Home

tp6161 - Pelican Services, Inc.

1. 27 3 6 5 Carburetor Adjustment 27 3 6 6 Fuel System Maintenance 27 TP 6161 1 08 Table of Contents 3 Table of Contents continued 3 7 Cooling SM ii a dead dee e a aP ea A eed 28 3 7 1 Coolant Level Check 28 3 7 2 Cooling System Component Inspection 28 3 7 8 Cooling System Drainage Procedure 28 3 7 4 Cooling System Flush and Clean Procedure 29 3 7 5 Cooling System Refilling Procedure 29 3 8 Radiator Fan Bolt Retorque a a 29 3 9 Radiator Fan Bearing Lubrication 30 3 10 Battery u u cya A A Mex e ie s 31 9 10 Cleaning o2 uu ees aa inte Ava atlas Mis 33 3 10 2 Electrolyte Level Inspection 33 3 10 3 Specific Gravity Check 33 3 10 4 Charging anses rn opa a oh ee A ere a aaa OAs 34 3 11 Detroit Diesel Engine Control Systems 34 SMT 2Eeat res eis Fs ese sEnint a fa aou aot S kashamanta 34 3 11 2 DDEC Engine Diagnostics 34 3 12 Engine Control Systems 35 3 13 Storage Procedu
2. SECTION A A GM18401 J 4 32 blade retention bolts nuts 136 Nm 100 ft Ib 5 12 hub boss cap screws 102 Nm 75 ft Ib 6 3 bushing cap screws 43 Nm 32 ft Ib Figure 3 7 Fan Hardware Location and Torque 7 Retorque the 12 qty hub boss cap screws to 102 Nm 75 ft Ib There are six screws on each side of the fan 8 Retorque the 3 qty bushing cap screws to 43 Nm 32 ft Ib 9 Replace the fan guards screens and covers that were removed to access the radiator fan hardware 10 Checkthat the generator set master switch is in the OFF position 11 Reconnect the generator set engine starting battery negative lead last 12 Reconnect power to the battery charger if equipped 30 Section 3 Scheduled Maintenance 13 Place the generator set master switch to the RUN position to start the generator set Refer to the respective generator set operation manual as needed 14 Listen and observe the fan operation 15 Immediately shut down the generator set if abnormal noise or fan assembly vibration is observed Correct the problem and go back to step 13 16 After several minutes of generator set operation without abnormal noise or vibration shut down the generator set by placing the generator set master Switch to the OFF RESET position 3 9 Radiator Fan Bearing Lubrication The following procedure applies only to 1200 2000 kW generator sets Lubricate the rad
3. irs regulator or switchgear Use the applicable 1 Lamp Jumper technical manual for voltage regulator adjustment Figure 5 5 Meter Scale Lamp Jumper 7 Stop the generator set after completing the voltage 5 Set the phase selector switch to the L1 L2 position adjustment Replace the controller cover 1 phase or 3 phase depending on generator set connection Connect a voltmeter across leads L1 and L2 if the controller has no meters 46 Section 5 Generator Set Reconnection TP 6161 1 08 6 1 Accessories Several electrical accessories and controls help finalize installation add convenience to operation and service and establish state and local code compliance Accessories vary with each generator set model and controller Select factory installed and or shipped loose accessories Kit and installation instruction part numbers change Obtain the most current accessory information from your local authorized service distributor dealer This section illustrates several accessories available at the time of print of this publication Accessory kits generally include installation instructions See the wiring diagrams manual for electrical connections not shown in this section See the installation instructions and drawings supplied with the kit for information on the kit mounting location The instructions provided with the accessory kit supersede these instructions where there are differences In general run AC and DC w
4. GM32644 B 1 Communication circuit board GM47242 or GM49791 1 Note Circuit board GM 49791 2 is a gauge driver and is not a communications circuit board Figure 6 13 16 Light Controller with Installed Comm Module controller top view TP 6161 1 08 6 1 14 Run Relay Kit The run relay kit includes three sets of contacts that energize only during generator set operation The run relay kit can control air intake louvers radiator louvers alarms and other signaling See Figure 6 14 Figure 6 14 Run Relay Kit 6 1 15 Safeguard Breaker The safeguard breaker senses output current on each generator phase and shuts off the AC voltage regulator if a sustained overload or short circuit occurs It is not a line circuit breaker and does not disconnect the generator set from the load See Figure 6 15 X NIN TI TU Figure 6 15 Safeguard Breaker Section 6 Accessories 51 6 2 Accessory and Prime Power Terminal Strip Connections M The 16 light controller circuit board has terminal strips for use in connecting a controller connection kit Do not connect accessories directly to the controller terminal strip s Connect accessories to either a controller connection kit or dry contact kit Connectthe dry contact kit s to the controller connection kit Connect alarms battery chargers remote switches and other accessories to the dry contact kit relay s The 16 light controller has two terminal strips TB
5. GM32644 E Communication module circuit board and or gauge driver circuit board Figure 6 19 Communication Module Circuit Board Location and Connection 54 Section 6 Accessories TP 6161 1 08 6 3 1 Communication Modules Circuit Board Versions GM47242 Circuit Board This is the communication module for all models except the 450 500REOZVB models and is superceded by GM49791 1 See Figure 6 20 T DC DC DC I gt mo mo mo mA m m m0 CXCAICAIC GM47242 a 1 P9 connector 10 position 2 SW2 DIP switches set to open position 3 TB5 Terminal connectors 4 P8 connector 24 position Figure 6 20 Communication Circuit Board GM47242 GM49791 1 Circuit Board This is the communication module for all models and includes the gauge driver provision needed to drive the oil pressure and water temperature gauges for some models requires application software version 1 23 or later See Figure 6 21 GM49791 2 Circuit Board This is the interface circuit board with the gauge drivers required on the 450 500REOZVB models only For communication purposes replace GM49791 2 with GM49791 1 GM49791 2 is mounted in the communication module location but does not provide the communication function See Figure 6 22 6 3 2 Circuit Boards Views
6. 2 Place the generator set master switch in the OFF RESET position 36 Section 3 Scheduled Maintenance If a fogging agent is not available perform the following 1 Remove the spark plugs 2 Pour 15 cc 0 5 oz of engine oil into each spark plug hole Ignition System Damage Refer to the engine operation manual for ignition system precautions before cranking the engine while the spark plug wires are disconnected 3 Toggle the generator set master switch to crank the engine two or three revolutions to lubricate the cylinders 4 Reinstall the spark plugs and torque them to specifications 3 13 5 Exterior 1 Clean the exterior surface of the generator set 2 Seal all engine openings except for the air intake with nonabsorbent adhesive tape 3 To prevent impurities from entering the air intake and to allow moisture to escape from the engine secure a cloth over the air intake 4 Mask electrical connections 5 Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion 3 13 6 Battery Perform battery storage after all other storage procedures 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the battery ies negative lead first 3 Clean the battery Refer to Section 3 10 1 for the battery cleaning procedure 4 Place the battery in a cool dry location 5 Connect the battery to a float equalize battery charger or charge it month
7. Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin A WARNING Explosion Can cause severe injury or death Relays in the battery charger cause arcs or sparks Locate the battery in a well ventilated area Isolate the battery charger from explosive fumes Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the battery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seekimmediate medical aid inthe case of eye contact Never add acid to a battery after placing the battery in service asthis may resultin hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceas
8. 153 500 305 1000 Gauge Figure 6 9 Switch Rating and Wiring Recommendation 6 1 11 Remote Annunciator Kit M A remote annunciator provides convenient monitoring of the generator set s condition from a remote location See Figure 6 10 The remote annunciator includes an alarm horn alarm silence switch lamp test and the same lamp indicators except air damper as the 16 light controller plus the following lamps Line Power lamp illuminates to indicate that the commercial utility is the power source Generator Power lamp illuminates to indicate that the generator set is the power source 50 Section 6 Accessories PREALARM _ HIGH ENGINE TEMPERATURE gt HIGH ENGINE y BATTERY gt UNE TEMPERATURE M7 CHARGER FAULT _ POWER PREALARM _ Lowo PRESSURE y LOW OIL y y LOW BATTERY Cy GENERATOR _ PRESSURE VOLTAGE POWER 7 LOW WATER EMERGENCY gt AUXILARY SYSTEM 4 TEMPERATURE STOP FAULT V7 READY GENERATOR SWITCH NOT IN AUTO a Low FUEL O OVERSPEED O OVERCRANK M Acad SILENCE NORMAL ALARM LAMP O TEST Remote Annunciator wet 23 oS FBA 1 10 AMP 14 Relay Dry Contact Box Figure 6 10 Remote Annunciator with 14 Relay Dry Contact Box 6 1 12 Remote Emergency Stop Kit M The emergency stop kit shuts down
9. A WARNING Qe KS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery TP 6161 1 08 Section 3 Scheduled Maintenance Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master switch to the OFF position 2 Disconnectthe power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Servicing the generator set when it is oper
10. SHIM YOLVNY311V GVST Zl Figure 5 2 20 300 kW Permanent Magnet and 20 60 kW Wound Field Alternators ADV 5875B H Section 5 Generator Set Reconnection 43 1 08 TP 6161 gl Cl L1 9 g v NOILV1OY JSVHd SIJS TIV NO Q3Sn LON S33 38305 OIVS3N3O GSHVAO1 LH YO LOG S3AHOJSNVHI LN33309 S31ON AINN envi orenean SEL H 1d OL 1 e oi z on 81 z AIAN divi or zafan FEL ZH Zld OL c Twos YIN L3 SA 9 q 9 R ANOS HAIN a 96 8 c 4 cio CS a 19 dNOO Aie A dOOMQ TVNOILdO 19 b E 0 does Lia 01 ON c3 Y p S No 19 anoo E A MAZO E E dH E doosa TWNOlLdo 3 9 ced 1X LH N 15 AR 119 ws za Ta pre E BA z1 AS Y L7 o 5 g PS P D 6 eo Sy HO 119 e Oe i 3 M gt I ral I 13 ar 8 G Mn o E Benes PM a 11 dOOMQ IWNOILAO IH 0 OD lC bz o P SL E Llc l BA LA 11 zH 11d OL A917 09Z ZH OS A08r ZH 09 ABOZ 0ZL ZH OG A09Z 6 L ZH 09 ADOv O Z ZH OS A9Lv 09Z ZH 09 ADOZ SLL ZH OS OZZ LZVA ZH 09 009 Lv ZH 09 A08 0CC ZH OS AOBS OZZ ZH 09 061 011 ZH OS A80Z OCL ZH 09 vt MOIVNMJLIV Gv31 9 JAM IH SIM BSWOIVNH3LIV AVJI cl SAM MOT 3MIM v MOIVNM3LIV GV31 L 19 dNOO Maar amv os r
11. See selections for DIP switch 4 and DIP switch 5 below Value 0 Value 2 Value 0 Value 4 Value 0 Value 8 Open Open MDEC Comm Closed Isochronous Open Open Closed MDEC Comm Closed Governor VSG Closed Engine Comm Setting Modbus Address Bit 0 Modbus Address Bit 1 Modbus Address Bit 2 No ECM 41939 Communication aA AJA OI O OINI O a AJO Figure 1 9 DIP Switch Functions Note After setting DIP switches to the generator set application be sure to power down and then power up the controller disconnect the battery and then reconnect the battery of the generator set or use the prime power switch if equipped The controller will NOT acknowledge the DIP switch change until after generator set controller is powered up Push down the end of the DIP switch near the OPEN label to open the switch or push down the other end to close it See Figure 1 10 OPEN 1 Push this side down to open circuit Figure 1 10 DIP Switch Open Position Modbus is a registered trademark of Schneider Electric TP 6161 1 08 Typically the factory default settings have all the DIP switches in the closed position except the crank mode selection switch SW3 which is open for cyclic cranking The overspeed selection switch SW1 is open on 50 Hz units Be sure to select the correct DIP switc
12. sjuauodulo9 esoo ue1ui AISS8OXe VONBIQIA W S Uan 4 J0je1s ay eoe deJ Jo pue se pepunoi6 10 uedo anlyesadout 101818 W S Uan 4 10301 ay ese de Jo pue 1se papuno b Jo uedo aniyesadout 10104 pjay Ue lN G M W S ueo ynupuos JO YO YD uedo pjey Jeyoxe ay ui uid 10 speuiuuJej BULA W S W O SLV s ejep au pue 1inoJio JajsueJ ay 100use qnoJ uonisod OLNY eui oi u91Is 159 SLY eui AON peo J9 sue o1 Se U91IAS JeJsuei W O SLV uonisod OLNY eui 01 uos 1se1 YO IMS 19JsueJ eui AON uonisod 30 94 ut YOUMS 188 y9 ms 4ejsueJ J194e91q 1n9JI9 ay jo epis JoyeJaua6 ay ye eBeyoA OV 104 4oeuo pue JexeeJq eui 1eseH uedo jexyeeJq N3119 jndjno oY 492ueJejeH uoneorqnd JO uonoes suonoy pepueuiuio2aH s sneo ajqeqoig esiou jeuuouqe JO AIss 5 xg uonduunsuoo Jen uBiH eunsseJd sjesylano Jewod sx9e7 Ajueppns sdojs eBeyo 1ndino MO JO ON pey sueis peys jou seop yng syuelD jou s oq suiojdui AS lqnoiL 1 08 6161 TP 40 Section 4 Troubleshooting Section 5 Generator Set Reconnection A WARNING To change the voltage of 10 or 12 lead generator sets use the following voltage reconnection procedure Adjustthe governor and voltage regulator for frequency changes Consult the generator set service manual for frequency adjustment information Voltage reconnect
13. 0 uonisod NNY 2U o1 uos Jejseul J loluo5 eu SAON uedo ynoJro pe s aulbuy z uonoeg uonisod OLNY JO NH 24 o1 uos 1ejseui Je oJ1u09 SY SAO uonisod 13S34 4J4O y ul U91IMS Je1seuu 43 04 U0D YOUMS Je1seui Je o Juoo eui aoejday eAneJedoul YOUWMS Je1seui Jej o uoo Q M z uonoes 19 101JuO9 ay 1oous lqno4 ureBe smojq asnj ay J sni 1e ojjuoo Umo q eui aoejday UMO ASN Ja Jo1Juoo W S Ue 4 Je o 3u09 ay JOOUSE qnol_L yney 1 lonuoo W S Ue p1eoq 1n2Jo Jej ouoo 94 soejdey eNmejedoui s pyeoq qnoJr 1 lo uoo x x x 5u 1 J t uoneoiiqnd JO uonoes suonoy pepueuluio2eH sasney a qeqoJd 19 101JU09 asiou euJouqe JO 9AISSDIXY uonduunsuoo Jen u amp iH eunsseJd s y Jamod sxyoe1 Ajueppns sdojs eDeyoA 1ndino MO JO ON peu sueis peys jou seop jng sxyueJS suwoxdui s l qnoiuL 1 08 6161 TP 38 Section 4 Troubleshooting W s 8u3 Bulg uonoefur jen eur isnipy Ajuo jeseip 1u uisn pe Jo 1no Buruun uonoefur jany eotes SIU uuoped Jepeep 1ojnquisip asias pezuouine ue BAeH 4 enuen weber BuutlM Q M 4224S eds s s enuey aamua s NW S enuey uoeiado W o enuen uolleije1lsui NW I J9S JoyesoUety uec eulGuy Bug uS1IAS 1eJsue oneuo1ny S v fenuew siy jo uon9 s pajequuinu uonoeg 9es y ueo S S 4 SeA eA pue Ajddns jan y 49ayo Ajuo
14. 08f O 2004 2005 2006 2007 2008 by Kohler Co All rights reserved KOHLER POVVER SYSTEMS KOHLER CO Kohler Wisconsin 53044 Phone 920 565 3381 Fax 920 459 1646 For the nearest sales service outlet in the US and Canada phone 1 800 544 2444 KohlerPower com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455
15. Figure 6 20 Figure 6 21 and Figure 6 22 show the differences between the communication circuit boards and the interface circuit board with gauge drivers The SW2 DIP switches should be set to the open position unless the instructions supplied with the kit indicate another configuration TP 6161 1 08 C21 c19 cis cis CO Ce Edmo ECT c 7 SW2IKBUto D2 D3 D4 D5 3 ra rara ra GM47242 1 P9 connector 10 position 2 SW2 DIP switches set to open position 3 TB5 Terminal connectors 4 P8 connector 24 position Figure 6 21 Communication Circuit Board GM49791 1 C2 cis cis CIs CIO Ce ER 2 ra aao c29 D2 D3 D4 D5 Ratna ear 000 GM47242 1 P8 connector Figure 6 22 Gauge Driver Circuit Board GM49791 2 Section 6 Accessories 55 Notes 56 Section 6 Access
16. Remote Emergency Stop Kit M 50 6 1 13 Remote Serial Annunciator M 51 614 Run Relay Kit iore REM exe ed Sad doped dn 51 6 1 15 Safeguard Breaker 00 cece teens 51 6 2 Accessory and Prime Power Terminal Strip Connections M 52 6 3 Communication Module Kit and Gauge Driver Circuit Board 54 6 3 1 Communication Modules Circuit Board Versions 55 6 3 2 Circuit Boards Views 55 Appendix A Abbreviations 0 c cece eee eee eee eee hh hn 57 4 Table of Contents TP 6161 1 08 Safety Precautions and Instructions IMPORTANT SAFETY INSTRUCTIONS Electromechanical equipment including generator sets transfer switches switchgear and accessories can cause bodily harm and pose life threatening danger when improperly installed operated or maintained To prevent accidents be aware of potential dangers and act safely Read and follow all safety precautions and instructions SAVE THESE INSTRUCTIONS This manual has several types of safety precautions and instructions Danger Warning Caution and Notice A DANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage A WARNING Warning indicates the presence of a hazard that can cause severe personal injury death or substa
17. The alarm horn and the lamp are not energized The alarm horn and lamp activate when a fuel leak occurs If the alarm switch is moved to the silence position the lamp stays on until the fuel leak fault is corrected Closed The alarm horn sounds to alert the user that the alarm horn switch is not in the normal position and that the alarm horn will not sound should a fuel leak occur Figure 3 3 Inner Fuel Tank Leak Alarm Troubleshooting TP 6161 1 08 Resetting Procedure Use the following procedure to reset the alarm after a fault alarm 1 Move alarm switch to the SILENCE position to stop alarm horn Lamp will remain lit 2 Disconnect generator set from load with line circuit breaker or automatic transfer switch 3 Repair or replace the inner fuel tank 4 Move generator set master switch to the OFF RESET position and then to the RUN position for startup Alarm horn sounds and lamp goes out 5 Reconnect generator set to load via line circuit breaker or automatic transfer switch 6 Move generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Move alarm switch to the NORMAL position 3 6 Gas Gasoline Fuel Systems This section describes fuel systems that are not covered in the engine operation manual or engine service manual 3 6 1 Gaseous Fuel System Concept The gaseous fuel system uses a fuel valve with a solenoid to control th
