Kohler 20-3250 kW Generator Set Manual

The 20-3250 kW generator sets are designed to provide reliable power for a variety of industrial applications. These generator sets feature a built-in voltage regulator and provide complete compatibility with select engine electronic control module (ECM) and non-ECM equipped generator set engines.

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Controller Setup and Application

Industrial Generator Sets

Models:

20--3250 kW

Controllers:

Decision-Makerr 550

TP-6140 10/01c

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

Controller Identification

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

Controller Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

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

Safety Precautions and Instructions

Introduction

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

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

List of Related Materials

Service Assistance

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

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

Section 1 Features and Operation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.1

Controller Overview

1.2

Controller Operation

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

1.2.1

Cooldown Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2

Idle (Speed) Mode

(ECM equipped engines only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.4

Controller Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5

Controller Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.1

Main Logic Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5.2

Interconnection Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.1

ECM Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2

ECM Engines and Controller Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3

20--300 kW Voltage Regulator (Brushless Alternator with Brushless Exciter) . . .

2.4

350--3250 kW Voltage Regulator (Brushless Alternator with

Brushless Pilot Exciter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5

Interface Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

Voltage Regulator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1

Voltage Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.2

Underfrequency Unload Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.3

Frequency Setpoint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.4

Underfrequency Unload Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Paralleling Applications (Reactive Droop) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1

Reactive Droop Enable

2.7.2

Voltage Droop

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

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

2.8

Paralleling Applications with Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.1

VAR Control Enable

2.8.2

KVAR Adjust

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

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

2.8.3

Generating/Absorbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8.4

Power Factor Adjust

2.8.5

Lagging/Leading

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

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

2.9

Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Load Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 Controller with Marathon DVR 2000 Voltage Regulator Substitution . . . . . . . . . .

Section 3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.1

Voltage and Current Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.3

Current Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4

Calibration: Voltage and Amperage (Menu 12) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5

Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1

Idle Mode Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.2

Define Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.3

TB1 Customer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.4

TB3 Accessory Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.5

TB2 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6140 10/01 Table of Contents

Table of Contents, continued

3.6

Zeroing Auxiliary Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7

Analog Inputs (Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.8

Alternative Calibration Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9

Analog Input (Warning/ Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Relay Driver Outputs (Menu 10)

3.10.1

NFPA Defaults

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

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

3.10.2

Common Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Accessory Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.1

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

4.2

Controller (Customer) Connection Kit

4.3

Interconnect Circuit Board

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

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

Section 5 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.1

Factory Setup

5.2

Program Loader

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

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

5.3

Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4

Personal Computer Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.5

Remote LAN Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.6

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

Section 6 Controller Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1

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

6.2

Installation

6.2.1

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

Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2.2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Appendix B Display Items for Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C Controller User-Defined Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix D Relay Driver Output (RDO) Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents TP-6140 10/01

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely.

Read and follow all safety precautions and instructions.

SAVE

THESE INSTRUCTIONS.

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.

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

TP-6140 10/01

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.

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

Safety Precautions and Instructions 5

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.

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.

Carbon monoxide symptoms.

Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. 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.

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 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.

6 Safety Precautions and Instructions TP-6140 10/01

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/Moving Parts

DANGER

Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

WARNING

Hazardous voltage.

Moving parts.

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. Ensure you comply with all applicable codes and standards.

Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

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).

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.

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)

WARNING

Airborne particles.

Can cause severe injury or blindness.

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

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.

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.

TP-6140 10/01 Safety Precautions and Instructions 7

WARNING

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

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.

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.

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.

8 Safety Precautions and Instructions TP-6140 10/01

Introduction

This manual provides setup and application information for 20--3250 kW generator sets equipped with the following controller:

Decision-Maker r 550

In addition, some diagnostic information is shown for selected components.

This manual may be used for models not listed on the front cover.

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.

Generator set controller setup and diagnostic work must be performed by appropriately skilled and suitably trained 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.

List of Related Materials

Separate literature contains communication and software information not provided in this manual. The following table lists the available literature part numbers.

550 Controller

Literature Description

550 Controller Spec Sheet

550 Controller Generator Set

Operation Manual

Generator Set/Controller

Wiring Diagram Manual

550 Communications Spec Sheet

KBUS Communications Spec Sheet

Monitor II Software

Operation/Installation Manual

Modbus Communication Operation

Manual

Program Loader Software

Installation

Communication Kits Installation

Literature

Part Number

G6--46

TP-6083 or TP-6200

Multiple Part Numbers

Contact your

Distributor/Dealer

G6--50

G6--38

TP--5972

TP--6113

TT--1285

TT-847

TP-6140 10/01 Introduction 9

Service Assistance

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

Consult the Yellow Pages under the heading

Generators—Electric.

Visit the Kohler Power Systems website at

KohlerPower.com.

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

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

Outside the US and Canada, call the nearest regional office.

Headquarters Europe, Middle East, Africa

(EMEA)

Kohler Power Systems

3 rue de Brennus

93200 Saint Denis

France

Phone: (33) 1 49 178300

Fax: (33) 1 49 178301

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

10 Service Assistance TP-6140 10/01

Section 1 Features and Operation Overview

The 550 controller, available on 20--3250 kW generator sets, meets the requirements of NFPA 99 and

NFPA 110.

The controller contains microprocessorbased logic and communicates with a personal computer (PC) individually or on a network when equipped with optional communication software products.

The controller provides complete compatibility with select engine electronic control module (ECM) and non-ECM equipped generator set engines.

Refer to Section 2.2, ECM Engines and

Controller Displays, for identification of compatible ECM engines. All other engines, even if ECM equipped, are not compatible and considered non-ECM engines. The controller is compatible with 12- or 24-volt engine battery systems. See Figure 1-1.

The controller displays both engine and generator conditions as well as numerous system functions. The controller monitors engine and generator parameters

1 2 3 4 and displays and stores 100 system events. Optional menu-driven, Windows r-based PC software monitors engine and alternator parameters and also provides control capability. The controller supports the Modbus r remote terminal unit (RTU), an industry standard open communication protocol.

The 550 controller standard features include:

Built-in digital voltage regulator.

Inherent alternator protection including overload and short circuit matched to each alternator.

User-programmable load shed function.

Smart-starting idle mode for noncritical operation.

Digital inputs, analog inputs, and digital outputs for system control.

5 6

TP-6083-2

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 Controller Front View

5. Digital display

6. Keypad

7. Operating guide

8. Controller terminal strips (on circuit board)

TP-6140 10/01 Section 1 Features and Operation Overview 11

1.1 Controller Overview

The 550 controller features a built-in voltage regulator to better match engine and generator performance. The

550 controller regulates voltage internally without using an external voltage regulator board.

Each controller/generator set is loaded with a unique, factory-loaded personality parameter file.

The controller personality file is specific to the generator set application.

The personality parameter file can be reinstalled at the installation site when required.

The controller circuit has a speed sensor and uses the voltage input as a secondary means of crank disconnect and overspeed. ECM equipped engines use the ECM speed signal as a basis for engine crank termination and overspeed shutdown.

If the ECM signal circuit is interrupted, the engine shuts down.

No safeguard breaker option is required. The controller has overload and short circuit protection with the data built into the personality parameter file.

Communication is possible using the controller KBUS and Modbus r RS-232 and RS-485 connections.

The 550 controller engine harness is unique and not compatible with Decision-Maker 3+ or Decision-

Maker 340 controller applications.

Engine sensors for oil and coolant are 3-wire types on non-ECM engines providing system integrity monitoring. ECM engines utilize ECM communications to provide engine faults and warnings. ECM engines utilize SAE J1939 serial communication to the 550 controller and allow information captured by the ECM to be used for controller system functions, eliminating redundant sensors on the engine.

The engine monitoring menu or the monitoring software displays additional status information.

The 550 controller requires a customer connection kit when relay driver outputs are used for remote annunciation.

Customer-specified analog inputs are provided with 0--5 VDC signals and/or digital inputs are available where the signal goes to chassis ground.

1.2 Controller Operation

The generator set master RUN-OFF/RESET-AUTO switch is a 3-position, rotary, selector switch.

See

Figure 1-2. The RUN position starts the generator set locally.

The AUTO position starts and stops the generator set remotely. OFF stops the generator set without any time delay when operating locally in the

RUN position. When the generator set shuts down due

Modbus r is a registered trademark of Schneider Electric

12 Section 1 Features and Operation Overview to a fault, reset the control system by moving the selector to the center

OFF/RESET

position prior to a restart. Controllers are available with a key-operated switch.

TP-6083-2

Figure 1-2 Switches and Alarm Horn

Pressing the emergency stop switch bypasses any time delays and provides an immediate engine shutdown when operating. The switch latches in the open position; pull the switch knob outward to reset it.

The alarm horn sounds whenever the selector switch is not in the AUTO position or a fault shutdown occurs.

The alarm also sounds along with various warning indications. To silence the horn, place the generator set master switch in the AUTO position and depress the keypad alarm off button.

1.2.1 Cooldown Mode

The cooldown period is based on coolant temperature.

The engine shuts down early if it reaches the engine cooldown temperature (which is part of the personality profile) before the engine cooldown time delay period times out. If the engine does not reach the defined engine warmed-up temperature before being put into the cooldown mode, it will shut down immediately.

1.2.2 Idle (Speed) Mode

(ECM equipped engines only)

The idle (speed) mode function 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 overrides the idle speed mode if the engine reaches the preprogrammed engine warmed-up 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.

TP-6140 10/01

The controller overrides the idle speed function when the generator set is signaled to start while in the AUTO position. This override provides immediate emergency generator set power in the event of a utility power failure.

When the utility power returns and the generator set is signaled to stop, the generator set will continue to run until the idle mode switch circuit is opened. If idle mode is not active, the generator set will enter a cooldown period as discussed earlier.

Use menu 9 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.

1.3 Keypad

Use the keypad to interact locally with the controller by accessing generator set data and preset settings.

Program crank cycles and time delays under password control with the keypad. Pressing any key activates the controller panel display. The 2-line vacuum fluorescent display provides generator set and engine condition information. See Figure 1-3.

TP-5829-2

Figure 1-3 Digital Display and Keypad

The 14 available menus are listed in Figure 1-4.

Additionally, menu 20 allows factory setup.

To enter a menu:

1. Clear the display by pressing RESET MENU.

2. Enter menu number 1--14.

3. Press ENTER.

4. Once in the menu, use the arrow keys to navigate.

TP-6140 10/01

Menu Title

Generator

Monitoring

Function

Provides generator set output data including line-to-line and line-to-neutral voltages, current, frequency, power factor (PF), kW, kVA, and kVAR.

Engine

Monitoring

Analog

Monitoring

Provides engine operating data including oil pressure, coolant temperature, engine RPM, and battery voltage. Additional monitoring is available on ECM-equipped engines depending on the engine family selected.

Provides battery voltage status and up to 7 user-defined analog monitoring inputs. On non-ECM engines, inputs

03--07 are available where analog inputs 01 and 02 are reserved for engine oil pressure and coolant temperature.

Operational

Records

Event History

Time and Date Sets time, date, and internal calendar.

Necessary for exercise run time and event records. The starting battery must remain connected for time and date to stay valid.

Generator

System

Contains factory-preset generator set voltage and frequency data. Data may be changed if the unit is reconnected.

Overvoltage, undervoltage, overfrequency, underfrequency, and overspeed settings are also located in menu 7.

Time Delays

Provides generator set operational records including operating start date, last logged maintenance, total run time loaded and unloaded, run time since last maintenance, number of starts, and number of running days.

Provides up to 100 stored warning and shutdown events that are day and time dated.

Input Setup

Output Setup

Displays and sets up cycle cranking, start and shutdown functions, and auxiliary shutdown and inhibit time delays.

Provides setup of user-defined digital and analog warning and shutdown inputs. These inputs are dictated by the generator set application and are field-installed. There is a default for factory setup.

Provides setup of user-defined outputs.

Voltage

Regulation

Calibration

Provides voltage regulator function setup including line-to-line voltages, underfrequency unloading, reactive droop, PF, and kVAR adjustments.

Provides voltage sensing logic calibration. Calibration is set at the factory. Recalibration is necessary only when the generator set is reconnected for an optional voltage or the controller is replaced.

Communications Provides local or remote access to the control logic and displays by a PC or other system.

Programming

Mode

Provides local or remote access to the programming function. The user enters a password to access the programming mode. Default password is 0. Monitoring is always allowed.

