Kohler 20-3250 kW manual

Industrial Generator Sets Models: 20 - 3250 kW Controllers: Decision-Maker r 550 Software (Code) V ersion 2.10 or higher TP-6200 10/12i Operation[...]

Engine exhaust from this product contains chemicals known to the State of California to cause cancer , birth defects, or other reproductive harm. W ARNING California Proposition 65 Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately afte[...]

T able of Contents TP-6200 10/12 T able of Contents 3 Product Identification Information 2 ............................................................ Safety Precautions and Instructions 7 ........................................................ Introduction 13 ............................................................................... Abbrevi[...]

T able of Contents, continued TP-6200 10/12 T able of Contents 4 2.7.13 Menu 13—Communications 68 .................................... 2.7.14 Menu 14—Programming Mode 69 .................................. 2.7.15 Menu 15—Protective Relays (PR) 70 ............................... 2.7.16 Menu 20—Factory Setup (V ersion 2.10) 71 ................[...]

T able of Contents, continued TP-6200 10/12 T able of Contents 5 3.12 Detroit Diesel Engine Control Systems 152 ................................... 3.12.1 Features 152 ..................................................... 3.12.2 DDEC Engine Diagnostics 152 ...................................... 3.13 Engine Control Systems 153 ......................[...]

6 TP-6200 10/12 Notes[...]

7 Safety Precautions and Instructions TP-6200 10/12 Safety Precautions and Instructions IMPORT ANT 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. T o prevent acciden[...]

8 Safety Precautions and Instructions TP-6200 10/12 Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. T o prevent burns and sparks that could cause an ex[...]

9 Safety Precautions and Instructions TP-6200 10/12 The fuel system. Explosive fuel vapors can cause severe injury or death. V aporized fuels are highly explosive. Use extreme care when handling and storing fuels. Store fuels i naw e l l - v e n t i l a t e da r e aa w a yf r o m spark-producing equipment and out of the reach of children. Never add[...]

10 Safety Precautions and Instructions TP-6200 10/12 High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the test equipment manufacturer when performing high-voltage tests on the rotor or stator . An improper test procedure can damage equipment or lead to generator set failure. T esting the photo transi[...]

11 Safety Precautions and Instructions TP-6200 10/12 Hot Parts Hot coolant and steam. Can cause severe injury or death. Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen the pressure cap to relieve pressure. W ARNING Hot engine and exhaust system. Can cause severe injury or death. Do not work on the generato[...]

12 Safety Precautions and Instructions TP-6200 10/12 Notes[...]

13 Introduction TP-6200 10/12 Introduction This manual provides operation instructions for 20 kW and larger generator sets equipped with the following controller: D Decision r 550, Software (Code) V ersion 2.10 or higher V ersion 2.10 refers to the controller application software. T o determine the generator set controller software version, go to M[...]

14 Service Assistance TP-6200 10/12 Service Assistance For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer . D Consult the Y ellow Pages under the heading Generators—Electric. D Visit the Kohler Power Systems website at KohlerPower .com. D Look at the labe[...]

TP-6200 10/12 15 Section 1 Specifications and Features Section 1 Specifications and Features 1.1 Introduction The spec sheets for each generator set provide model- specific generator and engine information. The controller spec sheet provides specifications for this controller . Refer to the respective spec sheet for data not supplied in this manual[...]

TP-6200 10/12 16 Section 1 Specifications and Features 1. Generator set master switch, run/off-reset/auto positions (keyswitch option) 2. Emergency stop switch 3. Alarm horn (see keypad for alarm silence) 4. Annunciator lamps (see keypad for lamp test) 5. Digital display 6. Keypad 7. Operating guide 8. Controller terminal strips (on circuit board) [...]

TP-6200 10/12 17 Section 1 Specifications and Features System W arning. Y ellow lamp identifies an existing fault condition that does not shut down the generator set. A continuing system warning fault condition may cause a system shutdown. Correct all system warnings as soon as practical. See Section 2.3.5, System W arning Lamp, for definitions of [...]

TP-6200 10/12 18 Section 1 Specifications and Features 1.2.2 Digital Display and Keypad Figure 1-5 illustrates the digital display and keypad. Note: Press any key on the keypad to turn on the controller lights and display . The lights and display turn off 5 minutes after t he last keypad entry . The 2-line vacuum fluorescent display provides genera[...]

TP-6200 10/12 19 Section 1 Specifications and Features Engine Displays (Menu 2) Some engine displays are available with selected generator set engines using engine ECMs only . The controller display shows N/A (not available) for items that are unavailable. See the controller spec sheet for applicable generator set models. Ambient T emperature displ[...]

TP-6200 10/12 20 Section 1 Specifications and Features 1.2.3 Switches and Controls See Figure 1-6 and Figure 1-8 for switches and controls. TP-6083-2 1. Emergency stop switch 2. Alarm horn 3. Generator set master switch 12 3 Figure 1-6 Switches and Alarm Horn Note: Find additional switches and controls in Section 2.5.1, Keypad Operation. Alarm Horn[...]

TP-6200 10/12 21 Section 1 Specifications and Features 1.2.4 Controller Circuit Boards The controller has five circuit boards—indicator , interconnection, keypad, digital display , and main logic/ communication. See Figure 1-9 for circuit board locations. 12 GM10193B-A 3 4 1. AC fuse block (TB5) 2. Interconnection circuit board TB1, TB2, TB3, and[...]

TP-6200 10/12 22 Section 1 Specifications and Features Figure 1-10 shows locations of the terminal strips on the controller interconnection circuit board. See Section 6.2, Accessory and Connections, for specific terminal identification information. Refer to the wiring diagrams for additional information on connecting accessories to the terminal str[...]

TP-6200 10/12 23 Section 1 Specifications and Features 1.2.8 Communication Ports The main logic circuit board contains several communication ports for Modbus r and KBUS connections. See Figure 1-12. Refer to the List of Related Materials in the Introduction for corresponding communication installation information. 1. P19—unused isolated connectio[...]

TP-6200 10/12 24 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Refer to Menu Digital Display Relay Driver Output (RDO) Alarm Horn Lamp Range Setting Default Selection Inhibit Time Delay (sec.) Time Delay (sec.) Access Code (password) 14 User-Selectable 0( z e r o ) AC Sensing Loss 10 AC SENSING LOSS RDO-25 * O[...]

TP-6200 10/12 25 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu Analog Aux. Input A07 9 A07 ANALOG VOL T ADJUST ± 10% of system voltage over the range of 0.5 - - 4[...]

TP-6200 10/12 26 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu Digital Aux. Input D12 Detonation War ni ng ] 9, 10 D12 DETON WARNING On War ni ng Fixed 2 sec. inhi[...]

TP-6200 10/12 27 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu Fuel Level (see A04) Fuel V alve Relay ] 10 FUEL V AL VE RELA Y RDO-23 ] Generator Set Running 10 RD[...]

TP-6200 10/12 28 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu Locked Rotor Shutdown 10 LOCKED ROTOR On Shutdown Loss of ECM Communication (ECM only) 10 LOSS OF EC[...]

TP-6200 10/12 29 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu Overcurrent 10 OVER CURRENT On War ni ng 1 10% 10 Over Current PR Shutdown w 10 SD OVER CURRENT PR O[...]

