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Kohler Industrial Generator Set Operation Manual

10-1000 kw with apm402 controller; decision-makerr 3000 controller
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Operation
Industrial Generator Sets
Models:
10-1000 kW
Controller:
APM402/Decision-Makerr 3000
TP-6694 7/18j

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Table of Contents
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Summary of Contents for Kohler Industrial Generator Set

  • Page 1 Operation Industrial Generator Sets Models: 10-1000 kW Controller: APM402/Decision-Makerr 3000 TP-6694 7/18j...

  • Page 2: Product Identification Information

    WARNING: This product can expose you WARNING: Breathing diesel engine to chemicals, including carbon monoxide exhaust exposes you to chemicals known to and benzene, which are known to the State the State of California to cause cancer and of California to cause cancer and birth birth defects or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents Product Identification Information ............Safety Precautions and Instructions .
  • Page 4 Table of Contents, continued 2.7.9 Voltage Regulator ..........2.7.10 Digital Inputs .
  • Page 5 Table of Contents, continued Section 6 Accessories ..............Accessories and Connections .
  • Page 6 Notes TP-6694 7/18...

  • Page 7: Safety Precautions And Instructions

    Safety Precautions and Instructions Accidental Starting IMPORTANT SAFETY INSTRUCTIONS. WARNING Electromechanical equipment, including generator sets, transfer WARNING switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, maintained. To prevent accidents be Explosion. Can cause severe injury or death. aware of potential dangers and act safely.
  • Page 8 Engine Backfire/Flash Exhaust System Battery gases. Explosion can cause severe injury or death. Battery gases Fire can cause an explosion. Do not smoke WARNING or permit flames or sparks to occur near a battery at any time, particularly when WARNING it is charging.
  • Page 9 Fuel System Hazardous Voltage/ Draining the fuel system. Explosive fuel vapors can cause severe injury Moving Parts or death. Spilled fuel can cause an WARNING explosion. Use a container to catch fuel when draining the fuel system. Wipe up DANGER spilled fuel after draining the system.
  • Page 10 Hot Parts High voltage test. Hazardous Testing live electrical circuits. voltage will cause severe injury or Hazardous voltage or current will death. Follow the instructions of the cause severe injury or death. Have WARNING test equipment manufacturer when trained and qualified personnel take performing high-voltage tests on the diagnostic measurements...
  • Page 11 Notice NOTICE This generator set has been rewired from its nameplate voltage 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 authorized service...
  • Page 12 Notes Safety Precautions and Instructions TP-6694 7/18...

  • Page 13: Introduction

    Information in this publication represents data available List of Related Materials at the time of print. Kohler Co. reserves the right to change this publication and the products represented Separate literature contains communication and without notice and without any obligation or liability software information not provided in this manual.

  • Page 14: Service Assistance

    Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455 China Look at the labels and decals on your Kohler product North China Regional Office, Beijing or review the appropriate literature or documents Phone: (86) 10 6518 7950 included with the product.

  • Page 15: Section 1 Specifications And Features

    Section 1 Specifications and Features 1.1 Introduction The controller features, accessories, and menu displays depend upon the engine electronic control module The spec sheets for each generator set provide model- (ECM) setup and features. Controller features apply to specific generator and engine information. generator set models with ECM and non-ECM engines controller spec sheet provides specifications for this unless otherwise noted.

  • Page 16: Switches And Controls

    1.2.1 Switches and Controls The pushbutton/rotary selector dial has several features and functions: Note: US/Metric Display is selectable in Section Momentarily press the dial to activate the digital 1.2.3—Digital Display—Generator Set System display if dark. Menu. Rotate the dial to navigate through the main menus—turn clockwise to go forward (down) and Alarm Horn.
  • Page 17 Alarm Silence Lamp. Yellow lamp illuminates System Shutdown Fault Lamp. Red lamp indicates indicating the alarm horn was silenced. that the generator set has shut down because of a fault condition. The unit will not start without resetting the (System) Fault Lamp. Yellow lamp illuminates controller, see Section 2.4.8, Controller Resetting indicating a warning condition or red lamp illuminates...

