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Kohler KD700 Operation

Industrial generator sets
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Operation
Industrial Generator Sets
Models:
KD700-KD4000
Controller:
APM802
TP-7070 11/22g

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Summary of Contents for Kohler KD700

  • Page 1 Operation Industrial Generator Sets Models: KD700-KD4000 Controller: APM802 TP-7070 11/22g...
  • Page 2 WARNING: This product can expose you to chemicals, including carbon monoxide and benzene, which are known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65warnings.ca.gov WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the State of California to cause cancer and birth defects or other reproductive harm.

  • Page 3: Table Of Contents

    Table of Contents Safety Precautions and Instructions ............................5 Introduction ....................................11 Service Assistance................................... 13 Section 1. Specifications and Features ......................... 15 Introduction ................................15 Controller Specifications............................15 1.2.1 Controller Specifications .......................... 15 1.2.2 Display and Touchscreen......................... 15 Controller Features..............................16 1.3.1 Connections .............................
  • Page 4 2.11 Applications ................................48 2.11.1 Reference ..............................49 2.11.2 Region Settings ............................50 2.11.3 HMI Settings ............................52 2.11.4 Restart ..............................54 2.11.5 Display Cleaning ............................54 2.11.6 Firmware Update ............................. 55 2.11.7 Screenshot ............................... 56 2.11.8 Ladder Tools ............................57 2.11.9 Save Parameters .............................

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.
  • Page 6 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.
  • Page 7 Engine Backfire/Flash Fire WARNING Risk of fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed.
  • Page 8 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.
  • Page 9 Hazardous Voltage/Moving Parts DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. DANGER Hazardous voltage. Moving parts. Will cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. WARNING Hazardous voltage.
  • Page 10 Heavy Equipment WARNING Unbalanced and elevated weight. Improper lifting can cause severe injury or death and equipment damage Do not lift the generator set from the engine or alternator eyes. Never stand under a unit being lifted. Always maintain a safe distance from the unit being lifted. See the lifting instructions in the installation manual that was provided with the unit.

  • Page 11: Introduction

    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.
  • Page 12 Abbreviations This publication makes use of numerous abbreviations. Typically, the word(s) are spelled out along with the abbreviation in parentheses when shown for the first time in a section. Appendix A, Abbreviations, also includes many abbreviation definitions. Nameplate Location Generator sets and their components (engine, alternator) are identified with decals or nameplates. For future reference during routine maintenance or to order service parts, copy the model number, serial number, and specification number from the generator set nameplate into the spaces provided in the product information section on the inside front cover of this manual.

  • Page 13: Service Assistance

    (86) 10 6518 7950 • Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7951 • Look at the labels and decals on your Kohler product (86) 10 6518 7952 or review the appropriate literature or documents Fax: (86) 10 6518 7955 included with the product.
  • Page 14 Notes TP-7070 11/22...

  • Page 15: Specifications And Features

    Screen Size: 305 mm (12 inches) • Viewing Angle: 140° horizontal and vertical • Languages: English, French Note: Have setup and adjustments of the controller performed only by an authorized Kohler distributor. The setup and adjustments are password protected. TP-7070 11/22...

  • Page 16: Controller Features

    Controller Features The controller features include a 307 mm (12.1 inch) touchscreen with backlight and wide viewing angle (140 ° horizontal and vertical) and terminal blocks for input and output connections. See Figure 3 for an illustration of the controller front panel and the customer connection area.

  • Page 17: Connections

    1.3.1 Connections DANGER Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure. Inputs and outputs from the controller base module are brought out to TB10 in the connection box. See the figure titled: APM802 Controller and Customer Connection Box for the terminal block location.

  • Page 18: Modbus Connections

    1.3.2 Modbus Connections Use RS-485 cable for Modbus RTU connections. Belden #9841 or equivalent shielded, twisted-pair cable is recommended. See Figure 5. See the generator set wiring diagram for the Modbus connection location on TB10. The controller also supports Modbus TCP over Ethernet. Connect to the RJ45 port labeled Ethernet 3 on the controller’s base module.