18. an EL M3awnr env o1 zafan 84 43awnr dv ow z pn 84 dOONQ WNOILdO Fos H3ldN CI aos YILIN 11 gt Me pp LN 8A N OA OA 119 6A 6 W I O WA 9 ED 01 y 1 M H9 OL XOK E p VS t es Z c Y L Cis 5 ANY Z E P y E Uh Q OL 5 n o 9 Tye SE 19 dWOO dOONQ ro AVNOILdO e E ANNONS NOX r O pa E 31WINSNI OL 3dvL SN q3sn LON 19 AR b SIVANVW 338 3SvHd 319NIS gy 3SN LON 19 X04 O3lvM LON S13S 3WOS SA SUN AOZC OLL ZH OS AINO 3NIelVIN A00Z 00L ZH OS NOZZ OLL ZH OS NOZZ ZH OS A0yZ 0Z1 ZH 09 NOYZ 07 1 ZH 09 AObZ ZH 09 O0Z 001 ZH 09 VII3Q SHIM Y HOIVNN3ITIV AVFI ZL jSVHd 319NIS AHIM JOLVNY31 IV Ov3l Cl jSVHd 319NIS 3MIM S8SOIVNS3LIV Ov41 El Figure 5 3 60 with Oversize Alternator 300 kW Wound Field Alternators ADV 5875C H 1 08 TP 6161 44 Section 5 Generator Set Reconnection 21 c1 L1 9 H V NOI 1V108 3SVHd 3 Sadnnr dav o1 2afen 84 M3dWnr dWvi o1 zafen EL en 84 Hd Sid 3S S ta 358 3 bce sone ai 31vOS YILIN LJ 31vOS YILIN I c1 LI 6 0 o I o 01 T o 1 zu id 01 a 3 eL cj EL BA TAS 6 o I o 1 a el 19 BIN X eH j ZH Z LX IH C12 p ei 8 o t O 1 13 Zld 61 ZX ZH el N 11 d 01 iH 11d OL ex lez A a O
19. by height Ib pound pounds Ibm ft3 pounds mass per cubic feet LCB line circuit breaker LCD liquid crystal display ld shd load shed LED light emitting diode Lph liters per hour Lpm liters per minute LOP low oil pressure LP liquefied petroleum LPG liquefied petroleum gas LS left side Lwa sound power level A weighted LWL low water level LWT low water temperature m meter milli 1 1000 M mega 109 when used with SI units male ms cubic meter m hr cubic meters per hour m min cubic meters per minute mA milliampere man manual max maximum MB megabyte 22 bytes MCCB molded case circuit breaker MCM one thousand circular mils meggar megohmmeter MHz megahertz mi mile mil one one thousandth of an inch min minimum minute misc miscellaneous MJ megajoule mJ millijoule mm millimeter mOhm mQmillionm MOhm MQmegohm MOV MPa mpg mph MS ms m sec MTBF metal oxide varistor megapascal miles per gallon miles per hour military standard millisecond meters per second mean time between failure 58 Appendix MTBO mtg MTU MW mW uF N norm NA nat gas NBS NC NEC NEMA NFPA OZ p Pp PC PCB pF PF ph PHC PHH PHM PLC PMG pot ppm PROM psi psig pt PTC PTO PVC qt qty R rad RAM RDO ref rem Res Coml RFI RH RHM rly mean time between overhauls mounting Motoren und Turbinen Union megawatt milliwatt mic
20. eoe deJ Jo ue o peBBojo 1eueejo sy Q M W S Jeoujoeje pue INO3 eurfBue Joouseqnol INO3 euifu3 492ueJojoH uoneorqnd JO uonoes suonoy pepueuiuio2aH s sneo ajqeqoig esiou jeuuouqe JO AIss 5 xg uonduunsuoo Jen uBiH eunsseJd sjesylano Jewod sx9e7 Ajueppns sdojs eBeyo 1ndino MO JO ON pey sueis peys jou seop yng syuelD yuelo you seog suiojdui AS lqnoiL Section 4 Troubleshooting 39 1 08 TP 6161 18A9 lO ay YOBUD UMOpinus eJnsseJd Io Mo IAJ S SIY uuojied Jepeep 1o01nquisip eones pezuouine ue aney I enuen webe BuutIM Q M 3eeus oeds s s enue 39 M93S N S enuen uojejed o qW O enuen uoneeisu qW 36S 101849u86 uec eutBu3 Bua yoyms 1eJsuei1 oewojny s_Ly jJenueuu sy jo uonoes pejequinu uomnoeg 29S y SXee llo JO jos 101eJeueB eui joedsu J A llo ay eJojseH MOJ A IIO ayewo Bupesedo eui 104 jqeyns ysoosia e UM lo asn 10 ay eBueuS aunyesodwa qua quie JO j99 109U1 ad llo aseoquelo W S Uan Joyje nBa eBeyoA y ysnipy 1yu uulsn pe jo 1no soyeinBas eDeyoA W S ue5 1o1e nB 1 aBeyon y 100use qnouy ureBe swo q esnj ay j esny 1ole nB 1 eBejo eui eoejdeu eAmgea4edour JojenBal eBeyoA LL nue z oes J401e n881 eBeyoA ay ysnipy Ajuo 1ejoajuoo eubip 12e400uI sBumes eufip joyejn8e J eBeyoA
21. seb uapynsu alnsseld any W s 8u3 plouajos jan ay 100use qno1 enmjeledou piouejos jeny W O 8u3 JOY Jen ay eoejdeJ Jo ue O 10191489 Je3ll any W s Bug 4 10joefui any eAnejedour y aoejda Jo pue 488 ue o Ajuo jeseip ynej 10 uip sJojoefur jen Jo jen4 w s 8u3 4 duund uonoefui y asejda Jo p inqay Ajuo jeseip eAnejedoui duund uonoefui 10 pas any Uonisod NO 34 01 SAJEA an eui anou pue jen ppy Jo 1nus anea Jan 10 Aydwea yue jeny W O Bug uejs s Bulue s Jeuje eu 1redei Jo eoe deu Ajuo jeseip peddinbe ji eaeaedour uu 1s s Jo iduie 1ejsiueo 19443 W O 8u3 Ulejs s any Jeseip eui peeig Ajuo jeseip WaysAs any u Jv 08 sam Bnjd xreds snid yds uejs s uoniuBi y yayo Ajuo eujoseb seb eAmgeaedour uu 1s s uoniuB eJeMpieu esoo je uay L AISS8OXE UOneJgiA 4 SeA e y ysnipy JO9JOOU eoueJee o SAA 44OWJaA06 eui ISN py eAneJedour JouJeAoc 4 sjueuodujoo uleijs s 1sneuxe esoo ay u luBil uiejs s sneyxe eu joadsu pej e1sut jeJnoes you uiejs s 1sneux3 4 sjueuoduuoo ujejs s sneuxe eAgejedoui eui aoejday uejs s 1sneuxe eu joadsul yea uleis s 1sneux3 suomeoyioeds abeyem 10 jays oeds jes 101eJeueB ay ses peo jeouioeje eu sonpay peo ie o euiBu3 W S 4 uoisseJdujoo y YOBYD yeem uolss iduloo W O jueujeje Je ay
22. shutdowns only Use the generator set master switch for normal shutdowns The local emergency stop switch is standard on selected generator sets Generator Switch functions as the controller reset and set master generator set operation switch Refer to Switch Section 2 3 1 Normal Operation Section 2 3 2 Prime Power Mode Operation and Section 2 3 5 Controller Resetting After a Fault Shutdown Lamp test Switch displays the controller indicator lamps switch Selector Switch selects the generator set output circuits to switch measure When switched to a position with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage Control fine tunes 5 the generator set output adjustment voltage Used with 20 400 kW permanent control if magnet wound field alternator models only The equipped voltage adjustment on 350 2000 kW pilot excited models is located in the generator junction box Figure 1 6 Switches and Controls Modbus is a registered trademark of Schneider Electric 14 Section 1 Specifications and Features 1 2 6 Terminal Strips Two terminal strips are mounted on the controller circuit board See Figure 1 7 and Figure 1 8 Refer to Section 2 3 2 Prime Power Mode Operation for information on enabling prime power
23. the engine block heater plug from the electrical outlet before working on the block heater electrical connections Handling the capacitor Hazardous voltage can cause severe injury or death Electrical shock results from touching the charged capacitor terminals Discharge the capacitor by shorting the terminals together Capacitor excited models only Electrical backfeed to the utility Hazardous backfeed voltage can cause severe injury or death Install a transfer switch in standby power installations to prevent the connection of standby and other sources of power Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines Testing live electrical circuits Hazardous voltage or current can cause severe injury or death Have trained and qualified personnel take diagnostic measurements of live circuits Use adequately rated test equipment with electrically insulated probes andfollowthe instructions ofthe test equipment manufacturer when performing voltage tests Observe the following precautions when performing voltage tests 1 Remove all jewelry 2 Stand on a dry approved electrically insulated mat 3 Do not touch the enclosure or components inside the enclosure 4 Be prepared for the system to operate automatically 600 volts and under 8 Safety Precautions and Instructions A WARNING Z Airborne particles Can cause severe injury
24. the parts often and perform required service at the prescribed intervals Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service Abbreviations This publication makes use of numerous abbreviations Typically the word s are spelled out along with the abbreviation in parentheses when shown for the first time in a section Appendix A Abbreviations also includes many abbreviation definitions List of Related Materials Separate literature contains communication and software information for the 16 Light Controller with communications not provided in this manual Figure 1 lists the available literature part numbers Modbus is a registered trademark of Schneider Electric TP 6161 1 08 Communication and Software Manual Description 16 Light Controller Spec Sheet Literature Part No G6 30 Decision Maker 1 Controller G6 29 Spec Sheet Multiple Part Numbers Contact your Distributor Dealer Generator Set Controller Wiring Diagram Manual Modbus Communications Protocol Operation Manual TP 6113 TP 6009 TT 1285 TT 1377 TT 1310 Service Parts Controllers Program Loader Software Installation Remote Serial Annunciator RSA Controller Service Replacement Monitor IIl Converters Connections and Controller Setup Monitor Ill Software Spec Sheet G6 76 Monitor III Converter G6 79
25. to flow from them 4 Add coolant additives or water pump lubricants according to the engine manufacturer s recommendations in the engine operation manual 5 Fill the cooling system with the recommended coolant antifreeze mixture of 50 ethylene glycol and 50 clean softened water to inhibit rust corrosion and prevent freezing Note A coolant solution of 50 ethylene glycol provides freezing protection to 37 C 34 F and overheating protection to 129 C 265 F A coolant solution containing less than 5096 ethylene glycol may not provide adequate freezing and overheating protection A coolant solution containing more than 5096 ethylene glycol can cause engine or component damage Do not use alcohol or methanol antifreeze or mix them with the specified coolant Refer to the engine operation manual for recommendations regarding the coolant mixture to use in extreme temperatures TP 6161 1 08 6 Replace the pressure cap 7 Fill the coolant recovery tank to the low mark 8 Operate the generator set until the thermostat opens when the upper cooling system hose warms 9 Stop the engine and allow it to cool 10 Remove the pressure cap 11 Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck 12 Replace the pressure cap 13 Maintain the coolant level in the coolant recovery tank between the high and low marks Note Air pockets often form in the engine water jacke
26. used does not have a correction table consult Figure 3 14 TP 6161 1 08 Determine the specific gravity and electrolyte temperature of the battery cells Locate the temperature in Figure 3 14 and correct the specific gravity by the amount shown The battery is fully charged if the specific gravity is 1 260 at an electrolyte temperature of 26 7 C 80 F Maintain the specific gravities between cells within 0 01 of each other Charge the battery if the specific gravity is below 1 215 at an electrolyte temperature of 26 7 C 80 F Example No 1 Temperature below 26 7 C 80 F Hydrometer Reading 1 250 Acid Temperature 6 7 C 20 F Subtract 024 Specific Gravity Corrected Specific Gravity is 1 226 1 250 024 1 226 Example No 2 Temperature above 26 7 C 80 F Hydrometer Reading 1 235 Acid Temperature 37 8 C 100 F Add 008 Specific Gravity Corrected Specific Gravity is 1 243 1 235 008 1 243 The temperature correction amounts to about 004 4 points of specific gravity for each 5 5 C 10 F change in temperature 1 787 Figure 3 14 Specific Gravity Temperature Correction Section 3 Scheduled Maintenance 33 Note Some battery testers have four or five beads in a test tube Draw electrolyte into the tube as with the battery hydrometer described in this section Use the tester manufacturer s instructions Figure 3 15 shows typical test results Number of Floating Beads Battery Condi
27. 0 6518 7955 East China Regional Office Shanghai Phone 86 21 6288 0500 Fax 86 21 6288 0550 India Bangladesh Sri Lanka India Regional Office Bangalore India Phone 91 80 3366208 91 80 3366231 Fax 91 80 3315972 Japan Korea North Asia Regional Office Tokyo Japan Phone 813 3440 4515 Fax 813 3440 2727 Latin America Latin America Regional Office Lakeland Florida USA Phone 863 619 7568 Fax 863 701 7131 TP 6161 1 08 Section 1 Specifications and Features 1 1 The specification sheets for each generator set provide specific generator and engine information Refer to the respective specification sheet for data not supplied in this manual Consult the generator set service manual installation manual engine operation manual and engine service manual for additional specifications Introduction 1 2 16 Light Controller Features The 16 light controller can operate in either the normal mode or the prime power mode The prime power mode allows reduced controller current draw in applications without a battery charger minimizing battery drain by the controller circuitry See Section 2 3 2 Prime Power Mode Operation for more information Figure 1 1 shows the 16 light level 1 controller The 16 light controller features include annunciator panel lamps analog meters switches and controls and fuses and terminal strips For identification and an explanation of the functions see Sections 1 2
28. 1 and TB2 on the controller circuit board and prime power choices are made on TB2 See Figure 6 16 for controller configurations See Figure 6 17 and Figure 6 18 for controller terminal strip identification Lower the controller circuit board panel until it is lying flat when connecting the dry contact kits to the controller TB1 terminal strip Route dry contact relay leads through the controller grommet and guide loops to the circuit board terminal strip Place the controller circuit board panel flat to ensure adequate slack in the dry contact relay leads For specific information on accessory connections refer to the accessory wiring diagrams in the Wiring Diagram Manual and the instruction sheet accompanying the kit Note Not all terminals are used for all generator sets see appropriate wiring diagrams for specific generator set models Note To use the prime power mode use jumpers to connect TB2 1P to TB2 2P TB2 3P to TB2 4P and TB2 3 to TB2 4 To deactivate the prime power mode remove these jumpers 52 Section 6 Accessories N elle p2 P1 A 336415 A 1 TB1 TB1A terminal strip 2 TB2 terminal strip 3 TB3 TB1B terminal strip Figure 6 16 TB1 and TB2 Terminal Stri
29. 1 through 1 2 7 installations use modified 16 light microprocessor controllers with switchgear applications These nonstandard controllers may have remote start and no time delay for engine cooldown circuitry Consult the switchgear literature for configuration and function Note Some A ALC VOLTS A C AMPERES ad e A J LOWER METER SCALES VOLTAGE EMERGENCY STOP Y oom S TOTAL HOURS ONLY DEN Tw N N AN J BATTERY a PREALARM HIGH ENGINE 5 TEMPERATURE 7 HIGH ENGINE l y AUXILIARY 3 HIGH BATTERY TEMPERATURE FAULT Gi PREALARM LOW OIL 4 LOW OIL V PRESSURE y LOW Ol O BATTERY y AIR N PRESSURE _ CHA Fi _ DAMPER y LOW WATER EMERGENCY LOW BATTERY gt SYSTEM _ TEMPERATURE STOP VOLTAGE READY s Sa GENERATOR LOW FUEL OVERSPEED OVERCRANK SWITCH A a NOT IN AUTO RUN OFF RESET AUTO SILENCE JAMAL ALARM 16 Fuses inside controller Selector switch Frequency meter AC voltmeter Controller TB1 and TP2 terminal strips on circuit board AC ammeter Scale lamps upper lower Lamp test Alarm horn Figure 1 1 16 Light Decision Maker 3 Controller TP 6161 1 08 Annunciator panel lamps Alarm silence switch Generator set master switch ADV 5849A DC voltmeter Water temperature ga
30. A X 3C oz o 9 OA zi o EN Lid MOD 19 dNOO Te NY dooua 2 19 zr E s WNOILdO QA ou Rua a eL uc LL E o ig 23 gt L EL ay 5 119 a SD eo OO dooud za 11d OL 11 el T 10 dNOO n za ey d 2 i WNOILdO dOONd WNOILdO ANY i1 8A A A00011 OSE9 ZH OG 23 a erem 008 1 0464 ZH 09 009 v ZH 09 AODZE1 OZ9L ZH 09 1009 0188 ZH OS AQL Obz ZH OG 08 LLE ZH 09 A9lv OvZ ZH OG AO8v LLZ ZH 09 AOLVCi O0CL ZH 09 DOOEE SOG EZH OS A009 0 Z ZH OS 9lv OvC ZH 09 OOv 0 Z ZH OG 9lv OvZ ZH 09 AO0ZL 0891v ZH 09 09 1 00v2 ZH 09 AO82 0ZZ ZH OS O8 0Z6 ZH 09 A08 0ZZ ZH OS AO08 0ZZ ZH 09 O a JAM JAM y HOIVNS3II VIT y JAM IH JAM v YOLWNYSDW VST CT SO OT en E u3amnr anvi pijp 8L 6 fA t3 A aadnnr dvi o pz an 81 a JWS YILIN LI ees ES TT ly 11 3WOS YILIN LI ea 8l 61 AAA LI O 1 N 91 L SL o e V 01 SL H OA 13 19 7 S gA a I ij LA y WWW LL ZL orl a s a 01 L POL Apa Lb Li Ni 91 _ zi 119 id E O 2 19 NOD 2 fe dOONQ el v WNOILdO Elo M3dWne anya orJznfen 81 d3Sh ION 19 D pil JOS Hil3 TI z 3 19 H9 cope Y 19 noo SIWANYN 33S 3SvHd 39NIS Z do X04 GdlvH LON SI3S 3WOS a FRE IVNOLLAO SC yl AOZZ Oll ZH OS P ABOZ OZL ZH OG AOYZ 6 L ZH 09 LA e AOQOZ O0L ZH OS Q AO0Z SLl ZH OG OZZ ZL ZH O9 13 AOZZ OLL ZH OG AOvZ OZL ZH 09 i 061 01L ZH OS A80C 0 L ZH 09 8 Z3 AOvZ OZL ZH 09 A00Z 001 ZH 09 JAM MOT 3MIM v YJOIVNY311V 0V31 cl NO O
31. L 1130 SHIM HOIVNHAJLIV Gv31 Cl jSVHd 319NIS SHIM YOLVNYSL IV Gv31 l SNOILOINNOO YOLVYSNAS 45 Section 5 Generator Set Reconnection 1 08 Figure 5 4 350 2000 kW Pilot Excited Permanent Magnet Alternator ADV 5875D H TP 6161 4 Remove the controller cover and reposition the 6 Reconnect the starting battery negative lead meter scale lamp jumper see Figure 5 5 to match last Place the generator set master switch in the the position for desired voltage shown in RUN position to start the generator set Check the Figure 5 1 Figure 5 2 Figure 5 3 and voltmeter to verify that the voltage changed to the Figure 5 4 Replace the controller cover desired value a 20 300 kW Models Adjust the voltage with the aed ee 1 voltage adjustment control on the generator set Eal E E controller front panel or switchgear See Figure 5 6 LOW V7F ORREN O HEBER e OMY C MUNG Oihe ORe O BAE rauer O Buren ORA ONPE ORRE ORI O gt ADV 5849A 1 1 Output voltage adjustment control Figure 5 6 Voltage Adjustment b 350 2000 kW Models Adjust the voltage with the voltage adjustment control on the voltage
