DEC 550 Controller Operation

Operation
Industrial Generator Sets
Models:
20--2000 kW
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
2 TP-6083 7/05
Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.1 Annunciator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 Digital Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.3 Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.4 Controller Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.6 Terminal Strips and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.7 Circuit Board Interconnections for Calibration Procedure . . . . . . . . . . . . 21
1.2.8 Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3 Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3.1 Status Event and Fault Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.3.2 Voltage Regulator and Calibration Specifications . . . . . . . . . . . . . . . . . . 25
1.3.3 Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.2 Exercising Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.2 Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.3 Emergency Stop Switch Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.4 System Ready Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.5 System Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.3.6 System Shutdown Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.3.7 Controller Reset Procedure (Following System Shutdown
or Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.4 Menu List Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.5 Digital Display Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.6 Reviewing Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6.1 Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6.2 Auto-Scroll Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6.3 Request and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.7 Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.7.1 Personal Computer (PC) Communications . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7.2 Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
TP-6083 7/05 Table of Contents 3

Table of Contents, continued
2.8 Reviewing Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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

3.5 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

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

Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6.1 Accessories and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.1.1 Audiovisual Alarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.1.2 Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.1.3 Controller (Customer) Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.1.4 Float/Equalize Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . . 138
6.1.5 Idle (Speed) Mode Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.1.6 Low Fuel (Level/Pressure) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.1.7 Prime Power Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.1.8 Remote Annunciator Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.1.9 Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.1.10 Remote Reset Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.1.11 Remote Serial Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) . . . . 146
6.1.13 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.1.14 Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.1.15 Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.1.16 Twenty-Relay Dry Contact Kit (450--2000 kW Models Only) . . . . . . . . . 149
6.1.17 Wireless Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
6.2 Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Appendix B User-Defined Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
6 Table of Contents TP-6083 7/05

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the case
Warning indicates the presence of a battery cables, negative (--) lead first. of eye contact. Never add acid to a
hazard that can cause severe Reconnect the negative (--) lead last battery after placing the battery in
personal injury, death, or substantial when reconnecting the battery. Follow service, as this may result in hazardous
property damage. these precautions to prevent starting of spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery gases. Explosion can cause
CAUTION switch, or engine start command from a severe injury or death. Battery gases
remote computer. can cause an explosion. Do not smoke
Caution indicates the presence of a or permit flames or sparks to occur near
hazard that will or can cause minor a battery at any time, particularly when
personal injury or property damage. Battery it is charging. Do not dispose of a
battery in a fire. To prevent burns and
NOTICE sparks that could cause an explosion,
avoid touching the battery terminals
Notice communicates installation, WARNING with tools or other metal objects.
operation, or maintenance information
Remove all jewelry before servicing the
that is safety related but not hazard
equipment. Discharge static electricity
related.
from your body before touching
Safety decals affixed to the equipment batteries by first touching a grounded
in prominent places alert the operator metal surface away from the battery. To
or service technician to potential avoid sparks, do not disturb the battery
Sulfuric acid in batteries. charger connections while the battery
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this is charging. Always turn the battery
publication to improve operator Wear protective goggles and charger off before disconnecting the
recognition. Replace missing or clothing. Battery acid may cause battery connections. Ventilate the
damaged decals. blindness and burn skin. compartments containing batteries to
prevent accumulation of explosive
gases.
TP-6083 7/05 Safety Precautions and Instructions 7

Engine Backfire/Flash Generator set operation. Carbon The fuel system. Explosive fuel
monoxide can cause severe nausea, vapors can cause severe injury or
Fire fainting, or death. Carbon monoxide death. Vaporized fuels are highly
is an odorless, colorless, tasteless, explosive. Use extreme care when
WARNING nonirritating gas that can cause death if handling and storing fuels. Store fuels
inhaled for even a short time. Avoid in a well-ventilated area away from
breathing exhaust fumes when working spark-producing equipment and out of
on or near the generator set. Never the reach of children. Never add fuel to
operate the generator set inside a the tank while the engine is running
building unless the exhaust gas is because spilled fuel may ignite on
Fire. piped safely outside. Never operate contact with hot parts or from sparks.
Can cause severe injury or death. the generator set where exhaust gas Do not smoke or permit flames or
could accumulate and seep back inside sparks to occur near sources of spilled
Do not smoke or permit flames or a potentially occupied building. fuel or fuel vapors. Keep the fuel lines
sparks near fuels or the fuel system. and connections tight and in good
Carbon monoxide symptoms. condition. Do not replace flexible fuel
Servicing the fuel system. A flash Carbon monoxide can cause severe lines with rigid lines. Use flexible
fire can cause severe injury or death. nausea, fainting, or death. Carbon sections to avoid fuel line breakage
Do not smoke or permit flames or monoxide is a poisonous gas present in caused by vibration. Do not operate the
sparks near the carburetor, fuel line, exhaust gases. Carbon monoxide generator set in the presence of fuel
fuel filter, fuel pump, or other potential poisoning symptoms include but are leaks, fuel accumulation, or sparks.
sources of spilled fuels or fuel vapors. not limited to the following: Repair fuel systems before resuming
Catch fuels in an approved container D Light-headedness, dizziness generator set operation.
when removing the fuel line or D Physical fatigue, weakness in
carburetor. joints and muscles Explosive fuel vapors can cause
D Sleepiness, mental fatigue, severe injury or death. Take
Servicing the air cleaner. A sudden inability to concentrate additional precautions when using the
backfire can cause severe injury or or speak clearly, blurred vision following fuels:
death. Do not operate the generator D Stomachache, vomiting, nausea
set with the air cleaner removed. If experiencing any of these symptoms Gasoline—Store gasoline only in
and carbon monoxide poisoning is approved red containers clearly
Combustible materials. A fire can possible, seek fresh air immediately marked GASOLINE.
cause severe injury or death. and remain active. Do not sit, lie down,
Generator set engine fuels and fuel Propane (LP)—Adequate ventilation
or fall asleep. Alert others to the is mandatory. Because propane is
vapors are flammable and explosive. possibility of carbon monoxide
Handle these materials carefully to heavier than air, install propane gas
poisoning. Seek medical attention if detectors low in a room. Inspect the
minimize the risk of fire or explosion. the condition of affected persons does
Equip the compartment or nearby area detectors per the manufacturer’s
not improve within minutes of breathing instructions.
with a fully charged fire extinguisher. fresh air.
Select a fire extinguisher rated ABC or Natural Gas—Adequate ventilation is
BC for electrical fires or as Copper tubing exhaust systems. mandatory. Because natural gas rises,
recommended by the local fire code or Carbon monoxide can cause severe install natural gas detectors high in a
an authorized agency. Train all nausea, fainting, or death. Do not room. Inspect the detectors per the
personnel on fire extinguisher use copper tubing in diesel exhaust manufacturer’s instructions.
operation and fire prevention systems. Sulfur in diesel exhaust
procedures. causes rapid deterioration of copper Fuel tanks. Explosive fuel vapors
tubing exhaust systems, resulting in can cause severe injury or death.
exhaust leakage. Gasoline and other volatile fuels stored
Exhaust System in day tanks or subbase fuel tanks can
cause an explosion. Store only diesel
WARNING Fuel System fuel in tanks.

Draining the fuel system. Explosive
fuel vapors can cause severe injury
WARNING or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
Carbon monoxide. spilled fuel after draining the system.
Can cause severe nausea,
fainting, or death.
Explosive fuel vapors.
The exhaust system must be Can cause severe injury or death.
leakproof and routinely inspected.
Use extreme care when handling,
storing, and using fuels.
8 Safety Precautions and Instructions TP-6083 7/05

Gas fuel leaks. Explosive fuel Hazardous Voltage/ Disconnecting the electrical load.
vapors can cause severe injury or Hazardous voltage can cause
death. Fuel leakage can cause an Electrical Shock severe injury or death. Disconnect
explosion. Check the LP vapor gas or the generator set from the load by
natural gas fuel system for leakage by DANGER opening the line circuit breaker or by
using a soap and water solution with disconnecting the generator set output
the fuel system test pressurized to leads from the transfer switch and
6--8 ounces per square inch heavily taping the ends of the leads.
(10--14 inches water column). Do not High voltage transferred to the load
use a soap solution containing either during testing may cause personal
ammonia or chlorine because both Hazardous voltage. injury and equipment damage. Do not
prevent bubble formation. A successful Will cause severe injury or death. use the safeguard circuit breaker in
test depends on the ability of the place of the line circuit breaker. The
solution to bubble. Disconnect all power sources before safeguard circuit breaker does not
opening the enclosure. disconnect the generator set from the
LP liquid withdrawal fuel leaks. load.
Explosive fuel vapors can cause
severe injury or death. Fuel leakage WARNING High voltage test. Hazardous
can cause an explosion. Check the LP voltage can cause severe injury or
liquid withdrawal gas fuel system for death. Follow the instructions of the
leakage by using a soap and water test equipment manufacturer when
solution with the fuel system test performing high-voltage tests on the
pressurized to at least 90 psi rotor or stator. An improper test
(621 kPa). Do not use a soap solution Hazardous voltage. Moving rotor. procedure can damage equipment or
containing either ammonia or chlorine Can cause severe injury or death. lead to generator set failure.
because both prevent bubble
formation. A successful test depends Operate the generator set only when Testing the photo transistor circuit
on the ability of the solution to bubble. all guards and electrical enclosures board. Hazardous voltage can
are in place. cause severe injury or death. When
the end cover is removed, do not
expose the photo transistor circuit
Hazardous Noise board mounted on the generator set
WARNING end bracket to any external light
CAUTION 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
Hazardous voltage. the circuit board before starting the
Backfeed to the utility system can generator set.
Hazardous noise. cause property damage, severe
Can cause hearing loss. injury, or death. Installing the photo transistor circuit
board. Hazardous voltage can
Never operate the generator set If the generator set is used for cause severe injury or death. Ensure
without a muffler or with a faulty standby power, install an automatic that the foil side of the photo transistor
exhaust system. transfer switch to prevent inadvertent circuit board, the end of the shaft, and
interconnection of standby and the threaded holes are clean and free of
Engine noise. Hazardous noise can normal sources of supply. metal particles and chips. Metal debris
cause hearing loss. Generator sets may short-circuit the photo transistor
not equipped with sound enclosures Grounding electrical equipment. circuit board and cause hazardous
can produce noise levels greater than Hazardous voltage can cause voltage in the generator set. Do not
105 dBA. Prolonged exposure to noise severe injury or death. Electrocution reconnect the generator set to the load
levels greater than 85 dBA can cause is possible whenever electricity is until the AC voltmeter shows the
permanent hearing loss. Wear hearing present. Open the main circuit correct output.
protection when near an operating breakers of all power sources before Connecting the SCR assembly.
generator set. servicing the equipment. Configure the Hazardous voltage can cause
installation to electrically ground the severe injury or death. Connect leads
generator set, transfer switch, and C and E to the corresponding terminals
related equipment and electrical of the one-piece SCR assembly. The
circuits to comply with applicable codes SCR assembly will turn full on and
and standards. Never contact cause hazardous output voltage if the
electrical leads or appliances when leads are connected in reverse or if the
standing in water or on wet ground C (red) lead is grounded.
because these conditions increase the (One-piece SCR models only. Does
risk of electrocution. not apply to current split activator
models.)

Installing the battery charger. Engine block heater. Hazardous Hot Parts
Hazardous voltage can cause voltage can cause severe injury or
severe injury or death. An death. The engine block heater can
ungrounded battery charger may cause electrical shock. Remove the WARNING
cause electrical shock. Connect the engine block heater plug from the
battery charger enclosure to the ground electrical outlet before working on the
of a permanent wiring system. As an block heater electrical connections.
alternative, install an equipment
grounding conductor with circuit Handling the capacitor. Hazardous
conductors and connect it to the voltage can cause severe injury or Hot coolant and steam.
equipment grounding terminal or the death. Electrical shock results from Can cause severe injury or death.
lead on the battery charger. Install the touching the charged capacitor
terminals. Discharge the capacitor by Before removing the pressure cap,
battery charger as prescribed in the
shorting the terminals together. stop the generator set and allow it to
equipment manual. Install the battery
(Capacitor-excited models only) cool. Then loosen the pressure cap
charger in compliance with local codes
to relieve pressure.
and ordinances. Electrical backfeed to the utility.
Connecting the battery and the Hazardous backfeed voltage can
cause severe injury or death. Install
battery charger. Hazardous voltage
a transfer switch in standby power
WARNING
can cause severe injury or death.
Reconnect the battery correctly, installations to prevent the connection
positive to positive and negative to of standby and other sources of power.
negative, to avoid electrical shock and Electrical backfeed into a utility
damage to the battery charger and electrical system can cause severe
battery(ies). Have a qualified injury or death to utility personnel Hot engine and exhaust system.
electrician install the battery(ies). working on power lines. Can cause severe injury or death.
Servicing the day tank. Hazardous Testing live electrical circuits.
Do not work on the generator set until
voltage can cause severe injury or Hazardous voltage or current can
it cools.
death. Service the day tank electrical cause severe injury or death. Have
control module (ECM) as prescribed in trained and qualified personnel take
diagnostic measurements of live Servicing the alternator. Hot parts
the equipment manual. Disconnect the can cause severe injury or death.
power to the day tank before servicing. circuits. Use adequately rated test
equipment with electrically insulated Avoid touching the alternator field or
Press the day tank ECM OFF exciter armature. When shorted, the
pushbutton to disconnect the power. probes and follow the instructions of the
test equipment manufacturer when alternator field and exciter armature
Notice that line voltage is still present become hot enough to cause severe
within the ECM when the POWER ON performing voltage tests. Observe the
following precautions when performing burns.
light is lit. Ensure that the generator set
and day tank are electrically grounded. voltage tests: (1) Remove all jewelry. Checking the coolant level. Hot
Do not operate the day tank when (2) Stand on a dry, approved electrically coolant can cause severe injury or
standing in water or on wet ground insulated mat. (3) Do not touch the death. Allow the engine to cool.
because these conditions increase the enclosure or components inside the Release pressure from the cooling
risk of electrocution. enclosure. (4) Be prepared for the system before removing the pressure
system to operate automatically. cap. To release pressure, cover the
Short circuits. Hazardous (600 volts and under) pressure cap with a thick cloth and then
voltage/current can cause severe slowly turn the cap counterclockwise to
injury or death. Short circuits can the first stop. Remove the cap after
cause bodily injury and/or equipment Heavy Equipment pressure has been completely
damage. Do not contact electrical released and the engine has cooled.
connections with tools or jewelry while Check the coolant level at the tank if the
making adjustments or repairs. WARNING
generator set has a coolant recovery
Remove all jewelry before servicing the tank.
equipment.
Servicing the exhaust system. Hot
Testing the voltage regulator. parts can cause severe injury or
Hazardous voltage can cause death. Do not touch hot engine parts.
severe injury or death. High voltage The engine and exhaust system
is present at the voltage regulator heat Unbalanced weight. components become extremely hot
sink. To prevent electrical shock do not Improper lifting can cause severe during operation.
touch the voltage regulator heat sink injury or death and equipment
when testing the voltage regulator. damage.
(PowerBoostt, PowerBoostt III, and
PowerBoostt V voltage regulator Do not use lifting eyes.
models only) Lift the generator set using lifting bars
inserted through the lifting holes on
the skid.

Combustible materials. Fire can Tightening the hardware. Flying NOTICE
cause severe injury or death. A hot projectiles can cause severe injury When replacing hardware, do not
exhaust system can ignite adjacent or death. Loose hardware can cause substitute with inferior grade
combustible materials. Do not locate the hardware or pulley to release from hardware. Screws and nuts are
electrical wiring, fuel lines, or the generator set engine and can cause available in different hardness ratings.
combustible materials above the personal injury. Retorque all To indicate hardness, American
exhaust muffler. Exercise caution crankshaft and rotor hardware after Standard hardware uses a series of
when parking your vehicle to prevent servicing. Do not loosen the crankshaft markings, and metric hardware uses a
the exhaust system and hot exhaust hardware or rotor thrubolt when making numeric system. Check the markings
gases from starting grass fires. adjustments or servicing the generator on the bolt heads and nuts for
set. Rotate the crankshaft manually in identification.
a clockwise direction only. Turning the
Moving Parts crankshaft bolt or rotor thrubolt NOTICE
counterclockwise can loosen the
Canadian installations only. For
hardware.
WARNING standby service connect the output of
Servicing the generator set when it the generator set to a suitably rated
is operating. Exposed moving parts transfer switch in accordance with
can cause severe injury or death. Canadian Electrical Code, Part 1.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
Hazardous voltage. Moving rotor. pulleys when the generator set is
Can cause severe injury or death. running. Replace guards, screens, and
covers before operating the generator
Operate the generator set only when set.
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
246242
all guards, screens, and covers are in
place.
NOTICE
Voltage reconnection. Affix a notice
WARNING 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.
Airborne particles.
NOTICE
Can cause severe injury or
blindness. Hardware damage. The engine and
generator set may use both American
Wear protective goggles and clothing Standard and metric hardware. Use
when using power tools, hand tools, the correct size tools to prevent
or compressed air. rounding of the bolt heads and nuts.

Notes

Introduction
This manual provides operation instructions for skilled and suitably-trained maintenance personnel
20--2000 kW generator sets equipped with the following familiar with generator set operation and service.
controller:
The disc supplied with this generator set is a backup
D Decision-Makert 550, Software (Code) Version copy of the generator set personality program
Prior to 2.10 containing data specific to the engine and alternator.
The engine and alternator data was preprogrammed in
Version 2.10 refers to the controller application the controller at the factory and no further use of the disc
software. To determine the generator set controller should be necessary. Typically, your authorized
software version, go to Menu 20—Factory Setup and distributor stores this disc for possible future use such as
scroll down to Code Version. The code version is the controller replacement or other circumstances requiring
controller software version. a backup.
Wiring diagram manuals are available separately. Refer

to the engine operation manual for generator set engine List of Related Materials
scheduled maintenance information.
Separate literature contains communication and
Information in this publication represents data available software information not provided in this manual. The
at the time of print. Kohler Co. reserves the right to following table lists the available literature part numbers.
change this publication and the products represented
without notice and without any obligation or liability Communication and Software Literature Part
whatsoever. Manual Description Number
550 Controller Spec Sheet G6--46
Read this manual and carefully follow all procedures
Multiple Part Numbers
and safety precautions to ensure proper equipment Generator Set/Controller
Contact your
Wiring Diagram Manual
operation and to avoid bodily injury. Read and follow the Distributor/Dealer
Safety Precautions and Instructions section at the 550 Communications Spec Sheet G6--50
beginning of this manual. Keep this manual with the KBUS Communications Spec Sheet G6--38
equipment for future reference. Monitor II Software
Operation/Installation Manual TP--5972
The equipment service requirements are very important Modbus Communication
to safe and efficient operation. Inspect the parts often Operation/Installation Manual TP--6113
and perform required service at the prescribed intervals. Program Loader Software Installation TT--1285
Maintenance work must be performed by appropriately KBUS Communication Kits Installation TT-847
TP-6083 7/05 Introduction 13

Service Assistance
For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955
D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
ZI Senia 122
Latin America
12, rue des Hauts Flouviers
Latin America Regional Office
94517 Thiais Cedex
Lakeland, Florida, USA
France
Phone: (863) 619-7568
Phone: (33) 1 41 735500
Fax: (863) 701-7131
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 (ECM) setup and features. Controller features apply to

generator set models with ECM and non-ECM engines
The spec sheets for each generator set provide model unless otherwise noted.
specific generator and engine information. The
controller spec sheet provides specifications for this Note: Press any key on the keypad to turn on the
controller. Refer to the respective spec sheet for data controller lights and display. The lights and
not supplied in this manual. Consult the generator set display turn off 5 minutes after the last keypad
service manual, installation manual, engine operation entry.
manual, and engine service manual for additional
specifications. Note: There are two operating modes: prime power or
standby. The operating mode selection alters the
displays involving generator set ratings. Change
1.2 Controller Features this setting using Menu 14—Programming Mode
Menu and Menu 7—Generator System Menu.
The controller features include the annunciator lamps,
digital display and keypad, switches and controls, and Note: Measurements display in metric or English. See
fuses and terminal strip. The following paragraphs Menu 7—Generator System.
detail the features by general topics.
See Figure 1-1 for an illustration of the controller front
The controller features, accessories, and menu displays panel.
depend upon the engine electronic control module
1 2 3 4 5 6
8 7 TP-6083-2
1. Emergency stop switch 5. Digital display

2. Alarm horn (see keypad for alarm silence) 6. Keypad
3. Annunciator lamps (see keypad for lamp test) 7. Operating guide
4. Generator set master switch, run/off-reset/auto positions 8. Controller terminal strips (on circuit board)
Figure 1-1 Controller
TP-6083 7/05 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.
Five annunciator lamps provide visual generator set
status. See Figure 1-2. The following conditions cause a system warning:
D Engine functions:
d High battery voltage
d High coolant temperature
d Low battery voltage
d Low coolant temperature
d Low fuel (level or pressure)*
TP-6083-2
d Low oil pressure
Figure 1-2 Annunciator Lamps d Speed sensor fault
d Starting aid (status)
System Ready. Green lamp illuminates when the d Weak battery
generator set master switch is in the AUTO (automatic D General functions:
start) position and the system senses no faults. The unit
d Auxiliary—Analog up to 7 inputs each with a high
is ready to start.
and low programmable warning level
Not in Auto (NIA). Yellow lamp illuminates when the NOTE: Non-ECM models have 5 programmable
generator set master switch is not in the AUTO warnings
(automatic start) position. d Auxiliary—Digital up to 21 programmable
warnings
Programming Mode. Yellow programming lamp d Battery charger fault*
indicates the user selected programming mode. See d Emergency power system (EPS) supplying load
Figure 1-3. d Engine cooldown delay
d Engine start delay
Programming Lamp Programming Mode Selection
d Load shed kW overload
Lamp Flashing Local Programming d Load shed underfrequency
Lamp Steady On Remote Programming d Master switch not in AUTO (automatic start)
Lamp Off Programming Disabled
position
d NFPA-110 fault (National Fire Protection
Figure 1-3 Programming Lamp Mode Association)
d System ready (status)
Note: Find additional information for the programming D Generator functions:
mode lamp function and access to the local or
d AC sensing loss
remote programming modes in Section 2.9, Local
d Generator running (status)
Programming Mode On, Menu 14—Programming
d Ground fault*
Mode.
d Overcurrent
System Warning. Yellow lamp identifies an existing * Requires optional input sensors.
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.
16 Section 1 Specifications and Features TP-6083 7/05

System Shutdown. Red lamp indicates that the Keypad Functions
generator set has shut down because of a fault
condition. Unit will not start without resetting controller, Alarm (horn) off key silences the alarm horn at the
see Section 2.3.7, Controller Reset Procedure. operator’s discretion. Place the generator set master
switch in the AUTO position before silencing the alarm
See Section 2.3.6, System Shutdown Lamp, for horn. See Section 2.3.7, Controller Reset Procedure,
definitions of the items listed. and Section 1.2.3, Switches and Controls.
The following conditions cause a system shutdown: AM/PM key provides time of day data entries when
programming.
D Engine functions:
d Air damper closed (status), if equipped Enter ↵ key provides confirmation entry when selecting
d Coolant temperature signal loss menu or programming.
d High coolant temperature
d High oil temperature Lamp test key tests the controller indicator lamps, horn,
d Low coolant level and digital display. See Section 1.2.3, Switches and
d Low oil pressure Controls.
d Oil pressure signal loss
d Overcrank Menu down ↓ key provides navigation within menus
d Overspeed when necessary.
D General functions: Menu right → key provides navigation within menus
d Auxiliary—Analog up to 7 inputs each with a high when necessary.
and low programmable shutdown level
NOTE: Non-ECM models have 5 programmable Numeric 0--9 keys provide numeric data entries when
shutdowns selecting menus or programming.
d Auxiliary—Digital up to 21 programmable
Reset menu key exits a menu, clears incorrect entries,
shutdowns
and cancels the auto-scroll feature.
d ECM communications loss (ECM models only)
d Emergency stop Stop prog (program) run key allows the user to stop
d Internal fault any previously programmed generator set run
d Master switch in OFF/RESET position sequence. See Section 1.2.3, Switches and Controls.
d Master switch error
d Master switch open Yes/No keys provides data answer entries when
d NFPA 110 fault programming.
D Generator functions:
d AC output overvoltage
d AC output undervoltage
d Alternator protection against overload and short
circuits
d Field overvoltage (M4, M5, or M7 alternator only)
d Locked rotor (failed to crank)
d Overfrequency
d 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 TP-5829-2

generator set and engine condition information. Figure 1-4 Digital Display and Keypad
The 16-button keypad gives the user information access
and local programming capability.

Generator Output Displays Fuel Pressure displays the fuel supply pressure.
AC Amps displays the generator output current. The Fuel Rate displays the calculated fuel consumption rate
display shows each line of 3-phase models. based on fuel injector outputs.
AC Volts displays the generator output voltages. The Fuel Temperature displays the fuel supply
display shows all line-to-neutral and line-to-line voltage temperature.
combinations.
Oil Level displays the engine oil level as a percent of full
Alternator duty level displays the actual load kW capacity.
divided by the nameplate kW rating as a percentage.
Oil Pressure displays the engine oil pressure.
Frequency displays the frequency (Hz) of generator
output voltage. Oil Temperature displays the engine oil temperature.
Hourmeter displays the generator set operating hours RPM (Tachometer) displays the engine speed.
loaded and unloaded for reference in scheduling
maintenance. Used Last Run displays the accumulated amount of
fuel used since last reset by the engine DDEC reader.
KVA displays the total and individual L1, L2, and L3 kVA.
Operational Record Displays
KVAR displays the total and individual L1, L2, and L3
kVAR. The operational record displays events since last reset.
See Section 2.9.4, Menu 4—Operational Records, for
Power factor displays the leading/lagging L1, L2, L3, resetting procedure.
and total power factor.
Engine Start Countdown displays the time remaining
Watts displays the total and individual L1, L2, L3 before the next generator set startup.
kilowatts.
Event History displays up to 100 stored system events
Engine Displays including status, warnings, and shutdowns.
Some engine displays are available with selected Last Start Date displays the date when the generator
generator set engines using engine electronic control set last operated.
modules (ECM) only. The controller display shows N/A
(not available) for items that are unavailable. See the Number of Starts displays the total number of
controller spec sheet for applicable generator set generator set startup events.
models.
Number of Starts (Since) Last Maintenance displays
Ambient Temperature displays the generator set area the total number of generator set startup events since
ambient temperature. the last maintenance date.
Coolant Level displays the engine coolant level. Operating Days (Since) Last Maintenance displays
the total number of days of operation since the last
Coolant Pressure displays the engine coolant maintenance date. A counted day of operation can be
pressure. 1--24 hours.
Coolant Temperature displays the engine coolant Run Time displays the total loaded hours, total
temperature. unloaded hours, and total kW hours.
Crankcase Pressure displays the engine crankcase Run Time Since Maintenance displays the total loaded
pressure. hours, total unloaded hours, and total kW hours.
DC Volts displays the voltage of starting battery(ies).

Time Delay Displays Alarm Horn. The alarm horn alerts the operator or other
attendants that a shutdown or warning condition exists.
The time delays are user adjustable. See Section 2.9.8, See Section 1.3, Controller Logic Specifications, for
Menu 8—TIme Delays, for time delay adjustments. See conditions. Place the generator set master switch in the
Section 1.3.1, Status Event and Fault Specifications, for AUTO position before silencing the alarm horn. The
range and default settings. alarm horn cannot be silenced unless the generator set
master switch is in the AUTO position. See
Crank On/Crank Pause displays the time allocated for
Section 2.3.7, Controller Reset Procedure.
generator set crank on and crank pause in
minutes:seconds. Alarm (Horn) Off. The keypad switch silences the
alarm horn at the operator’s discretion. Place the
Engine Cooldown displays the time delay for engine
generator set master switch in the AUTO position before
cooldown while the master switch is in the AUTO or RUN silencing the alarm horn. Restore alarm horn switches
positions and not in the idle mode.
at all locations including those on remote annunciator
and audiovisual alarm kits to the normal position after
Engine Start displays the time delay before the
correcting the fault shutdown to avoid reactivating the
generator set starts while the master switch is in AUTO
or RUN positions. alarm horn. See Section 2.3.7, Controller Reset
Procedure.
Overcrank Shutdown (Number of) Crank Cycles
Emergency Stop. The operator-activated switch
displays the number of unsuccessful crank cycles
(crank on/crank pause) before the generator set shuts immediately shuts down the generator set in emergency
situations. Reset the emergency stop switch after
down on an overcrank fault.
shutdown by pulling the switch knob outward. Use the
Overvoltage displays the time delay before the emergency stop switch for emergency shutdowns only.
generator set shuts down because of an overvoltage Use the generator set master switch for normal
condition. shutdowns.
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.
1.2.3 Switches and Controls

See Figure 1-5 and Figure 1-6 for switches and
controls.
Note: Find additional switches and controls in

Section 2.6.1, Keypad Operation.
1
2
3 TP-5829-2
1. Lamp test
2. Alarm horn silence
3. Stop program run
Figure 1-6 Keypad Switches
TP-6083-2
Figure 1-5 Switches and Alarm Horn

Generator Set Master Switch (Run/Off-Reset/Auto). Indicator Circuit Board includes the LED status lamps
This switch resets the controller fault lamps and and alarm horn.
start/stops the generator set. Refer to Section 2.3.1,
Starting, Section 2.3.2, Stopping, and Section 2.3.3, Interconnection Circuit Board provides the terminal
Emergency Stop Switch Reset Procedure. strips to connect the customer connection and/or dry
contact kits and three fuses (F1, F2, and F3).
Lamp Test. Keypad switch tests the controller indicator
lamps, horn, and digital display. Press the reset menu Keypad Circuit Board provides the keypad to navigate
key before pressing the lamp test key. the generator set displays and enter data.
Stop Prog (Program) Run. Keypad switch allows the Digital Display Circuit Board provides the digital
user to stop any previously programmed generator set display for monitoring the generator set functions and
run sequence. output values.
Main Logic (Microprocessor)/Communication

1.2.4 Controller Circuit Boards Circuit Board provides the controller operation logic
and provides PC communication locally (direct) or
The controller has five circuit boards—indicator,
remotely (via modem) using RS-232 or RS-485
interconnection, keypad, digital display, and main connectors.
logic/communication. See Figure 1-7 for circuit board
locations.
1.2.5 Fuses
1 2 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.


DC Circuit Fuses fuses are located on the controller

5 4 3
D 5-Amp Remote Annunciator (F1) fuse protects the
GM10193B-A
dry contact kit if equipped and the controller panel
1. AC fuse block (TB6) lamps.
2. Interconnection circuit board TB1, TB2, TB3, and TB4
terminal strips and F1, F2, and F3 fuses
3. Main logic (microprocessor)/communication circuit D 5-Amp Controller (F2) fuse protects the controller
board circuitry.
4. Keypad and digital display circuit boards
5. Indicator circuit board (LED and alarm horn) D 15-Amp Engine and Accessories (F3) fuse
Figure 1-7 Controller Circuit Boards and Fuses protects the engine/starting circuitry and
(Controller Top View) accessories.