  • Page 19: Nfpa Requirements

    NFPA Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine/generator functions and fau lts shown below. Engine functions: • Overcrank • Low coolant temperature warning • High coolant temperature warning • High coolant temperature shutdown •...

  • Page 20: Parameter Settings

    Parameter Settings Controller parameter settings are factory-set and password-protected. Selected settings are shown in Figure 8. If changes are required, contact your distributor. Parameter Setting Preheat duration* Air-preheater maximum delay (at each start attempt)* 30 s Number of starting attempts Time between starting attempts 15 s Fault inhibition time in starting phase...
  • Page 21 Output Relay Outputs Factory Setting Configuration Digital Outputs Form C Common Fault Form C System Ready Form C Common Warning Form C Reserved for Factory Use Form A Horn Form A Low Coolant Temp Warning Form A Shunt Trip Form A Not in Auto Form A BCA Excitation...
  • Page 22 Notes TP-7070 11/22...

  • Page 23: Operation

    Section 2. Operation Prestart Checklist To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designa ted, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. DANGER Hazardous voltage.

  • Page 24: Exercising Generator Set

    Visual Inspection. Walk around the generator set and look for leaking fluids, loose or dangling wiring, and loose or missing hardware. Repair as needed before starting the generator set. This visual inspection should be routinely done while the unit is running.

  • Page 25: Stop Signal

    2.4.2 Stop Signal A stop signal includes the following: • Removal of start signal via contacts 3 and 4 when the controller is in AUTO mode. The remote start contacts may be connected to an ATS (used during a power outage, exercise period, etc.) or a remote panel. •...

  • Page 26: Controller Operation Modes

    Controller Operation Modes The controller operation includes several types of starting and stopping functions. There are three primary modes of operatio n, selected from the controller touchscreen or the optional keyswitch: • Auto (Automatic mode) • Manual • Out of Service (Off mode) See Figure 11 for the location of the mode selection switch on the controller touchscreen.

  • Page 27: Out Of Service Mode

    Operating Action/Event Operation Notes Mode Press Auto or place the optional Responds to remote start/stop keyswitch into the AUTO position (if commands from an ATS or remote start Auto is the recommended mode. equipped). panel. * Engine runs at 1000 RPM for 5 Idle switch on contacts 5 and 6 Customer-supplied idle switch is minutes, then ramps up to normal...

  • Page 28: Manual Mode

    2.5.2 Manual Mode In manual mode, engine start and stop are controlled manually by the operator using the Engine Start and Engine Stop buttons on the controller’s touchscreen. If the controller is equipped with an optional keyswitch and manual start/stop button, use the start/stop button for manual operation in the procedures below.

  • Page 29: Load Shed

    Load Shed The manual key switch/ load shed module is available as an optional kit. The load shed function drives outputs to four Form C dry contacts to remove non-critical loads. If the generator set load reaches or exceeds the level set in power threshold #9, loads are shed until the total load drops below the threshold level. Loads are added again when the total load drops below the level in threshold #9.
  • Page 30 ORIGINAL MANUAL KEY SWITCH/ DIGITAL 8 INPUT/OUTPUT LOAD SHED I/O MODULE MODULE Load Shed Customer Connections Load Shed 1 Key switch factory Load Shed 2 connections Load Shed 3 Load Shed 4 Key switch factory connections Key Switch AUTO Key Switch MANUAL Key Switch OFF Load Shed Start/Stop Button...

  • Page 31: Hmi Screen Layout

    HMI Screen Layout 2.7.1 Home Screen The home screen of the APM802 controller’s human-machine interface (HMI) contains status messages, navigation buttons, data displays, and controls described briefly in the following sections. See Figure 15. Top bar Control Panel Generator view Figure 15 Home Screen 2.7.2...

