Tp6083 Dec550 Operation

Operation
Industrial Generator Sets
20-2000 kW
Models:
Controllers: Decision-Makert 550
Software (Code) Version Prior to 2.10
TP-6083 7/05a
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 nameplate. Manufacturer Model Designation Serial Number
TP-6083 7/05
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.1 1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.8 1.3 1.3.1 1.3.2 1.3.3 Annunciator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Digital Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Controller Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Terminal Strips and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Circuit Board Interconnections for Calibration Procedure . . . . . . . . . . . . 21 Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Status Event and Fault Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Voltage Regulator and Calibration Specifications . . . . . . . . . . . . . . . . . . 25 Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 2.1 2.2 2.3 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Exercising Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 2.3.1 2.3.2 2.3.3 2.3.4 2.3.5 2.3.6 2.3.7 2.4 2.5 2.6 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Emergency Stop Switch Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . 29 System Ready Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 System Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 System Shutdown Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Controller Reset Procedure (Following System Shutdown or Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Menu List Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Digital Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Reviewing Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 2.6.1 2.6.2 2.6.3 Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Auto-Scroll Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Request and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Personal Computer (PC) Communications . . . . . . . . . . . . . . . . . . . . . . . . 42 Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7
Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.7.1 2.7.2
TP-6083 7/05
Table of Contents
Table of Contents, continued

2.8 Reviewing Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 2.8.1 2.8.2 2.8.3 2.8.4 2.8.5 2.8.6 2.8.7 2.8.8 2.8.9 2.8.10 2.8.11 2.8.12 2.8.13 2.8.14 2.8.15 2.9 2.9.1 2.9.2 2.9.3 2.9.4 2.9.5 2.9.6 2.9.7 2.9.8 2.9.9 2.9.10 2.9.11 2.9.12 2.9.13 2.9.14 2.9.15 Menu 1Generator Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Menu 2Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Menu 3Analog Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Menu 4Operational Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Menu 5Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Menu 6Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Menu 7Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Menu 8Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Menu 9Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Menu 10Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Menu 11Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Menu 12Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Menu 13Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Menu 14Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Menu 20Factory Setup (Version 2.10) . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Menu 1Generator Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Menu 2Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Menu 3Analog Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Menu 4Operational Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Menu 5Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Menu 6Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Menu 7Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Menu 8Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Menu 9Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Menu 10Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Menu 11Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Menu 12Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Menu 13Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Menu 14Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Menu 20Factory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Local Programming Mode On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 3.1 3.2 3.3 3.4 Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110 Alternator Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3.4.1 3.4.2 3.4.3 20--300 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 350--2000 kW Models with Single-Bearing Alternator . . . . . . . . . . . . . . . 112 1250--2800 kW Models with Two-Bearing Alternator . . . . . . . . . . . . . . . . 112
Table of Contents
TP-6083 7/05

3.5 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 3.5.1 3.5.2 3.5.3 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.7 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.8 3.9 Bleeding Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 Subbase Fuel Day Tank Electronic Control Module (ECM) . . . . . . . . . . 113 Subbase Inner Fuel Tank Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Gaseous Fuel System Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 LP Liquid Withdrawal Fuel System Concept . . . . . . . . . . . . . . . . . . . . . . . 115 LP Gas/Natural Gas Conversion for Straight Gas Fuel System . . . . . . . 115 Fuel System Changeover Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Cooling System Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 Cooling System Drainage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 Cooling System Flushing and Cleaning Procedure . . . . . . . . . . . . . . . . . 118 Cooling System Refilling Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Gas/Gasoline Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Radiator Expansion Joint LooseningInitial Setup Only . . . . . . . . . . . . . . . . . . . . 119 Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119 3.10.1 3.10.2 3.10.3 3.10.4 3.11.1 3.11.2 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Electrolyte Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 DDEC Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 DDEC Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.11 Detroit Diesel Engine Control (DDEC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.12 Deutz Engine Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 3.13 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 3.13.1 3.13.2 3.13.3 3.13.4 3.13.5 3.13.6 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Internal Engine Components (Gas/Gasoline-Fueled Engines) . . . . . . . 125 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Section 4 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Section 5 Generator Set Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 5.1 5.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Voltage Reconnection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
TP-6083 7/05
Table of Contents

Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 6.1 Accessories and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.1.7 6.1.8 6.1.9 6.1.10 6.1.11 6.1.12 6.1.13 6.1.14 6.1.15 6.1.16 6.1.17 6.2 Audiovisual Alarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Controller (Customer) Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Float/Equalize Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . . 138 Idle (Speed) Mode Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Low Fuel (Level/Pressure) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Prime Power Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Remote Annunciator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Remote Reset Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 Remote Serial Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) . . . . 146 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147 Twenty-Relay Dry Contact Kit (450--2000 kW Models Only) . . . . . . . . . 149 Wireless Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 Appendix B User-Defined Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Table of Contents
TP-6083 7/05
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.
Accidental Starting
WARNING
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 connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
Explosion. Can cause severe injury or death. Relays in the battery charger cause arcs or sparks. Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes. Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. 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. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.
DANGER
Danger indicates the presence of a hazard that will cause severe personal injury, death, or substantial property damage.
WARNING
Warning indicates the presence of a hazard that can cause severe personal injury, death, or substantial property damage.
CAUTION
Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.
Battery
WARNING
NOTICE
Notice communicates installation, operation, or maintenance information that is safety related but not hazard related. Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.
Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
TP-6083 7/05
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 or death. Do not smoke or permit flames or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor. Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the air cleaner removed. Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.
Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building. Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a poisonous gas present in exhaust gases. Carbon monoxide poisoning symptoms include but are not limited to the following: D Light-headedness, dizziness D Physical fatigue, weakness in joints and muscles D Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision D 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. Copper tubing exhaust systems. Carbon monoxide can cause severe nausea, fainting, or death. Do not use copper tubing in diesel exhaust systems. Sulfur in diesel exhaust causes rapid deterioration of copper tubing exhaust systems, resulting in exhaust leakage.
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. Explosive fuel vapors can cause severe injury or death. Take additional precautions when using the following fuels: GasolineStore gasoline only in approved red containers clearly marked GASOLINE. Propane (LP)Adequate ventilation is mandatory. Because propane is heavier than air, install propane gas detectors low in a room. Inspect the detectors per the manufacturers instructions. Natural GasAdequate ventilation is mandatory. Because natural gas rises, install natural gas detectors high in a room. Inspect the detectors per the manufacturers instructions. Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks. Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
Exhaust System
WARNING
Fuel System
WARNING
Carbon monoxide. Can cause severe fainting, or death.
nausea, Explosive fuel vapors. Can cause severe injury or death. Use extreme care when handling, storing, and using fuels.
The exhaust system must be leakproof and routinely inspected.
TP-6083 7/05
Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble. LP liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.
Hazardous Voltage/ Electrical Shock

DANGER
Hazardous voltage. Will cause severe injury or death. Disconnect all power sources before opening the enclosure.
Disconnecting the electrical load. Hazardous voltage can cause severe injury or death. Disconnect the generator set from the load by opening 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. 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. When the end cover is removed, do not expose the photo transistor circuit board mounted on the generator set end bracket to any external light source, as exposure to light causes high voltage. Keep foreign sources of light away from the photo transistor circuit board during testing. Place black electrical tape over the LED on the circuit board before starting the generator set. Installing the photo transistor circuit board. Hazardous voltage can cause severe injury or death. Ensure that the foil side of the photo transistor circuit board, the end of the shaft, and the threaded holes are clean and free of metal particles and chips. Metal debris may short-circuit the photo transistor circuit board and cause hazardous voltage in the generator set. Do not reconnect the generator set to the load until the AC voltmeter shows the correct output. Connecting the SCR assembly. Hazardous voltage can cause severe injury or death. Connect leads C and E to the corresponding terminals of the one-piece SCR assembly. The SCR assembly will turn full on and cause hazardous output voltage if the leads are connected in reverse or if the C (red) lead is grounded. (One-piece SCR models only. Does not apply to current split activator models.)
Safety Precautions and Instructions 9
WARNING
Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
Hazardous Noise
WARNING CAUTION
Hazardous noise. Can cause hearing loss. Never operate the generator set without a muffler or with a faulty exhaust system. Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.
Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death. If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.
TP-6083 7/05
Installing the battery charger. Hazardous voltage can cause severe injury or death. An ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances. Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death. Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies). Servicing the day tank. Hazardous voltage can cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power. Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank 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. Testing the voltage regulator. Hazardous voltage can cause severe injury or death. High voltage is present at the voltage regulator heat sink. To prevent electrical shock do not touch the voltage regulator heat sink when testing the voltage regulator. (PowerBoostt, PowerBoostt III, and PowerBoostt V voltage regulator models only)
Engine block heater. Hazardous voltage can cause severe injury or death. The engine block heater can cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections. Handling the capacitor. Hazardous voltage can cause severe injury or death. Electrical shock results from touching the charged capacitor terminals. Discharge the capacitor by shorting the terminals together. (Capacitor-excited models only) Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines. Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under)
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 alternator. Hot parts can cause severe injury or death. Avoid touching the alternator field or exciter armature. When shorted, the alternator field and exciter armature become hot enough to cause severe burns. Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the 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. 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.
Heavy Equipment
WARNING
Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage. Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.
10
TP-6083 7/05
Combustible materials. Fire can cause severe injury or death. A hot exhaust system can ignite adjacent combustible materials. Do not locate electrical wiring, fuel lines, or combustible materials above the exhaust muffler. Exercise caution when parking your vehicle to prevent the exhaust system and hot exhaust gases from starting grass fires.
Moving Parts
WARNING
Tightening the hardware. Flying projectiles can cause severe injury or death. Loose hardware can cause the hardware or pulley to release from the generator set engine and can cause personal injury. Retorque all crankshaft and rotor hardware after servicing. Do not loosen the crankshaft hardware or rotor thrubolt when making adjustments or servicing the generator set. Rotate the crankshaft manually in a clockwise direction only. Turning the crankshaft bolt or rotor thrubolt counterclockwise can loosen the hardware. Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.
NOTICE
When replacing hardware, do not substitute with inferior grade hardware. Screws and nuts are available in different hardness ratings. To indicate hardness, American Standard hardware uses a series of markings, and metric hardware uses a numeric system. Check the markings on the bolt heads and nuts for identification.
NOTICE
Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.
Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place.
Notice
WARNING NOTICE
This generator set has been rewired from its nameplate voltage to Rotating parts. Can cause severe injury or death. Operate the generator set only when all guards, screens, and covers are in place.
246242
NOTICE
WARNING
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. or
Airborne particles. Can cause severe blindness.
injury
NOTICE
Hardware damage. The engine and generator set may use both American Standard and metric hardware. Use the correct size tools to prevent rounding of the bolt heads and nuts.
Wear protective goggles and clothing when using power tools, hand tools, or compressed air.
TP-6083 7/05
11
Notes
12
TP-6083 7/05
Introduction
This manual provides operation instructions for 20--2000 kW generator sets equipped with the following controller:
D Decision-Makert 550, Software (Code) Version
skilled and suitably-trained maintenance personnel familiar with generator set operation and service. The disc supplied with this generator set is a backup copy of the generator set personality program containing data specific to the engine and alternator. The engine and alternator data was preprogrammed in the controller at the factory and no further use of the disc should be necessary. Typically, your authorized distributor stores this disc for possible future use such as controller replacement or other circumstances requiring a backup.
Prior to 2.10 Version 2.10 refers to the controller application software. To determine the generator set controller software version, go to Menu 20Factory Setup and scroll down to Code Version. The code version is the controller software version. Wiring diagram manuals are available separately. Refer to the engine operation manual for generator set engine scheduled maintenance information. Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference. The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Maintenance work must be performed by appropriately
List of Related Materials

Separate literature contains communication and software information not provided in this manual. The following table lists the available literature part numbers.
Communication and Software Manual Description
550 Controller Spec Sheet Generator Set/Controller Wiring Diagram Manual 550 Communications Spec Sheet KBUS Communications Spec Sheet Monitor II Software Operation/Installation Manual Modbus Communication Operation/Installation Manual Program Loader Software Installation KBUS Communication Kits Installation
Literature Part Number

G6--46 Multiple Part Numbers Contact your Distributor/Dealer G6--50 G6--38 TP--5972 TP--6113 TT--1285 TT-847
TP-6083 7/05
Introduction
13
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
GeneratorsElectric
D Visit
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
the Kohler Power Systems website at KohlerPowerSystems.com or review the appropriate literature or documents included with the product
D Look at the labels and stickers on your Kohler product
D Call toll free in the US and Canada 1-800-544-2444 D Outside the US and Canada, call the nearest regional
office Headquarters Europe, Middle East, Africa (EMEA) Kohler Power Systems ZI Senia 122 12, rue des Hauts Flouviers 94517 Thiais Cedex France Phone: (33) 1 41 735500 Fax: (33) 1 41 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455
14
Service Assistance
TP-6083 7/05
Section 1 Specifications and Features

1.1 Introduction
The spec sheets for each generator set provide model specific generator and engine information. The controller spec sheet provides specifications for this controller. Refer to the respective spec sheet for data not supplied in this manual. Consult the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications. (ECM) setup and features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted. 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. Note: There are two operating modes: prime power or standby. The operating mode selection alters the displays involving generator set ratings. Change this setting using Menu 14Programming Mode Menu and Menu 7Generator System Menu. Note: Measurements display in metric or English. See Menu 7Generator System. See Figure 1-1 for an illustration of the controller front panel.
1.2 Controller Features

The controller features include the annunciator lamps, digital display and keypad, switches and controls, and fuses and terminal strip. The following paragraphs detail the features by general topics. The controller features, accessories, and menu displays depend upon the engine electronic control module
1 2 3 4
8
1. 2. 3. 4. Emergency stop switch Alarm horn (see keypad for alarm silence) Annunciator lamps (see keypad for lamp test) Generator set master switch, run/off-reset/auto positions 5. 6. 7. 8.
7
Digital display Keypad Operating guide Controller terminal strips (on circuit board)
TP-6083-2
Figure 1-1
TP-6083 7/05
Controller
Section 1 Specifications and Features 15
1.2.1
Annunciator Lamps
See Section 2.3.5, System Warning Lamp, for definitions of the items listed. The following conditions cause a system warning:
D Engine functions:
Five annunciator lamps provide visual generator set status. See Figure 1-2.
TP-6083-2
Figure 1-2
Annunciator Lamps
System Ready. Green lamp illuminates when the generator set master switch is in the AUTO (automatic start) position and the system senses no faults. The unit is ready to start. Not in Auto (NIA). Yellow lamp illuminates when the generator set master switch is not in the AUTO (automatic start) position. Programming Mode. Yellow programming lamp indicates the user selected programming mode. See Figure 1-3.
Programming Lamp Programming Mode Selection Lamp Flashing Lamp Steady On Lamp Off Local Programming Remote Programming Programming Disabled
High battery voltage High coolant temperature Low battery voltage Low coolant temperature Low fuel (level or pressure)* Low oil pressure Speed sensor fault Starting aid (status) Weak battery D General functions:
d AuxiliaryAnalog up to 7 inputs each with a high
d d d d d d d d d
Figure 1-3
Programming Lamp Mode
Note: Find additional information for the programming mode lamp function and access to the local or remote programming modes in Section 2.9, Local Programming Mode On, Menu 14Programming 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.
and low programmable warning level NOTE: Non-ECM models have 5 programmable warnings d AuxiliaryDigital up to 21 programmable warnings d Battery charger fault* d Emergency power system (EPS) supplying load d Engine cooldown delay d Engine start delay d Load shed kW overload d Load shed underfrequency d Master switch not in AUTO (automatic start) position d NFPA-110 fault (National Fire Protection Association) d System ready (status) D Generator functions:
d d d d
AC sensing loss Generator running (status) Ground fault* Overcurrent
* Requires optional input sensors.
16
TP-6083 7/05
System Shutdown. Red lamp indicates that the generator set has shut down because of a fault condition. Unit will not start without resetting controller, see Section 2.3.7, Controller Reset Procedure. See Section 2.3.6, System Shutdown Lamp, for definitions of the items listed. The following conditions cause a system shutdown:
D Engine functions: d d d d d d d d d
Keypad Functions
Alarm (horn) off key silences the alarm horn at the operators discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. See Section 2.3.7, Controller Reset Procedure, and Section 1.2.3, Switches and Controls. AM/PM key provides time of day data entries when programming. Enter key provides confirmation entry when selecting menu or programming. Lamp test key tests the controller indicator lamps, horn, and digital display. See Section 1.2.3, Switches and Controls. Menu down key provides navigation within menus when necessary. Menu right key provides navigation within menus when necessary. Numeric 0- keys provide numeric data entries when -9 selecting menus or programming. Reset menu key exits a menu, clears incorrect entries, and cancels the auto-scroll feature. Stop prog (program) run key allows the user to stop any previously programmed generator set run sequence. See Section 1.2.3, Switches and Controls. Yes/No keys provides data answer entries when programming.
Air damper closed (status), if equipped Coolant temperature signal loss High coolant temperature High oil temperature Low coolant level Low oil pressure Oil pressure signal loss Overcrank Overspeed D General functions:
d AuxiliaryAnalog up to 7 inputs each with a high
and low programmable shutdown level NOTE: Non-ECM models have 5 programmable shutdowns d AuxiliaryDigital up to 21 programmable shutdowns d ECM communications loss (ECM models only) d Emergency stop d Internal fault d Master switch in OFF/RESET position d Master switch error d Master switch open d NFPA 110 fault D Generator functions:
d AC output overvoltage d AC output undervoltage d Alternator protection against overload and short d d d d
circuits Field overvoltage (M4, M5, or M7 alternator only) Locked rotor (failed to crank) Overfrequency Underfrequency
1.2.2
Digital Display and Keypad
Figure 1-4 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.
TP-6083 7/05 Section 1 Specifications and Features 17
TP-5829-2
Figure 1-4
Digital Display and Keypad
Generator Output Displays

AC Amps displays the generator output current. The display shows each line of 3-phase models. AC Volts displays the generator output voltages. The display shows all line-to-neutral and line-to-line voltage combinations. Alternator duty level displays the actual load kW divided by the nameplate kW rating as a percentage. Frequency displays the frequency (Hz) of generator output voltage. Hourmeter displays the generator set operating hours loaded and unloaded for reference in scheduling maintenance. KVA displays the total and individual L1, L2, and L3 kVA. KVAR displays the total and individual L1, L2, and L3 kVAR. Power factor displays the leading/lagging L1, L2, L3, and total power factor. Watts displays the total and individual L1, L2, L3 kilowatts.
Fuel Pressure displays the fuel supply pressure. Fuel Rate displays the calculated fuel consumption rate based on fuel injector outputs. Fuel Temperature temperature. displays the fuel supply
Oil Level displays the engine oil level as a percent of full capacity. Oil Pressure displays the engine oil pressure. Oil Temperature displays the engine oil temperature. RPM (Tachometer) displays the engine speed. Used Last Run displays the accumulated amount of fuel used since last reset by the engine DDEC reader.
Operational Record Displays

The operational record displays events since last reset. See Section 2.9.4, Menu 4Operational Records, for resetting procedure. Engine Start Countdown displays the time remaining before the next generator set startup. Event History displays up to 100 stored system events including status, warnings, and shutdowns. Last Start Date displays the date when the generator set last operated. Number of Starts displays the total number of generator set startup events. Number of Starts (Since) Last Maintenance displays the total number of generator set startup events since the last maintenance date. Operating Days (Since) Last Maintenance displays the total number of days of operation since the last maintenance date. A counted day of operation can be 1--24 hours. Run Time displays the total loaded hours, total unloaded hours, and total kW hours. Run Time Since Maintenance displays the total loaded hours, total unloaded hours, and total kW hours.
Engine Displays
Some engine displays are available with selected generator set engines using engine electronic control modules (ECM) 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. Coolant Level displays the engine coolant level. Coolant Pressure displays the engine coolant pressure. Coolant Temperature displays the engine coolant temperature. Crankcase Pressure displays the engine crankcase pressure. DC Volts displays the voltage of starting battery(ies).
18
TP-6083 7/05
Time Delay Displays

The time delays are user adjustable. See Section 2.9.8, Menu 8TIme Delays, for time delay adjustments. See Section 1.3.1, Status Event and Fault Specifications, for range and default settings. Crank On/Crank Pause displays the time allocated for generator set crank on and crank pause in minutes:seconds. Engine Cooldown displays the time delay for engine cooldown while the master switch is in the AUTO or RUN positions and not in the idle mode. Engine Start displays the time delay before the generator set starts while the master switch is in AUTO or RUN positions. Overcrank Shutdown (Number of) Crank Cycles displays the number of unsuccessful crank cycles (crank on/crank pause) before the generator set shuts down on an overcrank fault. Overvoltage displays the time delay before the generator set shuts down because of an overvoltage condition. Starting Aid displays the engine starting aid activation time. Undervoltage displays the time delay before the generator set shuts down because of an undervoltage condition.
Alarm Horn. The alarm horn alerts the operator or other attendants that a shutdown or warning condition exists. See Section 1.3, Controller Logic Specifications, for conditions. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the generator set master switch is in the AUTO position. See Section 2.3.7, Controller Reset Procedure. Alarm (Horn) Off. The keypad switch silences the alarm horn at the operators discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. Restore alarm horn switches at all locations including those on remote annunciator and audiovisual alarm kits to the normal position after correcting the fault shutdown to avoid reactivating the alarm horn. See Section 2.3.7, Controller Reset Procedure. Emergency Stop. The operator-activated switch immediately shuts down the generator set in emergency situations. Reset the emergency stop switch after shutdown by pulling the switch knob outward. Use the emergency stop switch for emergency shutdowns only. Use the generator set master switch for normal shutdowns.
1.2.3
Switches and Controls
See Figure 1-5 and Figure 1-6 for switches and controls. Note: Find additional switches and Section 2.6.1, Keypad Operation. controls in
1 2 3
1. Lamp test 2. Alarm horn silence 3. Stop program run
TP-5829-2
Figure 1-6
TP-6083-2
Keypad Switches
Figure 1-5
Switches and Alarm Horn
TP-6083 7/05
19
Generator Set Master Switch (Run/Off-Reset/Auto). This switch resets the controller fault lamps and start/stops the generator set. Refer to Section 2.3.1, Starting, Section 2.3.2, Stopping, and Section 2.3.3, Emergency Stop Switch Reset Procedure. Lamp Test. Keypad switch tests the controller indicator lamps, horn, and digital display. Press the reset menu key before pressing the lamp test key. Stop Prog (Program) Run. Keypad switch allows the user to stop any previously programmed generator set run sequence.
Indicator Circuit Board includes the LED status lamps and alarm horn. Interconnection Circuit Board provides the terminal strips to connect the customer connection and/or dry contact kits and three fuses (F1, F2, and F3). Keypad Circuit Board provides the keypad to navigate the generator set displays and enter data. Digital Display Circuit Board provides the digital display for monitoring the generator set functions and output values. Main Logic (Microprocessor)/Communication Circuit Board provides the controller operation logic and provides PC communication locally (direct) or remotely (via modem) using RS-232 or RS-485 connectors.
1.2.4
Controller Circuit Boards
The controller has five circuit boardsindicator, interconnection, keypad, digital display, and main logic/communication. See Figure 1-7 for circuit board locations.
1 2
1.2.5
Fuses
AC Circuit Fuses (TB6). Fuses are located inside the controller. See Figure 1-7.
D 1.5-Amp (V7) fuse protects L1 sensing input to
interconnection circuit board.

interconnection circuit board.

interconnection circuit board. DC Circuit Fuses fuses are located on the controller interconnection circuit board.
5 4 3
GM10193B-A
D 5-Amp Remote Annunciator (F1) fuse protects the
1. AC fuse block (TB6) 2. Interconnection circuit board TB1, TB2, TB3, and TB4 terminal strips and F1, F2, and F3 fuses 3. Main logic (microprocessor)/communication circuit board 4. Keypad and digital display circuit boards 5. Indicator circuit board (LED and alarm horn)
dry contact kit if equipped and the controller panel lamps.

D 5-Amp Controller (F2) fuse protects the controller
circuitry.
D 15-Amp
Figure 1-7
Controller Circuit Boards and Fuses (Controller Top View)
Engine and Accessories (F3) fuse protects the engine/starting circuitry and accessories.
20
TP-6083 7/05
1.2.6
Terminal Strips and Connectors
1.2.7
Terminal strips and connectors for inputs and outputs are located on the interconnection circuit board. See Section 6, Accessories. TB1 Input Connection Terminal Strip provides input connections for remote start and emergency stop (E-Stop). TB2 Analog Input Connection Terminal Strip provides analog input connections, including non-ECM sensor connections. TB3 Accessory Power Output Connection Terminal Strips provides a generator set power supply for factory use. TB4 Digital Input Connection Terminal Strips connect external devices (engine ECM and user supplied) to the generator set digital inputs. P23 Connector connects the interconnection circuit board to the (customer) connection terminal strip (connector P25) inside the junction box. Figure 1-8 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
Circuit Board Interconnections for Calibration Procedure
The interconnection circuit board shown in Figure 1-9 contains a ribbon connector that requires disconnection during the calibration procedure in Menu 12 Calibration. Disconnect ribbon connector P2 prior to zeroing out (resetting) the auxiliary analog inputs.
1 2
ADV-6533-A
1. Interconnection circuit board 2. P2 ribbon connector 3. P12 ribbon connector
Figure 1-9
Interconnection Circuit Board Ribbon Connector P2 (Top View of Circuit Board)
1. 2. 3. 4. 5.
TB1 terminal strip TB2 terminal strip P23 Connector TB3 terminal strip TB4 terminal strip
ADV-6533-A
Figure 1-8
Interconnection Circuit Board Terminal Strips and Connectors
TP-6083 7/05
21
1.2.8
Communication Ports
1.3 Controller Logic Specifications

The Controller Logic Specifications section is an overview of the various features and functions of the controller. Certain features function only when optional accessories are connected. See Section 2, Operation, for details. The default selection time delays and relay driver outputs (RDOs) are factory set and adjustable with the programming mode on. Some data entries require using a PC in the Remote Programming mode. See the Software Operation Manual for details. Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect the fault or status events. Select the desired inhibit time delay 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. Select the desired time delay from 0 to 60 seconds.
The main logic circuit board contains several communication ports for KBUS and Modbus connections. See Figure 1-10. Refer to the List of Related Materials in the Introduction section for corresponding communication installation information.
1.3.1
Status Event and Fault Specifications
The table starting on the next page contains all faults with ranges and time delays including items that do not have adjustments. The engine ECM may limit the crank cycle even if the controller is set to a longer time period.
6
ADV-6533-A
1. 2. 3. 4. 5. 6.
P19unused ISO2, RS-485 port P21KBUS ISO1, RS-485 port P18KBUS or Modbus, RS-232 port P20Modbus, RS-485 port P22ECM connector Main logic circuit board
Figure 1-10 Main Logic Circuit Board Communication Ports (Top View of Circuit Board)
22
TP-6083 7/05
Status Event or Fault

Access Code (password) AC Sensing Loss Air Damper Indicator (if used) Digital Aux. Input 20 Alternator Protection Battery Charger Fault, Digital Aux. Input 1 Battle Switch (see Fault Shutdown Override Switch) Analog Aux. Inputs 1--7
Refer to Menu
14 10 10
Digital Display
Relay Driver Output (RDO)
Alarm Horn
Lamp
Range Setting
Default Selection
0 (zero)
Inhibit Time Delay (sec.)
Time Delay (sec.)
AC Sensing Loss Air Damper Indicator Alternator Protection Battery Charger Fault Battle Switch
RDO--25 RDO--23 (lead 56)
On On
Warning Shutdown 0 sec. inhibit, 0 sec. delay
10 10
On RDO--11 (lead 61) Off
Shutdown Warning 0 sec. inhibit, 0 sec. delay
Off
Warning
User-Defined A1--A7
On
Shutdown Default Values with or Warning Enabled: Warning HI warning 90% LO warning 10% HI shutdown 100% LO shutdown 1%
30 sec. inhibit, 5 sec. delay
0--60
0--60
Analog Aux. Input 1 (non-ECM only)
Coolant Temp
On
Shutdown Default Values with 30 sec. or Warning Enabled: inhibit, Warning HI/LO warning and 0 sec. delay HI/LO shutdown are all engine dependent Shutdown Default Values with 30 sec. or Warning Enabled: inhibit, Warning HI/LO warning and 0 sec. delay HI/LO shutdown are warning, 5 all engine dependent sec. delay (255 psi max.) shutdown Shutdown or Warning 1--6 crank cycles 10--30 sec. crank on 1--60 sec. pause Shutdown Default shutdowns or include: Warning Emergency stop High coolant temp Low oil pressure Overcrank Overspeed 30 sec. inhibit, 5 sec. delay 3 15 sec. 15 sec. 30 sec. inhibit, 5 sec. delay
0--60
0--60
Analog Aux. Input 2 (non-ECM only)
Oil Pressure
On
0--60
0--60
Digital Aux. Input 1--21
User-Defined D1--D21
On
0--60
0--60
Cyclic Cranking
Off
Defined Common Faults
10
Defined Common Fault
RDO--18 (lead 32A)
On
0--60
0--60
EEPROM Write Failure Engine Cooldown (see Time Delay--) Engine Start (see Time Delay--) Emergency Stop Shutdown EPS (Emergency Power System) Supplying Load Fault Shutdown Override Switch Field Overvoltage Digital Aux. Input 4 (M4, M5, or M7 alternator only)
10
EEPROM Write Failure
On
10 10
Emergency Stop EPS Supplying Load Battle Switch Field Overvoltage
RDO--14 (lead 48) RDO--22
Off Off
Shutdown 5% of rated line current Warning Shutdown 1 sec. inhibit, 15 sec. delay
9 9
Off On
TP-6083 7/05
23
Status Event and Fault Specifications, continued

Refer to Menu
10 10 10 10 Ground Fault High Battery Voltage Hi Cool Temp Shutdown Hi Cool Temp Warning Hi Oil Temp Shutdown Idle Mode Active RDO--21 RDO--13 RDO--03 (lead 36) RDO--06 (lead 40)
Status Events or Fault

Generator Running Ground Fault Detected High Battery Voltage High Coolant Temperature Shutdown High Coolant Temperature Warning High Oil Temperature Shutdown Idle (speed) Mode Function Digital Aux. Input 21 Internal Fault Shutdown kW Overload (see Load Shed) Load Shed kW Overload Load Shed Underfrequency
Digital Display

RDO--15 (lead 70R)
Alarm Horn
Off On Off On
Lamp
Range Setting
Default Selection
Time Delay (sec.)
Warning Warning Shutdown 14.5--16.5 V (12 V) 29--33 V (24 V) 16 V (12 V) 32 V (24 V) 30 10 5
10
On
Warning
30
10 10
On Off
Shutdown Warning 0 sec. inhibit, 60 sec. delay
30
5 0--600
10
Internal Fault
On
Shutdown
10
Load Shed KW Over Load Shed Under Frequency Locked Rotor
RDO--30
Off
Warning
100% of kW rating with 5 sec. delay 59 Hz with (60 Hz) 49 Hz with (50 Hz)
10
RDO--31
Off
Warning
Locked Rotor Shutdown Loss of ECM Communication Low Battery Voltage Low Coolant Level Low Coolant Temperature, Digital Aux. Input 3 (ECM) Low Fuel, Digital Aux. Input 2 (Low) Oil Pressure Shutdown (Low) Oil Pressure Warning Master Not In Auto (generator switch) Master Switch Error Master Switch Open NFPA 110 Fault
10 10 10 10 10
On On Off On On
Shutdown Shutdown Warning Shutdown Warning 0 sec. inhibit, 0 sec. delay 0 sec. inhibit, 0 sec. delay 30 30 5 10--12.5 V (12 V) 20--25 V (24 V) 12 V (12 V) 24 V (24 V) 30 4 10 5
Loss of ECM RDO--26 Comm Low Battery Voltage Low Coolant Level Low Coolant Temp Low Fuel RDO--12 (lead 62) RDO--19 RDO--05 (lead 35) RDO--08 (lead 63) RDO--04 (lead 38) RDO--07 (lead 41) RDO--09 (lead 80)
10
On
Warning
10 10 10 10 10 10
Oil Pressure Shutdown Oil Pressure Warning Not In Auto Master Switch Error Master Switch Open NFPA 110 Fault No Cool Temp Signal No Oil Pressure Signal
On On On On On
Shutdown Warning Not In Auto Shutdown Shutdown Shutdown or Warning Shutdown Shutdown
RDO--10 (lead 32)
On
No Coolant Temperature Signal No Oil Pressure Signal
10 10
Off Off
30 30
4 4
24
TP-6083 7/05
Status Event and Fault Specifications, continued

Refer to Menu
8 10 7, 10 7, 10 7, 8, 10
status events or Fault

Overcrank Shutdown Overcurrent Overfrequency Shutdown Overspeed Shutdown Overvoltage Shutdown
Digital Display
Over Crank Over Current Over Frequency Over Speed Over Voltage

