Kohler 20-3250 kW User Manual

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Page 1

Operation

Industrial Generator Sets

Models:

20-3250 kW

Controllers:

Decision-Makerr 550

Software (Code) Version 2.10 or higher

TP-6200 10/12i

Page 2

California Proposition 65

WARNING

Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

Generator Set Identification Numbers

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

Model Designation

Specification Number

Serial Number

Accessory Number Accessory Description

Controller Identification

Record the controller description from the generator set operation manual, spec sheet, or sales invoice. Record the Controller Serial Number from the controller nameplate.

Controller Description

Controller Serial Number

Decision-Makerr 550

Firmware/Software Version Numbers

Record the version and reference numbers as shipped from the manufacturer. Determine the Application Program Version Number as shown in Menu 20. Determine the Personality Profile Reference Number from the disk supplied with the literature packet.

Application Program Version Number

Personality Profile Reference Number

User Parameter File Reference Number

Version Number Upgrades/Updates

Record the version number upgrade/updates when installed.

Engine Identification

Record the product identification information from the engine nameplate.

Manufacturer

Model Designation

Serial Number

Version No./Date Installed

Software Options

Record the software options.

Number and Description

Page 3

Table of Contents

Product Identification Information 2............................................................

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

Introduction 13...............................................................................

Abbreviations 13..............................................................

List of Related Materials 13.....................................................

Service Assistance 14........................................................................

Section 1 Specifications and Features 15......................................................

1.1 Introduction 15..........................................................

1.2 Controller Features 15....................................................

1.2.1 Annunciator Lamps 16............................................

1.2.2 Digital Display and Keypad 18.....................................

1.2.3 Switches and Controls 20.........................................

1.2.4 Controller Circuit Boards 21.......................................

1.2.5 Fuses 21.......................................................

1.2.6 Terminal Strips and Connectors 21.................................

1.2.7 Circuit Board Interconnections for Calibration Procedure 22............

1.2.8 Communication Ports 23..........................................

1.3 Controller Logic Specifications 23..........................................

1.3.1 Status Event and Fault Specifications 23............................

1.3.2 Voltage Regulator and Calibration Specifications 30..................

1.3.3 Voltage Regulator Adjustments 30..................................

Section 2 Operation 33.......................................................................

2.1 Prestart Checklist 33.....................................................

2.2 Exercising Generator Set 33...............................................

2.3 Controller Operation 33...................................................

2.3.1 Starting 33......................................................

2.3.2 Stopping (User Stopping and Fault Shutdown) 35....................

2.3.3 Emergency Stop Switch Resetting 35...............................

2.3.4 Status Lamps 35.................................................

2.3.5 System Warning Lamp 35.........................................

2.3.6 System Shutdown Lamp 38.......................................

2.3.7 Controller Resetting (Following System Shutdown or Warning) 41......

2.4 Menu List Summary 41...................................................

2.5 Reviewing Digital Display 47..............................................

2.5.1 Keypad Operation 47.............................................

2.5.2 Auto-Scroll Function 48...........................................

2.5.3 Request and Error Messages 48...................................

2.6 Monitoring and Programming Setup 49......................................

2.6.1 PC Communications 50...........................................

2.6.2 Modbus Communications 51.......................................

2.7 Reviewing Menu Displays 52..............................................

2.7.1 Menu 1—Generator Monitoring 53..................................

2.7.2 Menu 2—Engine Monitoring 55....................................

2.7.3 Menu 3—Analog Monitoring 57....................................

2.7.4 Menu 4—Operational Records 58..................................

2.7.5 Menu 5—Event History 59.........................................

2.7.6 Menu 6—Time and Date 59.......................................

2.7.7 Menu 7—Generator System 59....................................

2.7.8 Menu 8—Time Delays 61

2.7.9 Menu 9—Input Setup 62..........................................

2.7.10 Menu 10—Output Setup 64........................................

2.7.11 Menu 11—Voltage Regulator 66....................................

2.7.12 Menu 12—Calibration 67..........................................

.........................................

TP-6200 10/12 Table of Contents 3

Page 4

Table of Contents, continued

2.7.13 Menu 13—Communications 68....................................

2.7.14 Menu 14—Programming Mode 69..................................

2.7.15 Menu 15—Protective Relays (PR) 70...............................

2.7.16 Menu 20—Factory Setup (Version 2.10) 71..........................

2.7.17 Menu 20—Factory Setup (Version 2.21) 72..........................

2.8 Local Programming Mode On 74...........................................

2.8.1 Menu 1—Generator Monitoring 75..................................

2.8.2 Menu 2—Engine Monitoring 79....................................

2.8.3 Menu 3—Analog Monitoring 83....................................

2.8.4 Menu 4—Operational Records 86..................................

2.8.5 Menu 5—Event History 88.........................................

2.8.6 Menu 6—Time and Date 89.......................................

2.8.7 Menu 7—Generator System 90....................................

2.8.8 Menu 8—Time Delays 96.........................................

2.8.9 Menu 9—Input Setup 98..........................................

2.8.10 Menu 10—Output Setup 104........................................

2.8.11 Menu 11—Voltage Regulator 114....................................

2.8.12 Menu 12—Calibration 120..........................................

2.8.13 Menu 13—Communications 125....................................

2.8.14 Menu 14—Programming Mode 129..................................

2.8.15 Menu 15—Protective Relays (PR) 131...............................

2.8.16 Menu 20—Factory Setup 135.......................................

Section 3 Scheduled Maintenance 137..........................................................

3.1 Alternator Service 137.....................................................

3.2 Engine Service 137.......................................................

3.3 Service Schedule 138.....................................................

3.4 Alternator Bearing Service 140..............................................

3.4.1 20--300 kW Models 140............................................

3.4.2 300--2250 kW Models with Single-Bearing Alternator 140...............

3.4.3 1250 kW and Larger Models with Two-Bearing Alternator 140...........

3.5 Diesel Fuel Systems 140...................................................

3.5.1 Bleeding Air from Fuel System 140..................................

3.5.2 Subbase Fuel Day Tank Electronic Control Module (ECM) 141..........

3.5.3 Subbase Inner Fuel Tank Alarm 142.................................

3.6 Gas Fuel Systems (REZG_ and REZX_/RZX_ models) 142.....................

3.6.1 Gas Fuel System Concept (Single Fuel) 142..........................

3.6.2 LPG Liquid Withdrawal Fuel System Concept 142.....................

3.6.3 Natural Gas and LPG Conversion 143...............................

3.6.4 Fuel System Changeover Kits (Dual Fuel) 143........................

3.6.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1

(125/150REZG models) 145........................................

3.7 Cooling System 145.......................................................

3.7.1 Coolant Level Check 145...........................................

3.7.2 Cooling System Component Inspection 146...........................

3.7.3 Procedure to Drain Cooling System 146..............................

3.7.4 Procedure to Flush and Clean Cooling System 146....................

3.7.5 Procedure to Refill Cooling System 146..............................

3.8 Radiator Fan Bolt Retorque 147.............................................

3.9 Radiator Expansion Joint Loosening—Initial Setup Only 148....................

3.10 Radiator Fan Bearing Lubrication 148........................................

3.11 Battery 149

3.11.1 Clean Battery 149.................................................

3.11.2 Electrolyte Level Inspection 150.....................................

3.11.3 Specific Gravity Check 151.........................................

3.11.4 Charge Battery 151................................................

...............................................................

TP-6200 10/12Table of Contents4

Page 5

Table of Contents, continued

3.12 Detroit Diesel Engine Control Systems 152...................................

3.12.1 Features 152.....................................................

3.12.2 DDEC Engine Diagnostics 152......................................

3.13 Engine Control Systems 153................................................

3.14 Storage Procedure 153....................................................

3.14.1 Lubricating System 153............................................

3.14.2 Cooling System 153...............................................

3.14.3 Fuel System 154..................................................

3.14.4 Internal Engine Components (Gas-Fueled Engines) 154................

3.14.5 Exterior 154......................................................

3.14.6 Battery 154.......................................................

Section 4 General Troubleshooting 155.........................................................

4.1 General Troubleshooting Chart 156..........................................

4.2 Controller Display and Voltage Regulation Troubleshooting Chart 159............

Section 5 Generator Set Reconnection 161.....................................................

5.1 Introduction 161..........................................................

5.2 Voltage Reconnection Procedure 162........................................

Section 6 Accessories 167.....................................................................

6.1 Accessories and Connections 167...........................................

6.1.1 Audiovisual Alarm Kit 167..........................................

6.1.2 Common Failure Relay Kit 168......................................

6.1.3 Controller (Customer) Connection Kit 168............................

6.1.4 Float/Equalize Battery Charger Kit with Alarm Option 168...............

6.1.5 Ground Fault Annunciation 170.....................................

6.1.6 Idle (Speed) Mode Feature 171.....................................

6.1.7 Low Fuel (Level/Pressure) Switch 172...............................

6.1.8 Prime Power Switch Kit 172........................................

6.1.9 Remote Emergency Stop Kit 173....................................

6.1.10 Remote Reset Feature 173.........................................

6.1.11 Remote Serial Annunciator 174.....................................

6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) 181....

6.1.13 Run Relay Kit 181.................................................

6.1.14 Shunt-Trip Line Circuit Breaker 181..................................

6.1.15 Single-Relay Dry Contact Kit 182....................................

6.1.16 Ten-Relay Dry Contact Kit 182......................................

6.1.17 Twenty-Relay Dry Contact Kit 184...................................

6.1.18 Wireless Monitor 185..............................................

6.2 Accessory Connections 186................................................

Appendix A Abbreviations 193................................................................

Appendix B User-Defined Settings 195........................................................

Appendix C Voltage Regulator Definitions and Adjustments 202.................................

Appendix D Alternator Protection 208.........................................................

Appendix E Inputs and System Events by Application 209......................................

TP-6200 10/12 Table of Contents 5

Page 6

Notes

6 TP-6200 10/12

Page 7

Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment, including generator sets, transfer switches, switchgear, and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained. To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions. SAVE THESE INSTRUCTIONS.

This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.

DANGER

Danger indicates the presence of a hazard that will cause severe

personal injury, death,or substantial property damage.

WARNING

Warning indicates the presence of a hazard that can cause severe

personal injury, death, or substantial property damage.

CAUTION

Caution indicates the presence of a hazard that will or can cause minor personal injury or property damage.

NOTICE

Notice communicates installation, operation, or maintenance information that is safety related but not hazard related.

Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or damaged decals.

Accidental Starting

WARNING

Accidental starting. Can cause severe injury or death.

Disconnect the battery cables before working on the generator set. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery.

Disabling the generator set. Accidental starting can cause severe injury or death. Before

working on the generator set or connected equipment, disable the generator set as follows: (1) Move the generator set master switch to the OFF position. (2) Disconnect the power to the battery charger. (3) Remove the battery cables, negative (--) lead first. Reconnect the negative (--) lead last when reconnecting the battery. Follow these precautions to prevent starting of the generator set by an automatic transfer switch, remote start/stop switch, or engine start command from a remote computer.

Battery

WARNING

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

Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.

WARNING

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

Locate the battery in a well-ventilated area. Isolate the battery charger from explosive fumes.

Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery

acid can cause blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.

Battery acid cleanup. Battery acid can cause severe injury or death.

Battery acid is electrically conductive and corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a containerwith4L(1gal.)ofwaterand mix the neutralizing solution. Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.

7Safety Precautions and InstructionsTP-6200 10/12

Page 8

Battery gases. Explosion can cause severe injury or death. Battery gases

can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects. Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the compartments containing batteries to prevent accumulation of explosive gases.

Battery short circuits. Explosion can cause severe injury or death.

Short circuits can cause bodily injury and/or equipment damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the equipment. Use tools with insulated handles. Remove the negative (--) lead first when disconnecting the battery. Reconnect the negative (--) lead last when reconnecting the battery. Never connect the negative (--) battery cable to the positive (+) connection terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

Engine Backfire/Flash Fire

Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames

or sparks near the carburetor, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an approved container when removing the fuel line or carburetor.

Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator

set with the air cleaner removed.

Combustible materials. A fire can cause severe injury or death.

Generator set engine fuels and fuel vapors are flammable and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.

Exhaust System

WARNING

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

The exhaust system must be leakproof and routinely inspected.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is a poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:

D Light-headedness, dizziness D Physical fatigue, weakness in

joints and muscles

D Sleepiness, mental fatigue,

inability to concentrate or speak clearly, blurred vision

D Stomachache, vomiting, nausea

If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active. Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the condition of affected persons does not improve within minutes of breathing fresh air.

Fuel System

WARNING

Explosive fuel vapors. Can cause severe injury or death.

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

WARNING

Fire. Can cause severe injury or death.

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

8 Safety Precautions and Instructions TP-6200 10/12

Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon

monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied building.

Page 9

The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly

explosive. Use extreme care when handling and storing fuels. Store fuels inawell-ventilatedareaawayfrom spark-producing equipment and out of the reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks. Repair fuel systems before resuming generator set operation.

Explosive fuel vapors can cause severe injury or death. Ta k e

additional precautions when using the following fuels:

Gasoline—Store gasoline only in approved red containers clearly marked GASOLINE.

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

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

Fuel tanks. Explosive fuel vapors can cause severe injury or death.

Gasoline and other volatile fuels stored in day tanks or subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.

Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an

explosion. Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.

Gas fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage can cause an

explosion. Check the LP vapor gas or natural gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to 6--8 ounces per square inch (10--14 inches water column). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

LP liquid withdrawal fuel leaks. Explosive fuel vapors can cause severe injury or death. Fuel leakage

can cause an explosion. Check the LP liquid withdrawal gas fuel system for leakage by using a soap and water solution with the fuel system test pressurized to at least 90 psi (621 kPa). Do not use a soap solution containing either ammonia or chlorine because both prevent bubble formation. A successful test depends on the ability of the solution to bubble.

Hazardous Noise

CAUTION

Hazardous noise. Can cause hearing loss.

Never operate the generator set without a muffler or with a faulty exhaust system.

Engine noise. Hazardous noise can cause hearing loss. Generator sets

not equipped with sound enclosures can produce noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss. Wear hearing protection when near an operating generator set.

Hazardous Voltage/ Moving Parts

DANGER

Hazardous voltage. Will cause severe injury or death.

Disconnect all power sources before opening the enclosure.

WARNING

Hazardous voltage. Can cause severe injury or death.

Operate the generator set only when all guards and electrical enclosures areinplace.

WARNING

Hazardous voltage. Backfeed to the utility system can cause property damage, severe injury, or death.

If the generator set is used for standby power, install an automatic transfer switch to prevent inadvertent interconnection of standby and normal sources of supply.

Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution

is possible whenever electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocution.

Moving parts.

9Safety Precautions and InstructionsTP-6200 10/12

Page 10

High voltage test. Hazardous voltage can cause severe injury or death. Follow the instructions of the

test equipment manufacturer when performing high-voltage tests on the rotor or stator. An improper test procedure can damage equipment or lead to generator set failure.

Testing the photo transistor circuit board. Hazardous voltage can cause severe injury or death. When

the end cover is removed, do not expose the photo transistor circuit board mounted on the generator set end bracket to any external light source, as exposure to light causes high voltage. Keep foreign sources of light away from the photo transistor circuit board during testing. Place black electrical tape over the LED on the circuit board before starting the generator set.

Installing the photo transistor circuit board. Hazardous voltage can cause severe injury or death.

Ensure that the foil side of the photo transistor circuit board, the end of the shaft, and the threaded holes are clean and free of metal particles and chips. Metal debris may short-circuit the photo transistor circuit board and cause hazardous voltage in the generator set. Do not reconnect the generator set to the load until the AC voltmeter shows the correct output.

Installing the battery charger. Hazardous voltage can cause severe injury or death. An

ungrounded battery charger may cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative, install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in compliance with local codes and ordinances.

Servicing the day tank. Hazardous voltage can cause severe injury or death. Service the day tank electrical

control module (ECM) as prescribed in the equipment manual. Disconnect the power to the day tank before servicing. Press the day tank ECM OFF pushbutton to disconnect the power. Notice that line voltage is still present within the ECM when the POWER ON light is lit. Ensure that the generator set and day tank are electrically grounded. Do not operate the day tank when standing in water or on wet ground because these conditions increase the risk of electrocution.

Short circuits. Hazardous voltage/current can cause severe injury or death. Short circuits can

cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all jewelry before servicing the equipment.

Engine block heater. Hazardous voltage can cause severe injury or death. The engine block heater can

cause electrical shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.

Handling the capacitor. Hazardous voltage can cause severe injury or death. Electrical shock results from

touching the charged capacitor terminals. Discharge the capacitor by shorting the terminals together.

(Capacitor-excited models only)

Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Install

a transfer switch in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility electrical system can cause severe injury or death to utility personnel working on power lines.

Testing live electrical circuits. Hazardous voltage or current can cause severe injury or death. Have

trained and qualified personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically.

(600 volts and under)

WARNING

Airborne particles. Can cause severe injury or blindness.

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

Servicing the generator set when it is operating. Exposed moving parts can cause severe injury or death.

Keep hands, feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens, and covers before operating the generator set.

Heavy Equipment

WARNING

Connecting the battery and the battery charger. Hazardous voltage can cause severe injury or death.

Reconnect the battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and battery(ies). Have a qualified electrician install the battery(ies).

10 Safety Precautions and Instructions TP-6200 10/12

Unbalanced weight. Improper lifting can cause severe injury or death and equipment damage.

Do not use lifting eyes. Lift the generator set using lifting bars inserted through the lifting holes on the skid.

Page 11

Hot Parts

Notice

WARNING

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

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

WARNING

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

Do not work on the generator set until it cools.

Servicing the alternator. Hot parts can cause severe injury or death.

Avoid touching the alternator field or exciter armature. When shorted, the alternator field and exciter armature become hot enough to cause severe burns.

NOTICE

This generator set has been rewired from its nameplate voltage to

246242

NOTICE

Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.

NOTICE

Canadian installations only.For standby service connect the output of the generator set to a suitably rated transfer switch in accordance with Canadian Electrical Code, Part 1.

Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts.

The engine and exhaust system components become extremely hot during operation.

11Safety Precautions and InstructionsTP-6200 10/12

Page 12

Notes

12 Safety Precautions and Instructions TP-6200 10/12

Page 13

Introduction

This manual provides operation instructions for 20 kW and larger generator sets equipped with the following controller:

D Decisionr 550, Software (Code) Version 2.10 or

higher

Version2.10 refers to the controller application software. To determine the generator set controller software version, go to Menu 20—Factory Setup and scroll down to Code Version. The code version is the controller software version.

Wiring diagram manuals are available separately. Refer to the engine operation manual for generator set engine scheduled maintenance information.

Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.

Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual with the equipment for future reference.

The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform required service at the prescribed intervals. Maintenance work must be performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set operation and service.

The disk supplied with this generator set is a backup copy of the generator set personality program containing data specific to the engine and alternator. The engine and alternator data was preprogrammed in the controller at the factory and no further use of the disk should be necessary. Typically, your authorized distributor stores this disk for possible future use such as controller replacement or other circumstances requiring a backup.

Abbreviations

This publication makes use of numerous abbreviations. Typically, the word(s) are spelled out along with the abbreviation in parentheses when shown for the first time in a section. Appendix A, Abbreviations, also includes many abbreviation definitions.

List of Related Materials

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

Communication and Software Manual Description

550 Controller Spec Sheet

Generator Set/Controller Wiring Diagram Manual

550 Communications Spec Sheet

Monitor III Converters, Connections, and Controller Setup

Monitor III Software Spec Sheet G6-76

Monitor III Converter, Modbusr/Ethernet Spec Sheet

Monitor III Software Operation Manual TP-6347

Modbusr Communications Protocol Operation Manual

Setup and Application Manual TP-6140

Service Parts Controllers TP-6780

Program Loader Software Installation TT-1285

SiteTecht Software Operation Manual

Remote Serial Annunciator (RSA) TT-1377

Remote Serial Annunciator (RSA II) TT-1485

Controller Service Replacement TT-1310

Figure 1 Related Literature

Literature Part No.

G6-46

Multiple Part Numbers

Contact your

Distributor/Dealer

G6-50

TT-1405

G6-79

TP-6113

TP-6701

Modbusr is a registered trademark of Schneider Electric.

13IntroductionTP-6200 10/12

Page 14

Service Assistance

For professional advice on generator set power requirements and conscientious service, please contact your nearest Kohler distributor or dealer.

D Consult the Yellow Pages under the heading

Generators—Electric.

D Visit the Kohler Power Systems website at

KohlerPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents included with the product.

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

D Outside the US and Canada, call the nearest regional

office.

Headquarters Europe, Middle East, Africa (EMEA)

Kohler Power Systems 3 rue de Brennus 93200 Saint Denis France Phone: (33) 1 49 178300 Fax: (33) 1 49 178301

Asia Pacific

Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455

China

North China Regional Office, Beijing Phone: (86) 10 6518 7950

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

Fax: (86) 10 6518 7955

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

India, Bangladesh, Sri Lanka

India Regional Office Bangalore, India Phone: (91) 80 3366208

(91) 80 3366231

Fax: (91) 80 3315972

Japan, Korea

North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727

Latin America

Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131

14 Service Assistance TP-6200 10/12

Page 15

Section 1 Specifications and Features

1.1 Introduction

The spec sheets for each generator set provide modelspecific generator and engine information. The controller spec sheet provides specifications for this controller. Refer to the respective spec sheet for data not supplied in this manual. Consult the generator set service manual, installation manual, engine operation manual, and engine service manual for additional specifications.

1.2 Controller Features

The controller features include the annunciator lamps, digital display and keypad, switches and controls, and fuses and terminal strip. The following paragraphs detail the features by general topics.

124 5

The controller features, accessories, and menu displays depend upon the engine electronic control module (ECM) setup and features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted.

Note: Press any key on the keypad to turn on the

controller lights and display. The lights and display turn off 5 minutes after the last keypad entry.

Note: Measurements display in metric or English. Use

Menu 7—Generator System to change the measurement display.

See Figure 1-1 for an illustration of the controller front panel. See Figure 1-2 for an illustration of the controller with the keyswitch option.

1. Emergency stop switch

2. Alarm horn (see keypad for alarm silence)

3. Annunciator lamps (see keypad for lamp test)

4. Generator set master switch, run/off-reset/auto positions

5. Digital display

6. Keypad

7. Operating guide

8. Controller terminal strips (on circuit board)

Figure 1-1 550 Controller with Three-Position Selector Switch

TP-6200 10/12 15Section 1 Specifications and Features

TP-6083-2

Page 16

12 4 5

1. Generator set master switch, run/off-reset/auto positions (keyswitch option)

2. Emergency stop switch

3. Alarm horn (see keypad for alarm silence)

4. Annunciator lamps (see keypad for lamp test)

Figure 1-2 550 Controller with Keyswitch Option

1.2.1 Annunciator Lamps

Five annunciator lamps provide visual generator set status. See Figure 1-3.

TP-6083-2

Figure 1-3 Annunciator Lamps

System Ready. Green lamp illuminates when the

generator set master switch is in the AUTO (automatic start) position and the system senses no faults. The unit is ready to start.

TP-6083-2

5. Digital display

6. Keypad

7. Operating guide

8. Controller terminal strips (on circuit board)

Programming Mode. Yellow programming lamp indicates the user selected programming mode. See Figure 1-4.

Programming Lamp Programming Mode Selection

Lamp Flashing Local Programming

Lamp Steady On Remote Programming

Lamp Off Programming Disabled

Figure 1-4 Programming Lamp Mode

Note: Find additional information for the programming

mode lamp function and access to the local or remote programming modes in Section 2.8, Local Programming Mode On, Menu 14—Programming Mode.

Not in Auto (NIA). Yellow lamp illuminates when the generator set master switch is not in the AUTO (automatic start) position.

TP-6200 10/1216 Section 1 Specifications and Features

Page 17

System Warning. Yellow lamp identifies an existing fault condition that does not shut down the generator set. A continuing system warning fault condition may cause a system shutdown. Correct all system warnings as soon as practical.

System Shutdown. Red lamp indicates that the generator set has shut down because of a fault condition. The unit will not start without resetting the controller, see Section 2.3.7, Controller Reset Procedure.

See Section 2.3.5, System Warning Lamp, for definitions of the items listed.

The following conditions cause a system warning:

D Engine functions:

d ECM yellow alarm

(DDC/MTU engine with MDEC/ADEC)

d High battery voltage d High coolant temperature d Low battery voltage d Low coolant temperature d Low fuel (level or pressure)* d Low oil pressure d Speed sensor fault d Starting aid (system status) d Weak battery

D General functions:

d Auxiliary—Analog up to 7 user-selectable inputs

each with a high and low programmable warning level

d Auxiliary—Digital up to 21 user-selectable

warnings

d Battery charger fault* d Emergency power system (EPS) supplying load d Engine cooldown delay d Engine start delay d Load shed kW overload d Load shed underfrequency d Master switch not in AUTO (automatic start)

position

d NFPA 110 fault (National Fire Protection

Association)

d System ready (system status)

D Alternator functions:

d AC sensing loss d Ground fault* d Overcurrent

* Requires optional input sensors.

Note: See Figure 2-8 in User Inputs for factory-

reserved analog and digital inputs that are not user-selectable.

See Section 2.3.6, System Shutdown Lamp, for definitions of the items listed.

