Manuals / Kohler / Lawn and Garden / Portable Generator

Kohler 20-3250 kW manual 160 TP-6200 10/12

Models: 20-3250 kW

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Troubleshooting Specs Error codes Alarm Fault Time Delay Displays Menu Wireless Monitor Maintenance Resetting Procedure Ddec Engine Diagnostics

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Notes

160	TP-6200 10/12

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Kohler 20-3250 kW manual 160 TP-6200 10/12

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Contents

Models TP-6200 10/12i Version Number Upgrades/Updates Product Identification InformationController Identification Firmware/Software Version Numbers Table of Contents Table of Contents TP-6200 10/12 Table of Contents TP-6200 10/12 Safety Precautions and Instructions BatteryImportant Safety Instructions Accidental Starting Exhaust System Engine Backfire/Flash FireFuel System Hazardous Noise Hazardous Voltage/ Moving Parts Heavy Equipment Hot Parts Safety Precautions and Instructions TP-6200 10/12 Abbreviations IntroductionList of Related Materials Service Assistance Specifications and Features Introduction Controller Features 550 Controller with Keyswitch Option Annunciator Lamps Requires optional input sensors Keypad Functions Digital Display and KeypadAlternator Output Displays Menu Engine Displays Menu Time Delay Displays MenuOperational Record Displays Menus 4 Switches and Controls See -6 and -8 for switches and controls Controller Circuit Boards Terminal Strips and ConnectorsFuses Circuit Board Interconnections for Calibration Procedure Status Event and Fault Specifications Controller Logic SpecificationsCommunication Ports Factory-Defined Settings Adjust SwitchFault D01 Battery Idle Mode AlarmDeton Knock Battery TemperatureRelay Ground LOW Battery Switch ErrorSwitch to Switch Open Power Sensor FaultDelay ENG Current Voltage Regulator and Calibration Specifications Voltage Regulator Adjustments TP-6200 10/12 Specifications and Features Specifications and Features TP-6200 10/12 Prestart Checklist OperationExercising Generator Set Controller Operation Idle Speed Mode Warmup and Cooldown Function Run Time FeaturePrime Power Switch Auto Starting Stopping User Stopping and Fault Shutdown Emergency Stop Switch ResettingStatus Lamps System Warning Lamp Operation TP-6200 10/12 TP-6200 10/12 Operation System Shutdown Lamp TP-6200 10/12 Operation Overfrequency Specs Controller Resetting Following System Shutdown or Warning Menu List Summary DDC/MTU MDEC/ADEC Menu Output Setup AVG L-L Paralleling Relays PR Reviewing Digital Display Keypad Operation Request and Error Messages Error MessagesAuto-Scroll Function Request and Status Messages Monitoring and Programming Setup PC Communications Local Single ConnectionLocal Area Network LAN LAN? Remote Single Connection Modbus CommunicationsRemote Area Network 17 Menu Displays for Viewing and Adjusting Reviewing Menu Displays Menu 1 Overview Three-Phase Connections Menu 1-Generator Monitoring Menu 1 Overview Single-Phase Connections Menu 2 Overview Menu 2-Engine MonitoringDDEC/JDEC/EMS2/EDC3- Equipped Engines only MDEC/ADEC-Equipped Engines only Menu 3-Analog Monitoring Menu 3 Overview ECM EnginesMenu 3 Overview Non-ECM Engines Menu 3 Overview Waukesha Engines Menu 4-Operational Records Menu 4 Overview Menu 5-Event History Menu 6-Time and DateMenu 7-Generator System Menu 5 Overview Menu 7 Overview Menu 8-Time Delays Menu 8 Overview Menu 9-Input Setup Delay Time Menu 9 Overview Menu 10-Output Setup Common FaultsRelay Driver Outputs RDOs Menu 10 Overview Defined Common Fault Menu 11-Voltage Regulator Menu 11 Overview Menu 12-Calibration Menu 12 Overview Menu 13-Communications Menu 13 Overview Menu 14-Programming Mode Menu 14 Overview Menu 15 Overview Menu 20-Factory Setup