TP-6200 10/12 30 Section 1 Specifications and Features Factory-Defined Settings Status Event or Fault Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Lamp Alarm Horn Relay Driver Output (RDO) Digital Display Refer to Menu V oltage Raise (see D19) Weak Battery 10 WEAK BA TTERY Off War ni ng 60% of nominal 2 * All models, [...]

TP-6200 10/12 31 Section 1 Specifications and Features Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions. The underfrequency unload setting should match the engine speed recovery characteristics for the application. Underfrequency Unload Slope. This setting determines how much th[...]

TP-6200 10/12 32 Section 1 Specifications and Features Notes[...]

TP-6200 10/12 33 Section 2 Operation Section 2 Operation 2.1 Prestart Checklist T o 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 . [...]

TP-6200 10/12 34 Section 2 Operation Auto Starting Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or remote start/stop switch (connected to controller terminals 3 and 4). T erminals 3 and 4 connect to a circuit that automatically starts the generator set crank cycle when an external sourc[...]

TP-6200 10/12 35 Section 2 Operation 2.3.2 Stopping (User Stopping and Fault Shutdown) Normal Stopping Run the generator set without load for 5 minutes to ensure adequate engine cooldown. The controller has a programmable cooldown timer that functions only when the master switch is in the AUTO position. T o stop the generator set, place the generat[...]

TP-6200 10/12 36 Section 2 Operation Note: T ext shown in italics in this manual represents digital display messages. AC Sensing Loss. The lamp illuminates when the controller does not detect nominal generator set AC output voltage after crank disconnect. The local display shows AC sensing loss . Battery Charger Fault. The lamp illuminates when the[...]

TP-6200 10/12 37 Section 2 Operation When the generator set frequency drops to less than 59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system for more than 5 seconds, the local display shows load shed under freq . When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp latches and remains on until the genera[...]

TP-6200 10/12 38 Section 2 Operation 2.3.6 System Shutdown Lamp The red lamp illuminates, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the following conditions. See Section 2.3.7, Controller Reset Procedure, for information on resetting a system shutdown. Use the Alarm Off keypad switch to silence the alarm horn[...]

TP-6200 10/12 39 Section 2 Operation High Oil T emperature. The lamp illuminates and the unit shuts down because of high engine oil temperature. The shutdown occurs 5 seconds after the engine oil reaches the temperature shutdown range. The high engine oil temperature shutdown does not function during the first 30 seconds after startup. The local di[...]

TP-6200 10/12 40 Section 2 Operation Over Current VR Shutdown. The lamp illuminates and the unit shuts down when the controller detects an overcurrent fault with voltage restraint. The local display shows sd over current pr . (Paralleling applications only .) Overfrequency . The lamp illuminates and the unit shuts down when the frequency is above t[...]

TP-6200 10/12 41 Section 2 Operation 2.3.7 Controller Resetting (Following System Shutdown or W arning) Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition. This procedure includes the resetting of the optional remote annunciator and the audiovisual alarm. Refer to Section 2.3.3, Eme[...]

TP-6200 10/12 42 Section 2 Operation Input Ty p e Specific Applications ECM Engine Non-ECM Engine NFP A 1 10 Waukesha- Powered Engine with Menu 15 (Paralleling Application) DDC/MTU Engine with MDEC/ADEC Other Specialized Application Analog Inputs A1 X Coolant T emperature * X Coolant T emperature * X X X A2 X Oil Pressure * X Oil Pressure * X X X A[...]

TP-6200 10/12 43 Section 2 Operation Menu List Summary (Legend: D First level submenu, d second level submenu) Engine Monitoring Detailed (MDEC/ADEC equipped engines only) Engine Fuel D Fuel Pressure Fuel T emperature D Charge Air Pressure Charge Air T emperature D Fuel Rate D Daily Fuel Used D T otal Fuel Used Engine Oil D Oil Pressure Oil T emper[...]

TP-6200 10/12 44 Section 2 Operation Menu List Summary , continued (Legend: D First level submenu, d second level submenu) Menu 9 Input Setup Menu 9 Input Setup, cont. Menu 7 Generator System D Operating Mode d Standby Y/N d Prime Power N/Y D System V oltage Line-Line D System Frequency D Phase d 3-Phase Delta Y/N d 3-Phase WYE N/Y d 1-Phase N/Y D [...]

TP-6200 10/12 45 Section 2 Operation Menu List Summary , continued (Legend: D First level submenu, d second level submenu) Menu 1 1 V oltage Regulator Group B, continued Reverse Power Shutdown [ Over Power Shutdown [ Loss of Field Shutdown [ Overcurrent VR Shutdown [ Common Protective Relay Output [ In Synchronization [ Breaker T rip [ Fuel V alve [...]

TP-6200 10/12 46 Section 2 Operation Menu List Summary , continued (Legend: D First level submenu, d second level submenu) Menu 20 Factory Setup Menu D Programming Mode d Local? Y/N d Remote? Y/N d Off? Y/N D Programming Mode Change, Access Code d Enter Old Code d Enter New Code Menu 15 Paralleling Relays (PR) Purchased Option D PR Overvoltage V AC[...]

TP-6200 10/12 47 Section 2 Operation 2.5 Reviewing Digital D isplay The user interacts with the controller with a keypad and digital display . Use the keypad to access the generator set informational data and preset settings. This review section shows how to access the data. See Section 2.8, Local Programming Mode On, for instructions on how to cha[...]

TP-6200 10/12 48 Section 2 Operation 2.5.2 Auto - Scroll Function The auto-scroll function continuously shows voltage and current data from Menu 1—Generator Monitoring, V & A Summary without the need to press the down arrow for each display . For auto-scroll function press ENTER at the V & A Summary menu. Press the Reset Menu key or Menu [...]

TP-6200 10/12 49 Section 2 Operation D Fixed V oltage when entry is beyond the range of limited entries for the respective alternator . Occurs when the alternator is not rated for the value entered. Updated parameter files may be available by contacting an authorized service dealer/distributor . Func (Function) Used by (RDO) XX Reassign? appears wh[...]

TP-6200 10/12 50 Section 2 Operation 2.6.1 PC Communications There are four ways to communicate between a PC and the generator set and/or transfer switch devices using KBUS communication protocol. The PC connections require optional software and possibly other hardware, communication modules in the generator set controller and/or transfer switch. S[...]

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

TP-6200 10/12 52 Section 2 Operation 2.7 Reviewing Menu Displays Use this section to review a summary of the generator set controller data. See Figure 2-17 for which menus provide data monitoring and adjusting data. Press the Reset key , enter the desired menu number key(s), and then press the Enter key . Use the down arrow and right arrow keys for[...]

TP-6200 10/12 53 Section 2 Operation 2.7.1 Menu 1—Generator Monitoring Menu 1 displays generator output data including line-to-line and line-to-neutral voltages, current, frequency , power factor , total kilowatts, percent of maximum kW , total kV A, and total kV AR. Menu 1 displays three-phase voltage and current readings when applicable. All me[...]

TP-6200 10/12 54 Section 2 Operation Menu 1—Generator Monitoring, continued V O L T S&A M P S → L1-L2 VOL TS # L1 AMPS # L1-L0 VOL TS # L1 AMPS # L2-L0 VOL TS # L2 AMPS # FREQUENCY # HZ V&AS UMMARY → For the auto-scroll function, press ENTER at V&AS UMMARY menu. POWER KW → TOTAL KW # PF # LEADING/LAGGING L1 KW # PF # LEADING/LAG[...]

