Kohler 20-3250 kW - Manuals

7 Safety Precautions and Instructions TP-6200 10/12 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harmand pose life-threatening danger whenimproperly installed...

8 Safety Precautions and Instructions TP-6200 10/12 Battery gases. Explosion can causesevere injury or death. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occurnear a battery at any time, particularlywhen it is charging. Do not dispose of abattery in a fire. To pre...

9 Safety Precautions and Instructions TP-6200 10/12 The fuel system. Explosive fuel vapors can cause severe injury ordeath. Vaporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe re...

10 Safety Precautions and Instructions TP-6200 10/12 High voltage test. Hazardous voltage can cause severe injury ordeath. Follow the instructions of the test equipment manufacturer whenperforming high-voltage tests on therotor or stator. An improper test procedure can damage equipment orlead to gen...

11 Safety Precautions and Instructions TP-6200 10/12 Hot Parts Hot coolant and steam.Can cause severe injury or death. Before removing the pressure cap,stop the generator set and allow it tocool. Then loosen the pressure capto relieve pressure. WARNING Hot engine and exhaust system.Can cause severe ...

13 Introduction TP-6200 10/12 Introduction This manual provides operation instructions for 20 kWand larger generator sets equipped with the followingcontroller: D Decision r 550, Software (Code) Version 2.10 or higher Version 2.10 refers to the controller application software.To determine the genera...

14 Service Assistance TP-6200 10/12 Service Assistance For professional advice on generator set powerrequirements and conscientious service, please contactyour nearest Kohler distributor or dealer. D Consult the Yellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems web...

TP-6200 10/12 15 Section 1 Specifications and Features Section 1 Specifications and Features 1.1 Introduction The spec sheets for each generator set provide model-specific generator and engine information. The controller spec sheet provides specifications for thiscontroller. Refer to the respective ...

TP-6200 10/12 16 Section 1 Specifications and Features 1. Generator set master switch, run/off-reset/auto positions (keyswitch option) 2. Emergency stop switch3. Alarm horn (see keypad for alarm silence)4. Annunciator lamps (see keypad for lamp test) 5. Digital display6. Keypad7. Operating guide8. C...

TP-6200 10/12 18 Section 1 Specifications and Features 1.2.2 Digital Display and Keypad Figure 1-5 illustrates the digital display and keypad. Note: Press any key on the keypad to turn on thecontroller lights and display. The lights and display turn off 5 minutes after the last keypadentry. The 2-li...

TP-6200 10/12 19 Section 1 Specifications and Features Engine Displays (Menu 2) Some engine displays are available with selectedgenerator set engines using engine ECMs only. Thecontroller display shows N/A (not available) for itemsthat are unavailable. See the controller spec sheet forapplicable gen...

TP-6200 10/12 20 Section 1 Specifications and Features 1.2.3 Switches and Controls See Figure 1-6 and Figure 1-8 for switches and controls. TP-6083-2 1. Emergency stop switch2. Alarm horn3. Generator set master switch 1 2 3 Figure 1-6 Switches and Alarm Horn Note: Find additional switches and contro...

TP-6200 10/12 21 Section 1 Specifications and Features 1.2.4 Controller Circuit Boards The controller has five circuit boards—indicator,interconnection, keypad, digital display, and main logic/communication. See Figure 1-9 for circuit board locations. 1 2 GM10193B-A 3 4 1. AC fuse block (TB5)2. Inte...

TP-6200 10/12 22 Section 1 Specifications and Features Figure 1-10 shows locations of the terminal strips on thecontroller interconnection circuit board. See Section 6.2,Accessory and Connections, for specific terminalidentification information. Refer to the wiring diagramsfor additional information...

TP-6200 10/12 23 Section 1 Specifications and Features 1.2.8 Communication Ports The main logic circuit board contains several communication ports for Modbus r and KBUS connections. See Figure 1-12. Refer to the List of Related Materials in the Introduction for correspondingcommunication installatio...

TP-6200 10/12 24 Section 1 Specifications and Features Factory-Defined Settings Status Eventor Fault Refer to Menu Digital Display Relay Driver Output (RDO) Alarm Horn Lamp Range Setting Default Selection Inhibit Time Delay (sec.) Time Delay (sec.) Access Code(password) 14 User-Selectable 0 (zero) A...

