Kohler Industrial Generator Set Operation Manual

Operation

Industrial Generator Sets

Models:

10-1000 kW

Controller:

APM402/Decision-Makerr 3000

TP-6694 7/18j

W ARNING: This product can expose you

to chemicals, including carbon monoxide
and benzene, which are known to the State
of California to cause cancer and birth
defects or other reproductive harm.
For more information go to
www.P65warnings.ca.gov

Product Identification Information

W ARNING: Breathing diesel engine

exhaust exposes you to chemicals known to
the State of California to cause cancer and
birth defects or other reproductive harm.

S Always start and operate the engine in

a well-ventilated area.

S If in an enclosed area, vent the exhaust

to the outside.

S Do not modify or tamper with the

exhaust system.

S Do not idle the engine except as

necessary.

For more information go to
www.P65warnings.ca.gov/diesel

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

Engine Identification

Record the product identification information from the
engine nameplate.

Manufacturer

Model Designation

Serial Number

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 DescriptionAPM402/Decision-Maker

Controller Serial Number

r 3000

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.

Version No./Date Installed

Software Options

Record the software options.

Number and Description

Table of Contents

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

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

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

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

SiteTech Software 13...........................................................

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

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

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

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

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

1.2.1 Switches and Controls 16..........................................

1.2.2 Annunciator Lamps 16............................................

1.2.3 Digital Display 18.................................................

1.2.4 Controller Fault Diagnostics 23.....................................

1.2.5 Digital Display Circuit Board and Connections 25.....................

1.2.6 Main Logic Circuit Board 25........................................

1.2.7 Terminal Jumper 26...............................................

1.2.8 Communication Ports 26..........................................

1.2.9 Fuses 26........................................................

1.3 Controller Logic Specifications 27...........................................

1.3.1 Status Event and Fault Specifications 27............................

1.3.2 Voltage Regulator and Calibration Specifications 33...................

1.3.3 Voltage Regulator Adjustments 33..................................

Section 2 Operation 35........................................................................

2.1 Prestart Checklist 35......................................................

2.2 Exercising Generator Set 35...............................................

2.3 Operation in Cold Weather Climates 36.....................................

2.4 Controller Operation 36...................................................

2.4.1 Starting 36.......................................................

2.4.2 Stopping (User Stopping and Fault Shutdown) 37.....................

2.4.3 Emergency Stop Switch Resetting 37...............................

2.4.4 System Status Lamps 38..........................................

2.4.5 System Fault Warning Lamp with Digital Displays 38..................

2.4.6 System Fault Shutdown Lamp With Digital Displays 40................

2.4.7 Status and Notice Digital Displays 43...............................

2.4.8 Controller Resetting (Following System Shutdown or Warning) 45.......

2.4.9 Powering Up the Engine Control Module (ECM) 45...................

2.5 Menu Displays 46........................................................

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

2.6.1 PC Communications 49...........................................

2.6.2 Modbus Communications 49.......................................

2.7 Reviewing Menu Displays 50...............................................

2.7.1 Error Messages 51...............................................

2.7.2 Overview 52.....................................................

2.7.3 Engine Metering 52...............................................

2.7.4 Generator Metering (and Calibration) 53

2.7.5 GenSet Information 54............................................

2.7.6 GenSet Run Time 54.............................................

2.7.7 GenSet System 54...............................................

2.7.8 GenSet Calibration 56.............................................

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

TP-6694 7/18 Table of Contents 3

Table of Contents, continued

2.7.9 Voltage Regulator 57..............................................

2.7.10 Digital Inputs 58..................................................

2.7.11 Digital Outputs 59................................................

2.7.12 Analog Inputs 60.................................................

2.7.13 Battery Charger 1 and 2 61........................................

2.7.14 Event Log 62....................................................

2.7.15 Volt Select 62....................................................

Section 3 Scheduled Maintenance 63..........................................................

3.1 Alternator Service 63......................................................

3.2 Engine Service 63........................................................

3.3 Service Schedule 64......................................................

3.4 Alternator Bearing Service 66..............................................

3.4.1 20--300 kW Models 66............................................

3.4.2 300--1000 kW Models with 4M/5M/7M Single-Bearing Alternator 66.....

3.5 Diesel Fuel Systems 66...................................................

3.5.1 Bleeding Air from Fuel System 66..................................

3.6 Gaseous Fuel Systems 67.................................................

3.6.1 Gaseous Fuel System Concept (Single Fuel) 67......................

3.6.2 LPG Liquid Withdrawal Fuel System Concept 67.....................

3.6.3 Natural Gas and LPG Conversion 67................................

3.6.4 Fuel System Changeover Kits (Dual Fuel) 68.........................

3.7 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 68.....................

3.8 Air Cleaner Restrictor Indicator (if equipped) 70..............................

3.9 Cooling System 70.......................................................

3.9.1 Coolant Level Check 70...........................................

3.9.2 Cooling System Component Inspection 70...........................

3.9.3 Procedure to Drain Cooling System 71..............................

3.9.4 Procedure to Flush and Clean Cooling System 71....................

3.9.5 Procedure to Refill Cooling System 71..............................

3.10 Battery 72...............................................................

3.10.1 Clean Battery 73.................................................

3.10.2 Electrolyte Level Inspection 73.....................................

3.10.3 Specific Gravity Check 73.........................................

3.10.4 Charge Battery 74................................................

3.11 Storage Procedure 74.....................................................

3.11.1 Lubricating System 75............................................

3.1 1.2 Cooling System 75...............................................

3.11.3 Fuel System 75..................................................

3.1 1.4 Internal Engine Components (Gaseous-Fueled Engines) 75............

3.11.5 Exterior 75.......................................................

3.11.6 Battery 76.......................................................

Section 4 General Troubleshooting 77.........................................................

4.1 General Troubleshooting Chart 78..........................................

4.2 Controller Display and Voltage Regulation Troubleshooting Chart 81............

Section 5 Voltage Reconnection 83............................................................

5.1 Introduction 83...........................................................

5.2 Voltage Reconnection Procedure 83........................................

5.3 Voltage Reconnection Procedure 84........................................

TP-6694 7/18Table of Contents4

Table of Contents, continued

Section 6 Accessories 89.....................................................................

6.1 Accessories and Connections 89...........................................

6.1.1 Battery Charger Kit with Alarm Option 89............................

6.1.2 Common Fault/Failure (32A) Relay Kit 90............................

6.1.3 Fifteen-Relay Dry Contact Kit 91....................................

6.1.4 Gas Fuel Valve Kit 94.............................................

6.1.5 Input/Output (I/O) Module Board 95.................................

6.1.6 Key Switch 96....................................................

6.1.7 Low Fuel (Level/Pressure) Switch 96................................

6.1.8 Manual Speed Adjust (Engine RPM Menu) 97........................

6.1.9 Prime Power Switch Kit 97.........................................

6.1.10 Remote Emergency Stop Kit 98....................................

6.1.11 Remote Reset Feature 98.........................................

6.1.12 Remote Serial Annunciator 99......................................

6.1.13 Run Relay Kit 101.................................................

6.1.14 Shunt-Trip Line Circuit Breaker 101..................................

6.2 Accessory Connections 102.................................................

Appendix A Abbreviations 107................................................................

