Operation

Industrial Generator Sets

Models:

20-3250 kW
Controllers:
Decision-Makerr 550

Software (Code) Version 2.10 or higher

TP-6200 10/12i
 California Proposition 65

WARNING
Engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth
defects, or other reproductive harm.

Product Identification Information

Product identification numbers determine service parts. Controller Identification

Record the product identification numbers in the spaces
Record the controller description from the generator set
below immediately after unpacking the products so that operation manual, spec sheet, or sales invoice. Record
the numbers are readily available for future reference.
the Controller Serial Number from the controller
Record field-installed kit numbers after installing the kits.
nameplate.
Generator Set Identification Numbers Controller Description Decision-Makerr 550
Record the product identification numbers from the Controller Serial Number
generator set nameplate(s).
Model Designation Firmware/Software Version Numbers
Specification Number Record the version and reference numbers as shipped
Serial Number from the manufacturer. Determine the Application
Program Version Number as shown in Menu 20.
Accessory Number Accessory Description
Determine the Personality Profile Reference Number
from the disk supplied with the literature packet.
Application Program Version Number
Personality Profile Reference Number
User Parameter File Reference Number

Version Number Upgrades/Updates

Record the version number upgrade/updates when
installed.
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Version No./Date Installed
Engine Identification
Version No./Date Installed
Record the product identification information from the
engine nameplate.
Software Options
Manufacturer
Record the software options.
Model Designation
Number and Description
Serial Number
Number and Description
Number and Description
 Table of Contents

Product Identification Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.1 Annunciator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 Digital Display and Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3 Switches and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.4 Controller Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.5 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.6 Terminal Strips and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.7 Circuit Board Interconnections for Calibration Procedure . . . . . . . . . . . . 22
1.2.8 Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3 Controller Logic Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.1 Status Event and Fault Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.3.2 Voltage Regulator and Calibration Specifications . . . . . . . . . . . . . . . . . . 30
1.3.3 Voltage Regulator Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.1 Prestart Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.2 Exercising Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3 Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3.1 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
2.3.2 Stopping (User Stopping and Fault Shutdown) . . . . . . . . . . . . . . . . . . . . 35
2.3.3 Emergency Stop Switch Resetting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.4 Status Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.5 System Warning Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.3.6 System Shutdown Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.3.7 Controller Resetting (Following System Shutdown or Warning) . . . . . . 41
2.4 Menu List Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5 Reviewing Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5.1 Keypad Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.5.2 Auto-Scroll Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.5.3 Request and Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.6 Monitoring and Programming Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.6.1 PC Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.6.2 Modbus Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.7 Reviewing Menu Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
2.7.1 Menu 1—Generator Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.7.2 Menu 2—Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.7.3 Menu 3—Analog Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.7.4 Menu 4—Operational Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.7.5 Menu 5—Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.7.6 Menu 6—Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.7.7 Menu 7—Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.7.8 Menu 8—Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.7.9 Menu 9—Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.7.10 Menu 10—Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.7.11 Menu 11—Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.7.12 Menu 12—Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

TP-6200 10/12 Table of Contents 3

Table of Contents, continued

2.7.13 Menu 13—Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.7.14 Menu 14—Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.7.15 Menu 15—Protective Relays (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.7.16 Menu 20—Factory Setup (Version 2.10) . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.7.17 Menu 20—Factory Setup (Version 2.21) . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.8 Local Programming Mode On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.8.1 Menu 1—Generator Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.8.2 Menu 2—Engine Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.8.3 Menu 3—Analog Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.8.4 Menu 4—Operational Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.8.5 Menu 5—Event History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.8.6 Menu 6—Time and Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.8.7 Menu 7—Generator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.8.8 Menu 8—Time Delays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.8.9 Menu 9—Input Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.8.10 Menu 10—Output Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.8.11 Menu 11—Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.8.12 Menu 12—Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
2.8.13 Menu 13—Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
2.8.14 Menu 14—Programming Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
2.8.15 Menu 15—Protective Relays (PR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
2.8.16 Menu 20—Factory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Section 3 Scheduled Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.1 Alternator Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.2 Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3 Service Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
3.4 Alternator Bearing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.4.1 20--300 kW Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.4.2 300--2250 kW Models with Single-Bearing Alternator . . . . . . . . . . . . . . . 140
3.4.3 1250 kW and Larger Models with Two-Bearing Alternator . . . . . . . . . . . 140
3.5 Diesel Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.5.1 Bleeding Air from Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
3.5.2 Subbase Fuel Day Tank Electronic Control Module (ECM) . . . . . . . . . . 141
3.5.3 Subbase Inner Fuel Tank Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.6 Gas Fuel Systems (REZG_ and REZX_/RZX_ models) . . . . . . . . . . . . . . . . . . . . . 142
3.6.1 Gas Fuel System Concept (Single Fuel) . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.6.2 LPG Liquid Withdrawal Fuel System Concept . . . . . . . . . . . . . . . . . . . . . 142
3.6.3 Natural Gas and LPG Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
3.6.4 Fuel System Changeover Kits (Dual Fuel) . . . . . . . . . . . . . . . . . . . . . . . . 143
3.6.5 Crankcase Ventilation (CCV) Heater Kit GM78171-KP1
(125/150REZG models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.7 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.7.1 Coolant Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.7.2 Cooling System Component Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.7.3 Procedure to Drain Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.7.4 Procedure to Flush and Clean Cooling System . . . . . . . . . . . . . . . . . . . . 146
3.7.5 Procedure to Refill Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3.8 Radiator Fan Bolt Retorque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.9 Radiator Expansion Joint Loosening—Initial Setup Only . . . . . . . . . . . . . . . . . . . . 148
3.10 Radiator Fan Bearing Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.11 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.11.1 Clean Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.11.2 Electrolyte Level Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.11.3 Specific Gravity Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
3.11.4 Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

4 Table of Contents TP-6200 10/12

 Table of Contents, continued

3.12 Detroit Diesel Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.12.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.12.2 DDEC Engine Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.13 Engine Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.14 Storage Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.14.1 Lubricating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.14.2 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
3.14.3 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.14.4 Internal Engine Components (Gas-Fueled Engines) . . . . . . . . . . . . . . . . 154
3.14.5 Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.14.6 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Section 4 General Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
4.1 General Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.2 Controller Display and Voltage Regulation Troubleshooting Chart . . . . . . . . . . . . 159
Section 5 Generator Set Reconnection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
5.2 Voltage Reconnection Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Section 6 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.1 Accessories and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.1.1 Audiovisual Alarm Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
6.1.2 Common Failure Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
6.1.3 Controller (Customer) Connection Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
6.1.4 Float/Equalize Battery Charger Kit with Alarm Option . . . . . . . . . . . . . . . 168
6.1.5 Ground Fault Annunciation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
6.1.6 Idle (Speed) Mode Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
6.1.7 Low Fuel (Level/Pressure) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
6.1.8 Prime Power Switch Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
6.1.9 Remote Emergency Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.1.10 Remote Reset Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
6.1.11 Remote Serial Annunciator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
6.1.12 Remote Speed Adjustment Potentiometer Kit (Non-ECM Models) . . . . 181
6.1.13 Run Relay Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.1.14 Shunt-Trip Line Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
6.1.15 Single-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.1.16 Ten-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
6.1.17 Twenty-Relay Dry Contact Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6.1.18 Wireless Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.2 Accessory Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Appendix B User-Defined Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Appendix C Voltage Regulator Definitions and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Appendix D Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Appendix E Inputs and System Events by Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

TP-6200 10/12 Table of Contents 5

 Notes

6 TP-6200 10/12
 Safety Precautions and Instructions

IMPORTANT SAFETY INSTRUCTIONS. Accidental Starting

Electromechanical equipment, WARNING
including generator sets, transfer
switches, switchgear, and WARNING
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be Explosion.
aware of potential dangers and act Can cause severe injury or death.
safely. Read and follow all safety Relays in the battery charger
precautions and instructions. SAVE Accidental starting. cause arcs or sparks.
THESE INSTRUCTIONS. Can cause severe injury or death.
Locate the battery in a well-ventilated
Disconnect the battery cables before area. Isolate the battery charger from
This manual has several types of working on the generator set.
safety precautions and instructions: explosive fumes.
Remove the negative (--) lead first
Danger, Warning, Caution, and Notice. when disconnecting the battery.
Reconnect the negative (--) lead last Battery electrolyte is a diluted
when reconnecting the battery. sulfuric acid. Battery acid can
DANGER cause severe injury or death. Battery
acid can cause blindness and burn
Disabling the generator set. skin. Always wear splashproof safety
Danger indicates the presence of a
Accidental starting can cause goggles, rubber gloves, and boots
hazard that will cause severe
severe injury or death. Before when servicing the battery. Do not
personal injury, death, or
working on the generator set or open a sealed battery or mutilate the
substantial property damage.
connected equipment, disable the battery case. If battery acid splashes in
generator set as follows: (1) Move the the eyes or on the skin, immediately
generator set master switch to the OFF flush the affected area for 15 minutes
WARNING
position. (2) Disconnect the power to with large quantities of clean water.
the battery charger. (3) Remove the Seek immediate medical aid in the
Warning indicates the presence of a battery cables, negative (--) lead first. case of eye contact. Never add acid to
hazard that can cause severe Reconnect the negative (--) lead last a battery after placing the battery in
personal injury, death, or when reconnecting the battery. Follow service, as this may result in
substantial property damage. these precautions to prevent starting of hazardous spattering of battery acid.
the generator set by an automatic
transfer switch, remote start/stop Battery acid cleanup. Battery acid
CAUTION switch, or engine start command from a can cause severe injury or death.
remote computer. Battery acid is electrically conductive
Caution indicates the presence of a and corrosive. Add 500 g (1 lb.) of
hazard that will or can cause minor bicarbonate of soda (baking soda) to a
personal injury or property damage. Battery container with 4 L (1 gal.) of water and
mix the neutralizing solution. Pour the
NOTICE neutralizing solution on the spilled
battery acid and continue to add the
Notice communicates installation, WARNING neutralizing solution to the spilled
operation, or maintenance information
battery acid until all evidence of a
that is safety related but not hazard
chemical reaction (foaming) has
related.
ceased. Flush the resulting liquid with
Safety decals affixed to the equipment water and dry the area.
in prominent places alert the operator
or service technician to potential Sulfuric acid in batteries.
hazards and explain how to act safely. Can cause severe injury or death.
The decals are shown throughout this
publication to improve operator Wear protective goggles and
recognition. Replace missing or clothing. Battery acid may cause
damaged decals. blindness and burn skin.

TP-6200 10/12 Safety Precautions and Instructions 7

Battery gases. Explosion can cause Servicing the fuel system. A flash Carbon monoxide symptoms.
severe injury or death. Battery gases fire can cause severe injury or Carbon monoxide can cause severe
can cause an explosion. Do not smoke death. Do not smoke or permit flames nausea, fainting, or death. Carbon
or permit flames or sparks to occur or sparks near the carburetor, fuel line, monoxide is a poisonous gas present
near a battery at any time, particularly fuel filter, fuel pump, or other potential in exhaust gases. Carbon monoxide is
when it is charging. Do not dispose of a sources of spilled fuels or fuel vapors. an odorless, colorless, tasteless,
battery in a fire. To prevent burns and Catch fuels in an approved container nonirritating gas that can cause death if
sparks that could cause an explosion, when removing the fuel line or inhaled for even a short time. Carbon
avoid touching the battery terminals carburetor. monoxide poisoning symptoms
with tools or other metal objects. include but are not limited to the
Remove all jewelry before servicing Servicing the air cleaner. A sudden following:
the equipment. Discharge static backfire can cause severe injury or D Light-headedness, dizziness
electricity from your body before death. Do not operate the generator D Physical fatigue, weakness in
touching batteries by first touching a set with the air cleaner removed. joints and muscles
grounded metal surface away from the Combustible materials. A fire can D Sleepiness, mental fatigue,
battery. To avoid sparks, do not disturb cause severe injury or death. inability to concentrate
the battery charger connections while Generator set engine fuels and fuel or speak clearly, blurred vision
the battery is charging. Always turn the vapors are flammable and explosive. D Stomachache, vomiting, nausea
battery charger off before Handle these materials carefully to If experiencing any of these symptoms
disconnecting the battery connections. minimize the risk of fire or explosion. and carbon monoxide poisoning is
Ventilate the compartments containing Equip the compartment or nearby area possible, seek fresh air immediately
batteries to prevent accumulation of with a fully charged fire extinguisher. and remain active. Do not sit, lie down,
explosive gases. Select a fire extinguisher rated ABC or or fall asleep. Alert others to the
BC for electrical fires or as possibility of carbon monoxide
Battery short circuits. Explosion poisoning. Seek medical attention if
can cause severe injury or death. recommended by the local fire code or
an authorized agency. Train all the condition of affected persons does
Short circuits can cause bodily injury not improve within minutes of breathing
and/or equipment damage. personnel on fire extinguisher
operation and fire prevention fresh air.
Disconnect the battery before
generator set installation or procedures.
maintenance. Remove all jewelry Fuel System
before servicing the equipment. Use
tools with insulated handles. Remove Exhaust System
the negative (--) lead first when
WARNING
disconnecting the battery. Reconnect WARNING
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the Explosive fuel vapors.
Carbon monoxide.
terminals together. Can cause severe injury or death.
Can cause severe nausea,
fainting, or death. Use extreme care when handling,
storing, and using fuels.
Engine Backfire/Flash The exhaust system must be
leakproof and routinely inspected.
Fire
Generator set operation. Carbon
WARNING monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is an odorless, colorless,
tasteless, nonirritating gas that can
cause death if inhaled for even a short
Fire. time. Avoid breathing exhaust fumes
Can cause severe injury or death. when working on or near the generator
set. Never operate the generator set
Do not smoke or permit flames or inside a building unless the exhaust
sparks near fuels or the fuel system. gas is piped safely outside. Never
operate the generator set where
exhaust gas could accumulate and
seep back inside a potentially occupied
building.

8 Safety Precautions and Instructions TP-6200 10/12

The fuel system. Explosive fuel Gas fuel leaks. Explosive fuel Hazardous Voltage/
vapors can cause severe injury or vapors can cause severe injury or
death. Vaporized fuels are highly death. Fuel leakage can cause an Moving Parts
explosive. Use extreme care when explosion. Check the LP vapor gas or
handling and storing fuels. Store fuels natural gas fuel system for leakage by DANGER
in a well-ventilated area away from using a soap and water solution with
spark-producing equipment and out of the fuel system test pressurized to
the reach of children. Never add fuel to 6--8 ounces per square inch
the tank while the engine is running (10--14 inches water column). Do not
because spilled fuel may ignite on use a soap solution containing either
contact with hot parts or from sparks. ammonia or chlorine because both Hazardous voltage.
Do not smoke or permit flames or prevent bubble formation. A Will cause severe injury or death.
sparks to occur near sources of spilled successful test depends on the ability
fuel or fuel vapors. Keep the fuel lines of the solution to bubble. Disconnect all power sources before
and connections tight and in good opening the enclosure.
condition. Do not replace flexible fuel LP liquid withdrawal fuel leaks.
lines with rigid lines. Use flexible Explosive fuel vapors can cause
sections to avoid fuel line breakage severe injury or death. Fuel leakage
can cause an explosion. Check the LP WARNING
caused by vibration. Do not operate
the generator set in the presence of liquid withdrawal gas fuel system for
fuel leaks, fuel accumulation, or leakage by using a soap and water
sparks. Repair fuel systems before solution with the fuel system test
resuming generator set operation. pressurized to at least 90 psi
(621 kPa). Do not use a soap solution
Explosive fuel vapors can cause containing either ammonia or chlorine Hazardous voltage. Moving parts.
severe injury or death. Take because both prevent bubble Can cause severe injury or death.
additional precautions when using the formation. A successful test depends Operate the generator set only when
following fuels: on the ability of the solution to bubble. all guards and electrical enclosures
Gasoline—Store gasoline only in are in place.
approved red containers clearly
marked GASOLINE.
Hazardous Noise
WARNING
Propane (LP)—Adequate ventilation
is mandatory. Because propane is CAUTION
heavier than air, install propane gas
detectors low in a room. Inspect the
detectors per the manufacturer’s
instructions.
Hazardous voltage.
Natural Gas—Adequate ventilation is Backfeed to the utility system can
mandatory. Because natural gas rises, Hazardous noise. cause property damage, severe
install natural gas detectors high in a Can cause hearing loss. injury, or death.
room. Inspect the detectors per the Never operate the generator set If the generator set is used for
manufacturer’s instructions. without a muffler or with a faulty standby power, install an automatic
Fuel tanks. Explosive fuel vapors exhaust system. transfer switch to prevent inadvertent
can cause severe injury or death. interconnection of standby and
Gasoline and other volatile fuels stored Engine noise. Hazardous noise can normal sources of supply.
in day tanks or subbase fuel tanks can cause hearing loss. Generator sets
cause an explosion. Store only diesel not equipped with sound enclosures Grounding electrical equipment.
fuel in tanks. can produce noise levels greater than Hazardous voltage can cause
105 dBA. Prolonged exposure to severe injury or death. Electrocution
Draining the fuel system. Explosive noise levels greater than 85 dBA can
fuel vapors can cause severe injury is possible whenever electricity is
cause permanent hearing loss. Wear present. Ensure you comply with all
or death. Spilled fuel can cause an hearing protection when near an
explosion. Use a container to catch applicable codes and standards.
operating generator set. Electrically ground the generator set,
fuel when draining the fuel system.
Wipe up spilled fuel after draining the transfer switch, and related equipment
system. and electrical circuits. Turn off the
main circuit breakers of all power
sources before servicing the
equipment. Never contact electrical
leads or appliances when standing in
water or on wet ground because these
conditions increase the risk of
electrocution.

TP-6200 10/12 Safety Precautions and Instructions 9

High voltage test. Hazardous Servicing the day tank. Hazardous Testing live electrical circuits.
voltage can cause severe injury or voltage can cause severe injury or Hazardous voltage or current can
death. Follow the instructions of the death. Service the day tank electrical cause severe injury or death. Have
test equipment manufacturer when control module (ECM) as prescribed in trained and qualified personnel take
performing high-voltage tests on the the equipment manual. Disconnect the diagnostic measurements of live
rotor or stator. An improper test power to the day tank before servicing. circuits. Use adequately rated test
procedure can damage equipment or Press the day tank ECM OFF equipment with electrically insulated
lead to generator set failure. pushbutton to disconnect the power. probes and follow the instructions of
Notice that line voltage is still present the test equipment manufacturer when
Testing the photo transistor circuit within the ECM when the POWER ON performing voltage tests. Observe the
board. Hazardous voltage can light is lit. Ensure that the generator set following precautions when performing
cause severe injury or death. When and day tank are electrically grounded. voltage tests: (1) Remove all jewelry.
the end cover is removed, do not Do not operate the day tank when (2) Stand on a dry, approved
expose the photo transistor circuit standing in water or on wet ground electrically insulated mat. (3) Do not
board mounted on the generator set because these conditions increase the touch the enclosure or components
end bracket to any external light risk of electrocution. inside the enclosure. (4) Be prepared
source, as exposure to light causes for the system to operate automatically.
high voltage. Keep foreign sources of Short circuits. Hazardous (600 volts and under)
light away from the photo transistor voltage/current can cause severe
circuit board during testing. Place injury or death. Short circuits can
black electrical tape over the LED on cause bodily injury and/or equipment WARNING
the circuit board before starting the damage. Do not contact electrical
generator set. connections with tools or jewelry while
making adjustments or repairs.
Installing the photo transistor Remove all jewelry before servicing
circuit board. Hazardous voltage the equipment.
can cause severe injury or death.
Ensure that the foil side of the photo Engine block heater. Hazardous Airborne particles.
transistor circuit board, the end of the voltage can cause severe injury or Can cause severe injury or
shaft, and the threaded holes are clean death. The engine block heater can blindness.
and free of metal particles and chips. cause electrical shock. Remove the
Wear protective goggles and clothing
Metal debris may short-circuit the engine block heater plug from the
when using power tools, hand tools,
photo transistor circuit board and electrical outlet before working on the
or compressed air.
cause hazardous voltage in the block heater electrical connections.
generator set. Do not reconnect the
generator set to the load until the AC Handling the capacitor. Hazardous Servicing the generator set when it
voltmeter shows the correct output. voltage can cause severe injury or is operating. Exposed moving parts
death. Electrical shock results from can cause severe injury or death.
Installing the battery charger. touching the charged capacitor Keep hands, feet, hair, clothing, and
Hazardous voltage can cause terminals. Discharge the capacitor by test leads away from the belts and
severe injury or death. An shorting the terminals together. pulleys when the generator set is
ungrounded battery charger may (Capacitor-excited models only) running. Replace guards, screens,
cause electrical shock. Connect the and covers before operating the
battery charger enclosure to the Electrical backfeed to the utility.
generator set.
ground of a permanent wiring system. Hazardous backfeed voltage can
As an alternative, install an equipment cause severe injury or death. Install
a transfer switch in standby power
grounding conductor with circuit
installations to prevent the connection Heavy Equipment
conductors and connect it to the
equipment grounding terminal or the of standby and other sources of power.
lead on the battery charger. Install the Electrical backfeed into a utility WARNING
battery charger as prescribed in the electrical system can cause severe
equipment manual. Install the battery injury or death to utility personnel
charger in compliance with local codes working on power lines.
and ordinances.
Connecting the battery and the
battery charger. Hazardous voltage
Unbalanced weight.
can cause severe injury or death.
Improper lifting can cause severe
Reconnect the battery correctly,
injury or death and equipment
positive to positive and negative to
damage.
negative, to avoid electrical shock and
damage to the battery charger and Do not use lifting eyes.
battery(ies). Have a qualified Lift the generator set using lifting bars
electrician install the battery(ies). inserted through the lifting holes on
the skid.

10 Safety Precautions and Instructions TP-6200 10/12

Hot Parts Notice
WARNING NOTICE
This generator set has been
rewired from its nameplate voltage
to
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap, 246242
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure. NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
WARNING the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.

Hot engine and exhaust system. NOTICE

Can cause severe injury or death. Canadian installations only. For
Do not work on the generator set until standby service connect the output of
it cools. the generator set to a suitably rated
transfer switch in accordance with
Canadian Electrical Code, Part 1.
Servicing the alternator. Hot parts
can cause severe injury or death.
Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Servicing the exhaust system. Hot
parts can cause severe injury or
death. Do not touch hot engine parts.
The engine and exhaust system
components become extremely hot
during operation.

TP-6200 10/12 Safety Precautions and Instructions 11

 Notes

12 Safety Precautions and Instructions TP-6200 10/12

 Introduction

This manual provides operation instructions for 20 kW Abbreviations

and larger generator sets equipped with the following
controller: This publication makes use of numerous abbreviations.
Typically, the word(s) are spelled out along with the
D Decisionr 550, Software (Code) Version 2.10 or abbreviation in parentheses when shown for the first
higher time in a section. Appendix A, Abbreviations, also
includes many abbreviation definitions.
Version 2.10 refers to the controller application software.
To determine the generator set controller software
version, go to Menu 20—Factory Setup and scroll down List of Related Materials
to Code Version. The code version is the controller
software version. Separate literature contains communication and
software information not provided in this manual.
Wiring diagram manuals are available separately. Refer Figure 1 lists the available literature part numbers.
to the engine operation manual for generator set engine
scheduled maintenance information. Communication and Software
Manual Description Literature Part No.
Information in this publication represents data available 550 Controller Spec Sheet G6-46
at the time of print. Kohler Co. reserves the right to Multiple Part Numbers
Generator Set/Controller
change this publication and the products represented Wiring Diagram Manual Contact your
Distributor/Dealer
without notice and without any obligation or liability
whatsoever. 550 Communications Spec Sheet G6-50
Monitor III Converters, Connections,
and Controller Setup TT-1405
Read this manual and carefully follow all procedures and
safety precautions to ensure proper equipment Monitor III Software Spec Sheet G6-76
operation and to avoid bodily injury. Read and follow the Monitor III Converter,
G6-79
Modbusr/Ethernet Spec Sheet
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the Monitor III Software Operation Manual TP-6347
equipment for future reference. Modbusr Communications Protocol
Operation Manual TP-6113

The equipment service requirements are very important Setup and Application Manual TP-6140
to safe and efficient operation. Inspect the parts often Service Parts Controllers TP-6780
and perform required service at the prescribed intervals. Program Loader Software Installation TT-1285
Maintenance work must be performed by appropriately SiteTecht Software Operation Manual TP-6701
skilled and suitably trained maintenance personnel Remote Serial Annunciator (RSA) TT-1377
familiar with generator set operation and service. Remote Serial Annunciator (RSA II) TT-1485
Controller Service Replacement TT-1310
The disk supplied with this generator set is a backup
copy of the generator set personality program Figure 1 Related Literature
containing data specific to the engine and alternator.
The engine and alternator data was preprogrammed in
the controller at the factory and no further use of the disk
should be necessary. Typically, your authorized
distributor stores this disk for possible future use such as
controller replacement or other circumstances requiring
a backup.

Modbusr is a registered trademark of Schneider Electric.

TP-6200 10/12 Introduction 13

Service Assistance

For professional advice on generator set power China

requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPower.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product. Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
D Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
3 rue de Brennus
93200 Saint Denis Latin America
France Latin America Regional Office
Phone: (33) 1 49 178300 Lakeland, Florida, USA
Fax: (33) 1 49 178301 Phone: (863) 619-7568
Fax: (863) 701-7131
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

14 Service Assistance TP-6200 10/12

 Section 1 Specifications and Features

1.1 Introduction The controller features, accessories, and menu displays

depend upon the engine electronic control module
The spec sheets for each generator set provide model- (ECM) setup and features. Controller features apply to
specific generator and engine information. The generator set models with ECM and non-ECM engines
controller spec sheet provides specifications for this unless otherwise noted.
controller. Refer to the respective spec sheet for data
not supplied in this manual. Consult the generator set Note: Press any key on the keypad to turn on the
service manual, installation manual, engine operation controller lights and display. The lights and
manual, and engine service manual for additional display turn off 5 minutes after the last keypad
specifications. entry.

Note: Measurements display in metric or English. Use

1.2 Controller Features Menu 7—Generator System to change the
measurement display.
The controller features include the annunciator lamps,
digital display and keypad, switches and controls, and See Figure 1-1 for an illustration of the controller front
fuses and terminal strip. The following paragraphs detail panel. See Figure 1-2 for an illustration of the controller
the features by general topics. with the keyswitch option.

1 2 3 4 5 6

TP-6083-2

8 7

1. Emergency stop switch 5. Digital display

2. Alarm horn (see keypad for alarm silence) 6. Keypad
3. Annunciator lamps (see keypad for lamp test) 7. Operating guide
4. Generator set master switch, run/off-reset/auto positions 8. Controller terminal strips (on circuit board)

Figure 1-1 550 Controller with Three-Position Selector Switch

TP-6200 10/12 Section 1 Specifications and Features 15

 1 2 3 4 5 6

TP-6083-2

8 7
1. Generator set master switch, run/off-reset/auto positions 5. Digital display
(keyswitch option) 6. Keypad
2. Emergency stop switch 7. Operating guide
3. Alarm horn (see keypad for alarm silence) 8. Controller terminal strips (on circuit board)
4. Annunciator lamps (see keypad for lamp test)

Figure 1-2 550 Controller with Keyswitch Option

1.2.1 Annunciator Lamps Programming Mode. Yellow programming lamp

indicates the user selected programming mode. See
Five annunciator lamps provide visual generator set Figure 1-4.
status. See Figure 1-3.
Programming Lamp Programming Mode Selection
Lamp Flashing Local Programming
Lamp Steady On Remote Programming
Lamp Off Programming Disabled

Figure 1-4 Programming Lamp Mode

TP-6083-2
Note: Find additional information for the programming
Figure 1-3 Annunciator Lamps
mode lamp function and access to the local or
System Ready. Green lamp illuminates when the remote programming modes in Section 2.8, Local
generator set master switch is in the AUTO (automatic Programming Mode On, Menu 14—Programming
start) position and the system senses no faults. The unit Mode.
is ready to start.

Not in Auto (NIA). Yellow lamp illuminates when the

generator set master switch is not in the AUTO
(automatic start) position.

16 Section 1 Specifications and Features TP-6200 10/12

System Warning. Yellow lamp identifies an existing System Shutdown. Red lamp indicates that the
fault condition that does not shut down the generator set. generator set has shut down because of a fault
A continuing system warning fault condition may cause condition. The unit will not start without resetting the
a system shutdown. Correct all system warnings as controller, see Section 2.3.7, Controller Reset
soon as practical. Procedure.
See Section 2.3.5, System Warning Lamp, for See Section 2.3.6, System Shutdown Lamp, for
definitions of the items listed. definitions of the items listed.
The following conditions cause a system warning:
The following conditions cause a system shutdown:
D Engine functions:
D Engine functions:
d ECM yellow alarm
(DDC/MTU engine with MDEC/ADEC) d Air damper closed (status), if equipped
d High battery voltage d Coolant temperature signal loss
d High coolant temperature d ECM red alarm
d Low battery voltage (DDC/MTU engine with MDEC/ADEC)
d Low coolant temperature d Engine stalled (ECM only)
d Low fuel (level or pressure)* d High coolant temperature
d Low oil pressure d High oil temperature
d Speed sensor fault d Low coolant level
d Starting aid (system status) d Low oil pressure
d Weak battery d Oil pressure signal loss
d Overcrank
D General functions:
d Overspeed
d Auxiliary—Analog up to 7 user-selectable inputs
D General functions:
each with a high and low programmable warning
level d Auxiliary—Analog up to 7 user-selectable inputs
d Auxiliary—Digital up to 21 user-selectable each with a high and low programmable
warnings shutdown level
d Battery charger fault* d Auxiliary—Digital up to 21 user-selectable
d Emergency power system (EPS) supplying load shutdowns
d Engine cooldown delay d ECM communications loss (ECM models only)
d Engine start delay d Emergency stop
d Load shed kW overload d Internal fault
d Load shed underfrequency d Master switch in OFF/RESET position
d Master switch not in AUTO (automatic start) d Master switch error
position d Master switch open
d NFPA 110 fault (National Fire Protection d NFPA 110 fault
Association) D Alternator functions:
d System ready (system status) d AC output overvoltage
D Alternator functions: d AC output undervoltage
d AC sensing loss d Alternator protection against overload and short
d Ground fault* circuits
d Overcurrent d Field overvoltage
(M4, M5, M7, or M10 alternator only)
* Requires optional input sensors.
d Locked rotor (failed to crank)
Note: See Figure 2-8 in User Inputs for factory- d Overfrequency
reserved analog and digital inputs that are not d Underfrequency
user-selectable. Note: See Figure 2-8 in User Inputs for factory-
reserved analog and digital inputs which are
not user-selectable.

TP-6200 10/12 Section 1 Specifications and Features 17

1.2.2 Digital Display and Keypad
Figure 1-5 illustrates the digital display and keypad.

Note: Press any key on the keypad to turn on the

controller lights and display. The lights and
display turn off 5 minutes after the last keypad
entry.

The 2-line vacuum fluorescent display provides

generator set and engine condition information.

The 16-button keypad gives the user information access

and local programming capability.

Keypad Functions
Alarm (Horn) Off key silences the alarm horn at the
operator’s discretion. Place the generator set master
switch in the AUTO position before silencing the alarm TP-5829-2

horn. See Section 2.3.7, Controller Reset Procedure, Figure 1-5 Digital Display and Keypad
and Section 1.2.3, Switches and Controls.

AM/PM key provides time of day data entries when Alternator Output Displays (Menu 1)
programming.
AC Amps displays the alternator output current. The
Enter ↵ key provides confirmation entry when selecting display shows each line of 3-phase models.
menu or programming.
AC Volts displays the alternator output voltages. The
Lamp Test key tests the controller indicator lamps, display shows all line-to-neutral and line-to-line voltage
horn, and digital display. See Section 1.2.3, Switches combinations.
and Controls.
Alternator Duty Level displays the actual load kW
Menu down ↓ key provides navigation within menus divided by the nameplate kW rating as a percentage.
when necessary.
Frequency displays the frequency (Hz) of alternator
Menu right → key provides navigation within menus output voltage.
when necessary.
Hourmeter displays the generator set operating hours
Numeric 0--9 keys provide numeric data entries when loaded and unloaded for reference in scheduling
selecting menus or programming. maintenance.

Reset Menu key exits a menu, clears incorrect entries, KVA displays the total and individual L1, L2, and L3 kVA.
and cancels the auto-scroll feature.
KVAR displays the total and individual L1, L2, and L3
Stop Prog (Program) Run key allows the user to stop kVAR.
any previously programmed generator set run
Power Factor displays the kW/kVA and the individual
sequence. See Section 1.2.3, Switches and Controls.
line power factor values.
Yes/No keys provides data answer entries when
Watts displays the total and individual L1, L2, and L3
programming.
kilowatts.

18 Section 1 Specifications and Features TP-6200 10/12

Engine Displays (Menu 2) Event History displays up to 100 stored system events
including status, warnings, and shutdowns.
Some engine displays are available with selected
generator set engines using engine ECMs only. The Last Start Date displays the date when the generator
controller display shows N/A (not available) for items set last operated.
that are unavailable. See the controller spec sheet for
applicable generator set models. Number of Starts displays the total number of
generator set startup events.
Ambient Temperature displays the generator set area
ambient temperature. Number of Starts (Since) Last Maintenance displays
the total number of generator set startup events since
Charge Air Pressure displays the engine turbocharger the last maintenance date.
boost air pressure.
Operating Days (Since) Last Maintenance displays
Charge Air Temperature displays the engine the total number of days of operation since the last
turbocharger boost air temperature. maintenance date. A counted day of operation can be
1--24 hours.
Coolant Level displays the engine coolant level.
Run Time displays the total loaded hours, total
Coolant Pressure displays the engine coolant unloaded hours, and total kW hours.
pressure.
Run Time Since Maintenance displays the total loaded
Coolant Temperature displays the engine coolant hours, total unloaded hours, and total kW hours.
temperature.

Crankcase Pressure displays the engine crankcase Time Delay Displays (Menu 8)
pressure.
The time delays are user adjustable. See Section 2.8.8,
DC Volts displays the voltage of starting battery(ies). Menu 8—TIme Delays, for time delay adjustments. See
Section 1.3.1, Status Event and Fault Specifications, for
Fuel Pressure displays the fuel supply pressure. range and default settings.

Fuel Rate displays the calculated fuel consumption rate Crank On/Crank Pause displays the time allocated for
based on fuel injector outputs. generator set crank on and crank pause in
minutes:seconds.
Fuel Temperature displays the fuel supply
temperature. Engine Cooldown displays the time delay for engine
cooldown while the master switch is in the AUTO or RUN
Oil Level displays the engine oil level as a percent of full positions and not in the idle mode.
capacity.
Engine Start displays the time delay before the
Oil Pressure displays the engine oil pressure. generator set starts while the master switch is in AUTO
or RUN positions.
Oil Temperature displays the engine oil temperature.
Overcrank Shutdown (Number of) Crank Cycles
RPM (Tachometer) displays the engine speed. displays the number of unsuccessful crank cycles
(crank on/crank pause) before the generator set shuts
Used Last Run displays the accumulated amount of down on an overcrank fault.
fuel used since last reset by the engine DDEC reader.
Overvoltage displays the time delay before the
Operational Record Displays (Menus 4 and 5) generator set shuts down because of an overvoltage
condition.
The operational record displays events since last reset.
See Section 2.8.4, Menu 4—Operational Records, for Starting Aid displays the engine starting aid activation
resetting procedure. time.

Engine Start Countdown displays the time remaining Undervoltage displays the time delay before the
before the next generator set startup. generator set shuts down because of an undervoltage
condition.

TP-6200 10/12 Section 1 Specifications and Features 19

1.2.3 Switches and Controls The generator set master switch with the keyswitch
option (Figure 1-7) is available to meet appropriate local
See Figure 1-6 and Figure 1-8 for switches and controls. code requirements. The key is removable in the AUTO
position only.

1 2 3

TP-6083-2

TP-6083-2 Figure 1-7 Generator Set Master Switch with

1. Emergency stop switch Keyswitch Option
2. Alarm horn
3. Generator set master switch
Lamp Test. The keypad switch tests the controller
Figure 1-6 Switches and Alarm Horn indicator lamps, horn, and digital display. Press the
reset menu key before pressing the lamp test key.
Note: Find additional switches and controls in
Section 2.5.1, Keypad Operation. Stop Prog (Program) Run. Keypad switch allows the
user to stop any previously programmed generator set
Alarm Horn. The alarm horn alerts the operator or other run sequence.
attendants that a shutdown or warning condition exists.
See Section 1.3, Controller Logic Specifications, for
conditions. Place the generator set master switch in the
AUTO position before silencing the alarm horn. The
alarm horn cannot be silenced unless the generator set
master switch is in the AUTO position. See
Section 2.3.7, Controller Reset Procedure.

Alarm (Horn) Off. The keypad switch silences the

alarm horn at the operator’s discretion. Place the
generator set master switch in the AUTO position before
silencing the alarm horn. Restore alarm horn switches
at all locations including those on remote annunciator
and audiovisual alarm kits to the normal position after
correcting the fault shutdown to avoid reactivating the
alarm horn. See Section 2.3.7, Controller Reset
Procedure. 1
2
AM/PM. This keypad switch provides time of day data
entries when programming. 3 TP-5829-2

Emergency Stop. The operator-activated pushbutton

1. Lamp test
immediately shuts down the generator set in emergency 2. Alarm horn silence
situations. Reset the emergency stop switch after 3. Stop program run
shutdown by pulling the switch knob outward. Use the
emergency stop switch for emergency shutdowns only. Figure 1-8 Keypad Switches
Use the generator set master switch for normal
shutdowns.

Generator Set Master Switch (Run/Off-Reset/Auto).

This switch resets the controller fault lamps and
start/stops the generator set. Refer to Section 2.3.1,
Starting, Section 2.3.2, Stopping, and Section 2.3.3,
Emergency Stop Switch Reset Procedure.

20 Section 1 Specifications and Features TP-6200 10/12

1.2.4 Controller Circuit Boards 1.2.5 Fuses
The controller has five circuit boards—indicator, AC Circuit Fuses (TB5). Fuses are located inside the
interconnection, keypad, digital display, and main logic/ controller. See Figure 1-9.
communication. See Figure 1-9 for circuit board
locations. D 1.5-Amp (V7) fuse protects L1 sensing input to
interconnection circuit board.

1 2 D 1.5-Amp (V8) fuse protects L2 sensing input to

interconnection circuit board.

D 1.5-Amp (V9) fuse protects L3 sensing input to

interconnection circuit board.

DC Circuit Fuses fuses are located on the controller

interconnection circuit board.

D 5-Amp Remote Annunciator (F1) fuse protects the

dry contact kit if equipped and the controller panel
lamps.

D 5-Amp Controller (F2) fuse protects the controller

circuitry.
5 4 3
GM10193B-A
D 15-Amp Engine and Accessories (F3) fuse protects
the engine/starting circuitry and accessories.
1. AC fuse block (TB5)
2. Interconnection circuit board TB1, TB2, TB3, and TB4
terminal strips and F1, F2, and F3 fuses 1.2.6 Terminal Strips and Connectors
3. Main logic (microprocessor)/communication circuit board
4. Keypad and digital display circuit boards Terminal strips and connectors for inputs and outputs
5. Indicator circuit board (LED and alarm horn)
are located on the interconnection circuit board. See
Figure 1-9 Controller Circuit Boards and Fuses Section 6, Accessories.
(Controller Top View)
TB1 Input Connection Terminal Strip provides input
Indicator (Status) Circuit Board includes the LED connections for remote start and emergency stop
status lamps, alarm horn, and generator set master (E-Stop).
switch.
TB2 Analog Input Connection Terminal Strip
Interconnection Circuit Board provides the terminal provides analog input connections, including non-ECM
strips to connect the controller (customer) connection sensor connections.
board and/or dry contact kits and three DC fuses (F1, F2,
and F3). See 6.1.3 for more information. TB3 Accessory Power Output Connection Terminal
Strips provides a generator set power supply for factory
Keypad (Switch Membrane) Circuit Board provides use.
the keypad to navigate the generator set displays and
enter data. TB4 Digital Input Connection Terminal Strips
connect external devices (engine ECM and user
Digital Display Circuit Board provides the vacuum supplied) to the generator set digital inputs.
fluorescent display (VFD) for monitoring the generator
set functions and output values. P23 Connector connects the interconnection circuit
board to the controller (customer) connection terminal
Main Logic (Microprocessor)/Communication strip (connector P25) inside the junction box. See 6.1.3
Circuit Board provides the controller operation logic for more information.
and provides PC communication locally (direct) or
remotely (via modem) using RS-232 or RS-485
connectors.

TP-6200 10/12 Section 1 Specifications and Features 21

Figure 1-10 shows locations of the terminal strips on the 1.2.7 Circuit Board Interconnections for
controller interconnection circuit board. See Section 6.2, Calibration Procedure
Accessory and Connections, for specific terminal
identification information. Refer to the wiring diagrams The interconnection circuit board shown in Figure 1-11
for additional information on connecting accessories to contains a ribbon connector that requires disconnection
the terminal strips. during the calibration procedure in Menu 12—
Calibration. Disconnect ribbon connector P2 prior to
zeroing out (resetting) the auxiliary analog inputs.
1 2 3 4 5 6

ADV-6533-A

1. TB1 terminal strip 4. P23 Connector

2. TB2 terminal strip 5. TB3 terminal strip 4
3. P1 Connector 6. TB4 terminal strip

Figure 1-10 Interconnection Circuit Board Terminal

Strips and Connectors

ADV-6533-A

1. Interconnection circuit board

2. P2 ribbon connector
3. P12 ribbon connector
4. Main logic circuit board

Figure 1-11 Interconnection Circuit Board Ribbon

Connector P2 (Top View of Circuit Board)

22 Section 1 Specifications and Features TP-6200 10/12

1.2.8 Communication Ports 1.3 Controller Logic Specifications
The main logic circuit board contains several The controller logic specifications section is an overview
communication ports for Modbusr and KBUS of the various features and functions of the controller.
connections. See Figure 1-12. Refer to the List of Certain features function only when optional
Related Materials in the Introduction for corresponding accessories are connected. See Section 2, Operation,
communication installation information. for details.

The default selection time delays and relay driver

1 2 3 4 5 outputs (RDOs) are factory set and adjustable with the
programming mode on (Menu 14). Some data entries
require using a PC in the Remote Programming mode.
See the monitor software operation manual for details.

Inhibit Time Delay. The inhibit time delay is the time

period following crank disconnect during which the
generator set stabilizes and the controller does not
detect a fault or status event. Select the desired inhibit
time delay from 0 to 60 seconds.

TIme Delay (Shutdown or Warning). The time delay

follows the inhibit time delay. The time delay is the time
period between when the controller first detects a fault or
status event and the controller warning or shutdown
lamp illuminates. The delay prevents any nuisance
alarms. Select the desired time delay from 0 to
60 seconds.

1.3.1 Status Event and Fault

Specifications
The table starting on the next page contains all status
events and faults with ranges and time delays including
items that do not have adjustments.

Note: The engine ECM may limit the crank cycle even if
the controller is set to a longer time period.
6
ADV-6533-A

1. P19—unused isolated connection (ISO2), RS-485 port

2. P21—KBUS isolated connection (ISO1), RS-485 port
3. P18—KBUS or Modbusr, RS-232 port
(Monitor III connection)
4. P20—Modbus, RS-485 port (Monitor III connection)
5. P22—ECM connector
6. Main logic circuit board

Figure 1-12 Main Logic Circuit Board Communication

Ports (Top View of Circuit Board)

Modbusr is a registered trademark of Schneider Electric.