TP-6200 10/12 30 Section 1 Specifications and Features Factory-Defined Settings Status Eventor Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu Voltage Raise(see D19) Weak Battery 10 WEAK BATTERY...

TP-6200 10/12 31 Section 1 Specifications and Features Engine speed recovery depends upon characteristicssuch as engine make, fuel type, load types, andoperating conditions. The underfrequency unload setting should match the engine speed recoverycharacteristics for the application. Underfrequency Un...

TP-6200 10/12 33 Section 2 Operation Section 2 Operation 2.1 Prestart Checklist To ensure continued satisfactory operation, perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverif...

TP-6200 10/12 34 Section 2 Operation Auto Starting Move the generator set master switch to the AUTOposition to allow startup by the automatic transfer switchor remote start/stop switch (connected to controllerterminals 3 and 4). Terminals 3 and 4 connect to a circuit that automaticallystarts the gen...

TP-6200 10/12 35 Section 2 Operation 2.3.2 Stopping (User Stopping andFault Shutdown) Normal Stopping Run the generator set without load for 5 minutes toensure adequate engine cooldown. The controller has a programmable cooldown timer thatfunctions only when the master switch is in the AUTOposition....

TP-6200 10/12 37 Section 2 Operation When the generator set frequency drops to less than59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system formore than 5 seconds, the local display shows load shed under freq . When the load shed alarm sounds and resets more than twice in 1 minute, the load shedwarni...

TP-6200 10/12 38 Section 2 Operation 2.3.6 System Shutdown Lamp The red lamp illuminates, the alarm horn sounds, andthe unit shuts down to indicate a fault shutdown underthe following conditions. See Section 2.3.7, ControllerReset Procedure, for information on resetting a systemshutdown. Use the Ala...

TP-6200 10/12 40 Section 2 Operation Over Current VR Shutdown. The lamp illuminates and the unit shuts down when the controller detects anovercurrent fault with voltage restraint. The local displayshows sd over current pr. (Paralleling applications only.) Overfrequency. The lamp illuminates and the ...

TP-6200 10/12 41 Section 2 Operation 2.3.7 Controller Resetting (FollowingSystem Shutdown or Warning) Use the following procedure to restart the generator setafter a system shutdown or to clear a warning lampcondition. This procedure includes the resetting of theoptional remote annunciator and the a...

TP-6200 10/12 43 Section 2 Operation Menu List Summary (Legend: D First level submenu, d second level submenu) Engine MonitoringDetailed (MDEC/ADECequipped engines only)Engine Fuel D Fuel Pressure Fuel Temperature D Charge Air Pressure Charge Air Temperature D Fuel Rate D Daily Fuel Used D Total Fue...

TP-6200 10/12 44 Section 2 Operation Menu List Summary, continued (Legend: D First level submenu, d second level submenu) Menu 9Input Setup Menu 9Input Setup, cont. Menu 7Generator System D Operating Mode d Standby Y/N d Prime Power N/Y D System Voltage Line-Line D System Frequency D Phase d 3-Phase...

TP-6200 10/12 47 Section 2 Operation 2.5 Reviewing Digital Display The user interacts with the controller with a keypad anddigital display. Use the keypad to access the generatorset informational data and preset settings. This reviewsection shows how to access the data. See Section 2.8,Local Program...

TP-6200 10/12 48 Section 2 Operation 2.5.2 Auto-Scroll Function The auto-scroll function continuously shows voltage andcurrent data from Menu 1—Generator Monitoring, V & ASummary without the need to press the down arrow foreach display. For auto-scroll function press ENTER at the V & ASummar...

TP-6200 10/12 49 Section 2 Operation D Fixed Voltage when entry is beyond the range of limited entries for the respective alternator. Occurswhen the alternator is not rated for the value entered.Updated parameter files may be available bycontacting an authorized service dealer/distributor. Func (Fun...

TP-6200 10/12 50 Section 2 Operation 2.6.1 PC Communications There are four ways to communicate between a PC andthe generator set and/or transfer switch devices usingKBUS communication protocol. The PC connectionsrequire optional software and possibly other hardware,communication modules in the gene...

TP-6200 10/12 51 Section 2 Operation Remote Single Connection A modem connects a PC to a single device. The PCcommunicates with the device via a telephone network.Locate the PC anywhere a telephone line is available.See Figure 2-14. Remote Area Network A PC connects to a modem. The devices connect t...

