Kohler 20-2000kW generator set Operation manual

The 20-2000kW generator set is a powerful and reliable source of power for industrial applications. It is equipped with a Decision-Maker™ 340 controller that provides a wide range of features and functions to ensure optimal performance.

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Document

Operation

Industrial Generator Sets

Models:

20--2000 kW

Controllers:

Decision-Makert 340

TP-5829 8/04f

California Proposition 65

WARNING

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

Product Identification Information

Product identification numbers determine service parts.

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

Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

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

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

2 TP-5829 8/04

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

Safety Precautions and Instructions

Introduction

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

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

List of Related Materials

Service Assistance

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

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

1.1

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

1.2

Digital Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1

Annunciator Panel Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.2

Digital Display and Keypad

1.2.3

Switches and Controls

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

1.2.4

Controller Circuit Boards

1.2.5

Fuses

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

1.2.6

Terminal Strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.7

Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3

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

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

2.1

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

2.2

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

2.3

Digital Controller Operation

2.3.1

Starting

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

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

2.3.2

Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.3

Resetting Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.4

System Ready Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.3.5

System Warning

2.3.6

System Shutdown

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

2.3.7

Controller Resetting Procedure

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

2.4

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

2.5

Reviewing the Digital Display

2.5.1

Keypad Operation

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

2.5.2

Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6

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

2.6.1

Personal Computer (PC) Communications . . . . . . . . . . . . . . . . . . . . . . . .

2.7

Local Programming Mode On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1

Menu 1—Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.2

Menu 2—Operational Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.3

Menu 3—Time & Date

2.7.4

Menu 4—Time Delays

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2.7.5

Menu 5—User-Defined Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.6

Menu 6—Generator System

2.7.7

Menu 7—Engine Status

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2.7.8

Menu 8—Source History

2.7.9

Menu 9—Calibration

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2.7.10

Menu 10—Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.11

Menu 11—Programming Mode

2.7.12

Menu 20—Factory Setup

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

3.1

Alternator Service

3.2

Engine Service

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3.3

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

3.4

Alternator Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1

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

3.4.2

350--2000 kW Models with Single- Bearing Alternator

3.4.3

2000 kW Models with Two-Bearing Alternator

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TP-5829 8/04 Table of Contents 3

Table of Contents, continued

3.5

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

3.5.1

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

3.5.2

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

3.5.3

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

3.5.4

Fuel System Changeover Kits

3.5.5

Carburetor Adjustment

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3.5.6

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

3.6

Turbocharger Maintenance on Ford-Powered Models

3.6.1

Oil Type Recommendations

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3.6.2

Turbocharger Oil Prime Procedure

3.6.3

Turbocharger Maintenance

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3.7

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

3.8

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

3.9

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

3.9.1

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.2

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

3.9.3

Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.4

Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Detroit Diesel Engine Control (DDEC) System

3.10.1

DDEC Features

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

3.10.2

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

3.11 Deutz Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.12.1

Lubricating System

3.12.2

Cooling System

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3.12.3

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

3.12.4

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

3.12.5

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

3.12.6

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

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

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

5.1

Voltage Reconnection Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.2

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

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

6.1

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1

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

6.1.2

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

6.1.3

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

6.1.4

Engine Prealarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.5

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

6.1.6

Prime Power Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.7

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

6.1.8

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

6.1.9

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

6.1.10

Remote Speed Adjustment Potentiometer Kit . . . . . . . . . . . . . . . . . . . . .

6.1.11

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

6.1.12

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

6.1.13

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

6.1.14

Voltage Adjustment Feature with Digital Voltage Regulator . . . . . . . . . .

100

6.2

Accessory and Prime Power Terminal Strip Connections . . . . . . . . . . . . . . . . . . . .

101

Appendix B Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103

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

105

4 Table of Contents TP-5829 8/04

IMPORTANT SAFETY INSTRUCTIONS.

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

Read and follow all safety precautions and instructions.

SAVE

THESE INSTRUCTIONS.

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

Warning, Caution, and Notice.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

Replace missing or damaged decals.

Safety Precautions and Instructions

Accidental Starting

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

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

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

Disabling the generator set.

Accidental starting can cause severe injury or death.

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

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

Battery

WARNING

Sulfuric acid in batteries.

Can cause severe injury or death.

Wear protective goggles and clothing.

Battery acid may cause blindness and burn skin.

WARNING

Explosion.

Can cause severe injury or death.

Relays in the battery charger cause arcs or sparks.

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

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

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

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

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

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

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

TP-5829 8/04 Safety Precautions and Instructions 5

Engine Backfire/Flash

Fire

WARNING

Fire.

Can cause severe injury or death.

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

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

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

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

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

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

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

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

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

Select a fire extinguisher rated ABC or

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

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

Exhaust System

WARNING

Carbon monoxide.

Can cause severe nausea, fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Generator set operation.

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

Carbon monoxide symptoms.

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

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

D Light-headedness, dizziness

D Physical fatigue, weakness in joints and muscles

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

D Stomachache, vomiting, nausea

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

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

Copper tubing exhaust systems.

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

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

Fuel System

WARNING

Explosive fuel vapors.

Can cause severe injury or death.

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

The fuel system.

Explosive fuel vapors can cause severe injury or death.

Vaporized fuels are highly explosive.

Use extreme care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks.

Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines.

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

Repair fuel systems before resuming generator set operation.

Explosive fuel vapors can cause severe injury or death.

Take additional precautions when using the following fuels:

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

Propane (LP)—Adequate ventilation is mandatory.

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

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

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

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

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

6 Safety Precautions and Instructions TP-5829 8/04

Gas fuel leaks.

Explosive fuel vapors can cause severe injury or death.

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

6--8 ounces per square inch

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

LP liquid withdrawal fuel leaks.

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

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

Hazardous Noise

CAUTION

Hazardous Voltage/

Electrical Shock

DANGER

Hazardous voltage.

Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

WARNING

Hazardous voltage.

Moving rotor.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

WARNING

Hazardous 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.

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

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

Grounding electrical equipment.

Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.

Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards.

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

TP-5829 8/04

Disconnecting the electrical load.

Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads.

High voltage transferred to the load during testing may cause personal injury and equipment damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not disconnect the generator set from the load.

High voltage test.

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

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

Testing the photo transistor circuit board.

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

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

Installing the photo transistor circuit board.

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

Connecting the SCR assembly.

Hazardous voltage can cause severe injury or death. Connect leads

C and E to the corresponding terminals of the one-piece SCR assembly. The

SCR assembly will turn full on and cause hazardous output voltage if the leads are connected in reverse or if the

C (red) lead is grounded.

(One-piece SCR models only. Does not apply to current split activator models.)

Safety Precautions and Instructions 7

Installing the battery charger.

Hazardous voltage can cause severe injury or death.

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

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

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

Have a qualified electrician install the battery(ies).

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

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

Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded.

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

Short circuits.

Hazardous voltage/current can cause severe injury or death.

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

Do not contact electrical connections with tools or jewelry while making adjustments or repairs.

Remove all jewelry before servicing the equipment.

Testing the voltage regulator.

Hazardous voltage can cause severe injury or death. High voltage is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator.

(PowerBoost t, PowerBoostt III, and

PowerBoost t V voltage regulator models only)

Engine block heater.

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

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

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

(Capacitor-excited models only)

Electrical backfeed to the utility.

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

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

Testing live electrical circuits.

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

Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry.

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

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

(600 volts and under)

Heavy Equipment

damage.

the skid.

WARNING

Unbalanced weight.

Improper lifting can cause severe injury or death and equipment

Do not use lifting eyes.

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

Hot Parts

WARNING

Hot coolant and steam.

Can cause severe injury or death.

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

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

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

Avoid touching the alternator field or exciter armature.

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

8 Safety Precautions and Instructions TP-5829 8/04

Checking the coolant level.

Hot coolant can cause severe injury or death.

Allow the engine to cool.

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

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

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

Combustible materials.

Fire can cause severe injury or death. A hot exhaust system can ignite adjacent combustible materials. Do not locate electrical wiring, fuel lines, or combustible materials above the exhaust muffler.

Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires.

Moving Parts

WARNING

Hazardous voltage.

Moving rotor.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

WARNING

Rotating parts.

Can cause severe injury or death.

Operate the generator set only when all guards, screens, and covers are in place.

Tightening the hardware.

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

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

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

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

Notice

NOTICE

This generator set has been rewired from its nameplate voltage to

246242

NOTICE

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

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

NOTICE

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

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

NOTICE

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

Screws and nuts are available in different hardness ratings.

To indicate hardness, American

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

NOTICE

Canadian installations only.

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

Canadian Electrical Code, Part 1.

TP-5829 8/04 Safety Precautions and Instructions 9

Notes

10 Safety Precautions and Instructions TP-5829 8/04

This manual provides operation instructions for

20--2000 kW generator sets equipped with the following controller:

Decision-Maker

™ 340

Wiring diagram manuals are available separately.

Refer to the engine operation manual for generator set engine scheduled maintenance information.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

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

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

Introduction

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

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

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.

Communication and Software

Manual Description

Communications Spec Sheet

Decision-Maker

™ 340 Controller Spec Sheet

Decision-Maker

™ 340 Software Operation

Manual

Generator Set/Controller

Wiring Diagram Manual

KBUS Communication Kits Installation

Modbus Interface Module

Monitor II Software

Operation/Installation Manual

Literature Part

Number

G6-38

G6-34

TP-5823

Contact your

Distributor/Dealer

TT-1283

G6-43

TP-5972

TP-5829 8/04 Introduction 11

Service Assistance

For professional advice on generator 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

KohlerPowerSystems.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

ZI Senia 122

12, rue des Hauts Flouviers

94517 Thiais Cedex

France

Phone: (33) 1 41 735500

Fax: (33) 1 41 735501

Asia Pacific

Power Systems Asia Pacific Regional Office

Singapore, Republic of Singapore

Phone: (65) 6264-6422

Fax: (65) 6264-6455

China

North China Regional Office, Beijing

Phone: (86) 10 6518 7950

(86) 10 6518 7951

(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, Shanghai

Phone: (86) 21 6288 0500

Fax: (86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office

Bangalore, India

Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office

Tokyo, Japan

Phone: (813) 3440-4515

Fax: (813) 3440-2727

Latin America

Latin America Regional Office

Lakeland, Florida, USA

Phone: (863) 619-7568

Fax: (863) 701-7131

12 Service Assistance TP-5829 8/04

1.1 Introduction

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

1.2 Digital Controller Features

The digital controller features include the annunciator panel lamps, digital display and keypad, switches and

Section 1 Specifications and Features

controls, and fuses and terminal strip. Each of these topics is covered in the following paragraphs.

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

Note: See Prime Power Mode under Section 1.2.6,

Terminal Strips, if no display appears and the keypad is not functional. Refer to Section 6.1.6,

Prime Power Switch Kit, for switch positions and function.

See Figure 1-1 for an illustration of the controller front panel and the following paragraphs for controller features.

1 2 3 4 5

10 9 8

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

2. Alarm horn (see keypad for alarm silence)

3. Annunciator panel lamps (see keypad for lamp test)

4. Digital display

5. Keypad

Figure 1-1 Digital Controller

TP-5829 8/04

7 6

6. Optional prime power switch (on back of controller)

7. Operating guide

8. Voltage adjustment (if equipped)

9. Emergency stop switch

10. Controller terminal strips (on circuit board)

TP-5829-2

Section 1 Specifications and Features 13

1.2.1 Annunciator Panel Lamps

Five annunciator panel lamps provide an immediate visual reference for generator set status.

See

Figure 1-2.

TP-5829-2

Figure 1-2 Annunciator Panel Lamps

System Ready.

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

Not in Auto (NIA).

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

Programming Mode. Yellow lamp in flashing mode indicates local programming selection or “steady on” for remote programming mode.

Note: Additional information for the programming mode lamp function and access to the local or remote programming mode are found in Section 2.7.11,

Operation, Local Programming Mode On,

Menu 11—Programming Mode.

System Warning. 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 following conditions cause a system warning:

Customer auxiliary warnings 1--4

Ground fault detected

Generator switch not in auto

Emergency power system supplying load

Speed sensor fault

Load shed

Overcurrent

Low battery voltage

Battery charger fault

High battery voltage

Weak battery

Low fuel

High coolant temperature

Low oil pressure

Low coolant temperature

Coolant temperature signal loss

Oil pressure signal loss

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

System Shutdown.

Red lamp identifies that the generator set has shut down because of a fault condition. A system shutdown may follow a system warning condition.

The following conditions cause a system shutdown:

Low oil pressure

High coolant temperature

Overcrank

Locked rotor

Overspeed

Emergency stop

Overvoltage

Undervoltage

Underfrequency

Overfrequency

Low coolant level

High oil temperature

Customer auxiliary shutdowns 1--4

Internal fault

Master switch in off/reset position

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

1.2.2 Digital Display and Keypad

See Figure 1-3 for illustration of the digital display and keypad.

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

Figure 1-3 Digital Display and Keypad

TP-5829-2

14 Section 1 Specifications and Features TP-5829 8/04

Digital Display

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

Generator Output Displays

AC Amps displays generator output current. Each line of three-phase models is available.

AC Volts displays generator output voltages.

All line-to-neutral and line-to-line voltages are available.

Frequency displays frequency (Hz) of generator output voltage.

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

Watts displays total kilowatt loading.

Engine Displays

DC Volts displays voltage of starting battery(ies).

Oil Pressure displays engine oil pressure.

Tachometer displays engine speed (rpm).

Water Temperature displays engine coolant temperature.

Keypad

The 16-button keypad provides information access and local programming capability.

1.2.3 Switches and Controls

See Figure 1-4 and Figure 1-5 for switches and controls.

Note: Find additional switches and controls in Section

2.5.1, Operation, Reviewing the DIgital Display,

Keypad Operation.

TP-5829-2

Figure 1-4 Switches and Adjustment Potentiometer

1. Lamp test

2. Alarm horn silence

Figure 1-5 Keypad Switches

TP-5829-2

TP-5829 8/04 Section 1 Specifications and Features 15

Alarm Horn.

Horn sounds if certain shutdown or warning conditions exist. See Section 1.3, Control Logic

Specifications, for specific items. Place generator set master switch in the AUTO position before silencing alarm horn. Alarm horn cannot be silenced unless the master switch is in the AUTO position. See Section 2.3.7,

Controller Resetting Procedure.

Alarm Silence. Keypad switch silences alarm during service. Place generator set master switch in the AUTO position before silencing alarm horn. Restore alarm horn switches at all locations including those on remote annunciator and audiovisual alarm kits to normal position after correcting fault shutdown to avoid reactivating alarm horn. See Section 2.3.7, Controller

Resetting Procedure.

Emergency Stop.

Switch instantly shuts down the generator set in emergency situations. Reset emergency stop switch after shutdown by rotating switch clockwise.

Use the emergency stop switch for emergency shutdowns only. Use the generator set master switch for normal shutdowns.

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

Switch functions as controller reset and generator operation switch.

Refer to Section 2.3 for starting, stopping, and controller resetting procedures.

Lamp Test. Keypad switch tests the controller indicator lamps, horn, and display.

Voltage Adjustment Potentiometer, if equipped.

Fine adjustment (

±5%) for generator output voltage.

Used with 20--300 kW models only.

Note: Adjust voltage

±10% on 350--2000 kW models using the keypad.

See Section 2.7.1, Local

Programming Mode On, Menu 1—Generator

Output, for complete information.

1.2.4 Controller Circuit Boards

The controller has several circuit boards and an optional communication circuit board. See Figure 1-6.

Communication Circuit Board (optional).

Board provides PC communication locally (direct) or remotely

(modem) using RS-232 or RS-485 connectors.

Indicator Circuit Board. Circuit board includes the

LED status lamps and alarm horn.

Input Conditioning Circuit Board. Board connects between the main logic and interconnection circuit boards.

Interconnection Circuit Board. Board provides the terminal strips for connecting the customer connection and/or dry contact kits.

Keypad and Digital Display Circuit Boards. Boards feature the keypad and digital display to monitor generator set functions.

Main Logic (Microprocessor) Circuit Board. Board has the controller logic and three fuses (F1, F2, and F3).

1 2 3

7 6 5 4

A-347946A-D

1. Interconnection circuit board

(TB1, TB2, TB3, and TB4 terminal strips)

2. Input conditioning circuit board

3. AC fuse block

4. Keypad and digital display circuit boards

5. Main Logic (microprocessor) circuit board with F1, F2, and F3 fuses

6. Indicator circuit board (LED and alarm horn)

7. Optional communication circuit board

(below indicator board)

Figure 1-6 Controller Circuit Boards and Fuses,

Controller Top View

16 Section 1 Specifications and Features TP-5829 8/04

1.2.5 Fuses

AC Circuit Fuses (TB6).

Fuses are located inside controller. See Figure 1-6.

1.5-Amp (V7).

Fuse protects L1 input to interconnection circuit board.

1.5-Amp (V8).

Fuse protects L2 input to interconnection circuit board.

1.5-Amp (V9).

Fuse protects L3 input to interconnection circuit board.

DC Circuit Fuses. Fuses are located on the controller main logic circuit board.

3-Amp Remote Annunciator (F1). Fuse protects dry contact kit if equipped.

3-Amp Controller (F2).

Fuse protects controller circuitry.

15-Amp Engine and Accessories (F3).

Fuse protects engine/starting circuitry and accessories.

1.2.6 Terminal Strips

Terminal Strips are located on the Interconnection

Circuit Board. These terminal strips provide various external input and output connections. See Section 6,

Accessories.

Note: Do not directly connect accessories to the controller terminal strip. Doing so may damage the controller. Connect all accessories to either a single-relay dry contact kit or a ten-relay dry contact kit.

TB1 Output Connection Terminal Strip.

TB1 provides relay driver outputs such as engine warning and shutdowns, voltage regulator adjustments, and other functions.

TB2 Input Connection Terminal Strip. TB2 provides input connections such as prime power mode, battery charger fault, low fuel, and remote reset ground fault.

TB3 Input Connection Terminal Strip. TB3 provides input connections such as remote start, emergency stop

(e-stop), engine gauge senders, and auxiliary connections.

TB4 AC Input Connection Terminal Strip.

TB4 provides connection to generator set output for sensing voltage and current.

Figure 1-7 shows locations of the terminal strips on the controller interconnection circuit board. See Section 6.2,

Accessory and Prime Power Terminal Strip

Connections, for specific terminal identification

TP-5829 8/04 information. Refer to the wiring diagrams for additional information on connecting accessories to the terminal strips.

TP5829-2

1. TB1 terminal strip

2. TB2 terminal strip

3. TB3 terminal strip

4. TB4 terminal strip

Figure 1-7 Interconnection Circuit Board Terminal

Strips, Circuit Board Top View

1.2.7 Communication Port

The main logic circuit board contains a communication port for either an RS-232 or RS-485 communication module kit. See Figure 1-8. Refer to the list of related literature in the introduction section for corresponding communication installation information.

P10

8471

1. Main logic circuit board

2. Ribbon cable included with communication board kit

3. RS-232 or RS-485 communication module kit

4. Front panel

Note: Front panel is shown swung open.

Figure 1-8 Main Logic Circuit Board Communication

Port

Section 1 Specifications and Features 17

1.3 Controller Logic Specifications

The Controller Logic Specifications is an overview of the various features and functions of the controller. Certain features are only operational when optional accessories are specified. See Section 2, Operation, for details.

Condition or Fault and

Menu Location for

Changes

Access Code (Password)

(see Menu 11)

Air Damper (if used)

(see Menu 5)

Battery Charger Fault

(see Menu 5)

Cyclic Cranking

(see Menu 4)

Digital Display

Air Damper

Battery Charger Fault

Alarm

Horn

Off

Relay

Driver

Output

(RDO)*

RDO-5

Std.

Panel

Lamp

Shutdown

Warning

Range Setting

Default

Selection

0 (zero)

Inhibit

Time

Delay

(sec.)

[

Time

Delay

(sec.)

Off 1--6 crank cycles

1--60 sec. crank

1--60 sec. pause

15 sec.