Figure 1-4 Menu Summary

Section 1 Features and Operation Overview 13

1.4 Controller Lights

Five annunciator panel lamps, as shown in Figure 1-5 and described in Figure 1-6, provide an immediate visual indication of generator set status. Conditions causing a system warning are listed in Figure 1-7.

Conditions causing a system shutdown are listed in

Figure 1-8.

Note: Lists are dependent on engine alternator combination.

Lamp Description

System Ready

Green lamp illuminates when the generator set master switch is in the AUTO position and the system senses no faults.

Not In Auto

Programming

Mode

System

Warning

System

Shutdown

Yellow lamp illuminates when the generator set master switch is not in the AUTO position.

Yellow lamp in flashing mode indicates local programming selection, steady on mode for remote programming mode. No light indicates controller is in the off programming mode.

Yellow lamp identifies an existing fault condition but does not shut down the generator set. A continuing system warning fault condition may cause a system shutdown if the source is not corrected.

The red lamp identifies generator set shutdown because of a fault condition. A system shutdown may follow a system warning condition.

Figure 1-6 Annunciator Panel Lamps

TP-6083-2

Figure 1-5 Annunciator Lamps

Engine Functions

Coolant temperature signal loss

High battery voltage

High coolant temperature

Low battery voltage

Low coolant temperature

Low fuel (level or pressure)*

Low oil pressure

Oil pressure signal loss

Speed sensor fault

Starting aid fault

Weak battery D

General Functions

Auxiliary-analog inputs (up to 7 programmable shutdowns or warnings)

Auxiliary-digital inputs (up to 21 programmable shutdowns or 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

Master switch open

NFPA 110 fault

Generator Functions

AC sensing loss

Generator running

Ground fault*

Overcurrent

*Requires optional input sensors

Figure 1-7 System Warning

Engine Functions

Air damper control fault, if equipped

Air damper indicator fault, if equipped

High coolant temperature

High oil temperature

Low coolant level

Low oil pressure

Overcrank

Overspeed

General Functions

Auxiliary-analog inputs (up to 7 programmable shutdowns or warnings)

Auxiliary-digital inputs (up to 21 programmable shutdowns or warnings)

ECM communications loss

Emergency stop

Internal fault

Master switch in off/reset position

Master switch error

Master switch open

NFPA 110 fault

Figure 1-8 System Shutdown

Generator Functions

Locked rotor (failed to crank)

AC output overvoltage

AC output undervoltage

Field overvoltage

Alternator protection, overloads, short circuits

Overfrequency

Underfrequency

14 Section 1 Features and Operation Overview TP-6140 10/01

1.5 Controller Circuit Boards

The controller has five circuit boards as listed in

Figure 1-9.

See Figure 1-10, Figure 1-11, and

Figure 1-12 for circuit board locations. See Figure 1-13 for controller connections.

Circuit Board

Indicator

Interconnection

Keypad

Digital Display

Main Logic

(Microprocessor)/

Communication

Description and Function

Includes the LED status lamps and alarm horn.

Provides the terminal strips to connect the customer connection and/or dry contact kits and three fuses (F1, F2, and F3).

Provides the keypad to navigate the generator set displays and enter data.

Provides the digital display for monitoring the generator set functions and output values.

Provides the controller operation logic and provides communication locally (direct) or remotely (via modem) using RS-232 or

RS-485 connectors.

Figure 1-9 Controller Circuit Boards

1 2

1. Main logic circuit board

2. Digital display circuit board

3. Indicator circuit board

4. Indicator circuit board

5. E-stop

Figure 1-11 Front Panel Controller Layout

5 4 3

GM10193B-A

1. AC fuse block (TB6)

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 1-10 Controller Circuit Boards and Fuses

(Controller Top View)

1. AC fuse block

2. Analog inputs

3. Start terminals 3--4

4. Interconnection board

5. Digital inputs

Figure 1-12 Back Panel Controller Layout

TP-6140 10/01 Section 1 Features and Operation Overview 15

Figure 1-13 Controller Connections

16 Section 1 Features and Operation Overview

ADV-6533B-G

TP-6140 10/01

1.5.1 Main Logic Circuit Board

The main logic circuit board is responsible for all microprocessor logic functions, remote communications, and display and keypad functions.

See Figure 1-14.

P19 RS-485 communication connection is a spare connection for factory use.

P22 SAE J1939 connector for communications with an

ECM, when equipped.

1.5.2 Interconnection Circuit Board

The interconnection circuit provides the terminal strips to connect the customer connection and/or dry contact kits and three fuses (F1, F2, and F3). See Figure 1-15 and Figure 1-16.

1 2

4 5

Figure 1-14 Main Logic Circuit Board

P10 Harnessed plug connection for the voltage and current inputs. The voltage inputs are from V7, V8, V9, and V0. The current inputs are from the CT burden resistor board.

P12 Ribbon cable connection from the interconnection board. This connection links the analog input terminal strip to the logic board.

P13 Modem power connection (future connection).

P14 Ribbon cable connection to the status board. This is the communications link for annunciation of alarms, digital display, and keypad.

P15 Harness connection from the interconnection board and power input to the main logic board.

P16 Ribbon cable connection for digital outputs from the main logic board.

P17 Ribbon cable connection for digital inputs. This connection links the interconnection board’s digital input terminal strip to the main logic board.

P18 RS-232 communication connection for communication to a PC at a distance of 15 m (50 ft.) or less.

P20 RS-485 communication connection for Modbus r communications.

P21 RS-485 communication connection for communication to a PC for distances of 15--1220 m

(50–4000 ft.).

This connection is used for KBUS communications.

1. TB1 terminal strip

2. TB2 terminal strip

3. P23 Connector

ADV-6533-A

4. TB3 terminal strip

5. TB4 terminal strip

Figure 1-15 Interconnection Circuit Board Terminal

Strips and Connectors

Figure 1-16 Interconnection Circuit Board

TP-6140 10/01 Section 1 Features and Operation Overview 17

P1 Main engine harness connection.

P2 Ribbon cable connection used to link the analog inputs to the main logic board.

P3 Harness connection for the DC power input to the main logic board.

P4 Ribbon cable connection to the main logic board

(used to link digital outputs from the main logic board).

P5 Ribbon cable connector that transfers the digital inputs to the main logic board.

P23 Output plug that transfers the digital output logic to the customer connection board.

TB1 Customer connection point for remote start (3-4) and emergency stop input (1-1A).

TB2 Customer connection point for the analog inputs.

TB3 Customer connection point for the DC control power.

TB4 Customer connection point for the digital inputs.

18 Section 1 Features and Operation Overview TP-6140 10/01

Section 2 Installation

2.1 ECM Communications

The J1939 serial communication link accesses information from certain Detroit Diesel engines with

DDEC ECMs. See Figure 2-1. The communication link provides access to DDEC data and is displayed in menu

2 of the 550 controller. The J1939 link also provides engine sensor data access eliminating redundant senders on the engine. If the J1939 communication link from the ECM to the 550 controller is lost, the generator set shuts down on a loss of ECM communication fault.

See Figure 2-2.

Menu 2, Engine Monitoring, provides information about the various engine parameters while the generator set is either operational or shut down. Menu 2 is only an informational menu, and the user cannot set or change engine parameters.

Some available engine data is dependent on the engine family. As a result, some monitoring displays may not be available with a given engine.

1. Connector from DDEC to controller

Figure 2-1 Detroit Diesel Engine DDEC Engine

Control Module (ECM)

Figure 2-2 J1939 Communication Link Between Engine ECM and 550 Controller

TP-6140 10/01 Section 2 Installation 19

2.2 ECM Engines and Controller

Displays

Detroit Diesel series 60, 2000, and 4000 engines are

ECM-equipped.

The controller displays provided by each engine are listed in Figure 2-3. Figure 2-4 lists references to typical wiring schematics on the following pages.

Display

Engine speed

Fuel pressure

Fuel temperature

Fuel consumption rate

Fuel used last run*

Coolant pressure

Coolant temperature

Oil pressure

Oil temperature

Crankcase pressure

Ambient temperature

ECM battery voltage

Engine model number

Engine serial number

Unit number

ECM serial number

Coolant level switch

Oil level switch

X Available display feature

* Value must be reset using the DDEC reader

# Not available at this time

230--400 kW

DDC Series 60 Diesel Engine

Figure 2-3 Controller Displays for ECM-Equipped Engines

Generator Set Models

450--1000 kW

DDC Series 2000 Engine

1250--2000 kW

DDC Series 4000 Engine

Wiring Schematic

ECM Equipped Engine and 200 kW Alternator

ECM Equipped Engine and 230--300 kW Alternator

ECM Equipped Engine and 350/400 kW Alternator

ECM Equipped Engine and 450--2000 kW Alternator

Non-ECM Equipped Engine and 20--300 kW Alternator

Non-ECM Equipped Engine and 350--2000 kW Alternator

Figure 2-4 Typical Wiring Schematics

Figure Number

Figure 2-5

Figure 2-6

Figure 2-7

Figure 2-8

Figure 2-9

Figure 2-10

20 Section 2 Installation TP-6140 10/01

Figure 2-5 ECM Equipped Engine and 200 kW Alternator

TP-6140 10/01

ADV-6596A-C

Section 2 Installation 21

Figure 2-6 ECM Equipped Engine and 230--300 kW Alternator

22 Section 2 Installation

ADV-6533A-G

TP-6140 10/01

Figure 2-7 ECM Equipped Engine and 350/400 kW Alternator

TP-6140 10/01

ADV-6534A-G

Section 2 Installation 23

Figure 2-8 ECM Equipped Engine and 450--2000 kW Alternator

24 Section 2 Installation

ADV-6602A-B

TP-6140 10/01

Figure 2-9 Non-ECM Equipped Engine and 20--300 kW Alternator

TP-6140 10/01

ADV-6599A-C

Section 2 Installation 25

Figure 2-10 Non-ECM Engine and 350--2000 kW Alternator

26 Section 2 Installation

ADV-6588A-D

TP-6140 10/01

2.3 20--300 kW Voltage Regulator

(Brushless Alternator with

Brushless Exciter)

The 550 controller voltage regulator provides

±0.25% regulation for single- or three-phase loading.

See

Figure 2-11. The three-phase voltage-sensing regulator is part of the main logic board software and is serviced as part of the complete controller.

Voltage regulation and stability controls are based on programmed parameters that are part of the 550 controller personality profile specific to the generator set application.

The regulator output is a pulse width modulation (PWM) signal. The PWM signal controls the current flow through the main rotor field, which in turn controls voltage supply at the alternator stator lead output. For any given load and alternator speed, the alternator output voltage is proportional to the regulator PWM signal level.

Menu 11 displays voltage regulator setup functions including line-to-line voltages, voltage adjustment, underfrequency unloading (volts per Hz), reactive droop, power factor (PF), and kVAR adjustments.

Reactive droop, PF, and kVAR adjustments are required only when the generator set is used in paralleling applications.

Main Logic

Circuit Board

Controller

Interconnection

Circuit Board

Figure 2-11 Main Logic Circuit Board and Controller Interconnection Circuit Board

TP-6140 10/01 Section 2 Installation 27

2.4 350--3250 kW Voltage Regulator

(Brushless Alternator with

Brushless Pilot Exciter)

The three-phase voltage-sensing regulator is built into the main controller logic board.

Additionally, an interface board excites the 350--3250 kW alternator.

See Figure 2-12. Voltage and stability control is based on programmed parameters that are part of the 550 controller personality profile for the specific generator set application. These programmed parameters are not field-adjustable. The voltage regulator output (3B--5B) is a pulse width modulation (PWM) signal. This PWM signal triggers the interface board excitation circuit allowing for DC main rotor field excitation.

2.5 Interface Board

The interface board is required as part of the voltage regulation for 350--3250 kW alternators.

The permanent magnet generator (PMG) input signal is rectified on the interface board. This rectified voltage provides the output stator excitation power.

The interface board requires battery voltage (12 or

24 volts) for control power. This power is fused with F3 located on the controller interconnect board.

The overvoltage adjustment potentiometer controls the shutdown point for field overvoltage (EOV). The EOV output signal from the interface board is wired to interconnect board digital input 4. This input is defaulted for 350--3250 kW alternators to activate the field overvoltage shutdown (Marathon Over V).

See

Figure 2-13.

