Operation

Industrial Generator Sets

Models:

10-1000 kW
Controller:

APM402/Decision-Makerr 3000

TP-6694 3/19k
 WARNING: This product can expose you WARNING: Breathing diesel engine
to chemicals, including carbon monoxide exhaust exposes you to chemicals known to
and benzene, which are known to the State the State of California to cause cancer and
of California to cause cancer and birth birth defects or other reproductive harm.
defects or other reproductive harm. S Always start and operate the engine in
For more information go to a well-ventilated area.
[Link] S If in an enclosed area, vent the exhaust
to the outside.
S Do not modify or tamper with the
exhaust system.
S Do not idle the engine except as
necessary.
For more information go to
[Link]/diesel
Product Identification Information

Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that
operation manual, spec sheet, or sales invoice. Record
the numbers are readily available for future reference.
the Controller Serial Number from the controller
Record field-installed kit numbers after installing the nameplate.
kits.
Controller DescriptionAPM402 /Decision-Makerr 3000
Generator Set Identification Numbers
Controller Serial Number
Record the product identification numbers from the
generator set nameplate(s). Firmware/Software Version Numbers
Model Designation Record the version and reference numbers as shipped
Specification Number from the manufacturer. Determine the Application
Serial Number Program Version Number as shown in Menu 20.
Determine the Personality Profile Reference Number
Accessory Number Accessory Description
from the disk supplied with the literature packet.
Application Program Version Number
Personality Profile Reference Number
User Parameter File Reference Number

Version Number Upgrades/Updates

Record the version number upgrade/updates when
installed.
Engine Identification
Record the product identification information from the Version No./Date Installed
engine nameplate.
Software Options
Manufacturer
Record the software options.
Model Designation
Serial Number Number and Description
 Table of Contents
Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SiteTecht Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.1 Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 Annunciator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3 Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.4 Controller Fault Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.5 Digital Display Circuit Board and Connections . . . . . . . . . . . . . . . . . . . . . 25
1.2.6 Main Logic Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.7 Terminal Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.8 Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.9 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.3 Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.1 Status Event and Fault Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.3.2 Voltage Regulator and Calibration Specifications . . . . . . . . . . . . . . . . . . . 33
1.3.3 Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.2 Exercising Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3 Operation in Cold Weather Climates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.4.2 Stopping (User Stopping and Fault Shutdown) . . . . . . . . . . . . . . . . . . . . . 37
2.4.3 Emergency Stop Switch Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.4.4 System Status Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.4.5 System Fault Warning Lamp with Digital Displays . . . . . . . . . . . . . . . . . . 38
2.4.6 System Fault Shutdown Lamp With Digital Displays . . . . . . . . . . . . . . . . 40
2.4.7 Status and Notice Digital Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.4.8 Controller Resetting (Following System Shutdown or Warning) . . . . . . . 45
2.4.9 Powering Up the Engine Control Module (ECM) . . . . . . . . . . . . . . . . . . . 45
2.5 Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.6 Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6.1 PC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6.2 Modbusr Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.7 Reviewing Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.7.1 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.7.2 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.7.3 Engine Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.7.4 Generator Metering (and Calibration) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.7.5 GenSet Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.7.6 GenSet Run Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.7.7 GenSet System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.7.8 GenSet Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.7.9 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.7.10 Digital Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.7.11 Digital Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.7.12 Analog Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

TP-6694 3/19 Table of Contents 3

Table of Contents, continued
2.7.13 Battery Charger 1 and 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.7.14 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7.15 Volt Select . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.1 Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
3.4 Alternator Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4.1 20--300 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4.2 300--1000 kW Models with 4M/5M/7M Single-Bearing Alternator . . . . . 66
3.5 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.5.1 Bleeding Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.6 Gaseous Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6.1 Gaseous Fuel System Concept
(Single Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.6.2 LPG Liquid Withdrawal Fuel System Concept . . . . . . . . . . . . . . . . . . . . . 67
3.6.3 Natural Gas and LPG Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.4 Fuel System Changeover Kits (Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.6.5 Fuel Conversion Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.7 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 . . . . . . . . . . . . . . . . . . . . . 73
3.8 Air Cleaner Restrictor Indicator (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.9 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.9.1 Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.9.2 Cooling System Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.9.3 Procedure to Drain Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.9.4 Procedure to Flush and Clean Cooling System . . . . . . . . . . . . . . . . . . . . 75
3.9.5 Procedure to Refill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.10 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.10.1 Clean Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.10.2 Electrolyte Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.10.3 Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.10.4 Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.11 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.11.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.11.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.11.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.11.4 Internal Engine Components (Gaseous-Fueled Engines) . . . . . . . . . . . . 79
3.11.5 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.11.6 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Section 4 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.1 General Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2 Controller Display and Voltage Regulation Troubleshooting Chart . . . . . . . . . . . . 85
Section 5 Voltage Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.2 Voltage Reconnection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.3 Voltage Reconnection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.1 Accessories and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.1.1 Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
6.1.2 Common Fault/Failure (32A) Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
6.1.3 Fifteen-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
6.1.4 Gas Fuel Valve Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
6.1.5 Input/Output (I/O) Module Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
6.1.6 Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
6.1.7 Low Fuel (Level/Pressure) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

4 Table of Contents TP-6694 3/19

 Table of Contents, continued
6.1.8 Manual Speed Adjust (Engine RPM Menu) . . . . . . . . . . . . . . . . . . . . . . . . 101
6.1.9 Prime Power Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
6.1.10 Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.1.11 Remote Reset Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
6.1.12 Remote Serial Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
6.1.13 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.1.14 Shunt-Trip Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
6.2 Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Appendix B Programmer-Defined Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Appendix D Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Appendix E Controller Displays from the Engine ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

TP-6694 3/19 Table of Contents 5

 Notes

6 TP-6694 3/19
 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
can cause bodily harm and pose
life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
equipment connected to the set, battery case. If battery acid splashes in
disable the generator set as follows: the eyes or on the skin, immediately
(1) Press the generator set off/reset flush the affected area for 15 minutes
WARNING button to shut down the generator set. with large quantities of clean water.
(2) Disconnect the power to the battery Seek immediate medical aid in the case
Warning indicates the presence of a charger, if equipped. (3) Remove the of eye contact. Never add acid to a
hazard that can cause severe battery cables, negative (--) lead first. battery after placing the battery in
personal injury, death, or substantial Reconnect the negative (--) lead last service, as this may result in hazardous
property damage. when reconnecting the battery. Follow spattering of battery acid.
these precautions to prevent the
starting of the generator set by the Battery acid cleanup. Battery acid
CAUTION remote start/stop switch. can cause severe injury or death.
Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor Battery bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
personal injury or property damage.
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
NOTICE WARNING battery acid and continue to add the
Notice communicates installation,
neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator Sulfuric acid in batteries.
or service technician to potential Can cause severe injury or death.
hazards and explain how to act safely.
The decals are shown throughout this Wear protective goggles and
publication to improve operator clothing. Battery acid may cause
recognition. Replace missing or blindness and burn skin.
damaged decals.

TP-6694 3/19 Safety Precautions and Instructions 7

Battery gases. Explosion can cause
severe injury or death. Battery gases
Engine Backfire/Flash Exhaust System
can cause an explosion. Do not smoke Fire
or permit flames or sparks to occur near WARNING
a battery at any time, particularly when WARNING
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. Carbon monoxide.
Remove all jewelry before servicing the Risk of fire. Can cause severe nausea,
equipment. Discharge static electricity Can cause severe injury or death. fainting, or death.
from your body before touching
batteries by first touching a grounded Do not smoke or permit flames or The exhaust system must be
metal surface away from the battery. To sparks near fuels or the fuel system. leakproof and routinely inspected.
avoid sparks, do not disturb the battery
charger connections while the battery Servicing the fuel system. A flash Generator set operation. Carbon
is charging. Always turn the battery fire can cause severe injury or death. monoxide can cause severe nausea,
charger off before disconnecting the Do not smoke or permit flames or fainting, or death. Carbon monoxide
battery connections. Ventilate the sparks near the carburetor, fuel line, is an odorless, colorless, tasteless,
compartments containing batteries to fuel filter, fuel pump, or other potential nonirritating gas that can cause death if
prevent accumulation of explosive sources of spilled fuels or fuel vapors. inhaled for even a short time. Avoid
gases. Catch fuels in an approved container breathing exhaust fumes when working
when removing the fuel line or on or near the generator set. Never
Battery short circuits. Explosion carburetor. operate the generator set inside a
can cause severe injury or death.
building unless the exhaust gas is
Short circuits can cause bodily injury Servicing the air cleaner. A sudden
piped safely outside. Never operate
and/or equipment damage. backfire can cause severe injury or
the generator set where exhaust gas
Disconnect the battery before death. Do not operate the generator
could accumulate and seep back inside
generator set installation or set with the air cleaner removed.
a potentially occupied building.
maintenance. Remove all jewelry
before servicing the equipment. Use Combustible materials. A fire can
Carbon monoxide symptoms.
tools with insulated handles. Remove cause severe injury or death.
Carbon monoxide can cause severe
the negative (--) lead first when Generator set engine fuels and fuel
nausea, fainting, or death. Carbon
disconnecting the battery. Reconnect vapors are flammable and explosive.
monoxide is a poisonous gas present in
the negative (--) lead last when Handle these materials carefully to
exhaust gases. Carbon monoxide is an
reconnecting the battery. Never minimize the risk of fire or explosion.
odorless, colorless, tasteless,
connect the negative (--) battery cable Equip the compartment or nearby area
nonirritating gas that can cause death if
to the positive (+) connection terminal with a fully charged fire extinguisher.
inhaled for even a short time. Carbon
of the starter solenoid. Do not test the Select a fire extinguisher rated ABC or
monoxide poisoning symptoms include
battery condition by shorting the BC for electrical fires or as
but are not limited to the following:
terminals together. recommended by the local fire code or
D Light-headedness, dizziness
an authorized agency. Train all
D Physical fatigue, weakness in
Battery gases. Explosion can cause personnel on fire extinguisher
joints and muscles
severe injury or death. Incorrect use operation and fire prevention
D Sleepiness, mental fatigue,
of the equalize charge state may lead to procedures.
inability to concentrate
hazardous situations. Equalization is
or speak clearly, blurred vision
ONLY applicable for flooded lead acid
D Stomachache, vomiting, nausea
(FLA) type batteries and will damage
If experiencing any of these symptoms
gel, absorbed glass mat (AGM), or
and carbon monoxide poisoning is
nickel-cadmium (NiCad) type batteries.
possible, seek fresh air immediately
In the controller menu or SiteTecht
and remain active. Do not sit, lie down,
settings, verify that the battery topology
or fall asleep. Alert others to the
is set correctly for the battery type used.
possibility of carbon monoxide
Do not smoke or permit flames, sparks,
poisoning. Seek medical attention if
or other sources of ignition to occur
the condition of affected persons does
near a battery at any time.
not improve within minutes of breathing
fresh air.

8 Safety Precautions and Instructions TP-6694 3/19

Fuel System Draining the fuel system. Explosive
fuel vapors can cause severe injury
Hazardous Voltage/
or death. Spilled fuel can cause an Moving Parts
WARNING explosion. Use a container to catch fuel
when draining the fuel system. Wipe up DANGER
spilled fuel after draining the system.
Gas fuel leaks. Explosive fuel
vapors can cause severe injury or
death. Fuel leakage can cause an
Explosive fuel vapors. explosion. Check the LPG vapor or
Can cause severe injury or death. natural gas fuel system for leakage by Hazardous voltage.
using a soap and water solution with Will cause severe injury or death.
Use extreme care when handling, the fuel system test pressurized to
storing, and using fuels. Disconnect all power sources before
6--8 ounces per square inch
opening the enclosure.
(10--14 inches water column). Do not
The fuel system. Explosive fuel
use a soap solution containing either
vapors can cause severe injury or
ammonia or chlorine because both
death. Vaporized fuels are highly
explosive. Use extreme care when
prevent bubble formation. A successful DANGER
test depends on the ability of the
handling and storing fuels. Store fuels
solution to bubble.
in a well-ventilated area away from
spark-producing equipment and out of LPG liquid withdrawal fuel leaks.
the reach of children. Never add fuel to Explosive fuel vapors can cause
the tank while the engine is running severe injury or death. Fuel leakage
because spilled fuel may ignite on can cause an explosion. Check the Hazardous voltage. Moving parts.
contact with hot parts or from sparks. LPG liquid withdrawal fuel system for Will cause severe injury or death.
Do not smoke or permit flames or leakage by using a soap and water Operate the generator set only when
sparks to occur near sources of spilled solution with the fuel system test all guards and electrical enclosures
fuel or fuel vapors. Keep the fuel lines pressurized to at least 90 psi are in place.
and connections tight and in good (621 kPa). Do not use a soap solution
condition. Do not replace flexible fuel containing either ammonia or chlorine
lines with rigid lines. Use flexible because both prevent bubble
sections to avoid fuel line breakage
WARNING
formation. A successful test depends
caused by vibration. Do not operate the on the ability of the solution to bubble.
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming Hazardous Noise
generator set operation.
Hazardous voltage.
Explosive fuel vapors can cause Backfeed to the utility system can
CAUTION cause property damage, severe
severe injury or death. Take
additional precautions when using the injury, or death.
following fuels:
If the generator set is used for
Propane (LPG)—Adequate ventilation standby power, install an automatic
is mandatory. Because propane is transfer switch to prevent inadvertent
heavier than air, install propane gas Hazardous noise. interconnection of standby and
detectors low in a room. Inspect the Can cause hearing loss. normal sources of supply.
detectors per the manufacturer’s
instructions. Never operate the generator set Grounding electrical equipment.
without a muffler or with a faulty Hazardous voltage will cause severe
Natural Gas—Adequate ventilation is exhaust system.
mandatory. Because natural gas rises, injury or death. Electrocution is
install natural gas detectors high in a possible whenever electricity is
room. Inspect the detectors per the Engine noise. Hazardous noise can present. Ensure you comply with all
manufacturer’s instructions. cause hearing loss. Generator sets applicable codes and standards.
not equipped with sound enclosures Electrically ground the generator set,
Fuel tanks. Explosive fuel vapors can produce noise levels greater than transfer switch, and related equipment
can cause severe injury or death. 105 dBA. Prolonged exposure to noise and electrical circuits. Turn off the main
Gasoline and other volatile fuels stored levels greater than 85 dBA can cause circuit breakers of all power sources
in day tanks or subbase fuel tanks can permanent hearing loss. Wear hearing before servicing the equipment. Never
cause an explosion. Store only diesel protection when near an operating contact electrical leads or appliances
fuel in tanks. generator set. when standing in water or on wet
ground because these conditions
increase the risk of electrocution.

TP-6694 3/19 Safety Precautions and Instructions 9

High voltage test. Hazardous
voltage will cause severe injury or
Testing live electrical circuits.
Hazardous voltage or current will
Hot Parts
death. Follow the instructions of the cause severe injury or death. Have
test equipment manufacturer when trained and qualified personnel take WARNING
performing high-voltage tests on the diagnostic measurements of live
rotor or stator. An improper test circuits. Use adequately rated test
procedure can damage equipment or equipment with electrically insulated
lead to generator set failure. probes and follow the instructions of the
test equipment manufacturer when
Installing the battery charger. performing voltage tests. Observe the Hot coolant and steam.
Hazardous voltage will cause severe following precautions when performing Can cause severe injury or death.
injury or death. An ungrounded voltage tests: (1) Remove all jewelry.
battery charger may cause electrical Before removing the pressure cap,
(2) Stand on a dry, approved electrically
shock. Connect the battery charger stop the generator set and allow it to
insulated mat. (3) Do not touch the
enclosure to the ground of a permanent cool. Then loosen the pressure cap
enclosure or components inside the
wiring system. As an alternative, install to relieve pressure.
enclosure. (4) Be prepared for the
an equipment grounding conductor system to operate automatically.
with circuit conductors and connect it to (600 volts and under)
the equipment grounding terminal or WARNING
the lead on the battery charger. Install Servicing the generator set when it
the battery charger as prescribed in the is operating. Exposed moving parts
equipment manual. Install the battery will cause severe injury or death.
charger in compliance with local codes Keep hands, feet, hair, clothing, and
and ordinances. test leads away from the belts and
pulleys when the generator set is Hot engine and exhaust system.
Connecting the battery and the running. Replace guards, screens, and Can cause severe injury or death.
battery charger. Hazardous voltage covers before operating the generator
will cause severe injury or death. set. Do not work on the generator set until
Reconnect the battery correctly, it cools.
positive to positive and negative to
negative, to avoid electrical shock and
damage to the battery charger and
Heavy Equipment Servicing the alternator. Hot parts
can cause severe injury or death.
battery(ies). Have a qualified Avoid touching the alternator field or
electrician install the battery(ies). WARNING exciter armature. When shorted, the
Short circuits. Hazardous alternator field and exciter armature
voltage/current will cause severe become hot enough to cause severe
injury or death. Short circuits can burns.
cause bodily injury and/or equipment Servicing the exhaust system. Hot
damage. Do not contact electrical parts can cause severe injury or
connections with tools or jewelry while death. Do not touch hot engine parts.
making adjustments or repairs. Unbalanced weight.
Improper lifting can cause severe The engine and exhaust system
Remove all jewelry before servicing the components become extremely hot
equipment. injury or death and equipment
damage. during operation.
Engine block heater. Hazardous
voltage will cause severe injury or Do not use lifting eyes.
death. The engine block heater can Lift the generator set using lifting bars
cause electrical shock. Remove the inserted through the lifting holes on
engine block heater plug from the the skid.
electrical outlet before working on the
block heater electrical connections.
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.

10 Safety Precautions and Instructions TP-6694 3/19

Notice
NOTICE
This generator set has been
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-6694 3/19 Safety Precautions and Instructions 11

 Notes

12 Safety Precautions and Instructions TP-6694 3/19

 Introduction

This manual provides operation instructions for 10 kW SiteTecht Software

and larger generator sets equipped with the following
controllers: Several instances in this manual refer to SiteTecht
software, which can be used for programming the
D APM402 generator set controller APM402 or Decision-Makerr 3000 controller.
SiteTecht software is required for updating the
D Decision-Makerr 3000 generator set controller controller application code (firmware), loading
personality profiles, and saving or loading controller
Note: In 2018, Kohler adopted a global controller
configuration files. Contact your local distributor/dealer
naming convention. To support this, the name of
for assistance.
the Decision-Makerr 3000 controller has
transitioned to APM402. The APM402 has the Note: The APM402 controller uses different firmware
same form, fit and function as the than the Decision-Makerr 3000 controller. Do
Decision-Makerr 3000 and supports the same not attempt to load Decision-Makerr 3000
accessories. firmware on an APM402 controller, or vice-versa.
Wiring diagram manuals are available separately. Refer To determine the generator set controller software
to the engine operation manual for generator set engine version, go to the Overview menu.
scheduled maintenance information.

Information in this publication represents data available List of Related Materials

at the time of print. Kohler Co. reserves the right to
change this publication and the products represented Separate literature contains communication and
without notice and without any obligation or liability software information not provided in this manual.
whatsoever. Figure 1 lists the available literature part numbers.

Read this manual and carefully follow all procedures Literature Description Literature Part No.
and safety precautions to ensure proper equipment APM402 Controller Spec Sheet G6-161
operation and to avoid bodily injury. Read and follow the
Decision-Makerr 3000 Controller Spec
Safety Precautions and Instructions section at the Sheet
G6-100
beginning of this manual. Keep this manual with the Multiple Part Numbers
equipment for future reference. Generator Set/Controller
Wiring Diagram Manual Contact your
Distributor/Dealer
The equipment service requirements are very important Modbusr Communications Protocol
TP-6113
to safe and efficient operation. Inspect the parts often Operation Manual
and perform required service at the prescribed intervals. SiteTecht Software Operation Manual TP-6701
Maintenance work must be performed by appropriately Remote Serial Annunciator (RSA III) TT-1625
skilled and suitably trained maintenance personnel Remote Serial Annunciator (RSA II) TT-1485
familiar with generator set operation and service. Converters, Connections, and Controller
TT-1405
Setup for Network Communication

Abbreviations Figure 1 Related Literature

This publication makes use of numerous abbreviations. Several engine manufacturers provide engines with
Typically, the word(s) are spelled out along with the electronic controls. These electronic controls indicate
abbreviation in parentheses when shown for the first engine fault codes in addition to the generator set
time in a section. Appendix A, Abbreviations, also controller. The engine operation and service literature
includes many abbreviation definitions. provide information for identifying engine fault codes.
For the latest literature part numbers, see the respective
Parts Catalog.

Modbusr is a registered trademark of Schneider Electric.

TP-6694 3/19 Introduction 13

Service Assistance

For professional advice on generator set power Asia Pacific

requirements and conscientious service, please contact Kohler Asia Pacific Headquarters
your nearest Kohler distributor or dealer. Singapore, Republic of Singapore
Phone: (65) 6264-6422
D Visit the Kohler Co. website at [Link]. Fax: (65) 6264-6455
D Look at the labels and decals on your Kohler product China
or review the appropriate literature or documents North China Regional Office, Beijing
included with the product. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Call toll free in the US and Canada 1-800-544-2444. (86) 10 6518 7952
Fax: (86) 10 6518 7955
D Outside the US and Canada, call the nearest regional
East China Regional Office, Shanghai
office.
Phone: (86) 21 6288 0500
Headquarters Europe, Middle East, Africa Fax: (86) 21 6288 0550
(EMEA) India, Bangladesh, Sri Lanka
Kohler EMEA Headquarters India Regional Office
Netherlands B.V. Bangalore, India
Kristallaan 1 Phone: (91) 80 3366208
4761 ZC Zevenbergen (91) 80 3366231
The Netherlands Fax: (91) 80 3315972
Phone: (31) 168 331630
Japan, Korea
Fax: (31) 168 331631
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727

14 Service Assistance TP-6694 3/19

 Section 1 Specifications and Features

1.1 Introduction The controller features, accessories, and menu displays

depend upon the engine electronic control module
The spec sheets for each generator set provide model- (ECM) setup and features. Controller features apply to
specific generator and engine information. The generator set models with ECM and non-ECM engines
controller spec sheet provides specifications for this unless otherwise noted.
controller. Refer to the respective spec sheet for data
not supplied in this manual. Refer to the generator set Note: Press the pushbutton/rotary selector dial to turn
service manual, installation manual, engine operation on the controller lights and display. The lights and
manual, and engine service manual for additional display turn off 60 minutes after the last entry
specifications. when in the AUTO mode.

Note: After about 5 minutes of no user input

1.2 Controller Features (pushbutton/rotary selector dial or buttons), the
menu is reset to the top of the main menus and
The controller features include the annunciator lamp, auto-paging activates for the Overview
digital display and pushbutton/rotary selector dial, submenus.
switches and controls, and fuses and terminal strip. The
following paragraphs detail the features by general Note: Measurements display in metric or English units.
topics. Use the Generator Set System menu to change
the measurement display.
See Figure 1-1 for an illustration of the controller front
panel.

1 2 3 4 5

8
FAULT

OFF/RESET AUTO RUN ALARM SILENCE/ 9

LAMP TEST

GM65741-
1. Emergency stop switch 5. Pushbutton/rotary selector dial
2. Generator set master control switches, 6. Annunciator fault lamp
OFF/RESET--AUTO--RUN buttons with lamps 7. Controller terminal strips (on circuit board)
3. Digital display 8. Alarm silence/lamp test button with lamp
4. Alarm horn (behind panel) 9. Mini USB connection

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

TP-6694 3/19 Section 1 Specifications and Features 15

1.2.1 Switches and Controls The pushbutton/rotary selector dial has several features
and functions:
Note: US/Metric Display is selectable in Section
D Momentarily press the dial to activate the digital
1.2.3—Digital Display—Generator Set System
Menu. display if dark.
D Rotate the dial to navigate through the main
Alarm Horn. The alarm horn alerts the operator or other menus—turn clockwise to go forward (down) and
attendants that a shutdown or warning condition exists. counterclockwise to go back (up). The menus do not
wrap to the beginning.
Alarm (Horn) Silence. The alarm silence/lamp test D Press the dial at a given main menu to access the
switch silences the alarm horn at the operator’s submenus within the selected main menu.
discretion. Press the master control switch AUTO
D When in the submenu, rotate the dial to navigate
button before pressing the alarm silence/lamp test
through the submenu—clockwise to go forward
button. The alarm horn cannot be silenced unless the
(down) and counterclockwise to go back (up). The
master control switch AUTO button is pressed.
menus do not wrap to the beginning.
Note: Additional alarm silencing options are shown in D Momentarily press the dial when in the submenu to
Section 1.2.3—Digital Display—Generator Set make a user selection choice (if available) or to go
System Menu. back to the respective main menu.
D Press the dial for at least 3 seconds to return to the top
Restore alarm horn switches at all locations including of the main menus (Overview) regardless if you are in
those on remote annunciator kits after correcting the the main menus or submenus.
fault shutdown to avoid reactivating the alarm horn. See
D After about 5 minutes of no user input (pushbutton/
Section 2—Operation, 2.4.8 Controller Resetting for
rotary selector dial or buttons), the menu resets to the
resetting the controller.
top of the main menus and auto-paging activates for
Emergency Stop. The operator-activated pushbutton the Overview submenus.
immediately shuts down the generator set in emergency
situations. Reset the emergency stop switch after 1.2.2 Annunciator Lamps
shutdown by pulling the emergency stop switch
outward. Use the emergency stop switch for emergency The controller has a single annunciator fault lamp
shutdowns only. Use the master control switch providing visual generator set status. In addition, each
OFF/RESET button for normal shutdowns. button has a corresponding lamp. See Figure 1-2.

Generator Set Master Control Switches Lamp/Button Lamp Color

(OFF/RESET--AUTO--RUN). These switches reset the Alarm (Fault) Lamp Yellow (Warning) or Red (Shutdown)
controller fault lamps and start/stops the generator set. Off/Reset Button Red
Additional information in shown in Section 2— Auto Button Green (System Ready)
Operation. Run Button Yellow
Alarm Silence/Lamp
Test Button Yellow
Lamp Test. Press and hold the Alarm Silence/Lamp
Test button for two seconds to test the controller Figure 1-2 Annunciator Lamps
indicator lamps, alarm horn, and digital display.

Manual Speed Adjust (Engine RPM). The control System Status Lamps (Master Control Switches)
allows varying the engine speed for applications using
The green lamp illuminates on the master control switch
closed transition ATS. The user can set the nominal
AUTO (automatic start) button indicating the system
running frequency slightly above or below the utility
senses no faults and the unit is ready to start by remote
frequency to ensure that synchronization occurs.
command.
Additional information is shown in 2.7.7 GenSet
System. Available as a factory-installed option or The red lamp illuminates on the master control switch
requires a new factory personality profile. OFF/RESET button indicating the generator set is
stopped.
Pushbutton/Rotary Selector Dial. This control
provides access to the menus for monitoring. Press the The yellow lamp illuminates on the master control switch
selector dial to activate the digital display and to select RUN button indicating the generator set is cranking or
choices shown on the display. Rotate the dial to running from a local command.
navigate through the menus.
Only one of the three master control switch lamps will
illuminate at any given time.

16 Section 1 Specifications and Features TP-6694 3/19

Alarm Silence Lamp. Yellow lamp illuminates System Shutdown Fault Lamp. Red lamp indicates
indicating the alarm horn was silenced. that the generator set has shut down because of a fault
condition. The unit will not start without resetting the
(System) Fault Lamp. Yellow lamp illuminates controller, see Section 2.4.8, Controller Resetting
indicating a warning condition or red lamp illuminates procedure.
indicating a shutdown condition. See System Warning
Fault Lamp and System Shutdown Fault Lamp following See Section 2.4.6, System Fault Shutdown Lamp with
for system fault conditions. Digital Displays, for definitions of the items listed. The
following conditions cause a system shutdown:
System Warning Fault Lamp. Yellow lamp identifies
D AC sensing loss
an existing fault condition that does not shut down the
generator set. A continuing system warning fault D Alternator protection
condition may cause a system shutdown. Correct all D Auxiliary input (analog or digital)
system warnings as soon as practical. D Common fault
D ECM address conflict
See Section 2.4.5, System Fault Warning Lamp with
Digital Displays, for definitions of the items listed. The D ECM communications loss
following conditions cause a system warning: D ECM diagnostics (multiple engine inputs)
D AC sensing loss D ECM model mismatch
D Auxiliary input (analog or digital) D Emergency stop
D Battery charger communication loss D Enclosure temperature: high shutdown (available on
D Battery charger fault *
select Telecom units only)
D Engine over speed
Note: Optional input sensors not required with charger D Engine under speed
GM87448. D File system error (controller firmware fault)
D Battery charger identity conflict D Fuel tank leak (diesel-powered models only) *
D Battery charger parameter mismatch D High coolant temperature
D Battery fault D Internal failure
D Common warning D kW overload
D Critical high fuel level (diesel-powered models only) * D Locked rotor (failed to crank)
D Default parameters loaded D Loss of fuel
D ECM diagnostics (multiple engine inputs) D Low coolant level *
D Fuel tank leak (diesel-powered models only) * D Low engine oil level *
D Ground fault * D Low fuel level (diesel-powered models only) *
D High battery voltage D Low oil pressure
D High coolant temperature D Megajector communications loss
D High fuel level (diesel-powered models only) * (GM/PSI and Doosan gas-powered models only)
D Input/output communication loss D Metering communication loss
D Low battery voltage D No coolant temperature signal
D Low coolant temperature D No oil pressure signal
D Low cranking voltage D Overcrank
D Low engine oil level * D Overfrequency
D Low fuel (level for diesel-powered models) * D Overvoltage (each phase)
D Low fuel (pressure for gas-powered models) * D Run relay overload
D Low oil pressure D Underfrequency
D Not-in-auto (master control switch) D Undervoltage (each phase)
D Speed sensor fault D (Voltage) regulator communication loss
* Requires optional input sensors with all battery chargers except * Requires optional input sensors.
battery charger GM87448.

