Kohler 20-3250 kW manual

Industrial Generator Sets

Models:

20-3250 kW

Controllers:

Decision-Makerr550

Software (Code) Version 2.10 or higher

TP-6200 10/12i

Operation

Contents

Main WARNING California Proposition 65 Product Identification Information Generator Set Identification Numbers Engine Identification Table of Contents Page Table of Contents, continued Page Safety Precautions and Instructions DANGER WARNING CAUTION Accidental Starting Engine Backfire/Flash Fire Exhaust System Fuel System Hazardous Noise CAUTION Hazardous Voltage/ Moving Parts DANGER Heavy Equipment Hot Parts Notice NOTICE Page Introduction Abbreviations List of Related Materials Service Assistance Section 1 Specifications and Features 1.1 Introduction 1.2 Controller Features 1.2.1 Annunciator Lamps Page 1.2.2 Digital Display and Keypad Keypad Functions Alternator Output Displays (Menu 1) Engine Displays (Menu 2) Operational Record Displays (Menus 4 and 5) Time Delay Displays (Menu 8) 1.2.3 Switches and Controls 1.2.4 Controller Circuit Boards 1.2.5 Fuses 1.2.6 Terminal Strips and Connectors 1.2.7 Circuit Board Interconnections for Calibration Procedure 1.2.8 Communication Ports 1.3 Controller Logic Specifications 1.3.1 Status Event and Fault Specifications Page Page Page Page Page Page 1.3.2 Voltage Regulator and Calibration Specifications 1.3.3 Voltage Regulator Adjustments Page Page Section 2 Operation 2.1 Prestart Checklist 2.2 Exercising Generator Set 2.3 Controller Operation 2.3.1 Starting Auto Starting Idle (Speed) Mode Warmup and Cooldown Function Run Time Feature Prime Power Switch 2.3.2 Stopping (User Stopping and Fault Shutdown) Normal Stopping Emergency Stopping Battle Switch/Fault Shutdown Override Switch 2.3.3 Emergency Stop Switch Resetting Page Page 2.3.6 System Shutdown Lamp Page Page 2.3.7 Controller Resetting (Following System Shutdown or Warning) 2.4 Menu List Summary Figure 2-8 User Inputs (X) and Factory-Reserved Inputs (as shown) Menu List Summary Menu 3 Analog Monitoring Menu 1 Generator Monitoring Menu 2 Engine Monitoring Menu 2 Engine Monitoring, cont. Menu 9 Input Setup Menu 9 Input Setup, cont. Menu 7 Generator System Menu 8 Time Delays Output Setup Menu 11 Voltage Regulator Menu 12 Calibration Menu 20 Factory Setup Menu Menu 15 Paralleling Relays (PR) Menu 13 Communications Menu 14 Programming Mode Menu 55 Load Factor 2.5 Reviewing Digital Display 2.5.1 Keypad Operation 2.5.2 Auto-Scroll Function 2.5.3 Request and Error Messages Request and Status Messages Error Messages 2.6 Monitoring and Programming Setup 2.6.1 PC Communications Local Single Connection Local Area Network (LAN) Remote Single Connection Remote Area Network 2.6.2 Modbus Communications 2.7 Reviewing Menu Displays 2.7.1 Menu 1Generator Monitoring Menu 1 Overview (Three-Phase Connections) Menu 1Generator Monitoring, continued Menu 1 Overview (Single-Phase Connections) 2.7.2 Menu 2Engine Monitoring ECM S/N # # Menu 2 Overview # Menu 2 Overview ECU HOURS # (MDEC/ADEC-Equipped Engines only) 2.7.3 Menu 3Analog Monitoring Menu 3 Overview (ECM Engines) Menu 3 Overview (Non-ECM Engines) Menu 3 Overview (Waukesha Engines) 2.7.4 Menu 4Operational Records Menu 4 Overview 2.7.5 Menu 5Event History Menu 5 Overview Menu 6 Overview 2.7.6 Menu 6Time and Date 