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Operation Decisionmaker 3000
Operation Decisionmaker 3000
Models:
10-1000 kW
Controller:
APM402/Decision-Makerr 3000
TP-6694 7/19l
WARNING: This product can expose you WARNING: Breathing diesel engine
to chemicals, including carbon monoxide exhaust exposes you to chemicals known to
and benzene, which are known to the State the State of California to cause cancer and
of California to cause cancer and birth birth defects or other reproductive harm.
defects or other reproductive harm. S Always start and operate the engine in
For more information go to a well-ventilated area.
www.P65warnings.ca.gov 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 Information
6 TP-6694 7/19
Safety Precautions and Instructions
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.
Read this manual and carefully follow all procedures Literature Description Literature Part No.
and safety precautions to ensure proper equipment APM402 Controller Spec Sheet G6-161
operation and to avoid bodily injury. Read and follow the
Decision-Makerr 3000 Controller Spec
Safety Precautions and Instructions section at the Sheet
G6-100
beginning of this manual. Keep this manual with the Multiple Part Numbers
equipment for future reference. Generator Set/Controller
Wiring Diagram Manual Contact your
Distributor/Dealer
The equipment service requirements are very important Modbusr Communications Protocol
TP-6113
to safe and efficient operation. Inspect the parts often Operation Manual
and perform required service at the prescribed intervals. SiteTecht Software Operation Manual TP-6701
Maintenance work must be performed by appropriately Remote Serial Annunciator (RSA III) TT-1625
skilled and suitably trained maintenance personnel Remote Serial Annunciator (RSA II) TT-1485
familiar with generator set operation and service. Converters, Connections, and Controller
TT-1405
Setup for Network Communication
This publication makes use of numerous abbreviations. Several engine manufacturers provide engines with
Typically, the word(s) are spelled out along with the electronic controls. These electronic controls indicate
abbreviation in parentheses when shown for the first engine fault codes in addition to the generator set
time in a section. Appendix A, Abbreviations, also controller. The engine operation and service literature
includes many abbreviation definitions. provide information for identifying engine fault codes.
For the latest literature part numbers, see the respective
Parts Catalog.
1 2 3 4 5
8
FAULT
GM65741-
1. Emergency stop switch 5. Pushbutton/rotary selector dial
2. Generator set master control switches, 6. Annunciator fault lamp
OFF/RESET- AUTO- RUN buttons with lamps 7. Controller terminal strips (on circuit board)
3. Digital display 8. Alarm silence/lamp test button with lamp
4. Alarm horn (behind panel) 9. Mini USB connection
Figure 1-1 Controller with Digital Display and Pushbutton/Rotary Selector Dial
Manual Speed Adjust (Engine RPM). The control System Status Lamps (Master Control Switches)
allows varying the engine speed for applications using
The green lamp illuminates on the master control switch
closed transition ATS. The user can set the nominal
AUTO (automatic start) button indicating the system
running frequency slightly above or below the utility
senses no faults and the unit is ready to start by remote
frequency to ensure that synchronization occurs.
command.
Additional information is shown in 2.7.7 GenSet
System. Available as a factory-installed option or The red lamp illuminates on the master control switch
requires a new factory personality profile. OFF/RESET button indicating the generator set is
stopped.
Pushbutton/Rotary Selector Dial. This control
provides access to the menus for monitoring. Press the The yellow lamp illuminates on the master control switch
selector dial to activate the digital display and to select RUN button indicating the generator set is cranking or
choices shown on the display. Rotate the dial to running from a local command.
navigate through the menus.
Only one of the three master control switch lamps will
illuminate at any given time.
The 12-character, 2-line backlit heated display provides Generator Set State displays the generator set status:
generator set and engine data, system status, and fault
D Off
information. See Figure 1-1. The digital display shows
abbreviations in some instances, refer to 1.3.1 Status D Standby
Event and Fault Specifications for the abbreviations and D Running
their full descriptions. D Cooldown
D Stopping
Note: US/Metric Unit Display is selectable in
Generator Set System. Average Volts Line-to-Line value displays. For
three-phase configurations the average line-to-line
Note: Display Contrast is selectable in Generator Set voltage of L1, L2, and L3 is displayed. Single-phase
System. The contrast display adjustment allows configurations show the L1-L2 voltage.
user selected resolution values to improve digital
display clarity. Frequency (Hz) value displays for the output AC
voltage.
Note: After about 5 minutes of no user input
(pushbutton/rotary selector dial or buttons), the Current value displays as the average for three-phase
menu resets to the top of the main menus and configurations or the current value for L1-L2 with
auto-paging activates for the Overview single-phase configurations.
submenus.
Average kW displays. For three-phase configurations
The main menus are listed below. Within each main the average line-to-line kilowatts of L1, L2, and L3 is
menu are multiple submenus with descriptions displayed. Single-phase configurations show the L1-L2
following. kilowatts.
D Overview
Coolant Temperature diplays for the engine coolant
D Engine Metering temperature.
D Generator Metering
D GenSet Information Oil Pressure displays the engine oil pressure.
D GenSet Run Time Fuel Level % displays the fuel tank level for diesel-
D GenSet System powered models when so equipped.
D GenSet Calibration (Decision-Makerr 3000
controllers before Version 3.0.25) Fuel Pressure displays fuel pressure for some engines.
D Voltage Regulation Refer to the Appendix, Controller Displays from the
Engine ECM.
D Digital Inputs
D Digital Outputs Battery displays the DC voltage of the engine starting
D Analog Inputs battery(ies).
D Event Log CHG1 and CHG2 display battery charger voltage and
D Volt Select current (amps) if one or two CAN-enabled 10 Amp
battery chargers (GM87448 only) have been
connected. Shows N/A if charger GM87448 was
Current displays the alternator output AC amps. The Engine Starts displays the total number of generator
display shows each line (L1-L2-L3) of three-phase set startup events.
models or L1-L2 current for single-phase models.
Total Energy displays the total kW hours.
Frequency (Hz) value displays for the output AC
voltage. This value also shows in the Overview Menu.
The user can change the individual value or can select The displays for digital outputs appear as shown in the
Reset VR?- Yes to reset to the default value. The Reset following list with Values as True or False. Items shown
VR Settings display will only show if editing is enabled. in the digital display as True are active.
D DOut A1 (digital output A1) standard
To disable calibration, Rotate the pushbutton/rotary
D DOut B1 (digital output B1) with I/O module board
selector dial until the <- Return popup appears.
Momentarily press the pushbutton/rotary selector dial. D DOut B2 (digital output B2) with I/O module board
Stop the generator set if not already done. D DOut B3 (digital output B3) with I/O module board
D DOut B4 (digital output B4) with I/O module board
D DOut B5 (digital output B5) with I/O module board
The displays for analog inputs appear as shown below Note: The volt select menu requires initial activation by
with Values of 0- 5 volts. SiteTecht software. In SiteTecht software,
D AIn A1 (analog input A1) standard
select True to activate the volt select menu.
(reserved and not user programmable) Note: The generator set output leads require voltage
D AIn A2 (analog input A2) standard reconnection if the generator set does not have a
D AIn B1 (analog input B1) with I/O module board voltage selector switch installed.
D AIn B2 (analog input B2) with I/O module board
With the generator set stopped, go to the Volt Select
Changes to the Analog Inputs menu requires the use of menu. Then push and hold the pushbutton/rotary
SiteTecht software. selector dial until the voltage selection starts to flash.
Volt selection is now available. Scroll to the desired
Event Log Menu voltage and momentarily press the pushbutton/rotary
selector dial to confirm the voltage selection.
This menu allows the user to review up to 1000 entries of
system events including shutdown faults, warning The displays for Volt Select appear as shown in the
faults, and status events. See 1.2.4 Controller Fault following list.
Diagnostics for a list of the items that appear on the
D 120/240 V 1 Ph
Event Log.
D 120/208 V 3 Ph
D 139/240 V 3 Ph
D 277/480 V 3 Ph
D 120/240 V 3 Ph
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)
GM64345-1-A
7 6 5
1. (4) push-on terminal connectors
2. TB2 4-position terminal block
3. TB3 6-position terminal block
4. P2 6-pin connector
5. P1 24-pin connector
GM65741-
6. TB1 6-position terminal block 1
7. P22 3-pin connector 1. Mini USB connection
8. P30 jumper (Wound Field or Fast Response)
9. P23 8-pin connector (RJ45)
Figure 1-6 Communication Port
10. P21 6-pin connector (for RS-485 communication)
P21 (6-Pin) Connector for (RS-485) connection of AC Circuit Fuses (TB5). Fuses are located inside the
optional RSA or Modbusr communication. generator set control box. See Figure 1-7
P22 (3-Pin) Connector for engine ECM. Alternate CAN D 1.5-Amp (V7) fuse protects L1 sensing input to
connection. interconnection circuit board.
