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Short circuits.
Hazardous voltage/current will cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage.
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
Installation Procedure
1.
Acquire the user parameters.
1.1
Read and follow all safety precautions at the
beginning of this publication.
1.2
Choose one of the following methods to retrieve
the user parameters:
Backup disk.
D
previously made, obtain the parameters
from this disk. If a disk was not previously
made, create a backup if possible using the
SiteTecht software. The existing controller
must function in order to create the file.
Paper form. Parameters may have been
D
previously recorded on the User-Defined
Settings form located in the appendix of the
Controller Operation Manual or other similar
form.
Controller menu.
D
controller menu displays if possible and
enter the parameter information in the
Controller Operation Manual appendix,
Programmer-Defined Settings form.
1.3
Save the user parameter data for step 6.3.
2.
Remove the generator set from service.
2.1
Press the generator set master control
OFF/RESET button.
2.2
Disconnect the power to the battery charger, if
equipped.
2.3
Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
2.4
Disconnect the generator set from load by
opening the line circuit breaker.
3.
Remove the existing controller and
disconnect the electrical connections.
3.1
Remove the junction box panels as needed to
access the wiring.
3.2
Remove the four controller panel screws.
TT-1757
7/18
Do not contact electrical
If a backup disk was
Manually review the
Note: Clearly mark all disconnected leads from
the controller with tape to simplify
reconnection.
3.3
Disconnect the controller harness leads. Listed
below are some common leads and plugs that
require removal or disconnection. Items below
in bold are shown in Figure 2 and Figure 3.
These connections are typical and may not
apply to all applications. See the corresponding
wiring diagram found in the respective wiring
diagrams manual.
Remote
Emergency
D
connections.
P1
(24-Pin)
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generator wiring harness.
P2 (6-Pin) Connector for AC current. P2 is
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only used on older versions of the
Decision--MakerR 3000 (GM65741, green
board) controller. Newer versions of the
Decision--MakerR 3000 (GM65741--1) and
APM402 controllers have the AC current
wiring included in the P1 connector. An
adapter harness may be required; see step
4.1.
(4) Push-on Terminal Connectors for
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V7/V8/V9/V0 for generator set output
voltage connection.
P21
(6-Pin)
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connection of optional RSA.
P23 (8-Pin) Connector (RJ45) for optional
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input/output (I/O) module circuit board.
P30 3-Pin Connector (2-Pin Jumper) for
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selection of alternator type—Wound Field
(300 kW and larger) or Fast Response (less
than 350 kW). Take note of the original
circuit board jumper position. See Figure 5.
TB1 (6-Position) Terminal Block for
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analog and digital inputs.
TB2 (4-Position) Terminal Block for K1
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relay outputs.
TB3 (6-Position) Terminal Block for
D
E-stop, remote start contacts, and aux. input
connections.
Stop
Switch
Connector
for
engine/
Connector
for
RS-485
3
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