Appendix B Programmer-Defined Settings 109.................................................

Appendix C Voltage Regulator Definitions and Adjustments 115.................................

Appendix D Alternator Protection 119..........................................................

Appendix E Controller Displays from the Engine ECM 121.......................................

TP-6694 7/18 Table of Contents 5

Notes

TP-6694 7/186

Safety Precautions and Instructions

IMPORTANTSAFETY 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,orsubstantial
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
equipment connected to the set,
disable the generator set as follows:
(1) Press the generator set off/reset
button to shut down the generator set.
(2) Disconnect the power to the battery
charger, if equipped. (3) Remove the
battery cables, negative (--) lead first.
Reconnect the negative (--) lead last
when reconnecting the battery. Follow
these precautions to prevent the
starting of the generator set by the
remote start/stop switch.

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
container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.

7Safety Precautions and InstructionsTP-6694 7/18

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 thebattery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.

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

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

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

of the equalize charge state may leadto
hazardous situations. Equalization is
ONLY applicable for flooded lead acid
(FLA) type batteries and will damage
gel, absorbed glass mat (AGM), or
nickel-cadmium (NiCad) type batteries.
In the controller menu or SiteTecht
settings, verify that the battery topology
is set correctly for the battery typeused.
Do not smoke or permit flames, sparks,
or other sources of ignition to occur
near a battery at any time.

Engine Backfire/Flash
Fire

WARNING

Risk of fire.
Can cause severe injury or death.

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

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.

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.

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.

8 Safety Precautions and Instructions TP-6694 7/18

Fuel System

WARNING

Explosive fuel vapors.
Can cause severe injury or death.

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

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

explosive. Use extreme care when
handling and storing fuels. Store fuels
in a well-ventilated area away from
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operatethe
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. Take

additional precautions when using the
following fuels:

Propane (LPG)—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 LPG vapor 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.

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

can cause an explosion. Check the
LPG liquid withdrawal 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.

DANGER

Hazardous voltage. Moving parts.
Will 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 will 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.

9Safety Precautions and InstructionsTP-6694 7/18

High voltage test. Hazardous
voltage will 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.

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

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

Connecting the battery and the
battery charger. Hazardous voltage
will 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).

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

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

Engine block heater. Hazardous
voltage will 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.

Testing live electrical circuits.
Hazardous voltage or current will
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)

Servicing the generator set when it
is operating. Exposed moving parts
will 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

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.

Hot Parts

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.

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.

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

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

10 Safety Precautions and Instructions TP-6694 7/18

Notice

NOTICE

This generator set has been
rewired from its nameplate voltage
to

246242

NOTICE

Voltage reconnection. Affix a notice

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

NOTICE

Canadian installations only.For

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

11Safety Precautions and InstructionsTP-6694 7/18

Notes

12 Safety Precautions and Instructions TP-6694 7/18

Introduction

This manual provides operation instructions for 10 kW
and larger generator sets equipped with the following
controllers:

D APM402 generator set controller

D Decision-Makerr 3000 generator set controller

Note: In 2018, Kohler adopted a global controller

naming convention. To support this, the name of
the Decision-Makerr 3000 controller has
transitioned to APM402. The APM402 has the
same form, fit and function as the
Decision-Makerr 3000 and supports the same
accessories.

Wiring diagram manuals are availableseparately. 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.

SiteTecht Software

Several instances in this manual refer to SiteTecht
software, which can be used for programming the
APM402 or Decision-Makerr 3000 controller.
SiteTecht software is required for updating the
controller application code (firmware), loading
personality profiles, and saving or loading controller
configuration files. Contact your local distributor/dealer
for assistance.

Note: The APM402 controller uses different firmware

than the Decision-Makerr 3000 controller. Do
not attempt to load Decision-Makerr 3000
firmware on an APM402 controller, or vice-versa.

To determine the generator set controller software
version, go to the Overview menu.

List of Related Materials

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

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation andto 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 equipmentservice requirements are very important
to safe and efficient operation. Inspect the parts often
and perform required service atthe prescribedintervals.
Maintenance work must be performed by appropriately
skilled and suitably trained maintenance personnel
familiar with generator set operation and service.

Abbreviations

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

Literature Description Literature Part No.

APM402 Controller Spec Sheet

Decision-Makerr 3000 Controller Spec
Sheet

Generator Set/Controller
Wiring Diagram Manual

Modbusr Communications Protocol
Operation Manual

SiteTecht Software Operation Manual

Remote Serial Annunciator (RSA III) TT-1625

Remote Serial Annunciator (RSA II) TT-1485

Converters, Connections, and Controller
Setup for Network Communication

G6-161

G6-100

Multiple Part Numbers

Contact your

Distributor/Dealer

TP-6113

TP-6701

TT-1405

Figure 1 Related Literature

Several engine manufacturers provide engines with
electronic controls. These electronic controls indicate
engine fault codes in addition to the generator set
controller. The engine operation and service literature
provide information for identifying engine fault codes.
For the latest literature part numbers,see therespective
Parts Catalog.

Modbusr is a registered trademark of Schneider Electric.

13IntroductionTP-6694 7/18

Service Assistance

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

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

D Look at the labels and decals 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 EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]

Asia Pacific

Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]

China

North China Regional Office, Beijing
Phone: [phone]

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

Fax: [phone]

East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: [phone]

(91) 80 3366231

Fax: [phone]

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

14 Service Assistance TP-6694 7/18

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. Refer to 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 lamp,
digital display and pushbutton/rotary selector dial,
switches and controls, and fuses and terminal strip. The
following paragraphs detail the features by general
topics.

See Figure 1-1 for an illustration of the controller front
panel.

12 45

3

The controller features,accessories, and menudisplays
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 the pushbutton/rotary selector dial to turn

on the controller lights and display. The lights and
display turn off 60 minutes after the last entry
when in the AUTO mode.

Note: After about 5 minutes of no user input

(pushbutton/rotary selector dial or buttons), the
menu is reset to the top of the main menus and
auto-paging activates for the Overview
submenus.

Note: Measurements display in metric or English units.

Use the Generator Set System menu to change
the measurement display.