32. Modbus Ethernet Spec Sheet 7 Monitor III Software Operation Manual TT 1405 TP 6347 Figure 1 Related Literature Several engine manufacturers provide engines with electronic controls These electronic controls indicate fault codes in addition to the generator set controller Use Figure 2 for literature part numbers relating to the identifying engine fault codes For the latest literature part numbers see the respective Parts Catalog Literature Part No Description 30 kW and 80 125 kW GM 80 200 kW John Deere 4045 6068 275 500 kW Kohler Branded Engines 135 275 kW DDC Series 50 60 Gas 230 450 kW DDC Series 60 230 450 kW DDC Series 60 450 500 kW DDC Series 2000 650 1000 kW DDC Series 2000 650 1000 kW Engine Operating DDC MTU Series 2000 TP 8502 instructions ADEC 1250 2250 kW Engine Operating DDC MTU Series 4000 1P 8503 instructions ADEC 1350 2000 kW TP 6215 Engine ECM Service Manual TP 6285 Engine Operation Manual TP 6218 Engine Operation Manual Natural Gas Generator Set Engine Operator s Guide DDEC IV Application and Installation Manual TP 5830 TP 6056 TP 5611 Engine Operator s Guide DDEC IV ECM TP 6361 Troubleshooting Guide Engine Operating TP 6375 instructions MDEC Engine Operating DDC MTU Series 4000 1P 8237 instructions MDEC Figure 2 Related Engine Literature Introduction 9 T
33. Operation Industrial Generator Sets di Models 20 2250 kW Controllers Decision Maker 3 16 Light Software Code Version 1 10 or higher Decision Maker 1 9001 KOHLER mum POVVER SYSTEMS KOHLER di POWER SYSTEMS mas se California Proposition 65 A WARNING Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Product Identification Information Product identification numbers determine service parts Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual spec sheet or sales invoice Controller Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model Designation Serial Number Table of Contents Product Identification Information oooccconncccnnnnor eH hh nnn 2 Safety Precautions and Instruct
34. S USD Uo1Ms eAmejedour ay aoejday eAneJedout U91IMs eJngeJeduue Jayem yBiH G M Ja ouo9 eui 0 y 12euuo921 UB s 019euuoo sseuey ulBu ay OSUUODSIG 1uBn pexoo jou s 4019euuoo sseujeu eui u3 w s Bug piouejos Jeueijs JO Jeuejs eui aoejday aAlyesadou piouejos Jeuejs Jeuels S S e uonoes Bunel WOO M peq pepueululooo4 sepi oJd jesys oeds eu eyeq y eoe deJ Jo abeyosy peep 10 yeem Auayeg x uono s ju8n pue ue 198 109 ae suono uuoo ueneq eui eu A 1oe4109UI JO pepoJu102 asoo suonoeuuoo uegeg x x w s Bug yESOWAY ey soe day eAmgeJedour ysowiay L 9419 OG uiejs S 891119913 g uonoeg Jena Bunelado jeuuou 0 juejooo ay eJo1seH paddinba Ji uwopinus ana juejoo9 MOT W O Buz e oes walsks Buiooo eui jooysajqno Uuay umop ooo O aUIBUS eui moly umopmys ainyesadwe yBiH W S 40 W O Bua dund sayem ay asejday eq au eoejdeJ Jo u 4 IL aneladou dund sayem Bullooo uono s l A Bunei do Ieuuiou 0 juejooo ay eJo1seH MO A JUB OOD sBuiuedo are ay ue oO paBBojo sBujuado itv G M W S Bu3 Buum eoujoeje pue N23 euiBue q0ayo NO3 aulbua o eoepeiul J lo uoo wajs s Buioo5 W S W O SLV W S W I ueo G M Z uonoes s e ep euin pue qnoJio uejs ome ay jooysa qno yes Jo1eJeueB ay 1S8
35. a damp cloth Keep electrical connections dry and tight If corrosion exists disconnect the cables from the battery and remove the corrosion with a wire brush Clean the battery and cables with a solution of baking soda and water Do not allow the cleaning solution to enter battery cells Flush the battery and cables with clean water and wipe the battery with a dry cloth 3 10 2 Electrolyte Level Inspection Check the electrolyte level and specific gravity of batteries that have filler caps Maintenance free batteries do not require electrolyte level checking or specific gravity testing Check the electrolyte level at the specified interval Remove the filler caps and verify that the electrolyte level reaches the bottom of each filler hole See Figure 3 13 Refill as necessary with distilled water or clean tap water Do not add fresh electrolyte Tighten the filler caps After adding water during freezing temperatures run the generator set 20 30 minutes to mix the electrolyte and the water to prevent battery damage from freezing 1 Filler caps 2 Electrolyte level Figure 3 13 Battery Electrolyte Level Inspection 3 10 3 Specific Gravity Check Use a battery hydrometer to check the specific gravity of the electrolyte in each battery cell of batteries with filler caps Holding the hydrometer vertically read the number on the glass bulb at the top of the electrolyte level or the number adjacent to the pointer If the hydrometer
36. abrasions where subject to motion Quarterly Safety and alarm operation Six Months Tighten control and power wiring connections Yearly Transfer switch main contacts Yearly Voltage sensing device relay adjustment Yearly Wire cable insulation breakdown 3 Years or 500 Hours Engine and Mounting General inspection Weekly Governor operation lubricate moving parts Monthly Air cleaner service Six Months Choke carburetor adjustment Six Months Governor oil mechanical governor only Yearly Ignition components Yearly Injector pump and injector flow rate pressure spray pattern Yearly Valve clearance 3 Years or 500 Hours Bolt torque 3 Years or 500 Hours Remote Control System etc Compartment condition Weekly Remote control Monthly Run generator set Monthly Alternator General inspection Weekly Rotor and stator Yearly Bearing condition Yearly Exciter Yearly Voltage regulator Yearly Measure and record resistance readings of windings with insulation tester Megger with SCR assembly or rectifier disconnected Yearly Blow dust out of alternator 2 Years or 300 Hours General Condition of Equipment Any condition of vibration leakage noise temperature or deterioration Weekly Ensure that system is set for automatic operation
37. agnostic Tester M The FASTCHECK diagnostic tester simulates engine operation to identify faults in the controller and engine circuitry Use the FASTCHECK when troubleshooting startup problems or to test and troubleshoot the controller when it is removed from the generator set Perform tests without starting the generator set FASTCHECK functions are listed below refer to Figure 6 5 to identify LEDs and switches Figure 6 5 FASTCHECKe Diagnostic Tester LEDs on the FASTCHECKe illuminate to indicate the energizing of the following circuits AC Voltage Regulator Battery Connection correct polarity Engine Ignition gas gasoline Engine Crank Engine Antidieseling Engine Malfunction Alarm and or Alarm Shutdown Fuel Solenoid diesel Switches on the FASTCHECK simulate the following Anticipatory High Engine Coolant Temperature Anticipatory Low Engine Oil Pressure Engine Crank Engine Overspeed Engine Running High Engine Coolant Temperature Low Engine Coolant Temperature Low Engine Oil Pressure Low Fuel TP 6161 1 08 6 1 8 Float Equalize Battery Charger Kit with Alarm Option M The float equalize battery charger with alarm option provides battery charging to the engine starting battery ies and connects to the controller for fault detection Battery chargers for 12 or 24 volt models are available as a generator set accessor
38. an 82 m NYOS YILIN LI R d JOS YIN LT CR JOS YILIN a 225 96 A 8 z Q a 19 ANO uo melo 0080 wwolldO 8 c o6 O 1 ETT 6A LL Ss e 0 0A 19 dWO2 07 i dOONG IWNOILdO AR Tt S u A A G A gA d Lig L ot ig A 19 G3i4I03dS N3HM Nee 5 vik Ob 5 ss Ove YIAVIN NOISIDIO M 7 I PH Mo OS OZ YO4 SNIHIA 12 n i jp 91 gt 6 O 119 pe d f i IA H L C L O ei LN L 19 NOD bA Hof V dOON WNOLLdO a E A919 09Z ZH OG O8v LLC ZH 09 80C OCL ZH OG OvZ 69 ZH 09 11 i1 OOv OCZC ZH OG N9Llv OvZ ZH 09 ADOZ SLL AOCZ LZl ZH 09 009 Lv9 ZH 09 AO8 0ZZ ZH OS A08 07Z ZH 09 A061 011 AB0Z 0Z ZH 09 JAM vr HOIVNMJdLIV GVd1 9 y YJOIVNW311W Gv31 El JAM MOI v YOIVNYSLIV QV3I El S3dNne dav o7 zafen 82 YIAN env orfan 81 Sanar dAvi or zafen 84 FIVOS HB3I3W CI JOS H313N CI JOS YILIN INNOYI NOMNJ ALVINSNI OL 3dvl Z O 19 19 dNO9 E 119 AV UR dooxd OZ zio AMA al I x lt gt TNOlLdo E 7 LS 9 Ta 1 I ES iz OL SU e H 8 A4 CX 7 UZ o LN BAO v q 4 dos om aL NO c cs d I OA c M i LA E a LLE e F3 OA 19 dN02 d 9 dOOHQ WNOlLdO 9 UP zip 03SN LON 19 vat SIYANYA 33S 3SvHd FIONIS d das LON 10 404 G3lve LON S13S 3WOS eae NOZZ OLL ZH OG AINO 3NIMV AD A00Z 001 ZH OS NOZZ OLL ZH OG NOZZ ZH OS AOvZ OCL ZH 09 AOvZ OZL ZH 09 AOYZ ZH 09 00Z 001 ZH 09 vVLI3U 38 y BOIVNS3ITV OV31 Zl ASVHd 319 MOIVNM3LIV 0V31 Cl jSvHd 319NIS
39. and coolant recovery tank City water cooled models have a heat exchanger and an expansion surge tank with a pressure cap A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure Allow the engine to cool Release pressure from the cooling system before removing the pressure cap To release pressure cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop Remove the cap after pressure has been completely released and the engine has cooled Check the coolant level at the tank if the generator set has a coolant recovery tank Note Engine damage Bleed the air from the cooling system to prevent overheating and subsequent engine damage Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater 3 7 4 Coolant Level Check Check the coolant level in the coolant recovery tank if equipped Maintain the coolant level between the high and low marks Note Periodically check the coolant level by removing the pressure cap Do notrely solely on the level in the coolant recovery tank Add fresh coolant until th
40. arburetor Adjustment Refer to the engine operation manual or engine service manual for gasoline carburetor adjustment information Gaseous Carburetor Fuel Mixer Adjustment Procedure Use the following procedure to adjust the carburetor fuel mixer 1 Start the generator set and run it at approximately half load 2 Adjust the engine fuel mixture screw Figure 3 6 until the engine runs smoothly 3 Apply varying loads and readjust the carburetor as necessary to achieve smooth engine performance at all load levels 4 Stop the generator set 1 Fuel adjusting screw 2 Lean 3 Rich Figure 3 6 Fuel Mixture Adjustment Typical 3 6 6 Fuel System Maintenance Gasoline Models Clean or replace the fuel filter at the specified interval Service the filters more frequently if the engine runs roughly as a clogged fuel filter can cause rough engine operation Some models use a disposable inline fuel filter which must be replaced Other models have a fuel pump with an integral fuel filter that requires cleaning at the specified interval Gaseous Models This fuel system requires no regular maintenance Section 3 Scheduled Maintenance 27 3 7 Cooling System The cooling system maintenance information applies to radiator cooled models and city water cooled heat exchanger models The cooling systems function similarly even though they use different components Radiator cooled models have a radiator with a pressure cap
41. ating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Section 3 Scheduled Maintenance 21 3 3 Service Schedule Action Visually Inspect Check Change System Component Interval Fuel Day tank level Weekly Flexible lines and connections Weekly Fuel level switch Weekly Main tank supply level Weekly Solenoid valve operation Weekly Transfer pump operation Weekly Water in system remove Weekly Filter s Quarterly Gasoline supply Six Months Fuel piping Yearly Tank vents and return lines for obstructions Yearly Lubrication Oil level Weekly Crankcase breather Quarterly Change oil Replace filter s First 50 Hours Then Every 250 Hours Cooling Radiator fan bolt torque 1500 2800REOZDC with unit mounted radiator Initially 8 Hours Then Every 100 Hours Air cleaner to room enclosure Weekly Block heater operation Weekly Coolant level Weekly Flexible hoses and connectors Weekly Water pump s Weekly Fan and alternator belts Monthly Coolant temperature protection level Six Months Lubricate fan bearings 1200 2000 kW 200 Hours or Six Months Ai
42. ator alarm switch to NORMAL 8 Move the controller alarm horn switch to the NORMAL position 2 4 Expanded Decision Maker 1 Controller 2 4 4 Generator Set Starting Local Starting Move the generator set to the RUN position to immediately start the generator set Automatic Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or the remote start stop switch connected to controller terminals TB1 3 and TB1 4 Note The controller allows up to 30seconds of continuous cranking before overcrank shutdown occurs Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period 2 4 2 Generator Set Stopping Local Stopping 1 Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Move the generator set master switch to the OFF RESET position The engine stops Automatic Stopping 1 The automatic transfer switch ATS or other device disconnects the load from the generator set 2 The generator set continues to run for a preset time if the ATS is equipped with an engine cooldown time delay 3 The ATS opens the connection between controller terminals TB1 3 and TB1 4 The generator set shuts down if the generator set master switch is in the AUTO position 2 4 3 Fault Shutdowns The generator set shuts down automatically under the fault conditions shown in Figure 2 3 and cannot be restarted unt
43. completely Note The generator set continues to run during a 5 minute cooldown cycle if a remote switch or automatic transfer switch signals the engine to stop Note The controller circuit board DIP switches allow disabling the engine cooldown function 2 3 2 Prime Power Mode Operation The controller can operate in either the normal mode or the prime power mode n prime power mode the controller draws less current when the generator set master switch is in the OFF RESET position minimizing the battery drain Use the prime power mode for installations that do not have a battery charger to help prevent discharging the battery when the generator set is not operating Moving the generator set master switch to the OFF RESET position disables all controller functions Moving the generator set master switch to the AUTO position restores controller functions 18 Section 2 Operation Enabling and Disabling the Prime Power Mode To enable the prime power mode use jumpers to connect TB2 1P to TB2 2P TB2 3P to TB2 4P and TB2 3 to TB2 4 To deactivate the prime power mode remove these jumpers See Figure 1 7 Figure 1 8 and Figure 2 1 Terminal Purpose Prime power operation Prime power operation Remote start ground Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Remote start Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power opera
44. e 5 4 to determine the generator set voltage configuration Note the original voltage and reconnect as needed Route leads through current transformers CTs and connect them according to the diagram for desired phase and voltage Note Position current transformers CT1 CT2 and CT3 with the dot or HI side toward the generator set Section 5 Generator Set Reconnection 41 LCOQV NON SQV1 YOLVLS SQV31 YOLVLS L yox Zo a4 O 3ais 3NI o YAV38E 3 H3ww388 5 __ 10081 H aqis LLI aqs _ Linoulo A als 3104 3NO dvo avo 310d 3NO eoi C n 17 ANNONS quo ayo o 01 7 o 01 01 T c IVeLN3N O Ovalln3N O Ive Ln3N O n a9 o 9 O 5 og p Log 01 gt tNMA E Z MAL NA Y L V 2 Y NN C NNN lt lt lt S lt lt N ZHOG AOvc O0cc 1 08 TP 6161 20 150 kW Permanent Magnet and Wound Field Single Phase Alternators ADV 5875A H 42 Section 5 Generator Set Reconnection Figure 5 1 e 17 SIJS TIV NO G3Sn LON SYHSWHOSSNVAL LIN3S8SDO g y YOLVYSNS9 GYVMOL LH YO LOG YSWYOASNVYL IN38809 NOLLVLOY 3SVHd SALON s3aAne dv ora M3dWne dvi or zafan 81 Madr dav orf
45. e fuel flow to the fuel regulator The generator set mounted regulator reduces the fuel pressure as fuel passes to the carburetor See Figure 3 4 Primary regulator supplied by gas supplier or customer Pressure gauge Solenoid valve Secondary regulator Carburetor Figure 3 4 Fuel Regulator and Valve Typical Section 3 Scheduled Maintenance 25 The carburetor mixer controls the ratio of fuel to air under varying load and speed conditions Because the carburetor receives fuel in a gaseous state it does not have to vaporize the fuel When switching from natural gas to LP gas or LP gas to natural gas verify that the electronic governor maintains the rated engine speed 1800 rpm at 60 Hz or 1500 rpm at 50 Hz If the engine speed is incorrect refer to the generator set service manual for the governor adjustment procedure 3 6 2 LP Liquid Withdrawal Fuel System Concept With the LP liquid withdrawal fuel system pressurized liquid LP fuel passes from the tank to a vaporizer The vaporizer converts the liquid fuel to gas before sending it to the carburetor The system also includes a fuel valve that shuts off the fuel flow when the engine stops Contact an authorized service distributor dealer for availability 3 6 3 LP Gas Natural Gas Conversion for Straight Gas Fuel System Most models operate on either LP gas or natural gas fuel by performing the fuel conversion procedure So
