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WARNING: This product can expose you WARNING: Breathing diesel engine to chemicals, including carbon monoxide exhaust exposes you to chemicals known to and benzene, which are known to the State the State of California to cause cancer and of California to cause cancer and birth birth defects or other reproductive harm.
Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting WARNING Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, WARNING can cause bodily harm and pose life-threatening danger when improperly installed, operated, Explosion. maintained. To prevent accidents be aware of potential dangers and act Can cause severe injury or death.
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Battery gases. Explosion can cause Combustible materials. A fire can Carbon monoxide symptoms. severe injury or death. Battery gases cause severe injury death. Carbon monoxide can cause severe can cause an explosion. Do not smoke Generator set engine fuels and fuel nausea, fainting, or death.
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Fuel tanks. Explosive fuel vapors Connecting the battery and the WARNING can cause severe injury or death. battery charger. Hazardous voltage Gasoline and other volatile fuels stored will cause severe injury or death. in day tanks or subbase fuel tanks can Reconnect battery correctly,...
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Servicing the generator set when it Servicing the alternator. Hot parts is operating. Exposed moving parts can cause severe injury or death. will cause severe injury or death. Avoid touching the alternator field or Keep hands, feet, hair, clothing, and exciter armature.
Information in this publication represents data available engine fault codes in addition to the generator set at the time of print. Kohler Co. reserves the right to controller. The engine operation and service literature change this publication and the products represented provide information for identifying engine fault codes.
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Nameplate Location Generator sets and their components (engine, alternator) are identified with decals or nameplates. For future reference during routine maintenance or to order service parts, copy the model number, serial number, and specification number from the generator set nameplate into the spaces provided in the product information section on the inside front cover of this manual.
Visit the Kohler Co. website at KOHLERPower.com. Fax: (65) 6264-6455 China Look at the labels and decals on your Kohler product North China Regional Office, Beijing or review the appropriate literature or documents Phone: (86) 10 6518 7950 included with the product.
Type: XGA TFT LED LCD 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 8/20...
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Human-Machine Interface (HMI) 11601000945 Note: Covers have been removed for illustration. 1. APM802 controller human-machine interface (HMI) 8. USB ports, qty. 2 (on the back of the HMI) 2. Emergency stop switch 9. Controller touchscreen 3. Key switch 10. Fault indicator/display button 4.
1.3.1 Connections 1.3.2 Modbus Connections Use RS-485 cable for Modbus RTU connections. DANGER Belden #9841 or equivalent shielded, twisted-pair cable is recommended. See Figure 1-3. See the generator set wiring diagram for the Modbus connection location on TB10. Hazardous voltage. The controller also supports Modbus TCP over Will cause severe injury or death.
1.3.3 Optional Keyswitch and Manual 1.4 NFPA Requirements Start/Stop Button In order to meet NFPA 110, Level 1 requirements, the Some controllers are equipped with the optional generator set controller monitors the engine/generator functions and faults shown below. keyswitch and manual start/stop button shown in Figure 1-4.
1.5 Parameter Settings Controller parameter settings are factory-set and password-protected. Selected settings are shown in Figure 1-6. If changes are required, contact your distributor. Parameter Setting Preheat duration* Air-preheater maximum delay 30 s (at each start attempt)* Number of starting attempts Time between starting attempts 15 s Fault inhibition time in starting phase...
1.6 Base Module Inputs and Outputs The inputs and outputs on the base module are factory set. See Figure 1-7 and Figure 1-8 for base module input and output factory settings. For optional input/output module settings, see Section 4, Accessories. Note: Make customer connections to TB10 in the connection box.
Section 2 Operation 2.1 Prestart Checklist Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and To ensure continued satisfactory operation, perform the check for tight exhaust system connections. following checks or inspections before or at each Inspect the exhaust system components (exhaust startup, as designated, and at the intervals specified in manifold, exhaust line, flexible exhaust, clamps,...
2.2 Exercising Generator Set 2.3 Operation in Cold Weather Climates DANGER Cold weather operation is generally considered ambient temperatures below freezing 0°C (32°F). The following items are recommended for cold weather starting and/or operation when the unit is located in an enclosure or unheated structure.
2.4 Generator Set Operation 2.4.4 Emergency Stop Use the controller emergency stop switch for immediate 2.4.1 Start Signal emergency shutdown. A start signal includes the following: The emergency stop switch bypasses the engine cooldown cycle and immediately shuts down the Remote start signal via contacts 3 and 4 when the generator set.