TP-6200 10/12 55 Section 2 Operation 2.7.2 Menu 2—Engine Monitoring Menu 2 displays engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooled-down temperat[...]

TP-6200 10/12 56 Section 2 Operation MENU 2 ENGINE MONITORING ENGINE MONITORING → BASIC OIL PRESSURE # PSI COOLANT TEMP # F ENGINE MONITORING → DET AILED ENGINE FUEL → FUEL PRES # PSI FUEL TEMP # F CHG AIR PRES # PSI CHG AIR TEMP # F Menu 2 Overview ENGINE OIL → OIL PRES # PS I OIL TEMP # F ENGINE MISC → ECU SUPPL Y VDC # AMBIENT TEMP # F[...]

TP-6200 10/12 57 Section 2 Operation 2.7.3 Menu 3—Analog Monitoring Menu 3 displays battery voltage and up to 7 user- defined analog items dependent upon the generator system. The User Defined Desc display refers to a description entered into the controller using the PC software. This description remains as the display for future review until cha[...]

TP-6200 10/12 58 Section 2 Operation 2.7.4 Menu 4—Operational Records Menu 4 displays the generator set’s operating record including operating start date, last logged maintenance, total run time loaded and unloaded, run time since last maintenance, number of starts, and number of days the unit ran. After performing maintenance, enter YES to res[...]

TP-6200 10/12 59 Section 2 Operation 2.7.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to 100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events. MENU 5 EVENT HISTORY (MESSAGE TEXT) ##-#[...]

TP-6200 10/12 60 Section 2 Operation MENU 7 GENERA TOR SYSTEM OPERA TING MODE → ST ANDBY Y/N SYSTEM VOL T AGE LINE-LINE ? SYSTEM FREQ # HZ PHASE → 3 PHASE DEL T A Y/N KW RA TING ? LOAD SHED OUTPUT → ?% # KW OVERVOL T AGE → ?% # V AC UNDERVOL T AGE → ?% # V AC OPERA TING MODE → PRIME POWER Y/N PHASE → 3 PHASE WYE N/Y TIME DELA Y MIN:SE[...]

TP-6200 10/12 61 Section 2 Operation 2.7.8 Menu 8—Time Delays Menu 8 displays the cyclic cranking cycles, various engine related starting and shutdown features, and auxiliary shutdown and inhibit time delays. The user must enable the programming mode to edit the display . See Section 2.8.8 to change settings in this menu. Cooldown T emperature Ov[...]

TP-6200 10/12 62 Section 2 Operation 2.7.9 Menu 9—Input Setup Menu 9 displays the setup of user-defined digital and analog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. The user must enable the programming mode to edit the display . See Section 2.8.9 to change settings in thi[...]

TP-6200 10/12 63 Section 2 Operation MENU 9 INPUT SETUP SETUP DIGIT AL → AUXILIARY INPUTS DIGIT AL INPUT 01 → (USER DEFINED DESC) Press the down arrow to scroll through additional DIGIT AL auxiliary inputs 1- - 21 or enter the input number . TO ANALOG INPUT SETUP (NEXT) DIGIT AL INPUT 01 → ENABLED YES/NO DIGIT AL INPUT 01 → INHIBIT TIME ?:?[...]

TP-6200 10/12 64 Section 2 Operation 2.7.10 Menu 10—Output Setup Menu 10 displays the setup of user-defined system, digital and analog status, and fault outputs and relay driver outputs (RDO) 1 - - 31. These RDO outputs provide multiple choices for configuring customized auxiliary outputs. Additional individual outputs are available for monitorin[...]

TP-6200 10/12 65 Section 2 Operation Group B, continued Paralleling applicatons: SD REVERSE POWER SD OVER POWER SD LOSS OF FIELD SD OVERCURRENT PR COMMON PR OUTPUT IN SYNCH BREAKER TRIP Waukesha-powered models: FUEL V AL VE RELA Y PRELUBE RELA Y AFM REMOTE ST ART NO OIL TEMP SIGNAL HI OIL TEMP WARNING NO AIR TEMP SIGNAL INT AKE AIR TEMP W ARN INT A[...]

TP-6200 10/12 66 Section 2 Operation 2.7.1 1 Menu 1 1—V oltage Regulator Menu 1 1 displays setup of the voltage regulator functions including line-to-line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor , and kV AR adjustments. The user must enable the programming mode to edit the display . See Section 2.8.1 1 to m[...]

TP-6200 10/12 67 Section 2 Operation 2.7.12 Menu 12—Calibration Menu 12 provides access to the calibration factors for metering (volts and amps) and auxiliary analog inputs. Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment. The user must enable the programming mode to edit the display .[...]

TP-6200 10/12 68 Section 2 Operation 2.7.13 Menu 13—Communications Menu 13 shows the settings for remote communications. See Section 2.8.13 to make changes in this menu. See the Modbus r Communications Protocol operation manual for a list of Modbus r registers for the 550 Controller . CONNECTION TYPE → (USER DEFINED) Y/N CONNECTION TYPES SINGLE[...]

TP-6200 10/12 69 Section 2 Operation 2.7.14 Menu 14—Programming Mode Menu 14 provides local or remote access to the programming function. The user enters a password to access the programming mode. Note: Log into the local programming mode to edit the programming access code. The factory default access code is the number 0. Use Menu 14 to change t[...]

TP-6200 10/12 70 Section 2 Operation 2.7.15 Menu 15—Protective Relays (PR) Menu 15 provides protective relay setup and time delays for units with the paralleling protection option. This menu will only be visible and accessible if this option is included. The shutdown (SD) settings override those in menu 7 and/or menu 8. See Section 2.8.15 to make[...]

TP-6200 10/12 71 Section 2 Operation 2.7.16 Menu 20—Factory Setup (V ersion 2.10) Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software (code) version. MENU 20 F ACTORY SETUP FINAL ASSEMBL Y DA TE[...]

TP-6200 10/12 72 Section 2 Operation 2.7.17 Menu 20—Factory Setup (V ersion 2.21) Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software (code) version. The temperature sensor setup applies to non-[...]

TP-6200 10/12 73 Section 2 Operation Notes[...]

TP-6200 10/12 74 Section 2 Operation Local Programming Mode On 2.8 Local Programming Mode On The Local Programming Mode On section explains how to program the generator set controller logic. Each menu contains a step-by-step procedure for programming the various logic groups. See Section 1, Specifications, for setting ranges and default settings. P[...]

TP-6200 10/12 75 Section 2 Operation Local Programming Mode On 2.8.1 Menu 1—Generator Monitoring Menu 1 provides generator output data including line-to-line and line-to-neutral voltages, current, frequency , power factor , total kilowatts, percent of maximum kW , total kV A and total kV AR displays. Menu 1 displays three-phase and single-phase c[...]

TP-6200 10/12 76 Section 2 Operation Local Programming Mode On Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description Displays L1, L2, and L3 amps. A L 1L 2L 3 ### V&AS U MMARY → Returns the user to the volts and amps summary heading. POWER KW → Displays the power ki[...]

TP-6200 10/12 77 Section 2 Operation Local Programming Mode On Menu 1—Generator Monitoring (Three-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description L3 KV A # POWER kV A → Displays L3 kV A. Returns the user to power kV A heading. Menu 1—Generator Monitoring (Single-Phase Connections) Menu 1 Displays w[...]

