Industrial Generator Sets -...

Industrial Generator Sets

TP-7070 7/18d

Operation

Models:

KD800--KD3250Controller:APM802

WARNING: This product can expose youto chemicals, including carbon monoxideand benzene, which are known to the Stateof California to cause cancer and birthdefects or other reproductive harm.For more information go towww.P65warnings.ca.gov

WARNING: Breathing diesel engineexhaust exposes you to chemicals known tothe State of California to cause cancer andbirth defects or other reproductive harm.S Always start and operate the engine ina well-ventilated area.

S If in an enclosed area, vent the exhaustto the outside.

S Do not modify or tamper with theexhaust system.

S Do not idle the engine except asnecessary.

For more information go towww.P65warnings.ca.gov/diesel

Product Identification Information

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

Generator Set Identification Numbers

Record the product identification numbers from thegenerator set nameplate(s).

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Engine Identification

Record the product identification information from theengine nameplate.

Manufacturer

Model Designation

Serial Number

Alternator Identification

Record the alternator model number from the generatorset nameplate(s).

Alternator Model

Controller Identification

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

Controller Description APM802

Controller Serial Number

Table of Contents

TP-7070 7/18 Table of Contents 3

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

Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Service Assistance 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 1 Specifications and Features 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.1 Introduction 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2 Controller Specifications 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.2.1 Controller Specifications 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.2.2 Display and Touchscreen 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.3 Controller Features 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.1 Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.2 Modbus Connections 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.3.3 Optional Keyswitch and Manual Start/Stop Button 18. . . . . . . . . . . . . . . . . .

1.4 NFPA Requirements 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.5 Parameter Settings 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.6 Base Module Inputs and Outputs 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 2 Operation 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.1 Prestart Checklist 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.2 Exercising Generator Set 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.3 Operation in Cold Weather Climates 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4 Generator Set Operation 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.4.1 Start Signal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.2 Stop Signal 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.3 Engine Cooldown 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.4 Emergency Stop 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.4.5 Idle Mode 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 Controller Operation Modes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.1 Out of Service Mode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.2 Manual Mode 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.5.3 Auto Mode (Standby or System Ready) 25. . . . . . . . . . . . . . . . . . . . . . . . . . .

2.6 Load Shed 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7 HMI Screen Layout 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.7.1 Home Screen 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.2 Top Bar 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.3 Generator View 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.4 Control Panel 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.7.5 Custom View Button 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.8 Operator Login 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9 Data Displays 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9.1 Generator Mechanical Values 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.2 Generator Electrical Values 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.3 Curve Display 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.9.4 Saved Electrical and Mechanical Data 35. . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.10 Events 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.1 Faults and Alarms 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.2 Resetting an Alarm 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.3 Resetting a Fault 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.4 Consulting Status Messages 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10.5 Full Event Log 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.11 Applications 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.1 Reference 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.2 Region Settings 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.3 HMI Settings 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.4 Restart 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-7070 7/18Table of Contents4

2.11.5 Display Cleaning 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.6 Firmware Update 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.7 Screenshot 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.8 Ladder Tools 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.9 Save Parameters 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.11.10 Upload Parameters 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.12 Menus 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12.1 Menu 1--Settings 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12.2 Menu 2--Measurements 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12.3 Menu 3--History 61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12.4 Menu 4--Diagnosis 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12.5 Menus 5 and 6 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12.6 Menu 6.5-Communication 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 3 Scheduled Maintenance 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.1 Introduction 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.2 Service Schedule 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3 APM802 Controller Maintenance 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4 Engine Maintenance 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5 Diesel Fuel Systems 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5.1 Fuel/Water Separator 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5.2 Manual Primer Pump 78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5.3 Bleeding Air from Fuel System 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5.4 Restriction Gauge (if equipped) 79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.6 Lubrication System 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.1 Oil Change 80. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6.2 Automatic Oil Replenishment System (Optional Kit) 80. . . . . . . . . . . . . . . .3.6.3 Oil Analysis 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.7 Air Cleaner System 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7.1 Air Filter Element 83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7.2 Air Cleaner Restrictor Indicator (if equipped) 83. . . . . . . . . . . . . . . . . . . . . .

3.8 Cooling System 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.1 Coolant System Safety 84. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.2 Coolant Level Check 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.3 Cooling System Component Inspection 85. . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.4 Procedure to Drain Cooling System 85. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.5 Procedure to Flush and Clean Cooling System 86. . . . . . . . . . . . . . . . . . . .3.8.6 Procedure to Refill Cooling System 87. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.7 Coolant Analysis 88. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.8 Radiator Maintenance 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8.9 Radiator Fan Bearing Lubrication (KD2000--KD3250) 90. . . . . . . . . . . . . . .3.8.10 Notched V-Belt Adjustment (KD2000--KD3250) 91. . . . . . . . . . . . . . . . . . . .

3.9 Battery Systems 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.1 Battery Safety 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.2 Absorbed Glass Mat (AGM) Battery 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.3 Clean Battery 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9.4 Charge Battery 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.10 Alternator Maintenance 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.1 Alternator Safety 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.2 Checking the Installation 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.3 Checking the Ventilation Circuit 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.4 Checking the Bearings 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.5 Checking the Windings 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10.6 Voltage Regulator 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contents, continued

TP-7070 7/18 Table of Contents 5

3.11 Storage Procedure 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.1 Storage Safety 97. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.2 Controller 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.3 Lubricating System 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.4 Cooling System 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.5 Diesel Fuel System 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.6 Exterior 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.7 Alternator Storage 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11.8 Battery 99. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 4 Troubleshooting 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1 Introduction 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.2 Generator Set and Controller 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.3 Engine 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.4 Transfer Switch 101. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.5 General Troubleshooting Chart 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Section 5 Accessories 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.1 Accessories and Connections 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2 Accessory Connections 107. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3 Input and Output Modules 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.3.1 Analog Input/Output Module 108. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.2 Digital Input/Output Module 109. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3.3 Thermocouple Input Module 110. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.4 Remote Serial Annunciator 111. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix A Abbreviations 113. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Appendix B Operating Hour Service Log 115. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TP-7070 7/186

Notes

7Safety Precautions and InstructionsTP-7070 7/18

Safety Precautions and Instructions

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

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

DANGER

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

WARNING

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

CAUTION

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

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

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

Accidental Starting

Accidental starting.Can cause severe injury or death.

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

WARNING

Disabling the generator set.Accidental starting can causesevere injury or death. Beforeworking on the generator set orequipment connected to the set,disable the generator set as follows:(1) Shut down the generator set. (2)Place the controller in Out of Servicemode. (3) Press the emergency stopbutton. (4) Disconnect the power to thebattery charger, if equipped.(5) Remove the battery cables,negative (--) lead first. Reconnect thenegative (--) lead last whenreconnecting the battery. Follow theseprecautions to prevent the starting ofthe generator set by the remotestart/stop switch.

Battery

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

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

WARNING

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

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

WARNING

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

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

8 Safety Precautions and Instructions TP-7070 7/18

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

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

Engine Backfire/FlashFire

Risk of fire.Can cause severe injury or death.

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

WARNING

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

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

Servicing the fuel system. A flashfire cancausesevere injuryor death.Do not smoke or permit flames orsparks near the fuel injection system,fuel line, fuel filter, fuel pump, or otherpotential sources of spilled fuels or fuelvapors. Catch fuels in an approvedcontainer when removing the fuel lineor fuel system.

Exhaust System

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

The exhaust system must beleakproof and routinely inspected.

WARNING

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

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

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

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

Fuel System

Explosive fuel vapors.Can cause severe injury or death.

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

WARNING

9Safety Precautions and InstructionsTP-7070 7/18

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

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

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

Hazardous Noise

Hazardous noise.Can cause hearing loss.

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

CAUTION

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

Hazardous Voltage/Moving Parts

Hazardous voltage. Moving parts.Will cause severe injury or death.

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

DANGER

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

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

WARNING

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER

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

Installing the battery charger.Hazardous voltagewill causesevereinjury or death. An ungroundedbattery charger may cause electricalshock. Connect the battery chargerenclosure to the ground of a permanentwiring system. As an alternative, installan equipment grounding conductorwith circuit conductors and connect it tothe equipment grounding terminal orthe lead on the battery charger. Installthe battery charger as prescribed in theequipment manual. Install the batterycharger in compliance with local codesand ordinances.

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

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

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

10 Safety Precautions and Instructions TP-7070 7/18

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

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

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

Heavy Equipment

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

Do not lift the generator set from theengine or alternator eyes. Neverstand under a unit being lifted.Always maintain a safe distance fromthe unit being lifted.See the lifting instructions in theinstallation manual that was providedwith the unit.

WARNING

Hot Parts

Hot coolant and steam.Can cause severe injury or death.

Before removing the pressure cap,stop the generator set and allow it tocool. Then loosen the pressure capto relieve pressure.

WARNING

Hot engine and exhaust system.Can cause severe injury or death.

Do not work on the generator set untilit cools.

WARNING

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

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

NoticeNOTICE

Parallel Operation. This productincludes features intended to supportoperation in parallel with the utility grid,but these features have not beenevaluated for compliance with specificutility interconnection protectionstandards or requirements.

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

11IntroductionTP-7070 7/18

Introduction

This manual provides generator set operation,maintenance, and basic troubleshooting instructions. Aseparate controller operation manual contains detailedcontroller operation information.

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

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

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

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

Abbreviations

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

List of Related Materials

Separate literature contains controller operationinstructions, engine and alternator maintenance, andaccessory information not provided in this manual.Figure 1 lists the available literature part numbers.

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

Literature Description Literature Part No.

APM802 Controller Spec Sheet G6-152

Generator Set Installation Manual TP-5700

Generator Set/Controller Wiring DiagramManual TP-7071

Operation and Maintenance Manual,KD27V12 Engine 33521029401





Remote Serial Annunciator III (RSA III) TT-1625

Figure 1 Related Literature

12 Introduction TP-7070 7/18

Nameplate Location

Generator sets and their components (engine,alternator) are identifiedwith decals or nameplates. Forfuture reference during routine maintenance or to orderservice parts, copy the model number, serial number,and specification number from the generator setnameplate into the spaces provided in the productinformation section on the inside front cover of thismanual.

The generator set nameplate is typically located on thealternator assembly as shown in Figure 3.

Service Duty

Voltage

Alt Model

Insulation

MFG Date

Amps

Phase

RPM

Battery

Fuel

kW

kVA

Hz

Genset Model

Spec Number

Serial Number

Material Number

PF

Figure 2 Generator Set Nameplate, Typical

1

11811000100--GR1

1. Nameplate location, typical

Figure 3 Generator Set Nameplate Location, Typical

13Service AssistanceTP-7070 7/18

Service Assistance

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

D Visit the Kohler Co. website at KOHLERPower.com.

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

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

D Outside theUSandCanada, call the nearest regionaloffice.

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

Asia PacificKohler Asia Pacific HeadquartersSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455

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

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

Fax: (86) 10 6518 7955

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

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

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

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

14 Service Assistance TP-7070 7/18

Notes

TP-7070 7/18 15Section 1 Specifications and Features

Section 1 Specifications and Features

1.1 Introduction

The spec sheets for each generator set provide model-specific generator and engine information. Thecontroller spec sheet provides specifications for thecontroller. Refer to the respective spec sheet for datanot supplied in this manual. Refer to the generator setservice manual, installation manual, engine operationmanual, and engine service manual for additionalspecifications.

1.2 Controller Specifications

1.2.1 Controller Specifications

D Power Supply Requirements:

d Nominal voltage: 24 VDC, reverse polarityprotected

d 240 VAC/60Hz customer-supplied; factory wiringto basic electrical package available

D Operating Temperature:--40_C to 70_C (--40_F to 158_F)

D Storage Temperature:--40_C to 70_C (--40_F to 158_F)

D Humidity: 5% to 95% non-condensing

D Protection Index:

d IP65 Front

d IP20 Rear

D Standards:

d NFPA 99

d NFPA 110, Level 1

d CSA 282-09

d UL 508

d IEC/EN60068-2-52 (salt spray)

d CE Directive

1.2.2 Display and Touchscreen

D Type: XGA TFT LED LCD

D Screen Size: 305 mm (12 inches)

D Viewing Angle: 140_ horizontal and vertical

D Languages: English, French

Note: Have setup and adjustments of the controllerperformed only by an authorized Kohlerdistributor. The setup and adjustments arepassword protected.

1.3 Controller Features

The controller features include a 307 mm (12.1 inch)touchscreen with backlight and wide viewing angle (140degrees horizontal and vertical) and terminal blocks forinput and output connections. See Figure 1-1 for anillustration of the controller front panel and the customerconnection area. Controller features include:

D 12-inch touchscreen with backlight and wide viewingangle for easy local access to data.

D System settings are password-protected.

D Measurements selectable in metric or English units.

D User language is selectable (English or French).

D Graphic displays show generator set mechanicalvalues including operating hours, fuel level*, batteryvoltage, coolant temperature, oil pressure, and oiltemperature.

D Meter displays provide a visual representation ofgenerator electrical values including power (kW),power factor, reactive power (kVAR), frequency,voltage, and current (amps).

D Two USB ports allow connection of a flash drive,mouse, or keypad.

D Electrical data,mechanical data, and systemsettingscan be saved to a flash drive.

D Recording feature allows data collection of keyvalues.

D Ethernet port allows connection to a PC typecomputer and/or Ethernet switch.

D Serial (RS-485) port.

D The controller supports Modbusr RTU and TCPprotocols.

D Real time clock with battery back-up.

D See the controller specification sheet or operationmanual for input and output specifications.

Modbusr is a registered trademark of Schneider Electric.

* Where applicable

TP-7070 7/1816 Section 1 Specifications and Features

1. APM802 controller human-machine interface (HMI)2. Emergency stop switch3. Key switch4. Manual start/stop button5. 240 VAC/60 Hz power supply connection (required)6. Terminal block TB10 for accessory connections7. Wiring harness connection

8. USB ports, qty. 2 (on the back of the HMI)9. Controller touchscreen10. Fault indicator/display button11. Mode selection switch12. Generator set electrical values13. Generator set mechanical data

1 9

12

10

13

7

112

11601000945

Note: Covers have been removed for illustration.

6

5

8

Human-Machine Interface (HMI)

3

4

Figure 1-1 APM802 Controller and Customer Connection Box


1.3.1 Connections

Hazardous voltage.Will cause severe injury or death.

Disconnect all power sources beforeopening the enclosure.

DANGER

Inputs and outputs from the controller base module arebrought out to TB10 in the connection box. SeeFigure 1-1 for the terminal block location. Do notconnect directly to the controller base module (exceptfor the Ethernet 3 connection).

TB10 Terminal Strip for input and output connections.See the generator set wiring diagram for connections.Inputs and outputs are factory-set; the default settingsare shown in Figure 1-8.

240 VAC Power Connection. The installer mustconnect a 240 VAC power source for the controllerheater. See Figure 1-1 and the wiring diagram for the240 VAC power connections to TB10.

Mini USB Connectors for connection to a PC forfirmware updates or saving data files. Two USB portsare located on the back of the controller’shuman-machine interface (HMI). See Figure 1-2. Liftthe hinged panel to access the USB ports.

Ethernet 3 port on the base module can be connectedto a personal computer or network to allow remotemonitoring using VNC.

Additional input and output connections are availablewith optional module kits. See Section 5 for accessoryconnection details.

1. USB Ports

1

Figure 1-2 USB Ports (back of HMI)

1.3.2 Modbus Connections

Use RS-485 cable for Modbus RTU connections.Belden #9841 or equivalent shielded, twisted-pair cableis recommended. See Figure 1-3. See the generatorset wiring diagram for the Modbus connection locationon TB10.

The controller also supports Modbus TCP overEthernet. Connect to the RJ45 port labeled Ethernet 3on the controller’s base module.

The controller communicates usingModbusras a slaveconnection with the Modbusr master initiating thecommunication. The controller seeks the system andalternator parameters and diagnostic information thenresponds back to the Modbusr master.

Note: Only one Modbusr master can be connected tothe controller. Examples include the remoteserial annunciator and switchgear applications.

Generator SetController Modbusr Master

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

Figure 1-3 Modbusr Connections


1.3.3 Optional Keyswitch and ManualStart/Stop Button

Some controllers are equipped with the optionalkeyswitch and manual start/stop button shown inFigure 1-4. See Figure 1-1 for the locations on thecontroller assembly.

Figure 1-4 Optional Keyswitch and ManualStart/Stop Button

Keyswitch. The keyswitch disables the modepushbutton on the controller touchscreen. Thetouchscreen will display the operation mode, but themode cannot be changed using the touchscreen if thecontroller isequippedwith thekeyswitch. Thekeyswitchpositions are described in Figure 1-5. See Section 2.5for more information on controller operation modes.

Manual Start/Stop Button. When the keyswitch is inthe Manual position, pressing the Start/Stop button willstart and stop the generator set.

Note: Pressing the manual stop button shuts down thegenerator set immediately, without running theengine cooldown cycle. Running the generatorset without load for 5 minutes before stoppingmanually is recommended.

Position Description

Manual Allows generator set start and stop usingthe manual pushbutton.

Off Places the generator set in OFF/Out ofService mode. The generator set will notstart, even if a remote start command isreceived or the Start button is pressed.

Auto Automatic operation allows a remoteswitch or automatic transfer switch to startand stop the generator set.

Figure 1-5 Keyswitch Positions

1.4 NFPA Requirements

In order to meet NFPA 110, Level 1 requirements, thegenerator set controller monitors the engine/generatorfunctions and faults shown below.

Engine functions:

D Overcrank

D Low coolant temperature warning

D High coolant temperature warning

D High coolant temperature shutdown

D Low oil pressure shutdown

D Low oil pressure warning

D Overspeed

D Low fuel level *

D Low coolant level

D EPS supplying load

D High battery voltage

D Low battery voltage

D Air damper indicator

General functions:

D Master switch not in auto

D Battery charger fault *

D Lamp test

D Contacts for local and remote common alarm

D Audible alarm silence switch

D Remote emergency stop

* Function requires optional input sensors or kits.


1.5 Parameter Settings

Controller parameter settings are factory-set andpassword-protected. Selected settings are shown inFigure 1-6. If changes are required, contact yourdistributor.