1.2.6 Terminal Strips and Connectors 1.2.7 Circuit Board Interconnections for
Calibration Procedure
Terminal strips and connectors for inputs and outputs
are located on the interconnection circuit board. See The interconnection circuit board shown in Figure 1-9
Section 6, Accessories. contains a ribbon connector that requires disconnection
during the calibration procedure in Menu 12—
TB1 Input Connection Terminal Strip provides input Calibration. Disconnect ribbon connector P2 prior to
connections for remote start and emergency stop zeroing out (resetting) the auxiliary analog inputs.
(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. 1
2
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, 3
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
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)
ADV-6533-A
1. TB1 terminal strip
3. P23 Connector
Figure 1-8 Interconnection Circuit Board Terminal

Strips and Connectors

1.2.8 Communication Ports 1.3 Controller Logic Specifications
The main logic circuit board contains several The Controller Logic Specifications section is an
communication ports for KBUS and Modbus overview of the various features and functions of the
connections. See Figure 1-10. Refer to the List of controller. Certain features function only when optional
Related Materials in the Introduction section for accessories are connected. See Section 2, Operation,
corresponding communication installation information. for details.
The default selection time delays and relay driver

1 2 3 4 5 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.
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. P19—unused ISO2, RS-485 port
2. P21—KBUS ISO1, RS-485 port
3. P18—KBUS or Modbus, RS-232 port
4. P20—Modbus, RS-485 port
5. P22—ECM connector
6. Main logic circuit board
Figure 1-10 Main Logic Circuit Board Communication

Ports (Top View of Circuit Board)

Relay Inhibit
Refer Driver Time Time
Status Event or to Digital Output Alarm Default Delay Delay
Fault Menu Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Access Code 14 0 (zero)
(password)
AC Sensing Loss 10 AC Sensing RDO--25 On Warning
Loss
Air Damper Indicator (if 10 Air Damper RDO--23 On Shutdown 0 sec.
used) Digital Aux. Indicator (lead 56) inhibit,
Input 20 0 sec. delay
Alternator Protection 10 Alternator On Shutdown
Protection
Battery Charger Fault, 10 Battery RDO--11 Off Warning 0 sec.
Digital Aux. Input 1 Charger (lead 61) inhibit,
Fault 0 sec. delay
Battle Switch (see 9 Battle Switch Off Warning
Fault Shutdown
Override Switch)
Analog Aux. Inputs 1--7 9 User-Defined On Shutdown Default Values with 30 sec. 0--60 0--60
A1--A7 or Warning Enabled: inhibit,
Warning HI warning 90% 5 sec. delay
LO warning 10%
HI shutdown 100%
LO shutdown 1%
Analog Aux. Input 1 9 Coolant On Shutdown Default Values with 30 sec. 0--60 0--60
(non-ECM only) Temp or Warning Enabled: inhibit,
Warning HI/LO warning and 0 sec. delay
HI/LO shutdown are
all engine dependent
Analog Aux. Input 2 9 Oil Pressure On Shutdown Default Values with 30 sec. 0--60 0--60
(non-ECM only) 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
Digital Aux. Input 1--21 9 User-Defined On Shutdown 30 sec. 0--60 0--60
D1--D21 or inhibit,
Warning 5 sec. delay
Cyclic Cranking 8 Off 1--6 crank cycles 3
10--30 sec. crank on 15 sec.
1--60 sec. pause 15 sec.
Defined Common 10 Defined RDO--18 On Shutdown Default shutdowns 30 sec. 0--60 0--60
Faults Common (lead 32A) or include: inhibit,
Fault Warning Emergency stop 5 sec. delay
High coolant temp
Low oil pressure
Overcrank
Overspeed
EEPROM Write Failure 10 EEPROM On
Write Failure
Engine Cooldown (see
Time Delay--)
Engine Start (see Time
Delay--)
Emergency Stop 10 Emergency RDO--14 Off Shutdown
Shutdown Stop (lead 48)
EPS (Emergency 10 EPS RDO--22 Off 5% of rated
Power System) Supplying line current
Supplying Load Load
Fault Shutdown 9 Battle Switch Off Warning
Override Switch
Field Overvoltage 9 Field On Shutdown 1 sec.
Digital Aux. Input 4 Overvoltage inhibit,
(M4, M5, or M7 15 sec.
alternator only) delay

Status Event and Fault Specifications, continued
Relay Inhibit
Status Events or to Digital Output Alarm Default Delay Delay
Generator Running 10 RDO--15 Off
(lead 70R)
Ground Fault Detected 10 Ground Fault On Warning
High Battery Voltage 10 High Battery RDO--13 Off Warning 14.5--16.5 V (12 V) 16 V (12 V) 10
Voltage 29--33 V (24 V) 32 V (24 V)
High Coolant 10 Hi Cool RDO--03 On Shutdown 30 5
Temperature Shutdown Temp (lead 36)
Shutdown
High Coolant 10 Hi Cool RDO--06 On Warning 30
Temperature Warning Temp (lead 40)
Warning
High Oil Temperature 10 Hi Oil Temp On Shutdown 30 5
Shutdown Shutdown
Idle (speed) Mode 10 Idle Mode RDO--21 Off Warning 0 sec. 0--600
Function Digital Aux. Active inhibit,
Input 21 60 sec.
delay
Internal Fault 10 Internal Fault On Shutdown
Shutdown
kW Overload
(see Load Shed)
Load Shed 10 Load Shed RDO--30 Off Warning 100% of kW 5
kW Overload KW Over rating with
5 sec. delay
Load Shed 10 Load Shed RDO--31 Off Warning 59 Hz with 5
Underfrequency Under (60 Hz)
Frequency 49 Hz with
(50 Hz)
Locked Rotor 10 Locked On Shutdown
Shutdown Rotor
Loss of ECM 10 Loss of ECM RDO--26 On Shutdown 4
Communication Comm
Low Battery Voltage 10 Low Battery RDO--12 Off Warning 10--12.5 V (12 V) 12 V (12 V) 10
Voltage (lead 62) 20--25 V (24 V) 24 V (24 V)
Low Coolant Level 10 Low Coolant RDO--19 On Shutdown 30 5
Level
Low Coolant 10 Low Coolant RDO--05 On Warning 0 sec.
Temperature, Digital Temp (lead 35) inhibit,
Aux. Input 3 (ECM) 0 sec. delay
Low Fuel, 10 Low Fuel RDO--08 On Warning 0 sec.
Digital Aux. Input 2 (lead 63) inhibit,
0 sec. delay
(Low) Oil Pressure 10 Oil Pressure RDO--04 On Shutdown 30 5
Shutdown Shutdown (lead 38)
(Low) Oil Pressure 10 Oil Pressure RDO--07 On Warning 30
Warning Warning (lead 41)
Master Not In Auto 10 Not In Auto RDO--09 On Not In
(generator switch) (lead 80) Auto
Master Switch Error 10 Master On Shutdown
Switch Error
Master Switch Open 10 Master On Shutdown
Switch Open
NFPA 110 Fault 10 NFPA 110 RDO--10 On Shutdown
Fault (lead 32) or
Warning
No Coolant 10 No Cool Off Shutdown 30 4
Temperature Signal Temp Signal
No Oil Pressure Signal 10 No Oil Off Shutdown 30 4
Pressure
Signal

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

Refer
to
Calibration Menu Digital Display Range Setting Default Selection
Underfrequency Unload Slope 11 Slope 0--10% of rated voltage 2 volts per cycle
volts per cycle
PF Adjust Control 11 PF Adj. 0.7 to 1.0 leading 0.8 lagging
0.6 to 1.0 lagging
Reactive Droop 11 Voltage Droop 0--10% of system voltage 4% of system voltage
Underfrequency Unload or 11 Frequency Setpoint 40 to 70 Hz 1 Hz below system frequency (ECM)
Frequency Setpoint 2 Hz below system frequency (non-ECM)
VAR Control 11 kVAR Adj. 0 to rated kVAR generating 0
0 to 35% of rated kVAR
absorbing
Voltage Adjustment 11 Volt Adj. ±20% of system voltage 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.

1.3.3 Voltage Regulator Adjustments Underfrequency Unload or Frequency Setpoint.
This adjustment affects the voltage droop (volts per Hz)
The descriptions of the voltage regulator adjustments when load is applied and underfrequency occurs. The
and features follow. See Appendix C, Voltage Regulator underfrequency unload setting defines the setpoint
Definitions and Adjustments, for additional information. where underfrequency starts. Any frequency below the
setpoint causes the voltage to drop and engine speed to
Underfrequency Unload Slope. This setting recover according to the underfrequency unload slope
determines how much the voltage drops during an setting.
underfrequency condition. Typically, applying a large
electrical load causes a dip in engine speed and Engine speed recovery depends upon characteristics
underfrequency. The voltage regulator reduces such as engine make, fuel type, load types, and
voltage, allowing engine speed recovery. The operating conditions. The underfrequency unload
volts-per-Hz setting determines the amount of voltage setting best matches engine speed recovery
drop. characteristics to the application.
Power Factor (PF) Adjust Control. Power factor VAR Control. VAR control provides reactive current
adjust controls the generator reactive load. The PF flow adjustment in the generator during
adjustment controls the excitation level for maintaining generator-to-utility paralleling applications. The
the PF setting. The PF adjust control setting determines controller displays the total kVAR generator load while
the reactive current (VARs) amount in relation to the real running in parallel with the utility.
current (watts) as regulated by the load-sharing module.
The utility supply, not the controller, determines terminal
Power is the cosine of the electrical angle between voltage. Engine fueling determines real power
current and voltage. The cosine function is positive for measured in watts using load sharing module control.
angles between --90 degrees (lagging) and +90 degrees
(leading). This adjustment requires the user to Voltage Adjustment. The voltage adjustment allows
determine whether the current leads (positive angle) or the customer to enter the desired generator set output
lags (negative angle) the voltage. level. This regulated level setting is the average of the
three line-to-neutral voltages in wye configurations or
Reactive Droop. Reactive droop compensation L1-to-L2 in single phase and delta configurations.
provides reactive current flow adjustment in the
generator during generator-to-generator paralleling Submenus display the individual line-to-line voltages.
applications. Reactive droop reduces excitation levels These voltages are relevant in unbalanced load
with increasing reactive current. A reduced excitation conditions. The voltage adjust setpoint can be changed
level removes generator reactive current or generates to accommodate an important phase in an unbalanced
VARs, improving stability. system.
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.

Section 2 Operation
2.1 Prestart Checklist D Check for corroded or broken metal parts and replace
them as needed.
To ensure continued satisfactory operation perform the
following checks or inspections before or at each D Check for loose, corroded, or missing clamps and
startup, as designated, and at the intervals specified in hangers. Tighten or replace the exhaust clamps
the service schedule. In addition, some checks require and/or hangers as needed.
verification after the unit starts.
D Check that the exhaust outlet is unobstructed.
Air Cleaner. Check for a clean and installed air cleaner
D Visually inspect for exhaust leaks (blowby). Check
element to prevent unfiltered air from entering the
for carbon or soot residue on exhaust components.
engine.
Carbon and soot residue indicates an exhaust leak.
Air Inlets. Check for clean and unobstructed air inlets. Seal leaks as needed.
Battery. Check for tight battery connections. Consult Fuel Level. Check the fuel level and keep the tank(s)
the battery manufacturer’s instructions regarding full to ensure adequate fuel supply.
battery care and maintenance.
Oil Level. Maintain the oil level at or near, not over, the
Controller. After reconnecting the battery, set the full mark on the dipstick.
controller time and date. See Section 2, Menu 14—
Operating Area. Check for obstructions that could
Programming Mode On and Menu 6—Time and Date.
block the flow of cooling air. Keep the air intake area
Coolant Level. Check the coolant level according to clean. Do not leave rags, tools, or debris on or near the
the cooling system maintenance information. generator set.
Note: Block heater damage. The block heater will fail 2.2 Exercising Generator Set
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning Operate the generator set under load once each week
on the block heater. Run the engine until it is for one hour. Perform the exercise in the presence of an
warm, and refill the radiator to purge the air from operator when the generator set does not have a
the system before energizing the block heater. programmed exercise mode or an automatic transfer
switch with an exercise option.
Drive Belts. Check the belt condition and tension of the
radiator fan, water pump, and battery charging During the exercise period apply a minimum of 35% load
alternator belt(s). based on the nameplate standby rating, unless
otherwise instructed in the engine operation manual.
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and The operator should perform all of the prestart checks
check for tight exhaust system connections. before starting the exercise procedure. Start the
generator set according to the starting procedure in
Inspect the exhaust system components (exhaust Section 2.3, Controller Operation. While the generator
manifold, exhaust line, flexible exhaust, clamps, set is operating, listen for a smooth-running engine and
silencer, and outlet pipe) for cracks, leaks, and visually inspect the generator set for fluid or exhaust
corrosion. leaks.
TP-6083 7/05 Section 2 Operation 27

2.3 Controller Operation The idle function also provides engine cooldown at idle
speed. The controller overrides the idle speed mode
when the engine reaches the preprogrammed engine
2.3.1 Starting cooldown temperature before the idle mode times out.
Local Starting During the idle (speed) mode the controller continues to
monitor critical engine parameters such as oil pressure,
Move the generator set master switch to the RUN coolant temperature, and engine speed. The voltage
position to start the generator set at the controller. regulator, thermal protection feature, and AC metering
are disabled in the idle speed mode.
Note: The alarm horn sounds and the Not-In-Auto lamp
lights whenever the generator set master switch The controller overrides the idle speed function when
is not in the AUTO position. the generator set is signaled to start while in the AUTO
position. This override provides emergency generator
Note: The transient start/stop function of the controller
set power in the event of a utility power failure. When the
prevents accidental cranking of the rotating
utility power returns and the generator set is signalled to
engine. The generator set stops and recranks
stop, the generator set continues to run for the duration
when the generator set master switch is
of the idle mode period when the idle mode is active.
momentarily placed in the OFF/RESET position
When the idle mode is not active, the generator set will
and then returned to RUN.
shut down in the normal stopping mode including time
delays.
Auto Starting
See Menu 9—Input Setup to activate the idle speed
Move the generator set master switch to the AUTO function as a user-defined digital input. The idle speed
position to allow startup by the automatic transfer switch feature requires an ECM-equipped engine with the idle
or remote start/stop switch (connected to controller speed function.
terminals 3 and 4).
Terminals 3 and 4 connect to a circuit that automatically Run Time Feature

starts the generator set crank cycle when an external
The run time feature allows the user to set up the
source closes the circuit.
generator set to run unassisted and automatically return
Note: The controller provides up to 60 seconds of to the standby mode. The user does not need to wait for
programmable cyclic cranking and up to the exercise period (run time) to conclude in order to
60 seconds rest with up to 6 cycles. The default place the unit back in the standby mode. See
setting is 15 seconds cranking and 15 seconds Menu 4—Operational Records for setup of this feature.
rest for 3 cycles. Make cyclic cranking
With the run time enabled, the generator set will begin to
adjustments using the keypad. See Section 2.9.14,
crank and run based on the run time period and all
Menu 14—Programming Mode, and Section 2.9.8,
previously established time delays from Menu 8—Time
Menu 8—Time Delays.
Delays.
Idle (Speed) Mode Warmup and Cooldown Generator set connected to an automatic transfer
Function switch. Should a utility power failure occur while the
unit is in the run time mode, the controller will bypass the
The idle (speed) mode function provides the ability to run time mode and function in the standby (backup)
start and run the engine at reduced speed for a mode. When the utility power returns, the generator set
selectable time period (0--10 minutes) during warmup. continues to run for the duration of the run time period
See Section 6.1.5, Idle (Speed) Mode Feature, for when not timed out.
installation information.
Note: Press the STOP PROG RUN key, when
The controller will override the idle speed mode when necessary, to stop the generator set when it is in
the engine reaches the preprogrammed engine the run time mode.
warm-up temperature before the idle mode times out.
28 Section 2 Operation TP-6083 7/05

Prime Power Switch Note: Use the emergency stop switch(es) for
emergency shutdowns only. Use the generator
The digital controller has an optional prime power mode set master switch for normal shutdowns.
of operation. The prime power mode requires
installation of an optional prime power switch kit. See The controller system shutdown lamp lights and the unit
Section 6, Accessories for instructions on how to install shuts down when the local or remote emergency stop
the optional prime power switch kit. The prime power switch activates.
switch kit prevents engine starting battery drain when
the generator set is shut down and no external battery
Battle Switch/Fault Shutdown Override
charging is available.
Switch
Move the prime power switch located on the back of the
The battle switch function forces the system to ignore
controller to the CONTROLLER ON position and set the
normal fault shutdowns such as low oil pressure and
controller time and date before attempting to start the
high engine temperature. The battle switch does not
generator set. When the prime power mode is off, all
override the emergency stop and overspeed shutdown.
controller functions including the digital display, LEDs,
When the battle switch function is enabled the generator
and alarm horn are operative.
set continues to run regardless of shutdown signals
Note: After energizing the controller using the prime where potential engine/generator damage can occur.
power switch, set the controller time and date.
When this input is enabled the yellow warning lamp
See Section 2.9.6, Menu 6—TIme and Date.
illuminates and stored warning/shutdown events that
Stop the generator set using the stopping procedures in are ignored continue to log in Menu 5— Event History.
2.3.2 before placing the generator set in the prime
See Section 2.9.9, Menu 9—Input Setup, for information
power mode. Move the prime power switch located on
on how to enable the battle switch feature.
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
2.3.3 Emergency Stop Switch Reset
display, LEDs, alarm horn, and communications are Procedure
inoperative.
Use the following procedure to reset the generator set
after shutdown by a local or remote emergency stop
2.3.2 Stopping switch. Refer to Section 2.3.7, Controller Reset
Procedure, to restart the generator set following a fault
Normal Stopping shutdown.
Run the generator set without load for 5 minutes to 1. Place the generator set master switch in the
ensure adequate engine cooldown. OFF/RESET position.
The controller has a programmable cooldown timer that 2. Investigate and correct the cause of the
functions only when the master switch is in the AUTO emergency stop.
position. To stop the generator set, place the generator
set master switch in the OFF/RESET position and wait 3. Reset the optional remote emergency stop switch by
until the generator set comes to a complete stop. replacing the glass piece, when equipped. Additional
glass rods are available as a service part. Reset the
Note: The cooldown cycle times out before the controller emergency stop switch by pulling the
generator set stops when a remote switch or switch knob outward.
automatic transfer switch initiates the generator
set start/stop sequence. 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
Emergency Stopping generator set will not crank until the reset
Use the controller emergency stop switch or optional procedure completes.
remote emergency stop for immediate shutdown.
2.3.4 System Ready Lamp
The emergency stop switch bypasses the time delay
engine cooldown and immediately shuts down the System Ready. The green lamp illuminates when the
generator set. generator set master switch is in the AUTO position and
the system has no fault conditions.

2.3.5 System Warning Lamp Emergency Power System (EPS) Supplying Load.
The lamp illuminates when the generator set supplies
The yellow warning lamp illuminates indicating a fault or more than 5% of the rated standby output current. The
status event but does not shut down the generator set local display shows EPS supplying load.
under the following conditions. In some cases the alarm
horn also sounds. See Section 2.3.7, Controller Reset Generator Switch Not in Auto. The lamp illuminates
Procedure, for instructions on resetting a system and the alarm horn sounds when the generator set
warning. master switch is in the RUN or OFF/RESET position.
The local display shows master switch not in auto.
When the system warning lamp is on and no message
displays, press the Reset Menu and the menu down ↓ Ground Fault Detected. The lamp illuminates and the
key to view messages. When the system warning alarm horn sounds when a user-supplied ground fault
continues, it may lead to a fault and cause a system detector signals the controller. The local display shows
shutdown. ground fault.
Use the Alarm Off keypad switch to silence the alarm High Battery Voltage. The lamp illuminates when the
horn at the operator’s discretion. Place the generator battery voltage rises above the preset level for more
set master switch in the AUTO position before silencing than 10 seconds. The local display shows high battery
the alarm horn. The alarm horn cannot be silenced voltage. Figure 2-1 shows high battery voltage
unless the master switch is in the AUTO position. specifications. The high battery voltage feature
monitors the battery and battery charging system in the
Note: Text shown in italics in this manual represents generator set operating and off modes.
digital display messages.
High Battery
AC Sensing Loss. The lamp illuminates when the
Engine Electrical High Battery Voltage Default
controller does not detect nominal generator set AC System Voltage Voltage Range Setting
output voltage after crank disconnect. The local display
12 14.5--16.5 16
shows AC sensing loss.
24 29--33 32
Battery Charger Fault. The lamp illuminates when the Figure 2-1 High Battery Voltage Specs
battery charger malfunctions. This fault feature requires
an optional battery charger with a malfunction output for High Coolant Temperature Warning. The lamp
the lamp to function. Local display shows battery illuminates and the alarm horn sounds when the engine
charger fault. coolant temperature approaches the shutdown range.
The local display shows high coolant temperature
Customer Auxiliary (Warning). The lamp illuminates warning.
and the alarm horn sounds when an auxiliary digital or
analog inputs signals the controller. The customer can Load Shed. The lamp illuminates when the generator
define inputs as shutdowns or warnings. The local set’s total kW load exceeds the programmed level for
display shows digital input 1-21 or analog input 1-7. more than the load shed time. When the load shed
alarm sounds and resets more than twice in 1 minute,
Using the remote communications package, the user the load shed warning lamp circuit latches and remains
can label the auxiliary functions. The controller displays on until the generator set shuts off. The local display
the selected name instead of digital input 1-21 or analog shows load shed kW over.
input 1-7.
When the generator set frequency drops to less than 59
EEPROM Write Failure. The lamp illuminates and the Hz on a 60 Hz system or 49 Hz on a 50 Hz system for
alarm horn sounds when the control logic detects a data more than 5 seconds, the local display shows load shed
save error. The local display shows EEPROM write under freq. When the load shed alarm sounds and
failure. resets more than twice in 1 minute, the load shed
warning lamp latches and remains on until the generator
set shuts down.

Low Battery Voltage. The lamp illuminates when the D Battery charger fault
battery voltage drops below a preset level for more than D EPS supplying load
10 seconds. The local display shows low battery D High battery voltage
voltage. See Figure 2-2 for low battery voltage D High coolant temperature warning
specifications.
D High coolant temperature shutdown
D Low battery voltage
Low Battery
D Low coolant level
Engine Electrical Low Battery Voltage Default
System Voltage Voltage Range Setting D Low coolant temperature warning
12 10--12.5 12 D Low fuel (level or pressure)
24 20--25 24 D Low oil pressure warning
D Low oil pressure shutdown
Figure 2-2 Low Battery Voltage Specs
D Master switch not in auto
The low battery voltage feature monitors the battery and D Overcrank
battery charging system in the generator set operating D Overspeed
and off modes. The controller logic inhibits the low
battery voltage warning during the crank cycle. Overcurrent. The lamp illuminates and the alarm horn
sounds when the generator set supplies more than
Low Coolant Temperature. The lamp illuminates and 110% of the rated standby output current for more than
the alarm horn sounds when the engine coolant 10 seconds. The local display shows overcurrent.
temperature is low. The local display shows low coolant
temperature. Speed Sensor Fault. The lamp illuminates and the
alarm horn sounds when the speed signal is absent for
Low Fuel (Level or Pressure). The lamp illuminates one second while the generator set runs. The local
and the alarm horn sounds when the fuel tank level on display shows speed sensor fault. This warning lamp
gasoline or diesel models approaches empty or low fuel remains on until the operator places the master switch in
pressure on gaseous fueled models occurs. This fault the OFF/RESET position.
requires an optional low fuel switch for the lamp to
function. The local display shows low fuel. Underfrequency. The lamp illuminates and the alarm
horn sounds when the frequency falls below the
(Low) Oil Pressure Warning. The lamp illuminates underfrequency setting. The local display shows
and the alarm horn sounds when the engine oil pressure underfrequency. See Figure 2-3.
approaches the shutdown range. The local display
shows oil press warning. Underfrequency Time Delay Underfrequency
Setting Range Range Default Setting
Master Switch in OFF/RESET Position. The lamp 80%--95% of nominal 10 sec. 90% of nominal
illuminates and the alarm horn sounds when the master
switch is placed in the OFF/RESET position. The local Figure 2-3 Underfrequency Specs
display shows master not in auto.
Weak Battery. The lamp illuminates when the battery
NFPA 110 Fault. The lamp illuminates and the alarm voltage falls below 60% of the nominal voltage (12 VDC
horn sounds when NFPA 110 faults signal the controller. or 24 VDC) for more than 2 seconds during the crank
The local display shows NFPA 110 fault. The NFPA 110 cycle. The local display shows weak battery.
faults include:
D Air damper indicator

2.3.6 System Shutdown Lamp High Coolant Temperature Shutdown. The lamp
illuminates and the unit shuts down because of high
The red lamp illuminates, the alarm horn sounds, and engine coolant temperature. The shutdown occurs
the unit shuts down to indicate a fault shutdown under 5 seconds after the engine reaches the temperature
the following conditions. See Section 2.3.7, Controller shutdown range. The high engine temperature
Reset Procedure, for information on resetting a system shutdown does not function during the first 30 seconds
shutdown. after startup. The local display shows high cool temp
shutdwn.
Use the Alarm Off keypad switch to silence the alarm
horn at the operator’s discretion. Place the generator Note: The high engine temperature shutdown function
set master switch in the AUTO position before silencing and the low coolant level shutdown function are
the alarm horn. The alarm horn will not stop sounding independent. A low coolant level condition may
unless the master switch is in the AUTO position. not activate the high engine temperature switch.
Note: The text shown in italics represents digital display High Oil Temperature. The lamp illuminates and the
messages. unit shuts down because of high engine oil temperature.
The shutdown occurs 5 seconds after the engine oil
Air Damper Indicator. The lamp illuminates and the reaches the temperature shutdown range. The high
unit shuts down when signaled by a closed air damper engine oil temperature shutdown does not function
circuit. The local display shows air damper indicator. during the first 30 seconds after startup. The local
display shows high oil temp.
Alternator Protection. The lamp illuminates and the
unit shuts down because of an alternator overload or Internal Fault. The lamp illuminates and the unit shuts
short circuit. The local display shows altrntr protect down when the internal diagnostic test detects a
sdwn. controller malfunction. The local display shows internal
fault.
Customer Auxiliary (Shutdown). The lamp
illuminates and the unit shuts down when an auxiliary Locked Rotor. If none of the speed sensing inputs
digital or analog input signals the controller. The show engine rotation within 5 seconds of initiating
customer can define inputs as shutdowns or warnings. engine cranking, the ignition and crank circuits turn off
The local display shows digital input 1-21 or analog input for 5 seconds and the cycle repeats. The unit shuts
1-7 when activated. down after the second cycle of 5 seconds of cranking.
The local display shows locked rotor.
Using the remote communications package, the user
can label the auxiliary functions. The controller displays Loss of ECM Communications. The lamp illuminates
the selected name instead of digital input 1-21 or analog and the unit shuts down when the ECM communication
input 1-7. link is disrupted. The local display shows loss of ECM
comm.
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.

Low Coolant Level. The lamp illuminates and the unit Note: The controller is equipped with an automatic
shuts down because of low coolant level. Shutdown restart function. When speed drops below 13 Hz
occurs 5 seconds after the controller detects low (390 rpm) while the engine is running, the unit
coolant level. The low coolant level shutdown does not attempts to recrank. The unit then follows the
function during first the 30 seconds after startup. The cyclic cranking cycle and, when the engine fails to
local display shows low coolant level. start, will shut down on an overcrank fault
condition.
Note: The high engine temperature shutdown function
and the low coolant level shutdown function are Overfrequency. The lamp illuminates and the unit
independent of each other. A low coolant level shuts down when the frequency is above the
condition may not activate the high engine overfrequency setting. The local display shows
temperature switch. overfrequency. See Figure 2-4.
(Low) Oil Pressure Shutdown. The lamp illuminates

Overfrequency Overfrequency
when the unit shuts down because of low oil pressure. Setting Range Time Delay Default Setting
The shutdown occurs 5 seconds after the engine
102%--140% of nominal 10 sec. 140% of nominal
pressure reaches the shutdown range. The low oil
pressure shutdown does not function during first the Figure 2-4 Overfrequency Specs
30 seconds after startup. The local display shows (low)
oil press shutdown. Overspeed. The lamp illuminates and the unit shuts
down immediately when the governed frequency on 50
Master Switch Error. The lamp illuminates and unit the and 60 Hz models exceeds the overspeed setting for
shuts down when the controller detects a fault in the 0.25 seconds. The local display shows overspeed. See
master switch position or circuit. The local display Figure 2-5 for overspeed specs.
shows master switch error.
Master Switch Open. The lamp illuminates and the unit Generator Set Overspeed Overspeed Default
shuts down when the controller detects an open circuit in Frequency Hz Range Hz Setting Hz
the master switch circuit. The local display shows 60 65--70 70
master switch open. 50 55--70 60
NFPA 110 Fault. The lamp illuminates and the unit Figure 2-5 Overspeed Specs
shuts down when NFPA 110 faults signal the controller.
The local display shows NFPA 110 fault. See Overvoltage. The lamp illuminates and the unit shuts
Section 2.4, Menu List Summary, Menu 10—Output down when the overvoltage setting exceeds the
Setup, for the NFPA 110 list. overvoltage setting for the time delay period. The local
display shows overvoltage. Overvoltage specifications
No Coolant Temperature Signal. The lamp follow. See Figure 2-6.
illuminates and the unit shuts down when the engine
coolant temperature sender circuit is open. The local Note: Overvoltage can damage sensitive equipment in
display shows no cool temp signal. less than one second. Install separate
overvoltage protection on online equipment
No Oil Pressure Signal. The lamp illuminates and the requiring faster than 2-second shutdown.
unit shuts down when the engine oil pressure sender
circuit is open. The local display shows no oil press Overvoltage Time Delay Overvoltage
signal. Setting Range Range Default Setting
105%--135% of nominal 2--10 sec. 115% at 2 sec.
Overcrank. The lamp illuminates and cranking stops
when the unit does not start within the defined cranking Figure 2-6 Overvoltage Specs
period. The local display shows overcrank. See
Section 2.3.1, Auto Starting, and Section 1,
Specifications and Features, for cyclic crank
specifications.

Underfrequency. The lamp illuminates and the unit 5. Start the generator set by moving the generator set
shuts down when the frequency falls below the master switch to the OFF/RESET position and then
underfrequency setting. The local display shows to the RUN position.
underfrequency. See Figure 2-7.
When equipped, the remote annunciator and/or
audiovisual alarm horn sounds when the alarm
Underfrequency Underfrequency
Setting Range Time Delay Default Setting
switch is in the NORMAL position. When
necessary, move the alarm switch to the SILENCE
80%--95% of nominal 10 sec. 90% of nominal
position to stop the alarm horn. The lamp turns off.
Figure 2-7 Underfrequency Specs
6. Test operate the generator set verifying correction
Undervoltage. The lamp illuminates and the unit shuts of the shutdown cause.
down when the voltage falls below the undervoltage
setting for the time delay period. The local display 7. Move the generator set master switch to the
shows undervoltage. Undervoltage specifications OFF/RESET position to stop the generator set.
follow. See Figure 2-8.
8. Move the generator set master switch to the AUTO
position.
Undervoltage Time Delay Undervoltage
Setting Range Range Default Setting 9. Silence the controller alarm horn by pressing the
85% of nominal alarm off key.
70%--95% of nominal 5--30 sec.
at 10 sec.
10. Reconnect the generator set load via the line circuit
Figure 2-8 Undervoltage Specs breaker or automatic transfer switch.
2.3.7 Controller Reset Procedure 11. Move the generator set master switch to the AUTO
position for startup by the remote transfer switch or
(Following System Shutdown or the remote start/stop switch.
Warning)
When equipped, move the remote annunciator
Use the following procedure to restart the generator set and/or audiovisual alarm switch to the NORMAL
after a system shutdown or to clear a warning lamp position.
condition. This procedure includes the resetting of the
optional remote annunciator and the audiovisual alarm.
2.4 Menu List Summary
Refer to Section 2.3.3, Emergency Stop Switch Reset
Procedure, to reset the generator set after an Use the Menu List Summary section on the following
emergency stop. pages after reading and understanding the features of
the keypad. See Section 1.2.2, Digital Display and
1. Move the generator set master switch to the AUTO Keypad.
position, if not already done.
The Menu List Summary provides a quick reference to
2. Silence the controller alarm horn by pressing the the digital display data. Some digital display data may
alarm off key. not be identical to your display due to generator set
application differences. The closed bullet items
When equipped, the optional remote annunciator represent main level data and the open bullet items are
and/or audiovisual alarm horn and lamp activate. sub-level data.
Move the alarm switch to the SILENCE position to
stop the alarm horn. The lamp stays lit. Section 2.8, Reviewing the Menu Displays, provides a
digital display menu overview and explains the
3. Disconnect the generator set load using the line navigation using the down and right arrow keys.
circuit breaker or automatic transfer switch.
Section 2.9, Local Programming Mode On, contains the
4. Correct the cause of the fault shutdown or warning. keystroke details of each menu when programming.
See Safety Precautions and Instructions section of
this manual before proceeding.