VOLTAGE REGULATOR OUTPUT

Controller

Interconnection

Circuit Board

Main Logic

Circuit Board

Figure 2-12 Main Logic Circuit Board and Controller Interconnection Circuit Board with 350--3250 kW Excitation

Interface Circuit Board

28 Section 2 Installation TP-6140 10/01

GM11718B-E

1. PMG input

2. Excitation F1-F2

Figure 2-13 Interface Board

2.6 Voltage Regulator Adjustment

2.6.1 Voltage Adjust

The voltage adjust is entered as the rated or otherwise desired line-to-line voltage.

See Figure 2-14.

The average of the line-to-neutral voltages is then regulated to the corresponding value. The setting may be as precise as one tenth of a volt. The voltage adjustment defaults to the rated system voltage. The voltage adjust may be set to any value within 20% of the system voltage.

The upper limit is 20% above the system voltage, and the lower limit is 20% below the system voltage. If a value beyond these limits is entered, a

RANGE ERROR message appears.

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, allowing the user to monitor any one phase if desired.

The voltage adjust setting may be changed by means other than the menu; i.e., digital input or communications. If this occurs, the new value displays accordingly in the voltage adjust menu.

2.6.2 Underfrequency Unload Enable

This menu turns the underfrequency unload on or off. 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.

The underfrequency unload defaults to an enabled (ON) condition.

Underfrequency unload lowers the output voltage when the frequency dips due to large loads.

Menu 11 Overview

MENU 11

VOLTAGE REGULATOR

AVG L-L V

VOLT ADJ

REACTIVE DROOP

ENABLED

→

?.?

UNDER FREQ UNLOAD

ENABLED

→

N/Y

→

N/Y

L1-L2 VOLTS

→

Enter required line-to-line volts

L2-L3 VOLTS (3 PHASE)

FREQUENCY

SETPOINT

# HZ

→

?.? HZ

Enable volts per hertz

.8 PF RATED LOAD

VOLTAGE DROOP

→

?.?%

SLOPE

?.? VOLTS-PER-CYCLE

Enter cut-in frequency

→

L3-L1 VOLTS (3 PHASE)

→

Enter voltage to rolloff per cycle

VAR CONTROL

ENABLED

PF CONTROL

ENABLED

→

N/Y

TOTAL KVAR

KVAR ADJ

→

N/Y

AVERAGE PF

PF ADJ

Figure 2-14 Menu 11, Voltage Regulator

→

?.?

GENERATING/

ABSORBING

→

?.?

LAGGING/

LEADING

Y/N

→

Y/N

→

Y/N

TP-6140 10/01 Section 2 Installation 29

2.6.3 Frequency Setpoint

Frequency setpoint is the cut-in point for the underfrequency unloading. At any operating frequency below this value, the output voltage is reduced. The frequency may be entered with resolution to tenths of a hertz. The range of acceptable entries is 40 to 70 Hz.

Any entry beyond these limits will cause a RANGE

ERROR display, and the setting will not change. The default value is 1 cycle per second (or 2 for non-ECM engines) below the system frequency normal.

The frequency setpoint changes to the default value if the system frequency changes.

A setting of 40 Hz will essentially disable the underfrequency unload feature because most engines will not normally drop to this low speed even during load applications.

2.6.4 Underfrequency Unload Slope

The slope determines how much the 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/Hz. A zero entry for the slope will in effect turn the underfrequency unload feature OFF.

2.7 Paralleling Applications

(Reactive Droop)

2.7.1 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. Use reactive droop in a generator set to generator set paralleling application.

2.7.2 Voltage Droop

The amount of reactive droop is entered as a percentage of system voltage when applying full rated load, at 0.8 PF. The entry is made as precise as one tenth of a volt. This entry determines how much the voltage droops 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 provides full rated load at 0.8 PF, the expected voltage change equals the voltage droop setting as a percentage of system voltage. A voltage droop setting of zero will in effect disable the reactive droop feature. The default value is 4% droop at full rated load at 0.8 PF. The voltage droop setting is displayed for reference.

As this value changes via the remote communications, the display setting changes.

2.8 Paralleling Applications with

Utility

2.8.1 VAR Control Enable

In order for the VAR control function to operate, it must be enabled. Entering yes at this menu turns the feature on. Because the function is designed to operate while in parallel with the utility, it 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, the action of turning VAR

Control on (ENABLED) turns the PF control off

(DISABLED) if it was previously ENABLED.

To activate the VAR or PF modes, a digital input to TB-4 is required. This input should indicate the generator set is paralleled to the utility.

After the digital input is grounded, the VAR or PF adjustment initiates.

Note: When the VAR control is enabled, the unit will not shut down when TB-4-17 is grounded.

2.8.2 KVAR Adjust

The KVAR adjustment is used to set the desired operating value for the generator set reactive load when in a utility paralleling application.

Enter the desired generator set load 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 this will not be accepted and a RANGE ERROR message is displayed.

The default value for KVAR adjust is zero. Any time the system rated kW is changed, the KVAR adjust will revert to this default value. Because the KVAR adjust may be changed via other inputs, the display setting changes.

30 Section 2 Installation TP-6140 10/01

2.8.3 Generating/Absorbing

While operating in the VAR control mode, the generator load may be specified to be out of (generating) or into

(absorbing) the generator.

Set through the generating/absorbing menu. Because the normal flow of reactive current is out of the generator, the default value for this setting 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 back to generating. It is assumed that this mode will not be changed when the generator set is running.

Therefore, an attempt to change the mode while running will return a RANGE

ERROR message.

Shut down the generator set to change this setting.

2.8.4 Power Factor Adjust

Use the PF adjust to set the desired operating relationship for the generator set output and current when connected in parallel with the utility. The regulated excitation maintains a PF that is equal to the entered value. The value entered may be 0.7 for leading PFs to

0.6 for lagging PFs. Any entries outside these limits cause a RANGE ERROR message display. The default value for PF adjust is 0.8 lagging. Whenever the system rated kW changes, the PF adjustment reverts to the default value. If the PF adjustment is changed via other inputs, the display setting changes.

2.8.5 Lagging/Leading

It is possible to select either a leading or lagging PF for utility parallel applications. The controller displays the selected mode. A NO entry switches the controller to use the opposite relationship for regulation purposes.

This may only be changed while the generator set is not running. Lagging is the default value because the most common mode of operation has a lagging PF.

2.9 Alternator Protection

Inherent alternator protection is part of the personality parameters program installed in the controller.

The parameters program is specific to the alternator listed in menu 20 of the controller. The alternator part number is listed on the controller software label located inside the

550 controller. The programmed protection limits for the controller/alternator cannot be adjusted.

When the alternator current output exceeds the programmed overload and short circuit limits, the generator set shuts down. The local display will read altrntr protect sdwn

(alternator protection shutdown).

2.10 Load Shed

The load shed feature is based on either kW overload or underfrequency. See Figure 2-15.

Figure 2-15 Load Shed Feature

TP-6140 10/01 Section 2 Installation 31

If the generator set output exceeds the kW load shed limits defined in menu 7, a local warning for load shed kW over is displayed. This warning, defined as a relay driver output (RDO), trips a downstream circuit breaker allowing the excess load to be shed when the generator set is online. If the generator set output frequency drops to 59 Hz for 60 Hz operation or 49 Hz for 50 Hz operation, the controller displays a load shed underfrequency local warning. This warning can be programmed as an RDO to trip a circuit breaker allowing load shedding. The underfrequency setpoint is a fixed nonadjustable setting and is programmed with a

5-second time delay.

2.11

Controller with Marathon DVR 2000

Voltage Regulator Substitution

Certain early shipments of the 550 controller were equipped with the Marathon DVR2000 voltage regulator.

Figure 2-16 shows the location of the

DVR 2000 voltage regulator inside the junction box.

The internal 550 controller voltage regulator and the

DVR2000 voltage regulator share most features. The following features, however, are not available with the

DVR 2000 voltage regulator:

Voltage regulator programming using the controller keypad. Make adjustments to the DVR 2000 voltage regulator at the voltage regulator.

Remove the junction box cover to adjust the DVR 2000 voltage regulator.

Voltage setting using the controller keypad.

Volts/Hz display.

VAR/power factor controller, display, and adjustment.

This feature is available as an accessory; order part number PA-347165 or PA-347165-SD.

Reactive droop controller, display, and adjustment.

Engine idle mode capability using the controller

(voltage regulator is deenergized).

The 550 controller spec sheet and operation manual provide only information regarding the controller voltage regulator.

For information regarding the DVR 2000 voltage regulator, obtain TP-5579, Operation Manual,

DVR 2000 Voltage Regulator.

Use Figure 2-17 for installation and troubleshooting of the electrical wiring system.

GM16780-A

1. DVR 2000 voltage regulator

Figure 2-16 DVR 2000 Voltage Regulator Mounting

Location

DVR 2000 is a trademark of Marathon Electric Mfg. Corp.

32 Section 2 Installation TP-6140 10/01

Junction Box Legend

PMG

STAT

-- Permanent Magnet Generator

-- Stator

TB5 -- Controller AC Fuse Block

QCON(#) -- Quick Connect

Generator

Figure 2-17 DVR 2000 Voltage Regulator/Alternator Interconnection Wiring Diagram, GM20500

TP-6140 10/01 Section 2 Installation 33

Notes

34 Section 2 Installation TP-6140 10/01

Section 3 Wiring

3.1 Voltage and Current Inputs

Voltage and current inputs enter the controller at P10 of the main logic board.

The inputs are required for metering calculations, voltage regulation, voltage and current protection, and secondary crank termination

(non-ECM engines). See Figure 3-1.

3.2 Voltage Measurement

The voltage inputs are V7, V8, V9, and V0 and terminate at generator windings 7,8,9, and neutral for 10- and

12-lead alternators.

For a 4-lead alternator, a transformer assembly is required to step down the voltage to input levels acceptable for the controller

(240 volts and below). TB5 is a fuse block for voltage input protection.

The fuse rating is 1.5 amps at

250 volts.

3.3 Current Measurement

For generator sets above 200 kW, a CT burden resistor board is included with the 550 controller application.

The board is located in the junction box with wiring between the 550 controller and the CT burden resistor board.

CTs with 0.5 amps secondary current are mounted in the junction box and wired to TB11. The CT burden resistor board converts the CT current input to a voltage output (P26) for the 550 controller main logic board.

The current input and voltage output are proportional; i.e., the greater the current sensed, the higher the voltage output. Generator sets 20--200 kW utilize a CT with the resistor installed as part of the CT, so no burden resistor board is required.

Note: The CTs with 0.5 amp secondary outputs are unique to the 550 controllers.

Figure 3-1 Voltage and Current Inputs

TP-6140 10/01 Section 3 Wiring 35

3.4 Calibration: Voltage and

Amperage (Menu 12)

The 550 controller requires voltage and current sensing input calibration. See Figure 3-2. Calibration is initially done at the factory and typically requires no adjustment in the field.

If, however, the system voltage is reprogrammed or the controller is replaced, calibration is necessary. Controller calibration is based on readings taken from the generator output windings using a multimeter with a minimum accuracy of +/--1%. Voltage readings are taken from line-to-neutral and must be done for L1, L2, and L3, if required.

Current measurement is based on readings taken with a handheld AC ammeter for L1, L2, and L3.

Menu 12 Overview

MENU 12

CALIBRATION

SCALE AC ANALOG

INPUTS

GEN L1-L0 V

CALIB REF

→

?.?

Value measured by controller

Value programmed during calibration

SCALE AUX. ANALOG

INPUTS

→

Press down arrow to scroll through

ANALOG auxiliary inputs 01--07 with ECM engines.

Press down arrow to scroll through

ANALOG auxiliary inputs 03--07 with non-ECM engines.

ZERO AUX. ANALOG

INPUTS?

GEN L2-L0 V

CALIB REF

?.?

ANALOG XX

SCALE VALUE 1

?.?

SCAL1

SCAL2

#.#--#.#V

GEN L3-L0 V (3 PHASE)

CALIB REF

?.?

ANALOG XX

SCALE VALUE 2

GEN L1 AMPS

CALIB REF

?.?

SCAL1

SCAL2

#.#--#.#V

Right Arrow between ENTRY and DISPLAY of setpoint

GEN L2 AMPS

CALIB REF

?.?

GEN L3 AMPS (3 PHASE)

CALIB REF

?.?

RESTORE

DEFAULTS?

