Operation Industrial Generator Sets Models: 20-3250 kW Controllers: Decision-Makerr 550 Software (Code) Version 2.
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.
Table of Contents Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 2.7.13 Menu 13—Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.14 Menu 14—Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.15 Menu 15—Protective Relays (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.16 Menu 20—Factory Setup (Version 2.10) . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.17 Menu 20—Factory Setup (Version 2.21) . . . . . . . . . . . . . . . . . . . . .
Table of Contents, continued 3.12 Detroit Diesel Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.12.2 DDEC Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.13 Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.
Notes 6 TP-6200 10/12
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.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment.
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.
High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure. Testing the photo transistor circuit board. Hazardous voltage can cause severe injury or death.
Hot Parts WARNING Notice NOTICE This generator set has been rewired from its nameplate voltage to 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 alternator. Hot parts can cause severe injury or death.
Notes 12 Safety Precautions and Instructions TP-6200 10/12
Introduction This manual provides operation instructions for 20 kW and larger generator sets equipped with the following controller: D Decisionr 550, Software (Code) Version 2.10 or higher Version 2.10 refers to the controller application software. To determine the generator set controller software version, go to Menu 20—Factory Setup and scroll down to Code Version. The code version is the controller software version. Wiring diagram manuals are available separately.
Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower.com. D Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. D Call toll free in the US and Canada 1-800-544-2444.
Section 1 Specifications and Features The controller features, accessories, and menu displays depend upon the engine electronic control module (ECM) setup and features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted. 1.1 Introduction The spec sheets for each generator set provide modelspecific generator and engine information. The controller spec sheet provides specifications for this controller.
1 2 3 4 5 6 TP-6083-2 7 8 1. Generator set master switch, run/off-reset/auto positions (keyswitch option) 2. Emergency stop switch 3. Alarm horn (see keypad for alarm silence) 4. Annunciator lamps (see keypad for lamp test) Figure 1-2 1.2.1 5. 6. 7. 8. Digital display Keypad Operating guide Controller terminal strips (on circuit board) 550 Controller with Keyswitch Option Annunciator Lamps Five annunciator lamps provide visual generator set status. See Figure 1-3. Programming Mode.
System Warning. 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. System Shutdown. 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 2.3.7, Controller Reset Procedure. See Section 2.3.
1.2.2 Digital Display and Keypad Figure 1-5 illustrates the digital display and keypad. Note: Press any key on the keypad to turn on the controller lights and display. The lights and display turn off 5 minutes after the last keypad entry. The 2-line vacuum fluorescent display provides generator set and engine condition information. The 16-button keypad gives the user information access and local programming capability.
Engine Displays (Menu 2) Some engine displays are available with selected generator set engines using engine ECMs only. The controller display shows N/A (not available) for items that are unavailable. See the controller spec sheet for applicable generator set models. Ambient Temperature displays the generator set area ambient temperature. Charge Air Pressure displays the engine turbocharger boost air pressure. Charge Air Temperature displays turbocharger boost air temperature.
1.2.3 Switches and Controls See Figure 1-6 and Figure 1-8 for switches and controls. 1 2 The generator set master switch with the keyswitch option (Figure 1-7) is available to meet appropriate local code requirements. The key is removable in the AUTO position only. 3 TP-6083-2 TP-6083-2 1. Emergency stop switch 2. Alarm horn 3. Generator set master switch Figure 1-6 Generator Set Master Switch with Keyswitch Option Lamp Test.
1.2.4 Controller Circuit Boards 1.2.5 The controller has five circuit boards—indicator, interconnection, keypad, digital display, and main logic/ communication. See Figure 1-9 for circuit board locations. Fuses AC Circuit Fuses (TB5). Fuses are located inside the controller. See Figure 1-9. D 1.5-Amp (V7) fuse protects L1 sensing input to interconnection circuit board. 1 D 1.5-Amp (V8) fuse protects L2 sensing input to 2 interconnection circuit board. D 1.
Figure 1-10 shows locations of the terminal strips on the controller interconnection circuit board. See Section 6.2, Accessory and Connections, for specific terminal identification information. Refer to the wiring diagrams for additional information on connecting accessories to the terminal strips. 1 2 3 4 5 1.2.
1.2.8 Communication Ports 1.3 Controller Logic Specifications The main logic circuit board contains several communication ports for Modbusr and KBUS connections. See Figure 1-12. Refer to the List of Related Materials in the Introduction for corresponding communication installation information. 1 2 3 4 5 The controller logic specifications section is an overview of the various features and functions of the controller. Certain features function only when optional accessories are connected.
Factory-Defined Settings Status Event or Fault Refer to Menu Access Code (password) 14 AC Sensing Loss 10 Air Damper Control (if used) ** 10 Relay Driver Output (RDO) Digital Display AC SENSING LOSS RDO-25 * Alarm Horn On Lamp Range Setting Default Selection User-Selectable 0 (zero) Inhibit Time Delay (sec.) Time Delay (sec.
Factory-Defined Settings Status Event or Fault Analog Aux.
Factory-Defined Settings Status Event or Fault Refer to Menu Relay Driver Output (RDO) Alarm Horn Default Selection Lamp Range Setting Digital Aux. Input D12 Detonation Warning ] 9, 10 D12 DETON WARNING On Warning Fixed 2 sec. inhibit, 0 sec. delay Digital Aux. Input D13 Detonation Sensing Module (DSM) Shutdown ] 9, 10 D13 DETON SHUTDOWN On Shutdown Fixed 0 sec. inhibit, 0 sec. delay Digital Aux.
Factory-Defined Settings Status Event or Fault Refer to Menu Relay Driver Output (RDO) Digital Display Alarm Horn Lamp Range Setting Default Selection 14.5--16.5 V (12 V) 29--33 V (24 V) 16 V (12 V) 32 V (24 V) Inhibit Time Delay (sec.) Time Delay (sec.
Factory-Defined Settings Status Event or Fault Refer to Menu Locked Rotor Shutdown 10 LOCKED ROTOR Loss of ECM Communication (ECM only) 10 LOSS OF ECM COMM Loss of Field Shutdown w 10 SD LOSS OF FIELD Low Battery Voltage 10 LOW BATTERY VOLTAGE 10 LOW COOLANT TEMP SHUTDOWN (Low) Oil Pressure Shutdown 10 OIL PRESSURE SHUTDOWN (Low) Oil Pressure Warning 10 OIL PRESSURE WARNING Maintenance Due 10 MAINTENANCE DUE Master Not In Auto (Generator Set Switch) 10 MASTER NOT IN AUTO Master S
Factory-Defined Settings Status Event or Fault Refer to Menu Relay Driver Output (RDO) Digital Display Alarm Horn Lamp Range Setting Default Selection Inhibit Time Delay (sec.) Time Delay (sec.
Factory-Defined Settings Status Event or Fault Refer to Menu Digital Display Relay Driver Output (RDO) Alarm Horn Lamp Off Warning Range Setting Default Selection Inhibit Time Delay (sec.) Time Delay (sec.) Voltage Raise (see D19) Weak Battery * [ ] w 10 WEAK BATTERY All models, except Waukesha-powered models.
Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions. The underfrequency unload setting should match the engine speed recovery characteristics for the application. Underfrequency Unload Slope. This setting determines how much the voltage drops during an underfrequency condition. Typically, applying a large electrical load causes a dip in engine speed and frequency. The voltage regulator reduces voltage, allowing engine speed recovery.
Notes 32 Section 1 Specifications and Features TP-6200 10/12
Section 2 Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts. Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply. Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick. Air Cleaner.
Auto Starting Run Time Feature Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or remote start/stop switch (connected to controller terminals 3 and 4). The run time feature allows the user to set up the generator set to run unassisted and automatically return to the standby mode. The user does not need to wait for the exercise period (run time) to conclude in order to place the unit back in the standby mode.
2.3.2 Stopping (User Stopping and Fault Shutdown) Normal Stopping Run the generator set without load for 5 minutes to ensure adequate engine cooldown. The controller has a programmable cooldown timer that functions only when the master switch is in the AUTO position. To stop the generator set, place the generator set master switch in the OFF/RESET position and wait until the generator set comes to a complete stop.
Note: Text shown in italics in this manual represents digital display messages. AC Sensing Loss. The lamp illuminates when the controller does not detect nominal generator set AC output voltage after crank disconnect. The local display shows AC sensing loss. Battery Charger Fault. The lamp illuminates when the battery charger malfunctions. This fault feature requires an optional battery charger with a malfunction output for the lamp to function. Local display shows bat chgr fault. Battle Switch.
