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TP-6861

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1. ADV 8501 4 Nameplate Water fill Oil drain valve Belt guard Controller Seawater pump Fuel filter Coolant Air cleaner Oil dipstick check Cable connector for Fuel injection pump Fuel return Seawater inlet customer load leads Anticorrosion zinc anode 2 Lifting eye Oil filter Cooling air inlets one on each end of the Fuel inlet Fuel filter water alternator heat exchanger Oil fill separator Coolant overflow bottle Positive battery connection Overflow tube Fuel pump Pressure cap Heat exchanger Crankcase vent filter Exhaust outlet Negative battery connection Figure 1 2 Service Views Typical 65EOZD C J 55EFOZD C J Model Shown O YN O CO bb OQ N TP 6861 10 14 Section 1 Specifications and Features 15 O O Q N Fuel filter water separator 16 Nameplate 9 Controller 10 Air cleaner 11 Fuel inlet 12 Lifting eye 13 Overflow tube 14 Water fill 15 Oil fill Seawater pump Seawater inlet Oil filter Oil check Fuel filter Oil drain Crankcase vent filter Cable connector for customer load leads Cooling air inlets alternator Coolant overflow bottle Pressure c
2. 1991409 335 NO 135 38 Ol G33N 504 LMS 035010 3NI9N3 WO3 NON 3NI9N3 N23 IMS 135 3NI9N3 WNOLLAO 1950 318VNAV3903d 0SrAd 553 135 NOIVH3N39 N39d O Na9d 39 O N39d O N35d N39d N3HM 3AIOV 110 3 5 N3NOLSnO xov NO1vN3N39 9 181 2428 z Svd BA N09 SNOILVOINGWWOO i HOLIMS s3Wolsno M 9015 AON3ON3W3 5 HOLIMS 4015 14 15 310W3H e W3TIOMINOO 0052030 WNIWH3L par HOLIMS did MS 9 N ond d ong LOVINOD 0L ONIBIM SNOLLdO 318VIVAV LON ONY RDT 2034 13SN39 S WNIeL Q3i38vINn 1N3S3Hd 39VLIOA SVH 04 2184 CL 9 gs T 153108 2181 z 9
3. MOLVH3N39 QNVMOL LH NO 100 M3WHOJSNVHLI 9 z 1 Nid SNOILOANNOD 924 9 924 uel 01 19 r 9zd 2 924 r6S W9 335 153 94 815 01 S N S N S N LIM LHM I H 5 H 8 0 09 4 H NOILdO SNOILOJNNOO avol ZLM 134 01 814 220 91M SIN wf SNOILOJNNOO 82d NOILONAr 9 d LNOHLIM SNOLLO3NNOO 3SVLIOA GM93791A A Maker 3500 Sheet 1 of 3 ision Dec iagram D iring C J Wi Figure 5 16 80 99EOZD C J and 70 80EFOZD 93 Section 5 Wiring Diagrams TP 6861 10 14 96 7 tH S N IH 3m8 9 N33M9 NYO 1 89 101 20 c 8d 00 19 v 8id 950 vi 8 814 MOTHA TA 53 O N veld 7 S N S N za S N 13 1 4 04 6 4 002 49 9 69 96 co zi zed 601 2 84 66 12 S N SIM 6N 28 4 901 18 w
4. 5301915 1915 GION310S 331915 SS YOLOW 931915 WS QNVOB 037 ANVNOLVIS HIS ATANASSV 9NUVIOM MOSN3S dHnss3Nd 103NNOO MOIND fNOOD HOIVH3N39 I3NOVA AWA 1 3N iSS3Hd HOLIMS 10 510 HOIIMS 3unss3Nd 10 540 MOSN3S ANAL 38055359 G1OJNVN dvi HOLIMS 34055384 W3lvM VIS MOT HOLIMS 73 37 10 101 HOLMS 13 31 INVIOOD MO 101 SINTINSNI 1nSNI 3NWA lind Ad MOSN3S dWil 7303 514 HOLIMS 3HnsS3Nd 7304 Wavy 133 7IOMINOO NOIO3PNI 1303 3553 3 1SnVHX3 S13 31000N 101409 A23 3000 Da MOSN3S TBAT 191009 510 MOSN3S dW3L INVIOOD 519 MANYOISNVAL INNO 12 MOSNIS NVMO SNO 3 055344 INVIOOD 540 YOSNIS WVO SVO NJOFT 93311041405 005 5 lt 85 0 335 33S_SNOLLO3NNOO MOIVM3N39 310N ova zi AVIS quu NIN 39vLIOA ov BIL 8 0 py mE w 9 ei m r 01315 Y3119X3 140 Ov
5. 62 14 SNOILOJNNOO 968 9 924 wel r 9zd z 9zd LIM MOIVH3N39 QNVMOL 10 H3JWHOJSNVHI IN33M00 v6scWo OMG 335 34 9d 915 01 aS Sas S H H 2 9 8 sd H v a vo ann LINDO 5 39VLT0A Vit Nid 5 8 d 9 29 M3 v348 LNOHLIM SNOILO3NNOO 3SVLIOA NOLLONRIP GM93792A A J Wiring Diagram Decision Maker 3500 Sheet 1 of 3 125 150EOZD C J and 100 125EFOZD C Figure 5 21 TP 6861 10 14 98 Section 5 Wiring Diagrams 59 9 601 096 8 EIM OIN v Nid SNOILDSNNOO 514 96 vH ZN S N 2 IH ma vo 0 9 101 29 001 19 TA 3 zi 14 v3 S N S N 23 S N 13 S N lt S N S N 601 0 96 697 66 19 v8 S N se SIN 28 SOL 18 O N vv S N ev 296 zv 5 Sd z eid vol 1 lt 34 0 S N S N S N ma S N 6 14 1 64 r iid 98v 85 1 109 Sv LHM 2 14 S
6. enuen 39S 101e1euecy ues euiBu3 Bug siy pejequinu uonoeg 28S x suoneuqi e5 1u uino pue qeun W O uo l l S 4 1sn pe ti ajqeysun enuen JO eJeuer 4 sjueuoduuoo 1ndino dn 8220 Aejdsiq uollo s eDesse N 10413 9 10109108 418101 10 eDesseui ue ejdsiq Aieyeg eDeyoA ejBuis smous ejdsiq e dsiq uoneoiqng 10 2 suonoy eys pue ejdsig 1 r s sneo o qeqoJd pue ejdsig 5 swojdwis lqnouL Section 4
7. 85 1 5 6 DNV 20606000000 a 2 2 g S N 8 8 SNOILOSNNOO d SNOILOANNOD 14 ZNOOD JHM 69 6 8 9 940 9 14 022 EZM 6 14 BA gt eed NYO LHM LHM ri zd z zd 9 8 za L zad 24 8 24 6 24 6 24 1 8 z1 485 Nas I 140 0 458 I 140 0 NSE 2 0 080 1 91M IM 5 5 0 d 90L 6819 5 S N S N 04 t t LIN ZIN 9d 1 Nid vd Nid 159405 ET T 2 1 90 01 80 7 8 0vO 1 158482 21 n ev avon iM89 11 91 19 LIM SUHM ELM MOTIJA 01 814 91M S N S N S N S N zzo iM 9 82 19
8. 3QIS 1vNOILdO 33389 u3xv3ug GSLNNOW Zv OW H 82 S N O N sv ON uyug2 v d 61M ld 1 080 2 082 6181 089 81M 1 Nid 17 SNOILO3NNOO Ord 35010 ltd 9141 Ord 6861 10 14 40EOZD C J and 33EFOZD C J Wiring Diagram Decision Maker 3500 Sheet 3 3 80 Section 5 Wiring Diagrams Figure 5 3 ADV 8717A A 4371031405 005 N3XvA NOISIO3Q 335 SNOUO3NNOO AAT 10 22 14 24 qau O 303 310N 8 5 JHM S 8S A0V 335 701 SINSNI d oy 14 104100 ava 21 O InSNI 1915 vay 1331 1NY1000 96 19 List vi Zd 50 1H i Zd ETNSNI 101 YINSNI Z Zd snivis mu mwa 1903 ee id 0 9 snivis y ON LNOHLIM 5 39VLTOA 5301509 8 SNOILOSNNOO G OT
9. pue uonoes UMO q esnj J asn y 880108 10 2 W S eui 100use qnou y OUD Bum s pieoq W S 5 1 llonuoo 499U94J9JoH suonoy sasneg 40 9 6 jue e 10 euin uni esioJex3 dn sxXooj eBesseui s ejdsiq asiou euuuouqe JO 9AISSG2X3 uonduunsuoo uBiH eunsseJd 0 wo Jamod sxoe1 lu ppns sdois 1 ndino 10 ON sueis seop jng jou seoq suuoldu S 1 6861 10 14 72 Section 4 Troubleshooting 9949 SIU uuoued J e p iolnqulsip 891S 1 399us oeds s s enuen enuen enuen 39 101e1euec ues euiBu3 YMS sy jo 296 y w s W O
10. REMOTE E STOP COM O4 RED P1 12 O BLK P1 11 CAN O YEL 1 9 O1 GRN 1 10 O AUX Ol 30 P1 27 CONNECTION O PGEN OL ORG 1 35 TO NEXT GENERATOR FOR PARALLELING O PGEN OL vEL P1 23 Mini USB connector Figure 7 2 DEC 3500 Controller Front Panel es TERMINAL SIGNAL DESCRIPTION POSITION CONNECTED NOT CONNECTED DROOP SELECT 937 ISOCHRONOUS DROOP 947 IDLE MODE 714 CONSULT FACTORY GM85936A E Figure 7 3 TB12 Terminal Strip Typical located inside the Junction Box 108 Section 7 Accessories TP 6861 10 14 P1 35 Pin Connector Engine Generator Wiring Harness Terminal Description Connection P1 1 71 P23 1 71 P1 2 Open P1 3 N P1B 31 P1 4 3B P6 2 3B P1 5 YEL P1B 34 YEL P1 6 GRN P1B 33 GRN P1 7 Open or BLU 40EOZD C J 33EFOZD C J or P1B 28 Blue 40EOZD C J 33EFOZD C J Open or GRN 40EOZD C J 33EFOZD C J or P1B 29 Green 40EOZD C J 33EFOZD C J YEL 12 GRN TB12 CAN BLK TB12 COM RED TB12 COM 70 P30 3 70 TB12 1 1 TB12 3 3 IR P26 2 IR 12 26 3 12 7 40EOZD C J 33EFOZD C J or P1B 13 7 40EOZD C J 33EFOZD C
11. 5 2 L eie gt 516 13 4 916 516 3 YOSNIS 156 456 NONN3AO9 HOOSI WHO 021 3005535 ILON 983 1 19 SOTVNV 9 84 3SN3S 2 62 14 10 11 18 2 10 82 14 29 91 19 19 8 14 HINO 19 84 be 334 9 14 TINO Nv2 13 N9 1 19 i vid gt 2181 Tom N 4 19 1 INFE TAIT 10 22 18 TBAAT INVI009 9 19 TINA 19 34055344 LNVI009 1 29 NAL 10 12 18 2 3unss3ud 10 61 14 331 101000 92 19 ANAL 21 24 MALVM V3S 25 14 z id N39d 9 19 DNVA Zz id 01 18 6 9z id 9015 3 310N3u dOLS IMVIS 3IOW3N 61 14 M V8A 92 14 33110109 0056 NiXvW NOSIO3Q O HM 9N a WINSNI TINSNI 1 1 9 101 aay STN Vu 05 69 O 510 2540 TwNOlLdO AINO STHQON solviQvs 13 N30d ANa F oe xw
12. HIIM 39VL10 lt v 8 08 X 1 94 2 99 gis 458 SNOILO3NNOO 0 01 lt 485 33 SNOIL23NNOO MOIVE3N3O N04 50 31 NOlviS 4400 31 1081 m 30150 AB NOILO3NNOO QvO1 5 NVIS 9 89 335 SNOLLO3NNOO MOIVS3N3O a 50 31 0115 VAYE SNOLLO3NNOO 3010 UNV LINDYIO NNOlLdO 2 133HS 325 985 Nes 089 980 v 8 9 1 Std 2 lt GNvOB SL z oza 1 00 SLI 01 fioe TOES zo E FS us IN QNVMOL YO 109 INJYYNO 1 2 8 29 v zzd 519 zzd 8 sid 02 919 Std Erid tla IId v eia 8 14 eia iN 5 1 18 d vv lal 1 d xe
13. 80 av N 61m Zd 989 181 280 c 35012 2 14 BIM f 0825 2181 089 81M dev Nid SNOIIO3NNOO 174 SNOIIO3NNOO Otd dbz 1 13348 OL GM93791C A Figure 5 18 80 99EOZD C J and 70 80EFOZD C J Wiring Diagram Decision Maker 3500 Sheet of 95 Section 5 Wiring Diagrams TP 6861 10 14 4371031405 005 H3 XYW NOISI23G ADV 8720A A LJ le LJ OW ov 13 31 10 22 14 2 S L 1 a38 O 335 E 9 85 9 14 1ndino 9N 33S_SNOLLO3NNOO NNA J m E MOIVM3N39 804 310N 3 2 94 vi Zd v N3NNO LA ov av zi vei Quvog EE ZaNsNI 1915 e HORIS qui Ol0Hd Suy aam ek e 458 2 64 snivis HIYA 50 SN SNI yinsN 8 9 24 11415 LINDUID SNOLLO3NNOO 3O IIOA 140 SNOLLO3NNOO 39VLTOA Y q svig E L zd
14. d voa SI N39d 1 940 J14 N394d Sz id 230 JIN XAY 22914 j 0 91 14 10 01 14 lao w 9 14 6 18 BA 5 2199 uo 4 39018 3NION3 8 14 amoia 21 14 ma 4 a NW 4016 3 92 14 vi 5 5 ux Victa Nn dolS 3 alone 3301510 00 gt lt wNINN3L 81 ET vi id L M3dWnn 3AONSY 301 1 en er GION310S 5318915 SS NTU YOLOW ALAVIS NS dOLS LYWIS 310W34 61 14 QuvOB 031 ABVNOLVIS 815 ASSY Milillo34 ONUVLOY val ld AWNINSAL 193NNOO HONO MHOIVH3JN39 IN3NVWH3d SNOILO3NNOO HOLIMS 8 OINVED d A 3unSS3ud 10 50 TRSM 1d Iv8 IV8A 92 14 WNOILAO 304 HOLIMS 34055344 VIS MOT dM ge ae HOLWS T3A31 10 MOT 101 INFE T3A31 INVIOOO MOT 121 1 M3TIOMINOO 005 M3 vW NOSIO3Q TNSNI Lg viqA GLO3NNOO ION di A3 JAWA 1903 Ad T 2264 98 oi dWil 15 S3 2181 30 5140519313 93 983 1 30
15. 10 510 HOLIMS 3NnSS3Nd 710 SdO MOSN3S dWil MN LV HOLIMS 3NnSS3Nd VIS HOLIMS 13431 10 301 HOLIMS 13437 LNVIOOD MO 191 8 INSNI 3NWA 1304 Ad MOSN3S TINA 511 Wavy 7303 VU 1051409 NOIO3NI TANS QION3IOS 10 1 02 1304 93 M30N3S 34hivH3dW3l 15 513 FINGOW 1OMINOO 3NION3 983 YOSNIS 13A31 INY1002 510 MOSN3S dWil INY1000 SIO LNFHYND 12 MOSN3S 580 MJON3S 34055344 141009 540 VOB GN3931 Yu 456 1 L InSNOO 90090 5 266 193135 30059 ION 03103900 _ 530 2181 VHS 2181 r S d sod 1 9 TWNOLLdO NPL 9 v 9d 9d 4 ns Y Sd 510 LIN suo zd H r18 418 91 Vid 341164 9 23 64 ASH pe 0L 2181 2 44 1540 44
16. A3118 A3118 Tt T y 6 vid svi v vid 24 vid GM93790B A OSN 2 s vid Z YA S N SNOLLO3NNOO 9 4 Ga Oi 2 ane GW IN S N W nn S N EN f1 S N ZIM si nu S N SIM EA 6 A SES oN OS A S N 4 zo S N er ci vid vig 9 9 9 z 11d 9 11d 9 19 ZIM LIN N S N zr S N 1 19 v eid v8 MET oe HO non B Sd 2 E 156 vH oi vid 6 o Lo ttd 18 4 n S N 8 6 ma ww SAN a 807 2 0 54 56 GAMES Z 1 S N 9 21 19 16 SRE e9 S N LH Wed N 1 Nid 9 viZ N Wit si vid 116 zo SNOILOSNNOD 24 S N 19 TA 5 vd MOOO OCCOOOSS 19 ved Suo Lo ved NYO 14 ved 983 10 LHM 0018 3 ved Y8 1 SNOIIO3NNOO Lid N Z r4 ved SOL Nid a 81d 134 MAE Elle meatal ats SNOILOJNNOO vid d 001 gd ved 001 66 2 Za ved LOL 1f Nid SNOIIO3NNOO 8d
17. snivis svi svia 93345 NAVIY VET 7303 6 19 548 03395 35055344 INVIOOD 1 24 35010 NYE 3SN3S 9 SNA bebe BSNS SNA 2 10 61 14 3SN3S sna 35835 39VLT0A 9 V 3SN3S 39VLTOA 3SN3S 2 V 3SN3S 39VIIOA 2 V 7381 191009 52 14 21 24 Gunss3Hd YIS MOT 25 14 z id N39d 9 14 22 18 82 14 210 1 14 NUN 19 5 14 9 14 01 14 6 1d k 34 11 19 la 92 14 dois 3 71 14 421 19 dOlS INVIS 3ION3N 51 14 41 14 95 19 MTIOMINOO 0056 21 14 S aa INSNI T G2 L 38 0 101 TINSNI 1 6 1 X8 0 ST0SNI ena STNSNI 101 vu 9 91is n Mid nSNI OZN 105 EEN SN S te 69 avid sio Ay 2580 ANO STON vie 4 50 EN 4 1 95 a in F 13 FE 940 xw lt S N uius 5
18. 1 6 2 SVI8 A8 NOILO3NNOO 001 1 SVI8 39VL10 avon SNOILO3NNOO y Zd 5 03385 53 4 1491009 MOT 1 24 UIE 8 24 548 03345 2 1 3 335 8 24 340 ANAL 10 12 14 5 85 0 335 6 24 35010 JIVE SNOILO3NNOO G 85 NOV 335 SNOILO3NNOO MOIVS3N39 50731 301915 MOIVE3N39 04 y d 3SN3S SNE 3 055344 10 61 14 50757 YOLWLS 8 84 3SN3S FOWLIOA SNE WNOLLdO S44OQNVLS 1 64 3SN3S 39110 08 93197109 XINO S13GON 1 64 3SN3S 0 2 3SN3S JOVLION TIAFI 1NV1009 52 14 S d 3SN3S 39VL10 9 64 3SN3S 3910 dW3L 1NV1009 06 14 91 610 3unss3Nd 10 81 14 9 avor 212 9 VOB 242 Y98 Ji 1d 21 24 2 QNVMOL IH NO 100 93N lt Z Ged M3ANHOJSNVML INSYSNO 33055344 VIS MOT Z Ld 8 soa 1 6 0 11 14 lt 2 14
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20. 3NI9N3 504 1 94 0 2 99 ks uo 5 1 sna dilvios MERE TWNINNAL 81 MOlVIS 1915 TWNOUdO 62 19 QION310S 5311 SS 1 1 53118 WS Ta N39d Quvo8 031 AMVNOLVIS 815 S 1d XATBW3SSV 9NUVIOM SD YOSNIS 380553 4 TVA Sd 42 14 la TWNINYSL 193NNOO XIND 020 N 18 074 9 I3NSVA INJNVWN3d BATA TOMINOO 3 553 4 Md URS 2 14 S19 Old 6 14 TA ona HOLMS 10 510 HOIIMS 35055394 10 590 sersal 308435 LYN 9 14 10 Stoa dOlS 3 310W38 Homs UNS EAT To 301 S ta 9 4 10 304 anadns 015 3 HOLIMS T3A31 LNV1009 MOJ 101 NM ANSNI 8 54 Ziva NAY adia INWA 1803 Ai MOSN3S TANA 13 sao 9 88 1 4 gt 4015 1 15 51 14 WOLNI and 13 87819 18 3584 4 919 14 19 M3ON3S 15 13 SINGOW 71091409 4 awi YO
21. 8105 SEN 1 QvO1l o vu ISNI SNOILO3NNOO 985 v zd svia 03345 MOLVN3dO YOLON avo NaS 24 5 8 03345 794040 N04 2 IHS 335 082 5 24 080 6 29 35010 15 SNOLLOINNOD GOT 3NnSS3Hd 1Nv1000 1 ANAL 10 12 14 SNOUORINNOBS ISNIS 3OVLTOA SNE 0 335 SOUND SNOULOANNOO ZI lt 4 3SN3S 3O ITOA SNA 5 1 SQv31 301915 d 3948 39110 sna 2e 1 1051 CELE WNOLLAO 3SN3S 39VLIOA 2 V 3SN3S 2 AINO STSGON NOIVIOVH 3SN3S JOVIIOA 2 3SN3S 3OVIT0A 2 1NY 1000 62 14 07 0 93N MR a i 1 YO 100 Sod 1 64 N M3W8O4SNVMI INWARD ANAL 1 21 24 2 01 TWNOILdO L y 62 14 10 3 055344 VIS MOT 25 14 aniona Su ds N 8 01d 219 5 1 J CON394 18 dilvios nasa 8 510 32
22. LEN ZS 17 21 68 11 64 01 64 6 69 2 69 1 64 eza 4 nna L 2 9 d01S 3 310W3M4 304 HOLIMS 5 B3Woisno ONAY SNOLLO3NNOO 30198340 NOLON Msg 790140 304 2 1338 335 4 WS 2 220 20 8 82 824 KINO Qas AB3LINB aoz zd U 8 VZd oz 2 ADV 8721A A 125 150EOZD C J and 100 125EFOZD C J Schematic Decision Maker 3500 Sheet 1 of 2 Figure 5 24 Section 5 Wiring Diagrams 101 TP 6861 10 14 LINE SIDE MOTOR OPERATOR OPTIONAL PART OF MOTOR OPERATOR 40 UNIT MOUNTED CIRCUIT BREAKER OPTIONAL LOAD SIDE P41 CLOSE RELAY P40 TRIP RELAY ADV 8721B A Figure 5 25 125 150EOZD C J 100 125EFOZD C J Schematic Decision Maker 3500 Sheet 2 of 2 102
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24. 8 19 eve 98 544 a ved TA 8 980 Nid SNOIIO3NNOO 814 540 248 OEN 983 98 LINSNI 8N 777 9N rinsN SN SIM 89 Section 5 Wiring Diagrams 8 OLM TA v Nd SNOIIO3NNOO 9d SS vid SNOILO3NNOO Ved Goooooooobes za ved 6N vd 4 98 zi vd ZIN Ved 91 99 LW 17 220 SIM S1300N 510 oed S N sz VId vie 8N Z L Nid SNOIIO3NNOO N Z ZM HOL 1 5 614 g Vid 69 WNOIlLdO 9 a lt vid ds I S InSNI QINSNI a EI 55 cal E 31HM H 16 CINSNI 4 81M SN FINSNI L vid 9 LINSNI SINSNI z vid N a 01d 94 IN 8 14 OIN lt 14 Svo 6d SIM zo ved 44 Gv ved ma 8 ri ved
25. SNOLLO3NNOO 9 D 339 348 LNOHLIM SNOLLO3NNOO 3500 Sheet 1 of 3 ision Dec iagram 40EOZD C J 33EFOZD C J Wiring D Figure 5 1 TP 6861 10 14 78 Section 5 Wiring Diagrams UITIOUINOD 005 YIAYN NOISIOIC SL Z7 g91nSNI r R 0 19 82 vNOlLdO 101 N Y InSNI oe SINSNI 1 ZINSNI 2 214 8N vu i Q LANSNI v9 810SNI 23020 62 14 ZNOOD 82 719 510 540 2510 oi vid 69 L vld ds 8 vid 8 z 9 d OEN ss dol sna IM 004 NOILOANNOOD Zd 983 saevo 2018 A3118 3NI9N3 g vid NPL 2 14 LEN 41 1 S oz vid 8 OCN Z s vid Nid NOL SNOILO3NNOO 9 d l Yld S N WNOILdO IM
26. PMG pot ppm PROM psi psig pt PTC PTO PVG qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM riy rms rnd RO ROM rot rpm RS RTDs National Bureau of Standards normally closed National Electrical Code National Electrical 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 root mean square round rea
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30. 8 14 29 4 u3wod 93514 ltd lo ved vB 91 aA p 22d AINO 9 Lld Gasnd 17 94 voro 8 824 XIV awaliva 24 aoz 5 19 94 13 v d 5 anv 91 Section 5 Wiring Figure 5 14 55 65EOZD C J 45 55EFOZD C J Schematic Decision Maker 3500 Sheet 1 of 2 TP 6861 10 14 00S 333VWA NOISIO3d 605 3015 gt 18 Y WOlVH3dO YOLON 10 lMVd ON YOLVYSdO YOLOW 301 01 IVNOILdO GSLNNOW LINN 35012 gt AV 1334 35010 ADV 8719B A Figure 5 15 55 65EOZD C J and 45 55EFOZD C J Schematic Decision Maker 3500 Sheet 2 of 2 TP 6861 10 14 92 Section 5 Wiring Diagrams N3349 ZM 1 19 3A 9 NEL S N S N e ze ig o
31. BUS OF RATED kW Y HHH HG nan OF RATED kW kW SHARING P GAIN kW SHARING GAIN kW SHARING D GAIN SPEED BIAS SYSTEM FREQUENCY GEN FREQUENCY FREQUENCY TRIM P GAIN FREQUENCY TRIM GAIN FREQUENCY TRIM D GAIN SPEED BIAS FREQ DEOOP AT 100 kW BUS OF RATED kVAR GEN OF RATED kVAR SHARING P GAIN SHARING GAIN 12 12 12 gt OVER POWER TRIP OVER POWER DELAY REVERSE POWER TRIP REVERSE POWER DELAY OVER VOLTAGE TRIP OVER VOLTAGE DELAY UNDER VOLTAGE TRIP UNDER VOLTAGE DELAY OVER FREQ OVER FREQ DELAY UNDER FREQ TRIP UNDER FREQ DELAY REVERSE VAR TRIP REVERSE VAR DELAY OVER CURRENT TRIP OVER CURRENT DELAY TRIP TO SHTDWN DELAY HHS 85 Hts SHARING D GAIN VOLTAGE BIAS SYSTEM VOLTAGE L L AVG GEN VOLTAGE L L VOLTAGE TRIM P GAIN VOLTAGE TRIM GAIN VOLTAGE TRIM GAIN bill VOLTAGE BIAS d Ht VOLT DROOP AT 100 A dian gini A GEN MANAGEMENT MODE MODE GEN MANAGEMENT ON OFF GEN MANAGEMENT ORDER START CAPACITY HHH START DELAY STOP HABA STOP DELAY TOTAL BUS tit kW BUS TOTAL POWER START kW kW STOP kW kW START ACCUMULATOR STOP ACCUMULATOR dH RUN TIME THRESHOLD hrs TOTAL RUN TIME FUEL LEV
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35. BA SLM ma S N 1 SNOIIOJNNOO vd 2 14 01 19 LIM 62 14 SNOIIOJNNOO 924 GM93788A A Ev6SEND OMG 335 143 9d 815 OL 304 6 81a svi S N oL 1 19 91 Z vd Nid 5 Zd 1 14 91M W SNOLLO3NNOO 304 5 uel 81 MOIVH3N3O NO ET 100 H3WHOJSNvHL INSYYNO z 1f Nid N39d Z181 le 1 81 9 oz ald 8 vz 8ld 01 919 5 1 92 9 92 81M 5 3 015092 LINN sim 304 SLINA gt NO SH3dWnr Sd d MONN3AO9 91401373 93 2181 o VL 81 819 N39a z181 2 01 819 89 819 e ala 4 4 e Zlal 1 18 L lt OL NOI Z1LB1 woo Z 181 gt na No zi8 I3N33HI3 YSTIONLNOD 005 930 ci 181 21 181 s ald S N 0890 9181 980 5
36. TP 6861 10 14 Section 5 Wiring Diagrams 77 S N 05 1 8 4 03 940 6 4 53 TA 26 NFL Le S N Of 81 14 62 ma sz S N 12 14 S N 92 5 24 S N sz 61 13 16 14 VOB Z 1 28 voL Z S N zz S N iz 2 19 Oz S N 62 14 vie 8 SNOIIO3NNOO 819 1 28 re ia 22 14 14 OTM oos TWNINYAL 81 GION310S ALVIS SS YOLON WS GNVOB 037 ABVNOLVIS 616 1 103NNOO 000 HOLIMS 10 50 10 590 OIL3NOVW dN HOLIMS 3 055344 YIS HOLIMS T3A31 30 101 HOLMS 73 31 1NV1002 MOT 191 330015 031 1051 OTSI OSI BSI VSI NOUD3INI di 0311091 891 INVA Bhd M N31 TANI vu M3ON3S 3snivsidhil ISnvHX3 SI3 MONM3AO9 OINOMIOT3 93 30018 3NIN3 983 3NH0IVH3dN3L LNVIOOD 19 15 HOLIMS 38155344 1002 540 ONS BAJI 1000 SD ADVA 1 ALIYE VO8 YONN Lov ON3931 3TIONINOO 0066 YIAYN
37. 107 Z f ACCOSSONCS REEF ae a eas ee Rp Ped 107 7 2 Accessory 107 Appendix A Abbreviations 111 Appendix Alternator Protection 113 Appendix C Operating Hour Service Log 115 4 Table of Contents TP 6861 10 14 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS 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
38. WSN 5 d L ur vo Se O09 c 90090970 2060600000600 2 L L E ld GS znooo 8 SNOILOJNNOO 8298 6 14 TA 134 134 940 9 14 NYO NOLLONRI 3E ZZ 2 un EZM 24090 LHM ezza LIM IHM MOIVH3N39 GYVMOL BO 100 YJWYOJSNYYL 1 348400 ALON 19 219 Sv6SEND OMG 335 53 94 815 OL S N 2 LLM LHM 4 4 H NOlLdO 33 v3M8 LINDYIO SNOLIO3NNOO MOTHA 13A 01 8919 220 91M vf SNOILOJNNOO 869 NOLLONAr 9 W3 xv388 5 GM93790A A 3500 Sheet 1 of 3 ision Dec iagram ing D Ir 55 65EOZD C J and 45 55EFOZD C J W Figure 5 11 TP 6861 10 14 88 Section 5 Wiring Diagrams A009 l YOLVAILOV 1 4 009 230 38330 M S9 SS 30A
39. 1 0 SIM 1 181 1 vz z181 1 zv v Obd vv 81M 8 XS MNOlVH3dO zi eign zi 30 458 5180 458 OOO ON 401994340 11 3015 GSLNNOW LINN zvy 5 S N S N 61 282 618 280 81 080 BIM f Nid SNOILO3NNOO ltd SNOILO3NNOO Otd 35010 4 Ord 3Xv348 1 IVNOILdO Figure 5 13 55 65EOZD C J 45 55EFOZD C J Wiring Diagram Decision Maker 3500 Sheet of TP 6861 10 14 90 Section 5 Wiring Diagrams ADV 8719A A 4311031405 005 M3MVA NOISIO3Q 1 1 SOTVNV E SNOLO3NNOO sje MOIVH3N39 ILON an 21 ld 1 3A1 110 22 14 z 1915 p s ne STNSNI 01315 W3lloX3 OLOHd m v HNO AVIY ZINSNI 1 Zd YIYO AVIY 1 1NV1009
40. 43 2 6 1 Emergency ce vox Rr qe ches 45 2 6 2 System Status Lamps 45 2 6 8 System Fault Warning Lamp with Digital Displays 46 2 6 4 System Fault Shutdown Lamp With Digital Displays 48 2 6 5 Status and Notice Digital Displays 51 2 6 6 Controller Resetting Following System Shutdown or Warning 52 2 7 Menu Displays ERI HEP ELE 52 2 8 Monitoring and Programming Setup 59 2 8 1 PG Communications hm DRE rh rer Reds 59 TP 6861 10 14 Table of Contents 3 Table of Contents continued 2 8 2 Modbus Communications 59 Section 3 Scheduled Maintenance 61 3 1 Alternator Service sud uer RR ERU ER Yen 61 3 2 Engine Sevice sessed sea de PR E ot 61 3 3 Generator Set Service Schedule 63 3 4 Alternator Bearing Service 65 3 4 1 20 300 kW Models 65 3 5 Diesel Fuel Systems 65 3 5 1 Bleeding Air from Fuel System 65 3 6 Cooling Syste
41. Reverse Trip Voltage Match D Gain Reverse VAR Delay s 2 me Knop ipability Voltage Bias Over Current Trip o Gen L1 LO Volts 444 4 V Frequency Matched TRUE FALSE O Over Current Delay s Frequency Window Hz Trip To Shtdwn Delay s Gen 12 10 Volts V Gen 13 10 Volts V Gen L1 L2 Volts V Gen L2 L3 Volts V Gen L3 L1 Volts V Gen L1 Current A Gen L2 Current A Gen L3 Current A Bus L1 L2 Volts V Bus L2 L3 Volts V Bus L3 L1 Volts V Reset Gen Volt Meter YES NO Reset Gen Amp Meter YES NO Reset Bus Volt Meter YES NO Reset All Meters YES NO Bus Frequency Hz Generator Management Gen Frequency 2 Gen Management Mode Freq Match P Gain INVALID MANUAL FIXED RUN Freq Match Gain TIME FUEL LEVEL Freq Match D Gain Gen Management ON OFF Speed Bias Gen Management Order Phase Matched TRUE FALSE will revert to previous setting in Phase Match Window run time or fuel level mode Phase Difference Start Capacity Phase Match P Gain Start Delay s Phase Match I Gain Stop Capacity Phase Match D Gain Stop Delay s Speed Bias Total Bus Capacity kW Dwell Time s Bus Total Power kW Dwell Time Remaining s Start KW kW
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45. I 8 noo p dols 3 i024 vi vi 303 HOLMS O3nddns u3HOLSNO ONY 1 N AON Oc d rea SNOILO3NNOO 3094340 NOLON 4 2 Ius 335 2 64 EZS 04 ORT aH Nolo voL 20 204 3 89 10 829 90L B gzd 2 1 904 ocd SS svi WS 0380 Di d OGAZL AMBLIVE OGAZL a04 ADV 8718A A 40EFOZD C J and 50EFOZD C J Schematic Decision Maker 3500 Sheet 1 of 2 Figure 5 9 TP 6861 10 14 86 Section 5 Wiring Diagrams Y3ATIONLNOD 0052 WN3XNVA NOISIO3Q 3015 930193340 YOLOW 30 IVNOILdO OW MOIVH3dO YOLOW 3015 AYON IVNOILdO 937 348 GSLNNOW LINA 35012 AV 35010
46. MOIVNSJIIV GV31 l Wiring Diagram Alternator Reconnections 12 Lead Sheet 1 of 1 ADV 5875F R Figure 6 1 TP 6861 10 14 106 Section 6 Voltage Reconnection 7 1 Accessories Several accessories help finalize installation add convenience to operation and service and establish state and local code compliance Accessories vary with each generator set model and controller Select factory installed and or shipped loose accessories Obtain the most current accessory information from your local authorized service distributor dealer Accessory kits generally include installation instructions See the wiring diagrams for electrical connections not shown in this section See the installation instructions and drawings supplied with the kit for information on 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 See Section 7 2 Accessory Connections for terminal identification TP 6861 10 14 Section 7 Accessories 7 2 Accessory Connections The controller contains a circuit board equipped with connectors for use in connecting external optional accessories including alarms battery chargers and remote switches The optional fifteen relay dry
47. e When two sensors are installed oil pressure and coolant temperature separate warning messages are initiated for each sensor when a warning limit is exceeded Should either sensor provide a reading that violates a shutdown limit a shutdown occurs regardless of the other sensor reading If either sensor signal is lost a Loss of Signal LOS warning will be initiated If both sensor signals are lost a Loss of Signal LOS shutdown occurs 40 Section 1 Specifications and Features TP 6861 10 14 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 andinstalled air cleaner element to prevent unfiltered air from entering the engine Air Inlets Check for clean and unobstructed air inlets Air Shrouding Check for securely installed and positioned air shrouding Battery Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Checkthe coolantlevelaccording 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
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50. Operation Marine Generator Sets Pleasure Craft Models 40 150EOZDJ 33 125EFOZDJ Commercial Models 40 150EOZCJ 33 125EFOZCJ Controller Decision Maker 3500 22001 mum POVVER SYSTEMS KOHLER Power Systems wes we California Proposition 65 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 Engine Identification Record the product identification information from the engine Manufacturer Model Designation Serial Number Table of Contents Product Identification Information 2 Safety Precautions and Instructions 5 Introduction SEES E EE E E i EA EAE A GENEE 9 Service Assistance aE A SOA AS E 10 Maintenance and Service
51. SIOVINOO AVI3M 6861 10 14 Figure 5 27 Interconnection Diagram for Decision Maker 3500 104 Section 5 Wiring Diagrams 6 1 Introduction Use the following voltage reconnection schematic to change the voltage of 12 lead generator sets Frequency changes require voltage regulator and governor adjustments Refer to the respective spec sheet to determine if frequency is fixed or field convertible If frequency is adjustable refer to the engine service manual and or governor literature for conversion information Refer to the following connection schematics Follow the safety precautions at the front of this manual and in the procedure text and observe National Electrical Code NEC guidelines 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 Note Equipment damage Verify that the voltage ratings of the transfer switch line circuit breakers and other accessories match the selected line voltage WARNING KS S 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 6861 10 14
52. Section 6 Voltage Reconnection Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact elec
53. d H Sd weld Z 0ed 4 224 v gld IN 896 lt 9 14 voe 61M LCIESSSSS 198 28 lt 4 SIN gt on 2228 Eid oN ELM ene 22 a ZIN ZIM 8 ed vi 2 11 SIM 220 Std LEN 2 214 YEN 2 zd vo 983 98 51 810 S N 304 1 SNOILOSNNOO 524 9 9 TWNOILdO sao 2 Sz vid vie Nid 5 gs zsdo AT as g vid 69 02 8 G30SNI em 9TNSNI pH sz 4 e via ZINSNI L 1m VINSNI wid Vid 9 ZANSNI S1NSNI zo sd 69 2 vo6 8 SIN v SNOIIO3NNOO 19 ZZM IZN Z s vid 4 01 Z 33 9uo CN if 94 54 THA SNOILO3NNOO 614 ma 980 734 S N S N S N 19 vd LHM 18 74 4 1 SNOIIO3NNOO 6d a Y Nid SNOIIO3NNOO 2
54. e O Setup See Section 1 11 e Active Events See Section 2 6 3 Section 2 6 4 and Section 2 6 5 TP 6861 10 14 1 8 Metering Menu 1 8 1 Generator Metering Submenu Volts displays the alternator output AC voltages The display shows line to neutral voltage combinations for three phase or single phase configurations The display also shows the average line to line and line to neutral voltages Current displays the alternator output AC amps The display shows each line L1 L2 L3 of three phase models or L1 L2 current for single phase models The display also shows the average current Frequency Hz displays the frequency Hz of alternator output voltage Power kW displays the total and the individual L1 L2 and L3 alternator output as actual output values Power Factor displays the total and individual line power factor values Rated kW displays alternator output as a percentage of the entered data value Reactive Power KVAR displays the total and individual L1 L2 and L3 kVAR Apparent Power kVA displays the total and individual L1 L2 and L3 KVA Rated displays alternator as a percentage of the entered data value Phase Rotation displays the actual generator rotation TP 6861 10 14 1 8 2 Engine Metering Submenu Note Not all of these engine metering submenus may apply Engine Speed Tachometer displays the engine speed RPM at which the engi