  • Page 18: Digital Display

    1.2.3 Digital Display Overview Menu When a new shutdown or warning fault occurs, the Press the pushbutton/rotary selector dial to turn on the auto-paging display feature activates. controller lamps and display. The lamps and display turn off 60 minutes after the last entry. Active Shutdowns display if any are present.
  • Page 19 connected and then removed. (DEC3000 version 4.11 The calibration values are reviewable at all times and or higher, and APM402) provide the calibration of the voltage and current sensing logic. Changing the system voltage or replacing Engine Run Time displays the total run time hours. the circuit board requires a calibration adjustment.
  • Page 20 Generator Set System Menu Generator Set (Reset) Calibration Menu The values in this menus are user-entered for the This menu is only available in Decision-Makerr 3000 generator set configuration and are NOT measured controller firmware versions before 3.0.25. values of the generator set. Decision-Makerr 3000 controllers with later firmware versions, or on APM402 controllers, go to Generator Changes to the Generator Set System menu require the...
  • Page 21 Voltage Regulator Menu Digital Inputs Menu Decision-Makerr 3000 Controller firmware before This menu allows the user to review the settings. There 3.0.25: are up to three digital inputs that are programmer selectable if not reserved by factory options. The voltage regulator value is reviewable at all times. In order to review the value when the generator set is NOT The displays for digital inputs appear as shown below running, enter Yes when the Enter volt reg? is displayed.
  • Page 22 Analog Inputs Menu Volt Select Menu This menu allows the user to review the settings. There Note: The generator set must be stopped before is one analog input that is programmer selectable if not changing the voltage selection. reserved by factory options. This menu allows the user to readily change controller There is an optional 2 input/5 output (I/O) module board voltage settings.

  • Page 23: Controller Fault Diagnostics

    1.2.4 Controller Fault Diagnostics that is NOT part of the event history. System events are available as a Relay Output as shown. This table provides descriptions of the system events and their types—warning, shutdown, status, and notice. Throughout this manual there are examples of the display text.
  • Page 24 Warning Shutdown Status/ Relay Function Function Notice Output Description Display Message General Functions Alarm horn silenced (Alarm Silence LED only) Alarm silence, auto only (NFPA 110) or always AlrmSilence: Auto Only or AlrmSilence: Always Aux. inputs 0--5 VDC, 1 analog Aux Input Warning (2 additional inputs available with I/O module option) Aux.

  • Page 25: Digital Display Circuit Board And Connections

    1.2.5 Digital Display Circuit Board and 1.2.6 Main Logic Circuit Board Connections The main logic circuit board provides the terminal strips and connection sockets to connect the controller to the The digital display circuit board provides: engine/generator, input/output connections, optional The backlit LCD (liquid crystal display) for monitoring I/O module kit, and circuit protection fuses.

  • Page 26: Terminal Jumper

    1.2.8 Communication Ports The main logic circuit board contains a single mini USB communication port for PC connections, see Figure 1-6. For Modbusr communication using RS-485, see Figure 1-5 (P21). Refer to the List of Related Materials in the Introduction for corresponding SiteTecht software and/or communication installation information.

  • Page 27: Controller Logic Specifications

    1.3 Controller Logic Specifications The controller logic specifications section is an overview of the various features and functions of the controller. Certain features function only when optional accessories are connected. See Section 2, Operation, for details. The default selection time delays and digital outputs are factory set and adjustable.
  • Page 28 Factory-Defined Settings List GenSet Fault Write Mode Time Default Lamp Access Delay Time Always Controller Display Alarm Range Default Range Delay Warning Display Running Message Horn Setting Selection Description (sec.) (sec.) Shutdown SiteTech Stopped Engine Functions Critically high fuel level Fuel Level Critically 0--100% 0--10...
  • Page 29 GenSet Fault Write Mode Time Default Lamp Access Delay Time Always Controller Display Alarm Range Default Range Delay Warning Display Running Message Horn Setting Selection Description (sec.) (sec.) Shutdown SiteTech Stopped No coolant temperature signal Temp Sig Loss Shutdwn No oil pressure signal Press Sig Loss Fixed Shutdwn...
  • Page 30 GenSet Fault Write Mode Time Default Lamp Access Delay Time Always Controller Display Alarm Range Default Range Delay Warning Display Running Message Horn Setting Selection Description (sec.) (sec.) Shutdown SiteTech Stopped Measurement Units, Measurement Display 0--1 0--English, 1--Metric Metering communication loss MeterCommLos Shutdwn NFPA 110 alarm active...
  • Page 31 GenSet Fault Write Mode Time Default Lamp Access Delay Time Always Controller Display Alarm Range Default Range Delay Warning Display Running Message Horn Setting Selection Description (sec.) (sec.) Shutdown SiteTech Stopped Charger Charge Cycles Between Auto Equalize Cycles 0 – 99 Note: Equalize is only available with FLA/VRLA topology selected.
  • Page 32 GenSet Fault Write Mode Time Default Lamp Access Delay Time Always Controller Display Alarm Range Default Range Delay Warning Display Running Message Horn Setting Selection Description (sec.) (sec.) Shutdown SiteTech Stopped Charger Temperature Active Inactive Compensation Enable Inactive Charger Temperature --40 –...