The following conditions cause a system shutdown:

D Engine functions:

d Air damper closed (status), if equipped d Coolant temperature signal loss d ECM red alarm

(DDC/MTU engine with MDEC/ADEC)

d Engine stalled (ECM only) d High coolant temperature d High oil temperature d Low coolant level d Low oil pressure d Oil pressure signal loss d Overcrank d Overspeed

D General functions:

d Auxiliary—Analog up to 7 user-selectable inputs

each with a high and low programmable shutdown level

d Auxiliary—Digital up to 21 user-selectable

shutdowns

d ECM communications loss (ECM models only) d Emergency stop d Internal fault d Master switch in OFF/RESET position d Master switch error d Master switch open d NFPA 110 fault

D Alternator functions:

d AC output overvoltage d AC output undervoltage d Alternator protection against overload and short

circuits

d Field overvoltage

(M4, M5, M7, or M10 alternator only)

d Locked rotor (failed to crank) d Overfrequency d Underfrequency

Note: See Figure 2-8 in User Inputs for factory-

reserved analog and digital inputs which are not user-selectable.

TP-6200 10/12 17Section 1 Specifications and Features

Page 18

1.2.2 Digital Display and Keypad

Figure 1-5 illustrates the digital display and keypad.

Note: Press any key on the keypad to turn on the

controller lights and display. The lights and display turn off 5 minutes after the last keypad entry.

The 2-line vacuum fluorescent display provides generator set and engine condition information.

The 16-button keypad gives the user information access and local programming capability.

Keypad Functions

Alarm (Horn) Off key silences the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. See Section 2.3.7, Controller Reset Procedure, and Section 1.2.3, Switches and Controls.

TP-5829-2

Figure 1-5 Digital Display and Keypad

AM/PM key provides time of day data entries when

programming.

Enter ↵ key provides confirmation entry when selecting menu or programming.

Lamp Test key tests the controller indicator lamps, horn, and digital display. See Section 1.2.3, Switches and Controls.

Menu down ↓ key provides navigation within menus when necessary.

Menu right → key provides navigation within menus when necessary.

Numeric 0--9 keys provide numeric data entries when selecting menus or programming.

Reset Menu key exits a menu, clears incorrect entries, and cancels the auto-scroll feature.

Stop Prog (Program) Run key allowstheusertostop any previously programmed generator set run sequence. See Section 1.2.3, Switches and Controls.

Yes/No keys provides data answer entries when programming.

Alternator Output Displays (Menu 1)

AC Amps displays the alternator output current. The display shows each line of 3-phase models.

AC Volts displays the alternator output voltages. The display shows all line-to-neutral and line-to-line voltage combinations.

Alternator Duty Level displays the actual load kW divided by the nameplate kW rating as a percentage.

Frequency displays the frequency (Hz) of alternator output voltage.

Hourmeter displays the generator set operating hours loaded and unloaded for reference in scheduling maintenance.

KVA displays the total and individual L1, L2, and L3 kVA.

KVAR displays the total and individual L1, L2, and L3

kVAR.

Power Factor displays the kW/kVA and the individual line power factor values.

Watts displays the total and individual L1, L2, and L3 kilowatts.

TP-6200 10/1218 Section 1 Specifications and Features

Page 19

Engine Displays (Menu 2)

Some engine displays are available with selected generator set engines using engine ECMs only. The controller display shows N/A (not available) for items that are unavailable. See the controller spec sheet for applicable generator set models.

Ambient Temperature displays the generator set area ambient temperature.

Charge Air Pressure displays the engine turbocharger boost air pressure.

Charge Air Temperature displays the engine turbocharger boost air temperature.

Coolant Level displays the engine coolant level.

Coolant Pressure displays the engine coolant

pressure.

Coolant Temperature displays the engine coolant temperature.

Event History displays up to 100 stored system events including status, warnings, and shutdowns.

Last Start Date displays the date when the generator set last operated.

Number of Starts displays the total number of generator set startup events.

Number of Starts (Since) Last Maintenance displays the total number of generator set startup events since the last maintenance date.

Operating Days (Since) Last Maintenance displays the total number of days of operation since the last maintenance date. A counted day of operation can be 1--24 hours.

Run Time displays the total loaded hours, total unloaded hours, and total kW hours.

Run Time Since Maintenance displays the total loaded hours, total unloaded hours, and total kW hours.

Crankcase Pressure displays the engine crankcase pressure.

DC Volts displays the voltage of starting battery(ies).

Fuel Pressure displays the fuel supply pressure.

Fuel Rate displays the calculated fuel consumption rate

based on fuel injector outputs.

Fuel Temperature displays the fuel supply temperature.

Oil Level displays the engine oil level as a percent of full capacity.

Oil Pressure displays the engine oil pressure.

Oil Temperature displays the engine oil temperature.

RPM (Tachometer) displays the engine speed.

Used Last Run displays the accumulated amount of

fuel used since last reset by the engine DDEC reader.

Operational Record Displays (Menus 4 and 5)

The operational record displays events since last reset. See Section 2.8.4, Menu 4—Operational Records, for resetting procedure.

Time Delay Displays (Menu 8)

The time delays are user adjustable. See Section 2.8.8, Menu 8—TIme Delays, for time delay adjustments. See Section 1.3.1, Status Event and Fault Specifications, for range and default settings.

Crank On/Crank Pause displays the time allocated for generator set crank on and crank pause in minutes:seconds.

Engine Cooldown displays the time delay for engine cooldown while the master switch is in the AUTO or RUN positions and not in the idle mode.

Engine Start displays the time delay before the generator set starts while the master switch is in AUTO or RUN positions.

Overcrank Shutdown (Number of) Crank Cycles

displays the number of unsuccessful crank cycles (crank on/crank pause) before the generator set shuts down on an overcrank fault.

Overvoltage displays the time delay before the generator set shuts down because of an overvoltage condition.

Starting Aid displays the engine starting aid activation time.

Engine Start Countdown displays the time remaining before the next generator set startup.

TP-6200 10/12 19Section 1 Specifications and Features

Undervoltage displays the time delay before the generator set shuts down because of an undervoltage condition.

Page 20

1.2.3 Switches and Controls

See Figure 1-6 and Figure 1-8 for switches and controls.

123

TP-6083-2

1. Emergency stop switch

2. Alarm horn

3. Generator set master switch

Figure 1-6 Switches and Alarm Horn

Note: Find additional switches and controls in

Section 2.5.1, Keypad Operation.

Alarm Horn. The alarm horn alerts the operator or other attendants that a shutdown or warning condition exists. See Section 1.3, Controller Logic Specifications, for conditions. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the generator set master switch is in the AUTO position. See Section 2.3.7, Controller Reset Procedure.

The generator set master switch with the keyswitch option (Figure 1-7) is available to meet appropriate local code requirements. The key is removable in the AUTO position only.

TP-6083-2

Figure 1-7 Generator Set Master Switch with

Keyswitch Option

Lamp Test. The keypad switch tests the controller indicator lamps, horn, and digital display. Press the reset menu key before pressing the lamp test key.

Stop Prog (Program) Run. Keypad switch allows the user to stop any previously programmed generator set run sequence.

Alarm (Horn) Off. The keypad switch silences the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. Restore alarm horn switches at all locations including those on remote annunciator and audiovisual alarm kits to the normal position after correcting the fault shutdown to avoid reactivating the alarm horn. See Section 2.3.7, Controller Reset Procedure.

AM/PM. This keypad switch provides time of day data entries when programming.

Emergency Stop. The operator-activated pushbutton immediately shuts down the generator set in emergency situations. Reset the emergency stop switch after shutdown by pulling the switch knob outward. Use the

emergency stop switch for emergency shutdowns only.

Use the generator set master switch for normal shutdowns.

Generator Set Master Switch (Run/Off-Reset/Auto). This switch resets the controller fault lamps and start/stops the generator set. Refer to Section 2.3.1, Starting, Section 2.3.2, Stopping, and Section 2.3.3, Emergency Stop Switch Reset Procedure.

1. Lamp test

2. Alarm horn silence

3. Stop program run

Figure 1-8 Keypad Switches

TP-5829-2

TP-6200 10/1220 Section 1 Specifications and Features

Page 21

1.2.4 Controller Circuit Boards

1.2.5 Fuses

The controller has five circuit boards—indicator, interconnection, keypad, digital display, and main logic/ communication. See Figure 1-9 for circuit board locations.

1. AC fuse block (TB5)

2. Interconnection circuit board TB1, TB2, TB3, and TB4 terminal strips and F1, F2, and F3 fuses

3. Main logic (microprocessor)/communication circuit board

4. Keypad and digital display circuit boards

5. Indicator circuit board (LED and alarm horn)

GM10193B-A

Figure 1-9 Controller Circuit Boards and Fuses

(Controller Top View)

Indicator (Status) Circuit Board includes the LED status lamps, alarm horn, and generator set master switch.

Interconnection Circuit Board provides the terminal strips to connect the controller (customer) connection board and/or dry contact kits and three DC fuses (F1, F2, and F3). See 6.1.3 for more information.

Keypad (Switch Membrane) Circuit Board provides the keypad to navigate the generator set displays and enter data.

Digital Display Circuit Board provides the vacuum fluorescent display (VFD) for monitoring the generator set functions and output values.

Main Logic (Microprocessor)/Communication Circuit Board provides the controller operation logic

and provides PC communication locally (direct) or remotely (via modem) using RS-232 or RS-485 connectors.

AC Circuit Fuses (TB5). Fuses are located inside the controller. See Figure 1-9.

D 1.5-Amp (V7) fuse protects L1 sensing input to

interconnection circuit board.

D 1.5-Amp (V8) fuse protects L2 sensing input to

interconnection circuit board.

D 1.5-Amp (V9) fuse protects L3 sensing input to

interconnection circuit board.

DC Circuit Fuses fuses are located on the controller interconnection circuit board.

D 5-Amp Remote Annunciator (F1) fuse protects the

dry contact kit if equipped and the controller panel lamps.

D 5-Amp Controller (F2) fuse protects the controller

circuitry.

D 15-Amp Engine and Accessories (F3) fuse protects

the engine/starting circuitry and accessories.

1.2.6 Terminal Strips and Connectors

Terminal strips and connectors for inputs and outputs are located on the interconnection circuit board. See Section 6, Accessories.

TB1 Input Connection Terminal Strip provides input connections for remote start and emergency stop (E-Stop).

TB2 Analog Input Connection Terminal Strip

provides analog input connections, including non-ECM sensor connections.

TB3 Accessory Power Output Connection Terminal Strips provides a generator set power supply for factory

use.

TB4 Digital Input Connection Terminal Strips

connect external devices (engine ECM and user supplied) to the generator set digital inputs.

P23 Connector connects the interconnection circuit board to the controller (customer) connection terminal strip (connector P25) inside the junction box. See 6.1.3 for more information.

TP-6200 10/12 21Section 1 Specifications and Features

Page 22

Figure 1-10 shows locations of the terminal strips on the controller interconnection circuit board. See Section 6.2, Accessory and Connections, for specific terminal identification information. Refer to the wiring diagrams for additional information on connecting accessories to the terminal strips.

ADV-6533-A

1.2.7 Circuit Board Interconnections for Calibration Procedure

The interconnection circuit board shown in Figure 1-11 contains a ribbon connector that requires disconnection during the calibration procedure in Menu 12— Calibration. Disconnect ribbon connector P2 prior to zeroing out (resetting) the auxiliary analog inputs.

1. TB1 terminal strip

2. TB2 terminal strip

3. P1 Connector

4. P23 Connector

5. TB3 terminal strip

6. TB4 terminal strip

Figure 1-10 Interconnection Circuit Board Terminal

Strips and Connectors

ADV-6533-A

1. Interconnection circuit board

2. P2 ribbon connector

3. P12 ribbon connector

4. Main logic circuit board

Figure 1-11 Interconnection Circuit Board Ribbon

Connector P2 (Top View of Circuit Board)

TP-6200 10/1222 Section 1 Specifications and Features

Page 23

1.2.8 Communication Ports

1.3 Controller Logic Specifications

The main logic circuit board contains several communication ports for Modbusr and KBUS connections. See Figure 1-12. Refer to the List of Related Materials in the Introduction for corresponding communication installation information.

12 34 5

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

The default selection time delays and relay driver outputs (RDOs) are factory set and adjustable with the programming mode on (Menu 14). Some data entries require using a PC in the Remote Programming mode. See the monitor software operation manual for details.

Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes and the controller does not detect a fault or status event. Select the desired inhibit time delay from 0 to 60 seconds.

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

ADV-6533-A

1. P19—unused isolated connection (ISO2), RS-485 port

2. P21—KBUS isolated connection (ISO1), RS-485 port

3. P18—KBUS or Modbusr, RS-232 port

(Monitor III connection)

4. P20—Modbus, RS-485 port (Monitor III connection)

5. P22—ECM connector

6. Main logic circuit board

Figure 1-12 Main Logic Circuit Board Communication

Ports (Top View of Circuit Board)

1.3.1 Status Event and Fault Specifications

The table starting on the next page contains all status events and faults with ranges and time delays including items that do not have adjustments.

Note: The engine ECM may limit the crank cycle even if

the controller is set to a longer time period.

Modbusr is a registered trademark of Schneider Electric.

TP-6200 10/12 23Section 1 Specifications and Features

Page 24

Factory-Defined Settings

Status Event or Fault

Access Code (password)

AC Sensing Loss 10 AC SENSING

Air Damper Control (if used) **

Air Damper Indicator (if used), see D20 **

Air/Fuel Module (AFM) Engine Start Delay ]

Air/Fuel Module (AFM) Remote Start]

Air/Fuel Module (AFM) Shutdown (see D11) ]

Alternator Protection Shutdown

Analog Aux. Input 0 9 LOCAL BATT

Analog Aux. Inputs A01--A07

Analog Aux. Input A01 (non-ECM only)

Analog Aux. Input A02 (non-ECM only)

Analog Aux. Input A03 ]

Analog Aux. Input A04 *

Analog Aux. Input A04 ]

Analog Aux. Input A06 VSG (Volvo, GM, Doosan only)

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Refer

Digital Display

14 User-Selectable 0(zero)

LOSS

10 AFM ENG

START DELAY

10 AFM REMOTE

10 ALTERNATOR

9 USER-DEFINED

9 A01

9 A02

9 A03

9 A04

9, 12 A06 ANALOG

START

PROTECTION

VDC

A01--A07

COOLANT

TEMP

OIL

PRESSURE

INTAKE AIR

TEMP

FUEL LEVEL

OIL TEMP

AUXILIARY IN

Relay

Driver

Output

(RDO)

RDO-25 * On Warning

RDO-25 ]

Alarm

Horn

Off

On Shutdown

On Warning Default Values with

Off Vol vo:

Lamp Range Setting

Warning

Shutdown

Warning

Fixed

Default Values with

Warning Enabled:

HI warning 90%

LO warning 10%

HI shutdown 100%

LO shutdown 1%

Default Values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are

all engine dependent

Default Values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are

all engine dependent

(255 psi max.)

Default Values with

Warning Enabled:

HI/LO warning and

HI/LO shutdown are

all engine dependent

Default Values with

Warning Enabled:

HI/LO warning are

engine dependent

Warning Enabled:

HI/LO warning are

engine dependent

Default

Selection

30 sec.

inhibit,

5 sec. delay

30 sec.

inhibit,

0 sec. delay

warning,

5 sec. delay

shutdown

30 sec.

inhibit,

0 sec. delay

warning,

5 sec. delay

shutdown

30 sec.

inhibit,

0 sec. delay

warning

30 sec.

inhibit,

0 sec. delay

warning

30 sec.

inhibit,

0 sec. delay

warning

0.5V=1250

4.5V=8750

GM/Doosan

60 Hz:

0.5V=2375

4.5V=2625 50 Hz:

0.5V=2327

4.5V=2624

Inhibit

Time

Delay

(sec.)

0--60 0--60

Time Delay (sec.)

TP-6200 10/1224 Section 1 Specifications and Features

Page 25

Factory-Defined Settings

Status Event or Fault

Analog Aux. Input A07

Battery Charger Fault (see D01) **

Battle Switch (Fault Shutdown Override Switch)

Block Heater Control [[

Breaker Trip w

Common Protective Relay Output w

Critical Overvoltage Shutdown

Cyclic Cranking 8 Off 1--6 crank cycles

Defined Common Faults (each input value is set separately)

Detonation Shutdown (see D13) ]

Detonation Warning (see D12) ]

Digital Aux. Input D01--D21

Digital Aux. Input D01 Battery Charger Fault **

Digital Aux. Input D02 Low Fuel Warning **

Digital Aux. Input D03 Low Coolant Temperature **

Digital Aux. Input D04 Field Overvoltage (M4, M5, M7, or M10 alt. only)

Digital Aux. Input D05 Breaker Closed w

Digital Aux. Input D06 w

Digital Aux. Input D09 Low Fuel Pressure Shutdown (125RZG only)

Digital Aux. Input D11 Air/Fuel Module (AFM) Shutdown ]

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Refer

Digital Display

9 A07

ANALOG VOLT

ADJUST

9 BATTLE

10 BLOCK HEATER

10 BREAKER

10 COMMON PR

10 CRITICAL

10 DEFINED

9, 10 USER-DEFINED

9, 10 D01 BATTERY

9, 10 D02

9, 10 D03 LOW

9, 10 D04

9, 10 D05

9, 10 D06 ENABLE

9, 10 D09

9, 10 D11

SWITCH

CONTROL

TRIP

OUTPUT

OVERVOLTAGE

COMMON

FAULT

D01--D21

CHARGER

FAULT

LOW FUEL

WARNING

COOLANT

TEMP

FIELD

OVERVOLTAGE

BREAKER

CLOSED

SYNCH

LOW FUEL

SHUTDOWN

AFM

SHUTDOWN

Relay Driver

Output

(RDO)

RDO only

RDO-30 Off Warning

RDO-31 w

RDO-18

(lead 32A)

RDO-11

(lead 61)

RDO-08 (lead 63)

RDO-05 (lead 35)

Alarm

Horn

Off Warning Fixed

Off Warning

On Shutdown Fixed 275 volts

On Shutdown

On Warning Fixed 0 sec.

On Shutdown Fixed 1 sec.

Off Warning Fixed 0 sec.

On Shutdown Fixed 5 sec.

On Shutdown Fixed 0 sec.

Warning

Range SettingLamp

±10% of system

voltage over the range

of 0.5--4.5 VDC

10--30 sec. crank on

1--60 sec. pause

Default shutdowns

include:

Emergency stop

High coolant temp

Low oil pressure

Overcrank

Overspeed

Default

Selection

(L1--L2)

15 sec. 15 sec.

30 sec.

inhibit,

5 sec. delay

30 sec.

inhibit,

5 sec. delay

inhibit,

0 sec. delay

inhibit,

0 sec. delay

inhibit,

0 sec. delay

inhibit,

15 sec.

delay

inhibit,

0 sec. delay

20 sec.

inhibit, 0

sec. delay

inhibit,

0 sec. delay

inhibit,

0 sec. delay

Inhibit

Time Delay (sec.)

0--60 0--60

Time Delay (sec.)

TP-6200 10/12 25Section 1 Specifications and Features

Page 26

Factory-Defined Settings

Status Event or Fault

Digital Aux. Input D12 Detonation Warning ]

Digital Aux. Input D13 Detonation Sensing Module (DSM) Shutdown ]

Digital Aux. Input D13 Knock Detection Module (KDM) Shutdown ]

Digital Aux. Input D14 Low Coolant Level, (with LCL switch) **

Digital Aux. Input D15 Remote Shutdown

Digital Aux. Input D16 Remote Reset

Digital Aux. Input D17 VAR/PF mode

Digital Aux. Input D18 Voltage Lower

Digital Aux. Input D19 Voltage Raise

Digital Aux. Input D20 Air Damper Indicator (if used) **

Digital Aux. Input D21 Idle (speed) Mode Function

ECM Red Alarm (was MDEC Red Alarm) [[

ECM Yellow Alarm (was MDEC Yellow Alarm) [[

EEPROM Write Failure

Emergency Stop Shutdown

Engine Cooldown (see Time Delay--)

Engine Derate Active 10 ENGINE

(Engine) J1939 CAN Shutdown (ECM only)

Engine Stalled (ECM only)

Engine Start (see Time Delay--)

EPS (Emergency Power System) Supplying Load

Field Overvoltage (see D04)

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Refer

Digital Display

9, 10 D12

9, 10 D13

9, 10 D14 LOW

9, 10 D15 REMOTE

9, 10

9, 10 D20

9, 10 D21

10 ECM RED

10 ECM YELLOW

10 EEPROM WRITE

10 EMERGENCY

10 J1939 CAN

10 ENGINE

10 EPS

DETON

WARNING

DETON

SHUTDOWN

KNOCK

SHUTDOWN

COOLANT LVL

SHUTDOWN

AIR DAMPER

IDLE MODE

ACTIVE

ALARM

FAILURE

STOP

DERATE

ACTIVE

SHUTDOWN

STALLED

SUPPLYING

LOAD

Relay Driver

Output

(RDO)

RDO-19 On Shutdown Fixed 30 sec.

RDO-23 *

(lead 56)

RDO-21 Off Warning Fixed inhibit time 0 sec.

RDO-14 (lead 48)

RDO-22 Off Warning Fixed 1% of rated

Alarm

Horn

On Warning Fixed 2 sec.

On Shutdown Fixed 0 sec.

On Shutdown 0 sec.

On Shutdown Fixed 0 sec.

On Shutdown

On Warning

On Shutdown

Range SettingLamp

Default

Selection

inhibit,

0 sec. delay

inhibit,

0 sec. delay

inhibit,

0 sec. delay

inhibit,

5 sec. delay

inhibit,

0 sec. delay

inhibit,

0 sec. delay

inhibit,

60 sec.

delay

line current

Inhibit

Time Delay (sec.)

0--600

or 9:99

for

infinity

TP-6200 10/1226 Section 1 Specifications and Features

Page 27

Factory-Defined Settings

Status Event or Fault

Fuel Level (see A04)

Fuel Valve Relay ]

Generator Set Running

Ground Fault Detected

High Battery Voltage 10 HIGH

High Coolant Temperature Shutdown

High Coolant Temperature Warning

High Oil Temperature Shutdown

High Oil Temperature Warning ][[

Idle (speed) Mode Function (see D21)

In Synch w

Intake Air Temperature Shutdown [[

Intake Air Temperature Warning

[[

Intake Air Temp Warning(seeA03)]

Intake Air Temp Shutdown (see A03)]

Internal Fault Shutdown

J1939 CAN Shutdown (see Engine J1939 CAN Shutdown)

Knock Shutdown (see D13) ]

kW Overload (see Load Shed)

Load Shed kW Overload ]]

Load Shed Over Temperature [[ (Activated by a High Coolant Temp. shutdown)

Load Shed Underfrequency [

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Refer

Digital Display

10 FUEL VALVE

10 RDO-15

10 GROUND

10 HI COOL

10 HI OIL TEMP

10 IN SYNCH RDO-29 *

10 INTAKE AIR

10 INTERNAL

10 LOAD SHED

RELAY

FAULT

BATTERY VOLTAGE

TEMP

SHUTDOWN

TEMP

WARNING

SHUTDOWN

WARNING

TEMP SDWN

TEMP WARN

FAULT

KW OVER

OVER

TEMPERATURE

UNDER

FREQUENCY

Relay Driver

Output

(RDO)

RDO-23 ]

(lead 70R)

RDO-13 Off Warning 14.5--16.5 V (12 V)

RDO-03 (lead 36)

RDO-06 (lead 40)

RDO-30 ]]

RDO only

RDO-31 [

Alarm

Horn

Off

On Warning

On Shutdown 30 5

On Warning 30

On Shutdown 30 5

On Warning 30

On Shutdown 30

On Warning 30

On Shutdown

Off Warning 80%--120% 100% of

Off Warning 59 Hz

Range SettingLamp

29--33 V (24 V)

Default

Selection

16 V (12 V) 32 V (24 V)

kW rating

with5sec.

delay

(60 Hz)

49 Hz

(50 Hz)

Inhibit

Time Delay (sec.)

Time

Delay

(sec.)

2--10

TP-6200 10/12 27Section 1 Specifications and Features

Page 28

Factory-Defined Settings

Status Event or Fault

Locked Rotor Shutdown

Loss of ECM Communication (ECM only)

Loss of Field Shutdown w

Low Battery Voltage 10 LOW BATTERY

Low Coolant Level (see D14) (with LCL switch) **

Low Coolant Temperature (see D03) **

Low Coolant Temperature Shutdown [[

Low Fuel (Level or Pressure) Warning (see D02) **

Low Fuel Pressure Shutdown (see D09) (125RZG only)

(Low) Oil Pressure Shutdown

(Low) Oil Pressure Warning

Maintenance Due 10 MAINTENANCE

Master Not In Auto (Generator Set Switch)

Master Switch Error 10 MASTER

Master Switch to Off 10 MASTER

Master Switch Open 10 MASTER

NFPA 110 Fault ** 10 NFPA 110

No Air Temperature Signal Warning ]

No Coolant Temperature Signal

No Oil Pressure Signal

No Oil Temperature Signal Warning ]

Overcrank Shutdown 8, 10 OVER CRANK RDO-02

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Refer

Digital Display

10 LOCKED

10 LOSS OF ECM

10 SD LOSS OF

10 LOW COOLANT

10 OIL

10 MASTER NOT

10 NO AIR TEMP

10 NO COOL

10 NO OIL

10 NO OIL TEMP

ROTOR

COMM

FIELD

VOLTAGE

TEMP

SHUTDOWN

PRESSURE

SHUTDOWN

PRESSURE

WARNING

DUE

IN AUTO

SWITCH

ERROR

SWITCH TO

OFF

SWITCH OPEN

FAULT

SIGNAL

TEMP SIGNAL

PRESSURE

SIGNAL

Relay Driver

Output

(RDO)

RDO-26 * On Shutdown 4

RDO-12 (lead 62)

RDO-04 (lead 38)

RDO-07 (lead 41)

RDO-09 (lead 80)

RDO-10 (lead 32)

(lead 12)

Alarm

Horn

On Shutdown

Off Warning 10--12.5 V (12 V)

On Shutdown

On Shutdown 30 5

On Warning 30

On Warning

and Not

In Auto

On Shutdown

and Not

in Auto

On Shutdown

On Warning 30 4

On Shutdown 30 4

On Warning 30 4

On Shutdown 0--6 Cycles 3 Cycles

Warning

Range SettingLamp

20--25 V (24 V)

Default

Selection

12 V (12 V) 24 V (24 V)

Inhibit

Time Delay (sec.)