TP-6200 10/12 78 Section 2 Operation Local Programming Mode On Menu 1—Generator Monitoring (Single-Phase Connections), continued Menu 1 Displays with Key Entries Key Entry Display Description POWER KW → Displays the power kilowatt heading. TOT AL K W # PF # LEADING/LAGGING Displays total kilowatts and leading or lagging power factor . L1 KW # P[...]

TP-6200 10/12 79 Section 2 Operation Local Programming Mode On 2.8.2 Menu 2—Engine Monitoring Menu 2 provides engine operating data including oil pressure and temperature, coolant temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooled-[...]

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

TP-6200 10/12 81 Section 2 Operation Local Programming Mode On Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description ENGINE MISC → Returns the user to the miscellaneous engine subheading. ENGINE SERIAL NO. # UNIT NO. # ECM S/N # Displays the engine serial number . Displays the unit number and ECM ser[...]

TP-6200 10/12 82 Section 2 Operation Local Programming Mode On Menu 2—Engine Monitoring, continued Menu 2 Displays with Key Entries Key Entry Display Description Displays the engine fuel subheading. ENGINE FUEL → ENGINE MONITORING → DET AILED Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature require[...]

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

TP-6200 10/12 84 Section 2 Operation Local Programming Mode On Menu 3—Analog Monitoring (Non-ECM Engines) Menu 3 Displays with Key Entries Key Entry Display Description Input a menu number . MENU 3 ANALOG MONITORING ANALOG 03 # (USER DEFINED DESC) Displays analog 03 and the user-defined description. ANALOG 04 # (USER DEFINED DESC) Displays analog[...]

TP-6200 10/12 85 Section 2 Operation Local Programming Mode On Menu 3—Analog Monitoring (W aukesha Engines) Menu 3 Displays with Key Entries Key Entry Display Description Input a menu number . MENU 3 ANALOG MONITORING LOCAL BA TT VDC # Displays the local battery VDC. ANALOG 05 # (USER DEFINED DESC) Displays analog 05 and the user-defined descript[...]

TP-6200 10/12 86 Section 2 Operation Local Programming Mode On 2.8.4 Menu 4—Operational Records Menu 4 provides the generator set operational records including the operating start date, last logged maintenance, total run time loaded and unloaded, run time since the last maintenance, number of starts, and number of running days. Run Time Feature. [...]

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

TP-6200 10/12 88 Section 2 Operation Local Programming Mode On 2.8.5 Menu 5—Event History Menu 5 stores and displays the times and dates of up to 100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events. Note: This men[...]

TP-6200 10/12 89 Section 2 Operation Local Programming Mode On 2.8.6 Menu 6—Time and Date Menu 6 sets the clock time and date and internal calendar . The controller uses set time for determining the exercise run time and event records. The time and date are valid only if the controller power (starting battery) remains connected. The user must ena[...]

TP-6200 10/12 90 Section 2 Operation Local Programming Mode On 2.8.7 Menu 7—Generator System Menu 7 contains the factory-preset generator set voltage and frequency data. Enter the corresponding data if the generator set requires voltage reconnection and/or frequency adjustment. It is imperative that the user enter the correct data because these s[...]

TP-6200 10/12 91 Section 2 Operation Local Programming Mode On Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description Displays the phase configuration selection. Note: The display sample may differ depending upon previous entries. The user-selected phase appears first, either wye, delta, or single phase.[...]

TP-6200 10/12 92 Section 2 Operation Local Programming Mode On Menu 7—Generator System, continued Menu 7 Displays with Key Entries OVERVOL T AGE → #% # V AC Key Entry Display Description TIME DELA Y MIN:SEC → ??:?? Displays the undervoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press t[...]

TP-6200 10/12 93 Section 2 Operation Local Programming Mode On Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description BA TTERY VOL T AGE → (see note) YES Displays the battery voltage selection. Note: The display sample may differ depending upon previous entries. The user-selected battery voltage appear[...]

TP-6200 10/12 94 Section 2 Operation Local Programming Mode On Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description ENABLE VSG YES/NO Displays the variable speed governor (VSG) yes or no selection for paralleling applications. When required, use the numeric keys to set the new value. Applies to DDC/MTU[...]

TP-6200 10/12 95 Section 2 Operation Local Programming Mode On Menu 7—Generator System, continued Menu 7 Displays with Key Entries Key Entry Display Description METRIC UNITS Y/N Displays the metric units selection. Enter YES to change to metric displays and press the Enter key . Confirms the entry . METRIC UNITS YES METRIC UNITS YES OR Enter NO t[...]

TP-6200 10/12 96 Section 2 Operation Local Programming Mode On 2.8.8 Menu 8—Time Delays Menu 8 displays the various time delays for cyclic cranking and other engine-related starting and shutdown features. The user must enable the programming mode to edit the display . Cooldown T emperature Override . This feature provides the ability to bypass (o[...]

TP-6200 10/12 97 Section 2 Operation Local Programming Mode On Menu 8—Time Delays, continued Menu 8 Displays with Key Entries Key Entry Display Description TIME DELA Y MIN:SEC UNDERVOL T AGE ??:?? Displays the undervoltage time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key . MENU 8 TIME DE[...]

TP-6200 10/12 98 Section 2 Operation Local Programming Mode On 2.8.9 Menu 9—Input Setup Menu 9 provides the setup of user-defined digital and analog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs. The user must enable the programming mode to edit the display . Note: Press the d[...]

TP-6200 10/12 99 Section 2 Operation Local Programming Mode On Analog Input V alues. The analog input selection typically requires entering four values: low warning, high warning, low shutdown, and high shutdown. The analog values and time delays affect how and when the controller reacts. See Figure 2-19. The user must set both the high and low lev[...]

TP-6200 10/12 100 Section 2 Operation Local Programming Mode On Menu 9—Input Setup Menu 9 Displays with Key Entries MAIN MENU NUMBER 9 MENU 9 INPUT SETUP Key Entry Display Description Input a menu number . Displays the setup of digital auxiliary inputs heading. Displays the digital input 01 with the user-defined description. Note : Press the down[...]

TP-6200 10/12 101 Section 2 Operation Local Programming Mode On Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description DIGIT AL INPUT 01 → DELA Y TIME ?:?? Displays the digital input 01 delay time (minutes:seconds) setting. When required, use the numeric keys to set the new values. Press the Enter key . Dis[...]

TP-6200 10/12 102 Section 2 Operation Local Programming Mode On Menu 9—Input Setup, continued Menu 9 Displays with Key Entries ANALOG INPUT 01 → SHUTDOWN ENABLED NO Key Entry Display Description ANALOG INPUT 01 → SHUTDOWN ENABLED Y/N Displays the analog input 01, shutdown enabled selection. Press the Enter key . AND Confirms the entry . OR Pr[...]

TP-6200 10/12 103 Section 2 Operation Local Programming Mode On Menu 9—Input Setup, continued Menu 9 Displays with Key Entries Key Entry Display Description Displays the analog input 01, high shutdown value. When required, use the numeric keys to set the new values. Press the Enter key . Note: The user must scale the analog input value in order t[...]

TP-6200 10/12 104 Section 2 Operation Local Programming Mode On 2.8.10 Menu 10—Output Setup Menu 10 provides setup of the user-defined system, digital and analog status and fault outputs, and relay driver outputs (RDO) 1 - -31. These outputs provide a multitude of choices for configuring customized auxiliary outputs. Additional individual outputs[...]