Coolant Temperature

Signal Loss

(see Menu 5)

Customer Auxiliary 1--4

Shutdown or Warning

(see Menus 4 and 5)

Defined Common Fault

(see Menu 5)

Emergency Power System

Supplying Load

(see Menu 5)

Emergency Stop

Shutdown

(see Menu 5)

No Temp Gauge Signal

Auxiliary 1--4

Defined Common Fault

EPS Supplying Load

Emergency Stop

Off

User

Defined

User

Defined

RDO-2

RDO-8

Std.

Warning

Shutdown or Warning

Warning

Shutdown

30 sec.

inhibit,

5 sec. delay

5% of line current

0--60

]

0--60

Generator Running

(see Menu 5)

Ground Fault Detected

(see Menu 5)

High Battery Voltage

(see Menu 5 and 6)

High Coolant Temperature

Shutdown

(see Menu 5)

High Coolant Temperature

Warning

(see Menu 5)

High Oil Temperature

Shutdown

(see Menu 5)

Ground Fault On User

Defined

Warning

High Battery Voltage Off RDO-10 Warning 14.5--16.5 (12V)

29--33 (24V)

High Coolant Temperature On Std.

Shutdown

High Coolant Temperature

Warning

High Oil Temperature

Off

RDO-3

Std.

User

Defined

Warning

Shutdown

16 (12V)

32 (24V)

Internal Fault Shutdown

(see Menu 5) kW Overload

(see Load Shed)

Load Shed

Internal Fault On User

Defined

Shutdown

Locked Rotor Shutdown

(see Menu 5)

Low AC Output

(see Menu 5)

Low Battery Voltage

(see Menu 5 and 6)

Low Coolant Level

Shutdown

(see Menu 5)

Load Shed KW Overload

Load Shed

Underfrequency

Locked Rotor

Low AC Output

Low Battery Voltage

Low Coolant Level

Off

User

Defined

User

Defined

User

Defined

User

Defined

Std.

RDO-7

Warning

Shutdown

Warning

Shutdown

10--12.5 (12V)

20--25 (24V)

100% of kW

Rating

59, (60 Hz)

49, (50 Hz)

12 (12V)

24 (24V)

Low Coolant Temperature

(see Menu 5)

Low Coolant Temperature On Std.

Warning

* RDO-1--10 represent user-defined default selections.

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

] If auxiliary input inhibit time is set to 0 seconds, the auxiliary input is active at all times and not dependent on time delay engine start

(TDES).

18 Section 1 Specifications and Features TP-5829 8/04

Condition or Fault and

Menu Location for

Changes

Low Fuel

(see Menu 5)

Low Oil Pressure

Shutdown

(see Menu 5)

Digital Display

Low Fuel

Low Oil Pressure

Alarm

Horn

Relay

Driver

Output

(RDO)*

Std.

Panel

Lamp

Warning

Shutdown

Range Setting

Default

Selection

Inhibit

Time

Delay

(sec.)

[

Time

Delay

(sec.)

Low Oil Pressure Warning

(see Menu 5)

Master Switch Open

NFPA Common Alarm

(see Menu 5)

Not In Auto

(Generator Switch)

(see Menu 5)

Overcrank Shutdown

(see Menu 5)

Overcurrent

(see Menu 5)

Overfrequency Shutdown

(see Menus 5 and 6)

Overspeed Shutdown

(see Menus 5 and 6)

Oil Pressure Signal Loss

(see Menu 5)

Overvoltage Shutdown

(see Menus 5 and 6)

Low Oil Pressure Warning

Master Switch Open

NFPA Common Alarm

Not In Auto

Overcrank

Overcurrent

Overfrequency

Overspeed

No Oil Gauge Signal

Off

Std.

Warning

Shutdown

RDO-1 Shutdown

Std.

or Warning

Not In

Auto

Shutdown

User

Defined

Warning

User

Defined

Std.

Shutdown 102%--140%

Shutdown 65--70 (60 Hz)

55--70 (50 Hz)

User

Defined

Warning

RDO-6 Shutdown 105%--135%

110%

140% Std.

103% FAA

70 (60 Hz)

70 (50 Hz)

0.25

Overvoltage On 115%

2-sec time delay

0 (zero)

2--10

Password (Access Code)

Speed Sensor Fault

(see Menu 5)

Starting Aid Function

(see Menus 4 and 5)

System Ready

Speed Sensor Fault On RDO-9

User

Defined

Std.

Warning

0--10 sec.

Off System

Ready

Time Delay Engine

Cooldown (TDEC)

(see Menu 4)

Time Delay Engine Start

(TDES)

(see Menu 4)

Off

RDO-4

User

Defined

00:00--10:00 min:sec

00:00--5:00 min:sec

5:00

00:01

Underfrequency Shutdown

(see Menus 5 and 6)

Undervoltage Shutdown

(see Menus 5 and 6)

Underfrequency

Undervoltage

User

Defined

User

Defined

Shutdown

80%--95%

70%--95%

90%

85%

10-sec time delay

5--30

Weak Battery

(see Menu 5)

Weak Battery Off User

Defined

Warning 60%

* RDO-1--10 represent user-defined default selections.

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

] If auxiliary input inhibit time is set to 0 seconds, the auxiliary input is active at all times and not dependent on time delay engine start

(TDES).

TP-5829 8/04 Section 1 Specifications and Features 19

Notes

20 Section 1 Specifications and Features TP-5829 8/04

2.1 Prestart Checklist

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

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

Air Inlets. Check for clean and unobstructed air inlets.

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

Controller. After energizing the controller using the prime power switch or reconnecting the battery, set the controller time and date.

See Section 2.7.3, Local

Programming Mode On, Menu 3—Time & Date.

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

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

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

Exhaust System.

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

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

Section 2 Operation

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

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

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

Check that the exhaust outlet is unobstructed.

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

Carbon and soot residue indicates an exhaust leak.

Seal leaks as needed.

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

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

Keep the oil level in the mechanical governor, if equipped, at or near the full level.

Operating Area.

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

2.2 Exercising Generator Set

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

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

The operator should perform all of the prestart checks before starting the exercise procedure.

Start the generator set according to the starting procedure in the controller section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks.

TP-5829 8/04 Section 2 Operation 21

2.3 Digital Controller Operation

2.3.1 Starting

Local Starting

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

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

Note: The transient start/stop function of the controller prevents accidental cranking of the rotating engine. The generator set slows to 249 rpm and recranks before returning to rated speed if the generator set master switch is momentarily placed in the OFF/RESET position and then returned to RUN.

Auto Starting

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

Terminals 3 and 4 connect to an open crank cycle circuit that, when closed by an external source, automatically starts the generator set crank cycle.

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

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

Make cyclic cranking adjustments using the keypad.

See Section

2.7.4, Local Programming Mode On, Menu 4—

Time Delays.

Prime Power Mode

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

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

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

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

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

See Section 2.7.3, Local Programming Mode On,

Menu 3—Time & Date.

Stop the generator set using the stopping procedures in

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

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

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

2.3.2 Stopping

Normal Stopping

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

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

Note: The generator set continues running during the cooldown cycle if a remote switch or automatic transfer switch signals the engine to stop.

Emergency Stopping

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

The emergency stop switch bypasses the time delay engine cooldown and causes an immediate shutdown.

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

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

22 Section 2 Operation TP-5829 8/04

2.3.3 Resetting Emergency Stop Switch

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

Refer to Section 2.3.7, Controller Resetting

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

1. Place generator set master switch in OFF/RESET position.

2. Investigate cause of emergency stop and correct.

3. Reset optional remote emergency stop switch by replacing glass piece, if equipped. Reset controller emergency stop switch by rotating switch clockwise until switch springs back to original position.

4. Reset air damper, if equipped, on engine by rotating air damper lever. See Figure 2-1.

TP-5633-2

Figure 2-1 Air Damper Lever on Detroit Diesel-

Powered Models (if equipped), Typical

Note: The engine air damper (air box) feature is available on some 200--2000 kW generator sets using 2-cycle Detroit Diesel Series 71,

92, and 149 engines.

5. After resetting all faults using the Controller

Resetting Procedure, toggle generator set master switch to RUN or AUTO to restart the generator set.

The generator set will not crank until the resetting procedure is completed.

2.3.4 System Ready Lamp

System Ready.

Green lamp illuminates when generator set master switch is in AUTO position and the system has no fault conditions.

2.3.5 System Warning

The yellow warning lamp illuminates indicating a fault but does not shut down the generator set under the following conditions. In some cases the alarm horn will also sound. See Section 2.3.7, Controller Resetting

Procedure, for resetting a system warning.

If system warning lamp is on and no message is displayed, press Reset Menu and the menu down

↓ key to view messages.

If the system warning continues, it may cause a system shutdown.

Keypad switch disconnects alarm during service. Place generator set master switch in the AUTO position before silencing alarm horn. Alarm horn cannot be silenced unless the master switch is in the AUTO position.

Note: Text shown in italics represents digital display messages.

Customer Auxiliary Warning. Lamp illuminates and alarm horn sounds if signalled by auxiliary inputs 1--4.

Customer can define up to four inputs as shutdowns or warnings. The local display shows auxiliary 1--4 when activated.

Using the remote communications package, the user can label the auxiliary 1--4 functions with an identifying name. The controller receives this warning information and displays the selected name instead of auxiliary 1--4.

Ground Fault Detected. Lamp illuminates and alarm horn sounds if signalled by a user-supplied ground fault detector. Local display shows ground fault.

Generator Switch Not in Auto. Lamp illuminates and alarm horn sounds when generator set master switch is in RUN or OFF/RESET position. Local display shows master switch not in auto.

TP-5829 8/04 Section 2 Operation 23

Emergency Power System Supplying Load. Lamp illuminates when the generator set supplies more than

5% of the rated standby output current. Local display shows EPS supplying load.

Speed Sensor Fault. Lamp illuminates and alarm horn sounds when speed signal is absent for 1 second while the generator set is running. Local display shows speed sensor fault. This warning lamp remains on until the user places the master switch in the OFF/RESET position.

Load Shed. Lamp illuminates when generator set total kW load exceeds 100% of the standby rating for more than 5 seconds. If the load shed alarm occurs and resets more than twice in 1 minute, the load shed warning lamp latches and remains on until the generator set shuts off. Local display shows load shed with kW overload at the next lower display level. Use the menu down

↓ key to review display.

If the generator set frequency drops to less than 59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system for more than 5 seconds, the local display shows load shed with underfrequency at the next lower display level. Use the menu down

↓ key to review display. If the load shed alarm occurs and resets more than twice in 1 minute, the load shed warning lamp latches and remains on until the generator set shuts off.

Overcurrent. Lamp illuminates and alarm horn sounds when the generator set supplies more than 110% of the rated standby output current for more than 10 seconds.

Local display shows overcurrent.

Low Battery Voltage.

Lamp illuminates if battery voltage drops below preset level for more than

10 seconds. Local display shows low battery voltage.

Low battery voltage specs follow. See Figure 2-2.

Engine Electrical

System Voltage

Low Battery

Voltage Range

10--12.5

20--25

Figure 2-2 Low Battery Voltage Specs

Low Battery

Voltage Default

Setting

The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes. Low battery voltage warning is inhibited during the crank cycle.

Battery Charger Fault.

Lamp illuminates if battery charger malfunctions.

Requires optional battery charger with malfunction output for lamp to function.

Local display shows battery charger fault.

High Battery Voltage Lamp illuminates if battery voltage rises above the preset level for more than

10 seconds. Local display shows high battery voltage.

High battery voltage specs follow. See Figure 2-3.

Engine Electrical

System Voltage

High Battery

Voltage Range

14.5--16.5

29--33

High Battery

Voltage Default

Setting

Figure 2-3 High Battery Voltage Specs

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

Weak Battery. Lamp illuminates if battery voltage is below 60% of the nominal voltage (12 VDC or 24 VDC) for more than 2 seconds during the crank cycle. Local display shows weak battery.

Low Fuel (Level or Pressure). Lamp illuminates and alarm horns sounds when fuel tank level approaches empty on gasoline or diesel models or low fuel pressure occurs on gaseous-fueled models. Requires optional low fuel switch for lamp to function. Local display shows low fuel.

Low AC Output. Lamp illuminates if nominal generator set AC output voltage is not detected after crank disconnect. Low AC output is inhibited for 10 seconds after crank disconnect. Local display shows low AC output.

High Coolant Temperature (Warning).

Lamp illuminates and alarm horn sounds if engine coolant temperature approaches shutdown range.

Requires optional prealarm sender kit for lamp to function. Local display shows high coolant temperature warning.

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

Requires optional prealarm sender kit for lamp to function. Local display shows low oil pressure warning.

24 Section 2 Operation TP-5829 8/04

Low Coolant Temperature.

Lamp illuminates and alarm horn sounds when engine coolant temperature is low. Requires optional prealarm sender kit for lamp to function. Local display shows low coolant temperature.

Coolant Temperature Gauge Signal Loss.

Lamp illuminates when the engine coolant temperature sender circuit is open. Local display shows no temp gauge signal.

Oil Pressure Gauge Signal Loss. Lamp illuminates when the engine oil pressure sender circuit is open.

Local display shows no oil gauge signal.

2.3.6 System Shutdown

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

Resetting Procedure, for resetting a system shutdown.

Note: Keypad switch disconnects alarm during service.

Place the generator set master switch in the

AUTO position before silencing alarm horn.

Alarm horn cannot be silenced unless the master switch is in the AUTO position.

Note: Text shown in italics represents digital display messages.

Low Oil Pressure. Lamp illuminates if unit shuts down because of low oil pressure.

Shutdown occurs

5 seconds after engine reaches pressure shutdown range. Low oil pressure shutdown is inhibited during first 30 seconds after startup. Local display shows low oil pressure.

High Coolant Temperature. Lamp illuminates when unit shuts down because of high engine coolant temperature. Shutdown occurs 5 seconds after engine reaches temperature shutdown range.

High engine temperature shutdown does not function during first

30 seconds after startup.

Local display shows high coolant temperature.

Note: The high engine temperature shutdown switch and low coolant level switch function independently of each other. Low coolant level may not activate the high engine temperature switch.

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

Local display shows overcrank. See Section 2.3.1, Auto

Starting, and Section 1, Specifications, for cyclic crank specs.

Note: The controller is equipped with an automatic restart function.

If while running the engine, speed drops below 13 Hz (390 rpm), the unit attempts to recrank. The unit then follows the cyclic cranking cycle and, if the engine fails to start, will shut down on an overcrank fault condition.

Locked Rotor. After initiating engine cranking and if none of the speed sensing inputs shows engine rotation during the first 5 seconds of the crank cycle, the ignition and crank circuits turn off for 5 seconds and the cycle repeats. If the condition still exists at the end of the second cycle of 5 seconds of cranking, the unit shuts down. Local display shows locked rotor.

Overspeed.

Lamp illuminates and unit shuts down immediately when the governed frequency on 50 and

60 Hz models exceeds the overspeed setting for

0.25 seconds.

Local display shows overspeed.

Overspeed specs follow. See Figure 2-4.

Generator Set

Frequency Hz

Overspeed

Range Hz

65--70

55--70

Figure 2-4 Overspeed Specs

Overspeed Default

Setting Hz

Emergency Stop.

Lamp illuminates and unit shuts down when local or optional remote emergency stop switch activates. Local display shows emergency stop.

TP-5829 8/04 Section 2 Operation 25

Overvoltage. Lamp illuminates and unit shuts down when the overvoltage setting exceeds the time delay period. Local display shows overvoltage. Overvoltage specs follow. See Figure 2-5.

Overvoltage

Setting Range

Time Delay

Range

105%--135% of nominal 2--10 sec.

Figure 2-5 Overvoltage Specs

Overvoltage

Default Setting

115% at 2 sec.

Note: Overvoltage can damage sensitive equipment in less than 1 second. Install separate overvoltage protection on online equipment requiring faster than 2 second shutdowns.

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

Local display shows undervoltage.

Undervoltage specs follow.

See

Figure 2-6.

Undervoltage

Setting Range

70%--95% of nominal

Time Delay

Range

5--30 sec.

Undervoltage

Default Setting

85% of nominal at 10 sec.

Figure 2-6 Undervoltage Specs

Underfrequency. Lamp illuminates and unit shuts down when the frequency is below the underfrequency setting.

Local display shows underfrequency.

See

Figure 2-7.

Underfrequency

Setting Range

80%--95% of nominal

Time Delay

Range

10 sec.

Figure 2-7 Underfrequency Specs

Underfrequency

Default Setting

90% of nominal

Low Coolant Level. Lamp illuminates and unit shuts down because of low coolant level. Shutdown occurs

5 seconds after low coolant level is detected.

Low coolant level shutdown is inhibited during first

30 seconds after startup.

Local display shows low coolant level.

Note: The high engine temperature shutdown switch and low coolant level switch function independently of each other. Low coolant level may not activate the high engine temperature switch.

High Oil Temperature. Lamp illuminates and unit shuts down because of high engine oil temperature.

Shutdown occurs 5 seconds after engine oil reaches temperature shutdown range.

High engine oil temperature shutdown is inhibited during first

30 seconds after startup. Optional high oil temperature switch required for lamp to function.

Local display shows high oil temperature.

Customer Auxiliary. Lamp illuminates and unit shuts down if signalled by auxiliary contact(s) 1--4. Customer can define up to four inputs for shutdowns or warnings.

When using customer auxiliary as a shutdown, the local display shows auxiliary 1--4.

When using customer auxiliary as a shutdown, the customer can define the following:

Delay time after crank disconnect (inhibit time).

Delay time before shutdown.

When used as a shutdown:

Auxiliaries 1 and 2 are latching shutdowns. Reset by placing the master switch in the OFF/RESET position.

Auxiliaries 3 and 4 are non-latching shutdowns and are reset when the input is no longer grounded.

Using the remote communications package, the user can label the auxiliary 1--4 functions with identifying names.

The controller receives this shutdown information and displays the selected name instead of auxiliary shutdown number.

Internal Fault. Lamp illuminates and unit shuts down when internal diagnostic test detects a controller malfunction. Local display shows internal fault.

Master Switch Open. Lamp illuminates and unit shuts down when master switch is in the open position. Local display shows master switch open.

26 Section 2 Operation TP-5829 8/04

2.3.7 Controller Resetting Procedure

(Following System Shutdown or

Warning)

Use the following procedure to restart the generator set after a system shutdown or warning.

Refer to

Section 2.3.3, Resetting Emergency Stop Switch, to reset the generator set after an emergency stop.

1. Silence the alarm horn by pressing the alarm off key. If equipped, audiovisual annunciator alarm horn and lamp activate.

Move audiovisual annunciator alarm switch to SILENCE to stop alarm horn. Audiovisual annunciator lamp stays lit.

2. Disconnect generator set from load with line circuit breaker or automatic transfer switch.

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

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

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

If equipped, audiovisual annunciator alarm horn sounds and the lamp turns off.

5. Test operate the generator set to verify that the cause of the shutdown has been corrected.

6. Reconnect generator to load via line circuit breaker or automatic transfer switch.

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

If equipped, move audiovisual annunciator alarm switch to the NORMAL position.

Note: Place generator set master switch in the

AUTO position before silencing alarm horn.

2.4 Menu List Summary

See the Menu List section on the following pages. Use the Menu List after reading and understanding the features of the keypad. Details of each menu selection appear immediately after the overview in two different operating modes—Local Programming Mode Off and

Local Programming Mode On.

The information in the Menu List boxes represents the digital display data.

Some digital display data represents actual data and may not be identical to your display due to application differences.

The arrows connecting the boxes represent use of the arrow down

↓ key or arrow right

→ key to access the next menu.

The arrows within the boxes inform the user that additional submenus are available using the arrow right

→ key.