P23 (8-Pin) Connector (RJ45) for optional input/output D 1.5-Amp (V8) fuse protects L2 sensing input to
(I/O) module circuit board. interconnection circuit board.
Refer to Section 6.2, Accessory Connections for D 1.5-Amp (V9) fuse protects L3 sensing input to
specific connections of the following terminal block interconnection circuit board.
connections.
DC Circuit Fuses are located on the controller circuit
TB1 (6-Position) Terminal Block for analog and digital board. See Figure 1-8.
inputs.
D 1-Amp (F1) auto-resettable, fuse protects the
TB2 (4-Position) Terminal Block for K1 relay outputs. controller circuits.
TB3 (6-Position) Terminal Block for E-stop, remote D 1-Amp (F2) auto-resettable fuse protects the
start contacts, and aux. input connections. controller circuits.
1 Note: The engine ECM may limit the crank cycle even if
the controller is set to a longer time period.
GM64345-C
1. F1 1 Amp. auto-resettable
2. F2 1 Amp. auto-resettable
3. F3 12 Amp. non-replaceable
2.1 Prestart Checklist D Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps
To ensure continued satisfactory operation, perform the and/or hangers as needed.
following checks or inspections before or at each
startup, as designated, and at the intervals specified in D Check that the exhaust outlet is unobstructed.
the service schedule. In addition, some checks require
D Visually inspect for exhaust leaks (blowby). Check
verification after the unit starts.
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
DANGER Seal leaks as needed.
Fuel Level. Check the fuel level and keep the tank(s)
full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the
Hazardous voltage. Moving parts. full mark on the dipstick.
Will cause severe injury or death.
Operate the generator set only when Operating Area. Check for obstructions that could
all guards and electrical enclosures block the flow of cooling air. Keep the air intake area
are in place. clean. Do not leave rags, tools, or debris on or near the
generator set.
Air Cleaner. Check for a clean and installed air cleaner
element to prevent unfiltered air from entering engine. 2.2 Exercising Generator Set
Air Inlets. Check for clean and unobstructed air inlets.
DANGER
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Auto Starting Note: The cooldown cycle times out before the
generator set stops when a remote switch or
Press the master control AUTO button to allow startup automatic transfer switch initiates the generator
by the automatic transfer switch or remote start/stop set start/stop sequence.
switch (connected to controller terminals 3 and 4).
Emergency Stopping
Terminals 3 and 4 connect to a circuit that automatically
starts the generator set crank cycle when an external Use the controller emergency stop switch or optional
source closes the circuit. remote emergency stop for immediate shutdown.
Note: The controller provides up to 30 seconds of The emergency stop switch bypasses the time delay
programmable cyclic cranking and up to engine cooldown and immediately shuts down the
60 seconds rest with up to 6 cycles. The default generator set.
setting is 15 seconds cranking and 15 seconds
rest for 3 cycles. Make cyclic cranking Note: Use the emergency stop switch(es) for
adjustments using SiteTecht software. emergency shutdowns only. Use the generator
set master control OFF/RESET button for normal
Prime Power Switch shutdowns.
The controller has an optional prime power mode of The controller fault lamp lights and the unit shuts down
operation. The prime power mode requires installation when the local or remote emergency stop switch
of an optional prime power switch kit. See Section 6, activates.
Accessories, for instructions on how to install the
optional prime power switch kit. The prime power switch 2.4.3 Emergency Stop Switch Resetting
kit prevents engine starting battery drain when the
generator set is shut down and no external battery Use the following procedure to reset the generator set
charging is available. after shutdown by a local or remote emergency stop
switch. Refer to Section 2.4.8, Controller Resetting
Move the prime power switch located on the junction box procedure, to restart the generator set following a fault
to the CONTROLLER ON position before attempting to shutdown.
start the generator set. When the prime power mode is
off, all controller functions including the digital display, 1. Investigate and correct the cause of the
LEDs, and alarm horn are operative. emergency stop.
Stop the generator set using the stopping procedures in 2. Reset the optional remote emergency stop switch by
Section 2.4.2 before placing the generator set in the replacing the glass piece, when equipped. Additional
prime power mode. Move the prime power switch glass rods are available as a service part. Reset the
located on the junction box to the CONTROLLER OFF controller emergency stop switch by pulling the
position. When the generator set is is the prime power switch dial outward.
mode, all controller functions including the digital
display, LEDs, alarm horn, and communications are 3. Press the generator set master control
OFF/RESET button.
inoperative.
4. After resetting all faults using the controller reset
2.4.2 Stopping (User Stopping and procedure in Section 2.4.8, press the generator set
Fault Shutdown) master control RUN or AUTO button to restart the
generator set. The generator set will not crank until
Normal Stopping the reset procedure completes.
Run the generator set without load for 5 minutes to
ensure adequate engine cooldown.
The green lamp illuminates on the master control AUTO Auxiliary Input (Warning). The fault lamp illuminates
(automatic start) button indicating the system senses no yellow and the alarm horn sounds when an auxiliary
faults and the unit is ready to start by remote command. digital or analog input signals the controller. The digital
inputs do not function during first the 30 seconds after
The red lamp illuminates on the master control startup. Use SiteTecht software to define inputs as
OFF/RESET button indicating the generator set is shutdowns or warnings. The local display shows Aux
stopped. Input Warning.
The yellow lamp illuminates on the master control RUN Battery Charger Communication Loss. The warning
button indicating the generator set is cranking or running fault lamp on the controller illuminates yellow and the
from a local command. alarm horn sounds when CAN communication with the
battery charger has been lost. Local display shows
Only one of the three master control button lamps will
either bat1CommLoss or bat2CommLoss.
illuminate at any given time.
Note: bat2CommLoss indicates communication loss
2.4.5 System Fault Warning Lamp with for battery charger number 2. bat2CommLoss is
Digital Displays only relevant for generator sets with more than
one battery charger.
The system FAULT lamp glows yellow and the alarm
horn sounds indicating a warning fault but does not shut Battery Charger Fault. The warning lamp on controller
down the generator set. The fault lamp illuminates illuminates yellow and the alarm horn sounds when the
yellow and the alarm horn sounds when the fuel tank battery charger malfunctions. Local display shows Batt
level on diesel-fueled models approaches empty. This Chg Flt.
fault requires an optional low fuel level switch for the
lamp to function. The local display shows Fuel Level Battery Charger Identity Conflict. The warning lamp
Low Warning. See Section 2.4.8, Controller Resetting on the controller illuminates yellow and the alarm horn
procedure, for instructions on resetting a system sounds when there is a CAN address communication
warning. error. The battery charger has the same CAN address
as another generator set component. To correct a CAN
When the system warning lamp is on and no message address error, verify the address identification in the
displays, rotate the selector dial to view messages. harness and power cycle the controller. Local display
When the system warning continues, it may lead to a shows BatIdErr.
fault and cause a system shutdown.
Battery Charger Parameter Mismatch. The warning
Use the Silence Alarm button to silence the alarm horn lamp on controller illuminates yellow and the alarm horn
at the operator’s discretion. sounds when the battery charger metering is not in
range of the specified parameters. Local display shows
If the controller is setup for an NFPA 110 application, ParMisatch.
press the AUTO button before silencing the alarm horn.
The alarm horn cannot be silenced unless the master Battery Fault. The warning lamp on controller
control button is in the AUTO mode. See 2.4.7 Status illuminates yellow and the alarm horn sounds when
and Notice Digital Displays for more information. there is an issue with the battery such as a connection
problem or a dead battery. When the temperature
Note: Text shown in italics in this section of the manual compensation sensor is connected, whether active or
represents digital display messages. inactive, and the temperature rises above 60_C (140_F)
or below - 20_C (- 4_F), the battery failure warning will
also be displayed indicating that the battery is unable to
take charge due to temperature. Absorption timeout will
also cause a failure since the battery was unable to
accept the expected charge in the time frame given
which indicates a potential battery issue. Local display
shows Battery Flt.
Critical High Fuel Level (diesel-powered models High Fuel Level (diesel-powered models only). The
only). The fault lamp illuminates yellow and the alarm fault lamp illuminates yellow and the alarm horn sounds
horn sounds when the fuel tank level on diesel models when the fuel tank level on diesel models approaches
approaches full. This fault requires an optional critical near full. This fault requires an optional high fuel switch
high fuel switch and fuel tank for the lamp to function. and fuel tank for the lamp to function. The local display
The local display shows Fuel Level Critically High. shows Fuel Level High Warning.
Default Parameters Loaded. The fault lamp Input/Output Communication Loss. The fault lamp
illuminates yellow and the alarm horn sounds when the illuminates yellow and the alarm horn sounds when the
controller detects that the default parameter software controller loses the input/output communication signal
was loaded using SiteTecht software. The local from the optional I/O module board. The local display
display shows Default Pars Warning. shows OB1 Com Loss.