Figure 3-2 Menu 12, Calibration

36 Section 3 Wiring TP-6140 10/01

3.5 Digital Inputs

Digital inputs are specific on-off inputs that monitor the external parameters. These inputs may come from a battery charger, switchgear, fuel tank, or other external devices.

Inputs may be wired as a single-wire connection with the return wire going to battery ground

(example: battery charger connection). Inputs can also be wired as a two-wire connection with the return ground going to TB4, 22-42 (example: idle mode switch). Inputs are based on the digital signal switching to battery ground or ground return of TB4 to initiate a controller action. Typically, the digital input signal switching is done with a relay dry contact and not with a powered contact. See Figure 3-3.

Factory programmed defaults for TB4 inputs 1 through

21 are as follows:

1. Battery Charger Fault

2. Low Fuel

3. Low Coolant Temperature

4. Excitation Overvoltage (Marathon alternator only)

5. Warning

6. Warning

7. Warning

8. Warning

9. Warning

10. Warning

11. Warning

12. Warning

13. Warning

14. Warning (all models except 50--100ROZK)

Low Coolant Level (50--100ROZK)

Note: All models, except 50--100ROZK use

P1-10 as the low coolant level.

15. Remote Shutdown

16. Remote Reset

17. VAR PF Model

18. Voltage Lower

19. Voltage Raise

20. Air Damper

21. Idle Mode

Figure 3-3 Digital Inputs

Each input (other than those predesignated) can be programmed as a warning or a shutdown and also can have an inhibit and a delay time.

If the controller is programmed to meet NFPA 110 requirements (the NFPA 110 setting is found in menu 7), inputs 1, 2, and 20 are factory-defined and the user cannot change the preset function. If the controller is used with an ECM-equipped engine, digital input 3 (low coolant temperature) is predefined. If the controller is used in conjunction with the Marathon alternator, digital input 4 (MARATHON OVER V) is predefined.

Both digital and analog input descriptions can be defined remotely with alphanumeric characters on the controller display.

Define inputs as needed by using the communication software and programming inputs as desired.

3.5.1 Idle Mode Switch

The idle mode input function is only active on

ECM-equipped engines. The idle speed function starts and runs the engine at idle during nonemergency operation. Closing the switch starts the generator set in idle mode, and the engine remains running at idle until the generator set reaches a predefined temperature or the idle timer is complete.

When warmed-up temperature is reached, the engine is ramped to rated speed and remains running until the switch is opened.

The alternator output is disabled during idle operation.

TP-6140 10/01 Section 3 Wiring 37

3.5.2 Define Digital Inputs

Menu 9 identifies the user-defined wired inputs to the

TB4 terminal strip. See Figure 3-4. Menu 9 allows the user to customize the digital inputs for the application required. Program menu 9 at the controller keypad or from a PC using the Monitor II software. If programming with the controller keypad, select the digital input descriptions in menu 9. See Figure 3-5.

When an input is activated, the controller displays the active input D1--D21 (after the inhibit time and delay time have timed out). The user can also program a relay driver output (RDO) in menu 10 that corresponds to the digital input.

Input

Warning

Shutdown Type A

Description

Horn sounds and customer auxiliary lamp lights

Initiates shutdown removing power to ignition and crank

Shutdown Type B Initiates shutdown similar to type A and activates the air damper RDO

Voltage Raise/Lower Remote input to adjust voltage

VAR/PF Mode Initiates VAR or power factor mode of voltage regulator (parallel with utility)

Remote Shutdown

Remote Reset

Used for remote shutdown from switchgear

Used to reset controller faults from remote location

Air Damper

Low Fuel

Marathon Over V

Battle Switch

Idle Mode

Initiates air damper shutdown

Warning for low fuel level or pressure

Field overvoltage shutdown (Marathon alternator)

Overrides all warnings and shutdowns except overspeed and air damper

ECM engines only; allows engine idle on startup and shutdown for programmed time

Ground Fault Indicates ground fault (ground fault sensor required)

Bat Chgr Fault Warns of battery charger malfunction

High Oil Temperature Initiates high oil temperature shutdown

Low Coolant Level

Low Coolant Temp

Initiates low coolant level shutdown

Activates digital input 3 (only available when used with ECM engines)

Figure 3-4 Selection Group Digital Inputs

Menu 9 Overview

MENU 9

INPUT SETUP

SETUP DIGITAL

AUXILIARY INPUTS

→

Wire input TB4, 1--21 select function from Group A.

Press YES to enable input.

Select the amount of time to inhibit input after crank termination. The input is active at all times with or without the generator set running when the inhibit time is set to 0.

Select delay time after the switch closes to activate a warning or shutdown.

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:

WARNING Y/N

SHUTDOWN TYPE A Y/N

SHUTDOWN TYPE B Y/N

VOLTAGE RAISE

VOLTAGE LOWER

Y/N

VAR PF MODE Y/N

REMOTE SHUTDOWN Y/N

REMOTE RESET Y/N

Group A, continued

AIR DAMPER

LOW FUEL

Y/N

FIELD OVERVOLTAGE Y/N

IDLE MODE ACTIVE Y/N

(ECM engine only)

BATTLE SWITCH

GROUND FAULT

BAT CHGR FAULT

Hi OIL TEMP

Y/N

LOW COOLANT LEVEL Y/N

LOW COOLANT TEMP Y/N

(not user selectable)

Figure 3-5 Menu 9, Input Setup (Programming of Digital Input 01 Shown, Repeat for Inputs 02--21 as needed)

38 Section 3 Wiring TP-6140 10/01

3.5.3 TB1 Customer Connection

TB1 provides access to remote start inputs 3--4. See

Figure 3-6. Contact closure on terminals 3--4 initiates an engine start sequence, provided the master control switch is in the auto position. Typical installation has the remote start wired to the automatic transfer switch.

TB1

Engine Start and

Stop Connections

3.5.5 TB2 Analog Inputs

TB2 provides 0--5 VDC analog signal inputs for customer connections. The installer must scale and calibrate each analog input before the input value becomes a warning or shutdown trip point value. See

Figure 3-8. Analog inputs 1--7 are available for userdefined applications on ECM-engine models.

Non-

ECM engines have analog inputs 3--7 available for optional applications, while inputs 1--2 are reserved for oil pressure and coolant temperature.

On ECM engines, oil pressure and coolant temperature come from the ECM. Refer to Section 2.2, ECM Engines and

Controller Displays, for identification of ECM engines.

Figure 3-6 TB1 Engine Start/Stop Connections

Terminals 1-1A are used for the emergency stop switch.

The switch is normally closed and opening causes an immediate engine shutdown. If adding remote E-stop switches, always use a series connection between switches.

3.5.4 TB3 Accessory Output

The TB3 output accessory terminal block provides connections for 12 VDC options that require a fused

5-amp power source. TB3 allows connection to 42A and battery ground. Terminal 42A is a fused 5-amp battery supply (fuse F1). See Figure 3-7.

TB-11

TB-12

TB-13

TB14

TB-15

TB-16

TB-17

TB-18

TB-19

TB-20

TB-21

TB-22

TB-23

TB2 Analog Input Connections

TB-1 Analog CH1

TB-2

TB-3

TB-4

TB-5

Analog CH1+

Analog CH2

Analog CH2+

Analog CH3

TB-6

TB-7

TB-8

TB-9

TB-10

Analog CH3+

Analog CH4

Analog CH4+

Analog CH5

Analog CH5+

TB-24

TB-25

TB-26

TB-27

TB-28

TB-29

TB-30

Analog CH6

Analog CH6+

Analog CH7

Analog CH7+

N/C

Analog CH1--

CH1 Shield Ground

Analog CH2--

CH2 Shield Ground

Analog CH3--

CH3 Shield Ground

Analog CH4--

CH4 Shield Ground

Analog CH5--

CH5 Shield Ground

Analog CH6--

CH6 Shield Ground

Analog CH7--

CH7 Shield Ground

N/C

Figure 3-7 TB3 Fused 5-Amp Power Source

Figure 3-8 TB2 Analog Inputs

The oil pressure input is responsible for low oil pressure warning and shutdown functions and for the oil pressure value (menu 2). The coolant temperature sender is responsible for high coolant temperature warning and shutdown functions, low coolant temperature warning, and coolant temperature value (menu 2).

Analog inputs 1--2 for non-ECM units do not have access for adjustment or calibration. The oil pressure and coolant temperature parameters and calibration are part of the factory-installed personality program for the controller, and no further adjustment is necessary.

TP-6140 10/01 Section 3 Wiring 39

3.6 Zeroing Auxiliary Analog

Inputs

In the calibration process for analog inputs (menu 12), the sender needs to be zeroed out. To accomplish this, disconnect the P2 ribbon cable prior to the zeroing out procedure.

See Figure 3-9.

After P2 has been disconnected, answer yes to the question ZERO AUX.

ANALOG INPUTS? Then reconnect P2 connector to complete the sender calibration.

3.7 Analog Inputs (Calibration)

Using the analog input requires a sender or device that is scaled based on a 0--5 VDC signal with a calibrated output. See Figure 3-10.

Example: Temperature Sender

.50 VDC @ 60

°F

4.50 VDC @ 275

°F

5 VDC

4.5 VDC = 275

1. Interconnection circuit board

2. P2 ribbon connector

(remove prior to zeroing out auxiliary analog inputs)

3. P12 ribbon connector

ADV-6533-A

Figure 3-9 Interconnection Circuit Board Ribbon

Connector P2 (Top View of Circuit Board)

.50 VDC = 60

0 VDC

Figure 3-10 Analog Input Scale Values (sample)

Analog calibration is required; see menu 12.

See

Figure 3-11. To calibrate analog inputs, program two scale values to allow the controller to create a linear scale between the two values that represents the selected device.

To set scale value 1, program a scale value based on the sender output voltage.

For example, if the sender device output is 0.50 VDC, the value represents 60

°F

(based on calibration data of temperature sender). To set scale value 2, increase the device output to 4.5 VDC and enter a value of 275 (representing 275

°F). This completes the linear scale setup.

The acceptable scale range is 0 to 9999, giving a resolution of one part in 10,000.

40 Section 3 Wiring TP-6140 10/01

Menu 12 Overview

MENU 12

CALIBRATION

SCALE AC ANALOG

INPUTS

GEN L1-L0 V

CALIB REF

GEN L2-L0 V

CALIB REF

→

SCALE AUX. ANALOG

INPUTS

→

?.?

ZERO AUX. ANALOG

INPUTS?

Press down arrow to scroll through ANALOG auxiliary inputs

01--07 with ECM engines.

Press down arrow to scroll through ANALOG auxiliary inputs

03--07 with non-ECM engines.

?.?

ANALOG XX

SCALE VALUE 1

?.?

SCAL1

SCAL2

#.#--#.#V

GEN L3-L0 V (3 PHASE)

CALIB REF

?.?

ANALOG XX

SCALE VALUE 2

GEN L1 AMPS

CALIB REF

?.?

SCAL1

SCAL2

#.#--#.#V

Right Arrow between ENTRY and DISPLAY of setpoint

GEN L2 AMPS

CALIB REF

?.?

GEN L3 AMPS (3 PHASE) #

CALIB REF ?.?

RESTORE

DEFAULTS?

Figure 3-11 Menu 12, Calibration

3.8 Alternative Calibration Method

Substitute a potentiometer for the sender or device to calibrate the input values if it is difficult to adjust the sender output. Install a potentiometer in place of the three-wire sender to adjust the voltage between

0--5 VDC, and enter the calibrated values when the input value matches the known calibrated value. See

Figure 3-12.

A 10-turn, 10 kOhm potentiometer is recommended for fine adjustment in calibration.

Note: Remember to zero auxiliary analog inputs before entering calibrated values.

Example: Temperature Sender

.50 VDC @ 60

°F

4.50 VDC @ 275

°F

1. Wire the potentiometer according to Figure 3-13.

2. Adjust the potentiometer for value 1 to read

0.5 volts and enter 60 for the known calibrated value.

3. Adjust the potentiometer for value 2 to read

4.5 volts and enter 275 for the known calibrated value.

Figure 3-12 Potentiometer Connections on TB2

TP-6140 10/01 Section 3 Wiring 41

3.9 Analog Input (Warning/

Shutdown)

Define the analog input as a warning and/or shutdown device or the analog input can be used for data information purposes only.

To program the desired function, the user defines variables in menu 9. This menu allows the user to define the analog input for the desired application.