2.5 Controller Operation Modes Note: To disable the generator set before servicing, shut down generator set, place The controller operation includes several types of Out-of-Service mode, and disconnect the starting and stopping functions. There are three primary batteries negative (- ) lead first. modes of operation, selected from the controller touchscreen or the optional keyswitch: 2.5.2...
1. Remove the load from the generator set. When the start signal is removed, the generator set will continue to run through the engine cooldown cycle, and 2. Wait five minutes to allow the engine to cool down. then shut down. 3.
2.6 Load Shed threshold #9. Load 1 (output #0) is shed first . Additional outputs are activated every 5 seconds as shown in The manual key switch/ load shed module is available as Figure 2-3 until the total load drops to the threshold an optional kit.
2.7 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 2-5. 1. Top bar 2. Control Panel 3.
2.7.3 Generator View The generator view displays engine mechanical data and alternator electrical data. When in manual mode, the Engine Start button also appears. See Figure 2-7. 1. Engine start appears in Manual mode only 2. Engine and mechanical view 3.
2.7.4 Control Panel 2.7.5 Custom View Button The control panel includes the generator set master On medium voltage units equipped with thermocouple switch and other controls. See Figure 2-8. modules, touch the custom view button to see alternator temperature readings from the thermocouple modules. If no thermocouple modules are installed, 32 F (or 0 C) is displayed for all temperatures.
2.8 Operator Login Some functions require logging in as an operator. 1. Touch the Operator button. See Figure 2-12. 2. 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.
2.9 Data Displays 2.9.1 Generator Mechanical Values Favorites 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) Starter battery voltage Coolant temperature (HT coolant temperature in the case of a dual circuit engine)
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Detailed View From an overview display of 6 mechanical values, we switch to a detailed display of 3 mechanical values. Pressing any area on an information bar on one of the mechanical value pages gives access to a detailed view Three tabs also appear: Fuel, Engine, and Cooling.
2.9.2 Generator Electrical Values Overview display Six electrical values are displayed and shown as meters. See Figure 2-18. 1. Curve button Figure 2-20 Detailed Electrical Values 2.9.3 Curve Display When you zoom into each mechanical or electrical value, the Curve button appears. Touch the Curve 1.
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On any curve displayed on the screen, inserting a USB key into the HMI port makes the USB key button appear. See Figure 2-23. Pressing this button automatically saves: A curve data file (.csv) containing the information (data points) described in Section 2.9.4. An image of the selected window in png format.
2.9.4 Saved Electrical and Mechanical Data The recording on a USB stick provides a curve data file All of this information is saved according to 4 different (.csv) containing the information shown in Figure 2-25. time periods: Depending on the engine type and sensors installed on 10 minutes: record values every 1 second the generator set, some of the 14 mechanical values 4 hours: record values every 30 seconds...
2.10 Events The controller displays status, alarm (warning), and fault (shutdown) messages. See Figure 2-26 for a list of possible alarms and faults. Internal Alarm Fault Internal Alarm Fault Number Description (Warning) (Shutdown) Number Description (Warning) (Shutdown) M3.10 Common fault M3.117 Engine coolant temperature fault...
2.10.1 Faults and Alarms Press the Alarm (!) button shown in Figure 2-27 to view a list of generator set events, including status messages, alarms, and faults. A status message communicates the state of the generator set (example: appearance of Stop mode). An alarm (warning) signals an impending problem (example: coolant temperature alarm).
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1. Alarm button with number of alarms (press to display list) 5. Date and time of event 2. Pull down tab (press to show full display of additional alarms) 6. Reset button (X) 3. Description 7. Active (on) 4. Internal variable number 8.
2.10.2 Resetting an Alarm 2.10.3 Resetting a Fault An alarm indicates that a problem has occurred, but the A fault turns off when the cause of the alarm is resolved generator is still able to run. Always correct an alarm by one of the two following methods: condition before it leads to a fault that will shut down the The operator has corrected the condition that is...
2.10.4 Consulting Status Messages Present/Not present Reviewing the status messages is possible at any time. Open/Close Depending on the status type, the APM802 will log On/Off different messages: Start/End Appearance After pressing the Alarm (!) button, and if no fault or Disappearance alarm is present, select Status messages history in Appearance/Disappearance...
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 2-37 for an example of the full event log. 1.
2.11 Applications Touch the Applications button in the top bar to open the Applications screen. See Figure 2-38. From this screen, you can access the screens listed in Figure 2-39. Note that access to some screens requires logging on as an operator. 1.
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 Reference Commercial case reference (manufacturer’s side) Genset serial number Generator set serial number associated with the HMI...
