Operation
Industrial Generator Sets
Models:
KD800--KD3250
Controller:
APM802
TP-7070 7/18d
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 a fter 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
Alternator Identification
Record the alternator model number from the generator
set nameplate(s).
Alternator Model
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 APM802
Controller Serial Number
Table of Contents
Safety Precautions and Instructions 7.........................................................
Introduction 11...............................................................................
Service Assistance 13.........................................................................
Section 1 Specifications and Features 15......................................................
1.1 Introduction 15...........................................................
1.2 Controller Specifications 15................................................
1.2.1 Controller Specifications 15........................................
1.2.2 Display and Touchscreen 15.......................................
1.3 Controller Features 15....................................................
1.3.1 Connections 17..................................................
1.3.2 Modbus Connections 17...........................................
1.3.3 Optional Keyswitch and Manual Start/Stop Button 18..................
1.4 NFPA Requirements 18...................................................
1.5 Parameter Settings 19....................................................
1.6 Base Module Inputs and Outputs 20........................................
Section 2 Operation 21........................................................................
2.1 Prestart Checklist 21......................................................
2.2 Exercising Generator Set 22...............................................
2.3 Operation in Cold Weather Climates 22.....................................
2.4 Generator Set Operation 23................................................
2.4.1 Start Signal 23...................................................
2.4.2 Stop Signal 23...................................................
2.4.3 Engine Cooldown 23..............................................
2.4.4 Emergency Stop 23...............................................
2.4.5 Idle Mode 23.....................................................
2.5 Controller Operation Modes 24.............................................
2.5.1 Out of Service Mode 24...........................................
2.5.2 Manual Mode 24.................................................
2.5.3 Auto Mode (Standby or System Ready) 25...........................
2.6 Load Shed 26............................................................
2.7 HMI Screen Layout 27....................................................
2.7.1 Home Screen 27.................................................
2.7.2 Top Bar 27.......................................................
2.7.3 Generator View 28................................................
2.7.4 Control Panel 29.................................................
2.7.5 Custom View Button 29...........................................
2.8 Operator Login 30........................................................
2.9 Data Displays 31.........................................................
2.9.1 Generator Mechanical Values 31...................................
2.9.2 Generator Electrical Values 33.....................................
2.9.3 Curve Display 33.................................................
2.9.4 Saved Electrical and Mechanical Data 35............................
2.10 Events 36...............................................................
2.10.1 Faults and Alarms 37.............................................
2.10.2 Resetting an Alarm 39............................................
2.10.3 Resetting a Fault 39..............................................
2.10.4 Consulting Status Messages 40....................................
2.10.5 Full Event Log 41.................................................
2.1 1 Applications 42
2.11.1 Reference 43....................................................
2.11.2 Region Settings 44...............................................
2.11.3 HMI Settings 45..................................................
2.11.4 Restart 47.......................................................
...........................................................
TP-7070 7/18 Table of Contents 3
Table of Contents, continued
2.1 1.5 Display Cleaning 47..............................................
2.11.6 Firmware Update 47..............................................
2.11.7 Screenshot 48...................................................
2.1 1.8 Ladder Tools 49..................................................
2.11.9 Save Parameters 51..............................................
2.11.10 Upload Parameters 51............................................
2.12 Menus 52...............................................................
2.12.1 Menu 1--Settings 54..............................................
2.12.2 Menu 2--Measurements 58........................................
2.12.3 Menu 3--History 61...............................................
2.12.4 Menu 4--Diagnosis 62.............................................
2.12.5 Menus 5 and 6 68................................................
2.12.6 Menu 6.5-Communication 68.......................................
Section 3 Scheduled Maintenance 71..........................................................