ECM Diagnostics (Multiple Engine Inputs). The fault Low Battery Voltage. The fault lamp illuminates yellow
lamp illuminates yellow and the alarm horn sounds and the alarm horn sounds when the battery voltage
when ECM diagnostics signals the controller. The local drops below a preset level for more than 90 seconds.
display shows ECM xxxxx Warning. The specific The local display shows Low Battery Warning. See
display (xxxxx) will be a brief message or fault code that Figure 2-3 for low battery voltage specifications.
is engine manufacturer dependent. The engine
literature provides the fault code description and further Engine Electrical Low Battery Low Battery Voltage
information. System Voltage Voltage Range Default Setting
12 9.6- 12.6 12
Fuel Tank Leak (diesel-powered models only). The
24 19.2- 25.2 24
fault lamp illuminates yellow and the alarm horn sounds
when the fuel tank signals a leak of the inner tank. This Figure 2-3 Low Battery Voltage Specs
fault requires an optional fuel tank leak switch for the
lamp to function. The local display shows Fuel Leak The low battery voltage feature monitors the battery and
Warning. battery charging system in the generator set operating
and off modes. The controller logic inhibits the low
Ground Fault. The fault lamp illuminates yellow and battery voltage warning during the crank cycle.
the alarm horn sounds when a user-supplied ground
fault detector signals the controller. The local display Low Coolant Temperature. The fault lamp illuminates
shows Ground Fault Warning. yellow and the alarm horn sounds when the engine
coolant temperature is low. The low coolant
High Battery Voltage. The fault lamp illuminates yellow temperature warning does not function during the preset
and the alarm horn sounds when the battery voltage inhibit time delay period after startup. The local display
rises above the preset level for more than 10 seconds. shows Coolant Temp Low Warning.
The local display shows Battery High Warning.
Figure 2-2 shows high battery voltage specifications. Low Cranking Voltage. The fault lamp illuminates
The high battery voltage feature monitors the battery yellow and the alarm horn sounds when the battery
and battery charging system in the generator set voltage drops below 60% of the nominal voltage (12
operating and off modes. VDC or 24 VDC) for more than 6 seconds during the
crank cycle. The local display shows Lo Crank Vlt
Engine Electrical High Battery High Battery Voltage Warning.
System Voltage Voltage Range Default Setting
12 13.2- 16.2 15
24 26.4- 32.4 30
Low Fuel Pressure (gas-powered models only). The Auxiliary Input (Shutdown). The fault lamp
fault lamp illuminates yellow and the alarm horn sounds illuminates red, the alarm horn sounds, and the unit
when low fuel pressure on gaseous-fueled models shuts down when an auxiliary digital or analog inputs
occurs. This fault requires an optional low fuel pressure signals the controller. The digital inputs do not function
switch for the lamp to function. The local display shows during first the 30 seconds after startup. Use SiteTecht
Fuel Press Low Warning. software to define inputs as shutdowns or warnings.
The local display shows Aux Input Shutdwn.
Low Oil Pressure. The fault lamp illuminates yellow
and the alarm horn sounds when the engine oil pressure Common Fault. The fault lamp illuminates red, the
approaches the shutdown range. The low oil pressure alarm horn sounds, and the unit shuts down when the
warning does not function during first the 30 seconds controller is signaled by a common fault. Use
after startup. The local display shows Oil Press Low SiteTecht software to activate the common fault
Warning. shutdown. The local display shows Common Fault
Shutdwn. The common fault comprises the following
Not in Auto (Generator Master Control Switches). shutdowns under a single alert.
The fault lamp illuminates yellow and the alarm horn
D Emergency stop
sounds when the generator set master control button is
in the RUN or OFF/RESET mode. The local display D Engine over speed
shows Not In Auto Warning. D High coolant temperature
D Low oil pressure
Speed Sensor Fault. The fault lamp illuminates yellow
D Overcrank
and the alarm horn sounds when the speed signal is
absent for one second while the generator set runs. The ECM Address Conflict. The fault lamp illuminates red,
local display shows Spd Sens Flt Warning. the alarm horn sounds, and the unit shuts down when
the controller detects an error with the ECM address.
2.4.6 System Fault Shutdown Lamp The local display shows ECMAddr Err Shutdwn.
With Digital Displays ECM Communications Loss. The fault lamp
The system FAULT lamp glows red, the alarm horn illuminates red, the alarm horn sounds, and the unit
sounds, and the unit shuts down to indicate a fault shuts down when the ECM communication link is
shutdown under the following conditions. See Section disrupted. The local display shows ECM Comm Err
2.4.8, Controller Resetting procedure, for information on Shutdwn.
resetting a system shutdown.
ECM Diagnostics (Multiple Engine Inputs). The fault
Use the Alarm Off button to silence the alarm horn at the lamp illuminates red, the alarm horn sounds, and the
operator’s discretion. unit shuts down when ECM diagnostics signals the
controller. The local display shows ECM xxxxx
If the controller is set up for an NFPA 110 application, Shutdwn. The specific display (xxxxx) will be a brief
press the AUTO button before silencing the alarm horn. message or fault code that is engine manufacturer
The alarm horn cannot be silenced unless the master dependent. The engine literature provides the fault
control button is in the AUTO mode. See 2.4.7 Status code description and further information.
and Notice Digital Displays for more information.
102%- 140% of nominal 10 sec. 110% of nominal 70%- 95% of 80% of nominal at
5- 30 sec.
nominal 10 sec.
Figure 2-4 Overfrequency Specs
Figure 2-7 Undervoltage Specs
Overvoltage (Each Phase). The fault lamp illuminates
red, the alarm horn sounds, and the unit shuts down (Voltage) Regulator Communications Loss. The
when the voltage exceeds the overvoltage setting for fault lamp illuminates red, the alarm horn sounds, and
the preset time delay period. The local display shows the unit shuts down when the voltage regulator to
Volts (L1- L2, L2- L3, or L3- L1) High Shutdwn. See controller communication link is disrupted. The local
Figure 2-5 for overvoltage specifications. display shows RegCommLos Shutdwn.
When calibrating current, the metered value must be at System Ready. This status indicates that the generator
least 25% of the rated current on units smaller than set is in the AUTO mode and available to start if the start
100 kW and at least 50 amps on units rated larger than circuit is closed. The local display shows System
100 kW. The number being entered as the calibrated Ready.
value must be within 10% of the metered value.
System Timer Failed. This notice indicates that the
Measurement Units (User Defined). This selectable controller timer logic has failed to time out a designated
display is in the GenSet System Menu allowing the user function. The local display shows Timer Error Notice.
to choose between Metric and English displays. Use the
Pushbutton/Rotary Selector Dial to navigate and select Voltage Regulator Adjustment (User Defined). This
this feature. Changes to this display can be done with feature is in the Voltage Regulator Menu allowing the
the generator set running or stopped. The local display user to fine adjust the output voltage. Use the
shows Meas Units: Metric or Meas Units: English. Pushbutton/Rotary Selector Dial to navigate and select
this feature. Changes to this display must be done with
the generator set running. The local display shows
Enter volt reg? No or Yes. Select No to exit the voltage
regulator menu. Select Yes to change the local display
VR Volt Adj: xxx.x V.
6. Press the generator set master control AUTO Figure 2-8 Overview Menu
button.
5. Press the selector dial at the Overview Menu in
7. Reconnect the generator set load via the line circuit order to access the Overview submenus.
breaker or automatic transfer switch.
6. Rotate the selector dial clockwise to navigate to the
(firmware) SW Version submenu as shown in
2.4.9 Powering Up the Engine Control
Figure 2-9.
Module (ECM)
Adapted from Service Bulletin SB-724 10/12. SW Version:
3.10
The Decision-Makerr 3000 controller (with firmware
version 3.10 and higher) and the APM402 controller Figure 2-9 SW Version Submenu
have the capability to power up the engine ECM. On
generator sets with John Deere engines, the engine 7. For Decision-Makerr 3000 controllers, if the
ECM power-up feature allows service technicians to firmware version is earlier than 3.10, go to the
access fault codes and other troubleshooting data using Procedure for Powering Up the Engine ECM using
their John Deere Diagnostic tools without the need to SiteTecht. For Decision-Makerr 3000 controllers
with firmware version 3.10 or higher, or for APM402
start the generator set. Refer to Procedure for Powering
controllers, continue to Procedure for Powering Up
Up the Engine ECM on the following pages.
the Engine ECM.
If the Decision-Makerr 3000 generator set controller
has a firmware version earlier than 3.10, there are two
Figure 2-10 SW Version Display Figure 2-13 SiteTecht Software Display Screen
ECM
Powered 2.5 Menu Displays
Use the Menu Summary List section after reading and
Figure 2-11 ECM Powered Display
understanding the features of the pushbutton/rotary
2. After several seconds, the display will change to selector dial. See Section 1.2.3, Digital Display.
provide the option to power down the controller.
