Section or Publication | Kohler 20-3250 kW guide

TP-6200 10/12

Section 4 Troubleshooting

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 keypad entry error	Review the Request and Error Message Section	Section 2.5.3

Display shows an EEPROM WRITE	EEPROM fault caused by component failure, lightening strike, or	Reinitialize the problem data block [	Contact an Authorized
ERROR message	voltage spike		Distributor/Dealer

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 [	Menu 11, Voltage Regulator
	TP-6200 10/12
Speed adjust does not function	Analog input A06 is supported with Doosan, GM, and Volvo	Check calibration values	Menu 12, Calibration
	engines only

Voltage adjust does not function for	Analog input A07 description does not match Analog Volt Adjust	Change description to Analog Volt Adjust using Monitor III	Monitor Software Manual,
paralleling applications		software or enable analog voltage adjust in Menu 11	Menu 9, Input Setup

* 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.

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Image 159

Kohler 20-3250 kW manual Section or Publication

Contents

TP-6200 10/12i Models Firmware/Software Version Numbers Version Number Upgrades/UpdatesProduct Identification Information Controller Identification Table of Contents Table of Contents TP-6200 10/12 Table of Contents TP-6200 10/12 Accidental Starting Safety Precautions and InstructionsBattery Important Safety Instructions Engine Backfire/Flash Fire Exhaust SystemFuel System Hazardous Voltage/ Moving Parts Hazardous Noise Heavy Equipment Hot Parts Safety Precautions and Instructions TP-6200 10/12 Introduction AbbreviationsList of Related Materials Service Assistance Introduction Controller Features Specifications and Features Annunciator Lamps 550 Controller with Keyswitch Option Requires optional input sensors Digital Display and Keypad Keypad FunctionsAlternator Output Displays Menu Time Delay Displays Menu Engine Displays MenuOperational Record Displays Menus 4 See -6 and -8 for switches and controls Switches and Controls Terminal Strips and Connectors Controller Circuit BoardsFuses Circuit Board Interconnections for Calibration Procedure Controller Logic Specifications Status Event and Fault SpecificationsCommunication Ports Factory-Defined Settings D01 Battery AdjustSwitch Fault Knock Idle ModeAlarm Deton Ground BatteryTemperature Relay Switch Open LOW BatterySwitch Error Switch to Current PowerSensor Fault Delay ENG Voltage Regulator Adjustments Voltage Regulator and Calibration Specifications TP-6200 10/12 Specifications and Features Specifications and Features TP-6200 10/12 Controller Operation Prestart ChecklistOperation Exercising Generator Set Auto Starting Idle Speed Mode Warmup and Cooldown FunctionRun Time Feature Prime Power Switch System Warning Lamp Stopping User Stopping and Fault ShutdownEmergency Stop Switch Resetting Status Lamps Operation TP-6200 10/12 TP-6200 10/12 Operation System Shutdown Lamp TP-6200 10/12 Operation Overfrequency Specs Menu List Summary Controller Resetting Following System Shutdown or Warning MDEC/ADEC DDC/MTU Menu Output Setup AVG L-L Paralleling Relays PR Keypad Operation Reviewing Digital Display Request and Status Messages Request and Error MessagesError Messages Auto-Scroll Function Monitoring and Programming Setup LAN? PC CommunicationsLocal Single Connection Local Area Network LAN Modbus Communications Remote Single ConnectionRemote Area Network Reviewing