RDO--02 (lead 12) RDO--28 RDO--01 (lead 39) RDO--20 (lead 26)
Alarm Horn
On On On On On
Lamp
Shutdown Warning Shutdown Shutdown Shutdown
Range Setting
0--6 Cycles
Default Selection
3 Cycles 110%
Time Delay (sec.)
10 10 0.25 2--10
102%--140% 65--70 Hz (60 Hz) 55--70 Hz (50 Hz) 105%--135%
140% Std. 103% FAA 70 (60 Hz) 60 (50 Hz) 115% 2-sec time delay
Password (see Access Code) Speed Sensor Fault Starting Aid (see Time Delay Starting Aid) System Ready Time Delay Engine Cooldown (TDEC) Time Delay Engine Start (TDES) Time Delay Starting Aid Underfrequency 10 8, 10 8, 10 8, 10 7, 10 Under Frequency Under Voltage Weak Battery RDO--29 RDO--17 (lead 60) RDO--16 (lead 70C) Off Off Off Off On Shutdown or Warning Shutdown System Ready 00:00--10:00 min:sec 00:00--5:00 min:sec 0--10 sec. 80%--95% 90% 10 5:00 00:01 10 Speed Sensor Fault RDO--24 On Warning
Undervoltage Shutdown Weak Battery
7, 8, 10 10
RDO--27
On
70%--95%
85% 10-sec time delay 60% of nominal
5--30
Off
Warning
1.3.2
Voltage Regulator and Calibration Specifications*

Refer to Menu
11 11 11 11 11
Calibration
Underfrequency Unload Slope PF Adjust Control Reactive Droop Underfrequency Unload or Frequency Setpoint VAR Control
Digital Display
Slope PF Adj. Voltage Droop Frequency Setpoint kVAR Adj.
Range Setting
0--10% of rated voltage volts per cycle 0.7 to 1.0 leading 0.6 to 1.0 lagging 0--10% of system voltage 40 to 70 Hz 0 to rated kVAR generating 0 to 35% of rated kVAR absorbing 20% of system voltage
Default Selection
2 volts per cycle 0.8 lagging 4% of system voltage 1 Hz below system frequency (ECM) 2 Hz below system frequency (non-ECM) 0
Voltage Adjustment
11
Volt Adj.
System voltage
* The controller-to-alternator interface circuit board was temporarily unavailable on early units. As a result, 350--2000 kW generator sets are equipped with a Marathon DVR 2000 voltage regulator and not the internal controller voltage regulator. Refer to the Marathon voltage regulator technical manual for specifications and all adjustments.
TP-6083 7/05
25
1.3.3
Voltage Regulator Adjustments
The descriptions of the voltage regulator adjustments and features follow. See Appendix C, Voltage Regulator Definitions and Adjustments, for additional information. 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 underfrequency. The voltage regulator reduces voltage, allowing engine speed recovery. The volts-per-Hz setting determines the amount of voltage drop. Power Factor (PF) Adjust Control. Power factor adjust controls the generator reactive load. The PF adjustment controls the excitation level for maintaining the PF setting. The PF adjust control setting determines the reactive current (VARs) amount in relation to the real current (watts) as regulated by the load-sharing module. Power is the cosine of the electrical angle between current and voltage. The cosine function is positive for angles between --90 degrees (lagging) and +90 degrees (leading). This adjustment requires the user to determine whether the current leads (positive angle) or lags (negative angle) the voltage. Reactive Droop. Reactive droop compensation provides reactive current flow adjustment in the generator during generator-to-generator paralleling applications. Reactive droop reduces excitation levels with increasing reactive current. A reduced excitation level removes generator reactive current or generates VARs, improving stability. Enter the gain setting as a percentage of system voltage causing output voltage drop when full-rated load with 0.8 power factor is applied. Any loads less than full load force voltage drop by the ratio of reactive volt-amps (VARs) to rated VARs.
Underfrequency Unload or Frequency Setpoint. This adjustment affects the voltage droop (volts per Hz) when load is applied and underfrequency occurs. The underfrequency unload setting defines the setpoint where underfrequency starts. Any frequency below the setpoint causes the voltage to drop and engine speed to recover according to the underfrequency unload slope setting. Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions. The underfrequency unload setting best matches engine speed recovery characteristics to the application. VAR Control. VAR control provides reactive current flow adjustment in the generator during generator-to-utility paralleling applications. The controller displays the total kVAR generator load while running in parallel with the utility. The utility supply, not the controller, determines terminal voltage. Engine fueling determines real power measured in watts using load sharing module control. Voltage Adjustment. The voltage adjustment allows the customer to enter the desired generator set output level. This regulated level setting is the average of the three line-to-neutral voltages in wye configurations or L1-to-L2 in single phase and delta configurations. Submenus display the individual line-to-line voltages. These voltages are relevant in unbalanced load conditions. The voltage adjust setpoint can be changed to accommodate an important phase in an unbalanced system.
26
TP-6083 7/05
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. Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine. Air Inlets. Check for clean and unobstructed air inlets. Battery. Check for tight battery connections. Consult the battery manufacturers instructions regarding battery care and maintenance. Controller. After reconnecting the battery, set the controller time and date. See Section 2, Menu 14 Programming Mode On and Menu 6Time and Date. Coolant Level. Check the coolant level according to the cooling system maintenance information. Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater. Drive Belts. Check the belt condition and tension of the radiator fan, water pump, and battery charging alternator belt(s). Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections. Inspect the exhaust system components (exhaust manifold, exhaust line, flexible exhaust, clamps, silencer, and outlet pipe) for cracks, leaks, and corrosion.
D Check for corroded or broken metal parts and replace
them as needed.
D Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps and/or hangers as needed.

D Check that the exhaust outlet is unobstructed. D Visually inspect for exhaust leaks (blowby). Check
for carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed. Fuel Level. Check the fuel level and 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. Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave rags, tools, or debris on or near the generator set.
2.2 Exercising Generator Set

Operate the generator set under load once each week for one hour. Perform the exercise in the presence of an operator when the generator set does not have a programmed exercise mode or an automatic transfer switch with an exercise option. During the exercise period apply a minimum of 35% load based on the nameplate standby rating, unless otherwise instructed in the engine operation manual. The operator should perform all of the prestart checks before starting the exercise procedure. Start the generator set according to the starting procedure in Section 2.3, Controller Operation. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator set for fluid or exhaust leaks.
TP-6083 7/05
Section 2 Operation
27
2.3 Controller Operation

2.3.1 Starting
The idle function also provides engine cooldown at idle speed. The controller overrides the idle speed mode when the engine reaches the preprogrammed engine cooldown temperature before the idle mode times out. During the idle (speed) mode the controller continues to monitor critical engine parameters such as oil pressure, coolant temperature, and engine speed. The voltage regulator, thermal protection feature, and AC metering are disabled in the idle speed mode. The controller overrides the idle speed function when the generator set is signaled to start while in the AUTO position. This override provides emergency generator set power in the event of a utility power failure. When the utility power returns and the generator set is signalled to stop, the generator set continues to run for the duration of the idle mode period when the idle mode is active. When the idle mode is not active, the generator set will shut down in the normal stopping mode including time delays. See Menu 9Input Setup to activate the idle speed function as a user-defined digital input. The idle speed feature requires an ECM-equipped engine with the idle speed function.
Local Starting
Move the generator set master switch to the RUN position to start the generator set at the controller. Note: The alarm horn sounds and the Not-In-Auto lamp lights whenever the generator set master switch is not in the AUTO position. Note: The transient start/stop function of the controller prevents accidental cranking of the rotating engine. The generator set stops and recranks when the generator set master switch is momentarily placed in the OFF/RESET position and then returned to RUN.
Auto Starting
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). Terminals 3 and 4 connect to a circuit that automatically starts the generator set crank cycle when an external source closes the circuit. Note: The controller provides up to 60 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 3 cycles. Make cyclic cranking adjustments using the keypad. See Section 2.9.14, Menu 14Programming Mode, and Section 2.9.8, Menu 8Time Delays.
Run Time Feature

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. See Menu 4Operational Records for setup of this feature. With the run time enabled, the generator set will begin to crank and run based on the run time period and all previously established time delays from Menu 8Time Delays. Generator set connected to an automatic transfer switch. Should a utility power failure occur while the unit is in the run time mode, the controller will bypass the run time mode and function in the standby (backup) mode. When the utility power returns, the generator set continues to run for the duration of the run time period when not timed out. Note: Press the STOP PROG RUN key, when necessary, to stop the generator set when it is in the run time mode.
Idle (Speed) Mode Warmup and Cooldown Function

The idle (speed) mode function provides the ability to start and run the engine at reduced speed for a selectable time period (0--10 minutes) during warmup. See Section 6.1.5, Idle (Speed) Mode Feature, for installation information. The controller will override the idle speed mode when the engine reaches the preprogrammed engine warm-up temperature before the idle mode times out.
28
Section 2 Operation
TP-6083 7/05
Prime Power Switch

The digital controller has an optional prime power mode of operation. The prime power mode requires installation of an optional prime power switch kit. See Section 6, Accessories for instructions on how to install the optional prime power switch kit. The prime power switch kit prevents engine starting battery drain when the generator set is shut down and no external battery charging is available. Move the prime power switch located on the back of the controller to the CONTROLLER ON position and set the controller time and date before attempting to start the generator set. When the prime power mode is off, all controller functions including the digital display, LEDs, and alarm horn are operative. Note: After energizing the controller using the prime power switch, set the controller time and date. See Section 2.9.6, Menu 6TIme and Date. Stop the generator set using the stopping procedures in 2.3.2 before placing the generator set in the prime power mode. Move the prime power switch located on the back of the controller to the CONTROLLER OFF position. When the generator set is is the prime power mode, all controller functions including the digital display, LEDs, alarm horn, and communications are inoperative.
Note: Use the emergency stop switch(es) for emergency shutdowns only. Use the generator set master switch for normal shutdowns. The controller system shutdown lamp lights and the unit shuts down when the local or remote emergency stop switch activates.
Battle Switch/Fault Shutdown Override Switch

The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown. When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/generator damage can occur. When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5 Event History. See Section 2.9.9, Menu 9Input Setup, for information on how to enable the battle switch feature.
2.3.3
Emergency Stop Switch Reset Procedure
2.3.2
Stopping
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: The cooldown cycle times out before the generator set stops when a remote switch or automatic transfer switch initiates the generator set start/stop sequence.
Use the following procedure to reset the generator set after shutdown by a local or remote emergency stop switch. Refer to Section 2.3.7, Controller Reset Procedure, to restart the generator set following a fault shutdown. 1. Place the generator set master switch in the OFF/RESET position. 2. Investigate and emergency stop. correct the cause of the
3. Reset the optional remote emergency stop switch by replacing the glass piece, when equipped. Additional glass rods are available as a service part. Reset the controller emergency stop switch by pulling the switch knob outward. 4. After resetting all faults using the Controller Reset Procedure, toggle the generator set master switch to RUN or AUTO to restart the generator set. The generator set will not crank until the reset procedure completes.
Emergency Stopping
Use the controller emergency stop switch or optional remote emergency stop for immediate shutdown. The emergency stop switch bypasses the time delay engine cooldown and immediately shuts down the generator set.
2.3.4
System Ready Lamp
System Ready. The green lamp illuminates when the generator set master switch is in the AUTO position and the system has no fault conditions.
TP-6083 7/05
Section 2 Operation
29
2.3.5
System Warning Lamp
The yellow warning lamp illuminates indicating a fault or status event but does not shut down the generator set under the following conditions. In some cases the alarm horn also sounds. See Section 2.3.7, Controller Reset Procedure, for instructions on resetting a system warning. When the system warning lamp is on and no message displays, press the Reset Menu and the menu down key to view messages. When the system warning continues, it may lead to a fault and cause a system shutdown. Use the Alarm Off keypad switch to silence the alarm horn at the operators discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the master switch is in the AUTO position. 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 battery charger fault. Customer Auxiliary (Warning). The lamp illuminates and the alarm horn sounds when an auxiliary digital or analog inputs signals the controller. The customer can define inputs as shutdowns or warnings. The local display shows digital input 1-21 or analog input 1-7. Using the remote communications package, the user can label the auxiliary functions. The controller displays the selected name instead of digital input 1-21 or analog input 1-7. EEPROM Write Failure. The lamp illuminates and the alarm horn sounds when the control logic detects a data save error. The local display shows EEPROM write failure.
Emergency Power System (EPS) Supplying Load. The lamp illuminates when the generator set supplies more than 5% of the rated standby output current. The local display shows EPS supplying load. Generator Switch Not in Auto. The lamp illuminates and the alarm horn sounds when the generator set master switch is in the RUN or OFF/RESET position. The local display shows master switch not in auto. Ground Fault Detected. The lamp illuminates and the alarm horn sounds when a user-supplied ground fault detector signals the controller. The local display shows ground fault. High Battery Voltage. The lamp illuminates when the battery voltage rises above the preset level for more than 10 seconds. The local display shows high battery voltage. Figure 2-1 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.
High Battery Voltage Default Setting
16 32
Engine Electrical System Voltage

12 24
High Battery Voltage Range

14.5--16.5 29--33
Figure 2-1
High Battery Voltage Specs
High Coolant Temperature Warning. The lamp illuminates and the alarm horn sounds when the engine coolant temperature approaches the shutdown range. The local display shows high coolant temperature warning. Load Shed. The lamp illuminates when the generator sets total kW load exceeds the programmed level for more than the load shed time. When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp circuit latches and remains on until the generator set shuts off. The local display shows load shed kW over. 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.
30
Section 2 Operation
TP-6083 7/05
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. See Figure 2-2 for low battery voltage specifications.
Low Battery Voltage Default Setting
12 24
Engine Electrical System Voltage

12 24
Low Battery Voltage Range

10--12.5 20--25
Figure 2-2
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 inhibits the low battery voltage warning during the crank cycle. Low Coolant Temperature. The lamp illuminates and the alarm horn sounds when the engine coolant temperature is low. The local display shows low coolant temperature. Low Fuel (Level or Pressure). The lamp illuminates and the alarm horn sounds when the fuel tank level on gasoline or diesel models approaches empty or low fuel pressure on gaseous fueled models occurs. This fault requires an optional low fuel switch for the lamp to function. The local display shows low fuel. (Low) Oil Pressure Warning. The lamp illuminates and the alarm horn sounds when the engine oil pressure approaches the shutdown range. The local display shows oil press warning. Master Switch in OFF/RESET Position. The lamp illuminates and the alarm horn sounds when the master switch is placed in the OFF/RESET position. The local display shows master not in auto. NFPA 110 Fault. The lamp illuminates and the alarm horn sounds when NFPA 110 faults signal the controller. The local display shows NFPA 110 fault. The NFPA 110 faults include:
D Air damper indicator
D D D D D D D D D D D D D D
Battery charger fault EPS supplying load High battery voltage High coolant temperature warning High coolant temperature shutdown Low battery voltage Low coolant level Low coolant temperature warning Low fuel (level or pressure) Low oil pressure warning Low oil pressure shutdown Master switch not in auto Overcrank Overspeed
Overcurrent. The lamp illuminates and the alarm horn sounds when the generator set supplies more than 110% of the rated standby output current for more than 10 seconds. The local display shows overcurrent. Speed Sensor Fault. The lamp illuminates and the alarm horn sounds when the speed signal is absent for one second while the generator set runs. The local display shows speed sensor fault. This warning lamp remains on until the operator places the master switch in the OFF/RESET position. Underfrequency. The lamp illuminates and the alarm horn sounds when the frequency falls below the underfrequency setting. The local display shows underfrequency. See Figure 2-3.
Underfrequency Setting Range
80%--95% of nominal
Time Delay Range

10 sec.
Underfrequency Default Setting

90% of nominal
Figure 2-3
Underfrequency Specs
Weak Battery. The lamp illuminates when the battery voltage falls below 60% of the nominal voltage (12 VDC or 24 VDC) for more than 2 seconds during the crank cycle. The local display shows weak battery.
TP-6083 7/05
Section 2 Operation
31
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 operators discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn will not stop sounding unless the master switch is in the AUTO position. Note: The text shown in italics represents digital display messages. Air Damper Indicator. The lamp illuminates and the unit shuts down when signaled by a closed air damper circuit. The local display shows air damper indicator. Alternator Protection. The lamp illuminates and the unit shuts down because of an alternator overload or short circuit. The local display shows altrntr protect sdwn. Customer Auxiliary (Shutdown). The lamp illuminates and the unit shuts down when an auxiliary digital or analog input signals the controller. The customer can define inputs as shutdowns or warnings. The local display shows digital input 1-21 or analog input 1-7 when activated. Using the remote communications package, the user can label the auxiliary functions. The controller displays the selected name instead of digital input 1-21 or analog input 1-7. Emergency Stop. The lamp illuminates and the unit shuts down when the local or optional remote emergency stop switch activates. The local display shows emergency stop.
High Coolant Temperature Shutdown. The lamp illuminates and the unit shuts down because of high engine coolant temperature. The shutdown occurs 5 seconds after the engine reaches the temperature shutdown range. The high engine temperature shutdown does not function during the first 30 seconds after startup. The local display shows high cool temp shutdwn. 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 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. Internal Fault. The lamp illuminates and the unit shuts down when the internal diagnostic test detects a controller malfunction. The local display shows internal fault. Locked Rotor. If none of the speed sensing inputs show engine rotation within 5 seconds of initiating engine cranking, the ignition and crank circuits turn off for 5 seconds and the cycle repeats. The unit shuts down after the second cycle of 5 seconds of cranking. The local display shows locked rotor. Loss of ECM Communications. The lamp illuminates and the unit shuts down when the ECM communication link is disrupted. The local display shows loss of ECM comm.
32
Section 2 Operation
TP-6083 7/05
Low Coolant Level. The lamp illuminates and the unit shuts down because of low coolant level. Shutdown occurs 5 seconds after the controller detects low coolant level. The low coolant level shutdown does not function during first the 30 seconds after startup. The local display shows low coolant level. Note: The high engine temperature shutdown function and the low coolant level shutdown function are independent of each other. A low coolant level condition may not activate the high engine temperature switch. (Low) Oil Pressure Shutdown. The lamp illuminates when the unit shuts down because of low oil pressure. The shutdown occurs 5 seconds after the engine pressure reaches the shutdown range. The low oil pressure shutdown does not function during first the 30 seconds after startup. The local display shows (low) oil press shutdown. Master Switch Error. The lamp illuminates and unit the shuts down when the controller detects a fault in the master switch position or circuit. The local display shows master switch error. Master Switch Open. The lamp illuminates and the unit shuts down when the controller detects an open circuit in the master switch circuit. The local display shows master switch open. NFPA 110 Fault. The lamp illuminates and the unit shuts down when NFPA 110 faults signal the controller. The local display shows NFPA 110 fault. See Section 2.4, Menu List Summary, Menu 10Output Setup, for the NFPA 110 list. No Coolant Temperature Signal. The lamp illuminates and the unit shuts down when the engine coolant temperature sender circuit is open. The local display shows no cool temp signal. No Oil Pressure Signal. The lamp illuminates and the unit shuts down when the engine oil pressure sender circuit is open. The local display shows no oil press signal. Overcrank. The lamp illuminates and cranking stops when the unit does not start within the defined cranking period. The local display shows overcrank. See Section 2.3.1, Auto Starting, and Section 1, Specifications and Features, for cyclic crank specifications.
Note: The controller is equipped with an automatic restart function. When speed drops below 13 Hz (390 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. Overfrequency. The lamp illuminates and the unit shuts down when the frequency is above the overfrequency setting. The local display shows overfrequency. See Figure 2-4.
Overfrequency Setting Range
102%--140% of nominal
Time Delay
10 sec.
Overfrequency Default Setting

140% of nominal
Figure 2-4
Overfrequency Specs
Overspeed. The lamp illuminates and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models exceeds the overspeed setting for 0.25 seconds. The local display shows overspeed. See Figure 2-5 for overspeed specs.
Generator Set Frequency Hz
60 50
Overspeed Range Hz
65--70 55--70
Overspeed Default Setting Hz

70 60
Figure 2-5
Overspeed Specs
Overvoltage. The lamp illuminates and the unit shuts down when the overvoltage setting exceeds the overvoltage setting for the time delay period. The local display shows overvoltage. Overvoltage specifications follow. See Figure 2-6. 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 Setting Range
105%--135% of nominal
Time Delay Range

2--10 sec.
Overvoltage Default Setting

115% at 2 sec.
Figure 2-6
Overvoltage Specs
TP-6083 7/05
Section 2 Operation
33
Underfrequency. The lamp illuminates and the unit shuts down when the frequency falls below the underfrequency setting. The local display shows underfrequency. See Figure 2-7.
Underfrequency Setting Range
80%--95% of nominal
5. Start the generator set by moving the generator set master switch to the OFF/RESET position and then to the RUN position. When equipped, the remote annunciator and/or audiovisual alarm horn sounds when the alarm switch is in the NORMAL position. When necessary, move the alarm switch to the SILENCE position to stop the alarm horn. The lamp turns off. 6. Test operate the generator set verifying correction of the shutdown cause. 7. Move the generator set master switch to the OFF/RESET position to stop the generator set. 8. Move the generator set master switch to the AUTO position. 9. Silence the controller alarm horn by pressing the alarm off key. 10. Reconnect the generator set load via the line circuit breaker or automatic transfer switch. 11. Move the generator set master switch to the AUTO position for startup by the remote transfer switch or the remote start/stop switch. When equipped, move the remote annunciator and/or audiovisual alarm switch to the NORMAL position.
Time Delay
10 sec.
Underfrequency Default Setting

90% of nominal
Figure 2-7
Underfrequency Specs
Undervoltage. The lamp illuminates and the unit shuts down when the voltage falls below the undervoltage setting for the time delay period. The local display shows undervoltage. Undervoltage specifications follow. See Figure 2-8.
Undervoltage Setting Range
70%--95% of nominal
Time Delay Range

5--30 sec.
Undervoltage Default Setting

85% of nominal at 10 sec.
Figure 2-8
Undervoltage Specs
2.3.7
Controller Reset Procedure (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. Silence the controller alarm horn by pressing the alarm off key. When equipped, the optional remote annunciator and/or audiovisual alarm horn and lamp activate. Move the alarm switch to the SILENCE position to stop the alarm horn. The lamp stays lit. 3. Disconnect the generator set load using the line circuit breaker or automatic transfer switch. 4. Correct the cause of the fault shutdown or warning. See Safety Precautions and Instructions section of this manual before proceeding.
2.4 Menu List Summary

Use the Menu List Summary section on the following pages after reading and understanding the features of the keypad. See Section 1.2.2, Digital Display and Keypad. The Menu List Summary provides 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 data and the open bullet items are sub-level data. Section 2.8, Reviewing the Menu Displays, provides a digital display menu overview and explains the navigation using the down and right arrow keys. Section 2.9, Local Programming Mode On, contains the keystroke details of each menu when programming.
34
Section 2 Operation
TP-6083 7/05
Menu List Summary

Menu 1 Generator Monitoring
Volts & Amps D L1-L2 Volts L1 Amps D L2-L3 Volts L2 Amps (3 phase) D L3-L1 Volts L3 Amps (3 phase) D L1-L0 Volts L1 Amps D L2-L0 Volts L2 Amps D L3-L0 Volts L3 Amps (3 phase) D Frequency D L1-L2 Volts L2 Amps (1 phase) V & A Summary D V L1-L2, L2-L3, L3-L1 (3 phase) D V L1-L0, L2-L0, L3-L0 (3 phase) D A L1, L2, L3 (3 phase) D V L1-L2, L1-L0, L2-L0 (1 phase) D A L1, L2 (1 phase) Power kW D Total kW Power Factor D L1 kW Power Factor D L2 kW Power Factor D L3 kW Power Factor (3 phase) D Total kW % of Rated kW Power kVAR D Total kVAR Absorbing/Generating D L1 kVAR Absorbing/Generating D L2 kVAR Absorbing/Generating D L3 kVAR Absorbing/Generating (3 phase) Power kVA D D D D Total kVA L1 kVA L2 kVA L3 kVA (3 phase)
Menu 2 Engine Monitoring

Engine Monitoring Basic D Oil Pressure Coolant Temperature D Engine RPM Local Battery VDC Engine Monitoring Detailed (ECM equipped engines only) Engine Fuel D Fuel Pressure Fuel Temperature D Fuel Rate D Used Last Run Engine Coolant D Coolant Pressure Coolant Temperature (ECM and non-ECM engines) D Coolant Level Engine Oil D Oil Pressure (ECM and non-ECM engines) Oil Temperature D Oil Level D Crackcase Pressure Engine Misc D ECM Battery VDC Ambient Temperature D Engine Model No. D Engine Serial No. D Unit No. ECM S/N
Menu 4 Operational Records

D Factory Test Date D Total Run Time D Total Run Time Loaded Hours D Total Run Time Unloaded Hours D Total Run Time kW Hours D No. of Starts D Engine Start Countdown d Run Time D Records-Maintenance d Reset Records D Run Time Since Maintenance Total Hours D Run Time Since Maintenance Loaded Hours D Run Time Since Maintenance Unloaded Hours D Run Time Since Maintenance kW Hours D Operating Days Last Maintenance D No. of Starts Last Maintenance D Last Start Date D Length of Run (Un)loaded Hours
Menu 7 Generator System

D Operating Mode d Standby Y/N d Prime Power N/Y D System Voltage Line-Line D System Frequency D Phase d 3-Phase Delta Y/N d 3-Phase WYE N/Y d 1-Phase N/Y D kW Rating D Rated Current D Load Shed Output d Time Delay D Overvoltage d Time Delay D Undervoltage d Time Delay D Overfrequency D Underfrequency D Overspeed D Battery Voltage d 12 VDC Y/N d 24 VDC N/Y D Low Battery Voltage D High Battery Voltage D Metric Units Y/N D Set NFPA-110 Defaults Y/N
Menu 8 Time Delays Menu 5 Event History

D (Message Text) D (Scroll through up to 100 stored events) D Time Delay Engine Start D Time Delay Starting Aid D Time Delay Crank On D Time Delay Crank Pause D Time Delay Eng. Cooldown D Overcrank Shutdown Crank Cycles D Time Delay Overvoltage D Time Delay Undervoltage D Time Delay Load Shed kW
Section 2 Operation 35
Menu 3 Analog Monitoring
D Local Batt VDC D Analog 01 to 07 (user-defined descriptions) (Scroll through 1--7 user-defined descriptions Menu 6 with ECM engines) Time and Date (Scroll through 3--7 user-defined descriptions D Time 00:00 AM/PM with non-ECM engines D Date where 01 is coolant temperature and 02 is oil pressure)
TP-6083 7/05
Menu List Summary, continued

Menu 9 Input Setup
Setup Digital Auxiliary Inputs D Digital Input (Scroll through up to 21 user defined desc) D Digital Input Message Text Y/N, see Group A Group A The preprogrammed selections include the following: Warning Shutdown Type A Shutdown Type B Voltage Raise Voltage Lower VAR PF Mode Remote Shutdown Remote Reset Air Damper Low Fuel Field Overvoltage Idle Mode Active (ECM engines only) Battle Switch Ground Fault Bat Chgr Fault Hi Oil Temperature Low Coolant Level Low Coolant Temperature (Not user selectable) D Digital Input Enable Y/N D Digital Input Inhibit TIme D Digital Input Delay Time
Menu 9 Input Setup, cont.

Setup Analog Auxiliary Inputs D Analog Input (Scroll through 1--7 user-defined descriptions with ECM engines) (Scroll through 3--7 user-defined descriptions with non-ECM engines) D Analog Input Warning Enabled Y/N D Analog Input Shutdown Enabled Y/N D Analog Input Inhibit Time 0--60 Sec. D Analog Input Warning Delay Time 0--60 Sec. D Analog Input Shutdown Delay Time 0--60 Sec. D Analog Input Low Shutdown Value D Analog Input Low Warning Value D Analog Input High Warning Value D Analog Input High Shutdown Value
Menu 10 Output Setup, cont.

Relay Driver Outputs (RDOs) D RDOs (Y/N) (Scroll through up to 31 status and fault choices from: d System events, see Group B d 21 digital inputs D01-D21 d 7 analog inputs A01--A07 Group B The system events include the following: Emergency Stop Over Speed Over Crank Hi Cool Temp Shutdown Oil Pressure Shutdown Low Coolant Temperature (non-ECM engines) Low Fuel Hi Cool Temp Warning Oil Pressure Warning Master Not in Auto NFPA 110 Fault* Low Battery Voltage High Battery Voltage Battery Charger Fault System Ready Loss of ECM Comm (ECM engines) No Oil Pressure Signal Hi Oil Temperature No Cool Temperature Signal Low Coolant Level Speed Sensor Fault Locked Rotor Master Switch Error Master Switch Open Master Switch to Off AC Sensing Loss Over Voltage Under Voltage Weak Battery Over Frequency Under Frequency

Group B, continued Load Shed kW Over Load Shed Under Freq Over Current EPS Supplying Load Internal Fault Delay Engine Cooldown Delay Engine Start Starting Aid Generator Running Air Damper Control Ground Fault EEPROM Write Failure Critical Overvoltage Alternator Protection SDWN Air Damper Indicator Defined Common Fault (RDO only) SCRDOs 1--4 (Software Controlled RDOs) *NFPA-110 Fault The 15 NFPA-110 Common Fault Alarms include the following: Overspeed Overcrank High Coolant Temperature Shutdown Oil Pressure Shutdown Low Coolant Temperature High Coolant Temperature Warning Oil Pressure Warning Low Fuel Master Not In Auto Battery Charger Fault Low Battery Voltage HIgh Battery Voltage Low Coolant Level EPS Supplying Load Air Damper Indicator
Menu 10 Output Setup

Defined Common Fault D Defined Common Fault (Y/N for a single defined common fault) Scroll through status and fault choices from: d System events, see Group B (except Defined Common Fault) d 21 digital inputs D01-D21 d 7 analog inputs A01--A07
36
Section 2 Operation
TP-6083 7/05
Menu List Summary, continued

Digital Inputs D Common Fault Y/N (Scroll through up to 21 user-defined descriptions shown as D01 to D21) Analog Inputs D Common Fault Y/N (Scroll through up to 7 user-defined descriptions shown as A01 to A07) (ECM engines) D Common Fault Y/N (Scroll through up to 5 user-defined descriptions shown as A03 to A07) (non-ECM engines) D Low Warning D High Warning D Low Shutdown D High Shutdown
Menu 12 Calibration
Scale AC Analog Inputs D Gen L1-L0 V Calibration Reference D Gen L2-L0 V Calibration Reference D Gen L3-L0 V (3 phase) Calibration Reference D Gen L1 Amps Calibration Reference D Gen L2 Amps Calibration Reference D Gen L3 Amps (3 phase) Calibration Reference D Restore Defaults? Y/N Scale Aux. Analog Inputs D Zero Aux. Analog Inputs (Scroll through additional analog auxiliary inputs 1--7 with ECM engines) (Scroll through additional analog auxiliary inputs 3--7 with non-ECM engines) D Analog 01 Scale Value 1 d Scale 1 V Scale 2 V D Analog 01 Scale Value 2 d Scale 1 V Scale 2 V
Menu 13 Communications
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) d BAUD Rate 1200 2400 9600 Protocol Modbus D Modbus Online N/Y D Connection Type (User-defined) d Single Y/N d Convertor Y/N D Primary Port d RS-485 d RS-232 D Address D BAUD Rate (User-defined) d 9600 d 19200
Menu 14 Programming Mode

D Programming Mode d Local? Y/N d Remote? Y/N d Off? Y/N D Programming Mode Change, Access Code d Enter Old Code d Enter New Code
Menu 11 Voltage Regulator

AVG L-L V Volt ADJ D L1-L2 Volts D L2-L3 Volts (3 phase) D L3-L1 Volts (3 phase) Under Freq. Unload Enabled N/Y D Frequency Setpoint (Cut-In Point) D Slope Volts-Per-Cycle Reactive Droop Enabled N/Y D 0.8 PF Rated Load Voltage Droop VAR Control Enabled N/Y D Total kVAR (Running) kVAR Adj D Generating/Absorbing Y/N PF Control Enabled N/Y D Average PF PF Adjustment D Lagging/Leading Y/N
TP-6083 7/05
Section 2 Operation
37
2.5 Digital Display Messages