TP-6200 10/12 52 Section 2 Operation 2.7 Reviewing Menu Displays Use this section to review a summary of the generatorset controller data. See Figure 2-17 for which menusprovide data monitoring and adjusting data. Press the Reset key, enter the desired menu numberkey(s), and then press the Enter key...

TP-6200 10/12 53 Section 2 Operation 2.7.1 Menu 1—Generator Monitoring Menu 1 displays generator output data includingline-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent ofmaximum kW, total kVA, and total kVAR. Menu 1 displays three-phase voltage and...

TP-6200 10/12 54 Section 2 Operation Menu 1—Generator Monitoring, continued VOLTS & AMPS → L1-L2 VOLTS # L1 AMPS # L1-L0 VOLTS # L1 AMPS # L2-L0 VOLTS # L2 AMPS # FREQUENCY # HZ V & A SUMMARY → For the auto-scroll function,press ENTER atV & A SUMMARY menu. POWER KW → TOTAL KW # PF # LEAD...

TP-6200 10/12 55 Section 2 Operation 2.7.2 Menu 2—Engine Monitoring Menu 2 displays engine operating data including oilpressure and temperature, coolant pressure andtemperature, fuel pressure and temperature, enginerpm, and battery voltage. Menu 2 also displays enginewarning and shutdown setpoints a...

TP-6200 10/12 57 Section 2 Operation 2.7.3 Menu 3—Analog Monitoring Menu 3 displays battery voltage and up to 7 user-defined analog items dependent upon the generatorsystem. The User Defined Desc display refers to a description entered into the controller using the PC software. Thisdescription remai...

TP-6200 10/12 58 Section 2 Operation 2.7.4 Menu 4—Operational Records Menu 4 displays the generator set’s operating recordincluding operating start date, last logged maintenance,total run time loaded and unloaded, run time since lastmaintenance, number of starts, and number of days theunit ran. Afte...

TP-6200 10/12 59 Section 2 Operation 2.7.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to100 stored status, warning, and shutdown events. Afterthe first 100 events, each additional new event replacesthe oldest event. See Menu 10—Output Setup for a listof possible events...

TP-6200 10/12 60 Section 2 Operation MENU 7GENERATOR SYSTEM OPERATING MODE → STANDBY Y/N SYSTEM VOLTAGELINE-LINE ? SYSTEM FREQ # HZ PHASE → 3 PHASE DELTA Y/N KW RATING ? LOAD SHED OUTPUT → ?% # KW OVERVOLTAGE → ?% # VAC UNDERVOLTAGE → ?% # VAC OPERATING MODE → PRIME POWER Y/N PHASE → 3 PHASE WYE N/Y...

TP-6200 10/12 61 Section 2 Operation 2.7.8 Menu 8—Time Delays Menu 8 displays the cyclic cranking cycles, variousengine related starting and shutdown features, andauxiliary shutdown and inhibit time delays. The user must enable the programming mode to edit thedisplay. See Section 2.8.8 to change set...

TP-6200 10/12 62 Section 2 Operation 2.7.9 Menu 9—Input Setup Menu 9 displays the setup of user-defined digital andanalog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. The user must enable the programming mode to edit thedisplay...

TP-6200 10/12 63 Section 2 Operation MENU 9 INPUT SETUP SETUP DIGITAL → AUXILIARY INPUTS DIGITAL INPUT 01 → (USER DEFINED DESC) Press the down arrow toscroll through additionalDIGITAL auxiliary inputs1-- 21 or enter the inputnumber. TO ANALOG INPUTSETUP (NEXT) DIGITAL INPUT 01 → ENABLED YES/NO DIGIT...

TP-6200 10/12 64 Section 2 Operation 2.7.10 Menu 10—Output Setup Menu 10 displays the setup of user-defined system,digital and analog status, and fault outputs and relaydriver outputs (RDO) 1--31. These RDO outputs providemultiple choices for configuring customized auxiliaryoutputs. Additional indiv...

TP-6200 10/12 65 Section 2 Operation Group B, continued Paralleling applicatons: SD REVERSE POWER SD OVER POWER SD LOSS OF FIELD SD OVERCURRENT PR COMMON PR OUTPUT IN SYNCH BREAKER TRIP Waukesha-powered models: FUEL VALVE RELAY PRELUBE RELAY AFM REMOTE START NO OIL TEMP SIGNAL HI OIL TEMP WARNING NO...

