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20-2250kW Operation manual

1. 16 Fuses inside controller Frequency meter AC voltmeter Controller TB1 and TP2 terminal strips on circuit board AC ammeter Scale lamps upper lower Lamp test Alarm horn Figure 1 1 16 Light Decision Maker 3 Controller TP 6161 1 07 Se PREALARM HIGH ENGINE AUXILIARY O HIGH BATTERY FAULT HIGH ENGINE O TEMPERATURE N TEMPERATURE x V VOLTAGE PREALARM Lowol LOW OIL PRESSURE _ PRESSURE gt BATTERY y AIR N CHAI Fi UY DAMPER y LOW WATER d EMERGENCY gt LOW BATTERY SYSTEM TEMPERATURE STOP L VOLTAGE READY a FN Sa 75 GENERATOR U LOW FUEL Iu OVERSPEED OVERCRANK SWITCH ES ed NOT IN AUTO RUN OFF RESET AUTO SILENCE JAMAL ALARM Selector switch Annunciator panel lamps 15 Water temperature gauge Alarm silence switch 16 Voltage adjustment if equipped ADV 5849A DC voltmeter 17 Oil pressure gauge Generator set master switch 18 Hourmeter Emergency stop switch if equipped Section 1 Specifications and Features 13 The 16 light controller with communications has a new circuit board GM28725 that is different in appearance and has additional functions from the earlier versions but is a direct replacement for earlier version circuit boards including A 336415 Features of the new circuit board include the following items New Application Program Softwar
2. Remote start Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Crank mode selection open cyclic crank ground continuous crank Connect TB2 9 to TB2 9A for continuous cranking leave TB2 9 open cyclic cranking see starting instructions in Section 2 Operation Crank mode ground Figure 6 17 16 Light Controller TB2 Terminal Strip TP 6161 1 07 Terminal on TB1 TB1A or TB3 TB1B Purpose Ground Emergency stop relay K4 Connect emergency stop across terminals TB1 1 and 1A Emergency stop relay K4 coil negative side Connect emergency stop across terminals TB1 1 and 1A Ground terminal Overcrank OC signal Auxiliary AUX signal Common fault prealarm line 1 audiovisual alarm or common fault relay activated by OC 12 AUX 26 LWT 35 HET 36 LOP 38 OS 39 AHET 40 ALOP 41 and LF 63 faults Common fault prealarm line 2 audiovisual alarm or common fault relay activated by AUX 26 HET 36 LOP 38 OS 39 and ES 48 faults Low water temperature LWT signal High engine temperature HET signal Low oil pressure LOP signal Overspeed OS signal Anticipatory high engine temperature AHET signal Anticipatory low oil pressure ALOP signal Battery voltage fuse 1 protected Accessory power supply Customer may also provide separate accessory power source
3. 48 Emergency stop ES signal 56 Air damper AD switch 60 System ready signal 61 Battery charger fault Connect battery charger alarm contact to activate fault lamp active low if used 62 Low battery volts Connect battery charger alarm contact to activate fault lamp active low if used 63 Low fuel LF fault Connect fuel level sensor to activate fault lamp active low if used 70C Generator in cool down mode signal 7OR Generator in running mode signal 80 Not in auto signal Connect jumper across terminals 1 and 1A if emergency stop switch is not used Use a remote annunciator and or audiovisual alarm kit as an indicator with a dry contact kit connected to controller terminal strip TB1 TB1A and TB3 TB1B Figure 6 18 16 Light Controller TB1 TB1A and TB3 TB1B Terminal Strips TP 6161 1 07 Section 6 Accessories 55 6 3 Communication Module Kit and Gauge Driver Circuit Board When a remote serial annunciator RSA is connected to a Decision Maker 3 controller a communication module circuit board is required See Figure 6 19 for location and connection The communication module circuit board location may also be occupied by an interface circuit board with gauge drivers required for some models Do not confuse the function of these circuit boards See the Introduction section and refer to Tech Tools Engine Electronic Mo
4. Fuel level switch Weekly Main tank supply level Weekly Solenoid valve operation Weekly Transfer pump operation Weekly Water in system remove Weekly Filter s Quarterly Gasoline supply Six Months Fuel piping Yearly Tank vents and return lines for obstructions Yearly Lubrication Oil level Weekly Crankcase breather Quarterly Change oil 50 Hours or Yearly Replace filter s 50 Hours or Yearly Cooling Air cleaner to room enclosure Weekly Block heater operation Weekly Coolant level Weekly Flexible hoses and connectors Weekly Water pump s Weekly Fan and alternator belts Monthly Coolant temperature protection level Six Months 200 Hours or Six Months Air ducts louvers x Yearly Coolant Yearly Heat exchanger Yearly Lubricate fan bearings 1200 2000 kW Louver motors and controls Yearly Radiator exterior Yearly Water supply to heat exchanger Yearly Exhaust Line Drain condensate trap Weekly Leakage Weekly Insulation fire hazards Quarterly Flexible connector s Six Months Excessive back pressure Yearly Hangers and supports Yearly DC Electrical System Battery charger operation charge rate Monthly Battery electrolyte level Monthly Battery specific gravity charge state Monthly Recharge after engine start Monthly Remove corrosion clean and dry battery and rack x Month
5. range Low coolant The low coolant level shutdown shuts down the level unit 5 seconds after the fault The shutdown if equipped does not function during the first 30 seconds following startup Low oil The low oil pressure shutdown shuts down the pressure unit 5 seconds after fault detection The shutdown does not function during the first 30 seconds following startup Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Overcrank shuts down the unit after 45 seconds of continuous cranking Shutdown occurs after 75 seconds of cyclic cranking crank 15 seconds reset 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 seconds if the engine or starter does not turn locked rotor Note The controller has an automatic restart function The generator set attempts to restart if the engine speed drops below 390 rpm output frequency of 13 Hz Continued low engine speed causes an overcrank fault condition Overcrank Overspeed Overspeed shuts down the unit immediately when governed frequency on 50 60 Hz models exceeds 60 70 Hz Note The controller circuit board DIP switches allow 50 Hz 60 Hz shutdown or 60 Hz 70 Hz shutdown selection Overvoltage if Overvoltage shuts down the unit and lights the equipped auxiliary lamp when voltage is at least 15 over the nominal voltage for longer than 2 seconds Note Overvol
6. when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A 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 electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case Ifbattery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seeki
7. 000 hours of operation in standby and prime power applications Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage Replace the tolerance ring if equipped following end bracket removal The sealed end bracket bearing requires no additional lubrication 3 4 2 350 2000 kW Models with Single Bearing Alternator The alternator bearing requires lubrication at intervals specified in the generator set technical manual Use Chevron SRI or equivalent antifriction high quality grease with a lubrication temperature range of 30 to 175 C 22 to 350 F 1250 2000 kW Model with Two Bearing Alternator 3 4 3 Refer to the generator set service manual for bearing maintenance information 3 5 Diesel Fuel Systems 3 5 1 Bleeding Air from Fuel System Bleed air from the fuel system after fuel system maintenance such as replacing the fuel filter s using the hand prime pump kit when equipped The hand prime fuel pump eliminates the need for cranking the engine to bleed air from the fuel system Note Bleed air from the fuel system according to the engine manufacturer s instructions Trapped air in the fuel system causes difficult starting and or erratic engine operation Note Correct any fuel leaks encountered during the priming procedure 1 Place the fuel valves in the fuel system prime position Close the fuel valve located between the pipe tee and the engine Open
8. 619 7568 Fax 863 701 7131 TP 6161 1 07 Section 1 Specifications and Features 1 1 Introduction The specification sheets for each generator set provide specific generator and engine information Refer to the respective specification sheet for data not supplied in this manual Consult the generator set service manual installation manual engine operation manual and engine service manual for additional specifications 1 2 16 Light Controller Features The 16 light controller can operate in either the normal mode or the prime power mode The prime power mode allows reduced controller current draw in applications without a battery charger minimizing battery drain by the controller circuitry See Section 2 3 2 Prime Power Mode Operation for more information Figure 1 1 shows the 16 light level 1 controller The 16 light controller features include annunciator panel lamps analog meters switches and controls and fuses and terminal strips For identification and an explanation ofthe functions see Sections 1 2 1 through 1 2 7 Note Some installations use modified 16 light microprocessor controllers with switchgear applications These nonstandard controllers may have remote start and no time delay for engine cooldown circuitry Consult the switchgear literature for configuration and function A ALC VOLTS A C AMPERES e VOLTAGE lt SN dos 000001 S
9. Elo MS 5 z 25 AAA L y ei x g s Z AA E A M Ea LA ol g Ga Q Op hs Eg 19 dWOO JOOYO Lol WNOILdO a e ANNONS NOX O b e 31WINSNI OL 3dV1l 9 9 q3sn LON 19 ZIS a SIVANVA JIS 3SvHd 319NIS Ge Coen LON 19 YO4 O3lvH LON SI3S 3NOS SEH AOZC OLL ZH OS e AINO ANIM A00Z 001L ZH OS NOZZ OLL ZH OS NOZZ ZH OS A0yZ 0Z1 ZH 09 NOYZ 07 1 ZH 09 MOPZ ZH 09 A00Z 001 ZH 09 V1 3G SHIM Y YOLVNY31L IV Gv31 l jSVHd 319NIS dMIM YOIVNY431 IV GV31 El jSVHd 319NIS 3MIM MOIVNH3LIV Qv4l Cl Figure 5 3 60 with Oversize Alternator 300 kW Wound Field Alternators ADV 5875C H 1 07 TP 6161 46 Section 5 Generator Set Reconnection el c1 L1 9 g V NOIIVIOM 3SVHd 3 Vid dng o1 zafen 84 M3dWnr dWvi Jolalenl EL en 84 Hd Sid 3S S EE 3 Lore etos PNG 31vOS YILIN CT 31vOS YILIN I e T 6A o oe DA O Oe x 9 can 9 1 ZH ld OL g cj ox OH x By iu de di af s 3 5 9 BA 6 o o 7 S E 12 CL 19 91 EX SH i Zx ZH q 2 IX tH CU I un gA o o z an Zld ZX ZH iA E l a ME E 01 iH 11d OL A 91 IH A E LR ck SII o Cae on ATA 01 OWN zuo 20 Hd iw Hd MOM 19 dNO2 5 ANY NY dooua al Ss ZL el LL Gs WNOILdO SEN r de A cx IL TAN LL
10. SNOILO3NNOO YOLVYSNAS 47 Section 5 Generator Set Reconnection 1 07 Figure 5 4 350 2000 kW Pilot Excited Permanent Magnet Alternator ADV 5875D H TP 6161 4 Remove the controller cover and reposition the 6 Reconnect the starting battery negative lead meter scale lamp jumper see Figure 5 5 to match last Place the generator set master switch in the the position for desired voltage shown in RUN position to start the generator set Check the Figure 5 1 Figure 5 2 Figure 5 3 and voltmeter to verify that the vollage changed to the Figure 5 4 Replace the controller cover desired value a 20 300 kW Models Adjust the voltage with the ANO A 1 voltage adjustment control on the generator set Eal EE E controller front panel or switchgear See Figure 5 6 LOW V7F ADV 5849A 1 1 Output voltage adjustment control Figure 5 6 Voltage Adjustment b 350 2000 kW Models Adjust the voltage with the voltage adjustment control on the voltage ee regulator or switchgear Use the applicable 1 Lamp Jumper technical manual for voltage regulator adjustment Figure 5 5 Meter Scale Lamp Jumper 7 Stop the gen
11. adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA CCW CEC cert cfh TP 6161 ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery charging battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake
12. and cables with clean water and wipe the battery with a dry cloth 3 9 2 Electrolyte Level Inspection Check the electrolyte level and specific gravity of batteries that have filler caps Maintenance free batteries do not require electrolyte level checking or specific gravity testing 34 Section 3 Scheduled Maintenance Check the electrolyte level at the specified interval Remove the filler caps and verify that the electrolyte level reaches the bottom of each filler hole See Figure 3 12 Refill as necessary with distilled water or clean tap water Do not add fresh electrolyte Tighten the filler caps After adding water during freezing temperatures run the generator set 20 30 minutes to mix the electrolyte and the water to prevent battery damage from freezing 1 Filler caps 2 Electrolyte level Figure 3 12 Battery Electrolyte Level Inspection 3 9 3 Specific Gravity Check 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 If the hydrometer used does not have a correction table consult Figure 3 13 Determine the specific gravity and electrolyte temperature ofthe battery cells Locate the temperature in Figure 3 13 and correct the specific gravity by the amount shown The battery is fully charged if the s
13. and other accessories match the selected line voltage A WARNING Sech x 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 Reconnect the negative lead last when reconnecting the battery 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 Turn the generator set master switch and switchgear engine control switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting ofthe generator set by an automatic transfer switch or a remote start stop switch Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop
14. connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is operating Exposed moving parts can 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 Replace guards screens and covers before operating the generator set Section 3 Scheduled Maintenance 23 3 3 Service Schedule Action System Component Visually Inspect Check Change Interval Fuel Day tank level Weekly Flexible lines and connections Weekly