MENU 9

INPUT SETUP

SETUP DIGITAL

AUXILIARY INPUTS

→

Procedure to define an analog input as a warning and/or shutdown:

1. After entering the analog input in menu 9, enable or activate the input as a warning and/or shutdown. If neither is selected, the input displays data but no action is associated with the input.

See

Figure 3-13.

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

→

?:??

Press down arrow to scroll through 1--7 additional

ANALOG auxiliary inputs or enter input number on ECM engines.

Press down arrow to scroll through 3--7 additional

ANALOG auxiliary inputs or enter input number on non-

ECM engines.

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

→

Figure 3-13 Menu 9, Input Setup

2. After the input is activated, program an inhibit time.

This is a time delay preventing an action for a time

(inhibit) after a crank disconnect. Typically this time is set at 30 seconds.

Note: To have the input active at all times, set the inhibit time to 0.

3. Program the delay time to function after the inhibit time delay has timed out. This time delay is the time period between when the controller first detects the fault and when the controller indicates a warning or shutdown. The fault must be present for the total delay time.

4. Enter values to initiate the controller action as a warning or shutdown. The operator determines the application values and enters the values based on the calibrated scale in menu 12. See Figure 3-14 for an example of warning and shutdown values.

Figure 3-14 Setting Warning and Shutdown Values

42 Section 3 Wiring TP-6140 10/01

3.10 Relay Driver Outputs (Menu 10)

Up to 31 RDOs are available to define using the system events, digital inputs, and analog inputs giving the user flexibility for control or remote annunciation.

RDOs provide only the relay driver, not the relay. RDOs are used in conjunction with the customer connection kit and, typically, will drive all relay kits. Refer to Appendix

D for RDO factory designations and user-defined designations.

3.10.1 NFPA Defaults

If the controller is programmed with NFPA enabled

(menu 7), the controller will automatically define a number of RDOs as defaults, and the user cannot reset these defaults. If the user attempts to reassign the default, a message displays Cannot Change NFPA is

Enabled.

3.10.2 Common Fault

The user can program the common faults (menu 10) from the list of system events, digital inputs, and analog inputs.

To define a common fault, go through the submenus and enter yes to any items wanted as part of a common fault. Then designate an RDO (1--31) to drive the common fault relay output. See Figure 3-15.

A common fault acts as an or function. The output occurs when any one of the items occur, such as A or B or C, etc.

TP-6140 10/01 Section 3 Wiring 43

Menu 10 Overview

MENU 10

OUTPUT SETUP

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

(see Group D) LO

WARNING→

Y/N COMMON FAULT Y/N

HI WARNING

→

RELAY DRV OUT XX

(see Group E)

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

→

Group B

For defined system events, choose from the following 46 status events and faults by changing selection to YES:

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

SYSTEM EVENTS

→

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 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)

DIGITAL INPUTS

→

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.

[DEFINED COMMON

FAULT

The 5 defined common faults include the following:

EMERGENCY STOP

HI COOL TEMP

SHUTDOWN

OIL PRESS SHUTDOWN

OVERCRANK

OVERSPEED

ANALOG INPUTS

→

COMMON FAULT Y/N

HI SHUTDOWN

→

*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

Press down arrow to scroll through RDO’s 1--31 or enter RDO number.

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)

RELAY DRV OUT XX Y/N

(see Group B)

Press down arrow to scroll through available RDO faults.

RELAY DRV OUT XX

(see Group C)

Y/N

Press down arrow to scroll through RDO digital auxiliary inputs.

RELAY DRV OUT XX Y/N

(see Group D) LO

WARNING→

Press down arrow to scroll through RDO analog auxiliary inputs.

RELAY DRV OUT Y/N

HI WARNING

→

RELAY DRV OUT Y/N

LO SHUTDOWN

→

RELAY DRV OUT Y/N

HI SHUTDOWN

→

Figure 3-15 Menu 10, Output Setup

44 Section 3 Wiring TP-6140 10/01

Section 4 Accessory Installations

4.1 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 4-1 for a list of available kits.

Kit and installation instruction part numbers change.

Obtain the most current accessory information from your local authorized service distributor/dealer.

This section describes several accessories available at the time of print of this publication. Accessory kits generally include installation instructions.

See the wiring diagram manual for electrical connections not shown in this section. See the installation instructions and drawings supplied with the kit for information on the kit mounting location. See Figure 4-2 and Figure 4-3.

The instructions provided with the accessory kit supersede these instructions where there are differences. Always run AC and DC wiring in separate conduit.

Use shielded cable for all analog inputs.

Observe all applicable national and local electrical codes during accessory installation.

Kit Description

Audiovisual Alarm

Battle Switch

Common Failure Relay (terminal 32A)

Kit Part Numbers

GM17070-KP1, GM17070-KP2,

GM17070-KP3

New

GM17028-KP2, GM17032-KP2,

365569-KP14

Installation Instructions

TT-1300

New

TT-1301

Controller (customer) Connection GM17028-KP1, GM17032-KP1 TT-1302

Float/Equalize Battery Charger (with alarms) PAD-292863 (12 volt), PAD-292865 (24 volt) TT-680

Idle (speed) Mode Feature

Key Switch

Low Fuel (level) Switch

No kit required. Use customer-supplied switch and leads.

New

Multiple kits based on generator set subbase fuel tank or day tank selection.

Note: The main fuel tank may include this switch as provided by the fuel tank supplier.

See operation manual (idle mode feature)

New

Multiple TTs or contact main fuel tank supplier.

Low Fuel (pressure) Switch Multiple TTs

Prime Power Switch

Remote Annunciator (16-light panel)

Remote Emergency Stop

Remote Reset Feature

Multiple kits based on generator set model number.

GM20652-KP1

GM17071-KP1, GM17071-KP2,

GM17071-KP3

PA-293906

No kit required. Use customer-supplied switch and leads.

PA-273768

New

TT--1303

New

See operation manual

(remote reset feature)

TT-774 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

PA-273743 (12 volt), PA-273744 (24 volt),

365569-KA8 (24 volt)

New

GM17068-KP1, GM17068-KP2, 365569-KP9 TT-1304

GM17069-KP1, GM17069-KP2,

365569-KP10

TT-1305

365569-KA13 New

Figure 4-1 Optional Accessories

TP-6140 10/01 Section 4 Accessory Installations 45

Figure 4-2 Accessory Connections, GM16088A-F

46 Section 4 Accessory Installations TP-6140 10/01

Figure 4-3 Accessory Connections, GM16088B-F

TP-6140 10/01 Section 4 Accessory Installations 47

4.2 Controller (Customer)

Connection Kit

A controller connection kit is required when a contact kit and/or the remote annunciator (NFPA remote audiovisual alarms) are specified.

The connection kit allows connection of accessories without opening the controller to make multiple terminal connections. The kit uses a wiring harness with plug connectors to link the controller’s RDOs and power connections to a customer connection board for easy connection and identification of outputs. Remote start terminals are also accessible from the customer connection board. See Figure 4-4 and Figure 4-5.

Figure 4-4 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 (39)

RDO2 Overcrank (12)

RDO3 High coolant temperature shutdown (36)

RDO4 Low oil pressure shutdown (38)

RDO5 Low coolant temperature (35)

RDO6 High coolant temperature warning (40)

RDO7 Low oil pressure warning (41)

TB7 Terminal Strip—RDOs 8--17

Term.

Description

RDO8 Low fuel (63)

RDO9 Master switch not in auto (80)

RDO10 NFPA 110 common alarm (32)*

RDO11 Battery charger fault (61)

RDO12 Low battery voltage (62)

RDO13 High battery voltage

RDO14 Emergency stop (48)

RDO15 Generator running (70R)

RDO16 Time delay engine cooldown (TDEC) (70C)

RDO17 System ready (60)

TB8 Terminal Strip—RDOs 18--23

Term.

Description

42A Battery (+)

42A

Battery (+)

Battery (--)

2 Battery (--)

RDO18 Defined common fault (32A)

RDO19 Low coolant level

RDO20 Overvoltage (26)

RDO21 Idle mode

RDO22 EPS supplying load

RDO23 Air damper indicator (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: RDO-1 though RDO-31 are customer definable with the following factory defaults: emergency stop, high coolant temperature, low oil pressure, overcrank, and overspeed. Numbers in parentheses are the factory wire designations.

NFPA 110 common alarm faults include:

Air damper indicator

Battery charger fault

EPS supplying load

High battery voltage

High coolant temperature warning

High coolant temperature shutdown

Low battery voltage

Low coolant level

Low coolant temperature warning

Low fuel (level or pressure)

Low oil pressure warning

Low oil pressure shutdown

Master switch not in auto

Overcrank

Overspeed

Figure 4-5 Controller (Customer) Connection Kit Terminal Strip Identification with Factory-Assigned Relay Driver

Outputs (RDOs)

48 Section 4 Accessory Installations TP-6140 10/01

4.3 Interconnect Circuit Board

The interconnect circuit board contains four control relays: K1 (crank), K2 (run), K3 (emergency stop), and

K4 (panel lamps). Main circuit board logic controls the

K1, K2, and K4 relays.

The manual E-Stop switch located on the control panel controls the K3 relay. See

Figure 4-6 and Figure 4-7.

Figure 4-6 Interconnect Circuit Board Schematic

Figure 4-7 Interconnect Circuit Board Layout

K1 Relay.

Energized only during the engine crank cycle. Wire 71 energizes when the K1 contact closes.

LED 1 lights when power is supplied to the K1 relay coil.

K2 Relay. Energized during engine cranking cycle and normal engine running. The relay energizes when the control logic issues a start command. Wire 70 energizes when the K2 contacts close. LED 2 lights when power is supplied to the K2 relay coil.

K3 Relay. Energized at all times unless the emergency stop switch activates. When activated, the K3 contact opens, disabling power to the K1 and K2 relay coils.

K4 Relay. Energized when the main logic board turns on the panel lamps. Touch the keypad to turn on the light. The light turns off five minutes after the last keypad entry.

Three fuses mounted to the board protect the controller, customer accessories, and engine wiring.

F1 Fuse. Provides 5-amp circuit protection to 42A, which powers the customer-connected options and the panel lamps.

F2 Fuse.

Provides 5-amp circuit protection for the controller’s 12-volt regulator circuit, including K1, K2,

K3, K4, and relay coils.

F3 Fuse. Provides 15-amp protection for the engine control circuit and other devices powered by wire 70 or wire 71.

TP-6140 10/01 Section 4 Accessory Installations 49

Notes

50 Section 4 Accessory Installations TP-6140 10/01

Section 5 Communication

5.1 Factory Setup

The controller is functional after the factory setup is complete. Both an application program and personality parameters are factory-entered into the 550 controller.

The application program controls the controller operating functions.

The personality parameter files specify the controller characteristics to match the alternator and engine requirements for generator set operation. Parameters include alternator characteristics for current and voltage protection, voltage regulation, calibration for oil pressure and water temperature if required, specification number, and serial number. A backup disk containing the personality parameters file and application file is created at the factory. The literature package shipped with the generator set includes the backup disk.

5.2 Program Loader

Use the Program Loader to load the files from a PC to the controller when replacing the 550 controller or upgrading the application program or personality files.

See Figure 5-1. This program allows the technician to access the files stored on the backup disk and download the files to non-volatile memory, overwriting the controller’s original program.

Refer to TT-1285, the program loader software instructions, for installation and operation. If the disk is damaged or misplaced, a copy can be created by the manufacturer using the generator set serial number as reference.

5.3 Communications

The 550 controller’s remote monitoring or programming is accomplished using the Monitor II communication software. The software is installed on a host PC, and a communication link (RS-232/RS485) is installed between the digital controller and the PC. The PC can then access data from the generator set controller. The software, under password control, also allows the operator to program the generator set remotely.

Connect the host PC to the controller using the RS-232 for a single controller or RS-485 for multiple controllers.

Access can also be made over phone lines with the addition of a modem.

The software package is a Windows r-based graphical user interface allowing the operator to build data windows specifically for their application. The software package also allows for multiple and simultaneous device displays when using a local area network. Refer to the software operation and installation manual when using the Monitor II software.

Figure 5-1 Program Loader Connections to the 550 Controller

Windows r is a registered trademark of Microsoft Corporation

TP-6140 10/01 Section 5 Communication 51

5.4 Personal Computer

Communications

Figure 5-2 identifies the four ways to communicate with a personal computer (PC) and the generator set using

KBUS protocol, the generator set manufacturer’s communication protocol. See Figure 5-3 and Figure 5-4.