TP-6694 3/19 Section 1 Specifications and Features 17

1.2.3 Digital Display Overview Menu
Press the pushbutton/rotary selector dial to turn on the When a new shutdown or warning fault occurs, the
controller lamps and display. The lamps and display auto-paging display feature activates.
turn off 60 minutes after the last entry.
Active Shutdowns display if any are present. This
Note: The APM402 controller takes about 5--10 alerts the user to single or multiple shutdown fault
seconds to power on. conditions. See 1.2.2—Annunciator Lamps—System
Shutdown Fault Lamp for a list of possible shutdown
The generator set must be running for some displays to faults.
indicate values. If the generator set is not running some
values will display zero or N/A (not available). Active Warnings display if any are present. This alerts
the user to single or multiple warning fault conditions.
Some displays are engine dependent, refer to the See 1.2.2—Annunciator Lamps—System Warning
Appendix, Controller Displays from the Engine ECM. Fault Lamp for a list of possible warning faults.

The 12-character, 2-line backlit heated display provides Generator Set State displays the generator set status:
generator set and engine data, system status, and fault
D Off
information. See Figure 1-1. The digital display shows
abbreviations in some instances, refer to 1.3.1 Status D Standby
Event and Fault Specifications for the abbreviations and D Running
their full descriptions. D Cooldown
D Stopping
Note: US/Metric Unit Display is selectable in
Generator Set System. Average Volts Line-to-Line value displays. For
three-phase configurations the average line-to-line
Note: Display Contrast is selectable in Generator Set voltage of L1, L2, and L3 is displayed. Single-phase
System. The contrast display adjustment allows configurations show the L1-L2 voltage.
user selected resolution values to improve digital
display clarity. Frequency (Hz) value displays for the output AC
voltage.
Note: After about 5 minutes of no user input
(pushbutton/rotary selector dial or buttons), the Current value displays as the average for three-phase
menu resets to the top of the main menus and configurations or the current value for L1-L2 with
auto-paging activates for the Overview single-phase configurations.
submenus.
Average kW displays. For three-phase configurations
The main menus are listed below. Within each main the average line-to-line kilowatts of L1, L2, and L3 is
menu are multiple submenus with descriptions displayed. Single-phase configurations show the L1-L2
following. kilowatts.
D Overview
Coolant Temperature diplays for the engine coolant
D Engine Metering temperature.
D Generator Metering
D GenSet Information Oil Pressure displays the engine oil pressure.
D GenSet Run Time Fuel Level % displays the fuel tank level for diesel-
D GenSet System powered models when so equipped.
D GenSet Calibration (Decision-Makerr 3000
controllers before Version 3.0.25) Fuel Pressure displays fuel pressure for some engines.
D Voltage Regulation Refer to the Appendix, Controller Displays from the
Engine ECM.
D Digital Inputs
D Digital Outputs Battery displays the DC voltage of the engine starting
D Analog Inputs battery(ies).
D Event Log CHG1 and CHG2 display battery charger voltage and
D Volt Select current (amps) if one or two CAN-enabled 10 Amp
battery chargers (GM87448 only) have been
connected. Shows N/A if charger GM87448 was

18 Section 1 Specifications and Features TP-6694 3/19

connected and then removed. (DEC3000 version 4.11 The calibration values are reviewable at all times and
or higher, and APM402) provide the calibration of the voltage and current
sensing logic. Changing the system voltage or replacing
Engine Run Time displays the total run time hours. the circuit board requires a calibration adjustment.
Software Version displays in the Overview menu. Use To enable calibration, start the generator set and select
the version number to determine if an upgrade is the Volts L1-L2 display. Then push and hold the
needed and/or when troubleshooting the controller. pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is
Engine Metering Menu now available. The display will show the following
values for three-phase generator sets. Single-phase
Note: The Engine Metering Menu may vary depending generator sets will only display items marked (*).
upon if the selector dial is rotated clockwise or
D Volts L1-L2 *
counterclockwise.
D Volts L2-L3
Engine Speed (Tachometer) displays the engine D Volts L3-L1
speed in RPM. D Volts L1-N *

Oil Pressure displays the engine oil pressure. This D Volts L2-N *
value also shows in the Overview Menu. D Volts L3-N
D Current L1 *
Coolant Temperature displays the engine coolant
D Current L2 *
temperature. This value also shows in the Overview
Menu. D Current L3

The user can change individual values or can select

Fuel Level % displays the fuel tank level for diesel-
Reset Calib?--Yes to reset all values. The Reset Calib?
powered models if so equipped. This value also shows
display will only show if calibration is enabled. Refer to
in the Overview Menu.
the requirements shown with Generator Set Calibration
Battery displays the DC voltage of the engine starting in 2.4.7 Status and Notice Digital Displays.
battery(ies). This value also shows in the Overview To disable calibration, Rotate the pushbutton/rotary
Menu. selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Fuel Pressure displays fuel pressure for some engines.
Stop the generator set if not already done.
Refer to the Appendix, Controller Displays from the
Engine ECM. This value also shows in the Overview
Menu. Generator Set Information Menu
GenSet M/N displays the generator set model number.
Generator Metering Menu
GenSet S/N displays the generator set serial number.
Total Power kVA and kW displays alternator output as
actual output values. Controller S/N displays the controller serial number.

Rated Power displays alternator output as a Generator Set Run Time Menu
percentage of the entered data value.
Engine Run Time displays the total run time hours.
Volts displays the alternator output AC voltages. The This value also shows in the Overview Menu.
display shows all line-to-line and line-to-neutral voltage
combinations for three-phase or single-phase Engine Loaded displays the total loaded hours.
configurations.
Engine Starts displays the total number of generator
Current displays the alternator output AC amps. The set startup events.
display shows each line (L1-L2-L3) of three-phase
models or L1-L2 current for single-phase models. Total Energy displays the total kW hours.

Frequency (Hz) value displays for the output AC

voltage. This value also shows in the Overview Menu.

Reset Calibration providing the means to reset the

configuration values is available in this menu.

TP-6694 3/19 Section 1 Specifications and Features 19

Generator Set System Menu Generator Set (Reset) Calibration Menu
The values in this menus are user-entered for the This menu is only available in Decision-Makerr 3000
generator set configuration and are NOT measured controller firmware versions before 3.0.25. On
values of the generator set. Decision-Makerr 3000 controllers with later firmware
versions, or on APM402 controllers, go to Generator
Changes to the Generator Set System menu require the Metering Menu—Reset Calibration.
use of SiteTecht software except for Measure System
and Contrast selections. The calibration values are reviewable at all times and
provide the calibration of the voltage and current
System Frequency displays the programmer-entered sensing logic. Changing the system voltage or replacing
L1-L2-L3 output voltage frequency for three-phase or the circuit board requires a calibration adjustment. In
the L1-L2 output voltage frequency for single-phase. order to review the values when the generator set is
NOT running, enter Yes when the Enter Calib? is
System Phase displays the programmer-entered
displayed. The user can review the values but
configuration as Single Phase, Single Phase Dog Leg,
attempting to change the values will cause a Cannot
Three Phase Wye, or Three Phase Delta.
calibrate error message.
System Voltage displays the programmer-entered
If the unit is NOT running and No is entered when the
L1-L2-L3 output voltage for three-phase or the L1-L2
Enter Calib? is shown, the display returns to the
output voltage for single-phase.
Generator Set Calibration main menu and entry to the
Power Rating displays the programmer entered kW Generator Set Calibration menu is denied.
value for the generator set.
If the unit is running and Yes is entered when the Enter
Amp Rating displays the programmer entered current Calib? is shown, the display will show the following
value for the generator set. values for three-phase generator sets. Single-phase
generator sets will only display items marked (*).
Power Type displays the programmer entered D Volts L1-L2 *
generator set application configuration as Standby or D Volts L2-L3
Prime.
D Volts L3-L1
Battery Voltage displays the engine electrical system D Volts L1-N *
12 or 24 volts. D Volts L2-N *
D Volts L3-N
Measurement System displays the user selected unit
of measure as Metric or English. D Current L1 *
D Current L2 *
Contrast displays user selected resolution values to D Current L3
improve digital display clarity.
The user can change individual values or can enter Yes
Alarm (Horn) Silence displays the programmer when Reset all Calib? is displayed. At the end of the
selected alarm silence method as Always or Auto Only Generator Set Calibration menu, Exit calibration is
using SiteTecht software. The Always selection allows shown. Press the pushbutton/rotary selector dial to exit
the alarm to be silenced in any of the this menu. Refer to the requirements shown with
OFF/RESET--AUTO--RUN modes. The Auto Only Generator Set Calibration in 2.4.7 Status and Notice
selection allows silencing of the alarm only while in the Digital Displays.
Auto mode.

Note: Press the Alarm Silence/Lamp Test button to

silence the alarm horn.

Manual Speed Adjust (Engine RPM) is available as a

user selectable adjustment. The user can set the
nominal running frequency slightly above or below the
utility frequency to ensure that synchronization occurs.
Refer to 2.7.7 GenSet System for more information.
Available as a factory-installed option or requires a new
factory personality profile.

20 Section 1 Specifications and Features TP-6694 3/19

Voltage Regulator Menu Digital Inputs Menu
Decision-Makerr 3000 Controller firmware before This menu allows the user to review the settings. There
3.0.25: are up to three digital inputs that are programmer
selectable if not reserved by factory options.
The voltage regulator value is reviewable at all times. In
order to review the value when the generator set is NOT The displays for digital inputs appear as shown below
running, enter Yes when the Enter volt reg? is displayed. with Values true or false. Items shown in the digital
The user can review the value but attempting to change display as True are active.
the value will cause a Cannot edit when stopped error D DIn A1 (digital input A1) standard
message.
D DIn A2 (digital input A2) standard
If the unit is NOT running and No is entered when the D DIn A3 (digital input A3) standard (see note below)
Enter volt reg? is shown, the display returns to the D DIn B1 (digital input B1) with I/O module board
Voltage Regulator main menu and entry to the Voltage D DIn B2 (digital input B2) with I/O module board
Regulator menu is denied.
Changes to the Digital Inputs menu requires the use of
If the unit is running and Yes is entered when the Enter SiteTecht software. The digital input can either open or
volt reg? is shown, the display will show the value. close the circuit to activate.
Note: DIn A3 digital input is factory reserved for
The user can change the value at this time. At the end of Enclosure Temperature: High Shutdown on
the Voltage Regulator menu, Exit voltage reg is select Telecom units.
shown----press the pushbutton/rotary selector dial to exit
this menu.
Digital Outputs Menu
Decision-Makerr 3000 Controller firmware 3.0.25 and
This menu allows the user to review the settings. There
higher, or APM402 Controller:
is one digital output standard with the controller that is
The voltage regulator value is reviewable at all times programmer selectable. The one SPDT switch has
and provides the ability to fine adjust voltage. Changing 2 amp. contacts at 32 VDC or 0.5 amp. contacts at
the system voltage or replacing the circuit board 120 VAC max.
typically requires a voltage adjustment.
There is an optional 2 input/5 output (I/O) module board
To enable calibration, start the generator set and select available that can provide five digital outputs. The
the VR Volt Adj display. Then push and hold the standard digital output on the controller is used to drive
pushbutton/rotary selector dial until the Editing Enabled the optional I/O Module board and becomes factory
popup appears. Editing of the voltage adjustment is now reserved and no longer available as programmer
available. selectable.

The user can change the individual value or can select The displays for digital outputs appear as shown in the
Reset VR?--Yes to reset to the default value. The Reset following list with Values as True or False. Items shown
VR Settings display will only show if editing is enabled. in the digital display as True are active.
D DOut A1 (digital output A1) standard
To disable calibration, Rotate the pushbutton/rotary
D DOut B1 (digital output B1) with I/O module board
selector dial until the <--Return popup appears.
Momentarily press the pushbutton/rotary selector dial. D DOut B2 (digital output B2) with I/O module board
Stop the generator set if not already done. D DOut B3 (digital output B3) with I/O module board
D DOut B4 (digital output B4) with I/O module board
D DOut B5 (digital output B5) with I/O module board

Changes to the Digital Outputs menu requires the use of

SiteTecht software. The digital output can either open
or close the circuit to activate.

TP-6694 3/19 Section 1 Specifications and Features 21

Analog Inputs Menu Volt Select Menu
This menu allows the user to review the settings. There Note: The generator set must be stopped before
is one analog input that is programmer selectable if not changing the voltage selection.
reserved by factory options.
This menu allows the user to readily change controller
There is an optional 2 input/5 output (I/O) module board voltage settings. The volt select feature is typically used
available that can provide two additional analog inputs. in towable or temporary applications.

The displays for analog inputs appear as shown below Note: The volt select menu requires initial activation by
with Values of 0--5 volts. SiteTecht software. In SiteTecht software,
D AIn A1 (analog input A1) standard
select True to activate the volt select menu.
(reserved and not user programmable) Note: The generator set output leads require voltage
D AIn A2 (analog input A2) standard reconnection if the generator set does not have a
D AIn B1 (analog input B1) with I/O module board voltage selector switch installed.
D AIn B2 (analog input B2) with I/O module board
With the generator set stopped, go to the Volt Select
Changes to the Analog Inputs menu requires the use of menu. Then push and hold the pushbutton/rotary
SiteTecht software. selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
Event Log Menu voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.
This menu allows the user to review up to 1000 entries of
system events including shutdown faults, warning The displays for Volt Select appear as shown in the
faults, and status events. See 1.2.4 Controller Fault following list.
Diagnostics for a list of the items that appear on the
D 120/240 V 1 Ph
Event Log.
D 120/208 V 3 Ph
D 139/240 V 3 Ph
D 277/480 V 3 Ph
D 120/240 V 3 Ph

22 Section 1 Specifications and Features TP-6694 3/19

1.2.4 Controller Fault Diagnostics that is NOT part of the event history. System events are
available as a Relay Output as shown.
This table provides descriptions of the system events
and their types—warning, shutdown, status, and notice. Throughout this manual there are examples of the
display text. In some cases, the message words and
Warnings show yellow fault lamp and signal an phrases are abbreviated or shortened to accommodate
impending problem. Shutdowns show red fault lamp the number of characters in the 12 x 2 digital display.
and stop the generator set. Status is an event that is not See the following table for a full description of the system
an alert but is part of the event history. Notice is an alert event display messages.

System Events Display Message List

Warning Shutdown Status/ Relay
Description Display Message Function Function Notice Output
Engine Functions
Critically high fuel level (diesel-powered models only) * Fuel Level Critically High X X
ECM communications loss ECM Comm Err Shutdwn X X
ECM diagnostics (multiple inputs) [ ECM xxxxxx Warning X X
ECM diagnostics (multiple inputs) [ ECM xxxxxx Shutdwn X X
ECM faults (address conflict) ECM Addr Err Shutdwn X X
ECM faults (model mismatch) ECM Mismatch Shutdwn X X
Engine over speed Eng Speed High Shutdwn X] X
Engine start aid active Starting Aid Notice N X
Engine under speed Eng Speed Low Shutdwn X X
Fuel tank leak * Fuel Leak Warning X X
Fuel tank leak * Fuel Leak Shutdwn X X
High battery voltage Battery High Warning X X
High coolant (engine) temperature Coolnt Temp High Warning X X
High coolant (engine) temperature Coolnt Temp High Shutdwn X] X
High fuel level (diesel-powered models only) * Fuel Level High Warning X X
Loss of fuel Loss of fuel X X
Low battery voltage Battery Low Warning X X
Low coolant level * Coolant Lvl Low Shutdwn X X
Low coolant temperature Coolant Temp Low Warning X X
Low cranking voltage Lo Crank Vlt Warning X X
Low engine oil level * Oil Level Low Warning X X
Low engine oil level * Oil Level Low Shutdwn X X
Low fuel level (diesel models) * Fuel Level Low Warning X X
Low fuel level (diesel models) * Fuel Level Low Shutdwn X X
Low fuel pressure (gas models) * Fuel Press Low Warning X X
Low oil pressure Oil Press Low Warning X X
Low oil pressure Oil Press Low Shutdwn X] X
No coolant temperature signal Temp Sig Loss Shutdwn X X
No oil pressure signal Press Sig Loss Shutdwn X X
Overcrank Over Crank Shutdwn X] X
Speed sensor fault Spd Sens Flt Warning X X

TP-6694 3/19 Section 1 Specifications and Features 23

 Warning Shutdown Status/ Relay
Description Display Message Function Function Notice Output
General Functions
Alarm horn silenced (Alarm Silence LED only) X
Alarm silence, auto only (NFPA 110) or always AlrmSilence: Auto Only or
S No
AlrmSilence: Always
Aux. inputs 0--5 VDC, 1 analog
Aux Input Warning X X
(2 additional inputs available with I/O module option)
Aux. inputs 0--5 VDC, 1 analog
Aux Input Shutdwn X X
(2 additional inputs available with I/O module option)
Auxiliary inputs, up to 3 digital
Aux Input Warning X X
(2 additional inputs available with I/O module option)
Auxiliary inputs, up to 3 digital
Aux Input Shutdwn X X
(2 additional inputs available with I/O module option)
Backup parameters loaded Backup Pars Status S No
Battery charger 1 communication loss Bat1CommLoss X
Battery charger 2 communication loss Bat2CommLoss X
Battery charger fault * (* does not apply to charger Batt Chg Flt X
X
GM87448)
Battery charger identity conflict BatIdErr X
Battery charger parameter mismatch Param Mismatch X
Battery Fault Battery Flt X
Chicago code active Auto Locked Notice N X
Common fault (includes ]) Common Fault Shutdwn X N X
Common warning fault Common Warng X N X
Default parameters loaded Default Pars Warning X X
Emergency stop Emerg Stop Shutdwn X] X
Enclosure temperature: high shutdown Enclsr Temp: High Shutdwn X X
Engine cooldown (delay) active Eng Cooldown Notice N X
Engine start delay active Start Delay Notice N X
Engine started Engine Start Status S X
Engine stopped Engine Stop Status S X
EPS supplying load Emerg Pwr On Notice N X
File system error (controller fault) File Error Shutdwn X X
Generator running Gen Running Notice N X
Input/output (module option board) communication loss OB1 Com Loss X X
Internal failure Intern Error Shutdwn X X
Metering communication loss MeterCommLos Shutdwn X X
NFPA 110 alarm active NFPA Alarm Notice N X
Not in auto (master switch) Not In Auto Warning X X
Remote start Remote Start Status S X
System ready System Ready Status S X
System timer failed Timer Error Notice N X
Generator Functions
AC sensing loss AC Sens Loss Warning X X
AC sensing loss AC Sens Loss Shutdwn X X
Alternator protection Alt Protect Shutdwn X X
Ground fault input * Ground Fault Warning X X
kW overload Total Power High Shutdwn X X
Locked rotor (failed to crank) Locked Rotor Shutdwn X X
Overfrequency Freq High Shutdwn X X
Overvoltage (each phase) Volts xx--xx High Shutdwn X X
Underfrequency Frequency Low Shutdwn X X
Undervoltage (each phase) Volts xx--xx Low Shutdwn X X
(Voltage) regulator communication loss RegCommLoss Shutdwn X X
* Function requires optional input sensors or kits or is engine ECM dependent on some generator set models.
[ ECM inputs are engine manufacturer dependent.
] The Common Fault Shutdown includes the items marked X] in the Shutdown Function column.

24 Section 1 Specifications and Features TP-6694 3/19

1.2.5 Digital Display Circuit Board and 1.2.6 Main Logic Circuit Board
Connections
The main logic circuit board provides the terminal strips
The digital display circuit board provides: and connection sockets to connect the controller to the
engine/generator, input/output connections, optional
D The backlit LCD (liquid crystal display) for monitoring
I/O module kit, and circuit protection fuses. See
the generator set functions and output values Figure 1-4 and Figure 1-5 for the circuit board
D Master control switches with status lights connections. See Section 6, Accessories for more
D Fault lamp information.
D Pushbutton/rotary selector dial to navigate the
generator set displays
1
D Alarm horn and alarm silence/lamp test switch/light 2
D Mini USB connector for PC setup using SiteTecht
software
See Figure 1-3 for the circuit board connections.

Circuit Board Connections

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

P10 Connector mini USB for PC upgrades located on

the front panel using SiteTecht software.

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

GM65741-
1. Main logic circuit board
2. Remote emergency stop switch

Figure 1-4 Main Circuit Board and Emergency Stop

Switch

Circuit Board Connections

P1 (24-Pin) Connector for engine/generator wiring
harness.
1 P2 (6-Pin) Connector for AC current.

(4) Push-on Connectors for V7/V8/V9/V0 for

generator set output voltage connection.
2
3

GM65741-
1. P9 24-pin connector (opposite side) connects to main board
2. P10 5-pin mini USB connector
3. P11 20-pin connector (not used)

Figure 1-3 Digital Display Circuit Board Connectors

TP-6694 3/19 Section 1 Specifications and Features 25

 1.2.8 Communication Ports
The main logic circuit board contains a single mini USB
1
communication port for PC connections, see Figure 1-6.
For Modbusr communication using RS-485, see
Figure 1-5 (P21). Refer to the List of Related Materials
10 in the Introduction for corresponding SiteTecht
2
software and/or communication installation information.
3
9

GM64345-1-A
7 6 5
1. (4) push-on terminal connectors
2. TB2 4-position terminal block
3. TB3 6-position terminal block
4. P2 6-pin connector
5. P1 24-pin connector
GM65741-
6. TB1 6-position terminal block 1
7. P22 3-pin connector 1. Mini USB connection
8. P30 jumper (Wound Field or Fast Response)
9. P23 8-pin connector (RJ45) Figure 1-6 Communication Port
10. P21 6-pin connector (for RS-485 communication)

Figure 1-5 Main Circuit Board Connectors 1.2.9 Fuses

P21 (6-Pin) Connector for (RS-485) connection of AC Circuit Fuses (TB5). Fuses are located inside the
optional RSA or Modbusr communication. generator set control box. See Figure 1-7

P22 (3-Pin) Connector for engine ECM. Alternate CAN D 1.5-Amp (V7) fuse protects L1 sensing input to
connection. interconnection circuit board.

P23 (8-Pin) Connector (RJ45) for optional input/output D 1.5-Amp (V8) fuse protects L2 sensing input to
(I/O) module circuit board. interconnection circuit board.

Refer to Section 6.2, Accessory Connections for D 1.5-Amp (V9) fuse protects L3 sensing input to
specific connections of the following terminal block interconnection circuit board.
connections.
DC Circuit Fuses are located on the controller circuit
TB1 (6-Position) Terminal Block for analog and digital board. See Figure 1-8.
inputs.
D 1-Amp (F1) auto-resettable, fuse protects the
TB2 (4-Position) Terminal Block for K1 relay outputs. controller circuits.

TB3 (6-Position) Terminal Block for E-stop, remote D 1-Amp (F2) auto-resettable fuse protects the
start contacts, and aux. input connections. controller circuits.

D 12-Amp (F3) non-replaceable fuse protects the

1.2.7 Terminal Jumper engine/starting circuitry and accessories.

A circuit board P30 jumper is set based on alternator

type—Wound Field (300 kW and larger) or
Fast Response (less than 350 kW). The jumper is
factory set and needs no further adjustment. See
Figure 1-5 for location of the P30 jumper.
Modbusr is a registered trademark of Schneider Electric.

26 Section 1 Specifications and Features TP-6694 3/19

 1.3 Controller Logic Specifications
The controller logic specifications section is an overview
of the various features and functions of the controller.
Certain features function only when optional
accessories are connected. See Section 2, Operation,
for details.

The default selection time delays and digital outputs are

factory set and adjustable. Data entries require using a
PC and SiteTecht software. See the SiteTecht
software operation manual for details.

Inhibit Time Delay. The inhibit time delay is the time

period following crank disconnect during which the
1 GM69407 generator set stabilizes and the controller does not
1. V7/V8/V9 fuses, 1.5 Amp. (qty. 3) detect a fault or status event. Select the desired inhibit
Figure 1-7 AC Circuit Fuses in Control Box time delay from 0 to 60 seconds.

TIme Delay (Shutdown or Warning). The time delay

follows the inhibit time delay. The time delay is the time
period between when the controller first detects a fault or
status event and the controller warning or shutdown
lamp illuminates. The delay prevents nuisance alarms.
Select the desired time delay from 0 to 60 seconds.

1.3.1 Status Event and Fault

Specifications
2
The Factory-Defined Settings List contains all status
3 events and faults with ranges and time delays including
items that do not have user adjustments.

1 Note: The engine ECM may limit the crank cycle even if
the controller is set to a longer time period.

GM64345-C
1. F1 1 Amp. auto-resettable
2. F2 1 Amp. auto-resettable
3. F3 12 Amp. non-replaceable

Figure 1-8 Controller DC Fuses

TP-6694 3/19 Section 1 Specifications and Features 27

Factory-Defined Settings List
GenSet
Fault Write Mode Time Default
Lamp Access Always Delay Time
Controller Display Alarm Warning Display Running Range Default Range Delay
Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.)
Engine Functions
Critically high fuel level Fuel Level Critically
On W 0--100% 95% 0--10 5
(diesel-powered models only) * High
ECM communications loss ECM Comm Err
On S Fixed 10
Shutdwn
ECM diagnostics (multiple
ECM xxxxxx Warning On W
inputs) [
ECM diagnostics (multiple
ECM xxxxxx Shutdwn On S
inputs) [
ECM faults (address conflict) ECM Addr Err
On S
Shutdwn
ECM faults (model mismatch) ECM Mismatch
On S 0--255 0
Shutdwn
Engine over speed Eng Speed High
On S S A 105--120% 115%
Shutdwn
Engine start aid active Starting Aid Notice
Engine under speed Eng Speed Low
On S S A 75--95% 85%
Shutdwn
Fuel tank leak * Fuel Leak Warning On W
Fuel tank leak * Fuel Leak Shutdwn On S
High battery voltage Battery High Warning On W S A 110--135% 125% Fixed 10
High coolant temperature 0
0--10
Coolnt Temp High (5 FAA)
On W (0--30
Warning (0
inhibit)
inhibit)
High coolant temperature 0--10 0
Coolnt Temp High
On S (0--30 (0
Shutdwn
inhibit) inhibit)
High fuel level (diesel-powered Fuel Level High
On W 0--100% 90% 0--10 5
models only) * Warning
Loss of fuel Loss of Fuel On S
Low battery voltage Battery Low Warning On W S A 80--105% 100% Fixed 90
Low coolant level * Coolant Lvl Low
On S Fixed 5
Shutdwn
Low coolant temperature 0--10 5
Coolant Temp Low 16_C
On W Fixed (0--30 (0
Warning (60_F)
inhibit) inhibit)
Low cranking voltage Lo Crank Vlt Warning On W Fixed 60% Fixed 6
Low engine oil level * Oil Level Low Warning On W
Low engine oil level * Oil Level Low Shutdwn On S
Low fuel level (diesel models) * Fuel Level Low
On W 0--100% 35% 0--10 10
Warning
Low fuel level (diesel models) * Fuel Level Low
On S 0--100% 5% 0--10 0
Shutdwn
Low fuel pressure Fuel Press Low
On W
(gas models) * Warning
Low oil pressure Fixed 0
Oil Press Low Warning On W (Fixed (30
inhibit) inhibit)
Low oil pressure Fixed 5
Oil Press Low
On S (Fixed (30
Shutdwn
inhibit) inhibit)
* Function requires optional input sensors or is engine ECM dependent on some generator set models.
[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
battery charger operation manual.

ST--Short Term, LT--Long Term

28 Section 1 Specifications and Features TP-6694 3/19

 GenSet
Fault Write Mode Time Default
Lamp Access Always Delay Time
Controller Display Alarm Warning Display Running Range Default Range Delay
Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.)
No coolant temperature signal Temp Sig Loss
On S
Shutdwn
No oil pressure signal Press Sig Loss
On S Fixed 5
Shutdwn
Overcrank (30
Over Crank Shutdwn On S Fixed
inhibit)
Speed sensor fault Spd Sens Flt Warning On W
General Functions
Alarm silence, 0--Auto only
AlarmSilenceMode S A 0--1 1
(NFPA 110), 1--Always
Aux. inputs 0--5 VDC, 1 analog Aux Input Warning On W 0--100% 100% 0--10 0
Aux. inputs 0--5 VDC, 1 analog Aux Input Shutdwn On S 0--100% 100% 0--10 0
Auxiliary inputs, up to 3 digital
0--10
(2 additional digital inputs 0 (0
Aux Input Warning On W (0--30
available with I/O module inhibit)
inhibit)
option)
Auxiliary inputs, up to 3 digital
0--10
(2 additional digital inputs 0 (0
Aux Input Shutdwn On S (0--30
available with I/O module inhibit)
inhibit)
option)
Backup parameters loaded Backup Pars Status
Battery charger 1
Bat1CommLoss On W
communication loss
Battery charger 2
Bat2CommLoss On W
communication loss
Battery charger fault *
(does not apply to charger Batt Chg Flt On W
GM87448)
Battery charger identity conflict BatIdErr On W
Battery charger parameter
ParMisatch On W
mismatch
Battery fault Battery Flt On W
Chicago code active * Auto Locked Notice
Common fault Common Fault
On S
Shutdwn
Common warning Common Warng On W
Default parameters loaded Default Pars Warning On W
Emergency stop Emerg Stop Shutdwn On S
Enclosure temperature: high Enclsr Temp: High 5 (20
On S Fixed Active Fixed
shutdown Shutdwn inhibit)
Engine cooldown (delay) active Eng Cooldown Notice
Engine start delay active Start Delay Notice
Engine started Engine Start Status
Engine stopped Engine Stop Status
EPS supplying load Emerg Pwr On Notice
File system error (controller
File Error Shutdwn On S
fault)
Generator running Gen Running Notice
Input/output (optional module
OB1 Com Loss On W
board) communication loss
Internal failure Intern Error Shutdwn On S
* Function requires optional input sensors or is engine ECM dependent on some generator set models.
[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
battery charger operation manual.