TP-5829 8/04 Section 2 Operation 27

Menu List

Menu 1

GENERATOR OUTPUT

Menu 2

OPERATIONAL RECORDS

Menu 3

TIME & DATE

Menu 4

TIME DELAYS

L1-L2 VOLTS

L1 AMPS

L2-L3 VOLTS

L2 AMPS

L3-L1 VOLTS

L3 AMPS

OPERATIONAL RECORDS

START DATE

TOTAL RUN TIME

LOADED HRS

TOTAL RUN TIME

UNLOADED HRS

0-00-00

0.0

(MONDAY)

(12:00 AM)

TIME

DATE

L1-L0 VOLTS

L1 AMPS

L2-L0 VOLTS

L2 AMPS

L3-L0 VOLTS

L3 AMPS

FREQUENCY

POWER FACTOR

TOTAL KILOWATTS

% MAX KW

TOTAL RUN TIME

KW HOURS

OPERATING DAYS

START DATE

0-00-00

00.0 HZ

1.00

NO. OF STARTS

START DATE

0-00-00

RECORDS -- MAINT

LAST MAINT

→

0-00-00 RESET RECORD?

RUN TIME SINCE MAINT

LOADED HRS 0.

RUN TIME SINCE MAINT

UNLOADED HRS

RUN TIME SINCE MAINT

KW HOURS

LAST START

DATE

OPERATING DAYS

LAST MAINT

0-00-00

NO. OF STARTS

LAST MAINT

0-00-00

(0:00 AM)→

0-00-00

LENGTH OF RUN

UNLOADED HRS

0-00-00

(12:00 AM)

0-00-00

TIME DELAY

ENGINE START

TIME DELAY

STARTING AID

MIN:SEC

:00

MIN:SEC

:00

TIME DELAY

ENG COOLDOWN

MIN:SEC

:00

0.0

TIME DELAY

CRANK ON

TIME DELAY

CRANK PAUSE

MIN:SEC

OVERCRANK SHUTDOWN

CRANK CYCLES

TIME DELAY

OVERVOLTAGE

TIME DELAY

UNDERVOLTAGE

MIN:SEC

:00

TIME DELAY

AUX 1 INHIBIT

TIME DELAY

AUX 1 DELAY

MIN:SEC

:00

MIN:SEC

:00

TIME DELAY

AUX 2 INHIBIT

TIME DELAY

AUX 2 DELAY

MIN:SEC

:00

(3)

MIN:SEC

:00

MIN:SEC

OVERCRANK SHUTDOWN

AUX 3 INHIBIT

:00

(3)

TIME DELAY

AUX 3 DELAY

TIME DELAY

AUX 4 INHIBIT

TIME DELAY

AUX 4 DELAY

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

28 Section 2 Operation TP-5829 8/04

AUXILIARY 2 WARNING

SHUTDOWN?

AUXILIARY 3 WARNING

SHUTDOWN?

AUXILIARY 4 WARNING

SHUTDOWN?

YES RELAY OUTPUT #1

(see Group A)

RELAY OUTPUT #2

(see Group A)

YES

RELAY OUTPUT #3

(see Group A)

RELAY OUTPUT #4

(see Group A)

YES

YES RELAY OUTPUT #5

(see Group A)

RELAY OUTPUT #6

(see Group A)

RELAY OUTPUT #7

(see Group A)

RELAY OUTPUT #8

(see Group A)

RELAY OUTPUT #9

(see Group A)

RELAY OUTPUT #10

(see Group A)

YES

Menu List, continued

Menu 5

USER-DEFINED FUNCTIONS

Menu 6

GENERATOR SYSTEM

AUXILIARY 1 WARNING

SHUTDOWN?

SYSTEM VOLTAGE

000

SYSTEM FREQUENCY

THREE PHASE WYE

DELTA?

→

KW RATING

OVERVOLTAGE

00%

UNDERVOLTAGE

00%

000VAC

OVERSPEED

00HZ 0000RPM

UNDERFREQUENCY

00% 00.0HZ

BATTERY VOLTAGE (12)

LOW BATTERY VOLTAGE

00.0

HIGH BATTERY VOLTAGE

00.0

DEFINED COMMON FAULT

COMMON FAULT

(see Group B)

YES

THREE PHASE DELTA

WYE?

→

SINGLE PHASE?

Group A

For relay outputs 1--10, choose one from the following 30 selections:

DEFINED COMMON FAULT

AIR DAMPER

OVERVOLTAGE

UNDERVOLTAGE

UNDERFREQ SHUTDOWN

LOW COOLANT LEVEL

HIGH OIL TEMPERATURE

AUXILIARY 1

AUXILIARY 2

AUXILIARY 3

AUXILIARY 4

LOCKED ROTOR

INTERNAL ERROR

EPS SUPPLYING LOAD

SPEED SENSOR FAULT

LOAD SHED

KW OVERLOAD

UNDERFREQ WARNING

HIGH BATTERY VOLTAGE

NO TEMP GAUGE SIGNAL

NO OIL GAUGE SIGNAL

GRND FAULT DETECTED

OVERCURRENT

ENG COOLDOWN

ENGINE START

GENERATOR RUNNING

NFPA 110 COMM ALARM

STARTING AID

WEAK BATTERY

LOW AC OUTPUT

→

YES

Group B

For defined common fault, choose from the following

44 selections:

AIR DAMPER

OVERVOLTAGE

UNDERVOLTAGE

UNDERFREQ SHUTDOWN

LOW COOLANT LEVEL

HIGH OIL TEMPERATURE

AUXILIARY 1

AUXILIARY 2

AUXILIARY 3

AUXILIARY 4

LOCKED ROTOR

INTERNAL ERROR

EPS SUPPLYING LOAD

SPEED SENSOR FAULT

LOAD SHED

KW OVERLOAD

UNDERFREQ WARNING

HIGH BATTERY VOLTAGE

NO TEMP GAUGE SIGNAL

NO OIL GAUGE SIGNAL

GRND FAULT DETECTED

OVERCURRENT

ENG COOLDOWN

ENGINE START

GENERATOR RUNNING

NFPA 110 COMM ALARM

STARTING AID

LOW OIL PRESSURE

HIGH COOLANT TEMP

OVERCRANK

OVERSPEED

EMERGENCY STOP

NOT IN AUTO

SYSTEM READY

LOW BATTERY VOLTAGE

BATT CHARGER FAULT

LOW FUEL

HIGH TEMP WARNING

LOW OIL PRES WARNING

LOW COOLANT TEMP

WEAK BATTERY

LOAD SHED UNDERFREQ

LOAD SHED EXCESS KW

LOW AC OUTPUT

TP-5829 8/04 Section 2 Operation 29

Menu List, continued

Menu 7

ENGINE STATUS

ENGINE RPM

BATTERY VDC

00.0

OIL PRESSURE

COOLANT TEMP

ENGINE START?

COUNTDOWN

00PSI→

000°F

NO→

:00

Menu 8

SOURCE HISTORY

(see Group C)

0-00-00

Menu 9

CALIBRATION

(00:00 AM)

AUTO-ZERO?

OIL PRESSURE

COOLANT TEMP

RUN TIME

00kPa→

000°C

HR:MN→

:00

Group C

The 28 fault warning and shutdowns include the following:

AIR DAMPER

UNDERFREQ SHUTDOWN

LOW COOLANT LEVEL

HIGH OIL TEMPERATURE

AUXILIARY 1

AUXILIARY 2

AUXILIARY 3

AUXILIARY 4

LOCKED ROTOR

INTERNAL ERROR

LOW OIL PRESSURE

HIGH COOLANT TEMP

OVERCRANK

OVERSPEED

EMERGENCY STOP

OVERVOLTAGE L1-L2

OVERVOLTAGE L2-L3

OVERVOLTAGE L3-L1

OVERVOLTAGE L1-L0

OVERVOLTAGE L2-L0

OVERVOLTAGE L3-L0

UNDERVOLTAGE L1-L2

UNDERVOLTAGE L2-L3

UNDERVOLTAGE L3-L1

UNDERVOLTAGE L1-L0

UNDERVOLTAGE L2-L0

UNDERVOLTAGE L3-L0

MASTER SWITCH OPEN

L1-L2 VOLTS

L2-L3 VOLTS

L3-L1 VOLTS

L1-L0 VOLTS

L2-L0 VOLTS

L3-L0 VOLTS

L1 AMPS

L2 AMPS

L3 AMPS

RESISTIVE LOAD?

BATTERY VDC

Y/N

00.0

30 Section 2 Operation TP-5829 8/04

Menu List, continued

Menu 10

REMOTE CONTROL

ON-LINE?

REMOTE CONTROL

LOCAL?

REMOTE CONTROL

LAN?

REMOTE CONTROL

REMOTE?

→

REMOTE CONTROL

ADDRESS

→

REMOTE CONTROL

SYSTEM ID

→

0000

REMOTE CONTROL

REMOTE LAN?

→

REMOTE CONTROL

BAUD RATE 0000

REMOTE CONTROL

SYSTEM ID

→

0000

REMOTE CONTROL

ADDRESS

→

Menu 11

PROGRAMMING MODE

PROGRAM MODE

LOCAL?

YES

LOCAL?

ENTER CODE

PROGRAM MODE

REMOTE?

YES

REMOTE?

ENTER CODE

PROGRAM MODE

OFF?

PROGRAM MODE

ACCESS

YES

OFF?

ENTER CODE

→ PROGRAM MODE ACCESS→

CHANGE CODE?

YES

PROGRAM MODE ACCESS→

ENTER OLD CODE

PROGRAM MODE ACCESS→

ENTER NEW CODE

TP-5829 8/04 Section 2 Operation 31

Menu List, continued

Menu 20

FINAL ASSEMBLY

DATE 0-00-00

FINAL ASSEMBLY

CLOCK #

MODEL #

(26 CHARACTERS MAX)

SPEC #

(16 CHARACTERS MAX)

SERIAL

00000

CODE #

(UNLOCKS SETUP)

CONTROL

VERSION NO.

# INITIALIZE EEPROM?

OIL SENDER RANGE

0--XXX PSI

COOLANT SENDER

XXXXXX

SETUP LOCK?

→ OIL SENDER RANGE →

0--100 PSI?

Y/N

OIL SENDER RANGE →

0--150 PSI?

Y/N

OIL SENDER RANGE →

0--200 PSI?

Y/N

→

Y/N

COOLANT SENDER

255240?

→

Y/N

COOLANT SENDER

226717?

→

Y/N

COOLANT SENDER

Deutz 20--40?

→

Y/N

COOLANT SENDER

Deutz 50--170?

→

Y/N

32 Section 2 Operation TP-5829 8/04

2.5 Reviewing the Digital Display

The user interacts with the digital controller by a keypad and digital display.

Use the keypad to access the generator set informational data and preset settings.

This review section shows how to access the data.

Instructions on how to change information is found in

Local Programming Mode On in Section 2.7.

See

Figure 2-8 for illustration of the digital display and keypad.

TP-5829-2

Figure 2-8 Digital Display and Keypad

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

See Section 2.7.3,

Local Programming Mode On, Menu 3—Time &

Date.

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

5 minutes after the last keypad entry.

2.5.1 Keypad Operation

Use the keypad to input information into the controller.

Some of the keys have two functions. Key functions include the following.

Number keys. If the controller asks a question requiring a numeric answer, the controller accepts a keypad number and ignores the secondary function of the key.

Number key secondary function.

If the controller asks a question requiring a nonnumeric answer (yes, no, weekday, a.m./p.m., etc.), the controller accepts the secondary key function and ignores the numeric value of the key.

Menu down

↓ key. The controller software consists of layered menus of data or programming steps. Use the menu down

↓ key to navigate through the menu layers.

Press the menu down

↓ key repeatedly to return the opening menu.

Note: Pressing the menu down

↓ key locks the user into the layers of that main menu. Press the reset menu key to access other main menus.

Menu right

→ key. Use the menu right → key to scroll the main menus. Within the layers of each main menu, several horizontal information displays or programming steps may appear. The display contains an arrow in the right-hand corner when there is a horizontal layer.

Pressing the menu right

→ key when no arrow is present does not affect the program.

Reset menu key.

The reset menu key takes the program back to the beginning or resets an incorrect keypad entry. Use the reset menu key to exit a menu or any layers within that menu.

Enter

↵ key. Use the enter ↵ key to input information on the display into the controller memory.

Lamp test key. Press the lamp test key to check that the status lamps illuminate and clear the digital display.

Press the reset menu key before pressing the lamp test key.

Alarm off key. Use the alarm off key to disconnect the horn during service. Place generator set master switch in the AUTO position before silencing alarm horn. Alarm horn cannot be silenced unless the master switch is in the AUTO position. See Section 2.3, Digital Controller

Operation, Switches and Controls, for more information on turning the alarm horn off.

Stop prog run key. Use the stop prog run key to end the generator set programmed exercise run in Menu 7—

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

TP-5829 8/04 Section 2 Operation 33

2.5.2 Display Messages

Arrow down

↓ display. Directs the user to the next menu within the same main menu. Menus loop; press the down arrow key to navigate to the next menu.

Arrow right

→ display. Directs the user to the next menu. Menus loop; press the right arrow key to the next menu.

Question mark ? display. The control firmware asks a question; answer the question by pressing the yes/no, digit, day, or a.m./p.m. key.

Code error.

If this message appears, the entered information is not within the required parameters. Press

Reset Menu and rekey information.

Entry accepted. This message appears for several seconds after pressing the Enter key during the programming mode. The display then reverts back to the previous display with the new data shown.

2.6 Monitoring and Programming

Setup

Access the controller system in several ways using

Menu 10—Remote Control and Menu 11—Programming

Mode.

The user can monitor the controller system without data changes or monitor using programmed control. Use the controller keypad and display or a personal computer (PC) with optional software to monitor and/or program. Access the controller system with a PC using local (direct) or remote (modem) systems.

While this manual focuses on access through the controller, it includes access using a PC for initial connection.

There are six basic configurations for data monitoring and programming. See Figure 2-9.

User Activity

Monitor only

Monitor and Program

Monitor only

Monitor and Program

Monitor only

Monitor and Program

Access Source

Controller

Direct PC

PC via Telephone Lines

Figure 2-9 Monitoring and Programming

Configurations

Other combinations of data review are possible, however perform programming from a single location.

Figure 2-10 for the Monitoring and Programming Matrix provides a brief description of the settings of Menu 10 and Menu 11 based on user-selected operating mode.

Initially set up the access configurations at the controller using the keypad and digital display. Go to Section 2.7,

Local Programming Mode On, and set the desired selection in Menu 10—Remote Control and Menu 11—

Programming Mode before accessing data.

User Operating Mode Selection

User Activity

Monitor only

Access

Source

Controller

Monitor and Program Controller

Monitor only Direct PC

Monitor and Program Direct PC

Monitor only PC via

Telephone

Lines

Monitor and Program PC via

Telephone

Lines

Menu 10—

Remote Control Settings

Line?

Local?

Remote?

Yes

Programming

Mode Off?

Yes

Menu 11—

Programming Mode

Local

Programming Mode?

Remote

Programming Mode?

Yes

Yes No

Figure 2-10 Monitoring and Programming Matrix

Yes No No Yes

34 Section 2 Operation TP-5829 8/04

2.6.1 Personal Computer (PC)

Communications

There are four ways to communicate with a PC and the generator set and/or transfer switch devices. The PC connections require optional software, communication modules in the generator set controller and/or transfer switch, and possibly other hardware.

See Software

Operation Manual for details. Contact your authorized distributor/dealer for availability.

Local Single Connection

A PC connects directly to the COM port of the communication module with an RS-232 cable when 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 2-11 or Figure 2-12.

Personal

Computer

RS-232 up to

15 m (50 ft.)

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

Generator Set

Controller or

Transfer Switch

Control

Local Area Network (LAN)

A PC connects directly to the device’s local area network. A LAN is a system that connects more than one device to a single PC. Acceptable devices include

Decision-Maker

™ 340 controller, M340 transfer switch control, and M340+ transfer switch control.

See

Figure 2-13.

Personal

Computer

RS-232 to RS-485 port converter

RS-485 up to

1220 m

(4000 ft.)

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Figure 2-13 Local Area Network

Personal

Computer

RS-232 to RS-485 port converter

RS-485 up to

1220 m

(4000 ft.)

Generator Set

Controller or

Transfer Switch

Control

Figure 2-12 Local Single Connection, up to 1220 m (4000 ft.)

TP-5829 8/04 Section 2 Operation 35

Remote Single Connection

A PC connects to a modem and a single device connects a modem.

The PC communicates to the device via a telephone network.

Locate the PC anywhere a telephone line is available.

See

Figure 2-14.

Remote Area Network

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

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

™340 controller, M340 transfer switch control, and M340+ transfer switch control.

Locate the PC anywhere a telephone line is available. See Figure 2-15.

Modem

Personal

Computer

RS-232 up to

15 m (50 ft.)

Figure 2-14 Remote Single Connection

Telephone

Lines

Modem

RS-232 up to

15 m (50 ft.)

Generator Set

Controller or

Transfer Switch

Control

Modem

Personal

Computer

Telephone

Lines

Figure 2-15 Remote Area Network

Modem

RS-232 to RS-485 port converter

RS-485 up to 1220 m

(4000 ft.)

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

36 Section 2 Operation TP-5829 8/04

2.7 Local Programming Mode On

The Local Programming Mode On section explains how to program the generator set controller logic.

Each menu contains a step-by-step procedure for programming the various logic groups. See Section 1,

Specifications for setting ranges and default settings.

Please read and understand the entire Local

Programming Mode On section before attempting any programming. The factory settings are adjustable and inadvertent changes can occur without full understanding of the logic features and functions.

The programming feature alters stored settings and changes characteristics of the logic. Do not operate the controller with the program mode on unless there is a need to edit program logic or clear stored data. Limit programming responsibilities to individuals with training and authority.

Note: Use the generator set controller to initially set up remote programming.

Remote programming cannot be accessed from a PC unless the controller is first set for remote programming using Menu 11.

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

Note: Press the Reset Menu key to clear the Error display.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 37

2.7.1 Menu 1—Generator Output

Menu 1 provides generator output data including line-toline and line-to-neutral voltages, current, frequency, power factor, total kilowatts, and percent of maximum kW. Logic displays three-phase voltage and current readings when applicable.

Key

Entry Display Description

Use the first menu to access the voltage regulator sensing calibration across L1 and L2 for 350--2000 kW models with digital voltage regulators.

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 1

Displays menu number.

GENERATOR OUTPUT

Displays menu name.

L1-L2 VOLTS

L1 AMPS

L1-L2 VOLTS

INCREASE VOLTAGE

L1-L2 VOLTS

INCREASE VOLTAGE

L1-L2 VOLTS

DECREASE VOLTAGE

L1-L2 VOLTS

DECREASE VOLTAGE

L1-L2 VOLTS

L1 AMPS

L2-L3 VOLTS

L2 AMPS

L3-L1 VOLTS

L3 AMPS

L1-L0 VOLTS

L1 AMPS

L2-L0 VOLTS

L2 AMPS

L3-L0 VOLTS

L3 AMPS

FREQUENCY

POWER FACTOR

TOTAL KILOWATTS

% MAX KW

GENERATOR OUTPUT

00.0 HZ

1.00

Displays L1-L2 volts and L1 amps.

Gives the user the option to fine adjust voltage on 350-2000 kW models with the DVR remote voltage adjust option connected. When required, use Yes key to increase volts. Note: Models below 350 kW have a voltage adjustment potentiometer on controller.

Increases voltage.

Press Yes key as necessary to reach required voltage.

Gives the user the option to fine adjust voltage on 350-2000 kW models.

When required, use Yes key to decrease volts.

Decreases voltage. Press Yes key as necessary to reach required voltage.

Returns user to L1-L2 volts and L1 amps menu.

Displays L2-L3 volts and L2 amps (three-phase models only).

Displays L3-L1 volts and L3 amps (three-phase models only).

Displays L1-L0 volts and L1 amps.

Displays L2-L0 volts and L2 amps.

Displays L3-L0 volts and L3 amps (three-phase models only).

Displays frequency and power factor.

Displays total kilowatts and percent of maximum standby kilowatts available from generator set.

Returns user to Menu 1—Generator Output.

38 Section 2 Operation Local Programming Mode On TP-5829 8/04

2.7.2 Menu 2—Operational Records

Menu 2 provides generator set operational records including operation start date, last logged maintenance, total run time loaded and unloaded, run time since last

Key

Entry Display Description maintenance, number of starts, number of running days, etc.

The user must reset the date after performing maintenance to keep records accurate.

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 2

Displays menu number.