3.1 Introduction 71...........................................................
3.2 Service Schedule 74......................................................
3.3 APM802 Controller Maintenance 76.........................................
3.4 Engine Maintenance 76...................................................
3.5 Diesel Fuel Systems 76...................................................
3.5.1 Fuel/Water Separator 77..........................................
3.5.2 Manual Primer Pump 78...........................................
3.5.3 Bleeding Air from Fuel System 79..................................
3.5.4 Restriction Gauge (if equipped) 79..................................
3.6 Lubrication System 80....................................................
3.6.1 Oil Change 80...................................................
3.6.2 Automatic Oil Replenishment System (Optional Kit) 80................
3.6.3 Oil Analysis 81...................................................
3.7 Air Cleaner System 83....................................................
3.7.1 Air Filter Element 83..............................................
3.7.2 Air Cleaner Restrictor Indicator (if equipped) 83......................
3.8 Cooling System 84.......................................................
3.8.1 Coolant System Safety 84.........................................
3.8.2 Coolant Level Check 85...........................................
3.8.3 Cooling System Component Inspection 85...........................
3.8.4 Procedure to Drain Cooling System 85..............................
3.8.5 Procedure to Flush and Clean Cooling System 86....................
3.8.6 Procedure to Refill Cooling System 87..............................
3.8.7 Coolant Analysis 88...............................................
3.8.8 Radiator Maintenance 89..........................................
3.8.9 Radiator Fan Bearing Lubrication (KD2000--KD3250) 90...............
3.8.10 Notched V-Belt Adjustment (KD2000--KD3250) 91....................
3.9 Battery Systems 93.......................................................
3.9.1 Battery Safety 93.................................................
3.9.2 Absorbed Glass Mat (AGM) Battery 94..............................
3.9.3 Clean Battery 94.................................................
3.9.4 Charge Battery 94................................................
3.10 Alternator Maintenance 95.................................................
3.10.1 Alternator Safety 95...............................................
3.10.2 Checking the Installation 96........................................
3.10.3 Checking the Ventilation Circuit 96..................................
3.10.4 Checking the Bearings 96.........................................
3.10.5 Checking the Windings 96.........................................
3.10.6 Voltage Regulator 96..............................................
TP-7070 7/18Table of Contents4
Table of Contents, continued
3.11 Storage Procedure 97.....................................................
3.11.1 Storage Safety 97................................................
3.11.2 Controller 98.....................................................
3.11.3 Lubricating System 98............................................
3.1 1.4 Cooling System 98...............................................
3.1 1.5 Diesel Fuel System 98............................................
3.11.6 Exterior 98.......................................................
3.11.7 Alternator Storage 99.............................................
3.11.8 Battery 99.......................................................
Section 4 Troubleshooting 101.................................................................
4.1 Introduction 101...........................................................
4.2 Generator Set and Controller 101............................................
4.3 Engine 101...............................................................
4.4 Transfer Switch 101........................................................
4.5 General Troubleshooting Chart 102..........................................
Section 5 Accessories 107.....................................................................
5.1 Accessories and Connections 107...........................................
5.2 Accessory Connections 107.................................................
5.3 Input and Output Modules 108..............................................
5.3.1 Analog Input/Output Module 108.....................................
5.3.2 Digital Input/Output Module 109.....................................
5.3.3 Thermocouple Input Module 110.....................................
5.4 Remote Serial Annunciator 1 11..............................................
Appendix A Abbreviations 113................................................................
Appendix B Operating Hour Service Log 115...................................................
TP-7070 7/18 Table of Contents 5
Notes
TP-7070 7/186
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,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) Shut down the generator set. (2)
Place the controller in Out of Service
mode. (3) Press the emergency stop
button. (4) Disconnect the power to the
battery charger, if equipped.
(5) 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 acidsplashes 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-7070 7/18
Battery gases. Explosion can cause
severe injury or death. Battery gases
can cause an explosion. Do not smoke
or permit flamesor 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.
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.
Servicing the fuel system. A flash
fire can cause severeinjury or death.
Do not smoke or permit flames or
sparks near the fuel injection system,
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 fuel system.
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.
Generator set operation. Carbon
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 air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner removed.
8 Safety Precautions and Instructions TP-7070 7/18
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.
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. Donot operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
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 drainingthe fuel system. Wipe up
spilled fuel after draining the system.
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. 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.
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
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.
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.
9Safety Precautions and InstructionsTP-7070 7/18
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 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)
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 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 and elevated weight.
Improper lifting can cause severe
injury or death and equipment
damage.
Do not lift the generator set from the
engine or alternator eyes. Never
stand under a unit being lifted.
Alwaysmaintainasafedistancefrom
the unit being lifted.
See the lifting instructions in the
installation manual that was provided
with the unit.
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.
Notice
NOTICE
Parallel Operation. This product
includes features intended to support
operation in parallel with the utility grid,
but these features have not been
evaluated for compliance with specific
utility interconnection protection
standards or requirements.
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.
10 Safety Precautions and Instructions TP-7070 7/18
Introduction
This manual provides generator set operation,
maintenance, and basic troubl eshooting instructions. A
separate controller operation manual contains detailed
controller operation information.
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.
Abbreviations
List of Related Materials
Separate literature contains controller operation
instructions, engine and alternator maintenance, and
accessory information not provided in this manual.
Figure 1 lists the available literature part numbers.
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 the respective
generator set parts catalog.
Literature Description Literature Part No.