TP-6200 10/12 66 Section 2 Operation 2.7.11 Menu 11—Voltage Regulator Menu 11 displays setup of the voltage regulator functionsincluding line-to-line voltages, underfrequency unloading(volts per Hz), reactive droop, power factor, and kVARadjustments. The user must enable the programming mode to edit...

TP-6200 10/12 67 Section 2 Operation 2.7.12 Menu 12—Calibration Menu 12 provides access to the calibration factors formetering (volts and amps) and auxiliary analog inputs.Changing the system voltage or replacing the main logiccontrol circuit board requires calibration adjustment. The user must enab...

TP-6200 10/12 68 Section 2 Operation 2.7.13 Menu 13—Communications Menu 13 shows the settings for remote communications. See Section 2.8.13 to make changes in this menu. See the Modbus r Communications Protocol operation manual for a list of Modbus r registers for the 550 Controller. CONNECTION TYPE...

TP-6200 10/12 69 Section 2 Operation 2.7.14 Menu 14—Programming Mode Menu 14 provides local or remote access to theprogramming function. The user enters a password toaccess the programming mode. Note: Log into the local programming mode to edit the programming access code. The factory default access...

TP-6200 10/12 70 Section 2 Operation 2.7.15 Menu 15—Protective Relays (PR) Menu 15 provides protective relay setup and time delaysfor units with the paralleling protection option. This menu will only be visible and accessible if this option isincluded. The shutdown (SD) settings override those inmen...

TP-6200 10/12 71 Section 2 Operation 2.7.16 Menu 20—Factory Setup (Version 2.10) Menu 20 provides factory setup information includingthe number of operating days, generator set information,alternator information, engine information, controllerinformation, and the controller software (code) version. ...

TP-6200 10/12 72 Section 2 Operation 2.7.17 Menu 20—Factory Setup (Version 2.21) Menu 20 provides factory setup information includingthe number of operating days, generator set information,alternator information, engine information, controllerinformation, and the controller software (code) version.T...

TP-6200 10/12 74 Section 2 Operation Local Programming Mode On 2.8 Local Programming Mode On The Local Programming Mode On section explains howto program the generator set controller logic. Each menu contains a step-by-step procedure for programming the various logic groups. See Section 1,Specificat...

TP-6200 10/12 75 Section 2 Operation Local Programming Mode On 2.8.1 Menu 1—Generator Monitoring Menu 1 provides generator output data includingline-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent ofmaximum kW, total kVA and total kVAR displays.Menu 1...

TP-6200 10/12 76 Section 2 Operation Local Programming Mode On Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries KeyEntry Display Description Displays L1, L2, and L3 amps. A L1 L2 L3 # # # V & A SUMMARY → Returns the user to the volts and amps summ...

TP-6200 10/12 79 Section 2 Operation Local Programming Mode On 2.8.2 Menu 2—Engine Monitoring Menu 2 provides engine operating data including oilpressure and temperature, coolant temperature, fuelpressure and temperature, engine rpm, and batteryvoltage. Menu 2 also displays engine warning and shutdo...

TP-6200 10/12 80 Section 2 Operation Local Programming Mode On Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries KeyEntry Display Description Displays the engine fuel subheading. ENGINE FUEL → ENGINE MONITORING → DETAILED Displays the detailed engine monitoring heading. Note: The ...

TP-6200 10/12 83 Section 2 Operation Local Programming Mode On 2.8.3 Menu 3—Analog Monitoring Menu 3 provides the battery voltage and up to 7 user-defined analog monitoring items dependent upon thegenerator system. The User Defined Desc display refers to a description entered into the controller usi...

TP-6200 10/12 85 Section 2 Operation Local Programming Mode On Menu 3—Analog Monitoring (Waukesha Engines) Menu 3 Displays with Key Entries KeyEntry Display Description Input a menu number. MENU 3 ANALOG MONITORING LOCAL BATT VDC # Displays the local battery VDC. ANALOG 05 # (USER DEFINED DESC) Disp...

TP-6200 10/12 86 Section 2 Operation Local Programming Mode On 2.8.4 Menu 4—Operational Records Menu 4 provides the generator set operational recordsincluding the operating start date, last logged maintenance, total run time loaded and unloaded, runtime since the last maintenance, number of starts, ...

