industrial generator sets - crg electric llc · disabling the generator set. accidental starting...

Industrial Generator Sets

Models:

10-1000 kWController:

Decision-Makerr 3000

Software (Code) Version 1.2 or higher

TP-6694 11/15e

Operation

Engine exhaust from this product contains chemicalsknown to the State of California to cause cancer, birthdefects, or other reproductive harm.

WARNINGCalifornia Proposition 65

Product Identification Information

Product identification numbers determine service parts.Record the product identification numbers in the spacesbelow immediately after unpacking the products so thatthe numbers are readily available for future reference.Record field-installed kit numbers after installing thekits.

Generator Set Identification NumbersRecord the product identification numbers from thegenerator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine IdentificationRecord the product identification information from theengine nameplate.

Manufacturer

Model Designation

Serial Number

Controller IdentificationRecord the controller description from the generator setoperationmanual, spec sheet, or sales invoice. Recordthe Controller Serial Number from the controllernameplate.

Controller Description Decision-Makerr 3000

Controller Serial Number

Firmware/Software Version NumbersRecord the version and reference numbers as shippedfrom the manufacturer. Determine the ApplicationProgram Version Number as shown in Menu 20.Determine the Personality Profile Reference Numberfrom the disk supplied with the literature packet.

Application Program Version Number

Personality Profile Reference Number

User Parameter File Reference Number

Version Number Upgrades/UpdatesRecord the version number upgrade/updates wheninstalled.

Version No./Date Installed








Software OptionsRecord the software options.

Number and Description



Table of Contents

TP-6694 11/15 Table of Contents 3

Product Identification Information 2

Safety Precautions and Instructions 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Abbreviations 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .List of Related Materials 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SiteTecht Software 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Specifications and Features 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Controller Features 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Switches and Controls 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.2 Annunciator Lamps 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.3 Digital Display 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.4 Controller Fault Diagnostics 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.5 Digital Display Circuit Board and Connections 22. . . . . . . . . . . . . . . . . . . . .1.2.6 Main Logic Circuit Board 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.7 Terminal Jumper 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.8 Communication Ports 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.9 Fuses 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Controller Logic Specifications 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Status Event and Fault Specifications 24. . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Voltage Regulator and Calibration Specifications 28. . . . . . . . . . . . . . . . . . .1.3.3 Voltage Regulator Adjustments 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Prestart Checklist 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Exercising Generator Set 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Operation in Cold Weather Climates 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Controller Operation 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Starting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Stopping (User Stopping and Fault Shutdown) 31. . . . . . . . . . . . . . . . . . . . .2.4.3 Emergency Stop Switch Resetting 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.4 System Status Lamps 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.5 System Fault Warning Lamp with Digital Displays 32. . . . . . . . . . . . . . . . . .2.4.6 System Fault Shutdown Lamp With Digital Displays 34. . . . . . . . . . . . . . . .2.4.7 Status and Notice Digital Displays 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.8 Controller Resetting (Following System Shutdown or Warning) 38. . . . . . .2.4.9 Powering Up the Engine Control Module (ECM) and Using John Deere

Diagnostic Tools (John Deere-powered models only) 38. . . . . . . . . . . . . . .2.5 Menu Displays 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6 Monitoring and Programming Setup 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6.1 PC Communications 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.6.2 Modbusr Communications 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-6694 11/15Table of Contents4

2.7 Reviewing Menu Displays 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.1 Error Messages 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.2 Overview 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.3 Engine Metering 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.4 Generator Metering (and Calibration) 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.5 GenSet Information 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.6 GenSet Run Time 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.7 GenSet System 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.8 GenSet Calibration 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.9 Voltage Regulator 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.10 Digital Inputs 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.11 Digital Outputs 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.12 Analog Inputs 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.13 Event Log 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.14 Volt Select 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Scheduled Maintenance 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Alternator Service 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Engine Service 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 Service Schedule 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Alternator Bearing Service 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.4.1 20--300 kW Models 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4.2 300--1000 kW Models with 4M/5M/7M Single-Bearing Alternator 56. . . . .

3.5 Diesel Fuel Systems 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5.1 Bleeding Air from Fuel System 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Gaseous Fuel Systems 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.1 Gaseous Fuel System Concept (Single Fuel) 57. . . . . . . . . . . . . . . . . . . . . .3.6.2 LPG Liquid Withdrawal Fuel System Concept 57. . . . . . . . . . . . . . . . . . . . .3.6.3 Natural Gas and LPG Conversion 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.4 Fuel System Changeover Kits (Dual Fuel) 58. . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 58. . . . . . . . . . . . . . . . . . . . .3.8 Air Cleaner Restrictor Indicator (if equipped) 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9 Cooling System 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.9.1 Coolant Level Check 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.2 Cooling System Component Inspection 60. . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.3 Procedure to Drain Cooling System 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.4 Procedure to Flush and Clean Cooling System 61. . . . . . . . . . . . . . . . . . . .3.9.5 Procedure to Refill Cooling System 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Battery 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.1 Clean Battery 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.2 Electrolyte Level Inspection 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.3 Specific Gravity Check 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.4 Charge Battery 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.11 Storage Procedure 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.1 Lubricating System 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.2 Cooling System 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.3 Fuel System 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.4 Internal Engine Components (Gaseous-Fueled Engines) 65. . . . . . . . . . . .3.11.5 Exterior 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.6 Battery 66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 General Troubleshooting 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 General Troubleshooting Chart 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Controller Display and Voltage Regulation Troubleshooting Chart 71. . . . . . . . . . . .

Table of Contents, continued

TP-6694 11/15 Table of Contents 5

Section 5 Voltage Reconnection 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Introduction 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Voltage Reconnection Procedure (Software version 2.8 or higher) 74. . . . . . . . . . . .5.3 Voltage Reconnection Procedure (Software version before 2.8) 74. . . . . . . . . . . . . .

Section 6 Accessories 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1 Accessories and Connections 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.1.1 Common Fault/Failure (32A) Relay Kit 79. . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.2 Float/Equalize Battery Charger Kit with Alarm Option 80. . . . . . . . . . . . . . .6.1.3 Gas Fuel Valve Kit 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.4 Input/Output (I/O) Module Board 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.5 Low Fuel (Level/Pressure) Switch 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.6 Manual Speed Adjust (Engine RPM Menu)

(Software version 3.10.3 or higher) 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.7 Prime Power Switch Kit 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.8 Remote Emergency Stop Kit 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.9 Remote Reset Feature 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.10 Remote Serial Annunciator 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.11 Run Relay Kit 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.1.12 Shunt-Trip Line Circuit Breaker 86. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.2 Accessory Connections 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Programmer-Defined Settings 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix C Voltage Regulator Definitions and Adjustments 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix D Alternator Protection 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix E Controller Displays from the Engine ECM 103. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-6694 11/156

Notes

7Safety Precautions and InstructionsTP-6694 11/15

Safety Precautions and Instructions

IMPORTANTSAFETY INSTRUCTIONS.Electromechanical equipment,including generator sets, transferswitches, switchgear, and accessories,can cause bodily harm and poselife-threatening danger whenimproperly installed, operated, ormaintained. To prevent accidents beaware of potential dangers and actsafely. Read and follow all safetyprecautions and instructions. SAVETHESE INSTRUCTIONS.

Thismanual has several types of safetyprecautions and instructions: Danger,Warning, Caution, and Notice.

DANGER

Danger indicates the presence of ahazard that will cause severepersonal injury, death, orsubstantialproperty damage.

WARNING

Warning indicates the presence of ahazard that can cause severepersonal injury, death, orsubstantialproperty damage.

CAUTION

Caution indicates the presence of ahazard that will or can cause minorpersonal injury or property damage.

NOTICENotice communicates installation,operation, or maintenance informationthat is safety related but not hazardrelated.

Safety decals affixed to the equipmentin prominent places alert the operatoror service technician to potentialhazards and explain how to act safely.The decals are shown throughout thispublication to improve operatorrecognition. Replace missing ordamaged decals.

Accidental Starting

Accidental starting.Can cause severe injury or death.

Disconnect the battery cables beforeworking on the generator set.Remove the negative (--) lead firstwhen disconnecting the battery.Reconnect the negative (--) lead lastwhen reconnecting the battery.

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Press the generator set off/resetbutton to shut down the generator set.(2) Disconnect the power to the batterycharger, if equipped. (3) Remove thebattery cables, negative (--) lead first.Reconnect the negative (--) lead lastwhen reconnecting the battery. Followthese precautions to prevent thestarting of the generator set by theremote start/stop switch.

Battery

Sulfuric acid in batteries.Can cause severe injury or death.

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

Explosion.Can cause severe injury or death.Relays in the battery chargercause arcs or sparks.

Locate the battery in a well-ventilatedarea. Isolate the battery charger fromexplosive fumes.

WARNING

Battery electrolyte is a dilutedsulfuric acid. Battery acid cancausesevere injury or death. Battery acidcan cause blindness and burn skin.Always wear splashproof safetygoggles, rubber gloves, and bootswhen servicing the battery. Do notopen a sealed battery or mutilate thebattery case. If battery acid splashes inthe eyes or on the skin, immediatelyflush the affected area for 15 minuteswith large quantities of clean water.Seek immediatemedical aid in the caseof eye contact. Never add acid to abattery after placing the battery inservice, as this may result in hazardousspattering of battery acid.

Battery acid cleanup. Battery acidcan cause severe injury or death.Battery acid is electrically conductiveand corrosive. Add 500 g (1 lb.) ofbicarbonate of soda (baking soda) to acontainer with 4 L (1 gal.) of water andmix the neutralizing solution. Pour theneutralizing solution on the spilledbattery acid and continue to add theneutralizing solution to the spilledbattery acid until all evidence of achemical reaction (foaming) hasceased. Flush the resulting liquid withwater and dry the area.

8 Safety Precautions and Instructions TP-6694 11/15

Battery gases. Explosion can causesevere injury or death. Battery gasescan cause an explosion. Do not smokeor permit flames or sparks to occur neara battery at any time, particularly whenit is charging. Do not dispose of abattery in a fire. To prevent burns andsparks that could cause an explosion,avoid touching the battery terminalswith tools or other metal objects.Remove all jewelry before servicing theequipment. Discharge static electricityfrom your body before touchingbatteries by first touching a groundedmetal surface away from thebattery. Toavoid sparks, do not disturb the batterycharger connections while the batteryis charging. Always turn the batterycharger off before disconnecting thebattery connections. Ventilate thecompartments containing batteries toprevent accumulation of explosivegases.

Battery short circuits. Explosioncan cause severe injury or death.Short circuits can cause bodily injuryand/or equipment damage.Disconnect the battery beforegenerator set installation ormaintenance. Remove all jewelrybefore servicing the equipment. Usetools with insulated handles. Removethe negative (--) lead first whendisconnecting the battery. Reconnectthe negative (--) lead last whenreconnecting the battery. Neverconnect the negative (--) battery cableto the positive (+) connection terminalof the starter solenoid. Do not test thebattery condition by shorting theterminals together.

Engine Backfire/FlashFire

Risk of fire.Can cause severe injury or death.

Do not smoke or permit flames orsparks near fuels or the fuel system.

WARNING

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the carburetor, fuel line,fuel filter, fuel pump, or other potentialsources of spilled fuels or fuel vapors.Catch fuels in an approved containerwhen removing the fuel line orcarburetor.

Servicing the air cleaner. A suddenbackfire can cause severe injury ordeath. Do not operate the generatorset with the air cleaner removed.

Combustible materials. A fire cancause severe injury or death.Generator set engine fuels and fuelvapors are flammable and explosive.Handle these materials carefully tominimize the risk of fire or explosion.Equip the compartment or nearby areawith a fully charged fire extinguisher.Select a fire extinguisher rated ABC orBC for electrical fires or asrecommended by the local fire code oran authorized agency. Train allpersonnel on fire extinguisheroperation and fire preventionprocedures.

Exhaust System

Carbon monoxide.Can cause severe nausea,fainting, or death.

The exhaust system must beleakproof and routinely inspected.

WARNING

Generator set operation. Carbonmonoxide can cause severe nausea,fainting, or death. Carbon monoxideis an odorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Avoidbreathing exhaust fumeswhenworkingon or near the generator set. Neveroperate the generator set inside abuilding unless the exhaust gas ispiped safely outside. Never operatethe generator set where exhaust gascould accumulate and seep back insidea potentially occupied building.

Carbon monoxide symptoms.Carbon monoxide can cause severenausea, fainting, or death. Carbonmonoxide is a poisonous gas present inexhaust gases. Carbonmonoxide is anodorless, colorless, tasteless,nonirritating gas that can cause death ifinhaled for even a short time. Carbonmonoxide poisoning symptoms includebut are not limited to the following:D Light-headedness, dizzinessD Physical fatigue, weakness injoints and muscles

D Sleepiness, mental fatigue,inability to concentrateor speak clearly, blurred vision

D Stomachache, vomiting, nauseaIf experiencing any of these symptomsand carbon monoxide poisoning ispossible, seek fresh air immediatelyand remain active. Do not sit, lie down,or fall asleep. Alert others to thepossibility of carbon monoxidepoisoning. Seek medical attention ifthe condition of affected persons doesnot improvewithinminutes of breathingfresh air.

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

Use extreme care when handling,storing, and using fuels.

WARNING

The fuel system. Explosive fuelvapors can cause severe injury ordeath. Vaporized fuels are highlyexplosive. Use extreme care whenhandling and storing fuels. Store fuelsin a well-ventilated area away fromspark-producing equipment and out ofthe reach of children. Never add fuel tothe tank while the engine is runningbecause spilled fuel may ignite oncontact with hot parts or from sparks.Do not smoke or permit flames orsparks to occur near sources of spilledfuel or fuel vapors. Keep the fuel linesand connections tight and in goodcondition. Do not replace flexible fuellines with rigid lines. Use flexiblesections to avoid fuel line breakagecausedby vibration. Donot operate thegenerator set in the presence of fuelleaks, fuel accumulation, or sparks.Repair fuel systems before resuminggenerator set operation.

9Safety Precautions and InstructionsTP-6694 11/15

Explosive fuel vapors can causesevere injury or death. Takeadditional precautions when using thefollowing fuels:

Propane (LPG)—Adequate ventilationis mandatory. Because propane isheavier than air, install propane gasdetectors low in a room. Inspect thedetectors per the manufacturer’sinstructions.

Natural Gas—Adequate ventilation ismandatory. Because natural gas rises,install natural gas detectors high in aroom. Inspect the detectors per themanufacturer’s instructions.

Fuel tanks. Explosive fuel vaporscan cause severe injury or death.Gasoline and other volatile fuels storedin day tanks or subbase fuel tanks cancause an explosion. Store only dieselfuel in tanks.

Draining the fuel system. Explosivefuel vapors can cause severe injuryor death. Spilled fuel can cause anexplosion. Usea container to catch fuelwhendraining the fuel system. Wipeupspilled fuel after draining the system.

Gas fuel leaks. Explosive fuelvapors can cause severe injury ordeath. Fuel leakage can cause anexplosion. Check the LPG vapor ornatural gas fuel system for leakage byusing a soap and water solution withthe fuel system test pressurized to6--8 ounces per square inch(10--14 inches water column). Do notuse a soap solution containing eitherammonia or chlorine because bothprevent bubble formation. A successfultest depends on the ability of thesolution to bubble.

LPG liquid withdrawal fuel leaks.Explosive fuel vapors can causesevere injury or death. Fuel leakagecan cause an explosion. Check theLPG liquid withdrawal fuel system forleakage by using a soap and watersolution with the fuel system testpressurized to at least 90 psi(621 kPa). Do not use a soap solutioncontaining either ammonia or chlorinebecause both prevent bubbleformation. A successful test dependson the ability of the solution to bubble.

Hazardous Noise

Hazardous noise.Can cause hearing loss.

Never operate the generator setwithout a muffler or with a faultyexhaust system.

CAUTION

Engine noise. Hazardous noise cancause hearing loss. Generator setsnot equipped with sound enclosurescan produce noise levels greater than105 dBA. Prolonged exposure to noiselevels greater than 85 dBA can causepermanent hearing loss. Wear hearingprotection when near an operatinggenerator set.

Hazardous Voltage/Moving Parts

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER

Hazardous voltage.Can cause severe injury or death.

Operate the generator set only whenall guards and electrical enclosuresare in place.

Moving parts.

WARNING

Hazardous voltage.Backfeed to the utility system cancause property damage, severeinjury, or death.

If the generator set is used forstandby power, install an automatictransfer switch to prevent inadvertentinterconnection of standby andnormal sources of supply.

WARNING

Grounding electrical equipment.Hazardous voltage can causesevere injury or death. Electrocutionis possible whenever electricity ispresent. Ensure you comply with allapplicable codes and standards.Electrically ground the generator set,transfer switch, and related equipmentand electrical circuits. Turn off themaincircuit breakers of all power sourcesbefore servicing the equipment. Nevercontact electrical leads or applianceswhen standing in water or on wetground because these conditionsincrease the risk of electrocution.

High voltage test. Hazardousvoltage can cause severe injury ordeath. Follow the instructions of thetest equipment manufacturer whenperforming high-voltage tests on therotor or stator. An improper testprocedure can damage equipment orlead to generator set failure.

Installing the battery charger.Hazardous voltage can causesevere injury or death. Anungrounded battery charger maycause electrical shock. Connect thebattery charger enclosure to thegroundof a permanent wiring system. As analternative, install an equipmentgrounding conductor with circuitconductors and connect it to theequipment grounding terminal or thelead on the battery charger. Install thebattery charger as prescribed in theequipment manual. Install the batterycharger in compliance with local codesand ordinances.

10 Safety Precautions and Instructions TP-6694 11/15

Connecting the battery and thebattery charger. Hazardous voltagecan cause severe injury or death.Reconnect the battery correctly,positive to positive and negative tonegative, to avoid electrical shock anddamage to the battery charger andbattery(ies). Have a qualifiedelectrician install the battery(ies).

Short circuits. Hazardousvoltage/current can cause severeinjury or death. Short circuits cancause bodily injury and/or equipmentdamage. Do not contact electricalconnections with tools or jewelry whilemaking adjustments or repairs.Remove all jewelry before servicing theequipment.

Engine block heater. Hazardousvoltage can cause severe injury ordeath. The engine block heater cancause electrical shock. Remove theengine block heater plug from theelectrical outlet before working on theblock heater electrical connections.

Electrical backfeed to the utility.Hazardous backfeed voltage cancause severe injury or death. Installa transfer switch in standby powerinstallations to prevent the connectionof standby and other sources of power.Electrical backfeed into a utilityelectrical system can cause severeinjury or death to utility personnelworking on power lines.

Testing live electrical circuits.Hazardous voltage or current cancause severe injury or death. Havetrained and qualified personnel takediagnostic measurements of livecircuits. Use adequately rated testequipment with electrically insulatedprobes and follow the instructions of thetest equipment manufacturer whenperforming voltage tests. Observe thefollowing precautions when performingvoltage tests: (1) Remove all jewelry.(2) Standonadry, approvedelectricallyinsulated mat. (3) Do not touch theenclosure or components inside theenclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Airborne particles.Can cause severe injury orblindness.

Wear protective goggles and clothingwhen using power tools, hand tools,or compressed air.

WARNING

Servicing the generator set when itis operating. Exposedmoving partscan cause severe injury or death.Keep hands, feet, hair, clothing, andtest leads away from the belts andpulleys when the generator set isrunning. Replace guards, screens, andcovers before operating the generatorset.

Heavy Equipment

Unbalanced weight.Improper lifting can cause severeinjury or death and equipmentdamage.

Do not use lifting eyes.Lift the generator set using lifting barsinserted through the lifting holes onthe skid.

WARNING

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 injury or death.

Do not work on the generator set untilit cools.

WARNING

Servicing the alternator. Hot partscan cause severe injury or death.Avoid touching the alternator field orexciter armature. When shorted, thealternator field and exciter armaturebecome hot enough to cause severeburns.

Servicing the exhaust system. Hotparts can cause severe injury ordeath. Do not touch hot engine parts.The engine and exhaust systemcomponents become extremely hotduring operation.

Notice

NOTICE

This generator set has beenrewired from its nameplate voltageto

246242

NOTICEVoltage reconnection. Affix a noticeto the generator set after reconnectingthe set to a voltage different from thevoltage on the nameplate. Ordervoltage reconnection decal 246242from an authorized servicedistributor/dealer.

NOTICECanadian installations only. Forstandby service connect the output ofthe generator set to a suitably ratedtransfer switch in accordance withCanadian Electrical Code, Part 1.

11IntroductionTP-6694 11/15

Introduction

This manual provides operation instructions for 10 kWand larger generator sets equipped with the followingcontroller:

D Decision-Makerr 3000, Software (Code) Version 1.2or higher

To determine the generator set controller softwareversion, go to the Overview menu.

Wiringdiagrammanualsareavailable separately. Referto the engine operationmanual for generator set enginescheduled maintenance information.

Information in this publication represents data availableat the time of print. Kohler Co. reserves the right tochange this publication and the products representedwithout notice and without any obligation or liabilitywhatsoever.

Read this manual and carefully follow all proceduresand safety precautions to ensure proper equipmentoperation and to avoid bodily injury. Readand follow theSafety Precautions and Instructions section at thebeginning of this manual. Keep this manual with theequipment for future reference.

The equipment service requirements are very importantto safe and efficient operation. Inspect the parts oftenandperform requiredserviceat theprescribed intervals.Maintenance work must be performed by appropriatelyskilled and suitably trained maintenance personnelfamiliar with generator set operation and service.

Abbreviations

This publicationmakes use of numerous abbreviations.Typically, the word(s) are spelled out along with theabbreviation in parentheses when shown for the firsttime in a section. Appendix A, Abbreviations, alsoincludes many abbreviation definitions.

List of Related Materials

Separate literature contains communication andsoftware information not provided in this manual.Figure 1 lists the available literature part numbers.

Literature Description Literature Part No.

Controller Spec Sheet G6-100

Generator Set/ControllerWiring Diagram Manual

Multiple Part NumbersContact your

Distributor/Dealer

Modbusr Communications ProtocolOperation Manual TP-6113

SiteTecht Software Operation Manual TP-6701

Remote Serial Annunciator (RSA III) TT-1625

Remote Serial Annunciator (RSA II) TT-1485

Converters, Connections, and ControllerSetup for Network Communication TT-1405

Figure 1 Related Literature

Several engine manufacturers provide engines withelectronic controls. These electronic controls indicateengine fault codes in addition to the generator setcontroller. The engine operation and service literatureprovide information for identifying engine fault codes.For the latest literature part numbers, see the respectiveParts Catalog.

SiteTecht Software

Several instances in this manual make reference toSiteTecht software which is required for programmingthe Decision-Makerr 3000 controller. SiteTechtsoftware is also needed for updating the controllerapplication code. Contact your local distributor/dealerfor assistance.

Requires SiteTech software version 1.02 or higher toupgrade the controller firmware.

Modbusr is a registered trademark of Schneider Electric.

12 Service Assistance TP-6694 11/15

Service Assistance

For professional advice on generator set powerrequirementsandconscientiousservice, pleasecontactyour nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the headingGenerators—Electric.

D Visit the Kohler Power Systems website atKOHLERPower.com.

D Look at the labels and decals on your Kohler productor review the appropriate literature or documentsincluded with the product.

D Call toll free in the US and Canada 1-800-544-2444.

D Outside theUSandCanada, call the nearest regionaloffice.

Headquarters Europe, Middle East, Africa(EMEA)Kohler Power Systems Netherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631

Asia PacificPower Systems Asia Pacific Regional OfficeSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950

(86) 10 6518 7951(86) 10 6518 7952

Fax: (86) 10 6518 7955

East China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550

India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208

(91) 80 3366231Fax: (91) 80 3315972

Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727

Latin AmericaLatin America Regional OfficeLakeland, Florida, USAPhone: (863) 619-7568Fax: (863) 701-7131

TP-6694 11/15 13Section 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. Thecontroller spec sheet provides specifications for thiscontroller. Refer to the respective spec sheet for datanot supplied in this manual. Refer to the generator setservice manual, installation manual, engine operationmanual, and engine service manual for additionalspecifications.

1.2 Controller Features

The controller features include the annunciator lamp,digital display and pushbutton/rotary selector dial,switchesand controls, and fusesand terminal strip. Thefollowing paragraphs detail the features by generaltopics.

See Figure 1-1 for an illustration of the controller frontpanel.

Thecontroller features, accessories,andmenudisplaysdepend upon the engine electronic control module(ECM) setup and features. Controller features apply togenerator set models with ECM and non-ECM enginesunless otherwise noted.

Note: Press the pushbutton/rotary selector dial to turnon the controller lights and display. The light anddisplay turn off 60 minutes after the last entrywhen in the AUTO mode.

Note: After about 5 minutes of no user input(pushbutton/rotary selector dial or buttons), themenu is reset to the top of the main menus andauto-paging activates for the Overviewsubmenus.

Note: Measurements display in metric or English units.Use the Generator Set System menu to changethe measurement display.

1. Emergency stop switch2. Generator set master control switches,

OFF/RESET--AUTO--RUN buttons with lamps3. Digital display4. Alarm horn (behind panel)

5. Pushbutton/rotary selector dial6. Annunciator fault lamp7. Controller terminal strips (on circuit board)8. Alarm silence/lamp test button with lamp9. Mini USB connection

GM65741-

1 2 4 5

7

8

3

6

FAULT

OFF/RESET AUTO RUN ALARM SILENCE/LAMP TEST

9

Figure 1-1 Decision-Makerr 3000 Controller with Digital Display and Pushbutton/Rotary Selector Dial

TP-6694 11/1514 Section 1 Specifications and Features

1.2.1 Switches and Controls

Note: US/Metric Display is selectable in Section1.2.3—Digital Display—Generator Set SystemMenu.

AlarmHorn. Thealarmhornalerts theoperator or otherattendants that a shutdown or warning condition exists.

Alarm (Horn) Silence. The alarm silence/lamp testswitch silences the alarm horn at the operator’sdiscretion. Press the master control switch AUTObutton before pressing the alarm silence/lamp testbutton. The alarm horn cannot be silenced unless themaster control switch AUTO button is pressed.

Note: Additional alarm silencing options are shown inSection 1.2.3—Digital Display—Generator SetSystem Menu.

Restore alarm horn switches at all locations includingthose on remote annunciator kits after correcting thefault shutdown to avoid reactivating the alarmhorn. SeeSection 2—Operation, 2.4.8 Controller Resetting forresetting the controller.

Emergency Stop. The operator-activated pushbuttonimmediately shuts down thegenerator set in emergencysituations. Reset the emergency stop switch aftershutdown by pulling the emergency stop switchoutward. Use the emergency stop switch foremergency shutdowns only. Use the master controlswitch OFF/RESET button for normal shutdowns.

Generator Set Master Control Switches(OFF/RESET--AUTO--RUN). These switches reset thecontroller fault lamps and start/stops the generator set.Additional information in shown in Section 2—Operation.

Lamp Test. Press and hold the Alarm Silence/LampTest button for two seconds to test the controllerindicator lamps, alarm horn, and digital display.

Manual Speed Adjust (Engine RPM) (Version 3.10.3orhigher). The control allows varying the engine speedfor applications using closed transition ATS. The usercan set the nominal running frequency slightly above orbelow the utility frequency to ensure thatsynchronization occurs. Additional information isshown in 2.7.7 GenSet System. Available as afactory-installed option or requires a new factorypersonality profile.

Pushbutton/Rotary Selector Dial. This controlprovides access to themenus for monitoring. Press theselector dial to activate the digital display and to selectchoices shown on the display. Rotate the dial tonavigate through the menus.

Thepushbutton/rotary selector dial has several featuresand functions:

D Momentarily press the dial to activate the digitaldisplay if dark.

D Rotate the dial to navigate through the mainmenus—turn clockwise to go forward (down) andcounterclockwise to go back (up). The menus do notwrap to the beginning.

D Press the dial at a given main menu to access thesubmenus within the selected main menu.

D When in the submenu, rotate the dial to navigatethrough the submenu—clockwise to go forward(down) and counterclockwise to go back (up). Themenus do not wrap to the beginning.

D Momentarily press the dial when in the submenu tomake a user selection choice (if available) or to goback to the respective main menu.

D Press thedial for at least 3 seconds to return to the topof themainmenus (Overview) regardless if you are inthe main menus or submenus.

D After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), themenu resets to thetop of the main menus and auto-paging activates forthe Overview submenus.

1.2.2 Annunciator Lamps

The controller has a single annunciator fault lampproviding visual generator set status. In addition, eachbutton has a corresponding lamp. See Figure 1-2.

Lamp/Button Lamp Color

Alarm (Fault) Lamp Yellow (Warning) or Red (Shutdown)

Off/Reset Button Red

Auto Button Green (System Ready)

Run Button Yellow

Alarm Silence/LampTest Button Yellow

Figure 1-2 Annunciator Lamps

System Status Lamps (Master Control Switches)

The green lamp illuminates on themaster control switchAUTO (automatic start) button indicating the systemsenses no faults and the unit is ready to start by remotecommand.

The red lamp illuminates on the master control switchOFF/RESET button indicating the generator set isstopped.