Parameter Setting

Preheat duration* 0 s

Air-preheater maximum delay(at each start attempt)*

30 s

Number of starting attempts 3

Time between starting attempts 15 s

Fault inhibition time in starting phase 10 s

Auxiliaries start time 5 s

Generators starting maximum delay(Dead Bus synchronizing)

5 s

Generator cooling time 300 s(5 min.)

Generator immobilization time 5 s

Ventilation time after generator stopped 10 s* Parameter settings not applicable for KD2000--KD3250

Figure 1-6 Factory Settings


1.6 Base Module Inputs and Outputs

The inputs and outputs on the basemodule are factory set. See Figure 1-7 and Figure 1-8 for basemodule input andoutput factory settings. For optional input/output module settings, see Section 5, Accessories.

Note: Make customer connections to TB10 in the connection box. See the generator set wiring diagram for details.

Inputs Factory Setting

Digital Inputs DI0 Remote Start

DI1 Low Fuel Level Switch

DI2 Breaker Open Status

DI3 Remote Reset

DI4 Aux Shutdown

DI5 High Fuel Level Switch

DI6 Aux Warning

DI7 Low Oil Level

DI8 Battery Charger Fault

DI9 Fuel Leak Alarm

DI10 Idle Mode

DI11 GFCI Tripped

DI12 Remote Speed Adjust Enable

DI13 Key Switch Enable

DI14 Load Shed Enable

DI15 Overcrank Test

DI16 Reserved for Factory Use

DI17 Emergency Stop

Analog Input AI0-- Remote Speed Adjust(+/-- 10 VDC)AI0+

Resistive Input RES0--Ambient Air Temperature

RES0+

Figure 1-7 APM802 Base Module Input Factory Settings

OutputsOutput RelayConfiguration Factory Setting

Digital Outputs DO0 Form C Common Fault

DO1 Form C System Ready

DO2 Form C Common Warning

DO3 Form C Reserved for Factory Use

DO4 Form A Horn

DO5 Form A Low Coolant Temp Warning

DO6 Form A Shunt Trip

DO7 Form A Not in Auto

DO8 Form A BCA Excitation

DO9 Form A Generator Running

DO10 Form A EPS supplying Load

DO11 Form A ECU Fault Reset

DO12 Form A Low Oil Pressure

DO13 Form A High Coolant Temp

DO14 Form A Low Coolant Level Fault

DO15 Form A Low Fuel Level

DO16 Form A Start Button Illuminate

DO17 Form A Watchdog

Figure 1-8 APM802 Base Module Output Factory Settings

TP-7070 7/18 21Section 2 Operation

Section 2 Operation

2.1 Prestart ChecklistTo ensure continued satisfactory operation, perform thefollowing checks or inspections before or at eachstartup, as designated, and at the intervals specified inthe service schedule. In addition, some checks requireverification after the unit starts.



DANGER

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

Air Inlets. Check for clean and unobstructed air inlets.

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

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

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

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

Enclosure Doors, if equipped. Check that the serviceaccess doors are closed and secured. Leaving thedoors open will create excessive noise.

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

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

D Check for corrodedor brokenmetal parts and replacethem as needed.

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

D Check that the exhaust outlet is unobstructed.

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

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

Controller Check. Touch the controller screen to verifythat it turnson. Thecontroller screendimsautomaticallyafter a period of time with no activity.

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

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

Radiator. Check that the radiator fins and airinlets/outlets are clean of leaves, insects, dirt, and otherdebris. Use compressed air to clear the obstructedpassages as needed.

Visual Inspection. Walk around the generator set andlook for leaking fluids, loose or dangling wiring, andloose or missing hardware. Repair as needed beforestarting the generator set. This visual inspection shouldbe routinely done while the unit is running.

TP-7070 7/1822 Section 2 Operation

2.2 Exercising Generator Set



DANGER

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

During theexerciseperiodapplyaminimumof 30% loadbased on the nameplate standby rating, unlessotherwise instructed in the engine operation manual.

The operator should perform all of the prestart checksbefore starting the manual exercise procedure. Startthe generator set according to the starting procedure inSection 2.5, Controller Operation. While the generatorset is operating, listen for a smooth-running engine andvisually inspect generator set for fluid or exhaust leaks.

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

2.3 Operation in Cold WeatherClimates

Coldweather operation isgenerally consideredambienttemperatures below freezing 0C (32F). The followingitemsare recommended for coldweather startingand/oroperation when the unit is located in an enclosure orunheated structure. Have a licensed electrician install240 VAC, 15 amp outlets as needed if not already in theimmediate area.

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

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

D Thecontroller heater is required for operationbelow--20C (--4F). The controller heater is a standardfeature. Make sure that 240VACpower for the heateris connected as shown on the generator set wiringdiagram.

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

D An alternator heater to prevent moisture and frostbuildup is available for most generator sets.


2.4 Generator Set Operation

2.4.1 Start Signal

A start signal includes the following:

D Remote start signal via contacts 3 and 4 when thecontroller is in AUTO mode. The remote startcontacts may be connected to an ATS (used during apower outage, exercise period, etc.) or a remotepanel.

D Engine Start signal from the controller. Put thecontroller into Manual mode. Then press the EngineStart button on the screen.

Note: The engine crank cycle is 15 seconds crankingand 15 seconds rest for 3 cycles.

2.4.2 Stop Signal

A stop signal includes the following:

D Removal of start signal via contacts 3 and 4 when thecontroller is in AUTO mode. The remote startcontacts may be connected to an ATS (used during apower outage, exercise period, etc.) or a remotepanel.

D Engine Stop signal from the controller when it is inManual mode. Press the Engine Stop button on thescreen.

D Emergency Stop signal. See Section 2.4.4.

2.4.3 Engine Cooldown

Engine Cooldown runs the generator set with no load toallow hot engine components time to cool slowly beforethe engine is stopped.

When the generator set is running in AUTO mode, anengine cooldown cycle begins when the remote startinput is deactivated. Also, if stopping due to a remotestop signal, a cooldown cycle begins. The engine runsfor 5 minutes in the cooldown cycle.

Note: No engine cooldown cycle occurs if the EngineStop button is pressed (in manual mode), theEmergency Stop button is pressed, or if a faultoccurs. The shutdown is immediate. If possible,run the generator setwithout load for 5minutes toensure adequate engine cooldown.

2.4.4 Emergency Stop

Use the controller emergency stop switch for immediateemergency shutdown.

The emergency stop switch bypasses the enginecooldown cycle and immediately shuts down thegenerator set.

Note: Use the emergency stop switch(es) foremergency shutdowns only. Use the controller’sManual mode or a remote stop switch for normalshutdowns.

The controller alarm (fault) button flashes red and theunit shutsdownwhen the local emergencystop switch isactivated (pressed).

Use the following procedure to reset the generator setafter shutdown by a local or remote emergency stopswitch.

1. Investigate and correct the cause of theemergency stop.

2. Reset the controller emergency stop switch bypulling the switch dial outward and/or reset theremote emergency stop switch (if equipped).

3. Reset the fault on the APM802 controller. SeeSection 2.10 for instructions.

4. After resetting all faults using the controller resetprocedure, place the controller into Auto mode oruseManual mode to restart the generator set. Thegenerator set will not crank until the resetprocedure completes.

2.4.5 Idle Mode

The generator set controller must be in AUTOmode foridle mode operation. Idle mode requires acustomer-supplied idle switch connected acrossterminals 5 and 6 on terminal block TB10.

When the idle switch on contacts 5 and 6 closes, theengine runs at low speed (1000 RPM) for 5 minutes.The engine then ramps up to normal speed and voltageandcontinues to rununtil the idle switchopens. After theidle switch opens, the engine continues to run throughthe cooldown cycle and then shuts down.


2.5 Controller Operation Modes

The controller operation includes several types ofstartingandstopping functions. Thereare threeprimarymodes of operation, selected from the controllertouchscreen or the optional keyswitch:

D Auto (Automatic mode)D ManualD Out of Service (Off mode)

See Figure 2-1 for the location of the mode selectionswitch on the controller touchscreen. See Section 1.3.3for more information about the optional keyswitch.

The Emergency Stop button and the optional remoteemergency stop switch will stop the generator setimmediately, with no engine cooldown period.

The three operation modes are briefly described belowand summarized in Figure 2-2.

1. Alarm (fault) button2. Mode selection switch

1

tp7070

2

Figure 2-1 Controller Mode Selection Switch

2.5.1 Out of Service Mode

Pressing the Out of Service button on the controllertouchscreen disables the generator set to preventstarting during generator set maintenance or service.The generator set remains off and will not respond to aremote start signal. If the generator set is running,pressing theOut of Service button immediately shuts offthe generator set, with no engine cooldown.

If a fault causes the generator set to shut down, thecontroller automatically enters theOut of Servicemode.

Note: To disable the generator set before servicing,shut down the generator set, place inOut-of-Service mode, and disconnect thebatteries negative (--) lead first.

2.5.2 Manual Mode

In manual mode, engine start and stop are controlledmanually by the operator using the Engine Start andEngine Stop buttons on the controller’s touchscreen. Ifthe controller is equippedwithanoptional keyswitchandmanual start/stop button, use the start/stop button formanual operation in the procedures below.

Manual start procedure, with optional keyswitch

1. Turn the key to theManual position. check that thecontroller touchscreen shows that the unit is inMANUAL mode.

2. Check the mechanical parameters (batteryvoltage, etc.) and verify that there are no faults.

3. To start the generator set, press the manualStart/Stop button. The engine speed, voltage, andfrequency will be displayed on the controllerscreen.

Manual start procedure, without optionalkeyswitch

1. Press and hold the Manual button on thecontroller’s touchscreen until Manual turns green.

2. Release the Manual button. The Engine Startbutton appears on the controller touchscreen.

3. Check the mechanical parameters (batteryvoltage, etc.) and verify that there are no faults.

4. Tostart thegenerator set, pressEngineStart on thecontroller touchscreen. The engine speed,voltage, and frequency will be displayed on thecontroller screen.

Manual stop procedure

Note: Pressing Engine Stop causes the generator setengine to stop immediately, without running theengine cooldown cycle.

The controller must be in Manual mode. Follow thesesteps to allow engine cooldown before stopping thegenerator set.


1. Remove the load from the generator set.

2. Wait five minutes to allow the engine to cool down.

3. To stop the generator set, pressEngineStop on thecontroller touchscreen or press the manualStart/Stop button (if equipped).

2.5.3 Auto Mode (Standby or SystemReady)

The generator set is waiting for a start signal. Thegenerator set will start and run when a start signal isreceived via a remote start signal or a local start signal.

The generator set will start when it receives a startsignal. If the generator set is not in Auto mode, it will notstart.

When the start signal is removed, the generator set willcontinue to run through the engine cooldown cycle, andthen shut down.

Idle Mode

If the generator set is equippedwith an idlemode switchacross contacts 5 and 6, the engine can operate in idlemode. When the idle mode switch closes, the engineruns at low speed (1000 RPM) for 5 minutes and thenramps up to normal speed and voltage. Idle Mode isdisplayed in the status message area on the controllerscreen. When the idle mode switch opens, the engineruns through the cooldown cycle and then shuts down.

The controller must be in Auto mode for idle modeoperation.

Operating Mode Action /Event Operation Notes

AUTO

Press Auto or place theoptional keyswitch into theAUTO position (if equipped).

Responds to remote start/stopcommands from an ATS orremote start panel. *

Auto is the recommended mode.

Idle switch on contacts 5and 6 closes.

Engine runs at 1000 RPM for 5minutes, then ramps up to normalspeed and voltage. *

Customer-supplied idle switch is required for idlemode operation. Controller must be in Auto foridle mode operation.Idle switch on contacts 5

and 6 opens.Engine runs through the 5 minutecooldown, then shuts down.

A warning condition occurs.Fault button flashes orange.

Horn may sound, if connected.

See Section 2.10 for instructions to view faultsand warnings (alarms).

A fault condition occurs.

Generator set shuts down andthe fault button flashes red. Themode changes to Out of Servicemode.

Horn may sound, if connected.

MANUAL

Press Manual or place theoptional keyswitch into theManual position (ifequipped).

Engine can only be started andstopped using the enginestart/stop buttons on thetouchscreen or the manualstart/stop button (if equipped). *

Engine start/stop is controlled manually by theoperator.

If equipped with the optional keyswitch andmanual Start/Stop button, the engine start andstop buttons on the controller touchscreen aredisabled. Use the manual Start/Stop button.

Wait 5 minutes after opening the circuit breakerfor engine cooldown before pressing EngineStop.

Press the Engine Startbutton or the manualStart/Stop button (ifequipped).

Starts the engine if there are noactive faults. *

Press the Engine Stopbutton or the manualStart/Stop button (ifequipped).

Stops the engine immediately,with no engine cooldown.

OUT OF SERVICE

Press the Out of Servicebutton or place the optionalkeyswitch into the OFFposition (if equipped).

Stops the engine immediately,with no cooldown.

System is locked and generatorstartup is not possible.

Put the generator set into Out of Service (OFF)mode and disable the generator set duringmaintenance or service.

Generator set shuts downon a fault.

A fault shutdown automatically puts thegenerator into Out of Service Mode. SeeSection 2.10 for instructions to view and resetfaults (shutdowns or warnings).

* The E-Stop button overrides the manual engine start/stop buttons and remote start signals. The engine will not start if the E-Stop button isactivated.

Figure 2-2 Operation Mode Summary


2.6 Load Shed

Themanual keyswitch/ loadshedmodule isavailableasan optional kit.

The load shed function drives outputs to four FormCdrycontacts to remove non-critical loads. If the generatorset load reaches or exceeds the level set in powerthreshold #9, loads are shed until the total load dropsbelow the threshold level.

Loads are added again when the total load drops belowthe level in threshold#9. Factory-set timedelaysensurethat the load is stable before loads are shed or added.Load 1 is shed first and added last. Load 4 is shed lastand added first.

The load shed level is set in Power Threshold 9 on theAPM802 controller. The factory default setting forthreshold 9 is 90%. The threshold setting can bechanged in Screen 1.2 after logging in with theoperator’s password. See Sections 2.8 and 2.12.1.

Do not connect critical loads to the load shed outputs.Only connect low-priority loads that can bedisconnected when necessary.

Connection

Controllerswith loadshedcapability areequippedwithaManualKeySwitch/LoadSheddigital I/OModule,whichis factory-installed in the first position. Connect up tofour non-critical loads to LoadShedOutputs 1 through 4on the Manual Key Switch/Load Shed Module. SeeFigure 2-4. The load shed outputs are FormC contacts.Connect to the normally open (NO) or normally closed(NC) contacts as required for the application.

LoadPower

Threshold *

Load Shed(Disconnect)Time Delay

Load Add(Reconnect)Time Delay

Displayedas

1 #9 5 seconds 60 seconds O #0




* Default setting = 90%. Power threshold setting can bechanged by the technician.

Figure 2-3 Load Shed Settings

Operation

The outputs are activated and loads are shed when thetotal generator set load reaches the level set in power

threshold #9. Load1 (output #0) is shed first . Additionaloutputs are activated every 5 seconds as shown inFigure 2-3 until the total load drops to the thresholdvalue or all four non-critical loads are shed. Messageson themain screenwill indicate that load shed outputs 1through 4 are active.

If all four loads are shed, the generator set will continueto run if the load remains at or below 100% of the ratedload.

When the generator set load drops below the level inthreshold 9, the outputs are deactivated one at a timestarting with Load 4 (output #3), reconnecting the loads.Adjust the loads, if necessary to avoid cyclic adding andshedding around the threshold #9 level.

GM103061

Load ShedCustomerConnections

Key switchfactoryconnections

MANUAL KEY SWITCH/LOAD SHED I/O MODULE

Figure 2-4 Load Shed Output Connections


2.7 HMI Screen Layout

2.7.1 Home Screen

The home screen of the APM802 controller’s human-machine interface (HMI) contains status messages, navigationbuttons, data displays, and controls described briefly in the following sections. See Figure 2-5.

1

1. Top bar2. Control Panel3. Generator view

32

Figure 2-5 Home Screen

2.7.2 Top Bar

The topbar isalwayspresent, it displayssystem informationandstatusmessages,and it hasshortcut buttons for quickaccess to other screens.

1. Shortcut to operating screen2. Operating status message3. Shortcut buttons4. Date and time display5. To home screen

6. Alarm indicator and access to events screen7. For future development8. To operator login9. To applications screen10. Operating sequence display

1 2 3 4

9 8 7 6 510

Figure 2-6 Top Bar


2.7.3 Generator View

Thegenerator viewdisplaysenginemechanical dataandalternator electrical data. When inmanualmode, theEngineStart button also appears. See Figure 2-7.

1

1. Engine start appears in Manual mode only2. Engine and mechanical view3. Alternator electrical view

23

Figure 2-7 Generator View


2.7.4 Control Panel

The control panel includes the generator set masterswitch and other controls. See Figure 2-8.

1. Mode selection touch pad2. Horn silence button appears for alarm or fault3. Start button in manual mode4. Voltage and frequency shown when running5. Touch Menu button for menu access6. Operator menus (operator login required)7. User menus

6

1

2

4

5

7

3

Figure 2-8 Control Panel

2.7.5 Custom View Button

On medium voltage units equipped with thermocouplemodules, touch the customviewbutton to see alternatortemperature readings from the thermocouple modules.

If no thermocouplemodules are installed, 32_F (or 0_C)is displayed for all temperatures. If nothing is connectedto one channel on a thermocouple module, --58_F (or--50_C) is displayed.

1 tp7070

1. Custom view button

Figure 2-9 Custom View Button

Figure 2-10 Custom View Temperature Display


2.8 Operator Login

Some functions require logging in as an operator.

1. Touch the Operator button. See Figure 2-12.

2. Use the virtual keypad to enter the login (1966).

Note: When logging on as operator 1966, apassword is not required.

When logged in as an Operator, the Modify buttonappears on screens where settings can be changed.See Figure 2-11 for an example.

The operator is automatically logged out after10 minutes.

1

1. Modify button

Figure 2-11 Modify Button

3

1. Operator button2. Virtual keypad3. Login (1966)

1

2

Figure 2-12 Operator Login


2.9 Data Displays

2.9.1 Generator Mechanical Values

Overview display

It is possible to display up to 6 mechanical values at thesame time. By default, the following values aredisplayed:

D Working hours counter (number of operating hours)

D Fuel level (daily service tank or main tank)

D Starter battery voltage

D Coolant temperature (HT coolant temperature in thecase of a dual circuit engine)

D Oil pressure

D Oil temperature

The display area showing six mechanical values iscalled the Favorites page. The content of this page canbe altered at any time. Each mechanical value isrepresented by an information bar containing theinformation shown in Figure 2-13.