TP-6200 10/12 87 Section 2 Operation Local Programming Mode On Menu 4—Operational Records, continued Menu 4 Displays with Key Entries KeyEntry Display Description Press the Enter key. Confirms the entry. The generator set will begin cranking and runbased on the run time (hours:minutes) period and al...

TP-6200 10/12 88 Section 2 Operation Local Programming Mode On 2.8.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to100 stored status, warning, and shutdown events. Afterthe first 100 events, each additional new event replacesthe oldest event. See Menu 10—Output Setup fo...

TP-6200 10/12 89 Section 2 Operation Local Programming Mode On 2.8.6 Menu 6—Time and Date Menu 6 sets the clock time and date and internalcalendar. The controller uses set time for determiningthe exercise run time and event records. The time anddate are valid only if the controller power (startingba...

TP-6200 10/12 90 Section 2 Operation Local Programming Mode On 2.8.7 Menu 7—Generator System Menu 7 contains the factory-preset generator setvoltage and frequency data. Enter the correspondingdata if the generator set requires voltage reconnectionand/or frequency adjustment. It is imperative that th...

TP-6200 10/12 91 Section 2 Operation Local Programming Mode On Menu 7—Generator System, continued Menu 7 Displays with Key Entries KeyEntry Display Description Displays the phase configuration selection. Note: The display sample may differ depending upon previous entries. Theuser-selected phase appe...

TP-6200 10/12 96 Section 2 Operation Local Programming Mode On 2.8.8 Menu 8—Time Delays Menu 8 displays the various time delays for cycliccranking and other engine-related starting and shutdown features. The user must enable the programming mode to edit thedisplay. Cooldown Temperature Override . Th...

TP-6200 10/12 97 Section 2 Operation Local Programming Mode On Menu 8—Time Delays, continued Menu 8 Displays with Key Entries KeyEntry Display Description TIME DELAY MIN:SEC UNDERVOLTAGE ??:?? Displays the undervoltage time delay in minutes:seconds. Whenrequired, use the numeric keys to set the new ...

TP-6200 10/12 98 Section 2 Operation Local Programming Mode On 2.8.9 Menu 9—Input Setup Menu 9 provides the setup of user-defined digital andanalog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. The user must enable the programmi...

TP-6200 10/12 99 Section 2 Operation Local Programming Mode On Analog Input Values. The analog input selection typically requires entering four values: low warning, highwarning, low shutdown, and high shutdown. The analogvalues and time delays affect how and when thecontroller reacts. See Figure 2-1...

TP-6200 10/12 100 Section 2 Operation Local Programming Mode On Menu 9—Input Setup Menu 9 Displays with Key Entries MAIN MENU NUMBER 9 MENU 9 INPUT SETUP KeyEntry Display Description Input a menu number. Displays the setup of digital auxiliary inputs heading. Displays the digital input 01 with the u...

TP-6200 10/12 101 Section 2 Operation Local Programming Mode On Menu 9—Input Setup, continued Menu 9 Displays with Key Entries KeyEntry Display Description DIGITAL INPUT 01 → DELAY TIME ?:?? Displays the digital input 01 delay time (minutes:seconds) setting.When required, use the numeric keys to set...

TP-6200 10/12 105 Section 2 Operation Local Programming Mode On Menu 10—Output Setup Menu 10 Displays with Key Entries KeyEntry Display Description Input a menu number. MENU 10 OUTPUT SETUP Displays the common faults heading. DEFINE COMMON → FAULTS SYSTEM EVENTS → Displays the system events heading....

TP-6200 10/12 106 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries KeyEntry Display Description DIGITAL INPUTS → Displays the digital inputs heading. Gives the user the option to add or delete selection from the defineddigital faults sta...

TP-6200 10/12 114 Section 2 Operation Local Programming Mode On 2.8.11 Menu 11—Voltage Regulator Menu 11 provides the setup of the voltage regulatorfunctions including the line-to-line voltages, underfrequency unloading (volts per Hz), reactivedroop, power factor, and kVAR adjustments. See Section 1...

TP-6200 10/12 115 Section 2 Operation Local Programming Mode On Menu 11—Voltage Regulator, continued Menu 11 Displays with Key Entries KeyEntry Display Description UNDER FREQ UNLOAD → ENABLED N/Y Displays the under frequency (volts per Hz) unloading (yes or no)selection. Press the Enter key. Confirm...