  • Page 32: Generator View

    2.7.3 Generator View The generator view displays engine mechanical data and alternator electrical data. When in manual mode, the Engine Start button also appears. See Figure 17. Engine start appears in Manual mode only Alternator electrical view Engine and mechanical view Figure 17 Generator View...

  • Page 33: Custom View Button

    2.7.5 Custom View Button On medium voltage units equipped with thermocouple modules, touch the custom view button to see alternator temperature readings from the thermocouple modules. If no thermocouple modules are installed, 32F (or 0C) is displayed for all temperatures. If nothing is connected to one channel on a thermocouple module, - 58F (or - 50C) is displayed.

  • Page 34: Operator Login

    Operator Login Some functions require logging in as an operator. Touch the Operator button. See Figure 22. Use the virtual keypad to enter the login (1966). Note: When logging on as operator 1966, a password is not required. When logged in as an Operator, the Modify button appears on screens where settings can be changed. See Figure 21 for an example.

  • Page 35: Data Displays

    Data Displays 2.9.1 Generator Mechanical Values Overview display It is possible to display up to 6 mechanical values at the same time. By default, the following values are displayed: • Working hours counter (number of operating hours) • Fuel level (daily service tank or main tank) •...
  • Page 36 Figure 25 Information Bar Selection Figure 26 Detailed Mechanical Values From an overview display of 6 mechanical values, we switch to a detailed display of 3 mechanical values. Three tabs also appear: Fuel, Engine, and Cooling. The mechanical values are all classed under these three tabs. Under each tab, the mechanical values displayed can be accessed by pressing the <...

  • Page 37: Generator Electrical Values

    2.9.2 Generator Electrical Values Overview display Six electrical values are displayed and shown as meters. See Figure 28. Power factor, PF Reactive power, Q, in kvar Active power, P, in kW Line-to-line voltage, U, in volts Frequency, F, in hertz Phase current, I, in amperes Figure 28 Electrical Values...

  • Page 38: Curve Display

    Curve button Figure 30 Detailed Electrical Values 2.9.3 Curve Display When you zoom into each mechanical or electrical value, the Curve button appears. Touch the Curve button to view the change over a variable period in real time of one of the 6 electrical values of the overview display. Figure 31 shows the location of the Curve button.
  • Page 39 Touch the recording period to select the time period: • 10 minutes: record values every 1 second • 4 hours: record values every 30 seconds • 8 hours: record values every 1 minute • 24 hours: record values every 3 minutes On any curve displayed on the screen, inserting a USB key into the HMI port makes the USB key button appear.

  • Page 40: Saved Electrical And Mechanical Data

    2.9.4 Saved Electrical and Mechanical Data The recording on a USB stick provides a curve data file (.csv) containing the information shown in Figure 35. Depending on the engine type and sensors installed on the generator set, some of the 14 mechanical values may not be used. In that case, 0 will appear in the Excel table for the value or values concerned.

  • Page 41: Events

    2.10 Events The controller displays status, alarm(warning), and fault Internal Alarm Fault Description Number (Warning) (Shutdown) (shutdown) messages. See Figure 36 for a list of possible M3.108 Over speed fault alarms and faults. M3.109 Speed detection fault Internal Alarm Fault Description M3.113 Low engine coolant level...

  • Page 42: Faults And Alarms

    2.10.1 Faults and Alarms Press the Alarm (⚠) button shown in Figure 37 to view a list of generator set events, including status messages, alarms, and faults. • A status message communicates the state of the generator set (example: appearance of Stop mode). •...
  • Page 43 Alarm (⚠) button is red Generator set has shut down and is in out of service mode Stop horn button Figure 39 Appearance of a Fault (shutdown) Not active (off) Alarm button with number of alarms (press to display list) Active (on) Reset button (X) Date and time of event...

