are available. Each of the

21 status events and faults are assignable as shutdowns or warnings.

Up to 7 user-defined analog status events and faults designated as A01 to A07 are available. Each of the

7 status events and faults are assignable as shutdowns or warnings with high or low settings for a total of up to

7 status events and fault functions.

Relay Driver Outputs (RDOs)

Up to 31 RDOs are available using the system, digital, and analog status events and faults. RDOs provide only the relay driver, not the relay. The contact relays that interface with other equipment are user supplied.

Note: Func(Function) Used by (RDO) XX Reassign?

appears when the user attempts to assign an

RDO to a function already assigned.

Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify an

RDO setting that is a NFPA 110 default requirement.

Software Controlled RDOs (SCRDOs)

The SCRDO is set up and enabled using the keypad or

PC. See the Monitor Software Operation Manual when reactivating the SCRDO. The user can deactivate an

SCRDO at the controller. The user cannot reactivate the

SCRDO at the controller. The procedure to deactivate the SCRDO appears at the end of Menu 10—Output

Setup, Displays with Entry Keys—Deactivating the

SCRDO. The user must enable the programming mode to edit the display.

NFPA 110 Faults

The 15 NFPA 110 fault alarms include the following:

D Overspeed

D Overcrank

D High Coolant Temperature Shutdown

D Oil Pressure Shutdown

D Low Coolant Temperature

D High Coolant Temperature Warning

D Oil Pressure Warning

D Low Fuel

D Master Not in Auto

D Battery Charger Fault

D Low Battery Voltage

D High Battery Voltage

D Low Coolant Level

D EPS Supplying Load

D Air Damper Indicator

Defined Common Faults

The 5 defined common faults include the following:

D Emergency Stop

D High Coolant Temperature Shutdown

D Oil Pressure Shutdown

D Overcrank

D Overspeed

TP-6200 3/06 Local Programming Mode On Section 2 Operation 101

Menu 10—Output Setup

Menu 10 Displays with Key Entries

Key

Entry Display

ENTER MENU NO. 1--15

Description

Input a menu number.

MAIN MENU NUMBER 10

Press the Enter key.

MENU 10

OUTPUT SETUP

DEFINE COMMON

FAULTS

→

SYSTEM EVENTS

→

Displays the menu number and name.

Displays the common faults heading.

COMMON FAULT

(see Group B)

COMMON FAULT

(see Group B)

COMMON FAULT

(see Group B)

Y/N

NO

YES

Displays the system events heading.

Gives the user the option to add or delete the selection from the defined system events group. Press the Menu Down key to continue to the next selection (repeat as necessary).

Entering YES adds the selection to the defined system event group.

Press the Enter key.

COMMON FAULT

(see Group B)

YES

Confirms the entry.

OR

COMMON FAULT

(see Group B)

COMMON FAULT

(see Group B)

YES

NO

Entering NO removes the selection from the defined system event group.

Press the Enter key.

COMMON FAULT

(see Group B)

Group B

For defined system events, choose from the following

62 status events and faults by changing selection to

YES. See Appendix E for application and restrictions with specific engines.

EMERGENCY STOP

OVER SPEED

OVER CRANK

HI COOL TEMP SHUTDWN

OIL PRESS SHUTDOWN

LOW COOLANT TEMP

(non-ECM engines)

LOW FUEL

HI COOL TEMP WARNING

OIL PRES WARNING

MASTER NOT IN AUTO

NFPA 110 FAULT (see

Menu 10 introduction for list)

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

BATTERY CHARGE FAULT

SYSTEM READY

NO

Confirms the entry.

Group B, continued

LOSS OF ECM COMM

(ECM engines)

NO OIL PRESS SIGNAL

HI OIL TEMP

NO COOL TEMP SIGNAL

LOW COOLANT LEVEL

SPEED SENSOR FAULT

LOCKED ROTOR

MASTER SWITCH ERROR

MASTER SWITCH OPEN

MASTER SWITCH TO OFF

AC SENSING LOSS

OVER VOLTAGE

UNDER VOLTAGE

WEAK BATTERY

OVER FREQUENCY

UNDER FREQUENCY

LOAD SHED KW OVER

LOAD SHED UNDER FREQ

OVER CURRENT

EPS SUPPLYING LOAD

INTERNAL FAULT

DELAY ENG COOLDOWN

Group B, continued

DELAY ENG START

STARTING AID

GENERATOR SET RUNNING

AIR DAMPER CONTROL

GROUND FAULT

EEPROM WRITE FAILURE

CRITICAL OVERVOLTAGE

ALTERNATOR PROTECTION

SHUTDOWN

AIR DAMPER INDICATOR

DEFINED COMMON FAULT

(RDO only) (see Menu 10 introduction for list)

SCRDOs 1--4 (software controlled RDOs)

Paralleling Applications only:

SD REVERSE POWER

SD OVER POWER

SD LOSS OF FIELD

SD OVERCURRENT PR

COMMON PR OUTPUT

IN SYNCH

BREAKER TRIP

Group B, continued

Waukesha-Powered models only:

FUEL VALVE RELAY

PRELUBE RELAY

AFM REMOTE START

NO OIL TEMP SIGNAL

HI OIL TEMP WARNING

NO AIR TEMP SIGNAL

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

AFM ENG START RELAY

DDC/MTU engine with

MDEC only:

HI OIL TEMP WARNING

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

MDEC YELLOW ALARM

MDEC RED ALARM

BLOCK HEATER CONTROL

LOW COOL TEMP SDOWN

LOAD SHED OVER TEMP

102 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display

DIGITAL INPUTS

→

COMMON FAULT

Dxx (see Group C)

COMMON FAULT

Dxx (see Group C)

COMMON FAULT

Dxx (see Group C)

Y/N

NO

YES

Description

Displays the digital inputs heading.

Gives the user the option to add or delete selection from the defined digital faults starting with D01. Note: Press the Menu Down key to continue to the next selection D02--D21 (repeat as necessary).

Entering YES adds the selection to the defined digital fault group.

Press the Enter key.

Confirms the entry.

COMMON FAULT

Dxx (see Group C)

OR

COMMON FAULT

Dxx (see Group C)

COMMON FAULT

Dxx (see Group C)

YES

YES

NO

COMMON FAULT

Dxx (see Group C)

NO

Group C

Up to 21 PC user-defined digital status and fault inputs designated as D01 to D21 can result in an digital input common fault.

ANALOG INPUTS

→

Entering NO removes the selection from the defined digital fault group.

Press the Enter key.

Confirms the entry.

Displays the analog inputs heading.

Gives the user the option to add or delete selection from the defined analog faults starting with A01. Note: Press the Menu Down key to continue to the next selection A02--A07 (repeat as necessary).

COMMON FAULT Y/N

Axx

(see Group D)

LO WARNING

→

Group D

Up to 7 analog inputs, PC userdefined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high and low settings.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 103

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display

COMMON FAULT

A01

Y/N

LO WARNING

→

COMMON FAULT

A01

NO

LO WARNING

→

COMMON FAULT

A01

YES

LO WARNING

→

COMMON FAULT

A01

YES

LO WARNING

→

OR

COMMON FAULT

A01

YES

LO WARNING

→

COMMON FAULT

A01

NO

LO WARNING

→

COMMON FAULT

A01

NO

LO WARNING

→

Description

Indicates whether the previously user-defined analog output was selected (yes or no) as a low warning fault.

Entering YES adds the low warning selection to the defined analog fault group.

Press the Enter key.

Confirms the entry.

Entering NO removes the low warning selection from the defined analog fault group.

Press the Enter key.

Confirms the entry.

COMMON FAULT

A01

Y/N

HI WARNING

→

COMMON FAULT

A01

NO

HI WARNING

→

COMMON FAULT

A01

YES

HI WARNING

→

COMMON FAULT

A01

YES

HI WARNING

→

OR

COMMON FAULT

A01

YES

HI WARNING

→

COMMON FAULT

A01

NO

HI WARNING

→

COMMON FAULT

A01

NO

HI WARNING

→

Indicates whether the previously user-defined analog output was selected (yes or no) as a high warning fault.

Entering YES adds the high warning selection to the defined analog fault group.

Press the Enter key.

Confirms the entry.

Entering NO removes the high warning selection from the defined analog fault group.

Press the Enter key.

Confirms the entry.

104 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display Description

COMMON FAULT

A01

Y/N

LO SHUTDOWN

→

COMMON FAULT

A01

NO

LO SHUTDOWN

→

COMMON FAULT

A01

YES

LO SHUTDOWN

→

COMMON FAULT

A01

YES

LO SHUTDOWN

→

OR

COMMON FAULT

A01

YES

LO SHUTDOWN

→

COMMON FAULT

A01

NO

LO SHUTDOWN

→

COMMON FAULT

A01

NO

LO SHUTDOWN

→

Indicates whether the previously user-defined analog output was selected (yes or no) as a low shutdown fault.

Entering YES adds the low shutdown selection to the defined analog fault group.

Press the Enter key.

Confirms the entry.

Entering NO removes the low shutdown selection from the defined analog fault group.

Press the Enter key.

Confirms the entry.

TP-6200 3/06

COMMON FAULT

A01

Y/N

HI SHUTDOWN

→

COMMON FAULT

A01

NO

HI SHUTDOWN

→

COMMON FAULT

A01

YES

HI SHUTDOWN

→

COMMON FAULT

A01

YES

HI SHUTDOWN

→

OR

COMMON FAULT

A01

YES

HI SHUTDOWN

→

COMMON FAULT

A01

NO

HI SHUTDOWN

→

COMMON FAULT

A01

NO

HI SHUTDOWN

→

Indicates whether the previously user-defined analog output was selected (yes or no) as a high shutdown fault.

Entering YES adds the high shutdown selection to the defined analog fault group.

Press the Enter key.

Confirms the entry.

Entering NO removes the high shutdown selection from the defined analog fault group.

Press the Enter key.

Confirms the entry.

COMMON FAULT

A01

Y/N

LO WARNING

→

COMMON FAULT Y/N

Axx

(see Group D)

LO WARNING

→

Group D

Up to 7 analog inputs, PC userdefined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high and low settings.

Returns the user to common fault (analog inputs) heading.

Press the Menu Down key to continue to the next selection A02--A07

(repeat as necessary).

Gives the user the option to add or delete selection from the next defined analog fault. Note: Use the A01 common fault analog input setup procedure shown above for A02--A07. Go to

Local Programming Mode On Section 2 Operation 105

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display

ANALOG INPUTS

→

Description

Returns the user to analog inputs heading.

DEFINE COMMON

FAULTS

RELAY DRV OUT 01

(user defined)

SYSTEM EVENTS

→

→

→

Returns the user to the define common faults heading.

Gives the user previously selected items for relay driver outputs (RDO) starting with 01. Note: Press the down arrow to continue to the next relay driver output 02--31 or enter the RDO number.

Note: The RDO can be assigned from the SYSTEM EVENTS, DIGITAL

INPUTS, or ANALOG INPUTS groups. The start of each of these groups are highlighted on the following pages.

Displays the system events heading.

RELAY DRV OUT 01

(see Group B)

RELAY DRV OUT 01

(see Group B)

Y/N

NO

Gives the user the option to assign a system event to an RDO. Press the

Menu Down key to continue to the next selection (repeat as necessary).

Entering YES adds the selection to the RDO group.

Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned.

Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify the RDO setting that is a NFPA 110 default requirement.

Press the Enter key.

RELAY DRV OUT 01

(see Group B)

YES

RELAY DRV OUT 01

(see Group B)

YES

Group B

For defined system events, choose from the following

62 status events and faults by changing selection to

YES. See Appendix E for application and restrictions with specific engines.

EMERGENCY STOP

OVER SPEED

OVER CRANK

HI COOL TEMP SHUTDWN

OIL PRESS SHUTDOWN

LOW COOLANT TEMP

(non-ECM engines)

LOW FUEL

HI COOL TEMP WARNING

OIL PRES WARNING

MASTER NOT IN AUTO

NFPA 110 FAULT*

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

BATTERY CHARGE FAULT

SYSTEM READY

LOSS OF ECM COMM

(ECM engines)

NO OIL PRESS SIGNAL

HI OIL TEMP

NO COOL TEMP SIGNAL

LOW COOLANT LEVEL

SPEED SENSOR FAULT

LOCKED ROTOR

Confirms the entry.

Group B, continued

MASTER SWITCH ERROR

MASTER SWITCH OPEN

MASTER SWITCH TO OFF

AC SENSING LOSS

OVER VOLTAGE

UNDER VOLTAGE

WEAK BATTERY

OVER FREQUENCY

UNDER FREQUENCY

LOAD SHED KW OVER

LOAD SHED UNDER FREQ

OVER CURRENT

EPS SUPPLYING LOAD

INTERNAL FAULT

DELAY ENG COOLDOWN

DELAY ENG START

STARTING AID

GENERATOR SET RUNNING

AIR DAMPER CONTROL

GROUND FAULT

EEPROM WRITE FAILURE

CRITICAL OVERVOLTAGE

ALTERNATOR

PROTECTION SHUTDOWN

AIR DAMPER INDICATOR

DEFINED COMMON FAULT

(RDO only)

[

SCRDOs 1--4 (software controlled RDOs)

Group B, continued

Paralleling Applications:

SD REVERSE POWER

SD OVER POWER

SD LOSS OF FIELD

SD OVERCURRENT PR

COMMON PR OUTPUT

IN SYNCH

BREAKER TRIP

Waukesha-powered models:

FUEL VALVE RELAY

PRELUBE RELAY

AFM REMOTE START

NO OIL TEMP SIGNAL

HI OIL TEMP WARNING

NO AIR TEMP SIGNAL

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

AFM ENG START DELAY

DDC/MTU engine with

MDEC:

HI OIL TEMP WARNING

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

MDEC YELLOW ALARM

MDEC RED ALARM

BLOCK HEATER CONTROL

LOW COOL TEMP SDOWN

LOAD SHED OVER TEMP

106 Section 2 Operation Local Programming Mode On

*NFPA 110 FAULT

The 15 NFPA-110 Fault

Alarms include the following:

OVERSPEED

OVERCRANK

HIGH COOLANT TEMP

SHUTDOWN

OIL PRESSURE

SHUTDOWN

LOW COOLANT

TEMPERATURE

HIGH COOLANT TEMP

WARNING

OIL PRESSURE WARNING

LOW FUEL

MASTER NOT IN AUTO

BATTERY CHARGER FAULT

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

LOW COOLANT LEVEL

EPS SUPPLYING LOAD

AIR DAMPER INDICATOR

[DEFINED COMMON FAULT

The 5 defined common faults include the following:

EMERGENCY STOP

HI COOL TEMP

SHUTDOWN

OIL PRESS SHUTDOWN

OVERCRANK

OVERSPEED

TP-6200 3/06

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display

DIGITAL INPUTS

→

RELAY DRV OUT 01

Dxx (see Group C)

RELAY DRV OUT 01

Dxx (see Group C)

Y/N

NO

Description

Displays the digital inputs heading.

Gives the user the option to assign a digital input to an RDO starting with

D01.

Press the Menu Down key to continue to the next selection

D02--D21 (repeat as necessary).

Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned.

Entering YES adds the selection to the RDO group.

Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned.

Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify the RDO setting that is a NFPA 110 default requirement.

Press the Enter key.

RELAY DRV OUT 01

Dxx (see Group C)

YES

RELAY DRV OUT 01

Dxx (see Group C)

YES

Group C

Up to user-defined digital status and fault inputs designated as

D01 to D21 can result in a digital input common fault.

ANALOG INPUTS

→

Confirms the entry.

Displays the analog inputs heading.

Gives the user the option to assign an analog input to an RDO starting with A01. Note: Press the Menu Down key to continue to the next selection A02-A07 (repeat as necessary).

RELAY DRV OUT 01 Y/N

Axx

(see Group D)

LO WARNING

→

Group D

Up to 7 analog inputs, userdefined status events and faults designated as A01 to

A07. Each of the 7 is assignable as a shutdown or warning with high or low settings.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 107

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display

RELAY DRV OUT 01

A01

Y/N

LO WARNING

→

RELAY DRV OUT 01

A01

NO

LO WARNING

→

RELAY DRV OUT 01

A01

YES

LO WARNING

→

RELAY DRV OUT 01

A01

YES

LO WARNING

→

OR

RELAY DRV OUT 01

A01

YES

LO WARNING

→

RELAY DRV OUT 01

A01

NO

LO WARNING

→

RELAY DRV OUT 01

A01

NO

LO WARNING

→

RELAY DRV OUT 01

A01

Y/N

HI WARNING

→

RELAY DRV OUT 01

A01

NO

HI WARNING

→

RELAY DRV OUT 01

A01

YES

HI WARNING

→

RELAY DRV OUT 01

A01

YES

HI WARNING

→

OR

RELAY DRV OUT 01

A01

YES

HI WARNING

→

RELAY DRV OUT 01

A01

NO

HI WARNING

→

RELAY DRV OUT 01

A01

NO

HI WARNING

→

Description

Indicates whether the previously user-defined analog RDO was selected

(yes or no) as a low warning fault.

Entering YES adds the low warning selection to the defined analog RDO group.

Press the Enter key.

Confirms the entry.

Entering NO removes the low warning selection from the defined analog

RDO group.

Press the Enter key.

Confirms the entry.

Indicates whether the previously user-defined analog RDO was selected

(yes or no) as a high warning fault.

Entering YES adds the high warning selection to the defined analog RDO group.

Press the Enter key.

Confirms the entry.

Entering NO removes the high warning selection from the defined analog

RDO group.

Press the Enter key.

Confirms the entry.

108 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries

Key

Entry Display

RELAY DRV OUT 01

A01

Y/N

LO SHUTDOWN

→

RELAY DRV OUT 01

A01

NO

LO SHUTDOWN

→

RELAY DRV OUT 01

A01

YES

LO SHUTDOWN

→

RELAY DRV OUT 01

A01

YES

LO SHUTDOWN

→

OR

RELAY DRV OUT 01

A01

YES

LO SHUTDOWN

→

RELAY DRV OUT 01

A01

NO

LO SHUTDOWN

→

RELAY DRV OUT 01

A01

NO

LO SHUTDOWN

→

Description

Indicates whether the previously user-defined analog RDO was selected

(yes or no) as a low shutdown fault.

Entering YES adds the low shutdown selection to the defined analog

RDO group.

Press the Enter key.

Confirms the entry.

Entering NO removes the low shutdown selection from the defined analog RDO group.

Press the Enter key.

Confirms the entry.

RELAY DRV OUT 01

A01

Y/N

HI SHUTDOWN

→

RELAY DRV OUT 01

A01

NO

HI SHUTDOWN

→

RELAY DRV OUT 01

A01

YES

HI SHUTDOWN

→

RELAY DRV OUT 01

A01

YES

HI SHUTDOWN

→

OR

RELAY DRV OUT 01

A01

YES

HI SHUTDOWN

→

RELAY DRV OUT 01

A01

NO

HI SHUTDOWN

→

RELAY DRV OUT 01

A01

NO

HI SHUTDOWN

→

RELAY DRV OUT 01

A01

Y/N

LO WARNING

→

RELAY DRV OUT 01 Y/N

Axx

(see Group D)

LO WARNING

→

ANALOG INPUTS

→

Indicates whether the previously user-defined analog RDO was selected

(yes or no) as a high shutdown fault.

Entering YES adds the high shutdown selection to the defined analog

RDO group.

Press the Enter key.

Confirms the entry.

Entering NO removes the high shutdown selection from the defined analog RDO group.

Press the Enter key.

Confirms the entry.

Returns the user to the analog RDO (analog inputs) heading. Press the

Menu Down key to continue to the next selection A02--A07 (repeat as necessary).

Gives the user the option to add or delete a selection for the next analog

RDO. Note: Use the A01 analog RDO setup procedure shown above for

A02--A07. Go to

Returns the user to the analog inputs heading. Press the Menu Right key.

TP-6200 3/06

RELAY DRV OUT 01

(user defined)

RELAY DRV OUT XX

(user defined)

→

Returns the user to the RDO 01 heading.

→

Gives the user the option to add or delete a selection for the next RDO.

Note: Use the RDO 01 setup procedure shown above for RDOs 02--31.

Go to

Local Programming Mode On Section 2 Operation 109

Menu 10—Output Setup, continued

Menu 10 Displays with Key Entries—

Deactivating the SCRDO

Key

Entry Display

ENTER MENU NO. 1--15

Description

Input a menu number.

MAIN MENU NUMBER 10

Press the Enter key.

MENU 10

OUTPUT SETUP

DEFINE COMMON

FAULTS

→

RELAY DRV OUT XX

S’WARE CONTROLLED #X

→

DEACTIVATE RDO?

→

Displays the menu number and name

Displays the common faults heading.

Gives the user previously selected items for the relay driver outputs

(RDO). Press the down arrow to scroll through relay driver outputs 1--31 or enter the RDO number. Locate the SCRDO display.

When required (SCRDO is currently active), enter the YES key to deactivate the SCRDO.

DEACTIVATE RDO?

YES

→

Press the Enter key.

RELAY DRV OUT XX

S’WARE CONTROLLED #X

→

110 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.11 Menu 11—Voltage Regulator

Menu 11 provides the setup of the voltage regulator functions including the line-to-line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor, and kVAR adjustments.

See

Section 1.3.3, Voltage Regulator Adjustments, and

Appendix C, Voltage Regulator Definitions and

Adjustments, for additional information.

The user must enable the programming mode to edit the display.

Note: Press the Menu Right

→ key prior to entering the decimal values where necessary.

Note: 350--2000 kW models only, see 1.3.2 Voltage

Regulator and Calibration Specifications regarding the use of the Marathon r DVRr 2000 voltage regulator on some earlier generator sets.