OPERATIONAL RECORDS

Displays menu name.

OPERATIONAL RECORDS

START DATE 0-00-00

TOTAL RUN TIME

LOADED HRS 0.0

TOTAL RUN TIME

UNLOADED HRS

TOTAL RUN TIME

KW HOURS

OPERATING DAYS

START DATE

NO. OF STARTS

START DATE

0.0

0-00-00

RECORDS—MAINT

LAST MAINT

→

0-00-00

Displays date generator set was placed in service.

Displays number of hours that generator set operated with load applied.

Displays numbers of hours that generator set operated without load applied.

Displays number of kilowatt hours.

Displays number of operating days and date since generator set installation.

Displays number of generator set starts and date when generator set started operating.

Displays date of last logged maintenance.

RESET RECORD?

Gives user option to reset last maintenance date.

Enter No to keep the previously logged date.

RESET RECORD?

AND

RESET RECORD?

AND

RESET RECORD?

YES

RECORDS—MAINT

LAST MAINT

→

0-00-00

RUN TIME SINCE MAINT

LOADED HRS 0.

Confirms entry.

Enter Yes to reset to the current date.

Confirms entry.

Returns user to Records Maintenance menu.

If Yes was entered on previous menu, current date appears as last maintenance date.

Displays number of hours that generator set operated with load applied.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 39

Menu 2—Operational Records, continued

Key

Entry Display Description

RUN TIME SINCE MAINT

UNLOADED HRS 0.

RUN TIME SINCE MAINT

KW HOURS 00

OPERATING DAYS

LAST MAINT

0-00-00

NO. OF STARTS

LAST MAINT

LAST START

DATE

0-00-00

(0:00 AM)→

0-00-00

LENGTH OF RUN

UNLOADED HRS 0.0

LAST START

DATE

(0:00 AM)→

0-00-00

OPERATIONAL RECORDS

Displays number of hours that generator set operated without load applied.

Displays number of kW hours since last logged maintenance.

Displays number of operating days and date of last logged maintenance.

Displays number of generator set starts and date of last logged maintenance.

Displays time and date when generator set last operated.

Displays number of hours that generator set operated without load applied.

Returns user to Last Start menu.

Returns user to Menu 2—Operational Records.

40 Section 2 Operation Local Programming Mode On TP-5829 8/04

2.7.3 Menu 3—Time & Date

Menu 3 sets the clock time and date and internal calendar. The controller uses set time to determine exercise run time. Time and date are valid only when controller power (starting battery) is connected.

Key

Entry Display Description

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 3

Displays menu number.

TIME & DATE

Displays menu name.

(MONDAY)

(12:00 AM)

0-00-00

TIME

DATE

(12:00 AM)

0-00-00

Displays day of the week, month-day-year, and time of day.

Displays time of day.

When required, use numeric and am/pm keys to set time and press Enter key.

Displays corrected time of day.

Displays month-day-year date.

When required, use numeric keys to set month-day-year date and press

Enter key.

Displays corrected month-day-year date.

DATE

TIME & DATE

Returns user to Menu 3—Time & Date.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 41

2.7.4 Menu 4—Time Delays

Code error. When code error message appears, the entered information is not within the required parameters. Press Reset Menu and rekey information.

and auxiliary shutdown and inhibit time delays.

Enter all time delays in minutes and seconds.

Note: Menu 4 sets the cyclic cranking, various engine-related starting and shutdown features,

Key

Entry Display Description

Note: If auxiliary input inhibit time is set to 0 seconds, the auxiliary input is active at all times and not dependent on time delay engine start (TDES).

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 4

Displays menu number.

TIME DELAYS

Displays menu name.

Displays engine start time delay in minutes:seconds.

When required, use numeric keys to set new time delay and press Enter key.

Displays corrected engine start time delay.

TIME DELAY

ENGINE START

TIME DELAY

ENGINE START

TIME DELAY

STARTING AID

TIME DELAY

STARTING AID

TIME DELAY

ENG COOLDOWN

TIME DELAY

ENG COOLDOWN

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

TIME DELAY

CRANK ON

TIME DELAY

CRANK ON

MIN:SEC

:00

MIN:SEC

:00

TIME DELAY

CRANK PAUSE

MIN:SEC

:00

TIME DELAY

CRANK PAUSE

MIN:SEC

:00

OVERCRANK SHUTDOWN

CRANK CYCLES (3)

OVERCRANK SHUTDOWN

CRANK CYCLES (3)

TIME DELAY

OVERVOLTAGE

MIN:SEC

:00

TIME DELAY

OVERVOLTAGE

MIN:SEC

:00

Displays engine starting aid time delay in minutes:seconds.

When required, use numeric keys to set new time delay and press Enter key.

Displays corrected engine starting aid time delay.

Displays engine cooldown time delay in minutes:seconds.

When required, use numeric keys to set new time delay and press Enter key.

Displays corrected engine cooldown time delay.

Displays engine cyclic cranking “on” time in minutes:seconds.

When required, use numeric keys to set new time delay and press Enter key.

Displays corrected engine cyclic cranking “on” time.

Displays engine cyclic cranking “off” time in minutes:seconds.

When required, use numeric keys to set new time delay and press Enter key.

Displays corrected engine cyclic cranking “off” time.

Displays engine crank cycles before shutdown.

When required, use numeric keys to set new quantity and press Enter key.

Displays corrected engine crank cycles before shutdown.

Displays overvoltage time delay shutdown in minutes:seconds.

When required, use numeric keys to set new time delay and press Enter key.

Displays corrected overvoltage time delay shutdown.

42 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 4—Time Delays, continued

Key

Entry Display

TIME DELAY

UNDERVOLTAGE

TIME DELAY

UNDERVOLTAGE

TIME DELAY

AUX 1 INHIBIT

TIME DELAY

AUX 1 INHIBIT

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

(3)

MIN:SEC

(3)

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

MIN:SEC

:00

TIME DELAY

AUX 3 INHIBIT

TIME DELAY

AUX 3 INHIBIT

TIME DELAY

AUX 3 DELAY

TIME DELAY

AUX 3 DELAY

TIME DELAY

AUX 4 INHIBIT

TIME DELAY

AUX 4 INHIBIT

TIME DELAY

AUX 4 DELAY

TIME DELAY

AUX 4 DELAY

TIME DELAYS

TIME DELAY

AUX 1 DELAY

TIME DELAY

AUX 1 DELAY

TIME DELAY

AUX 2 INHIBIT

TIME DELAY

AUX 2 INHIBIT

TIME DELAY

AUX 2 DELAY

TIME DELAY

AUX 2 DELAY

TP-5829 8/04

Description

Displays undervoltage time delay shutdown in minutes:seconds.

When required, use numeric keys to change time delay and press Enter key.

Displays corrected undervoltage time delay shutdown.

Displays auxiliary 1 inhibit time delay in minutes:seconds.

Inhibit time delay is time period after engine starting and before time delay begins. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 1 inhibit time delay.

Displays auxiliary 1 shutdown time delay in minutes:seconds.

Delay is time period after signal is received and before fault (warning or shutdown) occurs. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 1 time delay.

Displays auxiliary 2 inhibit time delay in minutes:seconds.

Inhibit time delay is time period after engine starting and before time delay begins. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 2 inhibit time delay.

Displays auxiliary 2 shutdown time delay in minutes:seconds.

Delay is time period after signal is received and before fault (warning or shutdown) occurs. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 2 time delay.

Displays auxiliary 3 inhibit time delay in minutes:seconds.

Inhibit time delay is time period after engine starting and before time delay begins. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 3 inhibit time delay.

Displays auxiliary 3 shutdown time delay in minutes:seconds.

Delay is time period after signal is received and before fault (warning or shutdown) occurs. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 3 time delay.

Displays auxiliary 4 inhibit time delay in minutes:seconds.

Inhibit time delay is time period after engine starting and before time delay begins. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 4 inhibit time delay.

Displays auxiliary 4 shutdown time delay in minutes:seconds.

Delay is time period after signal is received and before fault (warning or shutdown) occurs. When required, use numeric keys to set new time delay and press Enter key.

Displays corrected auxiliary 4 time delay.

Returns user to Menu 4—Time Delays.

Local Programming Mode On Section 2 Operation 43

2.7.5 Menu 5—User-Defined Functions

Menu 5 provides user options for auxiliary shutdowns and warnings 1--4 and relay driver outputs (RDO) 1--10.

Menu 5 also defines common fault inputs. For Menu 5 enter yes/no questions or a fault description.

Note: Code error. When code error message appears, the entered information is not within the required parameters.

Press Reset Menu and rekey information.

Key

Entry Description Display

ENTER NO. 1--11

When used as a shutdown

Auxiliaries 1 and 2 are latching shutdowns and are reset by placing the master switch in the OFF/RESET position.

Auxiliaries 3 and 4 are non-latching shutdowns and are reset when the input is no longer grounded.

Input a menu number.

MENU NUMBER 5

Displays menu number.

USER-DEFINED FUNCTIONS

Displays menu name.

AUXILIARY 1 WARNING

SHUTDOWN?

AUXILIARY 1 WARNING

SHUTDOWN?

AND

AUXILIARY 1 WARNING

SHUTDOWN?

AUXILIARY 1 WARNING

SHUTDOWN?

AND

AUXILIARY 1 WARNING

SHUTDOWN?

YES

AUXILIARY 2 WARNING

SHUTDOWN?

AUXILIARY 2 WARNING

SHUTDOWN?

AND

AUXILIARY 2 WARNING

SHUTDOWN?

AUXILIARY 2 WARNING

SHUTDOWN?

AND

AUXILIARY 2 WARNING

SHUTDOWN?

YES

AUXILIARY 3 WARNING

SHUTDOWN?

Asks the user if auxiliary 1 should cause a shutdown condition.

Entering Yes causes Auxiliary 1 to signal a fault shutdown.

Confirms entry.

Entering No causes Auxiliary 1 to signal a fault warning.

Confirms entry.

Asks the user if auxiliary 2 should cause a shutdown condition.

Entering Yes causes Auxiliary 2 to signal a fault shutdown.

Confirms entry.

Entering No causes Auxiliary 2 to signal a fault warning.

Confirms entry.

Asks the user if auxiliary 3 should cause a shutdown condition.

44 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 5—User-Defined Functions, continued

Key

Entry Display

AUXILIARY 3 WARNING

SHUTDOWN?

AND

AUXILIARY 3 WARNING

SHUTDOWN?

AUXILIARY 3 WARNING

SHUTDOWN?

AND

AUXILIARY 3 WARNING

SHUTDOWN?

YES

AUXILIARY 4 WARNING

SHUTDOWN?

AUXILIARY 4 WARNING

SHUTDOWN?

AND

AUXILIARY 4 WARNING

SHUTDOWN?

AUXILIARY 4 WARNING

SHUTDOWN?

AND

AUXILIARY 4 WARNING

SHUTDOWN?

YES

Description

Entering Yes causes Auxiliary 3 to signal a fault shutdown.

Confirms entry.

Entering No causes Auxiliary 3 to signal a fault warning.

Confirms entry.

Asks the user if auxiliary 4 should cause a shutdown condition.

Entering Yes causes Auxiliary 4 to signal a fault shutdown.

Confirms entry.

Entering No causes Auxiliary 4 to signal a fault warning.

Confirms entry.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 45

Menu 5—User-Defined Functions, continued

Key

Entry Display

RELAY OUTPUT #1

(see Group A)

RELAY OUTPUT #1

(see Group A)

YES

Group A

For relay outputs 1--10, choose one from the following 31 selections

DEFINED COMMON FAULT

AIR DAMPER

OVERVOLTAGE

UNDERVOLTAGE

UNDERFREQ SHUTDOWN

LOW COOLANT LEVEL

HIGH OIL TEMPERATURE

AUXILIARY 1

AUXILIARY 2

AUXILIARY 3

AUXILIARY 4

LOCKED ROTOR

INTERNAL ERROR

EPS SUPPLYING LOAD

SPEED SENSOR FAULT

LOAD SHED

KW OVERLOAD

UNDERFREQ WARNING

HIGH BATTERY VOLTAGE

NO TEMP GAUGE SIGNAL

NO OIL GAUGE SIGNAL

GRND FAULT DETECTED

OVERCURRENT

ENG COOLDOWN

ENGINE START

GENERATOR RUNNING

NFPA 110 COMM ALARM*

STARTING AID

WEAK BATTERY

LOW AC OUTPUT

OVERFREQUENCY

RELAY OUTPUT #1

(see Group A)

AND

RELAY OUTPUT #1

(see Group A)

YES

Description

Identifies signal source for relay output #1. When required, press Menu

Right

→ key and edit selection by choosing 1 of 30 selections.

Continue to press Menu Right

→ key until desired relay output selection is displayed. Press Yes key to select desired relay output.

Note: Menu 5 describes and provides selection of Defined Common

Fault components.

Note: Components of NFPA-110 Common Alarm include the 14 items listed below. The user cannot change NFPA-110 Common Alarm items.

*NFPA-110 Common Alarm 14 items include the following:

OVERCRANK

LOW COOLANT TEMPERATURE

HIGH COOLANT TEMPERATURE WARNING

HIGH COOLANT TEMPERATURE

LOW OIL PRESSURE WARNING

LOW OIL PRESSURE

OVERSPEED

LOW FUEL

NOT IN AUTO

BATTERY CHARGER FAULT

LOW BATTERY VOLTAGE

AIR DAMPER

EPS SUPPLYING LOAD

HIGH BATTERY VOLTAGE

Entering Yes selects displayed relay output.

Confirms entry.

Note: After pressing the Yes and Enter keys, any previous Yes selection defaults to No.

46 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 5—User-Defined Functions, continued

Key

Entry Display Description

Identifies signal source for relay outputs #2--10. When required, press

Menu Right

→ key and edit selection by choosing 1 of 30 selections. See

Relay Output #1 instructions for complete procedure and Group A.

RELAY OUTPUT #2

(see Group A)

RELAY OUTPUT #3

(see Group A)

RELAY OUTPUT #4

(see Group A)

RELAY OUTPUT #5

(see Group A)

RELAY OUTPUT #6

(see Group A)

RELAY OUTPUT #7

(see Group A)

RELAY OUTPUT #8

(see Group A)

RELAY OUTPUT #9

(see Group A)

RELAY OUTPUT #10

(see Group A)

YES

TP-5829 8/04 Local Programming Mode On Section 2 Operation 47

Menu 5—User-Defined Functions, continued

Key

Entry Display

DEFINED COMMON FAULT

→

COMMON FAULT

(see Group B)

YES COMMON FAULT

(see Group B)

AND

COMMON FAULT

(see Group B)

COMMON FAULT

(see Group B)

AND

COMMON FAULT

(see Group B)

YES

Group B

For defined common fault, choose from the following 45 selections

AIR DAMPER*

OVERVOLTAGE

UNDERVOLTAGE

UNDERFREQ SHUTDOWN

LOW COOLANT LEVEL

HIGH OIL TEMPERATURE

AUXILIARY 1

AUXILIARY 2

AUXILIARY 3

AUXILIARY 4

LOCKED ROTOR

INTERNAL ERROR

EPS SUPPLYING LOAD*

SPEED SENSOR FAULT

LOAD SHED

KW OVERLOAD

UNDERFREQ WARNING

HIGH BATTERY VOLTAGE*

NO TEMP GAUGE SIGNAL

NO OIL GAUGE SIGNAL

GRND FAULT DETECTED

Description

Provides user entry to defined common fault selections.

Gives user option to add or delete selection from defined common fault group. Press Menu Down key

↓ to continue to the next selection (repeat as necessary).

Entering Yes adds selection to the defined common fault group.

Confirms entry.

Entering No deletes selection from the defined common fault group.

Confirms entry.

OVERCURRENT

ENG COOLDOWN

ENGINE START

GENERATOR RUNNING

NFPA 110 COMM ALARM

(see Note)

STARTING AID

LOW OIL PRESSURE*

HIGH COOLANT TEMP*

OVERCRANK*

OVERSPEED*

EMERGENCY STOP

NOT IN AUTO*

SYSTEM READY

LOW BATTERY VOLTAGE*

BATT CHARGER FAULT*

LOW FUEL*

HIGH TEMP WARNING*

LOW OIL PRES WARNING*

LOW COOLANT TEMP*

WEAK BATTERY

LOAD SHED UNDERFREQ

LOAD SHED EXCESS KW

LOW AC OUTPUT

OVERFREQUENCY

Note: Components of NFPA-110

Common Alarm include the 14 items marked by an asterisk

(*). The user cannot change

NFPA-110 Common Alarm items.

DEFINED COMMON FAULT

→

USER-DEFINED FUNCTIONS

Returns user to beginning of defined common fault selections.

Returns user to Menu 5—User-Defined Functions.

48 Section 2 Operation Local Programming Mode On TP-5829 8/04

2.7.6 Menu 6—Generator System

Menu 6 contains factory-preset generator set voltage and frequency data. Enter corresponding data if the generator set requires voltage reconnection and/or frequency adjustment. It is imperative that the user enter correct data because these settings trigger all related shutdowns.

Key

Entry Description Display

ENTER NO. 1--11

Note: The user defines the data shown in Menu 6. It is

NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control.

Input a menu number.

MENU NUMBER 6

Displays menu number.

GENERATOR SYSTEM

Displays menu name.

SYSTEM VOLTAGE

000

SYSTEM VOLTAGE

000

SYSTEM FREQUENCY

THREE-PHASE WYE

DELTA?

THREE-PHASE DELTA

WYE?

→

THREE-PHASE WYE

DELTA?

AND

THREE-PHASE WYE

DELTA?

THREE-PHASE DELTA

WYE?

AND

THREE-PHASE DELTA

WYE?

→

YES

→

YES

→

YES

→

YES

SINGLE-PHASE?

THREE-PHASE?

Displays system voltage as entered data. When required, use numeric keys to set new value. Press Enter key.

Displays corrected system voltage.

Displays system frequency as entered data. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected system frequency.

Displays to the user if voltage configuration is wired for a wye connection as entered data. When required, use yes key to choose delta connection.

Displays to the user if voltage configuration is wired for a delta connection as entered data. When required, use Yes key to choose wye connection.

Enter Yes to change voltage configuration to a delta connection.

Displays corrected system phase configuration.

Enter Yes to change voltage configuration to a wye connection.

Displays corrected system phase configuration.

Displays voltage configuration is wired for three-phase as entered data.

When required, use yes key to choose single-phase.

Displays voltage configuration is wired for single-phase as entered data.

When required, use yes key to choose three-phase.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 49

Menu 6—Generator System, continued

Key

Entry Display Description

Enter Yes to change voltage configuration to single-phase

SINGLE-PHASE?

AND

THREE-PHASE?

AND

SINGLE-PHASE?

YES

THREE-PHASE WYE

DELTA?

KW RATING

OVERVOLTAGE

00%

OVERVOLTAGE

00%

→

000VAC

Displays corrected system phase configuration.

Enter Yes to change voltage configuration to three-phase.

Displays selected system phase configuration.

Returns user to three-phase wye/delta menu.

Note: Display sample may differ depending upon previous entries.

Displays generator set kW rating as entered data. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected system kilowatt rating.

Displays overvoltage setting. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected overvoltage setting.

UNDERVOLTAGE

00% 000VAC

UNDERVOLTAGE

00%

OVERSPEED

00HZ

000VAC

0000RPM

OVERSPEED

00HZ 0000RPM

UNDERFREQUENCY

00% 00.0HZ

UNDERFREQUENCY

00% 00.0HZ

OVERFREQUENCY

00%

OVERFREQUENCY

00%

00.0HZ

Displays undervoltage setting. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected undervoltage setting.

Displays overspeed setting. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected overspeed setting.

Displays underfrequency setting. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected underfrequency setting.

Displays overfrequency setting. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected underfrequency setting.

50 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 6—Generator System, continued

Key

Entry Display Description

BATTERY VOLTAGE (12)

Displays battery voltage setting as entered data. When required, use the numeric keys to set new value. Press Enter key.

BATTERY VOLTAGE (12)

Displays corrected battery voltage setting.

