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Kohler 1300REZCK Installation Manual
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Kohler 1300REZCK Installation Manual

Kohler 1300REZCK Installation Manual

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Installation
Engine Model:
HGM560
Generator Set Models:
1300REZCK
See Inside Front Cover for Service Assistance Information
TP-7023 8/18a

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Summary of Contents for Kohler 1300REZCK

  • Page 1 Installation Engine Model: HGM560 Generator Set Models: 1300REZCK See Inside Front Cover for Service Assistance Information TP-7023 8/18a...
  • Page 2 Visit the Kohler Co. website at KOHLERPower.com. (86) 10 6518 7952 Fax: (86) 10 6518 7955 Look at the labels and stickers on your Kohler product East China Regional Office, Shanghai or review the appropriate literature or documents Phone: (86) 21 6288 0500 included with the product.
  • Page 3 DN80/DIN 2576 (3”) GAS INLET FLEXIBLE - Ref.: 38.30.280 38.30.280 IT-C-A-40-001e INSTALLATION OF EXHAUST PIPELINE EXHAUST FLEXIBLE Ref.: 19.40.A60 (19.40.073) IT-C-A-40-002e ELECTRIC STARTING IT-C-A-55-001e HGM ENGINES INSTRUMENTATION IO-G-M-60-006e CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, KOHLER POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE.
  • Page 4 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION IT-G-A-50-022e GCS CONTROL SYSTEM MODBUS/TCP INTERFACE IT-G-A-50-023e GCS CONTROL SYSTEM J1939 INTERFACE IT-G-A-50-024e GCS CONTROL SYSTEM DATALOG CONFIGURATION CONSISTENTS WITH OUR CONTINUAL PRODUCT IMPROVEMENT POLICY, KOHLER POWER RESERVES THE RIGHT TO CHANGE ANY SPECIFICATION WITHOUT PRIOR NOTICE.
  • Page 5 Dear Customers,  This letter is to inform you of the EPA requirements for New Stationary Spark Ignition Internal  Combustion Engines. EPA regulation 40 CFR § 60.4230 et seq. (Subpart JJJJ: Standards  of  performance  for  Stationary  Spark  Ignition  Internal  Combustion  Engines)  place  certain  requirements  on  owners  and  operators  of  stationary  spark  ignition  internal  combustion  engines. Particularly, § 60.4243, requires that the engines be certified on‐site initially and then  every three years or 8,760 hours of operation.  However, in an effort to possibly simplify your compliance obligations, Dresser‐Rand has been  working with the EPA to certify our engines. This “pre‐certification” may eliminate the need to  test the engines onsite in accordance with EPA regulations. However, many States and local Air  Authorities now require onsite testing regardless of the EPA regulations. In fact, many of the  local regulations are stricter than the EPA’s regulations. We advise you to consult all applicable  regulations in determining your compliance obligations. ...
  • Page 6 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-00-008e February 2010 EMISSIONS - RELATED INSTALLATION INSTRUCTIONS 1. INTRODUCTION According to the United States Environmental Protection Agency (EPA) Ref. code of Federal Regulations 1048.130, these instructions are intended to give the installer of the engine all of the information that is necessary to properly install the engine.
  • Page 7 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-00-008e February 2010 EMISSIONS - RELATED INSTALLATION INSTRUCTIONS The exhaust pipeline and silencer shall be protected and heat-insulated to avoid big heat radiations into the engine room and the subsequent reduction in the engine performance. The exhaust pipeline must be laid for each engine individually.
  • Page 8 (Biogas) or IC-G-D-00-04e (syngas). Other gas qualities or failures in the specifications meeting can affect emissions levels, being out of the emissions levels according to the 40 CFR 60 subpart JJJJ standards. KOHLER POWER is not responsible for the emission level compliance in these situations Check leakages before engine first start.
  • Page 9 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-00-008e February 2010 EMISSIONS - RELATED INSTALLATION INSTRUCTIONS 4. ENGINE-ROOM VENTILATION The correct ventilation of the engine room allows the correct engine performance; especially in the case the engine takes the air from the room. In designing a ventilation system, the same importance should be given to the necessary volume of air as to the flow direction.

  • Page 10: Engine Instrumentation

    To “check / adjust fuel air ratio” the exhaust emissions and actual A/F ratios are confirmed. If adjustments are necessary, they are performed using KOHLER POWER proprietary software interface and only performed by KOHLER POWER authorized service technicians.

  • Page 11: Engine Design

    In this event, KOHLER POWER informs users of any residual hazards due to incomplete effectiveness of the protective measures, advising them that they must have specific training and use personal protective equipment where necessary.
  • Page 12 KOHLER Power shall not be liable for any injury or damage arising from any use of the engine other than that described in the instruction manual. Operating the engine beyond its nominal conditions (e.g. in terms of power, advance ignition, mixture strength - carburetion, etc.) can have serious consequences for the user, or...
  • Page 13 PRODUCT INFORMATION INDEX DATE Dept. 2 IC-G-D-60-003e August 2012 REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY REGULATIONS AND "CE" MARK 4.5.3. Forced Induction In the supercharging circuit (downstream of the turbocharger), sealing of the different components is by means of mechanical seals with Viton O-rings.
  • Page 14 PRODUCT INFORMATION INDEX DATE Dept. 2 IC-G-D-60-003e August 2012 REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY REGULATIONS AND "CE" MARK 4.9. Fuel System  The gas system design always conforms to the applicable regulations in force (UNE 60.620) and comprises the following elements: ERM.
  • Page 15 PRODUCT INFORMATION INDEX DATE Dept. 2 IC-G-D-60-003e August 2012 REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY REGULATIONS AND "CE" MARK 4.10. Blowby Gases Because it is impossible to have the combustion chamber completely sealed, combustion gases always accumulate in the crankcase and can give rise to oil splashing outside due to overpressure in the crankcase. As prevention against this occurrence, all the engines come complete with an explosion relief valve for the expulsion of those gases that are fed back, after filtering, into the engine intake system on environmental protection grounds.
  • Page 16 PRODUCT INFORMATION INDEX DATE Dept. 2 IC-G-D-60-003e August 2012 REVIEW OF COMPLIANCE WITH EUROPEAN MACHINERY SAFETY REGULATIONS AND "CE" MARK The instruction manuals include all necessary drawings and diagrams to install, operate, maintain, inspect the machine and check it for correct operation, and make any repair, if needed, in addition to other relevant recommendations, especially in relation to safety issues.

  • Page 17: Safety Precautions

    7. CONCLUSION The preceding review allows us to conclude that KOHLER POWER GAS engines have been designed in full awareness of and in compliance with the machinery safety regulations requirements, as specified in Directive 2006/42/EC and the harmonised standards UNE-EN ISO 12100-1 and UNE-EN ISO 12100-2.