1. Information bar2. Name/description of the mechanical value3. A visual display of the value: bar graph, thermometer, meter4. The numerical value (56_C, 28V, 5.1 bar, etc.)5. A pictogram

1

5

43

2Favorites

Figure 2-13 Favorites Page

Themechanical values can be scrolled through page bypage. Press the < and > buttons to scroll through thepages. See Figure 2-14

Favorites page Page 1/1

Favorites

Figure 2-14 Scrolling within the Favorites Page


Detailed View

Pressing any area on an information bar on one of themechanical value pages gives access to a detailed viewof the selected mechanical value.

The example below shows a user pressing on the Oilpressure information bar.

Favorites

Figure 2-15 Information Bar Selection

Figure 2-16 Detailed Mechanical Values

From an overview display of 6 mechanical values, weswitch to a detailed display of 3 mechanical values.

Three tabs also appear: Fuel, Engine, and Cooling. Themechanical values are all classed under these threetabs.

Under each tab, the mechanical values displayed canbe accessed by pressing the < or > buttons insuccession.

Once you zoom into each mechanical value, 2 or 3additional buttons appear:

Favorites button

The Favorites (+L) button is used to select the 6mechanical values most useful to the user. SeeFigure 2-17.

If the Favorites (+L) button is blue, the mechanicalvalues appear on the LFavorites page (limited to sixvalues).

If the Favorites (+L) button is gray, the mechanicalvalues do not appear in the L Favorites page, but inanother page.

1. Favorites button

1

Figure 2-17 Favorites Button in the Detailed View


2.9.2 Generator Electrical Values

Overview display

Six electrical values are displayed and shown asmeters. See Figure 2-18.

1. Active power, P, in kW2. Power factor, PF3. Reactive power, Q, in kvar4. Frequency, F, in hertz5. Phase current, I, in amperes6. Line-to-line voltage, U, in volts

1 2 3

4

5

6

Figure 2-18 Electrical Values

Detailed display

Touching any area of a meter gives access to anexpanded view of the selected electrical value. For anexample, see Figure 2-19 and Figure 2-20.

D From an overview display of 6 electrical values, weswitch to a detailed display of 3 electrical values.

D The electrical values which are not displayed can beaccessed by pressing the > or < buttons insuccession.

Figure 2-19 Electrical Values and Touching on ActivePower

1

1. Curve button

Figure 2-20 Detailed Electrical Values

2.9.3 Curve Display

When you zoom into each mechanical or electricalvalue, the Curve button appears. Touch the Curvebutton to view the change over a variable period in realtime of one of the 6 electrical values of the overviewdisplay.

Figure 2-21 shows the location of theCurvebutton. SeeFigure 2-22 for an example of a curve display.

1

1. Curve button

Figure 2-21 Curve Button on the Detailed View


1. Choice of recording period (10 minutes, 4 hours, 8 hours,24 hours)

2. Previous successive press3. Zoom out4. Zoom in5. After successive press6. Pause the recording or start the recording of the mechanical

value

1 2 3 4 5 6

Figure 2-22 Oil Pressure Curve (example)

Touch the recording period to select the time period:

D 10 minutes: record values every 1 second

D 4 hours: record values every 30 seconds

D 8 hours: record values every 1 minute

D 24 hours: record values every 3 minutes

On any curve displayed on the screen, inserting a USBkey into theHMI portmakes theUSBkey button appear.See Figure 2-23. Pressing this button automaticallysaves:

D A curve data file (.csv) containing the information(data points) described in Section 2.9.4.

D An image of the selected window in png format. SeeFigure 2-23 for an example showing the batterywindow.

1. Voltage2. USB button3. Current

1

3

2

Figure 2-23 Curve Window (battery data is shown forthis example)

Touch the Back (< ) button to return to the overviewdisplay. See Figure 2-24 for the location of the Backbutton.

1

1. Back button

Figure 2-24 Back Button


2.9.4 Saved Electrical and Mechanical DataThe recording on a USB stick provides a curve data file(.csv) containing the information shown in Figure 2-25.

Depending on the engine type and sensors installed onthe generator set, some of the 14 mechanical valuesmay not be used. In that case, 0 will appear in the Exceltable for the value or values concerned.

For electrical values, the voltage input U2 of theregulation module is present in the Excel table eventhough this input is not used.

The markers I3.x.x and I5.x.x correspond to the analogvariable numbers (see section 2.12.4).

All of this information is saved according to 4 differenttime periods:

D 10 minutes: record values every 1 second

D 4 hours: record values every 30 seconds

D 8 hours: record values every 1 minute

D 24 hours: record values every 3 minutes

Mechanical value Notes

I5.35: U bat #1 Battery voltage 1

I5.36: I bat #1 Battery current 1

I5.10: Engine speed

I5.21: Daily tank fuel level

I5.20: Engine cooling circuit coolant level

I5.15: Fuel temperature

I5.16: Oil temperature

I5.13: Engine cooling circuit coolant temperature

I5.14: Charge air cooling circuit coolant temperature

I5.17: Charge air temperature

I5.24: Oil pressure

I5.25: Low fuel pressure

I5.27: Charge air pressure

I5.115: ECU: Estimated instant fuel consumption

I5.131: ECU: Common rail fuel pressure

I5.110: ECU: Engine speed

I5.138: ECU: ECU voltage supply

I5.139: ECU: Engine running hours (hours)

I5.140: ECU: Engine running hours (seconds)

Electrical value (on generator set side) Notes

I3.1.50: Frequency -- Input1 -- Reg #1 On input U1 of regulation module 1

I3.1.55: U23 Line--to--line voltage -- Input1 -- Reg #1 On input U1 of regulation module 1

I3.1.57: I1 Current -- Input1 -- Reg #1 On input U1 of regulation module 1

I3.1.64: Total active power -- Input1 -- Reg#1 On input U1 of regulation module 1

I3.1.68: Total reactive power -- Input1 -- Reg#1 On input U1 of regulation module 1

I3.1.72: Total cosphi -- Input1 -- Reg #1 On input U1 of regulation module 1

Figure 2-25 Saved Data


2.10 Events

Thecontroller displaysstatus, alarm (warning), and fault(shutdown) messages. See Figure 2-26 for a list ofpossible alarms and faults.

InternalNumber Description

Alarm(Warning)

Fault(Shutdown)

M3.10 Common fault X

M3.16 Common warning X

M3.17 GFCI tripped X

M3.18 Over frequency fault(81H)

X

M3.19 Under frequency fault(81l)

X

M3.20 Over voltage fault (59) X

M3.21 Under voltage fault (27) X

M3.22 Overload active powerwarning (32PH)

X

M3.24 Reverse active powerfault (32RP)

X

M3.25 Overload reactivepower warning (32QH)

X

M3.26 Reverse reactive powerfault (32RQ)

X

M3.27 Over current fault (51) X

M3.29 Thermal overload fault X

M3.30 Low cranking voltage X

M3.31 Low controllertemperature

X

M3.42 Genset output greaterthan 80% of rated

X

M3.43 Load shed 1 active X




M3.63 Idle mode cancelledbefore idle timeout

X

M3.66 Alternator windingtemperature warning

X

M3.67 Alternator windingtemperature fault

X

M3.68 Alternator bearingtemperature warning

X

M3.69 Alternator bearingtemperature fault

X

M3.76 Not in auto warning X

M3.77 Power plant out ofservice fault

X

M3.80 Emergency push buttonengaged fault

X

M3.107 Under speed fault X

M3.108 Over speed fault X

M3.109 Speed detection fault X

M3.113 Low engine coolantlevel fault

X

M3.116 Engine coolanttemperature warning

X

InternalNumber Description

Alarm(Warning)

Fault(Shutdown)

M3.117 Engine coolanttemperature fault

X

M3.124 Low coolanttemperature warning

X

M3.128 Low oil level warning X

M3.132 Lube (engine) oilpressure warning

X

M3.133 Lube (engine) oilpressure fault

X

M3.134 Lube (engine) oiltemperature warning

X

M3.135 Lube (engine) oiltemperature fault

X

M3.142 Speed detection firststarter warning

X

M3.143 Speed detectionsecond starter warning

X

M3.153 Low fuel level X

M3.154 Fuel level critically low X

M3.155 High fuel level X

M3.156 Fuel daily tank veryhigh level warning

X

M3.158 Fuel leak alarm X

M3.192 First starter warning X

M3.193 Overcrank X

M3.198 Battery charger fault X

M3.200 Low battery voltage X

M3.201 High battery voltage X

M3.212 APM internal batterywarning

X

M3.550 Engine CAN buscommunication fault

X

M3.553 Regulation module 1communication fault

X

M3.567 APM802 watchdog X

M3.720 Analog sensor faultinput AI #0

X


X


X

Figure 2-26 Warning and Shutdown Messages


2.10.1 Faults and Alarms

Press theAlarm (!) button shown inFigure 2-27 to viewalist of generator set events, including status messages,alarms, and faults.

D A status message communicates the state of thegenerator set (example: appearance of Stop mode).

D An alarm (warning) signals an impending problem(example: coolant temperature alarm). The alarmbutton flashes orange. See Figure 2-28. A warning(alarm) appears in orangeon the screenanddoesnotcause the generator to shut down.

D A fault shuts down the generator set (example: oilpressure fault). The alarm button flashes red. SeeFigure 2-29. A fault appears in red on the screen andcauses the generator to shut down (instantly ordelayed, depending on the programmed incidence).

D Anumber on thealarmbutton indicates thenumberofactive faults and/or alarms.

Therearesomeexceptions. Aspecific faultmessageonthe HMI screen may be processed as an alarm by thePLC, so there is no engine shutdown.

Press the stop horn button. The horn (if equipped)turns off and the stop horn button disappears. Thealarmbutton stops flashing and turns orange.

Press the alarm (!) button. A list of the last three activealarms that have not been reset is displayed. SeeFigure 2-30. Alarms and faults are listed inchronological order.

1

1. Alarm button

Figure 2-27 Alarm Button

33508003101

1. Alarm (!) button is orange2. Stop horn button

1

2

Figure 2-28 Appearance of an Alarm (warning)

1

1. Alarm (!) button is red2. Stop horn button3. Generator set has shut down and is in out of service mode

3 2

Figure 2-29 Appearance of a Fault (shutdown)


1. Alarm button with number of alarms (press to display list)2. Pull down tab (press to show full display of additional alarms)3. Description4. Internal variable number

5. Date and time of event6. Reset button (X)7. Active (on)8. Not active (off)

8

7

6

1

3 245

Figure 2-30 Fault and Alarm List (three most recent faults or alarms)

Press the pull--down tab for access to a full screendisplay of any other additional alarms. See Figure 2-31.The full screen brings up the following:

D < Back button on the operating screen

D Drop-down menu A

D Drop-down menu B

D X button (general reset)

D Complete list of active faults and/or faults not reset

The 4th alarm in Figure 2-31 shows a fault that ismanaged as an alarm.

1. List of alarms in chronological order

1

Figure 2-31 Full Screen with Latest Alarms


2.10.2 Resetting an Alarm

An alarm indicates that a problem has occurred, but thegenerator is still able to run. Always correct an alarmcondition before it leads to a fault that will shut down thegenerator set. See the Safety Precautions andInstructions section of this manual before proceeding tocorrect an alarm condition. Contact an authorizeddistributor or dealer for service, if necessary.

An alarm turns off when the cause of the alarm isresolved:

D Theoperatormaycorrect thecondition that is causingthe alarm.

D The alarm condition may resolve itself; for example,the temperature drops, resolving a high temperaturealarm.

After the condition is resolved and the alarm turns off,RESET the alarm by pressing the X button. SeeFigure 2-32.

If the alarm does not appear on the list of the last threealarms, touch the pull-down tab to display additionalalarms.

1

1. Press the reset alarm button

Figure 2-32 Resetting an Alarm

2.10.3 Resetting a Fault

A fault turns off when the cause of the alarm is resolvedby one of the two following methods:

D The operator has corrected the condition that iscausing the fault.

D The fault condition has resolved itself; for example,the temperature drops, resolving a high temperaturefault.

Note: The generator set must not be restarted until thefault condition is identified and corrected.

Always identify and correct the cause of a faultshutdown before resetting the controller. See the SafetyPrecautions and Instructions section of this manualbefore proceeding to correct a fault condition. Contactan authorized distributor or dealer for service, ifnecessary.

To reset a fault, first correct the fault condition. The faultindicator will turn off. Then press the X button next to theindividual fault. See Figure 2-33.

Note that it is also possible to reset a fault from the tab ofthe last 3 alarms, if this fault is one of the 3 most recentalarms.

Emergency Stop Fault

Manually pressing the emergency stop button causes afault. After the emergency stop button is unlocked, thefault indicator will turn off, and it will then be possible toreset this fault with the X button.

Figure 2-33 Resetting a Fault


2.10.4 Consulting Status Messages

Reviewing the status messages is possible at any time.Depending on the status type, the APM802 will logdifferent messages:

D Appearance

D Disappearance

D Appearance/Disappearance

D Present/Not present

D Open/Close

D On/Off

D Start/End

After pressing the Alarm (!) button, and if no fault oralarm is present, select Status messages history indrop-down menu A. See Figure 2-34 and Figure 2-35.

1. Drop-down menu A (see Figure 2-35)2. Drop-down menu B (used to select between all, mechanical, or electrical type status messages)

1

2

Figure 2-34 Drop--down Menus

1. The most recent status in the sequence2. The oldest status in the sequence

1

2

Figure 2-35 Drop--down Menu A

1. Drop--down list A2. Drop--down list B

1 2

Figure 2-36 Drop--down Lists A and B


2.10.5 Full Event Log

To view all events (status messages, alarms, and faults, active or reset), select Full event log from drop-down list A,and select All from drop-down list B. See Figure 2-37 for an example of the full event log.

1

1. List A, Full event log selected2. List B, All selected

2

Figure 2-37 Full Event Log


2.11 ApplicationsTouch the Applications button in the top bar to open the Applications screen. See Figure 2-38. From this screen, youcan access the screens listed in Figure 2-39. Note that access to some screens requires logging on as an operator.

1. Reference2. Region settings3. HMI settings4. Restart5. Display cleaning6. Firmware update7. Screenshot8. Ladder tools9. Save parameters10. Upload parameters11. Applications button

1 2 3 4

7

8

9

5

6

11

10

Figure 2-38 Applications Screen

Number Operator User

1 Reference:

Information on the administrative characteristics of the installation: name of the site, casereference, software versions, etc.

X X

2 Region settings

Used to set the user language, the date, the time, the mechanical units used, insert acustomer--specific logo

X X

3 HMI settings:

Used to adjust the screen brightness in standby mode, and the calibration of the touchpanel

X X

4 Restart:

Used to reboot the HMI module

X

5 Display cleaning:

Used to lock the screen for 20 seconds to allow cleaning without adversely affectingoperation

X X

6Firmware update:

Used for the software update for the HMI module

X

7 Screenshot:

Used to take a screenshot to capture the installation at a given moment

X X

8 Ladder tools:

Used to view additional equations

X

9 Save parameters:

Used to save the parameters of the application onto a USB key

X X

10 Upload parameters:

Used to load parameters from a USB key

X X

Figure 2-39 Screens Accessed from the Applications Screen


2.11.1 Reference

1. Modify key (for data modification in Operator mode only)2. Scroll up or down as needed

1

33508003101

2

Figure 2-40 Reference Screen

Title Description and Possible Settings (or selections)Customer reference

Reference

APM identification

Customer case name (for example: computer center)

Option of assigning a name to the HMI (for example: GS parking number 1)

Kohler reference

Reference

Genset serial number

Commercial case reference (manufacturer’s side)

Generator set serial number associated with the HMI

Software version

HMI HMI module firmware version

System HMI module OS version

Base module Base module firmware version

System Base module OS version

Regulation module Regulation module firmware version X179


2.11.2 Region Settings

1

1. Select user language2. Set the date and time

3. Modify4. Date and time adjustment window

appears after touching the Modify key

24

3

Figure 2-41 Region Settings Screen

Title Description and Possible Settings (or selections)

Pressure

Temperature

Selection of the pressure display: bar, PSI

Selection of the temperature display: _C , _F

Customization

Display Selection of the logo at the top left of the screen

Logo Upload an image in JPEG or PNG format (see below)

Adding a logo

1. Press theModify button. An additionalUpload keyappears.

2. On a USB key, create a directory calledE:\apm802\ icon and copy the logo* to be insertedinto the main screen of the HMI.

3. Insert the USB key into the appropriate port andpress the Load key.

4. In the window shown in Figure 2-42, press thecentral field, select the desired image and confirm.

5. The image appears next to the Upload key (aDelete key also appears to delete or replace theimage on the screen).

6. Press on Apply. The logo then appears under the4--position switch.

The Region settings screen can also be accessed bytouching in the date/time area of the top bar.

Figure 2-42 Selecting the Logo Image File

* The ideal image size for the logo is 170 x 100 pixels.


2.11.3 HMI Settings

2

1. Touch the Modify button2. Slide to adjust the screen brightness during normal operation3. Slide to adjust brightness during standby operation

1

3

Figure 2-43 HMI settings

The sliders on this screen allow adjustment of thescreen brightness during operation and standby. Thetwo sliders are independent. However, if the brightnessin operation mode is near the brightness in standbymode, then the setting of the second follows the first, asshown. Conversely, if the brightness is increased instandby mode, the brightness during use alsoincreases.

Title Description and possible settings (or selections)

Standby mode

Time (min) Delay before activation of screen standby mode: from 10 to 600 minutes

HMI connectivity

HMI type * Use of HMI connected to the base module: Local, Remote

Mode of operation [ Use of HMI for remote mode: Full access, Operation, Visualization

Display blue background of lockedbutton (selector 0/1) ]

When the selector is at 1, the HMI is connected using the access code (seesection 9.4 -- Identification)

Remote HMI number [ Remote HMI number: from 1 to 50 in a complete power plant, but limited to 9HMIs for a base module

Addressing mode [ HMI addressing: System, Customer IP, DHCP

Eth1 IP address [ Permanent or temporary identification number for the HMI module connected toanother base or to a network (for example: redundant ring)

Eth1 MAC address [ Unique permanent physical identification number, which is stored in the HMImodule

* Several choices available for the parameter[ These parameters only appear if Remote has been selected] This parameter only appears if Remote and Display have been selected


The Home button on the Remote HMI looks differentthan the Home button on the local HMI. SeeFigure 2-44.