Version Menu 20 Overview Serial no Confirm Temp Sensor TP-6200 10/12 Operation Local Programming Mode On 18 Menu Number and Description Menu 1-Generator Monitoring Three-Phase Connections Menu 1 Displays with Key Entries 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-Analog Monitoring ECM Engines Menu 3 Displays with Key Entries 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 Software Controlled RDOs SCRDOs Nfpa 110 Faults Defined Common 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 Menu 15-Protective Relays PRMenu 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-Factory Setup Menu 20 Displays with Key Entries Menu 20-Factory Setup Alternator Service Scheduled MaintenanceEngine Service Service Schedule Transfer switch main contacts Alternator Bearing Service Diesel Fuel Systems Subbase Fuel Day Tank Electronic Control Module ECM Subbase Inner Fuel Tank Alarm Resetting ProcedureGas Fuel Systems Rezg and REZX/RZX models Gas Fuel System Concept Single Fuel Natural Gas and LPG Conversion Fuel System Changeover Kits Dual FuelAutomatic Changeover QCON--7 10 Gas Fuel Connections Wiring Diagram Cooling System Coolant Level Check Procedure to Drain Cooling System Procedure to Flush and Clean Cooling SystemProcedure to Refill Cooling System Cooling System Component Inspection Radiator Fan Bolt Retorque ProcedureRequired Tools Radiator Expansion Joint Loosening-Initial Setup Only Radiator Fan Bearing Lubrication Clean Battery 19 Battery Electrolyte Level Inspection Electrolyte Level Inspection Charge Battery Specific Gravity Check Features Ddec Engine DiagnosticsDetroit Diesel Engine Control Systems Code Types Storage Procedure Engine Control FeaturesEngine Control Systems Lubricating System Battery Fuel SystemInternal Engine Components Gas-Fueled Engines Exterior General Troubleshooting ATS O/M General Troubleshooting ChartATS O/M, S/M 6200 10/12 Doesnot crank Exerciserun time And/orevent Section or Publication 160 TP-6200 10/12 Generator Set Reconnection Introduction 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 Accessories Accessories and ConnectionsAudiovisual Alarm Kit Controller Connection KIT Mounted in Junction BOX Common Failure Relay Kit Float/Equalize Battery Charger Kit with Alarm OptionController Customer Connection Kit Alarm Terminal Strip Battery ChargerCharger Malfunction Ground Fault Annunciation Power Supply Idle Speed Mode Feature Idle Speed Mode Switch Low Fuel Level/Pressure Switch Prime Power Switch Kit Remote Reset Feature Remote Emergency Stop Kit Remote Serial Annunciator RSA 20 System Monitoring LEDs and Functions LED 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 Run Relay Kit Remote Speed Adjustment Potentiometer Kit Non-ECM ModelsShunt-Trip Line Circuit Breaker Single-Relay Dry Contact Kit Ten-Relay Dry Contact Kit 32 Ten-Relay Dry Contact Kit Twenty-Relay Dry Contact Kit 34 Twenty-Relay Dry Contact Kits Wireless Monitor 36 Wireless Monitor Accessory Connections TOP of Controller Back Panel 38 Controller Terminal Strip Identification RDO24 GNDRDO25 RDO26 41 Accessory Connections GM78247A-D 42 Accessory Connections GM78247C-D 43 Accessory Connections GM78247D-D Accessories TP-6200 10/12 Appendix a Abbreviations LAN LCBLCD LOP Appendix B User-Defined Settings 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% Appendix C Voltage Regulator Definitions and Adjustments DefinitionsUnderfrequency Unloading Underfrequency Unload Slope Three-Phase Sensing Frequency Setpoint or Cut-In Point Reactive Droop Power Factor Control VAR Control Adjustment and Setting Specifications Voltage AdjustUnderfrequency Unload Enable Reactive Droop Enable VAR Control Enable Kvar AdjustPF Adjust Voltage Droop 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

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