LOW BATTERY VOLTAGE

00.0

LOW BATTERY VOLTAGE

00.0

HIGH BATTERY VOLTAGE

00.0

HIGH BATTERY VOLTAGE

00.0

GENERATOR SYSTEM

Displays low battery voltage setting as entered data. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected low battery voltage setting.

Displays high battery voltage setting as entered data. When required, use the numeric keys to set new value. Press Enter key.

Displays corrected high battery voltage setting.

Returns user to Menu 6—Generator System.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 51

2.7.7 Menu 7—Engine Status

Menu 7 provides user with engine status, operating data, and time delay to start and run time.

Note: Use STOP PROG RUN key to stop generator set

Engine Start program.

Key

Entry Display Description

Note: Code error. When code error message appears, the entered information is not within the required parameters.

Press Reset Menu and rekey information.

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 7

Displays menu number.

ENGINE STATUS

Displays menu name.

ENGINE RPM

BATTERY VDC

OIL PRESSURE

COOLANT TEMP

OIL PRESSURE

COOLANT TEMP

OIL PRESSURE

COOLANT TEMP

ENGINE START?

COUNTDOWN

RUN TIME

00.0

00PSI→

000°F

00kPa→

000°C

00PSI→

000°F

NO→

:00

HR:MN→

:00

RUN TIME HR:MN→

:00

RUN TIME

AND

HR:MN→

:00

ENGINE START?

COUNTDOWN

NO→

:00

ENGINE START?

COUNTDOWN

AND

ENGINE START?

COUNTDOWN

NO→

:00

NO→

:00

Displays engine rpm and engine starting battery voltage.

Displays engine oil pressure in psi and engine coolant temperature in

°F.

Displays engine oil pressure in kPa and engine coolant temperature in

°C.

Returns user to Engine Oil Pressure in psi and engine Coolant

Temperature in

°F menu.

Gives user option to start generator set using run time feature.

Allows user to enter programmed run time.

Use numeric keys to enter desired programmed run time.

Confirms entry.

Returns user to Engine Start?—Countdown menu.

Use numeric keys to enter desired engine start countdown time.

Confirms entry.

52 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 7—Engine Status, continued

Key

Entry Display

ENGINE START?

COUNTDOWN

AND

ENGINE START?

COUNTDOWN

ENGINE STATUS

YES→

:00

YES→

:00

Description

Entering Yes starts generator set timed run after countdown period is completed.

Confirms entry.

Note: Use STOP PROG RUN key to stop generator set programmed run.

Returns user to Menu 7—Engine Status.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 53

2.7.8 Menu 8—Source History

Menu 8 indicates the source of a generator set shutdown or warning.

Multiple faults may simultaneously exist.

Correct each fault before attempting to restart the generator set.

Key

Entry Display Description

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 8

Displays menu number.

SOURCE HISTORY

Displays menu name.

Menu lists up to 4 fault descriptions with date and time of fault. Press

Menu Down

↓ key to continue.

See Section 2.3.5, System Warning, or Section 2.3.6, System Shutdown, at the beginning of Section 2 for fault definitions.

(see Group C)

0-00-00 (00:00 AM)

Group C

Fault warning and shutdowns include the following:

AIR DAMPER

UNDERFREQ SHUTDOWN

LOW COOLANT LEVEL

HIGH OIL TEMPERATURE

AUXILIARY 1

AUXILIARY 2

AUXILIARY 3

AUXILIARY 4

LOCKED ROTOR

INTERNAL ERROR

LOW OIL PRESSURE

HIGH COOLANT TEMP

OVERCRANK

OVERSPEED

EMERGENCY STOP

OVERVOLTAGE L1-L2

OVERVOLTAGE L2-L3

OVERVOLTAGE L3-L1

OVERVOLTAGE L1-L0

OVERVOLTAGE L2-L0

OVERVOLTAGE L3-L0

UNDERVOLTAGE L1-L2

UNDERVOLTAGE L2-L3

UNDERVOLTAGE L3-L1

UNDERVOLTAGE L1-L0

UNDERVOLTAGE L2-L0

UNDERVOLTAGE L3-L0

MASTER SWITCH OPEN

SOURCE HISTORY

Returns user to Menu 8—Source History.

54 Section 2 Operation Local Programming Mode On TP-5829 8/04

2.7.9 Menu 9—Calibration

Menu 9 provides calibration of the voltage sensing logic.

Changing system voltage or replacing the main logic control circuit board requires calibration adjustment.

Enable programming mode to edit display and/or files.

Connect a meter with a minimum accuracy of 1% to output leads to calibrate the voltage-sensing logic.

Adjust the generator set voltage at the controller voltage adjustment or using Menu 1 with digital voltage regulators. Adjust the frequency at the generator set governor before making calibration adjustments.

Key

Entry Description Display

ENTER NO. 1--11

Note: A purely resistive load must be connected when entering Yes to the Resistive Load? display in order for the controller to correctly show kW load and power factor values.

A resistive load is required and a Yes response is the only entry for this display. Failure to comply with this request will cause incorrect kW load and power factor values.

Input a menu number.

MENU NUMBER 9

Displays menu number.

CALIBRATION

AUTO-ZERO?

YES

Displays menu name.

Gives user the option to calibrate the voltage and current inputs for zero input signals.

Note: Perform this programming function only when the generator set is NOT running.

Entering Yes activates the auto-zero feature.

AUTO-ZERO?

AND

AUTO-ZERO?

AND

YES

Confirms entry.

Entering No prevents the auto-zero feature.

L1-L2 VOLTS

AND

L2-L3 VOLTS

AND

Confirms entry.

Measure generator set output voltage for single-phase and three-phase models between L1-L2 using a voltmeter and enter result using numeric keys.

Note: Generator set must be running for the following steps.

Confirms entry.

Measure generator set output voltage for three-phase models between

L2-L3 using a voltmeter and enter result using numeric keys.

Confirms entry.

L3-L1 VOLTS

AND

Measure generator set output voltage for three-phase models between

L3-L1 using a voltmeter and enter result using numeric keys.

Confirms entry.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 55

Menu 9—Calibration, continued

Key

Entry Display

00 L1-L0 VOLTS

L1-L0 VOLTS

AND

L2-L0 VOLTS

AND

L3-L0 VOLTS

AND

L1 AMPS

AND

L2 AMPS

AND

L3 AMPS

AND

RESISTIVE LOAD?

AND

RESISTIVE LOAD?

BATTERY VDC

AND

BATTERY VDC

CALIBRATION

56 Section 2 Operation

Description

Measure generator set output voltage for single-phase and three-phase models between L1-L0 using a voltmeter and enter result using numeric keys.

Confirms entry.

Measure generator set output voltage for single-phase and three-phase models between L1-L0 using a voltmeter and enter result using numeric keys.

Confirms entry.

Measure generator set output voltage for three-phase models between

L3-L0 using a voltmeter and enter result using numeric keys.

Confirms entry.

Measure generator set output current for single-phase and three-phase models at L1 using AC ammeter and enter result using numeric keys.

YES

Confirms entry.

Measure generator set output current for single-phase and three-phase models at L2 using AC ammeter and enter result using numeric keys.

Confirms entry.

Measure generator set output current for three-phase models at L3 using

AC ammeter and enter result using numeric keys.

Confirms entry.

Requests confirmation that a purely resistive load is connected allowing the software to determine the proper voltage and current zero-crossing phase-angle relationships when calculating kW load and power factor.

Note: Enter only a Yes response and apply only a purely resistive load.

Entering Yes confirms the calibration method.

00.0

Confirms entry.

Measure generator set battery voltage and enter result using numeric keys.

Confirms entry.

Returns user to Menu 9—Calibration.

Local Programming Mode On TP-5829 8/04

2.7.10 Menu 10—Remote Control

Menu 10 provides local or remote access to the control logic and displays. Use the LAN (local area network) to gain remote access to multiple devices/addresses.

Use the Software Operation Manual when accessing this menu, programming from a remote location, and determining address and system identification information.

Key

Entry Display Description

Note A: There are four PC remote control choices: local, LAN, remote, and remote LAN. Entering

Yes to one remote control choice changes the other three choices to No. Yes menus are highlighted in the following instructions. The dashed lines separate the four control choices.

ENTER NO. 1--11

Input a menu number.

MENU NUMBER 10

Displays menu number.

REMOTE CONTROL

ON-LINE?

REMOTE CONTROL

ON-LINE?

AND

REMOTE CONTROL

ON-LINE?

REMOTE CONTROL

ON-LINE?

AND

REMOTE CONTROL

ON-LINE?

YES

Displays menu name.

Gives the user the option for accessing the control using a PC connection.

Enter No to disable the on-line PC connection feature.

Access is available only through the keypad and digital display.

Confirms entry.

Enter Yes to enable the on-line PC connection. This entry establishes the first step for a PC connection.

Confirms entry.

Local Control

REMOTE CONTROL

LOCAL?

REMOTE CONTROL

LOCAL?

AND

REMOTE CONTROL

LOCAL?

YES

Indicates no local (direct) PC connection.

Enter Yes to enable the local (direct) PC connection to a single control.

See Note A above.

Confirms entry.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 57

Menu 10—Remote Control, continued

Key

Entry Display Description

Local LAN Control

REMOTE CONTROL

LAN?

REMOTE CONTROL

LAN?

AND

REMOTE CONTROL

LAN?

→

YES

→

YES

Indicates no LAN connection.

Enter Yes to enable a local area network (LAN) of controls and transfer switches with a local (direct) connected PC.

See Note A in

Section 2.7.10.

Confirms entry.

REMOTE CONTROL

ADDRESS

REMOTE CONTROL

ADDRESS

AND

REMOTE CONTROL

ADDRESS

REMOTE CONTROL

LAN?

Remote Control

REMOTE CONTROL

REMOTE?

REMOTE CONTROL

REMOTE?

AND

REMOTE CONTROL

REMOTE?

REMOTE CONTROL

SYSTEM ID

→

YES

→

0000

→

YES

→

YES

→

Indicates address of device.

Use numeric keys to enter desired address 1--128. Use one address number per unit and use consecutive numbers. Individual addresses are necessary for the software to call up the desired unit.

Confirms entry.

Returns user to remote control—LAN? menu.

Indicates no remote (modem) PC connection with a single device.

Enter Yes to enable a remote (modem) PC connection. See Note A in

Section 2.7.10.

Confirms entry.

Enter system ID of device. The system ID is a type of password. The user must use the same system ID as utilized within the PC control software.

REMOTE CONTROL

SYSTEM ID

AND

REMOTE CONTROL

SYSTEM ID

REMOTE CONTROL

REMOTE?

→

0000

→

0000

→

YES

Use numeric keys to enter desired system ID.

Confirms entry.

Returns user to remote control—REMOTE? menu.

58 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 10—Remote Control, continued

Key

Entry Display Description

Remote LAN Control

REMOTE CONTROL

REMOTE LAN?

REMOTE CONTROL

REMOTE LAN?

AND

REMOTE CONTROL

REMOTE LAN?

REMOTE CONTROL

SYSTEM ID

REMOTE CONTROL

SYSTEM ID

AND

REMOTE CONTROL

SYSTEM ID

REMOTE CONTROL

ADDRESS

REMOTE CONTROL

ADDRESS

AND

REMOTE CONTROL

ADDRESS

REMOTE CONTROL

REMOTE LAN?

→

0000

→

YES

→

0000

→

0000

→

YES

→

YES

Indicates no remote LAN connection.

Enter Yes to enable a remote (modem) PC connection with a network of devices at the site. See Note A in Section 2.7.10.

Confirms entry.

Enter system ID of remote LAN. The system ID is a password. The user must use the same password for all devices at a site.

Use numeric keys to enter desired system ID.

Confirms entry.

Indicates address of device.

Use numeric keys to enter desired address.

Confirms entry.

Returns user to remote control—REMOTE LAN? menu.

REMOTE CONTROL

BAUD RATE

REMOTE CONTROL

BAUD RATE

AND

REMOTE CONTROL

BAUD RATE

REMOTE CONTROL

0000

Indicates current baud rate. User must enter a baud rate for all on-line devices.

Use numeric keys to enter appropriate baud rate—2400, 4800, 9600.

This selection must match the baud rate of the companion modem (if used) and software program configuration. The default setting is 9600.

Confirms entry.

Returns user to Menu 10—Remote Control menu.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 59

2.7.11 Menu 11—Programming Mode

Menu 11 provides local or remote access to the programming function.

User enters a password to access the programming mode.

Note: Log into the local programming mode to edit the programming access code. The factory default access code is the number 0.

Note: Use Menu 11 to change the access code. Record the new number and give the access code to only authorized individuals.

Should the controller logic not accept the access code or if the new code number is lost, contact your local authorized distributor/dealer for password information.

Key

Entry Description Display

ENTER NO. 1--11

Note B: The user chooses one of three programming modes: local—using the controller keypad remote—using a PC off—no programming is permitted

Enter Yes to one mode to change the other two choices to No. Yes menus are highlighted in the following instructions.

Note: Use the generator set controller to initially set up remote programming.

Remote programming cannot be accessed from a PC unless the controller is first set for remote programming using Menu 11.

Input a menu number.

MENU NUMBER 11

PROGRAMMING MODE

Displays menu number.

Displays menu name. Choose from three programming modes—local, remote, or off. See Note B above. Press Menu Down

↓ key to access desired mode.

Local Programming

PROGRAM MODE

LOCAL?

PROGRAM MODE

LOCAL?

AND

PROGRAM MODE

LOCAL?

ENTER CODE

YES

Gives user the option for local programming mode.

Enter Yes to select local program mode. See Note B above.

Confirms entry.

Enter access code. The access code is a password.

Use numeric keys to enter access code (6 digits maximum).

LOCAL?

ENTER CODE

AND

LOCAL?

ENTER CODE

PROGRAM MODE

LOCAL?

YES

Confirms entry.

Returns user to Program Mode—Local? menu.

60 Section 2 Operation Local Programming Mode On TP-5829 8/04

Menu 11—Programming Mode, continued

Key

Entry Display

Remote Programming

PROGRAM MODE

REMOTE?

PROGRAM MODE

REMOTE?

AND

PROGRAM MODE

REMOTE?

YES

Description

Gives user the option for remote programming mode.

Enter Yes to select remote program mode. See Note B in

Section 2.7.11.

Confirms entry.

REMOTE?

ENTER CODE

REMOTE?

ENTER CODE

AND

REMOTE?

ENTER CODE

Enter access code. The access code is a password.

Use numeric keys to enter access code (6 digits maximum).

Confirms entry.

Returns user to Program Mode—Remote? menu.

PROGRAM MODE

REMOTE?

Programming Off

PROGRAM MODE

OFF?

PROGRAM MODE

OFF?

AND

PROGRAM MODE

OFF?

ENTER CODE

YES

Gives user the option for programming off mode.

Enter Yes to select programming off mode. See Note B in

Section 2.7.11.

Confirms entry.

Enter access code. The access code is a password.

Use numeric keys to enter access code (6 digits maximum).

OFF?

ENTER CODE

AND

OFF?

ENTER CODE

PROGRAM MODE

OFF?

YES

Confirms entry.

Returns user to Program Mode—Off? menu.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 61

Menu 11—Programming Mode, continued

Key

Entry Display Description

PROGRAM MODE

ACCESS

→

PROGRAM MODE ACCESS→C

HANGE CODE?

PROGRAM MODE ACCESS→C

HANGE CODE?

YES

AND

PROGRAM MODE ACCESS→

CHANGE CODE?

YES

PROGRAM MODE ACCESS→

ENTER OLD CODE

PROGRAM MODE ACCESS→

ENTER OLD CODE

AND

PROGRAM MODE ACCESS→

ENTER OLD CODE

PROGRAM MODE ACCESS→

ENTER NEW CODE

PROGRAM MODE ACCESS→

ENTER NEW CODE

AND

PROGRAM MODE ACCESS→

ENTER NEW CODE

PROGRAM MODE

ACCESS

→

PROGRAMMING MODE

Gives user option to change programming access code.

Allows user to change programming access code.

Note: User must be logged in the local programming mode to change the programming access code.

Enter Yes to change the programming access code.

Confirms entry.

Requires user to enter current access code.

Use numeric keys to enter access code (6 digits maximum).

Confirms entry.

Requires user to enter new access code.

Use numeric keys to enter new access code

(6 digits maximum).

Confirms entry.

Returns user to Program mode—Access menu.

Returns user to Menu 11—Programming Mode.

62 Section 2 Operation Local Programming Mode On TP-5829 8/04

2.7.12 Menu 20—Factory Setup

Menu 20 provides generator set model, spec, and serial numbers. The user can use this menu to identify the

(controller software code) version no. The factory setup menu information is locked by the manufacturer.

Menu 20—Factory Setup

Key

Entry Display Description

ENTER MENU NO. 1--11

Input a menu number.

MENU NUMBER 20

Press the Enter key.

FINAL ASSEMBLY

DATE DD/MM/YY

FINAL ASSEMBLY

CLOCK #

MODEL #

(26 CHARACTERS MAX)

SPEC

(16 CHARACTERS MAX)

SERIAL

Displays the final assembly date at the factory.

Displays the final assembly clock number at the factory.

Displays the generator set model number.

Displays the generator set specification number.

Displays the generator set serial number.

CONTROL #

Displays the controller serial number.

VERSION NO.

Displays the (controller software code) version no.

OIL SENDER RANGE

0--XXX PSI

COOLANT SENDER

XXXXXX

SETUP LOCKED?

→

YES

Displays the oil sender selection.

Displays the coolant sender selection.

Displays the setup locked by the manufacturer.

TP-5829 8/04 Local Programming Mode On Section 2 Operation 63

Notes

64 Section 2 Operation Local Programming Mode On TP-5829 8/04

Under normal operating conditions, the generator’s alternator requires no normal service.

Consult the prestart checklist in Section 2.1 for a list of routine checks.

3.1 Alternator Service

When operating the generator set under dusty or dirty conditions, use dry compressed air to blow dust out of the generator while the generator set is running. Direct the stream of air through openings in the generator set end bracket.

Section 3 Scheduled Maintenance

Disabling the generator set.

Accidental starting can cause severe injury or death.

Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the

OFF position. (2) Disconnect the power to the battery charger.

(3) Remove the battery cables, negative (--) lead first.

WARNING

3.2 Engine Service

Perform engine service at the intervals specified in the engine manufacturer’s service literature. Contact an authorized service distributor/dealer to obtain service literature.

Note: Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service.

WARNING

Hot engine and exhaust system.

Can cause severe injury or death.

Do not work on the generator set until it cools.

Servicing the exhaust system.

Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and exhaust system components become extremely hot during operation.

WARNING

Accidental starting.

Can cause severe injury or death.

Disconnect the battery cables before working on the generator set.

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

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

Hazardous voltage.

Moving rotor.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.

Replace guards, screens, and covers before operating the generator set.

TP-5829 8/04 Section 3 Scheduled Maintenance 65

3.3 Service Schedule

System—Component

Fuel

Day tank level

Flexible lines and connections

Fuel level switch

Main tank supply level

Solenoid valve operation

Transfer pump operation

Water in system, remove

Filter(s)

Gasoline supply

Fuel piping

Tank vents and return lines for obstructions

Lubrication

Oil level

Crankcase breather

Change oil

Replace filter(s)*

Cooling

Air cleaner to room/enclosure

Block heater operation

Coolant level

Flexible hoses and connectors

Water pump(s)

Fan and alternator belts

Coolant temperature protection level

Visually Inspect

Check

Action

Change

Clean

Test

Interval

Weekly

Quarterly

Six Months

Yearly

Weekly

Quarterly

50 Hours or Yearly

Lubricate fan bearings (1200--2000 kW)

Air ducts, louvers

Coolant

Heat exchanger

Louver motors and controls

Radiator exterior

Water supply to heat exchanger

Exhaust Line

Drain condensate trap

Leakage

Insulation, fire hazards

Flexible connector(s)

Excessive back pressure

Hangers and supports

Weekly

Monthly

Six Months

200 Hours or

Six Months

Yearly

Weekly

Quarterly

Six Months

Yearly

Yearly X

X Action

R Replace as necessary

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow this service schedule.

Some items may not pertain to specific generator sets.