Throughout this manual there are examples of the display text. In some cases, the message words and phrases are abbreviated or shortened to accommodate
Display Message
A01 through A07 AC SENSING LOSS AIR DAMPER CONTROL AIR DAMPER INDICATOR ALTRNTR PROTECT SDWN BATTERY CHRGR FAULT BATTLESWITCH CRITICAL OVERVOLTAGE D01 through D21 DEFINED COMMON FAULT DELAY ENG COOLDOWN DELAY ENG START EEPROM WRITE FAILURE EMERGENCY STOP EPS SUPPLYING LOAD GENERATOR RUNNING GROUND FAULT HI COOL TEMP WARNING HI COOL TEMP SHUTDOWN HI OIL TEMP HIGH BATTERY VOLTAGE INTERNAL FAULT LOAD SHED KW OVER LOAD SHED UNDER FREQ LOCKED ROTOR LOSS OF ECM COMM LOW BATTERY VOLTAGE LOW COOLANT LEVEL LOW COOLANT TEMP LOW FUEL MASTER SWITCH ERROR MASTER SWITCH TO OFF MASTER NOT IN AUTO MASTER SWITCH OPEN NFPA 110 FAULT NO COOL TEMP SIGNAL NO OIL PRESS SIGNAL OIL PRESS SHUTDOWN OIL PRESS WARNING OVER CRANK OVER CURRENT OVER FREQUENCY OVER SPEED OVER VOLTAGE SPEED SENSOR FAULT STARTING AID SWARE CONTROLLED #1 through #4 SYSTEM READY UNDER FREQUENCY UNDER VOLTAGE WEAK BATTERY
the 40-character display. See Figure 2-9 for a full description of the system event display messages.
Description
Analog auxiliary input 01 through 07 AC sensing loss Air damper control Air damper indicator Alternator protection shutdown Battery charger fault Battle Switch (fault shutdown override switch) Critical overvoltage Digital auxiliary input 01 through 21 Defined common fault (do not use for common fault) Time delay engine cooldown (TDEC) timing Time delay engine start (TDES) timing EEPROM write failure Emergency stop Emergency power system supplying load Generator running Ground fault detected High coolant temperature warning High coolant temperature shutdown High oil temperature shutdown High battery voltage Internal fault Load shed kW overload Load shed underfrequency Locked rotor Engine control module communications loss (ECM models only) Low battery voltage Low coolant level Low coolant temperature Low fuel level (gasoline or diesel) or pressure (gas) Master switch error Master switch in the OFF position (User must move master switch to OFF position) Master switch not in the AUTO position Master switch open NFPA 110 common fault Coolant temperature signal loss Oil pressure signal loss Oil pressure shutdown Oil pressure warning Overcrank shutdown Overcurrent warning Overfrequency shutdown Overspeed shutdown Overvoltage shutdown Speed sensor fault Starting aid status Software controlled #1 through #4 (RDO only) System ready Underfrequency shutdown Undervoltage Weak battery
Figure 2-9
38
System Events Display Message List

TP-6083 7/05
Section 2 Operation
2.6 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 2.9, Local Programming Mode On, for instructions on how to change the information. See Figure 2-10 for an illustration of the digital display and keypad.
Enter Key. Press the enter key to confirm the entered information on the display when selecting menus or programming. Lamp Test Key. Press the lamp test key to check that the status and fault lamps illuminate, the horn sounds, and the digital display clears. Press the reset menu key before pressing the lamp test key. Menu Down Key. The controller displays consist of menus with data levels or programming steps. Use the menu down key to navigate through the menu levels. Note: Pressing the menu down key locks the user into the levels of that main menu. Press the reset menu key to access other main menus. Menu Right Key. Press the menu right key to scroll through sub-levels of each main menu. The display contains an arrow in the right-hand corner when there is a sub-level. Pressing the menu right key when no arrow is present moves to the next submenu header. Press the menu right key prior to entering decimal values when required. Numeric 0- Keys. Press the numeric keys when -9 selecting menus or entering numeric values during programming. The controller ignores the secondary function of the key (yes, no, etc.) when numeric values are valid. Reset Menu Key. The reset menu key exits a menu, clears incorrect entries, and cancels the auto-scroll function. Press the reset menu key to exit a menu or any layer within that menu. Stop Prog Run Key. Press the stop prog run key to end the generator set programmed exercise run created in Menu 4Operational Records. The generator set shuts down after the time delay for engine cooldown ends. The stop prog run key does not affect the programmed transfer switch exercise function. Yes/No Keys. When the controller asks a question during programming requiring a nonnumeric answer (yes or no), the controller accepts the secondary key function and ignores the numeric value of the key.
TP-5829-2
Figure 2-10 Digital Display and Keypad Note: After energizing the controller by reconnecting the battery, set the controller time and date. See Section 2.9.6, Local Programming Mode On, Menu 6Time and Date. Pressing any key on the keypad activates the controller panel display. The panel lamps and display turn off 5 minutes after the last keypad entry.
2.6.1
Keypad Operation
Use the keypad to input information into the controller. Some of the keys have two functions. The following gives keypad definitions and functions. Alarm (Horn) Off Key. Press the alarm off key to silence the horn at the users discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the master switch is in the AUTO position. See Section 2.3.7, Controller Reset Procedure, for more information on turning the alarm horn off. AM/PM Key. When the controller asks a question during programming requiring a nonnumeric answer (am or pm), the controller accepts the secondary key function and ignores the numeric value of the key.
2.6.2
Auto-Scroll Function
The auto-scroll function continuously shows voltage and current data from Menu 1Generator 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.
TP-6083 7/05
Section 2 Operation
39
2.6.3
Request and Error Messages
Request Messages
Display messages require additional data, confirm the previous entry or require time to process as described below. Entry Accepted appears for several seconds after pressing the Enter key during the programming mode. The display then shows the new data. Reset Complete indicates the user:
D Reset the maintenance records or D Restored the AC analog inputs to the default settings.
Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify an RDO setting that is a NFPA 110 default requirement. Cannot Change Preset appears when the user attempts to change the preset factory digital input or input parameter. Entry Unacceptable appears when the user attempts an invalid input to the voltage regulator setup. Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned. Invalid Code appears when the user attempts to enter:
D An invalid access code for programming mode setup,
Right Arrow directs the user to the next menu. Menus loop; press the right arrow key to the next menu. Setup Complete indicates the completion of the analog input setup. (Question) ? asked by the control firmware; answer the question by pressing the yes/no, numeric digit, or am/pm key. Wait for System Reset (6 Sec) appears while the EEPROM initializes.
or
D An invalid access code for setup unlock.
No Input Assigned appears when the user attempts to assign any of the following system faults to an RDO where the digital input is not defined. See digital input scale requirements in Menu 12Calibration.
D Air damper indicator D Battery charger fault D Ground fault D High oil temperature shutdown D Low coolant level D Low fuel
Error Messages
When an error message appears, the entered information is not within the allowable parameters set by the control firmware or is not permitted as described below. In cases where the data was outside the parameters, press the Reset Menu key and enter the corrected information. Access Denied appears when the user attempts to:
D Enter data prohibited by the master switch position, D Enter data prohibited by the generator set state, or D Enable the LDD (load disturbance detection).
Not in Local Program Mode appears when the user attempts to program using the keypad when the programming mode is set for remote or off. Output in Use appears when the user attempts to modify or reassign an active RDO. Port in Use appears when the user attempts to use an already assigned communications port. Range Error appears when the user attempts to enter:
D A numeric input that is not within the required
Access Denied Idle Mode Active appears when the user attempts to modify the voltage regulator setup while the idle mode is active. Alarm Active appears when the user attempts to modify an active digital input. See Menu 9Input Setup.
parameters of addresses, etc.
system
settings,
time
delays,
D An invalid analog or digital input number or date/time.
Setpoint Values Cannot be Equal appears when the user attempts to enter the same value for both setpoints during the analog input calibration.
40
Section 2 Operation
TP-6083 7/05
2.7 Monitoring and Programming Setup

The user can access the controller data with the controller keypad and display or a PC (personal computer) with optional software to monitor and/or program. Access the controller system with a PC using local (direct) or remote (modem) systems. Refer to the Introduction, List of Related Materials for related software literature. See Menu 13Communications. The user can access the controller data while in the programming mode off or programming mode on. See Menu 14Programming Mode. While this manual focuses on data access and programming through the controller keypad and display, some data entries require input using a PC for initial setup. The PC entries typically include alpha characters such as digital input descriptions. The individual menus
User Operating Mode Selection
in Section 2.9, Local Programming Mode On, indicate where data requires entry using a PC. There are six basic configurations for data monitoring and programming using three access source options. See Figure 2-11. Other combinations of data monitoring and programming are possible but require programming from a single location. Figure 2-11, Monitoring and Programming Configurations, briefly describes the settings of Menu 13Communications and Menu 14 Programming Mode based on user-selected operating mode. Use the keypad and digital display to setup the access configurations the first time. Go to Section 2.9, Local Programming Mode On, and set the desired selection in Menu 13Communication and Menu 14Programming Mode before accessing data.
Menu 14Programming Mode
Programming Mode Off? Yes Yes Yes No No No Local Programming Mode? No No No Yes No No Remote Programming Mode? No No No No Yes Yes
Menu 13Communications Settings

Remote Single or LAN? No No Yes No No Yes
User Activity Access Source Controller Monitor only Direct PC PC via Telephone Lines Controller Monitor and Program Direct PC PC via Telephone Lines
On Line? No Yes Yes No Yes Yes
Local LAN? No Yes No No Yes No
Figure 2-11 Monitoring and Programming Configurations
TP-6083 7/05
Section 2 Operation
41
2.7.1
Personal Computer (PC) Communications
Local Area Network (LAN)

A PC connects to the devices LAN. A LAN is a system that connects more than one device to a single PC. Acceptable devices include Decision-Maker 550 controller, Decision-Maker 340 controller, M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor. See Figure 2-14.
Generator Set Controller or Transfer Switch Control Generator Set Controller or Transfer Switch Control RS-232 to RS-485 port converter RS-485 up to 1220 m (4000 ft.) Generator Set Controller or Transfer Switch Control Generator Set Controller or Transfer Switch Control
There are four ways to communicate between a PC and the generator set and/or transfer switch devices using KBUS communication protocol. The PC connections require optional software and possibly other hardware, communication modules in the generator set controller and/or transfer switch. See the Software Operation Manual for details. Contact your authorized distributor/dealer for availability.
Local Single Connection

A PC connects to the COM port of the controller module using an RS-232 cable when the PC is within 15 m (50 ft.) of the device or an RS-485 cable when the PC is within 1220 m (4000 ft.) of the device. See Figure 2-12 or Figure 2-13.
Personal Computer
Generator Set Controller or Transfer Switch Control Personal Computer RS-232 up to 15 m (50 ft.)
Figure 2-14 Local Area Network
Figure 2-12 Local Single Connection, up to 15 m (50 ft.)
RS-232 to RS-485 port converter RS-485 up to 1220 m (4000 ft.)
Generator Set Controller or Transfer Switch Control
Personal Computer
Figure 2-13 Local Single Connection, up to 1220 m (4000 ft.)
42
Section 2 Operation
TP-6083 7/05
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 2-15.
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 network. Acceptable devices include DecisionMaker 550 controller, Decision-Maker 340 controller, M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor. Locate the PC anywhere a telephone line is available. See Figure 2-16.
Modem RS-232 up to 15 m (50 ft.)
Modem RS-232 up to 15 m (50 ft.)
Personal Computer
Telephone Lines
Figure 2-15 Remote Single Connection
Generator Set Controller or Transfer Switch Control Modem Modem RS-232 to RS-485 port converter RS-485 up to 1220 m (4000 ft.) Generator Set Controller or Transfer Switch Control
Personal Computer
Telephone Lines
Figure 2-16 Remote Area Network
2.7.2
Modbus Communications
RS-485 up to 1220 m (4000 ft.) Generator Set Controller RS-232 up to 15 m (50 ft.) Modbusr Master
The controller communicates using Modbusr as a slave connection with the Modbusr master initiating the communication. The controller interrogates system and alternator parameters and diagnostic information. 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 Modbusr literature.
Figure 2-17 Modbusr Connections
Modbusr is a registered trademark of Schneider Electric. TP-6083 7/05 Section 2 Operation 43
2.8 Reviewing Menu Displays

Use this section to review generator set controller data while in the programming off mode. 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. The user must enable the programming mode to edit the display. See Menu 14Programming Mode and Section 2.9, Local Programming Mode On, for more information. Note: Press any key on the keypad to activate the controller panel display. The panel display turns off 5 minutes after the last keypad entry. Note: Press the Reset Menu key to clear error messages.
Note: Press the Menu Right key prior to entering decimal values where necessary. Menus displaying the # symbol represent one of the following data types:
D System-calculated data D System-measured data D User-entered data
Menus displaying the ? symbol require the user to enter data. Menus displaying the * symbol represent access code or password type entries. Actual key entry does not display. See Section 2.6.3, Request and Error Messages, for error display messages and explanations while navigating the menus.
44
Section 2 Operation
TP-6083 7/05
2.8.1
Menu 1Generator Monitoring

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. Note: Pressing a right arrow key from any submenu moves to the next submenu header.
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. All menu displays apply to both single-phase and three-phase voltages unless otherwise noted as (1 PH) or (3 PH) on the menu overview. The phase designation does not appear in the controller menu displays.
Menu 1 Overview
MENU 1 GENERATOR MONITORING
VOLTS & AMPS
V & A SUMMARY
POWER KW
POWER KVAR
POWER KVA
L1-L2 VOLTS L1 AMPS
# #
V L1-L2 (3 PH) #
L2-L3 #
L3-L1 #
TOTAL KW # PF # LEADING/LAGGING
TOTAL KVAR # ABSORBING/GENERATING
TOTAL KVA
L2-L3 VOLTS L2 AMPS (3 PH)
# #
V L1-L0 (3 PH) #
L2-L0 #
L3-L0 #
L1 KW # PF # LEADING/LAGGING
L1 KVAR # ABSORBING/GENERATING
L1 KVA
# #
V L1-L2 (1 PH) #
L1-L0 #
L2-L0 #
L2 KW # PF # LEADING/LAGGING
L2 KVAR # ABSORBING/GENERATING
L2 KVA
# #
A (3 PH)
L1 #
L2 #
L3 #
L3 KW (3 PH) # PF # LEADING/LAGGING
L3 KVAR (3 PH) # ABSORBING/GENERATING
L3 KVA
(3 PH)
L1-L0 VOLTS L1 AMPS
# #
A (1 PH)
L1 #
L2 #
TOTAL KW % OF RATED KW
# #
L2-L0 VOLTS L2 AMPS
# #
For the auto-scroll function, press ENTER at V & A SUMMARY menu.
# #
Use the MENU key to stop the auto-scroll function.
FREQUENCY
# HZ
TP-6083 7/05
Section 2 Operation
45
2.8.2
Menu 2Engine Monitoring

Note: A right arrow from any submenu moves to the next submenu header.
Menu 2 displays engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. The detailed engine monitoring feature functions only with an ECMequipped engine.
Menu 2 Overview
MENU 2 ENGINE MONITORING
ENGINE MONITORING BASIC
ENGINE MONITORING DETAILED
OIL PRESSURE COOLANT TEMP
# PSI #F
ENGINE FUEL
ENGINE COOLANT
ENGINE OIL
ENGINE MISC
ENGINE RPM LOCAL BATT VDC
# #
FUEL PRES FUEL TEMP
# PSI #F
COOLANT PRES COOLANT TEMP
# PSI #F
OIL PRES OIL TEMP
# PSI #F
ECM BATT VDC AMBIENT TEMP
# #F
FUEL RATE
# GPH
COOLANT LEVEL
#%
OIL LEVEL CRANKCASE PRES
#% # PSI
ENGINE MODEL NO.
USED LAST RUN # GAL
ENGINE SERIAL NO.
UNIT NO.
ECM S/N
46
Section 2 Operation
TP-6083 7/05
2.8.3
Menu 3Analog Monitoring

Note: If the analog display shows O/R (out of range), no input is connected. Note: ECM engines have user-defined analog inputs 01--07. Non-ECM engines have user-defined analog inputs 03--07 where analog inputs 01 and 02 are reserved for engine oil pressure and coolant temperature displays.
Menu 3 displays battery voltage and up to 7 userdefined analog items dependant upon the generator system. 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. The display has 20 characters maximum.
Menu 3 Overview
MENU 3 ANALOG MONITORING
LOCAL BATT VDC
ANALOG 01 (USER DEFINED DESC)
Press the down arrow to scroll through 1--7 additional ANALOG auxiliary inputs or enter input number with ECM engines.
Press the down arrow to scroll through 3--7 additional ANALOG auxiliary inputs or enter input number with nonECM engines.
TP-6083 7/05
Section 2 Operation
47
2.8.4
Menu 4Operational Records

After performing maintenance enter yes to reset records reflecting the current day. The user must enable the programming mode to edit the display.
Menu 4 displays the generator sets 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.
Menu 4 Overview
MENU 4 OPERATIONAL RECORDS NO. OF STARTS LAST MAINT # ##-###-##
FACTORY TEST DATE ##-###-##
LAST START DATE
##:## AM/PM ##-###-##
TOTAL RUN TIME HRS
LENGTH OF RUN (UN)LOADED HRS
TOTAL RUN TIME LOADED HRS
TOTAL RUN TIME UNLOADED HRS
TOTAL RUN TIME KW HRS
NO. OF STARTS
ENGINE START? COUNTDOWN
Y/N ##:##
RUN TIME
HR:MN ??:??
RECORDS-MAINT
RESET RECORDS?
Y/N
RUN TIME SINCE MAINT TOTAL HRS
RUN TIME SINCE MAINT LOADED HRS
RUN TIME SINCE MAINT UNLOADED HRS
RUN TIME SINCE MAINT KW HRS
OPERATING DAYS LAST MAINT
# ##-###-##
48
Section 2 Operation
TP-6083 7/05
2.8.5
Menu 5Event History
Menu 5 stores and displays the times and dates of up to 100 stored warning and shutdown events. See Menu 10Output Setup for a list of possible events.
Menu 5 Overview
MENU 5 EVENT HISTORY
(MESSAGE TEXT) ##-###-## ##:## AM/PM
SCROLL THROUGH 100 (max.) STORED EVENTS
2.8.6
Menu 6Time and Date
Menu 6 sets the clock time and date and internal calendar. The controller uses the set clock time to determine exercise run time and event records. The time and date are valid as long as the controller power (starting battery) remains connected. The user must enable the programming mode to edit the display.
Menu 6 Overview
MENU 6 TIME AND DATE
DAY OF WEEK ##-###-## ##:##AM/PM
TIME
??:?? AM/PM
DATE
??-???-??
TP-6083 7/05
Section 2 Operation
49
2.8.7
Menu 7Generator System

Note: The user defines the data shown in Menu 7. It is NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control. Note: Press the Menu Right key prior to entering decimal values where necessary.
Menu 7 displays factory-preset generator set voltage and frequency data. Enter the new voltage and/or frequency data when 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. The user must enable the programming mode to edit the display.
Menu 7 Overview
MENU 7 GENERATOR SYSTEM
OPERATING MODE STANDBY
Y/N
OPERATING MODE PRIME POWER
Y/N
SYSTEM VOLTAGE LINE-LINE
SYSTEM FREQ
# HZ
PHASE 3 PHASE DELTA
Y/N
PHASE 3 PHASE WYE
N/Y
PHASE SINGLE PHASE
N/Y
KW RATING
RATED CURRENT
LOAD SHED OUTPUT ?%
# KW
TIME DELAY
MIN:SEC ??:??
OVERVOLTAGE ?%
# VAC
TIME DELAY
MIN:SEC ??:??
UNDERVOLTAGE ?%
# VAC
TIME DELAY
MIN:SEC ??:??
OVERFREQUENCY ?%
# HZ
UNDERFREQUENCY ?%
# HZ
OVERSPEED ? HZ
# RPM
TO GENERATOR SYSTEM MENU ON NEXT PAGE
50
Section 2 Operation
TP-6083 7/05
Menu 7Generator System, continued

BATTERY VOLTAGE 12 VDC Y/N BATTERY VOLTAGE 24 VDC Y/N
LOW BATTERY VOLTAGE ?.? VDC
HIGH BATTERY VOLTAGE ?.? VDC
METRIC UNITS
Y/N
SET NFPA-110 DEFAULTS
Y/N
2.8.8
Menu 8Time Delays

The user must enable the programming mode to edit the display.
Menu 8 displays the cyclic cranking cycles, various engine related starting and shutdown features, and auxiliary shutdown and inhibit time delays.
Menu 8 Overview
MENU 8 TIME DELAYS
TIME DELAY ENGINE START
MIN:SEC ??:??
TIME DELAY STARTING AID
MIN:SEC ??:??
TIME DELAY CRANK ON
MIN:SEC ??:??
TIME DELAY CRANK PAUSE
MIN:SEC ??:??
TIME DELAY ENG COOLDOWN
MIN:SEC ??:??
OVERCRANK SHUTDOWN CRANK CYCLES
TIME DELAY OVERVOLTAGE
MIN:SEC ??:??
TIME DELAY UNDERVOLTAGE
MIN:SEC ??:??
TIME DELAY LOAD SHED KW
MIN:SEC ??:??
TP-6083 7/05
Section 2 Operation
51
2.8.9
Menu 9Input Setup

D Time Delay (shutdown or warning). The time delay
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. Note: Press the down arrow to move to the start of the next input setup. Note: ECM engines have user-defined analog inputs 01--07. Non-ECM engines have user-defined analog inputs 03--07 where analog inputs 01 and 02 are reserved for engine coolant temperature and oil pressure displays. Digital and Analog Inputs. After the user selects input, enter the following choices or valuesenabled (yes/no), inhibit time (min.:sec.), and delay time (min.:sec.).
D Enabled. This menu entry enables the input. The
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 valueslow warning, high warning, low shutdown, and high shutdown. Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown. When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/generator damage can occur. When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5 Event History. Shutdown Type A and Shutdown Type B. Choose shutdown type A for standard shutdown where red lamp illuminates and alarm horn sounds. Choose shutdown type B for shutdown where air damper indicator RDO-23 energizes for two seconds, red lamp illuminates, and alarm horn sounds.
previous yes/no selection does not activate the input. Analog inputs have separate warning and shutdown enabled choices.
D Inhibit Time Delay. The inhibit time delay 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 inhibit time delay range is from 0 to 60 seconds.
Menu 9 Overview
MENU 9 INPUT SETUP
SETUP DIGITAL AUXILIARY INPUTS
TO ANALOG INPUT SETUP (NEXT PAGE)
DIGITAL INPUT 01 (USER DEFINED DESC)
DIGITAL INPUT 01 (see Group A) YES/NO
DIGITAL INPUT 01 ENABLED YES/NO
DIGITAL INPUT 01 INHIBIT TIME
?:??
DIGITAL INPUT 01 DELAY TIME
?:??
Press the down arrow to scroll through additional DIGITAL auxiliary inputs 1--21 or enter the input number.
Group A
Group A, continued
The preprogrammed selections include the following: WARNING Y/N SHUTDOWN TYPE A Y/N SHUTDOWN TYPE B Y/N VOLTAGE RAISE Y/N VOLTAGE LOWER Y/N VAR PF MODE Y/N REMOTE SHUTDOWN Y/N REMOTE RESET Y/N
AIR DAMPER LOW FUEL FIELD OVERVOLTAGE IDLE MODE ACTIVE (ECM engine only) BATTLE SWITCH GROUND FAULT BAT CHGR FAULT Hi OIL TEMP LOW COOLANT LEVEL LOW COOLANT TEMP (not user selectable)
Y/N Y/N Y/N Y/N Y/N Y/N Y/N Y/N Y/N Y/N
52
Section 2 Operation
TP-6083 7/05
Menu 9Input Setup, continued

SETUP ANALOG AUXILIARY INPUTS
TO DIGITAL INPUT SETUP (PREV. PAGE)
ANALOG INPUT XX (USER DEFINED DESC)
ANALOG INPUT XX WARNING ENABLED
Y/N
ANALOG INPUT XX SHUTDOWN ENABLED Y/N
ANALOG INPUT XX INHIBIT TIME
?:??
Press down arrow to scroll through 1--7 additional ANALOG auxiliary inputs or enter input number on ECM engines.
Press down arrow to scroll through 3--7 additional ANALOG auxiliary inputs or enter input number on nonECM engines.
ANALOG INPUT XX WARN DELAY TIME
?:??
ANALOG INPUT XX SDWN DELAY TIME
?:??
ANALOG INPUT XX LO SDWN VALUE
??
ANALOG INPUT XX LO WARN VALUE
??
ANALOG INPUT XX HI WARN VALUE
??
ANALOG INPUT XX HI SDWN VALUE
??
2.8.10 Menu 10Output 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 a multitude of 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. Note: Some data require entry using a PC in the Remote Programming mode. See the Software Operation Manual for details. The user can select up to 21 user-defined digital status events and faults designated as D01 to D21. Each of the 21 status events and faults are assignable as shutdowns or warnings. The user can select up to 7 user-defined analog status events and faults designated as A01 to A07. Each of the 7 status events and faults are assignable as shutdowns or warnings with high or low settings for a total of up to 7 status events and fault functions.
Relay Driver Outputs (RDOs)

Up to 31 RDOs are available using the system, digital, and analog status events and faults. RDOs provide only the driver. The contact relays that interface with other equipment are optional. Note: Func(tion) Used By (RDO) XX Reassign? error message appears when the user attempts to duplicate an existing RDO selection. Note: Cannot Change NFPA is Enabled. error message appears when the user attempts to modify RDO setting defaulted as NFPA 110 requirement.
Common Faults
The user can program a single fault comprised of faults from 3 common fault programssystem, digital, and analog faults. Up to 46 user-defined system status events and faults are available. See Group B on the following pages for specific descriptions. The NFPA-110 faults are part of the system fault program and are comprised of 15 individual faults shown on the next page.
TP-6083 7/05
Section 2 Operation
53
Menu 10 Overview
MENU 10 OUTPUT SETUP
DEFINE COMMON FAULTS
SYSTEM EVENTS
DIGITAL INPUTS
ANALOG INPUTS
COMMON FAULT (see Group B)
Y/N
COMMON FAULT (see Group C)
Y/N
COMMON FAULT
Y/N
(see Group D)LO WARNING
COMMON FAULT Y/N HI WARNING
Press down arrow to scroll through available faults.
Press down arrow to scroll through digital auxiliary inputs. Group B, continued
Press down arrow to scroll through analog auxiliary inputs. Group C
COMMON FAULT Y/N LO SHUTDOWN
Group B
For defined system events, choose from the following 46 status events and faults by changing selection to YES: EMERGENCY STOP OVER SPEED OVER CRANK HI COOL TEMP SHUTDWN OIL PRESS SHUTDOWN LOW COOLANT TEMP (non-ECM engines) LOW FUEL HI COOL TEMP WARNING OIL PRES WARNING MASTER NOT IN AUTO NFPA 110 FAULT* LOW BATTERY VOLTAGE HIGH BATTERY VOLTAGE BATTERY CHARGE FAULT SYSTEM READY LOSS OF ECM COMM (ECM engines) NO OIL PRESS SIGNAL HI OIL TEMP NO COOL TEMP SIGNAL LOW COOLANT LEVEL SPEED SENSOR FAULT LOCKED ROTOR
RELAY DRV OUT XX (see Group E)
MASTER SWITCH ERROR Up to 21 user-defined digital status events and MASTER SWITCH OPEN fault inputs designated as MASTER SWITCH TO OFF D01 to D21 can result in a AC SENSING LOSS digital input common fault. OVER VOLTAGE UNDER VOLTAGE WEAK BATTERY OVER FREQUENCY
Group D
COMMON FAULT Y/N HI SHUTDOWN
*NFPA 110 FAULT The 15 NFPA-110 Fault Alarms include the following: OVERSPEED OVERCRANK HIGH COOLANT TEMP SHUTDOWN OIL PRESSURE SHUTDOWN LOW COOLANT TEMPERATURE HIGH COOLANT TEMP WARNING OIL PRESSURE WARNING LOW FUEL MASTER NOT IN AUTO BATTERY CHARGER FAULT LOW BATTERY VOLTAGE HIGH BATTERY VOLTAGE LOW COOLANT LEVEL EPS SUPPLYING LOAD AIR DAMPER INDICATOR
Up to 7 analog inputs, userdefined status events and faults designated as A01 to UNDER FREQUENCY A07. Each of the 7 is LOAD SHED KW OVER assignable as a shutdown LOAD SHED UNDER FREQ or warning with high or low settings. OVER CURRENT EPS SUPPLYING LOAD INTERNAL FAULT DELAY ENG COOLDOWN DELAY ENG START STARTING AID GENERATOR RUNNING AIR DAMPER CONTROL GROUND FAULT EEPROM WRITE FAILURE CRITICAL OVERVOLTAGE ALTERNATOR PROTECTION SHUTDOWN AIR DAMPER INDICATOR DEFINED COMMON FAULT (RDO only)[ SCRDOs 1--4 (software controlled RDOs) [DEFINED COMMON FAULT The 5 defined common faults include the following: EMERGENCY STOP HI COOL TEMP SHUTDOWN OIL PRESS SHUTDOWN OVERCRANK OVERSPEED
SYSTEM EVENTS
DIGITAL INPUTS
ANALOG INPUTS
Press down arrow to scroll through RDOs 1--31 or enter RDO number. Group E
RELAY DRV OUT XX (see Group B)
Y/N
RELAY DRV OUT XX (see Group C)
Y/N
RELAY DRV OUT XX
Y/N
(see Group D)LO WARNING
RELAY DRV OUT Y/N HI WARNING
Choose up to 31 status event and fault RDOs from the following: SYSTEM FAULTS (see Group B, 46 Items) DIGITAL INPUTS (see Group C, 21 Items) ANALOG INPUTS (see Group D, 7 Items)
Press down arrow to scroll through available RDO faults.
Press down arrow to scroll through RDO digital auxiliary inputs.
Press down arrow to scroll through RDO analog auxiliary inputs.
RELAY DRV OUT Y/N LO SHUTDOWN
RELAY DRV OUT Y/N HI SHUTDOWN
54
Section 2 Operation
TP-6083 7/05
2.8.11 Menu 11Voltage Regulator

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. Adjust the frequency at the generator sets governor before making voltage regulator adjustments. The user must enable the programming mode to edit the display. Note: Press the Menu Right key prior to entering decimal values where necessary.
Menu 11 Overview
MENU 11 VOLTAGE REGULATOR
AVG L-L V VOLT ADJ
# ?.?
L1-L2 VOLTS #
L2-L3 VOLTS (3 PHASE) #
L3-L1 VOLTS (3 PHASE) #
UNDER FREQ UNLOAD ENABLED
N/Y
FREQUENCY SETPOINT
# HZ ?.? HZ
SLOPE ?.? VOLTS-PER-CYCLE
REACTIVE DROOP ENABLED
N/Y
.8 PF RATED LOAD VOLTAGE DROOP
?.?%
VAR CONTROL ENABLED
N/Y
TOTAL KVAR KVAR ADJ
# ?.?
GENERATING/ ABSORBING
Y/N Y/N
PF CONTROL ENABLED
N/Y
AVERAGE PF PF ADJ
# ?.?
LAGGING/ LEADING
Y/N Y/N
TP-6083 7/05
Section 2 Operation
55
2.8.12 Menu 12Calibration

Menu 12 provides calibration of the voltage sensing logic and displays. Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment. The user must enable the programming mode to edit the display. Connect a meter with a minimum accuracy of 1% to the output leads to calibrate the voltage-sensing logic. Configure the generator set controller for the system operating configuration using Menu 7Generator System. If the generator set has a digital voltage regulator, adjust the generator set voltage using Menu 11Voltage Regulator. Adjust the frequency at the generator set governor before making calibration adjustments. Note: Press the Menu Right key prior to entering decimal values where necessary. Note: ECM engines have user-defined analog inputs A01--A07. Non-ECM engines have user-defined analog inputs A03--A07 where analog inputs 01 and 02 are reserved for engine oil pressure and coolant temperature displays.
Menu 12 Overview
MENU 12 CALIBRATION
SCALE AC ANALOG INPUTS
SCALE AUX. ANALOG INPUTS
Press down arrow to scroll through ANALOG auxiliary inputs 01--07 with ECM engines. Press down arrow to scroll through ANALOG auxiliary inputs 03--07 with non-ECM engines.
GEN L1-L0 V CALIB REF
# ?.?
ZERO AUX. ANALOG INPUTS?
GEN L2-L0 V CALIB REF
# ?.?
ANALOG XX SCALE VALUE 1
# ?.?
SCAL1 SCAL2
#.#--#.#V #.#--#.#V
GEN L3-L0 V (3 PHASE) CALIB REF
# ?.?
ANALOG XX SCALE VALUE 2
# ?.?
SCAL1 SCAL2
#.#--#.#V #.#--#.#V
GEN L1 AMPS CALIB REF
# ?.?
Right Arrow between ENTRY and DISPLAY of setpoint
# ?.?
GEN L3 AMPS (3 PHASE) CALIB REF
# ?.?
RESTORE DEFAULTS?
56
Section 2 Operation
TP-6083 7/05
2.8.13 Menu 13Communications

Menu 13 provides local or remote access to the control logic. Use the LAN (local area network) to gain remote access to multiple devices/addresses. Enable the local programming mode to edit the display using the keypad and digital display or the remote programming mode to edit the display using a PC. Use the Software Operation Manual when accessing this menu, programming from a remote location, and determining address and system identification information.
Menu 13 Overview
MENU 13 COMMUNICATIONS
PROTOCOL KBUS
PROTOCOL MODBUS
KBUS ONLINE
Y/N
MODBUS ONLINE
Y/N
CONNECTION TYPE (USER DEFINED)
Y/N
CONNECTION TYPES LOCAL SINGLE LOCAL LAN LOCAL LAN CONV REMOTE SINGLE REMOTE LAN REMOTE LAN CONV
Y/N Y/N Y/N Y/N Y/N Y/N
Y/N
CONNECTION TYPES SINGLE CONVERTOR PRIMARY PORTS RS-232 RS-485
Y/N Y/N
PRIMARY PORT (USER DEFINED)
Y/N
Y/N Y/N
PRIMARY PORTS RS-232 RS-485 ISO 1
ADDRESS Y/N Y/N BAUD RATE (USER DEFINED)
ADDRESS (LAN Connections)
Y/N
BAUD RATES 9600 19200
Y/N Y/N
SYSTEM ID (Remote Connections)
BAUD RATE (USER DEFINED)
Y/N
BAUD RATES 1200 2400 9600 Y/N Y/N Y/N
TP-6083 7/05
Section 2 Operation
57
2.8.14 Menu 14Programming 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. Should the controller logic not accept the access code or if the new code number is lost, contact your local authorized distributor/dealer for password information. The user chooses one of three programming modes:
D localusing the controller keypad D remoteusing a PC D offno programming is permitted
Note: Use the generator set controller to initially set up remote programming. Remote programming cannot be accessed from a PC unless the controller is first set for remote programming using Menu 14.
Menu 14 Overview
MENU 14 PROGRAMMING MODE
PROGRAMMING MODE LOCAL
Y/N
PROGRAMMING MODE REMOTE
Y/N
PROGRAMMING MODE OFF
Y/N
PROGRAMMING MODE CHANGE ACCESS CODE
PROGRAMMING MODE ENTER OLD CODE
PROGRAMMING MODE ENTER NEW CODE
58
Section 2 Operation
TP-6083 7/05
2.8.15 Menu 20Factory 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.
Menu 20 Overview
MENU 20 FACTORY SETUP
FINAL ASSEMBLY DATE DD/MM/YY
FINAL ASSEMBLY CLOCK NO ?
OPERATING DAYS
MODEL NO
SPEC NO
GENSET SERIAL NO
ALTERNATOR PART NO
ENGINE PART NO
SERIAL NO
CONTROLLER SERIAL NO
CODE VERSION COPYRIGHT
# XXXX
SETUP LOCKED
YES
TP-6083 7/05
Section 2 Operation
59
2.9 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. The factory settings are adjustable and programming without full understanding of the logic features and functions can cause inadvertent changes. Refer to Menu 14Programming Mode for information regarding menu programming activation. After completing the programming always place the controller back in the Programming Mode Off position to prevent inadvertent program changes. The programming feature alters stored settings and changes characteristics of the logic. Do not operate the controller with the program mode on unless there is a need to edit program logic or clear stored data. Limit programming responsibilities to individuals with training and authority. The product application requires expertise in the design and programming of control systems. Only qualified personnel should program, install, alter, and apply this product. Use Section 2.8, Reviewing the Menu Displays, to view the generator set operation data and review previously programmed information and to review the data when no programming is necessary. Menus displaying the # symbol represent one of the following data types:
D System-calculated data D System-measured data D User-entered data
Menus displaying the ? symbol require the user to enter data. Menus displaying the * symbol represent access code or password type entries. Actual key entry does not display. See Section 2.6.3, Request and Error Messages, for error display messages and explanations while navigating through the menus. All menu displays apply to both single-phase and three-phase voltages unless otherwise noted as (1 PH) or (3 PH) on the menu overview. The phase designation does not appear in the actual menu displays. Note: Place the generator set master switch in the OFF/RESET position when using the programming mode on. Note: Use the generator set controller to initially set up the remote programming. Set the controller for remote programming using Menu 14 and remote communication using Menu 13 before attempting remote programming. Note: Press any key on the keypad to activate the controller panel display. The panel display turns off 5 minutes after the last keypad entry. Note: Press the Reset Menu key to clear the Error display. Note: Press the Menu Right key prior to entering decimal values where necessary.
60
Section 2 Operation
Local Programming Mode On
TP-6083 7/05
2.9.1

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. Note: A right arrow from any submenu moves to the next submenu header.
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 voltage and current readings when applicable.