The Menu Summary List provides a quick reference to
See Figure 2-12.
the digital display data. Some digital display data may
not be identical to your display due to generator set
ECM powered application differences. The closed bullet items
Push to Stop represent main level data and the open bullet items are
sub-level data. The Menu Summary List indicates items
Figure 2-12 ECM Power Down Display that are user selectable. Use SiteTecht software for
changing all other programmable information.
3. If desired, press the selector dial to power down the
engine ECM. Some displays are engine dependent; refer to the
Appendix, Controller Displays from the Engine ECM.
OR
Section 2.7, Reviewing the Menu Displays, provides a
Rotate the selector dial to navigate to any of the
digital display menu overview and explains the
available menus.
navigation using the pushbutton/rotary selector dial.
Procedure for Powering Up the Engine ECM using
SiteTecht (for Decision-Makerr 3000 controllers
with Firmware Versions Before 3.10)
Connect a PC with SiteTecht software to the generator
set controller. Refer to the SiteTecht Software
Operation Manual TP-6701 as needed.
Follow the instructions shown in Figure 2-13.
* User-Defined (changeable) Menu Displays. Use SiteTecht software to change other settings including User-Defined Menu Displays.
NOTE: Some changes require activating the calibration or adjustment mode. Some displays may only appear when in the calibration or adjustment
mode. Refer to Section 2.7 Reviewing Menu Displays to activate the calibration or adjustment mode.
* User-Defined (changeable) Menu Displays. Use SiteTecht software to change other settings including User-Defined Menu Displays.
NOTE: Some changes require activating the calibration or adjustment mode. Some displays may only appear when in the calibration or adjustment
mode. Refer to Section 2.7 Reviewing Menu Displays to activate the calibration or adjustment mode.
While this manual focuses on data access through the Figure 2-15 Remote Single Connections
controller pushbutton/rotary selector dial and display,
most data entries require input using a PC for initial
setup. The PC entries typically include alpha characters 2.6.2 Modbusr Communications
such as digital input descriptions.
The controller communicates using Modbusr as a slave
connection with the Modbusr master initiating the
2.6.1 PC Communications communication. The controller seeks the system and
alternator parameters and diagnostic information then
Communicate between a PC and the generator set responds back to the Modbusr master. In addition, the
controller logic using USB communication protocol. The controller accepts information to alter controller
PC connections require optional SiteTecht software. parameters including generator set starting and
Contact your authorized distributor/dealer for stopping. See Figure 2-16. Refer to the List of Related
assistance. Materials for available Modbusr literature.
Local Single Connection Note: Only one Modbusr master can be connected to
the controller. Examples include the remote
A PC connects to the USB port of the generator set serial annunciator, Monitor III, and switchgear
controller using a mini USB connector. See Figure 2-14. applications.
GenSet Calibration X X Figure 2-19 Menu Displays for Viewing and Adjusting
Voltage Regulation X X X (DEC3000 firmware version 4.8.4 and
Digital Inputs X X higher, and APM402)
Digital Outputs X X
See Section 1, Specifications and Features, to review
Analog Inputs X X set point ranges and default settings for comparison to
Event Log X the actual setup.
Figure 2-17 Menu Displays for Viewing and Adjusting Menus displaying the # symbol represent one of the
(DEC3000 Before Firmware following data types:
Version 3.0.25)
D System-calculated data
D System-measured data
Controller Controller SiteTech
Menu Name Viewable Adjustable Adjustable D User-entered data
Overview X
Note: The examples given on the following pages
Engine Metering X represent digital displays with the Measurement
Generator Metering X X System set to English.
GenSet Information X X
Some displays are engine-dependent. Refer to the
GenSet Run Time X
Appendix, Controller Displays from the Engine ECM.
GenSet System X X X
Voltage Regulation X X X
Digital Inputs X X
Digital Outputs X X
Analog Inputs X X
Event Log X
Volt Select X X X*
* Requires initial activation using SiteTecht
Active Warnings
(if present)
The battery charger displays appear only if the
GenSet State ###### CAN-enabled 10 amp charger GM87448 has been
connected. Charger displays will show N/A if the
charger is connected and then removed.
Avg V L- L:
#.# V
2.7.3 Engine Metering
Frequency:
#.# Hz Displays engine operating data as measured by the
engine and other sensors.
Current:
#.# A Note: Some displays are engine dependent, refer to the
Appendix, Controller Displays from the Engine
Average kW ECM.
#### kW
Coolnt Temp:
Engine Dependent Fuel Pressure:
### F
(see NOTE above) - > ## PSI
Eng Runtime:
##.# h Battery:
##.# V
CHG1: ##.#V
With 10 Amp Charger ##.# A Engine Dependent Fuel Pressure:
GM87448 Only (see NOTE above) - > ## PSI
(N/A if no charger) - >
CHG2: ##.#V
##.# A
SW Version:
1.02
Display also provides access to the calibration factors When calibrating voltage, the metered value and the
for metering (volts and amps). Changing the system number being entered as the calibrated value must be
voltage or replacing the main logic control circuit board within 10% of the system operating voltage.
requires calibration adjustment. Connect a meter with a
minimum accuracy of 1% to the generator set output When calibrating current, the metered value must be at
leads to calibrate the voltage-sensing logic. least 25% of the rated current on units smaller than
100 kW and at least 50 amps on units rated larger than
To enable calibration, start the generator set and select 100 kW. The number being entered as the calibrated
the Volts L1-L2 display. Then push and hold the value must within 10% of the metered value.
pushbutton/rotary selector dial until the Calibration
Enabled popup appears. Calibration of each display is To disable calibration, Rotate the pushbutton/rotary
now available. The display will show the following selector dial until the <- Return popup appears.
Total Power:
#W GenSet S/N:
##
Rated Power:
#% Cntrllr S/N:
##
Volts L1- N:
#.# A
Eng Loaded:
#.# h
Volts L2- N:
#.# A
Eng Starts:
#
Volts L3- N:
#.# A
TotalEnergy:
#.# kWh
Current L1:
#.# A
2.7.7 GenSet System
Current L2: Display shows the generator set system data including
#.# A voltage, frequency, phase connection, etc. Use the
values entered in this menu to help determine shutdown
Current L3:
values and time delays.
#.# A
The programming user defines the data shown in the
GenSet System menu. It is NOT data measured by the
Frequency: controller and associated sensing devices. The
#.# Hz
programming user defines these values for purposes of
calibrating the control.
Reset
Calibration Some alternators are designed to operate at limited
voltage, frequency, or phase connections and as a result
some settings may have limited parameters.
Reset
Calib? No
Display for Measurement System is user selectable as
OR English or Metric.
Reset
Calib? Yes Contrast display is user adjustable to help improve
digital display visibility in dimly lit rooms or in direct
sunlight.
Meas System
User Selectable - > English or Metric
Contrast
User Selectable - > #####
AlrmSilence:
Always or Auto Only
User Selectable
(see manual speed Engine RPM
adjustment above) - > #####
GenSet Calibration
GenSet - - > Enter calib? GenSet - - >
Calibration No Calibration
OR
Enter calib?
User Selectable - > Yes
Volts L1- N:
#.# V
Volts L2- N:
#.# V
OR
Current L1: Reset Reset all
#.# A calibration calib? Yes
Displays the voltage regulator adjustment value. All If the unit is running and Yes is entered when the Enter
other voltage regulator adjustments are changed using volt reg? is shown, the display will show the value. The
SiteTecht software. user can change the value at this time.
The voltage regulator value is reviewable at all times. In
order to review the value when the generator set is NOT
Voltage Regulator
Voltage - - > Enter volt Voltage - - >
Regulator reg? No Regulator
OR
Enter volt
User Selectable - > reg? Yes
VR Volt Adj:
xxx.x
<- - Exit
voltage reg
Decision-Makerr 3000 Controllers with Firmware pushbutton/rotary selector dial until the Editing Enabled
Version 3.0.25 or Higher, or APM402 Controllers. popup appears. Editing of the voltage adjustment is now
available.
Displays the voltage regulator adjustment value. All
other voltage regulator adjustments are changed using The user can change the individual value or can select
SiteTecht software. Reset VR?- Yes to reset to the default value. The Reset
VR Settings display will only show if editing is enabled.
The voltage regulator value is reviewable at all times
and provides the ability to fine adjust voltage. Changing To disable calibration, Rotate the pushbutton/rotary
the system voltage or replacing the circuit board selector dial until the <- Return popup appears.
typically requires a voltage adjustment. Momentarily press the pushbutton/rotary selector dial.
Stop the generator set if not already done.
To enable calibration, start the generator set and select
the VR Volt Adj display. Then push and hold the
Voltage Regulator
Voltage - - > VR Volt Adj: <- Select this Display to
Regulator xxx.x Enable or Disable Editing
OR
Reset VR?
Yes
All digital input selection and setup adjustments are done DIn A2
using SiteTecht software. The following terms and Value: True or False
descriptions are part of the setup procedure.
DIn A3
Note: DIn A3 digital input is factory reserved for #####
Enclosure Temperature: High Shutdown on
select Telecom units.