  • Page 18: Preliminary Observations

    The aim of this document is to inform the users of KOHLER equipment on the safety precautions which are required for handling and operating it adequately.

  • Page 19: Exhaust Gases

    DATE Dep. 1 IC-G-D-60-002e June 2010 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES 4. EXHAUST GASES CAUTION IC engine exhaust products are toxic and may cause injury or death if inhaled. All engine installations must have an exhaust discharge pipe so that the exhaust gases are delivered into the outside air. A closed building or shelter must be adequately vented to provide a steady supply of fresh air.

  • Page 20: Ignition System

    DATE Dep. 1 IC-G-D-60-002e June 2010 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES 8. CRANKCASE GASES WARNING All the engines incorporate a crankcase gases vent to relieve pressure that builds up inside as a portion of the combustion gases flow in through the piston rings (blow by). Make sure the vent pipe is correctly fitted, allowing free passage of the gases.
  • Page 21 Proper service and repair is important to the safe, reliable operation of the engine and related equipment. The procedures recommended by KOHLER in this manual are effective methods for performing service and repair operations. Some of these procedures require the use of specially-designed tools. Special tools should be used when and as recommended.
  • Page 22 Do not modify or substitute any parts of the engine without the approval of the Service Department of KOHLER. Take special care not to make modifications which will increase the operating speed of the fan. Install the fan only if the engine has been approved for fan installation. Likewise, install a drive system defined by KOHLER.

  • Page 23: Fire Protection

    DATE Dep. 1 IC-G-D-60-002e June 2010 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES 15. TURBOCHARGERS CAUTION Turbochargers are designed specifically for each application. Turbochargers operate at high temperatures, therefore all inflammable material must be kept away from them. Engines must be shut down and at room temperature before working on turbochargers or burns will result.

  • Page 24: Electrical Tools

    INDEX DATE Dep. 1 IC-G-D-60-002e June 2010 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES 19. WELDING EQUIPMENT CAUTION Welding gas cylinders can explode if damaged. Cylinders must be stored in accordance with manufacturer’s specifications and applicable safety requirements. When using acetylene, check valves should be installed between the regulators and hoses to prevent flashback into the regulators and supply tanks.

  • Page 25: Compressed Air

    IC-G-D-60-002e June 2010 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES Never expose batteries to open flame or electric spark. The chemical action of the battery produces hydrogenous gas which is inflammable and explosive. Do not allow the battery fluid to contact skin, eyes, clothes or painted surfaces.
  • Page 26 IC-G-D-60-002e June 2010 SAFETY PRECAUTIONS FOR KOHLER GAS ENGINES Acids can react with metals to form various gases. Generally, acid solutions on lime scale and rust result in the formation of harmless carbon dioxide. However, when acids contact aluminium, zinc, cadmium, tin, sulphur, arsenic or cyanide, poisonous and explosive gases may be generated.

  • Page 29: General Standards

    1. INTRODUCTION The purpose of this product information sheet is to provide the general standards for the correct lifting of KOHLER POWER gas engines and ethanol engines, as well as the points where the engine must be lifted.. 2. GENERAL STANDARDS CAUTION Always be careful when the lifting the engine or its components.
  • Page 30 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-70-001e January 2015 GENERAL STANDARDS FOR THE CORRECT LIFTING OF GAS AND ETHANOL ENGINES 3. ENGINE RAISING The engines in line are raised at two points, one at the front of the engine and the other at the rear of the block. (See Fig.1) Fig.
  • Page 31 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-70-001e January 2015 GENERAL STANDARDS FOR THE CORRECT LIFTING OF GAS AND ETHANOL ENGINES The engines in V are lifted at 4 points, two in the front of the engine block and two on the rear of the block. To make its lifting it is necessary to use a perch.
  • Page 32 PRODUCT INFORMATION INDEX DATE Dep.1 IT-C-A-70-004e November 2014 FIXING OF LAND – BASED SETS 1. DEFINITION A land-based set is a unit made up by a engine and a driven equipment normally supported by a rigid metal bedframe. In given applications, auxiliary or complementary equipment (radiator, etc.) may be installed on the bedframe 2.
  • Page 33 PRODUCT INFORMATION INDEX DATE Dep.1 IT-C-A-70-004e November 2014 FIXING OF LAND – BASED SETS 3.2. CALCULATION OF SPECIFIC FLOOR LOAD "C" Specific floor load "C" is determined from the equation bellow: 2,5 ( P + F ) 2,5 ( P + F ) C = ---------------------- = (Kg./m2) C = ---------------------- = (lb/ft A x L...
  • Page 34 PRODUCT INFORMATION INDEX DATE Dep.1 IT-C-A-70-004e November 2014 FIXING OF LAND – BASED SETS 3.3. PREPARING THE FOUNDATION FOR SET ANCHORAGE For set anchorage into the foundation, it is essential that two steel sections are laid in the concrete mass itself, as they will allow fixing the metal bedframe of the set later on.
  • Page 35 PRODUCT INFORMATION INDEX DATE Dep.1 IT-C-A-70-004e November 2014 FIXING OF LAND – BASED SETS 4. FLEXIBLE ATTACHMENT Is the fixing used to attach the gen-set to the concrete foundation This attachment gives a vibration isolation between the engine and the foundation. In this fixing system, there are elastic components in order to achieve the absortion of the vibrations.
  • Page 36 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-70-005e March 2008 ALIGNMENT OF THE SET 1. INTRODUCTION For the purpose of this specification, "SET" means a complete unit made up by of a engine and any type of equipment driven by the same (alternators, pumps, hydraulic units, etc.), assembled by means of an intermediate flexible coupling and mounted on metal bedplate.
  • Page 37 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-70-005e March 2008 ALIGNMENT OF THE SET Fig. 1 – Location of Dial Comparators MAX. MISALIGNMENT 0,05 mm (0.019 inch) IN BOTH PLANES TOTAL ERROR OF COMPARATORS 0,10 mm (0.04 inch) PER COMPLETE TURN ENGINE SUPPORT ADJUSTABLE...
  • Page 38 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-70-010e June 2009 CHECK FOR ALIGNMENT OF FLANGED SETS 1. AIM This procedure aims to ensure that the factory alignment of the set remains unchanged at the final operating site. 2. DEFINITION Flanged sets refer to items of equipment where the engine and the alternator / gearbox / machine, etc. are mutually joined together, thus forming a single unit, namely by assembling the engine flywheel cover (flywheel housing) to the coupling cover of the alternator / gearbox etc., through a separator or frame.
  • Page 39 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-70-010e June 2009 CHECK FOR ALIGNMENT OF FLANGED SETS 0.05MM THICKNESS GAUGE Fig. 2 – Gap at the top of flanged joint 3.2.1. If the gap is wider at the TOP (Fig. 2), raise the front supports of the engine until the gap width is homogeneous from top to bottom.
  • Page 40 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-70-010e June 2009 CHECK FOR ALIGNMENT OF FLANGED SETS 3.3. Act on the anchorage of the engine supports in order to RAISE them with adjustable wedges (see Fig. 4) CLAMPING OR FIXING SCREW JACKSCREW ADJUSTABLE WEDGES OPENING TO TURN THE ADJUSTABLE WEDGES C-SPANNER TO DRIVE THE ADJUSTABLE WEDGES...
  • Page 41 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-70-010e June 2009 CHECK FOR ALIGNMENT OF FLANGED SETS 3.4. Act on the anchorage of the engine supports in order to LOWER them with adjustable wedges (see Fig. 5) CLAMPING OR FIXING SCREW JACKSCREW ADJUSTABLE WEDGES OPENING TO TURN THE ADJUSTABLE WEDGES C-SPANNER TO DRIVE THE ADJUSTABLE WEDGES...