Menu 1 Displays with Key Entries
Key Entry Display
ENTER MENU NO. 1--14
Description
Input a menu number.
MAIN MENU NUMBER 1
Press the Enter key.
MENU 1 GENERATOR MONITORING VOLTS & AMPS
Displays the menu number and name.
Displays the volts and amps heading.
L1-L2 VOLTS L1 AMPS L2-L3 VOLTS L2 AMPS L1-L2 VOLTS L2 AMPS L3-L1 VOLTS L3 AMPS L1-L0 VOLTS L1 AMPS L2-L0 VOLTS L2 AMPS L3-L0 VOLTS L3 AMPS
# # # # # # # # # # # # # #
Displays L1 and L2 volts and L1 amps.
Displays L2 and L3 volts and L2 amps. (3 ph. only)
Displays L1-L0 volts and L1 amps.
Displays L2 and L0 volts and L2 amps.
Displays L3-L0 volts and L3 amps. (3 ph. only)
FREQUENCY
# HZ
Displays the frequency. Returns the user to the menu number and name.
MENU 1 GENERATOR MONITORING VOLTS & AMPS
Returns the user to volts and amps heading.
V & A SUMMARY
Displays the volts and amps summary heading. Displays L1-L2, L2-L3, and L3-L1 volts. (3 ph. only)
L1-L2 #
L2-L3 #
L3-L1 #
TP-6083 7/05
Section 2 Operation
61
Menu 1Generator Monitoring, continued

Key Entry Display
V L1-L0 # L1-L2 # L1 # L1 # L2-L0 # L1-L0 # L2 # L2 # L3-L0 # L2-L0 # L3 #
Description
Displays L1-L0, L2-L0, and L3-L0 volts. (3 ph. only)
Displays L1-L2, L1-L0, and L2-L0 volts. (1 ph. only)
Displays L1, L2, and L3 amps. (3 ph. only)
Displays L1 and L2 amps. (1 ph. only)
V & A SUMMARY
Returns the user to the volts and amps summary heading.
POWER KW
Displays the power kilowatt heading. Displays total kilowatts and leading or lagging power factor.
TOTAL KW # PF # LEADING/LAGGING L1 KW PF # L2 KW PF # L3 KW PF # # LEADING/LAGGING # LEADING/LAGGING # LEADING/LAGGING # #
Displays total L1 kilowatts and leading or lagging power factor.
Displays total L2 kilowatts and leading or lagging power factor. Displays total L3 kilowatts and leading or lagging power factor. (3 ph. only)
TOTAL KW % OF RATED KW POWER KW
Displays the total kW and percent of rated kilowatts.
Returns the user to the power kilowatt heading.
POWER KVAR
Displays the power kVAR heading.
TOTAL KVAR # ABSORBING/GENERATING L1 KVAR # ABSORBING/GENERATING L2 KVAR # ABSORBING/GENERATING L3 KVAR # ABSORBING/GENERATING POWER KVAR
Displays total kVAR, absorbing or generating. Displays L1 kVAR, absorbing or generating.
Displays L2 kVAR, absorbing or generating.
Displays L3 kVAR, absorbing or generating. (3 ph. only)
Returns the user to power kVAR heading.
POWER KVA
Displays the power kVA heading.
62
Section 2 Operation
TP-6083 7/05
Menu 1Generator Monitoring, continued

Key Entry Display
TOTAL KVA #
Description
Displays total kVA.
L1 KVA
Displays L1 kVA.
L2 KVA
Displays L2 kVA.
L3 KVA
Displays L3 kVA. (3 ph. only) Returns the user to power kVA heading.
POWER kVA
TP-6083 7/05
Section 2 Operation
63
2.9.2
Menu 2Engine Monitoring

Note: A right arrow from any submenu moves to the next submenu header.
Menu 2 provides engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. The detailed engine monitoring feature requires an ECM-equipped engine.
Menu 2Engine Monitoring, continued

Key Entry Display
Description
MAIN MENU NUMBER 2
MENU 2 ENGINE MONITORING ENGINE MONITORING BASIC OIL PRESSURE COOLANT TEMP ENGINE RPM LOCAL BATT VDC MENU 2 ENGINE MONITORING ENGINE MONITORING BASIC ENGINE MONITORING DETAILED ENGINE FUEL
Displays the basic engine monitoring heading.
# PSI #F # #
Displays oil pressure and coolant temperature.
Displays engine rpm and local battery VDC.
Returns the user to the menu number and name.
Returns the user to basic engine monitoring heading. Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature requires an ECM-equipped engine. Displays the engine fuel subheading.
FUEL PRES FUEL TEMP FUEL RATE
# PSI #F # GPH
Displays the fuel pressure and fuel temperature.
Displays the fuel rate per hour.
USED LAST RUN # GAL ENGINE MONITORING DETAILED ENGINE FUEL
Displays the amount of fuel used during the last run.
Returns the user to the detailed engine monitoring heading.
Displays the engine fuel subheading.
ENGINE COOLANT
Displays the engine coolant subheading.
64
Section 2 Operation
TP-6083 7/05
Menu 2Engine Monitoring, continued

Key Entry Display
COOLANT PRES COOLANT TEMP # PSI #F
Description
Displays the coolant pressure and coolant temperature.
COOLANT LEVEL
#%
Displays the coolant level as a percent of full capacity.
ENGINE COOLANT
Returns the user to engine coolant subheading.
ENGINE OIL
Displays the engine oil subheading.
OIL PRES OIL TEMP
# PSI #F
Displays the oil pressure and oil temperature.
OIL LEVEL CRANKCASE PRES
#% # PSI
Displays the oil level as a percent of full capacity and crankcase pressure. Returns the user to engine oil subheading.
ENGINE OIL
ENGINE MISC
Displays the miscellaneous engine subheading.
ECM BATT VDC AMBIENT TEMP ENGINE MODEL NO. #
# #F
Displays the engine ECM battery VDC and ambient temperature.
Displays the engine model number.
ENGINE SERIAL NO. #
Displays the engine serial number.
UNIT NO. ECM S/N
# #
Displays the unit number and ECM serial number.
ENGINE MISC
Returns the user to the miscellaneous engine subheading.
TP-6083 7/05
Section 2 Operation
65
2.9.3

Note: If the analog display shows O/R (out of range), no input is connected. Note: Some data require entry using a PC in the Remote Programming mode. See the Software Operation Manual for details. Note: ECM engines have user-defined analog inputs A01--A07. Non-ECM engines have user-defined analog inputs A03--A07 where analog inputs 01 and 02 are reserved for the engine coolant temperature and oil pressure displays.
Menu 3 provides the battery voltage and up to 7 userdefined analog monitoring items dependent upon the generator system. 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. The display has 20 characters maximum.

Key Entry Display
Description
MAIN MENU NUMBER 3
MENU 3 ANALOG MONITORING LOCAL BATT VDC #
Displays the local battery VDC. Displays analog 01 and the user-defined description. Note: ECM engines have inputs 01--07 and non-ECM engines have inputs 03--07.
Displays analog 02 and the user defined description.
ANALOG 03 (USER DEFINED DESC) ANALOG 04 (USER DEFINED DESC) ANALOG 05 (USER DEFINED DESC)
Displays analog 03 and the user-defined description.
ANALOG 06 (USER DEFINED DESC) ANALOG 07 (USER DEFINED DESC)
Displays analog 06 end the user-defined description.
66
Section 2 Operation
TP-6083 7/05
2.9.4

mode, the controller bypasses the run time mode and functions in the standby (backup) mode. If the utility power returns, the generator set continues to run for the duration of the run time period if not timed out. Note: Press the STOP PROG RUN key to stop the generator set when in the run time mode, if necessary. After performing maintenance enter yes to reset records reflecting the current day. The user must enable the programming mode to edit the display.
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. Generator set connected to an automatic transfer switch. Should a utility power failure occur while the unit is in the run time

Key Entry Display
Description
Input a menu number. Press the Enter key.
MAIN MENU NUMBER 4
MENU 4 OPERATIONAL RECORDS FACTORY TEST DATE ##-###-##
Displays the factory test date (day-month-year).
TOTAL RUN TIME HRS TOTAL RUN TIME LOADED HRS TOTAL RUN TIME UNLOADED HRS TOTAL RUN TIME KW HRS
Displays the total run time (hours:minutes).
Displays the total run time for loaded hours.
Displays the total run time for unloaded hours.
Displays the total run time in kW hours.
NO. OF STARTS
Displays the number of engine starts.
Y/N ##:##
Displays the start and countdown subheading.
RUN TIME
HR:MN ??:?? HR:MN ##:##
Displays the run time (hours:minutes) feature. When required, use the numeric keys to enter the selected run time (hours:minutes) and press the Enter key. Confirms entry and displays the selected run time (hours:minutes). The generator set will start after activation. Note: Activate the generator set run time feature by pressing the Yes and Enter keys. See the following steps. Returns the user to the start and countdown subheading. Enter Yes to start the generator set.
RUN TIME
Y/N ##:##
TP-6083 7/05
Section 2 Operation
67
Menu 4Operational Records, continued

Key Entry Display
ENGINE START? COUNTDOWN RUN TIME YES ##:## HR:MN ##:##
Description
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 8Time Delays. Note: Press the STOP PROG RUN key to stop the generator set when in the run time mode, if necessary. Displays the records maintenance subheading.
RECORDS MAINT
RESET RECORDS?
Displays the reset records option. After performing maintenance or when required, enter Yes to reset. Enter Yes to reset to the current date and press the Enter key.
RESET RECORDS?
YES
RESET RECORDS?
YES
Confirms the entry.
RECORDS MAINT
Returns the user to records maintenance subheading.
RUN TIME SINCE MAINT TOTAL HRS
Displays the run time since the last maintenance with total hours.
RUN TIME SINCE MAINT LOADED HRS
Displays the run time since last the maintenance with loaded hours.
RUN TIME SINCE MAINT UNLOADED HRS RUN TIME SINCE MAINT KW HRS
Displays the run time since the last maintenance with unloaded hours.
Displays the run time since the last maintenance in kW hours.
OPERATING DAYS LAST MAINT
# ##-###-##
Displays the operating days since the last maintenance.
NO. OF STARTS LAST MAINT
# ##-###-##
Displays the number of starts since the last maintenance date (day-month-year). Displays last the start time (hours:minutes) and date (day-month-year).
LAST START DATE
##:## AM/PM ##-###-##
LENGTH OF RUN (UN)LOADED HRS
Displays the length of last run in (un)loaded hours.
MENU 4 OPERATIONAL RECORDS
Returns the user to the operational records heading.
68
Section 2 Operation
TP-6083 7/05
2.9.5
Menu 5Event History
Menu 5 provides up to 100 stored warning and shutdown events that are day and time dated. See Menu 10Output Setup for a list of possible events.
Menu 5Event History

Key Entry Display
Description
MAIN MENU NUMBER 5
MENU 5 EVENT HISTORY
(MESSAGE TEXT) ##-###-## ##:## AM/PM MENU 5 EVENT HISTORY
Displays the message text, date (day-month-year) and time (hours:minutes). Scroll through up to100 stored events. See Section 2.3.5, System Warning Lamp, for fault descriptions. Returns the user to event history heading.
TP-6083 7/05
Section 2 Operation
69
2.9.6
Menu 6Time 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.
Menu 6Time and Date

Key Entry Display
Description
MAIN MENU NUMBER 6
MENU 6 TIME AND DATE
DAY OF WEEK ##-###-## ##:## AM/PM
Displays the day of the week, date (day-month-year), and time (hours:minutes). Displays the time (hours:minutes) of day entry. When required, use the numeric and am/pm keys to set the time (hours:minutes) of day and press the Enter key. Displays the corrected time (hours:minutes) of day.
TIME
??:?? AM/PM
DAY OF WEEK ##-###-## ##:## AM/PM
DATE
??-???-??
Displays the date (day-month-year) entry. When required, use the numeric keys to set the day of the month. Use the Menu Right key to select the month.
AND
DATE ??-???-??
AND
DATE ??-???-??
Use the numeric keys to set the two-digit year and press the Enter key.
AND
DAY OF WEEK ##-###-## ##:## AM/PM
Displays the corrected date (day- month-year).
70
Section 2 Operation
TP-6083 7/05
2.9.7
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. The user must enable the programming mode to edit the display.
See Section 2.6.3, Request and Error Messages, for error display messages and explanations while navigating the menus. Note: The user defines the data shown in Menu 7. It is NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control. Note: Press the Menu Right key prior to entering decimal values where necessary.

Key Entry Display
Description
MAIN MENU NUMBER 7
MENU 7 GENERATOR SYSTEM OPERATING MODE (see note) YES
Displays the menu number and name. Displays the operating mode selection. Note: The display sample may differ depending upon previous entries. The previously selected operating mode appears first, either standby or prime power. Displays the optional operating mode selection. When required, enter YES for standby operating mode. Note: This display indicates the generator set application. Enter YES to change the operating mode selection to standby and press the Enter key.
OPERATING MODE STANDBY OPERATING MODE STANDBY
NO YES
OPERATING MODE STANDBY
YES
Confirms the entry.
OR
OPERATING MODE PRIME POWER OPERATING MODE PRIME POWER NO YES YES
Displays the optional operating mode selection. When required, enter YES for the prime power operating mode. Note: This display indicates the generator set application. Enter YES to change the operating mode selection to prime power and press the Enter key. Confirms the entry.
OPERATING MODE PRIME POWER
SYSTEM VOLTAGE LINE-LINE
Displays the line-to-line system voltage as entered data. When required, use the numeric keys to set new value. Press the Enter key.
SYSTEM VOLTAGE LINE-LINE SYSTEM FREQ
# # HZ
Displays the corrected line-to-line system voltage. Displays the system frequency as entered data. When required, use the numeric keys to set the new value. Press the Enter key.
TP-6083 7/05
Section 2 Operation
71

Key Entry Display
SYSTEM FREQ # HZ
Description
Displays the corrected system frequency. 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. Displays the optional phase configuration selection. When required, use the YES key to choose the delta phase configuration. Enter YES to change the phase configuration to a delta phase configuration and press the Enter key. Confirms the entry.
PHASE (see note) PHASE 3 PHASE DELTA PHASE 3 PHASE DELTA PHASE 3 PHASE DELTA
YES NO YES YES
OR
PHASE 3 PHASE WYE PHASE 3 PHASE WYE PHASE 3 PHASE WYE
NO YES YES
Displays the optional phase configuration selection. When required, use the YES key to choose the wye phase configuration. Enter YES to change the phase configuration to a wye phase configuration and press the Enter key. Confirms the entry.
OR
PHASE SINGLE-PHASE PHASE SINGLE-PHASE PHASE SINGLE-PHASE NO YES YES
Displays the optional phase configuration selection. When required, use YES key to choose the single-phase configuration. Enter YES to change the phase configuration to a single-phase configuration and press the Enter key. Confirms the entry.
KW RATING
Displays the generator set kW rating as entered data. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected system kilowatt rating. Displays the generator set rated current as entered data. Note: This is a read-only display. Displays the load shed output setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected load shed output setting. Displays the load shed time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected load shed time (minutes:seconds) delay setting.
KW RATING
RATED CURRENT
LOAD SHED OUTPUT ?% LOAD SHED OUTPUT #% TIME DELAY
# KW # KW
MIN:SEC ??:?? MIN:SEC ##:## # KW
TIME DELAY
LOAD SHED OUTPUT #%
Returns the user to the load shed output setting.

TP-6083 7/05
72
Section 2 Operation

Key Entry Display
OVERVOLTAGE ?% # VAC # VAC MIN:SEC ??:?? MIN:SEC ##:## # VAC # VAC # VAC MIN:SEC ??:?? MIN:SEC ##:## # VAC
Description
Displays the overvoltage setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected overvoltage setting. Displays the overvoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected overvoltage time (minutes:seconds) delay setting. Returns the user to the overvoltage setting.
OVERVOLTAGE #% TIME DELAY
TIME DELAY
OVERVOLTAGE #%
UNDERVOLTAGE ?% UNDERVOLTAGE #% TIME DELAY
Displays the undervoltage setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected undervoltage setting. Displays the undervoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected overvoltage time (minutes:seconds) delay setting. Returns the user to the undervoltage setting.
TIME DELAY
UNDERVOLTAGE #%
OVERFREQUENCY ?% OVERFREQUENCY #%
# HZ
Displays the overfrequency setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected overfrequency setting. Displays the underfrequency setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected underfrequency setting.
# HZ
UNDERFREQUENCY ?% UNDERFREQUENCY #%
# HZ
# HZ
OVERSPEED ? HZ OVERSPEED # HZ
# RPM
Displays the overspeed setting. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected overspeed setting.
# RPM
TP-6083 7/05
Section 2 Operation
73

Key Entry Display
BATTERY VOLTAGE (see note) YES
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. Displays the 12 VDC battery voltage selection. When required, use the YES key to choose the 12 VDC battery voltage. Enter YES to change the battery voltage to 12 VDC and press the Enter key. Confirms the entry.
BATTERY VOLTAGE 12 VDC BATTERY VOLTAGE 12 VDC BATTERY VOLTAGE 12 VDC
NO YES YES
OR
BATTERY VOLTAGE 24 VDC BATTERY VOLTAGE 24 VDC BATTERY VOLTAGE 24 VDC NO YES YES
Displays the 24 VDC battery voltage selection. When required, use the YES key to choose the 24 VDC battery voltage. Enter YES to change the battery voltage to 24 VDC and press the Enter key. Confirms the entry. Displays the low battery voltage setting. When required, use the numeric keys to set the new value. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
LOW BATTERY VOLTAGE #.# VDC HIGH BATTERY VOLTAGE ?.? VDC
Displays the corrected low battery voltage setting. Displays the high battery voltage setting. When required, use the numeric keys to set the new value. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
HIGH BATTERY VOLTAGE ?.? VDC HIGH BATTERY VOLTAGE #.# VDC METRIC UNITS Y/N
Displays the corrected high battery voltage setting.
Displays the metric units selection.
METRIC UNITS
YES
Enter YES to change to metric displays and press the Enter key. Confirms the entry.
METRIC UNITS
YES
OR
METRIC UNITS NO
Enter NO to change to English displays and press the Enter key.
METRIC UNITS
NO
Confirms the entry.
74
Section 2 Operation
TP-6083 7/05

Key Entry Display
SET NFPA-110 DEFAULTS Y/N
Description
Displays the NFPA 110 default selection. Note: See Menu 10Output Setup, Overview for a list of the NFPA-110 faults.
SET NFPA-110 DEFAULTS SET NFPA-110 DEFAULTS
YES
Enter YES to select the NFPA 110 default selection and press the Enter key. Confirms the entry.
YES
OR
SET NFPA-110 DEFAULTS SET NFPA-110 DEFAULTS NO
Enter NO to deselect the NFPA 110 default selection and press the Enter key. Confirms the entry.
NO
MENU 7 GENERATOR SYSTEM
Returns the user to the generator system heading.
TP-6083 7/05
Section 2 Operation
75
2.9.8
Menu 8Time Delays

Menu 8 displays the various time delays for cyclic cranking and other engine-related starting and shutdown features.
Menu 8Time Delays

Key Entry Display
Description
MAIN MENU NUMBER 8
MENU 8 TIME DELAYS
TIME DELAY ENGINE START
MIN:SEC ??:??
Displays the engine start time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected engine start time (minutes:seconds) delay setting. Displays the starting aid time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected starting aid time (minutes:seconds) delay setting.
TIME DELAY ENGINE START TIME DELAY STARTING AID TIME DELAY STARTING AID
MIN:SEC ##:## MIN:SEC ??:?? MIN:SEC ##:##
TIME DELAY CRANK ON TIME DELAY CRANK ON
MIN:SEC ??:?? MIN:SEC ##:##
Displays the crank on time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.
Displays the corrected crank on time (minutes:seconds) delay setting.
TIME DELAY CRANK PAUSE TIME DELAY CRANK PAUSE
Displays the crank pause time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected crank pause time (minutes:seconds) delay setting. Displays the engine cooldown time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected engine cooldown time (minutes:seconds) delay setting. Displays the engine crank cycles before overcrank shutdown. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected engine crank cycles before overcrank shutdown setting.
TIME DELAY ENG COOLDOWN TIME DELAY ENG COOLDOWN
OVERCRANK SHUTDOWN CRANK CYCLES OVERCRANK SHUTDOWN CRANK CYCLES
76
Section 2 Operation
TP-6083 7/05
Menu 8Time Delays, continued

Key Entry Display
TIME DELAY OVERVOLTAGE TIME DELAY OVERVOLTAGE TIME DELAY UNDERVOLTAGE TIME DELAY UNDERVOLTAGE TIME DELAY LOAD SHED KW TIME DELAY LOAD SHED KW MIN:SEC ??:?? MIN:SEC ##:## MIN:SEC ??:?? MIN:SEC ##:## MIN:SEC ??:?? MIN:SEC ##:##
Description
Displays the overvoltage time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected overvoltage time (minutes:seconds) delay setting. Displays the undervoltage time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected undervoltage time (minutes:seconds) delay setting. Displays the load shed time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key. Displays the corrected load shed time (minutes:seconds) delay setting.
MENU 8 TIME DELAYS
Returns the user to the time delays heading.
TP-6083 7/05
Section 2 Operation
77
2.9.9
Menu 9Input 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. Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown analog values based on a 0--5 VDC scale. See Menu 12Calibration. Note: If the ALARM ACTIVE message appears, the selected input has an active fault preventing the enabled choice change from yes to no. The LED display indicates whether the fault is a warning or shutdown. Correct the fault condition before attempting the keypad entry. Note: ECM engines have user-defined analog inputs A01--A07. Non-ECM engines have user-defined analog inputs A03--A07 where analog inputs A01 and A02 are reserved for the engine coolant temperature and oil pressure displays. Note: Some data requires entry by a PC in the Remote Programming mode. See the Software Operation Manual for details. Digital and Analog Inputs. After the user selects the input, the setup requires entering the following choices or values: enabled (yes/no), inhibit time, and delay time.
D Enabled. This menu entry enables the input. The
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 2-18. 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. Each analog input has the following nine features:
D One warning enabled and one shutdown enabled D One inhibit time period D One warning delay and one shutdown delay D Two warning levels and two shutdown levels Time after Crank Disconnect Analog Values
High shutdown value is above the high warning value High warning value is above the acceptable The value controller does not d t Acceptable analog view the value analog Low warning value is input signal below the acceptable value value Low shutdown value is below the low warning value The controller does view the th analog l input signal value and the time delay begins
Inhibit Time Period !
Time Delay Period !
Time Delay Complete

High shutdown function High warning function System ready status Low warning function Low shutdown function
Figure 2-18 Analog Input Logistics Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown. When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/generator damage can occur. When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5 Event History. Shutdown Type A and Shutdown Type B. Choose shutdown type A for standard shutdown where red lamp illuminates and alarm horn sounds. Choose shutdown type B for shutdown where air damper indicator RDO-23 energizes for two seconds, red lamp illuminates, and alarm horn sounds.
previous yes/no selection does not activate the input. Digital inputs have three tier groups: the selection group (25 total), the chosen group (up to 21 total), and the enabled group (up to 21 total based on the chosen group). Analog inputs have separate warning and shutdown enabled choices.
D Inhibit Time Delay. The inhibit time delay is the time
period following crank disconnect during which the generator set stabilizes and the controller does not detect fault or status events. The inhibit time delay range is from 0 to 60 seconds.
D TIme Delay (Shutdown or Warning).
The time delay follows the inhibit time delay. The time delay is the time period between the controller fault or status event detection and the controller warning or shutdown lamp illumination. The delay prevents any nuisance alarms. The time delay range is from 0 to 60 seconds.
Section 2 Operation
78
TP-6083 7/05
Menu 9Input Setup

Key Entry Display
Description
MAIN MENU NUMBER 9
MENU 9 INPUT SETUP SETUP DIGITAL AUXILIARY INPUTS
Displays the setup of digital auxiliary inputs heading.
DIGITAL INPUT 01 (USER DEFINED DESC)
Displays the digital input 01 with the user-defined description. Note: Press the down arrow to move to the start of the next input setup. Identifies the signal source for digital input 01. Use the menu down key to select the digital input.
Group A, continued
DIGITAL INPUT 01 (see Group A)

Group A
YES/NO
The preprogrammed selections include the following: WARNING SHUTDOWN TYPE A SHUTDOWN TYPE B VOLTAGE RAISE VOLTAGE LOWER VAR PF MODE REMOTE SHUTDOWN REMOTE RESET AIR DAMPER LOW FUEL DIGITAL INPUT 01 ENABLED
Y/N Y/N Y/N Y/N Y/N Y/N Y/N Y/N Y/N Y/N YES/NO NO YES YES
FIELD OVERVOLTAGE Y/N IDLE MODE ACTIVE Y/N (ECM engine only) BATTLE SWITCH Y/N (see Battle Switch/Fault Shutdown Override Switch on the previous page.) GROUND FAULT Y/N BAT CHGR FAULT Y/N HI OIL TEMP Y/N LOW COOLANT LVL Y/N LOW COOLANT TEMP Y/N (not user selectable)
Displays the digital input 01, enabled yes or no selection.
DIGITAL INPUT 01 ENABLED
Entering YES enables digital input 01.
Confirms the entry.
OR
YES NO NO
Entering NO disables digital input 01.
Confirms the entry.
TP-6083 7/05
Section 2 Operation
79

Key Entry Display
DIGITAL INPUT 01 INHIBIT TIME ?:??
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. Displays the corrected inhibit time (minutes:seconds) setting.
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. Displays the corrected delay time (minutes:seconds) setting.
DIGITAL INPUT 01 DELAY TIME DIGITAL INPUT 01 (USER DEFINED DESC) DIGITAL INPUT XX (USER DEFINED DESC)
Returns the user to digital input 01. Displays digital inputs 02 to 21. Note: Press the down arrow to scroll through additional digital auxiliary inputs or enter the input number. Note: Press the right arrow at each digital auxiliary input to enable the selection, inhibit time setting, and delay time setting. See Digital Input 01 instructions for complete procedure and Group A selections. Returns the user to the menu number and name.
MENU 9 INPUT SETUP SETUP DIGITAL AUXILIARY INPUTS
Returns the user to setup digital auxiliary inputs.
SETUP ANALOG AUXILIARY INPUTS ANALOG INPUT 01 (USER DEFINED DESC)
Displays the setup of analog auxiliary inputs heading. Displays the analog input 01 with user-defined description. Note: ECM engines have inputs 01--07 and non-ECM engines have inputs 03--07. Note: Press the down arrow to move to the start of the next input setup. Displays the analog input 01, warning enabled yes or no selection. Entering YES enables the warning analog input 01. Press the Enter key.
ANALOG INPUT 01 WARNING ENABLED ANALOG INPUT 01 WARNING ENABLED ANALOG INPUT 01 WARNING ENABLED
Y/N NO YES YES
AND
ANALOG INPUT 01 WARNING ENABLED
Confirms the entry.
OR
ANALOG INPUT 01 WARNING ENABLED YES NO NO
Entering NO disables the warning analog input 01.
AND
Confirms the entry.
80
Section 2 Operation
TP-6083 7/05

Key Entry Display
ANALOG INPUT 01 SHUTDOWN ENABLED ANALOG INPUT 01 SHUTDOWN ENABLED ANALOG INPUT 01 SHUTDOWN ENABLED Y/N NO YES YES
Description
Displays the analog input 01, shutdown enabled selection.
Entering YES enables the shutdown analog input 01. Press the Enter key.
AND
ANALOG INPUT 01 SHUTDOWN ENABLED
Confirms the entry.
OR
ANALOG INPUT 01 SHUTDOWN ENABLED ANALOG INPUT 01 SHUTDOWN ENABLED YES NO NO ?:?? #:##
Entering NO disables the shutdown analog input 01. Press the Enter key.
AND
ANALOG INPUT 01 SHUTDOWN ENABLED ANALOG INPUT 01 INHIBIT TIME ANALOG INPUT 01 INHIBIT TIME
Confirms the entry.
Displays the analog input 01, inhibit time (minutes:seconds) setting. When required, use the numeric keys to set the new values. Press the Enter key. Displays the corrected inhibit time (minutes:seconds) setting.
ANALOG INPUT 01 WARN DELAY TIME ANALOG INPUT 01 WARN DELAY TIME
?:?? #:## ?:?? #:## ?
Displays the analog input 01, warning time (minutes:seconds) delay setting. When required, use the numeric keys to set the new values. Press the Enter key. Displays the corrected warning time (minutes:seconds) delay setting.
ANALOG INPUT 01 SDWN DELAY TIME ANALOG INPUT 01 SDWN DELAY TIME ANALOG INPUT 01 LO SDWN VALUE
Displays the analog input 01, shutdown time (minutes:seconds) delay setting. When required, use the numeric keys to set the new values. Press the Enter key. Displays the corrected shutdown time (minutes:seconds) delay setting. Displays the analog input 01, low shutdown value. When required, use the numeric keys to set the new values. Press the Enter key. Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See Menu 12Calibration. Displays the corrected low shutdown value. Displays the analog input 01, low warning value. When required, use the numeric keys to set the new values. Press the Enter key. Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See Menu 12Calibration. Displays the corrected low warning value.
ANALOG INPUT 01 LO SDWN VALUE ANALOG INPUT 01 LO WARN VALUE
# ?
ANALOG INPUT 01 LO WARN VALUE
TP-6083 7/05
Section 2 Operation
81

Key Entry Display
ANALOG INPUT 01 HI WARN VALUE ?
Description
Displays the analog input 01, high warning value. When required, use the numeric keys to set the new values. Press the Enter key. Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See Menu 12Calibration. Displays the corrected high warning value. Displays the analog input 01, high shutdown value. When required, use the numeric keys to set the new values. Press the Enter key. Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See Menu 12Calibration. Displays the corrected high shutdown 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)
Returns the user to analog input 01. Displays analog inputs A02 to A07. Note: Press the down arrow to scroll through additional analog auxiliary inputs or enter the input number. Note: ECM engines have inputs A01--A07 and non-ECM engines have inputs A03--A07. Note: Press the right arrow at each analog auxiliary input for the following selections and settings: Warning enabled Shutdown enabled Inhibit time Warning delay time Shutdown delay time Low shutdown value Low warning value High warning value High shutdown value See the Analog Input 01 instructions for the complete procedure.
SETUP ANALOG AUXILIARY INPUTS
Returns the user to the setup analog auxiliary input heading.
SETUP DIGITAL AUXILIARY INPUTS
Returns the user to the setup digital auxiliary input heading.
82
Section 2 Operation
TP-6083 7/05
2.9.10 Menu 10Output 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. See the Software Operation Manual for details.
7 status events and faults are assignable as shutdowns or warnings with high or low settings for a total of up to 7 status events and fault functions.
Relay Driver Outputs (RDOs)

Up to 31 RDOs are available using the system, digital, and analog status events and faults. RDOs provide only the relay driver, not the relay. The contact relays that interface with other equipment are user supplied. Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned. Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify an RDO setting that is a NFPA 110 default requirement.
Common Faults
The user can program a single fault comprised of status and fault events from 3 common fault programs system, digital, and analog faults. Up to 46 user-defined system status and fault events are available. See Group B on the following pages for specific descriptions. The NFPA-110 faults are part of the system fault program and are comprised of 15 individual faults shown on the next page. Up to 21 user-defined digital status and fault events designated as D01 to D21 are available. Each of the 21 status events and faults are assignable as shutdowns or warnings. Up to 7 user-defined analog status events and faults designated as A01 to A07 are available. Each of the
Software Controlled RDOs (SCRDOs)

The SCRDO is set up and enabled using the keypad or PC. See the Software Operation Manual when reactivating the SCRDO. The user can deactivate an SCRDO at the controller. The user cannot reactivate the SCRDO at the controller. The procedure to deactivate the SCRDO appears at the end of Menu 10Output Setup, Displays with Entry KeysDeactivating the SCRDO. The user must enable the programming mode to edit the display.
TP-6083 7/05
Section 2 Operation
83
Menu 10Output Setup

Key Entry Display
Description
Input a menu number. Press the Enter key. Displays the menu number and name.
MAIN MENU NUMBER 10
MENU 10 OUTPUT SETUP DEFINE COMMON FAULTS SYSTEM EVENTS
Displays the common faults heading.
Displays the system events heading. Gives the user the option to add or delete the selection from the defined system events group. Press the Menu Down key to continue to the next selection (repeat as necessary). Entering YES adds the selection to the defined system event group. Press the Enter key.
COMMON FAULT (see Group B) COMMON FAULT (see Group B) COMMON FAULT (see Group B)
Y/N
NO
YES
COMMON FAULT (see Group B)
YES
Confirms the entry.
OR
COMMON FAULT (see Group B) COMMON FAULT (see Group B) COMMON FAULT (see Group B)
Group B
YES NO
Entering NO removes the selection from the defined system event group. Press the Enter key.
NO
Confirms the entry.