APM802 Controller Spec Sheet G6-152
Generator Set Installation Manual TP-5700
Generator Set/Controller Wiring Diagram
Manual
Operation and Maintenance Manual,
KD27V12 Engine
Operation and Maintenance Manual,
KD36V16 Engine
Operation and Maintenance Manual,
KD45V20 Engine
Operation and Maintenance Manual,
KD62V12 Engine
Operation and Maintenance Manual,
KD83V16 Engine
Remote Serial Annunciator III (RSA III) TT-1625
TP-7071
33521029401
33521029701
33521030001
33521030301
33521030601
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.
Figure 1 Related Literature
11IntroductionTP-7070 7/18
Nameplate Location
Generator sets and their components (engine,
alternator) are identified with decals or nameplates. For
future reference during routine maintenance or to order
service parts, copy the model number, serial number,
and specification number from the generator set
nameplate into the spaces provided in the product
information section on the inside front cover of this
manual.
The generator set nameplate is typically located on the
alternator assembly as shown in Figure 3.
Genset Model
Spec Number
Serial Number
Material Number
Service Duty
Voltage
Alt Model
Insulation
MFG Date
Amps
Phase
RPM
Battery
kW
kVA
PF
Hz
Fuel
1
11811000100--GR1
1. Nameplate location, typical
Figure 3 Generator Set Nameplate Location, Typical
Figure 2 Generator Set Nameplate, Typical
12 Introduction TP-7070 7/18
Service Assistance
For professional advice on generator set power
requirements and conscientious service, 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: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific
Kohler Asia Pacific Headquarters
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
13Service AssistanceTP-7070 7/18
Notes
14 Service Assistance TP-7070 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 the
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 Specifications
1.2.1 Contro ller Specifications
D Power Supply Requirements:
d Nominal voltage: 24 VDC, reverse polarity
protected
d 240 VAC / 60Hz customer-supplied; factory wiring
to basic electrical package available
D Operating Temperature:
-- 4 0 _Cto70_C(--40_F to 158_F)
D Storage Temperature:
-- 4 0 _Cto70_C(--40_F to 158_F)
D Humidity: 5% to 95% non-condensing
D Protection Index:
d IP65 Front
d IP20 Rear
D Standards:
d NFPA 99
d NFPA 110, Level 1
d CSA 282-09
d UL 508
d IEC/EN60068-2-52 (salt spray)
d CE Directive
1.2.2 Display and Touchscreen
1.3 Controller Features
The controller features include a 307 mm (12.1 inch)
touchscreen with backlight and wide viewing angle (140
degrees horizontal and vertical) and terminal blocks for
input and output connections. See Figure 1-1 for an
illustration of the controller front panel and the customer
connection area. Controller features include:
D 12-inch touchscreen with backlight and wide viewing
angle for easy local access to data.
D System settings are password-protected.
D Measurements selectable in metric or English units.
D User language is selectable (English or French).
D Graphic displays show generator set mechanical
values including operating hours, fuel level*, battery
voltage, coolant temperature, oil pressure, and oil
temperature.
D Meter displays provide a visual representation of
generator electrical values including power (kW),
power factor, reactive power (kVAR), frequency,
voltage, and current (amps).
D Two USB ports allow connection of a flash drive,
mouse, or keypad.
D Electrical data, mechanical data, and system settings
can be saved to a flash drive.
D Recording feature allows data collection of key
values.
D Ethernet port allows connection to a PC type
computer and/or Ethernet switch.
D Serial (RS-485) port.
D The controller supports Modbusr RTU and TCP
protocols.
D Real time clock with battery back-up.
D See the controller specification sheet or operation
manual for input and output specifications.
Modbusr is a registered trademark of Schneider Electric.
* Where applicable
D Type: XGA TFT LED LCD
D Screen Size: 305 mm (12 inches)
D Viewing Angle: 140_ horizontal and vertical
D Languages: English, French
Note: Have setup and adjustments of the controller
performed only by an authorized Kohler
distributor. The setup and adjustments are
password protected.
TP-7070 7/18 15Section 1 Specifications and Features
1
2
9
10
11
3
13
4
8
7
5
6
11601000945
Note: Covers have been removed for illustration.
1. APM802 controller human-machine interface (HMI)
2. Emergency stop switch
3. Key switch
4. Manual start/stop button
5. 240 VAC/ 60 Hz power supply connection (required)
6. Terminal block TB10 for accessory connections
7. Wiring harness connection
10. Fault indicator/display button
11. Mode selection switch
12. Generator set electrical values
13. Generator set mechanical data
Figure 1-1 APM802 Controller and Customer Connection Box
Human-Machine Interface (HMI)
8. USB ports, qty. 2 (on the back of the HMI)
9. Controller touchscreen
12
TP-7070 7/1816 Section 1 Specifications and Features
1.3.1 Connectio ns
1.3.2 Modbus Connections
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
Inputs and outputs from the controller base module are
brought out to TB10 in the connection box. See
Figure 1-1 for the terminal block location. Do not
connect directly to the controller base module (except
for the Ethernet 3 connection).
