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Kohler 60REOZK Operation

Kohler 60REOZK Operation

Industrial generator set 10-1000 kw
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Operation
Industrial Generator Set
Models:
10-1000 kW
Controller:
®
APM402/Decision-Maker
3000
TP 6694 2/25p

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Summary of Contents for Kohler 60REOZK

  • Page 1 Operation Industrial Generator Set Models: 10-1000 kW Controller: ® APM402/Decision-Maker 3000 TP 6694 2/25p...

  • Page 2: Product Identification Information

    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 ............................7 Introduction ....................................15 Service Assistance................................... 17 Section 1. Specifications and Features ......................... 19 Introduction ................................19 Controller Features..............................19 1.2.1 Switches and Controls ..........................20 1.2.2 Annunciator Lamps ..........................21 1.2.3 Digital Display ............................
  • Page 4 2.7.12 Analog Inputs ............................75 2.7.13 Battery Charger 1 and 2 ........................... 76 2.7.14 Event Log ..............................77 2.7.15 Volt Select ..............................77 Section 3. Scheduled Maintenance ........................79 Alternator Service ..............................79 Engine Service ............................... 79 Service Schedule ..............................80 Alternator Bearing Service .............................
  • Page 5 6.1.4 Four-Input/Fifteen-Output Module ......................136 6.1.5 Gas Fuel Valve Kit ..........................140 6.1.6 Two-Input/Five-Output Module ....................... 140 6.1.7 Manual Key Switch ..........................141 6.1.8 Low Fuel (Level/Pressure) Switch ......................142 6.1.9 Manual Speed Adjust (Engine RPM Menu).................... 142 6.1.10 Prime Power Switch Kit .......................... 143 6.1.11 Remote Emergency Stop Kit ........................
  • Page 6 TP-6694 2/25...

  • Page 7: 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 8 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 9: Exhaust System

    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 fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors.

  • Page 10: Fuel System

    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 11 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 12: Hot Parts

    Airborne particles. WARNING Can cause severe injury or blindness. Wear protective goggles and clothing when using power tools, hand tools, or compressed air. Servicing the generator set when it is operating. Exposed moving parts will cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running.
  • Page 13 Notice NOTICE This generator set has been rewired from its nameplate voltage to: 246242 NOTICE Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer. NOTICE Canadian installations only.
  • Page 14 TP-6694 2/25...

  • Page 15: Introduction

    Introduction This manual provides operation instructions for 10 kW and larger generator sets equipped with the following controllers: • APM402 generator set controller • ® Decision-Maker 3000 generator set controller Note: ® In 2018, the company adopted a global controller naming convention. To support this, the name of the Decision-Maker 3000 ®...

  • Page 16: List Of Related Materials

    List of Related Materials Separate literature contains communication and software information not provided in this manual. Figure 1 lists the available literature part numbers. Literature Description Literature Part No. APM402 Controller Spec Sheet G6-161 ® Decision-Maker 3000 Controller Spec Sheet G6-100 Multiple Part Numbers Contact Generator Set/Controller Wiring Diagram Manual...

  • Page 17: Service Assistance

    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 •...
  • Page 18 TP-6694 2/25...

  • Page 19: Section 1. Specifications And Features

    Section 1. Specifications and Features 1.1 Introduction The spec sheets for each generator set provide model-specific generator and engine information. The controller spec sheet provides specifications for this controller. Refer to the respective spec sheet for data not supplied in this manual. Refer to the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications.

  • Page 20: Switches And Controls

    1.2.1 Switches and Controls Note: US/Metric Display is selectable in the Generator Set System Menu. See the section titled: Digital Display-Generator Set System Menu. Alarm Horn. The alarm horn alerts the operator or other attendants that a shutdown or warning condition exists. Alarm (Horn) Silence.

  • Page 21: Annunciator Lamps

    1.2.2 Annunciator Lamps The controller has a single annunciator fault lamp providing visual generator set status. In addition, each button has a corresponding lamp. See Figure 3. Lamp/Button Lamp color Alarm (Fault) Lamp Yellow (Warning) or Red (Shutdown) Off/Reset Button Auto Button Green (System Ready) Run Button...
  • Page 22 • Input/output communication loss • Low battery voltage • Low coolant temperature • Low cranking voltage • Low engine oil level * • Low fuel (level for diesel-powered models) * • Low fuel (pressure for gas-powered models) * • Low oil pressure •...

  • Page 23: Digital Display

    (GM/PSI and Doosan gas-powered models only) • Metering communication loss • No coolant temperature signal • No oil pressure signal • Overcrank • Overfrequency • Overvoltage (each phase) • Run relay overload • Underfrequency • Undervoltage (each phase) • (Voltage) regulator communication loss * Requires optional input sensors 1.2.3 Digital Display Press the pushbutton/rotary selector dial to turn on the controller lamps and display.
  • Page 24 • Digital Outputs • Analog Inputs • Event Log • Volt Select Overview Menu When a new shutdown or warning fault occurs, the auto-paging display feature activates. Active Shutdowns display if any are present. This alerts the user to single or multiple shutdown fault conditions. See the section titled: Annunciator Lamps-System Shutdown Fault Lamp for a list of possible shutdown faults.
  • Page 25 Battery displays the DC voltage of the engine starting battery(ies). This value also shows in the Overview Menu. Fuel Pressure displays fuel pressure for some engines. Refer to the Appendix, Controller Displays from the Engine ECM. This value also shows in the Overview Menu. Generator Metering Menu Total Power kVA and kW displays alternator output as actual output values.
  • Page 26 Generator Set System Menu The values in this menus are user-entered for the generator set configuration and are NOT measured values of the generator set. Changes to the Generator Set System menu require the use of SiteTech™ software except for Measure System and Contrast selections.
  • Page 27 • Current L3 The user can change individual values or can enter Yes when Reset all Calib? is displayed. At the end of the Generator Set Calibration menu, Exit calibration is shown. Press the pushbutton/rotary selector dial to exit this menu. Refer to the requirements shown with Generator Set Calibration in the section titled: Status and Notice Digital Displays.
  • Page 28 The displays for digital outputs appear as shown in the following list with Values as True or False. Items shown in the digital display as True are active. • DOut A1 (digital output A1) standard • DOut B1 (digital output B1) with I/O module board •...