Protocol

Local Single

Connection

Local Area

Network

(LAN)

Remote

Single

Connection

Remote Area

Network

Description

A PC connects directly to the communication port with an RS-232 cable when the PC is within 15 m (50 ft.) of the device or RS-485* cable where the PC is up to 1220 m (4000 ft.) from the device. See Figure 5-5.

A PC connects directly to the device’s local area network through an address (1--128). A

LAN is a system that connects more than one device to a single PC. See Figure 5-6.

A PC connects to a modem and a single device connects to a modem. The PC communicates to the device via a telephone network. Locate the PC anywhere a telephone line is available.

See Figure 5-7.

A PC connects to a modem. The devices connect to a LAN network through a system ID and an address (1--128). The PC communicates to the devices via a telephone network that is interfaced to the LAN network.

Locate the PC anywhere a telephone line is available. See Figure 5-8.

Figure 5-2 KBUS Communication Protocol

TT847

1. RS-232 port (P18)

2. RS-232 cable

Figure 5-3 RS-232 Port Location and Connection for the 550 Generator Set Controller

TT847

1. KBUS RS-485* ISO1 port (P21) and RS-485* port connector

(green), 294619 (included with controller)

2. RS-485* cable, customer-supplied

Figure 5-4 RS-485* KBUS Port Location and

Connection for the 550 Generator Set

Controller

Personal computer

RS-232 up to

15 m (50 ft.) from

PC’s serial port

RS-232 to RS-485* port converter

RS-485* up to 1220 m

(4000 ft.)

Generator set controller, transfer switch controller, or power monitor

Figure 5-5 Local Single Connection, up to 1220 m

(4000 ft.)

Personal computer

RS-232 to RS-485* port converter

RS-232 up to

15 m (50 ft.) from

PC’s serial port

Generator set controller, transfer switch controller, or power monitor

RS-485* connects devices up to 1220 m (4000 ft.) of total length

Generator set controller, transfer switch controller, or power monitor

Figure 5-6 Local Area Network Connection, up to

128 Devices

* Belden #9841 or equivalent

52 Section 5 Communication TP-6140 10/01

Telephone line from internal modem

Personal computer or

External modem

RS-232 up to 15 m

(50 ft.) from PC’s serial port to external modem

Telephone lines

Generator set controller, transfer switch controller, or power monitor

Modem

RS-232 up to

15 m (50 ft.)

Figure 5-7 Remote Single Connection

Telephone line from internal modem

Personal computer or

External modem

RS-232 up to 15 m

(50 ft.) from PC’s serial port to external modem

Telephone lines

RS-232 to RS-485* port converter

RS-232 up to

15 m (50 ft.)

Modem

RS-485* connects devices up to 1220 m (4000 ft.) of total length

Generator set controller, transfer switch controller, or power monitor

Figure 5-8 Remote Area Network Connection

* Belden #9841 or equivalent

TP-6140 10/01 Section 5 Communication 53

5.5 Remote LAN Conversion

Use the 550 controller to convert RS-232 input signals from the PC to an RS-485* output for other network devices. This built-in converter eliminates the need for an external RS-232 to RS-485* converter. Use the 550 controller as a converter; connect the controller as the first device after the PC. Program (menu 13) them as either LOCAL LAN CONV or REMOTE LAN CONV depending on the application.

See Figure 5-9 or

Figure 5-10. To use the controller’s built-in converter, the PC or modem connection must be within 15 m

(50 ft.) of the 550 controller.

If this distance is not possible, use the external RS-232 to RS-485* converter.

LAN CONV sets the controller to convert the RS-232 signal to RS-485* output to other devices.

Personal computer

RS-232 up to

15 m (50 ft.) from

PC’s serial port

RS-485* connections

550 controller set for LAN

CONV

Generator set controller, transfer switch controller, or power monitor

550 controller set to

REMOTE

LAN CONV

Generator set controller, transfer switch controller, or power monitor

RS-485* connections

Figure 5-10 Remote Area Network Connection with a

550 Controller REMOTE LAN CONV

Setting

Figure 5-9 550 Controller LAN CONV Setting

Converts a RS-232 PC Signal to a

RS-485* Output to other Devices

Telephone line from internal modem

Personal computer or

External modem

RS-232 up to 15 m

(50 ft.) from PC’s serial port to external modem

Telephone lines

RS-232 up to

15 m (50 ft.)

Modem

* Belden #9841 or equivalent

54 Section 5 Communication TP-6140 10/01

5.6 Modbus Communications

Modbus r communications allow a host PC or Modbus master to obtain information from the generator set’s

550 controller using Modbus communication protocol.

See Figure 5-11. The Modbus protocol is viewed as an industry standard and was developed by the Modicon

Corporation.

The controller communicates using

Modbus as a slave connection with the Modbus master initiating the communications. See See Figure 5-12.

Modbus communications were developed so software applications other than Monitor II software can be used to gain access to 550 controller information. The

Modbus master interrogates the controller system for alternator and engine parameters and also for diagnostic information. The controller also accepts data to alter controller parameters, including generator set start and stop functions.

1. Modbus communication port RS232

2. Modbus communication port RS485*

Figure 5-12 Main Logic Board

1 2

Figure 5-11 Generator Set Controller to Modbus

Master Connections using RS-232 or

RS-485*

Modbus r is a registered trademark of Schneider Electric

* Belden #9841 or equivalent

TP-6140 10/01 Section 5 Communication 55

Notes

56 Section 5 Communication TP-6140 10/01

Section 6 Controller Replacement

6.1 Introduction

The 550 controller service replacement kit is available to replace a non-functional 550 controller.

Use the following procedure to install the replacement controller.

See Figure 6-1 for typical controller identification.

GM17028-A

1. Light bulbs

Figure 6-1 550 Controller Front Panel

When replacing the 550 controller, three files must be resident for the 550 controller to function.

Application program contains the software that controls system operation.

The application file is preprogrammed in the 550 controller at the factory.

Personality profile is specific to the engine and alternator and is preprogrammed in the 550 controller at the factory. A backup disk of the personality profile is supplied with the literature packet. Typically, the distributor stores this disk for possible future use such as controller replacement or other circumstances requiring a backup.

Note: If the personality disk is not available, request a replacement from the manufacturer using the generator set serial number or order number.

User parameters unique to an installation include timer values, setpoints, generator set data such as kW and voltage, and input/output selections. These parameters are typically set up for or by the installer at the time of installation. Created user parameters are typically documented and stored on the personality profile disk, a separate backup disk, or written in

Appendix C in the 550 controller operation manual.

See Appendix C of this manual for a copy of the

Controller User-Defined Settings form.

Note: If the user parameters are included on the personality disk, the disk label should indicate

Site Program—Yes.

Read the entire installation procedure and compare the kit parts with the parts list in this publication before beginning installation. Perform the steps in the order shown.

Always observe applicable local and national electrical codes.

Note: The following service kit procedure changes only the controller.

If the generator set requires voltage reconnection and/or frequency adjustment, see the 550 controller operation manual TP-6083 for Software (Code) Version

Prior to 2.10 and TP-6200 for Software (Code)

Version 2.0 or higher.

6.2 Installation

6.2.1 Requirements

The following items are necessary PC requirements for installing the controller service replacement kits.

Program loader kit GM17732 or GM17733. See the program loader kit instructions for additional items needed to complete the installation. The program loader kit includes the Monitor II software, version

2.2.5 or later.

Use the Monitor II software, version 2.2.5 or greater, to enter the user parameters from a backup disk and/or enter alphanumeric data. See the Monitor II software instructions for additional items.

Null modem RS-232 cable with a 9-pin male plug on the controller end, part no. GM16657 or kits

PA-294992 or PA-294992-SD.

TP-6140 10/01 Section 6 Controller Replacement 57

6.2.2 Procedure

Observe the following safety precautions while installing the kit.

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.

WARNING

Hazardous voltage.

Moving parts.

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. Ensure you comply with all applicable codes and standards.

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).

58 Section 6 Controller Replacement

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.

1. Acquire the user parameters.

a. Choose one of the following methods to retrieve the user parameters:

Backup disk.

If a backup disk was previously made, obtain the parameters from this disk. If a disk was not previously made, create a backup if possible using the

Monitor II software, version 2.2.5 or greater.

The existing controller must function in order to create the file.

Paper form. Parameters should have been recorded on the User-Defined Settings form located in the 550 controller operation manual, Appendix C, or other similar form.

Controller menu.

Manually review the controller menu displays if possible and enter the parameter information in the 550 controller operation manual, Appendix C,

User-Defined Settings, form.

b. Save the user parameter data.

2. Acquire display data from the old controller for entry in the new controller.

Certain data cannot be stored on electronic media for archival purposes and must be entered using a

PC or the controller keypad.

When possible, make note of the following data from the old controller for entry in the new controller. If the old controller is not functional, the installer must determine and document this information for entry later in this procedure. See

Appendix C for the Controller User-Defined

Settings form.

a. From menu 7, Generator System

Metric Units, yes or no b. From menu 12, Calibration

Scale Aux. Analog Inputs. Repeat for each input 01--07

Analog 01, scale value 1

Analog 01, scale value 2

TP-6140 10/01

c. From menu 13, Communication

(1) Protocol KBUS

KBUS online, yes or no

Connection type d d d d d d

Local single, yes or no

Local LAN, yes or no

Local LAN conv, yes or no

Remote single, yes or no

Remote LAN, yes or no

Remote LAN conv, yes or no

Primary port d d

RS-232, yes or no

RS-485 ISO1, yes or no

Address (LAN connections)

System ID (remote connections)

BAUD rate d d d

1200

2400

9600

(2) Protocol Modbus

Modbus online, yes or no

Connection type d d

Single, yes or no

Convertor, yes or no

Primary port d d

RS-485

RS-232

Address

BAUD rate d d

9600

19200 d. From menu 20, Factory Setup

Final assembly date

Final assembly clock number

Model number

Spec number

Serial number

3. Acquire display data from the old controller for reference purposes.

When possible, write down the old controller display data in Appendix B.

This data is not required for the new controller but may be needed for future reference.

If the old controller is not functional, the information is no longer retrievable.

4. Remove the generator set from service.

a. Place the generator set master switch in the

OFF position.

b. Disconnect power to battery charger, if equipped.

TP-6140 10/01

2 c. Disconnect the generator set engine starting

9 battery(ies), negative (--) lead first.

5. Disconnect the existing 550 controller electrical connections.

a. Remove the controller cover. If access to the interconnection circuit board on the rear panel and/or the main logic/communication circuit board on the front panel is difficult, partially disassemble the controller box. Remove the two controller panel top screws and center bottom screw and then loosen the bottom screw on each side to swing the controller panel down. See Figure 6-2.

Note: Clearly mark all disconnected leads from the 550 controller with tape to simplify reconnection.

A-365487-A/GM10193B

1. TB1 terminal strip

2. TB2 terminal strip

3. TB3 terminal strip

4. TB4 terminal strip

5. Interconnection circuit board (top view)

6. P23 connector

7. Interconnection circuit board mounted on the controller rear panel

8. P1 plug

9. TB5 terminal block (fuses)

10. P18 on main logic (microprocessor)/communication circuit board

Figure 6-2 Disconnecting Controller Circuit Board

External Wiring Connections

Section 6 Controller Replacement 59

b. Disconnect the 550 controller harness leads.

Listed below are some common leads and plugs that require removal or disconnection.

Items below in bold are shown in Figure 6-2.

These connections are typical and may not apply to all situations. See the corresponding wiring diagram found in the wiring diagrams manual.

AC fuse terminal block TB5 leads V7, V8, and V9

All external connections to terminal strips

TB1, TB2, TB3, and TB4

CT/meter scale terminal block lead V0

P24 connector to the CT burden resistor board

Plug P1 on the burden resistor board and the

350--3250 kW voltage regulator interface board

Plug P23 to the controller connection strip in the junction box

Plug P22 to the engine wiring harness

Plug P18 communication connection

Prime power kit

Any other external leads to the controller

6. Remove the existing 550 controller.

a. Remove the junction box panel(s) to gain access to the controller vibromount screws.

b. Remove the four controller vibromount screws from underneath the junction box top panel.

c. Lift off the existing 550 controller.

7. Install the replacement 550 controller.

a. Place the replacement 550 controller on the junction box top panel holes.

b. Align the 550 controller vibromounts with the mounting holes and install four screws.

c. Change the controller’s front display lamps, if required.