TP-6200 10/12 120 Section 2 Operation Local Programming Mode On 2.8.12 Menu 12—Calibration Menu 12 provides the calibration of the voltage andcurrent sensing logic. Changing the system voltage orreplacing the main logic control circuit board requires acalibration adjustment. The user must enable the...

TP-6200 10/12 121 Section 2 Operation Local Programming Mode On Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) KeyEntry Display Description GEN L2-L0 V # CALIB REF ? .? Measure the generator set output voltage for three-phase modelsbetween L2-L0 using a vol...

TP-6200 10/12 125 Section 2 Operation Local Programming Mode On 2.8.13 Menu 13—Communications Menu 13 enables communication with the controller formonitoring or controlling the generator set. KBUS allowsa variety of connection types while Modbus r follows Modbus r RTU protocols. Use the LAN (local a...

TP-6200 10/12 126 Section 2 Operation Local Programming Mode On Menu 13—Communications, continued Menu 13 Displays with Key Entries KeyEntry Display Description Confirms the entry. CONNECTION TYPE → (USER DEFINED) YES PRIMARY PORT → (USER DEFINED) Y/N Displays the user-defined primary port subheadin...

TP-6200 10/12 130 Section 2 Operation Local Programming Mode On Menu 14—Programming Mode, continued Menu 14 Displays with Key Entries Displays the user-defined programming mode. Press the Downarrow key if the correct programming mode is displayed. If thedesired programming mode is not displayed, pre...

TP-6200 10/12 131 Section 2 Operation Local Programming Mode On 2.8.15 Menu 15—Protective Relays (PR) Menu 15 provides the necessary protective relays forunits with the optional paralleling protection feature. If the generator set personality profile did not include theparalleling option this menu w...

TP-6200 10/12 132 Section 2 Operation Local Programming Mode On Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries KeyEntry Display Description Displays the underfrequency % value. When required, use thenumeric keys to enter the desired underfrequency % value and pressthe Enter k...

TP-6200 10/12 135 Section 2 Operation Local Programming Mode On 2.8.16 Menu 20—Factory Setup Menu 20 provides generator set, alternator, controller,and engine identification information. The user can usethis menu to determine the generator set operating daysand identify the controller software (code...

TP-6200 10/12 136 Section 2 Operation Local Programming Mode On Menu 20—Factory Setup, continued Menu 20 Displays with Key Entries KeyEntry Display Description CONTROLLER SERIAL NO # Displays the controller serial number. CODE VERSION # COPYRIGHT XXXX Displays the controller software (code) version....

TP-6200 10/12 137 Section 3 Scheduled Maintenance Section 3 Scheduled Maintenance Under normal operating conditions, the generator set’salternator requires no routine service. Consult Section 2.1, Prestart Checklist, for a list of routinechecks. 3.1 Alternator Service When operating the generator se...

TP-6200 10/12 139 Section 3 Scheduled Maintenance 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 su...

TP-6200 10/12 140 Section 3 Scheduled Maintenance 3.4 Alternator Bearing Service Have an authorized service distributor/dealer performservice. 3.4.1 20 -- 300 kW Models Replace the end bracket bearing every 10,000 hours ofoperation in standby and prime power applications.Service the bearing more fre...

TP-6200 10/12 141 Section 3 Scheduled Maintenance 3.5.2 Subbase Fuel Day Tank ElectronicControl Module (ECM) With an electronic control module (ECM), the optionalsubbase diesel fuel tank functions as a day tank.Following are operating information and features of theECM. See Figure 3-2 for the ECM fr...

TP-6200 10/12 142 Section 3 Scheduled Maintenance 3.5.3 Subbase Inner Fuel Tank Alarm This kit provides for both audible and visual alarms froma location remote from the generator set if a leak isdetected in the inner fuel tank of the double-wallsubbase fuel tanks. See Figure 3-6. If the inner tank ...

TP-6200 10/12 143 Section 3 Scheduled Maintenance SB-700 1. Electronic-controlled pressure regulator (EPR)2. Fuel mixer3. Fuel solenoid valve (UL--listed models require 2 fuel solenoid valves) 1 2 3 Figure 3-8 Fuel Regulator and Valve, Typical 3.6.3 Natural Gas and LPG Conversion Most models operate...

TP-6200 10/12 144 Section 3 Scheduled Maintenance ADV-7600B-B Figure 3-10 Gas Fuel Connections Wiring Diagram

TP-6200 10/12 145 Section 3 Scheduled Maintenance Emissions certified models use a single electronic-controlled pressure regulator (EPR) for both fuels. A teefitting connects both fuels together upstream of the EPR.During operation when using the secondary fuel, it isnormal for a small amount of sec...