  • Page 29: Controller Fault Diagnostics

    1.2.4 Controller Fault Diagnostics This table provides descriptions of the system events and their types—warning, shutdown, status, and notice. Warnings show yellow fault lamp and signal an impending problem. Shutdowns show red fault lamp and stop the generator set. Status is an event that is not an alert but is part of the event history. Notice is an alert that is NOT part of the event history. System events are available as a Relay Output as shown.
  • Page 30 Warning Shutdown Status/ Relay Description Display Message Function Function Notice Output General Functions Alarm horn silenced (Alarm Silence LED only) Alarm silence, auto only (NFPA 110) or always AlrmSilence: Auto Only or AlrmSilence: Always Aux. inputs 0- 5 VDC, 1 analog Aux Input Warning (2 additional inputs available with I/O module option) Aux.

  • Page 31: Digital Display Circuit Board And Connections

    1.2.5 Digital Display Circuit Board and Connections The digital display circuit board provides: • The backlit LCD (liquid crystal display) for monitoring the generator set functions and output values • Master control switches with status lights • Fault lamp • Pushbutton/rotary selector dial to navigate the generator set displays •...

  • Page 32: Main Logic Circuit Board

    1.2.6 Main Logic Circuit Board The main logic circuit board provides the terminal strips and connection sockets to connect the controller to the engine/generator, input/output connections, optional I/O module kit, and circuit protection fuses. See Figure 5 and Figure 6 for the circuit board connections.

  • Page 33: Terminal Jumper

    (4) push-on terminal connectors TB2 4-position terminal block P21 6-pin connector (for RS-485 communications) TB3 6-position terminal block P23 8-pin connector (RJ45) P30 jumper (Wound Field or Fast Response) P1 24-pin connector TB1 6-position terminal block GM102396 Figure 6 Main Circuit Board Connectors ®...

  • Page 34: Communication Ports

    1.2.8 Communication Ports ® The main logic circuit board contains a single mini USB communication port for PC connections, see Figure 7. For Modbus communication using RS-485, see the figure titled: Main Circuit Board Connectors (P21). Refer to the List of Related Materials in the Introduction for corresponding SiteTech™...

  • Page 35: Controller Logic Specifications

    V7/V8/V9 fuses, 1.5 Amp. (qty. 3) GM69407 Figure 8 AC Circuit Fuses in Control Box F2 1 Amp. auto-resettable F3 12 Amp. non-replaceable F1 1 Amp. auto-resettable GM6435-C Figure 9 Controller DC Fuses 1.3 Controller Logic Specifications The controller logic specifications section is an overview of the various features and functions of the controller. Certain features function only when optional accessories are connected.

  • Page 36: Status Event And Fault Specifications

    1.3.1 Status Event and Fault Specifications The Factory-Defined Settings List contains all status events and faults with ranges and time delays including items that do not have user adjustments. Note: The engine ECM may limit the crank cycle even if the controller is set to a longer time period. Factory-Defined Settings List GenSet Fault...
  • Page 37 GenSet Fault Write Mode Time Default Controller Lamp Access Always Delay Time Display Alarm Warning Display Running Range Default Range Delay Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.) Low cranking voltage Lo Crank Vlt Fixed Fixed Warning Low engine oil level * Oil Level Low Warning...
  • Page 38 GenSet Fault Write Mode Time Default Controller Lamp Access Always Delay Time Display Alarm Warning Display Running Range Default Range Delay Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.) Chicago Code Chicago code active * Active Common Fault Common fault Shutdwn Common...
  • Page 39 GenSet Fault Write Mode Time Default Controller Lamp Access Always Delay Time Display Alarm Warning Display Running Range Default Range Delay Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.) Alternator protection Alt Protect Shutdwn Ground fault input * Ground Fault Warning kW overload...
  • Page 40 GenSet Fault Write Mode Time Default Controller Lamp Access Always Delay Time Display Alarm Warning Display Running Range Default Range Delay Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.) Charger Depleted Battery 4–12 Voltage Target (12 V) (12 V) 18–24 (24 V) (24 V)
  • Page 41 GenSet Fault Write Mode Time Default Controller Lamp Access Always Delay Time Display Alarm Warning Display Running Range Default Range Delay Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.) Charger Voltage Absorption 13–15 14.25 (12 V)** (12 V) 26–30 28.5 (24 V)**...

  • Page 42: Voltage Regulator And Calibration Specifications

    1.3.2 Voltage Regulator and Calibration Specifications The controller has a voltage regulation function that is internal to the processor. This means that no external voltage regulator is necessary. The voltage regulation of the controller uses root mean square (rms) sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy.

  • Page 43: Section 2. Operation

    Section 2. Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. DANGER Hazardous voltage.

  • Page 44: Exercising Generator Set

    40- 60REOZK Models only. When the ambient temperature drops below - 15°C (5°F) a turbocharger pre-lube sequence begins when the crank cycle is initiated. During the first 10 seconds of cranking, the fuel system is disabled to ensure engine oil is present at the turbocharger.

  • Page 45: Controller Operation

    2.4 Controller Operation The controller operation includes several types of starting and stopping functions as detailed in the following paragraphs. The controller master control switch buttons, lamps, and alarm horn functions are summarized in the figure titled: Master Control Button Function Summary. 2.4.1 Starting Local Starting Press the master control RUN button to start the generator set at the controller.

  • Page 46: Stopping (User Stopping And Fault Shutdown)

    Prime Power Switch The controller has an optional prime power mode of operation. The prime power mode requires installation of an optional prime power switch kit. See the section titled: Accessories, for instructions on how to install the optional prime power switch kit. The prime power switch kit prevents engine starting battery drain when the generator set is shut down and no external battery charging is available.