  • Page 44: Resetting An Alarm

    2.10.2 Resetting an Alarm An alarm indicates that a problem has occurred, but the generator is still able to run. Always correct an alarm condition before it leads to a fault that will shut down the generator set. See the Safety Precautions and Instructions section of this manual be fore proceeding to correct an alarm condition.

  • Page 45: Consulting Status Messages

    Emergency Stop Fault Manually pressing the emergency stop button causes a fault. After the emergency stop button is unlocked, the fault indicator will turn off, and it will then be possible to reset this fault with the X button. Figure 43 Resetting a Fault 2.10.4 Consulting Status Messages Reviewing the status messages is possible at any time.
  • Page 46 The most recent status in the sequence The oldest status in the sequence Figure 45 Drop-down Menu A Drop-down list B Drop-down list A Figure 46 Drop-down Lists A and B TP-7070 11/22...

  • Page 47: Full Event Log

    2.10.5 Full Event Log To view all events (status messages, alarms, and faults, active or reset), select Full event log from drop-down list A, and select All from drop-down list B. See Figure 47 for an example of the full event log. List A, Full event log selected List B, All selected Figure 47...

  • Page 48: Applications

    2.11 Applications Touch the Applications button in the top bar to open the Applications screen. See Figure 48. From this screen, you can access the screens listed in Figure 49. Note that access to some screens requires logging on as an operator. HMI settings Applications button Region settings...

  • Page 49: Reference

    Reference Customer case name (for example: computer center) APM identification Option of assigning a name to the HMI (for example: GS parking number 1) Kohler reference Commercial case reference (manufacturer’s side) Reference Genset serial number Generator set serial number associated with the HMI...

  • Page 50: Region Settings

    2.11.2 Region Settings Modify Date and time adjustment window appears after touching the Modify Select user language Set the date and time Figure 51 Region Settings Screen Title Description and Possible Settings (or selections) Pressure Selection of the pressure display: bar, PSI Temperature Selection of the temperature display: °C , °F Customization...
  • Page 51 Adding a logo Press the Modify button. An additional Upload key appears. On a USB key, create a directory called E:\ apm802 \ icon and copy the logo* to be inserted into the main screen of the HMI. Insert the USB key into the appropriate port and press the Load key. In the window shown in Figure 52, press the central field, select the desired image and confirm.

  • Page 52: Hmi Settings

    2.11.3 HMI Settings Touch the Modify button Slide to adjust the screen brightness during normal operation Slide to adjust brightness during standby operation Figure 53 HMI settings The sliders on this screen allow adjustment of the screen brightness during operation and standby. The two sliders are independent.
  • Page 53 The Home button on the Remote HMI looks different than the Home button on the local HMI. See Figure 54. Remote HMI Local HMI Figure 54 Home Buttons In the case of a Remote HMI in Visualization mode, the icons in Figure 55 show the various displays of key 2. Figure 55 Remote HMI Indication In the case of a Remote HMI in Operation mode or in Full access mode, button 2 does not change appearance.

  • Page 54: Restart

    Figure 57 Selecting a Module from a Remote HMI 2.11.4 Restart Press the Restart icon to bring the window shown in Figure 58 to the front. Confirm the restart by pressing OK, or cancel the procedure by pressing Cancel. This operation will trigger a complete restart of the HMI module. Figure 58 Restart Window 2.11.5 Display Cleaning...

  • Page 55: Firmware Update

    2.11.6 Firmware Update Pressing the Firmware update icon carries out an update of the HMI firmware. The update requires that a USB key is inserted into the port provided on the bottom of the HMI. See Figure 60. USB Ports Figure 60 USB Port Location on HMI Module Firmware Update Procedure...
  • Page 56 2.11.7 Screenshot Before taking a screenshot, it is necessary to insert a USB key in the port provided on the bottom of the HMI module. See the USB Port Location on HMI Module figure. Pressing the Screenshot button enables the screenshot feature. The screenshot icon turns blue when enabled. Screenshot mode stays enabled until turned off.