TP-6200 10/12 Section 1 Specifications and Features 23

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Access Code 14 User-Selectable 0 (zero)
(password)
AC Sensing Loss 10 AC SENSING RDO-25 * On Warning
LOSS
Air Damper Control 10
(if used) **
Air Damper Indicator
(if used), see D20 **
Air/Fuel Module 10 AFM ENG Fixed
(AFM) Engine Start START DELAY
Delay ]
Air/Fuel Module 10 AFM REMOTE RDO-25 ] Off
(AFM) Remote START
Start ]
Air/Fuel Module
(AFM) Shutdown
(see D11) ]
Alternator Protection 10 ALTERNATOR On Shutdown
Shutdown PROTECTION
Analog Aux. Input 0 9 LOCAL BATT Fixed
VDC
Analog Aux. Inputs 9 USER-DEFINED On Shutdown Default Values with 30 sec. 0--60 0--60
A01--A07 A01--A07 or Warning Enabled: inhibit,
Warning HI warning 90% 5 sec. delay
LO warning 10%
HI shutdown 100%
LO shutdown 1%
Analog Aux. Input 9 A01 On Shutdown Default Values with 30 sec.
A01 (non-ECM only) COOLANT or Warning Enabled: inhibit,
TEMP Warning HI/LO warning and 0 sec. delay
HI/LO shutdown are warning,
all engine dependent 5 sec. delay
shutdown
Analog Aux. Input 9 A02 On Shutdown Default Values with 30 sec.
A02 (non-ECM only) OIL or Warning Enabled: inhibit,
PRESSURE Warning HI/LO warning and 0 sec. delay
HI/LO shutdown are warning,
all engine dependent 5 sec. delay
(255 psi max.) shutdown
Analog Aux. Input 9 A03 Shutdown Default Values with 30 sec.
A03 ] INTAKE AIR or Warning Enabled: inhibit,
TEMP Warning HI/LO warning and 0 sec. delay
HI/LO shutdown are warning
all engine dependent
Analog Aux. Input 9 A04 Default Values with 30 sec.
A04 * FUEL LEVEL Warning Enabled: inhibit,
HI/LO warning are 0 sec. delay
engine dependent warning
Analog Aux. Input 9 A04 On Warning Default Values with 30 sec.
A04 ] OIL TEMP Warning Enabled: inhibit,
HI/LO warning are 0 sec. delay
engine dependent warning
Analog Aux. Input 9, 12 A06 ANALOG Off Volvo:
A06 VSG (Volvo, AUXILIARY IN 0.5V=1250
GM, Doosan only) 4.5V=8750
GM/Doosan
60 Hz:
0.5V=2375
4.5V=2625
50 Hz:
0.5V=2327
4.5V=2624
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

24 Section 1 Specifications and Features TP-6200 10/12

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Analog Aux. Input 9 A07 ±10% of system
A07 ANALOG VOLT voltage over the range
ADJUST of 0.5--4.5 VDC
Battery Charger Fault
(see D01) **
Battle Switch 9 BATTLE Off Warning Fixed
(Fault Shutdown SWITCH
Override Switch)
Block Heater 10 BLOCK HEATER RDO only
Control [[ CONTROL
Breaker Trip w 10 BREAKER RDO-30 Off Warning
TRIP
Common Protective 10 COMMON PR RDO-31 w Off Warning
Relay Output w OUTPUT
Critical Overvoltage 10 CRITICAL On Shutdown Fixed 275 volts
Shutdown OVERVOLTAGE (L1--L2)
Cyclic Cranking 8 Off 1--6 crank cycles 3
10--30 sec. crank on 15 sec.
1--60 sec. pause 15 sec.
Defined Common 10 DEFINED RDO-18 On Shutdown Default shutdowns 30 sec. 0--60 0--60
Faults COMMON (lead 32A) or include: inhibit,
(each input value is FAULT Warning Emergency stop 5 sec. delay
set separately) High coolant temp
Low oil pressure
Overcrank
Overspeed
Detonation Shutdown
(see D13) ]
Detonation Warning
(see D12) ]
Digital Aux. Input 9, 10 USER-DEFINED On Shutdown 30 sec. 0--60 0--60
D01--D21 D01--D21 or inhibit,
Warning 5 sec. delay
Digital Aux. Input 9, 10 D01 BATTERY RDO-11 On Warning Fixed 0 sec.
D01 Battery Charger CHARGER (lead 61) inhibit,
Fault ** FAULT 0 sec. delay
Digital Aux. Input 9, 10 D02 RDO-08 On Warning Fixed 0 sec.
D02 Low Fuel LOW FUEL (lead 63) inhibit,
Warning ** WARNING 0 sec. delay
Digital Aux. Input 9, 10 D03 LOW RDO-05 On Warning Fixed 0 sec.
D03 Low Coolant COOLANT (lead 35) inhibit,
Temperature ** TEMP 0 sec. delay
Digital Aux. Input 9, 10 D04 On Shutdown Fixed 1 sec.
D04 Field FIELD inhibit,
Overvoltage (M4, OVERVOLTAGE 15 sec.
M5, M7, or M10 alt. delay
only)
Digital Aux. Input 9, 10 D05 Off Warning Fixed 0 sec.
D05 Breaker BREAKER inhibit,
Closed w CLOSED 0 sec. delay
Digital Aux. Input 9, 10 D06 ENABLE 20 sec.
D06 w SYNCH inhibit, 0
sec. delay
Digital Aux. Input 9, 10 D09 On Shutdown Fixed 5 sec.
D09 Low Fuel LOW FUEL inhibit,
Pressure Shutdown SHUTDOWN 0 sec. delay
(125RZG only)
Digital Aux. Input 9, 10 D11 On Shutdown Fixed 0 sec.
D11 Air/Fuel Module AFM inhibit,
(AFM) Shutdown ] SHUTDOWN 0 sec. delay
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Section 1 Specifications and Features 25

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Digital Aux. Input 9, 10 D12 On Warning Fixed 2 sec.
D12 Detonation DETON inhibit,
Warning ] WARNING 0 sec. delay
Digital Aux. Input 9, 10 D13 On Shutdown Fixed 0 sec.
D13 Detonation DETON inhibit,
Sensing Module SHUTDOWN 0 sec. delay
(DSM) Shutdown ]
Digital Aux. Input 9, 10 D13 On Shutdown Fixed 0 sec.
D13 Knock Detection KNOCK inhibit,
Module (KDM) SHUTDOWN 0 sec. delay
Shutdown ]
Digital Aux. Input D14 9, 10 D14 LOW RDO-19 On Shutdown Fixed 30 sec.
Low Coolant Level, COOLANT LVL inhibit,
(with LCL switch) ** 5 sec. delay
Digital Aux. Input 9, 10 D15 REMOTE On Shutdown 0 sec.
D15 Remote SHUTDOWN inhibit,
Shutdown 0 sec. delay
Digital Aux. Input 9, 10
D16 Remote Reset
Digital Aux. Input 9, 10
D17 VAR/PF mode
Digital Aux. Input 9, 10
D18 Voltage Lower
Digital Aux. Input 9, 10
D19 Voltage Raise
Digital Aux. Input 9, 10 D20 RDO-23 * On Shutdown Fixed 0 sec.
D20 Air Damper AIR DAMPER (lead 56) inhibit,
Indicator (if used) ** 0 sec. delay
Digital Aux. Input 9, 10 D21 RDO-21 Off Warning Fixed inhibit time 0 sec. 0--600
D21 Idle (speed) IDLE MODE inhibit, or 9:99
Mode Function ACTIVE 60 sec. for
delay infinity
ECM Red Alarm 10 ECM RED On Shutdown
(was MDEC Red ALARM
Alarm) [[
ECM Yellow Alarm 10 ECM YELLOW On Warning
(was MDEC Yellow ALARM
Alarm) [[
EEPROM Write 10 EEPROM WRITE On Shutdown
Failure FAILURE

Emergency Stop 10 EMERGENCY RDO-14 On Shutdown

Shutdown STOP (lead 48)
Engine Cooldown
(see Time Delay--)
Engine Derate Active 10 ENGINE
DERATE
ACTIVE
(Engine) J1939 CAN 10 J1939 CAN On Shutdown
Shutdown SHUTDOWN
(ECM only)
Engine Stalled 10 ENGINE On Shutdown
(ECM only) STALLED
Engine Start
(see Time Delay--)
EPS (Emergency 10 EPS RDO-22 Off Warning Fixed 1% of rated
Power System) SUPPLYING line current
Supplying Load LOAD
Field Overvoltage
(see D04)
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

26 Section 1 Specifications and Features TP-6200 10/12

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Fuel Level (see A04)
Fuel Valve Relay ] 10 FUEL VALVE RDO-23 ]
RELAY
Generator Set 10 RDO-15 Off
Running (lead 70R)
Ground Fault 10 GROUND On Warning
Detected FAULT
High Battery Voltage 10 HIGH RDO-13 Off Warning 14.5--16.5 V (12 V) 16 V (12 V) 10
BATTERY 29--33 V (24 V) 32 V (24 V)
VOLTAGE
High Coolant 10 HI COOL RDO-03 On Shutdown 30 5
Temperature TEMP (lead 36)
Shutdown SHUTDOWN
High Coolant 10 HI COOL RDO-06 On Warning 30
Temperature Warning TEMP (lead 40)
WARNING
High Oil Temperature 10 HI OIL TEMP On Shutdown 30 5
Shutdown SHUTDOWN
High Oil Temperature 10 HI OIL TEMP On Warning 30
Warning ] [[ WARNING
Idle (speed) Mode
Function (see D21)
In Synch w 10 IN SYNCH RDO-29 *
Intake Air 10 INTAKE AIR On Shutdown 30
Temperature TEMP SDWN
Shutdown [[
Intake Air 10 INTAKE AIR On Warning 30
Temperature Warning TEMP WARN
[[
Intake Air Temp
Warning (see A03) ]
Intake Air Temp
Shutdown (see
A03)]
Internal Fault 10 INTERNAL On Shutdown
Shutdown FAULT
J1939 CAN
Shutdown (see
Engine J1939 CAN
Shutdown)
Knock Shutdown
(see D13) ]
kW Overload
(see Load Shed)
Load Shed 10 LOAD SHED RDO-30 ]] Off Warning 80%--120% 100% of 2--10
kW Overload ]] KW OVER kW rating
with 5 sec.
delay
Load Shed Over 10 LOAD SHED RDO only
Temperature [[ OVER
(Activated by a High TEMPERATURE
Coolant Temp.
shutdown)
Load Shed 10 LOAD SHED RDO-31 [ Off Warning 59 Hz 5
Underfrequency [ UNDER (60 Hz)
FREQUENCY 49 Hz
(50 Hz)
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Section 1 Specifications and Features 27

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Locked Rotor 10 LOCKED On Shutdown
Shutdown ROTOR
Loss of ECM 10 LOSS OF ECM RDO-26 * On Shutdown 4
Communication COMM
(ECM only)
Loss of Field 10 SD LOSS OF On Shutdown
Shutdown w FIELD
Low Battery Voltage 10 LOW BATTERY RDO-12 Off Warning 10--12.5 V (12 V) 12 V (12 V) 0 10
VOLTAGE (lead 62) 20--25 V (24 V) 24 V (24 V)
Low Coolant Level
(see D14) (with LCL
switch) **
Low Coolant
Temperature (see
D03) **
Low Coolant 10 LOW COOLANT On Shutdown
Temperature TEMP
Shutdown [[ SHUTDOWN
Low Fuel (Level or
Pressure) Warning
(see D02) **
Low Fuel Pressure
Shutdown (see D09)
(125RZG only)
(Low) Oil Pressure 10 OIL RDO-04 On Shutdown 30 5
Shutdown PRESSURE (lead 38)
SHUTDOWN
(Low) Oil Pressure 10 OIL RDO-07 On Warning 30
Warning PRESSURE (lead 41)
WARNING
Maintenance Due 10 MAINTENANCE
DUE

Master Not In Auto 10 MASTER NOT RDO-09 On Warning

(Generator Set IN AUTO (lead 80) and Not
Switch) In Auto
Master Switch Error 10 MASTER On Shutdown
SWITCH
ERROR
Master Switch to Off 10 MASTER On Shutdown
SWITCH TO and Not
OFF in Auto
Master Switch Open 10 MASTER On Shutdown
SWITCH OPEN
NFPA 110 Fault ** 10 NFPA 110 RDO-10 On Shutdown
FAULT (lead 32) or
Warning
No Air Temperature 10 NO AIR TEMP On Warning 30 4
Signal Warning ] SIGNAL
No Coolant 10 NO COOL On Shutdown 30 4
Temperature Signal TEMP SIGNAL
No Oil Pressure 10 NO OIL On Shutdown 30 4
Signal PRESSURE
SIGNAL
No Oil Temperature 10 NO OIL TEMP On Warning 30 4
Signal Warning ] SIGNAL
Overcrank Shutdown 8, 10 OVER CRANK RDO-02 On Shutdown 0--6 Cycles 3 Cycles
(lead 12)
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

28 Section 1 Specifications and Features TP-6200 10/12

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Overcurrent 10 OVER On Warning 110% 10
CURRENT
Over Current PR 10 SD OVER On Shutdown
Shutdown w CURRENT PR
Overfrequency 7, 10 OVER RDO-28 On Shutdown 102%--140% 110% Std. 10
Shutdown FREQUENCY 103% FAA
Over Power 10 SD OVER On Shutdown 102%
Shutdown w POWER Stdby
112% Prime
Overspeed 7, 10 OVER SPEED RDO-01 On Shutdown 65--70 Hz (60 Hz) 70 (60 Hz) 0.25
Shutdown (lead 39) 55--70 Hz (50 Hz) 70 (50 Hz)
Overvoltage 7, 8, OVER RDO-20 On Shutdown 105%--135% 115% 2--10
Shutdown 10 VOLTAGE (lead 26) of nominal 2-sec time
delay[
135%
10-sec time
delayw
Password
(see Access Code)
Pre Lube Relay ] 10 PRE LUBE RDO-26 ] 4
RELAY
Remote Reset
(see D16)
Remote Shutdown
(see D15)
Reverse Power 10 SD REVERSE On Shutdown
Shutdown w POWER
Speed Sensor Fault 10 SPEED RDO-24 On Warning
SENSOR
FAULT
Starting Aid (see
Time Delay Starting
Aid)
System Ready 10 RDO-17 Off System
(lead 60) Ready
Time Delay Engine 8, 10 DELAY ENG RDO-16 Off 00:00--10:00 5:00
Cooldown (TDEC) COOLDOWN (lead 70C) min:sec
Time Delay Engine 8, 10 DELAY ENG Off 00:00--5:00 00:01
Start (TDES) START min:sec
Time Delay Starting 8, 10 Off 0--10 sec.
Aid
Underfrequency 7, 10 UNDER RDO-29 ] On Shutdown 80%--97% 97% FAA 10
FREQUENCY 90%[
80%w
Undervoltage 7, 8, UNDER RDO-27 On Shutdown 70%--95% 85% 5--30
Shutdown 10 VOLTAGE 10-sec time
delay[
70%
30-sec time
delayw
Variable Speed
Governor (VSG)
(see A06)
VAR/PF Mode
(see D17)
Voltage Lower
(see D18)
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Section 1 Specifications and Features 29

Factory-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Alarm Default Delay Delay
or Fault Menu Digital Display (RDO) Horn Lamp Range Setting Selection (sec.) (sec.)
Voltage Raise
(see D19)
Weak Battery 10 WEAK Off Warning 60% of 2
BATTERY nominal
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

Refer to
Calibration Menu Digital Display Range Setting Default Selection
Voltage Adjustment 11 VOLT ADJ ±10% of system voltage— System voltage
Version 2.10
±20% of system voltage—
Version 2.11 or higher
Underfrequency Unload 11 FREQUENCY 40 to 70 Hz 1 Hz below system frequency (ECM)
Frequency Setpoint SETPOINT 2 Hz below system frequency (non-ECM)
Underfrequency Unload 11 SLOPE 0--10% of rated voltage 3.1% of system voltage
Slope volts per cycle
Reactive Droop 11 VOLTAGE 0--10% of system voltage 4% of system voltage
DROOP
VAR Control 11 KVAR ADJ 0 to rated kVAR generating 0
0 to 35% of rated kVAR absorbing
Power Factor (PF) Adjust 11 PF ADJ 0.7 to 1.0 leading 0.8 lagging
Control 0.6 to 1.0 lagging
Controller Gain 11 REGULATOR 1--10000 100
GAIN
VAR/PF Gain or Utility 11 VAR/PF GAIN 1--10000 100
Stability

Figure 1-13 Settings for Controller Internal Voltage Regulation

1.3.2 Voltage Regulator and Calibration Voltage Adjustment. The voltage adjustment allows
Specifications the user to enter the desired generator set output level.
This regulated level setting is the average of the three
The 550 controller has a voltage regulation function that line-to-line voltages in three-phase configurations or
is internal to the processor. This means that no external L1-to-L2 in single phase configurations.
voltage regulator is necessary. The voltage regulation of
the controller uses root mean square (rms) sensing for Submenus display the individual line-to-line voltages.
fast response to changes in indicated and regulated These voltages are for reference only and are relevant in
voltages resulting in excellent regulation accuracy. unbalanced load conditions. The voltage adjust setpoint
can be changed to accommodate an important phase in
RMS voltage regulation is available for both paralleling an unbalanced system.
and utility application to control changes in the reactive
loads due to load changes, prime mover speed Underfrequency Unload Frequency Setpoint. This
variation, thermal drift, and other variations. See adjustment affects the voltage droop (volts per Hz) when
Figure 1-13 for data on the 550 controller voltage load is applied and underfrequency occurs. The
regulation. Refer to Appendix C to customize underfrequency unload setting defines the setpoint
adjustments for specific applications. where underfrequency starts. Any frequency below the
setpoint causes the voltage to drop thus reducing the
load allowing the engine speed to recover according to
1.3.3 Voltage Regulator Adjustments the underfrequency unload slope setting.
The descriptions of the voltage regulator adjustments
and features follow. See Appendix C, Voltage Regulator
Definitions and Adjustments, for additional information.

30 Section 1 Specifications and Features TP-6200 10/12

Engine speed recovery depends upon characteristics Regulator Gain. Regulator gain refers to the gain of the
such as engine make, fuel type, load types, and control system. Generally, the higher the gain the faster
operating conditions. The underfrequency unload the system responds to changes and the lower the gain,
setting should match the engine speed recovery the more stable the system.
characteristics for the application.
If the voltage is slow the recover when loads are applied
Underfrequency Unload Slope. This setting or removed, increase the regulator gain. If the voltage is
determines how much the voltage drops during an unstable, decrease the regulator gain. Regulator gain is
underfrequency condition. Typically, applying a large active only while not in the VAR/PF mode.
electrical load causes a dip in engine speed and
VAR/PF Gain. The VAR/PF gain also refers to the gain
frequency. The voltage regulator reduces voltage,
of the control system. Unlike the regulator gain, the
allowing engine speed recovery. The volts-per-Hz
response and stability of the system refers to the
setting determines the amount of voltage drop.
reactive current, or more specifically the VARs and/or
Reactive Droop. Reactive droop compensation power factor.
provides reactive current flow adjustment in the If the system is slow to recover to the desired VAR or PF
generator set during generator set-to-generator set setting, increase the VAR/PF gain. If the VARs or PF of
paralleling applications. Reactive droop reduces the system is unstable, decrease the VAR/PF gain.
excitation levels with increasing reactive current. A Because VAR/PF stability can be effected by the prime
reduced excitation level reduces generator set reactive mover (engine), VAR/PF gain adjustments should be
current or generated VARs, improving reactive load coordinated with the load sharing adjustment.
sharing.
Analog Voltage Adjust. Use Menu 11 to enable or
Enter the gain setting as a percentage of system voltage disable analog voltage adjust. Analog voltage adjust is
when full-rated load with 0.8 power factor is applied. Any commonly used for active control of voltage by some
loads less than full load force the voltage to drop by the external equipment in certain applications, like
ratio of reactive volt-amps (VARs) to rated VARs. synchronizing.
VAR Control. VAR control is used in some utility Enabling analog voltage adjust allows slight adjustment
paralleling applications. The excitation is regulated to to the operating voltage by use of auxiliary analog input
maintain the reactive load rather than output voltage. #7. This input signal provides a bias to the voltage adjust
The VAR adjust setting determines what reactive load is value. The range of input voltage is 0--5 VDC nominal
maintained at the generator set output. The VAR adjust (0.1--4.9 actual). The corresponding range of bias is
is the total reactive load (sum of three phases). ±10% of nominal or system voltage. If the input voltage
is at the midpoint (2.5 volts), the bias is zero and the
VAR control allows the user to define the direction of the voltage adjust value or regulation value will be equal to
reactive current out of the generator set (generating) or the system voltage. Likewise, if the input voltage is out of
into the generator set (absorbing). range (below 0.1 volt or above 4.9 volts), the bias will be
zero. For every 1 volt of input voltage, the operating
The utility supply, not the controller, determines terminal
voltage will vary 4%; this satisfies the nominal ratio of
voltage. Engine fueling determines real power,
±10% output voltage for 0--5 volts input.
measured in watts, using load sharing module control.
When analog voltage adjust is enabled, the description
Power Factor (PF) Adjust Control. Power factor shown for Auxiliary Analog Input 7 is Analog Volt Adjust.
control is used in some utility paralleling applications. Enable analog voltage adjust via KNET or MODBUS by
The excitation is regulated to maintain PF rather than setting the description for Analog Input 7 as Analog Volt
output voltage. The PF adjustment setting determines Adjust.
what PF is maintained at the generator set output. PF
adjustment is the average of three phases. Analog voltage adjust may be enabled only when the
master switch is in the OFF/RESET or AUTO positions
Power factor is defined as the ratio of real power (watts) and while the generator is not running.
over the volt-amps. Power factor can be calculated as
the cosine of the electrical angle between current and
voltage. The cosine function is positive for angles
between --90° and +90° including zero; and is negative
for angles between --90 and +90 including 180°. This
adjustment requires the user to determine whether the
current leads or lags the voltage.

TP-6200 10/12 Section 1 Specifications and Features 31

 Notes

32 Section 1 Specifications and Features TP-6200 10/12

 Section 2 Operation

2.1 Prestart Checklist Fuel Level. Check the fuel level and keep the tank(s) full
to ensure adequate fuel supply.
To ensure continued satisfactory operation, perform the
following checks or inspections before or at each Oil Level. Maintain the oil level at or near, not over, the
startup, as designated, and at the intervals specified in full mark on the dipstick.
the service schedule. In addition, some checks require
Operating Area. Check for obstructions that could
verification after the unit starts.
block the flow of cooling air. Keep the air intake area
Air Cleaner. Check for a clean and installed air cleaner clean. Do not leave rags, tools, or debris on or near the
element to prevent unfiltered air from entering engine. generator set.

Air Inlets. Check for clean and unobstructed air inlets. 2.2 Exercising Generator Set
Battery. Check for tight battery connections. Consult Operate the generator set under load once each week
the battery manufacturer’s instructions regarding for one hour. Perform the exercise in the presence of an
battery care and maintenance. operator when the generator set does not have a
programmed exercise mode or an automatic transfer
Controller. After reconnecting the battery, set the switch with an exercise option.
controller time and date. See Section 2, Menu 14—
Programming Mode On and Menu 6—Time and Date. During the exercise period apply a minimum of 35% load
based on the nameplate standby rating, unless
Coolant Level. Check the coolant level according to the otherwise instructed in the engine operation manual.
cooling system maintenance information.
The operator should perform all of the prestart checks
Note: Block Heater Damage. The block heater will fail before starting the manual exercise procedure. Start the
if the energized heater element is not immersed in generator set according to the starting procedure in
coolant. Fill the cooling system before turning on Section 2.3, Controller Operation. While the generator
the block heater. Run the engine until it is warm, set is operating, listen for a smooth-running engine and
and refill the radiator to purge the air from the visually inspect generator set for fluid or exhaust leaks.
system before energizing the block heater.
The generator set exercise time can be programmed for
Drive Belts. Check the belt condition and tension of the a one-time exercise period. See Menu 4—Operational
radiator fan, water pump, and battery charging Records. The generator set controller does not provide
alternator belt(s). weekly scheduled exercise periods. For scheduled
exercise periods, refer to the automatic transfer switch
Exhaust System. Check for exhaust leaks and
(if equipped) literature.
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.

Inspect the exhaust system components (exhaust

2.3 Controller Operation
manifold, exhaust line, flexible exhaust, clamps,
silencer, and outlet pipe) for cracks, leaks, and 2.3.1 Starting
corrosion.
Local Starting
D Check for corroded or broken metal parts and replace
them as needed. Move the generator set master switch to the RUN
position to start the generator set at the controller.
D Check for loose, corroded, or missing clamps and
hangers. Tighten or replace the exhaust clamps Note: The alarm horn sounds and the Not-In-Auto lamp
and/or hangers as needed. lights whenever the generator set master switch
is not in the AUTO position.
D Check that the exhaust outlet is unobstructed.
Note: The transient start/stop function of the controller
D Visually inspect for exhaust leaks (blowby). Check for prevents accidental cranking of the rotating engine.
carbon or soot residue on exhaust components. The generator set stops and recranks when the
Carbon and soot residue indicates an exhaust leak. generator set master switch is momentarily placed
Seal leaks as needed. in OFF/RESET position and then returned to RUN.

TP-6200 10/12 Section 2 Operation 33

Auto Starting Run Time Feature
Move the generator set master switch to the AUTO The run time feature allows the user to set up the
position to allow startup by the automatic transfer switch generator set to run unassisted and automatically return
or remote start/stop switch (connected to controller to the standby mode. The user does not need to wait for
terminals 3 and 4). the exercise period (run time) to conclude in order to
place the unit back in the standby mode. See
Terminals 3 and 4 connect to a circuit that automatically Menu 4—Operational Records for setup of this feature.
starts the generator set crank cycle when an external
source closes the circuit. With the run time enabled, the generator set will begin to
crank and run based on the run time period and all
Note: The controller provides up to 30 seconds of previously established time delays from Menu 8—Time
programmable cyclic cranking and up to Delays.
60 seconds rest with up to 6 cycles. The default
setting is 15 seconds cranking and 15 seconds Generator Set Connected to an Automatic Transfer
rest for 3 cycles. Make cyclic cranking Switch. Should a utility power failure occur while the
adjustments using the keypad. See Section 2.8.14, unit is in the run time mode, the controller will bypass the
Menu 14—Programming Mode, and Section 2.8.8, run time mode and function in the standby (backup)
Menu 8—Time Delays. mode. When the utility power returns, the generator set
continues to run for the duration of the run time period
Idle (Speed) Mode Warmup and Cooldown when not timed out.
Function Note: Press the STOP PROG RUN key, when
The idle (speed) mode function provides the ability to necessary, to stop the generator set when it is in
start and run the engine at reduced speed for a the run time mode.
selectable time period (0--10 minutes) during warmup.
See Section 6.1.5, Idle (Speed) Mode Feature, for Prime Power Switch
installation information.
The digital controller has an optional prime power mode
The controller will override the idle speed mode when of operation. The prime power mode requires
the engine reaches the preprogrammed engine installation of an optional prime power switch kit. See
warm-up temperature before the idle mode times out. Section 6, Accessories, for instructions on how to install
the optional prime power switch kit. The prime power
The idle function also provides engine cooldown at idle switch kit prevents engine starting battery drain when
speed. The controller overrides the idle speed mode the generator set is shut down and no external battery
when the engine reaches the preprogrammed engine charging is available.
cooldown temperature before the idle mode times out.
Move the prime power switch located on the back of the
During the idle (speed) mode the controller continues to controller to the CONTROLLER ON position and set the
monitor critical engine parameters such as oil pressure, controller time and date before attempting to start the
coolant temperature, and engine speed. The voltage generator set. When the prime power mode is off, all
regulator, thermal protection feature, and AC metering controller functions including the digital display, LEDs,
are disabled in the idle speed mode. and alarm horn are operative.

The controller overrides the idle speed function when Note: After energizing the controller using the prime
the generator set is signaled to start while in the AUTO power switch, set the controller time and date.
position. This override provides emergency generator See Section 2.8.6, Menu 6—TIme and Date.
set power in the event of a utility power failure. When the
utility power returns and the generator set is signalled to Stop the generator set using the stopping procedures in
stop, the generator set continues to run for the duration Section 2.3.2 before placing the generator set in the
of the idle mode period when the idle mode is active. prime power mode. Move the prime power switch
When the idle mode is not active, the generator set will located on the back of the controller to the
shut down in the normal stopping mode including time CONTROLLER OFF position. When the generator set
delays. is is the prime power mode, all controller functions
including the digital display, LEDs, alarm horn, and
See Menu 9—Input Setup to activate the idle speed communications are inoperative.
function as a user-defined digital input. The idle speed
feature requires an ECM-equipped engine with the idle
speed function.

34 Section 2 Operation TP-6200 10/12

2.3.2 Stopping (User Stopping and See Section 2.8.8, Menu 8—Time Delays, for
Fault Shutdown) information on how to enable the cooldown temperature
override feature.
Normal Stopping 2.3.3 Emergency Stop Switch Resetting
Run the generator set without load for 5 minutes to
Use the following procedure to reset the generator set
ensure adequate engine cooldown.
after shutdown by a local or remote emergency stop
The controller has a programmable cooldown timer that switch. Refer to Section 2.3.7, Controller Reset
functions only when the master switch is in the AUTO Procedure, to restart the generator set following a fault
position. To stop the generator set, place the generator shutdown.
set master switch in the OFF/RESET position and wait
until the generator set comes to a complete stop. 1. Place the generator set master switch in the
OFF/RESET position.
Note: The cooldown cycle times out before the
2. Investigate and correct the cause of the emergency
generator set stops when a remote switch or
stop.
automatic transfer switch initiates the generator
set start/stop sequence. 3. Reset the optional remote emergency stop switch by
replacing the glass piece, when equipped. Additional
Emergency Stopping glass rods are available as a service part. Reset the
controller emergency stop switch by pulling the
Use the controller emergency stop switch or optional switch knob outward.
remote emergency stop for immediate shutdown.
4. After resetting all faults using the controller reset
The emergency stop switch bypasses the time delay procedure in Section 2.3.7, toggle the generator
engine cooldown and immediately shuts down the set master switch to RUN or AUTO to restart the
generator set. generator set. The generator set will not crank until
the reset procedure completes.
Note: Use the emergency stop switch(es) for
emergency shutdowns only. Use the generator 2.3.4 Status Lamps
set master switch for normal shutdowns.
System Ready. The green lamp illuminates when the
The controller system shutdown lamp lights and the unit generator set master switch is in the AUTO position and
shuts down when the local or remote emergency stop the system has no fault conditions.
switch activates.
Not in Auto. The yellow lamp illuminates when the
Battle Switch/Fault Shutdown Override generator set master switch is not in the AUTO position.
Switch See Master (Switch) Not in Auto in 2.3.5 System
Warning Lamp.
The battle switch function forces the system to ignore
normal fault shutdowns such as low oil pressure and 2.3.5 System Warning Lamp
high engine temperature. The battle switch does not
override the emergency stop and overspeed shutdown. The yellow warning lamp illuminates indicating a fault or
When the battle switch function is enabled the generator status event but does not shut down the generator set
set continues to run regardless of shutdown signals under the following conditions. In some cases the alarm
where potential engine/alternator damage can occur. horn also sounds. See Section 2.3.7, Controller Reset
Procedure, for instructions on resetting a system
When this input is enabled the yellow warning lamp warning.
illuminates and stored warning/shutdown events that
are ignored continue to log in Menu 5— Event History. When the system warning lamp is on and no message
displays, press the Reset Menu and the menu down ↓
See Section 2.8.9, Menu 9—Input Setup, for information key to view messages. When the system warning
on how to enable the battle switch feature. continues, it may lead to a fault and cause a system
shutdown.
Cooldown Temperature Override Function. This
feature provides the ability to bypass (override) the Use the Alarm Off keypad switch to silence the alarm
generator set’s smart cooldown temperature shutdown horn at the operator’s discretion. Place the generator
and force the generator set to run for the full engine set master switch in the AUTO position before silencing
cooldown time delay. the alarm horn. The alarm horn cannot be silenced
unless the master switch is in the AUTO position.
TP-6200 10/12 Section 2 Operation 35
Note: Text shown in italics in this manual represents Emergency Power System (EPS) Supplying Load.
digital display messages. The lamp illuminates when the generator set supplies
more than 1% of the rated standby output current. The
AC Sensing Loss. The lamp illuminates when the local display shows EPS supplying load.
controller does not detect nominal generator set AC
output voltage after crank disconnect. The local display Ground Fault Detected. The lamp illuminates and the
shows AC sensing loss. alarm horn sounds when a user-supplied ground fault
detector signals the controller. The local display shows
Battery Charger Fault. The lamp illuminates when the ground fault.
battery charger malfunctions. This fault feature requires
an optional battery charger with a malfunction output for High Battery Voltage. The lamp illuminates when the
the lamp to function. Local display shows bat chgr fault. battery voltage rises above the preset level for more
than 10 seconds. The local display shows high battery
Battle Switch. The lamp illuminates when in the battle voltage. Figure 2-1 shows high battery voltage
switch mode. The local display shows battle switch. specifications. The high battery voltage feature
monitors the battery and battery charging system in the
Breaker Closed. The lamp illuminates when the generator set operating and off modes.
respective circuit breaker is closed. The local display
shows breaker closed. (Paralleling applications only.)
Engine Electrical High Battery High Battery Voltage
System Voltage Voltage Range Default Setting
Breaker Trip. The lamp illuminates when the respective
12 14.5--16.5 16
circuit breaker is tripped. The local display shows
breaker trip. (Paralleling applications only.) 24 29--33 32

Common Protective Relay Output. The lamp Figure 2-1 High Battery Voltage Specs
illuminates when a common protective relay fault
High Coolant Temperature Warning. The lamp
occurs. The local display shows common pr output.
illuminates and the alarm horn sounds when the engine
(Paralleling applications only.)
coolant temperature approaches the shutdown range.
Customer Auxiliary (Warning). The lamp illuminates The local display shows hi cool temp warning.
and the alarm horn sounds when an auxiliary digital or
High Oil Temperature Warning. The lamp illuminates
analog inputs signals the controller. The user can define
and the alarm horn sounds when the engine high oil
inputs as shutdowns or warnings. The local display
temperatuare approaches the shutdown range. The local
shows digital input D01-D21 or analog input A01-A07.
display shows hi oil temp warning (DDC/MTU models with
Using the remote communications package, the user MDEC/ADEC and Waukesha-powered models only).
can label the auxiliary functions. The controller displays
Idle (Speed) Mode. The lamp illuminates when in the
the selected name instead of digital input D01-D21 or
idle (speed) mode. The local display shows idle mode
analog input A01-A07.
active.
Defined Common Faults. The lamp illuminates and
Intake Air Temperature Warning. The lamp illuminates
the alarm horn sounds when one or more of the
and the alarm horn sounds when the engine intake air
(user-selected) defined common faults are energized.
temperature approaches the shutdown range. The local
The local display shows defined common fault.
display shows intake air temp warn (DDC/MTU models
Detonation Warning. The lamp illuminates and the with MDEC/ADEC) and 03 intake air temp warn
alarm horn sounds when the engine detects combustion (Waukesha-powered models).
system detonation. The local display shows deton
Load Shed. The lamp illuminates when the generator
warning. (Waukesha-powered models only.)
set’s total kW load exceeds the programmed level for
ECM Yellow Alarm. The lamp illuminates and the alarm more than the load shed time. When the load shed alarm
horn sounds when ECM yellow alarm signals the sounds and resets more than twice in 1 minute, the load
controller. The local display shows ECM yellow alarm. shed warning lamp circuit latches and remains on until
This fault only relates to the DDC/MTU engine with the generator set shuts down. The local display shows
MDEC/ADEC. The user can navigate the menus to load shed kW over.
access the fault code. The engine operation manual
provides the fault code descriptions.

36 Section 2 Operation TP-6200 10/12

When the generator set frequency drops to less than NFPA 110 Fault. The lamp illuminates and the alarm
59 Hz on a 60 Hz system or 49 Hz on a 50 Hz system for horn sounds when NFPA 110 faults signal the controller.
more than 5 seconds, the local display shows load shed The local display shows the respective fault message.
under freq. When the load shed alarm sounds and The NFPA 110 faults (Warning/Shutdown) include:
resets more than twice in 1 minute, the load shed D Air damper indicator (Factory-Reserved D20) (S)
warning lamp latches and remains on until the generator
D Battery charger fault (Factory-Reserved D01) (W)
set shuts down.
D EPS supplying load (W)
Low Battery Voltage. The lamp illuminates when the D High battery voltage (W)
battery voltage drops below a preset level for more than D High coolant temperature (W)
10 seconds. The local display shows low battery D High coolant temperature (S)
voltage. See Figure 2-2 for low battery voltage D Low battery voltage (W)
specifications.
D Low coolant level (Factory-Reserved D14) (S)
D Low coolant temperature
Engine Electrical Low Battery Low Battery Voltage
System Voltage Voltage Range Default Setting
(Factory-Reserved D03) (W)
D Low fuel (level or pressure)
12 10--12.5 12
(Factory-Reserved D02) (W)
24 20--25 24
D Low oil pressure (W)
Figure 2-2 Low Battery Voltage Specs D Low oil pressure (S)
D Master switch not in auto (W)
The low battery voltage feature monitors the battery and D Overcrank (S)
battery charging system in the generator set operating
D Overspeed (S)
and off modes. The controller logic inhibits the low
battery voltage warning during the crank cycle. No Air Temperature Signal. The lamp illuminates and
the alarm horn sounds when the air temperature sender
Low Coolant Temperature. The lamp illuminates and
circuit is open. The local display shows no air temp
the alarm horn sounds when the engine coolant
signal. (Waukesha-powered models only.)
temperature is low. The local display shows low coolant
temp. No Oil Temperature Signal. The lamp illuminates and
the alarm horn sounds when the oil temperature sender
Low Fuel (Level or Pressure) Warning. The lamp
circuit is open. The local display shows no oil temp
illuminates and the alarm horn sounds when the fuel
signal. (Waukesha-powered models only.)
tank level on gasoline or diesel models approaches
empty or low fuel pressure on gaseous fueled models Oil Temperature. The lamp illuminates and the alarm
occurs. This fault requires an optional low fuel switch for horn sounds when oil temperature approaches the
the lamp to function. The local display shows low fuel shutdown range. The local display shows oil temp.
warning. (Waukesha-powered models only.)
(Low) Oil Pressure Warning. The lamp illuminates and Overcurrent. The lamp illuminates and the alarm horn
the alarm horn sounds when the engine oil pressure sounds when the generator set supplies more than
approaches the shutdown range. The local display 110% of the rated standby output current for more than
shows oil press warning. 10 seconds. The local display shows overcurrent.
Master (Switch) Not in Auto. The lamp illuminates and Speed Sensor Fault. The lamp illuminates and the
the alarm horn sounds when the generator set master alarm horn sounds when the speed signal is absent for
switch is in the RUN or OFF/RESET position. The local one second while the generator set runs. The local
display shows master not in auto. The Not in Auto lamp display shows speed sensor fault. This warning lamp
will also illuminate. remains on until the operator places the master switch in
the OFF/RESET position.

Weak Battery. The lamp illuminates when the battery

voltage falls below 60% of the nominal voltage (12 VDC
or 24 VDC) for more than 2 seconds during the crank
cycle. The local display shows weak battery.

TP-6200 10/12 Section 2 Operation 37

2.3.6 System Shutdown Lamp Defined Common Faults. The lamp illuminates and
the unit shuts down when one or more of the
The red lamp illuminates, the alarm horn sounds, and (user-selected) defined common faults are energized.
the unit shuts down to indicate a fault shutdown under The local display shows defined common fault.
the following conditions. See Section 2.3.7, Controller
Reset Procedure, for information on resetting a system Detonation Shutdown. The lamp illuminates and the
shutdown. unit shuts down when the controller detects combustion
system detonation. The local display shows deton
Use the Alarm Off keypad switch to silence the alarm shutdown. (Waukesha-powered models only.)
horn at the operator’s discretion. Place the generator
set master switch in the AUTO position before silencing ECM Red Alarm. The lamp illuminates and the unit
the alarm horn. The alarm horn will not stop sounding shuts down when the controller receives a signal from
unless the master switch is in the AUTO position. the engine. The local display shows ECM red alarm.
This fault only relates to the DDC/MTU engine with
Note: The text shown in italics represents digital display MDEC/ADEC. The user can navigate the menus to
messages. access the fault code. The engine operation manual
provides the fault code descriptions.
Air Damper Indicator. The lamp illuminates and the
unit shuts down when signaled by a closed air damper EEPROM Write Failure. The lamp illuminates and the
circuit. The local display shows air damper indicator. unit shuts down when the control logic detects a data
save error. The local display shows EEPROM write
Air/Fuel Module. The lamp illuminates and the unit failure.
shuts down when the controller detects a fault with the
air/fuel module. The local display shows afm shutdown. (Engine) J1939 CAN Shutdown. The lamp illuminates
(Waukesha-powered models only.) and the unit shuts down when the control logic detects
an engine ECM communication signal interruption. The
Alternator Protection. The lamp illuminates and the local display shows J1939 CAN shutdown.
unit shuts down because of an alternator overload or
short circuit. The local display shows altrntr protect Engine Stalled. The lamp illuminates and the unit shuts
sdwn. See Appendix D, Alternator Protection for more down when the control logic detects an engine ECM
information. signal that the engine has stalled. The local display
shows engine stalled and no attempts to restart the
Critical Overvoltage. The lamp illuminates and the unit engine will occur.
shuts down when the voltage exceeds 275 volts. The
local display shows critical overvoltage. Emergency Stop. The lamp illuminates and the unit
shuts down when the local or optional remote
For voltages configurations of 240 volts and less, the emergency stop switch activates. The local display
critical voltage shutdown monitors nominal voltage shows emergency stop.
line-to-line. For voltage configurations greater than 240
volts and less than 600 volts, the critical voltage Field Overvoltage. The lamp illuminates and the unit
shutdown monitors nominal voltage line-to-line with a shuts down when the controller detects field
center tap connection. For voltage configurations of overvoltage. The local display shows field over volts.
600 volts and above, the critical voltage shutdown (350--2000 kW generator sets only)
monitors nominal voltage with a stepdown transformer
in the 208--240 voltage range. High Coolant Temperature Shutdown. The lamp
illuminates and the unit shuts down because of high
Customer Auxiliary (Shutdown). The lamp engine coolant temperature. The shutdown occurs
illuminates and the unit shuts down when an auxiliary 5 seconds after the engine reaches the temperature
digital or analog input signals the controller. The user shutdown range. The high engine temperature
can define inputs as shutdowns or warnings. The local shutdown does not function during the first 30 seconds
display shows digital input D01-D21 or analog input after startup. The local display shows hi cool temp
A01-A07 when activated. shutdwn.
Using the remote communications package, the user Note: The high engine temperature shutdown function
can label the auxiliary functions. The controller displays and the low coolant level shutdown function are
the selected name instead of digital input D01-D21 or independent. A low coolant level condition may
analog input A01-A07. not activate the high engine temperature switch.

38 Section 2 Operation TP-6200 10/12

High Oil Temperature. The lamp illuminates and the Low Fuel (Pressure) Shutdown. The lamp illuminates
unit shuts down because of high engine oil temperature. and the unit shuts down when the controller detects a
The shutdown occurs 5 seconds after the engine oil low fuel condition. The low fuel (pressure) shutdown
reaches the temperature shutdown range. The high does not function during the first 5 seconds after startup.
engine oil temperature shutdown does not function The local display shows low fuel shdown. (125RZG
during the first 30 seconds after startup. The local only.)
display shows high oil temp sdwn.
(Low) Oil Pressure Shutdown. The lamp illuminates
Intake Air Temperature. The lamp illuminates and the when the unit shuts down because of low oil pressure.
unit shuts down because of high intake air temperature. The shutdown occurs 5 seconds after the low pressure
The shutdown occurs 5 seconds after the engine intake condition is detected. The low oil pressure shutdown
air reaches the temperature shutdown range. The does not function during first the 30 seconds after
engine intake air temperature shutdown does not startup. The local display shows (low) oil press
function during the first 30 seconds after startup. The shutdown.
local display shows intake air temp shutdown
(DDC/MTU models with MDEC/ADEC) and 03 intake air Master Switch Error. The lamp illuminates and the unit
temp shutdown (Waukesha-powered models). shuts down when the controller detects a fault in the
master switch position or circuit. The local display
Internal Fault. The lamp illuminates and the unit shuts shows master switch error.
down when the internal diagnostics detect a controller
malfunction. The local display shows internal fault. Master Switch Open. The lamp illuminates and the unit
shuts down when the controller detects an open circuit in
Knock Shutdown. The lamp illuminates and the unit the master switch circuit. The local display shows
shuts down when the controller detects a detonation master switch open.
fault. The local display shows knock shutdown.
(Waukesha-powered models only.) Master Switch to Off. The lamp illuminates and the unit
shuts down when the master switch is moved to the off
Locked Rotor. If none of the speed sensing inputs position. The local display shows master switch to off.
show engine rotation within 5 seconds of initiating
engine cranking, the ignition and crank circuits turn off NFPA 110 Fault. The lamp illuminates and the unit
for 5 seconds and the cycle repeats. The unit shuts shuts down when NFPA 110 faults signal the controller.
down after the second cycle of 5 seconds of cranking. The local display shows the respective fault message.
The local display shows locked rotor. See Section 2.4, Menu List Summary, Menu 10—Output
Setup, for the NFPA 110 list.
Loss of ECM Communications. The lamp illuminates
and the unit shuts down when the ECM communication No Coolant Temperature Signal. The lamp illuminates
link is disrupted. The local display shows loss of ECM and the unit shuts down when the engine coolant
comm. temperature sender circuit is open. The local display
shows no cool temp signal.
Loss of Field (Reverse VARs). The lamp illuminates
and the unit shuts down when the reactive current into No Oil Pressure Signal. The lamp illuminates and the
the alternator (absorbing) exceeds the shutdown level. unit shuts down when the engine oil pressure sender
This could be caused by a disruption of the field signal. circuit is open. The local display shows no oil press
The local display shows sd loss of field. (Paralleling signal.
applications only.)
Overcrank. The lamp illuminates and cranking stops
Low Coolant Level. The lamp illuminates and the unit when the unit does not start within the defined cranking
shuts down because of low coolant level. Shutdown period. The local display shows overcrank. See
occurs 5 seconds after low coolant level is detected. Section 2.3.1, Auto Starting, and Section 1,
Low coolant level shutdown is inhibited during the first 30 Specifications and Features, for cyclic crank
seconds after startup. Local display shows low coolant specifications.
lvl.
Note: The controller is equipped with an automatic
Low Coolant Temperature. The lamp illuminates and restart function. When speed drops below 13 Hz
the unit shuts down because of low coolant temperature. (390 rpm) while the engine is running, the unit
Shutdown occurs 5 seconds after low coolant attempts to recrank. The unit then follows the
temperature is detected. Low coolant temperature cyclic cranking cycle and, when the engine fails to
shutdown is inhibited during the first 30 seconds after start, will shut down on an overcrank fault
startup. Local display shows low coolant temp condition.
shutdown. (DDC/MTU models with MDEC/ADEC only.)

TP-6200 10/12 Section 2 Operation 39

Over Current VR Shutdown. The lamp illuminates and Overvoltage
the unit shuts down when the controller detects an Overvoltage Time Default Setting Overvoltage
overcurrent fault with voltage restraint. The local display Setting Delay without Default Setting
shows sd over current pr. (Paralleling applications only.) Range Range Paralleling with Paralleling
105%--135%
2--10 sec. 115% at 2 sec. 135% at 10 sec.
Overfrequency. The lamp illuminates and the unit of nominal
shuts down when the frequency is above the
overfrequency setting. The local display shows Figure 2-5 Overvoltage Specs
overfrequency. See Figure 2-3.
Reverse Power. The lamp illuminates and the unit
shuts down when the controller detects a reverse power
Overfrequency Overfrequency condition. The reverse power relay senses AC power
Setting Range Time Delay Default Setting
flow into the generator set. If the generator set is being
102%--140% of nominal 10 sec. 110% of nominal feed power or being ”motored” by another generator set
or the utility, the reverse power relay senses this AC
Figure 2-3 Overfrequency Specs power flow and opens the generator set circuit breaker.
The local display shows sd reverse power. (Paralleling
Overpower. The lamp illuminates and the unit shuts
applications only.)
down when the controller detects a fault in the paralleling
system. The shutdown is set at 102% for standby and Underfrequency. The lamp illuminates and the unit
112% for prime power applications. The local display shuts down when the frequency falls below the
shows over power. (Paralleling applications only.) underfrequency setting. The local display shows
underfrequency. See Figure 2-6.
Overspeed. The lamp illuminates and the unit shuts
down immediately when the governed frequency on 50
and 60 Hz models exceeds the overspeed setting for Underfrequency
0.25 seconds. The local display shows overspeed. See Underfreq. Default Setting Underfrequency
Setting Time without Default Setting
Figure 2-4 for overspeed specs. Ranger Delay Paralleling with Paralleling

80%--95%
Generator Overspeed Overspeed Default 10 sec. 90% of nominal 80% of nominal
of nominal
Set Time Delay Range Hz Setting Hz
Frequency Hz Figure 2-6 Underfrequency Specs
60 0.25 sec. 65--70 70
Undervoltage. The lamp illuminates and the unit shuts
50 0.25 sec. 55--70 70 down when the voltage falls below the undervoltage
setting for the time delay period. The local display shows
Figure 2-4 Overspeed Specs
undervoltage. Undervoltage specifications follow. See
Overvoltage. The lamp illuminates and the unit shuts Figure 2-7.
down when the voltage exceeds the overvoltage setting
for the time delay period. The local display shows Undervoltage
overvoltage. Overvoltage specifications follow. See Undervoltage Default Setting Undervoltage
Setting Time Delay w-o/Parallelin Default Setting
Figure 2-5.
Range Range g w/Paralleling

Note: Overvoltage can damage sensitive equipment in 70%--95% of

5--30 sec.
85% of nominal 70% of nominal
less than one second. Install separate nominal at 10 sec. at 30 sec.
overvoltage protection on online equipment
Figure 2-7 Undervoltage Specs
requiring faster than 2-second shutdown.

40 Section 2 Operation TP-6200 10/12

2.3.7 Controller Resetting (Following 8. Move the generator set master switch to the AUTO
System Shutdown or Warning) position.

Use the following procedure to restart the generator set 9. Silence the controller alarm horn by pressing the
after a system shutdown or to clear a warning lamp alarm off key.
condition. This procedure includes the resetting of the
optional remote annunciator and the audiovisual alarm. 10. Reconnect the generator set load via the line circuit
breaker or automatic transfer switch.
Refer to Section 2.3.3, Emergency Stop Switch Reset
Procedure, to reset the generator set after an 11. Move the generator set master switch to the AUTO
emergency stop. position for startup by the remote transfer switch or
the remote start/stop switch.
1. Move the generator set master switch to the AUTO When equipped, move the remote annunciator
position, if not already done. and/or audiovisual alarm switch to the NORMAL
position.
2. Silence the controller alarm horn by pressing the
alarm off key.
2.4 Menu List Summary
When equipped, the optional remote annunciator
and/or audiovisual alarm horn and lamp activate. Use the Menu List Summary section on the following
Move the alarm switch to the SILENCE position to pages after reading and understanding the features of
stop the alarm horn. The lamp stays lit. the keypad. See Section 1.2.2, Digital Display and
Keypad.
3. Disconnect the generator set load using the line
circuit breaker or automatic transfer switch. The Menu List Summary provides a quick reference to
the digital display data. Some digital display data may
4. Correct the cause of the fault shutdown or warning. not be identical to your display due to generator set
See the Safety Precautions and Instructions application differences. The closed bullet items
section of this manual before proceeding. represent main level data and the open bullet items are
sub-level data.
5. Start the generator set by moving the generator set
master switch to the OFF/RESET position and then Section 2.7, Reviewing the Menu Displays, provides a
to the RUN position. digital display menu overview and explains the
When equipped, the remote annunciator and/or navigation using the down and right arrow keys.
audiovisual alarm horn sounds when the alarm
switch is in the NORMAL position. When Section 2.8, Local Programming Mode On, contains the
necessary, move the alarm switch to the SILENCE keystroke details of each menu when programming.
position to stop the alarm horn. The lamp turns off.
User Inputs. Available user inputs are dependent on
6. Test operate the generator set to verify correction factory-reserved inputs for specific engine types, engine
of the shutdown cause. controls, and paralleling applications. See Figure 2-8
for analog and digital inputs that are not user-selectable.
7. Move the generator set master switch to the
OFF/RESET position to stop the generator set.

TP-6200 10/12 Section 2 Operation 41

 Specific Applications
Waukesha- with Menu 15 DDC/MTU Other
Input Non-ECM Powered (Paralleling Engine with Specialized
Type ECM Engine Engine NFPA 110 Engine Application) MDEC/ADEC Application
Analog Inputs
Coolant Coolant
A1 X X X X X
Temperature * Temperature *
A2 X Oil Pressure * X Oil Pressure * X X X
Intake Air
A3 X X X X X X
Temperature *
Oil
A4 Fuel Level * Fuel Level * Fuel Level * Temperature Fuel Level * Fuel Level * Fuel Level *
Warning *
A5 X X X X X X X
A6 X X X X X X X (8) *
A7 (9) Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust Voltage Adjust
Digital Inputs
D1 X X Battery Charger Fault * X X X X
D2 X X Low Fuel Warning * X X X X
Low Coolant
D3 X Low Coolant Temp.* X X X X
Temp.
D4 X X X X X X X (1) *
Breaker
D5 X X X X X X
Closed *
D6 X X X X Enable Synch * X X
D7 X X X X X X X
D8 X X X X X X X
D9 X X X X X X X (2) *
D10 X X X X X X X
AFM
D11 X X X X X X
Shutdown *
Deton
D12 X X X X X X
Warning *
Deton/Knock
D13 X X X X X X
Shutdown *
Low Coolant Level
D14 X X X X X X
(with LCL Switch) *
D15 X X X X X X X (3) *
D16 X X X X X X X (4) *
D17 X X X X X X X (5) *
D18 X X X X X X X (6) *
D19 X X X X X X X (7) *
D20 X X Air Damper * X X X X
Idle Mode
D21 X X X X X X
Active
(1) D4 is preassigned as Field Overvolts when using a Marathon M4/M5/M7/M10 alternator.
(2) D9 is preassigned as Low Fuel Shutdown when using 125RZG (GM powered).
(3) D15 is preassigned as Remote Shutdown.
(4) D16 is preassigned as Remote Reset.
(5) D17 is preassigned as VAR/PF mode.
(6) D18 is preassigned as Voltage Lower.
(7) D19 is preassigned as Voltage Raise.
(8) A6 is preassigned as Variable Speed Governor (VSG) (Volvo, GM, and Doosan engines only)
(9) A7 is default location, however the default function is not Analog Voltage Adjust; the function must be enabled. See Section 1.3.3.
* Factory-reserved inputs that are fixed and not user-changeable.