46. e level is just below the overflow tube opening of the filler neck 28 Section 3 Scheduled Maintenance 3 7 2 Cooling System Component Inspection To prevent generator set shutdown or damage caused by overheating e Keep the cooling air inlets clean and unobstructed e Inspect the radiator s exterior for obstructions Remove dirt and foreign material using a soft brush or cloth to avoid damaging the radiator fins e Check the hoses and connections for leaks Replace any cracked frayed or spongy hoses e Check the condition and tension of the radiator fan and water pump belt s Follow the belt tension procedure in this manual and or the engine operation manual e Checkthe pressure cap seal and replace a cracked or deteriorated cap Remove dirt and other debris from the pressure cap and filler neck The pressure cap raises the boiling point of the coolant enabling higher operating temperatures Replace a leaking pressure cap with one rated for the same pressure The pressure cap rating usually appears on the pressure cap 3 7 8 Cooling System Drainage Procedure For optimum protection drain flush and refill the cooling system at the intervals listed in the service schedule Note Dispose of all waste materials oil fuel coolant filters and gaskets in an environmentally safe manner 1 Deenergize the block heater if equipped 2 Remove the pressure cap to allow the entire system to drain and prevent air pocke
47. e manual for bearing maintenance information 3 5 Diesel Fuel Systems 3 5 1 Bleeding Air from Fuel System Bleed air from the fuel system after fuel system maintenance such as replacing the fuel filter s using the hand prime pump kit when equipped The hand prime fuel pump eliminates the need for cranking the engine to bleed air from the fuel system Note Bleed air from the fuel system according to the engine manufacturer s instructions Trapped air in the fuel system causes difficult starting and or erratic engine operation Note Correct any fuel leaks encountered during the priming procedure 1 Place the fuel valves in the fuel system prime position Close the fuel valve located between the pipe tee and the engine Open the fuel valves on each side of the fuel prime pump See Figure 3 1 24 Section 3 Scheduled Maintenance Open this Valve Close this Valve Open this Valve Valve Open Valve Closed PK 272000 H Figure 3 1 Hand Prime Pump with Valve Positions for Fuel Priming Generator Set Without a Fuel Water Separator Shown Note The illustration shows a generator set without a fuel water separator The valve location and position for a generator set equipped with a fuel water separator is similar 2 Loosen the bleed screw at the engine Refer to the engine operation manual for location of the bleed screw s The bleed screw allows air to be
48. ech Tools Use your SecurlD to access the KOHLERnet and click on Tech Tools button to find the following topics Software used by generator set controllers including updates and documentation references Service Assistance e Network Communications provides basics to terms protocols standards wiring configurations and model e Engine Electronic Control Module ECM has information about electronic devices provided by the engine manufacturer to manage engine data For professional advice on generator set power requirements and conscientious service please contact your nearest Kohler distributor or dealer Consult the Yellow Pages under the heading Generators Electric Visit the Kohler KohlerPower com Power Systems website at Look atthe labels and stickers on your Kohler product or review the appropriate literature or documents included with the product Call toll free in the US and Canada 1 800 544 2444 Outside the US and Canada call the nearest regional office Headquarters Europe Middle East Africa EMEA Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone 33 1 49 178300 Fax 33 1 49 178301 Asia Pacific Power Systems Asia Pacific Regional Office Singapore Republic of Singapore Phone 65 6264 6422 Fax 65 6264 6455 10 Service Assistance China North China Regional Office Beijing Phone 86 10 6518 7950 86 10 6518 7951 86 10 6518 7952 Fax 86 1
49. ed Flush the resulting liquid with water and dry the area Safety Precautions and Instructions 5 Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do notsmoke or permit flames or sparks to occur near a battery at any time particularly when it is charging Do not dispose of a battery in a fire To prevent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the start
50. er solenoid Do not test the battery condition by shorting the terminals together Engine Backfire Flash Fire A WARNING Lh 4 Fire Can cause severe injury or death Do not smoke or permit flames or sparks near fuels or the fuel system 6 Safety Precautions and Instructions Servicing the fuel system A flash fire can cause severe injury or death Do not smoke or permit flames or sparks near the carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuels or fuel vapors Catch fuels in an approved container when removing the fuel line or carburetor Servicing the air cleaner A sudden backfire can cause severe injury or death Do not operate the generator set with the air cleaner removed Combustible materials A fire can cause severe injury or death Generator set engine fuels and fuel vapors are flammable and explosive Handle these materials carefully to minimize the risk of fire or explosion Equip the compartment or nearby area with a fully charged fire extinguisher Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency Train all personnel on fire extinguisher operation and fire prevention procedures Exhaust System A WARNING Carbon monoxide Can cause severe fainting or death nausea The exhaust system must be leakproof and routinely inspected Generator set operation Carbon mon
51. erature AHET signal Anticipatory low oil pressure ALOP signal Battery voltage fuse 1 protected Accessory power supply Customer may also provide separate accessory power source 48 Emergency stop ES signal 56 Air damper AD switch 60 System ready signal 61 Battery charger fault Connect battery charger alarm contact to activate fault lamp active low if used 62 Low battery volts Connect battery charger alarm contact to activate fault lamp active low if used 63 Low fuel LF fault Connect fuel level sensor to activate fault lamp active low if used 70C Generator in cool down mode signal 70R Generator in running mode signal 80 Not in auto signal Connect jumper across terminals 1 and 1A if emergency stop switch is not used Use aremote annunciator and or audiovisual alarm kit as an indicator with a dry contact kit connected to controller terminal strip TB1 TB1A and TB3 TB1B Figure 6 18 16 Light Controller TB1 TB1A and TB3 TB1B Terminal Strips TP 6161 1 08 Section 6 Accessories 53 6 3 Communication Module Kit and Gauge Driver Circuit Board When a remote serial annunciator RSA is connected to a Decision Maker 3 controller a communication module circuit board is required See Figure 6 19 for location and connection The communication module circuit board location may also be occupied b
52. ercrank fault condition Overcrank Overspeed Overspeed shuts down the unit immediately when governed frequency on 50 60 Hz models exceeds 60 70 Hz Note The controller circuit board DIP switches allow 50 Hz 60 Hz shutdown or 60 Hz 70 Hz shutdown selection Overvoltage if Overvoltage shuts down the unit and lights the equipped auxiliary lamp when voltage is at least 15 over the nominal voltage for longer than 2 seconds Note Overvoltage can damage sensitive equipment in less than 1 second Provide separate overvoltage protection for online equipment requiring faster shutdowns Figure 2 2 Fault Shutdowns 3 Correct the cause of fault shutdown See the Safety Precautions section of this manual before proceeding 4 Start the generator set by moving the generator set master switch to the OFF RESET position and then to the RUN position If equipped the audiovisual annunciator alarm horn sounds and lamp goes out 5 Verify that the cause of the shutdown was corrected by test operating the generator set 6 Reconnect the generator set to the load by using the line circuit breaker or the automatic transfer switch Note Place the generator set master switch in the AUTO position before silencing the alarm horn Section 2 Operation 19 7 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch If equipped move the audiovisual annunci
53. etting After a Fault Shutdown to restart the generator set following a fault shutdown Emergency Stop Switch Resetting Procedure 1 Investigate the cause of the emergency stop and correct the circuit or wiring problem s 2 If the remote emergency stop switch was activated reset the switch by replacing the glass piece If the controller mounted emergency stop switch if equipped was activated reset the controller emergency stop switch by rotating the switch clockwise until it springs back to its original position Note The controller auxiliary fault lamp lights if the generator set master switch is in the RUN or AUTO position during the resetting procedure 3 Toggle the generator set master switch to the OFF RESET position and then to the RUN or AUTO position to restart the generator set The generator set does not crank until the resetting procedure is completed 2 3 4 Fault Shutdowns The generator set shuts down automatically under the fault conditions listed in Figure 2 2 2 3 5 Controller Resetting After a Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown Refer to Section 2 3 3 Emergency Stopping to reset the generator set after an emergency stop 1 Move the controller alarm horn switch to the SILENCE position If equipped the audiovisual annunciator alarm horn and lamp are activated Move the audiovisual annunciator alarm switch to SILENCE to stop the alarm hor
54. expelled from the fuel system when the hand prime pump is operated 3 Rotate hand prime pump handle counterclockwise until fuel flows from the bleed screw Stop pumping 4 Tighten the bleed screw Wipe up any fuel leakage 5 Place the fuel valves in the normal operation position Open the fuel valve located between the pipe tee and the engine Close the fuel valves on each side of the fuel prime pump TP 6161 1 08 3 5 2 Subbase Inner Fuel Tank Alarm This kit provides for both audible and visual alarm from a location remote from the generator set if a leak is detected in the inner fuel tank of the double wall subbase fuel tanks See Figure 3 2 If the inner tank is leaking a sensor installed in the outer tank sends an electrical signal to the alarm plate when the sensor becomes immersed in the fuel collecting in the outer tank Ifa leak is detected the alarm horn will sound and the fault lamp will light The alarm horn is quieted by moving the alarm switch to the SILENCE position the alarm lamp remains lit until the fault is corrected See Figure 3 3 for troubleshooting information Inner Tank O Fuel Leak Alarm Alarm Normal IJ Silence S FF 273000 D Figure 3 2 Inner Fuel Tank Leak Alarm 20 300 kW Model Shown Alarm Float Switch Switch Position Position Observation Open
55. g battery charging alternator Battery Council International before dead center brake horsepower black paint color block engine block heater brake mean effective pressure bits per second brass before top dead center British thermal unit British thermal units per minute Celsius centigrade calorie controller area network California Air Resources Board circuit breaker cubic centimeter cold cranking amps counterclockwise Canadian Electrical Code certificate certification certified cubic feet per hour 1 08 cfm CG CID CL cm CMOS cogen com coml Coml Rec conn cont CPVC crit CRT CSA CT Cu cUL CUL cu in cw CWC cyl D A DAC dB dB A DC DCR deg dept DFMEA dia DI EO DIN DIP DPDT DPST DS DVR E emer ECM EDI EFR e g EG EGSA EIA El EO EMI emiss eng EPA EPS ES ESD cubic feet per minute center of gravity cubic inch displacement centerline centimeter complementary metal oxide substrate semiconductor cogeneration communications port commercial Commercial Recreational connection continued chlorinated polyvinyl chloride critical cathode ray tube Canadian Standards Association current transformer copper Canadian Underwriter s Laboratories Canadian Underwriter s Laboratories cubic inch clockwise city water cooled cylinder digital to analog digital to analog converter decibel decibel A
56. g Move the generator set master switch to the RUN position to start the generator set at the controller Normal Operation Note The alarm horn sounds and the Not in Auto lamp lights when the generator set master switch is not in the AUTO position Section 2 Operation 17 Note The transient start stop function of the 16 light controller prevents accidental cranking of the rotating engine If the generator set master switch is momentarily placed in the OFF RESET position and then is returned to the RUN position the generator set slows to 750 rpm 25 Hz and recranks before returning to rated speed Automatic Starting Move the generator set master switch to the AUTO position to allow startup by an automatic transfer switch or a remote start stop switch Refer to the wiring diagrams for remote switch connection information The engine cranks up to 30 seconds continuously or 75 seconds cyclically crank 15 seconds rest 15 seconds crank 15 seconds etc before shutting down on an overcrank fault Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period Select the cyclic or continuous cranking mode on the controller circuit board See Section 1 2 7 DIP switches Stopping Run the generator set without load for 5 minutes to ensure adequate engine cooldown To stop the generator set place the generator set master switch in the OFF RESET position and wait until the generator set stops
57. gure 1 12 L1 AMPS L112 VOLTS L2 AMPS 2 13 VOLTS Los L3 AMPS VOLTS Lti 3VOLTS U C UL USE LOWER METER SCALES RESET VOLTAGE RUN OFF AUTO ADV 5849E B Voltage adjustment control Fault lamp 10 amp controller fuse DC voltmeter Water temperature gauge Oil pressure gauge Frequency meter AC voltmeter AC ammeter Scale lamps upper lower Selector switch Hourmeter Generator set master switch Figure 1 12 Expanded Decision Maker 1 Controller Figure 1 13 and Figure 1 14 describe the controls and indicators located on the controller Item Description Hourmeter Item Description AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents Hourmeter records the generator set total operating hours for reference in maintenance scheduling Oil pressure gauge Gauge displays the engine oil pressure Scale lamps upper lower Lamps indicate which AC voltmeter and or ammeter scales to read AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits DC voltmeter Meter displays the voltage of the starting battery ies Fault lamp Lamp illuminates during engine shutdown if the engine shuts down because of one of the following faults high engine temperature low water level low oil pressure overcrank or overspeed See Sec
58. h configuration for each generator set application Overspeed Frequency DIP Switch 1 The generator set overspeed frequency is set using DIP switch 1 Select 70 Hz for 60 Hz voltages and 60 Hz for 50 Hz voltages Temperature Cooldown DIP Switch 2 The generator set will continue to run during a five minute cooldown cycle or shut down immediately The choice is made using DIP switch 2 Engine Cranking DIP Switch 3 The controller is factory set for cyclic cranking To change to the continuous cranking mode use DIP switch 3 Engine Configuration DIP Switches 4 and 5 See Figure 1 9 for the DIP switch positions based on engine configurations regarding non ECM MDEC and J1939 engine communication selections Modbus Address DIP Switches 6 8 Each Modbus device requires a unique address Address numbers are created using a binary number system with DIP switches 6 8 Figure 1 11 shows the DIP switch position for each address number DIP Switches 6 7 8 Value 4 Value 8 Open Open Open Modbus Address Value 2 Closed Open Open Open Closed Open Closed Closed Open Open Open Closed Closed Open Closed Open Closed Closed Closed Closed Closed Figure 1 11 Modbus Device Address Section 1 Specifications and Features 15 1 3 Expanded Decision Maker 1 Controller For identification of the expanded controller s indicators and controls and their functions refer to Fi
59. he manufacturer s instructions Fuel tanks Explosive fuel vapors can cause severe injury or death Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion Store only diesel fuel in tanks Draining the fuel system Explosive fuel vapors can cause severe injury or death Spilled fuel can cause an explosion Use a containerto catch fuel when draining the fuel system Wipe up spilled fuel after draining the system Gas fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6 8 ounces per square inch 10 14 inches water column Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation Asuccessful test depends on the ability of the solution to bubble LP liquid withdrawal fuel leaks Explosive fuel vapors can cause severe injury or death Fuel leakage can cause an explosion Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90psi 621 kPa Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation A successful test depends on the ability of the solution to bubble TP 6161 1 08 Hazardous Noise CAUTION Hazardo