Theyellow lamp illuminateson themaster control switchRUN button indicating the generator set is cranking orrunning from a local command.

Only one of the three master control switch lamps willilluminate at any given time.


Alarm Silence Lamp. Yellow lamp illuminatesindicating the alarm horn was silenced.

(System) Fault Lamp. Yellow lamp illuminatesindicating a warning condition or red lamp illuminatesindicating a shutdown condition. See System WarningFault LampandSystemShutdownFault Lamp followingfor system fault conditions.

System Warning Fault Lamp. Yellow lamp identifiesan existing fault condition that does not shut down thegenerator set. A continuing system warning faultcondition may cause a system shutdown. Correct allsystem warnings as soon as practical.

See Section 2.4.5, System Fault Warning Lamp withDigital Displays, for definitions of the items listed. Thefollowing conditions cause a system warning:

D AC sensing lossD Auxiliary input (analog or digital)D Battery charger fault *D Common warningD Critical high fuel level (diesel-poweredmodels only) *D Default parameters loadedD ECM diagnostics (multiple engine inputs)D Fuel tank leak (diesel-powered models only) *D Ground fault *D High battery voltageD High coolant temperatureD High fuel level (diesel-powered models only) *D Input/output communication lossD Low battery voltageD Low coolant temperatureD Low cranking voltageD Low engine oil level *D Low fuel (level for diesel-powered models) *D Low fuel (pressure for gas-powered models) *D Low oil pressureD Not-in-auto (master control switch)D Speed sensor fault

* Requires optional input sensors.

System Shutdown Fault Lamp. Red lamp indicatesthat the generator set has shut down because of a faultcondition. The unit will not start without resetting thecontroller, see Section 2.4.8, Controller Resettingprocedure.

See Section 2.4.6, System Fault Shutdown Lamp withDigital Displays, for definitions of the items listed. Thefollowing conditions cause a system shutdown:

D AC sensing lossD Alternator protectionD Auxiliary input (analog or digital)D Common faultD ECM address conflictD ECM communications lossD ECM diagnostics (multiple engine inputs)D ECM model mismatchD Emergency stopD Engine over speedD Engine under speedD File system error (controller firmware fault)D Fuel tank leak (diesel-powered models only) *D High coolant temperatureD Internal failureD kW overloadD Locked rotor (failed to crank)D Loss of fuelD Low coolant level *D Low engine oil level *D Low fuel level (diesel-powered models only) *D Low oil pressureD Megajector communications loss(GM/PSI and Doosan gas-powered models only)

D Metering communication lossD No coolant temperature signalD No oil pressure signalD OvercrankD OverfrequencyD Overvoltage (each phase)D Run relay overloadD UnderfrequencyD Undervoltage (each phase)D (Voltage) regulator communication loss* Requires optional input sensors.


1.2.3 Digital Display

Press the pushbutton/rotary selector dial to turn on thecontroller lamps and display. The lamps and displayturn off 60 minutes after the last entry.

The generator set must be running for some displays toindicate values. If the generator set is not running somevalues will display zero or N/A (not available).

Some displays are engine dependent, refer to theAppendix, Controller Displays from the Engine ECM.

The 12-character, 2-line backlit heated display providesgenerator set and engine data, system status, and faultinformation. See Figure 1-1. The digital display showsabbreviations in some instances, refer to 1.3.1 StatusEvent andFault Specifications for the abbreviations andtheir full descriptions.

Note: US/Metric Unit Display is selectable inGenerator Set System.

Note: Display Contrast is selectable in Generator SetSystem. The contrast display adjustment allowsuser selected resolution values to improve digitaldisplay clarity.

Note: After about 5 minutes of no user input(pushbutton/rotary selector dial or buttons), themenu resets to the top of the main menus andauto-paging activates for the Overviewsubmenus.

The main menus are listed below. Within each mainmenu are multiple submenus with descriptionsfollowing.

D OverviewD Engine MeteringD Generator MeteringD GenSet InformationD GenSet Run TimeD GenSet SystemD GenSet Calibration (Before Version 3.0.25)D Voltage RegulationD Digital InputsD Digital OutputsD Analog InputsD Event LogD Volt Select (Version 2.8.22 or higher)

Overview Menu

When a new shutdown or warning fault occurs, theauto-paging display feature activates.

Active Shutdowns display if any are present. Thisalerts the user to single or multiple shutdown faultconditions. See 1.2.2—Annunciator Lamps—SystemShutdown Fault Lamp for a list of possible shutdownfaults.

ActiveWarnings display if any are present. This alertsthe user to single or multiple warning fault conditions.See 1.2.2—Annunciator Lamps—System WarningFault Lamp for a list of possible warning faults.

Generator Set State displays the generator set status:

D OffD StandbyD RunningD CooldownD Stopping

Average Volts Line-to-Line value displays. Forthree-phase configurations the average line-to-linevoltage of L1, L2, and L3 is displayed. Single-phaseconfigurations show the L1-L2 voltage.

Frequency (Hz) value displays for the output ACvoltage.

Current value displays as the average for three-phaseconfigurations or the current value for L1-L2 withsingle-phase configurations.

Average kW displays. For three-phase configurationsthe average line-to-line kilowatts of L1, L2, and L3 isdisplayed. Single-phase configurations show the L1-L2kilowatts.

Coolant Temperature diplays for the engine coolanttemperature.

Oil Pressure displays the engine oil pressure.

Fuel Level % displays the fuel tank level for diesel-powered models when so equipped.

FuelPressuredisplays fuel pressure for someengines.Refer to the Appendix, Controller Displays from theEngine ECM.

Battery displays the DC voltage of the engine startingbattery(ies).

Engine Run Time displays the total run time hours.

Software Version displays in the Overviewmenu. Usethe version number to determine if an upgrade isneeded and/or when troubleshooting the controller.


Engine Metering Menu

Note: The Engine Metering Menu may vary dependingupon if the selector dial is rotated clockwise orcounterclockwise.

Engine Speed (Tachometer) displays the enginespeed in RPM.

Oil Pressure displays the engine oil pressure. Thisvalue also shows in the Overview Menu.

Coolant Temperature displays the engine coolanttemperature. This value also shows in the OverviewMenu.

Fuel Level % displays the fuel tank level for diesel-powered models if so equipped. This value also showsin the Overview Menu.

Battery displays the DC voltage of the engine startingbattery(ies). This value also shows in the OverviewMenu.

FuelPressuredisplays fuel pressure for someengines.Refer to the Appendix, Controller Displays from theEngine ECM. This value also shows in the OverviewMenu.

Generator Metering Menu

Total Power kVA and kW displays alternator output asactual output values.

Rated Power displays alternator output as apercentage of the entered data value.

Volts displays the alternator output AC voltages. Thedisplay shows all line-to-line and line-to-neutral voltagecombinations for three-phase or single-phaseconfigurations.

Current displays the alternator output AC amps. Thedisplay shows each line (L1-L2-L3) of three-phasemodels or L1-L2 current for single-phase models.

Frequency (Hz) value displays for the output ACvoltage. This value also shows in the Overview Menu.

Reset Calibration providing the means to reset theconfiguration values is available in this menu incontroller firmware version 3.0.25 or higher.

The calibration values are reviewable at all times andprovide the calibration of the voltage and currentsensing logic. Changing thesystemvoltageor replacingthe circuit board requires a calibration adjustment.

To enable calibration, start the generator set and selectthe Volts L1-L2 display. Then push and hold thepushbutton/rotary selector dial until the Calibration

Enabled popup appears. Calibration of each display isnow available. The display will show the followingvalues for three-phase generator sets. Single-phasegenerator sets will only display items marked (*).

D Volts L1-L2 *D Volts L2-L3D Volts L3-L1D Volts L1-N *D Volts L2-N *D Volts L3-ND Current L1 *D Current L2 *D Current L3

The user can change individual values or can selectReset Calib?--Yes to reset all values. TheReset Calib?display will only show if calibration is enabled. Refer tothe requirements shown with Generator Set Calibrationin 2.4.7 Status and Notice Digital Displays.

To disable calibration, Rotate the pushbutton/rotaryselector dial until the <--Return popup appears.Momentarily press the pushbutton/rotary selector dial.Stop the generator set if not already done.

Generator Set Information Menu

GenSet M/N displays the generator set model number.

GenSet S/N displays the generator set serial number.

Controller S/N displays the controller serial number.

Generator Set Run Time Menu

Engine Run Time displays the total run time hours.This value also shows in the Overview Menu.

Engine Loaded displays the total loaded hours.

Engine Starts displays the total number of generatorset startup events.

Total Energy displays the total kW hours.

Generator Set System Menu

The values in this menus are user-entered for thegenerator set configuration and are NOT measuredvalues of the generator set.

Changes to theGenerator Set Systemmenu require theuse of SiteTecht software except for Measure Systemand Contrast selections.

System Frequency displays the programmer-enteredL1-L2-L3 output voltage frequency for three-phase orthe L1-L2 output voltage frequency for single-phase.


System Phase displays the programmer-enteredconfiguration as Single Phase, Single Phase Dog Leg,Three Phase Wye, or Three Phase Delta.

System Voltage displays the programmer-enteredL1-L2-L3 output voltage for three-phase or the L1-L2output voltage for single-phase.

Power Rating displays the programmer entered kWvalue for the generator set.

Amp Rating displays the programmer entered currentvalue for the generator set.

Power Type displays the programmer enteredgenerator set application configuration as Standby orPrime.

Battery Voltage displays the engine electrical system12 or 24 volts.

Measurement System displays the user selected unitof measure as Metric or English.

Contrast displays user selected resolution values toimprove digital display clarity.

Alarm (Horn) Silence displays the programmerselected alarm silence method as Always or Auto OnlyusingSiteTecht software. TheAlways selection allowsthe alarm to be silenced in any of theOFF/RESET--AUTO--RUN modes. The Auto Onlyselection allows silencing of the alarm only while in theAuto mode.

Note: Press the Alarm Silence/Lamp Test button tosilence the alarm horn.

Manual Speed Adjust (Engine RPM) is available as auser selectable adjustment. The user can set thenominal running frequency slightly above or below theutility frequency to ensure that synchronization occurs.Refer to 2.7.7 GenSet System for more information.Available as a factory-installed option or requires a newfactory personality profile.

Generator Set (Reset) Calibration Menu

This menu is only available in controller firmwareversions before 3.0.25. Go to Generator MeteringMenu—Reset Calibration with controller firmwareversion 3.0.25 and higher.

The calibration values are reviewable at all times andprovide the calibration of the voltage and currentsensing logic. Changing thesystemvoltageor replacingthe circuit board requires a calibration adjustment. Inorder to review the values when the generator set is

NOT running, enter Yes when the Enter Calib? isdisplayed. The user can review the values butattempting to change the values will cause a Cannotcalibrate error message.

If the unit is NOT running and No is entered when theEnter Calib? is shown, the display returns to theGenerator Set Calibration main menu and entry to theGenerator Set Calibration menu is denied.

If the unit is running and Yes is entered when the EnterCalib? is shown, the display will show the followingvalues for three-phase generator sets. Single-phasegenerator sets will only display items marked (*).


The user can change individual values or can enter Yeswhen Reset all Calib? is displayed. At the end of theGenerator Set Calibration menu, Exit calibration isshown. Press the pushbutton/rotary selector dial to exitthis menu. Refer to the requirements shown withGenerator Set Calibration in 2.4.7 Status and NoticeDigital Displays.

Voltage Regulator Menu

Controller firmware before 3.0.25.

The voltage regulator value is reviewable at all times. Inorder to review the value when the generator set is NOTrunning, enter Yeswhen theEnter volt reg? is displayed.The user can review the value but attempting to changethe value will cause a Cannot edit when stopped errormessage.

If the unit is NOT running and No is entered when theEnter volt reg? is shown, the display returns to theVoltage Regulator main menu and entry to the VoltageRegulator menu is denied.

If the unit is running and Yes is entered when the Entervolt reg? is shown, the display will show the value.

The user can change the value at this time. At the end ofthe Voltage Regulator menu, Exit voltage reg isshown----press thepushbutton/rotaryselector dial toexitthis menu.


Controller firmware 3.0.25 and higher.

The voltage regulator value is reviewable at all timesand provides the ability to fine adjust voltage. Changingthe system voltage or replacing the circuit boardtypically requires a voltage adjustment.

To enable calibration, start the generator set and selectthe VR Volt Adj display. Then push and hold thepushbutton/rotary selector dial until theEditing Enabledpopupappears. Editingof the voltageadjustment isnowavailable.

The user can change the individual value or can selectReset VR?--Yes to reset to the default value. TheResetVR Settings display will only show if editing is enabled.


Digital Inputs Menu

This menu allows the user to review the settings. Thereare up to three digital inputs that are programmerselectable if not reserved by factory options.

The displays for digital inputs appear as shown belowwith Values true or false. Items shown in the digitaldisplay as True are active.

D DIn A1 (digital input A1) standardD DIn A2 (digital input A2) standardD DIn A3 (digital input A3) standardD DIn B1 (digital input B1) with I/O module boardD DIn B2 (digital input B2) with I/O module boardChanges to the Digital Inputs menu requires the use ofSiteTecht software. Thedigital input caneither openorclose the circuit to activate.

Digital Outputs Menu

This menu allows the user to review the settings. Thereis one digital output standard with the controller that isprogrammer selectable. The one SPDT switch has2 amp. contacts at 32 VDC or 0.5 amp. contacts at120 VAC max.

There is an optional 2 input/5 output (I/O) module boardavailable that can provide five digital outputs. Thestandard digital output on the controller is used to drivethe optional I/O Module board and becomes factoryreserved and no longer available as programmerselectable.

The displays for digital outputs appear as shown in thefollowing list with Values as True or False. Items shownin the digital display as True are active.

D DOut A1 (digital output A1) standardD DOut B1 (digital output B1) with I/O module boardD DOut B2 (digital output B2) with I/O module boardD DOut B3 (digital output B3) with I/O module boardD DOut B4 (digital output B4) with I/O module boardD DOut B5 (digital output B5) with I/O module board

Changes to theDigital Outputsmenu requires the useofSiteTecht software. The digital output can either openor close the circuit to activate.

Analog Inputs Menu

This menu allows the user to review the settings. Thereis one analog input that is programmer selectable if notreserved by factory options.

There is an optional 2 input/5 output (I/O) module boardavailable that can provide two additional analog inputs.

The displays for analog inputs appear as shown belowwith Values of 0--5 volts.

D AIn A1 (analog input A1) standard(reserved and not user programmable)

D AIn A2 (analog input A2) standardD AIn B1 (analog input B1) with I/O module boardD AIn B2 (analog input B2) with I/O module board

Changes to the Analog Inputs menu requires the use ofSiteTecht software.

Event Log Menu

Thismenuallows theuser to reviewup to1000entriesofsystem events including shutdown faults, warningfaults, and status events. See 1.2.4 Controller FaultDiagnostics for a list of the items that appear on theEvent Log.

Volt Select Menu

This menu is only available in controller firmwareversion 2.8.22 and higher.

Note: The generator set must be stopped beforechanging the voltage selection.

This menu allows the user to readily change controllervoltage settings. The volt select feature is typically usedin towable or temporary applications.

Note: The volt select menu requires initial activation bySiteTecht software. In SiteTecht software,select True to activate the volt select menu.


Note: The generator set output leads require voltagereconnection if the generator set does not have avoltage selector switch installed.

With the generator set stopped, go to the Volt Selectmenu. Then push and hold the pushbutton/rotaryselector dial until the voltage selection starts to flash.Volt selection is now available. Scroll to the desiredvoltage and momentarily press the pushbutton/rotaryselector dial to confirm the voltage selection.

The displays for Volt Select appear as shown in thefollowing list.

D 120/240 V 1 PhD 120/208 V 3 PhD 139/240 V 3 PhD 277/480 V 3 PhD 120/240 V 3 Ph

1.2.4 Controller Fault Diagnostics

This table provides descriptions of the system eventsand their types—warning, shutdown, status, and notice.

Warnings show yellow fault lamp and signal animpending problem. Shutdowns show red fault lampand stop the generator set. Status is an event that is notan alert but is part of the event history. Notice is an alertthat is NOT part of the event history. System events areavailable as a Relay Output as shown.

Throughout this manual there are examples of thedisplay text. In some cases, the message words andphrases are abbreviated or shortened to accommodatethe number of characters in the 12 x 2 digital display.See the following table for a full descriptionof thesystemevent display messages.

System Events Display Message List

Description Display MessageWarningFunction

ShutdownFunction

Status/Notice

RelayOutput

Engine Functions

Critically high fuel level (diesel-powered models only) * Fuel Level Critically High X X

ECM communications loss ECM Comm Err Shutdwn X X

ECM diagnostics (multiple inputs) [ ECM xxxxxx Warning X X

ECM diagnostics (multiple inputs) [ ECM xxxxxx Shutdwn X X

ECM faults (address conflict) ECM Addr Err Shutdwn X X

ECM faults (model mismatch) ECM Mismatch Shutdwn X X

Engine over speed Eng Speed High Shutdwn X] X

Engine start aid active Starting Aid Notice N X

Engine under speed Eng Speed Low Shutdwn X X

Fuel tank leak * Fuel Leak Warning X X

Fuel tank leak * Fuel Leak Shutdwn X X

High battery voltage Battery High Warning X X

High coolant (engine) temperature Coolnt Temp High Warning X X

High coolant (engine) temperature Coolnt Temp High Shutdwn X] X

High fuel level (diesel-powered models only) * Fuel Level High Warning X X

Loss of fuel Loss of fuel X X

Low battery voltage Battery Low Warning X X

Low coolant level * Coolant Lvl Low Shutdwn X X

Low coolant temperature Coolant Temp Low Warning X X

Low cranking voltage Lo Crank Vlt Warning X X

Low engine oil level * Oil Level Low Warning X X

Low engine oil level * Oil Level Low Shutdwn X X

Low fuel level (diesel models) * Fuel Level Low Warning X X

Low fuel level (diesel models) * Fuel Level Low Shutdwn X X

Low fuel pressure (gas models) * Fuel Press Low Warning X X

Low oil pressure Oil Press Low Warning X X

Low oil pressure Oil Press Low Shutdwn X] X

No coolant temperature signal Temp Sig Loss Shutdwn X X

No oil pressure signal Press Sig Loss Shutdwn X X

Overcrank Over Crank Shutdwn X] X

Speed sensor fault Spd Sens Flt Warning X X


DescriptionRelayOutput

Status/Notice

ShutdownFunction

WarningFunctionDisplay Message

General Functions

Alarm horn silenced (Alarm Silence LED only) X

Alarm silence, auto only (NFPA 110) or always AlrmSilence: Auto Only orAlrmSilence: Always S No

Aux. inputs 0--5 VDC, 1 analog(2 additional inputs available with I/O module option) Aux Input Warning X X

Aux. inputs 0--5 VDC, 1 analog(2 additional inputs available with I/O module option) Aux Input Shutdwn X X

Auxiliary inputs, up to 3 digital(2 additional inputs available with I/O module option) Aux Input Warning X X

Auxiliary inputs, up to 3 digital(2 additional inputs available with I/O module option) Aux Input Shutdwn X X

Backup parameters loaded Backup Pars Status S No

Battery charger fault * Batt Chg Flt Warning X X

Chicago code active Auto Locked Notice N X

Common fault (includes ]) Common Fault Shutdwn X N X

Common warning fault Common Warng X N X

Default parameters loaded Default Pars Warning X X

Emergency stop Emerg Stop Shutdwn X] X

Engine cooldown (delay) active Eng Cooldown Notice N X

Engine start delay active Start Delay Notice N X

Engine started Engine Start Status S X

Engine stopped Engine Stop Status S X

EPS supplying load Emerg Pwr On Notice N X

File system error (controller fault) File Error Shutdwn X X

Generator running Gen Running Notice N X

Input/output (module option board) communication loss OB1 Com Loss X X

Internal failure Intern Error Shutdwn X X

Metering communication loss MeterCommLos Shutdwn X X

NFPA 110 alarm active NFPA Alarm Notice N X

Not in auto (master switch) Not In Auto Warning X X

Remote start Remote Start Status S X

System ready System Ready Status S X

System timer failed Timer Error Notice N X

Generator Functions

AC sensing loss AC Sens Loss Warning X X

AC sensing loss AC Sens Loss Shutdwn X X

Alternator protection Alt Protect Shutdwn X X

Ground fault input * Ground Fault Warning X X

kW overload Total Power High Shutdwn X X

Locked rotor (failed to crank) Locked Rotor Shutdwn X X

Overfrequency Freq High Shutdwn X X

Overvoltage (each phase) Volts xx--xx High Shutdwn X X

Underfrequency Frequency Low Shutdwn X X

Undervoltage (each phase) Volts xx--xx Low Shutdwn X X

(Voltage) regulator communication loss RegCommLoss Shutdwn X X

* Function requires optional input sensors or kits or is engine ECM dependent on some generator set models.[ ECM inputs are engine manufacturer dependent.] The Common Fault Shutdown includes the items marked X] in the Shutdown Function column.


1.2.5 Digital Display Circuit Board andConnections

The digital display circuit board provides:

D The backlit LCD (liquid crystal display) for monitoringthe generator set functions and output values

D Master control switches with status lightsD Fault lampD Pushbutton/rotary selector dial to navigate thegenerator set displays

D Alarm horn and alarm silence/lamp test switch/lightD Mini USB connector for PC setup using SiteTechtsoftware

See Figure 1-3 for the circuit board connections.

Circuit Board Connections

P9 Connector the 24-pin connector attaches directly tothe main logic circuit board.

P10 Connector mini USB for PC upgrades located onthe front panel using SiteTecht software.

P11 Connector is a 20-pin connector (not used).

1. P9 24-pin connector (opposite side) connects to main board2. P10 5-pin mini USB connector3. P11 20-pin connector (not used)

GM65741-

1

23

Figure 1-3 Digital Display Circuit Board Connectors

1.2.6 Main Logic Circuit Board

Themain logic circuit board provides the terminal stripsand connection sockets to connect the controller to theengine/generator, input/output connections, optionalI/O module kit, and circuit protection fuses. SeeFigure 1-4 and Figure 1-5 for the circuit boardconnections. See Section 6, Accessories for moreinformation.

1. Main logic circuit board2. Remote emergency stop switch

GM65741-

12

Figure 1-4 Main Circuit Board and Emergency StopSwitch

Circuit Board Connections

P1 (24-Pin) Connector for engine/generator wiringharness.

P2 (6-Pin) Connector for AC current.

(4) Push-on Connectors for V7/V8/V9/V0 forgenerator set output voltage connection.


1. (4) push-on terminal connectors2. TB2 4-position terminal block3. TB3 6-position terminal block4. P2 6-pin connector5. P1 24-pin connector6. TB1 6-position terminal block7. P22 3-pin connector8. P30 jumper (Wound Field or Fast Response)9. P23 8-pin connector (RJ45)10. P21 6-pin connector (for RS-485 communication)

GM64345-1-A

1

2

3

4

56

10

7

9

8

Figure 1-5 Main Circuit Board Connectors

P21 (6-Pin) Connector for (RS-485) connection ofoptional RSA or Modbusr communication.

P22 (3-Pin)Connector for engineECM. AlternateCANconnection.

P23 (8-Pin) Connector (RJ45) for optional input/output(I/O) module circuit board.

Refer to Section 6.2, Accessory Connections forspecific connections of the following terminal blockconnections.

TB1 (6-Position) Terminal Block for analog and digitalinputs.

TB2 (4-Position) Terminal Block for K1 relay outputs.

TB3 (6-Position) Terminal Block for E-stop, remotestart contacts, and aux. input connections.

1.2.7 Terminal Jumper

A circuit board P30 jumper is set based on alternatortype—Wound Field (300 kW and larger) orFast Response (less than 350 kW). The jumper isfactory set and needs no further adjustment. SeeFigure 1-5 for location of the P30 jumper.

1.2.8 Communication Ports

The main logic circuit board contains a single mini USBcommunicationport forPCconnections, seeFigure 1-6.For Modbusr communication using RS-485, seeFigure 1-5 (P21). Refer to the List of Related Materialsin the Introduction for corresponding SiteTechtsoftware and/or communication installation information.

1. Mini USB connectionGM65741-

1

Figure 1-6 Communication Port

1.2.9 Fuses

AC Circuit Fuses (TB5). Fuses are located inside thegenerator set control box. See Figure 1-7

D 1.5-Amp (V7) fuse protects L1 sensing input tointerconnection circuit board.



DC Circuit Fuses are located on the controller circuitboard. See Figure 1-8.

D 1-Amp (F1) auto-resettable, fuse protects thecontroller circuits.

D 1-Amp (F2) auto-resettable fuse protects thecontroller circuits.

D 12-Amp (F3) non-replaceable fuse protects theengine/starting circuitry and accessories.



1. V7/V8/V9 fuses, 1.5 Amp. (qty. 3)

GM694071

Figure 1-7 AC Circuit Fuses in Control Box

1. F1 1 Amp. auto-resettable2. F2 1 Amp. auto-resettable3. F3 12 Amp. non-replaceable

GM64345-C

1

2

3

Figure 1-8 Controller DC Fuses

1.3 Controller Logic Specifications

Thecontroller logic specifications section is anoverviewof the various features and functions of the controller.Certain features function only when optionalaccessories are connected. See Section 2, Operation,for details.

The default selection time delays and digital outputs arefactory set and adjustable. Data entries require using aPC and SiteTecht software. See the SiteTechtsoftware operation manual for details.

Inhibit Time Delay. The inhibit time delay is the timeperiod following crank disconnect during which thegenerator set stabilizes and the controller does notdetect a fault or status event. Select the desired inhibittime delay from 0 to 60 seconds.

TIme Delay (Shutdown or Warning). The time delayfollows the inhibit time delay. The time delay is the timeperiodbetweenwhen thecontroller first detectsa fault orstatus event and the controller warning or shutdownlamp illuminates. The delay prevents nuisance alarms.Select the desired time delay from 0 to 60 seconds.

1.3.1 Status Event and FaultSpecifications

The Factory-Defined Settings List contains all statusevents and faults with ranges and time delays includingitems that do not have user adjustments.

Note: The engine ECMmay limit the crank cycle even ifthe controller is set to a longer time period.


Factory-Defined Settings List

DescriptionController Display

MessageAlarmHorn

FaultLampWarningShutdown

WriteAccessDisplaySiteTech

GenSetModeAlwaysRunningStopped

RangeSetting

DefaultSelection

TimeDelayRange(sec.)

DefaultTimeDelay(sec.)