Figure 2-8 User Inputs (X) and Factory-Reserved Inputs (as shown)

42 Section 2 Operation TP-6200 10/12

Menu List Summary (Legend: D First level submenu, d second level submenu)
Menu 1 Menu 2 Menu 2 Menu 4
Generator Monitoring Engine Monitoring Engine Monitoring, cont. Operational Records
Volts & Amps Engine Monitoring Basic Engine Monitoring D Factory Test Date
D L1-L2 Volts D Oil Pressure Detailed (MDEC/ADEC D Total Run Time
L1 Amps Coolant Temperature equipped engines only) D Total Run Time
D L2-L3 Volts D Intake Air Temperature Engine Fuel Loaded Hours
L2 Amps (3 phase) Oil Temperature D Fuel Pressure D Total Run Time
D L3-L1 Volts (DDC/MTU engine with Fuel Temperature Unloaded Hours
L3 Amps (3 phase) MDEC/ADEC and D Charge Air Pressure D Total Run Time
D L1-L2 Volts Waukesha engine only) Charge Air Temperature kW Hours
L2 Amps (1 phase) D Engine RPM D Fuel Rate D No. of Starts
D L1-L0 Volts Local Battery VDC D Daily Fuel Used D Engine Start Countdown
L1 Amps D High Coolant D Total Fuel Used d Run Time
D L2-L0 Volts Temperature Shutdown Engine Oil D Records-Maintenance
L2 Amps and Warning Setpoints D Oil Pressure d Reset Records
D L3-L0 Volts D Low Oil Pressure Oil Temperature D Run Time Since Maintenanc
L3 Amps (3 phase) Shutdown and Warning Engine Misc Total Hours
D Frequency Setpoints
D ECU Supply VDC D Run Time Since Maintenanc
V & A Summary D Engine Warmup Ambient Temperature Loaded Hours
Temperature Setpoint
D V L1-L2, L2-L3, L3-L1 D ECU Hours D Run Time Since Maintenanc
D Engine Cooldown
(3 phase) D ECU Fault Codes Unloaded Hours
Temperature Setpoint
D V L1-L0, L2-L0, L3-L0 D Run Time Since Maintenanc
(3 phase) Engine Monitoring Menu 3 kW Hours
D A L1, L2, L3 (3 phase) Detailed (DDEC/JDEC/ Analog Monitoring D Operating Days
EMS2/EDC3 equipped
D V L1-L2, L1-L0, L2-L0 D Local Batt VDC Last Maintenance
engines only)
(1 phase) D Analog 01 to 07 (user- D No. of Starts
Engine Fuel
D A L1, L2 (1 phase) defined descriptions) Last Maintenance
D Fuel Pressure D Last Start
Power kW (Scroll through 7 user-
Fuel Temperature Date
D Total kW defined descriptions. See
D Charge Air Pressure D Length of Run
Power Factor Figure 2-8 in User Inputs
Charge Air Temperature (Un)loaded Hours
D L1 kW for factory-reserved inputs
D Fuel Rate
Power Factor that are not user-
D Used Last Run Menu 5
D L2 kW selectable.)
Power Factor Engine Coolant Non-ECM Engines Event History
D L3 kW D Coolant Pressure D A03--A07 User-Defined D (Message Text)
Coolant Temperature
Power Factor (3 phase) ECM Engines D (Scroll through up to 100
D Total kW D Coolant Level
D A01 Coolant Temperature stored events)
% of Rated kW Engine Oil
D A02 Oil Pressure
Power kVAR D Oil Pressure Menu 6
D A03--A07 User-Defined
D Total kVAR Oil Temperature Time and Date
D A06 VSG (Doosan, GM,
Absorbing/Generating D Oil Level
Crankcase Pressure
Volvo only) D Time 00:00 AM/PM
D L1 kVAR Waukesha Engines D Date
Absorbing/Generating Engine Misc
D A05--A07 User-Defined
D L2 kVAR D ECM Battery VDC
Absorbing/Generating Ambient Temperature
D L3 kVAR D Engine Model No.
Absorbing/Generating D Engine Serial No.
(3 phase) D Unit No.
Power kVA ECM S/N
D Total kVA D ECM Fault Codes
D L1 kVA
D L2 kVA
D L3 kVA (3 phase)

TP-6200 10/12 Section 2 Operation 43

Menu List Summary, continued (Legend: D First level submenu, d second level submenu)
Menu 7 Menu 9 Menu 9 Menu 10
Generator System Input Setup Input Setup, cont. Output Setup, cont.
D Operating Mode Setup Digital Setup Analog Relay Driver Outputs
d Standby Y/N Auxiliary Inputs Auxiliary Inputs (RDOs)
d Prime Power N/Y D Digital Input D Analog Input D RDOs (Y/N)
D System Voltage (Scroll through up to 21 (Scroll through up to 7 (Scroll through up to
Line-Line user-defined user-defined descriptions. 31 status and fault choices
D System Frequency descriptions. See See Figure 2-8 in User from:
D Phase Figure 2-8 in User Inputs Inputs for factory-reserved d System events,
for factory-reserved inputs that are not user- see Group B
d 3-Phase Delta Y/N
inputs that are not user- selectable.) d 21 digital inputs
d 3-Phase WYE N/Y selectable.) D Analog Input D01-D21
d 1-Phase N/Y D Digital Input Warning Enabled Y/N d 7 analog inputs
D kW Rating Message Text Y/N, D Analog Input A01--A07
D Rated Current see Group A Shutdown Enabled Y/N Group B
D Load Shed Output Group A D Analog Input System events include the
d Time Delay Preprogrammed Inhibit Time 0--60 Sec. following:
D Overvoltage selections include the D Analog Input Emergency Stop
d Time Delay following: Warning Delay Time Over Speed
D Undervoltage Warning 0--60 Sec.
Overcrank
d Time Delay Shutdown Type A D Analog Input
High Cool Temp Shutdown
D Overfrequency Shutdown Type B Shutdown Delay Time
0--60 Sec. Oil Pressure Shutdown
D Underfrequency Voltage Raise
Low Coolant Temperature
D Overspeed D Analog Input
Voltage Lower (non-ECM engines)
Low Shutdown Value
D Battery Voltage VAR PF Mode Low Fuel Warning
D Analog Input
d 12 VDC Y/N Remote Shutdown Hi Cool Temp Warning
Low Warning Value
d 24 VDC N/Y Remote Reset D Analog Input Oil Pressure Warning
D Low Battery Voltage Air Damper High Warning Value Master Not in Auto
D High Battery Voltage Low Fuel D Analog Input NFPA 110 Fault[
D Block Heater ON [ Field Overvoltage High Shutdown Value [The 15 NFPA 110 Common
D Block Heater OFF [ Idle Mode Active Fault Alarms include the
D Enable VSG Y/N [ (ECM engines only) Menu 10
following:
D Enable DSC [ Battle Switch Output Setup
Over Speed
D Metric Units Y/N Ground Fault Defined Common Fault Overcrank
D Set NFPA110 Defaults Y/N Bat Chgr Fault D Defined Common Fault High Coolant Temperature
[ DDC/MTU engine (Y/N for a single defined
High Oil Temperature Shutdown
w/MDEC/ADEC only common fault)
(non-ECM only) Oil Pressure Shutdown
Menu 8 Low Coolant Level Scroll through status and
Low Coolant Temperature
Time Delays fault choices from:
Low Coolant Temperature High Coolant Temperature
D Time Delay (Not user-selectable) d System events,
Warning
Engine Start see Group B (except
Breaker Closed, (Paralleling Oil Pressure Warning
D Time Delay non-selectable)
Defined Common Fault)
Starting Aid d 21 digital inputs Low Fuel
Enable Synchronizer, Master Not In Auto
D Time Delay (Paralleling
D01-D21
Crank On d 7 analog inputs Battery Charger Fault
non-selectable)
D Time Delay A01--A07 Low Battery Voltage
Air/Fuel Module Shutdown*
Crank Pause HIgh Battery Voltage
Knock Shutdown*
D Time Delay Low Coolant Level
Eng. Cooldown Detonation Warning*
EPS Supplying Load
D Cooldown Temperature Detonation Shutdown*
Air Damper Indicator
Override Y/N Low Fuel Shutdown
D Overcrank Shutdown D Digital Input
Crank Cycles Enable Y/N
D Time Delay D Digital Input
Overvoltage Inhibit TIme
D Time Delay D Digital Input
Undervoltage Delay Time
*Waukesha engine only
D Time Delay
Load Shed kW

44 Section 2 Operation TP-6200 10/12

Menu List Summary, continued (Legend: D First level submenu, d second level submenu)
Menu 10 Menu 10 Menu 11 Menu 12
Output Setup, cont. Output Setup, cont. Voltage Regulator Calibration
Group B, continued Group B, continued AVG L-L V Scale AC Analog
Low Battery Voltage Reverse Power Shutdown[ Volt ADJ Inputs
High Battery Voltage Over Power Shutdown[ D L1-L2 Volts Generator Set Voltage LN
Battery Charger Fault Loss of Field Shutdown[ D L2-L3 Volts (3 phase) D Gen L1-L0 V
System Ready Overcurrent VR Shutdown[ D L3-L1 Volts (3 phase) Calibration Reference
Loss of ECM Comm Common Protective Relay Under Freq. Unload D Gen L2-L0 V
(ECM engines) Output[ Enabled N/Y Calibration Reference
No Oil Pressure Signal In Synchronization[ D Frequency D Gen L3-L0 V (3 phase)
Setpoint (Cut-In Point) Calibration Reference
High Oil Temperature Breaker Trip[
Shutdown D Slope Generator Set Voltage LL
Fuel Valve Relay*
No Temperature Signal Prelube Relay*
Volts-Per-Cycle D Gen L1-L2 V
Reactive Droop Calibration Reference
Low Coolant Level Air/Fuel Module Remote
Enabled N/Y D Gen L2-L3 V (3 phase)
Speed Sensor Fault Start*
D Voltage Droop at 0.8 PF Calibration Reference
Locked Rotor No Oil Temperature Signal* Rated Load D Gen L3-L1 V (3 phase)
Master Switch Error High Oil Temperature VAR Control Calibration Reference
Master Switch Open Warning*] Enabled N/Y D Calibrate Regulator Y/N
Master Switch to Off No Air Temperature Signal* D Total kVAR (Running) Generator Set Amps
AC Sensing Loss Intake Air Temperature kVAR Adj
Warning*] D Gen L1 Amps
Over Voltage D Generating/Absorbing Y/N Calibration Reference
Under Voltage Intake Air Temperature PF Control D Gen L2 Amps
Weak Battery Shutdown*] Enabled N/Y Calibration Reference
Air/Fuel Module Engine D Average PF
Over Frequency D Gen L3 Amps (3 phase)
Start Delay* PF Adjustment
Under Frequency Calibration Reference
ECM Yellow Alarm] D Lagging/Leading Y/N
Load Shed kW Over Load Voltage LN
ECM Red Alarm] Regulator Gain Adj.
Load Shed Under Freq (Paralleling Applications
Block Heater Control] D Gain only)
Over Current
Low Coolant Temperature Utility Gain Adj. D Load L1--L0 V
EPS Supplying Load
Shutdown] D Gain Calibration Reference
Internal Fault
Load Shed Analog Voltage Adjust D Load L3--L0 V
Delay Engine Cooldown Overtemperature] Enabled N/Y Calibration Reference
Delay Engine Start Maintenance Due Reset Regulator Defaults? Restore Defaults? Y/N
Starting Aid Engine Derate Active
Generator Set Running Scale Aux. Analog
Engine Stalled
Air Damper Control Inputs
(ECM engines)
Ground Fault D Zero Aux. Analog
J1939 CAN Shutdown
Inputs?
EEPROM Write Failure (ECM engines)
(Scroll through up to 7
Critical Overvoltage *Waukesha engine user-defined
Alternator Protection [Paralleling applications descriptions. See
Air Damper Indicator ]DDC/MTU engine with Figure 2-8 in User Inputs
Defined Common Fault MDEC/ADEC for factory-reserved
(RDO only) inputs that are not user-
SCRDOs 1--4 (Software- selectable.)
Controlled RDOs) D Analog 01
Scale Value 1
d Scale 1 V
Scale 2 V
D Analog 01
Scale Value 2
d Scale 1 V
Scale 2 V

TP-6200 10/12 Section 2 Operation 45

Menu List Summary, continued (Legend: D First level submenu, d second level submenu)
Menu 13 Menu 14 Menu 20 Menu 55
Communications Programming Mode Factory Setup Menu Load Factor
Protocol D Programming Mode D Final Assembly Date D 100%--125% Load
KBUS d Local? Y/N DD/MM/YY Factor
D KBUS Online Y/N d Remote? Y/N D Final Assembly Clock No. Hours
D Connection Type d Off? Y/N D Operating Days D 126%--150% Load
(User-defined) D Programming Mode D Model No. Factor
d Local Single Y/N Change, Access Code D Spec No. Hours
d Local LAN Y/N D Generator Set Serial No. D 151%--200% Load
d Enter Old Code
d Local LAN Conv Y/N D Alternator Part No. Factor
d Enter New Code
Hours
d Remote Single Y/N D Engine Part No.
D 201%+ Load Factor
d Remote LAN Y/N Menu 15 D Temp Sensor
Hours
d Remote LAN Conv Paralleling Relays (PR) d GM31045-X
Y/N Purchased Option d GM16787
D Primary Port D PR Overvoltage VAC d GM17362
(User-defined) D Serial No. Confirm
d Time Delay Seconds
d RS-232 Y/N d Confirm Serial?
D PR Undervoltage VAC
d RS-485 ISO1 Y/N D Controller Serial No.
d Time Delay Seconds
D Address D Code Version
D PR Overfrequency Hz
(LAN Connections) D Setup Locked
d Time Delay Seconds
D System ID
D PR Underfrequency Hz
(Remote Connections)
D BAUD Rate d Time Delay Seconds
(User-defined) D PR Reverse Power kW
d BAUD Rate d Time Delay Seconds
1200 D SD Reverse Power kW
2400 d Time Delay Seconds
9600 D PR Over Power kW
Protocol d Time Delay Seconds
Modbus D SD Over Power kW
D Modbus Online N/Y d Time Delay Seconds
D Connection Type D PR Loss of Field kVAR
(User-defined) d Time Delay Seconds
d Single Y/N D SD Loss of Field kVAR
d Convertor Y/N d Time Delay Seconds
D Primary Port D PR Overcurrent Amps
d RS-485 d Time Delay Seconds
d RS-232 D SD Overcurrent Amps
D Address d Time Delay Seconds
D BAUD Rate D Synchronization
(User-defined) d Synch Voltage Match
d 9600 VAC
d 19200 d Synch Freq. Match
Hz
d Synch Phase Match
Degrees
d Time Delay Seconds

46 Section 2 Operation TP-6200 10/12

2.5 Reviewing Digital Display Enter ↵ Key. Press the enter ↵ key to confirm the
entered information on the display when selecting
The user interacts with the controller with a keypad and menus or programming.
digital display. Use the keypad to access the generator
set informational data and preset settings. This review Lamp Test Key. Press the lamp test key to check that
section shows how to access the data. See Section 2.8, the status and fault lamps illuminate, the horn sounds,
Local Programming Mode On, for instructions on how to and the digital display clears. Press the reset menu key
change the information. See Figure 2-9 for an before pressing the lamp test key.
illustration of the digital display and keypad.
Menu Down ↓ Key. The controller displays consist of
menus with various data levels or programming steps.
Use the menu down ↓ key to navigate through the menu
levels.

Note: Pressing the menu down ↓ key in some menus

locks the user into that level structure of the menu
where the display will not change. Press the reset
menu key to access other main menus.

Menu Right → Key. Press the menu right → key to

scroll through sub-levels of each main menu. The
display contains an arrow in the right-hand corner when
there is a sub-level. Pressing the menu right → key
when no arrow is present moves to the next submenu
header. Press the menu right → key prior to entering
decimal values when required.

Note: Pressing the menu right → key in some menus

TP-5829-2
locks the user into that level structure of the menu
Figure 2-9 Digital Display and Keypad where the display will not change. Press the reset
menu key to access other main menus.
Note: After energizing the controller by reconnecting
the battery, set the controller time and date. See Numeric 0--9 Keys. Press the numeric keys when
Section 2.8.6, Local Programming Mode On, selecting menus or entering numeric values during
Menu 6—Time and Date. programming. The controller ignores the secondary
function of the key (yes, no, etc.) when only numeric
Pressing any key on the keypad activates the controller values are valid.
panel display. The panel lamps and display turn off
5 minutes after the last keypad entry. Reset Menu Key. The reset menu key exits a menu,
clears incorrect entries, and cancels the auto-scroll
2.5.1 Keypad Operation function. Press the reset menu key to exit a menu or any
layer within that menu.
Use the keypad to enter information into the controller.
Some of the keys have two functions. The following Stop Prog Run Key. Press the stop prog run key to end
gives keypad definitions and functions. the generator set programmed exercise run created in
Menu 4—Operational Records. The generator set shuts
Alarm (Horn) Off Key. Press the alarm off key to
down after the time delay for engine cooldown expires.
silence the horn at the user’s discretion. Place the
The stop prog run key does not affect the programmed
generator set master switch in the AUTO position before
transfer switch exercise function.
silencing the alarm horn. The alarm horn cannot be
silenced unless the master switch is in the AUTO Yes/No Keys. When the controller displays a question
position. See Section 2.3.7, Controller Reset Procedure, during programming requiring a nonnumeric answer (yes
for more information on turning the alarm horn off. or no), the controller accepts the secondary key function
and ignores the numeric value of the key. Press the
AM/PM Key. When the controller displays a question
ENTER key to confirm the response.
during programming requiring a nonnumeric answer (am
or pm), the controller accepts the secondary key function
and ignores the alarm off function of the key.

TP-6200 10/12 Section 2 Operation 47

2.5.2 Auto-Scroll Function Error Messages
The auto-scroll function continuously shows voltage and When an error message appears, the entered
current data from Menu 1—Generator Monitoring, V & A information is not within the allowable parameters set by
Summary without the need to press the down arrow for the control firmware or is not permitted as described
each display. below. In cases where the data was outside the
parameters, press the Reset Menu key and enter the
For auto-scroll function press ENTER at the V & A corrected information.
Summary menu. Press the Reset Menu key or Menu
Right → key to stop the auto-scroll function. Access Denied appears when the user attempts to:

D Enter data prohibited by the master switch position,

2.5.3 Request and Error Messages D Enter data prohibited by the generator set state, or
Note: When EEPROM errors occur or initializing the D Enable the LDD (load disturbance detection).
EEPROM is required, contact an authorized
distributor/dealer. Access Denied Idle Mode Active appears when the
user attempts to modify the voltage regulator setup while
the idle mode is active.
Request and Status Messages
Alarm Active appears when the user attempts to modify
Display messages require the user to enter additional
an analog or a digital input that is active. See Menu
data, confirm the previous entry or require time to
9—Input Setup.
process as described below.
Cannot Change (because the) NFPA is Enabled
Entry Accepted appears for several seconds after
appears when the user attempts to modify an RDO
pressing the Enter key during the programming mode.
setting that is a NFPA 110 default requirement.
The display then shows the new data.
Cannot Change Preset appears when the user
Initialize EEPROM? Prompt to confirm EEPROM
attempts to change the factory preset analog input,
initialization.
digital input, or input parameter.
Reset Complete indicates the user has successfully:
EEPROM Write Error appears when a component
D Reset the maintenance records or failure occurs. Contact an authorized distributor/dealer.
D Restored the AC analog inputs to the default settings.
Entry Unacceptable appears when the user attempts
D Restored voltage regulator settings to the defaults.
an invalid input to the voltage regulator setup.
Right Arrow → directs the user to the next menu. The
Some alternators are intended to operate within a
menus loop; press the right arrow key to move to the
specific, limited range of conditions (voltage, frequency,
next menu.
and phase or connection). The following error messages
Setup Complete indicates the completion of the analog can appear when attempts are made to enter system
input setup. values that do not match acceptable conditions for the
particular alternator.
Setup Locked appears when user attempts to change a
value or perform a function available only when the D Fixed Frequency when entry is beyond the range of
system is unlocked. limited entries for the respective alternator. Occurs
when the alternator is not rated for the value entered.
Setup Unlocked appears when user has unlocked the Updated parameter files may be available by
system for maintenance or troubleshooting. contacting an authorized service dealer/distributor.

(Question) ? asked by the control firmware; answer the D Fixed Phase when entry is beyond the range of
question by pressing the yes/no, numeric digit, or am/pm limited entries for the respective alternator. Occurs
key. when the alternator is not rated for the value entered.
Updated parameter files may be available by
Wait for System Reset (6 Sec) appears while the contacting an authorized service dealer/distributor.
EEPROM initializes.

48 Section 2 Operation TP-6200 10/12

D Fixed Voltage when entry is beyond the range of Range Error appears when the user attempts to enter:
limited entries for the respective alternator. Occurs D A numeric input that is not within the acceptable range
when the alternator is not rated for the value entered. of the system settings, time delays, addresses, etc.
Updated parameter files may be available by
D An invalid analog or digital input number.
contacting an authorized service dealer/distributor.
D An invalid date/time.
Func (Function) Used by (RDO) XX Reassign?
appears when the user attempts to assign an RDO to a Remove Load appears when trying to calibrate the
function already assigned. voltage regulator in menu 12 with load connection. The
voltage regulation calibration must be performed during
Internal Error appears when controller logic detects a a no load condition.
functional sequence error.
Setpoint Values Cannot be Equal appears when the
Invalid Code appears when the user attempts to enter: user attempts to enter the same value for both setpoints
during the analog input calibration.
D An invalid access code for programming mode setup,
or
D An invalid access code for setup unlock. 2.6 Monitoring and Programming
Setup
Invalid Menu ID appears when the user attempts to
enter a menu number that is unavailable or non- The user can access the controller data with the
functional. controller keypad and display or a personal computer
(PC) with optional software to monitor and/or program.
N/A appears when data to be displayed is not available. Access the controller system with a PC using local
(direct) or remote (modem) systems. Refer to the
No Input Assigned appears when the user attempts to
Introduction, List of Related Materials for related
assign any of the following system faults to an RDO
software literature. See Menu 13—Communications.
where the digital input is not defined. See digital input
scale requirements in Menu 12—Calibration. The user can access the controller data while in the
programming mode off or programming mode on. See
D Air damper indicator
Menu 14—Programming Mode.
D Battery charger fault
D Ground fault While this manual focuses on data access and
D High oil temperature shutdown programming through the controller keypad and display,
some data entries require input using a PC for initial
D Low coolant level
setup. The PC entries typically include alpha characters
D Low fuel such as digital input descriptions. The individual menus
in Section 2.8, Local Programming Mode On, indicate
Not in Local Program Mode appears when the user where data requires entry using a PC.
attempts to program using the keypad when the
programming mode is set for remote or off. There are six basic configurations for data monitoring
and programming using access source options. See
Not User-Selectable appears when the user attempts Figure 2-13.
to change an analog or digital input that is factory-
reserved. Items identified as not user-selectable are Other combinations of data monitoring and
included for specific applications. (Example: AFM programming are possible but require programming
SHUTDOWN is enabled with a Waukesha-powered from a single location. Figure 2-13, Monitoring and
model.) The user cannot disable an analog or digital Programming Configurations, briefly describes the
input when identified as not user-selectable. See settings of Menu 13—Communications and Menu 14—
Figure 2-8 in User Inputs for factory-reserved digital Programming Mode based on user-selected operating
and analog inputs that are not user-selectable. mode.
Output in Use appears when the user attempts to Use the keypad and digital display to setup the access
modify or reassign an active RDO. configurations the first time. Go to Section 2.8, Local
Programming Mode On, and set the desired
Port in Use appears when the user attempts to use an selection in Menu 13—Communication and Menu 14—
already assigned communications port. Programming Mode before accessing data.

TP-6200 10/12 Section 2 Operation 49

2.6.1 PC Communications Local Area Network (LAN)
There are four ways to communicate between a PC and A PC connects to the device’s LAN. A LAN is a system
the generator set and/or transfer switch devices using that connects more than one device to a single PC.
KBUS communication protocol. The PC connections Acceptable devices include the Decision-Makerr 550
require optional software and possibly other hardware, controller, Decision-Makerr 340 controller, M340
communication modules in the generator set controller transfer switch control, M340+ transfer switch control,
and/or transfer switch. See the monitor software and PM340 power monitor. See Figure 2-12.
operation manual for details. Contact your authorized
distributor/dealer for availability.
Generator Set
Controller,
Local Single Connection Transfer Switch
Control, or
A PC connects to the COM port of the controller module Power Monitor
using an RS-232 cable when the PC is within 15 m Generator Set
(50 ft.) of the device or an RS-485 cable when the PC is Controller,
within 1220 m (4000 ft.) of the device. See Figure 2-10 Transfer Switch
Control, or
or Figure 2-11. Power Monitor
RS-232 to RS-485
port converter
Generator Set
RS-485 Controller,
Personal up to Transfer Switch
Computer 1220 m Control, or
(4000 ft.) Power Monitor
Generator Set
Controller, Generator Set
Transfer Switch Controller,
Control, or Transfer Switch
Power Monitor Control, or
RS-232 Power Monitor
Personal up to
Computer 15 m (50 ft.)

Figure 2-12 Local Area Network

Figure 2-10 Local Single Connection,
up to 15 m (50 ft.) The 550 controller can be used as an RS-232 to RS-485
port converter in a LAN network if the 550 controller is
located within 15 m (50 ft.) of the PC. This configuration
is the Local LAN Conv option.

Generator Set
Controller,
RS-232 to RS-485
Transfer Switch
port converter
Control, or
RS-485 Power Monitor
Personal up to
Computer 1220 m
(4000 ft.)

Figure 2-11 Local Single Connection, up to

1220 m (4000 ft.)

User Operating Mode Selection Menu 13—Communications Settings Menu 14—Programming Mode
User On Local Remote Single Programming Local Programming Remote
Activity Access Source Line? LAN? or LAN? Mode Off? Mode? Programming Mode?
Controller No No No Yes No No
Monitor
Direct PC Yes Yes No Yes No No
only
PC via Telephone Lines Yes No Yes Yes No No
Controller No No No No Yes No
Monitor
and Direct PC Yes Yes No No No Yes
Program PC via Telephone Lines Yes No Yes No No Yes

Figure 2-13 Monitoring and Programming Configurations

50 Section 2 Operation TP-6200 10/12

Remote Single Connection network. Acceptable devices include the Decision-
Makerr 550 controller, Decision-Makerr 340 controller,
A modem connects a PC to a single device. The PC M340 transfer switch control, M340+ transfer switch
communicates with the device via a telephone network. control, and PM340 power monitor. Locate the PC
Locate the PC anywhere a telephone line is available. anywhere a telephone line is available. See
See Figure 2-14. Figure 2-15.

Remote Area Network The 550 controller can be used as an RS-232 to RS-485
port converter in a LAN network if the 550 controller is
A PC connects to a modem. The devices connect to a located within 15 m (50 ft.) of the device modem. This
LAN network. The PC communicates to the devices via configuration is the Remote LAN Conv option.
a telephone network that is interfaced to the LAN

Generator Set
Modem Modem Controller or
Transfer Switch
Control
RS-232 RS-232
Personal up to Telephone up to
Computer 15 m (50 ft.) Lines 15 m (50 ft.)

Figure 2-14 Remote Single Connection

Generator Set Generator Set

Controller or Controller or
Transfer Switch Transfer Switch
Control Control

Modem RS-232 to RS-485

Modem
port converter
RS-485 Generator Set Generator Set
Personal Telephone up to 1220 m Controller or Controller or
Computer Lines (4000 ft.) Transfer Switch Transfer Switch
Control Control

Figure 2-15 Remote Area Network

2.6.2 Modbus Communications

RS-485
The controller communicates using Modbusr as a slave up to 1220 m (4000 ft.)
connection with the Modbusr master initiating the Generator Set
communication. The controller seeks the system and Modbusr Master
Controller
alternator parameters and diagnostic information then RS-232
responds back to the Modbusr master. In addition, the up to 15 m (50 ft.)
controller accepts information to alter controller
parameters including generator set starting and
stopping. See Figure 2-16. Refer to the List of Related
Materials for available Modbusr literature. Figure 2-16 Modbusr Connections

Note: Only one Modbusr master can be connected to

the 550 controller. Examples include the remote
serial annunciator, Monitor III, and switchgear
applications.
Modbusr is a registered trademark of Schneider Electric.

TP-6200 10/12 Section 2 Operation 51

2.7 Reviewing Menu Displays See Section 2.5.3, Request and Error Messages, for
error display messages and explanations while
Use this section to review a summary of the generator navigating the menus.
set controller data. See Figure 2-17 for which menus
provide data monitoring and adjusting data. Legend:
Menu Down Key
Press the Reset key, enter the desired menu number
key(s), and then press the Enter key. Use the down Menu Right Key
arrow and right arrow keys for navigation.
Menu View Only View and
See Section 1, Specifications and Features, to review Number Menu Name Data Adjust Data
set point ranges and default settings for comparison to
1 Generator Monitoring X
the actual setup.
2 Engine Monitoring X
The user must enable the programming mode to edit the
3 Analog Monitoring X
display. See Menu 14—Programming Mode and
Section 2.8, Local Programming Mode On, for more 4 Operational Records X
information.
5 Event History X

Note: Press any key on the keypad to activate the 6 Time and Date X
controller panel display. The panel display turns
7 Generator System X
off 5 minutes after the last keypad entry.
8 Time Delays X
Note: Press the Reset Menu key to clear error
messages. 9 Input Setup X

10 Output Setup X
Note: Press the Menu Right → key prior to entering
decimal values where necessary. 11 Voltage Regulator X

12 Calibration X
Menus displaying the # symbol represent one of the
following data types: 13 Communications X

14 Programming Mode X
D System-calculated data
D System-measured data 15 Protective Relays X
D User-entered data 20 Factory Setup X

Menus displaying the ? symbol require the user to enter Figure 2-17 Menu Displays for Viewing and Adjusting
data.

Menus displaying the * symbol represent access code or

password type entries. The actual key entry does not
display.

52 Section 2 Operation TP-6200 10/12

2.7.1 Menu 1—Generator Monitoring Note: For the auto-scroll function, press ENTER at V &
A Summary menu. Press the Reset Menu key or
Menu 1 displays generator output data including Menu Right → key to stop the auto-scroll function.
line-to-line and line-to-neutral voltages, current,
frequency, power factor, total kilowatts, percent of Note: Pressing a right arrow key from any submenu
maximum kW, total kVA, and total kVAR. Menu 1 moves to the next submenu header.
displays three-phase voltage and current readings
when applicable.

All menu displays apply to both single-phase and three-

phase voltages unless otherwise noted as (1 PH) or
(3 PH) on the menu overview. The phase designation
does not appear in the controller menu displays.

Menu 1 Overview (Three-Phase Connections)

MENU 1
GENERATOR MONITORING

VOLTS & AMPS → V & A SUMMARY → POWER KW → POWER KVAR → POWER KVA →

L1-L2 VOLTS # V L1-L2 L2-L3 L3-L1 TOTAL KW # TOTAL KVAR # TOTAL KVA #
L1 AMPS # # # # PF # LEADING/LAGGING ABSORBING/GENERATING

L2-L3 VOLTS # V L1-L0 L2-L0 L3-L0 L1 KW # L1 KVAR # L1 KVA #

L2 AMPS # # # # PF # LEADING/LAGGING ABSORBING/GENERATING

L3-L1 VOLTS # A L1 L2 L3 L2 KW # L2 KVAR # L2 KVA #

L3 AMPS # # # # PF # LEADING/LAGGING ABSORBING/GENERATING

L1-L0 VOLTS # For the auto-scroll function, L3 KW (3 PH) # L3 KVAR (3 PH) # L3 KVA #
L1 AMPS # press ENTER at PF # LEADING/LAGGING ABSORBING/GENERATING
V & A SUMMARY menu.

L2-L0 VOLTS # TOTAL KW #

L2 AMPS # Use the MENU→ key to % OF RATED KW #
stop the auto-scroll function.

L3-L0 VOLTS #
L3 AMPS #

FREQUENCY # HZ

TP-6200 10/12 Section 2 Operation 53

Menu 1—Generator Monitoring, continued
Menu 1 Overview (Single-Phase Connections)
MENU 1
GENERATOR MONITORING

VOLTS & AMPS → V & A SUMMARY → POWER KW → POWER KVAR → POWER KVA →

L1-L2 VOLTS # V L1-L2 L1-L0 L2-L0 TOTAL KW # TOTAL KVAR # TOTAL KVA #
L1 AMPS # # # # PF # LEADING/LAGGING ABSORBING/GENERATING

L1-L2 VOLTS # A L1 L2 L1 KW # L1 KVAR # L1 KVA #

L2 AMPS # # # PF # LEADING/LAGGING ABSORBING/GENERATING

L1-L0 VOLTS # For the auto-scroll function, L2 KW # L2 KVAR # L2 KVA #

L1 AMPS # press ENTER at PF # LEADING/LAGGING ABSORBING/GENERATING
V & A SUMMARY menu.

L2-L0 VOLTS # TOTAL KW #

L2 AMPS # Use the MENU→ key to % OF RATED KW #
stop the auto-scroll function.

FREQUENCY # HZ

54 Section 2 Operation TP-6200 10/12

2.7.2 Menu 2—Engine Monitoring
Menu 2 displays engine operating data including oil
pressure and temperature, coolant pressure and
temperature, fuel pressure and temperature, engine
rpm, and battery voltage. Menu 2 also displays engine
warning and shutdown setpoints and engine warmed-up
and cooled-down temperature setpoints. The detailed
engine monitoring functions appear only for
DDEC/JDEC/EMS2/EDC3-equipped engine and
MDEC/ADEC-equipped engine versions.

Note: A right arrow from any submenu moves to the

next submenu header.

Menu 2 Overview
MENU 2
ENGINE MONITORING
(DDEC/JDEC/EMS2/EDC3-
Equipped Engines only)
ENGINE MONITORING → ENGINE MONITORING →
BASIC DETAILED

OIL PRESSURE # PSI ENGINE FUEL → ENGINE COOLANT → ENGINE OIL → ENGINE MISC →
COOLANT TEMP #F

INTAKE AIR #F FUEL PRES # PSI COOLANT PRES # PSI OIL PRES # PSI ECM BATT VDC #
OIL TEMP (Waukesha) #F FUEL TEMP #F COOLANT TEMP #F OIL TEMP #F AMBIENT TEMP #F

ENGINE RPM # CHG AIR PRES # PSI COOLANT LEVEL #% OIL LEVEL #% ENGINE MODEL NO.
LOCAL BATT VDC # CHG AIR TEMP #F CRANKCASE PRES # PSI #

HCT WARNING #F FUEL RATE # GPH ENGINE SERIAL NO.

HCT SHUTDOWN #F #

LOP WARNING # PSI USED LAST RUN UNIT NO. #

LOP SHUTDOWN # PSI # GAL ECM S/N #

ENGINE WARMED UP
ECM FAULTS CODES #
#F

ENGINE COOLED DOWN

#F

TP-6200 10/12 Section 2 Operation 55

Menu 2 Overview
MENU 2
ENGINE MONITORING
(MDEC/ADEC-Equipped Engines only)
ENGINE MONITORING → ENGINE MONITORING →
BASIC DETAILED

OIL PRESSURE # PSI ENGINE FUEL → ENGINE OIL → ENGINE MISC →

COOLANT TEMP #F

INTAKE AIR #F FUEL PRES # PSI OIL PRES # PSI ECU SUPPLY VDC #
OIL TEMP (Waukesha) #F FUEL TEMP #F OIL TEMP #F AMBIENT TEMP #F

ENGINE RPM # CHG AIR PRES # PSI ECU HOURS #

LOCAL BATT VDC # CHG AIR TEMP #F

HCT WARNING #F FUEL RATE * # GPH ECU FAULTS CODES #

HCT SHUTDOWN #F

LOP WARNING # PSI DAILY FUEL USED * # GAL

LOP SHUTDOWN # PSI

ENGINE WARMED UP TOTAL FUEL USED * # GAL

#F

ENGINE COOLED DOWN

#F

* While these menu displays do appear on the 550 controller, the engine ECM is not currently set up to provide this data.

56 Section 2 Operation TP-6200 10/12

2.7.3 Menu 3—Analog Monitoring Note: If the analog display shows O/R (out of range), no
input is connected or the input voltage is beyond
Menu 3 displays battery voltage and up to 7 user- the acceptable operating range (0--5 VDC).
defined analog items dependent upon the generator
system. Note: See Figure 2-8 in User Inputs for factory
reserved inputs which are not user selectable.
The User Defined Desc display refers to a description
entered into the controller using the PC software. This
description remains as the display for future review until
changed by the PC software user. The display has
20 characters maximum.

The default description is Analog Auxiliary In.

Menu 3 Overview (ECM Engines)

MENU 3 Menu 3 Overview (Non-ECM Engines)
ANALOG MONITORING
MENU 3
ANALOG MONITORING

LOCAL BATT VDC #

LOCAL BATT VDC #

ANALOG 01 #
(USER DEFINED DESC)
ANALOG 03 #
(USER DEFINED DESC)

ANALOG 02 #
(USER DEFINED DESC)
ANALOG 04 #
(USER DEFINED DESC)

ANALOG 03 #
(USER DEFINED DESC) ANALOG 05 #
(USER DEFINED DESC)

ANALOG 04 #
(USER DEFINED DESC) ANALOG 06 #
(USER DEFINED DESC)

ANALOG 05 #
(USER DEFINED DESC) ANALOG 07 #
(USER DEFINED DESC)

ANALOG 06 #
(USER DEFINED DESC)
Menu 3 Overview (Waukesha Engines)
ANALOG 07 # MENU 3
(USER DEFINED DESC) ANALOG MONITORING

LOCAL BATT VDC #

ANALOG 05 #
(USER DEFINED DESC)

ANALOG 06 #
(USER DEFINED DESC)

ANALOG 07 #
(USER DEFINED DESC)

TP-6200 10/12 Section 2 Operation 57

2.7.4 Menu 4—Operational Records After performing maintenance, enter YES to reset
records reflecting the current day. The user must enable
Menu 4 displays the generator set’s operating record the programming mode to edit the display.
including operating start date, last logged maintenance,
total run time loaded and unloaded, run time since last See Section 2.8.4 to make changes in this menu.
maintenance, number of starts, and number of days the
unit ran.

Menu 4 Overview
MENU 4 NO. OF STARTS #
OPERATIONAL RECORDS LAST MAINT ##-###-##

FACTORY TEST DATE LAST START ##:## AM/PM

##-###-## DATE ##-###-##

TOTAL RUN TIME LENGTH OF RUN

HRS # (UN)LOADED HRS #

TOTAL RUN TIME

LOADED HRS #

TOTAL RUN TIME

UNLOADED HRS #

TOTAL RUN TIME

KW HRS #

NO. OF STARTS #

ENGINE START? Y/N→ RUN TIME HR:MN →

COUNTDOWN ##:## ??:??

RECORDS-MAINT → RESET RECORDS? Y/N→

RUN TIME SINCE MAINT

TOTAL HRS #

RUN TIME SINCE MAINT

LOADED HRS #

RUN TIME SINCE MAINT

UNLOADED HRS #

RUN TIME SINCE MAINT

KW HRS #

OPERATING DAYS #
LAST MAINT ##-###-##

58 Section 2 Operation TP-6200 10/12

2.7.5 Menu 5—Event History 2.7.7 Menu 7—Generator System
Menu 5 stores and displays the times and dates of up to Menu 7 shows the generator set system data including
100 stored status, warning, and shutdown events. After voltage, frequency, phase connection, battery voltage,
the first 100 events, each additional new event replaces etc. Use the values entered in this menu to determine
the oldest event. See Menu 10—Output Setup for a list shutdown values and time delays.
of possible events.
The user must enable the programming mode to edit the
display.
Menu 5 Overview
See Section 2.8.7 to change system information in this
MENU 5 menu.
EVENT HISTORY

Note: Press the Menu Right → key prior to entering

(MESSAGE TEXT) decimal values where necessary.
##-###-## ##:## AM/PM
Note: The user defines the data shown in Menu 7. It is
NOT data measured by the controller and
SCROLL THROUGH 100 (max.) associated sensing devices. The user defines
STORED EVENTS
these values for purposes of calibrating the
control.

Note: Some alternators are designed to operate at

2.7.6 Menu 6—Time and Date limited voltage, frequency, or phase connections.
Menu 6 shows the internal clock time and calendar date. Settings outside of these parameters may cause
The controller uses the set clock time to determine a range error message.
exercise run time and event records. The time and date
Items marked * apply only to DDC/MTU engines using
are valid as long as the controller power (starting
MDEC/ADEC.
battery) remains connected.
Note: Menus include variable speed governor (VSG)
The user must enable the programming mode to edit the
and digital speed control (DSC).
display.

See Section 2.8.6 to change the time and/or date.

Menu 6 Overview
MENU 6
TIME AND DATE

DAY OF WEEK ##-###-##

##:##AM/PM

TIME ??:?? AM/PM

DATE ??-???-??

TP-6200 10/12 Section 2 Operation 59

Menu 7 Overview
MENU 7
GENERATOR SYSTEM

OPERATING MODE → OPERATING MODE →

STANDBY Y/N PRIME POWER Y/N

SYSTEM VOLTAGE
LINE-LINE ?

SYSTEM FREQ # HZ

PHASE → PHASE → PHASE →

3 PHASE DELTA Y/N 3 PHASE WYE N/Y SINGLE PHASE N/Y

KW RATING ?

RATED CURRENT #

LOAD SHED OUTPUT → TIME DELAY MIN:SEC →

?% # KW ??:??

OVERVOLTAGE → TIME DELAY MIN:SEC →

?% # VAC ??:??

UNDERVOLTAGE → TIME DELAY MIN:SEC →

?% # VAC ??:??

OVERFREQUENCY
?% # HZ

UNDERFREQUENCY
?% # HZ

OVERSPEED
? HZ # RPM

BATTERY VOLTAGE → BATTERY VOLTAGE →

12 VDC Y/N 24 VDC Y/N BLOCK HEATER OFF * #F

LOW BATTERY VOLTAGE

?.? VDC ENABLE VSG * Y/N

HIGH BATTERY VOLTAGE

?.? VDC ENABLE DSC * Y/N

BLOCK HEATER ON * #F METRIC UNITS Y/N

SET NFPA 110 Y/N

*DDC/MTU engine with MDEC/ADEC only DEFAULTS

60 Section 2 Operation TP-6200 10/12

2.7.8 Menu 8—Time Delays If the Cooldown Temperature Override is not enabled,
the unit will cease to run when the engine temperature
Menu 8 displays the cyclic cranking cycles, various falls below the ENGINE COOLED DOWN temperature
engine related starting and shutdown features, and (shown in Menu 2).
auxiliary shutdown and inhibit time delays.
Engine cooldown and this cooldown temperature
The user must enable the programming mode to edit the override feature apply to remote shutdown when the
display. master switch is in the AUTO position. No cooldown will
occur when the master switch is moved to the OFF
See Section 2.8.8 to change settings in this menu. position.
Cooldown Temperature Override. This feature allows
the user to bypass (override) the temperature-based
cooldown. When this feature is enabled, the engine will
run in cooldown mode for the entire time defined as
TIME DELAY ENG COOLDOWN, regardless of engine
temperature.

Menu 8 Overview
MENU 8
TIME DELAYS

TIME DELAY MIN:SEC

ENGINE START ??:??

TIME DELAY MIN:SEC

STARTING AID ??:??

TIME DELAY MIN:SEC

CRANK ON ??:??

TIME DELAY MIN:SEC

CRANK PAUSE ??:??

TIME DELAY MIN:SEC

ENG COOLDOWN ??:??

COOLDOWN TEMPERATURE
OVERRIDE Y/N

OVERCRANK SHUTDOWN
CRANK CYCLES ?

TIME DELAY MIN:SEC

OVERVOLTAGE ??:??

TIME DELAY MIN:SEC

UNDERVOLTAGE ??:??

TIME DELAY MIN:SEC

LOAD SHED KW ??:??

TP-6200 10/12 Section 2 Operation 61

2.7.9 Menu 9—Input Setup continues to run regardless of shutdown signals where
potential engine/generator damage can occur.
Menu 9 displays the setup of user-defined digital and
analog warning and shutdown inputs. These inputs When this input is enabled the yellow warning lamp
provide a multitude of choices for configuring illuminates and stored warning/shutdown events that
customized auxiliary inputs. are ignored continue to log in Menu 5— Event History.

The user must enable the programming mode to edit the Shutdown Type A and Shutdown Type B. Choose
display. shutdown type A for standard shutdown where red
lamp illuminates and alarm horn sounds. Choose
See Section 2.8.9 to change settings in this menu. shutdown type B for shutdown where air damper
indicator RDO-23 energizes for two seconds, red lamp
Note: Press the down arrow to move to the start of the illuminates, and alarm horn sounds.
next input setup.
Analog Input A06—Analog Speed Adjust (VSG).
Note: See Figure 2-8 in User Inputs for factory Analog Input A06 may be used for analog speed adjust
reserved inputs which are not user selectable. when external control of engine speed is desired such as
paralleling applications or closed transition ATS. To
D Enabled. The controller will ignore the input until the
utilize this capability, the input must be calibrated. Refer
inhibit time expires. If the inhibit time is set to zero, the
to 2.8.12, Menu 12—Calibration.
input is monitored at all times, even when the
generator is not running. Analog inputs have Note: This feature is supported for Doosan, GM, and
separate warning and shutdown enabled choices. Volvo engines only.
D Inhibit Time Delay. The inhibit time delay is the time Analog Input A07—Analog Voltage Adjust. Analog
period following crank disconnect during which the voltage adjust is a feature that the user may choose to
generator set stabilizes and the controller does not enable. The input designated for use as Analog Voltage
detect the fault or status event. This menu indicates Adjust is analog input A07.
whether or not the input is enabled. If the input is not
enabled, the controller will ignore this input signal. Enable Analog Voltage Adjust through Menu 11.
The inhibit time delay range is from 0 to 60 seconds. Additionally, Monitor 2 or Monitor 3 may be used to
enable Analog Voltage Adjust by entering the proper
D Time Delay (shutdown or warning). The time delay description (Analog Volt Adjust) for A07. When Analog
follows the inhibit time delay. The time delay is the Voltage Adjust is enabled, the description for A07 is
time period between when the controller first detects Analog Volt Adjust. Changing the description using
the fault or status event and the controller warning or Monitor 2 or Monitor 3 disables the analog voltage
shutdown lamp illuminates. The delay prevents any adjust feature.
nuisance alarms. The time delay range is from 0 to
60 seconds. When Analog Voltage Adjust is enabled, no warning or
shutdown may be enabled for A07.
Additional Analog Input Entries. The analog input
selection typically requires entering four values—low Note: If the analog input A07 description does not
warning, high warning, low shutdown, and high match Analog Volt Adjust, input A07 will not
shutdown. function as the voltage adjust.

Battle Switch/Fault Shutdown Override Switch. The Identification and Descriptions. Descriptions for user
battle switch function forces the system to ignore normal inputs (auxiliary analog or auxiliary digital) may be
fault shutdowns such as low oil pressure and high entered using the Monitor II software accessory where
engine temperature. The battle switch does not override the user determines the descriptions in upper and lower
the emergency stop and overspeed shutdown. When case.
the battle switch function is enabled the generator set

62 Section 2 Operation TP-6200 10/12

Menu 9 Overview
MENU 9
INPUT SETUP

SETUP DIGITAL → TO ANALOG INPUT

AUXILIARY INPUTS SETUP (NEXT)

DIGITAL INPUT 01 → DIGITAL INPUT 01 → DIGITAL INPUT 01 → DIGITAL INPUT 01 → DIGITAL INPUT 01 →
(USER DEFINED DESC) (see Group A) YES/NO ENABLED YES/NO INHIBIT TIME ?:?? DELAY TIME ?:??

Press the down arrow to

Group A Group A, continued Group A, continued
scroll through additional
DIGITAL auxiliary inputs The preprogrammed VAR PF MODE Y/N LOW COOLANT LEVEL Y/N
1--21 or enter the input selections include the REMOTE SHUTDOWN Y/N LOW COOLANT TEMP Y/N
number. following list. See REMOTE RESET Y/N BREAKER CLOSED Y/N
Appendix E for AIR DAMPER Y/N ENABLE SYNCH Y/N
application and LOW FUEL Y/N AFM SHUTDOWN Y/N
restrictions with specific FIELD OVERVOLTAGE Y/N KNOCK SHUTDOWN Y/N
engines. IDLE MODE ACTIVE Y/N DETON WARNING Y/N
WARNING Y/N BATTLE SWITCH Y/N DETON SHUTDOWN Y/N
SHUTDOWN TYPE A Y/N GROUND FAULT Y/N LOW FUEL SHUTDOWN Y/N
SHUTDOWN TYPE B Y/N BAT CHGR FAULT Y/N
VOLTAGE RAISE Y/N HIGH OIL TEMP Y/N
VOLTAGE LOWER Y/N

SETUP ANALOG → TO DIGITAL INPUT

AUXILIARY INPUTS SETUP (PREVIOUS)

ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX →

(USER DEFINED DESC) WARNING ENABLED Y/N SHUTDOWN ENABLED Y/N INHIBIT TIME ?:??

ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX → ANALOG INPUT XX →

WARN DELAY TIME ?:?? SDWN DELAY TIME ?:?? LO SDWN VALUE ?? LO WARN VALUE ??

ANALOG INPUT XX → ANALOG INPUT XX →

HI WARN VALUE ?? HI SDWN VALUE ??

Note: For ECM engines, auxiliary analog inputs

A01--A07 will appear.

Note: For non-ECM engines, auxiliary analog inputs

A03--A07 will appear.

Note: For Waukesha engines, auxiliary analog inputs

A05--A07 will appear.