OFF/RESET AUTO RUN ALARM SILENCE/

1. Emergency stop switch

2. Generator set master control switches,
OFF/RESET-- AUTO--RUN buttons with lamps

3. Digital display

4. Alarm horn (behind panel)

5. Pushbutton/rotary selector dial

6. Annunciator fault lamp

7. Controller terminal strips (on circuit board)

8. Alarm silence/lamp test button with lamp

9. Mini USB connection

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

FAU LT

LAMP TEST

6

7

8

9

GM65741-

TP-6694 7/18 15Section 1 Specifications and Features

1.2.1 Switches and Controls

Note: US/Metric Display is selectable in Section

1.2.3—Digital Display—Generator Set System
Menu.

Alarm Horn. The alarm horn alerts theoperator or other
attendants that a shutdown or warning condition exists.

Alarm (Horn) Silence. The alarm silence/lamp test
switch silences the alarm horn at the operator’s
discretion. Press the master control switch AUTO
button before pressing the alarm silence/lamp test
button. The alarm horn cannot be silenced unless the
master control switch AUTO button is pressed.

Note: Additional alarm silencing options are shown in

Section 1.2.3—Digital Display—Generator Set
System Menu.

Restore alarm horn switches at all locations including
those on remote annunciator kits after correcting the
fault shutdown to avoidreactivating the alarm horn. See
Section 2—Operation, 2.4.8 Controller Resetting for
resetting the controller.

Emergency Stop. The operator-activated pushbutton
immediately shuts down the generator set inemergency
situations. Reset the emergency stop switch after
shutdown by pulling the emergency stop switch
outward. Usethe emergency stopswitch for emergency
shutdowns only. Use the master control switch
OFF/RESET button for normal shutdowns.

The pushbutton/rotary selector dial hasseveral features
and functions:

D Momentarily press the dial to activate the digital

display if dark.

D Rotate the dial to navigate through the main

menus—turn clockwise to go forward (down) and
counterclockwise to go back (up). The menus do not
wrap to the beginning.

D Press the dial at a given main menu to access the

submenus within the selected main menu.

D When in the submenu, rotate the dial to navigate

through the submenu—clockwise to go forward
(down) and counterclockwise to go back (up). The
menus do not wrap to the beginning.

D Momentarily press the dial when in the submenu to

make a user selection choice (if available) or to go
back to the respective main menu.

D Press the dial forat least3 seconds to return tothe top

of the main menus (Overview) regardless if you are in
the main menus or submenus.

D After about 5 minutes of no user input (pushbutton/

rotary selector dial or buttons), the menu resets to the
top of the main menus and auto-paging activates for
the Overview submenus.

1.2.2 Annunciator Lamps

The controller has a single annunciator fault lamp
providing visual generator set status. In addition, each
button has a corresponding lamp. See Figure 1-2.

Generator Set Master Control Switches
(OFF/RESET--AUTO--RUN). These switches reset the

controller fault lamps and start/stops the generator set.
Additional information in shown in Section 2—
Operation.

Lamp Test. Press and hold the Alarm Silence/Lamp
Test button for two seconds to test the controller
indicator lamps, alarm horn, and digital display.

Manual Speed Adjust (Engine RPM). The control
allows varying the engine speed for applications using
closed transition ATS. The user can set the nominal
running frequency slightly above or below the utility
frequency to ensure that synchronization occurs.
Additional information is shown in 2.7.7 GenSet
System. Available as a factory-installed option o r
requires a new factory personality profile.

Pushbutton/Rotary Selector Dial. This control
provides access to the menus for monitoring. Press the
selector dial to activate the digital display and to select
choices shown on the display. Rotate the dial to
navigate through the menus.

Lamp/Button Lamp Color

Alarm (Fault) Lamp Yellow (Warning) or Red (Shutdown)

Off/Reset Button Red

Auto Button Green (System Ready)

Run Button Yellow

Alarm Silence/Lamp

Test Button

Yellow

Figure 1-2 Annunciator Lamps

System Status Lamps (Master Control Switches)

The green lamp illuminates on the master controlswitch
AUTO (automatic start) button indicating the system
senses no faults and the unit is ready to start by remote
command.

The red lamp illuminates on the master control switch
OFF/RESET button indicating the generator set is
stopped.

The yellow lamp illuminates onthe master control switch
RUN button indicating the generator set is cranking or
running from a local command.

Only one of the three master control switch lamps will
illuminate at any given time.

TP-6694 7/1816 Section 1 Specifications and Features

Alarm Silence Lamp. Yellow lamp illuminates
indicating the alarm horn was silenced.

(System) Fault Lamp. Yellow lamp illuminates
indicating a warning condition or red lamp illuminates
indicating a shutdown condition. See System Warning
Fault Lamp and System Shutdown Fault Lamp following
for system fault conditions.

System Warning Fault Lamp. 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.

See Section 2.4.5, System Fault Warning Lamp with
Digital Displays, for definitions of the items listed. The
following conditions cause a system warning:

D AC sensing loss
D Auxiliary input (analog or digital)
D Battery charger communication loss
D Battery charger fault *

Note: Optional input sensors not required with charger

GM87448.

D Battery charger identity conflict
D Battery charger parameter mismatch
D Battery fault
D Common warning
D Critical high fuel level (diesel-powered models only) *
D Default parameters loaded
D ECM diagnostics (multiple engine inputs)
D Fuel tank leak (diesel-powered models only) *
D Ground fault *
D High battery voltage
D High coolant temperature
D High fuel level (diesel-powered models only) *
D Input/output communication loss
D Low battery voltage
D Low coolant temperature
D Low cranking voltage
D Low engine oil level *
D Low fuel (level for diesel-powered models) *
D Low fuel (pressure for gas-powered models) *
D Low oil pressure
D Not-in-auto (master control switch)
D Speed sensor fault

* Requires optional input sensors with all battery chargers except

battery charger GM87448.

System Shutdown Fault Lamp. 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 2.4.8, Controller Resetting
procedure.

See Section 2.4.6, System Fault Shutdown Lamp with
Digital Displays, for definitions of the items listed. The
following conditions cause a system shutdown:

D AC sensing loss
D Alternator protection
D Auxiliary input (analog or digital)
D Common fault
D ECM address conflict
D ECM communications loss
D ECM diagnostics (multiple engine inputs)
D ECM model mismatch
D Emergency stop
D Enclosure temperature: high shutdown (available on

select Telecom units only)

D Engine over speed
D Engine under speed
D File system error (controller firmware fault)
D Fuel tank leak (diesel-powered models only) *
D High coolant temperature
D Internal failure
D kW overload
D Locked rotor (failed to crank)
D Loss of fuel
D Low coolant level *
D Low engine oil level *
D Low fuel level (diesel-powered models only) *
D Low oil pressure
D Megajector communications loss

(GM/PSI and Doosan gas-powered models only)

D Metering communication loss
D No coolant temperature signal
D No oil pressure signal
D Overcrank
D Overfrequency
D Overvoltage (each phase)
D Run relay overload
D Underfrequency
D Undervoltage (each phase)
D (Voltage) regulator communication loss

* Requires optional input sensors.