  • Page 47: System Status Lamps

    2.4.4 System Status Lamps The (OFF/RESET- AUTO- RUN) master control buttons indicate the status condition with an integrated lamp at the button. The green lamp illuminates on the master control AUTO (automatic start) button indicating the system senses no faults and the unit is ready to start by remote command.
  • Page 48 Common Warning. The fault lamp illuminates yellow and the alarm horn sounds when the controller is signaled by a common warning. Use SiteTech™ software to activate the common warning. The local display shows Common Warng. The common warning comprises all of the warnings under a single alert. Critical High Fuel Level (diesel-powered models only).

  • Page 49: System Fault Shutdown Lamp With Digital Displays

    Low Fuel Level (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel-fueled models approaches empty. This fault requires an optional low fuel level switch for the lamp to function. The local display shows Fuel Level Low Warning.
  • Page 50 ECM Model Mismatch. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller detects an error with the ECM model. The local display shows ECM Mismatch Shutdwn. Emergency Stop. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the local or optional remote emergency stop switch activates.
  • Page 51 Metering Communications Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the metering to controller communication link is disrupted. The local display shows MeterCommLos Shutdwn. No Coolant Temperature Signal. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the engine coolant temperature sender circuit is open.

  • Page 52: Status And Notice Digital Displays

    2.4.7 Status and Notice Digital Displays Warnings and shutdown faults appear on the digital display and become part of the event history. Beyond the warnings and shutdowns there are several events which also appear on the digital display. Status is an event that is not an alert but is part of the event history.
  • Page 53 • Current L1: x.x A • Current L2: x.x A • Current L3: x.x A The user can individually calibrate the values above or reset all of them. The local display Reset all calib? No or Yes. Select No to make no changes and exit GenSet Calibration. Select Yes to reset all of the values. When calibrating voltage, the metered value and the number being entered as the calibrated value must be within 10% of the system operating voltage.

  • Page 54: Controller Resetting (Following System Shutdown Or Warning)

    2.4.8 Controller Resetting (Following System Shutdown or Warning) Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition. This procedure includes the resetting of the optional remote annunciator. Refer to the section titled: Emergency Stop Switch Reset Procedure, to reset the generator set after an emergency stop. Disconnect the generator set load using the line circuit breaker or automatic transfer switch.
  • Page 55 SW Version: 3.10 Figure 18 SW Version Submenu ® For Decision-Maker 3000 controllers, if the firmware version is earlier than 3.10, go to the Procedure for Powering Up ® the Engine ECM using SiteTech™. For Decision-Maker 3000 controllers with firmware version 3.10 or higher, or for APM402 controllers, continue to Procedure for Powering Up the Engine ECM.
  • Page 56 Click drop down arrow and select True to Locate Genset System Configuration- power up the engine ECM ECM Power in SiteTech SB-724 Figure 22 SiteTech™ Software Display Screen TP-6694 2/25...

  • Page 57: Menu Displays

    2.5 Menu Displays Use the Menu Summary List section after reading and understanding the features of the pushbutton/rotary selector dial. See the section titled: Graphical Display. The Menu Summary List provide a quick reference to the digital display data. Some digital display data may not be identical to your display due to generator set application differences.
  • Page 58 Menu Summary List Continued (Legend: ● First level submenu, ○ second level submenu) Voltage Regulator Menu (DEC3000 before Digital Inputs Menu Analog Inputs Menu Event Log Menu Version 3.0.25) • • • • Enter Voltage Regulator? DIn A1 AIn A1 (factory See the section titled: •...

  • Page 59: Monitoring And Programming Setup

    2.6 Monitoring and Programming Setup The user programmer can access the controller data with the controller digital display or a personal computer (PC) with optional SiteTech™ software to monitor and/or program. Access the controller system with a PC using a USB cable with a mini USB plug.

  • Page 60: Modbus® Communications

    2.6.2 Modbus® Communications ® ® The controller communicates using Modbus as a slave connection with the Modbus master initiating the communication. The ® controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus master. In addition, the controller accepts information to alter controller parameters including generator set starting and stopping.
  • Page 61 Controller Controller SiteTech Menu Name Viewable Adjustable Adjustable Overview Engine Metering Generator Metering GenSet Information GenSet Run Time GenSet System Voltage Regulation Digital Inputs Digital Outputs Analog Inputs Event Log Volt Select * Requires initial activation using SiteTech™ Figure 27 Displays for Viewing and Adjusting (DEC3000 Firmware Version 3.0.25 to 4.8.4) Controller Controller...

  • Page 62: Error Messages

    2.7.1 Error Messages Certain entries or attempted entries may cause the controller to display an error message. Some of the error messages shown here are also shown as part of the section titled: System Fault Warning Lamp with Digital Displays and the section titled: System Fault Shutdown Lamp with Digital Displays.

  • Page 63: Overview

    2.7.2 Overview Displays basic and commonly sought after information about the generator set. This information scrolls automatically after about 5 minutes of no user input (pushbutton/rotary selector dial or button activity). To change from auto scrolling to fixed display, press the rotary dial and the main menu will appear. Press the rotary dial again to select the first menu item Overview.

  • Page 64: Engine Metering

    Overview (Fixed Display) Overview - - > ### V ##.# Hz ##.# hr ### A #### kW English Display ###_F ###% Measurements - > ### PSI ##.# V Metric Display ###_ C ##.# % Measurements - > #.# MPa ##.# V CHG1: ##.#V With 10 Amp Charger ##.# A...

  • Page 65: Generator Metering (And Calibration)

    2.7.4 Generator Metering (and Calibration) Displays generator output data including line-to-line and line-to-neutral voltages, current, frequency, total kilowatts, and total kVA. The menu displays three-phase voltage and current readings when applicable. All menu displays apply to both single-phase or three- phase voltages on the menu overview. The phase designation does not appear in the controller menu displays.
  • Page 66 Momentarily press the pushbutton/rotary selector dial. Stop the generator set if not already done. Generator Metering APM402 firmware versions before Generating - - > Total Power: Metering V1.6.3 show the power in VA and W. # kVA Total Power: #k W Rated Power: Select this Display to Enable or Disable...