DIn A3
D Enabled. This menu indicates whether or not the Value: True or False
DOut B5
#####
DOut B5
Value: True or False
2.7.12 Analog Inputs There is an optional 2 input/5 output (I/O) module board
available that can provide two additional analog (or
Displays the selected programming user-defined digital) inputs.
analog notice, warning, and shutdown inputs. These
inputs provide a multitude of choices for configuring The displays for analog inputs appear as shown below
customized auxiliary inputs. See Figure 2-20 for a list of and have an acceptable operating range (0- 5 VDC).
analog input choices. For descriptions of the inputs The analog input selection typically requires entering
listed refer to the following: four values—low warning, high warning, low shutdown,
D 2.4.5 System Fault Warning Lamp with Digital
and high shutdown.
Displays D AIn A1 (analog input A1) standard
D 2.4.6 System Fault Shutdown Lamp with Digital (reserved and not user programmable)
Displays D AIn A2 (analog input A2) standard
D 2.4.7 Status and Notice Digital Displays (Identified as A1 on SiteTecht software)
AIn B2
#####
Battery Charger 2 - - > Output Amps
SFWR Ver
Explosion.
Can cause severe injury or death. Reduced Out
Relays in the battery charger
cause arcs or sparks.
Locate the battery in a well-ventilated Temp Comp
area. Isolate the battery charger from
explosive fumes.
events.
277/480 V 3 Ph
(Scroll through up to 1000
max. stored events)
120/240 V 3 Ph
2.7.15 Volt Select
This menu is not available on Decision-Makerr 3000
Controllers with firmware versions before 2.8.22.
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.
WARNING
Hazardous voltage. Moving parts.
Will cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Accidental starting.
Can cause severe injury or death. Servicing the generator set when it is operating. Exposed
moving parts will cause severe injury or death. Keep
Disconnect the battery cables before hands, feet, hair, clothing, and test leads away from the belts
working on the generator set. and pulleys when the generator set is running. Replace
Remove the negative (- ) lead first guards, screens, and covers before operating the generator
when disconnecting the battery. set.
Reconnect the negative (- ) lead last
when reconnecting the battery.
3.1 Alternator Service
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the When operating the generator set under dusty or dirty
generator set or equipment connected to the set, disable the conditions, use dry compressed air to blow dust out of
generator set as follows: (1) Move the generator set master the alternator while the generator set is running. Direct
switch to the OFF position. (2) Disconnect the power to the the stream of air through openings in the generator set
battery charger. (3) Remove the battery cables, negative (- ) end bracket.
lead first. Reconnect the negative (- ) lead last when
reconnecting the battery. Follow these precautions to prevent
starting of the generator set by an automatic transfer switch,
remote start/stop switch, or engine start command from a
3.2 Engine Service
remote computer. Perform engine service at the intervals specified in the
engine manufacturer’s service literature. Contact an
WARNING authorized service distributor/dealer to obtain service
literature.
This section describes natural gas and liquified The fuel mixer controls the ratio of fuel to air under
petroleum gas (LPG) fuel systems that are not covered varying load and speed conditions. Because the fuel
in the engine operation manual or engine service mixer receives fuel in a gaseous state, it does not have
manual. to vaporize the fuel.
WARNING 1 2 3 4 5
2. Pressure gauge
The fuel system. Explosive fuel vapors can cause severe 3. Solenoid valve (UL- listed models require 2 solenoid valves)
injury or death. Vaporized fuels are highly explosive. Use 4. Secondary regulator
extreme care when handling and storing fuels. Store fuels in a 5. Fuel mixer
well-ventilated area away from spark-producing equipment
and out of the reach of children. Never add fuel to the tank Figure 3-2 Fuel Regulator and Valve, Typical
while the engine is running because spilled fuel may ignite on
contact with hot parts or from sparks. Do not smoke or permit 3.6.2 LPG Liquid Withdrawal Fuel
flames or sparks to occur near sources of spilled fuel or fuel System Concept
vapors. Keep the fuel lines and connections tight and in good
condition. Do not replace flexible fuel lines with rigid lines. Use With the LPG liquid withdrawal fuel system, pressurized
flexible sections to avoid fuel line breakage caused by liquid LPG fuel passes from the tank to a vaporizer. The
vibration. Do not operate the generator set in the presence of vaporizer converts the liquid fuel to gas before sending it
fuel leaks, fuel accumulation, or sparks. Repair fuel systems to the fuel mixer. The system also includes a fuel valve
before resuming generator set operation.
that shuts off the fuel flow when the engine stops.
Explosive fuel vapors can cause severe injury or death. Contact an authorized service distributor/dealer for
Take additional precautions when using the following fuels: availability.
Auto Changeover Natural Gas/LPG Vapor Auto Changeover Natural Gas/LPG Vapor
Operation Operation
D Connect 78/78a and 70G/70R to LP Fuel Valve D Connect the white fuel connector (P8 to J8).
assembly. D Connect the black fuel connectors together in
D Connect 77/77a and 70H/70T to NG fuel valve series (P7 to J7, P7A to J7A).
assembly. D Connect 49 to 49B (QCON10).
D Connect 49a to LFP2 normally closed terminal. D Connect 49B to LFP3, Normally Open Terminal.
D Connect N17 to LFP2 common terminal. D Connect LP1 to LFP3, Common Terminal.
Controller
LPG indicator light
Reset switch
UL required fuel
shutoff valve
Low fuel
pressure
switches
To ECM and
controller To ECM and
controller
LPG Liquid
To ECM and
controller
To ECM and
controller
ADV-7600B-F
Figure 3-7 Typical models with PSI, GM, Doosan Engines, Gaseous Fuel Connections Wiring Diagram
TP-6694 7/19 Section 3 Scheduled Maintenance 71
Natural Gas LPG Vapor
To ECM and
To ECM and controller
controller
To ECM and
controller
ADV-9007D-B
Figure 3-8 KG40- KG60 (KG6208), Gaseous Fuel Connections Wiring Diagram
72 Section 3 Scheduled Maintenance TP-6694 7/19
Natural Gas LPG Vapor
FV3
(UL VALVE)
FV3
(UL VALVE)
To ECM and
To ECM and controller
controller
NOT
USED
FV3
(UL VALVE)
To ECM and
controller
ADV-9052D-C
Figure 3-9 KG80- KG125/KG80R- KG125R (KG6208TA), Gaseous Fuel Connections Wiring Diagram
TP-6694 7/19 Section 3 Scheduled Maintenance 73
3.7 Crankcase Ventilation (CCV) 3.9 Cooling System
Heater Kit GM78171-KP1 The cooling system maintenance information applies to
radiator-cooled models which have a radiator with a
Applies to 125/150 kW, 8.1 L GM- and 8.8 L PSI- pressure cap and coolant recovery tank.
powered generator set models. Consult your local
generator set distributor/dealer for additional WARNING
information.
273113
4. If the inside of the radiator has mineral deposits or 7. Fill the coolant recovery tank to the low mark.
the used coolant contains dirt or grease, refer to
Section 3.9.4, Procedure to Flush and Clean the 8. Operate generator set until the thermostat opens
Cooling System. If the cooling system does not when the upper cooling system hose warms.
have mineral deposits, go to Section 3.9.5,
9. Stop the engine and allow it to cool.
Procedure to Refill the Cooling System.
10. Check and repair any coolant leaks.
3.9.4 Procedure to Flush and Clean
11. Remove the pressure cap.
Cooling System
12. Add coolant to bring the coolant level to just below
Use the instructions in the engine operation manual
the overflow tube opening of the filler neck.
when available to flush and clean the cooling system.
Otherwise, use the following procedure and the cooling 13. Replace the pressure cap.
system cleaner manufacturer’s instructions.
14. Maintain the coolant level in the coolant recovery
1. Flush the cooling system with clean water. tank between the high and low marks.
2. If the inside of the radiator still has mineral Air pockets often form in the engine water jacket
deposits, use a radiator cleaner to remove the when the coolant system is refilled. Check the
remaining deposits following the manufacturer’s coolant level in the coolant recovery tank after each
instructions. generator set operation and add coolant as
necessary until the coolant level stabilizes. Then
3. Drain, clean, and flush the coolant recovery tank.
check the coolant at the interval specified in the
service schedule.
3.9.5 Procedure to Refill Cooling
System 15. Reenergize the block heater, if equipped.