TP-6200 10/12 105 Section 2 Operation Local Programming Mode On Menu 10—Output Setup Menu 10 Displays with Key Entries Key Entry Display Description Input a menu number . MENU 10 OUTPUT SETUP Displays the common faults heading. DEFINE COMMON → FA ULT S SYSTEM EVENTS → Displays the system events heading. COMMON F AUL T Y/N (see Group B) Gives [...]

TP-6200 10/12 106 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description DIGIT AL INPUTS → Displays the digital inputs heading. Gives the user the option to add or delete selection from the defined digital faults starting with D01. Note: Press the Menu Down k[...]

TP-6200 10/12 107 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Indicates whether the previously user-defined analog output was selected (yes or no) as a low warning fault. COMMON F AUL T Y/N A01 LO WARNING → Key Entry Display Description OR Press the Enter key . Confirms the ent[...]

TP-6200 10/12 108 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description Indicates whether the previously user-defined analog output was selected (yes or no) as a low shutdown fault. COMMON F AUL T Y/N A01 LO SHUTDOWN → Press the Enter key . Confirms the entr[...]

TP-6200 10/12 109 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description ANALOG INPUTS → Returns the user to analog inputs heading. Returns the user to the define common faults heading. DEFINE COMMON → FA ULT S RELA Y DRV OUT 01 → (user defined) Gives the[...]

TP-6200 10/12 1 10 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Entering YES adds the selection to the RDO group. Note: Func(Function) Used by (RDO) XX Reassign? appears when the user attempts to assign an RDO to a function already assigned. Note: Cannot Change (because the) NFP A[...]

TP-6200 10/12 111 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Key Entry Display Description Indicates whether the previously user-defined analog RDO was selected (yes or no) as a low warning fault. RELA Y DRV OUT 01 Y/N A01 LO WARNING → OR Press the Enter key . Confirms the ent[...]

TP-6200 10/12 1 12 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries Indicates whether the previously user-defined analog RDO was selected (yes or no) as a low shutdown fault. RELA Y DRV OUT 01 Y/N A01 LO SHUTDOWN → Key Entry Display Description OR Press the Enter key . Confirms the [...]

TP-6200 10/12 11 3 Section 2 Operation Local Programming Mode On Menu 10—Output Setup, continued Menu 10 Displays with Key Entries— Deactivating the SCRDO Key Entry Display Description Input a menu number . MENU 10 OUTPUT SETUP MAIN MENU NUMBER 10 ENTER MENU NO. 1- - 15 Press the Enter key . Displays the menu number and name Displays the common[...]

TP-6200 10/12 1 14 Section 2 Operation Local Programming Mode On 2.8.1 1 Menu 1 1—V oltage Regulator Menu 1 1 provides the setup of the voltage regulator functions including the line-to-line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor , and kV AR adjustments. See Section 1.3.3, V oltage Regulator Adjustments, a[...]

TP-6200 10/12 11 5 Section 2 Operation Local Programming Mode On Menu 1 1—V oltage Regulator , continued Menu 1 1 Displays with Key Entries Key Entry Display Description UNDER FREQ UNLOAD → ENABLED N/Y Displays the under frequency (volts per Hz) unloading (yes or no) selection. Press the Enter key . Confirms the entry . UNDER FREQ UNLOAD → EN[...]

TP-6200 10/12 1 16 Section 2 Operation Local Programming Mode On Menu 1 1—V oltage Regulator , continued Menu 1 1 Displays with Key Entries Key Entry Display Description Displays the reactive droop selection (yes or no). REACTIVE DROOP → ENABLED N/Y OR Press the Enter key . Confirms the entry . Confirms the entry . Press the Enter key . REACTIV[...]

TP-6200 10/12 11 7 Section 2 Operation Local Programming Mode On Menu 1 1—V oltage Regulator , continued Menu 1 1 Displays with Key Entries Key Entry Display Description REACTIVE DROOP → ENABLED N/Y Returns the user to reactive droop selection heading. V AR CONTROL → ENABLED N/Y Displays the V AR control selection (yes or no). Press the Enter[...]

TP-6200 10/12 1 18 Section 2 Operation Local Programming Mode On Menu 1 1—V oltage Regulator , continued Menu 1 1 Displays with Key Entries Key Entry Display Description Displays the power factor control selection (yes or no). PF CONTROL → ENABLED N/Y Entering YES enables the power factor control feature. Note: A YES entry disables the kV AR co[...]

TP-6200 10/12 11 9 Section 2 Operation Local Programming Mode On Menu 1 1—V oltage Regulator , continued Menu 1 1 Displays with Key Entries Key Entry Display Description REGULA TOR GAIN ADJ GAIN # Displays the generator set voltage regulator gain adjustment. When required, use the numeric keys to enter the desired gain value. REGULA TOR GAIN ADJ [...]

TP-6200 10/12 120 Section 2 Operation Local Programming Mode On 2.8.12 Menu 12—Calibration Menu 12 provides the calibration of the voltage and current sensing logic. Changing the system voltage or replacing the main logic control circuit board requires a calibration adjustment. The user must enable the programming mode to edit the display . Conne[...]

TP-6200 10/12 121 Section 2 Operation Local Programming Mode On Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L2-L0 V # CALIB REF ? .? Measure the generator set output voltage for three-phase models between L2-L0 using a voltmeter and enter the result using the numeric [...]

TP-6200 10/12 122 Section 2 Operation Local Programming Mode On Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L3-L1 V # CALIB REF ? .? Three-Phase Models only . Measure the generator set output voltage for three-phase models between L3-L1 using a voltmeter and enter the[...]

TP-6200 10/12 123 Section 2 Operation Local Programming Mode On Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale AC Analog Inputs) Key Entry Display Description GEN L3 AMPS # CALIB REF ? .? Three-Phase Models only . Measure the generator set output current for three-phase models at L3 using an AC ammeter and enter the resul[...]

TP-6200 10/12 124 Section 2 Operation Local Programming Mode On Menu 12—Calibration, continued Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs) No calibration is available for inputs A01- - A02 for non-ECM engines. No calibration is available for inputs A01 - - A04 for Waukesha engines. Key Entry Display Description Input a menu numbe[...]

TP-6200 10/12 125 Section 2 Operation Local Programming Mode On 2.8.13 Menu 13—Communications Menu 13 enables communication with the controller for monitoring or controlling the generator set. KBUS allows a variety of connection types while Modbus r follows Modbus r RTU protocols. Use the LAN (local area network) to gain remote access to multiple[...]

TP-6200 10/12 126 Section 2 Operation Local Programming Mode On Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description Confirms the entry . CONNECTION TYPE → (USER DEFINED) YES PRIMARY PORT → (USER DEFINED) Y/N Displays the user-defined primary port subheading. Press the Down arrow key if the correct[...]

TP-6200 10/12 127 Section 2 Operation Local Programming Mode On Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description PROTOCOL → MODBUS Displays the Modbus protocol heading. MODBUS ONLINE Y/N Displays the Modbus online selection (yes or no). Press the Enter key . Confirms the entry . Confirms the entr[...]

TP-6200 10/12 128 Section 2 Operation Local Programming Mode On Menu 13—Communications, continued Menu 13 Displays with Key Entries Key Entry Display Description BAUD RA TES 9600 N/Y 19200 N/Y BAUD RA TE → (USER DEFINED) Y/N Displays the user-defined baud rate. Press the Down arrow key if the correct baud rate is displayed. If the desired baud [...]