15. controller circuit board panel until itis lying flat when connecting the dry contact kits to the controller TB1 terminal strip Route dry contact relay leads through the controller grommet and guide loops to the circuit board terminal strip Place the controller circuit board panel flat to ensure adequate slack in the dry contact relay leads For specific information on accessory connections refer to the accessory wiring diagrams in the Wiring Diagram Manual and the instruction sheet accompanying the kit Note Not all terminals are used for all generator sets see appropriate wiring diagrams for specific generator set models Note To use the prime power mode use jumpers to connect TB2 1P to TB2 2P TB2 3P to TB2 4P and TB2 3 to TB2 4 To deactivate the prime power mode remove these jumpers 54 Section 6 Accessories N efe e pe el p2 P1 A 336415 A 1 TB1 TB1A terminal strip 2 TB2 terminal strip 3 TB3 TB1B terminal strip Figure 6 16 TB1 and TB2 Terminal Strips on the 16 Light Controller Prime power operation Prime power operation Remote start ground Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation
16. flashing on the CEL lamp indicates a previous fault occurrence The ECM memory stores inactive codes with time date identification and the following information e First occurrence of each diagnostic code in engine operating hours e Last occurrence of each diagnostic code in engine operating hours e Total time in seconds that the diagnostic code was active 36 Section 3 Scheduled Maintenance 3 11 Engine Control Systems Some generator sets use an engine control system Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine Use the following data for general informational purposes only See the Engine Service Manual for complete information regarding operation and troubleshooting Contact an authorized service distributor dealer for service or diagnostic equipment Engine Control Features Engine control is an advanced technology electronic engine control system The system optimizes control of critical engine functions and provides protection against serious engine damage The major components include the engine control module engine sensors and control box located in the generator set junction box See Figure 3 16 for the John Deere engine control box features DIAGNOSTIC SHUTDOWN ES OVERRIDE GN Iw WARNING STOP ENGINE Figure 3 16 John Deere Engine Control Box GM30962 A See Figure 3 17 for
17. listed in Figure 1 4 protect the generator set Figure 1 5 describes the meters and gauges located on circuitry microprocessor controllers 3 amp remote annunciator fuse protects the dry contact kit if equipped 3 amp controller fuse protects the controller circuit board speed sensor and lamp circuit board 15 amp engine and accessories fuse protects engine starting circuitry and accessories AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents Figure 1 4 Controller Fuses DC voltmeter Meter displays the voltage of the starting battery ies Frequency Meter displays the frequency Hz of the meter generator set output Hourmeter Hourmeter records the generator set total operating hours for reference in maintenance scheduling Oil pressure Gauge measures the engine oil pressure gauge Scale lamps Lamps indicate which AC voltmeter and or upper lower ammeter scales to read Water Gauge displays the engine coolant temperature temperature gauge Figure 1 5 Analog Meters and Gauges TP 6161 1 07 Section 1 Specifications and Features 15 1 2 5 Switches and Controls Figure 1 6 describes the switches and controls located on microprocessor controllers Alarm horn Horn sounds if any fault or prealarm condition exis
18. or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air Fuel System A 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 Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation TP 6161 1 07 Explosive fuel vapors can cause severe injury or d
19. regulator 1 Remove the fuel regulator cover plug See Figure 3 5 28 Section 3 Scheduled Maintenance sus 1 Fuel regulator 2 Spring 3 Adjustment screw 4 Cover plug Figure 3 5 Fuel Regulator Typical 2 Remove the adjustment screw and spring from the fuel regulator Save the adjustment screw and spring for possible conversion back to natural gas 3 Reinstall the cover plug Natural Gas Fuel Conversion Procedure Use the following steps to convert the generator set to natural gas 1 Remove the fuel regulator cover plug See Figure 3 5 2 Replace the spring and adjustment screw 3 Connect a manometer to check the fuel supply pressure on the carburetor side of the regulator downstream of any fuel system equipment accessories The recommended fuel supply pressures are shown on the generator set spec sheet 4 Adjust the fuel supply pressure with the generator set running at full load Rotate the adjustment screw on the fuel regulator until the pressure indicated by the manometer matches the specified pressure Use the lower pressure value if the generator set still provides good response and full power Lower than specified pressures may result in poor response to load changes or lack of power 5 Reinstall the cover plug TP 6161 1 07 3 6 4 Fuel System Changeover Kits Automatic Changeover A changeover fuel system kit provides automatic changeover from natural gas to LP gas vapor o
20. switch is in the OFF RESET position minimizing the battery drain Use the prime power mode for installations that do not have a battery charger to help prevent discharging the battery when the generator set is not operating Moving the generator set master switch to the OFF RESET position disables all controller functions Moving the generator set master switch to the AUTO position restores controller functions 20 Section 2 Operation Enabling and Disabling the Prime Power Mode To enable the prime power mode use jumpers to connect TB2 1P to TB2 2P TB2 3P to TB2 4P and TB2 3 to TB2 4 To deactivate the prime power mode remove these jumpers See Figure 1 7 Figure 1 8 and Figure 2 1 Terminal Purpose Prime power operation Prime power operation Remote start ground Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Remote start Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Figure 2 1 16 Light Controller TB2 Terminal Strip Prime Power Starting The prime power mode provides local starting only at the controller The AUTO position no longer functions as a remote start When the generator set master switch is in the OFF RESET position the controller functions are inoperative Move the generator set master switch to the AUTO position to start the generator set Do not start the generator set with the master swi
21. temperature e Low oil pressure e High oil temperature The major components of the DDEC MDEC system include the electronic control module ECM and engine sensors The DDEC control box is located in the generator set junction box Section 3 Scheduled Maintenance 35 3 10 2 DDEC Engine Diagnostics The DDEC engine protection system monitors engine sensors and electronic components and recognizes system malfunctions Critical faults light the check engine CEL and stop engine SEL lamps on the control box ECM memory software logs malfunction codes Consult the engine operation manual or engine service manual to identify the stored failure code See Figure 3 15 for the DDEC control box features DIAGNOSTIC REQUEST O A O Z Q 9 STOP CHECK ENGINE ENGINE A 343591 C Figure 3 15 DDEC Control Box Access the stored codes in one of three ways e Place the switch in the DIAGNOSTIC REQUEST position The CEL or SEL flashes to identify the failure e Use a hand held diagnostic data reader DDR Place the switch in the DIAGNOSTIC DATA READER position Plug the DDR into the control box The DDR displays the stored failure codes e Useapersonal computer software package available from the manufacturer with a translator to access stored codes Follow the instructions provided with the software Code Types Active code A code flashing on the SEL lamp indicates a fault currently exists Inactive code A code
22. the OFF RESET position and then is returned to the RUN position the generator set slows to 750 rpm 25 Hz and recranks before returning to rated speed Automatic Starting Move the generator set master switch to the AUTO position to allow startup by an automatic transfer switch or a remote start stop switch Refer to the wiring diagrams for remote switch connection information The engine cranks up to 30 seconds continuously or 75 seconds cyclically crank 15 seconds rest 15 seconds crank 15 seconds etc before shutting down on an overcrank fault Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period Select the cyclic or continuous cranking mode on the controller circuit board See Section 1 2 7 DIP switches Stopping Run the generator set without load for 5 minutes to ensure adequate engine cooldown To stop the generator set place the generator set master switch in the OFF RESET position and wait until the generator set stops completely Note The generator set continues to run during a 5 minute cooldown cycle if a remote switch or automatic transfer switch signals the engine to stop Note The controller circuit board DIP switches allow disabling the engine cooldown function 2 3 2 Prime Power Mode Operation The controller can operate in either the normal mode or the prime power mode n prime power mode the controller draws less current when the generator set master
23. the first 30 seconds after crank disconnect Auxiliary Immediate Shutdown Lamp lights and the engine shuts down if activated by customer supplied sensing devices connected to auxiliary immediate shutdown ports P1 17 and P1 18 Emergency Stop Switch Reset Lamp lights if the optional emergency stop switch is reset while the generator set master switch is in the AUTO or RUN position Place the generator set master switch in the OFF RESET position to clear this fault Low Fuel Shutdown 125RZG only Lamp lights and the engine shuts down if activated by the low fuel pressure shutdown switch connected to the Auxiliary Immediate Shutdown port P1 17 Place the generator set master switch in the OFF RESET position to clear this fault No AC Output Lamp flashes if the controller senses no AC output with the unit running except during first 10 seconds after startup When the controller senses AC output the flashing stops and the lamp is unlit Does not require manual reset Overvoltage Shutdown Lamp lights and the engine shuts down immediately if an overvoltage condition arises if equipped with overvoltage shutdown kit Underfrequency Shutdown Lamp lights and the engine shuts down if the engine speed drops below 5 of the nominal engine speed 1710 for 1800 rpm or 1425 for 1500 rpm for a continuous 60 second period Figure 1 3 Auxiliary Fault Lamp Operation 1 2 3 Fuses 1 2 4 Analog Meters and Gauges The fuses
24. the fuel valves on each side of the fuel prime pump See Figure 3 1 26 Section 3 Scheduled Maintenance Open this Valve Close this Valve Open this Valve Valve Open Valve Closed PK 272000 H Figure 3 1 Hand Prime Pump with Valve Positions for Fuel Priming Generator Set Without a Fuel Water Separator Shown Note The illustration shows a generator set without a fuel water separator The valve location and position for a generator set equipped with a fuel water separator is similar 2 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 3 Rotate hand prime pump handle counterclockwise until fuel flows from the bleed screw Stop pumping 4 Tighten the bleed screw Wipe up any fuel leakage 5 Place the fuel valves in the normal operation position Open the fuel valve located between the pipe tee and the engine Close the fuel valves on each side of the fuel prime pump TP 6161 1 07 3 5 2 Subbase Inner Fuel Tank Alarm This kit provides for both audible and visual alarm from a location remote from the generator set if a leak is detected in the inner fuel tank of the double wall subbase fuel tanks See Figure 3 2 If the inner tank is leaking a sensor installed in the outer tank sends an elect
25. thrubolt counterclockwise can loosen the hardware Servicing the generator set when it is operating Exposed moving parts can 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 Replace guards screens and covers before operating the generator set TP 6161 1 07 Notice NOTICE This generator set has been rewired from its nameplate voltage to 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 Hardware damage The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding of the bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 Safety Precautions and Instructions 9 Notes 1
26. to diagnose and correct common problems First check for simple causes such as a dead engine starting battery or an open circuit breaker The chart includes a list of common problems possible causes of the problem recommended corrective actions and references to detailed information or repair procedures TP 6161 1 07 Section 4 Troubleshooting Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment Section 4 Troubleshooting 39 G M 10 W S u S uoyMs eAnejedour eui eoejdeu eAneJedout uos eungejeduje 1sneuxe uBiH IAJ S siu uuopied Jejeep 1o3nquisip eones pezuouine ue aney 4 enuen webe BuulIM Q M 4284S oeds s s enuey eoe s W S enuen uonejedo 4WN O enuen uoneesu NI 38S Joyesauay ues eulbuy Bugz YAMS Jajsue oneuioiny S v penueu siy JO uoroes palequinu uonoag 9988S x Z uono s Je o puo9 eut 1oous qno11 pue sayojms UEL y 19seH uMopihnus yney Q M 40 W S USD Uo1Ms eAmnejedour y aoejday eAneJedout Us eJngeJeduue Jayem yBiH G M Ja ouo9 eui 0 y 19 uuo2o 1 UB s io1 9 uuoo sseuey ulBu au yOSUUODSIG 1uBn pexoo jou s 4019euuoo sseujeu eui u3 w s 6ua plou os Jejeijs JO Jeuejs eui aoejday aAl
27. unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6161 1 07 TP 6161 1 07 Notes 61 62 Notes TP 6161 1 07 TP 6161 1 07e 2004 2005 2006 2007 by Kohler Co All rights reserved KOHLER POWER SYSTEMS KOH
28. 0 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 59 k kilo 1000 K kelvin kA kiloampere KB kilobyte 219 bytes KBus Kohler communication protocol kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical kWth kilowatt thermal E liter LAN local area network LxWxH length by width by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting di
29. 0 Hz If the engine speed is incorrect refer to the generator set service manual for the governor adjustment procedure 3 6 2 LP Liquid Withdrawal Fuel System Concept With the LP liquid withdrawal fuel system pressurized liquid LP fuel passes from the tank to a vaporizer The vaporizer converts the liquid fuel to gas before sending it to the carburetor The system also includes a fuel valve that shuts off the fuel flow when the engine stops Contact an authorized service distributor dealer for availability 3 6 3 LP Gas Natural Gas Conversion for Straight Gas Fuel System Most models operate on either LP gas or natural gas fuel by performing the fuel conversion procedure Some models require a different fuel kit when changing gas fuels Consult your local generator set distributor dealer for additional information Fuel conversion may decrease generator set output and affect exhaust emissions Consult your local generator set distributor dealer for additional information Fuel Conversion Procedure When converting the generator set to operate with LP gas remove the internal spring from the secondary regulator Install the spring to operate the generator set on natural gas Note Not all fuel regulators require spring and retainer removal for fuel conversion A hang tag on the fuel regulator identifies the conversion procedure LP Fuel Conversion Procedure Use the following steps to remove the internal spring from the fuel
30. 0 Safety Precautions and Instructions TP 6161 1 07 Introduction This manual provides operation instructions for 20 2250 kW generator sets equipped with the following controllers e Decision Maker 3 16 Light e Decision Maker 1 Wiring diagram manuals are available separately Refer to the engine operation manual for generator set engine scheduled maintenance information Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect the parts often and perform required service atthe prescribed intervals Maintenance work must be performed by appropriately skiled and suitably trained maintenance personnel familiar with generator set operation and service 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 Abbreviati
31. 1 07 Communication Modules Circuit Board Versions 6 3 1 GM47242 Circuit Board This is the communication module for all models except the 450 500REOZVB models and is superceded by GM49791 1 See Figure 6 20 H DC DC DC Hr mo mo mu ma om sm m0 CU CUCU GM47242 SES 1 P9 connector 10 position 2 SW2 DIP switches set to open position 3 TB5 Terminal connectors 4 P8 connector 24 position Figure 6 20 Communication Circuit Board GM47242 GM49791 1 Circuit Board This is the communication module for all models and includes the gauge driver provision needed for some models Requires application software version 1 23 or later See Figure 6 21 GM49791 2 Circuit Board This is the interface circuit board with the gauge drivers required on the 450 500REOZVB models only For communication purposes replace GM49791 2 with GM49791 1 GM49791 2 is mounted in the communication module location but does not provide the communication function See Figure 6 22 6 3 2 Circuit Boards Views Figure 6 20 Figure 6 21 and Figure 6 22 show the differences between the communication circuit boards and the interface circuit board with gauge drivers The SW2 DIP switches should be set to the open position unless the instructions supplied with the kit indi
32. 1 1 Audiovisual Alarm Mi 49 6 1 2 Common Failure Relay Kit M 49 6 1 8 Controller Connection Kit M 49 6 1 4 Dry Contact Kit Single Relay M 50 6 1 5 Dry Contact Kits 10 14 and 20 Relay M 50 6 1 6 Engine Prealarm Senders M 51 6 1 7 FASTCHECK Diagnostic Tester M 51 6 1 8 Float Equalize Battery Charger Kit with Alarm Option M 51 6 4 9 Line Circuit Breaker 51 6 1 10 Low Fuel Switch Mi 52 6 1 11 Remote Annunciator Kit MI 52 6 1 12 Remote Emergency Stop Kit M 52 6 1 13 Remote Serial Annunciator M 53 6 1 14 Run Relay Kiki soi teenie tasu u ah ii eae aa daha de 53 6 1 15 Safeguard Breaker 53 6 2 Accessory and Prime Power Terminal Strip Connections M 54 6 3 Communication Module Kit and Gauge Driver Circuit Board 56 6 3 1 Communication Modules Circuit Board Versions 57 6 3 2 Circuit Boards Views 57 Appendix A Abbreviations ooooccocnccccnn hh hh hh enn 59 4 Table of Contents TP 6161 1 07 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessori
33. Do not use alcohol or methanol antifreeze or mix them with the specified coolant Refer to the engine operation manual for recommendations regarding the coolant mixture to use in extreme temperatures 6 Replace the pressure cap 7 Fill the coolant recovery tank to the low mark 8 Operate the generator set until the thermostat opens when the upper cooling system hose warms 9 Stop the engine and allow it to cool 10 Remove the pressure cap 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 between the high and low marks Note Air pockets often form in the engine water jacket when the coolant system is refilled Check the coolant level in the coolant recovery tank after each generator set operation and add coolant as necessary until the coolant level stabilizes Then check the coolant at the interval specified in the service schedule 14 Reenergize the block heater if equipped 3 8 Fan Bearing Lubrication The following procedure applies only to 1200 2000 kW generator sets Lubricate the radiator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage Lubricate the bearings every 200 hours of operation when the generator set runs in ambient temperatures below 29 C 85 F or when the generator set runs in a dusty and or humid environment Lubri
34. El Ho z3 ZH Zld 01 Zl ZL 15 zr re Re 119 H 13 A o dWoo doowa H Hd OL i1 19 ou Ve a RYE A WNOILdO dOONG vNOILdO ANY L BA O 00011 08 9 ZH OG 23 Gee 008 1 0 64 ZH 09 O09 Lv ZH 09 AODZEl OZ9 ZH 09 1009 0188 ZH OS A919 0bZ ZH OG 08 LLE ZH 09 9lv OvZ ZH OG AO8v LLZ ZH 09 AOLVZi O0CL ZH 09 O0 8061 ZH OG OOv 0 Z ZH OS Olv OvC ZH 09 OOv 0 Z ZH OS 9lv OvZ ZH 09 e ZH 09 09 17 0072 E 09 A08 0ZZ ZH OS AO8 0ZZ ZH 09 A08 0ZZ ZH OS AO08 0ZZ ZH 09 YOUAVE NOHLYYYN M t GE m T ei ih Sin O o JAM 3HIM v HOIVNH3IIV VIT JAM IH GHI v HOIVNHJEW AVIT cL SO Ol 6 r2 Saannr avi o jan 84 6 4 SA e3aganr anv Jecke 82 39S XIN T S TIVOS YIN n 31VOS N3l3W TT obs oi ig sn TVOS SUIN TT e Sie LI O 1 A 91 tt 61 CL NV 4 Si Ll 01 L 19 A en 73 2i 3 Au ch Su sr OR Hs Da p A o Gal 1 ZL OL AA LE 4l u 8l zi 119 i 19 NOD 5 a cO d00 0 SL _ fl WNOILdO Zlo M3dWne de onf ajan SL q3Sn L N S12 Ai Ze Hil3 TI z Hia 1 19 oo SWANVN 33S 3SvHd 319NS dO X04 GdlvH LON SI3S 3WOS a el IVNOLLAO ey AOZZ OLL ZH OG ABOZ OZL ZH OG AOYZ G6EL ZH 09 LA e i A00Z 00L ZH OG Q AO0Z SLl ZH OG OZZ ZL ZH O9 13 AOZZ OLl ZH OS AOvZ OZL ZH 09 7 L 0LL ZH OG ABOZ OZL ZH 09 8 z3 AOVZ OZL ZH O9 00 001 ZH 09 JAM MOT 3MIM v MOIVNH3ILIV 0V31 Cl WHO OL VIIJ SHIM HOIVNHAJLIV Oval Cl jSVHd 319NIS SHIM MOIVNMdIIV Gv31 l
35. Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth 3 Change the fuel filter separator and bleed the fuel system See the engine owner s manual TP 6161 1 07 Gasoline Fueled Engines 1 Add stabilizer to the fuel system Follow the manufacturer s recommended procedure 2 Run the generator set for 15 minutes to ensure that the stabilized fuel reaches the carburetor 3 Place the generator set master switch in the OFF RESET position 4 Close the fuel valve Gas Fueled Engines 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position 3 12 4 Internal Engine Components Gas Gasoline Fueled Engines If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows 1 While the engine is running spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops 2 Place the generator set master switch in the OFF RESET position If a fogging agent is not available perform the following 1 Remove the spark plugs 2 Pour 15 cc 0 5 oz of engine oil into each spark plug hole Ignition System Damage Refer to the engine operation manual for ignition system precautions before cranking the en
36. Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ib ft min ftp H ga gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gross weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H2
37. LER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPowerSystems com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
38. Operation Industrial Generator Sets kee Models 20 2250 kW Controllers Decision Maker 3 16 Light Software Code Version 1 10 or higher Decision Maker 1 29001 koner mum OV ER SYSTEMS KOHLER ECTS POWER SYSTEMS mae i California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information 2 Safety Precautions and Instructions 5 Introductio
39. Pa Been Sr 71 L E E d Le uf DAMNIS Q3lJIO3dS N3HM M3TIOMINOCO I OL e 5 8 Ove M3XVN NOISO3O M SCH lo MA OS OZ YO4 ONINIM 12 n wa 2 6 OA 119 pq em d AN I L G LA O e p t o 19 dNOO uoc D H9 17 doo WNOLLdO A L A919 09Z ZH OG AO8v LLC ZH 09 80C OCL ZH OG OvZ 69 ZH 09 17 11 AO0v 0 ZH OG 9lv OvC ZH 09 DOZ SLL ZH OG AOZZ LTL ZH 09 009 1758 ZH 09 AO8 0ZZ ZH OS A08 07Z ZH 09 A061 011 ZH OG AB0Z 0Z 1 ZH 09 SAM SHIM v MNOlvNHdLIV Qv41 9 y MOIVNHJLIV Gv31 El SAM MOT 38 y MOIVNMALIV Qv4dl El SOND die o7 zafen 81 Y3dnnr env ow pn 81 YIAN dAvi lei Anker 84 Zv e YIN LT j1vOS YILIN TI 31vOS YILIN 17 INNOYI MOYA Pa JLVINSNI OL 3dVl ZL O 9 2 T5 19 dNO9 LLO 110 01 MW i 1l I1 A L dOOMQ QA 1 A zi OG gt WNOlLaO o v Lea E 01 9 L lt OS LR ee QUE CIO M t 8 2 Y 8 a i e A 01 LN See A g 4 6 Bang 11 NO c cs d I OA c Me LA E d LS e D O 19 dWOO d 9 dOOHQ WNOlLdO Bn w q3sn LON 19 Convoi 338 3SVHd 319NIS d das LON 19 JOY G3alve LON S13S 3NOS 0 AOZZ OLL ZH OG AINO 3NIMV AD A00Z 001 ZH OS AOZZ OLL ZH OG NOZZ ZH OG OvZ OZI ZH 09 AOvZ OZL ZH 09 AOvZ ZH 09 00Z 001 ZH 09 VLI3d 38 y MOIVNMHJLIV 0Ov31 l ASVHd 319 MHOIVNMJLIV Qv4I CL 3SvHd 319NIS 3HIM NJOIVNS3ITV Gv31 I Figure 5 2 20 300 kW Permanent Magnet and 20 60 kW Wound Field Alterna
40. Precautions at the beginning of this section before proceeding 2 Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding 3 Startthe generator set by moving the generator set master switch to RESET OFF and then to RUN 4 Verify that the cause of the shutdown has been corrected by test operating the generator set 5 Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch 6 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Fault Description High engine Shutdown occurs 5 seconds after the fault The temperature high engine temperature shutdown does not function during the first 5 seconds after startup Note The high temperature shutdown functions only when the coolant level is in the operating range Low coolant Shutdown occurs 5 seconds after the fault The level low coolant level shutdown does not function during the first 5 seconds after startup Shutdown occurs 5 seconds after the fault The low oil pressure shutdown does not function during the first 5 seconds after startup Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Low oil pressure Shutdown occurs after 30 seconds of continuous cranking Shutdown occurs 30 seconds after startup if there is no AC out
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42. alified electrician install the battery ies Safety Precautions and Instructions 7 Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections Handling the capacitor Hazardous voltage can cause severe injury or death Electrical shock results from touching the charged capacitor terminals Discharge the capacitor by shorting the terminals together Capacitor excited models only Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically i
43. all accessories except the emergency stop kit to the connection kit terminal strip Section 6 Accessories 49 6 1 4 Dry Contact Kit Single Relay M The single relay dry contact kit uses one set of contacts to trigger customer provided warning devices if a fault condition occurs Connect any controller fault output connection from the TB1 terminal strip to the single relay kit Use the single relay dry contact kit as a common fault relay for signaling any of the following common fault conditions e Emergency Stop e Auxiliary e Overspeed e Low Oil Pressure e High Engine Temperature Connect a maximum of three dry contact kits to a single controller output See Figure 6 3 Figure 6 3 Single Relay Dry Contact Kit Typical 6 1 5 Dry Contact Kits 10 14 and 20 Relay M Dry contact kits allow monitoring of the generator set system and provide the ability to activate warning devices and other customer provided accessories Available kits include 10 14 or 20 sets of relay contacts for connecting customer provided devices to desired generator set functions The 20 relay kits can be used on 450 kW and larger generator sets The 10 relay and 20 relay kits provide normally open and normally closed contacts The 14 relay kit provides normally open contacts only Warning devices lamp and or audible alarms and other accessories typically connect to the controller output connections listed below A total of three dry contac
44. battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Refer to this section for general battery information and maintenance All generator set models use a negative ground with a 12 volt or 24 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator set spec sheet for battery capacity recommendations for replacement purposes The wiring diagrams provide battery connection information See Figure 3 9 Figure 3 10 and Figure 3 11 for typical battery connections including multiple battery configurations After reconnecting the battery cables coat the terminals with petroleum jelly silicon grease or other nonconductive grease Note Some units require a reflective heat shield insulative sleeve on the battery cables and other wires that are fastened to the starter solenoid This sleeve is a conductive material and must be secured approximatel
45. cate another configuration TP 6161 1 07 CT D1 Ta Iogi ToC Q2 Q3 Q4 ra ra ra Ya Do c19 os C On Ce r Q r BUTTON o Ess WW o Sweet 2 o D2 D3 D4 D5 3 2 mort rra ann GM47242 Z gt oe el 1 P9 connector 10 position 2 SW2 DIP switches set to open position 3 TB5 Terminal connectors 4 P8 connector 24 position Figure 6 21 Communication Circuit Board GM49791 1 C2 og cis CIs Dn Ge Ke DESI D ra and EH D2 D3 D4 D5 Tor prr 00 GM47242 1 P8 connector Figure 6 22 Gauge Driver Circuit Board GM49791 2 Section 6 Accessories 57 Notes 58 Section 6 Accessories TP 6161 1 07 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC
46. cation and Drive Belt Adjustment Procedure Lubricate the fan shaft and idler shaft bearings with a lithium complex base multi purpose grease with antirust antifoam and extreme pressure additives having a minimum dropping point of 204 C 400 F Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent Section 3 Scheduled Maintenance 31 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the generator set engine starting battery ies negative lead first and disconnect power to the battery charger 3 Remove the belt guards to expose the fan shaft and idler shaft bearings 4 Inject grease into the two bearings on the fan shaft block and the two bearings on the idler shaft block using a grease gun until a 3 6 mm 0 13 0 25 in grease column shows at the bearing pressure relief port See Figure 3 7 Note The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication TP 5353 3 1 Grease fittings 2 Pressure relief port 3 Radiator assembly 4 Idler shaft grease fittings 5 Fan shaft grease fittings Figure 3 7 Radiator Fan Bearings and Pressure Relief Ports Typical 5 Remove excess grease from the bearing pressure relief ports 6 Inspect the fan drive belt and replace if itis damaged or worn Check the fan belt tension using a poly V belt tension gauge and ad
47. change to the continuous cranking mode use DIP switch 3 Engine Configuration DIP Switches 4 and 5 See Figure 1 9 for the DIP switch positions based on engine configurations regarding non ECM MDEC and J1939 engine communication selections Modbus Address DIP Switches 6 8 Each Modbus device requires a unique address Address numbers are created using a binary number system with DIP switches 6 8 Figure 1 11 shows the DIP switch position for each address number DIP Switches 6 7 8 Value 4 Value 8 Open Open Open Modbus Address Value 2 Closed Open Open Open Closed Open Closed Open Open Closed Open Closed Closed Closed Closed Closed Open Open Closed Closed Closed Figure 1 11 Modbus Device Address Section 1 Specifications and Features 17 1 3 Expanded Decision Maker 1 Controller For identification of the expanded controller s indicators and controls and their functions refer to Figure 1 12 SS Y USE UPPER METER SCALES N L1 AMPS L112 VOLTS L2 AMPS L2 L3 VOLTS Lows L3 AMPS VOLTS Lig voLTs O V USE LOWER METER SCALES RESET VOLTAGE RUN OFF AUTO ADV 5849E B Voltage adjustment control Fault lamp 10 amp controller fuse DC voltmeter Water temperature gauge Oil pressure gauge Frequency meter AC voltmeter AC ammeter Scale lamps upper lower Selector switch Hourmeter Generato
48. downs 22 2 4 4 Controller Resetting After a Fault Shutdown 22 Section 3 Scheduled Maintenance 23 3 1 Alternator Service uses esee Et Ye Ese Deer hd re e ne eene 23 3 2 Engine Service voto a Abu eam 23 3 9 Semrvice Schedule sc Cu seo sciet s enciende E 24 3 4 Alternator Bearing Service 26 3 4 1 20 300 kW Models ssssssss IH 26 3 4 2 350 2000 kW Models with Single Bearing Alternator 26 3 4 8 1250 2000 kW Model with Two Bearing Alternator 26 3 5 Diesel Fuel Systems u l EEN a Ee gas c dele s IT per eg 26 3 5 1 Bleeding Air from Fuel System 26 3 5 2 Subbase Inner Fuel Tank Alarm 27 3 6 Gas Gasoline Fuel Systems 27 3 6 1 Gaseous Fuel System Concept 27 3 6 2 LP Liquid Withdrawal Fuel System Concept 28 3 6 3 LP Gas Natural Gas Conversion for Straight Gas Fuel System 28 3 6 4 Fuel System Changeover Kits 29 3 6 5 Carburetor Adjustment 29 3 6 6 Fuel System Maintenance 29 TP 6161 1 07 Table of Contents 3 Table of Contents continued 3 7 Cool System ou u pin a Desa dee S ae Sk e au 30 3 7 1 Coolant Level Chec
49. dule ECM for the latest applications LEGEND CONTROLLER BOARD CMB COMMUNICATION MODULE BOARD TBIA lt lalelzlolels Sa SIISE IPA INDICATOR PANEL ASSEMBLY P PLUG TB1 TB2 CONTROLLER BOARD TERMINAL BLOCK TB5 COMMUNICATION INTERFACE BOARD TERMINAL BLOCK 24 ENGINE HARNESS ES 3 TB5 CONNECTIONS PIN N C 2 N C SW2 1N A SW2 2N A SW2 3N A SW2 4N A H GM21340 REF 3 ATS POSITION RETURN GM32632 REF 4 USER INPUT 1 RETURN 5 USER INPUT 2 RETIRN SW2 SETTINGS 6 USER INPUT 3 RETURN CMB 7 N C sw2 8 N C 213 4 9 ATS POSITION INPUT 10 USER INPUT 1 11 USER INPUT 2 12 USER INPUT 3 HIGH BATTERY VOLTAGE CONTACTS ON 7 y BATTERY CHARGER GM35318 REF Ribbon cable 10 position Ribbon cable 24 position Connector 6 position Indicator panel board existing E PART OF GM49791 1 In PCB ASSEMBLY GM32644 E Communication module circuit board and or gauge driver circuit board Figure 6 19 Communication Module Circuit Board Location and Connection 56 Section 6 Accessories TP 6161
50. e Contact your local authorized distributor for application program updates when instructed to do so during troubleshooting and or when adding specific accessories Refer to TT 1285 Program Loader Software instruction for additional download information Red circuit board previous versions are green Terminal strips TB1 TB2 and TB3 SW1 DIP switch 8 switches Communication connector P21 for Modbus to 1 2 1 Annunciator Panel Lamps Figure 1 2 lists the annunciator lamps included on each controller and describes the lamp functions download new application program software or to connect the remote serial annunciator using RS 485 communications Requires RS 485 to RS 232 converter for downloading application program e Communication connector P22 for J1939 engine communication Lamp Description Air damper This light is not used on current standard products Auxiliary fault Flashes or lights upon fault detection Figure 1 3 describes auxiliary fault conditions High engine temperature Lights if the engine has shut down because of high engine temperature The shutdown occurs 5 seconds after the engine reaches temperature shutdown range Low oil pressure Lamp lights H the generator set shuts down because of insufficient oil pressure The shutdown occurs 5 seconds after the engine reaches temperature shutdown range Overspeed Lamp lights H the generator set shuts down because the governed fr
51. e Parts Catalog Literature Part No Description 30 kW and 80 125 kW GM 80 200 kW John Deere 4045 6068 275 500 kW Kohler Branded Engines 135 275 kW DDC Series 50 60 Gas 230 450 kW DDC Series 60 230 450 kW DDC Series 60 450 500 kW DDC Series 2000 650 1000 kW DDC Series 2000 650 1000 kW TP 6502 Engine Operating DDC MTU Series 2000 E Instructions ADEC 1250 2250 kW DDC MTU Series 4000 1350 2000 kW Engine Operating DDC MTU Series 4000 1P 8237 instructions MDEC TP 6215 Engine ECM Service Manual TP 6285 Engine Operation Manual TP 6218 Engine Operation Manual Natural Gas Generator Set Engine Operator s Guide DDEC IV Application and Installation Manual TP 5830 TP 6056 TP 5611 Engine Operator s Guide DDEC IV ECM TP 6961 Troubleshooting Guide Engine Operating TP 6375 instructions MDEC Engine Operating TP 6503 instructions ADEC Figure 2 Related Engine Literature Introduction 11 Tech Tools Use your SecurlD to access the KOHLERnet and click on Tech Tools button to find the following topics Software used by generator set controllers including updates and documentation references Service Assistance e Network Communications provides basics to terms protocols standards wiring configurations and model e Engine Electronic Contro Module ECM has information about electronic devices provided by the engine ma
52. eath Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per the manufacturer s instructions Fuel tanks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when drainingthe fuel system Wipe up spilled fuel after draining the system Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble LP liquid withdrawal
53. equency on 50 60 Hz models exceeds 60 70 Hz Overcrank Cranking stops and the lamp lights H the engine does not start after 30 seconds of continuous cranking or 75 seconds of cyclic cranking See Section 2 3 1 Normal Operation Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period Cranking stops and the overcrank lamp lights after 25 seconds if the starter or engine does not turn locked rotor The overcrank lamp flashes if the speed sensor signal is absent for longer than one second Low water temperature Lights if water temperature falls below the minimum preset temperature This lamp may require an optional prealarm sender kit in order to function Battery charger fault Lights if the battery charger malfunctions This lamp requires an optional battery charger Emergency stop Lights and the generator set shuts down if the optional emergency stop switch is energized either locally or from a remote location The local emergency stop switch is standard on selected models Generator switch not in auto Lights when the generator set master switch is in the RUN or OFF RESET position High battery voltage Lights if the battery voltage rises above preset level An optional battery charger is required for the lamp to function Low battery voltage Lights if the battery voltage drops below a preset level This lamp requires an optional battery charger in order f
54. erator set after completing the voltage 5 Setthe phase selector switch to the L1 L2 position adjustment Replace the controller cover 1 phase or 3 phase depending on generator set connection Connect a voltmeter across leads L1 and L2 if the controller has no meters 48 Section 5 Generator Set Reconnection TP 6161 1 07 6 1 Accessories Several electrical accessories and controls help finalize installation add convenience to operation and service and establish state andlocal code compliance Accessories vary with each generator set model and controller Select factory installed and or shipped loose accessories Kit and installation instruction part numbers change Obtain the most current accessory information from your local authorized service distributor dealer This section illustrates several accessories available at the time of print of this publication Accessory kits generally include installation instructions See the wiring diagrams manual for electrical connections not shown in this section See the installation instructions and drawings supplied with the kit for information on the kit mounting location The instructions provided with the accessory kit supersede these instructions where there are differences In general run AC and DC wiring in separate conduit Use shielded cable for all analog inputs Observe all applicable national state and local electrical codes during accessory installation Note The accessorie
55. es 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 This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substantial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6161 1 07 Accidental Starting A WARNING or 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 Reconnect the negative lead last
56. frequently if the engine runs roughly as a clogged fuel filter can cause rough engine operation Some models use a disposable inline fuel filter which must be replaced Other models have a fuel pump with an integral fuel filter that requires cleaning at the specified interval Gaseous Models This fuel system requires no regular maintenance Section 3 Scheduled Maintenance 29 3 7 Cooling System The cooling system maintenance information applies to radiator cooled models and city water cooled heat exchanger models The cooling systems function similarly even though they use different components Radiator cooled models have a radiator with a pressure cap and coolant recovery tank City water cooled models have a heat exchanger and an expansion surge tank with a pressure cap A 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 Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure fromthe cooling system before removing the pressure cap To release pressure coverthe pressure cap with athick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recove
57. fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble TP 6161 1 07 Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Electrical Shock DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic tran
58. fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaust fumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate
59. gine while the spark plug wires are disconnected 3 Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 4 Reinstall the spark plugs and torque them to specifications Section 3 Scheduled Maintenance 37 3 12 5 Exterior 1 2 38 Clean the exterior surface of the generator set Seal all engine openings except for the air intake with nonabsorbent adhesive tape To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake Mask electrical connections Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion Section 3 Scheduled Maintenance 3 12 6 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position Disconnect the battery ies negative lead first Clean the battery Refer to Section 3 9 1 for the battery cleaning procedure Place the battery in a cool dry location Connect the battery to a float equalize battery charger or charge it monthly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life TP 6161 1 07 This section contains generator set troubleshooting diagnostic and repair information Use the chart on the following page