  • Page 33: Voltage Regulator And Calibration Specifications

    1.3.2 Voltage Regulator and Calibration Underfrequency Unload Frequency Setpoint. This adjustment affects the voltage droop (volts per Hz) when Specifications load is applied and underfrequency occurs. The controller has a voltage regulation function that is underfrequency unload setting defines the setpoint where underfrequency starts.
  • Page 34 Notes Section 1 Specifications and Features TP-6694 7/18...

  • Page 35: Section 2 Operation

    Section 2 Operation 2.1 Prestart Checklist Check for loose, corroded, or missing clamps and hangers. Tighten or replace the exhaust clamps and/or hangers as needed. To ensure continued satisfactory operation, perform the following checks or inspections before or at each Check that the exhaust outlet is unobstructed.

  • Page 36: Operation In Cold Weather Climates

    2.3 Operation in Cold Weather system and operated at or below 50% of rated load. Wrap the UL/CSA compliant heater tape around the Climates crankcase canister/breather system hose that runs from the crankcase to the air intake and use cable ties Cold weather operation is generally considered ambient as needed to secure the heater tape.

  • Page 37: Stopping (User Stopping And Fault Shutdown)

    Note: The transient start/stop function of the controller The controller has a programmable cooldown timer that prevents accidental cranking of the rotating engine. functions only when the master control button is in the The generator set stops and recranks when the AUTO mode.

  • Page 38: System Status Lamps

    2.4.4 System Status Lamps AC Sensing Loss. The fault lamp illuminates yellow and the alarm horn sounds when the controller does not The (OFF/RESET--AUTO--RUN) master control buttons detect the nominal generator set AC output voltage after indicate the status condition with an integrated lamp at crank disconnect.
  • Page 39 Common Warning. The fault lamp illuminates yellow High Coolant Temperature. The fault lamp illuminates and the alarm horn sounds when the controller is yellow and the alarm horn sounds when the engine signaled by a common warning. Use SiteTecht coolant temperature approaches the shutdown range. software to activate the common warning.

  • Page 40: System Fault Shutdown Lamp With Digital Displays

    Low Engine Oil Level. The fault lamp illuminates AC Sensing Loss. The fault lamp illuminates red, the yellow and the alarm horn sounds because of low alarm horn sounds, and the unit shuts down when the engine oil level. This fault feature requires an optional controller does not detect the nominal generator set AC low engine oil level sensor for the lamp to function.
  • Page 41 ECM Model Mismatch. The fault lamp illuminates red, kW Overload. The fault lamp illuminates red, the alarm the alarm horn sounds, and the unit shuts down when horn sounds, and the unit shuts down when the the controller detects an error with the ECM model. The generator set supplies more than 102% of the rated local display shows ECM Mismatch Shutdwn.
  • Page 42 Metering Communications Loss. The fault lamp Overvoltage Time Delay Overvoltage Default illuminates red, the alarm horn sounds, and the unit Setting Range Range Setting shuts down when metering controller 105%--135% of communication link is disrupted. The local display 2--10 sec. 120% at 2 sec.

  • Page 43: Status And Notice Digital Displays

    2.4.7 Status and Notice Digital Displays Engine Cooldown (Delay) Active. This notice message indicates that the delay for engine cooldown is Warnings and shutdown faults appear on the digital active where the generator set will continue to run after display and become part of the event history. Beyond the OFF/RESET button is pressed.
  • Page 44 Generator Set Calibration (User Defined). This NFPA 110 Alarm Active. This notice message selectable display is in the GenSet Calibration Menu indicates that the alarm for NFPA 110 is active. The fault allowing the user to calibrate the controller and lamp illuminates yellow (warning) or red (shutdown), the generator set.

  • Page 45: Controller Resetting (Following System Shutdown Or Warning)

    2.4.8 Controller Resetting (Following ways to power up the engine ECM without starting the generator set: System Shutdown or Warning) Use SiteTecht to power up the engine ECM. Refer Use the following procedure to restart the generator set to Procedure for Powering Up the Engine ECM using after a system shutdown or to clear a warning lamp SiteTecht for Firmware Versions Before 3.10 condition.