Group B, continued Group B, continued
For defined system events, choose from the following 46 status events and faults by changing selection to YES: EMERGENCY STOP OVER SPEED OVER CRANK HI COOL TEMP SHUTDWN OIL PRESS SHUTDOWN LOW COOLANT TEMP (non-ECM engines) LOW FUEL HI COOL TEMP WARNING OIL PRES WARNING MASTER NOT IN AUTO NFPA 110 FAULT (see Menu 10 overview for list) LOW BATTERY VOLTAGE HIGH BATTERY VOLTAGE BATTERY CHARGE FAULT
SYSTEM READY LOSS OF ECM COMM (ECM engines) NO OIL PRESS SIGNAL HI OIL TEMP NO COOL TEMP SIGNAL LOW COOLANT LEVEL SPEED SENSOR FAULT LOCKED ROTOR MASTER SWITCH ERROR MASTER SWITCH OPEN MASTER SWITCH TO OFF AC SENSING LOSS OVER VOLTAGE UNDER VOLTAGE WEAK BATTERY OVER FREQUENCY UNDER FREQUENCY LOAD SHED KW OVER
LOAD SHED UNDER FREQ OVER CURRENT EPS SUPPLYING LOAD INTERNAL FAULT DELAY ENG COOLDOWN DELAY ENG START STARTING AID GENERATOR RUNNING AIR DAMPER CONTROL GROUND FAULT EEPROM WRITE FAILURE CRITICAL OVERVOLTAGE ALTERNATOR PROTECTION SHUTDOWN AIR DAMPER INDICATOR DEFINED COMMON FAULT (RDO only) SCRDOs 1--4 (software controlled RDOs)
84
Section 2 Operation
TP-6083 7/05
Menu 10Output Setup, continued

Key Entry Display
DIGITAL INPUTS
Description
Displays the digital inputs heading. 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). Entering YES adds the selection to the defined digital fault group. Press the Enter key. Confirms the entry.
COMMON FAULT Dxx (see Group C) COMMON FAULT Dxx (see Group C) COMMON FAULT Dxx (see Group C) COMMON FAULT Dxx (see Group C)
Y/N
NO YES
YES
OR
COMMON FAULT Dxx (see Group C) COMMON FAULT Dxx (see Group C) COMMON FAULT Dxx (see Group C)
Group C
YES NO
Entering NO removes the selection from the defined digital fault group. Press the Enter key.
NO
Confirms the entry.
Up to 21 PC user-defined digital status and fault inputs designated as D01 to D21 can result in an digital input common fault.
ANALOG INPUTS
Displays the analog inputs heading. Gives the user the option to add or delete selection from the defined analog faults starting with A01. Note: Press the Menu Down key to continue to the next selection A02--A07 (repeat as necessary).
COMMON FAULT Y/N Axx(see Group D)LO WARNING

Group D
Up to 7 analog inputs, PC userdefined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high and low settings.
TP-6083 7/05
Section 2 Operation
85

Key Entry Display
COMMON FAULT Y/N A01 LO WARNING COMMON FAULT NO A01 LO WARNING COMMON FAULT YES A01 LO WARNING COMMON FAULT YES A01 LO WARNING
Description
Indicates whether the previously user-defined analog output was selected (yes or no) as a low warning fault. Entering YES adds the low warning selection to the defined analog fault group. Press the Enter key.
Confirms the entry.
OR
COMMON FAULT YES A01 LO WARNING COMMON FAULT NO A01 LO WARNING COMMON FAULT NO A01 LO WARNING
Entering NO removes the low warning selection from the defined analog fault group. Press the Enter key.
Confirms the entry.
COMMON FAULT Y/N A01 HI WARNING
Indicates whether the previously user-defined analog output was selected (yes or no) as a high warning fault. Entering YES adds the high warning selection to the defined analog fault group. Press the Enter key.
COMMON FAULT NO A01 HI WARNING COMMON FAULT YES A01 HI WARNING COMMON FAULT YES A01 HI WARNING
Confirms the entry.
OR
COMMON FAULT YES A01 HI WARNING COMMON FAULT NO A01 HI WARNING COMMON FAULT NO A01 HI WARNING
Entering NO removes the high warning selection from the defined analog fault group. Press the Enter key. Confirms the entry.
86
Section 2 Operation
TP-6083 7/05

Key Entry Display
COMMON FAULT Y/N A01 LO SHUTDOWN COMMON FAULT NO A01 LO SHUTDOWN COMMON FAULT YES A01 LO SHUTDOWN COMMON FAULT YES A01 LO SHUTDOWN
Description
Indicates whether the previously user-defined analog output was selected (yes or no) as a low shutdown fault. Entering YES adds the low shutdown selection to the defined analog fault group. Press the Enter key.
Confirms the entry.
OR
COMMON FAULT YES A01 LO SHUTDOWN COMMON FAULT NO A01 LO SHUTDOWN COMMON FAULT NO A01 LO SHUTDOWN
Entering NO removes the low shutdown selection from the defined analog fault group. Press the Enter key.
Confirms the entry.
COMMON FAULT Y/N A01 HI SHUTDOWN
Indicates whether the previously user-defined analog output was selected (yes or no) as a high shutdown fault. Entering YES adds the high shutdown selection to the defined analog fault group. Press the Enter key.
COMMON FAULT NO A01 HI SHUTDOWN COMMON FAULT YES A01 HI SHUTDOWN COMMON FAULT YES A01 HI SHUTDOWN
Confirms the entry.
OR
COMMON FAULT YES A01 HI SHUTDOWN COMMON FAULT NO A01 HI SHUTDOWN COMMON FAULT NO A01 HI SHUTDOWN COMMON FAULT Y/N A01 LO WARNING
Entering NO removes the high shutdown selection from the defined analog fault group. Press the Enter key.
Confirms the entry.
Returns the user to common fault (analog inputs) heading. Press the Menu Down key to continue to the next selection A02--A07 (repeat as necessary). Gives the user the option to add or delete selection from the next defined analog fault. Note: Use the A01 common fault analog input setup procedure shown above for A02--A07. To go
COMMON FAULT Y/N Axx(see Group D)LO WARNING

Group D
Up to 7 analog inputs, PC userdefined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high and low settings.
TP-6083 7/05
Section 2 Operation
87

Key Entry Display
ANALOG INPUTS
Description
Returns the user to analog inputs heading.
DEFINE COMMON FAULTS RELAY DRV OUT 01 (user defined)
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. Note: The RDO can be assigned from the SYSTEM EVENTS, DIGITAL INPUTS, or ANALOG INPUTS groups. The start of each of these groups are highlighted on the following pages.
SYSTEM EVENTS
Displays the system events heading.
RELAY DRV OUT 01 (see Group B)
Y/N
Gives the user the option to assign a system event to an RDO. Press the Menu Down key to continue to the next selection (repeat as necessary).
RELAY DRV OUT 01 (see Group B)
NO
Entering YES adds the selection to the RDO group. Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned. Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify the RDO setting that is a NFPA 110 default requirement. Press the Enter key.
RELAY DRV OUT 01 (see Group B) RELAY DRV OUT 01 (see Group B)
Group B
YES
YES
Confirms the entry.

Group B, continued
*NFPA 110 FAULT The 15 NFPA-110 Fault Alarms include the following: OVERSPEED OVERCRANK HIGH COOLANT TEMP SHUTDOWN OIL PRESSURE SHUTDOWN LOW COOLANT TEMPERATURE HIGH COOLANT TEMP WARNING OIL PRESSURE WARNING LOW FUEL MASTER NOT IN AUTO BATTERY CHARGER FAULT LOW BATTERY VOLTAGE HIGH BATTERY VOLTAGE LOW COOLANT LEVEL EPS SUPPLYING LOAD AIR DAMPER INDICATOR
For defined system events, choose from the following 46 status events and faults by changing selection to YES: EMERGENCY STOP OVER SPEED OVER CRANK HI COOL TEMP SHUTDWN OIL PRESS SHUTDOWN LOW COOLANT TEMP (non-ECM engines) LOW FUEL HI COOL TEMP WARNING OIL PRES WARNING MASTER NOT IN AUTO NFPA 110 FAULT* LOW BATTERY VOLTAGE HIGH BATTERY VOLTAGE BATTERY CHARGE FAULT SYSTEM READY LOSS OF ECM COMM (ECM engines) NO OIL PRESS SIGNAL HI OIL TEMP NO COOL TEMP SIGNAL LOW COOLANT LEVEL SPEED SENSOR FAULT LOCKED ROTOR
MASTER SWITCH ERROR MASTER SWITCH OPEN MASTER SWITCH TO OFF AC SENSING LOSS OVER VOLTAGE UNDER VOLTAGE WEAK BATTERY OVER FREQUENCY UNDER FREQUENCY LOAD SHED KW OVER LOAD SHED UNDER FREQ OVER CURRENT EPS SUPPLYING LOAD INTERNAL FAULT DELAY ENG COOLDOWN DELAY ENG START STARTING AID GENERATOR RUNNING AIR DAMPER INDICATOR GROUND FAULT EEPROM WRITE FAILURE CRITICAL OVERVOLTAGE ALTERNATOR PROTECTION SHUTDOWN DEFINED COMMON FAULT (RDO only)[ SCRDOs 1--4 (software controlled RDOs)
[DEFINED COMMON FAULT The 5 defined common faults include the following: EMERGENCY STOP HI COOL TEMP SHUTDOWN OIL PRESS SHUTDOWN OVERCRANK OVERSPEED
88
Section 2 Operation
TP-6083 7/05

Key Entry Display
DIGITAL INPUTS
Description
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.
RELAY DRV OUT 01 Dxx (see Group C)
Y/N
NO
Entering YES adds the selection to the RDO group. Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned. Note: Cannot Change (because the) NFPA is Enabled appears when the user attempts to modify the RDO setting that is a NFPA 110 default requirement. Press the Enter key.
YES

Group C
YES
Confirms the entry.
Up to user-defined digital status and fault inputs designated as D01 to D21 can result in a digital input common fault. ANALOG INPUTS
Displays the analog inputs heading. Gives the user the option to assign an analog input to an RDO starting with A01. Note: Press the Menu Down key to continue to the next selection A02-A07 (repeat as necessary).
RELAY DRV OUT 01 Y/N Axx(see Group D)LO WARNING

Group D
Up to 7 analog inputs, userdefined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high or low settings.
TP-6083 7/05
Section 2 Operation
89

Key Entry Display
RELAY DRV OUT 01 Y/N A01 LO WARNING RELAY DRV OUT 01 NO A01 LO WARNING RELAY DRV OUT 01 YES A01 LO WARNING RELAY DRV OUT 01 YES A01 LO WARNING
Description
Indicates whether the previously user-defined analog RDO was selected (yes or no) as a low warning fault. Entering YES adds the low warning selection to the defined analog RDO group. Press the Enter key.
Confirms the entry.
OR
RELAY DRV OUT 01 YES A01 LO WARNING RELAY DRV OUT 01 NO A01 LO WARNING RELAY DRV OUT 01 NO A01 LO WARNING RELAY DRV OUT 01 Y/N A01 HI WARNING RELAY DRV OUT 01 NO A01 HI WARNING RELAY DRV OUT 01 YES A01 HI WARNING RELAY DRV OUT 01 YES A01 HI WARNING
Entering NO removes the low warning selection from the defined analog RDO group. Press the Enter key.
Confirms the entry. Indicates whether the previously user-defined analog RDO was selected (yes or no) as a high warning fault. Entering YES adds the high warning selection to the defined analog RDO group.
Press the Enter key. Confirms the entry.
OR
RELAY DRV OUT 01 YES A01 HI WARNING RELAY DRV OUT 01 NO A01 HI WARNING RELAY DRV OUT 01 NO A01 HI WARNING
Entering NO removes the high warning selection from the defined analog RDO group. Press the Enter key.
Confirms the entry.
90
Section 2 Operation
TP-6083 7/05

Key Entry Display
RELAY DRV OUT 01 Y/N A01 LO SHUTDOWN RELAY DRV OUT 01 NO A01 LO SHUTDOWN RELAY DRV OUT 01 YES A01 LO SHUTDOWN RELAY DRV OUT 01 YES A01 LO SHUTDOWN
Description
Indicates whether the previously user-defined analog RDO was selected (yes or no) as a low shutdown fault. Entering YES adds the low shutdown selection to the defined analog RDO group. Press the Enter key. Confirms the entry.
OR
RELAY DRV OUT 01 YES A01 LO SHUTDOWN RELAY DRV OUT 01 NO A01 LO SHUTDOWN RELAY DRV OUT 01 NO A01 LO SHUTDOWN
Entering NO removes the low shutdown selection from the defined analog RDO group. Press the Enter key. Confirms the entry.
RELAY DRV OUT 01 Y/N A01 HI SHUTDOWN RELAY DRV OUT 01 NO A01 HI SHUTDOWN RELAY DRV OUT 01 YES A01 HI SHUTDOWN RELAY DRV OUT 01 YES A01 HI SHUTDOWN
Indicates whether the previously user-defined analog RDO was selected (yes or no) as a high shutdown fault. Entering YES adds the high shutdown selection to the defined analog RDO group. Press the Enter key. Confirms the entry.
OR
RELAY DRV OUT 01 YES A01 HI SHUTDOWN RELAY DRV OUT 01 NO A01 HI SHUTDOWN RELAY DRV OUT 01 NO A01 HI SHUTDOWN RELAY DRV OUT 01 Y/N A01 LO WARNING RELAY DRV OUT 01 Y/N Axx(see Group D)LO WARNING ANALOG INPUTS
Entering NO removes the high shutdown selection from the defined analog RDO group. Press the Enter key. Confirms the entry. Returns the user to the analog RDO (analog inputs) heading. Press the Menu Down key to continue to the next selection A02--A07 (repeat as necessary). Gives the user the option to add or delete a selection for the next analog RDO. Note: Use the A01 analog RDO setup procedure shown above for A02--A07. Go to Returns the user to the analog inputs heading. Press the Menu Right key.
RELAY DRV OUT 01 (user defined) RELAY DRV OUT XX (user defined)
Returns the user to the RDO 01 heading. Gives the user the option to add or delete a selection for the next RDO. Note: Use the RDO 01 setup procedure shown above for RDOs 02--31. Go to
TP-6083 7/05

Menu 10 Displays with Key Entries Deactivating the SCRDO
Key Entry Display
Description
MAIN MENU NUMBER 10
MENU 10 OUTPUT SETUP DEFINE COMMON FAULTS
Displays the menu number and name
Displays the common faults heading. Gives the user previously selected items for the relay driver outputs (RDO). Press the down arrow to scroll through relay driver outputs 1--31 or enter the RDO number. Locate the SCRDO display. When required (SCRDO is currently active), enter the YES key to deactivate the SCRDO.
RELAY DRV OUT XX SWARE CONTROLLED #X
DEACTIVATE RDO?
DEACTIVATE RDO?
YES
RELAY DRV OUT XX SWARE CONTROLLED #X
92
Section 2 Operation
TP-6083 7/05
2.9.11 Menu 11Voltage 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. Note: Press the Menu Right key prior to entering the decimal values where necessary. Note: 350-2000 kW models only, see 1.3.2 Voltage Regulator and Calibration Specifications regarding the use of the Marathon DVR 2000 voltage regulator.
Menu 11Voltage Regulator

Key Entry Display
Description
MAIN MENU NUMBER 11
MENU 11 VOLTAGE REGULATOR
AVG L-L V VOLT ADJ
# ?.?
AND
AVG L-L V VOLT ADJ AVG L-L V VOLT ADJ # ?.? # #.#
Displays the average line-to-line volts and voltage adjustment. Enter the desired nominal voltage using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
Confirms the entry.
L1-L2 VOLTS # L2-L3 VOLTS # L3-L1 VOLTS # AVG L-L V VOLT ADJ # #
Displays L1-L2 volts.
Displays L2-L3 volts (3 phase only).
Displays L3-L1 volts (3 phase only). Returns the user to the average line-to-line volts and voltage adjustment heading. Displays the under frequency (volts per Hz) unloading (yes or no) selection. Entering YES enables the underfrequency unloading feature. Press the Enter key. Confirms the entry.
UNDER FREQ UNLOAD ENABLED UNDER FREQ UNLOAD ENABLED UNDER FREQ UNLOAD ENABLED UNDER FREQ UNLOAD ENABLED
N/Y NO YES YES
TP-6083 7/05
Section 2 Operation
93
Menu 11Voltage Regulator

Key Entry Display
OR
UNDER FREQ UNLOAD ENABLED UNDER FREQ UNLOAD ENABLED UNDER FREQ UNLOAD ENABLED FREQUENCY SETPOINT # HZ ?.? HZ YES NO NO
Description
Entering NO disables the underfrequency unloading feature.
Press the Enter key. Confirms the entry.
Displays the operating frequency and underfrequency unloading cut-in point. Enter the desired underfrequency cut-in point using the numeric keys. Press the Menu Right key prior to entering the decimal value.
AND
FREQUENCY SETPOINT FREQUENCY SETPOINT # HZ ?.? HZ # HZ #.# HZ
Use the numeric keys to enter the decimal value. Press the Enter key.
Confirms the entry.
SLOPE ?.? VOLTS-PER-CYCLE
Displays the underfrequency unloading slope (volts-per-cycle). Enter the desired underfrequency unloading slope using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
SLOPE ?.? VOLTS-PER-CYCLE SLOPE #.# VOLTS-PER-CYCLE
Confirms the entry.
UNDER FREQ UNLOAD ENABLED REACTIVE DROOP ENABLED REACTIVE DROOP ENABLED REACTIVE DROOP ENABLED
N/Y N/Y NO YES YES
Returns the user to the underfrequency unloading heading.
Displays the reactive droop selection (yes or no).
Entering YES enables the reactive droop feature. Press the Enter key.
REACTIVE DROOP ENABLED
Confirms the entry.
OR
REACTIVE DROOP ENABLED REACTIVE DROOP ENABLED REACTIVE DROOP ENABLED YES NO NO
Entering NO disables the reactive droop feature. Press the Enter key.
Confirms the entry.
94
Section 2 Operation
TP-6083 7/05
Menu 11Voltage Regulator, continued

Key Entry Display
.8 PF RATED LOAD VOLTAGE DROOP ?.?%
Description
Displays the reactive (voltage) droop as a percentage of the rated voltage at rated load. When required, enter the desired reactive droop using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
.8 PF RATED LOAD VOLTAGE DROOP .8 PF RATED LOAD VOLTAGE DROOP ?.?% #.#%
Confirms the entry.
REACTIVE DROOP ENABLED VAR CONTROL ENABLED VAR CONTROL ENABLED VAR CONTROL ENABLED
N/Y N/Y NO YES YES
Returns the user to reactive droop selection heading. Displays the VAR control selection (yes or no). Entering YES enables the VAR control feature. Note: A YES entry disables the PF control if previously activated. Press the Enter key.
VAR CONTROL ENABLED
Confirms the entry.
OR
VAR CONTROL ENABLED VAR CONTROL ENABLED VAR CONTROL ENABLED YES NO NO
Entering NO disables the VAR control feature. Press the Enter key. Confirms the entry.
TOTAL KVAR KVAR ADJ
# ?.?
Displays total kVAR (running) and kVAR adjustment settings. Enter the desired kVAR adjustment using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
TOTAL KVAR KVAR ADJ TOTAL KVAR KVAR ADJ # ?.? # #.#
Confirms the entry. Displays the generating or absorbing kVAR selection. Note: The display sample may differ depending upon the previous entries. The generating selection is the factory default setting. Displays the generating kVAR selection. When required, use the NO key to choose absorbing kVAR. Press the Enter key.
GENERATING/ ABSORBING
N/Y
GENERATING
YES
GENERATING
NO
ABSORBING
YES
Confirms the entry.
TP-6083 7/05
Section 2 Operation
95

Key Entry Display
OR
ABSORBING ABSORBING YES NO
Description
Displays the absorbing kVAR selection. When required, use the NO key to choose generating kVAR. Press the Enter key.
GENERATING
YES
Confirms the entry.
VAR CONTROL ENABLED PF CONTROL ENABLED PF CONTROL ENABLED PF CONTROL ENABLED PF CONTROL ENABLED
N/Y N/Y NO YES YES
Returns the user to VAR control selection heading.
Displays the power factor control selection (yes or no). Entering YES enables the power factor control feature. Note: A YES entry disables the kVAR control if previously activated. Press the Enter key.
Confirms the entry.
OR
PF CONTROL ENABLED PF CONTROL ENABLED YES NO NO # ?.?
Entering NO disables the power factor conrol feature. Press the Enter key.
PF CONTROL ENABLED AVERAGE PF PF ADJ
Confirms the entry. Displays the average power factor and power factor adjustment settings. Enter the desired kVAR adjustment using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
AVERAGE PF PF ADJ AVERAGE PF PF ADJ # ?.? # #.#
Confirms the entry.
LAGGING/ LEADING
N/Y
Displays the lagging or leading PF selection. Note: The display sample may differ depending upon the previous entries. The lagging selection is the factory default setting. Displays the lagging PF selection. When required, use the NO key to choose leading PF. Press the Enter key.
LAGGING
YES
LAGGING
NO
LEADING
YES
Confirms the entry.
96
Section 2 Operation
TP-6083 7/05

Key Entry Display
OR
LEADING YES
Description
Displays the leading PF selection. When required, use the NO key to choose lagging PF. Press the Enter key.
LEADING
NO
LAGGING
YES
Confirms the entry.
PF CONTROL ENABLED
N/Y
Returns the user to the power factor control selection heading.
TP-6083 7/05
Section 2 Operation
97
2.9.12 Menu 12Calibration

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 7Generator System. Adjust the generator set voltage using Menu 11Voltage Regulator, when
required and adjust the frequency at the generator set governor before making calibration adjustments. Note: The user must scale the analog input value in order to calculate the low/high warning and shutdown analog values based on a 0--5 VDC scale. Note: ECM engines have user-defined analog inputs 01--07. Non-ECM engines have user-defined analog inputs 03--07 where analog inputs 01 and 02 are reserved for engine coolant temperature and oil pressure displays. Note: Press the Menu Right key prior to entering decimal values where necessary.
Menu 12Calibration
Key Entry Display
Description
MAIN MENU NUMBER 12
MENU 12 CALIBRATION
SCALE AC ANALOG INPUTS GEN L1-L0 V CALIB REF # ?.?
Displays the scale AC analog inputs heading. Measure the generator set output voltage for single and three-phase models between L1-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right key prior to entering the decimal value. Note: The generator set must be running for the following steps.
AND
GEN L1-L0 V CALIB REF # ?.?
GEN L1-L0 V CALIB REF GEN L2-L0 V CALIB REF
# #.# # ?.?
Confirms the entry. 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.
AND
GEN L2-L0 V CALIB REF GEN L2-L0 V CALIB REF # ?.? # #.#
Confirms the entry.
98
Section 2 Operation
TP-6083 7/05
Menu 12Calibration, continued

Key Entry Display
GEN L3-L0 V CALIB REF # ?.?
Description
Three-Phase Models only. Measure the generator set output voltage for three-phase models between L3-L0 using a voltmeter and enter the result using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
GEN L3-L0 V CALIB REF GEN L3-L0 V CALIB REF # ?.? # #
Confirms the entry.
# ?.?
Measure the generator set output current for single- and three-phase models at L1 using an AC ammeter and enter the result using the numeric keys. Press the Menu Right key prior to entering the decimal value.
AND
GEN L1 AMPS CALIB REF GEN L1 AMPS CALIB REF # ?.? # #
Confirms the entry.
# ?.?
Measure the generator set output current for three-phase models at L2 using an AC ammeter and enter the result using the numeric keys. Press the Menu Right key prior to entering the decimal value. Use the numeric keys to enter the decimal value. Press the Enter key.
AND
Confirms the entry.
# ?.?
AND
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. Use the numeric keys to enter the decimal value. Press the Enter key.
Confirms the entry.
RESTORE DEFAULTS? RESTORE DEFAULTS?
Displays the restore defaults selection (yes or no). When required, enter YES to activate the restore calibration defaults setting. Press the Enter key. Note: Entering Yes will delete all of the previously entered voltage and current data based on system voltage and kW and restore the calibration default settings. Confirms the entry.
YES
RESTORE DEFAULTS?
YES
TP-6083 7/05
Section 2 Operation
99
Menu 12Calibration, continued

Key Entry Display
MENU 12 CALIBRATION
Description
Returns the user to the menu number and name.
SCALE AC ANALOG INPUTS SCALE AUX. ANALOG INPUTS
Returns the user to the scale AC analog inputs heading.
Displays the scale auxiliary analog inputs heading. Gives the user the option to calibrate the auxiliary analog inputs for zero input signals. Note: ECM engines have inputs A01--A07 and non-ECM engines have inputs A03--A07. When required, enter YES to activate the auto-zero auxiliary analog inputs feature. Press the Enter key.
YES
YES
Confirms the entry.
ANALOG 01 SCALE VALUE 1
# ?
Displays the analog 01 and scale value 1 settings. Use the numeric keys to enter the minimum value based on the previously calculated 5 VDC analog input value. Note: There is no calibration available on analogs inputs 01 and 02 with non-ECM engines. Note: Press the Menu Right key to review both the scale value 1 and scale value 2 settings any time during the setup procedure. Displays analog 01 and scale value 2 settings. Use the numeric keys to enter the maximum value based on the previously calculated 5 VDC analog value. Returns the user to the scale auxiliary analog inputs heading.
SCAL 1 SCAL 2
#--#.#V #--#.#V
ANALOG 01 SCALE VALUE 2 SCALE AUX. ANALOG INPUTS
# ?
ZERO AUX. ANALOG INPUTS? ANALOG XX SCALE VALUE 1 # ?
Press the down arrow to go to the desired analog XX. Displays scale auxiliary analog inputs 01 to 07. Note: Press the down arrow to scroll through the additional analog auxiliary inputs 02--07. Note: Press the down arrow to scroll through the additional analog scale value 1 and value 2 for each analog selection. Note: Press the right arrow at each analog auxiliary input that provides display of the scale 1 and scale 2 voltage settings.
100 Section 2 Operation
TP-6083 7/05
2.9.13 Menu 13Communications

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. Use the Software Operation Manual when accessing this
menu, programming from a remote location, and determining address and system identification information. The user must enable the programming mode to edit the display. Modbusr is a registered trademark of Schneider Electric.
Menu 13Communications
Key Entry Display
Description
MAIN MENU NUMBER 13
MENU 13 COMMUNICATIONS PROTOCOL KBUS KBUS ONLINE
Displays the menu number and name. Displays the KBUS protocol heading.
Y/N
Displays the KBUS online selection. Entering YES activates the online KBUS selection. Press the Enter key.
KBUS ONLINE
NO
KBUS ONLINE
YES
KBUS ONLINE
YES
Confirms the entry.
OR
KBUS ONLINE KBUS ONLINE YES NO
Entering NO deactivates the online KBUS selection. Press the Enter key.
KBUS ONLINE
NO
Confirms the entry.
TP-6083 7/05
Menu 13Communications, continued

Key Entry Display
CONNECTION TYPE (USER DEFINED) Y/N
Description
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.
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
Entering YES selects the connection type shown. Note: Selecting one connection type deselects any previously selected choice.
YES YES Y/N
Confirms the entry. Displays the user-defined primary port subheading. Press the Down arrow key if the correct primary port type is displayed. If the desired primary port type is not displayed, press the Right arrow key until the desired primary port type appears. Entering YES selects the primary port shown. Note: Selecting one primary port deselects any previously selected choice.
PRIMARY PORTS RS-232 RS-485 ISO 1
Y/N N/Y
YES YES
Confirms the entry.
ADDRESS (LAN Connections)
Displays the LAN connection 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. Confirms the entry. Displays the system ID request. Use the numeric keys to enter the required system ID of remote connections. The system ID is a password. The user must use the same password for all devices at a site.
ADDRESS (LAN Connections) SYSTEM ID (Remote Connections)
SYSTEM ID (Remote Connections) BAUD RATE (USER DEFINED)
Confirms the entry. Displays the user-defined baud rate selection. Press the Down arrow key if the correct baud rate is displayed. If the desired baud rate is not displayed, press the Right arrow key until the desired baud rate appears.
Y/N
BAUD RATES 1200 2400 9600 Y/N N/Y N/Y
Entering YES selects the baud rate shown. Note: Selecting one baud rate deselects any previously selected choice.
TP-6083 7/05

Key Entry Display
BAUD RATE (USER DEFINED) BAUD RATE (USER DEFINED) YES YES
Description
Confirms the entry.
MENU 13 COMMUNICATIONS PROTOCOL KBUS PROTOCOL MODBUS MODBUS ONLINE
Returns the user to the menu number and name. Returns the user to kBUS protocol heading.
Displays the Modbus protocol heading.
Y/N
Displays the Modbus online selection (yes or no). Entering YES activates the online Modbus selection. Press the Enter key.
MODBUS ONLINE MODBUS ONLINE
NO YES
MODBUS ONLINE
YES
Confirms the entry.
OR
MODBUS ONLINE MODBUS ONLINE YES NO
Entering NO de-activates the online Modbus selection. Press the Enter key.
MODBUS ONLINE
NO
Confirms the entry. Displays the user-defined connection types. 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. Entering YES selects the connection type shown. Choices are a single or RS-232 to RS-485 convertor. Note: Selecting one connection type deselects any previously selected choice. Press the Enter key.
Y/N
CONNECTION TYPES SINGLE Y/N CONVERTOR N/Y YES YES Y/N
CONNECTION TYPE (USER DEFINED) CONNECTION TYPE (USER DEFINED)
Confirms the entry.
PRIMARY PORT (USER DEFINED) PRIMARY PORTS RS-232 RS-485
Displays the user-defined primary ports. Press the Down arrow if the correct primary port is displayed. If the desired primary port is not displayed, press the Right arrow key until the desired primary port appears. Entering YES selects the primary port shown. Note: Selecting one primary port deselects any previously selected choice.
Y/N N/Y
TP-6083 7/05