  • Page 67: Genset Information

    2.7.5 GenSet Information Displays generator set and controller information. Displayed data is factory entered. GenSet Information GenSet - - > Genset M/N: Information GenSet S/N: Cntrllr S/N: 2.7.6 GenSet Run Time Displays the generator set’s operating record including total run time loaded and unloaded, number of starts, and total energy kW hours GenSet Run Time GenSet - - >...

  • Page 68: Genset Calibration

    GenSet System GenSet - - > System System Freq: ##.# Hz SystemPhase: ##### System Volt: ###.# V Pwr Rating: ##.# kW Amp Rating: ##.# A Power Type: ##### Battery v: ## V Meas System User Selectable - > English or Metric Contrast User Selectable - >...
  • Page 69 GenSet Calibration GenSet - - > Enter Calib? GenSet - - > Calibration Calibration Enter Calib? User Selectable - > Volts L1- L2: #.# V Volts L2- L3: #.# V Volts L3- L1: #.# V Volts L1- N: #.# A Volts L2- N: #.# A Volts L3- N:...

  • Page 70: Voltage Regulator

    2.7.9 Voltage Regulator ® Decision-Maker 3000 Controllers with Firmware Versions Before 3.0.25. Displays the voltage regulator adjustment value. All other voltage regulator adjustments are changed using SiteTech™ software. The voltage regulator value is reviewable at all times. In order to review the value when the generator set is NOT running, enter Yes when the Enter volt reg? is displayed.

  • Page 71: Digital Inputs

    2.7.10 Digital Inputs Displays the selected programming user-defined digital notice, warning, and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. See Figure 29 for a list of digital input choices. For descriptions of the inputs listed refer to the following sections: •...

  • Page 72: Digital Outputs

    Critical Analog and Digital High High High Inputs Notice Warning Warning Warning Warning Shutdown Shutdown Shutdown Auxiliary Input Battery Charger Fault Chicago Code Active Enclosure Temperature: High Shutdown (Din A3) Engine Fuel Level Fuel Tank Leak Ground Fault Low Engine Oil Level Low Fuel Pressure Figure 29 Analog and Digital Inputs...
  • Page 73 Digital Outputs Digital - - > DOut A1 Outputs ##### DOut A1 Value: True or False DOut B1 ##### DOut B1 Value: True or False DOut B2 ##### DOut B2 Value: True or False DOut B3 ##### DOut B3 Value: True or False DOut B4 ##### DOut B4...
  • Page 74 Critical No Signal High High High Shut- Shut- Shut- Digital Outputs Notice Warning Warning Warning Warning Shutdown down down down AC Sensing Lost Alternator Protection Auxiliary Input Battery Charger Fault Battery Voltage Chicago Code Active Common Fault Common Warning Cranking Voltage ECM Comm Loss Emergency Stop Engine Coolant Level...

  • Page 75: Analog Inputs

    2.7.12 Analog Inputs Displays the selected programming user-defined analog notice, warning, and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. See the figure titled: Analog and Digital Inputs for a list of analog input choices.

  • Page 76: Battery Charger 1 And 2

    2.7.13 Battery Charger 1 and 2 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. Isolate the battery charger from explosive fumes. Battery gases. Explosion can cause severe injury or death. Incorrect use of the equalize charge state may lead to hazardous situations.

  • Page 77: Event Log

    2.7.14 Event Log Displays up to 1000 stored status, warning, and shutdown events. After the first 1000 events, each additional new event replaces the oldest event. See the section titled: Controller Fault Diagnostics for a list of possible events. Event Log Event Log - - >...
  • Page 78 TP-6694 2/25...

  • Page 79: Section 3. Scheduled Maintenance

    Section 3. Scheduled Maintenance Under normal operating conditions, the generator set’s alternator requires no routine service. Consult the section titled: Prestart Checklist, for a list of routine checks. WARNING Accidental starting. Can cause severe injury or death. Disconnect the battery cables before working on the generator set. Remove the negative (–) lead first when disconnecting the battery.

  • Page 80: Service Schedule

    3.3 Service Schedule Action System—Component Visually Inspect Check Change Clean Test Interval Fuel System Day tank level Weekly Flexible lines and connections Weekly Fuel level switch Weekly Main tank supply level Weekly Solenoid valve operation Weekly Transfer pump operation Weekly ●...
  • Page 81 Action System—Component Visually Inspect Check Change Clean Test Interval AC Electrical System Controller lamp test Weekly General Inspection Weekly Circuit breakers, fuses† Monthly Wire abrasions where subject to motion Quarterly Safety and alarm operation Six Months Tighten control and power wiring Yearly connections Transfer switch main contacts†...

  • Page 82: Alternator Bearing Service

    3.4 Alternator Bearing Service Have an authorized service distributor/dealer perform service. 3.4.1 20-300 kW Models Replace the end bracket bearing every 10,000 hours of operation. Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage. The sealed end bracket bearing requires no additional lubrication. 3.4.2 300-1000 kW Models with 4M/5M/7M Single-Bearing Alternator The alternator bearing requires lubrication at intervals specified in the alternator operation and maintenance manual.

  • Page 83: Gaseous Fuel Systems

    Close this valve Open this valve Valve Open Valve Closed Open this valve Note: Generator set without a fuel/water separator shown. Figure 31 Hand Prime Pump with Valve Positions for Fuel Priming, Typical Loosen the bleed screw at the engine. Refer to the engine operation manual for location of the bleed screw(s). The bleed screw allows air to be expelled from the fuel system when the hand prime pump is operated.

  • Page 84: Gaseous Fuel System Concept (Single Fuel)

    3.6.1 Gaseous Fuel System Concept (Single Fuel) The gaseous fuel system uses a fuel solenoid valve to control the fuel flow to the electronic-controlled pressure regulator (EPR) or direct acting electronic pressure regulator (DEPR). The generator set-mounted EPR or DEPR reduces the fuel pressure as fuel passes to the fuel mixer.