  • Page 46: Menu Displays

    Procedure for Powering Up the Engine ECM This procedure applies to Decision-Makerr 3000 controllers with firmware version 3.10 and higher and to APM402 controllers with firmware versions 1.0 and higher. 1. Navigate to the SW Version menu (Figure 2-10) as described in the previous procedure.
  • Page 47 Menu Summary List (Legend: D First level submenu, d second level submenu) Overview Menu Overview Menu Generator Metering GenSet System (DEC3000 (DEC3000 version 4.11 and APM402) Menu Menu before version 4.11) D System Frequency D Total Power kVA (shown Available as scrolling or Available as scrolling or as actual output values) D System Phase (Single...
  • Page 48 Menu Summary List Continued (Legend: D First level submenu, d second level submenu) Voltage Regulator Digital Inputs Analog Inputs Event Log Menu (DEC3000 before Menu Menu Menu Version 3.0.25) D DIn A1 D AIn A1 (factory reserved D See 1.2.4 for a list of and not user items that can appear in D Enter Voltage Regulator?

  • Page 49: Monitoring And Programming Setup

    2.6 Monitoring and Programming Setup Modbusr/ Ethernet Ethernet Network Converter The user programmer can access the controller data Generator Set Personal Controller or with the controller digital display or a personal computer Computer Transfer with NIC (PC) with optional SiteTecht software to monitor and/or Switch Control RS-232 to Remote...

  • Page 50: Reviewing Menu Displays

    2.7 Reviewing Menu Displays Controller Controller SiteTech Menu Name Viewable Adjustable Adjustable Use this section to review a summary of the generator Overview set controller data. See Figure 2-17 or Figure 2-18 for Engine Metering which menus provide data monitoring, data Generator Metering adjustments, or require SiteTecht software to make...

  • Page 51: Error Messages

    2.7.1 Error Messages ECM Address Conflict. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when Certain entries or attempted entries may cause the the controller detects an error with the ECM address. controller to display an error message. Some of the The local display shows ECMAddr Err Shutdwn.

  • Page 52: Overview

    2.7.2 Overview Overview (Fixed Display) Overview ----> ### V ##.# Hz Displays basic and commonly sought after information ##.# hr ### A #### kW about the generator set. This information scrolls automatically after about 5 minutes of no user input English Display (pushbutton/rotary selector dial or button activity).

  • Page 53: Generator Metering (And Calibration)

    2.7.4 Generator Metering (and values for three-phase generator sets. Single-phase generator sets will only display items marked (*). Calibration) Volts L1-L2 * Displays generator output data including line-to-line and Volts L2-L3 line-to-neutral voltages, current, frequency, total Volts L3-L1 kilowatts, and total kVA. The menu displays three-phase voltage and current readings when Volts L1-N *...

  • Page 54: Genset Information

    2.7.5 GenSet Information Momentarily press the pushbutton/rotary selector dial. Stop the generator set if not already done. Displays generator set and controller information. Displayed data is factory entered. Generator Metering GenSet Information Generating----> Total Power: GenSet ----> Genset M/N: Metering # VA Information Total Power:...
  • Page 55 GenSet System Note: The contrast feature is a controller hardware change and may not be available on older units GenSet ----> System Freq: even if the firmware is updated. System ##.# Hz The alarm (horn) silence display is programmer SystemPhase: selectable to Always or Auto Only using SiteTecht ##### software.

  • Page 56: Genset Calibration

    2.7.8 GenSet Calibration The user can individually calibrate the values or reset all of them. The local display Reset all calib? No or Yes. This menu is only available in Decision-Makerr 3000 Select No to make no changes and exit GenSet controllers with firmware versions before 3.0.25.

  • Page 57: Voltage Regulator

    2.7.9 Voltage Regulator running, enter Yes when the Enter volt reg? is displayed. The user can review the value but attempting to change Decision-Makerr 3000 Controllers with Firmware the value will cause a Cannot edit when stopped error Versions Before 3.0.25. message.

  • Page 58: Digital Inputs

    2.7.10 Digital Inputs Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the Displays the selected programming user-defined digital generator set stabilizes and the controller does not notice, warning, and shutdown inputs. These inputs detect the fault or status event.