TB10 Terminal Strip for input and output connections.
See the generator set wiring diagram for connections.
Inputs and outputs are factory-set; the default settings
are shown in Figure 1-8.
240 VAC Power Connection. The installer must
connect a 240 VAC power source for the controller
heater. See Figure 1-1 and the wiring diagram for the
240 VAC power connections to TB10.
Mini USB Connectors for connection to a PC for
firmware updates or saving data files. Two USB ports
are located on the back of the controller’s
human-machine interface (HMI). See Figure 1-2. Lift
the hinged panel to access the USB ports.
Use RS-485 cable for Modbus RTU connections.
Belden #9841 or equivalent shielded, twisted-pair cable
is recommended. See Figure 1-3. See the generator
set wiring diagram for the Modbus connection location
on TB10.
The controller also supports Modbus TCP over
Ethernet. Connect to the RJ45 port labeled Ethernet 3
on the controller’s base module.
The controller communicates using Modbusr as a slave
connection with the Modbusr master initiating the
communication. The controller seeks the system and
alternator parameters and diagnostic information then
responds back to the Modbusr master.
Note: Only one Modbusr master can be connected to
the controller. Examples include the remote
serial annunciator and switchgear applications.
RS-485
up to 1220 m (4000 ft.)
Generator Set
Controller
Modbusr Master
Figure 1-3 Modbusr Connections
Ethernet 3 port on the base module can be connected
to a personal computer or network to allow remote
monitoring using VNC.
Additional input and output connections are available
with optional module kits. See Section 5 for accessory
connection details.
1
1. USB Ports
Figure 1-2 USB Ports (back of HMI)
TP-7070 7/18 17Section 1 Specifications and Features
1.3.3 Option al Keyswitch and Manual
Start/Stop Button
Some controllers are equipped with the optional
keyswitch and manual start/stop button shown in
Figure 1-4. See Figure 1-1 for the locations on the
controller assembly.
1.4 NFPA Requirements
In order to meet NFPA 110, Level 1 requirements, the
generator set controller monitors the engine/generator
functions and faults shown below.
Engine functions:
D Overcrank
D Low coolant temperature warning
D High coolant temperature warning
D High coolant temperature shutdown
D Low oil pressure shutdown
D Low oil pressure warning
D Overspeed
D Low fuel level *
D Low coolant level
D EPS supplying load
D High battery voltage
D Low battery voltage
D Air damper indicator
Figure 1-4 Optional Keyswitch and Manual
Start/Stop Button
Keyswitch. The keyswitch disables the mode
pushbutton on the controller touchscreen. The
touchscreen will display the operation mode, but the
mode cannot be changed using the touchscreen if the
controller is equipped with thekeyswitch. The keyswitch
positions are described in Figure 1-5. See Section 2.5
for more information on controller operation modes.
Manual Start/Stop Button. When the keyswitch is in
the Manual position, pressing the Start/Stop button will
start and stop the generator set.
Note: Pressing the manual stop button shuts down the
generator set immediately, without running the
engine cooldown cycle. Running the generator
set without load for 5 minutes before stopping
manually is recommended.
Position Description
Manual Allows generator set start and stop using
the manual pushbutton.
Off Places the generator set in OFF/Out of
Service mode. The generator set will not
start, even if a remote start command is
received or the Start button is pressed.
Auto Automatic operation allows a remote
switch or automatic transfer switch to start
and stop the generator set.
Figure 1-5 Keyswitch Positions
General functions:
D Master switch not in auto
D Battery charger fault *
D Lamp test
D Contacts for local and remote common alarm
D Audible alarm silence switch
D Remote emergency stop
* Function requires optional input sensors or kits.
TP-7070 7/1818 Section 1 Specifications and Features
1.5 Parameter Settings
Controller parameter settings are factory-set and
password-protected. Selected settings are shown in
Figure 1-6. If changes are required, contact your
distributor.
Parameter Setting
Preheat duration* 0s
Air-preheater maximum delay
(at each s tart attempt)*
Number of starting attempts 3
Time between starting attempts 15 s
Fault inhibition time in starting phase 10 s
Auxiliaries start time 5s
Generators starting maximum delay
(Dead Bus synchronizing)
Generator cooling time 300 s
Generator immobilization time 5s
Ventilation time after generator stopped 10 s
* Parameter settings not applicable for KD2000--KD3250
Figure 1-6 Factory Settings
30 s
5s
(5 min.)