TP-6200 10/12 129 Section 2 Operation Local Programming Mode On 2.8.14 Menu 14—Programming Mode Menu 14 allows altering controller data either locally using the keypad or remotely using a PC or other device. The user must enter a password (access code) to enable the programming mode. Local Programming. Local programming is data alteration using t[...]

TP-6200 10/12 130 Section 2 Operation Local Programming Mode On Menu 14—Programming Mode, continued Menu 14 Displays with Key Entries Displays the user-defined programming mode. Press the Down arrow key if the correct programming mode is displayed. If the desired programming mode is not displayed, press the Right arrow key until the desired progr[...]

TP-6200 10/12 131 Section 2 Operation Local Programming Mode On 2.8.15 Menu 15—Protective Relays (PR) Menu 15 provides the necessary protective relays for units with the optional paralleling protection feature. If the generator set personality profile did not include the paralleling option this menu will not appear on the display . Available with[...]

TP-6200 10/12 132 Section 2 Operation Local Programming Mode On Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description Displays the underfrequency % value. When required, use the numeric keys to enter the desired underfrequency % value and press the Enter key . PR UNDERFREQUENCY → ?% #HZ Displays th[...]

TP-6200 10/12 133 Section 2 Operation Local Programming Mode On Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description Displays the loss of field % value. When required, use the numeric keys to enter the desired loss of field % value and press the Enter key . PR LOSS OF FIELD → ?% #KV AR Displays th[...]

TP-6200 10/12 134 Section 2 Operation Local Programming Mode On Menu 15—Protective Relays, continued Menu 15 Displays with Key Entries Key Entry Display Description Displays the over current shutdown with voltage restraint (VR) % value. When required, use the numeric keys to enter the desired over current shutdown % value and press the Enter key [...]

TP-6200 10/12 135 Section 2 Operation Local Programming Mode On 2.8.16 Menu 20—Factory Setup Menu 20 provides generator set, alternator , controller , and engine identification information. The user can use this menu to determine the generator set operating days and identify the controller software (code) version. The factory setup menu informati[...]

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

TP-6200 10/12 137 Section 3 Scheduled Maintenance Section 3 Scheduled Maintenance Under normal operating conditions, the generator set’s alternator requires no routine service. Consult Section 2.1, Prestart Checklist, for a list of routine checks. 3.1 Alternator Service When operating the generator set under dusty or dirty conditions, use dry com[...]

TP-6200 10/12 138 Section 3 Scheduled Maintenance 3.3 Service Schedule Action System—Component Visually Inspect Check Change Clean T est Interval Fuel System Day tank level X X W eekly Flexible lines and connections X R Weekly Fuel level switch X X Weekly Main tank supply level X Weekly Solenoid valve operation X X Weekly Transfer pump operation [...]

TP-6200 10/12 139 Section 3 Scheduled Maintenance Service Schedule, continued Action System—Component Visually Inspect Check Change Clean T est Interval AC Electrical System Controller lamp test X R Weekly General Inspection X Weekly Circuit breakers, fuses [ X X R X X Monthly Wire abrasions where subject to motion X X Quarterly Safety and alarm [...]

TP-6200 10/12 140 Section 3 Scheduled Maintenance 3.4 Alternator Bearing S ervice 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 ex[...]

TP-6200 10/12 141 Section 3 Scheduled Maintenance 3.5.2 Subbase Fuel Day T ank Electronic Control Module (ECM) With an electronic control module (ECM), the optional subbase diesel fuel tank functions as a day tank. Following are operating information and features of the ECM. See Figure 3-2 for the ECM front panel layout. 224825 Figure 3-2 ECM Front[...]

TP-6200 10/12 142 Section 3 Scheduled Maintenance 3.5.3 Subbase Inner Fuel T ank Alarm This kit provides for both audible and visual alarms from a location remote from the generator set if a leak is detected in the inner fuel tank of the double-wall subbase fuel tanks. See Figure 3-6. If the inner tank is leaking, a sensor installed in the outer ta[...]

TP-6200 10/12 143 Section 3 Scheduled Maintenance SB-700 1. Electronic-controlled pressure regulator (EPR) 2. Fuel mixer 3. Fuel solenoid valve (UL - - listed models require 2 fuel solenoid valves) 1 2 3 Figure 3-8 Fuel Regulator and V alve, T ypical 3.6.3 Natural Gas and LPG Conversion Most models operate on either natural gas or LPG fuel by perfo[...]

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

TP-6200 10/12 145 Section 3 Scheduled Maintenance Emissions certified models use a single electronic- controlled pressure regulator (EPR) for both fuels. A tee fitting connects both fuels together upstream of the EPR. During operation when using the secondary fuel, it is normal for a small amount of secondary fuel to seep back through the primary f[...]

TP-6200 10/12 146 Section 3 Scheduled Maintenance 3.7.2 Cooling System Component Inspection T o prevent generator set shutdown or damage caused by overheating: D Keep the cooling air inlets clean and unobstructed. D Inspect the radiator ’s exterior for obstructions. Remove dirt and foreign material using a soft brush or cloth to avoid damaging th[...]

TP-6200 10/12 147 Section 3 Scheduled Maintenance 6. Replace the pressure cap. 7. Fill the coolant recovery tank to the low mark. 8. Operate generator set until the thermostat opens when the upper cooling system hose warms. 9. Stop the engine and allow it to cool. 10. Check and repair any coolant leaks. 1 1. Remove the pressure cap. 12. Add coolant[...]

TP-6200 10/12 148 Section 3 Scheduled Maintenance 13. Place the generator set master switch to the RUN position to start the generator set. Refer to 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. C[...]

TP-6200 10/12 149 Section 3 Scheduled Maintenance 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 3-15 . 7. Reinstall the belt guards using the original h[...]

TP-6200 10/12 150 Section 3 Scheduled Maintenance After reconnecting the battery cables, coat the terminals with petroleum jelly , silicon grease, or other nonconductive grease. EZ-273000-J 1 2 12 12 1. T o positive (+) terminal on starter solenoid. 2. T o ground ( - -) terminal on or near starter motor. Figure 3-16 12-V olt Engine Electrical Syste[...]

TP-6200 10/12 151 Section 3 Scheduled Maintenance 3.1 1.3 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[...]

TP-6200 10/12 152 Section 3 Scheduled Maintenance 3.12 Detroit Diesel Engine Control Systems Some generator sets equipped with Detroit Diesel engines use a DDEC/MDEC/ADEC 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 engine[...]

TP-6200 10/12 153 Section 3 Scheduled Maintenance 3.13 Engine Control Systems Some generator sets use an engine control system. Access the control box inside the generator set junction box to retrieve codes when performing routine maintenance or troubleshooting engine. Use the following data for general informational purposes only . See the Engine [...]

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

TP-6200 10/12 155 Section 4 General Troubleshooting Section 4 General T roubleshooting This section contains generator set troubleshooting, diagnostic, and repair information. Note: The controller clock must be set each time the engine battery(ies) are disconnected. The controller clock determines exercise run time and event records. See Menu 6—T[...]

TP-6200 10/12 156 Section 4 Troubleshooting 4.1 General T roubleshooting Chart T rouble Symptoms Probable Causes Recommended Actions Section or Publication Reference* Does not crank Cranks but does not start Starts hard No or low output voltage Stops suddenly Lacks power Overheats Low oil pressure High fuel consumption Excessive or abnormal noise D[...]