Engine Functions

Critically high fuel level(diesel-powered models only) *

Fuel Level CriticallyHigh On W 0--100% 95% 0--10 5

ECM communications loss ECM Comm ErrShutdwn On S Fixed 10

ECM diagnostics (multipleinputs) [ ECM xxxxxx Warning On W

ECM diagnostics (multipleinputs) [ ECM xxxxxx Shutdwn On S

ECM faults (address conflict) ECM Addr ErrShutdwn On S

ECM faults (model mismatch) ECM MismatchShutdwn On S 0--255 0

Engine over speed Eng Speed HighShutdwn On S S A 105--120% 115%

Engine start aid active Starting Aid Notice

Engine under speed Eng Speed LowShutdwn On S S A 75--95% 85%

Fuel tank leak * Fuel Leak Warning On W

Fuel tank leak * Fuel Leak Shutdwn On S

High battery voltage Battery High Warning On W S A 110--135% 125% Fixed 10

High coolant temperature Coolnt Temp HighWarning On W

0--10(0--30inhibit)

0(0

inhibit)

High coolant temperature Coolnt Temp HighShutdwn On S

0--10(0--30inhibit)

0(0

inhibit)

High fuel level (diesel-poweredmodels only) *

Fuel Level HighWarning On W 0--100% 90% 0--10 5

Loss of fuel Loss of Fuel On S

Low battery voltage Battery Low Warning On W S A 80--105% 100% Fixed 90

Low coolant level * Coolant Lvl LowShutdwn On S Fixed 5

Low coolant temperature Coolant Temp LowWarning On W Fixed

16_C(60_F)

0--10(0--30inhibit)

5(0

inhibit)

Low cranking voltage Lo Crank Vlt Warning On W Fixed 60% Fixed 6

Low engine oil level * Oil Level Low Warning On W

Low engine oil level * Oil Level Low Shutdwn On S

Low fuel level (diesel models) * Fuel Level LowWarning On W 0--100% 35% 0--10 10

Low fuel level (diesel models) * Fuel Level LowShutdwn On S 0--100% 5% 0--10 0

Low fuel pressure(gas models) *

Fuel Press LowWarning On W

Low oil pressureOil Press Low Warning On W

Fixed(Fixedinhibit)

0(30

inhibit)

Low oil pressure Oil Press LowShutdwn On S

Fixed(Fixedinhibit)

5(30

inhibit)

No coolant temperature signal Temp Sig LossShutdwn On S

No oil pressure signal Press Sig LossShutdwn On S Fixed 5

OvercrankOver Crank Shutdwn On S Fixed

(30inhibit)

Speed sensor fault Spd Sens Flt Warning On W


Description



DefaultSelection

RangeSetting




AlarmHorn

Controller DisplayMessage

General Functions

Alarm silence, 0--Auto only(NFPA 110), 1--Always AlarmSilenceMode S A 0--1 1

Aux. inputs 0--5 VDC, 1 analog Aux Input Warning On W 0--100% 100% 0--10 0

Aux. inputs 0--5 VDC, 1 analog Aux Input Shutdwn On S 0--100% 100% 0--10 0

Auxiliary inputs, up to 3 digital(2 additional digital inputsavailable with I/O moduleoption)

Aux Input Warning On W0--10(0--30inhibit)

0 (0inhibit)


Aux Input Shutdwn On S0--10(0--30inhibit)

0 (0inhibit)

Backup parameters loaded Backup Pars Status

Battery charger fault * Batt Chg Flt Warning On W

Chicago code active * Auto Locked Notice

Common fault Common FaultShutdwn On S

Common warning Common Warng On W

Default parameters loaded Default Pars Warning On W

Emergency stop Emerg Stop Shutdwn On S

Engine cooldown (delay) active Eng Cooldown Notice

Engine start delay active Start Delay Notice

Engine started Engine Start Status

Engine stopped Engine Stop Status

EPS supplying load Emerg Pwr On Notice

File system error (controllerfault) File Error Shutdwn On S

Generator running Gen Running Notice

Input/output (optional moduleboard) communication loss OB1 Com Loss On W

Internal failure Intern Error Shutdwn On S

Measurement Units,0--English, 1--Metric Measurement Display DS A 0--1 1

Metering communication loss MeterCommLosShutdwn On S

NFPA 110 alarm active NFPA Alarm Notice

Not in auto (master controlbuttons) Not In Auto Warning On W

Prime power application,0--Standby, 1--Prime Power Type DS A 0--1 0

Remote start Remote Start Status

System ready System Ready Status

System timer failed Timer Error Notice

Generator Functions

AC sensing loss AC Sens LossWarning On W

AC sensing loss AC Sens LossShutdwn On S Fixed 3

Alternator protection Alt Protect Shutdwn On S

Ground fault input * Ground Fault Warning On W

kW overloadTotal Power High

Shutdwn On S Fixed

102%standby,112%prime

Fixed 60

Locked rotor (failed to crank) Locked Rotor Shutdwn On S S A 1--5 5

Overfrequency Freq High Shutdwn On S 102--140% 110% Fixed 10


Description



DefaultSelection

RangeSetting




AlarmHorn


Overvoltage (each phase) Volts (L1--L2, L2--L3,or L3--L1) High

ShutdwnOn S S A 105--135% 120% 2--10 2

Power rating Pwr Rating DS S 10--5000 275

System frequency System Freq DS S 50--60 60

System voltage System Volt DS S 110--600 208

Underfrequency Frequency LowShutdwn On S 80--95% 90% Fixed

10 ST60 LT

Undervoltage (each phase) Volts (L1--L2, L2--L3,or L3--L1) Low

ShutdwnOn S S A 70--95% 80% 5--30 10

Voltage/phase configuration,0--Single phase, 1--Singlephase dogleg, 2--three phasewye, 3--three phase delta

SystemPhase DS S 0--3 2

Voltage regulator averagevoltage adjustment VR Volt Adj DS R 108--600 208

(Voltage) regulatorcommunication loss

RegCommLossShutdwn On S

SiteTech Read/Write Display Only

Current transformer ratio ] S S 1-- 1200

ECM power S S 0--1 0

Engine cooldown delay S A 0--600 300

Engine (cyclic) crank on S A 10--30 15

Engine (cyclic) crank pause S A 1--60 15

Engine ECM start delay S A 0--300 0

Engine idle duration S A 0--60 60

Engine no. of (cyclic) crankcycles S S 1--6 3

Engine restart delay S A 1--10 10

Engine start aid delay S A 0--10 0

Engine start delay S A 0--300 0

System battery voltage ] S S 12--24 12

Voltage regulator gain S R 1--255 128

Voltage regulator stabilityadjust S R 1--255 128

Voltage regulator, volts perHertz slope S R 1--10 5

Voltage regulator, volts perHertz cut in frequency S R 42--62 57.5

* Function requires optional input sensors or is engine ECM dependent on some generator set models.[ ECM inputs are engine manufacturer dependent.] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).ST--Short Term, LT--Long Term


1.3.2 Voltage Regulator and CalibrationSpecifications

The controller has a voltage regulation function that isinternal to the processor. This means that no externalvoltage regulator is necessary. The voltage regulationof the controller uses root mean square (rms) sensingfor fast response to changes in indicated and regulatedvoltages resulting in excellent regulation accuracy.

1.3.3 Voltage Regulator Adjustments

The descriptions of the voltage regulator adjustmentsand features follow. Refer to the Factory-DefinedSettings List shown in 1.3.1 for voltage regulatoradjustments. See Appendix C, Voltage RegulatorDefinitions and Adjustments, for additional informationand to customize adjustments for specific applications.

Voltage Adjustment. The voltage adjustment allowsthe user to enter the desired generator set output level.This regulated level setting is the average of the threeline-to-line voltages in three-phase configurations orL1-to-L2 in single phase configurations.

Submenus display the individual line-to-line voltages.These voltages are for reference only and are relevantin unbalanced load conditions. The voltage adjustsetpoint can be changed to accommodate an importantphase in an unbalanced system.

Underfrequency Unload Frequency Setpoint. Thisadjustmentaffects thevoltagedroop (voltsperHz)whenload is applied and underfrequency occurs. Theunderfrequency unload setting defines the setpointwhere underfrequency starts. Any frequency below thesetpoint causes the voltage to drop thus reducing theload allowing the engine speed to recover according tothe underfrequency unload slope setting.

Engine speed recovery depends upon characteristicssuch as engine make, fuel type, load types, andoperating conditions. The underfrequency unloadsetting should match the engine speed recoverycharacteristics for the application.

Underfrequency Unload Slope. This settingdetermines how much the voltage drops during anunderfrequency condition. Typically, applying a largeelectrical load causes a dip in engine speed andfrequency. The voltage regulator reduces voltage,allowing engine speed recovery. The volts-per-Hzsetting determines the amount of voltage drop.

RegulatorGain. Regulator gain refers to the gain of thecontrol system. Generally, the higher the gain the fasterthe system responds to changes and the lower the gain,the more stable the system.

If the voltage is slow to recover when loads are appliedor removed, increase the regulator gain. If the voltage isunstable, decrease the regulator gain.

TP-6694 11/15 29Section 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 requireverification after the unit starts.



Moving parts.

WARNING

Air Cleaner. Check for a clean and installed air cleanerelement to prevent unfiltered air from entering engine.

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consultthe battery manufacturer’s instructions regardingbattery care and maintenance.

CoolantLevel. Check thecoolant level according to thecooling system maintenance information.

Note: BlockHeater Damage. The block heater will failif the energized heater element is not immersedin coolant. Fill the cooling system before turningon the block heater. Run the engine until it iswarm, and refill the radiator to purge the air fromthe system before energizing the block heater.

DriveBelts. Check the belt condition and tension of theradiator fan, water pump, and battery chargingalternator belt(s) according to the drive belt systemmaintenance information.

Exhaust System. Check for exhaust leaks andblockages. Check the silencer and piping condition andcheck for tight exhaust system connections.

Inspect the exhaust system components (exhaustmanifold, exhaust line, flexible exhaust, clamps,silencer, and outlet pipe) for cracks, leaks, andcorrosion.

D Check for corrodedor brokenmetal parts and replacethem as needed.

D Check for loose, corroded, or missing clamps andhangers. Tighten or replace the exhaust clampsand/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Checkfor carbon or soot residue on exhaust components.Carbon and soot residue indicates an exhaust leak.Seal leaks as needed.

Fuel Level. Check the fuel level and keep the tank(s)full to ensure adequate fuel supply.

Oil Level. Maintain the oil level at or near, not over, thefull mark on the dipstick.

Operating Area. Check for obstructions that couldblock the flow of cooling air. Keep the air intake areaclean. Do not leave rags, tools, or debris on or near thegenerator set.

2.2 Exercising Generator Set



Moving parts.

WARNING

Operate the generator set under load once each weekfor one hour. Perform the exercise in the presence of anoperator when the generator set does not have anautomatic transfer switch with an exercise option.

During the exercise period, apply a minimum of 35%load based on the nameplate standby rating, unlessotherwise instructed in the engine operation manual.

The operator should perform all of the prestart checksbefore starting the manual exercise procedure. Startthe generator set according to the starting procedure inSection 2.4, Controller Operation. While the generatorset is operating, listen for a smooth-running engine andvisually inspect generator set for fluid or exhaust leaks.

The generator set controller does not provide weeklyscheduled exercise periods. For scheduled exerciseperiods, refer to the automatic transfer switch (ifequipped) literature.

TP-6694 11/1530 Section 2 Operation

2.3 Operation in Cold WeatherClimates

Coldweather operation isgenerally consideredambienttemperatures below freezing 0C (32F). The followingitemsare recommended for coldweather startingand/oroperation when the unit is located in an enclosure orunheated structure. Have a licensed electrician install120 VAC, 15 amp outlets as needed if not already in theimmediate area.

Refer to the engine operation manual regarding engineoil viscosity, fuel composition, and coolant mixturerecommendations.

D The engine block heater is generally recommendedfor most units when operated below 0C (32F) andrequired as part of NFPA 110. Refer to the respectivespec sheet for temperature recommendations inavailable options.

D Abattery heater is generally recommended formostunits when operated below 0C (32F). Refer to therespective spec sheet for model availability.

D An alternator strip heater is available for mostgenerator sets providing a heat source to preventmoisture and frost buildup.

D The crankcase ventilation (CCV) heater kitprovidesa controlledheating source to the crankcaseventilation system preventing freezing water buildupduring cold weather. The thermostat turns on at 4_C(40_F) and turns off at 16_C (60_F). Refer toSection 3, Scheduled Maintenance for moreinformation. (Applies to 125/150 kW, 8.1 L GM- and8.8 L PSI- powered generator set models only.)

D Heater tape is recommendedwhen the generator setis equipped with a closed crankcase ventilation

system and operated at or below 50% of rated load.Wrap the UL/CSA compliant heater tape around thecrankcase canister/breather system hose that runsfrom the crankcase to the air intake and use cable tiesas needed to secure the heater tape. If the heatertape is within 152 mm (6 in.) of the exhaust system,use thermal insulation material to protect the heatertape.

40--60REOZK Models only. When the ambienttemperature drops below --15_C (5_F) a turbochargerpre-lube sequence begins when the crank cycle isinitiated. During the first 10secondsof cranking, the fuelsystem is disabled to ensure engine oil is present at theturbocharger. This is necessary for the longevity of theturbocharger on the KDI 3404TM engine. The fuelsystem is then enabled for the next 5 seconds of cycliccranking and the engine will start as normal.

2.4 Controller Operation

The controller operation includes several types ofstarting and stopping functions as detailed in thefollowing paragraphs. The controller master controlswitch buttons, lamps, and alarm horn functions aresummarized in Figure 2-1.

2.4.1 Starting

Local Starting

Press the master control RUN button to start thegenerator set at the controller.

Note: The alarm horn sounds and the Not-In-AutoWarning display appears whenever thegenerator set master control button is not in theAUTO mode.

Button ModeGenerator Set

StatusButtonLamp Fault Lamp

AlarmHorn

Alarm SilenceButton *

Alarm SilenceLamp Controller Display

AUTO

Off

Green

— Off — — Scrolling Overview MenuOnlyOn (or Cranking) — Off — —

Running and thenOff Red

On — —Shutdown Message

Off Pressed Yellow

OFF/RESET Off Red YellowOn — —

Not In Auto WarningOff Pressed Yellow

RUN(unit fails to start)

Off (or Cranking)

Yellow

YellowOn — —

Not in Auto WarningOff Pressed Yellow

Off RedOn — — Locked Rotor Shutdown (or

other shutdown message)Off Pressed Yellow

RUN(unit starts)

Off (or Cranking)Yellow Yellow

On — —Not in Auto Warming

On Off Pressed Yellow

Running and thenOff Yellow Red

On — —Shutdown Message

Off Pressed Yellow

* Alarm silence only works when in the Auto mode unless the Always selection is made using SiteTecht.Refer to 2.7.7 GenSet System for more information.

Figure 2-1 Master Control Button Function Summary


Note: The transient start/stop function of the controllerprevents accidental cranking of the rotating engine.The generator set stops and recranks when theOFF/RESET button is momentarily pressed andthen the RUN button is pressed.

Auto Starting

Press the master control AUTO button to allow startupby the automatic transfer switch or remote start/stopswitch (connected to controller terminals 3 and 4).

Terminals 3 and 4 connect to a circuit that automaticallystarts the generator set crank cycle when an externalsource closes the circuit.

Note: The controller provides up to 30 seconds ofprogrammable cyclic cranking and up to60 seconds rest with up to 6 cycles. The defaultsetting is 15 seconds cranking and 15 secondsrest for 3 cycles. Make cyclic crankingadjustments using SiteTecht software.

Prime Power Switch

The controller has an optional prime power mode ofoperation. The prime power mode requires installationof an optional prime power switch kit. See Section 6,Accessories, for instructions on how to install theoptional primepower switch kit. Theprimepower switchkit prevents engine starting battery drain when thegenerator set is shut down and no external batterycharging is available.

Move theprimepower switch locatedon the junctionboxto the CONTROLLER ON position before attempting tostart the generator set. When the prime power mode isoff, all controller functions including the digital display,LEDs, and alarm horn are operative.

Stop the generator set using the stopping procedures inSection 2.4.2 before placing the generator set in theprime power mode. Move the prime power switchlocated on the junction box to the CONTROLLER OFFposition. When the generator set is is the prime powermode, all controller functions including the digitaldisplay, LEDs, alarm horn, and communications areinoperative.

2.4.2 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 control button is in theAUTO mode. To stop the generator set, press thegenerator set master control OFF/RESET button andwait until the generator set comes to a complete stop.

Note: The cooldown cycle times out before thegenerator set stops when a remote switch orautomatic transfer switch initiates the generatorset start/stop sequence.

Emergency Stopping

Use the controller emergency stop switch or optionalremote emergency stop for immediate shutdown.

The emergency stop switch bypasses the time delayengine cooldown and immediately shuts down thegenerator set.

Note: Use the emergency stop switch(es) foremergency shutdowns only. Use the generatorsetmaster control OFF/RESET button for normalshutdowns.

The controller fault lamp lights and the unit shuts downwhen the local or remote emergency stop switchactivates.

2.4.3 Emergency Stop Switch Resetting

Use the following procedure to reset the generator setafter shutdown by a local or remote emergency stopswitch. Refer to Section 2.4.8, Controller Resettingprocedure, to restart the generator set following a faultshutdown.

1. Investigate and correct the cause of theemergency stop.

2. Reset the optional remote emergency stop switch byreplacing theglasspiece,whenequipped. Additionalglass rods are available as a service part. Reset thecontroller emergency stop switch by pulling theswitch dial outward.

3. Press the generator set master controlOFF/RESET button.

4. After resetting all faults using the controller resetprocedure inSection 2.4.8, press thegenerator setmaster control RUN or AUTO button to restart thegenerator set. The generator setwill not crankuntilthe reset procedure completes.


2.4.4 System Status Lamps

The (OFF/RESET--AUTO--RUN)master control buttonsindicate the status condition with an integrated lamp atthe button.

The green lamp illuminates on themaster control AUTO(automatic start) button indicating the systemsensesnofaults and the unit is ready to start by remote command.

The red lamp illuminates on the master controlOFF/RESET button indicating the generator set isstopped.

The yellow lamp illuminates on the master control RUNbutton indicating thegenerator set is crankingor runningfrom a local command.

Only one of the three master control button lamps willilluminate at any given time.

2.4.5 System Fault Warning Lamp withDigital Displays

The system FAULT lamp glows yellow and the alarmhorn sounds indicating a warning fault but does not shutdown the generator set. The fault lamp illuminatesyellow and the alarm horn sounds when the fuel tanklevel on diesel-fueled models approaches empty. Thisfault requires an optional low fuel level switch for thelamp to function. The local display shows Fuel LevelLow Warning. See Section 2.4.8, Controller Resettingprocedure, for instructions on resetting a systemwarning.

When the system warning lamp is on and no messagedisplays, rotate the selector dial to view messages.When the system warning continues, it may lead to afault and cause a system shutdown.

Use the Silence Alarm button to silence the alarm hornat the operator’s discretion.

If the controller is setup for an NFPA 110 application,press the AUTO button before silencing the alarm horn.The alarm horn cannot be silenced unless the mastercontrol button is in the AUTO mode. See 2.4.7 Statusand Notice Digital Displays for more information.

Note: Text shown in italics in this section of the manualrepresents digital display messages.

AC Sensing Loss. The fault lamp illuminates yellowand the alarm horn soundswhen the controller does notdetect the nominal generator set ACoutput voltage aftercrankdisconnect. Thecontroller displaysACSensLossWarning.

Auxiliary Input (Warning). The fault lamp illuminatesyellow and the alarm horn sounds when an auxiliarydigital or analog input signals the controller. The digitalinputs do not function during first the 30 seconds afterstartup. Use SiteTecht software to define inputs asshutdowns or warnings. The local display shows AuxInput Warning.

Battery Charger Fault. The fault lamp illuminatesyellow and the alarm horn sounds when the batterycharger malfunctions. This fault feature requires anoptional battery chargerwithamalfunctionoutput for thelamp to function. Local display shows Batt Chg FltWarning.

Common Warning. The fault lamp illuminates yellowand the alarm horn sounds when the controller issignaled by a common warning. Use SiteTechtsoftware to activate the common warning. The localdisplay shows Common Warng. The common warningcomprises all of the warnings under a single alert.

Critical High Fuel Level (diesel-powered modelsonly). The fault lamp illuminates yellow and the alarmhorn sounds when the fuel tank level on diesel modelsapproaches full. This fault requires an optional criticalhigh fuel switch and fuel tank for the lamp to function.The local display shows Fuel Level Critically High.

Default Parameters Loaded. The fault lampilluminates yellow and the alarm horn sounds when thecontroller detects that the default parameter softwarewas loaded using SiteTecht software. The localdisplay shows Default Pars Warning.

ECMDiagnostics (Multiple Engine Inputs). The faultlamp illuminates yellow and the alarm horn soundswhen ECM diagnostics signals the controller. The localdisplay shows ECM xxxxx Warning. The specificdisplay (xxxxx) will be a brief message or fault code thatis engine manufacturer dependent. The engineliterature provides the fault code description and furtherinformation.

Fuel Tank Leak (diesel-powered models only). Thefault lamp illuminates yellow and the alarm horn soundswhen the fuel tank signals a leak of the inner tank. Thisfault requires an optional fuel tank leak switch for thelamp to function. The local display shows Fuel LeakWarning.

GroundFault. The fault lamp illuminatesyellowand thealarm horn sounds when a user-supplied ground faultdetector signals the controller. The local display showsGround Fault Warning.


HighBatteryVoltage. The fault lamp illuminatesyellowand the alarm horn sounds when the battery voltagerises above the preset level for more than 10 seconds.The local display shows Battery High Warning.Figure 2-2 shows high battery voltage specifications.The high battery voltage feature monitors the batteryand battery charging system in the generator setoperating and off modes.

Engine ElectricalSystem Voltage

High BatteryVoltage Range

High Battery VoltageDefault Setting

12 13.2--16.2 15

24 26.4--32.4 30

Figure 2-2 High Battery Voltage Specs

High Coolant Temperature. The fault lamp illuminatesyellow and the alarm horn sounds when the enginecoolant temperature approaches the shutdown range.Thehigh coolant temperaturewarning does not functionduring the preset inhibit time delay period after startup.The local display shows Coolnt Temp High Warning.

High Fuel Level (diesel-powered models only). Thefault lamp illuminates yellow and the alarm horn soundswhen the fuel tank level on diesel models approachesnear full. This fault requires an optional high fuel switchand fuel tank for the lamp to function. The local displayshows Fuel Level High Warning.

Input/Output Communication Loss. The fault lampilluminates yellow and the alarm horn sounds when thecontroller loses the input/output communication signalfrom the optional I/O module board. The local displayshows OB1 Com Loss.

LowBatteryVoltage. The fault lamp illuminates yellowand the alarm horn sounds when the battery voltagedrops below a preset level for more than 90 seconds.The local display shows Low Battery Warning. SeeFigure 2-3 for low battery voltage specifications.

Engine ElectricalSystem Voltage

Low BatteryVoltage Range

Low Battery VoltageDefault Setting

12 9.6--12.6 12

24 19.2--25.2 24

Figure 2-3 Low Battery Voltage Specs

The lowbattery voltage featuremonitors the battery andbattery charging system in the generator set operatingand off modes. The controller logic inhibits the lowbattery voltage warning during the crank cycle.

LowCoolant Temperature. The fault lamp illuminatesyellow and the alarm horn sounds when the enginecoolant temperature is low. The low coolanttemperaturewarningdoesnot functionduring thepresetinhibit time delay period after startup. The local displayshows Coolant Temp Low Warning.

Low Cranking Voltage. The fault lamp illuminatesyellow and the alarm horn sounds when the batteryvoltage drops below 60% of the nominal voltage (12VDC or 24 VDC) for more than 6 seconds during thecrank cycle. The local display shows Lo Crank VltWarning.

Low Engine Oil Level. The fault lamp illuminatesyellow and the alarm horn sounds because of lowengine oil level. This fault feature requires an optionallowengineoil level sensor for the lamp to function. Localdisplay shows Oil Level Low Warning.

Low Fuel Level (diesel-powered models only). Thefault lamp illuminates yellow and the alarm horn soundswhen the fuel tank level on diesel-fueled modelsapproaches empty. This fault requires an optional lowfuel level switch for the lamp to function. The localdisplay shows Fuel Level Low Warning.

Low Fuel Pressure (gas-poweredmodels only). Thefault lamp illuminates yellow and the alarm horn soundswhen low fuel pressure on gaseous-fueled modelsoccurs. This fault requires an optional low fuel pressureswitch for the lamp to function. The local display showsFuel Press Low Warning.

Low Oil Pressure. The fault lamp illuminates yellowand the alarmhorn soundswhen the engine oil pressureapproaches the shutdown range. The low oil pressurewarning does not function during first the 30 secondsafter startup. The local display shows Oil Press LowWarning.

Not in Auto (Generator Master Control Switches).The fault lamp illuminates yellow and the alarm hornsounds when the generator set master control button isin the RUN or OFF/RESET mode. The local displayshows Not In Auto Warning.

Speed Sensor Fault. The fault lamp illuminates yellowand the alarm horn sounds when the speed signal isabsent for one secondwhile the generator set runs. Thelocal display shows Spd Sens Flt Warning.


2.4.6 System Fault Shutdown LampWith Digital Displays

The system FAULT lamp glows red, the alarm hornsounds, and the unit shuts down to indicate a faultshutdown under the following conditions. See Section2.4.8,ControllerResettingprocedure, for informationonresetting a system shutdown.

Use the AlarmOff button to silence the alarm horn at theoperator’s discretion.

If the controller is setup for an NFPA 110 application,press the AUTO button before silencing the alarm horn.The alarm horn cannot be silenced unless the mastercontrol button is in the AUTO mode. See 2.4.7 Statusand Notice Digital Displays for more information.


AC Sensing Loss. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when thecontroller does not detect the nominal generator set ACoutput voltage for more than 3 seconds after crankdisconnect. The controller displays AC Sens LossShutdwn.

Alternator Protection. The fault lamp illuminates redand the unit shuts down because of an alternatoroverload or short circuit. The local display shows AltProtect Shutdwn. See Appendix D, AlternatorProtection for more information.

Auxiliary Input (Shutdown). The fault lampilluminates red, the alarm horn sounds, and the unitshuts down when an auxiliary digital or analog inputssignals the controller. The digital inputs do not functionduring first the30 secondsafter startup. UseSiteTechtsoftware to define inputs as shutdowns or warnings.The local display shows Aux Input Shutdwn.

Common Fault. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when thecontroller is signaled by a common fault. UseSiteTecht software to activate the common faultshutdown. The local display shows Common FaultShutdwn. The common fault comprises the followingshutdowns under a single alert.

D Emergency stopD Engine over speedD High coolant temperatureD Low oil pressureD Overcrank

ECMAddressConflict. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts down whenthe controller detects an error with the ECM address.The local display shows ECMAddr Err Shutdwn.

ECM Communications Loss. The fault lampilluminates red, the alarm horn sounds, and the unitshuts down when the ECM communication link isdisrupted. The local display shows ECM Comm ErrShutdwn.

ECMDiagnostics (Multiple Engine Inputs). The faultlamp illuminates red, the alarm horn sounds, and theunit shuts down when ECM diagnostics signals thecontroller. The local display shows ECM xxxxxShutdwn. The specific display (xxxxx) will be a briefmessage or fault code that is engine manufacturerdependent. The engine literature provides the faultcode description and further information.

ECMModel Mismatch. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts down whenthe controller detects an error with the ECMmodel. Thelocal display shows ECM Mismatch Shutdwn.

Emergency Stop. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when thelocal or optional remote emergency stop switchactivates. The local display shows Emerg StopShutdwn.

Engine Over Speed. The fault lamp illuminates red, thealarmhorn sounds, and the unit shuts down immediatelywhen the governed frequency on 50 and 60 Hz modelsexceeds the over speed setting. The local displayshows Eng Speed High Shutdwn.

Engine Under Speed. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts downimmediately when the governed frequency on 50 and60 Hzmodelsdropsbelow theunder speedsetting. Thelocal display shows Eng Speed Low Shutdwn.

File System Error. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when theinternal controller diagnostics detect a firmware fileerror. The local display shows File Error Shutdwn.

Fuel Tank Leak (diesel-powered models only). Thefault lamp illuminates red, the alarm horn sounds, andthe uinit shuts down when the fuel tank signals a leak ofthe inner tank. This fault requires an optional fuel tankleak switch for the lamp to function. The local displayshows Fuel Leak Shutdwn.

HighCoolant Temperature. The fault lamp illuminatesred, the alarm horn sounds, and the unit shuts downbecause of high engine coolant temperature. The highcoolant temperature shutdown does not function duringthe preset inhibit time delay period after startup. Thelocal display shows Coolnt Temp High Shutdwn.

Note: The high engine temperature shutdown functionand the low coolant level shutdown function areindependent. A low coolant level condition maynot activate the high engine temperature switch.


Internal Fault. The fault lamp illuminates red, the alarmhorn sounds, and the unit shuts down when the internaldiagnostics detect a controller malfunction. The localdisplay shows Intern Error Shutdwn.

kWOverload. The fault lamp illuminates red, the alarmhorn sounds, and the unit shuts down when thegenerator set supplies more than 102% of the ratedstandby output kW (or 112% of the rated prime poweroutput kW) for more than 60 seconds. The local displayshows Total Power High Shutdwn.

Locked Rotor (failed to crank). If none of the speedsensing inputs show engine rotation within the presettime delay of initiating engine cranking, the ignition andcrank circuits turn off for the preset period and the cyclerepeats. The fault lamp illuminates red, the alarm hornsounds, and the unit shuts down after the second cycleof thepreset periodof cranking. The local display showsLocked Rotor Shutdown.

Loss of Fuel. The fault lamp illuminates red and thealarm horn sounds when the unit shuts down withoutreceiving a signal from the controller to do so. Ondiesel-fueled units this condition includes fuel pumpfailure, loss of fuel prime, and/or an empty fuel tank. Ongaseous-fueled units this condition includes loss of fuelpressure and/or an empty fuel tank. The local displayshows Loss of Fuel.

LowCoolant Level. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down because oflow coolant level. Shutdown occurs 5 seconds after lowcoolant level is detected. Local display shows CoolantLvl Low Shutdwn.

Low Engine Oil Level. The fault lamp illuminates red,thealarmhornsounds,and theunit shutsdownbecauseof low engine oil level. This fault feature requires anoptional low engine oil level sensor for the lamp tofunction. Local display shows Oil Level Low Shutdwn.

Low Fuel Level (diesel-powered models only). Thefault lamp illuminates red, the alarm horn sounds, andthe unit shuts down when the fuel tank level ondiesel-fueled models approaches empty. This faultrequires an optional low fuel level switch for the lamp tofunction. The local display shows Fuel Level LowShutdwn.

Low Oil Pressure. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down because oflow oil pressure. The shutdown occurs 5 seconds afterthe low pressure condition is detected. The low oilpressure shutdown does not function during first the30 seconds after startup. The local display shows OilPress Low Shutdwn.

MegaJector Communications Loss (GM/PSI andDoosan gas-powered models only). The fault lampilluminates red, the alarm horn sounds, and the unitshuts down when the communication link is disrupted.The local display shows MJ Comm Loss.

Metering Communications Loss. The fault lampilluminates red, the alarm horn sounds, and the unitshuts down when the metering to controllercommunication link is disrupted. The local displayshows MeterCommLos Shutdwn.

No Coolant Temperature Signal. The fault lampilluminates red, the alarm horn sounds, and the unitshuts down when the engine coolant temperaturesender circuit is open. The local display shows TempSig Loss Shutdwn.