TP-7070 7/18 19Section 1 Specifications and Features
1.6 Base Module Inputs and Outputs
The inputs and outputs on the base module are factory set. See Figure 1-7 and Figure 1-8 for base module input and
output factory settings. For optional input/output module settings, see Section 5, Accessories.
Note: Make customer connections to TB10 in the connection box. See the generator set wiring diagram for details.
Inputs Factory Setting
Digital Inputs
Analog Input
Resistive Input
Figure 1-7 APM802 Base Module Input Factory Settings
DI0 Remote Start
DI1 Low Fuel Level Switch
DI2 Breaker Open Status
DI3 Remote Reset
DI4 Aux Shutdown
DI5 High Fuel Level Switch
DI6 Aux Warning
DI7 Low Oil Level
DI8 Battery Charger Fault
DI9 Fuel Leak Alarm
DI10 Idle Mode
DI11 GFCI Tripped
DI12 Remote Speed Adjust Enable
DI13 Key Switch Enable
DI14 Load Shed Enable
DI15 Overcrank Test
DI16 Reserved for Factory Use
DI17 Emergency Stop
AI0--
AI0+
RES0--
RES0+
Remote Speed Adjust
(+/-- 10 VDC)
Ambient Air Temperature
Output Relay
Outputs
Digital Outputs
DO0 Form C Common Fault
DO1 Form C System Ready
DO2 Form C Common Warning
DO3 Form C Reserved for Factory Use
DO4 Form A Horn
DO5 Form A Low Coolant Temp Warning
DO6 Form A Shunt Trip
DO7 Form A Not in Auto
DO8 Form A BCA Excitation
DO9 Form A Generator Running
DO10 Form A EPS supplying Load
DO11 Form A ECU Fault Reset
DO12 Form A Low Oil Pressure
DO13 Form A High Coolant Temp
DO14 Form A Low Coolant Level Fault
DO15 Form A Low Fuel Level
DO16 Form A Start Button Illuminate
DO17 Form A Watchdog
Configuration
Factory Setting
Figure 1-8 APM802 Base Module Output Factory Settings
TP-7070 7/1820 Section 1 Specifications and Features
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.
DANGER
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
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.
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.
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Coolant Level. Checkthe 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) according to the drive belt system
maintenance information.
Enclosure Doors, if equipped. Check that the service
access doors are closed and secured. Leaving the
doors open will create excessive noise.
Controller Check. Touch the controller screen to verify
that it turns on. The controller screen dims automatically
after a period of time with no activity.
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.
Radiator. Check that the radiator fins and air
inlets/outlets are clean of leaves, insects, dirt, and other
debris. Use compressed air to clear the obstructed
passages as needed.
Visual Inspection. Walk around the generator set and
look for leaking fluids, loose or dangling wiring, and
loose or missing hardware. Repair as needed before
starting the generator set. This visual inspection should
be routinely done while the unit is running.
TP-7070 7/18 21Section 2 Operation
2.2 Exercising Generator Set
DANGER
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
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 n
automatic transfer switch with an exercise option.
During the exercise period apply a minimum of 30% 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 2.5, 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 controller does not provide weekly
scheduled exercise periods. For scheduled exercise
periods, refer to the automatic transfer switch (if
equipped) literature.
2.3 Operation in Cold Weather
Climates
Cold weather operation is generally considered ambient
temperatures below freezing 0C(32F). The following
items are recommended for cold weather starting and/or
operation when the unit is located in an enclosure or
unheated structure. Have a licensed electrician install
240 VAC, 15 amp outlets as needed if not already in the
immediate area.
Refer to the engine operation manual regarding engine
oil viscosity, fuel composition, and coolant mixture
recommendations.
D The engine block heater is generally recommended
for most units when operated below 0C(32F) and
required as part of NFPA 110. Refer to the respective
spec sheet for temperature recommendations in
available options.
D The controller heater is required for operation below
-- 2 0 C(--4F). The controller heater is a standard
feature. Make sure that 240 VAC power for the heater
is connected as shown on the generator set wiring
diagram.
D A battery heater is generally recommended for most
units when operated below 0C(32F). Refer to the
respective spec sheet for model availability.
D An alternator heater to prevent moisture and frost
buildup is available for most generator sets.
TP-7070 7/1822 Section 2 Operation
2.4 Generator Set Operation
2.4.1 Start Signal
2.4.4 Emergency Stop
Use the controller emergency stop switch for immediate
emergency shutdown.
A start signal includes the following:
D Remote start signal via contacts 3 and 4 when the
controller is in AUTO mode. The remote start
contacts may be connected to an ATS (used during a
power outage, exercise period, etc.) or a remote
panel.
D Engine Start signal from the controller. Put the
controller into Manual mode. Then press the Engine
Start button on the screen.