  • Page 59: Digital Outputs

    2.7.11 Digital Outputs Digital Outputs Digital ----> DOut A1 Displays the selected programming user-defined digital Outputs ##### notice, warning, and shutdown outputs. These outputs provide a multitude of choices for configuring customized auxiliary outputs. See Figure 2-21 for a list DOut A1 Value: True or False of digital output choices.

  • Page 60: Analog Inputs

    Critical High High No Signal High Warning Warning Shutdown Shutdown Shutdown Digital Outputs Notice Warning Warning Shutdown AC Sensing Lost Alternator Protection Auxiliary Input Battery Charger Fault Battery Voltage Chicago Code Active Common Fault Common Warning Cranking Voltage ECM Comm Loss Emergency Stop Engine Coolant Level Engine Coolant Temperature...

  • Page 61: Battery Charger 1 And 2

    AIn B1 (analog input B1) with I/O module board Battery gases. Explosion can cause severe injury or death. Incorrect use of the equalize charge state may lead to AIn B2 (analog input B2) with I/O module board hazardous situations. Equalization is ONLY applicable for flooded lead acid (FLA) type batteries and will damage gel, All analog input selection and setup adjustments are absorbed glass mat (AGM), or nickel-cadmium (NiCad) type...

  • Page 62: Event Log

    2.7.14 Event Log Volt Select Volt Select: ----> 120/240 V 1 Ph Displays up to 1000 stored status, warning, and ###/### V # Ph shutdown events. After the first 1000 events, each additional new event replaces the oldest event. See 1.2.4 Controller Fault Diagnostics for a list of possible 120/208 V 3 Ph events.

  • Page 63: Section 3 Scheduled Maintenance

    Can cause severe injury or death. Do not work on the generator set until Kohler recommends the use of Kohler Genuine oil and it cools. filters for maintenance and service. Servicing the exhaust system.

  • Page 64: Service Schedule

    3.3 Service Schedule Action System—Component Visually Inspect Check Change Clean Test Interval Fuel System Day tank level Weekly Flexible lines and connections Weekly Fuel level switch Weekly Main tank supply level Weekly Solenoid valve operation Weekly Transfer pump operation Weekly Water in system, remove Weekly Filter(s)
  • Page 65 Service Schedule, continued Action System—Component Visually Inspect Check Change Clean Test Interval AC Electrical System Controller lamp test Weekly General Inspection Weekly Circuit breakers, fuses[ Monthly Wire abrasions where subject to motion Quarterly Safety and alarm operation Six Months Tighten control and power wiring connections Yearly Transfer switch main contacts[ Yearly...

  • Page 66: Alternator Bearing Service

    3.4 Alternator Bearing Service 3.5.1 Bleeding Air from Fuel System Bleed air from the fuel system after fuel system Have an authorized service distributor/dealer perform maintenance, such as replacing the fuel filter(s). Use service. the hand prime pump kit, when equipped. The hand prime fuel pump eliminates the need for cranking the 3.4.1 20- -300 kW Models...

  • Page 67: Gaseous Fuel Systems

    3.6.1 Gaseous Fuel System Concept 3. Rotate hand prime pump handle counterclockwise until fuel flows from the bleed (Single Fuel) screw. Stop pumping. The gaseous fuel system uses a fuel valve with a 4. Tighten the bleed screw. Wipe up any fuel leakage. solenoid to control the fuel flow to the fuel regulator.

  • Page 68: Fuel System Changeover Kits (Dual Fuel)

    To change the fuel type, change the electrical primary fuel is natural gas; the backup fuel is LPG connections to the engine ECM. The engine ECM has vapor. Before starting, both fuel valves are closed. fuel tables and spark advance curves programmed for When the generator set starts, the primary fuel valve both natural gas and LPG.
  • Page 69 ADV-7600B-B Figure 3-5 Gaseous Fuel Connections Wiring Diagram TP-6694 7/18 Section 3 Scheduled Maintenance...

  • Page 70: Air Cleaner Restrictor Indicator (If Equipped)

    3.8 Air Cleaner Restrictor Indicator Note: Engine damage. Bleed the air from the cooling system to prevent overheating and subsequent (if equipped) engine damage. The air cleaner restriction gauge mounted on the air Note: Block heater damage. The block heater will fail cleaner(s) helps determine the air cleaner change if the energized heater element is not immersed interval.

  • Page 71: Procedure To Drain Cooling System

    3.9.3 Procedure to Drain Cooling 1. Remove the pressure cap. System 2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose For optimum protection, drain, flush, and refill the clamps. cooling system at the intervals listed in the service schedule.