ST--Short Term, LT--Long Term

TP-6694 3/19 Section 1 Specifications and Features 29

 GenSet
Fault Write Mode Time Default
Lamp Access Always Delay Time
Controller Display Alarm Warning Display Running Range Default Range Delay
Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.)
Measurement Units,
Measurement Display DS A 0--1 1
0--English, 1--Metric
Metering communication loss MeterCommLos
On S
Shutdwn
NFPA 110 alarm active NFPA Alarm Notice
Not in auto (master control
Not In Auto Warning On W
buttons)
Prime power application,
Power Type DS A 0--1 0
0--Standby, 1--Prime
Remote start Remote Start Status
System ready System Ready Status
System timer failed Timer Error Notice
Generator Functions
AC sensing loss AC Sens Loss
On W
Warning
AC sensing loss AC Sens Loss
On S Fixed 3
Shutdwn
Alternator protection Alt Protect Shutdwn On S
Ground fault input * Ground Fault Warning On W
kW overload 102%
Total Power High standby,
On S Fixed Fixed 60
Shutdwn 112%
prime
Locked rotor (failed to crank) Locked Rotor Shutdwn On S S A 1--5 5
Overfrequency Freq High Shutdwn On S 102--140% 110% Fixed 10
Overvoltage (each phase) Volts (L1--L2, L2--L3,
or L3--L1) High On S S A 105--135% 120% 2--10 2
Shutdwn
Power rating Pwr Rating DS S 10--5000 275
System frequency System Freq DS S 50--60 60
System voltage System Volt DS S 110--600 208
Underfrequency Frequency Low 10 ST
On S 80--95% 90% Fixed
Shutdwn 60 LT
Undervoltage (each phase) Volts (L1--L2, L2--L3,
or L3--L1) Low On S S A 70--95% 80% 5--30 10
Shutdwn
Voltage/phase configuration,
0--Single phase, 1--Single
SystemPhase DS S 0--3 2
phase dogleg, 2--three phase
wye, 3--three phase delta
Voltage regulator average
VR Volt Adj DS R 108--600 208
voltage adjustment
(Voltage) regulator RegCommLoss
On S
communication loss Shutdwn
SiteTech Read/Write Display Only
Charger Absorption Current
S A 1–5 2
Termination Target (A)
Charger Automatic Equalize
Enable
Active
Note: Equalize is only S A Inactive
Inactive
available with FLA/VRLA
topology selected.
* Function requires optional input sensors or is engine ECM dependent on some generator set models.
[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
battery charger operation manual.

ST--Short Term, LT--Long Term

30 Section 1 Specifications and Features TP-6694 3/19

 GenSet
Fault Write Mode Time Default
Lamp Access Always Delay Time
Controller Display Alarm Warning Display Running Range Default Range Delay
Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.)
Charger Charge Cycles
Between Auto Equalize Cycles
Note: Equalize is only S A 0 – 99
available with FLA/VRLA
topology selected.
Charger Custom Profile Enable Active
S A Inactive
Inactive
Charger Depleted Battery
S A 1–5 2
Current Limit
Charger Depleted Battery 4 – 12 10
Voltage Target (12 V) (12 V)
S A
18 – 24 20
(24 V) (24 V)
Charger Equalize Stage
Duration (Min)
Note: Equalize is only S A 60 – 480
available with FLA/VRLA
topology selected.
Charger Manual Equalize
Cycle Activation
Active
Note: Equalize is only S A Inactive
Inactive
available with FLA/VRLA
topology selected.
Charger Maximum Absorption 60 – 360
Time Threshold (Min.) 60 – 600
S A 240
(NiCad
only)
Charger Maximum Bulk Time
S A 60 – 600 480
Threshold (Min)
Charger Refresh Charge Cycle 0,
S A 335
Time (Hr) 23 – 672
Charger Return To Bulk State 10 – 13 12.8
Voltage Threshold (V) (12 V)** (12 V)
S A
20 – 26 25.6
(24 V)** (24 V)
Charger Starter Battery
Topology
Note: Verify that the battery Default
topology is set correctly for the FLA/VRLA
battery type that is used. S A AGM Default
Incorrect charger output Gel
system voltage may cause NiCad
irreversible damage to the
battery and abnormal out
gassing.
Charger System Battery
Voltage
Note: Verify that the system
voltage is set correctly for the System 12
battery type that is used. VDC
S A 12 VDC
Incorrect charger output System 24
system voltage may cause VDC
irreversible damage to the
battery and abnormal out
gassing.
* Function requires optional input sensors or is engine ECM dependent on some generator set models.
[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
battery charger operation manual.

ST--Short Term, LT--Long Term

TP-6694 3/19 Section 1 Specifications and Features 31

 GenSet
Fault Write Mode Time Default
Lamp Access Always Delay Time
Controller Display Alarm Warning Display Running Range Default Range Delay
Description Message Horn Shutdown SiteTech Stopped Setting Selection (sec.) (sec.)
Charger Temperature Active
S A Inactive
Compensation Enable Inactive
Charger Temperature --40 – 0 -30
Compensation Slope (mV/
C) (12 V) (12 V)
S A
-80 – 0 --60
(24 V) (24 V)
Charger Voltage Absorption 13 – 15 14.25
(V) (12 V)** (12 V)
S A
26 – 30 28.5
(24 V)** (24 V)
Charger Voltage Bulk (V) 13 – 15 14.25
(12 V)** (12 V)
S A
26 – 30 28.5
(24 V)** (24 V)
Charger Voltage Equalize (V) 14 – 16
Note: Equalize is only (12 V)
S A
available with FLA/VRLA 28 – 32
topology selected. (24 V)
Charger Voltage Float (V) 13 – 14 13.25
(12 V)** (12 V)
S A
26 – 28 26.5
(24 V)** (24 V)
Current transformer ratio ] S S 1-- 1200
ECM power S S 0--1 0
Engine cooldown delay S A 0--600 300
Engine (cyclic) crank on S A 10--30 15
Engine (cyclic) crank pause S A 1--60 15
Engine ECM start delay S A 0--300 0
Engine idle duration S A 0--60 60
Engine no. of (cyclic) crank
S S 1--6 3
cycles
Engine restart delay S A 1--10 10
Engine start aid delay S A 0--10 0
Engine start delay S A 0--300 0
Equalize Current Limit (A)
Note: Equalize is only S A 1–5
available with FLA/VRLA
topology selected.
Forced Charge Cycle Reset Active
S A Inactive
Inactive
Output Enable Fixed Active
System battery voltage ] S S 12--24 12
Voltage regulator gain S R 1--255 128
Voltage regulator stability
S R 1--255 128
adjust
Voltage regulator, volts per
S R 1--10 5
Hertz slope
Voltage regulator, volts per
S R 42--62 57.5
Hertz cut in frequency
* Function requires optional input sensors or is engine ECM dependent on some generator set models.
[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the
battery charger operation manual.

ST--Short Term, LT--Long Term

32 Section 1 Specifications and Features TP-6694 3/19

1.3.2 Voltage Regulator and Calibration Underfrequency Unload Frequency Setpoint. This
Specifications adjustment affects the voltage droop (volts per Hz) when
load is applied and underfrequency occurs. The
The controller has a voltage regulation function that is underfrequency unload setting defines the setpoint
internal to the processor. This means that no external where underfrequency starts. Any frequency below the
voltage regulator is necessary. The voltage regulation setpoint causes the voltage to drop thus reducing the
of the controller uses root mean square (rms) sensing load allowing the engine speed to recover according to
for fast response to changes in indicated and regulated the underfrequency unload slope setting.
voltages resulting in excellent regulation accuracy.
Engine speed recovery depends upon characteristics
such as engine make, fuel type, load types, and
1.3.3 Voltage Regulator Adjustments operating conditions. The underfrequency unload
setting should match the engine speed recovery
The descriptions of the voltage regulator adjustments
characteristics for the application.
and features follow. Refer to the Factory-Defined
Settings List shown in 1.3.1 for voltage regulator Underfrequency Unload Slope. This setting
adjustments. See Appendix C, Voltage Regulator determines how much the voltage drops during an
Definitions and Adjustments, for additional information underfrequency condition. Typically, applying a large
and to customize adjustments for specific applications. electrical load causes a dip in engine speed and
frequency. The voltage regulator reduces voltage,
Voltage Adjustment. The voltage adjustment allows
allowing engine speed recovery. The volts-per-Hz
the user to enter the desired generator set output level.
setting determines the amount of voltage drop.
This regulated level setting is the average of the three
line-to-line voltages in three-phase configurations or Regulator Gain. Regulator gain refers to the gain of the
L1-to-L2 in single phase configurations. control system. Generally, the higher the gain the faster
the system responds to changes and the lower the gain,
Submenus display the individual line-to-line voltages.
the more stable the system.
These voltages are for reference only and are relevant
in unbalanced load conditions. The voltage adjust If the voltage is slow to recover when loads are applied
setpoint can be changed to accommodate an important or removed, increase the regulator gain. If the voltage is
phase in an unbalanced system. unstable, decrease the regulator gain.

TP-6694 3/19 Section 1 Specifications and Features 33

 Notes

34 Section 1 Specifications and Features TP-6694 3/19

 Section 2 Operation

2.1 Prestart Checklist D Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps
To ensure continued satisfactory operation, perform the and/or hangers as needed.
following checks or inspections before or at each
startup, as designated, and at the intervals specified in D Check that the exhaust outlet is unobstructed.
the service schedule. In addition, some checks require
D Visually inspect for exhaust leaks (blowby). Check
verification after the unit starts.
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
DANGER Seal leaks as needed.

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

Oil Level. Maintain the oil level at or near, not over, the
Hazardous voltage. Moving parts. full mark on the dipstick.
Will cause severe injury or death.
Operate the generator set only when Operating Area. Check for obstructions that could
all guards and electrical enclosures block the flow of cooling air. Keep the air intake area
are in place. clean. Do not leave rags, tools, or debris on or near the
generator set.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering engine. 2.2 Exercising Generator Set
Air Inlets. Check for clean and unobstructed air inlets.
DANGER
Battery. 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

Hazardous voltage. Moving parts.
cooling system maintenance information.
Will cause severe injury or death.
Note: Block Heater Damage. The block heater will fail Operate the generator set only when
if the energized heater element is not immersed all guards and electrical enclosures
in coolant. Fill the cooling system before turning are in place.
on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from Operate the generator set under load once each week
the system before energizing the block heater. for one hour. Perform the exercise in the presence of an
operator when the generator set does not have an
Drive Belts. Check the belt condition and tension of the automatic transfer switch with an exercise option.
radiator fan, water pump, and battery charging
alternator belt(s) according to the drive belt system During the exercise period, apply a minimum of 35%
maintenance information. load based on the nameplate standby rating, unless
otherwise instructed in the engine operation manual.
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and The operator should perform all of the prestart checks
check for tight exhaust system connections. before starting the manual exercise procedure. Start
the generator set according to the starting procedure in
Inspect the exhaust system components (exhaust Section 2.4, Controller Operation. While the generator
manifold, exhaust line, flexible exhaust, clamps, set is operating, listen for a smooth-running engine and
silencer, and outlet pipe) for cracks, leaks, and visually inspect generator set for fluid or exhaust leaks.
corrosion.
The generator set controller does not provide weekly
D Check for corroded or broken metal parts and replace scheduled exercise periods. For scheduled exercise
them as needed. periods, refer to the automatic transfer switch (if
equipped) literature.

TP-6694 3/19 Section 2 Operation 35

2.3 Operation in Cold Weather system and operated at or below 50% of rated load.
Wrap the UL/CSA compliant heater tape around the
Climates crankcase canister/breather system hose that runs
Cold weather operation is generally considered ambient from the crankcase to the air intake and use cable ties
temperatures below freezing 0C (32F). The following as needed to secure the heater tape. If the heater
items are recommended for cold weather starting and/or tape is within 152 mm (6 in.) of the exhaust system,
operation when the unit is located in an enclosure or use thermal insulation material to protect the heater
unheated structure. Have a licensed electrician install tape.
120 VAC, 15 amp outlets as needed if not already in the
40--60REOZK Models only. When the ambient
immediate area.
temperature drops below --15_C (5_F) a turbocharger
Refer to the engine operation manual regarding engine pre-lube sequence begins when the crank cycle is
oil viscosity, fuel composition, and coolant mixture initiated. During the first 10 seconds of cranking, the fuel
recommendations. system is disabled to ensure engine oil is present at the
turbocharger. This is necessary for the longevity of the
D The engine block heater is generally recommended turbocharger on the KDI 3404TM engine. The fuel
for most units when operated below 0C (32F) and system is then enabled for the next 5 seconds of cyclic
required as part of NFPA 110. Refer to the respective cranking and the engine will start as normal.
spec sheet for temperature recommendations in
available options.
2.4 Controller Operation
D A battery heater is generally recommended for most
units when operated below 0C (32F). Refer to the The controller operation includes several types of
respective spec sheet for model availability. starting and stopping functions as detailed in the
following paragraphs. The controller master control
D An alternator strip heater is available for most switch buttons, lamps, and alarm horn functions are
generator sets providing a heat source to prevent summarized in Figure 2-1.
moisture and frost buildup.
D The crankcase ventilation (CCV) heater kit 2.4.1 Starting
provides a controlled heating source to the crankcase
ventilation system preventing freezing water buildup Local Starting
during cold weather. The thermostat turns on at 4_C
(40_F) and turns off at 16_C (60_F). Refer to Press the master control RUN button to start the
Section 3, Scheduled Maintenance for more generator set at the controller.
information. (Applies to 125/150 kW, 8.1 L GM- and
8.8 L PSI- powered generator set models only.) Note: The alarm horn sounds and the Not-In-Auto
Warning display appears whenever the
D Heater tape is recommended when the generator set generator set master control button is not in the
is equipped with a closed crankcase ventilation AUTO mode.
Generator Set Button Alarm Alarm Silence Alarm Silence
Button Mode Status Lamp Fault Lamp Horn Button * Lamp Controller Display
Off — Off — — Scrolling Overview Menu
On (or Cranking) — Off — — Only
AUTO Green
Running and then On — —
Red Shutdown Message
Off Off Pressed Yellow
On — —
OFF/RESET Off Red Yellow Not In Auto Warning
Off Pressed Yellow
On — —
Off (or Cranking) Yellow Not in Auto Warning
RUN Off Pressed Yellow
Yellow
(unit fails to start) On — — Locked Rotor Shutdown (or
Off Red
Off Pressed Yellow other shutdown message)
Off (or Cranking) On — —
Yellow Yellow Not in Auto Warming
RUN On Off Pressed Yellow
(unit starts) Running and then On — —
Yellow Red Shutdown Message
Off Off Pressed Yellow
* Alarm silence only works when in the Auto mode unless the Always selection is made using SiteTecht.
Refer to 2.7.7 GenSet System for more information.

Figure 2-1 Master Control Button Function Summary

36 Section 2 Operation TP-6694 3/19

Note: The transient start/stop function of the controller The controller has a programmable cooldown timer that
prevents accidental cranking of the rotating engine. functions only when the master control button is in the
The generator set stops and recranks when the AUTO mode. To stop the generator set, press the
OFF/RESET button is momentarily pressed and generator set master control OFF/RESET button and
then the RUN button is pressed. wait until the generator set comes to a complete stop.

Auto Starting Note: The cooldown cycle times out before the
generator set stops when a remote switch or
Press the master control AUTO button to allow startup automatic transfer switch initiates the generator
by the automatic transfer switch or remote start/stop set start/stop sequence.
switch (connected to controller terminals 3 and 4).
Emergency Stopping
Terminals 3 and 4 connect to a circuit that automatically
starts the generator set crank cycle when an external Use the controller emergency stop switch or optional
source closes the circuit. remote emergency stop for immediate shutdown.

Note: The controller provides up to 30 seconds of The emergency stop switch bypasses the time delay
programmable cyclic cranking and up to engine cooldown and immediately shuts down the
60 seconds rest with up to 6 cycles. The default generator set.
setting is 15 seconds cranking and 15 seconds
rest for 3 cycles. Make cyclic cranking Note: Use the emergency stop switch(es) for
adjustments using SiteTecht software. emergency shutdowns only. Use the generator
set master control OFF/RESET button for normal
Prime Power Switch shutdowns.

The controller has an optional prime power mode of The controller fault lamp lights and the unit shuts down
operation. The prime power mode requires installation when the local or remote emergency stop switch
of an optional prime power switch kit. See Section 6, activates.
Accessories, for instructions on how to install the
optional prime power switch kit. The prime power switch 2.4.3 Emergency Stop Switch Resetting
kit prevents engine starting battery drain when the
generator set is shut down and no external battery Use the following procedure to reset the generator set
charging is available. after shutdown by a local or remote emergency stop
switch. Refer to Section 2.4.8, Controller Resetting
Move the prime power switch located on the junction box procedure, to restart the generator set following a fault
to the CONTROLLER ON position before attempting to shutdown.
start the generator set. When the prime power mode is
off, all controller functions including the digital display, 1. Investigate and correct the cause of the
LEDs, and alarm horn are operative. emergency stop.

Stop the generator set using the stopping procedures in 2. Reset the optional remote emergency stop switch by
Section 2.4.2 before placing the generator set in the replacing the glass piece, when equipped. Additional
prime power mode. Move the prime power switch glass rods are available as a service part. Reset the
located on the junction box to the CONTROLLER OFF controller emergency stop switch by pulling the
position. When the generator set is is the prime power switch dial outward.
mode, all controller functions including the digital
display, LEDs, alarm horn, and communications are 3. Press the generator set master control
inoperative. OFF/RESET button.

4. After resetting all faults using the controller reset

2.4.2 Stopping (User Stopping and procedure in Section 2.4.8, press the generator set
Fault Shutdown) master control RUN or AUTO button to restart the
generator set. The generator set will not crank until
Normal Stopping the reset procedure completes.
Run the generator set without load for 5 minutes to
ensure adequate engine cooldown.

TP-6694 3/19 Section 2 Operation 37

2.4.4 System Status Lamps AC Sensing Loss. The fault lamp illuminates yellow
and the alarm horn sounds when the controller does not
The (OFF/RESET--AUTO--RUN) master control buttons detect the nominal generator set AC output voltage after
indicate the status condition with an integrated lamp at crank disconnect. The controller displays AC Sens Loss
the button. Warning.
The green lamp illuminates on the master control AUTO Auxiliary Input (Warning). The fault lamp illuminates
(automatic start) button indicating the system senses no yellow and the alarm horn sounds when an auxiliary
faults and the unit is ready to start by remote command. digital or analog input signals the controller. The digital
inputs do not function during first the 30 seconds after
The red lamp illuminates on the master control startup. Use SiteTecht software to define inputs as
OFF/RESET button indicating the generator set is shutdowns or warnings. The local display shows Aux
stopped. Input Warning.
The yellow lamp illuminates on the master control RUN Battery Charger Communication Loss. The warning
button indicating the generator set is cranking or running fault lamp on the controller illuminates yellow and the
from a local command. alarm horn sounds when CAN communication with the
battery charger has been lost. Local display shows
Only one of the three master control button lamps will
either bat1CommLoss or bat2CommLoss.
illuminate at any given time.
Note: bat2CommLoss indicates communication loss
2.4.5 System Fault Warning Lamp with for battery charger number 2. bat2CommLoss is
Digital Displays only relevant for generator sets with more than
one battery charger.
The system FAULT lamp glows yellow and the alarm
horn sounds indicating a warning fault but does not shut Battery Charger Fault. The warning lamp on controller
down the generator set. The fault lamp illuminates illuminates yellow and the alarm horn sounds when the
yellow and the alarm horn sounds when the fuel tank battery charger malfunctions. Local display shows Batt
level on diesel-fueled models approaches empty. This Chg Flt.
fault requires an optional low fuel level switch for the
lamp to function. The local display shows Fuel Level Battery Charger Identity Conflict. The warning lamp
Low Warning. See Section 2.4.8, Controller Resetting on the controller illuminates yellow and the alarm horn
procedure, for instructions on resetting a system sounds when there is a CAN address communication
warning. error. The battery charger has the same CAN address
as another generator set component. To correct a CAN
When the system warning lamp is on and no message address error, verify the address identification in the
displays, rotate the selector dial to view messages. harness and power cycle the controller. Local display
When the system warning continues, it may lead to a shows BatIdErr.
fault and cause a system shutdown.
Battery Charger Parameter Mismatch. The warning
Use the Silence Alarm button to silence the alarm horn lamp on controller illuminates yellow and the alarm horn
at the operator’s discretion. sounds when the battery charger metering is not in
range of the specified parameters. Local display shows
If the controller is setup for an NFPA 110 application, ParMisatch.
press the AUTO button before silencing the alarm horn.
The alarm horn cannot be silenced unless the master Battery Fault. The warning lamp on controller
control button is in the AUTO mode. See 2.4.7 Status illuminates yellow and the alarm horn sounds when
and Notice Digital Displays for more information. there is an issue with the battery such as a connection
problem or a dead battery. When the temperature
Note: Text shown in italics in this section of the manual compensation sensor is connected, whether active or
represents digital display messages. inactive, and the temperature rises above 60_C (140_F)
or below --20_C (--4_F), the battery failure warning will
also be displayed indicating that the battery is unable to
take charge due to temperature. Absorption timeout will
also cause a failure since the battery was unable to
accept the expected charge in the time frame given
which indicates a potential battery issue. Local display
shows Battery Flt.

38 Section 2 Operation TP-6694 3/19

Common Warning. The fault lamp illuminates yellow High Coolant Temperature. The fault lamp illuminates
and the alarm horn sounds when the controller is yellow and the alarm horn sounds when the engine
signaled by a common warning. Use SiteTecht coolant temperature approaches the shutdown range.
software to activate the common warning. The local The high coolant temperature warning does not function
display shows Common Warng. The common warning during the preset inhibit time delay period after startup.
comprises all of the warnings under a single alert. The local display shows Coolnt Temp High Warning.

Critical High Fuel Level (diesel-powered models High Fuel Level (diesel-powered models only). The
only). The fault lamp illuminates yellow and the alarm fault lamp illuminates yellow and the alarm horn sounds
horn sounds when the fuel tank level on diesel models when the fuel tank level on diesel models approaches
approaches full. This fault requires an optional critical near full. This fault requires an optional high fuel switch
high fuel switch and fuel tank for the lamp to function. and fuel tank for the lamp to function. The local display
The local display shows Fuel Level Critically High. shows Fuel Level High Warning.

Default Parameters Loaded. The fault lamp Input/Output Communication Loss. The fault lamp
illuminates yellow and the alarm horn sounds when the illuminates yellow and the alarm horn sounds when the
controller detects that the default parameter software controller loses the input/output communication signal
was loaded using SiteTecht software. The local from the optional I/O module board. The local display
display shows Default Pars Warning. shows OB1 Com Loss.

ECM Diagnostics (Multiple Engine Inputs). The fault Low Battery Voltage. The fault lamp illuminates yellow
lamp illuminates yellow and the alarm horn sounds and the alarm horn sounds when the battery voltage
when ECM diagnostics signals the controller. The local drops below a preset level for more than 90 seconds.
display shows ECM xxxxx Warning. The specific The local display shows Low Battery Warning. See
display (xxxxx) will be a brief message or fault code that Figure 2-3 for low battery voltage specifications.
is engine manufacturer dependent. The engine
literature provides the fault code description and further Engine Electrical Low Battery Low Battery Voltage
information. System Voltage Voltage Range Default Setting
12 9.6--12.6 12
Fuel Tank Leak (diesel-powered models only). The
24 19.2--25.2 24
fault lamp illuminates yellow and the alarm horn sounds
when the fuel tank signals a leak of the inner tank. This Figure 2-3 Low Battery Voltage Specs
fault requires an optional fuel tank leak switch for the
lamp to function. The local display shows Fuel Leak The low battery voltage feature monitors the battery and
Warning. battery charging system in the generator set operating
and off modes. The controller logic inhibits the low
Ground Fault. The fault lamp illuminates yellow and the battery voltage warning during the crank cycle.
alarm horn sounds when a user-supplied ground fault
detector signals the controller. The local display shows Low Coolant Temperature. The fault lamp illuminates
Ground Fault Warning. yellow and the alarm horn sounds when the engine
coolant temperature is low. The low coolant
High Battery Voltage. The fault lamp illuminates yellow temperature warning does not function during the preset
and the alarm horn sounds when the battery voltage inhibit time delay period after startup. The local display
rises above the preset level for more than 10 seconds. shows Coolant Temp Low Warning.
The local display shows Battery High Warning.
Figure 2-2 shows high battery voltage specifications. Low Cranking Voltage. The fault lamp illuminates
The high battery voltage feature monitors the battery yellow and the alarm horn sounds when the battery
and battery charging system in the generator set voltage drops below 60% of the nominal voltage (12
operating and off modes. VDC or 24 VDC) for more than 6 seconds during the
crank cycle. The local display shows Lo Crank Vlt
Engine Electrical High Battery High Battery Voltage Warning.
System Voltage Voltage Range Default Setting
12 13.2--16.2 15
24 26.4--32.4 30

Figure 2-2 High Battery Voltage Specs

TP-6694 3/19 Section 2 Operation 39

Low Engine Oil Level. The fault lamp illuminates AC Sensing Loss. The fault lamp illuminates red, the
yellow and the alarm horn sounds because of low alarm horn sounds, and the unit shuts down when the
engine oil level. This fault feature requires an optional controller does not detect the nominal generator set AC
low engine oil level sensor for the lamp to function. Local output voltage for more than 3 seconds after crank
display shows Oil Level Low Warning. disconnect. The controller displays AC Sens Loss
Shutdwn.
Low Fuel Level (diesel-powered models only). The
fault lamp illuminates yellow and the alarm horn sounds Alternator Protection. The fault lamp illuminates red
when the fuel tank level on diesel-fueled models and the unit shuts down because of an alternator
approaches empty. This fault requires an optional low overload or short circuit. The local display shows Alt
fuel level switch for the lamp to function. The local Protect Shutdwn. See Appendix D, Alternator
display shows Fuel Level Low Warning. Protection for more information.

Low Fuel Pressure (gas-powered models only). The Auxiliary Input (Shutdown). The fault lamp
fault lamp illuminates yellow and the alarm horn sounds illuminates red, the alarm horn sounds, and the unit
when low fuel pressure on gaseous-fueled models shuts down when an auxiliary digital or analog inputs
occurs. This fault requires an optional low fuel pressure signals the controller. The digital inputs do not function
switch for the lamp to function. The local display shows during first the 30 seconds after startup. Use SiteTecht
Fuel Press Low Warning. software to define inputs as shutdowns or warnings.
The local display shows Aux Input Shutdwn.
Low Oil Pressure. The fault lamp illuminates yellow
and the alarm horn sounds when the engine oil pressure Common Fault. The fault lamp illuminates red, the
approaches the shutdown range. The low oil pressure alarm horn sounds, and the unit shuts down when the
warning does not function during first the 30 seconds controller is signaled by a common fault. Use
after startup. The local display shows Oil Press Low SiteTecht software to activate the common fault
Warning. shutdown. The local display shows Common Fault
Shutdwn. The common fault comprises the following
Not in Auto (Generator Master Control Switches). shutdowns under a single alert.
The fault lamp illuminates yellow and the alarm horn
D Emergency stop
sounds when the generator set master control button is
in the RUN or OFF/RESET mode. The local display D Engine over speed
shows Not In Auto Warning. D High coolant temperature
D Low oil pressure
Speed Sensor Fault. The fault lamp illuminates yellow
D Overcrank
and the alarm horn sounds when the speed signal is
absent for one second while the generator set runs. The ECM Address Conflict. The fault lamp illuminates red,
local display shows Spd Sens Flt Warning. the alarm horn sounds, and the unit shuts down when
the controller detects an error with the ECM address.
2.4.6 System Fault Shutdown Lamp The local display shows ECMAddr Err Shutdwn.
With Digital Displays ECM Communications Loss. The fault lamp
The system FAULT lamp glows red, the alarm horn illuminates red, the alarm horn sounds, and the unit
sounds, and the unit shuts down to indicate a fault shuts down when the ECM communication link is
shutdown under the following conditions. See Section disrupted. The local display shows ECM Comm Err
2.4.8, Controller Resetting procedure, for information on Shutdwn.
resetting a system shutdown.
ECM Diagnostics (Multiple Engine Inputs). The fault
Use the Alarm Off button to silence the alarm horn at the lamp illuminates red, the alarm horn sounds, and the
operator’s discretion. unit shuts down when ECM diagnostics signals the
controller. The local display shows ECM xxxxx
If the controller is set up for an NFPA 110 application, Shutdwn. The specific display (xxxxx) will be a brief
press the AUTO button before silencing the alarm horn. message or fault code that is engine manufacturer
The alarm horn cannot be silenced unless the master dependent. The engine literature provides the fault
control button is in the AUTO mode. See 2.4.7 Status code description and further information.
and Notice Digital Displays for more information.

Note: Text shown in italics in this section of the manual

represents digital display messages.