Menu Displays 17 Menu Displays for Viewing and Adjusting Menu 1-Generator Monitoring Menu 1 Overview Three-Phase Connections Menu 1 Overview Single-Phase Connections Menu 2-Engine Monitoring Menu 2 OverviewDDEC/JDEC/EMS2/EDC3- Equipped Engines only MDEC/ADEC-Equipped Engines only Menu 3 Overview Waukesha Engines Menu 3-Analog MonitoringMenu 3 Overview ECM Engines Menu 3 Overview Non-ECM Engines Menu 4 Overview Menu 4-Operational Records Menu 5 Overview Menu 5-Event HistoryMenu 6-Time and Date Menu 7-Generator System Menu 7 Overview Menu 8 Overview Menu 8-Time Delays Menu 9-Input Setup Menu 9 Overview Delay Time Menu 10 Overview Menu 10-Output SetupCommon Faults Relay Driver Outputs RDOs Defined Common Fault Menu 11 Overview Menu 11-Voltage Regulator Menu 12 Overview Menu 12-Calibration Menu 13 Overview Menu 13-Communications Menu 14 Overview Menu 14-Programming Mode Menu 15 Overview Menu 20 Overview Menu 20-Factory Setup Version Serial no Confirm Temp Sensor TP-6200 10/12 Operation 18 Menu Number and Description Local Programming Mode On Menu 1 Displays with Key Entries Menu 1-Generator Monitoring Three-Phase Connections Summary Power KW Total KW Menu 1-Generator Monitoring Single-Phase Connections LEADING/LAGGING Menu 2 Displays with Key Entries DDEC/JDEC/EMS2/EDC3-Equipped Engines only Returns the user to the miscellaneous engine subheading MDEC-Equipped Engines only Menu 3 Displays with Key Entries Menu 3-Analog Monitoring ECM Engines Menu 3-Analog Monitoring Non-ECM Engines Menu 3-Analog Monitoring Waukesha Engines Menu 4 Displays with Key Entries Engine START? YES→ Countdown Menu 5 Displays with Key Entries Menu 6 Displays with Key Entries Menu 7 Displays with Key Entries Displays the corrected system frequency. See Note a Overvoltage # VAC Time Delay YES Battery Voltage YES/NO Metric Units YES SET NFPA-110 Defaults Menu Generator System Menu 8 Displays with Key Entries Time Delay Minsec Overvoltage Menu 9-Input Setup Time after Crank Disconnect Menu 9 Displays with Key Entries Digital Input Inhibit Time Analog Input Shutdown Enabled YES Inhibit Time Analog Input HI Warn Value Defined Common Faults Software Controlled RDOs SCRDOs Nfpa 110 Faults Menu 10 Displays with Key Entries Displays the digital inputs heading LO WARNING→ Common Fault LO SHUTDOWN→ Common Fault Analog Inputs Define Common Faults Relay DRV OUT Press the Enter key Confirms the entry LO WARNING→ HI SHUTDOWN→ Relay DRV OUT Menu 10 Displays with Key Entries Deactivating the Scrdo Menu 11 Displays with Key Entries Under Freq Unload Enabled YES Frequency Reactive Droop Enabled YES Reactive Droop Enabled VAR Control PF Control Enabled YES Average PF PF ADJ Menu 11-Voltage Regulator Menu 12 Displays with Key Entries Scale AC Analog Inputs GEN L3-L0 Calib REF GEN L3-L1 Calib REF GEN L3 Amps Calib REF Menu 12 Displays with Key Entries Scale Aux. Analog Inputs Menu 13 Displays with Key Entries Primary Port User Defined YES Address Baud Rate User Defined YES Primary Port User Defined YES Address Baud Rate Baud Rates Menu 14-Programming Mode Menu 14 Displays with Key Entries Menu 15-Protective Relays PR Menu 15-Protective RelaysMenu 15 Displays with Key Entries Menu 15-Protective Relays SD Over Power #KW Time Delay ?SEC #SEC PR Loss of Field Time Delay ?SEC #SEC SD Over Current VR Menu 20 Displays with Key Entries Menu 20-Factory Setup Menu 20-Factory Setup Scheduled Maintenance Alternator ServiceEngine Service Service Schedule Transfer switch main contacts Diesel