Menu 11—Voltage Regulator

Menu 11 Displays with Key Entries

Key

Entry Display Description

Paralleling Applications Only. Analog input A07 is the voltage adjustment for paralleling applications only.

This input adjusts the input up or down from the value entered in Menu 11, Voltage Regulator. If the keypad entry does not match the displayed value for voltage adjust, the analog input is not at zero (2.5 VDC). Analog input A07 can be monitored or checked in Menu 3,

Analog Monitoring.

Note: Paralleling applications require enabling the

VAR/PF controls. The Utility Gain Adjust is used for VAR or PF stability adjustment while paralleling to a utility.

Marathon r and DVRr are registered trademarks of Marathon Electric

Mfg. Corp.

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 11

Press the Enter key.

MENU 11

VOLTAGE REGULATOR

AVG L-L V

VOLT ADJ

AVG L-L V

VOLT ADJ

AND

AVG L-L V

VOLT ADJ

#

→

?.?

#

→

?.?

#

→

#.#

Displays the menu number and name.

Displays the average running line-to-line volts and voltage adjustment.

Enter the desired nominal voltage using the numeric keys. Press the

Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

L1-L2 VOLTS

#

L2-L3 VOLTS

#

L3-L1 VOLTS

#

AVG L-L V

VOLT ADJ

→

→

→

#

→

#

Displays L1-L2 volts.

Displays L2-L3 volts (3 phase only).

Displays L3-L1 volts (3 phase only).

Returns the user to the average line-to-line volts and voltage adjustment heading.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 111

Menu 11—Voltage Regulator, continued

Menu 11 Displays with Key Entries

Key

Entry Display Description

UNDER FREQ UNLOAD

ENABLED

→

N/Y

UNDER FREQ UNLOAD

ENABLED

UNDER FREQ UNLOAD

ENABLED

→

NO

→

YES

UNDER FREQ UNLOAD

ENABLED

→

YES

OR

UNDER FREQ UNLOAD

ENABLED

UNDER FREQ UNLOAD

ENABLED

→

YES

→

NO

UNDER FREQ UNLOAD

ENABLED

→

NO

Displays the under frequency (volts per Hz) unloading (yes or no) selection.

Entering YES enables the underfrequency unloading feature.

Press the Enter key.

Confirms the entry.

Entering NO disables the underfrequency unloading feature.

Press the Enter key.

Confirms the entry.

FREQUENCY

SETPOINT

# HZ

→

?.? HZ

Displays the present operating frequency and underfrequency unloading cut-in point. Enter the desired underfrequency cut-in point using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

FREQUENCY

SETPOINT

AND

# HZ

→

?.? HZ

FREQUENCY

SETPOINT

# HZ

→

#.# HZ

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

SLOPE

?.? VOLTS-PER-CYCLE

→

AND

SLOPE

?.? VOLTS-PER-CYCLE

→

SLOPE

#.# VOLTS-PER-CYCLE

→

UNDER FREQ UNLOAD

ENABLED

→

N/Y

Displays the underfrequency unloading slope (volts-per-cycle). Enter the desired underfrequency unloading slope using the numeric keys.

Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

Returns the user to the underfrequency unloading heading.

112 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 11—Voltage Regulator, continued

Menu 11 Displays with Key Entries

Key

Entry Display Description

REACTIVE DROOP

ENABLED

→

N/Y

Displays the reactive droop selection (yes or no).

REACTIVE DROOP

ENABLED

REACTIVE DROOP

ENABLED

→

NO

→

YES

Entering YES enables the reactive droop feature.

Press the Enter key.

→

YES

Confirms the entry.

REACTIVE DROOP

ENABLED

OR

REACTIVE DROOP

ENABLED

REACTIVE DROOP

ENABLED

REACTIVE DROOP

ENABLED

.8 PF RATED LOAD

VOLTAGE DROOP

→

YES

→

NO

→

NO

→

?.?%

Entering NO disables the reactive droop feature.

Press the Enter key.

Confirms the entry.

AND

.8 PF RATED LOAD

VOLTAGE DROOP

.8 PF RATED LOAD

VOLTAGE DROOP

→

?.?%

→

#.#%

Displays the reactive (voltage) droop as a percentage of the rated voltage at rated load. When required, enter the desired reactive droop using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 113

Menu 11—Voltage Regulator, continued

Menu 11 Displays with Key Entries

Key

Entry Display Description

REACTIVE DROOP

ENABLED

VAR CONTROL

ENABLED

→

N/Y

→

N/Y

Returns the user to reactive droop selection heading.

Displays the VAR control selection (yes or no).

VAR CONTROL

ENABLED

VAR CONTROL

ENABLED

VAR CONTROL

ENABLED

OR

VAR CONTROL

ENABLED

VAR CONTROL

ENABLED

→

NO

→

YES

→

YES

→

YES

→

NO

Entering YES enables the VAR control feature.

Note: A YES entry disables the PF control if previously activated.

Press the Enter key.

Confirms the entry.

Entering NO disables the VAR control feature.

Press the Enter key.

VAR CONTROL

ENABLED

→

NO

Confirms the entry.

TOTAL KVAR

KVAR ADJ

TOTAL KVAR

AND

KVAR ADJ

TOTAL KVAR

KVAR ADJ

GENERATING/

ABSORBING

#

→

?.?

#

→

?.?

#

→

#.#

N/Y

→

Displays total kVAR (running) and kVAR adjustment settings. Enter the desired kVAR adjustment using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

GENERATING

GENERATING

YES

→

NO

→

Displays the generating or absorbing kVAR selection.

Note: The display sample may differ depending upon the previous entries. The generating selection is the factory default setting.

Displays the generating kVAR selection. When required, use the NO key to choose absorbing kVAR.

Press the Enter key.

ABSORBING YES

→

Confirms the entry.

ABSORBING

OR

ABSORBING

YES

→

NO

→

GENERATING

VAR CONTROL

ENABLED

114 Section 2 Operation

Displays the absorbing kVAR selection. When required, use the NO key to choose generating kVAR.

Press the Enter key.

YES

→

Confirms the entry.

→

N/Y

Returns the user to VAR control selection heading.

Local Programming Mode On TP-6200 3/06

Menu 11—Voltage Regulator, continued

Menu 11 Displays with Key Entries

Key

Entry Display Description

PF CONTROL

ENABLED

PF CONTROL

ENABLED

PF CONTROL

ENABLED

→

N/Y

→

NO

→

YES

Displays the power factor control selection (yes or no).

Entering YES enables the power factor control feature.

Note: A YES entry disables the kVAR control if previously activated.

Press the Enter key.

→

YES

Confirms the entry.

PF CONTROL

ENABLED

PF CONTROL

ENABLED

OR

PF CONTROL

ENABLED

→

YES

→

NO

Entering NO disables the power factor control feature.

Press the Enter key.

PF CONTROL

ENABLED

AVERAGE PF

PF ADJ

AND

AVERAGE PF

PF ADJ

AVERAGE PF

PF ADJ

→

NO

#

→

?.?

#

→

?.?

#

→

#.#

Confirms the entry.

Displays the present running average power factor and power factor adjustment settings. Enter the desired kVAR adjustment using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

LAGGING/

LEADING

LAGGING

LAGGING

N/Y

→

YES

→

NO

→

Displays the lagging or leading PF selection.

Note: The display sample may differ depending upon the previous entries. The lagging selection is the factory default setting.

Displays the lagging PF selection. When required, use the NO key to choose leading PF.

Press the Enter key.

LEADING

LEADING

OR

LEADING

YES

→

YES

→

NO

→

Confirms the entry.

Displays the leading PF selection. When required, use the NO key to choose lagging PF.

Press the Enter key.

TP-6200 3/06

LAGGING

PF CONTROL

ENABLED

YES

→

Confirms the entry.

→

N/Y

Returns the user to the power factor control selection heading.

Local Programming Mode On Section 2 Operation 115

Menu 11—Voltage Regulator, continued

Menu 11 Displays with Key Entries

Key

Entry Display Description

REGULATOR GAIN ADJ

GAIN #

Displays the generator set voltage regulator gain adjustment. When required, use the numeric keys to enter the desired gain value.

REGULATOR GAIN ADJ

GAIN

UTILITY GAIN ADJ

GAIN

UTILITY GAIN ADJ

GAIN

RESET REGULATOR

DEFAULTS

#

#

#

Y/N

Confirms the entry.

Displays the utility (VAR/PF) gain adjustment. When required, use the numeric keys to enter the desired gain value.

Confirms the entry.

Displays the reset regulator defaults selection.

RESET REGULATOR

DEFAULTS

RESET REGULATOR

DEFAULTS

YES

Y/N

When required, use the YES key to reset the regulator defaults.

Confirms the entry.

116 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.12 Menu 12—Calibration

Menu 12 provides the calibration of the voltage and current sensing logic. Changing the system voltage or replacing the main logic control circuit board requires a calibration adjustment.

Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown analog values based on a 0--5 VDC scale.

The user must enable the programming mode to edit the display.

Connect a meter with a minimum accuracy of

ᐔ1% to the generator set output leads to calibrate the voltage-sensing logic.

Configure the generator set controller for the system operating configuration using

Menu 7—Generator System. Adjust the generator set voltage using Menu 11—Voltage Regulator, when required and adjust the frequency at the generator set governor before making calibration adjustments.

Note: ECM engines have user-defined analog inputs

A01--A07. Non-ECM engines have user-defined analog inputs A03--A07 where analog inputs A01 and A02 are reserved for the engine coolant temperature A01 and oil pressure A02 displays.

Note: Analog input A07 is the voltage adjustment for paralleling applications only. This input adjusts the input up or down from the value entered in

Menu 11, Voltage Regulator. Calibration is not necessary.

Note: Press the Menu Right

→ key prior to entering decimal values where necessary.

Reduce the voltage regulator gain using Menu 11,

Voltage Regulator until the voltage is stable prior to calibration.

Note: Changes to the generator set system parameters causes a CHECK CALIBRATION display message.

If the generator set system parameters are changed, verify the controller display calibration by comparing the results to a known measured value.

Menu 12—Calibration

Menu 12 Displays with Key Entries (Scale AC Analog Inputs)

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 12

Press the Enter key.

MENU 12

CALIBRATION

SCALE AC ANALOG

INPUTS

GEN VOLTAGE LN

Displays the menu number and name.

Displays the scale AC analog inputs heading.

GEN L1-L0 V

CALIB REF

GEN L1-L0 V

AND

CALIB REF

GEN L1-L0 V

CALIB REF

#

?.?

#

?.?

#

#.#

Displays the generator set voltage line-to-neutral heading.

Note: The generator set must be running for the following steps.

Measure the generator set output voltage for single and three-phase models between L1-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 117

Menu 12—Calibration, continued

Menu 12 Displays with Key Entries (Scale AC Analog Inputs)

Key

Entry Display

GEN L2-L0 V

CALIB REF

#

?.?

Description

Measure the generator set output voltage for three-phase models between L2-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

GEN L2-L0 V

AND

CALIB REF

#

?.?

Use the numeric keys to enter the decimal value. Press the Enter key.

GEN L2-L0 V

CALIB REF

#

#.#

Confirms the entry.

GEN L3-L0 V

CALIB REF

#

?.?

Three-Phase Models only. Measure the generator set output voltage for three-phase models between L3-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

GEN L3-L0 V

CALIB REF

AND

GEN L3-L0 V

CALIB REF

GEN VOLTAGE LN

#

?.?

#

#

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

Returns the user to the generator set voltage line-to-neutral heading.

GEN VOLTAGE LL

Displays the generator set voltage line-to-line heading.

GEN L1-L2 V

CALIB REF

#

?.?

Note: The generator set must be running for the following steps.

Measure the generator set output voltage for single and three-phase models between L1-L2 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

GEN L1-L2 V

AND

CALIB REF

GEN L1-L2 V

CALIB REF

GEN L2-L3 V

CALIB REF

GEN L2-L3 V

AND

CALIB REF

GEN L2-L3 V

CALIB REF

#

?.?

#

#.#

#

?.?

#

#.#

#

?.?

Confirms the entry.

Three-Phase Models only. Measure the generator set output voltage for three-phase models between L2-L3 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Note: The generator set must be running for the following steps.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

118 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 12—Calibration, continued

Menu 12 Displays with Key Entries (Scale AC Analog Inputs)

Key

Entry Display Description

GEN L3-L1 V

CALIB REF

#

?.?

Three-Phase Models only. Measure the generator set output voltage for three-phase models between L3-L1 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

GEN L3-L1 V

CALIB REF

AND

#

?.?

Use the numeric keys to enter the decimal value. Press the Enter key.

GEN L3-L1 V

CALIB REF

#

#

Confirms the entry.

CALIBRATE REGULATOR?

Y/N

Displays the calibrate regulator selection.

Note: After changing the meter calibration the voltage regulator should be calibrated—enter YES.

When required, use the YES key to calibrate the voltage regulator.

CALIBRATE REGULATOR?

YES

CALIBRATE REGULATOR?

Y/N

Confirms the entry.

GEN VOLTAGE LL

Returns the user to the generator set line-to-line voltage heading.

GEN AMPS

Displays the generator set amps heading.

GEN L1 AMPS

CALIB REF

#

?.?

Note: The generator set must be running for the following steps.

Measure the generator set output current for single- and three-phase models at L1 using an AC ammeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

AND

GEN L1 AMPS

CALIB REF

GEN L1 AMPS

CALIB REF

GEN L2 AMPS

CALIB REF

AND

GEN L2 AMPS

CALIB REF

GEN L2 AMPS

CALIB REF

#

?.?

#

#

#

?.?

#

#

#

?.?

Confirms the entry.

Measure the generator set output current for three-phase models at L2 using an AC ammeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Confirms the entry.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 119

Menu 12—Calibration, continued

Menu 12 Displays with Key Entries (Scale AC Analog Inputs)

Key

Entry Display Description

GEN L3 AMPS

CALIB REF

AND

GEN L3 AMPS

CALIB REF

#

?.?

#

?.?

Three-Phase Models only. Measure the generator set output current for three-phase models at L3 using an AC ammeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

GEN L3 AMPS

CALIB REF

#

#

Confirms the entry.

GEN AMPS

Returns the user to the generator set amps heading.

LOAD VOLTAGE LN

Displays the load voltage line-to-neutral voltage heading.

LOAD L1--L0 V #

CALIB REF (PARALLEL) ?.?

Note: The generator sets must be running for the following steps.

Paralleling Applications. Measure the load voltage between L1-L0 using a voltmeter and enter the result using the numeric keys. Press the

Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

GEN L1-L0 V

CALIB REF

GEN L1-L0 V

CALIB REF

AND

#

?.?

#

#

LOAD L3--L0 V #

CALIB REF (PARALLEL) ?.?

Confirms the entry.

Note: The generator sets must be running for the following steps.

Paralleling Applications. Measure the load voltage for three-phase models between L3-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right

→ key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

GEN L3-L0 V

CALIB REF

AND

GEN L3-L0 V

CALIB REF

LOAD VOLTAGE LN

#

?.?

#

#

Confirms the entry.

Returns the user to the load voltage line-to-neutral voltage heading.

RESTORE DEFAULTS?

Y/N

RESTORE DEFAULTS?

YES

RESTORE DEFAULTS?

Y/N

Displays the restore defaults selection.

When required, enter YES to activate the restore calibration defaults setting. Press the Enter key. Note: Entering Yes will delete all of the previously entered voltage and current data based on system voltage and kW and restore the calibration default settings.

Confirms the entry.

GEN VOLTAGE LN

Returns the user to the generator set voltage line-to-neutral heading.

120 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 12—Calibration, continued

Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs)

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 12

Press the Enter key.

MENU 12

CALIBRATION

SCALE AC ANALOG

INPUTS

SCALE AUX. ANALOG

INPUTS

ZERO AUX. ANALOG

INPUTS?

→

Displays the menu number and name.

Displays the scale AC analog inputs heading.

ZERO AUX. ANALOG

INPUTS?

ZERO AUX. ANALOG

INPUTS?

ANALOG 01

SCALE VALUE 1

YES

YES

#

?

SCAL 1

SCAL 2

ANALOG 01

SCALE VALUE 2

SCALE AUX. ANALOG

INPUTS

ZERO AUX. ANALOG

INPUTS?

ANALOG XX

SCALE VALUE 1

#--#.#V

#--#.#V

#

?

→

#

?

Displays the scale auxiliary analog inputs heading.

Gives the user the option to calibrate the auxiliary analog inputs for zero input signals. Note: ECM engines have inputs A01--A07 and non-ECM engines have inputs A03--A07. Paralleling applications only, use A07 for voltage adjustment.

When required, enter YES to activate the auto-zero auxiliary analog inputs feature. Press the Enter key.

Confirms the entry.

Displays the analog 01 and scale value 1 settings. Use the numeric keys to enter the minimum value based on the previously calculated 5 VDC analog input value. Note: There is no calibration available on analogs inputs 01 and 02 with non-ECM engines.

Note: Press the Menu Right

→ key to review both the scale value 1 and scale value 2 settings any time during the setup procedure.

Displays analog 01 and scale value 2 settings. Use the numeric keys to enter the maximum value based on the previously calculated 5 VDC analog value.

Returns the user to the scale auxiliary analog inputs heading.

Press the down arrow to go to the desired analog XX.

Displays scale auxiliary analog inputs 01 to 07.

Note: Press the down arrow to scroll through the additional analog auxiliary inputs 02--07.

Note: Press the down arrow to scroll through the additional analog scale value 1 and value 2 for each analog selection.

Note: Press the right arrow at each analog auxiliary input that provides display of the scale 1 and scale 2 voltage settings.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 121

2.9.13 Menu 13—Communications

Menu 13 enables communication with the controller for monitoring or controlling the generator set.

KBUS allows a variety of connection types while Modbus r follows Modbus r RTU protocols. Use the LAN (local area network) to gain remote access to multiple devices/addresses.

Use the KBUS enable local programming mode to edit displays in this menu. Use the Monitor Software Operation Manual when accessing this menu, programming from a remote location, and determining address and system identification information.

Menu 13—Communications

Menu 13 Displays with Key Entries

Key

Entry Display Description

The user must enable the programming mode to edit the display.

See Section 2.7 for descriptions of the different types of connections.

Modbus r is a registered trademark of Schneider

Electric.

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 13

Press the Enter key.

MENU 13

COMMUNICATIONS

PROTOCOL

KBUS

→

KBUS ONLINE Y/N

KBUS ONLINE

KBUS ONLINE

NO

YES

Displays the menu number and name.

Displays the KBUS protocol heading.

Displays the KBUS online selection.

Entering YES activates the online KBUS selection.

Press the Enter key.

KBUS ONLINE

KBUS ONLINE

OR

KBUS ONLINE

YES

YES

NO

Confirms the entry.

Entering NO deactivates the online KBUS selection.

Press the Enter key.

KBUS ONLINE NO

Confirms the entry.

122 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 13—Communications, continued

Menu 13 Displays with Key Entries

Key

Entry Display Description

CONNECTION TYPE

(USER DEFINED)

→

Y/N

Displays the user-defined connection type. Press the Down arrow key if the correct connection type is displayed. If the desired connection type is not displayed, press the Right arrow key until the desired connection type appears.

CONNECTION TYPES

LOCAL SINGLE Y/N

LOCAL LAN

LOCAL LAN CONV

REMOTE SINGLE

REMOTE LAN

REMOTE LAN CONV

N/Y

N/Y

N/Y

N/Y

N/Y

Entering YES selects the connection type shown. Note: Selecting one connection type deselects any previously selected choice.

CONNECTION TYPE

(USER DEFINED)

CONNECTION TYPE

(USER DEFINED)

PRIMARY PORT

(USER DEFINED)

→

YES

→

YES

→

Y/N

Press the Enter key.

Confirms the entry.

PRIMARY PORTS

RS-232

RS-485 ISO 1

Y/N

N/Y

Displays the user-defined primary port subheading. Press the Down arrow key if the correct primary port type is displayed. If the desired primary port type is not displayed, press the Right arrow key until the desired primary port type appears.

Entering YES selects the primary port shown. Note: Selecting one primary port deselects any previously selected choice.

TP-6200 3/06

PRIMARY PORT

(USER DEFINED)

PRIMARY PORT

(USER DEFINED)

ADDRESS

(LAN Connections)

→

YES

→

YES

?

Press the Enter key.

Confirms the entry.

ADDRESS

(LAN Connections)

SYSTEM ID

(Remote Connections)

#

?

Displays the LAN connection address number. Use the numeric keys to enter the desired address 1--128. Use one address number per unit and use consecutive numbers. Individual addresses are necessary for the software to call up the desired unit.

Confirms the entry.

Displays the system ID request. Use the numeric keys to enter the required system ID of remote connections. The system ID is a password.

The user must use the same password for all devices at a site.

SYSTEM ID

(Remote Connections)

BAUD RATE

(USER DEFINED)

#

→

Y/N

Confirms the entry.

Displays the user-defined baud rate selection. Press the Down arrow key if the correct baud rate is displayed. If the desired baud rate is not displayed, press the Right arrow key until the desired baud rate appears.

1200

2400

9600

BAUD RATES

Y/N

N/Y

N/Y

Entering YES selects the baud rate shown. Note: Selecting one baud rate deselects any previously selected choice.

Local Programming Mode On Section 2 Operation 123

Menu 13—Communications, continued

Menu 13 Displays with Key Entries

Key

Entry Display Description

BAUD RATE

(USER DEFINED)

BAUD RATE

(USER DEFINED)

→

YES

→

YES

Press the Enter key.

Confirms the entry.

MENU 13

COMMUNICATIONS

PROTOCOL

KBUS

→

→

PROTOCOL

MODBUS

MODBUS ONLINE Y/N

MODBUS ONLINE

MODBUS ONLINE

MODBUS ONLINE

NO

YES

YES

Returns the user to the menu number and name.