NoOil PressureSignal. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts down whenthe engine oil pressure sender circuit is open for morethan5seconds. The local display showsPressSig LossShutdwn.

Overcrank. The fault lamp illuminates red, the alarmhorn sounds, and cranking stopswhen the unit does notstart within the defined cranking period. The localdisplay showsOverCrankShutdwn. SeeSection 2.4.1,Auto Starting, andSection 1.3.1, StatusEvent and FaultSpecifications for cyclic crank specifications.

Note: The controller is equipped with an automaticrestart function. When speed drops below 25 Hz(750 rpm) while the engine is running, the unitattempts to recrank. The unit then follows thecyclic crankingcycleand,when theengine fails tostart, will shut down on an overcrank faultcondition.

Overfrequency. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when thefrequency is above the overfrequency setting. The localdisplay shows Freq High Shutdwn. See Figure 2-4.

OverfrequencySetting Range Time Delay

OverfrequencyDefault Setting

102%--140% of nominal 10 sec. 110% of nominal

Figure 2-4 Overfrequency Specs

Overvoltage (Each Phase). The fault lamp illuminatesred, the alarm horn sounds, and the unit shuts downwhen the voltage exceeds the overvoltage setting forthe preset time delay period. The local display showsVolts (L1--L2, L2--L3, or L3--L1) High Shutdwn. SeeFigure 2-5 for overvoltage specifications.


Note: Overvoltage can damage sensitive equipment inless than one second. Install separateovervoltage protection on online equipmentrequiring faster than 2-second shutdown.

OvervoltageSetting Range

Time DelayRange

Overvoltage DefaultSetting

105%--135% ofnominal 2--10 sec. 120% at 2 sec.

Figure 2-5 Overvoltage Specs

Run Relay Overload. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts down whenthe controller smart switch that operates generator setwire number 70 (Run) is overloaded. The local displayshows Run Relay Overload.

Underfrequency. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when thefrequencydropsbelow the underfrequency setting. Thelocal display shows Frequency Low Shutdwn. SeeFigure 2-6 for underfrequency specifications.

Underfreq. SettingRange Time Delay

UnderfrequencyDefault Setting

80%--95% ofnominal 10 sec. (short term) 90% of nominal

Figure 2-6 Underfrequency Specs

Note: The long-term shutdown occurs if the frequencyis 1 Hz or more below the system frequency for60 sec. The long-term shutdown is notadjustable.

Undervoltage. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when thevoltage drops below the undervoltage setting for thetime delay period. The local display shows Volts(L1--L2, L2--L3, or L3--L1) Low Shutdwn. SeeFigure 2-7 for undervoltage specifications

UndervoltageSetting Range Time Delay Range

UndervoltageDefault Setting

70%--95% ofnominal 5--30 sec.

80% of nominal at10 sec.

Figure 2-7 Undervoltage Specs

(Voltage) Regulator Communications Loss. Thefault lamp illuminates red, the alarm horn sounds, andthe unit shuts down when the voltage regulator tocontroller communication link is disrupted. The localdisplay shows RegCommLos Shutdwn.

2.4.7 Status and Notice Digital Displays

Warnings and shutdown faults appear on the digitaldisplay and become part of the event history. Beyondthe warnings and shutdowns there are several eventswhich also appear on the digital display. Status is anevent that is not an alert but is part of the event history.Notice is an alert that is not part of the event history.

The controller allows a selected number of changes bythe user for setting up the controller application whichare covered in this section.


AlarmSilence. This statusmessage indicateswhetherthe alarm horn can be silenced in any button mode(OFF/RESET--AUTO--RUN) or requires the AUTObutton be pressed first compliant per NFPA 110. UseSiteTecht software to change this setting. SeeSection2.4.8,ControllerResettingprocedure, for informationonresetting the system.

The local display shows AlrmSilence: Always when thealarm horn can be silenced with the master controlbuttons in any position (default setting).

The local display shows AlrmSilence: Auto Only whenthe alarm horn can be silenced only when in the AUTOmode.

Backup Parameters Loaded. This status messageindicates that backupparameter firmware is now loadedon the controller using SiteTecht software. The localdisplay shows Backup Pars Status.

Chicago Code Active. This notice message indicatesthat a pass code is required to access the controller.Use SiteTecht software to set up the feature. The localdisplay shows Auto Locked Notice.

Emergency Power System (EPS) Supplying Load.This notice message indicates when the generator setsupplies more than 1% of the rated standby outputcurrent. The local display showsEmerg Pwr OnNotice.

Engine Cooldown (Delay) Active. This noticemessage indicates that the delay for engine cooldown isactive where the generator set will continue to run afterthe OFF/RESET button is pressed. The unit willcontinue to run until the time delay times out. The localdisplay shows Eng Cooldown Notice.

Engine Start Aid Active. This notice messageindicates that the start aid is active and will energize anengine equipped preheat or ether system during thecrank cycle. Use SiteTecht software to set up thisfeature. The local display shows Starting Aid Notice.


Engine Start Delay Active. This notice messageindicates that the delay for engine start is active wherethe generator set will not start right after the RUN buttonis pressed. The unit will start cranking after the timedelay times out. The local display shows Start DelayNotice.

Engine Started. This status indicates that thegenerator set start circuit is closedallowing theengine tocrank and run. The local display shows Engine StartStatus.

Engine Stopped. This status indicates that thegenerator set start circuit is open causing the engine toshut down. The local display showsEngineStopStatus.

Generator Running. This notice indicates that thegenerator set has started and is running. The localdisplay shows Gen Running Notice.

Generator Set Calibration (User Defined). Thisselectable display is in the GenSet Calibration Menuallowing the user to calibrate the controller andgenerator set. Use thePushbutton/Rotary Selector Dialto navigate and select this feature.

Changes to this displaymust be donewith the generatorset running. The local display shows Enter calib? No orYes. Select No to make no change. Select Yes tocalibrate the following values:

D Volts L1--L2: x.x VD Volts L2--L3: x.x VD Volts L3--L1: x.x VD Volts L1--N: x.x VD Volts L2--N: x.x VD Volts L3--N: x.x VD Current L1: x.x AD Current L2: x.x AD Current L3: x.x A

The user can individually calibrate the values above orreset all of them. The local displayReset all calib?No orYes. Select No to make no changes and exit GenSetCalibration. Select Yes to reset all of the values.

When calibrating voltage, the metered value and thenumber being entered as the calibrated value must bewithin 10% of the system operating voltage.

When calibrating current, the metered value must be atleast 25% of the rated current on units smaller than100 kW and at least 50 amps on units rated larger than100 kW. The number being entered as the calibratedvalue must be within 10% of the metered value.

Measurement Units (User Defined). This selectabledisplay is in the GenSet SystemMenu allowing the userto choosebetweenMetric andEnglish displays. Use thePushbutton/Rotary Selector Dial to navigate and selectthis feature. Changes to this display can be done withthe generator set running or stopped. The local displayshows Meas Units: Metric or Meas Units: English.

NFPA 110 Alarm Active. This notice messageindicates that the alarm forNFPA110 is active. The faultlamp illuminates yellow (warning) or red (shutdown), thealarm horn sounds, and the units shuts down (if ashutdown fault is detected) when the NFPA 110 faultsignals the controller. The local display shows therespective faultmessage. TheNFPA110 faults include:

D Battery charger faultD EPS supplying loadD High battery voltageD High coolant temperature shutdownD High coolant temperature warningD High engine speedD Low battery voltageD Low coolant levelD Low coolant temperature warningD Low fuel (level or pressure)D Low oil pressure shutdownD Low oil pressure warningD Master switch not in autoD Overcrank

Remote Start. This status indicates that the generatorset start circuit was closed from a remote locationallowing the engine to crank and run. The remotelocation is typically a set of contacts on a transfer switchor remote start switch. The local display showsRemoteStart Status.

SystemReady. This status indicates that the generatorset is in theAUTOmode and available to start if the startcircuit is closed. The local display shows SystemReady.

System Timer Failed. This notice indicates that thecontroller timer logic has failed to time out a designatedfunction. The local display shows Timer Error Notice.

Voltage Regulator Adjustment (User Defined). Thisfeature is in the Voltage Regulator Menu allowing theuser to fine adjust the output voltage. Use thePushbutton/Rotary Selector Dial to navigate and selectthis feature. Changes to this display must be done withthe generator set running. The local display showsEnter volt reg? No or Yes. Select No to exit the voltageregulator menu. Select Yes to change the local displayVR Volt Adj: xxx.x V.


2.4.8 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.

Refer to Section 2.4.3, Emergency Stop Switch ResetProcedure, to reset the generator set after anemergency stop.

1. Disconnect the generator set load using the linecircuit breaker or automatic transfer switch.

2. Correct the cause of the fault shutdown orwarning.See the Safety Precautions and Instructionssection of this manual before proceeding.

3. Start the generator set by pressing the generatorset master control OFF/RESET button and thenpress the RUN button.

When equipped, the remote annunciator alarmhorn sounds. Press the ALARM SILENCE/LAMPTEST button to stop the alarm horn. The lampturns off.

4. Test operate the generator set to verify correctionof the shutdown cause.

5. Press the generator set master controlOFF/RESET button to stop the generator set.

6. Press the generator set master control AUTObutton.

7. Reconnect thegenerator set load via the line circuitbreaker or automatic transfer switch.

2.4.9 Powering Up the Engine ControlModule (ECM) and Using JohnDeere Diagnostic Tools (JohnDeere-powered models only)

Adapted from Service Bulletin SB-724 10/12.

With firmware version 3.10 and higher, theDecision-Makerr 3000 controller has the capability topower up the engine ECM. The engine ECM power upfeature allows service technicians to access fault codesand other troubleshooting data using their John DeereDiagnostic tools without the need to start the generator

set. Refer to Procedure for Powering Up the EngineECM with Firmware Version 3.10 and Higher following.

If the generator set controller has an earlier firmwareversion, there are twoways to power up the engineECMwithout starting the generator set:

D Use SiteTecht to power up the engine ECM. Referto Procedure for Powering Up the Engine ECM usingSiteTecht for Firmware Versions Before 3.10following.

D Update the firmware to version 3.10 or higher using aPC with SiteTecht software and access Tech Toolsfor the firmware update. Refer to the SiteTechtSoftware Operation Manual TP-6701 as needed.

Use the following information to determine the controllerfirmware version andperform the engineECMpower upprocedure.

Procedure for Checking the Firmware Version

1. Confirm that a fully charged battery is connected tothe generator set.

2. Press the generator set controller OFF/RESETkey.

3. Momentarily press the selector dial to activate thedigital display if dark.

4. Rotate the selector dial counterclockwise tonavigate through the main menus to the OverviewMenu as shown in Figure 2-8.

Overview ---->##.# hr

Figure 2-8 Overview Menu

5. Press the selector dial at the Overview Menu inorder to access the Overview submenus.

6. Rotate the selector dial clockwise to navigate to the(firmware) SW Version submenu as shown inFigure 2-9.

SW Version:3.10

Figure 2-9 SW Version Submenu

7. If firmware version 3.10 or higher appears,continue to Procedure for Powering Up the EngineECM.


Procedure for Powering Up the Engine ECM withFirmware Version 3.10 and Higher

1. If the (firmware) SW Version 3.10 is shown(Figure 2-10), press and hold the selector dial untilthe display screen confirms that the ECM ispowered as shown in Figure 2-11.

SW Version:3.10

Figure 2-10 SW Version 3.10 (or higher) Display

ECMPowered

Figure 2-11 ECM Powered Display

2. After several seconds, the display will change toprovide the option to power down the controller.See Figure 2-12.

ECM poweredPush to Stop

Figure 2-12 ECM Power Down Display

3. If desired, press the selector dial to power down theengine ECM.

OR

Rotate the selector dial to navigate to any of theavailable menus.

Procedure for Powering Up the Engine ECM usingSiteTecht for Firmware Versions Before 3.10

Connect a PC with SiteTecht software to theDecision-Makerr 3000 controller. Refer to theSiteTecht Software Operation Manual TP-6701 asneeded.

Follow the instructions shown in Figure 2-13.

1. Locate Genset System Configuration--ECM Power inSiteTecht

2. Click drop down arrow and select True to power up theengine ECM

SB-7241 2

Figure 2-13 SiteTecht Software Display Screen

2.5 Menu Displays

Use the Menu Summary List section after reading andunderstanding the features of the pushbutton/rotaryselector dial. See Section 1.2.3, Digital Display.

The Menu Summary List provides a quick reference tothe digital display data. Some digital display data maynot be identical to your display due to generator setapplication differences. The closed bullet itemsrepresent main level data and the open bullet items aresub-level data. TheMenuSummary List indicates itemsthat are user selectable. Use SiteTecht software forchanging all other programmable information.


Section 2.7, Reviewing the Menu Displays, provides adigital display menu overview and explains thenavigation using the pushbutton/rotary selector dial.


Menu Summary List (Legend: D First level submenu, d second level submenu)

Voltage RegulatorMenu (Version 3.0.25 orHigher)

D Voltage Regulator VoltageAdjust *

D Reset Voltage RegulatorSettings *d Reset VoltageRegulator?

Digital InputsMenu

D DIn A1D DIn A2D DIn A3D DIn B1 (with I/O Board)D DIn B2 (with I/O Board)

Digital OutputsMenu

D DOut A1D DOut B1 (with I/O Board)D DOut B2 (with I/O Board)D DOut B3 (with I/O Board)D DOut B4 (with I/O Board)D DOut B5 (with I/O Board)

Analog InputsMenu

D AIn A1 (factory reservedand not userprogrammable)

D AIn A2D AIn B1 (with I/O Board)D AIn B2 (with I/O Board)

Event LogMenu

D See 1.2.4 for a list ofitems that can appear inEvent Log

Volt SelectMenu (Version 2.8.22 orHigher)

D Volt Select: *d 120/240 V 1 Phd 120/208 V 3 Phd 139/240 V 3 Phd 277/480 V 3 Phd 120/240 V 3 Ph

D System FrequencyD System Phase (SinglePhase, Single PhaseDogleg, Three PhaseWye, or Three PhaseDelta)

D System VoltsD Power RatingD Amp RatingD Power Type (Standby orPrime)

D Battery DC VoltageD Measurement System(Metric or English) *

D Contrast (display) *D Alarm Silence (Always orAuto Only)

D Manual Speed Adjust(available option)

GenSet CalibrationMenu (Before Version3.0.25)

D Enter Calibration(Yes or No) *d Volts, L1--L2d Volts, L2--L3d Volts, L3--L1d Volts, L1--Nd Volts, L2--Nd Volts, L3--Nd Current, L1d Current, L2d Current, L3d Reset Calibrationd Reset All Calibration(Yes or No)

d Exit Calibration

Voltage RegulatorMenu (Before Version3.0.25)

D Enter Voltage Regulator?(Yes or No) *d Voltage RegulatorAdjust

d Exit Voltage Regulator

OverviewMenu

Generator MeteringMenu

Available as scrolling orfixed display textD Active Shutdowns (ifpresent)

D Active Warnings (ifpresent)

D Genset StateD Average VoltsLine-to-Line

D FrequencyD CurrentD Average kWD Coolant TemperatureD Oil PressureD Fuel Level % (withdiesel-powered modelsand optional fuel tanksender)

D Fuel Pressure (enginedependent)

D Battery DC VoltageD Engine Run TimeD Software Version

Engine MeteringMenu

D Engine Speed(Tachometer)

D Oil PressureD Coolant TemperatureD Fuel Level (withdiesel-powered modelsand optional fuel tanksender)

D Battery DC VoltageD Fuel Pressure (enginedependent)

D Total Power kVA (shownas actual output values)

D Total Power kW (shownas actual output values)

D Rated PowerD Volts, L1--L2 *D Volts, L2--L3 *D Volts, L3--L1 *D Volts, L1--N *D Volts, L2--N *D Volts, L3--N *D Current, L1 *D Current, L2 *D Current, L3 *D FrequencyD Reset Calibration (Usercan reset individual voltand current values orreset all values)

GenSet InformationMenu

D Generator Set Model No.D Generator Set Serial No.D Controller Serial No.

GenSet Run TimeMenu

D Engine Run TimeD Engine LoadedD Engine StartsD Total Energy kWh

GenSet SystemMenu

* User-Defined (changeable) Menu Displays. Use SiteTecht software to change other settings including User-Defined Menu Displays.

NOTE: Some changes require activating the calibration or adjustmentmode. Some displaysmay only appear when in the calibration or adjustmentmode. Refer to Section 2.7 Reviewing Menu Displays to activate the calibration or adjustment mode.


2.6 Monitoring and ProgrammingSetup

The user programmer can access the controller datawith the controller digital display or a personal computer(PC)with optionalSiteTecht software tomonitor and/orprogram. Access the controller system with a PC usinga USB cable with a mini USB plug. Refer to theIntroduction, List of Related Materials for relatedsoftware literature.

While this manual focuses on data access through thecontroller pushbutton/rotary selector dial and display,most data entries require input using a PC for initialsetup. ThePCentries typically includealpha characterssuch as digital input descriptions.

2.6.1 PC Communications

Communicate between a PC and the generator setcontroller logicusingUSBcommunicationprotocol. ThePC connections require optional SiteTecht software.Contact your authorized distributor/dealer forassistance.

Local Single Connection

A PC connects to the USB port of the generator setcontroller usingaminiUSBconnector. SeeFigure 2-14.

PersonalComputer

Generator SetController

USB Cable

Figure 2-14 Local Single Connection

Remote Single Connection

A modem connects a PC to a single device. The PCcommunicates with the device via telephone line or anethernet network. See Figure 2-15.

PersonalComputerwith NIC

Ether-netNet-work

RemoteNetwork(Modem)

Modbusr/EthernetConverter

OR

Telephonelines

PersonalComputer

Generator SetController orTransfer

Switch Control

PersonalComputerwith NIC

Ether-netNet-work

RemoteNetwork(Modem)

RS-232 toRS-485 PortConverter

Modbusr/EthernetConverter

OR

Telephonelines

PersonalComputer

Generator SetController orTransfer

Switch Control

RS-485 up to 1220 m (4000 ft.)

Figure 2-15 Remote Single Connections

2.6.2 Modbusr Communications

The controller communicates usingModbusras a slaveconnection with the Modbusr master initiating thecommunication. The controller seeks the system andalternator parameters and diagnostic information thenresponds back to the Modbusrmaster. In addition, thecontroller accepts information to alter controllerparameters including generator set starting andstopping. See Figure 2-16. Refer to the List of RelatedMaterials for available Modbusr literature.

Note: Only one Modbusr master can be connected tothe controller. Examples include the remoteserial annunciator, Monitor III, and switchgearapplications.

Generator SetController

Modbusr Master

RS-485up to 1220 m (4000 ft.)

Figure 2-16 Modbusr Connections



2.7 Reviewing Menu Displays

Use this section to review a summary of the generatorset controller data. See Figure 2-17 or Figure 2-18 forwhich menus provide data monitoring, dataadjustments, or require SiteTecht software to makedata adjustments.

Use the pushbutton/rotary selector dial to navigate tothe respective menus.

Menu NameControllerViewable

ControllerAdjustable

SiteTechAdjustable

Overview X

Engine Metering X

Generator Metering X

GenSet Information X X

GenSet Run Time X

GenSet System X X X

GenSet Calibration X X

Voltage Regulation X X X

Digital Inputs X X

Digital Outputs X X

Analog Inputs X X

Event Log X

Figure 2-17 Menu Displays for Viewing and Adjusting(Before Firmware Version 3.0.25)

Menu NameControllerViewable

ControllerAdjustable

SiteTechAdjustable

Overview X

Engine Metering X

Generator Metering X X

GenSet Information X X

GenSet Run Time X

GenSet System X X X

Voltage Regulation X X X

Digital Inputs X X

Digital Outputs X X

Analog Inputs X X

Event Log X

Volt Select X X X*

* Requires initial activation using SiteTecht

Figure 2-18 Menu Displays for Viewing and Adjusting(Firmware Version 3.0.25 and Higher)

See Section 1, Specifications and Features, to reviewset point ranges and default settings for comparison tothe actual setup.

Menus displaying the # symbol represent one of thefollowing data types:

D System-calculated dataD System-measured dataD User-entered data

Note: The examples given on the following pagesrepresent digital displays with the MeasurementSystem set to English.


2.7.1 Error Messages

Certain entries or attempted entries may cause thecontroller to display an error message. Some of theerror messages shown here are also shown as part of2.4.5 System Fault Warning Lamp with Digital Displaysand 2.4.6 System Fault Shutdown Lamp with DigitalDisplays.

CannotCalibrateappearswhenattempting to calibratethe voltageand current values in theGenSetCalibrationmenuwith the unit stopped. The unit must be running inorder to make adjustments.

Cannot Edit When Stopped appears in the VoltageRegulatormenu whenattempting to change theVRVoltAdj value when the unit is not running.

Default Parameters Loaded. The fault lampilluminates yellow and the alarm horn sounds when thecontroller detects that the default parameter settingswere loaded using SiteTecht software. The localdisplay shows Default Pars Warning.

ECMAddressConflict. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts down whenthe controller detects an error with the ECM address.The local display shows ECMAddr Err Shutdwn.

ECMModel Mismatch. The fault lamp illuminates red,the alarm horn sounds, and the unit shuts down whenthe controller detects an error with the ECMmodel. Thelocal display shows ECM Mismatch Shutdwn.

File System Error. The fault lamp illuminates red, thealarm horn sounds, and the unit shuts down when theinternal controller diagnostics detect a firmware fileerror. The local display shows File Error Shutdwn.

Max Alternator Current Low. The current value listedin the maximum alternator current personalityparameter is too low compared to the kW setting withinthe personality.


2.7.2 Overview

Displays basic and commonly sought after informationabout the generator set. This information scrollsautomatically after about 5 minutes of no user input(pushbutton/rotary selector dial or button activity).

To change from auto scrolling to fixed display, press therotary dial and the main menu will appear. Press therotary dial again to select the first menu item Overview.Turn the rotary dial to select the desired fixed view.

Note: Somedisplays areengine dependent, refer to theAppendix, Controller Displays from the EngineECM.

Overview (Auto Scrolling Display)Overview ---->##.# hr

Avg V L--L:#.# V

Active Shutdowns(if present)

Eng Runtime:##.# h

Current:#.# A

Frequency:#.# Hz

Fuel Level:# %

Average kW#### kW

Fuel Pressure:## PSI

Oil Pressure:# PSI

Battery:##.# V

SW Version:1.02

Active Warnings(if present)

GenSet State ######

Coolnt Temp:### F

Diesel PoweredModels (requires fueltank sensor) -->

Engine Dependent(see NOTE above) -->

Overview (Fixed Display)Overview ---->##.# hr

###_ C ##.# %#.# MPa ##.# V

### V ##.# Hz### A #### kW

###_F ###%### PSI ##.# V

English DisplayMeasurements -->

Metric DisplayMeasurements -->

2.7.3 Engine Metering

Displays engine operating data as measured by theengine and other sensors.

Note: Somedisplays areengine dependent, refer to theAppendix, Controller Displays from the EngineECM.

Engine MeteringEngine ---->Metering

Coolnt Temp:### F

Eng Speed:# R/min

Oil Pres:# PSI

Fuel Pressure:## PSI

Fuel Level:# %

Battery:##.# V

Diesel Powered Models(requires fuel tanksensor) -->

Engine Dependent(see NOTE above) -->


2.7.4 Generator Metering (andCalibration)

Displaysgenerator output data including line-to-lineandline-to-neutral voltages, current, frequency, totalkilowatts, and total kVA. The menu displaysthree-phase voltage and current readings whenapplicable.

All menu displays apply to both single-phase or three-phase voltages on the menu overview. The phasedesignation does not appear in the controller menudisplays. Some displays will show 0 values whensingle-phase connections are shown.

Firmware Version 3.0.25 and higher:

Display also provides access to the calibration factorsfor metering (volts and amps). Changing the systemvoltage or replacing the main logic control circuit boardrequires calibration adjustment. Connect ameter with aminimum accuracy of 1% to the generator set outputleads to calibrate the voltage-sensing logic.

To enable calibration, start the generator set and selectthe Volts L1-L2 display. Then push and hold thepushbutton/rotary selector dial until the CalibrationEnabled popup appears. Calibration of each display isnow available. The display will show the followingvalues for three-phase generator sets. Single-phasegenerator sets will only display items marked (*).


The user can change individual values or can selectReset Calib?--Yes to reset all voltage and currentvalues. The Reset Calib? display will only show ifcalibration is enabled.


When calibrating current, the metered value must be atleast 25% of the rated current on units smaller than100 kW and at least 50 amps on units rated larger than100 kW. The number being entered as the calibratedvalue must within 10% of the metered value.

To disable calibration, Rotate the pushbutton/rotaryselector dial until the <--Return popup appears.

Momentarily press the pushbutton/rotary selector dial.Stop the generator set if not already done.

Generator MeteringGenerating---->Metering

Rated Power:# %

Total Power:# VA

Total Power:# W

Volts L2--L3:#.# V

Volts L1--L2:#.# V

Volts L1--N:#.# A

Volts L3--L1:#.# V

Volts L3--N:#.# A

Volts L2--N:#.# A

Current L2:#.# A

Current L1:#.# A

Frequency:#.# Hz

Current L3:#.# A

Select this Display toEnable or DisableCalibration -->

ResetCalibration

ResetCalib? No

ResetCalib? Yes

OR


2.7.5 GenSet Information

Displays generator set and controller information.Displayed data is factory entered.

GenSet InformationGenSet ---->Information

Cntrllr S/N:##

Genset M/N:##

GenSet S/N:##

2.7.6 GenSet Run Time

Displays the generator set’s operating record includingtotal run time loaded and unloaded, number of starts,and total energy kW hours.

GenSet Run TimeGenSet ---->Run Time

Eng Starts:#

Eng Runtime:##.# h

Eng Loaded:#.# h

TotalEnergy:#.# kWh

2.7.7 GenSet System

Display shows the generator set system data includingvoltage, frequency, phase connection, etc. Use thevalues entered in thismenu to help determine shutdownvalues and time delays.

The programming user defines the data shown in theGenSet Systemmenu. It is NOT data measured by thecontroller and associated sensing devices. Theprogramming user defines these values for purposes ofcalibrating the control.

Some alternators are designed to operate at limitedvoltage, frequency,or phaseconnectionsandasa resultsome settings may have limited parameters.

Display for Measurement System is user selectable asEnglish or Metric.

Contrast display is user adjustable to help improvedigital display visibility in dimly lit rooms or in directsunlight.

Note: The contrast feature is a controller hardwarechange and may not be available on older unitseven if the firmware is updated.

The alarm (horn) silence display is programmerselectable to Always or Auto Only using SiteTechtsoftware. The Always selection allows the alarm to besilenced in any of the OFF/RESET--AUTO--RUNmodes. The Auto Only selection allows silencing of thealarm only while in the Auto mode.

The manual speed adjustment is made using theEngine RPM menu (version 3.10.3 or higher). Thisfeature is available as a factory-installed option orrequires a new factory personality profile. Adjustmentscan be made while the unit is running or stopped. Tomake adjustments, press and hold the selector dial andthe RPM display will start to flash. Then rotate theselector dial to the desired RPM and press and hold theselector dial until the RPM display stops flashing. Theadjustment range is 1751--1849 RPM (58--62 Hz) for60 Hz and 1451--1549 RPM (48--52 Hz) for 50 Hz.

GenSet SystemGenSet ---->System

SystemPhase:#####

System Volt:###.# V

System Freq:##.# Hz

Amp Rating:##.# A

Pwr Rating:##.# kW

Battery V:## V

Power Type:#####

AlrmSilence:Always or Auto Only

User Selectable -->Meas SystemEnglish or Metric

Contrast#####User Selectable -->

Engine RPM#####

User Selectable(see manual speedadjustment above) -->


2.7.8 GenSet Calibration

This menu is only available in controller firmwareversions before 3.0.25. Go to Generator MeteringMenu—Reset Calibration with controller firmwareversion 3.0.25 or higher.

Display provides access to the calibration factors formetering (volts and amps). Changing the systemvoltage or replacing the main logic control circuit boardrequires calibration adjustment. Connect ameter with aminimum accuracy of 1% to the generator set outputleads to calibrate the voltage-sensing logic.

The user can individually calibrate the values or reset allof them. The local display Reset all calib? No or Yes.Select No to make no changes and exit GenSetCalibration. Select Yes to reset all of the values.


When calibrating current, the metered value must be atleast 25% of the rated current on units smaller than100 kW and at least 50 amps on units rated larger than100 kW. The number being entered as the calibratedvalue must within 10% of the metered value.

GenSet CalibrationGenSet ---->Calibration

Volts L1--L2:#.# V

Enter calib?No

Enter calib?Yes

Volts L3--L1:#.# V

Volts L2--L3:#.# V

Volts L2--N:#.# V

Volts L1--N:#.# V

Current L1:#.# A

Volts L3--N:#.# V

Current L3:#.# A

Current L2:#.# A

Resetcalibration

Resetcalibration

GenSet ---->Calibration

<----ExitCalibration

Reset allcalib? No

Resetcalibration

Reset allcalib? Yes

OR

OR

User Selectable -->


2.7.9 Voltage Regulator

Before Firmware Version 3.0.25.