  • Page 72: Battery

    3.10 Battery Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a 12-volt or 24-volt engine electrical system. WARNING Consult the generator set nameplate for the engine electrical system voltage. Consult the generator set spec sheet for battery capacity recommendations for replacement purposes.

  • Page 73: Clean Battery

    1-046 1. Filler caps 2. Electrolyte level KW-272000-B 1. To positive (+) terminal on starter solenoid. Figure 3-10 Battery Electrolyte Level Inspection 2. To ground (--) terminal on or near starter motor. 3. To positive (+) terminal on second starter solenoid. 4.

  • Page 74: Charge Battery

    3.10.4 Charge Battery WARNING Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application. The engine battery-charging alternator charges the battery while the generator set is running. Accidental starting.  ...

  • Page 75: Lubricating System

    Servicing the generator set when it is operating. Exposed Gaseous-Fueled Engines moving parts will cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts 1. Start the generator set. and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator 2.

  • Page 76: Battery

    3.11.6 Battery 4. Place the battery in a cool, dry location. Perform battery storage after all other storage 5. Connect the battery to a battery charger or charge it procedures. monthly with a trickle battery charger. Refer to the battery charger manufacturer’s recommendations. 1.

  • Page 77: Section 4 General Troubleshooting

    Section 4 General Troubleshooting This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed diagnostic, and repair information. on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an Use the following charts to diagnose and correct authorized distributor/dealer.

  • Page 78: General Troubleshooting Chart

    Section 4 Troubleshooting TP-6694 7/18...
  • Page 79 TP-6694 7/18 Section 4 Troubleshooting...
  • Page 80 Section 4 Troubleshooting TP-6694 7/18...

  • Page 81: Controller Display And Voltage Regulation Troubleshooting Chart

    TP-6694 7/18 Section 4 Troubleshooting...
  • Page 82 Notes TP-6694 7/18...

  • Page 83: Section 5 Voltage Reconnection

    Section 5 Voltage Reconnection 5.1 Introduction Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the Use the following voltage reconnection procedure to generator set as follows: (1) Press the generator set off/reset change the voltage of 10- and 12-lead generator sets.

  • Page 84: Voltage Reconnection Procedure

    2. Turn the controller pushbutton/rotary selector dial Note: Position current transformers CT1, CT2, until it stops at the Volt Select menu. and CT3 with the dot or HI side CT marking Figure 5-1. toward the generator set. Note: If the Volt Select menu does not appear, the 9.
  • Page 85 Figure 5-2 20--150 kW Permanent Magnet Single-Phase Alternators, ADV-5875U-1 TP-6694 7/18 Section 5 Voltage Reconnection...
  • Page 86 Figure 5-3 20--300 kW Permanent Magnet Alternators, ADV-5875U-2 Section 5 Voltage Reconnection TP-6694 7/18...
  • Page 87 Figure 5-4 60 IMS--300 kW Wound Exciter Field & 20--300 kW, 600 V Perm. Magnet Alternators, ADV-5875U-3 TP-6694 7/18 Section 5 Voltage Reconnection...
  • Page 88 Figure 5-5 300 kW and Larger Pilot-Excited, Permanent Magnet 4M/5M/7M/10M Alternators, ADV-5875U-4 Section 5 Voltage Reconnection TP-6694 7/18...

  • Page 89: Accessories And Connections

    Section 6 Accessories 6.1 Accessories and Connections 6.1.1 Battery Charger Kit with Alarm Option Several accessories help finalize installation, add convenience to operation and service, and establish The battery charger with alarm option provides battery state and local code compliance. charging to the engine starting battery(ies) and connects to the controller for fault detection.

  • Page 90: Common Fault/Failure (32A) Relay Kit

    6.1.2 Common Fault/Failure (32A) Relay The common fault relay is standard on the controller circuit board and located at the TB2 terminal strip connections. Contacts are rated at 2 amps at 32 VDC or 0.5 amps at 120 VAC max. See Figure 6-4 and Figure 6-5.