TP-6200 10/12 147 Section 3 Scheduled Maintenance 6. Replace the pressure cap. 7. Fill the coolant recovery tank to the low mark. 8. Operate generator set until the thermostat opens when the upper cooling system hose warms. 9. Stop the engine and allow it to cool. 10. Check and repair any coolant le...

TP-6200 10/12 148 Section 3 Scheduled Maintenance 13. Place the generator set master switch to the RUN position to start the generator set. Refer to therespective generator set operation manual asneeded. 14. Listen and observe the fan operation. 15. Immediately shut down the generator set ifabnormal...

TP-6200 10/12 152 Section 3 Scheduled Maintenance 3.12 Detroit Diesel Engine Control Systems Some generator sets equipped with Detroit Dieselengines use a DDEC/MDEC/ADEC system. Access theDDEC control box inside the generator set junction boxto retrieve codes when performing routine maintenanceor tr...

TP-6200 10/12 153 Section 3 Scheduled Maintenance 3.13 Engine Control Systems Some generator sets use an engine control system.Access the control box inside the generator set junctionbox to retrieve codes when performing routinemaintenance or troubleshooting engine. Use the following data for genera...

TP-6200 10/12 154 Section 3 Scheduled Maintenance 3.14.3 Fuel System Prepare the fuel system for storage as follows: Diesel-Fueled Engines 1. Fill the fuel tank with #2 diesel fuel. 2. Condition the fuel system with compatible additives to control microbial growth. 3. Change the fuel filter/separato...

TP-6200 10/12 155 Section 4 General Troubleshooting Section 4 General Troubleshooting This section contains generator set troubleshooting,diagnostic, and repair information. Note: The controller clock must be set each time theengine battery(ies) are disconnected. The controller clock determines exer...

TP-6200 10/12 156 Section 4 Troubleshooting 4.1 General T roubleshooting C hart T rouble S ymptoms Probable C auses Recommended Actions Section o r Publication Reference* Doesnot crank Cranksbut doesnot start Startshard Noor lowoutput voltage Stopssuddenly Lackspower Overheats Lowoil pressure Highfu...

TP-6200 10/12 161 Section 5 Generator Set Reconnection Section 5 Generator Set Reconnection 5.1 Introduction Use the following voltage reconnection procedure tochange the voltage of 10- and 12-lead generator sets.Frequency changes require voltage regulator and governor adjustments. Refer to the resp...

TP-6200 10/12 162 Section 5 Generator Set Reconnection 5.2 Voltage Reconnection Procedure 1. Place the generator set master switch in the OFF/RESET position. 2. Disconnect the generator set engine starting battery, negative (--) lead first. Disconnect power tothe battery charger (if equipped). 3. Us...

TP-6200 10/12 167 Section 6 Accessories Section 6 Accessories 6.1 Accessories and Connections Several accessories help finalize installation, addconvenience to operation and service, and establishstate and local code compliance. Accessories vary with each generator set model andcontroller. Select fa...

TP-6200 10/12 168 Section 6 Accessories 6.1.2 Common Failure Relay Kit The common failure relay kit provides one set ofcontacts to trigger user-provided warning devices if afault occurs. The common failure relay faults are user-defined. See Section 2, Operation, Menu 10— Output Setup, for status and...

TP-6200 10/12 169 Section 6 Accessories GM16088A-A Figure 6-6 Controller (Customer) Connection Kit GM16088A-A BATTERY CHARGERALARM TERMINAL STRIP CHARGER MALFUNCTION LV HV CM Figure 6-7 Float/Equalize Battery Charger Connections

TP-6200 10/12 170 Section 6 Accessories 6.1.5 Ground Fault Annunciation A relay contact for customer connection indicates aground fault condition and is part of a ground fault alarm.See Figure 6-8 for electrical connections and thefollowing procedure for controller setup. Use the instructions with t...

TP-6200 10/12 172 Section 6 Accessories 6.1.7 Low Fuel (Level/Pressure) Switch Some gaseous-fueled models offer a low fuel pressureswitch. The low fuel pressure switch connects to thesame terminal as the low fuel level switch on diesel- or gasoline-fueled models. See Figure 6-10 and Figure 6-11. See...