Displays the voltage regulator adjustment value. Allother voltage regulator adjustments are changed usingSiteTecht software.

The voltage regulator value is reviewable at all times. Inorder to review the value when the generator set is NOT

running, enter Yeswhen theEnter volt reg? is displayed.The user can review the value but attempting to changethe value will cause a Cannot edit when stopped errormessage.

If the unit is running and Yes is entered when the Entervolt reg? is shown, the display will show the value. Theuser can change the value at this time.

Voltage RegulatorVoltage ---->Regulator

VR Volt Adj:xxx.x

Enter voltreg? No

Enter voltreg? Yes

<---- Exitvoltage reg

Voltage ---->Regulator

OR

User Selectable -->

Firmware Version 3.0.25 or Higher.

Displays the voltage regulator adjustment value. Allother voltage regulator adjustments are changed usingSiteTecht software.

The voltage regulator value is reviewable at all timesand provides the ability to fine adjust voltage. Changingthe system voltage or replacing the circuit boardtypically requires a voltage adjustment.

To enable calibration, start the generator set and selectthe VR Volt Adj display. Then push and hold the

pushbutton/rotary selector dial until theEditing Enabledpopupappears. Editingof the voltageadjustment isnowavailable.

The user can change the individual value or can selectReset VR?--Yes to reset to the default value. TheResetVR Settings display will only show if editing is enabled.


Voltage RegulatorVoltage ---->Regulator

VR Volt Adj:xxx.x

Reset VR?No

Reset VR?Yes

Reset VR -->Settings

OR

User Selectable -->

<-- Select this Display toEnable or Disable Editing


2.7.10 Digital Inputs

Displays the selected programming user-defined digitalnotice, warning, and shutdown inputs. These inputsprovide a multitude of choices for configuringcustomized auxiliary inputs. See Figure 2-19 for a list ofdigital input choices. For descriptions of the inputs listedrefer to the following:

D 2.4.5 System Fault Warning Lamp with DigitalDisplays

D 2.4.6 System Fault Shutdown Lamp with DigitalDisplays

D 2.4.7 Status and Notice Digital Displays

There is an optional 2 input/5 output (I/O) module boardavailable that can provide two additional digital (oranalog) inputs.

The displays for digital inputs appear as shown belowwith Values true or false. Items shown in the display asTrue are active.

D DIn A1 (digital input A1) standardD DIn A2 (digital input A2) standardD DIn A3 (digital input A3) standardD DIn B1 (digital input B1) with I/O module boardD DIn B2 (digital input B2) with I/O module board

All digital input selection and setup adjustments are doneusing SiteTecht software. The following terms anddescriptions are part of the setup procedure.

D Enabled. This menu indicates whether or not theinput is enabled. If the input is not enabled, thecontroller will ignore this input signal.

D Inhibit Time Delay. The inhibit time delay is the timeperiod following crank disconnect during which thegenerator set stabilizes and the controller does notdetect the fault or status event. The controller willignore the input until the inhibit time expires. If theinhibit time is set to zero, the input is monitored at alltimes, even when the generator is not running. Theinhibit time delay range is from 0 to 60 seconds.

D TimeDelay (shutdownorwarning). The timedelayfollows the inhibit time delay. The time delay is thetime period between when the controller first detectsthe fault or status event and the controller warning orshutdown lamp illuminates. The delay prevents anynuisance alarms. The time delay range is from 0 to60 seconds.

Digital InputsDigital ---->Inputs

DIn A2#####

DIn A1#####

DIn A1Value: True or False

DIn A3#####



Analog andDigital Inputs Notice Warning

LowWarning

HighWarning

Critical HighWarning Shutdown

LowShutdown

HighShutdown

Auxiliary Input AD ADBattery Charger Fault ADChicago Code Active ADEngine Fuel Level AD D D DFuel Tank Leak AD DGround Fault ADLow Engine Oil Level AD DLow Fuel Pressure AD

Figure 2-19 Analog and Digital Inputs


2.7.11 Digital Outputs

Displays the selected programming user-defined digitalnotice, warning, and shutdown outputs. These outputsprovide a multitude of choices for configuringcustomized auxiliary outputs. See Figure 2-20 for a listof digital output choices. For descriptions of the outputslisted refer to the following:




There is an optional 2 input/5 output (I/O) module boardavailable that can provide five additional digital outputs.

The displays for digital outputs appear as shown belowwith Values true or false. Items shown in the display asTrue are active.

D DOut A1 (digital output A1) standardD DOut B1 (digital output B1) with I/O module boardD DOut B2 (digital output B2) with I/O module boardD DOut B3 (digital output B3) with I/O module boardD DOut B4 (digital output B4) with I/O module boardD DOut B5 (digital output B5) with I/O module board

Use SiteTecht software for digital output selection andsetup adjustments. Each output is tied to auser-selectable function. The function can be acommon fault, common warning, NFPA 110 alarmactive, or a specific warning or shutdown.

Digital OutputsDigital ---->Outputs

DOut B1#####

DOut A1#####

DOut A1Value: True or False

DOut B2#####

DOut B1Value: True or False

DOut B3#####


DOut B4#####


DOut B5#####




Digital Outputs Notice WarningLow

WarningHigh

Warning

CriticalHigh

Warning ShutdownNo SignalShutdown

LowShutdown

HighShutdown

AC Sensing Lost X XAlternator Protection XAuxiliary Input X XBattery Charger Fault X*Battery Voltage X* X*Chicago Code Active XCommon Fault XCommon Warning XCranking Voltage XECM Comm Loss XEmergency Stop XEngine Coolant Level X*Engine Coolant Temperature X* X* X* X*Engine Cooldown Active XEngine Fuel Level X* X* X* X*Engine Oil Level X XEngine Oil Pressure X* X* X*Engine Speed X X*Engine Start Aid Active XEngine Start Delay Active XEPS Supplying Load XFuel Pressure X*Fuel Tank Leak X XGenerator Frequency Average X XGenerator Running XGenerator True Total Power XGenerator Voltage L1--L2 X XGenerator Voltage L2--L3 X XGenerator Voltage L3--L1 X XGround Fault XLocked Rotor XNFPA 110 Alarm Active XNot In Auto X*Overcrank X*Speed Sensor Fault XSystem Ready X

* NFPA 110 Defined Common Alarms

Figure 2-20 Digital Outputs with NFPA 110 Defined Common Alarms

2.7.12 Analog Inputs

Displays the selected programming user-definedanalog notice, warning, and shutdown inputs. Theseinputs provide a multitude of choices for configuringcustomized auxiliary inputs. See Figure 2-19 for a list ofanalog input choices. For descriptions of the inputslisted refer to the following:




There is an optional 2 input/5 output (I/O) module boardavailable that can provide two additional analog (ordigital) inputs.

The displays for analog inputs appear as shown belowand have an acceptable operating range (0--5 VDC).The analog input selection typically requires enteringfour values—low warning, high warning, low shutdown,and high shutdown.

D AIn A1 (analog input A1) standard(reserved and not user programmable)

D AIn A2 (analog input A2) standard(Identified as A1 on SiteTecht software)

D AIn B1 (analog input B1) with I/O module boardD AIn B2 (analog input B2) with I/O module board


All analog input selection and setup adjustments aredone using SiteTecht software. The following termsand descriptions are part of the setup procedure.

D Enabled. This menu indicates whether or not theinput is enabled. If the input is not enabled, thecontroller will ignore this input signal.

D Inhibit Time Delay. The inhibit time delay is the timeperiod following crank disconnect during which thegenerator set stabilizes and the controller does notdetect the fault or status event. The controller willignore the input until the inhibit time expires. If theinhibit time is set to zero, the input is monitored at alltimes, even when the generator is not running. Theinhibit time delay range is from 0 to 60 seconds.

D TimeDelay (shutdownorwarning). The timedelayfollows the inhibit time delay. The time delay is thetime period between when the controller first detectsthe fault or status event and the controller warning orshutdown lamp illuminates. The delay prevents anynuisance alarms. The time delay range is from 0 to60 seconds.

Analog InputsAnalog ---->Inputs

AIn B2#####

AIn A1#####

AIn B1#####

2.7.13 Event Log

Displays up to 1000 stored status, warning, andshutdown events. After the first 1000 events, eachadditional new event replaces the oldest event. See1.2.4 Controller Fault Diagnostics for a list of possibleevents.

Event LogEvent Log ----> #####

(Message Text)

(Scroll through up to 1000max. stored events)

2.7.14 Volt Select

This menu is only available in controller firmwareversion 2.8.22 and higher.

This menu allows the user to readily change controllervoltage settings. The volt select feature is typically usedin towable or temporary applications.

NOTICEVoltage reconnection. Affix a notice to thegenerator set afterreconnecting the set to a voltage different from the voltage onthe nameplate. Order voltage reconnection decal 246242from an authorized service distributor/dealer.

Note: The volt select menu requires initial activation bySiteTecht software. In SiteTecht software,select True to activate the volt select menu.

Note: The generator set output leads require voltagereconnection if the generator set does not have avoltage selector switch installed.

With the generator set stopped, go to the Volt Selectmenu. Then push and hold the pushbutton/rotaryselector dial until the voltage selection starts to flash.Volt selection is now available. Scroll to the desiredvoltage and momentarily press the pushbutton/rotaryselector dial to confirm the voltage selection.

Volt SelectVolt Select: ---->###/### V # Ph

120/240 V 1 Ph

120/208 V 3 Ph

139/240 V 3 Ph

277/480 V 3 Ph

120/240 V 3 Ph


Notes

TP-6694 11/15 53Section 3 Scheduled Maintenance

Section 3 Scheduled Maintenance

Under normal operating conditions, the generator set’salternator requires no routine service. ConsultSection 2.1, Prestart Checklist, for a list of routinechecks.



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Move the generator set masterswitch to the OFF position. (2) Disconnect the power to thebattery charger. (3) Remove the battery cables, negative (--)lead first. Reconnect the negative (--) lead last whenreconnecting the battery. Follow these precautions to preventstarting of the generator set by an automatic transfer switch,remote start/stop switch, or engine start command from aremote computer.



WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.



Moving parts.

WARNING

Servicing the generator setwhen it is operating. Exposedmoving parts can cause severe injury or death. Keephands, feet, hair, clothing, and test leads away from the beltsand pulleys when the generator set is running. Replaceguards, screens, and covers before operating the generatorset.

3.1 Alternator Service

When operating the generator set under dusty or dirtyconditions, use dry compressed air to blow dust out ofthe alternator while the generator set is running. Directthe stream of air through openings in the generator setend bracket.

3.2 Engine Service

Perform engine service at the intervals specified in theengine manufacturer’s service literature. Contact anauthorized service distributor/dealer to obtain serviceliterature.

Note: Have maintenance work, including batteryservice, performed by appropriately skilled andsuitably trained maintenance personnel familiarwith generator set operation and service.

TP-6694 11/1554 Section 3 Scheduled Maintenance

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

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

Change oil D First 50 Hrs., ThenEvery 250 Hrs.Replace filter(s)* D

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

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.


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

Wire-cable insulation breakdown X X3 Years or500 Hrs.

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

Valve clearance D3 Years or500 Hrs.

Bolt torque D D3 Years or500 Hrs.

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 withinsulation tester (Meggerr, with SCR assembly or rectifierdisconnected)

X Yearly

Blow dust out of alternator* X D2 Years or300 Hrs.

General Condition of Equipment

Any condition of vibration, leakage, noise, temperature, ordeterioration X X X Weekly

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.

Meggerr is a registered trademark of Biddle Instruments.


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 prime power applications. Service thebearing more frequently if the annual inspectionindicates excessive rotor end play or bearing damage.The sealed end bracket bearing requires no additionallubrication.

3.4.2 300--1000 kW Models with4M/5M/7M Single-BearingAlternator

The alternator bearing requires lubrication at intervalsspecified in the generator set technical manual. UseChevron SRI or equivalent antifriction, high-qualitygrease with a lubrication temperature range of --30C to175C (--22F to 350F).

3.5 Diesel Fuel Systems



WARNING

The fuel system. Explosive fuel vapors can cause severeinjury or death. Vaporized fuels are highly explosive. Useextreme care when handling and storing fuels. Store fuels in awell-ventilated area away from spark-producing equipmentand out of the reach of children. Never add fuel to the tankwhile the engine is running because spilled fuel may ignite oncontact with hot parts or from sparks. Do not smoke or permitflames or sparks to occur near sources of spilled fuel or fuelvapors. Keep the fuel lines and connections tight and in goodcondition. Donot replace flexible fuel lineswith rigid lines. Useflexible sections to avoid fuel line breakage caused byvibration. Do not operate the generator set in the presence offuel leaks, fuel accumulation, or sparks. Repair fuel systemsbefore resuming generator set operation.

Draining the fuel system. Explosive fuel vapors cancause severe injury or death. Spilled fuel can cause anexplosion. Use a container to catch fuel when draining the fuelsystem. Wipe up spilled fuel after draining the system.

3.5.1 Bleeding Air from Fuel System

Bleed air from the fuel system after fuel systemmaintenance, such as replacing the fuel filter(s). Usethe hand prime pump kit, when equipped. The handprime fuel pump eliminates the need for cranking theengine to bleed air from the fuel system.

Note: Bleed air from the fuel system according to theengine manufacturer’s instructions. Trapped airin the fuel system causes difficult starting and/orerratic engine operation.

Note: Correct any fuel leaks encountered during thepriming procedure.

1. Place the fuel valves in the fuel system primeposition. Close the fuel valve located between thepipe tee and the engine. Open the fuel valves oneach side of the fuel prime pump. See Figure 3-1.

Note: The illustration shows a generator setwithout a fuel/water separator. The valvelocation and position for a generator setequipped with a fuel/water separator issimilar.

2. Loosen the bleed screw at the engine. Refer to theengine operation manual for location of the bleedscrew(s). Thebleedscrewallowsair to beexpelledfrom the fuel system when the hand prime pump isoperated.

PK-272000-HValve Open Valve Closed

Close this Valve Open this Valve

Open this Valve

Figure 3-1 Hand Prime Pump with Valve Positionsfor Fuel Priming (generator set without afuel/water separator shown), Typical


3. Rotate the hand prime pump handlecounterclockwise until fuel flows from the bleedscrew. Stop pumping.

4. Tighten thebleed screw. Wipeupany fuel leakage.

5. Place the fuel valves in the normal operationposition. Open the fuel valve located between thepipe tee and the engine. Close the fuel valves oneach side of the fuel prime pump.

3.6 Gaseous Fuel SystemsGaseous fuel systems apply to REZG_/RZG_/ERES_(GM/PSI Powered) and REZX_/RZX_ (DoosanPowered) generator set models.

This section describes natural gas and liquifiedpetroleum gas (LPG) fuel systems that are not coveredin the engine operation manual or engine servicemanual.



WARNING

The fuel system. Explosive fuel vapors can cause severeinjury or death. Vaporized fuels are highly explosive. Useextreme care when handling and storing fuels. Store fuels in awell-ventilated area away from spark-producing equipmentand out of the reach of children. Never add fuel to the tankwhile the engine is running because spilled fuel may ignite oncontact with hot parts or from sparks. Do not smoke or permitflames or sparks to occur near sources of spilled fuel or fuelvapors. Keep the fuel lines and connections tight and in goodcondition. Donot replace flexible fuel lineswith rigid lines. Useflexible sections to avoid fuel line breakage caused byvibration. Do not operate the generator set in the presence offuel leaks, fuel accumulation, or sparks. Repair fuel systemsbefore resuming generator set operation.

Explosive fuel vapors can cause severe injury or death.Take additional precautions when using the following fuels:

Propane (LPG)—Adequate ventilation is mandatory.Because propane is heavier than air, install propane gasdetectors low in a room. Inspect the detectors per themanufacturer’s instructions.

Natural Gas—Adequate ventilation is mandatory. Becausenatural gas rises, install natural gas detectors high in a room.Inspect the detectors per the manufacturer’s instructions.

3.6.1 Gaseous Fuel System Concept(Single Fuel)

The gaseous fuel system uses a fuel valve with asolenoid to control the fuel flow to the fuel regulator. Thegenerator set-mounted regulator reduces the fuelpressure as fuel passes to the fuel mixer. SeeFigure 3-2.

The fuel mixer controls the ratio of fuel to air undervarying load and speed conditions. Because the fuelmixer receives fuel in a gaseous state, it does not haveto vaporize the fuel.

TP-5750-31. Primary regulator (supplied by gas supplier or user)2. Pressure gauge3. Solenoid valve (UL--listed models require 2 solenoid valves)4. Secondary regulator5. Fuel mixer

1 2 3 4 5

Figure 3-2 Fuel Regulator and Valve, Typical

3.6.2 LPG Liquid Withdrawal FuelSystem Concept

With the LPG liquid withdrawal fuel system, pressurizedliquid LPG fuel passes from the tank to a vaporizer. Thevaporizer converts the liquid fuel to gasbefore sending itto the fuel mixer. The system also includes a fuel valvethat shuts off the fuel flow when the engine stops.Contact an authorized service distributor/dealer foravailability.

3.6.3 Natural Gas and LPG ConversionMost models operate on either natural gas or LPG fuelby performing the fuel conversion procedure. A hangtag on the fuel regulator may provide additionalconversion setup information. Fuel conversion maydecrease generator set output. Refer to the respectivegenerator set spec sheet for ratings based on fuelselection. Changing fuel does not alter the emissionscompliance of the generator set engine. Consult yourlocal generator set distributor/dealer for additionalinformation.

Note: If a gaseous-fueled model has the fuel typechanged (LPG to natural gas or natural gas toLPG), order a new nameplate from an authorizeddistributor/ dealer with the updated ratings andattach to the generator set.


To change the fuel type, change the electricalconnections to the engine ECM. The engine ECM hasfuel tables and spark advance curves programmed forboth natural gas and LPG. The information following, inFigure 3-3, and in Figure 3-5 generally apply to allmodels and all fuels. Be sure to review the respectivewiring diagram for your specific model for possiblespecial applications.

Natural Gas Operation

D Disconnect lead 65 from lead N5.D Disconnect lead 73B from the fuel valve.D Connect lead 73A to the fuel valve.

LPG Vapor Operation

D Disconnect lead 73A from the fuel valve.D Connect lead 73B to the fuel valve (LPG vapor).D Connect lead 65 to lead N5 (ground).

LPG Liquid Withdrawal Operation

D Disconnect lead 73A from the fuel valve.D Connect lead 73B to the fuel valve (LPG liquidwithdrawal).

D Connect lead 65 to lead N5 (ground).

Auto Changeover Natural Gas/LPG VaporOperation

D Disconnect lead 65 from N5.D Connect lead N5 to LFP2 relay common terminal.D Connect lead 73A to the fuel valve (natural gas).D Connect lead 73B to the fuel valve (LPG vapor).

Eng.ECM

NaturalGas

LPGVapor

LPGLiquid

AutoChangeover

73AQCON--7(NG fuelvalve)

not usedQCON--7

(NG fuel valve)

N5 not used 65 65 LFP2--COM

73B not used QCON--10 (LPG fuel valve)

65 not used N5 N5 not used

63 LFP1--NC low fuel pressure sensor (if used)

70E2 P6--B (15 amp fuse)

Figure 3-3 Gaseous Fuel Electrical Connections

3.6.4 Fuel System Changeover Kits(Dual Fuel)

Automatic Changeover

A changeover fuel system kit provides automaticchangeover from natural gas to LPG vapor. Theprimary and backup fuels each have a fuel valve. The

primary fuel is natural gas; the backup fuel is LPGvapor. Before starting, both fuel valves are closed.When the generator set starts, the primary fuel valveopens. The primary fuel line has a pressure switch inseries with a relay connected to the start/run circuit.

When the primary fuel pressure drops below 0.6 kPa(1.4 oz./in.2) or 6.4 cm (2.5 in.) water column , a relayopens thebackup fuel valveandcloses theprimary fuelvalve. When the primary fuel pressure rises above 0.6kPa (1.4 oz./in.2) or 6.4 cm (2.5 in.) water column, thegenerator set uses the primary fuel. Contact anauthorized service distributor/dealer for kit availability.

Emissions certified models use a single electronic-controlled pressure regulator (EPR) for both fuels. A teefitting connects both fuels together upstream of theEPR. Duringoperationwhenusing thesecondary fuel, itis normal for a small amount of secondary fuel to seepback through the primary fuel valve. To counter thissituation, one of two methods is used depending uponthe generator set model: (1) a second valve (identical tothe primary fuel valve) is installed in a reverseconfiguration on the primary fuel side or (2) a small ventline is installed between the primary fuel inlet and the airintake through a solenoid valve.

3.7 Crankcase Ventilation (CCV)Heater Kit GM78171-KP1

Applies to 125/150 kW, 8.1 L GM- and 8.8 L PSI-powered generator set models. Consult your localgenerator set distributor/dealer for additionalinformation.

The crankcase ventilation (CCV) heater kit provides acontrolled heating source to the crankcase ventilationsystem preventing freezing water buildup during coldweather. The thermostat turns on at 4_C (40_F) andturns off at 16_C (60_F) reducing energy consumption.See Figure 3-4.

1. Heater element2. Inline connector

TT-1560

1 2

34

3. Thermostat4. AC power cord

Figure 3-4 Crankcase Ventilation Heater Kit


ADV-7600B-B

Figure 3-5 Gaseous Fuel Connections Wiring Diagram


3.8 Air Cleaner Restrictor Indicator(if equipped)

The air cleaner restriction gauge mounted on the aircleaner(s) helps determine the air cleaner changeinterval.

The air cleaner restriction gauge monitors air flow andcontinuously displays restriction readings indicated asvacuum (see Figure 3-6). Increased restrictionindicates a clogged air cleaner element.

Asmaximumallowable restriction is reached, the gaugewindow turns red indicating the air cleaner elementneeds replacement. To reset thegauge, push thegaugetop down and release.

273113

1015192225

1

23

1. Push down to reset 2. Display 3. Gauge window

Figure 3-6 Restriction Indicators (styles vary)

3.9 Cooling SystemThe cooling systemmaintenance information applies toradiator-cooled models which have a radiator with apressure cap and coolant recovery tank.

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

Allow the engine to cool. Release pressure from thecooling system before removing the pressure cap. Torelease pressure, cover the pressure cap with a thickcloth and then slowly turn the cap counterclockwise tothe first stop. Remove the cap after pressure has beencompletely released and the engine has cooled. Checkthe coolant level at the tank if the generator set has acoolant recovery tank.

Note: Engine damage. Bleed the air from the coolingsystem to prevent overheating and subsequentengine damage.

Note: Block heater damage. The block heater will failif the energized heater element is not immersedin coolant. Fill the cooling system before turningon the block heater. Run the engine until it iswarm, and refill the radiator to purge the air fromthe system before energizing the block heater.

3.9.1 Coolant Level Check

Check the coolant level in the coolant recovery tank.Maintain the coolant level between the high and lowmarks.

Note: Periodically check the coolant level by removingthepressure cap. Donot rely solely on the level inthe coolant recovery tank. Add fresh coolant untilthe level is just below the overflow tube openingof the filler neck.

3.9.2 Cooling System ComponentInspection

To prevent generator set shutdown or damage causedby overheating:

D Keep the cooling air inlets clean and unobstructed.

D Inspect the radiator’s exterior for obstructions.Remove dirt and foreignmaterial using a soft brush orcloth to avoid damaging the radiator fins.

D Check the hoses and connections for leaks. Replaceany cracked, frayed, or spongy hoses.

D Check the condition and tension of the radiator fanand water pump belt(s). Follow the belt tensionprocedure in this manual and/or the engine operationmanual.

D Check thepressurecapseal and replaceacrackedordeteriorated cap. Remove dirt and other debris fromthe pressure cap and filler neck. The pressure capraises the boiling point of the coolant, enabling higheroperating temperatures. Replace a leaking pressurecap with one rated for the same pressure. Thepressure cap rating usually appears on the pressurecap.


3.9.3 Procedure to Drain CoolingSystem

For optimum protection, drain, flush, and refill thecooling system at the intervals listed in the serviceschedule.

Note: Dispose of all waste materials (oil, fuel, coolant,filters, and gaskets) in an environmentally safemanner.

1. Deenergize the block heater, if equipped.

2. Remove the pressure cap to allow the entiresystem to drain and prevent air pockets fromrestricting coolant flow through the engine block.

3. Open the radiator and/or engine block coolantdrain valve(s) and allow the system to drain.

4. If the inside of the radiator has mineral deposits orthe used coolant contains dirt or grease, refer toSection 3.9.4, Procedure to Flush and Clean theCooling System. If the cooling system does nothave mineral deposits, go to Section 3.9.5,Procedure to Refill the Cooling System.

3.9.4 Procedure to Flush and CleanCooling System

Use the instructions in the engine operation manualwhen available to flush and clean the cooling system.Otherwise, use the following procedure and the coolingsystem cleaner manufacturer’s instructions.

1. Flush the cooling system with clean water.

2. If the inside of the radiator still has mineraldeposits, use a radiator cleaner to remove theremaining deposits following the manufacturer’sinstructions.

3. Drain, clean, and flush the coolant recovery tank.

3.9.5 Procedure to Refill CoolingSystem

See the generator set spec sheet for coolant capacity.

Note: Do not add coolant to a hot engine. Addingcoolant to a hot engine can cause the cylinderblock or cylinder head to crack. Wait until theengine has cooled.

1. Remove the pressure cap.

2. Close the radiator and/or engine block coolantdrain valve(s) and tighten the cooling system hoseclamps.

3. Open the air-bleed petcocks, if equipped. Closethe air-bleed petcocks when coolant begins to flowfrom them.

4. Add coolant additives or water pump lubricantsaccording to the engine manufacturer’srecommendations in the engine operationmanual.

5. Fill the cooling system with a coolant/antifreezemixture based on the engine manufacturer’srecommendation.

6. Replace the pressure cap.

7. Fill the coolant recovery tank to the low mark.

8. Operate generator set until the thermostat openswhen the upper cooling system hose warms.

9. Stop the engine and allow it to cool.

10. Check and repair any coolant leaks.

11. Remove the pressure cap.

12. Add coolant to bring the coolant level to just belowthe overflow tube opening of the filler neck.

13. Replace the pressure cap.

14. Maintain the coolant level in the coolant recoverytank between the high and low marks.

Air pockets often form in the engine water jacketwhen the coolant system is refilled. Check thecoolant level in thecoolant recovery tankafter eachgenerator set operation and add coolant asnecessary until the coolant level stabilizes. Thencheck the coolant at the interval specified in theservice schedule.

15. Reenergize the block heater, if equipped.


3.10 Battery

Sulfuric acid in batteries.Can cause severe injury or death.

Wear protective goggles andclothing. Battery acid may causeblindness and burn skin.

WARNING

Battery electrolyte is a diluted sulfuric acid. Battery acidcan cause severe injury or death. Battery acid can causeblindness and burn skin. Always wear splashproof safetygoggles, rubber gloves, and boots when servicing the battery.Do not open a sealed battery or mutilate the battery case. Ifbattery acid splashes in the eyes or on the skin, immediatelyflush the affected area for 15 minutes with large quantities ofclean water. Seek immediate medical aid in the case of eyecontact. Never add acid to a battery after placing the battery inservice, as this may result in hazardous spattering of batteryacid.

Battery acid cleanup. Battery acid can cause severeinjury or death. Battery acid is electrically conductive andcorrosive. Add 500 g (1 lb.) of bicarbonate of soda (bakingsoda) to a container with 4 L (1 gal.) of water and mix theneutralizing solution. Pour the neutralizing solution on thespilled battery acid and continue to add the neutralizingsolution to the spilled battery acid until all evidence of achemical reaction (foaming) has ceased. Flush the resultingliquid with water and dry the area.

Battery gases. Explosion can cause severe injury ordeath. Battery gases can cause an explosion. Do not smokeor permit flames or sparks to occur near a battery at any time,particularly when it is charging. Do not dispose of a battery in afire. To prevent burns and sparks that could cause anexplosion, avoid touching the battery terminals with tools orother metal objects. Remove all jewelry before servicing theequipment. Discharge static electricity from your body beforetouching batteries by first touching a grounded metal surfaceaway from the battery. To avoid sparks, do not disturb thebattery charger connections while the battery is charging.Always turn the battery charger off before disconnecting thebattery connections. Ventilate the compartments containingbatteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injuryor death. Short circuits can cause bodily injury and/orequipment damage. Disconnect the battery before generatorset installation or maintenance. Remove all jewelry beforeservicing the equipment. Use tools with insulated handles.Remove the negative (--) lead first when disconnecting thebattery. Reconnect the negative (--) lead last whenreconnecting the battery. Never connect the negative (--)battery cable to the positive (+) connection terminal of thestarter solenoid. Do not test the battery condition by shortingthe terminals together.

Refer to this section for general battery information andmaintenance. All generator set models use a negativegroundwitha12-volt or 24-volt engineelectrical system.Consult the generator set nameplate for the engineelectrical system voltage. Consult the generator setspec sheet for battery capacity recommendations forreplacement purposes. The wiring diagrams providebattery connection information. See Figure 3-7,Figure 3-8, and Figure 3-9 for typical batteryconnections, including multiple battery configurations.