TP-6694 7/18 17Section 1 Specifications and Features

1.2.3 Digital Display

Overview Menu

Press the pushbutton/rotary selector dial to turn on the
controller lamps and display. The lamps and display
turn off 60 minutes after the last entry.

Note: The APM402 controller takes about 5--10

seconds to power on.

The generator set must be running for some displays to
indicate values. If the generator set is not running some
values will display zero or N/A (not available).

Some displays are engine dependent, refer to the
Appendix, Controller Displays from the Engine ECM.

The 12-character, 2-line backlit heated display provides
generator set and engine data, system status, and fault
information. See Figure 1-1. The digital display shows
abbreviations in some instances, refer to 1.3.1 Status
Event and Fault Specifications for theabbreviations and
their full descriptions.

Note: US/Metric Unit Display is selectable in

Generator Set System.

Note: Display Contrast is selectable in Generator Set

System. The contrast display adjustment allows
user selected resolution values to improve digital
display clarity.

Note: After about 5 minutes of no user input

(pushbutton/rotary selector dial or buttons), the
menu resets to the top of the main menus and
auto-paging activates for the Overview
submenus.

The main menus are listed below. Within each main
menu are multiple submenus with descriptions
following.

D Overview
D Engine Metering
D Generator Metering
D GenSet Information
D GenSet Run Time
D GenSet System
D GenSet Calibration (Decision-Makerr 3000

controllers before Version 3.0.25)

D Voltage Regulation
D Digital Inputs
D Digital Outputs
D Analog Inputs
D Event Log
D Volt Select

When a new shutdown or warning fault occurs, the
auto-paging display feature activates.

Active Shutdowns display if any are present. This
alerts the user to single or multiple shutdown fault
conditions. See 1.2.2—Annunciator Lamps—System
Shutdown Fault Lamp for a list of possible shutdown
faults.

Active Warnings display if any are present. This alerts
the user to single or multiple warning fault conditions.
See 1.2.2—Annunciator Lamps—System Warning
Fault Lamp for a list of possible warning faults.

Generator Set State displays the generator set status:

D Off
D Standby
D Running
D Cooldown
D Stopping

Average Volts Line-to-Line value displays. For
three-phase configurations the average line-to-line
voltage of L1, L2, and L3 is displayed. Single-phase
configurations show the L1-L2 voltage.

Frequency (Hz) value displays for the output AC
voltage.

Current value displays as the average for three-phase
configurations or the current value for L1-L2 with
single-phase configurations.

Average kW displays. For three-phase configurations
the average line-to-line kilowatts of L1, L2, and L3 is
displayed. Single-phase configurations show the L1-L2
kilowatts.

Coolant Temperature diplays for the engine coolant
temperature.

Oil Pressure displays the engine oil pressure.

Fuel Level % displays the fuel tank level for diesel-

powered models when so equipped.

Fuel Pressure displays fuel pressurefor someengines.
Refer to the Appendix, Controller Displays from the
Engine ECM.

Battery displays the DC voltage of the engine starting
battery(ies).

CHG1 and CHG2 display battery charger voltage and
current (amps) if one or two CAN-enabled 10 Amp
battery chargers (GM87448 only) have been
connected. Shows N/A if charger GM87448 was

TP-6694 7/1818 Section 1 Specifications and Features

connected and then removed. (DEC3000 version 4.11
or higher, and APM402)

Engine Run Time displays the total run time hours.

The calibration values are r eviewable at all times and
provide the calibration of the voltage and current
sensing logic. Changing the systemvoltage or replacing
the circuit board requires a calibration adjustment.

Software Version displays in the Overview menu. Use
the version number to determine if an upgrade is
needed and/or when troubleshooting the controller.

Engine Metering Menu

Note: The Engine Metering Menu may vary depending

upon if the selector dial is rotated clockwise or
counterclockwise.

Engine Speed (Tachometer) displays the engine
speed in RPM.

Oil Pressure displays the engine oil pressure. This
value also shows in the Overview Menu.

Coolant Temperature displays the engine coolant
temperature. This value also shows in the Overview
Menu.

Fuel Level % displays the fuel tank level for diesel­powered models if so equipped. This value also shows
in the Overview Menu.

Battery displays the DC voltage of the engine starting
battery(ies). This value also shows in the Overview
Menu.

Fuel Pressure displays fuel pressurefor someengines.
Refer to the Appendix, Controller Displays from the
Engine ECM. This value also shows in the Overview
Menu.

Generator Metering Menu

Total Power kVA and kW displays alternator output as

actual output values.

To enable calibration

, start the generator set and select
the Volts L1-L2 display. Then push and hold the
pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is
now available. The display will show the following
values for three-phase generator sets. Single-phase
generator sets will only display items marked (*).

D Volts L1-L2 *
D Volts L2-L3
D Volts L3-L1
D Volts L1-N *
D Volts L2-N *
D Volts L3-N
D Current L1 *
D Current L2 *
D Current L3

The user can change individual values or can select
Reset Calib?--Yes to reset all values. The Reset Calib?
display will only show if calibration is enabled. Refer to
the requirements shown with Generator Set Calibration
in 2.4.7 Status and Notice Digital Displays.

To disable calibration

, Rotate the pushbutton/rotary
selector dial until the <-- Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.

Generator Set Information Menu

GenSet M/N displays the generator set model number.

GenSet S/N displays the generator set serial number.

Controller S/N displays the controller serial number.

Rated Power displays alternator output as a

percentage of the entered data value.

Volt s displays the alternator output AC voltages. The
display shows all line-to-line and line-to-neutral voltage
combinations for three-phase or single-phase
configurations.

Current displays the alternator output AC amps. The
display shows each line (L1-L2-L3) of three-phase
models or L1-L2 current for single-phase models.

Frequency (Hz) value displays for the output AC
voltage. This value also shows in the Overview Menu.

Reset Calibration providing the means to reset the
configuration values is available in this menu.

TP-6694 7/18 19Section 1 Specifications and Features

Generator Set Run Time Menu

Engine Run Time displays the total run time hours.

This value also shows in the Overview Menu.

Engine Loaded displays the total loaded hours.

Engine Starts displays the total number of generator

set startup events.

Total Ene rgy displays the total kW hours.

Generator Set System Menu

Generator Set (Reset) Calibration Menu

The values in this menus are user-entered for the
generator set configuration and are NOT measured
values of the generator set.

Changes to the Generator Set System menu require the
use of SiteTecht software except for Measure System
and Contrast selections.