0 10

Time

Delay

(sec.)

TP-6200 10/1228 Section 1 Specifications and Features

Page 29

Factory-Defined Settings

Status Event or Fault

Overcurrent 10 OVER

Over Current PR Shutdown w

Overfrequency Shutdown

Over Power Shutdown w

Overspeed Shutdown

Overvoltage Shutdown

Password (see Access Code)

Pre Lube Relay ]

Remote Reset (see D16)

Remote Shutdown (see D15)

Reverse Power Shutdown w

Speed Sensor Fault 10 SPEED

Starting Aid (see Time Delay Starting Aid)

System Ready 10 RDO-17

Time Delay Engine Cooldown (TDEC)

Time Delay Engine Start (TDES)

Time Delay Starting Aid

Underfrequency 7, 10 UNDER

Undervoltage Shutdown

Variable Speed Governor (VSG) (see A06)

VAR/PF Mode (see D17)

Voltage Lower (see D18)

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Refer

Digital Display

CURRENT

10 SD OVER

CURRENT PR

7, 10 OVER

7, 10 OVER SPEED RDO-01

8, 10 DELAY ENG

8, 10 Off 0--10 sec.

FREQUENCY

10 SD OVER

7, 8,

10 PRE LUBE

10 SD REVERSE

7, 8,

POWER

OVER

VOLTAGE

RELAY

POWER

SENSOR

FAULT

COOLDOWN

START

FREQUENCY

UNDER

VOLTAGE

Relay Driver

Output

(RDO)

RDO-28 On Shutdown 102%-- 140% 110% Std.

(lead 39)

RDO-20 (lead 26)

RDO-26 ]

RDO-24 On Warning

(lead 60)

RDO-16

(lead 70C)

RDO-29 ]

RDO-27 On Shutdown 70%-- 95% 85%

Alarm

Horn

On Warning 110% 10

On Shutdown

On Shutdown 102%

On Shutdown 65--70 Hz (60 Hz)

On Shutdown 105%--135%

On Shutdown

Off System

Ready

Off 00:00--10:00

Off 00:00--5:00

On Shutdown 80%--97% 97% FAA

Range SettingLamp

55--70 Hz (50 Hz)

of nominal

min:sec

Default

Selection

103% FAA

Stdby

112% Prime

70 (60 Hz) 70 (50 Hz)

115%

2-sec time

delay[

135%

10-sec time

delayw

5:00

00:01

90%[ 80%w

10-sec time

delay[

70%

30-sec time

delayw

Inhibit

Time Delay (sec.)

Time

Delay

(sec.)

0.25

2--10

5--30

TP-6200 10/12 29Section 1 Specifications and Features

Page 30

Factory-Defined Settings

Status Event or Fault

Voltage Raise (see D19)

Weak Battery 10 WEAK

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC ] Waukesha-powered models ]] FAA only w Paralleling applications

Calibration

Voltage Adjustment 11 VOLT ADJ ±10% of system voltage—

Underfrequency Unload Frequency Setpoint

Underfrequency Unload Slope

Reactive Droop 11 VOLTAGE

VAR Control 11 KVAR ADJ 0 to rated kVAR generating

Power Factor (PF) Adjust Control

Controller Gain 11 REGULATOR

VAR/PF Gain or Utility Stability

Refer

Digital Display

BATTERY

Refer to

11 FREQUENCY

11 SLOPE 0--10% of rated voltage

11 PF ADJ 0.7 to 1.0 leading

11 VAR/PF GAIN 1--10000 100

Digital Display Range Setting Default Selection

Relay Driver

Output

(RDO)

SETPOINT

DROOP

GAIN

Alarm

Horn

Off Warning 60% of

Ver sio n 2.10

±20% of system voltage—

Version 2.11 or higher

40 to 70 Hz 1 Hz below system frequency (ECM)

volts per cycle

0--10% of system voltage 4% of system voltage

0 to 35% of rated kVAR absorbing

0.6 to 1.0 lagging

1--10000 100

Range SettingLamp

2 Hz below system frequency (non-ECM)

Default

Selection

nominal

System voltage

3.1% of system voltage

0.8 lagging

Inhibit

Time Delay (sec.)

Time

Delay

(sec.)

Figure 1-13 Settings for Controller Internal Voltage Regulation

1.3.2 Voltage Regulator and Calibration Specifications

Voltage Adjustment. The voltage adjustment allows theusertoenter the desired generator set output level.

This regulated level setting is the average of the three The 550 controller has a voltage regulation function that is internal to the processor. This means that no external

line-to-line voltages in three-phase configurations or

L1-to-L2 in single phase configurations. voltage regulator is necessary. The voltage regulation of the controller uses root mean square (rms) sensing for fast response to changes in indicated and regulated voltages resulting in excellent regulation accuracy.

Submenus display the individual line-to-line voltages.

These voltages are for reference only and are relevant in

unbalanced load conditions. The voltage adjust setpoint

can be changed to accommodate an important phase in RMS voltage regulation is available for both paralleling

an unbalanced system. and utility application to control changes in the reactive loads due to load changes, prime mover speed variation, thermal drift, and other variations. See Figure 1-13 for data on the 550 controller voltage regulation. Refer to Appendix C to customize adjustments for specific applications.

Underfrequency Unload Frequency Setpoint. This

adjustment affects the voltage droop (volts per Hz) when

load is applied and underfrequency occurs. The

underfrequency unload setting defines the setpoint

where underfrequency starts. Any frequency below the

setpoint causes the voltage to drop thus reducing the

load allowing the engine speed to recover according to

1.3.3 Voltage Regulator Adjustments

the underfrequency unload slope setting.

The descriptions of the voltage regulator adjustments and features follow. See Appendix C, Voltage Regulator Definitions and Adjustments, for additional information.

TP-6200 10/1230 Section 1 Specifications and Features

Page 31

Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions. The underfrequency unload setting should match the engine speed recovery characteristics for the application.

Underfrequency Unload Slope. This setting determines how much the voltage drops during an underfrequency condition. Typically, applying a large electrical load causes a dip in engine speed and frequency. The voltage regulator reduces voltage, allowing engine speed recovery. The volts-per-Hz setting determines the amount of voltage drop.

Reactive Droop. Reactive droop compensation provides reactive current flow adjustment in the generator set during generator set-to-generator set paralleling applications. Reactive droop reduces excitation levels with increasing reactive current. A reduced excitation level reduces generator set reactive current or generated VARs, improving reactive load sharing.

Enter the gain setting as a percentage of system voltage when full-rated load with 0.8 power factor is applied. Any loads less than full load force the voltage to drop by the ratio of reactive volt-amps (VARs) to rated VARs.

Regulator Gain. Regulator gain refers to the gain of the

control system. Generally, the higher the gain the faster

the system responds to changes and the lower the gain,

the more stable the system.

If the voltage is slow the recover when loads are applied

or removed, increase the regulator gain. If the voltage is

unstable, decrease the regulator gain. Regulator gain is

active only while not in the VAR/PF mode.

VAR/PF Gain. The VAR/PF gain also refers to the gain

of the control system. Unlike the regulator gain, the

response and stability of the system refers to the

reactive current, or more specifically the VARs and/or

power factor.

If the system is slow to recover to the desired VAR or PF

setting, increase the VAR/PF gain. If the VARs or PF of

the system is unstable, decrease the VAR/PF gain.

Because VAR/PF stability can be effected by the prime

mover (engine), VAR/PF gain adjustments should be

coordinated with the load sharing adjustment.

Analog Voltage Adjust. Use Menu 11 to enable or

disable analog voltage adjust. Analog voltage adjust is

commonly used for active control of voltage by some

external equipment in certain applications, like

synchronizing.

VAR Control. VAR control is used in some utility paralleling applications. The excitation is regulated to maintain the reactive load rather than output voltage. The VAR adjust setting determines what reactive load is maintained at the generator set output. The VAR adjust is the total reactive load (sum of three phases).

VAR control allows the user to define the direction of the reactive current out of the generator set (generating) or into the generator set (absorbing).

The utility supply, not the controller, determines terminal voltage. Engine fueling determines real power, measured in watts, using load sharing module control.

Power Factor (PF) Adjust Control. Power factor control is used in some utility paralleling applications. The excitation is regulated to maintain PF rather than output voltage. The PF adjustment setting determines what PF is maintained at the generator set output. PF adjustment is the average of three phases.

Power factor is defined as the ratio of real power (watts) over the volt-amps. Power factor can be calculated as the cosine of the electrical angle between current and voltage. The cosine function is positive for angles between --90° and +90° including zero; and is negative for angles between --90 and +90 including 180°. This adjustment requires the user to determine whether the current leads or lags the voltage.

Enabling analog voltage adjust allows slight adjustment

to the operating voltage by use of auxiliary analog input

#7. This input signal provides a bias to the voltage adjust

value. The range of input voltage is 0-- 5 VDC nominal

(0.1--4.9 actual). The corresponding range of bias is

±10% of nominal or system voltage. If the input voltage

is at the midpoint (2.5 volts), the bias is zero and the

voltage adjust value or regulation value will be equal to

the system voltage. Likewise, if the input voltage is out of

range (below 0.1 volt or above 4.9 volts), the bias will be

zero. For every 1 volt of input voltage, the operating

voltage will vary 4%; this satisfies the nominal ratio of

±10% output voltage for 0--5 volts input.

When analog voltage adjust is enabled, the description

shown for Auxiliary Analog Input 7 is Analog Volt Adjust.

Enable analog voltage adjust via KNET or MODBUS by

setting the description for Analog Input 7 as Analog Volt

Adjust.

Analog voltage adjust may be enabled only when the

master switch is in the OFF/RESET or AUTO positions

and while the generator is not running.

TP-6200 10/12 31Section 1 Specifications and Features

Page 32

Notes

TP-6200 10/1232 Section 1 Specifications and Features

Page 33

Section 2 Operation

2.1 Prestart Checklist

To ensure continued satisfactory operation, perform the following checks or inspections before or at each startup, as designated, and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.

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

Air Inlets. Check for clean and unobstructed air inlets.

Battery. Check for tight battery connections. Consult

the battery manufacturer’s instructions regarding battery care and maintenance.

Controller. After reconnecting the battery, set the controller time and date. See Section 2, Menu 14— Programming Mode On and Menu 6—Time and Date.

Coolant Level. Check the coolant level according to the cooling system maintenance information.

Note: Block Heater Damage. The block heater will fail

if the energized heater element is not immersed in coolant. Fill the cooling system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system before energizing the block heater.

Drive Belts. Check the belt condition and tension of the radiator fan, water pump, and battery charging alternator belt(s).

Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.

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

D Check for corroded or broken metal parts and replace

them as needed.

D Check for loose, corroded, or missing clamps and

hangers. Tighten or replace the exhaust clamps and/or hangers as needed.

D Check that the exhaust outlet is unobstructed.

D Visually inspect for exhaust leaks (blowby). Check for

carbon or soot residue on exhaust components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.

Fuel Level. Check the fuel level and keep the tank(s) full

to ensure adequate fuel supply.

Oil Level. Maintain the oil level at or near, not over, the

full mark on the dipstick.

Operating Area. Check for obstructions that could

block the flow of cooling air. Keep the air intake area

clean. Do not leave rags, tools, or debris on or near the

generator set.

2.2 Exercising Generator Set

Operate the generator set under load once each week

for one hour. Perform the exercise in the presence of an

operator when the generator set does not have a

programmed exercise mode or an automatic transfer

switch with an exercise option.

During the exercise period apply a minimum of 35% load

based on the nameplate standby rating, unless

otherwise instructed in the engine operation manual.

The operator should perform all of the prestart checks

before starting the manual exercise procedure. Start the

generator set according to the starting procedure in

Section 2.3, Controller Operation. While the generator

set is operating, listen for a smooth-running engine and

visually inspect generator set for fluid or exhaust leaks.

The generator set exercise time can be programmed for

a one-time exercise period. See Menu 4—Operational

Records. The generator set controller does not provide

weekly scheduled exercise periods. For scheduled

exercise periods, refer to the automatic transfer switch

(if equipped) literature.

2.3 Controller Operation

2.3.1 Starting

Local Starting

Move the generator set master switch to the RUN

position to start the generator set at the controller.

Note: The alarm horn sounds and the Not-In-Auto lamp

lights whenever the generator set master switch is not in the AUTO position.

Note: The transient start/stop function of the controller

prevents accidental cranking of the rotating engine. The generator set stops and recranks when the generator set master switch is momentarily placed in OFF/RESET position and then returned to RUN.

TP-6200 10/12 33Section 2 Operation

Page 34

Auto Starting

Run Time Feature

Move the generator set master switch to the AUTO position to allow startup by the automatic transfer switch or remote start/stop switch (connected to controller terminals 3 and 4).

Terminals 3 and 4 connect to a circuit that automatically starts the generator set crank cycle when an external source closes the circuit.

Note: The controller provides up to 30 seconds of

programmable cyclic cranking and up to 60 seconds rest with up to 6 cycles. The default setting is 15 seconds cranking and 15 seconds rest for 3 cycles. Make cyclic cranking adjustments using the keypad. See Section 2.8.14, Menu 14—Programming Mode, and Section 2.8.8, Menu 8—Time Delays.

Idle (Speed) Mode Warmup and Cooldown Function

The idle (speed) mode function provides the ability to start and run the engine at reduced speed for a selectable time period (0--10 minutes) during warmup. See Section 6.1.5, Idle (Speed) Mode Feature, for installation information.

The controller will override the idle speed mode when the engine reaches the preprogrammed engine warm-up temperature before the idle mode times out.

The idle function also provides engine cooldown at idle speed. The controller overrides the idle speed mode when the engine reaches the preprogrammed engine cooldown temperature before the idle mode times out.

During the idle (speed) mode the controller continues to monitor critical engine parameters such as oil pressure, coolant temperature, and engine speed. The voltage regulator, thermal protection feature, and AC metering are disabled in the idle speed mode.

The run time feature allows the user to set up the

generator set to run unassisted and automatically return

to the standby mode. The user does not need to wait for

the exercise period (run time) to conclude in order to

place the unit back in the standby mode. See

Menu 4—Operational Records for setup of this feature.

With the run time enabled, the generator set will begin to

crank and run based on the run time period and all

previously established time delays from Menu 8—Time

Delays.

Generator Set Connected to an Automatic Transfer

Switch. Should a utility power failure occur while the

unit is in the run time mode, the controller will bypass the

run time mode and function in the standby (backup)

mode. When the utility power returns, the generator set

continues to run for the duration of the run time period

when not timed out.

Note: Press the STOP PROG RUN key, when

necessary, to stop the generator set when it is in the run time mode.

Prime Power Switch

The digital controller has an optional prime power mode

of operation. The prime power mode requires

installation of an optional prime power switch kit. See

Section 6, Accessories, for instructions on how to install

the optional prime power switch kit. The prime power

switch kit prevents engine starting battery drain when

the generator set is shut down and no external battery

charging is available.

Move the prime power switch located on the back of the

controller to the CONTROLLER ON position and set the

controller time and date before attempting to start the

generator set. When the prime power mode is off, all

controller functions including the digital display, LEDs,

and alarm horn are operative.

The controller overrides the idle speed function when the generator set is signaled to start while in the AUTO position. This override provides emergency generator set power in the event of a utility power failure. When the utility power returns and the generator set is signalled to stop, the generator set continues to run for the duration of the idle mode period when the idle mode is active. When the idle mode is not active, the generator set will shut down in the normal stopping mode including time delays.

See Menu 9—Input Setup to activate the idle speed function as a user-defined digital input. The idle speed feature requires an ECM-equipped engine with the idle speed function.

Note: After energizing the controller using the prime

power switch, set the controller time and date. See Section 2.8.6, Menu 6—TIme and Date.

Stop the generator set using the stopping procedures in

Section 2.3.2 before placing the generator set in the

prime power mode. Move the prime power switch

located on the back of the controller to the

CONTROLLER OFF position. When the generator set

is is the prime power mode, all controller functions

including the digital display, LEDs, alarm horn, and

communications are inoperative.

TP-6200 10/1234 Section 2 Operation

Page 35

2.3.2 Stopping (User Stopping and

Fault Shutdown)

See Section 2.8.8, Menu 8—Time Delays, for

information on how to enable the cooldown temperature

override feature.

Normal Stopping

Run the generator set without load for 5 minutes to ensure adequate engine cooldown.

The controller has a programmable cooldown timer that functions only when the master switch is in the AUTO position. To stop the generator set, place the generator set master switch in the OFF/RESET position and wait until the generator set comes to a complete stop.

Note: The cooldown cycle times out before the

generator set stops when a remote switch or automatic transfer switch initiates the generator set start/stop sequence.

Emergency Stopping

Use the controller emergency stop switch or optional remote emergency stop for immediate shutdown.

The emergency stop switch bypasses the time delay engine cooldown and immediately shuts down the generator set.

Note: Use the emergency stop switch(es) for

emergency shutdowns only. Use the generator set master switch for normal shutdowns.

The controller system shutdown lamp lights and the unit shuts down when the local or remote emergency stop switch activates.

Battle Switch/Fault Shutdown Override Switch

The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown. When the battle switch function is enabled the generator set continues to run regardless of shutdown signals where potential engine/alternator damage can occur.

When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5— Event History.

See Section 2.8.9, Menu 9—Input Setup, for information on how to enable the battle switch feature.

Cooldown Temperature Override Function. This feature provides the ability to bypass (override) the generator set’s smart cooldown temperature shutdown and force the generator set to run for the full engine cooldown time delay.

2.3.3 Emergency Stop Switch Resetting

Use the following procedure to reset the generator set

after shutdown by a local or remote emergency stop

switch. Refer to Section 2.3.7, Controller Reset

Procedure, to restart the generator set following a fault

shutdown.

1. Place the generator set master switch in the OFF/RESET position.

2. Investigate and correct the cause of the emergency stop.

3. Reset the optional remote emergency stop switch by replacing the glass piece, when equipped. Additional glass rods are available as a service part. Reset the controller emergency stop switch by pulling the switch knob outward.

4. After resetting all faults using the controller reset procedure in Section 2.3.7, toggle the generator set master switch to RUN or AUTO to restart the generator set. The generator set will not crank until the reset procedure completes.

2.3.4 Status Lamps

System Ready. The green lamp illuminates when the generator set master switch is in the AUTO position and the system has no fault conditions.

Not in Auto. The yellow lamp illuminates when the generator set master switch is not in the AUTO position. See Master (Switch) Not in Auto in 2.3.5 System Warning Lamp.

2.3.5 System Warning Lamp

The yellow warning lamp illuminates indicating a fault or status event but does not shut down the generator set under the following conditions. In some cases the alarm horn also sounds. See Section 2.3.7, Controller Reset Procedure, for instructions on resetting a system warning.

When the system warning lamp is on and no message displays, press the Reset Menu and the menu down ↓ key to view messages. When the system warning continues, it may lead to a fault and cause a system shutdown.

Use the Alarm Off keypad switch to silence the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the master switch is in the AUTO position.

TP-6200 10/12 35Section 2 Operation

Page 36

Note: Text shown in italics in this manual represents

digital display messages.

AC Sensing Loss. The lamp illuminates when the controller does not detect nominal generator set AC output voltage after crank disconnect. The local display shows AC sensing loss.

Battery Charger Fault. The lamp illuminates when the battery charger malfunctions. This fault feature requires an optional battery charger with a malfunction output for the lamp to function. Local display shows bat chgr fault .

Battle Switch. The lamp illuminates when in the battle switch mode. The local display shows battle switch.

Breaker Closed. The lamp illuminates when the respective circuit breaker is closed. The local display shows breaker closed. (Paralleling applications only.)

Breaker Trip. The lamp illuminates when the respective circuit breaker is tripped. The local display shows breaker trip. (Paralleling applications only.)

Emergency Power System (EPS) Supplying Load.

The lamp illuminates when the generator set supplies more than 1% of the rated standby output current. The local display shows EPS supplying load.

Ground Fault Detected. The lamp illuminates and the alarm horn sounds when a user-supplied ground fault detector signals the controller. The local display shows ground fault.

High Battery Voltage. The lamp illuminates when the battery voltage rises above the preset level for more than 10 seconds. The local display shows high battery voltage. Figure 2-1 shows high battery voltage specifications. The high battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes.

Engine Electrical

System Voltage

12 14.5--16.5 16

24 29--33 32

High Battery

Voltage Range

High Battery Voltage

Default Setting

Common Protective Relay Output. The lamp illuminates when a common protective relay fault occurs. The local display shows common pr output. (Paralleling applications only.)

Customer Auxiliary (Warning). The lamp illuminates and the alarm horn sounds when an auxiliary digital or analog inputs signals the controller. The user can define inputs as shutdowns or warnings. The local display shows digital input D01-D21 or analog input A01-A07.

Using the remote communications package, the user can label the auxiliary functions. The controller displays the selected name instead of digital input D01-D21 or analog input A01-A07.

Defined Common Faults. The lamp illuminates and the alarm horn sounds when one or more of the (user-selected) defined common faults are energized. The local display shows defined common fault.

Detonation Warning. The lamp illuminates and the alarm horn sounds when the engine detects combustion system detonation. The local display shows deton warning. (Waukesha-powered models only.)

ECM Yellow Alarm. The lamp illuminates and the alarm horn sounds when ECM yellow alarm signals the controller. The local display shows ECM yellow alarm. This fault only relates to the DDC/MTU engine with MDEC/ADEC. The user can navigate the menus to access the fault code. The engine operation manual provides the fault code descriptions.

Figure 2-1 High Battery Voltage Specs

High Coolant Temperature Warning. The lamp

illuminates and the alarm horn sounds when the engine coolant temperature approaches the shutdown range. The local display shows hi cool temp warning.

High Oil Temperature Warning. The lamp illuminates and the alarm horn sounds when the engine high oil temperatuare approaches the shutdown range. The local display shows hi oil temp warning (DDC/MTU models with MDEC/ADEC and Waukesha-powered models only).

Idle (Speed) Mode. The lamp illuminates when in the idle (speed) mode. The local display shows idle mode

active.

Intake Air Temperature Warning. The lamp illuminates and the alarm horn sounds when the engine intake air temperature approaches the shutdown range. The local display shows intake air temp warn (DDC/MTU models with MDEC/ADEC) and 03 intake air temp warn (Waukesha-powered models).

Load Shed. The lamp illuminates when the generator set’s total kW load exceeds the programmed level for more than the load shed time. When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp circuit latches and remains on until the generator set shuts down. The local display shows load shed kW over.

TP-6200 10/1236 Section 2 Operation

Page 37

When the generator set frequency drops to less than 59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system for more than 5 seconds, the local display shows load shed under freq. When the load shed alarm sounds and resets more than twice in 1 minute, the load shed warning lamp latches and remains on until the generator set shuts down.

Low Battery Voltage. The lamp illuminates when the battery voltage drops below a preset level for more than 10 seconds. The local display shows low battery voltage. See Figure 2-2 for low battery voltage specifications.

Engine Electrical

System Voltage

12 10--12.5 12

24 20--25 24

Low Battery

Voltage Range

Low Battery Voltage

Default Setting

Figure 2-2 Low Battery Voltage Specs

The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes. The controller logic inhibits the low battery voltage warning during the crank cycle.

Low Coolant Temperature. The lamp illuminates and the alarm horn sounds when the engine coolant temperature is low. The local display shows low coolant

temp.

Low Fuel (Level or Pressure) Warning. The lamp illuminates and the alarm horn sounds when the fuel tank level on gasoline or diesel models approaches empty or low fuel pressure on gaseous fueled models occurs. This fault requires an optional low fuel switch for the lamp to function. The local display shows low fuel warning.

NFPA 110 Fault. The lamp illuminates and the alarm horn sounds when NFPA 110 faults signal the controller. The local display shows the respective fault message. The NFPA 110 faults (W

D Air damper indicator (Factory-Reserved D20) (S) D Battery charger fault (Factory-Reserved D01) (W) D EPS supplying load (W) D High battery voltage (W) D High coolant temperature (W) D High coolant temperature (S) D Low battery voltage (W) D Low coolant level (Factory-Reserved D14) (S) D Low coolant temperature

arning/Shutdown) include:

(Factory-Reserved D03) (W)

D Low fuel (level or pressure)

(Factory-Reserved D02) (W)

D Low oil pressure (W) D Low oil pressure (S) D Master switch not in auto (W) D Overcrank (S) D Overspeed (S)

No Air Temperature Signal. The lamp illuminates and the alarm horn sounds when the air temperature sender circuit is open. The local display shows no air temp signal. (Waukesha-powered models only.)