  • Page 57: Ladder Tools

    2.11.8 Ladder Tools Ladder is a standardized graphic language which is very similar to a ladder diagram. Implemented in the base module of the APM802, it is used to define the PLC functions required for specific functions. Pressing the Ladder tools icon takes you to the screen shown in Figure 63. See the Applications Screen figure for the location of the Ladder tools icon on the applications screen.
  • Page 58 Input internal Input line title variable Input variable Normally closed contact Electrical connection Figure 64 Inputs Network Figure 65 Outputs network TP-7070 11/22...

  • Page 59: Save Parameters

    2.11.9 Save Parameters Insert a USB key into the port on the bottom of the HMI module. See the USB Port Location on HMI Module figure. Press on the Save Parameters icon; the screen shown in Figure 66. Saving starts automatically. When it is completed, the screen confirming that the save operation was performed successfully appears.

  • Page 60: Menus

    2.12 Menus Figure 67 shows the architecture of the screens accessible from the Menu button. Menu > 1-Settings 2-Measurements 3-History 4-Diagnostic 5-Configuration 6-Hardware Power Mechanical Archiving Variables Application Installation thresholds 5.1.1 6.1.1 Timers * Generator electrical Binary inputs General General 5.1.2 6.1.2 Auxiliaries...
  • Page 61 Menu Access 5.2.3 Excitation View * Some menus are view-only and do not allow modifications. 5.2.4 Miscellaneous View * Some menus require the operator password to view and/or 5.2.5 Timers View * modify. See Figure 68 for menu access information. 5.3 Regulation 1-Settings User...

  • Page 62: Menu 1-Settings

    2.12.1 Menu 1-Settings The 1-Settings menu can be accessed via the key with the same name. • 1.2 Power Thresholds • 1.5 Timers (not used) • 1.6 Auxiliaries • 1.8 Parameters Changing Settings Pressing the Modify button brings up text entry fields for settings that can be changed. See Figure 69. Pressing in the text entry field brings up the alphanumeric keypad shown in Figure 70.
  • Page 63 Screen 1.2-Power thresholds The 1.2-Power thresholds screen is used to set up to 10 active power thresholds. Threshold 9 is used for load shed. Display of the threshold setting result in kW Setting the threshold in % of the generator power Thresholds numbered from 1 to 10 Entry field for text...

  • Page 64: Menu 2-Measurements

    Screen 1.8 Parameters The 1.8-Parameters screen is used to set the engine speed (RPM). The speed can be adjusted by ±10RPM. Figure 73 Parameters Screen 2.12.2 Menu 2-Measurements The 2-Measurements menu can be accessed via the button with the same name. This gives access to the screens listed below. •...
  • Page 65 Note: Other values may be displayed depending on the engine selected in the 6.1.2 generator set screen. Screen 2.3-Generator electrical The 2.3-Generator electrical screen gives a detailed view of all the electrical values for the associated generator (on generator HMI only). Display for 3 phases Phase sequence indication : Green = Correct;...

  • Page 66: Menu 3-History

    2.12.3 Menu 3-History The 3-History menu can be accessed via the key with the same name. It gives access to Screen 3.1-Archiving. Screen 3.1-Archiving The 3.1-Archiving screen is used to store certain parameters in the controller’s memory. Press the Initialization button next to an item to reset the history to zero.