Key Entry Display
PRIMARY PORT (USER DEFINED) YES
Description
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. Confirms the entry. Displays the user-defined baud rate. Press the Down arrow key if the correct baud rate is displayed. If the desired baud rate is not displayed, press the Right arrow key until the desired baud rate appears. Entering YES selects the baud rate shown. Note: Selecting one baud rate deselects any previously selected choice. Press the Enter key.
ADDRESS
Y/N
BAUD RATES 9600 19200 BAUD RATE (USER DEFINED) N/Y N/Y YES
YES
Confirms the entry.
PROTOCOL MODBUS
Returns the user to Modbus protocol heading.
TP-6083 7/05
2.9.14 Menu 14Programming Mode

Menu 14 allows altering controller data either locally using the keypad or remotely using a PC or other device. 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. Remote programming is data alteration using devices connected to a communication port using KBUS or Modbusr. 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 to authorized individuals only. Should the controller logic not accept the access code or if the new code number is lost, contact your local authorized distributor/dealer for password information.
The user chooses one of three programming modes:

D Localusing the controller keypad D Remoteusing a PC D Offno programming is permitted
Enter Yes to one mode to change the other two choices to No. Note: Use the generator set controller to initially set up remote programming. Remote programming is not allowed from a PC unless the controller is first set for remote programming using Menu 14. Note: After completing the programming always place the controller back in the Programming Mode Off position to prevent inadvertent program changes. Modbusr is a registered trademark of Schneider Electric.
TP-6083 7/05
Menu 14Programming Mode

Key Entry Display
Description
MAIN MENU NUMBER 14
MENU 14 PROGRAMMING MODE PROGRAMMING MODE (USER DEFINED) Y/N
Displays the menu number and name. Displays the user-defined programming mode. Press the Down arrow key if the correct programming mode is displayed. If the desired programming mode is not displayed, press the Right arrow key until the desired programming mode appears. Entering YES selects the programming mode shown. Note: Selecting one programming mode deselects any previously selected choice. Press the Enter key. Changing the programming mode requires entering the access code. Enter the access code and press the Enter key. Note: The factory default access code is the number 0. Confirms the entry. Displays the programming mode and changes the access code. Press the Down arrow key if you do not wish to change the access code. To change the access code, press the Right arrow key. Enter the old access code and press the Enter key.
PROGRAMMING MODES OFF Y/N LOCAL N/Y REMOTE N/Y PROGRAMMING MODE (USER DEFINED) PROGRAMMING MODE ENTER CODE YES
PROGRAMMING MODE (USER DEFINED)
YES
PROGRAMMING MODE CHANGE ACCESS CODE
PROGRAMMING MODE ENTER OLD CODE PROGRAMMING MODE ENTER NEW CODE
Enter the new access code and press the Enter key.
PROGRAMMING MODE CHANGE ACCESS CODE MENU 14 PROGRAMMING MODE
Confirms the entry.
Returns the user to the programming mode heading.
TP-6083 7/05
2.9.15 Menu 20Factory 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.
Menu 20Factory Setup

Key Entry Display
Description
Input a menu number. Press the Enter key. Displays the menu number and name. Displays the final assembly date at the factory. Displays the final assembly clock number at the factory.
#
MAIN MENU NUMBER 20
MENU 20 FACTORY SETUP FINAL ASSEMBLY DATE DD/MM/YY FINAL ASSEMBLY CLOCK NO # OPERATING DAYS
Displays the generator set operating days. Displays the generator set model number. Displays the generator set specification number. Displays the generator set serial number. Displays the alternator part number. Displays the engine part number. Displays the generator set serial number. Displays the controller serial number. Displays the controller software (code) version.
MODEL NO
SPEC NO
GENSET SERIAL NO
ALTERNATOR PART NO
ENGINE PART NO
SERIAL NO
CONTROLLER SERIAL NO
CODE VERSION COPYRIGHT SETUP LOCKED
# XXXX YES
Displays the setup locked by the manufacturer.
TP-6083 7/05
Notes
TP-6083 7/05
Section 3 Scheduled Maintenance

Under normal operating conditions, the generator sets alternator requires no normal service. Consult Section 2.1, Prestart Checklist, for a list of routine checks.
Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
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.
WARNING
3.2 Engine Service

Perform engine service at the intervals specified in the engine manufacturers 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.
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
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.
Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Exposed moving parts can cause severe injury or death. Keep hands, feet, hair, and clothing away from belts and pulleys when unit is running. Replace guards, covers, and screens before operating generator set.
TP-6083 7/05
Section 3 Scheduled Maintenance 109
3.3 Service Schedule

Action SystemComponent Fuel System Day tank level Flexible lines and connections Fuel level switch Main tank supply level Solenoid valve operation Transfer pump operation Water in system, remove Filter(s) Gasoline supply Fuel piping Tank vents and return lines for obstructions Lubrication System Oil level Crankcase breather Change oil Replace filter(s)* Cooling System Air cleaner to room/enclosure Block heater operation Coolant level Flexible hoses and connectors Water pump(s) Fan and alternator belts Coolant temperature protection level Lubricate fan bearings (1350--2800 kW) Air ducts, louvers Coolant Heat exchanger Louver motors and controls Radiator exterior Water supply to heat exchanger Exhaust System Drain condensate trap Leakage Insulation, fire hazards Flexible connector(s) Excessive back pressure Hangers and supports DC Electrical System Battery charger operation, charge rate Battery electrolyte level Battery specific gravity, charge state Recharge after engine start Remove corrosion, clean and dry battery and rack Clean and tighten battery terminals Tighten DC electrical connections X X X X X X X X X Monthly Monthly Monthly Monthly Monthly Quarterly Six Months X X X X X X X Weekly Weekly Quarterly Six Months Yearly Yearly X X X X X D X X X X X D X D D D R D D X X D X Weekly Weekly Weekly Weekly Weekly Monthly Six Months 200 Hours or Six Months Yearly Yearly Yearly Yearly Yearly Yearly D D D D D D Weekly Quarterly 50 Hours or Yearly 50 Hours or Yearly X X X X D D R D X X X X X X X R X Weekly Weekly Weekly Weekly Weekly Weekly Weekly Quarterly Six Months Yearly Yearly Visually Inspect Check Change Clean Test Interval
D Follow procedures and frequencies indicated in the engine manufacturers maintenance manual. If not indicated, follow this service schedule. Some items may not apply to all generator sets. R Replace as necessary. X Action * Service more frequently if operated in dusty areas. 110 Section 3 Scheduled Maintenance TP-6083 7/05
Service Schedule, continued

Action SystemComponent 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 Transfer switch main contacts[ Voltage-sensing device/relay adjustment[ Wire-cable insulation breakdown Engine and Mounting General inspection Governor operation, lubricate moving parts Air cleaner service Choke, carburetor adjustment Governor oil (mechanical governor only) Ignition components Injector pump and injector flow rate, pressure, spray pattern Valve clearance Bolt torque Remote Control System, etc. Compartment condition Remote control Run generator set Alternator General inspection Rotor and stator Bearing condition Exciter Voltage regulator Measure and record resistance readings of windings with insulation tester (Megger, with SCR assembly or rectifier disconnected) Blow dust out of alternator* General Condition of Equipment Any condition of vibration, leakage, noise, temperature, or deterioration Ensure that system is set for automatic operation Interior of equipment room or outdoor weather housing X X X X X X Weekly Weekly Weekly X D X X X X X X X X R X X X X Weekly Yearly Yearly Yearly Yearly Yearly 2 Years or 300 Hours X X X X Weekly Monthly Monthly D D D D D D D D D D D D D D Weekly Monthly Six Months Six Months Yearly Yearly Yearly 3 Years or 500 Hours 3 Years or 500 Hours X X D X X X X X X X X X D X X R X X R Weekly Weekly Monthly Quarterly Six Months Yearly Yearly Yearly 3 Years or 500 Hours Visually Inspect Check Change Clean Test Interval
D Follow procedures and frequencies indicated in the engine manufacturers maintenance manual. If not indicated, follow this service schedule. Some items may not apply to all generator sets. R Replace as necessary. X Action. * Service more frequently if operated in dusty areas. [ Do not break manufacturers seals or internally inspect these devices.
TP-6083 7/05
3.4 Alternator Bearing Service

Have an authorized service distributor/dealer perform generator service.
Note: The illustration shows a generator set without a fuel/water separator. The valve location and position for a generator set equipped with a fuel/water separator is similar. 2. Loosen the bleed screw at the engine. Refer to the engine operation manual for location of the bleed screw(s). The bleed screw allows air to be expelled from the fuel system when the hand prime pump is operated. 3. Rotate the hand prime pump handle counterclockwise until fuel flows from the bleed screw. Stop pumping. 4. Tighten the bleed screw. Wipe up any fuel leakage. 5. Place the fuel valves in the normal operation position. Open the fuel valve located between the pipe tee and the engine. Close the fuel valves on each side of the fuel prime pump.
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.
3.4.2
350-2000 kW Models with Single-Bearing Alternator
The alternator bearing requires lubrication at intervals specified in the generator set technical manual. Use Chevron SRI or equivalent antifriction, high-quality grease with a lubrication temperature range of --30 to +175C (--22 to +350F).
3.4.3
1250-2800 kW Models with Two-Bearing Alternator
Refer to the generator set service manual for bearing maintenance information.
3.5 Diesel Fuel Systems

3.5.1 Bleeding Air from Fuel System
Close this Valve Open this Valve Open this Valve
Bleed air from the fuel system after fuel system maintenance, such as replacing the fuel filter(s) using the hand prime pump kit, when equipped. The hand prime fuel pump eliminates the need for cranking the engine to bleed air from the fuel system. Note: Bleed air from the fuel system according to the engine manufacturers instructions. Trapped air in the fuel system causes difficult starting and/or erratic engine operation. Note: Correct any fuel leaks encountered during the priming procedure. 1. Place the fuel valves in the fuel system prime position. Close the fuel valve located between the pipe tee and the engine. Open the fuel valves on each side of the fuel prime pump. See Figure 3-1.
Valve Open Figure 3-1
Valve Closed
PK-272000-H
Hand Prime Pump with Valve Positions for Fuel Priming (Generator Set Without a Fuel/Water Separator Shown)
112 Section 3 Scheduled Maintenance
TP-6083 7/05
3.5.2
Subbase Fuel Day Tank Electronic Control Module (ECM)
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.
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.
ECM Mode
The ECM has three pushbutton switches for normal operation and one internal test button. See Figure 3-4.
Pushbutton
Off On
Description
Pushbutton disables the ECM for routine maintenance to the tank system. Pushbutton activates the ECM after the OFF pushbutton is depressed. On power-up after a power outage, the ECM automatically turns on. Pushbutton lights front panel LEDs for 3 seconds and activates the pump/motor for as long as the pushbutton is depressed. The alarm relays maintain their original positions. Pushbutton (located inside the ECM) tests each alarm LED and remote annunciation relay in sequential order (high fuel to ECM functional).
Test
Internal test
224825
Figure 3-2
ECM Front Panel Layout Figure 3-4
Servicing the day tank. Hazardous voltage can cause severe injury or death. Service the day tank electrical control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power. Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution.
ECM Pushbuttons
ECM Alarms
The ECM has five standard alarm conditions indicated locally by LEDs and remotely by relays. Figure 3-5 describes the five alarm conditions. Make customer connections to the normally open and normally closed relay contacts provided.
Alarm
High fuel Low fuel
ECM General Function

The ECM controls a pump/motor that maintains the day tank fuel level. The ECM motor relay is connected to the pump/motor. The ECM starts the pump when the fuel level drops to 87% of full and stops the pump when the day tank is full.
Description
Alarm activates at 106% of normal fuel level. Alarm activates at 62% of normal fuel level. The alarm provides time to respond to a potential problem before a low fuel shutdown occurs. Alarm activates at 6% of normal fuel level to warn the operator to shut down the generator set before fuel runs out. Alarm activates when the ECM detects fuel in the rupture basin. Alarm activates to indicate a problem with the ECM operation. Note: The ECM functional alarm relay activates a customer-installed alarm when the relay deenergizes.
Critical low fuel (engine shutdown) Fuel in rupture basin, if equipped ECM functional
ECM Function Indicator LEDs

Two LEDs on the front panel indicate ECM operation. See Figure 3-2 for the locations of the LEDs. Figure 3-3 describes the LED functions.
Function
Power On Pump Running
Description
LED lights to indicate that power is applied to the ECM. LED lights when the pump starts.
Figure 3-5
ECM Alarms
Figure 3-3
ECM Function Indicator LEDs
TP-6083 7/05
3.5.3
Subbase Inner Fuel Tank Alarm
Resetting Procedure
Use the following procedure to reset the alarm after a fault alarm. 1. Move alarm switch to the SILENCE position to stop alarm horn. Lamp will remain lit. 2. Disconnect generator set from load with line circuit breaker or automatic transfer switch. 3. Repair or replace the inner fuel tank. 4. Move generator master switch to the OFF/RESET position and then to the RUN position for startup. Alarm horn sounds and lamp goes out. 5. Reconnect generator to load via line circuit breaker or automatic transfer switch. 6. Move generator master switch to the AUTO position for startup by remote transfer switch or remote start/stop switch. Move alarm switch to the NORMAL position.
Alarm Float Switch Switch Position Position Observation
Normal Normal Open Closed The alarm horn and the lamp are not energized. The alarm horn and lamp activate when a fuel leak occurs. If the alarm switch is moved to the silence position the lamp stays on until the fuel leak fault is corrected. The alarm horn sounds to alert the user that the alarm horn switch is not in the normal position and that the alarm horn will not sound should a fuel leak occur.
This kit provides for both audible and visual alarm from a location remote from the generator set if a leak is detected in the inner fuel tank of the double-wall subbase fuel tanks. See Figure 3-6. 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. The alarm horn is quieted by moving the alarm switch to the SILENCE position; the alarm lamp remains lit until the fault is corrected. See Figure 3-7 for troubleshooting information.
Inner Tank Fuel Leak Alarm
Alarm Normal Silence
Leak Alarm Panel
Silence
Open
Figure 3-7
Inner Fuel Tank Leak Alarm Troubleshooting
FF-273000-D
Figure 3-6
Inner Fuel Tank Leak Alarm (20--300 kW Model Shown)
TP-6083 7/05
3.6 Gas/Gasoline Fuel Systems

This section describes fuel systems that are not covered in the engine operation manual or engine service manual.
models require a different fuel kit when changing gas fuels. Consult your local generator distributor/dealer for additional information. Fuel conversion may decrease generator set output and affect exhaust emissions. Consult your local generator distributor/dealer for additional information. Fuel Conversion Procedure When converting the generator set to operate with LP gas, remove the internal spring from the secondary regulator. Install the spring to operate the generator set on natural gas. Note: Not all fuel regulators require spring and retainer removal for fuel conversion. A hang tag on the fuel regulator identifies the conversion procedure. LP Fuel Conversion Procedure Use the following steps to remove the internal spring from the fuel regulator: 1. Remove the fuel regulator cover plug. Figure 3-9. See
3.6.1
Gaseous Fuel System Concept
The gaseous fuel system uses a fuel valve with a solenoid to control the fuel flow to the fuel regulator. The generator-mounted regulator reduces the fuel pressure as fuel passes to the carburetor. See Figure 3-8. The carburetor/mixer controls the ratio of fuel to air under varying load and speed conditions. Because the carburetor receives fuel in a gaseous state, it does not have to vaporize the fuel. When switching from natural gas to LP gas or LP gas to natural gas, verify that the electronic governor maintains the rated engine speed (1800 rpm at 60 Hz or 1500 rpm at 50 Hz). If the engine speed is incorrect, refer to the generator service manual for the governor adjustment procedure.
2. Remove the adjustment screw and spring from the fuel regulator. Save the adjustment screw and spring for possible conversion back to natural gas. 3. Reinstall the cover plug. Natural Gas Fuel Conversion Procedure
TP-5750-3
1. 2. 3. 4. 5.
Primary regulator (supplied by gas supplier or customer) Pressure gauge Solenoid valve Secondary regulator Carburetor
Use the following steps to convert the generator set to natural gas: 1. Remove the fuel regulator cover plug. Figure 3-9. See
Figure 3-8
Fuel Regulator and Valve, Typical

1
3.6.2
LP Liquid Withdrawal Fuel System Concept
With the LP liquid withdrawal fuel system, pressurized liquid LP fuel passes from the tank to a vaporizer. The vaporizer converts the liquid fuel to gas before sending it to the carburetor. The system also includes a fuel valve that shuts off the fuel flow when the engine stops. Contact an authorized service distributor/dealer for availability.
3.6.3
LP Gas/Natural Gas Conversion for Straight Gas Fuel System
SB-527
Most models operate on either LP gas or natural gas fuel by performing the fuel conversion procedure. Some
TP-6083 7/05
1. Fuel regulator 2. Spring
3. Adjustment screw 4. Cover plug
Figure 3-9
Fuel Regulator, Typical

2. Replace the spring and adjustment screw. 3. Connect a manometer to check the fuel supply pressure on the carburetor side of the regulator after any fuel system equipment accessories. The recommended fuel supply pressures are shown in Figure 3-10 and on the generator set spec sheet.
Fuel Supply Pressure Generator Set Model
20--100 kW 30--100 kW 115/135 kW 135--180 kW 200--275 kW
Manual Changeover
A manual changeover fuel system allows manual changeover from gasoline to natural gas or LP gas, or from natural gas or LP gas to gasoline. Typically, the combination system uses gas as the primary, preferred fuel and gasoline in emergencies. If the primary fuel is unavailable (an empty fuel tank or fuel supply disruption), the system uses gasoline. A toggle switch on the generator set controls the fuel choice and energizes either a fuel solenoid and electric fuel pump for gasoline or a fuel valve for gas. Pull out the control cable for gasoline and push in the control cable for gas.
Engine
Ford GM Cummins Detroit Diesel Series 50 Detroit Diesel Series 60
kPa (oz./in.2)
1.7--27.4 (4--6) 1.7--27.4 (4--6) 3.5 (8) 1.2--5 (2.9--11.6) 1.2--5 (2.9--11.6)
Water Column, cm (in.)

18--28 (7--11) 18--28 (7--11) 36 (14) 13--51 (5--20) 13--51 (5--20)
3.6.5
Carburetor Adjustment
Figure 3-10 Recommended Fuel Supply Pressures 4. Adjust the fuel supply pressure with the generator set running at full load. Rotate the adjustment screw on the fuel regulator until the pressure indicated by the manometer matches the specified pressure. Use the lower pressure value if the generator set still provides good response and full power. Lower-than-specified pressures may result in poor response to load changes or lack of power. 5. Reinstall the cover plug.
Before adjusting the carburetor, verify that the engine compression and the ignition system meet specifications. Do not adjust the carburetor to compensate for other engine disorders. If the engine speed is incorrect, adjust the electronic governor to achieve 1800 rpm (at 60 Hz) or 1500 rpm (at 50 Hz). Adjust the carburetor if governor adjustment alone does not result in the desired engine speed. Adjusting the carburetor affects the engine fuel mixture. Routine carburetor adjustment is not necessary. However, if the carburetor is removed or tampered with, the carburetor may require adjustment to achieve optimum engine performance. Some engines have sealed carburetors that are not adjustable.
3.6.4
Fuel System Changeover Kits
Gasoline Carburetor Adjustment

Refer to the engine operation manual or engine service manual for gasoline carburetor adjustment information. Gaseous Carburetor (Fuel Mixer) Adjustment Procedure Use the following procedure to adjust the carburetor (fuel mixer). 1. Start the generator set and run it at approximately half load. 2. Adjust the engine fuel mixture screw (Figure 3-11) until the engine runs smoothly. 3. Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels. 4. Stop the generator set.
Automatic Changeover
A changeover fuel system kit provides automatic changeover from natural gas to LP gas vapor or from LP gas vapor to natural gas. The primary and backup fuels each have a secondary fuel regulator and a fuel valve. Typically, the primary fuel is natural gas; the backup fuel is LP gas vapor. When the generator set starts, the primary fuel valve opens and the backup fuel valve closes. The primary fuel line has a vacuum switch in series with a relay connected to the start/run circuit. When the primary fuel pressure drops below 0.6 kPa (1.4 oz./in.2) or 6.4 cm (2.5 in.) water column , a relay opens the backup fuel valve and closes the primary fuel valve. When the primary fuel pressure rises above 0.6 kPa (1.4 oz./in.2) or 6.4 cm (2.5 in.) water column, the generator set uses the primary fuel. Contact an authorized service distributor/dealer for kit availability.
TP-6083 7/05
3.6.6
Fuel System Maintenance
Gasoline Models
Clean or replace the fuel filter at the specified interval. Service the filters more frequently if the engine runs roughly, as a clogged fuel filter can cause rough engine operation. Some models use a disposable inline fuel filter, which must be replaced. Other models have a fuel pump with an integral fuel filter that requires cleaning at the specified interval.
Checking the coolant level. Hot coolant can cause severe injury or death. Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure, cover the 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.
Note: Engine damage. Bleed the air from the cooling system to prevent overheating and subsequent engine damage. Note: Block heater damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater.
Gaseous Models
This fuel system requires no regular maintenance.
1 2
3.7.1
3
Coolant Level Check
Check the coolant level in the coolant recovery tank. Maintain the coolant level between the high and low marks.
TP-5750-3
1. Fuel adjusting screw 2. Lean 3. Rich
Figure 3-11 Fuel Mixture Adjustment, Typical
Note: Periodically check the coolant level by removing the pressure cap. Do not rely solely on the level in the coolant recovery tank. Add fresh coolant until the level is just below the overflow tube opening of the filler neck.
3.7 Cooling System

The cooling system maintenance information applies to radiator-cooled models and city-water-cooled (heat exchanger) models. The cooling systems function similarly even though they use different components. Radiator-cooled models have a radiator with a pressure cap and coolant recovery tank. City-water-cooled models have a heat exchanger and an expansion/surge tank with a pressure cap. Note: The 20--40 kW Deutz engine-powered generator sets are oil cooled and therefore do not have a water cooling system.
3.7.2
Cooling System Component Inspection
To prevent generator shutdown or damage caused by overheating:

D Keep the cooling air inlets clean and unobstructed. D Inspect the radiators 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
any cracked, frayed, or spongy hoses.

D Check the condition and tension of the radiator fan
WARNING
and water pump belt(s). Follow the belt tension procedure in this manual and/or the engine operation manual.
D Check the pressure cap seal and replace a cracked or
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.
deteriorated cap. Remove dirt and other debris from the pressure cap and filler neck. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures. Replace a leaking pressure cap with one rated for the same pressure. The pressure cap rating usually appears on the pressure cap.
TP-6083 7/05
3.7.3
Cooling System Drainage Procedure
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 manufacturers 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. Note: A coolant solution of 50% ethylene glycol provides freezing protection to --37C (--34F) and overheating protection to 129C (265F). 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 regarding the coolant mixture to use in extreme temperatures. 6. Replace the pressure cap. 7. Fill the coolant recovery tank to the low mark. 8. Operate the generator set until the thermostat opens when the upper cooling system hose warms. 9. Stop the engine and allow it to cool. 10. Remove the pressure cap. 11. Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck. 12. Replace the pressure cap. 13. Maintain the coolant level in the coolant recovery tank between the high and low marks. Note: Air pockets often form in the engine water jacket when the coolant system is refilled. Check the coolant level in the coolant recovery tank after each generator set operation and add coolant as necessary until the coolant level stabilizes. Then check the coolant at the interval specified in the service schedule. 14. Reenergize the block heater, if equipped.
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 3.7.4, Procedure to Flush and Clean the Cooling System. If the cooling system does not have mineral deposits, go to Section 3.7.5, Procedure to Refill the Cooling System.
3.7.4
Cooling System Flushing and Cleaning Procedure
Use the instructions in the engine operation manual when available to flush and clean the cooling system. Otherwise, use the following procedure and the cooling system cleaner manufacturers 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 remove the remaining deposits following the manufacturers instructions. 3. Drain, clean, and flush the coolant recovery tank.
3.7.5
Cooling System Refilling Procedure
See the generator set spec sheet for coolant capacity. Note: Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait until the engine has cooled. 1. Remove the pressure cap. 2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps.
TP-6083 7/05
3.8 Radiator Expansion Joint LooseningInitial Setup Only

Loosen the radiator expansion joint nuts on 1200--2000 kW generator sets that have radiators manufactured by Young Radiator Company. Expansion joints located on each side of the radiator permit differential thermal expansion of the radiator tank. The factory tightens the 12 expansion joint nuts before generator set shipment. Loosen the expansion joint nuts one full turn before running the generator set. See Figure 3-12.
4 1 2 3
4. Inject grease into the two bearings on the fan shaft block and the two bearings on the idler shaft block using a grease gun until a 3--6 mm (0.13--0.25 in.) grease column shows at the bearing pressure relief port. See Figure 3-13.
1
5 2
TP-5353-3
4 2 3 1
1. 2. 3. 4. 5. Grease fittings Pressure relief port Radiator assembly Idler shaft grease fittings Fan shaft grease fittings
TP-5353-3
1. 2. 3. 4.
Air flow Expansion joint nuts for rear tank, left side Expansion joint nuts for front tank, left side Top front of radiator
Figure 3-12 Expansion Joint Nuts, Top Left Side of Radiator, Typical
3.9 Fan Bearing Lubrication

The following procedure applies only to 1200--2800 kW generator sets. Lubricate the radiator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage. Lubricate the bearings every 200 hours of operation when the generator set runs in ambient temperatures below 29C (85F) or when the generator set runs in a dusty and/or humid environment. Lubrication and Drive Belt Adjustment Procedure Lubricate the fan shaft and idler shaft bearings with a lithium-complex base, multi-purpose grease with antirust, antifoam, and extreme-pressure additives having a minimum dropping point of 204C (400F). Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent. 1. Place the generator set master switch in the OFF/RESET position. 2. Disconnect the generator set engine starting battery(ies), negative (--) lead first, and disconnect power to the battery charger. 3. Remove the belt guards to expose the fan shaft and idler shaft bearings.
Figure 3-13 Radiator Fan Bearings and Pressure Relief Ports, Typical Note: The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication. 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 3-14. If the belt slips after the belt tension procedure, clean the pulley surfaces and repeat the belt tension procedure. If slippage continues, replace the fan belt.
Generator Set Model
1200-2800 kW
New Belt, N (lbf.)

2450--2890 (550--650)
Used Belt*, N (lbf.)

1650--1910 (370--430)
* A belt is considered used after 50 hours of service.
Figure 3-14 Poly V-Belt Tension Specifications

TP-6083 7/05 Section 3 Scheduled Maintenance 119
7. Reinstall the belt guards using the original hardware. 8. Reconnect the generator set engine starting battery(ies), negative (--) lead last. 9. Test run the generator set for a few minutes and listen for belt noise (squeal) indicating a slipping belt. Stop the generator set.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid. Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
3.10 Battery
WARNING
Sulfuric acid in batteries. Can cause severe injury or death. Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
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. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases. Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.
Refer to this section for general battery information and maintenance. All generator set models use a negative ground with a 12-volt or 24-volt engine electrical system. Consult the generator set nameplate for the engine electrical system voltage. Consult the generator spec sheet for battery capacity recommendations for replacement purposes. The wiring diagrams provide battery connection information. See Figure 3-15, Figure 3-16, and Figure 3-17 for typical battery connections, including multiple battery configurations.
1 2 1 2
EZ-273000-J
1. To positive (+) terminal on starter solenoid. 2. To ground (--) terminal on or near starter motor.
Figure 3-15 12-Volt Engine Electrical System Single Starter Motor Typical Battery Connection
TP-6083 7/05
3.10.1 Cleaning
Clean the battery and cables and tighten the battery terminals according to the service schedule recommendations. Clean the battery by wiping it with a damp cloth. Keep the electrical connections dry and tight. If corrosion exists, disconnect the cables from the battery and remove the corrosion with a wire brush. Clean the battery and cables with a solution of baking soda and water. Do not allow the cleaning solution to enter battery cells. Flush the battery and cables with clean water and wipe the battery with a dry cloth.
2 1
1 2
After reconnecting the battery cables, coat the terminals with petroleum jelly, silicon grease, or other nonconductive grease.
3.10.2 Electrolyte Level Inspection

1. To positive (+) terminal on starter solenoid. 2. To ground (--) terminal on or near starter motor.
Check the electrolyte level and specific gravity of batteries that have filler caps. Maintenance-free batteries do not require electrolyte level checking or specific gravity testing. Check the electrolyte level before each startup. Remove the filler caps and verify that the electrolyte level reaches the bottom of each filler hole. See Figure 3-18. Refill as necessary with distilled water or clean tap water. Do not add fresh electrolyte. Tighten the filler caps. After adding water during freezing temperatures, run the generator set 20--30 minutes to mix the electrolyte and the water to prevent battery damage from freezing.
1
Figure 3-16 24-Volt Engine Electrical System Single Starter Motor Typical Battery Connection
KW-272000-B
1. 2. 3. 4.
To positive (+) terminal on starter solenoid. To ground (--) terminal on or near starter motor. To positive (+) terminal on second starter solenoid. To ground (--) terminal on or near second starter motor.
2
1-046
Figure 3-17 24-Volt Engine Electrical System Dual Starter Motors Typical Battery Connections
1. Filler caps 2. Electrolyte level
Figure 3-18 Battery Electrolyte Level Inspection
TP-6083 7/05
3.10.3 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. Locate the temperature in Figure 3-20 and correct the specific gravity by the amount shown. The battery is fully charged if the specific gravity is 1.260 at an electrolyte temperature of 26.7_C (80_F). Maintain the specific gravities between cells within 0.01 of each other. Charge the battery if the specific gravity is below 1.215 at an electrolyte temperature of 26.7_C (80_F). Note: Some battery testers have four or five beads in a test tube. Draw electrolyte into the tube as with the battery hydrometer described in this section or use the manufacturers instructions. Use Figure 3-19 to interpret typical test results.
Number of Floating Beads
71.1
160
Correction + .032 + .030
65.6
150
+ .028 + .026
Example No. 1 Temperature below 26.7C (80F) Hydrometer Reading 1.250 Acid Temperature --6.7C (20F) Subtract .024 Specific Gravity Corrected Specific Gravity is 1.226 1.250 -- .024 = 1.226
60.0
140
+ .024 + .022
54.4
130
+ .020 + .018
48.9
120
+ .016 + .014
43.3
110
+ .012 + .010
37.8
100
+ .008 + .006
Example No. 2 Temperature above 26.7C (80F) Hydrometer Reading 1.235 Acid Temperature 37.8C (100F) Add .008 Specific Gravity Corrected Specific Gravity is 1.243 1.235 + .008 = 1.243
32.2
90
+ .004 + .002
26.7
80
0 - .002 -
21.1
70
- .004 - 006 -.
15.6
60
- .008 - .010 -
10
50
- .012 - .014 -
Battery Condition
5 4 3 1 or 2 0
Overcharged Fully charged A good charge A low charge A dead battery
4.4
40
- .016 - .018 -
- 1.1 -
30
- .020 - .022 -
- 6.7 -
20
- .024 - .026 -
Figure 3-19 Bead-Type Test Interpretation
- 12.2 -
10
- .028 -
3.10.4 Charging
Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application. The engine battery-charging alternator charges the battery while the generator set is running. Note: If the generator set is in a temporary prime power application in which the generator set has periods of inactivity, the controller circuitry may drain the battery. If there is no power source for a battery charger, place the controller in the prime power mode, if equipped, or disconnect the battery from the generator set.
The temperature correction amounts to about .004 (4 points) of specific gravity for each 5.5C (10F) change in temperature.
1-787
Figure 3-20 Specific Gravity Temperature Correction
TP-6083 7/05
3.11 Detroit Diesel Engine Control (DDEC) System

Some generator sets equipped with Detroit Diesel engines use a DDEC system. Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting the engine. Use the following data for informational purposes only. Consult the engine literature for complete information regarding DDEC operation and troubleshooting. See List of Related Literature in the Introduction. Contact an authorized service distributor/dealer for service or diagnostic equipment.
Access the stored codes in one of three ways:

D Place the switch in the DIAGNOSTIC REQUEST
position. The CEL or SEL flashes to identify the failure.