* Service more frequently if operated in dusty areas.

[ Do not break manufacturer’s seals or internally inspect these devices.

66 Section 3 Scheduled Maintenance TP-5829 8/04

Visually Inspect

Action

Check Change Clean Test

DC Electrical System

Battery charger operation, charge rate

Battery electrolyte level

Battery specific gravity, charge state

Recharge after engine start

Remove corrosion, clean and dry battery and rack

Clean and tighten battery terminals

Tighten DC electrical connections

AC Electrical System

Controller lamp test

General Inspection

Circuit breakers, fuses

[

Wire abrasions where subject to motion

Safety and alarm operation

Tighten control and power wiring connections

Transfer switch main contacts

[

Voltage-sensing device/relay adjustment

[

Wire-cable insulation breakdown

Engine and Mounting

General inspection

Governor operation, lubricate moving parts

Air cleaner service

Choke, carburetor adjustment

Governor oil (mechanical gov. only)

Ignition components

Injector pump and injector flow rate, pressure, spray pattern

Valve clearance

Bolt torque

Remote Control System, etc.

Compartment condition

Remote control

Run generator set

Alternator

General inspection

Rotor and stator

Bearing condition

Exciter

Voltage regulator

Measure and record resistance readings of windings with insulation tester (Megger with SCR assembly or rectifier disconnected)

Blow dust out of alternator*

General Condition OF Equipment

Any condition of vibration, leakage, noise, temperature, or deterioration

Ensure that system is set for automatic operation

Interior of equipment room or outdoor weather housing

Monthly

Quarterly

Six Months

Weekly

Monthly

Quarterly

Six Months

Yearly

3 Years or 500 Hours

Weekly

Monthly

Six Months

Yearly

3 Years or 500 Hours

Weekly

Monthly

Weekly

Yearly

2 Years or 300 Hours

Weekly

X X

Weekly

X Action

R Replace as necessary

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow this service schedule.

Some items may not pertain to specific generator sets.

* Service more frequently if operated in dusty areas.

[ Do not break manufacturer’s seals or internally inspect these devices.

TP-5829 8/04 Section 3 Scheduled Maintenance 67

3.4 Alternator Bearing

Have an authorized service distributor/dealer perform alternatorservice.

3.4.1 20--300 kW Models

Replace the end bracket bearing every 10,000 hours of operation in standby and prime power applications.

Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage.

Replace the tolerance ring, if equipped, following end bracket is removed.

The sealed end bracket bearing requires no additional lubrication.

3.4.2 350--2000 kW Models with Single-

Bearing

Alternator

The alternator bearing requires lubrication at intervals specified in the generator set technical manual. Use

Chevron SRI or equivalent antifriction, high-quality grease with a lubrication temperature range of --30

° to

+175

° C (--22° to +350° F).

3.4.3 2000 kW Models with Two-Bearing

Alternator

Refer to the generator set technical manual for bearing maintenance information.

3.5 Gas/Gasoline Fuel Systems

This section describes fuel systems that are not covered in the engine operation manual or engine service manual.

3.5.1 Gaseous Fuel System Concept

The gaseous fuel system uses a fuel valve with a solenoid to control the fuel flow to the fuel regulator. The generator-mounted regulator reduces the fuel pressure as fuel passes to the carburetor. See Figure 3-1. The carburetor/mixer controls the ratio of fuel to air under varying load and speed conditions.

Because the carburetor receives fuel in a gaseous state, it does not have to vaporize the fuel. When switching from natural gas to LP gas or LP gas to natural gas, verify that the electronic governor maintains the rated engine speed

(1800 rpm at 60 Hz or 1500 rpm at 50 Hz). If the engine speed is incorrect, refer to generator service manual for the governor adjustment procedure.

1. Primary regulator (supplied by gas supplier or customer)

2. Pressure gauge

3. Solenoid valve

4. Secondary regulator

5. Carburetor

Figure 3-1 Fuel Regulator and Valve, Typical

TP-5750-3

3.5.2 LP Liquid Withdrawal Fuel System

Concept

With the LP liquid withdrawal fuel system, pressurized liquid LP fuel passes from the tank to a vaporizer. The vaporizer converts the liquid fuel to gas before sending it to the carburetor. The system also includes a fuel valve that shuts off the fuel flow when the engine stops.

Contact an authorized service distributor/dealer for availability.

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

By performing the fuel conversion, the 20, 30 (with

CSG-649 engine only), 50, 60, 70, 80, and 100 kW generator sets operate on LP gas or natural gas fuel.

The 35 and 45 kW models require different fuel kits when changing gas fuels. Consult your local generator distributor/dealer for additional information.

Fuel conversion may decrease generator set output and affect exhaust emissions. Consult your local generator distributor/dealer for additional information.

Fuel Conversion Procedure

To convert the generator set to operate with LP gas, remove the internal spring from the secondary regulator.

Install the spring to operate the generator set on natural gas.

Note: Not all fuel regulators require spring and retainer removal for fuel conversion. A hang tag on the fuel regulator identifies the conversion procedure.

68 Section 3 Scheduled Maintenance TP-5829 8/04

Use the following steps to remove the internal spring from the gas regulator:

1. Remove the retainer and spring.

Save the regulator spring and retainer for possible conversion back to natural gas.

2. Reinstall the retaining screw.

Use the following steps to convert the generator set to natural gas:

1. Remove the retaining screw from the regulator.

See Figure 3-2.

SB-527

1. Regulator

2. Spring

3. Retaining screw

4. Retainer

Figure 3-2 Regulator Spring and Retainer, Typical

2. Install the spring and retainer, and replace the retaining screw.

3. Use a manometer to check the fuel supply pressure on the carburetor side of the regulator.

4. With the generator set running at full load, rotate the spring retainer on the regulator to adjust the fuel supply pressure. The recommended fuel supply pressures are shown on the generator set spec sheet.

Use the lower pressure value if the generator set still provides good response and full power.

Lower-than-specified pressures may cause poor response to load changes or lack of power.

3.5.4 Fuel System Changeover Kits

Automatic Changeover

A changeover fuel system kit provides automatic changeover from natural gas to LP gas vapor or from

LP gas vapor to natural gas. The primary and backup fuels each have a secondary fuel regulator and a fuel valve. Contact an authorized service distributor/dealer for kit availability.

Typically, the primary fuel is natural gas; the backup fuel is LP gas vapor. When the generator set starts, the primary fuel valve opens and the backup fuel valve closes. The primary fuel line has a vacuum switch in series with a relay connected to the start/run circuit.

When the primary fuel pressure drops below 0.6 kPa

(1.4 oz./in.

) or 6.4 cm (2.5 in.) water column, a relay opens the backup fuel valve and closes the primary fuel valve. When the primary fuel pressure rises above

0.6 kPa (1.4 oz./in.

) or 6.4 cm (2.5 in.) water column, the generator set uses the primary fuel.

Manual Changeover

A manual changeover fuel system allows manual changeover from gasoline to natural gas or LP gas, or from natural gas or LP gas to gasoline. Typically, the combination system uses gas as the primary, preferred fuel and gasoline in emergencies. If the primary fuel is unavailable (an empty fuel tank or fuel supply disruption), the system uses gasoline.

A toggle switch on the generator set controls the fuel choice and energizes either a fuel solenoid and electric fuel pump for gasoline or a fuel valve for gas. Pull out the control cable for gasoline and push in the control cable for gas.

TP-5829 8/04 Section 3 Scheduled Maintenance 69

3.5.5 Carburetor Adjustment

Adjusting the carburetor changes the engine fuel mixture.

Routine carburetor adjustment is not necessary. However, if the carburetor is removed or tampered with, the carburetor may require adjustment to achieve optimum engine performance.

Some engines have sealed carburetors that are not adjustable.

Do not adjust the carburetor to compensate for other engine disorders. Before adjusting the carburetor, verify that the engine compression and the ignition system meet specifications. If the engine speed is incorrect, adjust the electronic governor to achieve 1800 rpm (at

60 Hz) or 1500 rpm (at 50 Hz). Adjust the carburetor if governor adjustment alone does not result in the desired engine speed.

Gasoline Models

Consult the engine operation manual or engine service manual for gasoline carburetor adjustment information.

Gaseous Models

Use the following procedure to adjust the carburetor.

1. Start the generator set and run it at approximately half load.

2. Adjust the engine fuel mixture screw (Figure 3-3) until the engine runs smoothly.

1. Fuel adjusting screw

2. Lean

3. Rich

Figure 3-3 Fuel Mixture Adjustment, Typical

TP-5750-3

3. Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels.

4. Stop the generator set.

3.5.6 Fuel System Maintenance

Gasoline Models

Clean or replace the fuel filter at the specified interval.

Service the filter more frequently if the engine runs roughly, because a clogged fuel filter can cause rough engine operation. Some models use a disposable inline fuel filter that must be replaced. Other models have a fuel pump with an integral fuel filter that requires cleaning at the specified interval.

Gaseous Models

Some models use a disposable inline fuel filter. Inspect and replace the fuel filter at the intervals shown in the service schedule.

3.6 Turbocharger Maintenance on

Ford-Powered Models

The oil recommendations, turbocharger oil priming, and turbocharger maintenance procedures are for

Ford-powered 30 (with LSG-423 engine), 80, and

100 kW models with turbochargers not described or explained in the engine operation manual.

Use the following turbocharger maintenance information for the above-listed models.

3.6.1 Oil Type Recommendations

The engine and generator manufacturers’ engine oil viscosity recommendations for engines used in generator applications differ from the recommendations for engines used in other applications. Use oil that has a minimum rating of (API) classification SH/CD, SG/CD,

SH/CC, or SG/CC to ensure long life and minimal engine wear. See Figure 3-4 for oil viscosity selection for the

Ford-powered models listed above.

For Air Temperatures

Consistently Above

°C (32°F)

--23

°C (--10°F)

Figure 3-4 Oil Viscosity Selection

Use Viscosity

20W50 or 10W40

10W40 or 10W50

70 Section 3 Scheduled Maintenance TP-5829 8/04

3.6.2 Turbocharger Oil Prime Procedure

After changing the engine lube oil, use the following procedure to prime the turbocharger bearing to prevent premature turbocharger bearing wear.

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the wire between the ignition coil and the distributor at the distributor terminal. Connect a jumper wire from the ignition coil lead to the engine block.

Note: Electronic Ignition Damage. Ground the ignition coil to the engine block to prevent electronic ignition system damage.

3. Place an oil-collection container under the oil drain line. Disconnect the turbocharger oil drain line at the engine connection.

4. Place the generator set master switch in the RUN position to crank the engine until fresh oil flows from the turbocharger oil drain line.

Note: Starter Damage. Do not crank the engine continuously for longer than 10 seconds.

Allow a 60-second cooldown period between cranking cycles to prevent starter motor and/or starter solenoid failure caused by overheating.

5. Place the generator set master switch in the

OFF/RESET position.

6. Reconnect the turbocharger oil drain line at the engine connection.

7. Remove the jumper wire and reconnect the ignition coil wire to the distributor.

8. Place the generator set master switch in the RUN position, run the generator set for a few minutes, and check for oil leaks at the turbocharger drain line connection. Stop the generator set.

9. Check the oil level. Add oil to bring the level up to the full mark. Consult the engine operation manual for oil capacity.

10. Wipe up spilled oil and dispose of rags in a fireproof container.

3.6.3 Turbocharger Maintenance

See Figure 3-5 for the turbocharger maintenance service schedule.

Service

Check for abnormal turbo rotor noise during operation

(e.g., high frequency pitch) and check for oil leakage at the turbocharger.

Check turbo rotor shaft for wear (end play and radial tolerances).

Overhaul turbocharger.*

500 Hours or 6 Months

1000

Hours

2000

Hours

Change lube oil.

Change lube oil filter.

Change air filter.

Refer to engine operation manual.

* Have service performed by an authorized distributor/dealer.

Figure 3-5 Turbocharger Maintenance Service

Schedule

3.7 Radiator Expansion Joint

Loosening—Initial Setup Only

Loosen the radiator expansion joint nuts on

1200--2000 kW generator sets that have radiators manufactured by Young Radiator Company. Expansion joints located on each side of the radiator permit differential thermal expansion of the radiator tank. The factory tightens the 12 expansion joint nuts before generator set shipment. Loosen the expansion joint nuts one full turn before running the generator set. See

Figure 3-6.

TP-5353-3

1. Air flow

2. Expansion joint nuts for rear tank, left side

3. Expansion joint nuts for front tank, left side

4. Top front of radiator

Figure 3-6 Expansion Joint Nuts, Top Left Side of

Radiator, Typical

TP-5829 8/04 Section 3 Scheduled Maintenance 71

3.8 Fan Bearing Lubrication

The following procedure applies to 1200--2000 kW generator sets with DDC engines. Lubricate the radiator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage.

Lubricate the bearings every 200 hours of operation when the generator set runs in ambient temperatures below 29

°C

(85

°F) or when the generator set runs in a dusty or humid environment.

Lubricate the fan shaft and idler shaft bearings with a lithium-complex base, multi-purpose grease with antirust, antifoam, extreme-pressure additives, and a minimum dropping point of 204

°C (400°F). Use Mobil

Mobilith AW2 NLGI Grade 2 or equivalent.

Lubrication and Drive Belt Tension Adjustment

Procedure

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the generator set engine starting battery(ies), negative (--) lead first, and disconnect power to the battery charger.

3. Remove the belt guards to expose the fan shaft and idler shaft bearings.

4. Use a grease gun to inject grease into the two bearings on the fan shaft block and the two bearings on the idler shaft block until a 3--6 mm

(0.13--0.25 in.) grease column shows at the bearing pressure relief port. See Figure 3-8.

Note: The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage from over lubrication.

5. Remove excess grease from the bearing pressure relief ports.

6. Inspect the fan drive belt and replace if it is damaged or worn. Check the fan belt tension using a poly

V-belt tension gauge and adjust the tension, if necessary. See Figure 3-7.

Generator Set

Model

New Belt,

N (lbf.)

Used Belt*,

N (lbf.)

1200-2000 kW

2450--2890

(550--650)

1650--1910

(370--430)

* A belt is considered used after 50 hours of service.

Figure 3-7 Fan Belt Tension

7. Reinstall the belt guards using the original hardware.

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

9. Test run the generator set for a few minutes and listen for belt noise (squeal) indicating a slipping belt. Stop the generator set. If belt slippage occurs after the belt tension procedure, clean the pulley surfaces and repeat the belt tension procedure. If slippage continues, replace the fan belt.

TP-5353-3

1. Grease fittings

2. Pressure relief port

3. Radiator assembly

4. Idler shaft grease fittings

5. Fan shaft grease fittings

Figure 3-8 Radiator Fan Bearings and Pressure

Relief Ports, Typical

72 Section 3 Scheduled Maintenance TP-5829 8/04

3.9 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.

Battery gases.

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

To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging.

Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles.

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

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

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery.

Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup.

Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

TP-5829 8/04 Section 3 Scheduled Maintenance 73

Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a12-volt or 24-volt engine electrical system.

Consult the generator set nameplate for engine electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. Wiring diagrams provide battery connection information. See Figure 3-9, Figure 3-10, and Figure 3-11 for typical battery connections, including multiple battery configurations.

1 2

2 1 1 2

1 2

EZ-273000-J

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-9 12-Volt Engine Electrical System with

Single Starter Motor Typical Battery

Connections

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-10 24-Volt Engine Electrical System with

Single Starter Motor Typical Battery

Connections

1 2 3 4

KW-272000-B

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

3. To positive (+) terminal on second starter solenoid.

4. To ground (--) terminal on or near second starter motor.

Figure 3-11 24-Volt Engine Electrical System with

Dual Starter Motors Typical Battery

Connections

74 Section 3 Scheduled Maintenance TP-5829 8/04

3.9.1 Cleaning

Clean the battery and cables and tighten battery terminals according to the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight.

To remove corrosion, disconnect the cables from the battery and remove the corrosion with a wire brush.

Clean the battery and cables with a solution of baking soda and water. Do not allow the cleaning solution to enter battery cells. Flush the battery and cables with clean water and wipe the battery with a dry cloth.

After reconnecting the battery cables, coat the terminals with petroleum jelly, silicon grease, or other nonconductive grease.

3.9.2 Electrolyte Level Inspection

Check the electrolyte level and specific gravity of batteries that have filler caps.

Maintenance-free batteries do not require electrolyte level checking or specific gravity testing.

Check the electrolyte level before each startup.

Remove the filler caps and verify that the electrolyte level reaches the bottom of each filler hole.

See

Figure 3-12. Refill as necessary with distilled water or clean tap water. Do not add fresh electrolyte. Tighten the filler caps.

After adding water during freezing temperatures, run the generator set 20--30 minutes to mix the electrolyte and the water to prevent battery damage from freezing.

1. Filler caps

2. Electrolyte level

Figure 3-12 Battery Electrolyte Level Inspection

1-046

3.9.3 Specific Gravity Check

Note: Some battery testers have four or five beads in a test tube. Draw electrolyte into the tube as with the battery hydrometer described in this section.

Use the tester manufacturer’s instructions.

Figure 3-13 shows typical test results.

Number of Floating Beads

1 or 2

Battery Condition

Overcharged

Fully charged

A good charge

A low charge

A dead battery

Figure 3-13 Bead-Type Test Interpretation

TP-5829 8/04 Section 3 Scheduled Maintenance 75

71.1

160

26.7

21.1

15.6

10 50

4.4

-- 1.1

-- 6.7

-- 12.2

65.6

150

60.0

140

54.4

130

48.9

120

43.3

110

37.8

100

32.2

Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps.

Holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer.

If the hydrometer used does not have a correction table, consult Figure 3-14. Determine the specific gravity and electrolyte temperature of the battery cells. Locate the temperature in Figure 3-14 and correct the specific gravity by the amount shown.

The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 26.7

_C (80_F). Maintain the specific gravities between cells within

±0.01 of each other.

Charge the battery if the specific gravity is below 1.215

at an electrolyte temperature of 26.7

_C (80_F).

Correction

-- .016

-- .018

-- .020

-- .022

-- .024

-- .026

-- .028

-- .002

-- .004

--. 006

-- .008

-- .010

-- .012

-- .014

+ .016

+ .014

+ .012

+ .010

+ .008

+ .006

+ .004

+ .002

+ .032

+ .030

+ .028

+ .026

+ .024

+ .022

+ .020

+ .018

Example No. 1

Temperature below 26.7

Hydrometer Reading 1.250

Acid Temperature --6.7

Subtract .024 Specific Gravity

Corrected Specific Gravity is 1.226

1.250 -- .024 = 1.226

Example No. 2

Temperature above 26.7

Hydrometer Reading 1.235

Acid Temperature 37.8

C (80

C (20

C (80

C (100

Add .008 Specific Gravity

Corrected Specific Gravity is

1.243

1.235 + .008 = 1.243

3.9.4 Charging

Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application.

The engine battery-charging alternator charges the battery only while the generator set is running.

Note: If the generator set is in a temporary prime power application in which the generator set has periods of inactivity, the controller circuitry may drain the battery. If there is no power source for a battery charger, place the controller in the prime power mode, if equipped, or disconnect the battery from the generator set.

3.10 Detroit Diesel Engine Control

(DDEC) System

Some generator sets equipped with Detroit Diesel engines use a DDEC system. Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine.

Use the following data for informational purposes only.

Consult the engine literature for complete information regarding DDEC operation and troubleshooting.

Contact an authorized service distributor/dealer for service or diagnostic equipment.

3.10.1 DDEC Features

The DDEC system optimizes control of critical engine functions and protects against serious engine damage resulting from conditions such as the following:

Low coolant level

Low coolant pressure

High coolant temperature

Low oil pressure

High oil temperature

The major components of the DDEC system include the engine electronic control module (ECM), engine sensors, and control box located in the generator set junction box.

The temperature correction amounts to about .004 (4 points) of specific gravity for each 5.5

°C (10°F) change in temperature.

1-787

Figure 3-14 Specific Gravity Temperature Correction

76 Section 3 Scheduled Maintenance TP-5829 8/04

3.10.2 DDEC Engine Diagnostics

The DDEC engine protection system monitors engine sensors and electronic components and recognizes system malfunctions.