No Oil Temperature Signal. The lamp illuminates and the alarm horn sounds when the oil temperature sender circuit is open. The local display shows no oil temp signal. (Waukesha-powered models only.)

Oil Temperature. The lamp illuminates and the alarm horn sounds when oil temperature approaches the shutdown range. The local display shows oil temp. (Waukesha-powered models only .)

(Low) Oil Pressure Warning. The lamp illuminates and the alarm horn sounds when the engine oil pressure approaches the shutdown range. The local display shows oil press warning.

Master (Switch) Not in Auto. The lamp illuminates and the alarm horn sounds when the generator set master switch is in the RUN or OFF/RESET position. The local display shows master not in auto. The Not in Auto lamp will also illuminate.

Overcurrent. The lamp illuminates and the alarm horn sounds when the generator set supplies more than 110% of the rated standby output current for more than 10 seconds. The local display shows overcurrent.

Speed Sensor Fault. The lamp illuminates and the alarm horn sounds when the speed signal is absent for one second while the generator set runs. The local display shows speed sensor fault. This warning lamp remains on until the operator places the master switch in the OFF/RESET position.

Weak Battery. The lamp illuminates when the battery voltage falls below 60% of the nominal voltage (12 VDC or 24 VDC) for more than 2 seconds during the crank cycle. The local display shows weak battery.

TP-6200 10/12 37Section 2 Operation

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2.3.6 System Shutdown Lamp

The red lamp illuminates, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the following conditions. See Section 2.3.7, Controller Reset Procedure, for information on resetting a system shutdown.

Use the Alarm Off keypad switch to silence the alarm horn at the operator’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn will not stop sounding unless the master switch is in the AUTO position.

Note: The text shown in italics represents digital display

messages.

Air Damper Indicator. The lamp illuminates and the unit shuts down when signaled by a closed air damper circuit. The local display shows air damper indicator.

Air/Fuel Module. The lamp illuminates and the unit shuts down when the controller detects a fault with the air/fuel module. The local display shows afm shutdown . (Waukesha-powered models only .)

Alternator Protection. The lamp illuminates and the unit shuts down because of an alternator overload or short circuit. The local display shows altrntr protect sdwn. See Appendix D, Alternator Protection for more information.

Critical Overvoltage. The lamp illuminates and the unit shuts down when the voltage exceeds 275 volts. The local display shows critical overvoltage.

For voltages configurations of 240 volts and less,the critical voltage shutdown monitors nominal voltage line-to-line. For voltage configurations greater than 240 volts and less than 600 volts, the critical voltage shutdown monitors nominal voltage line-to-line with a center tap connection. For voltage configurations of 600 volts and above, the critical voltage shutdown monitors nominal voltage with a stepdown transformer in the 208--240 voltage range.

Customer Auxiliary (Shutdown). The lamp illuminates and the unit shuts down when an auxiliary digital or analog input signals the controller. The user can define inputs as shutdowns or warnings. The local display shows digital input D01-D21 or analog input A01-A07 when activated.

Defined Common Faults. The lamp illuminates and the unit shuts down when one or more of the (user-selected) defined common faults are energized. The local display shows defined common fault.

Detonation Shutdown. The lamp illuminates and the unit shuts down when the controller detects combustion system detonation. The local display shows deton shutdown. (Waukesha-powered models only.)

ECM Red Alarm. The lamp illuminates and the unit shuts down when the controller receives a signal from the engine. The local display shows ECM red alarm. This fault only relates to the DDC/MTU engine with MDEC/ADEC. The user can navigate the menus to access the fault code. The engine operation manual provides the fault code descriptions.

EEPROM Write Failure. The lamp illuminates and the unit shuts down when the control logic detects a data save error. The local display shows EEPROM write

failure.

(Engine) J1939 CAN Shutdown. The lamp illuminates and the unit shuts down when the control logic detects an engine ECM communication signal interruption. The local display shows J1939 CAN shutdown.

Engine Stalled. The lamp illuminates and the unit shuts down when the control logic detects an engine ECM signal that the engine has stalled. The local display shows engine stalled and no attempts to restart the engine will occur.

Emergency Stop. The lamp illuminates and the unit shuts down when the local or optional remote emergency stop switch activates. The local display shows emergency stop.

Field Overvoltage. The lamp illuminates and the unit shuts down when the controller detects field overvoltage. The local display shows field over volts. (350--2000 kW generator sets only)

High Coolant Temperature Shutdown. The lamp illuminates and the unit shuts down because of high engine coolant temperature. The shutdown occurs 5 seconds after the engine reaches the temperature shutdown range. The high engine temperature shutdown does not function during the first 30 seconds after startup. The local display shows hi cool temp shutdwn.

Using the remote communications package, the user can label the auxiliary functions. The controller displays the selected name instead of digital input D01-D21 or analog input A01-A07.

Note: The high engine temperature shutdown function

and the low coolant level shutdown function are independent. A low coolant level condition may not activate the high engine temperature switch.

TP-6200 10/1238 Section 2 Operation

Page 39

High Oil Temperature. The lamp illuminates and the unit shuts down because of high engine oil temperature. The shutdown occurs 5 seconds after the engine oil reaches the temperature shutdown range. The high engine oil temperature shutdown does not function during the first 30 seconds after startup. The local display shows high oil temp sdwn.

Intake Air Temperature. The lamp illuminates and the unit shuts down because of high intake air temperature. The shutdown occurs 5 seconds after the engine intake air reaches the temperature shutdown range. The engine intake air temperature shutdown does not function during the first 30 seconds after startup. The local display shows intake air temp shutdown (DDC/MTU models with MDEC/ADEC) and 03 intake air temp shutdown (Waukesha-powered models).

Internal Fault. The lamp illuminates and the unit shuts down when the internal diagnostics detect a controller malfunction. The local display shows internal fault.

Knock Shutdown. The lamp illuminates and the unit shuts down when the controller detects a detonation fault. The local display shows knock shutdown. (Waukesha-powered models only .)

Locked Rotor. If none of the speed sensing inputs show engine rotation within 5 seconds of initiating engine cranking, the ignition and crank circuits turn off for 5 seconds and the cycle repeats. The unit shuts down after the second cycle of 5 seconds of cranking. The local display shows locked rotor.

Loss of ECM Communications. The lamp illuminates and the unit shuts down when the ECM communication link is disrupted. The local display shows loss of ECM

comm.

Loss of Field (Reverse VARs). The lamp illuminates and the unit shuts down when the reactive current into the alternator (absorbing) exceeds the shutdown level. This could be caused by a disruption of the field signal. The local display shows sd loss of field. (Paralleling applications only.)

Low Coolant Level. The lamp illuminates and the unit shuts down because of low coolant level. Shutdown occurs 5 seconds after low coolant level is detected. Low coolant level shutdown is inhibited during the first 30 seconds after startup. Local display shows low coolant lvl.

Low Coolant Temperature. The lamp illuminates and the unit shuts down because of low coolant temperature. Shutdown occurs 5 seconds after low coolant temperature is detected. Low coolant temperature shutdown is inhibited during the first 30 seconds after startup. Local display shows low coolant temp shutdown. (DDC/MTU models with MDEC/ADEC only.)

Low Fuel (Pressure) Shutdown. The lamp illuminates and the unit shuts down when the controller detects a low fuel condition. The low fuel (pressure) shutdown does not function during the first 5 seconds after startup. The local display shows low fuel shdown. (125RZG only .)

(Low) Oil Pressure Shutdown. The lamp illuminates when the unit shuts down because of low oil pressure. The shutdown occurs 5 seconds after the low pressure condition is detected. The low oil pressure shutdown does not function during first the 30 seconds after startup. The local display shows (low) oil press shutdown.

Master Switch Error. The lamp illuminates and the unit shuts down when the controller detects a fault in the master switch position or circuit. The local display shows master switch error.

Master Switch Open. The lamp illuminates and the unit shuts down when the controller detects an open circuit in the master switch circuit. The local display shows master switch open.

Master Switch to Off. The lamp illuminates and the unit shuts down when the master switch is moved to the off position. The local display shows master switch to off.

NFPA 110 Fault. The lamp illuminates and the unit shuts down when NFPA 110 faults signal the controller. The local display shows the respective fault message. See Section 2.4, Menu List Summary, Menu 10—Output Setup, for the NFPA 110 list.

No Coolant Temperature Signal. The lamp illuminates and the unit shuts down when the engine coolant temperature sender circuit is open. The local display shows no cool temp signal.

No Oil Pressure Signal. The lamp illuminates and the unit shuts down when the engine oil pressure sender circuit is open. The local display shows no oil press

signal.

Overcrank. The lamp illuminates and cranking stops when the unit does not start within the defined cranking period. The local display shows overcrank. See Section 2.3.1, Auto Starting, and Section 1, Specifications and Features, for cyclic crank specifications.

Note: The controller is equipped with an automatic

restart function. When speed drops below 13 Hz (390 rpm) while the engine is running, the unit attempts to recrank. The unit then follows the cyclic cranking cycle and, when the engine fails to start, will shut down on an overcrank fault condition.

TP-6200 10/12 39Section 2 Operation

Page 40

Over Current VR Shutdown. The lamp illuminates and the unit shuts down when the controller detects an overcurrent fault with voltage restraint. The local display shows sd over current pr. (Paralleling applications only.)

Overfrequency. The lamp illuminates and the unit shuts down when the frequency is above the overfrequency setting. The local display shows overfrequency. See Figure 2-3.

Overfrequency Setting Range

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

Time Delay

Overfrequency Default Setting

Figure 2-3 Overfrequency Specs

Overpower. The lamp illuminates and the unit shuts

down when the controller detects a fault in the paralleling system. The shutdown is set at 102% for standby and 112% for prime power applications. The local display shows over power. (Paralleling applications only.)

Overspeed. The lamp illuminates and the unit shuts down immediately when the governed frequency on 50 and 60 Hz models exceeds the overspeed setting for

0.25 seconds. The local display shows overspeed. See Figure 2-4 for overspeed specs.

Generator

Set

Frequency Hz

60 0.25 sec. 65--70 70

50 0.25 sec. 55--70 70

Time Delay

Overspeed

Range Hz

Overspeed Default

Setting Hz

Figure 2-4 Overspeed Specs

Overvoltage. The lamp illuminates and the unit shuts

down when the voltage exceeds the overvoltage setting for the time delay period. The local display shows overvoltage. Overvoltage specifications follow. See Figure 2-5.

Note: Overvoltage can damage sensitive equipment in

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

Overvoltage

Setting

Range

105%--135%

of nominal

Time

Delay

Range

2--10 sec. 115% at 2 sec. 135% at 10 sec.

Default Setting

without

Paralleling

Overvoltage

Default Setting

with Paralleling

Figure 2-5 Overvoltage Specs

Reverse Power. The lamp illuminates and the unit

shuts down when the controller detects a reverse power condition. The reverse power relay senses AC power flow into the generator set. If the generator set is being feed power or being ”motored” by another generator set or the utility, the reverse power relay senses this AC power flow and opens the generator set circuit breaker. The local display shows sd reverse power. (Paralleling applications only.)

Underfrequency. The lamp illuminates and the unit shuts down when the frequency falls below the underfrequency setting. The local display shows underfrequency. See Figure 2-6.

Underfrequency

Underfreq.

Setting Ranger

80%--95% of nominal

Time

Delay

10 sec. 90% of nominal 80% of nominal

Default Setting

without

Paralleling

Underfrequency

Default Setting

with Paralleling

Figure 2-6 Underfrequency Specs

Undervoltage. The lamp illuminates and the unit shuts

down when the voltage falls below the undervoltage setting for the time delay period. The local display shows undervoltage. Undervoltage specifications follow. See Figure 2-7.

Undervoltage

Setting

Range

70%--95% of

nominal

Time Delay

Range

5--30 sec.

Default Setting

w-o/Parallelin

85% of nominal

at 10 sec.

Undervoltage

Default Setting

w/Paralleling

70% of nominal

at 30 sec.

Figure 2-7 Undervoltage Specs

TP-6200 10/1240 Section 2 Operation

Page 41

2.3.7 Controller Resetting (Following System Shutdown or Warning)

8. Move the generator set master switch to the AUTO position.

Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition. This procedure includes the resetting of the optional remote annunciator and the audiovisual alarm.

Refer to Section 2.3.3, Emergency Stop Switch Reset Procedure, to reset the generator set after an emergency stop.

1. Move the generator set master switch to the AUTO position, if not already done.

2. Silence the controller alarm horn by pressing the alarm off key.

When equipped, the optional remote annunciator and/or audiovisual alarm horn and lamp activate. Move the alarm switch to the SILENCE position to stop the alarm horn. The lamp stays lit.

3. Disconnect the generator set load using the line circuit breaker or automatic transfer switch.

4. Correct the cause of the fault shutdown or warning. See the Safety Precautions and Instructions section of this manual before proceeding.

5. Start the generator set by moving the generator set master switch to the OFF/RESET position and then to the RUN position.

When equipped, the remote annunciator and/or audiovisual alarm horn sounds when the alarm switch is in the NORMAL position. When necessary, move the alarm switch to the SILENCE position to stop the alarm horn. The lamp turns off.

6. Test operate the generator set to verify correction of the shutdown cause.

7. Move the generator set master switch to the OFF/RESET position to stop the generator set.

9. Silence the controller alarm horn by pressing the alarm off key.

10. Reconnect the generator set load via the line circuit breaker or automatic transfer switch.

11. Move the generator set master switch to the AUTO position for startup by the remote transfer switch or the remote start/stop switch.

When equipped, move the remote annunciator and/or audiovisual alarm switch to the NORMAL position.

2.4 Menu List Summary

Use the Menu List Summary section on the following pages after reading and understanding the features of the keypad. See Section 1.2.2, Digital Display and Keypad.

The Menu List Summary provides a quick reference to the digital display data. Some digital display data may not be identical to your display due to generator set application differences. The closed bullet items represent main level data and the open bullet items are sub-level data.

Section 2.7, Reviewing the Menu Displays, provides a digital display menu overview and explains the navigation using the down and right arrow keys.

Section 2.8, Local Programming Mode On, contains the keystroke details of each menu when programming.

User Inputs. Available user inputs are dependent on factory-reserved inputs for specific engine types, engine controls, and paralleling applications. See Figure 2-8 for analog and digital inputs that are not user-selectable.

TP-6200 10/12 41Section 2 Operation

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Specific Applications

Input Typ e

Analog Inputs

A1 X

A2 X Oil Pressure * X Oil Pressure * X X X

A3 X X X

A4 Fuel Level * Fuel Level * Fuel Level *

A5 X X X X X X X

A6 X X X X X X X (8) *

A7 (9) Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust

Digital Inputs

D1 X X Battery Charger Fault * X X X X

D2 X X Low Fuel Warning * X X X X

D4 X X X X X X X (1) *

D5 X X X X

D6 X X X X Enable Synch * X X

D7 X X X X X X X

D8 X X X X X X X

D9 X X X X X X X (2) *

D10 X X X X X X X

D11 X X X

D12 X X X

D13 X X X

D14 X X

D15 X X X X X X X (3) *

D16 X X X X X X X (4) *

D17 X X X X X X X (5) *

D18 X X X X X X X (6) *

D19 X X X X X X X (7) *

D20 X X Air Damper * X X X X

D21

(1) D4 is preassigned as Field Overvolts when using a Marathon M4/M5/M7/M10 alternator. (2) D9 is preassigned as Low Fuel Shutdown when using 125RZG (GM powered). (3) D15 is preassigned as Remote Shutdown. (4) D16 is preassigned as Remote Reset. (5) D17 is preassigned as VAR/PF mode. (6) D18 is preassigned as Voltage Lower. (7) D19 is preassigned as Voltage Raise. (8) A6 is preassigned as Variable Speed Governor (VSG) (Volvo, GM, and Doosan engines only) (9) A7 is default location, however the default function is not Analog Voltage Adjust; the function must be enabled. See Section 1.3.3. * Factory-reserved inputs that are fixed and not user-changeable.

ECM Engine

Low Coolant

Tem p .

Idle Mode

Active

Non-ECM

Engine

Coolant

Temperature *

X Low Coolant Temp.* X X X X

X X X X X X

NFPA 110

Low Coolant Level (with LCL Switch)*

Waukesha-

Powered

Engine

Coolant

Temperature *

Intake Air

Temperature *

Oil

Temperature

Warning *

AFM

Shutdown *

Deton

Warning *

Deton/Knock

Shutdown *

X X X X

with Menu 15

(Paralleling

Application)

X X X

Fuel Level * Fuel Level * Fuel Level *

Breaker Closed *

X X X

DDC/MTU

Engine with

MDEC/ADEC

X X

Other Specialized Application

Figure 2-8 User Inputs (X) and Factory-Reserved Inputs (as shown)

TP-6200 10/1242 Section 2 Operation

Page 43

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

Menu 1 Generator Monitoring

Volts & Amps

D L1-L2 Volts

L1 Amps

D L2-L3 Volts

L2 Amps (3 phase)

D L3-L1 Volts

L3 Amps (3 phase)

D L1-L2 Volts

L2 Amps (1 phase)

D L1-L0 Volts

L1 Amps

D L2-L0 Volts

L2 Amps

D L3-L0 Volts

L3 Amps (3 phase)

D Frequency

V&ASummary

D V L1-L2, L2-L3, L3-L1

(3 phase)

D V L1-L0, L2-L0, L3-L0

(3 phase)

D A L1, L2, L3 (3 phase) D V L1-L2, L1-L0, L2-L0

(1 phase)

D A L1, L2 (1 phase)

Power kW

D To ta l k W

Power Factor

D L1 kW

Power Factor

D L2 kW

Power Factor

D L3 kW

Power Factor (3 phase)

D To ta l k W

% of Rated kW

Power kVAR

D To ta l k VAR

Absorbing/Generating

D L1 kVAR

Absorbing/Generating

D L2 kVAR

Absorbing/Generating

D L3 kVAR

Absorbing/Generating (3 phase)

Power kVA

D To ta l k VA D L1 kVA D L2 kVA D L3 kVA (3 phase)

Menu 2 Engine Monitoring

Engine Monitoring Basic

D Oil Pressure

Coolant Temperature

D Intake Air Temperature

Oil Temperature (DDC/MTU engine with MDEC/ADEC and Waukesha engine only)

D Engine RPM

Local Battery VDC

D High Coolant

Temperature Shutdown and Warning Setpoints

D Low Oil Pressure

Shutdown and Warning Setpoints

D Engine Warmup

Temperature Setpoint

D Engine Cooldown

Temperature Setpoint

Engine Monitoring Detailed (DDEC/JDEC/ EMS2/EDC3 equipped engines only)

Engine Fuel

D Fuel Pressure

Fuel Temperature

D Charge Air Pressure

Charge Air Temperature

D Fuel Rate D Used Last Run

Engine Coolant

D Coolant Pressure

Coolant Temperature

D Coolant Level

Engine Oil

D Oil Pressure

Oil Temperature

D Oil Level

Crankcase Pressure

Engine Misc

D ECM Battery VDC

Ambient Temperature

D Engine Model No. D Engine Serial No. D Unit No.

ECM S/N

D ECM Fault Codes

Menu 2 Engine Monitoring, cont.

Engine Monitoring Detailed (MDEC/ADEC equipped engines only)

Engine Fuel

D Fuel Pressure

Fuel Temperature

D Charge Air Pressure

Charge Air Temperature

D Fuel Rate D Daily Fuel Used D Total Fuel Used

Engine Oil

D Oil Pressure

Oil Temperature

Engine Misc

D ECU Supply VDC

Ambient Temperature

D ECU Hours D ECU Fault Codes

Menu 3 Analog Monitoring

D Local Batt VDC D Analog 01 to 07 (user-

defined descriptions) (Scroll through 7 userdefined descriptions. See Figure 2-8 in User Inputs for factory-reserved inputs that are not userselectable.)

Non-ECM Engines

D A03--A07 User-Defined

ECM Engines

D A01 Coolant Temperature D A02 Oil Pressure D A03--A07 User-Defined D A06 VSG (Doosan, GM,

Volvo only)

Waukesha Engines

D A05--A07 User-Defined

Menu 4 Operational Records

D Factory Test Date D To ta l R u n Ti m e D To ta l R u n Ti m e

Loaded Hours

D To ta l R u n Ti m e

Unloaded Hours

D To ta l R u n Ti m e

kW Hours

D No. of Starts D Engine Start Countdown

d Run Time

D Records-Maintenance

d Reset Records

D Run Time Since Maintenan

Total Hours

D Run Time Since Maintenan

Loaded Hours

D Run Time Since Maintenan

Unloaded Hours

D Run Time Since Maintenan

kW Hours

D Operating Days

Last Maintenance

D No. of Starts

Last Maintenance

D Last Start

Date

D Length of Run

(Un)loaded Hours

Menu 5 Event History

D (Message Text) D (Scroll through up to 100

stored events)

Menu 6 Time and Date

D Time 00:00 AM/PM D Date

TP-6200 10/12 43Section 2 Operation

Page 44

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

Menu 7 Generator System

D Operating Mode

d Standby Y/N d Prime Power N/Y

D System Voltage

Line-Line

D System Frequency D Phase

d 3-Phase Delta Y/N d 3-Phase WYE N/Y

d 1-Phase N/Y D kW Rating D Rated Current D Load Shed Output

d Time Delay D Overvoltage

d Time Delay D Undervoltage

d Time Delay D Overfrequency D Underfrequency D Overspeed D Battery Voltage

d 12 VDC Y/N

d 24 VDC N/Y D Low Battery Voltage D High Battery Voltage D Block Heater ON D Block Heater OFF [ D Enable VSG Y/N [ D Enable DSC [ D Metric Units Y/N D Set NFPA110 Defaults Y/N

[ DDC/MTU engine

w/MDEC/ADEC only

[

Menu 8 Time Delays

D Time Delay

Engine Start D Time Delay

Starting Aid D Time Delay

Crank On D Time Delay

Crank Pause D Time Delay

Eng. Cooldown D Cooldown Temperature

Override Y/N D Overcrank Shutdown

Crank Cycles D Time Delay

Overvoltage D Time Delay

Undervoltage D Time Delay

Load Shed kW

Menu 9 Input Setup

Setup Digital Auxiliary Inputs

D Digital Input

(Scroll through up to 21 user-defined descriptions. See Figure 2-8 in User Inputs for factory-reserved inputs that are not userselectable.)

D Digital Input

Message Text Y/N, see Group A

Group A Preprogrammed

selections include the following:

Warning Shutdown Type A Shutdown Type B Voltage Raise Voltage Lower VAR PF Mode Remote Shutdown Remote Reset Air Damper Low Fuel Field Overvoltage Idle Mode Active

(ECM engines only) Battle Switch Ground Fault Bat Chgr Fault High Oil Temperature

(non-ECM only) Low Coolant Level Low Coolant Temperature

(Not user-selectable) Breaker Closed, (Paralleling

non-selectable) Enable Synchronizer,

(Paralleling

non-selectable) Air/Fuel Module Shutdown* Knock Shutdown* Detonation Warning* Detonation Shutdown* Low Fuel Shutdown D Digital Input

Enable Y/N

D Digital Input

Inhibit TIme

D Digital Input

Delay Time

*Waukesha engine only

Menu 9 Input Setup, cont.

Setup Analog Auxiliary Inputs

D Analog Input

(Scroll through up to 7 user-defined descriptions. See Figure 2-8 in User Inputs for factory-reserved inputs that are not userselectable.)

D Analog Input

Warning Enabled Y/N

D Analog Input

Shutdown Enabled Y/N

D Analog Input

Inhibit Time 0--60 Sec.

D Analog Input

Warning Delay Time 0--60 Sec.

D Analog Input

Shutdown Delay Time 0--60 Sec.

D Analog Input

Low Shutdown Value

D Analog Input

Low Warning Value

D Analog Input

High Warning Value

D Analog Input

High Shutdown Value

Menu 10 Output Setup

Defined Common Fault

D Defined Common Fault

(Y/N for a single defined common fault) Scroll through status and fault choices from:

d System events,

see Group B (except Defined Common Fault)

d 21 digital inputs

D01-D21

d 7 analog inputs

A01--A07

Menu 10 Output Setup, cont.

Relay Driver Outputs (RDOs)

D RDOs (Y/N)

(Scroll through up to 31 status and fault choices from:

d System events,

see Group B

d 21 digital inputs

D01-D21

d 7 analog inputs

A01--A07

Group B System events include the following:

Emergency Stop Over Speed Overcrank High Cool Temp Shutdown Oil Pressure Shutdown Low Coolant Temperature

(non-ECM engines)

Low Fuel Warning Hi Cool Temp Warning Oil Pressure Warning Master Not in Auto NFPA 110 Fault

The 15 NFPA 110 Common

[

Fault Alarms include the following:

Over Speed Overcrank High Coolant Temperature

Shutdown Oil Pressure Shutdown Low Coolant Temperature High Coolant Temperature

Warning Oil Pressure Warning Low Fuel Master Not In Auto Battery Charger Fault Low Battery Voltage HIgh Battery Voltage Low Coolant Level EPS Supplying Load Air Damper Indicator

[

TP-6200 10/1244 Section 2 Operation

Page 45

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

Menu 10 Output Setup, cont.