1 2 3 4
2
1-046
1. Filler caps
2. Electrolyte level
KW-272000-B
1. To positive (+) terminal on starter solenoid.
Figure 3-15 Battery Electrolyte Level Inspection
2. To ground (- ) terminal on or near starter motor.
3. To positive (+) terminal on second starter solenoid.
4. To ground (- ) terminal on or near second starter motor.
3.10.3 Specific Gravity Check
Figure 3-14 24-Volt Engine Electrical System Dual
Starter Motors Typical Battery Use a battery hydrometer to check the specific gravity of
Connections the electrolyte in each battery cell of batteries with filler
caps. Holding the hydrometer vertically, read the
number on the glass bulb at the top of the electrolyte
3.10.1 Clean Battery level or the number adjacent to the pointer. If the
Clean the battery and cables and tighten the battery hydrometer used does not have a correction table,
terminals according to the service schedule consult Figure 3-17. Determine the specific gravity and
recommendations. Clean the battery by wiping it with a electrolyte temperature of the battery cells. Locate the
damp cloth. Keep the electrical connections dry and temperature in Figure 3-17 and correct the specific
tight. gravity by the amount shown. The battery is fully
charged if the specific gravity is 1.260 at an electrolyte
If corrosion exists, disconnect the cables from the temperature of 26.7_C (80_F). Maintain the specific
battery and remove the corrosion with a wire brush. gravities between cells within 0.01 of each other.
Clean the battery and cables with a solution of baking Charge the battery if the specific gravity is below 1.215
soda and water. Do not allow the cleaning solution to at an electrolyte temperature of 26.7_C (80_F).
enter battery cells. Flush the battery and cables with
clean water and wipe the battery with a dry cloth. Note: Some battery testers have four or five beads in a
test tube. Draw electrolyte into the tube as with
After reconnecting the battery cables, coat the terminals the battery hydrometer described in this section
with petroleum jelly, silicon grease, or other or use the manufacturer’s instructions. Use
nonconductive grease. Figure 3-16 to interpret typical test results.
3.11.1 Lubricating System 3. Run the generator set until the engine stops.
Prepare the engine lubricating system for storage as 4. Stop the generator set.
follows:
2. Stop the generator set. If you have access to a fogging agent or SAE 10 oil
prepare the pistons and cylinders for storage as follows:
3. With the engine still warm, drain the oil from the
crankcase. 1. Start the generator set.
4. Remove and replace the oil filter. 2. While the engine is running, spray a fogging agent
or SAE 10 engine oil into the air intake for about two
5. Refill the crankcase with oil suited to the climate. minutes until the engine stops.
6. Run the generator set for two minutes to distribute 3. Stop the generator set.
the clean oil.
If a fogging agent is not available perform the following:
7. Stop the generator set.
1. Remove the spark plugs.
8. Check the oil level and adjust, if needed.
2. Pour 15 cc (0.5 oz.) of engine oil into each spark
plug hole.
3.11.2 Cooling System
Ignition System Damage. Refer to the engine
Prepare the cooling system for storage as follows: operation manual for ignition system precautions
before cranking the engine while the spark plug
1. Check the coolant freeze protection using a wires are disconnected.
coolant tester.
3. Crank the engine two or three revolutions to
2. Add or replace coolant as necessary to ensure lubricate the cylinders.
adequate freezing protection. Use the guidelines
included in the engine operation manual. 4. Reinstall the spark plugs and torque them to
specifications.
3. Run the generator set for 30 minutes to redistribute
added coolant.
3.11.5 Exterior
3.11.3 Fuel System 1. Clean the exterior surface of the generator set.
Prepare the fuel system for storage as follows: 2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
Diesel-Fueled Engines
3. To prevent impurities from entering the air intake
1. Fill the fuel tank with #2 diesel fuel. and to allow moisture to escape from the engine,
secure a cloth over the air intake.
2. Condition the fuel system with compatible
additives to control microbial growth. 4. Mask electrical connections.
3. Change the fuel filter/separator and bleed the fuel 5. Spread a light film of oil over unpainted metallic
system. See the engine owner’s manual. surfaces to inhibit rust and corrosion.
Perform battery storage after all other storage 5. Connect the battery to a battery charger or charge
procedures. it monthly with a trickle battery charger. Refer to the
battery charger manufacturer’s recommendations.
1. Confirm that the generator set is stopped.
Maintain a full charge to extend battery life.
2. Disconnect the battery(ies), negative (- ) lead first.
This section contains generator set troubleshooting, Maintain a record of repairs and adjustments performed
diagnostic, and repair information. on the equipment. If the procedures in this manual do
not explain how to correct the problem, contact an
Use the following charts to diagnose and correct authorized distributor/dealer. Use the record to help
common problems. First check for simple causes such describe the problem and repairs or adjustments made
as a dead engine starting battery or an open circuit to the equipment.
breaker. The charts include a list of common problems,
possible causes of the problem, recommended
corrective actions, and references to detailed
information or repair procedures.
TP-6694 7/19
Section or
Publication
Cranks but
does not start
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Probable Causes Recommended Actions Reference*
Controller
x x Controller circuit board(s) inoperative Replace the controller. Gen. S/M
x x Controller circuit board(s) wiring fault Check the wiring. W/D
x TP-6694 Controller
7/19 fault Troubleshoot the controller.[ Gen. S/M
x x x Controller fuse blown Check for continuity across fuse. If fuse is blown, Section 1, W/D
troubleshoot the controller wiring and replace circuit board.[
x Controller master control buttons Replace the controller master control button circuit board. —
inoperative
x Controller master control button in the Press the controller master control RUN or AUTO button. Section 2
OFF/RESET mode
x Engine start circuit open Press the controller master control RUN button to test the Section 2, W/D,
generator set. Troubleshoot the auto start circuit and time Gen. I/M, S/M
delays. ATS O/M, S/M
x x Voltage regulation inoperative Replace the junction box sensing fuses. If the fuse blows W/D, Gen. S/M
again, troubleshoot the controller.
x Controller firmware error Review the controller display troubleshooting chart. Section 4.2
Alternator
x AC output circuit breaker open Reset the breaker and check for AC voltage at the generator —
set side of the circuit breaker.
x Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO position. ATS O/M
position
x Transfer switch fails to transfer load Move the ATS test switch to the AUTO position. ATS O/M, S/M
Troubleshoot the transfer circuit and time delays.
x Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
field open
x Main field (rotor) inoperative Test and/or replace the rotor.[ Gen. S/M
(open or grounded)
x Stator inoperative (open or grounded) Test and/or replace the stator.[ Gen. S/M
x Vibration excessive Tighten loose components.[ —
x Voltage regulator settings incorrect Adjust the voltage regulator. Section 1.3.3,
SiteTech O/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
Section 4 Troubleshooting
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
83
84
Trouble Symptoms
Section or
Publication
Cranks but
does not start
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Probable Causes Recommended Actions Reference*
Electrical System (DC Circuits)
x x Battery connections loose, corroded, Verify that the battery connections are correct, clean, and Section 3
Section 4 Troubleshooting
or incorrect tight.
x x Battery weak or dead Recharge or replace the battery. The spec sheet provides Section 3, S/S
recommended battery CCA rating.
x x Starter/starter solenoid inoperative Replace the starter or starter solenoid. Eng. S/M
x x Engine harness connector(s) not Disconnect the engine harness connector(s) then reconnect W/D
locked tight it to the controller.
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
Engine
x x x x Air cleaner clogged Clean or replace the filter element. Eng. O/M
x x x x x Compression weak Check the compression.[ Eng. S/M
x x x x x Engine overload Reduce the electrical load. See the generator set spec S/S
sheet for wattage specifications.
x Exhaust system leak Inspect the exhaust system. Replace the inoperative I/M
exhaust system components.[
x Exhaust system not securely installed Inspect the exhaust system. Tighten the loose exhaust I/M
system components.[
x x x x Governor inoperative Adjust the governor.[ Eng. S/M
x x Valve clearance incorrect Adjust the valves.[ Eng. S/M
x Vibration excessive Tighten all loose hardware. —
x x x Ignition system inoperative (gas Check the ignition system Eng. O/M, Eng.
models only) (spark plugs, spark plug wires, etc.). S/M
x x x x x Engine ECM and/or sensors Troubleshoot the engine ECM and/or sensors. Eng. O/M, Eng.