2.11.2 Region Settings 1. Select user language 3. Modify 2. Set the date and time 4. Date and time adjustment window appears after touching the Modify key Figure 2-41 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...
2.11.3 HMI Settings 1. Touch the Modify button 2. Slide to adjust the screen brightness during normal operation 3. Slide to adjust brightness during standby operation Figure 2-43 HMI settings The sliders on this screen allow adjustment of the screen brightness during operation and standby. The two sliders are independent.
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The Home button on the Remote HMI looks different the search for base modules connected to the ring is in than the Home button on the local HMI. progress. Figure 2-44. At the end of the search, the IP addresses of the modules connected to the Ethernet ring are shown (see Figure 2-46).
2.11.4 Restart 2.11.6 Firmware Update Press the Restart icon to bring the window shown in Pressing the Firmware update icon carries out an Figure 2-48 to the front. Confirm the restart by pressing update of the HMI firmware. OK, or cancel the procedure by pressing Cancel. The update requires that a USB key is inserted into the This operation will trigger a complete restart of the HMI port provided on the bottom of the HMI.
2.11.7 Screenshot Go into the screen to be copied and press the camera button. The screenshot is automatically saved to the Before taking a screenshot, it is necessary to insert a USB key in the directory “E:\apm802\screenshot. USB key in the port provided on the bottom of the HMI module.
2.11.8 Ladder Tools Pressing the Ladder tools icon takes you to the screen shown in Figure 2-53. See Figure 2-38 for the location Ladder is a standardized graphic language which is very of the Ladder tools icon on the applications screen. similar to a ladder diagram.
2.11.9 Save Parameters 2.11.10 Upload Parameters 1. Insert a USB key into the port on the bottom of the An authorized service technician can obtain and load HMI module. See Figure 2-50. parameter files following the instructions in the controller service manual. 2.
2.12 Menus Figure 2-57 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 thresholds Mechanical Archiving Variables Application Installation 5.1.1 6.1.1 Timers * Generator electrical Binary inputs General...
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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 2-58 for menu access information. 1 - Settings User Operator * 5.3 Regulation 1.2 Power thresholds View Modify * 5.3.1 Regulation parameters View *...
2.12.1 Menu 1- Settings Changing Settings Pressing the Modify button brings up text entry fields for The 1- Settings menu can be accessed via the key with settings that can be changed. See Figure 2-59. the same name. Pressing in the text entry field brings up the 1.2 Power Thresholds alphanumeric keypad shown in Figure 2-60.
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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. 1. Threshold reached = green (in this example, thresholds #1 to #4 are reached or exceeded) 2.
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Screen 1.6- Auxiliaries The 1.6- Auxiliaries screen is used to set the auxiliary parameters for the generator set fuel warning levels. Figure 2-62 Auxiliaries screen Title Description and possible settings (or selections) Fuel pumps Low fuel level fault (%) Low fuel level at which the fault is triggered, expressed as a percentage Low fuel level warning (%) Low fuel level at which the alarm is triggered, expressed as a...
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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 2-63 Parameters Screen TP-7070 8/20 Section 2 Operation...
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. Screen 2.2 - Mechanical Screen 2.3 - Generator electrical Screen 2.6 - Harmonics Note: The measurements menus are view-only; no modifications are possible from these menus. Screen 2.2- Mechanical The 2.2- Mechanical screen gives an overview of all the mechanical values for the associated generator.
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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). 1. Display for 3 phases 2. Phase sequence indication : Green = Correct; Red = Inverse; Off = Not Activated 3.
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Screen 2.6- Harmonics The 2.6- Harmonics screen is used to monitor the change in harmonics in real time on the generator set. 1. Harmonics 2. Line-to-neutral voltage 3. Current Figure 2-66 Harmonics Screen Section 2 Operation TP-7070 8/20...
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. 1.
2.12.4 Menu 4- Diagnosis Screen 4.1- Variables The 4.1- Variables screen is used to read all the system The 4- Diagnosis menu can be accessed via the key variables, regardless of whether these are logic or with the same name. it gives access to the 5 screens analog variables.
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Type Enter on screen keypad Enter on external keypad Complete write access examples Logic input variable I0.0.0 Analog input variable I5.21 Internal variable (input or M3.112 output) M1.0 M1.1 Logic output variable Q0.0.0 Analog output variable Figure 2-69 Sample Variable Identification Refer to the example in Figure 2-68 and the variables listed in Figure 2-70.
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Screen 4.2- Binary inputs The 4.2- Binary inputs screen is used to get a quick overview of the following logic states: Eighteen binary inputs for the base module Eight binary inputs for each remote module connected to the base module Red = Not Active (off) Green = Active (on) 1.