60. her locally or from a remote location The local emergency stop switch is standard on selected models Generator switch not in auto Lights when the generator set master switch is in the RUN or OFF RESET position High battery voltage Lights if the battery voltage rises above preset level An optional battery charger is required for the lamp to function Low battery voltage Lights if the battery voltage drops below a preset level This lamp requires an optional battery charger in order for the lamp to function Low fuel warning Lights if the fuel level in tank approaches empty This lamp requires a low fuel sensor in the fuel tank in order to function On gas fueled systems this lamp lights if the gas line pressure drops below a preset level Prealarm high engine temperature Lights if the engine temperature approaches the shutdown range This lamp may require an optional prealarm sender kit Prealarm low oil pressure Lights if the engine oil pressure approaches the shutdown range This lamp may require an optional prealarm sender kit in order to function System ready Lights when the generator set master switch is in the AUTO position and the system senses no faults Indicates that the generator set is ready for operation Figure 1 2 Annunciator Panel Lamps Modbus is a registered trademark of Schneider Electric 12 Section 1 Specifications and Features TP 6161 1 08 1 2 2 Auxiliary Fa
61. iator fan shaft and idler shaft bearings at every engine oil change to avoid bearing damage Lubricate the bearings every 200 hours of operation when the generator set runs in ambient temperatures below 29 C 85 F or when the generator set runs in a dusty and or humid environment Lubrication and Drive Belt Adjustment Procedure Lubricate the fan shaft and idler shaft bearings with a lithium complex base multi purpose grease with antirust antifoam and extreme pressure additives having a minimum dropping point of 204 C 400 F Use Mobil Mobilith AW2 NLGI Grade 2 or equivalent 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the generator set engine starting battery ies negative lead first and disconnect power to the battery charger 3 Remove the belt guards to expose the fan shaft and idler shaft bearings 4 Inject grease into the two bearings on the fan shaft block and the two bearings on the idler shaft block using a grease gun until a 3 6 mm 0 13 0 25 in grease column shows atthe bearing pressure relief port See Figure 3 8 Note The fan shaft and idler shaft bearings have pressure relief ports to prevent bearing damage caused by overlubrication TP 6161 1 08 TP 5353 3 1 Grease fittings 2 Pressure relief port 3 Radiator assembly 4 Idler shaft grease fittings 5 Fan shaft g
62. ice distributor dealer for service or diagnostic equipment 34 Section 3 Scheduled Maintenance 3 11 1 Features The DDEC MDEC system optimizes control of critical engine functions and protects against serious engine damage resulting from conditions such as the following e Low coolant level e Low coolant pressure e High coolant temperature e Low oil pressure e High oil temperature The major components of the DDEC MDEC system include the electronic control module ECM and engine sensors The DDEC control box is located in the generator set junction box 3 11 2 DDEC Engine Diagnostics The DDEC engine protection system monitors engine sensors and electronic components and recognizes system malfunctions Critical faults light the check engine CEL and stop engine SEL lamps on the control box ECM memory software logs malfunction codes Consult the engine operation manual or engine service manual to identify the stored failure code See Figure 3 16 for the DDEC control box features DIAGNOSTIC REQUEST IAS PR a Y A ff V um V STOP CHECK ENGINE ENGINE A 343591 C Figure 3 16 DDEC Control Box Access the stored codes in one of three ways e Place the switch in the DIAGNOSTIC REQUEST position The CEL or SEL flashes to identify the failure e Use a hand held diagnostic data reader DDR Place the switch in the DIAGNOSTIC DATA READER position Plug the DDR into the control box The DDR dis
63. il the fault condition is corrected Reset the controller after a fault shutdown 20 Section 2 Operation The fault lamp does not stay lit after the generator set shuts down on a fault condition 2 4 4 Controller Resetting After a Fault Shutdown Use the following procedure to restart the generator set after a fault shutdown 1 Disconnect the generator set from the load using the line circuit breaker or automatic transfer switch See the Safety Precautions at the beginning of this section before proceeding 2 Correct the cause of the fault shutdown See the Safety Precautions at the beginning of this section before proceeding 3 Startthe generator set by moving the generator set master switch to RESET OFF and then to RUN 4 Verify that the cause of the shutdown has been corrected by test operating the generator set 5 Reconnect the generator set to the load using the line circuit breaker or automatic transfer switch 6 Move the generator set master switch to the AUTO position for startup by remote transfer switch or remote start stop switch Fault Description High engine Shutdown occurs 5 seconds after the fault The temperature high engine temperature shutdown does not function during the first 5 seconds after startup Note The high temperature shutdown functions only when the coolant level is in the operating range Low coolant Shutdown occurs 5 seconds after the fault The level low coolant level sh
64. ing a coolant tester Section 3 Scheduled Maintenance 35 2 Add or replace coolant as necessary to ensure adequate freezing protection Use the guidelines included in the engine operation manual 3 Run the generator set for 30 minutes to redistribute added coolant 3 13 3 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition the fuel system with compatible additives to control microbial growth 3 Change the fuel filter separator and bleed the fuel system See the engine owner s manual Gasoline Fueled Engines 1 Add stabilizer to the fuel system Follow the manufacturer s recommended procedure 2 Run the generator set for 15 minutes to ensure that the stabilized fuel reaches the carburetor 3 Place the generator set master switch in the OFF RESET position 4 Close the fuel valve Gas Fueled Engines 1 Start the generator set 2 With the generator set running shut off the gas supply 3 Run the generator set until the engine stops 4 Place the generator set master switch in the OFF RESET position 3 13 4 Internal Engine Components Gas Gasoline Fueled Engines If you have access to a fogging agent or SAE 10 oil prepare the pistons and cylinders for storage as follows 1 While the engine is running spray a fogging agent or SAE 10 engine oil into the air intake for about two minutes until the engine stops
65. ion Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer Equipment damage Verify that the voltage ratings of the transfer switch line circuit breakers and other accessories match the selected line voltage A WARNING Qe aS x Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or equipment connected to the set disable the generator set as follows 1 Turn the generator set master switch and switchgear engine control switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to preventthe starting ofthe generator set by an automatic transfer switch or a remote start stop switch Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator setas follows 1 Move the generator set master swi
66. ions o oooocccccccnnnnn nnn nnn 5 Introduction iE aa RR E RPG RR RARE RUM PRU EUR A RC ACAD A 9 Abbreviations ui pu rasa aq RE ip tu b Doi ER 9 List of Related Materials _ 9 Service Assistance drid oidos 10 Section 1 Specifications and Features oooococccccconcnn eens 11 1 r trod ctiOm S rie A geb de ade i 11 1 2 16 Light Controller Features 11 1 2 1 Annunciator Panel Lamps 00 cece eee 12 1 2 2 Auxiliary Fault Lamp a 13 1 2 3 FUSES ii 13 1 2 4 Analog Meters and Gauges 13 1 25 Switches and Controls 14 1 2 6 Terminal Strips vss a 14 T1 2 7 DIPSSWIICDeS ooo xbox e 15 1 3 Expanded Decision Maker 1 Controller 16 Section 2 Operation u edi da 17 2 1 Prestar Checklist e ok RIDERE IRR a ee de a RM RE pix 17 2 2 Generator Set Exercising i ma susme 00 c cect eee eect ee eens 17 23 16 Light Controller Features a 17 2 3 1 Normal Operation ur sr u upo l cect eet t suu a 17 2 3 2 Prime Power Mode Operation 18 2 3 3 Emergency Stopping 18 2 3 4 Fault Shutdowns 19 2 8 55 Controller Re
67. iring in separate conduit Use shielded cable for all analog inputs Observe all applicable national state and local electrical codes during accessory installation Note The accessories with the M notation are available only on models with 16 light microprocessor controllers 6 1 1 Audiovisual Alarm M An audiovisual alarm warns the operator of fault shutdowns and prealarm conditions except battery charger fault and low battery voltage from a remote location Audiovisual alarms include an alarm horn an alarm silence switch and a common fault lamp See Figure 6 1 Note Use the audiovisual alarm with a dry contact kit Front View Side View Figure 6 1 Audiovisual Alarm TP 6161 1 08 Section 6 Accessories 6 1 2 Common Failure Relay Kit M The common failure relay kit provides one set of contacts to trigger user provided warning devices if a fault occurs The common failure relay faults are user defined Connect up to three common failure relay kits to the controller output See Figure 6 2 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Figure 6 2 Common Failure Relay Kit 6 1 3 Controller Connection Kit M The controller connection kit allows easy connection of controller accessories without accessing the controller terminal strip The kit uses a 165 cm 65 in wiring harness to link the controller terminal stri
68. lly open contacts only Warning devices lamp and or audible alarms and other accessories typically connect to the controller output connections listed below A total of three dry contact kits may connect to a specific output connection on the controller Figure 6 4 shows some typical dry contact kits mounted on an assembly panel for 450 kW and larger generator sets Typical 10 and 14 relay contact kit output connections include e Overspeed e Overcrank e High engine temperature e Low oil pressure 48 Section 6 Accessories e Low water temperature e Auxiliary fault e Anticipatory high engine temperature e Anticipatory low oil pressure e Emergency stop Additional connections available with the 20 relay kits include e Battery charger fault e Low battery voltage e Low fuel level e Engine trouble e Notin AUTO e System ready e Common fault e Overcrank e Crank terminate e Cooldown CENON E 365569A C 1 10 relay kit 2 20 relay kit Figure 6 4 Dry Contact Kits shown mounted on assembly panel for 450 kW and larger generator sets TP 6161 1 08 6 1 6 Engine Prealarm Senders M Alert the user of low water temperature approaching low oil pressure and approaching high engine temperature Kits for gas fueled models include a low fuel pressure switch 6 1 7 FASTCHECK Di
69. ly with a trickle battery charger Refer to the battery charger manufacturer s recommendations Maintain a full charge to extend battery life TP 6161 1 08 This section contains generator set troubleshooting diagnostic and repair information Use the chart on the following page to diagnose and correct common problems First check for simple causes such as a dead engine starting battery or an open circuit breaker The chart includes a list of common problems possible causes of the problem recommended corrective actions and references to detailed information or repair procedures TP 6161 1 08 Section 4 Troubleshooting Maintain a record of repairs and adjustments performed on the equipment If the procedures in this manual do not explain how to correct the problem contact an authorized distributor dealer Use the record to help describe the problem and repairs or adjustments made to the equipment Section 4 Troubleshooting 37 G M 40 W S u S YOUMS eAnejedour eui eoejdey eAneJedout uos eungejeduje 1sneuxe uBiH IAJ S siu uuopied Jepeep 1o3nquisip eones pezuouine ue e eH 4 enuen webe BuuIM Q M 4284S oeds s s enuey eoe S NW S enuen voneladO MN O enuen uoneesu NI 38S Joyesouay ues eulbuy Bugz YAMS Jajsue oneuoiny S v fenuewW siy Jo uoroes palequinu uonoag 9988 x Z uono s Ja 101JUO9 BU 100use qnoJ pue SAYIIMS JNE eui 19seH uMopihnus yney G M 40 W
70. me models require a different fuel kit when changing gas fuels Consult your local generator set distributor dealer for additional information Fuel conversion may decrease generator set output and affect exhaust emissions Consult your local generator set distributor dealer for additional information Fuel Conversion Procedure When converting the generator set to operate with LP gas remove the internal spring from the secondary regulator Install the spring to operate the generator set on natural gas Note Not all fuel regulators require spring and retainer removal for fuel conversion A hang tag on the fuel regulator identifies the conversion procedure LP Fuel Conversion Procedure Use the following steps to remove the internal spring from the fuel regulator 1 Remove the fuel regulator cover plug See Figure 3 5 26 Section 3 Scheduled Maintenance X w 1 Fuel regulator 2 Spring 3 Adjustment screw 4 Cover plug P 3 Figure 3 5 Fuel Regulator Typical 2 Remove the adjustment screw and spring from the fuel regulator Save the adjustment screw and spring for possible conversion back to natural gas 3 Reinstall the cover plug Natural Gas Fuel Conversion Procedure Use the following steps to convert the generator set to natural gas 1 Remove the fuel regulator cover plug See Figure 3 5 2 Replace the spring and adjustment screw 3 Connect a manometer to check the f
71. mode Terminal Strip TB1 TB3 Description Terminal strip for connecting generator set accessories such as an emergency stop switch a remote start stop switch audiovisual alarms etc Refer to the wiring diagrams for information on connecting accessories to the TB1 terminal strip Terminal strip for selecting the remote start stop switch inputs and prime power mode Communication module connection for remote serial annunciator RSA or network communication RS 485 communication connection for Modbus to download new application program software or for connecting the remote serial annunciator CAN engine communication connection Figure 1 7 Controller Terminal Strips Connections GM28725 TB1 TB1A terminal strip TB3 TB1B terminal strip TB2 terminal strip P3 annunciator panel lamp and RSA communication module connections P21 for Modbus RS 485 communication connection P22 for CAN engine communication connection SW1 DIP switch 8 positions P7 RSA communication module connection Fuses Figure 1 8 Controller DIP Switches TP 6161 1 08 1 2 7 DIP Switches The controller circuit board contains eight DIP switches see Figure 1 9 Switch Position Description Open Closed Overspeed selection 60 Hz 70 Hz Temperature Cooldown Cooldown Cooldown Enable Disabled Functional Crank Mode Selection Cyclic Continuous Engine Comm Setting
72. n Figure 1 3 describes auxiliary fault conditions High engine temperature Lights if the engine has shut down because of high engine temperature The shutdown occurs 5 seconds after the engine reaches temperature shutdown range Low oil pressure Lamp lights if the generator set shuts down because of insufficient oil pressure The shutdown occurs 5 seconds after the engine reaches temperature shutdown range Overspeed Lamp lights if the generator set shuts down because the governed frequency on 50 60 Hz models exceeds 60 70 Hz Overcrank Cranking stops and the lamp lights if the engine does not start after 30 seconds of continuous cranking or 75 seconds of cyclic cranking See Section 2 3 1 Normal Operation Note The engine ECM may limit the crank cycle even if the controller is set to a longer time period Cranking stops and the overcrank lamp lights after 25 seconds if the starter or engine does not turn locked rotor The overcrank lamp flashes if the speed sensor signal is absent for longer than one second Low water temperature Lights if water temperature falls below the minimum preset temperature This lamp may require an optional prealarm sender kit in order to function Battery charger fault Lights if the battery charger malfunctions This lamp requires an optional battery charger Emergency stop Lights and the generator set shuts down if the optional emergency stop switch is energized eit
73. n The audiovisual annunciator lamp stays lit 2 Disconnect the generator set from the load by using the line circuit breaker or the automatic transfer switch TP 6161 1 08 High engine The high engine temperature shutdown shuts temperature down the unit 5 seconds after a fault The shutdown does not function during the first 30 seconds following startup Note The high temperature shutdown functions only when the coolant level is in the operating range Low coolant The low coolant level shutdown shuts down the level unit 5 seconds after the fault The shutdown if equipped does not function during the first 30 seconds following startup Low oil The low oil pressure shutdown shuts down the pressure unit 5 seconds after fault detection The shutdown does not function during the first 30 seconds following startup Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Overcrank shuts down the unit after 45 seconds of continuous cranking Shutdown occurs after 75 seconds of cyclic cranking crank 15 seconds reset 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 seconds if the engine or starter does not turn locked rotor Note The controller has an automatic restart function The generator set attempts to restart if the engine speed drops below 390 rpm output frequency of 13 Hz Continued low engine speed causes an ov