D Use a hand-held diagnostic data reader (DDR).
Place the switch in the DIAGNOSTIC DATA READER position. Plug the DDR into the control box. The DDR displays the stored failure codes.
D Use a personal computer software package with a
translator to access stored codes. Follow the instructions provided with the software.
Code Types
Active code. A code flashing on the SEL lamp indicates a fault currently exists. Inactive code. A code flashing on the CEL lamp indicates a previous fault occurrence. The ECM memory stores inactive codes with time/date identification and the following information:
D First occurrence of each diagnostic code in engine
3.11.1 DDEC Features

The DDEC system optimizes control of critical engine functions and protects against serious engine damage resulting from conditions such as the following:
D Low coolant level D Low coolant pressure D High coolant temperature D Low oil pressure D High oil temperature
operating hours.
D Last occurrence of each diagnostic code in engine
operating hours. The major components of the DDEC system include the electronic control module (ECM), engine sensors, and control box, located in the generator set junction box.
D Total time in seconds that the diagnostic code was
active.
3.11.2 DDEC Engine Diagnostics

The DDEC engine protection system monitors engine sensors and electronic components and recognizes system malfunctions. Critical faults light the check engine (CEL) and stop engine (SEL) lamps on the control box. ECM memory software logs malfunction codes. Consult the engine operation manual or engine service manual to identify the stored failure code. See Figure 3-21 for the DDEC control box features.
3.12 Deutz Engine Control System

Some generator sets equipped with Deutz engines 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.
Deutz Engine Control Features

The Deutz engine control is an advanced-technology, electronic engine control system. The system optimizes control of critical engine functions and provides protection against serious engine damage.
A-343591-C
Figure 3-21 DDEC Control Box

TP-6083 7/05 Section 3 Scheduled Maintenance 123
The major components include the engine control module (EMR), engine sensors, and control box located in the generator set junction box. See Figure 3-22 for the Deutz control box features.
3.13.2 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. Run the generator set for 30 minutes to redistribute added coolant.
3.13.3 Fuel System

Prepare the fuel system for storage as follows: Diesel-Fueled Engines
A-364162-B
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 owners manual. Gasoline-Fueled Engines 1. Add stabilizer to the fuel system. Follow the manufacturers recommended procedure. 2. Run the generator set for 15 minutes to ensure that the stabilized fuel reaches the carburetor. Gas-Fueled Engines 1. Start the generator set.
Figure 3-22 Deutz Control Box
3.13 Storage Procedure

Perform the following storage procedure before taking a generator set out of service for three months or longer. Follow the engine manufacturers recommendations, if available, for fuel system and internal engine component storage.
3.13.1 Lubricating System

Prepare the engine lubricating system for storage as follows: 1. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature. 2. Stop the generator set.
2. With the generator set running, shut off the gas supply. 3. Run the generator set until the engine stops.
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.
4. Place the generator set master switch in the OFF/RESET position.
TP-6083 7/05
3.13.4 Internal Engine Components (Gas/Gasoline-Fueled Engines)

If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows: 1. While the engine is running, spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops. 2. Place the generator set master switch in the OFF/RESET position. If a fogging agent is not available perform the following: 1. Remove the spark plugs. 2. Pour 15 cc (0.5 oz.) of engine oil into each spark plug hole. Ignition System Damage. Refer to the engine operation manual for ignition system precautions before cranking the engine while the spark plug wires are disconnected. 3. Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders. 4. Reinstall the spark plugs and torque them to specifications.
3.13.5 Exterior
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 oil over unpainted metallic surfaces to inhibit rust and corrosion.
3.13.6 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 Section 3.10.1 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 manufacturers recommendations. Maintain a full charge to extend battery life.
TP-6083 7/05
Notes
TP-6083 7/05
Section 4 General Troubleshooting

This section contains generator set troubleshooting, diagnostic, and repair information. Use the following charts to diagnose and correct common problems. First check for simple causes such as a dead engine starting battery or an open circuit breaker. The charts include a list of common problems, possible causes of the problem, recommended corrective actions, and references to detailed information or repair procedures. Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or adjustments made to the equipment. Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown. When the battle switch function is enabled, the generator set continues to run regardless of shutdown signals where potential engine/generator damage can occur. When this input is enabled, the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5 Event History. See Section 2.9.9, Menu 9Input Setup, for information on how to enable the battle switch feature.
TP-6083 7/05
Section 4 General Troubleshooting 127
Trouble Symptoms
Excessive or abnormal noise
Cranks but does not start
Starts hard
No or low output voltage
Stops suddenly
Lacks power Overheats Low oil pressure
Does not crank
High fuel consumption
Probable Causes
Controller circuit board(s) inoperative Controller fault Troubleshoot the controller.[ Replace the blown controller fuse. If the fuse blows again, troubleshoot the controller.[ Replace the controller master switch. Controller fuse blown Controller master switch inoperative Controller master switch in the OFF/RESET position Engine start circuit open Replace the controller circuit board.
Recommended Actions
Section or Publication Reference*

Gen. S/M Gen. S/M Section 2, W/D
Controller
128 Section 4 Troubleshooting Move the controller master switch to the RUN or AUTO position. Section 2 x Air openings clogged Coolant level low Cooling water pump inoperative High temperature shutdown Low coolant level shutdown, if equipped x Thermostat inoperative Battery connections loose, corroded, or incorrect Battery weak or dead Starter/starter solenoid inoperative Engine harness connector(s) not locked tight High water temperature switch inoperative Fault shutdown High exhaust temperature switch inoperative x x x Clean the air openings. Restore the coolant to normal operating level. Tighten or replace the belt. Replace the water pump. Allow the engine to cool down. Then troubleshoot the cooling system. Restore the coolant to normal operating level. Replace the thermostat. Verify that the battery connections are correct, clean, and tight. Recharge or replace the battery. The spec sheet provides recommended battery CCA rating. Replace the starter or starter solenoid. Section 3 Section 3 Eng. S/M Section 3 Eng. S/M Disconnect the engine harness connector(s) then reconnect it to W/D the controller. Replace the inoperative switch. Reset the fault switches and troubleshoot the controller. Replace the inoperative switch. Section 2
Move the controller master switch to the RUN position to test the Section 2, W/D, generator set. Troubleshoot the auto start circuit and time Gen. I/M, S/M delays. ATS O/M, S/M
Cooling System
Eng. O/M or S/M Sec. 3, Eng. O/M
Electrical System (DC circuits)
Section 3, S/S
Gen. S/M or W/D
Gen. S/M or W/D
TP-6083 7/05
* Sec./Sectionnumbered section of this manual; ATSAutomatic Transfer Switch; Eng.Engine; Gen.Generator Set; I/MInstallation Manual; O/MOperation Manual; S/MService Manual; S/SSpec Sheet; W/DWiring Diagram Manual [ Have an authorized service distributor/dealer perform this service.
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
Does not crank
TP-6083 7/05
Trouble Symptoms
Probable Causes
Air cleaner clogged Clean or replace the filter element. Check the compression.[
Recommended Actions

Eng. O/M Eng. S/M
Engine x x Compression weak Engine overload x x Exhaust system leak TP-6083 7/05 x Exhaust system not securely installed Governor inoperative Adjust the governor.[ Adjust the valves.[ Tighten all loose hardware. Check the ignition system (spark plugs, spark plug wires, etc.). x Valve clearance incorrect Vibration excessive Ignition system inoperative (gas/gasoline only) Air in fuel system (diesel only) Ether canister empty or system inoperative, if equipped (diesel only) Fuel tank empty or fuel valve shut off x x x Fuel filter restriction Fuel solenoid inoperative x x x Fuel pressure insufficient (gas only) Fuel injection timing out of adjustment (diesel only) Fuel or fuel injectors dirty or faulty (diesel only) x x x x x x x x x x x x
Reduce the electrical load. See the generator set spec sheet for S/S wattage specifications. Inspect the exhaust system. Replace the inoperative exhaust system components.[ Inspect the exhaust system. Tighten the loose exhaust system components.[ I/M I/M Gen. S/M Eng. S/M Eng. O/M
Fuel System x Bleed the diesel fuel system. Replace or repair the ether starting system. Add fuel and move the fuel valve to the ON position. Eng. O/M Eng. O/M Eng. S/M Clean, test, and/or replace the inoperative fuel injector.[ Clean or replace the fuel filter. Troubleshoot the fuel solenoid.[ Check the fuel supply and valves.[ Adjust the fuel injection timing.[ Eng. S/M Eng. O/M Eng. S/M S/S, Gen. O/M Eng. S/M
Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ (diesel only)
Section 4 Troubleshooting 129
Trouble Symptoms
Starts hard
Stops suddenly
Lacks power Overheats Low oil pressure
Does not crank
Probable Causes
AC output circuit breaker open Transfer switch test switch in the OFF position Transfer switch fails to transfer load Wiring, terminals, or pin in the exciter field open Main field (rotor) inoperative (open or grounded) Stator inoperative (open or grounded) Test and/or replace the rotor.[ Test and/or replace the stator.[ Tighten loose components.[ Adjust the voltage regulator. Replace the voltage regulator fuse, If the fuse blows again, troubleshoot the voltage regulator. Adjust the voltage regulator. Check for continuity. Reset the breaker and check for AC voltage at the generator side of the circuit breaker. Move the transfer switch test switch to the AUTO position.
Recommended Actions

ATS O/M ATS O/M, S/M Gen. S/M, W/D Gen. S/M Gen. S/M Sec. 2, Menu 11 Gen. S/M Gen. S/M
Alternator
130 Section 4 Troubleshooting Move the ATS test switch to the AUTO position. Troubleshoot the transfer circuit and time delays. x Vibration excessive Voltage regulator digital settings incorrect (digital controller only) Voltage regulator inoperative Voltage regulator out of adjustment x Crankcase oil type incorrect for ambient temperature Oil level low Low oil pressure shutdown x x x x Change the oil. Use oil with a viscosity suitable for the operating Eng. O/M climate. Restore the oil level. Inspect the generator set for oil leaks. Check the oil level. Eng. O/M Eng. O/M
Lube System
bp #
TP-6083 7/05
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. Consult the generator set service manual for frequency adjustment information. Refer to the following procedure and the 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.
Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.
WARNING
Hazardous voltage. Moving rotor. Can cause severe injury or death. Operate the generator set only when all guards and electrical enclosures are in place. Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit breakers of all power sources before servicing the equipment. Configure the installation to electrically ground the generator set, transfer switch, and related equipment and electrical circuits to comply with applicable codes and standards. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution. 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.
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) Turn the generator set master switch and switchgear engine control switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the generator set by an automatic transfer switch or a remote start/stop switch.
TP-6083 7/05
Section 5 Generator Set Reconnection 131
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. Route leads through current transformers (CTs) and connect them according to the diagram for the desired phase and voltage. Note: Position current transformers CT1, CT2, and CT3 with the dot or HI side CT marking toward the generator set. 4. Reconnect the battery, negative lead last. 5. Go to Menu 14Programming Mode and select the Program ModeLocal. See Section 2.9.14, Menu 14Programming Mode, for the complete procedure.
6. Go to Menu 7Generator System and update the voltage information. See Section 2.9.7, Menu 7 Generator System, for the complete procedure. 7. Go to Menu 12Calibration and perform the calibration procedure. See Section 2.9.12, Menu 12Calibration, for the complete procedure. 8. Go to Menu 11Voltage Regulator and perform the voltage regulator setup procedure. See Section 2.9.11, Menu 11Voltage Regulator, for the complete procedure. 9. Move the generator set master switch to the RUN position to start the generator set. Check the digital display for correct voltages using Menu 1 Generator Monitoring. 10. Move the generator set master switch to the OFF/RESET position to stop the generator set after completing the voltage adjustments. 11. Replace the controller cover. 12. Place the generator set master switch in the AUTO or RUN position.
132 Section 5 Generator Set Reconnection
TP-6083 7/05
Figure 5-1
TP-6083 7/05
20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5857-B

Figure 5-2
20--400 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875A-F

TP-6083 7/05
Figure 5-3
TP-6083 7/05
60 (with Oversize Alternator)--400 kW Wound Field Alternators, ADV-5875B-F

Figure 5-4
350--2800 kW Pilot-Excited, Permanent Magnet Alternator, ADV-5875C-F

TP-6083 7/05
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. This section illustrates several accessories available at print time of this publication. Accessory kits generally include installation instructions. See wiring diagrams manual for electrical connections not shown in this section. See the installation instructions and drawings supplied with 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.
Kit Description Audiovisual Alarm Common Failure Relay (Terminal 32A) Controller (Customer) Connection Float/Equalize Battery Charger (with alarms) Idle (Speed) Mode Feature Low Fuel (Level) Switch Low Fuel (Pressure) Switch Prime Power Switch Remote Annunciator (16-light panel) Remote Emergency Stop Remote Reset Feature Remote Serial Annunciator (RSA 1000) Remote Speed Adjustment Potentiometer (requires electronic governor) Non-ECM models only Run Relay Single-Relay Dry Contact Ten-Relay Dry Contact Twenty-Relay Dry Contact Wireless Monitor
Figure 6-1
Optional Accessories
Front View Side View
6.1.1
Audiovisual Alarm Kit

FAULT
An audiovisual alarm warns the operator at a remote location of fault shutdowns and prealarm conditions. Audiovisual alarms include an alarm horn, an alarm silence switch, and common fault lamp. See Figure 6-2 and Figure 6-3. See Section 6.2, Accessory Connections, for terminal identification. Note: Use the audiovisual alarm with a dry contact kit. Figure 6-2
A-292887
Audiovisual Alarm
CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX
GM13984-
Figure 6-3
TP-6083 7/05
Audiovisual Alarm Connections

Section 6 Accessories 137
6.1.2
Common Failure Relay Kit
6.1.3
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.
Controller (Customer) Connection Kit
The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip. The supplied wiring harness connects controller connector P23 and terminal strips TB1-3 and TB1-4 to the controller connection kit connector P25 and terminal strips TB6, TB7, TB8, and TB9. Connect all accessories (except the emergency stop kit) to the controller connection kit terminal strips. See Figure 6-6. See Section 6.2, Accessory Connections, for terminal identification.
6.1.4
Float/Equalize Battery Charger Kit with Alarm Option
The float/equalize battery charger with alarm option provides battery charging to the engine starting battery(ies) and connects to the controller for fault detection. Battery chargers for 12- or 24-volt models are available as a generator set accessory. See Figure 6-7. See Section 6.2, Accessory Connections, for terminal identification.
C-294301
Figure 6-4
Common Failure Relay Kit
GM13984-
Figure 6-5
Common Failure Relay Kit Connections
138 Section 6 Accessories
TP-6083 7/05
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-6083 7/05
6.1.5
Idle (Speed) Mode Feature
The idle (speed) mode feature provides the ability to start and run the engine at idle (reduced) speed for a selectable time period (0--10 minutes) during warm-up. The controller will override the idle speed mode if the engine reaches the preprogrammed engine warmed-up temperature before the idle mode times out. See Figure 6-8 for user-supplied switch connection.
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.
6.1.7
Prime Power Switch Kit
The prime power switch kit prevents battery drain during generator set nonoperation periods and when the generator set battery cannot be maintained by an AC battery charger. See Figure 6-11 for an illustration of the kit and Figure 6-12 for the electrical connections.
1
PRIME POWER SWITCH
GM20652GM16088A-A
1. Prime power decal (293668)
2. Toggle switch (354464)
Figure 6-8
Idle (Speed) Mode Switch
Figure 6-11 Prime Power Switch Installation Location
6.1.6
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 6-9 and Figure 6-10. See Section 6.2, Accessory Connections, for terminal identification.
Toggle switch shown in the prime power mode off position (contacts open)
GM16088A-D GM16088A-A
Figure 6-12 Prime Power Switch Connections Figure 6-9 Low Fuel Switch (Level or Pressure)
12 volts DC min., 0.5 amp min. Low Fuel Switch Rating
Wiring Recommendation Gauge 18--20 14 10 mm (ft.) 30.5 (100) 153 (500) 305 (1000)
Stop the generator set using the stopping procedures in Section 2.3.2, Stopping, before placing the generator set in the prime power mode. Move the prime power switch located on the back of the controller to the DOWN position. The controller including the digital display, LEDs, and alarm horn does not function when the generator set is in the prime power mode. Move the prime power switch located on the back of the controller to the UP position and reset the controller time and date before attempting to start the generator set.
TP-6083 7/05
Figure 6-10 Switch Rating and Wiring Recommendation
6.1.8
Remote Annunciator Kit
Line Power. Lamp illuminates to indicate the power source is a commercial utility. Generator Power. Lamp illuminates to indicate the power source is the generator set. Also refer to Remote Serial Annunciator (RSA1000) in Section 6.1.11 for using Modbusr communications via RS-485 network.
A remote annunciator monitors the generator sets condition from a remote location. See Figure 6-13 and Figure 6-14. The remote annunciator includes an alarm horn, an alarm silence switch, a lamp test, and lamp indicators similar to the digital controller, plus the following:
Remote Annunciator
A-258782
14-Relay Dry Contact Box
42A
K1
K2
K3
K4
K5
K6
K7
K8
K9
K10
K11
K12
K13
K14
INPUT
CONTACT RATINGS: 10A @120VAC RES. LOAD .01A @28VDC MIN. 10A @28VDC MAX.
PCB ASSY A-320639
LOT NO.
NO
K1
NO
K2
NO
K3
NO
K4
NO
K5
NO
K6
NO
K7
NO
K8
NO
K9
NO
K10
NO
K11
NO
K12
NO
K13
NO
K14
42B P FBA-1 10 AMP
A-293983
Figure 6-13 Remote Annunciator with 14-Relay Dry Contact Kit
Modbusr is a registered trademark of Schneider Electric. TP-6083 7/05 Section 6 Accessories 141

GM13984-
354246B-
Figure 6-14 Remote Annunciator with 14-Relay Dry Contact Kit Connections
TP-6083 7/05
6.1.9
Remote Emergency Stop Kit
6.1.10 Remote Reset Feature

The remote reset switch provides generator set resetting after a fault shutdown at a remote location. See Figure 6-17 and Figure 6-18 for user-supplied switch connection. Press and hold the switch for 2--3 seconds and release to reset the generator set controller.
The emergency stop kit allows immediate shutdown of the generator set from a remote location. See Figure 6-15 and Figure 6-16. 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.
REMOTE RESET SWITCH CONTACTS NORMALLY OPEN MOMENTARY CLOSED TO ACTIVATE
A-222654 TP-5352-1
Figure 6-15 Emergency Stop Kit
GM16088A-A-
Figure 6-17 Remote Reset Switch Connections

Remote Reset Switch Rating 12 volts DC min., 1 amp min.
Wiring Recommendation Gauge 18--20 14 10

GM16088A-A
mm (ft.) 30.5 (100) 153 (500) 305 (1000)
Figure 6-18 Remote Reset Switch Rating and Wiring Recommendations
Figure 6-16 Remote Emergency Stop Kit Connections Use the single glass piece located inside the switch for replacement and order additional glass pieces as service parts. See Section 2.3.3, Emergency Stop Switch Reset Procedure. See Section 6.2, Accessory Connections, for terminal identifications.
TP-6083 7/05
6.1.11 Remote Serial Annunciator

The remote serial annunciator (RSA 1000) (Figure 6-19) monitors the condition of the generator set from a location remote from the generator set. If a generator set alarm condition occurs, the remote annunciator alerts the operator through visual and audible signals. The remote serial annunciator kit includes components for flush and surface mounting. One RSA (master) can support up to a maximum of three additional RSAs (slaves). The RSA will function as master or slave by changing the DIP switch position on the RSA board. If a generator set fault occurs, the RSA 1000 horn activates and the corresponding LED illuminates. Figure 6-20 shows the status of the system ready LED, generator set running LED, communication status LED, common fault LED, common fault output, and horn for each fault or status condition. See Figure 6-21 for RSA wiring connections. The RSA requires connection to the controller Modbusr RS-485 port. If the RS-485 port is needed for switchgear monitoring or a wireless monitor, the RSA cannot be connected to the controller. If the RS-485 port is unavailable, please select an alternate annunciator kit.
Overcrank High Engine Temp. Low Oil Pressure Overspeed Emergency Stop Low Coolant Level Low Coolant Temp. Low Fuel Battery Voltage User Input #1 User Input #2 User Input #3 Alarm Silenced
On=High, Blink=Low
Not-In-Auto Common Fault
System Ready Generator Running
Figure 6-19 Remote Serial Annunciator (RSA 1000)

Modbusr is a registered trademark of Schneider Electric.
Fault and Status Condition Overcrank Shutdown High Engine Temperature Warning High Engine Temperature Shutdown Low Oil Pressure Warning Low Oil Pressure Shutdown Overspeed Shutdown Emergency Stop Low Coolant Level Low Coolant Temperature Low FuelLevel or Pressure * EPS Supplying Load (550 Controller) EPS Supplying Load (RSA) System Ready System Not Ready No Device at Powerup Loss of Controller Comm. (Master RSA) Loss of Controller Comm. (Slave RSA) Not-In-Auto Battery Charger Fault * High Battery Voltage Low Battery Voltage User Input #1 (RSA) User Input #2 (RSA) User Input #1 (550 Controller) User Input #2 (550 Controller) User Input #3 (550 Controller) Common Fault SF = Slow Flash, FF = Fast Flash * May require optional kit or user-provided device to enable function and LED indication.
Fault LEDs Red Yellow Red Yellow Red Red Red Red Yellow Yellow Yellow Yellow Green Red Red Red Red Red Yellow Yellow Yellow Red Red Red Red Red Red
System Ready LED Red SF Red SF Red SF Red SF Red SF Red SF Red SF Red SF Red SF Red SF Green Green Green Red SF Off Off Off Red SF Red SF Green Green Green Green Red SF Red SF Red SF Green
System Monitoring LEDs and Functions Generator Comm. Common Common Running LED Status LED Fault LED Fault Output Off Green Off On Green Green Off On Off Green Off On Green Green Off On Off Green Off On Off Green Off On Off Green Off On Off Green Off On Off Green Off On Green Green Off On Green Green Off Off Green or Off Green Off Off Green or Off Green Off Off Green or Off Green Off On Off Red SF Off On Off Red FF Off On Off Red SF Off On Green or Off Green Off On Green or Off Green Off On Green or Off Green Off Off Green or Off Green Off Off Green or Off Green Off On Green or Off Green Off On Green or Off Green Off On Green or Off Green Off On Green or Off Green Off On Green or Off Green Red SF On
Horn On On On On On On On On On On Off Off Off On On On On On On Off Off On On On On On On
Figure 6-20 System Monitoring LEDs and Functions

144 Section 6 Accessories TP-6083 7/05
550 CONTROLLER
Figure 6-21 RSA Wiring Connections

TP-6083 7/05 Section 6 Accessories 145
16-LIGHT CONTROLLER
550 CONTROLLER
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 6-22. See Section 6.2, Accessory Connections, for terminal identifications.
6.1.13 Run Relay Kit

The run relay kit energizes only when the generator set runs. Use the run relay kit to control air intake and radiator louvers, alarms, and/or other signalling devices. See Figure 6-23 and Figure 6-24.
273705
Figure 6-23 Run Relay Kit
TB10
1
1. Optional Remote Speed Pot
BR-273000-C GM16088A-A
Figure 6-22 Remote Speed Adjustment Potentiometer Connection, Typical
Figure 6-24 Run Relay Connections
TP-6083 7/05
6.1.14 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. A total of three dry contact kits may connect to a single controller output. See Figure 6-25 and Figure 6-26. See Section 6.2, Accessory Connections, for terminal identifications.
Refer to Figure 6-27 for an internal view of the contact kit. See Figure 6-28 for electrical connections. See Section 6.2, Accessory Connections, for terminal identifications.
6.1.15 Ten-Relay Dry Contact Kit

The ten-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. Connect any controller fault output to the ten-relay dry contact kit. Typically, lamps, audible alarms, or other devices signal the fault conditions.
A-273945
Figure 6-25 Single-Relay Dry Contact Kit, Typical
GM16088A-A
Figure 6-26 Single-Relay Dry Contact Kit Connections
TP-6083 7/05
A-273936
Figure 6-27 Ten-Relay Dry Contact Kit
GM13984-/354246B-
Figure 6-28 Ten-Relay Dry Contact Kit Connections
TP-6083 7/05
6.1.16 Twenty-Relay Dry Contact Kit (450-2000 kW Models Only)

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 6-29 for an internal view of the contact kit. See Figure 6-30 for electrical connections. See Section 6.2, Accessory Connections, for terminal identifications. Figure 6-29 Twenty-Relay Dry Contact Kits
D-294303-D
GM16759D-C
Figure 6-30 Twenty-Relay Dry Contact Relay Kit Connections
TP-6083 7/05
6.1.17 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. There are three monitor models: GM23409-KP1 for use with hardwire inputs; GM23409-KP2 for use with a 550 controller using Modbusr communication; and GM23409-KP3 for use with a 550 controller using hardwire inputs that require a customer interface board. Note: The 550 controller supports only one connection for Modbusr communication. If the controllers RS-485 connection is already used for Modbusr communication with other equipment, use wireless monitor model GM23409-KP1 or -KP3 with hardwire inputs through a customer connection board for monitoring. Typical messages might include:
D Overcrank D Low oil pressure D Overspeed D Common fault
the wireless monitor is properly functioning, powered, and able to generate messages. If a device fails to report a nightly heartbeat for more than a day, the system sends a Unit Failed to Report Heartbeat alarm message to the website. Generator set run times and the number of cycles are reported. Models GM23409-KP1 and -KP3 accumulate run times over a 24-hour period and report the run times with the heartbeat message. Model GM23409-KP2 (for the 550 controller only) reports the total accumulated run time and the total number of starts. Run times for model GM23409-KP2 are also totaled using the Control Panel function and can be updated upon request. Upon power loss, a rechargeable battery powers the wireless monitor. The monitor continues to transmit messages for 15 minutes, then transmits a loss of power signal and enters the sleep mode. The sleep mode can last up to 18 hours, until the battery completely discharges or power is restored. The wireless monitor continues to send scheduled heartbeat messages during the sleep mode until the battery discharges completely.
86 [3.4]
At the website, the user configures which individuals will receive messages regarding selected operating conditions and the message delivery method. Delivery methods include pagers (alphanumeric, numeric), fax, XML, e-mail, PCS, or telephone (voice delivery). Each message sent will contain the condition that generated the transmission and also the make, model, and location of the equipment. Up to 40 messages each day can be delivered. Single or multiple messages can be sent to selected recipients via multiple delivery methods. More than one delivery method can be used for each recipient. The wireless monitor is powered by the equipment power source or by the generator set and constantly monitors the inputs. When an input is triggered, the wireless monitor sends the condition over the North American AMPS (advanced mobile phone system). An operations center server receives the transmission and forwards the message to the selected recipients according to the configured delivery method. Every 24 hours, the wireless monitor also sends information about itself and the system it is monitoring. This heartbeat transmission tells the Kohlerr center that
275 [10.8] 244 [9.6]
181 [7.1] 211 [8.3]
95 [3.75]
Dimensions are mm [in.]. All dimensions are approximate.
51 [2] C L
51 [2]
27 [1.06] G6-53
Figure 6-31 Wireless Monitor For additional information, please see TT-1370, Wireless Monitor Kits GM23409-KP4, KP5, and KP6, and TP-6223, PowerScant Wireless Monitor, operation manual.
Modbusr is a registered trademark of Schneider Electric 150 Section 6 Accessories TP-6083 7/05
6.2 Accessory Connections

The 550 controller contains circuit boards equipped with terminal strip(s) for easy connection of generator set accessories. Do not connect accessories directly to the controller terminal strip. Connect accessories to either a controller connection kit or a dry contact kit. Connect alarms, battery chargers, remote switches, and other accessories to the dry contact kit relay(s) using 18- or 20-gauge stranded wire up to 305 m (1000 ft.).
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 6-32 and Figure 6-33 for controller interconnection circuit board connections. See Figure 6-34 and Figure 6-35 for controller (customer) connection kit connections.
TOP OF CONTROLLER BACK PANEL
2 4
1. TB1 terminal strip 2. TB2 terminal strip 3. TB3 terminal strip
4. TB4 terminal strip 5. P23 Connector
GM16088A-A/GM10193B-A
Figure 6-32 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)
TP-6083 7/05
TB1 Terminal StripEngine Start and Emergency Stop Connections Term. 1 1A 3 4 Description Emergency stop ground Emergency stop Remote start Remote start
TB4 Terminal StripInput Factory Connections Term. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Description DCH1 Battery charger fault DCH2 Low fuel DCH3 Low coolant temp. with ECM models or warning default with non-ECM models DCH4 Field overvoltage with M4/M5/M7 alternators or warning default with non-M4/M5/M7 alternators DCH5 Breaker Closed, Paralleling Applications DCH6 Enable Synch, Paralleling Applications DCH7 Warning DCH8 Warning DCH9 Warning DCH10 Warning DCH11 AFM Shutdown, Waukesha engine DCH12 Detonation Warning, Waukesha engine DCH13 Detonation Shutdown, Waukesha engine DCH14 Low coolant level with 50--100ROZK models or warning default with all models except 50--100ROZK DCH15 Remote shutdown DCH16 Remote reset DCH17 VAR PF mode DCH18 Voltage lower DCH19 Voltage raise DCH20 Air damper DCH21 Idle mode functional with ECM-equipped engines only DCH1 Return DCH2 Return DCH3 Return DCH4 Return DCH5 Return DCH6 Return DCH7 Return DCH8 Return DCH9 Return DCH10 Return DCH11 Return DCH12 Return DCH13 Return DCH14 Return DCH15 Return DCH16 Return DCH17 Return DCH18 Return DCH19 Return DCH20 Return DCH21 Return
TB2 Terminal StripAnalog Input Connections Term. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Description ACH1 (CTS) Signal (non-ECM) ACH1 (CTS) Supply (non-ECM) ACH2 (OPS) Signal (non-ECM) ACH2 (OPS) Supply (non-ECM ACH3 Signal ACH3 Supply ACH4 Signal ACH4 Supply ACH5 Signal ACH5 Supply ACH6 Signal ACH6 Supply ACH7 Signal ACH7 Supply N/C ACH1 (CTS) Return (non-ECM) ACH1 (CTS) Shield ground (non-ECM) ACH2 (OPS) Return (non-ECM) ACH2 (OPS) Shield ground (non-ECM) ACH3 Return ACH3 Shield ground ACH4 Return ACH4 Shield ground ACH5 Return ACH5 Shield ground ACH6 Return ACH6 Shield ground ACH7 Return ACH7 Shield ground N/C
TB3 Terminal StripAccessory Power Output Connections Term. 1 2 3 4 5 6 7 8 9 10 11 12 Description +12 VDC (OEM use only) +12 VDC (OEM use only) +12 VDC (OEM use only) Fused battery (+) (42A) (5 Amp) Fused battery (+) (42A) (5 Amp) Fused battery (+) (42A) (5 Amp) Battery (--) Battery (--) Battery (--) Battery (--) Battery (--) Panel lamp output
Note: TB4-1 through TB4-21 are user definable with factory defaults listed. Terminals TB4-3, TB4-4, TB4-14, and TB4-21 have different functions depending upon the generator set configuration. See comments above. See Menu 9Input Setup for changing inputs.
Figure 6-33 Controller Terminal Strip Identification
TP-6083 7/05
GM13984-
Figure 6-34 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box
TB6 Terminal StripRDOs 1-7

Term. 42A GND N/C RDO1 RDO2 RDO3 RDO4 RDO5 RDO6 RDO7 Term. RDO8 RDO9 RDO10 RDO11 RDO12 RDO13 RDO14 RDO15 RDO16 RDO17 Term. 42A 42A 2 2 RDO18 RDO19 RDO20 RDO21 RDO22 RDO23 Description Battery (+) Battery (--) Overspeed (lead 39) Overcrank (lead 12) High coolant temperature shutdown (lead 36) Low oil pressure shutdown (lead 38) Low coolant temperature (lead 35) High coolant temperature warning (lead 40) Low oil pressure warning (lead 41) Description Low fuel (lead 63) Master switch not in auto ( lead 80) NFPA 110 common alarm (lead 32)* Battery charger fault (lead 61) Low battery voltage (lead 62) High battery voltage Emergency stop (lead 48) Generator set running (lead 70R) Time delay engine cooldown (TDEC) (lead 70C) System ready (lead 60) Description Battery (+) Battery (+) Battery (--) Battery (--) Defined common fault (lead 32A) Low coolant level Overvoltage (lead 26) Idle mode EPS supplying load Air damper indicator (lead 56)

Term. RDO24 RDO25 RDO26 RDO27 RDO28 RDO29 RDO30 RDO31 3 4 Description Speed sensor fault Loss of AC sensing ECM loss of communication Undervoltage Overfrequency Underfrequency Load shed kW overload Load shed underfrequency Remote start Remote start