When the generator set frequency drops to less than 59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system for more than 5 seconds, the local display shows load shed under freq. When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp latches and remains on until the generator set shuts down. Low Battery Voltage. The lamp illuminates when the battery voltage drops below a preset level for more than 10 seconds. The local display shows low battery voltage.
2.3.6 System Shutdown Lamp The red lamp illuminates, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the following conditions. See Section 2.3.7, Controller Reset Procedure, for information on resetting a system shutdown. Use the Alarm Off keypad switch to silence the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn.
High Oil Temperature. The lamp illuminates 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. The local display shows high oil temp sdwn. Intake Air Temperature. The lamp illuminates and the unit shuts down because of high intake air temperature.
Over Current VR Shutdown. The lamp illuminates and the unit shuts down when the controller detects an overcurrent fault with voltage restraint. The local display shows sd over current pr. (Paralleling applications only.) Overfrequency. The lamp illuminates and the unit shuts down when the frequency is above the overfrequency setting. The local display shows overfrequency. See Figure 2-3. Overfrequency Setting Range Time Delay Overfrequency Default Setting 102%--140% of nominal 10 sec.
2.3.7 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 and the audiovisual alarm. Refer to Section 2.3.3, Emergency Stop Switch Reset Procedure, to reset the generator set after an emergency stop. 1. Move the generator set master switch to the AUTO position, if not already done. 2.
Specific Applications Input Type ECM Engine Non-ECM Engine NFPA 110 WaukeshaPowered Engine with Menu 15 (Paralleling Application) DDC/MTU Engine with MDEC/ADEC Other Specialized Application Analog Inputs A1 X Coolant Temperature * X Coolant Temperature * X X X A2 X Oil Pressure * X Oil Pressure * X X X X X X Fuel Level * A3 X X X Intake Air Temperature * A4 Fuel Level * Fuel Level * Fuel Level * Oil Temperature Warning * Fuel Level * Fuel Level * A5 X X X X X X
Menu List Summary (Legend: D First level submenu, d second level submenu) Menu 1 Generator Monitoring Menu 2 Engine Monitoring Menu 2 Engine Monitoring, cont.
Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 7 Generator System Menu 9 Input Setup Menu 9 Input Setup, cont. Menu 10 Output Setup, cont.
Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 10 Output Setup, cont. Menu 10 Output Setup, cont.
Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 13 Communications Menu 14 Programming Mode Menu 20 Factory Setup Menu Menu 55 Load Factor Protocol KBUS D KBUS Online Y/N D Connection Type (User-defined) d Local Single Y/N d Local LAN Y/N d Local LAN Conv Y/N d Remote Single Y/N d Remote LAN Y/N d Remote LAN Conv Y/N D Primary Port (User-defined) d RS-232 Y/N d RS-485 ISO1 Y/N D Address (LAN Connections) D System ID (Remote Connections) D BAUD Rate (User-defined)
2.5 Reviewing Digital Display The user interacts with the controller with a keypad and digital display. Use the keypad to access the generator set informational data and preset settings. This review section shows how to access the data. See Section 2.8, Local Programming Mode On, for instructions on how to change the information. See Figure 2-9 for an illustration of the digital display and keypad. Enter ↵ Key.
2.5.2 Auto-Scroll Function The auto-scroll function continuously shows voltage and current data from Menu 1—Generator Monitoring, V & A Summary without the need to press the down arrow for each display. For auto-scroll function press ENTER at the V & A Summary menu. Press the Reset Menu key or Menu Right → key to stop the auto-scroll function. 2.5.3 Request and Error Messages Note: When EEPROM errors occur or initializing the EEPROM is required, contact an authorized distributor/dealer.
D Fixed Voltage when entry is beyond the range of Range Error appears when the user attempts to enter: limited entries for the respective alternator. Occurs when the alternator is not rated for the value entered. Updated parameter files may be available by contacting an authorized service dealer/distributor. D A numeric input that is not within the acceptable range Func (Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned.
2.6.1 PC Communications Local Area Network (LAN) A PC connects to the device’s LAN. A LAN is a system that connects more than one device to a single PC. Acceptable devices include the Decision-Makerr 550 controller, Decision-Makerr 340 controller, M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor. See Figure 2-12. There are four ways to communicate between a PC and the generator set and/or transfer switch devices using KBUS communication protocol.
Remote Single Connection A modem connects a PC to a single device. The PC communicates with the device via a telephone network. Locate the PC anywhere a telephone line is available. See Figure 2-14. Remote Area Network A PC connects to a modem. The devices connect to a LAN network. The PC communicates to the devices via a telephone network that is interfaced to the LAN Modem Personal Computer network.
2.7 Reviewing Menu Displays Use this section to review a summary of the generator set controller data. See Figure 2-17 for which menus provide data monitoring and adjusting data. Press the Reset key, enter the desired menu number key(s), and then press the Enter key. Use the down arrow and right arrow keys for navigation. See Section 1, Specifications and Features, to review set point ranges and default settings for comparison to the actual setup. See Section 2.5.
2.7.1 Menu 1—Generator Monitoring Menu 1 displays generator output data including line-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent of maximum kW, total kVA, and total kVAR. Menu 1 displays three-phase voltage and current readings when applicable. Note: For the auto-scroll function, press ENTER at V & A Summary menu. Press the Reset Menu key or Menu Right → key to stop the auto-scroll function.
Menu 1—Generator Monitoring, continued Menu 1 Overview (Single-Phase Connections) MENU 1 GENERATOR MONITORING VOLTS & AMPS → V & A SUMMARY → L1-L2 VOLTS L1 AMPS # # V L1-L2 # L1-L0 # L1-L2 VOLTS L2 AMPS # # A L1 # L2 # L1-L0 VOLTS L1 AMPS # # For the auto-scroll function, press ENTER at V & A SUMMARY menu. L2-L0 VOLTS L2 AMPS # # FREQUENCY # HZ 54 Section 2 Operation L2-L0 # Use the MENU→ key to stop the auto-scroll function.
2.7.2 Menu 2—Engine Monitoring Menu 2 displays engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooled-down temperature setpoints. The detailed engine monitoring functions appear only for DDEC/JDEC/EMS2/EDC3-equipped engine and MDEC/ADEC-equipped engine versions.
Menu 2 Overview MENU 2 ENGINE MONITORING (MDEC/ADEC-Equipped Engines only) → ENGINE MONITORING BASIC OIL PRESSURE COOLANT TEMP INTAKE AIR OIL TEMP (Waukesha) # PSI #F #F #F ENGINE RPM LOCAL BATT VDC # # HCT WARNING HCT SHUTDOWN #F #F LOP WARNING LOP SHUTDOWN # PSI # PSI ENGINE WARMED UP #F ENGINE MONITORING DETAILED → ENGINE FUEL → FUEL PRES FUEL TEMP # PSI #F CHG AIR PRES CHG AIR TEMP # PSI #F FUEL RATE * # GPH ENGINE OIL OIL PRES OIL TEMP → # PSI #F ENGINE MISC ECU SUPPLY VDC
2.7.3 Menu 3—Analog Monitoring Menu 3 displays battery voltage and up to 7 userdefined analog items dependent upon the generator system. Note: If the analog display shows O/R (out of range), no input is connected or the input voltage is beyond the acceptable operating range (0--5 VDC). Note: See Figure 2-8 in User Inputs for factory reserved inputs which are not user selectable. The User Defined Desc display refers to a description entered into the controller using the PC software.
2.7.4 Menu 4—Operational Records Menu 4 displays the generator set’s operating record including operating start date, last logged maintenance, total run time loaded and unloaded, run time since last maintenance, number of starts, and number of days the unit ran. After performing maintenance, enter YES to reset records reflecting the current day. The user must enable the programming mode to edit the display. See Section 2.8.4 to make changes in this menu. Menu 4 Overview MENU 4 OPERATIONAL RECORDS NO.
2.7.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to 100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events. 2.7.7 Menu 7—Generator System Menu 7 shows the generator set system data including voltage, frequency, phase connection, battery voltage, etc. Use the values entered in this menu to determine shutdown values and time delays.