Group B, continued

Low Battery Voltage High Battery Voltage Battery Charger Fault System Ready Loss of ECM Comm

(ECM engines)

No Oil Pressure Signal High Oil Temperature

Shutdown No Temperature Signal Low Coolant Level Speed Sensor Fault Locked Rotor Master Switch Error Master Switch Open Master Switch to Off AC Sensing Loss Over Voltage Under Voltage Weak Battery Over Frequency Under Frequency Load Shed kW Over Load Shed Under Freq Over Current EPS Supplying Load Internal Fault Delay Engine Cooldown Delay Engine Start Starting Aid Generator Set Running Air Damper Control Ground Fault EEPROM Write Failure Critical Overvoltage Alternator Protection Air Damper Indicator Defined Common Fault

(RDO only) SCRDOs 1--4 (Software-

Controlled RDOs)

Menu 10 Output Setup, cont.

Group B, continued

Reverse Power Shutdown[ Over Power Shutdown[ Loss of Field Shutdown[ Overcurrent VR Shutdown[ Common Protective Relay

Output[ In Synchronization[ Breaker Trip[ Fuel Valve Relay* Prelube Relay* Air/Fuel Module Remote

Start* No Oil Temperature Signal* High Oil Temperature

Warning* No Air Temperature Signal* Intake Air Temperature

Warning* Intake Air Temperature

Shutdown* Air/Fuel Module Engine

Start Delay* ECM Yellow Alarm ECM Red Alarm] Block Heater Control] Low Coolant Temperature

Shutdown] Load Shed

Overtemperature Maintenance Due Engine Derate Active Engine Stalled

(ECM engines)

J1939 CAN Shutdown

(ECM engines)

*Waukesha engine

[Paralleling applications ]DDC/MTU engine with

MDEC/ADEC

]

Menu 11 Voltage Regulator

AVG L -L V Volt ADJ

D L1-L2 Volts D L2-L3 Volts (3 phase) D L3-L1 Volts (3 phase)

Under Freq. Unload Enabled N/Y

D Frequency

Setpoint (Cut-In Point)

D Slope

Volts-Per-Cycle

Reactive Droop Enabled N/Y

D Voltage Droop at 0.8 PF

Rated Load

VAR Control Enabled N/Y

D Total kVAR (Running)

kVAR Adj

D Generating/Absorbing Y/N

PF Control Enabled N/Y

D Average PF

PF Adjustment

D Lagging/Leading Y/N

Regulator Gain Adj.

D Gain

Utility Gain Adj.

D Gain

Analog Voltage Adjust Enabled N/Y

Reset Regulator Defaults?

Menu 12 Calibration

Scale AC Analog Inputs

Generator Set Voltage LN D Gen L1-L0 V

Calibration Reference

D Gen L2-L0 V

Calibration Reference

D Gen L3-L0 V (3 phase)

Calibration Reference

Generator Set Voltage LL D Gen L1-L2 V

Calibration Reference

D Gen L2-L3 V (3 phase)

Calibration Reference

D Gen L3-L1 V (3 phase)

Calibration Reference

D Calibrate Regulator Y/N

Generator Set Amps D Gen L1 Amps

Calibration Reference

D Gen L2 Amps

Calibration Reference

D Gen L3 Amps (3 phase)

Calibration Reference

Load Voltage LN (Paralleling Applications only)

D Load L1--L0 V

Calibration Reference

D Load L3--L0 V

Calibration Reference

Restore Defaults? Y/N

Scale Aux. Analog Inputs

D Zero Aux. Analog

Inputs? (Scroll through up to 7 user-defined descriptions. See Figure 2-8 in User Inputs for factory-reserved inputs that are not userselectable.)

D Analog 01

Scale Value 1 d Scale1V

Scale2V

D Analog 01

Scale Value 2 d Scale1V

Scale2V

TP-6200 10/12 45Section 2 Operation

Page 46

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

Menu 13 Communications

Protocol KBUS

D KBUS Online Y/N D Connection Type

(User-defined)

d Local Single Y/N d Local LAN Y/N d Local LAN Conv Y/N d Remote Single Y/N d Remote LAN Y/N d Remote LAN Conv

Y/N

D Primary Port

(User-defined)

d RS-232 Y/N d RS-485 ISO1 Y/N

D Address

(LAN Connections)

D System ID

(Remote Connections)

D BAUD Rate

(User-defined) d BAUD Rate

1200 2400 9600

Protocol Modbus

D Modbus Online N/Y D Connection Type

(User-defined)

d Single Y/N d Convertor Y/N

D Primary Port

d RS-485

d RS-232 D Address D BAUD Rate

(User-defined)

d 9600

d 19200

Menu 14 Programming Mode

D Programming Mode

d Local? Y/N d Remote? Y/N d Off? Y/N

D Programming Mode

Change, Access Code

d Enter Old Code d Enter New Code

Menu 15 Paralleling Relays (PR)

Purchased Option

D PR Overvoltage VAC

d Time Delay Seconds

D PR Undervoltage VAC

d Time Delay Seconds

D PR Overfrequency Hz

d Time Delay Seconds

D PR Underfrequency Hz

d Time Delay Seconds

D PR Reverse Power kW

d Time Delay Seconds

D SD Reverse Power kW

d Time Delay Seconds

D PR Over Power kW

d Time Delay Seconds

D SD Over Power kW

d Time Delay Seconds

D PR Loss of Field kVAR

d Time Delay Seconds

D SD Loss of Field kVAR

d Time Delay Seconds

D PR Overcurrent Amps

d Time Delay Seconds

D SD Overcurrent Amps

d Time Delay Seconds

D Synchronization

d Synch Voltage Match

VAC

d Synch Freq. Match

d Synch Phase Match

Degrees

d Time Delay Seconds

Menu 20 Factory Setup Menu

D Final Assembly Date

DD/MM/YY

D Final Assembly Clock No. D Operating Days D Model No. D Spec No. D Generator Set Serial No. D Alternator Part No. D Engine Part No. D Temp Sensor

d GM31045-X d GM16787 d GM17362

D Serial No. Confirm

d Confirm Serial? D Controller Serial No. D Code Version D Setup Locked

Menu 55 Load Factor

D 100%--125% Load

Factor Hours

D 126%--150% Load

Factor Hours

D 151%--200% Load

Factor Hours

D 201%+ Load Factor

Hours

TP-6200 10/1246 Section 2 Operation

Page 47

2.5 Reviewing Digital Display

The user interacts with the controller with a keypad and digital display. Use the keypad to access the generator set informational data and preset settings. This review section shows how to access the data. See Section 2.8, Local Programming Mode On, for instructions on how to change the information. See Figure 2-9 for an illustration of the digital display and keypad.

Enter ↵ Key. Press the enter ↵ key to confirm the entered information on the display when selecting menus or programming.

Lamp Test Key. Press the lamp test key to check that the status and fault lamps illuminate, the horn sounds, and the digital display clears. Press the reset menu key before pressing the lamp test key.

Menu Down ↓ Key. The controller displays consist of menus with various data levels or programming steps. Use the menu down ↓ key to navigate through the menu levels.

Note: Pressing the menu down ↓ key in some menus

locks the user into that level structure of the menu where the display will not change. Press the reset menu key to access other main menus.

Menu Right → Key. Press the menu right → key to scroll through sub-levels of each main menu. The display contains an arrow in the right-hand corner when there is a sub-level. Pressing the menu right → key when no arrow is present moves to the next submenu header. Press the menu right → key prior to entering decimal values when required.

TP-5829-2

Figure 2-9 Digital Display and Keypad

Note: After energizing the controller by reconnecting

the battery, set the controller time and date. See Section 2.8.6, Local Programming Mode On, Menu 6—Time and Date.

Pressing any key on the keypad activates the controller panel display. The panel lamps and display turn off 5 minutes after the last keypad entry.

2.5.1 Keypad Operation

Use the keypad to enter information into the controller. Some of the keys have two functions. The following gives keypad definitions and functions.

Alarm (Horn) Off Key. Press the alarm off key to silence the horn at the user’s discretion. Place the generator set master switch in the AUTO position before silencing the alarm horn. The alarm horn cannot be silenced unless the master switch is in the AUTO position. See Section 2.3.7, Controller Reset Procedure, for more information on turning the alarm horn off.

AM/PM Key . When the controller displays a question during programming requiring a nonnumeric answer (am or pm), the controller accepts the secondary key function and ignores the alarm off function of the key .

Note: Pressing the menu right → key in some menus

locks the user into that level structure of the menu where the display will not change. Press the reset menu key to access other main menus.

Numeric 0--9 Keys. Press the numeric keys when selecting menus or entering numeric values during programming. The controller ignores the secondary function of the key (yes, no, etc.) when only numeric values are valid.

Reset Menu Key. The reset menu key exits a menu, clears incorrect entries, and cancels the auto-scroll function. Press the reset menu key to exit a menu or any layer within that menu.

Stop Prog Run Key. Press the stop prog run key to end the generator set programmed exercise run created in Menu 4—Operational Records. The generator set shuts down after the time delay for engine cooldown expires. The stop prog run key does not affect the programmed transfer switch exercise function.

Yes/No Keys. When the controller displays a question during programming requiring a nonnumeric answer (yes or no), the controller accepts the secondary key function and ignores the numeric value of the key. Press the ENTER key to confirm the response.

TP-6200 10/12 47Section 2 Operation

Page 48

2.5.2 Auto-Scroll Function

Error Messages

The auto-scroll function continuously shows voltage and current data from Menu 1—Generator Monitoring, V & A Summary without the need to press the down arrow for each display.

For auto-scroll function press ENTER at the V & A Summary menu. Press the Reset Menu key or Menu Right → key to stop the auto-scroll function.

2.5.3 Request and Error Messages

Note: When EEPROM errors occur or initializing the

EEPROM is required, contact an authorized distributor/dealer.

Request and Status Messages

Display messages require the user to enter additional data, confirm the previous entry or require time to process as described below.

Entry Accepted appears for several seconds after pressing the Enter key during the programming mode. The display then shows the new data.

Initialize EEPROM? Prompt to confirm EEPROM initialization.

Reset Complete indicates the user has successfully:

D Reset the maintenance records or D Restored the AC analog inputs to the default settings. D Restored voltage regulator settings to the defaults.

Right Arrow → directs the user to the next menu. The menus loop; press the right arrow key to move to the next menu.

Setup Complete indicates the completion of the analog input setup.

Setup Locked appears when user attempts to change a value or perform a function available only when the system is unlocked.

Setup Unlocked appears when user has unlocked the system for maintenance or troubleshooting.

When an error message appears, the entered information is not within the allowable parameters set by the control firmware or is not permitted as described below. In cases where the data was outside the parameters, press the Reset Menu key and enter the corrected information.

Access Denied appears when the user attempts to:

D Enter data prohibited by the master switch position, D Enter data prohibited by the generator set state, or D Enable the LDD (load disturbance detection).

Access Denied Idle Mode Active appears when the user attempts to modify the voltage regulator setup while the idle mode is active.

Alarm Active appears when the user attempts to modify an analog or a digital input that is active. See Menu 9—Input Setup.

Cannot Change (because the) NFPA is Enabled

appears when the user attempts to modify an RDO setting that is a NFPA 110 default requirement.

Cannot Change Preset appears when the user attempts to change the factory preset analog input, digital input, or input parameter.

EEPROM Write Error appears when a component failure occurs. Contact an authorized distributor/dealer.

Entry Unacceptable appears when the user attempts an invalid input to the voltage regulator setup.

Some alternators are intended to operate within a specific, limited range of conditions (voltage, frequency, and phase or connection). The following error messages can appear when attempts are made to enter system values that do not match acceptable conditions for the particular alternator.

D Fixed Frequency when entry is beyond the range of

limited entries for the respective alternator. Occurs when the alternator is not rated for the value entered. Updated parameter files may be available by contacting an authorized service dealer/distributor.

(Question) ? asked by the control firmware; answer the question by pressing the yes/no, numeric digit, or am/pm key.

Wait for System Reset (6 Sec) appears while the EEPROM initializes.

D Fixed Phase when entry is beyond the range of

TP-6200 10/1248 Section 2 Operation

Page 49

D Fixed Voltage when entry is beyond the range of

Func (Function) Used by (RDO) XX Reassign?

appears when the user attempts to assign an RDO to a function already assigned.

Internal Error appears when controller logic detects a functional sequence error.

Invalid Code appears when the user attempts to enter:

D An invalid access code for programming mode setup,

D An invalid access code for setup unlock.

Invalid Menu ID appears when the user attempts to enter a menu number that is unavailable or nonfunctional.

N/A appears when data to be displayed is not available.

No Input Assigned appears when the user attempts to

assign any of the following system faults to an RDO where the digital input is not defined. See digital input scale requirements in Menu 12—Calibration.

D Air damper indicator D Battery charger fault D Ground fault D High oil temperature shutdown D Low coolant level D Low fuel

Not in Local Program Mode appears when the user attempts to program using the keypad when the programming mode is set for remote or off.

Not User-Selectable appears when the user attempts to change an analog or digital input that is factoryreserved. Items identified as not user-selectable are included for specific applications. (Example: AFM SHUTDOWN is enabled with a Waukesha-powered model.) The user cannot disable an analog or digital input when identified as not user-selectable. See Figure 2-8 in User Inputs for factory-reserved digital and analog inputs that are not user-selectable.

Range Error appears when the user attempts to enter:

D A numeric input that is not within the acceptable range

of the system settings, time delays, addresses, etc.

D An invalid analog or digital input number. D An invalid date/time.

Remove Load appears when trying to calibrate the voltage regulator in menu 12 with load connection. The voltage regulation calibration must be performed during a no load condition.

Setpoint Values Cannot be Equal appears when the user attempts to enter the same value for both setpoints during the analog input calibration.

2.6 Monitoring and Programming Setup

The user can access the controller data with the controller keypad and display or a personal computer (PC) with optional software to monitor and/or program. Access the controller system with a PC using local (direct) or remote (modem) systems. Refer to the Introduction, List of Related Materials for related software literature. See Menu 13—Communications.

The user can access the controller data while in the programming mode off or programming mode on. See Menu 14—Programming Mode.

While this manual focuses on data access and programming through the controller keypad and display, some data entries require input using a PC for initial setup. The PC entries typically include alpha characters such as digital input descriptions. The individual menus in Section 2.8, Local Programming Mode On, indicate where data requires entry using a PC.

There are six basic configurations for data monitoring and programming using access source options. See Figure 2-13.

Other combinations of data monitoring and programming are possible but require programming from a single location. Figure 2-13, Monitoring and Programming Configurations, briefly describes the settings of Menu 13—Communications and Menu 14— Programming Mode based on user-selected operating mode.

Output in Use appears when the user attempts to modify or reassign an active RDO.

Port in Use appears when the user attempts to use an already assigned communications port.

TP-6200 10/12 49Section 2 Operation

Use the keypad and digital display to setup the access configurations the first time. Go to Section 2.8, Local Programming Mode On, and set the desired selection in Menu 13—Communication and Menu 14— Programming Mode before accessing data.

Page 50

2.6.1 PC Communications

Local Area Network (LAN)

There are four ways to communicate between a PC and the generator set and/or transfer switch devices using KBUS communication protocol. The PC connections require optional software and possibly other hardware, communication modules in the generator set controller and/or transfer switch. See the monitor software operation manual for details. Contact your authorized distributor/dealer for availability.

Local Single Connection

A PC connects to the COM port of the controller module using an RS-232 cable when the PC is within 15 m (50 ft.) of the device or an RS-485 cable when the PC is within 1220 m (4000 ft.) of the device. See Figure 2-10 or Figure 2-11.

Generator Set

Controller,

Transfer Switch

Control, or

RS-232

Personal

Computer

up to

15 m (50 ft.)

Figure 2-10 Local Single Connection,

up to 15 m (50 ft.)

Power Monitor

A PC connects to the device’s LAN. A LAN is a system that connects more than one device to a single PC. Acceptable devices include the Decision-Makerr 550 controller, Decision-Makerr 340 controller, M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor. See Figure 2-12.

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Personal

Computer

RS-232 to RS-485

port converter

RS-485

up to

1220 m

(4000 ft.)

Figure 2-12 Local Area Network

The 550 controller can be used as an RS-232 to RS-485 port converter in a LAN network if the 550 controller is located within 15 m (50 ft.) of the PC. This configuration is the Local LAN Conv option.

Generator Set

Controller,

Transfer Switch

Control, or

Power Monitor

Personal

Computer

RS-232 to RS-485

port converter

RS-485

up to

1220 m

(4000 ft.)

Figure 2-11 Local Single Connection, up to

1220 m (4000 ft.)

User Operating Mode Selection Menu 13—Communications Settings Menu 14—Programming Mode

User

Activity

Monitor only

Monitor and Program

Access Source

Controller No No No Yes No No

Direct PC Yes Yes No Ye s No No

PC via Telephone Lines Yes No Yes Yes No No

Controller No No No No Yes No

Direct PC Yes Yes No No No Ye s

PC via Telephone Lines Yes No Yes No No Ye s

Line?

Local LAN?

Remote Single

or LAN?

Programming

Mode Off?

Local Programming

Mode?

Programming Mode?

Figure 2-13 Monitoring and Programming Configurations

Remote

TP-6200 10/1250 Section 2 Operation

Page 51

Remote Single Connection

A modem connects a PC to a single device. The PC communicates with the device via a telephone network. Locate the PC anywhere a telephone line is available. See Figure 2-14.

network. Acceptable devices include the DecisionMakerr 550 controller, Decision-Makerr 340 controller, M340 transfer switch control, M340+ transfer switch control, and PM340 power monitor. Locate the PC anywhere a telephone line is available. See Figure 2-15.

Remote Area Network

A PC connects to a modem. The devices connect to a LAN network. The PC communicates to the devices via a telephone network that is interfaced to the LAN

RS-232

Personal

Computer

up to

15 m (50 ft.)

Figure 2-14 Remote Single Connection

Modem

Personal

Computer

Telephone

Lines

Telephone

Lines

Modem

The 550 controller can be used as an RS-232 to RS-485 port converter in a LAN network if the 550 controller is located within 15 m (50 ft.) of the device modem. This configuration is the Remote LAN Conv option.

Generator Set

ModemModem

RS-232 to RS-485

port converter

RS-485

up to 1220 m

(4000 ft.)

RS-232

up to

15 m (50 ft.)

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Generator Set

Controller or

Transfer Switch

Control

Figure 2-15 Remote Area Network

2.6.2 Modbus Communications

RS-485

The controller communicates using Modbusr as a slave connection with the Modbusr master initiating the communication. The controller seeks the system and

Generator Set

Controller

alternator parameters and diagnostic information then responds back to the Modbusr master. In addition, the controller accepts information to alter controller parameters including generator set starting and stopping. See Figure 2-16. Refer to the List of Related Materials for available Modbusr literature.

Figure 2-16 Modbusr Connections

Note: Only one Modbusr master can be connected to

the 550 controller. Examples include the remote serial annunciator, Monitor III, and switchgear applications.

Modbusr is a registered trademark of Schneider Electric.

TP-6200 10/12 51Section 2 Operation

up to 1220 m (4000 ft.)

Modbusr Master

RS-232

up to 15 m (50 ft.)

Page 52

2.7 Reviewing Menu Displays

Use this section to review a summary of the generator set controller data. See Figure 2-17 for which menus provide data monitoring and adjusting data.

Press the Reset key, enter the desired menu number key(s), and then press the Enter key. Use the down arrow and right arrow keys for navigation.

See Section 1, Specifications and Features, to review set point ranges and default settings for comparison to the actual setup.

The user must enable the programming mode to edit the display. See Menu 14—Programming Mode and Section 2.8, Local Programming Mode On, for more information.

Note: Press any key on the keypad to activate the

controller panel display. The panel display turns off 5 minutes after the last keypad entry.

Note: Press the Reset Menu key to clear error

messages.

Note: Press the Menu Right → key prior to entering

decimal values where necessary.

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

See Section 2.5.3, Request and Error Messages, for error display messages and explanations while navigating the menus.

Legend:

Menu Down Key

Menu Right Key

Number

1 Generator Monitoring X

2 Engine Monitoring X

3 Analog Monitoring X

4 Operational Records X

5 Event History X

6 Time and Date X

7 Generator System X

8 Time Delays X

9 Input Setup X

10 Output Setup X

11 Voltage Regulator X

12 Calibration X

13 Communications X

Menu Name

View Only

Data

View and

Adjust Data

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

Menus displaying the ? symbol require the user to enter data.

Menus displaying the * symbol represent access code or password type entries. The actual key entry does not display.

14 Programming Mode X

15 Protective Relays X

20 Factory Setup X

Figure 2-17 Menu Displays for Viewing and Adjusting

TP-6200 10/1252 Section 2 Operation

Page 53

2.7.1 Menu 1—Generator Monitoring

Menu 1 displays generator output data including line-to-line and line-to-neutral voltages, current, frequency, power factor, total kilowatts, percent of maximum kW, total kVA, and total kVAR. Menu 1 displays three-phase voltage and current readings when applicable.

All menu displays apply to both single-phase and threephase voltages unless otherwise noted as (1 PH) or (3 PH) on the menu overview. The phase designation does not appear in the controller menu displays.

Menu 1 Overview (Three-Phase Connections)

MENU 1

GENERATOR MONITORING

Note: For the auto-scroll function, press ENTER at V &

A Summary menu. Press the Reset Menu key or Menu Right → key to stop the auto-scroll function.

Note: Pressing a right arrow key from any submenu

moves to the next submenu header.

VOLTS&S →

L1-L2 VOLTS # L1 AMPS #

L2-L3 VOLTS # L2 AMPS #

L3-L1 VOLTS # L3 AMPS #

L1-L0 VOLTS # L1 AMPS #

L2-L0 VOLTS # L2 AMPS #

L3-L0 VOLTS # L3 AMPS #

FREQUENCY # HZ

V&ASUMMARY →

V L1-L2 L2-L3 L3-L1

###

V L1-L0 L2-L0 L3-L0

###

A L1L2L3

###

For the auto-scroll function, press ENTER at V&ASUMMARY menu.

Use the MENU→ key to stop the auto-scroll function.

POWER KW →

TOTAL KW # PF # LEADING/LAGGING

L1 KW # PF # LEADING/LAGGING

PF # LEADING/LAGGING

L3 KW (3 PH) # PF # LEADING/LAGGING

TOTAL KW # % OF RATED KW #

POWER KVAR →

TOTAL KVAR # ABSORBING/GENERATING

L1 KVAR # ABSORBING/GENERATING

L2 KVAR # ABSORBING/GENERATING

L3 KVAR (3 PH) # ABSORBING/GENERATING

POWER KVA →

TOTAL KVA #

L1 KVA #

L2 KVA #L2 KW #

L3 KVA #

TP-6200 10/12 53Section 2 Operation

Page 54

Menu 1—Generator Monitoring, continued

Menu 1 Overview (Single-Phase Connections)

MENU 1

GENERATOR MONITORING

VOLTS&S →

L1-L2 VOLTS # L1 AMPS #

L1-L2 VOLTS # L2 AMPS #

L1-L0 VOLTS # L1 AMPS #

L2-L0 VOLTS # L2 AMPS #

FREQUENCY # HZ

V&ASUMMARY →

V L1-L2 L1-L0 L2-L0

###

AL1L2

For the auto-scroll function, press ENTER at V&ASUMMARY menu.

Use the MENU→ key to stop the auto-scroll function.

POWER KW →

TOTAL KW # PF # LEADING/LAGGING

L1 KW # PF # LEADING/LAGGING

PF # LEADING/LAGGING

TOTAL KW # % OF RATED KW #

POWER KVAR →

TOTAL KVAR # ABSORBING/GENERATING

L1 KVAR # ABSORBING/GENERATING

L2 KVAR # ABSORBING/GENERATING

POWER KVA →

TOTAL KVA #

L1 KVA #

L2 KVA #L2 KW #

TP-6200 10/1254 Section 2 Operation

Page 55

2.7.2 Menu 2—Engine Monitoring

Menu 2 displays engine operating data including oil pressure and temperature, coolant pressure and temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and shutdown setpoints and engine warmed-up and cooled-down temperature setpoints. The detailed engine monitoring functions appear only for DDEC/JDEC/EMS2/EDC3-equipped engine and MDEC/ADEC-equipped engine versions.

Note: A right arrow from any submenu moves to the

next submenu header.

Menu 2 Overview

MENU 2 ENGINE MONITORING

ENGINE MONITORING → BASIC

ENGINE MONITORING → DETAILED

(DDEC/JDEC/EMS2/EDC3-

Equipped Engines only)

OIL PRESSURE # PSI COOLANT TEMP # F

INTAKE AIR # F OIL TEMP (Waukesha) # F

ENGINE RPM # LOCAL BATT VDC #

HCT WARNING # F HCT SHUTDOWN # F

LOP WARNING # PSI LOP SHUTDOWN # PSI

ENGINE WARMED UP #F

ENGINE COOLED DOWN #F

ENGINE FUEL →

FUEL PRES # PSI FUEL TEMP # F

CHG AIR PRES # PSI CHG AIR TEMP # F

FUEL RATE # GPH

USED LAST RUN # GAL

ENGINE COOLANT →

COOLANT PRES # PSI COOLANT TEMP # F

COOLANT LEVEL #%

ENGINE OIL →

OIL PRES # PSI OIL TEMP # F

OIL LEVEL #% CRANKCASE PRES # PSI

ENGINE MISC →

ECM BATT VDC # AMBIENT TEMP # F

ENGINE MODEL NO.

ENGINE SERIAL NO.