TP-6200 10/12 Section 2 Operation 63

2.7.10 Menu 10—Output Setup The user can select up to 21 user-defined digital status
events and faults designated as D01 to D21. Each of the
Menu 10 displays the setup of user-defined system, 21 status events and faults are assignable as
digital and analog status, and fault outputs and relay shutdowns or warnings.
driver outputs (RDO) 1--31. These RDO outputs provide
multiple choices for configuring customized auxiliary The user can select up to 7 user-defined analog status
outputs. Additional individual outputs are available for events and faults designated as A01 to A07. Each of the
monitoring, diagnostics, and control functions. 7 status events and faults are assignable as shutdowns
or warnings with high or low settings for a total of up to
The user must enable the programming mode to edit the 7 status events and fault functions.
display. See Section 2.8.10 to change this menu.
Relay Driver Outputs (RDOs)
Note: Some data require entry using a PC in the
Remote Programming mode. See the Monitor Up to 31 RDOs are available using the system, digital,
Software operation manual for details. and analog status events and faults. RDOs provide only
the driver. The contact relays that interface with other
Note: See Figure 2-8 in User Inputs for factory equipment are optional.
reserved inputs which are not user selectable.
Note: Func(tion) Used By (RDO) XX Reassign? error
Common Faults message appears when the user attempts to
duplicate an existing RDO selection.
The user can program a single fault comprised of faults
from 3 common fault programs—system, digital, and Note: Cannot Change NFPA is Enabled. error message
analog faults. appears when the user attempts to modify RDO
setting defaulted as NFPA 110 requirement.
Up to 62 user-defined system status events and faults
are available. See Group B on the following pages for
specific descriptions. The NFPA 110 faults are part of
the system fault program and are comprised of
15 individual faults shown on the next page.

Menu 10 Overview
MENU 10
OUTPUT SETUP

DEFINE COMMON → SYSTEM EVENTS → DIGITAL INPUTS → ANALOG INPUTS →

FAULTS

COMMON FAULT Y/N COMMON FAULT Y/N COMMON FAULT Y/N COMMON FAULT Y/N
(see Group B) (see Group C) (see Group D)LO WARNING→ HI WARNING→

Press down arrow to scroll Press down arrow to scroll Press down arrow to scroll COMMON FAULT Y/N
through available faults. through digital auxiliary through analog auxiliary LO SHUTDOWN→
inputs. inputs.

COMMON FAULT Y/N

HI SHUTDOWN→

RELAY DRV OUT XX → SYSTEM EVENTS → DIGITAL INPUTS → ANALOG INPUTS →

(see Group E)

Press down arrow to scroll

through RDO’s 1--31 or enter RELAY DRV OUT XX Y/N RELAY DRV OUT XX Y/N RELAY DRV OUT XX Y/N RELAY DRV OUT Y/N
RDO number. (see Group B) (see Group C) (see Group D)LO WARNING→ HI WARNING→

Press down arrow to scroll Press down arrow to scroll Press down arrow to scroll
RELAY DRV OUT Y/N
through available RDO through RDO digital auxiliary through RDO analog
LO SHUTDOWN→
faults. inputs. auxiliary inputs.

RELAY DRV OUT Y/N

HI SHUTDOWN→

64 Section 2 Operation TP-6200 10/12

Menu 10 Overview, continued
Group B *NFPA 110 FAULT Group B, continued
For defined system events, choose The 15 NFPA 110 Fault Alarms Paralleling applicatons:
from the following 66 status events and include the following: SD REVERSE POWER
faults by changing selection to YES. OVERSPEED
See Appendix E for application and SD OVER POWER
restrictions with specific engines. OVERCRANK SD LOSS OF FIELD
EMERGENCY STOP HIGH COOLANT TEMP SHUTDOWN SD OVERCURRENT PR
OVER SPEED OIL PRESSURE SHUTDOWN COMMON PR OUTPUT
OVER CRANK LOW COOLANT TEMPERATURE IN SYNCH
HI COOL TEMP SHUTDWN HIGH COOLANT TEMP WARNING BREAKER TRIP
OIL PRESS SHUTDOWN OIL PRESSURE WARNING Waukesha-powered models:
LOW COOLANT TEMP (non-ECM LOW FUEL FUEL VALVE RELAY
engines) MASTER NOT IN AUTO PRELUBE RELAY
LOW FUEL BATTERY CHARGER FAULT AFM REMOTE START
HI COOL TEMP WARNING LOW BATTERY VOLTAGE NO OIL TEMP SIGNAL
OIL PRES WARNING HIGH BATTERY VOLTAGE HI OIL TEMP WARNING
MASTER NOT IN AUTO LOW COOLANT LEVEL NO AIR TEMP SIGNAL
NFPA 110 FAULT* EPS SUPPLYING LOAD INTAKE AIR TEMP WARN
LOW BATTERY VOLTAGE AIR DAMPER INDICATOR INTAKE AIR TEMP SDWN
HIGH BATTERY VOLTAGE AFM ENG START DELAY
BATTERY CHARGE FAULT DDC/MTU engine with MDEC/ADEC:
SYSTEM READY HI OIL TEMP WARNING
LOSS OF ECM COMM (ECM engines) INTAKE AIR/TEMP WARN
NO OIL PRESS SIGNAL INTAKE AIR TEMP SDWN
HI OIL TEMP ECM YELLOW ALARM
NO COOL TEMP SIGNAL ECM RED ALARM
LOW COOLANT LEVEL [DEFINED COMMON FAULT
BLOCK HEATER CONTROL
SPEED SENSOR FAULT The 5 defined common
faults include the following: LOW COOL TEMP SDOWN
LOCKED ROTOR LOAD SHED OVER TEMP
EMERGENCY STOP
MASTER SWITCH ERROR
HI COOL TEMP SHUTDOWN Group C
MASTER SWITCH OPEN
OIL PRESS SHUTDOWN Up to 21 user-defined digital status
MASTER SWITCH TO OFF
OVERCRANK events and fault inputs designated as
AC SENSING LOSS D01 to D21 can result in a digital input
OVERSPEED
OVER VOLTAGE common fault.
UNDER VOLTAGE Group D
WEAK BATTERY Up to 7 analog inputs, user- defined
OVER FREQUENCY status events and faults designated as
A01 to A07. Each of the 7 is assignable
UNDER FREQUENCY as a shutdown or warning with high or
LOAD SHED KW OVER low settings.
LOAD SHED UNDER FREQ Group E
OVER CURRENT Choose up to 31 status event and
EPS SUPPLYING LOAD fault RDOs from the following:
SYSTEM FAULTS
INTERNAL FAULT (see Group B, 66 Items)
DELAY ENG COOLDOWN DIGITAL INPUTS
DELAY ENG START (see Group C, 21 Items)
STARTING AID ANALOG INPUTS
GENERATOR RUNNING (see Group D, 7 Items)
AIR DAMPER CONTROL
GROUND FAULT
EEPROM WRITE FAILURE
CRITICAL OVERVOLTAGE
ALTERNATOR PROTECTION
SHUTDOWN
AIR DAMPER INDICATOR
DEFINED COMMON FAULT (RDO only)[
SCRDOs 1--4 (software controlled RDOs)
MAINTENANCE DUE
ENGINE DERATE ACTIVE
ENGINE STALLED
J1939 CAN SHUTDOWN

TP-6200 10/12 Section 2 Operation 65

2.7.11 Menu 11—Voltage Regulator See Section 2.8.11 to make changes in this menu.

Menu 11 displays setup of the voltage regulator functions Note: The individual line-to-line voltages are displayed
including line-to-line voltages, underfrequency unloading for review purposes only.
(volts per Hz), reactive droop, power factor, and kVAR
adjustments. Note: Voltage regulator gain is used for adjusting
voltage stability and/or response.
The user must enable the programming mode to edit the
display. Note: Utility gain is used for VAR or PF stability adjust
while paralleling to a utility.

Menu 11 Overview
MENU 11
VOLTAGE REGULATOR

AVG L-L V # → L1-L2 VOLTS → L2-L3 VOLTS (3 PHASE) → L3-L1 VOLTS (3 PHASE) →
VOLT ADJ ?.? # # #

UNDER FREQ UNLOAD → FREQUENCY # HZ→ SLOPE →

ENABLED Y/N SETPOINT ?.? HZ ?.? VOLTS-PER-CYCLE

REACTIVE DROOP → .8 PF RATED LOAD →

ENABLED Y/N VOLTAGE DROOP ?.?%

VAR CONTROL → TOTAL KVAR # → GENERATING/ Y/N→

ENABLED Y/N KVAR ADJ ?.? ABSORBING Y/N

PF CONTROL → AVERAGE PF # → LAGGING/ Y/N→

ENABLED Y/N PF ADJ ?.? LEADING Y/N

REGULATOR GAIN ADJ

GAIN #

UTILITY GAIN ADJUST

GAIN #

ANALOG VOLTAGE ADJUST

ENABLED Y/N

RESET REGULATOR
DEFAULTS? Y/N

66 Section 2 Operation TP-6200 10/12

2.7.12 Menu 12—Calibration The user must enable the programming mode to edit the
display.
Menu 12 provides access to the calibration factors for
metering (volts and amps) and auxiliary analog inputs. See Section 2.8.12 to make calibration changes.
Changing the system voltage or replacing the main logic
control circuit board requires calibration adjustment.

Menu 12 Overview
MENU 12
CALIBRATION

SCALE AC ANALOG TO SCALE AUX. ANALOG

INPUTS INPUTS SETUP (NEXT)

GEN VOLTAGE LN GEN VOLTAGE LL GEN AMPS LOAD VOLTAGE LN RESTORE DEFAULTS Y/N

GEN L1--L0 V # GEN L1--L2 V # GEN L1 AMPS # LOAD L1--L0 V #

CALIB REF ? CALIB REF ? CALIB REF ? CALIB REF (PARALLEL) ?

GEN L2--L0 V # GEN L2--L3 V (3 PHASE) # GEN L2 AMPS (3 PHASE) # LOAD L3--L0 V #
CALIB REF ? CALIB REF ? CALIB REF ? CALIB REF (PARALLEL) ?

GEN L3--L0 V (3 PHASE) # GEN L3--L1 V (3 PHASE) # GEN L3 AMPS (3 PHASE) #

CALIB REF ? CALIB REF ? CALIB REF ?

CALIBRATE REGULATOR?
Y/N

SCALE AUX. ANALOG TO AC ANALOG INPUTS

INPUTS SETUP (PREVIOUS)

ZERO AUX. ANALOG Press YES or NO. Text

INPUTS? Y/N appears on display lower line.
Pressing ENTER confirms
YES or NO selection.

ANALOG XX # SCAL 1 #V
SCALE VALUE 1 ? SCAL 2 #V

ANALOG XX # SCAL 1 #V
SCALE VALUE 2 ? SCAL 2 #V

TP-6200 10/12 Section 2 Operation 67

2.7.13 Menu 13—Communications
Menu 13 shows the settings for remote
communications.

See Section 2.8.13 to make changes in this menu.

See the Modbusr Communications Protocol operation

manual for a list of Modbusr registers for the 550
Controller.

Menu 13 Overview
MENU 13
COMMUNICATIONS

PROTOCOL → PROTOCOL →
KBUS MODBUS

KBUS ONLINE Y/N MODBUS ONLINE Y/N

CONNECTION TYPE → CONNECTION TYPES CONNECTION TYPE → CONNECTION TYPES

(USER DEFINED) Y/N LOCAL SINGLE Y/N (USER DEFINED) Y/N SINGLE Y/N
LOCAL LAN Y/N CONVERTOR Y/N
LOCAL LAN CONV Y/N
REMOTE SINGLE Y/N
REMOTE LAN Y/N PRIMARY PORT → PRIMARY PORTS
(USER DEFINED) Y/N RS-232 Y/N
REMOTE LAN CONV Y/N
RS-485 Y/N

PRIMARY PORT → PRIMARY PORTS ADDRESS ?

(USER DEFINED) RS-232 Y/N
RS-485 ISO 1 Y/N

ADDRESS ? BAUD RATE → BAUD RATES

(LAN Connections) (USER DEFINED) Y/N 9600 Y/N
19200 Y/N

SYSTEM ID ?
(Remote Connections)

BAUD RATE → BAUD RATES

(USER DEFINED) Y/N 1200 Y/N
2400 Y/N
9600 Y/N

Modbusr is a registered trademark of Schneider Electric.

68 Section 2 Operation TP-6200 10/12

2.7.14 Menu 14—Programming Mode
Menu 14 provides local or remote access to the
programming function. The user enters a password to
access the programming mode.

Note: Log into the local programming mode to edit the

programming access code. The factory default
access code is the number 0.

Use Menu 14 to change the access code. Record the

new number and give the access code only to
authorized individuals. Should the controller logic not
accept the access code or if the new code number is lost,
contact your local authorized distributor/dealer for
password information.

The user chooses one of three programming modes:

D Local—using the controller keypad

D Remote—using a PC
D Off—no programming is permitted

Note: Use the generator set controller to initially set up

remote programming. Remote programming
cannot be accessed from a PC unless the
controller is first set for remote programming
using Menu 14.

See Section 2.8.14.

Menu 14 Overview
MENU 14
PROGRAMMING MODE

PROGRAMMING MODE → PROGRAMMING MODE → PROGRAMMING MODE →

LOCAL Y/N REMOTE Y/N OFF Y/N

PROGRAMMING MODE → PROGRAMMING MODE → PROGRAMMING MODE →

CHANGE ACCESS CODE ENTER OLD CODE # ENTER NEW CODE #

TP-6200 10/12 Section 2 Operation 69

2.7.15 Menu 15—Protective Relays (PR)
Menu 15 provides protective relay setup and time delays
for units with the paralleling protection option. This
menu will only be visible and accessible if this option is
included. The shutdown (SD) settings override those in
menu 7 and/or menu 8.

See Section 2.8.15 to make changes in this menu, when

the paralleling option is enabled.

Menu 15 Overview
MENU 15
PROTECTIVE RELAYS

PR OVERVOLTAGE → TIME DELAY →

?% # VAC ? SEC

PR UNDERVOLTAGE → TIME DELAY →

?% # VAC ? SEC

PR OVERFREQUENCY → TIME DELAY →

?% # HZ ? SEC

PR UNDERFREQUENCY → TIME DELAY →

?% # HZ ? SEC

PR REVERSE POWER → TIME DELAY →

?% # KW ? SEC

SD REVERSE POWER → TIME DELAY →

?% # KW ? SEC

PR OVER POWER → TIME DELAY →

?% # KW ? SEC

SD OVER POWER → TIME DELAY →

?% # KW ? SEC

PR LOSS OF FIELD → TIME DELAY →

?% # KVAR ? SEC

SD LOSS OF FIELD → TIME DELAY →

?% # KVAR ? SEC

PR OVER CURRENT VR → TIME DELAY →

?% # AMPS ? SEC

SD OVER CURRENT VR → TIME DELAY →

?% # AMPS ? SEC

SYNC VOLTAGE MATCH → SYNC FREQ MATCH → SYNC PHASE MATCH → TIME DELAY →
? VAC ? HZ ? DEG ? SEC

70 Section 2 Operation TP-6200 10/12

2.7.16 Menu 20—Factory Setup
(Version 2.10)
Menu 20 provides factory setup information including
the number of operating days, generator set information,
alternator information, engine information, controller
information, and the controller software (code) version.

Menu 20 Overview
MENU 20
FACTORY SETUP

FINAL ASSEMBLY DATE

DD/MM/YY

FINAL ASSEMBLY
CLOCK NO ?

OPERATING DAYS #

MODEL NO #

SPEC NO #

GENSET SERIAL NO #

ALTERNATOR PART NO #

ENGINE PART NO #

SERIAL NO #

CONTROLLER SERIAL NO

CODE VERSION #
COPYRIGHT XXXX

SETUP LOCKED YES

TP-6200 10/12 Section 2 Operation 71

2.7.17 Menu 20—Factory Setup Note: For Version 2.69 and lower, enter the numeric
(Version 2.21) serial number from the generator set nameplate.
For Version 2.70 and higher, confirm that the
Menu 20 provides factory setup information including alpha-numeric number shown on the display
the number of operating days, generator set information, matches the serial number shown on the
alternator information, engine information, controller generator set nameplate. If the serial numbers
information, and the controller software (code) version. match, press the YES key and then press
The temperature sensor setup applies to non-ECM ENTER. If the serial numbers do not match, the
engines only. wrong personality parameter file is installed.
Refer to the Program Loader documentation for
See Section 2.8.16 to make changes in this menu. instructions on reloading the personality
parameter file.
Menu 20 Overview
MENU 20
FACTORY SETUP

FINAL ASSEMBLY DATE

DD/MM/YY

FINAL ASSEMBLY
CLOCK NO ?

OPERATING DAYS #

MODEL NO #

SPEC NO #

GENSET SERIAL NO #

ALTERNATOR PART NO #

ENGINE PART NO #

TEMP SENSOR YES TEMP SENSOR NO TEMP SENSOR NO

GM31045--X GM16787 GM17362

SERIAL NO CONFIRM → CONFIRM SERIAL? YES

######

CONTROLLER SERIAL NO

CODE VERSION #
COPYRIGHT XXXX

SETUP LOCKED YES

72 Section 2 Operation TP-6200 10/12

 Notes

TP-6200 10/12 Section 2 Operation 73

2.8 Local Programming Mode On All menu displays apply to both single-phase and
three-phase voltages unless otherwise noted as (1 PH)
The Local Programming Mode On section explains how or (3 PH) on the menu overview. The phase designation
to program the generator set controller logic. Each does not appear in the actual menu displays.
menu contains a step-by-step procedure for
programming the various logic groups. See Section 1, Note: Place the generator set master switch in the OFF/
Specifications, for setting ranges and default settings. RESET position when using local programming
mode on.
Please read and understand the entire Local
Programming Mode On section before attempting any Note: Use the generator set controller to initially set up
programming. The factory settings are adjustable and the remote programming. Set the controller for
programming without full understanding of the logic remote programming using Menu 14 and remote
features and functions can cause inadvertent changes. communication using Menu 13 before attempting
remote programming.
Refer to Menu 14—Programming Mode for information
regarding menu programming activation. After Note: Press any key on the keypad to activate the
completing the programming always place the controller controller panel display. The panel display turns
back in the Programming Mode Off position to prevent off 5 minutes after the last keypad entry.
inadvertent program changes.
Note: Press the Reset Menu key to clear the Error
The programming feature alters stored settings and display.
changes characteristics of the logic. Do not operate the
controller with the program mode on unless there is a Note: Press the Menu Right → key prior to entering
need to edit program logic or clear stored data. Limit decimal values where necessary.
programming responsibilities to individuals with training
Refer to Figure 2-18 for a quick reference to the menu
and authority.
number and description.
The product application requires expertise in the design
and programming of control systems. Only qualified Menu No. Menu Description
personnel should program, install, alter, and apply this 1 Generator Monitoring (Three-Phase Connections)
product. 1 Generator Monitoring (Single-Phase Connections)
2 Engine Monitoring
Use Section 2.7, Reviewing the Menu Displays, to view
the generator set operation data and review previously 3 Analog Monitoring
programmed information and to review the data when no 4 Operational Records
programming is necessary. 5 Event History
6 Time and Date
Menus displaying the # symbol represent one of the
7 Generator System
following data types:
8 Time Delays
D System-calculated data
9 Input Setup
D System-measured data
10 Output Setup
D User-entered data
11 Voltage Regulator
Menus displaying the ? symbol require the user to enter 12 Calibration
data. 13 Communication
14 Programming Mode
Menus displaying the * symbol represent access code or
15 Protective Relays
password type entries. Actual key entry does not
display. 20 Factory Setup Menu

Figure 2-18 Menu Number and Description

See Section 2.5.3, Request and Error Messages, for
error display messages and explanations should they
appear while navigating through the menus.

74 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.1 Menu 1—Generator Monitoring Note: For the auto-scroll function, press ENTER at the
V & A Summary menu. Press the Reset Menu
Menu 1 provides generator output data including key or Menu Right → key to stop the auto-scroll
line-to-line and line-to-neutral voltages, current, function.
frequency, power factor, total kilowatts, percent of
maximum kW, total kVA and total kVAR displays. Note: A right arrow from any submenu moves to the
Menu 1 displays three-phase and single-phase next submenu header.
connections separately.

Menu 1—Generator Monitoring (Three-Phase Connections)

Menu 1 Displays with Key Entries
Note: This menu is for monitoring only; no adjustments or user settings can be entered.

Key Entry Display Description

ENTER MENU NO. 1--15
Input a menu number.

MAIN MENU NUMBER 1

Press the Enter key.

MENU 1
GENERATOR MONITORING
Displays the menu number and name.

VOLTS & AMPS →

Displays the volts and amps heading.

L1-L2 VOLTS #
L1 AMPS #
Displays L1 and L2 volts and L1 amps.

L2-L3 VOLTS #
Displays L2 and L3 volts and L2 amps.
L2 AMPS #

L3-L1 VOLTS #
L3 AMPS #
Displays L3 and L1 volts and L3 amps.

L1-L0 VOLTS #
L1 AMPS #
Displays L1-L0 volts and L1 amps.

L2-L0 VOLTS #
L2 AMPS #
Displays L2 and L0 volts and L2 amps.

L3-L0 VOLTS #
L3 AMPS #
Displays L3-L0 volts and L3 amps.

FREQUENCY # HZ Displays the frequency.

MENU 1
Returns the user to the menu number and name.
GENERATOR MONITORING

VOLTS & AMPS →

Returns the user to volts and amps heading.

V & A SUMMARY →
Displays the volts and amps summary heading.

V L1-L2 L2-L3 L3-L1

# # # Displays L1-L2, L2-L3, and L3-L1 volts.

V L1-L0 L2-L0 L3-L0

# # # Displays L1-L0, L2-L0, and L3-L0 volts. (3 ph. only)

TP-6200 10/12 Local Programming Mode On Section 2 Operation 75

Menu 1—Generator Monitoring (Three-Phase Connections), continued
Menu 1 Displays with Key Entries
Key
Entry Display Description

A L1 L2 L3
# # # Displays L1, L2, and L3 amps.

V & A SUMMARY →
Returns the user to the volts and amps summary heading.

POWER KW →
Displays the power kilowatt heading.

TOTAL KW #
Displays total kilowatts and leading or lagging power factor.
PF # LEADING/LAGGING

L1 KW #
PF # LEADING/LAGGING
Displays total L1 kilowatts and leading or lagging power factor.

L2 KW #
Displays total L2 kilowatts and leading or lagging power factor.
PF # LEADING/LAGGING

L3 KW # Displays total L3 kilowatts and leading or lagging power factor.

PF # LEADING/LAGGING

TOTAL KW #
% OF RATED KW # Displays the total kW and percent of rated kilowatts.

POWER KW →
Returns the user to the power kilowatt heading.

POWER KVAR →
Displays the power kVAR heading.

TOTAL KVAR #
ABSORBING/GENERATING
Displays total kVAR, absorbing or generating.

L1 KVAR #
ABSORBING/GENERATING
Displays L1 kVAR, absorbing or generating.

L2 KVAR #
ABSORBING/GENERATING Displays L2 kVAR, absorbing or generating.

L3 KVAR #
ABSORBING/GENERATING
Displays L3 kVAR, absorbing or generating. (3 ph. only)

POWER KVAR →
Returns the user to power kVAR heading.

POWER KVA →
Displays the power kVA heading.

TOTAL KVA #
Displays total kVA.

L1 KVA #
Displays L1 kVA.

L2 KVA #
Displays L2 kVA.

76 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 1—Generator Monitoring (Three-Phase Connections), continued
Menu 1 Displays with Key Entries
Key
Entry Display Description

L3 KVA #
Displays L3 kVA.

POWER kVA →
Returns the user to power kVA heading.

Menu 1—Generator Monitoring (Single-Phase Connections)

Menu 1 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 1

Press the Enter key.

MENU 1
GENERATOR MONITORING
Displays the menu number and name.

VOLTS & AMPS →

Displays the volts and amps heading.

L1-L2 VOLTS #
L1 AMPS #
Displays L1 and L2 volts and L1 amps.

L1-L2 VOLTS #
L2 AMPS #
Displays L1 and L2 volts and L2 amps.

L1-L0 VOLTS #
L1 AMPS #
Displays L1-L0 volts and L1 amps.

L2-L0 VOLTS #
L2 AMPS #
Displays L2 and L0 volts and L2 amps.

FREQUENCY # HZ Displays the frequency.

MENU 1
Returns the user to the menu number and name.
GENERATOR MONITORING

VOLTS & AMPS →

Returns the user to volts and amps heading.

V & A SUMMARY →
Displays the volts and amps summary heading.

V L1-L2 L1-L0 L2-L0

# # # Displays L1-L2, L1-L0, and L2-L0 volts.

A L1 L2
# # Displays L1 and L2 amps.

V & A SUMMARY →
Returns the user to the volts and amps summary heading.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 77

Menu 1—Generator Monitoring (Single-Phase Connections), continued
Menu 1 Displays with Key Entries
Key
Entry Display Description

POWER KW →
Displays the power kilowatt heading.

TOTAL KW #
Displays total kilowatts and leading or lagging power factor.
PF # LEADING/LAGGING

L1 KW #
PF # LEADING/LAGGING
Displays total L1 kilowatts and leading or lagging power factor.

L2 KW #
Displays total L2 kilowatts and leading or lagging power factor.
PF # LEADING/LAGGING

TOTAL KW #
% OF RATED KW # Displays the total kW and percent of rated kilowatts.

POWER KW →
Returns the user to the power kilowatt heading.

POWER KVAR →
Displays the power kVAR heading.

TOTAL KVAR #
ABSORBING/GENERATING
Displays total kVAR, absorbing or generating.

L1 KVAR #
ABSORBING/GENERATING
Displays L1 kVAR, absorbing or generating.

L2 KVAR #
ABSORBING/GENERATING Displays L2 kVAR, absorbing or generating.

POWER KVAR →
Returns the user to power kVAR heading.

POWER KVA →
Displays the power kVA heading.

TOTAL KVA #
Displays total kVA.

L1 KVA #
Displays L1 kVA.

L2 KVA #
Displays L2 kVA.

POWER kVA →
Returns the user to power kVA heading.

78 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.2 Menu 2—Engine Monitoring
Menu 2 provides engine operating data including oil The detailed engine monitoring functions appear only for
pressure and temperature, coolant temperature, fuel DDEC (DDC/MTU), JDEC (John Deere), EMS2 (Volvo),
pressure and temperature, engine rpm, and battery EDC3 (Volvo), or MDEC/ADEC (DDC/MTU)- equipped
voltage. Menu 2 also displays engine warning and engines.
shutdown setpoints and engine warmed-up and cooled-
down temperature setpoints. Note: A right arrow from any submenu moves to the
next submenu header.

Menu 2—Engine Monitoring

Menu 2 Displays with Key Entries
Note: This menu is for monitoring only; no adjustments or user settings can be entered.

Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 2

Press the Enter key.

MENU 2
Displays the menu number and name.
ENGINE MONITORING

ENGINE MONITORING →
Displays the basic engine monitoring heading.
BASIC

OIL PRESSURE # PSI

Displays the oil pressure and coolant temperature.
COOLANT TEMP #F

INTAKE AIR #F Displays the intake air and oil temperature

OIL TEMP (Waukesha) #F (Waukesha-powered models only)

ENGINE RPM #
Displays the engine rpm and local battery VDC.
LOCAL BATT VDC #

HCT WARN #F
Displays the high coolant temperature warning and shutdown
HCT SDOWN #F
setpoints.

LOP WARN # PSI

Displays the low oil pressure warning and shutdown setpoints.
LOP SDOWN # PSI

ENGINE WARMED UP
#F Displays the engine warmed up temperature setpoint.

ENGINE COOLED DOWN

#F Displays the engine cooled down temperature setpoint.

MENU 2
ENGINE MONITORING Returns the user to the menu number and name.

ENGINE MONITORING →
Returns the user to basic engine monitoring heading.
BASIC

TP-6200 10/12 Local Programming Mode On Section 2 Operation 79

Menu 2—Engine Monitoring, continued
Menu 2 Displays with Key Entries
Key
Entry Display Description
(DDEC/JDEC/EMS2/EDC3-Equipped Engines only)
ENGINE MONITORING → Displays the detailed engine monitoring heading.
DETAILED Note: The detailed engine monitoring feature requires a
DDEC/JDEC/EMS2/EDC3-equipped engine.
ENGINE FUEL →
Displays the engine fuel subheading.

FUEL PRES # PSI

Displays the fuel pressure and fuel temperature.
FUEL TEMP #F

CHR AIR PRESS # PSI

Displays the charge air pressure and temperature.
CHR AIR TEMP #F

FUEL RATE # GPH

Displays the fuel rate per hour.

USED LAST RUN

Displays the amount of fuel used during the last run.
# GAL

ENGINE MONITORING →
Returns the user to the detailed engine monitoring heading.
DETAILED

ENGINE FUEL →
Displays the engine fuel subheading.

ENGINE COOLANT →
Displays the engine coolant subheading.

COOLANT PRES # PSI

Displays the coolant pressure and coolant temperature.
COOLANT TEMP #F

COOLANT LEVEL #%
Displays the coolant level as a percent of full capacity.

ENGINE COOLANT →
Returns the user to engine coolant subheading.

ENGINE OIL →
Displays the engine oil subheading.

OIL PRES # PSI

Displays the oil pressure and oil temperature.
OIL TEMP #F

OIL LEVEL #% Displays the oil level as a percent of full capacity and crankcase
CRANKCASE PRES # PSI pressure.

ENGINE OIL →
Returns the user to engine oil subheading.

ENGINE MISC →
Displays the miscellaneous engine subheading.

ECM BATT VDC #

Displays the engine ECM battery VDC and ambient temperature.
AMBIENT TEMP #F

80 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 2—Engine Monitoring, continued
Menu 2 Displays with Key Entries
Key
Entry Display Description

(DDEC/JDEC/EMS2/EDC3-Equipped Engines only, continued)

ENGINE MODEL NO.
Displays the engine model number.
#

ENGINE SERIAL NO.

Displays the engine serial number.
#

UNIT NO. #
ECM S/N # Displays the unit number and ECM serial number.

ECM FAULT CODES #

Displays the ECM fault codes.

ENGINE MISC →
Returns the user to the miscellaneous engine subheading.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 81

Menu 2—Engine Monitoring, continued
Menu 2 Displays with Key Entries
Key
Entry Display Description

(MDEC-Equipped Engines only)

ENGINE MONITORING → Displays the detailed engine monitoring heading.
DETAILED Note: The detailed engine monitoring feature requires a
DDC/MTU MDEC/ADEC-equipped engine.
ENGINE FUEL →
Displays the engine fuel subheading.

FUEL PRES # PSI

Displays the fuel pressure and fuel temperature.
FUEL TEMP #F

CHG AIR PRESSURE # PSI

Displays the turbocharger air pressure and temperature.
CHG AIR TEMP #F

FUEL RATE * # GPH

Displays the fuel rate per hour.

DAILY FUEL USED * # GAL

Displays the amount of fuel used during the last 24 hours.

TOTAL FUEL USED * # GAL

Displays the amount of fuel used since the last reset.

ENGINE MONITORING →
Returns the user to the detailed engine monitoring heading.
DETAILED

ENGINE FUEL →
Displays the engine fuel subheading.

ENGINE OIL →
Displays the engine oil subheading.

OIL PRES # PSI

Displays the oil pressure and oil temperature.
OIL TEMP #F

ENGINE OIL →
Returns the user to engine oil subheading.

ENGINE MISC →
Displays the miscellaneous engine subheading.

ECU SUPPLY VDC #

Displays the engine ECU supply VDC and ambient temperature.
AMBIENT TEMP #F

ECU HOURS #
Displays the ECU operating hours.

ECU FAULT CODES #

Displays the ECU fault codes.

ENGINE MISC →
Returns the user to the miscellaneous engine subheading.

* While these menu displays do appear on the 550 controller, the engine ECM is not currently set up to provide this data.

82 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.3 Menu 3—Analog Monitoring
Menu 3 provides the battery voltage and up to 7 user- midpoint 2.5 volts corresponds to 0 volts offset. If there
defined analog monitoring items dependent upon the is no connection at analog input 7, no voltage adjust is
generator system. recognized.

The User Defined Desc display refers to a description Note: If the analog display shows O/R (out of range), no
entered into the controller using the PC software. This input is connected.
description remains as the display for future review until
changed by the PC software user. The display has Note: Some data require entry using a PC in the
20 characters maximum. Remote Programming mode. See the monitor
software operation manual for details.
Analog Voltage Adjust. When the analog voltage
adjust option is enabled (see Menu 11), analog input 7 is Note: See Figure 2-8 in User Inputs for factory
predefined as voltage adjust. The voltage of this input reserved inputs which are not user selectable.
will define the adjustment from the setting in Menu 11,
Voltage Regulator. The normal analog input range of Note: This menu is for monitoring only; no adjustments
0.5 to 4.5 corresponds to a ±10% of system voltage. The or user settings can be entered.

Menu 3—Analog Monitoring (ECM Engines)

Menu 3 Displays with Key Entries
Key Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 3

Press the Enter key.

MENU 3
Displays the menu number and name.
ANALOG MONITORING

LOCAL BATT VDC #

Displays the local battery VDC.

ANALOG 01 #
Displays analog 01 and the user-defined description.
(USER DEFINED DESC)

ANALOG 02 #
(USER DEFINED DESC) Displays analog 02 and the user defined description.

ANALOG 03 #
Displays analog 03 and the user-defined description.
(USER DEFINED DESC)

ANALOG 04 #
Displays analog 04 and the user-defined description.
(USER DEFINED DESC)

ANALOG 05 #
Displays analog 05 and the user-defined description.
(USER DEFINED DESC)

ANALOG 06 #
Displays analog 06 end the user-defined description.
(USER DEFINED DESC)

ANALOG 07 #
Displays analog 07 and the user-defined description.
(USER DEFINED DESC)

OR
ANALOG 07 # Displays analog 07 voltage adjustment VDC value when analog
ANALOG VOLT ADJUST voltage adjust is enabled.

ANALOG MONITORING Returns user to analog monitoring heading.

MENU 3 Note: Enter data using a PC in the Remote Programming Mode.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 83

Menu 3—Analog Monitoring (Non-ECM Engines)
Menu 3 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 3

Press the Enter key.

MENU 3
Displays the menu number and name.
ANALOG MONITORING

LOCAL BATT VDC #

Displays the local battery VDC.

ANALOG 03 #
Displays analog 03 and the user-defined description.
(USER DEFINED DESC)

ANALOG 04 #
Displays analog 04 and the user-defined description.
(USER DEFINED DESC)

ANALOG 05 #
Displays analog 05 and the user-defined description.
(USER DEFINED DESC)

ANALOG 06 #
Displays analog 06 end the user-defined description.
(USER DEFINED DESC)

ANALOG 07 #
Displays analog 07 and the user-defined description.
(USER DEFINED DESC)

OR
Displays analog 07 voltage adjustment VDC value when this option is
ANALOG 07 #
enabled. Note: This function may be overridden by changing the
ANALOG VOLT ADJUST
description using the optional Monitor III software or by disabling in
Menu 11.
ANALOG MONITORING Returns user to analog monitoring heading.
MENU 3 Note: Enter data using a PC in the Remote Programming Mode.

84 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 3—Analog Monitoring (Waukesha Engines)
Menu 3 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 3

Press the Enter key.

MENU 3
Displays the menu number and name.
ANALOG MONITORING

LOCAL BATT VDC #

Displays the local battery VDC.

ANALOG 05 #
Displays analog 05 and the user-defined description.
(USER DEFINED DESC)

ANALOG 06 #
Displays analog 06 end the user-defined description.
(USER DEFINED DESC)

ANALOG 07 #
Displays analog 07 and the user-defined description.
(USER DEFINED DESC)

OR
Displays analog 07 voltage adjustment VDC value when this option is
ANALOG 07 #
enabled. Note: This function may be overridden by changing the
ANALOG VOLT ADJUST
description using the optional Monitor III software or by disabling in
Menu 11.
ANALOG MONITORING Returns user to analog monitoring heading.
MENU 3 Note: Enter data using a PC in the Remote Programming Mode.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 85

2.8.4 Menu 4—Operational Records
Menu 4 provides the generator set operational records Generator set connected to an automatic transfer
including the operating start date, last logged switch. Should a utility power failure occur while the unit
maintenance, total run time loaded and unloaded, run is in the run time mode, the controller bypasses the run
time since the last maintenance, number of starts, and time mode and functions in the standby (backup) mode.
number of running days. If the utility power returns, the generator set continues to
run for the duration of the run time period if not timed out.
Run Time Feature. This menu provides the ability to run
the generator set for a designated time. After the run time Note: Press the STOP PROG RUN key to stop the
elapses. the generator set shuts down and functions in generator set when in the run time mode, if
the standby mode. The generator set controller does not necessary.
provide weekly scheduled exercise periods.
After performing maintenance, enter yes to reset
records reflecting the current day. The user must enable
the programming mode to edit the display.
Menu 4—Operational Records
Menu 4 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 4

Press the Enter key.

MENU 4
Displays the menu number and name.
OPERATIONAL RECORDS

FACTORY TEST DATE

##-###-## Displays the factory test date (day-month-year).

TOTAL RUN TIME

HRS #
Displays the total run time (hours:minutes).

TOTAL RUN TIME

Displays the total run time for loaded hours.
LOADED HRS #

TOTAL RUN TIME

UNLOADED HRS #
Displays the total run time for unloaded hours.

TOTAL RUN TIME

KW HRS # Displays the total run time in kW hours.

NO. OF STARTS #
Displays the number of engine starts.

ENGINE START? Y/N→

Displays the start and countdown subheading.
COUNTDOWN ##:##

RUN TIME HR:MN→ Displays the run time (hours:minutes) feature. When required, use
??:?? the numeric keys to enter the selected run time (hours:minutes) and
press the Enter key.
RUN TIME HR:MN→ Confirms entry and displays the selected run time (hours:minutes).
##:## The generator set will start after activation. Note: Activate the
generator set run time feature by pressing the Yes and Enter keys.
See the following steps.
ENGINE START? Y/N→ Returns the user to the start and countdown subheading. Enter Yes
COUNTDOWN ##:## to start the generator set.

86 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 4—Operational Records, continued
Menu 4 Displays with Key Entries
Key
Entry Display Description

ENGINE START? YES→

Press the Enter key.
COUNTDOWN ##:##

RUN TIME HR:MN→ Confirms the entry. The generator set will begin cranking and run
##:## based on the run time (hours:minutes) period and all previously
established time (hours:minutes) delays from Menu 8—Time Delays.
Note: Press the STOP PROG RUN key to stop the generator set
when in the run time mode, if necessary.
RECORDS MAINT → Displays the records maintenance subheading.

RESET RECORDS? → Displays the reset records option. After performing maintenance or
when required, enter Yes to reset.

RESET RECORDS? YES→

Enter Yes to reset to the current date and press the Enter key.

RESET RECORDS? YES→

Confirms the entry.

RECORDS MAINT →
Returns the user to records maintenance subheading.

RUN TIME SINCE MAINT

TOTAL HRS # Displays the run time since the last maintenance with total hours.

RUN TIME SINCE MAINT

LOADED HRS # Displays the run time since last the maintenance with loaded hours.

RUN TIME SINCE MAINT

UNLOADED HRS # Displays the run time since the last maintenance with unloaded
hours.
RUN TIME SINCE MAINT
KW HRS #
Displays the run time since the last maintenance in kW hours.

OPERATING DAYS #
LAST MAINT ##-###-##
Displays the operating days since the last maintenance.

NO. OF STARTS # Displays the number of starts since the last maintenance date
LAST MAINT ##-###-## (day-month-year).

LAST START ##:## AM/PM

Displays last the start time (hours:minutes) and date
DATE ##-###-##
(day-month-year).

LENGTH OF RUN
Displays the length of last run in (un)loaded hours.
(UN)LOADED HRS #

MENU 4
OPERATIONAL RECORDS Returns the user to the operational records heading.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 87

2.8.5 Menu 5—Event History
Menu 5 stores and displays the times and dates of up to
100 stored status, warning, and shutdown events. After
the first 100 events, each additional new event replaces
the oldest event. See Menu 10—Output Setup for a list
of possible events.

Note: This menu is for monitoring only; no adjustments

or user settings can be entered.

Menu 5—Event History

Menu 5 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 5

Press the Enter key.

MENU 5 Displays the menu number and name.

EVENT HISTORY

(MESSAGE TEXT) Displays the message text, date (day-month-year) and time
##-###-## ##:## AM/PM (hours:minutes). Scroll through up to 100 stored events. See
Section 2.3.5, System Warning Lamp, for fault descriptions.

MENU 5
Returns the user to event history heading.
EVENT HISTORY

88 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.6 Menu 6—Time and Date
Menu 6 sets the clock time and date and internal Note: A change to the time/date is recorded as a system
calendar. The controller uses set time for determining event. The time/date reset and other events are
the exercise run time and event records. The time and viewable (up to 100 events). For events that
date are valid only if the controller power (starting occurred prior to a date change, use the previous
battery) remains connected. date as the reference point for determining the
event’s actual date.
The user must enable the programming mode to edit the
display.

Menu 6—Time and Date

Menu 6 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 6

Press the Enter key.

MENU 6
Displays the menu number and name.
TIME AND DATE

DAY OF WEEK ##-###-## Displays the day of the week, date (day-month-year), and time
##:## AM/PM (hours:minutes).

TIME ??:?? AM/PM Displays the time (hours:minutes) of day entry. When required, use
the numeric and am/pm keys to set the time (hours:minutes) of day
and press the Enter key.
DAY OF WEEK ##-###-##
##:## AM/PM
Displays the corrected time (hours:minutes) of day.

DATE ??-???-?? Displays the date (day-month-year) entry. When required, use the
numeric keys to set the day of the month.
AND
DATE ??-???-?? Use the Menu Right → key to select the month.

AND
DATE ??-???-?? Use the numeric keys to set the two-digit year and press the Enter
key.
AND
DAY OF WEEK ##-###-##
##:## AM/PM
Displays the corrected date (day- month-year).

TP-6200 10/12 Local Programming Mode On Section 2 Operation 89

2.8.7 Menu 7—Generator System Note A:Some alternators have limited voltage and
frequency configurations. Inappropriate
Menu 7 contains the factory-preset generator set voltage or frequency entries will cause a
voltage and frequency data. Enter the corresponding RANGE ERROR message.
data if the generator set requires voltage reconnection
and/or frequency adjustment. It is imperative that the Note: The user defines the data shown in Menu 7. It is
user enter the correct data because these settings NOT data measured by the controller and
trigger all related shutdowns. associated sensing devices. The user defines
these values for purposes of calibrating the
See Section 2.5.3, Request and Error Messages, for control.
error display messages and explanations while
navigating the menus. Note: Press the Menu Right → key prior to entering
decimal values where necessary.
The user must enable the programming mode to edit the
display. Note: The variable speed governor (VSG) display
provides the ability to parallel the generator set.

Menu 7—Generator System

Menu 7 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 7

Press the Enter key.

MENU 7 Displays the menu number and name.

GENERATOR SYSTEM

OPERATING MODE → Displays the operating mode selection. Note: The display sample
(see note) YES may differ depending upon previous entries. The previously selected
operating mode appears first, either standby or prime power.

OPERATING MODE → Displays the optional operating mode selection. When required, enter
STANDBY NO YES for standby operating mode. Note: This display indicates the
generator set application.
OPERATING MODE → Enter YES to change the operating mode selection to standby and
STANDBY YES press the Enter key.

OPERATING MODE →
STANDBY YES
Confirms the entry.

OR
OPERATING MODE → Displays the optional operating mode selection. When required, enter
PRIME POWER NO YES for the prime power operating mode. Note: This display
indicates the generator set application.
OPERATING MODE → Enter YES to change the operating mode selection to prime power
PRIME POWER YES and press the Enter key.

OPERATING MODE →
PRIME POWER YES
Confirms the entry.

SYSTEM VOLTAGE Displays the line-to-line system voltage as entered data. When
LINE-LINE ? required, use the numeric keys to set new value. Press the Enter
key.
SYSTEM VOLTAGE
Displays the corrected line-to-line system voltage. See NOTE A.
LINE-LINE #

SYSTEM FREQ # HZ Displays the system frequency as entered data. When required, use
the numeric keys to set the new value. Press the Enter key.

90 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 7—Generator System, continued
Menu 7 Displays with Key Entries
Key
Entry Display Description

SYSTEM FREQ # HZ
Displays the corrected system frequency. See NOTE A.

PHASE → Displays the phase configuration selection. Note: The display

(see note) YES sample may differ depending upon previous entries. The
user-selected phase appears first, either wye, delta, or single phase.
PHASE → Displays the optional phase configuration selection. When required,
3 PHASE DELTA NO use the YES key to choose the delta phase configuration.

PHASE → Enter YES to change the phase configuration to a delta phase

3 PHASE DELTA YES configuration and press the Enter key.

PHASE →
3 PHASE DELTA YES Confirms the entry. See NOTE A.

OR
PHASE → Displays the optional phase configuration selection. When required,
3 PHASE WYE NO use the YES key to choose the wye phase configuration.
PHASE → Enter YES to change the phase configuration to a wye phase
3 PHASE WYE YES configuration and press the Enter key.

PHASE →
3 PHASE WYE YES Confirms the entry. See NOTE A.

OR
PHASE → Displays the optional phase configuration selection. When required,
SINGLE-PHASE NO use the YES key to choose the single-phase configuration.

PHASE → Enter YES to change the phase configuration to a single-phase

SINGLE-PHASE YES configuration and press the Enter key.

PHASE →
SINGLE-PHASE YES Confirms the entry. See NOTE A.

KW RATING ? Displays the generator set kW rating as entered data. When

required, use the numeric keys to set the new value. Press the Enter
key.
KW RATING #
Displays the corrected system kilowatt rating.

RATED CURRENT # Displays the generator set rated current as entered data. Note: This
is a read-only display.

LOAD SHED OUTPUT → Displays the load shed output setting. When required, use the
?% # KW numeric keys to set the new value. Press the Enter key. See Menu
10, Output Setup for Group B User-Defined Systems Events
LOAD SHED OUTPUT →
#% # KW Displays the corrected load shed output setting.

TIME DELAY MIN:SEC → Displays the load shed time (minutes:seconds) delay setting. When
??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC →
##:##
Displays the corrected load shed time (minutes:seconds) delay
setting.
LOAD SHED OUTPUT →
#% # KW
Returns the user to the load shed output setting.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 91

Menu 7—Generator System, continued
Menu 7 Displays with Key Entries
Key
Entry Display Description

OVERVOLTAGE → Displays the overvoltage setting. When required, use the numeric
?% # VAC keys to set the new value. Press the Enter key.

OVERVOLTAGE →
Displays the corrected overvoltage setting.
#% # VAC

TIME DELAY MIN:SEC → Displays the overvoltage time (minutes:seconds) delay setting. When
??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC → Displays the corrected overvoltage time (minutes:seconds) delay
##:## setting.

OVERVOLTAGE →
#% # VAC
Returns the user to the overvoltage setting.

UNDERVOLTAGE → Displays the undervoltage setting. When required, use the numeric
?% # VAC keys to set the new value. Press the Enter key.

UNDERVOLTAGE →
#% # VAC
Displays the corrected undervoltage setting.

TIME DELAY MIN:SEC → Displays the undervoltage time (minutes:seconds) delay setting.
??:?? When required, use the numeric keys to set the new value. Press the
Enter key.
TIME DELAY MIN:SEC → Displays the corrected overvoltage time (minutes:seconds) delay
##:## setting.

UNDERVOLTAGE →
Returns the user to the undervoltage setting.
#% # VAC

OVERFREQUENCY Displays the overfrequency setting. When required, use the numeric
?% # HZ keys to set the new value. Press the Enter key.

OVERFREQUENCY
#% # HZ Displays the corrected overfrequency setting.

UNDERFREQUENCY Displays the underfrequency setting. When required, use the

?% # HZ numeric keys to set the new value. Press the Enter key.

UNDERFREQUENCY
Displays the corrected underfrequency setting.
#% # HZ

OVERSPEED
Displays the overspeed setting. When required, use the numeric
? HZ # RPM
keys to set the new value. Press the Enter key.

OVERSPEED
# HZ # RPM Displays the corrected overspeed setting.

92 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 7—Generator System, continued
Menu 7 Displays with Key Entries
Key
Entry Display Description

BATTERY VOLTAGE → Displays the battery voltage selection. Note: The display sample
(see note) YES may differ depending upon previous entries. The user-selected
battery voltage appears first, either 12 VDC or 24 VDC.
BATTERY VOLTAGE → Displays the 12 VDC battery voltage selection. When required, use
12 VDC NO the YES key to choose the 12 VDC battery voltage.

BATTERY VOLTAGE → Enter YES to change the battery voltage to 12 VDC and press the
12 VDC YES Enter key.

BATTERY VOLTAGE →
12 VDC YES Confirms the entry.

OR
BATTERY VOLTAGE → Displays the 24 VDC battery voltage selection. When required, use
24 VDC NO the YES key to choose the 24 VDC battery voltage.

BATTERY VOLTAGE → Enter YES to change the battery voltage to 24 VDC and press the
24 VDC YES Enter key.

BATTERY VOLTAGE →
24 VDC YES Confirms the entry.

LOW BATTERY VOLTAGE Displays the low battery voltage setting. When required, use the
?.? VDC numeric keys to set the new value. Press the Menu Right → key
AND prior to entering the decimal value.
LOW BATTERY VOLTAGE
?.? VDC Use the numeric keys to enter the decimal value. Press the Enter
key.
LOW BATTERY VOLTAGE
Displays the corrected low battery voltage setting.
#.# VDC

HIGH BATTERY VOLTAGE Displays the high battery voltage setting. When required, use the
?.? VDC numeric keys to set the new value. Press the Menu Right → key
AND prior to entering the decimal value.
HIGH BATTERY VOLTAGE
?.? VDC
Use the numeric keys to enter the decimal value. Press the Enter
key.

HIGH BATTERY VOLTAGE

Displays the corrected high battery voltage setting.
#.# VDC

BLOCK HEATER ON #F Displays the block heater energize temperature setting. When
required, use the numeric keys to set the new value. Applies to
DDC/MTU engines with MDEC/ADEC only.
AND
BLOCK HEATER ON ?F
Use the numeric keys to enter the decimal value. Press the Enter
key.
BLOCK HEATER ON #F
Displays the corrected block heater energize temperature setting.