System Frequency displays the programmer-entered
L1-L2-L3 output voltage frequency for three-phase or
the L1-L2 output voltage frequency for single-phase.

System Phase displays the programmer-entered
configuration as Single Phase, Single Phase Dog Leg,
Three Phase Wye, or Three Phase Delta.

System Voltage displays the programmer-entered
L1-L2-L3 output voltage for three-phase or the L1-L2
output voltage for single-phase.

Power Rating displays the programmer entered kW
value for the generator set.

Amp Rating displays the programmer entered current
value for the generator set.

Power Type displays the programmer entered
generator set application configuration as Standby or
Prime.

Battery Voltage displays the engine electrical system
12 or 24 volts.

Measurement System displays the user selected unit
of measure as Metric or English.

Contrast displays user selected resolution values to
improve digital display clarity.

Alarm (Horn) Silence displays the programmer
selected alarm silence method as Always or Auto Only
using SiteTecht software. TheAlways selectionallows
the alarm to be silenced in any of the
OFF/RESET--AUTO--RUN modes. The Auto Only
selection allows silencing of the alarm only while in the
Auto mode.

This menu is only available in Decision-Makerr 3000
controller firmware versions before 3.0.25. On
Decision-Makerr 3000 controllers with later firmware
versions, or on APM402 controllers, go to Generator
Metering Menu—Reset Calibration.

The calibration values are r eviewable at all times and
provide the calibration of the voltage and current
sensing logic. Changing the systemvoltage or replacing
the circuit board requires a calibration adjustment. In
order to review the values when the generator set is
NOT running, enter Yes when the Enter Calib? is
displayed. The user can review the values but
attempting to change the values will cause a Cannot
calibrate error message.

If the unit is NOT running and No is entered when the
Enter Calib? is shown, the display returns to the
Generator Set Calibration main menu and entry to the
Generator Set Calibration menu is denied.

If the unit is running and Yes is entered when the Enter
Calib? is shown, the display will show the following
values for three-phase generator sets. Single-phase
generator sets will only display items marked (*).

D Volts L1-L2 *
D Volts L2-L3
D Volts L3-L1
D Volts L1-N *
D Volts L2-N *
D Volts L3-N
D Current L1 *
D Current L2 *
D Current L3

The user can change individual values or can enter Yes
when Reset all Calib? is displayed. At the end of the
Generator Set Calibration menu, Exit calibration is
shown. Press the pushbutton/rotary selector dial to exit
this menu. Refer to the requirements shown with
Generator Set Calibration in 2.4.7 Status and Notice
Digital Displays.

Note: Press the Alarm Silence/Lamp Test button to

silence the alarm horn.

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

TP-6694 7/1820 Section 1 Specifications and Features

Voltage Regulator Menu

Digital Inputs Menu

Decision-Makerr 3000 Controller firmware before

3.0.25:

The voltage regulator value is reviewable at all times. In
order to review the value when the generator set is NOT
running, enter Yes when the Enter volt reg? is displayed.
The user can review the value but attempting to change
the value will cause a Cannot edit when stopped error
message.

If the unit is NOT running and No is entered when the
Enter volt reg? is shown, the display returns to the
Voltage Regulator main menu and entry to the Voltage
Regulator menu is denied.

If the unit is running and Yes is entered when the Enter
volt reg? is shown, the display will show the value.

The usercan change the value at this time. At the endof
the Voltage Regulator menu, Exit voltage reg is
shown----press the pushbutton/rotary selector dial to exit
this menu.

Decision-Makerr 3000 Controller firmware 3.0.25 and
higher, or APM402 Controller:

The voltage regulator value is reviewable at all times
and provides the ability to fine adjust voltage. Changing
the system voltage or replacing the circuit board
typically requires a voltage adjustment.

To enable calibration

, start the generator set and select
the VR Volt Adj display. Then push and hold the
pushbutton/rotary selector dial until the Editing Enabled
popup appears. Editing of thevoltage adjustment isnow
available.

This menu allows the user to review the settings. There
are up to three digital inputs that are programmer
selectable if not reserved by factory options.

The displays for digital inputs appear as shown below
with Values true or false. Items shown in the digital
displayasTrueareactive.

D DIn A1 (digital input A1) standard
D DIn A2 (digital input A2) standard
D DIn A3 (digital input A3) standard (see note below)
D DIn B1 (digital input B1) with I/O module board
D DIn B2 (digital input B2) with I/O module board

Changes to the Digital Inputs menu requires the use of
SiteTecht software. The digitalinput caneither openor
close the circuit to activate.

Note: DIn A3 digital input is factory reserved for

Enclosure Temperature: High Shutdown on
select Telecom units.

Digital Outputs Menu

This menu allows the user to review the settings. There
is one digital output standard with the controller that is
programmer selectable. The one SPDT switch has
2 amp. contacts at 32 VDC or 0.5 amp. contacts at
120 VAC max.

There is an optional 2 input/5 output (I/O) module board
available that can provide five digital outputs. The
standard digital output on the controller is used to drive
the optional I/O Module board and becomes factory
reserved and no longer available as programmer
selectable.

The user can change the individual value or can select

Reset VR?--Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.

To disable calibration

, Rotate the pushbutton/rotary
selector dial until the <-- Return popup appears.
Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.

The displays for digital outputs appear as shown in the
following list with Values as True or False. Items shown
in the digital display as True are active.

D DOut A1 (digital output A1) standard
D DOut B1 (digital output B1) with I/O module board
D DOut B2 (digital output B2) with I/O module board
D DOut B3 (digital output B3) with I/O module board
D DOut B4 (digital output B4) with I/O module board
D DOut B5 (digital output B5) with I/O module board

Changes to the Digital Outputs menu requires the use of
SiteTecht software. The digital output can either open
or close the circuit to activate.

TP-6694 7/18 21Section 1 Specifications and Features

Analog Inputs Menu

Volt Select Menu

This menu allows the user to review the settings. There
is one analog input that is programmer selectable if not
reserved by factory options.

There is an optional 2 input/5 output (I/O) module board
available that can provide two additional analog inputs.

The displays for analog inputs appear as shown below
with Values of 0--5 volts.

D AIn A1 (analog input A1) standard

(reserved and not user programmable)

D AIn A2 (analog input A2) standard
D AIn B1 (analog input B1) with I/O module board
D AIn B2 (analog input B2) with I/O module board

Changes to the Analog Inputs menu requires the use of
SiteTecht software.

Event Log Menu

This menu allows the user to reviewup to1000 entries of
system events including shutdown faults, warning
faults, and status events. See 1.2.4 Controller Fault
Diagnostics for a list of the items that appear on the
Event Log.

Note: The generator set must be stopped before

changing the voltage selection.