55. 2 Reed valve 3 Mounting base Figure 3 1 Siphon Break TP 6861 10 14 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 3 1 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockage from the reed valve opening 5 Replace the siphon break if the reed valve is cracked if the reed valve material has hardened or deteriorated 6 Install the reed valve into the mounting base with the valve downward See Figure 3 1 item 2 7 Install and only finger tighten the retaining cap Do not overtighten it 3 6 6 Impeller Inspection and Replacement Procedure The gear driven seawater pump is located on the service side of the generator set Check and change the seawater pump impeller at the interval specified in the service schedule Follow the instructions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure 1 Close the seacock 2 Remove the seawater pump cover plate See Figure 3 2 14 8 Drive shaft 9 Washer 10 Nut 1 Seawater pump 2 Cover plate 3 Gasket 4 Impeller 5 Bearing 6 Housing 7 Pulley Figure 3 2 Seawater Pump Typical Section 3 Scheduled Maintenance 67 3 Remove the impeller 4 Inspectthe impeller for damaged cracked broken missing or flattened vanes The impeller v
56. 5 Tid OM NYO oe S N S N S N 82 4 iz GS Zid 52 510 69 S N S N S N 18 02 29 54 1 ss S N 105 2781 1 5 Vid Sid 5 914 GM93791B A 3500 Sheet 2 of 3 ision Dec iagram ing D Ir J Wi Figure 5 17 80 99EOZD C J and 70 80EFOZD C TP 6861 10 14 94 Section 5 Wiring Diagrams 0052 333MVNW NOISI93d 0 a zi81 Zd ld PE 3QIS O C2vz zi8l iv 9 1 zv vV 0 za 9 BIM v8 ao 358 6181 458 OOOH Nsa 301943340 YOLON 30 1 OW 90193340 YOLOW 1 Obd dev STM 1 181 1 Op mw n 2015 QAYOT vNOLIdO 82 LINN
57. 64 P1B 1 64 31 P1B 3 81 TP 6861 10 14 TB12 PGEN 4 ORG P3 7 L1 Bus Voltage Sense TB13 L1 P3 8 P4 Connector RJ45 Ethernet L2 Bus Voltage Sense TB13 L2 Open Network communications NSA INSB INSC INSLO Insulated Standoff CBRK Circuit Breaker Figure 7 4 Controller Connections Section 7 Accessories 109 Notes 110 Section 7 Accessories TP 6861 10 14 Appendix Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx APU 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 CAT5 CB CC cc CCA 6861 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 approximat
58. 95 19 T pie X18 0 zd SN 39VITOA 140 SNOLLO3NNOD 39VLIOA z zd LINDO ENI n 9 snuvis 301510 VOT Za 4310151 AB 907 Bhd 55 14 n0 L d 3 SNOLLO3NNOO ud MOIvN3dO NOLON 5578 ds 2 SWE 03345 3unsssud 14 1000 MOT 1 WNOlldo 2 335 SNI 335 6 64 35010 dNaL 10 HOH 1 14 69 SONGS 3sN3s sna 5504 0931 501415 SNOLLO3NNOO MOLVH3N39 9 d 3SN3S 39VL10A 508 RINSSRd 10 61 14 50731 80115 2540 S4400NVIS 1 84 3SN3S 508 937108 1 69 3SN3S 9 KINO ST300N BOlVIOVH 2 35N3S 39VIT0A O v 6 3SN3S 2 9 d 3SN3S 3OVIIOA 2 THAT INv1000 52 14 ANIL IShNHX3 HOIH 21 24 93N lt 5 Std 1 Sa YOLVYJNI9 OYVMOL 100
59. Fail to Sync Time s Stop kW kW Sync Time Remaining s Start Accumulator OQOQOOOQOOQOOOOOOOOOOOOOOOOOOOOOOO oo 000000000000 00 0 OOOO OO OOO User Defined changeable Menu Displays Use SiteTech software to change other settings including User Defined Menu Displays 54 Section 2 Operation TP 6861 10 14 1 0 Menu e Resistive Input Analog Input 0 1 Analog Input 0 2 Analog Input 0 3 Analog Input 0 4 Analog Input 0 5 Analog Input 0 6 Description function by default unless modified via Site Tech Measurement Ohms Shutdown Input Enabled ON OFF Sensor Type Warning ON OFF Low Protective Inhibit s Low Warning ON OFF Low Warning Limit Low Warning Delay s Low Shutdown ON OFF Low Shutdown Limit Low Shutdown Delay s High Protective Inhibit s High Warning ON OFF High Warning Limit High Warning Delay s High Shutdown ON OFF High Shutdown Limit High Shutdown Delay s Board Number X TO 0 O 9 KO O OE G p O 9 1 0 Menu Continued e Digital Input Digital Input 0 1 Digital Input 0 2 Digital Input 0 3 Digital Input 0 4 Digital Input 0 5 Digital Input 0 6 Description function by default unless modified via SiteTech Status ACTIVE INACTIVE Function Event Enabled ON OFF Inhibit Time s Delay Time s Board Number X e Digital Output Digital Output 0 1 Digital O
60. HOLIMS 34055344 1491000 540 M3ON3S 13A31 INV1000 12 YAYI 105535 SUO 0056 3 01 939 1g ald ENNE LEM 39 2181 14 1 14 oz aid 22 819 1 924 8 928 2181 641 2181 814 FIM 1 1 2 814 8 81 81 819 9 LIM 2 2181 1 218 Noo Z18L woo zi81 No ziaD Nvo z 181 2 94 1 29 SNOILO3NNOO 8 ZM MOTA ig v9 18 S N oc vi ld 5 69 4 k 04 3A 134 N 9 N 13385 01 8148 335 5 404 r za 3019 LINSNOO 40084 SNONOSHOOSI 56 103135 40080 1 24 1 LON G3193NNO9 NOILISOd _ ILL 8 829 904 92 814 504 7 04 2181 YOL 9 05 404 1 68 134 95 819 T34 ee 8id 40530 TNO 5 VNIN2 31 2181 2 24 458 9 Ns8 NOLLO3NNOO 2181 1 06 9d a ve 1d ld 1 2 vd 4 181
61. Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal uniform resource locator web address undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with write only without weight transformer TP 6861 10 14 The controller has built in thermal protection for the alternator This feature functions similarly to a thermal circuit breaker When the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown The amount oftime at which current is over the rating is inversely related to the amount of current above the nominal rating In other words the higher the current the shorter the acceptable time TP 6861 10 14 Appendix B Alternator Protection The current and time limits are defined by actual test data and are maintained in the personality parameter file Although the equation for detecting a fault is proprietary some of the important limits are shown below for informational purposes Rated Current Time Delay 200 40 seconds 300 10 seconds 425 5 seconds 950 1 second Appendix 113 Notes 114 Appendix TP 6861 10 14 Appendix C Operating Hour Service Log Use the log below to keep a cumulative record of required s
62. dvz 3015 2 2181 iv S ivd O O V 81M v8 Sop 30199340 YOLOW 30 194 458 18 458 Wwse eien NSB 130 ON NOlVN3dO YOLOW 1 0 c1 181 1 21 11 181 131 395 QAYOT 3489 1 v 0N uyug0 zv 61M zd 080 218 080 2 dzv 35079 SNOILO3NNOO sv OW w N82 ld 181 080 2 SLM SNOILO3NNOO Ord 9141 Ord v I3Hs OL GM93789C A 40EFOZD C J 50EFOZD C J Wiring Diagram Decision Maker 3500 Sheet 3 of 3 Figure 5 8 85 Section 5 Wiring Diagrams TP 6861 10 14 39018 3NIN3 YATIONLNOD 005 N3X4VA NOISIO3Q 9 s z gt SL8S AQV 335 SNOLIO3NNOO MOIVM3N39 ALON ova zi 1315 LINDYID SNOLLO3NNOO LJ ov vay bd La X 27 mals 9 9 NIV m 050 zi 97513 H3llo
63. requires the use of SiteTech software The digital output can either open or close the circuit to activate Optional Dry Contact Kit Dry contact kits provide an isolated interconnection between the generator set controller and optional devices Up to fourteen conditions can be specifically identified with this kit A relay coil will be energized when the corresponding engine or generator sensing device or switch monitored by the microprocessor control board is activated Each relay provides one set of SPST contacts for field connection of customer supplied indicators or alarms Contacts are rated for a maximum resistive load of 10A at 120VAC The fifteen relay dry contact board has four digital inputs and two analog inputs There are fourteen programmable relay outputs and one common fault relay output The relay contacts K1 to K14 are rated e 10 amp 120 VAC e 10 amp 28 VDC max e 0 01 amp 28 VDC min The common fault relay contact K15 is rated e 500 mA 125 VAC e 2 amp 2 30 VDC TP 6861 10 14 The default selection time delays and digital outputs are factory set and adjustable Some data entries require using a PC SiteTech software 1 11 1 Controller Fault Diagnostics Figure 1 11 provides descriptions of the system events andtheirtypes vwarning shutdown status and notice ACTIVE EVENTS 01 02 2013 11 40 31 AM 11 44 AM 01 02 13 Warnings show yellow warning l
64. 1 9 3 Configuration Submenu 23 1 9 4 Voltage Regulation Submenu 25 1 9 5 Voltage Selector Switch 26 1 9 6 Paralleling Operation 26 1 10 Controller Configuration 34 1 10 1 Controller Configuration Submenu 34 1 10 2 Communication Setup Submenu 34 1 10 3 Calibration Submenu 35 141 Setup Menu isch Ia Eidem as 36 1 11 1 Controller Fault Diagnostics 37 1 11 2 Main Logic Circuit 39 1 11 3 For Units Equipped with 3rd Party Marine Option 40 Section 2 Operation zou dede ee Oa COUR UR Sa 41 21 Prestart Checklist 41 2 2 Marine Inspection e uy ec pue ied dere ie EP eda 42 2 3 Angular Limits During Operation 42 2 4 Operation in European Union Member Countries 42 2 5 Load Profile nere aed eme asas dpa d 42 2 6 Controller Operation
65. 14 MONIS 191 XY 42 14 QION310S 314915 SS 82 14 20 D AN BOLON UIMIS NS 096 91 19 NENA 19 02 QNVOB 031 ABVNOLVIS 815 YOSNAS 38055354 594 2414 002 IIHS 22 K 193NNOO HOND tam Lid WOIVUINAS I3NSVW atia 58 14 AWA 1051409 3N SS3Hd Add 18 59 9 14 INO Dd WA 9015 3 HOLIMS 10 510 son 04 HOLIMS Q3nadns HOLMS 3unss3sd 10 540 1 Wale e 1 19 S 5 ONY MOSN3S dWil IVA ai L AANA MHOSN3S 354055344 Gad eid 8 4 ONS HOLIMS 3 055344 YIS MOT 96 HOLMS 13A31 JO 101 896 dOIS INVIS 3ION3N 51 14 e HOLMS 13A31 1NV1005 MO 191 1N v sd 21 INTINSNI 5 2 89 j 6 4 AHO 02 1 19 INYO 3AWA 1304 Ad sao sa WOLSISS YOSNIS AWIL 1304 514 9 z a HOLMS 34055344 IINA 543 8 814 B
66. 1915 GION3I0S 5311 SS YOLOW 931915 NS 05908 037 AYVNOLWLS HIS MOSN3S 340553444 IVY 584 1934409 f NOOD I3NOVW IN3NVHid 10MINOO 3HfnSS3Nd Add wo193NNO9 HOLIMS 110 510 3035 34155339 10 540 MOSN3S ANAL LVN 3HnSS3Nd dv HOLIMS 34055344 YIS HOLIMS 73 31 10 101 HOLMS T3A31 INVIOOO MOT 707 n INSNI 3400NVIS 03491051 015 OSNI BSN SNI Sn8 GNNOYS 5 89 INWA 133 Ad MOSN3S AWAL TINA 14 30436 13A31 7304 SU 330435 13A31 7303 574 Wavy 1304 Vid 30438 ISnvHX3 13 0018 ANION 983 MOSN3S 713431 11009 510 MOSN3S INVIOOD 510 M3WHOJSNvHL LNSYYND 19 MOSN3S SYD HOLIMS 853 9 LNVIOOD 540 HOLMS T3A31 INV1005 519 NEO MOSN3S SVO VOB GN3931 1 92 9 92 2181 2181 52 814 na9d Z 181 Z ld 8 81 81 819 e 92d LIN z181 e 08d Woo z 18 Woo Z 18 Nvo z181 CNvo z18D 2 94 c eza 6 819 SSS ie v9 18 S
67. 5 5 TP 6861 10 14 82 Section 5 Wiring Diagrams ELM MOTHA N3349 LLM 15 1 Sim 18 14 61 14 TA S N 2 S N vos 204 vie S N S N 9 N 18 ve ze i og 62 82 Lz 92 sz 2 ez 2 0z 116 2181 106 2181 04 2181 s ezd 12 14 1 14 rim 22 14 SNOILOANNOO 819 OINOS 39018 TWNINYAL SS YOLOW 9315915 NS 95908 037 5 875 13141038 1O3NNOO HOLIMS 1 710 510 YOSNIS 3 0553 4 10 SdO MOSN3S AWIL Q103INVW HOLIMS 38055344 VIS dii HOLIMS T3A31 10 101 HOLIMS 13A31 1491009 MOT 191 ADVT DINTINSNI 1nSNI 1 Q31v10SNI OTSI OSI BSI 0311051 891 INVA TANA Ad MOSNAS ANAL 1303 14 NAVIY 931 1304 GION310S 1051 09 TANA 503 5 AWIL 1SnVHX3 S13 TINTON 1081409 ANNOYS 309018 3NI9N3 983 30010 Da MOSN3S dW3l 1002 519 33 HOJSNvaLL 12
68. 500 Hrs Check engine speeds Yearly or 500 Hrs Check engine electrical ground Yearly or 500 Hrs Governor oil mechanical governor only 33 40 kW Yearly Ignition components Yearly Injector pump amp injector flow rate pressure spray pattern Yearly Check and adjust valve clearance 2 Years or 2000 Hrs Check crankshaft vibration damper 100 150 kW 2 Years or 2000 Hrs Bolt torque 3 Years Check front PTO if equipped As required Remote Control System etc Compartment condition Weekly Remote control Monthly Run generator set Monthly Alternator 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 General Condition of Equipment Visual walkaround general inspection X Before operation Any condition of vibration leakage noise temperature or deterioration X X Weekly 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 dust
69. 540 HOLIMS 13 31 INY1000 19 MIWNGNB 54589 MOSN3S SVO 9NIONVHO ON3931 1 922 924 181 wi ZLa sz 819 FIM N39d z 181 2 81 8 81 81 818 c 922 LIM 2181 1 2181 lt woo z 181 woo z 181 nvyo z 181 nyo z 181 EZM vem 2 94 aim g za GA Vf SNOILOANNOD v gt LCL8 AOV 335 5 03 25 91 1e 81d NPL ES is oz oL 038 S N TA ac N S N SIN S 0 d 90 1 05 9d 14 14 aes 1 vd vl d Z181 z sead zz ve ald THE 0 82 134 SIM 1 ed 9 99 14 ZIR 0 89 430153 1105409 76 300N SnoNoHoOS 266 103135 40080 C3103NNOO ION G3193NNOO TWNOIS 2181 2181 66 19 ouo 01 14 14 TA O N39d O 10 19 o o xnv jo IO CONO 6 14 01 19 woo sed jm al LHM ze 81d 3 82d 1HM lt OZN
70. 584 518 9 zer L zer 304 1 zer va z zer za e zer 14 22 054 601 3 61M v96 8 SIN v Nid SNOIIO3NNOO 514 IWNOlLdO SNOILO3NNOO 9 L 584 918 4 054 8 H ved 01 Z 92089 v Nid 5 24 za Nid SNOILO3NNOO 601 21 S N OL SNOIIL23NNOO 814 540 814 204 ag 69 2 ZZN Za wed co ved 9 za Nid SNOILOJNNOO Zed SVO 99 098 ma 69 054 12 089 590 99 540 019 62 064 56 2 896 8 Zo ved 85 19 IHM 510 Old OW 8 ca osd v SNOIO3NNOO lt 14 SNOILO3NNOO 19 054 001 12 064 66 z 29 064 101 1 SNOIIO3NNOO 8d EIM N 18 054 SOL I SNOIIO3NNOO ld HM m re vid 134 Al TBA 2j TA 18 8 94 1 40 Z8 rd 804 a 2e3 30 7 sz vid 204 3NION3 SNOIIOJNNOO Old 10 18 SNOILO3NNOO Sd Hg ee me to ved NYO 13 ved
71. 9d 30010 C Nn INV1009 510 aisi A3WHO3SNvHI IN3NMMDO 19 330N3S 34065384 1000 589 WNOILAO Spl HONS 13421 INVIOOD 50 AMiIIVB LOW 043557 980 KINO 304 d3sn 13 20 21 Ayauya 20 21 G31SIML 81 Section 5 Wiring Diagrams 40EOZD C J and 33EFOZD C J Schematic Decision Maker9 3500 Sheet 1 of 2 Figure 5 4 TP 6861 10 14 YATIONLNOD 0052 YANVN NOISIOAC 3015 605 gt 18 N 3O1V33dO 30 Yd OW 30199340 MOION 3015 M3xv3MH 35070 i d AV 134 dll Otd 35010 ADV 8717B A 40EOZD C J and 33EFOZD C J Schematic Decision Maker 3500 Sheet 2 of 2 Figure
72. CRNT FAULT DELAY Hit Hs CB PHASE FAULT LIMIT Deg CB PHASE FAULT DELAY RAMP RATE HHS kW DISCONNECT LEVEL dH doo TRIMS ENABLE STATE LOAD ENABLE STATE SYSTEM LOAD CONTROL STATE SYSTEM SYNC CONTROL STATE STANDALONE MODE STATE SYNC MODE IN AUTO MODE SYNCMODEINRUN MODE DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH SYNCHRONIZING SETUP 12 00 AM SHARING SETUP 12 00 AM lt PROTECTIVE RELAYS 200 AM 12 00 AM GEN MANAGEMENT 12122 12 00 AM LOAD CONTROL 205 12 12 12 5 MODE IN RUN MODE SYNC MODE IN AUTO MODE CONNECTED TO BUS TRUE FALSE VOLTS Hz OK TRUE FALSE IN SYNC TRUE FALSE VOLTAGE MATCHED TRUE FALSE VOLTAGE MATCH WINDOW AVG BUS VOLTAGE L L dina AVG GEN VOLTAGE L L VOLTAGE MATCH P GAIN p VOLTAGE MATCH I GAIN di VOLTAGE MATCH D GAIN VOLTAGE BIAS FREQUENCY MATCHED TRUE FALSE FREQUENCY WINDOW 2 BUS FREQUENCY Hz GEN FREQUENCY Hz FREQUENCY MATCH GAIN FREQUENCY MATCH FREQUENCY MATCH D GAIN SPEED BIAS ate ae PHASE MATCHED YES NO PHASE MATCH WINDOW Deg PHASE DIFFERENCE Deg PHASE MATCH P GAIN HHHH PHASE MATCH GAIN PHASE MATCH D GAIN SPEED BIAS DWELL TIME 845 DWELL TIME REMAINING 645 FAIL SYNC TIME SYNC TIME REMAINING BUS PHASE ROTATION ROTATION GEN PHASE ROTATION ROTATION
73. HOL Nid 9 O smousswwoo 6 vid ss r vid A3118 A3118 vog dol LM 902 a04 1 4 HOL go IN cz vid VOL AINO ST300N 8N 8 81 4 vie Y Nid SNOUO3NNOO Zld 19v 020 24090 583 01 219 SNOILO3NNOO Vid NE voz vod L 133HS 819 OL S 199 wNOl1dO ce vid ouo ze vid Stl GM93788B A 40EOZD C J and 33EFOZD C J Wiring Diagram Decision Maker 3500 Sheet 2 of 3 Figure 5 2 79 Section 5 Wiring Diagrams TP 6861 10 14 GM93788C A YATIOULNOD 009 YIAYN NOISIOJA IVNOILdO v 1 13395 OL 1 Zd SSS d zi8l d Ovd ld 61M v8 OW ibhMBO 78 ET 1 14 vz zi8l doz 1 0 4 1 BIM e1 e181 1 Cvz zi81 S id ZV v8 40194340 SOLON 21 zi JO 458 6181 458 OOOH NS8 130 vNOI1dO OW 30193340 YOLON
74. High Engine Coolant Temperature Shutdown On Red AD D Open Circuit Engine Coolant Temperature Shutdown On Red D Shorted High 3 Engine Coolant Temperature Shutdown On Red D Shorted Low 4 Engine Coolant Temperature Shutdown On Red D High Lube Oil Temperature Warning On Yellow AD High Lube Oil Temperature Shutdown On Red D Low Engine Coolant Level Shutdown On Red D D Low Engine Fuel Level Warning On Yellow AD D Low Engine Fuel Level Shutdown On Red D D High Engine Fuel Level Warning On Yellow D D Critically High Engine Fuel Level Warning On Yellow D D Low Fuel Pressure Warning On Yellow AD D Low Fuel Pressure Shutdown On Red AD D Low Gen Battery Voltage Warning On Yellow D High Gen Battery Voltage Warning On Yellow D Low Cranking Voltage Warning On Yellow D Low Engine Oil Level Warning On Yellow AD D Low Engine Oil Level Shutdown On Red D D Low Generator Voltage L1 L2 Shutdown On Red D High Generator Voltage L1 L2 Shutdown On Red D Low Generator Voltage L2 L3 Shutdown On Red D High Generator Voltage L2 L3 Shutdown On Red D Low Generator Voltage L3 L1 Shutdown On Red D High Generator Voltage L3 L1 Shutdown On Red D Low Avg Gen Voltage L L Warning On Yellow D High Avg Gen Voltage L L Warning On Yellow D Low Generator Frequency Warning On Yellow D High Generator Frequency Warning On Yellow D Low Generator Frequency Shutdown On Red D High Generator Frequency Shutdown On Red D TP 6861 10 14 Section 1 Specifications and Fe
75. J 69 P1B 8 69 Open 37 P1B 5 37 25 P1B 2 25 TB12 PGEN YEL P1 P1B 4 P1 P1B 25 31A 1A TB12 1A 1 30 TB12 AUX 30 P2 14 Pin Connector Analog Digital Input and Relay Driver Output Connections Terminal Description Connection P2 1 87 P1B 20 P2 2 BSP Circuit Breaker Status TB13 BSP VBP Voltage Bias TB13 VBP SBP Speed Bias TB13 SBP CBO Circuit Breaker Open TB13 CBO BSN Circuit Breaker Status TB13 BSN VBN Voltage Bias TB13 VBN SBN Speed Bias TB13 SBN CBC Circuit Breaker Close TB13 CBC P2 10 5P P1B 7 P2 11 Open P2 12 7 P1B 18 P2 13 RD3 Relay Driver 3 TB13 12 P2 14 RD4 Relay Driver 4 TB13 13 P3 8 Pin Con nector Output Voltage and Paralleling Bus Voltage Sensing Connections Terminal Description Connection P3 1 A INSA without C B CBRK Line A with C B P3 2 B INSB without C B B with C B P3 3 Open P3 4 L3 Bus Voltage Sense TB13 L3 P3 5 C INSC without C B CBRK Line C with C B I3 P26 5 P3 6 NEU INSLO l1 P26 1 11 Open or 5 40EOZD C J 33EFOZD C J or P1B 17 5 40EOZD C J 33EFOZD C J BGA P1B 27 BGA Open
76. Level Management Frequency OK Dropout 44 4 Hz Gen 96 of Rated kW Fuel Level Volts Hz OK Delay 5 kW Sharing P Gain Stable Delay s First On Delay s kW Sharing l Gain Minimum Gens Online Fail To Open Delay s kW Sharing D Gain O Min Loads Added Speed Bias Stopped By Gen Mgmt Fail To Close Delay s Reclose Delay s Max Close Attempts CB Current Fault Limit CB Current Fault Delay s CB Phase Fault Limit CB Phase Fault Delay s kW Ramp Rate s kW Disconnect Level Trims Enable ON OFF Load Enable ON OFF System Load Control ON OFF System Sync Control ON OFF Stand Alone Mode ON OFF Sync Mode In Auto INVALID OFF PASSIVE CHECK System Frequency Hz TRUE FALSE Gen Frequency Hz Load Control Freq Trim P Gain Gen Max Cap Freq Trim Gain Gen Overload 96 Freq Trim D Gain s Bias 4 Controller Configuration Freq Droop at 100 kw Menu Bus of Rated Controller Configuration Gen of Rated kVAR o Lan ieh guage English kVAR Sh P Gain ARIO N Units Metric English KVAR Sharing Gain Time Format 12 24 kVAR Sharing D Gain Voltage Bias Date Format Month Date Year System Voltage L L V Date Month Year AVG G
77. NOISIO3A LLL8 AOV 33S OLVW3HOS 403 91M ZN atd 01 Bid 01 ma cz 8id VOL 1 v 81d e Ged OZN IZM ZNYL ZAC E 6 vd 93 904 EZ T3 s 0 d 304 m vd 9 2181 Sd 9 79 93 2 G zi8 4 14 mg 4 5 ma 13305 01 v gt 8 14 01 rd 93 14 13 95 19 940 42 18 01 14 6 14 BA 11 19 x18 21 14 2181 404 1 ld ld 4015 3 310N3M 2 14 vi Gi id 1 91 91 19 4 05908 SL WNOLLdO Ol EZM Ni389 9 OZN MOTA GA FIM Wf 5 SEd LEM c id N NZ 2181 NL 1 94 85 3AOW33 9015 1915 310W3N 10 49480 1v SUNN NO 20 ri zd zi zd cau z zd asa 9 Nsa Z r zd 485 8 4 Nas 6 24 089 140 0W tiN80 458 130 8 NSB z ovd z ivd 9 27 17 6 24 280 rea 1 zi a 0 6 11 S N S N Nu SIM 904 ce 8id
78. OL Sd 2181 6 24 z 0vd 089 5 d lt z ivd 6 0 1 8 337105105 0066 9230 S 8ld 8 181 989 1 NES NBA 181 58 181 985 181 485 98 181 458 181 458 G 8id ds 5 21 181 11 6181 2 5 1 181 8 2 85 8 2 SNOIIO3NNOO d Hf Lit S 0206000000000 OOOO er L 5 ld Lit SNOILO3NNOO id ZNOOD C ZZM LHM 9 84 ouo 8 14 60 6 TA 6 14 13 yea a 24050 HM NOILONNT LLM LHM LIM 82 14 LIM 4 14 LIM 62 14 g avo1 uyugo 21 1 17
79. Precautions TP 5620 Installation Manual TP 6862 Service Manual Generator TP 6863 Parts Catalog TP 6864 Operation Manual Engine TP 6444 TP 6889 Service Manual Engine TP 5854 Service Manual Fuel System Engine TP 6829 TP 6830 TP 6454 Modbus Communications Protocol Operation Manual TP 6113 SiteTech Software Operation Manual TP 6701 ncludes the generator and engine information Literature Type Specification Sheet Pleasure Craft Models EOZDJ EFOZDJ Specification Sheet Commercial Models EOZCJ EFOZCJ Pleasure Craft Models 80EOZDJ 99EOZDJ 125EOZDJ 150EOZDJ 70EFOZDJ 80EFOZDJ 100EFOZDJ 125EFOZDJ Commercial Models 80EOZCJ 99EOZCJ 125EOZCJ 150EOZCJ 70EFOZCJ 80EFOZCJ 100EFOZCJ G2 166 125EFOZCJ Marine Safety Precautions TP 5620 Installation Manual TP 6862 Service Manual Generator TP 6863 Parts Catalog TP 6864 Operation Manual Engine TP 6889 Service Manual Engine TP 5854 Service Manual Fuel System Engine TP 6456 Modbus Communications Protocol Operation Manual TP 6113 SiteTech Software Operation Manual TP 6701 ncludes the generator and engine information Figure 1 2 Generator Set Literature 12 Maintenance and Service Parts Related Literature TP 6861 10 14 Section 1 Sp
80. Remaining The remaining time before the controller issues a Failure to Synchronize warning The Failure to Synchronize warning will cause the generator management to consider this generator unreliable and to start another generator if available If the system commissioning has been performed properly this warning should only occur if the system is overloaded or if there is a malfunction on this generator This value is only populated when the generator is actively synchronizing Sync Mode Active breaker is open generator is running Note Dwell Time Remaining and Sync Time Remaining are not supported on all firmware versions If the controller firmware does not support the time remaining parameters they will be populated with N A 28 Section 1 Specifications and Features Sharing Setup Bus of Rated kW The ratio of the total load on the bus sum of the loads on all connected generators to the total bus capacity sum of all the connected generator capacities expressed as a percentage This value can be monitored to determine system loading also found on Bus Metering screen and Generator Management screen Gen of Rated kW The ratio of the total load on this generator to its rated capacity expressed as a percentage This value can be compared to the Bus of Rated kW directly above it to determine if the system is sharing load properly The acceptable difference between the generator and bus is site dependent The
81. Remove the battery cables negative lead first Reconnectthe negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch TP 6861 10 14 WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Disconnecting the electricalload Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions i
82. Sd TIA 0 824 BA 0 8 NYO 2 14 TBA 14 940 2 14 01 14 6 14 134 1 18 O N39d jo N30d lo No woo sea WEZZE ZZM 1HM ze 8id LHM 3 87d 1HM OZN TIM 2 LIN 21 14 92 14 1 19 00000 L 91N 2 ZIN v 91M 91 19 91 814 18 1 21 819 616 IZM SNL 91M N NL Z181 NL 91 819 116 00000000 4015 3 SLOWSY 804 SAOWSY 4015 1 91 310W3N 2181 335 24 dan 4 24 das 8 24 6 24 4 6 24 280 J r 6S N9 OMG 335 184 98 815 OL 140 8 458 9 29 1 27 4 110 0 5 480 NSA z 0vd 2 1 080 9 0 01 5 580 1 5 8 avo1 uyugo 21 99 avo 1 354880 11 LiM 82 14 LIM 41 14 SIM 304 S N c1 1d 04 IN 9 SNOILO3NNOO Ord 6 814 S N 0 19 14 ZIN 9 5 Nn sn ue
83. Service Log Use the Operating Hour Service Log located in the back of this manual to document performed services Service Schedule Perform maintenance on each item in the service schedule at the designated intervals for the life of the generator set For example an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6 months 300 hours or 9 months and so on TP 6861 10 14 3 3 Generator Set Service Schedule Note Have maintenance work including battery suitably trained maintenance personnel familiar service performed by appropriately skilled with generator set operation and service Action System Component Visually Inspect Check Change Interval Fuel System Drain water from fuel filter Before operation Flexible lines and connections Weekly Solenoid valve operation Weekly Transfer pump operation Weekly Replace fuel filter elements Yearly or 500 Hrs Fuel piping Yearly Return lines for obstructions Yearly Bleed fuel system As required Lubrication System Check oil level Before operation Change oil First 50 Hrs Then Every 250 Hrs or Replace filter s 6 months Crankcase breather Quarterly Replace crankcase filter if equipped Yearly or 500 Hrs Clean crankcase ventilation system if equipped Yearly or 500 Hrs Cooling System Check the seawater outlet and clean as necessary Daily Check coolant level Before opera
84. ZIN 2181 v IZM e 1d N 21 14 31033 92 14 vi vL L 91M 91 19 4 91 819 01 819 6 SAOWSY 4015 1015 310W3N 196 NZ Zi8I 1 99 1 1 81M OZN SIM NOTIS 3A 2 if c 81d 1 818 oz aid 02 819 1 24 s 9zd xnv ziei vi zial sz B8id 1 1 z 8id 8 81 81 814 9 4 lt 2181 1 218 lt Noo Z 181 woo z18l nvo z 181 1 1 EZM vem 2 94 91M c eza te v9 18 S N gl oc 1 69 S N L 71 0L 038 we NYO 134 S N 9 134 ac N Lit SNOILO3NNOO id PZM MOTHA SNOILO3NNOO Ged Sed QNvO8 AVI3M Gl T VNOILdO OL si 81d 116 0 116 11 819 186 0 6 1 2 o 505 INNHO 2181 335 NO OGAZ 5 u3aworsno 1 LINN 91M NL gt suadnne Sim O OL IM 81 4 2181 1 vau 1 24 458 9
85. contact board provides an additional four digital inputs and two analog inputs For specific information on accessory connections refer to the accessory wiring diagrams in the wiring diagram manual and the instruction sheet accompanying the kit See Figure 7 4 for controller circuit board connections Circuit Board Connections see Figure 7 1 Consult the wiring diagrams in Section 5 for more detail and model specific information e 35 Pin Connector for engine generator wiring harness e P2 14 Pin Connector for sensor input connections and relay driver output connections e P3 8 Pin Connector for generator set output voltage connection and paralleling bus voltage sensing connections e P4 Ethernet RG 45 Connector connects to a network communication line DEC 3500 Controller Figure 7 2 e Mini USB Connector for connection of a PC with SiteTech software programming or for firmware updates TB12 Terminal Strip see Figure 7 3 for CAN PGEN remote emergency stop and remote start connections Consult the wiring diagrams in Section 5 for more detail and model specific information Front Panel see Section 7 Accessories 107 P1 CONNECTIONS PN 1 71 P23 3 25 N W16 1 52566 9553 va Wy 00006 6992 san n2 06055 6026660076006 14 T24 AMP 357 YEL TB12 CAN GRN 812 P2 CONNECTIONS BLK TB12 COM P3 CONNECTIONS MERE RED TB12 COM 4 PIN 1
86. 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 6 2 Procedure to Drain Cooling System For optimum protection drain flush and refill the cooling system at the intervals listed in the service schedule Note Dispose of all waste materials oil fuel coolant filters and gaskets in an environmentally safe manner 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 4 If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease refer to Section 3 6 3 Procedure to Flush and Clean the Cooling System If the cooling system does not have mineral deposits go to Section 3 6 4 Procedure to Refill the Cooling System 66 Section Scheduled Maintenance 3 6 3 Procedure to Flush and Clean Cooling System 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 cooling system with clean water 2 If the inside of the radiator still has mineral deposits use a radiator cleaner to r
87. fault lamp illuminates yellow and the alarm horn sounds when the engine high oil temperature approaches the shutdown range High Max Close Attempts The fault lamp illuminates yellow and the alarm horn sounds when the circuit breaker did not close even after the controller attempted to close it as many times as specified by the max close attempts Invalid Generator Management Enabled The fault lamp illuminates yellow and the alarm horn sounds when the generator management has been disabled because the generator management configuration of this generator does not match the generator management configuration of another generator that is connected to the same PGEN network The local display shows Generator Management Invalid Genset Voltage Phase Connection The fault lamp illuminates yellow and the alarm horn sounds when another generator in the paralleling system has a different phase connection than this generator The local display shows System Phase Low Battery Voltage The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below a preset level for more than 90 seconds Engine Electrical Low Battery Low Battery Voltage System Voltage Voltage Range Default Setting 12 9 6 12 6 12 24 19 2 25 2 24 Figure 2 5 Low Battery Voltage Specs The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes The controller logic inhibit