  • Page 67: Menu 4-Diagnosis

    2.12.4 Menu 4-Diagnosis The 4-Diagnosis menu can be accessed via the key with the same name. it gives access to the 5 screens below: 4.1-Variables 4.2-Binary inputs 4.3-Binary outputs 4.4-Regulation & Protection 4.5-Regulation The Diagnosis menu may be used for troubleshooting by factory service support personnel. Active faults and events can be viewed using the alarm button or the Event Log.
  • Page 68 Refer to the example in Figure 78 and the variables listed in Figure 80. Other variables and events are shown in the Saved Electrical and Mechanical Data and Events sections. Title Color Name State or value %M3.112 Green Low engine coolant warning %I5.21 Fuel level %M1.0...
  • Page 69 Screen 4.3-Binary outputs The 4.3-Binary outputs screen is used to get a quick overview of the following logic states: • Eighteen base module outputs • Eight outputs for each extension module connected to the base module Output number (DO- #0 to DO- Output status indicators: #8 &DO- #9 to DO- #16+ WDG *) Red = 0 (output inactive);...
  • Page 70 Screen 4.4-Regulation & protection The 4.4-Regulation and protection screen is used to read all the internal variables for the regulation and protection modules. Entry field for a variable name Value or status of the variable Numeric keypad for entering the variable name Figure 83 Regulation and Protection Screen The process for entering a regulation or protection variable is the same as for the 4.1-Mapping screen.

  • Page 71: Menus 5 And 6

    2.12.5 Menus 5 and 6 Except for menu 6.5, communication, menus 5 and 6 are view-only menus that can be seen when logged in as an operator (1966). The view-only menus are not shown in this document. 2.12.6 Menu 6.5-Communication Screen 6.5.1-Ethernet The 6.5.1-Ethernet screen defines the computer addresses for the Ethernet connections for the base module and the HMI module.
  • Page 72 Screen 6.5.2-Serial link The 6.5.2-Serial link screen defines the specifications of the RS485 type serial link available on the base module. Figure 87 Serial Link Screen The screen is accessible for modification at the operator level. Figure 88 shows the range of possible settings and the factory default settings, which are configured for communication with the RSA III remote serial annunciator.

  • Page 73: Troubleshooting

    Section 3. Troubleshooting Introduction This section contains generator set, controller, general engine, and customer connection panel troubleshooting, diagnostic, and repair information. This section may refer to other literature for procedures and additional information. See the list of rel ated materials in the Introduction of this manual for literature part numbers. The information in this section is a guideline for generator set operating technicians and/or maintenance personnel.

  • Page 74: General Troubleshooting Chart

    General Troubleshooting Chart Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7070...
  • Page 75 Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7070 11/22...
  • Page 76 Exercise run time and/or event records inoperative Displays error message/locks Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7070 11/22...
  • Page 77 Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressure Overheats Lacks power Stops suddenly No or low output voltage Starts hard Cranks but does not start Does not crank TP-7070 11/22...
  • Page 78 Notes TP-7070 11/22...

  • Page 79: Accessories

    Section 4. Accessories Accessories and Connections Factory-installed accessories are available to help finalize installation, add convenience to operation and service, and establish state and local code compliance. See Figure 89 for a list of available kits. Obtain the most current accessory information from your local authorized service distributor/dealer.

  • Page 80: Battery Chargers

    Factory-installed battery charger kits are available for KD model generator sets with a single starter or redundant starters. The 20 Amp, 24 VDC Kohler High Frequency Battery is used with these models. The battery charger sends a fault message to the APM802 controller in the event of a battery charger fault. See TP -7072, Battery Charger Installation and Operation Manual, for information about fault conditions and for battery charger operation instructions.

  • Page 81: Analog Input/Output Module

    The Analog Input/Output (I/O) Module provides two output connections and four input connections. See Figure 92 for I/O specifications and Figure 93 for connections. The factory default input and output settings are undefined. I/O settings can be loaded by an authorized service technician. Contact your Kohler distributor with your requirements for inputs and outputs. Input/Output Specifications...