Menu 7 Overview MENU 7 GENERATOR SYSTEM OPERATING MODE STANDBY → Y/N SYSTEM VOLTAGE LINE-LINE ? SYSTEM FREQ # HZ PHASE 3 PHASE DELTA → Y/N KW RATING ? RATED CURRENT # OPERATING MODE PRIME POWER → Y/N PHASE 3 PHASE WYE → N/Y → # KW TIME DELAY MIN:SEC → ??:?? OVERVOLTAGE ?% → # VAC TIME DELAY MIN:SEC → ??:?? UNDERVOLTAGE ?% → # VAC TIME DELAY MIN:SEC → ??:?? LOAD SHED OUTPUT ?% OVERFREQUENCY ?% # HZ UNDERFREQUENCY ?% # HZ OVERSPEED ? HZ PHASE SINGLE PHASE → N/Y # RPM BATTE
2.7.8 Menu 8—Time Delays Menu 8 displays the cyclic cranking cycles, various engine related starting and shutdown features, and auxiliary shutdown and inhibit time delays. The user must enable the programming mode to edit the display. See Section 2.8.8 to change settings in this menu. If the Cooldown Temperature Override is not enabled, the unit will cease to run when the engine temperature falls below the ENGINE COOLED DOWN temperature (shown in Menu 2).
2.7.9 Menu 9—Input Setup Menu 9 displays the setup of user-defined digital and analog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. The user must enable the programming mode to edit the display. See Section 2.8.9 to change settings in this menu. Note: Press the down arrow to move to the start of the next input setup. Note: See Figure 2-8 in User Inputs for factory reserved inputs which are not user selectable. D Enabled.
Menu 9 Overview MENU 9 INPUT SETUP SETUP DIGITAL AUXILIARY INPUTS → TO ANALOG INPUT SETUP (NEXT) DIGITAL INPUT 01 → (USER DEFINED DESC) DIGITAL INPUT 01 → (see Group A) YES/NO Press the down arrow to scroll through additional DIGITAL auxiliary inputs 1--21 or enter the input number. DIGITAL INPUT 01 INHIBIT TIME Group A Group A, continued The preprogrammed selections include the following list. See Appendix E for application and restrictions with specific engines.
2.7.10 Menu 10—Output Setup Menu 10 displays the setup of user-defined system, digital and analog status, and fault outputs and relay driver outputs (RDO) 1--31. These RDO outputs provide multiple choices for configuring customized auxiliary outputs. Additional individual outputs are available for monitoring, diagnostics, and control functions. The user must enable the programming mode to edit the display. See Section 2.8.10 to change this menu.
Menu 10 Overview, continued Group B *NFPA 110 FAULT Group B, continued For defined system events, choose from the following 66 status events and faults by changing selection to YES. See Appendix E for application and restrictions with specific engines.
2.7.11 Menu 11—Voltage Regulator See Section 2.8.11 to make changes in this menu. Menu 11 displays setup of the voltage regulator functions including line-to-line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor, and kVAR adjustments. Note: The individual line-to-line voltages are displayed for review purposes only. The user must enable the programming mode to edit the display. Note: Voltage regulator gain is used for adjusting voltage stability and/or response.
The user must enable the programming mode to edit the display. 2.7.12 Menu 12—Calibration Menu 12 provides access to the calibration factors for metering (volts and amps) and auxiliary analog inputs. Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment. See Section 2.8.12 to make calibration changes. Menu 12 Overview MENU 12 CALIBRATION SCALE AC ANALOG INPUTS TO SCALE AUX.
2.7.13 Menu 13—Communications Menu 13 shows communications. the settings for remote See Section 2.8.13 to make changes in this menu. See the Modbusr Communications Protocol operation manual for a list of Modbusr registers for the 550 Controller.
2.7.14 Menu 14—Programming Mode Menu 14 provides local or remote access to the programming function. The user enters a password to access the programming mode. Note: Log into the local programming mode to edit the programming access code. The factory default access code is the number 0. Use Menu 14 to change the access code. Record the new number and give the access code only to authorized individuals.
2.7.15 Menu 15—Protective Relays (PR) Menu 15 provides protective relay setup and time delays for units with the paralleling protection option. This menu will only be visible and accessible if this option is included. The shutdown (SD) settings override those in menu 7 and/or menu 8. See Section 2.8.15 to make changes in this menu, when the paralleling option is enabled.
2.7.16 Menu 20—Factory Setup (Version 2.10) Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software (code) version.
2.7.17 Menu 20—Factory Setup (Version 2.21) Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software (code) version. The temperature sensor setup applies to non-ECM engines only. See Section 2.8.16 to make changes in this menu. Note: For Version 2.69 and lower, enter the numeric serial number from the generator set nameplate. For Version 2.
Notes TP-6200 10/12 Section 2 Operation 73
2.8 Local Programming Mode On The Local Programming Mode On section explains how to program the generator set controller logic. Each menu contains a step-by-step procedure for programming the various logic groups. See Section 1, Specifications, for setting ranges and default settings. Please read and understand the entire Local Programming Mode On section before attempting any programming.
2.8.1 Menu 1—Generator Monitoring Menu 1 provides generator output data including line-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent of maximum kW, total kVA and total kVAR displays. Menu 1 displays three-phase and single-phase connections separately. Note: For the auto-scroll function, press ENTER at the V & A Summary menu. Press the Reset Menu key or Menu Right → key to stop the auto-scroll function.
Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display A Description L1 # L3 # V & A SUMMARY → POWER KW → Displays L1, L2, and L3 amps. Returns the user to the volts and amps summary heading. Displays the power kilowatt heading. TOTAL KW # PF # LEADING/LAGGING Displays total kilowatts and leading or lagging power factor. L1 KW PF # # LEADING/LAGGING Displays total L1 kilowatts and leading or lagging power factor.
Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description L3 KVA # → POWER kVA Displays L3 kVA. Returns the user to power kVA heading. Menu 1—Generator Monitoring (Single-Phase Connections) Menu 1 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 1 Press the Enter key. MENU 1 GENERATOR MONITORING → VOLTS & AMPS Displays the volts and amps heading.
Menu 1—Generator Monitoring (Single-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description POWER KW Displays the power kilowatt heading. TOTAL KW # PF # LEADING/LAGGING Displays total kilowatts and leading or lagging power factor. L1 KW PF # # LEADING/LAGGING Displays total L1 kilowatts and leading or lagging power factor. L2 KW PF # # LEADING/LAGGING Displays total L2 kilowatts and leading or lagging power factor.
2.8.2 Menu 2—Engine Monitoring Menu 2 provides engine operating data including oil pressure and temperature, coolant temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooleddown temperature setpoints. The detailed engine monitoring functions appear only for DDEC (DDC/MTU), JDEC (John Deere), EMS2 (Volvo), EDC3 (Volvo), or MDEC/ADEC (DDC/MTU)- equipped engines.
Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description (DDEC/JDEC/EMS2/EDC3-Equipped Engines only) ENGINE MONITORING DETAILED → ENGINE FUEL → Displays the engine fuel subheading. FUEL PRES FUEL TEMP # PSI #F Displays the fuel pressure and fuel temperature. CHR AIR PRESS CHR AIR TEMP # PSI #F Displays the charge air pressure and temperature.
Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description (DDEC/JDEC/EMS2/EDC3-Equipped Engines only, continued) ENGINE MODEL NO. # Displays the engine model number. ENGINE SERIAL NO. # Displays the engine serial number. UNIT NO. ECM S/N # # ECM FAULT CODES # ENGINE MISC TP-6200 10/12 → Displays the unit number and ECM serial number. Displays the ECM fault codes. Returns the user to the miscellaneous engine subheading.
Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description (MDEC-Equipped Engines only) ENGINE MONITORING DETAILED → ENGINE FUEL → Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature requires a DDC/MTU MDEC/ADEC-equipped engine. Displays the engine fuel subheading. FUEL PRES FUEL TEMP # PSI #F Displays the fuel pressure and fuel temperature.
2.8.3 Menu 3—Analog Monitoring Menu 3 provides the battery voltage and up to 7 userdefined analog monitoring items dependent upon the generator system. midpoint 2.5 volts corresponds to 0 volts offset. If there is no connection at analog input 7, no voltage adjust is recognized. The User Defined Desc display refers to a description entered into the controller using the PC software. This description remains as the display for future review until changed by the PC software user.
Menu 3—Analog Monitoring (Non-ECM Engines) Menu 3 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 3 Press the Enter key. MENU 3 ANALOG MONITORING Displays the menu number and name. LOCAL BATT VDC # ANALOG 03 (USER DEFINED DESC) # ANALOG 04 (USER DEFINED DESC) # Displays analog 04 and the user-defined description. ANALOG 05 (USER DEFINED DESC) # Displays analog 05 and the user-defined description.