88. indicated Overfrequency displays the percentage of the system frequency that the generator frequency must exceed for an overfrequency condition to be indicated Underfrequency displays the percentage of the system frequency that the generator frequency must drop below for an under frequency condition to be indicated Overspeed displays the engine speed that the engine must exceed for an overspeed condition to be indicated Low Battery Voltage displays the system battery voltage that the battery voltage must drop below for a low battery voltage condition to be indicated High Battery Voltage displays the system battery voltage that the battery voltage must exceed for a high battery voltage condition to be indicated TP 6861 10 14 1 9 4 Voltage Regulation Submenu Note Have setup and adjustments of the Decision Maker 3500 controller performed only by an authorized Kohler distributor dealer The setup and adjustments are password protected The Decision Maker 3500 controller has a built in voltage regulation function This means that no external voltage regulator is necessary The voltage regulation of the controller uses Root Mean Square RMS sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy The descriptions of the voltage regulator adjustments and features follow Voltage Adjust The voltage adjust allows the user to enter the desired generator set
89. it is warm and refill the radiator to purge the air from the system before energizing the block heater Drive Belts Check the belt condition and tension of the water pump and battery charging alternator belt Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections TP 6861 10 14 Section 2 Operation Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and exhaust outlet for cracks leaks and corrosion e Check the hoses for softness cracks leaks or dents Replace the hoses as needed e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps 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 e Ensure that the carbon monoxide detector s is 1 in the craft 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the o
90. only The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel models approaches full This fault requires an optional critical high fuel switch and fuel tank for the lamp to function ECM Diagnostics Multiple Engine Inputs The fault lamp illuminates yellow and the alarm horn sounds when ECM diagnostics signals the controller The specific display xxxxx will be a brief message or fault code that is engine manufacturer dependant The engine literature provides the fault code description and further information Failure to Synchronize The fault lamp illuminates yellow and the alarm horn sounds when the generator set does not successfully synchronize to the live bus within the time delay as defined in the synchronizing setup menu The controller will continue attempting to synchronize to the bus after the time delay expires and the warning occurs Generator Management will start another generator set if this warning occurs Fuel Tank Leak The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank signals a leak of the inner tank This fault requires an optional fuel tank leak switch for the lamp to function Generator Frequency High The fault lamp illuminates yellow and the alarm horn sounds when the generator has an overfrequency condition The output breaker trips This condition can be caused by various mechanical failures loss of speed signal to ECU improperly controlled
91. 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 6861 10 14 Accidental Starting WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery 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 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Engine Backfire Flash Fire WARNING Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the fuel system A flash fire can cause severe injury
92. or death Do not smoke or permit flames or sparks near the fuel injection system 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 fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer removed Combustible materials A fire can cause severe injury or death Generator set engine 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 fire extinguisher operation fire prevention procedures Safety Precautions and Instructions 5 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but a
93. or inadvertent injection of gaseous fuel etc TP 6861 10 14 Generator Frequency Low The fault lamp illuminates yellow and the alarm horn sounds when the generator has an underfrequency condition The output breaker trips Generator Total Real Power High The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters excessive load or a downstream fault The output breaker trips Generator Total Real Power Low The fault lamp illuminates yellow and the alarm horn sounds when the generator is no longer producing power loss of fuel bearing failure fuel system failure ECU problem or speed bias connection failure on non ECM engines The output breaker trips Ground Fault Input The fault lamp illuminates yellow and the alarm horn sounds when a user supplied ground fault detector signals the controller High Battery Voltage The faultlamp illuminates yellow and the alarm horn sounds when the battery voltage rises above the preset level for more than 10 seconds Figure 2 4 shows high battery voltage specifications The high battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes Engine Electrical High Battery High Battery Voltage System Voltage Voltage Range Default Setting 12 13 2 16 2 15 24 26 4 32 4 30 Figure 2 4 High Battery Voltage Specs High Coolant Temperature The fault lamp illuminates yellow and the alarm horn sounds
94. output level The voltage regulator controls the average of the three output phase voltages to this target in a three phase configuration and L1L2 voltage to this target in a single phase configuration Submenus display the individual line to line voltages and the individual phase voltages These voltages are for reference only and are relevant in unbalanced load conditions The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system Target Voltage The voltage that the Decision Maker 3500 controller is trying to achieve including droop and parallelling bias Volts Hz The excitation control system includes an under frequency unloading feature This is sometimes referred to as Volts per Hertz or V Hz When the frequency drops below a certain value the output voltage is reducedto decrease engine load allowing the engine speed to recover more quickly The output voltage reduction is based on the frequency Volts per Hz Settings The amount of voltage reduction can be adjusted to achieve the desired transient response ofthe engine andalternator system The V Hz function will use the following parameter settings e V Hz Setpoint Hz e V Hz Slope Hz e V Hz reduction limit fixed at 5096 of rated voltage Volts per Hz Adjustment The V Hz settings can be changed using the PC based setup program or at the front panel using the password The setup program will read current settings to de
95. pressed Note Additional alarm silencing options are shown in Section 1 10 Controller Configuration Menu Restore alarm horn switches at all locations including those on remote annunciator kits after correcting the fault shutdown to avoid reactivating the alarm horn See Section 2 Operation 2 6 6 Controller Resetting for resetting the controller Emergency Stop The operator activated pushbutton immediately shuts down the generator set emergency situations Reset the emergency stop switch after shutdown by pulling the emergency stop switch outward Use the emergency stop switch for emergency shutdowns only Use the master control switch OFF RESET button for normal shutdowns Generator Set Master Control OFF RESET AUTO RUN These buttons reset the controller fault lamps and start stop the generator set Additional information in shown in Section 2 Operation Lamp Test Press and hold the Alarm Silence Lamp Test button to test the controller indicator lamps alarm horn and digital display TP 6861 10 14 Pushbutton Rotary Selector Dial This control provides access to the menus for monitoring Press the selector dial to activate the graphical display and to select choices shown on the display Rotate the dial to navigate through the menus The pushbutton rotary selector dial has several features and functions e Momentarily press the dial to activate the graphical display if dark e Rotate the dial to navigat
96. rate Choose the same baud rate for the Modbus master modems and connected devices See Figure 1 9 Each generator set controller must have a unique Modbus address and PGEN node number 1 4 Note The PGEN node number is automatically determined The number of nodes online should match the number of installed generators TP 6861 10 14 1 10 3 Calibration Submenu The calibration values are reviewable at all times and provide the calibration of the voltage and current sensinglogic Changingthe system voltage or replacing the circuit board requires a calibration adjustment Note Have calibration adjustments performed by an authorized Kohler distributor dealer To enable calibration when the line is highlighted push and hold the pushbutton rotary selector dial to enable the calibration capability The user is prompted with a Yes No prompt for calibration The display will show the following Gen 11 10 Volts Gen 12 10 Volts Gen 13 10 Volts Gen L1 L2 Volts Gen L2 L3 Volts Gen L3 L1 Volts Gen L1 Current Gen L2 Current Gen L3 Current Bus L1 L2 Volts Bus L2 L3 Volts Bus L3 L1 Volts Reset Gen Volt Meter Yes No Reset Gen Amp Meter Yes No Reset Bus Volt Meter Yes No Reset All Meters Yes No TP 6861 10 14 The user can change individual values or can select the individual Reset to reset certain values The Reset selections will only show if calibration is enabled Refer to the requirements
97. set has started and is running Load Priority Shed This status message indicates the digital output for load priority 1 2 3 4 5 or 6 shed is active contacts closed indicating the 151 279 379 4th 5th or 6th priority load shed has been activated Remote Start This notice indicates that the generator set start circuit was closed from a remote location allowing the engine to crank and run The remote location is typically a set of contacts a transfer switch or remote start switch Remove Breaker Trip This notice message indicates that the controller considers the breaker to be safe to close The breaker may be closed or preparing to close when this notice is displayed This notice only appears in paralleling applications where the bus sensing is connected to the bus side of the paralleling breaker Run Button Acknowledged This notice message indicates thatthe RUN button on the controller has been pushed System Ready This status indicates thatthe generator setis inthe AUTO mode and available to start if the start circuit is closed Section 2 Operation 51 2 6 6 Controller Resetting Following System Shutdown or Warning Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition This procedure includes the resetting of the optional remote annunciator Refer to Section 2 6 1 Emergency Stop to reset the generator set after an emergency stop
98. system are identical between all controllers e No generators have recently failed Load control has added priorities through the Min Loads Added Threshold e The generator management order is valid Once active generator management will only go inactive if e A generator fails shuts down with either a fault or user input All generators are disconnected from the bus The Start Signal is removed Generator Management is disabled The configuration on any controller on the network is changed by a user e The order becomes invalid All the generators in the system must have the same setting for the stable delay for the generator management to operate If this parameter is changed it will be updated on all the generators which are connected to the PGEN network Minimum Gens Online Generator Management will always try to keep this many generators online even if they are not needed All the generators in the system must have the same setting for the Minimum Gens Online for the generator management to operate If this parameter is changed it will be updated on all the generators which are connected to the PGEN network The purpose of this setting is to allow configuration to support large transient loads or potential generator failure N 1 redundancy 32 Section 1 Specifications and Features Note Only 1 and 2 Minimum Gens Online is supported at this time Min Loads Added The Load Shed priority that must be online
99. the date when the generator set last operated Last Run Length displays the length of time that the engine ran the last time it was started via the generator set controller Controller Serial No displays the controller serial number Software Version displays the software version number Use the version number to determine ifan upgrade is needed and or when troubleshooting the controller ECM Serial No displays the ECM serial number Genset Model No displays the generator set model number Only adjustable from SiteTech Genset Spec No displays the generator set specification number Only adjustable from SiteTech Genset Serial No displaysthe generator set serial number Only adjustable from SiteTech Alternator Part No displays the alternator part number Only adjustable from SiteTech e Engine Part No displays the engine part number Only adjustable from SiteTech Engine Model No displays the engine model number Only adjustable from SiteTech Engine Serial No displays the engine serial number Only adjustable from SiteTech 1 9 2 Event History Submenu Generator Event History This menu allows the userto review upto 1000 entries of generator system events including shutdown faults warning faults notices and status events with date and time stamp See 1 11 1 Controller Fault Diagnostics for a list of the items that appear on the Generator Event History Engine Event Log A mes
100. when the engine coolant temperature approaches the shutdown range The high coolant temperature warning does not function during the preset inhibit time delay period after startup High Fail To Close Delay The fault lamp illuminates yellow and the alarm horn sounds when the circuit breaker did not close within the allocated breaker closure time High Fail To Open Delay The fault lamp illuminates yellow and the alarm horn sounds when the circuit breaker did not open as quickly as the controller expected High Fuel Level diesel powered models only The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel models approaches near full This fault requires an optional high fuel switch and fuel tank for the lamp to function TP 6861 10 14 High Genset System Frequency The fault lamp illuminates yellow and the alarm horn sounds when another generator in the paralleling system has a lower system frequency than this generator The local display shows System Frequency FMI High High Genset System Voltage The fault lamp illuminates yellow and the alarm horn sounds when another generator in the paralleling system has a lower system voltage than this generator The local display shows System Voltage FMI High High Intake Air Temperature The fault lamp illuminates yellow and the alarm horn sounds when the engine intake air temperature approaches the shutdown range High Lube Oil Temperature The
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102. 05 IN d lid Ive Q3snd vl vd M u3wod vB dasn4 L1 vd ZZ0 Z20 8 8zd 5 Bea 2 ovid 824 03 Ved za ved 91d TP 6861 10 14 Figure 5 19 80 99EOZD C J and 70 80EFOZD C J Schematic Decision Maker 3500 Sheet 1 of 2 96 Section 5 Wiring Diagrams 3311O31NOO 006 5193 3015 605 M18 N 30193330 30101 10 lyd 0 OW YOLWYSdO YOLOW 3015 avo M3Mv3H8 Q31NnOW LINR 39010 GA AVI did 074 Lal 35010 ADV 8720B A Figure 5 20 80 99EOZD C J and 70 80EFOZD C J Schematic Decision Maker 3500 Sheet 2 of 2 97 Section 5 Wiring Diagrams TP 6861 10 14 005 51230 e 8 82a 12 218 116 2181 359 LLM TA JHM ze Le S N oc S N 6z S N z 204 9 S N vc S N S
103. 1 Disconnect the generator set load using the line circuit breaker or automatic transfer switch 2 Correctthe cause of the fault shutdown or warning See the Safety Precautions and Instructions section of this manual before proceeding 3 Start the generator set by pressing the generator set OFF RESET button and then press the RUN button When equipped the remote annunciator alarm horn sounds Press the ALARM SILENCE LAMP TEST button to stop the alarm horn The lamp turns off 4 Test operate the generator set to verify correction of the shutdown cause 5 Press the generator set OFF RESET button to stop the generator set 6 Press the generator set AUTO button 7 Silence the controller alarm horn by pressing the ALARM SILENCE button 8 Reconnectthe generator set load via the line circuit breaker or automatic transfer switch 9 When equipped the remote annunciator alarm horn sounds Press the ALARM SILENCE LAMP TEST button to stop the alarm horn The lamp turns off 52 Section 2 Operation 2 7 Menu Displays Use the Menu Summary List and Figure 2 10 after reading and understanding the features of the pushbutton rotary selector dial See Section 1 7 3 Digital Display The Menu Summary List and Figure 2 10 provide a quick reference to the digital display data Some digital display data may not be identical to your display due to generator set application differences The closed bullet items represent main level
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105. 2 Operation 2 3 Angular Limits During Operation See Figure 2 1 for angular operation limits for units covered in this manual Intermittent Model Continuous 3 minutes or less 40EOZD C J 33EFOZD C J 20 30 40EFOZD C J 50EFOZD C J 55 65EOZD C J 45 55EFOZD C J 80 99EOZD C J 70 80EFOZD C J 125 150EOZD C J 100 125EFOZD C J 25 Maximum value directions Figure 2 1 Angular Limits During Operation 2 4 Operation in European Union Member Countries This generator setis specifically intended and approved for operation belowthe deckinthe engine compartment Operation above the deck and or outdoors would constitute a violation of European Union Directive 2000 14 EC noise emission standard 2 5 Load Profile Whenever operating the generator set Kohler Co recommends maintaining the minimum load profile indicated in Figure 2 2 Maintaining the load profile prevents corrosion formation on internal engine components when they re exposed to the breakdown of exhaust gases Extended light loading may result in engine wet stacking Minimum Ideal Load Requirement Load Requirement 30 load 70 load or more Figure 2 2 Load Profile Wet Stacking occurs when water vapor condenses in the exhaust system At normal combustion temperatures water stays vaporized but at low combustion temperatures it condenses back to a liquid When running the generator set under normal loads 30 lo
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107. 25EOZDJ 125EOZCJ 150EOZDJ 150EOZCJ 70EFOZDJ 70EFOZCJ 80EFOZDJ 80EFOZCJ 4045AFM85 100EFOZDJ 100EFOZCJ 125EFOZDJ 125EFOZCJ 6068AFM85 Air Filter Element GM87479 GM90310 Belt Alternator and Seawater Pump GM88686 GM88686 Fuel Filter Element Primary Standard GM48729 Fuel Filter Element Secondary Standard GM48730 Fuel Filter Element Primary with 3rd Party Option Fuel Filter Element Secondary with 3rd Party Option GM50263 GM50263 Oil Filter GM32809 GM32809 Seawater Pump Impeller Kit GM18793 GM18793 Zinc Anode Includes primary and secondary fuel filter element Figure 1 1 TP 6861 10 14 Maintenance and Service Parts 352142 352142 Maintenance and Service Parts Related Literature 11 Related Literature Figure 1 2 identifies related literature available for the generator sets covered this manual Only trained and qualified personnel should install or service generator set the Pleasure Craft Models 40EOZDJ 33EFOZDJ 40EFOZDJ 50EFOZDJ 55EOZDJ 65EOZDJ 45EFOZDJ 55EFOZDJ Commercial Models 40EOZCJ Literature Type Specification Sheet Pleasure Craft Models EOZDJ EFOZDJ Specification Sheet Commercial Models EOZCJ EFOZCJ 33EFOZCJ 40EFOZCJ 50EFOZCJ G2 169 55EOZCJ 65EOZCJ 45EFOZCJ 55EFOZCJ Marine Safety
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109. 87 1 20 70 p30 3 PIN 1 INSA WITHOUT C B u BSP 1 CBRKR LINE A WITH C B VBP 12 3 INSB WITHOUT C B SBP TB13 SBP 3500 CONTROLLER IR 17 CBRKR LINE B WITH TB13 CBO 2 P26 3 BSN TB13 BSN N C VBN TB13 VBN 4 INSC WITHOUT SBN me co WITH CBC 813 37 P1B 5 INSLO TB13 L1 MG e IM 813 12 7 PIB 18 PMERNET 1 W14 1813 12 P18 25 TB13 13 TB12 1A 30 TB12 AUX I 26 5 P26 1 N C 1 27 64 18 1 31 P1B 3 1B12 PGEN P1 A TB13 13 GM85936A E Figure 7 1 Main Circuit Board Connectors Typical Back of DEC 3500 Controller See Wiring Diagrams See Wiring in Section 5 Diagrams in Section 5 P W19 PS w14 I 70A W15 ADD JUMPERS ON 4 24V UNITS WITH 7N 7N W16 ane ta 24VDC ON 12V UNITS 24V OJ A1 CBRKR MO A1 937 O4 937 1 11 SOC GO 911 911 P1B 15 947 01 947 P18 10 O1 714 18 16 Q1 3 P1 15 O1 O1 KOHLER EMERGENCY uiv SEE TB12 CHART REMOTE START STOP 4 416 REMOVE JUMPER y awe fo 1 1 14 FOR 14 O 1A 1 26
110. ADV 8718B A Figure 5 10 40EFOZD C J and 50EFOZD C J Schematic Decision Maker 3500 Sheet 2 of 2 87 Section 5 Wiring Diagrams TP 6861 10 14 SIM JUHM TIA 8 824 12 2181 LLM IHM Z 116 2181 IZM Ig 3 S N of S N 62 S N 82 18 19 2 Sim 902 92 62 14 vie S N 2 S N ez S N S N 18 02 S N 6l 18 166 2180 6 1 1 2 19 1 14 22 14 ce ia SNOIIO3NNOO Eld ONOS M QION3 OS N3lNVIS SS 314915 WS 031 ANVNOLIVIS 815 MOSN3S 3 066344 TWNINSAL 193NNOO AONO NOID 7081409 Add HOLMS 3MnivH3dW3l 10 510 HONS 10 540 MOSN3S HOLIMS 5 vds HOLIMS 13 31 300 MOT 101 HOLIMS T3A31 1 1002 n AVT F 340059415 GALLVINSNI OSNI OSNI BSNI VSNI sna qQ3lvloSl 891 MOSN3S dil 3nd 13 1304 vili 7051409 TANA Oli M3ON3S 3HnlVH3dWil 3NION3 513 GNNOYD 4001 983 MOS
111. EL THRESHOLD FUEL LEVEL STABLE DELAY MINIMUM GENS ONLINE MIN LOADS ADDED STOPPED GEN MGMTRUE FALSE GEN MAX CAP IGEN OVERLAOD HH Figure 2 12 Generator Information Menu TP 6861 10 14 Section 2 Operation 57 12 00 AM 12 12 12 CONTROLLER CONFIG CONFIGURATION COMMUNICATION SETUP CALIBRATION DIAL TURN DIAL PUSH DIAL PUSH DIAL PUSH CONTROL CONFIG 12 00 AM 12 12 12 12 00 COMM SETUP 1200AN 12 00 AM CALIBRATION 12 12 12 LANGUAGES ENGLISH UNITS METRIC LANGUAGE UNITS TIME FORMAT DATE FORMAT DATE TIME CONTRAST ALARM SILENCE LANGUAGE UNITS TIME FORMAT DATE FORMAT ALARM MODBUS BAUD RATE MODBUS ADDRESS PGEN BAUD RATE PGEN NODE ID PGEN NODES ONLINE PGEN NODES OFFLINE M RATE RATE HHH ENGLISH 11 10 VOLTS 12 10 VOLTS GEN L3 LO VOLTS GEN L1 L2 VOLTS GEN L2 L3 VOLTS GEN L3 L1 VOLTS GEN L1 CURRENT GEN L2 CURRENT GEN L3 CURRENT BUS L1 L2 VOLTS HRV HHA HV HHH AV A A A TIME FORMAT 12hr 24hr DATE FORMAT mm dd yyyy dd mm yyyy BUS L2 L3 VOLTS HRV BUS L3 L1 VOLTS HHH HV RESET GEN VOLT METER YES NO RESET GEN AMP METER YES NO RESET BUS VOLT METER YES NO RESET ALL METERS YES NO ALARM ALWAYS AUTO ONLY Fig
112. FREQUENCY AVG CURRENT AIR F GEN FREQUENCY Hz L1 POWER kW L2 POWER kW L3 POWER kW A Hz TOTAL POWER kW GEN OF RATED kW n Alternates every L1 REACTIVE POWER kVAR 8 seconds L2 REACTIVE POWER kKVAR SYSTEM STATUS 12 00 AM L3 REACTIVE POWER kVAR 12 12 12 TOTAL REACTIVE POWER kVAR FUELPRESSURA TOTAL POWER TOTAL BUN L1 APPARENT POWER kVA L2 APPARENT POWER kVA L3 APPARENT POWER kVA TOTAL APPARENT PWR kVA GEN OF RATED kVA 11 PSI HRS L2 PF L3 PF TOTAL PF GEN PHASE ROTATION XXX Figure 2 11 Metering Menu 56 Section 2 Operation TP 6861 10 14 12 00 AM 12 12 12 GENERATOR INFO GENERATOR INFO EVENT HISTORY CONFIGURATION VOLTAGE REGULATOR VOLTAGE SELECTOR SWITCH See Note Note Voltage Selector Switch menu PARALLELING OPERATION options do not apply to these mod els DIAL TURN DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH 12 00 3 1220 CONFIGURATION 12 00AM VOLT REG CONFIG 12 00AM AM 2 12 12 12 12 1121272 gt GENERATOR CONFIG gt AVG GEN VOLTAGE L L VOLTAGE ADJUST PROTECTIVE CONFIG HAV i hrs_ TARGET VOLTAGE i kWh L1 L2 VOLTS HEHN it hrs L2 L3 VOLTS TOTAL STARTS nnn L3 L1 VOLTS LAST MAINTENANCE GEN
113. FREQUENCY duci OP HRS SINCE MAINT hrs V Hz SETPOINT ENG HAS SINCE MAIN VOLT DROOP AT 100 KVAR HEHE ENGHRSSINCEMAINT hrs LOADED SINCE MAINT hrs DIAL TURN DIAL TURN VOLTAGE GAIN ADJUST UNLOADED SINCE MAINT hrs START UP RAMP RATE kW HRS SINCE MAINT RESET REG DEFAULTS YES NO kWh RESET MAINT RECORDS DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH LAST RUN LENGTH W209AM lt TI200 AM A GENERATOR CONFIG 3 4 lt PROTECTION coNFIG 2 ethrs CTRL SERIAL XXX0000000 SOFTWARE VER XXXXXXXXXX ECM SERIAL XXXXXXXXXX GENSET MODEL XXXXXXXXXX GENSET SPEC GENSET SERIAL ALT PART XXXXXXXXXX 12 12 12 12 12 12 12 12 12 ENGINE PART XXXXXXXXXX gt OPERATING MODE MODE OVER VOLTAGE ENGINE MODEL XXXXXXXXXX APPLICATION TYPE APP TYPE OVER VOLTAGE ENGINE SERIAL XXXXXXXXXX SYSTEM VOLTAGE L L OVER VOLTAGE DELAY Hits SYSTEM FREQUENCY Hz UNDER VOLTAGE SYSTEM PHASE PHASE UNDER VOLTAGE ENGINE SPEED RPM UNDER VOLTAGE DELAY ENGINE SPEED ADJUSTMENT FREQUENCY ADJUSTED ENGINE RUN OVER FREQUENCY Hz kW RATING UNDER FREQUENCY KVA RATING kVA UNDER FREQUENCY Hz RATED CURRENT A OVER SPEED t Hz GENERATOR INFO TOTAL RUN
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115. N oc ld 5 59 S N ul 0L 038 TA S N TA Be N S N 8 MOTTA SNOILO3NNOO 91M z sed E a eus TUA B 0 824 19 9 EZM ZUM 2 s 1d 980 tO NOILO3NNOO N39d 12 19 o 01 19 6 14 lo sed LHM ZZM LHM 1 12 woo 9015 3 26 814 LHM 1HW 9 OZN IZM NFL LN 91 ZIN la N IZM INFE 21 19 ALOW3Y 2 14 vi 1 L 91M lo 91 819 i 303 4 15 1 1 310N3N NZ ZLBL NL 1 94 INL NYO 91M ON MOTTA A 2 PIM 1 SNOIIO3NNOO Sed 08908 Gl WNOLdO OL 01 814 L6 91 818 116 0 116 05505 11 919 186 0 156 1 0 1v 81M Cz 2181 335 SUINN AZL NO OGAbZ 53104509 SLINA P NO sN3dWnn 91M NL SIM voc O
116. N S N 2 64 01 69 940 SNOIIO3NNOO 21 69 S N ZNN 1 N TIN 1HM 11 0 46 S N S N S N 116 ZL Ayauya ZL A318 WS Tm ss 6 Vid SrL v vzd Id S N 1 S N v3 S N a S N 23 S N 13 S N ex S N 0 1002 1 SNOILO3NNOO 194 8 vog og 508 QNhnON9 93191051 1002 cep ld doz ta vh S N er 9 zr S N S N 19 ol wid v6 v8 H S N 06 98 i 3 6IN 98 Neim 198 18 S N 7 S N v 79 S N zv 19 BA 5 d 8 01M GA V Std sim ss id 5 OOGOOOOSO 0000000009080 96 STNSNI SS FINSNI SEN 5 v rn voz
117. N 22 9 N 1 18 02 S N 226 2181 r6 Z181 s ezd 12 19 1 14 2 14 21 24 IM 95 19 22 14 SNOILOJNNOO Eld jos 18 1 N39d Z 181 e 81d 1 819 02 819 02 1 ONOS N3JSNVML dL 39018 TVNIW83L QION310S HAVIS SS MOIOW 9314915 WS avoa 431 ANVNOUVIS 815 MOSN3S 3 0553 4 IVY I93NNOO f NOOD MOIVHJN39 INGNYWHid 1091409 34055384 Add 5 10 510 HOLIMS 3 055384 10 540 YOSNAS dW3l GIOJINVA IYW 3 553 4 HOLIMS 3WnSS3Nd M3lvM VIS HOLMS TBAT 10 MOT 101 HOLIMS TBAT INV1009 MOT JRI Sr INSNI 3400 15 9317109 OJSNI OSNI ASNI SNI SNE 031 1051 89 3AWA nd Ad MOSN3S AWIL TANA 14 HOLIMS 5 TINA 544 13 31 1304 V 1303 Vid 39435 15 513 9018 263 MOSN3S 13 31 INY1000 510 dW3L 1 1002 512 YINYOASNYYL IN3HNDO 19 MNOSN3S SHO 34056344 INV1002
118. N3S 13 31 101000 512 YOSNIS dW3l 1 1002 515 1 610 30545 SNO M3QN3S 3HhSS3Hd 1002 540 HOLIMS 13 31 1000 579 W3 v3HB J489 MOSN3S WYO SVO MOLVNH3T ONIDNNHO AM3LIVB QN3911 A009 ONY l 17185 W23 M 0082 23d 3NIHVA 38330 69 66 1e aia SS LZM 133 5 01 v gt TWNOILAO 6148 0 33S OIIVW3HOS 91M 2 92 819 201 EZZZZA 02 2181 lt 4 90 1 9 024 6 4 9d gt 2 14 ld rela sa ZZ fed YTM 9 2181 Sd TA 0 82a A Z sed 13 Ge eid BT E 0500 8 CIM 2401993 LINSNOO IL 195 300W 90090 SNONOYHOOSI 256 193135 90084 ION Q3193NNOO NolLdINOS3Q TVN9IS VNIN231 IMVHO 2181 o rz 1d A 96 19 980 Gz id O 1 14 9 6 14 34 NOIVN3N3O LGN OL NOILO3NNOS 3991 O O sed LHM ze 8id LHM ti ta one 9015 3 2 89 LHM ged OZN IZM ZNvL 2 4 LIN v 8zd 91 z ezd