TP-6200 10/12 TP-6200 10/12 157 Section 4 Troubleshooting Section or Publication Reference* Recommended Actions Probable Causes T rouble Symptoms Section or Publication Reference* Recommended Actions Probable Causes Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption L[...]

TP-6200 10/12 158 Section 4 Troubleshooting Section or Publication Reference* Recommended Actions Probable Causes T rouble Symptoms Section or Publication Reference* Recommended Actions Probable Causes Exercise run time and/or event records inoperative Displays error message/locks up Excessive or abnormal noise High fuel consumption Low oil pressur[...]

TP-6200 10/12 TP-6200 10/12 159 Section 4 Troubleshooting 4.2 Controller Display and V oltage Regulation T roubleshooting Chart T rouble Symptoms Probable Causes Recommended Actions Section or Publication Reference* Controller Display and V oltage Regulator Display is black No/low battery charge Recharge/replace battery Section 3, Battery Display s[...]

TP-6200 10/12 160 Notes[...]

TP-6200 10/12 161 Section 5 Generator Set Reconnection Section 5 Generator Set Reconnection 5.1 Introduction Use the following voltage reconnection procedure to change the voltage of 10- and 12-lead generator sets. Frequency changes require voltage regulator and governor adjustments. Refer to the respective spec sheet to determine if frequency is f[...]

TP-6200 10/12 162 Section 5 Generator Set Reconnection 5.2 V oltage Reconnection Procedure 1. Place the generator set master switch in the OFF/RESET position. 2. Disconnect the generator set engine starting battery , negative ( - - ) lead first. Disconnect power to the battery charger (if equipped). 3. Use Figure 5-1, Figure 5-2, Figure 5-3, or Fig[...]

TP-6200 10/12 163 Section 5 Generator Set Reconnection Figure 5-1 20 - - 150 kW Permanent Magnet and W ound Field Single-Phase Alternators, ADV -5875A-P[...]

TP-6200 10/12 164 Section 5 Generator Set Reconnection Figure 5-2 20 - - 400 kW Permanent Magnet and 20- - 60 kW Wound Field Alternators, ADV -5875B-P[...]

TP-6200 10/12 165 Section 5 Generator Set Reconnection Figure 5-3 60 (with Oversize Alternator) - - 400 kW W ound Field Alternators, ADV -5875C-P[...]

TP-6200 10/12 166 Section 5 Generator Set Reconnection Figure 5-4 350 kW and Larger Pilot-Excited, Permanent Magnet Alternator , ADV -5875D-P[...]

TP-6200 10/12 167 Section 6 Accessories Section 6 Accessories 6.1 Accessories and Connections Several accessories help finalize installation, add convenience to operation and service, and establish state and local code compliance. Accessories vary with each generator set model and controller . Select factory-installed and/or shipped- loose accessor[...]

TP-6200 10/12 168 Section 6 Accessories 6 . 1 . 2 Common Failure Relay Kit The common failure relay kit provides one set of contacts to trigger user-provided warning devices if a fault occurs. The common failure relay faults are user-defined. See Section 2, Operation, Menu 10— Output Setup, for status and faults available for this function. Conne[...]

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

TP-6200 10/12 170 Section 6 Accessories 6.1.5 Ground Fault Annunciation A relay contact for customer connection indicates a ground fault condition and is part of a ground fault alarm. See Figure 6-8 for electrical connections and the following procedure for controller setup. Use the instructions with the kit when provided to install and setup this [...]

TP-6200 10/12 171 Section 6 Accessories g. Press to enter the inhibit time. Entry Accepted is displayed and the inhibit time 0:00 is now displayed. h. Press to display Digital Input #06 Delay TIme . i. Press to enter delay time. Entry Accepted is displayed. Default delay time is 5 sec. j. Press . 7. V erify Programming. a. Move handle of ground fau[...]

TP-6200 10/12 172 Section 6 Accessories 6.1.7 Low Fuel (Level/Pressure) Switch Some gaseous-fueled models offer a low fuel pressure switch. The low fuel pressure switch connects to the same terminal as the low fuel level switch on diesel- or gasoline-fueled models. See Figure 6-10 and Figure 6-1 1. See Section 6.2, Accessory Connections, for termin[...]

TP-6200 10/12 173 Section 6 Accessories 6 . 1 . 9 Remote Emergency Stop Kit The emergency stop kit allows immediate shutdown of the generator set from a remote location. See Figure 6-14 and Figure 6-15. If the emergency stop switch activates, the EMERGENCY STOP lamp lights and the unit shuts down. Before attempting to restart the generator set, res[...]

TP-6200 10/12 174 Section 6 Accessories 6.1.1 1 Remote Serial Annunciator RSA II is an annunciator panel offered in several kit configurations to support Kohler power equipment. The RSA is a remote serial annunciator Figure 6-18 and Figure 6-19 that monitors the condition of the generator set and/or A TS from a remote location. The RSA alerts the o[...]

TP-6200 10/12 175 Section 6 Accessories Fault and Status Condition Fault LED System Monitoring LEDs and Functions System Ready LED Generator Running LED Communication Status LED Common Fault LED Common Fault Output Horn Overcrank Shutdown Red Red SF Off Green Red SF On On High Engine T emperature Warning * Y ellow Red SF Green Green Red SF On On Hi[...]

TP-6200 10/12 176 Section 6 Accessories Figure 6-21 RSA Wiring Connections GM62554A-G[...]

TP-6200 10/12 177 Section 6 Accessories Figure 6-22 RSA Wiring Connections GM62554B-G[...]

TP-6200 10/12 178 Section 6 Accessories Figure 6-23 RSA Wiring Connections GM62554C-G[...]

TP-6200 10/12 179 Section 6 Accessories Figure 6-24 RSA Wiring Connections GM62554D-G[...]

TP-6200 10/12 180 Section 6 Accessories Figure 6-25 RSA Wiring Connections GM62554E-G[...]

TP-6200 10/12 181 Section 6 Accessories 6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) The remote speed adjustment potentiometer kit provides controller-mounted engine speed adjustment. The adjustment range is approximately ± 5%. Some applications locate this potentiometer with the switchgear . This kit requires an electronic go[...]

TP-6200 10/12 182 Section 6 Accessories 6 . 1 . 1 5 Single -Relay Dry Contact Kit The single-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user- provided accessories allowing remote monitoring of the generator set. T ypically , lamps, audible alarms, or othe[...]

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

TP-6200 10/12 184 Section 6 Accessories 6.1.17 T wenty -Relay Dry Contact Kit The twenty-relay dry contact kit provides normally open and normally closed contacts in a form C configuration to activate warning devices and other user-provided accessories allowing remote monitoring of the generator set. T ypically , lamps, audible alarms, or other dev[...]

TP-6200 10/12 185 Section 6 Accessories 6.1.18 Wireless Monitor The wireless monitor system has two components: a wireless monitor unit and a website. The monitor unit transmits messages in response to signals received from the equipment controller and notifies designated recipients of selected operating conditions. The website monitors these messa[...]

TP-6200 10/12 186 Section 6 Accessories 6.2 Accessory Connections The 550 controller contains circuit boards equipped with terminal strip(s) 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 a dry contact kit. Conne[...]