  • Page 42: Engine Room Ventilation

    PRODUCT INFORMATION INDEX DATE Dep. 3 IT-C-A-35-001e November 2014 VENTILATION 1. ENGINE ROOM VENTILATION Two fundamental functions must be complied with in respect of ventilating the engine room: Guarantee the environmental conditions, which permit the optimum performance level of the engine and equipment.

  • Page 43: Ventilation Systems

    PRODUCT INFORMATION INDEX DATE Dep. 3 IT-C-A-35-001e November 2014 VENTILATION 2. VENTILATION SYSTEMS 2.1. FORCED VENTILATION (EXHAUST FAN & PUSHER FAN) We recommend this ventilation system for all machine rooms in general. The exhaust fan must be less powerful than the pusher fan, since the engine consumes part of the air inflow. Both air inlet and outlet depend on the location of the air filters and alternator, as the following picture shows: AIR FILTER 1 9 .
  • Page 44 PRODUCT INFORMATION INDEX DATE Dep. 3 IT-C-A-35-001e November 2014 VENTILATION 3. INSTALLATION OF AIR FILTERS The filters should be installed in every case in the most optimum place according to the layout of the engine room. A sufficient quantity of combustion air should be guaranteed. In case of an external air inlet, avoid any risk of water entering into the filter.
  • Page 45 PRODUCT INFORMATION INDEX DATE Dep. 3 IT-C-A-35-001e November 2014 VENTILATION In any case, the air temperature for combustion should not exceed in general 25°C (77ºF) at the filter entry point, otherwise it will be necessary to reduce the engine power. For more detail see Product Information IC-G-B-00-001 for the Series FG/FGLD/SFGLD/SFGM/HGM and IC-C-D-00-007 for the Series E/F/SF.

  • Page 46: Cooling Circuit Diagram

    COOLING SYSTEM FOR KOHLER ENGINES 1. INTRODUCTION KOHLER engines require a cooling system able to dissipate the thermal energy they generate when in operation. In order to cool the engine, water is used as the coolant fluid, after being treated to ensure optimum heat transfer and the non-appearance of problems related to the lowquality of the same.
  • Page 47 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-20-003e February 2011 COOLING SYSTEM FOR KOHLER ENGINES 1. Main circuit water impeller pump 2. Main circuit oil cooler 3. Engine block. Linings and cylinder heads 4. Turbocharger bearing body 5. Main circuit temperature regulator 6.

  • Page 48: Cooling System Components

    DATE Dep. 2 IT-C-A-20-003e February 2011 COOLING SYSTEM FOR KOHLER ENGINES 3. COOLING SYSTEM COMPONENTS 3.1 . IMPELLER PUMP Responsable for passing the right amount and pressure of cooling water past all elements of the engine. It can be operated mechanically by the engine itself or electrically from outside the engine.
  • Page 49 KOHLER recommends having a reserve capacity of 15%. • The cooling liquid must satisfy the requirements listed in product information IO-C-M-20-001. The cooling circuit must be designed to take into account the fact that using antifreeze in the coolant reduces heat transfer by 3% for each 10% of antifreeze added to the coolant.

  • Page 50: Installation Criteria

    PRODUCT INFORMATION INDEX DATE Dep. 8 IT-O-A-2-001903-20-01e December 2014 WATER PREHEATING WITH ELECTRO-PUMP REF. 38.20.A10 HGM560 ENGINES 1. AIM The aim of this production information sheet is to indicate the correct application (installation) of water preheating for engines. 2. INSTALLATION CRITERIA The water, from the top of the engine, is connected to the inlet (low level) of the preheating box.
  • Page 51 RODUCT INFOR RMATION INDEX DATE Dep. IT-O-A A-2-00190 03-20-01e Dece ember 2014 TER PREH HEATING WITH ELE ECTRO-PU UMP REF. . 38.20.A1 HGM560 E NGINES Fig. 1 - HGM560 0 Engines To water r manifold right side To the cylin nder block left s side...
  • Page 52 RODUCT INFOR MATION INDEX DATE Dep. T-C-A-20- -034e gust 2014 SAFETY Y VALVE U USER AND D INSTALL LATION G GUIDE 1. OVERV VIEW Safety valve es are high- -responsibility y accessorie es that are m manufactured d with great precision.
  • Page 53 RODUCT INFOR MATION INDEX DATE Dep. T-C-A-20- -034e gust 2014 SAFETY Y VALVE U USER AND D INSTALL LATION G GUIDE 2.3. INSULA ATION The valve m must be insta alled uncover red, to preve ent the spring g from heatin g up.
  • Page 54 RODUCT INFOR MATION INDEX DATE Dep. T-C-A-20- -034e gust 2014 SAFETY Y VALVE U USER AND D INSTALL LATION G GUIDE 3.2. CHARA ACTERIZAT TION All safety v valves are a assembled a and checked d in the wo orkshop, me ethodically a adjusted in l line with rel...
  • Page 55 This means that you should consult with KOHLER before carrying out any such actions. Clean all valves before sending and indicate if they have been used with dangerous liquids. Help us to prevent...
  • Page 56 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-20-014e October 2005 TECHNICAL INFORMATION OF STANDARD FLEXIBLES JOINTS APLICATION Flexibles joints for water circuit below 100°C. CHARACTERISTIC Ø NOMINAL 32 a 300 350 a 500 WORKIN PRESSURE 15 kg/cm 8 kg/cm BREAK PRESSURE 60 kg/cm 24 kg/cm VACUUM...
  • Page 57 PRODUCT INFORMATION INDEX DATE Dep. 8 IT-C-A-20-014e October 2005 TECHNICAL INFORMATION OF STANDARD FLEXIBLES JOINTS NORMAL POSITION COMPRESSED EXTENDED RADIAL OFFSET ANGULAR DEFLECTION OFFSET (mm) AXIAL ANGULAR NOMINAL Ø RADIAL DEFLECTION (D+E) COMPRESSION EXTENSION 15° 15° 15° 15° 15° 15° 15°...
  • Page 58 Gas outlet pipe Oil blowdown pipe Fig. 1 – Crankcase Gas Breather KOHLER engines may have a passive or active ventilation system.  Open or passive system (diesel and gas engines): This is the standard ventilation system. The passive system has a vent which allows the vapours and gases to vent into the atmosphere via a venting pipe.