119. NFO Go to Figure 2 12 DIAL PUSH at CONTROLLER CONFIG Go to Figure 2 13 DIAL PUSH at I O Go to Figure 2 14 Figure 2 10 Decision Maker 3500 Controller Information Menu Structure METERING 121242 GENERATOR METERING ENGINE METERING OVERVIEW PARALLELING METERING DIAL TURN DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH 12 00 AM 12 00 AM 12 00 AM 12 00 AM GENERATOR METER 12 12 12 ENGINE METERING 24212 ENGINE STATUS 12 12 12 PARALLEL METERING 52 15 12 L1 L2 VOLTS V ENGINE SPEED RPM COOLANT OIL PRESSURE GEN BATTERY CONNECTED TO BUS TRUE FALSE L2 L3 VOLTS OIL PRESSURE PSI AVG BUS VOLTAGE L L HAV L3 L1 VOLTS TH COOLANT TEMPERATURE F AVG GEN VOLTAGE L L V AVG GEN VOLTAGE L L V FUEL RATE GPH ur BUS FREQUENCY Hz bere d GEN FREQUENCY Hz GEN BATTERY VOLTAGE VDC GEN FREQUENCY Hz L1 L0 VOLTS V BATTERY VOLTAGE VDC BUS TOTAL POWER KW L2 L0 VOLTS OIL TEMPERATURE F Hz BUS OF RATED kW 13 10 VOLTS COOLANT PRESSURE PSI Alternates every BUS OF RATED kVAR HHH GEN VOLTAGE L N FUEL PRESSURE PSI 8 seconds FUEL TEMPERATURE F L1 CURRENT HHA FUEL USED LAST RUN GAL GENERATOR STATUS 1270917 L2 CURENT CRANKCASE PRESSURE PSI AVG GEN AVG CURRENT GEN L3 CURRENT HHA INTAKE AIR PRESSURE PSI VOLTAGE L L
120. P 6861 10 14 Section 4 Troubleshooting NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example 3AB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown or questionable Maintain a record 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 71 IAJ S 14 4 1 e p iolnqulsip 3IA 9s 1 3994 oeds s s enuen 99149S I S enuen enuen uomejeisu WN I 39 101eeuec ues oulHuy Bug youms 6 v siy Jo uonoes 99 x 6 1291439919 W O 9115 y 1snfpy eDeyoA esoo uay L eNSSeoxe W S 4 40818 9 eoejdau 159 pepunoJD 10 uedo 105816 W S 440104 992199 1 159 10 uedo 10101 uedo
121. PROTECTIVE INHIBIT _ 8 5 DELAY TIME 25 LOW WARNING ON OFF BOARD NUMBER LOW WARNING LIMIT LOW WARNING DELAY His LOW SHUTDOWN ON OFF LOW SHUTDOWN LIMIT LOW SHUTDOWN DELAY HIGH PROTECTIVE INHIBIT HIGH WARNING HIGH WARNING LIMIT HIGH WARNING DELAY HIGH SHUTDOWN HIGH SHUTDOWN LIMIT HIGH SHUTDOWN DELAY 895 IVO BOARD NUMBER I lt DIGITAL OUTPUT 0 1 1200 AM 121212 gt DESCRIPTION MODE STATUS HHEH FUNCTION FUNCTION EVENT ON OFF LOGIC LOGIC VO BOARD NUMBER DIGITAL INPUT X X gt DESCRIPTION STATUS FUNCTION FUNCTION EVENT ON OFF ENABLED ON OFF INHIBIT TIME DELAY TIME 5 BOARD NUMBER DIGITAL OUTPUT XX 12 12 12 gt DESCRIPTION MODE STATUS FUNCTION FUNCTION EVENT LOGIC LOGIC VO BOARD NUMBER ON OFF dnd ditiis ON OFF ditiis ON OFF ON OFF s ON OFF Figure 2 14 I O Menu 58 Section 2 Operation TP 6861 10 14 2 8 Monitoring and Programming Setup The user programmer can access the controller data with the controller digital display or a personal computer PC with optional Site Tech software to monitor and or program Access the controller system with a PC using a USB cable with a mini USB plug Refer to the Introduction List of Related Materials for related software literature While this manual focuses on data access through the controller pushb
122. Parts Related Literature 11 Section 1 Specifications and Features 13 1 1 Introduction RR Re ee T EP denken 13 12 Permanent Magnet Alternator Concept 13 1 3 Short Circuit Performance 13 1 4 Service VIEWS EF IRE Sade X e ex eT 15 1 5 Introd ctionk 22 reete E BRE T S 18 1 6 Controller Specifications 18 1 7 Controller Features 18 1 7 1 Switches and 5 19 1 2 2 AnnunciatorLamps disses da e ERR ER ENDE 20 1 7 3 Graphical Display p RR IRR 20 1 8 Metering Menu sess stesso asad adie saa eta dp 21 1 8 1 Generator Metering Submenu 21 1 8 2 Engine Metering Submenu 21 1 8 3 Overview Submenu 22 1 8 4 Paralleling Metering Submenu 22 1 9 Generator Information Menu 22 1 9 1 Generator Information Submenu 22 1 9 2 Event History Submenu 23
123. SI Fuel Pressure PSI Fuel Temperature F Fuel Used Last Run GAL shown if available from ECM Crankcase Pressure PSI Intake Air Pressure PSI Intake Air Temperature e Overview Generator Status AVG Gen Voltage L L V AVG Current A Gen Frequency Hz Engine Status Metering Coolant Temperature Oil Pressure PSI Gen Battery Voltage V System Status Fuel Pressure PSI Total Power kW Total Run Time Hours e Paralleling Metering Connected to Bus TRUE FALSE AVG Bus Voltage L L V AVG Gen Voltage L L V Bus Frequency Hz Gen Frequency Hz Bus Total Power kW Bus of Rated kW Bus of Rated kVAR Generator Information Menu e Generator Information Total Time hrs Hours Loaded hrs Hours Unloaded hrs kW Hours kWh Operating Hours hrs Total of Starts Last Maintenance Op Hrs Since Maint hrs Starts Since Maint Eng Hrs Since Maint hrs Loaded Since Maint hrs Unloaded Since Maint hrs kW Hrs Since Maint kWh Reset Maint Records YES NO Last Start Last Run Length hrs Controller Serial XXXXXXXXX Software Version XXXXXXXXX ECM Serial XXXXXXXXX Genset Model XXX
124. Section 5 Wiring Diagrams TP 6861 10 14 MOlVIS 1915 QMVOS 30010 SNLLIN3 1 AYWNOLLWLS 875 9NIVION YYY MOIVM3N3O IN3NVANM3d 9Wd QN3931 33S SNOILO3NNOO 5 86 0 MNOIVH3N39 310N avan 9 x 020 4 6 S81 6 8 981 8 j 48 881 4 AINO 009 QV31 9 SNOILO3NNOO av S 8S AGV 1V1S ov 1135 SNOIL23NNOO 9 303 SION qui NIV 9 Ov 6A SEL 6A 8A SEL 8A L LNOOD OA 957 A S81 LA 02 14 95 91 14 82 YOLVYANAD GM35943 D Figure 5 26 DWG 35943 Wiring Diagram Drawing Section 5 Wiring Diagrams 103 TP 6861 10 14 GM88254 981 NONI ON Wer Ver AG 14 INA AG Zdh ZNA QNO 6 9 O Q cio We
125. TIME HOURS LOADED HOURS UNLOADED kW HOURS OPERATING HOURS EVENT HISTORY gt GENERATOR EVENT HISTORY ENGINE EVENT LOG EVENT HISTORY 12 12 2012 10 17 37 AM EVENT INFORMATION ENGINE EVENTS SPN FMI DESCRIPTION gt OCCURRENCE COUNT EVENT X OF Y 55 STATE TO RETURN MAIN EVENT X OF Y PRESS STATE TO RETURN TO MAIN BATTERY VOLTAGE OVER SPEED ENGINE START DELAY RPM STARTING AID DELAY RANK ON DELAY RANK PAUSE DELAY ENGINE WARMED UP COOLED DOWN COOLDOWN DELAY COOLDOWN OVERRIDE FUEL TYPE RANK CYCLES LIMIT NFPA DEFAULTS ON OFF EMERGENCY BATTLEMODE ON OFF OVER SPEED LOW BATTERY VOLTAGE LOW BATTERY VOLTAGE HIGH BATTERY VOLTAGE HIGH BATTERY VOLTAGE s s s s HF dna 85 ON OFF FUEL TYPE Lid DIAL PUSH PARALLEL OPERATION 1290 AM 12 12 12 gt PARALLELING SETUP SYNCHRONIZING SETUP SHARING SETUP PROTECTIVE RELAYS GENERATOR MANAGEMENT LOAD CONTROL DIAL TURN DIAL PUSH 12 00 AM PARALLELING SETUP 1290 gt DEAD BUS LEVEL 6 99 VOLTAGE PICKUP VOLTAGE OK DROPOUT PICKUP Hz FREQUENCY OK DROPOUT Hz VOLTS Hz OK DELAY s FIRST ON DELAY s FAIL TO OPEN DELAY s FAIL TO CLOSE DELAY s RECLOSE DELAY MAX CLOSE ATTEMPTS CRNT FAULT LIMIT t CB
126. Troubleshooting 75 TP 6861 10 14 Notes 76 Section 4 Troubleshooting TP 6861 10 14 Section 5 Wiring Diagrams WARNING Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery 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 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnectthe negative lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circui
127. X3 140 SNOIO3NNOO 39VLT0A 43101510 AB SNOILO3NNOO 5485 0 335 SNOUO3NNOO MOIVH3N39 S0V31 301915 S440QNvIS 3IV10SI AB NOLLO3NNOO QvOl lt 86 0 335 SNOLLO3NNOO HOLVAN 50 31 YOIVIS 8 d NOLON YIU LINDY MNOlLdO 2 1 5 335 y 1d 1 WOIVNH3LV vi Zd v i Zd JNO AVIY z zd 5 5 9 snivIS unoulo zd svia 39 L d 5 8 SWE 03385 8 03345 S Zd NONIO 6 24 35010 3SN3S SNE 8 64 35435 SNE 1 84 3SN3S SNE 1 64 3SN3S 39VL 0A 2 2 84 3SN3S SOVLIOA 2 lt 3SN3S FOVLIOA 9 MOIVH3N3O OMVMOL LH NO 100 33 OSNVHL LNIYYNI lt lt sng 0311051 301915 191 GION310S 5301 SS YOLON 5315915 WS vog 031 ANVNOLVIS 815 AT8N3SSV ONIVIOM Val JVNINH3l 1 090 MHOIVH3N3O9 13NSVW IN3NVAM3d om
128. XXXXXX Genset Spec XXXXXXXXX Genset Serial XXXXXXXXX Alternator Part Engine Part XXXXXXXXX Engine Model XXXXXXXXX Engine Serial XXXXXXXXX e Event History H HH HHHH Date Time Event HHHH Parameter FMI ZHEHBHHHHHBHHHE Event X of Y Engine Event Log SPN FMI Occurrence Count Event X of Y Generator Information Menu Menu Continued Menu Continued e Generator Metering e Configuration Generator Configuration Operating Mode Standby Prime Application Type None Marine Mobile Standby Prime System Voltage L L V System Frequency Hz System Phase Single Single Dog Three Wye Three Delta Rated Engine Speed RPM Engine Speed Adjustment Adjusted Engine Run Speed RPM kW Rating kW kVA Rating kVA Rated Current A Battery Voltage VDC Engine Start Delay s Starting Aid Delay s Crank On Delay s Crank Pause Delay s Engine Warmed Up F Engine Cooled Down F Cooldown Delay s Cooldown Override ON OFF Fuel Type Natural Gas LP Gasoline Diesel Unknown Crank Cycles Limit NFPA Defaults ON OFF Emergency Battlemode ON OFF Protection Configuration Overvoltage Overvoltage V Overvoltage Delay s Undervoltage Undervoltage V Undervoltage Delay s O
129. a period of time With removal of the start signal all generator sets will shutdown with the appropriate engine cooldown e AUTO RUN Press AUTO and RUN together for a system start signal All generator sets in the system start and run close to bus synchronize parallel share load etc Some generator sets may shut down after a period of time indicated by Generator Management but they remain in Standby Mode ready to start and run if needed e AUTO OFF Press AUTO and OFF together to remove a system start signal if AUTO RUN is active All generator sets in the system open their breakers enter engine cooldown shut down and enter Standby Mode Closing the remote start contacts accomplishes nothing Generator sets in the system will enter Standby Mode Section 2 Operation 43 Start Signal A start signal includes the following e Remote start signal via contacts 3 and 4 An ATS used during a power outage exercise period etc or a remote panel used in the vessel take precedence over all other start signals e System Start AUTO START Press AUTO and RUN simultaneously to send a start signal e Communications based start message from SiteTech or a CAN based remote panel Hardwired contacts remote start contacts 3 and 4 have priority over all other start signals If the remote start contacts are activated the generator sets in the system that are in AUTO will start and run If the generator sets were already runn
130. ad or more diesel exhaust stays hot enough to prevent water vapor from condensing At low load situations wet stacking can occur TP 6861 10 14 The operator should perform all of the prestart checks Start the generator set according to the starting procedure inthe controller section ofthis manual While the generator set is operating listen for a smooth running engine and visually inspectthe generator setfor fluid or exhaust leaks 2 6 Controller Operation Note Opening seacock Before startingthe generator set open the seacock to allow cooling water passage Failure to do so could damage the seawater pump impeller and cause serious engine overheating damage Note Transfer switch Check that the marine ship to shore transfer switch if equipped is in the ship position Note If the generator set does start after crank attempts an overcrank fault occurs 1 Close the seacock 2 Completely drain the water from the exhaust system at the silencer s drain plug 3 Do not attempt generator set restart 4 Contact an authorized Kohler distributor dealer A water filled exhaust piping and silencer may further hinder generator starting and cause seawater entry into the engine cylinders through the exhaust valves Water ingested into the engine may cause major engine damage that the Kohler Co warranty does not cover The controller operation includes several types of starting and stopping functions as detailed be
131. adjustment of the parameters on this screen during commissioning will determine how closely the generators share load Speed Bias The amount that the controller is attempting to adjust the output frequency of the generator 100 bias 5 on the engine speed 100 596 on the engine speed The controller adjusts the speed bias to share load between the generators connected to the paralleling bus Bus of Rated kVAR The ratio of the total reactive load on the bus sum of the reactive loads on all connected generators to the total bus reactive capacity sum of all the connected generator reactive capacities expressed as a percentage This value can be monitored to determine system loading also found on Bus Metering screen The Reactive Power rating of the generator is fixed at 3 4 of the rated kW capacity of the generator even in single phase applications Gen of Rated kVAR The ratio of the total reactive load on this generator to its rated reactive capacity expressed as a percentage This value can be compared to the Bus of Rated kVAR directly above it to determine if the system is sharing reactive load properly The acceptable difference between the generator and bus is site dependent The adjustment of the parameters on this screen during commissioning will determine how closely the generators share reactive load The Reactive Power rating of the generator is fixed at 3 4 of the rated kW capacity of the generat
132. amp sound audible alarm to signal an abnormal condition Parameter Value Abnormal Warning warning does not shut down the unit but indicates attention is required Shutdowns show a red fault lamp sound an audible alarm and stop the generator set Statuses do not require user interaction but are part of the event history Notices are used for controlling outputs and notifying the user of the operating status Notices are NOT part of the event history PARAMETER GEN BATTERY VOLTAGE FMI High Event 4 or 4 PRESS OFF TO RETURN TO MAIN MENU Figure 1 10 Event Screen Capture Example FMI Alarm Fault Programmed Programmed Failure Mode Indicator Event ID Parameter at Local Display Level Horn Lamp Input Output Protectives Low Engine Speed Shutdown On Red D High Engine Speed Shutdown On Red D Shorted High Engine Oil Pressure Warning On Yellow AD D Shorted High Engine Oil Pressure Shutdown On Red AD D Shorted Low Engine Oil Pressure Shutdown On Red D Low Engine Oil Pressure Warning On Yellow AD D Low Engine Oil Pressure Shutdown On Red D D Open Circuit Engine Oil Pressure Shutdown On Red D Low Engine Coolant Temperature Warning On Yellow AD D Low Engine Coolant Temperature Shutdown On Red D High Engine Coolant Temperature Warning On Yellow AD D
133. amp See Figure 1 7 Lamp Button Lamp Color Alarm Fault Lamp Yellow Warning or Red Shutdown Off Reset Button Blue Auto Button Blue System Ready Run Button Blue Orange Alarm Silence Button Figure 1 7 Lamps System Status Lamps Master Control Switches The lamp illuminates on the master control switch AUTO automatic start button indicating the system senses no faults and the unit is ready to start by remote command The lamp illuminates on the master control switch OFF RESET button indicating the generator set is stopped The lamp illuminates on the master control switch RUN button indicating the generator set is cranking or running from a local command Only one of the three master control switch lamps will illuminate at any given time Alarm Silence Lamp Orange lamp illuminates indicating the alarm horn was silenced Alarm Fault Lamp Yellow lamp illuminates indicating a warning condition or red lamp illuminates indicating a shutdown condition See System Warning Fault Lamp and System Shutdown Fault Lamp following for system fault conditions System Warning Fault Lamp Yellow lamp identifies an existing fault condition that does not shut down the generator set A continuing system warning fault condition may cause a system shutdown Correct all system warnings as soon as practical See Section 2 6 3 System Fault Warning Lamp with Digital Displays for definitions of t
134. and features Controller features apply to generator set models with ECM and non ECM engines unless otherwise noted 7 6 Mini USB connection 7 Generator set master control OFF RESET AUTO RUN buttons with lamps 8 Alarm silence button with lamp press and hold for 3 seconds for lamp test Figure 1 5 Decision Maker9 3500 Controller with Digital Display Pushbutton Rotary Selector Dial 18 Section 1 Specifications and Features TP 6861 10 14 Note Press the pushbutton rotary selector dial to turn onthe controller lights and display The backlight turns off 60 minutes after the last entry when in the AUTO mode Note After about 15 minutes of no user input pushbutton rotary selector dial or buttons the menu is reset to the top of the main menus and auto paging activates for the Overview submenus Note Measurements display in metric or English units Use the Controller Configuration menu to change the measurement display 1 7 1 Switches and Controls Note US Metric Display is selectable in Section 1 10 Controller Configuration Menu Alarm Horn The alarm horn alerts the operator or other attendants that a warning or shutdown condition exists Alarm Horn Silence The alarm silence switch silences the alarm horn at the operator s discretion Press the master control switch AUTO button before pressing the alarm silence button The alarm horn cannot be silenced unless the master control switch AUTO button is
135. and the generator will remain running The protective relay can be reset by pressing the AUTO button note if the generator is in Run the protective relay will have to be cleared by stopping the generator Pressing OFF RESET or removing the remote start signal to the generator system also clears any active protective relays Gen Management Generator Management is intended to minimize wear and tear fuel consumption pollutant sound emissions and generated heat It acts by signaling each generator to stop when it is unneeded If generator management for a generator is disabled the generator will start generator management failures will result in additional generators running any time the system receives a start signal this unit or others Generator management sequences the generators off in a predetermined order The highest order generators stop first when load is low enough and re start last when load is too high The order can be viewed on the front panel of the controller but can only be adjusted under certain conditions see Gen Management Order later in this section The time to start a generator if the load increases varies with the degree of overload TP 6861 10 14 The time to stop a generator if the load is low enough that the generator is no longer needed varies with the degree of available capacity Note Receipt of a start signal will cause all generators to start synchronize and close to the bus G
136. anes should be straight and flexible See Figure 3 3 Replace the impeller if it is damaged 1 Flattened vane 2 Crack 3 Broken vane Figure 3 3 Worn Impeller 5 Lubricate the impeller with soapy water before installation 6 Install the impeller Note During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated in the impeller housing 7 Inspect the cover plate and gasket for corrosion and or damage Replace components as necessary 8 Lubricate the gasket with silicon grease and attach the gasket and cover plate to the seawater pump housing 9 Open the seacock 10 Start the generator set and check for leaks 11 Stop the generator set and repair leaks or replace damaged or worn components 68 Section Scheduled Maintenance 3 7 Exhaust System WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the crafts occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use At the interval specified in the service schedule inspect the exhaust system components exhaust manifold mixing elbow exhaust hose hose clamps silencer a
137. ap Exhaust outlet Coolant drain Belt guard Figure 1 3 Service Views Typical 99EOZD C J 80EFOZD C J Model Shown 16 Section 1 Specifications and Features ADV 8506 Fuel injection pump Positive battery connection Heat exchanger Anticorrosion zinc anode 2 Negative battery connection Fuel return TP 6861 10 14 ADV 8508 Nameplate Seawater pump Oil filter Fuel return Controller Coolant overflow bottle Oil check Positive battery connection Air filter inside of tray Pressure cap Fuel filter Heat exchanger Crankcase vent filter Exhaust outlet Fuel filter water separator Anticorrosion zinc anode 2 Lifting eye Coolant drain Oil drain Negative battery connection Overflow tube Belt guard Cable connector for customer Fuel injection pump Water fill Fuel inlet load leads Oil fill Seawater inlet Cooling air inlets alternator Figure 1 4 Service Views Typical 150EOZD C J 125EFOZD C J Model Shown TP 6861 10 14 Section 1 Specifications and Features 17 1 5 Introduction The spec sheets for each generator set provide model specific generator and engine information Refer to the respective spec sheet for data not supplied in this manual Refer to the generator set service manual installation manual engine operation manual and engine service manual for additional specifications 1 6 Control
138. ardless of output configuration or external connection status All generators on the PGEN network initiate load control at the same time and use the same measured values to determine the Add and Shed timing Bus kW and Bus Frequency If the load control settings are set identically each load control priority will add at the same time on all generators in the paralleling system This allows Priorities 1 and 2 to be connected to one generator while Priorities 3 and 4 can be connected to another generator Note Load Control in a paralleling system operates identically to the load control on a single generator except that it takes different metered values into consideration TP 6861 10 14 Load Control Description The purpose of Load Control is to permit a generator to support load which may occasionally exceed the rated capacity of the generator In paralleling systems load shed permits the bus to stay at rated voltage and frequency while an additional generator is synchronizing to it In single generator applications load control may shed unimportant but highly demanding loads when the generator is overloaded preventing a power outage caused by the generator going offline The Load Control in the Decision Maker 3500 controller supports 6 load control priorities These priorities generate internal notices for the shed condition The internal notices are generated any time load is shed but they will only operate a load cont
139. ations port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical 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 diameter dual inlet end outlet Deutsches 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 EEPROM electrically erasable programmable read only memory 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 estimated emergency stop et cetera and so forth IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext ISO J JIS k K kA KB KBus kg exhaust external Fahrenheit female flat head
140. ators with a higher order higher order generators stop before lower order generators If the Generator Management Order for a generator changes generator management will start any generators which were involved in the order changing process including automatic re sort After the incoming generators connect to the paralleling bus the generators with a high enough order to stop will start filling their accumulators to stop The generator order is adjustable in Manual Fixed Order selection mode Itis only adjustable in Runtime or Fuel level mode if the generators have identical runtime or fuel level Total Bus Capacity The total bus capacity is simply the sum of the kW rating of all generators that are connected TP 6861 10 14 to the paralleling bus running with paralleling breaker closed Generators in Baseload System Control or Unload mode are not taking into consideration for this capacity Bus Total Power The sum of the power output of all generators which are connected to the bus and available for sharing load Generators in Baseload System Control or Unload mode are not taking into consideration for this level The Bus Total Power is compared to the Start kW and Stop kW ofthe generator to determine ifthe generator should be started stopped or remain as is StartkW Thethreshold Bus Total Power above which the Start Accumulator for this generator will start filling Note The Accumulator fill rate is higher fo
141. atures 37 FMI Alarm Fault Programmed Programmed Failure Mode Indicator Event ID Parameter at Local Display Level Horn Lamp Input Output Low Total Power Generator Total Real Power Warning On Yellow D High Total Power Generator Total Real Power Warning Yellow D High Total Power Generator Total Real Power Shutdown On Red D Low Total Reactive Power Warning On Yellow D High Avg Current Warning On Yellow D Low Maximum Alternator Current Shutdown On Red D High Intake Air Temperature Warning On Yellow D High Intake Air Temperature Shutdown On Red D High Fuel Temperature Warning On Yellow D High Fuel Temperature Shutdown On Red D Low Coolant Pressure Warning On Yellow AD D AC Sensing Lost Warning On Yellow D AC Sensing Lost Shutdown On Red D Alternator Protection Shutdown On Red D Auxiliary Input Warning On Yellow AD D Auxiliary Input Shutdown On Red D D Battery Charger Fault Warning On Yellow AD D Ecm Communication Loss Shutdown On Red D Ecm Model Mismatch Shutdown On Red Emergency Stop Shutdown On Red D Fuel Tank Leak Warning On Yellow AD D Fuel Tank Leak Shutdown On Red D D Ground Fault Input Warning On Yellow AD D Locked Rotor Shutdown On Red D Electrical Metering Communication Loss Shutdown On Red Over Crank Shutdown On Red D Speed Sensor Fault Warning On Yello
142. ault shutdown under the following conditions See Section 2 6 6 Controller Resetting procedure for information resetting a system shutdown When the system shutdown lamp is on and no message displays rotate the dial to the Active Events menu Press the dial to view messages Rotate the dial to view additional messages Press the OFF button to return to the main menu Use the Alarm Off button to silence the alarm horn at the operator s discretion If the controller is setup for an NFPA 110 application press the AUTO button before silencing the alarm horn The alarm horn cannot be silenced unless the button is in the AUTO mode See 2 6 5 Status and Notice Digital Displays for more information AC Sensing Lost controller in AUTO and voltage was previously present The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the controller does not detect the nominal generator set AC output voltage for more than 3 seconds after crank disconnect Alternator Protection The fault lamp illuminates red and the unit shuts down because of an alternator overload or short circuit See Appendix D Alternator Protection for more information Auxiliary Input Shutdown The fault lamp illuminates red the alarm horn sounds and the unit shuts down when an auxiliary digital or analog inputs signals the controller The digital inputs do not function during the first 30 seconds after startup Use SiteTech softwa
143. ay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect the fault or status event The controller will ignore the input until the inhibit time expires Ifthe inhibit time is set to zero input is monitored at alltimes even when the generator set is not running The inhibit time delay range is from 0 to 60 seconds Time Delay shutdown or warning The time delay follows the inhibit time delay The time delay is the time period between when the controller first detects the fault or status event and the controller warning or shutdown lamp illuminates The delay prevents any nuisance alarms The time delay range is from 0 to 60 seconds Additional Analog Input Entries The analog input selection typically requires entering four values low warning high warning low shutdown and high shutdown 36 Section 1 Specifications and Features Digital Output and Relay Driver Output Setup The I O Setup Menu displays the setup of digital status and fault outputs and relay driver outputs RDO These outputs provide choices for configuring customized auxiliary outputs Additional individual outputs are available for monitoring diagnostics and control functions See Optional Dry Contact Kit following The user must enable the programming mode to edit the display See Section 2 7 for changeable settings in this menu Note Changes to the Digital Outputs description