TP-6200 10/12 173 Section 6 Accessories 6.1.9 Remote Emergency Stop Kit The emergency stop kit allows immediate shutdown ofthe generator set from a remote location. See Figure 6-14 and Figure 6-15. If the emergency stopswitch activates, the EMERGENCY STOP lamp lightsand the unit shuts down. Before a...

TP-6200 10/12 174 Section 6 Accessories 6.1.11 Remote Serial Annunciator RSA II is an annunciator panel offered in several kitconfigurations to support Kohler power equipment. TheRSA is a remote serial annunciator Figure 6-18 andFigure 6-19 that monitors the condition of the generatorset and/or ATS ...

TP-6200 10/12 175 Section 6 Accessories Fault and Status Condition Fault LED System Monitoring LEDs and Functions System Ready LED Generator Running LED Communication Status LED Common Fault LED Common Fault Output Horn Overcrank Shutdown Red Red SF Off Green Red SF On On High Engine Temperature War...

TP-6200 10/12 182 Section 6 Accessories 6.1.15 Single-Relay Dry Contact Kit The single-relay dry contact kit provides normally openand normally closed contacts in a form C configuration toactivate warning devices and other user- providedaccessories allowing remote monitoring of the generatorset. Typ...

TP-6200 10/12 183 Section 6 Accessories A-273936 Figure 6-32 Ten-Relay Dry Contact Kit GM13984-/354246B- CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX Figure 6-33 Ten-Relay Dry Contact Kit Connections

TP-6200 10/12 185 Section 6 Accessories 6.1.18 Wireless Monitor The wireless monitor system has two components: awireless monitor unit and a website. The monitor unittransmits messages in response to signals receivedfrom the equipment controller and notifies designatedrecipients of selected operatin...

TP-6200 10/12 186 Section 6 Accessories 6.2 Accessory Connections The 550 controller contains circuit boards equipped withterminal strip(s) for use in connecting a controllerconnection kit. Do not connect accessories directly tothe controller terminal strip(s). Connect accessories toeither a control...

TP-6200 10/12 187 Section 6 Accessories TB1 Terminal Strip—Engine Start andEmergency Stop Connections Term. Description 1 Emergency stop ground 1A Emergency stop 3 Remote start 4 Remote start TB2 Terminal Strip—Analog Input Connections Term. Description 1 ACH1 (CTS) Signal (non-ECM including Waukesh...

TP-6200 10/12 Appendix 193 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC advanced digital control;analog to digital converter adj. adjust, adjustment...

TP-6200 10/12 Appendix 195 Appendix B User-Defined Settings Use the table below to record user-defined settingsduring the generator set controller setup and calibration.The controller default settings and ranges provideguidelines. The table contains all faults with ranges andtime delays including it...

TP-6200 10/12 202 Appendix Appendix C Voltage Regulator Definitions and Adjustments The following definitions and adjustment/setting specifications are intended for users planning to adjustthe voltage regulator beyond the default settings in orderto customize the alternator for a specific applicatio...

TP-6200 10/12 Appendix 203 Frequency Setpoint or Cut-In Point The point at which the underfrequency unloading beginsto take effect is adjustable, allowing the system to betailored for each application. Because the characteristics of the engine have the largest effect onthe system’s performance, the ...

TP-6200 10/12 204 Appendix Reactive Droop Reactive droop refers to another compensation technique used in excitation control systems. Reactivedroop means that the generator set voltage droops withincreasing reactive current. Although this sounds like anundesirable effect, it is quite beneficial in p...

TP-6200 10/12 Appendix 205 135 amps = ( 112500 / 3) / 277 Where: acos is arccosine or inverse cosine W is Watt L-N is line-to-neutral PF is power factor VA is volt-ampere k is kilo ( = 1000 ) Therefore, each generator set in this case should carry113 amps per phase or half the 226 calculated lineamp...

TP-6200 10/12 208 Appendix Appendix D Alternator Protection The 550 controller has built-in thermal protection for thealternator. This feature functions similarly to a thermalcircuit breaker. When the output current exceeds thenominal rating for a short period of time the conditioncauses the fault s...

TP-6200 10/12 Appendix 209 Appendix E Inputs and System Events by Application The controller inputs and system events are typicallydriven by the engine manufacturer’s ECM. NFPA 110guidelines provide specific requirements that allcontrollers must have for compliance. While the controller displays all...