Critical faults light the check engine (CEL) and stop engine (SEL) lamps on the control box.

The ECM memory software logs malfunction codes.

Consult the engine operation manual or engine service manual to identify the stored failure code. See Figure 3-15 for DDEC control box features.

CHECK ENGINE STOP ENGINE

DIAGNOSTIC

CODE

DIAGNOSTIC

DATA

READER

OFF/RESET

First occurrence of each diagnostic code in engine operating hours.

Last occurrence of each diagnostic code in engine operating hours.

Total time in seconds that the diagnostic code was active.

3.11 Deutz Engine Control System

Some generator sets equipped with Deutz engines use an engine control system. Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine.

Use the following data for general informational purposes only.

See the Engine Service Manual for complete information regarding operation and troubleshooting.

Contact an authorized service distributor/dealer for service or diagnostic equipment.

The Deutz engine control is an advanced-technology, electronic engine control system. The system optimizes control of critical engine functions and provides protection against serious engine damage.

The major components include the engine electronic control module (ECM), engine sensors, and control box located in the generator set junction box.

See

Figure 3-16 for the Deutz control box features.

A-343090-B

Figure 3-15 DDEC Control Box

Access the stored codes in one of three ways:

Place the switch in the DIAGNOSTIC CODE position.

The CEL or SEL flashes to identify the failure.

Use a hand-held diagnostic data reader (DDR).

Place the switch in the DIAGNOSTIC DATA READER position. Plug the DDR into the control box. The DDR displays the stored failure codes.

Use a personal computer software package with a translator to access stored codes.

Follow the instructions provided with the software.

Code Types

Active code. A code flashing on the SEL lamp indicates a fault currently exists.

Inactive code.

A code flashing on the CEL lamp indicates a previous fault occurrence.

The ECM memory stores inactive codes with time/date identification and the following information:

Figure 3-16 Deutz Control Box

A-364162-B

TP-5829 8/04 Section 3 Scheduled Maintenance 77

3.12 Storage Procedure

Perform the following storage procedure before taking a generator set out of service for three months or longer.

Follow the engine manufacturer’s recommendations, if available, for fuel system and internal engine component storage.

3.12.1 Lubricating System

Prepare the engine lubricating system for storage as follows:

1. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature.

2. Stop the generator set.

3. With the engine still warm, drain the oil from the crankcase.

4. Remove and replace the oil filter.

5. Refill the crankcase with oil suited to the climate.

6. Run the generator set for two minutes to distribute the clean oil.

7. Stop the generator set.

8. Check the oil level and adjust, if needed.

3.12.2 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using a coolant tester.

2. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines included in the engine operation manual.

3. Run the generator set for 30 minutes to redistribute added coolant.

3.12.3 Fuel System

Prepare the fuel system for storage as follows:

Gasoline-Fueled Engines

1. Add stabilizer to the fuel system.

Follow the manufacturer’s recommended procedure.

2. Run the generator set for 15 minutes to ensure that the stabilized fuel reaches the carburetor.

3. Place the generator set master switch in the

OFF/RESET position.

4. Close the fuel valve.

Gas-Fueled Engines

1. Start the generator set.

2. With the generator set running, shut off the gas supply.

3. Run the generator set until the engine stops.

4. Place the generator set master switch in the

OFF/RESET position.

3.12.4 Internal Engine Components

(Gas/Gasoline-Fueled Engines)

If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows:

1. While the engine is running, spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops.

2. Place the generator set master switch in the

OFF/RESET position.

If a fogging agent is not available perform the following:

1. Remove the spark plugs.

2. Pour 15 cc (0.5 oz.) of engine oil into each spark plug hole.

Ignition System Damage. Refer to the engine operation manual for ignition system precautions before cranking the engine while the spark plug wires are disconnected.

3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders.

4. Reinstall the spark plugs and torque them to specifications.

78 Section 3 Scheduled Maintenance TP-5829 8/04

3.12.5 Exterior

1. Clean the exterior surface of the generator set.

2. Seal all engine openings except for the air intake with nonabsorbent adhesive tape.

3. To prevent impurities from entering the air intake and to allow moisture to escape from the engine, secure a cloth over the air intake.

4. Mask electrical connections.

5. Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion.

3.12.6 Battery

Perform battery storage after all other storage procedures.

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the battery(ies), negative (--) lead first.

3. Clean the battery. Refer to Section 3.9.1 for the battery cleaning procedure.

4. Place the battery in a cool, dry location.

5. Connect the battery to a float/equalize battery charger or charge it monthly with a trickle battery charger.

Refer to the battery charger manufacturer’s recommendations.

Maintain a full charge to extend battery life.

TP-5829 8/04 Section 3 Scheduled Maintenance 79

Notes

80 Section 3 Scheduled Maintenance TP-5829 8/04

Section 4 General Troubleshooting

This section contains generator set troubleshooting, diagnostic, and repair information.

Use the following chart to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or an open circuit breaker. The chart includes a list of common problems, possible causes of the problem, recommended corrective actions, and references to detailed information or repair procedures.

Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment.

Problem

C t ll di l i

Unit will not crank t t i

Possible Cause

Five-minute time delay for inactive use

Prime power mode

Weak or dead battery

Reversed or poor battery connections

Corrective Action

Press any key

Place prime power switch to Controller On position

Recharge or replace; check charger operation

Check connections

Fuse blown in controller

Controller malfunction

Weak or dead battery

Reversed or poor battery connections

Fuse blown in controller

Emergency stop switch activated (local or remote)

Fault shutdown

Generator set master switch in OFF position

(attempting startup from remote switch)

Improper fuel

Replace fuse

Contact an authorized service distributor

Recharge or replace; check charger operation

Check connections

Replace fuse

See Resetting Emergency Stop Switches

Correct fault and reset controller

Move generator set master switch to AUTO position

Replace fuel

No fuel

Air in fuel system (diesel models)

Add fuel; check fuel control circuit

Bleed air from system

Defective ignition system (gas/gasoline models) Check ignition system (spark plugs, spark plug wires, etc.)

Air cleaner clogged Clean or replace filter element

Overcrank shutdown

Line circuit breaker or safeguard breaker (if equipped) in the OFF position

Generator set problem such as defective voltage regulator or other internal fault

Unit overloaded

Engine speed too low

Faulty voltage rheostat or voltage regulator

Reset; if overcrank fault reoccurs, check DDEC engine controls (if so equipped).

See Section 3, Scheduled Maintenance, Detroit

Diesel Engine Control (DDEC) System and/or contact an authorized service distributor

Return circuit breaker to the ON position

Contact an authorized service distributor

Reduce load

Contact an authorized service distributor

TP-5829 8/04 Section 4 General Troubleshooting 81

Problem

Unit stops suddenly

Possible Cause

Low oil pressure shutdown

High temperature shutdown

Low coolant level shutdown

Out of fuel

Overcrank shutdown

Fuse blown in controller

Engine malfunction

Overspeed shutdown

High oil temperature shutdown

Overvoltage shutdown

Generator set master switch in OFF/RESET position

Emergency stop switch activated (local or remote)

Corrective Action

Check oil level (if low, check for leaks)

Check for cooling air restrictions or poor belt tension

Check coolant level (if low, check for leaks); see Safety Precautions and Instructions Section

Add fuel

Reset; if overcrank fault reoccurs, check DDEC engine controls (if so equipped).

See Section 3, Scheduled Maintenance, Detroit

Diesel Engine Control (DDEC) System and/or contact an authorized service distributor

Replace fuse; if fuse blows again contact an authorized service distributor

Contact an authorized service distributor

Reset; if unit overspeeds, contact an authorized service distributor

Check oil level and type. If shutdown reoccurs, contact an authorized service distributor

Contact an authorized service distributor

Move switch to RUN or AUTO position

See Resetting Emergency Stop Switches

82 Section 4 General Troubleshooting TP-5829 8/04

Section 5 Generator Set Reconnection

5.1 Voltage Reconnection

Introduction

Use the following voltage reconnection procedure to change the voltage of 10- and 12-lead generator sets.

Consult the generator set service manual for frequency and governor adjustment information.

Note: Electronic engine controls prevent generator set frequency conversion on some models. Refer to the respective generator set spec sheet or contact your authorized distributor/dealer for applicable models.

Refer to Section 5.2, Voltage Reconnection Procedure, and the connection schematics.

Follow the safety precautions at the front of this manual and in the procedure text and observe National Electrical Code

(NEC) guidelines.

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/ dealer

NOTICE

This generator set has been rewired from its nameplate voltage to

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

246242

Note: Equipment damage.

Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the desired line voltage.

Hazardous voltage.

Moving rotor.

Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures are in place.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present.

Open the main circuit breakers of all power sources before servicing the equipment.

Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Short circuits.

Hazardous voltage/current can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage.

Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

TP-5829 8/04 Section 5 Generator Set Reconnection 83

5.2 Voltage Reconnection

Procedure

1. Place the generator set master switch in the

OFF/RESET position.

2. Disconnect the generator set engine starting battery, negative (--) lead first. Disconnect power to the battery charger (if equipped).

3. Use Figure 5-2, Figure 5-3, Figure 5-4, or

Figure 5-5 to determine the generator set voltage configuration.

Note the original voltage and reconnect as needed. Route leads through current transformers (CTs) and connect them according to the diagram for desired phase and voltage.

Note: Position the current transformers with the dot or HI side CT marking toward the generator set.

Note: Only generator sets equipped with AC meter controllers and/or safeguard circuit breakers require CTs.

4. Reconnect battery, negative lead last.

5. Go to Menu 11—Programming Mode and access

Program Mode—Local.

See Section 2.7, Local

Programming Mode On, Section 2.7.11, Menu 11—

Programming Mode, for the complete procedure.

6. Go to Menu 6—Generator System and update the voltage information.

See Section 2.7, Local

Programming Mode On, Section 2.7.6, Menu 6—

Generator System for complete procedure.

7. Go to Menu 9—Calibration and perform the calibration procedure.

Section 2.7, Local

Programming Mode On, Section 2.7.9, Menu 9—

Calibration for complete procedure.

8. Move the generator set master switch to the RUN position to start the generator set.

9. Check voltage display for selected voltage. See

Section 2.7.1, Menu 1—Generator Output, for access to voltage data.

10. Stop the generator set after completing voltage adjustment. Replace controller cover.

1. Voltage adjustment

Figure 5-1 Voltage Adjustment

TP-5829-5

84 Section 5 Generator Set Reconnection TP-5829 8/04

Figure 5-2 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5857-B

TP-5829 8/04 Section 5 Generator Set Reconnection 85

Reconnection Notes

Note: Position the current transformers with the dot or HI side

CT mark toward the generator set. Some generator sets have no current transformers.

Note: Phase Rotation: A = L1, B = L2, and C = L3.

Note: All 12-lead generator sets are reconnectable. The

6-lead, 600-volt generator set is not reconnectable. Some specially wound stators made for a single voltage are also not reconnectable.

Note: (600-volt models only) Use 1 turn of the output lead through the current transformer on 6-lead, 600-volt stators.

Some stators may have two turns of the output lead through the current transformer. Continue using the original factory two-turn current transformer wiring system.

ADV-5875A-F

Figure 5-3 Generator Set Reconnections, 20--300 kW Permanent Field Alternators and

20--60 kW Wound Field Alternators

86 Section 5 Generator Set Reconnection TP-5829 8/04

Reconnection Notes

Note: Position the current transformers with the dot or HI side

CT mark toward the generator set. Some generator sets have no current transformers.

Note: Phase Rotation: A = L1, B = L2, and C = L3.

Note: All 12-lead generator sets are reconnectable. The

6-lead, 600-volt generator set is not reconnectable. Some specially wound stators made for a single voltage are also not reconnectable.

Note: (600-volt models only) Use 1 turn of the output lead through the current transformer on 6-lead, 600-volt stators.

Some stators may have two turns of the output lead through the current transformer. Continue using the original factory two-turn current transformer wiring system.

ADV-5875B-F

Figure 5-4 Generator Set Reconnections, 60--300 kW Wound Field Alternators

TP-5829 8/04 Section 5 Generator Set Reconnection 87

See Note A below before making delta connections.

Reconnection Notes

Note: The factory connects leads T10, T11, and T12 together and labels this connection as T0 on 10-lead generators.

Note: Position the current transformers with the dot or HI side

CT mark toward the generator set. Some generator sets have no current transformers.

Note: Phase Rotation: A = L1, B = L2, and C = L3.

Note: All 10- and 12-lead generator sets are reconnectable.

The 4-lead generator set is not reconnectable.

Some specially wound stators made for a single voltage are also not reconnectable.

Note A: Use the delta connection shown in this illustration to ensure correct phase sensing. Do not use the configuration shown in the alternator technical manual.

ADV-5875C-F

Figure 5-5 Generator Set Reconnections, 350--2000 kW Models

88 Section 5 Generator Set Reconnection TP-5829 8/04

Section 6 Accessories

6.1 Accessories

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 shipped-loose accessories. See the matrix in Figure 6-1 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 illustrates several accessories available at the time of print of this publication. Accessory kits generally include installation instructions.

See the wiring diagrams manual for electrical connections not shown in this section. See the installation instructions supplied with the kit for information on kit mounting location.

The instruction provided with the accessory kit supersedes these instructions where there are differences.

In general, run AC and DC wiring in separate conduit.

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

Kit Description

Audiovisual Alarm

Common Failure Relay (Terminal 32A)

Controller (Customer) Connection

Engine Prealarm (prealarm low oil pressure, prealarm high water temperature, and low water temperature) Some kits used on gaseous-fueled models include the low fuel pressure switch.

Float/Equalize Battery Charger (with alarms)

Prime Power Switch

Remote Annunciator (16-light panel)

Remote Emergency Stop

Remote Speed Adjustment Potentiometer (requires electronic governor)

Run Relay

Single-Relay Dry Contact

Ten-Relay Dry Contact

Voltage Adjustment (with digital voltage regulator)

Remote Reset Feature

Kit Part No.

PA-292856

PA-347274

PA-328911 or PA-347428

Multiple kits based on engine model number and generator set model number.

PAD-292863 (12 volt) or

PAD-292865 (24 volt)

PA-354395

PA-293991

PA-293906

PA-273768

PA-273743 (12 volt) or

PA-273744 (24 volt)

PA-273912

PA-273913

No kit required. Use customer-supplied leads.

Figure 6-1 Optional Accessories for Digital Controller

Installation Instruction

TT-639

TT-1068

TT-1070

Multiple TTs

TT-680

TT-1155

TT-1023

TT-940

TT-774

TT-700

TT-722

TT-723

See Accessory Wiring

Diagram 354246

See Accessory,

Section 6.1.9

TP-5829 8/04 Section 6 Accessories 89

6.1.1 Audiovisual Alarm Kit

An audiovisual alarm warns the operator at a remote location of fault shutdowns and prealarm conditions.

Audiovisual alarms include alarm horn, alarm silence switch, and common fault lamp. See Figure 6-2 and

Figure 6-4.

See Section 6.2, Accessory and Prime

Power Terminal Strip Connections, for terminal identification.

Note: Use the audiovisual alarm with a dry contact kit.

6.1.2 Common Failure Relay Kit

The common failure relay kit provides one set of contacts to trigger customer-provided warning devices if a fault occurs. The common failure relay faults are user defined with up to 44 selections available.

See

Section 2, Operation, Menu 5—User Defined Functions for faults available for this function. The factory default settings are:

Emergency Stop

High Engine Temperature

Low Oil Pressure

Overcrank

Overspeed

Connect up to three defined common fault relay kits to the controller output. See Figure 6-3 and Figure 6-5.

See Section 6.2, Accessory and Prime Power Terminal

Strip Connections, for terminal identification.

Front View

Figure 6-2 Audiovisual Alarm

Side View

A-292887

A-273945

Figure 6-3 Common Failure Relay Kit

Figure 6-4 Audiovisual Alarm Connections

90 Section 6 Accessories

354246A-

TP-5829 8/04

354246A-

Figure 6-5 Common Failure Relay Kit Connections

6.1.3 Controller (Customer) Connection

Kit

The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip. The kit uses a 165 cm (65 in.) wiring harness to link the controller terminal strip(s) with a remote terminal strip.

With the exception of a few terminals, the remote terminal strip has the same terminals as in the controller. Connect all accessories

(except the emergency stop kit) to the connection kit terminal strip.

See Figure 6-6.

See Section 6.2,

Accessory and Prime Power Terminal Strip

Connections, for terminal identification.

Figure 6-6 Controller (Customer) Connection Kit

TP-5829 8/04

354246A-

Section 6 Accessories 91

6.1.4 Engine Prealarm Kit

The engine prealarm kit provides engine switches for prealarm low oil pressure, prealarm high water temperature, and low water temperature.

Kit components and hardware vary with engine model.

Some kits for gaseous-fueled models include a low fuel pressure switch. The low fuel pressure switch connects to the same terminals as the low fuel level switch on diesel- or gasoline-fueled models. See Figure 6-7. See

Section 6.2, Accessory and Prime Power Terminal Strip

Connections, for terminal identification.

Note: The main tank or the transfer/day tank includes the low fuel level switch. The fuel tank supplier typically provides the low fuel level switch. The engine prealarm kit does not include the low fuel level switch although this section illustrates the electrical connection.

LOW FUEL PRESSURE SWITCH

LOW FUEL LEVEL SWITCH

CONNECTION

354246A-

P21 CONNECTOR IN CONTROLLER

ENGINE WIRING HARNESS

Figure 6-7 Engine Prealarm Kit Connections, Typical

92 Section 6 Accessories

347940/A-B

TP-5829 8/04

6.1.5 Float/Equalize Battery Charger Kit with Alarm Option

The float/equalize battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects to the controller for fault detection. Battery chargers for 12 or 24 volt models are available as a generator set accessory. See Figure 6-8 and Figure 6-9. See Section 6.2, Accessory and Prime

Power Terminal Strip Connections, for terminal identification.

EXPLOSION. Battery gases can cause explosion and severe injury or death.

Remove AC power from charger before connecting or disconnecting to battery terminals.

Figure 6-8 Float/Equalize Battery Charger

CHARGER MALFUNCTION

G6-15

LV HV CM

BATTERY CHARGER

ALARM TERMINAL STRIP

TT-680

Figure 6-9 Float/Equalize Battery Charger Connections

TP-5829 8/04

354246A-

Section 6 Accessories 93

6.1.6 Prime Power Switch Kit

The prime power switch kit prevents battery drain during generator set non-operation periods and without battery charging. See Figure 6-10.

PRIME POWER SWITCH

SWITCH SHOWN IN PRIME

POWER MODE

(CONTACTS CLOSED)

Figure 6-10 Prime Power Switch Connections

354246A-

Stop the generator set using the stopping procedures in

Section 2.3.2, Stopping, before placing the generator set in the prime power mode. Move the prime power switch located on the back of the controller to the

CONTROLLER OFF position. The controller including the digital display, LEDs, and alarm horn does not function when the generator set is in the prime power mode.

Move the prime power switch located on the back of the controller to the CONTROLLER ON position and reset the controller time and date before attempting to start the generator set.

See Section 6.2, Accessory and Prime Power Terminal

Strip Connections, for terminal identification.

6.1.7 Remote Annunciator Kit

A remote annunciator monitors the generator set’s condition from a location remote of the generator set.

See Figure 6-11. Remote annunciator includes alarm horn, alarm silence switch, lamp test, and lamp indicators similar to the digital controller, plus the following:

Line Power. Lamp illuminates to indicate power source is commercial utility.

Generator Power. Lamp illuminates to indicate power source is generator set.

Remote Annunciator 14-Relay Dry Contact Box

42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11

INPUT CONTACT RATINGS: 10A @120VAC RES. LOAD

10A @28VDC MAX.

K12 K13 K14

PCB ASSY A--320639

LOT NO.

C NO

C NO C NO

K11

C NO C NO C NO

K14

42B

FBA--1

A-258782

Figure 6-11 Remote Annunciator with 14-Relay Dry Contact Kit

A-293983

94 Section 6 Accessories TP-5829 8/04

354246A-

354246B-

Figure 6-12 Remote Annunciator with 14-Relay Dry Contact Kit Connections

TP-5829 8/04 Section 6 Accessories 95

6.1.8 Remote Emergency Stop Kit

The emergency stop kit allows immediate shutdown of the generator set from a remote location.