  • Page 59: Configuration And Installation

    Dep. 2 IT-C-A-25-001e January 2015 BLOW-BY GASES VENT ON KOHLER ENGINES 2. CONFIGURATION AND INSTALLATION The standard gas venting system is the open system with oil separation and venting into the open air. The open system comprises the following components: A crankcase where the gases that are vented from the combustion chamber through the interstice between the piston rings and the cylinder liner end up.
  • Page 60 IT-C-A-25-001e January 2015 BLOW-BY GASES VENT ON KOHLER ENGINES In open ventilation systems, the pressure in the crankcase of the engine should be checked periodically and always with the engine running at FULL LOAD, so that the engine is operating within the limits specified by performing over time as shown in the chart below.
  • Page 61 Dep. 2 IT-C-A-25-001e January 2015 BLOW-BY GASES VENT ON KOHLER ENGINES Vent piping The crankcase gas outlet should be vented to the open air via a pipe. The design criteria for the pipe is such that at no time does it exceed the maximum pressure in the crankcase, at FULL LOAD, which is 10 mm WC for a new engine.
  • Page 62 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-001e January 2015 BLOW-BY GASES VENT ON KOHLER ENGINES Ø 60,3 [2 "] Ø 76,1 [2 ”] ELEMENTO FLEXIBLE Fig. 5– HGM240 engine blow-by gases vent layout Ø 76,1 [2" ELEMENTO FLEXIBLE...
  • Page 63 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-001e January 2015 BLOW-BY GASES VENT ON KOHLER ENGINES Fig. 6 – FGLD/SFGLD/SFGM/SFGRD/SFE360/480 and SFGLD/SFGM/SFGRD560 engines blow-by gases vent layout Fig. 7 – HGM560/HGM420 engines blow-by gases vent layout...
  • Page 64 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-00-008e July 2015 OIL AND WATER PRE-LUBRICATION, POST-LUBRICATION AND PRE-HEATING APPLICATION 1. OIL PRE-HEATING APPLICATION. The purpose of PRE-HEATING the oil is to get the oil to a minimum temperature, before starting up the engine, which ensures suitable oil viscosity for starting the engine.
  • Page 65 PRODUCT INFORMATION INDEX DATE Dep. 2 IC-C-D-00-008e July 2015 OIL AND WATER PRE-LUBRICATION, POST-LUBRICATION AND PRE-HEATING APPLICATION 3. ENGINE PRE-LUBRICATION APPLICATION. The purpose of pre-lubricating the engine is to ensure the oil is distributed in all engine lubrication circuits and thereby provide sufficient oil pressure for the engine to operate properly.
  • Page 66 KOHLER MOTOROIL 3040 PLUS has been specially designed and is recommended for providing the highest performance in KOHLER engines that operate on natural gas and ethanol. It can however be used in all kinds of naturally-aspirated or supercharged four-stroke engines, whether high or medium rated, that require a lubricant having a medium ash content.

  • Page 67: Health And Safety

    DATE Dep. 2 IC-G-D-25-003e October 2012 KOHLER MOTOROIL 3040 PLUS LUBE OIL FOR NATURAL GAS-FUELLED AND ETHANOL ENGINES 4. ADVANTAGES AND BENEFITS Excellent resistance in the presence of oxidation and nitration. Very high protection of cylinder head valve seats and guides.
  • Page 68 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-037e October 2011 PRELUBING HGM SERIES ENGINE 1. DISPOSITION OF PRE AND POST-LUBING PUMP. Fig 1.General disposition pre/postlube pump HGM 240 Fig 2. General disposition pre/postlube pump HGM 560 Electro pump Engine Reference Device for prelube and filling oil sump HGM 240 38.25.660 Flexible pipe connection from prelube pump to engine...
  • Page 69 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-037e October 2011 PRELUBING HGM SERIES ENGINE Fig 3: Device for prelube and filling oil sump HGM560 Do not use prelube pump for filling or draining oil sump.
  • Page 70 PRODUCT INFORMATION INDEX DATE Sce. 1 IT-C-A-25-035e December 2009 24 V. PRELUBING ELECTRO-PUMP – REF. 76.28.284 Fig. 1 – General Dimensions Fig. 2 – Electric Drawing POWER SPEED PRESSURE FLOW WEIGHT 0,55 kW 1450 RPM 10 kg/cm (142 psi) 800 l/h (211 gal/h) 16 kg (35.2 lb) Dimensions : Millímetres &...
  • Page 71 PRODUCT INFORMATION INDEX DATE Sce. 1 IT-C-A-25-035e December 2009 24 V. PRELUBING ELECTRO-PUMP – REF. 76.28.284 IMPORTANT Before start up the electro-pump, take up the pressure with the tightening screw (view Photo 1) to zero. Once activate the electro-pump increase the pressure with the tightening screw until 1.5-2 Kg/cm measure. By-pass head Photo 1...
  • Page 72 DATE Dep. 2 IT-C-A-25-030e January 2015 KOHLER POWER ENGINES SUBMERGED OIL PREHEATING SYSTEM 1. INTRODUCTION The aim of preheating oil is to raise the oil temperature before starting the engine up to the appropriate minimum value (about 40ºC) that ensures adequate oil viscosity for loading the engine.
  • Page 73 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-030e January 2015 KOHLER POWER ENGINES SUBMERGED OIL PREHEATING SYSTEM ENGINE TYPE REFERENCE VOLTAGE POWER No. of Units 180/240 360/480 31.25.A50 230 V/50 Hz 1500 W. SFGLD/SFGM/SFGRD 560 HGM 420/560 180/240 360/480 31.25.A60 400 V/50Hz 1500 W.

  • Page 74: Operation

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-C-A-25-030e January 2015 KOHLER POWER ENGINES SUBMERGED OIL PREHEATING SYSTEM Fig. 5 - General Layout – HGM420/560 Engines 4. PERFORMANCE Warming expected from the proposed preheating system is 40ºC over 2 hours. 5. OPERATION Switching on/off of the preheating resistances is through a control integrated into the engine control panels, which assures thermal/magnetic protection of each resistance.
  • Page 75 GCS SECTION HGM560N/55/4 (1800 RPM) Equipment: VEC001903 Order: KOLHER CO Customer:...

  • Page 76: Table Of Contents

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS TABLE OF CONTENTS 1 GCS ECU INTRODUCTION ........................2 2 MAIN MODULE CONNECTIONS ......................... 4 3 EID MODULE CONNECTIONS ........................5 4 AUX MODULE CONNECTIONS ........................6 5 CONNECTOR CONTACT INSTALLATION/REMOVAL ................