This menu allows the user to readily change controller
voltage settings. Thevolt select feature is typically used
in towable or temporary applications.

Note: The volt select menu requires initial activation by

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

Note: The generator set output leads require voltage

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

With the generator set stopped, go to the Volt Select
menu. Then push and hold the pushbutton/rotary
selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.

The displays for Volt Select appear as shown in the
following list.

D 120/240 V 1 Ph
D 120/208 V 3 Ph
D 139/240 V 3 Ph
D 277/480 V 3 Ph
D 120/240 V 3 Ph

TP-6694 7/1822 Section 1 Specifications and Features

1.2.4 Controller Fault Diagnostics

This table provides descriptions of the system events
and their types—warning, shutdown, status, and notice.

Warnings show yellow fault lamp and signal an
impending problem. Shutdowns show red fault lamp
and stopthe generator set. Status isan event that is not
an alert but is part of the event history. Notice is an alert

System Events Display Message List

that is NOT part of the event history. System events are
available as a Relay Output as shown.

Throughout this manual there are examples of the
display text. In some cases, the message words and
phrases are abbreviated or shortened to accommodate
the number of characters in the 12 x 2 digital display.
See the following table fora full description of thesystem
event display messages.

Warning

Description Display Message

Engine Functions

Critically high fuel level (diesel-powered models only) * Fuel Level Critically High X X

ECM communications loss ECM Comm Err Shutdwn X X

ECM diagnostics (multiple inputs) [

ECM diagnostics (multiple inputs) [

ECM faults (address conflict) ECM Addr Err Shutdwn X X

ECM faults (model mismatch) ECM Mismatch Shutdwn X X

Engine over speed Eng Speed High Shutdwn X] X

Engine start aid active Starting Aid Notice N X

Engine under speed Eng Speed Low Shutdwn X X

Fuel tank leak * Fuel Leak Warning X X

Fuel tank leak * Fuel Leak Shutdwn X X

High battery voltage Battery High Warning X X

High coolant (engine) temperature Coolnt Temp High Warning X X

High coolant (engine) temperature Coolnt Temp High Shutdwn X] X

High fuel level (diesel-powered models only) * Fuel Level High Warning X X

Loss of fuel Loss of fuel X X

Low battery voltage Battery Low Warning X X

Low coolant level * Coolant Lvl Low Shutdwn X X

Low coolant temperature Coolant Temp Low Warning X X

Low cranking voltage Lo Crank Vlt Warning X X

Low engine oil level * Oil Level Low Warning X X

Low engine oil level * Oil Level Low Shutdwn X X

Low fuel level (diesel models) * Fuel Level Low Warning X X

Low fuel level (diesel models) * Fuel Level Low Shutdwn X X

Low fuel pressure (gas models) * Fuel Press Low Warning X X

Low oil pressure Oil Press Low Warning X X

Low oil pressure Oil Press Low Shutdwn X] X

No coolant temperature signal Temp Sig Loss Shutdwn X X

No oil pressure signal Press Sig Loss Shutdwn X X

Overcrank Over Crank Shutdwn X] X

Speed sensor fault Spd Sens Flt Warning X X

ECM xxxxxx Warning X X

ECM xxxxxx Shutdwn X X

Function

Shutdown

Function

Status/

Notice

Relay

Output

TP-6694 7/18 23Section 1 Specifications and Features

Warning

Description

General Functions

Alarm horn silenced (Alarm Silence LED only) X

Alarm silence, auto only (NFPA 110) or always AlrmSilence: Auto Only or

Aux. inputs 0--5 VDC, 1 analog
(2 additional inputs available with I/O module option)

Aux. inputs 0--5 VDC, 1 analog
(2 additional inputs available with I/O module option)

Auxiliary inputs, up to 3 digital
(2 additional inputs available with I/O module option)

Auxiliary inputs, up to 3 digital
(2 additional inputs available with I/O module option)

Backup parameters loaded Backup Pars Status S No

Battery charger 1 communication loss Bat1CommLoss X

Battery charger 2 communication loss Bat2CommLoss X

Battery charger fault * (* does not apply to charger
GM87448)

Battery charger identity conflict BatIdErr X

Battery charger parameter mismatch Param Mismatch X

Battery Fault Battery Flt X

Chicago code active Auto Locked Notice N X

Common fault (includes ])

Common warning fault Common Warng X N X

Default parameters loaded Default Pars Warning X X

Emergency stop Emerg Stop Shutdwn X] X

Enclosure temperature: high shutdown Enclsr Temp: High Shutdwn X X

Engine cooldown (delay) active Eng Cooldown Notice N X

Engine start delay active Start Delay Notice N X

Engine started Engine Start Status S X

Engine stopped Engine Stop Status S X

EPS supplying load Emerg Pwr On Notice N X

File system error (controller fault) File Error Shutdwn X X

Generator running Gen Running Notice N X

Input/output (module option board) communication loss OB1 Com Loss X X

Internal failure Intern Error Shutdwn X X

Metering communication loss MeterCommLos Shutdwn X X

NFPA 110 alarm active NFPA Alarm Notice N X

Not in auto (master switch) Not In Auto Warning X X

Remote start Remote Start Status S X

System ready System Ready Status S X

System timer failed TimerErrorNotice N X

Generator Functions

AC sensing loss AC Sens Loss Warning X X

AC sensing loss AC Sens Loss Shutdwn X X

Alternator protection Alt Protect Shutdwn X X

Ground fault input * Ground Fault Warning X X

kW overload Total Power High Shutdwn X X

Locked rotor (failed to crank) Locked Rotor Shutdwn X X

Overfrequency Freq High Shutdwn X X

Overvoltage (each phase) Volts xx--xx High Shutdwn X X

Underfrequency Frequency Low Shutdwn X X

Undervoltage (each phase) Volts xx--xx Low Shutdwn X X

(Voltage) regulator communication loss RegCommLoss Shutdwn X X

* Function requires optional input sensors or kits or is engine ECM dependent on some generator set models.

[ ECM inputs are engine manufacturer dependent.
] The Common Fault Shutdown includes the items marked X] in the Shutdown Function column.

Display Message

AlrmSilence: Always

Aux Input Warning X X

Aux Input Shutdwn X X

Aux Input Warning X X

Aux Input Shutdwn X X

Batt Chg Flt X

Common Fault Shutdwn X N X

Function

Shutdown

Function

Status/

Notice

S No

Relay

Output

X

TP-6694 7/1824 Section 1 Specifications and Features

1.2.5 Digital Display Circuit Board and

Connections

The digital display circuit board provides:

D The backlit LCD (liquid crystal display) for monitoring

the generator set functions and output values

D Master control switches with status lights
D Fault lamp
D Pushbutton/rotary selector dial to navigate the

generator set displays

D Alarm horn and alarm silence/lamp test switch/light
D Mini USB connector for PC setup using SiteTecht

software

See Figure 1-3 for the circuit board connections.