Returns the user to KBUS protocol heading.

Displays the Modbus protocol heading.

Displays the Modbus online selection (yes or no).

Entering YES activates the online Modbus selection.

Press the Enter key.

Confirms the entry.

OR

MODBUS ONLINE

MODBUS ONLINE

YES

NO

Entering NO deactivates the online Modbus selection.

Press the Enter key.

MODBUS ONLINE NO

Confirms the entry.

CONNECTION TYPE

(USER DEFINED)

→

Y/N

CONNECTION TYPES

SINGLE Y/N

CONVERTOR N/Y

CONNECTION TYPE

(USER DEFINED)

CONNECTION TYPE

(USER DEFINED)

→

YES

→

YES

Displays the user-defined connection types. Press the Down arrow key if the correct connection type is displayed. If the desired connection type is not displayed, press the Right arrow key until the desired connection type appears.

Entering YES selects the connection type shown. Choices are a single or RS-232 to RS-485 convertor. Note: Selecting one connection type deselects any previously selected choice.

Press the Enter key.

Confirms the entry.

PRIMARY PORT

(USER DEFINED)

→

Y/N

PRIMARY PORTS

RS-232

RS-485

Y/N

N/Y

124 Section 2 Operation

Displays the user-defined primary ports. Press the Down arrow if the correct primary port is displayed. If the desired primary port is not displayed, press the Right arrow key until the desired primary port appears.

Entering YES selects the primary port shown. Note: Selecting one primary port deselects any previously selected choice.

Local Programming Mode On TP-6200 3/06

Menu 13—Communications, continued

Menu 13 Displays with Key Entries

Key

Entry Display Description

PRIMARY PORT

(USER DEFINED)

→

YES

Press the Enter key.

PRIMARY PORT

(USER DEFINED)

→

YES

Confirms the entry.

ADDRESS ?

ADDRESS #

BAUD RATE

(USER DEFINED)

PROTOCOL

MODBUS

→

Y/N

9600

19200

BAUD RATES

BAUD RATE

(USER DEFINED)

N/Y

N/Y

→

YES

BAUD RATE

(USER DEFINED)

→

YES

→

Displays the address number. Use the numeric keys to enter the desired address 1--128. Use one address number per unit and use consecutive numbers. Individual addresses are necessary for the software to call up the desired unit.

Confirms the entry.

Displays the user-defined baud rate. Press the Down arrow key if the correct baud rate is displayed. If the desired baud rate is not displayed, press the Right arrow key until the desired baud rate appears.

Entering YES selects the baud rate shown. Note: Selecting one baud rate deselects any previously selected choice.

Press the Enter key.

Confirms the entry.

Returns the user to Modbus protocol heading.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 125

2.9.14 Menu 14—Programming Mode

Menu 14 allows altering controller data either locally using the keypad or remotely using a PC or other device.

The user must enter a password (access code) to enable the programming mode.

Local Programming.

Local programming is data alteration using the controller keypad and display.

Remote Programming. Remote programming is data alteration using devices connected to a communication port using KBUS or Modbus r.

Note: Log into the local programming mode to edit the programming access code. The factory default access code is the number 0.

Use Menu 14 to change the access code. Record the new number and give the access code to authorized individuals only. Should the controller logic not accept the access code or if the new code number is lost, contact your local authorized distributor/dealer for password information.

The user chooses one of three programming modes:

D

D

D

Local—using the controller keypad

Remote—using a PC

Off—no programming is permitted

Enter Yes to one mode to change the other two choices to No.

Note: Use the generator set controller to initially set up remote programming. Remote programming is not allowed from a PC unless the controller is first set for remote programming using Menu 14.

Note: After completing the programming always place the controller back in the Programming Mode Off position to prevent inadvertent program changes.

Modbus r is a registered trademark of Schneider

Electric.

126 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 14—Programming Mode, continued

Menu 14 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 14

Press the Enter key.

MENU 14

PROGRAMMING MODE

PROGRAMMING MODE

(USER DEFINED)

→

Y/N

PROGRAMMING MODES

OFF

LOCAL

REMOTE

Y/N

N/Y

N/Y

PROGRAMMING MODE

(USER DEFINED)

→

YES

PROGRAMMING MODE

ENTER CODE *

PROGRAMMING MODE

(USER DEFINED)

→

YES

PROGRAMMING MODE

CHANGE ACCESS CODE

→

PROGRAMMING MODE

ENTER OLD CODE *

PROGRAMMING MODE

ENTER NEW CODE *

PROGRAMMING MODE

CHANGE ACCESS CODE

→

MENU 14

PROGRAMMING MODE

Displays the menu number and name.

Displays the user-defined programming mode. Press the Down arrow key if the correct programming mode is displayed.

If the desired programming mode is not displayed, press the Right arrow key until the desired programming mode appears.

Entering YES selects the programming mode shown.

Note: Selecting one programming mode deselects any previously selected choice.

Press the Enter key.

Changing the programming mode requires entering the access code.

Enter the access code and press the Enter key.

Note: The factory default access code is the number 0.

Confirms the entry.

Displays the programming mode and changes the access code. Press the Down arrow key if you do not wish to change the access code. To change the access code, press the Right arrow key.

Enter the old access code and press the Enter key.

Enter the new access code and press the Enter key.

Confirms the entry.

Returns the user to the programming mode heading.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 127

2.9.15 Menu 15—Paralleling Relays (PR)

Menu 15 provides the necessary paralleling relays for units with the optional paralleling protection feature. If

Menu 15—Paralleling Relays

Menu 15 Displays with Key Entries

Key

Entry Display Description the generator set personality profile did not include the paralleling option this menu will not appear on the display.

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 15

Press the Enter key.

MENU 15

PARALLELING RELAYS

PR OVERVOLTAGE

?%

PR OVERVOLTAGE

#%

TIME DELAY

?SEC

→

#VAC

→

#VAC

→

TIME DELAY

#SEC

→

PR OVERVOLTAGE

?%

PR UNDERVOLTAGE

?%

PR UNDERVOLTAGE

#%

TIME DELAY

?SEC

→

#VAC

→

#VAC

→

#VAC

→

TIME DELAY

#SEC

→

PR OVERVOLTAGE

?%

→

#VAC

PR OVERFREQUENCY

?%

→

#HZ

PR OVERFREQUENCY

#%

TIME DELAY

?SEC

→

#HZ

→

TIME DELAY

#SEC

→

PR OVERFREQUENCY

?%

→

#VAC

128 Section 2 Operation

Displays the menu number and name.

Displays the overvoltage % value. When required, use the numeric keys to enter the desired overvoltage % value and press the Enter key.

Displays the corrected overvoltage % value.

Displays the overvoltage time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected overvoltage time delay value.

Returns the user to the overvoltage % value display.

Displays the undervoltage % value. When required, use the numeric keys to enter the desired undervoltage % value and press the Enter key.

Displays the corrected undervoltage % value.

Displays the undervoltage time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected undervoltage time delay value.

Returns the user to the overvoltage % value display.

Displays the overvoltage % value. When required, use the numeric keys to enter the desired overvoltage % value and press the Enter key.

Displays the corrected overvoltage % value.

Displays the overvoltage time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected overvoltage time delay value.

Returns the user to the overvoltage % value display.

Local Programming Mode On TP-6200 3/06

Menu 15—Paralleling Relays, continued

Menu 15 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 15

Press the Enter key.

PR OVERVOLTAGE

?%

MENU 15

PARALLELING RELAYS

→

#VAC

PR OVERVOLTAGE

#%

TIME DELAY

?SEC

→

#VAC

→

→

TIME DELAY

#SEC

PR OVERVOLTAGE

?%

PR UNDERVOLTAGE

?%

PR UNDERVOLTAGE

#%

TIME DELAY

?SEC

→

#VAC

→

#VAC

→

#VAC

→

TIME DELAY

#SEC

→

PR OVERVOLTAGE

?%

→

#VAC

PR OVERFREQUENCY

?%

→

#HZ

PR OVERFREQUENCY

#%

TIME DELAY

?SEC

→

#HZ

→

TIME DELAY

#SEC

→

PR OVERFREQUENCY

?%

→

#HZ

Displays the menu number and name.

Displays the overvoltage % value. When required, use the numeric keys to enter the desired overvoltage % value and press the Enter key.

Displays the corrected overvoltage % value.

Displays the overvoltage time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected overvoltage time delay value.

Returns the user to the overvoltage % value display.

Displays the undervoltage % value. When required, use the numeric keys to enter the desired undervoltage % value and press the Enter key.

Displays the corrected undervoltage % value.

Displays the undervoltage time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected undervoltage time delay value.

Returns the user to the overvoltage % value display.

Displays the overfrequency % value. When required, use the numeric keys to enter the desired overfrequency % value and press the Enter key.

Displays the corrected overfrequency % value.

Displays the overfrequency time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected overfrequency time delay value.

Returns the user to the overfrequency % value display.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 129

Menu 15—Paralleling Relays, continued

Menu 15 Displays with Key Entries

Key

Entry Display Description

PR UNDERFREQUENCY

→

?% #HZ

PR UNDERFREQUENCY

→

#% #HZ

TIME DELAY

?SEC

→

TIME DELAY

#SEC

→

PR UNDERFREQUENCY

→

?% #HZ

PR REVERSE POWER

?%

→

#KW

PR REVERSE POWER

#%

TIME DELAY

?SEC

→

#KW

→

TIME DELAY

#SEC

TIME DELAY

#SEC

→

PR REVERSE POWER

?%

SD REVERSE POWER

?%

→

#KW

→

#KW

SD REVERSE POWER

#%

TIME DELAY

?SEC

→

#KW

→

→

SD REVERSE POWER

?%

PR OVER POWER

?%

→

#KW

→

#KW

PR OVER POWER

#%

TIME DELAY

?SEC

→

#KW

→

TIME DELAY

#SEC

→

PR OVER POWER

?%

→

#KW

Displays the underfrequency % value. When required, use the numeric keys to enter the desired underfrequency % value and press the Enter key.

Displays the corrected underfrequency % value.

Displays the underfrequency time delay.

When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected underfrequency time delay value.

Returns the user to the underfrequency % value display.

Displays the reverse power % value. When required, use the numeric keys to enter the desired reverse power % value and press the Enter key.

Displays the corrected reverse power % value.

Displays the reverse power time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected reverse power time delay value.

Returns the user to the reverse power % value display.

Displays the reverse power shutdown % value. When required, use the numeric keys to enter the desired reverse power shutdown % value and press the Enter key.

Displays the corrected reverse power shutdown % value.

Displays the reverse power shutdown time delay. When required, use the numeric keys to enter the desired time delay value and press the

Enter key.

Displays the corrected reverse power shutdown time delay value.

Returns the user to the reverse power shutdown % value display.

Displays the over power % value. When required, use the numeric keys to enter the desired over power % value and press the Enter key.

Displays the corrected over power % value.

Displays the over power time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected over power time delay value.

Returns the user to the over power % value display.

130 Section 2 Operation Local Programming Mode On TP-6200 3/06

Menu 15—Paralleling Relays, continued

Menu 15 Displays with Key Entries

Key

Entry Display Description

SD OVER POWER

?%

SD OVER POWER

#%

TIME DELAY

?SEC

TIME DELAY

#SEC

→

#KW

→

#KW

→

→

Displays the over power shutdown % value. When required, use the numeric keys to enter the desired over power shutdown % value and press the Enter key.

Displays the corrected over power shutdown % value.

Displays the over power shutdown time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected over power shutdown time delay value.

SD OVER POWER

?%

PR LOSS OF FIELD

?%

PR LOSS OF FIELD

#%

TIME DELAY

?SEC

→

#KW

→

#KVAR

→

#KVAR

→

Returns the user to the over power shutdown % value display.

Displays the loss of field % value. When required, use the numeric keys to enter the desired loss of field % value and press the Enter key.

Displays the corrected loss of field % value.

Displays the loss of field time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

TIME DELAY

#SEC

→

Displays the corrected loss of field time delay value.

PR LOSS OF FIELD

?%

SD LOSS OF FIELD

?%

SD LOSS OF FIELD

#%

TIME DELAY

?SEC

→

#KVAR

→

#KVAR

→

#KVAR

→

Returns the user to the loss of field % value display.

Displays the loss of field shutdown % value. When required, use the numeric keys to enter the desired loss of field % value and press the

Enter key.

Displays the corrected loss of field shutdown % value.

Displays the loss of field shutdown time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected loss of field shutdown time delay value.

TIME DELAY

#SEC

→

SD LOSS OF FIELD

?%

→

#KVAR

PR OVERCURRENT VR

?%

→

#AMPS

PR OVERCURRENT VR

#%

→

#AMPS

TIME DELAY

?SEC

→

TIME DELAY

#SEC

→

Returns the user to the loss of field shutdown % value display.

Displays the voltage regulator overcurrent % value. When required, use the numeric keys to enter the desired voltage regulator overcurrent % value and press the Enter key.

Displays the corrected voltage regulator overcurrent % value.

Displays the voltage regulator overcurrent time delay. When required, use the numeric keys to enter the desired time delay value and press the

Enter key.

Displays the corrected voltage regulator overcurrent time delay value.

PR OVERCURRENT VR

?%

→

#AMPS

Returns the user to the voltage regulator overcurrent % value display.

TP-6200 3/06 Local Programming Mode On Section 2 Operation 131

Menu 15—Paralleling Relays, continued

Menu 15 Displays with Key Entries

Key

Entry Display Description

SD OVER CURRENT VR

?%

→

#AMPS

Displays the voltage regulator over current shutdown % value. When required, use the numeric keys to enter the desired voltage regulator over current shutdown % value and press the Enter key.

Displays the corrected voltage regulator over current shutdown % value.

SD OVER CURRENT VR

#%

→

#AMPS

TIME DELAY

?SEC

→

TIME DELAY

#SEC

SYNC VOLTAGE MATCH

# VAC

→

SD OVER CURRENT VR

?%

→

#AMPS

SYNC VOLTAGE MATCH

? VAC

→

→

Displays the voltage regulator over current shutdown time delay. When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected voltage regulator over current shutdown time delay value.

Returns the user to the voltage regulator over current shutdown % value display.

Displays the synchronization matching voltage value. When required, use the numeric keys to enter the desired synchronization matching voltage value and press the Enter key.

Displays the corrected synchronization matching voltage value.

SYNC FREQ MATCH

? HZ

→

→

Displays the synchronization matching frequency value. When required, use the numeric keys to enter the desired synchronization matching frequency value and press the Enter key.

Displays the corrected synchronization matching frequency value.

SYNC FREQ MATCH

# HZ

SYNC PHASE MATCH

? DEG

→

→

Displays the synchronization matching phase value. When required, use the numeric keys to enter the desired synchronization matching phase value and press the Enter key.

Displays the corrected synchronization matching phase value.

SYNC FREQ MATCH

# DEG

TIME DELAY

?SEC

TIME DELAY

#SEC

→

→

Displays the synchronization time delay.

When required, use the numeric keys to enter the desired time delay value and press the Enter key.

Displays the corrected synchronization time delay value.

SYNC VOLTAGE MATCH

? VAC

→

Returns the user to the synchronization matching voltage value display.

132 Section 2 Operation Local Programming Mode On TP-6200 3/06

2.9.16 Menu 20—Factory Setup

Menu 20 provides generator set, alternator, controller, and engine identification information. The user can use this menu to determine the generator set operating days and identify the controller software (code) version. The factory setup menu information is locked by the manufacturer. The temperature sensor setup applies to non-ECM engines only.

Menu 20—Factory Setup

Menu 20 Displays with Key Entries

Key

Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 20

MENU 20

FACTORY SETUP

FINAL ASSEMBLY DATE

DD/MM/YY

FINAL ASSEMBLY

CLOCK NO #

OPERATING DAYS #

MODEL NO

SPEC NO

GENSET SERIAL NO

#

#

#

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the final assembly date at the factory.

Displays the final assembly clock number at the factory.

Displays the generator set operating days.

Displays the generator set model number.

Displays the generator set specification number.

Displays the generator set serial number.

ALTERNATOR PART NO #

Displays the alternator part number.

ENGINE PART NO #

TEMP SENSOR

GM31045-X

SERIAL NO

CONTROLLER SERIAL NO #

CODE VERSION

COPYRIGHT

SETUP LOCKED

YES

#

#

XXXX

YES

Displays the engine part number.

TEMP SENSOR

GM16787

NO TEMP SENSOR

GM17362

Displays the generator set serial number.

Displays the controller serial number.

Displays the controller software (code) version.

Displays the setup locked by the manufacturer.

NO

TP-6200 3/06 Local Programming Mode On Section 2 Operation 133

Notes

134 Section 2 Operation Local Programming Mode On TP-6200 3/06

Under normal operating conditions, the generator set’s alternator requires no routine service.

Consult

Section 2.1, Prestart Checklist, for a list of routine checks.

3.1 Alternator Service

When operating the generator set under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator while the generator set is running. Direct the stream of air through openings in the generator set end bracket.

Section 3 Scheduled Maintenance

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

WARNING

3.2 Engine Service

Perform engine service at the intervals specified in the engine manufacturer’s service literature. Contact an authorized service distributor/dealer to obtain service literature.

Note: Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service.

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

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.

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

Hazardous voltage.

Moving rotor.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.

Replace guards, screens, and covers before operating the generator set.

TP-6200 3/06 Section 3 Scheduled Maintenance 135

3.3 Service Schedule

System—Component

Fuel System

Day tank level

Flexible lines and connections

Fuel level switch

Main tank supply level

Solenoid valve operation

Transfer pump operation

Water in system, remove

Filter(s)

Gasoline supply

Fuel piping

Tank vents and return lines for obstructions

Lubrication System

Oil level

Crankcase breather

Change oil

Visually Inspect

X

X

X

X

X

X

Check

X

X

D

X

Action

Change

R

D

D

D

Replace filter(s)*

D

Cooling System

Air cleaner to room/enclosure

Block heater operation

Coolant level

Flexible hoses and connectors

Water pump(s)

Fan and alternator belts

Coolant temperature protection level

D

X

D

D

X

X

D

X

D

R

Lubricate fan bearings (1350--2800 kW) X X

Air ducts, louvers

Coolant

Heat exchanger

Louver motors and controls

Radiator exterior

Water supply to heat exchanger

Exhaust System

Drain condensate trap

Leakage

Insulation, fire hazards

Flexible connector(s)

Excessive back pressure

Hangers and supports

X

X

X

X

X

X

X

X

X

DC Electrical System

Battery charger operation, charge rate

Battery electrolyte level

Battery specific gravity, charge state

X

X

Recharge after engine start

Remove corrosion, clean and dry battery and rack

Clean and tighten battery terminals

X

X

X

X

Tighten DC electrical connections X

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.

If not indicated, follow this service schedule. Some items may not apply to all generator sets.

R Replace as necessary.

X Action

* Service more frequently if operated in dusty areas.

D

D

D

D

R

Clean

D

X

X

X

X

X

Test

X

X

X

D

X

X

X

Interval

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Weekly

Quarterly

Six Months

Yearly

Yearly

Weekly

Quarterly

50 Hours or Yearly

50 Hours or Yearly

Weekly

Weekly

Weekly

Weekly

Weekly

Monthly

Six Months

200 Hours or

Six Months

Yearly

Yearly

Yearly

Yearly

Yearly

Yearly

Weekly

Weekly

Quarterly

Six Months

Yearly

Yearly

Monthly

Monthly

Monthly

Monthly

Monthly

Quarterly

Six Months

136 Section 3 Scheduled Maintenance TP-6200 3/06

Service Schedule, continued

System—Component

AC Electrical System

Controller lamp test

General Inspection

Circuit breakers, fuses

[

Wire abrasions where subject to motion

Safety and alarm operation

Tighten control and power wiring connections

Transfer switch main contacts

[

Voltage-sensing device/relay adjustment

[

Wire-cable insulation breakdown

Engine and Mounting

General inspection

Governor operation, lubricate moving parts

Air cleaner service

Choke, carburetor adjustment

Governor oil (mechanical governor only)

Ignition components

Injector pump and injector flow rate, pressure, spray pattern

Valve clearance

Visually Inspect

X

X

X

X

X

X

D

D

D

Action

Check

X

X

X

X

D

D

D

D

D

Change

R

D

D

D

Bolt torque

D

Remote Control System, etc.

Compartment condition

Remote control

Run generator set

Alternator

General inspection

Rotor and stator

Bearing condition

Exciter

Voltage regulator

Measure and record resistance readings of windings with insulation tester (Megger r, with SCR assembly or rectifier disconnected)

X

X

X

X

X

X

X

X

X

Blow dust out of alternator* X

General Condition of Equipment

Any condition of vibration, leakage, noise, temperature, or deterioration

Ensure that system is set for automatic operation

X X

X

Interior of equipment room or outdoor weather housing X

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.

If not indicated, follow this service schedule. Some items may not apply to all generator sets.

R Replace as necessary.

X Action.

* Service more frequently if operated in dusty areas.

[ Do not break manufacturer’s seals or internally inspect these devices.

R

Clean

X

X

D

X

X

X

X

D

X

X

Test

R

X

X

D

X

D

D

X

X

X

Weekly

Monthly

Six Months

Six Months

Yearly

Yearly

Yearly

3 Years or

500 Hours

3 Years or

500 Hours

Weekly

Monthly

Monthly

Weekly

Yearly

Yearly

Yearly

Yearly

Yearly

2 Years or

300 Hours

Interval

Weekly

Weekly

Monthly

Quarterly

Six Months

Yearly

Yearly

Yearly

3 Years or

500 Hours

Weekly

Weekly

Weekly

Megger r is a registered trademark of Biddle Instruments.