  • Page 77: Gcs Ecu Introduction

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS 1 GCS ECU INTRODUCTION The GCS Ecu is made of three modules stacked together and interconnected internally. Each module has its own microprocessor running its own program with shared information between modules so that all the modules play together as a seamless system, see Fig.

  • Page 78: Fig. 2 Gcs Ecu Real Photo

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS Fig. 2 GCS Ecu Real Photo This purpose of this document is to detail the Pin-Outs of the GCS ECU Connectors in case are needed for throubleshooting of wiring/harness.

  • Page 79: Main Module Connections

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS 2 MAIN MODULE CONNECTIONS All connections are located on the top face of the GCS Ecu Main Module. Signals are grouped by type within each connector. See Fig. 4 for reference of J1, J2, & J3 location. There are 7 tri-color LEDs available for application control.

  • Page 80: Fig. 7 Eid Module Terminal Locations

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS 3 EID MODULE CONNECTIONS All connections are located on the top face of the LECM via connector J5. Signals are grouped by type within the connector. See Fig. 7 for reference of J5 connector location. The status LEDs are not visible in a stack configuration with the Main module.

  • Page 81: Fig. 9 Aux Module Terminal Locations

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS 4 AUX MODULE CONNECTIONS All connections are located on the top face of the LECM. Signals are grouped by type. See Fig. 9 for reference of connector location. J4 (80 pins) Fig.

  • Page 82: Connector Contact Installation/Removal

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS 5 CONNECTOR CONTACT INSTALLATION/REMOVAL 5.1 CONNECTOR CONTACT INSTALLATION With the grey TPA (Terminal, Position, Assurance) section of the connector removed, or open (as shown in the photos), follow the instructions to install contacts in the LECM Deutsch connectors. Properly terminated contacts of the appropriate size and type should be utilized in each the 12 AWG and 18 AWG locations.

  • Page 83: Fig. 13 Tpa Lock

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS After confirming that all contacts are seated properly by gently tugging each wire, push the grey TPA section into the body of the connector as shown in 4a and 4b until the part locks into position with an audible ‘click’. Fig.

  • Page 84: Fig. 14 Tpa Removal

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-50-005e May 2015 GCS CONTROL SYSTEM ECU PIN-OUTS Fig. 14 TPA Removal All contacts in the connector can be accessed after removing the grey section of the connector. To remove individual contacts, follow the instructions illustrated on this page: 5a.
  • Page 85 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION CONTENTS 1 INTRODUCTION ............................2 2 SENSOR INFORMATION ..........................2 TABLE INDEX Table 1 sensor information ..........................7 1/11...

  • Page 86: Sensor Information

    PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION 1 INTRODUCTION The purpose of this document is to provide the electrical information of the sensors installed on the HGM engines. The positions of these sensors depend on the engine type and are defined on the following documents: ...
  • Page 87 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION Electrical signal Electrical interface Part number Used for Range Mechanical interface properties connection 175301-803A (DIN 43650) Manifold Output signal: 0,5-4,5 V pressure 1 Manifold Supply voltage: 8-30 V DC 76.00.A12 pressure 2 (absolute...
  • Page 88 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION Electrical signal Electrical interface Part number Used for Range Mechanical interface properties connection Pressure connections 1/2" conduit connection. 1/4" female Signal: NO/NC contact connections pressure (high differential) Range: 0.5–...
  • Page 89 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION Electrical signal Electrical interface Part number Used for Range Mechanical interface properties connection Visual Indicator, electrical connection Visual air filter Switches if air depression is 76.50.319 restriction No electrical connection indicator 35±3 mbar...
  • Page 90 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION Electrical signal Electrical interface Part number Used for Range Mechanical interface properties connection 175301-803 (DIN 43 650), IP 65 1xNTC (4h) -50..+150 °C 76.00.A05 conversion from temperature resistance to temperature is the on 3.1 G 1/4 B...
  • Page 91 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION Electrical signal Electrical interface Part number Used for Range Mechanical interface properties connection Individual Thermocouple K type cylinder Thermocouple 76.00.A26 exhaust K type pins and scaling apply temperatures MIL THREADED 3-WAY FEMALE...
  • Page 92 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION 3 ANNEX 3.1 RESISTANCE TO TEMPERATURE CONVERSION TABLE FOR NTC7600A04, 7600A05, 7601586 Table 3 is included for converting from resistance to temperature. For converting to the voltage value read by the GCS, the following formula should be used: 5����������...
  • Page 93 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION 9/11...
  • Page 94 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION 10/11...
  • Page 95 PRODUCT INFORMATION INDEX DATE Dep. 2 IO-G-M-60-022e May 2015 GCS INSTRUMENTATION ELECTRICAL INFORMATION Table 3 NTC resistance to temperature conversion 11/11...
  • Page 96 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION CONTENTS 1 INTRODUCTION ............................3 1.1 DOCUMENT OVERVIEW............................ 3 2 GCS CONTROL SYSTEM CUSTOMER INTERFACE INPUT SIGNAL OPTIONS ........4 2.1 DIGITAL SIGNALS .............................. 4 2.1.1 START ENGINE REQUEST ........................
  • Page 97 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 3.5 MAJOR ALARM RELAY, MINOR ALARM RELAY .................... 14 3.6 SPEED SWITCHES 1, 2 ........................... 14 FIGURES Figure 1 Customer digital inputs: digital input/coms selector ................4 Figure 2 Customer analogue inputs: analogue input/coms selector ..............

  • Page 98: Introduction

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 1 INTRODUCTION The purpose of this document is to explain the options available in the GCS control system for configuring and interfacing customer signals such as power set point, etc. It also includes the most common questions from integrators to make the integration of the GCS control system with external customer devices easier.

  • Page 99: Gcs Control System Customer Interface Input Signal Options

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2 GCS CONTROL SYSTEM CUSTOMER INTERFACE INPUT SIGNAL OPTIONS The GCS control system requires signals such as power measured, start request, stop request, etc, to be commanded from an external customer device.

  • Page 100: Start Engine Request

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.1.1 START ENGINE REQUEST The start request signal is used for commanding engine start. This signal must be configured in the toolkit so that the GCS control system uses any of the previously mentioned options (ANALOGUE-DIGITAL, CANOPEN, J1939, MODBUS_TCP, TUNABLE).

  • Page 101: Immediate Stop (Fuel On)

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.1.5 IMMEDIATE STOP (FUEL ON) This is the stop command for a fast engine stop. The post-lubrication is carried out by the GCS after the engine stop.

  • Page 102: Enable External Speed Set Point

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.1.11 ENABLE EXTERNAL SPEED SET POINT When active this signal allows a different speed set point to be sent to the engine once the engine reaches the RATED SPEED state.