  • Page 85: Fuel System Changeover Kits (Dual Fuel)

    3.6.4 Fuel System Changeover Kits (Dual Fuel) A changeover fuel system kit provides automatic changeover from natural gas to LPG vapor. The primary and backup fuels each have a fuel solenoid valve. The primary fuel is natural gas; the backup fuel is LPG vapor. Before starting, both fuel solenoid valves are closed.

  • Page 86: Fuel Conversion Connections

    3.6.5 Fuel Conversion Connections To change the fuel type, change the wiring harness connections. The engine ECM has fuel tables and spark advance curves programmed for both natural gas and LPG. Use the following fuel connection tables and wiring diagrams to determine the applicable connections for your generator set model.
  • Page 87 Natural Gas LPG Vapor To ECM To ECM controller controller LPG Liquid To ECM controller Auto Changeover Natural Gas and LPG Vapor To ECM controller ADV-7600B-F Figure 34 Gaseous Fuel Connections Wiring Diagram, Typical 25-45 kW Models with PSI or GM Engines TP-6694 2/25...
  • Page 88 50-150 kW Models See Figure 35 and Figure 36. Natural Gas Connections • Disconnect lead 65 from lead N5. • Disconnect leads 70G, 73B, and N8 from fuel solenoid valve FV2 (LPG vapor). • Connect leads 70E, 73A, and 73B to fuel solenoid valve FV1 (NG). LPG Vapor Connections •...
  • Page 89 LPG Vapor Natural Gas To ECM To ECM controller controller LPG Liquid To ECM controller Auto Changeover Natural Gas and LPG Vapor To ECM controller ADV-8557 Figure 36 Gaseous Fuel Connections Wiring Diagram, Typical 50-150 kW Models with PSI or GM Engines TP-6694 2/25...
  • Page 90 For KG25, KG30, and KG40A (KG02L04T Engine), use the following: See Figure 37. Natural Gas Operation • Disconnect FSN from FS. • Connect 70NG1 and NGN to FV1. • Connect 70NG2 and NG to FV3. LPG Vapor Operation • Connect FSN to FS. •...
  • Page 91 For KG40, KG45, KG50, KG60 (KG6208 Engine), use the following: See Figure 39 and Figure 40. Natural Gas Operation • Disconnect 78/N32 and 70G/70R from the fuel valve. • Disconnect 49 and N17. • Connect 77/N31 and 70H/70T to the fuel valve. LPG Vapor Operation •...
  • Page 92 Natural Gas LPG Vapor To ECM To ECM controller controller Auto Changeover Natural Gas and LPG Vapor To ECM controller To ECM controller ADV-9774D Figure 40 Gaseous Fuel Connections Wiring Diagram, KG40–KG60 (KG6208) TP-6694 2/25...
  • Page 93 For KG40 and KG50 (Kohler Engine KG04V06T), use the following: See Figure 41. Natural Gas Operation • Disconnect N4 and FS • Connect 70NG1 and N16 to FV1 • Connect 70NG2 and NG to FV3 LPG Vapor Operation • Connect N4 and FS •...
  • Page 94 For KG80–KG125, KG80R–KG125R (KG6208TSD and KG6208THD Engines), use the following: See Figure 43 and Figure 44. Natural Gas Operation • Disconnect the black fuel connector (J7). • Disconnect 49 and N17. • Connect the white fuel connector (J8). • For UL applications, connect the optional UL fuel blocking valve (J30). LPG Vapor Operation •...
  • Page 95 Natural Gas LPG Vapor To ECM To ECM controller controller Auto Changeover Natural Gas and LPG Vapor To ECM controller ADV-9052D-D Figure 44 Gaseous Fuel Connections Wiring Diagram, KG80–KG125/KG80R–KG125R TP-6694 2/25...
  • Page 96 KG80–KG125, KG80R–KG125R Dual Fuel Operation The dual fuel system for the KG80–KG125 and KG80R–KG125R includes an LPG indicator light and a reset switch. This LPG indicator light turns on when the NG fuel valve closes and the LP fuel valve opens, indicating that the fuel source has switched. The reset switch resets the fuel source to natural gas.
  • Page 97 For KG150, KG180, and KG200 (KG10V08T-6CGS and KG10V08T-6DGS Engines), use the following: To change the fuel type, change the wiring harness connections. The engine ECM has fuel tables and spark advance curves programmed for both natural gas and LPG. Use the following fuel connection tables and wiring diagrams to determine the applicable connections for your generator set model.
  • Page 98 Natural Gas LPG Vapor To ECM and To ECM and controller controller ADV-9087 Figure 47 Gaseous Fuel Connections Wiring Diagram, Single Fuel, KG150, KG180, and KG200 KG150, KG180, and KG200 (KG10V08T Engine) Dual Fuel Connections See the following dual-fuel connections with the APM402. Be sure to review the wiring diagram for special applications. The dual fuel kits are factory installed.
  • Page 99 For 180-500 RZXB/REZXB/REZXC/RZXD/REZXD (PSI/ Doosan 11.1L, 14.6L, 18.3L, and 21.9L Engines), use the following: To change the fuel type, change the wiring harness connections. The engine ECM has fuel tables and spark advance curves programmed for both natural gas and LPG. Use the following fuel connection lists and wiring diagrams to determine the applicable connections for your generator set model.
  • Page 100 180-500 RZXB/REZXB/REZXC/RZXD/REZXD (PSI/ Doosan 11.1L, 14.6L, 18.3L, and 21.9L Engines) Natural Gas with Additional Fuel Valve, Required for UL Approval See Figure 50. • Disconnect lead N5. • Disconnect lead 65. • Disconnect lead 65A. • Disconnect lead 73B. • Connect lead 70B2 to fuel valve 1 (FV1), red/black wire.
  • Page 101 Natural Gas 250 – 300 kW (14.6 L) 180 – 200 kW (11 L) ADV-7968-G ADV-7968-G 300 – 500 kW (18 – 22 L) ADV-7994-K Figure 50 Natural Gas with Additional UL Fuel Valve TP-6694 2/25...
  • Page 102 180-500 RZXB/REZXB/REZXC/RZXD/REZXD (PSI/ Doosan 11.1L, 14.6L, 18.3L, and 21.9L Engines) LPG Vapor or Liquid Withdrawal with Single Fuel Valve See Figure 51. • Disconnect lead 70E. • Disconnect lead N6. • Disconnect lead N11 (250 – 500 kW). • Disconnect lead 73A (180 – 200 kW). •...
  • Page 103 180-500 RZXB/REZXB/REZXC/RZXD/REZXD (PSI/ Doosan 11.1L, 14.6L, 18.3L, and 21.9L Engines) LPG Vapor or Liquid Withdrawal with Additional Fuel Valve, Required for UL Approval See Figure 52. • Disconnect lead 73A (180 – 200 kW). • Disconnect lead 73A and 73A1 (250 – 500 kW). •...
  • Page 104 LPG Vapor and Liquid Withdrawal UL Valve 180 – 200 kW (11 L) ADV-7968-G 250 – 300 kW (14.6 L) ADV-7970-G 300 – 500 kW (18 – 22 L) ADV-7994-K Figure 52 LPG Vapor or Liquid Withdrawal with Additional UL Fuel Valve TP-6694 2/25...