TP-6200 3/06 Section 3 Scheduled Maintenance 137

3.4 Alternator Bearing Service

Have an authorized service distributor/dealer perform service.

3.4.1

20--300 kW Models

Replace the end bracket bearing every 10,000 hours of operation in standby and prime power applications.

Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage.

Replace the tolerance ring, if equipped, following end bracket removal. The sealed end bracket bearing requires no additional lubrication.

3.4.2

350--2000 kW Models with

Single-Bearing Alternator

The alternator bearing requires lubrication at intervals specified in the generator set technical manual. Use

Chevron SRI or equivalent antifriction, high-quality grease with a lubrication temperature range of --30

°C to

175

°C (--22°F to 350°F).

3.4.3

1250--2800 kW Models with

Two-Bearing Alternator

Refer to the generator set service manual for bearing maintenance information.

3.5 Diesel Fuel Systems

3.5.1

Bleeding Air from Fuel System

Bleed air from the fuel system after fuel system maintenance, such as replacing the fuel filter(s). Use the hand prime pump kit, when equipped. The hand prime fuel pump eliminates the need for cranking the engine to bleed air from the fuel system.

Note: Bleed air from the fuel system according to the engine manufacturer’s instructions. Trapped air in the fuel system causes difficult starting and/or erratic engine operation.

Note: Correct any fuel leaks encountered during the priming procedure.

1. Place the fuel valves in the fuel system prime position. Close the fuel valve located between the pipe tee and the engine. Open the fuel valves on each side of the fuel prime pump. See Figure 3-1.

Note: The illustration shows a generator set without a fuel/water separator. The valve location and position for a generator set equipped with a fuel/water separator is similar.

2. Loosen the bleed screw at the engine. Refer to the engine operation manual for location of the bleed screw(s). The bleed screw allows air to be expelled from the fuel system when the hand prime pump is operated.

3. Rotate the hand prime pump handle counterclockwise until fuel flows from the bleed screw. Stop pumping.

4. Tighten the bleed screw. Wipe up any fuel leakage.

5. Place the fuel valves in the normal operation position. Open the fuel valve located between the pipe tee and the engine. Close the fuel valves on each side of the fuel prime pump.

Close this Valve

Open this Valve

Open this Valve

Valve Open Valve Closed

PK-272000-H

Figure 3-1 Hand Prime Pump with Valve Positions for Fuel Priming (generator set without a fuel/water separator shown), Typical

138 Section 3 Scheduled Maintenance TP-6200 3/06

3.5.2

Subbase Fuel Day Tank Electronic

Control Module (ECM)

With an electronic control module (ECM), the optional subbase diesel fuel tank functions as a day tank.

Following are operating information and features of the

ECM. See Figure 3-2 for the ECM front panel layout.

224825

Figure 3-2 ECM Front Panel Layout

Servicing the day tank. Hazardous voltage can cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual.

Disconnect the power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power.

Notice that line voltage is still present within the ECM when the

POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution.

ECM General Function

The ECM controls a pump/motor that maintains the day tank fuel level. The ECM motor relay is connected to the pump/motor. The ECM starts the pump when the fuel level drops to 87% of full and stops the pump when the day tank is full.

ECM Function Indicator LEDs

Two LEDs on the front panel indicate ECM operation.

See Figure 3-2 for the locations of the LEDs. Figure 3-3 describes the LED functions.

Function

Power On

Description

LED lights to indicate that power is applied to the ECM.

LED lights when the pump starts.

Pump Running

Figure 3-3 ECM Function Indicator LEDs

Level Sensor

An electronic analog float gauge located below the ECM on the mounting bracket determines the day tank fuel level. Nine LEDs on the ECM indicate the day tank fuel level from full to empty.

ECM Mode

The ECM has three pushbutton switches for normal operation and one internal test button. See Figure 3-4.

Pushbutton

Off

On

Test

Internal test

Description

Pushbutton disables the ECM for routine maintenance to the tank system.

Pushbutton activates the ECM after the

OFF pushbutton is depressed. On power-up after a power outage, the ECM automatically turns on.

Pushbutton lights front panel LEDs for

3 seconds and activates the pump/motor for as long as the pushbutton is depressed.

The alarm relays maintain their original positions.

Pushbutton (located inside the ECM) tests each alarm LED and remote annunciation relay in sequential order (high fuel to ECM functional).

Figure 3-4 ECM Pushbuttons

ECM Alarms

The ECM has five standard alarm conditions indicated locally by LEDs and remotely by relays.

Figure 3-5 describes the five alarm conditions. Make controller connections to the normally open and normally closed relay contacts provided.

Alarm

High fuel

Low fuel

Critical low fuel

(engine shutdown)

Fuel in rupture basin, if equipped

ECM functional

Description

Alarm activates at 106% of normal fuel level.

Alarm activates at 62% of normal fuel level. The alarm provides time to respond to a potential problem before a low fuel shutdown occurs.

Alarm activates at 6% of normal fuel level to warn the operator to shut down the generator set before fuel runs out.

Alarm activates when the ECM detects fuel in the rupture basin.

Alarm activates to indicate a problem with the ECM operation.

Note: The ECM functional alarm relay activates a user-installed alarm when the relay deenergizes.

Figure 3-5 ECM Alarms

TP-6200 3/06 Section 3 Scheduled Maintenance 139

3.5.3

Subbase Inner Fuel Tank Alarm

This kit provides for both audible and visual alarms from a location remote from the generator set if a leak is detected in the inner fuel tank of the double-wall subbase fuel tanks. See Figure 3-6. If the inner tank is leaking, a sensor installed in the outer tank sends an electrical signal to the alarm plate when the sensor becomes immersed in the fuel collecting in the outer tank. If a leak is detected, the alarm horn will sound and the fault lamp will light. The alarm horn is quieted by moving the alarm switch to the SILENCE position; the alarm lamp remains lit until the fault is corrected. See

Figure 3-7 for troubleshooting information.

Inner Tank

Fuel Leak

Alarm

Normal

Alarm

Silence

Leak Alarm Panel

Resetting Procedure

Use the following procedure to reset the alarm after a fault alarm.

1. Move the alarm switch to the SILENCE position to stop the alarm horn. The lamp will remain lit.

2. Disconnect the generator set from the load with the line circuit breaker or the automatic transfer switch.

3. Repair or replace the inner fuel tank.

4. Move the generator set master switch to the

OFF/RESET position and then to the RUN position for startup. The alarm horn sounds and the lamp goes out.

5. Reconnect the generator set to the load via the line circuit breaker or the automatic transfer switch.

6. Move the generator set master switch to the

AUTO position for startup by remote transfer switch or remote start/stop switch.

Move the alarm switch to the NORMAL position.

3.6 Gas/Gasoline Fuel Systems

This section describes fuel systems that are not covered in the engine operation manual or engine service manual.

3.6.1

Gaseous Fuel System Concept

The gaseous fuel system uses a fuel valve with a solenoid to control the fuel flow to the fuel regulator. The generator set-mounted regulator reduces the fuel pressure as fuel passes to the carburetor.

See

Figure 3-8.

FF-273000-D

Figure 3-6 Inner Fuel Tank Leak Alarm

(20--300 kW Model Shown)

1 2 3 4 5

Switch Position

Alarm Float

Observation

Normal Open The alarm horn and the lamp are not energized.

Normal Closed The alarm horn and lamp activate when a fuel leak occurs. If the alarm switch is moved to the silence position, the lamp stays on until the fuel leak fault is corrected.

Silence Open The alarm horn sounds to alert the user that the alarm horn switch is not in the normal position and that the alarm horn will not sound should a fuel leak occur.

Figure 3-7 Inner Fuel Tank Leak Alarm

Troubleshooting

140 Section 3 Scheduled Maintenance

1. Primary regulator (supplied by gas supplier or user)

2. Pressure gauge

3. Solenoid valve

4. Secondary regulator

5. Carburetor

TP-5750-3

Figure 3-8 Fuel Regulator and Valve, Typical

TP-6200 3/06

The carburetor/mixer controls the ratio of fuel to air under varying load and speed conditions. Because the carburetor receives fuel in a gaseous state, it does not have to vaporize the fuel. When switching from natural gas to LP gas or LP gas to natural gas, verify that the electronic governor maintains the rated engine speed

(1800 rpm at 60 Hz or 1500 rpm at 50 Hz). If the engine speed is incorrect, refer to the generator set service manual for the governor adjustment procedure.

3.6.2

LP Liquid Withdrawal Fuel System

Concept

With the LP liquid withdrawal fuel system, pressurized liquid LP fuel passes from the tank to a vaporizer. The vaporizer converts the liquid fuel to gas before sending it to the carburetor. The system also includes a fuel valve that shuts off the fuel flow when the engine stops.

Contact an authorized service distributor/dealer for availability.

3.6.3

LP Gas/Natural Gas Conversion for Straight Gas Fuel System

Most models operate on either LP gas or natural gas fuel by performing the fuel conversion procedure. Some models require a different fuel kit when changing gas fuels. Consult your local generator set distributor/dealer for additional information.

Fuel conversion may decrease generator set output and affect exhaust emissions. Consult your local generator set distributor/dealer for additional information.

Fuel Conversion Procedure

When converting the generator set to operate with LP gas, remove the internal spring from the secondary regulator. Install the spring to operate the generator set on natural gas.

Note: Not all fuel regulators require spring and retainer removal for fuel conversion. A hang tag on the fuel regulator identifies the conversion procedure.

TP-6200 3/06

LP Fuel Conversion Procedure

Use the following steps to remove the internal spring from the fuel regulator:

1. Remove the fuel regulator cover plug.

See

Figure 3-9.

4 3

1

2

SB-527

1. Fuel regulator

2. Spring

3. Adjustment screw

4. Cover plug

Figure 3-9 Fuel Regulator, Typical

2. Remove the adjustment screw and spring from the fuel regulator.

Save the adjustment screw and spring for possible conversion back to natural gas.

3. Reinstall the cover plug.

Natural Gas Fuel Conversion Procedure

Use the following steps to convert the generator set to natural gas:

1. Remove the fuel regulator cover plug.

See

Figure 3-9.

2. Replace the spring and adjustment screw.

3. Connect a manometer to check the fuel supply pressure on the carburetor side of the regulator after any fuel system equipment accessories. The recommended fuel supply pressures are shown in the generator set spec sheet.

4. Adjust the fuel supply pressure with the generator set running at full load.

Rotate the adjustment screw on the fuel regulator until the pressure indicated by the manometer matches the specified pressure.

Use the lower pressure value if the generator set still provides good response and full power. Lower-than-specified pressures may result in poor response to load changes or lack of power.

5. Reinstall the cover plug.

Section 3 Scheduled Maintenance 141

3.6.4

Fuel System Changeover Kits

Automatic Changeover

A changeover fuel system kit provides automatic changeover from natural gas to LP gas vapor or from

LP gas vapor to natural gas. The primary and backup fuels each have a secondary fuel regulator and a fuel valve. Typically, the primary fuel is natural gas; the backup fuel is LP gas vapor. When the generator set starts, the primary fuel valve opens and the backup fuel valve closes.

The primary fuel line has a vacuum switch in series with a relay connected to the start/run circuit. When the primary fuel pressure drops below

0.6 kPa (1.4 oz./in.

2

) or 6.4 cm (2.5 in.) water column , a relay opens the backup fuel valve and closes the primary fuel valve. When the primary fuel pressure rises above 0.6 kPa (1.4 oz./in.

2

) or 6.4 cm (2.5 in.) water column, the generator set uses the primary fuel.

Contact an authorized service distributor/dealer for kit availability.

Manual Changeover

A manual changeover fuel system allows manual changeover from gasoline to natural gas or LP gas, or from natural gas or LP gas to gasoline. Typically, the combination system uses gas as the primary, preferred fuel and gasoline in emergencies. If the primary fuel is unavailable (an empty fuel tank or fuel supply disruption), the system uses gasoline.

A toggle switch on the generator set controls the fuel choice and energizes either a fuel solenoid and electric fuel pump for gasoline or a fuel valve for gas. Pull out the control cable for gasoline and push in the control cable for gas.

3.6.5

Carburetor Adjustment

Before adjusting the carburetor, verify that the engine compression and the ignition system meet specifications.

Do not adjust the carburetor to compensate for other engine disorders. If the engine speed is incorrect, adjust the electronic governor to achieve 1800 rpm (at 60 Hz) or 1500 rpm (at 50 Hz).

Adjust the carburetor if governor adjustment alone does not result in the desired engine speed.

Adjusting the carburetor affects the engine fuel mixture.

Routine carburetor adjustment is not necessary.

However, if the carburetor is removed or tampered with, the carburetor may require adjustment to achieve optimum engine performance.

Some engines have sealed carburetors that are not adjustable.

Gasoline Carburetor Adjustment

Refer to the engine operation manual or engine service manual for gasoline carburetor adjustment information.

Gaseous Carburetor (Fuel Mixer) Adjustment

Procedure

Use the following procedure to adjust the carburetor

(fuel mixer).

1. Start the generator set and run it at approximately half load.

2. Adjust the engine fuel mixture screw (Figure 3-10) until the engine runs smoothly.

1

2

3

1. Fuel adjusting screw

2. Lean

3. Rich

Figure 3-10 Fuel Mixture Adjustment, Typical

TP-5750-3

3. Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels.

4. Stop the generator set.

3.6.6

Fuel System Maintenance

Gasoline Models

Clean or replace the fuel filter at the specified interval.

Service the filters more frequently if the engine runs roughly, as a clogged fuel filter can cause rough engine operation. Some models use a disposable inline fuel filter, which must be replaced. Other models have a fuel pump with an integral fuel filter that requires cleaning at the specified interval.

Gaseous Models

This fuel system requires no regular maintenance.

142 Section 3 Scheduled Maintenance TP-6200 3/06

3.7 Cooling System

The cooling system maintenance information applies to radiator-cooled models and city-water-cooled (heat exchanger) models.

The cooling systems function similarly even though they use different components.

Radiator-cooled models have a radiator with a pressure cap and coolant recovery tank.

City-water-cooled models have a heat exchanger and an expansion/surge tank with a pressure cap.

Note: The 20--40 kW Deutz engine-powered generator sets are oil-cooled and, therefore, do not have a water cooling system.

WARNING

Hot coolant and steam.

Can cause severe injury or death.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop.

Remove the cap after pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has a coolant recovery tank.

Note: Engine damage. Bleed the air from the cooling system to prevent overheating and subsequent engine damage.

Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater.

3.7.1

Coolant Level Check

Check the coolant level in the coolant recovery tank.

Maintain the coolant level between the high and low marks.

Note: Periodically check the coolant level by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant until the level is just below the overflow tube opening of the filler neck.

3.7.2

Cooling System Component

Inspection

To prevent generator set shutdown or damage caused by overheating:

D

Keep the cooling air inlets clean and unobstructed.

D

Inspect the radiator’s exterior for obstructions.

Remove dirt and foreign material using a soft brush or cloth to avoid damaging the radiator fins.

D

Check the hoses and connections for leaks. Replace any cracked, frayed, or spongy hoses.

D

Check the condition and tension of the radiator fan and water pump belt(s).

Follow the belt tension procedure in this manual and/or the engine operation manual.

D

Check the pressure cap seal and replace a cracked or deteriorated cap. Remove dirt and other debris from the pressure cap and filler neck. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures. Replace a leaking pressure cap with one rated for the same pressure.

The pressure cap rating usually appears on the pressure cap.

TP-6200 3/06 Section 3 Scheduled Maintenance 143

3.7.3

Procedure to Drain Cooling

System

For optimum protection, drain, flush, and refill the cooling system at the intervals listed in the service schedule.

Note: Dispose of all waste materials (oil, fuel, coolant, filters, and gaskets) in an environmentally safe manner.

1. Deenergize the block heater, if equipped.

2. Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow through the engine block.

3. Open the radiator and/or engine block coolant drain valve(s) and allow the system to drain.

4. If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease, refer to

Section 3.7.4, Procedure to Flush and Clean the

Cooling System. If the cooling system does not have mineral deposits, go to Section 3.7.5,

Procedure to Refill the Cooling System.

3.7.4

Procedure to Flush and Clean

Cooling System

Use the instructions in the engine operation manual when available to flush and clean the cooling system.

Otherwise, use the following procedure and the cooling system cleaner manufacturer’s instructions.

1. Flush the cooling system with clean water.

2. If the inside of the radiator still has mineral deposits, use a radiator cleaner to remove the remaining deposits following the manufacturer’s instructions.

3. Drain, clean, and flush the coolant recovery tank.

3.7.5

Procedure to Refill Cooling

System

See the generator set spec sheet for coolant capacity.

Note: Do not add coolant to a hot engine.

Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until the engine has cooled.

1. Remove the pressure cap.

2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps.

144 Section 3 Scheduled Maintenance

3. Open the air-bleed petcocks, if equipped. Close the air-bleed petcocks when coolant begins to flow from them.

4. Add coolant additives or water pump lubricants according to the engine manufacturer’s recommendations in the engine operation manual.

5. Fill the cooling system with the recommended coolant/antifreeze mixture of 50% ethylene glycol and 50% clean, softened water to inhibit rust/corrosion and prevent freezing.

Note: A coolant solution of 50% ethylene glycol provides freezing protection to --37

°C

(--34

°F) and overheating protection to

129

°C (265°F).

A coolant solution containing less than 50% ethylene glycol may not provide adequate freezing and overheating protection. A coolant solution containing more than 50% ethylene glycol can cause engine or component damage.

Do not use alcohol or methanol antifreeze or mix them with the specified coolant.

Refer to the engine operation manual for recommendations regarding the coolant mixture to use in extreme temperatures.

6. Replace the pressure cap.

7. Fill the coolant recovery tank to the low mark.

8. Operate generator set until the thermostat opens when the upper cooling system hose warms.

9. Stop the engine and allow it to cool.

10. Check and repair any coolant leaks.

11. Remove the pressure cap.

12. Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck.

13. Replace the pressure cap.

14. Maintain the coolant level in the coolant recovery tank between the high and low marks.

Note: Air pockets often form in the engine water jacket when the coolant system is refilled.

Check the coolant level in the coolant recovery tank after each generator set operation and add coolant as necessary until the coolant level stabilizes. Then check the coolant at the interval specified in the service schedule.

15. Reenergize the block heater, if equipped.

TP-6200 3/06

3.8 Radiator Expansion Joint

Loosening—Initial Setup Only

Loosen the radiator expansion joint nuts on

1200--2000 kW generator sets that have radiators manufactured by Young Radiator Company. Expansion joints located on each side of the radiator permit differential thermal expansion of the radiator tank. The factory tightens the 12 expansion joint nuts before generator set shipment. Loosen the expansion joint nuts one full turn before running the generator set. See

Figure 3-11.

4

2

1

3

4. Inject grease into the two bearings on the fan shaft block and the two bearings on the idler shaft block using a grease gun until a 3--6 mm (0.13--0.25 in.) grease column shows at the bearing pressure relief port. See Figure 3-12.

1

5

2

1. Air flow

2. Expansion joint nuts for rear tank, left side

3. Expansion joint nuts for front tank, left side

4. Top front of radiator

TP-5353-3

Figure 3-11 Expansion Joint Nuts, Top Left Side of

Radiator, Typical

3.9 Fan Bearing Lubrication

The following procedure applies only to 1200--2800 kW generator sets. Lubricate the radiator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage.

Lubricate the bearings every

200 hours of operation when the generator set runs in ambient temperatures below 29

°C (85°F) or when the generator set runs in a dusty and/or humid environment.

Lubrication and Drive Belt Adjustment Procedure

Lubricate the fan shaft and idler shaft bearings with a lithium-complex base, multi-purpose grease with antirust, antifoam, and extreme-pressure additives having a minimum dropping point of 204

°C (400°F).

Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent.

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the generator set engine starting battery(ies), negative (--) lead first, and disconnect power to the battery charger.

3. Remove the belt guards to expose the fan shaft and idler shaft bearings.

4

2

3

TP-5353-3

1

1. Grease fittings

2. Pressure relief port

3. Radiator assembly

4. Idler shaft grease fittings

5. Fan shaft grease fittings

Figure 3-12 Radiator Fan Bearings and Pressure

Relief Ports, Typical

Note: The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication.

5. Remove excess grease from the bearing pressure relief ports.

6. Inspect the fan drive belt and replace if it is damaged or worn. Check the fan belt tension using a poly

V-belt tension gauge and adjust the tension, if necessary. See Figure 3-13.

Generator Set Model

New Belt,

N (lbf.)

Used Belt*,

N (lbf.)

1200-2000 kW

2450--2890

(550--650)

1650--1910

(370--430)

* A belt is considered used after 50 hours of service.

Figure 3-13 Poly V-Belt Tension Specifications

TP-6200 3/06 Section 3 Scheduled Maintenance 145

7. Reinstall the belt guards using the original hardware.

8. Reconnect the generator set engine starting battery(ies), negative (--) lead last.

9. Test run the generator set for a few minutes and listen for belt noise (squeal) indicating a slipping belt. Stop the generator set.

If the belt slips after the belt tension procedure, clean the pulley surfaces and repeat the belt tension procedure. If slippage continues, replace the fan belt.

3.10 Battery

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

fire.

To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.

Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a 12-volt or 24-volt engine electrical system.

Consult the generator set nameplate for the engine electrical system voltage. Consult the generator set spec sheet for battery capacity recommendations for replacement purposes. The wiring diagrams provide battery connection information.

See Figure 3-14,

Figure 3-15, and Figure 3-16 for typical battery connections, including multiple battery configurations.

1

2

1 2

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

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.

Battery gases.

Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a

1 2

EZ-273000-J

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-14 12-Volt Engine Electrical System Single

Starter Motor Typical Battery Connection

146 Section 3 Scheduled Maintenance TP-6200 3/06

1

1

2

2 1 1 2

2

1

2

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-15 24-Volt Engine Electrical System Single

Starter Motor Typical Battery Connection

1 2 3 4

3.10.1 Clean Battery

Clean the battery and cables and tighten the battery terminals according to the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight.

If corrosion exists, disconnect the cables from the battery and remove the corrosion with a wire brush.

Clean the battery and cables with a solution of baking soda and water. Do not allow the cleaning solution to enter battery cells. Flush the battery and cables with clean water and wipe the battery with a dry cloth.

After reconnecting the battery cables, coat the terminals with petroleum jelly, silicon grease, or other nonconductive grease.

3.10.2 Electrolyte Level Inspection

Check the electrolyte level and specific gravity of batteries that have filler caps.

Maintenance-free batteries do not require electrolyte level checking or specific gravity testing.

Check the electrolyte level at the specified interval.

Remove the filler caps and verify that the electrolyte level reaches the bottom of each filler hole.

See

Figure 3-17. Refill as necessary with distilled water or clean tap water. Do not add fresh electrolyte. Tighten the filler caps.

After adding water during freezing temperatures, run the generator set 20--30 minutes to mix the electrolyte and the water to prevent battery damage from freezing.

1

1 2 3 4

KW-272000-B

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

3. To positive (+) terminal on second starter solenoid.

4. To ground (--) terminal on or near second starter motor.

Figure 3-16 24-Volt Engine Electrical System Dual

Starter Motors Typical Battery

Connections

2

1. Filler caps

2. Electrolyte level

Figure 3-17 Battery Electrolyte Level Inspection

1-046

TP-6200 3/06 Section 3 Scheduled Maintenance 147

3.10.3 Specific Gravity Check

Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps.

Holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer.

If the hydrometer used does not have a correction table, consult Figure 3-19. Determine the specific gravity and electrolyte temperature of the battery cells. Locate the temperature in Figure 3-19 and correct the specific gravity by the amount shown.

The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 26.7

_C (80_F). Maintain the specific gravities between cells within

±0.01 of each other.

Charge the battery if the specific gravity is below 1.215

at an electrolyte temperature of 26.7

_C (80_F).

Note: Some battery testers have four or five beads in a test tube. Draw electrolyte into the tube as with the battery hydrometer described in this section or use the manufacturer’s instructions.

Use

Figure 3-18 to interpret typical test results.

Number of Floating Beads Battery Condition

5 Overcharged

4 Fully charged

3

1 or 2

0

A good charge

A low charge

A dead battery

Figure 3-18 Bead-Type Test Interpretation

3.10.4 Charge Battery

Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application.

The engine battery-charging alternator charges the battery while the generator set is running.

Note: If the generator set is in a temporary prime power application in which the generator set has periods of inactivity, the controller circuitry may drain the battery. If there is no power source for a battery charger, place the controller in the prime power mode, if equipped, or disconnect the battery from the generator set.

°

C

°

F

71.1

160

26.7

80

21.1

70

15.6

60

10 50

4.4

40

-- 1.1

30

-- 6.7

20

-- 12.2

10

65.6

150

60.0

140

54.4

130

48.9

120

43.3

110

37.8

100

32.2

90

Correction

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

0

-- .002

-- .004

--. 006

-- .008

-- .010

-- .012

-- .014

+ .016

+ .014

+ .012

+ .010

+ .008

+ .006

+ .004

+ .002

+ .032

+ .030

+ .028

+ .026

+ .024

+ .022

+ .020

+ .018

Example No. 1

Temperature below 26.7

Hydrometer Reading 1.250

Acid Temperature --6.7

Subtract .024 Specific Gravity

Corrected Specific Gravity is 1.226

1.250 -- .024 = 1.226

Example No. 2

Temperature above 26.7

Hydrometer Reading 1.235

Acid Temperature 37.8

°

C (80

°

F)

°

C (20

°

F)

°

C (80

°

F)

°

C (100

°

F)

Add .008 Specific Gravity

Corrected Specific Gravity is

1.243

1.235 + .008 = 1.243

The temperature correction amounts to about .004 (4 points) of specific gravity for each 5.5

°C (10°F) change in temperature.

1-787

Figure 3-19 Specific Gravity Temperature Correction

148 Section 3 Scheduled Maintenance TP-6200 3/06

3.11 Detroit Diesel Engine Control

Systems

Some generator sets equipped with Detroit Diesel engines use a DDEC/MDEC system. Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting the engine.

Note: DDC/MTU engines with MDEC use the 550 controller to display all engine fault code numbers. The engine operation manual provides the fault code description.

Use the following data for informational purposes only.

Consult the engine literature for complete information regarding DDEC/MDEC operation and troubleshooting.

See List of Related Materials in the Introduction section.

Contact an authorized service distributor/dealer for service or diagnostic equipment.

3.11.1 Features

The engine control system optimizes control of critical engine functions and protects against serious engine damage resulting from conditions such as the following:

D

D

D

D

D

Low coolant level

Low coolant pressure

High coolant temperature

Low oil pressure

High oil temperature

The major components of the DDEC/MDEC system include the electronic control module (ECM) and engine sensors.

The DDEC control box is located in the generator set junction box.

3.11.2 DDEC Engine Diagnostics

The DDEC engine protection system monitors engine sensors and electronic components and recognizes system malfunctions.

Critical faults light the check engine (CEL) and stop engine (SEL) lamps on the control box. ECM memory software logs malfunction codes. Consult the engine operation manual or engine service manual to identify the stored failure code. See

Figure 3-20 for the DDEC control box features.

1

A-343591-C

1. Diagnostic request switch

Figure 3-20 DDEC Control Box

Access the stored codes in one of three ways:

D

Place the switch in the DIAGNOSTIC REQUEST position.

The CEL or SEL flashes to identify the failure.

D

Use a hand-held diagnostic data reader (DDR).

Place the switch in the DIAGNOSTIC DATA READER position. Plug the DDR into the control box. The DDR displays the stored failure codes.

D

Use a personal computer software package available from the manufacturer with a translator to access stored codes. Follow the instructions provided with the software.

Code Types

Active code. A code flashing on the SEL lamp indicates a fault currently exists.

Inactive code.

A code flashing on the CEL lamp indicates a previous fault occurrence.

The ECM memory stores inactive codes with time/date identification and the following information:

D

First occurrence of each diagnostic code in engine operating hours.

D

Last occurrence of each diagnostic code in engine operating hours.

D

Total time in seconds that the diagnostic code was active.

TP-6200 3/06 Section 3 Scheduled Maintenance 149

3.12 Engine Control Systems

Some generator sets use an engine control system.

Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine.

Use the following data for general informational purposes only.

See the Engine Service Manual for complete information regarding operation and troubleshooting.

Contact an authorized service distributor/dealer for service or diagnostic equipment.

Engine Control Features

Engine control is an advanced-technology, electronic engine control system. The system optimizes control of critical engine functions and provides protection against serious engine damage.

The major components include the engine control module, engine sensors, and control box located in the generator set junction box.

See Figure 3-21 for the Deutz control box features.

A-364162-B

Figure 3-21 Deutz Engine Control Box

See Figure 3-22 for the John Deere engine control box features.

See Figure 3-23 for the Kohler-branded D300, D350,

D400, D450, and D500 engine control box features.

GM23666-

Figure 3-23 Kohler-Branded Engine Control Box

3.13 Storage Procedure

Perform the following storage procedure before taking a generator set out of service for three months or longer.

Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine component storage.

3.13.1 Lubricating System

Prepare the engine lubricating system for storage as follows:

1. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature.

2. Stop the generator set.

3. With the engine still warm, drain the oil from the crankcase.

4. Remove and replace the oil filter.

5. Refill the crankcase with oil suited to the climate.

6. Run the generator set for two minutes to distribute the clean oil.

7. Stop the generator set.

8. Check the oil level and adjust, if needed.

Figure 3-22 John Deere Engine Control Box

GM30962-A

150 Section 3 Scheduled Maintenance TP-6200 3/06

3.13.2 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using a coolant tester.

2. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines included in the engine operation manual.

3. Run the generator set for 30 minutes to redistribute added coolant.

3.13.3 Fuel System

Prepare the fuel system for storage as follows:

Diesel-Fueled Engines

1. Fill the fuel tank with #2 diesel fuel.

2. Condition the fuel system with compatible additives to control microbial growth.

3. Change the fuel filter/separator and bleed the fuel system. See the engine owner’s manual.

Gasoline-Fueled Engines

1. Add stabilizer to the fuel system.

Follow the manufacturer’s recommended procedure.

2. Run the generator set for 15 minutes to ensure that the stabilized fuel reaches the carburetor.

Gas-Fueled Engines

1. Start the generator set.

2. With the generator set running, shut off the gas supply.

3. Run the generator set until the engine stops.

4. Place the generator set master switch in the

OFF/RESET position.

3.13.4 Internal Engine Components

(Gas/Gasoline-Fueled Engines)

If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows:

1. While the engine is running, spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops.

2. Place the generator set master switch in the

OFF/RESET position.

TP-6200 3/06

If a fogging agent is not available perform the following:

1. Remove the spark plugs.

2. Pour 15 cc (0.5 oz.) of engine oil into each spark plug hole.

Ignition System Damage. Refer to the engine operation manual for ignition system precautions before cranking the engine while the spark plug wires are disconnected.

3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders.

4. Reinstall the spark plugs and torque them to specifications.

3.13.5 Exterior

1. Clean the exterior surface of the generator set.

2. Seal all engine openings except for the air intake with nonabsorbent adhesive tape.

3. To prevent impurities from entering the air intake and to allow moisture to escape from the engine, secure a cloth over the air intake.

4. Mask electrical connections.

5. Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion.

3.13.6 Battery

Perform battery storage after all other storage procedures.

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the battery(ies), negative (--) lead first.

3. Clean the battery. Refer to Section 3.10.1 for the battery cleaning procedure.

4. Place the battery in a cool, dry location.

5. Connect the battery to a float/equalize battery charger or charge it monthly with a trickle battery charger.

Refer to the battery charger manufacturer’s recommendations.

Maintain a full charge to extend battery life.

Section 3 Scheduled Maintenance 151

Notes

152 Section 3 Scheduled Maintenance TP-6200 3/06

Section 4 General Troubleshooting

This section contains generator set troubleshooting, diagnostic, and repair information.

Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, recommended corrective actions, and references to detailed information or repair procedures.

Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment.

Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature.

The battle switch does not override the emergency stop and overspeed shutdown.

When the battle switch function is enabled, the generator set continues to run regardless of shutdown signals where potential engine/alternator damage can occur.

When this input is enabled, the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5— Event History.

See Section 2.9.9, Menu 9—Input Setup, for information on how to enable the battle switch feature.

Cooldown Temperature Override Function.

This function provides the ability to bypass the generator set cooldown temperature shutdown and force the unit to wait for the engine cooldown time delay.

See Section 2.9.8, Menu 8—Time Delays, for information on how to enable the cooldown temperature override feature.

TP-6200 3/06 Section 4 General Troubleshooting 153

abnormalnoise

Excessiveor consumption

Highfuel pressure

Lowoil

Overheats

Lackspower suddenly

Stops outputvoltage low Noor

Startshard start doesnot

Cranksbut crank

Doesnot

154 Section 4 Troubleshooting

TP-6200 3/06

start

TP-6200 3/06 low outputvoltage

Noor

Stops suddenly

Startshard doesnot

Cranksbut crank

Doesnot

Lackspower

Overheats pressure

Lowoil

Highfuel consumption

Excessiveor abnormalnoise

Section 4 Troubleshooting 155

abnormalnoise

Excessiveor consumption

Highfuel pressure

Lowoil

Overheats

Lackspower suddenly

Stops outputvoltage low Noor

Startshard start doesnot

Cranksbut crank

Doesnot

156 Section 4 Troubleshooting

TP-6200 3/06

TP-6200 3/06 Section 4 Troubleshooting 157

Notes

158 TP-6200 3/06

Section 5 Generator Set Reconnection

5.1 Introduction

Use the following voltage reconnection procedure to change the voltage of 10- and 12-lead generator sets.

Frequency changes require voltage regulator and governor adjustments. Refer to the respective spec sheet to determine if frequency is fixed or fieldconvertible.

If frequency is adjustable, refer to the engine service manual and/or governor literature for conversion information.

Refer to the following procedure and the connection schematics. Follow the safety precautions at the front of this manual and in the procedure text and observe

National Electrical Code (NEC) guidelines.

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/ dealer

.

Note: Equipment damage.

Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the selected line voltage.

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

Remove the negative (--) lead first when disconnecting the battery.

Reconnect the negative (--) lead last when reconnecting the battery.

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) Turn the generator set master switch and switchgear engine control switch to the OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery 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 an automatic transfer switch or a remote start/stop switch.

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.

Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

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.

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.

Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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.

TP-6200 3/06 Section 5 Generator Set Reconnection 159

5.2 Voltage Reconnection

Procedure

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the generator set engine starting battery, negative (--) lead first. Disconnect power to the battery charger (if equipped).

3. Use Figure 5-1, Figure 5-2, Figure 5-3, or

Figure 5-4 to determine the generator set voltage configuration.

Note the original voltage and reconnect as needed. Route leads through current transformers (CTs) and connect them according to the diagram for the desired phase and voltage.

Note: Position current transformers CT1, CT2, and CT3 with the dot or HI side CT marking toward the generator set.

4. Reconnect the battery, negative lead last.

5. Go to Menu 14—Programming Mode and select the Program Mode—Local. See Section 2.9.14,

Menu 14—Programming Mode, for the complete procedure.

6. Go to Menu 7—Generator System and update the voltage information. See Section 2.9.7, Menu 7—

Generator System, for the complete procedure.

7. Go to Menu 12—Calibration and perform the calibration procedure.

See Section 2.9.12,

Menu 12—Calibration, procedure.

for the complete

8. Go to Menu 11—Voltage Regulator and perform the voltage regulator setup procedure.

See

Section 2.9.11, Menu 11—Voltage Regulator, for the complete procedure.

9. Move the generator set master switch to the RUN position to start the generator set. Check the digital display for correct voltages using Menu 1—

Generator Monitoring.

10. Move the generator set master switch to the

OFF/RESET position to stop the generator set after completing the voltage adjustments.

11. Replace the controller cover.

12. Place the generator set master switch in the AUTO or RUN position.

160 Section 5 Generator Set Reconnection TP-6200 3/06

Figure 5-1 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5857-B

TP-6200 3/06 Section 5 Generator Set Reconnection 161

Figure 5-2 20--400 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875A-G

162 Section 5 Generator Set Reconnection TP-6200 3/06

Figure 5-3 60 (with Oversize Alternator)--400 kW Wound Field Alternators, ADV-5875B-G

TP-6200 3/06 Section 5 Generator Set Reconnection 163

Figure 5-4 350--2800 kW Pilot-Excited, Permanent Magnet Alternator, ADV-5875C-G

164 Section 5 Generator Set Reconnection TP-6200 3/06

Section 6 Accessories

6.1 Accessories and Connections

Several accessories help finalize installation, add convenience to operation and service, and establish state and local code compliance.

Accessories vary with each generator set model and controller. Select factory-installed and/or shippedloose accessories. See Figure 6-1 for a list of available kits. Obtain the most current accessory information from your local authorized service distributor/dealer.

This section illustrates several accessories available at print time of this publication. Accessory kits generally include installation instructions. See wiring diagrams manual for electrical connections not shown in this section. See the installation instructions and drawings supplied with kit for information on kit mounting location.

The instructions provided with the accessory kit supersede these instructions where there are differences.

In general, run AC and DC wiring in separate conduit. Use shielded cable for all analog inputs. Observe all applicable national, state, and local electrical codes during accessory installation.

6.1.1

Audiovisual Alarm Kit

An audiovisual alarm warns the operator at a remote location of fault shutdowns and prealarm conditions.

Audiovisual alarms include an alarm horn, an alarm silence switch, and common fault lamp. See Figure 6-2 and Figure 6-3.

See Section 6.2, Accessory

Connections, for terminal identification.

Note: Use the audiovisual alarm with a dry contact kit.

Kit Description

Audiovisual Alarm

Common Failure Relay (Terminal 32A)

Controller (Customer) Connection

Float/Equalize Battery Charger (with alarms)

Idle (Speed) Mode Feature

Low Fuel (Level) Switch

Low Fuel (Pressure) Switch

Prime Power Switch

Remote Annunciator (16-light panel)

Remote Emergency Stop

Remote Reset Feature

Remote Serial Annunciator (RSA 1000)

Remote Speed Adjustment Potentiometer (requires electronic governor) Non-ECM models only

Run Relay

Single-Relay Dry Contact

Ten-Relay Dry Contact

Twenty-Relay Dry Contact

Wireless Monitor

Figure 6-1 Optional Accessories

Front View

Side View

FAULT

A-292887

Figure 6-2 Audiovisual Alarm

Figure 6-3 Audiovisual Alarm Connections

TP-6200 3/06

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM13984-

Section 6 Accessories 165

6.1.2

Common Failure Relay Kit

The common failure relay kit provides one set of contacts to trigger user-provided warning devices if a fault occurs.

The common failure relay faults are user-defined.

See Section 2, Operation, Menu 10—

Output Setup, for status and faults available for this function.

Connect up to three common failure relay kits to the controller output. See Figure 6-4 and Figure 6-5. See

Section 6.2, Accessory Connections, for terminal identification.

6.1.3

Controller (Customer) Connection

Kit

The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip. The supplied wiring harness connects controller connector P23 and terminal strips TB1-3 and

TB1-4 to the controller connection kit connector P25 and terminal strips TB6, TB7, TB8, and TB9. Connect all accessories (except the emergency stop kit) to the controller connection kit terminal strips. See Figure 6-6.

See Section 6.2, Accessory Connections, for terminal identification.

6.1.4

Float/Equalize Battery Charger Kit with Alarm Option

The float/equalize battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects to the controller for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. See Figure 6-7.

See Section 6.2, Accessory Connections, for terminal identification.

Figure 6-4 Common Failure Relay Kit

C-294301

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

Figure 6-5 Common Failure Relay Kit Connections

GM13984-

166 Section 6 Accessories TP-6200 3/06

GM16088A-A

Figure 6-6 Controller (Customer) Connection Kit

CHARGER MALFUNCTION

LV HV CM

BATTERY CHARGER

ALARM TERMINAL STRIP

Figure 6-7 Float/Equalize Battery Charger Connections

GM16088A-A

TP-6200 3/06 Section 6 Accessories 167

6.1.5

Idle (Speed) Mode Feature

The idle (speed) mode feature provides the ability to start and run the engine at idle (reduced) speed for a selectable time period (0--10 minutes) during warm-up.

The controller will override the idle speed mode if the engine reaches the preprogrammed engine warmed-up temperature before the idle mode times out.

See

Figure 6-8 for user-supplied switch connection.

6.1.6

Low Fuel (Level/Pressure) Switch

Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel- or gasoline-fueled models.

See Figure 6-9 and

Figure 6-10. See Section 6.2, Accessory Connections, for terminal identification.

Note: The main tank or the transfer/day tank includes the low fuel level switch. The fuel tank supplier typically provides the low fuel level switch.

6.1.7

Prime Power Switch Kit

The prime power switch kit prevents battery drain during generator set nonoperation periods and when the generator set battery cannot be maintained by an AC battery charger. See Figure 6-11 for an illustration of the kit and Figure 6-12 for the electrical connections.

Stop the generator set using the stopping procedures in

Section 2.3.2, Stopping, before placing the generator set in the prime power mode. Move the prime power switch located on the back of the controller to the DOWN position.

The controller including the digital display,

LEDs, and alarm horn does not function when the generator set is in the prime power mode.

Move the prime power switch located on the back of the controller to the UP position and reset the controller time and date before attempting to start the generator set.

GM16088A-A

Figure 6-9 Low Fuel Switch (Level or Pressure)

Switch Rating

Gauge

18--20

14

10

12 volts DC minimum, 0.5 amp minimum

Wiring Recommendation mm (ft.)

30.5 (100)

153 (500)

305 (1000)

Figure 6-10 Switch Rating & Wiring Recommendation

PRIME POWER

SWITCH

1

2

GM20652-

2. Toggle switch (354464) 1. Prime power decal (293668)

Figure 6-11 Prime Power Switch Installation Location

Figure 6-8 Idle (Speed) Mode Switch

168 Section 6 Accessories

GM16088A-A

Toggle switch shown in the prime power mode off position (contacts open)

GM16088A-D

Figure 6-12 Prime Power Switch Connections

TP-6200 3/06

6.1.8

Remote Annunciator Kit

A remote annunciator monitors the generator set’s condition from a remote location. See Figure 6-13 and

Figure 6-14. The remote annunciator includes an alarm horn, an alarm silence switch, a lamp test, and lamp indicators similar to the digital controller, plus the following:

Line Power. Lamp illuminates to indicate the power source is a commercial utility.

Generator Power. Lamp illuminates to indicate the power source is the generator set.

Also refer to Remote Serial Annunciator (RSA1000) in

Section 6.1.11 for using Modbus r communications via

RS-485 network.

Remote Annunciator

A-258782

14-Relay Dry Contact Box

42A 2

INPUT

K1 K2 K3 K4 K5 K6 K7

CONTACT RATINGS: 10A @120VAC RES. LOAD

.01A @28VDC MIN.

10A @28VDC MAX.

K8 K9 K10 K11 K12

PCB ASSY A--320639

LOT NO.