Local HMI Remote HMI

Figure 2-44 Home Buttons

In the case of a Remote HMI in Visualization mode, theicons in Figure 2-45 show the various displays of key 2.

Figure 2-45 Remote HMI Indication

In the caseof aRemoteHMI inOperationmodeor inFullaccess mode, button 2 does not change appearance.

A remote HMI is connected to the Ethernet ring. WhentheHomebutton is pressed, a pop--upwindowappears;

the search for base modules connected to the ring is inprogress.

At the end of the search, the IP addresses of themodules connected to the Ethernet ring are shown (seeFigure 2-46). It is alsopossible to seewhether oneof theconnected generator sets has a fault (red indicator).

Figure 2-46 IP Address Display

Select the base module to connect to (in the example,there is only one generator set). A Connect Generator#1 button also appears.

Press the Connect Generator #1 button. The windowchanges as shown in Figure 2-47.

Press the magnifying glass at the top left-hand of thescreen to start a new search to select another moduleconnected to the Ethernet ring.

Figure 2-47 Selecting a Module from a Remote HMI


2.11.4 Restart

Press the Restart icon to bring the window shown inFigure 2-48 to the front. Confirm the restart by pressingOK, or cancel the procedure by pressing Cancel.

This operation will trigger a complete restart of the HMImodule.

Figure 2-48 Restart Window

2.11.5 Display Cleaning

Before wiping the screen, press the Display cleaningicon. The window shown in Figure 2-49 appears.

The entire screen is disabled for 20 seconds, allowingyou to clean the touch panel.

After 20 seconds, the Applications screen appearsagain.

Figure 2-49 Display Cleaning Window

2.11.6 Firmware Update

Pressing the Firmware update icon carries out anupdate of the HMI firmware.

The update requires that a USB key is inserted into theport provided on the bottom of the HMI. SeeFigure 2-50.

1. USB Ports

1

Figure 2-50 USB Port Location on HMI Module

Firmware Update Procedure

1. Tap the selection field area (Figure 2-51) andselect the desired software version.

2. Press OK to start the software update operation.

Figure 2-51 Firmware Update Screen

At the end of the update, the HMI will automaticallyrestart.

For this update operation, theUSB keymust contain thefollowing type of directory: E:\apm802\update. Thesoftware versions (or firmware) are of the following type:IHM_APM802_V1_x_x.z208.

Note: The HMI firmware version number must matchthe firmwareversion installed in thebasemodule.


2.11.7 Screenshot

Before taking a screenshot, it is necessary to insert aUSB key in the port provided on the bottom of the HMImodule. See Figure 2-50.

Pressing theScreenshot button enables the screenshotfeature. The screenshot icon turns blue when enabled.Screenshotmode stays enabled until turned off. Returnto the Applications screen and click on the camerabutton to turn off the screenshot mode.

The button shown in Figure 2-52, which symbolizes acamera, then appears at the top right of the screen.

1

1. Camera button

Figure 2-52 Camera Button (for screenshots)

Go into the screen to be copied and press the camerabutton. The screenshot is automatically saved to theUSB key in the directory “E:\apm802\screenshot.

Note: During the time it takes to create the screenshot,the camera button remains blue.

Note: The images are in PNG format. It is not possibleto create a partial screenshot.


2.11.8 Ladder Tools

Ladder is a standardizedgraphic languagewhich is verysimilar to a ladder diagram. Implemented in the basemodule of the APM802, it is used to define the PLCfunctions required for specific functions.

Pressing the Ladder tools icon takes you to the screenshown in Figure 2-53. See Figure 2-38 for the locationof the Ladder tools icon on the applications screen.

1. Network access keys2. Press one of these button to exit the ladder screen

1

2

Figure 2-53 Ladder Screen

To exit the Ladder screen, press the Applications buttonor the Home button on the top bar.

Generally speaking, there will be at least 2 networks:

D The inputs network (accessed via the Inputs key)

D The outputs network (accessed via theOutputs key).

Depending on the complexity of the application, theremay be an intermediate network.

The Inputsnetworkdefinesall the inputequations for thesystem. These inputs correspond to the physical inputsfor the base module.

The #1 network defines all the intermediate equationsused for the connection between inputs and outputs.

TheOutputs network defines all the output equations forthe system. These outputs correspond to the physicaloutputs for the base module. See Figure 2-55.

In all networks, press on the contact or the coil to accessmore information.


1. Input line title2. Electrical connection3. Input internal variable4. Normally closed contact5. Input variable

4

1

5

2 3

Figure 2-54 Inputs Network

Figure 2-55 Outputs network


2.11.9 Save Parameters

1. Insert a USB key into the port on the bottom of theHMI module. See Figure 2-50.

2. Press on the Save Parameters icon; the screenshown in Figure 2-56. Saving starts automatically.When it is completed, the screen confirming thatthe save operation was performed successfullyappears.

3. Press on OK to close the window.

Figure 2-56 Save Parameters Windows

On the USB stick, four files are saved in a directorycalled case number:

D Parameters (file *****_params.x208)

D Traceability (file *****_apm_info.i208)

D Events (file *****_events.txt)

D Curve data (file *****_curve_data.csv)

where ***** is: 0_gs1_<genset serial number>_.

2.11.10 Upload Parameters

An authorized service technician can obtain and loadparameter files following the instructions in thecontroller service manual.

Parameter files are specific to the individual generatorset, as identified by the generator set serial number. Donot attempt to load parameters that have been savedfrom a different generator set.


2.12 MenusFigure 2-57 shows the architecture of the screens accessible from the Menu button.Menu >

1--Settings 2--Measurements 3--History 4--Diagnostic 5--Configuration 6--Hardware

1.2 2.2 3.1 4.1 5.1 6.1

Power thresholds Mechanical Archiving Variables Application Installation

1.5 2.3 4.2 5.1.1 6.1.1

Timers * Generator electrical Binary inputs General General

1.6 2.6 4.3 5.1.2 6.1.2

Auxiliaries Harmonics Binary outputs Alarms Generator set

1.8 4.4 5.1.3 6.1.3

Parameters Regulation/Protection Status messages Regulator

4.5 5.1.4 6.1.4

* Not used. Regulation Function key Engine sensor

5.1.5 6.1.5

Custom view--Visualization

Auxiliaries

5.1.6 6.2

Custom view --Parameters

Base inputs/outputs

5.1.7 6.2.1

Main screen customview

Configurable binaryinputs

5.1.8 6.2.2

Time slots Resistive inputs

5.1.9 6.2.3

Advanced setpoints Analog inputs

5.1.10 6.2.4

Customer messages Analog outputs

5.2 6.3

Generator Extensioninputs/outputs

5.2.1 6.3.1

Starting CAN#1 inputs/outputs

5.2.2 6.4

Speed Regulation/Protection

5.2.3 6.4.1

Excitation General

5.2.4 6.4.2

Miscellaneous Regulation modules

5.2.5 6.5

Timers Communication

5.3 6.5.1

Regulation Ethernet

5.3.1 6.5.2

Regulation parameters Serial link

5.3.2

Speed regulation PID

5.3.3

Voltage regulation PID

5.3.4

Synchronization PID

Figure 2-57 Screen Architecture


Menu Access

Some menus are view-only and do not allowmodifications. Some menus require the operatorpassword to view and/or modify. See Figure 2-58 formenu access information.

1 -- Settings User Operator *

1.2 Power thresholds View Modify *

1.5 Timers (not used) View Modify *

1.6 Auxiliaries View Modify *

1.8 Parameters View Modify *

2 -- Measurements

2.2 Mechanical View View

2.3 Generator electrical View View

2.6 Harmonics View View

3 -- History

3.1 Archiving View Modify *

4 -- Diagnosis

4.1 Variables Modify Modify

4.2 Binary Inputs View View

4.3 Binary Outputs View View

4.4 Regulation / protection Modify *

4.5 Regulation Modify *

5 -- Configuration

5.1 Application

5.1.1 General View *

5.1.2 Alarms View *

5.1.3 Status Messages View *

5.1.4 Function Key View *

5.1.5 Custom view--Visualization View *

5.1.6 Custom view--Parameters View *

5.1.7 Main screen custom view View *

5.1.8 Time slots View *

5.1.9 Advanced setpoints View *

5.1.10 Customer messages View *

5.2 Generator

5.2.1 Starting View *

5.2.2 Speed View *

5.2.3 Excitation View *

5.2.4 Miscellaneous View *

5.2.5 Timers View *

5.3 Regulation

5.3.1 Regulation parameters View *

5.3.2 Speed regulation PID View *

5.3.3 Voltage regulation PID View *

5.3.4 Synchronization PID View *

5.4 Protection

5.4.1 Low level View *

5.4.4 Grid View *

6 -- Hardware

6.1 Installation


6.1.2 Generator View *

6.1.3 Regulator View *

6.1.4 Engine Sensor View *

6.1.5 Auxiliaries View *

6.2 Base inputs/outputs

6.2.1 Configurable binary inputs View *

6.2.2 Resistive inputs View *

6.2.3 Analog inputs View *

6.2.4 Analog outputs View *

6.3 Extension inputs/outputs

6.3.1 CAN inputs/outputs View *

6.4 Regulation/protection


6.4.2 Regulation modules View *

6.5 Communication

6.5.1 Ethernet [ Modify *[

6.5.2 Serial link Modify *

* Operator password (1966) is required to view and/or modifysettings.

[ Controller must be in Out of Service mode to modify thesesettings.

Figure 2-58 Menu Access


2.12.1 Menu 1--Settings

The 1--Settings menu can be accessed via the key withthe same name.

D 1.2 Power Thresholds

D 1.5 Timers (not used)

D 1.6 Auxiliaries

D 1.8 Parameters

Changing Settings

Pressing theModify button brings up text entry fields forsettings that can be changed. See Figure 2-59.

Pressing in the text entry field brings up thealphanumeric keypad shown in Figure 2-60.

1

#1. Modify button

Figure 2-59 Modify Button

1. All CAPS: All letters in upper case2. Shift: One letter in upper case3. Displays the numeric keypad

4. Returns to the alphabetical keypad

3

1

2

4

Figure 2-60 Keypad


Screen 1.2--Power thresholds

The1.2--Power thresholds screen is used to set up to 10active power thresholds. Threshold 9 is used for loadshed.

1. Threshold reached = green (in this example, thresholds #1 to #4 are reached or exceeded)2. Thresholds numbered from 1 to 103. Setting the threshold in % of the generator power4. Display of the threshold setting result in kW5. Entry field for text

1 2

3

4

5

Figure 2-61 Power Thresholds Screen


Screen 1.6--Auxiliaries

The 1.6--Auxiliaries screen is used to set the auxiliary parameters for the generator set fuel warning levels.

Figure 2-62 Auxiliaries screen

Title Description and possible settings (or selections)

Fuel pumps

Low fuel level fault (%) Low fuel level at which the fault is triggered, expressed as apercentage

Low fuel level warning (%) Low fuel level at which the alarm is triggered, expressed as apercentage

High fuel level warning (%) High fuel level at which the alarm is triggered, expressed asa percentage

High fuel level fault (%) High fuel level at which the fault is triggered, expressed as apercentage


Screen 1.8 Parameters

The 1.8--Parameters screen is used to set the engine speed (RPM). The speed can be adjusted by±10RPM.

Figure 2-63 Parameters Screen


2.12.2 Menu 2--Measurements

The 2--Measurements menu can be accessed via the button with the same name. This gives access to the screenslisted below.

D Screen 2.2 -- Mechanical

D Screen 2.3 -- Generator electrical

D Screen 2.6 -- Harmonics

Note: The measurements menus are view-only; no modifications are possible from these menus.

Screen 2.2--Mechanical

The 2.2--Mechanical screen gives an overview of all the mechanical values for the associated generator.

1. Separation of themechanical values into three categories

1

Figure 2-64 Mechanical Screen

Note: Other values may be displayed depending on the engine selected in the 6.1.2 generator set screen.


Screen 2.3--Generator electrical

The 2.3--Generator electrical screen gives a detailed view of all the electrical values for the associated generator (ongenerator HMI only).

1. Display for 3 phases2. Phase sequence indication : Green = Correct; Red = Inverse; Off = Not Activated3. Active and reactive energy metering

3

2

1

Figure 2-65 Generator Electrical Screen


Screen 2.6--Harmonics

The 2.6--Harmonics screen is used to monitor the change in harmonics in real time on the generator set.

2

1. Harmonics2. Line-to-neutral voltage3. Current

3

1

Figure 2-66 Harmonics Screen


2.12.3 Menu 3--History

The 3--History menu can be accessed via the key with the same name. It gives access to Screen 3.1 -- Archiving.

Screen 3.1--Archiving

The 3.1--Archiving screen is used to store certain parameters in the controller’s memory.

1

1. Press the Initialization button next to an item to reset the history to zero. (Operator login required)

Figure 2-67 Archiving Screen

List of archived parameters:

Energy Meters

D Active energy (in MWh)

D Reactive energy (in Mvarh)

Operating hours

D Total (in hours)

D In override mode (in hours)

Starter

D Number of starter attempts

If the Operator is logged in with their access code or ifthe User has entered the code 1966 (access limited totenminutes), then opposite each parameter, on the rightof the screen, an Initialization button appears. SeeFigure 2-67.

Eachbutton is used to reset the parameter concerned tozero or to initialize to a given value.


2.12.4 Menu 4--Diagnosis

The 4--Diagnosis menu can be accessed via the keywith the same name. it gives access to the 5 screensbelow:

4.1 -- Variables

4.2 -- Binary inputs

4.3 -- Binary outputs

4.4 -- Regulation & Protection

4.5 -- Regulation

The Diagnosis menu may be used for troubleshootingby factory service support personnel. Active faults andevents can be viewed using the alarm button or theEvent Log. See Section 2.10 for more information.

Screen 4.1--Variables

The 4.1--Variables screen is used to read all the systemvariables, regardless of whether these are logic oranalog variables.

When the screen is called up, no value is displayed. Thekeypad appears automatically at the bottom of thescreen and is used to enter the name of the variable orvariables to be consulted.

When the variable is a logic variable (values 0or 1), thenthe color red or green [0 (off)=red, 1 (on)=green] isassociated with the status of the variable.

See Figure 2-69 for variable identification.

1. Variable title2. Entry field for a variable name3. Virtual keypad4. Type of variable (see Figure 2-69)5. Color associated with the variable status. 0 = red; 1 = green6. Value or status of the variable

4

5

6

1

2

3

Figure 2-68 Variables Screen


Type Enter on screen keypad Enter on external keypad Complete write accessexamples

Logic input variable %I I I0.0.0

Analog input variable %I I I5.21

Internal variable (input oroutput)

%M M

M3.112

M1.0

M1.1

Logic output variable %Q Q Q0.0.0

Analog output variable %Q Q

Figure 2-69 Sample Variable Identification

Refer to the example in Figure 2-68 and the variables listed in Figure 2-70. Other variables and events are shown inSections 2.9.4 and 2.10.

Title Color Name State or value

%M3.112 Green Low engine coolant warning 1

%I5.21 Fuel level 4

%M1.0 Red Auto mode 0

%M1.1 Green Manual mode 1

%I0.0.0 Red Input #0 (base module) 0

%Q0.0.0 Red Output #0 (base module) 0

Figure 2-70 Sample Variables Shown in Figure 2-68


Screen 4.2--Binary inputs

The 4.2--Binary inputs screen is used to get a quick overview of the following logic states:

D Eighteen binary inputs for the base module

D Eight binary inputs for each remote module connected to the base module

1. Input number (DI A#10 to DI A#18 & DI B#19 to DI B#27)2. Input status indicators: Red = 0 (input inactive); Green = 1 (input active)3. Extension I/O module inputs appear here, if equipped

2

3

1

Red = Not Active (off)Green = Active (on)

Figure 2-71 Binary Inputs Screen


Screen 4.3--Binary outputs

The 4.3--Binary outputs screen is used to get a quick overview of the following logic states:

D Eighteen base module outputs

D Four outputs for each extension module connected to the base module

1. Output number (DO--#0 to DO--#8 &DO--#9 to DO--#16+ WDG *)2. Output status indicators: Red = 0 (output inactive); Green = 1 (output active)3. Number of the remote module (only appears if there is a single remote module)4. Selection of remote module n+15. Output status indicators for optional I/O modules: Red = 0 (output inactive); Green = 1 (output active)6. Selection of remote module n--17. Choice of CAN I/O bus (only appears if there is a single CAN bus )

* The output WDG (Watchdog) cannot be used.

6

2

7

3

4

1

Red = Not Active (off)Green = Active (on)

5

Figure 2-72 Binary Outputs Screen

Module #0 is reserved for the optional Manual KeySwitch/Load Shed Module. Outputs #0 through #3represent loads 1 through 4. When the output isdeactivated, the output indicator is red and the load is

connected. When an output is activated, the indicatorturns green and the load is shed. See Section 2.6 formore information about the load shed function.


Screen 4.4--Regulation & protection

The 4.4--Regulation and protection screen is used to read all the internal variables for the regulation and protectionmodules.

1. Entry field for a variable name2. Value or status of the variable3. Numeric keypad for entering the variable name

1

2

3

Figure 2-73 Regulation and Protection Screen

The process for entering a regulation or protection variable is the same as for the 4.1--Mapping screen.

By default, the diagnostic table for the regulation and protection variables is already completed with the name of thecurrent variables.


Screen 4.5--Regulation

The 4.5--Regulation screen is used to read all of the internal variables for the regulation modules.

1. Entry field for a variable name2. Value or status of the variable3. Regulation status

1

2

3

Figure 2-74 Regulation Screen

The virtual numeric keypad appears after the variable entry field has been pressed.


2.12.5 Menus 5 and 6

Except for menu 6.5, communication, menus 5 and 6 are view-only menus that can be seen when logged in as anoperator (1966). The view-only menus are not shown in this document.