  • Page 91: Fifteen-Relay Dry Contact Kit

    6.1.3 Fifteen-Relay Dry Contact Kit When a generator fault condition occurs, the contact kit relay energizes. The relay energization corresponds to The optional 15-relay dry contact kit is available for the controller output being activated. selected models. The 15--relay dry contact kit is not available with the input/output module (2-input/5-output Check the electrical requirements of the user-supplied board) described in Section 6.1.5.
  • Page 92 GM78246E-2 1. TB5 output connections C and NO for the common fault relay K15 (other TB5 terminals are factory connections only) 2. P35 4-position jack connects to controller (factory-connected) 3. TB6 8-position terminal block, digital inputs/digital returns (D11, D12, D13, and D14) 4.
  • Page 93 accessories require separate leads connected directly 7. Supply two lengths of stranded wire to make leads long enough to connect the user- supplied device to the battery for the voltage supply. Attach to the dry contact terminals and power supply. Use user-supplied 12/24-volt DC accessories to the battery color-coded wire for easy identification.

  • Page 94: Gas Fuel Valve Kit

    Program the inputs and outputs using SiteTecht Digital Output C6 TB9 K6 Digital Output C7 TB10 K7 Use a computer with Kohler SiteTecht software to Digital Output C8 TB10 K8 assign functions to digital and analog inputs and outputs. Each input and output corresponds to a...

  • Page 95: Input/Output (I/O) Module Board

    Digital Output B3 P31 (K3) identification. Digital Output B4 P32 (K4) Use a computer with Kohler SiteTecht software to Digital Output B5 P32 (K5) assign functions to digital outputs. Each input and Figure 6-11 I/O Module Input/Output Assignments output corresponds to a controller connection. Verify that the settings are appropriate for the connected sensor, switch, or equipment.

  • Page 96: Key Switch

    6.1.6 Key Switch 6.1.7 Low Fuel (Level/Pressure) Switch A two-position key switch is available for selected Some gas-fueled models offer a low fuel pressure models. Turn the key to the ON position to lock the switch. The low fuel pressure switch connects to the controller in AUTO mode.

  • Page 97: Manual Speed Adjust (Engine Rpm Menu)

    6.1.8 Manual Speed Adjust (Engine 6.1.9 Prime Power Switch Kit RPM Menu) The prime power switch kit prevents battery drain during generator set non--operation periods and when the Note: Not available Decision-Makerr 3000 generator set battery cannot be maintained by an AC controllers with software versions before 3.10.3.

  • Page 98: Remote Emergency Stop Kit

    6.1.10 Remote Emergency Stop Kit 6.1.11 Remote Reset Feature The emergency stop kit allows immediate shutdown of The remote reset switch provides generator set the generator set from a remote location. controller resetting after a fault shutdown at a remote Figure 6-20 and Figure 6-21.

  • Page 99: Remote Serial Annunciator

    6.1.12 Remote Serial Annunciator RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA III is a remote serial annunciator (Figure 6-24, Figure 6-25, and Figure 6-26) that monitors the condition of the generator set and/or ATS from a remote location.
  • Page 100 System Monitoring LEDs and Functions Common System Generator Communications Common Fault Fault Ready LED Running LED Status LED Fault LED Output Horn Fault and Status Condition Overcrank (Shutdown) Red SF Red SF Green Red SF High Engine Temperature (Warning) Yellow SF Red SF Green Green...

  • Page 101: Run Relay Kit

    6.1.13 Run Relay Kit 6.1.14 Shunt-Trip Line Circuit Breaker The run relay kit energizes only when the generator set A shunt-trip line circuit breaker provides a 12- or 24-DC runs. Use the run relay kit to control air intake and volt solenoid within the line circuit breaker case that can radiator louvers, alarms, and/or other signalling energize the trip mechanism.