UNIT NO. #

ECM S/N #

ECM FAULTS CODES #

TP-6200 10/12 55Section 2 Operation

Page 56

Menu 2 Overview

MENU 2 ENGINE MONITORING

(MDEC/ADEC-Equipped Engines only)

ENGINE MONITORING → BASIC

OIL PRESSURE # PSI COOLANT TEMP # F

INTAKE AIR # F OIL TEMP (Waukesha) # F

ENGINE RPM # LOCAL BATT VDC #

HCT WARNING # F HCT SHUTDOWN # F

LOP WARNING # PSI LOP SHUTDOWN # PSI

ENGINE WARMED UP #F

ENGINE COOLED DOWN #F

ENGINE MONITORING → DETAILED

ENGINE FUEL →

FUEL PRES # PSI FUEL TEMP # F

CHG AIR PRES # PSI CHG AIR TEMP # F

FUEL RATE * # GPH

DAILY FUEL USED * # GAL

TOTAL FUEL USED * # GAL

ENGINE OIL →

OIL PRES # PSI OIL TEMP # F

ENGINE MISC →

ECU SUPPLY VDC # AMBIENT TEMP # F

ECU HOURS #

ECU FAULTS CODES #

* While these menu displays do appear on the 550 controller, the engine ECM is not currently set up to provide this data.

TP-6200 10/1256 Section 2 Operation

Page 57

2.7.3 Menu 3—Analog Monitoring

Menu 3 displays battery voltage and up to 7 userdefined analog items dependent upon the generator system.

The User Defined Desc display refers to a description entered into the controller using the PC software. This description remains as the display for future review until changed by the PC software user. The display has 20 characters maximum.

The default description is Analog Auxiliary In.

Menu 3 Overview (ECM Engines)

MENU 3 ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 01 # (USER DEFINED DESC)

Note: If the analog display shows O/R (out of range), no

input is connected or the input voltage is beyond the acceptable operating range (0--5 VDC).

Note: See Figure 2-8 in User Inputs for factory

reserved inputs which are not user selectable.

Menu 3 Overview (Non-ECM Engines)

MENU 3 ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 03 # (USER DEFINED DESC)

ANALOG 02 # (USER DEFINED DESC)

ANALOG 03 # (USER DEFINED DESC)

ANALOG 04 # (USER DEFINED DESC)

ANALOG 05 # (USER DEFINED DESC)

ANALOG 06 # (USER DEFINED DESC)

ANALOG 07 # (USER DEFINED DESC)

ANALOG 04 # (USER DEFINED DESC)

ANALOG 05 # (USER DEFINED DESC)

ANALOG 06 # (USER DEFINED DESC)

ANALOG 07 # (USER DEFINED DESC)

Menu 3 Overview (Waukesha Engines)

MENU 3 ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 05 # (USER DEFINED DESC)

ANALOG 06 # (USER DEFINED DESC)

ANALOG 07 # (USER DEFINED DESC)

TP-6200 10/12 57Section 2 Operation

Page 58

2.7.4 Menu 4—Operational Records

Menu 4 displays the generator set’s operating record including operating start date, last logged maintenance, total run time loaded and unloaded, run time since last maintenance, number of starts, and number of days the unit ran.

Menu 4 Overview

MENU 4 OPERATIONAL RECORDS

After performing maintenance, enter YES to reset records reflecting the current day. The user must enable the programming mode to edit the display.

See Section 2.8.4 to make changes in this menu.

NO. OF STARTS # LAST MAINT ##-###-##

FACTORY TEST DATE ##-###-##

TOTAL RUN TIME HRS #

TOTAL RUN TIME LOADED HRS #

TOTAL RUN TIME UNLOADED HRS #

TOTAL RUN TIME KW HRS #

NO. OF STARTS #

ENGINE START? Y/N→ COUNTDOWN ##:##

RECORDS-MAINT →

LAST START ##:## AM/PM DATE ##-###-##

LENGTH OF RUN (UN)LOADED HRS #

RUN TIME HR:MN →

??:??

RESET RECORDS? Y/N→

RUN TIME SINCE MAINT TOTAL HRS #

RUN TIME SINCE MAINT LOADED HRS #

RUN TIME SINCE MAINT UNLOADED HRS #

RUN TIME SINCE MAINT KW HRS #

OPERATING DAYS # LAST MAINT ##-###-##

TP-6200 10/1258 Section 2 Operation

Page 59

2.7.5 Menu 5—Event History

2.7.7 Menu 7—Generator System

Menu 5 stores and displays the times and dates of up to 100 stored status, warning, and shutdown events. After the first 100 events, each additional new event replaces the oldest event. See Menu 10—Output Setup for a list of possible events.

Menu 5 Overview

MENU 5 EVENT HISTORY

(MESSAGE TEXT) ##-###-## ##:## AM/PM

SCROLL THROUGH 100 (max.) STORED EVENTS

2.7.6 Menu 6—Time and Date

Menu 6 shows the internal clock time and calendar date. The controller uses the set clock time to determine exercise run time and event records. The time and date are valid as long as the controller power (starting battery) remains connected.

The user must enable the programming mode to edit the display.

Menu 7 shows the generator set system data including voltage, frequency, phase connection, battery voltage, etc. Use the values entered in this menu to determine shutdown values and time delays.

The user must enable the programming mode to edit the display.

See Section 2.8.7 to change system information in this menu.

Note: Press the Menu Right → key prior to entering

decimal values where necessary.

Note: The user defines the data shown in Menu 7. It is

NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control.

Note: Some alternators are designed to operate at

limited voltage, frequency, or phase connections. Settings outside of these parameters may cause a range error message.

Items marked * apply only to DDC/MTU engines using MDEC/ADEC.

Note: Menus include variable speed governor (VSG)

and digital speed control (DSC).

See Section 2.8.6 to change the time and/or date.

Menu 6 Overview

MENU 6 TIME AND DATE

DAY OF WEEK ##-###-##

TIME ??:?? AM/PM

DATE ??-???-??

##:##AM/PM

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Menu 7 Overview

MENU 7 GENERATOR SYSTEM

OPERATING MODE → STANDBY Y/N

SYSTEM VOLTAGE LINE-LINE ?

SYSTEM FREQ # HZ

PHASE → 3 PHASE DELTA Y/N

KW RATING ?

RATED CURRENT #

LOAD SHED OUTPUT → ?% # KW

OVERVOLTAGE → ?% # VAC

OPERATING MODE → PRIME POWER Y/N

PHASE → 3 PHASE WYE N/Y

TIME DELAY MIN:SEC →

??:??

TIME DELAY MIN:SEC →

??:??

PHASE → SINGLE PHASE N/Y

UNDERVOLTAGE → ?% # VAC

OVERFREQUENCY ?% # HZ

UNDERFREQUENCY ?% # HZ

OVERSPEED ?HZ #RPM

BATTERY VOLTAGE → 12 VDC Y/N

LOW BATTERY VOLTAGE ?.? VDC

HIGH BATTERY VOLTAGE ?.? VDC

BLOCK HEATER ON * # F

TIME DELAY MIN:SEC →

??:??

BATTERY VOLTAGE → 24 VDC Y/N

BLOCK HEATER OFF * # F

ENABLE VSG * Y/N

ENABLE DSC * Y/N

METRIC UNITS Y/N

*DDC/MTU engine with MDEC/ADEC only

SET NFPA 110 Y/N DEFAULTS

TP-6200 10/1260 Section 2 Operation

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2.7.8 Menu 8—Time Delays

Menu 8 displays the cyclic cranking cycles, various engine related starting and shutdown features, and auxiliary shutdown and inhibit time delays.

The user must enable the programming mode to edit the display.

See Section 2.8.8 to change settings in this menu.

Cooldown Temperature Override. This feature allows the user to bypass (override) the temperature-based cooldown. When this feature is enabled, the engine will run in cooldown mode for the entire time defined as TIME DELAY ENG COOLDOWN, regardless of engine temperature.

Menu 8 Overview

MENU 8 TIME DELAYS

TIME DELAY MIN:SEC ENGINE START ??:??

If the Cooldown Temperature Override is not enabled, the unit will cease to run when the engine temperature falls below the ENGINE COOLED DOWN temperature (shown in Menu 2).

Engine cooldown and this cooldown temperature override feature apply to remote shutdown when the master switch is in the AUTO position. No cooldown will occur when the master switch is moved to the OFF position.

TIME DELAY MIN:SEC STARTING AID ??:??

TIME DELAY MIN:SEC CRANK ON ??:??

TIME DELAY MIN:SEC CRANK PAUSE ??:??

TIME DELAY MIN:SEC ENG COOLDOWN ??:??

COOLDOWN TEMPERATURE OVERRIDE Y/N

OVERCRANK SHUTDOWN CRANK CYCLES ?

TIME DELAY MIN:SEC OVERVOLTAGE ??:??

TIME DELAY MIN:SEC UNDERVOLTAGE ??:??

TIME DELAY MIN:SEC LOAD SHED KW ??:??

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2.7.9 Menu 9—Input Setup

Menu 9 displays the setup of user-defined digital and analog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs.

continues to run regardless of shutdown signals where potential engine/generator damage can occur.

When this input is enabled the yellow warning lamp illuminates and stored warning/shutdown events that are ignored continue to log in Menu 5— Event History.

The user must enable the programming mode to edit the display.

See Section 2.8.9 to change settings in this menu.

Note: Press the down arrow to move to the start of the

next input setup.

Note: See Figure 2-8 in User Inputs for factory

reserved inputs which are not user selectable.

D Enabled. The controller will ignore the input until the

inhibit time expires. If the inhibit time is set to zero, the input is monitored at all times, even when the generator is not running. Analog inputs have separate warning and shutdown enabled choices.

D Inhibit Time Delay. The inhibit time delay is the time

period following crank disconnect during which the generator set stabilizes and the controller does not detect the fault or status event. This menu indicates whether or not the input is enabled. If the input is not enabled, the controller will ignore this input signal. The inhibit time delay range is from 0 to 60 seconds.

D Time Delay (shutdown or warning). The time delay

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

Additional Analog Input Entries. The analog input selection typically requires entering four values—low warning, high warning, low shutdown, and high shutdown.

Shutdown Type A and Shutdown Type B. Choose shutdown type A for standard shutdown where red

lamp illuminates and alarm horn sounds. Choose shutdown type B for shutdown where air damper indicator RDO-23 energizes for two seconds, red lamp illuminates, and alarm horn sounds.

Analog Input A06—Analog Speed Adjust (VSG).

Analog Input A06 may be used for analog speed adjust when external control of engine speed is desired such as paralleling applications or closed transition ATS. To utilize this capability, the input must be calibrated. Refer to 2.8.12, Menu 12—Calibration.

Note: This feature is supported for Doosan, GM, and

Volvo engines only.

Analog Input A07—Analog Voltage Adjust. Analog voltage adjust is a feature that the user may choose to enable. The input designated for use as Analog Voltage Adjust is analog input A07.

Enable Analog Voltage Adjust through Menu 11. Additionally, Monitor 2 or Monitor 3 may be used to enable Analog Voltage Adjust by entering the proper description (Analog Volt Adjust) for A07. When Analog Voltage Adjust is enabled, the description for A07 is Analog Volt Adjust. Changing the description using Monitor 2 or Monitor 3 disables the analog voltage adjust feature.

When Analog Voltage Adjust is enabled, no warning or shutdown may be enabled for A07.

Note: If the analog input A07 description does not

match Analog Volt Adjust, input A07 will not function as the voltage adjust.

Battle Switch/Fault Shutdown Override Switch. The battle switch function forces the system to ignore normal fault shutdowns such as low oil pressure and high engine temperature. The battle switch does not override the emergency stop and overspeed shutdown. When the battle switch function is enabled the generator set

Identification and Descriptions. Descriptions for user inputs (auxiliary analog or auxiliary digital) may be entered using the Monitor II software accessory where the user determines the descriptions in upper and lower case.

TP-6200 10/1262 Section 2 Operation

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Menu 9 Overview

MENU 9

INPUT SETUP

SETUP DIGITAL → AUXILIARY INPUTS

DIGITAL INPUT 01 → (USER DEFINED DESC)

Press the down arrow to scroll through additional DIGITAL auxiliary inputs 1--21 or enter the input number.

SETUP ANALOG → AUXILIARY INPUTS

ANALOG INPUT XX → (USER DEFINED DESC)

DIGITAL INPUT 01 → (see Group A) YES/NO

Group A

The preprogrammed selections include the following list. See Appendix E for application and restrictions with specific engines.

WARNING Y/N SHUTDOWN TYPE A Y/N SHUTDOWN TYPE B Y/N VOLTAGE RAISE Y/N VOLTAGE LOWER Y/N

ANALOG INPUT XX → WARNING ENABLED Y/N

DIGITAL INPUT 01 → ENABLED YES/NO

Group A, continued

VAR PF MODE Y/N REMOTE SHUTDOWN Y/N REMOTE RESET Y/N AIR DAMPER Y/N LOW FUEL Y/N FIELD OVERVOLTAGE Y/N IDLE MODE ACTIVE Y/N BATTLE SWITCH Y/N GROUND FAULT Y/N BAT CHGR FAULT Y/N HIGH OIL TEMP Y/N

ANALOG INPUT XX → SHUTDOWN ENABLED Y/N

DIGITAL INPUT 01 → INHIBIT TIME ?:??

Group A, continued

LOW COOLANT LEVEL Y/N LOW COOLANT TEMP Y/N BREAKER CLOSED Y/N ENABLE SYNCH Y/N AFM SHUTDOWN Y/N KNOCK SHUTDOWN Y/N DETON WARNING Y/N DETON SHUTDOWN Y/N LOW FUEL SHUTDOWN Y/N

ANALOG INPUT XX → INHIBIT TIME ?:??

TO ANALOG INPUT SETUP (NEXT)

DIGITAL INPUT 01 → DELAY TIME ?:??

TO DIGITAL INPUT SETUP (PREVIOUS)

ANALOG INPUT XX → WARN DELAY TIME ?:??

ANALOG INPUT XX → HI WARN VALUE ??

ANALOG INPUT XX → SDWN DELAY TIME ?:??

ANALOG INPUT XX → HI SDWN VALUE ??

ANALOG INPUT XX → LO SDWN VALUE ??

Note: For ECM engines, auxiliary analog inputs

A01--A07 will appear.

Note: For non-ECM engines, auxiliary analog inputs

A03--A07 will appear.

Note: For Waukesha engines, auxiliary analog inputs

A05--A07 will appear.

ANALOG INPUT XX → LO WARN VALUE ??

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2.7.10 Menu 10—Output Setup

Menu 10 displays the setup of user-defined system, digital and analog status, and fault outputs and relay driver outputs (RDO) 1--31. These RDO outputs provide multiple choices for configuring customized auxiliary outputs. Additional individual outputs are available for monitoring, diagnostics, and control functions.

The user must enable the programming mode to edit the display. See Section 2.8.10 to change this menu.

Note: Some data require entry using a PC in the

Remote Programming mode. See the Monitor Software operation manual for details.

Note: See Figure 2-8 in User Inputs for factory

reserved inputs which are not user selectable.

Common Faults

The user can program a single fault comprised of faults from 3 common fault programs—system, digital, and analog faults.

Up to 62 user-defined system status events and faults are available. See Group B on the following pages for specific descriptions. The NFPA 110 faults are part of the system fault program and are comprised of 15 individual faults shown on the next page.

The user can select up to 21 user-defined digital status events and faults designated as D01 to D21. Each of the 21 status events and faults are assignable as shutdowns or warnings.

The user can select up to 7 user-defined analog status events and faults designated as A01 to A07. Each of the 7 status events and faults are assignable as shutdowns or warnings with high or low settings for a total of up to 7 status events and fault functions.

Relay Driver Outputs (RDOs)

Up to 31 RDOs are available using the system, digital, and analog status events and faults. RDOs provide only the driver. The contact relays that interface with other equipment are optional.

Note: Func(tion) Used By (RDO) XX Reassign? error

message appears when the user attempts to duplicate an existing RDO selection.

Note: Cannot Change NFPA is Enabled. error message

appears when the user attempts to modify RDO setting defaulted as NFPA 110 requirement.

Menu 10 Overview

MENU 10 OUTPUT SETUP

DEFINE COMMON → FAULTS

RELAY DRV OUT XX → (see Group E)

Press down arrow to scroll through RDO’s 1--31 or enter RDO number.

SYSTEM EVENTS →

COMMON FAULT Y/N (see Group B)

Press down arrow to scroll through available faults.

SYSTEM EVENTS →

RELAY DRV OUT XX Y/N (see Group B)

Press down arrow to scroll through available RDO faults.

DIGITAL INPUTS →

COMMON FAULT Y/N (see Group C)

Press down arrow to scroll through digital auxiliary inputs.

DIGITAL INPUTS →

RELAY DRV OUT XX Y/N (see Group C)

Press down arrow to scroll through RDO digital auxiliary inputs.

ANALOG INPUTS →

COMMON FAULT Y/N

(see Group D)LO WARNING→

Press down arrow to scroll through analog auxiliary inputs.

ANALOG INPUTS →

RELAY DRV OUT XX Y/N

(see Group D)LO WARNING→

Press down arrow to scroll through RDO analog auxiliary inputs.

COMMON FAULT Y/N

HI WARNING

COMMON FAULT Y/N

LO SHUTDOWN

COMMON FAULT Y/N

HI SHUTDOWN

RELAY DRV OUT Y/N

HI WARNING

RELAY DRV OUT Y/N

LO SHUTDOWN

→

RELAY DRV OUT Y/N

HI SHUTDOWN

TP-6200 10/1264 Section 2 Operation

→

Page 65

Menu 10 Overview, continued

Group B

For defined system events, choose from the following 66 status events and faults by changing selection to YES. See Appendix E for application and restrictions with specific engines.

EMERGENCY STOP

OVER SPEED

OVER CRANK

HI COOL TEMP SHUTDWN

OIL PRESS SHUTDOWN

LOW COOLANT TEMP (non-ECM

engines)

LOW FUEL

HI COOL TEMP WARNING

OIL PRES WARNING

MASTER NOT IN AUTO

NF PA 110 FAULT*

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

BATTERY CHARGE FAULT

SYSTEM READY

LOSS OF ECM COMM (ECM engines)

NO OIL PRESS SIGNAL

HI OIL TEMP

NO COOL TEMP SIGNAL

LOW COOLANT LEVEL

SPEED SENSOR FAULT

LOCKED ROTOR

MASTER SWITCH ERROR

MASTER SWITCH OPEN

MASTER SWITCH TO OFF

AC SENSING LOSS

OVER VOLTAGE

UNDER VOLTAGE

WEAK BATTERY

OVER FREQUENCY

UNDER FREQUENCY

LOAD SHED KW OVER

LOAD SHED UNDER FREQ

OVER CURRENT

EPS SUPPLYING LOAD

INTERNAL FAULT

DELAY ENG COOLDOWN

DELAY ENG START

STARTING AID

GENERATOR RUNNING

AIR DAMPER CONTROL

GROUND FAULT

EEPROM WRITE FAILURE

CRITICAL OVERVOLTAGE

ALTERNATOR PROTECTION SHUTDOWN

AIR DAMPER INDICATOR DEFINED COMMON FAULT (RDO only)[

SCRDOs 1--4 (software controlled RDOs)

MAINTENANCE DUE

ENGINE DERATE ACTIVE

ENGINE STALLED

J1939 CAN SHUTDOWN

*NFPA 110 FAULT

The 15 NFPA 110 Fault Alarms include the following:

OVERSPEED

OVERCRANK

HIGH COOLANT TEMP SHUTDOWN

OIL PRESSURE SHUTDOWN

LOW COOLANT TEMPERATURE

HIGH COOLANT TEMP WARNING

OIL PRESSURE WARNING

LOW FUEL

MASTER NOT IN AUTO

BATTERY CHARGER FAULT

LOW BATTERY VOLTAGE

HIGH BATTERY VOLTAGE

LOW COOLANT LEVEL

EPS SUPPLYING LOAD

AIR DAMPER INDICATOR

[DEFINED COMMON FAULT

The 5 defined common faults include the following:

EMERGENCY STOP

HI COOL TEMP SHUTDOWN

OIL PRESS SHUTDOWN

OVERCRANK

OVERSPEED

Group B, continued

Paralleling applicatons:

SD REVERSE POWER

SD OVER POWER

SD LOSS OF FIELD

SD OVERCURRENT PR

COMMON PR OUTPUT

IN SYNCH

BREAKER TRIP

Waukesha-powered models:

FUEL VALVE RELAY

PRELUBE RELAY

AFM REMOTE START

NO OIL TEMP SIGNAL

HI OIL TEMP WARNING

NO AIR TEMP SIGNAL

INTAKE AIR TEMP WARN

INTAKE AIR TEMP SDWN

AFM ENG START DELAY

DDC/MTU engine with MDEC/ADEC:

HI OIL TEMP WARNING

INTAKE AIR/TEMP WARN

INTAKE AIR TEMP SDWN

ECM YELLOW ALARM

ECM RED ALARM

BLOCK HEATER CONTROL

LOW COOL TEMP SDOWN

LOAD SHED OVER TEMP

Group C

Up to 21 user-defined digital status events and fault inputs designated as D01 to D21 can result in a digital input common fault.

Group D

Up to 7 analog inputs, user- defined status events and faults designated as A01 to A07. Each of the 7 is assignable as a shutdown or warning with high or low settings.

Group E

Choose up to 31 status event and fault RDOs from the following:

SYSTEM FAULTS (see Group B, 66 Items)

DIGITAL INPUTS (see Group C, 21 Items)

ANALOG INPUTS (see Group D, 7 Items)

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2.7.11 Menu 11—Voltage Regulator

See Section 2.8.11 to make changes in this menu.

Menu 1 1 displays setup of the voltage regulator functions including line-to-line voltages, underfrequency unloading (volts per Hz), reactive droop, power factor, and kVAR adjustments.

The user must enable the programming mode to edit the display.

Menu 11 Overview

MENU 11 VOLTAGE REGULATOR

AVG L-L V # → VOLT ADJ ?.?

UNDER FREQ UNLOAD → ENABLED Y/N

REACTIVE DROOP → ENABLED Y/N

VAR CONTROL → ENABLED Y/N

L1-L2 VOLTS → #

FREQUENCY # HZ→ SETPOINT ?.? HZ

.8 PF RATED LOAD → VOLTAGE DROOP ?.?%

TO TA L KVA R # → KVAR ADJ ?.?

Note: The individual line-to-line voltages are displayed

for review purposes only.

Note: Voltage regulator gain is used for adjusting

voltage stability and/or response.

Note: Utility gain is used for VAR or PF stability adjust

while paralleling to a utility.

L2-L3 VOLTS (3 PHASE) → #

SLOPE → ?.? VOLTS-PER-CYCLE

GENERATING/ Y/N→ ABSORBING Y/N

L3-L1 VOLTS (3 PHASE) → #

PF CONTROL → ENABLED Y/N

REGULATOR GAIN ADJ GAIN #

UTILITY GAIN ADJUST GAIN #

ANALOG VOLTAGE ADJUST ENABLED Y/N

RESET REGULATOR DEFAULTS? Y/N

AVERAGE PF # → PF ADJ ?.?

LAGGING/ Y/N→ LEADING Y/N

TP-6200 10/1266 Section 2 Operation

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2.7.12 Menu 12—Calibration

Menu 12 provides access to the calibration factors for metering (volts and amps) and auxiliary analog inputs. Changing the system voltage or replacing the main logic control circuit board requires calibration adjustment.

Menu 12 Overview

MENU 12

CALIBRATION

The user must enable the programming mode to edit the display.

See Section 2.8.12 to make calibration changes.

SCALE AC ANALOG INPUTS

GEN VOLTAGE LN

GEN L1--L0 V # CALIB REF ?

GEN L2--L0 V # CALIB REF ?

GEN L3--L0 V (3 PHASE) # CALIB REF ?

SCALE AUX. ANALOG INPUTS

ZERO AUX. ANALOG INPUTS? Y/N

GEN L1--L2 V #

CALIB REF ?

GEN L2--L3 V (3 PHASE) #

CALIB REF ?

GEN L3--L1 V (3 PHASE) #

CALIB REF ?

CALIBRATE REGULATOR?

Y/N

Press YES or NO. Text appears on display lower line. Pressing ENTER confirms YES or NO selection.

GEN AMPS LOAD VOLTAGE LN

GEN L1 AMPS # CALIB REF ?

GEN L2 AMPS (3 PHASE)# CALIB REF ?

GEN L3 AMPS (3 PHASE)# CALIB REF ?

LOAD L1--L0 V # CALIB REF (PARALLEL) ?

LOAD L3--L0 V # CALIB REF (PARALLEL) ?

TO SCALE AUX. ANALOG INPUTS SETUP (NEXT)

RESTORE DEFAULTS Y/NGEN VOLTAGE LL

TO AC ANALOG INPUTS SETUP (PREVIOUS)

ANALOG XX # SCALE VALUE 1 ?

ANALOG XX # SCALE VALUE 2 ?

SCAL1 #V SCAL2 #V

SCAL 1 # V SCAL 2 # V

TP-6200 10/12 67Section 2 Operation

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2.7.13 Menu 13—Communications

Menu 13 shows the settings for remote communications.

See Section 2.8.13 to make changes in this menu.

See the Modbusr Communications Protocol operation manual for a list of Modbusr registers for the 550 Controller.