60. harging alternator charges the battery only while the generator set is running Note If the generator set is in a temporary prime power application in which the generator set has periods of inactivity the controller circuitry may drain the battery If there is no power source for a battery charger place the controller in the prime power mode if equipped or disconnect the battery from the generator set 3 10 Detroit Diesel Engine Control Systems Some generator sets equipped with Detroit Diesel engines use a DDEC MDEC system Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting the engine Note DDC MTU engines with MDEC requires the following method e Useapersonal computer software package available from the manufacturer with a translator to access stored codes Follow the instructions provided with the software Use the following data for informational purposes only Consult the engine literature for complete information regarding operation and troubleshooting See List of Related Materials in the Introduction section Contact an authorized service distributor dealer for service or diagnostic equipment 3 10 1 Features The DDEC MDEC system optimizes control of critical engine functions and protects against serious engine damage resulting from conditions such as the following e Low coolant level e Low coolant pressure e High coolant
61. ical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay rms rnd ROM rot rpm RS RTU RTV SAE scfm SCR s sec SI SI EO sil SNMP SPDT SPST spec specs sq sq cm sq in ss std stl tach root mean square round read only memory rotate rotating revolutions per minute right side remote terminal
62. ing the switch clockwise until it springs back to its original position Note The controller auxiliary fault lamp lights ifthe generator set master switch is in the RUN or AUTO position during the resetting procedure 3 Toggle the generator set master switch to the OFF RESET position and then to the RUN or AUTO position to restart the generator set The generator set does not crank until the resetting procedure is completed 2 3 4 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 2 2 3 5 Controller Resetting After a Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown Refer to Section 2 3 3 Emergency Stopping to reset the generator set after an emergency stop 1 Move the controller alarm horn switch to the SILENCE position If equipped the audiovisual annunciator alarm horn and lamp are activated Move the audiovisual annunciator alarm switch to SILENCE to stop the alarm horn The audiovisual annunciator lamp stays lit 2 Disconnect the generator set from the load by using the line circuit breaker or the automatic transfer switch TP 6161 1 07 High engine The high engine temperature shutdown shuts temperature down the unit 5 seconds after a fault The shutdown does not function during the first 30 seconds following startup Note The high temperature shutdown functions only when the coolant level is in the operating
63. ition with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage adjustment control Control fine tunes 2 596 the generator set output voltage Water temperature gauge Gauge displays the engine coolant temperature 10 amp controller fuse Fuse protects the controller circuitry from short circuits and overloads Figure 1 14 Controls and Indicators continued TP 6161 1 07 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 Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator t
64. jesylano Jewod sxyoe Ajueppns sdojs eBeyo 1ndino MOL JO ON pey sueis yeys jou seop yng syueio yuelo you s oq suiojdui AS lqnoiL Section 4 Troubleshooting 41 1 07 TP 6161 18A9 Io ay YOBUD UMOpinus eJnsseJd Io Mo IAJ S SIY uuojied Jepeep 1o01nquisip ailes pezuouine ue aney 1 enuen webe BuutIM Q M 3eeus oeds s s enuen 39 M93S N S enuen uoejed o qW O enuen uoneeisu W 18S 101849u86 uec eutBu3 Bua yoyms 1eJsuei1 oewojny s_Ly jJenueuu sy jo uonoes pejequinu uomnoeg 29S y SXee 10 JO jos 101eJeueB eui joedsu Texel llo ay eJojseH MOJ A IIO ayewo Bunejedo eui 104 ejqeyns ysoosia e yym lo asn llo ay eBueuS aunyesodwa jueiquue JO 2 109U ad llo aseoquelo W S Uan yoyeinBas eBeyoA y 1sn py 1yu uulsn pe jo 1no Jomginfa eDeyoA W S ue5 4 01e nBaJ aBeyon ay jooysaqno1 ureBe swo q snj ay Jl asny 1ole nB 1 eBejo ay eoejdeu enyesedou1 JojenBal eBeyoA LL nua z oes 401e n881 eBeyoA ay 1sn fpy Ajuo 1ejoajuoo eubip 12e400uI sBumes eufip joyejn8e J eBeyoA 4 sjueuoduuoo esoo u 1uB l AISS 5X UODEIOIA W S Uan 4 J0Je s ay eoe deJ Jo pue 1s pepunoi6 10 uedo anlyesadout Joe W S ue5 4 1030 ay eoejdei Jo pue 1s pepunoJ6 Jo uedo eAneaedout 10101 Diet US OI W S ueo ynunuoo JO YO YD uedo pjey Je
65. just the tension if necessary See Figure 3 8 32 Section 3 Scheduled Maintenance New Belt Used Belt Generator Set Model N Ibf N Ibf 2450 2890 1650 1910 550 650 370 430 A belt is considered used after 50 hours of service 1200 2000 kW Figure 3 8 Poly V Belt Tension Specifications 7 Reinstall the belt guards using the original hardware 8 Reconnect the generator set engine starting battery ies negative lead last 9 Test run the generator set for a few minutes and listen for belt noise squeal indicating a slipping belt Stop the generator set If the belt slips after the belt tension procedure clean the pulley surfaces and repeat the belt tension procedure If slippage continues replace the fan belt 3 9 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a gro
66. k 30 3 7 2 Cooling System Component Inspection 30 3 7 8 Cooling System Drainage Procedure 30 3 7 4 Cooling System Flush and Clean Procedure 31 3 7 5 Cooling System Refilling Procedure 31 3 8 Fan Bearing Lubrication 1 nets 31 3 9 SR 32 3 9 1 Cleaning s E Rr e d E eed ke P ree te he a 34 3 9 2 Electrolyte Level Inspection 34 3 9 3 Specific Gravity Check 34 39 4 Charging eb vrR YER Sade CPU UE PSP 35 3 10 Detroit Diesel Engine Control Systems 35 3 102341 Features RE hee a cda 35 3 10 2 DDEC Engine Diagnostics 36 3 11 Engine Control Systems 000 cc kada s sa ee 36 3 12 Storage Procedure 37 3 12 1 Lubricating System 37 3 12 2 Cooling System 37 3 12 3 Fuel System 37 3 12 4 Internal Engine Components Gas Gasoline Fueled Engines 37 3 12 5 EMO O inn Bierg Ke Sasa eeh EUER a a Deg 38 3 120 E EE adea PE ar E a Ya 38 Section 4 Troubleshooting v eoe le Ire E nadie i teuer Rn Seeded e ens 39 Section 5 Generator Set Reconnection 43 Section 6 Accessories 00 sven ceva Vul NIE er ENEE EEN de bake ANNE de eee ee de 49 631 ACCeSSOLIBS tat aiii Ex a Ee vae ed dnd d ar ecd 49 6
67. l Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Generator Set Exercising Operate the generator set under load once each week for one hour Perform the exercise in the presence of an operator if the generator set does not have a programmed exercise mode or an automatic transfer switch with an exercise option During the exercise period apply a minimum of 35 load based on the nameplate standby rating unless otherwise instructed in the engine operation manual The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks 2 3 16 Light Controller Features 2 3 1 Local Starting Move the generator set master switch to the RUN position to start the generator set at the controller Normal Operation Note The alarm horn sounds and the Not in Auto lamp lights when the generator set master switch is not in the AUTO position Section 2 Operation 19 Note The transient start stop function of the 16 light controller prevents accidental cranking of the rotating engine If the generator set master switch is momentarily placed in
68. lace a cracked or deteriorated cap Remove dirt and other debris from the pressure cap and filler neck The pressure cap raises the boiling point of the coolant enabling higher operating temperatures Replace a leaking pressure cap with one rated for the same pressure The pressure cap rating usually appears on the pressure cap 3 7 8 Cooling System Drainage Procedure 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 1 Deenergize the block heater if equipped 2 Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow through the engine block 3 Open the radiator and or engine block coolant drain valve s and allow the system to drain TP 6161 1 07 4 If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease refer to Section 3 7 4 Cooling System Flush and Clean Procedure If the cooling system does not have mineral deposits go to Section 3 7 5 Cooling System Refilling Procedure 3 7 4 Cooling System Flush and Clean Procedure Use the instructions in the engine operation manual when available to flush and clean the cooling system Otherwise use the following procedure and the cooling system cleaner manufacturer s instructions 1 Flush the coo
69. lects the generator set output circuits to switch measure When switched to a position with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage Control fine tunes 5 the generator set output adjustment voltage Used with 20 400 kW permanent control if magnet wound field alternator models only The equipped voltage adjustment on 350 2000 kW pilot excited models is located in the generator junction box Figure 1 6 Switches and Controls Modbus is a registered trademark of Schneider Electric 16 Section 1 Specifications and Features 1 2 6 Terminal Strips Two terminal strips are mounted on the controller circuit board See Figure 1 7 and Figure 1 8 Refer to Section 2 3 2 Prime Power Mode Operation for information on enabling prime power mode Terminal Strip TB1 TB3 Description Terminal strip for connecting generator set accessories such as an emergency stop switch a remote start stop switch audiovisual alarms etc Refer to the wiring diagrams for information on connecting accessories to the TB1 terminal strip Terminal strip for selecting the remote start stop switch inputs and prime power mode Communication module connection for remote serial annunciator RSA or network communication RS 485 communica
70. ling system with clean water 2 If the inside of the radiator still has mineral deposits use a radiator cleaner to remove the remaining deposits following the manufacturer s instructions 3 Drain clean and flush the coolant recovery tank 3 7 5 Cooling System Refilling Procedure See the generator set spec sheet for coolant capacity Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled 1 Remove the pressure cap 2 Close radiator and or engine block coolant drain valve s and tighten cooling system hose clamps 3 Open the air bleed petcocks if equipped Close the air bleed petcocks when coolant begins to flow from them 4 Add coolant additives or water pump lubricants according to the engine manufacturer s recommendations in the engine operation manual 5 Fill the cooling system with the recommended coolant antifreeze mixture of 5096 ethylene glycol and 5096 clean softened water to inhibit rust corrosion and prevent freezing Note A coolant solution of 5096 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution containing less than 5096 ethylene glycol may not provide adequate freezing and TP 6161 1 07 overheating protection A coolant solution containing more than 5096 ethylene glycol can cause engine or component damage
71. ly Clean and tighten battery terminals x x Quarterly Tighten DC electrical connections x Six Months e Follow procedures and frequencies indicated in the engine manufacturer s maintenance manual If not indicated follow this service schedule Some items may not apply to all generator sets R Replace as necessary X Action Service more frequently if operated in dusty areas 24 Section 3 Scheduled Maintenance TP 6161 1 07 Service Schedule continued System Component AC Electrical System Action Visually Inspect Check Change Interval 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 connections Yearly Transfer switch main contacts Yearly Voltage sensing device relay adjustment Yearly Wire cable insulation breakdown 3 Years or 500 Hours Engine and Mounting General inspection Weekly Governor operation lubricate moving parts Monthly Air cleaner service Six Months Choke carburetor adjustment Six Months Governor oil mechanical governor only Yearly Ignition components Yearly Injector pump and injector flow rate pressure spray pattern Yearly Valve clearance 3 Years or 500 Hours Bolt torq
72. mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour 1 07 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EG EGSA EIA EI EO EMI emiss eng EPA EPS ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A weighted direct current direct current resistance degree department Design Failure Mode and Effects Analysis diameter dual inlet end outlet Deutsches
73. mmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 5 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permitflames or sparksto occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away fromthe battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connection
74. n u u u uu aa GO EAR E REG EAR RR ACE AURA EE 11 Abbreviations ui I ERES ESI ua RE ipu b Doi ees s 11 List of Related Materials 11 Service Assistance tidad oi 12 Section 1 Specifications and Features 0 cece cece n nnn nn nnn 13 TT Introductio is ker Seed onde e a Ee dE 13 1 2 16 Light Controller Features 13 1 2 1 Annunciator Panel Lamps 14 1 22 Auxiliary Fault Lamp 15 1 2 3 FUSES nee se teu ca 15 1 2 4 Analog Meters and Gauges 15 1 25 Switches and Controls 16 1 2 6 Terminal Strips oic eme km Rn nm es 16 12 7 BDIP SWIChes EE 17 1 3 Expanded Decision Maker 1 Controller 18 Section 2 Operation ee ed Io ENNER EEN EE Rate e eere bes EE nee EDGE 19 SI Prestart Checklist e ok RIDERE IRR a hed dea RM RE SAN 19 2 2 Generator Set Exercising 00ooococooorrrrara rr 19 2 3 16 Light Controller Features 19 2 3 1 Normal Operation 19 2 3 2 Prime Power Mode Operation 20 2 3 3 Emergency Stopping 20 2 3 4 Fault Shutdowns 21 235 Controller Resetting After a Fault Shutdown 21 2 4 Expanded Decision Maker 1 Controller 22 2 4 1 Generator Set Starting 22 2 4 2 Generator Set Stopping 22 2 4 3 Fault Shut