  • Page 102: Accessory Connections

    6.2 Accessory Connections The controller contains a circuit board equipped with terminal strip(s) for use in connecting external optional accessories including alarms, battery chargers, and remote switches. The optional I/O board provides an additional two analog or digital inputs and five digital outputs.
  • Page 103 TB1 Terminal Strip P1 24-Pin Connector Analog and Digital Input Connections Engine Wiring Harness Terminal Description Connection Terminal Description Connection TB1--DI 1 DCH1 No Function P1--12 14P +12VDC Prime Power Switch TB1--DI 2 DCH2 Aux. Warning Switch P21 6-Pin Connector TB1--DI 3 DCH3 (see Note below)
  • Page 104 P25 Connector P30 Connector RJ45 Remote I/O In 2 Amp. K2 Relay Output (2.2) Connections Connects to controller P23 Terminal Description P26 Connector P30--NC Normally Closed RJ45 Remote I/O Out P30--COM Common Open P30--NO Normally Open P27 Connector P31 Connector CAN Terminator 2 Amp.
  • Page 105 Figure 6-35 Controller Wiring Connections GM78246E-1 TP-6694 7/18 Section 6 Accessories...
  • Page 106 Figure 6-36 Controller Wiring Connections GM78246E-2 106 Section 6 Accessories TP-6694 7/18...
  • Page 107 (2 bytes) est. estimated Canadian Electrical Code KBus Kohler communication protocol E-Stop emergency stop cert. certificate, certification, certified kilogram etc. et cetera (and so forth) cubic feet per hour TP-6694 7/18 Appendix 107...
  • Page 108 kg/cm kilograms per square National Bureau of Standards remote terminal unit centimeter normally closed room temperature vulcanization kilogram-meter National Electrical Code read/write kg/m kilograms per cubic meter NEMA National Electrical Society of Automotive kilohertz Manufacturers Association Engineers kilojoule NFPA National Fire Protection scfm standard cubic feet per minute Association...
  • Page 109 Appendix B Programmer-Defined Settings Use the table below to record programmer-defined SiteTecht setup software is required for programming the controller. Contact your local distributor/dealer for assistance. settings during the generator set controller setup and calibration. The controller default settings and ranges Note: Inhibit time delay is the time delay period after provide guidelines.
  • Page 110 GenSet Write Mode Time Default Programmer- Access Delay Time Always Controller Display Range Default Range Delay Defined Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped Low engine oil level * Oil Level Low Not adjustable Shutdwn Low fuel level (diesel models) * Fuel Level Low 0--100% 0--10...
  • Page 111 GenSet Write Mode Time Default Programmer- Access Delay Time Always Controller Display Range Default Range Delay Defined Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped Engine started Engine Start Status Not adjustable Engine stopped Engine Stop Status Not adjustable EPS supplying load Emerg Pwr On Notice...
  • Page 112 GenSet Write Mode Time Default Programmer- Access Delay Time Always Controller Display Range Default Range Delay Defined Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped Charger Automatic Equalize Enable Active Inactive Note: Equalize is only Inactive available with FLA/VRLA topology selected.
  • Page 113 GenSet Write Mode Time Default Programmer- Access Delay Time Always Controller Display Range Default Range Delay Defined Display Running Message Setting Selection Settings Description (sec.) (sec.) SiteTech Stopped Charger Temperature --40 – 0 Adjustable with Compensation Slope (mV/_C) (12 V) (12 V) Charger Custom -80 –...
  • Page 114 Notes 114 Appendix TP-6694 7/18...
  • Page 115 Appendix C Voltage Regulator Definitions and Adjustments The following definitions and adjustment/setting mathematically by Ohm’s law, which states that power is specifications are intended for users planning to adjust equal to the voltage squared divided by the impedance. the voltage regulator beyond the default settings in As the voltage is reduced, the power delivered by the order to customize the alternator for a specific alternator decreases by a squared relationship.
  • Page 116 Frequency Setpoint or Cut-In Point general, the phase with the greatest load will have the lowest voltage while the phase with the least load will The point at which the underfrequency unloading begins have the highest voltage. This is true regardless of the to take effect is adjustable, allowing the system to be type of sensing used in the regulator system.
  • Page 117 Frequency Setpoint As a reference, the present voltage adjust setting is displayed as well as the average value of the line-to-line The frequency setpoint is the cut-in point for voltages. The individual line-to-line voltages are also underfrequency unloading. At any operating frequency displayed on the subsequent menu screens.
  • Page 118 Notes 118 Appendix TP-6694 7/18...
  • Page 119 Appendix D Alternator Protection The controller has built-in thermal protection for the The current and time limits are defined by actual test alternator. This feature functions similarly to a thermal data and are maintained in the personality parameter circuit breaker. When the output current exceeds the file.
  • Page 120 Notes 120 Appendix TP-6694 7/18...
  • Page 121 ECM. Note: See the generator set specification sheet for engine model identification. Engine Manufacturer (and model) GM/ PSI and Controller Displays Kohler Kohler Kohler Gas Kohler Gas as Provided by the Diesel Diesel (KG2204, (KG6208, John Engine ECM...
  • Page 122 Notes 122 Appendix TP-6694 7/18...
  • Page 124 TP-6694 7/18j KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 Original Instructions (English) For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2010, 2011, 2014, 2015, 2017, 2018 by Kohler Co. All rights reserved.

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