Note:Lead numbers shown in parentheses are the factory default wire designations. Note:RDO-1 though RDO-31 are user definable with the following factory defaults: emergency stop, high coolant temperature, low oil pressure, overcrank, and overspeed *NFPA-110 common alarm faults include: Air damper indicator (RDO--23) Battery charger fault (RDO--11) EPS supplying load (RDO--22) High battery voltage (RDO--13) High coolant temperature warning (RDO--06) High coolant temperature shutdown (RDO--03) Low battery voltage (RDO--012) Low coolant level (RDO--19) Low coolant temperature warning (RDO--05) Low fuel (level or pressure) (RDO--08) Low oil pressure warning (RDO--07) Low oil pressure shutdown (RDO--04) Master switch not in auto (RDO--09) Overcrank (RDO--02) Overspeed (RDO--01)
Figure 6-35 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)
TP-6083 7/05
Notes
TP-6083 7/05
Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI ampere after bottom dead center alternating current analog to digital analog to digital converter adjust, adjustment advertising dimensional drawing 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 American Petroleum Institute approximate, approximately 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 audiovisual 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 California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate, certification, certified cubic feet per hour cfm CG CID CL cm CMOS cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate (semiconductor) cogen. cogeneration com communications (port) coml commercial Coml/Rec Commercial/Recreational conn. connection cont. continued CPVC chlorinated polyvinyl chloride crit. critical CRT cathode ray tube CSA Canadian Standards Association CT current transformer Cu copper cu. in. cubic inch cw. clockwise CWC city water-cooled cyl. cylinder D/A digital to analog DAC digital to analog converter dB decibel dBA decibel (A weighted) DC direct current DCR direct current resistance deg., degree dept. department dia. diameter DI/EO dual inlet/end outlet DIN Deutsches Institut fur Normung e. V. (also Deutsche Industrie Normenausschuss) DIP dual inline package DPDT double-pole, double-throw DPST double-pole, single-throw DS disconnect switch DVR digital voltage regulator E, emer. emergency (power source) EDI electronic data interchange EFR emergency frequency relay e.g. for example (exempli gratia) EG electronic governor EGSA Electrical Generating Systems Association EIA Electronic Industries Association EI/EO end inlet/end outlet EMI electromagnetic interference emiss. emission eng. engine EPA Environmental Protection Agency EPS emergency power system ER emergency relay ES engineering special, engineered special ESD electrostatic discharge est. estimated E-Stop emergency stop etc. et cetera (and so forth) exh. exhaust ext. F fglass. FHM fl. oz. flex. freq. FS ft. ft. lb. ft./min. g ga. gal. gen. genset GFI GND, gov. gph gpm gr. GRD gr. wt. HxWxD HC HCHT HD HET hex Hg HH HHC HP hr. HS hsg. HVAC HWT Hz IC ID IEC IEEE IMS in. in. H2O in. Hg in. lb. Inc. ind. int. int./ext. I/O IP ISO J JIS k K external Fahrenheit, female fiberglass flat head machine (screw) fluid ounce flexible frequency full scale foot, feet foot pounds (torque) feet per minute 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 temperature, high engine temperature hexagon mercury (element) hex head hex head cap horsepower hour heat shrink housing heating, ventilation, and air conditioning high water temperature hertz (cycles per second) integrated circuit inside diameter, identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal/external input/output iron pipe International Organization for Standardization joule Japanese Industry Standard kilo (1000) kelvin Appendix 155
AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert. cfh
TP-6083 7/05
kiloampere kilobyte (210 bytes) kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, k 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 L liter LAN local area network L x W x H length by width by height lb. pound, pounds lbm/ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld. shd. load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level, A weighted LWL low water level LWT low water temperature m meter, milli (1/1000) M mega (106 when used with SI units), male m3 cubic meter m3/min. cubic meters per minute mA milliampere man. manual max. maximum MB megabyte (220 bytes) MCM one thousand circular mils MCCB molded-case circuit breaker meggar megohmmeter MHz megahertz mi. mile mil one one-thousandth of an inch min. minimum, minute misc. miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm, m milliohm MOhm, M megohm MOV metal oxide varistor MPa megapascal mpg miles per gallon mph miles per hour MS military standard m/sec. meters per second MTBF mean time between failure
kA KB kg kg/cm2
mean time between overhauls mounting megawatt milliwatt microfarad normal (power source) not available, not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association NFPA National Fire Protection Association Nm newton meter NO normally open no., nos. number, numbers NPS National Pipe, Straight NPSC National Pipe, Straight-coupling NPT National Standard taper pipe thread per general use NPTF National Pipe, Taper-Fine NR not required, normal relay ns nanosecond OC overcrank OD outside diameter OEM original equipment manufacturer OF overfrequency opt. option, optional OS oversize, overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz. ounce p., pp. page, pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph., phase PHC Phillips head crimptite (screw) PHH Phillips hex head (screw) PHM pan head machine (screw) PLC programmable logic control PMG permanent-magnet generator pot potentiometer, potential ppm parts per million PROM programmable read-only memory psi pounds per square inch pt. pint PTC positive temperature coefficient PTO power takeoff PVC polyvinyl chloride qt. quart, quarts qty. quantity R replacement (emergency) power source rad. radiator, radius RAM random access memory RDO relay driver output ref. reference rem. remote Res/Coml Residential/Commercial RFI radio frequency interference RH round head RHM round head machine (screw)
MTBO mtg. MW mW F N, norm. NA nat. gas NBS NC NEC NEMA
rly. rms rnd. ROM rot. rpm RS RTV SAE scfm SCR s, sec. SI SI/EO sil. SN SPDT SPST spec, specs sq. sq. cm sq. in. SS std. stl. tach. TD TDC TDEC TDEN TDES TDNE TDOE TDON temp. term. TIF TIR tol. turbo. typ. UF UHF UL UNC UNF univ. US UV V VAC VAR VDC VFD VGA VHF W WCR w/ w/o wt. xfmr
relay root mean square round read only memory rotate, rotating revolutions per minute right side room temperature vulcanization Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international dunites, International System of Units side in/end out silencer serial number single-pole, double-throw single-pole, single-throw specification(s) square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal telephone influence factor total indicator reading tolerance turbocharger typical (same in multiple locations) underfrequency ultrahigh frequency Underwriters Laboratories, Inc. unified coarse thread (was NC) unified fine thread (was NF) universal undersize, underspeed ultraviolet, undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer
156 Appendix
TP-6083 7/05
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.
RDO-25 0 (zero) User-Defined A1--A7 Default values with Warning Enabled: HI warning 90%, LO warning 10%, HI shutdown 100%, LO shutdown 1% Default values with Warning Enabled: HI/LO warning and HI/LO shutdown are all engine dependant 30 sec. inhibit, 5 sec. delay 0--60 0--60
Note: The engine ECM may limit the crank cycle even if the controller is set to a longer time period.
Status or Fault
AC Sensing Loss Access Code (password) Analog Aux. Inputs 1--7
Refer to Menu
10 14 9
Digital Display
AC Sensing Loss
Range Setting
Inhibit Time Time Delay* Delay Default Selection (sec.) (sec.)
User-Defined Settings
Not adjustable
Analog Aux. Input 1
Coolant Temperature
30 sec. inhibit, 0 sec. delay
0--60
0--60
Analog Aux. Input 2
Oil Pressure
Default values with 30 sec. Warning Enabled: inhibit, HI/LO warning and 0 sec. delay HI/LO shutdown are warning, all engine dependant 5 sec. delay (255 psi max.) shutdown 1--6 crank cycles 10--30 sec. crank on 1--60 sec. pause 3 cycles 15 sec. 15 sec. 30 sec. inhibit, 5 sec. delay
0--60
0--60
Cyclic Cranking
Defined Common Faults
10
User-Defined
RDO-18
Default shutdowns include: Emergency stop High coolant temp Low oil pressure Overcrank Overspeed
0--60
0--60
Digital Aux. Inputs 1--21 EPS (Emergency Power System) Supplying Load High Battery Voltage High Coolant Temperature Shutdown High Coolant Temperature Warning High Oil Temperature Shutdown
User-Defined D1--D21 EPS Supplying Load High Battery Voltage Hi Cool Temp Shutdown Hi Cool Temp Warning Hi Oil Temp Shutdown RDO-15
30 sec. inhibit, 5 sec. delay 5% of rated line current
0--60
0--60
10
10 10
RDO-13 RDO-03
14.5--16.5 (12V) 29--33 (24V)
16 (12V) 32 (24V) 30
10 5 Not adjustable
10
RDO-06
30
Not adjustable
10
RDO-17
30
Not adjustable
* Inhibited time delay is the time delay period after crank disconnect. TP-6083 7/05 Appendix 157
Status or Fault
Idle (speed) Mode Function Digital Aux. Input D21 Load Shed kW Overload Load Shed Underfrequency Low Battery Voltage Low Coolant Level (Low) Oil Pressure Shutdown (Low) Oil Pressure Warning No Coolant Temperature Signal No Oil Pressure Signal Overcrank Shutdown Overcurrent Overfrequency Shutdown Overspeed Shutdown Overvoltage Shutdown Password (access code) Time Delay Engine Cooldown (TDEC) Time Delay Engine Start (TDES) Time Delay Starting Aid Underfrequency Shutdown Undervoltage Shutdown Weak Battery
Refer to Menu
9
Digital Display
Idle Mode Active

RDO--21
Range Setting
Inhibit Time Time Default Delay* Delay Selection (sec.) (sec.)

0 sec. inhibit, 60 sec. delay 0--600
User-Defined Settings
10
Load Shed KW Over Load Shed Under Frequency Low Battery Voltage Low Coolant Level Oil Pressure Shutdown Oil Pressure Warning No Cool Temp Signal No Oil Pressure Signal Over Crank Over Current Over Frequency Over Speed Over Voltage
RDO-30
80%--120%
100% of kW rating with 5 sec. delay 59, (60 Hz) 49, (50 Hz)
2--10
10
RDO-31
10 10 10
RDO-12 RDO-14 RDO-04
10--12.5 (12V) 20--25 (24V)
12 (12V) 24 (24V) 30 30
10 5 5 Not adjustable Not adjustable
10
RDO-07
30
Not adjustable
10
30
Not adjustable
10
30
Not adjustable
8 10 7, 10 7, 10 7, 8, 10 14 8, 10
RDO-02
0--6 cycles
3 cycles 110% 10 10 0.25 2--10
RDO-28 RDO-01 RDO-20
102%--140% 65--70 (60 Hz) 55--70 (50 Hz) 105%--135%
140% std. 103% FAA 70 (60 Hz) 60 (50 Hz) 115% 2-sec time delay 0 (zero)
See Access Code entry
RDO-23
00:00--10:00 min:sec
5:00
8, 10
00:00--5:00 min:sec 0--10 sec. Under Frequency Under Voltage Weak Battery RDO-29 RDO-27 80%--95% 70%--95%
00:01
8, 10 7, 10 7, 8, 10 10
90% 85% 10-sec time delay 60% of nominal
10 5--30
RDO-26
* Inhibited time delay is the time delay period after crank disconnect.
158 Appendix
TP-6083 7/05
Appendix C Voltage Regulator Definitions and Adjustments

The following Definitions and Adjustment and Setting Specifications are intended for users planning to adjust the voltage regulator beyond the default settings in order to customize the voltage regulator 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. Any user planning to change the generator set controller adjustment settings or to apply the generator set to these types of applications should understand these terms. This appendix contains references to other sections of this manual. Please refer to these sections for further information and explanation. Paralleling generator sets can be a complicated and dangerous exercise. Application programming must be performed by appropriately skilled and suitably-trained personnel. since it is the power in the alternator that translates into engine torque, the engine load is also reduced. By changing various parameters of this compensation technique, the controlling system can be tailored to match the performance capabilities of nearly any combination of engine and alternator. The point at which the unloading begins to act or how much unloading occurs can be adjusted to impact such things as maximum voltage droop, maximum speed droop, or time to recover. Some applications may not need any unloading and, in these cases, set the unloading parameter to disable the function. These parameters are further described below. An example is provided to help clarify the relationship between these parameters.
Underfrequency Unload Slope

Underfrequency unload slope is the term used to describe the amount that the voltage is reduced, per-cycle-per-second or per-hertz (Hz), when in an underfrequency condition. The slope or schedule is sometimes called the volts-per-hertz slope. When the electrical frequency drops below the cut-in point (see below), the excitation control system temporarily reduces the regulated voltage to reduce the subsequent torque on the engine. The amount that the control system reduces voltage is defined as the product or multiplication of the slope and the amount of frequency or speed below the cut-in point. For every Hz below the cut-in point, the control system reduces the line-to-line voltage by an amount equal to the slope. Because each engine responds differently to the various loads encountered, the slope may be adjusted to improve the system response. If, when large loads are applied to the generator set, the engine speed drops below the acceptable limit (as determined by the particular loads applied), the slope may need to be increased. Increasing the slope will cause the voltage to droop more during load applications, consequently reducing the load torque on the engine and allowing the speed to increase. If, however, the voltage drops below an acceptable lower limit (as determined by the particular loads connected to the generator set), a lower slope may work better. The underfrequency unloading function may be disabled by setting the slope to zero.
Definitions
Underfrequency Unloading
Underfrequency unloading is a function used in the generator excitation control system to improve the overall generator set system (engine and alternator) response. In particular, underfrequency unloading relates to large-block load applications. When applied to engine-driven generators, large-block loads cause a subsequent transient torque load on the engine. This torque load can reduce the engines speed below the normal operating point. Typically, the engine speed controller or governor will compensate for this by commanding an increase in fuel. If, however, the fuel system is inadequate to recover from a relatively large load, the speed may never recover. In these instances, other measures must be taken. This is where the underfrequency unloading occurs. When the excitation control system detects a drop in the speed or electrical frequency below some predetermined point, the control system enters an unloading condition. This can be described as moving to a lower voltage regulation point. By reducing the output voltage of the alternator, the load on the generator set is, in effect, reduced. This can be shown mathematically by Ohms law, which states that power is equal to the voltage squared divided by the impedance. As the voltage is reduced, the power delivered by the alternator decreases by a squared relationship and
TP-6083 7/05
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 systems performance, the engines response
Appendix 159
should determine the unloading point. The unloading setpoint is the frequency below which the excitation control will reduce the voltage so that the engine may begin to recover. The cut-in point, or frequency setpoint, should be set 0.5--1.0 Hz lower than the normal steady-state band of operation. If the engine normally operates within a very narrow range of speeds close to the nominal, a setpoint of 0.5 to 1.0 Hz below nominal should be suitable. If the engine normally operates over a wide range of speeds, the setpoint may need to be 2.0--3.0 Hz from the nominal. The underfrequency unloading function can be eliminated by setting the cut-in point below the minimum expected operating frequency. Example A 90 kW load is applied to a 100 kW, 60 Hz generator set driven by a turbocharged diesel engine with an electronical control module (ECM). The speed drops 10% and takes 20 seconds to recover to at least 59.5 Hz. The voltage, meanwhile, drops from 480 to 460 and recovers to 480 within 15 seconds. Therefore, some underfrequency unloading should be provided. A good starting point would be a frequency setpoint or cut-in of 59 Hz. A slope of 8 volts per-cycle-per-second is appropriate as well. If after these adjustments the speed recovers very quickly, in about 5 seconds, but the voltage drops below 440 volts, the slope should be reduced to 6 volts per cycle. More adjusting may be required to get the most desirable compromise between speed and voltage.
single-phase sensing excitation controller will keep the voltage of the sensed phase at the voltage adjustment value. A three-phase sensing system will average the three phases and hold the average to the adjustment setting. The average is the sum of the voltages of three phases divided by 3. As stated above, three-phase sensing does not eliminate the unequal voltage phenomenon. Three-phase sensing balances the inequality of voltage between the phases to the desired value. In other words, if a system with unbalanced loads uses a single-phase control feedback, the voltage on the sensed phase would be at the setpoint while the other two phases would vary by their proportional loads. For example, if the sensed phase had rated load while the two other phases were only loaded at half the rated value, those two phases would have higher-than-rated voltage which may be undesirable. If a three-phase sensing feedback were utilized, the phase with rated load would be regulated to a voltage slightly below the rated voltage while the other two phases would be slightly above the rated voltage (but lower than in the previous case). The line-to-line voltages and line-to-neutral voltages have a known relationship of the 3 (square root of 3): V l-l = V l-n * 3 Where: V l-l is the line-to-line voltage V l-n is the line-to-neutral voltage It is possible to regulate the line-to-line voltage by monitoring the line-to-neutral voltages. This is the method used by the 550 controller. The average of the line-to-neutral voltages is regulated (try to keep constant) to a value corresponding to the line-to-line voltage adjust setting. See Adjustment and Setting Specifications. In a single-phase system, the average value of the two line-to-neutral voltages is held equal to the line-to-line voltage adjust setting divided by two. In a three-phase system, the line-to-line neutral voltage (average of three) is regulated to the voltage adjust setting divided by 3. Because these relationships (1/3 in three phase or 1/2 in single phase) may vary when the loading is severely unbalanced or nonlinear, the average of the line-to-line voltages may vary slightly from the actual setting. In some cases, it may be desirable to keep one phase at a particular value. Modify the voltage adjust setting higher or lower accordingly for any unique requirements for the particular application.
Three-Phase Sensing
Three-phase sensing describes how the excitation control or voltage regulator determines the condition of the generator output voltage. Early types of regulators sensed the voltage on just one phase of the alternator. Single-phase sensing is not uncommon today as most alternators are designed to produce balanced, equal voltage on all three phases. If the loads applied to the generator set including no load are equal and balanced, the output voltage on each phase will be nearly equal. However, in some applications, individual phases may have unequal or unbalanced loads. In these cases, the output voltages will not be equal on each phase. In general, the phase with the greatest load will have the lowest voltage while the phase with the least load will have the highest voltage. This is true regardless of the type of sensing used in the regulator system. A
160 Appendix
TP-6083 7/05
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 sets excitation. Rather, it is determined by the combination of the excitation level, the generated voltage, and the voltage drop across the armature impedance or armature reactance for each generator set. Normally the generated voltage is higher than the voltage at the terminals because the generator set current causes a drop across the armature impedance. In a parallel application, the generated voltage of one generator set may be slightly higher than the generated voltage of another generator set. Differences in potential between the generator sets will cause current to flow into the lower voltage generator set and will also cause the generator sets to share the load current disproportionately. Both results are undesirable. By introducing reactive droop, the reactive current can be better predicted and controlled. If the current is measured, the regulator/controller can adjust the excitation up or down accordingly, reducing excitation as more current is supplied or increasing excitation as the reactive current decreases. If all the parallel generator sets incorporate this type of compensation, the reactive current can be shared equally based on the proportional size of the generator sets. For an example, see below. The stability and accuracy of this technique depends on several factors. Most important, the regulation point for each generator set must be equal. That is, each voltage adjust setting must be the equal to the other(s). This is a basic requirement prior to the actual paralleling connection. Also, the effects of the reactive current in each generator set must be compensated for individually, which requires an adjustable droop for each generator set. This adjustment happens to be the reactive droop adjust. The reactive droop adjust is quantified as the droop in voltage from the adjusted setting when full rated load with 0.8 power factor (PF) is applied. A droop setting of 4% voltage at full rated load is a recommended starting point. If the reactive current is not shared proportionately in each generator set, the respective droops may need adjustment. Adjust those generator sets that have proportionately higher current for more droop and those generator sets with lower reactive current for less droop. If the reactive current is
not stable in the system, adjust the droop lower in all generator sets. As implied above, the reactive droop is not usually necessary in stand-alone applications. Therefore, some means of disabling the feature is provided. If the generator set will not be paralleled with other generator sets, the reactive droop feature should be disabled. A reactive droop setting of 0 will also effectively disable the reactive droop feature. It should be noted that disabling reactive droop applies strictly to the reactive current or volt-ampere-reactive (VAR) loading. Primarily, the fueling or speed governing system controls the real current which contributes to watts loading. The gain of the reactive droop function is determined by the voltage droop setting. For most applications, a droop of 3%--5% of rated voltage at rated load at 0.8 PF is adequate. Prior to actually connecting the generator sets in parallel, test the droop by applying full rated load at 0.8 PF. The system is operating correctly if this test shows a reduction in voltage equal to the voltage droop setting. If the available load is less than full load, the correct voltage droop should be proportional to the applied VAR load as a fraction of the rated VAR output for the generator set. For instance, a 480-volt generator set with a voltage droop setting of 4% should drop 19.2 volts with full rated (0.8 PF) load applied (480 x 0.04) or 9.6 volts with half the rated load applied (480 x 0.04 / 2). 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. Example Two 100 kilowatt (kW) generator sets are paralleled to provide 150 kW of power at 0.8 PF and wired for a 277/480-volt wye system. Total kVA load: kVA = kW / PF 187.5 = 150 / 0.8 KVAR load: kVAR = kVA * sin (acos [ PF ] ) 112.5 = 187.5 * 0.6 Line current: I = ( VA / 3 ) / VL-N 226 amps = (187500 / 3 / 277 )
TP-6083 7/05
Appendix 161
Reactive current: I = (VAR / 3) / VL-N 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. The load sharing control should be adjusted so that real current and/or watts are shared equally as well. If one generator set is larger than the other, it should be adjusted to carry proportionate current. For this example, if a 150 kW generator set is paralleled to a 75 kW generator set, the larger generator set would carry 90 amps reactive (135 * 2 / 3) and the other would carry 45 amps reactive (135 * 1 / 3). Adjust the reactive droop based on the ratio of the actual measured currents, not the calculated values.
The term rated VARs is a bit obscure. In essence, it is a value derived from the rated kW of the generator set. For a typical standby rating, the full load of the generator set is defined to have 0.8 PF. This means that the kW load is eight-tenths of the VA load. As described earlier, the PF for a linear load may be calculated as the cosine of the angle between voltage and current. This relationship is based on the power triangle. Using this power triangle concept, it can be shown that the reactive power for a linear load is equal to the sine of the power angle. Then, using these trigonomic functions, it can be shown that for a PF of 0.8, the VARs are related similarly to the VA by a factor of 0.6. More explicitly, the power angle is equal to the inverse cosine (arccosine) of the PF. For a PF of 0.8, the power angle is 36.9 degrees (0.2 radians). The sine of this angle, sine (36.9 degrees) is 0.6. This is the factor for calculating rated VARs from the rated VA. The ratio of these two factors is 0.75 (0.6 / 0.8), which can be used to calculate rated VARs directly from the rated kW, VARs equals watts * 0.75. When a generator set will be connected in parallel with the utility, VAR or PF control should be ENABLED. If multiple generator sets are in parallel as well, then reactive droop should be ENABLED also. Additionally, note that VAR control should be used only when the generator set is connected in parallel with the utility. Parallel connection with the utility requires the logical indication that the circuit breakers tying the generator set bus to the utility bus are closed. This indication is made by use of the programmable digital input for VAR/PF mode. If this input function is activated, the excitation control changes to the selected VAR or PF control. If the logical indicator is not present and the VAR or PF control is not enabled, the control will not switch to VAR or PF control. Because the active state for the digital input is a HI or open connection, the default for the digital input (VAR/PF Mode) is DISABLED (displays ENABLED NO). If the input is ENABLED by the user, it should be held low by a contact or jumper until the actual closing of the connecting circuit breaker(s). The proper control method, VAR or PF must be ENABLED within the regulators configuration menu.
VAR Control
VAR control is analogous to the reactive droop function described above. It differs in that it applies to utility paralleling applications. Because the utility represents a nearly infinite bus, the voltage at the load terminals is not controlled at all by the generator set, and it is impossible to compare the ratio of the generator set current to the utility based on its rated output. In this situation, the excitation control changes from voltage feedback to VAR feedback. More specifically, the excitation is controlled to maintain a certain VAR output rather than a voltage output. This is called VAR control and again is used only in utility paralleling applications. The VAR adjust can be set to any value within the generator sets rated capability. Because the VARs cause heating in the armature, any value beyond the generator sets rating could damage the alternator. In most cases, the generator set will be adjusted to generate VAR (lagging PF) but could absorb VARs (leading PF) as well. However, the VAR setting is maintained regardless of the relative PF. If the particular load requires more VARs than the generator set can provide, the excess is derived from the utility bus.
Power Factor Control

PF control is much like the VAR control above. PF control is used only when the generator set is paralleled to the utility grid. The difference is that the PF of the generator set current is held constant. The setting for the PF adjust determines the relationship of the current and voltage from the generator set. The PF is a term that defines the ratio of real watts to the volt-ampere (VA) product. For linear loads, a trigonomic relationship can describe the PF. The PF equals the cosine of the angle between the current and voltage. PF is further defined
162 Appendix
TP-6083 7/05
as leading or lagging. That is to say, if the current lags the voltage (i.e., is later in time), the PF is lagging; if the current leads the voltage (i.e., is earlier in time), the PF is leading. Inductive loads have lagging PF while capacitive loads have leading PF. The current in a purely resistive load is in phase with the voltage (not leading or lagging) and the PF is 1.0 (cos. [0] ). 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. Parallel connection with the utility requires the logical indication that the circuit breakers tying the generator set bus to the utility bus are closed. This indication is made by use of the programmable digital input for VAR/PF mode. If this input function is activated, the excitation control changes to the selected VAR or PF control. If the logical indicator is not present and the VAR or PF control is not enabled, the control will not switch to VAR or PF control. Because the active state for the digital input is a HI or open connection, the default for the digital input (VAR/PF mode) is DISABLED (displays ENABLED NO). If the input is ENABLED by the user, it should be held low by a contact or jumper until the actual closing of the connecting circuit breaker(s). The proper control method, VAR or PF must be ENABLED within the regulators configuration menu.
displayed on the subsequent menu screens. This allows the user to monitor any one phase, if desired. The voltage adjust setting may be changed by means other than the menu including user-defined digital input or remote communications. If voltage adjustment occurs, the new value will be displayed accordingly in the voltage adjust menu.
Underfrequency Unload Enable

The underfrequency unload enable menu is used to turn the underfrequency unload on or off. A YES entry will turn the feature on and the display will show ENABLED YES. A NO entry will turn the feature off and the display will show ENABLED NO. The underfrequency unload defaults to an enabled (ON) condition.
Frequency Setpoint
The frequency setpoint is the cut-in point for underfrequency unloading. At any operating frequency below the frequency setpoint, the output voltage will be reduced. The frequency may be entered with resolution to tenths of a Hz. The range of acceptable entries is 40 to 70 Hz. Any entry beyond these limits causes a RANGE ERROR display and the setting will not change. The default value is one cycle-per-second (or two for non-ECM engines) below the normal system frequency. The frequency setpoint changes to the default value if the system frequency changes. A setting of 40 Hz essentially disables the underfrequency unload feature because most engines do not normally drop to speeds this low, even during load applications.
Adjustment and Setting Specifications

Voltage Adjust
The voltage adjust is entered as the rated or otherwise desired line-to-line voltage. The average of the line-to-neutral voltages is then regulated to the corresponding value as previously described. The setting may be as fine as tenths of volts. The voltage adjust defaults to the rated system voltage whenever the system voltage is changed. The voltage adjust may be set to any value within 20% of the system voltage. The upper limit is 20% above the system voltage and the lower limit is 20% below the system voltage. If a value beyond these limits is entered, a RANGE ERROR message will be displayed. As a reference, the present voltage adjust setting is displayed as well as the average value of the line-to-line voltages. The individual line-to-line voltages are also
Underfrequency Unload Slope

The slope determines how much voltage is reduced during an unloading condition. The line-to-line voltage is regulated to a value less than the voltage adjust setting by this amount for every cycle below the frequency setpoint. The voltage may be entered with resolution as fine as one-tenth of one volt. The default value is 2.0 volts per-cycle-per-second. A zero entry for the slope in effect turns the underfrequency unload feature off.
Reactive Droop Enable

This menu allows the user to enable the reactive droop feature. A YES entry turns the feature on and the display shows ENABLED YES. A NO entry turns the feature off and the display shows ENABLED NO. Reactive droop is intended to be used in a generator set-to-generator set paralleling application.
TP-6083 7/05
Appendix 163
Voltage Droop
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). If the generator set were providing full rated load (at 0.8 PF), the expected voltage change would equal the voltage droop setting as a percentage of system voltage. A voltage droop setting of zero in effect disables the reactive droop feature. The default value is 4% droop at full rated load at 0.8 PF. The present voltage droop setting is displayed for reference. The display may change if this value is changed via remote communication.
Generating/Absorbing
While operating in the VAR control mode, the reactive load on the generator set may be specified to be out of GENERATING or into ABSORBING the generator set. Specifying the VAR type or direction is done through the GENERATING/ABSORBING menu. Because the normal flow of reactive current is out of the generator set, the default value is GENERATING. If ABSORBING is desired, a NO entry at this menu will change the control mode to ABSORBING. When ABSORBING is selected, another NO entry will revert the control mode back to GENERATING. It is assumed that this mode will not be changed when the generator set is running. Therefore, an attempt to change the mode while running will return a RANGE ERROR message. The generator set will need to be shut down in order to change this setting.
PF Adjust
Use the PF adjust to set the desired operating relationship for the generator sets output voltage and current when the generator set is connected in parallel with the utility. The excitation is regulated to maintain a PF equal to the entered value. The value entered may be as low as 0.7 for leading PFs or as low as 0.6 for lagging PFs. Any entries below these limits will cause a RANGE ERROR message to display. The upper limit for PF adjust is 1.0 and the default value is 0.8 lagging. Each time the systems rated kW is changed, the PF adjust will revert to this default value. The PF adjust display setting may change if the PF adjust is changed via other inputs.
VAR Control Enable

In order for the VAR control function to operate, it must be enabled. Entering YES at this menu will turn the feature on. Because the function is designed to operate while the generator set is in parallel with the utility, VAR control also requires the proper indication that all tying circuit breakers are closed. This is done through the user-programmable digital inputs. Because VAR control cannot be enabled at the same time that PF control is enabled, turning VAR control on (ENABLED) when PF control is enabled turns the PF control off (DISABLED).
KVAR Adjust
Using the kVAR adjust sets the desired operating value for the generator sets reactive load when the generator set operates in a utility paralleling application. The desired generator set load is entered directly as kVARs. The value entered may be as low as zero or as high as the rated value (rated kW x 0.75). Any entry beyond the rated value will not be accepted, and a RANGE ERROR message will be displayed. The default value for kVAR adjust is zero. Each time the systems rated kW is changed, the kVAR adjust will revert to zero. The displayed kVAR setting may change if the kVAR setting is changed via other inputs.
Lagging/Leading
It is possible to select either a leading or lagging PF for utility parallel applications. The selected mode is displayed. A NO entry switches the controller to use the other reference. Lagging/leading may only be changed while the generator set is not running. Because the most common mode of operation will be with a lagging PF, LAGGING is the default value. Because this mode should not be changed while the generator set is running, attempting to change this mode during operation will return a RANGE ERROR message. Always shut down the generator set to change the lagging/leading mode setting.
164 Appendix
TP-6083 7/05
Notes
TP-6083 7/05
165
Notes
166
TP-6083 7/05
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455
TP-6083 7/05a
E 2001, 2005 by Kohler Co. All rights reserved.

Tp6083 Dec550 Operation

Uploaded by

Copyright:

Available Formats

Tp6083 Dec550 Operation

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Tp6083 Dec550 Operation

Uploaded by

Copyright:

Available Formats

What information is contained in the product identification section?

What information is contained in the product identification section?

What topics are covered in the table of contents?

What topics are covered in the table of contents?

Operation

Industrial Generator Sets

Controllers: Decision-Makert 550

Software (Code) Version Prior to 2.10

Product Identification Information

Generator Set Identification Numbers

Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 2.7.1 2.7.2

Table of Contents, continued

Local Programming Mode On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Table of Contents, continued

Gas/Gasoline Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

3.11 Detroit Diesel Engine Control (DDEC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Table of Contents, continued

Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Safety Precautions and Instructions

Safety Precautions and Instructions

Engine Backfire/Flash Fire

Carbon monoxide. Can cause severe fainting, or death.

The exhaust system must be leakproof and routinely inspected.

Safety Precautions and Instructions

Hazardous Voltage/ Electrical Shock

Safety Precautions and Instructions

Airborne particles. Can cause severe blindness.

Safety Precautions and Instructions

Safety Precautions and Instructions

List of Related Materials

Literature Part Number

D Look at the labels and stickers on your Kohler product

Section 1 Specifications and Features

1.2 Controller Features

Programming Lamp Mode

AC sensing loss Generator running (status) Ground fault* Overcurrent

* Requires optional input sensors.

Section 1 Specifications and Features

Digital Display and Keypad

Digital Display and Keypad

Generator Output Displays

Operational Record Displays

Section 1 Specifications and Features

Time Delay Displays

Switches and Controls

Switches and Alarm Horn

Section 1 Specifications and Features

Controller Circuit Boards

interconnection circuit board.

interconnection circuit board.

D 5-Amp Remote Annunciator (F1) fuse protects the

dry contact kit if equipped and the controller panel lamps.

Controller Circuit Boards and Fuses (Controller Top View)

Section 1 Specifications and Features

Terminal Strips and Connectors

Circuit Board Interconnections for Calibration Procedure

1. Interconnection circuit board 2. P2 ribbon connector 3. P12 ribbon connector