BLOCK HEATER OFF #F Displays the block heater deenergize temperature setting. When
required, use the numeric keys to set the new value. Applies to
Detroit Diesel engines with MDEC/ADEC engine controls only.
AND
BLOCK HEATER OFF ?F
Use the numeric keys to enter the decimal value. Press the Enter
key.
BLOCK HEATER OFF #F
Displays the corrected block heater deenergize temperature setting.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 93

Menu 7—Generator System, continued
Menu 7 Displays with Key Entries
Key
Entry Display Description

ENABLE VSG YES/NO

Displays the variable speed governor (VSG) yes or no selection for
paralleling applications. When required, use the numeric keys to set
the new value. Applies to DDC/MTU MDEC/ADEC engine only.
ENABLE VSG NO

ENABLE VSG YES Entering YES enables the VSG function.

ENABLE VSG YES

Confirms the entry..

OR
ENABLE VSG YES

ENABLE VSG NO Entering NO disables the VSG function.

ENABLE VSG NO
Confirms the entry..

ENABLE DSC YES/NO

Displays the digital speed control (DSC) yes or no selection for
paralleling applications. When required, use the numeric keys to set
the new value. Applies to DDC/MTU MDEC/ADEC engine only.
ENABLE DSC NO

ENABLE DSC YES

Entering YES enables the DSC function.

ENABLE DSC YES

Confirms the entry..

OR
ENABLE DSC YES

ENABLE DSC NO Entering NO disables the DSC function.

ENABLE DSC NO
Confirms the entry..

94 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 7—Generator System, continued
Menu 7 Displays with Key Entries
Key
Entry Display Description

METRIC UNITS Y/N

Displays the metric units selection.

METRIC UNITS NO

METRIC UNITS YES Enter YES to change to metric displays and press the Enter key.

METRIC UNITS YES

Confirms the entry.

OR
METRIC UNITS YES

METRIC UNITS NO
Enter NO to change to English displays and press the Enter key.

METRIC UNITS NO
Confirms the entry.

SET NFPA-110 Y/N Displays the NFPA 110 default yes or no selection. Note: See
DEFAULTS Menu 10—Output Setup, Overview for a list of the NFPA-110 faults.

SET NFPA-110 NO
DEFAULTS
SET NFPA-110 YES Enter YES to select the NFPA 110 default selection and press the
DEFAULTS Enter key.
SET NFPA-110 YES
Confirms the entry.
DEFAULTS

OR
SET NFPA-110 YES
DEFAULTS
SET NFPA-110 NO Enter NO to deselect the NFPA 110 default selection and press the
DEFAULTS Enter key.

SET NFPA-110 NO
Confirms the entry.
DEFAULTS

MENU 7
Returns the user to the generator system heading.
GENERATOR SYSTEM

TP-6200 10/12 Local Programming Mode On Section 2 Operation 95

2.8.8 Menu 8—Time Delays
Menu 8 displays the various time delays for cyclic the generator set to run for the full engine cooldown time
cranking and other engine-related starting and delay.
shutdown features.
If the engine is above the preset temperature and the
The user must enable the programming mode to edit the unit is signalled to shut down, the unit will continue to run
display. for the duration of the TDEC.

Cooldown Temperature Override. This feature If the engine is at or below the preset temperature and
provides the ability to bypass (override) the generator the unit is signalled to shut down or the TDES is running,
set’s smart cooldown temperature shutdown and force the unit will shut down without waiting for the time delay
to expire.

Menu 8—Time Delays

Menu 8 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 8

Press the Enter key.

MENU 8 Displays the menu number and name.

TIME DELAYS

Displays the engine start time delay in minutes:seconds. When

TIME DELAY MIN:SEC
ENGINE START ??:??
required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC Displays the corrected engine start time (minutes:seconds) delay
ENGINE START ##:## setting.

TIME DELAY MIN:SEC Displays the starting aid time delay in minutes:seconds. When
STARTING AID ??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC Displays the corrected starting aid time (minutes:seconds) delay
STARTING AID ##:## setting.

TIME DELAY MIN:SEC Displays the crank on time delay in minutes:seconds. When required,
CRANK ON ??:?? use the numeric keys to set the new value. Press the Enter key.

TIME DELAY MIN:SEC

CRANK ON ##:## Displays the corrected crank on time (minutes:seconds) delay setting.

TIME DELAY MIN:SEC Displays the crank pause time delay in minutes:seconds. When
CRANK PAUSE ??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC
Displays the corrected crank pause time (minutes:seconds) delay
CRANK PAUSE ##:##
setting.
TIME DELAY MIN:SEC Displays the engine cooldown time delay in minutes:seconds. When
ENG COOLDOWN ??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC Displays the corrected engine cooldown time (minutes:seconds)
ENG COOLDOWN ##:## delay setting.

COOLDOWN TEMPERATURE Displays the cooldown temperature override. When required, use the
OVERRIDE Y/N Yes key to override the cooldown temperature time delay.

96 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 8—Time Delays, continued
Menu 8 Displays with Key Entries
Key
Entry Display Description

COOLDOWN TEMPERATURE Enter YES to select cooldown temperature override time delay and
OVERRIDE YES press the Enter key.

COOLDOWN TEMPERATURE
Confirms the entry.
OVERRIDE Y/N

OVERCRANK SHUTDOWN Displays the engine crank cycles before overcrank shutdown. When
CRANK CYCLES ? required, use the numeric keys to set the new value. Press the Enter
key.
OVERCRANK SHUTDOWN Displays the corrected engine crank cycles before overcrank
CRANK CYCLES # shutdown setting.

TIME DELAY MIN:SEC Displays the overvoltage time delay in minutes:seconds. When
OVERVOLTAGE ??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC Displays the corrected overvoltage time (minutes:seconds) delay
OVERVOLTAGE ##:## setting.

TIME DELAY MIN:SEC Displays the undervoltage time delay in minutes:seconds. When
UNDERVOLTAGE ??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC Displays the corrected undervoltage time (minutes:seconds) delay
UNDERVOLTAGE ##:## setting.

TIME DELAY MIN:SEC

Displays the load shed time delay in minutes:seconds. When
LOAD SHED KW ??:?? required, use the numeric keys to set the new value. Press the Enter
key.
TIME DELAY MIN:SEC Displays the corrected load shed time (minutes:seconds) delay
LOAD SHED KW ##:## setting.

MENU 8
Returns the user to the time delays heading.
TIME DELAYS

TP-6200 10/12 Local Programming Mode On Section 2 Operation 97

2.8.9 Menu 9—Input Setup D TIme Delay (Shutdown or Warning). The time
delay follows the inhibit time delay. The time delay is
Menu 9 provides the setup of user-defined digital and the time period between the controller fault or status
analog warning and shutdown inputs. These inputs event detection and the controller warning or
provide a multitude of choices for configuring shutdown lamp illumination. The delay prevents any
customized auxiliary inputs. nuisance alarms. The time delay range is from 0 to
60 seconds.
The user must enable the programming mode to edit the
display. Digital Inputs. Items identified as not user selectable
are included for specific applications. (Example: AFM
Note: Press the down arrow to move to the start of the SHUTDOWN is enabled with a Waukesha-powered
next input setup. model.) The user can not disable a digital input when
identified as not user selectable.
Note: The user must scale the analog input value in
order to calculate the low/high warning and Analog Inputs. View up to 7 user-defined analog inputs
shutdown analog values based on a 0--5 VDC A01--A07.
scale. See Menu 12, Calibration.
Analog Input A06—Analog Speed Adjust (VSG).
Note: If the ALARM ACTIVE message appears, the Analog Input A06 may be used for analog speed adjust
selected input has an active fault disabling the when external control of engine speed is desired such as
input. This prevents the enabled choice change paralleling applications or closed transition ATS. To
from yes to no. The LED display indicates utilize this capability, the input must be calibrated. Refer
whether the fault is a warning or shutdown. to 2.8.12, Menu 12—Calibration.
Correct the fault condition before attempting the
keypad entry. Note: This feature is supported for Doosan, GM, and
Volvo engines only.
Note: Some data requires entry by a PC in the Remote
Programming mode. See the monitor software Analog Input A07—Analog Voltage Adjust. Analog
operation manual for details. voltage adjust is a feature that the user may choose to
enable. The input designated for use as Analog Voltage
Digital and Analog Inputs. After the user selects the Adjust is analog input A07.
input, the setup requires entering the following choices
or values: enabled (yes/no), inhibit time, and delay time. Enable Analog Voltage Adjust through Menu 11.
Additionally, Monitor 2 or Monitor 3 may be used to
Note: See Figure 2-8 in User Inputs for factory enable Analog Voltage Adjust by entering the proper
reserved digital and analog inputs which are not description (Analog Volt Adjust) for A07. When Analog
user selectable. Voltage Adjust is enabled, the description for A07 is
Analog Volt Adjust. Changing the description using
D Enabled. This menu entry enables the input. The
Monitor 2 or Monitor 3 disables the analog voltage
previous yes/no selection does not activate the input.
adjust feature.
Digital inputs have three tier groups: the selection
group (25 total), the chosen group (up to 21 total), and When Analog Voltage Adjust is enabled, no warning or
the enabled group (up to 21 total based on the chosen shutdown may be enabled for A07.
group). Analog inputs have separate warning and
shutdown enabled choices. Note: If the analog input A07 description does not
match Analog Volt Adjust, input A07 will not
D Inhibit Time Delay. The inhibit time delay is the time function as the voltage adjust.
period following crank disconnect during which the
generator set stabilizes and the controller does not Identification and Descriptions. Descriptions for user
detect fault or status events. The inhibit time delay inputs (auxiliary analog or auxiliary digital) may be
range is from 0 to 60 seconds. entered using the Monitor III software accessory where
the user determines the descriptions in upper and lower
case.

98 Section 2 Operation Local Programming Mode On TP-6200 10/12

Analog Input Values. The analog input selection Battle Switch/Fault Shutdown Override Switch. The
typically requires entering four values: low warning, high battle switch function forces the system to ignore normal
warning, low shutdown, and high shutdown. The analog fault shutdowns such as low oil pressure and high
values and time delays affect how and when the engine temperature. The battle switch does not override
controller reacts. See Figure 2-19. The user must set the emergency stop and overspeed shutdown. When
both the high and low levels so the unit will not the battle switch function is enabled the generator set
inadvertently trigger the adjacent high or low value to continues to run regardless of shutdown signals where
cause a warning or shutdown fault. potential engine/generator damage can occur.

Each analog input has the following nine features: When this input is enabled the yellow warning lamp
illuminates and stored warning/shutdown events that
D One warning enabled and one shutdown enabled are ignored continue to log in Menu 5—Event History.
D One inhibit time period
Idle Mode Active. The idle time is defined by the digital
D One warning delay and one shutdown delay
input time delay. Set the desired time in
D Two warning levels (high and low) minutes:seconds,up to 10 minutes (600 seconds). If
D Two shutdown levels (high and low) manual control of the idle mode is desired, an unlimited
time can be entered as 9:99. The generator set will
Note: The user must scale the analog input value in remain at idle speed as long as the input is active and the
order to calculate the low/high warning and generator set master switch is in the AUTO position.
shutdown values based on a 0--5 VDC scale.
See Menu 12—Calibration. Shutdown Type A and Shutdown Type B. Choose
shutdown type A for standard shutdowns where the
Time after Crank Disconnect red lamp illuminates and the alarm horn sounds.
Inhibit Time Time Choose shutdown type B for shutdowns where air
Analog Time Delay Delay damper indicator RDO-23 energizes for two seconds,
Values Period ! Period ! Complete
the red lamp illuminates, and the alarm horn sounds.
High shutdown value High
is above the high shutdown
warning value function
High warning value is The High warning
above the acceptable The controller function
value controller does view
does not the analog
Acceptable analog System ready
view the input signal
value status
analog value and
Low warning value is input signal the time Low warning
below the acceptable value delay function
value begins
Low shutdown value Low
is below the low shutdown
warning value function

Figure 2-19 Analog Input Logistics

TP-6200 10/12 Local Programming Mode On Section 2 Operation 99

Menu 9—Input Setup
Menu 9 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 9

Press the Enter key.

MENU 9
Displays the menu number and name.
INPUT SETUP

SETUP DIGITAL →
AUXILIARY INPUTS
Displays the setup of digital auxiliary inputs heading.

DIGITAL INPUT 01 → Displays the digital input 01 with the user-defined description.
(USER DEFINED DESC) Note: Press the down arrow to move to the start of the next input
setup.

DIGITAL INPUT 01 → Identifies the signal source for digital input 01. Use the menu down ↓
(see Group A) YES/NO key to select the digital input.

Group A Group A, continued Group A, continued

The preprogrammed VAR PF MODE Y/N LOW COOLANT LEVEL Y/N
selections include the REMOTE SHUTDOWN Y/N LOW COOLANT TEMP Y/N
following list. See REMOTE RESET Y/N BREAKER CLOSED Y/N
Appendix E for AIR DAMPER Y/N ENABLE SYNCH Y/N
application and LOW FUEL Y/N AFM SHUTDOWN Y/N
restrictions with specific FIELD OVERVOLTAGE Y/N KNOCK SHUTDOWN Y/N
engines. IDLE MODE ACTIVE Y/N DETON WARNING Y/N
WARNING Y/N BATTLE SWITCH Y/N DETON SHUTDOWN Y/N
SHUTDOWN TYPE A Y/N GROUND FAULT Y/N LOW FUEL SHUTDOWN Y/N
SHUTDOWN TYPE B Y/N BAT CHGR FAULT Y/N
VOLTAGE RAISE Y/N HIGH OIL TEMP Y/N
VOLTAGE LOWER Y/N

DIGITAL INPUT 01 →
Displays the digital input 01, enabled yes or no selection.
ENABLED YES/NO

DIGITAL INPUT 01 →
Entering YES enables digital input 01.
ENABLED NO

DIGITAL INPUT 01 →
Press the Enter key.
ENABLED YES

DIGITAL INPUT 01 →
Confirms the entry.
ENABLED YES

OR
DIGITAL INPUT 01 →
ENABLED YES Entering NO disables digital input 01.

DIGITAL INPUT 01 →
ENABLED NO Press the Enter key.

DIGITAL INPUT 01 →
Confirms the entry.
ENABLED NO

100 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 9—Input Setup, continued
Menu 9 Displays with Key Entries
Key
Entry Display Description

DIGITAL INPUT 01 → Displays the digital input 01 inhibit time (minutes:seconds) setting.
INHIBIT TIME ?:?? When required, use the numeric keys to set the new values. Press
the Enter key.

DIGITAL INPUT 01 Displays the corrected inhibit time (minutes:seconds) setting.

INHIBIT TIME #:##

Displays the digital input 01 delay time (minutes:seconds) setting.

DIGITAL INPUT 01 →
When required, use the numeric keys to set the new values. Press
DELAY TIME ?:??
the Enter key.

DIGITAL INPUT 01 → Displays the corrected delay time (minutes:seconds) setting.

DELAY TIME #:##

DIGITAL INPUT 01 → Returns the user to digital input 01.

(USER DEFINED DESC)
Displays digital inputs 02 to 21. Note: Press the down arrow to scroll
through additional digital auxiliary inputs or enter the input number.
DIGITAL INPUT XX → Note: Press the right arrow at each digital auxiliary input to enable the
(USER DEFINED DESC) selection, inhibit time setting, and delay time setting. See Digital
Input 01 instructions for complete procedure and Group A
selections.See Figure 2-8 in User Inputs for factory reserved digital
and analog inputs which are not user selectable.
MENU 9
Returns the user to the menu number and name.
INPUT SETUP

SETUP DIGITAL →
AUXILIARY INPUTS Returns the user to setup digital auxiliary inputs.

SETUP ANALOG →
AUXILIARY INPUTS Displays the setup of analog auxiliary inputs heading.

ANALOG INPUT 01 → Displays the analog input 01 with user-defined description.

(USER DEFINED DESC) Note: ECM engines have inputs 01--07 and non-ECM engines have
inputs 03--07. Waukesha engines have inputs 05--07. Note: Press
the down arrow to move to the start of the next input setup.
ANALOG INPUT 01 →
WARNING ENABLED Y/N Displays the analog input 01, warning enabled yes or no selection.

ANALOG INPUT 01 →
Entering YES enables the warning analog input 01.
WARNING ENABLED NO

ANALOG INPUT 01 →
Press the Enter key.
WARNING ENABLED YES
AND
ANALOG INPUT 01 →
Confirms the entry.
WARNING ENABLED YES

OR
ANALOG INPUT 01 →
WARNING ENABLED YES Entering NO disables the warning analog input 01.

ANALOG INPUT 01 →
WARNING ENABLED NO Press the Enter key.

AND
ANALOG INPUT 01 →
Confirms the entry.
WARNING ENABLED NO

TP-6200 10/12 Local Programming Mode On Section 2 Operation 101

Menu 9—Input Setup, continued
Menu 9 Displays with Key Entries
Key
Entry Display Description

ANALOG INPUT 01 →
SHUTDOWN ENABLED Y/N
Displays the analog input 01, shutdown enabled selection.

ANALOG INPUT 01 →
SHUTDOWN ENABLED NO Entering YES enables the shutdown analog input 01.

ANALOG INPUT 01 →
Press the Enter key.
SHUTDOWN ENABLED YES
AND
ANALOG INPUT 01 →
Confirms the entry.
SHUTDOWN ENABLED YES

OR
ANALOG INPUT 01 →
Entering NO disables the shutdown analog input 01.
SHUTDOWN ENABLED YES

ANALOG INPUT 01 →
Press the Enter key.
SHUTDOWN ENABLED NO
AND
ANALOG INPUT 01 →
Confirms the entry.
SHUTDOWN ENABLED NO

ANALOG INPUT 01 → Displays the analog input 01, inhibit time (minutes:seconds) setting.
INHIBIT TIME ?:?? When required, use the numeric keys to set the new values. Press
the Enter key.
ANALOG INPUT 01 →
Displays the corrected inhibit time (minutes:seconds) setting.
INHIBIT TIME #:##

ANALOG INPUT 01 → Displays the analog input 01, warning time (minutes:seconds) delay
WARN DELAY TIME ?:?? setting. When required, use the numeric keys to set the new values.
Press the Enter key.
ANALOG INPUT 01 →
Displays the corrected warning time (minutes:seconds) delay setting.
WARN DELAY TIME #:##

ANALOG INPUT 01 → Displays the analog input 01, shutdown time (minutes:seconds) delay
SDWN DELAY TIME ?:?? setting. When required, use the numeric keys to set the new values.
Press the Enter key.
ANALOG INPUT 01 → Displays the corrected shutdown time (minutes:seconds) delay
SDWN DELAY TIME #:## setting.

ANALOG INPUT 01 → Displays the analog input 01, low shutdown value. When required,
LO SDWN VALUE ? use the numeric keys to set the new values. Press the Enter key.
Note: The user must scale the analog input value in order to calculate
the low/high warning and shutdown values based on a 0--5 VDC
scale. See Menu 12—Calibration.

ANALOG INPUT 01 →
LO SDWN VALUE #
Displays the corrected low shutdown value.

ANALOG INPUT 01 → Displays the analog input 01, low warning value. When required, use
LO WARN VALUE ? the numeric keys to set the new values. Press the Enter key.
Note: The user must scale the analog input value in order to calculate
the low/high warning and shutdown values based on a 0--5 VDC
scale. See Menu 12—Calibration.
ANALOG INPUT 01 →
Displays the corrected low warning value.
LO WARN VALUE #

102 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 9—Input Setup, continued
Menu 9 Displays with Key Entries
Key
Entry Display Description

ANALOG INPUT 01 → Displays the analog input 01, high warning value. When required,
HI WARN VALUE ? use the numeric keys to set the new values. Press the Enter key.
Note: The user must scale the analog input value in order to calculate
the low/high warning and shutdown values based on a 0--5 VDC
scale. See Menu 12—Calibration.
ANALOG INPUT 01 →
Displays the corrected high warning value.
HI WARN VALUE #

ANALOG INPUT 01 → Displays the analog input 01, high shutdown value. When required,
HI SDWN VALUE ? use the numeric keys to set the new values. Press the Enter key.
Note: The user must scale the analog input value in order to calculate
the low/high warning and shutdown values based on a 0--5 VDC
scale. See Menu 12—Calibration.

ANALOG INPUT 01 →
Displays the corrected high shutdown value.
HI SDWN VALUE #

ANALOG INPUT 01 →
Returns the user to analog input 01.
(USER DEFINED DESC)

ANALOG INPUT XX → Displays analog inputs A02 to A07. Note: Press the down arrow to
(USER DEFINED DESC) scroll through additional analog auxiliary inputs or enter the input
number. Note: ECM engines have inputs A01--A07 and non-ECM
engines have inputs A03--A07. Waukesha engines have inputs
A05--A07.
Note: Press the right arrow at each analog auxiliary input for the
following selections and settings:
Warning enabled
Shutdown enabled
Inhibit time
Warning delay time
Shutdown delay time
Low shutdown value
Low warning value
High warning value
High shutdown value
See the Analog Input 01 instructions for the complete procedure.
SETUP ANALOG →
AUXILIARY INPUTS
Returns the user to the setup analog auxiliary input heading.

SETUP DIGITAL →
Returns the user to the setup digital auxiliary input heading.
AUXILIARY INPUTS

TP-6200 10/12 Local Programming Mode On Section 2 Operation 103

2.8.10 Menu 10—Output Setup Note: Cannot Change (because the) NFPA is Enabled
appears when the user attempts to modify an
Menu 10 provides setup of the user-defined system, RDO setting that is a NFPA 110 default
digital and analog status and fault outputs, and relay requirement.
driver outputs (RDO) 1--31. These outputs provide a
multitude of choices for configuring customized auxiliary Software Controlled RDOs (SCRDOs)
outputs. Additional individual outputs are available for
monitoring, diagnostic, and control functions. The SCRDO is set up and enabled using the keypad or
PC. See the monitor software operation manual when
The user must enable the programming mode to edit the reactivating the SCRDO. The user can deactivate an
display. SCRDO at the controller. The user cannot reactivate the
SCRDO at the controller. The procedure to deactivate
Note: Some data require entry using a PC in the the SCRDO appears at the end of Menu 10—Output
Remote Programming mode. See the monitor Setup, Displays with Entry Keys—Deactivating the
software operation manual for details. SCRDO. The user must enable the programming mode
to edit the display.
Common Faults
NFPA 110 Faults
The user can program a single fault comprised of status
and fault events from 3 common fault programs— The 15 NFPA 110 fault alarms include the following:
system, digital, and analog faults.
D Overspeed
Up to 66 user-defined system events are available, D Overcrank
which provide status and fault information. See Group B D High Coolant Temperature Shutdown
on the following pages for specific descriptions. The D Oil Pressure Shutdown
NFPA-110 faults are part of the system fault program D Low Coolant Temperature
and are comprised of 15 individual faults shown on this D High Coolant Temperature Warning
page.
D Oil Pressure Warning
Up to 21 user-defined digital status and fault events D Low Fuel
designated as D01 to D21 are available. Each of the D Master Not in Auto
21 status events and faults are assignable as D Battery Charger Fault
shutdowns or warnings. D Low Battery Voltage
D High Battery Voltage
Up to 7 user-defined analog status events and faults D Low Coolant Level
designated as A01 to A07 are available. Each of the
D EPS Supplying Load
7 status events and faults are assignable as shutdowns
D Air Damper Indicator
or warnings with high or low settings for a total of up to
7 status events and fault functions. Defined Common Faults
Relay Driver Outputs (RDOs) The 5 defined common faults include the following:
Up to 31 RDOs are available using the system, digital, D Emergency Stop
and analog status events and faults. RDOs provide only D High Coolant Temperature Shutdown
the relay driver, not the relay. The contact relays that D Oil Pressure Shutdown
interface with other equipment are user supplied. D Overcrank
D Overspeed
Note: Func(Function) Used by (RDO) XX Reassign?
appears when the user attempts to assign an
RDO to a function already assigned.

104 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 10—Output Setup
Menu 10 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 10

Press the Enter key.

MENU 10 Displays the menu number and name.

OUTPUT SETUP

DEFINE COMMON →
FAULTS
Displays the common faults heading.

SYSTEM EVENTS →
Displays the system events heading.

COMMON FAULT Y/N Gives the user the option to add or delete the selection from the
(see Group B) defined system events group. Press the Menu Down key to continue
to the next selection (repeat as necessary).
COMMON FAULT NO
(see Group B)
Entering YES adds the selection to the defined system event group.

COMMON FAULT YES

(see Group B)
Press the Enter key.

COMMON FAULT YES

(see Group B)
Confirms the entry.

OR
COMMON FAULT YES Entering NO removes the selection from the defined system event
(see Group B) group.
COMMON FAULT NO
Press the Enter key.
(see Group B)

COMMON FAULT NO
(see Group B)
Confirms the entry.

Group B Group B, continued Group B, continued Group B, continued

For defined system events, NO OIL PRESS SIGNAL AIR DAMPER CONTROL Waukesha-Powered
choose from the following 66 HI OIL TEMP GROUND FAULT models only:
status events and faults by NO COOL TEMP SIGNAL EEPROM WRITE FAILURE FUEL VALVE RELAY
changing selection to YES. See LOW COOLANT LEVEL CRITICAL OVERVOLTAGE PRELUBE RELAY
Appendix E for application and AFM REMOTE START
restrictions with specific SPEED SENSOR FAULT ALTERNATOR PROTECTION
engines. LOCKED ROTOR SHUTDOWN NO OIL TEMP SIGNAL
EMERGENCY STOP MASTER SWITCH ERROR AIR DAMPER INDICATOR HI OIL TEMP WARNING
OVER SPEED MASTER SWITCH OPEN DEFINED COMMON FAULT NO AIR TEMP SIGNAL
MASTER SWITCH TO OFF (RDO only) (see Menu 10 INTAKE AIR TEMP WARN
OVER CRANK introduction for list)
HI COOL TEMP SHUTDWN AC SENSING LOSS INTAKE AIR TEMP SDWN
SCRDOs 1--4 AFM ENG START RELAY
OIL PRESS SHUTDOWN OVER VOLTAGE
(software controlled RDOs)
LOW COOLANT TEMP UNDER VOLTAGE DDC/MTU engine with
MAINTENANCE DUE MDEC/ADEC only:
(non-ECM engines) WEAK BATTERY
ENGINE DERATE ACTIVE HI OIL TEMP WARNING
LOW FUEL OVER FREQUENCY
ENGINE STALLED (ECM engine) INTAKE AIR TEMP WARN
HI COOL TEMP WARNING UNDER FREQUENCY
J1939 CAN SHUTDOWN INTAKE AIR TEMP SDWN
OIL PRES WARNING LOAD SHED KW OVER (ECM engine)
MASTER NOT IN AUTO LOAD SHED UNDER FREQ ECM YELLOW ALARM
Paralleling Applications only:
NFPA 110 FAULT (see OVER CURRENT ECM RED ALARM
SD REVERSE POWER
Menu 10 introduction for list) EPS SUPPLYING LOAD BLOCK HEATER CONTROL
SD OVER POWER
LOW BATTERY VOLTAGE INTERNAL FAULT LOW COOL TEMP SDOWN
SD LOSS OF FIELD
HIGH BATTERY VOLTAGE DELAY ENG COOLDOWN LOAD SHED OVER TEMP
SD OVERCURRENT PR
BATTERY CHARGE FAULT DELAY ENG START COMMON PR OUTPUT
SYSTEM READY STARTING AID IN SYNCH
LOSS OF ECM COMM GENERATOR SET RUNNING BREAKER TRIP
(ECM engines)

TP-6200 10/12 Local Programming Mode On Section 2 Operation 105

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description

DIGITAL INPUTS →
Displays the digital inputs heading.

COMMON FAULT Y/N Gives the user the option to add or delete selection from the defined
Dxx (see Group C) digital faults starting with D01. Note: Press the Menu Down key to
continue to the next selection D02--D21 (repeat as necessary).
COMMON FAULT NO Entering YES adds the selection to the defined digital fault group.
Dxx (see Group C)

COMMON FAULT YES

Dxx (see Group C) Press the Enter key.

COMMON FAULT YES Confirms the entry.

Dxx (see Group C)
OR
COMMON FAULT YES Entering NO removes the selection from the defined digital fault
Dxx (see Group C) group.
COMMON FAULT NO
Dxx (see Group C)
Press the Enter key.

COMMON FAULT NO
Confirms the entry.
Dxx (see Group C)

Group C
Up to 21 PC user-defined digital
status and fault inputs designated
as D01 to D21 can result in an
digital input common fault.

ANALOG INPUTS →
Displays the analog inputs heading.

COMMON FAULT Y/N Gives the user the option to add or delete selection from the defined
Axx(see Group D) LO analog faults starting with A01. Note: Press the Menu Down key to
WARNING→ continue to the next selection A02--A07 (repeat as necessary).
Group D
Up to 7 analog inputs, PC user-
defined status events and faults
designated as A01 to A07.
Each of the 7 is assignable as a
shutdown or warning with high
and low settings.

106 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description
COMMON FAULT Y/N Indicates whether the previously user-defined analog output was
A01 LO WARNING→ selected (yes or no) as a low warning fault.

COMMON FAULT NO Entering YES adds the low warning selection to the defined analog
A01 LO WARNING→ fault group.
COMMON FAULT YES Press the Enter key.
A01 LO WARNING→

COMMON FAULT YES

Confirms the entry.
A01 LO WARNING→

OR
COMMON FAULT YES Entering NO removes the low warning selection from the defined
A01 LO WARNING→ analog fault group.
COMMON FAULT NO
A01 LO WARNING→ Press the Enter key.

COMMON FAULT NO
Confirms the entry.
A01 LO WARNING→

COMMON FAULT Y/N Indicates whether the previously user-defined analog output was
A01 HI WARNING→ selected (yes or no) as a high warning fault.

COMMON FAULT NO Entering YES adds the high warning selection to the defined analog
A01 HI WARNING→ fault group.

COMMON FAULT YES

A01 HI WARNING→ Press the Enter key.

COMMON FAULT YES

A01 HI WARNING→
Confirms the entry.

OR
COMMON FAULT YES Entering NO removes the high warning selection from the defined
A01 HI WARNING→ analog fault group.
COMMON FAULT NO
A01 HI WARNING→ Press the Enter key.

COMMON FAULT NO
Confirms the entry.
A01 HI WARNING→

TP-6200 10/12 Local Programming Mode On Section 2 Operation 107

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description

COMMON FAULT Y/N Indicates whether the previously user-defined analog output was
A01 LO SHUTDOWN→ selected (yes or no) as a low shutdown fault.

COMMON FAULT NO Entering YES adds the low shutdown selection to the defined analog
A01 LO SHUTDOWN→ fault group.
COMMON FAULT YES Press the Enter key.
A01 LO SHUTDOWN→

COMMON FAULT YES

Confirms the entry.
A01 LO SHUTDOWN→

OR
COMMON FAULT YES Entering NO removes the low shutdown selection from the defined
A01 LO SHUTDOWN→ analog fault group.

COMMON FAULT NO
A01 LO SHUTDOWN→ Press the Enter key.

COMMON FAULT NO
A01 LO SHUTDOWN→ Confirms the entry.

COMMON FAULT Y/N Indicates whether the previously user-defined analog output was
A01 HI SHUTDOWN→ selected (yes or no) as a high shutdown fault.

COMMON FAULT NO Entering YES adds the high shutdown selection to the defined analog
A01 HI SHUTDOWN→ fault group.
COMMON FAULT YES Press the Enter key.
A01 HI SHUTDOWN→

COMMON FAULT YES

Confirms the entry.
A01 HI SHUTDOWN→

OR
COMMON FAULT YES Entering NO removes the high shutdown selection from the defined
A01 HI SHUTDOWN→ analog fault group.
COMMON FAULT NO Press the Enter key.
A01 HI SHUTDOWN→

COMMON FAULT NO Confirms the entry.

A01 HI SHUTDOWN→

COMMON FAULT Y/N Returns the user to common fault (analog inputs) heading.
A01 LO WARNING→ Press the Menu Down key to continue to the next selection A02--A07
(repeat as necessary).
COMMON FAULT Y/N Gives the user the option to add or delete selection from the next
Axx(see Group D) LO defined analog fault. Note: Use the A01 common fault analog input
WARNING→ setup procedure shown above for A02--A07. Go to
Group D
Up to 7 analog inputs, PC user-
defined status events and faults
designated as A01 to A07.
Each of the 7 is assignable as a
shutdown or warning with high
and low settings.

108 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description
ANALOG INPUTS → Returns the user to analog inputs heading.

DEFINE COMMON →
FAULTS
Returns the user to the define common faults heading.

RELAY DRV OUT 01 → Gives the user previously selected items for relay driver outputs
(user defined) (RDO) starting with 01. Note: Press the down arrow to continue to
the next relay driver output 02--31 or enter the RDO number.
Note: The RDO can be assigned from the SYSTEM EVENTS,
DIGITAL INPUTS, or ANALOG INPUTS groups. The start of each of
these groups are highlighted on the following pages.
SYSTEM EVENTS →
Displays the system events heading.

RELAY DRV OUT 01 Y/N Gives the user the option to assign a system event to an RDO. Press
(see Group B) the Menu Down key to continue to the next selection (repeat as
necessary).
RELAY DRV OUT 01 NO Entering YES adds the selection to the RDO group.
(see Group B) Note: Func(Function) Used by (RDO) XX Reassign? appears when
the user attempts to assign an RDO to a function already assigned.
Note: Cannot Change (because the) NFPA is Enabled appears when
the user attempts to modify the RDO setting that is a NFPA 110
default requirement.
RELAY DRV OUT 01 YES
Press the Enter key.
(see Group B)

RELAY DRV OUT 01 YES

(see Group B) Confirms the entry.
Group B Group B, continued Group B, continued *NFPA 110 FAULT
For defined system events, MASTER SWITCH TO OFF Paralleling Applications: The 15 NFPA-110 Fault
choose from the following 66 AC SENSING LOSS SD REVERSE POWER Alarms include the
status events and faults by OVER VOLTAGE SD OVER POWER following:
changing selection to YES. See UNDER VOLTAGE SD LOSS OF FIELD OVERSPEED
Appendix E for application and
restrictions with specific engines. WEAK BATTERY SD OVERCURRENT PR OVERCRANK
EMERGENCY STOP OVER FREQUENCY COMMON PR OUTPUT HIGH COOLANT TEMP
UNDER FREQUENCY IN SYNCH SHUTDOWN
OVER SPEED
LOAD SHED KW OVER BREAKER TRIP OIL PRESSURE
OVER CRANK
LOAD SHED UNDER FREQ Waukesha-powered SHUTDOWN
HI COOL TEMP SHUTDWN
OVER CURRENT models: LOW COOLANT
OIL PRESS SHUTDOWN TEMPERATURE
EPS SUPPLYING LOAD FUEL VALVE RELAY
LOW COOLANT TEMP HIGH COOLANT TEMP
(non-ECM engines) INTERNAL FAULT PRELUBE RELAY
AFM REMOTE START WARNING
LOW FUEL DELAY ENG COOLDOWN
NO OIL TEMP SIGNAL OIL PRESSURE WARNING
HI COOL TEMP WARNING DELAY ENG START
HI OIL TEMP WARNING LOW FUEL
OIL PRES WARNING STARTING AID
NO AIR TEMP SIGNAL MASTER NOT IN AUTO
MASTER NOT IN AUTO GENERATOR SET RUNNING
INTAKE AIR TEMP WARN BATTERY CHARGER FAULT
NFPA 110 FAULT* AIR DAMPER CONTROL
INTAKE AIR TEMP SDWN LOW BATTERY VOLTAGE
LOW BATTERY VOLTAGE GROUND FAULT
AFM ENG START DELAY HIGH BATTERY VOLTAGE
HIGH BATTERY VOLTAGE EEPROM WRITE FAILURE
DDC/MTU engine with LOW COOLANT LEVEL
BATTERY CHARGE FAULT CRITICAL OVERVOLTAGE
MDEC/ADEC: EPS SUPPLYING LOAD
SYSTEM READY ALTERNATOR PROTECTION
SHUTDOWN HI OIL TEMP WARNING AIR DAMPER INDICATOR
LOSS OF ECM COMM [DEFINED COMMON
(ECM engines) AIR DAMPER INDICATOR INTAKE AIR TEMP WARN
INTAKE AIR TEMP SDWN FAULT
NO OIL PRESS SIGNAL DEFINED COMMON FAULT
(RDO only)[ ECM YELLOW ALARM The 5 defined common
HI OIL TEMP faults include the
NO COOL TEMP SIGNAL SCRDOs 1--4 (software controlled ECM RED ALARM
RDOs) following:
LOW COOLANT LEVEL BLOCK HEATER
MAINTENANCE DUE CONTROL EMERGENCY STOP
SPEED SENSOR FAULT HI COOL TEMP
ENGINE DERATE ACTIVE LOW COOL TEMP
LOCKED ROTOR SHUTDOWN
ENGINE STALLED (ECM engines) SDOWN
MASTER SWITCH ERROR LOAD SHED OVER TEMP OIL PRESS SHUTDOWN
J1939 CAN ENGINE SHUTDOWN
MASTER SWITCH OPEN OVERCRANK
(ECM engines)
TP-6200 10/12 Local Programming Mode On Section 2 Operation 109
Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description

DIGITAL INPUTS →
Displays the digital inputs heading.

Gives the user the option to assign a digital input to an RDO starting
RELAY DRV OUT 01 Y/N
with D01. Press the Menu Down key to continue to the next selection
Dxx (see Group C)
D02--D21 (repeat as necessary).
Note: Func(Function) Used by (RDO) XX Reassign? appears when
the user attempts to assign an RDO to a function already assigned.

RELAY DRV OUT 01 NO Entering YES adds the selection to the RDO group.
Dxx (see Group C) Note: Func(Function) Used by (RDO) XX Reassign? appears when
the user attempts to assign an RDO to a function already assigned.
Note: Cannot Change (because the) NFPA is Enabled appears when
the user attempts to modify the RDO setting that is a NFPA 110
default requirement.
RELAY DRV OUT 01 YES
Press the Enter key.
Dxx (see Group C)

RELAY DRV OUT 01 YES

Confirms the entry.
Dxx (see Group C)

Group C
Up to user-defined digital status
and fault inputs designated as
D01 to D21 can result in a digital
input common fault.

ANALOG INPUTS →
Displays the analog inputs heading.

RELAY DRV OUT 01 Y/N Gives the user the option to assign an analog input to an RDO
Axx(see Group D) LO starting with A01. Note: Press the Menu Down key to continue to the
WARNING→ next selection A02-A07 (repeat as necessary).
Group D
Up to 7 analog inputs, user-
defined status events and
faults designated as A01 to
A07. Each of the 7 is
assignable as a shutdown or
warning with high or low
settings.

110 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description

RELAY DRV OUT 01 Y/N Indicates whether the previously user-defined analog RDO was
A01 LO WARNING→ selected (yes or no) as a low warning fault.

RELAY DRV OUT 01 NO Entering YES adds the low warning selection to the defined analog
A01 LO WARNING→ RDO group.

RELAY DRV OUT 01 YES

Press the Enter key.
A01 LO WARNING→

RELAY DRV OUT 01 YES

Confirms the entry.
A01 LO WARNING→

OR
RELAY DRV OUT 01 YES Entering NO removes the low warning selection from the defined
A01 LO WARNING→ analog RDO group.

RELAY DRV OUT 01 NO

A01 LO WARNING→
Press the Enter key.

RELAY DRV OUT 01 NO

Confirms the entry.
A01 LO WARNING→

RELAY DRV OUT 01 Y/N Indicates whether the previously user-defined analog RDO was
A01 HI WARNING→ selected (yes or no) as a high warning fault.

RELAY DRV OUT 01 NO Entering YES adds the high warning selection to the defined analog
A01 HI WARNING→ RDO group.

RELAY DRV OUT 01 YES

A01 HI WARNING→ Press the Enter key.

RELAY DRV OUT 01 YES

A01 HI WARNING→
Confirms the entry.

OR
RELAY DRV OUT 01 YES Entering NO removes the high warning selection from the defined
A01 HI WARNING→ analog RDO group.

RELAY DRV OUT 01 NO Press the Enter key.

A01 HI WARNING→

RELAY DRV OUT 01 NO

Confirms the entry.
A01 HI WARNING→

TP-6200 10/12 Local Programming Mode On Section 2 Operation 111

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries
Key
Entry Display Description

RELAY DRV OUT 01 Y/N Indicates whether the previously user-defined analog RDO was
A01 LO SHUTDOWN→ selected (yes or no) as a low shutdown fault.

RELAY DRV OUT 01 NO Entering YES adds the low shutdown selection to the defined analog
A01 LO SHUTDOWN→ RDO group.
RELAY DRV OUT 01 YES
A01 LO SHUTDOWN→ Press the Enter key.

RELAY DRV OUT 01 YES

A01 LO SHUTDOWN→ Confirms the entry.

OR
RELAY DRV OUT 01 YES Entering NO removes the low shutdown selection from the defined
A01 LO SHUTDOWN→ analog RDO group.

RELAY DRV OUT 01 NO

A01 LO SHUTDOWN→ Press the Enter key.

RELAY DRV OUT 01 NO

A01 LO SHUTDOWN→
Confirms the entry.

RELAY DRV OUT 01 Y/N Indicates whether the previously user-defined analog RDO was
A01 HI SHUTDOWN→ selected (yes or no) as a high shutdown fault.

RELAY DRV OUT 01 NO Entering YES adds the high shutdown selection to the defined analog
A01 HI SHUTDOWN→ RDO group.

RELAY DRV OUT 01 YES

A01 HI SHUTDOWN→
Press the Enter key.

RELAY DRV OUT 01 YES

Confirms the entry.
A01 HI SHUTDOWN→

OR
RELAY DRV OUT 01 YES Entering NO removes the high shutdown selection from the defined
A01 HI SHUTDOWN→ analog RDO group.

RELAY DRV OUT 01 NO

A01 HI SHUTDOWN→ Press the Enter key.

RELAY DRV OUT 01 NO

Confirms the entry.
A01 HI SHUTDOWN→

RELAY DRV OUT 01 Y/N Returns the user to the analog RDO (analog inputs) heading. Press
A01 LO WARNING→ the Menu Down key to continue to the next selection A02--A07
(repeat as necessary).
RELAY DRV OUT 01 Y/N Gives the user the option to add or delete a selection for the next
Axx(see Group D) LO analog RDO. Note: Use the A01 analog RDO setup procedure
WARNING→ shown above for A02--A07. Go to
ANALOG INPUTS → Returns the user to the analog inputs heading. Press the Menu Right
key.

RELAY DRV OUT 01 →

Returns the user to the RDO 01 heading.
(user defined)

RELAY DRV OUT XX → Gives the user the option to add or delete a selection for the next
(user defined) RDO. Note: Use the RDO 01 setup procedure shown above for
RDOs 02--31. Go to

112 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 10—Output Setup, continued
Menu 10 Displays with Key Entries—
Deactivating the SCRDO
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 10

Press the Enter key.

MENU 10
Displays the menu number and name
OUTPUT SETUP

DEFINE COMMON →
FAULTS
Displays the common faults heading.

RELAY DRV OUT XX → Gives the user previously selected items for the relay driver outputs
S’WARE CONTROLLED #X (RDO). Press the down arrow to scroll through relay driver outputs
1--31 or enter the RDO number. Locate the SCRDO display.

DEACTIVATE RDO? → When required (SCRDO is currently active), enter the YES key to
deactivate the SCRDO.

DEACTIVATE RDO? YES→ Press the Enter key.

RELAY DRV OUT XX →

S’WARE CONTROLLED #X

TP-6200 10/12 Local Programming Mode On Section 2 Operation 113

2.8.11 Menu 11—Voltage Regulator
Menu 11 provides the setup of the voltage regulator Analog Voltage Adjust. Analog input A07 is the voltage
functions including the line-to-line voltages, adjustment for paralleling applications only. This input
underfrequency unloading (volts per Hz), reactive adjusts the input up or down from the value entered in
droop, power factor, and kVAR adjustments. See Menu 11, Voltage Regulator. If the keypad entry does
Section 1.3.3, Voltage Regulator Adjustments, and not match the displayed value for voltage adjust, the
Appendix C, Voltage Regulator Definitions and analog input is likely not at zero (2.5 VDC). Analog input
Adjustments, for additional information. A07 can be monitored or checked in Menu 3, Analog
Monitoring.
The user must enable the programming mode to edit the
display. Note: Utility paralleling applications require enabling
the VAR/PF controls. The Utility Gain Adjust is
Note: Press the Menu Right → key prior to entering the used for VAR or PF stability adjustment while
decimal values where necessary. paralleling to a utility.

Note: 350--2000 kW models only, see 1.3.2 Voltage Marathonr and DVRr are registered trademarks of Marathon Electric
Regulator and Calibration Specifications Mfg. Corp.
regarding the use of the Marathonr DVRr 2000
voltage regulator on some earlier generator sets.

Menu 11—Voltage Regulator

Menu 11 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15 Input a menu number.

MAIN MENU NUMBER 11

Press the Enter key.

MENU 11
Displays the menu number and name.
VOLTAGE REGULATOR

AVG L-L V #→ Displays the average running line-to-line volts and voltage
VOLT ADJ ?.? adjustment. Enter the desired nominal voltage using the numeric
keys. Press the Menu Right → key prior to entering the decimal
AND
value.
AVG L-L V #→
VOLT ADJ ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.
AVG L-L V #→
Confirms the entry.
VOLT ADJ #.#

L1-L2 VOLTS →
Displays L1-L2 volts.
#

L2-L3 VOLTS → Displays L2-L3 volts (3 phase only).

#

L3-L1 VOLTS →
Displays L3-L1 volts (3 phase only).
#

AVG L-L V #→ Returns the user to the average line-to-line volts and voltage
VOLT ADJ # adjustment heading.

114 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 11—Voltage Regulator, continued
Menu 11 Displays with Key Entries
Key
Entry Display Description

UNDER FREQ UNLOAD → Displays the under frequency (volts per Hz) unloading (yes or no)
ENABLED N/Y selection.

UNDER FREQ UNLOAD →

ENABLED NO Entering YES enables the underfrequency unloading feature.

UNDER FREQ UNLOAD →

Press the Enter key.
ENABLED YES

UNDER FREQ UNLOAD → Confirms the entry.

ENABLED YES

OR
UNDER FREQ UNLOAD → Entering NO disables the underfrequency unloading feature.
ENABLED YES

UNDER FREQ UNLOAD →

ENABLED NO Press the Enter key.

UNDER FREQ UNLOAD →

Confirms the entry.
ENABLED NO

FREQUENCY # HZ→ Displays the present operating frequency and underfrequency

SETPOINT ?.? HZ unloading cut-in point. Enter the desired underfrequency cut-in point
using the numeric keys. Press the Menu Right → key prior to
entering the decimal value.
AND
FREQUENCY # HZ→
Use the numeric keys to enter the decimal value. Press the Enter
SETPOINT ?.? HZ
key.
FREQUENCY # HZ→
SETPOINT #.# HZ
Confirms the entry.

SLOPE → Displays the underfrequency unloading slope (volts-per-cycle). Enter

?.? VOLTS-PER-CYCLE the desired underfrequency unloading slope using the numeric keys.
Press the Menu Right → key prior to entering the decimal value.
AND
SLOPE →
Use the numeric keys to enter the decimal value. Press the Enter
?.? VOLTS-PER-CYCLE
key.

SLOPE →
Confirms the entry.
#.# VOLTS-PER-CYCLE

UNDER FREQ UNLOAD →

ENABLED N/Y
Returns the user to the underfrequency unloading heading.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 115

Menu 11—Voltage Regulator, continued
Menu 11 Displays with Key Entries
Key
Entry Display Description

REACTIVE DROOP →
Displays the reactive droop selection (yes or no).
ENABLED N/Y

REACTIVE DROOP →
ENABLED NO
Entering YES enables the reactive droop feature.

REACTIVE DROOP →
Press the Enter key.
ENABLED YES

REACTIVE DROOP →
ENABLED YES
Confirms the entry.

OR
REACTIVE DROOP →
Entering NO disables the reactive droop feature.
ENABLED YES

REACTIVE DROOP →
Press the Enter key.
ENABLED NO

REACTIVE DROOP → Confirms the entry.

ENABLED NO

.8 PF RATED LOAD → Displays the reactive (voltage) droop as a percentage of the rated
VOLTAGE DROOP ?.?% voltage at rated load. When required, enter the desired reactive
droop using the numeric keys. Press the Menu Right → key prior to
entering the decimal value.
AND
.8 PF RATED LOAD →
Use the numeric keys to enter the decimal value. Press the Enter
VOLTAGE DROOP ?.?%
key.

.8 PF RATED LOAD →
Confirms the entry.
VOLTAGE DROOP #.#%

116 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 11—Voltage Regulator, continued
Menu 11 Displays with Key Entries
Key
Entry Display Description

REACTIVE DROOP →
ENABLED N/Y Returns the user to reactive droop selection heading.

VAR CONTROL →
Displays the VAR control selection (yes or no).
ENABLED N/Y

VAR CONTROL → Entering YES enables the VAR control feature.

ENABLED NO Note: A YES entry disables the PF control if previously activated.
VAR CONTROL →
Press the Enter key.
ENABLED YES

VAR CONTROL →
Confirms the entry.
ENABLED YES

OR
VAR CONTROL →
ENABLED YES Entering NO disables the VAR control feature.

VAR CONTROL →
ENABLED NO
Press the Enter key.

VAR CONTROL →
Confirms the entry.
ENABLED NO

TOTAL KVAR #→ Displays total kVAR (running) and kVAR adjustment settings. Enter
KVAR ADJ ?.? the desired kVAR adjustment using the numeric keys. Press the
Menu Right → key prior to entering the decimal value.
AND
TOTAL KVAR #→
Use the numeric keys to enter the decimal value. Press the Enter
KVAR ADJ ?.?
key.
TOTAL KVAR #→
KVAR ADJ #.# Confirms the entry.