Note: The engine crank cycle is 15 seconds cranking
and 15 seconds rest for 3 cycles.
2.4.2 Stop Signal
A stop signal includes the following:
D Removal of start signal via contacts 3 and 4 when the
controller is in AUTO mode. The remote start
contacts may be connected to an ATS (used during a
power outage, exercise period, etc.) or a remote
panel.
D Engine Stop signal from the controller when it is in
Manual mode. Press the Engine Stop button on the
screen.
D Emergency Stop signal. See Section 2.4.4.
2.4.3 Engine Cooldown
Engine Cooldown runs the generator set with no load to
allow hot engine components time to cool slowly before
the engine is stopped.
When the generator set is running in AUTO mode, an
engine cooldown cycle begins when the remote start
input is deactivated. Also, if stopping due to a remote
stop signal, a cooldown cycle begins. The engine runs
for 5 minutes in the cooldown cycle.
Note: No engine cooldown cycle occurs if the Engine
Stop button is pressed (in manual mode), the
Emergency Stop button is pressed, or if a fault
occurs. The shutdown is immediate. If possible,
run the generator set without load for 5 minutes to
ensure adequate engine cooldown.
The emergency stop switch bypasses the engine
cooldown cycle and immediately shuts down the
generator set.
Note: Use the emergency stop switch(es) for
emergency shutdowns only. Use the controller’s
Manual mode or a remote stop switch for normal
shutdowns.
The controller alarm (fault) button flashes red and the
unit shuts down when the local emergency stop switch is
activated (pressed).
Use the following procedure to reset the generator set
after shutdown by a local or remote emergency stop
switch.
1. Investigate and correct the cause of the
emergency stop.
2. Reset the controller emergency stop switch by
pulling the switch dial outward and/or reset the
remote emergency stop switch (if equipped).
3. Reset the fault on the APM802 controller. See
Section 2.10 for instructions.
4. After resetting all faults using the controller reset
procedure, place the controller into Auto mode or
use Manual mode to restart the generator set. The
generator set will not crank until the reset
procedure completes.
2.4.5 Idle Mode
The generator set controller must be in AUTO mode for
idle mode operation. Idle mode requires a
customer-supplied idle switch connected across
terminals 5 and 6 on terminal block TB10.
When the idle switch on contacts 5 and 6 closes, the
engine runs at low speed (1000 RPM) for 5 minutes.
The engine then ramps up to normal speed and voltage
and continues to run until the idle switch opens. Afterthe
idle switch opens, the engine continues to run through
the cooldown cycle and then shuts down.
TP-7070 7/18 23Section 2 Operation
2.5 Controller Operation Modes
The controller operation includes several types of
starting and stopping functions. Thereare three primary
modes of operation, selected from the controller
touchscreen or the optional keyswitch:
D Auto (Automatic mode)
D Manual
D Out of Service (Off mode)
See Figure 2-1 for the location of the mode selection
switch on the controller touchscreen. See Section 1.3.3
for more information about the optional keyswitch.
Note: To disable the generator set before servicing,
shut down the generator set, place in
Out-of-Service mode, and disconnect the
batteries negative (--) lead first.
2.5.2 Manual Mode
In manual mode, engine start and stop are controlled
manually by the operator using the Engine Start and
Engine Stop buttons on the controller’s touchscreen. If
the controller is equipped with an optional keyswitchand
manual start/stop button, use the start/stop button for
manual operation in the procedures below.
The Emergency Stop button and the optional remote
emergency stop switch will stop the generator set
immediately, with no engine cooldown period.
The three operation modes are briefly described below
and summarized in Figure 2-2.
1
2
1. Alarm (fault) button
2. Mode selection switch
tp7070
Figure 2-1 Controller Mode Selection Switch
2.5.1 Out of Service Mode
Manual start procedure, with optional keyswitch
1. Turn the key to the Manual position. check that the
controller touchscreen shows that the unit is in
MANUAL mode.
2. Check the mechanical parameters (battery
voltage, etc.) and verify that there are no faults.
3. To start the generator set, press the manual
Start/Stop button. The engine speed, voltage, and
frequency will be displayed o n the controller
screen.
Manual start procedure, without optional
keyswitch
1. Press and hold the Manual button on the
controller’s touchscreen until Manual turns green.
2. Release the Manual button. The Engine Start
button appears on the controller touchscreen.
3. Check the mechanical parameters (battery
voltage, etc.) and verify that there are no faults.
4. To start the generator set, press Engine Start on the
controller touchscreen. The engine speed,
voltage, and frequency will be displayed on the
controller screen.
Pressing the Out of Service button on the controller
touchscreen disables the generator set to prevent
starting during generator set maintenance or service.