  • Page 103: Measured Power

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.2.1 MEASURED POWER This signal is the power measured and it is critical because it is used for AFR control in close loop and in Island for improving engine response.
  • Page 104 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION This signal is directly added to the speed setting, meaning that the input signal needs to be configured with a null point. This voltage will give a bias of 0 rpm. Figure 4 Customer analogue inputs: (SPD BIAS/REM REF) Figure 5 Customer analogue inputs: analogue input/coms selector 9/14...

  • Page 105: Speed Set Point

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.2.3 SPEED SET POINT The rated speed set point can be modified once the engine is at rated speed with this signal. If using communications the speed set point comes directly from the communication used by the customer but when using an analogue wiring signal, the speed set point comes from the analogue input remote reference, which can be used for commanding a speed or a load set point depending on the configuration of the power set point.

  • Page 106: Lambda/Afr Trim

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION Figure 7 Customer analogue inputs: (speed bias/Rem. Ref) 2.2.5 LAMBDA/AFR TRIM The customer can connect an external Lambda correction potentiometer or send the value by communications.

  • Page 107: Ch4/Gas Quality

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.2.6 CH4/GAS QUALITY An external CH4 signal can be configured. The user must configure the source of this signal and in the case of an analogue signal, adjust the conversion from voltage to CH4%. Figure 9 Customer analogue inputs: (CH4) 2.2.7 DROOP An external DROOP percentage can be configured.

  • Page 108: Timing

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 2.2.8 TIMING An external TIMING set point signal can be forced. The user must configure the source of this forced signal value. To enable the forced value the user must enable the forced bit. Figure 11 Customer analogue inputs: timing (fix) 3 GCS CONTROL SYSTEM CUSTOMER INTERFACE OUTPUT SIGNAL Some important signals are given below that the customer should use.
  • Page 109 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-019e May 2015 GCS CONTROL SYSTEM CUSTOMER SIGNAL CONFIGURATION 3.5 MAJOR ALARM RELAY, MINOR ALARM RELAY This signals notifies external low cost controllers that there is a major or minor alarm in the GCS. IMPORTANT: The user should just monitor this signal and not command a stop based on it to the GCS to avoid a close loop situation.
  • Page 110 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION CONTENTS 1 INTRODUCTION ............................3 2 IEC GCS CONNECTORS ..........................3 3 POWER CONNECTORS (2X0 AC POWER SUPPLY & 2X1 DC POWER SUPPLY) ........ 5 4 CUSTOMER INTERFACE CONNECTOR SIGNALS (CI1 CONNECTOR) ..........
  • Page 111 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Figure 19 Potentiomenter connetion to 4..20mA Analog Input Wiring Diagram ..........21 Figure 20 Potentiometer to input voltage read conversion ................21 Figure 21 Potentiomenter connetion to 0-5v Analog Input Wiring Diagram ............ 22 Figure 22 Isolation Diagram ...........................
  • Page 112 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 1 INTRODUCTION This document provides information on the electrical connection interface of the IEC GCS control system. For an overview of the GCS control system, see document IC-G-D-50-004 GCS Control System Overview. 2 IEC GCS CONNECTORS When the customer receives the engine, only the following three connectors on the IEC GCS need be connected and interfaced (see Figure 1):...
  • Page 113 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Figure 1 IEC cabinet connectors identification Figure 2 Customer interface connector 1 (CI1) DC HE 24 MP/1873590000 4/27...

  • Page 114: Table 1 Ac Supply 2X0 Connector

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 3 POWER CONNECTORS (2X0 AC POWER SUPPLY & 2X1 DC POWER SUPPLY) Figure 3 Power connector 3.1 2X0 AC POWER SUPPLY The customer needs to connect three phase AC power to the 2X0 connector as in the following table. 2X0 Pin DESCRIPTION SIGNAL TYPE...

  • Page 115: Table 2 Dc Supply 2X1 Connector

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 3.2 2X1 DC POWER SUPPLY The customer needs to connect 24 DC power to the 2X1 connector as in the following table. 2X0 Pin DESCRIPTION SIGNAL TYPE a1/4 24 DC VOLTAGE...
  • Page 116 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 4 CUSTOMER INTERFACE CONNECTOR SIGNALS (CI1 CONNECTOR) The customer interface connector (CI1) should be used to connect the digital and analogue signals (i.e., measured power, start, etc). The following shows the connector that includes the HDC 48B SDLU 1M32G / 1904150000 housing and two stacked 24-pole inserts HDC HE 24 MP/1873590000 (48 in total).
  • Page 117 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Figure 7 Customer interface connector 1 (CI1) The following table defines the customer interface connector 1 signal to pin mapping. The “Signal Type” column indicates the schematic connection that should be done by the customer and it explained below on this document.

  • Page 118: Table 3 Customer Interface Connector 1

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION SHUTDOWN needs to stop the engine quickly but no fire is detected, it should be use fuel on (fast stop input so that the post-lubrication will be carried out) CI1-014 ENABLE EXT GCS DIGITAL INPUT...
  • Page 119 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION GCS DIGITAL INPUTS These are digital inputs to the GCS system that should be connected as below. The +HV_XDRC (20 V output from GCS system) should be connected to an external customer relay and the other pole of the relay should be connected to the digital input.
  • Page 120 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Figure 9 GCS Digital Low side Output Connection (external relay VBAT+ powered) Figure 10 GCS Digital Low side Output Connection (external relay HV_XDRG powered) 11/27...
  • Page 121 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION The internal supply of the GCS_ECU is limited to 0.5Amps. In case that it is needed to active more than this load in total in the Low side Output Connection the coil of the external coild should be connected to VBAT+ instead of HV_XDRC.

  • Page 122: Table 4 Main Differential Analog Input Capability

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 4-20 mA 0-5 V 0-1.25 V ±2.5 V Input 1 - Measured Power Input 2 - CH4% Input 3 - Lambda / AFR Trim Input 4 - Speed Bias Input 5 - Remote Reference Table 4 Main Differential Analog Input Capability By default the harness will be configured for 4..20mA.

  • Page 123: Table 5 Ainx Assignment For Each Analog Input

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION ANALOG INPUT CUSTOMER SIGNAL GCS ECU PIN AIN_1- PMEAS- J1-043 AIN_1+ PMEAS+ J1-055 AIN_2- CH4% - J1-091 AIN_2+ CH4%+ J1-079 AIN_3- POTENTIOMETER- J1-044 AIN_3+ POTENTIOMETER+ J1-056 AIN_4- SPEED_BIAS-...

  • Page 124: Current Input Wiring

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 4.3.2 CURRENT INPUT WIRING Wiring for analog inputs must be shielded cable. Shielding should be unbroken between the sensor and the GCS ECU. Shielding should not be grounded anywhere in the system along the cable length. The shield should be connected to the correct Analog Input shield pin on the GCS ECU.
  • Page 125 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Figure 14 Current Input Wiring Diagram; Loop Powered by GCS ECU Figure 15 Current Input Wiring Diagram; Self Powered 16/27...