74. ntial property damage A CAUTION Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage NOTICE Notice communicates _ installation operation or maintenance information that is safety related but not hazard related Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely The decals are shown throughout this publication to improve operator recognition Replace missing or damaged decals TP 6161 1 08 Accidental Starting A WARNING FS Accidental starting Can cause severe injury or death Disconnect the battery cables before working on the generator set Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Disabling the generator set Accidental starting can cause severe injury or death Before working on the generator set or connected equipment disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer
75. ontact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution Installing the battery charger Hazardous voltage can cause severe injury or death An ungrounded battery charger may cause electrical shock Connect the battery charger enclosure to the ground of a permanent wiring system As an alternative install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger Install the battery charger as prescribed in the equipment manual Install the battery charger in compliance with local codes and ordinances Connecting the battery and the battery charger Hazardous voltage can cause severe injury or death Reconnect the battery correctly positive to positive and negative to negative to avoid electrical shock and damage to the battery charger and battery ies Have a qualified electrician install the battery ies Safety Precautions and Instructions 7 Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Engine block heater Hazardous voltage can cause severe injury or death The engine block heater can cause electrical shock Remove
76. or blindness Wearprotective goggles and clothing when using power tools hand tools or compressed air Servicing the generator set when it is operating Exposed moving parts can cause severe injury or death Keep hands feet hair clothing and test leads away from the belts and pulleys when the generator set is running Replace guards screens and covers before operating the generator set Heavy Equipment Unbalanced weight Improper lifting can cause severe injury or death and equipment damage Do not use lifting eyes Liftthe generator set using lifting bars inserted through the lifting holes on the skid Hot Parts A WARNING Hot coolant and steam Can cause severe injury or death Before removing the pressure cap stop the generator set and allow it to cool Then loosen the pressure cap to relieve pressure A WARNING Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools Servicing the alternator Hot parts can cause severe injury or death Avoid touching the alternator field or exciter armature When shorted the alternator field and exciter armature become hot enough to cause severe burns Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Notice NOTICE This generator set has been
77. ories TP 6161 1 08 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication A amp ABDC AC A D ADC adj ADV Ah AHWT AISI ALOP alt Al ANSI AO APDC API approx AQMD AR AS ASE ASME assy ASTM ATDC ATS auto aux avg AVR AWG AWM bat BBDC BC BCA BCI BDC BHP blk blk htr BMEP bps br BTDC Btu Btu min C cal CAN CARB CB cc CCA CCW CEC cert cfh TP 6161 ampere after bottom dead center alternating current analog to digital advanced digital control analog to digital converter adjust adjustment advertising dimensional drawing amp hour anticipatory high water temperature American Iron and Steel Institute anticipatory low oil pressure alternator aluminum American National Standards Institute formerly American Standards Association ASA anticipatory only Air Pollution Control District American Petroleum Institute approximate approximately Air Quality Management District as required as requested as supplied as stated as suggested American Society of Engineers American Society of Mechanical Engineers assembly American Society for Testing Materials after top dead center automatic transfer switch automatic auxiliary average automatic voltage regulator American Wire Gauge appliance wiring material battery before bottom dead center battery charger battery chargin
78. oxide can cause severe nausea fainting or death Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Avoid breathing exhaustfumes when working on or near the generator set Never operate the generator set inside a building unless the exhaust gas is piped safely outside Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas presentin exhaust gases Carbon monoxide is an odorless colorless tasteless nonirritating gas that can cause death if inhaled for even a short time Carbon monoxide poisoning symptoms include but are not limited to the following e Light headedness dizziness e Physical fatigue weakness in joints and muscles e Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision e Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poisoning is possible seek fresh air immediately and remain active Do notsit lie down or fall asleep Alert others to the possibility of carbon monoxide poisoning Seek medical attention if the condition of affected persons does notimprove within minutes of breathing fresh air Fuel System A WARNING Explosive fuel vapors Can cause severe injury or death U
79. p s with a remote terminal strip located in the generator set junction box With the exception of a few terminals the remote terminal strip is identical to that of the controller Connect all accessories except the emergency stop kit to the connection kit terminal strip Section 6 Accessories 47 6 1 4 Dry Contact Kit Single Relay M The single relay dry contact kit uses one set of contacts to trigger customer provided warning devices if a fault condition occurs Connect any controller fault output connection from the TB1 terminal strip to the single relay kit Use the single relay dry contact kit as a common fault relay for signaling any of the following common fault conditions e Emergency Stop e Auxiliary e Overspeed e Low Oil Pressure e High Engine Temperature Connect a maximum of three dry contact kits to a single controller output See Figure 6 3 Figure 6 3 Single Relay Dry Contact Kit Typical 6 1 5 Dry Contact Kits 10 14 and 20 Relay M Dry contact kits allow monitoring of the generator set system and provide the ability to activate warning devices and other customer provided accessories Available kits include 10 14 or 20 sets of relay contacts for connecting customer provided devices to desired generator set functions The 20 relay kits can be used on 450 kW and larger generator sets The 10 relay and 20 relay kits provide normally open and normally closed contacts The 14 relay kit provides norma
80. pecs sq sq cm sq in ss std stl tach root mean square round read only memory rotate rotating revolutions per minute right side remote terminal unit room temperature vulcanization read write Society of Automotive Engineers standard cubic feet per minute silicon controlled rectifier second Systeme international d unites International System of Units side in end out silencer serial number simple network management protocol single pole double throw single pole single throw specification specification s square square centimeter square inch stainless steel standard steel tachometer time delay top dead center time delay engine cooldown time delay emergency to normal time delay engine start time delay normal to emergency time delay off to emergency time delay off to normal temperature terminal total harmonic distortion telephone influence factor total indicator reading tolerance turbocharger typical same in multiple locations underfrequency ultrahigh frequency Underwriter s Laboratories Inc unified coarse thread was NC unified fine thread was NF universal undersize underspeed ultraviolet undervoltage volt volts alternating current voltampere reactive volts direct current vacuum fluorescent display video graphics adapter very high frequency watt withstand and closing rating with without weight transformer TP 6161 1 08 TP 6161 1
81. plays the stored failure codes e Use a personal computer software package available from the manufacturer with a translator to access stored codes Follow the instructions provided with the software TP 6161 1 08 Code Types Active code A code flashing on the SEL lamp indicates a fault currently exists Inactive code A code flashing on the CEL lamp indicates a previous fault occurrence The ECM memory stores inactive codes with time date identification and the following information e First occurrence of each diagnostic code in engine operating hours e Last occurrence of each diagnostic code in engine operating hours e Total time in seconds that the diagnostic code was active 3 12 Engine Control Systems Some generator sets use an engine control system Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine Use the following data for general informational purposes only See the Engine Service Manual for complete information regarding operation and troubleshooting Contact an authorized service distributor dealer for service or diagnostic equipment Engine Control Features Engine control is an advanced technology electronic engine control system The system optimizes control of critical engine functions and provides protection against serious engine damage The major components include the engine control module engine senso
82. ps on the 16 Light Controller Prime power operation Prime power operation Remote start ground Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Remote start Connect transfer switch or remote start switch to TB2 3 and TB2 4 Prime power operation Crank mode selection open cyclic crank ground continuous crank Connect TB2 9 to TB2 9A for continuous cranking leave TB2 9 open cyclic cranking see starting instructions in Section 2 Operation Crank mode ground Figure 6 17 16 Light Controller TB2 Terminal Strip TP 6161 1 08 Terminal on TB1 TB1A or TB3 TB1B Purpose Ground Emergency stop relay K4 Connect emergency stop across terminals TB1 1 and 1A Emergency stop relay K4 coil negative side Connect emergency stop across terminals TB1 1 and 1A Ground terminal Overcrank OC signal Auxiliary AUX signal Common fault prealarm line 1 audiovisual alarm or common fault relay activated by OC 12 AUX 26 LWT 35 HET 36 LOP 38 OS 39 AHET 40 ALOP 41 and LF 63 faults Common fault prealarm line 2 audiovisual alarm or common fault relay activated by AUX 26 HET 36 LOP 38 OS 39 and ES 48 faults Low water temperature LWT signal High engine temperature HET signal Low oil pressure LOP signal Overspeed OS signal Anticipatory high engine temp
83. r ducts louvers Yearly Coolant Yearly Heat exchanger Yearly Louver motors and controls Yearly Radiator exterior Yearly Water supply to heat exchanger Yearly Exhaust Line Drain condensate trap Weekly Leakage Weekly Insulation fire hazards Quarterly Flexible connector s Six Months Excessive back pressure Yearly Hangers and supports Yearly DC Electrical System Battery charger operation charge rate Monthly Battery electrolyte level Monthly Battery specific gravity charge state Monthly Recharge after engine start Monthly Remove corrosion clean and dry battery and rack x Monthly Clean and tighten battery terminals x x Quarterly Tighten DC electrical connections x Six Months e 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 22 Section 3 Scheduled Maintenance TP 6161 1 08 Service Schedule continued System Component AC Electrical System Action Visually Inspect Check Change Interval Controller lamp test Weekly General Inspection Weekly Circuit breakers fuses Monthly Wire
84. r set uses the primary fuel Contact an authorized service distributor dealer for kit availability Manual Changeover A manual changeover fuel system allows manual changeover from gasoline to natural gas or LP gas or from natural gas or LP gas to gasoline Typically the combination system uses gas as the primary preferred fuel and gasoline in emergencies If the primary fuel is unavailable an empty fuel tank or fuel supply disruption the system uses gasoline A toggle switch on the generator set controls the fuel choice and energizes either a fuel solenoid and electric fuel pump for gasoline or a fuel valve for gas Pull out the control cable for gasoline and push in the control cable for gas 3 6 5 Carburetor Adjustment Before adjusting the carburetor verify that the engine compression and ignition system meet specifications Do not adjust the carburetor to compensate for other engine disorders Ifthe engine speed is incorrect adjust the electronic governor to achieve 1800 rpm at 60 Hz or 1500 rpm at 50 Hz Adjustthe carburetor if governor adjustment alone does not result in the desired engine speed Adjusting the carburetor affects the engine fuel mixture Routine carburetor adjustment is not necessary However if the carburetor is removed or tampered with the carburetor may require adjustment to achieve optimum engine performance Some engines have sealed carburetors that are not adjustable TP 6161 1 08 Gasoline C
85. re mini fics bw uda er e pui ed a eee 35 3 13 1 Lubricating System 35 3 13 2 Cooling System isores iie nienia ie E ei A a a a e e e oaa 35 3 13 37 Fuel System uso a a ad 36 3 13 4 Internal Engine Components Gas Gasoline Fueled Engines 36 SAS EXterior aere e ae AG refero ae dre ON Pur ie and 36 3 19 6 Battery vd ose ELE ve LG oe eae ng 36 Section 4 Troubleshooting oi ere Rc RE REGE Re EX e rex Re eee ee rote es 37 Section 5 Generator Set Reconnection ooocccccccccccccnn n nnn 41 Section 6 Accessories iia plaire o a lia 47 6 1 ACCcessofies tii AAA VE 47 6 1 1 Audiovisual Alarm M a 47 6 1 2 Common Failure Relay Kit M 47 6 1 8 Controller Connection Kit M 47 6 1 4 Dry Contact Kit Single Relay M 48 6 1 5 Dry Contact Kits 10 14 and 20 Relay M 48 6 1 6 Engine Prealarm Senders M 49 6 1 7 FASTCHECK Diagnostic Tester M 49 6 1 8 Float Equalize Battery Charger Kit with Alarm Option M 49 6 4 9 Line Circuit Breaker 49 6 1 10 Low Fuel Switch M 50 6 1 11 Remote Annunciator Kit M 50 6 1 12
86. rease fittings Figure 3 8 Radiator Fan Bearings and Pressure Relief Ports Typical 5 Remove excess grease from the bearing pressure relief ports 6 Inspect the fan drive belt and replace if it is damaged or worn Check the fan belt tension using a poly V belt tension gauge and adjust the tension if necessary See Figure 3 9 New Belt Used Belt Generator Set Model N Ibf N Ibf 2450 2890 1650 1910 1200 2000 kW 550 650 370 430 A belt is considered used after 50 hours of service Figure 3 9 Poly V Belt Tension Specifications 7 Reinstall the belt guards using the original hardware 8 Reconnect the generator set engine starting battery ies negative lead last 9 Test run the generator set for a few minutes and listen for belt noise squeal indicating a slipping belt Stop the generator set If the belt slips after the belt tension procedure clean the pulley surfaces and repeat the belt tension procedure If slippage continues replace the fan belt TP 6161 1 08 3 10 Battery A WARNING Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin Battery gases Explosion can cause severe injury or death Battery gases can cause an explosion Do not smoke or permit flames or sparks to occur near a battery at any time particularly when itis charging Do not dispose of a battery ina fire To p
87. revent burns and sparks that could cause an explosion avoid touching the battery terminals with tools or other metal objects Remove all jewelry before servicing the equipment Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery To avoid sparks do not disturb the battery charger connections while the battery is charging Always turn the battery charger off before disconnecting the battery connections Ventilate the compartments containing batteries to prevent accumulation of explosive gases Battery short circuits Explosion can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Disconnect the battery before generator set installation or maintenance Remove all jewelry before servicing the equipment Use tools with insulated handles Remove the negative lead first when disconnecting the battery Reconnect the negative lead last when reconnecting the battery Never connect the negative battery cable to the positive connection terminal of the starter solenoid Do not test the battery condition by shorting the terminals together Battery electrolyte is a diluted sulfuric acid Battery acid can cause severe injury or death Battery acid can cause blindness and burn skin Always wear splashproof safety goggles rubber gloves and boots when servicing the battery Do not open a sealed battery or mutilate the ba
88. rewired from its nameplate voltage to 246242 NOTICE Voltage reconnection Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate Order voltage reconnection decal 246242 from an authorized service distributor dealer NOTICE Canadian installations only For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code Part 1 TP 6161 1 08 Introduction This manual provides operation instructions for 20 2250 kW generator sets equipped with the following controllers e Decision Maker 3 16 Light e Decision Maker 1 Wiring diagram manuals are available separately Refer to the engine operation manual for generator set engine scheduled maintenance information Information in this publication represents data available at the time of print Kohler Co reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury Read and follow the Safety Precautions and Instructions section at the beginning of this manual Keep this manual with the equipment for future reference The equipment service requirements are very important to safe and efficient operation Inspect