K13 K14

NO

K1

C NO

K2

C NO

K3

C NO

K4

C NO

K5

C NO

K6

C NO

K7

C NO

K8

C NO

K9

C NO

K10

C NO

K11

C NO

K12

C NO

K13

C NO

K14

C

N

P

42B

FBA--1 10 AMP

P

A-293983

Figure 6-13 Remote Annunciator with 14-Relay Dry Contact Kit

Modbus r is a registered trademark of Schneider Electric.

TP-6200 3/06 Section 6 Accessories 169

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM13984-

354246B-

Figure 6-14 Remote Annunciator with 14-Relay Dry Contact Kit Connections

170 Section 6 Accessories TP-6200 3/06

6.1.9

Remote Emergency Stop Kit

The emergency stop kit allows immediate shutdown of the generator set from a remote location.

See

Figure 6-15 and Figure 6-16. If the emergency stop switch activates, the EMERGENCY STOP lamp lights and the unit shuts down. Before attempting to restart the generator set, reset the emergency stop switch (by replacing the glass piece) and reset the generator set by placing the master switch in the OFF/RESET position.

Use the single glass piece located inside the switch for replacement and order additional glass pieces as service parts.

See Section 2.3.3, Emergency Stop

Switch Reset Procedure. See Section 6.2, Accessory

Connections, for terminal identifications.

6.1.10 Remote Reset Feature

The remote reset switch provides generator set resetting after a fault shutdown at a remote location.

See Figure 6-17 and Figure 6-18 for user-supplied switch connection.

Press and hold the switch for 2--3 seconds and release to reset the generator set controller.

≈

REMOTE RESET SWITCH

CONTACTS NORMALLY OPEN

MOMENTARY CLOSED TO

ACTIVATE

Figure 6-15 Emergency Stop Kit

A-222654

TP-5352-1

GM16088A-A-

Figure 6-17 Remote Reset Switch Connections

Switch Rating

Gauge

18--20

14

10

12 volts DC minimum, 1 amp minimum

Wiring Recommendation mm (ft.)

30.5 (100)

153 (500)

305 (1000)

Figure 6-18 Switch Rating and Wiring

Recommendations

Figure 6-16 Remote Emergency Stop Kit

Connections

GM16088A-A

TP-6200 3/06 Section 6 Accessories 171

6.1.11 Remote Serial Annunciator

The remote serial annunciator (RSA 1000) (Figure 6-19) monitors the condition of the generator set from a location remote from the generator set. If a generator set alarm condition occurs, the remote annunciator alerts the operator through visual and audible signals.

The remote serial annunciator kit includes components for flush and surface mounting. One RSA (master) can support up to a maximum of three additional RSAs

(slaves). The RSA will function as master or slave by changing the DIP switch position on the RSA board. If a generator set fault occurs, the RSA 1000 horn activates and the corresponding LED illuminates.

Figure 6-20 shows the status of the system ready LED, generator set running LED, communication status LED, common fault LED, common fault output, and horn for each fault or status condition. See Figure 6-21 for RSA wiring connections.

The RSA requires connection to the controller Modbus r

RS-485 port. If the RS-485 port is needed for switchgear monitoring or a wireless monitor, the RSA cannot be connected to the controller.

If the RS-485 port is unavailable, please select an alternate annunciator kit.

Overcrank

High Engine Temp.

Low Oil Pressure

Overspeed

Emergency Stop

Low Coolant Level

Low Coolant Temp.

Low Fuel

System Ready

Generator Running

Not-In-Auto

Common Fault

Battery Voltage

On=High, Blink=Low

User Input #1

User Input #2

User Input #3

Alarm Silenced

Figure 6-19 Remote Serial Annunciator (RSA 1000)

Modbus r is a registered trademark of Schneider Electric.

Fault and Status Condition

Overcrank Shutdown

High Engine Temperature Warning

High Engine Temperature Shutdown

Low Oil Pressure Warning

Low Oil Pressure Shutdown

Overspeed Shutdown

Emergency Stop

Low Coolant Level

Low Coolant Temperature

Low Fuel—Level or Pressure *

EPS Supplying Load (550 Controller)

EPS Supplying Load (RSA)

Fault

LEDs

Red

Yellow

Red

Yellow

Red

Red

Red

Red

Yellow

Yellow

Yellow

Yellow

System

Ready LED

Red SF

Red SF

Red SF

Red SF

Red SF

Red SF

Red SF

Red SF

Red SF

Red SF

Green

Green

System Monitoring LEDs and Functions

Generator

Running LED

Off

Comm.

Status LED

Green

Common

Fault LED

Off

Common

Fault Output Horn

On On

Green

Off

Green

Off

Green

Green

Green

Green

Off

Off

Off

Off

On

On

On

On

On

On

On

On

Off

Off

Off

Off

Green

Green

Green or Off

Green

Green

Green

Green

Green

Green

Green

Off

Off

Off

Off

Off

Off

Off

On

On

On

On

On

Off

Off

On

On

On

On

On

Off

Off

System Ready

System Not Ready

Green

Red

No Device at Powerup Red

Loss of Controller Comm. (Master RSA) Red

Loss of Controller Comm. (Slave RSA)

Not-In-Auto

Battery Charger Fault *

High Battery Voltage

Low Battery Voltage

User Input #1 (RSA)

User Input #2 (RSA)

Red

Red

Yellow

Yellow

Yellow

Red

Red

Green

Red SF

Off

Off

Off

Red SF

Red SF

Green

Green

Green

Green

Green or Off

Green or Off

Off

Off

Off

Green or Off

Green or Off

Green or Off

Green or Off

Green or Off

Green or Off

User Input #1 (550 Controller)

User Input #2 (550 Controller)

User Input #3 (550 Controller)

Common Fault

Red

Red

Red

Red

Red SF

Red SF

Red SF

Green

Green or Off

Green or Off

Green or Off

Green or Off

SF = Slow Flash, FF = Fast Flash

* May require optional kit or user-provided device to enable function and LED indication.

Green

Green

Red SF

Red FF

Red SF

Green

Green

Green

Green

Green

Green

Green

Green

Green

Green

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Off

Red SF

Off

On

On

On

On

On

On

Off

Off

On

On

On

On

On

On

On

On

On

Off

Off

On

On

On

Off

On

On

On

On

On

On

Figure 6-20 System Monitoring LEDs and Functions

172 Section 6 Accessories TP-6200 3/06

Figure 6-21 RSA Wiring Connections

TP-6200 3/06 Section 6 Accessories 173

6.1.12 Remote Speed Adjustment

Potentiometer Kit (Non-ECM

Models)

The remote speed adjustment potentiometer kit provides controller-mounted engine speed adjustment.

The adjustment range is approximately

±5%. Some applications locate this potentiometer with the switchgear. This kit requires an electronic governor on the generator set. See Figure 6-22. See Section 6.2,

Accessory Connections, for terminal identifications.

6.1.13 Run Relay Kit

The run relay kit energizes only when the generator set runs. Use the run relay kit to control air intake and radiator louvers, alarms, and/or other signalling devices. See Figure 6-23 and Figure 6-24.

Figure 6-23 Run Relay Kit

273705

TB10

1

BR-273000-C

1. Optional Remote Speed Pot

Figure 6-22 Remote Speed Adjustment

Potentiometer Connection, Typical

Figure 6-24 Run Relay Connections

GM16088A-A

174 Section 6 Accessories TP-6200 3/06

6.1.14 Single-Relay Dry Contact Kit

The single-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user- provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms, or other devices signal faults or status conditions. Connect any controller fault output to the single-relay dry contact kit.

A total of three dry contact kits may connect to a single controller output. See Figure 6-25 and Figure 6-26. See

Section 6.2, Accessory Connections, for terminal identifications.

6.1.15 Ten-Relay Dry Contact Kit

The ten-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. Connect any controller fault output to the ten-relay dry contact kit.

Typically, lamps, audible alarms, or other devices signal the fault conditions.

Refer to Figure 6-27 for an internal view of the contact kit. See Figure 6-28 for electrical connections. See

Section 6.2, Accessory Connections, for terminal identifications.

A-273945

Figure 6-25 Single-Relay Dry Contact Kit, Typical

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM16088A-A

Figure 6-26 Single-Relay Dry Contact Kit Connections

TP-6200 3/06 Section 6 Accessories 175

Figure 6-27 Ten-Relay Dry Contact Kit

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

A-273936

Figure 6-28 Ten-Relay Dry Contact Kit Connections

176 Section 6 Accessories

GM13984-/354246B-

TP-6200 3/06

6.1.16 Twenty-Relay Dry Contact Kit

(450--2000 kW Models Only)

The twenty-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms, or other devices signal faults or status conditions. Connect any generator set fault output to the dry contact kit.

Refer to Figure 6-29 for an internal view of the contact kit. See Figure 6-30 for electrical connections. See

Section 6.2, Accessory Connections, for terminal identifications.

Figure 6-29 Twenty-Relay Dry Contact Kits

D-294303-D

Figure 6-30 Twenty-Relay Dry Contact Relay Kit Connections

TP-6200 3/06

GM16759D-C

Section 6 Accessories 177

6.1.17 Wireless Monitor

The wireless monitor system has two components: a wireless monitor unit and a website. The monitor unit transmits messages in response to signals received from the equipment controller and notifies designated recipients of selected operating conditions. The website monitors these messages.

There are three monitor models: GM23409-KP1 for use with hardwire inputs; GM23409-KP2 for use with a 550 controller using Modbus r communication; and

GM23409-KP3 for use with a 550 controller using hardwire inputs that require a customer interface board.

Note: The 550 controller supports only one connection for Modbus r communication. If the controller’s

RS-485 connection is already used for Modbus r communication with other equipment, use wireless monitor model GM23409-KP1 or -KP3 with hardwire inputs through a customer connection board for monitoring.

Typical messages might include:

D

D

D

D

Overcrank

Low oil pressure

Overspeed

Common fault

At the website, the user configures which individuals will receive messages regarding selected operating conditions and the message delivery method. Delivery methods include pagers (alphanumeric, numeric), fax,

XML, e-mail, PCS, or telephone (voice delivery). Each message sent will contain the condition that generated the transmission and also the make, model, and location of the equipment. Up to 40 messages each day can be delivered. Single or multiple messages can be sent to selected recipients via multiple delivery methods. More than one delivery method can be used for each recipient.

The wireless monitor is powered by the equipment power source or by the generator set and constantly monitors the inputs. When an input is triggered, the wireless monitor sends the condition over the North

American AMPS (advanced mobile phone system). An operations center server receives the transmission and forwards the message to the selected recipients according to the configured delivery method.

Every 24 hours, the wireless monitor also sends information about itself and the system it is monitoring.

This heartbeat transmission tells the Kohlerr center that the wireless monitor is properly functioning, powered, and able to generate messages. If a device fails to report a nightly heartbeat for more than a day, the system sends a Unit Failed to Report Heartbeat alarm message to the website.

Generator set run times and the number of cycles are reported. Models GM23409-KP1 and -KP3 accumulate run times over a 24-hour period and report the run times with the heartbeat message. Model GM23409-KP2 (for the 550 controller only) reports the total accumulated run time and the total number of starts. Run times for model GM23409-KP2 are also totaled using the Control

Panel function and can be updated upon request.

Upon power loss, a rechargeable battery powers the wireless monitor. The monitor continues to transmit messages for 15 minutes, then transmits a loss of power signal and enters the sleep mode. The sleep mode can last up to 18 hours, until the battery completely discharges or power is restored. The wireless monitor continues to send scheduled heartbeat messages during the sleep mode until the battery discharges completely.

86

[3.4]

181

[7.1]

211

[8.3]

244

[9.6]

275

[10.8]

51

[2]

51

[2]

27

[1.06]

Figure 6-31 Wireless Monitor

95

[3.75]

Dimensions are mm [in.]. All dimensions are approximate.

G6-53

Modbus r is a registered trademark of Schneider Electric

178 Section 6 Accessories TP-6200 3/06

6.2 Accessory Connections

The 550 controller contains circuit boards equipped with terminal strip(s) for use in connecting a controller connection kit. Do not connect accessories directly to the controller terminal strip(s). Connect accessories to either a controller connection kit or a dry contact kit.

Connect the dry contact kit(s) to the controller connection kit.

Connect alarms, battery chargers, remote switches, and other accessories to the dry contact kit relay(s).

For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the instruction sheet accompanying the kit.

See Figure 6-32 and Figure 6-33 for controller interconnection circuit board connections.

See

Figure 6-34 and Figure 6-35 for controller (customer) connection kit connections.

TOP OF CONTROLLER BACK PANEL

1

3

2

4

5

4. TB4 terminal strip

5. P23 Connector

GM16088A-A/GM10193B-A

1. TB1 terminal strip

2. TB2 terminal strip

3. TB3 terminal strip

Figure 6-32 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)

TP-6200 3/06 Section 6 Accessories 179

TB1 Terminal Strip—Engine Start and

Emergency Stop Connections

Term.

Description

1 Emergency stop ground

1A

3

4

Emergency stop

Remote start

Remote start

TB2 Terminal Strip—Analog Input Connections

25

26

27

28

21

22

23

24

29

30

14

15

16

17

10

11

12

13

18

19

20

Term.

Description

1 ACH1 (CTS) Signal (non-ECM)

2

3

4

5

ACH1 (CTS) Supply (non-ECM)

ACH2 (OPS) Signal (non-ECM)

ACH2 (OPS) Supply (non-ECM

ACH3 Signal

8

9

6

7

ACH3 Supply

ACH4 Signal

ACH4 Supply

ACH5 Signal

ACH5 Supply

ACH6 Signal

ACH6 Supply

ACH7 Signal

ACH7 Supply

N/C

ACH1 (CTS) Return (non-ECM)

ACH1 (CTS) Shield ground (non-ECM)

ACH2 (OPS) Return (non-ECM)

ACH2 (OPS) Shield ground (non-ECM)

ACH3 Return

ACH3 Shield ground

ACH4 Return

ACH4 Shield ground

ACH5 Return

ACH5 Shield ground

ACH6 Return

ACH6 Shield ground

ACH7 Return

ACH7 Shield ground

N/C

TB3 Terminal Strip—Accessory Power Output

Connections

Term.

Description

1 +12 VDC (OEM use only)

2

3

+12 VDC (OEM use only)

+12 VDC (OEM use only)

6

7

8

9

4

5

Fused battery (+) (42A) (5 Amp)

Fused battery (+) (42A) (5 Amp)

Fused battery (+) (42A) (5 Amp)

Battery (--)

Battery (--)

Battery (--)

10

11

12

Battery (--)

Battery (--)

Panel lamp output

Figure 6-33 Controller Terminal Strip Identification

TB4 Terminal Strip—Input Factory Connections

37

38

39

40

41

42

33

34

35

36

29

30

31

32

22

23

24

25

26

27

28

15

16

17

18

19

20

21

Term.

Description

1 DCH1 Battery charger fault

2

3

DCH2 Low fuel

DCH3 Low coolant temp. with ECM models or warning default with non-ECM models

4 DCH4 Field overvoltage with M4/M5/M7 alternators or warning default with non-M4/M5/M7 alternators

DCH5 Breaker Closed, Paralleling Applications

7

8

5

6 DCH6 Enable Synch, Paralleling Applications

DCH7 Warning

DCH8 Warning

DCH9 Warning 9

10

11

12

13

DCH10 Warning

DCH11 AFM Shutdown, Waukesha engine

DCH12 Detonation Warning, Waukesha engine

DCH13 Detonation Shutdown,

14

Waukesha engine

DCH14 Low coolant level with 50--100ROZK models or warning default with all models except 50--100ROZK

DCH15 Remote shutdown

DCH16 Remote reset

DCH17 VAR PF mode

DCH18 Voltage lower

DCH19 Voltage raise

DCH20 Air damper

DCH21 Idle mode functional with

ECM-equipped engines only

DCH1 Return

DCH2 Return

DCH3 Return

DCH4 Return

DCH5 Return

DCH6 Return

DCH7 Return

DCH8 Return

DCH9 Return

DCH10 Return

DCH11 Return

DCH12 Return

DCH13 Return

DCH14 Return

DCH15 Return

DCH16 Return

DCH17 Return

DCH18 Return

DCH19 Return

DCH20 Return

DCH21 Return

Note: TB4-1 through TB4-21 are user definable with factory defaults listed.

Terminals TB4-3, TB4-4, TB4-14, and TB4-21 have different functions depending upon the generator set configuration. See comments above.

See Menu 9—Input Setup for changing inputs.

180 Section 6 Accessories TP-6200 3/06

Figure 6-34 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box

GM13984-

TB6 Terminal Strip—RDOs 1--7

Term.

Description

42A Battery (+)

GND

N/C

Battery (--)

RDO1 Overspeed (lead 39)

RDO2 Overcrank (lead 12)

RDO3 High coolant temperature shutdown (lead 36)

RDO4 Low oil pressure shutdown (lead 38)

RDO5 Low coolant temperature (lead 35)

RDO6 High coolant temperature warning (lead 40)

RDO7 Low oil pressure warning (lead 41)

TB7 Terminal Strip—RDOs 8--17

Term.

Description

RDO8 Low fuel (lead 63)

RDO9 Master switch not in auto ( lead 80)

RDO10 NFPA 110 common alarm (lead 32)*

RDO11 Battery charger fault (lead 61)

RDO12 Low battery voltage (lead 62)

RDO13 High battery voltage

RDO14 Emergency stop (lead 48)

RDO15 Generator set running (lead 70R)

RDO16 Time delay engine cooldown (TDEC) (lead 70C)

RDO17 System ready (lead 60)

TB8 Terminal Strip—RDOs 18--23

Term.

Description

42A

42A

Battery (+)

Battery (+)

2

2

Battery (--)

Battery (--)

RDO18 Defined common fault (lead 32A)

RDO19 Low coolant level

RDO20 Overvoltage (lead 26)

RDO21 Idle mode

RDO22 EPS supplying load

RDO23 Air damper indicator (lead 56)

TB9 Terminal Strip—RDOs 24--31

Term.

Description

RDO24 Speed sensor fault

RDO25 Loss of AC sensing

RDO26 ECM loss of communication

RDO27 Undervoltage

RDO28 Overfrequency

RDO29 Underfrequency

RDO30 Load shed kW overload

RDO31 Load shed underfrequency

3 Remote start

4 Remote start

Note:Lead numbers shown in parentheses are the factory default wire designations.

Note:RDO-1 though RDO-31 are user definable with the following factory defaults: emergency stop, high coolant temperature, low oil pressure, overcrank, and overspeed

*

NFPA-110 common alarm faults include:

Air damper indicator (RDO--23)

Battery charger fault (RDO--11)

EPS supplying load (RDO--22)

High battery voltage (RDO--13)

High coolant temperature warning (RDO--06)

High coolant temperature shutdown (RDO--03)

Low battery voltage (RDO--012)

Low coolant level (RDO--19)

Low coolant temperature warning (RDO--05)

Low fuel (level or pressure) (RDO--08)

Low oil pressure warning (RDO--07)

Low oil pressure shutdown (RDO--04)

Master switch not in auto (RDO--09)

Overcrank (RDO--02)

Overspeed (RDO--01)

Figure 6-35 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)

TP-6200 3/06 Section 6 Accessories 181

Notes

182 Section 6 Accessories TP-6200 3/06

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

ATDC

ATS auto.

aux.

A/V avg.

AVR

AWG

AWM bat.

BBDC

BC

A, amp ampere

ABDC after bottom dead center

AC

A/D alternating current analog to digital

ADC adj.

ADV

AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature

AISI

ALOP alt.

Al

ANSI

American Iron and Steel

Institute anticipatory low oil pressure alternator aluminum

American National Standards

Institute

(formerly American Standards

Association, ASA)

AO

API approx.

approximate, approximately

AR as required, as requested

AS anticipatory only

American Petroleum Institute

ASE

ASME as supplied, as stated, as suggested

American Society of Engineers assy.

ASTM

American Society of

Mechanical Engineers assembly

American Society for Testing

Materials

BCA

BCI

BDC

BHP blk.

after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator

American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator

Battery Council International before dead center brake horsepower black (paint color), block

(engine) blk. htr.

block heater

BMEP brake mean effective pressure bps br.

bits per second brass

BTDC before top dead center

Btu British thermal unit

Btu/min.

British thermal units per minute

C cal.

CARB

CB cc

CCA ccw.

CEC cert.

cfh

Celsius, centigrade calorie

California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise

Canadian Electrical Code certificate, certification, certified cubic feet per hour

CT

Cu cu. in.

cw.

CWC cyl.

D/A

DAC dB cfm

CG

CID

CL cm

CMOS cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen.

com cogeneration communications (port) coml commercial

Coml/Rec Commercial/Recreational conn.

cont.

connection continued

CPVC crit.

CRT

CSA chlorinated polyvinyl chloride critical cathode ray tube

Canadian Standards

Association current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel dBA

DC

DCR deg.,

° dept.

decibel (A weighted) direct current direct current resistance degree dia.

DI/EO

DIN department diameter dual inlet/end outlet

Deutsches Institut fur Normung e. V.

(also Deutsche Industrie

Normenausschuss) dual inline package DIP

DPDT

DPST

DS

DVR double-pole, double-throw double-pole, single-throw disconnect switch digital voltage regulator

E, emer.

emergency (power source)

EDI electronic data interchange

EFR e.g.

EG

EGSA emergency frequency relay for example (exempli gratia) electronic governor

Electrical Generating Systems

Association

EIA

EI/EO

EMI emiss.

eng.

EPA

Electronic Industries

Association end inlet/end outlet electromagnetic interference emission

EPS

ER

ES engine

Environmental Protection

Agency emergency power system emergency relay engineering special, engineered special

ESD est.

electrostatic discharge estimated

E-Stop emergency stop etc.

et cetera (and so forth)

TP-6200 3/06 exh.

ext.