  • Page 126: Table 7 Main Differential Analog Input Connections

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Analog Input 1 (+) J1-55 Analog Input 2 (+) J1-79 Analog Input 1 (–) J1-43 Analog Input 2 (–) J1-91 Analog Input 1&2 shield J1-67 Analog Input 1&2 shield J1-67 Current use jumper (in)

  • Page 127: Table 8 Main Voltage Input Specification

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 4.3.3 VOLTAGE INPUT (0–5 V) If interfacing to a non-isolated device that may have the potential of reaching over 20 Vdc with respect to the control’s common, the use of a signal isolator is recommended to break any return current paths that could produce erroneous readings.

  • Page 128: Table 9 Main Voltage Input Connections

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Connection Input (+) Input (–) Shield Analog In #1 J1-55 J1-43 J1-67 Analog In #2 J1-79 J1-91 J1-67 Analog In #3 J1-56 J1-44 J1-68 Analog In #4 J1-80 J1-92 J1-68...
  • Page 129 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Figure 17 SPM-A Input Wiring Diagram Figure 18 SPM-D Input Wiring Diagram 4.3.7 POTENTIOMETER CONNECTION 4.3.7.1 POTENTIOMETER CONNETION IN MODE 4..20mA Below is a graph showing what the AIN output would be if you used a 500 ohm pull-up to +20V and a 1k potentiometer across the AIN+ &...
  • Page 130 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Twisted, Shielded cable J1-67 +20V_XDCR J1-126 Potentiometer J1-55 AI #1 133k J1-43 J1-125 Insert short jumper for reference J1-19 Insert short jumper for 4-20 mA use J1-31 Figure 19 Potentiomenter connetion to 4..20mA Analog Input Wiring Diagram Figure 20 Potentiometer to input voltage read conversion...
  • Page 131 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 4.3.7.2 POTENTIOMETER CONNETION IN MODE 0-5v Figure 21 Potentiomenter connetion to 0-5v Analog Input Wiring Diagram The input needs to be in the 0-5V mode. The 5V transducer power output should be used as shown. It is a simple voltage divider where the GCS ECU internal input impedance is 133kohms.
  • Page 132 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION Shorting 24V here will not cause any problem ISO GND 24VDC Chassis Shorting 24V here is a BATT+ BATT- problem the power source is grounded. Typical (see Typical COMM SHLD...
  • Page 133 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION The conductor providing the connection must have a properly sized ring lug and wire gauge larger than or equal to 4 mm² (12 AWG). The ring lug should be placed between the nut and star washer. The calibration and checkout procedure should only be performed by authorized personnel.

  • Page 134: Shields And Grounding

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 7.2.1 SHIELDS AND GROUNDING Signals that require shielding include speed inputs, some analog inputs, PWM inputs, communications links, and signaling PWM outputs. Relay outputs, contact inputs, high current PWM outputs, and power supply wiring does not normally require shielding but can be shielded if desired.
  • Page 135 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 7.2.2 ISOLATION Figure 23 shows how the I/O is isolated with regard the input power supply and other I/O types. Each wiring diagram also shows how an input or output type is isolated in more detail. This isolation diagram is shown so that the power and return wiring can be properly grouped and so that ground loops can be avoided.
  • Page 136 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-020e May 2015 GCS CONTROL SYSTEM IEC ELECTRICAL CONNECTION 7.2.3 POWER SUPPLY GROUNDING The GCS ECU has been tested to operate properly in both grounded and ungrounded systems. In the case of a grounded power supply system, the following guidelines must be observed for the GCS ECU power source connections.
  • Page 137 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE CONTENTS 1 MODBUS/TCP GCS COMMUNICATIONS ....................2 2 ERRORS TO MODBUS ADDRESS MAPPING ................... 2 3 ENGINE PARAMETERS TO MODBUS ADDRESS MAPPING ..............2 TABLES TABLE 1 Modbus address / engine parameter mapping ................11 1/11...
  • Page 138 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE 1 MODBUS/TCP GCS COMMUNICATIONS The GCS ECU supports Modbus TCP/IP communications. This allows parameters to be read/written to the GCS ECU using an external device that supports Modbus/TCP (Modbus, Iphone, etc). 2 ERRORS TO MODBUS ADDRESS MAPPING Errors are also mapped to the addresses from 10000 to 19999.
  • Page 139 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION ‘1’ Emergency push activated. ‘0’ Emergency push not activated. 00011 BOOL WRITE (Emcy Push) ‘1’ Enable droop. ‘0’ Disable droop 00012 BOOL WRITE ‘1’...
  • Page 140 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION ‘1’ Emergency push active 00123 BOOL READ ‘1’ fuel on active 00124 BOOL READ ‘1’ generator/group breaker closed (GCB) 00125 BOOL READ ‘1’...
  • Page 141 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30001 REAL READ Power set point applied (including deratings, etc.) 30002 REAL READ Final engine speed set point 30003 REAL READ Pressure after throttle 1 (MAP1) 30004 REAL...
  • Page 142 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30034 REAL READ Exhaust temperature in cylinder 6 (ºC) 30035 REAL READ Exhaust temperature in cylinder 7 (ºC) 30036 REAL READ Exhaust temperature in cylinder 8 (ºC) 30037 REAL...
  • Page 143 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30066 REAL READ Methane number 30067 REAL READ Ambient temperature (ºC) 30068 Temperature difference between C1 and the mean of the temperatures REAL READ of the other cylinders...
  • Page 144 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30089 REAL READ Timing C2 30090 REAL READ Timing C3 30091 REAL READ Timing C4 30092 REAL READ Timing C5 30093 REAL READ Timing C6...
  • Page 145 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30122 REAL READ Knocking C12 statistics 30123 REAL READ Knocking C13 statistics 30124 REAL READ Knocking C14 statistics 30125 REAL READ Knocking C15 statistics 30126 REAL...
  • Page 146 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30155 REAL READ dP mix. throttle 30156 REAL READ Mixture flow (Qmn) 30157 REAL READ Gas flow (Qgn) 30158 REAL READ Speed Bias set point 30159 REAL...
  • Page 147 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-022e May 2015 GCS CONTROL SYSTEM MODBUS/TCP INTERFACE ADDRESS TYPE RD/WR MULT DESCRIPTION 30188 REAL READ Total running hours for maintenance stop 30189 REAL READ Total running hours for maintenance warning 30190 REAL READ Total running hours 40001-4FFFF Holding Registers (Analogue READ/WRITE) 40001...
  • Page 148 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE CONTENTS INTRODUCTION ..........................2 J1939 COMMUNICATIONS CONFIGURATION ................2 GCS ECU TX/RX MESSAGES ......................2 3.1. GCS ECU TX MAPPING ......................2 3.2. GCS ECU RX MAPPING ......................6 ALARMS .............................