Menu List Summary
Menu 1 Menu 2 Menu 4 Menu 7
Generator Monitoring Engine Monitoring Operational Records Generator System
Volts & Amps Engine Monitoring D Factory Test Date D Operating Mode
D L1-L2 Volts Basic D Total Run Time d Standby Y/N
L1 Amps D Oil Pressure D Total Run Time d Prime Power N/Y
D L2-L3 Volts Coolant Temperature Loaded Hours D System Voltage
L2 Amps (3 phase) D Engine RPM D Total Run Time Line-Line
D L3-L1 Volts Local Battery VDC Unloaded Hours D System Frequency
L3 Amps (3 phase) Engine Monitoring D Total Run Time D Phase
D L1-L0 Volts Detailed (ECM equipped kW Hours
d 3-Phase Delta Y/N
L1 Amps engines only) D No. of Starts
d 3-Phase WYE N/Y
D L2-L0 Volts Engine Fuel D Engine Start Countdown
L2 Amps d 1-Phase N/Y
D Fuel Pressure d Run Time
D L3-L0 Volts Fuel Temperature D kW Rating
D Records-Maintenance
L3 Amps (3 phase) D Fuel Rate D Rated Current
d Reset Records
D Frequency D Used Last Run D Load Shed Output
D Run Time Since
D L1-L2 Volts Engine Coolant d Time Delay
Maintenance
L2 Amps (1 phase)
D Coolant Pressure Total Hours D Overvoltage
V & A Summary Coolant Temperature D Run Time Since d Time Delay
D V L1-L2, L2-L3, L3-L1 (ECM and non-ECM Maintenance D Undervoltage
(3 phase) engines) Loaded Hours d Time Delay
D V L1-L0, L2-L0, L3-L0 D Coolant Level D Run Time Since D Overfrequency
(3 phase) Engine Oil Maintenance D Underfrequency
D A L1, L2, L3 (3 phase) D Oil Pressure (ECM and Unloaded Hours
D Overspeed
D V L1-L2, L1-L0, L2-L0 non-ECM engines) D Run Time Since
Maintenance D Battery Voltage
(1 phase) Oil Temperature
kW Hours d 12 VDC Y/N
D A L1, L2 (1 phase) D Oil Level
D Operating Days d 24 VDC N/Y
Power kW D Crackcase Pressure
Last Maintenance D Low Battery Voltage
D Total kW Engine Misc
Power Factor D No. of Starts D High Battery Voltage
D ECM Battery VDC Last Maintenance
D L1 kW Ambient Temperature D Metric Units Y/N
Power Factor D Last Start D Set NFPA-110 Defaults
D Engine Model No. Date
D L2 kW Y/N
D Engine Serial No. D Length of Run
Power Factor
D Unit No. (Un)loaded Hours
D L3 kW ECM S/N
Power Factor (3 phase) Menu 8
D Total kW Time Delays
% of Rated kW Menu 5 D Time Delay
Power kVAR Menu 3 Event History Engine Start
D Total kVAR Analog Monitoring D (Message Text) D Time Delay
Absorbing/Generating
D Local Batt VDC D (Scroll through up to 100 Starting Aid
D L1 kVAR stored events) D Time Delay
D Analog 01 to 07
Absorbing/Generating Crank On
(user-defined descriptions)
D L2 kVAR (Scroll through 1--7 D Time Delay
Absorbing/Generating user-defined descriptions Crank Pause
Menu 6
D L3 kVAR with ECM engines) Time and Date D Time Delay
Absorbing/Generating (Scroll through 3--7 Eng. Cooldown
(3 phase) user-defined descriptions D Time 00:00 AM/PM D Overcrank Shutdown
Power kVA with non-ECM engines D Date Crank Cycles
where 01 is coolant D Time Delay
D Total kVA
temperature and 02 is oil Overvoltage
D L1 kVA pressure)
D L2 kVA D Time Delay
Undervoltage
D L3 kVA (3 phase)
D Time Delay
Load Shed kW

Menu List Summary, continued
Input Setup Input Setup, cont. Output Setup, cont. Output Setup, cont.
Setup Digital Setup Analog Relay Driver Outputs Group B, continued
Auxiliary Inputs Auxiliary Inputs (RDOs) Load Shed kW Over
D Digital Input D Analog Input D RDOs (Y/N) Load Shed Under Freq
(Scroll through up to 21 (Scroll through 1--7 (Scroll through up to
Over Current
user defined desc) user-defined descriptions 31 status and fault choices
with ECM engines) from: EPS Supplying Load
D Digital Input
Message Text Y/N, (Scroll through 3--7 d System events, Internal Fault
see Group A user-defined descriptions see Group B Delay Engine Cooldown
with non-ECM engines)
d 21 digital inputs Delay Engine Start
Group A D Analog Input D01-D21 Starting Aid
The preprogrammed Warning Enabled Y/N
d 7 analog inputs
selections include the D Analog Input Generator Running
A01--A07
following: Shutdown Enabled Y/N Air Damper Control
Warning D Analog Input Group B Ground Fault
Shutdown Type A Inhibit Time 0--60 Sec. The system events include
EEPROM Write Failure
the following:
Shutdown Type B D Analog Input Critical Overvoltage
Warning Delay Time Emergency Stop
Voltage Raise Alternator Protection SDWN
0--60 Sec. Over Speed
Voltage Lower Air Damper Indicator
D Analog Input Over Crank
VAR PF Mode Shutdown Delay Time Defined Common Fault
Hi Cool Temp Shutdown
Remote Shutdown 0--60 Sec. (RDO only)
Oil Pressure Shutdown
Remote Reset D Analog Input SCRDOs 1--4 (Software
Low Shutdown Value Low Coolant Temperature Controlled RDOs)
Air Damper (non-ECM engines)
Low Fuel D Analog Input
Low Fuel *NFPA-110 Fault
Low Warning Value
Field Overvoltage The 15 NFPA-110 Common
D Analog Input Hi Cool Temp Warning
Fault Alarms include the
Idle Mode Active High Warning Value Oil Pressure Warning
(ECM engines only) following:
D Analog Input Master Not in Auto
Battle Switch Overspeed
High Shutdown Value NFPA 110 Fault*
Ground Fault Overcrank
Menu 10 Low Battery Voltage High Coolant Temperature
Bat Chgr Fault
Output Setup High Battery Voltage Shutdown
Hi Oil Temperature
Defined Common Fault Battery Charger Fault Oil Pressure Shutdown
Low Coolant Level
D Defined Common Fault System Ready Low Coolant Temperature
Low Coolant Temperature
(Y/N for a single defined Loss of ECM Comm High Coolant Temperature
(Not user selectable)
common fault) (ECM engines) Warning
D Digital Input Scroll through status and No Oil Pressure Signal Oil Pressure Warning
Enable Y/N fault choices from:
D Digital Input Hi Oil Temperature Low Fuel
d System events,
Inhibit TIme see Group B (except No Cool Temperature Signal Master Not In Auto
D Digital Input Defined Common Low Coolant Level Battery Charger Fault
Delay Time Fault) Speed Sensor Fault Low Battery Voltage
d 21 digital inputs Locked Rotor HIgh Battery Voltage
D01-D21
Master Switch Error Low Coolant Level
d 7 analog inputs
A01--A07 Master Switch Open EPS Supplying Load
Master Switch to Off Air Damper Indicator
AC Sensing Loss
Over Voltage
Under Voltage
Weak Battery
Over Frequency
Under Frequency

Menu List Summary, continued
Output Setup, cont. Calibration Communications Programming Mode
Digital Inputs Scale AC Analog Protocol D Programming Mode
D Common Fault Y/N Inputs KBUS d Local? Y/N
(Scroll through up to 21 D Gen L1-L0 V D KBUS Online Y/N d Remote? Y/N
user-defined Calibration Reference D Connection Type d Off? Y/N
descriptions shown as D Gen L2-L0 V (User-defined)
D01 to D21) D Programming Mode
Calibration Reference d Local Single Y/N Change, Access Code
Analog Inputs D Gen L3-L0 V (3 phase) d Local LAN Y/N d Enter Old Code
D Common Fault Y/N Calibration Reference
d Local LAN Conv Y/N d Enter New Code
(Scroll through up to D Gen L1 Amps
7 user-defined d Remote Single Y/N
Calibration Reference
descriptions shown d Remote LAN Y/N
D Gen L2 Amps
as A01 to A07)
Calibration Reference d Remote LAN Conv Y/N
(ECM engines) D Primary Port
D Gen L3 Amps (3 phase)
D Common Fault Y/N (User-defined)
Calibration Reference
(Scroll through up to d RS-232 Y/N
5 user-defined D Restore Defaults? Y/N
descriptions shown d RS-485 ISO1 Y/N
as A03 to A07) Scale Aux. Analog D Address
(non-ECM engines) Inputs (LAN Connections)
D Low Warning D Zero Aux. Analog Inputs D System ID
D High Warning (Scroll through additional (Remote Connections)
D Low Shutdown analog auxiliary inputs D BAUD Rate
1--7 with ECM engines) (User-defined)
D High Shutdown
(Scroll through additional d BAUD Rate
analog auxiliary inputs 1200
Menu 11 3--7 with non-ECM 2400
Voltage Regulator engines) 9600
D Analog 01
AVG L-L V
Scale Value 1 Protocol
Volt ADJ
d Scale 1 V Modbus
D L1-L2 Volts Scale 2 V D Modbus Online N/Y
D L2-L3 Volts (3 phase) D Analog 01 D Connection Type
D L3-L1 Volts (3 phase) Scale Value 2 (User-defined)
Under Freq. Unload d Scale 1 V d Single Y/N
Enabled N/Y Scale 2 V
d Convertor Y/N
D Frequency
Setpoint (Cut-In Point) D Primary Port
D Slope d RS-485
Volts-Per-Cycle d RS-232
Reactive Droop D Address
Enabled N/Y D BAUD Rate
D 0.8 PF Rated Load (User-defined)
Voltage Droop d 9600
VAR Control d 19200
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

2.5 Digital Display Messages
Throughout this manual there are examples of the the 40-character display. See Figure 2-9 for a full
display text. In some cases, the message words and description of the system event display messages.
phrases are abbreviated or shortened to accommodate
Display Message Description

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

2.6 Reviewing Digital Display Enter ↵ Key. Press the enter ↵ key to confirm the
entered information on the display when selecting
The user interacts with the controller with a keypad and menus or programming.
digital display. Use the keypad to access the generator
set informational data and preset settings. This review Lamp Test Key. Press the lamp test key to check that
section shows how to access the data. See Section 2.9, the status and fault lamps illuminate, the horn sounds,
Local Programming Mode On, for instructions on how to and the digital display clears. Press the reset menu key
change the information. See Figure 2-10 for an before pressing the lamp test key.
illustration of the digital display and keypad.
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--9 Keys. Press the numeric keys when

selecting menus or entering numeric values during
programming. The controller ignores the secondary
TP-5829-2
function of the key (yes, no, etc.) when numeric values
Figure 2-10 Digital Display and Keypad are valid.
Note: After energizing the controller by reconnecting Reset Menu Key. The reset menu key exits a menu,
the battery, set the controller time and date. See clears incorrect entries, and cancels the auto-scroll
Section 2.9.6, Local Programming Mode On, function. Press the reset menu key to exit a menu or any
Menu 6—Time and Date. layer within that menu.
Pressing any key on the keypad activates the controller Stop Prog Run Key. Press the stop prog run key to end
panel display. The panel lamps and display turn off the generator set programmed exercise run created in
5 minutes after the last keypad entry. Menu 4—Operational Records. The generator set
shuts down after the time delay for engine cooldown
2.6.1 Keypad Operation ends. The stop prog run key does not affect the
programmed transfer switch exercise function.
Use the keypad to input information into the controller.
Some of the keys have two functions. The following Yes/No Keys. When the controller asks a question
gives keypad definitions and functions. during programming requiring a nonnumeric answer (yes
or no), the controller accepts the secondary key function
Alarm (Horn) Off Key. Press the alarm off key to
and ignores the numeric value of the key.
silence the horn at the user’s discretion. Place the
generator set master switch in the AUTO position before
silencing the alarm horn. The alarm horn cannot be 2.6.2 Auto-Scroll Function
silenced unless the master switch is in the AUTO
position. See Section 2.3.7, Controller Reset The auto-scroll function continuously shows voltage
Procedure, for more information on turning the alarm and current data from Menu 1—Generator Monitoring,
horn off. V & A Summary without the need to press the down
arrow for each display.
AM/PM Key. When the controller asks a question during
programming requiring a nonnumeric answer (am or For auto-scroll function press ENTER at the V & A
pm), the controller accepts the secondary key function Summary menu. Press the Reset Menu key or Menu
and ignores the numeric value of the key. Right → key to stop the auto-scroll function.

2.6.3 Request and Error Messages Cannot Change (because the) NFPA is Enabled
appears when the user attempts to modify an RDO
Request Messages setting that is a NFPA 110 default requirement.
Display messages require additional data, confirm the Cannot Change Preset appears when the user
previous entry or require time to process as described attempts to change the preset factory digital input or
below. input parameter.
Entry Accepted appears for several seconds after Entry Unacceptable appears when the user attempts
pressing the Enter key during the programming mode. an invalid input to the voltage regulator setup.
The display then shows the new data.
Func(Function) Used by (RDO) XX Reassign?
Reset Complete indicates the user: appears when the user attempts to assign an RDO to a
function already assigned.
D Reset the maintenance records or
Invalid Code appears when the user attempts to enter:
D Restored the AC analog inputs to the default settings.
D An invalid access code for programming mode setup,
Right Arrow → directs the user to the next menu.
or
Menus loop; press the right arrow key to the next menu.
D An invalid access code for setup unlock.
Setup Complete indicates the completion of the analog
No Input Assigned appears when the user attempts to
input setup.
assign any of the following system faults to an RDO
(Question) ? asked by the control firmware; answer the where the digital input is not defined. See digital input
question by pressing the yes/no, numeric digit, or scale requirements in Menu 12—Calibration.
am/pm key.
D Air damper indicator
Wait for System Reset (6 Sec) appears while the D Battery charger fault
EEPROM initializes. D Ground fault
D High oil temperature shutdown
Error Messages D Low coolant level
When an error message appears, the entered D Low fuel

information is not within the allowable parameters set by
Not in Local Program Mode appears when the user
the control firmware or is not permitted as described
attempts to program using the keypad when the
below. In cases where the data was outside the
programming mode is set for remote or off.
parameters, press the Reset Menu key and enter the
corrected information. Output in Use appears when the user attempts to
modify or reassign an active RDO.
Access Denied appears when the user attempts to:
Port in Use appears when the user attempts to use an
D Enter data prohibited by the master switch position,
already assigned communications port.
D Enter data prohibited by the generator set state, or
D Enable the LDD (load disturbance detection). Range Error appears when the user attempts to enter:
Access Denied Idle Mode Active appears when the D A numeric input that is not within the required
user attempts to modify the voltage regulator setup parameters of system settings, time delays,
while the idle mode is active. addresses, etc.
Alarm Active appears when the user attempts to D An invalid analog or digital input number or date/time.
modify an active digital input. See Menu 9—Input
Setup. Setpoint Values Cannot be Equal appears when the
user attempts to enter the same value for both setpoints
during the analog input calibration.

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

2.7.1 Personal Computer (PC) Local Area Network (LAN)
Communications A PC connects to the device’s LAN. A LAN is a system
There are four ways to communicate between a PC and that connects more than one device to a single PC.
the generator set and/or transfer switch devices using Acceptable devices include Decision-Maker™ 550
KBUS communication protocol. The PC connections controller, Decision-Maker™ 340 controller, M340
require optional software and possibly other hardware, transfer switch control, M340+ transfer switch control,
communication modules in the generator set controller and PM340 power monitor. See Figure 2-14.
and/or transfer switch. See the Software Operation
Manual for details. Contact your authorized Generator Set
distributor/dealer for availability. Controller or
Transfer Switch
Control
Local Single Connection
Generator Set
A PC connects to the COM port of the controller module Controller or
using an RS-232 cable when the PC is within 15 m (50 Transfer Switch
ft.) of the device or an RS-485 cable when the PC is Control
RS-232 to RS-485
within 1220 m (4000 ft.) of the device. See Figure 2-12 port converter
or Figure 2-13. Generator Set
RS-485 Controller or
up to Transfer Switch
Personal 1220 m Control
Computer (4000 ft.)
Generator Set
Controller or
Generator Set Transfer Switch
Controller or Control
Transfer Switch
Control
Figure 2-14 Local Area Network
RS-232
Personal up to
Computer 15 m (50 ft.)
Figure 2-12 Local Single Connection,

up to 15 m (50 ft.)
Generator Set
RS-232 to RS-485 Controller or
port converter Transfer Switch
Control
RS-485
up to
Personal 1220 m
Computer (4000 ft.)
Figure 2-13 Local Single Connection, up to

1220 m (4000 ft.)

Remote Single Connection Remote Area Network
A modem connects a PC to a single device. The PC A PC connects to a modem. The devices connect to a
communicates with the device via a telephone network. LAN network. The PC communicates to the devices via
Locate the PC anywhere a telephone line is available. a telephone network that is interfaced to the LAN
See Figure 2-15. network. Acceptable devices include Decision-
Maker™ 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.
Generator Set
Modem Modem Controller or
Transfer Switch
Control
RS-232 RS-232
up to Telephone up to
Personal 15 m (50 ft.) Lines 15 m (50 ft.)
Computer
Figure 2-15 Remote Single Connection
Generator Set Generator Set

Controller or Controller or
Transfer Switch Transfer Switch
Control Control
Modem RS-232 to RS-485

Modem
port converter
RS-485 Generator Set Generator Set
Telephone up to 1220 m Controller or Controller or
Personal Lines (4000 ft.) Transfer Switch Transfer Switch
Computer Control Control
Figure 2-16 Remote Area Network
2.7.2 Modbus Communications

RS-485
The controller communicates using Modbusr as a slave up to 1220 m (4000 ft.)
connection with the Modbusr master initiating the Generator Set
communication. The controller interrogates system and Modbusr Master
Controller
alternator parameters and diagnostic information. In RS-232
addition, the controller accepts information to alter up to 15 m (50 ft.)
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.

2.8 Reviewing Menu Displays Note: Press the Menu Right → key prior to entering
decimal values where necessary.
Use this section to review generator set controller data
while in the programming off mode. Menus displaying the # symbol represent one of the
following data types:
Press the Reset key, enter the desired menu number
key(s), and then press the Enter key. Use the down D System-calculated data
arrow and right arrow keys for navigation. D System-measured data
D User-entered data
See Section 1, Specifications and Features, to review
set point ranges and default settings for comparison to Menus displaying the ? symbol require the user to enter
the actual setup. data.
The user must enable the programming mode to edit the Menus displaying the * symbol represent access code
display. See Menu 14—Programming Mode and or password type entries. Actual key entry does not
Section 2.9, Local Programming Mode On, for more display.
information.
See Section 2.6.3, Request and Error Messages, for
Note: Press any key on the keypad to activate the error display messages and explanations while
controller panel display. The panel display turns navigating the menus.
off 5 minutes after the last keypad entry.
Note: Press the Reset Menu key to clear error

messages.

2.8.1 Menu 1—Generator Monitoring
Menu 1 displays generator output data including Note: For the auto-scroll function, press ENTER at V &
line-to-line and line-to-neutral voltages, current, A Summary menu. Press the Reset Menu key or
frequency, power factor, total kilowatts, percent of Menu Right → key to stop the auto-scroll function.
maximum kW, total kVA, and total kVAR. Menu 1
displays three-phase voltage and current readings Note: Pressing a right arrow key from any submenu
when applicable. moves to the next submenu header.
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 # V L1-L2 L2-L3 L3-L1 TOTAL KW # TOTAL KVAR # TOTAL KVA #
L1 AMPS # (3 PH) # # # PF # LEADING/LAGGING ABSORBING/GENERATING
L2-L3 VOLTS # V L1-L0 L2-L0 L3-L0 L1 KW # L1 KVAR # L1 KVA #

L2 AMPS (3 PH) # (3 PH) # # # PF # LEADING/LAGGING ABSORBING/GENERATING
L1-L2 VOLTS # V L1-L2 L1-L0 L2-L0 L2 KW # L2 KVAR # L2 KVA #

L2 AMPS (1 PH) # (1 PH) # # # PF # LEADING/LAGGING ABSORBING/GENERATING
L3-L1 VOLTS # A L1 L2 L3 L3 KW (3 PH) # L3 KVAR (3 PH) # L3 KVA #

L3 AMPS (3 PH) # (3 PH) # # # PF # LEADING/LAGGING ABSORBING/GENERATING (3 PH)
L1-L0 VOLTS # A L1 L2 TOTAL KW #

L1 AMPS # (1 PH) # # % OF RATED KW #
For the auto-scroll function,

L2-L0 VOLTS #
press ENTER at
L2 AMPS #
V & A SUMMARY menu.
L3-L0 VOLTS #
L3 AMPS (3 PH) # Use the MENU→ key to
stop the auto-scroll function.
FREQUENCY # HZ

2.8.2 Menu 2—Engine Monitoring
Menu 2 displays engine operating data including oil Note: A right arrow from any submenu moves to the
pressure and temperature, coolant pressure and next submenu header.
temperature, fuel pressure and temperature, engine
rpm, and battery voltage. The detailed engine
monitoring feature functions only with an ECM-
equipped engine.
Menu 2 Overview
MENU 2
ENGINE MONITORING
ENGINE MONITORING → ENGINE MONITORING →

BASIC DETAILED
OIL PRESSURE # PSI ENGINE FUEL → ENGINE COOLANT → ENGINE OIL → ENGINE MISC →
COOLANT TEMP #F
ENGINE RPM # FUEL PRES # PSI COOLANT PRES # PSI OIL PRES # PSI ECM BATT VDC #
LOCAL BATT VDC # FUEL TEMP #F COOLANT TEMP #F OIL TEMP #F AMBIENT TEMP #F
FUEL RATE # GPH COOLANT LEVEL #% OIL LEVEL #% ENGINE MODEL NO.
CRANKCASE PRES # PSI #
USED LAST RUN ENGINE SERIAL NO.

# GAL #
UNIT NO. #
ECM S/N #

2.8.3 Menu 3—Analog Monitoring
Menu 3 displays battery voltage and up to 7 user- Note: If the analog display shows O/R (out of range), no
defined analog items dependant upon the generator input is connected.
system.
Note: ECM engines have user-defined analog inputs
The User Defined Desc display refers to a description 01--07. Non-ECM engines have user-defined
entered into the controller using the PC software. This analog inputs 03--07 where analog inputs 01 and
description remains as the display for future review until 02 are reserved for engine oil pressure and
changed by the PC software user. The display has coolant temperature displays.
20 characters maximum.
Menu 3 Overview
MENU 3
ANALOG MONITORING
LOCAL BATT VDC #
ANALOG 01 # Press the down arrow to Press the down arrow to

(USER DEFINED DESC) scroll through 1--7 additional scroll through 3--7 additional
ANALOG auxiliary inputs or ANALOG auxiliary inputs or
enter input number with ECM enter input number with non-
engines. ECM engines.
ANALOG 02 #
(USER DEFINED DESC)
ANALOG 03 #
(USER DEFINED DESC)
ANALOG 04 #
(USER DEFINED DESC)
ANALOG 05 #
(USER DEFINED DESC)
ANALOG 06 #
(USER DEFINED DESC)
ANALOG 07 #
(USER DEFINED DESC)

2.8.4 Menu 4—Operational Records
Menu 4 displays the generator set’s operating record After performing maintenance enter yes to reset records
including operating start date, last logged maintenance, reflecting the current day. The user must enable the
total run time loaded and unloaded, run time since last programming mode to edit the display.
maintenance, number of starts, and number of days the
unit ran.
Menu 4 Overview
MENU 4 NO. OF STARTS #
OPERATIONAL RECORDS LAST MAINT ##-###-##
FACTORY TEST DATE LAST START ##:## AM/PM

##-###-## DATE ##-###-##
TOTAL RUN TIME LENGTH OF RUN

HRS # (UN)LOADED HRS #
TOTAL RUN TIME

LOADED HRS #
TOTAL RUN TIME

UNLOADED HRS #
TOTAL RUN TIME

KW HRS #
NO. OF STARTS #
ENGINE START? Y/N→ RUN TIME HR:MN →

COUNTDOWN ##:## ??:??
RECORDS-MAINT → RESET RECORDS? Y/N→
RUN TIME SINCE MAINT

TOTAL HRS #

LOADED HRS #

UNLOADED HRS #

KW HRS #
OPERATING DAYS #
LAST MAINT ##-###-##

2.8.5 Menu 5—Event History
Menu 5 stores and displays the times and dates of up to
100 stored warning and shutdown events. See
Menu 10—Output 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 6—Time 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 ??-???-??

2.8.7 Menu 7—Generator System
Menu 7 displays factory-preset generator set voltage Note: The user defines the data shown in Menu 7. It is
and frequency data. Enter the new voltage and/or NOT data measured by the controller and
frequency data when the generator set requires voltage associated sensing devices. The user defines
reconnection and/or frequency adjustment. It is these values for purposes of calibrating the
imperative that the user enter the correct data because control.
these settings trigger all related shutdowns.
Note: Press the Menu Right → key prior to entering
The user must enable the programming mode to edit the decimal values where necessary.
display.
Menu 7 Overview
MENU 7
GENERATOR SYSTEM
OPERATING MODE → OPERATING MODE →

STANDBY Y/N PRIME POWER Y/N
SYSTEM VOLTAGE
LINE-LINE ?
SYSTEM FREQ # HZ
PHASE → PHASE → PHASE →

3 PHASE DELTA Y/N 3 PHASE WYE N/Y SINGLE PHASE N/Y
KW RATING ?
RATED CURRENT #
LOAD SHED OUTPUT → TIME DELAY MIN:SEC →

?% # KW ??:??
OVERVOLTAGE → TIME DELAY MIN:SEC →

?% # VAC ??:??
UNDERVOLTAGE → TIME DELAY MIN:SEC →

?% # VAC ??:??
OVERFREQUENCY
?% # HZ
UNDERFREQUENCY
?% # HZ
OVERSPEED
? HZ # RPM
TO GENERATOR SYSTEM
MENU ON NEXT PAGE

Menu 7—Generator System, continued
BATTERY VOLTAGE → BATTERY VOLTAGE →

12 VDC Y/N 24 VDC Y/N
LOW BATTERY VOLTAGE

?.? VDC
HIGH BATTERY VOLTAGE

?.? VDC
METRIC UNITS Y/N
SET NFPA-110 Y/N

DEFAULTS
2.8.8 Menu 8—Time Delays

Menu 8 displays the cyclic cranking cycles, various The user must enable the programming mode to edit the
engine related starting and shutdown features, and display.
auxiliary shutdown and inhibit time delays.
Menu 8 Overview
MENU 8
TIME DELAYS
TIME DELAY MIN:SEC

ENGINE START ??:??
TIME DELAY MIN:SEC

STARTING AID ??:??
TIME DELAY MIN:SEC

CRANK ON ??:??
TIME DELAY MIN:SEC

CRANK PAUSE ??:??
TIME DELAY MIN:SEC

ENG COOLDOWN ??:??
OVERCRANK SHUTDOWN
CRANK CYCLES ?
TIME DELAY MIN:SEC

OVERVOLTAGE ??:??
TIME DELAY MIN:SEC

UNDERVOLTAGE ??:??
TIME DELAY MIN:SEC

LOAD SHED KW ??:??

2.8.9 Menu 9—Input Setup
Menu 9 displays the setup of user-defined digital and D Time Delay (shutdown or warning). The time delay
analog warning and shutdown inputs. These inputs follows the inhibit time delay. The time delay is the
provide a multitude of choices for configuring time period between when the controller first detects
customized auxiliary inputs. the fault or status event and the controller warning or
shutdown lamp illuminates. The delay prevents any
The user must enable the programming mode to edit the nuisance alarms. The time delay range is from 0 to 60
display. seconds.
Note: Press the down arrow to move to the start of the Additional Analog Input Entries. The analog input
next input setup. selection typically requires entering four values—low
warning, high warning, low shutdown, and high
Note: ECM engines have user-defined analog inputs shutdown.
01--07. Non-ECM engines have user-defined
analog inputs 03--07 where analog inputs 01 and Battle Switch/Fault Shutdown Override Switch. The
02 are reserved for engine coolant temperature battle switch function forces the system to ignore normal
and oil pressure displays. fault shutdowns such as low oil pressure and high
engine temperature. The battle switch does not
Digital and Analog Inputs. After the user selects input, override the emergency stop and overspeed shutdown.
enter the following choices or values—enabled When the battle switch function is enabled the generator
(yes/no), inhibit time (min.:sec.), and delay time set continues to run regardless of shutdown signals
(min.:sec.). where potential engine/generator damage can occur.
D Enabled. This menu entry enables the input. The When this input is enabled the yellow warning lamp
previous yes/no selection does not activate the input. illuminates and stored warning/shutdown events that
Analog inputs have separate warning and shutdown are ignored continue to log in Menu 5— Event History.
enabled choices.
Shutdown Type A and Shutdown Type B. Choose
D Inhibit Time Delay. The inhibit time delay is the time shutdown type A for standard shutdown where red
period following crank disconnect during which the lamp illuminates and alarm horn sounds. Choose
generator set stabilizes and the controller does not shutdown type B for shutdown where air damper
detect the fault or status event. The inhibit time delay indicator RDO-23 energizes for two seconds, red lamp
range is from 0 to 60 seconds. illuminates, and alarm horn sounds.
Menu 9 Overview
MENU 9
INPUT SETUP
SETUP DIGITAL → TO ANALOG INPUT

AUXILIARY INPUTS SETUP (NEXT PAGE)
DIGITAL INPUT 01 → DIGITAL INPUT 01 → DIGITAL INPUT 01 → DIGITAL INPUT 01 → DIGITAL INPUT 01 →
(USER DEFINED DESC) (see Group A) YES/NO ENABLED YES/NO INHIBIT TIME ?:?? DELAY TIME ?:??
Press the down arrow to Group A Group A, continued

scroll through additional The preprogrammed AIR DAMPER Y/N
DIGITAL auxiliary inputs selections include the LOW FUEL Y/N
1--21 or enter the input following: FIELD OVERVOLTAGE Y/N
number. IDLE MODE ACTIVE Y/N
WARNING Y/N
SHUTDOWN TYPE A Y/N (ECM engine only)
SHUTDOWN TYPE B Y/N BATTLE SWITCH Y/N
VOLTAGE RAISE Y/N GROUND FAULT Y/N
VOLTAGE LOWER Y/N BAT CHGR FAULT Y/N
VAR PF MODE Y/N Hi OIL TEMP Y/N
REMOTE SHUTDOWN Y/N LOW COOLANT LEVEL Y/N
REMOTE RESET Y/N LOW COOLANT TEMP Y/N
(not user selectable)

Menu 9—Input Setup, continued
SETUP ANALOG → TO DIGITAL INPUT

AUXILIARY INPUTS SETUP (PREV. PAGE)
ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX →

(USER DEFINED DESC) WARNING ENABLED Y/N SHUTDOWN ENABLED Y/N INHIBIT TIME ?:??
Press down arrow to scroll Press down arrow to scroll

through 1--7 additional through 3--7 additional
ANALOG auxiliary inputs or ANALOG auxiliary inputs or
enter input number on ECM enter input number on non-
engines. ECM engines.
ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX →

WARN DELAY TIME ?:?? SDWN DELAY TIME ?:?? LO SDWN VALUE ?? LO WARN VALUE ??
ANALOG INPUT XX → ANALOG INPUT XX →

HI WARN VALUE ?? HI SDWN VALUE ??
2.8.10 Menu 10—Output Setup

Menu 10 displays the setup of user-defined system, The user can select up to 21 user-defined digital status
digital, and analog status and fault outputs and relay events and faults designated as D01 to D21. Each of the
driver outputs (RDO) 1--31. These RDO outputs provide 21 status events and faults are assignable as
a multitude of choices for configuring customized shutdowns or warnings.
auxiliary outputs. Additional individual outputs are
available for monitoring, diagnostics, and control The user can select up to 7 user-defined analog status
functions. events and faults designated as A01 to A07. Each of the
7 status events and faults are assignable as shutdowns
The user must enable the programming mode to edit the or warnings with high or low settings for a total of up to 7
display. status events and fault functions.
Note: Some data require entry using a PC in the Relay Driver Outputs (RDOs)
Remote Programming mode. See the Software
Operation Manual for details. Up to 31 RDOs are available using the system, digital,
and analog status events and faults. RDOs provide only
Common Faults the driver. The contact relays that interface with other
equipment are optional.
The user can program a single fault comprised of faults
from 3 common fault programs—system, digital, and Note: Func(tion) Used By (RDO) XX Reassign? error
analog faults. message appears when the user attempts to
duplicate an existing RDO selection.
Up to 46 user-defined system status events and faults
are available. See Group B on the following pages for Note: Cannot Change NFPA is Enabled. error message
specific descriptions. The NFPA-110 faults are part of appears when the user attempts to modify RDO
the system fault program and are comprised of 15 setting defaulted as NFPA 110 requirement.
individual faults shown on the next page.