See Figure 6-1 for location.

See

Figure 6-3 for lamp identification. The factory ships the 550 controller with 12-volt lamps.

Replace the bulbs in the controller with the lamps provided in the replacement kit if the generator set has a 24-volt engine electrical system.

Determine the engine electrical system voltage using the generator set nameplate information.

Lamp Part Number Voltage Bulb Part Number

255126 12 1892

283420 24 313

Figure 6-3 Lamp Identification

8. Connect the replacement 550 controller.

a. Remove the controller cover. If access to the interconnection circuit board on the rear panel and/or the communication circuit board on the front panel is difficult, partially disassemble the controller box.

Remove the two controller panel top screws and center bottom screw and then loosen the bottom screw on each side to swing the controller panel down.

See

Figure 6-2.

b. Reconnect the controller wiring that was previously removed. See the corresponding wiring diagram found in the wiring diagrams manual. Listed below are some common leads and plugs that may require reconnection.

These connections are typical and may not apply to all situations.

AC fuse terminal block TB5 leads V7, V8, and V9

All external connections to terminal strips

TB1, TB2, TB3, and TB4

CT/meter scale terminal block lead V0

P24 connector to the CT burden resistor board

Plug P1 on the burden resistor board and the

350--3250 kW voltage regulator interface board

Plug P23 to the controller connection strip in the junction box

Plug P22 to the engine wiring harness

Prime power kit

Any other external leads to the controller

60 Section 6 Controller Replacement TP-6140 10/01

c. Swing the rear controller panel up and replace and tighten the screws, as necessary.

d. Replace the junction box panel(s) and screws.

9. Restore power to the generator set.

a. Check that the generator set master switch is in the OFF position.

b. Reconnect the generator set engine starting battery, negative (--) lead last.

c. Reconnect power to the battery charger, if equipped.

10. Install the program/data files.

a. Connect the PC serial port to the controller

RS-232 port using a null modem RS-232 cable with a 9-pin male plug on the controller end.

See TT-1285 for details.

b. Install the Program Loader program into the PC using the procedure outlined in TT-1285.

c. Insert the personality profile backup disk and load the data. See TT-1285 for details.

11. Establish the controller identity in menu 20.

The controller displays the following error message: GENSET S/N WARNING.

This procedure includes instructions on how to unlock and lock the factory setup after entering menu 20. Use the down arrow key to go to the setup lock menu for determining the setup status.

Note: After completing the factory setup always return the controller to the setup lock position to prevent inadvertent program changes.

a. Press the RESET MENU key on the controller keypad.

b. Use the controller keypad to go to menu 14,

Programming Mode, and select programming mode—local. Use the information from the 550 controller operation manual as necessary.

Note: The factory default access code is the number 0.

c. Press the RESET MENU key on the controller keypad.

d. Use the controller keypad to go to menu 20,

Factory Setup. See Figure 6-4 for displays.

e. Arrow down to the SETUP LOCK display.

If the SETUP LOCK display indicates YES, go to step f.

If the SETUP LOCK display indicates NO, go to step g.

f. Unlock the setup.

(1) Arrow down to the FINAL ASSEMBLY,

CLOCK NO. display. Record the clock number on the controller display.

(2) Arrow right to ENTER CODE display.

(3) Use the controller keypad to enter the clock number previously recorded.

(4) Press the ENTER key.

Changes to menu 20, Factory Setup, are now possible.

g. Initialize the EEPROM.

(1) Arrow down to the CODE VERSION display.

(2) Arrow right to the INITIALIZE EEPROM display.

(3) Press the YES key to initialize the

EEPROM.

(4) Press the ENTER key.

h. Wait for completion of the system reset

(approx. 5--10 seconds).

TP-6140 10/01 Section 6 Controller Replacement 61

i. Go to menu 20, Factory Setup. See Figure 6-4 for displays.

FACTORY SETUP

FINAL ASSEMBLY DATE

01-JAN-90

FINAL ASSEMBLY

CLOCK NO.

OPERATING DAYS

00000

ENTER CODE

(UNLOCKS SETUP)

MODEL NO.

(26 CHARACTERS MAX)

SPEC NO.

(16 CHARACTERS MAX)

GENSET SERIAL NO.

ALTERNATOR PART NO.

ENGINE PART NO.

SERIAL NO.

CONTROLLER SERIAL NO.

CODE VERSION

SETUP LOCK

Y/N

INITIALIZE EEPROM? Y/N

Figure 6-4 Menu 20, Factory Setup j. Change the final assembly date.

(1) Arrow down to the FINAL ASSEMBLY

DATE display.

(2) Enter the final assembly date using the data recorded from the old controller. If data from the old controller is not available, keep the default setting.

(3) Press the ENTER key if making a new entry.

k. Change the final assembly clock number.

(1) Arrow down to the FINAL ASSEMBLY

CLOCK NO. display.

(2) Enter the final assembly clock number using the data recorded from the old controller. If data from the old controller is not available, keep the default setting.

(3) Press the ENTER key if making a new entry.

l. Change the serial number.

(1) Arrow down to the SERIAL NO. display.

(2) Enter the serial number of the generator set using the data recorded from the old controller or as shown on the generator set nameplate. If the serial number is six digits, enter a leading zero to create a seven-digit serial number.

(3) Press the ENTER key. The GENSET S/N

WARNING display no longer appears.

12. Perform the menu 13, Communications, entries.

a. Press the RESET MENU key on controller keypad.

b. Use the controller keypad to go to menu 13,

Communications.

c. Complete the communication entries as necessary for remote programming. Use the information from the 550 controller operation manual as necessary.

Use the information from the Monitor II software, version 2.2.5 or greater as necessary.

62 Section 6 Controller Replacement TP-6140 10/01

13. Perform the menu 14, Programming Mode, entries.

a. Press the RESET MENU key on controller keypad.

b. Use the controller keypad to go to menu 14,

Programming Mode, and select programming mode—remote. Use the information from the

Monitor II software, version 2.2.5 or greater.

14. Perform the menu 20, Factory Setup, entries using the Monitor II software generator info window. Use the information from the Monitor II software, version 2.2.5 or greater.

a. Change the model number.

(1) Go to the MODEL NO. display.

(2) Enter the model number using the data recorded from the old controller or as shown on the generator set nameplate.

b. Change the spec (specification) number.

(1) Go to the SPEC NO. display.

(2) Enter the spec number using the data recorded from the old controller or as shown on the generator set nameplate.

15. Perform the menu 14, Programming Mode, entries.

a. Press the RESET MENU key on the controller keypad.

b. Use the controller keypad to go to menu 14,

Programming Mode and select programming mode—local. Use the information from the 550 controller operation manual as necessary.

16. Lock the menu 20, Factory Setup, entries.

a. Press the SETUP MENU key on the controller keypad.

b. Use the controller keypad to go to menu 20,

Factory Setup.

c. Arrow down to the SETUP LOCK display.

d. Press the YES key to lock the setup and prevent alterations to menu 20, Factory Setup.

17. Enter the menu 6, Time and Date, settings.

a. Press the RESET MENU key on the controller keypad.

b. Use the controller keypad to go to menu 6, Time and Date. Use the information from the 550 controller operation manual as necessary to set the time and date.

18. Perform the menu 7, Generator System, entries for

English or metric displays.

a. Press the RESET MENU key on the controller keypad.

b. Use the controller keypad to go to menu 7,

Generator System. Use the information from the 550 controller operation manual as necessary to change Metric Unit, yes or no.

19. Perform the menu 12, Calibration, entries.

a. Press the RESET MENU key on the controller keypad.

b. Use the controller keypad to go to menu 12,

Calibration. Use the information from the 550 controller operation manual as necessary to scale AC analog inputs.

c. With the information previously recorded from step 2b, scale the auxiliary analog inputs. Use the information from the 550 controller operation manual as necessary.

20. Perform the menu 14, Programming Mode, entries.

a. Press the RESET MENU key on the controller keypad.

b. Use the controller keypad to go to menu 14,

Programming Mode.

Select programming mode—remote when adding user parameter from a backup disk or PC.

Use the information from the

Monitor II software, version 2.2.5 or greater.

Select programming mode—local for keypad entries. Use the information from the 550 controller operation manual as necessary.

TP-6140 10/01 Section 6 Controller Replacement 63

21. Add the user parameters.

a. Choose one of the following methods to load the user parameters.

Backup disk. Use a PC to load the data from the user parameter backup disk. Enable menu 14, Programming Mode—Remote.

See the information from the Monitor II software manual.

Paper form. Use a PC to enter the user parameter data from the filled-out 550 controller operation manual, Appendix C,

User-Defined Settings form or other similar form.

Enable menu 14, Programming

Mode—Remote.

See the information supplied with the Monitor II software manual.

Controller menu. Use the controller keypad to manually enter the user parameter data from the filled-out 550 controller operation manual, Appendix C, User-Defined Settings form.

Enable menu 14, Programming

Mode—Local. Use the information from the

550 controller operation manual as necessary.

b. Create a new user parameter data backup disk if any changes are made. See the Monitor II software manual.

c. Disconnect the PC null modem RS-232 cable.

d. Install the P18 communication connection, as necessary.

e. Swing the front controller panel up and replace and tighten the screws, as necessary.

f. Replace the controller cover and hardware.

Tighten all controller screws.

22. Restore the generator set to service.

a. Perform the menu 13, Communication, entries.

(1) Press the RESET MENU key on controller keypad.

(2) Use the controller keypad to go to menu 13, Communications.

(3) With the information previously recorded, complete the communication entries as necessary for the application.

Use the information from the 550 controller operation manual as necessary.

b. Perform the menu 14, Programming Mode entries.

(1) Press the RESET MENU key on controller keypad.

(2) Use the controller keypad to go to menu 14, Programming Mode.

(3) Change the entries for the application as necessary. Use the information from the

550 controller operation manual as necessary.

c. The generator set system is now ready to function.

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

64 Section 6 Controller Replacement TP-6140 10/01

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampere

ABDC

A/D

ADC after bottom dead center alternating current analog to digital adj.

ADV advanced digital control; analog to digital converter adjust, adjustment advertising dimensional drawing

AHWT

AISI amp-hour anticipatory high water temperature

American Iron and Steel

Institute

ALOP alt.

ANSI

APDC

API approx.

approximate, approximately

AQMD Air Quality Management District

AR as required, as requested

AS anticipatory only

Air Pollution Control District

American Petroleum Institute

ASE

ASME as supplied, as stated, as suggested

American Society of Engineers

American Society of

Mechanical Engineers assy.

ASTM anticipatory low oil pressure alternator aluminum

American National Standards

Institute (formerly American

Standards Association, ASA)

ATDC

ATS auto.

aux.

assembly

American Society for Testing

Materials after top dead center automatic transfer switch automatic auxiliary avg.

AVR

AWG

AWM bat.

BBDC

BCA

BCI 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

BDC

BHP before dead center brake horsepower blk.

black (paint color), block

(engine) blk. htr.

block heater

BMEP bps br.

brake mean effective pressure bits per second brass

BTDC

Btu before top dead center

British thermal unit

Btu/min.

British thermal units per minute

C cal.

CAN

CARB

CB cc

Celsius, centigrade calorie controller area network

California Air Resources Board circuit breaker cubic centimeter

CCA ccw.

CEC cert.

cfh cold cranking amps counterclockwise

Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm

CID

CL cm

CMOS cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogeneration cogen.

com coml communications (port) commercial

Coml/Rec Commercial/Recreational conn.

cont.

CPVC crit.

CRT

CSA connection continued chlorinated polyvinyl chloride critical cathode ray tube

Canadian Standards

Association

Cu cUL

CUL cu. in.

cw.

CWC cyl.

D/A

DAC dB dB(A)

DCR deg.,

° dept.

current transformer copper

Canadian Underwriter’s

Laboratories

Canadian Underwriter’s

Laboratories cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel decibel (A weighted) direct current direct current resistance degree department

DFMEA Design Failure Mode and

Effects Analysis dia.

DI/EO diameter dual inlet/end outlet

DIN

DIP

DPDT

Deutsches Institut fur Normung e. V. (also Deutsche Industrie

Normenausschuss) dual inline package double-pole, double-throw

DPST

DVR e.g.