Menu 3—Analog Monitoring (Waukesha Engines) Menu 3 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 3 Press the Enter key. MENU 3 ANALOG MONITORING Displays the menu number and name. LOCAL BATT VDC # ANALOG 05 (USER DEFINED DESC) # Displays analog 05 and the user-defined description. ANALOG 06 (USER DEFINED DESC) # Displays analog 06 end the user-defined description.
2.8.4 Menu 4—Operational Records Menu 4 provides the generator set operational records including the operating start date, last logged maintenance, total run time loaded and unloaded, run time since the last maintenance, number of starts, and number of running days. Run Time Feature. This menu provides the ability to run the generator set for a designated time. After the run time elapses. the generator set shuts down and functions in the standby mode.
Menu 4—Operational Records, continued Menu 4 Displays with Key Entries Key Entry Display Description ENGINE START? COUNTDOWN YES→ ##:## RUN TIME HR:MN→ ##:## RECORDS MAINT → RESET RECORDS? → RESET RECORDS? YES→ RESET RECORDS? YES→ → RECORDS MAINT Confirms the entry. The generator set will begin cranking and run based on the run time (hours:minutes) period and all previously established time (hours:minutes) delays from Menu 8—Time Delays.
2.8.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to 100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events. Note: This menu is for monitoring only; no adjustments or user settings can be entered. Menu 5—Event History Menu 5 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number.
2.8.6 Menu 6—Time and Date Menu 6 sets the clock time and date and internal calendar. The controller uses set time for determining the exercise run time and event records. The time and date are valid only if the controller power (starting battery) remains connected. Note: A change to the time/date is recorded as a system event. The time/date reset and other events are viewable (up to 100 events).
2.8.7 Menu 7—Generator System Menu 7 contains the factory-preset generator set voltage and frequency data. Enter the corresponding data if the generator set requires voltage reconnection and/or frequency adjustment. It is imperative that the user enter the correct data because these settings trigger all related shutdowns. See Section 2.5.3, Request and Error Messages, for error display messages and explanations while navigating the menus. The user must enable the programming mode to edit the display.
Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description SYSTEM FREQ # HZ Displays the corrected system frequency. See NOTE A. PHASE (see note) → YES Displays the phase configuration selection. Note: The display sample may differ depending upon previous entries. The user-selected phase appears first, either wye, delta, or single phase. PHASE 3 PHASE DELTA → NO Displays the optional phase configuration selection.
Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description OVERVOLTAGE ?% → # VAC Displays the overvoltage setting. When required, use the numeric keys to set the new value. Press the Enter key. OVERVOLTAGE #% → # VAC Displays the corrected overvoltage setting. TIME DELAY MIN:SEC → ??:?? Displays the overvoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.
Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description Displays the battery voltage selection. Note: The display sample may differ depending upon previous entries. The user-selected battery voltage appears first, either 12 VDC or 24 VDC. BATTERY VOLTAGE (see note) → YES BATTERY VOLTAGE 12 VDC → NO BATTERY VOLTAGE 12 VDC → YES Enter YES to change the battery voltage to 12 VDC and press the Enter key. BATTERY VOLTAGE 12 VDC → YES Confirms the entry.
Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description Displays the variable speed governor (VSG) yes or no selection for paralleling applications. When required, use the numeric keys to set the new value. Applies to DDC/MTU MDEC/ADEC engine only. ENABLE VSG YES/NO ENABLE VSG NO ENABLE VSG YES Entering YES enables the VSG function. ENABLE VSG YES Confirms the entry.. OR ENABLE VSG YES ENABLE VSG NO Entering NO disables the VSG function.
Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description METRIC UNITS Y/N METRIC UNITS NO METRIC UNITS YES Enter YES to change to metric displays and press the Enter key. METRIC UNITS YES Confirms the entry. Displays the metric units selection.
2.8.8 Menu 8—Time Delays Menu 8 displays the various time delays for cyclic cranking and other engine-related starting and shutdown features. The user must enable the programming mode to edit the display. Cooldown Temperature Override. This feature provides the ability to bypass (override) the generator set’s smart cooldown temperature shutdown and force the generator set to run for the full engine cooldown time delay.
Menu 8—Time Delays, continued Menu 8 Displays with Key Entries Key Entry Display Description COOLDOWN TEMPERATURE OVERRIDE YES Enter YES to select cooldown temperature override time delay and press the Enter key. COOLDOWN TEMPERATURE OVERRIDE Y/N Confirms the entry. OVERCRANK SHUTDOWN CRANK CYCLES ? Displays the engine crank cycles before overcrank shutdown. When required, use the numeric keys to set the new value. Press the Enter key.
2.8.9 D TIme Delay (Shutdown or Warning). Menu 9—Input Setup Menu 9 provides the setup of user-defined digital and analog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. The user must enable the programming mode to edit the display. Note: Press the down arrow to move to the start of the next input setup.
Analog Input Values. The analog input selection typically requires entering four values: low warning, high warning, low shutdown, and high shutdown. The analog values and time delays affect how and when the controller reacts. See Figure 2-19. The user must set both the high and low levels so the unit will not inadvertently trigger the adjacent high or low value to cause a warning or shutdown fault. Battle Switch/Fault Shutdown Override Switch.
Menu 9—Input Setup Menu 9 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 9 Press the Enter key. MENU 9 INPUT SETUP Displays the menu number and name. SETUP DIGITAL AUXILIARY INPUTS → DIGITAL INPUT 01 (USER DEFINED DESC) → DIGITAL INPUT 01 (see Group A) → YES/NO Displays the setup of digital auxiliary inputs heading. Displays the digital input 01 with the user-defined description.
Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description Displays the digital input 01 inhibit time (minutes:seconds) setting. When required, use the numeric keys to set the new values. Press the Enter key. DIGITAL INPUT 01 INHIBIT TIME → ?:?? DIGITAL INPUT 01 INHIBIT TIME #:## DIGITAL INPUT 01 DELAY TIME → ?:?? Displays the digital input 01 delay time (minutes:seconds) setting. When required, use the numeric keys to set the new values. Press the Enter key.
Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description ANALOG INPUT 01 SHUTDOWN ENABLED → Y/N Displays the analog input 01, shutdown enabled selection. ANALOG INPUT 01 SHUTDOWN ENABLED → NO Entering YES enables the shutdown analog input 01. ANALOG INPUT 01 SHUTDOWN ENABLED → YES Press the Enter key. → YES Confirms the entry. ANALOG INPUT 01 SHUTDOWN ENABLED → YES Entering NO disables the shutdown analog input 01.
Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description ANALOG INPUT 01 HI WARN VALUE → ? ANALOG INPUT 01 HI WARN VALUE → # ANALOG INPUT 01 HI SDWN VALUE → ? ANALOG INPUT 01 HI SDWN VALUE → # ANALOG INPUT 01 (USER DEFINED DESC) → ANALOG INPUT XX (USER DEFINED DESC) → Displays the analog input 01, high warning value. When required, use the numeric keys to set the new values. Press the Enter key.
2.8.10 Menu 10—Output Setup Menu 10 provides setup of the user-defined system, digital and analog status and fault outputs, and relay driver outputs (RDO) 1--31. These outputs provide a multitude of choices for configuring customized auxiliary outputs. Additional individual outputs are available for monitoring, diagnostic, and control functions. The user must enable the programming mode to edit the display. Note: Some data require entry using a PC in the Remote Programming mode.