Menu 10 Overview
MENU 10
OUTPUT SETUP
DEFINE COMMON → SYSTEM EVENTS → DIGITAL INPUTS → ANALOG INPUTS →

FAULTS
COMMON FAULT Y/N COMMON FAULT Y/N COMMON FAULT Y/N COMMON FAULT Y/N
(see Group B) (see Group C) (see Group D)LO WARNING→ HI WARNING→
Press down arrow to scroll Press down arrow to scroll Press down arrow to scroll COMMON FAULT Y/N
through available faults. through digital auxiliary through analog auxiliary LO SHUTDOWN→
inputs. inputs.
Group B Group B, continued Group C

COMMON FAULT Y/N
For defined system events, MASTER SWITCH ERROR Up to 21 user-defined HI SHUTDOWN→
choose from the following MASTER SWITCH OPEN digital status events and
46 status events and faults fault inputs designated as
by changing selection to MASTER SWITCH TO OFF D01 to D21 can result in a
YES: AC SENSING LOSS digital input common fault. *NFPA 110 FAULT
EMERGENCY STOP OVER VOLTAGE The 15 NFPA-110 Fault
Alarms include the
OVER SPEED UNDER VOLTAGE Group D following:
OVER CRANK WEAK BATTERY Up to 7 analog inputs, user- OVERSPEED
HI COOL TEMP SHUTDWN OVER FREQUENCY defined status events and OVERCRANK
OIL PRESS SHUTDOWN UNDER FREQUENCY faults designated as A01 to
A07. Each of the 7 is HIGH COOLANT TEMP
LOW COOLANT TEMP LOAD SHED KW OVER assignable as a shutdown SHUTDOWN
(non-ECM engines) LOAD SHED UNDER FREQ or warning with high or low OIL PRESSURE
LOW FUEL OVER CURRENT settings. SHUTDOWN
HI COOL TEMP WARNING EPS SUPPLYING LOAD LOW COOLANT
[DEFINED COMMON TEMPERATURE
OIL PRES WARNING INTERNAL FAULT FAULT
MASTER NOT IN AUTO HIGH COOLANT TEMP
DELAY ENG COOLDOWN The 5 defined common WARNING
NFPA 110 FAULT* DELAY ENG START faults include the
OIL PRESSURE
LOW BATTERY VOLTAGE following:
STARTING AID WARNING
HIGH BATTERY VOLTAGE EMERGENCY STOP
GENERATOR RUNNING LOW FUEL
BATTERY CHARGE FAULT HI COOL TEMP
AIR DAMPER CONTROL MASTER NOT IN AUTO
SHUTDOWN
SYSTEM READY GROUND FAULT BATTERY CHARGER
OIL PRESS SHUTDOWN
LOSS OF ECM COMM EEPROM WRITE FAILURE FAULT
(ECM engines) OVERCRANK
CRITICAL OVERVOLTAGE LOW BATTERY VOLTAGE
NO OIL PRESS SIGNAL OVERSPEED
ALTERNATOR PROTECTION HIGH BATTERY VOLTAGE
HI OIL TEMP SHUTDOWN LOW COOLANT LEVEL
NO COOL TEMP SIGNAL AIR DAMPER INDICATOR EPS SUPPLYING LOAD
LOW COOLANT LEVEL DEFINED COMMON FAULT AIR DAMPER INDICATOR
SPEED SENSOR FAULT (RDO only)[
LOCKED ROTOR SCRDOs 1--4 (software
controlled RDOs)
RELAY DRV OUT XX → SYSTEM EVENTS → DIGITAL INPUTS → ANALOG INPUTS →
(see Group E)
Press down arrow to scroll

through RDO’s 1--31 or enter RELAY DRV OUT XX Y/N RELAY DRV OUT XX Y/N RELAY DRV OUT XX Y/N RELAY DRV OUT Y/N
RDO number. (see Group B) (see Group C) (see Group D)LO WARNING→ HI WARNING→
Group E
Choose up to 31 status Press down arrow to scroll Press down arrow to scroll Press down arrow to scroll
event and fault RDOs RELAY DRV OUT Y/N
through available RDO through RDO digital auxiliary through RDO analog
from the following: LO SHUTDOWN→
faults. inputs. auxiliary inputs.
SYSTEM FAULTS
(see Group B, 46 Items)
DIGITAL INPUTS RELAY DRV OUT Y/N
(see Group C, 21 Items) HI SHUTDOWN→
ANALOG INPUTS
(see Group D, 7 Items)

2.8.11 Menu 11—Voltage Regulator
Menu 11 displays setup of the voltage regulator functions The user must enable the programming mode to edit the
including line-to-line voltages, underfrequency unloading display.
(volts per Hz), reactive droop, power factor, and kVAR
adjustments. Note: Press the Menu Right → key prior to entering
Adjust the frequency at the generator set’s governor
before making voltage regulator adjustments.
Menu 11 Overview
MENU 11
VOLTAGE REGULATOR
AVG L-L V # → L1-L2 VOLTS → L2-L3 VOLTS (3 PHASE) → L3-L1 VOLTS (3 PHASE) →
VOLT ADJ ?.? # # #
UNDER FREQ UNLOAD → FREQUENCY # HZ → SLOPE →

ENABLED N/Y SETPOINT ?.? HZ ?.? VOLTS-PER-CYCLE
REACTIVE DROOP → .8 PF RATED LOAD →

ENABLED N/Y VOLTAGE DROOP ?.?%
VAR CONTROL → TOTAL KVAR # → GENERATING/ Y/N→

ENABLED N/Y KVAR ADJ ?.? ABSORBING Y/N
PF CONTROL → AVERAGE PF # → LAGGING/ Y/N→

ENABLED N/Y PF ADJ ?.? LEADING Y/N

2.8.12 Menu 12—Calibration
Menu 12 provides calibration of the voltage sensing regulator, adjust the generator set voltage using
logic and displays. Changing the system voltage or Menu 11—Voltage Regulator. Adjust the frequency at
replacing the main logic control circuit board requires the generator set governor before making calibration
calibration adjustment. adjustments.
The user must enable the programming mode to edit the Note: Press the Menu Right → key prior to entering
display. decimal values where necessary.
Connect a meter with a minimum accuracy of ᐔ1% to Note: ECM engines have user-defined analog inputs
the output leads to calibrate the voltage-sensing logic. A01--A07. Non-ECM engines have user-defined
Configure the generator set controller for the system analog inputs A03--A07 where analog inputs 01
operating configuration using Menu 7—Generator and 02 are reserved for engine oil pressure and
System. If the generator set has a digital voltage coolant temperature displays.
Menu 12 Overview
MENU 12
CALIBRATION
SCALE AC ANALOG → SCALE AUX. ANALOG →

INPUTS INPUTS
Press down arrow to scroll through Press down arrow to scroll through
ANALOG auxiliary inputs 01--07 ANALOG auxiliary inputs 03--07
GEN L1-L0 V # ZERO AUX. ANALOG with ECM engines. with non-ECM engines.
CALIB REF ?.? INPUTS?
GEN L2-L0 V # ANALOG XX # SCAL1 #.#--#.#V

CALIB REF ?.? SCALE VALUE 1 ?.? SCAL2 #.#--#.#V
GEN L3-L0 V (3 PHASE) # ANALOG XX # SCAL1 #.#--#.#V

CALIB REF ?.? SCALE VALUE 2 ?.? SCAL2 #.#--#.#V
Right Arrow between ENTRY

GEN L1 AMPS # and DISPLAY of setpoint
CALIB REF ?.?
GEN L2 AMPS #
CALIB REF ?.?
GEN L3 AMPS (3 PHASE) #

CALIB REF ?.?
RESTORE
DEFAULTS?

2.8.13 Menu 13—Communications
Menu 13 provides local or remote access to the control and digital display or the remote programming mode to
logic. edit the display using a PC. Use the Software Operation
Manual when accessing this menu, programming from a
Use the LAN (local area network) to gain remote access remote location, and determining address and system
to multiple devices/addresses. Enable the local identification information.
programming mode to edit the display using the keypad
Menu 13 Overview
MENU 13
COMMUNICATIONS
PROTOCOL → PROTOCOL →
KBUS MODBUS
KBUS ONLINE Y/N MODBUS ONLINE Y/N
CONNECTION TYPE → CONNECTION TYPES CONNECTION TYPE → CONNECTION TYPES

(USER DEFINED) Y/N LOCAL SINGLE Y/N (USER DEFINED) Y/N SINGLE Y/N
LOCAL LAN Y/N CONVERTOR Y/N
LOCAL LAN CONV Y/N
REMOTE SINGLE Y/N
REMOTE LAN Y/N PRIMARY PORT → PRIMARY PORTS
(USER DEFINED) Y/N RS-232 Y/N
REMOTE LAN CONV Y/N
RS-485 Y/N
PRIMARY PORT → PRIMARY PORTS ADDRESS ?

(USER DEFINED) RS-232 Y/N
RS-485 ISO 1 Y/N
ADDRESS ? BAUD RATE → BAUD RATES

(LAN Connections) (USER DEFINED) Y/N 9600 Y/N
19200 Y/N
SYSTEM ID ?
(Remote Connections)
BAUD RATE → BAUD RATES

(USER DEFINED) Y/N 1200 Y/N
2400 Y/N
9600 Y/N

2.8.14 Menu 14—Programming Mode
Menu 14 provides local or remote access to the The user chooses one of three programming modes:
programming function. The user enters a password to
access the programming mode. D local—using the controller keypad
D remote—using a PC
Note: Log into the local programming mode to edit
D off—no programming is permitted
the programming access code. The factory
default access code is the number 0. Note: Use the generator set controller to initially set up
remote programming. Remote programming
Use Menu 14 to change the access code. Record the
cannot be accessed from a PC unless the
new number and give the access code only to controller is first set for remote programming
authorized individuals. Should the controller logic not
using Menu 14.
accept the access code or if the new code number is
lost, contact your local authorized distributor/dealer for
password information.
Menu 14 Overview
MENU 14
PROGRAMMING MODE
PROGRAMMING MODE → PROGRAMMING MODE → PROGRAMMING MODE →

LOCAL Y/N REMOTE Y/N OFF Y/N
PROGRAMMING MODE → PROGRAMMING MODE → PROGRAMMING MODE →

CHANGE ACCESS CODE ENTER OLD CODE # ENTER NEW CODE #

2.8.15 Menu 20—Factory Setup
(Version 2.10)
Menu 20 provides factory setup information including
the number of operating days, generator set
information, alternator information, engine information,
controller information, and the controller software
(code) version.
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

2.9 Local Programming Mode On Menus displaying the ? symbol require the user to enter
data.
The Local Programming Mode On section explains how
to program the generator set controller logic. Each Menus displaying the * symbol represent access code
menu contains a step-by-step procedure for or password type entries. Actual key entry does not
programming the various logic groups. See Section 1, display.
Specifications, for setting ranges and default settings.
See Section 2.6.3, Request and Error Messages, for
Please read and understand the entire Local error display messages and explanations while
Programming Mode On section before attempting any navigating through the menus.
programming. The factory settings are adjustable and
programming without full understanding of the logic All menu displays apply to both single-phase and
features and functions can cause inadvertent changes. three-phase voltages unless otherwise noted as (1 PH)
or (3 PH) on the menu overview. The phase designation
Refer to Menu 14—Programming Mode for information does not appear in the actual menu displays.
regarding menu programming activation. After
completing the programming always place the controller Note: Place the generator set master switch in the
back in the Programming Mode Off position to prevent OFF/RESET position when using the
inadvertent program changes. programming mode on.
The programming feature alters stored settings and Note: Use the generator set controller to initially set up
changes characteristics of the logic. Do not operate the the remote programming. Set the controller for
controller with the program mode on unless there is a remote programming using Menu 14 and remote
need to edit program logic or clear stored data. Limit communication using Menu 13 before attempting
programming responsibilities to individuals with training remote programming.
and authority.
Note: Press any key on the keypad to activate the
The product application requires expertise in the design controller panel display. The panel display turns
and programming of control systems. Only qualified off 5 minutes after the last keypad entry.
personnel should program, install, alter, and apply this
Note: Press the Reset Menu key to clear the Error
product.
display.
Use Section 2.8, Reviewing the Menu Displays, to view
Note: Press the Menu Right → key prior to entering
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
60 Section 2 Operation Local Programming Mode On TP-6083 7/05

2.9.1 Menu 1—Generator Monitoring
Menu 1 provides generator output data including Note: For the auto-scroll function, press ENTER at the
line-to-line and line-to-neutral voltages, current, V & A Summary menu. Press the Reset Menu
frequency, power factor, total kilowatts, percent of key or Menu Right → key to stop the auto-scroll
maximum kW, total kVA and total kVAR displays. function.
Menu 1 displays three-phase voltage and current
readings when applicable. Note: A right arrow from any submenu moves to the
next submenu header.
Menu 1—Generator Monitoring

Menu 1 Displays with Key Entries
Key
Entry Display Description
ENTER MENU NO. 1--14

Input a menu number.
MAIN MENU NUMBER 1

Press the Enter key.
MENU 1
Displays the menu number and name.
VOLTS & AMPS →

Displays the volts and amps heading.
L1-L2 VOLTS #
L1 AMPS #
Displays L1 and L2 volts and L1 amps.
L2-L3 VOLTS #
Displays L2 and L3 volts and L2 amps. (3 ph. only)
L2 AMPS #
L1-L2 VOLTS #
L2 AMPS #
L3-L1 VOLTS #
L3 AMPS #
L1-L0 VOLTS #
L1 AMPS #
Displays L1-L0 volts and L1 amps.
L2-L0 VOLTS #
L2 AMPS #
Displays L2 and L0 volts and L2 amps.
L3-L0 VOLTS #
L3 AMPS #
Displays L3-L0 volts and L3 amps. (3 ph. only)
FREQUENCY # HZ Displays the frequency.
MENU 1
Returns the user to the menu number and name.
VOLTS & AMPS →

Returns the user to volts and amps heading.
V & A SUMMARY →
Displays the volts and amps summary heading.
V L1-L2 L2-L3 L3-L1

# # # Displays L1-L2, L2-L3, and L3-L1 volts. (3 ph. only)
TP-6083 7/05 Local Programming Mode On Section 2 Operation 61

Menu 1—Generator Monitoring, continued
Key
V L1-L0 L2-L0 L3-L0

V L1-L2 L1-L0 L2-L0

A L1 L2 L3
# # # Displays L1, L2, and L3 amps. (3 ph. only)
A L1 L2
# # 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.
TOTAL KW #
Displays total kilowatts and leading or lagging power factor.
PF # LEADING/LAGGING
L1 KW #
Displays total L1 kilowatts and leading or lagging power factor.
L2 KW #
Displays total L2 kilowatts and leading or lagging power factor.
L3 KW # Displays total L3 kilowatts and leading or lagging power factor.

PF # LEADING/LAGGING (3 ph. only)
TOTAL KW #
% OF RATED KW # Displays the total kW and percent of rated kilowatts.
POWER KW →
Returns the user to the power kilowatt heading.
POWER KVAR →
Displays the power kVAR heading.
TOTAL KVAR #
ABSORBING/GENERATING
Displays total kVAR, absorbing or generating.
L1 KVAR #
Displays L1 kVAR, absorbing or generating.
L2 KVAR #
ABSORBING/GENERATING Displays L2 kVAR, absorbing or generating.
L3 KVAR #
Displays L3 kVAR, absorbing or generating. (3 ph. only)
POWER KVAR →
Returns the user to power kVAR heading.
POWER KVA →
Displays the power kVA heading.

Menu 1—Generator Monitoring, continued
Key
TOTAL KVA #
Displays total kVA.
L1 KVA #
Displays L1 kVA.
L2 KVA #
Displays L2 kVA.
L3 KVA #
Displays L3 kVA. (3 ph. only)
POWER kVA →
Returns the user to power kVA heading.

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

Key

MAIN MENU NUMBER 2

MENU 2
ENGINE MONITORING
ENGINE MONITORING →
Displays the basic engine monitoring heading.
BASIC
OIL PRESSURE # PSI

Displays oil pressure and coolant temperature.
COOLANT TEMP #F
ENGINE RPM #
Displays engine rpm and local battery VDC.
LOCAL BATT VDC #
MENU 2
ENGINE MONITORING Returns the user to the menu number and name.
Returns the user to basic engine monitoring heading.
BASIC
ENGINE MONITORING → Displays the detailed engine monitoring heading. Note: The detailed
DETAILED engine monitoring feature requires an ECM-equipped engine.
ENGINE FUEL →
Displays the engine fuel subheading.
FUEL PRES # PSI

Displays the fuel pressure and fuel temperature.
FUEL TEMP #F
FUEL RATE # GPH

Displays the fuel rate per hour.
USED LAST RUN

Displays the amount of fuel used during the last run.
# GAL
Returns the user to the detailed engine monitoring heading.
DETAILED
ENGINE FUEL →
Displays the engine fuel subheading.
ENGINE COOLANT →
Displays the engine coolant subheading.

Menu 2—Engine Monitoring, continued
Key
COOLANT PRES # PSI

Displays the coolant pressure and coolant temperature.
COOLANT TEMP #F
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 # PSI

Displays the oil pressure and oil temperature.
OIL TEMP #F
OIL LEVEL #%
CRANKCASE PRES # PSI Displays the oil level as a percent of full capacity and crankcase
pressure.
ENGINE OIL →
Returns the user to engine oil subheading.
ENGINE MISC →
Displays the miscellaneous engine subheading.
ECM BATT VDC #

Displays the engine ECM battery VDC and ambient temperature.
AMBIENT TEMP #F
ENGINE MODEL NO.

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.

2.9.3 Menu 3—Analog Monitoring
Menu 3 provides the battery voltage and up to 7 user- Note: If the analog display shows O/R (out of range), no
defined analog monitoring items dependent upon the input is connected.
generator system.
Note: Some data require entry using a PC in the
The User Defined Desc display refers to a description Remote Programming mode. See the Software
entered into the controller using the PC software. This Operation Manual for details.
description remains as the display for future review until
changed by the PC software user. The display has Note: ECM engines have user-defined analog inputs
20 characters maximum. 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—Analog Monitoring

Key

MAIN MENU NUMBER 3

MENU 3
ANALOG MONITORING
LOCAL BATT VDC #

Displays the local battery VDC.
ANALOG 01 # Displays analog 01 and the user-defined description. Note: ECM

(USER DEFINED DESC) engines have inputs 01--07 and non-ECM engines have inputs 03--07.
ANALOG 02 # Displays analog 02 and the user defined description.

(USER DEFINED DESC)
ANALOG 03 # Displays analog 03 and the user-defined description.

(USER DEFINED DESC)

(USER DEFINED DESC)

(USER DEFINED DESC)
ANALOG 06 # Displays analog 06 end the user-defined description.

(USER DEFINED DESC)

(USER DEFINED DESC)

2.9.4 Menu 4—Operational Records
Menu 4 provides the generator set operational records mode, the controller bypasses the run time mode and
including the operating start date, last logged functions in the standby (backup) mode. If the utility
maintenance, total run time loaded and unloaded, run power returns, the generator set continues to run for the
time since the last maintenance, number of starts, and duration of the run time period if not timed out.
number of running days.
Note: Press the STOP PROG RUN key to stop the
Run Time Feature. This menu provides the ability to generator set when in the run time mode, if
run the generator set for a designated time. After the run necessary.
time elapses the generator set shuts down and
functions in the standby mode. Generator set After performing maintenance enter yes to reset records
connected to an automatic transfer switch. Should a reflecting the current day. The user must enable the
utility power failure occur while the unit is in the run time programming mode to edit the display.
Menu 4—Operational Records

Key

MAIN MENU NUMBER 4

MENU 4 Displays the menu number and name.

OPERATIONAL RECORDS
FACTORY TEST DATE

##-###-## Displays the factory test date (day-month-year).
TOTAL RUN TIME

HRS #
Displays the total run time (hours:minutes).
TOTAL RUN TIME

Displays the total run time for loaded hours.
LOADED HRS #
TOTAL RUN TIME

UNLOADED HRS #
Displays the total run time for unloaded hours.
TOTAL RUN TIME

KW HRS # Displays the total run time in kW hours.
NO. OF STARTS #
Displays the number of engine starts.
ENGINE START? Y/N→

Displays the start and countdown subheading.
COUNTDOWN ##:##
RUN TIME 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.
RUN TIME HR:MN→ 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.
ENGINE START? Y/N→ Returns the user to the start and countdown subheading. Enter Yes to
COUNTDOWN ##:## start the generator set.

Menu 4—Operational Records, continued
Key
ENGINE START? YES→

COUNTDOWN ##:##
RUN TIME HR:MN→ Confirms the entry. The generator set will begin cranking and run based
##:## on the run time (hours:minutes) period and all previously established
time (hours:minutes) delays from Menu 8—Time Delays. Note: Press
the STOP PROG RUN key to stop the generator set when in the run time
mode, if necessary.
RECORDS MAINT → Displays the records maintenance subheading.
RESET RECORDS? → Displays the reset records option. After performing maintenance or
when required, enter Yes to reset.
RESET RECORDS? YES→

Enter Yes to reset to the current date and press the Enter key.
RESET RECORDS? YES→

Confirms the entry.
RECORDS MAINT →
Returns the user to records maintenance subheading.

TOTAL HRS # Displays the run time since the last maintenance with total hours.

LOADED HRS # Displays the run time since last the maintenance with loaded hours.

UNLOADED HRS # Displays the run time since the last maintenance with unloaded hours.

KW HRS #
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 # Displays the number of starts since the last maintenance date
LAST MAINT ##-###-## (day-month-year).
LAST START ##:## AM/PM Displays last the start time (hours:minutes) and date (day-month-year).
DATE ##-###-##
LENGTH OF RUN
Displays the length of last run in (un)loaded hours.
(UN)LOADED HRS #
MENU 4
OPERATIONAL RECORDS Returns the user to the operational records heading.

2.9.5 Menu 5—Event History
Menu 5 provides up to 100 stored warning and
shutdown events that are day and time dated. See
Menu 10—Output Setup for a list of possible events.
Menu 5—Event History

Key

MAIN MENU NUMBER 5


EVENT HISTORY
(MESSAGE TEXT) Displays the message text, date (day-month-year) and time
##-###-## ##:## AM/PM (hours:minutes). Scroll through up to100 stored events. See
Section 2.3.5, System Warning Lamp, for fault descriptions.
MENU 5
Returns the user to event history heading.
EVENT HISTORY

2.9.6 Menu 6—Time and Date
Menu 6 sets the clock time and date and internal The user must enable the programming mode to edit the
calendar. The controller uses set time for determining display.
the exercise run time and event records. The time and
date are valid only if the controller power (starting
battery) remains connected.
Menu 6—Time and Date

Key

MAIN MENU NUMBER 6

MENU 6
TIME AND DATE
DAY OF WEEK ##-###-## Displays the day of the week, date (day-month-year), and time
##:## AM/PM (hours:minutes).
TIME ??:?? AM/PM 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.
##:## AM/PM
Displays the corrected time (hours:minutes) of day.
DATE ??-???-?? Displays the date (day-month-year) entry. When required, use the
numeric keys to set the day of the month.
AND
DATE ??-???-?? Use the Menu Right → key to select the month.
AND
DATE ??-???-?? Use the numeric keys to set the two-digit year and press the Enter key.
AND
##:## AM/PM
Displays the corrected date (day- month-year).

2.9.7 Menu 7—Generator System See Section 2.6.3, Request and Error Messages, for
error display messages and explanations while
Menu 7 contains the factory-preset generator set navigating the menus.
voltage and frequency data. Enter the corresponding
data if the generator set requires voltage reconnection Note: The user defines the data shown in Menu 7. It is
and/or frequency adjustment. It is imperative that the NOT data measured by the controller and
user enter the correct data because these settings associated sensing devices. The user defines
trigger all related shutdowns. these values for purposes of calibrating the
control.
display. Note: Press the Menu Right → key prior to entering
Menu 7—Generator System

Key

MAIN MENU NUMBER 7


GENERATOR SYSTEM
OPERATING MODE → Displays the operating mode selection. Note: The display sample may
(see note) YES differ depending upon previous entries. The previously selected
operating mode appears first, either standby or prime power.
OPERATING MODE → Displays the optional operating mode selection. When required, enter
STANDBY NO YES for standby operating mode. Note: This display indicates the
generator set application.
OPERATING MODE → Enter YES to change the operating mode selection to standby and press
STANDBY YES the Enter key.
OPERATING MODE →
STANDBY YES
Confirms the entry.
OR
OPERATING MODE → Displays the optional operating mode selection. When required, enter
PRIME POWER NO YES for the prime power operating mode. Note: This display indicates
the generator set application.
OPERATING MODE → Enter YES to change the operating mode selection to prime power and
PRIME POWER YES press the Enter key.
OPERATING MODE →
PRIME POWER YES
Confirms the entry.
SYSTEM VOLTAGE Displays the line-to-line system voltage as entered data. When required,
LINE-LINE ? use the numeric keys to set new value. Press the Enter key.
SYSTEM VOLTAGE
LINE-LINE # Displays the corrected line-to-line system voltage.
SYSTEM FREQ # HZ Displays the system frequency as entered data. When required, use the
numeric keys to set the new value. Press the Enter key.

Key
SYSTEM FREQ # HZ
Displays the corrected system frequency.
PHASE → Displays the phase configuration selection. Note: The display sample
(see note) YES may differ depending upon previous entries. The user-selected phase
appears first, either wye, delta, or single phase.
PHASE → Displays the optional phase configuration selection. When required, use
3 PHASE DELTA NO the YES key to choose the delta phase configuration.
PHASE → Enter YES to change the phase configuration to a delta phase

3 PHASE DELTA YES configuration and press the Enter key.
PHASE →
3 PHASE DELTA YES Confirms the entry.
OR
3 PHASE WYE NO the YES key to choose the wye phase configuration.
PHASE → Enter YES to change the phase configuration to a wye phase
3 PHASE WYE YES configuration and press the Enter key.
PHASE →
3 PHASE WYE YES Confirms the entry.
OR
SINGLE-PHASE NO YES key to choose the single-phase configuration.
PHASE → Enter YES to change the phase configuration to a single-phase
SINGLE-PHASE YES configuration and press the Enter key.
PHASE →
SINGLE-PHASE YES 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.
KW RATING #
Displays the corrected system kilowatt rating.
RATED CURRENT # Displays the generator set rated current as entered data. Note: This is
a read-only display.
LOAD SHED OUTPUT → Displays the load shed output setting. When required, use the numeric
?% # KW keys to set the new value. Press the Enter key.
LOAD SHED OUTPUT →

#% # KW Displays the corrected load shed output setting.
TIME DELAY MIN:SEC → Displays the load shed time (minutes:seconds) delay setting. When
??:?? required, use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC →

##:##
Displays the corrected load shed time (minutes:seconds) delay setting.
LOAD SHED OUTPUT →

#% # KW
Returns the user to the load shed output setting.

Key
OVERVOLTAGE → Displays the overvoltage setting. When required, use the numeric keys
?% # VAC to set the new value. Press the Enter key.
OVERVOLTAGE →
Displays the corrected overvoltage setting.
#% # VAC
TIME DELAY MIN:SEC → Displays the overvoltage time (minutes:seconds) delay setting. When
TIME DELAY MIN:SEC → Displays the corrected overvoltage time (minutes:seconds) delay
##:## setting.
OVERVOLTAGE →
#% # VAC
Returns the user to the overvoltage setting.
UNDERVOLTAGE → Displays the undervoltage setting. When required, use the numeric keys
?% # VAC to set the new value. Press the Enter key.
UNDERVOLTAGE →
#% # VAC
Displays the corrected undervoltage setting.
TIME DELAY MIN:SEC → Displays the undervoltage time (minutes:seconds) delay setting. When
TIME DELAY MIN:SEC → Displays the corrected overvoltage time (minutes:seconds) delay
##:## setting.
UNDERVOLTAGE →
Returns the user to the undervoltage setting.
#% # VAC
OVERFREQUENCY Displays the overfrequency setting. When required, use the numeric
?% # HZ keys to set the new value. Press the Enter key.
OVERFREQUENCY
#% # HZ Displays the corrected overfrequency setting.
UNDERFREQUENCY Displays the underfrequency setting. When required, use the numeric
?% # HZ keys to set the new value. Press the Enter key.
UNDERFREQUENCY
Displays the corrected underfrequency setting.
#% # HZ
OVERSPEED
Displays the overspeed setting. When required, use the numeric keys
? HZ # RPM
to set the new value. Press the Enter key.
OVERSPEED
# HZ # RPM Displays the corrected overspeed setting.

Key
BATTERY VOLTAGE → Displays the battery voltage selection. Note: The display sample may
(see note) YES differ depending upon previous entries. The user-selected battery
voltage appears first, either 12 VDC or 24 VDC.
BATTERY VOLTAGE → Displays the 12 VDC battery voltage selection. When required, use the
12 VDC NO YES key to choose the 12 VDC battery voltage.
BATTERY VOLTAGE → Enter YES to change the battery voltage to 12 VDC and press the Enter
12 VDC YES key.
BATTERY VOLTAGE →
12 VDC YES Confirms the entry.
OR
BATTERY VOLTAGE → Displays the 24 VDC battery voltage selection. When required, use the
24 VDC NO YES key to choose the 24 VDC battery voltage.
BATTERY VOLTAGE → Enter YES to change the battery voltage to 24 VDC and press the Enter
24 VDC YES key.
BATTERY VOLTAGE →
24 VDC YES Confirms the entry.
LOW BATTERY VOLTAGE Displays the low battery voltage setting. When required, use the numeric
?.? VDC keys to set the new value. Press the Menu Right → key prior to entering
the decimal value.
AND
LOW BATTERY VOLTAGE
?.? VDC Use the numeric keys to enter the decimal value. Press the Enter key.
LOW BATTERY VOLTAGE

Displays the corrected low battery voltage setting.
#.# VDC
HIGH BATTERY VOLTAGE Displays the high battery voltage setting. When required, use the
?.? VDC numeric keys to set the new value. Press the Menu Right → key prior
AND to entering the decimal value.
HIGH BATTERY VOLTAGE Use the numeric keys to enter the decimal value. Press the Enter key.
?.? VDC

Displays the corrected high battery voltage setting.
#.# VDC
METRIC UNITS Y/N

Displays the metric units selection.
METRIC UNITS YES

Enter YES to change to metric displays and press the Enter key.
METRIC UNITS YES

Confirms the entry.
OR
METRIC UNITS NO
Enter NO to change to English displays and press the Enter key.
METRIC UNITS NO
Confirms the entry.

Key
SET NFPA-110 Y/N Displays the NFPA 110 default selection. Note: See Menu 10—Output
DEFAULTS Setup, Overview for a list of the NFPA-110 faults.
SET NFPA-110 YES Enter YES to select the NFPA 110 default selection and press the Enter
DEFAULTS key.
SET NFPA-110 YES

Confirms the entry.
DEFAULTS
OR
SET NFPA-110 NO Enter NO to deselect the NFPA 110 default selection and press the Enter
DEFAULTS key.
SET NFPA-110 NO
Confirms the entry.
DEFAULTS
MENU 7
Returns the user to the generator system heading.
GENERATOR SYSTEM

2.9.8 Menu 8—Time Delays
Menu 8 displays the various time delays for cyclic The user must enable the programming mode to edit the
cranking and other engine-related starting and display.
shutdown features.
Menu 8—Time Delays

Key

MAIN MENU NUMBER 8


TIME DELAYS
TIME DELAY MIN:SEC Displays the engine start time delay in minutes:seconds. When required,
ENGINE START ??:?? use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC Displays the corrected engine start time (minutes:seconds) delay
ENGINE START ##:## setting.
TIME DELAY MIN:SEC Displays the starting aid time delay in minutes:seconds. When required,
STARTING AID ??:?? use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC Displays the corrected starting aid time (minutes:seconds) delay setting.
STARTING AID ##:##
TIME DELAY MIN:SEC Displays the crank on time delay in minutes:seconds. When required,
CRANK ON ??:?? use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC

CRANK ON ##:## Displays the corrected crank on time (minutes:seconds) delay setting.
TIME DELAY MIN:SEC Displays the crank pause time delay in minutes:seconds. When
CRANK PAUSE ??:?? required, use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC

Displays the corrected crank pause time (minutes:seconds) delay
CRANK PAUSE ##:##
setting.
TIME DELAY MIN:SEC Displays the engine cooldown time delay in minutes:seconds. When
ENG COOLDOWN ??:?? required, use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC

Displays the corrected engine cooldown time (minutes:seconds) delay
ENG COOLDOWN ##:##
setting.
OVERCRANK SHUTDOWN Displays the engine crank cycles before overcrank shutdown. When
CRANK CYCLES ? required, use the numeric keys to set the new value. Press the Enter key.
OVERCRANK SHUTDOWN Displays the corrected engine crank cycles before overcrank shutdown
CRANK CYCLES # setting.

Menu 8—Time Delays, continued
Key
TIME DELAY MIN:SEC Displays the overvoltage time delay in minutes:seconds. When required,
OVERVOLTAGE ??:?? use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC Displays the corrected overvoltage time (minutes:seconds) delay
OVERVOLTAGE ##:## setting.
TIME DELAY MIN:SEC Displays the undervoltage time delay in minutes:seconds. When
UNDERVOLTAGE ??:?? required, use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC Displays the corrected undervoltage time (minutes:seconds) delay
UNDERVOLTAGE ##:## setting.
TIME DELAY MIN:SEC Displays the load shed time delay in minutes:seconds. When required,
LOAD SHED KW ??:?? use the numeric keys to set the new value. Press the Enter key.
TIME DELAY MIN:SEC Displays the corrected load shed time (minutes:seconds) delay setting.
LOAD SHED KW ##:##
MENU 8
Returns the user to the time delays heading.
TIME DELAYS

2.9.9 Menu 9—Input Setup Analog Input Values. The analog input selection
typically requires entering four values: low warning, high
Menu 9 provides the setup of user-defined digital and warning, low shutdown, and high shutdown. The analog
analog warning and shutdown inputs. These inputs values and time delays affect how and when the
provide a multitude of choices for configuring controller reacts. See Figure 2-18. The user must set
customized auxiliary inputs. both the high and low levels so the unit will not
inadvertently trigger the adjacent high or low value to
The user must enable the programming mode to edit the cause a warning or shutdown fault.
display.
Each analog input has the following nine features:
Note: Press the down arrow to move to the start of the
next input setup. D One warning enabled and one shutdown enabled
D One inhibit time period
Note: The user must scale the analog input value in
order to calculate the low/high warning and D One warning delay and one shutdown delay
shutdown analog values based on a 0--5 VDC D Two warning levels and two shutdown levels
scale. See Menu 12—Calibration.
Time after Crank Disconnect
Note: If the ALARM ACTIVE message appears, the
Inhibit Time Time
selected input has an active fault preventing the Analog Time Delay Delay
enabled choice change from yes to no. The LED Values Period ! Period ! Complete
display indicates whether the fault is a warning or High shutdown value High
shutdown. Correct the fault condition before is above the high shutdown
attempting the keypad entry. warning value function
High warning value is The High warning
Note: ECM engines have user-defined analog inputs above the acceptable The controller function
A01--A07. Non-ECM engines have user-defined value controller does view
d
does nott th analog
the l
analog inputs A03--A07 where analog inputs A01 Acceptable analog
view the
System ready
input signal
and A02 are reserved for the engine coolant value status
analog value and
temperature and oil pressure displays. Low warning value is input signal the time Low warning
below the acceptable value delay function
value begins
Note: Some data requires entry by a PC in the Remote
Programming mode. See the Software Low shutdown value Low
is below the low shutdown
Operation Manual for details. warning value function
Digital and Analog Inputs. After the user selects the Figure 2-18 Analog Input Logistics
input, the setup requires entering the following choices
or values: enabled (yes/no), inhibit time, and delay time.
Battle Switch/Fault Shutdown Override Switch. The
D Enabled. This menu entry enables the input. The battle switch function forces the system to ignore normal
previous yes/no selection does not activate the input. fault shutdowns such as low oil pressure and high
Digital inputs have three tier groups: the selection engine temperature. The battle switch does not
group (25 total), the chosen group (up to 21 total), and override the emergency stop and overspeed shutdown.
the enabled group (up to 21 total based on the chosen When the battle switch function is enabled the generator
group). Analog inputs have separate warning and set continues to run regardless of shutdown signals
shutdown enabled choices. where potential engine/generator damage can occur.
D Inhibit Time Delay. The inhibit time delay is the time

When this input is enabled the yellow warning lamp
period following crank disconnect during which the illuminates and stored warning/shutdown events that
generator set stabilizes and the controller does not are ignored continue to log in Menu 5— Event History.
detect fault or status events. The inhibit time delay
Shutdown Type A and Shutdown Type B. Choose
range is from 0 to 60 seconds.
shutdown type A for standard shutdown where red
D TIme Delay (Shutdown or Warning). The time lamp illuminates and alarm horn sounds. Choose
delay follows the inhibit time delay. The time delay is shutdown type B for shutdown where air damper
the time period between the controller fault or status indicator RDO-23 energizes for two seconds, red lamp
event detection and the controller warning or illuminates, and alarm horn sounds.
shutdown lamp illumination. The delay prevents any
nuisance alarms. The time delay range is from 0 to 60
seconds.