S/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
TP-6694 7/19
Trouble Symptoms
TP-6694 7/19
Section or
Publication
Cranks but
does not start
Starts hard
Stops suddenly
Lacks power
Overheats
Low oil pressure
High fuel
consumption
Excessive or
abnormal noise
Displays error
message/locks up
Probable Causes Recommended Actions Reference*
Cooling System
x x Air openings clogged Clean the air openings. —
x Coolant level low Restore the coolant to normal operating level. Section 3
x Cooling water pump inoperative Tighten or replace the belt. Replace the water pump. Eng. O/M or S/M
x High temperature shutdown Allow the engine to cool down. Then troubleshoot the Sec. 3, Eng. O/M
TP-6694 7/19 cooling system.
x Low coolant level shutdown, if Restore the coolant to normal operating level. Section 3
equipped
x Thermostat inoperative Replace the thermostat. Eng. S/M
Fuel System
x x x Air in fuel system (diesel only) Bleed the diesel fuel system. Eng. O/M
x x Ether canister empty or system Replace or repair the ether starting system. Eng. O/M
inoperative, if equipped (diesel only)
x x Fuel tank empty or fuel valve shut off Add fuel and move the fuel valve to the ON position. —
x x x Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ Eng. S/M
(diesel only)
x x x Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel injector.[ Eng. S/M
(diesel only)
x x x x Fuel filter restriction Clean or replace the fuel filter. Eng. O/M
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
x x Fuel pressure insufficient (gas only) Check the fuel supply and valves.[ S/S, Gen. O/M
x x x x Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
(diesel only)
Lube System
x x x x Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the Eng. O/M
ambient temperature operating climate.
x x x Oil level low Restore the oil level. Inspect the generator set for oil leaks. Eng. O/M
x Low oil pressure shutdown Check the oil level. Eng. O/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
Section 4 Troubleshooting
85
86
4.2 Controller Display and Voltage Regulation Troubleshooting Chart
Section or
Publication
Trouble Symptoms Probable Causes Recommended Actions Reference*
Controller Display and Voltage Regulator
Display is black No/low battery charge Recharge/replace battery Section 3, Battery
Display shows single segment Low battery voltage Recharge battery Section 3, Battery
Display shows an error message Controller firmware or pushbutton/ Review the Error Message Section Section 2.7.1
Section 4 Troubleshooting
rotary selector dial entry error
Display locks up No/low battery charge Recharge/replace battery Section 3, Battery
Output voltage ramps Defective exciter winding Troubleshoot alternator components [ Generator Service
Manual
Output voltage unstable Voltage regulation calibration incorrect Readjust voltage regulation [ Section 1.3.3,
SiteTech O/M
Unable to change voltage and current calibrations Calibration not enabled Enable calibration in Generator Metering section Section 1.2.3
Digital Display,
Section 2.6.4
Unable to find volt select menu Volt select not enabled Enable volt select in SiteTech SiteTech O/M
* Sec./Section—numbered section of this manual; ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; I/M—Installation Manual; O/M—Operation Manual;
S/M—Service Manual; S/S—Spec Sheet; W/D—Wiring Diagram Manual
[ Have an authorized service distributor/dealer perform this service.
TP-6694 7/19
Notes
TP-6694 7/19 87
Section 5 Voltage Reconnection
Note: If the Volt Select menu does not appear, the 9. Reconnect the battery, negative lead last.
controller voltage selection feature was not
activated using SiteTecht software. 10. Press the generator set master control RUN button
to start the generator set. Check the digital display
Volt Select: --> 120/240 V 1 Ph for correct voltages using 2.7.4 Generator
###/### V # Ph
Metering.
120/208 V 3 Ph
11. Press the generator set master control
OFF/RESET button to stop the generator set after
completing the voltage adjustments.
139/240 V 3 Ph
4. Turn the selector dial clockwise or 3. Use Figure 5-2, Figure 5-3, Figure 5-4, or
counterclockwise until the desired voltage Figure 5-5 to determine the generator set voltage
selection option appears. configuration. Note the original voltage and
reconnect as needed. Route leads through current
5. Press the selector dial. The second line on the transformers (CTs) and connect them according to
display will stop flashing and the new voltage will the diagram for the desired phase and voltage.
appear.
Note: Position current transformers CT1, CT2,
6. Rotate the generator set voltage selector switch (if and CT3 with the dot or HI side CT marking
equipped) to match the desired voltage shown on toward the generator set.
the controller display. Skip steps 7- 9 and go to
step 10. 4. Reconnect the battery, negative lead last.
If the generator set does not have a voltage 5. Use SiteTecht software to update the information.
selection switch, continue to step 7
6. Refer to 2.7.8 for generator set calibration at the
7. Disconnect the generator set engine starting controller.
battery, negative (- ) lead first. Disconnect power to
the battery charger (if equipped). 7. Press the generator set master control RUN button
to start the generator set. Check the digital display
8. Use Figure 5-2, Figure 5-3, or Figure 5-5 to for correct voltages using 2.7.4 Generator
determine the generator set voltage configuration. Metering.
Note the original voltage and reconnect as needed.
Route leads through current transformers (CTs) 8. Press the generator set master control
and connect them according to the diagram for the OFF/RESET button to stop the generator set after
desired phase and voltage. completing the voltage adjustments.
6.1 Accessories and Connections 6.1.1 Battery Charger Kit with Alarm
Option
Several accessories help finalize installation, add
convenience to operation and service, and establish The battery charger with alarm option provides battery
state and local code compliance. charging to the engine starting battery(ies) and
connects to the controller for fault detection. Battery
Accessories vary with each generator set model and chargers for 12- or 24-volt models are available as a
controller. Select factory-installed and/or shipped- generator set accessory. See Figure 6-2 and Figure 6-3
loose accessories. See Figure 6-1 for a list of available and the battery charger manual for battery charger fault
kits. Obtain the most current accessory information connections.
from your local authorized service distributor/dealer.
Note: On charger GM87448, the Battery Charger Fault
This section illustrates several accessories available at is communicated through CAN communication
print time of this publication. Accessory kits generally and the connection on TB1 is not used.
include installation instructions. See wiring diagrams
manual for electrical connections not shown in this
section. See the installation instructions and drawings
supplied with kit for information on kit mounting location.
CONNECT TO TB1
The instructions provided with the accessory kit
supersede these instructions where there are CHARGER
differences. In general, run AC and DC wiring in MALFUNCTION
separate conduit. Use shielded cable for all analog
inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.
LV HV CM BATTERY CHARGER
See Section 6.2, Accessory Connections, for terminal ALARM TERMINAL
identification. STRIP
Kit Description
GM16088A-A/TP- 6694
Battery Charger (with alarms)
Common Fault/Failure (32A) Connections
Figure 6-2 Battery Charger Connections
Fifteen-Relay Dry Contact Board with NO and NC Contacts
Gas Fuel Valve
Input/Output Module Board
Key Switch
Low Fuel (Level) Switch
Low Fuel (Pressure) Switch
Manual Speed Adjust
Prime Power Switch
Remote Emergency Stop
Remote Reset Feature
Remote Serial Annunciator
Run Relay
Shunt-Trip Line Circuit Breaker
GM67191-B
Figure 6-1 Optional Accessories
GM67191-B
GM67191-B
1 2
GM75749K-3
GM78246E-2
5
1. TB5 output connections C and NO for the common fault relay K15 (other TB5 terminals are factory connections only)
2. P35 4-position jack connects to controller (factory-connected)
3. TB6 8-position terminal block, digital inputs/digital returns (D11, D12, D13, and D14)
4. P36 8-position pin, analog inputs (see Figure 6-8 for connections)
5. TB7 through TB13, connections for relays K1 through K14 with Normally Open (NO) and Normally Closed (NC) contacts
Note: A maximum of three inputs may be connected to 8. 12/24-Volt DC Devices. Attach the user-supplied
a single relay driver output. Inputs include dry 12/24-volt DC accessories to the starting battery
contacts, remote annunciator, common failure positive (+) connection at the starter solenoid and
alarm, A/V alarm, and shunt trip line circuit to the battery negative (- ) connection at the engine
breaker. ground. Otherwise, use a separate 12/24-volt DC
supply. Do not use terminals 42A and 2 on the
Note: Only one 15-relay dry contact kit can be controller connection kit terminal strip to supply the
connected to the controller. voltage to the relay contacts. Supply separate
leads connected directly to the battery for the
Electrical Connection Procedure supply voltage. The circuit must include fuse or
circuit breaker protection.
1. Press the generator set master control
OFF/RESET button. 9. 120-Volt AC Devices. Connect the user- supplied
accessories to a separate 120-volt AC power
2. Disconnect the power to the battery charger, if supply. The circuit must include fuse or circuit
equipped. breaker protection.
3. Disconnect the generator set engine starting 10. Connect the user-supplied device per the
battery(ies), negative (- ) lead first. Instructions and/or schematic supplied with the
device to a power source and to the dry contact
4. Remove the top panel of the controller connection terminals. Cut the user-supplied leads to length,
box. See Figure 6-6 for location of the relay board. strip lead ends, crimp on spade terminals (not
supplied), and connect the leads to the relay
5. See Figure 6-8 for connections of analog inputs. contact screw terminals. Route the wiring for the
relay dry contacts away from the generator set
6. Select the normally open (NO) contacts of the
output leads.
relay, Form A dry contact, depending upon the
application. Use a two-wire harness for the NO 11. Repeat Step 6 for the remaining dry contact relays.
connections.
Verify the dry contact relay function by using the Typical for PSI, GM, and Doosan Engines
following procedure when troubleshooting.
ADV-9052D-C
See Figure 6-12 for circuit board components and Optional I/O Module
SiteTech I/O Name Board Connection
electrical connections to the controller.