40 Section 2 Operation TP-6694 3/19

ECM Model Mismatch. The fault lamp illuminates red, kW Overload. The fault lamp illuminates red, the alarm
the alarm horn sounds, and the unit shuts down when horn sounds, and the unit shuts down when the
the controller detects an error with the ECM model. The generator set supplies more than 102% of the rated
local display shows ECM Mismatch Shutdwn. standby output kW (or 112% of the rated prime power
output kW) for more than 60 seconds. The local display
Emergency Stop. The fault lamp illuminates red, the shows Total Power High Shutdwn.
alarm horn sounds, and the unit shuts down when the
local or optional remote emergency stop switch Locked Rotor (failed to crank). If none of the speed
activates. The local display shows Emerg Stop sensing inputs show engine rotation within the preset
Shutdwn. time delay of initiating engine cranking, the ignition and
crank circuits turn off for the preset period and the cycle
Enclosure Temperature: High Shutdown (Available repeats. The fault lamp illuminates red, the alarm horn
on select Telecom units only). The fault lamp sounds, and the unit shuts down after the second cycle
illuminates red, the alarm horn sounds, and the unit of the preset period of cranking. The local display shows
shuts down when the enclosure reaches high Locked Rotor Shutdown.
temperature. The digital input does not function during
first the 20 seconds after startup and has a 5 second Loss of Fuel. The fault lamp illuminates red and the
delay. The local display shows Enclsr Temp: High alarm horn sounds when the unit shuts down without
Shutdwn. receiving a signal from the controller to do so. On
diesel-fueled units this condition includes fuel pump
Engine Over Speed. The fault lamp illuminates red, the failure, loss of fuel prime, and/or an empty fuel tank. On
alarm horn sounds, and the unit shuts down immediately gaseous-fueled units this condition includes loss of fuel
when the governed frequency on 50 and 60 Hz models pressure and/or an empty fuel tank. The local display
exceeds the over speed setting. The local display shows Loss of Fuel.
shows Eng Speed High Shutdwn.
Low Coolant Level. The fault lamp illuminates red, the
Engine Under Speed. The fault lamp illuminates red, alarm horn sounds, and the unit shuts down because of
the alarm horn sounds, and the unit shuts down low coolant level. Shutdown occurs 5 seconds after low
immediately when the governed frequency on 50 and coolant level is detected. Local display shows Coolant
60 Hz models drops below the under speed setting. The Lvl Low Shutdwn.
local display shows Eng Speed Low Shutdwn.
Low Engine Oil Level. The fault lamp illuminates red,
File System Error. The fault lamp illuminates red, the the alarm horn sounds, and the unit shuts down because
alarm horn sounds, and the unit shuts down when the of low engine oil level. This fault feature requires an
internal controller diagnostics detect a firmware file optional low engine oil level sensor for the lamp to
error. The local display shows File Error Shutdwn. function. Local display shows Oil Level Low Shutdwn.

Fuel Tank Leak (diesel-powered models only). The Low Fuel Level (diesel-powered models only). The
fault lamp illuminates red, the alarm horn sounds, and fault lamp illuminates red, the alarm horn sounds, and
the unit shuts down when the fuel tank signals a leak of the unit shuts down when the fuel tank level on
the inner tank. This fault requires an optional fuel tank diesel-fueled models approaches empty. This fault
leak switch for the lamp to function. The local display requires an optional low fuel level switch for the lamp to
shows Fuel Leak Shutdwn. function. The local display shows Fuel Level Low
Shutdwn.
High Coolant Temperature. The fault lamp illuminates
red, the alarm horn sounds, and the unit shuts down Low Oil Pressure. The fault lamp illuminates red, the
because of high engine coolant temperature. The high alarm horn sounds, and the unit shuts down because of
coolant temperature shutdown does not function during low oil pressure. The shutdown occurs 5 seconds after
the preset inhibit time delay period after startup. The the low pressure condition is detected. The low oil
local display shows Coolnt Temp High Shutdwn. pressure shutdown does not function during first the
30 seconds after startup. The local display shows Oil
Note: The high engine temperature shutdown function
Press Low Shutdwn.
and the low coolant level shutdown function are
independent. A low coolant level condition may MegaJector Communications Loss (GM/PSI and
not activate the high engine temperature switch. Doosan gas-powered models only). The fault lamp
illuminates red, the alarm horn sounds, and the unit
Internal Fault. The fault lamp illuminates red, the alarm shuts down when the communication link is disrupted.
horn sounds, and the unit shuts down when the internal The local display shows MJ Comm Loss.
diagnostics detect a controller malfunction. The local
display shows Intern Error Shutdwn.

TP-6694 3/19 Section 2 Operation 41

Metering Communications Loss. The fault lamp Overvoltage Time Delay Overvoltage Default
illuminates red, the alarm horn sounds, and the unit Setting Range Range Setting
shuts down when the metering to controller
105%--135% of
communication link is disrupted. The local display nominal
2--10 sec. 120% at 2 sec.
shows MeterCommLos Shutdwn.
Figure 2-5 Overvoltage Specs
No Coolant Temperature Signal. The fault lamp
illuminates red, the alarm horn sounds, and the unit Run Relay Overload. The fault lamp illuminates red,
shuts down when the engine coolant temperature the alarm horn sounds, and the unit shuts down when
sender circuit is open. The local display shows Temp the controller smart switch that operates generator set
Sig Loss Shutdwn. wire number 70 (Run) is overloaded. The local display
shows Run Relay Overload.
No Oil Pressure Signal. The fault lamp illuminates red,
the alarm horn sounds, and the unit shuts down when Underfrequency. The fault lamp illuminates red, the
the engine oil pressure sender circuit is open for more alarm horn sounds, and the unit shuts down when the
than 5 seconds. The local display shows Press Sig Loss frequency drops below the underfrequency setting. The
Shutdwn. local display shows Frequency Low Shutdwn. See
Figure 2-6 for underfrequency specifications.
Overcrank. The fault lamp illuminates red, the alarm
horn sounds, and cranking stops when the unit does not
Underfreq. Setting Underfrequency
start within the defined cranking period. The local Range Time Delay Default Setting
display shows Over Crank Shutdwn. See Section 2.4.1,
Auto Starting, and Section 1.3.1, Status Event and Fault 80%--95% of
10 sec. (short term) 90% of nominal
nominal
Specifications for cyclic crank specifications.
Figure 2-6 Underfrequency Specs
Note: The controller is equipped with an automatic
restart function. When speed drops below 25 Hz Note: The long-term shutdown occurs if the frequency
(750 rpm) while the engine is running, the unit is 1 Hz or more below the system frequency for
attempts to recrank. The unit then follows the 60 sec. The long-term shutdown is not
cyclic cranking cycle and, when the engine fails to adjustable.
start, will shut down on an overcrank fault
condition. Undervoltage. The fault lamp illuminates red, the
alarm horn sounds, and the unit shuts down when the
Overfrequency. The fault lamp illuminates red, the voltage drops below the undervoltage setting for the
alarm horn sounds, and the unit shuts down when the time delay period. The local display shows Volts
frequency is above the overfrequency setting. The local (L1--L2, L2--L3, or L3--L1) Low Shutdwn. See
display shows Freq High Shutdwn. See Figure 2-4. Figure 2-7 for undervoltage specifications

Overfrequency Overfrequency Undervoltage Undervoltage

Setting Range Time Delay Default Setting Setting Range Time Delay Range Default Setting

102%--140% of nominal 10 sec. 110% of nominal 70%--95% of 80% of nominal at

5--30 sec.
nominal 10 sec.
Figure 2-4 Overfrequency Specs
Figure 2-7 Undervoltage Specs
Overvoltage (Each Phase). The fault lamp illuminates
red, the alarm horn sounds, and the unit shuts down (Voltage) Regulator Communications Loss. The
when the voltage exceeds the overvoltage setting for fault lamp illuminates red, the alarm horn sounds, and
the preset time delay period. The local display shows the unit shuts down when the voltage regulator to
Volts (L1--L2, L2--L3, or L3--L1) High Shutdwn. See controller communication link is disrupted. The local
Figure 2-5 for overvoltage specifications. display shows RegCommLos Shutdwn.

Note: Overvoltage can damage sensitive equipment in

less than one second. Install separate
overvoltage protection on online equipment
requiring faster than 2-second shutdown.

42 Section 2 Operation TP-6694 3/19

2.4.7 Status and Notice Digital Displays Engine Cooldown (Delay) Active. This notice
message indicates that the delay for engine cooldown is
Warnings and shutdown faults appear on the digital active where the generator set will continue to run after
display and become part of the event history. Beyond the OFF/RESET button is pressed. The unit will
the warnings and shutdowns there are several events continue to run until the time delay times out. The local
which also appear on the digital display. Status is an display shows Eng Cooldown Notice.
event that is not an alert but is part of the event history.
Notice is an alert that is not part of the event history. Engine Start Aid Active. This notice message
indicates that the start aid is active and will energize an
The controller allows a selected number of changes by engine equipped preheat or ether system during the
the user for setting up the controller application which crank cycle. Use SiteTecht software to set up this
are covered in this section. feature. The local display shows Starting Aid Notice.
Note: Text shown in italics in this section of the manual Engine Start Delay Active. This notice message
represents digital display messages. indicates that the delay for engine start is active where
the generator set will not start right after the RUN button
Alarm Silence. This status message indicates whether is pressed. The unit will start cranking after the time
the alarm horn can be silenced in any button mode delay times out. The local display shows Start Delay
(OFF/RESET--AUTO--RUN) or requires the AUTO Notice.
button be pressed first compliant per NFPA 110. Use
SiteTecht software to change this setting. See Section Engine Started. This status indicates that the
2.4.8, Controller Resetting procedure, for information on generator set start circuit is closed allowing the engine to
resetting the system. crank and run. The local display shows Engine Start
Status.
The local display shows AlrmSilence: Always when the
alarm horn can be silenced with the master control Engine Stopped. This status indicates that the
buttons in any position (default setting). generator set start circuit is open causing the engine to
shut down. The local display shows Engine Stop Status.
The local display shows AlrmSilence: Auto Only when
the alarm horn can be silenced only when in the AUTO Generator Running. This notice indicates that the
mode. generator set has started and is running. The local
display shows Gen Running Notice.
Backup Parameters Loaded. This status message
indicates that backup parameter firmware is now loaded
on the controller using SiteTecht software. The local
display shows Backup Pars Status.

Chicago Code Active. This notice message indicates

that a pass code is required to access the controller.
Use SiteTecht software to set up the feature. The local
display shows Auto Locked Notice.

Emergency Power System (EPS) Supplying Load.

This notice message indicates when the generator set
supplies more than 1% of the rated standby output
current. The local display shows Emerg Pwr On Notice.

TP-6694 3/19 Section 2 Operation 43

Generator Set Calibration (User Defined). This NFPA 110 Alarm Active. This notice message
selectable display is in the GenSet Calibration Menu indicates that the alarm for NFPA 110 is active. The fault
allowing the user to calibrate the controller and lamp illuminates yellow (warning) or red (shutdown), the
generator set. Use the Pushbutton/Rotary Selector Dial alarm horn sounds, and the units shuts down (if a
to navigate and select this feature. shutdown fault is detected) when the NFPA 110 fault
signals the controller. The local display shows the
Changes to this display must be done with the generator respective fault message. The NFPA 110 faults include:
set running. The local display shows Enter calib? No or
Yes. Select No to make no change. Select Yes to D Battery charger fault
calibrate the following values: D EPS supplying load
D High battery voltage
D Volts L1--L2: x.x V
D High coolant temperature shutdown
D Volts L2--L3: x.x V
D High coolant temperature warning
D Volts L3--L1: x.x V D High engine speed
D Volts L1--N: x.x V D Low battery voltage
D Volts L2--N: x.x V D Low coolant level
D Volts L3--N: x.x V D Low coolant temperature warning
D Current L1: x.x A D Low fuel (level or pressure)
D Current L2: x.x A D Low oil pressure shutdown
D Current L3: x.x A D Low oil pressure warning
D Master switch not in auto
The user can individually calibrate the values above or
D Overcrank
reset all of them. The local display Reset all calib? No or
Yes. Select No to make no changes and exit GenSet Remote Start. This status indicates that the generator
Calibration. Select Yes to reset all of the values. set start circuit was closed from a remote location
allowing the engine to crank and run. The remote
When calibrating voltage, the metered value and the location is typically a set of contacts on a transfer switch
number being entered as the calibrated value must be or remote start switch. The local display shows Remote
within 10% of the system operating voltage. Start Status.

When calibrating current, the metered value must be at System Ready. This status indicates that the generator
least 25% of the rated current on units smaller than set is in the AUTO mode and available to start if the start
100 kW and at least 50 amps on units rated larger than circuit is closed. The local display shows System
100 kW. The number being entered as the calibrated Ready.
value must be within 10% of the metered value.
System Timer Failed. This notice indicates that the
Measurement Units (User Defined). This selectable controller timer logic has failed to time out a designated
display is in the GenSet System Menu allowing the user function. The local display shows Timer Error Notice.
to choose between Metric and English displays. Use the
Pushbutton/Rotary Selector Dial to navigate and select Voltage Regulator Adjustment (User Defined). This
this feature. Changes to this display can be done with feature is in the Voltage Regulator Menu allowing the
the generator set running or stopped. The local display user to fine adjust the output voltage. Use the
shows Meas Units: Metric or Meas Units: English. Pushbutton/Rotary Selector Dial to navigate and select
this feature. Changes to this display must be done with
the generator set running. The local display shows
Enter volt reg? No or Yes. Select No to exit the voltage
regulator menu. Select Yes to change the local display
VR Volt Adj: xxx.x V.

44 Section 2 Operation TP-6694 3/19

2.4.8 Controller Resetting (Following ways to power up the engine ECM without starting the
System Shutdown or Warning) generator set:
D Use SiteTecht to power up the engine ECM. Refer
Use the following procedure to restart the generator set to Procedure for Powering Up the Engine ECM using
after a system shutdown or to clear a warning lamp SiteTecht for Firmware Versions Before 3.10
condition. This procedure includes the resetting of the following.
optional remote annunciator.
D Update the firmware to version 3.10 or higher using a
Refer to Section 2.4.3, Emergency Stop Switch Reset PC with SiteTecht software and access Tech Tools
Procedure, to reset the generator set after an for the firmware update. Refer to the SiteTecht
emergency stop. Software Operation Manual TP-6701 as needed.
Use the following information to determine the controller
1. Disconnect the generator set load using the line
firmware version and perform the engine ECM power up
circuit breaker or automatic transfer switch.
procedure.
2. Correct the cause of the fault shutdown or warning. Procedure for Checking the Firmware Version
See the Safety Precautions and Instructions
section of this manual before proceeding. 1. Confirm that a fully charged battery is connected to
the generator set.
3. Start the generator set by pressing the generator
set master control OFF/RESET button and then 2. Press the generator set controller OFF/RESET
press the RUN button. key.
When equipped, the remote annunciator alarm
3. Momentarily press the selector dial to activate the
horn sounds. Press the ALARM SILENCE/LAMP
digital display if dark.
TEST button to stop the alarm horn. The lamp
turns off. 4. Rotate the selector dial counterclockwise to
navigate through the main menus to the Overview
4. Test operate the generator set to verify correction
Menu as shown in Figure 2-8.
of the shutdown cause.

5. Press the generator set master control Overview ---->

OFF/RESET button to stop the generator set. ##.# hr

6. Press the generator set master control AUTO Figure 2-8 Overview Menu
button.
5. Press the selector dial at the Overview Menu in
7. Reconnect the generator set load via the line circuit order to access the Overview submenus.
breaker or automatic transfer switch.
6. Rotate the selector dial clockwise to navigate to the
(firmware) SW Version submenu as shown in
2.4.9 Powering Up the Engine Control
Figure 2-9.
Module (ECM)
Adapted from Service Bulletin SB-724 10/12. SW Version:
3.10
The Decision-Makerr 3000 controller (with firmware
version 3.10 and higher) and the APM402 controller Figure 2-9 SW Version Submenu
have the capability to power up the engine ECM. On
generator sets with John Deere engines, the engine 7. For Decision-Makerr 3000 controllers, if the
ECM power-up feature allows service technicians to firmware version is earlier than 3.10, go to the
access fault codes and other troubleshooting data using Procedure for Powering Up the Engine ECM using
their John Deere Diagnostic tools without the need to SiteTecht. For Decision-Makerr 3000 controllers
with firmware version 3.10 or higher, or for APM402
start the generator set. Refer to Procedure for Powering
controllers, continue to Procedure for Powering Up
Up the Engine ECM on the following pages.
the Engine ECM.
If the Decision-Makerr 3000 generator set controller
has a firmware version earlier than 3.10, there are two

TP-6694 3/19 Section 2 Operation 45

Procedure for Powering Up the Engine ECM

This procedure applies to Decision-Makerr 3000

controllers with firmware version 3.10 and higher and to
APM402 controllers with firmware versions 1.0 and
higher.

1. Navigate to the SW Version menu (Figure 2-10) as

described in the previous procedure. Press and
hold the selector dial until the display screen
confirms that the ECM is powered as shown in
Figure 2-11. 1 2
SB-724
1. Locate Genset System Configuration--ECM Power in
SW Version: SiteTecht
3.10 2. Click drop down arrow and select True to power up the
engine ECM

Figure 2-10 SW Version Display Figure 2-13 SiteTecht Software Display Screen

ECM
Powered 2.5 Menu Displays
Use the Menu Summary List section after reading and
Figure 2-11 ECM Powered Display
understanding the features of the pushbutton/rotary
2. After several seconds, the display will change to selector dial. See Section 1.2.3, Digital Display.
provide the option to power down the controller.
The Menu Summary List provides a quick reference to
See Figure 2-12.
the digital display data. Some digital display data may
not be identical to your display due to generator set
ECM powered application differences. The closed bullet items
Push to Stop represent main level data and the open bullet items are
sub-level data. The Menu Summary List indicates items
Figure 2-12 ECM Power Down Display that are user selectable. Use SiteTecht software for
changing all other programmable information.
3. If desired, press the selector dial to power down the
engine ECM. Some displays are engine dependent; refer to the
Appendix, Controller Displays from the Engine ECM.
OR
Section 2.7, Reviewing the Menu Displays, provides a
Rotate the selector dial to navigate to any of the
digital display menu overview and explains the
available menus.
navigation using the pushbutton/rotary selector dial.
Procedure for Powering Up the Engine ECM using
SiteTecht (for Decision-Makerr 3000 controllers
with Firmware Versions Before 3.10)
Connect a PC with SiteTecht software to the generator
set controller. Refer to the SiteTecht Software
Operation Manual TP-6701 as needed.
Follow the instructions shown in Figure 2-13.

46 Section 2 Operation TP-6694 3/19

Menu Summary List (Legend: D First level submenu, d second level submenu)
Overview Menu (DEC3000 Overview Menu (DEC3000 Generator Metering GenSet System
before version 4.11) version 4.11 and APM402) Menu Menu
Available as scrolling or Available as scrolling or D Total Power kVA (shown D System Frequency
fixed display text fixed display text as actual output values) D System Phase (Single
D Total Power kW (shown Phase, Single Phase
D Active Shutdowns (if D Active Shutdowns (if
as actual output values) Dogleg, Three Phase
present) present)
D Rated Power Wye, or Three Phase
D Active Warnings (if D Active Warnings (if
D Volts, L1--L2 * Delta)
present) present)
D Volts, L2--L3 * D System Volts
D Genset State D Genset State
D Volts, L3--L1 * D Power Rating
D Average Volts D Average Volts
D Volts, L1--N * D Amp Rating
Line-to-Line Line-to-Line
D Volts, L2--N * D Power Type (Standby or
D Frequency D Frequency
D Volts, L3--N * Prime)
D Current D Current
D Current, L1 * D Battery DC Voltage
D Average kW D Average kW
D Current, L2 * D Measurement System
D Coolant Temperature D Coolant Temperature
(Metric or English) *
D Oil Pressure D Oil Pressure D Current, L3 *
D Contrast (display) *
D Fuel Level % (with D Fuel Level % (with D Frequency
D Alarm Silence (Always or
diesel-powered models diesel-powered models D Reset Calibration (User
Auto Only)
and optional fuel tank and optional fuel tank can reset individual volt
sender) sender) and current values or D Manual Speed Adjust
reset all values) (available option)
D Fuel Pressure (engine D Fuel Pressure (engine
dependent) dependent)
GenSet Information GenSet Calibration
D Battery DC Voltage D Battery DC Voltage
Menu Menu (DEC3000 before
D Engine Run Time D Engine Run Time
version 3.0.25)
D Software Version D Battery Charger Volts D Generator Set Model No.
and Amps, CHG1 and D Generator Set Serial No. D Enter Calibration
CHG2 (with charger (Yes or No) *
D Controller Serial No.
GM87448 only) d Volts, L1--L2
D Software Version GenSet Run Time d Volts, L2--L3
Menu d Volts, L3--L1
Engine Metering d Volts, L1--N
D Engine Run Time
Menu d Volts, L2--N
D Engine Loaded
D Engine Speed D Engine Starts d Volts, L3--N
(Tachometer) d Current, L1
D Total Energy kWh
D Oil Pressure d Current, L2
D Coolant Temperature d Current, L3
D Fuel Level (with d Reset Calibration
diesel-powered models d Reset All Calibration
and optional fuel tank (Yes or No)
sender)
d Exit Calibration
D Battery DC Voltage
D Fuel Pressure (engine
dependent)

* User-Defined (changeable) Menu Displays. Use SiteTecht software to change other settings including User-Defined Menu Displays.
NOTE: Some changes require activating the calibration or adjustment mode. Some displays may only appear when in the calibration or adjustment
mode. Refer to Section 2.7 Reviewing Menu Displays to activate the calibration or adjustment mode.

TP-6694 3/19 Section 2 Operation 47

Menu Summary List Continued (Legend: D First level submenu, d second level submenu)
Voltage Regulator Digital Inputs Analog Inputs Event Log
Menu (DEC3000 before Menu Menu Menu
Version 3.0.25) D DIn A1 D AIn A1 (factory reserved D See 1.2.4 for a list of
D Enter Voltage Regulator? D DIn A2 and not user items that can appear in
(Yes or No) * D DIn A3 (Reserved for programmable) Event Log
d Voltage Regulator Enclosure Temperature: D AIn A2
Adjust High Shutdown on select D AIn B1 (with I/O Board) Volt Select Menu
d Exit Voltage Regulator Telecom units only) D AIn B2 (with I/O Board) (DEC3000 Version 2.8.22
D DIn B1 (with I/O Board) or higher, and APM402)
Voltage Regulator Menu D DIn B2 (with I/O Board) Battery Charger 1 D Volt Select: *
(DEC3000 Version 3.0.25 Menu d 120/240 V 1 Ph
or higher, and APM402) Digital Outputs D Output Volts d 120/208 V 3 Ph
Menu Output Amps
D Voltage Regulator Voltage D d 139/240 V 3 Ph
Adjust * D DOut A1 D Charger State d 277/480 V 3 Ph
D Reset Voltage Regulator D DOut B1 (with I/O Board) D Software Version d 120/240 V 3 Ph
Settings * D DOut B2 (with I/O Board) D Reduced Out
d Reset Voltage D DOut B3 (with I/O Board) D Temperature
Regulator? D DOut B4 (with I/O Board) Compensation
D DOut B5 (with I/O Board)
Battery Charger 2
Menu
D Output Volts
D Output Amps
D Charger State
D Software Version
D Reduced Out
D Temperature
Compensation

* User-Defined (changeable) Menu Displays. Use SiteTecht software to change other settings including User-Defined Menu Displays.
NOTE: Some changes require activating the calibration or adjustment mode. Some displays may only appear when in the calibration or adjustment
mode. Refer to Section 2.7 Reviewing Menu Displays to activate the calibration or adjustment mode.

48 Section 2 Operation TP-6694 3/19

2.6 Monitoring and Programming
Setup Ethernet Modbusr/
Network Ethernet
Converter
The user programmer can access the controller data Personal Generator Set
Controller or
with the controller digital display or a personal computer Computer
with NIC
OR
Transfer
(PC) with optional SiteTecht software to monitor and/or Switch Control
Remote RS-232 to
program. Access the controller system with a PC using Network RS-485 Port
(Modem) Converter
a USB cable with a mini USB plug. Refer to the
Introduction, List of Related Materials for related
Personal Telephone RS-485 up to 1220 m (4000 ft.)
software literature. Computer lines

While this manual focuses on data access through the Figure 2-15 Remote Single Connections
controller pushbutton/rotary selector dial and display,
most data entries require input using a PC for initial
setup. The PC entries typically include alpha characters 2.6.2 Modbusr Communications
such as digital input descriptions.
The controller communicates using Modbusr as a slave
connection with the Modbusr master initiating the
2.6.1 PC Communications communication. The controller seeks the system and
alternator parameters and diagnostic information then
Communicate between a PC and the generator set responds back to the Modbusr master. In addition, the
controller logic using USB communication protocol. The controller accepts information to alter controller
PC connections require optional SiteTecht software. parameters including generator set starting and
Contact your authorized distributor/dealer for stopping. See Figure 2-16. Refer to the List of Related
assistance. Materials for available Modbusr literature.

Local Single Connection Note: Only one Modbusr master can be connected to
the controller. Examples include the remote
A PC connects to the USB port of the generator set serial annunciator, Monitor III, and switchgear
controller using a mini USB connector. See Figure 2-14. applications.

Generator Set RS-485

Controller up to 1220 m (4000 ft.)

USB Cable Generator Set Modbusr Master

Controller
Personal
Computer

Figure 2-14 Local Single Connection

Figure 2-16 Modbusr Connections
Remote Single Connection
A modem connects a PC to a single device. The PC
communicates with the device via telephone line or an
ethernet network. See Figure 2-15.

Modbusr is a registered trademark of Schneider Electric.

TP-6694 3/19 Section 2 Operation 49

2.7 Reviewing Menu Displays Controller Controller SiteTech
Menu Name Viewable Adjustable Adjustable
Use this section to review a summary of the generator Overview X
set controller data. See Figure 2-17 or Figure 2-18 for
Engine Metering X
which menus provide data monitoring, data
adjustments, or require SiteTecht software to make Generator Metering X X
data adjustments. GenSet Information X X
GenSet Run Time X
Use the pushbutton/rotary selector dial to navigate to
GenSet System X X X
the respective menus.
Voltage Regulation X X X
Digital Inputs X X
Controller Controller SiteTech
Menu Name Viewable Adjustable Adjustable Digital Outputs X X

Overview X Analog Inputs X X

Engine Metering X Battery Charger 1 X X

Generator Metering X Battery Charger 2 X X

GenSet Information X X Event Log X

GenSet Run Time X Volt Select X X X*

GenSet System X X X * Requires initial activation using SiteTecht

GenSet Calibration X X Figure 2-19 Menu Displays for Viewing and Adjusting
Voltage Regulation X X X (DEC3000 firmware version 4.8.4 and
Digital Inputs X X higher, and APM402)
Digital Outputs X X
See Section 1, Specifications and Features, to review
Analog Inputs X X set point ranges and default settings for comparison to
Event Log X the actual setup.
Figure 2-17 Menu Displays for Viewing and Adjusting Menus displaying the # symbol represent one of the
(DEC3000 Before Firmware following data types:
Version 3.0.25)
D System-calculated data
D System-measured data
Controller Controller SiteTech
Menu Name Viewable Adjustable Adjustable D User-entered data
Overview X
Note: The examples given on the following pages
Engine Metering X represent digital displays with the Measurement
Generator Metering X X System set to English.
GenSet Information X X
Some displays are engine-dependent. Refer to the
GenSet Run Time X
Appendix, Controller Displays from the Engine ECM.
GenSet System X X X
Voltage Regulation X X X
Digital Inputs X X
Digital Outputs X X
Analog Inputs X X
Event Log X
Volt Select X X X*
* Requires initial activation using SiteTecht

Figure 2-18 Menu Displays for Viewing and Adjusting

(DEC3000 Firmware Version 3.0.25 to
4.8.4)

50 Section 2 Operation TP-6694 3/19

2.7.1 Error Messages ECM Address Conflict. The fault lamp illuminates red,
the alarm horn sounds, and the unit shuts down when
Certain entries or attempted entries may cause the the controller detects an error with the ECM address.
controller to display an error message. Some of the The local display shows ECMAddr Err Shutdwn.
error messages shown here are also shown as part of
2.4.5 System Fault Warning Lamp with Digital Displays ECM Model Mismatch. The fault lamp illuminates red,
and 2.4.6 System Fault Shutdown Lamp with Digital the alarm horn sounds, and the unit shuts down when
Displays. the controller detects an error with the ECM model. The
local display shows ECM Mismatch Shutdwn.
Cannot Calibrate appears when attempting to calibrate
the voltage and current values in the GenSet Calibration File System Error. The fault lamp illuminates red, the
menu with the unit stopped. The unit must be running in alarm horn sounds, and the unit shuts down when the
order to make adjustments. internal controller diagnostics detect a firmware file
error. The local display shows File Error Shutdwn.
Cannot Edit When Stopped appears in the Voltage
Regulator menu when attempting to change the VR Volt Max Alternator Current Low. The current value listed
Adj value when the unit is not running. in the maximum alternator current personality
parameter is too low compared to the kW setting within
Default Parameters Loaded. The fault lamp the personality.
illuminates yellow and the alarm horn sounds when the
controller detects that the default parameter settings
were loaded using SiteTecht software. The local
display shows Default Pars Warning.