Menu 9—Input Setup
Key

MAIN MENU NUMBER 9


INPUT SETUP
SETUP DIGITAL →
AUXILIARY INPUTS
Displays the setup of digital auxiliary inputs heading.
DIGITAL INPUT 01 → Displays the digital input 01 with the user-defined description.
(USER DEFINED DESC) Note: Press the down arrow to move to the start of the next input setup.
DIGITAL INPUT 01 → Identifies the signal source for digital input 01. Use the menu down ↓ key
(see Group A) YES/NO to select the digital input.
Group A Group A, continued
The preprogrammed FIELD OVERVOLTAGE Y/N
selections include the IDLE MODE ACTIVE Y/N
following: (ECM engine only)
WARNING Y/N BATTLE SWITCH Y/N
SHUTDOWN TYPE A Y/N (see Battle Switch/Fault
SHUTDOWN TYPE B Y/N Shutdown Override Switch
VOLTAGE RAISE Y/N on the previous page.)
VOLTAGE LOWER Y/N GROUND FAULT Y/N
VAR PF MODE Y/N BAT CHGR FAULT Y/N
REMOTE SHUTDOWN Y/N HI OIL TEMP Y/N
REMOTE RESET Y/N LOW COOLANT LVL Y/N
AIR DAMPER Y/N LOW COOLANT TEMP Y/N
LOW FUEL Y/N (not user selectable)
DIGITAL INPUT 01 →
Displays the digital input 01, enabled yes or no selection.
ENABLED YES/NO
Entering YES enables digital input 01.
ENABLED NO
ENABLED YES
Confirms the entry.
ENABLED YES
OR
ENABLED YES Entering NO disables digital input 01.
ENABLED NO Press the Enter key.
Confirms the entry.
ENABLED NO

Key
DIGITAL INPUT 01 → Displays the digital input 01 inhibit time (minutes:seconds) setting. When
INHIBIT TIME ?:?? required, use the numeric keys to set the new values. Press the Enter
key.
DIGITAL INPUT 01
Displays the corrected inhibit time (minutes:seconds) setting.
INHIBIT TIME #:##
DIGITAL INPUT 01 → Displays the digital input 01 delay time (minutes:seconds) setting. When
DELAY TIME ?:?? required, use the numeric keys to set the new values. Press the Enter
key.
Displays the corrected delay time (minutes:seconds) setting.
DELAY TIME #:##
(USER DEFINED DESC) Returns the user to digital input 01.
DIGITAL INPUT XX → Displays digital inputs 02 to 21. Note: Press the down arrow to scroll
(USER DEFINED DESC) 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.
MENU 9
Returns the user to the menu number and name.
INPUT SETUP
SETUP DIGITAL →
AUXILIARY INPUTS Returns the user to setup digital auxiliary inputs.
SETUP ANALOG →
AUXILIARY INPUTS Displays the setup of analog auxiliary inputs heading.
ANALOG INPUT 01 → Displays the analog input 01 with user-defined description.

(USER DEFINED DESC) 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.
ANALOG INPUT 01 →
WARNING ENABLED Y/N Displays the analog input 01, warning enabled yes or no selection.
ANALOG INPUT 01 →
Entering YES enables the warning analog input 01.
WARNING ENABLED NO
ANALOG INPUT 01 →
WARNING ENABLED YES
AND
ANALOG INPUT 01 →
Confirms the entry.
WARNING ENABLED YES
OR
ANALOG INPUT 01 →
WARNING ENABLED YES Entering NO disables the warning analog input 01.
ANALOG INPUT 01 →
WARNING ENABLED NO Press the Enter key.
AND
ANALOG INPUT 01 →
Confirms the entry.
WARNING ENABLED NO

Key
ANALOG INPUT 01 →
SHUTDOWN ENABLED Y/N
Displays the analog input 01, shutdown enabled selection.
ANALOG INPUT 01 →
SHUTDOWN ENABLED NO Entering YES enables the shutdown analog input 01.
ANALOG INPUT 01 →
SHUTDOWN ENABLED YES Press the Enter key.
AND
ANALOG INPUT 01 →
Confirms the entry.
SHUTDOWN ENABLED YES
OR
ANALOG INPUT 01 →
Entering NO disables the shutdown analog input 01.
SHUTDOWN ENABLED YES
ANALOG INPUT 01 →
SHUTDOWN ENABLED NO
AND
ANALOG INPUT 01 →
Confirms the entry.
SHUTDOWN ENABLED NO
ANALOG INPUT 01 → Displays the analog input 01, inhibit time (minutes:seconds) setting.
INHIBIT TIME ?:?? When required, use the numeric keys to set the new values. Press the
Enter key.
ANALOG INPUT 01 →
Displays the corrected inhibit time (minutes:seconds) setting.
INHIBIT TIME #:##
ANALOG INPUT 01 → Displays the analog input 01, warning time (minutes:seconds) delay
WARN DELAY TIME ?:?? setting. When required, use the numeric keys to set the new values.
ANALOG INPUT 01 → Displays the corrected warning time (minutes:seconds) delay setting.
WARN DELAY TIME #:##
ANALOG INPUT 01 → Displays the analog input 01, shutdown time (minutes:seconds) delay
SDWN DELAY TIME ?:?? setting. When required, use the numeric keys to set the new values.
ANALOG INPUT 01 →
SDWN DELAY TIME #:##
Displays the corrected shutdown time (minutes:seconds) delay setting.
ANALOG INPUT 01 → Displays the analog input 01, low shutdown value. When required, use
LO SDWN VALUE ? 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 12—Calibration.
ANALOG INPUT 01 →
LO SDWN VALUE #
Displays the corrected low shutdown value.
ANALOG INPUT 01 → Displays the analog input 01, low warning value. When required, use the
LO WARN VALUE ? numeric keys to set the new values. Press the Enter key.
ANALOG INPUT 01 →
Displays the corrected low warning value.
LO WARN VALUE #

Key
ANALOG INPUT 01 → Displays the analog input 01, high warning value. When required, use
HI WARN VALUE ? the numeric keys to set the new values. Press the Enter key.
ANALOG INPUT 01 →
Displays the corrected high warning value.
HI WARN VALUE #
ANALOG INPUT 01 → Displays the analog input 01, high shutdown value. When required, use
HI SDWN VALUE ? the numeric keys to set the new values. Press the Enter key.
ANALOG INPUT 01 →
Displays the corrected high shutdown value.
HI SDWN VALUE #
ANALOG INPUT 01 →
Returns the user to analog input 01.
(USER DEFINED DESC)
ANALOG INPUT XX → Displays analog inputs A02 to A07. Note: Press the down arrow to scroll
(USER DEFINED DESC) 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 →
Returns the user to the setup digital auxiliary input heading.
AUXILIARY INPUTS

2.9.10 Menu 10—Output Setup 7 status events and faults are assignable as shutdowns
or warnings with high or low settings for a total of up to 7
Menu 10 provides setup of the user-defined system, status events and fault functions.
digital and analog status and fault outputs, and relay
driver outputs (RDO) 1--31. These outputs provide a Relay Driver Outputs (RDOs)
multitude of choices for configuring customized auxiliary
outputs. Additional individual outputs are available for Up to 31 RDOs are available using the system, digital,
monitoring, diagnostic, and control functions. and analog status events and faults. RDOs provide only
the relay driver, not the relay. The contact relays that
The user must enable the programming mode to edit the interface with other equipment are user supplied.
display.
Note: Func(Function) Used by (RDO) XX Reassign?
Note: Some data require entry using a PC in the appears when the user attempts to assign an
Remote Programming mode. See the Software RDO to a function already assigned.
Operation Manual for details.
Note: Cannot Change (because the) NFPA is Enabled
Common Faults appears when the user attempts to modify an
RDO setting that is a NFPA 110 default
The user can program a single fault comprised of status requirement.
and fault events from 3 common fault programs—
system, digital, and analog faults. Software Controlled RDOs (SCRDOs)
Up to 46 user-defined system status and fault events are The SCRDO is set up and enabled using the keypad or
available. See Group B on the following pages for PC. See the Software Operation Manual when
specific descriptions. The NFPA-110 faults are part of reactivating the SCRDO. The user can deactivate an
the system fault program and are comprised of SCRDO at the controller. The user cannot reactivate the
15 individual faults shown on the next page. SCRDO at the controller. The procedure to deactivate
the SCRDO appears at the end of Menu 10—Output
Up to 21 user-defined digital status and fault events Setup, Displays with Entry Keys—Deactivating the
designated as D01 to D21 are available. Each of the 21 SCRDO. The user must enable the programming mode
status events and faults are assignable as shutdowns or to edit the display.
warnings.
Up to 7 user-defined analog status events and faults

designated as A01 to A07 are available. Each of the

Menu 10—Output Setup
Key

MAIN MENU NUMBER 10


OUTPUT SETUP
DEFINE COMMON →
FAULTS
Displays the common faults heading.
SYSTEM EVENTS →
Displays the system events heading.
COMMON FAULT Y/N Gives the user the option to add or delete the selection from the defined
(see Group B) system events group. Press the Menu Down key to continue to the next
selection (repeat as necessary).
COMMON FAULT NO
(see Group B)
Entering YES adds the selection to the defined system event group.
COMMON FAULT YES

(see Group B)
COMMON FAULT YES

(see Group B)
Confirms the entry.
OR
COMMON FAULT YES Entering NO removes the selection from the defined system event group.
(see Group B)
COMMON FAULT NO
(see Group B)
COMMON FAULT NO
(see Group B)
Confirms the entry.
Group B Group B, continued Group B, continued

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

Menu 10—Output Setup, continued
Key
DIGITAL INPUTS →
Displays the digital inputs heading.
COMMON FAULT Y/N Gives the user the option to add or delete selection from the defined
Dxx (see Group C) digital faults starting with D01. Note: Press the Menu Down key to
continue to the next selection D02--D21 (repeat as necessary).
COMMON FAULT NO Entering YES adds the selection to the defined digital fault group.
Dxx (see Group C)
COMMON FAULT YES
Dxx (see Group C) Press the Enter key.
COMMON FAULT YES Confirms the entry.

Dxx (see Group C)
OR
COMMON FAULT YES Entering NO removes the selection from the defined digital fault group.
Dxx (see Group C)
COMMON FAULT NO
Dxx (see Group C)
COMMON FAULT NO
Confirms the entry.
Dxx (see Group C)
Group C
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.
COMMON FAULT Y/N Gives the user the option to add or delete selection from the defined
Axx(see Group D)LO WARNING→ analog faults starting with A01. Note: Press the Menu Down key to
continue to the next selection A02--A07 (repeat as necessary).
Group D
Up to 7 analog inputs, PC user-
defined 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.

Key
COMMON FAULT Y/N Indicates whether the previously user-defined analog output was
A01 LO WARNING→ selected (yes or no) as a low warning fault.
COMMON FAULT NO Entering YES adds the low warning selection to the defined analog fault
A01 LO WARNING→ group.
COMMON FAULT YES Press the Enter key.
A01 LO WARNING→
COMMON FAULT YES

Confirms the entry.
A01 LO WARNING→
OR
COMMON FAULT YES Entering NO removes the low warning selection from the defined analog
A01 LO WARNING→ fault group.
COMMON FAULT NO
A01 LO WARNING→ Press the Enter key.
COMMON FAULT NO
Confirms the entry.
A01 LO WARNING→
A01 HI WARNING→ selected (yes or no) as a high warning fault.
COMMON FAULT NO Entering YES adds the high warning selection to the defined analog fault
A01 HI WARNING→ group.
COMMON FAULT YES

A01 HI WARNING→ Press the Enter key.
COMMON FAULT YES

A01 HI WARNING→
Confirms the entry.
OR
COMMON FAULT YES Entering NO removes the high warning selection from the defined analog
A01 HI WARNING→ fault group.
COMMON FAULT NO
COMMON FAULT NO
Confirms the entry.
A01 HI WARNING→

Key
A01 LO SHUTDOWN→ selected (yes or no) as a low shutdown fault.
COMMON FAULT NO Entering YES adds the low shutdown selection to the defined analog fault
A01 LO SHUTDOWN→ group.
A01 LO SHUTDOWN→
COMMON FAULT YES

Confirms the entry.
A01 LO SHUTDOWN→
OR
COMMON FAULT YES Entering NO removes the low shutdown selection from the defined
A01 LO SHUTDOWN→ analog fault group.
COMMON FAULT NO
A01 LO SHUTDOWN→ Press the Enter key.
COMMON FAULT NO
A01 LO SHUTDOWN→ Confirms the entry.
A01 HI SHUTDOWN→ selected (yes or no) as a high shutdown fault.
COMMON FAULT NO Entering YES adds the high shutdown selection to the defined analog
A01 HI SHUTDOWN→ fault group.
A01 HI SHUTDOWN→
COMMON FAULT YES

Confirms the entry.
A01 HI SHUTDOWN→
OR
COMMON FAULT YES Entering NO removes the high shutdown selection from the defined
A01 HI SHUTDOWN→ analog fault group.
COMMON FAULT NO Press the Enter key.
A01 HI SHUTDOWN→
COMMON FAULT NO Confirms the entry.

A01 HI SHUTDOWN→
COMMON FAULT Y/N Returns the user to common fault (analog inputs) heading.
A01 LO WARNING→ Press the Menu Down key to continue to the next selection A02--A07
(repeat as necessary).
COMMON FAULT Y/N Gives the user the option to add or delete selection from the next defined
Axx(see Group D)LO WARNING→ analog fault. Note: Use the A01 common fault analog input setup
procedure shown above for A02--A07. To go
Group D
Up to 7 analog inputs, PC user-
defined 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.

Key
ANALOG INPUTS → Returns the user to analog inputs heading.
DEFINE COMMON →
FAULTS
Returns the user to the define common faults heading.
RELAY DRV OUT 01 → Gives the user previously selected items for relay driver outputs (RDO)
(user defined) 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 Y/N Gives the user the option to assign a system event to an RDO. Press the
(see Group B) Menu Down key to continue to the next selection (repeat as necessary).
RELAY DRV OUT 01 NO Entering YES adds the selection to the RDO group.
(see Group B) 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.
RELAY DRV OUT 01 YES

(see Group B)

(see Group B) Confirms the entry.
Group B Group B, continued *NFPA 110 FAULT [DEFINED COMMON

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

Key
DIGITAL INPUTS →
Displays the digital inputs heading.
RELAY DRV OUT 01 Y/N Gives the user the option to assign a digital input to an RDO starting with
Dxx (see Group C) 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
RELAY DRV OUT 01 NO Entering YES adds the selection to the RDO group.
Dxx (see Group C) Note: Func(Function) Used by (RDO) XX Reassign? appears when the
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.

Dxx (see Group C)

Confirms the entry.
Dxx (see Group C)
Group C
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.
RELAY DRV OUT 01 Y/N Gives the user the option to assign an analog input to an RDO starting
Axx(see Group D)LO WARNING→ with A01. Note: Press the Menu Down key to continue to the next
selection A02-A07 (repeat as necessary).
Group D
Up to 7 analog inputs, user-
defined 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.

Key
RELAY DRV OUT 01 Y/N Indicates whether the previously user-defined analog RDO was selected
A01 LO WARNING→ (yes or no) as a low warning fault.
RELAY DRV OUT 01 NO Entering YES adds the low warning selection to the defined analog RDO
A01 LO WARNING→ group.

A01 LO WARNING→

Confirms the entry.
A01 LO WARNING→
OR
RELAY DRV OUT 01 YES Entering NO removes the low warning selection from the defined analog
A01 LO WARNING→ RDO group.
RELAY DRV OUT 01 NO

A01 LO WARNING→
RELAY DRV OUT 01 NO

Confirms the entry.
A01 LO WARNING→
A01 HI WARNING→ (yes or no) as a high warning fault.
RELAY DRV OUT 01 NO Entering YES adds the high warning selection to the defined analog RDO
A01 HI WARNING→ group.


A01 HI WARNING→
Confirms the entry.
OR
RELAY DRV OUT 01 YES Entering NO removes the high warning selection from the defined analog
A01 HI WARNING→ RDO group.
RELAY DRV OUT 01 NO Press the Enter key.

A01 HI WARNING→
RELAY DRV OUT 01 NO

Confirms the entry.
A01 HI WARNING→

Key
A01 LO SHUTDOWN→ (yes or no) as a low shutdown fault.
RELAY DRV OUT 01 NO Entering YES adds the low shutdown selection to the defined analog
A01 LO SHUTDOWN→ RDO group.

OR
RELAY DRV OUT 01 YES Entering NO removes the low shutdown selection from the defined
A01 LO SHUTDOWN→ analog RDO group.
RELAY DRV OUT 01 NO

RELAY DRV OUT 01 NO

A01 HI SHUTDOWN→ (yes or no) as a high shutdown fault.
RELAY DRV OUT 01 NO Entering YES adds the high shutdown selection to the defined analog
A01 HI SHUTDOWN→ RDO group.
A01 HI SHUTDOWN→ Press the Enter key.

Confirms the entry.
A01 HI SHUTDOWN→
OR
RELAY DRV OUT 01 YES Entering NO removes the high shutdown selection from the defined
A01 HI SHUTDOWN→ analog RDO group.
RELAY DRV OUT 01 NO

A01 HI SHUTDOWN→ Press the Enter key.
RELAY DRV OUT 01 NO

Confirms the entry.
A01 HI SHUTDOWN→
RELAY DRV OUT 01 Y/N Returns the user to the analog RDO (analog inputs) heading. Press the
A01 LO WARNING→ Menu Down key to continue to the next selection A02--A07 (repeat as
necessary).
RELAY DRV OUT 01 Y/N Gives the user the option to add or delete a selection for the next analog
Axx(see Group D)LO WARNING→ RDO. Note: Use the A01 analog RDO setup procedure shown above for
A02--A07. Go to
ANALOG INPUTS → Returns the user to the analog inputs heading. Press the Menu Right key.
RELAY DRV OUT 01 →

Returns the user to the RDO 01 heading.
(user defined)
RELAY DRV OUT XX → Gives the user the option to add or delete a selection for the next RDO.
(user defined) Note: Use the RDO 01 setup procedure shown above for RDOs 02--31.
Go to

Menu 10 Displays with Key Entries—
Deactivating the SCRDO
Key

MAIN MENU NUMBER 10

MENU 10 Displays the menu number and name

OUTPUT SETUP
DEFINE COMMON →
FAULTS
Displays the common faults heading.
RELAY DRV OUT XX → Gives the user previously selected items for the relay driver outputs
S’WARE CONTROLLED #X (RDO). Press the down arrow to scroll through relay driver outputs 1--31
or enter the RDO number. Locate the SCRDO display.
DEACTIVATE RDO? → When required (SCRDO is currently active), enter the YES key to
deactivate the SCRDO.
DEACTIVATE RDO? YES→

RELAY DRV OUT XX →

S’WARE CONTROLLED #X

2.9.11 Menu 11—Voltage Regulator
Menu 11 provides the setup of the voltage regulator Note: Press the Menu Right → key prior to entering the
functions including the line-to-line voltages, decimal values where necessary.
underfrequency unloading (volts per Hz), reactive
droop, power factor, and kVAR adjustments. See Note: 350--2000 kW models only, see 1.3.2 Voltage
Section 1.3.3, Voltage Regulator Adjustments, and Regulator and Calibration Specifications
Appendix C, Voltage Regulator Definitions and regarding the use of the Marathon DVR 2000
Adjustments, for additional information. voltage regulator.

display.
Menu 11—Voltage Regulator

Key
ENTER MENU NO. 1--14 Input a menu number.
MAIN MENU NUMBER 11


VOLTAGE REGULATOR
AVG L-L V # → Displays the average line-to-line volts and voltage adjustment. Enter the
VOLT ADJ ?.? desired nominal voltage using the numeric keys. Press the Menu Right
→ key prior to entering the decimal value.
AND
AVG L-L V # →
VOLT ADJ ?.? Use the numeric keys to enter the decimal value. Press the Enter key.
AVG L-L V # →
Confirms the entry.
VOLT ADJ #.#
L1-L2 VOLTS →
Displays L1-L2 volts.
#
L2-L3 VOLTS → Displays L2-L3 volts (3 phase only).

#
L3-L1 VOLTS →
Displays L3-L1 volts (3 phase only).
#
AVG L-L V # → Returns the user to the average line-to-line volts and voltage adjustment
VOLT ADJ # heading.
UNDER FREQ UNLOAD → Displays the under frequency (volts per Hz) unloading (yes or no)
ENABLED N/Y selection.
UNDER FREQ UNLOAD →

ENABLED NO Entering YES enables the underfrequency unloading feature.

ENABLED YES
UNDER FREQ UNLOAD → Confirms the entry.

ENABLED YES

Menu 11—Voltage Regulator
Key
OR
UNDER FREQ UNLOAD → Entering NO disables the underfrequency unloading feature.
ENABLED YES


Confirms the entry.
ENABLED NO
FREQUENCY # HZ → Displays the operating frequency and underfrequency unloading cut-in

SETPOINT ?.? HZ 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 # HZ →
Use the numeric keys to enter the decimal value. Press the Enter key.
SETPOINT ?.? HZ
FREQUENCY # HZ →
SETPOINT #.# HZ
Confirms the entry.
SLOPE → Displays the underfrequency unloading slope (volts-per-cycle). Enter

?.? VOLTS-PER-CYCLE the desired underfrequency unloading slope using the numeric keys.
Press the Menu Right → key prior to entering the decimal value.
AND
SLOPE →
?.? VOLTS-PER-CYCLE
SLOPE →
#.# VOLTS-PER-CYCLE Confirms the entry.

ENABLED N/Y
Returns the user to the underfrequency unloading heading.
REACTIVE DROOP →
Displays the reactive droop selection (yes or no).
ENABLED N/Y
REACTIVE DROOP →
ENABLED NO
Entering YES enables the reactive droop feature.
REACTIVE DROOP →
ENABLED YES Press the Enter key.
REACTIVE DROOP →
ENABLED YES
Confirms the entry.
OR
REACTIVE DROOP →
Entering NO disables the reactive droop feature.
ENABLED YES
REACTIVE DROOP →
ENABLED NO
REACTIVE DROOP → Confirms the entry.

ENABLED NO

Menu 11—Voltage Regulator, continued
Key
.8 PF RATED LOAD → Displays the reactive (voltage) droop as a percentage of the rated
VOLTAGE DROOP ?.?% 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.
AND
.8 PF RATED LOAD →
VOLTAGE DROOP ?.?%
.8 PF RATED LOAD →
Confirms the entry.
VOLTAGE DROOP #.#%
REACTIVE DROOP →
ENABLED N/Y Returns the user to reactive droop selection heading.
VAR CONTROL →
Displays the VAR control selection (yes or no).
ENABLED N/Y
VAR CONTROL → Entering YES enables the VAR control feature.

ENABLED NO Note: A YES entry disables the PF control if previously activated.
VAR CONTROL →
ENABLED YES
VAR CONTROL →
Confirms the entry.
ENABLED YES
OR
VAR CONTROL →
ENABLED YES Entering NO disables the VAR control feature.
VAR CONTROL →
VAR CONTROL →
Confirms the entry.
ENABLED NO
TOTAL KVAR # → Displays total kVAR (running) and kVAR adjustment settings. Enter the
KVAR ADJ ?.? desired kVAR adjustment using the numeric keys. Press the Menu Right
→ key prior to entering the decimal value.
AND
TOTAL KVAR # →
KVAR ADJ ?.? Use the numeric keys to enter the decimal value. Press the Enter key.
TOTAL KVAR # →
KVAR ADJ #.# Confirms the entry.
GENERATING/ N/Y → Displays the generating or absorbing kVAR selection.

ABSORBING Note: The display sample may differ depending upon the previous
entries. The generating selection is the factory default setting.
GENERATING YES → Displays the generating kVAR selection. When required, use the NO key
to choose absorbing kVAR.
GENERATING NO → Press the Enter key.
ABSORBING YES → Confirms the entry.

Key
OR
ABSORBING YES → Displays the absorbing kVAR selection. When required, use the NO key
to choose generating kVAR.
ABSORBING NO →
GENERATING YES →
Confirms the entry.
VAR CONTROL →
Returns the user to VAR control selection heading.
ENABLED N/Y
PF CONTROL →
ENABLED N/Y
Displays the power factor control selection (yes or no).
PF CONTROL → Entering YES enables the power factor control feature.

ENABLED NO Note: A YES entry disables the kVAR control if previously activated.
PF CONTROL →
ENABLED YES
PF CONTROL →
Confirms the entry.
ENABLED YES
OR
PF CONTROL → Entering NO disables the power factor conrol feature.
ENABLED YES
PF CONTROL →
ENABLED NO
PF CONTROL →
Confirms the entry.
ENABLED NO
AVERAGE PF # → Displays the average power factor and power factor adjustment settings.
PF ADJ ?.? Enter the desired kVAR adjustment using the numeric keys. Press the
Menu Right → key prior to entering the decimal value.
AND
AVERAGE PF # →
PF ADJ ?.?
AVERAGE PF # →
PF ADJ #.# Confirms the entry.
LAGGING/ N/Y → Displays the lagging or leading PF selection.

LEADING Note: The display sample may differ depending upon the previous
entries. The lagging selection is the factory default setting.
LAGGING YES → Displays the lagging PF selection. When required, use the NO key to
choose leading PF.
LAGGING NO → Press the Enter key.
LEADING YES → Confirms the entry.

Key
OR
LEADING YES → Displays the leading PF selection. When required, use the NO key to
choose lagging PF.
LEADING NO → Press the Enter key.
LAGGING YES →
Confirms the entry.
PF CONTROL →
Returns the user to the power factor control selection heading.
ENABLED N/Y

2.9.12 Menu 12—Calibration required and adjust the frequency at the generator set
governor before making calibration adjustments.
Menu 12 provides the calibration of the voltage and
current sensing logic. Changing the system voltage or Note: The user must scale the analog input value in
replacing the main logic control circuit board requires a order to calculate the low/high warning and
calibration adjustment. shutdown analog values based on a 0--5 VDC
scale.
display. Note: ECM engines have user-defined analog inputs
01--07. Non-ECM engines have user-defined
Connect a meter with a minimum accuracy of ᐔ1% to analog inputs 03--07 where analog inputs 01 and
the generator set output leads to calibrate the 02 are reserved for engine coolant temperature
voltage-sensing logic. Configure the generator set and oil pressure displays.
controller for the system operating configuration using
Menu 7—Generator System. Adjust the generator set Note: Press the Menu Right → key prior to entering
voltage using Menu 11—Voltage Regulator, when decimal values where necessary.
Menu 12—Calibration
Key

MAIN MENU NUMBER 12


CALIBRATION
SCALE AC ANALOG
Displays the scale AC analog inputs heading.
INPUTS
GEN L1-L0 V # Measure the generator set output voltage for single and three-phase
CALIB REF ?.? 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 #
Confirms the entry.
CALIB REF #.#
GEN L2-L0 V # Measure the generator set output voltage for three-phase models
CALIB REF ?.? between L2-L0 using a voltmeter and enter the result using the numeric
AND
GEN L2-L0 V # Use the numeric keys to enter the decimal value. Press the Enter key.
CALIB REF ?.?
GEN L2-L0 V #
Confirms the entry.
CALIB REF #.#

Menu 12—Calibration, continued
Key
GEN L3-L0 V # Three-Phase Models only. Measure the generator set output voltage
CALIB REF ?.? 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.
AND
GEN L3-L0 V # Use the numeric keys to enter the decimal value. Press the Enter key.
CALIB REF ?.?
GEN L3-L0 V #
Confirms the entry.
CALIB REF #
GEN L1 AMPS # Measure the generator set output current for single- and three-phase
CALIB REF ?.? models at L1 using an AC ammeter and enter the result using the numeric
AND
GEN L1 AMPS # Use the numeric keys to enter the decimal value. Press the Enter key.
CALIB REF ?.?
GEN L1 AMPS #
CALIB REF # Confirms the entry.
GEN L2 AMPS # Measure the generator set output current for three-phase models at L2
CALIB REF ?.? using an AC ammeter and enter the result using the numeric keys. Press
the Menu Right → key prior to entering the decimal value.
AND
CALIB REF ?.?
GEN L2 AMPS # Confirms the entry.

CALIB REF #
GEN L3 AMPS # Three-Phase Models only. Measure the generator set output current
CALIB REF ?.? 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.
AND
CALIB REF ?.?
GEN L3 AMPS #
CALIB REF #
Confirms the entry.
RESTORE
DEFAULTS?
Displays the restore defaults selection (yes or no).
RESTORE When required, enter YES to activate the restore calibration defaults
DEFAULTS? YES 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.
RESTORE
Confirms the entry.
DEFAULTS? YES

Menu 12—Calibration, continued
Key
MENU 12 Returns the user to the menu number and name.

CALIBRATION
SCALE AC ANALOG →
INPUTS
Returns the user to the scale AC analog inputs heading.
SCALE AUX. ANALOG →

Displays the scale auxiliary analog inputs heading.
INPUTS
ZERO AUX. ANALOG Gives the user the option to calibrate the auxiliary analog inputs for zero
INPUTS? input signals. Note: ECM engines have inputs A01--A07 and non-ECM
engines have inputs A03--A07.
ZERO AUX. ANALOG When required, enter YES to activate the auto-zero auxiliary analog
INPUTS? YES inputs feature. Press the Enter key.
ZERO AUX. ANALOG

Confirms the entry.
INPUTS? YES
ANALOG 01 # Displays the analog 01 and scale value 1 settings. Use the numeric keys
SCALE VALUE 1 ? 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.
SCAL 1 #--#.#V Note: Press the Menu Right → key to review both the scale value 1 and
SCAL 2 #--#.#V scale value 2 settings any time during the setup procedure.
ANALOG 01 # Displays analog 01 and scale value 2 settings. Use the numeric keys to
SCALE VALUE 2 ? enter the maximum value based on the previously calculated 5 VDC
analog value.
SCALE AUX. ANALOG →
Returns the user to the scale auxiliary analog inputs heading.
INPUTS
ZERO AUX. ANALOG

INPUTS?
Press the down arrow to go to the desired analog XX.
ANALOG XX # Displays scale auxiliary analog inputs 01 to 07.

SCALE VALUE 1 ? 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.

2.9.13 Menu 13—Communications menu, programming from a remote location, and
determining address and system identification
Menu 13 enables communication with the controller for information.
monitoring or controlling the generator set. KBUS
allows a variety of connection types while Modbusr The user must enable the programming mode to edit the
follows Modbusr RTU protocols. Use the LAN (local display.
area network) to gain remote access to multiple
devices/addresses. Use the KBUS enable local Modbusr is a registered trademark of Schneider
programming mode to edit displays in this menu. Use Electric.
the Software Operation Manual when accessing this
Menu 13—Communications
Key
MAIN MENU NUMBER 13

MENU 13
COMMUNICATIONS Displays the menu number and name.
PROTOCOL →
Displays the KBUS protocol heading.
KBUS
KBUS ONLINE Y/N

Displays the KBUS online selection.
KBUS ONLINE NO Entering YES activates the online KBUS selection.
KBUS ONLINE YES Press the Enter key.
KBUS ONLINE YES

Confirms the entry.
OR
KBUS ONLINE YES Entering NO deactivates the online KBUS selection.
KBUS ONLINE NO Press the Enter key.
KBUS ONLINE NO
Confirms the entry.

Menu 13—Communications, continued
Key
CONNECTION TYPE → Displays the user-defined connection type. Press the Down arrow key
(USER DEFINED) Y/N 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 Entering YES selects the connection type shown. Note: Selecting one
REMOTE SINGLE N/Y connection type deselects any previously selected choice.
REMOTE LAN N/Y
REMOTE LAN CONV N/Y
CONNECTION TYPE → Press the Enter key.

(USER DEFINED) YES
CONNECTION TYPE →
(USER DEFINED) YES
Confirms the entry.
PRIMARY PORT → Displays the user-defined primary port subheading. Press the Down
(USER DEFINED) Y/N 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.
PRIMARY PORTS Entering YES selects the primary port shown. Note: Selecting one
RS-232 Y/N primary port deselects any previously selected choice.
RS-485 ISO 1 N/Y
PRIMARY PORT → Press the Enter key.

(USER DEFINED) YES
PRIMARY PORT →
Confirms the entry.
(USER DEFINED) YES
ADDRESS ? Displays the LAN connection address number. Use the numeric keys to
(LAN Connections) enter the desired address 1--128. Use one address number per unit and
use consecutive numbers. Individual addresses are necessary for the
software to call up the desired unit.
ADDRESS #
Confirms the entry.
(LAN Connections)
SYSTEM ID ? Displays the system ID request. Use the numeric keys to enter the
(Remote Connections) 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.
SYSTEM ID #
Confirms the entry.
(Remote Connections)
BAUD RATE → Displays the user-defined baud rate selection. Press the Down arrow
(USER DEFINED) Y/N 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.
BAUD RATES
1200 Y/N
Entering YES selects the baud rate shown. Note: Selecting one baud
2400 N/Y
9600 N/Y
rate deselects any previously selected choice.

