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.
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.
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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.
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.
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.
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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.
Heavy Equipment WARNING Lifting eye failure. 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.
This manual provides generator set operation information and basic troubleshooting instructions. 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.
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 durin g 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.
Service Assistance China For professional advice and conscientious service, please contact your nearest authorized distributor or dealer. North China Regional Office, Beijing Phone: (86) 10 6518 7950 • Visit the company website at (86) 10 6518 7951 powersystems.rehlko.com. (86) 10 6518 7952 •...
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 4/25...
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.
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.
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.
NFPA Requirements In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors the engine/generator functions and faults shown below. Engine functions: • Overcrank • Low coolant temperature warning • High coolant temperature warning • High coolant temperature shutdown •...
Auxiliaries start time Generators starting maximum delay (Dead Bus synchronizing) Generator cooling time 300 s (5 min.) Generator immobilization time Ventilation time after generator stopped 10 s Parameter settings not applicable for KD2000-KD4000 Figure 8 Factory Settings TP-7070 4/25...
Base Module Inputs and Outputs The inputs and outputs on the base module are factory set. See Figure 9 and Figure 10 for base module input and output factory settings. For optional input/output module settings, see the Accessories section. Note: Make customer connections to TB10 in the connection box.
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.
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.
Conscious Care maintenance program is not available for generator sets with exhaust aftertreament systems (EATS). The Conscious Care™ maintenance program requires a service agreement to ensure that proper operation and maintenance procedures are followed. Contact an authorized Kohler distributor or dealer to sign up for a service agreement. Monthly Exercise with Conscious Care™...
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Extended Exercise (4-month intervals) with Conscious Care™ Exercising the generator set every four months further reduces fuel emissions and fuel consumption; however, additional preparation and requirements must be taken to ensure reliable starts. In addition to the previous list, see the following lis t of requirements and recommendations for extended exercise with Conscious Care™: Required: •...
Generator Set Operation 2.4.1 Start Signal A start signal includes the following: • Remote 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. •...
2.4.5 Idle Mode The generator set controller must be in AUTO mode for idle mode operation. Idle mode requires a customer-supplied idle switch connected across terminals 5 and 6 on terminal block TB10. When the idle switch on contacts 5 and 6 closes, the engine runs at low speed (1000 RPM) for 5 minutes. The engine then ramps up to normal speed and voltage and continues to run until the idle switch opens.
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...
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.
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.
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 TP-7070...
2.7.2 Top Bar The top bar is always present. It displays system information and status messages, and includes shortcut buttons for quick access to other screens. Operating status Shortcut to operating Date and time display Shortcut buttons message screen To home To applications screen Alarm indicator and Operating sequence display...
2.7.4 Control Panel The control panel includes the generator set master switch and other controls. See Figure 18. Mode selection touch pad Start button in manual mode Horn silence button appears for alarm or fault Voltage and frequency shown when running Operator menus User menus...
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, 32F (or 0C) is displayed for all temperatures. If nothing is connected to one channel on a thermocouple module, - 58F (or - 50C) is displayed.
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.
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) •...
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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 <...
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...
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.
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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.
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.
2.10 Events The controller displays status, alarm(warning), and fault (shutdown) messages. See Figure 36 for a list of possible alarms and faults. Internal Number Description Alarm (Warning) Fault (Shutdown) M3.10 Common fault M3.16 Common warning M3.17 GFCI tripped M3.18 Over frequency fault (81H) M3.19 Under frequency fault (81l) M3.20...
Internal Number Description Alarm (Warning) Fault (Shutdown) M3.198 Battery charger fault M3.200 Low battery voltage M3.201 High battery voltage M3.212 APM internal battery warning M3.550 Engine CAN bus communication fault M3.553 Regulation module 1 communication fault M3.567 APM802 watchdog M3.720 Analog sensor fault input AI #0 M3.721 Analog sensor fault input AI #1...
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Alarm button is orange Stop horn button 33508003101 Figure 38 Appearance of an Alarm (warning) 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...
List of alarms in chronological order Figure 41 Full Screen with Latest Alarms 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 bef ore it leads to a fault that will shut down the generator set.
2.10.3 Resetting a Fault A fault turns off when the cause of the alarm is resolved by one of the two following methods: • The operator has corrected the condition that is causing the fault. • The fault condition has resolved itself; for example, the temperature drops, resolving a high temperature fault. Note: The generator set must not be restarted until the fault condition is identified and corrected.
2.10.4 Consulting Status Messages Reviewing the status messages is possible at any time. Depending on the status type, the APM802 will log different messages: • Appearance • Disappearance • Appearance/Disappearance • Present/Not present • Open/Close • On/Off • Start/End After pressing the Alarm button, and if no fault or alarm is present, select Status messages history in drop -down menu A. See Figure 44 and Figure 45.
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...
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...
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...
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...
Figure 52 Selecting the Logo Image File The ideal image size for the logo is 170 x 100 pixels. 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...
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Title Description and possible settings (or selections) Standby mode Time (min) Delay before activation of screen standby mode: from 10 to 600 minutes HMI connectivity HMI type * Use of HMI connected to the base module: Local, Remote Mode of operation † Use of HMI for remote mode: Full access, Operation, Visualization Display blue background of locked button When the selector is at 1, the HMI is connected using the access code (see section 9.4 -...
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In the case of a Remote HMI in Operation mode or in Full access mode, button 2 does not change appearance. A remote HMI is connected to the Ethernet ring. When the Home button is pressed, a pop- up window appears the search for base modules connected to the ring is in progress.
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...
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...
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.
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.
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.
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...
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Menu Access Some menus are view-only and do not allow modifications. Some menus require the operator password to view and/or modify. See Figure 68 for menu access information. 1-Settings User Operator * 1.2 Power thresholds View Modify * 1.5 Timers (not used) View Modify * 1.6 Auxiliaries...
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.
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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...
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. •...
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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;...
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.
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.
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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...
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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);...
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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.
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.
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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.
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 related 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.
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...
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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 4/25...
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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 4/25...
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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 4/25...
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. Available kits are listed below. Obtain the most current accessory information from your local authorized service distributor/dealer.
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.
AIOTM module. See Figure 91 to compare the original and updated modules. The module is factory-installed and used on selected generator sets equipped with Kohler APM802 or APM603 controllers. Combined Analog I/O and...
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Relative humidity 98% at 40ºC (104ºF) Altitude 3000 meters (9843 ft.) For additional specifications, see the Kohler specification sheet for the Analog I/O and Thermocouple Module. Switches and Indicators The module is equipped with the following switches and indicators. •...
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.
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See the table below for contact specifications. Refer to the D8IOM specification sheets, UL and CE versions, for additional specifications. Inputs Number of inputs 8 configurable inputs Input voltage 12 VDC/24VDC Contacts Normally open (NO). Activates on ground connection Connection 0.75 to 1.5 mm2 (20AWG-16AWG) Inputs isolated Outputs...
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.
Remote Serial Annunciator RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA III is a rem ote serial annunciator (Figure 98) 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.
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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...
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;...
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(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...
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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...
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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...
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...
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Operating Hours Service Record Date Run Hours Run Total Hours Service Date Service TP-7070 4/25...
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