144. before generator management will consider stopping a generator This is implemented so that generators aren t stopped prematurely before all the available load has been applied to the system All the generators in the system must have the same setting for Min Loads Added for the generator management to operate If this parameter is changed it will be updated on all the generators which are connected to the PGEN network Note Min Loads Added should be set up to support the load control outputs which are connected to actual loads There is no reason to wait for a load control output to add if no load will be added to the system when it does At the same time it is important that all load which the paralleling system will have to support be supplied by the system before generator management makes the determination to stop a generator The load control outputs should be capable of shedding enough load that a single generator can support what remains this should be handled during commissioning but is included for consideration as loads grow Load Control Load Control drives 6 outputs Load Priority 1 Shed through Load Priority 6 Shed to remove loads from the paralleling bus when the attached generators are unable to support them See the Load Control Description Section following for more information The outputs must be tied to programmable outputs in the configuration before they can be used but they are controlled internally reg
145. ce as necessary X Action Service more frequently if operated in dusty areas Should be performed by your local distributor dealer 8 Consult the battery manufacturer s instructions TP 6861 10 14 Section 3 Scheduled Maintenance 63 Service Schedule continued System Component Visually Inspect Interval DC Electrical System Keep the battery charged and in good condition 8 Before operation Check and tighten the electrical connections Monthly or 50 Hrs Clean the battery cables Yearly or 500 Hrs AC Electrical System Controller lamp test Weekly General Inspection Weekly Circuit breakers fusest Monthly Wire abrasions where subject to motion Quarterly Safety and alarm operation 6 Months Tighten control and power wiring connections Yearly Transfer switch main contactst Yearly Voltage sensing device relay adjustmentt Yearly Wire cable insulation breakdown 3 Years Engine and Mounting Check air cleaner dust unloader valve Before operation General inspection Before operation Governor operation lubricate moving parts 33 40 kW Monthly Check belt Monthly Check engine mounts 6 Months or 250 Hrs Inspect the air cleaner element and clean or replace as necessary 6 Months or 250 Hrs Check air intake hoses connections and system Yearly or
146. ches the temperature shutdown range The engine intake air temperature shutdown does not function during the first 30 seconds after startup High Generator Frequency The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the frequency is above the overfrequency setting See Figure 2 6 Overfrequency Overfrequency Setting Range Time Delay Default Setting 102 140 of nominal 110 of nominal Figure 2 6 Overfrequency Specs High Generator Voltage Each Phase The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the voltage exceeds the overvoltage setting for the preset time delay period See Figure 2 7 for overvoltage specifications Note Overvoltage can damage sensitive equipment in less than one second Install separate overvoltage protection on online equipment requiring faster than 2 second shutdown Overvoltage Time Delay Overvoltage Default Setting Range Range Setting 105 135 of Figure 2 7 Overvoltage Specs High Lube Oil Temperature The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of high engine oil temperature The shutdown occurs 5 seconds after the engine oil reaches the temperature shutdown range The high engine oil temperature shutdown does not function during the first 30 seconds after startup Section 2 Operation 49 Locked Rotor failed to crank If none of the speed sensing inputs show engine rotatio
147. connected to the controller to operate Operation of Fuel Level mode without sensors is not defined Note If the load on the system requires an additional generator to start the generator with the lowest fuel level will always be the one to stop the threshold is no longer taken into consideration as soon as the generator is connected to the paralleling bus Gen Management Allows permanent disabling of the generator management on this generator This parameter can be set individually for each generator and wil inhibit the Generator Management Configuration Mismatch Warning for this generator if set to OFF Note Disabling the generator management on one generator in a paralleling system will not keep the other generators in the paralleling system from alarming if the generator management configuration of any of the other nodes differs from the disabled generator Note Generators with Generator Management disabled are not taking into consideration for generator management on the other generators It is not recommended to disable any of the generators in a_ paralleling system where generator management is intended to be used the generator management may operate too many generators in these cases Generator management defaults to OFF It should be enabled on all generators in the system if it is desired Gen Management Order Determines the Start Stop Order of this generator Generators with a lower order will start before gener
148. d 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 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 Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Connect the generator set to the building marina electrical system only through an approved device and after the building marina main switch is turned off Backfeed connections can cause severe injury or death to utility personnel working on power lines and or personnel near the work area Some states and localities prohibit unauthorized connection to the utility electrical system Install a ship to shore transfer switch to prevent interconnection of the generator set power and shore power TP 6861 10 14 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 insulated probes and follow the instructions of the test equip
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150. d the alarm horn sounds and the unit shuts down when the engine oil pressure sender circuit is open for more than 5 seconds Overcrank The fault lamp illuminates red the alarm horn sounds and cranking stops when the unit does not start within the defined cranking period See Section 2 6 for cyclic crank specifications Note The controller is equipped with an automatic restart function When speed drops below 25 Hz 750 rpm while the engine is running the unit attempts to recrank The unit then follows the cyclic cranking cycle and when the engine fails to start will shut down on an overcrank fault condition Run Relay Coil Overload The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the current draw on the 70 wire from the controller has exceeded 40 amps or has exceeded 10 amps for at least 10 ms Starter Relay Coil Overload The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the current draw on the 71 wire from the controller has exceeded 40 amps or has exceeded 10 amps for at least 10 ms Tripto Shutdown Delay The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the generator is stopped ifthe circuit breaker has tripped fora Protective Relay function and the trip to shutdown time delay has expired This delay allows mitigation of problem conditions without engine shutdown If the delay expires it is presumed no successful actio
151. d Control adds loads based on the capacity of the system loads will add more quickly if the available capacity is higher Load Control sheds loads based on the degree of overload ofthe system loads will shed more quickly as the degree of the system overload increases TP 6861 10 14 Note The generator management start should be significantly lower than the Gen Overload Percent so that additional generators will come online before a load is shed An under frequency event will also shed load the under frequency threshold is not adjustable from the User Interface The load control will shed subsequent loads more quickly if shedding a load did not remove the overload or underfrequency condition In a standard application single generator or generator controlled by external switchgear the load control logic uses the Gen 96 or Rated kW and the Gen Frequency In paralleling application where the Decision Maker 3500 controller is responsible for first on synchronizing load sharing and generator management the load control logic uses the Bus of Rated kW and Bus Frequency All generators use the same start signal load and frequency values to determine load control timing hence each controller will shed and add a given load priority at the same time provided that the load control settings are identical in each controller a paralleling application where Generator Management is used some generator sets may be
152. d only read only memory rotate rotating revolutions per minute right side Resistance Temperature Detectors RTU RTV RW SAE scfm SCR 5 sec SI SI EO sil SMTP SNMP SPDT SPST spec specs sq sq sq in SMS ss std stl tach TB TCP TDC TDEC TDEN TDES TDNE TDOE TDON temp term THD TIF tol turbo typ UF UHF UIF UL UNC UNF univ URL US VAC VAR VDC VFD VGA VHF WCR w WO w o xfmr remote terminal 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 simple mail transfer protocol serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch short message service stainless steel standard steel tachometer terminal block transmission control protocol 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 tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency user interface
153. data and the open bullet items are sub level data The Menu Summary List indicates items that are user selectable Use SiteTech software for changing programmable information TP 6861 10 14 Menu Summary List Legend e First level submenu second level submenu O third level submenu Metering Q 67 9 OOOO QvQ ON O 97 Q Qo 0 O0 O0 Q 720 L1 L2 Volts V L2 L3 Volts V L3 L1 Volts V AVG Gen Voltage L L V Gen Frequency Hz L1 LO Volts V L2 LO Volts V L3 LO Volts V AVG Gen Voltage L N V Gen Frequency Hz L1 Current A L2 Current A L3 Current A AVG Current A Gen Frequency 2 L1 Power W L2 Power W L3 Power W Total Power W Gen of Rated kW L1 Reactive Power VAR L2 Reactive Power VAR L3 Reactive Power VAR Total Reactive Power VAR L1 Apparent Power VA L2 Apparent Power VA L3 Apparent Power VA Total Apparent Power VA Gen of Rated kVA L1 PF 2 448 L2 PF 2 448 PF 2 448 Total PF 2 24 Gen Phase Rotation e Engine Metering O O O O OU Qo 9 Engine Speed RPM Oil Pressure PSI Coolant Temperature F Fuel Rate GAL h shown if available from ECM Gen Battery Voltage 4VDC ECM Battery Voltage 4VDC Oil Temperature F Coolant Pressure P
154. de Status Off Fault Lamp Alarm Silence Alarm Button Horn Lamp Controller Display Scrolling Overview Menu On or Cranking Only Running and then Off OFF RESET Yellow Off or Cranking Yellow RUN Shutdown Message Pressed g Not In Auto Warnin Pressed 9 Not in Auto Warnin Pressed 9 unit fails to start Off Red Off or Cranking RUN On Yellow m Locked Rotor Shutdown or Pressed other shutdown message Not in Auto Warmin Pressed Yellow g unit starts Red Running and then Off Figure 2 3 Button Function Summary 2 6 1 Emergency Stop Use the controller emergency stop switch for immediate emergency shutdown The emergency stop switch bypasses the time delay engine cooldown and immediately shuts down the generator set Note Use the emergency stop switch es for emergency shutdowns only Use the generator set OFF RESET button for normal shutdowns The controller fault lamp lights and the unit shuts down when the local emergency stop switch activates Use the following procedure to reset the generator set after shutdown by a local or remote emergency stop switch Refer to Section 2 6 6 Controller Resetting procedure to restart the generator set following a fault shutdown 1 Investigate and correct the cause of the emergency stop 2 Reset the controller emergency stop switch by pulling the switch dial outward 3 Press the generator s
155. e Bus of Rated kVAR displays the ratio between the reactive load on all generators in the paralleling system and the bus reactive capacity the sum of 3 4 of the rated kW of all connected generators expressed as a percentage 1 9 Generator Information Menu 1 9 1 Generator Information Submenu Total Run Time displays the total run time hours Hours Loaded displays the total loaded hours Hours Unloaded displays the total unloaded hours kW Hours displays the total kW hours Operating Hours displays the total operating hours Total Number of Starts displays the total number of times that the engine was started via the generator set controller Last Maintenance displays the date on the controller system clock when the last maintenance was performed Operating Hours Since Maintenance displays the total number of hours of operation since the last maintenance date Starts Since Maintenance displays the total number of generator set startup events since the last maintenance date Engine Hours Since Maintenance displays the total engine hours since last maintenance Loaded Since Maintenance displays the total loaded hour since last maintenance Unloaded Since Maintenance displays the unloaded hours since last maintenance kW Hours Since Maintenance displays the total kW hours since last maintenance TP 6861 10 14 Reset Maintenance Records displays a Yes No choice for the user to select Last Start displays
156. e battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch 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 WARNING Hazardous voltage Moving parts 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 62 Section Scheduled Maintenance Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk o
157. e in load demand 1 3 Short Circuit Performance When a short circuit occurs in the load circuit s being served output voltage drops and amperage momentarily rises to 600 1000 of the generator set s rated current until the short is removed The SCR assembly sends full exciter power to the main field The alternator then sustains up to 300 of its rated current Sustained high current will cause correspondingly rated load circuit fuses breakers to trip The controller alternator protection feature serves to collapse the alternator s main field in the event of a sustained heavy overload or short circuit Section 1 Specifications and Features 13 NA B C 16 Rotor shaft Rotor field windings rotor assembly Stator main windings stator assembly Alternator assembly Exciter assembly Exciter armature connected to rotor Figure 1 1 Alternator Schematic 14 Section 1 Specifications and Features Exciter armature windings Exciter field magnets FRX activator photo transistor board Photo transistor LED optic board Engine starting battery TP 6863 1 13 Alternator protection controller 14 Generator set controller 15 AC voltage regulator controller 16 AC output leads 17 Current sensing TP 6861 10 14 1 4 Service Views
158. e through the main menus turn counterclockwise to go forward down and clockwise to go back up The menus wrapto the beginning e Press the dial at a given main menu to access the submenus within the selected main menu e When in the submenu rotate the dial to navigate through the submenu counterclockwise to go forward down and clockwise to go back up The menus wrap to the beginning e Momentarily press the dial when in the submenu to make a user selection choice if available or to go back to the respective main menu e To return to the previous menu rotate the dial counterclockwise or clockwise until the back arrow appears in the upper left corner and press the dial GENERATOR METER 2 5 L1 L2 VOLTS L2 L3 VOLTS HHH HV L3 L1 VOLTS AVG GEN VOLTAGE L L FREQUENCY Hz s METER 2 267 L 1 L2 VOLTS L2 L3 VOLTS L3 L1 VOLTS AVG GEN VOLTAGE L L HHHHV GEN FREQUENCY HZ 1 Back arrow Figure 1 6 Back Arrow Location e After about 15 minutes of no user input pushbutton rotary selector dial or buttons the menu resets to the top of the main menus and auto paging activates for the Overview submenus Section 1 Specifications and Features 19 1 7 2 Annunciator Lamps The controller has single fault lamp providing visual generator set status In addition each button has a l
159. ecifications and Features 1 1 Introduction The specification sheets for each generator set provide specific alternator and engine information Refer to the respective specification sheet for data not supplied in this manual Consult the generator set operation manual installation manual engine operation manual and engine service manual for additional specifications A permanent magnet alternator is identified with one of the following designations 4P_X 4Q X 4R X 45 or4T_X Example Gen Model 4S12X The first alpha character S identifies the alternator family and the last character X denotes the Fast Response X alternator The generator set has a rotating field alternator with a smaller rotating armature alternator turned by a common shaft The main rotating field alternator supplies current to load circuits while the rotating armature exciter alternator supplies DC to excite the main alternator s field The generator set has a 4 pole rotating field with brushless permanent magnet alternator excitation system The PM system provides short circuit excitation current up to 300 at 60 Hz approximately 275 at 50 Hz for a minimum of 10 seconds to allow selective circuit breaker tripping Voltage regulation is provided by the generator set controller Refer to the Service Manual for additional voltage regulator information TP 6861 10 14 1 2 Permanent Magnet Alternator Concept The alternator excitation syst
160. ely Auxiliary Power Unit 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 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 Category 5 network cable circuit breaker crank cycle cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour 10 14 cfm CG CID CL cm CMOS com coml Coml Rec conn cont CPVC crit CSA CT Cu cUL CUL DVR E2PROM E emer ECM EDI EFR e g EG EGSA EIA emiss eng EPA EPS ER ES ESD est E Stop etc cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor communic
161. ely if the coolant temperature is below the engine cooled threshold but will run for the duration of the cooldown cycle otherwise If set to OFF the engine will always complete the cooldown cycle Fuel Type displays the programmer entered fuel type as NG Natural Gas LP Liquefied Petroleum Gasoline Diesel or Unknown Crank Cycles Limit displays the programmer entered crank cycle Enable NFPA Defaults Allows the user to Enable or Disable the NFPA defaults Enable Emergency Battlemode Allows the user to turn On Off the emergency battlemode feature Note Conditional for certain units 24 Section 1 Specifications and Features Protection Configuration Note The time delays are user adjustable using SiteTech Have setup and adjustments of the Decision Maker 3500 controller performed only by an authorized Kohler distributor dealer The setup and adjustments are password protected Overvoltage displays the percentage of the system voltage that the generator voltage must exceed for an overvoltage condition to be indicated Overvoltage Delay displays the time that the generator voltage must be in an overvoltage condition before a fault is indicated Undervoltage displays the percentage of the system voltage that the generator voltage must drop below for an undervoltage condition to be indicated Undervoltage Delay displays the time that the generator voltage must be in an undervoltage condition before a fault is
162. em uses a permanent rare earth magnet exciter with a silicon controlled rectifier SCR assembly which controls the amount of DC current fed to the alternator field This type of system uses voltage regulator located within the Decision Maker 3500 controller which provides a signal to control the SCR assembly through an optical coupling The voltage regulator monitors engine speed and alternator output voltage to turn a stationary light emitting diode LED on or off according to engine speed and output voltage The LED is mounted on the end bracket opposite a photo transistor board which rotates on the shaft The photo transistor picks up the signal from the LED and tells the SCR assembly to turn on or off depending upon the need as dictated by the voltage regulator See Figure 1 1 The voltage recovery period of this type of alternator is several times faster than the conventionally wound field brushless alternator because it does not have to contend with the inductance of the exciter field It also has better recovery characteristics than the static excited machine because it is not dependent upon the generator set output voltage for excitation power Possibly the greatest advantage of this type machine is its inherent ability to support short circuit current and allow system coordination for tripping downstream branch circuit breakers The alternator system delivers exciter current to the main field within 0 05 seconds of a chang
163. emove the remaining deposits following the manufacturer s instructions 3 Drain clean and flush the coolant recovery tank 3 6 4 Procedure to Refill Cooling System 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 the radiator and or engine block coolant drain valve s and tighten the 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 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing Acoolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution containing less than 50 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution containing more than 50 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Refer to the engine operation manual for recommendations
164. en Voltage L L V OO OOO OOOO OOOO OOO OOO OOOO OOOO OOO OOOO OOO OG OOO OOOO OOOO ACTIVE DEAD FIELD Volt Trim P Gain cna Lad Sync Mode In Run Volt Trim Gain Time XM INVALID OFF PASSIVE CHECK Volt Trim D Gain Contrast ACTIVE DEAD FIELD Voltage Bias Alarm Silence ALWAYS AUTO Synchronizing Setup Volt Droop at 100 kVAR ONLY Sync Mode In Run Communication Setup INVALID OFF PASSIVE CHECK Protective Relay Setup Modbus Baud Rate OFF 9600 b s ACTIVE DEAD FIELD Over Power Trip 19200 b s 38400 b s 57600 b s Sync Mode in Auto Over Power Delay s INVALID OFF PASSIVE CHECK Reverse Power Trip 115200 b s ACTIVE DEAD FIELD Reverse Power Delay s Modbus Address Connected to Bus TRUE FALSE Over Voltage Trip PGEN Baud Rate OFF 9600 b s Volts Hz OK TRUE FALSE Over Voltage Delay 19200 b s 38400 b s 57600 b s In Sync TRUE FALSE Under Voltage Trip 115200 b s Voltage Matched TRUE FALSE Under Voltage Delay s Voltage Match Window Over Freq Trip PGEN Node ID AVG Bus Voltage L L 4V Over Freq Delay s PGEN Nodes Online AVG Gen Voltage L L V Under Freq Trip PGEN Nodes Offline Voltage Match P Gain Under Freq Delay s e Calibration Voltage Match Gain
165. enerator management requires that the generators are available not faulted in order to be permitted to stop If a generator is faulted or manually stopped and then placed back in Auto Generator Management will require the generator to start and connect to the bus before it is considered available and permitted to stop again even if generator management had previously signaled the generator to stop Start Capacity The percent of generator rated kW of the running generators thatthe system allows before the accumulator to start this generator begins filling The Start Capacity is set during commissioning and should not be changed Start Delay The time to decide to start the generator at 1096 over capacity The Start Delay is set during commissioning and should not be changed Stop Capacity The percent of generator rated kW of the other running generators that the system allows before the accumulator to stop this generator begins filling The Stop Capacity is set during commissioning and should not be changed Stop Delay The time to decide to stop the generator at 1096 available capacity The Stop Delay is set during commissioning and should not be changed Gen Management Modes The method that generator management uses to determine the starting and stopping order of the available generators All the generators in the system must have the same setting for this parameter for the generator management to operate If this parameter
166. ervices were performed Enter hours to the operating hours on your generator set and the dates nearest quarter hour Operating Hours Service Record Date Total Service Run Hours Date TP 6861 10 14 Appendix 115 Notes 116 Appendix TP 6861 10 14 TP 6861 10 14 117 118 TP 6861 10 14 TP 6861 10 14 119 TP 6861 10 14b 2013 and 2014 by Kohler All rights reserved KOHLER Power Systems KOHLER CO Kohler Wisconsin 53044 Phone 920 457 4441 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KOHLERPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
167. et OFF RESET button 4 After resetting all faults using the controller reset procedure in Section 2 6 6 press the generator set RUN and or AUTO button to restart the generator set The generator set will not crank until the reset procedure completes TP 6861 10 14 Shutdown Message Pressed Yellow 9 2 6 22 System Status Lamps The OFF RESET AUTO RUN buttons indicate the status condition with an integrated lamp at the button The lamp illuminates on the AUTO automatic start button indicating the system senses no faults and the unit is ready to start by remote command The lamp illuminates on the OFF RESET button indicating the generator set is stopped The lamp illuminates on the RUN button indicating the generator set is cranking or running from a local command Only one of the three button lamps will illuminate at any given time Section 2 Operation 45 2 6 3 System Fault Warning Lamp with Digital Displays The system FAULT lamp glows yellow and the alarm horn sounds indicating a warning fault but does not shut down the generator set The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel fueled models approaches empty This fault requires an optional low fuel level switch for the lamp to function Section 2 6 6 Controller Resetting procedure for instructions on resetting a system warning When the system warning lamp is on and no messa
168. f electrocution Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the load 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 See the Safety Precautions and Instructions at the beginning of this manual before attempting to service repair or operate the generator set Have an authorized distributor dealer perform generator set service Routine Maintenance Refertothefollowing generator set service schedule the engine service schedule and the hourmeter located on the generator set controller to determine when to schedule routine maintenance Service more frequently generator sets that are subject to extreme weather or dusty or dirty conditions