Key
BAUD RATE →
(USER DEFINED) YES
BAUD RATE →
Confirms the entry.
(USER DEFINED) YES
MENU 13
COMMUNICATIONS Returns the user to the menu number and name.
PROTOCOL →
Returns the user to kBUS protocol heading.
KBUS
PROTOCOL →
MODBUS
Displays the Modbus protocol heading.
MODBUS ONLINE Y/N

Displays the Modbus online selection (yes or no).
MODBUS ONLINE NO Entering YES activates the online Modbus selection.
MODBUS ONLINE YES

MODBUS ONLINE YES

Confirms the entry.
OR
MODBUS ONLINE YES Entering NO de-activates the online Modbus selection.
MODBUS ONLINE NO Press the Enter key.
MODBUS ONLINE NO
Confirms the entry.
CONNECTION TYPE → Displays the user-defined connection types. Press the Down arrow key
(USER DEFINED) Y/N 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
Entering YES selects the connection type shown. Choices are a single
SINGLE Y/N
or RS-232 to RS-485 convertor. Note: Selecting one connection type
CONVERTOR N/Y
deselects any previously selected choice.
CONNECTION TYPE → Press the Enter key.

(USER DEFINED) YES
CONNECTION TYPE →
Confirms the entry.
(USER DEFINED) YES
PRIMARY PORT → Displays the user-defined primary ports. Press the Down arrow if the
(USER DEFINED) Y/N correct primary port is displayed. If the desired primary port is not
displayed, press the Right arrow key until the desired primary port
appears.
PRIMARY PORTS
RS-232 Y/N Entering YES selects the primary port shown. Note: Selecting one
RS-485 N/Y primary port deselects any previously selected choice.

Key
PRIMARY PORT →
(USER DEFINED) YES
PRIMARY PORT →
(USER DEFINED) YES Confirms the entry.
ADDRESS ? Displays the address number. Use the numeric keys to enter the desired
address 1--128. Use one address number per unit and use consecutive
numbers. Individual addresses are necessary for the software to call up
the desired unit.
ADDRESS #
Confirms the entry.
BAUD RATE → Displays the user-defined baud rate. Press the Down arrow key if the
(USER DEFINED) Y/N correct baud rate is displayed. If the desired baud rate is not displayed,
press the Right arrow key until the desired baud rate appears.
BAUD RATES
9600 N/Y Entering YES selects the baud rate shown. Note: Selecting one baud
19200 N/Y rate deselects any previously selected choice.
BAUD RATE → Press the Enter key.

(USER DEFINED) YES
BAUD RATE →
Confirms the entry.
(USER DEFINED) YES
PROTOCOL →
Returns the user to Modbus protocol heading.
MODBUS

2.9.14 Menu 14—Programming Mode The user chooses one of three programming modes:
Menu 14 allows altering controller data either locally D Local—using the controller keypad
using the keypad or remotely using a PC or other device. D Remote—using a PC
The user must enter a password (access code) to D Off—no programming is permitted
enable the programming mode.
Enter Yes to one mode to change the other two choices
Local Programming. Local programming is data to No.
alteration using the controller keypad and display.
Note: Use the generator set controller to initially set up
Remote Programming. Remote programming is data remote programming. Remote programming is
alteration using devices connected to a communication not allowed from a PC unless the controller is first
port using KBUS or Modbusr. set for remote programming using Menu 14.
Note: Log into the local programming mode to edit Note: After completing the programming always place
the programming access code. The factory the controller back in the Programming Mode Off
default access code is the number 0. position to prevent inadvertent program changes.
Use Menu 14 to change the access code. Record the Modbusr is a registered trademark of Schneider
new number and give the access code to authorized Electric.
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.

Menu 14—Programming Mode
Key
MAIN MENU NUMBER 14


PROGRAMMING MODE
PROGRAMMING MODE → Displays the user-defined programming mode. Press the Down arrow
(USER DEFINED) Y/N 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.
PROGRAMMING MODES
OFF Y/N Entering YES selects the programming mode shown.
LOCAL N/Y Note: Selecting one programming mode deselects any previously
REMOTE N/Y selected choice.
PROGRAMMING MODE → Press the Enter key.

(USER DEFINED) YES
PROGRAMMING MODE Changing the programming mode requires entering the access code.
ENTER CODE * Enter the access code and press the Enter key.
Note: The factory default access code is the number 0.
PROGRAMMING MODE →
Confirms the entry.
(USER DEFINED) YES
PROGRAMMING MODE → Displays the programming mode and changes the access code. Press
CHANGE ACCESS CODE the Down arrow key if you do not wish to change the access code. To
change the access code, press the Right arrow key.
PROGRAMMING MODE
Enter the old access code and press the Enter key.
ENTER OLD CODE *
PROGRAMMING MODE
Enter the new access code and press the Enter key.
ENTER NEW CODE *
PROGRAMMING MODE →
Confirms the entry.
CHANGE ACCESS CODE
MENU 14
PROGRAMMING MODE
Returns the user to the programming mode heading.

2.9.15 Menu 20—Factory Setup
Menu 20 provides generator set, alternator, controller,
and engine identification information. The user can use
this menu to determine the generator set operating days
and identify the controller software (code) version. The
factory setup menu information is locked by the
manufacturer. The temperature sensor setup applies to
non-ECM engines only.
Menu 20—Factory Setup

Key
MAIN MENU NUMBER 20


FACTORY SETUP
FINAL ASSEMBLY DATE

Displays the final assembly date at the factory.
DD/MM/YY
FINAL ASSEMBLY
Displays the final assembly clock number at the factory.
CLOCK NO #
OPERATING DAYS #
Displays the generator set operating days.
MODEL NO #
Displays the generator set model number.
SPEC NO #
Displays the generator set specification number.
GENSET SERIAL NO #
Displays the generator set serial number.
ALTERNATOR PART NO #
Displays the alternator part number.
ENGINE PART NO #
Displays the engine part number.
SERIAL NO #
Displays the generator set serial number.
CONTROLLER SERIAL NO #
Displays the controller serial number.
CODE VERSION #
Displays the controller software (code) version.
COPYRIGHT XXXX
SETUP LOCKED YES

Displays the setup locked by the manufacturer.

Notes

Section 3 Scheduled Maintenance
Under normal operating conditions, the generator set’s Disabling the generator set. Accidental starting can
alternator requires no normal service. Consult cause severe injury or death. Before working on the
Section 2.1, Prestart Checklist, for a list of routine generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
checks.
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
3.1 Alternator Service battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
When operating the generator set under dusty or dirty start/stop switch, or engine start command from a remote
conditions, use dry compressed air to blow dust out of computer.
the alternator while the generator set is running. Direct
the stream of air through openings in the generator set
WARNING
end bracket.
3.2 Engine Service

Perform engine service at the intervals specified in the Hot engine and exhaust system.
engine manufacturer’s service literature. Contact an Can cause severe injury or death.
authorized service distributor/dealer to obtain service Do not work on the generator set until
literature. it cools.
Note: Have maintenance work, including battery

Servicing the exhaust system. Hot parts can cause
service, performed by appropriately skilled and severe injury or death. Do not touch hot engine parts. The
suitably trained maintenance personnel familiar engine and exhaust system components become extremely
with generator set operation and service. hot during operation.
WARNING WARNING
Hazardous voltage. Moving rotor.

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

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

3.4 Alternator Bearing Service Note: The illustration shows a generator set
without a fuel/water separator. The valve
Have an authorized service distributor/dealer perform location and position for a generator set
generator service. equipped with a fuel/water separator is
similar.
3.4.1 20--300 kW Models 2. Loosen the bleed screw at the engine. Refer to the
engine operation manual for location of the bleed
Replace the end bracket bearing every 10,000 hours of
operation in standby and prime power applications. screw(s). The bleed screw allows air to be expelled
from the fuel system when the hand prime pump is
Service the bearing more frequently if the annual
inspection indicates excessive rotor end play or bearing operated.
damage. Replace the tolerance ring, if equipped,
3. Rotate the hand prime pump handle
following end bracket removal. The sealed end bracket counterclockwise until fuel flows from the bleed
bearing requires no additional lubrication.
screw. Stop pumping.
3.4.2 350--2000 kW Models with 4. Tighten the bleed screw. Wipe up any fuel leakage.
Single-Bearing Alternator 5. Place the fuel valves in the normal operation
The alternator bearing requires lubrication at intervals position. Open the fuel valve located between the
specified in the generator set technical manual. Use pipe tee and the engine. Close the fuel valves on
Chevron SRI or equivalent antifriction, high-quality each side of the fuel prime pump.
grease with a lubrication temperature range of --30° to
+175°C (--22° to +350°F).
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

Bleed air from the fuel system after fuel system Close this Valve Open this Valve
maintenance, such as replacing the fuel filter(s) using Open this Valve
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 Valve Open Valve Closed PK-272000-H
engine manufacturer’s instructions. Trapped air

Figure 3-1 Hand Prime Pump with Valve Positions
in the fuel system causes difficult starting and/or
for Fuel Priming (Generator Set Without
erratic engine operation.
a Fuel/Water Separator Shown)
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.

3.5.2 Subbase Fuel Day Tank Electronic Level Sensor
Control Module (ECM) An electronic analog float gauge located below the ECM
With an electronic control module (ECM), the optional on the mounting bracket determines the day tank fuel
subbase diesel fuel tank functions as a day tank. level. Nine LEDs on the ECM indicate the day tank fuel
Following are operating information and features of the level from full to empty.
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 Description
Off Pushbutton disables the ECM for routine
maintenance to the tank system.
On Pushbutton activates the ECM after the
OFF pushbutton is depressed. On
power-up after a power outage, the ECM
automatically turns on.
Test 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.
Internal test Pushbutton (located inside the ECM) tests
224825
each alarm LED and remote annunciation
relay in sequential order (high fuel to ECM
Figure 3-2 ECM Front Panel Layout functional).
Servicing the day tank. Hazardous voltage can cause Figure 3-4 ECM Pushbuttons
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 ECM Alarms
the day tank ECM OFF pushbutton to disconnect the power.
The ECM has five standard alarm conditions indicated
Notice that line voltage is still present within the ECM when the
POWER ON light is lit. Ensure that the generator set and day locally by LEDs and remotely by relays. Figure 3-5
tank are electrically grounded. Do not operate the day tank describes the five alarm conditions. Make customer
when standing in water or on wet ground because these connections to the normally open and normally closed
conditions increase the risk of electrocution. relay contacts provided.
ECM General Function Alarm Description

High fuel Alarm activates at 106% of normal fuel
The ECM controls a pump/motor that maintains the day level.
tank fuel level. The ECM motor relay is connected to the Low fuel Alarm activates at 62% of normal fuel
pump/motor. The ECM starts the pump when the fuel level. The alarm provides time to respond
level drops to 87% of full and stops the pump when the to a potential problem before a low fuel
shutdown occurs.
day tank is full.
Critical low fuel Alarm activates at 6% of normal fuel level
(engine shutdown) to warn the operator to shut down the
ECM Function Indicator LEDs generator set before fuel runs out.
Fuel in rupture Alarm activates when the ECM detects fuel
Two LEDs on the front panel indicate ECM operation. basin, if equipped in the rupture basin.
See Figure 3-2 for the locations of the LEDs. Figure 3-3 ECM functional Alarm activates to indicate a problem with
describes the LED functions. the ECM operation.
Note: The ECM functional alarm relay
activates a customer-installed alarm when
Function Description the relay deenergizes.
Power On LED lights to indicate that power is applied
to the ECM. Figure 3-5 ECM Alarms
Pump Running LED lights when the pump starts.
Figure 3-3 ECM Function Indicator LEDs

3.5.3 Subbase Inner Fuel Tank Alarm Resetting Procedure
This kit provides for both audible and visual alarm from a Use the following procedure to reset the alarm after a
location remote from the generator set if a leak is fault alarm.
detected in the inner fuel tank of the double-wall
1. Move alarm switch to the SILENCE position to
subbase fuel tanks. See Figure 3-6. If the inner tank is
stop alarm horn. Lamp will remain lit.
leaking, a sensor installed in the outer tank sends an
electrical signal to the alarm plate when the sensor 2. Disconnect generator set from load with line circuit
becomes immersed in the fuel collecting in the outer breaker or automatic transfer switch.
tank. If a leak is detected, the alarm horn will sound and
the fault lamp will light. The alarm horn is quieted by 3. Repair or replace the inner fuel tank.
moving the alarm switch to the SILENCE position; the
alarm lamp remains lit until the fault is corrected. See 4. Move generator master switch to the OFF/RESET
Figure 3-7 for troubleshooting information. position and then to the RUN position for startup.
Alarm horn sounds and lamp goes out.
5. Reconnect generator to load via line circuit

Inner Tank breaker or automatic transfer switch.
Fuel Leak 6. Move generator master switch to the AUTO
Alarm
position for startup by remote transfer switch or
Alarm remote start/stop switch. Move alarm switch to the
Normal Silence NORMAL position.
Alarm Float
Switch Switch
Leak Alarm Panel Position Position Observation
Normal Open The alarm horn and the lamp are not
energized.
Normal Closed 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.
Silence Open The alarm horn sounds to alert the user
that the alarm horn switch is not in the
normal position and that the alarm horn
will not sound should a fuel leak occur.
Figure 3-7 Inner Fuel Tank Leak Alarm

Troubleshooting
FF-273000-D
Figure 3-6 Inner Fuel Tank Leak Alarm

(20--300 kW Model Shown)

3.6 Gas/Gasoline Fuel Systems models require a different fuel kit when changing gas
fuels. Consult your local generator distributor/dealer for
This section describes fuel systems that are not covered additional information.
in the engine operation manual or engine service
manual. Fuel conversion may decrease generator set output and
affect exhaust emissions. Consult your local generator
distributor/dealer for additional information.
3.6.1 Gaseous Fuel System Concept
The gaseous fuel system uses a fuel valve with a Fuel Conversion Procedure
solenoid to control the fuel flow to the fuel regulator. The
When converting the generator set to operate with LP
generator-mounted regulator reduces the fuel pressure
gas, remove the internal spring from the secondary
as fuel passes to the carburetor. See Figure 3-8. The
regulator. Install the spring to operate the generator set
carburetor/mixer controls the ratio of fuel to air under
on natural gas.
varying load and speed conditions. Because the
carburetor receives fuel in a gaseous state, it does not Note: Not all fuel regulators require spring and retainer
have to vaporize the fuel. When switching from natural removal for fuel conversion. A hang tag on the
gas to LP gas or LP gas to natural gas, verify that the fuel regulator identifies the conversion procedure.
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 LP Fuel Conversion Procedure
for the governor adjustment procedure. Use the following steps to remove the internal spring
from the fuel regulator:
1 2 3 4 5 1. Remove the fuel regulator cover plug. See

Figure 3-9.
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. Primary regulator (supplied by gas supplier or customer) Use the following steps to convert the generator set to
2. Pressure gauge natural gas:
3. Solenoid valve
4. Secondary regulator 1. Remove the fuel regulator cover plug. See
5. Carburetor
Figure 3-9.
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 2
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. 4 3
3.6.3 LP Gas/Natural Gas Conversion SB-527
for Straight Gas Fuel System

1. Fuel regulator 3. Adjustment screw
2. Spring 4. Cover plug
Most models operate on either LP gas or natural gas fuel
by performing the fuel conversion procedure. Some Figure 3-9 Fuel Regulator, Typical

2. Replace the spring and adjustment screw. Manual Changeover
3. Connect a manometer to check the fuel supply A manual changeover fuel system allows manual
pressure on the carburetor side of the regulator changeover from gasoline to natural gas or LP gas, or
after any fuel system equipment accessories. The from natural gas or LP gas to gasoline. Typically, the
recommended fuel supply pressures are shown in combination system uses gas as the primary, preferred
Figure 3-10 and on the generator set spec sheet. fuel and gasoline in emergencies. If the primary fuel is
unavailable (an empty fuel tank or fuel supply disruption),
Fuel Supply Pressure the system uses gasoline. A toggle switch on the
generator set controls the fuel choice and energizes
Generator Water Column,
Set Model Engine kPa (oz./in.2) cm (in.) either a fuel solenoid and electric fuel pump for gasoline
20--100 kW Ford 1.7--27.4 (4--6) 18--28 (7--11) or a fuel valve for gas. Pull out the control cable for
30--100 kW GM 1.7--27.4 (4--6) 18--28 (7--11) gasoline and push in the control cable for gas.
115/135 kW Cummins 3.5 (8) 36 (14)
135--180 kW
Detroit Diesel
1.2--5 (2.9--11.6) 13--51 (5--20) 3.6.5 Carburetor Adjustment
Series 50
200--275 kW
Detroit Diesel
1.2--5 (2.9--11.6) 13--51 (5--20)
Before adjusting the carburetor, verify that the engine
Series 60 compression and the ignition system meet
Figure 3-10 Recommended Fuel Supply Pressures specifications. Do not adjust the carburetor to
compensate for other engine disorders. If the engine
4. Adjust the fuel supply pressure with the generator speed is incorrect, adjust the electronic governor to
set running at full load. Rotate the adjustment achieve 1800 rpm (at 60 Hz) or 1500 rpm (at 50 Hz).
screw on the fuel regulator until the pressure Adjust the carburetor if governor adjustment alone does
indicated by the manometer matches the specified not result in the desired engine speed.
pressure. Use the lower pressure value if the
generator set still provides good response and full Adjusting the carburetor affects the engine fuel mixture.
power. Lower-than-specified pressures may result Routine carburetor adjustment is not necessary.
in poor response to load changes or lack of power. However, if the carburetor is removed or tampered with,
the carburetor may require adjustment to achieve
5. Reinstall the cover plug. optimum engine performance. Some engines have
sealed carburetors that are not adjustable.
3.6.4 Fuel System Changeover Kits
Gasoline Carburetor Adjustment
Automatic Changeover Refer to the engine operation manual or engine service
manual for gasoline carburetor adjustment information.
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 Gaseous Carburetor (Fuel Mixer) Adjustment
fuels each have a secondary fuel regulator and a fuel Procedure
valve. Typically, the primary fuel is natural gas; the Use the following procedure to adjust the carburetor
backup fuel is LP gas vapor. When the generator set (fuel mixer).
starts, the primary fuel valve opens and the backup fuel
valve closes. The primary fuel line has a vacuum 1. Start the generator set and run it at approximately
switch in series with a relay connected to the start/run half load.
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 2. Adjust the engine fuel mixture screw (Figure 3-11)
relay opens the backup fuel valve and closes the until the engine runs smoothly.
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.) 3. Apply varying loads and readjust the carburetor as
water column, the generator set uses the primary fuel. necessary to achieve smooth engine performance
Contact an authorized service distributor/dealer for kit at all load levels.
availability.
4. Stop the generator set.

3.6.6 Fuel System Maintenance 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
Gasoline Models release pressure, cover the pressure cap with a thick cloth and
then slowly turn the cap counterclockwise to the first stop.
Clean or replace the fuel filter at the specified interval. Remove the cap after pressure has been completely released
Service the filters more frequently if the engine runs and the engine has cooled. Check the coolant level at the tank
roughly, as a clogged fuel filter can cause rough engine if the generator set has a coolant recovery tank.
operation. Some models use a disposable inline fuel
filter, which must be replaced. Other models have a fuel Note: Engine damage. Bleed the air from the cooling
pump with an integral fuel filter that requires cleaning at system to prevent overheating and subsequent
the specified interval. engine damage.
Note: Block heater damage. The block heater will fail

Gaseous Models if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
This fuel system requires no regular maintenance.
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
1 2 the system before energizing the block heater.
3.7.1 Coolant Level Check
3 Check the coolant level in the coolant recovery tank.

Maintain the coolant level between the high and low
marks.
TP-5750-3 Note: Periodically check the coolant level by removing

1. Fuel adjusting screw the pressure cap. Do not rely solely on the level in
2. Lean
3. Rich the coolant recovery tank. Add fresh coolant until
the level is just below the overflow tube opening
Figure 3-11 Fuel Mixture Adjustment, Typical of the filler neck.
3.7 Cooling System 3.7.2 Cooling System Component

Inspection
The cooling system maintenance information applies to
radiator-cooled models and city-water-cooled (heat To prevent generator shutdown or damage caused by
exchanger) models. The cooling systems function overheating:
similarly even though they use different components.
Radiator-cooled models have a radiator with a pressure D Keep the cooling air inlets clean and unobstructed.
cap and coolant recovery tank. City-water-cooled
models have a heat exchanger and an expansion/surge D Inspect the radiator’s exterior for obstructions.
tank with a pressure cap. Remove dirt and foreign material using a soft brush or
cloth to avoid damaging the radiator fins.
Note: The 20--40 kW Deutz engine-powered generator
sets are oil cooled and therefore do not have a D Check the hoses and connections for leaks. Replace
water cooling system. 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. deteriorated cap. Remove dirt and other debris from
Can cause severe injury or death. the pressure cap and filler neck. The pressure cap
raises the boiling point of the coolant, enabling higher
Before removing the pressure cap,
operating temperatures. Replace a leaking pressure
stop the generator set and allow it to
cool. Then loosen the pressure cap cap with one rated for the same pressure. The
to relieve pressure. pressure cap rating usually appears on the pressure
cap.

3.7.3 Cooling System Drainage 3. Open the air-bleed petcocks, if equipped. Close
Procedure the air-bleed petcocks when coolant begins to flow
from them.
For optimum protection, drain, flush, and refill the
cooling system at the intervals listed in the service 4. Add coolant additives or water pump lubricants
schedule. according to the engine manufacturer’s
recommendations in the engine operation manual.
Note: Dispose of all waste materials (oil, fuel, coolant,
filters, and gaskets) in an environmentally safe 5. Fill the cooling system with the recommended
manner. coolant/antifreeze mixture of 50% ethylene glycol
and 50% clean, softened water to inhibit
1. Deenergize the block heater, if equipped. rust/corrosion and prevent freezing.
2. Remove the pressure cap to allow the entire Note: A coolant solution of 50% ethylene glycol
system to drain and prevent air pockets from provides freezing protection to --37°C
restricting coolant flow through the engine block. (--34°F) and overheating protection to
129°C (265°F). A coolant solution
3. Open the radiator and/or engine block coolant containing less than 50% ethylene glycol
drain valve(s) and allow the system to drain. may not provide adequate freezing and
overheating protection. A coolant solution
4. If the inside of the radiator has mineral deposits or containing more than 50% ethylene glycol
the used coolant contains dirt or grease, refer to can cause engine or component damage.
Section 3.7.4, Procedure to Flush and Clean the Do not use alcohol or methanol antifreeze
Cooling System. If the cooling system does not or mix them with the specified coolant.
have mineral deposits, go to Section 3.7.5, Refer to the engine operation manual for
Procedure to Refill the Cooling System. recommendations regarding the coolant
mixture to use in extreme temperatures.
3.7.4 Cooling System Flushing and
6. Replace the pressure cap.
Cleaning Procedure
7. Fill the coolant recovery tank to the low mark.
Use the instructions in the engine operation manual
when available to flush and clean the cooling system. 8. Operate the generator set until the thermostat
Otherwise, use the following procedure and the cooling opens when the upper cooling system hose
system cleaner manufacturer’s instructions. warms.
1. Flush the cooling system with clean water. 9. Stop the engine and allow it to cool.
2. If the inside of the radiator still has mineral 10. Remove the pressure cap.
deposits, use a radiator cleaner to remove the
remaining deposits following the manufacturer’s 11. Add coolant to bring the coolant level to just below
instructions. the overflow tube opening of the filler neck.
3. Drain, clean, and flush the coolant recovery tank. 12. Replace the pressure cap.
13. Maintain the coolant level in the coolant recovery

3.7.5 Cooling System Refilling tank between the high and low marks.
Procedure
Note: Air pockets often form in the engine water
See the generator set spec sheet for coolant capacity. jacket when the coolant system is refilled.
Check the coolant level in the coolant
Note: Do not add coolant to a hot engine. Adding
recovery tank after each generator set
coolant to a hot engine can cause the cylinder
operation and add coolant as necessary
block or cylinder head to crack. Wait until the
until the coolant level stabilizes. Then check
engine has cooled.
the coolant at the interval specified in the
1. Remove the pressure cap. service schedule.
2. Close the radiator and/or engine block coolant 14. Reenergize the block heater, if equipped.
drain valve(s) and tighten the cooling system hose
clamps.

3.8 Radiator Expansion Joint 4. Inject grease into the two bearings on the fan shaft
block and the two bearings on the idler shaft block
Loosening—Initial Setup Only using a grease gun until a 3--6 mm (0.13--0.25 in.)
Loosen the radiator expansion joint nuts on grease column shows at the bearing pressure relief
1200--2000 kW generator sets that have radiators port. See Figure 3-13.
manufactured by Young Radiator Company. Expansion
joints located on each side of the radiator permit 1
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 5
2
1
2
3
TP-5353-3 4
1. Air flow
2. Expansion joint nuts for rear tank, left side 2
3. Expansion joint nuts for front tank, left side
4. Top front of radiator 3
TP-5353-3
Figure 3-12 Expansion Joint Nuts, Top Left Side of 1
Radiator, Typical 1. Grease fittings
2. Pressure relief port
3. Radiator assembly
3.9 Fan Bearing Lubrication 4.
5.
Idler shaft grease fittings
Fan shaft grease fittings
The following procedure applies only to 1200--2800 kW Figure 3-13 Radiator Fan Bearings and Pressure
generator sets. Lubricate the radiator fan shaft and idler Relief Ports, Typical
shaft bearings at every engine oil change to avoid
bearing damage. Lubricate the bearings every Note: The fan shaft and idler shaft bearings have
200 hours of operation when the generator set runs in pressure relief ports to prevent bearing
ambient temperatures below 29°C (85°F) or when the damage caused by overlubrication.
generator set runs in a dusty and/or humid environment.
5. Remove excess grease from the bearing pressure
Lubrication and Drive Belt Adjustment Procedure relief ports.
Lubricate the fan shaft and idler shaft bearings with a 6. Inspect the fan drive belt and replace if it is damaged
lithium-complex base, multi-purpose grease with or worn. Check the fan belt tension using a poly
antirust, antifoam, and extreme-pressure additives V-belt tension gauge and adjust the tension, if
having a minimum dropping point of 204°C (400°F). necessary. See Figure 3-14.
Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent.
If the belt slips after the belt tension procedure, clean the
1. Place the generator set master switch in the pulley surfaces and repeat the belt tension procedure. If
OFF/RESET position. slippage continues, replace the fan belt.
2. Disconnect the generator set engine starting Generator Set New Belt, Used Belt*,
battery(ies), negative (--) lead first, and disconnect Model N (lbf.) N (lbf.)
power to the battery charger.
2450--2890 1650--1910
1200-2800 kW
(550--650) (370--430)
3. Remove the belt guards to expose the fan shaft and
* A belt is considered used after 50 hours of service.
idler shaft bearings.
Figure 3-14 Poly V-Belt Tension Specifications

7. Reinstall the belt guards using the original Battery electrolyte is a diluted sulfuric acid. Battery acid
hardware. can cause severe injury or death. Battery acid can cause
blindness and burn skin. Always wear splashproof safety
8. Reconnect the generator set engine starting goggles, rubber gloves, and boots when servicing the battery.
battery(ies), negative (--) lead last. 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
9. Test run the generator set for a few minutes and
clean water. Seek immediate medical aid in the case of eye
listen for belt noise (squeal) indicating a slipping contact. Never add acid to a battery after placing the battery in
belt. Stop the generator set. service, as this may result in hazardous spattering of battery
acid.
3.10 Battery 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
WARNING 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.
Sulfuric acid in batteries. Refer to this section for general battery information and
Can cause severe injury or death. maintenance. All generator set models use a negative
ground with a 12-volt or 24-volt engine electrical system.
Wear protective goggles and
Consult the generator set nameplate for the engine
clothing. Battery acid may cause
blindness and burn skin. 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,
Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke
Figure 3-16, and Figure 3-17 for typical battery
or permit flames or sparks to occur near a battery at any time, connections, including multiple battery configurations.
particularly when it is charging. Do not dispose of a battery in a
fire. To prevent burns and sparks that could cause an 1 2
explosion, avoid touching the battery terminals with tools or
other metal objects. Remove all jewelry before servicing the 1 2
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 1 2
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 (--) EZ-273000-J
battery cable to the positive (+) connection terminal of the 1. To positive (+) terminal on starter solenoid.
starter solenoid. Do not test the battery condition by shorting 2. To ground (--) terminal on or near starter motor.
the terminals together.
Figure 3-15 12-Volt Engine Electrical System Single
Starter Motor Typical Battery Connection

1 2 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
2 1 tight.
1 2
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

Check the electrolyte level and specific gravity of
1. To positive (+) terminal on starter solenoid. batteries that have filler caps. Maintenance-free
2. To ground (--) terminal on or near starter motor. batteries do not require electrolyte level checking or
specific gravity testing.
Figure 3-16 24-Volt Engine Electrical System Single
Starter Motor Typical Battery Connection 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
1 2 3 4 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 2 3 4
KW-272000-B
1. To positive (+) terminal on starter solenoid. 2
2. To ground (--) terminal on or near starter motor.
3. To positive (+) terminal on second starter solenoid. 1-046
4. To ground (--) terminal on or near second starter motor.
1. Filler caps
2. Electrolyte level
Figure 3-17 24-Volt Engine Electrical System Dual
Starter Motors Typical Battery Figure 3-18 Battery Electrolyte Level Inspection
Connections

3.10.3 Specific Gravity Check Correction
°C °F
Use a battery hydrometer to check the specific gravity of 71.1 160 + .032
the electrolyte in each battery cell of batteries with filler + .030
caps. Holding the hydrometer vertically, read the 65.6 150 + .028
Example No. 1
number on the glass bulb at the top of the electrolyte + .026
60.0 140 + .024

Temperature below 26.7°C (80°F)
level or the number adjacent to the pointer. If the
hydrometer used does not have a correction table, + .022 Hydrometer Reading 1.250
consult Figure 3-20. Determine the specific gravity and 54.4 130 + .020
Acid Temperature --6.7°C (20°F)
electrolyte temperature of the battery cells. Locate the + .018
temperature in Figure 3-20 and correct the specific 48.9 120 + .016 Subtract .024 Specific Gravity
+ .014
Corrected Specific Gravity is 1.226
gravity by the amount shown. The battery is fully
charged if the specific gravity is 1.260 at an electrolyte 43.3 110 + .012 1.250 -- .024 = 1.226
temperature of 26.7_C (80_F). Maintain the specific + .010
gravities between cells within ±0.01 of each other. 37.8 100 + .008
Charge the battery if the specific gravity is below 1.215 + .006 Example No. 2
at an electrolyte temperature of 26.7_C (80_F). 32.2 90 + .004
Temperature above 26.7°C (80°F)
+ .002
Note: Some battery testers have four or five beads in a 26.7 80 0 Hydrometer Reading 1.235
test tube. Draw electrolyte into the tube as with -- .002
Acid Temperature 37.8°C (100°F)
the battery hydrometer described in this section 21.1 70 -- .004
or use the manufacturer’s instructions. Use --. 006 Add .008 Specific Gravity
Corrected Specific Gravity is
Figure 3-19 to interpret typical test results. 15.6 60 -- .008
1.243
-- .010
Number of 10 50 -- .012 1.235 + .008 = 1.243

Floating Beads Battery Condition -- .014
5 Overcharged 4.4 40 -- .016
4 Fully charged -- .018
-- 1.1 30 -- .020
3 A good charge
-- .022
1 or 2 A low charge
-- 6.7 20 -- .024
0 A dead battery -- .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 The temperature correction amounts to about .004 (4 points) of
battery while the generator set is running. specific gravity for each 5.5°C (10°F) change in temperature.
1-787
Note: If the generator set is in a temporary prime power
application in which the generator set has periods Figure 3-20 Specific Gravity Temperature Correction
of inactivity, the controller circuitry may drain the
battery. If there is no power source for a battery
charger, place the controller in the prime power
mode, if equipped, or disconnect the battery from
the generator set.