EGSA double-pole, single-throw disconnect switch digital voltage regulator

E, emer.

emergency (power source)

ECM electronic control module, engine control module

EDI

EFR electronic data interchange emergency frequency relay for example (exempli gratia) electronic governor

EIA

EI/EO

EMI

Electrical Generating Systems

Association

Electronic Industries

Association end inlet/end outlet electromagnetic interference emiss.

eng.

EPA

EPS

ESD emission engine

Environmental Protection

Agency emergency power system emergency relay engineering special, engineered special electrostatic discharge

TP-6140 10/01 Appendix 65 freq.

FS ft.

ft. lb.

ft./min.

ftp g ga.

gal.

gen.

genset

GFI est.

E-Stop etc.

exh.

ext.

F fglass.

FHM fl. oz.

flex.

estimated emergency stop et cetera (and so forth) exhaust external

Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute file transfer protocol gram gauge (meters, wire size) gallon generator generator set ground fault interrupter

GND, gov.

gph gpm gr.

GRD ground governor gallons per hour gallons per minute grade, gross equipment ground gr. wt.

gross weight

H x W x D height by width by depth

HC hex cap

HCHT

HET hex high cylinder head temperature heavy duty high exhaust temp., high engine temp.

hexagon

HHC

HP hr.

HS hsg.

HVAC mercury (element) hex head hex head cap horsepower hour

HWT

ID heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification

IEC

IEEE

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers improved motor starting IMS in.

inch in. H

2 in. Hg

O inches of water inches of mercury in. lb.

Inc.

ind.

JIS inch pounds incorporated industrial int.

internal int./ext.

internal/external

I/O input/output

ISO iron pipe

International Organization for

Standardization joule

Japanese Industry Standard

K kA

KBus kg kg/cm

2 kgm kg/m

3 kHz kilo (1000) kelvin kiloampere kilobyte (2

10 bytes)

Kohler communication protocol kilogram kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kJ kilojoule km kilometer kOhm, k

Ω kilo-ohm kPa kilopascal kph kV kilometers per hour kilovolt kVA kVAR kW kWh kWm kWth kilovolt ampere kilovolt ampere reactive kilowatt kilowatt-hour kilowatt mechanical kilowatt-thermal

LAN liter local area network

L x W x H length by width by height lb.

lbm/ft

LCB pound, pounds pounds mass per cubic feet line circuit breaker

LPG

L wa

LWL

LWT

LCD liquid crystal display ld. shd.

load shed

LED

Lph light emitting diode liters per hour

Lpm

LOP liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side 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 m

/hr.

/min.

units), male cubic meter cubic meters per hour cubic meters per minute mA man.

milliampere manual max.

MCCB maximum megabyte (2

20 bytes) molded-case circuit breaker

MCM one thousand circular mils meggar megohmmeter

MHz mi.

mil min.

misc.

MJ megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule mJ millijoule mm millimeter mOhm, m

Ωmilliohm

MOhm, M

Ωmegohm

MOV metal oxide varistor

MPa mpg megapascal miles per gallon mph

MS ms m/sec.

MTBF miles per hour military standard millisecond meters per second mean time between failure psi psig pt.

PTC

PTO

PVC qt.

qty.

OV oz.

p., pp.

PCB pF

PF ph.,

∅

PHC

MTBO mtg.

MTU

MW mean time between overhauls mounting

Motoren-und Turbinen-Union megawatt mW

μF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

NBS National Bureau of Standards

NEC

NEMA normally closed

National Electrical Code

National Electrical

Manufacturers Association

NFPA

NO no., nos.

number, numbers

NPS National Pipe, Straight

NPSC National Pipe, Straight-coupling

NPT

National Fire Protection

Association newton meter normally open

NPTF

National Standard taper pipe thread per general use

National Pipe, Taper-Fine not required, normal relay ns

OEM nanosecond overcrank outside diameter original equipment manufacturer

OF opt.

OSHA

PHH

PHM

PLC

PMG pot ppm

PROM overfrequency option, optional oversize, overspeed

Occupational Safety and Health

Administration overvoltage ounce page, pages personal computer printed circuit board picofarad power factor phase

Phillips r head Crimptiter

(screw)

Phillips r 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 pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart, quarts quantity replacement (emergency) power source rad.

RAM

RDO radiator, radius random access memory relay driver output ref.

rem.

reference remote

Res/Coml Residential/Commercial

RFI

RHM rly.

radio frequency interference round head round head machine (screw) relay

SPDT

SPST spec specs sq.

sq. cm sq. in.

SS std.

stl.

tach.

TDC

TDEC

TDEN

TDES

TDNE scfm

SCR s, sec.

SI/EO sil.

SNMP rms rnd.

ROM rot.

rpm

RTU

RTV

SAE

VDC

VFD

VGA

VHF

WCR w/ w/o wt.

xfmr

UHF

UNC

UNF univ.

VAC

VAR

TDOE

TDON temp.

term.

THD

TIF

TIR tol.

turbo.

typ.

root mean square round read only memory rotate, rotating revolutions per minute right side remote terminal unit room temperature vulcanization read/write

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units side in/end out silencer serial number simple network management protocol single-pole, double-throw single-pole, single-throw specification specification(s) 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 total harmonic distortion 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

66 Appendix TP-6140 10/01

Menu 4

Operational Records

D Factory Test Date

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

Maintenance

Total Hours

D Run Time Since

Maintenance

Loaded Hours

D Run Time Since

Maintenance

Unloaded Hours

D Run Time Since

Maintenance kW Hours

D Operating Days

Last Maintenance

D No. of Starts

Last Maintenance

D Last Start

Date

D Length of Run

(Un)loaded Hours

Appendix B Display Items for Reference

Menu 5

Event History

D (Message Text)

D (Scroll through up to 100 stored events)

Menu 20

Factory Setup

D Final Assembly Date

D Final Assembly

Clock No.

D Operating Days

TP-6140 10/01 Appendix 67

Appendix C Controller 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.

Status or

Fault

AC Sensing

Loss

Access Code

(password)

Analog Aux.

Inputs 1--7

Analog Aux.

Input 1

Analog Aux.

Input 2

Cyclic Cranking

Defined

Common Faults

Digital Aux.

Inputs 1--21

EPS

(Emergency

Power System)

Supplying Load

High Battery

Voltage

High Coolant

Temperature

Shutdown

High Coolant

Temperature

Warning

High Oil

Temperature

Shutdown

Refer to

Digital

Display

10 AC Sensing

Loss

Relay

Driver

Output

(RDO)

RDO-25

Range Setting

Default

Selection

Inhibit

Time

Delay*

(sec.)

Time

Delay

(sec.)

User-Defined Settings

Not adjustable

10 High Battery

Voltage

10 Hi Cool

Temp

Shutdown

10 Hi Cool

Temp

Warning

10 Hi Oil Temp

Shutdown

RDO-13

RDO-03

RDO-06

RDO-17

14.5--16.5 (12V)

29--33 (24V)

0 (zero)

User-Defined

A1--A7

Coolant

Temperature

Oil Pressure

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 dependant

Default values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are all engine dependant (255 psi max.)

1--6 crank cycles

1--60 sec. crank on

1--60 sec. pause

10 User-Defined RDO-18 Default shutdowns include:

Emergency stop

High coolant temp

Low oil pressure

Overcrank

Overspeed

9 User-Defined

D1--D21

10 EPS

Supplying

Load

RDO-15

30 sec.

inhibit, 5 sec. delay

30 sec.

inhibit, 0 sec. delay

30 sec.

inhibit,

0 sec. delay warning,

5 sec. delay shutdown

3 cycles

15 sec.

30 sec.

inhibit,

5 sec. delay

30 sec.

inhibit, 5 sec. delay

5% of rated line current

0--60

16 (12V)

32 (24V)

0--60

Not adjustable

* Inhibited time delay is the time delay period after crank disconnect.

68 Appendix TP-6140 10/01

Status or

Fault

Idle (speed)

Mode Function

Digital Auz.

Input 21

Load Shed kW Overload

Load Shed

Underfrequency

Low Battery

Voltage

Low Coolant

Level

(Low) Oil

Pressure

Shutdown

(Low) Oil

Pressure

Warning

No Coolant

Temperature

Signal

No Oil Pressure

Signal

Refer to

Digital

Display

Idle Mode

Active

10 Load Shed

KW Over

10 Load Shed

Under

Frequency

10 Low Battery

Voltage

10 Low Coolant

Level

10 Oil Pressure

Shutdown

10 Oil Pressure

Warning

10 No Cool

Temp Signal

Relay

Driver

Output

(RDO)

RDO-21

RDO-30

RDO-31

RDO-12

RDO-14

RDO-04

RDO-07

10 No Oil

Pressure

Signal

8 Over Crank RDO-02 Overcrank

Shutdown

Overcurrent

Overfrequency

Shutdown

Overspeed

Shutdown

Overvoltage

Shutdown

10 Over Current

7, 10 Over

Frequency

RDO-28

7, 10 Over Speed RDO-01

7, 8,

Over Voltage RDO-20

Range Setting

Default

Selection

0 sec.

inhibit,

60 sec.

delay

100% of kW rating

59, (60 Hz)

49, (50 Hz)

Inhibit

Time

Delay*

(sec.)

Time

Delay

(sec.)

0--600

User-Defined Settings

10--12.5 (12V)

20--25 (24V)

0--6 cycles

102%--140%

65--70 (60 Hz)

55--70 (50 Hz)

105%--135%

12 (12V)

24 (24V)

3 cycles

110%

140% std.

103% FAA

70 (60 Hz)

60 (50 Hz)

115%

2-sec time delay

0 (zero)

0.25

2--10

Not adjustable

See Access Code entry Password

(access code)

Time Delay

Engine

Cooldown

(TDEC)

Time Delay

Engine Start

(TDES)

Time Delay

Starting Aid

Underfrequency

Shutdown

Undervoltage

Shutdown

8, 10

7, 10 Under

Frequency

7, 8,

Under

Voltage

RDO-23

RDO-29

RDO-27

00:00--10:00 min:sec

00:00--5:00 min:sec

0--10 sec.

80%--95%

70%--95%

Weak Battery 10 Weak

Battery

RDO-26

* Inhibited time delay is the time delay period after crank disconnect.

5:00

00:01

90%

85%

10-sec time delay

60% of nominal

5--30

TP-6140 10/01 Appendix 69

Appendix D Relay Driver Output (RDO) Designations

Use the table below to record user-defined description changes to the individual RDO selections.

RDO

Number

RDO1

Factory Default RDO

Designation

Overspeed

RDO2

RDO3

Overcrank

High coolant temperature shutdown

RDO12

RDO13

RDO14

RDO15

RDO16

RDO17

RDO18

RDO19

RDO4

RDO5

RDO6

RDO7

RDO8

RDO9

RDO10

RDO11

RDO20

RDO21

RDO22

RDO23

RDO24

RDO25

RDO26

RDO27

RDO28

RDO29

RDO30

RDO31

Low oil pressure shutdown

Low coolant temperature

High coolant temperature

Low oil pressure warning

Low fuel

Master switch not in auto

NFPA 110 common alarm

Battery charger fault

Low battery voltage

High battery voltage

Emergency stop

Generator running

Time delay engine cooldown

System ready

Defined common fault

Low coolant level

Overvoltage

Idle mode

EPS supplying load

Air damper indicator

Speed sensor fault

Loss of AC sensing

ECM loss of communication

Undervoltage

Overfrequency

Underfrequency

Load shed kW overload

Load shed underfrequency

User-Defined RDO Designation

70 Appendix TP-6140 10/01

TP-6140 10/01c

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-457-4441, Fax 920-459-1646

For the nearest sales/service outlet in the

US and Canada, phone 1-800-544-2444

KohlerPower.com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65) 264-6422, Fax (65) 264-6455

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Key Features

Built-in voltage regulator
Complete compatibility with select ECM and non-ECM engines
Inherent alternator protection
User-programmable load shed function
Smart-starting idle mode for noncritical operation

Frequently Answers and Questions

What types of engines are compatible with the generator set?

The generator set is compatible with select engine electronic control module (ECM) and non-ECM equipped generator set engines.

What are the safety features of the generator set?

The generator set features inherent alternator protection, including overload and short circuit protection. The controller also has a user-programmable load shed function, which can be used to shed load in the event of an overload or other emergency.

What are the communication capabilities of the generator set?

The generator set utilizes the controller KBUS and Modbus RS-232 and RS-485 connections for communication.