EZ-273000-J

1 2

1 2

1 2

1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.

Figure 3-7 12-Volt Engine Electrical System SingleStarter Motor Typical Battery Connection

1

11

1 1

2

2

2

2

2

1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.

Figure 3-8 24-Volt Engine Electrical System SingleStarter Motor Typical Battery Connection


4321

1 2 3 4

KW-272000-B1. To positive (+) terminal on starter solenoid.2. To ground (--) terminal on or near starter motor.3. To positive (+) terminal on second starter solenoid.4. To ground (--) terminal on or near second starter motor.

Figure 3-9 24-Volt Engine Electrical System DualStarter Motors Typical BatteryConnections

3.10.1 Clean Battery

Clean the battery and cables and tighten the batteryterminals according to the service schedulerecommendations. Clean the battery by wiping it with adamp cloth. Keep the electrical connections dry andtight.

If corrosion exists, disconnect the cables from thebattery and remove the corrosion with a wire brush.Clean the battery and cables with a solution of bakingsoda and water. Do not allow the cleaning solution toenter battery cells. Flush the battery and cables withclean water and wipe the battery with a dry cloth.

After reconnecting the battery cables, coat the terminalswith petroleum jelly, silicon grease, or othernonconductive grease.

3.10.2 Electrolyte Level Inspection

Check the electrolyte level and specific gravity ofbatteries that have filler caps. Maintenance-freebatteries do not require electrolyte level checking orspecific gravity testing.

Check the electrolyte level at the specified interval.Remove the filler caps and verify that the electrolytelevel reaches the bottom of each filler hole. SeeFigure 3-10. Refill as necessary with distilled water orclean tap water. Do not add fresh electrolyte. Tightenthe filler caps. After adding water during freezingtemperatures, run the generator set 20--30 minutes tomix the electrolyte and the water to prevent batterydamage from freezing.

1-046

1

2

1. Filler caps2. Electrolyte level

Figure 3-10 Battery Electrolyte Level Inspection

3.10.3 Specific Gravity Check

Useabattery hydrometer to check the specific gravity ofthe electrolyte in each battery cell of batteries with fillercaps. Holding the hydrometer vertically, read thenumber on the glass bulb at the top of the electrolytelevel or the number adjacent to the pointer. If thehydrometer used does not have a correction table,consult Figure 3-12. Determine the specific gravity andelectrolyte temperature of the battery cells. Locate thetemperature in Figure 3-12 and correct the specificgravity by the amount shown. The battery is fullycharged if the specific gravity is 1.260 at an electrolytetemperature of 26.7_C (80_F). Maintain the specificgravities between cells within 0.01 of each other.Charge the battery if the specific gravity is below 1.215at an electrolyte temperature of 26.7_C (80_F).

Note: Some battery testers have four or five beads in atest tube. Draw electrolyte into the tube as withthe battery hydrometer described in this sectionor use the manufacturer’s instructions. UseFigure 3-11 to interpret typical test results.

Number of Floating Beads Battery Condition

5 Overcharged

4 Fully charged

3 A good charge

1 or 2 A low charge

0 A dead battery

Figure 3-11 Bead-Type Test Interpretation


3.10.4 Charge Battery

Useabattery charger tomaintain a fully charged batterywhen the generator set is used in a standby application.The engine battery-charging alternator charges thebattery while the generator set is running.

10

20

30

40

50

60

70

80

90

100

110

120

130

140

150

160

-- 12.2

-- 6.7

-- 1.1

4.4

10

21.1

26.7

32.2

37.8

43.3

48.9

54.4

60.0

65.6

71.1

15.6

+ .032+ .030

+ .028+ .026

+ .024+ .022

+ .020

+ .018+ .016+ .014

+ .012+ .010+ .008+ .006

+ .004+ .002

-- .002

-- .004--. 006-- .008-- .010

-- .012-- .014-- .016-- .018

-- .020

-- .022-- .024-- .026

-- .028

C F

Example No. 1

Temperature below 26.7C (80F)

Hydrometer Reading 1.250

Acid Temperature --6.7C (20F)

Subtract .024 Specific GravityCorrected Specific Gravity is 1.226

1.250 -- .024 = 1.226

Example No. 2

Temperature above 26.7C (80F)

Hydrometer Reading 1.235

Acid Temperature 37.8C (100F)

Add .008 Specific GravityCorrected Specific Gravity is1.243

1.235 + .008 = 1.243

The temperature correctionamountsto about .004 (4 points) of specificgravity for each 5.5C (10F) changein temperature.

Correction

TP6895--6

0

Figure 3-12 Specific Gravity Temperature Correction

Note: If the generator set is in a temporary prime powerapplication inwhich thegenerator set hasperiodsof inactivity, the controller circuitry may drain thebattery. If there is no power source for a batterycharger, place the controller in the prime powermode, if equipped, or disconnect the battery fromthe generator set.

3.11 Storage Procedure

Perform the following storage procedure before taking agenerator set out of service for three months or longer.Follow the engine manufacturer’s recommendations, ifavailable, for fuel system and internal enginecomponent storage.



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Move the generator set masterswitch to the OFF position. (2) Disconnect the power to thebattery charger. (3) Remove the battery cables, negative (--)lead first. Reconnect the negative (--) lead last whenreconnecting the battery. Follow these precautions to preventstarting of the generator set by an automatic transfer switch,remote start/stop switch, or engine start command from aremote computer.



WARNING

Servicing the exhaust system. Hot parts can causesevere injury or death. Do not touch hot engine parts. Theengine and exhaust system components become extremelyhot during operation.



Moving parts.

WARNING


Servicing the generator setwhen it is operating. Exposedmoving parts can cause severe injury or death. Keephands, feet, hair, clothing, and test leads away from the beltsand pulleys when the generator set is running. Replaceguards, screens, and covers before operating the generatorset.

3.11.1 Lubricating System

Prepare the engine lubricating system for storage asfollows:

1. Run the generator set for aminimum of 30minutesto bring it to normal operating temperature.

2. Stop the generator set.

3. With the engine still warm, drain the oil from thecrankcase.

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 distributethe clean oil.


8. Check the oil level and adjust, if needed.

3.11.2 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using acoolant tester.

2. Add or replace coolant as necessary to ensureadequate freezing protection. Use the guidelinesincluded in the engine operation manual.

3. Run the generator set for 30minutes to redistributeadded coolant.

3.11.3 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 compatibleadditives to control microbial growth.

3. Change the fuel filter/separator and bleed the fuelsystem. See the engine owner’s manual.

Gaseous-Fueled Engines

1. Start the generator set.

2. With the generator set running, shut off the gassupply.

3. Run the generator set until the engine stops.


3.11.4 Internal Engine Components(Gaseous-Fueled Engines)

If you have access to a fogging agent or SAE 10 oilprepare the pistons and cylinders for storage as follows:

1. Start the generator set.

2. While the engine is running, spray a fogging agentor SAE10engine oil into the air intake for about twominutes until the engine stops.


If a fogging agent is not available perform the following:

1. Remove the spark plugs.

2. Pour 15 cc (0.5 oz.) of engine oil into each sparkplug hole.

Ignition System Damage. Refer to the engineoperation manual for ignition system precautionsbefore cranking the engine while the spark plugwires are disconnected.

3. Crank the engine two or three revolutions tolubricate the cylinders.

4. Reinstall the spark plugs and torque them tospecifications.

3.11.5 Exterior

1. Clean the exterior surface of the generator set.

2. Seal all engine openings except for the air intakewith nonabsorbent adhesive tape.

3. To prevent impurities from entering the air intakeand to allow moisture to escape from the engine,secure a cloth over the air intake.

4. Mask electrical connections.

5. Spread a light film of oil over unpainted metallicsurfaces to inhibit rust and corrosion.


3.11.6 Battery

Perform battery storage after all other storageprocedures.

1. Confirm that the generator set is stopped.

2. Disconnect the battery(ies), negative (--) lead first.

3. Clean the battery. Refer to Section 3.10.1 for thebattery cleaning procedure.

4. Place the battery in a cool, dry location.

5. Connect the battery to a float/equalize batterycharger or charge it monthly with a trickle batterycharger. Refer to the battery chargermanufacturer’s recommendations.

Maintain a full charge to extend battery life.

TP-6694 11/15 67Section 4 General Troubleshooting

Section 4 General Troubleshooting

This section contains generator set troubleshooting,diagnostic, and repair information.

Use the following charts to diagnose and correctcommon problems. First check for simple causes suchas a dead engine starting battery or an open circuitbreaker. The charts include a list of common problems,possible causes of the problem, recommendedcorrective actions, and references to detailedinformation or repair procedures.

Maintain a record of repairs and adjustments performedon the equipment. If the procedures in this manual donot explain how to correct the problem, contact anauthorized distributor/dealer. Use the record to helpdescribe the problem and repairs or adjustments madeto the equipment.

TP-6694 11/1568 Section 4 Troubleshooting

4.1

GeneralTroubleshootingChart

TroubleSym

ptoms

ProbableCauses

Recommended

Actions

Sectionor

Publication

Reference*

Doesnotcrank

Cranksbutdoesnotstart

Startshard

Noorlowoutputvoltage

Stopssuddenly

Lackspower

Overheats

Lowoilpressure

Highfuelconsumption

Excessiveorabnormalnoise

Displayserrormessage/locksup

Exerciseruntimeand/oreventrecordsinoperative

Controller

xx

Controllercircuitboard(s)inoperative

Replace

thecontroller.

Gen.S

/M

xx

Controllercircuitboard(s)wiring

fault

Check

thewiring.

W/D

xControllerfault

Troubleshootthecontroller.[

Gen.S

/M

xx

xControllerfuse

blow

nCheck

forcontinuityacross

fuse.Iffuse

isblow

n,troubleshootthecontrollerwiring

andreplacecircuitboard.[

Section1,W/D

xControllermastercontrolbuttons

inoperative

Replace

thecontrollermastercontrolbuttoncircuitboard.

—

xControllermastercontrolbuttoninthe

OFF/RESETmode

Press

thecontrollermastercontrolR

UNorAUTObutton.

Section2

xEnginestartcircuitopen

Press

thecontrollermastercontrolR

UNbuttontotestthe

generatorset.Troubleshoottheautostartcircuitand

time

delays.

Section2,W/D,

Gen.I/M,S

/MATSO/M,S

/M

xx

Voltage

regulationinoperative

Replace

thejunctionboxsensingfuses.

Ifthefuse

blow

sagain,troubleshootthecontroller.

W/D,G

en.S

/M

xControllerfirmwareerror

Reviewthecontrollerdisplaytroubleshootingchart.

Section4.2

Alternator

xACoutputcircuitbreakeropen

ResetthebreakerandcheckforACvoltage

atthegenerator

setsideofthecircuitbreaker.

—

xTransfersw

itchtestsw

itchintheOFF

position

Movethetransfersw

itchtestsw

itchtotheAUTOposition.

ATSO/M

xTransfersw

itchfails

totransferload

MovetheATStestsw

itchtotheAUTOposition.

Troubleshootthetransfercircuitand

timedelays.

ATSO/M,S

/M

xWiring,terminals,orpinintheexciter

fieldopen

Check

forcontinuity.

Gen.S

/M,W

/D

xMainfield(rotor)inoperative

(openorgrounded)

Testand/orreplacetherotor.[

Gen.S

/M

xStatorinoperative(openorgrounded)

Testand/orreplacethestator.[

Gen.S

/M

xVibrationexcessive

Tightenloosecomponents.[

—

xVoltage

regulatorsettingsincorrect

Adjustthe

voltage

regulator.

Section1.3.3,

SiteTech

O/M

*Sec./S

ection—

numberedsectionofthismanual;ATS—Autom

aticTransferSwitch;Eng.—

Engine;Gen.—

GeneratorSet;I/M—InstallationManual;O/M—OperationManual;

S/M—Service

Manual;S/S—SpecSheet;W

/D—Wiring

Diagram

Manual

[Havean

authorized

servicedistributor/dealerperformthisservice.

TP-669411/15

TP-6694 11/15 69Section 4 Troubleshooting

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses




Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

ElectricalS

ystem(DCCircuits)

xx

Batteryconnections

loose,corroded,

orincorrect

Verify

thatthebatteryconnections

arecorrect,clean,and

tight.

Section3

xx

Batteryweakordead

Rechargeorreplacethebattery.The

spec

sheetprovides

recommendedbatteryCCArating.

Section3,S/S

xx

Starter/startersolenoidinoperative

Replace

thestarterorstartersolenoid.

Eng.S

/M

xx

Engineharnessconnector(s)not

locked

tight

Disconnectthe

engine

harnessconnector(s)then

reconnect

ittothecontroller.

W/D

xFaultshutdown

Resetthefaultswitchesandtroubleshootthecontroller.

Section2

Engine x

xx

xAircleanerclogged

Clean

orreplacethefilterelem

ent.

Eng.O

/M

xx

xx

xCom

pression

weak

Check

thecompression.[

Eng.S

/M

xx

xx

xEngineoverload

Reducetheelectricalload.See

thegeneratorsetspec

sheetforwattage

specifications.

S/S

xExhaustsystem

leak

Inspectthe

exhaustsystem.Replace

theinoperative

exhaustsystemcomponents.[

I/M

xExhaustsystem

notsecurelyinstalled

Inspectthe

exhaustsystem.Tightenthelooseexhaust

system

components.[

I/M

xx

xx

Governorinoperative

Adjustthe

governor.[

Eng.S

/M

xx

Valve

clearanceincorrect

Adjustthe

valves.[

Eng.S

/M

xVibrationexcessive

Tightenallloose

hardware.

—

xx

xIgnitionsystem

inoperative(gas

modelsonly)

Check

theignitionsystem

(sparkplugs,sparkplug

wires,etc.).

Eng.O

/M,E

ng.

S/M

xx

xx

xEngineECMand/orsensors

Troubleshoottheengine

ECMand/orsensors.

Eng.O

/M,E

ng.

S/M

*Sec./S

ection—



Engine;Gen.—


S/M—Service


/D—Wiring

Diagram

Manual

[Havean

authorized


TP-6694 11/1570 Section 4 Troubleshooting

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses




Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

CoolingSystem

xx

Airopenings

clogged

Clean

theairopenings.

—

xCoolantlevellow

Restorethecoolanttonormaloperatinglevel.

Section3

xCoolingwaterpumpinoperative

Tightenorreplacethebelt.Replace

thewaterpump.

Eng.O

/MorS/M

xHightemperatureshutdown

Allowtheengine

tocooldown.

Thentroubleshootthe

coolingsystem

.Sec.3,E

ng.O

/M

xLowcoolantlevelshutdown,if

equipped

Restorethecoolanttonormaloperatinglevel.

Section3

xThermostatinoperative

Replace

thethermostat.

Eng.S

/M

FuelSystem

xx

xAirinfuelsystem

(dieselonly)

Bleed

thedieselfuelsystem

.Eng.O

/M

xx

Ethercanisterem

ptyorsystem

inoperative,ifequipped

(dieselonly)

Replace

orrepairtheetherstartingsystem

.Eng.O

/M

xx

Fueltankem

ptyorfuelvalveshutoff

Add

fuelandmovethefuelvalvetotheONposition.

—

xx

xFuelfeedorinjectionpumpinoperative

(dieselonly)

Rebuildorreplacetheinjectionpump.[

Eng.S

/M

xx

xFuelorfuelinjectorsdirtyorfaulty

(dieselonly)

Clean,test,and/orreplacetheinoperativefuelinjector.[

Eng.S

/M

xx

xx

Fuelfilterrestriction

Clean

orreplacethefuelfilter.

Eng.O

/M

xFuelsolenoidinoperative

Troubleshootthefuelsolenoid.[

Eng.S

/M

xx

Fuelpressureinsufficient(gasonly)

Check

thefuelsupplyandvalves.[

S/S,G

en.O

/M

xx

xx

Fuelinjectiontim

ingoutofadjustment

(dieselonly)

Adjustthe

fuelinjectiontim

ing.[

Eng.S

/M

LubeSystem

xx

xx

Crankcase

oiltypeincorrectfor

ambienttem

perature

Changetheoil.Use

oilw

ithaviscosity

suitableforthe

operatingclimate.

Eng.O

/M

xx

xOillevellow

Restoretheoillevel.Inspectthe

generatorsetforoilleaks.

Eng.O

/M

xLowoilpressureshutdown

Check

theoillevel.

Eng.O

/M

*Sec./S

ection—



Engine;Gen.—


S/M—Service


/D—Wiring

Diagram

Manual

[Havean

authorized


TP-669411/15

TP-6694 11/15 71Section 4 Troubleshooting

4.2

ControllerDisplayandVoltageRegulationTroubleshootingChart

TroubleSym

ptoms

ProbableCauses

Recommended

Actions

Sectionor

Publication

Reference*

ControllerDisplayandVo

ltageRegulator

Display

isblack

No/lowbatterycharge

Recharge/replacebattery

Section3,Battery

Display

show

ssinglesegm

ent

Lowbatteryvoltage

Rechargebattery

Section3,Battery

Display

show

san

errormessage

Controllerfirmwareorpushbutton/

rotaryselectordialentryerror

ReviewtheErrorMessage

Section

Section2.7.1

Display

locksup

No/lowbatterycharge

Recharge/replacebattery

Section3,Battery

Outputvoltage

ramps

Defectiveexciterwinding

Troubleshootalternatorcomponents[

GeneratorService

Manual

Outputvoltage

unstable

Voltage

regulationcalibrationincorrect

Readjustvoltage

regulation[

Section1.3.3,

SiteTech

O/M

Unabletochange

voltage

andcurrentcalibrations

Calibrationnotenabled

EnablecalibrationinGeneratorMeteringsection

Section1.2.3

DigitalD

isplay,

Section2.6.4

Unabletofindvoltselectmenu

Voltselectnotenabled

EnablevoltselectinSiteTech

SiteTech

O/M

*Sec./S

ection—



Engine;Gen.—


S/M—Service


/D—Wiring

Diagram

Manual

[Havean

authorized


TP-6694 11/1572

Notes

TP-6694 11/15 73Section 5 Voltage Reconnection

Section 5 Voltage 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 andgovernor adjustments. Refer to the respective specsheet to determine if frequency is fixed or field-convertible. If frequency is adjustable, refer to theengine service manual and/or governor literature forconversion information.

Refer to the following procedure and the connectionschematics. Follow the safety precautions at the front ofthis manual and in the procedure text and observeNational Electrical Code (NEC) guidelines.

NOTICEVoltage reconnection. Affix a notice to thegenerator setafter reconnecting the set to a voltage different from thevoltage on the nameplate. Order voltage reconnectiondecal 246242 from an authorized service distributor/dealer.

Note: Equipment damage. Verify that the voltageratingsof the transfer switch, line circuit breakers,and other accessories match the selected linevoltage.



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Press the generator set off/resetbutton to shut down the generator set. (2) Disconnect thepower to the battery charger, if equipped. (3) Remove thebattery cables, negative (--) lead first. Reconnect the negative(--) lead last when reconnecting the battery. Follow theseprecautions to prevent the starting of the generator set by theremote start/stop switch.



Moving parts.

WARNING

Grounding electrical equipment. Hazardous voltage cancause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set, transfer switch, and related equipment andelectrical circuits. Turn off the main circuit breakers of allpower sources before servicing the equipment. Never contactelectrical leads or appliances when standing inwater or onwetground because these conditions increase the risk ofelectrocution.

Short circuits. Hazardous voltage/current can causesevere injury or death. Short circuits can cause bodily injuryand/or equipment damage. Do not contact electricalconnections with tools or jewelry while making adjustments orrepairs. Remove all jewelry before servicing the equipment.

TP-6694 11/1574 Section 5 Voltage Reconnection

5.2 Voltage ReconnectionProcedure(Software version 2.8 or higher)


2. Turn the controller pushbutton/rotary selector dialuntil it stops at the Volt Select menu. SeeFigure 5-1.

Note: If the Volt Select menu does not appear, thecontroller voltage selection feature was notactivated using SiteTecht software.

Volt Select: ---->###/### V # Ph

139/240 V 3 Ph

120/240 V 1 Ph

120/208 V 3 Ph

120/240 V 3 Ph

277/480 V 3 Ph

TP-6694-2

Figure 5-1 Volt Select Menu

3. Press the selector dial and the voltage selectionoption (second line on thedisplay)will start to flash.

4. Turn the selector dial clockwise orcounterclockwise until the desired voltageselection option appears.

5. Press the selector dial. The second line on thedisplay will stop flashing and the new voltage willappear.

6. Rotate the generator set voltage selector switch (ifequipped) to match the desired voltage shown onthe controller display. Skip steps 7--9 and go tostep 10.

If the generator set does not have a voltageselection switch, continue to step 7

7. Disconnect the generator set engine startingbattery, negative (--) lead first. Disconnect power tothe battery charger (if equipped).

8. Use Figure 5-2, Figure 5-3, or Figure 5-5 todetermine the generator set voltage configuration.Note theoriginal voltageand reconnect asneeded.Route leads through current transformers (CTs)and connect them according to the diagram for thedesired phase and voltage.

Note: Position current transformers CT1, CT2,and CT3 with the dot or HI side CT markingtoward the generator set.

9. Reconnect the battery, negative lead last.

10. Press the generator setmaster control RUNbuttonto start the generator set. Check the digital displayfor correct voltages using 2.7.4 GeneratorMetering.

11. Press the generator set master controlOFF/RESET button to stop the generator set aftercompleting the voltage adjustments.

5.3 Voltage ReconnectionProcedure(Software version before 2.8)


2. Disconnect the generator set engine startingbattery, negative (--) lead first. Disconnect power tothe battery charger (if equipped).

3. Use Figure 5-2, Figure 5-3, Figure 5-4, orFigure 5-5 to determine the generator set voltageconfiguration. Note the original voltage andreconnect as needed. Route leads through currenttransformers (CTs) and connect them according tothe diagram for the desired phase and voltage.

Note: Position current transformers CT1, CT2,and CT3 with the dot or HI side CT markingtoward the generator set.

4. Reconnect the battery, negative lead last.

5. UseSiteTecht software to update the information.

6. Refer to 2.7.8 for generator set calibration at thecontroller.

7. Press the generator setmaster control RUNbuttonto start the generator set. Check the digital displayfor correct voltages using 2.7.4 GeneratorMetering.

8. Press the generator set master controlOFF/RESET button to stop the generator set aftercompleting the voltage adjustments.


Figure 5-2 20--150 kW Permanent Magnet Single-Phase Alternators, ADV-5875T-1


Figure 5-3 20--300 kW Permanent Magnet Alternators, ADV-5875T-2


Figure 5-4 60 IMS--300 kW Wound Exciter Field & 20--300 kW, 600 V Perm. Magnet Alternators, ADV-5875T-3


Figure 5-5 300 kW and Larger Pilot-Excited, Permanent Magnet 4M/5M/7M/10M Alternators, ADV-5875T-4

TP-6694 11/15 79Section 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 factory-installed and/or shipped-looseaccessories. SeeFigure 6-1 for a list of availablekits. Obtain the most current accessory informationfrom your local authorized service distributor/dealer.

This section illustrates several accessories available atprint time of this publication. Accessory kits generallyinclude installation instructions. See wiring diagramsmanual for electrical connections not shown in thissection. See the installation instructions and drawingssuppliedwith kit for information on kitmounting location.

The instructions provided with the accessory kitsupersede these instructions where there aredifferences. In general, run AC and DC wiring inseparate conduit. Use shielded cable for all analoginputs. Observeall applicable national, state, and localelectrical codes during accessory installation.

See Section 6.2, Accessory Connections, for terminalidentification.

Kit Description

Common Fault/Failure (32A) Connections

Float/Equalize Battery Charger (with alarms)

Gas Fuel Valve

Input/Output Module Board

Low Fuel (Level) Switch

Low Fuel (Pressure) Switch

Manual Speed Adjust

Prime Power Switch

Remote Emergency Stop

Remote Reset Feature

Remote Serial Annunciator

Run Relay

Shunt-Trip Line Circuit Breaker

Figure 6-1 Optional Accessories

6.1.1 Common Fault/Failure (32A) RelayKit

The common fault relay is standard on the controllercircuit board and located at the TB2 terminal stripconnections. Contacts are rated at 2 amps at 32 VDCor 0.5 amps at 120 VAC max. See Figure 6-2 andFigure 6-3.

The optional common fault relay shown in Figure 6-3 asDCB2 has contacts rated at 10 amps at 28 VDC or120 VAC and can be connected to user-suppliedaccessories.

The optional common fault relay shown in Figure 6-3 asDCB1 has contacts rated at 10 amps at 28 VDC or120 VAC and is used to trigger the shunt-trip line circuitbreaker kit (mentioned later in this section).

GM67191-B

Figure 6-2 Common Fault Relay Wiring (Standard)

GM67191-B

Figure 6-3 Common Fault Relay Kit and Shunt-TripRelay Kit Wiring

TP-6694 11/1580 Section 6 Accessories

6.1.2 Float/Equalize Battery Charger Kitwith Alarm Option

The float/equalize battery charger with alarm optionprovides battery charging to the engine startingbattery(ies) and connects to the controller for faultdetection. Battery chargers for 12- or 24-voltmodelsareavailable as a generator set accessory. See Figure 6-4and Figure 6-5 for battery connections.

GM16088A-A/TP--6694

BATTERY CHAR-GERALARM TERMINALSTRIP

CHARGERMALFUNCTION

LV HV CM

CONNECT TO TB1

Figure 6-4 Float/Equalize Battery ChargerConnections

GM67191-B

Figure 6-5 Battery Charger to ControllerConnections

6.1.3 Gas Fuel Valve Kit

This section provides the wiring information for anadditional gas fuel valve kit required for UL Approval.See Figure 6-6. Refer to the respective generator setwiring diagrams for additional information and for LPliquid applications.

GM72401D-D

Figure 6-6 Gas Fuel Valve Kit Connections


6.1.4 Input/Output (I/O) Module Board

The I/Omoduleboardprovidesagenerator setmountedpanel with two analog inputs and five digital outputs.See Figure 6-7 for circuit board components andelectrical connections to the controller.

Analog Inputs

The inputs are set as analog inputs in SiteTecht(Analog input B1 and Analog input B2). See Figure 6-8for connections of analog inputs. Refer to Figure 6-28for accessory connections.

See Section 6.2, Accessory Connections, for terminalidentification.

GM64493

1. P29/P30/P31 K1/K2/K3 2-amp relay outputs2. P32 K4/K5 10-amp relay outputs3. SW1 switch4. P28 In1/In2 analog inputs

1 2

5. P25 RJ45 In (DEC 3000 P23)6. P26 RJ45 Out7. P27 CAN terminator

3

4

5

6

7

Figure 6-7 Input/Output (I/O) Module Board Kit

TP-6694-6

+5

VPx

VNx

GND

P28

100 ohm min. or 50 mA max. current

+5

VPx

VNx

GND

P28

AnalogDevice

GND

Output

Optional 5 V power(50 mA max.)

+5

VPx

VNx

GND

P28

AnalogDevice

GND

Optional 5 V power(50 mA max.)

+

--

0--5 Volt Ratiometric Sensor 0--5 Volt Analog Device +/-- 3 Volt Analog Device

Figure 6-8 Analog Input Connections P28


6.1.5 Low Fuel (Level/Pressure) Switch

Some gas-fueled models offer a low fuel pressureswitch. The low fuel pressure switch connects to thesame controller terminal as the low fuel level switch ondiesel-fueledmodels. See Figure 6-9, Figure 6-10, andFigure 6-11.

Note: The main tank or the transfer/day tank includesthe low fuel level switch. The fuel tank suppliertypically provides the low fuel level switch.

GM16088A-A/TP-6694

CONNECT TO TB1(for warning) or TB3 (forshutdown)

Figure 6-9 Low Fuel Switch (Level or Pressure)

GM67191-B

Figure 6-10 Low Fuel Switch Connection toController Connection

Switch Rating 12 volts DC minimum, 0.5 amp minimum

Wiring Recommendation

Gauge mm (ft.)

18--20 30.5 (100)

14 153 (500)

10 305 (1000)

Figure 6-11 Switch Rating & Wiring Recommendation

6.1.6 Manual Speed Adjust (EngineRPM Menu) (Software version 3.10.3 orhigher)

The control allows varying the engine speed forapplications using closed transition ATS. The user canset the nominal running frequency slightly above orbelow the utility frequency to ensure thatsynchronization occurs. Available as a factory-installed

option or requires a new factory personality profile.Additional information is shown in 2.7.7 GenSetSystem.

6.1.7 Prime Power Switch Kit

Theprimepower switch kit prevents battery drain duringgenerator set non--operation periods and when thegenerator set battery cannot be maintained by an ACbattery charger. SeeFigure 6-12 for an illustrationof thekit and Figure 6-13 for the electrical connections.

Stop the generator set using the stopping procedures inSection 2.4.2, Stopping, before placing the generatorset in the prime power mode. Move the prime powerswitch located on the junction box to the DOWNposition. The controller including the digital display,LEDs, and alarm horn does not function when thegenerator set is in the prime power mode.