89. rofarad normal power source not available not applicable natural gas National Bureau of Standards normally closed National Electrical Code National Electrical Manufacturers Association National Fire Protection Association newton meter normally open number numbers National Pipe Straight National Pipe Straight coupling National Standard taper pipe thread per general use National Pipe Taper Fine not required normal relay nanosecond overcrank outside diameter original equipment manufacturer overfrequency option optional oversize overspeed Occupational Safety and Health Administration overvoltage ounce page pages personal computer printed circuit board picofarad power factor phase Phillips head Crimptite screw Phillips hex head screw pan head machine screw programmable logic control permanent magnet generator potentiometer potential parts per million programmable read only memory pounds per square inch pounds per square inch gauge pint positive temperature coefficient power takeoff polyvinyl chloride quart quarts quantity replacement emergency power source radiator radius random access memory relay driver output reference remote Residential Commercial radio frequency interference round head round head machine screw relay rms rnd ROM rot rpm RS RTU RTV SAE scfm SCR s Sec Sl SI EO sil SNMP SPDT SPST spec s
90. rs and control box located in the generator set junction box See Figure 3 17 for the John Deere engine control box features DIAGNOSTIC SHUTDOWN OVERRIDE a M WARNING STOP ENGINE D Z GM30962 A Figure 3 17 John Deere Engine Control Box TP 6161 1 08 See Figure 3 18 for the Kohler branded D300 D350 D400 D450 and D500 engine control box features e a A A Ne IGNITION bu y Nx DIAGNOSTIC REQUEST DIAGNOSTIC Figure 3 18 Kohler Branded Engine Control Box GM23666 3 13 Storage Procedure Perform the following storage procedure before taking a generator set out of service for three months or longer Follow the engine manufacturer s recommendations if available for fuel system and internal engine component storage 3 13 1 Lubricating System Prepare the engine lubricating system for storage as follows 1 Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature 2 Stop the generator set 3 With the engine still warm drain the oil from the crankcase 4 Remove and replace the oil filter 5 Refill the crankcase with oil suited to the climate 6 Run the generator set for two minutes to distribute the clean oil 7 Stop the generator set 8 Check the oil level and adjust if needed 3 13 2 Cooling System Prepare the cooling system for storage as follows 1 Check the coolant freeze protection us
91. ry Check for tight battery connections Consult the battery manufacturer s instructions regarding battery care and maintenance Coolant Level Check the coolant level according to the cooling system maintenance information Note Block heater damage The block heater will fail if the energized heater element is not immersed in coolant Fill the cooling system before turning on the block heater Run the engine until it is warm and refill the radiator to purge the air from the system before energizing the block heater Drive Belts Check the belt condition and tension ofthe radiator fan water pump and battery charging alternator belt s Exhaust System Check for exhaust leaks and blockages Check the silencer and piping condition and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold exhaust line flexible exhaust clamps silencer and outlet pipe for cracks leaks and corrosion e Check for corroded or broken metal parts and replace them as needed e Check for loose corroded or missing clamps and hangers Tighten or replace the exhaust clamps and or hangers as needed e Check that the exhaust outlet is unobstructed e Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed Fuel Level Check the fuel level and fill the tank s regularly to ensure adeq
92. s with petroleum jelly silicon grease or other nonconductive grease Note Some units require a reflective heat shield insulative sleeve on the battery cables and other wires that are fastened to the starter solenoid This sleeve is a conductive material and must be secured approximately 25 mm 1 in away from the exposed cable terminal EZ 273000 J 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 10 12 Volt Engine Electrical System Single Starter Motor Typical Battery Connection 32 Section 3 Scheduled Maintenance 1 To positive terminal on starter solenoid 2 To ground terminal on or near starter motor Figure 3 11 24 Volt Engine Electrical System Single Starter Motor Typical Battery Connection KW 272000 B 1 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 12 24 Volt Engine Electrical System Dual Starter Motors Typical Battery Connections TP 6161 1 08 3 10 1 Cleaning Clean the battery and cables and tighten the battery terminals according to the service schedule recommendations Clean the battery by wiping it with
93. s unlit Does not require manual reset Overvoltage Shutdown Lamp lights and the engine shuts down immediately if an overvoltage condition arises if equipped with overvoltage shutdown kit Underfrequency Shutdown Lamp lights and the engine shuts down if the engine speed drops below 5 of the nominal engine speed 1710 for 1800 rpm or 1425 for 1500 rpm for a continuous 60 second period Figure 1 3 Auxiliary Fault Lamp Operation 1 2 3 Fuses 1 2 4 Analog Meters and Gauges The fuses listed in Figure 1 4 protect the generator set Figure 1 5 describes the meters and gauges located on circuitry microprocessor controllers 3 amp remote annunciator fuse protects the dry contact kit if equipped 3 amp controller fuse protects the controller circuit board speed sensor and lamp circuit board 15 amp engine and accessories fuse protects engine starting circuitry and accessories AC voltmeter Meter displays the AC output voltage Use the selector switch to choose the output lead circuits AC ammeter Meter displays the AC output amperage Use the selector switch to choose the phase currents Figure 1 4 Controller Fuses DC voltmeter Meter displays the voltage of the starting battery ies Frequency Meter displays the frequency Hz of the meter generator set output Hourmeter Hourmeter records the generator set total operating hours for reference in maintenance scheduling Oil press
94. s weight H x W x D height by width by depth HC HCHT HD HET hex Hg HH HHC HP hr HS hsg HVAC HWT Hz IC ID IEC IEEE IMS in in H20 in Hg in Ib Inc ind int int ext 1 0 IP ISO J JIS hex cap high cylinder head temperature heavy duty high exhaust temp high engine temp hexagon mercury element hex head hex head cap horsepower hour heat shrink housing heating ventilation and air conditioning high water temperature hertz cycles per second integrated circuit inside diameter identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers improved motor starting inch inches of water inches of mercury inch pounds incorporated industrial internal internal external input output iron pipe International Organization for Standardization joule Japanese Industry Standard Appendix 57 k kilo 1000 K kelvin kA kiloampere KB kilobyte 219 bytes KBus Kohler communication protocol kg kilogram kg cm kilograms per square centimeter kgm kilogram meter kg m3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm kQ kilo ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt hour kWm kilowatt mechanical kWth kilowatt thermal E liter LAN local area network LxWxH length by width
95. se extreme care when handling storing and using fuels The fuel system Explosive fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equipment and out of the reach of children Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors Keep the fuel lines and connections tight and in good condition Do not replace flexible fuel lines with rigid lines Use flexible sections to avoid fuel line breakage caused by vibration Donot operate the generator set in the presence of fuel TP 6161 1 08 leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Explosive fuel vapors can cause severe injury or death Take additional precautions when using the following fuels Gasoline Store gasoline only in approved red containers clearly marked GASOLINE Propane LP Adequate ventilation is mandatory Because propane is heavier than air install propane gas detectors low in a room Inspect the detectors per the manufacturer s instructions Natural Gas Adequate ventilation is mandatory Because natural gas rises install natural gas detectors high in a room Inspect the detectors per t
96. setting After a Fault Shutdown 19 2 4 Expanded Decision Maker 1 Controller 20 2 4 1 Generator Set Starting 20 2 4 2 Generator Set Stopping 20 2 4 3 Fault Shutdowns 0 e 20 2 4 4 Controller Resetting After a Fault Shutdown 20 Section 3 Scheduled Maintenance oooocccccccnnccn e nnn nnn 21 3 1 Alternator Service uses esee E kt eese cbe rrr ere ees 21 312 Engine Service oo teo dead is 21 3 3 Service Sched le ide etae hr e nee aaa colegas 22 3 4 Alternator Bearing Service 24 3 4 1 20 300 kW Models ssssssss IH 24 3 4 2 350 2000 kW Models with Single Bearing Alternator 24 3 4 8 1250 2000 kW Model with Two Bearing Alternator 24 3 5 DieselFuel Systems u eR a esee delV s C oa eee 24 3 5 1 Bleeding Air from Fuel System 24 3 5 2 Subbase Inner Fuel Tank Alarm 25 3 6 Gas Gasoline Fuel Systems 25 3 6 1 Gaseous Fuel System Concept 25 3 6 2 LP Liquid Withdrawal Fuel System Concept 26 3 6 3 LP Gas Natural Gas Conversion for Straight Gas Fuel System 26 3 6 A Fuel System Changeover Kits
97. t when the coolant system is refilled Check the coolant level in the coolant recovery tank after each generator set operation and add coolant as necessary until the coolant level stabilizes Then check the coolant at the interval specified in the service schedule 14 Reenergize the block heater if equipped 3 8 Radiator Fan Bolt Retorque Adapted from Service Bulletin SB 683 12 07a The radiator fan bolts must be initially checked after approximately 8 hours of operation and then rechecked after each 100 hours of operation This scheduled service is required on all 1500 2800REOZDC unit mounted radiator models using a 2743 mm 108 in diameter fan Perform the scheduled service steps in the order shown Required Tools e Socket wrench sets American Standard and Metric sizes e Torque wrench up to 203 Nm 150 ft Ib Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the power to the battery charger if equipped Section 3 Scheduled Maintenance 29 3 Disconnect the generator set engine starting battery ies negative lead first 4 Remove the fan guards screens and covers as necessary to access the radiator fan hardware 5 Inspect the blades for cracks or other damage Verify that all hardware is present Replace as needed 6 Retorque the 32 aty blade retention bolts nuts to 136 Nm 100 ft Ib See Figure 3 7 s UJ L wy
98. tch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Reconnect the negative lead last when reconnecting the battery Follow these precautions to prevent starting of the generator set by an automatic transfer switch remote start stop switch or engine start command from a remote computer TP 6161 1 08 Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place Short circuits Hazardous voltage current can cause severe injury or death Short circuits can cause bodily injury and or equipment damage Do not contact electrical connections with tools or jewelry while making adjustments or repairs Remove all jewelry before servicing the equipment Reconnect the generator set stator leads to change the output phase or voltage Refer to the following procedure and the connection schematics shown in Figure 5 1 Figure 5 2 Figure 5 3 and Figure 5 4 Follow the safety precautions at the front of this manual and in the text and observe National Electrical Code NEC guidelines Voltage Reconnection Procedure 1 Place the generator set master switch in the OFF RESET position 2 Disconnect the generator set engine starting battery negative lead first Disconnect power to the battery charger if equipped 3 Use Figure 5 1 Figure 5 2 Figure 5 3 and Figur
99. the generator set from a remote location in an emergency See Figure 6 11 Activating the emergency stop switch lights the EMERGENCY STOP lamp and shuts down the unit Before restarting the generator set reset emergency stop switch by replacing the glass piece and reset the generator set by placing the master switch in the OFF RESET position The switch holds a single replacement glass piece which is available as a service TO eub EA ff BRASS II 9 EA jis Figure 6 11 Emergency Stop Kit TP 6161 1 08 6 1 13 Remote Serial Annunciator M The remote serial annunciator monitors the condition of the generator set from a location remote from the generator set Ifa generator alarm condition occurs the remote annunciator alerts the operator through visual and audible signals using a RS 485 controller connection See Figure 6 12 Requires a controller communication module kit installed in the controller See Figure 6 13 Overcrank Not In Auto High Engine Temp Common Fault Low Oil Pressure Battery Charger Battery Voltage Overspeed On Higli Blink Low Emergency Stop Low Coolant Level Low Coolant Temp Low Fuel Alarm Silenced Generator ID 1 Location EPS Supplying Load System Ready RSA 1000 Generator Running Communication Status Figure 6 12 Remote Serial Annunciator RSA im
100. tion Figure 2 1 16 Light Controller TB2 Terminal Strip Prime Power Starting The prime power mode provides local starting only atthe controller The AUTO position no longer functions as a remote start When the generator set master switch is in the OFF RESET position the controller functions are inoperative Move the generator set master switch to the AUTO position to start the generator set Do not start the generator set with the master switch in the RUN position because the alarm horn will sound Note Move the generator set master switch to the AUTO position to return controller functions to normal Prime Power Stopping Move the generator set master switch to the OFF RESET position to stop the generator set and power down the controller Note The controller functions are inoperative when the generator set master switch is in the OFF RESET position 2 3 3 Emergency Stopping Activate the controller emergency stop switch if equipped or the optional remote emergency stop switch for immediate shutdown Use the emergency stop switch es for emergency shutdowns only Use the generator set master switch for normal shutdowns TP 6161 1 08 The unit shuts down and the controller emergency stop lamp lights if an operator activates either the local or remote emergency stop switch Use the following procedure to restart the generator set after shutdown by an emergency stop switch Refer to Section 2 3 5 Controller Res
101. tion Overcharged Fully charged A good charge A low charge A dead battery Figure 3 15 Bead Type Test Interpretation 3 10 4 Charging Use a battery charger to maintain a fully charged battery when the generator set is used in a standby application The engine battery charging alternator charges the battery only while the generator set is running Note If the generator set is in a temporary prime power application in which the generator set has periods of inactivity the controller circuitry may drain the battery If there is no power source for a battery charger place the controller in the prime power mode if equipped or disconnect the battery from the generator set 3 11 Detroit Diesel Engine Control Systems Some generator sets equipped with Detroit Diesel engines use aDDEC MDEC system Access the DDEC control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting the engine Note DDC MTU engines with MDEC requires the following method e Use a personal computer software package available from the manufacturer with a translator to access stored codes Follow the instructions provided with the software Use the following data for informational purposes only Consult the engine literature for complete information regarding operation and troubleshooting See List of Related Materials in the Introduction section Contact an authorized serv
102. tion 2 4 3 Fault Shutdowns for additional shutdown information Frequency meter Meter displays the frequency Hz of the generator set output Generator set master switch Switch functions as the controller reset and generator set operation switch Figure 1 13 Controls and Indicators 16 Section 1 Specifications and Features Selector switch Switch selects the generator set output circuits to measure When switched to a position with three circuit labels the meters display the amperage on the lead shown in the upper label and the voltage between the two leads shown in the lower label The AC ammeter and voltmeter function only with the switch in the ON position Voltage adjustment control Control fine tunes 5 the generator set output voltage Water temperature gauge Gauge displays the engine coolant temperature 10 amp controller fuse Fuse protects the controller circuitry from short circuits and overloads Figure 1 14 Controls and Indicators continued TP 6161 1 08 2 1 Prestart Checklist To ensure continued satisfactory operation perform the following checks or inspections before or at each startup as designated and at the intervals specified in the service schedule In addition some checks require verification after the unit starts Air Cleaner Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine Batte