169. f the coolant temperature If the Cooldown Override is enabled ON in the Generator Configuration Menu coolanttemperature will be considered for cooldown The generator will enter cooldown when the start signal is removed only if the engine control switch is in AUTO The engine will run until the coolant temperature is below the Engine Cooled Down parameter setting or until the Cooldown Delay has expired The cooldown cycle lasts for some predetermined amount of time The cooldown delay is an adjustable parameter The Engine Cooled Down temperature is not adjustable Note No engine cooldown cycle occurs if the OFF button is pressed or if a fault occurs The shutdown is immediate If possible run the generator set without load for 5 minutesto ensure adequate engine cooldown Note The alarm horn sounds and the Not In Auto Warning display appears whenever the generator set is not in the AUTO mode Note The transient start stop function of the controller prevents accidental cranking of the rotating engine The generator set stops and recranks when the OFF RESET button is momentarily pressed and then the RUN button is pressed Note The controller provides up to 30 seconds of programmable cyclic cranking and up to 60 seconds rest with up to 6 cycles The default setting is 15 seconds cranking and 15 seconds rest for cycles Make cyclic cranking adjustments using SiteTech software TP 6861 10 14 Generator Set Button Mo
170. g 62 82 15 24 riz zi8D 116 2181 186 2181 026 2181 005 H33VW NOISIO3Q 0 8 33S 5 3803 01 v Nolo 92 819 oon 04 2181 voL TM s ocd 904 L sed 81d YTM 1 0 d ld 1 29 d Zlal ANOIOv LINSNOD VIL 256 300N 10090 SnoNosHoos 6 2103135 40080 G3103NNOO 10N CaLOaNNOO 1509 NOlLdIHOS3Q TvN9IS 2181 NOLO3NNOO ZIAL 82 19 TA 303 GN OL vi zd ci zd z zd asa 9 0 r zd 485 Nas I 110 0 34580 458 NSB 904 ici OL 91M LIN Z if 6 812 1 19 Se ZIN 5 NAY 4 12 14 1 SIM 904 92 6 14 vie 52 S N cc S N 19 8 02 61 19 28 z za rela 22 14 14 5 819 LZM N39d Z 181 gla 1 02 819 22 819 OINOS dl WNINNSL BL 30 915
171. ge displays rotate the dial to the Active Events menu Press the dialto view messages Rotate the dial to view additional messages Press the OFF button to return to the main menu When the system warning continues it may lead to a fault and cause a system shutdown Use the Silence Alarm button to silence the alarm horn at the operator s discretion If the controller is setup for 110 application pressthe AUTO button before silencing the alarm horn The alarm horn cannot be silenced unless the button is inthe AUTO mode See 2 6 5 Status and Notice Digital Displays for more information AC Sensing Lost controller in RUN or AUTO and voltage was never present The fault lamp illuminates yellow and the alarm horn sounds when the controller does not detect the nominal generator set output voltage after crank disconnect Auxiliary Input The fault lamp illuminates yellow and the alarm horn sounds when an auxiliary digital or analog input signals the controller The digital inputs do not function during the first 30 seconds after startup Use SiteTech software to define inputs as shutdowns or warnings Average Current High The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters excessive load or a downstream fault The output breaker trips The available sustained fault current of the generator can be obtained from the per unit transient reactance of the generator and the system v
172. h 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 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 TP 6861 10 14 3 2 Engine Service WARNING a G gt 2 fuel cause severe 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 ina 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 Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set
173. he items listed System Shutdown Fault Lamp Red lamp indicates that the generator set has shut down because of a fault condition The unit will not start without resetting the controller see Section 2 6 6 Controller Resetting procedure See Section 2 6 4 System Fault Shutdown Lamp with Digital Displays for definitions of the items listed 20 Section 1 Specifications and Features 1 7 3 Graphical Display Press the pushbutton rotary selector dial to turn on the controller lamps and display The backlightturns off 60 minutes after the last entry when in the AUTO mode The generator set must be running for some displays to indicate values Ifthe generator set is not running some values will display zero or N A not available The 5 line 35 character per line backlit heated display provides generator set and engine data system status and fault information See Figure 1 5 The graphical display shows abbreviations in some instances Note US Metric Unit Display is selectable in the Controller Configuration menu Note After about 15 minutes of no user input pushbutton rotary selector dial or buttons the menu resets to the top of the main menus and auto paging activates for the Overview submenus The main menus are listed below Within each main menu are multiple submenus with descriptions following e Metering See Section 1 8 e Generator Information See Section 1 9 e Controller Configuration See Section 1 10
174. ice 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 863 619 7568 Fax 863 701 7131 6861 10 14 Maintenance and Service Parts Related Literature Maintenance and Service Parts Figure 1 1 identifies maintenance and service parts for your generator set Obtain a complete list of maintenance and service parts from your authorized generator distributor dealer Models 40EOZDJ 55EOZDJ 65EOZDJ 40EOZCJ 55EOZCJ 65EOZCJ 33EFOZDJ 40EFOZDJ 50EFOZDJ 45EFOZDJ 55EFOZDJ Part Descri 33EFOZCJ 40EFOZCJ 50EFOZCJ 45EFOZCJ 55EFOZCJ Engine 4045DFM70 4045TFM75 4045TFM85 Air Filter Element 226915 GM86446 Belt Alternator and Seawater Pump GM15402 Fuel Filter Element Primary GM48727 GM48729 Fuel Filter Element Secondary GM48728 GM48730 Oil Filter GM32809 Seawater Pump Impeller Kit GM50644 Zinc Anode 352142 Part Description Engine Models 80EOZDJ 80EOZCJ 99EOZDJ 99EOZCJ 1
175. il level at or near not over the full mark on the dipstick 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 Seawater Pump Priming Prime the seawater pump before initial startup To prime the pump 1 close the seacock 2 remove the hose from the water filter outlet 3 fill the hose and seawater pump with clean water 4 reconnect the hose to the water filter outlet and 5 open the seacock Confirm seawater pump operation on startup as indicated by water discharge from the exhaust outlet Section 2 Operation 41 2 22 Marine Inspection Kohler Co recommends that all boat owners have their vessels inspected at the start of each boating season the US Coast Guard the local Coast Guard Auxiliary or local state agency Kohler Co also recommends having the generator s exhaust system inspected at the start of each boating season by an authorized Kohler distributor dealer Repair any problems identified before operating the generator set WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas present in exhaust gases Carbon monoxide is an odorless colorless tasteless nonirri
176. ilohertz kilojoule kilometer kilo ohm kilopascal kilometers per hour kilovolt kilovolt ampere kilovolt ampere reactive kilowatt kilowatt hour kilowatt mechanical kilowatt thermal liter local area network length by width by height pound pounds pounds mass per cubic feet line circuit breaker liquid crystal display light emitting diode liters per hour liters per minute low oil pressure liquefied petroleum liquefied petroleum gas left side sound power level weighted low water level low water temperature meter milli 1 1000 mega 106 when used with SI units male cubic meter cubic meters per hour cubic meters per minute milliampere manual maximum megabyte 220 bytes molded case circuit breaker one thousand circular mils megohmmeter megahertz mile one one thousandth of an inch minimum minute miscellaneous megajoule millijoule millimeter mOhm mQmilliohm MOhm MQmegohm MOV MPa mpg mph MS ms nat gas metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mounting Motoren und Turbinen Union megawatt milliwatt microfarad normal power source not available not applicable natural gas 112 Appendix NBS NEC NEMA NFPA Nm NO no nos NPS NPSC NPT NPTF NR ns OC OD OEM OF opt OS OSHA OV 07 ph 2
177. ing they will remain running but the original source of that start signal will be ignored The contacts now have control Stop Signal A stop signal includes the following e Removal of start signal via contacts 3 and 4 An ATS used during a power outage exercise period etc or a remote panel used in the vessel take precedence over all other start signals e System Stop AUTO OFF Press AUTO and OFF simultaneously to send a stop signal to cancel the system start NOTE This will not do anything if the System start is not active Press AUTO and OFF on any controller in the system e Communications based stop message from SiteTech or a CAN based remote panel 44 Section 2 Operation Engine Cooldown Cooldownis a state where the generator is running at no load to allow hot engine components time to cool slowly before the engine is stopped In paralleling applications this occurs with the circuit breaker open When the generator set is running in AUTO mode AUTO RUN an engine cooldown cycle begins when the remote start input is deactivated Also if stopping due to a stop signal a cooldown cycle begins If the Cooldown Override is disabled OFF in the Generator Configuration Menu coolant temperature is ignored The generator will enter cooldown when the start signal is removed only ifthe engine control switch is in AUTO The engine will run for a period of time equal to the Cooldown Delay parameter setting regardless o
178. ircuit breaker a close command is being sent to the circuit breaker This notice only appears in paralleling applications where the bus sensing is connected to the bus side of the paralleling breaker Contactor This notice message indicates that the controller wants to be connected to the paralleling bus If a contactor is used for paralleling this output controls it This notice only appears in paralleling applications where the bus sensing is connected to the bus side of the paralleling breaker Emergency Power System EPS Supplying Load This notice message indicates when the generator set supplies more than 1 of the rated standby output current Engine Cooldown Delay Active This notice message indicates that the delay for engine cooldown is active where the generator set will continue to run after the OFF RESET button is pressed The unit will continue to run until the time delay times out TP 6861 10 14 Engine Start Aid Active This notice message indicates that the start aid is active and will energize an engine equipped preheat or ether system during the crank cycle Use SiteTech software to set up this feature Engine Started This status indicates that the generator set start circuit is closed allowing the engine to crank and run Engine Stopped This status indicates that the generator set start circuit is open causing the engine to shut down Generator Running This notice indicates that the generator
179. is changed it will be updated on all the generators which are connected tothe PGEN network This parameter can be setto one of the following e Manual Fixed The order of the generators is manually set In this mode the order is set once by the user Note The controllers require that the order be valid Iftwo nodes share a common order or there is a gap in the order sequence the controllers will attempt to re sort the order until it is valid If the order is not valid automatic re sorting failed generator management will be disabled all generators will run all the time Section 1 Specifications and Features 29 e Run Time The generator management start stop order is determined by the runtime hours on the generators In this mode the order is determined to ensure that the generator with the fewest runtime hours is the last to stop Each subsequent order is assigned to generators with increasing runtime hours If a generator is not running the system will add the Run Time Threshold to the runtime hours for that generator before it considers it in the order this allows the generators to avoid starting and stopping continuously The actual runtime will have to differ by more than the threshold to force the generator order to switch the stopped generator will start synchronize to the paralleling bus and begin sharing load the running generator will soft unload disconnect from the bus cool down and stop The generato
180. ition when the generator comes online First On Delay The time that the system will wait before closing the first generator to the bus This delay should be set as low as possible but can be extended to ensure that a different generator will be the first to close One generator in the system should have the first on delay set to a low number to minimize the delay before the generator can supply power to the load 26 Section 1 Specifications and Features kW Ramp Rate The generator will load and unload against the other generators at this rate The default rate 5 sec requires 20 sec to accept 100 load Increasing the ramp rate will allow the generator to disconnect more quickly from the bus when signal to stop by generator management but may result in variations in the output voltage or frequency of the generator system The ramp rate can be decreased if there is noticeable fluctuation in the voltage or frequency when a generator is loading or unloading Trims Enable The trims are the mechanism that the paralleling system uses to keep the output voltage and frequency near the rated values when the generator system is operating The trims default is enabled on all generators but they can be disabled on some generators in the system to improve load sharing The trims should be enabled on at least one generator in the paralleling system or the voltage and frequency may drift significantly during the operation of the system Load Enab
181. jury 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 Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation 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 draining the fuel system Wipe up spilled fuel after draining the system Hazardous Noise CAUTION Hazardous noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Hazardous Voltage Moving Parts WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only whe
182. l 1 98 89 91M OZN SIM TA Z TA FIM f 5 SEd Q3VOH Avia SIL INNOlLdO OL iv oW ihigo v 81M datz N SUNN AZL NO OQ vZ 5 YIWOLSNI LINN 5 11 819 126 Sim 3 NO suadwnr Sd d NH vd HJTIOMINOO 0069 9348 6 Ze 2 080 5 Nas 181 Ns8 ei8l 181 985 8181 das 8 58 5181 458 1 81 5 1 01 S 2900 000020 OOQ 2060000666009 COO o0eO J CS 21 5180 30 6181 8 2 0 3 5 1 181 8 9 8SNI 8 WSNI 5 6 14 BA 134 cll 77771 22224
183. le The generator will unload and trip the circuit breaker when this setting is set to OFF This can be used to force a generator to soft unload and shut down for service To keep the breaker from reclosing the Sync Mode in Auto can be set to OFF see Sync Mode In Auto below A generator is not considered for generator management when Load Enable is set to OFF This parameter should always be returned to ON after the generator has been stopped for service as it will keep the generator from sharing load or stopping for generator management if it is set to OFF Stand Alone Mode This will tell the controller that it is a paralleling controller even if it does not see another generator on the communication lines This may be required if all other generator controllers are removed from service for a period of time in which the battery power to this controller will be cycled the controller remembers that itis in a paralleling system until power is cycled If the controller sees another controller on the PGEN communication network this parameter will not change the operation of the system in any way TP 6861 10 14 Sync Mode In Auto This should be left in Active but can be used to keep the controller from closing the paralleling breaker to complete a test or to take a generator out of service Setting the Sync Mode to OFF will disable the synchronizer the paralleling breaker will not close with the synchronizer disabled To remove a genera
184. ler Specifications Decision Maker 3500 Power source with circuit protection 12 or 24 volt DC 400 milliamps at 12V 200 milliamps at 24V 5 95 40 to 70 C 40 to 158 F 40 to 85 C 40 to 185 F Power drain Humidity range Operating temperature Storage temperature Note Have setup adjustments of Decision Maker 3500 controller performed only by an authorized Kohler distributor dealer The setup and adjustments are password protected EMERGENCY STOP ONLY 8 Emergency stop switch Graphical display Annunciator fault lamp Alarm horn behind panel Pushbutton rotary selector dial 1 7 Controller Features The controller features include the annunciator lamp graphical display and pushbutton rotary selector dial switches and controls and terminal blocks See Figure 1 5 for an illustration of the controller front panel The following paragraphs detail the features by general topics The controller provides e The backlit LCD liquid crystal display for monitoring the generator set functions and output values e Master control buttons with status lights e Fault lamp e Pushbutton rotary selector dial to navigate the generator set displays e Alarm horn and alarm silence switch light e Mini USB connector for PC setup using SiteTech software The controller features accessories and menu displays depend upon the engine electronic control module ECM setup
185. low The controller buttons lamps and alarm horn functions are summarized in Figure 2 3 There are three primary modes of operation selected by pressing the respective buttons e OFF e RUN e AUTO Standby Mode When the OFF button is pressed the generator set is in OFF or goes to OFF and will not start When the RUN button is pressed the generator set starts and runs until the OFF or AUTO button is pressed or until a fault is received When the AUTO button is pressed the generator set enters the Standby Mode STANDBY RUNNING or STANDBY OFF depending upon the start signal TP 6861 10 14 e OFF If the generator set was previously running pressing the OFF button immediately shuts off the generator set with no engine cooldown The generator set remains off and will not respond to a remote start signal e RUN Local Start A single generator set starts No other generator sets in the system will start or stop e AUTO Standby or System Ready The generator set is waiting for a start signal The generator set will start and run when a start signal is received via a remote start local auto start or communications based start All generator sets in the system connected by PGEN and in Standby Mode by pressing AUTO will start when any one of the generator sets receives a start signal Any generator set in the system not in AUTO will not start If Generator Management is on some generator sets may shutdown after
186. m ictu A ded eae RA 65 3 6 1 Cooling System Component Inspection 66 3 6 2 Procedure to Drain Cooling System 66 3 6 3 Procedure to Flush and Clean Cooling System 66 3 6 4 Procedure to Refill Cooling System 66 3 6 5 om s Lett eae e LEE RE 67 3 6 6 Impeller Inspection and Replacement Procedure 67 3 Exhaust System ziii ce pats dee tad a 68 3 8 Storage 69 3 8 1 Lubricating System 69 3 8 2 Cooling System 69 3 8 3 Fuel System neres oue HALE RR Aaa 69 3 8 4 ee PER 69 3 8 5 Battery sce Diac ua kn EI RR Sampa MUI 69 Section 4 Troubleshooting 71 4 1 Controller Display and Voltage Regulation Troubleshooting Chart 75 Section 5 Wiring Diagrams 77 Section 6 Voltage Reconnection 105 6 1 Introduction RR fia eg eine ay etm 105 Section 7 Accessories 5 sR
187. 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 height by width by depth 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 International Building Code 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 internet protocol International Organization for Standardization joule Japanese Industry Standard kilo 1000 kelvin kiloampere kilobyte 21 bytes Kohler communication protocol kilogram Appendix 111 kg cm2 kgm kg m3 kHz kJ km kOhm kPa kph kV kVA kVAR m3 m3 hr man max MB MCCB MCM meggar MHz mi mil min misc MJ mJ mm kilograms per square centimeter kilogram meter kilograms per cubic meter k
188. ment 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 Hot Parts 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 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 Notice NOTICE Fuse replacement Replace fuses with fuses of the same ampere rating and type for example SAB or 314 ceramic Do not substitute clear glass type fuses for ceramic fuses Refer to the wiring diagram when the ampere rating is unknown questionable NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Safety Precautions and Instructions 7 Notes 8 Safety Precautions and Instructions TP 6861 10 14 This manual provides operation ins
189. n 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 Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity 15 present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn off the main circuit breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution TP 6861 10 14 Disconnecting the electrical load Hazardous voltage can cause severe injury or death Disconnect the generator set from the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and heavily taping the ends of the leads High voltage transferred to the load during testing may cause personal injury and equipment damage Do not use the safeguard circuit breaker in place of the line circuit breaker The safeguard circuit breaker does not disconnect the generator set from the loa
190. n a section Appendix A Abbreviations also includes many abbreviation definitions Tech Tools Note Tech Tools is for Kohler authorized personnel only Access Tech Tools to find the following topics e Software used by generator set controllers including updates and documentation references e Network Communications provides basics to terms protocols standards wiring configurations and model e Engine Electronic Control Module ECM has information about electronic devices provided by the engine manufacturer to manage engine data Introduction 9 Service Assistance For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer e Consult the Yellow Pages under the heading Generators Electric e Visit the Kohler Power Systems website at KOHLERPower com e Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product e Call toll free in the US and Canada 1 800 544 2444 e Outsidethe US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Serv
191. n was taken in the allotted time TP 6861 10 14 2 6 5 Status and Notice Digital Displays Warnings and shutdown faults appear on the digital display under the Active Events menu and become part of the event history Beyond the warnings and shutdowns there are several events which also appear on the digital display under the Active Events menu Status is an event that is not an alert but is part of the event history Notice is an alert that is not part of the event history The controller allows a selected number of changes by the user for setting up the controller application which are covered in this section Alarm Horn Silence This status message indicates whether the alarm horn can be silenced in any button mode OFF RESET AUTO RUN or requires the AUTO button be pressed first compliant per NFPA 110 Use SiteTech software to change this setting See Section 2 6 6 Controller Resetting procedure for information on resetting the system The local display shows Alarm Silence Always when the alarm horn can be silenced with the master control buttons in any position default setting The local display shows Alarm Silence Auto Only when the alarm horn can be silenced only when in the AUTO mode The correct reset sequence requires pressing the OFF RESET button then pressing the AUTO button and then pressing the ALARM SILENCE button Close Breaker This notice message indicates that the controller is attempting to close the c
192. n within the preset time delay of initiating engine cranking the ignition and crank circuits turn off for the preset period and the cycle repeats The fault lamp illuminates red the alarm horn sounds and the unit shuts down after the second cycle of the preset period of cranking Low Coolant Level The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of low coolant level Shutdown occurs 5 seconds after low coolant level is detected Low Engine Oil Level The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of low engine oil level This fault feature requires an optional low engine oil level sensor for the lamp to function Low Engine Speed The fault lamp illuminates red the alarm horn sounds and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models drops below the under speed setting Low Fuel Level diesel powered models only The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the fuel tank level on diesel fueled models approaches empty This fault requires an optional low fuel level switch for the lamp to function Low Fuel Pressure The fault lamp illuminates red the alarm horn sounds and the unit shuts down when low fuel pressure occurs This fault requires an optional low fuel pressure switch for the lamp to function Low Generator Frequency The fault lamp illuminates red the alarm horn sou
193. ncrease the risk of electrocution 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 Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure 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 if the generator set has a coolant recovery tank Section 3 Scheduled Maintenance 65 3 6 4 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 Check the pressure cap seal and replace 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
194. nd outlet flapper for cracks leaks and corrosion Ensure that the carbon monoxide detector s is 1 inthe craft 2 functional and 3 energized whenever the generator set operates For your safety Never operate the generator set without a functioning carbon monoxide detector s for your safety and the safety of others on your vessel Exhaust System Inspection Points Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections e Check the hoses for softness cracks leaks or dents Replace the hoses as needed e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect the exhaust system 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 TP 6861 10 14 3 8 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 8 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 generator set for a minimum of 30 minutes to bri
195. nd the unit shuts down when the local or optional remote emergency stop switch activates Fuel Tank Leak The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the fuel tank signals a leak of the inner tank This fault requires an optional fuel tank leak switch for the lamp to function Generator Total Real Power High The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the generator set supplies more than 102 of the rated standby output kW or 112 of the rated prime power output kW for more than 60 seconds High Coolant Temperature The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of high engine coolant temperature The high coolant temperature shutdown does not function during the preset inhibit time delay period after startup TP 6861 10 14 Note The high engine temperature shutdown function and the low coolant level shutdown function are independent A low coolant level condition may not activate the high engine temperature switch High Engine Speed The fault lamp illuminates red the alarm horn sounds and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models exceeds the over speed setting High Intake Air Temperature The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of high intake air temperature The shutdown occurs 5 seconds after the engine intake air rea
