Main
WARNING
California Proposition 65
Product Identification Information
Generator Set Identification Numbers
Engine Identification
Table of Contents
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Table of Contents, continued
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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
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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
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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
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1.3.2 Voltage Regulator and Calibration Specifications
1.3.3 Voltage Regulator Adjustments
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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
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2.3.6 System Shutdown Lamp
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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
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2.8 Local Programming Mode On
2.8.1 Menu 1Generator Monitoring
Menu 1Generator Monitoring (Three-Phase Connections)
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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
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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
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Menu 9Input Setup
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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.
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Returns the user to the define common faults heading.
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Menu 10 Displays with Key Entries Deactivating the SCRDO
2.8.11 Menu 11VoltageRegulator
Menu 11VoltageRegulator
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2.8.12 Menu 12Calibration
Menu 12Calibration
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Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs)
2.8.13 Menu 13Communications
Menu 13Communications
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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
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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
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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
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4.2 Controller Display and Voltage Regulation Troubleshooting Chart
Section or Publication
Trouble Symptoms Probable Causes RecommendedActions
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Section 5 Generator Set Reconnection
5.1 Introduction
5.2 Voltage Reconnection Procedure
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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
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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
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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
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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
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Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
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Appendix B User-Defined Settings
User-Defined Settings
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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
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TP-6200 10/12i