  • Page 82: Digital Input/Output Module

    4.4.2 Digital Input/Output Module The Digital 8 Input/Output Module Kit is available as an optional accessory. The modules are factory-installed in the customer connection box. Module power and CAN communication with the controller are factory-connected. The module CAN address is factory-set.
  • Page 83 The DIOM kit includes two digital input/output modules, referred to as DIOM 1 and DIOM 2. The digital inputs and outputs on DIOM 1 and DIOM 2 can be configured by an authorized service technician using Kohler SiteTech software. On KD Series generator sets with the APM802 controller, the Module #0 position is reserved for the Manual Key Switch/Load Shed module.
  • Page 84 Factory Settings Module 0 Digital Inputs/ Outputs (Key Switch/ Load Shed Only) Optional Module 1 Input DI0 Key switch AUTO Undefined Input DI1 Key switch Manual Undefined Input DI2 Key switch OFF Undefined Input DI3 Start/Stop Button Undefined Input DI4 Reserved Undefined Input DI5...

  • Page 85: Thermocouple Input Module

    4.4.3 Thermocouple Input Module Up to three thermocouples can be connected to the Thermocouple Module. Type K or PT100 thermocouples can be connected. See Figure 99 for thermocouple specifications. See Figure 101 and Figure 102 for connections. Medium voltage (larger than 600 volts) units are equipped with two thermocouple modules with the settings shown in Figure 100.

  • Page 86: Remote Emergency Stop Kit

    Ground 24VDC Power Supply (9-40 VDC) 0-20 mA PT100 Shielding Connection Note: Cable shields must be grounded as shown. 31613391201 Figure 102 Connections Remote Emergency Stop Kit The emergency stop (E-stop) kit allows immediate shutdown of the generator set from a remote location. If the emergency stop switch is activated, the EMERGENCY STOP lamp lights and the unit shuts down immediately, bypassing the engine cooldown cycle.

  • Page 87: Remote Emergency Stop Kit

    4.5.1 Remote Emergency Stop Kit This switch uses a glass piece that must be replaced after activation. To stop the generator set, pull down on the handle, breaking the glass piece. To reset the emergency stop switch, return the handle to the original position and replace the glass piece with a new one.

  • Page 88: Remote Serial Annunciator

    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 104) that monitors the condition of the generator set and/or ATS from a remote location. The RSA III alerts the operator through visual and audible signals using LED indication and a horn.
  • Page 89 System Monitoring LEDs and Functions System Generator Common Ready Running Communications Common Fault Fault and Status Condition Fault LED Status LED Fault LED Output Horn Overcrank (Shutdown) Red SF Red SF Green Red SF High Engine Temperature (Warning) Yellow SF Red SF Green Green...
  • Page 90 Notes TP-7070 11/22...

  • Page 91: Appendix A. Abbreviations

    Appendix A. Abbreviations A, amp ampere blk. htr. block heater digital to analog converter ABDC after bottom dead center BMEP brake mean effective pressure decibel alternating current bits per second dB(A) decibel (A weighted) analog to digital Brass direct current advanced digital control;...
  • Page 92 (2 bytes) megabyte (2 bytes) gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker gallons per minute kilogram one thousand circular mils grade, gross kg/cm kilograms per square meggar megohmmeter centimeter...
  • Page 93 N, norm. normal (power source) permanent magnet generator silicon controlled rectifier (electrical), selective catalytic reduction (exhaust emissions) not available, not applicable potentiometer, potential s, sec. second Systeme international d’unites, nat. gas natural gas parts per million International System of Units National Bureau of Standards PROM programmable read-only...
  • Page 94 ultrahigh frequency user interface Underwriter’s Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) univ. universal uniform resource locator (web address) undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt...

  • Page 95: Appendix B. Operating Hours And Service Log

    Appendix B. Operating Hours and Service Log Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were performed. Enter hours to the nearest quarter hour. Operating Hours Service Record Total Date Run Hours Run...
  • Page 96 Operating Hours Service Record Date Run Hours Run Total Hours Service Date Service TP-7070 11/22...
  • Page 97 TP-7070 11/22...
  • Page 98 TP-7070 11/22...
  • Page 99 TP-7070 11/22...
  • Page 100 TP-7070 11/22g KOHLER CO. Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 For the nearest sales/service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 KOHLERPower.com © 2017 Kohler Co. All rights reserved.

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