Circuit Board Connections

P9 Connector the 24-pin connector attaches directly to

the main logic circuit board.

P10 Connector mini USB for PC upgrades located on
the front panel using SiteTecht software.

1.2.6 Main Logic Circuit Board

The main logic circuit board provides the terminal strips
and connection sockets to connect the controller to the
engine/generator, input/output connections, optional
I/O module kit, and circuit protection fuses. See
Figure 1-4 and Figure 1-5 for the circuit board
connections. See Section 6, Accessories for more
information.

1

2

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

1

2

3

GM65741-

1. P9 24-pin connector (opposite side) connects to main board

2. P10 5-pin mini USB connector

3. P11 20-pin connector (not used)

Figure 1-3 Digital Display Circuit Board Connectors

1. Main logic circuit board

2. Remote emergency stop switch

GM65741-

Figure 1-4 Main Circuit Board and Emergency Stop

Switch

Circuit Board Connections

P1 (24-Pin) Connector for engine/generator wiring

harness.

P2 (6-Pin) Connector for AC current.

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

generator set output voltage connection.

TP-6694 7/18 25Section 1 Specifications and Features

1.2.8 Communication Ports

10

9

8

7

1. (4) push-on terminal connectors

2. TB2 4-position terminal block

3. TB3 6-position terminal block

4. P2 6-pin connector

5. P1 24-pin connector

6. TB1 6-position terminal block

7. P22 3-pin connector

8. P30 jumper (Wound Field or Fast Response)

9. P23 8-pin connector (RJ45)

10. P21 6-pin connector (for RS-485 communication)

6

5

Figure 1-5 Main Circuit Board Connectors

4

GM64345-1-A

1

The main logic circuit board contains a single mini USB
communication port forPC connections, seeFigure 1-6.
For Modbusr communication using RS-485, see
Figure 1-5 (P21). Refer to the List of Related Materials

2

in the Introduction for corresponding SiteTecht
software and/orcommunication installationinformation.

3

GM65741-

1. Mini USB connection

1

Figure 1-6 Communication Port

1.2.9 Fuses

P21 (6-Pin) Connector for (RS-485) connection of

optional RSA or Modbusr communication.

P22 (3-Pin) Connector for engine ECM. Alternate CAN
connection.

P23 (8-Pin) Connector (RJ45) for optional input/output
(I/O) module circuit board.

Refer to Section 6.2, Accessory Connections for
specific connections of the following terminal block
connections.

TB1 (6-Position) Terminal Block for analog and digital
inputs.

TB2 (4-Position) Terminal Block for K1 relay outputs.

TB3 (6-Position) Terminal Block for E-stop, remote

start contacts, and aux. input connections.

1.2.7 Terminal Jumper

A circuit board P30 jumper is set based on alternator
type—Wound Field (300 kW and larger) or
Fast Response (less than 350 kW). The jumper is
factory set and needs no further adjustment. See
Figure 1-5 for location of the P30 jumper.

AC Circuit Fuses (TB5). Fuses are located inside the
generator set control box. See Figure 1-7

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 are located on the controller circuit
board. See Figure 1-8.

D 1-Amp (F1) auto-resettable, fuse protects the

controller circuits.

D 1-Amp (F2) auto-resettable fuse protects the

controller circuits.

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

engine/starting circuitry and accessories.

Modbusr is a registered trademark of Schneider Electric.

TP-6694 7/1826 Section 1 Specifications and Features

1

1. V7/V8/V9 fuses, 1.5 Amp. (qty. 3)

Figure 1-7 AC Circuit Fuses in Control Box

GM69407

1.3 Controller Logic Specifications

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

The default selection time delays and digital outputs are
factory set and adjustable. Data entries require using a
PC and SiteTecht software. See the SiteTecht
software operation manual for details.

Inhibit Time Delay. The inhibit time delay is the time
period following crank disconnect during which the
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 whenthe controller first detects a fault or
status event and the controller warning or shutdown
lamp illuminates. The delay prevents nuisance alarms.
Select the desired time delay from 0 to 60 seconds.

1

1. F1 1 Amp. auto-resettable

2. F2 1 Amp. auto-resettable

3. F3 12 Amp. non-replaceable

Figure 1-8 Controller DC Fuses

GM64345-C

1.3.1 Status Event and Fault

2

The Factory-Defined Settings List contains all status

3

events and faults with ranges and time delays including
items that do not have user adjustments.

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

Specifications

the controller is set to a longer time period.

TP-6694 7/18 27Section 1 Specifications and Features

Factory-Defined Settings List

Description

Controller Display

Message

Alarm

Horn

Fault

Lamp

Warning

hutdown

S

Write

Access

Display

Si

Engine Functions

Critically high fuel level
(diesel-powered models only) *

ECM communications loss ECMCommErr

ECM diagnostics (multiple
inputs) [

ECM diagnostics (multiple
inputs) [

ECM faults (address conflict) ECM Addr Err

ECM faults (model mismatch) ECM Mismatch

Engine over speed Eng Speed High

Fuel Level Critically

High

Shutdwn

On W 0--100% 95% 0--10 5

On S Fixed 10

ECM xxxxxx Warning On W

ECM xxxxxx Shutdwn On S

Shutdwn

Shutdwn

Shutdwn

On S

On S 0--255 0

On S S A 105-- 120% 115%

Engine start aid active Starting Aid Notice

Engine under speed Eng Speed Low

Shutdwn

On S S A 75--95% 85%

Fuel tank leak * Fuel Leak Warning On W

Fuel tank leak * Fuel Leak Shutdwn On S

High battery voltage Battery High Warning On W S A 110--135% 125% Fixed 10

High coolant temperature

High coolant temperature

High fuel level (diesel-powered
models only) *

Coolnt Temp High

Warning

Coolnt Temp High

Shutdwn

Fuel Level High

Warning

On W

On S

On W 0--100% 90% 0--10 5

Loss of fuel Loss of Fuel On S

Low battery voltage Battery Low Warning On W S A 80--105% 100% Fixed 90

Low coolant level * Coolant Lvl Low

Shutdwn

Low coolant temperature

Coolant Temp Low

Warning

On S Fixed 5

On W Fixed

Low cranking voltage Lo Crank Vlt Warning On W Fixed 60% Fixed 6

Low engine oil level * Oil Level Low Warning On W

Low engine oil level * Oil Level Low Shutdwn On S

Low fuel level (diesel models) * Fuel Level Low

Warning

Low fuel level (diesel models) * Fuel Level Low

Shutdwn

Low fuel pressure
(gas models) *

Fuel Press Low

Warning

On W 0--100% 35% 0--10 10

On S 0--100% 5% 0--10 0

On W

Low oil pressure

Oil Press Low Warning On W

Low oil pressure

Oil Press Low

Shutdwn

On S

* Function requires optional input sensors or is engine ECM dependent on some generator set models.