Move theprimepower switch locatedon the junctionboxto the UP position. The generator set is now ready forstarting.

1. Prime power decal (293668)

PRIMEPOWERSWITCH GM20652-/

TP-6694

1

2

2. Toggle switch (354464)

Figure 6-12 Prime Power Switch

GM64345-/TP-6694

Toggle switch shown in theprime power mode offposition (contacts open)

Figure 6-13 Prime Power Switch Connections


6.1.8 Remote Emergency Stop Kit

The emergency stop kit allows immediate shutdown ofthe generator set from a remote location. SeeFigure 6-14 and Figure 6-15. If the emergency stopswitch activates, the EMERGENCY STOP lamp lightsand theunit shuts down. Before attempting to restart thegenerator set, reset the emergency stop switch (byreplacing the glass piece) and reset the generator set bypressing the master control switch OFF/RESET button.

Use the single glass piece located inside the switch forreplacement and order additional glass pieces asservice parts. See Section 2.4.3, Emergency StopSwitch Resetting.

See Section 6.2, Accessory Connections, for terminalidentifications.

A-222654TP-5352-1

Figure 6-14 Emergency Stop Kit

GM67191-B

Figure 6-15 Remote Emergency Stop KitConnections

6.1.9 Remote Reset Feature

The remote reset switch provides generator setcontroller resetting after a fault shutdown at a remotelocation. See Figure 6-16 and Figure 6-17 foruser-supplied switch connection.

Press and hold the switch for 2--3 seconds and releaseto reset the generator set controller.


REMOTE RESET SWITCHCONTACTS NORMALLY OPENMOMENTARY CLOSED TOACTIVATE

GM16088A-A-/TP--6694

CONNECT TO TB1 as a Di-gital Input

Figure 6-16 Remote Reset Switch Connections

Switch Rating 12 volts DC minimum, 1 amp minimum

Wiring Recommendation

Gauge m (ft.)

18--20 30.5 (100)

14 153 (500)

10 305 (1000)

Figure 6-17 Switch Rating and WiringRecommendations


6.1.10 Remote Serial Annunciator

RSA III is an annunciator panel offered in several kitconfigurations to support Kohler power equipment. TheRSA III is a remote serial annunciator (Figure 6-18,Figure 6-19, and Figure 6-20) that monitors thecondition of the generator set and/or ATS from a remotelocation. The RSA III alerts the operator through visualandaudible signals using LED indication and ahorn. Analarm silence and lamp test switch are included.

Figure 6-18 Remote Serial Annunciator (RSA III)

The RSA III meets NFPA 110, Level 1 (2005)applications that require remote controls and alarms bepowered by a storage battery such as the enginestarting battery. AC adaptor kit GM62466-KP1 isavailable when NFPA is not required.

The front panel decals include areas that can be used toidentify user-selected fault inputs and identifyassociated power system equipment.

An RSA III annunciator can be used for a singlegenerator set or with a combination of a generator setand automatic transfer switch. In systems using morethan a single RSA III, one must be designated as themaster device to broadcast to additional RSA IIIannunciators, designated as slave devices. Up to fiveRSA III slave devices can be used with an RSA IIImaster device. All RSA III annunciators are factory setas the master device, but can be changed to a slavedevice using a PC and SiteTecht software thatconnects to the RSA III front panel via a universal serialbus (USB) connection.

The RSA II and RSA 1000 can be connected with theRSA III provided that the master remote annunciator isan RSA III.

Refer to TT-1625 Remote Serial Annunciator (RSA III)Kits for operation and installation instructions.


Figure 6-19 RSA III with Single ATS Control

Figure 6-20 RSA III with Four ATS Controls

A PC with SiteTecht software is required to makethe RSA III functional. Use your SecurID to accessKOHLERnet, click on the TechTools button, and followthe instructions to download the files. See SiteTechtSoftware Settings and refer to TP-6701 SiteTechtSoftware Operation Manual for more information.

The RSA III kits include components for surfacemounting or flush mounting.

Figure 6-21 shows the status of the system ready LED,generator set running LED, communication status LED,common fault LED, common fault output, and horn foreach fault or status condition.

If a fault occurs, the RSA III horn activates and thecorresponding LED illuminates.

If the RSA III is used with an Ethernet communicationnetwork, order Modbusr Ethernet converterGM41143-KP2 and refer to TT-1405 Converters,Connections, and Controller Setup for NetworkCommunication for system installation.


Fault and Status ConditionFaultLED

System Monitoring LEDs and Functions

SystemReady LED

GeneratorRunning LED

CommunicationsStatus LED

CommonFault LED

CommonFaultOutput Horn

Overcrank (Shutdown) Red SF Red SF Off Green Red SF On On

High Engine Temperature (Warning) Yellow SF Red SF Green Green Red SF On On

High Engine Temperature (Shutdown) Red SF Red SF Off Green Red SF On On

Low Oil Pressure (Warning) Yellow SF Red SF Green Green Red SF On On

Low Oil Pressure (Shutdown) Red SF Red SF Off Green Red SF On On

Overspeed (Shutdown) Red SF Red SF Off Green Red SF On On

Emergency Stop Red SF Red SF Off Green Off On On

Low Coolant Level/Aux (Shutdown) Red SF Red SF Off Green Red SF On On

Low Coolant Temperature Yellow SF Red SF Green or Off Green Red SF On On

Low Fuel Yellow SF Red SF Green or Off Green Red SF On On

Low Cranking Voltage Yellow SF Red SF Off Green Red SF On On

Battery Charger Fail Yellow SF Green Green or Off Green Off On On

Battery Voltage (Hi) Yellow SF Green Green or Off Green Off On On

Battery Voltage (Lo) Yellow SF Green Green or Off Green Off Off Off

Common Fault (Warning) Yellow SF Green Green or Off Green Red SF On Off

Common Fault (Shutdown) Red SF Green Green or Off Green Red SF On On

User Input #1 (Warning) Yellow SF Green Green or Off Green Off Off Off

User Input #1 (Shutdown) Red FF Green Green or Off Green Off On On









ATS Position N (RSA III with ATS only) Green Green Green or Off Green Off Off Off

ATS Position E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off

ATS Available N (RSA III with ATS only) Green Green Green or Off Green Off Off Off

ATS Available E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off

ATS Test (RSA III with ATS only, Testinitiated at ATS)

Yellow Green Green or Off Green Off Off On

ATS Test (RSA III with ATS only, Testinitiated at RSA)

Green Green Green or Off Green Off Off On

ATS Fault (RSA III with ATS only, No fault) Green Green Green or Off Green Off Off On

ATS Fault (RSA III with ATS only, Withfault)

Red FF Red SF Green or Off Green Off Off On

EPS Supplying Load Green Green Green or Off Green Off Off Off

Not-In-Auto Red FF Red SF Off Green Red SF On On

Communication Status (Loss - Master) Red FF Off Off Red FF Off On On

Communication Status (Loss - Slave) Red SF Off Off Red SF Off On On

Note: SF = Slow Flash (once per second), FF = Fast Flash (five times per second)

Figure 6-21 System Monitoring LEDs and Functions



6.1.11 Run Relay Kit

The run relay kit energizes only when the generator setruns. Use the run relay kit to control air intake andradiator louvers, alarms, and/or other signallingdevices. See Figure 6-22 and Figure 6-23.


273705

Figure 6-22 Run Relay Kit

GM67191-B

Figure 6-23 Run Relay Connections

6.1.12 Shunt-Trip Line Circuit Breaker

A shunt-trip line circuit breaker provides a 12- or 24-DCvolt solenoid within the line circuit breaker case that canenergize the trip mechanism. This feature allows thecircuit breaker to be tripped by the common fault (32A).Connection requires a shunt-trip wiring kit and a drycontact kit. See Figure 6-24 and Figure 6-25.

The optional common fault relay shown in Figure 6-25as DCB1 has contacts rated at 10 amps at 28 VDC or120 VAC and is used to trigger the shunt-trip line circuitbreaker kit.

GM67191-B

Figure 6-24 Shunt-Trip Wiring (Standard)

GM67191-B

Figure 6-25 Shunt-Trip Relay Kit and Line CircuitBreaker Wiring (Shown with CommonFault/Failure Relay Kit)


6.2 Accessory Connections

The controller contains a circuit board equipped withterminal strip(s) for use in connecting external optionalaccessories including alarms, battery chargers, andremote switches. The optional I/O board provides anadditional two analog or digital inputs and five digitaloutputs.

For specific informationonaccessoryconnections, referto the accessory wiring diagrams in the wiring diagrammanual and the instruction sheet accompanying the kit.See Figure 6-26, Figure 6-27, and Figure 6-29 forcontroller circuit board connections.

1. (4) push-on terminal connectors2. TB2 4-position terminal block3. TB3 6-position terminal block4. P2 6-pin connector5. P1 24-pin connector6. TB1 6-position terminal block7. P22 3-pin connector8. P23 8-pin connector (RJ45)9. P21 6-pin connector

GM64345-C

1

2

3

4

56

9

7

8

Figure 6-26 Controller Circuit Board Connections


TB1 Terminal Strip

Analog and Digital Input Connections

Terminal Description Connection

TB1--DI 1 DCH1 No Function

TB1--DI 2 DCH2 Aux. Warning Switch

TB1--DI 3 DCH3 Battery Charger Fault

TB1--AI 1 ACH1 No Function

TB1--AI 2 ACH2 No Function

TB1--GND Ground Common A/D Ground

TB2 Terminal Strip

KI Relay Outputs


TB2--COM Common User--Defined

TB2--COM Common Common Fault (2)

TB2--NO Normally Open Common Fault (32A)

TB2--NC NormallyClosed User--Defined

TB3 Terminal Strip

Accessory Power Output Connections


TB3--1 E--Stop E--Stop Ground

TB3--1A E--Stop E--Stop

TB3--3 Remote Start Remote Start

TB3--4 Remote Start Remote Start

TB3--AUX Auxiliary Aux. Shutdown Sw.

TB3--AUXR Auxiliary--R Aux. Shutdown Sw.

P1 24-Pin Connector

Engine Wiring Harness


P1--12 14P +12VDC Prime Power Switch

P21 6-Pin Connector

RS-485 (RSA II)


P21--1 GND Shield

P21--2 (+) Red

P21--3 (--) Black

P21--4 GND Shield

P21--5 (+) Red

P21--6 (--) Black

TB1 Terminal Strip Designations

Analog and Digital Input Connections

Terminalson Board

ControllerDesignation

SiteTechDesignation

TB1--DI 1 DIn A1 A1

TB1--DI 2 DIn A2 A2

TB1--DI 3 DIn A3 A3

TB1--AI 1 AIn A1 —

TB1--AI 2 AIn A2 A1

TB1--GND — —

Figure 6-27 Controller Connections


P25 Connector

RJ45 Remote I/O In

Connects to DEC 3000 P23

P26 Connector

RJ45 Remote I/O Out

Open

P27 Connector

CAN Terminator

Place the P27 jumper on the IN pins

P28 Connector

Single-Ended (0--5 V) Analog Input Connections

Terminal Description

P28--GND AGND Analog Return

P28--VN1 NO Connection

P28--VP1 ACH1 Signal

P28--+5V Supply (.05 amp max.)

P28--GND AGND Analog Return

P28--VN2 NO Connection

P28--VP2 ACH2 Signal

P28--+5V Supply (0.05 amp max.)

P28 Connector

Differential (+/--3 V) Analog Input Connections


P28--GND AGND Analog Reference

P28--VN1 ACH1 Negative Differential Signal

P28--VP1 ACH1 Positive Differential Signal

P28--+5V Supply (.05 amp max.)

P28--GND AGND Analog Reference

P28--VN2 ACH2 Negative Differential Signal

P28--VP2 ACH2 Positive Differential Signal

P28--+5V Supply (0.05 amp max.)

P29 Connector

2 Amp. K1 Relay Output (2.1) Connections


P29--NC Normally Closed

P29--COM Common

P29--NO Normally Open

P30 Connector




P30--COM Common


P31 Connector




P31--COM Common


P32 Connector




P32--COM Common





P32--COM Common


P28 Connector Designations

Terminalson Board

ControllerDesignation

SiteTechDesignation

P28--GND

DIn B1 B1P28--VN1

P28--VP1

P28--+5V

P28--GND

Din B2 B2P28--VN2

P28--VP2

P28--+5V

Figure 6-28 Input/Output Module Board Connections


Figure 6-29 Decision-Makerr 3000 Wiring Connections GM67191-B

TP-6694 11/15 Appendix 91

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAh amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certifiedcfh cubic feet per hour

cfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistancedeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered specialESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)

exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvinkA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogram

TP-6694 11/1592 Appendix

kg/cm2 kilograms per squarecentimeter

kgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)NA not available, not applicablenat. gas natural gas

NBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifiers, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer


Appendix B Programmer-Defined Settings

Use the table below to record programmer-definedsettings during the generator set controller setup andcalibration. The controller default settings and rangesprovide guidelines. The table contains all faults withranges and time delays including items that do not haveadjustments. Some notices give the programmer achoice to make them active Not adjustableprogrammer-defined settings result when the controllerlogic does not allow changes or the values are enginelimited.

SiteTecht setup software is required for programming theDecision-Makerr 3000 controller. Contact your localdistributor/dealer for assistance.

Note: Inhibit time delay is the time delay period aftercrank disconnect.

Note: The engine ECMmay limit the crank cycle even ifthe controller is set to a longer time period.

Programmer-Defined Settings

DescriptionController Display

Message



RangeSetting

DefaultSelection



Programmer-DefinedSettings

Engine Functions

Critically high fuel level(diesel-powered models only) *

Fuel Level CriticallyHigh 0--100% 95% 0--10 5

ECM communications loss ECM Comm ErrShutdwn Fixed 10 Not adjustable

ECM diagnostics (multipleinputs) [ ECM xxxxxx Warning Not adjustable

ECM diagnostics (multipleinputs) [ ECM xxxxxx Shutdwn Not adjustable

ECM faults (address conflict) ECM Addr ErrShutdwn Not adjustable

ECM faults (model mismatch) ECM MismatchShutdwn 0--255 0

Engine over speed Eng Speed HighShutdwn S A 105--120% 115%

Engine RPM(manual speed adjust)Version 3.10.3 or higher Engine RPM Display DS A

60 Hz:1751--184950Hz:

1451--1549

60 Hz:180050 Hz:1500

Engine start aid active Starting Aid Notice

Engine under speed Eng Speed LowShutdwn S A 75--95% 85%

Fuel tank leak * Fuel Leak Warning Not adjustable

Fuel tank leak * Fuel Leak Shutdwn Not adjustable

High battery voltage Battery High Warning S A 110--135% 125% Fixed 10 Not adjustable

High coolant temperature Coolnt Temp HighWarning

0--10(0--30inhibit)

0(0

inhibit)

High coolant temperature Coolnt Temp HighShutdwn

0--10(0--30inhibit)

0(0

inhibit)

High fuel level (diesel-poweredmodels only) *

Fuel Level HighWarning 0--100% 90% 0--10 5

Loss of fuel Loss of fuel Not adjustable

Low battery voltage Battery Low Warning S A 80--105% 100% Fixed 90 Not adjustable

Low coolant level * Coolant Lvl LowShutdwn Fixed 5 Not adjustable

Low coolant temperature Coolant Temp LowWarning Fixed

16_C(60_F)

0--10(0--30inhibit)

5(0

inhibit)

Low cranking voltage Lo Crank Vlt Warning Fixed 60% Fixed 6 Not adjustable

Low engine oil level * Oil Level Low Warning Not adjustable


Description




DefaultSelection

RangeSetting




Low engine oil level * Oil Level Low Shutdwn Not adjustable

Low fuel level (diesel models) * Fuel Level LowWarning 0--100% 35% 0--10 10

Low fuel level (diesel models) * Fuel Level LowShutdwn 0--100% 5% 0--10 0

Low fuel pressure(gas models) *

Fuel Press LowWarning Not adjustable

Low oil pressureOil Press Low Warning

Fixed(Fixedinhibit)

0(30

inhibit)Not adjustable

Low oil pressureOil Press Low Shutdwn

Fixed(Fixedinhibit)

5(30

inhibit)Not adjustable

No coolant temperature signal Temp Sig LossShutdwn Not adjustable

No oil pressure signal Press Sig LossShutdwn Fixed 5 Not adjustable

OvercrankOver Crank Shutdwn Fixed

(30inhibit) Not adjustable

Speed sensor fault Spd Sens Flt Warning Not adjustable

General Functions

Alarm silence, 0--Auto only(NFPA 110), 1--Always AlarmSilenceMode S A 0--1 1

Aux. inputs 0--5 VDC, 1 analog Aux Input Warning 0--100% 100% 0--10 0

Aux. inputs 0--5 VDC, 1 analog Aux Input Shutdwn 0--100% 100% 0--10 0


Aux Input Warning0--10(0--30inhibit)

0 (0inhibit)


Aux Input Shutdwn0--10(0--30inhibit)

0 (0inhibit)

Backup parameters loaded Backup Pars Status Not adjustable

Battery charger fault * Batt Chg Flt Warning Not adjustable

Chicago code active * Auto Locked Notice

Common fault Common FaultShutdwn Not adjustable

Common warning Common Warng Not adjustable

Contrast (see 2.7.7 GenSetSystem) Contrast Display D A 1--10 5

Default parameters loaded Default Pars Warning Not adjustable

Emergency stop Emerg Stop Shutdwn Not adjustable

Engine cooldown (delay) active Eng Cooldown Notice

Engine start delay active Start Delay Notice

Engine started Engine Start Status Not adjustable

Engine stopped Engine Stop Status Not adjustable

EPS supplying load Emerg Pwr On Notice Not adjustable

File system error (controllerfault) File Error Shutdwn Not adjustable

Generator running Gen Running Notice Not adjustable

Input/output (optional moduleboard) communication loss OB1 Com Loss Not adjustable

Internal failure Intern Error Shutdwn Not adjustable

Measurement Units,0--English, 1--Metric Measurement Display DS A 0--1 1

Metering communication loss MeterCommLosShutdwn Not adjustable


Description




DefaultSelection

RangeSetting




NFPA 110 alarm active NFPA Alarm Notice

Not in auto (master controlbuttons) Not In Auto Warning Not adjustable

Prime power application,0--Standby, 1--Prime Power Type DS A 0--1 0

Remote start Remote Start Status Not adjustable

System ready System Ready Status Not adjustable

System timer failed Timer Error Notice Not adjustable

Generator Functions

AC sensing loss AC Sens Loss Warning Not adjustable

AC sensing loss AC Sens LossShutdwn Fixed 3 Not adjustable

Alternator protection Alt Protect Shutdwn Not adjustable

Ground fault input * Ground Fault Warning Not adjustable

kW overloadTotal Power High

Shutdwn Fixed

102%standby,112%prime

Fixed 60 Not adjustable

Locked rotor (failed to crank) Locked Rotor Shutdwn S A 1--5 5

Overfrequency Freq High Shutdwn 102--140% 110% Fixed 10 Not adjustable

Overvoltage (each phase) Volts (L1--L2, L2--L3, orL3--L1) High Shutdwn S A 105--135% 120% 2--10 2

Power rating Pwr Rating DS S 10--5000 275

System frequency System Freq DS S 50--60 60

System voltage System Volt DS S 110--600 208

Underfrequency Frequency LowShutdwn 80--95% 90% Fixed

10 ST60 LT Not adjustable

Undervoltage (each phase) Volts (L1--L2, L2--L3, orL3--L1) Low Shutdwn S A 70--95% 80% 5--30 10

Voltage/phase configuration,0--Single phase, 1--Singlephase dogleg, 2--three phasewye, 3--three phase delta

SystemPhase DS S 0--3 2

Voltage regulator averagevoltage adjustment VR Volt Adj DS R 108--600 208

(Voltage) regulatorcommunication loss

RegCommLossShutdwn Not adjustable

SiteTech Read/Write Display Only

Current transformer ratio ] S S 1-- 1200

ECM power S S 0--1 0

Engine cooldown delay S A 0--600 300

Engine (cyclic) crank on S A 10--30 15

Engine (cyclic) crank pause S A 1--60 15

Engine ECM start delay S A 0--300 0

Engine idle duration S A 0--60 60

Engine no. of (cyclic) crankcycles S S 1--6 3

Engine restart delay S A 1--10 10

Engine start aid delay S A 0--10 0

Engine start delay S A 0--300 0

System battery voltage ] S S 12--24 12

Voltage regulator gain S R 1--255 128

Voltage regulator stabilityadjust S R 1--255 128


Description




DefaultSelection

RangeSetting




Voltage regulator, volts perHertz slope S R 1--10 5

Voltage regulator, volts perHertz cutin frequency S R 42--62 57.5

* Some functions require optional input sensors or are engine ECM dependent on some generator set models.[ ECM inputs are engine manufacturer dependent.] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).

ST--Short Term, LT--Long Term


Appendix C Voltage Regulator Definitions and Adjustments

The following definitions and adjustment/settingspecifications are intended for users planning to adjustthe voltage regulator beyond the default settings inorder to customize the alternator for a specificapplication.

This information is not intended to be a comprehensiveexplanation of all the terms mentioned. There arenumerous documents available that define these termsmore completely than described herein. Any userplanning to change the generator set controlleradjustment settings or to apply the generator set tothese types of applications should understand theseterms.

This appendix contains references to other sections ofthis manual. Please refer to these sections for furtherinformation and explanation.

Paralleling generator sets can be a complicated anddangerous exercise. Application programmingmust beperformed by appropriately skilled and suitably-trainedpersonnel.

Definitions

Underfrequency Unloading

Underfrequency unloading is a function used in thealternator excitation control system to improve theoverall generator set system (engine and alternator)response. In particular, underfrequency unloadingrelates to large-block load applications. When appliedto engine-driven alternators, large-block loads cause asubsequent transient torque load on the engine. Thistorque load can reduce the engine’s speed below thenormal operating point. Typically, the engine speedcontroller or governor will compensate for this bycommanding an increase in fuel. If, however, the fuelsystem is inadequate to recover from a relatively largeload, the speed may never recover. In these instances,other measures must be taken. This is where theunderfrequency unloading occurs.

When the excitation control systemdetects a drop in thespeed or electrical frequency below somepredetermined point, the control system enters anunloading condition. This can be described as movingto a lower voltage regulation point. By reducing theoutput voltage of the alternator, the load on thegenerator set is reduced. This can be shown

mathematically byOhm’s law,which states that power isequal to the voltage squared divided by the impedance.As the voltage is reduced, the power delivered by thealternator decreases by a squared relationship. Since itis the power in the alternator that translates into enginetorque, the engine load is also reduced.

By changing various parameters of this compensationtechnique, the controlling system can be tailored tomatch the performance capabilities of most engine andalternator combinations. The point at which theunloading begins to act or how much unloading occurscan be adjusted to impact maximum voltage droop,maximum speed droop, or time to recover. Someapplications may not need unloading and, in thesecases, set the unloading parameter to disable thefunction. These parameters are further describedbelow. An example is provided to help clarify therelationship between these parameters.

Underfrequency Unload Slope

Underfrequency unload slope is the term used todescribe the amount that the voltage is reduced,per-cycle-per-second or per-hertz (Hz), when in anunderfrequency condition. The slope or schedule issometimes called the volts-per-hertz slope. When theelectrical frequency drops below the cut-in point (seebelow), the excitation control system temporarilyreduces the regulated voltage to reduce the subsequenttorque on the engine. The amount that the controlsystem reduces voltage is defined as the product ormultiplication of the slope and the amount of frequencyor speed below the cut-in point. For every Hz below thecut-in point, the control system reduces the line-to-linevoltage by an amount equal to the slope.

Becauseeachengine respondsdifferently to thevariousloads encountered, the slope may be adjusted toimprove the system response. If, when large loads areapplied to the generator set, the engine speed dropsbelow the acceptable limit (as determined by theparticular loads applied), the slope may need to beincreased. Increasing the slopewill cause the voltage todroop more during load applications, consequentlyreducing the load torque on the engine and allowing thespeed to increase. If, however, the voltage drops belowan acceptable lower limit (as determined by theparticular loads connected to the generator set), a lowerslope may work better. The underfrequency unloadingfunction may be disabled by setting the slope to zero.


Frequency Setpoint or Cut-In Point

Thepoint atwhich theunderfrequencyunloadingbeginsto take effect is adjustable, allowing the system to betailored for each application. Because thecharacteristics of the engine have the largest effect onthe system’s performance, the engine’s responseshould determine the unloading point. The unloadingsetpoint is the frequency below which the excitationcontrol will reduce the voltage so that the engine maybegin to recover.

The cut-in point, or frequency setpoint, should be set0.5--3.0 Hz lower than the normal steady-state band ofoperation. If the engine normally operates within a verynarrow range of speeds close to the nominal, a setpointof 0.5 to 1.0 Hz below nominal should be suitable. If theengine normally operates over a wide range of speeds,the setpoint may need to be 2.0--3.0 Hz from thenominal. The underfrequency unloading function canbe eliminated by setting the cut-in point below theminimum expected operating frequency.

Example

A90 kW load is applied to a 100 kW, 60Hz generator setdriven by a turbocharged diesel engine with anelectronic controlmodule (ECM). Thespeeddrops10%and takes20 seconds to recover to at least 59.5Hz. Thevoltage,meanwhile, drops from480 to460and recoversto 480 within 15 seconds. Therefore, someunderfrequency unloading should be provided. A goodstarting point would be a frequency setpoint or cut-in of59 Hz. A slope of 15 volts per-cycle-per-second isappropriateaswell. If after theseadjustments thespeedrecovers very quickly, in about 5 seconds, but thevoltage drops below 440 volts, the slope should bereduced to 12 volts per cycle. More adjusting may berequired to get themost desirable compromise betweenspeed and voltage.

Three-Phase Sensing

Three-phase sensing describes how the excitationcontrol or voltage regulator determines the condition ofthe alternator output voltage. Early types of regulatorssensed the voltage on just one phase of the alternator.Single-phase sensing is not uncommon today as mostalternators are designed to produce balanced, equalvoltage on all three phases. If the loads applied to thegenerator set including no load are equal and balanced,the output voltage on each phase will be nearly equal.

However, in some applications, individual phases mayhave unequal or unbalanced loads. In these cases, theoutput voltages will not be equal on each phase. In

general, the phase with the greatest load will have thelowest voltage while the phase with the least load willhave the highest voltage. This is true regardless of thetype of sensing used in the regulator system. Asingle-phase sensing excitation controller will keep thevoltage of the sensed phase at the voltage adjustmentvalue. A three-phase sensing system will average thethree phases and hold the average to the adjustmentsetting. The average is the sum of the voltages of threephases divided by 3.

As stated above, three-phase sensing does noteliminate the unequal voltage phenomenon.Three-phase sensing balances the inequality of voltagebetween the phases to the desired value. In otherwords, if a system with unbalanced loads uses asingle-phase control feedback, the voltage on thesensed phase would be at the setpoint while the othertwo phases would vary by their proportional loads. Forexample, if the sensed phase had rated load while thetwo other phases were only loaded at half the ratedvalue, those two phases would have higher-than-ratedvoltage which may be undesirable. If a three-phasesensing feedback were utilized, the phase with ratedload would be regulated to a voltage slightly below therated voltage while the other two phases would beslightly above the rated voltage (but lower than in theprevious case). The sum of the three, divided by 3,would be equal to the regulation setpoint.

In a single-phase system, line-to-line voltage is heldequal to the line-to-line voltage adjust setting. In athree-phasesystem, theaverageof the three line-to-linevoltage is regulated to the voltage adjust setting. Insome cases, it may be desirable to keep one phase at aparticular value. Modify thevoltageadjust settinghigheror lower accordingly for any unique requirements for theparticular application.

Adjustment and SettingSpecifications

Voltage Adjust

The voltage adjust is entered as the rated or otherwisedesired line-to-line voltage. The average of theline-to-line voltages is then regulated to thecorresponding value as previously described. Thesetting may be as fine as tenths of volts. The voltageadjust defaults to the rated system voltage wheneverthe system voltage is changed. The voltage adjust maybe set to any value within 10% of the system voltage.The upper limit is 10% above the system voltage andthe lower limit is 10% below the system voltage.


As a reference, the present voltage adjust setting isdisplayed aswell as the average value of the line-to-linevoltages. The individual line-to-line voltages are alsodisplayed on the subsequent menu screens. Thisallows the user to monitor any individual phase, ifdesired.

The voltage adjust setting may be changed by meansother than the menu including user-defined digital inputor remote communications. If voltage adjustmentoccurs, the new value will be displayed accordingly inthe voltage adjust menu.

Underfrequency Unload Enable

Theunderfrequencyunloadenablemenu is used to turnthe underfrequency unload on or off. A YES entry willturn the feature on and the display will show ENABLEDYES. A NO entry will turn the feature off and the displaywill show ENABLED NO. The underfrequency unloaddefaults to an enabled (ON) condition.