  • Page 105: Crankcase Ventilation (Ccv) Heater Kit Gm78171-Kp1

    3.7 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 Applies to 125/150 kW, 8.1 L GM-powered and 8.8 L PSI-powered generator set models. Consult your local generator set distributor/dealer for additional information. The crankcase ventilation (CCV) heater kit provides a controlled heating source to the crankcase ventilation system preventing freezing water buildup during cold weather.

  • Page 106: Cooling System

    3.9 Cooling System The cooling system maintenance information applies to radiator-cooled models which have a radiator with a pressure cap and coolant recovery tank. WARNING Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure.

  • Page 107: Procedure To Drain Cooling System

    3.9.3 Procedure to Drain Cooling System For optimum protection, drain, flush, and refill the cooling system at the intervals listed in the service schedule. Note: Dispose of all waste materials (oil, fuel, coolant, filters, and gaskets) in an environmentally safe manner. Before removing the pressure cap, stop the generator set and allow it to cool.

  • Page 108: Battery

    11. Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck. 12. Replace the pressure cap. 13. Maintain the coolant level in the coolant recovery tank (if equipped) between the high and low marks. Check the coolant level at the radiator fill on models without a coolant recovery tank.
  • Page 109 12-Volt 24-Volt To positive (+) terminal on starter solenoid. To ground (-) terminal on or near starter motor. EZ-273000-J Figure 55 Engine Electrical System Single Starter Motor Typical Battery Connection To positive (+) terminal on starter solenoid. To ground (-) terminal on or near starter motor.

  • Page 110: Clean Battery

    3.10.1 Clean Battery Clean the battery and cables and tighten the battery terminals according to the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight. If corrosion exists, disconnect the cables from the battery and remove the corrosion with a wire brush. Clean the battery and cables with a solution of baking soda and water.

  • Page 111: Specific Gravity Check

    3.10.3 Specific Gravity Check Note: Rehlko recommends the use of SLA batteries that are maintenance free. Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps. Holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer.

  • Page 112: Charge Battery

    3.10.4 Charge Battery Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application. The engine battery-charging alternator charges the battery while the generator set is running. Refer to the battery charger operation manual for installation, operation, and service procedures.

  • Page 113: Lubrication System

    3.11.1 Lubrication System Prepare the engine lubricating system for storage as follows: Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature. Stop the generator set. With the engine still warm, drain the oil from the crankcase. Remove and replace the oil filter.

  • Page 114: Exterior

    Ignition System Damage. Refer to the engine operation manual for ignition system precautions before cranking the engine while the spark plug wires are disconnected. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders. Reinstall the spark plugs and torque them to specifications.

  • Page 115: Battery

    3.11.7 Battery 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. Isolate the battery charger from explosive fumes. Perform battery storage after all other storage procedures. Confirm that the generator set is stopped.
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  • Page 117: Section 4. General Troubleshooting

    Section 4. General Troubleshooting This section contains generator set troubleshooting, diagnostic, and repair information. Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, recommended corrective actions, and references to detailed information or repair procedures.

  • Page 118: General Troubleshooting Chart

    4.1 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-6694...
  • Page 119 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-6694 2/25...
  • Page 120 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-6694 2/25...
  • Page 121 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-6694 2/25...
  • Page 122 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-6694 2/25...

  • Page 123: Controller Display And Voltage Regulation Troubleshooting Chart

    4.2 Controller Display and Voltage Regulation Troubleshooting Chart TP-6694 2/25...
  • Page 124 TP-6694 2/25...

  • Page 125: Section 5. Voltage Reconnection

    Section 5. Voltage Reconnection 5.1 Introduction Use the following voltage reconnection procedure to change the voltage of 10- and 12- lead generator sets. Frequency changes require voltage regulator and governor adjustments. Refer to the respective spec sheet to determine if frequency is fixed or field- convertible.

  • Page 126: Voltage Reconnection Procedure

    5.2 Voltage Reconnection Procedure Note: ® For Decision-Maker 3000 Controllers with software versions before 2.8, go to the next Section. Press the generator set master control OFF/RESET button Turn the controller pushbutton/rotary selector dial until it stops at the Volt Select menu. See Figure 60 Note: If the Volt Select menu does not appear, the controller voltage selection feature was not activated using SiteTech™...