3.11 Detroit Diesel Engine Control Access the stored codes in one of three ways:
(DDEC) System D Place the switch in the DIAGNOSTIC REQUEST
position. The CEL or SEL flashes to identify the
Some generator sets equipped with Detroit Diesel
failure.
engines use a DDEC system. Access the DDEC control
box inside the generator set junction box to retrieve D Use a hand-held diagnostic data reader (DDR).
codes when performing routine maintenance or Place the switch in the DIAGNOSTIC DATA READER
troubleshooting the engine. position. Plug the DDR into the control box. The DDR
displays the stored failure codes.
Use the following data for informational purposes only.
Consult the engine literature for complete information D Use a personal computer software package with a
regarding DDEC operation and troubleshooting. See translator to access stored codes. Follow the
List of Related Literature in the Introduction. Contact an instructions provided with the software.
authorized service distributor/dealer for service or
diagnostic equipment.
Code Types
3.11.1 DDEC Features Active code. A code flashing on the SEL lamp indicates
a fault currently exists.
The DDEC system optimizes control of critical engine
functions and protects against serious engine damage Inactive code. A code flashing on the CEL lamp
resulting from conditions such as the following: indicates a previous fault occurrence. The ECM
memory stores inactive codes with time/date
D Low coolant level identification and the following information:
D Low coolant pressure
D First occurrence of each diagnostic code in engine
D High coolant temperature
operating hours.
D Low oil pressure
D High oil temperature 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 D Total time in seconds that the diagnostic code was
control box, located in the generator set junction box. active.
3.11.2 DDEC Engine Diagnostics 3.12 Deutz Engine Control System

The DDEC engine protection system monitors engine Some generator sets equipped with Deutz engines use
sensors and electronic components and recognizes an engine control system. Access the control box inside
system malfunctions. Critical faults light the check the generator set junction box to retrieve codes when
engine (CEL) and stop engine (SEL) lamps on the performing routine maintenance or troubleshooting
control box. ECM memory software logs malfunction engine.
codes. Consult the engine operation manual or engine
Use the following data for general informational
service manual to identify the stored failure code. See
purposes only. See the Engine Service Manual for
Figure 3-21 for the DDEC control box features.
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

The major components include the engine control 3.13.2 Cooling System
module (EMR), engine sensors, and control box located
in the generator set junction box. See Figure 3-22 for Prepare the cooling system for storage as follows:
the Deutz control box features.
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.
Figure 3-22 Deutz Control Box 2. Condition the fuel system with compatible
additives to control microbial growth.
3.13 Storage Procedure 3. Change the fuel filter/separator and bleed the fuel
system. See the engine owner’s manual.
Perform the following storage procedure before taking a
generator set out of service for three months or longer. Gasoline-Fueled Engines
Follow the engine manufacturer’s recommendations, if
available, for fuel system and internal engine 1. Add stabilizer to the fuel system. Follow the
component storage. manufacturer’s recommended procedure.
2. Run the generator set for 15 minutes to ensure that

3.13.1 Lubricating System the stabilized fuel reaches the carburetor.
Prepare the engine lubricating system for storage as Gas-Fueled Engines

follows:
1. Start the generator set.
1. Run the generator set for a minimum of 30 minutes
to bring it to normal operating temperature. 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. Place the generator set master switch in the
OFF/RESET position.
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.
8. Check the oil level and adjust, if needed.

3.13.4 Internal Engine Components 3.13.5 Exterior
(Gas/Gasoline-Fueled Engines)
1. Clean the exterior surface of the generator set.
If you have access to a fogging agent or SAE 10 oil
prepare the pistons and cylinders for storage as follows: 2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
1. While the engine is running, spray a fogging agent
or SAE 10 engine oil into the air intake for about two 3. To prevent impurities from entering the air intake
minutes until the engine stops. and to allow moisture to escape from the engine,
secure a cloth over the air intake.
2. Place the generator set master switch in the
OFF/RESET position. 4. Mask electrical connections.
If a fogging agent is not available perform the following: 5. Spread a light film of oil over unpainted metallic
surfaces to inhibit rust and corrosion.
1. Remove the spark plugs.
2. Pour 15 cc (0.5 oz.) of engine oil into each spark

3.13.6 Battery
plug hole. Perform battery storage after all other storage
procedures.
Ignition System Damage. Refer to the engine
operation manual for ignition system precautions 1. Place the generator set master switch in the
before cranking the engine while the spark plug OFF/RESET position.
wires are disconnected.
2. Disconnect the battery(ies), negative (--) lead first.
3. Toggle the generator set master switch to crank the
engine two or three revolutions to lubricate the 3. Clean the battery. Refer to Section 3.10.1 for the
cylinders. battery cleaning procedure.
4. Reinstall the spark plugs and torque them to 4. Place the battery in a cool, dry location.
specifications.
5. Connect the battery to a float/equalize battery
charger or charge it monthly with a trickle battery
charger. Refer to the battery charger
manufacturer’s recommendations.
Maintain a full charge to extend battery life.

Notes

Section 4 General Troubleshooting
This section contains generator set troubleshooting, Battle Switch/Fault Shutdown Override Switch. The
diagnostic, and repair information. battle switch function forces the system to ignore normal
fault shutdowns such as low oil pressure and high
Use the following charts to diagnose and correct engine temperature. The battle switch does not
common problems. First check for simple causes such override the emergency stop and overspeed shutdown.
as a dead engine starting battery or an open circuit When the battle switch function is enabled, the
breaker. The charts include a list of common problems, generator set continues to run regardless of shutdown
possible causes of the problem, recommended signals where potential engine/generator damage can
corrective actions, and references to detailed occur.
information or repair procedures.
When this input is enabled, the yellow warning lamp
Maintain a record of repairs and adjustments performed illuminates and stored warning/shutdown events that
on the equipment. If the procedures in this manual do are ignored continue to log in Menu 5— Event History.
not explain how to correct the problem, contact an
authorized distributor/dealer. Use the record to help See Section 2.9.9, Menu 9—Input Setup, for information
describe the problem and repairs or adjustments made on how to enable the battle switch feature.
to the equipment.
TP-6083 7/05 Section 4 General Troubleshooting 127

Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Probable Causes Recommended Actions Reference*
Controller
x x Controller circuit board(s) inoperative Replace the controller circuit board. Gen. S/M
128 Section 4 Troubleshooting

x Controller fault Troubleshoot the controller.[ Gen. S/M
x x x Controller fuse blown Replace the blown controller fuse. If the fuse blows again, Section 2, W/D
troubleshoot the controller.[
x Controller master switch inoperative Replace the controller master switch. —
x Controller master switch in the Move the controller master switch to the RUN or AUTO position. Section 2
OFF/RESET position
x Engine start circuit open 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
x x Air openings clogged Clean the air openings. —
x Coolant level low Restore the coolant to normal operating level. Section 3
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
x High temperature shutdown Allow the engine to cool down. Then troubleshoot the cooling Sec. 3, Eng. O/M
system.
x Low coolant level shutdown, if Restore the coolant to normal operating level. Section 3
equipped
x Thermostat inoperative Replace the thermostat. Eng. S/M
Electrical System (DC circuits)
x x Battery connections loose, corroded, Verify that the battery connections are correct, clean, and tight. Section 3
or incorrect
x x Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
recommended battery CCA rating.
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
x x Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect it to W/D
locked tight the controller.
x High water temperature switch Replace the inoperative switch. Gen. S/M or W/D
inoperative
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
x High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
inoperative
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
TP-6083 7/05
Trouble Symptoms
TP-6083 7/05
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Engine
x x x x Air cleaner clogged Clean or replace the filter element. Eng. O/M
x x x x x Compression weak Check the compression.[ Eng. S/M
x x x x x Engine overload Reduce the electrical load. See the generator set spec sheet for S/S
wattage specifications.
x Exhaust system leak Inspect the exhaust system. Replace the inoperative exhaust I/M
TP-6083 7/05 system components.[
x Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust system I/M
components.[
x x x x Governor inoperative Adjust the governor.[ Gen. S/M
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —
x x x Ignition system inoperative Check the ignition system (spark plugs, spark plug wires, etc.). Eng. O/M
(gas/gasoline only)
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
x x Ether canister empty or system Replace or repair the ether starting system. Eng. O/M
inoperative, if equipped (diesel only)
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
x x x Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ Eng. S/M
(diesel only)
x x x Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
(diesel only)
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x Fuel pressure insufficient (gas only) Check the fuel supply and valves.[ S/S, Gen. O/M
x x x x Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
(diesel only)
Section 4 Troubleshooting 129

Trouble Symptoms
Section or
Publication
Starts hard
Excessive or
abnormal noise
Cranks but
does not start
No or low
output voltage
Stops
suddenly
Lacks power
Overheats
Low oil
pressure
High fuel
consumption
Does not
crank
Alternator
x AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
130 Section 4 Troubleshooting

side of the circuit breaker.
x Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. ATS O/M
position
x Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. Troubleshoot ATS O/M, S/M
the transfer circuit and time delays.
x Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
field open
x Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Gen. S/M
grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
x x Voltage regulator digital settings Adjust the voltage regulator. Sec. 2, Menu 11
incorrect (digital controller only)
x x Voltage regulator inoperative Replace the voltage regulator fuse, If the fuse blows again, Gen. S/M
troubleshoot the voltage regulator.
x x Voltage regulator out of adjustment Adjust the voltage regulator. Gen. S/M
Lube System
x x x x Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the operating Eng. O/M
ambient temperature climate.
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x Low oil pressure shutdown Check the oil level. Eng. O/M
bp #
TP-6083 7/05
Section 5 Generator Set Reconnection
5.1 Introduction Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
Use the following voltage reconnection procedure to generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
change the voltage of 10- and 12-lead generator sets.
OFF position. (2) Disconnect the power to the battery charger.
Frequency changes require voltage regulator and (3) Remove the battery cables, negative (--) lead first.
governor adjustments. Consult the generator set Reconnect the negative (--) lead last when reconnecting the
service manual for frequency adjustment information. battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
Refer to the following procedure and the connection start/stop switch, or engine start command from a remote
schematics. Follow the safety precautions at the front of computer.
this manual and in the procedure text and observe
National Electrical Code (NEC) guidelines. WARNING
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
Hazardous voltage. Moving rotor.
decal 246242 from an authorized service distributor/
dealer.
Note: Equipment damage. Verify that the voltage all guards and electrical enclosures
ratings of the transfer switch, line circuit breakers, are in place.
and other accessories match the selected line
voltage. Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Open the main circuit
WARNING 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
Accidental starting. electrocution.
Can cause severe injury or death. Short circuits. Hazardous voltage/current can cause
Disconnect the battery cables before severe injury or death. Short circuits can cause bodily injury
working on the generator set. and/or equipment damage. Do not contact electrical
Remove the negative (--) lead first connections with tools or jewelry while making adjustments or
when disconnecting the battery. repairs. Remove all jewelry before servicing the equipment.
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 6. Go to Menu 7—Generator System and update the
voltage information. See Section 2.9.7, Menu 7—
Procedure Generator System, for the complete procedure.
1. Place the generator set master switch in the
7. Go to Menu 12—Calibration and perform the
OFF/RESET position.
calibration procedure. See Section 2.9.12,
2. Disconnect the generator set engine starting Menu 12—Calibration, for the complete
battery, negative (--) lead first. Disconnect power to procedure.
the battery charger (if equipped).
8. Go to Menu 11—Voltage Regulator and perform
3. Use Figure 5-1, Figure 5-2, Figure 5-3, or the voltage regulator setup procedure. See
Figure 5-4 to determine the generator set voltage Section 2.9.11, Menu 11—Voltage Regulator, for
configuration. Note the original voltage and the complete procedure.
reconnect as needed. Route leads through current
9. Move the generator set master switch to the RUN
transformers (CTs) and connect them according to
position to start the generator set. Check the digital
the diagram for the desired phase and voltage.
display for correct voltages using Menu 1—
Note: Position current transformers CT1, CT2, Generator Monitoring.
and CT3 with the dot or HI side CT marking
10. Move the generator set master switch to the
toward the generator set.
OFF/RESET position to stop the generator set
4. Reconnect the battery, negative lead last. after completing the voltage adjustments.
5. Go to Menu 14—Programming Mode and select 11. Replace the controller cover.
the Program Mode—Local. See Section 2.9.14,
12. Place the generator set master switch in the AUTO
Menu 14—Programming Mode, for the complete
or RUN position.
procedure.
132 Section 5 Generator Set Reconnection TP-6083 7/05

Figure 5-1 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

Figure 5-3 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

Section 6 Accessories
6.1 Accessories and Connections Kit Description

Audiovisual Alarm
Several accessories help finalize installation, add Common Failure Relay (Terminal 32A)
convenience to operation and service, and establish
Controller (Customer) Connection
state and local code compliance.
Float/Equalize Battery Charger (with alarms)
Accessories vary with each generator set model and Idle (Speed) Mode Feature
controller. Select factory-installed and/or shipped- Low Fuel (Level) Switch
loose accessories. See Figure 6-1 for a list of available Low Fuel (Pressure) Switch
kits. Obtain the most current accessory information Prime Power Switch
from your local authorized service distributor/dealer. Remote Annunciator (16-light panel)
Remote Emergency Stop
This section illustrates several accessories available at Remote Reset Feature
print time of this publication. Accessory kits generally
Remote Serial Annunciator (RSA 1000)
include installation instructions. See wiring diagrams
Remote Speed Adjustment Potentiometer (requires electronic
manual for electrical connections not shown in this governor) Non-ECM models only
section. See the installation instructions and drawings Run Relay
supplied with kit for information on kit mounting location. Single-Relay Dry Contact
Ten-Relay Dry Contact
The instructions provided with the accessory kit
Twenty-Relay Dry Contact
supersede these instructions where there are
differences. In general, run AC and DC wiring in Wireless Monitor
separate conduit. Use shielded cable for all analog Figure 6-1 Optional Accessories
inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.
Front View Side View
6.1.1 Audiovisual Alarm Kit

An audiovisual alarm warns the operator at a remote
location of fault shutdowns and prealarm conditions. FAULT
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.
A-292887
Note: Use the audiovisual alarm with a dry contact kit.
Figure 6-2 Audiovisual Alarm
CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX
GM13984-
Figure 6-3 Audiovisual Alarm Connections
TP-6083 7/05 Section 6 Accessories 137

6.1.2 Common Failure Relay Kit 6.1.3 Controller (Customer) Connection
Kit
The common failure relay kit provides one set of
contacts to trigger user-provided warning devices if a The controller connection kit allows easy connection of
fault occurs. The common failure relay faults are controller accessories without accessing the controller
user-defined. See Section 2, Operation, Menu 10— terminal strip. The supplied wiring harness connects
Output Setup, for status and faults available for this controller connector P23 and terminal strips TB1-3 and
function. TB1-4 to the controller connection kit connector P25 and
terminal strips TB6, TB7, TB8, and TB9. Connect all
Connect up to three common failure relay kits to the accessories (except the emergency stop kit) to the
controller output. See Figure 6-4 and Figure 6-5. See controller connection kit terminal strips. See Figure 6-6.
Section 6.2, Accessory Connections, for terminal See Section 6.2, Accessory Connections, for terminal
identification. 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

6.1.5 Idle (Speed) Mode Feature Note: The main tank or the transfer/day tank includes
the low fuel level switch. The fuel tank supplier
The idle (speed) mode feature provides the ability to typically provides the low fuel level switch.
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 6.1.7 Prime Power Switch Kit
engine reaches the preprogrammed engine warmed-up
The prime power switch kit prevents battery drain during
temperature before the idle mode times out. See
generator set nonoperation periods and when the
Figure 6-8 for user-supplied switch connection. 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 2
GM20652-
GM16088A-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)
Stop the generator set using the stopping procedures in
Low Fuel Switch Rating 12 volts DC min., 0.5 amp min. Section 2.3.2, Stopping, before placing the generator
Wiring Recommendation set in the prime power mode. Move the prime power
Gauge mm (ft.) switch located on the back of the controller to the DOWN
18--20 30.5 (100) position. The controller including the digital display,
14 153 (500) LEDs, and alarm horn does not function when the
10 305 (1000) generator set is in the prime power mode.
Figure 6-10 Switch Rating and Wiring Move the prime power switch located on the back of the
Recommendation controller to the UP position and reset the controller time
and date before attempting to start the generator set.

6.1.8 Remote Annunciator Kit Line Power. Lamp illuminates to indicate the power
source is a commercial utility.
A remote annunciator monitors the generator set’s
condition from a remote location. See Figure 6-13 and Generator Power. Lamp illuminates to indicate the
Figure 6-14. The remote annunciator includes an alarm power source is the generator set.
horn, an alarm silence switch, a lamp test, and lamp
indicators similar to the digital controller, plus the Also refer to Remote Serial Annunciator (RSA1000) in
following: Section 6.1.11 for using Modbusr communications via
RS-485 network.
Remote Annunciator
A-258782
14-Relay Dry Contact Box
42A 2 K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14

INPUT CONTACT RATINGS: 10A @120VAC RES. LOAD PCB ASSY A--320639
.01A @28VDC MIN.
10A @28VDC MAX. LOT NO.
NO C NO C NO C NO C NO C NO C NO C NO C NO C NO C NO C NO C NO C NO C
K1 K2 K3 K4 K5 K6 K7 K8 K9 K10 K11 K12 K13 K14
P
42B
P
FBA--1 10 AMP
A-293983
Figure 6-13 Remote Annunciator with 14-Relay Dry Contact Kit

GM13984-
354246B-
Figure 6-14 Remote Annunciator with 14-Relay Dry Contact Kit Connections

6.1.9 Remote Emergency Stop Kit 6.1.10 Remote Reset Feature
The emergency stop kit allows immediate shutdown of The remote reset switch provides generator set
the generator set from a remote location. See resetting after a fault shutdown at a remote location.
Figure 6-15 and Figure 6-16. If the emergency stop See Figure 6-17 and Figure 6-18 for user-supplied
switch activates, the EMERGENCY STOP lamp lights switch connection.
and the unit shuts down. Before attempting to restart the
generator set, reset the emergency stop switch (by Press and hold the switch for 2--3 seconds and release
replacing the glass piece) and reset the generator set by to reset the generator set controller.
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 mm (ft.)
18--20 30.5 (100)
14 153 (500)
10 305 (1000)
Figure 6-18 Remote Reset Switch Rating and Wiring

GM16088A-A
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.

6.1.11 Remote Serial Annunciator
The remote serial annunciator (RSA 1000) (Figure 6-19)
Overcrank Not-In-Auto
monitors the condition of the generator set from a
High Engine Temp. Common Fault
location remote from the generator set. If a generator
set alarm condition occurs, the remote annunciator Low Oil Pressure
alerts the operator through visual and audible signals. Overspeed Battery Voltage
On=High, Blink=Low
The remote serial annunciator kit includes components Emergency Stop User Input #1
for flush and surface mounting. One RSA (master) can Low Coolant Level User Input #2
support up to a maximum of three additional RSAs Low Coolant Temp. User Input #3
(slaves). The RSA will function as master or slave by Low Fuel Alarm Silenced
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.
System Ready
Figure 6-20 shows the status of the system ready LED,
Generator Running
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 Figure 6-19 Remote Serial Annunciator (RSA 1000)
connected to the controller. If the RS-485 port is
unavailable, please select an alternate annunciator kit.
System Monitoring LEDs and Functions

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

550 CONTROLLER
550 CONTROLLER
16--LIGHT CONTROLLER
Figure 6-21 RSA Wiring Connections

6.1.12 Remote Speed Adjustment 6.1.13 Run Relay Kit
Potentiometer Kit (Non-ECM
The run relay kit energizes only when the generator set
Models) runs. Use the run relay kit to control air intake and
The remote speed adjustment potentiometer kit radiator louvers, alarms, and/or other signalling
provides controller-mounted engine speed adjustment. devices. See Figure 6-23 and Figure 6-24.
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.
273705
Figure 6-23 Run Relay Kit
TB10
BR-273000-C GM16088A-A
1. Optional Remote Speed Pot
Figure 6-24 Run Relay Connections
Figure 6-22 Remote Speed Adjustment
Potentiometer Connection, Typical

6.1.14 Single-Relay Dry Contact Kit Refer to Figure 6-27 for an internal view of the contact
kit. See Figure 6-28 for electrical connections. See
The single-relay dry contact kit provides normally open Section 6.2, Accessory Connections, for terminal
and normally closed contacts in a form C configuration identifications.
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.
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
A-273945
generator set. Connect any controller fault output to the
ten-relay dry contact kit. Typically, lamps, audible Figure 6-25 Single-Relay Dry Contact Kit, Typical
alarms, or other devices signal the fault conditions.
GM16088A-A
Figure 6-26 Single-Relay Dry Contact Kit Connections

A-273936
Figure 6-27 Ten-Relay Dry Contact Kit
GM13984-/354246B-
Figure 6-28 Ten-Relay Dry Contact Kit Connections

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
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 D-294303-D
identifications.
Figure 6-29 Twenty-Relay Dry Contact Kits
GM16759D-C
Figure 6-30 Twenty-Relay Dry Contact Relay Kit Connections

6.1.17 Wireless Monitor the wireless monitor is properly functioning, powered,
and able to generate messages. If a device fails to
The wireless monitor system has two components: a report a nightly heartbeat for more than a day, the
wireless monitor unit and a website. The monitor unit system sends a Unit Failed to Report Heartbeat alarm
transmits messages in response to signals received message to the website.
from the equipment controller and notifies designated
recipients of selected operating conditions. The website Generator set run times and the number of cycles are
monitors these messages. reported. Models GM23409-KP1 and -KP3 accumulate
run times over a 24-hour period and report the run times
There are three monitor models: GM23409-KP1 for use with the heartbeat message. Model GM23409-KP2 (for
with hardwire inputs; GM23409-KP2 for use with a 550 the 550 controller only) reports the total accumulated
controller using Modbusr communication; and run time and the total number of starts. Run times for
GM23409-KP3 for use with a 550 controller using model GM23409-KP2 are also totaled using the Control
hardwire inputs that require a customer interface board. Panel function and can be updated upon request.
Note: The 550 controller supports only one connection Upon power loss, a rechargeable battery powers the
for Modbusr communication. If the controller’s wireless monitor. The monitor continues to transmit
RS-485 connection is already used for Modbusr messages for 15 minutes, then transmits a loss of power
communication with other equipment, use signal and enters the sleep mode. The sleep mode can
wireless monitor model GM23409-KP1 or -KP3 last up to 18 hours, until the battery completely
with hardwire inputs through a customer discharges or power is restored. The wireless monitor
connection board for monitoring. continues to send scheduled heartbeat messages
during the sleep mode until the battery discharges
Typical messages might include: completely.
D Overcrank
D Low oil pressure
86
D Overspeed [3.4]
D Common fault
At the website, the user configures which individuals will

receive messages regarding selected operating
conditions and the message delivery method. Delivery 275
[10.8]
methods include pagers (alphanumeric, numeric), fax, 244
[9.6]
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 181
[7.1]
selected recipients via multiple delivery methods. More 211
95
[3.75]
[8.3]
than one delivery method can be used for each
recipient.
Dimensions are mm [in.]. All
dimensions are approximate.
The wireless monitor is powered by the equipment
power source or by the generator set and constantly
51
monitors the inputs. When an input is triggered, the 51
[2] [2]
27
[1.06]
C
wireless monitor sends the condition over the North L
G6-53
American AMPS (advanced mobile phone system). An
operations center server receives the transmission and Figure 6-31 Wireless Monitor
forwards the message to the selected recipients
For additional information, please see TT-1370,
according to the configured delivery method.
Wireless Monitor Kits GM23409-KP4, KP5, and KP6,
Every 24 hours, the wireless monitor also sends and TP-6223, PowerScant Wireless Monitor, operation
information about itself and the system it is monitoring. manual.
This heartbeat transmission tells the Kohlerr center that
Modbusr is a registered trademark of Schneider Electric

6.2 Accessory Connections For specific information on accessory connections, refer
to the accessory wiring diagrams in the wiring diagram
The 550 controller contains circuit boards equipped with manual and the instruction sheet accompanying the kit.
terminal strip(s) for easy connection of generator set See Figure 6-32 and Figure 6-33 for controller
accessories. Do not connect accessories directly to the interconnection circuit board connections. See
controller terminal strip. Connect accessories to either a Figure 6-34 and Figure 6-35 for controller (customer)
controller connection kit or a dry contact kit. Connect connection kit connections.
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.).
TOP OF CONTROLLER BACK PANEL
2
4
GM16088A-A/GM10193B-A
1. TB1 terminal strip 4. TB4 terminal strip
2. TB2 terminal strip 5. P23 Connector
Figure 6-32 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)

TB1 Terminal Strip—Engine Start and TB4 Terminal Strip—Input Factory Connections
Emergency Stop Connections
Term. Description
Term. Description 1 DCH1 Battery charger fault
1 Emergency stop ground 2 DCH2 Low fuel
1A Emergency stop 3 DCH3 Low coolant temp. with ECM models or
3 Remote start warning default with non-ECM models
4 Remote start 4 DCH4 Field overvoltage with M4/M5/M7
alternators or warning default with
TB2 Terminal Strip—Analog Input Connections non-M4/M5/M7 alternators
5 DCH5 Breaker Closed, Paralleling Applications
Term. Description 6 DCH6 Enable Synch, Paralleling Applications
1 ACH1 (CTS) Signal (non-ECM) 7 DCH7 Warning
2 ACH1 (CTS) Supply (non-ECM) 8 DCH8 Warning
3 ACH2 (OPS) Signal (non-ECM) 9 DCH9 Warning
4 ACH2 (OPS) Supply (non-ECM 10 DCH10 Warning
5 ACH3 Signal 11 DCH11 AFM Shutdown, Waukesha engine
6 ACH3 Supply 12 DCH12 Detonation Warning, Waukesha engine
7 ACH4 Signal 13 DCH13 Detonation Shutdown,
8 ACH4 Supply Waukesha engine
9 ACH5 Signal 14 DCH14 Low coolant level with 50--100ROZK
10 ACH5 Supply models or warning default with all models
11 ACH6 Signal except 50--100ROZK
12 ACH6 Supply 15 DCH15 Remote shutdown
13 ACH7 Signal 16 DCH16 Remote reset
14 ACH7 Supply 17 DCH17 VAR PF mode
15 N/C 18 DCH18 Voltage lower
16 ACH1 (CTS) Return (non-ECM) 19 DCH19 Voltage raise
17 ACH1 (CTS) Shield ground (non-ECM) 20 DCH20 Air damper
18 ACH2 (OPS) Return (non-ECM) 21 DCH21 Idle mode functional with
19 ACH2 (OPS) Shield ground (non-ECM) ECM-equipped engines only
20 ACH3 Return 22 DCH1 Return
21 ACH3 Shield ground 23 DCH2 Return
30 N/C 32 DCH11 Return
33 DCH12 Return
34 DCH13 Return
TB3 Terminal Strip—Accessory Power Output
35 DCH14 Return
Connections 36 DCH15 Return
Term. Description 37 DCH16 Return
1 +12 VDC (OEM use only) 38 DCH17 Return
4 Fused battery (+) (42A) (5 Amp) 41 DCH20 Return
5 Fused battery (+) (42A) (5 Amp) 42 DCH21 Return
6 Fused battery (+) (42A) (5 Amp)
7 Battery (--) Note: TB4-1 through TB4-21 are user definable with
8 Battery (--) factory defaults listed.
9 Battery (--) Terminals TB4-3, TB4-4, TB4-14, and TB4-21 have
10 Battery (--) different functions depending upon the generator set
11 Battery (--) configuration. See comments above.
12 Panel lamp output See Menu 9—Input Setup for changing inputs.
Figure 6-33 Controller Terminal Strip Identification

GM13984-
Figure 6-34 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box
TB6 Terminal Strip—RDOs 1--7 TB9 Terminal Strip—RDOs 24--31

Term. Description Term. Description
42A Battery (+) RDO24 Speed sensor fault
GND Battery (--) RDO25 Loss of AC sensing
N/C RDO26 ECM loss of communication
RDO1 Overspeed (lead 39) RDO27 Undervoltage
RDO2 Overcrank (lead 12) RDO28 Overfrequency
RDO3 High coolant temperature shutdown (lead 36) RDO29 Underfrequency
RDO4 Low oil pressure shutdown (lead 38) RDO30 Load shed kW overload
RDO5 Low coolant temperature (lead 35) RDO31 Load shed underfrequency
RDO6 High coolant temperature warning (lead 40) 3 Remote start
RDO7 Low oil pressure warning (lead 41) 4 Remote start
TB7 Terminal Strip—RDOs 8--17
Term. Description Note:Lead numbers shown in parentheses are the factory
RDO8 Low fuel (lead 63) default wire designations.
RDO9 Master switch not in auto ( lead 80)
RDO10 NFPA 110 common alarm (lead 32)* Note:RDO-1 though RDO-31 are user definable with the
RDO11 Battery charger fault (lead 61) following factory defaults: emergency stop, high coolant
RDO12 Low battery voltage (lead 62) temperature, low oil pressure, overcrank, and overspeed
RDO13 High battery voltage
RDO14 Emergency stop (lead 48)
*NFPA-110 common alarm faults include:
RDO15 Generator set running (lead 70R)
RDO16 Time delay engine cooldown (TDEC) (lead 70C) Air damper indicator (RDO--23)
RDO17 System ready (lead 60) Battery charger fault (RDO--11)
EPS supplying load (RDO--22)
TB8 Terminal Strip—RDOs 18--23 High battery voltage (RDO--13)
Term. Description High coolant temperature warning (RDO--06)
42A Battery (+) High coolant temperature shutdown (RDO--03)
42A Battery (+) Low battery voltage (RDO--012)
2 Battery (--) Low coolant level (RDO--19)
2 Battery (--) Low coolant temperature warning (RDO--05)
RDO18 Defined common fault (lead 32A) Low fuel (level or pressure) (RDO--08)
RDO19 Low coolant level Low oil pressure warning (RDO--07)
RDO20 Overvoltage (lead 26) Low oil pressure shutdown (RDO--04)
RDO21 Idle mode Master switch not in auto (RDO--09)
RDO22 EPS supplying load Overcrank (RDO--02)
RDO23 Air damper indicator (lead 56) Overspeed (RDO--01)
Figure 6-35 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)

Notes

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute ext. external
ABDC after bottom dead center CG center of gravity F Fahrenheit, female
AC alternating current CID cubic inch displacement fglass. fiberglass
A/D analog to digital CL centerline FHM flat head machine (screw)
ADC analog to digital converter cm centimeter fl. oz. fluid ounce
adj. adjust, adjustment CMOS complementary metal oxide flex. flexible
ADV advertising dimensional substrate (semiconductor) freq. frequency
drawing cogen. cogeneration FS full scale
AHWT anticipatory high water com communications (port) ft. foot, feet
temperature coml commercial ft. lb. foot pounds (torque)
AISI American Iron and Steel Coml/Rec Commercial/Recreational ft./min. feet per minute
Institute conn. connection
ALOP anticipatory low oil pressure g gram
cont. continued ga. gauge (meters, wire size)
alt. alternator CPVC chlorinated polyvinyl chloride
Al aluminum gal. gallon
crit. critical gen. generator
ANSI American National Standards CRT cathode ray tube
Institute genset generator set
(formerly American Standards CSA Canadian Standards GFI ground fault interrupter
Association, ASA) Association
CT current transformer GND, ground
AO anticipatory only
Cu copper gov. governor
API American Petroleum Institute
cu. in. cubic inch gph gallons per hour
approx. approximate, approximately
cw. clockwise gpm gallons per minute
AR as required, as requested
CWC city water-cooled gr. grade, gross
AS as supplied, as stated, as
suggested cyl. cylinder GRD equipment ground
ASE American Society of Engineers D/A digital to analog gr. wt. gross weight
ASME American Society of DAC digital to analog converter HxWxD height by width by depth
Mechanical Engineers dB decibel HC hex cap
assy. assembly dBA decibel (A weighted) HCHT high cylinder head temperature
ASTM American Society for Testing DC direct current HD heavy duty
Materials DCR direct current resistance HET high exhaust temperature,
ATDC after top dead center high engine temperature
deg., ° degree
ATS automatic transfer switch hex hexagon
dept. department
auto. automatic Hg mercury (element)
dia. diameter
aux. auxiliary HH hex head
DI/EO dual inlet/end outlet
A/V audiovisual HHC hex head cap
DIN Deutsches Institut fur Normung
avg. average e. V. (also Deutsche Industrie HP horsepower
AVR automatic voltage regulator Normenausschuss) hr. hour
AWG American Wire Gauge DIP dual inline package HS heat shrink
AWM appliance wiring material DPDT double-pole, double-throw hsg. housing
bat. battery DPST double-pole, single-throw HVAC heating, ventilation, and air
BBDC before bottom dead center DS disconnect switch conditioning
BC battery charger, battery DVR digital voltage regulator HWT high water temperature
charging E, emer. emergency (power source) Hz hertz (cycles per second)
BCA battery charging alternator EDI electronic data interchange IC integrated circuit
BCI Battery Council International EFR emergency frequency relay ID inside diameter, identification
BDC before dead center e.g. for example (exempli gratia) IEC International Electrotechnical
BHP brake horsepower Commission
EG electronic governor
blk. black (paint color), block IEEE Institute of Electrical and
EGSA Electrical Generating Systems Electronics Engineers
(engine) Association
blk. htr. block heater IMS improved motor starting
EIA Electronic Industries
BMEP brake mean effective pressure Association in. inch
bps bits per second EI/EO end inlet/end outlet in. H2O inches of water
br. brass EMI electromagnetic interference in. Hg inches of mercury
BTDC before top dead center emiss. emission in. lb. inch pounds
Btu British thermal unit eng. engine Inc. incorporated
Btu/min. British thermal units per minute EPA Environmental Protection ind. industrial
C Celsius, centigrade Agency int. internal
cal. calorie EPS emergency power system int./ext. internal/external
CARB California Air Resources Board ER emergency relay I/O input/output
CB circuit breaker ES engineering special, IP iron pipe
cc cubic centimeter engineered special ISO International Organization for
ESD electrostatic discharge Standardization
CCA cold cranking amps
est. estimated J joule
ccw. counterclockwise
E-Stop emergency stop JIS Japanese Industry Standard
CEC Canadian Electrical Code
etc. et cetera (and so forth) k kilo (1000)
cert. certificate, certification, certified
exh. exhaust K kelvin
cfh cubic feet per hour
TP-6083 7/05 Appendix 155

kA kiloampere MTBO mean time between overhauls rly. relay
KB kilobyte (210 bytes) mtg. mounting rms root mean square
kg kilogram MW megawatt rnd. round
kg/cm2 kilograms per square mW milliwatt ROM read only memory
centimeter μF microfarad rot. rotate, rotating
kgm kilogram-meter N, norm. normal (power source) rpm revolutions per minute
kg/m3 kilograms per cubic meter NA not available, not applicable RS right side
kHz kilohertz nat. gas natural gas RTV room temperature vulcanization
kJ kilojoule NBS National Bureau of Standards SAE Society of Automotive
km kilometer NC normally closed Engineers
kOhm, kΩ kilo-ohm NEC National Electrical Code scfm standard cubic feet per minute
kPa kilopascal NEMA National Electrical SCR silicon controlled rectifier
kph kilometers per hour Manufacturers Association s, sec. second
kV kilovolt NFPA National Fire Protection SI Systeme international d’unites,
kVA kilovolt ampere Association International System of Units
kVAR kilovolt ampere reactive Nm newton meter SI/EO side in/end out
kW kilowatt NO normally open sil. silencer
kWh kilowatt-hour no., nos. number, numbers SN serial number
kWm kilowatt mechanical NPS National Pipe, Straight SPDT single-pole, double-throw
L liter NPSC National Pipe, Straight-coupling SPST single-pole, single-throw
LAN local area network NPT National Standard taper pipe spec,
L x W x H length by width by height thread per general use specs specification(s)
lb. pound, pounds NPTF National Pipe, Taper-Fine sq. square
lbm/ft3 pounds mass per cubic feet NR not required, normal relay sq. cm square centimeter
LCB line circuit breaker ns nanosecond sq. in. square inch
LCD liquid crystal display OC overcrank SS stainless steel
ld. shd. load shed OD outside diameter std. standard
LED light emitting diode OEM original equipment stl. steel
manufacturer tach. tachometer
Lph liters per hour
OF overfrequency TD time delay
Lpm liters per minute opt. option, optional
LOP low oil pressure TDC top dead center
OS oversize, overspeed TDEC time delay engine cooldown
LP liquefied petroleum OSHA Occupational Safety and Health
LPG liquefied petroleum gas TDEN time delay emergency to
Administration normal
LS left side OV overvoltage TDES time delay engine start
Lwa sound power level, A weighted oz. ounce TDNE time delay normal to
LWL low water level p., pp. page, pages emergency
LWT low water temperature PC personal computer TDOE time delay off to emergency
m meter, milli (1/1000) PCB printed circuit board TDON time delay off to normal
M mega (106 when used with SI pF picofarad temp. temperature
units), male PF power factor term. terminal
m3 cubic meter ph., ∅ phase TIF telephone influence factor
m3/min. cubic meters per minute PHC Phillips head crimptite (screw) TIR total indicator reading
mA milliampere
PHH Phillips hex head (screw) tol. tolerance
man. manual
PHM pan head machine (screw) turbo. turbocharger
max. maximum
PLC programmable logic control typ. typical (same in multiple
MB megabyte (220 bytes) locations)
PMG permanent-magnet generator
MCM one thousand circular mils UF underfrequency
pot potentiometer, potential
MCCB molded-case circuit breaker ppm parts per million UHF ultrahigh frequency
meggar megohmmeter PROM programmable read-only UL Underwriter’s Laboratories, Inc.
MHz megahertz memory UNC unified coarse thread (was NC)
mi. mile psi pounds per square inch UNF unified fine thread (was NF)
mil one one-thousandth of an inch pt. pint univ. universal
min. minimum, minute PTC positive temperature coefficient US undersize, underspeed
misc. miscellaneous PTO power takeoff UV ultraviolet, undervoltage
MJ megajoule PVC polyvinyl chloride V volt
mJ millijoule qt. quart, quarts VAC volts alternating current
mm millimeter qty. quantity VAR voltampere reactive
mOhm, R replacement (emergency) VDC volts direct current
mΩ milliohm power source VFD vacuum fluorescent display
MOhm, rad. radiator, radius VGA video graphics adapter
MΩ megohm RAM random access memory
MOV metal oxide varistor VHF very high frequency
RDO relay driver output W watt
MPa megapascal ref. reference
mpg miles per gallon WCR withstand and closing rating
rem. remote w/ with
mph miles per hour Res/Coml Residential/Commercial
MS military standard w/o without
RFI radio frequency interference wt. weight
m/sec. meters per second
RH round head xfmr transformer
MTBF mean time between failure
RHM round head machine (screw)
156 Appendix TP-6083 7/05