75. nals TB1 3 and TB1 4 Note The controller allows up to 30 seconds of continuous cranking before overcrank shutdown occurs Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period 2 4 2 Generator Set Stopping Local Stopping 1 Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Automatic Stopping 1 The automatic transfer switch ATS or other device disconnects the load from the generator set 2 The generator set continues to run for a preset time if the ATS is equipped with an engine cooldown time delay 3 The ATS opens the connection between controller terminals TB1 3 and TB1 4 The generator set shuts down if the generator set master switch is in the AUTO position 2 4 3 Fault Shutdowns The generator set shuts down automatically under the fault conditions shown in Figure 2 3 and cannot be restarted until the fault condition is corrected Reset the controller after a fault shutdown 22 Section 2 Operation The fault lamp does not stay lit after the generator set shuts down on a fault condition 2 4 4 Controller Resetting After a Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown 1 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch See the Safety
76. ng the generator set reset emergency stop switch by replacing the glass piece and reset the generator set by placing the master switch in the OFF RESET position The switch holds a single replacement glass piece which is available as a service part EN zl ed el Figure 6 11 Emergency Stop Kit TP 6161 1 07 6 1 13 Remote Serial Annunciator M The remote serial annunciator monitors the condition of the generator set from a location remote from the generator set If a generator alarm condition occurs the remote annunciator alerts the operator through visual and audible signals using a RS 485 controller connection See Figure 6 12 Requires a controller communication module kit installed in the controller See Figure 6 13 Overcrank Not In Auto High Engine Temp Common Fault Low Oil Pressure Battery Charger Battery Voltage Overspeed On Higli Blink Low Emergency Stop Low Coolant Level Low Coolant Temp Low Fuel m Alarm Silenced Generator ID 1 e Location EPS Supplying Load System Ready RSA 1000 Generator Running Communicaton Status Figure 6 12 Remote Serial Annunciator RSA ed GM32644 B 1 Communication circuit board GM47242 or GM49791 1 Note Circuit board GM 49791 2 is a gauge driver and is not a communications circuit board Figure 6 13 16 Light Controller with Ins
77. ngine compression and ignition system meet specifications Do not adjust the carburetor to compensate for other engine disorders Ifthe engine speed is incorrect adjust the electronic governor to achieve 1800 rpm at 60 Hz or 1500 rpm at 50 Hz Adjustthe carburetor if governor adjustment alone does not result in the desired engine speed Adjusting the carburetor affects the engine fuel mixture Routine carburetor adjustment is not necessary However if the carburetor is removed or tampered with the carburetor may require adjustment to achieve optimum engine performance Some engines have sealed carburetors that are not adjustable TP 6161 1 07 Gasoline Carburetor Adjustment Refer to the engine operation manual or engine service manual for gasoline carburetor adjustment information Gaseous Carburetor Fuel Mixer Adjustment Procedure Use the following procedure to adjust the carburetor fuel mixer 1 Start the generator set and run it at approximately half load 2 Adjust the engine fuel mixture screw Figure 3 6 until the engine runs smoothly 3 Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels 4 Stop the generator set 1 Fuel adjusting screw 2 Lean 3 Rich Figure 3 6 Fuel Mixture Adjustment Typical 3 6 6 Fuel System Maintenance Gasoline Models Clean or replace the fuel filter at the specified interval Service the filters more
78. nsulated probes andfollowthe instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under 8 Safety Precautions and Instructions Heavy Equipment Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Hot Parts A 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 A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns Checking the coolant level Hot coolant can cause severe injury or death Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the p
79. nufacturer to manage engine data For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler Power KohlerPowerSystems com Systems website at Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Zl Senia 122 12 rue des Hauts Flouviers 94517 Thiais Cedex France Phone 33 1 41 735500 Fax 33 1 41 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 12 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 10 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863
80. o purge the air from the system before energizing the block heater Drive Belts Check the belt condition and tension of the radiator fan water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion e Checkfor corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Fuel Level Check the fuel level and fill the tank s regularly to ensure adequate fuel supply TP 6161 1 07 Section 2 Operation Ignition System Ensure that the ends of all spark plug wires are properly seated onto the coil distributor and the spark plug Lamp Test Press the lamp test button if equipped to verify that all controller LEDs illuminate Oil Level Maintain the oil level at or near not over the full mark on the dipstick Keep the oil level in the mechanical governor if equipped at or near the full leve
81. ode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 109 when used with SI units male ms cubic meter m hr cubic meters per hour m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 229 bytes MCCB molded case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQmillionm MOhm MQmegohm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure 60 Appendix MTBO mtg MTU MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA OZ D pp PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electr
82. ons also includes many abbreviation definitions List of Related Materials Separate literature contains communication and software information for the 16 Light Controller with communications not provided in this manual Figure 1 lists the available literature part numbers Modbus is a registered trademark of Schneider Electric TP 6161 1 07 Communication and Software Manual Description 16 Light Controller Spec Sheet Literature Part No G6 30 Decision Maker 1 Controller G6 29 Spec Sheet Multiple Part Numbers Contact your Distributor Dealer Generator Set Controller Wiring Diagram Manual Modbus Communications Protocol Operation Manual TP 6113 TP 6009 TT 1285 TT 1377 TT 1310 Service Parts Controllers Program Loader Software Installation Remote Serial Annunciator RSA Controller Service Replacement Monitor Ill Converters Connections and Controller Setup Monitor Ill Software Spec Sheet G6 76 Monitor IIl Converter G6 79 Modbus Ethernet Spec Sheet gt Monitor Ill Software Operation Manual TT 1405 TP 6347 Figure 1 Related Literature Several engine manufacturers provide engines with electronic controls These electronic controls indicate fault codes in addition to the generator set controller Use Figure 2 for literature part numbers relating to the identifying engine fault codes For the latest literature part numbers see the respectiv
83. or the lamp to function Low fuel warning Lights if the fuel level in tank approaches empty This lamp requires a low fuel sensor in the fuel tank in order to function On gas fueled systems this lamp lights if the gas line pressure drops below a preset level Prealarm high engine temperature Lights if the engine temperature approaches the shutdown range This lamp may require an optional prealarm sender kit Prealarm low oil pressure Lights if the engine oil pressure approaches the shutdown range This lamp may require an optional prealarm sender kit in order to function System ready Lights when the generator set master switch is in the AUTO position and the system senses no faults Indicates that the generator set is ready for operation Figure 1 2 Annunciator Panel Lamps Modbus is a registered trademark of Schneider Electric 14 Section 1 Specifications and Features TP 6161 1 07 1 2 2 Auxiliary Fault Lamp The auxiliary fault lamp flashes or lights continuously to indicate different conditions Figure 1 3 describes the auxiliary fault lamp conditions Lamp Illumination Generator Condition Flashing Continuous Auxiliary Delay Shutdown Lamp lights and the engine shuts down 5 seconds after high oil temperature P1 13 low coolant level P1 10 2 wire sender or P1 14 3 wire switch or auxiliary delay shutdown P1 15 faults if equipped occur These fault conditions are inhibited during
84. pecific gravity is 1 260 at an electrolyte temperature of 26 7 C 80 F Maintain the specific gravities between cells within 0 01 of each other Charge the battery if the specific gravity is below 1 215 at an electrolyte temperature of 26 7 C 80 F TP 6161 1 07 Example No 1 Temperature below 26 7 C 80 F Hydrometer Reading 1 250 Acid Temperature 6 7 C 20 F Subtract 024 Specific Gravity Corrected Specific Gravity is 1 226 1 250 024 1 226 Example No 2 Temperature above 26 7 C 80 F Hydrometer Reading 1 235 Acid Temperature 37 8 C 100 F Add 008 Specific Gravity Corrected Specific Gravity is 1 243 1 235 008 1 243 Thetemperature correction amounts to about 004 4 points of specific gravity for each 5 5 C 10 F change in temperature 1 787 Figure 3 13 Specific Gravity Temperature Correction Note Some battery testers have four or five beads in a test tube Draw electrolyte into the tube as with the battery hydrometer described in this section Use the tester manufacturer s instructions Figure 3 14 shows typical test results Number of Floating Beads Battery Condition Overcharged Fully charged A good charge A low charge A dead battery Figure 3 14 Bead Type Test Interpretation TP 6161 1 07 3 9 4 Charging Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application The engine battery c
85. put Overcrank Overspeed Shutdown occurs immediately when the governed frequency on the 50 and 60 Hz models exceeds 70 Hz Figure 2 3 Fault Shutdowns TP 6161 1 07 Under normal operating conditions the generator set s alternator requires no normal service Consult the prestart checklist in Section 2 1 for a list of routine checks 3 1 Alternator Service When operating the generator set under dusty or dirty conditions use dry compressed air to blow dust out of the alternator while the generator set is running Direct the stream of air through openings in the generator set end bracket 3 2 Engine Service Perform engine service at the intervals specified in the engine manufacturer s service literature Contact an authorized service distributor dealer to obtain service literature Note Have maintenance work including battery service performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service A WARNING Qe KS x 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 Reconnect the negative lead last when reconnecting the battery TP 6161 1 07 Section 3 Scheduled Maintenance Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or
86. r HI side toward the generator set Section 5 Generator Set Reconnection 43 LCO0V NON SOV31 YOLVLS SQV31 YOLVLS Y L v lt e t E an EN O dis SH3Mv1HB NA Ould D ERDER 3 gt EE gt 109X19 L 3qis LLLI sais LINDMIO A als 3104 3NO ben vor 3104 3NO vol C Cla K n n ANNONS quo no STE 01 z lt gp 01 01 T c WYLNSN O Gwen Ova ln3N O Civaln3N O o a9 o 9 ml 8 O y so 5 p Log 01 o os d o j Y NNN TNA 1 NA Y L NAA Y NN C NNN T lt lt lt lt lt ES CN ZH0S ZHOS AOvc 0cc 1 07 TP 6161 20 150 kW Permanent Magnet and Wound Field Single Phase Alternators ADV 5875A H 44 Section 5 Generator Set Reconnection Figure 5 1 oq zi J SI3S TIV NO G4SNM LON SMHJAMNOJSNVML LIN3SSDO 3 g y HOIVM3N3O QMVMOL LH YO LOG YSINYOASNVYL LNSYYNO NOIIVIOM 3SVHd SALON u3dAne divi afan 8L elo 1 MW3dWnr avi oz pn 84 Haut dvi oai 84 31vOS YILIN 2 R Sa TIVOS YILIN LJ p JIS YILIN gt 3 OX 96r 8 z jJ E Y ae 19 dWOO ANIG ey 90030 TVNOILdO 86 Ve 0 6 2 ef 6A 19 dNOO SC o 9 anoo dOONa auto a
87. r from LP gas vapor to natural gas The primary and backup fuels each have a secondary fuel regulator and a fuel valve Typically the primary fuel is natural gas the backup fuel is LP gas vapor When the generator set starts the primary fuel valve opens and the backup fuel valve closes The primary fuel line has a vacuum switch in series with a relay connected to the start run circuit When the primary fuel pressure drops below 0 6 kPa 1 4 oz in or 6 4 cm 2 5 in water column a relay opens the backup fuel valve and closes the primary fuel valve When the primary fuel pressure rises above 0 6 kPa 1 4 oz in 2 or 6 4 cm 2 5 in water column the generator set uses the primary fuel Contact an authorized service distributor dealer for kit availability Manual Changeover A manual changeover fuel system allows manual changeover from gasoline to natural gas or LP gas or from natural gas or LP gas to gasoline Typically the combination system uses gas as the primary preferred fuel and gasoline in emergencies If the primary fuel is unavailable an empty fuel tank or fuel supply disruption the system uses gasoline A toggle switch on the generator set controls the fuel choice and energizes either a fuel solenoid and electric fuel pump for gasoline or a fuel valve for gas Pull out the control cable for gasoline and push in the control cable for gas 3 6 5 Carburetor Adjustment Before adjusting the carburetor verify that the e