Menu 10—Output Setup Menu 10 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 10 Press the Enter key. MENU 10 OUTPUT SETUP Displays the menu number and name. DEFINE COMMON FAULTS → SYSTEM EVENTS → COMMON FAULT (see Group B) Y/N COMMON FAULT (see Group B) NO COMMON FAULT (see Group B) YES COMMON FAULT (see Group B) YES Displays the common faults heading. Displays the system events heading.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description DIGITAL INPUTS → Displays the digital inputs heading. COMMON FAULT Dxx (see Group C) Y/N Gives the user the option to add or delete selection from the defined digital faults starting with D01. Note: Press the Menu Down key to continue to the next selection D02--D21 (repeat as necessary). COMMON FAULT Dxx (see Group C) NO Entering YES adds the selection to the defined digital fault group.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description COMMON FAULT Y/N A01 LO WARNING→ Indicates whether the previously user-defined analog output was selected (yes or no) as a low warning fault. COMMON FAULT NO A01 LO WARNING→ Entering YES adds the low warning selection to the defined analog fault group. COMMON FAULT YES A01 LO WARNING→ Press the Enter key. COMMON FAULT YES A01 LO WARNING→ Confirms the entry.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description COMMON FAULT Y/N A01 LO SHUTDOWN→ Indicates whether the previously user-defined analog output was selected (yes or no) as a low shutdown fault. COMMON FAULT NO A01 LO SHUTDOWN→ Entering YES adds the low shutdown selection to the defined analog fault group. COMMON FAULT YES A01 LO SHUTDOWN→ Press the Enter key. COMMON FAULT YES A01 LO SHUTDOWN→ Confirms the entry.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description ANALOG INPUTS → DEFINE COMMON FAULTS → RELAY DRV OUT 01 (user defined) → Returns the user to analog inputs heading. Returns the user to the define common faults heading. Gives the user previously selected items for relay driver outputs (RDO) starting with 01. Note: Press the down arrow to continue to the next relay driver output 02--31 or enter the RDO number.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description → DIGITAL INPUTS RELAY DRV OUT 01 Dxx (see Group C) Y/N Displays the digital inputs heading. Gives the user the option to assign a digital input to an RDO starting with D01. Press the Menu Down key to continue to the next selection D02--D21 (repeat as necessary). Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description RELAY DRV OUT 01 Y/N A01 LO WARNING→ Indicates whether the previously user-defined analog RDO was selected (yes or no) as a low warning fault. RELAY DRV OUT 01 NO A01 LO WARNING→ Entering YES adds the low warning selection to the defined analog RDO group. RELAY DRV OUT 01 YES A01 LO WARNING→ Press the Enter key. RELAY DRV OUT 01 YES A01 LO WARNING→ Confirms the entry.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description RELAY DRV OUT 01 Y/N A01 LO SHUTDOWN→ Indicates whether the previously user-defined analog RDO was selected (yes or no) as a low shutdown fault. RELAY DRV OUT 01 NO A01 LO SHUTDOWN→ Entering YES adds the low shutdown selection to the defined analog RDO group. RELAY DRV OUT 01 YES A01 LO SHUTDOWN→ Press the Enter key. RELAY DRV OUT 01 YES A01 LO SHUTDOWN→ Confirms the entry.
Menu 10—Output Setup, continued Menu 10 Displays with Key Entries— Deactivating the SCRDO Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 10 Press the Enter key. MENU 10 OUTPUT SETUP DEFINE COMMON FAULTS Displays the menu number and name → RELAY DRV OUT XX → S’WARE CONTROLLED #X DEACTIVATE RDO? → DEACTIVATE RDO? YES→ Displays the common faults heading. Gives the user previously selected items for the relay driver outputs (RDO).
2.8.11 Menu 11—Voltage Regulator Menu 11 provides the setup of the voltage regulator functions including the line-to-line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor, and kVAR adjustments. See Section 1.3.3, Voltage Regulator Adjustments, and Appendix C, Voltage Regulator Definitions and Adjustments, for additional information. The user must enable the programming mode to edit the display.
Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description UNDER FREQ UNLOAD ENABLED → N/Y Displays the under frequency (volts per Hz) unloading (yes or no) selection. UNDER FREQ UNLOAD ENABLED → NO Entering YES enables the underfrequency unloading feature. UNDER FREQ UNLOAD ENABLED → YES Press the Enter key. UNDER FREQ UNLOAD ENABLED → YES Confirms the entry. UNDER FREQ UNLOAD ENABLED → YES Entering NO disables the underfrequency unloading feature.
Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description REACTIVE DROOP ENABLED → N/Y Displays the reactive droop selection (yes or no). REACTIVE DROOP ENABLED → NO Entering YES enables the reactive droop feature. REACTIVE DROOP ENABLED → YES Press the Enter key. REACTIVE DROOP ENABLED → YES Confirms the entry. REACTIVE DROOP ENABLED → YES Entering NO disables the reactive droop feature. REACTIVE DROOP ENABLED → NO Press the Enter key.
Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description REACTIVE DROOP ENABLED → N/Y Returns the user to reactive droop selection heading. VAR CONTROL ENABLED → N/Y Displays the VAR control selection (yes or no). VAR CONTROL ENABLED → NO Entering YES enables the VAR control feature. Note: A YES entry disables the PF control if previously activated. VAR CONTROL ENABLED → YES Press the Enter key. VAR CONTROL ENABLED → YES Confirms the entry.
Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry Display Description PF CONTROL ENABLED → N/Y Displays the power factor control selection (yes or no). PF CONTROL ENABLED → NO Entering YES enables the power factor control feature. Note: A YES entry disables the kVAR control if previously activated. PF CONTROL ENABLED → YES Press the Enter key. PF CONTROL ENABLED → YES Confirms the entry.
Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries Key Entry TP-6200 10/12 Display Description REGULATOR GAIN ADJ GAIN # REGULATOR GAIN ADJ GAIN # VAR/PF GAIN ADJ GAIN # VAR/PF GAIN ADJ GAIN # ANALOG VOLT ADJUST ENABLED? Y/N RESET REGULATOR DEFAULTS Y/N RESET REGULATOR DEFAULTS YES RESET REGULATOR DEFAULTS Y/N Displays the generator set voltage regulator gain adjustment. When required, use the numeric keys to enter the desired gain value. Confirms the entry.
2.8.12 Menu 12—Calibration Menu 12 provides the calibration of the voltage and current sensing logic. Changing the system voltage or replacing the main logic control circuit board requires a calibration adjustment. The user must enable the programming mode to edit the display. Connect a meter with a minimum accuracy of 1% to the generator set output leads to calibrate the voltage-sensing logic. Configure the generator set controller for the system operating configuration using Menu 7—Generator System.
Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description # ?.? Measure the generator set output voltage for three-phase models between L2-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right → key prior to entering the decimal value. GEN L2-L0 V CALIB REF # ?.? Use the numeric keys to enter the decimal value. Press the Enter key. GEN L2-L0 V CALIB REF # #.# Confirms the entry.
Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L3-L1 V CALIB REF # ?.? Three-Phase Models only. Measure the generator set output voltage for three-phase models between L3-L1 using a voltmeter and enter the result using the numeric keys. Press the Menu Right → key prior to entering the decimal value. AND GEN L3-L1 V CALIB REF # ?.? GEN L3-L1 V CALIB REF # # Use the numeric keys to enter the decimal value.
Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description # ?.? Three-Phase Models only. Measure the generator set output current for three-phase models at L3 using an AC ammeter and enter the result using the numeric keys. Press the Menu Right → key prior to entering the decimal value. GEN L3 AMPS CALIB REF # ?.? Use the numeric keys to enter the decimal value. Press the Enter key.
Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs) No calibration is available for inputs A01--A02 for non-ECM engines. No calibration is available for inputs A01--A04 for Waukesha engines. Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 12 Press the Enter key. MENU 12 CALIBRATION Displays the menu number and name. SCALE AC ANALOG INPUTS SCALE AUX. ANALOG INPUTS Displays the scale AC analog inputs heading.
The user must enable the programming mode to edit the display. 2.8.13 Menu 13—Communications Menu 13 enables communication with the controller for monitoring or controlling the generator set. KBUS allows a variety of connection types while Modbusr follows Modbusr RTU protocols. Use the LAN (local area network) to gain remote access to multiple devices/addresses. Use the KBUS enable local programming mode to edit displays in this menu.
Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description CONNECTION TYPE (USER DEFINED) → Y/N CONNECTION TYPES LOCAL SINGLE Y/N LOCAL LAN N/Y LOCAL LAN CONV N/Y REMOTE SINGLE N/Y REMOTE LAN N/Y REMOTE LAN CONV N/Y Displays the user-defined connection type. Press the Down arrow key if the correct connection type is displayed. If the desired connection type is not displayed, press the Right arrow key until the desired connection type appears.
Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description BAUD RATE (USER DEFINED) → YES Press the Enter key. BAUD RATE (USER DEFINED) → YES Confirms the entry. MENU 13 COMMUNICATIONS Returns the user to the menu number and name. PROTOCOL KBUS → PROTOCOL MODBUS → MODBUS ONLINE Y/N MODBUS ONLINE NO MODBUS ONLINE YES MODBUS ONLINE YES Returns the user to KBUS protocol heading. Displays the Modbus protocol heading.
Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description PRIMARY PORT (USER DEFINED) → YES Press the Enter key. PRIMARY PORT (USER DEFINED) → YES Confirms the entry. ADDRESS ? Displays the address number. Use the numeric keys to enter the desired address 1--128. Use one address number per unit and use consecutive numbers. Individual addresses are necessary for the software to call up the desired unit. ADDRESS # Confirms the entry.