TP-6200 10/12 187 Section 6 Accessories TB1 T erminal Strip—Engine Start and Emergency Stop Connections T erm. Description 1 Emergency stop ground 1A Emergency stop 3 Remote start 4 Remote start TB2 T erminal Strip—Analog Input Connections T erm. Description 1 ACH1 (CTS) Signal (non-ECM including W aukesha) 2 ACH1 (CTS) Supply (non-ECM includin[...]

TP-6200 10/12 188 Section 6 Accessories GM13984- Figure 6-39 T erminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box TB6 T erminal Strip—RDOs 1 - - 7 T erm. Description 42A Battery (+) G ND B at t e r y (- -) N/C RDO1 Overspeed (lead 39) RDO2 Overcrank (lead 12) RDO3 High coolant temperature shutdown (lead 36)[...]

TP-6200 10/12 189 Section 6 Accessories Figure 6-41 Accessory Connections GM78247A-D[...]

TP-6200 10/12 190 Section 6 Accessories Figure 6-42 Accessory Connections GM78247C-D[...]

TP-6200 10/12 191 Section 6 Accessories Figure 6-43 Accessory Connections GM78247D-D[...]

TP-6200 10/12 192 Section 6 Accessories Notes[...]

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

TP-6200 10/12 194 Appendix K kelvin kA kiloampere KB kilobyte (2 10 bytes) KBus Kohler communication protocol kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k Ω kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV [...]

TP-6200 10/12 Appendix 195 Appendix B User - Defined Settings Use the table below to record user-defined settings during the generator set controller setup and calibration. The controller default settings and ranges provide guidelines. The table contains all faults with ranges and time delays including items that do not have adjustments. Not adjust[...]

TP-6200 10/12 196 Appendix Status Event or Fault User-Defined Settings Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Relay Driver Output (RDO) Digital Display Refer to Menu Analog Aux. Input A04 ] 9 A04 OIL TEMP Default V alues with Warning Enabled: HI/LO warning are engine dependent 30 sec. inhibit, 0 sec. delay warni[...]

TP-6200 10/12 Appendix 197 Status Event or Fault User-Defined Settings Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Relay Driver Output (RDO) Digital Display Refer to Menu Digital Aux. Input D05 Breaker Closed w 9, 10 D05 BREAKER CLOSED Fixed 0 sec. inhibit, 0 sec. delay Not adjustable Digital Aux. Input D06 w 9, 10 D[...]

TP-6200 10/12 198 Appendix Status Event or Fault User-Defined Settings Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Relay Driver Output (RDO) Digital Display Refer to Menu (Engine) J1939 CAN Engine Shutdown 10 J1939 CAN SHUTDOWN Not adjustable Engine Stalled 10 ENGINE ST ALLED Not adjustable Engine Start (see Time Del[...]

TP-6200 10/12 Appendix 199 Status Event or Fault User-Defined Settings Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Relay Driver Output (RDO) Digital Display Refer to Menu Load Shed kW Overload ]] 10 LOAD SHED KW OVER RDO-30 ]] 80% - - 120% 100% of kW rating w i t h5s e c . delay 2- -1 0 Load Shed Over T emperature [[[...]

TP-6200 10/12 200 Appendix Status Event or Fault User-Defined Settings Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Relay Driver Output (RDO) Digital Display Refer to Menu No Coolant T emperature Signal 10 NO COOL TEMP SIGNAL 30 4 Not adjustable No Oil Pressure Signal 10 NO OIL PRESSURE SIGNAL 30 4 Not adjustable No O[...]

TP-6200 10/12 Appendix 201 Status Event or Fault User-Defined Settings Time Delay (sec.) Inhibit Time Delay (sec.) Default Selection Range Setting Relay Driver Output (RDO) Digital Display Refer to Menu Undervoltage Shutdown 7, 8, 10 UNDER VOL T AGE RDO-27 70% - - 95% 85% 10-sec time delay [ 70% 30-sec time delay w 5- -3 0 V ariable Speed Governor [...]

TP-6200 10/12 202 Appendix Appendix C V oltage Regulator Definitions and Adjustments The following definitions and adjustment/setting specifications are intended for users planning to adjust the voltage regulator beyond the default settings in order to customize the alternator for a specific application. This information is not intended to be a com[...]

TP-6200 10/12 Appendix 203 Frequency Setpoint or Cut-In Point The point at which the underfrequency unloading begins to take effect is adjustable, allowing the system to be tailored for each application. Because the characteristics of the engine have the largest effect on the system’s performance, the engine’s response should determine the unlo[...]

TP-6200 10/12 204 Appendix Reactive Droop Reactive droop refers to another compensation technique used in excitation control systems. Reactive droop means that the generator set voltage droops with increasing reactive current. Although this sounds like an undesirable effect, it is quite beneficial in paralleling applications with multiple generator[...]

TP-6200 10/12 Appendix 205 135 amps = ( 1 12500 / 3) / 277 Where: acos is arccosine or inverse cosine W is W att L-N is line-to-neutral PF is power factor V A is volt-ampere k is kilo ( = 1000 ) Therefore, each generator set in this case s hould carry 1 13 amps per phase or half the 226 calculated line amps. The 1 13 amps includes 67.5 amps of reac[...]

TP-6200 10/12 206 Appendix Set the PF adjust according to the requirements of the application. When a generator set will be connected in parallel with the utility , V AR or PF control should be ENABLED. If there are multiple generator sets in parallel as well, then reactive droop should be ENABLED also. Additionally , note that PF control should be[...]

TP-6200 10/12 Appendix 207 V oltage Droop The amount of reactive droop is entered here. The droop is entered as a percentage of system voltage when a fully rated load at 0.8 PF is applied. The entry may be made with resolution as fine as one-tenth of one volt. This entry determines how much the voltage will droop when the alternator provides reacti[...]

TP-6200 10/12 208 Appendix Appendix D Alternator Protection The 550 controller has built-in thermal protection for the alternator . This feature functions similarly to a thermal circuit breaker . When the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of time at which current[...]

TP-6200 10/12 Appendix 209 Appendix E Inputs and System Events by Application The controller inputs and system events are typically driven by the engine manufacturer’s ECM. NFP A 1 10 guidelines provide specific requirements that all controllers must have for compliance. While the controller displays all NFP A 1 10 required data, some engine ECMs[...]

TP-6200 10/12 210 Appendix Controller Inputs and System Events 125RZG Waukesha Engines DD/MTU Engines with MDEC/ADEC Paralleling Applications NFP A 1 10 Applications Digital Aux. Input D17 V AR/PF mode Digital Aux. Input D18 V oltage Lower Digital Aux. Input D19 V oltage Raise Digital Aux. Input D20 Air Damper Indicator Shutdown (if engine equipped[...]

TP-6200 10/12 Appendix 21 1 Controller Inputs and System Events 125RZG Waukesha Engines DD/MTU Engines with MDEC/ADEC Paralleling Applications NFP A 1 10 Applications NFP A 1 10 Fault (Warning or Shutdown) X No Air T emperature Signal Warning X No Coolant T emperature Signal Shutdown No Oil Pressure Signal Shutdown No Oil T emperature Signal Warnin[...]

TP-6200 10/12 212 Appendix Notes[...]

TP-6200 10/12 213 Notes[...]

TP-6200 10/12 214 Notes[...]

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E 2004, 2005, 2006, 2008, 2009, 201 1, 2012 by Kohler Co. All rights reserved. TP-6200 10/12i KOHLER CO. Kohler , Wisconsin 53044 Phone 920-457-4441, 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 Pho[...]