  • Page 127: Voltage Reconnection Procedure

    5.3 Voltage Reconnection Procedure Note: ® This procedure applies to Decision-Maker 3000 Controllers with software versions before 2.8 only. Press the generator set master control OFF/RESET button. Disconnect the generator set engine starting battery, negative (-) lead first. Disconnect power to the battery charger (if equipped) Use Figure 61, Figure 62, Figure 63, or Figure 64 to determine the generator set voltage configuration.
  • Page 128 Figure 61 20-150 kW Permanent Magnet Single-Phase Alternators, ADV-5875AG-1 TP-6694 2/25...
  • Page 129 Figure 62 20-300 kW Permanent Magnet Alternators, ADV-5875AG-2 TP-6694 2/25...
  • Page 130 Figure 63 60 IMS-300 kW Wound Exciter Field & 20-300 kW, 600 V Perm. Magnet Alternators, ADV-5875AG-3 TP-6694 2/25...
  • Page 131 Figure 64 300 kW and Larger Pilot-Excited, Permanent Magnet 4M/5M/7M/10M Alternators, ADV-5875AG-4 TP-6694 2/25...
  • Page 132 TP-6694 2/25...

  • Page 133: Section 6. Accessories

    Section 6. Accessories 6.1 Accessories and Connections Several accessories help finalize installation, add convenience to operation and service, and establish state and local code compliance. Accessories vary with each generator set model and controller. Select factory-installed and/or shipped-loose accessories. See Figure 65 for a list of available kits. Obtain the most current accessory information from your local authorized service distributor/dealer.

  • Page 134: Battery Chargers

    6.1.1 Battery Chargers The following battery chargers are available for the generator sets covered in this manual: • 6 amp, 12 volt battery charger • 10 amp battery charger with alarms (meets NFPA requirements) Refer to the documentation provided with the battery charger for installation and operation instructions. Communication port 6 Amp Battery Charger 10 Amp Battery Charger w/Alarms...

  • Page 135: Common Fault/Failure (32A) Relay

    DEC 3000 Controller Figure 68 Battery Charger to Controller Connections 6.1.3 Common Fault/Failure (32A) Relay The common fault relay is standard on the controller circuit board and located at the TB2 terminal strip connections. Contacts are rated at 2 amps at 32 VDC or 0.5 amps at 120 VAC max. See Figure 69 and Figure 70. The optional common fault relay shown in Figure 70 as DCB2 has contacts rated at 10 amps at 28 VDC or 120 VAC and can be connected to user-supplied accessories.

  • Page 136: Four-Input/Fifteen-Output Module

    Figure 70 Common Fault Relay Kit and Shunt-Trip Relay Kit Wiring 6.1.4 Four-Input/Fifteen-Output Module The optional 4-input/15-output module is available for selected models. The 4-input/15-output module is not available with the 2-input/5-output module. Typical Configuration Alternate Configuration 4-Input/15-Output Module (most models) (25-40CCL) 4-Input/15-Output Module Controller Location...
  • Page 137 Connect to the normally open (NO) or normally closed (NC) terminals as required for each accessory. The relay contacts (K1 to K14) are rated: • 10 amp @ 120 VAC • 10 amp @ 28 VDC (max.) • 0.01 amp @ 28 VDC (min.) The common fault relay contact (K15) is rated: •...
  • Page 138 Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down the generator set.
  • Page 139 Optional 5 V Power Optional 5 V Power (50 mA max.) (50 mA max.) Output Analog Analog Device Device 100 ohm min. or TP-6694-6 50 mA max. current +/- 3 Volt Analog Device 0-5 Volt Ratiometric Sensor 0-5 Volt Analog Device Figure 73 Dry Contact Kit Analog Input Connections P36 Program the inputs and outputs using SiteTech™...

  • Page 140: Gas Fuel Valve Kit

    6.1.5 Gas Fuel Valve Kit This section provides the wiring information for an additional gas fuel valve kit required for UL Approval. See the figure below. Refer to the respective generator set wiring diagrams for additional information and for LP liquid applications. Typical for PSI, GM, and Doosan Engines KG80–KG125, KG80R–KG125R (KG6208TA Engine) Connections...

  • Page 141: Manual Key Switch

    P29/P30/P31 K1/K2/K3 2-amp relay outputs P32 K4/K5 10-amp relay outputs P27 CAN terminator P26 RJ45 Out SW1 switch P25 RJ45 In (APM402/DEC 3000 P23) P28 In1/In2 analog or digital inputs Figure 78 Two-Input/Five-Output Module Board Optional 5 V Power Optional 5 V Power (50 mA max.) (50 mA max.) Output...

  • Page 142: Low Fuel (Level/Pressure) Switch

    6.1.8 Low Fuel (Level/Pressure) Switch Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same controller terminal as the low fuel level switch on diesel-fueled models. See Figure 81, Figure 82, and Figure 83. Note: The main tank or the transfer/day tank includes the low fuel level switch.

  • Page 143: Prime Power Switch Kit

    6.1.10 Prime Power Switch Kit The prime power switch kit prevents battery drain during generator set no -operation periods and when the generator set battery cannot be maintained by an AC battery charger. See Figure 84 for an illustration of the kit and Figure 85 for the electrical connections.

  • Page 144: Remote Emergency Stop Kit

    6.1.11 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 145: Remote Reset Feature

    6.1.14 Remote Reset Feature The remote reset switch provides generator set controller resetting after a fault shutdown at a remote location. See Figure 87 and Figure 88 for user-supplied switch connection. Press and hold the switch for 2-3 seconds and release to reset the generator set controller. See the following subsection, “Accessory Connections,”...

  • Page 146: Remote Serial Annunciator

    6.1.15 Remote Serial Annunciator The RSA III is an annunciator panel offered in several kit configurations to support power equipment. See Figure 89. The RSA III is a remote serial annunciator that monitors the status 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 147 System Monitoring LEDs and Functions System Common Ready Generator Communications Common Fault Fault and Status Condition Fault LED Running 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 148: Run Relay Kit

    6.1.16 Run Relay Kit The run relay kit energizes only when the generator set runs. Use the run relay kit to control air intake and radiator louvers, alarms, and/or other signalling devices. See Figure 91 and Figure 92. See the section titled: Accessory Connections, for terminal identifications. 273705 Figure 91 Run Relay Kit...