  • Page 149: Introduction

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE 1. INTRODUCTION The purpose of this document is to describe the J1939 communication protocol implemented by the GCS ECU. This protocol makes it possible to read/write certain parameters from/to the GCS ECU control unit. The information is transmitted using the J1939 protocol through specific data frames, referred as messages.
  • Page 150 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE For example, to receive the exhaust temperature by J1939, the PLC or receiving device must rescale it by applying the above equation. If the calculated exhaust temperature that is transmitted through the CAN bus is 550 °C at that time, the GCS ECU unit has scaled it to (550+273)*32=26336.
  • Page 151 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE Exhaust Temperature 1000 °C EPT3 FEA1 1145 0,03125 -273 -273 1735 Cylinder 9 Exhaust Temperature 1000 °C EPT3 FEA1 1146 0,03125 -273 -273 1735 Cylinder 10 Exhaust Temperature 1000 °C...
  • Page 152 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE Knocking Level GCS_tx2 FF42 NOX 1 emissions GCS_tx2 FF42 3000 Shutdown GCS_tx2 FF42 Power Derate GCS_tx2 FF42 Alarm GCS_tx2 FF42 Ramp Stop GCS_tx2 FF42 Engine Running GCS_tx2 FF42 Gas Request...

  • Page 153: Gcs Ecu Tx Mapping

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE Feedback Oil Charger Pressure 1000 GCS_tx10 FF4A 1000 Right Bank Idle = 1 1000 GCS_tx10 FF4A NOx_1 sensor error 1000 GCS_tx10 FF4A Fuel Blending Ratio 1000 GCS_tx13 FF4D 0,001...
  • Page 154 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE The table below shows all the existing frames in the communication with the GCS ECU unit Name Type Priority Period Identifier Index Bits Factor Offset High Speed Set point AOUT FEDF...

  • Page 155: Alarms

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-023e May 2015 GCS CONTROL SYSTEM J1939 INTERFACE Starting RPM AOUT 1000 GCS_rx6 FF57 6500 MínimumPowerPcent AOUT 1000 GCS_rx6 FF57 6500 Cooling Time AOUT 1000 GCS_rx6 FF57 65000 Fuel Blending Ratio set AOUT 1000 GCS_rx7 FF58 0,001...
  • Page 156 ECU Values Value Standard Name Name Type Priority Period Dim Identifier PGN SPN BitIndex NumBits Factor Offset dec Low High READ Calc Load Pcent Percent Load At Current Speed Calculated Load Percentage EEC2 F003 Engine Speed Filtered Speed rpm EEC1 F004 0,125 8031,875 Engine Spark Voltage 13 Engine Spark Voltage 13 Engine Spark Voltage 13 FD74 65535 Engine Spark Voltage 14 Engine Spark Voltage 14 Engine Spark Voltage 14 FD74 65535 Engine Spark Voltage 15 Engine Spark Voltage 15...
  • Page 157 Turbo Oil IN Temp Turbo Oil Temperature Turbo Oil Inlet Temperature 1000 FEEE 16 0,03125 ‐273 ‐273 1735 °C Main Water Temp Engine Coolant Temperature Main Water Circuit Temperature 1000 °C FEEE ‐40 ‐40 Fuel Temp Fuel Temperature Gas Temperature 1000 °C FEEE ‐40 ‐40 Lube Oil Press Engine Oil Pressure Lube Oil Pressure EFL/P1 FEEF 1000 Main Water Press Coolant Pressure Main Water Circuit Pressure EFL/P1 FEEF 1000 Throttle Postion Mixture Throttle Position FEF2 Desired Fuel Flow...
  • Page 158 Engine state Engine State 1000 GCS_tx9 FF49 Serial number Engine serial number 1000 GCS_tx9 FF49 32000 Engine Timing Engine Timing 1000 º GCS_tx10 FF4A Byp 2 Final SP Bypass 2 Position Setpoint 1000 GCS_tx10 FF4A Byp 2 Pos Bypass 2 Position Feedback 1000 GCS_tx10 FF4A Byp 3 Final SP Bypass 3 Position Setpoint 1000 GCS_tx10 FF4A Byp 3 Pos Bypass 3 Position Feedback 1000 GCS_tx10 FF4A P Oil Charger Right Oil Charger Pressure Right Bank 1000 GCS_tx10 FF4A 1000...
  • Page 159 Speed down ramp Speed down ramp AOUT 1000 rpm/sec GCS_rx4 FF55 Rated speed Rated speed AOUT 1000 GCS_rx4 FF55 6500 Cooling  speed Cooling speed AOUT 1000 GCS_rx4 FF55 6500 Fast Stop (fuel on) Fast Stop (fuel on) BOUT 1000 GCS_rx5 FF56 Gas sel Gas Selector On (Gas 1/Gas 2) BOUT 1000 GCS_rx5 FF56 Generator Breaker BOUT 1000 GCS_rx5 FF56 Idle‐rated Idle ‐ Rated BOUT 1000 GCS_rx5...
  • Page 160 PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-024e May 2015 GCS CONTROL SYSTEM CANOPEN INTERFACE CONTENTS INTRODUCCIÓN ........................2 PROCESS DATA OBJECTS (PDOS) ..................2 2.1. GCS ECU PDOs COB-IDs ..................... 2 2.1.1. GCS ECU TPDO COB-ID ..................... 2 2.1.2. GCS ECU RPDO COB-ID ...................

  • Page 161: Process Data Objects (Pdos)

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-024e May 2015 GCS CONTROL SYSTEM CANOPEN INTERFACE 1. INTRODUCTION The purpose of this document is to describe the CANopen communication protocol implemented in the GCS ECU. This protocol makes it possible to read/write certain parameters from/to the control unit. Dresser-Rand also provides an .eds file relating to this CANopen implementation so that it can be used in PLCs that support eds import.

  • Page 162: Gcs Ecu Rpdos Cob-Ids

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-024e May 2015 GCS CONTROL SYSTEM CANOPEN INTERFACE TPDO # COB-ID T-PDO-1 0x180 + NodeId T-PDO-2 0x280 + NodeId T-PDO-3 0x380 + NodeId T-PDO-4 0x480 + NodeId Table 1 - GCS ECU TPDOs COB-IDs 2.1.2.

  • Page 168: Other Canopen Comments

    PRODUCT INFORMATION INDEX DATE Dep. 2 IT-G-A-50-024e May 2015 GCS CONTROL SYSTEM CANOPEN INTERFACE 3. OTHER CANOPEN COMMENTS The node-id can be configured with values of between 1 and 32. 3.1. HEARTBEAT SERVICE The GCS ECU unit sends the heartbeat message at a period of 1 second. When the GCS ECU starts or is reset, the heartbeat message indicates that the unit is in the pre-operational state.
  • Page 170 KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7023 8/18a (VEC001903) For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com E 2015, 2018 by Kohler Co. All rights reserved.