2.7.7 Menu 7Generator System Menu 7 Overview *DDC/MTU engine with MDEC/ADEC only 2.7.8 Menu 8Time Delays Menu 8 Overview 2.7.9 Menu 9Input Setup Menu 9 Overview 2.7.10 Menu 10Output Setup Common Faults Relay Driver Outputs (RDOs) Menu 10 Overview Menu 10 Overview, continued 2.7.11 Menu 11VoltageRegulator Menu 11 Overview 2.7.12 Menu 12Calibration Menu 12 Overview 2.7.13 Menu 13Communications Modbusris a registered trademark of Schneider Electric. Menu 13 Overview 2.7.14 Menu 14Programming Mode Menu 14 Overview 2.7.15 Menu 15Protective Relays (PR) Menu 15 Overview 2.7.16 Menu 20Factory Setup (Version 2.10) Menu 20 Overview 2.7.17 Menu 20Factory Setup (Version 2.21) Menu 20 Overview Page 2.8 Local Programming Mode On 2.8.1 Menu 1Generator Monitoring Menu 1Generator Monitoring (Three-Phase Connections) Page Menu 1Generator Monitoring (Three-Phase Connections), continued Menu 1Generator Monitoring (Single-Phase Connections) Menu 1Generator Monitoring (Single-Phase Connections), continued 2.8.2 Menu 2Engine Monitoring Menu 2Engine Monitoring (DDEC/JDEC/EMS2/EDC3-Equipped Engines only) (DDEC/JDEC/EMS2/EDC3-Equipped Engines only, continued) (MDEC-Equipped Engines only) 2.8.3 Menu 3Analog Monitoring Menu 3Analog Monitoring (ECM Engines) Menu 3Analog Monitoring (Non-ECM Engines) Menu 3Analog Monitoring (Waukesha Engines) 2.8.4 Menu 4Operational Records Menu 4Operational Records Menu 4 Displays with Key Entries Menu 4Operational Records, continued Menu 4 Displays with Key Entries 2.8.5 Menu 5Event History Menu 5Event History Menu 5 Displays with Key Entries 2.8.6 Menu 6Time and Date Menu 6Time and Date Menu 6 Displays with Key Entries 2.8.7 Menu 7Generator System Menu 7Generator System Page Page Page Page Page 2.8.8 Menu 8Time Delays Menu 8Time Delays Menu 8 Displays with Key Entries Menu 8Time Delays, continued Menu 8 Displays with Key Entries 2.8.9 Menu 9Input Setup Page Menu 9Input Setup Page Page Page 2.8.10 Menu 10Output Setup Common Faults Relay Driver Outputs (RDOs) Software Controlled RDOs (SCRDOs) NFPA 110Faults Menu 10Output Setup Input a menu number. OR Displays the common faults heading. Displays the menu number and name. Page Page Page Returns the user to the define common faults heading. Page Page Page Menu 10 Displays with Key Entries Deactivating the SCRDO 2.8.11 Menu 11VoltageRegulator Menu 11VoltageRegulator Page Page Page Page Page 2.8.12 Menu 12Calibration Menu 12Calibration Page Page Page Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs) 2.8.13 Menu 13Communications Menu 13Communications Page Page Page 2.8.14 Menu 14Programming Mode Menu 14Programming Mode, continued Menu 14 Displays with Key Entries 2.8.15 Menu 15Protective Relays (PR) Menu 15Protective Relays Page Page Page 2.8.16 Menu 20Factory Setup Menu 20Factory Setup Menu 20 Displays with Key Entries Menu 20Factory Setup, continued Menu 20 Displays with Key Entries Section 3 Scheduled Maintenance 3.1 Alternator Service 3.2 Engine Service 3.3 Service Schedule Service Schedule, continued 3.4 Alternator Bearing Service 3.4.1 20--300 kW Models 3.4.2 300--2250 kW Models with Single-Bearing Alternator 3.4.3 1250 kW and Larger Models with Two-Bearing Alternator 3.5 Diesel Fuel Systems 3.5.2 Subbase Fuel Day Tank Electronic Control Module (ECM) ECM General Function ECM Function Indicator LEDs Level Sensor ECM Mode 3.6 Gas Fuel Systems (REZG_ and REZX_/RZX_ models) 3.6.1 Gas Fuel System Concept (Single Fuel) 3.6.2 LPG Liquid Withdrawal Fuel System Concept 3.6.3 Natural Gas and LPG Conversion 3.6.4 Fuel System Changeover Kits (Dual Fuel) Automatic Changeover Page 3.6.