GENERATING/ N/Y→ Displays the generating or absorbing kVAR selection.

ABSORBING Note: The display sample may differ depending upon the previous
entries. The generating selection is the factory default setting.

GENERATING YES→ Displays the generating kVAR selection. When required, use the NO
key to choose absorbing kVAR.
GENERATING NO→ Press the Enter key.

ABSORBING YES→
Confirms the entry.

OR
ABSORBING YES→ Displays the absorbing kVAR selection. When required, use the NO
key to choose generating kVAR.
ABSORBING NO→
Press the Enter key.

GENERATING YES→
Confirms the entry.

VAR CONTROL →
Returns the user to VAR control selection heading.
ENABLED N/Y

TP-6200 10/12 Local Programming Mode On Section 2 Operation 117

Menu 11—Voltage Regulator, continued
Menu 11 Displays with Key Entries
Key
Entry Display Description

PF CONTROL →
ENABLED N/Y
Displays the power factor control selection (yes or no).

PF CONTROL → Entering YES enables the power factor control feature.

ENABLED NO Note: A YES entry disables the kVAR control if previously activated.
PF CONTROL →
Press the Enter key.
ENABLED YES

PF CONTROL →
Confirms the entry.
ENABLED YES

OR
PF CONTROL → Entering NO disables the power factor control feature.
ENABLED YES

PF CONTROL →
Press the Enter key.
ENABLED NO

PF CONTROL →
Confirms the entry.
ENABLED NO

AVERAGE PF #→ Displays the present running average power factor and power factor
PF ADJ ?.? adjustment settings. Enter the desired kVAR adjustment using the
numeric keys. Press the Menu Right → key prior to entering the
decimal value.
AND
AVERAGE PF #→
Use the numeric keys to enter the decimal value. Press the Enter
PF ADJ ?.?
key.
AVERAGE PF #→
PF ADJ #.# Confirms the entry.

LAGGING/ N/Y→ Displays the lagging or leading PF selection.

LEADING Note: The display sample may differ depending upon the previous
entries. The lagging selection is the factory default setting.

LAGGING YES→ Displays the lagging PF selection. When required, use the NO key to
choose leading PF.

LAGGING NO→
Press the Enter key.

LEADING YES→ Confirms the entry.

OR
LEADING YES→ Displays the leading PF selection. When required, use the NO key to
choose lagging PF.

LEADING NO→ Press the Enter key.

LAGGING YES→
Confirms the entry.

PF CONTROL →
Returns the user to the power factor control selection heading.
ENABLED N/Y

118 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 11—Voltage Regulator, continued
Menu 11 Displays with Key Entries
Key
Entry Display Description

REGULATOR GAIN ADJ Displays the generator set voltage regulator gain adjustment. When
GAIN # required, use the numeric keys to enter the desired gain value.

REGULATOR GAIN ADJ

Confirms the entry.
GAIN #

VAR/PF GAIN ADJ Displays the utility (VAR/PF) gain adjustment. When required, use
GAIN # the numeric keys to enter the desired gain value.

VAR/PF GAIN ADJ

Confirms the entry.
GAIN #

ANALOG VOLT ADJUST

Displays current status and provides a means to change the status.
ENABLED? Y/N

RESET REGULATOR
Displays the reset regulator defaults selection.
DEFAULTS Y/N

RESET REGULATOR When required, use the YES key to reset the regulator defaults.
DEFAULTS YES

RESET REGULATOR
DEFAULTS Y/N Confirms the entry.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 119

2.8.12 Menu 12—Calibration inputs A03--A07 where analog inputs A01 and A02 are
reserved for the engine coolant temperature A01 and oil
Menu 12 provides the calibration of the voltage and pressure A02 displays.
current sensing logic. Changing the system voltage or
replacing the main logic control circuit board requires a Analog Input A06—Analog Speed Adjust (VSG).
calibration adjustment. Analog Input A06 may be used for analog speed adjust
when external control of engine speed is desired such as
The user must enable the programming mode to edit the paralleling applications or closed transition ATS. To
display. utilize this capability, the input must be calibrated.

Connect a meter with a minimum accuracy of 1% to Note: For VSG on Analog Aux. Input 06 calibrate:
the generator set output leads to calibrate the Volvo: 0.5V=1250; 4.5V=8750
voltage-sensing logic. Configure the generator set GM/Doosan at 60 Hz: 0.5V=2375; 4.5V=2625
controller for the system operating configuration using GM/Doosan at 50 Hz: 4.5V=2327; 4.5V=2624
Menu 7—Generator System. Adjust the generator set
voltage using Menu 11—Voltage Regulator, when Analog input A07 is the voltage adjustment for
required and adjust the frequency at the generator set paralleling applications only. This input adjusts the input
governor before making calibration adjustments. up or down from the value entered in Menu 11, Voltage
Regulator. Calibration is not necessary.
Reduce the voltage regulator gain using Menu 11,
Voltage Regulator until the voltage is stable prior to Note: Press the Menu Right → key prior to entering
calibration. decimal values where necessary.

The user must scale the analog input value in order to Changes to the generator set system parameters
calculate the low/high warning and shutdown analog causes a CHECK CALIBRATION display message. If
values based on a 0--5 VDC scale. the generator set system parameters are changed,
verify the controller display calibration by comparing the
ECM engines have user-defined analog inputs results to a known measured value.
A01--A07. Non-ECM engines have user-defined analog

Menu 12—Calibration
Menu 12 Displays with Key Entries (Scale AC Analog Inputs)
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 12

Press the Enter key.

MENU 12 Displays the menu number and name.

CALIBRATION

SCALE AC ANALOG
Displays the scale AC analog inputs heading.
INPUTS

GEN VOLTAGE LN
Displays the generator set voltage line-to-neutral heading.

GEN L1-L0 V # Note: The generator set must be running for the following steps.
CALIB REF ?.?
Measure the generator set output voltage for single and three-phase
models between L1-L0 using a voltmeter and enter the result using
the numeric keys. Press the Menu Right → key prior to entering the
decimal value.
AND
GEN L1-L0 V # Use the numeric keys to enter the decimal value. Press the Enter
CALIB REF ?.? key.

GEN L1-L0 V #
Confirms the entry.
CALIB REF #.#

120 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 12—Calibration, continued
Menu 12 Displays with Key Entries (Scale AC Analog Inputs)
Key
Entry Display Description

GEN L2-L0 V # Measure the generator set output voltage for three-phase models
CALIB REF ?.? between L2-L0 using a voltmeter and enter the result using the
numeric keys. Press the Menu Right → key prior to entering the
decimal value.
AND
GEN L2-L0 V # Use the numeric keys to enter the decimal value. Press the Enter
CALIB REF ?.? key.

GEN L2-L0 V #
Confirms the entry.
CALIB REF #.#

GEN L3-L0 V # Three-Phase Models only. Measure the generator set output
CALIB REF ?.? voltage for three-phase models between L3-L0 using a voltmeter and
enter the result using the numeric keys. Press the Menu Right → key
prior to entering the decimal value.
AND
GEN L3-L0 V #
CALIB REF ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.
GEN L3-L0 V #
Confirms the entry.
CALIB REF #

GEN VOLTAGE LN
Returns the user to the generator set voltage line-to-neutral heading.

GEN VOLTAGE LL
Displays the generator set voltage line-to-line heading.

GEN L1-L2 V # Note: The generator set must be running for the following steps.
CALIB REF ?.?
Measure the generator set output voltage for single and three-phase
models between L1-L2 using a voltmeter and enter the result using
the numeric keys. Press the Menu Right → key prior to entering the
decimal value.
AND
GEN L1-L2 V #
CALIB REF ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.

GEN L1-L2 V #
Confirms the entry.
CALIB REF #.#

GEN L2-L3 V # Three-Phase Models only. Measure the generator set output
CALIB REF ?.? voltage for three-phase models between L2-L3 using a voltmeter and
enter the result using the numeric keys. Press the Menu Right → key
prior to entering the decimal value.
Note: The generator set must be running for the following steps.
AND
GEN L2-L3 V #
CALIB REF ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.

GEN L2-L3 V #
Confirms the entry.
CALIB REF #.#

TP-6200 10/12 Local Programming Mode On Section 2 Operation 121

Menu 12—Calibration, continued
Menu 12 Displays with Key Entries (Scale AC Analog Inputs)
Key
Entry Display Description

GEN L3-L1 V # Three-Phase Models only. Measure the generator set output
CALIB REF ?.? voltage for three-phase models between L3-L1 using a voltmeter and
enter the result using the numeric keys. Press the Menu Right → key
prior to entering the decimal value.
AND
GEN L3-L1 V #
CALIB REF ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.
GEN L3-L1 V #
Confirms the entry.
CALIB REF #

CALIBRATE REGULATOR? Displays the calibrate regulator selection.

Y/N Note: After changing the meter calibration the voltage regulator
should be calibrated—enter YES.
CALIBRATE REGULATOR?
YES When required, use the YES key to calibrate the voltage regulator.

CALIBRATE REGULATOR?
Confirms the entry.
Y/N

GEN VOLTAGE LL
Returns the user to the generator set line-to-line voltage heading.

GEN AMPS
Displays the generator set amps heading.

GEN L1 AMPS # Note: The generator set must be running for the following steps.
CALIB REF ?.? Measure the generator set output current for single- and three-phase
models at L1 using an AC ammeter and enter the result using the
numeric keys. Press the Menu Right → key prior to entering the
AND decimal value.
GEN L1 AMPS # Use the numeric keys to enter the decimal value. Press the Enter
CALIB REF ?.? key.

GEN L1 AMPS #
CALIB REF # Confirms the entry.

GEN L2 AMPS # Measure the generator set output current for three-phase models at
CALIB REF ?.? L2 using an AC ammeter and enter the result using the numeric keys.
Press the Menu Right → key prior to entering the decimal value.
AND
GEN L2 AMPS #
Use the numeric keys to enter the decimal value. Press the Enter
CALIB REF ?.?
key.

GEN L2 AMPS # Confirms the entry.

CALIB REF #

122 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 12—Calibration, continued
Menu 12 Displays with Key Entries (Scale AC Analog Inputs)
Key
Entry Display Description

GEN L3 AMPS # Three-Phase Models only. Measure the generator set output
CALIB REF ?.? current for three-phase models at L3 using an AC ammeter and enter
the result using the numeric keys. Press the Menu Right → key prior
to entering the decimal value.
AND
GEN L3 AMPS # Use the numeric keys to enter the decimal value. Press the Enter
CALIB REF ?.? key.

GEN L3 AMPS #
CALIB REF #
Confirms the entry.

GEN AMPS
Returns the user to the generator set amps heading.

LOAD VOLTAGE LN
Displays the load voltage line-to-neutral voltage heading.

LOAD L1--L0 V # Note: The generator sets must be running for the following steps.
CALIB REF (PARALLEL) ?.?
Paralleling Applications. Measure the load voltage between L1-L0
using a voltmeter and enter the result using the numeric keys. Press
the Menu Right → key prior to entering the decimal value.
AND
GEN L1-L0 V #
CALIB REF ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.
GEN L1-L0 V #
Confirms the entry.
CALIB REF #

LOAD L3--L0 V # Note: The generator sets must be running for the following steps.
CALIB REF (PARALLEL) ?.?
Paralleling Applications. Measure the load voltage for three-phase
models between L3-L0 using a voltmeter and enter the result using
the numeric keys. Press the Menu Right → key prior to entering the
decimal value.
AND
GEN L3-L0 V #
CALIB REF ?.?
Use the numeric keys to enter the decimal value. Press the Enter
key.
GEN L3-L0 V #
Confirms the entry.
CALIB REF #

LOAD VOLTAGE LN
Returns the user to the load voltage line-to-neutral voltage heading.

RESTORE DEFAULTS? Y/N

Displays the restore defaults selection.

RESTORE DEFAULTS? YES When required, enter YES to activate the restore calibration defaults
setting. Press the Enter key. Note: Entering Yes will delete all of the
previously entered voltage and current data based on system voltage
and kW and restore the calibration default settings.
RESTORE DEFAULTS? Y/N
Confirms the entry.

GEN VOLTAGE LN
Returns the user to the generator set voltage line-to-neutral heading.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 123

Menu 12—Calibration, continued
Menu 12 Displays with Key Entries (Scale Aux. Analog Inputs)
No calibration is available for inputs A01--A02 for
non-ECM engines. No calibration is available for inputs
A01--A04 for Waukesha engines.
Key
Entry Display Description

ENTER MENU NO. 1--15

Input a menu number.

MAIN MENU NUMBER 12

Press the Enter key.

MENU 12 Displays the menu number and name.

CALIBRATION

SCALE AC ANALOG
Displays the scale AC analog inputs heading.
INPUTS

SCALE AUX. ANALOG →

Displays the scale auxiliary analog inputs heading.
INPUTS

ZERO AUX. ANALOG Gives the user the option to calibrate the auxiliary analog inputs for
INPUTS? zero input signals. Note: ECM engines have inputs A01--A07 and
non-ECM engines have inputs A03--A07. A07 may be used for
analog voltage adjust. Waukesha engines have inputs A05-- A07.

ZERO AUX. ANALOG When required, enter YES to activate the auto-zero auxiliary analog
INPUTS? YES inputs feature. Press the Enter key.

ZERO AUX. ANALOG

Confirms the entry.
INPUTS? YES

ANALOG 01 # Displays the analog 01 and scale value 1 settings. Use the numeric
SCALE VALUE 1 ? keys to enter the minimum value based on the previously calculated
5 VDC analog input value.

SCAL 1 #--#.#V Note: Press the Menu Right → key to review both the scale value 1
SCAL 2 #--#.#V and scale value 2 settings any time during the setup procedure.

ANALOG 01 # Displays analog 01 and scale value 2 settings. Use the numeric keys
SCALE VALUE 2 ? to enter the maximum value based on the previously calculated
5 VDC analog value.

SCALE AUX. ANALOG →

Returns the user to the scale auxiliary analog inputs heading.
INPUTS

ZERO AUX. ANALOG

INPUTS?
Press the down arrow to go to the desired analog XX.

ANALOG XX # Displays scale auxiliary analog inputs 01 to 07.

SCALE VALUE 1 ? Note: Press the down arrow to scroll through the additional analog
auxiliary inputs 02--07.
Note: Press the down arrow to scroll through the additional analog
scale value 1 and value 2 for each analog selection.
Note: Press the right arrow at each analog auxiliary input that
provides display of the scale 1 and scale 2 voltage settings.

124 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.13 Menu 13—Communications The user must enable the programming mode to edit the
display.
Menu 13 enables communication with the controller for
monitoring or controlling the generator set. KBUS allows See Section 2.6 for descriptions of the different types of
a variety of connection types while Modbusr follows connections.
Modbusr RTU protocols. Use the LAN (local area
network) to gain remote access to multiple Modbusr is a registered trademark of Schneider
devices/addresses. Use the KBUS enable local Electric.
programming mode to edit displays in this menu. Use
the monitor software operation manual when accessing The user must enable local programming to make
this menu, programming from a remote location, and changes in Menu 13; see Section 2.8.14. After the
determining address and system identification communications settings have been appropriately
information. entered, set the programming mode to REMOTE to
utilize remote programming.

Menu 13—Communications
Menu 13 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15 Input a menu number.

MAIN MENU NUMBER 13

Press the Enter key.

MENU 13
COMMUNICATIONS Displays the menu number and name.

PROTOCOL →
Displays the KBUS protocol heading.
KBUS

KBUS ONLINE Y/N

Displays the KBUS online selection.

KBUS ONLINE NO Entering YES activates the online KBUS selection.

KBUS ONLINE YES Press the Enter key.

KBUS ONLINE YES

Confirms the entry.

OR
KBUS ONLINE YES Entering NO deactivates the online KBUS selection.

KBUS ONLINE NO Press the Enter key.

KBUS ONLINE NO
Confirms the entry.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 125

Menu 13—Communications, continued
Menu 13 Displays with Key Entries
Key
Entry Display Description

CONNECTION TYPE → Displays the user-defined connection type. Press the Down arrow
(USER DEFINED) Y/N key if the correct connection type is displayed. If the desired
connection type is not displayed, press the Right arrow key until the
desired connection type appears.
CONNECTION TYPES
LOCAL SINGLE Y/N
LOCAL LAN N/Y
LOCAL LAN CONV N/Y Entering YES selects the connection type shown. Note: Selecting
REMOTE SINGLE N/Y one connection type deselects any previously selected choice.
REMOTE LAN N/Y
REMOTE LAN CONV N/Y

CONNECTION TYPE →
Press the Enter key.
(USER DEFINED) YES

CONNECTION TYPE →
(USER DEFINED) YES
Confirms the entry.

PRIMARY PORT → Displays the user-defined primary port subheading. Press the Down
(USER DEFINED) Y/N arrow key if the correct primary port type is displayed. If the desired
primary port type is not displayed, press the Right arrow key until the
desired primary port type appears.

PRIMARY PORTS Entering YES selects the primary port shown. Note: Selecting one
RS-232 Y/N primary port deselects any previously selected choice.
RS-485 ISO 1 N/Y

PRIMARY PORT →
Press the Enter key.
(USER DEFINED) YES

PRIMARY PORT →
Confirms the entry.
(USER DEFINED) YES

ADDRESS ? Displays the LAN connection address number. Use the numeric keys
(LAN Connections) to enter the desired address 1--128. Use one address number per
unit and use consecutive numbers. Individual addresses are
necessary for the software to call up the desired unit.
ADDRESS #
Confirms the entry.
(LAN Connections)

SYSTEM ID ? Displays the system ID request. Use the numeric keys to enter the
(Remote Connections) required system ID of remote connections. The system ID is a
password. The user must use the same password for all devices at a
site.
SYSTEM ID #
Confirms the entry.
(Remote Connections)

BAUD RATE → Displays the user-defined baud rate selection. Press the Down arrow
(USER DEFINED) Y/N key if the correct baud rate is displayed. If the desired baud rate is
not displayed, press the Right arrow key until the desired baud rate
appears.
BAUD RATES
1200 Y/N Entering YES selects the baud rate shown. Note: Selecting one
2400 N/Y
baud rate deselects any previously selected choice.
9600 N/Y

126 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 13—Communications, continued
Menu 13 Displays with Key Entries
Key
Entry Display Description

BAUD RATE →
Press the Enter key.
(USER DEFINED) YES

BAUD RATE →
Confirms the entry.
(USER DEFINED) YES

MENU 13
COMMUNICATIONS Returns the user to the menu number and name.

PROTOCOL →
Returns the user to KBUS protocol heading.
KBUS

PROTOCOL →
MODBUS
Displays the Modbus protocol heading.

MODBUS ONLINE Y/N

Displays the Modbus online selection (yes or no).

MODBUS ONLINE NO Entering YES activates the online Modbus selection.

MODBUS ONLINE YES

Press the Enter key.

MODBUS ONLINE YES

Confirms the entry.

OR
MODBUS ONLINE YES Entering NO deactivates the online Modbus selection.

MODBUS ONLINE NO
Press the Enter key.

MODBUS ONLINE NO
Confirms the entry.

CONNECTION TYPE → Displays the user-defined connection types. Press the Down arrow
(USER DEFINED) Y/N key if the correct connection type is displayed. If the desired
connection type is not displayed, press the Right arrow key until the
desired connection type appears.
CONNECTION TYPES Entering YES selects the connection type shown. Choices are a
SINGLE Y/N single or RS-232 to RS-485 convertor. Note: Selecting one
CONVERTOR N/Y connection type deselects any previously selected choice.

CONNECTION TYPE →
Press the Enter key.
(USER DEFINED) YES

CONNECTION TYPE →
Confirms the entry.
(USER DEFINED) YES

PRIMARY PORT → Displays the user-defined primary ports. Press the Down arrow if the
(USER DEFINED) Y/N correct primary port is displayed. If the desired primary port is not
displayed, press the Right arrow key until the desired primary port
appears.
PRIMARY PORTS
RS-232 Y/N Entering YES selects the primary port shown. Note: Selecting one
RS-485 N/Y primary port deselects any previously selected choice.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 127

Menu 13—Communications, continued
Menu 13 Displays with Key Entries
Key
Entry Display Description

PRIMARY PORT →
Press the Enter key.
(USER DEFINED) YES

PRIMARY PORT →
(USER DEFINED) YES Confirms the entry.

ADDRESS ? Displays the address number. Use the numeric keys to enter the
desired address 1--128. Use one address number per unit and use
consecutive numbers. Individual addresses are necessary for the
software to call up the desired unit.

ADDRESS #
Confirms the entry.

BAUD RATE → Displays the user-defined baud rate. Press the Down arrow key if the
(USER DEFINED) Y/N correct baud rate is displayed. If the desired baud rate is not
displayed, press the Right arrow key until the desired baud rate
appears.
BAUD RATES
9600 N/Y Entering YES selects the baud rate shown. Note: Selecting one
19200 N/Y baud rate deselects any previously selected choice.

BAUD RATE →
(USER DEFINED) YES Press the Enter key.

BAUD RATE →
Confirms the entry.
(USER DEFINED) YES

PROTOCOL →
Returns the user to Modbus protocol heading.
MODBUS

128 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.14 Menu 14—Programming Mode The user chooses one of three programming modes:

Menu 14 allows altering controller data either locally D Local—using the controller keypad
using the keypad or remotely using a PC or other device. D Remote—using a PC
D Off—no programming is permitted
The user must enter a password (access code) to
enable the programming mode. Enter Yes to one mode to change the other two choices
to No.
Local Programming. Local programming is data
alteration using the controller keypad and display.
Note: Use the generator set controller to initially set up
remote programming. Remote programming is
Remote Programming. Remote programming is data
alteration using devices connected to a communication not allowed from a PC unless the controller is first
port using KBUS or Modbusr including Monitor III set for remote programming using Menu 14.
software. Note: After completing the programming always place
Note: Log into the local programming mode to edit the the controller back in the Programming Mode Off
position to prevent inadvertent program changes.
programming access code. The factory default
access code is the number 0. Modbusr is a registered trademark of Schneider
Use Menu 14 to change the access code. Record the Electric.
new number and give the access code to authorized
individuals only. Should the controller logic not accept
the access code or if the new code number is lost,
contact your local authorized distributor/dealer for
password information.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 129

Menu 14—Programming Mode, continued
Menu 14 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15 Input a menu number.

MAIN MENU NUMBER 14

Press the Enter key.

MENU 14 Displays the menu number and name.

PROGRAMMING MODE

PROGRAMMING MODE → Displays the user-defined programming mode. Press the Down
(USER DEFINED) Y/N arrow key if the correct programming mode is displayed. If the
desired programming mode is not displayed, press the Right arrow
key until the desired programming mode appears.
PROGRAMMING MODES
OFF Y/N Entering YES selects the programming mode shown.
LOCAL N/Y Note: Selecting one programming mode deselects any previously
REMOTE N/Y selected choice.

PROGRAMMING MODE → Press the Enter key.

(USER DEFINED) YES

PROGRAMMING MODE Changing the programming mode requires entering the access code.
ENTER CODE * Enter the access code and press the Enter key.
Note: The factory default access code is the number 0.

PROGRAMMING MODE →
Confirms the entry.
(USER DEFINED) YES

PROGRAMMING MODE → Displays the programming mode and changes the access code.
CHANGE ACCESS CODE Press the Down arrow key if you do not wish to change the access
code. To change the access code, press the Right arrow key.

PROGRAMMING MODE
Enter the old access code and press the Enter key.
ENTER OLD CODE *

PROGRAMMING MODE
Enter the new access code and press the Enter key.
ENTER NEW CODE *

PROGRAMMING MODE →
Confirms the entry.
CHANGE ACCESS CODE

MENU 14
PROGRAMMING MODE
Returns the user to the programming mode heading.

130 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.15 Menu 15—Protective Relays (PR) the generator set personality profile did not include the
paralleling option this menu will not appear on the
Menu 15 provides the necessary protective relays for display. Available with PD-Series switchgear only.
units with the optional paralleling protection feature. If

Menu 15—Protective Relays

Menu 15 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15 Input a menu number.

MAIN MENU NUMBER 15

Press the Enter key.

MENU 15 Displays the menu number and name.

PROTECTIVE RELAYS

PR OVERVOLTAGE → Displays the overvoltage % value. When required, use the numeric
?% #VAC keys to enter the desired overvoltage % value and press the Enter
key.
PR OVERVOLTAGE →
Displays the corrected overvoltage % value.
#% #VAC

TIME DELAY → Displays the overvoltage time delay. When required, use the numeric
?SEC keys to enter the desired time delay value and press the Enter key.

TIME DELAY →
Displays the corrected overvoltage time delay value.
#SEC

PR OVERVOLTAGE →
Returns the user to the overvoltage % value display.
?% #VAC

PR UNDERVOLTAGE → Displays the undervoltage % value. When required, use the numeric
?% #VAC keys to enter the desired undervoltage % value and press the Enter
key.
PR UNDERVOLTAGE →
Displays the corrected undervoltage % value.
#% #VAC

TIME DELAY → Displays the undervoltage time delay. When required, use the
?SEC numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected undervoltage time delay value.
#SEC

PR UNDERVOLTAGE →
Returns the user to the undervoltage % value display.
?% #VAC

PR OVERFREQUENCY → Displays the overfrequency % value. When required, use the

?% #HZ numeric keys to enter the desired overfrequency % value and press
the Enter key.
PR OVERFREQUENCY →
Displays the corrected overfrequency % value.
#% #HZ

TIME DELAY → Displays the overfrequency time delay. When required, use the
?SEC numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected overfrequency time delay value.
#SEC

PR OVERFREQUENCY →
Returns the user to the overfrequency % value display.
?% #VAC

TP-6200 10/12 Local Programming Mode On Section 2 Operation 131

Menu 15—Protective Relays, continued
Menu 15 Displays with Key Entries
Key
Entry Display Description

PR UNDERFREQUENCY → Displays the underfrequency % value. When required, use the

?% #HZ numeric keys to enter the desired underfrequency % value and press
the Enter key.
PR UNDERFREQUENCY →
Displays the corrected underfrequency % value.
#% #HZ

TIME DELAY → Displays the underfrequency time delay. When required, use the
?SEC numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected underfrequency time delay value.
#SEC

PR UNDERFREQUENCY →
Returns the user to the underfrequency % value display.
?% #HZ

PR REVERSE POWER → Displays the reverse power % value. When required, use the
?% #KW numeric keys to enter the desired reverse power % value and press
the Enter key.
PR REVERSE POWER →
Displays the corrected reverse power % value.
#% #KW

TIME DELAY → Displays the reverse power time delay. When required, use the
?SEC numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected reverse power time delay value.
#SEC

PR REVERSE POWER →
Returns the user to the reverse power % value display.
?% #KW

SD REVERSE POWER → Displays the reverse power shutdown % value. When required, use
?% #KW the numeric keys to enter the desired reverse power shutdown %
value and press the Enter key.
SD REVERSE POWER →
Displays the corrected reverse power shutdown % value.
#% #KW

TIME DELAY → Displays the reverse power shutdown time delay. When required,
?SEC use the numeric keys to enter the desired time delay value and press
the Enter key.
TIME DELAY →
Displays the corrected reverse power shutdown time delay value.
#SEC

SD REVERSE POWER →
Returns the user to the reverse power shutdown % value display.
?% #KW

PR OVER POWER → Displays the over power % value. When required, use the numeric
?% #KW keys to enter the desired over power % value and press the Enter
key.
PR OVER POWER →
Displays the corrected over power % value.
#% #KW

TIME DELAY → Displays the over power time delay. When required, use the numeric
?SEC keys to enter the desired time delay value and press the Enter key.

TIME DELAY →
Displays the corrected over power time delay value.
#SEC

PR OVER POWER →
?% #KW
Returns the user to the over power % value display.

132 Section 2 Operation Local Programming Mode On TP-6200 10/12

Menu 15—Protective Relays, continued
Menu 15 Displays with Key Entries
Key
Entry Display Description

SD OVER POWER → Displays the over power shutdown % value. When required, use the
?% #KW numeric keys to enter the desired over power shutdown % value and
press the Enter key.
SD OVER POWER →
Displays the corrected over power shutdown % value.
#% #KW

TIME DELAY → Displays the over power shutdown time delay. When required, use
?SEC the numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected over power shutdown time delay value.
#SEC

SD OVER POWER →
Returns the user to the over power shutdown % value display.
?% #KW

PR LOSS OF FIELD → Displays the loss of field % value. When required, use the numeric
?% #KVAR keys to enter the desired loss of field % value and press the Enter
key.
PR LOSS OF FIELD →
Displays the corrected loss of field % value.
#% #KVAR

TIME DELAY → Displays the loss of field time delay. When required, use the numeric
?SEC keys to enter the desired time delay value and press the Enter key.

TIME DELAY →
Displays the corrected loss of field time delay value.
#SEC

PR LOSS OF FIELD →
Returns the user to the loss of field % value display.
?% #KVAR

SD LOSS OF FIELD → Displays the loss of field shutdown % value. When required, use the
?% #KVAR numeric keys to enter the desired loss of field % value and press the
Enter key.
SD LOSS OF FIELD →
Displays the corrected loss of field shutdown % value.
#% #KVAR

TIME DELAY → Displays the loss of field shutdown time delay. When required, use
?SEC the numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected loss of field shutdown time delay value.
#SEC

SD LOSS OF FIELD →
Returns the user to the loss of field shutdown % value display.
?% #KVAR

PR OVERCURRENT VR → Displays the over current with voltage restraint (VR) % value. When
?% #AMPS required, use the numeric keys to enter the desired over current %
value and press the Enter key.
PR OVERCURRENT VR →
Displays the corrected over current % value.
#% #AMPS

TIME DELAY → Displays the over current time delay. When required, use the numeric
?SEC keys to enter the desired time delay value and press the Enter key.

TIME DELAY →
Displays the corrected over current time delay value.
#SEC

PR OVERCURRENT VR →
Returns the user to the over current % value display.
?% #AMPS

TP-6200 10/12 Local Programming Mode On Section 2 Operation 133

Menu 15—Protective Relays, continued
Menu 15 Displays with Key Entries
Key
Entry Display Description

SD OVER CURRENT VR → Displays the over current shutdown with voltage restraint (VR) %
?% #AMPS value. When required, use the numeric keys to enter the desired over
current shutdown % value and press the Enter key.
SD OVER CURRENT VR →
Displays the corrected over current shutdown % value.
#% #AMPS

TIME DELAY → Displays the over current shutdown time delay. When required, use
?SEC the numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY → Displays the corrected over current shutdown time delay value.
#SEC

SD OVER CURRENT VR → Returns the user to the over current shutdown % value display.
?% #AMPS

SYNC VOLTAGE MATCH → Displays the synchronization matching voltage value. When required,
? VAC use the numeric keys to enter the desired synchronization matching
voltage value and press the Enter key.
SYNC VOLTAGE MATCH →
Displays the corrected synchronization matching voltage value.
# VAC

SYNC FREQ MATCH → Displays the synchronization matching frequency value. When
? HZ required, use the numeric keys to enter the desired synchronization
matching frequency value and press the Enter key.
SYNC FREQ MATCH →
# HZ Displays the corrected synchronization matching frequency value.

SYNC PHASE MATCH → Displays the synchronization matching phase value. When required,
? DEG use the numeric keys to enter the desired synchronization matching
phase value and press the Enter key.
SYNC FREQ MATCH →
# DEG Displays the corrected synchronization matching phase value.

TIME DELAY → Displays the synchronization time delay. When required, use the
?SEC numeric keys to enter the desired time delay value and press the
Enter key.
TIME DELAY →
Displays the corrected synchronization time delay value.
#SEC

SYNC VOLTAGE MATCH → Returns the user to the synchronization matching voltage value
? VAC display.

134 Section 2 Operation Local Programming Mode On TP-6200 10/12

2.8.16 Menu 20—Factory Setup Note: For Version 2.69 and lower, enter the numeric
serial number from the generator set nameplate.
Menu 20 provides generator set, alternator, controller, For Version 2.70 and higher, confirm that the
and engine identification information. The user can use alphanumeric number shown on the display
this menu to determine the generator set operating days matches the serial number shown on the
and identify the controller software (code) version. The generator set nameplate. If the serial numbers
factory setup menu information is locked by the match, press the YES key and then press
manufacturer. The temperature sensor setup applies to ENTER. If the serial numbers do not match, the
non-ECM engines only. wrong personality parameter file is installed.
Refer to the Program Loader documentation for
Note: This menu is for monitoring only; no adjustments instructions on reloading the personality
or user settings can be entered. parameter file.
Menu 20—Factory Setup
Menu 20 Displays with Key Entries
Key
Entry Display Description

ENTER MENU NO. 1--15 Input a menu number.

MAIN MENU NUMBER 20

Press the Enter key.

MENU 20 Displays the menu number and name.

FACTORY SETUP

FINAL ASSEMBLY DATE

Displays the final assembly date at the factory.
DD/MM/YY

FINAL ASSEMBLY
Displays the final assembly clock number at the factory.
CLOCK NO #

OPERATING DAYS #
Displays the generator set operating days.

MODEL NO #
Displays the generator set model number.

SPEC NO #
Displays the generator set specification number.

GENSET SERIAL NO #
Displays the generator set serial number.

ALTERNATOR PART NO #
Displays the alternator part number.

ENGINE PART NO #
Displays the engine part number.

TEMP SENSOR YES TEMP SENSOR NO TEMP SENSOR NO

GM31045-X GM16787 GM17362

SERIAL NO CONFIRM →
Displays the generator set serial number confirmation display.

CONFIRM SERIAL? Y/N Press YES, if the display matches the generator set nameplate serial
###### number. Refer to the Menu 20 NOTE above if the serial numbers do
not match.
CONFIRM SERIAL? YES
Press the Enter key.
######

SERIAL NO CONFIRM →
Returns user to the Serial No. Confirm display.

TP-6200 10/12 Local Programming Mode On Section 2 Operation 135

Menu 20—Factory Setup, continued
Menu 20 Displays with Key Entries
Key
Entry Display Description

CONTROLLER SERIAL NO #
Displays the controller serial number.

CODE VERSION #
Displays the controller software (code) version.
COPYRIGHT XXXX

SETUP LOCKED YES

Displays the setup locked by the manufacturer.

136 Section 2 Operation Local Programming Mode On TP-6200 10/12

 Section 3 Scheduled Maintenance

Under normal operating conditions, the generator set’s Disabling the generator set. Accidental starting can
alternator requires no routine service. Consult cause severe injury or death. Before working on the
Section 2.1, Prestart Checklist, for a list of routine generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
checks.
OFF position. (2) Disconnect the power to the battery
charger. (3) Remove the battery cables, negative (--) lead
first. Reconnect the negative (--) lead last when reconnecting
3.1 Alternator Service the battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
When operating the generator set under dusty or dirty start/stop switch, or engine start command from a remote
conditions, use dry compressed air to blow dust out of computer.
the alternator while the generator set is running. Direct
the stream of air through openings in the generator set
WARNING
end bracket.

3.2 Engine Service

Perform engine service at the intervals specified in the Hot engine and exhaust system.
engine manufacturer’s service literature. Contact an Can cause severe injury or death.
authorized service distributor/dealer to obtain service Do not work on the generator set until
literature. it cools.

Note: Have maintenance work, including battery

Servicing the exhaust system. Hot parts can cause
service, performed by appropriately skilled and severe injury or death. Do not touch hot engine parts. The
suitably trained maintenance personnel familiar engine and exhaust system components become extremely
with generator set operation and service. hot during operation.

WARNING WARNING

Hazardous voltage. Moving parts.

Accidental starting. Can cause severe injury or death.
Can cause severe injury or death.
Operate the generator set only when
Disconnect the battery cables before all guards and electrical enclosures
working on the generator set. are in place.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last Servicing the generator set when it is operating. Exposed
when reconnecting the battery. moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.

TP-6200 10/12 Section 3 Scheduled Maintenance 137

3.3 Service Schedule
Action
System—Component Visually Inspect Check Change Clean Test Interval
Fuel System
Day tank level X X Weekly
Flexible lines and connections X R Weekly
Fuel level switch X X Weekly
Main tank supply level X Weekly
Solenoid valve operation X X Weekly
Transfer pump operation X X Weekly
Water in system, remove D D Weekly
Filter(s) D Quarterly
Gasoline supply R Six Months
Fuel piping X Yearly
Tank vents and return lines for obstructions X Yearly
Lubrication System
Oil level D D Weekly
Crankcase breather D D Quarterly
Change oil D First 50 Hrs., Then
Replace filter(s)* D Every 250 Hrs.
Cooling System
Radiator fan bolt torque (1500--2800REOZDC,
Initially 8 Hrs., Then
2500--2800REOZDB, and 3000/3250REOZD with X
Every 100 Hrs.
unit-mounted radiator)
Air cleaner to room/enclosure X Weekly
Block heater operation X Weekly
Coolant level D D Weekly
Flexible hoses and connectors X X Weekly
Water pump(s) D Weekly
Fan and alternator belts D D R Monthly
Coolant temperature protection level D Six Months
Lubricate fan bearings (1350 kW and larger) X X 200 Hrs. or Six Months
Air ducts, louvers X X Yearly
Coolant D Yearly
Heat exchanger X Yearly
Louver motors and controls X X X Yearly
Radiator exterior X Yearly
Water supply to heat exchanger X Yearly
Exhaust System
Drain condensate trap X Weekly
Leakage X X Weekly
Insulation, fire hazards X Quarterly
Flexible connector(s) X Six Months
Excessive back pressure X Yearly
Hangers and supports X Yearly
DC Electrical System
Battery charger operation, charge rate X Monthly
Battery electrolyte level X Monthly
Battery specific gravity, charge state X Monthly
Recharge after engine start X Monthly
Remove corrosion, clean and dry battery and rack X X Monthly
Clean and tighten battery terminals X X Quarterly
Tighten DC electrical connections X Six Months
D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action
* Service more frequently if operated in dusty areas.

138 Section 3 Scheduled Maintenance TP-6200 10/12

Service Schedule, continued
Action
System—Component Visually Inspect Check Change Clean Test Interval
AC Electrical System
Controller lamp test X R Weekly
General Inspection X Weekly
Circuit breakers, fuses[ X X R X X Monthly
Wire abrasions where subject to motion X X Quarterly
Safety and alarm operation X X Six Months
Tighten control and power wiring connections X Yearly
Transfer switch main contacts[ X X Yearly
Voltage-sensing device/relay adjustment[ D D Yearly
3 Years or
Wire-cable insulation breakdown X X
500 Hrs.
Engine and Mounting
General inspection D Weekly
Governor operation, lubricate moving parts D D Monthly
Air cleaner service D D Six Months
Choke, carburetor adjustment D Six Months
Governor oil (mechanical governor only) D Yearly
Ignition components D D Yearly
Injector pump and injector flow rate, pressure, spray pattern D D Yearly
3 Years or
Valve clearance D 500 Hrs.
3 Years or
Bolt torque D D 500 Hrs.
Remote Control System, etc.
Compartment condition X X Weekly
Remote control X Monthly
Run generator set X Monthly
Alternator
General inspection X Weekly
Rotor and stator X X Yearly
Bearing condition X X R Yearly
Exciter X X X Yearly
Voltage regulator X X X Yearly
Measure and record resistance readings of windings with
insulation tester (Meggerr, with SCR assembly or rectifier X Yearly
disconnected)
2 Years or
Blow dust out of alternator* X D 300 Hrs.
General Condition of Equipment
Any condition of vibration, leakage, noise, temperature, or
X X X Weekly
deterioration
Ensure that system is set for automatic operation X Weekly
Interior of equipment room or outdoor weather housing X X Weekly
D Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual.
If not indicated, follow this service schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action.
* Service more frequently if operated in dusty areas.
[ Do not break manufacturer’s seals or internally inspect these devices.

Meggerr is a registered trademark of Biddle Instruments.

TP-6200 10/12 Section 3 Scheduled Maintenance 139

3.4 Alternator Bearing Service Note: The illustration shows a generator set
without a fuel/water separator. The valve
Have an authorized service distributor/dealer perform location and position for a generator set
service. equipped with a fuel/water separator is
similar.
3.4.1 20--300 kW Models 2. Loosen the bleed screw at the engine. Refer to the
engine operation manual for location of the bleed
Replace the end bracket bearing every 10,000 hours of
operation in standby and prime power applications. screw(s). The bleed screw allows air to be expelled
from the fuel system when the hand prime pump is
Service the bearing more frequently if the annual
inspection indicates excessive rotor end play or bearing operated.
damage. Replace the tolerance ring, if equipped,
3. Rotate the hand prime pump handle
following end bracket removal. The sealed end bracket counterclockwise until fuel flows from the bleed
bearing requires no additional lubrication.
screw. Stop pumping.

3.4.2 300--2250 kW Models with 4. Tighten the bleed screw. Wipe up any fuel leakage.
Single-Bearing Alternator 5. Place the fuel valves in the normal operation
The alternator bearing requires lubrication at intervals position. Open the fuel valve located between the
specified in the generator set technical manual. Use pipe tee and the engine. Close the fuel valves on
Chevron SRI or equivalent antifriction, high-quality each side of the fuel prime pump.
grease with a lubrication temperature range of --30°C to
175°C (--22°F to 350°F).

3.4.3 1250 kW and Larger Models with

Two-Bearing Alternator
Refer to the generator set service manual for bearing
maintenance information.

3.5 Diesel Fuel Systems

3.5.1 Bleeding Air from Fuel System

Bleed air from the fuel system after fuel system Close this Valve Open this Valve
maintenance, such as replacing the fuel filter(s). Use Open this Valve
the hand prime pump kit, when equipped. The hand
prime fuel pump eliminates the need for cranking the
engine to bleed air from the fuel system.

Note: Bleed air from the fuel system according to the Valve Open Valve Closed PK-272000-H

engine manufacturer’s instructions. Trapped air

Figure 3-1 Hand Prime Pump with Valve Positions
in the fuel system causes difficult starting and/or
for Fuel Priming (generator set without a
erratic engine operation.
fuel/water separator shown), Typical
Note: Correct any fuel leaks encountered during the
priming procedure.

1. Place the fuel valves in the fuel system prime

position. Close the fuel valve located between the
pipe tee and the engine. Open the fuel valves on
each side of the fuel prime pump. See Figure 3-1.

140 Section 3 Scheduled Maintenance TP-6200 10/12

3.5.2 Subbase Fuel Day Tank Electronic Level Sensor
Control Module (ECM) An electronic analog float gauge located below the ECM
With an electronic control module (ECM), the optional on the mounting bracket determines the day tank fuel
subbase diesel fuel tank functions as a day tank. level. Nine LEDs on the ECM indicate the day tank fuel
Following are operating information and features of the level from full to empty.
ECM. See Figure 3-2 for the ECM front panel layout.
ECM Mode
The ECM has three pushbutton switches for normal
operation and one internal test button. See Figure 3-4.

Pushbutton Description
Off Pushbutton disables the ECM for routine
maintenance to the tank system.
On Pushbutton activates the ECM after the
OFF pushbutton is depressed. On
power-up after a power outage, the ECM
automatically turns on.
Test Pushbutton lights front panel LEDs for
3 seconds and activates the pump/motor
for as long as the pushbutton is
depressed. The alarm relays maintain
their original positions.
Internal test Pushbutton (located inside the ECM) tests
224825
each alarm LED and remote annunciation
relay in sequential order (high fuel to ECM
Figure 3-2 ECM Front Panel Layout functional).

Servicing the day tank. Hazardous voltage can cause Figure 3-4 ECM Pushbuttons
severe injury or death. Service the day tank electrical
control module (ECM) as prescribed in the equipment
manual. Disconnect the power to the day tank before
ECM Alarms
servicing. Press the day tank ECM OFF pushbutton to The ECM has five standard alarm conditions indicated
disconnect the power. Notice that line voltage is still present
within the ECM when the POWER ON light is lit. Ensure that
locally by LEDs and remotely by relays. Figure 3-5
the generator set and day tank are electrically grounded. Do describes the five alarm conditions. Make controller
not operate the day tank when standing in water or on wet connections to the normally open and normally closed
ground because these conditions increase the risk of relay contacts provided.
electrocution.
Alarm Description
ECM General Function High fuel Alarm activates at 106% of normal fuel
level.
The ECM controls a pump/motor that maintains the day Low fuel Alarm activates at 62% of normal fuel
tank fuel level. The ECM motor relay is connected to the level. The alarm provides time to respond
pump/motor. The ECM starts the pump when the fuel to a potential problem before a low fuel
shutdown occurs.
level drops to 87% of full and stops the pump when the
Critical low fuel Alarm activates at 6% of normal fuel level
day tank is full. (engine shutdown) to warn the operator to shut down the
generator set before fuel runs out.
ECM Function Indicator LEDs Fuel in rupture Alarm activates when the ECM detects
basin, if equipped fuel in the rupture basin.
Two LEDs on the front panel indicate ECM operation. ECM functional Alarm activates to indicate a problem with
See Figure 3-2 for the locations of the LEDs. Figure 3-3 the ECM operation.
describes the LED functions. Note: The ECM functional alarm relay
activates a user-installed alarm when the
relay deenergizes.
Function Description
Power On LED lights to indicate that power is applied Figure 3-5 ECM Alarms
to the ECM.
Pump Running LED lights when the pump starts.

Figure 3-3 ECM Function Indicator LEDs

TP-6200 10/12 Section 3 Scheduled Maintenance 141

3.5.3 Subbase Inner Fuel Tank Alarm Resetting Procedure
This kit provides for both audible and visual alarms from Use the following procedure to reset the alarm after a
a location remote from the generator set if a leak is fault alarm.
detected in the inner fuel tank of the double-wall
1. Move the alarm switch to the SILENCE position to
subbase fuel tanks. See Figure 3-6. If the inner tank is
stop the alarm horn. The lamp will remain lit.
leaking, a sensor installed in the outer tank sends an
electrical signal to the alarm plate when the sensor 2. Disconnect the generator set from the load with
becomes immersed in the fuel collecting in the outer the line circuit breaker or the automatic transfer
tank. If a leak is detected, the alarm horn will sound and switch.
the fault lamp will light. The alarm horn is quieted by
moving the alarm switch to the SILENCE position; the 3. Repair or replace the inner fuel tank.
alarm lamp remains lit until the fault is corrected. See 4. Move the generator set master switch to the
Figure 3-7 for troubleshooting information. OFF/RESET position and then to the RUN position
for startup. The alarm horn sounds and the lamp
goes out.
Inner Tank 5. Reconnect the generator set to the load via the line
circuit breaker or the automatic transfer switch.
Fuel Leak
Alarm
6. Move the generator set master switch to the AUTO
position for startup by remote transfer switch or
Alarm
Normal Silence remote start/stop switch. Move the alarm switch to
the NORMAL position.

3.6 Gas Fuel Systems (REZG_ and

Leak Alarm Panel
REZX_/RZX_ models)
This section describes natural gas and liquified
petroleum gas (LPG) fuel systems that are not covered
in the engine operation manual or engine service
manual.

3.6.1 Gas Fuel System Concept

(Single Fuel)
The gas fuel system uses a fuel solenoid valve to control
the fuel flow to the electronic-controlled pressure
regulator (EPR). The generator set-mounted EPR
FF-273000-D
reduces the fuel pressure as fuel passes to the fuel
Figure 3-6 Inner Fuel Tank Leak Alarm mixer. See Figure 3-8.
(20--300 kW Model Shown)
The fuel mixer controls the ratio of fuel to air under
varying load and speed conditions. Because the fuel
Switch Position mixer receives fuel in a gaseous state, it does not have to
vaporize the fuel.
Alarm Float Observation
Normal Open The alarm horn and the lamp are not
energized. 3.6.2 LPG Liquid Withdrawal Fuel
Normal Closed The alarm horn and lamp activate when a System Concept
fuel leak occurs. If the alarm switch is
moved to the silence position, the lamp
stays on until the fuel leak fault is corrected. With the LPG liquid withdrawal fuel system, pressurized
liquid LPG fuel passes from the tank to a vaporizer. The
Silence Open The alarm horn sounds to alert the user that
the alarm horn switch is not in the normal vaporizer converts the liquid fuel to gas before sending it
position and that the alarm horn will not to the fuel EPR. The system also includes a fuel
sound should a fuel leak occur.
solenoid valve that shuts off the fuel flow when the
engine stops. Contact an authorized service
Figure 3-7 Inner Fuel Tank Leak Alarm
distributor/dealer for availability.
Troubleshooting

142 Section 3 Scheduled Maintenance TP-6200 10/12

 2 LPG Liquid Withdrawal Operation
1
D Disconnect lead 73A from the fuel solenoid valve.
D Connect lead 73B to the fuel solenoid valve (LPG
liquid withdrawal).
D Connect lead 65 to lead N5 (ground).