The generator set remains off and will not respond to a
remote start signal. If the generator set is running,
pressing the Out of Service button immediately shuts off
the generator set, with no engine cooldown.
If a fault causes the generator set to shut down, the
controller automatically enters the Out o f Service mode.
Manual stop procedure
Note: Pressing Engine Stop causes the generator set
engine to stop immediately, without running the
engine cooldown cycle.
The controller must be in Manual mode. Follow these
steps to allow engine cooldown before stopping the
generator set.
TP-7070 7/1824 Section 2 Operation
1. Remove the load from the generator set.
2. Wait five minutes to allow the engine to cool down.
When the start signal is removed, the generator set will
continue to run through the engine cooldown cycle, and
then shut down.
3. To stop the generator set, press Engine Stop on the
controller touchscreen or press the manual
Start/Stop button (if equipped).
Idle Mode
If the generator set is equipped with an idle mode switch
across contacts 5 and 6, the engine can operate in idle
2.5.3 Auto Mode (Standby or System
Ready)
The generator set is waiting for a start signal. The
generator set will start and run when a start signal is
received via a remote start signal or a local start signal.
The generator set will start when it receives a start
signal. If the generator set is not in Auto mode, it will not
mode. When the idle mode switch closes, the engine
runs at low speed (1000 RPM) for 5 minutes and then
ramps up to normal speed and voltage. Idle Mode is
displayed in the status message area on the controller
screen. When the idle mode switch opens, the engine
runs through the cooldown cycle and then shuts down.
The controller must be in Auto mode for idle mode
operation.
start.
Operating Mode Action / Event Operation Notes
Press Auto or place the
optional keyswitch into the
AUTO position (if equipped).
Idle switch on contacts 5
and 6 closes.
Idle switch on contacts 5
AUTO
MANUAL
OUT OF SERVICE
* The E-Stop button overrides the manual engine start/stop buttons and remote start signals. The engine will not start if the E-Stop button is
activated.
and 6 opens.
A warning condition occurs.
A fault condition occurs.
Press Manual or place the
optional keyswitch into the
Manual position (if
equipped).
Press the Engine Start
button or the manual
Start/Stop button (if
equipped).
Press the Engine Stop
button or the manual
Start/Stop button (if
equipped).
Press the Out of Service
button or place the optional
keyswitch into the OFF
position (if equipped).
Generator set shuts down
on a fault.
Responds to remote start/stop
commands from an ATS or
remote start panel. *
Engine runs at 1000 RPM for 5
minutes, then ramps up to normal
speed and voltage. *
Engine runs through the 5 minute
cooldown, then shuts down.
Fault button flashes orange.
Horn may sound, if connected.
Generator set shuts down and
the fault button flashes red. The
mode changes to Out of Service
mode.
Horn may sound, if connected.
Engine can only be started and
stopped using the engine
start/stop buttons on the
touchscreen or the manual
start/stop button (if equipped). *
Starts the engine if there are no
active faults. *
Stops the engine immediately,
with no engine cooldown.
Stops the engine immediately,
with no cooldown.
System is locked and generator
startup is not possible.
Auto is the recommended mode.
Customer-supplied idle switch is required for idle
mode operation. Controller must be in Auto for
idle mode operation.
See Section 2.10 for instructions to view faults
and warnings (alarms).
Engine start/stop is controlled manually by the
operator.
If equipped with the optional keyswitch and
manual Start/Stop button, the engine start and
stop buttons on the controller touchscreen are
disabled. Use the manual Start/Stop button.
Wait 5 minutes after opening the circuit breaker
for engine cooldown before pressing Engine
Stop.
Put the generator set into Out of Service (OFF)
mode and disable the generator set during
maintenance or service.
A fault shutdown automatically puts the
generator into Out of Service Mode. See
Section 2.10 for instructions to view and reset
faults (shutdowns or warnings).
Figure 2-2 Operation Mode Summary
TP-7070 7/18 25Section 2 Operation
2.6 Load Shed
The manual key switch/ load shed module isavailable as
an optional kit.
The load shed function drives outputs to four Form C dry
contacts to remove non-critical loads. If the generator
set load reaches or exceeds the level set in power
threshold #9, loads are shed until the total load drops
below the threshold level.
threshold #9. Load 1 (output #0) is shed first . Additional
outputs are activated every 5 seconds as shown in
Figure 2-3 until the total load drops to the threshold
value or all four non-critical loads are shed. Messages
on the main screen will indicate that load shed outputs 1
through 4 are active.
If all four loads are shed, the generator set will continue
to run if the load remains at or below 100% of the rated
load.