Fuel Systems Alternator Bearing Service Subbase Fuel Day Tank Electronic Control Module ECM Gas Fuel System Concept Single Fuel Subbase Inner Fuel Tank AlarmResetting Procedure Gas Fuel Systems Rezg and REZX/RZX models QCON--7 Natural Gas and LPG ConversionFuel System Changeover Kits Dual Fuel Automatic Changeover 10 Gas Fuel Connections Wiring Diagram Coolant Level Check Cooling System Cooling System Component Inspection Procedure to Drain Cooling SystemProcedure to Flush and Clean Cooling System Procedure to Refill Cooling System Procedure Radiator Fan Bolt RetorqueRequired Tools Radiator Fan Bearing Lubrication Radiator Expansion Joint Loosening-Initial Setup Only Clean Battery Electrolyte Level Inspection 19 Battery Electrolyte Level Inspection Specific Gravity Check Charge Battery Code Types FeaturesDdec Engine Diagnostics Detroit Diesel Engine Control Systems Lubricating System Storage ProcedureEngine Control Features Engine Control Systems Exterior BatteryFuel System Internal Engine Components Gas-Fueled Engines General Troubleshooting General Troubleshooting Chart ATS O/MATS O/M, S/M 6200 10/12 Doesnot crank Exerciserun time And/orevent Section or Publication 160 TP-6200 10/12 Introduction Generator Set Reconnection Voltage Reconnection Procedure TP-6200 10/12 Generator Set Reconnection Generator Set Reconnection TP-6200 10/12 TP-6200 10/12 Generator Set Reconnection Generator Set Reconnection TP-6200 10/12 Controller Connection KIT Mounted in Junction BOX AccessoriesAccessories and Connections Audiovisual Alarm Kit Float/Equalize Battery Charger Kit with Alarm Option Common Failure Relay KitController Customer Connection Kit Battery Charger Alarm Terminal StripCharger Malfunction Power Supply Ground Fault Annunciation Idle Speed Mode Switch Idle Speed Mode Feature Prime Power Switch Kit Low Fuel Level/Pressure Switch Remote Emergency Stop Kit Remote Reset Feature RSA Remote Serial Annunciator LED 20 System Monitoring LEDs and Functions 21 RSA Wiring Connections GM62554A-G 22 RSA Wiring Connections GM62554B-G 23 RSA Wiring Connections GM62554C-G 24 RSA Wiring Connections GM62554D-G 25 RSA Wiring Connections GM62554E-G Remote Speed Adjustment Potentiometer Kit Non-ECM Models Run Relay KitShunt-Trip Line Circuit Breaker Ten-Relay Dry Contact Kit Single-Relay Dry Contact Kit 32 Ten-Relay Dry Contact Kit 34 Twenty-Relay Dry Contact Kits Twenty-Relay Dry Contact Kit 36 Wireless Monitor Wireless Monitor TOP of Controller Back Panel Accessory Connections 38 Controller Terminal Strip Identification RDO26 RDO24GND RDO25 41 Accessory Connections GM78247A-D 42 Accessory Connections GM78247C-D 43 Accessory Connections GM78247D-D Accessories TP-6200 10/12 Appendix a Abbreviations LOP LANLCB LCD User-Defined Settings Appendix B User-Defined Settings Analog Digital Aux. Input D05 Fixed Sec Settings Engine J1939 can Not adjustable Engine Shutdown Switch to OFF Current VR RDO-27 70%--95% Underfrequency Unload Slope Appendix C Voltage Regulator Definitions and AdjustmentsDefinitions Underfrequency Unloading Frequency Setpoint or Cut-In Point Three-Phase Sensing Reactive Droop VAR Control Power Factor Control Reactive Droop Enable Adjustment and Setting SpecificationsVoltage Adjust Underfrequency Unload Enable Voltage Droop VAR Control EnableKvar Adjust PF Adjust Appendix D Alternator Protection Appendix E Inputs and System Events by Application Page Page Appendix TP-6200 10/12 TP-6200 10/12 213 214 TP-6200 10/12 Page TP-6200 10/12i