Auto Changeover Natural Gas/LPG Vapor

Operation
3
D Disconnect lead 65 from N5.
D Connect lead N5 to LFP2 relay common terminal.
D Connect lead 73A to the fuel solenoid valve (natural
gas).
D Connect lead 73B to the fuel solenoid valve (LPG
1. Electronic-controlled pressure regulator (EPR)
SB-700 vapor).
2. Fuel mixer
3. Fuel solenoid valve Eng. Natural LPG LPG Auto
(UL--listed models require 2 fuel solenoid valves) ECM Gas Vapor Liquid Changeover
Figure 3-8 Fuel Regulator and Valve, Typical QCON--7
QCON--7
(NG fuel
73A not used (NG fuel
solenoid
3.6.3 Natural Gas and LPG Conversion valve)
solenoid valve)

Most models operate on either natural gas or LPG fuel N5 not used 65 65 LFP2--COM
by performing the fuel conversion procedure. A hang 73B not used QCON--10 (LPG fuel solenoid valve)
tag on the fuel regulator may provide additional 65 not used N5 N5 not used
conversion setup information. Fuel conversion may 63 LFP1--NC low fuel pressure sensor (if used)
decrease generator set output. Refer to the respective
70E2 P6--B (15 amp fuse)
generator set spec sheet for ratings based on fuel
selection. Changing fuel does not alter the emissions Figure 3-9 Gas Fuel Electrical Connections
compliance of the generator set engine. Consult your
local generator set distributor/dealer for additional
3.6.4 Fuel System Changeover Kits
information.
(Dual Fuel)
Note: If a gas-fueled model has the fuel type changed
(LPG to natural gas or natural gas to LPG), order Automatic Changeover
a new nameplate from an authorized distributor/
dealer with the updated ratings and attach to the A changeover fuel system kit provides automatic
generator set. changeover from natural gas to LPG vapor. The
primary and backup fuels each have a fuel solenoid
To change the fuel type, change the electrical valve. The primary fuel is natural gas; the backup fuel is
connections between the fuel system and the engine LPG vapor. Before starting, both fuel solenoid valves
ECM. The engine ECM has fuel tables and spark are closed. When the generator set starts, the primary
advance curves programmed for both natural gas and fuel solenoid valve opens. The primary fuel line has a
LPG. The information shown below, in Figure 3-9, and in pressure switch in series with a relay connected to the
Figure 3-10 generally apply to all models and all fuels. start/run circuit.
Be sure to review the respective wiring diagram for your
specific model for possible special applications. When the primary fuel pressure drops below 0.6 kPa
(1.4 oz./in.2) or 6.4 cm (2.5 in.) water column , a relay
Natural Gas Operation opens the backup fuel solenoid valve and closes the
D Disconnect lead 65 from lead N5. primary fuel solenoid valve. When the primary fuel
pressure rises above 0.6 kPa (1.4 oz./in.2) or 6.4 cm
D Disconnect lead 73B from the fuel solenoid valve.
(2.5 in.) water column, the generator set uses the
D Connect lead 73A to the fuel solenoid valve. primary fuel. Contact an authorized service
distributor/dealer for kit availability.
LPG Vapor Operation
D Disconnect lead 73A from the fuel solenoid valve.
D Connect lead 73B to the fuel solenoid valve (LPG
vapor).
D Connect lead 65 to lead N5 (ground).

TP-6200 10/12 Section 3 Scheduled Maintenance 143

 ADV-7600B-B

Figure 3-10 Gas Fuel Connections Wiring Diagram

144 Section 3 Scheduled Maintenance TP-6200 10/12
Emissions certified models use a single electronic- Note: The 20--40 kW Deutz engine-powered generator
controlled pressure regulator (EPR) for both fuels. A tee sets are oil-cooled and, therefore, do not have a
fitting connects both fuels together upstream of the EPR. water cooling system.
During operation when using the secondary fuel, it is
normal for a small amount of secondary fuel to seep WARNING
back through the primary fuel solenoid valve. To counter
this situation, one of two methods is used depending
upon the generator set model: (1) a second solenoid
valve (identical to the primary fuel solenoid valve) is
installed in a reverse configuration on the primary fuel
Hot coolant and steam.
side or (2) a small vent line is installed between the
Can cause severe injury or death.
primary fuel inlet and the air intake through a fuel
solenoid valve. Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
3.6.5 Crankcase Ventilation (CCV) to relieve pressure.
Heater Kit GM78171-KP1
(125/150REZG models) Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
The crankcase ventilation (CCV) heater kit provides a release pressure, cover the pressure cap with a thick
controlled heating source to the crankcase ventilation cloth and then slowly turn the cap counterclockwise to
system preventing freezing water buildup during cold the first stop. Remove the cap after pressure has been
weather. The thermostat turns on at 4_C (40_F) and completely released and the engine has cooled. Check
turns off at 16_C (60_F) reducing energy consumption. the coolant level at the tank if the generator set has a
See Figure 3-11. coolant recovery tank.

Note: Engine damage. Bleed the air from the cooling

1 2 system to prevent overheating and subsequent
engine damage.

Note: Block heater damage. The block heater will fail

if the energized heater element is not immersed in
coolant. Fill the cooling system before turning on
the block heater. Run the engine until it is warm,
and refill the radiator to purge the air from the
system before energizing the block heater.

TT-1560
3.7.1 Coolant Level Check
4 3
1. Heater element Check the coolant level in the coolant recovery tank.
2. Inline connector Maintain the coolant level between the high and low
3. Thermostat marks.
4. AC power cord
Note: Periodically check the coolant level by removing
Figure 3-11 Crankcase Ventilation Heater Kit
the pressure cap. Do not rely solely on the level in
the coolant recovery tank. Add fresh coolant until
3.7 Cooling System the level is just below the overflow tube opening of
the filler neck.
The cooling system maintenance information applies to
radiator-cooled models and city-water-cooled (heat
exchanger) models. The cooling systems function
similarly even though they use different components.
Radiator-cooled models have a radiator with a pressure
cap and coolant recovery tank. City-water-cooled
models have a heat exchanger and an expansion/surge
tank with a pressure cap.

TP-6200 10/12 Section 3 Scheduled Maintenance 145

3.7.2 Cooling System Component 3.7.4 Procedure to Flush and Clean
Inspection Cooling System
To prevent generator set shutdown or damage caused Use the instructions in the engine operation manual
by overheating: when available to flush and clean the cooling system.
Otherwise, use the following procedure and the cooling
D Keep the cooling air inlets clean and unobstructed. system cleaner manufacturer’s instructions.

D Inspect the radiator’s exterior for obstructions. 1. Flush the cooling system with clean water.
Remove dirt and foreign material using a soft brush or
cloth to avoid damaging the radiator fins. 2. If the inside of the radiator still has mineral deposits,
use a radiator cleaner to remove the remaining
D Check the hoses and connections for leaks. Replace deposits following the manufacturer’s instructions.
any cracked, frayed, or spongy hoses.
3. Drain, clean, and flush the coolant recovery tank.
D Check the condition and tension of the radiator fan
and water pump belt(s). Follow the belt tension 3.7.5 Procedure to Refill Cooling
procedure in this manual and/or the engine operation
manual.
System
See the generator set spec sheet for coolant capacity.
D Check the pressure cap seal and replace a cracked or
deteriorated cap. Remove dirt and other debris from Note: Do not add coolant to a hot engine. Adding
the pressure cap and filler neck. The pressure cap coolant to a hot engine can cause the cylinder
raises the boiling point of the coolant, enabling higher block or cylinder head to crack. Wait until the
operating temperatures. Replace a leaking pressure engine has cooled.
cap with one rated for the same pressure. The
pressure cap rating usually appears on the pressure 1. Remove the pressure cap.
cap.
2. Close the radiator and/or engine block coolant
drain valve(s) and tighten the cooling system hose
3.7.3 Procedure to Drain Cooling clamps.
System
3. Open the air-bleed petcocks, if equipped. Close
For optimum protection, drain, flush, and refill the the air-bleed petcocks when coolant begins to flow
cooling system at the intervals listed in the service from them.
schedule.
4. Add coolant additives or water pump lubricants
Note: Dispose of all waste materials (oil, fuel, coolant, according to the engine manufacturer’s
filters, and gaskets) in an environmentally safe recommendations in the engine operation manual.
manner.
5. Fill the cooling system with the recommended
1. Deenergize the block heater, if equipped. coolant/antifreeze mixture of 50% ethylene glycol
and 50% clean, softened water to inhibit
2. Remove the pressure cap to allow the entire
rust/corrosion and prevent freezing.
system to drain and prevent air pockets from
restricting coolant flow through the engine block. Note: A coolant solution of 50% ethylene glycol
provides freezing protection to --37°C
3. Open the radiator and/or engine block coolant drain
(--34°F) and overheating protection to
valve(s) and allow the system to drain.
129°C (265°F). A coolant solution
4. If the inside of the radiator has mineral deposits or containing less than 50% ethylene glycol
the used coolant contains dirt or grease, refer to may not provide adequate freezing and
Section 3.7.4, Procedure to Flush and Clean the overheating protection. A coolant solution
Cooling System. If the cooling system does not containing more than 50% ethylene glycol
have mineral deposits, go to Section 3.7.5, can cause engine or component damage.
Procedure to Refill the Cooling System. Do not use alcohol or methanol antifreeze
or mix them with the specified coolant.
Refer to the engine operation manual for
recommendations regarding the coolant
mixture to use in extreme temperatures.

146 Section 3 Scheduled Maintenance TP-6200 10/12

 6. Replace the pressure cap. 3. Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
7. Fill the coolant recovery tank to the low mark.
4. Remove the fan guards, screens, and covers as
8. Operate generator set until the thermostat opens necessary to access the radiator fan hardware.
when the upper cooling system hose warms.
5. Inspect the blades for cracks or other damage.
9. Stop the engine and allow it to cool. Verify that all hardware is present. Replace as
needed.
10. Check and repair any coolant leaks.
6. Retorque the (32 qty.) blade retention bolts/nuts to
11. Remove the pressure cap. 136 Nm (100 ft. lb.). See Figure 3-12.
12. Add coolant to bring the coolant level to just below 7. Retorque the (12 qty.) hub boss cap screws to
the overflow tube opening of the filler neck. 102 Nm (75 ft. lb.). There are six screws on each
side of the fan.
13. Replace the pressure cap.

14. Maintain the coolant level in the coolant recovery

2
tank between the high and low marks. 1

Note: Air pockets often form in the engine water

jacket when the coolant system is refilled.
Check the coolant level in the coolant 3
recovery tank after each generator set
operation and add coolant as necessary
until the coolant level stabilizes. Then check
the coolant at the interval specified in the
service schedule.

15. Reenergize the block heater, if equipped.

3.8 Radiator Fan Bolt Retorque

Adapted from Service Bulletin SB-683.

Check the radiator fan bolts after approximately 8 hours

SECTION A--A
of operation and then recheck after each 100 hours of GM18401-J

operation. This scheduled service is required on 1500--

2250REOZDC, 2500--2800REOZDB, and 3000/ 1. Blade retention bolts/nuts, 136 Nm (100 ft. lb.), qty. 32
3250REOZD unit-mounted radiator models using a 2. Hub boss cap screws, 102 Nm (75 ft. lb.), qty. 12
3. Bushing cap screws, 43 Nm (32 ft. lb.), qty. 3
2743 mm (108 in.) diameter fan.
Figure 3-12 Fan Hardware Location and Torque
Perform the scheduled service steps in the order shown.
8. Retorque the (3 qty.) bushing cap screws to 43 Nm
Required Tools (32 ft. lb.).

D Socket wrench sets American Standard and Metric 9. Replace the fan guards, screens, and covers that
sizes were removed to access the radiator fan hardware.
D Torque wrench, up to 203 Nm (150 ft. lb.)
10. Check that the generator set master switch is in the
OFF position.
Procedure
11. Reconnect the generator set engine starting
1. Place the generator set master switch in the OFF/
battery, negative (--) lead last.
RESET position.
12. Reconnect power to the battery charger, if
2. Disconnect the power to the battery charger, if
equipped.
equipped.

TP-6200 10/12 Section 3 Scheduled Maintenance 147

13. Place the generator set master switch to the RUN Lubrication and Drive Belt Adjustment Procedure
position to start the generator set. Refer to the
respective generator set operation manual as Lubricate the fan shaft and idler shaft bearings with a
needed. lithium-complex base, multi-purpose grease with
antirust, antifoam, and extreme-pressure additives
14. Listen and observe the fan operation. having a minimum dropping point of 204°C (400°F). Use
Mobil Mobilith AW2 NLGI Grade 2 or equivalent.
15. Immediately shut down the generator set if
abnormal noise or fan assembly vibration is 1. Place the generator set master switch in the
observed. Correct the problem and go back to OFF/RESET position.
step 13.
2. Disconnect the generator set engine starting
16. After several minutes of generator set operation battery(ies), negative (--) lead first, and disconnect
without abnormal noise or vibration, shut down the power to the battery charger.
generator set by placing the generator set master
switch to the OFF/RESET position. 3. Remove the belt guards to expose the fan shaft and
idler shaft bearings.

3.9 Radiator Expansion Joint 4. Inject grease into the two bearings on the fan shaft
block and the two bearings on the idler shaft block
Loosening—Initial Setup Only using a grease gun until a 3--6 mm (0.13--0.25 in.)
grease column shows at the bearing pressure relief
Loosen the radiator expansion joint nuts on
port. See Figure 3-14.
1200--2000 kW generator sets that have radiators
manufactured by Young Radiator Company. Expansion Note: The fan shaft and idler shaft bearings have
joints located on each side of the radiator permit pressure relief ports to prevent bearing
differential thermal expansion of the radiator tank. The damage caused by overlubrication.
factory tightens the 12 expansion joint nuts before
generator set shipment. Loosen the expansion joint
nuts one full turn before running the generator set. See 1
Figure 3-13.

2 5
3 2

TP-5353-3
1. Air flow
2. Expansion joint nuts for rear tank, left side
3. Expansion joint nuts for front tank, left side
4. Top front of radiator

Figure 3-13 Expansion Joint Nuts, Top Left Side of 4

Radiator, Typical
2

3
3.10 Radiator Fan Bearing TP-5353-3

Lubrication 1
1. Grease fittings
The following procedure applies only to 1200 kW and 2. Pressure relief port
larger generator sets. Lubricate the radiator fan shaft 3. Radiator assembly
4. Idler shaft grease fittings
and idler shaft bearings at every engine oil change to 5. Fan shaft grease fittings
avoid bearing damage. Lubricate the bearings every
200 hours of operation when the generator set runs in Figure 3-14 Radiator Fan Bearings and Pressure
ambient temperatures below 29°C (85°F) or when the Relief Ports, Typical
generator set runs in a dusty and/or humid environment.

148 Section 3 Scheduled Maintenance TP-6200 10/12

 5. Remove excess grease from the bearing pressure Battery acid cleanup. Battery acid can cause severe
relief ports. injury or death. Battery acid is electrically conductive and
corrosive. Add 500 g (1 lb.) of bicarbonate of soda (baking
6. Inspect the fan drive belt and replace if it is damaged soda) to a container with 4 L (1 gal.) of water and mix the
or worn. Check the fan belt tension using a poly neutralizing solution. Pour the neutralizing solution on the
spilled battery acid and continue to add the neutralizing
V-belt tension gauge and adjust the tension, if solution to the spilled battery acid until all evidence of a
necessary. See Figure 3-15. chemical reaction (foaming) has ceased. Flush the resulting
liquid with water and dry the area.
7. Reinstall the belt guards using the original
hardware. Battery gases. Explosion can cause severe injury or
death. Battery gases can cause an explosion. Do not smoke
or permit flames or sparks to occur near a battery at any time,
New Belt, Used Belt*, particularly when it is charging. Do not dispose of a battery in
Generator Set Model N (lbf.) N (lbf.)
a fire. To prevent burns and sparks that could cause an
2450--2890 1650--1910 explosion, avoid touching the battery terminals with tools or
1200-2250 kW
(550--650) (370--430) other metal objects. Remove all jewelry before servicing the
* A belt is considered used after 50 hours of service. equipment. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface
Figure 3-15 Poly V-Belt Tension Specifications away from the battery. To avoid sparks, do not disturb the
battery charger connections while the battery is charging.
8. Reconnect the generator set engine starting Always turn the battery charger off before disconnecting the
battery(ies), negative (--) lead last. battery connections. Ventilate the compartments containing
batteries to prevent accumulation of explosive gases.
9. Test run the generator set for a few minutes and
Battery short circuits. Explosion can cause severe injury
listen for belt noise (squeal) indicating a slipping or death. Short circuits can cause bodily injury and/or
belt. Stop the generator set. equipment damage. Disconnect the battery before generator
set installation or maintenance. Remove all jewelry before
If the belt slips after the belt tension procedure, clean the servicing the equipment. Use tools with insulated handles.
pulley surfaces and repeat the belt tension procedure. If Remove the negative (--) lead first when disconnecting the
slippage continues, replace the fan belt. battery. Reconnect the negative (--) lead last when
reconnecting the battery. Never connect the negative (--)
battery cable to the positive (+) connection terminal of the
3.11 Battery starter solenoid. Do not test the battery condition by shorting
the terminals together.
WARNING
Refer to this section for general battery information and
maintenance. All generator set models use a negative
ground with a 12-volt or 24-volt engine electrical system.
Consult the generator set nameplate for the engine
electrical system voltage. Consult the generator set
spec sheet for battery capacity recommendations for
Sulfuric acid in batteries. replacement purposes. The wiring diagrams provide
Can cause severe injury or death. battery connection information. See Figure 3-16,
Wear protective goggles and Figure 3-17, and Figure 3-18 for typical battery
clothing. Battery acid may cause connections, including multiple battery configurations.
blindness and burn skin.
3.11.1 Clean Battery

Battery electrolyte is a diluted sulfuric acid. Battery acid Clean the battery and cables and tighten the battery
can cause severe injury or death. Battery acid can cause terminals according to the service schedule
blindness and burn skin. Always wear splashproof safety recommendations. Clean the battery by wiping it with a
goggles, rubber gloves, and boots when servicing the battery. damp cloth. Keep the electrical connections dry and
Do not open a sealed battery or mutilate the battery case. If tight.
battery acid splashes in the eyes or on the skin, immediately
flush the affected area for 15 minutes with large quantities of If corrosion exists, disconnect the cables from the
clean water. Seek immediate medical aid in the case of eye battery and remove the corrosion with a wire brush.
contact. Never add acid to a battery after placing the battery in
Clean the battery and cables with a solution of baking
service, as this may result in hazardous spattering of battery
acid. soda and water. Do not allow the cleaning solution to
enter battery cells. Flush the battery and cables with
clean water and wipe the battery with a dry cloth.

TP-6200 10/12 Section 3 Scheduled Maintenance 149

After reconnecting the battery cables, coat the terminals
with petroleum jelly, silicon grease, or other 1 2 3 4
nonconductive grease.

1 2 1 2

1 2
1 2 3 4

KW-272000-B
EZ-273000-J 1. To positive (+) terminal on starter solenoid.
1. To positive (+) terminal on starter solenoid. 2. To ground (--) terminal on or near starter motor.
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.
Figure 3-16 12-Volt Engine Electrical System Single
Starter Motor Typical Battery Connection Figure 3-18 24-Volt Engine Electrical System Dual
Starter Motors Typical Battery
1 2
Connections

3.11.2 Electrolyte Level Inspection

Check the electrolyte level and specific gravity of
2 1 batteries that have filler caps. Maintenance-free
1 2 batteries do not require electrolyte level checking or
specific gravity testing.

Check the electrolyte level at the specified interval.

Remove the filler caps and verify that the electrolyte
level reaches the bottom of each filler hole. See
Figure 3-19. Refill as necessary with distilled water or
clean tap water. Do not add fresh electrolyte. Tighten
2 1 1 2 the filler caps. After adding water during freezing
temperatures, run the generator set 20--30 minutes to
mix the electrolyte and the water to prevent battery
damage from freezing.

1. To positive (+) terminal on starter solenoid.

2. To ground (--) terminal on or near starter motor.

Figure 3-17 24-Volt Engine Electrical System Single

Starter Motor Typical Battery Connection

1-046

1. Filler caps
2. Electrolyte level

Figure 3-19 Battery Electrolyte Level Inspection

150 Section 3 Scheduled Maintenance TP-6200 10/12
3.11.3 Specific Gravity Check Correction
°C °F
Use a battery hydrometer to check the specific gravity of 71.1 160 + .032

the electrolyte in each battery cell of batteries with filler + .030

caps. Holding the hydrometer vertically, read the 65.6 150 + .028
Example No. 1
number on the glass bulb at the top of the electrolyte + .026

60.0 140 + .024

Temperature below 26.7°C (80°F)
level or the number adjacent to the pointer. If the
hydrometer used does not have a correction table, + .022 Hydrometer Reading 1.250
consult Figure 3-20. Determine the specific gravity and 54.4 130 + .020
Acid Temperature --6.7°C (20°F)
electrolyte temperature of the battery cells. Locate the + .018

temperature in Figure 3-20 and correct the specific 48.9 120 + .016 Subtract .024 Specific Gravity
+ .014
Corrected Specific Gravity is 1.226
gravity by the amount shown. The battery is fully
charged if the specific gravity is 1.260 at an electrolyte 43.3 110 + .012 1.250 -- .024 = 1.226
temperature of 26.7_C (80_F). Maintain the specific + .010

gravities between cells within ±0.01 of each other. 37.8 100 + .008

Charge the battery if the specific gravity is below 1.215 + .006 Example No. 2
at an electrolyte temperature of 26.7_C (80_F). 32.2 90 + .004
Temperature above 26.7°C (80°F)
+ .002
Note: Some battery testers have four or five beads in a 26.7 80 0 Hydrometer Reading 1.235
test tube. Draw electrolyte into the tube as with -- .002
Acid Temperature 37.8°C (100°F)
the battery hydrometer described in this section 21.1 70 -- .004
or use the manufacturer’s instructions. Use --. 006 Add .008 Specific Gravity
Corrected Specific Gravity is
Figure 3-21 to interpret typical test results. 15.6 60 -- .008
1.243
-- .010

10 50 -- .012 1.235 + .008 = 1.243

3.11.4 Charge Battery -- .014

Use a battery charger to maintain a fully charged battery 4.4 40 -- .016

when the generator set is used in a standby application. -- .018

The engine battery-charging alternator charges the -- 1.1 30 -- .020

battery while the generator set is running. -- .022

-- 6.7 20 -- .024

Note: If the generator set is in a temporary prime power -- .026

application in which the generator set has periods -- 12.2 10 -- .028

of inactivity, the controller circuitry may drain the

battery. If there is no power source for a battery
charger, place the controller in the prime power
mode, if equipped, or disconnect the battery from
the generator set.
The temperature correction amounts to about .004 (4 points) of
specific gravity for each 5.5°C (10°F) change in temperature.
1-787

Figure 3-20 Specific Gravity Temperature Correction

Number of Floating Beads Battery Condition

5 Overcharged
4 Fully charged
3 A good charge
1 or 2 A low charge
0 A dead battery

Figure 3-21 Bead-Type Test Interpretation

TP-6200 10/12 Section 3 Scheduled Maintenance 151

3.12 Detroit Diesel Engine Control
1
Systems
Some generator sets equipped with Detroit Diesel
engines use a DDEC/MDEC/ADEC system. Access the
DDEC control box inside the generator set junction box
to retrieve codes when performing routine maintenance
or troubleshooting the engine.

Note: DDC/MTU engines with MDEC/ADEC use the

550 controller to display all engine fault code
numbers. The engine operation manual provides A-343591-C

the fault code description. 1. Diagnostic request switch

Figure 3-22 DDEC Control Box

Use the following data for informational purposes only.
Consult the engine literature for complete information Access the stored codes in one of three ways:
regarding DDEC/MDEC/ADEC operation and
troubleshooting. See List of Related Materials in the D Place the switch in the DIAGNOSTIC REQUEST
Introduction section. Contact an authorized service position. The CEL or SEL flashes to identify the
distributor/dealer for service or diagnostic equipment. failure.

D Use a hand-held diagnostic data reader (DDR).

3.12.1 Features
Place the switch in the DIAGNOSTIC DATA READER
The engine control system optimizes control of critical position. Plug the DDR into the control box. The DDR
engine functions and protects against serious engine displays the stored failure codes.
damage resulting from conditions such as the following:
D Use a personal computer software package available
D Low coolant level from the manufacturer with a translator to access
D Low coolant pressure
stored codes. Follow the instructions provided with
the software.
D High coolant temperature
D Low oil pressure
Code Types
D High oil temperature
Active code. A code flashing on the SEL lamp indicates
The major components of the DDEC/MDEC/ADEC a fault currently exists.
system include the electronic control module (ECM) and
engine sensors. The DDEC control box is located in the Inactive code. A code flashing on the CEL lamp
generator set junction box. indicates a previous fault occurrence. The ECM
memory stores inactive codes with time/date
identification and the following information:
3.12.2 DDEC Engine Diagnostics
The DDEC engine protection system monitors engine D First occurrence of each diagnostic code in engine
sensors and electronic components and recognizes operating hours.
system malfunctions. Critical faults light the check
D Last occurrence of each diagnostic code in engine
engine (CEL) and stop engine (SEL) lamps on the
operating hours.
control box. ECM memory software logs malfunction
codes. Consult the engine operation manual or engine D Total time in seconds that the diagnostic code was
service manual to identify the stored failure code. See active.
Figure 3-22 for the DDEC control box features.

152 Section 3 Scheduled Maintenance TP-6200 10/12

3.13 Engine Control Systems
Some generator sets use an engine control system.
Access the control box inside the generator set junction
box to retrieve codes when performing routine
maintenance or troubleshooting engine.
Use the following data for general informational
purposes only. See the Engine Service Manual for
complete information regarding operation and
troubleshooting. Contact an authorized service
distributor/dealer for service or diagnostic equipment.
GM23666-

Engine Control Features

Figure 3-25 Kohler-Branded Engine Control Box
Engine control is an advanced-technology, electronic
engine control system. The system optimizes control of
critical engine functions and provides protection against
3.14 Storage Procedure
serious engine damage. Perform the following storage procedure before taking a
The major components include the engine control generator set out of service for three months or longer.
module, engine sensors, and control box located in the Follow the engine manufacturer’s recommendations, if
generator set junction box. available, for fuel system and internal engine
component storage.
See Figure 3-23 for the Deutz control box features.

3.14.1 Lubricating System

Prepare the engine lubricating system for storage as
follows:

1. Run the generator set for a minimum of 30 minutes

to bring it to normal operating temperature.

2. Stop the generator set.

3. With the engine still warm, drain the oil from the
crankcase.
A-364162-B

4. Remove and replace the oil filter.

Figure 3-23 Deutz Engine Control Box
5. Refill the crankcase with oil suited to the climate.
See Figure 3-24 for the John Deere engine control box
features. 6. Run the generator set for two minutes to distribute
the clean oil.

7. Stop the generator set.

8. Check the oil level and adjust, if needed.

3.14.2 Cooling System

Prepare the cooling system for storage as follows:

1. Check the coolant freeze protection using a coolant

tester.
GM30962-A
2. Add or replace coolant as necessary to ensure
Figure 3-24 John Deere Engine Control Box adequate freezing protection. Use the guidelines
included in the engine operation manual.
See Figure 3-25 for the Kohler-branded D300, D350,
D400, D450, and D500 engine control box features. 3. Run the generator set for 30 minutes to redistribute
added coolant.

TP-6200 10/12 Section 3 Scheduled Maintenance 153

3.14.3 Fuel System 3. Toggle the generator set master switch to crank the
engine two or three revolutions to lubricate the
Prepare the fuel system for storage as follows: cylinders.

Diesel-Fueled Engines 4. Reinstall the spark plugs and torque them to

specifications.
1. Fill the fuel tank with #2 diesel fuel.

2. Condition the fuel system with compatible additives 3.14.5 Exterior

to control microbial growth.
1. Clean the exterior surface of the generator set.
3. Change the fuel filter/separator and bleed the fuel
system. See the engine owner’s manual. 2. Seal all engine openings except for the air intake
with nonabsorbent adhesive tape.
Gas-Fueled Engines
3. To prevent impurities from entering the air intake
1. Start the generator set. and to allow moisture to escape from the engine,
secure a cloth over the air intake.
2. With the generator set running, shut off the gas
supply. 4. Mask electrical connections.

3. Run the generator set until the engine stops. 5. Spread a light film of oil over unpainted metallic
surfaces to inhibit rust and corrosion.
4. Place the generator set master switch in the
OFF/RESET position.
3.14.6 Battery
3.14.4 Internal Engine Components Perform battery storage after all other storage
(Gas-Fueled Engines) procedures.

If you have access to a fogging agent or SAE 10 oil 1. Place the generator set master switch in the
prepare the pistons and cylinders for storage as follows: OFF/RESET position.

1. While the engine is running, spray a fogging agent 2. Disconnect the battery(ies), negative (--) lead first.
or SAE 10 engine oil into the air intake for about two
3. Clean the battery. Refer to Section 3.11.1 for the
minutes until the engine stops.
battery cleaning procedure.
2. Place the generator set master switch in the
4. Place the battery in a cool, dry location.
OFF/RESET position.
5. Connect the battery to a float/equalize battery
If a fogging agent is not available perform the following:
charger or charge it monthly with a trickle battery
1. Remove the spark plugs. charger. Refer to the battery charger
manufacturer’s recommendations.
2. Pour 15 cc (0.5 oz.) of engine oil into each spark
plug hole. Maintain a full charge to extend battery life.

Ignition System Damage. Refer to the engine

operation manual for ignition system precautions
before cranking the engine while the spark plug
wires are disconnected.

154 Section 3 Scheduled Maintenance TP-6200 10/12

 Section 4 General Troubleshooting

This section contains generator set troubleshooting, Battle Switch/Fault Shutdown Override Switch. The
diagnostic, and repair information. battle switch function forces the system to ignore normal
fault shutdowns such as low oil pressure and high
Note: The controller clock must be set each time the engine temperature. The battle switch does not override
engine battery(ies) are disconnected. The the emergency stop and overspeed shutdown. When
controller clock determines exercise run time and the battle switch function is enabled, the generator set
event records. See Menu 6—Time and Date, for continues to run regardless of shutdown signals where
setup. potential engine/alternator damage can occur.

Use the following charts to diagnose and correct When this input is enabled, the yellow warning lamp
common problems. First check for simple causes such illuminates and stored warning/shutdown events that
as a dead engine starting battery or an open circuit are ignored continue to log in Menu 5—Event History.
breaker. The charts include a list of common problems,
possible causes of the problem, recommended See Section 2.8.9, Menu 9—Input Setup, for information
corrective actions, and references to detailed on how to enable the battle switch feature.
information or repair procedures.
Cooldown Temperature Override Function. This
Maintain a record of repairs and adjustments performed function provides the ability to bypass the generator set
on the equipment. If the procedures in this manual do cooldown temperature shutdown and force the unit to
not explain how to correct the problem, contact an wait for the engine cooldown time delay.
authorized distributor/dealer. Use the record to help
describe the problem and repairs or adjustments made See Section 2.8.8, Menu 8—Time Delays, for
to the equipment. information on how to enable the cooldown temperature
override feature.

TP-6200 10/12 Section 4 General Troubleshooting 155

 4.1 General Troubleshooting Chart
Trouble Symptoms

Section or
Publication

Does not crank

No or low output
voltage
Exercise run time
and/or event
records inoperative

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*

156 Section 4 Troubleshooting

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 digital settings Adjust the voltage regulator. Sec. 2.8.11,
incorrect (digital controller only) Menu 11
x Light flicker caused by armature leads Check that AC1, AC2, and AC3 from exciter armature are Gen. S/M, W/D
incorrectly connected to FRX activator correctly connected to the FRX activator board terminals.
board (FRX alternator only)
Electrical System (DC Circuits)
x x Battery connections loose, corroded, Verify that the battery connections are correct, clean, and Section 3
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 High water temperature switch Replace the inoperative switch. Gen. S/M or W/D
inoperative
x Fault shutdown Reset the fault switches and troubleshoot the controller. Section 2
x High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
inoperative

* 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-6200 10/12
 Trouble Symptoms

TP-6200 10/12
Section or
Publication

Does not crank

No or low output
voltage
Exercise run time
and/or event
records inoperative

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 circuit board. Gen. S/M
x Controller fault Troubleshoot the controller.[ Gen. S/M
x x x Controller fuse blown Replace the blown controller fuse. If the fuse blows again, Section 2, W/D
troubleshoot the controller.[
x 10/12
TP-6200 Controller master switch inoperative Replace the controller master switch. —
x Controller master switch in the Move the controller master switch to the RUN or AUTO Section 2
OFF/RESET position position.
x Engine start circuit open Move the controller master switch to the RUN position to Section 2, W/D,
test the generator set. Troubleshoot the auto start circuit Gen. I/M, S/M
and time delays. ATS O/M, S/M
x x Voltage regulation inoperative Replace the controller fuse, If the fuse blows again, Section Fuses,
troubleshoot the controller. Gen. S/M
x Controller firmware error Review the controller display troubleshooting chart. Section 4.2
x Controller clock not set Reset time and date. Section 2.8.6,
Menu 6
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.[ Gen. 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 Check the ignition system Eng. O/M
(gas/gasoline only) (spark plugs, spark plug wires, etc.).

* 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 157

 Trouble Symptoms

Section or
Publication

Does not crank

No or low output
voltage
Exercise run time
and/or event
records inoperative

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. —

158 Section 4 Troubleshooting

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
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 Rebuild or replace the injection pump.[ Eng. S/M
inoperative (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.

TP-6200 10/12
 4.2 Controller Display and Voltage Regulation Troubleshooting Chart
Section or Publication
Trouble Symptoms Probable Causes Recommended Actions Reference*
Controller Display and Voltage Regulator

TP-6200 10/12
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
TP-6200 10/12 Readjust voltage regulation [ Menu 11, Voltage Regulator
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.

Section 4 Troubleshooting 159

 Notes

160 TP-6200 10/12

 Section 5 Generator Set Reconnection

5.1 Introduction Disabling the generator set. Accidental starting can

cause severe injury or death. Before working on the
Use the following voltage reconnection procedure to generator set or equipment connected to the set, disable the
generator set as follows: (1) Turn the generator set master
change the voltage of 10- and 12-lead generator sets.
switch and switchgear engine control switch to the OFF
Frequency changes require voltage regulator and position. (2) Disconnect the power to the battery charger.
governor adjustments. Refer to the respective spec (3) Remove the battery cables, negative (--) lead first.
sheet to determine if frequency is fixed or field- Reconnect the negative (--) lead last when reconnecting the
convertible. If frequency is adjustable, refer to the battery. Follow these precautions to prevent the starting of the
engine service manual and/or governor literature for generator set by an automatic transfer switch or a remote
conversion information. start/stop switch.
Disabling the generator set. Accidental starting can
Refer to the following procedure and the connection cause severe injury or death. Before working on the
schematics. Follow the safety precautions at the front of generator set or connected equipment, disable the generator
this manual and in the procedure text and observe set as follows: (1) Move the generator set master switch to the
National Electrical Code (NEC) guidelines. OFF position. (2) Disconnect the power to the battery
charger. (3) Remove the battery cables, negative (--) lead
NOTICE first. Reconnect the negative (--) lead last when reconnecting
the battery. Follow these precautions to prevent starting of the
Voltage reconnection. Affix a notice to the generator set
generator set by an automatic transfer switch, remote
after reconnecting the set to a voltage different from the start/stop switch, or engine start command from a remote
voltage on the nameplate. Order voltage reconnection computer.
decal 246242 from an authorized service distributor/
dealer.
WARNING
Note: Equipment damage. Verify that the voltage
ratings of the transfer switch, line circuit breakers,
and other accessories match the selected line
voltage.
Hazardous voltage. Moving parts.
Can cause severe injury or death.
WARNING
Operate the generator set only when
all guards and electrical enclosures
are in place.

Grounding electrical equipment. Hazardous voltage can

Accidental starting. cause severe injury or death. Electrocution is possible
Can cause severe injury or death. whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
Disconnect the battery cables before generator set, transfer switch, and related equipment and
working on the generator set. electrical circuits. Turn off the main circuit breakers of all
Remove the negative (--) lead first power sources before servicing the equipment. Never
when disconnecting the battery. contact electrical leads or appliances when standing in water
Reconnect the negative (--) lead last or on wet ground because these conditions increase the risk
when reconnecting the battery. of electrocution.
Short circuits. Hazardous voltage/current can cause
severe injury or death. Short circuits can cause bodily injury
and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.

TP-6200 10/12 Section 5 Generator Set Reconnection 161

5.2 Voltage Reconnection 6. Go to Menu 7—Generator System and update the
voltage information. See Section 2.8.7, Menu 7—
Procedure Generator System, for the complete procedure.
1. Place the generator set master switch in the
7. Go to Menu 12—Calibration and perform the
OFF/RESET position.
calibration procedure. See Section 2.8.12,
2. Disconnect the generator set engine starting Menu 12—Calibration, for the complete procedure.
battery, negative (--) lead first. Disconnect power to
8. Go to Menu 11—Voltage Regulator and perform the
the battery charger (if equipped).
voltage regulator setup procedure. See Section
3. Use Figure 5-1, Figure 5-2, Figure 5-3, or 2.8.11, Menu 11—Voltage Regulator, for the
Figure 5-4 to determine the generator set voltage complete procedure.
configuration. Note the original voltage and
9. Move the generator set master switch to the RUN
reconnect as needed. Route leads through current
position to start the generator set. Check the digital
transformers (CTs) and connect them according to
display for correct voltages using Menu 1—
the diagram for the desired phase and voltage.
Generator Monitoring.
Note: Position current transformers CT1, CT2,
10. Move the generator set master switch to the
and CT3 with the dot or HI side CT marking
OFF/RESET position to stop the generator set after
toward the generator set.
completing the voltage adjustments.
4. Reconnect the battery, negative lead last.
11. Replace the controller cover.
5. Go to Menu 14—Programming Mode and select
12. Place the generator set master switch in the AUTO
the Program Mode—Local. See Section 2.8.14,
or RUN position.
Menu 14—Programming Mode, for the complete
procedure.

162 Section 5 Generator Set Reconnection TP-6200 10/12

Figure 5-1 20--150 kW Permanent Magnet and Wound Field Single-Phase Alternators, ADV-5875A-P

TP-6200 10/12 Section 5 Generator Set Reconnection 163

Figure 5-2 20--400 kW Permanent Magnet and 20--60 kW Wound Field Alternators, ADV-5875B-P

164 Section 5 Generator Set Reconnection TP-6200 10/12

Figure 5-3 60 (with Oversize Alternator)--400 kW Wound Field Alternators, ADV-5875C-P

TP-6200 10/12 Section 5 Generator Set Reconnection 165

Figure 5-4 350 kW and Larger Pilot-Excited, Permanent Magnet Alternator, ADV-5875D-P

166 Section 5 Generator Set Reconnection TP-6200 10/12

 Section 6 Accessories

6.1 Accessories and Connections Kit Description

Audiovisual Alarm
Several accessories help finalize installation, add Common Failure Relay (Terminal 32A)
convenience to operation and service, and establish
Controller (Customer) Connection
state and local code compliance.
Float/Equalize Battery Charger (with alarms)
Accessories vary with each generator set model and Ground Fault Annunciation
controller. Select factory-installed and/or shipped- Idle (Speed) Mode Feature
loose accessories. See Figure 6-1 for a list of available Low Fuel (Level) Switch
kits. Obtain the most current accessory information Low Fuel (Pressure) Switch
from your local authorized service distributor/dealer. Prime Power Switch
Remote Emergency Stop
This section illustrates several accessories available at Remote Reset Feature
print time of this publication. Accessory kits generally
Remote Serial Annunciator
include installation instructions. See wiring diagrams
Remote Speed Adjustment Potentiometer
manual for electrical connections not shown in this (requires electronic governor), Non-ECM Models only
section. See the installation instructions and drawings Run Relay
supplied with kit for information on kit mounting location.
Shunt-Trip Line Circuit Breaker and Shunt-Trip Wiring

The instructions provided with the accessory kit Single-Relay Dry Contact
supersede these instructions where there are Ten-Relay Dry Contact
differences. In general, run AC and DC wiring in Twenty-Relay Dry Contact
separate conduit. Use shielded cable for all analog Wireless Monitor
inputs. Observe all applicable national, state, and local
electrical codes during accessory installation. Figure 6-1 Optional Accessories

Front View Side View

6.1.1 Audiovisual Alarm Kit
An audiovisual alarm warns the operator at a remote
location of fault shutdowns and prealarm conditions.
Audiovisual alarms include an alarm horn, an alarm
silence switch, and common fault lamp. See Figure 6-2
and Figure 6-3. See Section 6.2, Accessory
Connections, for terminal identification.

Note: Use the audiovisual alarm with a dry contact kit.

A-292887

Figure 6-2 Audiovisual Alarm

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM13984-

Figure 6-3 Audiovisual Alarm Connections

TP-6200 10/12 Section 6 Accessories 167

6.1.2 Common Failure Relay Kit 6.1.4 Float/Equalize Battery Charger Kit
with Alarm Option
The common failure relay kit provides one set of
contacts to trigger user-provided warning devices if a The float/equalize battery charger with alarm option
fault occurs. The common failure relay faults are provides battery charging to the engine starting
user-defined. See Section 2, Operation, Menu 10— battery(ies) and connects to the controller for fault
Output Setup, for status and faults available for this detection. Battery chargers for 12- or 24-volt models are
function. available as a generator set accessory. See Figure 6-7.
See Section 6.2, Accessory Connections, for terminal
Connect up to three common failure relay kits to the identification.
controller output. See Figure 6-4 and Figure 6-5. See
Section 6.2, Accessory Connections, for terminal
identification.

6.1.3 Controller (Customer) Connection

Kit
The controller connection kit allows easy connection of
controller accessories without accessing the controller
terminal strip. The supplied wiring harness connects
controller connector P23 and terminal strips TB1-3 and
TB1-4 to the controller connection kit connector P25 and
terminal strips TB6, TB7, TB8, and TB9. Connect all
accessories (except the emergency stop kit) to the
controller connection kit terminal strips. See Figure 6-6.
See Section 6.2, Accessory Connections, for terminal C-294301

identification.
Figure 6-4 Common Failure Relay Kit

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM13984-

Figure 6-5 Common Failure Relay Kit Connections

168 Section 6 Accessories TP-6200 10/12

 GM16088A-A

Figure 6-6 Controller (Customer) Connection Kit

CHARGER MALFUNCTION

LV HV CM BATTERY CHARGER
ALARM TERMINAL STRIP

GM16088A-A

Figure 6-7 Float/Equalize Battery Charger Connections

TP-6200 10/12 Section 6 Accessories 169

6.1.5 Ground Fault Annunciation Ground Fault Controller Setup Procedure

A relay contact for customer connection indicates a 1. Reconnect battery, if not already done.
ground fault condition and is part of a ground fault alarm.
See Figure 6-8 for electrical connections and the 2. Place the controller master switch to the AUTO
following procedure for controller setup. Use the position.
instructions with the kit when provided to install and
3. Press the Alarm Off key to silence the alarm horn, if
setup this accessory.
necessary.
POWER SUPPLY GENERATOR
DC 12 -- TB3-9 N
4. If the programming mode LED is not flashing, go to
or 24 V + TB3-4 See assembly
drawing and the step 5. If the programming mode LED is
pick list for
neutral to
ground cable.
flashing, go to step 6.
GFA 300

5. Set Programming Mode to Local.

Generator
system
a. Press keys .
ground
connect to
ground bus.

b. Press key until Programming Mode--

TB4-6 (DCH6) Local is displayed.
TB4-27 (GND)

GFI WIRED TO DEC550 GM53026-

c. Press the YES key .
Figure 6-8 Ground Fault Connections
d. When the Enter Code displays, press the

factory default or the user password

WARNING
keys and . The programming mode LED
should be flashing.

6. Set digital input #6 to ground fault.

Accidental starting.
Can cause severe injury or death.
a. Press . Menu 9 Input Setup
Disconnect the battery cables before should be displayed.
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
b. Press until Digital Input 06 Warning is
Reconnect the negative (--) lead last
when reconnecting the battery.
displayed.

Disabling the generator set. Accidental starting can c. Press once to select this input.
cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery d. Press until Ground Fault is displayed.
charger. (3) Remove the battery cables, negative (--) lead
first. Reconnect the negative (--) lead last when reconnecting
the battery. Follow these precautions to prevent starting of the e. Press to define Digital Input #06 as
generator set by an automatic transfer switch, remote ground fault. Entry Accepted is displayed.
start/stop switch, or engine start command from a remote
computer.
f. Press to display Digital Input #06 Inhibit
Time.

170 Section 6 Accessories TP-6200 10/12

 9. Place the controller master switch to the OFF/
g. Press to enter the inhibit time. Entry RESET position.
Accepted is displayed and the inhibit time 0:00
is now displayed. 10. Disconnect the battery negative (--) lead to power
down the generator set.

h. Press to display Digital Input #06 Delay 11. After 2-3 minutes, reconnect the battery negative
TIme. (--) lead.

12. Reset the controller clock. See Menu 6—Time and

Date.
i. Press to enter delay time. Entry
Accepted is displayed. Default delay time is
5 sec. 6.1.6 Idle (Speed) Mode Feature
The idle (speed) mode feature provides the ability to
start and run the engine at idle (reduced) speed for a
j. Press .
selectable time period (0--10 minutes) during warm-up.
7. Verify Programming. The controller will override the idle speed mode if the
engine reaches the preprogrammed engine warmed-up
a. Move handle of ground fault circuit breaker at temperature before the idle mode times out. See
generator set to simulate a ground fault. Figure 6-9 for user-supplied switch connection.

b. Verify that display shows D06 Ground Fault.

The System Warning LED should be
illuminated and the alarm horn should sound. If
these indicators are not present, recheck steps
6a. through 6j.

c. Return handle of ground fault circuit breaker to

the non-ground fault position. D06 Ground
Fault display should now be cleared.

8. Set Programming Mode to Off.

GM16088A-A
a. Press .
Figure 6-9 Idle (Speed) Mode Switch

b. Press key until Programming Mode Off is

displayed.

c. Press the YES key .

d. When the Enter Code displays, press the

factory default or the user password

keys and . The programming mode LED

should now be off.

TP-6200 10/12 Section 6 Accessories 171

6.1.7 Low Fuel (Level/Pressure) Switch
Some gaseous-fueled models offer a low fuel pressure
switch. The low fuel pressure switch connects to the
same terminal as the low fuel level switch on diesel- or
gasoline-fueled models. See Figure 6-10 and 1
PRIME POWER
Figure 6-11. See Section 6.2, Accessory Connections, SWITCH 2
for terminal identification.

Note: The main tank or the transfer/day tank includes GM20652-

the low fuel level switch. The fuel tank supplier

1. Prime power decal (293668) 2. Toggle switch (354464)
typically provides the low fuel level switch.
Figure 6-12 Prime Power Switch Installation Location

GM16088A-A

Figure 6-10 Low Fuel Switch (Level or Pressure)

Switch Rating 12 volts DC minimum, 0.5 amp minimum

Wiring Recommendation
Gauge mm (ft.)
18--20 30.5 (100)
14 153 (500) Toggle switch shown in
the prime power mode off
10 305 (1000)
position (contacts open)
GM16088A-D
Figure 6-11 Switch Rating & Wiring Recommendation
Figure 6-13 Prime Power Switch Connections
6.1.8 Prime Power Switch Kit Stop the generator set using the stopping procedures in
The prime power switch kit prevents battery drain during Section 2.3.2, Stopping, before placing the generator
generator set nonoperation periods and when the set in the prime power mode. Move the prime power
generator set battery cannot be maintained by an AC switch located on the back of the controller to the DOWN
battery charger. See Figure 6-12 for an illustration of the position. The controller including the digital display,
kit and Figure 6-13 for the electrical connections. LEDs, and alarm horn does not function when the
generator set is in the prime power mode.

Move the prime power switch located on the back of the

controller to the UP position and reset the controller time
and date before attempting to start the generator set.

172 Section 6 Accessories TP-6200 10/12

6.1.9 Remote Emergency Stop Kit 6.1.10 Remote Reset Feature
The emergency stop kit allows immediate shutdown of The remote reset switch provides generator set
the generator set from a remote location. See resetting after a fault shutdown at a remote location. See
Figure 6-14 and Figure 6-15. If the emergency stop Figure 6-16 and Figure 6-17 for user-supplied switch
switch activates, the EMERGENCY STOP lamp lights connection.
and the unit shuts down. Before attempting to restart the
generator set, reset the emergency stop switch (by Press and hold the switch for 2--3 seconds and release
replacing the glass piece) and reset the generator set by to reset the generator set controller.
placing the master switch in the OFF/RESET position.

Use the single glass piece located inside the switch for REMOTE RESET SWITCH ≈
CONTACTS NORMALLY OPEN
replacement and order additional glass pieces as MOMENTARY CLOSED TO
service parts. See Section 2.3.3, Emergency Stop ACTIVATE
Switch Reset Procedure. See Section 6.2, Accessory
Connections, for terminal identifications.

A-222654 GM16088A-A-
TP-5352-1

Figure 6-14 Emergency Stop Kit Figure 6-16 Remote Reset Switch Connections

Switch Rating 12 volts DC minimum, 1 amp minimum

Wiring Recommendation
Gauge mm (ft.)
18--20 30.5 (100)
14 153 (500)
10 305 (1000)

Figure 6-17 Switch Rating and Wiring

Recommendations

GM16088A-A

Figure 6-15 Remote Emergency Stop Kit

Connections

TP-6200 10/12 Section 6 Accessories 173

6.1.11 Remote Serial Annunciator
RSA II is an annunciator panel offered in several kit
configurations to support Kohler power equipment. The
RSA is a remote serial annunciator Figure 6-18 and
Figure 6-19 that monitors the condition of the generator
set and/or ATS from a remote location. The RSA alerts
the operator through visual and audible signals using
LED indication and a horn. An alarm silence and lamp /Aux.

test switch are included.