103. ts from restricting coolant flow through the engine block 3 Open the radiator and or engine block coolant drain valve s and allow the system to drain 4 If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease refer to Section 3 7 4 Cooling System Flush and Clean Procedure If the cooling system does not have mineral deposits go to Section 3 7 5 Cooling System Refilling Procedure TP 6161 1 08 3 7 4 Cooling System Flush and Clean Procedure Use the instructions in the engine operation manual when available to flush and clean the cooling system Otherwise use the following procedure and the cooling system cleaner manufacturer s instructions 1 Flush the cooling system with clean water 2 If the inside of the radiator still has mineral deposits use a radiator cleaner to remove the remaining deposits following the manufacturer s instructions 3 Drain clean and flush the coolant recovery tank 3 7 5 Cooling System Refilling Procedure See the generator set spec sheet for coolant capacity Note Do not add coolant to a hot engine Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Wait until the engine has cooled 1 Remove the pressure cap 2 Close radiator and or engine block coolant drain valve s and tighten cooling system hose clamps 3 Open the air bleed petcocks if equipped Close the air bleed petcocks when coolant begins
104. ttery case If battery acid splashes in the eyes or on the skin immediately flush the affected area for 15 minutes with large quantities of clean water Seek immediate medical aid in the case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery acid cleanup Battery acid can cause severe injury or death Battery acid is electrically conductive and corrosive Add 500 g 1 Ib of bicarbonate of soda baking soda to a container with 4 L 1 gal of water and mix the neutralizing solution Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction foaming has ceased Flush the resulting liquid with water and dry the area Section 3 Scheduled Maintenance 31 Refer to this section for general battery information and maintenance All generator set models use a negative ground with a 12 volt or 24 volt engine electrical system Consult the generator set nameplate for the engine electrical system voltage Consult the generator set spec sheet for battery capacity recommendations for replacement purposes The wiring diagrams provide battery connection information See Figure 3 10 Figure 3 11 and Figure 3 12 for typical battery connections including multiple battery configurations After reconnecting the battery cables coat the terminal
105. uate fuel supply TP 6161 1 08 Section 2 Operation Ignition System Ensure that the ends of all spark plug wires are properly seated onto the coil distributor and the spark plug Lamp Test Press the lamp test button if equipped to verify that all controller LEDs illuminate Oil Level Maintain the oil level at or near not over the full mark on the dipstick Keep the oil level in the mechanical governor if equipped at or near the full level Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools or debris on or near the generator set 2 2 Generator Set Exercising Operate the generator set under load once each week for one hour Perform the exercise in the presence of an operator if the generator set does not have a programmed exercise mode or an automatic transfer switch with an exercise option During the exercise period apply a minimum of 35 load based on the nameplate standby rating unless otherwise instructed in the engine operation manual The operator should perform all of the prestart checks before starting the exercise procedure Start the generator set according to the starting procedure in the controller section of this manual While the generator set is operating listen for a smooth running engine and visually inspect the generator set for fluid or exhaust leaks 2 3 16 Light Controller Features 2 3 1 Local Startin
106. uel supply pressure on the carburetor side of the regulator downstream of any fuel system equipment accessories The recommended fuel supply pressures are shown on the generator set spec sheet 4 Adjust the fuel supply pressure with the generator set running at full load Rotate the adjustment screw on the fuel regulator until the pressure indicated by the manometer matches the specified pressure Use the lower pressure value if the generator set still provides good response and full power Lower than specified pressures may result in poor response to load changes or lack of power 5 Reinstall the cover plug TP 6161 1 08 3 6 4 Fuel System Changeover Kits Automatic Changeover A changeover fuel system kit provides automatic changeover from natural gas to LP gas vapor or from LP gas vapor to natural gas The primary and backup fuels each have a secondary fuel regulator and a fuel valve Typically the primary fuel is natural gas the backup fuel is LP gas vapor When the generator set starts the primary fuel valve opens and the backup fuel valve closes The primary fuel line has a vacuum switch in series with a relay connected to the start run circuit When the primary fuel pressure drops below 0 6 kPa 1 4 oz in or 6 4 cm 2 5 in water column a relay opens the backup fuel valve and closes the primary fuel valve When the primary fuel pressure rises above 0 6 kPa 1 4 oz in 2 or 6 4 cm 2 5 in water column the generato
107. uge Voltage adjustment if equipped Oil pressure gauge Hourmeter Emergency stop switch if equipped Section 1 Specifications and Features 11 The 16 light controller with communications has a new circuit board GM28725 that is different in appearance and has additional functions from the earlier versions but is a direct replacement for earlier version circuit boards including A 336415 Features of the new circuit board include the following items New Application Program Software Contact your local authorized distributor for application program updates when instructed to do so during troubleshooting and or when adding specific accessories Refer to TT 1285 Program Loader Software instruction for additional download information Red circuit board previous versions are green Terminal strips TB1 TB2 and TB3 SW1 DIP switch 8 switches Communication connector P21 for Modbus to 1 2 1 Annunciator Panel Lamps Figure 1 2 lists the annunciator lamps included on each controller and describes the lamp functions download new application program software or to connect the remote serial annunciator using RS 485 communications Requires RS 485 to RS 232 converter for downloading application program e Communication connector P22 for J1939 engine communication Lamp Description Air damper This light is not used on current standard products Auxiliary fault Flashes or lights upon fault detectio
108. ult Lamp The auxiliary fault lamp flashes or lights continuously to indicate different conditions Figure 1 3 describes the auxiliary fault lamp conditions Lamp Illumination Generator Condition Flashing Continuous Auxiliary Delay Shutdown Lamp lights and the engine shuts down 5 seconds after high oil temperature P1 13 low coolant level P1 10 2 wire sender or P1 14 3 wire switch or auxiliary delay shutdown P1 15 faults if equipped occur These fault conditions are inhibited during the first 30 seconds after crank disconnect Auxiliary Immediate Shutdown Lamp lights and the engine shuts down if activated by customer supplied sensing devices connected to auxiliary immediate shutdown ports P1 17 and P1 18 Emergency Stop Switch Reset Lamp lights if the optional emergency stop switch is reset while the generator set master switch is in the AUTO or RUN position Place the generator set master switch in the OFF RESET position to clear this fault Low Fuel Shutdown 125RZG only Lamp lights and the engine shuts down if activated by the low fuel pressure shutdown switch connected to the Auxiliary Immediate Shutdown port P1 17 Place the generator set master switch in the OFF RESET position to clear this fault No AC Output Lamp flashes if the controller senses no AC output with the unit running except during first 10 seconds after startup When the controller senses AC output the flashing stops and the lamp i
109. ure Gauge Measures the engine oil pressure gauge Scale lamps Lamps indicate which AC voltmeter and or upper lower ammeter scales to read Water Gauge displays the engine coolant temperature temperature gauge Figure 1 5 Analog Meters and Gauges TP 6161 1 08 Section 1 Specifications and Features 13 1 25 Switches and Controls Figure 1 6 describes the switches and controls located on microprocessor controllers Alarm horn Horn sounds if any fault or prealarm condition exists except emergency stop battery charger fault high battery voltage or low battery voltage Place the generator set master switch in the AUTO position before silencing the alarm horn See controller resetting procedure in Section 2 3 5 Controller Resetting After a Fault Shutdown Alarm Switch silences the alarm during service Place silence the generator set master switch in the AUTO switch position before silencing the alarm horn To avoid reactivating the alarm horn restore all alarm horn Switches controller remote annunciator and audiovisual alarm to their normal positions after correcting the fault See controller resetting procedure in Section 2 3 5 Controller Resetting After a Fault Shutdown Emergency Switch if equipped immediately shuts down the stop switch generator set in emergency situations Reset the emergency stop switch after shutdown by pulling the knob slightly outward Use the emergency stop switch for emergency
110. us noise Can cause hearing loss Never operate the generator set without a muffler or with a faulty exhaust system Engine noise Hazardous noise can cause hearing loss Generator sets not equipped with sound enclosures can produce noise levels greater than 105 dBA Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss Wear hearing protection when near an operating generator set Hazardous Voltage Moving Parts DANGER Hazardous voltage Will cause severe injury or death Disconnect all power sources before opening the enclosure A WARNING Hazardous voltage Moving parts Can cause severe injury or death Operate the generator set only when all guards and electrical enclosures are in place WARNING Hazardous voltage Backfeed to the utility system can cause property damage severe injury or death If the generator set is used for standby power install an automatic transfer switch to preventinadvertent interconnection of standby and normal sources of supply Grounding electrical equipment Hazardous voltage can cause severe injury or death Electrocution is possible whenever electricity is present Ensure you comply with all applicable codes and standards Electrically ground the generator set transfer switch and related equipment and electrical circuits Turn offthe main circuit breakers of all power sources before servicing the equipment Never c
111. utdown does not function during the first 5 seconds after startup Shutdown occurs 5 seconds after the fault The low oil pressure shutdown does not function during the first 5 seconds after startup Note The low oil pressure shutdown does not protect against low oil level Check the oil level at the engine Low oil pressure Shutdown occurs after 30 seconds of continuous cranking Shutdown occurs 30 seconds after startup if there is no AC output Overcrank Overspeed Shutdown occurs immediately when the governed frequency on the 50 and 60 Hz models exceeds 70 Hz Figure 2 3 Fault Shutdowns TP 6161 1 08 Under normal operating conditions the generator set s alternator requires no normal service Consult the prestart checklist in Section 2 1 for a list of routine checks 3 1 Alternator Service When operating the generator set under dusty or dirty conditions use dry compressed air to blow dust out of the alternator while the generator set is running Direct the stream of air through openings in the generator set end bracket 3 2 Engine Service Perform engine service at the intervals specified in the engine manufacturer s service literature Contact an authorized service distributor dealer to obtain service literature Note Have maintenance work including battery service performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service
112. weighted direct current direct current resistance degree department Design Failure Mode and Effects Analysis diameter dual inlet end outlet Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss dual inline package double pole double throw double pole single throw disconnect switch digital voltage regulator emergency power source electronic control module engine control module electronic data interchange emergency frequency relay for example exempli gratia electronic governor Electrical Generating Systems Association Electronic Industries Association end inlet end outlet electromagnetic interference emission engine Environmental Protection Agency emergency power system emergency relay engineering special engineered special electrostatic discharge est E Stop etc exh ext F fglass FHM fl oz flex freq FS ft ft Ib ft min ftp g ga gal gen genset GFI GND gov gph gpm gr GRD gr wt estimated emergency stop et cetera and so forth exhaust external Fahrenheit female fiberglass flat head machine screw fluid ounce flexible frequency full scale foot feet foot pounds torque feet per minute file transfer protocol gram gauge meters wire size gallon generator generator set ground fault interrupter ground governor gallons per hour gallons per minute grade gross equipment ground gros
113. x Weekly Interior of equipment room or outdoor weather housing x Weekly 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 Megger is a registered trademark of Biddle Instruments TP 6161 1 08 Section 3 Scheduled Maintenance 23 3 4 Alternator Bearing Service Have an authorized service distributor dealer perform service 3 4 1 20 300 kW Models Replace the end bracket bearing every 10 000 hours of operation in standby and prime power applications Service the bearing more frequently if the annual inspection indicates excessive rotor end play or bearing damage Replace the tolerance ring if equipped following end bracket removal The sealed end bracket bearing requires no additional lubrication 3 4 2 350 2000 kW Models with Single Bearing Alternator The alternator bearing requires lubrication at intervals specified in the generator set technical manual Use Chevron SRI or equivalent antifriction high quality grease with a lubrication temperature range of 30 to 175 C 22 to 350 F 1250 2000 kW Model with Two Bearing Alternator 3 4 3 Refer to the generator set servic
114. y See Figure 6 6 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Low Voltage Controller Terminal Strip Charger Malfunction Engine Ground Alarm Terminal Strip Figure 6 6 Float Equalize Battery Charger Connections 6 1 9 Line Circuit Breaker The line circuit breaker interrupts generator output if an overload or short circuit occurs Use the line circuit breaker to manually disconnect the generator set from the load during generator set service See Figure 6 7 Figure 6 7 Line Circuit Breaker Section 6 Accessories 49 6 1 10 Low Fuel Switch M Some gaseous fueled models offer a low fuel pressure switch as part of the Engine Prealarm Senders kit The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel or gasoline fueled models See Figure 6 8 and Figure 6 9 See Section 6 2 Accessory and Prime Power Terminal Strip Connections for terminal identification Note The subbase fuel tank or main tank may include the low fuel level switch The fuel tank supplier typically provides the low fuel level switch LOW FUEL SWITCH OPTIONAL LOCATED IN MAIN TANK S PROVIDED BY FUEL TANK SUPPLIER 2 BATTERY GROUND GM16088A A Figure 6 8 Low Fuel Switch Level or Pressure Switch Rating 12 volts DC minimum 0 5 amp minimum Wiring Recommendation mm ft 30 5 100
115. y an interface circuit board with gauge drivers required for some models Do not confuse the function of these circuit boards See the Introduction section and refer to Tech Tools Engine Electronic Module ECM for the latest applications LEGEND CONTROLLER BOARD CMB COMMUNICATION MODULE BOARD TBIA lt lalelzlolels Sa FRR ss IPA INDICATOR PANEL ASSEMBLY P PLUG TB1 TB2 CONTROLLER BOARD TERMINAL BLOCK TBS COMMUNICATION INTERFACE BOARD TERMINAL BLOCK 24 ENGINE HARNESS s 3 TB5 CONNECTIONS PIN N C 2 N C SW2 1N A SW2 2N A SW2 3N A SW2 4N A ft GM21340 REF 3 ATS POSITION RETURN GM32632 REF 4 USER INPUT 1 RETURN 5 USER INPUT 2 RETIRN SW2 SETTINGS 6 USER INPUT 3 RETURN CMB 7 N C sw2 8 N C 213 9 ATS POSITION INPUT 10 USER INPUT 1 11 USER INPUT 2 12 USER INPUT 3 HIGH BATTERY VOLTAGE CONTACTS ON 7 BATTERY CHARGER GM35318 REF Ribbon cable 10 position Ribbon cable 24 position Connector 6 position Indicator panel board existing NC PART OF GM49791 1 n PCB ASSEMBLY

tp6161 - Pelican Services, Inc.

Contents

Download Pdf Manuals

Related Search

Related Contents