88. r replace the inner fuel tank 4 Move generator set master switch to the OFF RESET position and then to the RUN position for startup Alarm horn sounds and lamp goes out 5 Reconnect generator set to load via line circuit breaker or automatic transfer switch 6 Move generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Move alarm switch to the NORMAL position 3 6 Gas Gasoline Fuel Systems This section describes fuel systems that are not covered in the engine operation manual or engine service manual 3 6 1 Gaseous Fuel System Concept The gaseous fuel system uses a fuel valve with a solenoid to control the fuel flow to the fuel regulator The generator set mounted regulator reduces the fuel pressure as fuel passes to the carburetor See Figure 3 4 Primary regulator supplied by gas supplier or customer Pressure gauge Solenoid valve Secondary regulator Carburetor Figure 3 4 Fuel Regulator and Valve Typical Section 3 Scheduled Maintenance 27 The carburetor mixer controls the ratio of fuel to air under varying load and speed conditions Because the carburetor receives fuel in a gaseous state it does not have to vaporize the fuel When switching from natural gas to LP gas or LP gas to natural gas verify that the electronic governor maintains the rated engine speed 1800 rpm at 60 Hz or 1500 rpm at 5
89. r set master switch Figure 1 12 Expanded Decision Maker 1 Controller Figure 1 13 and Figure 1 14 describe the controls and indicators located on the controller Item Description AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents Item Description Hourmeter Hourmeter records the generator set total operating hours for reference in maintenance scheduling Oil pressure gauge Gauge displays the engine oil pressure Scale lamps upper lower Lamps indicate which AC voltmeter and or ammeter scales to read AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits DC voltmeter Meter displays the voltage of the starting battery ies Fault lamp Lamp illuminates during engine shutdown if the engine shuts down because of one of the following faults high engine temperature low water level low oil pressure overcrank or overspeed See Section 2 4 3 Fault Shutdowns for additional shutdown information Frequency meter Meter displays the frequency Hz of the generator set output Generator set master switch Switch functions as the controller reset and generator set operation switch Figure 1 13 Controls and Indicators 18 Section 1 Specifications and Features Selector switch Switch selects the generator set output circuits to measure When switched to a pos
90. ressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank ifthe generator set has a coolant recovery tank Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Moving Parts A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place A WARNING Rotating parts Can cause severe injury or death Operate the generator set only when all guards screens and covers are in place TP 6161 1 07 A WARNING Airborne particles Can cause severe blindness injury or Wearprotective goggles and clothing when using power tools hand tools or compressed air Tightening the hardware Flying projectiles can cause severe injury or death Loose hardware can cause the hardware or pulley to release from the generator setengine and can cause personal injury Retorque all crankshaft and rotor hardware after servicing Do notloosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set Rotate the crankshaft manually in a clockwise direction only Turning the crankshaft bolt or rotor
91. rical signal to the alarm plate when the sensor becomes immersed in the fuel collecting in the outer tank If aleak is detected the alarm horn will sound and the fault lamp will light The alarm horn is quieted by moving the alarm switch to the SILENCE position the alarm lamp remains lit until the fault is corrected See Figure 3 3 for troubleshooting information N E Inner Tank O Fuel Leak Alarm FF 273000 D Figure 3 2 Inner Fuel Tank Leak Alarm 20 300 kW Model Shown Alarm Float Switch Switch Position Position Observation Open The alarm horn and the lamp are not energized The alarm horn and lamp activate when a fuel leak occurs If the alarm switch is moved to the silence position the lamp stays on until the fuel leak fault is corrected Closed The alarm horn sounds to alert the user that the alarm horn switch is not in the normal position and that the alarm horn will not sound should a fuel leak occur Figure 3 3 Inner Fuel Tank Leak Alarm Troubleshooting TP 6161 1 07 Resetting Procedure Use the following procedure to reset the alarm after a fault alarm 1 Move alarm switch to the SILENCE position to stop alarm horn Lamp will remain lit 2 Disconnect generator set from load with line circuit breaker or automatic transfer switch 3 Repair o
92. rip Charger Malfunction Engine Ground Alarm Terminal Strip Figure 6 6 Float Equalize Battery Charger Connections 6 1 9 Line Circuit Breaker The line circuit breaker interrupts generator output if an overload or short circuit occurs Use the line circuit breaker to manually disconnect the generator set from the load during generator set service See Figure 6 7 Figure 6 7 Line Circuit Breaker Section 6 Accessories 51 6 1 10 Low Fuel Switch M Some gaseous fueled models offer a low fuel pressure switch as part of the Engine Prealarm Senders kit The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel or gasoline fueled models See Figure 6 8 and Figure 6 9 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Note The subbase fuel tank or main tank may include the low fuel level switch The fuel tank supplier typically provides the low fuel level switch LOW FUEL SWITCH OPTIONAL LOCATED IN MAIN TANK S PROVIDED BY FUEL TANK SUPPLIER 2 BATTERY GROUND GM16088A A Figure 6 8 Low Fuel Switch Level or Pressure Switch Rating 12 volts DC minimum 0 5 amp minimum Wiring Recommendation mm ft 30 5 100 153 500 305 1000 Gauge Figure 6 9 Switch Rating and Wiring Recommendation 6 1 11 Remote Annunciator Kit M A remote annunciator p
93. rovides convenient monitoring of the generator set s condition from a remote location See Figure 6 10 The remote annunciator includes an alarm horn alarm silence switch lamp test and the same lamp indicators except air damper as the 16 light controller plus the following lamps Line Power lamp illuminates to indicate that the commercial utility is the power source Generator Power lamp illuminates to indicate that the generator set is the power source 52 Section 6 Accessories y PREALARM HIGH ENGINE TEMPERATURE y HIGH ENGINE BATTERY V UNE X7 TEMPERATURE X7 CHARGER FAULT N POWER PREALARM D gt Low OIL PRESSURE y LOW OIL y LOW BATTERY y GENERATOR _ PRESSURE 4 VOLTAGE _ POWER LOW WATER EMERGENCY gt AUXILARY y SYSTEM V7 TEMPERATURE STOP MC FAULT V READY GENERATOR i SN 7 ay LOW FUEL _ OVERSPEED OVERCRANK SWITCH NOT IN AUTO SILENCE NORMAL ALARM LAMP O TEST y ek weer e BERE 23 o ES CE EBA TIOAME 14 Relay Dry Contact Box Figure 6 10 Remote Annunciator with 14 Relay Dry Contact Box 6 1 12 Remote Emergency Stop Kit M The emergency stop kit shuts down the generator set from a remote location in an emergency See Figure 6 11 Activating the emergency stop switch lights the EMERGENCY STOP lamp and shuts down the unit Before restarti
94. rtup problems or to test and troubleshoot the controller when it is removed from the generator set Perform tests without starting the generator set FASTCHECK functions are listed below refer to Figure 6 5 to identify LEDs and switches Figure 6 5 FASTCHECKe Diagnostic Tester LEDs on the FASTCHECKe illuminate to indicate the energizing of the following circuits e AC Voltage Regulator e Battery Connection correct polarity e Engine Ignition gas gasoline e Engine Crank e Engine Antidieseling e Engine Malfunction Alarm and or Alarm Shutdown e Fuel Solenoid diesel Switches on the FASTCHECKe simulate the following Anticipatory High Engine Coolant Temperature Anticipatory Low Engine Oil Pressure Engine Crank Engine Overspeed Engine Running High Engine Coolant Temperature Low Engine Coolant Temperature Low Engine Oil Pressure Low Fuel TP 6161 1 07 6 1 8 Float Equalize Battery Charger Kit with Alarm Option M The float equalize battery charger with alarm option provides battery charging to the engine starting battery ies and connects to the controller for fault detection Battery chargers for 12 or 24 volt models are available as a generator set accessory See Figure 6 6 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Low Voltage Controller Terminal St
95. ry tank Note Engine damage Bleed the air from the cooling system to prevent overheating and subsequent engine damage Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater 3 7 1 Coolant Level Check Check the coolant level in the coolant recovery tank if equipped Maintain the coolant level between the high and low marks Note Periodically check the coolant level by removing the pressure cap Do not rely solely on the level in the coolant recovery tank Add fresh coolant until the level is just below the overflow tube opening of the filler neck 30 Section 3 Scheduled Maintenance 3 7 2 Cooling System Component Inspection To prevent generator set shutdown or damage caused by overheating e Keep the cooling air inlets clean and unobstructed e Inspect the radiator s exterior for obstructions Remove dirt and foreign material using a soft brush or cloth to avoid damaging the radiator fins e Check the hoses and connections for leaks Replace any cracked frayed or spongy hoses e Check the condition and tension of the radiator fan and water pump belt s Follow the belt tension procedure in this manual and or the engine operation manual e Checkthe pressure cap seal and rep
96. s Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING Lh d Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions 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 Catch fuels in an approved container when removing the fuel line or carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Combustible materials A fire can cause severe injury or death Generator set engine
97. s with the M notation are available only on models with 16 light microprocessor controllers 6 1 1 Audiovisual Alarm M An audiovisual alarm warns the operator of fault shutdowns and prealarm conditions except battery charger fault and low battery voltage from a remote location Audiovisual alarms include an alarm horn an alarm silence switch and a common fault lamp See Figure 6 1 Note Use the audiovisual alarm with a dry contact kit Front View Side View Figure 6 1 Audiovisual Alarm TP 6161 1 07 Section 6 Accessories 6 1 2 Common Failure Relay Kit M The common failure relay kit provides one set of contacts to trigger user provided warning devices if a fault occurs The common failure relay faults are user defined Connect up to three common failure relay kits to the controller output See Figure 6 2 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Figure 6 2 Common Failure Relay Kit 6 1 3 Controller Connection Kit M The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip The kit uses a 165 cm 65 in wiring harness to link the controller terminal strip s with a remote terminal strip located in the generator set junction box With the exception of a few terminals the remote terminal strip is identical to that of the controller Connect
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99. sfer switch to prevent inadvertent interconnection of standby and normal sources of supply Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Open the main circuit breakers of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicable codes and standards Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qu
100. switch or engine start command from a remote computer TP 6161 1 07 A WARNING Hazardous voltage Moving rotor Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Reconnect the generator set stator leads to change the output phase or voltage Refer to the following procedure and the connection schematics shown in Figure 5 1 Figure 5 2 Figure 5 3 and Figure 5 4 Follow the safety precautions at the front of this manual and in the text and observe National Electrical Code NEC guidelines Voltage Reconnection Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the generator set engine starting battery negative lead first Disconnect power to the battery charger if equipped 3 Use Figure 5 1 Figure 5 2 Figure 5 3 and Figure 5 4 to determine the generator set voltage configuration Note the original voltage and reconnect as needed Route leads through current transformers CTs and connect them according to the diagram for desired phase and voltage Note Position current transformers CT1 CT2 and CTS with the dot o
101. t kits may connect to a specific output connection on the controller Figure 6 4 shows some typical dry contact kits mounted on an assembly panel for 450 kW and larger generator sets Typical 10 and 14 relay contact kit output connections include e Overspeed e Overcrank e High engine temperature e Low oil pressure 50 Section 6 Accessories e Low water temperature e Auxiliary fault e Anticipatory high engine temperature e Anticipatory low oil pressure e Emergency stop Additional connections available with the 20 relay kits include e Battery charger fault e Low battery voltage e Low fuel level e Engine trouble e Notin AUTO e System ready e Common fault e Overcrank e Crank terminate e Cooldown CENON See B 365569A C 1 10 relay kit 2 20 relay kit Figure 6 4 Dry Contact Kits shown mounted on assembly panel for 450 kW and larger generator sets TP 6161 1 07 6 1 6 Engine Prealarm Senders M Alert the user of low water temperature approaching low oil pressure and approaching high engine temperature Kits for gas fueled models include a low fuel pressure switch 6 1 7 FASTCHECK Diagnostic Tester M The FASTCHECK diagnostic tester simulates engine operation to identify faults in the controller and engine circuitry Use the FASTCHECK when troubleshooting sta