Analog Input B1 P28 Analog Input VN1/VP1
See Figure 6-13 for connections of analog inputs. Refer Analog Input B2 P28 Analog Input VN2/VP2
to Figure 6-34 for accessory connections. Digital Output B1 P29 (K1)
Digital Output B2 P30 (K2)
See Section 6.2, Accessory Connections, for terminal
identification. Digital Output B3 P31 (K3)
Digital Output B4 P32 (K4)
Use a computer with Kohler SiteTecht software to Digital Output B5 P32 (K5)
assign functions to digital outputs. Each input and
Figure 6-11 I/O Module Input/Output Assignments
output corresponds to a controller connection. Verify
that the settings are appropriate for the connected
sensor, switch, or equipment.
2
1
4
GM78246E-2
1. P29/P30/P31 K1/K2/K3 2-amp relay outputs 4. P25 RJ45 In (to controller P23)
2. P32 K4/K5 10-amp relay outputs 5. P27 CAN terminator
3. P28 In1/In2 analog inputs
GM16088A-A/TP-6694
Figure 6-14 Optional Key Switch
Figure 6-15 Low Fuel Switch (Level or Pressure)
GM67191-B
1
PRIME POWER
SWITCH
2
GM20652-/
TP-6694
GM16088A-A-/TP- 6694
Figure 6-20 Emergency Stop Kit Figure 6-23 Switch Rating and Wiring
Recommendations
GM67191-B
273705 GM67191-B
Figure 6-28 Run Relay Kit Figure 6-30 Shunt-Trip Wiring (Standard)
GM67191-B
GM67191-B
GM64345-C
7 6 5
1. (4) push-on terminal connectors
2. TB2 4-position terminal block
3. TB3 6-position terminal block
4. P2 6-pin connector
5. P1 24-pin connector
6. TB1 6-position terminal block
7. P22 3-pin connector
8. P23 8-pin connector (RJ45)
9. P21 6-pin connector
Figure 6-32 Controller Circuit Board Connections
Use the table below to record programmer-defined SiteTecht setup software is required for programming the
settings during the generator set controller setup and controller. Contact your local distributor/dealer for assistance.
calibration. The controller default settings and ranges Note: Inhibit time delay is the time delay period after
provide guidelines. The table contains all faults with crank disconnect.
ranges and time delays including items that do not have
adjustments. Some notices give the programmer a Note: The engine ECM may limit the crank cycle even if
choice to make them active Not adjustable the controller is set to a longer time period.
programmer-defined settings result when the controller
logic does not allow changes or the values are engine
limited.
Programmer-Defined Settings
GenSet
Write Mode Time Default
Access Always Delay Time Programmer-
Controller Display Display Running Range Default Range Delay Defined
Description Message SiteTech Stopped Setting Selection (sec.) (sec.) Settings
Engine Functions
Critically high fuel level Fuel Level Critically
0- 100% 95% 0- 10 5
(diesel-powered models only) * High
ECM communications loss ECM Comm Err
Fixed 10 Not adjustable
Shutdwn
ECM diagnostics (multiple
ECM xxxxxx Warning Not adjustable
inputs) [
ECM diagnostics (multiple
ECM xxxxxx Shutdwn Not adjustable
inputs) [
ECM faults (address conflict) ECM Addr Err
Not adjustable
Shutdwn
ECM faults (model mismatch) ECM Mismatch
0- 255 0
Shutdwn
Engine over speed Eng Speed High
S A 105- 120% 115%
Shutdwn
Engine RPM 60 Hz: 60 Hz:
(manual speed adjust) 1751- 1849 1800
Engine RPM Display DS A
Version 3.10.3 or higher 50Hz: 50 Hz:
1451- 1549 1500
Engine start aid active Starting Aid Notice
Engine under speed Eng Speed Low
S A 75- 95% 85%
Shutdwn
Fuel tank leak * Fuel Leak Warning Not adjustable
Fuel tank leak * Fuel Leak Shutdwn Not adjustable
High battery voltage Battery High Warning S A 110- 135% 125% Fixed 10 Not adjustable
High coolant temperature 0- 10 5
Coolnt Temp High
(0- 30 (0
Warning
inhibit) inhibit)
High coolant temperature 0- 10 5
Coolnt Temp High
(0- 30 (0
Shutdwn
inhibit) inhibit)
High fuel level (diesel-powered Fuel Level High
0- 100% 90% 0- 10 5
models only) * Warning
Loss of fuel Loss of fuel Not adjustable
Low battery voltage Battery Low Warning S A 80- 105% 100% Fixed 90 Not adjustable
Low coolant level * Coolant Lvl Low
Fixed 5 Not adjustable
Shutdwn
Low coolant temperature 0- 10 5
Coolant Temp Low 16_C
Fixed (0- 30 (0
Warning (60_F)
inhibit) inhibit)
Low cranking voltage Lo Crank Vlt Warning Fixed 60% Fixed 6 Not adjustable
Low engine oil level * Oil Level Low Warning Not adjustable
The following definitions and adjustment/setting mathematically by Ohm’s law, which states that power is
specifications are intended for users planning to adjust equal to the voltage squared divided by the impedance.
the voltage regulator beyond the default settings in As the voltage is reduced, the power delivered by the
order to customize the alternator for a specific alternator decreases by a squared relationship. Since it
application. is the power in the alternator that translates into engine
torque, the engine load is also reduced.
This information is not intended to be a comprehensive
explanation of all the terms mentioned. There are By changing various parameters of this compensation
numerous documents available that define these terms technique, the controlling system can be tailored to
more completely than described herein. Any user match the performance capabilities of most engine and
planning to change the generator set controller alternator combinations. The point at which the
adjustment settings or to apply the generator set to unloading begins to act or how much unloading occurs
these types of applications should understand these can be adjusted to impact maximum voltage droop,
terms. maximum speed droop, or time to recover. Some
applications may not need unloading and, in these
This appendix contains references to other sections of cases, set the unloading parameter to disable the
this manual. Please refer to these sections for further function. These parameters are further described
information and explanation. below. An example is provided to help clarify the
relationship between these parameters.
Paralleling generator sets can be a complicated and
dangerous exercise. Application programming must be
performed by appropriately skilled and suitably-trained Underfrequency Unload Slope
personnel.
Underfrequency unload slope is the term used to
describe the amount that the voltage is reduced,
Definitions per-cycle-per-second or per-hertz (Hz), when in an
underfrequency condition. The slope or schedule is
sometimes called the volts-per-hertz slope. When the
Underfrequency Unloading electrical frequency drops below the cut-in point (see
Underfrequency unloading is a function used in the below), the excitation control system temporarily
alternator excitation control system to improve the reduces the regulated voltage to reduce the subsequent
torque on the engine. The amount that the control
overall generator set system (engine and alternator)
response. In particular, underfrequency unloading system reduces voltage is defined as the product or
relates to large-block load applications. When applied multiplication of the slope and the amount of frequency
to engine-driven alternators, large-block loads cause a or speed below the cut-in point. For every Hz below the
subsequent transient torque load on the engine. This cut-in point, the control system reduces the line-to-line
voltage by an amount equal to the slope.
torque load can reduce the engine’s speed below the
normal operating point. Typically, the engine speed Because each engine responds differently to the
controller or governor will compensate for this by various loads encountered, the slope may be adjusted
commanding an increase in fuel. If, however, the fuel to improve the system response. If, when large loads
system is inadequate to recover from a relatively large are applied to the generator set, the engine speed drops
load, the speed may never recover. In these instances,
below the acceptable limit (as determined by the
other measures must be taken. This is where the particular loads applied), the slope may need to be
underfrequency unloading occurs. increased. Increasing the slope will cause the voltage to
When the excitation control system detects a drop in the droop more during load applications, consequently
speed or electrical frequency below some reducing the load torque on the engine and allowing the
speed to increase. If, however, the voltage drops below
predetermined point, the control system enters an
unloading condition. This can be described as moving an acceptable lower limit (as determined by the
to a lower voltage regulation point. By reducing the particular loads connected to the generator set), a lower
output voltage of the alternator, the load on the slope may work better. The underfrequency unloading
generator set is reduced. This can be shown function may be disabled by setting the slope to zero.
The controller has built-in thermal protection for the The current and time limits are defined by actual test
alternator. This feature functions similarly to a thermal data and are maintained in the personality parameter
circuit breaker. When the output current exceeds the file. Although the equation for detecting a fault is
nominal rating for a short period of time the condition proprietary, some of the important limits are shown
causes the fault shutdown. The amount of time at which below for informational purposes.
current is over the rating is inversely related to the
amount of current above the nominal rating. In other Rated Current Time Delay
words, the higher the current, the shorter the acceptable 200% 40 seconds
time.
300% 10 seconds
425% 5 seconds
950% 1 second
The controller display showing engine information is Some engines do not have an ECM and in some cases
dependent upon the engine manufacturer and the the ECM information is not available as a controller
corresponding Engine Control Module (ECM). The display. In these situations, critical information like oil
following list indicates which engine displays are pressure and coolant temperature are displayed by the
available by the engine manufacturer. This information controller using independent engine sensors not used
is subject to change by the engine manufacturer. by the ECM.