Menu 13 Overview

MENU 13 COMMUNICATIONS

PROTOCOL → KBUS

KBUS ONLINE Y/N

CONNECTION TYPE → (USER DEFINED) Y/N

PRIMARY PORT → (USER DEFINED)

ADDRESS ? (LAN Connections)

SYSTEM ID ? (Remote Connections)

BAUD RATE → (USER DEFINED) Y/N

CONNECTION TYPES LOCAL SINGLE Y/N LOCAL LAN Y/N LOCAL LAN CONV Y/N REMOTE SINGLE Y/N REMOTE LAN Y/N REMOTE LAN CONV Y/N

PRIMARY PORTS RS-232 Y/N RS-485 ISO 1 Y/N

BAUD RATES

1200 Y/N 2400 Y/N 9600 Y/N

PROTOCOL → MODBUS

MODBUS ONLINE Y/N

CONNECTION TYPE → (USER DEFINED) Y/N

PRIMARY PORT → (USER DEFINED) Y/N

ADDRESS ?

BAUD RATE → (USER DEFINED) Y/N

CONNECTION TYPES SINGLE Y/N CONVERTOR Y/N

PRIMARY PORTS RS-232 Y/N RS-485 Y/N

BAUD RATES 9600 Y/N 19200 Y/N

Modbusr is a registered trademark of Schneider Electric.

TP-6200 10/1268 Section 2 Operation

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2.7.14 Menu 14—Programming Mode

Menu 14 provides local or remote access to the programming function. The user enters a password to access the programming mode.

Note: Log into the local programming mode to edit the

programming access code. The factory default

access code is the number 0.

Use Menu 14 to change the access code. Record the new number and give the access code only to authorized individuals. Should the controller logic not accept the access code or if the new code number is lost, contact your local authorized distributor/dealer for password information.

The user chooses one of three programming modes:

D Local—using the controller keypad D Remote—using a PC D Off—no programming is permitted

Note: Use the generator set controller to initially set up

remote programming. Remote programming cannot be accessed from a PC unless the controller is first set for remote programming using Menu 14.

See Section 2.8.14.

Menu 14 Overview

MENU 14 PROGRAMMING MODE

PROGRAMMING MODE → LOCAL Y/N

PROGRAMMING MODE → CHANGE ACCESS CODE

PROGRAMMING MODE → REMOTE Y/N

PROGRAMMING MODE → ENTER OLD CODE #

PROGRAMMING MODE → OFF Y/N

PROGRAMMING MODE → ENTER NEW CODE #

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2.7.15 Menu 15—Protective Relays (PR)

Menu 15 provides protective relay setup and time delays for units with the paralleling protection option. This menu will only be visible and accessible if this option is included. The shutdown (SD) settings override those in menu 7 and/or menu 8.

See Section 2.8.15 to make changes in this menu, when the paralleling option is enabled.

Menu 15 Overview

MENU 15 PROTECTIVE RELAYS

PR OVERVOLTAGE → ?% # VAC

PR UNDERVOLTAGE → ?% # VAC

PR OVERFREQUENCY → ?% # HZ

PR UNDERFREQUENCY → ?% # HZ

PR REVERSE POWER → ?% # KW

SD REVERSE POWER → ?% # KW

PR OVER POWER → ?% # KW

SD OVER POWER → ?% # KW

TIME DELAY → ? SEC

PR LOSS OF FIELD → ?% # KVAR

SD LOSS OF FIELD → ?% # KVAR

PR OVER CURRENT VR → ?% # AMPS

SD OVER CURRENT VR → ?% # AMPS

SYNC VOLTAGE MATCH → ?VAC

TIME DELAY → ? SEC

SYNC FREQ MATCH → ?HZ

SYNC PHASE MATCH → ?DEG

TIME DELAY → ? SEC

TP-6200 10/1270 Section 2 Operation

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2.7.16 Menu 20—Factory Setup (Version 2.10)

Menu 20 provides factory setup information including the number of operating days, generator set information, alternator information, engine information, controller information, and the controller software (code) version.

Menu 20 Overview

MENU 20 FACTORY SETUP

FINAL ASSEMBLY DATE DD/MM/YY

FINAL ASSEMBLY CLOCK NO ?

OPERATING DAYS #

MODEL NO #

SPEC NO #

GENSET SERIAL NO #

ALTERNATOR PART NO #

ENGINE PART NO #

SERIAL NO #

CONTROLLER SERIAL NO

CODE VERSION # COPYRIGHT XXXX

SETUP LOCKED YES

TP-6200 10/12 71Section 2 Operation

Page 72

2.7.17 Menu 20—Factory Setup (Version 2.21)

See Section 2.8.16 to make changes in this menu.

Menu 20 Overview

MENU 20 FACTORY SETUP

FINAL ASSEMBLY DATE DD/MM/YY

FINAL ASSEMBLY CLOCK NO ?

OPERATING DAYS #

Note: For Version 2.69 and lower, enter the numeric

serial number from the generator set nameplate. For Version 2.70 and higher, confirm that the alpha-numeric number shown on the display matches the serial number shown on the generator set nameplate. If the serial match

, press the YES key and then press

ENTER. If the serial numbers do not match

numbers

,the wrong personality parameter file is installed. Refer to the Program Loader documentation for instructions on reloading the personality parameter file.

MODEL NO #

SPEC NO #

GENSET SERIAL NO #

ALTERNATOR PART NO #

ENGINE PART NO #

TEMP SENSOR YES GM31045--X

SERIAL NO CONFIRM →

CONTROLLER SERIAL NO

TEMP SENSOR NO GM16787

CONFIRM SERIAL? YES ######

TEMP SENSOR NO GM17362

CODE VERSION # COPYRIGHT XXXX

SETUP LOCKED YES

TP-6200 10/1272 Section 2 Operation

Page 73

Notes

TP-6200 10/12 73Section 2 Operation

Page 74

2.8 Local Programming Mode On

The Local Programming Mode On section explains how to program the generator set controller logic. Each menu contains a step-by-step procedure for programming the various logic groups. See Section 1, Specifications, for setting ranges and default settings.

Please read and understand the entire Local Programming Mode On section before attempting any programming. The factory settings are adjustable and programming without full understanding of the logic features and functions can cause inadvertent changes.

Refer to Menu 14—Programming Mode for information regarding menu programming activation. After completing the programming always place the controller back in the Programming Mode Off position to prevent inadvertent program changes.

The programming feature alters stored settings and changes characteristics of the logic. Do not operate the controller with the program mode on unless there is a need to edit program logic or clear stored data. Limit programming responsibilities to individuals with training and authority.

The product application requires expertise in the design and programming of control systems. Only qualified personnel should program, install, alter, and apply this product.

Use Section 2.7, Reviewing the Menu Displays, to view the generator set operation data and review previously programmed information and to review the data when no programming is necessary.

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

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

Menus displaying the ? symbol require the user to enter data.

Menus displaying the * symbol represent access code or password type entries. Actual key entry does not display.

See Section 2.5.3, Request and Error Messages, for error display messages and explanations should they appear while navigating through the menus.

All menu displays apply to both single-phase and three-phase voltages unless otherwise noted as (1 PH) or (3 PH) on the menu overview. The phase designation does not appear in the actual menu displays.

Note: Place the generator set master switch in the OFF/

RESET position when using local programming mode on.

Note: Use the generator set controller to initially set up

the remote programming. Set the controller for remote programming using Menu 14 and remote communication using Menu 13 before attempting remote programming.

Note: Press any key on the keypad to activate the

controller panel display. The panel display turns off 5 minutes after the last keypad entry.

Note: Press the Reset Menu key to clear the Error

display.

Note: Press the Menu Right → key prior to entering

decimal values where necessary.

Refer to Figure 2-18 for a quick reference to the menu number and description.

Menu No. Menu Description

1 Generator Monitoring (Three-Phase Connections)

1 Generator Monitoring (Single-Phase Connections)

2 Engine Monitoring

3 Analog Monitoring

4 Operational Records

5 Event History

6 Time and Date

7 Generator System

8 Time Delays

9 Input Setup

10 Output Setup

11 Voltage Regulator

12 Calibration

13 Communication

14 Programming Mode

15 Protective Relays

20 Factory Setup Menu

Figure 2-18 Menu Number and Description

Local Programming Mode On

TP-6200 10/1274 Section 2 Operation

Page 75

2.8.1 Menu 1—Generator Monitoring

Note: For the auto-scroll function, press ENTER at the

V & A Summary menu. Press the Reset Menu

Menu 1 provides generator output data including line-to-line and line-to-neutral voltages, current,

key or Menu Right → key to stop the auto-scroll function.

frequency, power factor, total kilowatts, percent of maximum kW, total kVA and total kVAR displays. Menu 1 displays three-phase and single-phase

Note: A right arrow from any submenu moves to the

next submenu header.

connections separately.

Menu 1—Generator Monitoring (Three-Phase Connections)

Menu 1 Displays with Key Entries

Note: This menu is for monitoring only; no adjustments or user settings can be entered.

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 1

MENU 1

GENERATOR MONITORING

VOLTS & AMPS →

L1-L2 VOLTS # L1 AMPS #

L2-L3 VOLTS # L2 AMPS #

L3-L1 VOLTS # L3 AMPS #

L1-L0 VOLTS # L1 AMPS #

L2-L0 VOLTS # L2 AMPS #

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the volts and amps heading.

Displays L1 and L2 volts and L1 amps.

Displays L2 and L3 volts and L2 amps.

Displays L3 and L1 volts and L3 amps.

Displays L1-L0 volts and L1 amps.

Displays L2 and L0 volts and L2 amps.

L3-L0 VOLTS # L3 AMPS #

FREQUENCY # HZ

GENERATOR MONITORING

VOLTS & AMPS →

V&ASUMMARY →

V L1-L2 L2-L3 L3-L1

V L1-L0 L2-L0 L3-L0

TP-6200 10/12 75Section 2 Operation

MENU 1

###

Local Programming Mode On

Displays L3-L0 volts and L3 amps.

Displays the frequency.

Returns the user to the menu number and name.

Returns the user to volts and amps heading.

Displays the volts and amps summary heading.

Displays L1-L2, L2-L3, and L3-L1 volts.

Displays L1-L0, L2-L0, and L3-L0 volts. (3 ph. only)

Page 76

Menu 1—Generator Monitoring (Three-Phase Connections), continued

Menu 1 Displays with Key Entries

Key Entry Display Description

A L1L2L3

###

V&ASUMMARY →

POWER KW →

TOTAL KW # PF # LEADING/LAGGING

L1 KW # PF # LEADING/LAGGING

L2 KW # PF # LEADING/LAGGING

L3 KW # PF # LEADING/LAGGING

TOTAL KW # %OFRATEDKW #

POWER KW →

Displays L1, L2, and L3 amps.

Returns the user to the volts and amps summary heading.

Displays the power kilowatt heading.

Displays total kilowatts and leading or lagging power factor.

Displays total L1 kilowatts and leading or lagging power factor.

Displays total L2 kilowatts and leading or lagging power factor.

Displays total L3 kilowatts and leading or lagging power factor.

Displays the total kW and percent of rated kilowatts.

Returns the user to the power kilowatt heading.

POWER KVAR →

TO TA L KVA R # ABSORBING/GENERATING

L1 KVAR # ABSORBING/GENERATING

L2 KVAR # ABSORBING/GENERATING

L3 KVAR # ABSORBING/GENERATING

POWER KVAR →

POWER KVA →

TO TA L KVA #

L1 KVA #

Displays the power kVAR heading.

Displays total kVAR, absorbing or generating.

Displays L1 kVAR, absorbing or generating.

Displays L2 kVAR, absorbing or generating.

Displays L3 kVAR, absorbing or generating. (3 ph. only)

Returns the user to power kVAR heading.

Displays the power kVA heading.

Displays total kVA.

Displays L1 kVA.

L2 KVA #

Displays L2 kVA.

Local Programming Mode On

TP-6200 10/1276 Section 2 Operation

Page 77

Menu 1—Generator Monitoring (Three-Phase Connections), continued

Menu 1 Displays with Key Entries

Key Entry Display Description

L3 KVA #

POWER kVA →

Displays L3 kVA.

Returns the user to power kVA heading.

Menu 1—Generator Monitoring (Single-Phase Connections)

Menu 1 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 1

MENU 1

GENERATOR MONITORING

VOLTS & AMPS →

L1-L2 VOLTS # L1 AMPS #

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the volts and amps heading.

Displays L1 and L2 volts and L1 amps.

L1-L2 VOLTS # L2 AMPS #

L1-L0 VOLTS # L1 AMPS #

L2-L0 VOLTS # L2 AMPS #

FREQUENCY # HZ

MENU 1

GENERATOR MONITORING

VOLTS & AMPS →

V&ASUMMARY →

V L1-L2 L1-L0 L2-L0

###

AL1L2

Displays L1 and L2 volts and L2 amps.

Displays L1-L0 volts and L1 amps.

Displays L2 and L0 volts and L2 amps.

Displays the frequency.

Returns the user to the menu number and name.

Returns the user to volts and amps heading.

Displays the volts and amps summary heading.

Displays L1-L2, L1-L0, and L2-L0 volts.

Displays L1 and L2 amps.

V&ASUMMARY →

TP-6200 10/12 77Section 2 Operation

Local Programming Mode On

Returns the user to the volts and amps summary heading.

Page 78

Menu 1—Generator Monitoring (Single-Phase Connections), continued

Menu 1 Displays with Key Entries

Key Entry Display Description

POWER KW →

TOTAL KW # PF # LEADING/LAGGING

L1 KW # PF # LEADING/LAGGING

L2 KW # PF # LEADING/LAGGING

TOTAL KW # %OFRATEDKW #

POWER KW →

POWER KVAR →

TO TA L KVA R # ABSORBING/GENERATING

L1 KVAR # ABSORBING/GENERATING

L2 KVAR # ABSORBING/GENERATING

Displays the power kilowatt heading.

Displays total kilowatts and leading or lagging power factor.

Displays total L1 kilowatts and leading or lagging power factor.

Displays total L2 kilowatts and leading or lagging power factor.

Displays the total kW and percent of rated kilowatts.

Returns the user to the power kilowatt heading.

Displays the power kVAR heading.

Displays total kVAR, absorbing or generating.

Displays L1 kVAR, absorbing or generating.

Displays L2 kVAR, absorbing or generating.

POWER KVAR →

POWER KVA →

TO TA L KVA #

L1 KVA #

L2 KVA #

POWER kVA →

Returns the user to power kVAR heading.

Displays the power kVA heading.

Displays total kVA.

Displays L1 kVA.

Displays L2 kVA.

Returns the user to power kVA heading.

Local Programming Mode On

TP-6200 10/1278 Section 2 Operation

Page 79

2.8.2 Menu 2—Engine Monitoring

Menu 2 provides engine operating data including oil pressure and temperature, coolant temperature, fuel pressure and temperature, engine rpm, and battery voltage. Menu 2 also displays engine warning and

The detailed engine monitoring functions appear only for DDEC (DDC/MTU), JDEC (John Deere), EMS2 (Volvo), EDC3 (Volvo), or MDEC/ADEC (DDC/MTU)- equipped

engines. shutdown setpoints and engine warmed-up and cooleddown temperature setpoints.

Note: A right arrow from any submenu moves to the

next submenu header.

Menu 2—Engine Monitoring

Menu 2 Displays with Key Entries

Note: This menu is for monitoring only; no adjustments or user settings can be entered.

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 2

MENU 2

ENGINE MONITORING

ENGINE MONITORING → BASIC

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the basic engine monitoring heading.

OIL PRESSURE # PSI COOLANT TEMP # F

INTAKE AIR # F OIL TEMP (Waukesha) # F

ENGINE RPM # LOCAL BATT VDC #

HCT WARN # F HCT SDOWN # F

LOP WARN # PSI LOP SDOWN # PSI

ENGINE WARMED UP #F

ENGINE COOLED DOWN #F

MENU 2

ENGINE MONITORING

ENGINE MONITORING → BASIC

Displays the oil pressure and coolant temperature.

Displays the intake air and oil temperature (Waukesha-powered models only)

Displays the engine rpm and local battery VDC.

Displays the high coolant temperature warning and shutdown setpoints.

Displays the low oil pressure warning and shutdown setpoints.

Displays the engine warmed up temperature setpoint.

Displays the engine cooled down temperature setpoint.

Returns the user to the menu number and name.

Returns the user to basic engine monitoring heading.

TP-6200 10/12 79Section 2 Operation

Local Programming Mode On

Page 80

Menu 2—Engine Monitoring, continued

Menu 2 Displays with Key Entries

Key Entry Display Description

(DDEC/JDEC/EMS2/EDC3-Equipped Engines only)

ENGINE MONITORING → DETAILED

ENGINE FUEL →

FUEL PRES # PSI FUEL TEMP # F

CHR AIR PRESS # PSI CHR AIR TEMP # F

FUEL RATE # GPH

USED LAST RUN #GAL

ENGINE MONITORING → DETAILED

ENGINE FUEL →

ENGINE COOLANT →

Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature requires a DDEC/JDEC/EMS2/EDC3-equipped engine.

Displays the engine fuel subheading.

Displays the fuel pressure and fuel temperature.

Displays the charge air pressure and temperature.

Displays the fuel rate per hour.

Displays the amount of fuel used during the last run.

Returns the user to the detailed engine monitoring heading.

Displays the engine fuel subheading.

Displays the engine coolant subheading.

COOLANT PRES # PSI COOLANT TEMP # F

COOLANT LEVEL #%

ENGINE COOLANT →

ENGINE OIL →

OIL PRES # PSI OILTEMP #F

OIL LEVEL #% CRANKCASE PRES # PSI

ENGINE OIL →

ENGINE MISC →

ECMBATTVDC # AMBIENT TEMP # F

Displays the coolant pressure and coolant temperature.

Displays the coolant level as a percent of full capacity.

Returns the user to engine coolant subheading.

Displays the engine oil subheading.

Displays the oil pressure and oil temperature.

Displays the oil level as a percent of full capacity and crankcase pressure.

Returns the user to engine oil subheading.

Displays the miscellaneous engine subheading.

Displays the engine ECM battery VDC and ambient temperature.

Local Programming Mode On

TP-6200 10/1280 Section 2 Operation

Page 81

Menu 2—Engine Monitoring, continued

Menu 2 Displays with Key Entries

Key Entry Display Description

(DDEC/JDEC/EMS2/EDC3-Equipped Engines only, continued)

ENGINE MODEL NO. #

ENGINE SERIAL NO. #

UNIT NO. # ECM S/N #

ECM FAULT CODES #

ENGINE MISC →

Displays the engine model number.

Displays the engine serial number.

Displays the unit number and ECM serial number.

Displays the ECM fault codes.

Returns the user to the miscellaneous engine subheading.

TP-6200 10/12 81Section 2 Operation

Local Programming Mode On

Page 82

Menu 2—Engine Monitoring, continued

Menu 2 Displays with Key Entries

Key Entry Display Description

(MDEC-Equipped Engines only)

ENGINE MONITORING → DETAILED

ENGINE FUEL →

FUEL PRES # PSI FUEL TEMP # F

CHG AIR PRESSURE # PSI CHG AIR TEMP # F

FUEL RATE * # GPH

DAILY FUEL USED * # GAL

TOTALFUELUSED* #GAL

ENGINE MONITORING → DETAILED

ENGINE FUEL →

Displays the detailed engine monitoring heading. Note: The detailed engine monitoring feature requires a DDC/MTU MDEC/ADEC-equipped engine.

Displays the engine fuel subheading.

Displays the fuel pressure and fuel temperature.

Displays the turbocharger air pressure and temperature.

Displays the fuel rate per hour.

Displays the amount of fuel used during the last 24 hours.

Displays the amount of fuel used since the last reset.

Returns the user to the detailed engine monitoring heading.

Displays the engine fuel subheading.

ENGINE OIL →

OIL PRES # PSI OILTEMP #F

ENGINE OIL →

ENGINE MISC →

ECU SUPPLY VDC # AMBIENT TEMP # F

ECU HOURS #

ECU FAULT CODES #

ENGINE MISC →

* While these menu displays do appear on the 550 controller, the engine ECM is not currently set up to provide this data.

Displays the engine oil subheading.

Displays the oil pressure and oil temperature.

Returns the user to engine oil subheading.

Displays the miscellaneous engine subheading.

Displays the engine ECU supply VDC and ambient temperature.

Displays the ECU operating hours.

Displays the ECU fault codes.

Returns the user to the miscellaneous engine subheading.

Local Programming Mode On

TP-6200 10/1282 Section 2 Operation

Page 83

2.8.3 Menu 3—Analog Monitoring

Menu 3 provides the battery voltage and up to 7 userdefined analog monitoring items dependent upon the generator system.

Analog Voltage Adjust. When the analog voltage adjust option is enabled (see Menu 11), analog input 7 is predefined as voltage adjust. The voltage of this input will define the adjustment from the setting in Menu 11, Voltage Regulator. The normal analog input range of

0.5 to 4.5 corresponds to a ±10% of system voltage. The

Menu 3—Analog Monitoring (ECM Engines)

Menu 3 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 3

Input a menu number.

Press the Enter key.

midpoint 2.5 volts corresponds to 0 volts offset. If there

is no connection at analog input 7, no voltage adjust is

recognized.

Note: If the analog display shows O/R (out of range), no

input is connected.

Note: Some data require entry using a PC in the

Remote Programming mode. See the monitor software operation manual for details.

Note: See Figure 2-8 in User Inputs for factory

reserved inputs which are not user selectable.

Note: This menu is for monitoring only; no adjustments

or user settings can be entered.

MENU 3

ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 01 # (USER DEFINED DESC)

ANALOG 02 # (USER DEFINED DESC)

ANALOG 03 # (USER DEFINED DESC)

ANALOG 04 # (USER DEFINED DESC)

ANALOG 05 # (USER DEFINED DESC)

ANALOG 06 # (USER DEFINED DESC)

ANALOG 07 # (USER DEFINED DESC)

ANALOG 07 # ANALOG VOLT ADJUST

Displays the menu number and name.

Displays the local battery VDC.

Displays analog 01 and the user-defined description.

Displays analog 02 and the user defined description.

Displays analog 03 and the user-defined description.

Displays analog 04 and the user-defined description.

Displays analog 05 and the user-defined description.

Displays analog 06 end the user-defined description.

Displays analog 07 and the user-defined description.

Displays analog 07 voltage adjustment VDC value when analog voltage adjust is enabled.

ANALOG MONITORING

MENU 3

TP-6200 10/12 83Section 2 Operation

Local Programming Mode On

Returns user to analog monitoring heading. Note: Enter data using a PC in the Remote Programming Mode.

Page 84

Menu 3—Analog Monitoring (Non-ECM Engines)

Menu 3 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 3

MENU 3

ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 03 # (USER DEFINED DESC)

ANALOG 04 # (USER DEFINED DESC)

ANALOG 05 # (USER DEFINED DESC)

ANALOG 06 # (USER DEFINED DESC)

ANALOG 07 # (USER DEFINED DESC)

ANALOG 07 # ANALOG VOLT ADJUST

ANALOG MONITORING

MENU 3

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the local battery VDC.

Displays analog 03 and the user-defined description.

Displays analog 04 and the user-defined description.

Displays analog 05 and the user-defined description.

Displays analog 06 end the user-defined description.

Displays analog 07 and the user-defined description.

Displays analog 07 voltage adjustment VDC value when this option is enabled.Note:This function may be overridden by changing the description using the optional Monitor III software or by disabling in Menu 11.

Returns user to analog monitoring heading. Note: Enter data using a PC in the Remote Programming Mode.

Local Programming Mode On

TP-6200 10/1284 Section 2 Operation

Page 85

Menu 3—Analog Monitoring (Waukesha Engines)

Menu 3 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 3

MENU 3

ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 05 # (USER DEFINED DESC)

ANALOG 06 # (USER DEFINED DESC)

ANALOG 07 # (USER DEFINED DESC)

ANALOG 07 # ANALOG VOLT ADJUST

ANALOG MONITORING

MENU 3

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the local battery VDC.

Displays analog 05 and the user-defined description.

Displays analog 06 end the user-defined description.

Displays analog 07 and the user-defined description.

Returns user to analog monitoring heading. Note: Enter data using a PC in the Remote Programming Mode.

TP-6200 10/12 85Section 2 Operation

Local Programming Mode On

Page 86

2.8.4 Menu 4—Operational Records

Menu 4 provides the generator set operational records including the operating start date, last logged maintenance, total run time loaded and unloaded, run time since the last maintenance, number of starts, and number of running days.

Run Time Feature. This menu provides the ability to run the generator set for a designated time. After the run time elapses. the generator set shuts down and functions in the standby mode. The generator set controller does not provide weekly scheduled exercise periods.

Menu 4—Operational Records

Menu 4 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 4

Input a menu number.

Press the Enter key.

Generator set connected to an automatic transfer

switch. Should a utility power failure occur while the unit

is in the run time mode, the controller bypasses the run

time mode and functions in the standby (backup) mode.

If the utility power returns, the generator set continues to

run for the duration of the run time period if not timed out.

Note: Press the STOP PROG RUN key to stop the

generator set when in the run time mode, if necessary.

After performing maintenance, enter yes to reset

records reflecting the current day. The user must enable

the programming mode to edit the display.

OPERATIONAL RECORDS

MENU 4

FACTORY TEST DATE ##-###-##

TOTAL RUN TIME HRS #

TOTAL RUN TIME LOADED HRS #

TOTAL RUN TIME UNLOADED HRS #

TOTAL RUN TIME KW HRS #

NO. OF STARTS #

ENGINE START? Y/N→ COUNTDOWN ##:##

RUN TIME HR:MN→

??:??

RUN TIME HR:MN→

##:##

Displays the menu number and name.

Displays the factory test date (day-month-year).

Displays the total run time (hours:minutes).

Displays the total run time for loaded hours.