TP-6694 3/19 Section 2 Operation 51

2.7.2 Overview Overview (Fixed Display)
Overview ----> ### V ##.# Hz
Displays basic and commonly sought after information ##.# hr ### A #### kW
about the generator set. This information scrolls
automatically after about 5 minutes of no user input
(pushbutton/rotary selector dial or button activity). English Display ###_F ###%
Measurements --> ### PSI ##.# V
To change from auto scrolling to fixed display, press the
rotary dial and the main menu will appear. Press the
Metric Display ###_ C ##.# %
rotary dial again to select the first menu item Overview. Measurements --> #.# MPa ##.# V
Turn the rotary dial to select the desired fixed view.
Note: Some displays are engine dependent; refer to the
CHG1: ##.# V
Appendix, Controller Displays from the Engine ##.# A
ECM. With 10 Amp Charger
GM87448 Only
Overview (Auto Scrolling Display) (N/A if no charger) -->
Overview ----> Active Shutdowns CHG1: ##.# V
##.# hr (if present) ##.# A

Active Warnings
(if present)
The battery charger displays appear only if the
GenSet State ###### CAN-enabled 10 amp charger GM87448 has been
connected. Charger displays will show N/A if the
charger is connected and then removed.
Avg V L--L:
#.# V
2.7.3 Engine Metering
Frequency:
#.# Hz Displays engine operating data as measured by the
engine and other sensors.
Current:
#.# A Note: Some displays are engine dependent, refer to the
Appendix, Controller Displays from the Engine
Average kW ECM.
#### kW

Coolnt Temp: Engine Metering

### F
Engine ----> Eng Speed:
Metering # R/min
Oil Pressure:
# PSI
Diesel Powered Oil Pres:
Models (requires fuel Fuel Level: # PSI
tank sensor) --> #%

Coolnt Temp:
Engine Dependent Fuel Pressure:
### F
(see NOTE above) --> ## PSI

Battery: Diesel Powered Models

(requires fuel tank Fuel Level:
##.# V #%
sensor) -->

Eng Runtime:
##.# h Battery:
##.# V

CHG1: ##.#V
With 10 Amp Charger ##.# A Engine Dependent Fuel Pressure:
GM87448 Only (see NOTE above) --> ## PSI
(N/A if no charger) -->
CHG2: ##.#V
##.# A

SW Version:
1.02

52 Section 2 Operation TP-6694 3/19

2.7.4 Generator Metering (and values for three-phase generator sets. Single-phase
Calibration) generator sets will only display items marked (*).
D Volts L1-L2 *
Displays generator output data including line-to-line and
D Volts L2-L3
line-to-neutral voltages, current, frequency, total
kilowatts, and total kVA. The menu displays D Volts L3-L1
three-phase voltage and current readings when D Volts L1-N *
applicable. D Volts L2-N *
D Volts L3-N
All menu displays apply to both single-phase or three-
phase voltages on the menu overview. The phase D Current L1 *
designation does not appear in the controller menu D Current L2 *
displays. Some displays will show 0 values when D Current L3
single-phase connections are shown.
The user can change individual values or can select
Note: For Decision-Makerr 3000 controllers with Reset Calib?--Yes to reset all voltage and current
firmware versions before 3.0.25, see Section values. The Reset Calib? display will only show if
2.7.8 for generator calibration. calibration is enabled.

Display also provides access to the calibration factors When calibrating voltage, the metered value and the
for metering (volts and amps). Changing the system number being entered as the calibrated value must be
voltage or replacing the main logic control circuit board within 10% of the system operating voltage.
requires calibration adjustment. Connect a meter with a
minimum accuracy of 1% to the generator set output When calibrating current, the metered value must be at
leads to calibrate the voltage-sensing logic. least 25% of the rated current on units smaller than
100 kW and at least 50 amps on units rated larger than
To enable calibration, start the generator set and select 100 kW. The number being entered as the calibrated
the Volts L1-L2 display. Then push and hold the value must within 10% of the metered value.
pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is To disable calibration, Rotate the pushbutton/rotary
now available. The display will show the following selector dial until the <--Return popup appears.

TP-6694 3/19 Section 2 Operation 53

Momentarily press the pushbutton/rotary selector dial. 2.7.5 GenSet Information
Stop the generator set if not already done.
Displays generator set and controller information.
Displayed data is factory entered.
Generator Metering
GenSet Information
Generating----> Total Power:
Metering # VA GenSet ----> Genset M/N:
Information ##

Total Power:
#W GenSet S/N:
##

Rated Power:
#% Cntrllr S/N:
##

Select this Display to

Enable or Disable Volts L1--L2:
Calibration --> #.# V 2.7.6 GenSet Run Time
Displays the generator set’s operating record including
Volts L2--L3: total run time loaded and unloaded, number of starts,
#.# V
and total energy kW hours.

Volts L3--L1: GenSet Run Time

#.# V
GenSet ----> Eng Runtime:
Run Time ##.# h

Volts L1--N:
#.# A
Eng Loaded:
#.# h

Volts L2--N:
#.# A
Eng Starts:
#

Volts L3--N:
#.# A
TotalEnergy:
#.# kWh

Current L1:
#.# A
2.7.7 GenSet System
Current L2: Display shows the generator set system data including
#.# A
voltage, frequency, phase connection, etc. Use the
values entered in this menu to help determine shutdown
Current L3:
values and time delays.
#.# A
The programming user defines the data shown in the
GenSet System menu. It is NOT data measured by the
Frequency: controller and associated sensing devices. The
#.# Hz
programming user defines these values for purposes of
calibrating the control.
Reset
Calibration Some alternators are designed to operate at limited
voltage, frequency, or phase connections and as a result
some settings may have limited parameters.
Reset
Calib? No
Display for Measurement System is user selectable as
OR English or Metric.
Reset
Calib? Yes Contrast display is user adjustable to help improve
digital display visibility in dimly lit rooms or in direct
sunlight.

54 Section 2 Operation TP-6694 3/19

Note: The contrast feature is a controller hardware GenSet System
change and may not be available on older units GenSet ----> System Freq:
even if the firmware is updated. System ##.# Hz

The alarm (horn) silence display is programmer

selectable to Always or Auto Only using SiteTecht SystemPhase:
#####
software. The Always selection allows the alarm to be
silenced in any of the OFF/RESET--AUTO--RUN
modes. The Auto Only selection allows silencing of the System Volt:
alarm only while in the Auto mode. ###.# V

The manual speed adjustment is made using the

Pwr Rating:
Engine RPM menu. This feature is available as a ##.# kW
factory-installed option or requires a new factory
personality profile. Adjustments can be made while the
unit is running or stopped. To make adjustments, press Amp Rating:
##.# A
and hold the selector dial and the RPM display will start
to flash. Then rotate the selector dial to the desired RPM
and press and hold the selector dial until the RPM Power Type:
display stops flashing. The adjustment range is #####
1751--1849 RPM (58--62 Hz) for 60 Hz and 1451--1549
RPM (48--52 Hz) for 50 Hz.
Battery V:
## V

Meas System
User Selectable --> English or Metric

Contrast
User Selectable --> #####

AlrmSilence:
Always or Auto Only

User Selectable
(see manual speed Engine RPM
adjustment above) --> #####

TP-6694 3/19 Section 2 Operation 55

2.7.8 GenSet Calibration The user can individually calibrate the values or reset all
of them. The local display Reset all calib? No or Yes.
This menu is only available in Decision-Makerr 3000 Select No to make no changes and exit GenSet
controllers with firmware versions before 3.0.25. Go to Calibration. Select Yes to reset all of the values.
Generator Metering Menu—Reset Calibration with
controller firmware version 3.0.25 or higher. When calibrating voltage, the metered value and the
number being entered as the calibrated value must be
Display provides access to the calibration factors for within 10% of the system operating voltage.
metering (volts and amps). Changing the system
voltage or replacing the main logic control circuit board When calibrating current, the metered value must be at
requires calibration adjustment. Connect a meter with a least 25% of the rated current on units smaller than
minimum accuracy of 1% to the generator set output 100 kW and at least 50 amps on units rated larger than
leads to calibrate the voltage-sensing logic. 100 kW. The number being entered as the calibrated
value must within 10% of the metered value.

GenSet Calibration
GenSet ----> Enter calib? GenSet ---->
Calibration No Calibration

OR
Enter calib?
User Selectable -->
Yes

Volts L1--L2:
#.# V

Volts L2--L3:
#.# V

Volts L3--L1:
#.# V

Volts L1--N:
#.# V

Volts L2--N:
#.# V

Volts L3--N: Reset Reset all

#.# V calibration calib? No

OR
Current L1: Reset Reset all
#.# A calibration calib? Yes

Current L2: Reset

#.# A calibration

Current L3: <----Exit

#.# A Calibration

56 Section 2 Operation TP-6694 3/19

2.7.9 Voltage Regulator running, enter Yes when the Enter volt reg? is displayed.
The user can review the value but attempting to change
Decision-Makerr 3000 Controllers with Firmware the value will cause a Cannot edit when stopped error
Versions Before 3.0.25. message.
Displays the voltage regulator adjustment value. All If the unit is running and Yes is entered when the Enter
other voltage regulator adjustments are changed using volt reg? is shown, the display will show the value. The
SiteTecht software. user can change the value at this time.
The voltage regulator value is reviewable at all times. In
order to review the value when the generator set is NOT

Voltage Regulator
Voltage ----> Enter volt Voltage ---->
Regulator reg? No Regulator

OR
Enter volt
User Selectable -->
reg? Yes

VR Volt Adj:
xxx.x

<---- Exit
voltage reg

Decision-Makerr 3000 Controllers with Firmware pushbutton/rotary selector dial until the Editing Enabled
Version 3.0.25 or Higher, or APM402 Controllers. popup appears. Editing of the voltage adjustment is now
available.
Displays the voltage regulator adjustment value. All
other voltage regulator adjustments are changed using The user can change the individual value or can select
SiteTecht software. Reset VR?--Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.
The voltage regulator value is reviewable at all times
and provides the ability to fine adjust voltage. Changing To disable calibration, Rotate the pushbutton/rotary
the system voltage or replacing the circuit board selector dial until the <--Return popup appears.
typically requires a voltage adjustment. Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.
To enable calibration, start the generator set and select
the VR Volt Adj display. Then push and hold the

Voltage Regulator
Voltage ----> VR Volt Adj: <-- Select this Display to
Regulator xxx.x Enable or Disable Editing

Reset VR --> Reset VR?

User Selectable -->
Settings No

OR
Reset VR?
Yes

TP-6694 3/19 Section 2 Operation 57

2.7.10 Digital Inputs D Inhibit Time Delay. The inhibit time delay is the time
period following crank disconnect during which the
Displays the selected programming user-defined digital generator set stabilizes and the controller does not
notice, warning, and shutdown inputs. These inputs detect the fault or status event. The controller will
provide a multitude of choices for configuring ignore the input until the inhibit time expires. If the
customized auxiliary inputs. See Figure 2-20 for a list of inhibit time is set to zero, the input is monitored at all
digital input choices. For descriptions of the inputs listed times, even when the generator is not running. The
refer to the following: inhibit time delay range is from 0 to 60 seconds.
D 2.4.5 System Fault Warning Lamp with Digital
D Time Delay (shutdown or warning). The time delay
Displays
follows the inhibit time delay. The time delay is the
D 2.4.6 System Fault Shutdown Lamp with Digital time period between when the controller first detects
Displays the fault or status event and the controller warning or
D 2.4.7 Status and Notice Digital Displays shutdown lamp illuminates. The delay prevents any
nuisance alarms. The time delay range is from 0 to
There is an optional 2 input/5 output (I/O) module board
60 seconds.
available that can provide two additional digital (or
analog) inputs.
Digital Inputs
The displays for digital inputs appear as shown below Digital ----> DIn A1
with Values true or false. Items shown in the display as Inputs #####

True are active.

D DIn A1 (digital input A1) standard DIn A1
Value: True or False
D DIn A2 (digital input A2) standard
D DIn A3 (digital input A3) standard (see note below)
DIn A2
D DIn B1 (digital input B1) with I/O module board #####
D DIn B2 (digital input B2) with I/O module board

All digital input selection and setup adjustments are done DIn A2
using SiteTecht software. The following terms and Value: True or False
descriptions are part of the setup procedure.
DIn A3
Note: DIn A3 digital input is factory reserved for #####
Enclosure Temperature: High Shutdown on
select Telecom units.
DIn A3
D Enabled. This menu indicates whether or not the Value: True or False

input is enabled. If the input is not enabled, the

controller will ignore this input signal.

Analog and Low High Critical High Low High

Digital Inputs Notice Warning Warning Warning Warning Shutdown Shutdown Shutdown
Auxiliary Input AD AD
Battery Charger Fault AD
Chicago Code Active AD
Enclosure Temperature: High
D
Shutdown (Din A3)
Engine Fuel Level AD D D D
Fuel Tank Leak AD D
Ground Fault AD
Low Engine Oil Level AD D
Low Fuel Pressure AD
Figure 2-20 Analog and Digital Inputs

58 Section 2 Operation TP-6694 3/19

2.7.11 Digital Outputs Digital Outputs
Digital ----> DOut A1
Displays the selected programming user-defined digital Outputs #####
notice, warning, and shutdown outputs. These outputs
provide a multitude of choices for configuring
customized auxiliary outputs. See Figure 2-21 for a list DOut A1
Value: True or False
of digital output choices. For descriptions of the outputs
listed refer to the following:
DOut B1
D 2.4.5 System Fault Warning Lamp with Digital
#####
Displays
D 2.4.6 System Fault Shutdown Lamp with Digital
Displays DOut B1
Value: True or False
D 2.4.7 Status and Notice Digital Displays

There is an optional 2 input/5 output (I/O) module board DOut B2

available that can provide five additional digital outputs. #####

The displays for digital outputs appear as shown below

with Values true or false. Items shown in the display as DOut B2
Value: True or False
True are active.
D DOut A1 (digital output A1) standard
DOut B3
D DOut B1 (digital output B1) with I/O module board #####
D DOut B2 (digital output B2) with I/O module board
D DOut B3 (digital output B3) with I/O module board DOut B3
D DOut B4 (digital output B4) with I/O module board Value: True or False

D DOut B5 (digital output B5) with I/O module board

DOut B4
Use SiteTecht software for digital output selection and #####
setup adjustments. Each output is tied to a user-
selectable function. The function can be a common
fault, common warning, NFPA 110 alarm active, or a DOut B4
Value: True or False
specific warning or shutdown.

DOut B5
#####

DOut B5
Value: True or False

TP-6694 3/19 Section 2 Operation 59

 Critical
Low High High No Signal Low High
Digital Outputs Notice Warning Warning Warning Warning Shutdown Shutdown Shutdown Shutdown
AC Sensing Lost X X
Alternator Protection X
Auxiliary Input X X
Battery Charger Fault X*
Battery Voltage X* X*
Chicago Code Active X
Common Fault X
Common Warning X
Cranking Voltage X
ECM Comm Loss X
Emergency Stop X
Engine Coolant Level X*
Engine Coolant Temperature X* X* X* X*
Engine Cooldown Active X
Engine Fuel Level X* X* X* X*
Engine Oil Level X X
Engine Oil Pressure X* X* X*
Engine Speed X X*
Engine Start Aid Active X
Engine Start Delay Active X
EPS Supplying Load X
Fuel Pressure X*
Fuel Tank Leak X X
Generator Frequency Average X X
Generator Running X
Generator True Total Power X
Generator Voltage L1--L2 X X
Generator Voltage L2--L3 X X
Generator Voltage L3--L1 X X
Ground Fault X
Locked Rotor X
NFPA 110 Alarm Active X
Not In Auto X*
Overcrank X*
Speed Sensor Fault X
System Ready X
* NFPA 110 Defined Common Alarms
Figure 2-21 Digital Outputs with NFPA 110 Defined Common Alarms

2.7.12 Analog Inputs There is an optional 2 input/5 output (I/O) module board
available that can provide two additional analog (or
Displays the selected programming user-defined digital) inputs.
analog notice, warning, and shutdown inputs. These
inputs provide a multitude of choices for configuring The displays for analog inputs appear as shown below
customized auxiliary inputs. See Figure 2-20 for a list of and have an acceptable operating range (0--5 VDC).
analog input choices. For descriptions of the inputs The analog input selection typically requires entering
listed refer to the following: four values—low warning, high warning, low shutdown,
D 2.4.5 System Fault Warning Lamp with Digital
and high shutdown.
Displays D AIn A1 (analog input A1) standard
D 2.4.6 System Fault Shutdown Lamp with Digital (reserved and not user programmable)
Displays D AIn A2 (analog input A2) standard
D 2.4.7 Status and Notice Digital Displays (Identified as A1 on SiteTecht software)

60 Section 2 Operation TP-6694 3/19

D AIn B1 (analog input B1) with I/O module board Battery gases. Explosion can cause severe injury or
death. Incorrect use of the equalize charge state may lead to
D AIn B2 (analog input B2) with I/O module board
hazardous situations. Equalization is ONLY applicable for
All analog input selection and setup adjustments are flooded lead acid (FLA) type batteries and will damage gel,
done using SiteTecht software. The following terms absorbed glass mat (AGM), or nickel-cadmium (NiCad) type
batteries. In the controller menu or SiteTecht settings, verify
and descriptions are part of the setup procedure.
that the battery topology is set correctly for the battery type
used. Do not smoke or permit flames, sparks, or other sources
D Enabled. This menu indicates whether or not the of ignition to occur near a battery at any time.
input is enabled. If the input is not enabled, the
controller will ignore this input signal. Battery charger menus are available on
Decision-Makerr 3000 Controllers with controller
D Inhibit Time Delay. The inhibit time delay is the time
firmware version 4.8.4 and higher, and on APM402
period following crank disconnect during which the
controllers.
generator set stabilizes and the controller does not
detect the fault or status event. The controller will Battery Charger 1 and 2 menus provide battery charger
ignore the input until the inhibit time expires. If the information and metering. Use this menu to view the
inhibit time is set to zero, the input is monitored at all charger output metering and charger states.
times, even when the generator is not running. The
inhibit time delay range is from 0 to 60 seconds. Note: Incorrect charger output system voltage may
cause irreversible damage to the battery and
D Time Delay (shutdown or warning). The time delay abnormal out gassing. Ensure that the battery
follows the inhibit time delay. The time delay is the charger parameters match the battery
time period between when the controller first detects manufacturer’s specifications before using. In the
the fault or status event and the controller warning or controller user interface settings, verify that the
shutdown lamp illuminates. The delay prevents any battery topology and system voltage is set
nuisance alarms. The time delay range is from 0 to correctly for the battery type that is used.
60 seconds.
Note: The battery charger menus are designed to work
Analog Inputs with charger GM87448. Unless connected to
Analog ----> AIn A1 charger GM87448 through CAN communication,
Inputs #####
the battery charger menus, although visible, have
no effect on the battery charger.
AIn B1
##### Battery Charger 1 and 2
Battery Charger 1 ----> Output Volts

AIn B2
#####
Battery Charger 2 ----> Output Amps

2.7.13 Battery Charger 1 and 2

Chrgr State
WARNING

SFWR Ver

Explosion.
Can cause severe injury or death. Reduced Out
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated Temp Comp
area. Isolate the battery charger from
explosive fumes.

TP-6694 3/19 Section 2 Operation 61

2.7.14 Event Log Volt Select
Volt Select: ----> 120/240 V 1 Ph
Displays up to 1000 stored status, warning, and ###/### V # Ph
shutdown events. After the first 1000 events, each
additional new event replaces the oldest event. See
1.2.4 Controller Fault Diagnostics for a list of possible 120/208 V 3 Ph

events.

Event Log 139/240 V 3 Ph

Event Log ----> #####
(Message Text)

277/480 V 3 Ph
(Scroll through up to 1000
max. stored events)

120/240 V 3 Ph
2.7.15 Volt Select
This menu is not available on Decision-Makerr 3000
Controllers with firmware versions before 2.8.22.

This menu allows the user to readily change controller

voltage settings. The volt select feature is typically used
in towable or temporary applications.

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.

Note: The volt select menu requires initial activation by

SiteTecht software. In SiteTecht software,
select True to activate the volt select menu.

Note: The generator set output leads require voltage

reconnection if the generator set does not have a
voltage selector switch installed.

With the generator set stopped, go to the Volt Select

menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.

62 Section 2 Operation TP-6694 3/19

 Section 3 Scheduled Maintenance

Under normal operating conditions, the generator set’s

DANGER
alternator requires no routine service. Consult
Section 2.1, Prestart Checklist, for a list of routine
checks.

WARNING
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Accidental starting.
Can cause severe injury or death. Servicing the generator set when it is operating. Exposed
moving parts will cause severe injury or death. Keep
Disconnect the battery cables before hands, feet, hair, clothing, and test leads away from the belts
working on the generator set. and pulleys when the generator set is running. Replace
Remove the negative (--) lead first guards, screens, and covers before operating the generator
when disconnecting the battery. set.
Reconnect the negative (--) lead last
when reconnecting the battery.
3.1 Alternator Service
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the When operating the generator set under dusty or dirty
generator set or equipment connected to the set, disable the conditions, use dry compressed air to blow dust out of
generator set as follows: (1) Move the generator set master the alternator while the generator set is running. Direct
switch to the OFF position. (2) Disconnect the power to the the stream of air through openings in the generator set
battery charger. (3) Remove the battery cables, negative (--) end bracket.
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, 3.2 Engine Service
remote start/stop switch, or engine start command from a
remote computer. Perform engine service at the intervals specified in the
engine manufacturer’s service literature. Contact an
WARNING authorized service distributor/dealer to obtain service
literature.

Note: Have maintenance work, including battery

service, performed by appropriately skilled and
Hot engine and exhaust system. suitably trained maintenance personnel familiar
Can cause severe injury or death. with generator set operation and service.
Do not work on the generator set until Kohler recommends the use of Kohler Genuine oil and
it cools. filters for maintenance and service.

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.

TP-6694 3/19 Section 3 Scheduled Maintenance 63

3.3 Service Schedule
Action
System—Component Visually Inspect Check Change Clean Test Interval
Fuel System
Day tank level X X Weekly
Flexible lines and connections X R Weekly
Fuel level switch X X Weekly
Main tank supply level X Weekly
Solenoid valve operation X X Weekly
Transfer pump operation X X Weekly
Water in system, remove D D Weekly
Refer to engine
operation manual
Filter(s) D
for service intervals
and instructions.
Fuel piping X Yearly
Tank vents and return lines for obstructions X Yearly
Lubrication System
Oil level D D Weekly
Crankcase breather D D Quarterly

Change oil D Refer to engine

operation manual
for service intervals
Replace filter(s)* D
and instructions.
Cooling System
Air cleaner to room/enclosure X Weekly
Block heater operation X Weekly
Coolant level D D Weekly
Flexible hoses and connectors X X Weekly
Water pump(s) D Weekly
Fan and alternator belts D D R Monthly
Coolant temperature protection level D Six Months
Air ducts, louvers X X Yearly
Coolant D Yearly
Heat exchanger X Yearly
Louver motors and controls X X X Yearly
Radiator exterior X Yearly
Water supply to heat exchanger X Yearly
Exhaust System
Drain condensate trap X Weekly
Leakage X X Weekly
Insulation, fire hazards X Quarterly
Flexible connector(s) X Six Months
Excessive back pressure X Yearly
Hangers and supports X Yearly
DC Electrical System
Battery charger operation, charge rate X Monthly
Battery electrolyte level X Monthly
Battery specific gravity, charge state X Monthly
Recharge after engine start X Monthly
Remove corrosion, clean and dry battery and rack X X Monthly
Clean and tighten battery terminals X X Quarterly
Tighten DC electrical connections X Six Months
D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action
* Service more frequently if operated in dusty areas.

64 Section 3 Scheduled Maintenance TP-6694 3/19

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

Meggerr is a registered trademark of Biddle Instruments.

TP-6694 3/19 Section 3 Scheduled Maintenance 65

3.4 Alternator Bearing Service 3.5.1 Bleeding Air from Fuel System
Have an authorized service distributor/dealer perform Bleed air from the fuel system after fuel system
service. maintenance, such as replacing the fuel filter(s). Use
the hand prime pump kit, when equipped. The hand
3.4.1 20--300 kW Models prime fuel pump eliminates the need for cranking the
engine to bleed air from the fuel system.
Replace the end bracket bearing every 10,000 hours of
operation in prime power applications. Service the Note: Bleed air from the fuel system according to the
bearing more frequently if the annual inspection engine manufacturer’s instructions. Trapped air
indicates excessive rotor end play or bearing damage. in the fuel system causes difficult starting and/or
The sealed end bracket bearing requires no additional erratic engine operation.
lubrication.
Note: Correct any fuel leaks encountered during the
priming procedure.
3.4.2 300--1000 kW Models with
4M/5M/7M Single-Bearing 1. Place the fuel valves in the fuel system prime
position. Close the fuel valve located between the
Alternator
pipe tee and the engine. Open the fuel valves on
The alternator bearing requires lubrication at intervals each side of the fuel prime pump. See Figure 3-1.
specified in the generator set technical manual. Use Note: The illustration shows a generator set
Chevron SRI or equivalent antifriction, high-quality without a fuel/water separator. The valve
grease with a lubrication temperature range of --30C to location and position for a generator set
175C (--22F to 350F). equipped with a fuel/water separator is
similar.
3.5 Diesel Fuel Systems 2. Loosen the bleed screw at the engine. Refer to the
engine operation manual for location of the bleed
WARNING screw(s). The bleed screw allows air to be expelled
from the fuel system when the hand prime pump is
operated.

Explosive fuel vapors.

Can cause severe injury or death.
Use 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 Close this Valve Open this Valve
condition. Do not replace flexible fuel lines with rigid lines. Use
Open this Valve
flexible sections to avoid fuel line breakage caused by
vibration. Do not operate the generator set in the presence of
fuel leaks, fuel accumulation, or sparks. Repair fuel systems
before resuming generator set operation.
Valve Open Valve Closed
Draining the fuel system. Explosive fuel vapors can PK-272000-H

cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when draining the fuel
Figure 3-1 Hand Prime Pump with Valve Positions
system. Wipe up spilled fuel after draining the system. for Fuel Priming (generator set without a
fuel/water separator shown), Typical

66 Section 3 Scheduled Maintenance TP-6694 3/19

 3. Rotate the hand prime pump handle Propane (LPG)—Adequate ventilation is mandatory.
counterclockwise until fuel flows from the bleed Because propane is heavier than air, install propane gas
screw. Stop pumping. detectors low in a room. Inspect the detectors per the
manufacturer’s instructions.
4. Tighten the bleed screw. Wipe up any fuel leakage. Natural Gas—Adequate ventilation is mandatory. Because
natural gas rises, install natural gas detectors high in a room.
5. Place the fuel valves in the normal operation Inspect the detectors per the manufacturer’s instructions.
position. Open the fuel valve located between the
pipe tee and the engine. Close the fuel valves on 3.6.1 Gaseous Fuel System Concept
each side of the fuel prime pump. (Single Fuel)
3.6 Gaseous Fuel Systems The gaseous fuel system uses a fuel valve with a
solenoid to control the fuel flow to the fuel regulator. The
Gaseous fuel systems apply to REZG_/RZG_/ERES_ generator set-mounted regulator reduces the fuel
(GM/PSI Powered) and REZX_/RZX_ (Doosan pressure as fuel passes to the fuel mixer. See
Powered) generator set models. Figure 3-2.

This section describes natural gas and liquified The fuel mixer controls the ratio of fuel to air under
petroleum gas (LPG) fuel systems that are not covered varying load and speed conditions. Because the fuel
in the engine operation manual or engine service mixer receives fuel in a gaseous state, it does not have
manual. to vaporize the fuel.

WARNING 1 2 3 4 5

Explosive fuel vapors.

Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels. 1. Primary regulator (supplied by gas supplier or user)
TP-5750-3

2. Pressure gauge
The fuel system. Explosive fuel vapors can cause severe 3. Solenoid valve (UL--listed models require 2 solenoid valves)
injury or death. Vaporized fuels are highly explosive. Use 4. Secondary regulator
extreme care when handling and storing fuels. Store fuels in a 5. Fuel mixer
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank Figure 3-2 Fuel Regulator and Valve, Typical
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit 3.6.2 LPG Liquid Withdrawal Fuel
flames or sparks to occur near sources of spilled fuel or fuel System Concept
vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexible fuel lines with rigid lines. Use With the LPG liquid withdrawal fuel system, pressurized
flexible sections to avoid fuel line breakage caused by liquid LPG fuel passes from the tank to a vaporizer. The
vibration. Do not operate the generator set in the presence of vaporizer converts the liquid fuel to gas before sending it
fuel leaks, fuel accumulation, or sparks. Repair fuel systems to the fuel mixer. The system also includes a fuel valve
before resuming generator set operation.
that shuts off the fuel flow when the engine stops.
Explosive fuel vapors can cause severe injury or death. Contact an authorized service distributor/dealer for
Take additional precautions when using the following fuels: availability.