F fglass.

FHM fl. oz.

flex.

freq.

exhaust external

Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency

FS ft.

full scale foot, feet ft. lbs.

foot pounds (torque) ft./min.

feet per minute g ga.

gal.

gen.

genset

GFI gram gauge (meters, wire size) gallon generator generator set ground fault interrupter

GND, gov.

gph gpm gr.

GRD gr. wt.

ground governor gallons per hour gallons per minute grade, gross equipment ground gross weight

H x W x D height by width by depth

HC hex cap

HCHT

HD

HET high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hex

Hg

HH

HHC hexagon mercury (element) hex head hex head cap

HP hr.

HS hsg.

HVAC horsepower hour heat shrink housing heating, ventilation, and air conditioning

HWT

Hz

IC

ID

IEC high water temperature hertz (cycles per second) integrated circuit inside diameter, identification

IEEE

IMS in.

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers improved motor starting inch in. H

2 in. Hg

O inches of water inches of mercury in. lbs.

Inc.

inch pounds incorporated ind.

int.

industrial internal int./ext.

internal/external

I/O input/output

IP

ISO

J

JIS iron pipe

International Organization for

Standardization joule

Japanese Industry Standard

Appendix 183

k

K kA

KB kg kg/cm

2 kilo (1000) kelvin kiloampere kilobyte (2 kilogram

10 bytes) kgm kg/m

3 kHz kJ kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k

Ω kilo-ohm kPa kilopascal kph kV kVA kVAR kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kW kWh kWm

L kilowatt kilowatt-hour kilowatt mechanical liter

LAN local area network

L x W x H length by width by height lb.

lbm/ft

3 pound, pounds pounds mass per cubic feet

LCB

LCD line circuit breaker liquid crystal display ld. shd.

load shed

LED light emitting diode

Lph

Lpm

LOP

LP liters per hour liters per minute low oil pressure liquefied petroleum

LPG

LS liquefied petroleum gas left side

L wa

LWL

LWT sound power level, A weighted low water level low water temperature m

M meter, milli (1/1000) mega (10

6 when used with SI m

3 m

3 units), male cubic meter

/min.

cubic meters per minute mA man.

milliampere manual max.

MB maximum megabyte (2

20 bytes) one thousand circular mils MCM

MCCB molded-case circuit breaker meggar megohmmeter

MHz mi.

mil min.

megahertz mile one one-thousandth of an inch minimum, minute misc.

MJ miscellaneous megajoule mJ millijoule mm millimeter mOhm, m

Ω milliohm

MOhm, M

Ω megohm

MOV

MPa mpg mph

MS m/sec.

metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second

MTBF

MTBO mtg.

MW mean time between failure mean time between overhauls mounting megawatt mW

μF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

NBS

NC

NEC

NEMA

NFPA

National Bureau of Standards normally closed

National Electrical Code

National Electrical

Manufacturers Association

National Fire Protection

Association

Nm

NO newton meter normally open no., nos.

number, numbers

NPS National Pipe, Straight

NPSC

NPT

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

NPTF

NR ns

OC

OD

OEM

OV oz.

p., pp.

PC

PCB pF

PF ph.,

∅

PHC

PHH

PHM

PLC

PMG pot ppm

PROM

National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option, optional

OF opt.

OS

OSHA oversize, overspeed

Occupational Safety and Health

Administration overvoltage ounce page, pages personal computer printed circuit board picofarad power factor phase

Phillips head crimptite (screw)

Phillips hex head (screw) pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory pounds per square inch psi pt.

PTC

PTO

PVC qt.

qty.

R pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source rad.

RAM

RDO ref.

radiator, radius random access memory relay driver output reference rem.

remote

Res/Coml Residential/Commercial

RFI

RH radio frequency interference round head

RHM rly.

rms rnd.

ROM rot.

rpm

RS

RTV

SAE scfm

SCR s, sec.

SI round head machine (screw) relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units

UV

V

VAC

VAR

VDC

VFD

VGA

VHF

UF

UHF

UL

UNC

UNF univ.

US

W

WCR w/ w/o wt.

xfmr

TDOE

TDON temp.

term.

TIF

TIR tol.

turbo.

typ.

SI/EO sil.

SN

SPDT side in/end out silencer serial number single-pole, double-throw

SPST single-pole, single-throw spec, specs specification(s) sq.

sq. cm sq. in.

SS std.

stl.

tach.

TD

TDC

TDEC

TDEN

TDES

TDNE square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency

Underwriter’s Laboratories, Inc.

unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer

184 Appendix TP-6200 3/06

Appendix B User-Defined Settings

Use the table below to record user-defined settings during the generator set controller setup and calibration.

The controller default settings and ranges provide guidelines. The table contains all faults with ranges and time delays including items that do not have adjustments.

User-Defined Settings

Status Event or Fault

Access Code

(password)

AC Sensing Loss

Refer to

Menu

14

Digital

Display

Relay

Driver

Output

(RDO)

RDO-25*

Note: Inhibit time delay is the time delay period after crank disconnect.

Note: The engine ECM may limit the crank cycle even if the controller is set to a longer time period.

Range Setting

User Selectable

Default

Selection

0 (zero)

Inhibit

Time

Delay

(sec.)

Time

Delay

(sec.)

User-Defined

Settings

Not adjustable 10

10

AC Sensing

Loss

Air Damper

Control

9, 10 Air Damper

D20

RDO-23*

(lead 56)

Fixed 0 sec.

inhibit,

0 sec. delay

Not adjustable

Not adjustable

Air Damper Control

(if used) **

Air Damper

Indicator (if used)

Digital Aux.

Input D20 **

Air/Fuel Module

(AFM) Engine Start

Delay

]

Air/Fuel Module

(AFM) Remote

Start

]

Air/Fuel Module

(AFM) Shutdown

]

Alternator

Protection

Shutdown

Analog Aux. Inputs

A01--A07

10

10

9, 10

10

9

AFM Eng

Start Delay

AFM Remote

Start

RDO-25

]

AFM

Shutdown

Alternator

Protection

User-Defined

A01--A07

Fixed

Fixed

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Analog Aux. Input

A01

(non-ECM only)

Analog Aux. Input

A02

(non-ECM only)

Analog Aux. Input

A03

]

Analog Aux. Input

A04

]

Analog Aux. Input

A07 w

9

9

9

9

9

A01 Coolant

Temp

A02 Oil

Pressure

A03 Intake

Air

Temperature

A04 Oil

Temperature

A07 Voltage

Adjust

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

Default Values with

Warning Enabled:

HI warning 90%

LO warning 10%

HI shutdown 100%

LO shutdown 1%

Default Values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are all engine dependent

Default Values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are all engine dependent

(255 psi max.)

Default Values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are all engine dependent

Default Values with

Warning Enabled:

HI/LO warning are engine dependent

±10% of system voltage over the range of 0.5--4.5 VDC

30 sec.

inhibit,

5 sec. delay

30 sec.

inhibit,

0 sec. delay warning,

5 sec. delay shutdown

30 sec.

inhibit,

0 sec. delay warning,

5 sec. delay shutdown

30 sec.

inhibit,

0 sec. delay warning

30 sec.

inhibit,

0 sec. delay warning

0--60 w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

0--60

Not adjustable

Not adjustable

Not adjustable

Not adjustable

TP-6200 3/06 Appendix 185

User-Defined Settings

Status Event or Fault

Battery Charger

Fault, Digital Aux.

Input

D01 **

Battle Switch

(Fault Shutdown

Override Switch)

Block Heater

Control

[[

Breaker Trip w

Common

Paralleling Relay

Output w

Critical Overvoltage

Shutdown

Cyclic Cranking

Refer to

Menu

9, 10

9

10

10

10

Digital

Display

Battery

Charger

Fault

Battle Switch

Block Heater

Control

Relay

Driver

Output

(RDO)

RDO-11

(lead 61)

RDO only

Breaker Trip RDO-30

Common PR

Output

RDO-31

Range Setting

Fixed

Fixed

Default

Selection

0 sec.

inhibit,

0 sec. delay

Inhibit

Time

Delay

(sec.)

Defined Common

Faults

(each input value is set separately)

Detonation

Shutdown

D01--D21

]

Detonation Warning

]

Digital Aux. Input

Digital Aux. Input

D05

Digital Aux. Input

D06

Digital Aux. Input

D11 w w

]

Digital Aux. Input

D12

]

10

8

10

Critical

Overvoltage

Defined

Common

Fault

9, 10

9, 10

Deton

Shutdown

Deton

Warning

9, 10 User-Defined

D01--D21

RDO-18

(lead 32A)

Fixed

1--6 crank cycles

10--30 sec. crank on

1--60 sec. pause

Default shutdowns include:

Emergency stop High coolant temp Low oil pressure Overcrank

Overspeed

Fixed

275 volts

(L1--L2)

3

15 sec.

15 sec.

30 sec.

inhibit,

5 sec. delay

Fixed

30 sec.

inhibit,

5 sec. delay

9, 10 D05 Breaker

Closed

9, 10 D06 Enable

Synch

9, 10 D11 AFM

Shutdown

9, 10

9, 10

D12 Deton

Warning

D13 Deton

Shutdown

0 sec.

inhibit,

0 sec. delay

0 sec.

inhibit,

0 sec. delay

0 sec.

inhibit,

0 sec. delay

Digital Aux. Input

D13 Detonation

Sensing Module

(DSM)

]

Digital Aux.

Input D13 Knock

Detection Module

(KDM)

]

EEPROM Write

Failure

Emergency Stop

Shutdown

Engine Cooldown

(see Time Delay--)

Engine Start

(see Time Delay--)

EPS (Emergency

Power System)

Supplying Load

9, 10

10

10

10

D13 Knock

Shutdown

EEPROM

Write Failure

Emergency

Stop

EPS

Supplying

Load

RDO-14

(lead 48)

RDO-22

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

Fixed

0 sec.

inhibit,

0 sec. delay

1% of rated line current

0--60

0--60 w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

Time

Delay

(sec.)

0--60

0--60

186 Appendix

User-Defined

Settings

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

TP-6200 3/06

User-Defined Settings

Status Event or Fault

Field Overvoltage

Digital Aux.

Input D04

(M4, M5, or M7 alternator only)

Fuel Valve Relay

]

Generator Set

Running

Ground Fault

Detected

High Battery

Voltage

High Coolant

Temperature

Shutdown

High Coolant

Temperature

Warning

High Oil

Temperature

Shutdown

High Oil

Temperature

Warning

] [[

Idle (speed) Mode

Function Digital

Aux. Input D21

Refer to

Menu

9, 10

Digital

Display

Field

Overvoltage

10

10

10

10

10

10

10

10

9, 10

Fuel Valve

Relay

Ground Fault

High Battery

Voltage

Hi Cool

Temp

Shutdown

Hi Cool

Temp

Warning

Hi Oil Temp

Shutdown

Hi Oil Temp

Warning

Idle Mode

Active

Relay

Driver

Output

(RDO)

RDO-23

]

RDO-15

(lead 70R)

RDO-13

RDO-03

(lead 36)

RDO-06

(lead 40)

RDO-21

Intake Air

Temperature

Shutdown

] [[

Intake Air

Temperature

Warning

] [[

Internal Fault

Shutdown

Knock Shutdown

] kW Overload

(see Load Shed)

Load Shed kW Overload

10

10

10

10

10

Intake Air

Temp Sdwn

Intake

Airtemp

Warn

Internal Fault

Knock

Shutdown

Load Shed

KW Over

RDO-30

]]

Range Setting

Fixed

14.5--16.5 V (12 V)

29--33 V (24 V)

Fixed inhibit time

Fixed

80%--120%

Default

Selection

1 sec.

inhibit,

15 sec.

delay

Inhibit

Time

Delay

(sec.)

16 V (12 V)

32 V (24 V)

0 sec.

inhibit,

60 sec.

delay

100% of kW rating with

5 sec. delay

30

30

30

30

30

30

Load Shed Over

Temperature

Load Shed

[[

Underfrequency

10

10

Load Shed

Over

Temperature

Load Shed

Under

Frequency

RDO only

RDO-31

[

Locked Rotor

Shutdown

Loss of ECM

Communication

(ECM only)

Loss of Field

Shutdown w

10

10

10

Low Battery Voltage 10

Locked

Rotor

Loss of ECM

Comm

SD Loss of

Field

Low Battery

Voltage

RDO-26*

RDO-12

(lead 62)

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

59 Hz with

(60 Hz)

49 Hz with

(50 Hz)

Time

Delay

(sec.)

10

5

5

0--600

2--10

5

4

10--12.5 V (12 V)

20--25 V (24 V)

12 V (12 V)

24 V (24 V) w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

10

TP-6200 3/06

User-Defined

Settings

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Appendix 187

User-Defined Settings

Status Event or Fault

Low Coolant Level

Low Coolant Level,

Digital Aux. Input

D14

(with LCL switch) **

Low Coolant

Temperature

Refer to

Menu

10

Digital

Display

Low Coolant

Level

9, 10 Low Coolant

Level

10 Low Coolant

Temp

Relay

Driver

Output

(RDO)

RDO-19

RDO-05

(lead 35)

Low Coolant

Temperature,

Digital Aux. Input

D03 **

Low Coolant

Temperature

Shutdown

[[

Low Fuel Warning,

Digital Aux. Input

D02

Low Fuel (Level or

Pressure) Warning,

Digital Aux. Input

D02 **

Low Fuel Pressure

Shutdown, Digital

Aux. Input D09

(125RZG only)

(Low) Oil Pressure

Shutdown

9, 10

10

9, 10

9, 10

9, 10

10

(Low) Oil Pressure

Warning

Master Not In Auto

(Generator Set

Switch)

10

10

Master Switch Error 10

Low Coolant

Temp

Low Coolant

Temperature

Shutdown

Low Fuel

Low Fuel

Warning

Low Fuel

Shutdown

Oil Pressure

Shutdown

Oil Pressure

Warning

RDO-08

(lead 63)

RDO-04

(lead 38)

RDO-07

(lead 41)

Not In Auto RDO-09

(lead 80)

Master Switch to

Off

Master Switch

Open

MDEC Yellow

Alarm

[[

MDEC Red Alarm

[[

NFPA 110 Fault

No Air Temperature

Signal Warning

No Coolant

Signal w

Temperature Signal

No Oil Pressure

10

10

10

10

10

10

10

10

Master

Switch Error

Master

Switch to Off

Master

Switch Open

MDEC

Yellow Alarm

MDEC Red

Alarm

NFPA 110

Fault

No Air Temp

Signal

No Cool

Temp Signal

No Oil

Pressure

Signal

RDO-10

(lead 32)

No Oil Temperature

Signal Warning w

Overcrank

Shutdown

Overcurrent

10 No Oil Temp

Signal

8, 10 Over Crank RDO-02

(lead 12)

10 Over Current

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

Range Setting

Default

Selection

Inhibit

Time

Delay

(sec.)

30

Time

Delay

(sec.)

5

Fixed

0 sec.

inhibit,

0 sec. delay

0 sec.

inhibit,

0 sec. delay

30

30

5

30

30

30 4

0--6 Cycles 3 Cycles

110% w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

10

4

4

User-Defined

Settings

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

188 Appendix TP-6200 3/06

User-Defined Settings

Status Event or Fault

Over Current

Voltage Regulator

Shutdown w

Overfrequency

Shutdown

Over Power

Shutdown w

Overspeed

Shutdown

Overvoltage

Shutdown

Refer to

Menu

10

Digital

Display

SD Over

Current VR

Relay

Driver

Output

(RDO)

7, 10

10

Over

Frequency

SD Over

Power

RDO-28

7, 10 Over Speed RDO-01

(lead 39)

7, 8,

10

Over Voltage RDO-20

(lead 26)

Range Setting

Default

Selection

Inhibit

Time

Delay

(sec.)

Time

Delay

(sec.)

102%--140%

65--70 Hz (60 Hz)

55--70 Hz (50 Hz)

105%--135% of nominal

140% Std.

103% FAA

102% Stdby

112% Prime

70 (60 Hz)

70 (50 Hz)

115%

2-sec time delay

[

135%

10-sec time delay w

10

0.25

2--10

Password

(see Access Code)

Pre Lube Relay

]

Reverse Power

Shutdown w

10

10

Speed Sensor Fault 10

Pre Lube

Relay

SD Reverse

Power

Speed

Sensor Fault

RDO-26

RDO-24

Starting Aid

(see Time Delay

Starting Aid)

Synchronized

System Ready

10

10

In Synch

Time Delay Engine

Cooldown (TDEC)

Time Delay Engine

Start (TDES)

Time Delay Starting

Aid

Underfrequency

8, 10 Delay Eng

Cooldown

8, 10 Delay Eng

Start

8, 10

7, 10 Under

Frequency

RDO-29 w

RDO-17

(lead 60)

RDO-16

(lead 70C)

RDO-29

]

Undervoltage

Shutdown

7, 8,

10

Under

Voltage

RDO-27

Weak Battery 10 Weak

Battery

* All models, except Waukesha-powered models.

[ Non-paralleling applications

** NFPA applications

] Waukesha-powered models

4

00:00--10:00 min:sec

00:00--5:00 min:sec

0--10 sec.

5:00

00:01

80%--97%

70%--95%

97% FAA

90%

[

80% w

85%

10-sec time delay

[

70%

30-sec time delay w

60% of nominal w Paralleling applications

[[ DDC/MTU engine with MDEC

]] FAA only

10

5--30

2

User-Defined

Settings

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

Not adjustable

TP-6200 3/06 Appendix 189

Appendix C Voltage Regulator Definitions and Adjustments

The following definitions and adjustment/setting specifications are intended for users planning to adjust the voltage regulator beyond the default settings in order to customize the alternator for a specific application.

This information is not intended to be a comprehensive explanation of all the terms mentioned.

There are numerous documents available that define these terms more completely than described herein.

Any user planning to change the generator set controller adjustment settings or to apply the generator set to these types of applications should understand these terms.

This appendix contains references to other sections of this manual. Please refer to these sections for further information and explanation.

Paralleling generator sets can be a complicated and dangerous exercise. Application programming must be performed by appropriately skilled and suitably-trained personnel.

Definitions

Underfrequency Unloading

Underfrequency unloading is a function used in the alternator excitation control system to improve the overall generator set system (engine and alternator) response.

In particular, underfrequency unloading relates to large-block load applications. When applied to engine-driven alternators, large-block loads cause a subsequent transient torque load on the engine. This torque load can reduce the engine’s speed below the normal operating point.

Typically, the engine speed controller or governor will compensate for this by commanding an increase in fuel. If, however, the fuel system is inadequate to recover from a relatively large load, the speed may never recover. In these instances, other measures must be taken.

This is where the underfrequency unloading occurs.

When the excitation control system detects a drop in the speed or electrical frequency below some predetermined point, the control system enters an unloading condition. This can be described as moving to a lower voltage regulation point. By reducing the output voltage of the alternator, the load on the generator set is reduced.

This can be shown mathematically by Ohm’s law, which states that power is equal to the voltage squared divided by the impedance.

As the voltage is reduced, the power delivered by the alternator decreases by a squared relationship. Since it is the power in the alternator that translates into engine torque, the engine load is also reduced.

By changing various parameters of this compensation technique, the controlling system can be tailored to match the performance capabilities of most engine and alternator combinations.

The point at which the unloading begins to act or how much unloading occurs can be adjusted to impact maximum voltage droop, maximum speed droop, or time to recover.

Some applications may not need unloading and, in these cases, set the unloading parameter to disable the function.

These parameters are further described below.

An example is provided to help clarify the relationship between these parameters.

Underfrequency Unload Slope

Underfrequency unload slope is the term used to describe the amount that the voltage is reduced, per-cycle-per-second or per-hertz (Hz), when in an underfrequency condition. The slope or schedule is sometimes called the volts-per-hertz slope. When the electrical frequency drops below the cut-in point (see below), the excitation control system temporarily reduces the regulated voltage to reduce the subsequent torque on the engine.

The amount that the control system reduces voltage is defined as the product or multiplication of the slope and the amount of frequency or speed below the cut-in point. For every Hz below the cut-in point, the control system reduces the line-to-line voltage by an amount equal to the slope.

Because each engine responds differently to the various loads encountered, the slope may be adjusted to improve the system response. If, when large loads are applied to the generator set, the engine speed drops below the acceptable limit (as determined by the particular loads applied), the slope may need to be increased. Increasing the slope will cause the voltage to droop more during load applications, consequently reducing the load torque on the engine and allowing the speed to increase. If, however, the voltage drops below an acceptable lower limit (as determined by the particular loads connected to the generator set), a lower slope may work better. The underfrequency unloading function may be disabled by setting the slope to zero.

190 Appendix TP-6200 3/06

Frequency Setpoint or Cut-In Point

The point at which the underfrequency unloading begins to take effect is adjustable, allowing the system to be tailored for each application.

Because the characteristics of the engine have the largest effect on the system’s performance, the engine’s response should determine the unloading point. The unloading setpoint is the frequency below which the excitation control will reduce the voltage so that the engine may begin to recover.

The cut-in point, or frequency setpoint, should be set

0.5--3.0 Hz lower than the normal steady-state band of operation. If the engine normally operates within a very narrow range of speeds close to the nominal, a setpoint of 0.5 to 1.0 Hz below nominal should be suitable. If the engine normally operates over a wide range of speeds, the setpoint may need to be 2.0--3.0 Hz from the nominal. The underfrequency unloading function can be eliminated by setting the cut-in point below the minimum expected operating frequency.

Example

A 90 kW load is applied to a 100 kW, 60 Hz generator set driven by a turbocharged diesel engine with an electronical control module (ECM). The speed drops

10% and takes 20 seconds to recover to at least 59.5 Hz.