Frequency Setpoint

The frequency setpoint is the cut-in point forunderfrequency unloading. At any operating frequencybelow the frequency setpoint, the output voltage will bereduced. The frequencymay be enteredwith resolutionto tenths of a Hz. The range of acceptable entries is 30to 70 Hz. The default value is one cycle-per-second (ortwo for non-ECM engines) below the normal systemfrequency. The frequency setpoint changes to thedefault value if the system frequency changes. Asettingof 30Hzessentially disables theunderfrequencyunloadfeature because most engines do not normally drop tospeeds this low, even during load applications.

Underfrequency Unload Slope

The slope determines how much voltage is reducedduring an unloading condition. The line-to-line voltageis regulated to a value less than the voltage adjustsetting by this amount for every cycle below thefrequency setpoint. The voltage may be entered withresolution as fine as one-tenth of one volt. The defaultvalue is 2.0 volts per-cycle-per-second. A zero entry forthe slope in effect turns the underfrequency unloadfeature off.


Notes

TP-6694 11/15 Appendix 101

Appendix D Alternator Protection

The 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 shutdown. The amount of time at whichcurrent is over the rating is inversely related to theamount of current above the nominal rating. In otherwords, the higher the current, the shorter the acceptabletime.

The current and time limits are defined by actual testdata and are maintained in the personality parameterfile. Although the equation for detecting a fault isproprietary, some of the important limits are shownbelow for informational purposes.

Rated Current Time Delay

200% 40 seconds

300% 10 seconds

425% 5 seconds

950% 1 second


Notes

TP-6694 11/15 Appendix 103

Appendix E Controller Displays from the Engine ECM

The controller display showing engine information isdependent upon the engine manufacturer and thecorresponding Engine Control Module (ECM). Thefollowing list indicates what engine displays areavailable by the engine manufacturer. This informationis subject to change by the engine manufacturer.

Some engines do not have an ECM and in some casesthe ECM information is not available as a controllerdisplay. In these situations, critical information like oilpressure and coolant temperature are displayed by thecontroller using independent engine sensors not usedby the ECM.

Controller Displays as Provided by the Engine ECM (availability subject to change by the engine manufacturer)Display GM/PSI Doosan John Deere (JDEC) Volvo (EMS II) Volvo (EDC III) DD/MTU (ADEC)

Ambient temperature XCharge air pressure X X X X XCharge air temperature X X X X XCoolant level X X XCoolant pressure X XCoolant temperature X X X X X XCrankcase pressure X XECM battery voltage X X XECM fault codes X X X X X XECM serial number XEngine model number X XEngine serial number X XEngine speed X X X X X XFuel pressure X XFuel rate X X X X X XFuel temperature X X X XOil level XOil pressure X X X X X XOil temperature X X XTrip fuel X X X

Note: 15--60REOZK (Kohler KDI engines) do not have an ECM. REOZMD/ROZMC (Mitsubishi engines) have anECM but do not send signals to the Decision-Makerr 3000 controller.


Notes

TP-6694 11/15 105

Notes

TP-6694 11/15106

Notes

E 2010, 2011, 2014, 2015 by Kohler Co. All rights reserved.

TP-6694 11/15e

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455

OPERATION AND MAINTENANCE MANUAL

CERTIFIED STATIONARY PRODUCT

361000014F A Product by Power Solutions International

Wood Dale, IL

TP-6101 8/13N

2

Operation and Maintenance Manual Certified Stationary Product

TOPIC PAGE

Introduction 4

How to Use This Manual 4

Engine Identification 4

Parts and Service 5

Service Literature 5

Operating Instructions 5

Fuel Systems 5

Governors 5

Oil Pressure Gauge 5

Temperature Gauge 6

Voltmeter 6

Tachometer/Hourmeter 6

Starting the Engine 6

LPG or NG Fuel Systems 7

Stopping the Engine 7

Fuel Recommendations 7

Fuel Quality 7

Spark Plugs 8

Power Loss at Higher Elevations 8

Maintenance Instructions 8

Initial Start Up Maintenance 8

Routine Maintenance 8

Scheduled Preventive Maintenance 8

Engine Oil Level Check 9

Adding Engine Oil 9

Changing Engine Oil and Filter 9

Table of Contents

3


TOPIC PAGE

Engine Oil Quality 9

Engine Oil Recommendation 10

Oil Filter 10

Engine Air Cleaner 10

Safety Element 11

Cooling System 11

Coolant Level 11

Radiator 12

Fan Belts 12

Serpentine Belt 12

V-Type Belt 12

Fuel Filter 12

Fuel Shut Off 13

Ignition Systems 13

Types of Ignition Systems 13

Ignition Timing 13

Spark Plugs 13

Storage 14

One to Six Months 14

Extended Periods 14

Removing the Engine From Storage 14

Maintenance Schedule 15

General Specifi cations 16

No part of this publication may be reproduced without written permission from Power Solutions, Inc.

At the time of publication, all of the information included in this publication is accurate to the best of

our knowledge. Power Solutions, Inc. cannot be responsible for information that has changed after

this book was published.

4


Introduction

Power Solutions, Inc. is pleased that you have selected our engine for your requirements. Power

Solutions, Inc. takes great pride in our tradition of quality products produced from our line of industrial

gasoline and alternative fuel engines.

Prior to starting the engine at your facility, certain checks should be made. Please read the Initial Start-

Up inspection requirements in the Maintenance Section of this manual. If you have further questions

please contact your PSI account representative or Customer Support Engineer

How to Use this Manual

This manual contains instructions on the safe operation and preventive maintenance of your PSI

industrial engine. We urge you to read this manual prior to start up or operation of the engine.

The Table of Contents permits you to quickly open the manual to any section.

Power Solutions, Inc., engines are built with a variety of standard and/or optional components to suit a

broad range of customer requirements. This manual does not identify equipment as standard or

optional. All the equipment described in this manual may not be found on your engine or power unit.

Please pay special attention to the NOTES, CAUTIONS, and WARNINGS. WARNINGS remind you

to be careful in areas where carelessness can cause personal injury. CAUTIONS are given to prevent

you from error that could cause damage to the equipment. NOTES give you added information

designed to help you.

The descriptions and specifications contained in this manual were in effect at the time of publication.

Power Solutions, Inc. reserves the right to discontinue models at any time, or to change specifications

or design without notice and without incurring obligation.

Engine Identification

An identification label is affixed to the right side

of the engine on the rocker cover when looking

at the engine from the flywheel end. (The engine

serial number is also stamped into the left side of

the cylinder block near the engine flywheel.) The

label contains the engine family number and a

serial number which identifies the engine from

other PSI engines. The engine model and serial

number are required when seeking information

concerning the engine and/or ordering replace-

ment service parts.

5


Parts and Service

Replacement parts can be obtained from Power Solutions, Inc. by calling the Aftermarket Parts

Department at 888-331-5769. The engine model and serial number will be required when seeking

information and/or ordering parts.

Service and technical support for PSI engines can be obtained by contacting the Service Department at

888-331-5764 or via email at [email protected].

Service Literature

Additional operator manuals and service manuals for specific PSI engines can be obtained by

contacting the Parts or Service Department at 888-331-5769 or [email protected].

Operating Instructions

Fuel Systems

The fuel system installed on your engine operates with an Electronic Pressure Regulator (EPR) and a

diaphragm style variable venturi mixer. The EPR will regulate the fuel pressure being delivered to the

mixer; these parts are not adjustable and should not be tampered with. Proper inlet fuel pressure is

critical to the proper operation of the fuel system and engine; you should the review the pressure,

volume, and BTU recommendations prior to commissioning the engine.

Governors

PSI engines have an isochronous governor installed. The governor controls the movement of the

throttle plate via a 0-12 volt signal and a ground provided by the Engine Control Module. The

throttle plate allows the correct amount of air to enter the engine; this movement is monitored by

using 2 throttle position sensors located internal to the governor. The ECM monitors various engine

sensors to determine what the correct throttle position should be.

Oil Pressure Reading

The oil pressure reading shows the engine lubrication system pressure in pounds per square inch

(psi) and should be checked frequently to ensure that the system is functioning correctly. Should the

pressure fluctuate or drop, stop the engine and find the cause. Do not operate the engine at lower than

normal oil pressure (see maintenance schedule for minimum engine oil pressure).

6


CAUTION: Do not continue to operate your engine below the normal operating range. Severe

engine damage could occur.

Temperature Reading

The coolant temperature reading will indicate overheating which may arise from low coolant level,

plugged radiator, loose fan belt or faulty thermostat. Coolant level should be checked daily.

CAUTION: If the engine continues to overheat, have the cooling system checked and serviced.

Voltage Reading

The voltage reading indicates the battery charging voltage. If the meter consistently indicates less than

13 volts or more than 15.7 volts under normal operating conditions, you should have the engine

electrical system checked by a qualified service technician.

Tachometer/Hourmeter

The tachometer indicates the engine speed in hundreds of revolutions per minute (rpm). It serves, as a

guide to insure that engine speed is set correctly.

The hour meter records the hours of operation and is used to determine when periodic maintenance is

required.

Starting the Engine

Warning: All internal combustion engines give off various fumes and gases while running. Do not

start or run the engine in a closed or poorly ventilated building where exhaust gases can accumulate.

Avoid breathing these gases as they may contain poisonous carbon monoxide, which can endanger

your health or life if inhaled steadily for even a few minutes.

If the engine is equipped with a manual clutch it must be disengaged prior to starting the engine.

Starting the engine with the clutch engaged imposes unnecessary strain on the battery, starter, and

driven components.

CAUTION: If the engine stalls or falters during starting, wait 3 to 4 seconds before re-engaging the

starter. This will prevent possible damage to the starter or the engine. DO NOT operate the starter for

periods longer than 30 seconds at a time. An interval of at least 1-minute should be observed between

cranking periods to protect the starter from overheating.

7


LPG or NG Fuel Systems

Turn on the gas supply to the engine. Turn the ignition key to the START position. After the engine

starts release the key to the ON position.

Stopping the Engine

Return the engine to idle speed. If the machine is equipped with a clutch, move the clutch lever to

the disengaged position. Run engine for a few minutes at idle to allow the coolant system to cool

down before turning the ignition switch to the OFF position.

Note: Gasoline fuel injected engines will generally shut off immediately when the key is switched to

the off position. When the key is switched off, power to the fuel injector(s), fuel pump and engine

control module (ECM) is removed.

Note: LPG engines equipped with a distributorless ignition system (DIS) may run on several seconds

after the key is switched to the off position. This may be a normal function of the engine control

system running fuel out of the vapor hose to prevent engine backfiring on restart. The engine may run

up to 5 seconds after the key is switched to off. Check with the Equipment Manufacture for proper

shut down operation.

WARNING: Avoid injury when checking a Hot Engine. Allow the engine to cool down before

removing the radiator cap.

CAUTION: Before restarting the engine ensure that both the coolant system and the engine oil level

have been checked and re-filled if necessary.

Fuel Recommendations

Fuel Quality

PSI NG engines are designed to operate on pipeline quality natural gas with a heat value of 1050 BTU

or higher. LPG engines and fuel systems are designed to operate on HD-5 or HD-10 specification LPG

fuel. Fuel other than HD-5 or HD-10 may cause harm to the engine’s emission control system and a

warranty claim may be denied on this basis if operators can readily find the proper fuel. Use of any

other fuel may result in your engine no longer operating in compliance with CARB or EPA emissions

requirements.

8


Spark plugs

Always use the recommended spark plugs for your engine. Hotter or colder plugs, or similar plugs

that are not exact equivalents to the recommended plugs, can cause permanent engine damage,

reduce the engines useful life, and cause many other problems such as hard starting, spark knock and

run-on. Installing new spark plugs regularly is one of the best ways to keep your engine at peak

performance.

Power Loss at Higher Elevations

All engines will experience power loss when operated at elevations above sea level, unless they

are turbocharged or supercharged. Turbochargers and superchargers are mechanical pumps that

put extra air into the engine to make up for the lower air density at higher elevations.

MAINTENANCE INSTRUCTIONS

Initial Start Up Maintenance

The initial start-up checks must be made before putting the engine into service. Please refer to the

Maintenance Schedule and perform the initial start-up operations in the sequence shown in column 1.

Routine Maintenance

Routine maintenance provides the best solution for making sure that the engine is ready when you are.

The following are some routine service points:

Make daily checks of the engine oil and coolant levels

Repair any oil or coolant leaks immediately

Check battery condition and cables frequently

Keep the engine air filter clean

Monitor engine coolant temperature

Monitor engine oil pressure

Check voltmeter and charging system

Scheduled Preventive Maintenance

Refer to the Maintenance Schedule to ensure that all of the maintenance items listed are checked and

replaced as recommended at the hours shown.

9


Engine Oil Level Check

The engine oil level should be checked daily. It is recommended that the oil be checked just before

the engine is started for the first time for that day. The oil level should be between the ‘Add’ and the

‘Full’ marks on the dipstick.

CAUTION: Do not operate the engine with the oil level below the bottom or ‘Add’ mark on the

dipstick, or above the top or ‘Full’ mark on the dipstick.

Adding Engine Oil

It is normal to add some oil in the period of time between oil changes. The amount will vary with the

severity of operation. When adding or replacing engine oil, be sure the oil meets or exceeds the

recommended specification.

Changing Engine Oil and Filter

The engine oil and filter must be changed every 150 hours or every 3 months whichever occurs first.

Under normal operating conditions, you do not need to change them more often if you use oil and

filters of the recommended quality.

The oil and filter should be changed more often if the engine is operating in dusty or extremely dirty

areas, or during cold weather. No oil additives or break-in oil change is required.

Engine Oil Quality

To achieve proper engine performance and durability, it is important that you use only engine

lubricating oils of the correct quality in your engine. Proper quality oils also provide maximum

efficiency for crankcase ventilation systems, which reduces pollution.

Important: use only engine oils displaying the American Petroleum Institute (API) “Starburst”

Certification Mark ‘FOR GASOLINE ENGINES’ on the container.

10


PSI recommends using engine oils that have an API rating of SM or newer. Gasoline engines that are

converted for LPG or NG fuels MUST use oils labeled ‘FOR GASOLINE ENGINES’. Do not use oils

that are specifically formulated for Diesel Engines only. CC or CD classifications oils, even when

labeled Heavy Duty or for Natural Gas Engines, ARE NOT ACCEPTABLE.

Engine Oil Recommendation

Multi-viscosity oils are recommended. SAE 10W-30 is recommended for your engine from 0

degrees F (-18 degrees C) or above. If ambient temperatures are consistently below 0 degrees F,

SAE 5W-30 oil can be used. Synthetic oils are not required for industrial or stationary engines.

Oil Filter

The filter protects your engine from harmful, abrasive, or sludgy particles without blocking the

flow of oil to vital engine parts.

To replace the filter, use a proper filter wrench to remove the filter.

Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil.

Hand tighten the filter until the gasket contacts the base, then tighten another ½ turn. Fill the engine

with the correct amount of oil and run the engine. Verify oil pressure is okay and check for oil leaks

at the drain plug and oil filter gasket. Tighten as necessary to stop any oil leakage noted.

Engine Air Cleaner

The engine air cleaner filters air entering the engine intake system and acts as a silencer and flame

arrester when assembled to the intake system. Air that contains dirt and grit produces an abrasive fuel

mixture and can cause severe damage to the cylinder walls and piston rings. Damage to the cylinder

walls and piston rings will cause high oil consumption and shorten engine life. A restricted or dirty air

cleaner will also cause a rich fuel mixture. Thus, it is extremely important that the air cleaner be

serviced properly at the recommended intervals.

CAUTION: Service the air cleaner more frequently under severe dusty or dirty conditions.

Remove the primary air cleaner element from the air cleaner assembly and inspect the element for

foreign material restrictions or signs of excessive wear or damage. Replace the element if necessary.

Remove all dust and foreign matter from the air cleaner housing. Reinstall the air cleaner element.

Reinstall the air cleaner cup, and securely fasten the retaining clips.

11


Safety Element

If your engine is equipped with an air cleaner which utilizes a safety element, ensure that the

element is properly in place before installing the primary element.

Change the safety element annually.

Cooling System

Coolant Level

Check the coolant level of the radiator daily and only when the engine is cool. Generally a good time

to do this is just prior to starting the engine for the first time each day.

Maintain the coolant level at ¾ to 1½ inches below the filler neck seat of the radiator when the coolant

is cold. When ever coolant level checks are made inspect the condition of the radiator cap rubber seal.

Make sure it is clean and free of any dirt particles which would keep it from seating on the filler neck

seat. Rinse off with clean water if necessary. Also make sure that the filler neck seat is free of any dirt

particles.

WARNING: Never remove the radiator cap under any conditions while the engine is operating.

Failure to follow these instructions could result in damage to the cooling system, engine, or cause

personal injury. To avoid having scalding hot coolant or steam blow out of the radiator, use extreme

caution when removing the radiator cap from a hot radiator. If possible, wait until the engine has

cooled, then wrap a thick cloth around the radiator cap and turn slowly to the first stop. Step back

while the pressure is released from the cooling system. When all the pressure has been released, press

down on the cap and remove it slowly.

DO NOT add coolant to any engine that has become overheated until the engine cools. Adding

coolant to an extremely hot engine can result in a cracked block or cylinder head.

The engine manufacturer recommends the cooling system be filled with a 50/50 mixture of coolant and

water. The use of “Long Life” type coolant is required. This coolant is typically a bright orange in

color and should meet the requirements outlined in engineering standard GM6277M (hard copy

of GM6277M is available by contacting PSI Technical Support). Coolant should have a minimum

boiling point of 300F (149c) and a freezing point no higher than -34F (-37c).

Plain water may be used in an emergency (except in freezing temperatures), but replace it with the

specified coolant as quickly as possible to avoid damage to the system.

12


Radiator

Inspect the exterior of the radiator for obstructions. Remove all bugs, dirt or foreign material with a

soft brush or cloth. Use care to avoid damaging the core fins. If available, use low pressure

compressed air or a stream of water in the opposite direction of the normal air flow. Check all hoses

and connections for leaks. If any of the hoses are cracked, frayed, or feel spongy, they must be

replaced.

Fan Belts

The water pump is belt driven. The same belt may also drive the fan and/or the alternator. The drive

belts should be properly adjusted at all times. A loose belt can cause improper alternator, fan and

water pump operation, in addition to overheating.

Serpentine Belt

Some PSI engines utilize serpentine belts on the front of the engine. This type of belt system incor-

porates a belt tensioning device which keeps the belt at the proper tension.

This belt should be checked routinely for cracks or ‘checking’ on the groove side of the belt. If cracks

or ‘checking’ are apparent the belt must be changed.

V-Type Belt

V-Type belts are generally tensioned by adjusting the

alternator, or through a mechanical belt tensioner. The belt is

generally correctly tensioned when there is 7-10mm of

deflection on the belt between the water pump and alternator.

Fuel Filter

LPG Engines

LP, fuel like all other motor fuels is subject to contamination from outside sources. Refueling of the

equipment tank and removal of the tank from the equipment can inadvertently introduce dirt and other

foreign matter into the fuel system. It is therefore necessary to filter the fuel prior to entering the fuel

system components down stream of the tank. An inline fuel filter has been installed in the fuel system

to remove the dirt and foreign matter from the fuel, which is replaceable as a unit only. Maintenance

of the filter is critical to proper operation of the fuel system and should be replaced according to the

maintenance schedule or more frequently under severe operating conditions.

13


Fuel Shut-Off

LPG and NG engines are equipped with a fuel shut-off. The fuel shut-off is located between the fuel

supply and the IEPR/DEPR. The purpose of the fuel shut off is to prevent or allow fuel flow from the

supply source to the engine fuel system. The shut off is a 12 volt solenoid (Normally closed) that is

controlled by the engine ECM.

Ignition Systems

Types of Ignition Systems

PSI engines use two types of ignition systems. 1) Distributor-less electronic ignition and 2) High

Voltage Switch (HVS) ignition. Both types of ignition are controlled by the engine ECU.

Distributor-less electronic ignition is utilized on the 1.6L, 8.1L, and 8.8L engines. All other engine

models use a HVS ignition system which consists of a distributor and HVS ignition coil.

Ignition Timing

Proper adjustment of the ignition timing must be obtained to provide the optimum engine power

output and economy. Ignition timing for both the Distributor-less and HVS systems are controlled

by the ECU and is not adjustable.

NOTE: Do not attempt to adjust timing on the ignition systems. Timing is not adjustable.

Spark Plugs

Spark plugs should be replaced at the recommended intervals described in the Maintenance Schedule.

Use only the recommended spark plug or an equivalent as described in the General Specifications.

Spark plug gap should be adjusted as recommended in the General Specifications.

When removing spark plugs, always note which cylinder each plug came out of. Look at the porcelain

around the center electrode of each plug. You can detect many engine problems from the color and

type of deposits that have built up on the white porcelain. For example, if the deposits are a glossy

brown, that cylinder is burning excess oil. If the deposits are a very dark gray or sooty black color,

your engine is running rich, and you are burning excess fuel. The optimum color of the deposits on the

porcelain is light tan or light brown. This shows optimum fuel mixture and proper engine running

conditions. If the deposits are almost white, the engine may be running excessively lean.

Lean running is very detrimental to your engine life, and should be corrected immediately. If one or

more cylinders are burning oil, the smoke from the engine will be a blue-gray color. Most common

causes are piston rings (worn out or not broken in) and valve stem seals (cut, nicked, or worn out). If

14


the engine is running rich the exhaust smoke will be a sooty black color and it will smell like gasoline

(on gasoline engines).

Storage

One to Six Months

If the engine or machine is to be placed in storage for a period of one to six months it is recommended

that the following steps be followed:

• Protect the air cleaner inlet from water entry

• Protect the exhaust outlet or muffler outlet from water entry

• Check the coolant protection and top off radiator

• Store indoors if possible

For Extended Periods

Follow the above recommended procedures, plus do the following:

• Drain the engine crankcase and refill with recommended oil

• Change the oil filter

• Disconnect and remove the battery

• Clean exterior surface of the engine

• If the engine is equipped with an automotive type clutch or PTO clutch, make sure that the clutch is

disengaged

Removing the Engine From Extended Storage

When removing the engine from extended storage:

• Install a fully charged battery

• Remove all protective coverings from the air inlet, air cleaner, exhaust, and muffler openings

• Check the coolant level in the radiator and verify the protection level of the coolant

• Check the engine oil level.

• Start the engine and allow it to run at slow idle. Verify engine oil pressure

• Run the engine at idle until the coolant temperature approaches 120 degrees F (49 degrees C)

• Run the engine a various speeds for approximately 15 minutes

• Shut the engine down, drain the oil, change the oil filter, and re-fill with the recommended grade of

oil

15


Daily 1000 1500 2000 2500 3000 3500 4000 4500 5000

General Maintenance Section

Visual check for fluid leaks X

Check engine oil level X

Check coolant level X

Change engine oil and filter

Check LPG system for leaks

Inspect accessory drive belts for cracks, breaks, splits or glazing X X X X X

Inspect electrical system wiring for cuts, abrasions or corrosion X X

Replace crankcase breather element - 8.1L/8.8L Engine

Inspect all vacuum lines and fittings for cracks, breaks or hardening X X

Engine Coolant Section

Clean debris from radiator core

Change coolant1

X

Inspect coolant hoses for cracks, swelling or deterioration X X X X X

Engine Ignition System X X X X X

Replace spark plugs X X

Clean secondary ignition coil tower X X X X X

Check spark plug wires for cuts abrasions or hardening X

Replace distributor cap and rotor X X

Replace spark plug wires X X

Fuel System Maintenance

Inspect air cleaner

Replace filter element

Replace fuel filter X X X X X

Inspect Shut-off Valve for leaks and closing X X

Leak check fuel lines X X

Check air induction for leaks X X X X X

Check manifold for vacuum leaks X X X X X

Drain Vaporizer oil build up

Engine Exhaust System

Inspect exhaust manifold for leaks X X

Inspect exhaust piping for leaks X X

Check HEGO sensor(s) connector and w ires for burns, cuts or damage X X

Inspect catalyst for mechanical damage X X

CERTIFIED STATIONARY ENGINE MAINTENANCE REQUIREMENTSPerform the following maintenance on the engine at the hours indicated and at equivalent hour intervals thereafter.

Interval Hours

Every 150 hours or 120 days of operation

Annually, or as required in dusty environments

Every 2500 hrs or As Required

Every 200 hours, or every 100 hours in dusty environment

Prior to any service or maintenance activity



Note 1 = PSI requires the use of coolant meeting GM specification GM6277M. When used, this coolant change interval is 5,000 hours or 5 years (whichever occurs first).

Changing of coolant types (typically indicated by color) and mixing of coolants is not allowed as this can result in a loss of coolant protection during the engine life. Consult the

OEM for the correct replacement interval if you use coolant other than GM6277M

SPECIAL NOTES SECTION

16


GENERAL SPECIFICATIONS Power Solutions, Inc.

Engine 1.6L 3.0L 4.3L 5.0L/5.7L 8.1L/8.1L

Turbo

8.8L/8.8L

Turbo

Type 1.6-2V 3.0L L4 4.3L V-6 5.7L V-8

GEN-1E 8.1L V-8 8.8L V-8

Displacement cc

(c.i.d.) 1600 (98) 2966 (181) 4294 (262) 5735 (350) 8127 (496) 8800 (537)

Compression Ratio 9.5:1 10.5:1 9.4:1 9.4:1 9.1:1 10:1

Valve Configuration Overhead Cam

Push Rod

Actuated Push Rod Actuated

Overhead Valve

Push Rod

Actuated

Push Rod

Actuated Push Rod Actuated

Overhead

Valve Overhead Valve Overhead Valve Overhead Valve

Valve Lifters Hydraulic Flat Follower Hydraulic Roller Hydraulic

Roller Hydraulic Roller Hydraulic Roller

Bore x Stroke mm

(inches)

79.0x81.5

(3.11x3.21)

101.60x91.44

(4.00x3.60)

101.60x88.39

(4.00x3.48)

101.60x88.39

(4.00x3.48)

107.95x111

(4.25x4.37)

110.49x114.30

(4.35x4.50)

Main Bearing Caps 2 Bolt 2 Bolt 2 Bolt 2 Bolt 4 Bolt 4 Bolt

Firing Order 1-3-4-2 1-3-4-2 1-6-5-4-3-2 1-8-4-3-6-5-7-2 1-8-7-2-6-5-4-3 1-8-7-2-6-5-4-3

Oil Capacity 3.4 qts. (3.2L) 4 qts. (3.8L) 4.5 qts. (4.3L) 4.5 qts. (4.3L) 8 qts. (7.6L) 8 qts. (7.6L)

With Oil Filter 3.7 qts. (3.5L) 5 qts. (4.7L) 5 qts. (4.7L) 5 qts. (4.7L) 9 qts (8.5L) 9 qts (8.5L)

Oil Filter

PF-25 or

Equivalent

PF-47/PF-52 or

Equivalent

PF-1218 or

Equivalent

PF-454 or

Equivalent

30100345 or

Equivalent

Minimum Oil

Pressure (Hot) 21 psi @ idle

6 psi @ 1000 rpm

6 psi @1000 rpm 6 psi @ 1000

rpm 5 psi @ 1000 rpm 5 psi @ 1000 rpm

18 psi @ 2000

rpm 18 psi @ 2000 rpm

18 psi @ 2000

rpm

15 psi @ 2000

rpm 15 psi @ 2000 rpm

Coolant Capacity

(Engine) 3.5 qts. 4 qts. (3.78L) 7.75 qts. (7.3L) 8.1 qts (7.8L) 14.5 qts (13.7L) 14.2 qts (13.4 L)

Coolant Capacity

(W/PSI Rad) 10 qts

12 qts. (11.4L)

17 qts. (16L) 17.5 qts. (16.6L)

28 qts (26.5L) 26.9 qts (25.5L)

Fuel Type NG, LPG LPG, NG LPG, NG LPG, NG LPG, NG LPG, NG,

Gasoline

Engine Rotation

(Flywheel End) CCW CCW CCW CCW CCW CCW

Ignition System Distributor-less

Electronic (ECU)

High Voltage

Switch (HVS)

High Voltage

Switch (HVS)

High Voltage

Switch (HVS)

Distributor-less Distributor-less

Electronic (ECU) Electronic (ECU)

Ignition Timing

ECM Controlled ECM

Controlled ECM Controlled

ECM Controlled

ECM Controlled ECM Controlled

Not Adjustable Not

Adjustable Not Adjustable Not Adjustable Not Adjustable Not Adjustable

Spark Plugs AC Delco

93206675

AC Delco

R42LTS or R44LTS

AC Delco R42LTS

or R44LTS

AC Delco

R42LTS or R44LTS

AC Delco

R42LTS or R44LTS

33000562 or

Equivalent

Spark Plug Gap 0.035” 0.035” 0.035” 0.035”

0.035” (Natural) 0.030” (Non-

Turbo)

023” +/- .002”

(Turbo) .025" (Turbo)

Valve Clearance

(Lash)

Intake No Adjustment ½ to 1 Turn Down From

Net Lash 1 Turn Down

From Net Lash Net Lash

Exhaust OHC Engine 0 Lash No Adjustment 0 Lash No Adjustment No Adjustment

Manufactured Toluca, Mexico Toluca, Mexico

Romulus, MI Toluca, Mexico Tonawanda, NY Wood Dale, IL

Revised 10/2012

TP-6101 8/13N

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