TP-6694 3/19 Section 3 Scheduled Maintenance 67

3.6.3 Natural Gas and LPG Conversion 3.6.5 Fuel Conversion Connections
Most models operate on either natural gas or LPG fuel To change the fuel type, change the electrical
by performing the fuel conversion procedure. A hang connections to the engine ECM. The engine ECM has
tag on the fuel regulator may provide additional fuel tables and spark advance curves programmed for
conversion setup information. Fuel conversion may both natural gas and LPG. Use the following connection
decrease generator set output. Refer to the respective tables and wiring diagrams (Figure 3-3, Figure 3-4,
generator set spec sheet for ratings based on fuel Figure 3-5, Figure 3-6, Figure 3-7, Figure 3-8) to
selection. Changing fuel does not alter the emissions determine the applicable connections for your generator
compliance of the generator set engine. Consult your set model. Be sure to review the respective wiring
local generator set distributor/dealer for additional diagram for your specific model for possible special
information. applications.
Note: If a gaseous-fueled model has the fuel type
changed (LPG to natural gas or natural gas to For typical models with PSI, GM, and Doosan
LPG), order a new nameplate from an authorized engines, use the following:
distributor/ dealer with the updated ratings and Natural Gas Operation
attach to the generator set. D Disconnect lead 65 from lead N5.
D Disconnect lead 73B from the fuel valve.
3.6.4 Fuel System Changeover Kits D Connect lead 73A to the fuel valve.
(Dual Fuel)
LPG Vapor Operation
Automatic Changeover D Disconnect lead 73A from the fuel valve.
D Connect lead 73B to the fuel valve (LPG vapor).
A changeover fuel system kit provides automatic
D Connect lead 65 to lead N5 (ground).
changeover from natural gas to LPG vapor. The
primary and backup fuels each have a fuel valve. The LPG Liquid Withdrawal Operation
primary fuel is natural gas; the backup fuel is LPG D Disconnect lead 73A from the fuel valve.
vapor. Before starting, both fuel valves are closed.
D Connect lead 73B to the fuel valve (LPG liquid
When the generator set starts, the primary fuel valve
withdrawal).
opens. The primary fuel line has a pressure switch in
series with a relay connected to the start/run circuit. D Connect lead 65 to lead N5 (ground).

When the primary fuel pressure drops below 0.6 kPa Auto Changeover Natural Gas/LPG Vapor
(1.4 oz./in.2) or 6.4 cm (2.5 in.) water column , a relay Operation
opens the backup fuel valve and closes the primary fuel D Disconnect lead 65 from N5.
valve. When the primary fuel pressure rises above 0.6 D Connect lead N5 to LFP2 relay common terminal.
kPa (1.4 oz./in.2) or 6.4 cm (2.5 in.) water column, the D Connect lead 73A to the fuel valve (natural gas).
generator set uses the primary fuel. Contact an
D Connect lead 73B to the fuel valve (LPG vapor).
authorized service distributor/dealer for kit availability.
Natural LPG LPG Auto
Emissions certified models use a single electronic- Gas Vapor Liquid Changeover
Harness
controlled pressure regulator (EPR) for both fuels. A tee
QCON--7
fitting connects both fuels together upstream of the 73A (NG fuel not used
QCON--7
EPR. During operation when using the secondary fuel, it (NG fuel valve)
valve)
is normal for a small amount of secondary fuel to seep N5 not used 65 65 LFP2--COM
back through the primary fuel valve. To counter this 73B not used QCON--10 (LPG fuel valve)
situation, one of two methods is used depending upon
65 not used N5 N5 not used
the generator set model: (1) a second valve (identical to
63 LFP1--NC low fuel pressure sensor (if used)
the primary fuel valve) is installed in a reverse
configuration on the primary fuel side or (2) a small vent 70E2 P6--B (15 amp fuse)
line is installed between the primary fuel inlet and the air Figure 3-3 Gaseous Fuel Electrical Connections
intake through a solenoid valve.

68 Section 3 Scheduled Maintenance TP-6694 3/19

For KG40, KG45, KG50, KG60 (Koher Engine For KG80, KG80R (Kohler Engine KG6208TA), use
KG6208), use the following: the following:
Natural Gas Operation Natural Gas Operation
D Disconnect 78/78a and 70G/70R from the fuel valve D Disconnect the black fuel connector (J7)
D Connect 77/77a and 70H/70T to the fuel valve D Disconnect 49 and N17
D Connect 49 and N17 D Connect the white fuel connector (J8)

LPG Vapor Operation LPG Vapor Operation

D Disconnect 77/77a and 70H/70T from the fuel valves D Disconnect the white fuel connector (J8)
D Disconnect 49 and N17 D Connect the black fuel connector (J7)
D Connect 78/78a and 70G/70R to the fuel valves D Connect 49 and N17

Auto Changeover Natural Gas/LPG Vapor Harness Natural Gas LPG Vapor
Operation White Connector
NG fuel valve not used
D Connect 78/78a and 70G/70R to LP Fuel Valve (J8)
assembly N17 not used 49, QCON 10
D Connect 77/77a and 70H/70T to NG fuel valve 49 not used N17, QCON 9
assembly 49a not used not used
D Connect 49a to LFP2 normally closed terminal Black Connector
not used LPG fuel valve
(J7)
D Connect N17 to LFP2 common terminal
63 LFP1--NC, Optional alarm
Auto N16 LFP1--COM, Optional alarm
Harness Natural Gas LPG Vapor Changeover
Figure 3-5 KG80/KG80R Fuel Connections
QCON--14, QCON--14,
77/77a QCON--15 not used QCON--15
(NG fuel valve) (NG fuel valve)
70H/70T QCON--12, not used QCON--12,
QCON--13 QCON--13
(NG fuel valve) (NG fuel valve)
N17 49, QCON 10 not used LFP2--COM
49 N17, QCON 9 not used not used
49a not used not used LFP2--NC
78/78a not used QCON--17, QCON--19
(LPG fuel valve)
70G/70R QCON--16, QCON--18
(LPG fuel valve)
63 LFP1--NC, Optional alarm
N16 LFP1--COM, Optional alarm

Figure 3-4 KG40--KG60 Fuel Connections

TP-6694 3/19 Section 3 Scheduled Maintenance 69

 Natural Gas LPG Vapor

To ECM and
controller To ECM and
controller

LPG Liquid

To ECM and
controller

Auto Changeover Natural Gas and LPG Vapor

To ECM and
controller

ADV-7600B-F

Figure 3-6 Typical models with PSI, GM, Doosan Engines, Gaseous Fuel Connections Wiring Diagram
70 Section 3 Scheduled Maintenance TP-6694 3/19
 Natural Gas LPG Vapor

To ECM and
controller To ECM and
controller

Auto Changeover Natural Gas and LPG Vapor

To ECM and
controller

ADV-9007-A

Figure 3-7 KG40--KG60 (KG6208), Gaseous Fuel Connections Wiring Diagram

TP-6694 3/19 Section 3 Scheduled Maintenance 71
 Natural Gas LPG Vapor

To ECM and
To ECM and controller
controller

Auto Changeover Natural Gas and LPG Vapor

To ECM and
controller

ADV-9052-A

Figure 3-8 KG80/KG80R (KG6208TA), Gaseous Fuel Connections Wiring Diagram

72 Section 3 Scheduled Maintenance TP-6694 3/19
3.7 Crankcase Ventilation (CCV) 3.9 Cooling System
Heater Kit GM78171-KP1 The cooling system maintenance information applies to
radiator-cooled models which have a radiator with a
Applies to 125/150 kW, 8.1 L GM- and 8.8 L PSI- pressure cap and coolant recovery tank.
powered generator set models. Consult your local
generator set distributor/dealer for additional WARNING
information.

The crankcase ventilation (CCV) heater kit provides a

controlled heating source to the crankcase ventilation
system preventing freezing water buildup during cold
Hot coolant and steam.
weather. The thermostat turns on at 4_C (40_F) and
Can cause severe injury or death.
turns off at 16_C (60_F) reducing energy consumption.
See Figure 3-9. Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.

1 2 Allow the engine to cool. Release pressure from the

cooling system before removing the pressure cap. To
3 release pressure, cover the pressure cap with a thick
4 cloth and then slowly turn the cap counterclockwise to
the first stop. Remove the cap after pressure has been
TT-1560
completely released and the engine has cooled. Check
1. Heater element 3. Thermostat the coolant level at the tank if the generator set has a
2. Inline connector 4. AC power cord coolant recovery tank.
Figure 3-9 Crankcase Ventilation Heater Kit
Note: Engine damage. Bleed the air from the cooling
system to prevent overheating and subsequent
3.8 Air Cleaner Restrictor Indicator engine damage.
(if equipped)
Note: Block heater damage. The block heater will fail
The air cleaner restriction gauge mounted on the air if the energized heater element is not immersed
cleaner(s) helps determine the air cleaner change in coolant. Fill the cooling system before turning
interval. on the block heater. Run the engine until it is
warm, and refill the radiator to purge the air from
The air cleaner restriction gauge monitors air flow and
the system before energizing the block heater.
continuously displays restriction readings indicated as
vacuum (see Figure 3-10). Increased restriction
indicates a clogged air cleaner element. 3.9.1 Coolant Level Check
Check the coolant level in the coolant recovery tank.
As maximum allowable restriction is reached, the gauge
Maintain the coolant level between the high and low
window turns red indicating the air cleaner element
marks.
needs replacement. To reset the gauge, push the gauge
top down and release. Note: Periodically check the coolant level by removing
1 the pressure cap. Do not rely solely on the level in
the coolant recovery tank. Add fresh coolant until
the level is just below the overflow tube opening
3 10
2 of the filler neck.
15
19
22
25

273113

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

Figure 3-10 Restriction Indicators (styles vary)

TP-6694 3/19 Section 3 Scheduled Maintenance 73

3.9.2 Cooling System Component D Check the condition and tension of the radiator fan
Inspection and water pump belt(s). Follow the belt tension
procedure in this manual and/or the engine operation
To prevent generator set shutdown or damage caused manual.
by overheating:
D Check the pressure cap seal and replace a cracked or
D Keep the cooling air inlets clean and unobstructed. deteriorated cap. Remove dirt and other debris from
the pressure cap and filler neck. The pressure cap
D Inspect the radiator’s exterior for obstructions. raises the boiling point of the coolant, enabling higher
Remove dirt and foreign material using a soft brush or operating temperatures. Replace a leaking pressure
cloth to avoid damaging the radiator fins. cap with one rated for the same pressure. The
pressure cap rating usually appears on the pressure
D Check the hoses and connections for leaks. Replace cap.
any cracked, frayed, or spongy hoses.

74 Section 3 Scheduled Maintenance TP-6694 3/19

3.9.3 Procedure to Drain Cooling 1. Remove the pressure cap.
System
2. Close the radiator and/or engine block coolant
For optimum protection, drain, flush, and refill the drain valve(s) and tighten the cooling system hose
cooling system at the intervals listed in the service clamps.
schedule.
3. Open the air-bleed petcocks, if equipped. Close
Note: Dispose of all waste materials (oil, fuel, coolant, the air-bleed petcocks when coolant begins to flow
filters, and gaskets) in an environmentally safe from them.
manner.
4. Add coolant additives or water pump lubricants
1. Deenergize the block heater, if equipped. according to the engine manufacturer’s
recommendations in the engine operation manual.
2. Remove the pressure cap to allow the entire
system to drain and prevent air pockets from 5. Fill the cooling system with a coolant/antifreeze
restricting coolant flow through the engine block. mixture based on the engine manufacturer’s
recommendation.
3. Open the radiator and/or engine block coolant
drain valve(s) and allow the system to drain. 6. Replace the pressure cap.

4. If the inside of the radiator has mineral deposits or 7. Fill the coolant recovery tank to the low mark.
the used coolant contains dirt or grease, refer to
Section 3.9.4, Procedure to Flush and Clean the 8. Operate generator set until the thermostat opens
Cooling System. If the cooling system does not when the upper cooling system hose warms.
have mineral deposits, go to Section 3.9.5,
9. Stop the engine and allow it to cool.
Procedure to Refill the Cooling System.
10. Check and repair any coolant leaks.
3.9.4 Procedure to Flush and Clean
11. Remove the pressure cap.
Cooling System
12. Add coolant to bring the coolant level to just below
Use the instructions in the engine operation manual
the overflow tube opening of the filler neck.
when available to flush and clean the cooling system.
Otherwise, use the following procedure and the cooling 13. Replace the pressure cap.
system cleaner manufacturer’s instructions.
14. Maintain the coolant level in the coolant recovery
1. Flush the cooling system with clean water. tank between the high and low marks.
2. If the inside of the radiator still has mineral Air pockets often form in the engine water jacket
deposits, use a radiator cleaner to remove the when the coolant system is refilled. Check the
remaining deposits following the manufacturer’s coolant level in the coolant recovery tank after each
instructions. generator set operation and add coolant as
necessary until the coolant level stabilizes. Then
3. Drain, clean, and flush the coolant recovery tank.
check the coolant at the interval specified in the
service schedule.
3.9.5 Procedure to Refill Cooling
System 15. Reenergize the block heater, if equipped.

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.

TP-6694 3/19 Section 3 Scheduled Maintenance 75

3.10 Battery Refer to this section for general battery information and
maintenance. All generator set models use a negative
WARNING 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 3-11,
Figure 3-12, and Figure 3-13 for typical battery
Sulfuric acid in batteries. connections, including multiple battery configurations.
Can cause severe injury or death.
Wear protective goggles and 1 2
clothing. Battery acid may cause
blindness and burn skin. 1 2

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 1 2
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. 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.
EZ-273000-J
Battery acid cleanup. Battery acid can cause severe
1. To positive (+) terminal on starter solenoid.
injury or death. Battery acid is electrically conductive and
2. To ground (--) terminal on or near starter motor.
corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
soda) to a container with 4 L (1 gal.) of water and mix the Figure 3-11 12-Volt Engine Electrical System Single
neutralizing solution. Pour the neutralizing solution on the
Starter Motor Typical Battery Connection
spilled battery acid and continue to add the neutralizing
solution to the spilled battery acid until all evidence of a
1 2
chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
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, 2 1
particularly when it is charging. Do not dispose of a battery in a 1 2
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 2 1 1 2
battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury
or death. Short circuits can cause bodily injury and/or
equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
servicing the equipment. Use tools with insulated handles. 1. To positive (+) terminal on starter solenoid.
Remove the negative (--) lead first when disconnecting the 2. To ground (--) terminal on or near starter motor.
battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--) Figure 3-12 24-Volt Engine Electrical System Single
battery cable to the positive (+) connection terminal of the Starter Motor Typical Battery Connection
starter solenoid. Do not test the battery condition by shorting
the terminals together.

76 Section 3 Scheduled Maintenance TP-6694 3/19

 1 2 3 4 1

1 2 3 4
2

1-046

1. Filler caps
2. Electrolyte level
KW-272000-B
1. To positive (+) terminal on starter solenoid.
Figure 3-14 Battery Electrolyte Level Inspection
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.
3.10.3 Specific Gravity Check
Figure 3-13 24-Volt Engine Electrical System Dual
Starter Motors Typical Battery Use a battery hydrometer to check the specific gravity of
Connections 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
3.10.1 Clean Battery level or the number adjacent to the pointer. If the
Clean the battery and cables and tighten the battery hydrometer used does not have a correction table,
terminals according to the service schedule consult Figure 3-16. Determine the specific gravity and
recommendations. Clean the battery by wiping it with a electrolyte temperature of the battery cells. Locate the
damp cloth. Keep the electrical connections dry and temperature in Figure 3-16 and correct the specific
tight. gravity by the amount shown. The battery is fully
charged if the specific gravity is 1.260 at an electrolyte
If corrosion exists, disconnect the cables from the temperature of 26.7_C (80_F). Maintain the specific
battery and remove the corrosion with a wire brush. gravities between cells within 0.01 of each other.
Clean the battery and cables with a solution of baking Charge the battery if the specific gravity is below 1.215
soda and water. Do not allow the cleaning solution to at an electrolyte temperature of 26.7_C (80_F).
enter battery cells. Flush the battery and cables with
clean water and wipe the battery with a dry cloth. Note: Some battery testers have four or five beads in a
test tube. Draw electrolyte into the tube as with
After reconnecting the battery cables, coat the terminals the battery hydrometer described in this section
with petroleum jelly, silicon grease, or other or use the manufacturer’s instructions. Use
nonconductive grease. Figure 3-15 to interpret typical test results.

Number of Floating Beads Battery Condition

3.10.2 Electrolyte Level Inspection
5 Overcharged
Check the electrolyte level and specific gravity of 4 Fully charged
batteries that have filler caps. Maintenance-free 3 A good charge
batteries do not require electrolyte level checking or
1 or 2 A low charge
specific gravity testing.
0 A dead battery
Check the electrolyte level at the specified interval.
Figure 3-15 Bead-Type Test Interpretation
Remove the filler caps and verify that the electrolyte
level reaches the bottom of each filler hole. See
Figure 3-14. 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.

TP-6694 3/19 Section 3 Scheduled Maintenance 77

3.10.4 Charge Battery
WARNING
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 while the generator set is running.
Accidental starting.
C F Correction
Can cause severe injury or death.
71.1 160 + .032 Example No. 1
+ .030
Disconnect the battery cables before
65.6 150 + .028 Temperature below 26.7C (80F)
working on the generator set.
+ .026 Remove the negative (--) lead first
60.0 140 + .024 Hydrometer Reading 1.250 when disconnecting the battery.
+ .022
Reconnect the negative (--) lead last
54.4 130 + .020 Acid Temperature --6.7C (20F) when reconnecting the battery.
+ .018
48.9 120 + .016 Subtract .024 Specific Gravity
+ .014 Corrected Specific Gravity is 1.226
43.3 110 + .012
Disabling the generator set. Accidental starting can
+ .010 1.250 -- .024 = 1.226 cause severe injury or death. Before working on the
37.8 100 + .008 generator set or equipment connected to the set, disable the
+ .006 generator set as follows: (1) Move the generator set master
Example No. 2
32.2 90 + .004 switch to the OFF position. (2) Disconnect the power to the
+ .002
0 Temperature above 26.7C (80F) battery charger. (3) Remove the battery cables, negative (--)
26.7 80
-- .002 lead first. Reconnect the negative (--) lead last when
Hydrometer Reading 1.235 reconnecting the battery. Follow these precautions to prevent
21.1 70 -- .004
--. 006
Acid Temperature 37.8C (100F) starting of the generator set by an automatic transfer switch,
15.6 60 -- .008 remote start/stop switch, or engine start command from a
-- .010
Add .008 Specific Gravity remote computer.
10 50 -- .012 Corrected Specific Gravity is
-- .014
1.243
4.4 40 --
--
.016
.018
WARNING
1.235 + .008 = 1.243
-- 1.1 30 -- .020
-- .022
-- 6.7 20 -- .024 The temperature correction amounts
-- .026 to about .004 (4 points) of specific
-- 12.2 10 -- .028 gravity for each 5.5C (10F) change
in temperature. Hot engine and exhaust system.
Can cause severe injury or death.
TP6895--6 Do not work on the generator set until
it cools.
Figure 3-16 Specific Gravity Temperature Correction
Servicing the exhaust system. Hot parts can cause
Note: If the generator set is in a temporary prime power severe injury or death. Do not touch hot engine parts. The
application in which the generator set has periods engine and exhaust system components become extremely
of inactivity, the controller circuitry may drain the hot during operation.
battery. If there is no power source for a battery
charger, place the controller in the prime power DANGER
mode, if equipped, or disconnect the battery from
the generator set.

3.11 Storage Procedure

Hazardous voltage. Moving parts.
Perform the following storage procedure before taking a Will cause severe injury or death.
generator set out of service for three months or longer.
Follow the engine manufacturer’s recommendations, if Operate the generator set only when
available, for fuel system and internal engine all guards and electrical enclosures
are in place.
component storage.

78 Section 3 Scheduled Maintenance TP-6694 3/19

Servicing the generator set when it is operating. Exposed Gaseous-Fueled Engines
moving parts will cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts 1. Start the generator set.
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator 2. With the generator set running, shut off the gas
set. supply.

3.11.1 Lubricating System 3. Run the generator set until the engine stops.

Prepare the engine lubricating system for storage as 4. Stop the generator set.
follows:

1. Run the generator set for a minimum of 30 minutes

3.11.4 Internal Engine Components
to bring it to normal operating temperature. (Gaseous-Fueled Engines)

2. Stop the generator set. If you have access to a fogging agent or SAE 10 oil
prepare the pistons and cylinders for storage as follows:
3. With the engine still warm, drain the oil from the
crankcase. 1. Start the generator set.

4. Remove and replace the oil filter. 2. While the engine is running, spray a fogging agent
or SAE 10 engine oil into the air intake for about two
5. Refill the crankcase with oil suited to the climate. minutes until the engine stops.

6. Run the generator set for two minutes to distribute 3. Stop the generator set.
the clean oil.
If a fogging agent is not available perform the following:
7. Stop the generator set.
1. Remove the spark plugs.
8. Check the oil level and adjust, if needed.
2. Pour 15 cc (0.5 oz.) of engine oil into each spark
plug hole.
3.11.2 Cooling System
Ignition System Damage. Refer to the engine
Prepare the cooling system for storage as follows: operation manual for ignition system precautions
before cranking the engine while the spark plug
1. Check the coolant freeze protection using a wires are disconnected.
coolant tester.
3. Crank the engine two or three revolutions to
2. Add or replace coolant as necessary to ensure lubricate the cylinders.
adequate freezing protection. Use the guidelines
included in the engine operation manual. 4. Reinstall the spark plugs and torque them to
specifications.
3. Run the generator set for 30 minutes to redistribute
added coolant.
3.11.5 Exterior
3.11.3 Fuel System 1. Clean the exterior surface of the generator set.
Prepare the fuel system for storage as follows: 2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
Diesel-Fueled Engines
3. To prevent impurities from entering the air intake
1. Fill the fuel tank with #2 diesel fuel. and to allow moisture to escape from the engine,
secure a cloth over the air intake.
2. Condition the fuel system with compatible
additives to control microbial growth. 4. Mask electrical connections.
3. Change the fuel filter/separator and bleed the fuel 5. Spread a light film of oil over unpainted metallic
system. See the engine owner’s manual. surfaces to inhibit rust and corrosion.

TP-6694 3/19 Section 3 Scheduled Maintenance 79

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

Perform battery storage after all other storage 5. Connect the battery to a battery charger or charge it
procedures. monthly with a trickle battery charger. Refer to the
battery charger manufacturer’s recommendations.
1. Confirm that the generator set is stopped.
Maintain a full charge to extend battery life.
2. Disconnect the battery(ies), negative (--) lead first.

3. Clean the battery. Refer to Section 3.10.1 for the

battery cleaning procedure.

80 Section 3 Scheduled Maintenance TP-6694 3/19

 Section 4 General Troubleshooting

This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed
diagnostic, and repair information. on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
Use the following charts to diagnose and correct authorized distributor/dealer. Use the record to help
common problems. First check for simple causes such describe the problem and repairs or adjustments made
as a dead engine starting battery or an open circuit to the equipment.
breaker. The charts include a list of common problems,
possible causes of the problem, recommended
corrective actions, and references to detailed
information or repair procedures.

TP-6694 3/19 Section 4 General Troubleshooting 81

82
4.1 General Troubleshooting Chart
Trouble Symptoms

Section or
Publication

Does not crank

No or low output
voltage
Exercise run time
and/or event
records inoperative

Cranks but
does not start
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Probable Causes Recommended Actions Reference*

Section 4 Troubleshooting
Controller
x x Controller circuit board(s) inoperative Replace the controller. Gen. S/M
x x Controller circuit board(s) wiring fault Check the wiring. W/D
x Controller fault Troubleshoot the controller.[ Gen. S/M
x x x Controller fuse blown Check for continuity across fuse. If fuse is blown, Section 1, W/D
troubleshoot the controller wiring and replace circuit board.[
x Controller master control buttons Replace the controller master control button circuit board. —
inoperative
x Controller master control button in the Press the controller master control RUN or AUTO button. Section 2
OFF/RESET mode
x Engine start circuit open Press the controller master control RUN button to test the Section 2, W/D,
generator set. Troubleshoot the auto start circuit and time Gen. I/M, S/M
delays. ATS O/M, S/M
x x Voltage regulation inoperative Replace the junction box sensing fuses. If the fuse blows W/D, Gen. S/M
again, troubleshoot the controller.
x Controller firmware error Review the controller display troubleshooting chart. Section 4.2
Alternator
x AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
set side of the circuit breaker.
x Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. ATS O/M
position
x Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. ATS O/M, S/M
Troubleshoot the transfer circuit and time delays.
x Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
field open
x Main field (rotor) inoperative Test and/or replace the rotor.[ Gen. S/M
(open or grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
x Voltage regulator settings incorrect Adjust the voltage regulator. Section 1.3.3,
SiteTech O/M

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.

TP-6694 3/19
 Trouble Symptoms

TP-6694 3/19
Section or
Publication

Does not crank

No or low output
voltage
Exercise run time
and/or event
records inoperative

Cranks but
does not start
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Probable Causes Recommended Actions Reference*
Electrical System (DC Circuits)
x x Battery connections loose, corroded, Verify that the battery connections are correct, clean, and Section 3
or incorrect tight.
x x Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
recommended battery CCA rating.
x x TP-6694 Starter/starter
3/19 solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
x x Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect W/D
locked tight it to the controller.
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
Engine
x x x x Air cleaner clogged Clean or replace the filter element. Eng. O/M
x x x x x Compression weak Check the compression.[ Eng. S/M
x x x x x Engine overload Reduce the electrical load. See the generator set spec S/S
sheet for wattage specifications.
x Exhaust system leak Inspect the exhaust system. Replace the inoperative I/M
exhaust system components.[
x Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust I/M
system components.[
x x x x Governor inoperative Adjust the governor.[ Eng. S/M
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —
x x x Ignition system inoperative (gas Check the ignition system Eng. O/M, Eng.
models only) (spark plugs, spark plug wires, etc.). S/M
x x x x x Engine ECM and/or sensors Troubleshoot the engine ECM and/or sensors. Eng. O/M, Eng.
S/M

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.

Section 4 Troubleshooting
83
84
Trouble Symptoms

Section or
Publication

Does not crank

No or low output
voltage
Exercise run time
and/or event
records inoperative

Cranks but
does not start
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Probable Causes Recommended Actions Reference*
Cooling System
x x Air openings clogged Clean the air openings. —

Section 4 Troubleshooting
x Coolant level low Restore the coolant to normal operating level. Section 3
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
x High temperature shutdown Allow the engine to cool down. Then troubleshoot the Sec. 3, Eng. O/M
cooling system.
x Low coolant level shutdown, if Restore the coolant to normal operating level. Section 3
equipped
x Thermostat inoperative Replace the thermostat. Eng. S/M
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
x x Ether canister empty or system Replace or repair the ether starting system. Eng. O/M
inoperative, if equipped (diesel only)
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
x x x Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ Eng. S/M
(diesel only)
x x x Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
(diesel only)
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x Fuel pressure insufficient (gas only) Check the fuel supply and valves.[ S/S, Gen. O/M
x x x x Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
(diesel only)
Lube System
x x x x Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the Eng. O/M
ambient temperature operating climate.
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x Low oil pressure shutdown Check the oil level. Eng. O/M

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.

TP-6694 3/19
 4.2 Controller Display and Voltage Regulation Troubleshooting Chart
Section or
Publication

TP-6694 3/19
Trouble Symptoms Probable Causes Recommended Actions Reference*
Controller Display and Voltage Regulator
Display is black No/low battery charge Recharge/replace battery Section 3, Battery
Display shows single segment Low battery voltage Recharge battery Section 3, Battery
Display shows an error message Controller firmware or pushbutton/ Review the Error Message Section Section 2.7.1
rotary selector dial entry error
Display locks up No/low battery charge Recharge/replace battery Section 3, Battery
Output voltage ramps Defective exciter winding Troubleshoot alternator components [ Generator Service
Manual
Output voltage unstable TP-6694
Voltage
3/19regulation calibration incorrect Readjust voltage regulation [ Section 1.3.3,
SiteTech O/M
Unable to change voltage and current calibrations Calibration not enabled Enable calibration in Generator Metering section Section 1.2.3
Digital Display,
Section 2.6.4
Unable to find volt select menu Volt select not enabled Enable volt select in SiteTech SiteTech O/M

* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.

Section 4 Troubleshooting
85
 Notes

86 TP-6694 3/19
 Section 5 Voltage Reconnection

5.1 Introduction Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
Use the following voltage reconnection procedure to generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset
change the voltage of 10- and 12-lead generator sets.
button to shut down the generator set. (2) Disconnect the
Frequency changes require voltage regulator and power to the battery charger, if equipped. (3) Remove the
governor adjustments. Refer to the respective spec battery cables, negative (--) lead first. Reconnect the negative
sheet to determine if frequency is fixed or field- (--) lead last when reconnecting the battery. Follow these
convertible. If frequency is adjustable, refer to the precautions to prevent the starting of the generator set by the
engine service manual and/or governor literature for remote start/stop switch.
conversion information.
DANGER
Refer to the following procedure and the connection
schematics. Follow the safety precautions at the front of
this manual and in the procedure text and observe
National Electrical Code (NEC) guidelines.

NOTICE Hazardous voltage. Moving parts.

Voltage reconnection. Affix a notice to the generator set Will cause severe injury or death.
after reconnecting the set to a voltage different from the Operate the generator set only when
voltage on the nameplate. Order voltage reconnection all guards and electrical enclosures
decal 246242 from an authorized service distributor/ are in place.
dealer.
Grounding electrical equipment. Hazardous voltage will
Note: Equipment damage. Verify that the voltage cause severe injury or death. Electrocution is possible
ratings of the transfer switch, line circuit breakers, whenever electricity is present. Ensure you comply with all
and other accessories match the selected line applicable codes and standards. Electrically ground the
voltage. generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all
power sources before servicing the equipment. Never contact
WARNING electrical leads or appliances when standing in water or on wet
ground because these conditions increase the risk of
electrocution.
Short circuits. Hazardous voltage/current will cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
Accidental starting. connections with tools or jewelry while making adjustments or
Can cause severe injury or death. repairs. Remove all jewelry before servicing the equipment.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
5.2 Voltage Reconnection
when disconnecting the battery. Procedure
Reconnect the negative (--) lead last
when reconnecting the battery. Note: For Decision-Makerr 3000 Controllers with
software versions before 2.8, go to Section 5.3.