  • Page 149: Shunt-Trip Line Circuit Breaker

    6.1.17 Shunt-Trip Line Circuit Breaker A shunt-trip line circuit breaker provides a 12- or 24-DC volt solenoid within the line circuit breaker case that can energize the trip mechanism. This feature allows the circuit breaker to be tripped by the common fault (32A). Connection requires a shunt- trip wiring kit and a dry contact kit.

  • Page 150: Accessory Connections

    6.2 Accessory Connections The controller contains a circuit board equipped with terminal strip(s) for use in connecting external optional accessories including alarms, battery chargers, and remote switches. The optional I/O board provides an additional two analog or digital inputs and five digital outputs. For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the instruction sheet accompanying the kit.
  • Page 151 TB3 Terminal Strip Accessory Power Output Connections Terminal Description Connection TB3-1 E-Stop E- Stop Ground TB3-1A E-Stop E- Stop TB3-3 Remote Start Remote Start TB3-4 Remote Start Remote Start TB3-AUX Auxiliary Aux. Shutdown Sw. TB3-AUXR Auxiliary-R Aux. Shutdown Sw. P1 24-Pin Connector Engine Wiring Harness Terminal Description...
  • Page 152 P28 Connector Single-Ended (0-5 V) Analog Input Connections Terminal Description P28-GND AGND Analog Return P28-VN1 NO Connection P28-VP1 ACH1 Signal P28-+5V Supply (.05 amp max.) P28-GND AGND Analog Return P28-VN2 NO Connection P28-VP2 ACH2 Signal P28-+5V Supply (0.05 amp max.) P28 Connector Differential (+/- 3 V) Analog Input Connections Terminal...
  • Page 153 P28 Connector Designations Terminals on Controller SiteTech Board Designation Designation P28-GND P28-VN1 DIn B1 P28-VP1 P28- +5V P28-GND P28-VN2 Din B2 P28-VP2 P28- +5V Figure 97 Input/Output Module Board Connections TP-6694 2/25...
  • Page 154 Figure 98 Controller Wiring Connections GM78246H-1 TP-6694 2/25...
  • Page 155 Figure 99 Controller Wiring Connections GM78246H-2 TP-6694 2/25...
  • Page 156 TP-6694 2/25...

  • Page 157: 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 158 (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 159 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 160 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 161: Appendix B. Programmer-Defined Settings

    Appendix B. Programmer-Defined Settings Use the table below to record programmer-defined settings during the generator set controller setup and calibration. The controller default settings and ranges provide guidelines. The table contains all faults with ranges and time delays including items that do not have adjustments. Some notices give the programmer a choice to make them active Not adjustable programmer-defined settings result when the controller logic does not allow changes or the values are engine limited.
  • Page 162 GenSet Write Mode Time Default Controller Access Always Delay Time Programmer- Display Display Running Range Default Range Delay Defined Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings Coolant Lvl Low Low coolant level * Fixed Not adjustable Shutdwn 0-10 Low coolant Coolant Temp 16°C...
  • Page 163 GenSet Write Mode Time Default Controller Access Always Delay Time Programmer- Display Display Running Range Default Range Delay Defined Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings Battery fault Battery Flt Not adjustable Chicago Code Chicago code active Active Common Fault Common fault Not adjustable...
  • Page 164 GenSet Write Mode Time Default Controller Access Always Delay Time Programmer- Display Display Running Range Default Range Delay Defined Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings Ground Fault Ground fault input * Not adjustable Warning 102% Total Power standby, kW overload Fixed...
  • Page 165 GenSet Write Mode Time Default Controller Access Always Delay Time Programmer- Display Display Running Range Default Range Delay Defined Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings Charger Equalize Stage Duration (Min) Note: Equalize is only 60–480 available with FLA/VRLA topology selected.
  • Page 166 GenSet Write Mode Time Default Controller Access Always Delay Time Programmer- Display Display Running Range Default Range Delay Defined Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings 13–15 14.25 Adjustable with Charger Voltage Bulk (12 V)§ (12 V) Charger 26–30 28.5 Custom Profile...

  • Page 167: Appendix C. Voltage Regulator Definitions And Adjustments

    Appendix C. Voltage Regulator Definitions and Adjustments The following definitions and adjustment/setting specifications are intended for users planning to adjust the voltage regulator beyond the default settings in order to customize the alternator for a specific application. This information is not intended to be a comprehensive explanation of all the terms mentioned. There are numerous documents available that define these terms more completely than described herein.
  • Page 168 response should determine the unloading point. The unloading setpoint is the frequency below which the excitation control will reduce the voltage so that the engine may begin to recover. The cut-in point, or frequency setpoint, should be set 0.5- 3.0 Hz lower than the normal steady-state band of operation. If the engine normally operates within a very narrow range of speeds close to the nominal, a setpoint of 0.5 to 1.0 Hz below nominal should be suitable.
  • Page 169 The underfrequency unload enable menu is used to turn the underfrequency unload on or off. A YES entry will turn the feature on and the display will show ENABLED YES. A NO entry will turn the feature off and the display will show ENABLED NO. The underfrequency unload defaults to an enabled (ON) condition.
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  • Page 171: Appendix D. Alternator Protection

    Appendix D. Alternator Protection The controller has built-in thermal protection for the alternator. This feature functions similarly to a thermal circuit breaker. When the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of time at which current is over the rating is inversely related to the amount of current above the nominal rating.
  • Page 172 TP-6694 2/25...

  • Page 173: Appendix E. Controller Displays From The Engine Ecm

    Appendix E. Controller Displays from the Engine ECM The controller display showing engine information is dependent upon the engine manufacturer and the corresponding Engine Control Module (ECM). The following list indicates which engine displays are available by the engine manufacturer. This information is subject to change by the engine manufacturer.
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  • Page 176 TP-6694 2/25p Discovery Energy, LLC 200 Twin Oaks Road, Kohler, WI 53044 USA For the nearest sales and service outlet in the Original Instructions (English) US and Canada, phone 1-800-544-2444 powersystems.rehlko.com © 2025 Discovery Energy, LLC - All rights reserved.

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