Appendix B User-Defined Settings
Use the table below to record user-defined settings Note: The engine ECM may limit the crank cycle even if
during the generator set controller setup and calibration. the controller is set to a longer time period.
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.
Relay Inhibit
Status or to Digital Output Default Delay* Delay
Fault Menu Display (RDO) Range Setting Selection (sec.) (sec.) User-Defined Settings
AC Sensing 10 AC Sensing RDO-25 Not adjustable
Loss Loss
Access Code 14 0 (zero)
(password)
Analog Aux. 9 User-Defined Default values with 30 sec. 0--60 0--60
Inputs 1--7 A1--A7 Warning Enabled: inhibit, 5
HI warning 90%, sec. delay
LO warning 10%,
HI shutdown 100%,
LO shutdown 1%
Analog Aux. 9 Coolant Default values with 30 sec. 0--60 0--60
Input 1 Temperature Warning Enabled: inhibit, 0
HI/LO warning and sec. delay
HI/LO shutdown are
all engine dependant
Analog Aux. 9 Oil Pressure Default values with 30 sec. 0--60 0--60
Input 2 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
Cyclic Cranking 8 1--6 crank cycles 3 cycles
10--30 sec. crank on 15 sec.
1--60 sec. pause 15 sec.
Defined 10 User-Defined RDO-18 Default shutdowns 30 sec. 0--60 0--60
Common Faults include: inhibit,
Emergency stop 5 sec. delay
High coolant temp
Low oil pressure
Overcrank
Overspeed
Digital Aux. 9 User-Defined 30 sec. 0--60 0--60
Inputs 1--21 D1--D21 inhibit, 5
sec. delay
EPS 10 EPS RDO-15 5% of rated
(Emergency Supplying line current
Power System) Load
Supplying Load
High Battery 10 High Battery RDO-13 14.5--16.5 (12V) 16 (12V) 10
Voltage Voltage 29--33 (24V) 32 (24V)
High Coolant 10 Hi Cool RDO-03 30 5 Not adjustable
Temperature Temp
Shutdown Shutdown
High Coolant 10 Hi Cool RDO-06 30 Not adjustable
Temperature Temp
Warning Warning
High Oil 10 Hi Oil Temp RDO-17 30 5 Not adjustable
Temperature Shutdown
Shutdown
* Inhibited time delay is the time delay period after crank disconnect.

Relay Inhibit
Status or to Digital Output Default Delay* Delay
Fault Menu Display (RDO) Range Setting Selection (sec.) (sec.) User-Defined Settings
Idle (speed) 9 Idle Mode RDO--21 0 sec. 0--600
Mode Function Active inhibit,
Digital Aux. 60 sec.
Input D21 delay
Load Shed 10 Load Shed RDO-30 80%--120% 100% of kW 2--10
kW Overload KW Over rating with
5 sec. delay
Load Shed 10 Load Shed RDO-31 59, (60 Hz) 5
Underfrequency Under 49, (50 Hz)
Frequency
Low Battery 10 Low Battery RDO-12 10--12.5 (12V) 12 (12V) 10
Voltage Voltage 20--25 (24V) 24 (24V)
Low Coolant 10 Low Coolant RDO-14 30 5 Not adjustable
Level Level
(Low) Oil 10 Oil Pressure RDO-04 30 5 Not adjustable
Pressure Shutdown
Shutdown
(Low) Oil 10 Oil Pressure RDO-07 30 Not adjustable
Pressure Warning
Warning
No Coolant 10 No Cool 30 Not adjustable
Temperature Temp Signal
Signal
No Oil Pressure 10 No Oil 30 Not adjustable
Signal Pressure
Signal
Overcrank 8 Over Crank RDO-02 0--6 cycles 3 cycles
Shutdown
Overcurrent 10 Over Current 110% 10
Overfrequency 7, 10 Over RDO-28 102%--140% 140% std. 10
Shutdown Frequency 103% FAA
Overspeed 7, 10 Over Speed RDO-01 65--70 (60 Hz) 70 (60 Hz) 0.25
Shutdown 55--70 (50 Hz) 60 (50 Hz)
Overvoltage 7, 8, Over Voltage RDO-20 105%--135% 115% 2--10
Shutdown 10 2-sec time
delay
Password 14 0 (zero) See Access Code entry
(access code)
Time Delay 8, 10 RDO-23 00:00--10:00 5:00
Engine min:sec
Cooldown
(TDEC)
Time Delay 8, 10 00:00--5:00 00:01
Engine Start min:sec
(TDES)
Time Delay 8, 10 0--10 sec.
Starting Aid
Underfrequency 7, 10 Under RDO-29 80%--95% 90% 10
Shutdown Frequency
Undervoltage 7, 8, Under RDO-27 70%--95% 85% 5--30
Shutdown 10 Voltage 10-sec time
delay
Weak Battery 10 Weak RDO-26 60% of 2
Battery nominal
* Inhibited time delay is the time delay period after crank disconnect.

Appendix C Voltage Regulator Definitions and Adjustments
The following Definitions and Adjustment and since it is the power in the alternator that translates into
Setting Specifications are intended for users planning engine torque, the engine load is also reduced.
to adjust the voltage regulator beyond the default
settings in order to customize the voltage regulator for a By changing various parameters of this compensation
specific application. technique, the controlling system can be tailored to
match the performance capabilities of nearly any
This information is not intended to be a comprehensive combination of engine and alternator. The point at
explanation of all the terms mentioned. There are which the unloading begins to act or how much
numerous documents available that define these terms unloading occurs can be adjusted to impact such things
more completely than described herein. Any user as maximum voltage droop, maximum speed droop, or
planning to change the generator set controller time to recover. Some applications may not need any
adjustment settings or to apply the generator set to unloading and, in these cases, set the unloading
these types of applications should understand these parameter to disable the function. These parameters
terms. are further described below. An example is provided to
help clarify the relationship between these parameters.
This appendix contains references to other sections of
this manual. Please refer to these sections for further
information and explanation. Underfrequency Unload Slope
Paralleling generator sets can be a complicated and Underfrequency unload slope is the term used to
dangerous exercise. Application programming must be describe the amount that the voltage is reduced,
performed by appropriately skilled and suitably-trained per-cycle-per-second or per-hertz (Hz), when in an
personnel. 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
Definitions below), the excitation control system temporarily
reduces the regulated voltage to reduce the subsequent
torque on the engine. The amount that the control
Underfrequency Unloading system reduces voltage is defined as the product or
multiplication of the slope and the amount of frequency
Underfrequency unloading is a function used in the
generator excitation control system to improve the or speed below the cut-in point. For every Hz below the
cut-in point, the control system reduces the line-to-line
overall generator set system (engine and alternator)
voltage by an amount equal to the slope.
response. In particular, underfrequency unloading
relates to large-block load applications. When applied
Because each engine responds differently to the
to engine-driven generators, large-block loads cause a various loads encountered, the slope may be adjusted
subsequent transient torque load on the engine. This
to improve the system response. If, when large loads
torque load can reduce the engine’s speed below the
are applied to the generator set, the engine speed drops
normal operating point. Typically, the engine speed below the acceptable limit (as determined by the
controller or governor will compensate for this by
particular loads applied), the slope may need to be
commanding an increase in fuel. If, however, the fuel increased. Increasing the slope will cause the voltage to
system is inadequate to recover from a relatively large droop more during load applications, consequently
load, the speed may never recover. In these instances,
reducing the load torque on the engine and allowing the
other measures must be taken. This is where the speed to increase. If, however, the voltage drops below
underfrequency unloading occurs.
an acceptable lower limit (as determined by the
When the excitation control system detects a drop in the particular loads connected to the generator set), a lower
slope may work better. The underfrequency unloading
speed or electrical frequency below some
predetermined point, the control system enters an function may be disabled by setting the slope to zero.
unloading condition. This can be described as moving
to a lower voltage regulation point. By reducing the Frequency Setpoint or Cut-In Point
output voltage of the alternator, the load on the
generator set is, in effect, reduced. This can be shown The point at which the underfrequency unloading begins
mathematically by Ohm’s law, which states that power is to take effect is adjustable, allowing the system to be
equal to the voltage squared divided by the impedance. tailored for each application. Because the
As the voltage is reduced, the power delivered by the characteristics of the engine have the largest effect on
alternator decreases by a squared relationship and the system’s performance, the engine’s response

should determine the unloading point. The unloading single-phase sensing excitation controller will keep the
setpoint is the frequency below which the excitation voltage of the sensed phase at the voltage adjustment
control will reduce the voltage so that the engine may value. A three-phase sensing system will average the
begin to recover. three phases and hold the average to the adjustment
setting. The average is the sum of the voltages of three
The cut-in point, or frequency setpoint, should be set phases divided by 3.
0.5--1.0 Hz lower than the normal steady-state band of
operation. If the engine normally operates within a very As stated above, three-phase sensing does not
narrow range of speeds close to the nominal, a setpoint eliminate the unequal voltage phenomenon.
of 0.5 to 1.0 Hz below nominal should be suitable. If the Three-phase sensing balances the inequality of voltage
engine normally operates over a wide range of speeds, between the phases to the desired value. In other
the setpoint may need to be 2.0--3.0 Hz from the words, if a system with unbalanced loads uses a
nominal. The underfrequency unloading function can single-phase control feedback, the voltage on the
be eliminated by setting the cut-in point below the sensed phase would be at the setpoint while the other
minimum expected operating frequency. two phases would vary by their proportional loads. For
example, if the sensed phase had rated load while the
Example two other phases were only loaded at half the rated
value, those two phases would have higher-than-rated
A 90 kW load is applied to a 100 kW, 60 Hz generator set voltage which may be undesirable. If a three-phase
driven by a turbocharged diesel engine with an sensing feedback were utilized, the phase with rated
electronical control module (ECM). The speed drops load would be regulated to a voltage slightly below the
10% and takes 20 seconds to recover to at least 59.5 Hz. rated voltage while the other two phases would be
The voltage, meanwhile, drops from 480 to 460 and slightly above the rated voltage (but lower than in the
recovers to 480 within 15 seconds. Therefore, some previous case).
underfrequency unloading should be provided. A good
starting point would be a frequency setpoint or cut-in of The line-to-line voltages and line-to-neutral voltages
59 Hz. A slope of 8 volts per-cycle-per-second is have a known relationship of the √3 (square root of 3):
appropriate as well. If after these adjustments the
speed recovers very quickly, in about 5 seconds, but the V l-l = V l-n * √3
voltage drops below 440 volts, the slope should be Where: V l-l is the line-to-line voltage
reduced to 6 volts per cycle. More adjusting may be
V l-n is the line-to-neutral voltage
required to get the most desirable compromise between
speed and 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
Three-Phase Sensing
line-to-neutral voltages is regulated (try to keep
Three-phase sensing describes how the excitation constant) to a value corresponding to the line-to-line
control or voltage regulator determines the condition of voltage adjust setting. See Adjustment and Setting
the generator output voltage. Early types of regulators Specifications.
sensed the voltage on just one phase of the alternator.
Single-phase sensing is not uncommon today as most In a single-phase system, the average value of the two
alternators are designed to produce balanced, equal line-to-neutral voltages is held equal to the line-to-line
voltage on all three phases. If the loads applied to the voltage adjust setting divided by two. In a three-phase
generator set including no load are equal and balanced, system, the line-to-line neutral voltage (average of
the output voltage on each phase will be nearly equal. three) is regulated to the voltage adjust setting divided
by √3. Because these relationships (1/√3 in three phase
However, in some applications, individual phases may or 1/2 in single phase) may vary when the loading is
have unequal or unbalanced loads. In these cases, the severely unbalanced or nonlinear, the average of the
output voltages will not be equal on each phase. In line-to-line voltages may vary slightly from the actual
general, the phase with the greatest load will have the setting. In some cases, it may be desirable to keep one
lowest voltage while the phase with the least load will phase at a particular value. Modify the voltage adjust
have the highest voltage. This is true regardless of the setting higher or lower accordingly for any unique
type of sensing used in the regulator system. A requirements for the particular application.

Reactive Droop not stable in the system, adjust the droop lower in all
generator sets.
Reactive droop refers to another compensation
technique used in excitation control systems. Reactive As implied above, the reactive droop is not usually
droop means that the generator set voltage droops with necessary in stand-alone applications. Therefore,
increasing reactive current. Although this sounds like some means of disabling the feature is provided. If the
an undesirable effect, it is quite beneficial in paralleling generator set will not be paralleled with other generator
applications with multiple generator sets. Because the sets, the reactive droop feature should be disabled. A
terminals of the generator set are connected to another reactive droop setting of 0 will also effectively disable the
generator set(s), the voltage at the terminals is not reactive droop feature. It should be noted that disabling
solely determined by either generator set’s excitation. reactive droop applies strictly to the reactive current or
Rather, it is determined by the combination of the volt-ampere-reactive (VAR) loading. Primarily, the
excitation level, the generated voltage, and the voltage fueling or speed governing system controls the real
drop across the armature impedance or armature current which contributes to watts loading.
reactance for each generator set.
The gain of the reactive droop function is determined by
Normally the generated voltage is higher than the the voltage droop setting. For most applications, a
voltage at the terminals because the generator set droop of 3%--5% of rated voltage at rated load at 0.8 PF
current causes a drop across the armature impedance. is adequate. Prior to actually connecting the generator
In a parallel application, the generated voltage of one sets in parallel, test the droop by applying full rated load
generator set may be slightly higher than the generated at 0.8 PF. The system is operating correctly if this test
voltage of another generator set. Differences in shows a reduction in voltage equal to the voltage droop
potential between the generator sets will cause current setting. If the available load is less than full load, the
to flow into the lower voltage generator set and will also correct voltage droop should be proportional to the
cause the generator sets to share the load current applied VAR load as a fraction of the rated VAR output
disproportionately. Both results are undesirable. for the generator set. For instance, a 480-volt generator
set with a voltage droop setting of 4% should drop 19.2
By introducing reactive droop, the reactive current can volts with full rated (0.8 PF) load applied (480 x 0.04) or
be better predicted and controlled. If the current is 9.6 volts with half the rated load applied (480 x 0.04 / 2).
measured, the regulator/controller can adjust the
excitation up or down accordingly, reducing excitation When a generator set will be connected in parallel with
as more current is supplied or increasing excitation as the utility, VAR or PF control should be ENABLED. If
the reactive current decreases. If all the parallel there are multiple generator sets in parallel as well, then
generator sets incorporate this type of compensation, reactive droop should be ENABLED also.
the reactive current can be shared equally based on the
proportional size of the generator sets. For an example, Example
see below.
Two 100 kilowatt (kW) generator sets are paralleled to
The stability and accuracy of this technique depends on provide 150 kW of power at 0.8 PF and wired for a
several factors. Most important, the regulation point for 277/480-volt wye system.
each generator set must be equal. That is, each voltage
adjust setting must be the equal to the other(s). This is a Total kVA load:
basic requirement prior to the actual paralleling
connection. Also, the effects of the reactive current in kVA = kW / PF
each generator set must be compensated for
187.5 = 150 / 0.8
individually, which requires an adjustable droop for each
generator set. This adjustment happens to be the KVAR load:
reactive droop adjust. The reactive droop adjust is
quantified as the droop in voltage from the adjusted kVAR = kVA * sin (acos [ PF ] )
setting when full rated load with 0.8 power factor (PF) is
applied. A droop setting of 4% voltage at full rated load 112.5 = 187.5 * 0.6
is a recommended starting point. If the reactive current
is not shared proportionately in each generator set, the Line current:
respective droops may need adjustment. Adjust those
generator sets that have proportionately higher current I = ( VA / 3 ) / VL-N
for more droop and those generator sets with lower
226 amps = (187500 / 3 / 277 )
reactive current for less droop. If the reactive current is

Reactive current: The term rated VARs is a bit obscure. In essence, it is a
value derived from the rated kW of the generator set.
I = (VAR / 3) / VL-N For a typical standby rating, the full load of the generator
set is defined to have 0.8 PF. This means that the kW
135 amps = ( 112500 / 3) / 277 load is eight-tenths of the VA load. As described earlier,
the PF for a linear load may be calculated as the cosine
Where: acos is arccosine or inverse cosine
of the angle between voltage and current. This
W is Watt relationship is based on the power triangle. Using this
L-N is line-to-neutral power triangle concept, it can be shown that the reactive
PF is power factor power for a linear load is equal to the sine of the power
angle. Then, using these trigonomic functions, it can be
VA is volt-ampere
shown that for a PF of 0.8, the VARs are related similarly
k is kilo ( = 1000 ) to the VA by a factor of 0.6. More explicitly, the power
Therefore, each generator set in this case should carry angle is equal to the inverse cosine (arccosine) of the
113 amps per phase or half the 226 calculated line PF. For a PF of 0.8, the power angle is 36.9 degrees (0.2
amps. The 113 amps includes 67.5 amps of reactive radians). The sine of this angle, sine (36.9 degrees) is
current half of the calculated reactive current of 135 0.6. This is the factor for calculating rated VARs from the
amps. The reactive droop should be adjusted until each rated VA. The ratio of these two factors is 0.75 (0.6 /
generator set carries equal reactive current. The load 0.8), which can be used to calculate rated VARs directly
sharing control should be adjusted so that real current from the rated kW, VARs equals watts * 0.75.
and/or watts are shared equally as well.
When a generator set will be connected in parallel with
If one generator set is larger than the other, it should be the utility, VAR or PF control should be ENABLED. If
adjusted to carry proportionate current. For this multiple generator sets are in parallel as well, then
example, if a 150 kW generator set is paralleled to a reactive droop should be ENABLED also. Additionally,
75 kW generator set, the larger generator set would note that VAR control should be used only when the
carry 90 amps reactive (135 * 2 / 3) and the other would generator set is connected in parallel with the utility.
carry 45 amps reactive (135 * 1 / 3). Adjust the reactive Parallel connection with the utility requires the logical
droop based on the ratio of the actual measured indication that the circuit breakers tying the generator
currents, not the calculated values. 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
VAR Control excitation control changes to the selected VAR or PF
control. If the logical indicator is not present and the
VAR control is analogous to the reactive droop function VAR or PF control is not enabled, the control will not
described above. It differs in that it applies to utility switch to VAR or PF control. Because the active state for
paralleling applications. Because the utility represents the digital input is a HI or open connection, the default for
a nearly infinite bus, the voltage at the load terminals is the digital input (VAR/PF Mode) is DISABLED (displays
not controlled at all by the generator set, and it is ENABLED NO). If the input is ENABLED by the user, it
impossible to compare the ratio of the generator set should be held low by a contact or jumper until the actual
current to the utility based on its rated output. In this closing of the connecting circuit breaker(s). The proper
situation, the excitation control changes from voltage control method, VAR or PF must be ENABLED within
feedback to VAR feedback. More specifically, the the regulator’s configuration menu.
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. Power Factor Control
The VAR adjust can be set to any value within the PF control is much like the VAR control above. PF
generator set’s rated capability. Because the VARs control is used only when the generator set is paralleled
cause heating in the armature, any value beyond the to the utility grid. The difference is that the PF of the
generator set’s rating could damage the alternator. In generator set current is held constant. The setting for
most cases, the generator set will be adjusted to the PF adjust determines the relationship of the current
generate VAR (lagging PF) but could absorb VARs and voltage from the generator set. The PF is a term that
(leading PF) as well. However, the VAR setting is defines the ratio of real watts to the volt-ampere (VA)
maintained regardless of the relative PF. If the particular product. For linear loads, a trigonomic relationship can
load requires more VARs than the generator set can describe the PF. The PF equals the cosine of the angle
provide, the excess is derived from the utility bus. between the current and voltage. PF is further defined

as leading or lagging. That is to say, if the current lags displayed on the subsequent menu screens. This
the voltage (i.e., is later in time), the PF is lagging; if the allows the user to monitor any one phase, if desired.
current leads the voltage (i.e., is earlier in time), the PF is
leading. Inductive loads have lagging PF while The voltage adjust setting may be changed by means
capacitive loads have leading PF. The current in a other than the menu including user-defined digital input
purely resistive load is in phase with the voltage (not or remote communications. If voltage adjustment
leading or lagging) and the PF is 1.0 (cos. [0] ). occurs, the new value will be displayed accordingly in
the voltage adjust menu.
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
Underfrequency Unload Enable
ENABLED. If there are multiple generator sets in The underfrequency unload enable menu is used to turn
parallel as well, then reactive droop should be the underfrequency unload on or off. A YES entry will
ENABLED also. Additionally, note that PF control turn the feature on and the display will show ENABLED
should be used only while the generator set is YES. A NO entry will turn the feature off and the display
connected in parallel with the utility. Parallel connection will show ENABLED NO. The underfrequency unload
with the utility requires the logical indication that the defaults to an enabled (ON) condition.
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 Frequency Setpoint
input function is activated, the excitation control
The frequency setpoint is the cut-in point for
changes to the selected VAR or PF control. If the logical
indicator is not present and the VAR or PF control is not underfrequency unloading. At any operating frequency
below the frequency setpoint, the output voltage will be
enabled, the control will not switch to VAR or PF control.
reduced. The frequency may be entered with resolution
Because the active state for the digital input is a HI or
open connection, the default for the digital input to tenths of a Hz. The range of acceptable entries is 40
to 70 Hz. Any entry beyond these limits causes a
(VAR/PF mode) is DISABLED (displays ENABLED NO).
RANGE ERROR display and the setting will not change.
If the input is ENABLED by the user, it should be held low
The default value is one cycle-per-second (or two for
by a contact or jumper until the actual closing of the
non-ECM engines) below the normal system frequency.
connecting circuit breaker(s). The proper control
method, VAR or PF must be ENABLED within the The frequency setpoint changes to the default value if
the system frequency changes. A setting of 40 Hz
regulator’s configuration menu.
essentially disables the underfrequency unload feature
because most engines do not normally drop to speeds
Adjustment and Setting this low, even during load applications.
Specifications
Underfrequency Unload Slope
Voltage Adjust The slope determines how much voltage is reduced
during an unloading condition. The line-to-line voltage
The voltage adjust is entered as the rated or otherwise
is regulated to a value less than the voltage adjust
desired line-to-line voltage. The average of the
setting by this amount for every cycle below the
line-to-neutral voltages is then regulated to the
frequency setpoint. The voltage may be entered with
corresponding value as previously described. The
resolution as fine as one-tenth of one volt. The default
setting may be as fine as tenths of volts. The voltage
value is 2.0 volts per-cycle-per-second. A zero entry for
adjust defaults to the rated system voltage whenever
the slope in effect turns the underfrequency unload
the system voltage is changed. The voltage adjust may
feature off.
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 Reactive Droop Enable
beyond these limits is entered, a RANGE ERROR
message will be displayed. This menu allows the user to enable the reactive droop
feature. A YES entry turns the feature on and the display
As a reference, the present voltage adjust setting is shows ENABLED YES. A NO entry turns the feature off
displayed as well as the average value of the line-to-line and the display shows ENABLED NO. Reactive droop is
voltages. The individual line-to-line voltages are also intended to be used in a generator set-to-generator set
paralleling application.

Voltage Droop Generating/Absorbing
The amount of reactive droop is entered here. The While operating in the VAR control mode, the reactive
droop is entered as a percentage of system voltage load on the generator set may be specified to be out of
when a fully rated load at 0.8 PF is applied. The entry GENERATING or into ABSORBING the generator set.
may be made with resolution as fine as one-tenth of one Specifying the VAR type or direction is done through the
volt. This entry determines how much the voltage will GENERATING/ABSORBING menu. Because the
droop when the alternator provides reactive current. normal flow of reactive current is out of the generator
The actual amount the voltage changes is equal to the set, the default value is GENERATING. If ABSORBING
voltage droop setting times the VAR load as a fraction of is desired, a NO entry at this menu will change the
the rated VARs (at 0.8 PF). If the generator set were control mode to ABSORBING. When ABSORBING is
providing full rated load (at 0.8 PF), the expected selected, another NO entry will revert the control mode
voltage change would equal the voltage droop setting as back to GENERATING. It is assumed that this mode will
a percentage of system voltage. A voltage droop setting not be changed when the generator set is running.
of zero in effect disables the reactive droop feature. The Therefore, an attempt to change the mode while running
default value is 4% droop at full rated load at 0.8 PF. will return a RANGE ERROR message. The generator
set will need to be shut down in order to change this
The present voltage droop setting is displayed for setting.
reference. The display may change if this value is
changed via remote communication.
PF Adjust
VAR Control Enable Use the PF adjust to set the desired operating
relationship for the generator set’s output voltage and
In order for the VAR control function to operate, it must current when the generator set is connected in parallel
be enabled. Entering YES at this menu will turn the with the utility. The excitation is regulated to maintain a
feature on. Because the function is designed to operate PF equal to the entered value. The value entered may
while the generator set is in parallel with the utility, VAR be as low as 0.7 for leading PFs or as low as 0.6 for
control also requires the proper indication that all tying lagging PFs. Any entries below these limits will cause a
circuit breakers are closed. This is done through the RANGE ERROR message to display.
user-programmable digital inputs.
The upper limit for PF adjust is 1.0 and the default value
Because VAR control cannot be enabled at the same is 0.8 lagging. Each time the system’s rated kW is
time that PF control is enabled, turning VAR control on changed, the PF adjust will revert to this default value.
(ENABLED) when PF control is enabled turns the PF The PF adjust display setting may change if the PF
control off (DISABLED). adjust is changed via other inputs.
KVAR Adjust Lagging/Leading

Using the kVAR adjust sets the desired operating value It is possible to select either a leading or lagging PF for
for the generator set’s reactive load when the generator utility parallel applications. The selected mode is
set operates in a utility paralleling application. The displayed. A NO entry switches the controller to use the
desired generator set load is entered directly as kVARs. other reference. Lagging/leading may only be changed
The value entered may be as low as zero or as high as while the generator set is not running. Because the most
the rated value (rated kW x 0.75). Any entry beyond the common mode of operation will be with a lagging PF,
rated value will not be accepted, and a RANGE ERROR LAGGING is the default value. Because this mode
message will be displayed. should not be changed while the generator set is
running, attempting to change this mode during
The default value for kVAR adjust is zero. Each time the operation will return a RANGE ERROR message.
system’s rated kW is changed, the kVAR adjust will Always shut down the generator set to change the
revert to zero. The displayed kVAR setting may change lagging/leading mode setting.
if the kVAR setting is changed via other inputs.

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
TP-6083 7/05a 7 Jurong Pier Road
Singapore 619159
E 2001, 2005 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

DEC 550 Controller Operation

Uploaded by

Copyright:

Available Formats

DEC 550 Controller 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

DEC 550 Controller Operation

Uploaded by

Copyright:

Available Formats

What safety precautions should be taken when handling fuel?

What safety precautions should be taken when handling fuel?

What safety precautions should be taken regarding electrical hazards?

What safety precautions should be taken regarding electrical hazards?

Operation

Industrial Generator Sets

Software (Code) Version Prior to 2.10

Product Identification Information

Product identification numbers determine service parts.

Accessory Number Accessory Description

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

TP-6083 7/05 Table of Contents 3

2.8 Reviewing Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

4 Table of Contents TP-6083 7/05

3.5 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

TP-6083 7/05 Table of Contents 5

Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

6 Table of Contents TP-6083 7/05

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

TP-6083 7/05 Safety Precautions and Instructions 7

WARNING Fuel System fuel in tanks.

8 Safety Precautions and Instructions TP-6083 7/05

TP-6083 7/05 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-6083 7/05

TP-6083 7/05 Safety Precautions and Instructions 11

12 Safety Precautions and Instructions TP-6083 7/05

Wiring diagram manuals are available separately. Refer

TP-6083 7/05 Introduction 13

For professional advice on generator set power China

14 Service Assistance TP-6083 7/05

1.1 Introduction (ECM) setup and features. Controller features apply to

1. Emergency stop switch 5. Digital display

Figure 1-1 Controller

TP-6083 7/05 Section 1 Specifications and Features 15

16 Section 1 Specifications and Features TP-6083 7/05

1.2.2 Digital Display and Keypad

Note: Press any key on the keypad to turn on the

The 2-line vacuum fluorescent display provides TP-5829-2

TP-6083 7/05 Section 1 Specifications and Features 17

DC Volts displays the voltage of starting battery(ies).

18 Section 1 Specifications and Features TP-6083 7/05

Starting Aid displays the engine starting aid activation

Undervoltage displays the time delay before the

1.2.3 Switches and Controls

Note: Find additional switches and controls in

Figure 1-6 Keypad Switches

Figure 1-5 Switches and Alarm Horn

TP-6083 7/05 Section 1 Specifications and Features 19

Main Logic (Microprocessor)/Communication

D 1.5-Amp (V7) fuse protects L1 sensing input to

D 1.5-Amp (V8) fuse protects L2 sensing input to

D 1.5-Amp (V9) fuse protects L3 sensing input to

DC Circuit Fuses fuses are located on the controller

20 Section 1 Specifications and Features TP-6083 7/05

TB2 Analog Input Connection Terminal Strip

TB3 Accessory Power Output Connection Terminal

P23 Connector connects the interconnection circuit

Figure 1-8 shows locations of the terminal strips on the

Figure 1-9 Interconnection Circuit Board Ribbon

Figure 1-8 Interconnection Circuit Board Terminal