2.12.6 Menu 6.5-CommunicationScreen 6.5.1- Ethernet

The 6.5.1-Ethernet screen defines the computer addresses for theEthernet connections for the basemodule and theHMI module.

Figure 2-75 Ethernet Screen

The screen is accessible for modification at the operator level, but only for the TCP/IP configuration section.

Group Title Description and Possible Settings

TCP/IPSettings

Addressing mode * Choice of address type for the TCP/IP connection: System, CustomerIP, or DHCP. w

DNS server IP address of the DNS server. The DNS server is used to make theconnection between an APM802 system and an IP address.

Fault Finding Base - Eth3/4 IP address * ] Permanent or temporary identification number for the base moduleconnected to another base or to a mains.

Base - Eth3/4 MAC address * ] Unique permanent physical identification number, which is stored inthe base module.

HMI - Eth1 IP address * [ Permanent or temporary identification number for the HMI moduleconnected to another base or to a mains.

HMI - Eth1 MAC address * [ Unique permanent physical identification number, which is stored inthe HMI module.

HMI - Eth2 IP address Not used.

* IP = Internet Protocol; MAC = Media Access Control.[ Eth1 = Ethernet port marked 1 at the rear of the HMI module] Eth3/4 = Ethernet ports marked 3 or 4 on the front of the base modulew DHCP: the DHCP protocol (Dynamic Host Configuration Protocol) allows an APM system to connect to a network, which dynamicallyassigns it an IP address

Figure 2-76 Ethernet Settings


Screen 6.5.2-Serial link

The 6.5.2-Serial link screen defines the specifications of the RS485 type serial link available on the base module.

Figure 2-77 Serial Link Screen

The screen is accessible for modification at the operator level. Figure 2-78 shows the range of possible settings andthe factory default settings, which are configured for communication with the RSA III remote serial annunciator.

Group Parameter Description and Possible Settings Factory Settings

Configuration Speed (baud rate) * Communication speed: 9600, 19200, 38400, or57600

19200

Stop bits 1 or 2 1

Parity Without, odd, or even Without

Modbus [ Activation (0/1 selector) Set to 1 to activate the slave Modbus function 1 (Modbus slave)

Slave number Choice of sub-system number (address) on theRS-485 serial network: from 1 to 255 (only appears ifthe activation selector is set to 1)

1 (must matchconnected gensetaddress on the RSA III)

* Baud rate= unit of measurement for the number of symbols transmitted per second[ Modbus is a communication protocol. It is formed of frames containing the address of the PLC in question, the function to be processed(read only, write access), the data, and the verification code called the cyclic redundancy check.

Figure 2-78 Serial Communication Settings


Notes

TP-7070 7/18 71Section 3 Scheduled Maintenance

Section 3 Scheduled Maintenance

3.1 Introduction

This section deals with general maintenance of thegenerator set andaccessories. This sectionmay refer toother literature for procedures and additionalinformation.

Refer to Appendix B, Operating Hour Service Log for ameans to document maintenance.

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



WARNING

Disabling the generator set. Accidental starting cancause severe injury or death. Before working on thegenerator set or equipment connected to the set, disable thegenerator set as follows: (1) Shut down the generator set. (2)Place the controller in Out of Service mode. (3) Press theemergency stop button. (4) Disconnect the power to thebattery charger, if equipped. (5) Remove the battery cables,negative (--) lead first. Reconnect the negative (--) lead lastwhen reconnecting the battery. Follow these precautions toprevent the starting of the generator set by the remotestart/stop switch.



WARNING

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



DANGER

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

TP-7070 7/1872 Section 3 Scheduled Maintenance



WARNING

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

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



WARNING




WARNING

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

Hot surfaces.

CAUTION

Servicing the alternator. Hot parts can cause severeinjury or death. Avoid touching the alternator field or exciterarmature. When shorted, the alternator field and exciterarmature become hot enough to cause severe burns.


WARNING

Servicing the fuel system. A flash fire can cause severeinjuryor death. Donot smokeor permit flames or sparks nearthe fuel injection system, fuel line, fuel filter, fuel pump, or otherpotential sources of spilled fuels or fuel vapors. Catch fuels inan approved container when removing the fuel line or fuelsystem.

Combustible materials. A fire can cause severe injury ordeath. If using generator heaters during storage, removecombustible materials such as covers from contact with theheater or from areas where heat could potentially cause a fire.




WARNING



WARNING

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

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

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

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


3.2 Service Schedule

Enginemaintenance intervalsandproceduresmayvaryfor different enginemodels, types, and applications. Fortasks marked with the symbol D in the service schedule,

refer to the Engine Operation Manual or contact anauthorized distributor/dealer. If the schedule is notincluded in the Engine Operation Manual, follow theservice schedule in Section 3.2. Some items in the listmay not apply to all generator sets.

Action

System—Component Visually Inspect Check Change Clean Test Interval

Fuel System

Day tank level X X Weekly

Prefilter(s) D 2 Years or 500 Hrs.

Main Filter(s) D 2 Years or 1000 Hrs.

Flexible lines and connections X R Weekly

Fuel level switch X X Weekly

Fuel piping X Yearly

Main tank supply level X Weekly

Tank vents and return lines for obstructions X Yearly

Water in system, remove D D Weekly

Lubrication System

Oil level D D Weekly

Oil analysis DSee Section 3.6 andthe Engine O/M

Change oil and oil filter elements D

Centrifugal oil filter D

Crankcase breather filter(s) D Quarterly

Crankcase breather belt (KD800--KD1000)and oil separator filter insert D 2 Years or 1000 Hrs.

Cooling System

Air cleaner to room/enclosure * X Weekly

Air ducts, louvers X X Yearly

Block heater operation X Weekly

Coolant level D D Weekly

Coolant temperature D 6 Months

Coolant analysis D See the Engine O/M

Coolant, replace D 4 Years or 6000 Hrs.

Fan belt(s) D D R Yearly or 500 Hrs.

Fan bearing lubrication (KD2000--KD3250) X 500 Hrs.

Flexible hoses and connectors X X Weekly

Louver motors and controls X X X Yearly

Radiator exterior X Yearly

Water pump(s) D Weekly

Water pump and alternator belts D D R 2 Years or 2000 Hrs.

Exhaust System

Drain condensate trap X Weekly

Excessive back pressure X Yearly

Flexible connector(s) X 6 Months

Hangers and supports X Yearly

Insulation, fire hazards X Quarterly

Leakage X X Weekly

APM802 Controller

Battery ] R Every 3 Years

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow thisservice schedule. Some items may not apply to all generator sets.

R Replace as necessary.X Action

* Service more frequently if operated in dusty areas.] Service must be performed by an authorized Kohler service representative.


Service Schedule, continuedAction

System—Component Visually Inspect Check Change Clean Test Interval

DC Electrical System

Battery charger operation, charge rate X Monthly

Battery electrolyte level (not necessary with AGMbatteries) X Monthly

Battery specific gravity, charge state (not necesary withAGM batteries) X Monthly

Clean and tighten battery terminals X X Quarterly

Recharge after engine start X Monthly

Remove corrosion, clean and dry battery and rack X X Monthly

Tighten DC electrical connections X 6 Months

AC Electrical System

General Inspection X Weekly

Circuit breakers, fuses[ X X R X X Monthly

Safety and alarm operation X X 6 Months

Tighten control and power wiring connections X Yearly

Transfer switch main contacts[ X X Yearly

Wire abrasions where subject to motion X X Quarterly

Wire-cable insulation breakdown X X 3 Years or 500 Hrs.

Engine and Mounting

General inspection D Weekly

Air cleaner service D D 2 Years or 3000 Hrs.

Bolt torque D D 3 Years or 500 Hrs.

Lines and hoses D R 4 Years or 2000 Hrs.

Injector pump, fuel lines, and injectors D D D 2000 Hrs.

Valve clearance D

See the Engine O/M.Viscous damper D

Turbocharger D D

Water pump 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

Bearing condition ] ] ] ] Yearly

Exciter ] ] ] ] Yearly

Rotor and stator ] ] ] Yearly

Voltage regulator ] ] ] ] Yearly

Measure and record resistance readings of windingswith insulation tester (Meggerr, with SCR assembly orrectifier disconnected) ]

] Yearly

Blow dust out of alternator*] ] ] 2 Years

General Condition of Equipment

Any condition of vibration, leakage, unusual noise,excessive temperature, damage, or deterioration X X X Weekly

Ensure that system is set for automatic operation X Weekly

Interior of equipment room or outdoor weather housing X X Weekly

D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow thisservice 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.] Alternator service must be performed by an authorized Kohler service representative.

Meggerr is a registered trademark of Biddle Instruments.


3.3 APM802 ControllerMaintenance

The APM802 controller uses two BR2032 internalbatteries in the controller base module and HMI topreserve the time, date, and generator set events. Ifbattery power is low, an alarm,M3.212 APM INTERNALBATTERY WARNING, appears on the controller. Havean authorized Kohler service representative service thecontroller.

3.4 Engine Maintenance

Regular engine maintenance is essential. Performengine maintenance at the intervals specified in theengine operation and maintenance manuals. Contactan authorized service distributor/dealer to obtain engineliterature. Refer to the engine operation manual for thefollowing:

D Engine operation

D Enginemaintenance schedules (can vary dependingon engine application)

D Engine maintenance procedures

D Fuel, lubricant, and coolant specifications

3.5 Diesel Fuel Systems



WARNING

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

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


3.5.1 Fuel/Water Separator

Fuel/water separators (fuel prefilters) ensure clean fuelis delivered to the engine by removing contaminantsand water. Providing clean fuel prevents cloggedinjectors and allows the engine to runmore efficiently. Ina fuel/water separator, water collects in the lower cavityof the filter.

Periodically, the water must be checked and drainedand the filter must be changed. A sensor on thefuel/water separator indicates when the collected waterneeds to be drained. Refer to the engine operationmanual for scheduled maintenance and procedures.

Draining the water

To drain the water from the fuel/water separator, use thefollowing procedure:

1. Read and follow the safety precautions inSection 3.1.

2. Before working on the generator set or connectedequipment, remove the generator set from service.Refer to the safety precautions for preventingaccidental starts and disabling the generator set.

a. Remove the load from the generator set.

b. Shut down the generator set.

c. Place the generator set controller intoOut-of-Service mode and press theemergency stop button.

d. Disconnect the power to the battery charger.

e. Remove the battery cables negative (--) leadfirst to disable the generator set.

3. Hold a suitable container beneath the fuel/waterseparator.

4. Open the vent plug and the manually operateddrain.

5. See Figure 3-1. Close the drain when fuel (free ofwater) flows from the fuel/water separator.

6. Use themanual primer pump to prime the filter untilfuel flows from the vent plug.

7. Close the vent plug.

Note: If the fuel/water separator will not stay primed,check that the vent plug, drain, filter element,water collection bowl, and fuel lines are securelytightenedandverify that fuel flow isunobstructed.

1. Fuel outlet hose2. Manual primer pump3. Vent plug (optional restriction

gauge installs here)4. Fuel inlet hose5. Filter element6. Water collection bowl7. Water-in-fuel sensor8. Manually operated drain 10501000200

7

5

32

8

6

14

Figure 3-1 Fuel/Water Separator

Replacing the filter element

At the interval specified in the service schedule, replacethe fuel/water separator element. Have a suitablecontainer with the required capacity ready.








3. Make sure engine is off and cool to the touch.

4. If a fuel shut-off valve is present, close the fuelshut-off valve at the nearest point to the fuel/waterseparator inlet or at the fuel tank.

5. Disconnect the fuel-in-water sensor.

6. Open the vent plug on the mounting head. SeeFigure 3-1.


7. Remove the water drain plug (or push up the drainvalve) and allow water and fuel to flow into asuitable container.

Note: Depending upon the location of the fuelvalve, a considerable amount of fuel maydrain out.

8. Remove the separator’s element from themounting head by twisting in a counterclockwisedirection.

9. Remove the bowl from the fuel/water separatorelement. Wipe the excess fuel from the bowl andthe O--ring. Do not discard the bowl or O--ring.

10. Inspect the components for wear or damage.Replace parts as necessary.

11. Lubricate the O--ring with clean diesel fuel andreplace it in the bowl.

12. Install the bowl onto a new fuel/water separatorfilter element.

13. Lubricate the bowl/element assembly with cleanfuel. Install the bowl/element onto the filtermounting head.

14. Replace the water drain plug (if removed).

15. Connect the fuel-in-water sensor.

16. Open the fuel shut-off valve.

17. Use themanual primer pump to prime the filter untilfuel flows from the vent plug.

18. Close the vent plug.

Note: If the fuel/water separator will not stay primed,check that the vent plug, drain, filter element,water collection bowl, and fuel lines are securelytightenedandverify that fuel flow isunobstructed.

3.5.2 Manual Primer Pump

The manual primer pump, located on the fuel/waterseparator, allows the operator to pump fuel through thefuel system without cranking the engine. Prime the fuelsystem under the following conditions:

D Before starting the engine for the first time

D After running out of fuel and adding fuel to the tank

D After fuel systemmaintenance such as changing thefuel filter, draining the fuel/water separator, orreplacing a fuel system component

The manual primer pump is actuated by pressing downon the primer pump.

1. Manual primer pump2. Vent plug

10501000200

1

2

Figure 3-2 Manual Primer Pump

To bleed air from the fuel system, see Section 3.5.3.


3.5.3 Bleeding Air from Fuel System

Trapped air in the fuel system causes difficult startingand/or erratic engine operation. The fuel system usesan automatic bleed line which allows fuel and air to flowback to the tank. To bleed the fuel line, crank the engineand allow the fuel to circulate through the system forapproximately 5 minutes. After an initial rough start, thefuel line should be bled.

3.5.4 Restriction Gauge (if equipped)

The fuel/water restrictiongaugemounts to the fuelwaterseparator head in the vent plug port. This gauge helpsdetermine the filter element change interval for thefuel/water separator and allows visual monitoring of thefilter condition.

The restriction gauge monitors fuel flow andcontinuously displays restriction readings indicated asvacuum. Increased restriction indicates a cloggedfuel/water separator element.

As the filter getsdirty, a yellowplungermoves toward thered service area on the indicator. To reset the indicator,simply press the button on the top. See Figure 3-3.

1

2

1. Reset button2. Restriction gauge

Figure 3-3 Restriction gauge

To install the restriction gauge, use the followinginstructions.

1. Read and follow the safety precautions at thebeginning of the section.

2. Before working on the generator set or connectedequipment, remove the generator set from service.

Refer to the safety precautions for preventingaccidental starts and disabling the generator set.






3. If a fuel shut-off valve is present, close the fuelshut-off valve at the nearest point to the fuel/waterseparator inlet or at the fuel tank.

4. Coat the the threads and O-ring with motor oilbefore installation.

Note: Do not use thread tapes. Loose particlescould work their way into the fuel system.

5. Thread the restriction gauge into the vent plug porton the fuel/water separator. See Figure 3-4. Use a16 mm wrench to install or remove the restrictiongauge (do not tighten by hand).

6. Open the fuel shut-off valve when the installation iscomplete.

1. Manual primer pump2. Vent plug

10501000200

1

2

Figure 3-4 Vent Plug Port


3.6 Lubrication System

3.6.1 Oil Change

The engine oil change interval varies for differentengines, applications, and oil type. Identify the followingfor your application and then refer to the EngineOperation and Maintenance Manual for oil changeintervals and oil specifications.

D Engine model. See the engine nameplate or thegenerator set specification sheet to identify theengine.

D Engine oil type (category 1, 2, 3). See the engineOperation Manual for definitions.

D Generator set engine type (fuel-optimized oremission-optimized). Generator set models with a -Fin the model designation are fuel-optimized.

D Generator set application (standby, prime, orcontinuous).

Note: Change both the oil filters and centrifugal oil filter(if applicable) during the oil change.

3.6.2 Automatic Oil ReplenishmentSystem (Optional Kit)

1. Shutoff valve2. Regulator supply line

(inlet port)3. Shutoff valve4. Oil level regulator

5. Sight glass6. Bracket7. Vent line8. Oil pan9. Engine supply line

10404000145-KA

8

67

9

5

1

3

2

4

Figure 3-5 Automatic Oil Replenishment System

The oil replenishment system typically works with an oilreservoir to maintain a constant oil level in the enginecrankcase. As the oil level in the crankcase drops, thevalve inside the oil level regulator opens to supply freshoil from the oil reservoir.

Note: Thepressure-equalizing vent line between the oilregulator and the engine prevents positive ornegative crankcase pressure.

Adjusting the oil level regulator position

The oil level regulator can be adjusted by changing thepositioning of the regulator on the mounting bracket.Use the following procedure:

Note: If the oil level regulator runs continuously, lowerthe oil level regulator position approximately10 mm (3/8 in.) on the bracket to prevent theexcess use of oil.

1. Start the engine and allow the oil level to stabilize.

2. Check the oil level on the dipstick. If the oil level islow, adjust the regulator higher on the bracket toallow more oil into the crankcase. If the oil level isabove the full line on the regulator, drain theexcessoil out of the crankcase and move the regulatordown on the bracket.

3. Repeat until desired running oil level is achieved.


3.6.3 Oil Analysis

The engine oil analysis interval varies for differentengines, applications, and oil types. Refer to the EngineOperation and Maintenance Manual for oil analysisintervals.

Follow the procedures and recommendations in thissection to ensure that samples provide a goodrepresentation of the engine oil condition. Always usethe same procedure for oil sampling to allow reliablecomparisons.

In extreme conditions, perform the oil analysis morefrequently. For example:

D In extreme climates

D When the generator set is subject to repeated starts

D When theengine is running for a long timeon low load

D If there is high sulphur content in the fuel (from 0.5 to1.5% by weight)

Some signs that the oil is no longer carrying out itsfunction may include:

D Unusually large deposits or precipitations on theinside of the engine and its components such asfilters, centrifuges or separators, in particular whencompared with the previous analysis

D Unusual discoloration of components

As a precaution, also send a bottle containing a new oilsample which will serve as a reference point for theanalysis of the used oil.

Sampling Point

Sampling is carried out at a representative point in thesystem, preferably just after the machine is shut down.

D Always sample at the designated sampling point(s).See the engine Operation Manual for therecommended sampling point.

D Failing this, sample via the dipstickwell with a syringeand flexible hose.

D As a last resort, sample directly from the sump drainpoint after draining the dirty fluid at the bottom of thesump.