2.8.14 Menu 14—Programming Mode The user chooses one of three programming modes: Menu 14 allows altering controller data either locally using the keypad or remotely using a PC or other device. D Local—using the controller keypad The user must enter a password (access code) to enable the programming mode. Local Programming. Local programming is data alteration using the controller keypad and display. Remote Programming.
Menu 14—Programming Mode, continued Menu 14 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 14 Press the Enter key. MENU 14 PROGRAMMING MODE PROGRAMMING MODE (USER DEFINED) Displays the menu number and name.
2.8.15 Menu 15—Protective Relays (PR) Menu 15 provides the necessary protective relays for units with the optional paralleling protection feature. If the generator set personality profile did not include the paralleling option this menu will not appear on the display. Available with PD-Series switchgear only. Menu 15—Protective Relays Menu 15 Displays with Key Entries Key Entry Display Description ENTER MENU NO. 1--15 Input a menu number. MAIN MENU NUMBER 15 Press the Enter key.
Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description PR UNDERFREQUENCY → ?% #HZ PR UNDERFREQUENCY → #% #HZ TIME DELAY ?SEC → TIME DELAY #SEC → PR UNDERFREQUENCY → ?% #HZ PR REVERSE POWER ?% → #KW PR REVERSE POWER #% → #KW TIME DELAY ?SEC → TIME DELAY #SEC → PR REVERSE POWER ?% → #KW SD REVERSE POWER ?% → #KW SD REVERSE POWER #% → #KW TIME DELAY ?SEC → TIME DELAY #SEC → SD REVERSE POWER ?% → #KW PR OVER POWER ?% → #KW PR OVER POWER
Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description SD OVER POWER ?% → #KW SD OVER POWER #% → #KW TIME DELAY ?SEC → TIME DELAY #SEC → SD OVER POWER ?% → #KW PR LOSS OF FIELD ?% → #KVAR PR LOSS OF FIELD #% → #KVAR TIME DELAY ?SEC → TIME DELAY #SEC → PR LOSS OF FIELD ?% → #KVAR SD LOSS OF FIELD ?% → #KVAR SD LOSS OF FIELD #% → #KVAR TIME DELAY ?SEC → TIME DELAY #SEC → SD LOSS OF FIELD ?% → #KVAR PR OVERCURRENT VR → ?% #AMPS PR O
Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description SD OVER CURRENT VR → ?% #AMPS SD OVER CURRENT VR → #% #AMPS Displays the over current shutdown with voltage restraint (VR) % value. When required, use the numeric keys to enter the desired over current shutdown % value and press the Enter key. Displays the corrected over current shutdown % value. TIME DELAY ?SEC → Displays the over current shutdown time delay.
2.8.16 Menu 20—Factory Setup Menu 20 provides generator set, alternator, controller, and engine identification information. The user can use this menu to determine the generator set operating days and identify the controller software (code) version. The factory setup menu information is locked by the manufacturer. The temperature sensor setup applies to non-ECM engines only. Note: This menu is for monitoring only; no adjustments or user settings can be entered. Note: For Version 2.
Menu 20—Factory Setup, continued Menu 20 Displays with Key Entries Key Entry Display Description CONTROLLER SERIAL NO # CODE VERSION COPYRIGHT # XXXX SETUP LOCKED YES 136 Section 2 Operation Displays the controller serial number. Displays the controller software (code) version. Displays the setup locked by the manufacturer.
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 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. Disabling the generator set.
3.
Service Schedule, continued System—Component AC Electrical System Controller lamp test General Inspection Circuit breakers, fuses[ Wire abrasions where subject to motion Safety and alarm operation Tighten control and power wiring connections Visually Inspect X X X X Transfer switch main contacts[ Voltage-sensing device/relay adjustment[ X Wire-cable insulation breakdown X Engine and Mounting General inspection Governor operation, lubricate moving parts Air cleaner service Choke, carburetor adjustment
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 standby and prime power applications. Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage. Replace the tolerance ring, if equipped, following end bracket removal. The sealed end bracket bearing requires no additional lubrication. 3.4.
3.5.2 Subbase Fuel Day Tank Electronic Control Module (ECM) With an electronic control module (ECM), the optional subbase diesel fuel tank functions as a day tank. Following are operating information and features of the ECM. See Figure 3-2 for the ECM front panel layout. Level Sensor An electronic analog float gauge located below the ECM on the mounting bracket determines the day tank fuel level. Nine LEDs on the ECM indicate the day tank fuel level from full to empty.
3.5.3 Subbase Inner Fuel Tank Alarm This kit provides for both audible and visual alarms from a location remote from the generator set if a leak is detected in the inner fuel tank of the double-wall subbase fuel tanks. See Figure 3-6. If the inner tank is leaking, a sensor installed in the outer tank sends an electrical signal to the alarm plate when the sensor becomes immersed in the fuel collecting in the outer tank. If a leak is detected, the alarm horn will sound and the fault lamp will light.
LPG Liquid Withdrawal Operation 2 1 D Disconnect lead 73A from the fuel solenoid valve. D Connect lead 73B to the fuel solenoid valve (LPG liquid withdrawal). D Connect lead 65 to lead N5 (ground). Auto Changeover Natural Gas/LPG Vapor Operation 3 D Disconnect lead 65 from N5. D Connect lead N5 to LFP2 relay common terminal. D Connect lead 73A to the fuel solenoid valve (natural 1. Electronic-controlled pressure regulator (EPR) 2. Fuel mixer 3.
ADV-7600B-B Figure 3-10 Gas Fuel Connections Wiring Diagram 144 Section 3 Scheduled Maintenance TP-6200 10/12
Emissions certified models use a single electroniccontrolled pressure regulator (EPR) for both fuels. A tee fitting connects both fuels together upstream of the EPR. During operation when using the secondary fuel, it is normal for a small amount of secondary fuel to seep back through the primary fuel solenoid valve.
3.7.2 Cooling System Component Inspection To prevent generator set shutdown or damage caused by overheating: D Keep the cooling air inlets clean and unobstructed. D Inspect the radiator’s exterior for obstructions. Remove dirt and foreign material using a soft brush or cloth to avoid damaging the radiator fins. D Check the hoses and connections for leaks. Replace 3.7.
6. Replace the pressure cap. 3. Disconnect the generator set engine starting battery(ies), negative (--) lead first. 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.
13. Place the generator set master switch to the RUN position to start the generator set. Refer to the respective generator set operation manual as needed. 14. Listen and observe the fan operation. 15. Immediately shut down the generator set if abnormal noise or fan assembly vibration is observed. Correct the problem and go back to step 13. 16.
5. Remove excess grease from the bearing pressure relief ports. 6. Inspect the fan drive belt and replace if it is damaged or worn. Check the fan belt tension using a poly V-belt tension gauge and adjust the tension, if necessary. See Figure 3-15. 7. Reinstall the belt guards using the original hardware. Generator Set Model 1200-2250 kW New Belt, N (lbf.) Used Belt*, N (lbf.) 2450--2890 (550--650) 1650--1910 (370--430) * A belt is considered used after 50 hours of service.
After reconnecting the battery cables, coat the terminals with petroleum jelly, silicon grease, or other nonconductive grease. 1 2 1 1 1 2 3 4 2 2 1 2 3 4 KW-272000-B EZ-273000-J 1. To positive (+) terminal on starter solenoid. 2. To ground (--) terminal on or near starter motor. Figure 3-16 12-Volt Engine Electrical System Single Starter Motor Typical Battery Connection 1 2 1. 2. 3. 4. To positive (+) terminal on starter solenoid. To ground (--) terminal on or near starter motor.
3.11.3 Specific Gravity Check Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps. Holding the hydrometer vertically, read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer. If the hydrometer used does not have a correction table, consult Figure 3-20. Determine the specific gravity and electrolyte temperature of the battery cells.
3.12 Detroit Diesel Engine Control Systems 1 Some generator sets equipped with Detroit Diesel engines use a DDEC/MDEC/ADEC system. Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting the engine. Note: DDC/MTU engines with MDEC/ADEC use the 550 controller to display all engine fault code numbers. The engine operation manual provides the fault code description. Use the following data for informational purposes only.
3.13 Engine Control Systems Some generator sets use an engine control system. Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine. Use the following data for general informational purposes only. See the Engine Service Manual for complete information regarding operation and troubleshooting. Contact an authorized service distributor/dealer for service or diagnostic equipment.
3.14.3 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 engine owner’s manual. Gas-Fueled Engines 3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders. 4. Reinstall the spark plugs and torque them to specifications. 3.