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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 Four outputs for each extension module connected to the base module Red = Not Active (off) Green = Active (on) 1.
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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. 1. Entry field for a variable name 2. Value or status of the variable 3. Numeric keypad for entering the variable name Figure 2-73 Regulation and Protection Screen The process for entering a regulation or protection variable is the same as for the 4.1- Mapping screen.
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Screen 4.5- Regulation The 4.5- Regulation screen is used to read all of the internal variables for the regulation modules. 1. Entry field for a variable name 2. Value or status of the variable 3. Regulation status Figure 2-74 Regulation Screen The virtual numeric keypad appears after the variable entry field has been pressed.
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 6.5.1Ethernet 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 6.5.2Serial link screen defines the specifications of the RS485 type serial link available on the base module. Figure 2-77 Serial Link Screen The screen is accessible for modification at the operator level. Figure 2-78 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 3.1 Introduction 3.2 Generator Set and Controller This section contains generator set, controller, general Refer to the following charts for generator set and engine, customer connection panel controller troubleshooting. Some of the corrective troubleshooting, diagnostic, and repair information. actions may reference the alternator and/or controller This section may refer to other literature for procedures service...
Section 4 Accessories 4.1 Accessories and Connections 4.2 Accessory Connections Factory-installed accessories are available to help Connect external optional accessories including finalize installation, add convenience to operation and alarms, battery chargers, thermocouples, and remote service, and establish state and local code compliance. switches to the terminal block or modules in the customer connection box.
The following factory-installed modules are available as KD model generator sets with a single starter or optional accessories. redundant starters. The 20 Amp, 24 VDC Kohler High Analog Input/Output Module Frequency Battery is used with these models. Digital I/O Module The battery charger sends a fault message to the APM802 controller in the event of a battery charger fault.
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31613391201/301/401 1. Factory connections or settings 2. Analog output connections 0 and 1 3. Analog input connections 0 - 3 Figure 4-5 Analog Input/Output Module Description LED Operation Power LED Green: The module is correctly powered. Off: Module is not powered. Can bus 1 Communication LED Flashing green: CAN communication is consistent.
Different I/O settings for the optional I/O module can be Output DO0 Load 1 Undefined loaded by an authorized service technician. Contact Output DO1 Load 2 Undefined your Kohler distributor with your requirements for digital Output DO2 Load 3 Undefined inputs and outputs. Output DO3 Load 4 Undefined...
4.4.3 Thermocouple Input Module Up to three thermocouples can be connected to the Thermocouple Module. Type PT100 thermocouples can be connected. See Figure 4-10 for thermocouple specifications. See Figure 4-12 and Figure 4-13 for connections. Medium voltage (larger than 600 volts) units are equipped with two thermocouple modules with the settings shown in Figure 4-11.
4.5 Remote Emergency Stop Kit 4.5.2 Lockable Emergency Stop Switch This switch can be locked in the activated position to The emergency stop (E-stop) kit allows immediate prevent generator set starting. Use a customer provided shutdown of the generator set from a remote location. If locking device inserted into the holes in the shroud to emergency stop...
4.6 Remote Serial Annunciator RSA III is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA III is a remote serial annunciator (Figure 4-15, Figure 4-16, and Figure 4-17) that monitors the condition of the generator set and/or ATS from a remote location.
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System Monitoring LEDs and Functions Common System Generator Communications Common Fault Fault Ready LED Running LED Status LED Fault LED Output Horn Fault and Status Condition Overcrank (Shutdown) Red SF Red SF Green Red SF High Engine Temperature (Warning) Yellow SF Red SF Green Green...
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere cubic feet per hour electrostatic discharge ABDC after bottom dead center cubic feet per minute est. estimated alternating current center of gravity E-Stop emergency stop analog to digital cubic inch displacement...
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(2 bytes) nat. gas natural gas room temperature vulcanization KBus Kohler communication protocol National Bureau of Standards read/write kilogram normally closed Society of Automotive Engineers kg/cm kilograms per square National Electrical Code...
Appendix B Operating Hour Service Log Use the log below to keep a cumulative record of required services were performed. Enter hours to the operating hours on your generator set and the dates nearest quarter hour. Operating Hours Service Record Date Hours Total...
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Operating Hours Service Record Date Hours Total Service Hours Date Service 86 Appendix TP-7070 8/20...
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KOHLER CO., Kohler, Wisconsin 53044 Phone 920-457-4441, Fax 920-459-1646 TP-7070 8/20f For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KOHLERPower.com 2017 Kohler Co. All rights reserved.
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