Preparation of Sampling Point

In order to avoid contaminating the sample:

D Carefully clean the sampling point and the samplingequipment before each sample is taken and beforeopening the system.

D If possible, avoid environmental disturbances whentaking the sample (wind, dust, rain,...).

The laboratory-supplied bottle should be filled to 3/4 full.In the absence of a laboratory-supplied bottle, makesure there is a minimum amount of 125 ml (4.3 oz.).

Use an appropriately labeled and cleaned bottle. Someimportant points to note during sampling are:

D Oil brand and type

D Sampling date

D Equipment type and serial number

D Operating hours since commissioning (startup)

D Operating hours since oil change

D Sampling type: during draining or during a sampling

D If oil was added (topped up) since the last oil change,indicate how many liters (quarts) were added.

D Interventions carried out


Sampling Methods

Method 1: Sampling with a Syringe


2. Connect a flexible hose to the syringe.

3. Insert the other end of the hose into the dipstickwell, taking care not to reach the bottom of thesump.

4. Draw the oil into the syringe until it is completelyfilled..

5. Once the syringe is full, remove the hose, emptythe syringe into the bottle and seal it as soon aspossible.

6. If necessary, repeat the operation until the bottle is3/4 full.

7. Close the bottle by tightly screwing the cap andcheck the information on the label.

Method 2: Sampling at the Drainage Point

This method can be used by adapting the periodicdraining of the oil sump.


2. Place a basin under the drain point.

3. Open the drain point.

4. Allow a little oil to flow out before collecting thesample.

5. Fill the bottle tightly to 3/4 full.


7. Close the drain point.

8. Top up the engine oil if necessary.

Recommended Tests

The recommended tests for the analysis are shown inFigure 3-6 and Figure 3-7.

Spectrometric Analysis (wear) Units

Iron (Fe) DIN 51399-1:2012-5 mg/kg

Chromium (Cr) DIN 51399-1:2012-5 mg/kg

Tin (Sn) DIN 51399-1:2012-5 mg/kg

Aluminum (Al) DIN 51399-1:2012-5 mg/kg

Nickel (Ni) DIN 51399-1:2012-5 mg/kg

Copper (Cu) DIN 51399-1:2012-5 mg/kg

Lead (Pb) DIN 51399-1:2012-5 mg/kg

Molybdenum (Mo) DIN 51399-1:2012-5 mg/kg

PQ Index

Impurities

Silicon (Si) DIN 51399-1:2012-5 mg/kg

Potassium (K) DIN 51399-1:2012-5 mg/kg

Sodium (Na) DIN 51399-1:2012-5 mg/kg

Water DIN 51,451 %

Glycol DIN 51375-1 %

Vegetable oil DIN 51639-4:2010-02 %

Diesel fuel DIN 51375-1 %

Biodiesel DIN 51375-1 %

Soot DIN 51452 %

Figure 3-6 Oil Spectrometric Analysis

Physical parameters Units

Viscosity at 40_C DIN 51562 mm2/s

Viscosity at 100_C DIN 51562 mm2/s

Viscosity Index (VI) calc.

Oxidation DIN 51451, DIN 51453 A/cm

Nitration DIN 51451, DIN 51453 A/cm

Salvation DIN 51451, DIN 51453 A/cm

Dirt moving capability %

TBN (total base number) DIN ISO 3771 mgKOH/g

TAN (total acid number) DIN EN 12634-1999-02 mgKOH/g

pH

Additives

Calcium (Ca) DIN 51399-1:2012-5 mg/kg

Magnesium (Mg) DIN 51399-1:2012-5 mg/kg

Boron (B) DIN 51399-1:2012-5 mg/kg

Zinc (Zn) DIN 51399-1:2012-5 mg/kg

Phosphorous (P) DIN 51399-1:2012-5 mg/kg

Barium (Ba) DIN 51399-1:2012-5 mg/kg

Molybdenum (Mo) DIN 51399-1:2012-5 mg/kg

Sulphur (S) DIN 51399-1:2012-5 mg/kg

Figure 3-7 Oil Physical Parameters


3.7 Air Cleaner SystemThe air cleaner requires periodic maintenance. See themaintenance schedule. A dusty environment orconditions may require the use of a heavy duty air filterand/or more frequent maintenance.

3.7.1 Air Filter Element

Follow this procedure to replace the air filter element forstandard-duty and heavy-duty air filters.








3. For standard-duty filters:

a. Loosen the filter clamp and remove the filterelement from the air intake elbow.

b. Replace the filter and tighten the filter clamp.

1. Filter element2. Clamp3. Air intake elbow

1

2

3

Figure 3-8 Standard Air Filter

4. For heavy-duty filters:

a. Release the cover clips (KD2000--KD2500) orremove the wingnut (KD2800--KD3250) andremove the cover. See Figure 3-9.

b. Remove the filter element.

c. Clean the internal components with a dampcloth.

d. Install the new element.

e. Replace the cover. For modelsKD2000--KD2500, point the dust ejector on thecover downward. See Figure 3-9.

1. Filter element2. Cover3. Dust ejector

1

2

3

Figure 3-9 Heavy-Duty Air Filter(KD2000--KD2500 shown)

3.7.2 Air Cleaner Restrictor Indicator (ifequipped)

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

The air cleaner restriction gauge monitors air flow andcontinuously displays restriction readings indicated asvacuum (see Figure 3-10). Increased restrictionindicates a clogged air cleaner element.

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

273113

1015192225

1

23

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

Figure 3-10 Restriction Indicators (styles vary)


3.8 Cooling SystemKD series generator sets in the range of 800--2500 kWuse two-slab radiators with a multi--core constructionand expansion tanks. The multi-core constructionallows the isolation of cooling circuits and improves theserviceability of the product.

KD series generator sets in the range of 2800 kW andabove use a two-slab, single core radiator construction.

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

Note: Blockheaterdamage.Theblockheaterwill fail ifthe energized heater element is not immersed incoolant. Fill the cooling system before turning onthe block heater. Run the engine until it is warm,and refill the radiator to purge the air from thesystem before energizing the block heater.

3.8.1 Coolant System Safety



WARNING

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



DANGER




WARNING



3.8.2 Coolant Level Check

Check the coolant level in the coolant expansion tank.Maintain the coolant level between the high and lowmarks on the radiator sight glass.

3.8.3 Cooling System ComponentInspection

To prevent generator set shutdown or damage causedby overheating:

D Keep the cooling air inlets clean and unobstructed.

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

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

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

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

3.8.4 Procedure to Drain CoolingSystem

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

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

1. Read and follow the safety precautions inSections 3.1 and 3.8.1.

2. Allow the engine to cool.

3. Deenergize the block heater, if equipped.

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

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

Note: The drain valve(s) are typically locatedalong the bottom of the skid. SeeFigure 3-11.ModelsKD2000--KD3250havetwo drains, one for each coolant circuit, onthe skid plus a drain valve for each coolanttube. See Figure 3-12.

1. Radiator drain valve (typical)

1

Figure 3-11 Radiator Drain Valve, TypicalKD800--KD1750


1. Drain valve for high and low temperature cooling circuits2. Drain valve for hoses

1

2

Figure 3-12 Radiator Drain Valves, KD2000--KD3250

6. On models KD2000--KD3250, use the enginedrainage ports to drain coolant from the hightemperature and low temperature water pumpsand the oil cooler. See Figure 3-13.

1. Water pump port, low temperature2. Oil cooler port3. Water pump port, high temperature

1

3

2

Figure 3-13 Engine Drainage Ports,KD2000--KD2500 Shown

7. If the inside of the radiator has mineral deposits orthe used coolant contains dirt or grease, refer toSection 3.8.5, Procedure to Flush and Clean theCooling System. If the cooling system does nothave mineral deposits, go to Section 3.8.6,Procedure to Refill the Cooling System.

3.8.5 Procedure to Flush and CleanCooling System

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

1. Flush the cooling system with clean water.

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

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


3.8.6 Procedure to Refill CoolingSystem

See the generator set spec sheet for coolant capacity.

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

1. Remove the pressure cap.

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

3. Fill the cooling system with the recommendedcoolant/antifreeze mixture based on the enginemanufacturer’s recommendation.

4. Fill the coolant expansion tank to the middle of thesight glass.

5. For models KD2000--KD3250, use the manualengine venting ports to bleed trapped air from thesystem. Refer to the engine operation manual forthe venting locations on the water pumps,thermostat housing, and engine block. SeeFigure 3-14.

Note: Toopen theventingports, thread theventingtool into the port.

1. Manual engine venting ports, typical

1

Figure 3-14 Engine Coolant Venting or Bleeding,KD2000--KD3250

6. Leave the radiator cap off and run for 5 minuteswith no load.

7. Stop the engine and allow it to cool.

8. Check and repair any coolant leaks.

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

10. Replace the pressure cap.

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

12. Maintain the coolant level in the coolant expansiontank between the high and low marks.

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

13. Reenergize the block heater, if equipped.


3.8.7 Coolant Analysis

The coolant analysis interval varies for differentengines, applications, and oil types. Refer to the EngineOperationandMaintenanceManual for coolantanalysisintervals.

Follow the procedures and recommendations in thissection to ensure that samples provide a goodrepresentation of the coolant condition. Always use thesame procedure for coolant sampling to allow reliablecomparisons.

Regular analysis of the coolant will allow you to preventengine problems well before they present themselves,improve equipment performance, and reduce costlyrepairs.

The test can detect:

D Cavitation corrosion

D Chemical distribution

D Leakage of combustion gases

D Contamination

D Electrical earthing (grounding) problems

In extreme conditions, perform the analysis morefrequently. For example:

D In extreme climates

D When the generator set is subject to repeated starts

D When the engine often runs for a long time on lowload

Some signs that the coolant is no longer carrying out itsfunction may include:

D Engine overheating

D Color alteration

D Deposits present

Sampling Point

Sampling is carried out at a representative point in thesystem, preferably just after the machine is shut down.

D On KD2000--KD3250 models, take the samplethrough the engine venting/bleeding ports, or throughthe coolant hose drain ports.

D If there are no other accessible coolant venting/bleeding ports or drain valves, then take the samplethrough the radiator coolant drain valve after drainingthe dirty fluid at the bottom of the radiator.

Preparation of Sampling Point

In order to avoid contaminating the sample:

D The sampling point and the sampling equipmentmust be meticulously cleaned before each sample istaken and before opening the system.

D If possible, avoid environmental disturbances whentaking the sample (wind, dust, rain,...).

The laboratory supplied bottle should be filled to 3/4 full.In the absence of a laboratory supplied bottle, makesure there is a minimum amount of 250 ml (8.5 oz.).

Use an appropriately labelled and cleaned bottle. Someimportant points to note during sampling are:

D Brand and type

D Date of sampling

D Type of equipment and serial number

D Operating hours since commissioning

D Operating hours since last draining

D Type of Sampling: during draining or during asampling

D Any coolant top ups. If this is the case, indicate howmany liters (quarts) were added.

D Interventions carried out.

The recommended tests for the coolant analysis are asfollows:

D pH

D Spectrometric analysis (Phosphorus, Zinc, Calcium,etc.)

D Additives

D Percentage of coolant/water

D Physicochemical analysis (reservealkalinity, density,etc.)

D Conductivity.


Sampling Method

1. Read and follow the safety precautions inSections 3.1 and 3.8.1.

2. Place a basin under the drain point.

3. Turn thecapon theexpansion tank to the first notchto release the pressure, then remove it completely.

4. Open the drain point.

5. Allow about one liter (1 qt.) of liquid to flow outbefore collecting the sample

6. Collect about 1 liter (1 qt.) of liquid.


8. Close the drain point.

9. Top up the engine coolant if necessary.

10. Put the expansion tank cap in place and close.

3.8.8 Radiator Maintenance

Use the following list for radiator maintenance:

D Periodically check for leakage from the core or tankconnections.

D Inspect the liquid level at regular intervals using thetop tank sight glass.

D Test antifreeze before cold weather periods.

D If the unit is on stand-by for long periods of time,check the interior of the top tank through the fill neckfor signs of scale or rust every one to three months. Ifnecessary, the radiator should be cleaned, flushed,and treated.

D Dirt and debris can be removed from the core facewith compressed air, steam, or water, if required. Ifwater is used, slowly increase the pressure and standat least 0.9 m (3 feet) away from the core. Keep thewater stream parallel with the fins in order to avoiddamaging them.

Note: Ensure that fins and tubes are not damaged fromrough brushing or excessive jet pressure of thesteam, air, or water.

D Clean fanbladesonceper year.Useastiff brushor anair nozzle for loose dirt and a nonflammable solventwith brush for solid deposits. Care must be taken notto damage the fan blades as a resultingout-of--balance condition might cause vibration anddamage to fan bearings or motor bearings.


3.8.9 Radiator Fan Bearing Lubrication(KD2000--KD3250)

Note: The following content on fan bearing lubricationdoes not apply to models KD800--KD1750.

The system should be checked periodically (dependingon usage) to prevent equipment damage or failure.

d Check and maintain correct tension of fan belts.d Check for frame imbalance, bearing wear, or loosedrive components.

d Check and maintain alignment of sheaves byadjusting their location on fan shaft and idler shaft.

Lubricate the bearings through the remote greasefittings every 500 hours.

Use lithium grease with EP additive, conforming toNLGI 2 consistency, suitable for --28_C to +121_C(--20_F to +250_F). Re-lubrication should bediscontinued when clean grease has purged throughthe seal, regardless of the quantity added. Approximatequantities are listed in Figure 3-15.

Shaft Size Amount -- ml (Oz.)

1--1/8 in. to 1--1/4 in. 3.0 (.10)

1--3/8 in. to 1--7/16 in. 6.5 (.22)

1--1/2 in. to 1--11/16 in. 9.5 (.32)

1--3/4 in. to 2 in. 14.8 (.50)

2 in. to 2--3/16 in. 16.3 (.55)

2--1/4 in. to 2--1/2 in. 19.2 (.65)

2--11/16 in. to 3 in. 25.1 (.85)

3--3/16 in. to 3--1/2 in. 37.0 (1.25)

3--15/16 in. to 4 in. 74.0 (2.50)

4--7/16 in. to 4--1/2 in. 91.7 (3.10)

4--15/16 in. to 5 in. 140.5 (4.75)

Figure 3-15 Grease Quantity







e. Remove the battery cables, negative (--) leadfirst, to disable the generator set.

3. To grease the bearings, inject grease at theremotely located grease fittings located on theleft-hand side of the radiator. See Figure 3-16.Grease slowly to prevent over-greasing thebearings.

4. Remove any excess grease.

5. Reconnect the generator set engine startingbattery(ies), negative (--) lead last and return thegenerator set to service.

103010011011

1. Grease fittings

Figure 3-16 Fan Bearings Grease Fittings


3.8.10 Notched V-Belt Adjustment(KD2000--KD3250)

For models KD2000--KD3250, use the followingprocedure to adjust the tension on the six notchedV-belts which turn the fan pulley.

Note: The following content on fan bearing adjustmentdoes not apply to models KD800--KD1750. Onmodels KD800--KD1000, the fan belt tension isself-tensioning and maintenance-free. OnModels KD1250--KD1750, the tensioner islocated on the engine. Refer to the engineoperation manual to adjust the tension.








3. Remove the fan guard rear face panel. Inspect thefan drive belt and replace if it is damaged or worn.See Figure 3-17.

103010011011

1. Rear face panel

Figure 3-17 Fan Guard

4. Check the fan belt tension and adjust, if necessary.Set the tension by using either a sonic tensionmeter or by setting the belt deflection. SeeFigure 3-19.

Note: For either method, measure only a singlebelt. Do not overlap multiple belts in themeasurement.

a. To adjust the tension with an sonic tensionmeter, use the following procedure:

(1) Check the tension at the front and rear beltof the fan pulley to understand alignmentcharacteristics. See Figure 3-18. Use asonic tension meter and compare thereading to the frequency setting inFigure 3-19.

(2) If a large deviation exists between the twobelts, then the pulleys may be misaligned.

1

1. Tension measurement location2. Access panel

2

Figure 3-18 Tension Measurement Location


b. To check the fan belt tension using beltdeflection, use the following procedure:

(1) Measure the belt span (center line of pulley#1 to center line of pulley #2).

(2) Use the measurement to determine themiddle of the belt.

(3) Press on the V--Belt at themiddle point andmeasure the deflection from its originalposition.

(4) For the maximum deflection, refer toFigure 3-19.

Engine to Fan Sheave (Driver to Driver)

KD2000 to KD2500

Frequency (Hz) Deflection

New Belt 78.4--81.2 81--86 N @ 9 mm(18--19 lbs @ 0.4 in.)

UsedBelt

72.6--75.6 70--75 N @ 9 mm(16--17 lbs. @ 0.4 in.)

KD2800 to KD3250

Frequency (Hz) Deflection

New Belt 62.7--64.9 89--95 N @ 12 mm(20--21 lbs @ 0.5 in.)

UsedBelt

58.1–60.5 77--83 N @ 12 mm(17--19 lbs. @ 0.5 in.)

Note: Tension chart is only applicable for modelsKD2000--KD3250.

Figure 3-19 Belt Tension and Deflection

5. Before making adjustments to the tension, loosenthe four 3/4” undercarriage bolts. Then, adjust thetensioner pulley along the tensioner slots via thelead screw. See Figure 3-20.

1. Fan pulley2. 3/4” undercarriage bolt locations3. Lead screw4. Tensioner pulley5. Engine pulley

10301001101

2

3

1

4

5

Figure 3-20 Tension Adjustment, KD2000--KD3250

6. Make the necessary adjustments until belt tensionfalls into the range listed in Figure 3-19.

7. Check the pulley alignment on the fan shaft forangularity.

8. Adjust the fan sheaves and tensioner sheaves toeliminate or reduce the pulley angularity.

9. Tighten the 3/4” undercarriage bolts.

10. Reinstall the belt guards using the originalhardware.

11. Reconnect the generator set engine startingbattery(ies), negative (--) lead last and return thegenerator set to service.

12. Test run the generator set for a few minutes andlisten for belt noise (squeal) indicating a slippingbelt. Stop the generator set.

If the belt slips after thebelt tensionprocedure, clean thepulley surfaces and repeat the belt tension procedure. Ifslippage continues, replace the fan belt.