102. tage can damage sensitive equipment in less than 1 second Provide separate overvoltage protection for online equipment requiring faster shutdowns Figure 2 2 Fault Shutdowns 3 Correct the cause of fault shutdown See the Safety Precautions section of this manual before proceeding 4 Startthe generator set by moving the generator set master switch to the OFF RESET position and then to the RUN position If equipped the audiovisual annunciator alarm horn sounds and lamp goes out 5 Verify that the cause of the shutdown was corrected by test operating the generator set 6 Reconnect the generator set to the load by using the line circuit breaker or the automatic transfer switch Note Place the generator set master switch in the AUTO position before silencing the alarm horn Section 2 Operation 21 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch If equipped move the audiovisual annunciator alarm switch to NORMAL 8 Move the controller alarm horn switch to the NORMAL position 2 4 Expanded Decision Maker 1 Controller 2 4 4 Generator Set Starting Local Starting Move the generator set to the RUN position to immediately start the generator set Automatic Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start stop switch connected to controller termi
103. talled Comm Module controller top view TP 6161 1 07 6 1 14 Run Relay Kit The run relay kit includes three sets of contacts that energize only during generator set operation The run relay kit can control air intake louvers radiator louvers alarms and other signaling See Figure 6 14 Figure 6 14 Run Relay Kit 6 1 15 Safeguard Breaker The safeguard breaker senses output current on each generator phase and shuts offthe AC voltage regulator if a sustained overload or short circuit occurs It is not a line circuit breaker and does not disconnect the generator set from the load See Figure 6 15 CSC T TU Figure 6 15 Safeguard Breaker Section 6 Accessories 53 6 2 Accessory and Prime Power Terminal Strip Connections M The 16 light controller circuit board has terminal strips for use in connecting a controller connection kit Do not connect accessories directly to the controller terminal strips Connect accessories to either a controller connection kit or dry contact kit Connectthe dry contact kit s to the controller connection kit Connect alarms battery chargers remote switches and other accessories to the dry contact kit relay s The 16 light controller has two terminal strips TB1 and TB2 on the controller circuit board and prime power choices are made on TB2 See Figure 6 16 for controller configurations See Figure 6 17 and Figure 6 18 for controller terminal strip identification Lower the
104. tch in the RUN position because the alarm horn will sound Note Move the generator set master switch to the AUTO position to return controller functions to normal Prime Power Stopping Move the generator set master switch to the OFF RESET position to stop the generator set and power down the controller Note The controller functions are inoperative when the generator set master switch is in the OFF RESET position 2 3 3 Emergency Stopping Activate the controller emergency stop switch if equipped or the optional remote emergency stop switch for immediate shutdown Use the emergency stop switch es for emergency shutdowns only Use the generator set master switch for normal shutdowns TP 6161 1 07 The unit shuts down and the controller emergency stop lamp lights if an operator activates either the local or remote emergency stop switch Use the following procedure to restart the generator set after shutdown by an emergency stop switch Refer to Section 2 3 5 Controller Resetting After a Fault Shutdown to restart the generator set following a fault shutdown Emergency Stop Switch Resetting Procedure 1 Investigate the cause of the emergency stop and correct the circuit or wiring problem s 2 If the remote emergency stop switch was activated reset the switch by replacing the glass piece If the controller mounted emergency stop switch if equipped was activated reset the controller emergency stop switch by rotat
105. ter setting DIP switches to the generator set application be sure to power down and then power up the controller disconnect the battery and then reconnect the battery of the generator set or use the prime power switch if equipped The controller will NOT acknowledge the DIP switch change until after generator set controller is powered up Push down the end of the DIP switch near the OPEN label to open the switch or push down the other end to close it See Figure 1 10 OPEN 1 Push this side down to open circuit Figure 1 10 DIP Switch Open Position Modbus is a registered trademark of Schneider Electric TP 6161 1 07 Typically the factory default settings have all the DIP Switches in the closed position except the crank mode selection switch SW3 which is open for cyclic cranking The overspeed selection switch SW1 is open on 50 Hz units Be sure to select the correct DIP switch configuration for each generator set application Overspeed Frequency DIP Switch 1 The generator set overspeed frequency is set using DIP switch 1 Select 70 Hz for 60 Hz voltages and 60 Hz for 50 Hz voltages Temperature Cooldown DIP Switch 2 The generator set will continue to run during a five minute cooldown cycle or shut down immediately The choice is made using DIP switch 2 Engine Cranking DIP Switch 3 The controller is factory set for cyclic cranking To
106. the Kohler branded D300 D350 D400 D450 and D500 engine control box features AN A WI JJ V wy EY IGNITION DIAGNOSTIC REQUEST d DIAGNOSTIC GM23666 Figure 3 17 Kohler Branded Engine Control Box TP 6161 1 07 3 12 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system and internal engine component storage 3 12 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if needed 3 12 2 Cooling System Prepare the cooling system for storage as follows 1 Check the coolant freeze protection using a coolant tester 2 Add or replace coolant as necessary to ensure adequate freezing protection Use the guidelines included in the engine operation manual 3 Runthe generator set for 30 minutes to redistribute added coolant 3 12 3 Fuel System Prepare the fuel system for storage as follows Diesel
107. tion connection for Modbus to download new application program software or for connecting the remote serial annunciator CAN engine communication connection Figure 1 7 Controller Terminal Strips Connections GM28725 TB1 TB1A terminal strip TB3 TB1B terminal strip TB2 terminal strip P3 annunciator panel lamp and RSA communication module connections P21 for Modbus RS 485 communication connection P22 for CAN engine communication connection SW1 DIP switch 8 positions P7 RSA communication module connection Fuses Figure 1 8 Controller DIP Switches TP 6161 1 07 1 2 7 The controller circuit board contains eight DIP switches DIP Switches see Figure 1 9 Description Overspeed selection Switch Position Open 60 Hz Closed 70 Hz Temperature Cooldown Enable Cooldown Disabled Cooldown Functional Crank Mode Selection Continuous Cyclic Engine Comm Setting See selections for DIP switch 4 and DIP switch 5 below Value 2 Value 4 Value 8 Engine Comm Setting Modbus Address Bit O Value 0 Modbus Address Bit 1 Value 0 Modbus Address Bit 2 Value 0 Open Open MDEC Comm Closed Isochronous Open Open Closed Closed Closed No ECM J1939 Communication MDEC Comm Governor VSG Ob O i OI 0 O T O Q 0 Figure 1 9 DIP Switch Functions Note Af
108. tors ADV 5875B H Section 5 Generator Set Reconnection 45 1 07 TP 6161 e a E SHAS TIV NO G 3S n LON SSHJAMNOJSNVHI 1N333029 2 8 y YOLVYJNJ OSVMOL LH YO 100 S3NNHOJSNVMHL IN3S809 NOVIOS 3SVHd SALON yacnno ve Jorzalan SEL zH 1d O1 7 o1fzajan 81 AIAN divi on z jen ER ESO TOS MAIN SS gA R cl 3IVOS YILIN Ga y 2 2 SM ae fe 19 dNOO Clo up e 90080 wNOlldO Ma am PC KON w e 6 G oa 01 ees Lael 01 ON Ge M d e lud E AER doosa wNOudo n Z ru 1X LH 119 SZ Za gt SR pre TE BA E DN p LN L7 07 L D x3 zi9 8 x Lo ags Zld M 5 E j gt M e f GES El o fe Aut 70 2 19 dNOO ilt 119 a ms SD n dOONd TvNO 1dO o C S o x Llc N BA LA 11 ZH Lld OL A917 09Z ZH OG A08r ZH 09 ABOZ 0ZL ZH OG OTZ G6 l ZH 09 O00v OC Z ZH OS A9Lv 09Z ZH 09 ADOZ SLL ZH OS AOZZ LZL ZH 09 009 Lv ZH 09 A08 0ZZ ZH OS A08 0ZZ ZH 09 061 01L ZH OS ABOZ OZL ZH 09 29014 v YOIVNY31 lv GVv31 9 JAM IH 3MIM SWOIVNMH3LIV vii cl SAM MO 3MIM v MOIVNM3LIV GV31 ZL 19 dNOO YISA ig onean EL M3awnr env o1 zafan 84 43awnr dng ow z gn 84 d00Y0 TvNOIlLdO j1vOS YN T T j1vOS BH3ldNWN Me g p LA 8A on 119 6A SAW GE ANB i Sn et n PAS ee ol 2 LLO S Zz Ol L P B
109. ts except emergency stop battery charger fault high battery voltage or low battery voltage Place the generator set master switch in the AUTO position before silencing the alarm horn See controller resetting procedure in Section 2 3 5 Controller Resetting After a Fault Shutdown Alarm Switch silences the alarm during service Place silence the generator set master switch in the AUTO switch position before silencing the alarm horn To avoid reactivating the alarm horn restore all alarm horn Switches controller remote annunciator and audiovisual alarm to their normal positions after correcting the fault See controller resetting procedure in Section 2 3 5 Controller Resetting After a Fault Shutdown Emergency Switch if equipped immediately shuts down the stop switch generator set in emergency situations Reset the emergency stop switch after shutdown by pulling the knob slightly outward Use the emergency stop switch for emergency shutdowns only Use the generator set master switch for normal shutdowns The local emergency stop switch is standard on selected generator sets Generator Switch functions as the controller reset and set master generator set operation switch Refer to Switch Section 2 3 1 Normal Operation Section 2 3 2 Prime Power Mode Operation and Section 2 3 5 Controller Resetting After a Fault Shutdown Lamp test Switch displays the controller indicator lamps switch Selector Switch se
110. ue 3 Years or 500 Hours Remote Control System etc Compartment condition Weekly Remote control Monthly Run generator set Monthly Alternator General inspection Weekly Rotor and stator Yearly Bearing condition Yearly Exciter Yearly Voltage regulator Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier disconnected Yearly Blow dust out of alternator 2 Years or 300 Hours General Condition of Equipment Any condition of vibration leakage noise temperature or deterioration Weekly Ensure that system is set for automatic operation X Weekly Interior of equipment room or outdoor weather housing X Weekly Follow procedures and frequencies indicated in the engine manufacturer s maintenance manual If not indicated follow this service schedule Some items may not apply to all generator sets R Replace as necessary X Action Service more frequently if operated in dusty areas Do not break manufacturer s seals or internally inspect these devices Megger is a registered trademark of Biddle Instruments TP 6161 1 07 Section 3 Scheduled Maintenance 25 3 4 Alternator Bearing Service Have an authorized service distributor dealer perform service 3 4 4 20 300 kW Models Replace the end bracket bearing every 10
111. unded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases TP 6161 1 07 Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the
112. y 25 mm 1 in away from the exposed cable terminal TP 6161 1 07 EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 9 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection 1 To positive 4 terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 10 24 Volt Engine Electrical System Single Starter Motor Typical Battery Connection Section 3 Scheduled Maintenance 33 KW 272000 B 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor 3 To positive terminal on second starter solenoid 4 To ground terminal on or near second starter motor Figure 3 11 24 Volt Engine Electrical System Dual Starter Motors Typical Battery Connections 3 9 1 Cleaning 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 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 Do not allow the cleaning solution to enter battery cells Flush the battery
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114. yoxe eut ul uid Jo seutua DUU W S W O SLV shejap au pue 1InoJro Jajsued ul1oous lqnoJ1 uonisod OLNY eui oi u91Is 159 SLY eui AON peo JeJsueJ o1 s Ie YOUMS JeJsuei W O SLV uonisod OLNY eui 0 U31IAS jeet U31IAS 19JsueJ eui AON uonisod 130 eut ui yo ms jeet U91IAS JeJsuel Jayeadq N0119 eu JO epis JoyeJeueB ay ye eBeyoA OV 104 4oeuo pue JexeeJq eui jeseH uedo jexyeeJq N3119 Indino oY 492ueJejeH uoneorqnd JO uonoes suonoy pepueuiuio2aH s sneo ajqeqoig asiou jeuuouqe JO AIss 5 xg uonduunsuoo Jen uBiH eunsseJd sjesylano Jewod sxyoe Ajueppns sdojs eBeyo 1ndino MOL JO ON pey sueis peys jou s op yng syueio jou s oq suiojdui AS lqnoiL 1 07 6161 TP 42 Section 4 Troubleshooting Section 5 Generator Set Reconnection To change the voltage of 10 or 12 lead generator sets use the following voltage reconnection procedure Adjust the governor and voltage regulator for frequency changes Consult the generator set service manual for frequency adjustment information 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 Equipment damage Verify that the voltage ratings of the transfer switch line circuit breakers

20-2250kW Operation manual

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