Section 4 General Troubleshooting This section contains generator set troubleshooting, diagnostic, and repair information. Note: The controller clock must be set each time the engine battery(ies) are disconnected. The controller clock determines exercise run time and event records. See Menu 6—Time and Date, for setup. Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or an open circuit breaker.
Section 4 Troubleshooting TP-6200 10/12 Cranks but does not start Does not crank No or low output voltage Stator inoperative (open or grounded) x x x x x Starts hard Engine harness connector(s) not locked tight High water temperature switch inoperative Fault shutdown High exhaust temperature switch inoperative x x x x Starter/starter solenoid inoperative Battery weak or dead Replace the inoperative switch. Reset the fault switches and troubleshoot the controller.
TP-6200 10/12 Section 4 Troubleshooting 157 Cranks but does not start Does not crank x x No or low output voltage Lacks power x Overheats Starts hard x x x x x x x x x x x x x x Exhaust system leak Exhaust system not securely installed x x Vibration excessive x Ignition system inoperative (gas/gasoline only) Valve clearance incorrect x Governor inoperative Engine overload x Compression weak Air cleaner clogged Controller clock not set Controller firmware error Voltage re
Section 4 Troubleshooting TP-6200 10/12 Starts hard Cranks but does not start Does not crank x x x x x x x x x Low oil pressure shutdown Oil level low Crankcase oil type incorrect for ambient temperature Check the oil level. Restore the oil level. Inspect the generator set for oil leaks. Change the oil. Use oil with a viscosity suitable for the operating climate. Adjust the fuel injection timing.[ Check the fuel supply and valves.[ Troubleshoot the fuel solenoid.
TP-6200 10/12 Section 4 Troubleshooting 159 Probable Causes Low battery voltage Controller firmware or keypad entry error EEPROM fault caused by component failure, lightening strike, or voltage spike No/low battery charge Defective exciter winding Voltage regulation calibration incorrect TP-6200 10/12 Analog input A06 is supported with Doosan, GM, and Volvo engines only Analog input A07 description does not match Analog Volt Adjust Display shows single segment Display shows an error message Display sh
Notes 160 TP-6200 10/12
Section 5 Generator Set Reconnection 5.1 Introduction Use the following voltage reconnection procedure to change the voltage of 10- and 12-lead generator sets. Frequency changes require voltage regulator and governor adjustments. Refer to the respective spec sheet to determine if frequency is fixed or fieldconvertible. If frequency is adjustable, refer to the engine service manual and/or governor literature for conversion information. Refer to the following procedure and the connection schematics.
5.2 Voltage Reconnection Procedure 1. Place the generator set master switch in the OFF/RESET position. 2. Disconnect the generator set engine starting battery, negative (--) lead first. Disconnect power to the battery charger (if equipped). 3. Use Figure 5-1, Figure 5-2, Figure 5-3, or Figure 5-4 to determine the generator set voltage configuration. Note the original voltage and reconnect as needed.
Figure 5-1 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-P TP-6200 10/12 Section 5 Generator Set Reconnection 163
Figure 5-2 20--400 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875B-P 164 Section 5 Generator Set Reconnection TP-6200 10/12
Figure 5-3 60 (with Oversize Alternator)--400 kW Wound Field Alternators, ADV-5875C-P TP-6200 10/12 Section 5 Generator Set Reconnection 165
Figure 5-4 350 kW and Larger Pilot-Excited, Permanent Magnet Alternator, ADV-5875D-P 166 Section 5 Generator Set Reconnection TP-6200 10/12
Section 6 Accessories 6.1 Accessories and Connections Several accessories help finalize installation, add convenience to operation and service, and establish state and local code compliance. Accessories vary with each generator set model and controller. Select factory-installed and/or shippedloose accessories. See Figure 6-1 for a list of available kits. Obtain the most current accessory information from your local authorized service distributor/dealer.
6.1.2 Common Failure Relay Kit The common failure relay kit provides one set of contacts to trigger user-provided warning devices if a fault occurs. The common failure relay faults are user-defined. See Section 2, Operation, Menu 10— Output Setup, for status and faults available for this function. Connect up to three common failure relay kits to the controller output. See Figure 6-4 and Figure 6-5. See Section 6.2, Accessory Connections, for terminal identification. 6.1.3 6.1.
GM16088A-A Figure 6-6 Controller (Customer) Connection Kit CHARGER MALFUNCTION LV HV CM BATTERY CHARGER ALARM TERMINAL STRIP GM16088A-A Figure 6-7 Float/Equalize Battery Charger Connections TP-6200 10/12 Section 6 Accessories 169
Ground Fault Annunciation Ground Fault Controller Setup Procedure A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. See Figure 6-8 for electrical connections and the following procedure for controller setup. Use the instructions with the kit when provided to install and setup this accessory. 1. Reconnect battery, if not already done. 6.1.
g. Press to enter the inhibit time. Entry Accepted is displayed and the inhibit time 0:00 is now displayed. h. Press TIme. to display Digital Input #06 Delay to enter delay time. Entry i. Press Accepted is displayed. Default delay time is 5 sec. j. Press . 7. Verify Programming. a. Move handle of ground fault circuit breaker at generator set to simulate a ground fault. 9. Place the controller master switch to the OFF/ RESET position. 10.
6.1.7 Low Fuel (Level/Pressure) Switch Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel- or gasoline-fueled models. See Figure 6-10 and Figure 6-11. See Section 6.2, Accessory Connections, for terminal identification. Note: The main tank or the transfer/day tank includes the low fuel level switch. The fuel tank supplier typically provides the low fuel level switch.
6.1.9 Remote Emergency Stop Kit 6.1.10 Remote Reset Feature The emergency stop kit allows immediate shutdown of the generator set from a remote location. See Figure 6-14 and Figure 6-15. If the emergency stop switch activates, the EMERGENCY STOP lamp lights and the unit shuts down. Before attempting to restart the generator set, reset the emergency stop switch (by replacing the glass piece) and reset the generator set by placing the master switch in the OFF/RESET position.
6.1.11 Remote Serial Annunciator RSA II is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA is a remote serial annunciator Figure 6-18 and Figure 6-19 that monitors the condition of the generator set and/or ATS from a remote location. The RSA alerts the operator through visual and audible signals using LED indication and a horn. An alarm silence and lamp test switch are included. /Aux.
System Monitoring LEDs and Functions Fault and Status Condition Overcrank Shutdown Fault LED System Ready LED Generator Running LED Communication Status LED Common Fault LED Common Fault Output Horn Red Red SF Off Green Red SF On On High Engine Temperature Warning * Yellow Red SF Green Green Red SF On On High Engine Temperature Shutdown Red Red SF Off Green Red SF On On Low Oil Pressure Warning * Yellow Red SF Green Green Red SF On On Low Oil Pressure Shutdown Red R
Figure 6-21 RSA Wiring Connections GM62554A-G 176 Section 6 Accessories TP-6200 10/12
Figure 6-22 RSA Wiring Connections GM62554B-G TP-6200 10/12 Section 6 Accessories 177
Figure 6-23 RSA Wiring Connections GM62554C-G 178 Section 6 Accessories TP-6200 10/12
Figure 6-24 RSA Wiring Connections GM62554D-G TP-6200 10/12 Section 6 Accessories 179
Figure 6-25 RSA Wiring Connections GM62554E-G 180 Section 6 Accessories TP-6200 10/12
6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) The remote speed adjustment potentiometer kit provides controller-mounted engine speed adjustment. The adjustment range is approximately ±5%. Some applications locate this potentiometer with the switchgear. This kit requires an electronic governor on the generator set. See Figure 6-26. See Section 6.2, Accessory Connections, for terminal identifications.
6.1.15 Single-Relay Dry Contact Kit The single-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user- provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms, or other devices signal faults or status conditions. Connect any controller fault output to the single-relay dry contact kit. Refer to Figure 6-32 for an internal view of the contact kit.
A-273936 Figure 6-32 Ten-Relay Dry Contact Kit CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX GM13984-/354246B- Figure 6-33 Ten-Relay Dry Contact Kit Connections TP-6200 10/12 Section 6 Accessories 183
6.1.17 Twenty-Relay Dry Contact Kit The twenty-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. Typically, lamps, audible alarms, or other devices signal faults or status conditions. Connect any generator set fault output to the dry contact kit. Refer to Figure 6-34 for an internal view of the contact kit.
6.1.18 Wireless Monitor The wireless monitor system has two components: a wireless monitor unit and a website. The monitor unit transmits messages in response to signals received from the equipment controller and notifies designated recipients of selected operating conditions. The website monitors these messages.