3.9 Battery SystemsRefer to this section for general battery information andmaintenance. All generator set models use a negativeground with a 24-volt engine electrical system. Consultthe generator set nameplate for the engine electricalsystemvoltage.Consult the generator set spec sheet forbattery capacity recommendations for replacementpurposes. The wiring diagrams provide batteryconnection information. See Figure 3-21 for typicalbattery connections, including multiple batteryconfigurations.

4321

1 2 3 4

KW-272000-B

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

Figure 3-21 24-Volt Electrical System, Dual StarterMotors, Typical Battery Connections

3.9.1 Battery Safety



WARNING



WARNING

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

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

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


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

3.9.2 Absorbed Glass Mat (AGM)Battery

Absorbed Glass Mat (AGM) type batteries do notrequire electrolyte level inspection or specific gravitycheck.

AGM batteries use the same general maintenanceinstructions for battery cleaning and charging as shownin Sections 3.9.3 and 3.9.4. For specific maintenanceinstructions, refer to the battery manufacturer’sinstructions.

Note: Ensure that thebattery charger is compatiblewithAGM type batteries before charging.

3.9.3 Clean Battery

Clean the battery and cables and tighten the batteryterminals according to the service schedulerecommendations. Clean the battery by wiping it with a

damp cloth. Keep the electrical connections dry andtight.

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

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

3.9.4 Charge Battery

Useabattery charger tomaintain a fully charged batterywhen the generator set is used in a standby application.The engine battery-charging alternator charges thebattery while the generator set is running. Refer to thebattery charger operation manual for installation,operation, and service procedures.

Note: If the battery is an AGM type, ensure that thebattery charger is compatible with AGM typebatteries before charging.

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


3.10 Alternator Maintenance

This section covers alternator maintenance for severaldifferent types of alternators and voltage regulators.Refer to the instructions that correspond to the relevantalternator models.

D Refer to the generator set specification sheet foralternator models.

D Have an authorized distributor/dealer performservice.

3.10.1 Alternator Safety



WARNING


Testing live electrical circuits. Hazardous voltage orcurrent will cause severe injury or death. Have trained andqualified personnel take diagnostic measurements of livecircuits. Use adequately rated test equipment with electricallyinsulated probes and follow the instructions of the testequipment manufacturer when performing voltage tests.Observe the following precautions when performing voltagetests: (1) Remove all jewelry. (2) Stand on a dry, approvedelectrically insulated mat. (3) Do not touch the enclosure orcomponents inside the enclosure. (4) Be prepared for thesystem to operate automatically.(600 volts and under)

Grounding electrical equipment. Hazardous voltage willcause severe injury or death. Electrocution is possiblewhenever electricity is present. Ensure you comply with allapplicable codes and standards. Electrically ground thegenerator set and related equipment and electrical circuits.Turn off the main circuit breakers of all power sources beforeservicing the equipment. Never contact electrical leads orappliances when standing in water or on wet ground becausethese conditions increase the risk of electrocution.

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

Hot surfaces.

CAUTION

Servicing the alternator. Hot parts can cause severeinjury or death. Avoid touching the alternator field or exciterarmature. When shorted, the alternator field and exciterarmature become hot enough to cause severe burns.



DANGER



3.10.2 Checking the Installation

1. Check the operation at regular intervals (noabnormal noise or vibration).

2. Check the tightness of all nuts and bolts. Payparticular attention to the electrical connections.

3.10.3 Checking the Ventilation Circuit








3. Ensure that air flow is not reduced by partialblocking of the air inlet and discharge grids bymud,fiber, grease, etc.

4. Check for corrosion or abrasion on the air outletgrids .

5. If your system is equipped with filters:

a. Remove the grid and remove the filter.

b. Clean the filter with low pressure compressedair or replace if it is clogged. See Figure 3-22.

1. Air inlet2. Filter3. Support

1

3

2

Figure 3-22 Ventilation of alternator

3.10.4 Checking the Bearings

Have an authorized distributor/dealer perform service.

3.10.5 Checking the Windings

Have an authorized distributor/dealer perform service.

3.10.6 Voltage Regulator

To make adjustments to the voltage regulator settings,contact an authorized Kohler distributor. Have anauthorized distributor/dealer perform service.

Note: For models that use the DER2 voltage regulator,the potentiometers (VOLT, STAB, Hz, AMP.) aredisabled.


3.11 Storage Procedure

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

3.11.1 Storage Safety



WARNING




WARNING




DANGER



WARNING




WARNING


3.11.2 Controller

If the generator set is stored in a location where thetemperature drops below --20_C (--4_F), connect powerto the controller heater.

3.11.3 Lubricating System

Prepare the engine lubricating system for storage asfollows:

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

2. Stop the generator set.

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

4. Remove and replace the oil filter.

5. Refill the crankcase with oil suited to the climate.

6. Run the generator set for two minutes to distributethe clean oil.

7. Stop the generator set.

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

3.11.4 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using acoolant tester.

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

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

3.11.5 Diesel Fuel System

Prepare the fuel system for storage as follows:

1. Fill the fuel tank.

2. Condition the fuel system with compatibleadditives to control microbial growth.

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

3.11.6 Exterior

1. Clean the exterior surface of the generator set.

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

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

4. Mask electrical connections.

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


3.11.7 Alternator Storage


WARNING


Humidity, moisture, and dust can damage the alternatorduring storage. Store the generator set in a clean, dryarea and protect the alternator from inclement weather.Keep room temperatures relatively constant to preventcondensation on the windings. Cover ventilation andother entry points to prevent damage by rodents, birds,and insects.

For medium voltage generator sets (larger than 600volts), store the units with the generator heateroperational and check periodically throughout thestorage period to confirm operation. To eliminate theformation of condensation in the alternator winding,maintain an AC alternator temperature above theambient dew point.

Before returning the alternator to service, have anauthorized service distributor/dealer, perform thefollowing alternator service:

D Clean the ventilation circuit.

D Blow dust off the windings.

D Check the rotor and stator winding insulation.

D Check the rotor and stator winding resistance andcontinuity.

D On units with regreasable bearings, grease thebearings and rotate the shaft to distribute grease onthe bearings.

3.11.8 Battery



WARNING

Perform battery storage after all other storageprocedures.

1. Confirm that the generator set is stopped.

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

3. Clean the battery. Refer to Section 3.9.3 for thebattery cleaning procedure.

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

5. Connect thebattery toabattery chargeror charge itmonthly with a trickle battery charger. Refer to thebattery chargermanufacturer’s recommendations.

Maintain a full charge to extend battery life.

Note: If the battery is an absorbed glass mat(AGM) type, ensure that the battery chargeris compatible with AGM type batteriesbefore charging.


Notes

TP-7070 7/18 101Section 4 Troubleshooting

Section 4 Troubleshooting

4.1 Introduction

This section contains generator set, controller, generalengine, and customer connection paneltroubleshooting, diagnostic, and repair information.This section may refer to other literature for proceduresand additional information. See the list of relatedmaterials in the Introduction on page 11 of this manualfor literature part numbers. The information in thissection is a guideline for generator set operatingtechnicians and/or maintenance personnel.

Corrective action and testing often require knowledgeofelectrical and electronic circuits. To avoid additionalproblems caused by incorrect repairs, have anauthorized service distributor/dealer perform service.

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

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

4.2 Generator Set and Controller

Refer to the following charts for generator set andcontroller troubleshooting. Some of the correctiveactions may reference the alternator and/or controllerservice manual for additional troubleshootinginformation.

4.3 Engine

Refer to the following charts for general enginetroubleshooting. Refer to the engine operation manualand/or engine service manual for all specific enginetroubleshooting.

4.4 Transfer Switch

Some applications may use an automatic transferswitch. Some of the following charts may referencetransfer switch components and/or literature. Refer tothe respective transfer switch manuals as needed.

TP-7070 7/18102 Section 4 Troubleshooting

4.5

GeneralTroubleshootingChart

TroubleSym

ptoms

ProbableCauses

Recommended

Actions

Sectionor

Publication

Reference*

Doesnotcrank

Cranksbutdoesnotstart

Startshard

Noorlowoutputvoltage

Stopssuddenly

Lackspower

Overheats

Lowoilpressure

Highfuelconsumption

Excessiveorabnormalnoise

Displayserrormessage/locksup

Exerciseruntimeand/oreventrecordsinoperative

ControllerandEmergency

StopSwitch

xx

Controllercircuitboard(s)inoperative

Replace

thecontroller’s

base

module,ifnecessary.

Cont.S/M

xx

Controllercircuitboard(s)wiring

fault

Check

thewiring.

W/D

xControllerfault

Troubleshootthecontroller.[

Cont.S/M

xx

xControllerfuse

blow

nCheck

forbatterypowertothecontrollerandreplacethe

fuse.Ifreplacingthefuse

doesn’tfixtheproblem,

troubleshootthecontrollerwiring.[

W/D

xControllerHMIinoperative

Replace

thecontrollerHMIm

odule,ifnecessary.

Cont.S/M

xControllerintheOUTOFSERVICE

mode

Changetheoperatingmodeon

thecontroller.

Section2

xEnginestartcircuitopen

Starttheengine

with

thecontrollerinMANUALmodetotest

thegeneratorset.

Troubleshoottheengine

startcircuitand

timedelays.

Section2,W/D,

Gen.I/M,S

/MATSO/M,S

/M

xx

Emergencystop

switchactivated

Resettheem

ergencystop

switch.

Check

remoteem

ergencystop

switch,ifequipped.

Section2

xx

Voltage

regulationinoperative

Replace

thejunctionboxsensingfuses.

Ifthefuse

blow

sagain,troubleshootthecontroller.

W/D,A

lt.O/S/M

*Sec./S

ection—

numberedsectionofthismanual;Alt.—Alternator;ATS—Autom

aticTransferSwitch;Eng.—

Engine;Cont.—

Controller;Gen.—

GeneratorSet;I/M—InstallationManual;

O/M—OperationManual;S/M—Service

Manual;S/S—SpecSheet;W

/D—Wiring

Diagram

Manual

[Havean

authorized

servicedistributor/dealerperformthisservice.

TP-7070

7/18


Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses




Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

Alternator

xACoutputcircuitbreakeropen

ResetthebreakerandcheckforACvoltage

atthegenerator

setsideofthecircuitbreaker.

—

xTransfersw

itchtestsw

itchintheOFF

position

Movethetransfersw

itchtestsw

itchtotheAUTOposition.

ATSO/M

xTransfersw

itchfails

totransferload

MovetheATStestsw

itchtotheAUTOposition.

Troubleshootthetransfercircuitand

timedelays.

ATSO/M,S

/M

xWiring,terminals,orpinintheexciter

fieldopen

Check

forcontinuity.

Alt.O/S/M

W/D

xMainfield(rotor)inoperative

(openorgrounded)

Testand/orreplacetherotor.[

Alt.O/S/M

xStatorinoperative(openorgrounded)

Testand/orreplacethestator.[

Alt.O/S/M

xVibrationexcessive

Tightenloosecomponents.[

—

xx

Voltage

regulatorsettingsincorrect

Adjustthe

voltage

regulator.[

—

ElectricalS

ystem(DCCircuits)

xx

Batteryconnections

loose,corroded,

orincorrect

Verify

thatthebatteryconnections

arecorrect,clean,and

tight.

Section3

xx

Batteryweakordead

Rechargeorreplacethebattery.The

spec

sheetprovides

recommendedbatteryCCArating.

Section3,S/S

xx

Starter/startersolenoidinoperative

Replace

thestarterorstartersolenoid.

Eng.S

/M

xx

Engineharnessconnector(s)not

locked

tight

Disconnectthe

engine

harnessconnector(s)then

reconnect

ittothecontroller.

W/D

xFaultshutdown

Identifyandcorrectthe

faultcondition,then

resetthe

faulton

thecontroller.

Section2.10

*Sec./S

ection—



Engine;Cont.—

Controller;Gen.—




/D—Wiring

Diagram

Manual

[Havean

authorized


TP-7070 7/18104 Section 4 Troubleshooting

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses




Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

Engine x

xx

xAircleanerclogged

Clean

orreplacethefilterelem

ent.

Section3.7

xx

xx

xCom

pression

weak

Check

thecompression.[

Eng.S

/M

xx

xx

xEngineoverload

Reducetheelectricalload.See

thegeneratorsetspec

sheetforwattage

specifications.

S/S

xExhaustsystem

leak

Inspectthe

exhaustsystem.Replace

damaged

ordeterioratedexhaustsystemcomponents.[

I/M

xExhaustsystem

notsecurelyinstalled

Inspectthe

exhaustsystem.Tightenthelooseexhaust

system

components.[

I/M

xx

xx

Faultinengine’selectronicsystem

Check

faultrecords

inengine

ECU.[

Eng.O

/M,

KODIA

O/M

xx

Valve

clearanceincorrect

Adjustthe

valves.[

Eng.O

/M

xVibrationexcessive

Tightenallloose

hardware.

—

xx

xx

xEngineECUand/orsensors

Troubleshoottheengine

ECUand/orsensors.

Eng.S

/M

CoolingSystem

xx

Airopenings

clogged

Clean

theairopenings.

—

xCoolantlevellow

Restorethecoolanttonormaloperatinglevel.

Eng.O

/M

xCoolingwaterpumpinoperative

Tightenorreplacethebelt(KD800--KD1000).Replace

the

waterpump.

Eng.O

/MorS/M

xHightemperatureshutdown

Allowtheengine

tocooldown.

Thentroubleshootthe

coolingsystem

.Sec.3.8,

Eng.O

/M

xLowcoolantlevelshutdown,if

equipped

Restorethecoolanttonormaloperatinglevel.

Eng.O

/M

xThermostatinoperative

Replace

thethermostat.

Eng.S

/M

*Sec./S

ection—



Engine;Cont.—

Controller;Gen.—




/D—Wiring

Diagram

Manual

[Havean

authorized


TP-7070

7/18


Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses

TroubleSym

ptoms

Sectionor

Publication

Reference*

Recommended

Actions

ProbableCauses




Highfuelconsumption

Lowoilpressure

Overheats

Lackspower

Stopssuddenly


Startshard


Doesnotcrank

FuelSystem

xx

Fueltankem

ptyorfuelvalveshutoff

Add

fuelandmovethefuelvalvetotheONposition.

—

xx

xAirinfuelsystem

Bleed

thedieselfuelsystem

.Sec.3.5.3

xx

xx

Fuelfilterrestriction

Clean

orreplacethefuelfilter.

Eng.O

/M

xx

xFuelorfuelinjectorsdirtyorfaulty

Clean,test,and/orreplacetheinoperativefuelinjector.[

Eng.S

/M

xx

xx

Fuelinjectiontim

ingoutofadjustment

Adjustthe

fuelinjectiontim

ing.[

Eng.S

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TP-7070 7/18106

Notes

TP-7070 7/18 107Section 5 Accessories

Section 5 Accessories

5.1 Accessories and Connections

Factory-installed accessories are available to helpfinalize installation, add convenience to operation andservice, andestablishstateand local codecompliance.

See Figure 5-1 for a list of available kits. Obtain themost current accessory information from your localauthorized service distributor/dealer.

Kit Description

Analog Input/Output Module

Digital Input/Output Module

Thermocouple Input Module

Remote Serial Annunciator

Figure 5-1 Optional Accessories

This section illustrates several accessories available atprint time of this publication. Accessory kits generallyinclude installation instructions. See wiring diagramsmanual for electrical connections not shown in thissection. See the installation instructions and drawingssuppliedwith kit for information on kitmounting location.

The instructions provided with the accessory kitsupersede these instructions where there aredifferences. In general, run AC and DC wiring inseparate conduit. Use shielded cable for all analoginputs. Observeall applicable national, state, and localelectrical codes during accessory installation.

See Section 5.2, Accessory Connections, and thegenerator set wiring diagrams for terminal identification.

5.2 Accessory Connections

Connect external optional accessories includingalarms, battery chargers, thermocouples, and remoteswitches to the terminal block or modules in thecustomer connection box. See Figure 5-2. Do notattempt to connect directly to the APM802 controller orbase module.

For specific informationonaccessoryconnections, referto the accessory wiring diagrams in the wiring diagrammanual and the instruction sheet accompanying the kit.See the generator set wiring diagram for TB10connections.

Note: Covers have been removed for illustration.

1. USB port (under hinged panel)2. 240 VAC/60 Hz power supply connection3. Terminal block TB10 for accessory connections4. Optional module locations

3

2

1

116010009454

Figure 5-2 APM802 Controller and CustomerConnection Box

TP-7070 7/18108 Section 5 Accessories

5.3 Input and Output Modules

The following factory-installedmodules are available asoptional accessories.

D Analog Input/Output Module

D Digital I/O Module

D Thermocouple Input Module

The modules are factory-installed in the customerconnection box. Module power and CAN Buscommunications with the controller are factoryconnected. The communication speed and moduleCAN addresses are factory set. Do not change thespeed or CAN address DIP switch settings.

The modules are equipped with two diagnostic LEDsthat can be used for troubleshooting. See Figure 5-5.

5.3.1 Analog Input/Output Module

The Analog Input/Output (I/O) Module provides twooutput connections and four input connections. SeeFigure 5-3 for I/O specifications and Figure 5-4 forconnections.

The factory default input and output settings areundefined. I/O settings can be loaded by an authorizedservice technician. Contact your Kohler distributor withyour requirements for inputs and outputs.

Input/Output Specifications Connection

Input0 -- 20 mAmps

Impedance 100 ohms 0.75 to 1.5 mm2

Output0 -- 20 mAmps100 -- 600 ohms 0.75 to 1.5 mm2

Figure 5-3 Analog Input/Output Specifications

1

2

3

31613391201/301/401

1. Factory connections or settings2. Analog output connections 0 and 13. Analog input connections 0 -- 3

Figure 5-4 Analog Input/Output Module

LED Description LED Operation

1 Power LED Green: The module is correctly powered.

Off: Module is not powered.

2 Can bus 1 Communication LED Flashing green: CAN communication is consistent.

Steady green: No CAN communication.

Off: No CAN communication.

Figure 5-5 Module Diagnostic LEDs


5.3.2 Digital Input/Output Module

TheDigital Input/OutputModuleprovides8digital inputsand 4 digital (relay) outputs. See Figure 5-6 for contactspecifications and Figure 5-7 for input and outputconnections.

The Module #0 position is reserved for the optionalManual Key Switch/Load Shed module.