196. nds and the unit shuts down when the frequency drops below the underfrequency setting See Figure 2 8 for underfrequency specifications Underfreq Setting Underfrequency Range Time Delay Default Setting 8096 9596 of 10 sec short term nominal 60 sec long term 90 of nominal Figure 2 8 Underfrequency Specs Low Generator Voltage Each Phase The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the voltage drops below the undervoltage setting for the time delay period See Figure 2 9 for undervoltage specifications 50 Section 2 Operation Undervoltage Undervoltage Setting Range Time Delay Range Default Setting 7096 9596 of nominal 8096 of nominal at 5 30 sec 10 sec Figure 2 9 Undervoltage Specs Low Oil Pressure The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of low oil pressure The shutdown occurs 5 seconds after the low pressure condition is detected The low oil pressure shutdown does not function during first the 30 seconds after startup Max Alternator Current Low The fault lamp illuminates red the alarm horn sounds and the unit shuts down when Alternator Protection Configuration in the personality profile is not correct The controller may need a new personality profile Check the voltage frequency and connection settings Consult your local authorized distributor Cil Pressure Open Circuit The fault lamp illuminates re
197. ne is presently running Oil Pressure displays the engine oil pressure Coolant Temperature displays the engine coolant temperature Fuel Rate displays the calculated fuel consumption rate based on fuel injector outputs if available from ECM Gen Battery Voltage displays the DC voltage of the generator starting battery ies as measured by the controller ECM Battery Voltage displays the DC voltage of the engine starting battery ies as reported from the ECM Oil Temperature displays temperature the engine oil Coolant Pressure displays for the engine coolant pressure Fuel Pressure displays the fuel line pressure atthe generator set inlet for gas powered models Fuel Temperature displays the fuel supply temperature Fuel Used Last Run displays the accumulated amount of fuel used since last reset if available from ECM Crankcase Pressure displays crankcase pressure the engine Intake Air Pressure displays the engine intake manifold air pressure if available Intake Air Temperature displays the engine intake manifold air temperature if available Section 1 Specifications and Features 21 1 8 3 Overview Submenu Generator Status Average Volts Line to Line For three phase configurations the average line to line voltage of 11 12 and 13 is displayed Single phase configurations show the L1 L2 voltage Average Current value displays as the average for three phase configurations or the current val
198. ng 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 8 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 TP 6861 10 14 3 8 3 Fuel System Prepare the fuel system for storage as follows Diesel 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 service manual 3 8 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of
199. oil over unpainted metallic surfaces to inhibit rust and corrosion 3 8 5 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to the battery manufacturer s instructions for the battery cleaning procedure 4 Place the battery in a cool dry location 5 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 6 Maintain a full charge to extend battery life Section 3 Scheduled Maintenance 69 Notes 70 Section 3 Scheduled Maintenance TP 6861 10 14 This section contains generator set troubleshooting diagnostic and repair information Use the following charts as a quick troubleshooting reference The table groups generator set faults and suggests likely causes and remedies The table also refers you to more detailed information including sections of this manual the generator set service manual S M the generator set installation manual and the engine service manual Engine S M to correct the indicated problem Corrective action andtesting often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service distributor dealer perform service T
200. oltage connection and paralleling bus voltage sensing connections Ethernet Connector connects to a network communication line TP 6861 10 14 Note A Analog D Digital Section 1 Specifications and Features 39 1 11 3 For Units Equipped with 3rd Party e Every ECM handles their respective sensor readings Marine Option and values independently and the ECM may send warnings or cause shutdowns on their own Refer to Additional engine sensors are provided to satisfy 37 the respective Engine ECM documentation for unique party approval requirements Handling of these handling redundant sensors is described below e Lowcoolant pressure and or loss of coolant pressure e All units will have two oil pressure sensors If the readings will cause a warning only not a shutdown engine is equipped with an ECM the primary oil pressure sensor 1 will go to the ECM and the All 3rd party marine agency approved kits include a primary oil pressure readings are derived from CAN secondary fuel shut off A secondary fuel shut off is communications If the engine is not equipped with required for 3rd party approval See Figure 1 12 an ECM the primary oil pressure sensor connects to the genset controller at one of the auxiliary analog inputs and primary oil pressure readings will be measured directly by the controller On all units the secondary oil pressure sensor 2 connects to the genset controller at one of the auxiliary analog in
201. oltage and power Average Generator Voltage High The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters an over voltage condition This condition can be caused by a loss of sensing wire a winding failure voltage regulator failure etc The output breaker trips The generator may continue to produce excessive voltage until it is shut down 46 Section 2 Operation Average Generator Voltage Low The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters an under voltage condition This condition can be caused by a loss of a diode on the rectifier bridge sensing problem a winding failure voltage regulator failure etc The output breaker trips The generator may continue to produce insufficient voltage until it is shut down Battery Charger Fault The fault lamp illuminates yellow and the alarm horn sounds when the battery charger malfunctions This fault feature requires an optional battery charger with a malfunction output for the lamp to function Cabinet Intrusion The fault lamp illuminates yellow and the alarm horn sounds when the door to the unit was opened Common Warning The fault lamp illuminates yellow and the alarm horn sounds when the controller is signaled by a common warning Use SiteTech software to activate the common warning The common warning comprises all of the warnings under a single alert Critically High Fuel Level diesel powered models
202. on level reduces generator set reactive current or generated VARs improving reactive load sharing Enter the parameter as a percentage of system voltage when full rated load with 0 8 power factor is applied Any loads less than full load force the voltage to drop by the ratio of reactive volt amps VARs to rated VARs Voltage Gain Adjust Regulator gain refers to the gain of the control system Generally the higher the gain the faster the system responds to changes and the lower the gain the more stable the system If the voltage is slow to recover when loads are applied or removed increase the regulator gain Ifthe voltage is unstable decrease the regulator gain The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage Changing the system voltage or replacing the circuit board typically requires a voltage adjustment The user can change the individual value or can select Reset Regulator Defaults Yes to reset to the default value The Reset Regulator Defaults display will only show if editing is enabled Start Up Ramp Rate Slowly ramps the voltage to its target to minimize voltage overshoot at startup Section 1 Specifications and Features 25 1 9 5 Voltage Selector Switch The voltage selector switch menu does not apply to the EOZDJ EFOZDJ and EOZCJ EFOZCJ models 1 9 6 Paralleling Operation Note Have paralleling setup performed by appropriately skilled suitably
203. operation Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a container to catch fuel when draining the fuel system Wipe up spilled fuel after draining the system WARNING 0 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner silencer removed NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces Section 3 Scheduled Maintenance 61 WARNING KS 2 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 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting th
204. or even in single phase applications Voltage Bias The amount that the controller is attempting to adjust the output voltage of the generator 10096 bias 10 on the output voltage 100 1096 on the output voltage The controller adjusts the voltage bias to share reactive load between the generators connected to the paralleling bus TP 6861 10 14 Note The metering values in this screen are populated regardless of the state of the generator system but the system must be a sharing mode before it will attempt to match generator and bus loading Protective Relays The protective relays serve two purposes 1 To protect the generator from damage and 2 To protect the loads supplied by the generator from damage The protective relays are configured during commissioning and should not be adjusted except by a trained commissioning agent These settings are often taken into consideration for breaker trip curves load control settings and generator management settings The adjustment without careful consideration of the implications may mask a problem in the system and cause another Properly configured protective relays should only trip due to a failure Note All protective relay events will trip the breaker but will not stop the generator until the Trip to Shutdown Delay has expired During this time the protective relay which tripped the breaker will be listed under the Active Events the warning LED will be active
205. ority is shed the accumulator for shedding load is reset Note Additional load control settings are provided in SiteTech but they are configured during commissioning and should not require adjustment after commissioning is complete Have setup and adjustments of the Decision Maker 3500 controller performed only by an authorized Kohler distributor dealer 1 10 Controller Configuration Menu 1 10 1 Controller Configuration Submenu Language displays the user selected language At this time English is the only available option Units displays the user selected unit of measure as Metric or English Time Format displays the user selected time format as 12 hours or 24 hours Date Format displays the user selected date format as mm dd yyyy or dd mm yyyy Contrast displays user selected resolution values to improve digital display clarity Alarm Silence displays the programmer selected alarm silence method Always or Auto Only using SiteTech software The Always selection activates the alarm horn in any of the OFF RESET AUTO RUN modes The Auto Only selection activates the alarm horn only when in the Auto mode Note Press the Alarm Silence Lamp Test button to silence the alarm horn 1 10 2 Communication Setup Submenu Modbus Communications The controller communicates using Modbus as a slave connection with the Modbus master initiating the communication The controller seeks the system and alternator paramete
206. puts and secondary oil pressure readings will be measured directly by the controller e All units will have a single analog coolant pressure sensor This sensor connects to the genset controller at one of the auxiliary analog inputs and coolant pressure readings will be measured directly by the controller GM88314 A e All units will have a single analog oil temperature sensor This sensor connects to the genset controller 1 Transfer pump supplied by engine manufacturer as part of the filter assembly at one of the auxiliary analog inputs and oil 2 Secondary fuel shut off valve temperature readings will be measured directly by the controller Figure 1 12 Secondary Fuel Shut Off Valve Location Equipped On Agency Approved Kits e Allunits will have two coolanttemperature sensors If 80 99 kW shown the engine is equipped with an ECM the primary coolant temperature sensor 1 will go to the ECM and the primary coolant temperature readings are derived from CAN communications If the engine is not equipped with an ECM the primary coolant temperature sensor connects to the genset controller at one of the auxiliary analog inputs and primary coolant temperature readings will be measured directly by the controller On all units the secondary coolant temperature sensor 2 connects to the genset controller at one of the auxiliary analog inputs and the secondary coolant temperature readings will be measured directly by the controller
207. r larger differences between Bus Total Power and Start kW Stop kW The threshold of Bus Total Power below which the Stop Accumulator for this generator will start filling Note The Accumulator fill rate is higher for larger differences between Stop kW and the Bus Total Power Preemptive Warnings A preemptive warning tells the system that a generator may have a problem in the future If Generator Management has stopped the generators it will start one of the unused generators but keep the running generator with the preemptive fault online The following conditions are considered preemptive warnings e Low Oil Pressure Warning e Low Fuel Pressure Warning e High Coolant Temperature Warning e Failure to Synchronize Warning e Water in Fuel Warning e Fuel Tank Leak Warning e Loss of Fuel Warning Apreemptive warning disables Generator Management on the unit which has the warning It will run as long as the start signal is present Note Most of the preemptive warnings have a shutdown which follows shortly after the warning The intent of starting another generator is that it will be able to supply the load when the generator shuts down on a fault TP 6861 10 14 Start Accumulator The Start Accumulator fills from 096 to 100 while the Bus Total Load remains above the Start kW This generator will be signaled to start when this accumulator reaches 100 Note The Start Accumulator will reset to 096 if the Bus Total Power d
208. r management order is not user adjustable in runtime mode Note If the load on the system requires an additional generator to start the generator with the most runtime hours will always be the first one to stop if the load decreases enough to permit it the threshold is no longer taken into consideration as soon as the generator is connected to the paralleling bus Fuel Level The generator management start stop order ofthe generators is determined by the level of the fuel in the tank which supplies each generator In this mode the order is determined to ensure that the generator with the most fuel is the last to stop Each subsequent order is assigned to generators with decreasing fuel percentage If a generator is running the system will add the Fuel Level Threshold to the measured Fuel Level for that generator before it considers it in the order This allows the generators to avoid starting and stopping continuously The actual fuel level will have to differ by more than the threshold to force the generator order to switch the stopped generator will start synchronize to the paralleling bus and begin sharing load and the running generator will soft unload disconnect from the bus cool down and stop The generator management order is not user adjustable in Fuel Level mode 30 Section 1 Specifications and Features Note Fuel Level Order Selection mode requires separate fuel tanks for the generators and fuel level senders
209. re not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate 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 not sit 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 Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings 6 Safety Precautions and Instructions Fuel System WARNING Explosive fuel vapors Can cause severe in
210. re to define inputs as shutdowns or warnings TP 6861 10 14 Common Fault The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the controller is signaled by a common fault Use SiteTech software to activate the common fault shutdown The common fault comprises of any combination of the fault shutdowns under a single alert Coolant Temperature Open Circuit The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the engine coolant temperature sender circuit is open ECM Communications Loss The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the ECM communication link is disrupted ECM Diagnostics Multiple Engine Inputs The fault lamp illuminates red the alarm horn sounds and the unit shuts down when ECM diagnostics signals the controller The specific display xxxxx will be a brief message or fault code that is engine manufacturer dependant The engine literature provides the fault code description and further information ECM Model Mismatch The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the controller detects an error with the ECM model Electrical Metering Communication Loss The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the metering to the controller communication link is disrupted Emergency Stop The fault lamp illuminates red the alarm horn sounds a
211. regarding the coolant mixture to use in extreme temperatures TP 6861 10 14 6 Replace the pressure cap 7 Fill the coolant recovery tank to the low mark 8 Operate generator set until the thermostat opens when the upper cooling system hose warms 9 Stop the engine and allow it to cool 10 Check and repair any coolant leaks 11 Remove the pressure cap 12 Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck 13 Replace the pressure cap 14 Maintain the coolant level in the coolant recovery tank between the high and low marks 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 coolantlevelstabilizes Then checkthe coolant at the interval specified in the service schedule 15 Reenergize the block heater if equipped 3 6 5 Siphon Break A siphon break prevents seawater entry into the generator set s engine when the engine exhaust manifold outlet is less than 230 mm 9 in above the waterline of a fully loaded docked or stationary craft The siphon break may malfunction when the generator set operates while the craft is in contaminated waters or saltwater Use the following procedure to inspect the siphon break at the intervals listed in the service schedule Siphon Break Inspection 1 Cap
212. rol relay if they are configured to a digital output Only 4 load control priorities can be configured to the RDO outputs on the controller 2 in paralleling applications but the optional 14 relay dry contact kit will permit all 6 load control priorities to be accessed and configured to disconnect 6 different loads each load priority can interrupt several devices In paralleling applications the load shed priorities can be divided between all the generators For instance Generator 1 can support Load Priorities 1 4 Generator 2 can support Priorities 2 and 5 and Generator 3 can support Priorities 3 and 6 This configuration does not require the 14 relay dry contact kit and permits partial load shed functionality even if one controller is powered down or fails redundancy Load Priority 1 is shed last and added first the priorities are added in increasing sequence and shed decreasing sequence All Load Priorities are immediately shed when load control is initiated Load control is initiated when the system receives a start signal a system start a remote start or a start by communication In a paralleling application the controller can receive a start signal from any generator which is connected to the PGEN communication network Pressing RUN the controller will not cause the loads to shed All loads are added immediately when Load Control is de activated this occurs when the start signal is removed Loa
213. rops below the Start kW for one second The Start Accumulator may be filling while the engine is running in cooldown If it reaches 100 before the cooldown is complete the generator will synchronize and close to the bus it will not have to go through a start sequence Stop Accumulator The Stop Accumulator fills from 0 to 10096 while the Bus Total Load remains below the Stop kW This generator will be signaled to stop when this accumulator reaches 100 Note The Stop Accumulator will reset to 0 if the Bus Total Power exceeds the Stop kW for one second The generator may remain running and connected to the paralleling bus for a few seconds after the Stop Accumulator reaches 096 During this time the generator is unloading so that it can trip the circuit breaker connecting itto the bus with minimal wear onthe contacts in the breaker and minimal disturbance to the voltage and frequency of the system Run Time Threshold The maximum difference in runtime hours that generator management will accept before it re sorts the Start Stop Order of the generators to equalize hours see Gen Management Order earlier in this section All the generators in the system must have the same setting for the Run Time Threshold for the generator management operate If this parameter is changed it will be updated on all the generators which are connected to the PGEN network Total Run Time The actual runtime hours of this generator to the neares
214. rs and diagnostic information then responds back to the Modbus master In addition the controller accepts information to alter controller parameters including generator set starting and stopping See Figure 1 8 Refer to the List of Related Materials for available Modbus literature Modbus is a registered trademark of Schneider Electric 34 Section 1 Specifications and Features Note Only one Modbus master can be connected to the controller Examples include the remote serial annunciator monitoring software and switchgear applications RS 485 up to 1220 m 4000 ft Generator Set Modbus Master Controller RS 232 up to 15 m 50 tt Figure 1 8 Modbus Connections A controller can communicate directly to a Modbus master or participate in a network of devices It can also be used to interface a local master to a network of devices The Modbus master polls slave devices for data Controller devices are slaves Examples of master devices are a personal computer running monitoring software and the remote serial annunciator SiteTech Group Parameter Modbus Address Setting Use a unique network address between 1 and 247 for each unit Use 1 for a single connection Do not use 0 zero Baud rate 9600 19200 38400 or 57600 Must match the PC and all devices in the system Figure 1 9 Decision Maker 3500 Communication Parameters Select the baud
215. rsonal Telephone Computer lines Figure 2 16 Remote Single Connections 2 8 2 Modbus Communications The controller communicates using Modbus as a slave connection with the Modbus master initiating the communication The controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus master In addition the controller accepts information to alter controller parameters including generator set starting and stopping See Figure 2 17 Refer to the List of Related Materials for available Modbus literature Note Only one Modbus master can be connected to the controller Examples include the remote serial annunciator Monitor and switchgear applications RS 485 up to 1220 m 4000 ft Generator Set Modbus Master Controller Figure 2 17 Modbus Connections Section 2 Operation 59 Notes 60 Section 2 Operation TP 6861 10 14 Section 3 Scheduled Maintenance Under normal operating conditions the generator set s alternator requires no routine service Consult Section 2 1 Prestart Checklist for a list of routine checks 3 1 Alternator Service WARNING Hazardous voltage Moving parts 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 deat
216. s the low battery voltage warning during the crank cycle Section 2 Operation 47 Low Coolant Temperature The fault lamp illuminates yellow and the alarm horn sounds when the engine coolant temperature is low The low coolant temperature warning does not function during the preset inhibit time delay period after startup Low Cranking Voltage The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below 60 of the nominal voltage 12 VDC or 24 VDC for more than 6 seconds during the crank cycle Low Engine Oil Level The fault lamp illuminates yellow and the alarm horn sounds because of low engine oil level This fault feature requires an optional low engine oil level sensor for the lamp to function Low Fuel Level The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel fueled models approaches empty This fault requires an optional low fuel level switch for the lamp to function Low Fuel Pressure The fault lamp illuminates yellow and the alarm horn sounds when low fuel pressure occurs This fault requires an optional low fuel pressure switch for the lamp to function Low Genset System Frequency The fault lamp illuminates yellow and the alarm horn sounds when another generator in the paralleling system has a higher system frequency than this generator The local display shows System Frequency FMI Low Low Genset System Voltage The fault lamp illumina
217. s value is only updated when the controller is synchronizing Synch Mode Active Passive or Check breaker is open generator is running Section 1 Specifications and Features 27 Bus Frequency The operating frequency of the paralleling bus Gen Frequency The operating frequency of this generator Speed Bias The amount that the controller is attempting to adjust the output frequency of the generator 100 bias 5 onthe engine speed 100 5 on the engine speed The controller adjusts the Speed Bias to match frequency and phase with the paralleling bus Phase Matched The phase between the generator voltage and the bus voltage is within the acceptable window This value is only updated when the controller is synchronizing Synch Mode Active Passive or Check breaker is open generator is running Phase Difference The phase angle between the generator and the bus Note This value is only accurate if the generator is running and the bus is energized The phase angle must be established between two waveforms Dwell Time Remaining The remaining time for the dwell timer in seconds The generator is considered to be in Sync when the dwell timer expires If this value is resetting to the Dwell Time directly above it the generator is not holding synchronism This value is only updated when the controller is synchronizing Synch Mode Active Passive or Check breaker is open generator is running Sync Time
218. sage is sent each time there is a change in a monitored engine condition i e fault becomes active fault is cleared Upon broadcast of this message the controller will request another message that contains the following information for each fault TP 6861 10 14 SPN Suspect Parameter Number is a four digit code that represents an engine component FMI Failure Mode Indicator is a two digit code that represents the type of fault that occurred i e short circuit out of range Occurrence Count is a count of how many times a fault has occurred 1 9 3 Configuration Submenu Generator Configuration The values in this menu are user entered for the generator set configuration and are NOT measured values of the generator set Note Have setup and adjustments of the Decision Maker 3500 controller performed only by an authorized Kohler distributor dealer The setup and adjustments are password protected Operating Mode displays the programmer entered generator set application configuration as Standby or Prime Application Type displays the programmer entered generator set application type as None Marine Mobile Standby or Prime e System Voltage displays the programmer entered L1 L2 L3 output voltage for three phase or the L1 L2 output voltage for single phase System Frequency displays the programmer entered L1 L2 L3 output voltage frequency for three phase or the L1 L2 output voltage frequency for single phase S