Loads are added again when the total load drops below
the level in threshold #9. Factory-settime delays ensure
that the load is stable before loads are shed or added.
Load 1 is shed first and added last. Load 4 is shed last
and added first.
The load shed level is set in Power Threshold 9 on the
APM802 controller. The factory default setting for
threshold 9 is 90%. The threshold setting can be
changed in Screen 1.2 after logging in with the
operator’s password. See Sections 2.8 and 2.12.1.
Do not connect critical loads to the load shed outputs.
Only connect low-priority loads that can be
disconnected when necessary.
Connection
Controllers with load shed capability are equipped with a
Manual Key Switch/Load Shed digital I/O Module, which
is factory-installed in the first position. Connect up to
four non-critical loads to Load Shed Outputs 1 through 4
on the Manual Key Switch/Load Shed Module. See
Figure 2-4. The load shed outputs are Form C contacts.
Connect to the normally open (NO) or normally closed
(NC) contacts as required for the application.
When the generator set load drops below the level in
threshold 9, the outputs are deactivated one at a time
starting with Load 4 (output #3), reconnecting the loads.
Adjust the loads, if necessary to avoid cyclic adding and
shedding around the threshold #9 level.
MANUAL KEY SWITCH/
LOAD SHED I/O MODULE
Key switch
factory
connections
Load Shed
Power
Threshold *
Load
1 #9 5 seconds 60 seconds O#0
2 #9 5 seconds 45 seconds O#1
3 #9 5 seconds 30 seconds O#2
4 #9 5 seconds 15 seconds O#3
* Default setting = 90%. Power threshold setting can be
changed by the technician.
(Disconnect)
Time Delay
Load Add
(Reconnect)
Time Delay
Displayed
as
Figure 2-3 Load Shed Settings
Operation
The outputs are activated and loads are shed when the
total generator set load reaches the level set in power
Load Shed
Customer
Connections
GM103061
Figure 2-4 Load Shed Output Connections
TP-7070 7/1826 Section 2 Operation
2.7 HMI Screen Layout
2.7.1 Home Screen
The home screen of the APM802 controller’s human-machine interface (HMI) contains status messages, navigation
buttons, data displays, and controls described briefly in the following sections. See Figure 2-5.
1
3
1. Top bar
2. Control Panel
3. Generator view
2
Figure 2-5 Home Screen
2.7.2 Top Bar
The top bar is alwayspresent, it displays system information and status messages, and ithas shortcut buttons for quick
access to other screens.
1 2
9 8 7 6 510
1. Shortcut to operating screen
2. Operating status message
3. Shortcut buttons
4. Date and time display
5. To home screen
6. Alarm indicator and access to events screen
7. For future development
8. To operator login
9. To applications screen
10. Operating sequence display
Figure 2-6 Top B ar
TP-7070 7/18 27Section 2 Operation
3
4
2.7.3 Generator View
The generator view displays engine mechanical data and alternator electrical data. Whenin manual mode, the Engine
Start button also appears. See Figure 2-7.
1
2
1. Engine start appears in Manual mode only
2. Engine and mechanical view
3. Alternator electrical view
Figure 2-7 Generator View
3
TP-7070 7/1828 Section 2 Operation
2.7.4 Control Panel
2.7.5 Custom View Button
The control panel includes the generator set master
switch and other controls. See Figure 2-8.
1
2
4
5
1. Mode selection touch pad
2. Horn silence button appears for alarm or fault
3. Start button in manual mode
4. Voltage and frequency shown when running
5. Touch Menu button for menu access
6. Operator menus (operator login required)
7. User menus
3
6
7
On medium voltage units equipped with thermocouple
modules, touch the custom view button to see alternator
temperature readings from the thermocouple modules.
If no thermocouple modules are installed, 32_F(or0_C)
is displayed for all temperatures. If nothing is connected
to one channel on a thermocouple module, --58_F(or
-- 5 0 _C) is displayed.
1
1. Custom view button
tp7070
Figure 2-9 Custom View Button
Figure 2-8 Control Panel
Figure 2-10 Custom View Temperature Display
TP-7070 7/18 29Section 2 Operation
2.8 Operator Login
Some functions require logging in as an operator.
1. Touch the Operator button. See Figure 2-12.
2. Use the virtual keypad to enter the login (1966).
Note: When logging on as operator 1966, a
password is not required.
When logged in as an Operator, the Modify button
appears on screens where settings can be changed.
See Figure 2-11 for an example.
1
1. Modify button
The operator is automatically logged out after
10 minutes.
3
1. Operator button
2. Virtual keypad
3. Login (1966)
Figure 2-11 Modify Button
1
2
Figure 2-12 Operator Login
TP-7070 7/1830 Section 2 Operation
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