1. Press the generator set master control

OFF/RESET button.

TP-6694 3/19 Section 5 Voltage Reconnection 87

 2. Turn the controller pushbutton/rotary selector dial Note: Position current transformers CT1, CT2,
until it stops at the Volt Select menu. See and CT3 with the dot or HI side CT marking
Figure 5-1. toward the generator set.

Note: If the Volt Select menu does not appear, the 9. Reconnect the battery, negative lead last.
controller voltage selection feature was not
activated using SiteTecht software. 10. Press the generator set master control RUN button
to start the generator set. Check the digital display
Volt Select: ----> 120/240 V 1 Ph for correct voltages using 2.7.4 Generator
###/### V # Ph
Metering.

120/208 V 3 Ph
11. Press the generator set master control
OFF/RESET button to stop the generator set after
completing the voltage adjustments.
139/240 V 3 Ph

5.3 Voltage Reconnection

Procedure
277/480 V 3 Ph
Note: This procedure applies to Decision-Makerr 3000
Controllers with software versions before 2.8
120/240 V 3 Ph only.
TP-6694-2
1. Press the generator set master control
Figure 5-1 Volt Select Menu OFF/RESET button.

2. Disconnect the generator set engine starting

3. Press the selector dial and the voltage selection battery, negative (--) lead first. Disconnect power to
option (second line on the display) will start to flash. the battery charger (if equipped).
4. Turn the selector dial clockwise or 3. Use Figure 5-2, Figure 5-3, Figure 5-4, or
counterclockwise until the desired voltage Figure 5-5 to determine the generator set voltage
selection option appears. configuration. Note the original voltage and
reconnect as needed. Route leads through current
5. Press the selector dial. The second line on the transformers (CTs) and connect them according to
display will stop flashing and the new voltage will the diagram for the desired phase and voltage.
appear.
Note: Position current transformers CT1, CT2,
6. Rotate the generator set voltage selector switch (if and CT3 with the dot or HI side CT marking
equipped) to match the desired voltage shown on toward the generator set.
the controller display. Skip steps 7--9 and go to
step 10. 4. Reconnect the battery, negative lead last.
If the generator set does not have a voltage 5. Use SiteTecht software to update the information.
selection switch, continue to step 7
6. Refer to 2.7.8 for generator set calibration at the
7. Disconnect the generator set engine starting controller.
battery, negative (--) lead first. Disconnect power to
the battery charger (if equipped). 7. Press the generator set master control RUN button
to start the generator set. Check the digital display
8. Use Figure 5-2, Figure 5-3, or Figure 5-5 to for correct voltages using 2.7.4 Generator
determine the generator set voltage configuration. Metering.
Note the original voltage and reconnect as needed.
Route leads through current transformers (CTs) 8. Press the generator set master control
and connect them according to the diagram for the OFF/RESET button to stop the generator set after
desired phase and voltage. completing the voltage adjustments.

88 Section 5 Voltage Reconnection TP-6694 3/19

Figure 5-2 20--150 kW Permanent Magnet Single-Phase Alternators, ADV-5875U-1

TP-6694 3/19 Section 5 Voltage Reconnection 89

Figure 5-3 20--300 kW Permanent Magnet Alternators, ADV-5875U-2

90 Section 5 Voltage Reconnection TP-6694 3/19

Figure 5-4 60 IMS--300 kW Wound Exciter Field & 20--300 kW, 600 V Perm. Magnet Alternators, ADV-5875U-3

TP-6694 3/19 Section 5 Voltage Reconnection 91

Figure 5-5 300 kW and Larger Pilot-Excited, Permanent Magnet 4M/5M/7M/10M Alternators, ADV-5875U-4

92 Section 5 Voltage Reconnection TP-6694 3/19

 Section 6 Accessories

6.1 Accessories and Connections 6.1.1 Battery Charger Kit with Alarm
Option
Several accessories help finalize installation, add
convenience to operation and service, and establish The battery charger with alarm option provides battery
state and local code compliance. charging to the engine starting battery(ies) and
connects to the controller for fault detection. Battery
Accessories vary with each generator set model and chargers for 12- or 24-volt models are available as a
controller. Select factory-installed and/or shipped- generator set accessory. See Figure 6-2 and Figure 6-3
loose accessories. See Figure 6-1 for a list of available and the battery charger manual for battery charger fault
kits. Obtain the most current accessory information connections.
from your local authorized service distributor/dealer.
Note: On charger GM87448, the Battery Charger Fault
This section illustrates several accessories available at is communicated through CAN communication
print time of this publication. Accessory kits generally and the connection on TB1 is not used.
include installation instructions. See wiring diagrams
manual for electrical connections not shown in this
section. See the installation instructions and drawings
supplied with kit for information on kit mounting location.
CONNECT TO TB1
The instructions provided with the accessory kit
supersede these instructions where there are CHARGER
differences. In general, run AC and DC wiring in MALFUNCTION
separate conduit. Use shielded cable for all analog
inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.
LV HV CM BATTERY CHARGER
See Section 6.2, Accessory Connections, for terminal ALARM TERMINAL
identification. STRIP

Kit Description
GM16088A-A/TP--6694
Battery Charger (with alarms)
Common Fault/Failure (32A) Connections
Figure 6-2 Battery Charger Connections
Fifteen-Relay Dry Contact Board with NO and NC Contacts
Gas Fuel Valve
Input/Output Module Board
Key Switch
Low Fuel (Level) Switch
Low Fuel (Pressure) Switch
Manual Speed Adjust
Prime Power Switch
Remote Emergency Stop
Remote Reset Feature
Remote Serial Annunciator
Run Relay
Shunt-Trip Line Circuit Breaker
GM67191-B
Figure 6-1 Optional Accessories

Figure 6-3 Battery Charger to Controller Connection

TP-6694 3/19 Section 6 Accessories 93

6.1.2 Common Fault/Failure (32A) Relay
Kit
The common fault relay is standard on the controller
circuit board and located at the TB2 terminal strip
connections. Contacts are rated at 2 amps at 32 VDC
or 0.5 amps at 120 VAC max. See Figure 6-4 and
Figure 6-5.

The optional common fault relay shown in Figure 6-5 as

DCB2 has contacts rated at 10 amps at 28 VDC or
120 VAC and can be connected to user-supplied
accessories.

The optional common fault relay shown in Figure 6-5 as

DCB1 has contacts rated at 10 amps at 28 VDC or
120 VAC and is used to trigger the shunt-trip line circuit
breaker kit (mentioned later in this section).

GM67191-B

Figure 6-5 Common Fault Relay Kit and Shunt-Trip

Relay Kit Wiring

GM67191-B

Figure 6-4 Common Fault Relay Wiring (Standard)

94 Section 6 Accessories TP-6694 3/19

6.1.3 Fifteen-Relay Dry Contact Kit When a generator fault condition occurs, the contact kit
relay energizes. The relay energization corresponds to
The optional 15-relay dry contact kit is available for the controller output being activated.
selected models. The 15--relay dry contact kit is not
available with the input/output module (2-input/5-output Check the electrical requirements of the user-supplied
board) described in Section 6.1.5. accessories prior to installation of the relay dry contact
kit. User-supplied accessories require their own
Introduction electrical source and must not exceed the relay contact
ratings.
The optional 15-relay dry contact kit (see Figure 6-6 and
Figure 6-7) provides normally open and normally closed Connect to the normally open (NO) or normally closed
contacts to activate warning devices and other (NC) terminals as required for each [Link] relay
user-provided accessories allowing remote monitoring contacts (K1 to K14) are rated:
of the generator set. Connect any controller fault output
D 10 amp @ 120 VAC
to the dry contact kit. Typically, lamps, audible alarms,
or other devices signal the fault conditions. D 10 amp @ 28 VDC (max.)
D 0.01 amp @ 28 VDC (min.)
The 15-relay dry contact board has four digital inputs
and two analog inputs. There are fourteen The common fault relay contact (K15) is rated:
programmable relay outputs (K1--K14) and one D 500 mA @ 125 VAC
common fault relay output (K15). D 2 amp @ 30 VDC

1 2

GM75749K-3

1. 15-relay dry contact kit

2. Controller location

Figure 6-6 Optional 15-Relay Dry Contact Kit

TP-6694 3/19 Section 6 Accessories 95

 1
2 3 4

GM78246E-2
5

1. TB5 output connections C and NO for the common fault relay K15 (other TB5 terminals are factory connections only)
2. P35 4-position jack connects to controller (factory-connected)
3. TB6 8-position terminal block, digital inputs/digital returns (D11, D12, D13, and D14)
4. P36 8-position pin, analog inputs (see Figure 6-8 for connections)
5. TB7 through TB13, connections for relays K1 through K14 with Normally Open (NO) and Normally Closed (NC) contacts

Figure 6-7 15-Relay Dry Contact Board

Connections Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
For field connections, read the entire Electrical generator set or equipment connected to the set, disable the
Connection procedure and perform the steps in the generator set as follows: (1) Press the generator set off/reset
order shown. Observe applicable local and national button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
electrical codes when installing the wiring system.
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
Observe the following safety precautions while making precautions to prevent the starting of the generator set by the
connections to the kit. remote start/stop switch.
Battery short circuits. Explosion can cause severe injury
WARNING 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 (--)
Accidental starting. battery cable to the positive (+) connection terminal of the
Can cause severe injury or death. starter solenoid. Do not test the battery condition by shorting
the terminals together.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first Leads 42A and 2 provide power to the relays. Do not
when disconnecting the battery. use terminals 42A (+) or 2 (GND) on the controller
Reconnect the negative (--) lead last connection kit terminal strip to supply voltage to
when reconnecting the battery. user-supplied accessories. User-supplied DC

96 Section 6 Accessories TP-6694 3/19

accessories require separate leads connected directly 7. Supply two lengths of stranded wire to make leads
to the battery for the voltage supply. Attach long enough to connect the user- supplied device
user-supplied 12/24-volt DC accessories to the battery to the dry contact terminals and power supply. Use
positive (+) connection at the starter solenoid and to the color-coded wire for easy identification. Make
battery negative (--) connection at the engine ground. leads long enough to allow for walls, ductwork, and
The 120 VAC accessories require a user-supplied other obstructions. Use separate conduit for the
voltage source. dry contact wiring.

Note: A maximum of three inputs may be connected to 8. 12/24-Volt DC Devices. Attach the user-supplied
a single relay driver output. Inputs include dry 12/24-volt DC accessories to the starting battery
contacts, remote annunciator, common failure positive (+) connection at the starter solenoid and
alarm, A/V alarm, and shunt trip line circuit to the battery negative (--) connection at the engine
breaker. ground. Otherwise, use a separate 12/24-volt DC
supply. Do not use terminals 42A and 2 on the
Note: Only one 15-relay dry contact kit can be controller connection kit terminal strip to supply the
connected to the controller. voltage to the relay contacts. Supply separate
leads connected directly to the battery for the
Electrical Connection Procedure supply voltage. The circuit must include fuse or
circuit breaker protection.
1. Press the generator set master control
OFF/RESET button. 9. 120-Volt AC Devices. Connect the user- supplied
accessories to a separate 120-volt AC power
2. Disconnect the power to the battery charger, if supply. The circuit must include fuse or circuit
equipped. breaker protection.

3. Disconnect the generator set engine starting 10. Connect the user-supplied device per the
battery(ies), negative (--) lead first. Instructions and/or schematic supplied with the
device to a power source and to the dry contact
4. Remove the top panel of the controller connection terminals. Cut the user-supplied leads to length,
box. See Figure 6-6 for location of the relay board. strip lead ends, crimp on spade terminals (not
supplied), and connect the leads to the relay
5. See Figure 6-8 for connections of analog inputs. contact screw terminals. Route the wiring for the
relay dry contacts away from the generator set
6. Select the normally open (NO) contacts of the
output leads.
relay, Form A dry contact, depending upon the
application. Use a two-wire harness for the NO 11. Repeat Step 6 for the remaining dry contact relays.
connections.

P36 Optional 5 V P36 Optional 5 V P36

power power
+5 (50 mA max.) +5 (50 mA max.) +5

VPx VPx + VPx

Output
Analog Analog
VNx VNx -- VNx
Device Device
GND GND GND
GND
GND
100 ohm min. or 50 mA max. current
TP-6694-6
0--5 Volt Ratiometric Sensor 0--5 Volt Analog Device +/-- 3 Volt Analog Device

Figure 6-8 Dry Contact Kit Analog Input Connections P36

TP-6694 3/19 Section 6 Accessories 97

12. Replace the cover on the controller connection Optional Dry Contact
box. SiteTech I/O Name Board Connection
Analog Input C1 P36 Analog Input VN1/VP1
13. Check that the generator set is in the OFF mode.
Analog Input C2 P36 Analog Input VN2/VP2
14. Reconnect the generator set engine starting Digital Input C1 TB6 DI1
battery, negative (--) lead last. Digital Input C2 TB6 DI2
Digital Input C3 TB6 DI3
15. Reconnect power to the battery charger, if
Digital Input C4 TB6 DI4
equipped.
Digital Output C1 TB7 K1
The relay kit is factory-installed and connected to the Digital Output C2 TB7 K2
controller. See Figure 6-36 for connections to the Digital Output C3 TB8 K3
controller, if necessary. Digital Output C4 TB8 K4
Digital Output C5 TB9 K5
Program the inputs and outputs using SiteTecht Digital Output C6 TB9 K6
Use a computer with Kohler SiteTecht software to Digital Output C7 TB10 K7
assign functions to digital and analog inputs and Digital Output C8 TB10 K8
outputs. Each input and output corresponds to a Digital Output C9 TB11 K9
controller connection. Verify that the settings are Digital Output C10 TB11 K10
appropriate for the connected sensor, switch, or Digital Output C11 TB12 K11
equipment. Do not change factory-set inputs and
Digital Output C12 TB12 K12
outputs without verifying the input and output
Digital Output C13 TB13 K13
connections.
Digital Output C14 TB13 K14
Refer to Introduction—List of Related Materials for the Figure 6-9 Optional Inputs and Outputs with Dry
SiteTecht Software Operation Manual part no. Contact Kit
SiteTecht input and output parameters C1 through C14
are designated for use on the optional 15-relay dry 6.1.4 Gas Fuel Valve Kit
contact board. See Figure 6-9.
This section provides the wiring information for an
Note: See Figure 6-7 for P36 and TB7--TB13 locations. additional gas fuel valve kit required for UL Approval.
See Figure 6-10. Refer to the respective generator set
Test Dry Contact Relays wiring diagrams for additional information and for LP
liquid applications.
Verify the dry contact relay function by using the
following procedure when troubleshooting. Typical for PSI, GM, and Doosan Engines
1. Remove the user-supplied device wiring from the
relay dry contact terminals.

2. Test the relay operation by connecting an

ohmmeter across the NO and C terminals on the
relay terminal strip.

3. Use a jumper wire to ground the selected fault

terminal on the controller connection terminal strip.
The relay contacts should close and the ohmmeter GM72401D-D

should display a low resistance reading KG80, KG80R (KG6208TA Engine) Connections
(continuity).

4. Install the user-supplied device wiring on the relay

dry contact output terminals.

ADV-9052-D
Note: UL fuel valve is standard on KG40--KG60 (KG6208).

Figure 6-10 Gas Fuel Valve Kit Connections

98 Section 6 Accessories TP-6694 3/19
6.1.5 Input/Output (I/O) Module Board Refer to Introduction—List of Related Materials for the
SiteTecht Software Operation Manual part no.
The I/O module board provides a generator set mounted
panel with two analog inputs and five digital outputs. SiteTecht analog inputs B1 and B2 and digital outputs
The I/O module is not available with the 15-relay board B1 through B5 are designated for use on the optional I/O
described in Section 6.1.3. Module. See Figure 6-11.

See Figure 6-12 for circuit board components and Optional I/O Module
SiteTech I/O Name Board Connection
electrical connections to the controller.
Analog Input B1 P28 Analog Input VN1/VP1
See Figure 6-13 for connections of analog inputs. Refer Analog Input B2 P28 Analog Input VN2/VP2
to Figure 6-34 for accessory connections. Digital Output B1 P29 (K1)
Digital Output B2 P30 (K2)
See Section 6.2, Accessory Connections, for terminal
identification. Digital Output B3 P31 (K3)
Digital Output B4 P32 (K4)
Use a computer with Kohler SiteTecht software to Digital Output B5 P32 (K5)
assign functions to digital outputs. Each input and
Figure 6-11 I/O Module Input/Output Assignments
output corresponds to a controller connection. Verify
that the settings are appropriate for the connected
sensor, switch, or equipment.

2
1

4
GM78246E-2

1. P29/P30/P31 K1/K2/K3 2-amp relay outputs 4. P25 RJ45 In (to controller P23)
2. P32 K4/K5 10-amp relay outputs 5. P27 CAN terminator
3. P28 In1/In2 analog inputs

Figure 6-12 Input/Output (I/O) Module Board Kit

P28 Optional 5 V power P28 Optional 5 V power P28

(50 mA max.) (50 mA max.)
+5 +5 +5

VPx VPx + VPx

Output Analog
Analog
VNx Device VNx Device -- VNx
GND GND GND
GND
GND
100 ohm min. or 50 mA max. current
TP-6694-6
0--5 Volt Ratiometric Sensor 0--5 Volt Analog Device +/-- 3 Volt Analog Device

Figure 6-13 I/O Module Analog Input Connections P28

TP-6694 3/19 Section 6 Accessories 99

6.1.6 Key Switch 6.1.7 Low Fuel (Level/Pressure) Switch
A two-position key switch is available for selected Some gas-fueled models offer a low fuel pressure
models. Turn the key to the ON position to lock the switch. The low fuel pressure switch connects to the
controller in AUTO mode. The key can be removed same controller terminal as the low fuel level switch on
when the switch is in the ON position. diesel-fueled models. See Figure 6-15, Figure 6-16,
and Figure 6-17.

1 Note: The main tank or the transfer/day tank includes

the low fuel level switch. The fuel tank supplier
typically provides the low fuel level switch.

OFF/RESET AUTO RUN CONNECT TO TB1

(for warning) or TB3 (for
shutdown)

1. Optional key switch GM103075

GM16088A-A/TP-6694
Figure 6-14 Optional Key Switch
Figure 6-15 Low Fuel Switch (Level or Pressure)

GM67191-B

Figure 6-16 Low Fuel Switch Connection to

Controller Connection
Switch Rating 12 volts DC minimum, 0.5 amp minimum
Wiring Recommendation
Gauge mm (ft.)
18--20 30.5 (100)
14 153 (500)
10 305 (1000)

Figure 6-17 Switch Rating & Wiring Recommendation

100 Section 6 Accessories TP-6694 3/19

6.1.8 Manual Speed Adjust (Engine 6.1.9 Prime Power Switch Kit
RPM Menu)
The prime power switch kit prevents battery drain during
Note: Not available for Decision-Makerr 3000 generator set non--operation periods and when the
controllers with software versions before 3.10.3. generator set battery cannot be maintained by an AC
battery charger. See Figure 6-18 for an illustration of the
The control allows varying the engine speed for kit and Figure 6-19 for the electrical connections.
applications using closed transition ATS. The user can
set the nominal running frequency slightly above or Stop the generator set using the stopping procedures in
below the utility frequency to ensure that Section 2.4.2, Stopping, before placing the generator
synchronization occurs. Available as a factory-installed set in the prime power mode. Move the prime power
option or requires a new factory personality profile. switch located on the junction box to the DOWN
Additional information is shown in 2.7.7 GenSet position. The controller including the digital display,
System. LEDs, and alarm horn does not function when the
generator set is in the prime power mode.

Move the prime power switch located on the junction box

to the UP position. The generator set is now ready for
starting.

1
PRIME POWER
SWITCH
2
GM20652-/
TP-6694

1. Prime power decal (293668) 2. Toggle switch (354464)

Figure 6-18 Prime Power Switch

Toggle switch shown in the

prime power mode off
position (contacts open) GM64345-/TP-6694

Figure 6-19 Prime Power Switch Connections

TP-6694 3/19 Section 6 Accessories 101

6.1.10 Remote Emergency Stop Kit 6.1.11 Remote Reset Feature
The emergency stop kit allows immediate shutdown of The remote reset switch provides generator set
the generator set from a remote location. See controller resetting after a fault shutdown at a remote
Figure 6-20 and Figure 6-21. If the emergency stop location. See Figure 6-22 and Figure 6-23 for
switch activates, the EMERGENCY STOP lamp lights user-supplied switch connection.
and the unit shuts down. Before attempting to restart the
generator set, reset the emergency stop switch (by Press and hold the switch for 2--3 seconds and release
replacing the glass piece) and reset the generator set by to reset the generator set controller.
pressing the master control switch OFF/RESET button.
See Section 6.2, Accessory Connections, for terminal
Use the single glass piece located inside the switch for identifications.
replacement and order additional glass pieces as
service parts. See Section 2.4.3, Emergency Stop
Switch Resetting.

REMOTE RESET SWITCH
See Section 6.2, Accessory Connections, for terminal CONTACTS NORMALLY OPEN
identifications. MOMENTARY CLOSED TO
ACTIVATE

CONNECT TO TB1 as a Di-

gital Input

GM16088A-A-/TP--6694

Figure 6-22 Remote Reset Switch Connections

Switch Rating 12 volts DC minimum, 1 amp minimum

Wiring Recommendation
Gauge m (ft.)
18--20 30.5 (100)
14 153 (500)
A-222654
TP-5352-1 10 305 (1000)

Figure 6-20 Emergency Stop Kit Figure 6-23 Switch Rating and Wiring
Recommendations

GM67191-B

Figure 6-21 Remote Emergency Stop Kit

Connections

102 Section 6 Accessories TP-6694 3/19

6.1.12 Remote Serial Annunciator
RSA III is an annunciator panel offered in several kit
configurations to support Kohler power equipment. The
RSA III is a remote serial annunciator (Figure 6-24,
Figure 6-25, and Figure 6-26) that monitors the
condition of the generator set and/or ATS from a remote
location. The RSA III alerts the operator through visual
and audible signals using LED indication and a horn. An
alarm silence and lamp test switch are included.

Figure 6-25 RSA III with Single ATS Control

Figure 6-24 Remote Serial Annunciator (RSA III)

The RSA III meets NFPA 110, Level 1 (2005)

applications that require remote controls and alarms be
powered by a storage battery such as the engine
starting battery. AC adaptor kit GM62466-KP1 is
available when NFPA is not required.
The front panel decals include areas that can be used to
Figure 6-26 RSA III with Four ATS Controls
identify user-selected fault inputs and identify
associated power system equipment. A PC with SiteTecht software is required to make
An RSA III annunciator can be used for a single the RSA III functional. Use your SecurID to access
generator set or with a combination of a generator set KOHLERnet, click on the TechTools button, and follow
and automatic transfer switch. In systems using more the instructions to download the files. See SiteTecht
than a single RSA III, one must be designated as the Software Settings and refer to TP-6701 SiteTecht
master device to broadcast to additional RSA III Software Operation Manual for more information.
annunciators, designated as slave devices. Up to five The RSA III kits include components for surface
RSA III slave devices can be used with an RSA III mounting or flush mounting.
master device. All RSA III annunciators are factory set
as the master device, but can be changed to a slave Figure 6-27 shows the status of the system ready LED,
device using a PC and SiteTecht software that generator set running LED, communication status LED,
connects to the RSA III front panel via a universal serial common fault LED, common fault output, and horn for
bus (USB) connection. each fault or status condition.
The RSA II and RSA 1000 can be connected with the If a fault occurs, the RSA III horn activates and the
RSA III provided that the master remote annunciator is corresponding LED illuminates.
an RSA III. If the RSA III is used with an Ethernet communication
Refer to TT-1625 Remote Serial Annunciator (RSA III) network, order Modbusr Ethernet converter
Kits for operation and installation instructions. GM41143-KP2 and refer to TT-1405 Converters,
Connections, and Controller Setup for Network
See Section 6.2, Accessory Connections, for terminal Communication for system installation.
identifications.

TP-6694 3/19 Section 6 Accessories 103

 System Monitoring LEDs and Functions
Common
Fault System Generator Communications Common Fault
Fault and Status Condition LED Ready LED Running LED Status LED Fault LED Output Horn
Overcrank (Shutdown) Red SF Red SF Off Green Red SF On On
High Engine Temperature (Warning) Yellow SF Red SF Green Green Red SF On On
High Engine Temperature (Shutdown) Red SF Red SF Off Green Red SF On On
Low Oil Pressure (Warning) Yellow SF Red SF Green Green Red SF On On
Low Oil Pressure (Shutdown) Red SF Red SF Off Green Red SF On On
Overspeed (Shutdown) Red SF Red SF Off Green Red SF On On
Emergency Stop Red SF Red SF Off Green Off On On
Low Coolant Level/Aux (Shutdown) Red SF Red SF Off Green Red SF On On
Low Coolant Temperature Yellow SF Red SF Green or Off Green Red SF On On
Low Fuel Yellow SF Red SF Green or Off Green Red SF On On
Low Cranking Voltage Yellow SF Red SF Off Green Red SF On On
Battery Charger Fail Yellow SF Green Green or Off Green Off On On
Battery Voltage (Hi) Yellow SF Green Green or Off Green Off On On
Battery Voltage (Lo) Yellow SF Green Green or Off Green Off Off Off
Common Fault (Warning) Yellow SF Green Green or Off Green Red SF On Off
Common Fault (Shutdown) Red SF Green Green or Off Green Red SF On On
User Input #1 (Warning) Yellow SF Green Green or Off Green Off Off Off
User Input #1 (Shutdown) Red FF Green Green or Off Green Off On On
User Input #2 (Warning) Yellow SF Green Green or Off Green Off Off Off
User Input #2 (Shutdown) Red FF Green Green or Off Green Off On On
User Input #3 (Warning) Yellow SF Green Green or Off Green Off Off Off
User Input #3 (Shutdown) Red FF Green Green or Off Green Off On On
User Input #4 (Warning) Yellow SF Green Green or Off Green Off Off Off
User Input #4 (Shutdown) Red FF Green Green or Off Green Off On On
User Input #5 (Warning) Yellow SF Green Green or Off Green Off Off Off
User Input #5 (Shutdown) Red FF Green Green or Off Green Off On On
ATS Position N (RSA III with ATS only) Green Green Green or Off Green Off Off Off
ATS Position E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off
ATS Available N (RSA III with ATS only) Green Green Green or Off Green Off Off Off
ATS Available E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off
ATS Test (RSA III with ATS only, Test Yellow Green Green or Off Green Off Off On
initiated at ATS)
ATS Test (RSA III with ATS only, Test Green Green Green or Off Green Off Off On
initiated at RSA)
ATS Fault (RSA III with ATS only, No fault) Green Green Green or Off Green Off Off On
ATS Fault (RSA III with ATS only, With Red FF Red SF Green or Off Green Off Off On
fault)
EPS Supplying Load Green Green Green or Off Green Off Off Off
Not-In-Auto Red FF Red SF Off Green Red SF On On
Communication Status (Loss - Master) Red FF Off Off Red FF Off On On
Communication Status (Loss - Slave) Red SF Off Off Red SF Off On On
Note: SF = Slow Flash (once per second), FF = Fast Flash (five times per second)

Figure 6-27 System Monitoring LEDs and Functions

Modbusr is a registered trademark of Schneider Electric.

104 Section 6 Accessories TP-6694 3/19

6.1.13 Run Relay Kit 6.1.14 Shunt-Trip Line Circuit Breaker
The run relay kit energizes only when the generator set A shunt-trip line circuit breaker provides a 12- or 24-DC
runs. Use the run relay kit to control air intake and volt solenoid within the line circuit breaker case that can
radiator louvers, alarms, and/or other signalling energize the trip mechanism. This feature allows the
devices. See Figure 6-28 and Figure 6-29. circuit breaker to be tripped by the common fault (32A).
Connection requires a shunt-trip wiring kit and a dry
See Section 6.2, Accessory Connections, for terminal contact kit. See Figure 6-30 and Figure 6-31.
identifications.
The optional common fault relay shown in Figure 6-31
as DCB1 has contacts rated at 10 amps at 28 VDC or
120 VAC and is used to trigger the shunt-trip line circuit
breaker kit.