[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).

** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the

battery charger operation manual.

teTech

GenSet

Mode

Always

unning

R
S

topped

Range

Setting

Default

Selection

16_C

(60_F)

Time

Delay

Range

(sec.)

0--10

(0--30

inhibit)

0--10

(0--30

inhibit)

0--10

(0--30

inhibit)

Fixed
(Fixed
inhibit)

Fixed
(Fixed
inhibit)

Default

Delay
(sec.)

(5 FAA)

inhibit)

inhibit)

inhibit)

inhibit)

inhibit)

Time

0

(0

0
(0

5
(0

0

(30

5

(30

ST-- Short Term, LT--Long Term

TP-6694 7/1828 Section 1 Specifications and Features

GenSet

Time

Default

Time
Delay
(sec.)

inhibit)

Controller Display

Description

Message

No coolant temperature signal Temp Sig Loss

Shutdwn

No oil pressure signal Press Sig Loss

Shutdwn

Overcrank

Over Crank Shutdwn On S Fixed

Write

Access

Display

teTech

Si

Mode

Always

unning

R

topped

S

Range

Setting

Default

Selection

Delay

Range

(sec.)

Alarm

Horn

Fault

Lamp

Warning

hutdown

S

On S

On S Fixed 5

Speed sensor fault Spd Sens Flt Warning On W

General Functions

Alarm silence, 0--Auto only
(NFPA 110), 1--Always

AlarmSilenceMode S A 0--1 1

Aux. inputs 0--5 VDC, 1 analog Aux Input Warning On W 0--100% 100% 0--10 0

Aux. inputs 0--5 VDC, 1 analog Aux Input Shutdwn On S 0--100% 100% 0--10 0

Auxiliary inputs, up to 3 digital
(2 additional digital inputs
available with I/O module
option)

Auxiliary inputs, up to 3 digital
(2 additional digital inputs
available with I/O module
option)

Aux Input Warning On W

Aux Input Shutdwn On S

0--10

(0--30

inhibit)

0--10

(0--30

inhibit)

0(0

inhibit)

0(0

inhibit)

Backup parameters loaded Backup Pars Status

Battery charger 1
communication loss

Battery charger 2
communication loss

Bat1CommLoss On W

Bat2CommLoss On W

Battery charger fault *
(does not apply to charger

Batt Chg Flt On W

GM87448)

Battery charger identity conflict BatIdErr On W

Battery charger parameter
mismatch

ParMisatch On W

Battery fault Battery Flt On W

Chicago code active * Auto Locked Notice

Common fault Common Fault

Shutdwn

On S

Common warning Common Warng On W

Default parameters loaded Default Pars Warning On W

Emergency stop Emerg Stop Shutdwn On S

Enclosure temperature: high
shutdown

Enclsr Temp: High

Shutdwn

On S Fixed Active Fixed

5(20

inhibit)

Engine cooldown (delay) active Eng Cooldown Notice

Engine start delay active Start Delay Notice

Engine started Engine Start Status

Engine stopped Engine Stop Status

EPS supplying load Emerg Pwr On Notice

File system error (controller
fault)

File Error Shutdwn On S

Generator running Gen Running Notice

Input/output (optional module
board) communication loss

OB1 Com Loss On W

Internal failure Intern Error Shutdwn On S
* Function requires optional input sensors or is engine ECM dependent on some generator set models.

[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).

** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the

battery charger operation manual.

(30

ST-- Short Term, LT--Long Term

TP-6694 7/18 29Section 1 Specifications and Features

GenSet

Time

Default

Time
Delay
(sec.)

Controller Display

Description

Measurement Units,
0--English, 1--Metric

Message

Measurement Display DS A 0--1 1

Metering communication loss MeterCommLos

Shutdwn

Alarm

Horn

On S

Fault

Lamp

Warning

hutdown

S

Write

Access

Display

teTech

Si

Mode

Always

unning

R

topped

S

Range

Setting

Default

Selection

Delay

Range

(sec.)

NFPA 110 alarm active NFPA Alarm Notice

Not in auto (master control
buttons)

Prime power application,
0-- Standby, 1--Prime

Not In Auto Warning On W

Power Type DS A 0--1 0

Remote start Remote Start Status

System ready System Ready Status

System timer failed TimerErrorNotice

Generator Functions

AC sensing loss AC Sens Loss

Warning

AC sensing loss AC Sens Loss

Shutdwn

On W

On S Fixed 3

Alternator protection Alt Protect Shutdwn On S

Ground fault input * Ground Fault Warning On W

kW overload

Total Power High

Shutdwn

On S Fixed

102%

standby,

112%

Fixed 60

prime

Locked rotor (failed to crank) Locked Rotor Shutdwn On S S A 1--5 5

Overfrequency Freq High Shutdwn On S 102--140% 110% Fixed 10

Overvoltage (each phase) Volts (L1--L2, L2--L3,

or L3-- L1) High

On S S A 105-- 135% 120% 2--10 2

Shutdwn

Power rating Pwr Rating DS S 10--5000 275

System frequency System Freq DS S 50--60 60

System voltage System Volt DS S 110--600 208

Underfrequency Frequency Low

Shutdwn

On S 80--95% 90% Fixed

10 ST
60 LT

Undervoltage (each phase) Volts (L1--L2, L2--L3,

or L3-- L1) Low

On S S A 70--95% 80% 5--30 10

Shutdwn

Voltage/phase configuration,
0--Single phase, 1--Single
phase dogleg, 2--three phase

SystemPhase DS S 0--3 2

wye, 3--three phase delta

Voltage regulator average
voltage adjustment

(Voltage) regulator
communication loss

VR Volt Adj DS R 108--600 208

RegCommLoss

Shutdwn

On S

SiteTech Read/Write Display Only

Charger Absorption Current
Termination Target (A)

S A 1–5 2

Charger Automatic Equalize
Enable

Note: Equalize is only
available with FLA/VRLA

S A

Active

Inactive

Inactive

topology selected.
* Function requires optional input sensors or is engine ECM dependent on some generator set models.

[ ECM inputs are engine-manufacturer dependent.
] Changeable only by resetting the controller with a personality profile (SiteTech 1.4 or higher).

** Denotes the default parameter range. Typically, ranges for the NiCad battery topology are slightly wider. For more details, refer to the

battery charger operation manual.

ST-- Short Term, LT--Long Term

TP-6694 7/1830 Section 1 Specifications and Features