The voltage, meanwhile, drops from 480 to 460 and recovers to 480 within 15 seconds. Therefore, some underfrequency unloading should be provided. A good starting point would be a frequency setpoint or cut-in of

59 Hz.

A slope of 15 volts per-cycle-per-second is appropriate as well.

If after these adjustments the speed recovers very quickly, in about 5 seconds, but the voltage drops below 440 volts, the slope should be reduced to 12 volts per cycle. More adjusting may be required to get the most desirable compromise between speed and voltage.

Three-Phase Sensing

Three-phase sensing describes how the excitation control or voltage regulator determines the condition of the alternator output voltage. Early types of regulators sensed the voltage on just one phase of the alternator.

Single-phase sensing is not uncommon today as most alternators are designed to produce balanced, equal voltage on all three phases. If the loads applied to the generator set including no load are equal and balanced, the output voltage on each phase will be nearly equal.

However, in some applications, individual phases may have unequal or unbalanced loads. In these cases, the output voltages will not be equal on each phase. In general, the phase with the greatest load will have the lowest voltage while the phase with the least load will have the highest voltage. This is true regardless of the type of sensing used in the regulator system.

A single-phase sensing excitation controller will keep the voltage of the sensed phase at the voltage adjustment value. A three-phase sensing system will average the three phases and hold the average to the adjustment setting. The average is the sum of the voltages of three phases divided by 3.

As stated above, three-phase sensing does not eliminate the unequal voltage phenomenon.

Three-phase sensing balances the inequality of voltage between the phases to the desired value.

In other words, if a system with unbalanced loads uses a single-phase control feedback, the voltage on the sensed phase would be at the setpoint while the other two phases would vary by their proportional loads. For example, if the sensed phase had rated load while the two other phases were only loaded at half the rated value, those two phases would have higher-than-rated voltage which may be undesirable. If a three-phase sensing feedback were utilized, the phase with rated load would be regulated to a voltage slightly below the rated voltage while the other two phases would be slightly above the rated voltage (but lower than in the previous case). The sum of the three, divided by 3, would be equal to the regulation setpoint.

In a single-phase system, line-to-line voltage is held equal to the line-to-line voltage adjust setting.

In a three-phase system, the average of the three line-to-line voltage is regulated to the voltage adjust setting. In some cases, it may be desirable to keep one phase at a particular value. Modify the voltage adjust setting higher or lower accordingly for any unique requirements for the particular application.

Each of the individual phase voltages is available in Menu 11, Voltage Regulator.

TP-6200 3/06 Appendix 191

Reactive Droop

Reactive droop refers to another compensation technique used in excitation control systems. Reactive droop means that the generator set voltage droops with increasing reactive current. Although this sounds like an undesirable effect, it is quite beneficial in paralleling applications with multiple generator sets. Because the terminals of the generator set are connected to another generator set(s), the voltage at the terminals is not solely determined by either generator set’s excitation.

Rather, it is determined by the combination of the excitation level, the generated voltage, and the voltage drop across the armature impedance or armature reactance for each generator set.

Normally the generated voltage is higher than the voltage at the terminals because the generator set current causes a drop across the armature impedance.

In a parallel application, the generated voltage of one generator set may be slightly higher than the generated voltage of another generator set.

Differences in potential between the generator sets will cause current to flow into the lower voltage generator set and will also cause the generator sets to share the load current disproportionately. Both results are undesirable.

By introducing reactive droop, the reactive current can be better predicted and controlled.

If the current is measured, the regulator/controller can adjust the excitation up or down accordingly, reducing excitation as more current is supplied or increasing excitation as the reactive current decreases.

If all the parallel generator sets incorporate this type of compensation, the reactive current can be shared equally based on the proportional size of the generator sets. For an example, see below.

The stability and accuracy of this technique depends on several factors. Most important, the regulation point for each generator set must be equal. That is, each voltage adjust setting must be the equal to the other(s). This is a basic requirement prior to the actual paralleling connection. Also, the effects of the reactive current in each generator set must be compensated for individually, which requires an adjustable droop for each generator set.

This adjustment happens to be the reactive droop adjust.

The reactive droop adjust is quantified as the droop in operating voltage from the adjusted setting when full rated load with 0.8 power factor (PF) is applied. A droop setting of 4% voltage at full rated load is a recommended starting point. If the reactive current is not shared proportionately in each generator set, the respective droops may need adjustment.

Adjust those generator sets that have proportionately higher current for more droop and those generator sets with lower reactive current for less droop.

If the reactive current is not stable in the system, adjust the droop lower in all generator sets.

As implied above, the reactive droop is not usually necessary in stand-alone applications.

Therefore, some means of disabling the feature is provided. If the generator set will not be paralleled with other generator sets, the reactive droop feature should be disabled. A reactive droop setting of 0 will also effectively disable the reactive droop feature. It should be noted that reactive droop applies strictly to the reactive current or volt-ampere-reactive (VAR) loading.

Primarily, the fueling or speed governing system controls the real current which contributes to watts loading.

The gain of the reactive droop function is determined by the voltage droop setting.

For most applications, a droop of 3%--5% of rated voltage at rated load at 0.8 PF is adequate. Prior to actually connecting the generator sets in parallel, test the droop by applying full rated load at 0.8 PF. The system is operating correctly if this test shows a reduction in voltage equal to the voltage droop setting. If the available load is less than full load, the correct voltage droop should be proportional to the applied VAR load as a fraction of the rated VAR output for the generator set. For instance, a 480-volt generator set with a voltage droop setting of 4% should drop 19.2

volts with full rated (0.8 PF) load applied (480 x 0.04) or

9.6 volts with half the rated load applied (480 x 0.04 / 2).

When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If there are multiple generator sets in parallel as well, then reactive droop should be ENABLED also.

Example

Two 100 kilowatt (kW) generator sets are paralleled to provide 150 kW of power at 0.8 PF and wired for a

277/480-volt wye system.

Total kVA load: kVA = kW / PF

187.5 = 150 / 0.8

KVAR load: kVAR = kVA * sin (acos [ PF ] )

112.5 = 187.5 * 0.6

Line current:

I = ( VA / 3 ) / V

L-N

226 amps = (187500 / 3) / 277

192 Appendix TP-6200 3/06

Reactive current:

I = (VAR / 3) / V

L-N

135 amps = ( 112500 / 3) / 277

Where: acos is arccosine or inverse cosine

W is Watt

L-N is line-to-neutral

PF is power factor

VA is volt-ampere k is kilo ( = 1000 )

Therefore, each generator set in this case should carry

113 amps per phase or half the 226 calculated line amps. The 113 amps includes 67.5 amps of reactive current, half of the calculated reactive current of

135 amps. The reactive droop should be adjusted until each generator set carries equal reactive current. The load sharing control should be adjusted so that real current and/or watts are shared equally as well.

If one generator set is larger than the other, it should be adjusted to carry proportionate current.

For this example, if a 150 kW generator set is paralleled to a

75 kW generator set, the larger generator set would carry 90 amps reactive (135 * 2 / 3) and the other would carry 45 amps reactive (135 * 1 / 3). Adjust the reactive droop based on the ratio of the actual measured currents, not the calculated values.

VAR Control

VAR control is analogous to the reactive droop function described above. It differs in that it applies to utility paralleling applications. Because the utility represents a nearly infinite bus, the voltage at the load terminals is not controlled at all by the generator set, and it is impossible to compare the ratio of the generator set current to the utility based on its rated output. In this situation, the excitation control changes from voltage feedback to VAR feedback.

More specifically, the excitation is controlled to maintain a certain VAR output rather than a voltage output. This is called VAR control and again is used only in utility paralleling applications.

The VAR adjust can be set to any value within the generator set’s rated capability.

Because the VARs cause heating in the armature, any value beyond the generator set’s rating could damage the alternator. In most cases, the generator set will be adjusted to generate VAR (lagging PF) but could absorb VARs

(leading PF) as well.

However, the VAR setting is maintained regardless of the relative PF. If the particular load requires more VARs than the generator set setting, the excess is derived from the utility bus.

The term rated VARs is a bit obscure. In essence, it is a value derived from the rated kW of the generator set.

For a typical standby rating, the full load of the generator set is defined to have 0.8 PF. This means that the kW load is eight-tenths of the VA load. As described earlier, the PF for a linear load may be calculated as the cosine of the angle between voltage and current. This relationship is based on the power triangle. Using this power triangle concept, it can be shown that the reactive power for a linear load is equal to the sine of the power angle. Then, using these trigonomic functions, it can be shown that for a PF of 0.8, the VARs are related similarly to the VA by a factor of 0.6. More explicitly, the power angle is equal to the inverse cosine (arccosine) of the

PF. For a PF of 0.8, the power angle is 36.9 degrees

(0.2 radians). The sine of this angle, sine (36.9 degrees) is 0.6. This is the factor for calculating rated VARs from the rated VA. The ratio of these two factors is 0.75 (0.6 /

0.8), which can be used to calculate rated VARs directly from the rated kW; rated VARs equals rated watts * 0.75.

When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If multiple generator sets are in parallel as well, then reactive droop should be ENABLED also. Additionally, note that VAR control should be used only when the generator set is connected in parallel with the utility.

Parallel connection with the utility requires the logical indication that the circuit breakers tying the generator set bus to the utility bus are closed. This indication is made by use of the programmable digital input for

VAR/PF mode. If this input function is activated, the excitation control changes to the selected VAR or PF control. If the logical indicator is not present and the

VAR or PF control is not enabled, the control will not switch to VAR or PF control. Because the active state for the digital input is a HI or open connection, the default for the digital input (VAR/PF Mode) is DISABLED (displays

ENABLED NO). If the input is ENABLED by the user, it should be held low by a contact or jumper until the actual closing of the connecting circuit breaker(s). The proper control method, VAR or PF, must be ENABLED within the regulator’s configuration menu.

Power Factor Control

PF control is much like the VAR control above. PF control is used only when the generator set is paralleled to the utility grid. The difference is that the PF of the generator set current is held constant. The setting for the PF adjust determines the relationship of the current and voltage from the generator set. The PF is a term that defines the ratio of real watts to the volt-ampere (VA) product. For linear loads, a trigonomic relationship can describe the PF. The PF equals the cosine of the angle between the current and voltage. PF is further defined

TP-6200 3/06 Appendix 193

as leading or lagging. That is to say, if the current lags the voltage (i.e., is later in time), the PF is lagging; if the current leads the voltage (i.e., is earlier in time), the PF is leading.

Inductive loads have lagging PF while capacitive loads have leading PF.

The current in a purely resistive load is in phase with the voltage (not leading or lagging) and the PF is 1.0 (cos. [0] ).

Set the PF adjust according to the requirements of the application. When a generator set will be connected in parallel with the utility, VAR or PF control should be

ENABLED.

If there are multiple generator sets in parallel as well, then reactive droop should be

ENABLED also.

Additionally, note that PF control should be used only while the generator set is connected in parallel with the utility. Parallel connection with the utility requires the logical indication that the circuit breakers tying the generator set bus to the utility bus are closed. This indication is made by use of the programmable digital input for VAR/PF mode. If this input function is activated, the excitation control changes to the selected VAR or PF control. If the logical indicator is not present and the VAR or PF control is not enabled, the control will not switch to VAR or PF control.

Because the active state for the digital input is a HI or open connection, the default for the digital input

(VAR/PF mode) is DISABLED (displays ENABLED NO).

If the input is ENABLED by the user, it should be held low by a contact or jumper until the actual closing of the connecting circuit breaker(s).

The proper control method, VAR or PF must be ENABLED within the regulator’s configuration menu.

Adjustment and Setting

Specifications

Voltage Adjust

The voltage adjust is entered as the rated or otherwise desired line-to-line voltage.

The average of the line-to-line voltages is then regulated to the corresponding value as previously described.

The setting may be as fine as tenths of volts. The voltage adjust defaults to the rated system voltage whenever the system voltage is changed. The voltage adjust may be set to any value within

±10% of the system voltage.

The upper limit is

±10% above the system voltage and the lower limit is

±10% below the system voltage. If a value beyond these limits is entered, a RANGE ERROR message will be displayed.

As a reference, the present voltage adjust setting is displayed as well as the average value of the line-to-line voltages. The individual line-to-line voltages are also displayed on the subsequent menu screens.

This allows the user to monitor any individual phase, if desired.

194 Appendix

The voltage adjust setting may be changed by means other than the menu including user-defined digital input or remote communications.

If voltage adjustment occurs, the new value will be displayed accordingly in the voltage adjust menu.

Underfrequency Unload Enable

The underfrequency unload enable menu is used to turn the underfrequency unload on or off. A YES entry will turn the feature on and the display will show ENABLED

YES. A NO entry will turn the feature off and the display will show ENABLED NO. The underfrequency unload defaults to an enabled (ON) condition.

Frequency Setpoint

The frequency setpoint is the cut-in point for underfrequency unloading. At any operating frequency below the frequency setpoint, the output voltage will be reduced. The frequency may be entered with resolution to tenths of a Hz. The range of acceptable entries is 30 to 70 Hz.

Any entry beyond these limits causes a

RANGE ERROR display and the setting will not change.

The default value is one cycle-per-second (or two for non-ECM engines) below the normal system frequency.

The frequency setpoint changes to the default value if the system frequency changes.

A setting of 30 Hz essentially disables the underfrequency unload feature because most engines do not normally drop to speeds this low, even during load applications.

Underfrequency Unload Slope

The slope determines how much voltage is reduced during an unloading condition. The line-to-line voltage is regulated to a value less than the voltage adjust setting by this amount for every cycle below the frequency setpoint. The voltage may be entered with resolution as fine as one-tenth of one volt. The default value is 2.0 volts per-cycle-per-second. A zero entry for the slope in effect turns the underfrequency unload feature off.

Reactive Droop Enable

This menu allows the user to enable the reactive droop feature. A YES entry turns the feature on and the display shows ENABLED YES. A NO entry turns the feature off and the display shows ENABLED NO. Reactive droop is intended to be used in a generator set-to-generator set paralleling application.

TP-6200 3/06

Voltage Droop

The amount of reactive droop is entered here. The droop is entered as a percentage of system voltage when a fully rated load at 0.8 PF is applied. The entry may be made with resolution as fine as one-tenth of one volt. This entry determines how much the voltage will droop when the alternator provides reactive current.

The actual amount the voltage changes is equal to the voltage droop setting times the VAR load as a fraction of the rated VARs (at 0.8 PF). If the generator set were providing full rated load (at 0.8 PF), the expected voltage change would equal the voltage droop setting as a percentage of system voltage. A voltage droop setting of zero in effect disables the reactive droop feature. The default value is 4% droop at full rated load at 0.8 PF.

The present voltage droop setting is displayed for reference.

The display may change if this value is changed via remote communication.

VAR Control Enable

In order for the VAR control function to operate, it must be enabled. Entering YES at this menu will turn the feature on. Because the function is designed to operate while the generator set is in parallel with the utility, VAR control also requires the proper indication that all tying circuit breakers are closed. This is done through the user-programmable digital inputs.

Because VAR control cannot be enabled at the same time that PF control is enabled, turning VAR control on

(ENABLED) when PF control is enabled turns the PF control off (DISABLED).

KVAR Adjust

Using the kVAR adjust sets the desired operating value for the generator set’s reactive load when the generator set operates in a utility paralleling application.

The desired generator set load is entered directly as kVARs.

The value entered may be as low as zero or as high as the rated value (rated kW x 0.75). Any entry beyond the rated value will not be accepted, and a RANGE ERROR message will be displayed.

The default value for kVAR adjust is zero. Each time the system’s rated kW is changed, the kVAR adjust will revert to zero. The displayed kVAR setting may change if the kVAR setting is changed via other inputs.

Generating/Absorbing

While operating in the VAR control mode, the reactive load on the generator set may be specified to be out of

GENERATING or into ABSORBING the generator set.

Specifying the VAR type or direction is done through the

GENERATING/ABSORBING menu.

Because the normal flow of reactive current is out of the generator set, the default value is GENERATING. If ABSORBING is desired, a NO entry at this menu will change the control mode to ABSORBING. When ABSORBING is selected, another NO entry will revert the control mode back to GENERATING. It is assumed that this mode will not be changed when the generator set is running. An attempt to change the mode while running will return a

RANGE ERROR message. The generator set will need to be shut down in order to change this setting.

PF Adjust

Use the PF adjust to set the desired operating relationship for the generator set’s output voltage and current when the generator set is connected in parallel with the utility. The excitation is regulated to maintain a

PF equal to the entered value. The value entered may be as low as 0.7 for leading PFs or as low as 0.6 for lagging PFs. Any entries below these limits will cause a

RANGE ERROR message to display.

The upper limit for PF adjust is 1.0 and the default value is 0.8 lagging. Each time the system’s rated kW is changed, the PF adjust will revert to this default value.

The PF adjust display setting may change if the PF adjust is changed via other inputs.

Lagging/Leading

It is possible to select either a leading or lagging PF for utility parallel applications.

The selected mode is displayed. A NO entry switches the controller to use the other reference. Because the most common mode of operation will be with a lagging PF, LAGGING is the default value.

Because this mode should not be changed while the generator set is running, attempting to change this mode during operation will return a

RANGE ERROR message. Always shut down the generator set to change the lagging/leading mode setting.

TP-6200 3/06 Appendix 195

Appendix D Alternator Protection

The 550 controller has built-in thermal protection for the alternator. This feature functions similarly to a thermal circuit breaker. When the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of time at which current is over the rating is inversely related to the amount of current above the nominal rating. In other words, the higher the current, the shorter the acceptable time.

The current and time limits are defined by actual test data and are maintained in the personality parameter file.

Although the equation for detecting a fault is proprietary, some of the important limits are shown below for informational purposes.

Rated Current

200%

300%

425%

950%

Time Delay

40 seconds

10 seconds

5 seconds

1 second

196 Appendix TP-6200 3/06

Appendix E Inputs and System Events by Engine

The controller inputs and system events are typically driven by the engine manufacturer’s ECM. NFPA 110 guidelines provide specific requirements that all controllers must have for compliance.

While the controller displays all NFPA 110 required data, some engine ECMs provide additional items that the controller will display. The following table illustrates the available alternator and engine outputs for monitoring.

STANDARD 550 CONTROLLER

Input Functions (Group A)

Warning

Shutdown Type A

Shutdown Type B

Voltage Raise

Voltage Lower

VAR PF Mode

Remote Shutdown

Remote Reset

Air Damper (if engine equipped)

Low Fuel

Field Over Volts

Battleswitch

Ground Fault

Battery Charger Fault

High Oil Temperature (non-ECM only)

Low Coolant Level

Low Coolant Temperature (not user-selectable)

Idle Mode Active

System Events (Group B)

Emergency Stop

Overspeed

Overcrank

High Cool Temperature Shutdown

Oil Pressure Shutdown

Low Coolant Temperature

Low Fuel Warning

High Coolant Temperature Warning

Oil Pressure Warning

Master (Switch) Not in Auto

NFPA110 Fault

Low Battery Voltage

High Battery Voltage

Battery Charger Fault

System Ready

No Oil Pressure Signal

High Oil Temperature Shutdown

No Coolant Temperature Signal

Low Coolant Level

Speed Sensor Fault

Locked Rotor

Master Switch Error

Master Switch Open

Master Switch to Off

AC Sensing Loss

TP-6200 3/06

STANDARD 550 CONTROLLER, continued

Overvoltage

Undervoltage

Weak Battery

Over Frequency

Under Frequency

Load Shed kW Overload

Load Shed Under Frequency

Over Current

EPS Supplying Load

Internal Fault

Delay Engine Cooldown

Delay Engine Start

Starting Aid (if engine equipped)

Generator Set Running

Air Damper Control (if engine equipped)

Ground Fault

EEPROM Write Failure

Critical Overvoltage

Alternator Protection Shutdown

Air Damper Indicator (if engine equipped)

Defined Common Fault (RDO)

Software Controlled (RDO)

CONTROLLER WITH MENU 15

(standard controller items plus:)

Input Functions (Group A)

Breaker Closed

Enable Synch

System Events (Group B)

Reverse Power Shutdown

Over Power Shutdown

Loss of Field Shutdown

Over Current Voltage Regulator Shutdown

Common Protective Relay Output (RDO)

In Synch

Breaker Trip

CONTROLLER WITH WAUKESHA-POWERED ENGINE

(standard 550 controller items plus:)

Input Functions (Group A)

Air/Fuel Module Shutdown

Knock Shutdown

Detonation Warning

Detonation Shutdown

System Events (Group B)

Fuel Valve Relay

Pre Lube Relay

Air/Fuel Module Remote Start

No Oil Temperature Signal

High Oil Temperature Warning

No Air Temperature Signal

Intake Air Temperature Warning

Intake Air Temperature Shutdown

AFM Engine Start Delay

Appendix 197

CONTROLLER WITH DDC/MTU-POWERED ENGINE AND

MDEC (standard 550 controller items plus:)

System Events (Group B)

Loss of ECM Communication

High Oil Temperature Warning

Intake Air Temperature Warning

Intake Air Temperature Shutdown

MDEC Yellow Alarm

MDEC Red Alarm

Block Heater Control

Low Coolant Temperature Warning and Shutdown

Load Shed Over Temperature

CONTROLLER WITH 275--400REOZV

(standard 550 controller items plus:)

System Events(Group B)

Loss of ECM Communication

CONTROLLER WITH 125 kW WITH 8.1 L GM ENGINE

(standard 550 controller items plus:)

Input Functions (Group A)

Low Fuel Shutdown

198 Appendix TP-6200 3/06

TP-6200 3/06e

E 2002, 2003, 2004, 2005, 2006 by Kohler Co. All rights reserved.

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

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65) 264-6422, Fax (65) 264-6455