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1 (125/150REZG models) 3.7 Cooling System 3.7.1 Coolant Level Check 3.7.2 Cooling System Component Inspection 3.7.3 Procedure to Drain Cooling System 3.7.4 Procedure to Flush and Clean Cooling System 3.7.5 Procedure to Refill Cooling System 3.8 Radiator Fan Bolt Retorque Required Tools Procedure 3.9 Radiator Expansion Joint LooseningInitial Setup Only 3.10 Radiator Fan Bearing Lubrication 3.11 Battery 3.11.1 Clean Battery 3.11.2 Electrolyte Level Inspection 3.11.3 Specific Gravity Check 3.11.4 Charge Battery 3.12 Detroit Diesel Engine Control Systems 3.12.1 Features 3.12.2 DDEC Engine Diagnostics Code Types 3.13 Engine Control Systems Engine Control Features 3.14 Storage Procedure 3.14.1 Lubricating System 3.14.2 Cooling System 3.14.3 Fuel System 3.14.4 Internal Engine Components (Gas-Fueled Engines) 3.14.5 Exterior 3.14.6 Battery Section 4 General Troubleshooting 4.1 General Troubleshooting Chart Probable Causes Recommended Actions Page Page 4.2 Controller Display and Voltage Regulation Troubleshooting Chart Section or Publication Trouble Symptoms Probable Causes RecommendedActions Page Section 5 Generator Set Reconnection 5.1 Introduction 5.2 Voltage Reconnection Procedure Page Page Page Page Section 6 Accessories 6.1 Accessories and Connections 6.1.1 Audiovisual Alarm Kit 6.1.2 Common Failure Relay Kit 6.1.3 Controller (Customer) Connection Kit 6.1.4 Float/Equalize Battery Charger Kit with Alarm Option Page 6.1.5 Ground Fault Annunciation 6.1.6 Idle (Speed) Mode Feature 6.1.7 Low Fuel (Level/Pressure) Switch 6.1.8 Prime Power Switch Kit 6.1.9 Remote Emergency Stop Kit 6.1.10 Remote Reset Feature 6.1.11 Remote Serial Annunciator Figure 6-20 System Monitoring LEDs and Functions Page Page Page Page Page 6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) 6.1.13 Run Relay Kit 6.1.14 Shunt-Trip Line Circuit Breaker 6.1.1 5 Single-Relay Dry Contact Kit 6.1.16 Ten-Relay Dry Contact Kit Page 6.1.17 Twenty-Relay Dry Contact Kit 6.1.18 Wireless Monitor 6.2 Accessory Connections Figure 6-38 Controller Terminal Strip Identification TB6 TerminalStripRDOs 1 --7 TB7 TerminalStripRDOs 8 --17 TB8 TerminalStripRDOs 18 --23 TB9 TerminalStripRDOs 24 --31 Page Page Page Page Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. Page Appendix B User-Defined Settings User-Defined Settings Page Page Page Page Page Page Appendix C Voltage Regulator Definitions and Adjustments Definitions Underfrequency Unloading Underfrequency Unload Slope Frequency Setpoint or Cut-In Point Three-Phase Sensing Reactive Droop VAR Control Power Factor Control Adjustment and Setting Specifications Voltage Adjust Underfrequency Unload Enable Frequency Setpoint Underfrequency Unload Slope Voltage Droop VAR Control Enable KVAR Adjust Generating/Absorbing PF Adjust Appendix D Alternator Protection Appendix E Inputs and System Events by Application Page Page Page Page Page Page TP-6200 10/12i