Factory input settings are undefined. Outputs arefactory-set to the default settings shown in Figure 5-8.Different I/O settings for the optional I/O module can beloaded by an authorized service technician. Contactyour Kohler distributor with your requirements for digitalinputs and outputs.

Input/Output Contacts Connection

Input contactsNormally open (NO).Activates on ground

connection.0.75 to 1.5 mm2

Output contacts240 VAC/8 A30VDC/8A48VDC/0.5 A

0.75 to 1.5 mm2

Figure 5-6 Digital Input/Output ContactSpecifications

1

2

3

31613391201/301/401

1. Factory connections or settings2. Digital input connections 0 --73. Digital (relay) output connections 0 -- 3

Figure 5-7 Digital Input/Output Module

Digital Inputs/Outputs

Factory Settings

Module 0(Key Switch /Load

Shed Only) Module 1

Input DI0 Keyswitch AUTO Undefined

Input DI1 Keyswitch Manual Undefined

Input DI2 Keyswitch OFF Undefined

Input DI3 Start/Stop Button Undefined

Input DI4 Reserved Undefined




Output DO0 Load 1 Undefined




Figure 5-8 Digital I/O Module Default Settings


5.3.3 Thermocouple Input Module

Up to three thermocouples can be connected to theThermocouple Module. Type K or PT100thermocouples can be connected. See Figure 5-9 forthermocouple specifications. See Figure 5-11 andFigure 5-12 for connections.

Medium voltage (larger than 600 volts) units areequipped with two thermocouple modules with thesettings shown in Figure 5-10.

Temperaturedatacanbeviewedusing theCustomViewbutton on the controller. See Section 2.7.5. If nothermocouple modules are installed, all temperatureswill display 32_F (0_C). If nothing is connected to achannel on a thermocouple module, --58_F (--50_C) isdisplayed.

ThermocoupleType

TemperatureRange Connection

PT1000 -- 200_C(32 -- 392_F) 0.75 to 1.5 mm2

K Thermocouple--20 -- 1000_C(--4 --1832_F) 0.75 to 1.5 mm2

Figure 5-9 Thermocouple Types and Connections

Thermocouple Module 1 Thermocouple Module 2

Phase A Temp Front Bearing Temp

Phase B Temp Rear Bearing Temp

Phase C Temp User PT100 Temp

Figure 5-10 Thermocouple Module Default Settingsfor Medium Voltage Generators

1

2

31613391201/301/401

1. Factory connections or settings2. Thermocouple connections 0 -- 2, Type K or PT100

Figure 5-11 Thermocouple Module

24V

1

2

3

4

2

3

+

+

+

+

--

--

--

--

24VDC Power Supply(9 -- 40 VDC)

31613391201

0 -- 20 mA

PT100

K

2XGround

Shielding Connection

Note: Cable shieldsmust be grounded as shown.

Figure 5-12 Connections


5.4 Remote Serial Annunciator

RSA III is an annunciator panel offered in several kitconfigurations to support Kohler power equipment. TheRSA III is a remote serial annunciator (Figure 5-13,Figure 5-14, and Figure 5-15) that monitors thecondition of the generator set and/or ATS from a remotelocation. The RSA III alerts the operator through visualandaudible signals using LED indication and ahorn. Analarm silence and lamp test switch are included.

The RSA III meets NFPA 110, Level 1 (2005)applications that require remote controls and alarms bepowered by a storage battery such as the enginestarting battery. AC adaptor kit GM62466-KP1 isavailable when NFPA is not required.

The front panel decals include areas that can be used toidentify user-selected fault inputs and identifyassociated power system equipment.

An RSA III annunciator can be used for a singlegenerator set or with a combination of a generator setand automatic transfer switch. In systems using morethan a single RSA III, one must be designated as themaster device to broadcast to additional RSA IIIannunciators, designated as slave devices. Up to fiveRSA III slave devices can be used with an RSA IIImaster device. All RSA III annunciators are factory setas the master device, but can be changed to a slavedevice using a PC and SiteTecht software thatconnects to the RSA III front panel via a universal serialbus (USB) connection.

Connect the RSA III to the RS-485 connections onTB-10. See Section 1.3 and refer to the generator setwiring diagram for connections. The communicationsettings on the APM802 controller are factory-set forcommunication with the RSA III. See Section 2.12.6,Screen 6.5.2 Serial Link.

Refer to TT-1625 Remote Serial Annunciator (RSA III)Kits for operation and installation instructions.

A PC with SiteTecht software is required to makethe RSA III functional. Use your SecurID to accessKOHLERnet, click on the TechTools button, and followthe instructions to download the files. See TT-1625 andrefer toTP-6701SiteTechtSoftwareOperationManualfor more information.

The RSA III kits include components for surfacemounting or flush mounting.

If the RSA III is used with an Ethernet communicationnetwork, order Modbusr Ethernet converterGM41143-KP2 and refer to TT-1405 Converters,Connections, and Controller Setup for NetworkCommunication for system installation.

Figure 5-13 Remote Serial Annunciator (RSA III)

Figure 5-14 RSA III with Single ATS Control

Figure 5-15 RSA III with Four ATS Controls

Figure 5-16 shows the status of the system ready LED,generator set running LED, communication status LED,common fault LED, common fault output, and horn foreach fault or status condition.

If a fault occurs, the RSA III horn activates and thecorresponding LED illuminates.

Modbusr is a registered trademark of Schneider Electric.


Fault and Status ConditionFaultLED

System Monitoring LEDs and Functions

SystemReady LED

GeneratorRunning LED

CommunicationsStatus LED

CommonFault LED

CommonFaultOutput Horn

Overcrank (Shutdown) Red SF Red SF Off Green Red SF On On

High Engine Temperature (Warning) Yellow SF Red SF Green Green Red SF On On

High Engine Temperature (Shutdown) Red SF Red SF Off Green Red SF On On

Low Oil Pressure (Warning) Yellow SF Red SF Green Green Red SF On On

Low Oil Pressure (Shutdown) Red SF Red SF Off Green Red SF On On

Overspeed (Shutdown) Red SF Red SF Off Green Red SF On On

Emergency Stop Red SF Red SF Off Green Off On On

Low Coolant Level/Aux (Shutdown) Red SF Red SF Off Green Red SF On On

Low Coolant Temperature Yellow SF Red SF Green or Off Green Red SF On On

Low Fuel Yellow SF Red SF Green or Off Green Red SF On On

Low Cranking Voltage Yellow SF Red SF Off Green Red SF On On

Battery Charger Fail Yellow SF Green Green or Off Green Off On On

Battery Voltage (Hi) Yellow SF Green Green or Off Green Off On On

Battery Voltage (Lo) Yellow SF Green Green or Off Green Off Off Off

Common Fault (Warning) Yellow SF Green Green or Off Green Red SF On Off

Common Fault (Shutdown) Red SF Green Green or Off Green Red SF On On

User Input #1 (Warning) Yellow SF Green Green or Off Green Off Off Off

User Input #1 (Shutdown) Red FF Green Green or Off Green Off On On









ATS Position N (RSA III with ATS only) Green Green Green or Off Green Off Off Off

ATS Position E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off

ATS Available N (RSA III with ATS only) Green Green Green or Off Green Off Off Off

ATS Available E (RSA III with ATS only) Red Red SF Green or Off Green Off Off Off

ATS Fault (RSA III with ATS only) Yellow SF ??? Green or Off Green Off Off On

ATS Fault (RSA III with ATS only) Red FF Red SF Green or Off Green Off Off On

EPS Supplying Load Green Green Green or Off Green Off Off Off

Not-In-Auto Red FF Red SF Off Green Red SF On On

Communication Status (Loss - Master) Red FF Off Off Red FF Off On On

Communication Status (Loss - Slave) Red SF Off Off Red SF Off On On

Note: SF = Slow Flash (1 second intervals), FF = Fast Flash (200 millisecond intervals)

Figure 5-16 System Monitoring LEDs and Functions

TP-7070 7/18 Appendix 113

Appendix A Abbreviations

The following list contains abbreviations that may appear in this publication.

A, amp ampereABDC after bottom dead centerAC alternating currentA/D analog to digitalADC advanced digital control;

analog to digital converteradj. adjust, adjustmentADV advertising dimensional

drawingAGM absorbed glass mat (battery)Ah amp-hourAHWT anticipatory high water

temperatureAISI American Iron and Steel

InstituteALOP anticipatory low oil pressurealt. alternatorAl aluminumANSI American National Standards

Institute (formerly AmericanStandards Association, ASA)

AO anticipatory onlyAPDC Air Pollution Control DistrictAPI American Petroleum Instituteapprox. approximate, approximatelyAPU Auxiliary Power UnitAQMD Air Quality Management DistrictAR as required, as requestedAS as supplied, as stated, as

suggestedASE American Society of EngineersASME American Society of

Mechanical Engineersassy. assemblyASTM American Society for Testing

MaterialsATDC after top dead centerATS automatic transfer switchauto. automaticaux. auxiliaryavg. averageAVR automatic voltage regulatorAWG American Wire GaugeAWM appliance wiring materialbat. batteryBBDC before bottom dead centerBC battery charger, battery

chargingBCA battery charging alternatorBCI Battery Council InternationalBDC before dead centerBHP brake horsepowerblk. black (paint color), block

(engine)blk. htr. block heaterBMEP brake mean effective pressurebps bits per secondbr. brassBTDC before top dead centerBtu British thermal unitBtu/min. British thermal units per minuteC Celsius, centigradecal. calorieCAN controller area networkCARB California Air Resources BoardCAT5 Category 5 (network cable)CB circuit breakerCC crank cyclecc cubic centimeterCCA cold cranking ampsccw. counterclockwiseCEC Canadian Electrical Codecert. certificate, certification, certified

cfh cubic feet per hourcfm cubic feet per minuteCG center of gravityCID cubic inch displacementCL centerlinecm centimeterCMOS complementary metal oxide

substrate (semiconductor)com communications (port)coml commercialComl/Rec Commercial/Recreationalconn. connectioncont. continuedCPVC chlorinated polyvinyl chloridecrit. criticalCSA Canadian Standards

AssociationCT current transformerCu coppercUL Canadian Underwriter’s

LaboratoriesCUL Canadian Underwriter’s

Laboratoriescu. in. cubic inchcw. clockwiseCWC city water-cooledcyl. cylinderD/A digital to analogDAC digital to analog converterdB decibeldB(A) decibel (A weighted)DC direct currentDCR direct current resistanceDEF diesel exhaust fluiddeg., degreedept. departmentdia. diameterDI/EO dual inlet/end outletDIN Deutsches Institut fur Normung

e. V. (also Deutsche IndustrieNormenausschuss)

DIP dual inline packageDPDT double-pole, double-throwDPST double-pole, single-throwDS disconnect switchDVR digital voltage regulatorE2PROM, EEPROM

electrically-erasableprogrammable read-onlymemory

E, emer. emergency (power source)ECM electronic control module,

engine control moduleECU electronic control unit,

engine control unitEDI electronic data interchangeEFR emergency frequency relaye.g. for example (exempli gratia)EG electronic governorEGSA Electrical Generating Systems

AssociationEIA Electronic Industries

AssociationEI/EO end inlet/end outletEMI electromagnetic interferenceemiss. emissioneng. engineEPA Environmental Protection

AgencyEPS emergency power systemER emergency relayES engineering special,

engineered special

ESD electrostatic dischargeest. estimatedE-Stop emergency stopetc. et cetera (and so forth)exh. exhaustext. externalF Fahrenheit, femaleFHM flat head machine (screw)fl. oz. fluid ounceflex. flexiblefreq. frequencyFS full scaleft. foot, feetft. lb. foot pounds (torque)ft./min. feet per minuteftp file transfer protocolg gramga. gauge (meters, wire size)gal. gallongen. generatorgenset generator setGFI ground fault interrupter

GND, groundgov. governorgph gallons per hourgpm gallons per minutegr. grade, grossGRD equipment groundgr. wt. gross weightH x W x D height by width by depthHC hex capHCHT high cylinder head temperatureHD heavy dutyHET high exhaust temp., high

engine temp.hex hexagonHg mercury (element)HH hex headHHC hex head capHP horsepowerhr. hourHS heat shrinkhsg. housingHVAC heating, ventilation, and air

conditioningHWT high water temperatureHz hertz (cycles per second)IBC International Building CodeIC integrated circuitID inside diameter, identificationIEC International Electrotechnical

CommissionIEEE Institute of Electrical and

Electronics EngineersIMS improved motor startingin. inchin. H2O inches of waterin. Hg inches of mercuryin. lb. inch poundsInc. incorporatedind. industrialint. internalint./ext. internal/externalI/O input/outputIP internet protocolISO International Organization for

StandardizationJ jouleJIS Japanese Industry Standardk kilo (1000)K kelvin

TP-7070 7/18114 Appendix

kA kiloampereKB kilobyte (210 bytes)KBus Kohler communication protocolkg kilogramkg/cm2 kilograms per square

centimeterkgm kilogram-meterkg/m3 kilograms per cubic meterkHz kilohertzkJ kilojoulekm kilometerkOhm, k kilo-ohmkPa kilopascalkph kilometers per hourkV kilovoltkVA kilovolt amperekVAR kilovolt ampere reactivekW kilowattkWh kilowatt-hourkWm kilowatt mechanicalkWth kilowatt-thermalL literLAN local area networkL x W x H length by width by heightlb. pound, poundslbm/ft3 pounds mass per cubic feetLCB line circuit breakerLCD liquid crystal displayLED light emitting diodeLph liters per hourLpm liters per minuteLOP low oil pressureLP liquefied petroleumLPG liquefied petroleum gasLS left sideLwa sound power level, A weightedLWL low water levelLWT low water temperaturem meter, milli (1/1000)M mega (106 when used with SI

units), malem3 cubic meterm3/hr. cubic meters per hourm3/min. cubic meters per minutemA milliampereman. manualmax. maximumMB megabyte (220 bytes)MCCB molded-case circuit breakerMCM one thousand circular milsmeggar megohmmeterMHz megahertzmi. milemil one one-thousandth of an inchmin. minimum, minutemisc. miscellaneousMJ megajoulemJ millijoulemm millimetermOhm, mmilliohmMOhm, MmegohmMOV metal oxide varistorMPa megapascalmpg miles per gallonmph miles per hourMS military standardms millisecondm/sec. meters per secondmtg. mountingMTU Motoren-und Turbinen-UnionMW megawattmW milliwattF microfaradN, norm. normal (power source)

NA not available, not applicablenat. gas natural gasNBS National Bureau of StandardsNC normally closedNEC National Electrical CodeNEMA National Electrical

Manufacturers AssociationNFPA National Fire Protection

AssociationNm newton meterNO normally openno., nos. number, numbersNPS National Pipe, StraightNPSC National Pipe, Straight-couplingNPT National Standard taper pipe

thread per general useNPTF National Pipe, Taper-FineNR not required, normal relayns nanosecondOC overcrankOD outside diameterOEM original equipment

manufacturerOF overfrequencyopt. option, optionalOS oversize, overspeedOSHA Occupational Safety and Health

AdministrationOV overvoltageoz. ouncep., pp. page, pagesPC personal computerPCB printed circuit boardpF picofaradPF power factorph., phasePHC Phillipsr head Crimptiter

(screw)PHH Phillipsr hex head (screw)PHM pan head machine (screw)PLC programmable logic controlPMG permanent magnet generatorpot potentiometer, potentialppm parts per millionPROM programmable read-only

memorypsi pounds per square inchpsig pounds per square inch gaugept. pintPTC positive temperature coefficientPTO power takeoffPVC polyvinyl chlorideqt. quart, quartsqty. quantityR replacement (emergency)

power sourcerad. radiator, radiusRAM random access memoryRDO relay driver outputref. referencerem. remoteRes/Coml Residential/CommercialRFI radio frequency interferenceRH round headRHM round head machine (screw)rly. relayrms root mean squarernd. roundRO read onlyROM read only memoryrot. rotate, rotatingrpm revolutions per minuteRS right sideRTDs Resistance Temperature

Detectors

RTU remote terminal unitRTV room temperature vulcanizationRW read/writeSAE Society of Automotive

Engineersscfm standard cubic feet per minuteSCR silicon controlled rectifier,

selective catalytic reductions, sec. secondSI Systeme international d’unites,

International System of UnitsSI/EO side in/end outsil. silencerSMTP simple mail transfer protocolSN serial numberSNMP simple network management

protocolSPDT single-pole, double-throwSPST single-pole, single-throwspec specificationspecs specification(s)sq. squaresq. cm square centimetersq. in. square inchSMS short message serviceSS stainless steelstd. standardstl. steeltach. tachometerTB terminal blockTCP transmission control protocolTD time delayTDC top dead centerTDEC time delay engine cooldownTDEN time delay emergency to

normalTDES time delay engine startTDNE time delay normal to

emergencyTDOE time delay off to emergencyTDON time delay off to normaltemp. temperatureterm. terminalTHD total harmonic distortionTIF telephone influence factortol. toleranceturbo. turbochargertyp. typical (same in multiple

locations)UF underfrequencyUHF ultrahigh frequencyUIF user interfaceUL Underwriter’s Laboratories, Inc.UNC unified coarse thread (was NC)UNF unified fine thread (was NF)univ. universalURL uniform resource locator

(web address)US undersize, underspeedUV ultraviolet, undervoltageV voltVAC volts alternating currentVAR voltampere reactiveVDC volts direct currentVFD vacuum fluorescent displayVGA video graphics adapterVHF very high frequencyW wattWCR withstand and closing ratingw/ withWO write onlyw/o withoutwt. weightxfmr transformer

TP-7070 7/18 Appendix 115

Appendix B Operating Hour Service Log

Use the log below to keep a cumulative record ofoperating hours on your generator set and the dates

required services were performed. Enter hours to thenearest quarter hour.

Operating Hours Service Record

DateRun

HoursRun

TotalHours

ServiceDate Service

TP-7070 7/18116 Appendix

Operating Hours Service Record

DateRun

HoursRun

TotalHours

ServiceDate Service

TP-7070 7/18 117

Notes

TP-7070 7/18118

Notes

TP-7070 7/18 119

E 2017, 2018 by Kohler Co. All rights reserved.

TP-7070 7/18dKOHLER CO., Kohler, Wisconsin 53044Phone 920-457-4441, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KOHLERPower.com

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