6.2 Accessory Connections The 550 controller contains circuit boards equipped with terminal strip(s) for use in connecting a controller connection kit. Do not connect accessories directly to the controller terminal strip(s). Connect accessories to either a controller connection kit or a dry contact kit. Connect the dry contact kit(s) to the controller connection kit. Connect alarms, battery chargers, remote switches, and other accessories to the dry contact kit relay(s).
TB1 Terminal Strip—Engine Start and Emergency Stop Connections Term. 1 1A 3 4 Description Emergency stop ground Emergency stop Remote start Remote start TB2 Terminal Strip—Analog Input Connections Term.
GM13984- Figure 6-39 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box TB6 Terminal Strip—RDOs 1--7 TB9 Terminal Strip—RDOs 24--31 Term. 42A GND N/C RDO1 RDO2 RDO3 RDO4 RDO5 RDO6 RDO7 Term.
Figure 6-41 Accessory Connections GM78247A-D TP-6200 10/12 Section 6 Accessories 189
Figure 6-42 Accessory Connections GM78247C-D 190 Section 6 Accessories TP-6200 10/12
Figure 6-43 Accessory Connections GM78247D-D TP-6200 10/12 Section 6 Accessories 191
Notes 192 Section 6 Accessories TP-6200 10/12
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC 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 ccw.
K kA KB KBus kg kg/cm2 kelvin kiloampere kilobyte (210 bytes) Kohler communication protocol kilogram kilograms per square centimeter kgm kilogram-meter kg/m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, kΩ kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical kWth kilowatt-thermal L liter LAN local area network L x W x H length by width by height lb.
Appendix B User-Defined Settings Use the table below to record user-defined settings during the generator set controller setup and calibration. The controller default settings and ranges provide guidelines. The table contains all faults with ranges and time delays including items that do not have adjustments. Not adjustable user-defined settings result when the controller logic does not allow changes or the values are engine limited. Note: Inhibit time delay is the time delay period after crank disconnect.
Status Event or Fault Refer to Menu Relay Driver Output (RDO) Digital Display A04 OIL TEMP Analog Aux. Input A04 ] 9 Analog Aux. Input A06 VSG (Volvo, GM, Doosan only) 9, 12 A06 ANALOG AUXILIARY IN Analog Aux. Input A07 9, 11 A07 ANALOG VOLT ADJUST Range Setting Default Values with Warning Enabled: HI/LO warning are engine dependent Default Selection Inhibit Time Delay (sec.) Time Delay (sec.) User-Defined Settings 30 sec. inhibit, 0 sec. delay warning Not adjustable Volvo: 0.5V=1250 4.
Status Event or Fault Refer to Menu Digital Aux. Input D05 Breaker Closed w 9, 10 Digital Display D05 BREAKER CLOSED Digital Aux. Input D06 w 9, 10 D06 ENABLE SYNCH Digital Aux. Input D09 Low Fuel Pressure Shutdown (125RZG only) 9, 10 D09 LOW FUEL SHUTDOWN Digital Aux. Input D11 Air/Fuel Module (AFM) Shutdown ] 9, 10 Digital Aux. Input D12 Detonation Warning ] Relay Driver Output (RDO) Range Setting Fixed Default Selection Inhibit Time Delay (sec.) Time Delay (sec.
Status Event or Fault Refer to Menu (Engine) J1939 CAN Engine Shutdown 10 Digital Display J1939 CAN SHUTDOWN Engine Stalled 10 ENGINE STALLED Relay Driver Output (RDO) Range Setting Default Selection Inhibit Time Delay (sec.) Time Delay (sec.
Status Event or Fault Refer to Menu Relay Driver Output (RDO) Digital Display LOAD SHED RDO-30 ]] KW OVER Load Shed kW Overload ]] 10 Load Shed Over Temperature [[ (Activated by a High Coolant Temp.
Status Event or Fault Refer to Menu Relay Driver Output (RDO) Digital Display NO COOL TEMP SIGNAL Range Setting Default Selection Inhibit Time Delay (sec.) Time Delay (sec.
Status Event or Fault Refer to Menu Undervoltage Shutdown 7, 8, 10 Digital Display UNDER VOLTAGE Relay Driver Output (RDO) RDO-27 Range Setting 70%--95% Default Selection 85% 10-sec time delay[ 70% 30-sec time delayw Inhibit Time Delay (sec.) Time Delay (sec.) User-Defined Settings 5--30 Variable Speed Governor (VSG) (see A06) — VAR/PF Mode (see D17) — Voltage Lower (see D18) — Voltage Raise (see D19) — Weak Battery * [ ] w 10 WEAK BATTERY All models, except Waukesha-powered models.
Appendix C Voltage Regulator Definitions and Adjustments The following definitions and adjustment/setting specifications are intended for users planning to adjust the voltage regulator beyond the default settings in order to customize the alternator for a specific application. This information is not intended to be a comprehensive explanation of all the terms mentioned. There are numerous documents available that define these terms more completely than described herein.
Frequency Setpoint or Cut-In Point The point at which the underfrequency unloading begins to take effect is adjustable, allowing the system to be tailored for each application. Because the characteristics of the engine have the largest effect on the system’s performance, the engine’s response should determine the unloading point. The unloading setpoint is the frequency below which the excitation control will reduce the voltage so that the engine may begin to recover.
Reactive Droop Reactive droop refers to another compensation technique used in excitation control systems. Reactive droop means that the generator set voltage droops with increasing reactive current. Although this sounds like an undesirable effect, it is quite beneficial in paralleling applications with multiple generator sets. Because the terminals of the generator set are connected to another generator set(s), the voltage at the terminals is not solely determined by either generator set’s excitation.
135 amps = ( 112500 / 3) / 277 Where: acos is arccosine or inverse cosine W is Watt L-N is line-to-neutral PF is power factor VA is volt-ampere k is kilo ( = 1000 ) Therefore, each generator set in this case should carry 113 amps per phase or half the 226 calculated line amps. The 113 amps includes 67.5 amps of reactive current, half of the calculated reactive current of 135 amps. The reactive droop should be adjusted until each generator set carries equal reactive current.
Set the PF adjust according to the requirements of the application. When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If there are multiple generator sets in parallel as well, then reactive droop should be ENABLED also. Additionally, note that PF control should be used only while the generator set is connected in parallel with the utility.
Voltage Droop Generating/Absorbing The amount of reactive droop is entered here. The droop is entered as a percentage of system voltage when a fully rated load at 0.8 PF is applied. The entry may be made with resolution as fine as one-tenth of one volt. This entry determines how much the voltage will droop when the alternator provides reactive current. The actual amount the voltage changes is equal to the voltage droop setting times the VAR load as a fraction of the rated VARs (at 0.8 PF).
Appendix D Alternator Protection The 550 controller has built-in thermal protection for the alternator. This feature functions similarly to a thermal circuit breaker. When the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of time at which current is over the rating is inversely related to the amount of current above the nominal rating. In other words, the higher the current, the shorter the acceptable time.
Appendix E Inputs and System Events by Application The controller inputs and system events are typically driven by the engine manufacturer’s ECM. NFPA 110 guidelines provide specific requirements that all controllers must have for compliance. While the controller displays all NFPA 110 required data, some Controller Inputs and System Events engine ECMs provide additional items that the controller will display.
Controller Inputs and System Events NFPA 110 Applications Paralleling Applications DD/MTU Engines with MDEC/ADEC Waukesha Engines 125RZG Digital Aux. Input D17 VAR/PF mode Digital Aux. Input D18 Voltage Lower Digital Aux. Input D19 Voltage Raise Digital Aux. Input D20 Air Damper Indicator Shutdown (if engine equipped) X Digital Aux.
Controller Inputs and System Events NFPA 110 Applications NFPA 110 Fault (Warning or Shutdown) X Paralleling Applications No Air Temperature Signal Warning DD/MTU Engines with MDEC/ADEC Waukesha Engines 125RZG X No Coolant Temperature Signal Shutdown No Oil Pressure Signal Shutdown No Oil Temperature Signal Warning X Overcrank Shutdown Over Current Voltage Restraint Shutdown X Over Current Warning Over Frequency Shutdown Over Power Shutdown X Over Speed Shutdown Overvoltage Shutdown Pre Lube
Notes 212 Appendix TP-6200 10/12
Notes TP-6200 10/12 213
Notes 214 TP-6200 10/12
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 TP-6200 10/12i E 2004, 2005, 2006, 2008, 2009, 2011, 2012 by Kohler Co. All rights reserved.