Displays the total run time for unloaded hours.

Displays the total run time in kW hours.

Displays the number of engine starts.

Displays the start and countdown subheading.

Displays the run time (hours:minutes) feature. When required, use the numeric keys to enter the selected run time (hours:minutes) and press the Enter key.

Confirms entry and displays the selected run time (hours:minutes). The generator set will start after activation. Note: Activate the generator set run time feature by pressing the Yes and Enter keys. See the following steps.

ENGINE START? Y/N→ COUNTDOWN ##:##

Returns the user to the start and countdown subheading. Enter Yes to start the generator set.

Local Programming Mode On

TP-6200 10/1286 Section 2 Operation

Page 87

Menu 4—Operational Records, continued

Menu 4 Displays with Key Entries

Key Entry Display Description

ENGINE START? YES→ COUNTDOWN ##:##

RUN TIME HR:MN→

##:##

RECORDS MAINT →

RESET RECORDS? →

RESET RECORDS? YES→

RECORDS MAINT →

RUN TIME SINCE MAINT TOTAL HRS #

RUN TIME SINCE MAINT LOADED HRS #

Press the Enter key.

Confirms the entry. The generator set will begin cranking and run based on the run time (hours:minutes) period and all previously established time (hours:minutes) delays from Menu 8—Time Delays. Note: Press the STOP PROG RUN key to stop the generator set when in the run time mode, if necessary.

Displays the records maintenance subheading.

Displays the reset records option. After performing maintenance or when required, enter Yes to reset.

Enter Yes to reset to the current date and press the Enter key.

Confirms the entry.

Returns the user to records maintenance subheading.

Displays the run time since the last maintenance with total hours.

Displays the run time since last the maintenance with loaded hours.

RUN TIME SINCE MAINT UNLOADED HRS #

RUN TIME SINCE MAINT KW HRS #

OP E R ATING D AY S # LAST MAINT ##-###-##

NO. OF STARTS # LAST MAINT ##-###-##

LAST START ##:## AM/PM DATE ##-###-##

LENGTH OF RUN (UN)LOADED HRS #

MENU 4

OPERATIONAL RECORDS

Displays the run time since the last maintenance with unloaded hours.

Displays the run time since the last maintenance in kW hours.

Displays the operating days since the last maintenance.

Displays the number of starts since the last maintenance date (day-month-year).

Displays last the start time (hours:minutes) and date (day-month-year).

Displays the length of last run in (un)loaded hours.

Returns the user to the operational records heading.

TP-6200 10/12 87Section 2 Operation

Local Programming Mode On

Page 88

2.8.5 Menu 5—Event History

Note: This menu is for monitoring only; no adjustments

or user settings can be entered.

Menu 5—Event History

Menu 5 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 5

MENU 5

EVENT HISTORY

(MESSAGE TEXT) ##-###-## ##:## AM/PM

MENU 5

EVENT HISTORY

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the message text, date (day-month-year) and time (hours:minutes). Scroll through up to 100 stored events. See Section 2.3.5, System Warning Lamp, for fault descriptions.

Returns the user to event history heading.

Local Programming Mode On

TP-6200 10/1288 Section 2 Operation

Page 89

2.8.6 Menu 6—Time and Date

Menu 6 sets the clock time and date and internal calendar. The controller uses set time for determining the exercise run time and event records. The time and date are valid only if the controller power (starting battery) remains connected.

The user must enable the programming mode to edit the display.

Menu 6—Time and Date

Menu 6 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 6

MENU 6

TIME AND DATE

DAY OF WEEK ##-###-##

##:## AM/PM

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the day of the week, date (day-month-year), and time (hours:minutes).

Note: A change to the time/date is recorded as a system

event. The time/date reset and other events are viewable (up to 100 events). For events that occurred prior to a date change, use the previous date as the reference point for determining the event’s actual date.

TIME ??:?? AM/PM

DAY OF WEEK ##-###-##

##:## AM/PM

DATE ??-???-??

AND

DATE ??-???-??

AND

DATE ??-???-??

AND

DAY OF WEEK ##-###-##

##:## AM/PM

Displays the time (hours:minutes) of day entry. When required, use the numeric and am/pm keys to set the time (hours:minutes) of day and press the Enter key.

Displays the corrected time (hours:minutes) of day.

Displays the date (day-month-year) entry. When required, use the numeric keys to set the day of the month.

Use the Menu Right → key to select the month.

Use the numeric keys to set the two-digit year and press the Enter key.

Displays the corrected date (day- month-year).

TP-6200 10/12 89Section 2 Operation

Local Programming Mode On

Page 90

2.8.7 Menu 7—Generator System

Menu 7 contains the factory-preset generator set voltage and frequency data. Enter the corresponding data if the generator set requires voltage reconnection and/or frequency adjustment. It is imperative that the user enter the correct data because these settings trigger all related shutdowns.

See Section 2.5.3, Request and Error Messages, for error display messages and explanations while navigating the menus.

The user must enable the programming mode to edit the display.

Menu 7—Generator System

Menu 7 Displays with Key Entries

Key Entry Display Description

Note A:Some alternators have limited voltage and

frequency configurations. Inappropriate voltage or frequency entries will cause a RANGE ERROR message.

Note: The user defines the data shown in Menu 7. It is

NOT data measured by the controller and associated sensing devices. The user defines these values for purposes of calibrating the control.

Note: Press the Menu Right → key prior to entering

decimal values where necessary.

Note: The variable speed governor (VSG) display

provides the ability to parallel the generator set.

ENTER MENU NO. 1--15

MAIN MENU NUMBER 7

MENU 7

GENERATOR SYSTEM

OPERATING MODE → (see note) YES

OPERATING MODE → STANDBY NO

OPERATING MODE → STANDBY YES

OPERATING MODE → PRIME POWER NO

OPERATING MODE → PRIME POWER YES

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the operating mode selection. Note: The display sample may differ depending upon previous entries. The previously selected operating mode appears first, either standby or prime power.

Displays the optional operating mode selection. When required, enter YES for standby operating mode. Note: This display indicates the generator set application.

Enter YES to change the operating mode selection to standby and press the Enter key.

Confirms the entry.

Displays the optional operating mode selection. When required, enter YES for the prime power operating mode. Note: This display indicates the generator set application.

Enter YES to change the operating mode selection to prime power and press the Enter key.

OPERATING MODE → PRIME POWER YES

SYSTEM VOLTAGE LINE-LINE ?

SYSTEM VOLTAGE LINE-LINE #

SYSTEM FREQ # HZ

Confirms the entry.

Displays the line-to-line system voltage as entered data. When required, use the numeric keys to set new value. Press the Enter key.

Displays the corrected line-to-line system voltage. See NOTE A.

Displays the system frequency as entered data. When required, use the numeric keys to set the new value. Press the Enter key.

Local Programming Mode On

TP-6200 10/1290 Section 2 Operation

Page 91

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key Entry Display Description

SYSTEM FREQ # HZ

PHASE → (see note) YES

PHASE → 3 PHASE DELTA NO

PHASE → 3 PHASE DELTA YES

PHASE → 3 PHASE WYE NO

PHASE → 3 PHASE WYE YES

PHASE → SINGLE-PHASE NO

Displays the corrected system frequency. See NOTE A.

Displays the phase configuration selection. Note: The display sample may differ depending upon previous entries. The user-selected phase appears first, either wye, delta, or single phase.

Displays the optional phase configuration selection. When required, use the YES key to choose the delta phase configuration.

Enter YES to change the phase configuration to a delta phase configuration and press the Enter key.

Confirms the entry. See NOTE A.

Displays the optional phase configuration selection. When required, use the YES key to choose the wye phase configuration.

Enter YES to change the phase configuration to a wye phase configuration and press the Enter key.

Confirms the entry. See NOTE A.

Displays the optional phase configuration selection. When required, use the YES key to choose the single-phase configuration.

PHASE → SINGLE-PHASE YES

KW RATING ?

KW RATING #

RATED CURRENT #

LOAD SHED OUTPUT → ?% # KW

LOAD SHED OUTPUT → #% # KW

TIME DELAY MIN:SEC →

??:??

TIME DELAY MIN:SEC →

##:##

LOAD SHED OUTPUT → #% # KW

Enter YES to change the phase configuration to a single-phase configuration and press the Enter key.

Confirms the entry. See NOTE A.

Displays the generator set kW rating as entered data. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected system kilowatt rating.

Displays the generator set rated current as entered data. Note: This is a read-only display.

Displays the load shed output setting. When required, use the numeric keys to set the new value. Press the Enter key. See Menu 10, Output Setup for Group B User-Defined Systems Events

Displays the corrected load shed output setting.

Displays the load shed time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected load shed time (minutes:seconds) delay setting.

Returns the user to the load shed output setting.

TP-6200 10/12 91Section 2 Operation

Local Programming Mode On

Page 92

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key Entry Display Description

OVERVOLTAGE → ?% # VAC

OVERVOLTAGE → #% # VAC

TIME DELAY MIN:SEC →

??:??

TIME DELAY MIN:SEC →

##:##

OVERVOLTAGE → #% # VAC

UNDERVOLTAGE → ?% # VAC

UNDERVOLTAGE → #% # VAC

TIME DELAY MIN:SEC →

??:??

TIME DELAY MIN:SEC →

##:##

Displays the overvoltage setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overvoltage setting.

Displays the overvoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overvoltage time (minutes:seconds) delay setting.

Returns the user to the overvoltage setting.

Displays the undervoltage setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected undervoltage setting.

Displays the undervoltage time (minutes:seconds) delay setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overvoltage time (minutes:seconds) delay setting.

UNDERVOLTAGE → #% # VAC

OVERFREQUENCY ?% # HZ

OVERFREQUENCY #% # HZ

UNDERFREQUENCY ?% # HZ

UNDERFREQUENCY #% # HZ

OVERSPEED ?HZ #RPM

OVERSPEED #HZ #RPM

Returns the user to the undervoltage setting.

Displays the overfrequency setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overfrequency setting.

Displays the underfrequency setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected underfrequency setting.

Displays the overspeed setting. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overspeed setting.

Local Programming Mode On

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Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key Entry Display Description

BATTERY VOLTAGE → (see note) YES

BATTERY VOLTAGE → 12 VDC NO

BATTERY VOLTAGE → 12 VDC YES

BATTERY VOLTAGE → 24 VDC NO

BATTERY VOLTAGE → 24 VDC YES

LOW BATTERY VOLTAGE ?.? VDC

AND

LOW BATTERY VOLTAGE ?.? VDC

LOW BATTERY VOLTAGE #.# VDC

Displays the battery voltage selection. Note: The display sample may differ depending upon previous entries. The user-selected battery voltage appears first, either 12 VDC or 24 VDC.

Displays the 12 VDC battery voltage selection. When required, use the YES key to choose the 12 VDC battery voltage.

Enter YES to change the battery voltage to 12 VDC and press the Enter key.

Confirms the entry.

Displays the 24 VDC battery voltage selection. When required, use the YES key to choose the 24 VDC battery voltage.

Enter YES to change the battery voltage to 24 VDC and press the Enter key.

Confirms the entry.

Displays the low battery voltage setting. When required, use the numeric keys to set the new value. Press the Menu Right → key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Displays the corrected low battery voltage setting.

HIGH BATTERY VOLTAGE ?.? VDC

AND

HIGH BATTERY VOLTAGE ?.? VDC

HIGH BATTERY VOLTAGE #.# VDC

BLOCK HEATER ON # F

AND

BLOCK HEATER ON ? F

BLOCK HEATER ON # F

BLOCK HEATER OFF # F

AND

BLOCK HEATER OFF ? F

BLOCK HEATER OFF # F

Displays the high battery voltage setting. When required, use the numeric keys to set the new value. Press the Menu Right → key prior to entering the decimal value.

Use the numeric keys to enter the decimal value. Press the Enter key.

Displays the corrected high battery voltage setting.

Displays the block heater energize temperature setting. When required, use the numeric keys to set the new value. Applies to DDC/MTU engines with MDEC/ADEC only.

Use the numeric keys to enter the decimal value. Press the Enter key.

Displays the corrected block heater energize temperature setting.

Displays the block heater deenergize temperature setting. When required, use the numeric keys to set the new value. Applies to Detroit Diesel engines with MDEC/ADEC engine controls only.

Use the numeric keys to enter the decimal value. Press the Enter key.

Displays the corrected block heater deenergize temperature setting.

TP-6200 10/12 93Section 2 Operation

Local Programming Mode On

Page 94

Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key Entry Display Description

ENABLE VSG YES/NO

ENABLE VSG NO

ENABLE VSG YES

ENABLE VSG NO

ENABLE DSC YES/NO

ENABLE DSC NO

ENABLE DSC YES

Displays the variable speed governor (VSG) yes or no selection for paralleling applications. When required, use the numeric keys to set the new value. Applies to DDC/MTU MDEC/ADEC engine only.

Entering YES enables the VSG function.

Confirms the entry..

Entering NO disables the VSG function.

Confirms the entry..

Displays the digital speed control (DSC) yes or no selection for paralleling applications. When required, use the numeric keys to set the new value. Applies to DDC/MTU MDEC/ADEC engine only.

Entering YES enables the DSC function.

ENABLE DSC YES

ENABLE DSC NO

Confirms the entry..

Entering NO disables the DSC function.

Confirms the entry..

Local Programming Mode On

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Menu 7—Generator System, continued

Menu 7 Displays with Key Entries

Key Entry Display Description

METRIC UNITS Y/N

METRIC UNITS NO

METRIC UNITS YES

METRIC UNITS NO

SET NFPA-110 Y/N DEFAULTS

SET NFPA-110 NO DEFAULTS

SET NFPA-110 YES DEFAULTS

Displays the metric units selection.

Enter YES to change to metric displays and press the Enter key.

Confirms the entry.

Enter NO to change to English displays and press the Enter key.

Confirms the entry.

Displays the NFPA 110 default yes or no selection. Note: See Menu 10—Output Setup, Overview for a list of the NFPA-110 faults.

Enter YES to select the NFPA 110 default selection and press the Enter key.

SET NFPA-110 YES DEFAULTS

SET NFPA-110 NO DEFAULTS

MENU 7

GENERATOR SYSTEM

Confirms the entry.

Enter NO to deselect the NFPA 110 default selection and press the Enter key.

Confirms the entry.

Returns the user to the generator system heading.

TP-6200 10/12 95Section 2 Operation

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Page 96

2.8.8 Menu 8—Time Delays

Menu 8 displays the various time delays for cyclic cranking and other engine-related starting and shutdown features.

The user must enable the programming mode to edit the display.

Cooldown Temperature Override. This feature provides the ability to bypass (override) the generator set’s smart cooldown temperature shutdown and force

Menu 8—Time Delays

Menu 8 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 8

MENU 8

TIME DELAYS

TIME DELAY MIN:SEC ENGINE START ??:??

TIME DELAY MIN:SEC ENGINE START ##:##

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the engine start time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected engine start time (minutes:seconds) delay setting.

the generator set to run for the full engine cooldown time

delay.

If the engine is above the preset temperature and the

unit is signalled to shut down, the unit will continue to run

for the duration of the TDEC.

If the engine is at or below the preset temperature and

the unit is signalled to shut down or the TDES is running,

the unit will shut down without waiting for the time delay

to expire.

TIME DELAY MIN:SEC STARTING AID ??:??

TIME DELAY MIN:SEC STARTING AID ##:##

TIME DELAY MIN:SEC CRANK ON ??:??

TIME DELAY MIN:SEC CRANK ON ##:##

TIME DELAY MIN:SEC CRANK PAUSE ??:??

TIME DELAY MIN:SEC CRANK PAUSE ##:##

TIME DELAY MIN:SEC ENG COOLDOWN ??:??

TIME DELAY MIN:SEC ENG COOLDOWN ##:##

COOLDOWN TEMPERATURE OVERRIDE Y/N

Displays the starting aid time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected starting aid time (minutes:seconds) delay setting.

Displays the crank on time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected crank on time (minutes:seconds) delay setting.

Displays the crank pause time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected crank pause time (minutes:seconds) delay setting.

Displays the engine cooldown time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected engine cooldown time (minutes:seconds) delay setting.

Displays the cooldown temperature override. When required, use the Yes key to override the cooldown temperature time delay.

Local Programming Mode On

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Page 97

Menu 8—Time Delays, continued

Menu 8 Displays with Key Entries

Key Entry Display Description

COOLDOWN TEMPERATURE OVERRIDE YES

COOLDOWN TEMPERATURE OVERRIDE Y/N

OVERCRANK SHUTDOWN CRANK CYCLES ?

OVERCRANK SHUTDOWN CRANK CYCLES #

TIME DELAY MIN:SEC OVERVOLTAGE ??:??

TIME DELAY MIN:SEC OVERVOLTAGE ##:##

TIME DELAY MIN:SEC UNDERVOLTAGE ??:??

TIME DELAY MIN:SEC UNDERVOLTAGE ##:##

TIME DELAY MIN:SEC LOAD SHED KW ??:??

Enter YES to select cooldown temperature override time delay and press the Enter key.

Confirms the entry.

Displays the engine crank cycles before overcrank shutdown. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected engine crank cycles before overcrank shutdown setting.

Displays the overvoltage time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected overvoltage time (minutes:seconds) delay setting.

Displays the undervoltage time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

Displays the corrected undervoltage time (minutes:seconds) delay setting.

Displays the load shed time delay in minutes:seconds. When required, use the numeric keys to set the new value. Press the Enter key.

TIME DELAY MIN:SEC LOAD SHED KW ##:##

MENU 8

TIME DELAYS

Displays the corrected load shed time (minutes:seconds) delay setting.

Returns the user to the time delays heading.

TP-6200 10/12 97Section 2 Operation

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Page 98

2.8.9 Menu 9—Input Setup

Menu 9 provides the setup of user-defined digital and analog warning and shutdown inputs. These inputs provide a multitude of choices for configuring customized auxiliary inputs.

The user must enable the programming mode to edit the display.

Note: Press the down arrow to move to the start of the

next input setup.

Note: The user must scale the analog input value in

order to calculate the low/high warning and shutdown analog values based on a 0--5 VDC scale. See Menu 12, Calibration.

Note: If the ALARM ACTIVE message appears, the

selected input has an active fault disabling the input. This prevents the enabled choice change from yes to no. The LED display indicates whether the fault is a warning or shutdown. Correct the fault condition before attempting the keypad entry.

Note: Some data requires entry by a PC in the Remote

Programming mode. See the monitor software operation manual for details.

Digital and Analog Inputs. After the user selects the input, the setup requires entering the following choices or values: enabled (yes/no), inhibit time, and delay time.

Note: See Figure 2-8 in User Inputs for factory

reserved digital and analog inputs which are not user selectable.

D Enabled. This menu entry enables the input. The

previous yes/no selection does not activate the input. Digital inputs have three tier groups: the selection group (25 total), the chosen group (up to 21 total), and the enabled group (up to 21 total based on the chosen group). Analog inputs have separate warning and shutdown enabled choices.

D Inhibit Time Delay. The inhibit time delay is the time

period following crank disconnect during which the generator set stabilizes and the controller does not detect fault or status events. The inhibit time delay range is from 0 to 60 seconds.

D TIme Delay (Shutdown or Warning). The time

delay follows the inhibit time delay. The time delay is the time period between the controller fault or status event detection and the controller warning or shutdown lamp illumination. The delay prevents any nuisance alarms. The time delay range is from 0 to 60 seconds.

Digital Inputs. Items identified as not user selectable

are included for specific applications. (Example: AFM

SHUTDOWN is enabled with a Waukesha-powered

model.) The user can not disable a digital input when

identified as not user selectable.

Analog Inputs. View up to 7 user-defined analog inputs

A01--A07.

Analog Input A06—Analog Speed Adjust (VSG).

Analog Input A06 may be used for analog speed adjust

when external control of engine speed is desired such as

paralleling applications or closed transition ATS. To

utilize this capability, the input must be calibrated. Refer

to 2.8.12, Menu 12—Calibration.

Note: This feature is supported for Doosan, GM, and

Volvo engines only.

Analog Input A07—Analog Voltage Adjust. Analog

voltage adjust is a feature that the user may choose to

enable. The input designated for use as Analog Voltage

Adjust is analog input A07.

Enable Analog Voltage Adjust through Menu 11.

Additionally, Monitor 2 or Monitor 3 may be used to

enable Analog Voltage Adjust by entering the proper

description (Analog Volt Adjust) for A07. When Analog

Voltage Adjust is enabled, the description for A07 is

Analog Volt Adjust. Changing the description using

Monitor 2 or Monitor 3 disables the analog voltage

adjust feature.

When Analog Voltage Adjust is enabled, no warning or

shutdown may be enabled for A07.

Note: If the analog input A07 description does not

match Analog Volt Adjust, input A07 will not function as the voltage adjust.

Identification and Descriptions. Descriptions for user

inputs (auxiliary analog or auxiliary digital) may be

entered using the Monitor III software accessory where

the user determines the descriptions in upper and lower

case.

Local Programming Mode On

TP-6200 10/1298 Section 2 Operation

Page 99

Analog Input Values. The analog input selection typically requires entering four values: low warning, high warning, low shutdown, and high shutdown. The analog values and time delays affect how and when the controller reacts. See Figure 2-19. The user must set both the high and low levels so the unit will not inadvertently trigger the adjacent high or low value to cause a warning or shutdown fault.

Battle Switch/Fault Shutdown Override Switch. The

battle switch function forces the system to ignore normal

fault shutdowns such as low oil pressure and high

engine temperature. The battle switch does not override

the emergency stop and overspeed shutdown. When

the battle switch function is enabled the generator set

continues to run regardless of shutdown signals where

potential engine/generator damage can occur.

Each analog input has the following nine features:

D One warning enabled and one shutdown enabled D One inhibit time period D One warning delay and one shutdown delay D Two warning levels (high and low) D Two shutdown levels (high and low)

Note: The user must scale the analog input value in

order to calculate the low/high warning and shutdown values based on a 0--5 VDC scale. See Menu 12—Calibration.

Time after Crank Disconnect

Analog Val ues

High shutdown value is above the high warning value

High warning value is above the acceptable value

Acceptable analog value

Low warning value is below the acceptable value

Low shutdown value is below the low warning value

Inhibit Time Period !

The controller

does not

view the analog input signal value

Time Delay Period !

The controller does view the analog input signal value and the time

delay begins

Time Delay Complete

High shutdown function

High warning function

System ready status

Low warning function

Low shutdown function

When this input is enabled the yellow warning lamp

illuminates and stored warning/shutdown events that

are ignored continue to log in Menu 5—Event History.

Idle Mode Active. The idle time is defined by the digital

input time delay. Set the desired time in

minutes:seconds,up to 10 minutes (600 seconds). If

manual control of the idle mode is desired, an unlimited

time can be entered as 9:99. The generator set will

remain at idle speed as long as the input is active and the

generator set master switch is in the AUTO position.

Shutdown Type A and Shutdown Type B. Choose

shutdown type A for standard shutdowns where the

red lamp illuminates and the alarm horn sounds.

Choose shutdown type B for shutdowns where air

damper indicator RDO-23 energizes for two seconds,

the red lamp illuminates, and the alarm horn sounds.

Figure 2-19 Analog Input Logistics

TP-6200 10/12 99Section 2 Operation

Local Programming Mode On

Page 100

Menu 9—Input Setup

Menu 9 Displays with Key Entries

Key Entry Display Description

ENTER MENU NO. 1--15

MAIN MENU NUMBER 9

MENU 9

INPUT SETUP

SETUP DIGITAL → AUXILIARY INPUTS

DIGITAL INPUT 01 → (USER DEFINED DESC)

DIGITAL INPUT 01 → (see Group A) YES/NO

Group A

The preprogrammed selections include the following list. See Appendix E for application and restrictions with specific engines.

WARNING Y/N SHUTDOWN TYPE A Y/N SHUTDOWN TYPE B Y/N VOLTAGE RAISE Y/N VOLTAGE LOWER Y/N

Input a menu number.

Press the Enter key.

Displays the menu number and name.

Displays the setup of digital auxiliary inputs heading.

Displays the digital input 01 with the user-defined description. Note: Press the down arrow to move to the start of the next input setup.

Identifies the signal source for digital input 01. Use the menu down ↓ key to select the digital input.

Group A, continued

VAR PF MODE Y/N REMOTE SHUTDOWN Y/N REMOTE RESET Y/N AIR DAMPER Y/N LOW FUEL Y/N FIELD OVERVOLTAGE Y/N IDLE MODE ACTIVE Y/N BATTLE SWITCH Y/N GROUND FAULT Y/N BAT CHGR FAULT Y/N HIGH OIL TEMP Y/N

Group A, continued

LOW COOLANT LEVEL Y/N LOW COOLANT TEMP Y/N BREAKER CLOSED Y/N ENABLE SYNCH Y/N AFM SHUTDOWN Y/N KNOCK SHUTDOWN Y/N DETON WARNING Y/N DETON SHUTDOWN Y/N LOW FUEL SHUTDOWN Y/N

DIGITAL INPUT 01 → ENABLED YES/NO

DIGITAL INPUT 01 → ENABLED NO

DIGITAL INPUT 01 → ENABLED YES

DIGITAL INPUT 01 → ENABLED NO

Displays the digital input 01, enabled yes or no selection.

Entering YES enables digital input 01.

Press the Enter key.

Confirms the entry.

Entering NO disables digital input 01.

Press the Enter key.

Confirms the entry.

Local Programming Mode On

TP-6200 10/12100 Section 2 Operation