See

Figure 6-13 and Figure 6-14. If the emergency stop switch activates, the EMERGENCY STOP lamp lights and the unit shuts down. Before attempting to restart the generator set, reset the emergency stop switch (by replacing glass piece) and reset the generator set by placing the master switch in the OFF/RESET position.

Use the single glass piece located inside the switch for replacement and order additional glass pieces as service parts. Reset the engine air damper switch, if equipped, on 200--2000 kW models with 2-cycle Detroit

Diesel engines.

See Section 2.3.3, Resetting

Emergency Stop Switch. See Section 6.2, Accessory and Prime Power Terminal Strip Connections, for terminal identifications.

Figure 6-13 Emergency Stop Kit

A-222654

TP-5352-1

354246A-

Figure 6-14 Remote Emergency Stop Kit Connections

96 Section 6 Accessories TP-5829 8/04

6.1.9 Remote Reset Feature

The remote reset switch provides generator set resetting after a fault shutdown at a remote location.

See Figure 6-15.

Press and hold the switch for

2--3 seconds and release.

Switch Rating

125 volts AC maximum

15 amps minimum

Wiring Recommendation

Gauge mm (ft.)

18--20

30.5 (100)

153 (500)

305 (1000)

REMOTE RESET SWITCH

CONTACTS NORMALLY OPEN

MOMENTARY CLOSED TO

ACTIVATE

≈

6.1.10 Remote Speed Adjustment

Potentiometer Kit

The remote speed adjustment potentiometer kit provides controller-mounted engine speed adjustment.

The speed adjustment range is approximately

±5%.

Some applications locate this potentiometer with the switchgear. This kit requires an electronic governor on the generator set. See Figure 6-16. See Section 6.2,

Accessory and Prime Power Terminal Strip

Connections, for terminal identifications.

Figure 6-15 Remote Reset Switch Connections

354246A-

BR-273000-C

1. Governor control unit

2. Actuator

3. Remote speed potentiometer

4. Mag pickup

5. Optional remote speed potentiometer

Figure 6-16 Remote Speed Adjustment

Potentiometer Connection, Typical

TP-5829 8/04 Section 6 Accessories 97

6.1.11 Run Relay Kit

The run relay kit energizes only when the generator set runs. Typically the run relay kit controls air intake and/or radiator louvers or uses the kit for alarms and other signaling devices. See Figure 6-17 and Figure 6-18.

6.1.12 Single-Relay Dry Contact Kit

The single-relay dry contact kit uses one set of contacts to trigger customer-provided warning devices when a fault condition occurs. Any controller fault output (from

TB1 terminal strip) can connect to the single-relay kit.

A total of three dry contact kits may connect to a single controller output. See Figure 6-19 and Figure 6-20. See

Section 6.2, Accessory and Prime Power Terminal Strip

Connections, for terminal identifications.

Figure 6-18 Run Relay Connections

354246A-

Figure 6-17 Run Relay Kit

273705

Figure 6-19 Single-Relay Dry Contact Kit

A-273945

Figure 6-20 Single-Relay Dry Contact Kit Connections

98 Section 6 Accessories

354246A-

TP-5829 8/04

6.1.13 Ten-Relay Dry Contact Kit

The ten-relay dry contact kit allows monitoring of the standby system and/or the ability to activate accessories such as derangement panels.

The kit includes ten sets of relay contacts for connection of customer-provided devices to desired generator functions.

Connect warning devices (lamps and/or audible alarms) and other accessories to the controller outputs listed below. Connect a total of three dry contact kits to a controller output. Refer to Figure 6-21 for an internal view of the contact kit. See Figure 6-22 for electrical connections.

Typical contact kit output connections include the following:

Overspeed

Overcrank

High Engine Temperature

Low Oil Pressure

Low Water Temperature

Low Battery Voltage

Air Damper (if equipped)

Prealarm High Engine Temperature

Prealarm Low Oil Pressure

Emergency Stop

See Section 6.2, Accessory and Prime Power Terminal

Strip Connections, for terminal identifications.

A-273936

Figure 6-21 Ten-Relay Dry Contact Kit

Figure 6-22 Ten-Relay Dry Contact Kit Connections

TP-5829 8/04

354246A-/354246B-

Section 6 Accessories 99

6.1.14 Voltage Adjustment Feature with

Digital Voltage Regulator

The voltage adjustment feature provides remote fine adjustment of

±10% of generator output voltage.

Generator sets 350--2000 kW use digital voltage regulators.

Connect the voltage adjustment feature using customer-supplied 18 ga. leads between the digital voltage regulator and the digital controller. See

Figure 6-23. See Section 6.2, Accessory and Prime

Power Terminal Strip Connections, for terminal identifications.

CTA1

CTA2

CTA1

CTA2

VOLTAGE

REGULATOR

PMG

F---

F+

GND

52J

52K

52L

52M

CTB2

CTB1

CUSTOMER-SUPPLIED

18 GA. WIRING

Figure 6-23 Voltage Adjustment with Digital Voltage Regulator Connections

100 Section 6 Accessories

A-273936

TP-5829 8/04

6.2 Accessory and Prime Power

Terminal Strip Connections

The digital controller contains circuit boards equipped with terminal strip(s) for easy connection of generator set accessories. Do not directly connect accessories to the controller terminal strip. Connect accessories to either a controller connection kit or a dry contact kit.

Connect alarms, battery chargers, remote switches, and other accessories to the dry contact kit relay(s) using 18- or 20-gauge stranded wire up to 305 m

(1000 ft.).

For specific information on accessory connections, refer to the accessory wiring diagrams in the Wiring Diagram

Manual and the instruction sheet accompanying the kit.

See Figure 6-24 through Figure 6-28.

TOP OF CONTROLLER BACK PANEL

A-347946A-D/ADV-6130B-

1. TB1 terminal strip 2. TB2 terminal strip 3. TB3 terminal strip 4. TB4 terminal strip

Figure 6-24 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)

TP-5829 8/04 Section 6 Accessories 101

Terminal Description

1 Engine ground (--)

Engine ground (--)

Panel lamp output

Relay driver output (RDO)—10

Relay driver output (RDO)—9

Relay driver output (RDO)—7

Relay driver output (RDO)—5

Not in auto relay output (80)

Overcrank relay output (12)

Low battery voltage relay output

Low coolant temperature relay output (35)

Low oil pressure relay output (38)

High coolant temperature relay output (36)

Low oil pressure warning relay output (41)

High coolant temperature warning relay output

(40)

42A battery voltage (+)—accessory power supply

Digital voltage regulator (DVR) adjustment down

Digital voltage regulator (DVR) adjustment common

Digital voltage regulator (DVR) adjustment up

Relay driver output (RDO)—8

Relay driver output (RDO)—6

Relay driver output (RDO)—4

Relay driver output (RDO)—3

Relay driver output (RDO)—2

Relay driver output (RDO)—1

System ready relay output (60)

Emergency stop relay output (48)

Battery charger fault relay output (61)

Low fuel relay output

34 Overspeed relay output (39)

NOTE: RDO outputs are active low, battery voltage (--).

* Connect to ground to activate.

Figure 6-25 TB1 Terminal Strip Output Connections

Terminal Description

REM RST Remote reset*

GND FLT Ground fault*

SP1 Not used

SP2 Not used

BCF

Battery charger fault*

Low fuel*

Prime power mode*

GND

Engine ground

* Connect to ground to activate.

Figure 6-26 TB2 Terminal Strip Input Connections

Terminal Description

1 Emergency stop ground

Emergency stop

Remote start

AX1

AX2

AX3

AX4

Auxiliary 1*

Auxiliary 2*

Auxiliary 3*

Auxiliary 4*

Oil pressure

Coolant temperature

* Connect to ground to activate.

Figure 6-27 TB3 Terminal Strip Input Connections

Terminal Description

L0 L0 (V0)

L1 (V7)

L2 (V8)

L3 (V9)

—

Not used

Figure 6-28 TB4 Terminal Strip AC Input Connections

102 Section 6 Accessories TP-5829 8/04

Appendix A Abbreviations

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

ATDC

ATS auto.

aux.

A/V avg.

AVR

AWG

AWM bat.

BBDC

A, amp ampere

ABDC after bottom dead center

A/D alternating current analog to digital

ADC adj.

ADV

AHWT analog to digital converter adjust, adjustment advertising dimensional drawing anticipatory high water temperature

AISI

ALOP alt.

ANSI

American Iron and Steel

Institute anticipatory low oil pressure alternator aluminum

American National Standards

Institute

(formerly American Standards

Association, ASA)

API approx.

approximate, approximately

AR as required, as requested

AS anticipatory only

American Petroleum Institute

ASE

ASME as supplied, as stated, as suggested

American Society of Engineers assy.

ASTM

American Society of

Mechanical Engineers assembly

American Society for Testing

Materials

BCA

BCI

BDC

BHP blk.

after top dead center automatic transfer switch automatic auxiliary audiovisual average automatic voltage regulator

American Wire Gauge appliance wiring material battery before bottom dead center battery charger, battery charging battery charging alternator

Battery Council International before dead center brake horsepower black (paint color), block

(engine) blk. htr.

block heater

BMEP brake mean effective pressure bps br.

bits per second brass

BTDC before top dead center

Btu British thermal unit

Btu/min.

British thermal units per minute

C cal.

CARB

CB cc

CCA ccw.

CEC cert.

cfh

Celsius, centigrade calorie

California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise

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

Cu cu. in.

cw.

CWC cyl.

D/A

DAC dB cfm

CID

CL cm

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

com cogeneration communications (port) coml commercial

Coml/Rec Commercial/Recreational conn.

cont.

connection continued

CPVC crit.

CRT

CSA chlorinated polyvinyl chloride critical cathode ray tube

Canadian Standards

Association current transformer copper cubic inch clockwise city water-cooled cylinder digital to analog digital to analog converter decibel dBA

DCR deg.,

° dept.

dia.

DI/EO

DIN decibel (A weighted) direct current direct current resistance degree department diameter dual inlet/end outlet

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

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

DIP

DPDT

DPST

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

E, emer.

emergency (power source)

EDI electronic data interchange

EFR e.g.

emergency frequency relay for example (exempli gratia)

EGSA electronic governor

Electrical Generating Systems

Association

EIA

EI/EO

EMI emiss.

eng.

EPA

Electronic Industries

Association end inlet/end outlet electromagnetic interference emission engine

Environmental Protection

Agency

EPS

ES emergency power system emergency relay engineering special, engineered special

ESD est.

electrostatic discharge estimated

E-Stop emergency stop etc.

et cetera (and so forth) exh.

exhaust

TP-5829 8/04 ext.

F fglass.

FHM fl. oz.

flex.

freq.

FS external

Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale ft.

ft. lb.

foot, feet foot pounds (torque) ft./min.

feet per minute g gram ga.

gal.

gen.

genset

GFI gauge (meters, wire size) gallon generator generator set ground fault interrupter hex

HHC

HP hr.

HS hsg.

HVAC

GND, gov.

gph gpm ground governor gallons per hour gallons per minute gr.

GRD grade, gross equipment ground gr. wt.

gross weight

H x W x D height by width by depth

HCHT

HET hex cap high cylinder head temperature heavy duty high exhaust temperature, high engine temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning

HWT

IEC

IEEE high water temperature hertz (cycles per second) integrated circuit inside diameter, identification

International Electrotechnical

Commission

Institute of Electrical and

Electronics Engineers

IMS in.

improved motor starting inch in. H

2 in. Hg

O inches of water inches of mercury in. lb.

inch pounds

Inc.

ind.

incorporated industrial int.

internal int./ext.

internal/external

I/O

ISO input/output iron pipe

International Organization for

Standardization

JIS k

K joule

Japanese Industry Standard kilo (1000) kelvin

Appendix 103

KB kg kg/cm

2 kiloampere kilobyte (2 kilogram

10 bytes) kgm kg/m

3 kHz kJ kilograms per square centimeter kilogram-meter kilograms per cubic meter kilohertz kilojoule km kilometer kOhm, k

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

LAN kilowatt-hour kilowatt mechanical liter local area network

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

lbm/ft

3 pound, pounds pounds mass per cubic feet

LCB

LCD line circuit breaker liquid crystal display mJ mm mOhm, m

Ω

MOhm,

Ω

MOV

MPa mpg mph

MS m/sec.

MTBF ld. shd.

load shed

LED light emitting diode

Lph

Lpm liters per hour liters per minute

LOP

LPG

LS low oil pressure liquefied petroleum liquefied petroleum gas left side

L wa

LWL

LWT sound power level, A weighted low water level low water temperature m

M meter, milli (1/1000) mega (10

6 when used with SI m

3 m

3 units), male cubic meter

/min.

cubic meters per minute mA man.

milliampere manual max.

MB maximum megabyte (2

20 bytes) one thousand circular mils MCM

MCCB molded-case circuit breaker meggar megohmmeter

MHz mi.

mil min.

misc.

MJ megahertz mile one one-thousandth of an inch minimum, minute miscellaneous megajoule millijoule millimeter milliohm megohm metal oxide varistor megapascal miles per gallon miles per hour military standard meters per second mean time between failure

MTBO mtg.

mean time between overhauls mounting

MW megawatt mW

μF milliwatt microfarad

N, norm.

normal (power source)

NA not available, not applicable nat. gas natural gas

NBS

National Bureau of Standards normally closed

NEC

NEMA

National Electrical Code

National Electrical

Manufacturers Association

NFPA

National Fire Protection

Association newton meter normally open no., nos.

number, numbers

NPS National Pipe, Straight

NPSC

NPT

NPTF

NR ns

OEM

National Pipe, Straight-coupling

National Standard taper pipe thread per general use

National Pipe, Taper-Fine not required, normal relay nanosecond overcrank outside diameter original equipment manufacturer

OF opt.

OSHA overfrequency option, optional oversize, overspeed

Occupational Safety and Health

Administration

OV oz.

p., pp.

PCB pF

PF ph.,

∅

PHC

PHH

PHM

PLC

PMG pot ppm

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

Phillips head crimptite (screw)

Phillips hex head (screw) pan head machine (screw) programmable logic control permanent-magnet generator potentiometer, potential parts per million programmable read-only memory psi pt.

PTC

PTO

PVC qt.

qty.

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

RAM

RDO ref.

radiator, radius random access memory relay driver output reference rem.

remote

Res/Coml Residential/Commercial

RFI

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

TDES

TDNE

TDOE

TDON temp.

term.

TIF

TIR tol.

turbo.

typ.

VAC

VAR

VDC

VFD

VGA

VHF

UHF

UNC

UNF univ.

WCR w/ w/o wt.

xfmr rly.

rms rnd.

ROM rot.

rpm

RTV

SAE scfm

SCR s, sec.

SI/EO sil.

SPDT

SPST spec, specs sq.

sq. cm sq. in.

SS std.

stl.

tach.

TDC

TDEC

TDEN relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization

Society of Automotive

Engineers standard cubic feet per minute silicon controlled rectifier second

Systeme international d’unites,

International System of Units side in/end out silencer serial number single-pole, double-throw single-pole, single-throw 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 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

104 Appendix TP-5829 8/04

Appendix B User-Defined Settings

Use the table below to record user-defined settings during the generator set controller setup and calibration.

The controller default settings and ranges provide guidelines. The table contains all faults with ranges and time delays including items which do not have adjustments.

Status or Fault

Access Code

(Password)

Cyclic Cranking

Refer to

Digital

Display

Relay

Driver

Output

(RDO) Range Setting

4 1--6 crank cycles

1--60 sec. crank

1--60 sec. pause

Coolant

Temperature Signal

Loss

Customer Auxiliary

1--4 Shutdown or

Warning

Emergency Power

System Supplying

Load

4, 5

No Temp Gauge

Signal

Auxiliary 1--4

EPS Supplying

Load

High Battery Voltage 5, 6 High Battery

Voltage

High Coolant

Temperature

Shutdown

5 High Coolant

Temperature

5 High Coolant

Temperature

Warning

High Oil

Temperature

Shutdown

High Coolant

Temperature

Warning

High Oil

Temperature kW Overload (Load

Shed)

Load Shed

Low AC Output 5

Load Shed

KW Overload

Load Shed

Underfrequency

Low AC Output

Low Battery Voltage

User

Defined

User

Defined

RDO—8

RDO—10 14.5--16.5 (12V)

29--33 (24V)

Std.

User

Defined

User

Defined

User

Defined

User

Defined

Std.

10--12.5 (12V)

20--25 (24V)

Low Coolant Level

Shutdown

Low Oil Pressure

Shutdown

Low Oil Pressure

Warning

Overcrank

Shutdown

Overcurrent

5, 6 Low Battery

Voltage

5 Low Coolant

Level

Low Oil

Pressure

Low Oil

Pressure

Warning

5 Overcrank

5 Overcurrent

RDO—7

Std.

Overfrequency

Shutdown

Overspeed

Shutdown

5, 6

Overfrequency

Overspeed

User

Defined

User

Defined

Std.

102%--140%

65--70 (60 Hz)

55--70 (50 Hz)

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

Default

Selection

0 (zero)

15 sec.

30 sec.

inhibit,

5 sec. delay

5% of line current

16 (12V)

32 (24V)

100% of kW

Rating

59, (60 Hz)

49, (50 Hz)

12 (12V)

24 (24V)

110%

140% Std.

103% FAA

70 (60 Hz)

70 (50 Hz)

Inhibit

Time

Delay*

(sec.)

0--60

Time

Delay

(sec.)

0--60

0.25

User-Defined

Settings

Not adjustable

TP-5829 8/04 Appendix 105

Status or Fault

Oil Pressure Signal

Loss

Overvoltage

Shutdown

Password (Access

Code)

Starting Aid

Function

Time Delay Engine

Cooldown (TDEC)

Time Delay Engine

Start (TDES)

Underfrequency

Shutdown

Undervoltage

Shutdown

Refer to

Digital

Display

5 No Oil Gauge

Signal

5, 6 Overvoltage

4, 5

User

Defined

RDO—4

5, 6 Underfrequency

5, 6 Undervoltage

User

Defined

User

Defined

User

Defined

Relay

Driver

Output

(RDO)

User

Defined

RDO—6

Range Setting

105%--135%

Default

Selection

Inhibit

Time

Delay*

(sec.)

115%

2-sec time delay

0 (zero)

Time

Delay

(sec.)

2--10

0--10 sec.

00:00--10:00 min:sec

00:00--5:00 min:sec

80%--95%

70%--95%

5:00

00:01

90%

85%

10-sec time delay

60%

5--30

2 Weak Battery 5 Weak Battery User

Defined

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

User-Defined

Settings

Not adjustable

106 Appendix TP-5829 8/04

TP-5829 8/04f

KOHLER CO. Kohler, Wisconsin 53044

Phone 920-565-3381, Fax 920-459-1646

For the nearest sales/service outlet in the

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

KohlerPowerSystems.com

Kohler Power Systems

Asia Pacific Headquarters

7 Jurong Pier Road

Singapore 619159

Phone (65) 6264-6422, Fax (65) 6264-6455

Hello! I've reviewed the Kohler 20-2000kW Industrial Generator Set Operation Manual. This document details the operation, maintenance, and troubleshooting of these generator sets, including the Decision-Maker 340 controller. Ask me your Kohler generator questions!

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Key features

20-2000kW output
Decision-Maker™ 340 controller
Reliable operation
Wide range of features
Industrial applications

Frequently asked questions

The generator set is designed to provide electrical power for various industrial applications, such as factories, construction sites, and data centers.

The generator set has an output power range of 20-2000kW, depending on the specific model.

The generator set is equipped with a Decision-Maker™ 340 controller, which provides advanced features and monitoring capabilities.

The Decision-Maker™ 340 controller includes features such as remote monitoring, automatic start/stop, and fault detection.

You can find additional information about the generator set, including specifications, installation instructions, and troubleshooting tips, in the accompanying service manual and engine operation manual.