219. shown with Generator Set Calibration in 2 6 5 Status and Notice Digital Displays disable calibration Rotate the pushbutton rotary selector dial until the lt Return popup appears Momentarily press the pushbutton rotary selector dial Stop the generator set if not already done Section 1 Specifications and Features 35 1 11 Setup Menu Note Have setup and adjustments of the Decision Maker 3500 controller performed only by an authorized Kohler distributor dealer Analog and Digital Input Setup There are three types of inputs setups 1 Analog Resistive 2 Analog Differential used in paralleling applications 3 Digital Note Analog a sender variable resistant device Digital a switch with contacts The I O Setup Menu displays the setup of digital and analog warning and shutdown inputs These inputs provide choices for configuring customized auxiliary inputs The user must enable the programming mode to edit the display See Section 2 7 for changeable settings in this menu Descriptions Descriptions for user inputs auxiliary analog or auxiliary digital may be entered using the SiteTech software accessory where the user determines the descriptions Enabled This menu indicates whether or not the input is enabled If the input is not enabled the controller will ignore this input signal Analog inputs have separate warning and shutdown enabled choices Inhibit Time Delay The inhibit time del
220. shut down turned Off by Generator Management Even if the generator set is Off it may de activate its Load Control outputs to energize those loads This may seem counter intuitive but the generator sets are acting asa system If voltage and frequency of the paralleling bus are adequate and Load Add accumulators are met the loads will be enabled even if a particular generator set is shut down by the Generator Management Description of User Adjustable Load Control Settings The Load Control settings are found under GENERATOR INFO gt PARALLEL OPERATION gt LOAD CONTROL Load control is active even if the generator is not operating in a paralleling application Gen Max Cap The load level on the generator or paralleling bus in a paralleling application that the load control will not intentionally exceed If the load is within 15 of this load level the load control will not add the next priority until the load decreases or another generator starts synchronizes and closes its paralleling breaker in a paralleling application Gen Overload Percent The load level on the generator or paralleling bus in a paralleling application above which the load Control will start to consider shedding loads Loads will shed more quickly if the generator is heavily overloaded more slowly if the Section 1 Specifications and Features 33 generator is barely overloaded If the load drops below the Gen Overload Percent before a load pri
221. t breakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution 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 Wiring Voltage Model Controller Diagram Figure Schematic Figure Reconnection Figure Figure 5 1 40EOZD C J Figure 5 4 GM93788 A Figure 5 2 ADV 8717 A 33EFOZD C J Figure 5 3 Figure 5 5 40EFOZD C J Figure 5 6 GM93789 A Figure5 7 ADV 8718 A 50EFOZD C J Figure 5 8 g 55EOZD C J 45EFOZD C J Figure 5 11 _ 93790 Figure 5 12 ADV 8719 A Figure 5 14 65EOZD C J m Figure 5 13 igure 5 15 55EFOZD C J Decision Maker 3500 ADV 5875F R Figure 6 1 80EOZD C J 7OEFOZD C J igure 5 GM93791 A Figure 5 17 ADV 8720 A Figure 5 19 99EOZD C J Figure 5 18 igure 5 20 80EFOZD C J 125EOZD C J EN 100EFOZD C J igure 5 I a GM93792 A Figure 5 22 ADV 8721 Figure 5 24 150EOZD C J Figure 5 23 Figure 5 25 125EFOZD C J DWG GM35943 Wiring Diagram GM35943 D Figure 5 26 Interconnection Diagram for Decision Maker 3500 GM88254 Figure 5 27
222. t tenth of an hour This parameter is also available in the Generator Information screen but is rounded to the nearest hour Fuel Level Threshold The maximum difference in fuel level that generator management will accept before it re sorts the Start Stop Order of the generators to equalize fuel level See Gen Management Order earlier in this section All the generators in the system must have the same setting for the Fuel Level Threshold for the generator operate If this parameter is changed it will be updated on all the generators which are connected to the PGEN network Section 1 Specifications and Features 31 Fuel Level The level of the fuel in the tank supplying this generator This is available in the engine metering section in SiteTech but not elsewhere on the User Interface If no fuel level sensor is connected this parameter will display N A Do not use Fuel Level as the Generator Management Mode if there is no fuel level sensor connected the operation of the system is not defined in this case Stable Delay The time between the system entering a valid generator management state and the time that generator management becomes active A valid generator management state requires e A Start Signal is present Local start remote start or communications start A least one generator is closed to the paralleling bus Generator Management is enabled The configuration of vital parameters of the
223. tating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles Sleepiness mental fatigue inability to concentrate 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 not sit 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 Inspecting the exhaust system Carbon monoxide can cause severe nausea fainting or death For the safety of the craft s occupants install a carbon monoxide detector Never operate the generator set without a functioning carbon monoxide detector Inspect the detector before each generator set use Operating the generator set Carbon monoxide can cause severe nausea fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the craft so that the exhaust discharges on the lee side the side sheltered from the wind Always be aware of others making sure your exhaust is directed away from other boats and buildings 42 Section
224. termine a similar function when making changes to alternator connections system voltages or operating frequency TP 6861 10 14 Volts Hz Setpoint This adjustment affects the voltage droop volts per Hz when load is applied and underfrequency occurs The volts Hz setpoint setting defines the threshold below which the underfrequency unloading is active Any frequency below the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the volts Hz slope setting Engine speed recovery depends upon characteristics such as engine make fuel type load types and operating conditions The volts Hz setpoint setting is set at the factory to match the engine speed recovery characteristics for the application Volts Hz Slope This setting determines how much the voltage drops during an underfrequency condition The Volts Hz Slope setting is set at the factory Typically applying a large electrical load causes a dip in engine speed and frequency The voltage regulator reduces voltage allowing engine speed recovery The volts per Hz setting determines the degree of unloading that occurs for each 1 Hz decrease in frequency Voltage Droop at 100 kVAR Reactive Droop Reactive droop compensation provides reactive current flow adjustment in the generator set when connected in paralleling applications Reactive droop reduces excitation levels with increasing reactive current A reduced excitati
225. tes yellow and the alarm horn sounds when another generator in the paralleling system has a higher system voltage than this generator The local display shows System Voltage FMI Low Low Oil Pressure The fault lamp illuminates yellow and the alarm horn sounds when the engine oil pressure approaches the shutdown range The low oil pressure warning does not function during first the 30 seconds after startup Not in Auto Generator Master Control Switches The fault lamp illuminates yellow and the alarm horn sounds when the generator set button is in the RUN or OFF RESET mode Option Board 2X Communication Loss The fault lamp illuminates yellow and the alarm horn sounds when the communication with option board 2X A B or C has been lost 48 Section 2 Operation Reserve Oil Empty The fault lamp illuminates yellow and the alarm horn sounds when the oil makeup kit level has dropped below a threshold Speed Sensor Fault The fault lamp illuminates yellow and the alarm horn sounds when the speed signal is absent for one second while the generator set runs Total Reactive Power Low The fault lamp illuminates yellow and the alarm horn sounds when the generator has a loss of field condition due to insufficient reactive load production to support real load The output breaker trips 2 6 4 System Fault Shutdown Lamp With Digital Displays The system FAULT lamp glows red the alarm horn sounds and the unit shuts down to indicate a f
226. tion Check seawater strainer Before operation Block heater operation if equipped Weekly Flexible hoses and connectors x Weekly Water pump s Weekly Check the function of the siphon break if equipped 3 Months or 100 Hrs Inspect and replace zinc plugs 6 Months or 250 Hrs Check the seawater pump impeller x 6 Months or 250 Hrs Coolant temperature protection level 6 Months or 250 Hrs Check cooling system Yearly or 500 Hrs Inspect and clean heat exchanger core and aftercoolor core if equipped Replace the seawater pump impeller Yearly or 500 Hrs Pressure test cooling system 2 years or 2000 Hrs Test thermostats 2 years or 2000 Hrs Flush and refill cooling system 2 years or 2000 Hrs Inspect and repair seawater pump 2 years or 2000 Hrs Add coolant R As required Exhaust System Inspect the exhaust system components Before operation Check the exhaust gas condition If the exhaust is blue or black contact your local distributor dealer Yearly or 500 Hrs During operation Clean the exhaust water mixing elbow 6 Months or 250 Hrs Inspect the complete exhaust system Yearly or 500 Hrs Excessive back pressure Yearly Hangers and supports x Yearly 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 Repla
227. tor from service manually set the Sync Mode in Auto to OFF wait for any additional generators to start and set the Load Enable to When the breaker trips stop the generator by pressing the OFF button then set the Sync Mode back to Active and the Load Enable back to ON Note Pressing the OFF button will also disconnect the generator from the paralleling bus but it will not give the other generators any opportunity to negotiate an arrangement to support the load Even if there are enough generators online to support the load the voltage and frequency may dip when the other running generators are required to pick up the load formerly supported by this generator Sync Mode In Run The default setting for this parameter is Check In Check mode the controller will close the paralleling breaker to a dead bus no other generators supplying the load but will hold synchronism with the bus without closing the paralleling breaker if it is already supplied by another generator This allows operational verification of the synchronizer but does not allow the generator to supply the load If the generator system is to be operated with the engine control switch in Run the Sync Mode in Run may need to be set to Active Note System Start AUTO RUN is the preferred method of operating a generator system RUN is intended for testing or verification only Note Sync Mode in Auto and Sync Mode in Run can also be found on the Synchronizing Set
228. trained maintenance personnel familiar with generator set operation and service The Decision Maker 3500 controller is a paralleling controller and provides varying degrees of paralleling functionality While the Decision Maker 3500 controller can also be used with external switchgear controlling the speed voltage and paralleling breaker the Parallel Operation menu is used to configure settings for parallel operation where the controller is communicating on a network with other controllers and provides integral paralleling functionality Paralleling Setup The Paralleling Setup menu is intended to configure the basic settings for the parallel operation of the controller Most of the settings in this menu are configured during commissioning and do not require user adjustment There are a few settings that may be viewed or adjusted after commissioning is complete Volts Hz OK Delay The time that the voltage and frequency must remain within the acceptable window before the controller considers them to be stable The voltage window requires the output voltage of the generator to be within the Voltage OK Pickup of the system voltage the frequency window requires the operating frequency of the generator to be within the Frequency OK Pickup of the system frequency This delay may need to be increased if the first generator to close to the bus has not yet reached rated operating parameters or if the speed voltage is in an overshoot cond
229. trical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Section 6 Voltage Reconnection 105 00 934 75135 CASN LON SYSNYOSSNVAL L1 HOIVH3N39 LH 100 S3ASHOJSNVSHL g V NOIIVIOM 5 SALON SYOLVNYSLTV 3NOS NO OL SV 100 1H9n038 34V 9 CNV S ALON 1 0082030 OL A009 y ZH 09 YOLVNYSL 0931 9 1 Z10111 0092034 OL A9Lv OvZ ZH OG AO8v LLZ ZH 09 00 062 ZH OG A9Lv OvZ ZH 09 082 022 ZH 09 8 0 ZH 09 IH 210111 OL 805 051 ZH OG AOYZ 6 ZH 09 AO0Z SLL ZH OG AOZZ ZZL ZH 09 061 011 ZH OG 802 001 ZH 09 v QV3l 710717 AOZZ OLL ZH 05 0082034 OL OYZ OZL ZH O9 SHIM v GVST 01 1 Z10111 0057934 OL 0 2 002 021 001 ZH OS 0 2 002 021 001 ZH 09 3SVHd FIONIS NOIVNM3IIV OV3I 1 Z10111 0056230 Ol qQ3Sn LON 9 5 445 ASVHd 5 03 LON 5135 3WOS AOZZ OLL ZH OG 005 001 ZH OG AOvZ OZL ZH 09 AO0Z 001 ZH 09 jSVHd 5 JHM
230. tructions for 40 150EOZDJ EOZCJ and 33 125EFOZDJ EFOZCJ John Deere powered marine model generator sets equipped with the following controller e Decision Maker 3500 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 Obtain service from an authorized service distributor dealer to keep equipment in top condition Before installing a marine generator set obtain the most current installation manual from your local distributor dealer Only qualified persons should install the generator set TP 6861 10 14 Introduction 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 i
231. ue for L1 L2 with single phase configurations Frequency Hz value displays for the output AC voltage Engine Status Coolant Temperature displays the engine coolant temperature Oil Pressure displays the engine oil pressure Battery Voltage displays the DC voltage of the engine starting battery ies System Status 1 8 4 Fuel Pressure displays fuel injection pressure Total Power displays the generator operating power rating in kW Engine Run Time displays the total runtime hours Paralleling Metering Submenu Note The paralleling metering is only valid if the 22 Decision Maker 3500 controller is controlling the circuit breaker Connected to Bus displays if the generator is connected to the paralleling bus the output breaker or contactor is closed Avg Bus Voltage L L displays the average of the three phase line to line voltage measured by the paralleling bus sensing Avg Gen Voltage L L displays the average of the three phase line to line voltage of the generator output Bus Frequency displays the cycle frequency of the paralleling bus Gen Frequency displays the cycle frequency of the generator Section 1 Specifications and Features Bus Total Power displays the real power provided by all the generators in the paralleling system Bus of Rated kW displays the ratio between the Bus Total Power and the Bus Total Capacity found in the Generator Management screen expressed as a percentag
232. up screen TP 6861 10 14 Synchronizing Setup This screen is primarily used to configure the synchronizer There is a lot of metering information that can be accessed on this screen but the parameters should be adjusted only during commissioning Volts Hz OK The voltage and frequency have been within the acceptable window for the Volts Hz OK Delay In Sync The frequency voltage and phase rotation of the generator have matched that of the bus and the generator and bus have phase for the duration of the dwell timer This value is only updated when the controller is synchronizing Synch Mode Active Passive or Check breaker is open generator is running Voltage Matched The difference between the generator voltage and the bus voltage is within the acceptable window This value is only updated when the controller is synchronizing Synch Mode Active Passive or Check breaker is open generator is running AVG Bus Voltage L L The average voltage of the paralleling bus AVG Gen Voltage L L The average voltage of this generator Voltage Bias The amount that the controller is attempting to adjust the output voltage 100 bias 10 on the output voltage 100 10 on the output voltage The controller adjusts the Voltage Bias to match the generator voltage to the bus voltage Frequency Matched The difference between the generator frequency and the bus frequency is within the acceptable window Thi
233. ure 2 13 Controller Configuration Menu 12 00 AM 12 12 12 yo RESISTIVE INPUT SETUP DIGITAL INPUT SETUP DIGITAL OUTPUT SETUP DIAL Tun DIAL PUSH DIAL PUSH DIAL PUSH RESISTIVE INPUT SETUP 200 AM lt DIGITAL INPUT 5 200 AM DIGITAL OUTPUT SETUP 220 12 12 12 12 12 12 1212 12 gt RESISTIVE INPUT 0 1 gt DIGITAL INPUT 0 1 DIGITAL OUTPUT 0 1 RESISTIVE INPUT 0 2 DIGITAL INPUT 0 2 DIGITAL OUTPUT 0 2 RESISTIVE INPUT X X DIGITAL INPUT X X DIGITAL OUTPUT X X DIAL TURN DIAL TURN DIAL TURN DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH 12 00 AM 12 12 12 MODE FUNCTION ON OFF 12 00 AM 12 12 12 MODE RESISTIVE INPUT 0 1 220 12 12 12 DESCRIPTION MODE MEASUREMENT HH SHUTDOWN NONE INPUT ENABLED ON OFF SENSOR TYPE SENSOR WARNING ON OFF LOW PROTECTIVE INHIBIT HHS LOW WARNING ON OFF LOW WARNING LIMIT HERH LOW WARNING DELAY s_ LOW SHUTDOWN ON OFF LOW SHUTDOWN LIMIT LOW SHUTDOWN DELAY HIGH PROTECTIVE INHIBIT HIGH WARNING HIGH WARNING LIMIT HIGH WARNING DELAY HIGH SHUTDOWN HIGH SHUTDOWN LIMIT HIGH SHUTDOWN DELAY BOARD NUMBER RESISTIVE INPUT lt DIGITAL INPUT 0 1 gt DESCRIPTION MODE gt DESCRIPTION MEASUREMENT STATUS SHUTDOWN NONE FUNCTION INPUT ENABLED SENSOR TYPE SENSOR ENABLED WARNING ON OFF INHIBIT TIME 885 LOW
234. utput 0 2 Digital Output 0 3 Digital Output 0 4 Digital Output 1 1 Note Only displayed if the 15 Relay Dry Contact Kit is installed OO O 0 0 0 Description function by default unless modified via Site Tech Status ACTIVE INACTIVE Function Event G I O Board Number X Logic ACTIVE ON ACTIVE OFF Active Events Menu Rotate the dial to view Active Events Warnings Shutdowns Statuses Notices See Section 2 6 3 Section 2 6 4 and Section 2 6 5 for descriptions Press the OFF button to return to the main menu User Defined changeable Menu Displays Use SiteTech software to change other settings including User Defined Menu Displays TP 6861 10 14 Section 2 Operation 55 From Controller Power Up From Controller Sleep Idle Operation 12 00 AM e ENGINESTATUS 200A lt GENERATOR STATUS 209 AM SYSTEMSTATUS 4 COOLANT OIL PRESSURE GEN BATTERY AVG GEN AVG CURRENT GEN UELPRESSURBTOTALPOWER TOTAL RUN ITEMPERATURE VOLTAGE Altern VOLTAGE L L FREQUENCY Altern TIME KOHLER Er 1 AN ap HHV HHA 2 8 atav A Hz 8 L PSI kW HRS seconds seconds DIAL CLICK MAIN MENU 200AM 1121212 gt METERING GENERATOR INFO CONTROLLER CONFIG 1 0 ACTIVE EVENTS Changes after 3 seconds DIAL TURN DIAL PUSH at METERING Go to Figure 2 11 DIAL PUSH at GENERATOR I
235. utton rotary selector dial and display most data entries require input using a PC for initial setup The PC entriestypically include alpha characters such as digital input descriptions 2 8 1 PC Communications Communicate between a PC and the generator set controllerlogicusing USB communication protocol The PC connections require optional SiteTech software Contact your authorized distributor dealer for assistance Local Single Connection A PC connects to the USB port of the generator set controller using amini USB connector See Figure 2 15 Generator Set Controller USB Cable Personal Computer Figure 2 15 Local Single Connection Remote Single Connection A modem connects a PC to a single device The PC communicates with the device via telephone line or an ethernet network See Figure 2 16 Modbus Ethernet Converter Personal Generator Set Computer lor aon Controller or with NIC sS Transfer Switch Control Remote Network Modem Personal Telephone Computer lines Modbus is a registered trademark of Schneider Electric TP 6861 10 14 Modbus Ethernet Converter Personal Generator Set Computer Controller a gt with NIC Transfer Switch Control Remote RS 232 to Network RS 485 Port Modem Converter RS 485 up to 1220 m 4000 ft Pe
236. verfrequency Overfrequency 2 Underfrequency Underfrequency Hz Overspeed Overspeed Hz Overspeed RPM Low Battery Voltage Low Battery Voltage 4VDC High Battery Voltage High Battery Voltage 4VDC 9990 COO YOO OOOO OOO ooo ooo oo OOOO OOO OOOO OOO OOO Voltage Regulation 20 OQ Cy 0 AVG Gen voltage L L V Voltage Adjust V Target Voltage V L1 L2 Volts V L2 L3 Volts V L3 L1 Volts V Gen Frequency Hz V Hz Setpoint Hz V Hz Slope Hz Volt Droop at 100 kVAR Voltage Gain Adjust Start Up Ramp Rate s Reset Regulator Defaults YES NO User Defined changeable Menu Displays Use SiteTech software to change other settings including User Defined Menu Displays TP 6861 10 14 Section 2 Operation 53 Generator Information Generator Information Generator Information Menu Continued Menu Continued Menu Continued e Paralleling Operation Bus Phase Rotation Stop Accumulator Paralleling Setup DISABLED A B C C B A Run Time Threshold hrs Dead Bus Level Gen Phase Rotation only if in Run Time Management Voltage OK Pickup DISABLED A B C C B A Total Run Time hrs Voltage OK Dropout o Sharing Setup o Fuel Level Threshold Frequency OK Pickup Hz Bus 96 of Rated kW only if in Fuel
237. w D Other Alerts Alarm Horn Silenced Status Engine Cool Down Active Notice D Engine Start Aid Active Notice D Engine Started Status Engine Stopped Status Emergency Power System Supplying Load Notice D Generator Running Notice D Not In Auto Warning On Yellow D Option Board 2A Communication Loss Notice Option Board 2B Communication Loss Notice Option Board 2C Communication Loss Notice Remote Start Status Load Priority 1 Shed Notice D Load Priority 2 Shed Notice D Load Priority 3 Shed Notice D Load Priority 4 Shed Notice D Load Priority 5 Shed Notice D Load Priority 6 Shed Notice D Cabinet Intrusion Alarm Warning On Yellow D D Reserve Oil Empty Warning On Yellow D D Stopped By Generator Management Status D Failure To Synchronize Warning On Yellow D High Fail To Open Delay Warning On Yellow High Fail To Close Delay Warning On Yellow High Max Close Attempts Warning On Yellow Erroneous Data Received Generator Management Invalid Generator Warning On Yellow Management Enabled 38 Section 1 Specifications and Features TP 6861 10 14 FMI Alarm Fault Programmed Programmed Failure Mode Indicator Event ID Parameter at Local Display Level Horn Lamp Input Output High Trip To Shutdown Delay Shutdown On Red Run Relay Coil Overload Shutdown On Red Starter Relay Coil Overload Shutdown On Red High System Frequenc
238. y Warning On Yellow Low System Frequency Warning On Yellow High System Voltage Warning On Yellow Low System Voltage Warning On Yellow Erroneous Data Received System Phase Warning On Yellow ECM Diagnostics Engine Derate Active Warning On Yellow Injector Wiring Fault Warning On Yellow Run Relay Coil Overload Warning On Yellow Sensor Supply Voltage Warning On Yellow Speed Sensor Fault Warning On Yellow Starter Relay Coil Overload Warning On Yellow Water In Fuel Warning On Yellow Notices Excluded From Display Common Fault Notice D Common Warning Notice D System Ready Notice D Remote Start Command Issued Notice Run Button Acknowledged Notice Contactor Notice D Close Breaker Notice D Remove Breaker Trip Notice D Standalone Operation Status D Load Enable Status D Baseload Mode Status D System Control Mode Status D System Sync Mode Status D Enable Trims Status D Sensor dependent Figure 1 11 System Events Display Message List 1 11 2 Main Logic Circuit Board The main logic circuit board provides the connection sockets to connect the controller to the engine generator input output connections optional module kit and circuit protection fuses See Section 7 for the circuit board connectors Circuit Board Connections P1 35 Pin Connector for engine generator wiring harness P2 14 Pin Connector for sensor input connections and relay driver output connections P3 8 Pin Connector for generator set output v
239. y areas Do not break manufacturer s seals or internally inspect these devices Megger is a registered trademark of Biddle Instruments 64 Section 3 Scheduled Maintenance TP 6861 10 14 3 4 Alternator Bearing Service Have an authorized service distributor dealer perform service 3 4 1 20 300 kW Models Replace the end bracket bearing every 10 000 hours of operation in prime power applications Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage The sealed end bracket bearing requires no additional lubrication 3 5 Diesel Fuel Systems 3 5 4 Bleeding Air from Fuel System Bleed air from the fuel system after fuel system maintenance such as replacing the fuel filter s Use the information provided in the engine operation manual 3 6 Cooling System WARNING KS 2 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 Press the generator set off reset button to shut down the generator set 2 Disconnect the power to the battery charger if equipped 3
240. ystem Phase displays the programmer entered configuration as Single Phase Single Phase Dogleg Three Phase Wye or Three Phase Delta e Rated Engine Speed displays the programmer entered engine speed in RPM Adjusted Engine RPM displays the target engine speed setting kW Rating displays the programmer entered kW value for the generator set e kVA Rating displays the programmer entered kVA value for the generator set Rated Current displays the programmer entered current value for the generator set Section 1 Specifications and Features 23 Battery Voltage displays the programmer entered battery voltage Engine Start Delay displays the time delay before the generator set starts while the master switch is in AUTO or RUN positions Starting Aid Delay displays the engine starting aid activation time Crank On Delay displays the time allocated for generator set crank on in seconds Crank Pause Delay displays the time allocated for generator set crank pause in seconds Engine Warmed Up displays the temperature when the engine is warmed up enough to be loaded Engine Cooled Down displays the temperature below which the engine cooldown can be overridden Cooldown Delay displays the time delay for engine cooldown while the master switch is in the AUTO or RUN positions and not in the idle mode Cooldown Override allows the user to select the Cooldown Temperature Override Mode If set to ON the engine will stop immediat

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