273705 GM67191-B

Figure 6-28 Run Relay Kit Figure 6-30 Shunt-Trip Wiring (Standard)

GM67191-B

Figure 6-29 Run Relay Connections

GM67191-B

Figure 6-31 Shunt-Trip Relay Kit and Line Circuit

Breaker Wiring (Shown with Common
Fault/Failure Relay Kit)

TP-6694 3/19 Section 6 Accessories 105

6.2 Accessory Connections
The controller contains a circuit board equipped with 1
terminal strip(s) for use in connecting external optional
accessories including alarms, battery chargers, and
remote switches. The optional I/O board provides an
9
additional two analog or digital inputs and five digital 2
outputs.
3
For specific information on accessory connections, refer 8
to the accessory wiring diagrams in the wiring diagram
manual and the instruction sheet accompanying the kit.
See Figure 6-32, Figure 6-33, and Figure 6-35 for
controller circuit board connections.
4

GM64345-C
7 6 5
1. (4) push-on terminal connectors
2. TB2 4-position terminal block
3. TB3 6-position terminal block
4. P2 6-pin connector
5. P1 24-pin connector
6. TB1 6-position terminal block
7. P22 3-pin connector
8. P23 8-pin connector (RJ45)
9. P21 6-pin connector
Figure 6-32 Controller Circuit Board Connections

106 Section 6 Accessories TP-6694 3/19

TB1 Terminal Strip P1 24-Pin Connector
Analog and Digital Input Connections Engine Wiring Harness
Terminal Description Connection Terminal Description Connection
TB1--DI 1 DCH1 No Function P1--12 14P +12VDC Prime Power Switch
TB1--DI 2 DCH2 Aux. Warning Switch P21 6-Pin Connector
TB1--DI 3 DCH3 (see Note below) RS-485 (RSA II)
TB1--AI 1 ACH1 No Function Terminal Description Connection
TB1--AI 2 ACH2 No Function P21--1 GND Shield
TB1--GND Ground Common A/D Ground P21--2 (+) Red
TB2 Terminal Strip P21--3 (--) Black
KI Relay Outputs P21--4 GND Shield
Terminal Description Connection P21--5 (+) Red
TB2--COM Common User--Defined P21--6 (--) Black
TB2--COM Common Common Fault (2) TB1 Terminal Strip Designations
TB2--NO Normally Open Common Fault (32A) Analog and Digital Input Connections
TB2--NC Normally Terminals Controller SiteTech
User--Defined
Closed on Board Designation Designation
TB3 Terminal Strip TB1--DI 1 DIn A1 A1
Accessory Power Output Connections TB1--DI 2 DIn A2 A2
Terminal Description Connection TB1--DI 3 DIn A3 A3
TB3--1 E--Stop E--Stop Ground TB1--AI 1 AIn A1 —
TB3--1A E--Stop E--Stop TB1--AI 2 AIn A2 A1
TB3--3 Remote Start Remote Start TB1--GND — —
TB3--4 Remote Start Remote Start
TB3--AUX Auxiliary Aux. Shutdown Sw.
TB3--AUXR Auxiliary--R Aux. Shutdown Sw.
Figure 6-33 Controller Connections

Note: When battery charger GM87448 is used, the

Battery Charger Fault is communicated through
CAN communication and the connection on TB1
is not used. Also, this connection is factory
reserved for Enclosure Temperature: High
Shutdown on select Telecom units.

TP-6694 3/19 Section 6 Accessories 107

P25 Connector P30 Connector
RJ45 Remote I/O In 2 Amp. K2 Relay Output (2.2) Connections
Connects to controller P23 Terminal Description
P26 Connector P30--NC Normally Closed
RJ45 Remote I/O Out P30--COM Common
Open P30--NO Normally Open
P27 Connector P31 Connector
CAN Terminator 2 Amp. K3 Relay Output (2.3) Connections
Place the P27 jumper on the IN pins Terminal Description
P28 Connector P31--NC Normally Closed
Single-Ended (0--5 V) Analog Input Connections P31--COM Common
Terminal Description P31--NO Normally Open
P28--GND AGND Analog Return P32 Connector
P28--VN1 NO Connection 10 Amp. K4 Relay Output (2.4) Connections
P28--VP1 ACH1 Signal Terminal Description
P28--+5V Supply (.05 amp max.) P32--NC Normally Closed
P28--GND AGND Analog Return P32--COM Common
P28--VN2 NO Connection P32--NO Normally Open
P28--VP2 ACH2 Signal 10 Amp. K5 Relay Output (2.5) Connections
P28--+5V Supply (0.05 amp max.) Terminal Description
P28 Connector P32--NC Normally Closed
Differential (+/--3 V) Analog Input Connections P32--COM Common
Terminal Description P32--NO Normally Open
P28--GND AGND Analog Reference
P28 Connector Designations
P28--VN1 ACH1 Negative Differential Signal
Terminals Controller SiteTech
P28--VP1 ACH1 Positive Differential Signal
on Board Designation Designation
P28--+5V Supply (.05 amp max.)
P28--GND
P28--GND AGND Analog Reference
P28--VN1
P28--VN2 ACH2 Negative Differential Signal DIn B1 B1
P28--VP1
P28--VP2 ACH2 Positive Differential Signal
P28--+5V
P28--+5V Supply (0.05 amp max.)
P28--GND
P29 Connector
P28--VN2
2 Amp. K1 Relay Output (2.1) Connections Din B2 B2
P28--VP2
Terminal Description
P28--+5V
P29--NC Normally Closed
P29--COM Common
P29--NO Normally Open
Figure 6-34 Input/Output Module Board Connections

108 Section 6 Accessories TP-6694 3/19

Figure 6-35 Controller Wiring Connections GM78246E-1
TP-6694 3/19 Section 6 Accessories 109
Figure 6-36 Controller Wiring Connections GM78246E-2
110 Section 6 Accessories TP-6694 3/19
 Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute exh. exhaust
ABDC after bottom dead center CG center of gravity ext. external
AC alternating current CID cubic inch displacement F Fahrenheit, female
A/D analog to digital CL centerline FHM flat head machine (screw)
ADC advanced digital control; cm centimeter fl. oz. fluid ounce
analog to digital converter CMOS complementary metal oxide flex. flexible
adj. adjust, adjustment substrate (semiconductor) freq. frequency
ADV advertising dimensional com communications (port) FS full scale
drawing coml commercial ft. foot, feet
Ah amp-hour Coml/Rec Commercial/Recreational ft. lb. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued ftp file transfer protocol
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride g gram
Institute crit. critical ga. gauge (meters, wire size)
ALOP anticipatory low oil pressure CSA Canadian Standards gal. gallon
alt. alternator Association gen. generator
Al aluminum CT current transformer genset generator set
ANSI American National Standards Cu copper
Institute (formerly American GFI ground fault interrupter
cUL Canadian Underwriter’s
Standards Association, ASA) Laboratories GND, ground
AO anticipatory only CUL Canadian Underwriter’s gov. governor
APDC Air Pollution Control District Laboratories gph gallons per hour
API American Petroleum Institute cu. in. cubic inch gpm gallons per minute
approx. approximate, approximately cw. clockwise gr. grade, gross
APU Auxiliary Power Unit CWC city water-cooled GRD equipment ground
AQMD Air Quality Management District cyl. cylinder gr. wt. gross weight
AR as required, as requested D/A digital to analog HxWxD height by width by depth
AS as supplied, as stated, as DAC digital to analog converter HC hex cap
suggested dB decibel HCHT high cylinder head temperature
ASE American Society of Engineers dB(A) decibel (A weighted) HD heavy duty
ASME American Society of DC direct current HET high exhaust temp., high
Mechanical Engineers engine temp.
DCR direct current resistance
assy. assembly hex hexagon
deg.,  degree
ASTM American Society for Testing Hg mercury (element)
Materials dept. department
dia. diameter HH hex head
ATDC after top dead center HHC hex head cap
ATS automatic transfer switch DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung HP horsepower
auto. automatic hr. hour
e. V. (also Deutsche Industrie
aux. auxiliary Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E2PROM, EEPROM IBC International Building Code
BC battery charger, battery electrically-erasable IC integrated circuit
charging programmable read-only ID inside diameter, identification
BCA battery charging alternator memory IEC International Electrotechnical
BCI Battery Council International E, emer. emergency (power source) Commission
BDC before dead center ECM electronic control module, IEEE Institute of Electrical and
BHP brake horsepower engine control module Electronics Engineers
blk. black (paint color), block EDI electronic data interchange IMS improved motor starting
(engine) EFR emergency frequency relay in. inch
blk. htr. block heater e.g. for example (exempli gratia) in. H2O inches of water
BMEP brake mean effective pressure EG electronic governor in. Hg inches of mercury
bps bits per second EGSA Electrical Generating Systems in. lb. inch pounds
br. brass Association Inc. incorporated
BTDC before top dead center EIA Electronic Industries ind. industrial
Btu British thermal unit Association int. internal
Btu/min. British thermal units per minute EI/EO end inlet/end outlet int./ext. internal/external
C Celsius, centigrade EMI electromagnetic interference I/O input/output
cal. calorie emiss. emission IP internet protocol
CAN controller area network eng. engine ISO International Organization for
CARB California Air Resources Board EPA Environmental Protection Standardization
CAT5 Category 5 (network cable) Agency J joule
CB circuit breaker EPS emergency power system JIS Japanese Industry Standard
CC crank cycle ER emergency relay k kilo (1000)
cc cubic centimeter ES engineering special, K kelvin
CCA cold cranking amps engineered special kA kiloampere
ccw. counterclockwise ESD electrostatic discharge KB kilobyte (210 bytes)
CEC Canadian Electrical Code est. estimated KBus Kohler communication protocol
cert. certificate, certification, certified E-Stop emergency stop kg kilogram
cfh cubic feet per hour etc. et cetera (and so forth)

TP-6694 3/19 Appendix 111

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

112 Appendix TP-6694 3/19

 Appendix B Programmer-Defined Settings

Use the table below to record programmer-defined SiteTecht setup software is required for programming the
settings during the generator set controller setup and controller. Contact your local distributor/dealer for assistance.
calibration. The controller default settings and ranges Note: Inhibit time delay is the time delay period after
provide guidelines. The table contains all faults with crank disconnect.
ranges and time delays including items that do not have
adjustments. Some notices give the programmer a Note: The engine ECM may limit the crank cycle even if
choice to make them active Not adjustable the controller is set to a longer time period.
programmer-defined settings result when the controller
logic does not allow changes or the values are engine
limited.
Programmer-Defined Settings
GenSet
Write Mode Time Default
Access Always Delay Time Programmer-
Controller Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Engine Functions
Critically high fuel level Fuel Level Critically
0--100% 95% 0--10 5
(diesel-powered models only) * High
ECM communications loss ECM Comm Err
Fixed 10 Not adjustable
Shutdwn
ECM diagnostics (multiple
ECM xxxxxx Warning Not adjustable
inputs) [
ECM diagnostics (multiple
ECM xxxxxx Shutdwn Not adjustable
inputs) [
ECM faults (address conflict) ECM Addr Err
Not adjustable
Shutdwn
ECM faults (model mismatch) ECM Mismatch
0--255 0
Shutdwn
Engine over speed Eng Speed High
S A 105--120% 115%
Shutdwn
Engine RPM 60 Hz: 60 Hz:
(manual speed adjust) 1751--1849 1800
Engine RPM Display DS A
Version 3.10.3 or higher 50Hz: 50 Hz:
1451--1549 1500
Engine start aid active Starting Aid Notice
Engine under speed Eng Speed Low
S A 75--95% 85%
Shutdwn
Fuel tank leak * Fuel Leak Warning Not adjustable
Fuel tank leak * Fuel Leak Shutdwn Not adjustable
High battery voltage Battery High Warning S A 110--135% 125% Fixed 10 Not adjustable
High coolant temperature 0--10 5
Coolnt Temp High
(0--30 (0
Warning
inhibit) inhibit)
High coolant temperature 0--10 5
Coolnt Temp High
(0--30 (0
Shutdwn
inhibit) inhibit)
High fuel level (diesel-powered Fuel Level High
0--100% 90% 0--10 5
models only) * Warning
Loss of fuel Loss of fuel Not adjustable
Low battery voltage Battery Low Warning S A 80--105% 100% Fixed 90 Not adjustable
Low coolant level * Coolant Lvl Low
Fixed 5 Not adjustable
Shutdwn
Low coolant temperature 0--10 5
Coolant Temp Low 16_C
Fixed (0--30 (0
Warning (60_F)
inhibit) inhibit)
Low cranking voltage Lo Crank Vlt Warning Fixed 60% Fixed 6 Not adjustable
Low engine oil level * Oil Level Low Warning Not adjustable

TP-6694 3/19 Appendix 113

 GenSet
Write Mode Time Default
Access Always Delay Time Programmer-
Controller Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Low engine oil level * Oil Level Low
Not adjustable
Shutdwn
Low fuel level (diesel models) * Fuel Level Low
0--100% 35% 0--10 10
Warning
Low fuel level (diesel models) * Fuel Level Low
0--100% 5% 0--10 0
Shutdwn
Low fuel pressure Fuel Press Low
Not adjustable
(gas models) * Warning
Low oil pressure Fixed 5
Oil Press Low
(Fixed (5 Not adjustable
Warning
inhibit) inhibit)
Low oil pressure Fixed 5
Oil Press Low
(Fixed (5 Not adjustable
Shutdwn
inhibit) inhibit)
No coolant temperature signal Temp Sig Loss
Not adjustable
Shutdwn
No oil pressure signal Press Sig Loss
Fixed 5 Not adjustable
Shutdwn
Overcrank (30
Over Crank Shutdwn Fixed Not adjustable
inhibit)
Speed sensor fault Spd Sens Flt Warning Not adjustable
General Functions
Alarm silence, 0--Auto only
AlarmSilenceMode S A 0--1 1
(NFPA 110), 1--Always
Aux. inputs 0--5 VDC, 1 analog Aux Input Warning 0--100% 100% 0--10 0
Aux. inputs 0--5 VDC, 1 analog Aux Input Shutdwn 0--100% 100% 0--10 0
Auxiliary inputs, up to 3 digital
0--10
(2 additional digital inputs 0 (0
Aux Input Warning (0--30
available with I/O module inhibit)
inhibit)
option)
Auxiliary inputs, up to 3 digital
0--10
(2 additional digital inputs 0 (0
Aux Input Shutdwn (0--30
available with I/O module inhibit)
inhibit)
option)
Backup parameters loaded Backup Pars Status Not adjustable
Battery charger 1
Bat1CommLoss Not adjustable
communication loss
Battery charger 2
Bat2CommLoss Not adjustable
communication loss
Battery charger fault *
(* does not apply to charger Batt Chg Flt Warning Not adjustable
GM87448)
Battery charger identity conflict BatIdErr Not adjustable
Battery charger parameter
ParMisatch Not adjustable
mismatch
Battery fault Battery Flt Not adjustable
Chicago code active * Auto Locked Notice
Common fault Common Fault
Not adjustable
Shutdwn
Common warning Common Warng Not adjustable
Contrast (see 2.7.7 GenSet
Contrast Display D A 1--10 5
System)
Default parameters loaded Default Pars Warning Not adjustable
Emergency stop Emerg Stop Shutdwn Not adjustable
Enclosure temperature: high Enclsr Temp: High 5 (20
S R Fixed Active Fixed Not adjustable
shutdown Shutdwn inhibit)
Engine cooldown (delay) active Eng Cooldown Notice
Engine start delay active Start Delay Notice

114 Appendix TP-6694 3/19

 GenSet
Write Mode Time Default
Access Always Delay Time Programmer-
Controller Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Engine started Engine Start Status Not adjustable
Engine stopped Engine Stop Status Not adjustable
EPS supplying load Emerg Pwr On Notice Not adjustable
File system error (controller
File Error Shutdwn Not adjustable
fault)
Generator running Gen Running Notice Not adjustable
Input/output (optional module
OB1 Com Loss Not adjustable
board) communication loss
Internal failure Intern Error Shutdwn Not adjustable
Measurement Units,
Measurement Display DS A 0--1 1
0--English, 1--Metric
Metering communication loss MeterCommLos
Not adjustable
Shutdwn
NFPA 110 alarm active NFPA Alarm Notice
Not in auto (master control
Not In Auto Warning Not adjustable
buttons)
Prime power application,
Power Type DS A 0--1 0
0--Standby, 1--Prime
Remote start Remote Start Status Not adjustable
System ready System Ready Status Not adjustable
System timer failed Timer Error Notice Not adjustable
Generator Functions
AC sensing loss AC Sens Loss
Not adjustable
Warning
AC sensing loss AC Sens Loss
Fixed 3 Not adjustable
Shutdwn
Alternator protection Alt Protect Shutdwn Not adjustable
Ground fault input * Ground Fault Warning Not adjustable
kW overload 102%
Total Power High standby,
Fixed Fixed 60 Not adjustable
Shutdwn 112%
prime
Locked rotor (failed to crank) Locked Rotor
S A 1--5 5
Shutdwn
Overfrequency Freq High Shutdwn 102--140% 110% Fixed 10 Not adjustable
Overvoltage (each phase) Volts (L1--L2, L2--L3,
or L3--L1) High S A 105--135% 120% 2--10 2
Shutdwn
Power rating Pwr Rating DS S 10--5000 275
System frequency System Freq DS S 50--60 60
System voltage System Volt DS S 110--600 208
Underfrequency Frequency Low 10 ST
80--95% 90% Fixed Not adjustable
Shutdwn 60 LT
Undervoltage (each phase) Volts (L1--L2, L2--L3,
or L3--L1) Low S A 70--95% 80% 5--30 10
Shutdwn
Voltage/phase configuration,
0--Single phase, 1--Single
SystemPhase DS S 0--3 2
phase dogleg, 2--three phase
wye, 3--three phase delta
Voltage regulator average
VR Volt Adj DS R 108--600 208
voltage adjustment
(Voltage) regulator RegCommLoss
Not adjustable
communication loss Shutdwn
SiteTech Read/Write Display Only
Charger Absorption Current
S A 1–5 2
Termination Target (A)

TP-6694 3/19 Appendix 115

 GenSet
Write Mode Time Default
Access Always Delay Time Programmer-
Controller Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Charger Automatic Equalize
Enable
Active
Note: Equalize is only S A Inactive
Inactive
available with FLA/VRLA
topology selected.
Charger Charge Cycles
Between Auto Equalize Cycles Adjustable with
Note: Equalize is only S A 0 – 99 Charger Custom
available with FLA/VRLA Profile enabled.
topology selected.
Charger Custom Profile Enable Active
S A Inactive
Inactive
Charger Depleted Battery
S A 1–5 2
Current Limit
Charger Depleted Battery 4 – 12 10
Voltage Target (12 V) (12 V) Adjustable with
S A Charger Custom
18 – 24 20 Profile enabled.
(24 V) (24 V)
Charger Equalize Stage
Duration (Min)
Note: Equalize is only S A 60 – 480
available with FLA/VRLA
topology selected.
Charger Manual Equalize
Cycle Activation
Active
Note: Equalize is only S A Inactive
Inactive
available with FLA/VRLA
topology selected.
Charger Maximum Absorption 60 – 360
Time Threshold (Min.) Adjustable with
S A 60 – 600 240 Charger Custom
(NiCad Profile enabled.
only)
Charger Maximum Bulk Time Adjustable with
Threshold (Min) S A 60 – 600 480 Charger Custom
Profile enabled.
Charger Refresh Charge Cycle 0,
S A 335
Time (Hr) 23 – 672
Charger Return To Bulk State 10 – 13 12.8
Voltage Threshold (V) (12 V)** (12 V) Adjustable with
S A Charger Custom
20 – 26 25.6 Profile enabled.
(24 V)** (24 V)
Charger Starter Battery
Topology
Note: Verify that the battery Default
topology is set correctly for the FLA/VRLA
battery type that is used. S A AGM Default
Incorrect charger output Gel
system voltage may cause NiCad
irreversible damage to the
battery and abnormal out
gassing.
Charger System Battery
Voltage
Note: Verify that the system
voltage is set correctly for the System 12
battery type that is used. VDC
S A 12 VDC
Incorrect charger output System 24
system voltage may cause VDC
irreversible damage to the
battery and abnormal out
gassing.
Charger Temperature Active
S A Inactive
Compensation Enable Inactive

116 Appendix TP-6694 3/19

 GenSet
Write Mode Time Default
Access Always Delay Time Programmer-
Controller Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Charger Temperature --40 – 0 -30
Compensation Slope (mV/_C) (12 V) (12 V) Adjustable with
S A Charger Custom
-80 – 0 --60 Profile enabled.
(24 V) (24 V)
Charger Voltage Absorption 13 – 15 14.25
(V) (12 V)** (12 V) Adjustable with
S A Charger Custom
26 – 30 28.5 Profile enabled.
(24 V)** (24 V)
Charger Voltage Bulk (V) 13 – 15 14.25
(12 V)** (12 V) Adjustable with
S A Charger Custom
26 – 30 28.5 Profile enabled.
(24 V)** (24 V)
Charger Voltage Equalize (V) 14 – 16
(12 V) Adjustable with
Note: Equalize is only S A Charger Custom
available with FLA/VRLA 28 – 32 Profile enabled.
topology selected. (24 V)
Charger Voltage Float (V) 13 – 14 13.25
(12 V)** (12 V) Adjustable with
S A Charger Custom
26 – 28 26.5 Profile enabled.
(24 V)** (24 V)
Current transformer ratio ] S S 1-- 1200
ECM power S S 0--1 0
Engine cooldown delay S A 0--600 300
Engine (cyclic) crank on S A 10--30 15
Engine (cyclic) crank pause S A 1--60 15
Engine ECM start delay S A 0--300 0
Engine idle duration S A 0--60 60
Engine no. of (cyclic) crank
S S 1--6 3
cycles
Engine restart delay S A 1--10 10
Engine start aid delay S A 0--10 0
Engine start delay S A 0--300 0
Equalize Current Limit (A)
Adjustable with
Note: Equalize is only S A 1–5 Charger Custom
available with FLA/VRLA Profile enabled.
topology selected.
Forced Charge Cycle Reset Active
S A Inactive
Inactive
Output Enable Reduced Out S A Fixed Active
Voltage regulator gain S R 1--255 128
Voltage regulator stability
S R 1--255 128
adjust
Voltage regulator, volts per
S R 1--10 5
Hertz slope
Voltage regulator, volts per
S R 42--62 57.5
Hertz cutin frequency
* Some functions require optional input sensors or are engine ECM dependent on some generator set models.
[ ECM inputs are engine manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).
** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the battery
charger operation manual.
ST--Short Term, LT--Long Term

TP-6694 3/19 Appendix 117

 Notes

118 Appendix TP-6694 3/19

 Appendix C Voltage Regulator Definitions and Adjustments

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

TP-6694 3/19 Appendix 119

Frequency Setpoint or Cut-In Point general, the phase with the greatest load will have the
lowest voltage while the phase with the least load will
The point at which the underfrequency unloading begins have the highest voltage. This is true regardless of the
to take effect is adjustable, allowing the system to be type of sensing used in the regulator system. A
tailored for each application. Because the single-phase sensing excitation controller will keep the
characteristics of the engine have the largest effect on voltage of the sensed phase at the voltage adjustment
the system’s performance, the engine’s response value. A three-phase sensing system will average the
should determine the unloading point. The unloading three phases and hold the average to the adjustment
setpoint is the frequency below which the excitation setting. The average is the sum of the voltages of three
control will reduce the voltage so that the engine may phases divided by 3.
begin to recover.
As stated above, three-phase sensing does not
The cut-in point, or frequency setpoint, should be set eliminate the unequal voltage phenomenon.
0.5--3.0 Hz lower than the normal steady-state band of Three-phase sensing balances the inequality of voltage
operation. If the engine normally operates within a very between the phases to the desired value. In other
narrow range of speeds close to the nominal, a setpoint words, if a system with unbalanced loads uses a
of 0.5 to 1.0 Hz below nominal should be suitable. If the single-phase control feedback, the voltage on the
engine normally operates over a wide range of speeds, sensed phase would be at the setpoint while the other
the setpoint may need to be 2.0--3.0 Hz from the two phases would vary by their proportional loads. For
nominal. The underfrequency unloading function can example, if the sensed phase had rated load while the
be eliminated by setting the cut-in point below the two other phases were only loaded at half the rated
minimum expected operating frequency. value, those two phases would have higher-than-rated
voltage which may be undesirable. If a three-phase
Example sensing feedback were utilized, the phase with rated
load would be regulated to a voltage slightly below the
A 90 kW load is applied to a 100 kW, 60 Hz generator set rated voltage while the other two phases would be
driven by a turbocharged diesel engine with an slightly above the rated voltage (but lower than in the
electronic control module (ECM). The speed drops 10% previous case). The sum of the three, divided by 3,
and takes 20 seconds to recover to at least 59.5 Hz. The would be equal to the regulation setpoint.
voltage, meanwhile, drops from 480 to 460 and recovers
to 480 within 15 seconds. Therefore, some In a single-phase system, line-to-line voltage is held
underfrequency unloading should be provided. A good equal to the line-to-line voltage adjust setting. In a
starting point would be a frequency setpoint or cut-in of three-phase system, the average of the three line-to-line
59 Hz. A slope of 15 volts per-cycle-per-second is voltage is regulated to the voltage adjust setting. In
appropriate as well. If after these adjustments the speed some cases, it may be desirable to keep one phase at a
recovers very quickly, in about 5 seconds, but the particular value. Modify the voltage adjust setting higher
voltage drops below 440 volts, the slope should be or lower accordingly for any unique requirements for the
reduced to 12 volts per cycle. More adjusting may be particular application.
required to get the most desirable compromise between
speed and voltage.
Adjustment and Setting
Three-Phase Sensing Specifications
Three-phase sensing describes how the excitation
control or voltage regulator determines the condition of
Voltage Adjust
the alternator output voltage. Early types of regulators The voltage adjust is entered as the rated or otherwise
sensed the voltage on just one phase of the alternator. desired line-to-line voltage. The average of the
Single-phase sensing is not uncommon today as most line-to-line voltages is then regulated to the
alternators are designed to produce balanced, equal corresponding value as previously described. The
voltage on all three phases. If the loads applied to the setting may be as fine as tenths of volts. The voltage
generator set including no load are equal and balanced, adjust defaults to the rated system voltage whenever
the output voltage on each phase will be nearly equal. the system voltage is changed. The voltage adjust may
be set to any value within 10% of the system voltage.
However, in some applications, individual phases may The upper limit is 10% above the system voltage and
have unequal or unbalanced loads. In these cases, the the lower limit is 10% below the system voltage.
output voltages will not be equal on each phase. In

120 Appendix TP-6694 3/19

As a reference, the present voltage adjust setting is Frequency Setpoint
displayed as well as the average value of the line-to-line
voltages. The individual line-to-line voltages are also The frequency setpoint is the cut-in point for
displayed on the subsequent menu screens. This underfrequency unloading. At any operating frequency
allows the user to monitor any individual phase, if below the frequency setpoint, the output voltage will be
desired. reduced. The frequency may be entered with resolution
to tenths of a Hz. The range of acceptable entries is 30
The voltage adjust setting may be changed by means to 70 Hz. The default value is one cycle-per-second (or
other than the menu including user-defined digital input two for non-ECM engines) below the normal system
or remote communications. If voltage adjustment frequency. The frequency setpoint changes to the
occurs, the new value will be displayed accordingly in default value if the system frequency changes. A setting
the voltage adjust menu. of 30 Hz essentially disables the underfrequency unload
feature because most engines do not normally drop to
speeds this low, even during load applications.
Underfrequency Unload Enable
The underfrequency unload enable menu is used to turn Underfrequency Unload Slope
the underfrequency unload on or off. A YES entry will
turn the feature on and the display will show ENABLED The slope determines how much voltage is reduced
YES. A NO entry will turn the feature off and the display during an unloading condition. The line-to-line voltage
will show ENABLED NO. The underfrequency unload is regulated to a value less than the voltage adjust
defaults to an enabled (ON) condition. setting by this amount for every cycle below the
frequency setpoint. The voltage may be entered with
resolution as fine as one-tenth of one volt. The default
value is 2.0 volts per-cycle-per-second. A zero entry for
the slope in effect turns the underfrequency unload
feature off.

TP-6694 3/19 Appendix 121

 Notes

122 Appendix TP-6694 3/19

Appendix D Alternator Protection

The controller has built-in thermal protection for the The current and time limits are defined by actual test
alternator. This feature functions similarly to a thermal data and are maintained in the personality parameter
circuit breaker. When the output current exceeds the file. Although the equation for detecting a fault is
nominal rating for a short period of time the condition proprietary, some of the important limits are shown
causes the fault shutdown. The amount of time at which below for informational purposes.
current is over the rating is inversely related to the
amount of current above the nominal rating. In other Rated Current Time Delay
words, the higher the current, the shorter the acceptable 200% 40 seconds
time.
300% 10 seconds
425% 5 seconds
950% 1 second

TP-6694 3/19 Appendix 123

 Notes

124 Appendix TP-6694 3/19

 Appendix E Controller Displays from the Engine ECM

The controller display showing engine information is Some engines do not have an ECM and in some cases
dependent upon the engine manufacturer and the the ECM information is not available as a controller
corresponding Engine Control Module (ECM). The display. In these situations, critical information like oil
following list indicates which engine displays are pressure and coolant temperature are displayed by the
available by the engine manufacturer. This information controller using independent engine sensors not used
is subject to change by the engine manufacturer. by the ECM.

Note: See the generator set specification sheet for

engine model identification.

Engine Manufacturer (and model)

GM/ PSI and
Controller Displays Kohler Kohler Kohler Gas Kohler Gas
as Provided by the Diesel Diesel (KG2204, (KG6208, John
Engine ECM (KDI M, TM*) (KDI TCR) KG2204T) KG6208T) DD/MTU Doosan Deere Volvo
Intake air pressure S/D D
Intake air Temperature D D S/D D D D
Coolant level D D D D D D
Coolant temperature D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D
Crankcase pressure D
ECM battery voltage S S/D S S S
Engine model number S S S S S S S
Engine serial number S S S S S S S
Engine speed C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D C/S/D
Fuel pressure D C/S/D C/S C/S/D C/S[ C/S/D
Fuel rate S S S S S
Fuel temperature D S S/D S
Oil level S[ S/D[ S[ S[ S[
Oil pressure C/S/D D C/S/D C/S/D C/S/D C/S/D C/S/D
Oil temperature S D SD
C = Value displayed on controller, S = Value displayed in Site Tech, D = ECU diagnostic is supported
* Electronic governor and ECM are optional on KDI M and TM engines.
[ Controller uses local analog input to obtain this information
NOTE: REOZMD/ROZMC (Mitsubishi engines) have an ECM but do not send signals to the generator set controller.

TP-6694 3/19 Appendix 125

 Notes

126 Appendix TP-6694 3/19

TP-6694 3/19k KOHLER CO., Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
Original Instructions (English) For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
E 2010, 2011, 2014, 2015, 2017, 2018, 2019 by Kohler Co. All rights reserved. [Link]