The RSA meets NFPA 110, Level 1 (2005) applications
that require remote controls and alarms be powered by a
storage battery such as the engine starting battery. AC
adaptor kit GM62466-KP1 is available when NFPA is not
required.
The front panel decals include areas that can be used to
identify user-selected fault inputs and identify
associated power system equipment.
An RSA annunciator can be used for a single generator
set or with a combination of a generator set and
automatic transfer switch. In systems using more than a
single RSA, one must be designated as the master Figure 6-18 Remote Serial Annunciator (RSA II)
device to broadcast to additional RSA annunciators,
designated as slave devices. Up to five RSA slave
devices can be used with an RSA master device. All
RSA annunciators factory default to the master device,
but can be changed with RSA II setup software that can
be connected to the RSA front panel via a universal
serial bus (USB) connection.
The RSA 1000 can be connected with the RSA II
provided that the master remote annunciator is an
RSA II.
RSA II setup software is required to make the RSA II
functional. Use your SecurID to access KOHLERnet,
click on the TechTools button, and follow the instructions
to download the files. See RSA II Setup Software at the
end of this document.
The RSA kits include components for surface mounting
or flush mounting.
Figure 6-20 shows the status of the system ready LED,
generator set running LED, communication status LED,
common fault LED, common fault output, and horn for
each fault or status condition. See Figure 6-21 to
Figure 6-25 for RSA wiring connections. Figure 6-19 RSA II with ATS Controls

If the RSA II is used with an Ethernet communication

network, order Modbusr Ethernet converter
GM41143-KP2 and refer to TT-1405 Converters,
Connections, and Controller Setup for Network
Communication for system installation.

Modbusr is a registered trademark of Schneider Electric.

174 Section 6 Accessories TP-6200 10/12

 System Monitoring LEDs and Functions
Generator Common
Fault System Running Communication Common Fault
Fault and Status Condition LED Ready LED LED Status LED Fault LED Output Horn
Overcrank Shutdown Red Red SF Off Green Red SF On On
High Engine Temperature Warning * Yellow Red SF Green Green Red SF On On
High Engine Temperature Shutdown Red Red SF Off Green Red SF On On
Low Oil Pressure Warning * Yellow Red SF Green Green Red SF On On
Low Oil Pressure Shutdown Red Red SF Off Green Red SF On On
Overspeed Shutdown Red Red SF Off Green Red SF On On
Emergency Stop * Red Red SF Off Green Off On On
Low Coolant Level/Auxiliary Shutdown * Red Red SF Off Green Red SF On On
Low Coolant Temperature * Yellow Red SF Off Green Red SF On On
Low Fuel—Level or Pressure * Yellow Red SF Off Green Red SF On On
EPS Supplying Load (RSA II) Green Green Green or Off Green Off Off Off
System Ready Green Green Green or Off Green Off Off Off
System Not Ready Red Red SF Green or Off Green Off On On
Low Cranking Voltage Yellow Red SF Off Green Red SF On On
(Loss of) Communication Status Red Off Off Red FF Off On On
(Master RSA II)
(Loss of) Communication Status (Slave RSA II) Red Off Off Red SF Off On On
Not-In-Auto Red Red SF Green or Off Green Red SF On On
Battery Charger Fault * Yellow Green Green or Off Green Off On On
High Battery Voltage * Yellow Green Green or Off Green Off On On
Low Battery Voltage * Yellow Green Green or Off Green Off Off Off
User Input #1 (RSA II) Warning Yellow Green Green or Off Green Off On On
User Input #1 (RSA II) Shutdown Red Green Green or Off Green Off On On
User Input #2 (RSA II) Warning Yellow Green Green or Off Green Off On On
User Input #2 (RSA II) Shutdown Red Green Green or Off Green Off On On
User Input #3 (RSA II) Warning Yellow Green Green or Off Green Off On On
User Input #3 (RSA II) Shutdown Red Green Green or Off Green Off On On
Common Fault Warning Yellow Green Green or Off Green Red SF On Off
Common Fault Shutdown Red Green Green or Off Green Red SF On On
ATS Position N (RSA II with ATS only) Green Green Green or Off Green Off Off Off
ATS Position E (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
ATS Available N (RSA II with ATS only) Green Green Green or Off Green Off Off Off
ATS Available E (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
ATS Fault (RSA II with ATS only) Yellow Yellow Green or Off Green Off Off On
ATS Fault (RSA II with ATS only) Red Red SF Green or Off Green Off Off On
SF = Slow Flash (1 second intervals), FF = Fast Flash (200 ms intervals)
* May require optional kit or user-provided device to enable function and LED indication.

Figure 6-20 System Monitoring LEDs and Functions

TP-6200 10/12 Section 6 Accessories 175

Figure 6-21 RSA Wiring Connections GM62554A-G
176 Section 6 Accessories TP-6200 10/12
Figure 6-22 RSA Wiring Connections GM62554B-G
TP-6200 10/12 Section 6 Accessories 177
Figure 6-23 RSA Wiring Connections GM62554C-G
178 Section 6 Accessories TP-6200 10/12
Figure 6-24 RSA Wiring Connections GM62554D-G
TP-6200 10/12 Section 6 Accessories 179
Figure 6-25 RSA Wiring Connections GM62554E-G
180 Section 6 Accessories TP-6200 10/12
6.1.12 Remote Speed Adjustment
Potentiometer Kit (Non-ECM
Models)
The remote speed adjustment potentiometer kit
provides controller-mounted engine speed adjustment.
The adjustment range is approximately ±5%. Some
applications locate this potentiometer with the
switchgear. This kit requires an electronic governor on
the generator set. See Figure 6-26. See Section 6.2,
Accessory Connections, for terminal identifications.

273705

Figure 6-27 Run Relay Kit

TB10

GM16088A-A

Figure 6-28 Run Relay Connections

BR-273000-C
1. Optional Remote Speed Pot

Figure 6-26 Remote Speed Adjustment

Potentiometer Connection, Typical

6.1.13 Run Relay Kit

The run relay kit energizes only when the generator set
runs. Use the run relay kit to control air intake and
radiator louvers, alarms, and/or other signalling devices.
See Figure 6-27 and Figure 6-28.

6.1.14 Shunt-Trip Line Circuit Breaker

A shunt-trip line circuit breaker provides a 12- or 24-DC Typical Connection:
TB6--RDO1 Overspeed (39),
volt solenoid within the line circuit breaker case that can TB8--RDO18 Defined Common Fault (32A),
energize the trip mechanism. This feature allows the
circuit breaker to be tripped by a customer-selected fault TB8--RDO20 Overvoltage (26), or GM16088A-H
TB9--RDO30 Load Shed kW Overload
such as alternator overload, overspeed, overvoltage, or
defined common fault. Connection requires a shunt-trip Figure 6-29 Shunt-Trip Line Circuit Breaker and
wiring kit and a dry contact kit. See Figure 6-29. Shunt-Trip Wiring Kit Connections
TP-6200 10/12 Section 6 Accessories 181
6.1.15 Single-Relay Dry Contact Kit Refer to Figure 6-32 for an internal view of the contact
kit. See Figure 6-33 for electrical connections. See
The single-relay dry contact kit provides normally open Section 6.2, Accessory Connections, for terminal
and normally closed contacts in a form C configuration to identifications.
activate warning devices and other user- provided
accessories allowing remote monitoring of the generator
set. Typically, lamps, audible alarms, or other devices
signal faults or status conditions. Connect any controller
fault output to the single-relay dry contact kit.

A total of three dry contact kits may connect to a single

controller output. See Figure 6-30 and Figure 6-31. See
Section 6.2, Accessory Connections, for terminal
identifications.

6.1.16 Ten-Relay Dry Contact Kit

The ten-relay dry contact kit provides normally open and
normally closed contacts in a form C configuration to
activate warning devices and other user-provided
accessories allowing remote monitoring of the generator
A-273945
set. Connect any controller fault output to the ten-relay
dry contact kit. Typically, lamps, audible alarms, or other Figure 6-30 Single-Relay Dry Contact Kit, Typical
devices signal the fault conditions.

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM16088A-A

Figure 6-31 Single-Relay Dry Contact Kit Connections

182 Section 6 Accessories TP-6200 10/12

 A-273936

Figure 6-32 Ten-Relay Dry Contact Kit

CONTROLLER CONNECTION KIT MOUNTED IN JUNCTION BOX

GM13984-/354246B-

Figure 6-33 Ten-Relay Dry Contact Kit Connections

TP-6200 10/12 Section 6 Accessories 183

6.1.17 Twenty-Relay Dry Contact Kit
The twenty-relay dry contact kit provides normally open
and normally closed contacts in a form C configuration to
activate warning devices and other user-provided
accessories allowing remote monitoring of the generator
set. Typically, lamps, audible alarms, or other devices
signal faults or status conditions. Connect any
generator set fault output to the dry contact kit.

Refer to Figure 6-34 for an internal view of the contact

kit. See Figure 6-35 for electrical connections. See
Section 6.2, Accessory Connections, for terminal
identifications.
D-294303-D

Figure 6-34 Twenty-Relay Dry Contact Kits

GM16759D-C

Figure 6-35 Twenty-Relay Dry Contact Relay Kit Connections

184 Section 6 Accessories TP-6200 10/12

6.1.18 Wireless Monitor This heartbeat transmission tells the Kohler center that
the wireless monitor is properly functioning, powered,
The wireless monitor system has two components: a and able to generate messages. If a device fails to report
wireless monitor unit and a website. The monitor unit a nightly heartbeat for more than a day, the system
transmits messages in response to signals received sends a Unit Failed to Report Heartbeat alarm message
from the equipment controller and notifies designated to the website.
recipients of selected operating conditions. The website
monitors these messages. Generator set run times and the number of cycles are
reported. Models GM23409-KP1 and -KP3 accumulate
There are three monitor models: GM23409-KP1 for use run times over a 24-hour period and report the run times
with hardwire inputs; GM23409-KP2 for use with a 550 with the heartbeat message. Model GM23409-KP2 (for
controller using Modbusr communication; and the 550 controller only) reports the total accumulated run
GM23409-KP3 for use with a 550 controller using time and the total number of starts. Run times for model
hardwire inputs that require a customer interface board. GM23409-KP2 are also totaled using the Control Panel
function and can be updated upon request.
Note: The 550 controller supports only one connection
for Modbusr communication. If the controller’s Upon power loss, a rechargeable battery powers the
RS-485 connection is already used for Modbusr wireless monitor. The monitor continues to transmit
communication with other equipment, use messages for 15 minutes, then transmits a loss of power
wireless monitor model GM23409-KP1 or -KP3 signal and enters the sleep mode. The sleep mode can
with hardwire inputs through a customer last up to 18 hours, until the battery completely
connection board for monitoring. discharges or power is restored. The wireless monitor
continues to send scheduled heartbeat messages
Typical messages might include: during the sleep mode until the battery discharges
D Overcrank completely.
D Low oil pressure
D Overspeed
86
D Common fault [3.4]

At the website, the user configures which individuals will

receive messages regarding selected operating
conditions and the message delivery method. Delivery
methods include pagers (alphanumeric, numeric), fax, 275
[10.8]
XML, e-mail, PCS, or telephone (voice delivery). Each 244
[9.6]
message sent will contain the condition that generated
the transmission and also the make, model, and location
of the equipment. Up to 40 messages each day can be
delivered. Single or multiple messages can be sent to
selected recipients via multiple delivery methods. More 181
[7.1]
than one delivery method can be used for each recipient. 211
95
[3.75]
[8.3]

The wireless monitor is powered by the equipment

power source or by the generator set and constantly Dimensions are mm [in.]. All
dimensions are approximate.
monitors the inputs. When an input is triggered, the
wireless monitor sends the condition over the North
51
American AMPS (advanced mobile phone system). An 51
[2] [2]
27
[1.06]
C
operations center server receives the transmission and L
G6-53
forwards the message to the selected recipients
according to the configured delivery method. Figure 6-36 Wireless Monitor

Every 24 hours, the wireless monitor also sends

information about itself and the system it is monitoring.

Modbusr is a registered trademark of Schneider Electric

TP-6200 10/12 Section 6 Accessories 185

6.2 Accessory Connections For specific information on accessory connections, refer
to the accessory wiring diagrams in the wiring diagram
The 550 controller contains circuit boards equipped with manual and the instruction sheet accompanying the kit.
terminal strip(s) for use in connecting a controller See Figure 6-37 and Figure 6-38 for controller
connection kit. Do not connect accessories directly to interconnection circuit board connections. See
the controller terminal strip(s). Connect accessories to Figure 6-39 and Figure 6-40 for controller (customer)
either a controller connection kit or a dry contact kit. connection kit connections. See Figure 6-41 and
Connect the dry contact kit(s) to the controller Figure 6-42 for accessory connection wiring diagrams.
connection kit. Connect alarms, battery chargers,
remote switches, and other accessories to the dry
contact kit relay(s).

TOP OF CONTROLLER BACK PANEL

2
5

GM16088A-A/GM10193B-A
1. TB1 terminal strip 4. TB4 terminal strip
2. TB2 terminal strip 5. P23 Connector
3. TB3 terminal strip

Figure 6-37 Terminal Strips on Controller Interconnection Circuit Board (Controller Back Panel Folded Down)

186 Section 6 Accessories TP-6200 10/12

 TB1 Terminal Strip—Engine Start and TB4 Terminal Strip—Input Factory Connections
Emergency Stop Connections
Term. Description
Term. Description 1 DCH1 Battery charger fault
1 Emergency stop ground 2 DCH2 Low fuel
1A Emergency stop 3 DCH3 Low coolant temp. with ECM models or
3 Remote start warning default with non-ECM models
4 Remote start 4 DCH4 Field overvoltage with M4/M5/M7
alternators or warning default with
TB2 Terminal Strip—Analog Input Connections non-M4/M5/M7 alternators
5 DCH5 Breaker Closed, Paralleling Applications
Term. Description 6 DCH6 Enable Synch, Paralleling Applications
1 ACH1 (CTS) Signal (non-ECM including Waukesha) 7 DCH7 Warning
2 ACH1 (CTS) Supply (non-ECM including Waukesha) 8 DCH8 Warning
3 ACH2 (OPS) Signal (non-ECM including Waukesha) 9 DCH9 Warning
4 ACH2 (OPS) Supply (non-ECM including Waukesha
10 DCH10 Warning
5 ACH3 Signal (air intake temp. for Waukesha)
11 DCH11 AFM Shutdown, Waukesha engine
6 ACH3 Supply (air intake temp. for Waukesha)
12 DCH12 Detonation Warning, Waukesha engine
7 ACH4 Signal (oil temp. for Waukesha)
13 DCH13 Detonation Shutdown,
8 ACH4 Supply (oil temp. for Waukesha)
Waukesha engine
9 ACH5 Signal
14 DCH14 Warning
10 ACH5 Supply
15 DCH15 Remote shutdown
11 ACH6 Signal
16 DCH16 Remote reset
12 ACH6 Supply (VSG for Volvo, GM, Doosan)
17 DCH17 VAR PF mode
13 ACH7 Signal (optional analog voltage adjust signal)
14 ACH7 Supply 18 DCH18 Voltage lower
15 N/C 19 DCH19 Voltage raise
16 ACH1 (CTS) Return (non-ECM) 20 DCH20 Air damper
17 ACH1 (CTS) Shield ground (non-ECM) 21 DCH21 Idle mode functional with
18 ACH2 (OPS or OPS2) Return (non-ECM) ECM-equipped engines only
19 ACH2 (OPS) Shield ground (non-ECM) 22 DCH1 Return
20 ACH3 (IAT or OPS1) Return 23 DCH2 Return
21 ACH3 Shield ground 24 DCH3 Return
22 ACH4 (Oil Temp) Return 25 DCH4 Return
23 ACH4 Shield ground 26 DCH5 Return
24 ACH5 Return 27 DCH6 Return
25 ACH5 Shield ground 28 DCH7 Return
26 ACH6 Return 29 DCH8 Return
27 ACH6 Shield ground 30 DCH9 Return
28 ACH7 Return 31 DCH10 Return
29 ACH7 Shield ground 32 DCH11 Return
30 N/C 33 DCH12 Return
34 DCH13 Return
35 DCH14 Return
TB3 Terminal Strip—Accessory Power Output 36 DCH15 Return
Connections 37 DCH16 Return
Term. Description 38 DCH17 Return
1 +12 VDC (OEM use only) 39 DCH18 Return
2 +12 VDC (OEM use only) 40 DCH19 Return
3 +12 VDC (OEM use only) 41 DCH20 Return
4 Fused battery (+) (42A) (5 amp) 42 DCH21 Return
5 Fused battery (+) (42A) (5 amp)
6 Fused battery (+) (42A) (5 amp)
7 Battery (--) Note: TB4-1 through TB4-21 are user definable with
8 Battery (--) factory defaults listed. Terminals TB4-3, TB4-4,
9 Battery (--) TB4-14, and TB4-21 have different functions
10 Battery (--) depending upon the generator set configuration.
11 Battery (--) See comments above.
12 Panel lamp output See Menu 9—Input Setup for changing inputs.

Figure 6-38 Controller Terminal Strip Identification

TP-6200 10/12 Section 6 Accessories 187

 GM13984-

Figure 6-39 Terminal Strips TB6, TB7, TB8, and TB9 on the Controller Connection Kit in the Junction Box

TB6 Terminal Strip—RDOs 1--7 TB9 Terminal Strip—RDOs 24--31

Term. Description Term. Description
42A Battery (+) RDO24 Speed sensor fault
GND Battery (--) RDO25 Loss of AC sensing
N/C RDO26 ECM loss of communication
RDO1 Overspeed (lead 39) RDO27 Undervoltage
RDO2 Overcrank (lead 12) RDO28 Overfrequency
RDO3 High coolant temperature shutdown (lead 36) RDO29 Underfrequency
RDO4 Low oil pressure shutdown (lead 38) RDO30 Load shed kW overload
RDO5 Low coolant temperature (lead 35) RDO31 Load shed underfrequency
RDO6 High coolant temperature warning (lead 40) 3 Remote start
RDO7 Low oil pressure warning (lead 41) 4 Remote start
TB7 Terminal Strip—RDOs 8--17
Term. Description Note:Lead numbers shown in parentheses are the factory
RDO8 Low fuel (lead 63) default wire designations.
RDO9 Master switch not in auto ( lead 80)
RDO10 NFPA 110 common alarm (lead 32)* Note:RDO-1 though RDO-31 are user definable with the
RDO11 Battery charger fault (lead 61) following factory defaults: emergency stop, high coolant
RDO12 Low battery voltage (lead 62) temperature, low oil pressure, overcrank, and overspeed
RDO13 High battery voltage
RDO14 Emergency stop (lead 48)
*NFPA-110 common alarm faults include:
RDO15 Generator set running (lead 70R)
RDO16 Time delay engine cooldown (TDEC) (lead 70C) Air damper indicator (RDO--23)
RDO17 System ready (lead 60) Battery charger fault (RDO--11)
EPS supplying load (RDO--22)
TB8 Terminal Strip—RDOs 18--23 High battery voltage (RDO--13)
Term. Description High coolant temperature warning (RDO--06)
42A Battery (+) High coolant temperature shutdown (RDO--03)
42A Battery (+) Low battery voltage (RDO--012)
GND Battery (--) Low coolant level (RDO--19)
GND Battery (--) Low coolant temperature warning (RDO--05)
RDO18 Defined common fault (lead 32A) Low fuel (level or pressure) (RDO--08)
RDO19 Low coolant level Low oil pressure warning (RDO--07)
RDO20 Overvoltage (lead 26) Low oil pressure shutdown (RDO--04)
RDO21 Idle mode Master switch not in auto (RDO--09)
RDO22 EPS supplying load Overcrank (RDO--02)
RDO23 Air damper indicator (lead 56) Overspeed (RDO--01)

Figure 6-40 Controller (Customer) Connection Kit Terminal Strip Identification with Relay Driver Outputs (RDOs)

188 Section 6 Accessories TP-6200 10/12

Figure 6-41 Accessory Connections GM78247A-D
TP-6200 10/12 Section 6 Accessories 189
Figure 6-42 Accessory Connections GM78247C-D
190 Section 6 Accessories TP-6200 10/12
Figure 6-43 Accessory Connections GM78247D-D
TP-6200 10/12 Section 6 Accessories 191
 Notes

192 Section 6 Accessories TP-6200 10/12

 Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cert. certificate, certification, ESD electrostatic discharge
ABDC after bottom dead center certified est. estimated
AC alternating current cfh cubic feet per hour E-Stop emergency stop
A/D analog to digital cfm cubic feet per minute etc. et cetera (and so forth)
ADC advanced digital control; CG center of gravity exh. exhaust
analog to digital converter CID cubic inch displacement ext. external
adj. adjust, adjustment CL centerline F Fahrenheit, female
ADV advertising dimensional cm centimeter FHM flat head machine (screw)
drawing CMOS complementary metal oxide fl. oz. fluid ounce
Ah amp-hour substrate (semiconductor) flex. flexible
AHWT anticipatory high water com communications (port) freq. frequency
temperature coml commercial FS full scale
AISI American Iron and Steel Coml/Rec Commercial/Recreational ft. foot, feet
Institute conn. connection ft. lb. foot pounds (torque)
ALOP anticipatory low oil pressure cont. continued ft./min. feet per minute
alt. alternator CPVC chlorinated polyvinyl chloride ftp file transfer protocol
Al aluminum crit. critical g gram
ANSI American National Standards CSA Canadian Standards
Institute (formerly American ga. gauge (meters, wire size)
Association gal. gallon
Standards Association, ASA) CT current transformer
AO anticipatory only gen. generator
Cu copper genset generator set
APDC Air Pollution Control District cUL Canadian Underwriter’s
API American Petroleum Institute GFI ground fault interrupter
Laboratories
approx. approximate, approximately CUL Canadian Underwriter’s GND, ground
APU Auxiliary Power Unit Laboratories gov. governor
AQMD Air Quality Management cu. in. cubic inch gph gallons per hour
District cw. clockwise gpm gallons per minute
AR as required, as requested CWC city water-cooled gr. grade, gross
AS as supplied, as stated, as cyl. cylinder GRD equipment ground
suggested D/A digital to analog gr. wt. gross weight
ASE American Society of Engineers DAC digital to analog converter HxWxD height by width by depth
ASME American Society of dB decibel HC hex cap
Mechanical Engineers HCHT high cylinder head temperature
dB(A) decibel (A weighted)
assy. assembly HD heavy duty
DC direct current
ASTM American Society for Testing HET high exhaust temp., high
Materials DCR direct current resistance
deg., ° degree engine temp.
ATDC after top dead center hex hexagon
ATS automatic transfer switch dept. department
dia. diameter Hg mercury (element)
auto. automatic HH hex head
aux. auxiliary DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung HHC hex head cap
avg. average HP horsepower
e. V. (also Deutsche Industrie
AVR automatic voltage regulator Normenausschuss) hr. hour
AWG American Wire Gauge DIP dual inline package HS heat shrink
AWM appliance wiring material DPDT double-pole, double-throw hsg. housing
bat. battery DPST double-pole, single-throw HVAC heating, ventilation, and air
BBDC before bottom dead center DS disconnect switch conditioning
BC battery charger, battery DVR digital voltage regulator HWT high water temperature
charging
E2PROM, EEPROM Hz hertz (cycles per second)
BCA battery charging alternator electrically-erasable IBC International Building Code
BCI Battery Council International programmable read-only IC integrated circuit
BDC before dead center memory ID inside diameter, identification
BHP brake horsepower E, emer. emergency (power source) IEC International Electrotechnical
blk. black (paint color), block ECM electronic control module, Commission
(engine) engine control module IEEE Institute of Electrical and
blk. htr. block heater EDI electronic data interchange Electronics Engineers
BMEP brake mean effective pressure EFR emergency frequency relay IMS improved motor starting
bps bits per second e.g. for example (exempli gratia) in. inch
br. brass EG electronic governor in. H2O inches of water
BTDC before top dead center EGSA Electrical Generating Systems in. Hg inches of mercury
Btu British thermal unit Association in. lb. inch pounds
Btu/min. British thermal units per minute EIA Electronic Industries Inc. incorporated
C Celsius, centigrade Association ind. industrial
cal. calorie EI/EO end inlet/end outlet int. internal
CAN controller area network EMI electromagnetic interference int./ext. internal/external
CARB California Air Resources Board emiss. emission I/O input/output
CAT5 Category 5 (network cable) eng. engine IP internet protocol
CB circuit breaker EPA Environmental Protection ISO International Organization for
CC crank cycle Agency Standardization
cc cubic centimeter EPS emergency power system J joule
CCA cold cranking amps ER emergency relay JIS Japanese Industry Standard
ccw. counterclockwise ES engineering special, k kilo (1000)
CEC Canadian Electrical Code engineered special

TP-6200 10/12 Appendix 193

K kelvin NA not available, not applicable RTU remote terminal unit
kA kiloampere nat. gas natural gas RTV room temperature
KB kilobyte (210 bytes) NBS National Bureau of Standards vulcanization
KBus Kohler communication protocol NC normally closed RW read/write
kg kilogram NEC National Electrical Code SAE Society of Automotive
kg/cm2 kilograms per square NEMA National Electrical Engineers
centimeter Manufacturers Association scfm standard cubic feet per minute
kgm kilogram-meter NFPA National Fire Protection SCR silicon controlled rectifier
kg/m3 kilograms per cubic meter Association s, sec. second
kHz kilohertz Nm newton meter SI Systeme international d’unites,
kJ kilojoule NO normally open International System of Units
km kilometer no., nos. number, numbers SI/EO side in/end out
kOhm, kΩ kilo-ohm NPS National Pipe, Straight sil. silencer
kPa kilopascal NPSC National Pipe, SMTP simple mail transfer protocol
kph kilometers per hour Straight-coupling SN serial number
kV kilovolt NPT National Standard taper pipe SNMP simple network management
kVA kilovolt ampere thread per general use protocol
kVAR kilovolt ampere reactive NPTF National Pipe, Taper-Fine SPDT single-pole, double-throw
kW kilowatt NR not required, normal relay SPST single-pole, single-throw
kWh kilowatt-hour ns nanosecond spec specification
kWm kilowatt mechanical OC overcrank specs specification(s)
kWth kilowatt-thermal OD outside diameter sq. square
L liter OEM original equipment sq. cm square centimeter
manufacturer sq. in. square inch
LAN local area network
OF overfrequency SMS short message service
L x W x H length by width by height
opt. option, optional SS stainless steel
lb. pound, pounds
OS oversize, overspeed std. standard
lbm/ft3 pounds mass per cubic feet
OSHA Occupational Safety and stl. steel
LCB line circuit breaker Health Administration
LCD liquid crystal display tach. tachometer
OV overvoltage TB terminal block
LED light emitting diode oz. ounce
Lph liters per hour TCP transmission control protocol
p., pp. page, pages TD time delay
Lpm liters per minute PC personal computer
LOP low oil pressure TDC top dead center
PCB printed circuit board TDEC time delay engine cooldown
LP liquefied petroleum pF picofarad
LPG liquefied petroleum gas TDEN time delay emergency to
PF power factor normal
LS left side ph., ∅ phase TDES time delay engine start
Lwa sound power level, A weighted PHC Phillipsr head Crimptiter TDNE time delay normal to
LWL low water level (screw) emergency
LWT low water temperature PHH Phillipsr hex head (screw) TDOE time delay off to emergency
m meter, milli (1/1000) PHM pan head machine (screw) TDON time delay off to normal
M mega (106 when used with SI PLC programmable logic control temp. temperature
units), male PMG permanent magnet generator term. terminal
m3 cubic meter pot potentiometer, potential THD total harmonic distortion
m3/hr. cubic meters per hour ppm parts per million TIF telephone influence factor
m3/min. cubic meters per minute PROM programmable read-only tol. tolerance
mA milliampere memory turbo. turbocharger
man. manual psi pounds per square inch typ. typical (same in multiple
max. maximum psig pounds per square inch gauge locations)
MB megabyte (220 bytes) pt. pint UF underfrequency
MCCB molded-case circuit breaker PTC positive temperature coefficient UHF ultrahigh frequency
MCM one thousand circular mils PTO power takeoff UIF user interface
meggar megohmmeter PVC polyvinyl chloride UL Underwriter’s Laboratories, Inc.
MHz megahertz qt. quart, quarts UNC unified coarse thread (was NC)
mi. mile qty. quantity UNF unified fine thread (was NF)
mil one one-thousandth of an inch R replacement (emergency) univ. universal
min. minimum, minute power source URL uniform resource locator
misc. miscellaneous rad. radiator, radius (web address)
MJ megajoule RAM random access memory US undersize, underspeed
mJ millijoule RDO relay driver output UV ultraviolet, undervoltage
mm millimeter ref. reference V volt
mOhm, mΩ rem. remote VAC volts alternating current
milliohm Res/Coml Residential/Commercial VAR voltampere reactive
MOhm, MΩmegohm RFI radio frequency interference VDC volts direct current
MOV metal oxide varistor RH round head VFD vacuum fluorescent display
MPa megapascal RHM round head machine (screw) VGA video graphics adapter
mpg miles per gallon rly. relay VHF very high frequency
mph miles per hour rms root mean square W watt
MS military standard rnd. round WCR withstand and closing rating
ms millisecond RO read only w/ with
m/sec. meters per second ROM read only memory WO write only
mtg. mounting rot. rotate, rotating w/o without
MTU Motoren-und Turbinen-Union rpm revolutions per minute wt. weight
MW megawatt RS right side xfmr transformer
mW milliwatt RTDs Resistance Temperature
μF microfarad Detectors
N, norm. normal (power source)

194 Appendix TP-6200 10/12

 Appendix B User-Defined Settings

Use the table below to record user-defined settings Note: Inhibit time delay is the time delay period after
during the generator set controller setup and calibration. crank disconnect.
The controller default settings and ranges provide
guidelines. The table contains all faults with ranges and Note: The engine ECM may limit the crank cycle even if
time delays including items that do not have the controller is set to a longer time period.
adjustments. Not adjustable user-defined settings
result when the controller logic does not allow changes
or the values are engine limited.
User-Defined Settings
Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Access Code 14 User-Selectable 0 (zero)
(password)
AC Sensing Loss 10 AC SENSING RDO-25 * Not adjustable
LOSS
Air Damper Control 10 Not adjustable
(if used) **
Air Damper Indicator —
(if used), see D20 **
Air/Fuel Module 10 AFM ENG Fixed Not adjustable
(AFM) Engine Start START DELAY
Delay ]
Air/Fuel Module 10 AFM REMOTE RDO-25 ] Not adjustable
(AFM) Remote START
Start ]
Air/Fuel Module Not adjustable
(AFM) Shutdown
(see D11) ]
Alternator Protection 10 ALTERNATOR Not adjustable
Shutdown PROTECTION
Analog Aux. Input 0 9 LOCAL BATT Fixed Not adjustable
VDC
Analog Aux. Inputs 9 USER-DEFINED Default Values with 30 sec. 0--60 0--60
A01--A07 A01--A07 Warning Enabled: inhibit,
HI warning 90% 5 sec. delay
LO warning 10%
HI shutdown 100%
LO shutdown 1%
Analog Aux. Input 9 A01 Default Values with 30 sec. Not adjustable
A01 (non-ECM only) COOLANT Warning Enabled: inhibit,
TEMP HI/LO warning and 0 sec. delay
HI/LO shutdown are warning,
all engine dependent 5 sec. delay
shutdown
Analog Aux. Input 9 A02 Default Values with 30 sec. Not adjustable
A02 (non-ECM only) OIL Warning Enabled: inhibit,
PRESSURE HI/LO warning and 0 sec. delay
HI/LO shutdown are warning,
all engine dependent 5 sec. delay
(255 psi max.) shutdown
Analog Aux. Input 9 A03 Default Values with 30 sec. Not adjustable
A03 ] INTAKE AIR Warning Enabled: inhibit,
TEMP HI/LO warning are 0 sec. delay
all engine dependent warning
Analog Aux. Input 9 A04 Default Values with 30 sec.
A04 * FUEL LEVEL Warning Enabled: inhibit,
HI/LO warning are 0 sec. delay
engine dependent warning
* All models, except Waukesha-powered models. ** NFPA applications
[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Appendix 195

 Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Analog Aux. Input 9 A04 Default Values with 30 sec. Not adjustable
A04 ] OIL TEMP Warning Enabled: inhibit,
HI/LO warning are 0 sec. delay
engine dependent warning
Analog Aux. Input 9, 12 A06 Volvo: —
A06 VSG (Volvo, ANALOG 0.5V=1250
GM, Doosan only) AUXILIARY IN 4.5V=8750
GM/Doosan
60 Hz:
0.5V=2375
4.5V=2625
50 Hz:
0.5V=2327
4.5V=2624
Analog Aux. Input 9, 11 A07 ±10% of system
A07 ANALOG VOLT voltage over the range
ADJUST of 0.5--4.5 VDC
Battery Charger Fault —
(see D01) **
Battle Switch 9 BATTLE Fixed Not adjustable
(Fault Shutdown SWITCH
Override Switch)
Block Heater 10 BLOCK HEATER RDO only
Control [[ CONTROL
Breaker Trip w 10 BREAKER RDO-30 Not adjustable
TRIP
Common Protective 10 COMMON PR RDO-31 w Not adjustable
Relay Output w OUTPUT
Critical Overvoltage 10 CRITICAL Fixed 275 volts Not adjustable
Shutdown OVERVOLTAGE (L1--L2)
Cyclic Cranking 8 1--6 crank cycles 3
10--30 sec. crank on 15 sec.
1--60 sec. pause 15 sec.
Defined Common 10 DEFINED RDO-18 Default shutdowns 30 sec. 0--60 0--60
Faults COMMON (lead 32A) include: inhibit,
(each input value is FAULT Emergency stop 5 sec. delay
set separately) High coolant temp
Low oil pressure
Overcrank
Overspeed
Detonation Shutdown —
(see D13) ]
Detonation Warning —
(see D12) ]
Digital Aux. Input 9, 10 USER-DEFINED 30 sec. 0--60 0--60
D01--D21 D01--D21 inhibit,
5 sec. delay
Digital Aux. Input 9, 10 D01 BATTERY RDO-11 Fixed 0 sec. Not adjustable
D01 Battery Charger CHARGER (lead 61) inhibit,
Fault ** FAULT 0 sec. delay
Digital Aux. Input 9, 10 D02 RDO-08 Fixed 0 sec. Not adjustable
D02 Low Fuel LOW FUEL (lead 63) inhibit,
Warning ** WARNING 0 sec. delay
Digital Aux. Input 9, 10 D03 LOW RDO-05 Fixed 0 sec. Not adjustable
D03 Low Coolant COOLANT (lead 35) inhibit,
Temperature ** TEMP 0 sec. delay
Digital Aux. Input 9, 10 D04 Fixed 1 sec. Not adjustable
D04 Field FIELD inhibit,
Overvoltage (M4, OVERVOLTAGE 15 sec.
M5, or M7 alternator delay
only)

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

196 Appendix TP-6200 10/12

 Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Digital Aux. Input 9, 10 D05 Fixed 0 sec. Not adjustable
D05 Breaker BREAKER inhibit,
Closed w CLOSED 0 sec. delay
Digital Aux. Input 9, 10 D06 ENABLE 20 sec. Not adjustable
D06 w SYNCH inhibit,
0 sec. delay
Digital Aux. Input 9, 10 D09 Fixed 5 sec. Not adjustable
D09 Low Fuel LOW FUEL inhibit,
Pressure Shutdown SHUTDOWN 0 sec. delay
(125RZG only)
Digital Aux. Input 9, 10 D11 Fixed 0 sec. Not adjustable
D11 Air/Fuel Module AFM inhibit,
(AFM) Shutdown ] SHUTDOWN 0 sec. delay
Digital Aux. Input 9, 10 D12 Fixed 2 sec. Not adjustable
D12 Detonation DETON inhibit,
Warning ] WARNING 0 sec. delay
Digital Aux. Input 9, 10 D13 Fixed 0 sec. Not adjustable
D13 Detonation DETON inhibit,
Sensing Module SHUTDOWN 0 sec. delay
(DSM) Shutdown ]
Digital Aux. Input 9, 10 D13 Fixed 0 sec. Not adjustable
D13 Knock Detection KNOCK inhibit,
Module (KDM) SHUTDOWN 0 sec. delay
Shutdown ]
Digital Aux. Input D14 9, 10 D14 LOW RDO-19 Fixed 30 sec. Not adjustable
Low Coolant Level, COOLANT LVL inhibit,
(with LCL switch) ** 5 sec. delay
Digital Aux. Input 9, 10 D15 REMOTE 0 sec. Not adjustable
D15 Remote SHUTDOWN inhibit,
Shutdown 0 sec. delay
Digital Aux. Input 9, 10 Not adjustable
D16 Remote Reset
Digital Aux. Input 9, 10 Not adjustable
D17 VAR/PF mode
Digital Aux. Input 9, 10 Not adjustable
D18 Voltage Lower
Digital Aux. Input 9, 10 Not adjustable
D19 Voltage Raise
Digital Aux. Input 9, 10 D20 RDO-23 * Fixed 0 sec. Not adjustable
D20 Air Damper AIR DAMPER (lead 56) inhibit,
Indicator (if used) ** 0 sec. delay
Digital Aux. Input 9, 10 D21 RDO-21 Fixed inhibit time 0 sec. 0--600 Not adjustable
D21 Idle (speed) IDLE MODE inhibit, or 9:99
Mode Function ACTIVE 60 sec. for
delay infinity
ECM Red Alarm 10 ECM RED ALARM Not adjustable
(was MDEC Yellow
Alarm) [[
ECM Yellow Alarm 10 ECM YELLOW Not adjustable
(was MDEC Yellow ALARM
Alarm) [[
EEPROM Write 10 EEPROM WRITE Not adjustable
Failure FAILURE

Emergency Stop 10 EMERGENCY RDO-14 Not adjustable

Shutdown STOP (lead 48)
Engine Cooldown —
(see Time Delay--)
Engine Derate Active 10 ENGINE DERATE Not adjustable
ACTIVE

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Appendix 197

 Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
(Engine) J1939 CAN 10 J1939 CAN Not adjustable
Engine Shutdown SHUTDOWN
Engine Stalled 10 ENGINE Not adjustable
STALLED
Engine Start —
(see Time Delay--)
EPS (Emergency 10 EPS RDO-22 Fixed 1% of rated Not adjustable
Power System) SUPPLYING line current
Supplying Load LOAD
Field Overvoltage Not adjustable
(see D04)
Fuel Level (see A04) —
Fuel Valve Relay ] 10 FUEL VALVE RDO-23 ] Not adjustable
RELAY
Generator Set 10 RDO-15 Not adjustable
Running (lead 70R)
Ground Fault 10 GROUND Not adjustable
Detected FAULT
High Battery Voltage 10 HIGH RDO-13 14.5--16.5 V (12 V) 16 V (12 V) 10
BATTERY 29--33 V (24 V) 32 V (24 V)
VOLTAGE
High Coolant 10 HI COOL RDO-03 30 5 Not adjustable
Temperature TEMP (lead 36)
Shutdown SHUTDOWN
High Coolant 10 HI COOL RDO-06 30 Not adjustable
Temperature Warning TEMP (lead 40)
WARNING
High Oil Temperature 10 HI OIL TEMP 30 5 Not adjustable
Shutdown SHUTDOWN
High Oil Temperature 10 HI OIL TEMP 30 Not adjustable
Warning ] [[ WARNING
Idle (speed) Mode —
Function (see D21)
In Synch w 10 IN SYNCH RDO-29 * Not adjustable
Intake Air 10 INTAKE AIR 30 Not adjustable
Temperature TEMP SDWN
Shutdown [[
Intake Air Temp. 10 INTAKE AIR 30 Not adjustable
Warning [[ TEMP WARN
Intake Air Temp. —
Warning (see A03) ]
Intake Air Temp. —
Shutdown (see
A03)]
Internal Fault 10 INTERNAL Not adjustable
Shutdown FAULT
J1939 CAN —
Shutdown (see
Engine J1939 CAN
Shutdown)
Knock Shutdown —
(see D13) ]
kW Overload —
(see Load Shed)

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

198 Appendix TP-6200 10/12

 Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Load Shed 10 LOAD SHED RDO-30 ]] 80%--120% 100% of 2--10
kW Overload ]] KW OVER kW rating
with 5 sec.
delay
Load Shed Over 10 LOAD SHED RDO only Not adjustable
Temperature [[ OVER
(Activated by a High TEMPERATURE
Coolant Temp.
shutdown)
Load Shed 10 LOAD SHED RDO-31 [ 59 Hz 5 Not adjustable
Underfrequency [ UNDER (60 Hz)
FREQUENCY 49 Hz
(50 Hz)
Locked Rotor 10 LOCKED Not adjustable
Shutdown ROTOR
Loss of ECM 10 LOSS OF ECM RDO-26 * 4 Not adjustable
Communication COMM
(ECM only)
Loss of Field 10 SD LOSS OF Not adjustable
Shutdown w FIELD
Low Battery Voltage 10 LOW BATTERY RDO-12 10--12.5 V (12 V) 12 V (12 V) 0 10
VOLTAGE (lead 62) 20--25 V (24 V) 24 V (24 V)
Low Coolant Level —
(see D14) (with LCL
switch) **
Low Coolant —
Temperature (see
D03) **
Low Coolant 10 LOW COOLANT Not adjustable
Temperature TEMP
Shutdown [[ SHUTDOWN

Low Fuel (Level or —

Pressure) Warning
(see D02) **
Low Fuel Pressure —
Shutdown (see D09)
(125RZG only)
(Low) Oil Pressure 10 OIL RDO-04 30 5 Not adjustable
Shutdown PRESSURE (lead 38)
SHUTDOWN
(Low) Oil Pressure 10 OIL RDO-07 30 Not adjustable
Warning PRESSURE (lead 41)
WARNING
Maintenance Due 10 MAINTENANCE Not adjustable
DUE

Master Not In Auto 10 MASTER NOT RDO-09 Not adjustable

(Generator Set IN AUTO (lead 80)
Switch)
Master Switch Error 10 MASTER Not adjustable
SWITCH
ERROR
Master Switch to Off 10 MASTER Not adjustable
SWITCH TO
OFF
Master Switch Open 10 MASTER Not adjustable
SWITCH OPEN
NFPA 110 Fault ** 10 NFPA 110 RDO-10 Not adjustable
FAULT (lead 32)
No Air Temperature 10 NO AIR TEMP 30 4 Not adjustable
Signal Warning ] SIGNAL

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Appendix 199

 Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
No Coolant 10 NO COOL 30 4 Not adjustable
Temperature Signal TEMP SIGNAL
No Oil Pressure 10 NO OIL 30 4 Not adjustable
Signal PRESSURE
SIGNAL
No Oil Temperature 10 NO OIL TEMP 30 4 Not adjustable
Signal Warning ] SIGNAL
Overcrank Shutdown 8, 10 OVER CRANK RDO-02 0--6 Cycles 3 Cycles
(lead 12)
Overcurrent 10 OVER 110% 10 Not adjustable
CURRENT
Over Current VR 10 SD OVER Not adjustable
(voltage restraint) CURRENT VR
Shutdown w
Overfrequency 7, 10 OVER RDO-28 102%--140% 110% Std. 10
Shutdown FREQUENCY 103% FAA
Over Power 10 SD OVER 102% Not adjustable
Shutdown w POWER Stdby
112% Prime
Overspeed 7, 10 OVER SPEED RDO-01 65--70 Hz (60 Hz) 70 (60 Hz) 0.25
Shutdown (lead 39) 55--70 Hz (50 Hz) 70 (50 Hz)
Overvoltage 7, 8, OVER RDO-20 105%--135% 115% 2--10
Shutdown 10 VOLTAGE (lead 26) of nominal 2-sec time
delay[
135%
10-sec time
delayw
Password —
(see Access Code)
Pre Lube Relay ] 10 PRE LUBE RDO-26 ] 4 Not adjustable
RELAY
Remote Reset —
(see D16)
Remote Shutdown —
(see D15)
Reverse Power 10 SD REVERSE Not adjustable
Shutdown w POWER
Speed Sensor Fault 10 SPEED RDO-24 Not adjustable
SENSOR
FAULT
Starting Aid (see —
Time Delay Starting
Aid)
System Ready 10 RDO-17 Not adjustable
(lead 60)
Time Delay Engine 8, 10 DELAY ENG RDO-16 00:00--10:00 5:00
Cooldown (TDEC) COOLDOWN (lead 70C) min:sec
Time Delay Engine 8, 10 DELAY ENG 00:00--5:00 00:01
Start (TDES) START min:sec
Time Delay Starting 8, 10 0--10 sec.
Aid
Underfrequency 7, 10 UNDER RDO-29 ] 80%--97% 97% FAA 10
FREQUENCY 90%[
80%w

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

200 Appendix TP-6200 10/12

 Relay Inhibit
Refer Driver Time Time
Status Event to Output Default Delay Delay User-Defined
or Fault Menu Digital Display (RDO) Range Setting Selection (sec.) (sec.) Settings
Undervoltage 7, 8, UNDER RDO-27 70%--95% 85% 5--30
Shutdown 10 VOLTAGE 10-sec time
delay[
70%
30-sec time
delayw
Variable Speed —
Governor (VSG) (see
A06)
VAR/PF Mode —
(see D17)
Voltage Lower —
(see D18)
Voltage Raise —
(see D19)
Weak Battery 10 WEAK 60% of 2
BATTERY nominal

* All models, except Waukesha-powered models. ** NFPA applications

[ Non-paralleling applications [[ DDC/MTU engine with MDEC/ADEC
] Waukesha-powered models ]] FAA only
w Paralleling applications

TP-6200 10/12 Appendix 201

Appendix C Voltage Regulator Definitions and Adjustments

The following definitions and adjustment/setting squared divided by the impedance. As the voltage is
specifications are intended for users planning to adjust reduced, the power delivered by the alternator
the voltage regulator beyond the default settings in order decreases by a squared relationship. Since it is the
to customize the alternator for a specific application. 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
reduces the regulated voltage to reduce the subsequent
alternator excitation control system to improve the
overall generator set system (engine and alternator) torque on the engine. The amount that the control
system reduces voltage is defined as the product or
response. In particular, underfrequency unloading
multiplication of the slope and the amount of frequency
relates to large-block load applications. When applied to
engine-driven alternators, large-block loads cause a or speed below the cut-in point. For every Hz below the
cut-in point, the control system reduces the line-to-line
subsequent transient torque load on the engine. This
torque load can reduce the engine’s speed below the voltage by an amount equal to the slope.
normal operating point. Typically, the engine speed
Because each engine responds differently to the various
controller or governor will compensate for this by loads encountered, the slope may be adjusted to
commanding an increase in fuel. If, however, the fuel
improve the system response. If, when large loads are
system is inadequate to recover from a relatively large 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
droop more during load applications, consequently
When the excitation control system detects a drop in the
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 to an acceptable lower limit (as determined by the
particular loads connected to the generator set), a lower
a lower voltage regulation point. By reducing the output
slope may work better. The underfrequency unloading
voltage of the alternator, the load on the generator set is
reduced. This can be shown mathematically by Ohm’s function may be disabled by setting the slope to zero.
law, which states that power is equal to the voltage

202 Appendix TP-6200 10/12

Frequency Setpoint or Cut-In Point alternators are designed to produce balanced, equal
voltage on all three phases. If the loads applied to the
The point at which the underfrequency unloading begins generator set including no load are equal and balanced,
to take effect is adjustable, allowing the system to be the output voltage on each phase will be nearly equal.
tailored for each application. Because the
characteristics of the engine have the largest effect on However, in some applications, individual phases may
the system’s performance, the engine’s response have unequal or unbalanced loads. In these cases, the
should determine the unloading point. The unloading output voltages will not be equal on each phase. In
setpoint is the frequency below which the excitation general, the phase with the greatest load will have the
control will reduce the voltage so that the engine may lowest voltage while the phase with the least load will
begin to recover. have the highest voltage. This is true regardless of the
type of sensing used in the regulator system. A
The cut-in point, or frequency setpoint, should be set single-phase sensing excitation controller will keep the
0.5--3.0 Hz lower than the normal steady-state band of voltage of the sensed phase at the voltage adjustment
operation. If the engine normally operates within a very value. A three-phase sensing system will average the
narrow range of speeds close to the nominal, a setpoint three phases and hold the average to the adjustment
of 0.5 to 1.0 Hz below nominal should be suitable. If the setting. The average is the sum of the voltages of three
engine normally operates over a wide range of speeds, phases divided by 3.
the setpoint may need to be 2.0--3.0 Hz from the
nominal. The underfrequency unloading function can be As stated above, three-phase sensing does not
eliminated by setting the cut-in point below the minimum eliminate the unequal voltage phenomenon.
expected operating frequency. Three-phase sensing balances the inequality of voltage
between the phases to the desired value. In other
Example words, if a system with unbalanced loads uses a
single-phase control feedback, the voltage on the
A 90 kW load is applied to a 100 kW, 60 Hz generator set sensed phase would be at the setpoint while the other
driven by a turbocharged diesel engine with an two phases would vary by their proportional loads. For
electronical control module (ECM). The speed drops example, if the sensed phase had rated load while the
10% and takes 20 seconds to recover to at least 59.5 Hz. two other phases were only loaded at half the rated
The voltage, meanwhile, drops from 480 to 460 and value, those two phases would have higher-than-rated
recovers to 480 within 15 seconds. Therefore, some voltage which may be undesirable. If a three-phase
underfrequency unloading should be provided. A good sensing feedback were utilized, the phase with rated
starting point would be a frequency setpoint or cut-in of load would be regulated to a voltage slightly below the
59 Hz. A slope of 15 volts per-cycle-per-second is rated voltage while the other two phases would be
appropriate as well. If after these adjustments the speed slightly above the rated voltage (but lower than in the
recovers very quickly, in about 5 seconds, but the previous case). The sum of the three, divided by 3,
voltage drops below 440 volts, the slope should be would be equal to the regulation setpoint.
reduced to 12 volts per cycle. More adjusting may be
required to get the most desirable compromise between In a single-phase system, line-to-line voltage is held
speed and voltage. equal to the line-to-line voltage adjust setting. In a
three-phase system, the average of the three line-to-line
voltage is regulated to the voltage adjust setting. In
Three-Phase Sensing some cases, it may be desirable to keep one phase at a
particular value. Modify the voltage adjust setting higher
Three-phase sensing describes how the excitation
control or voltage regulator determines the condition of or lower accordingly for any unique requirements for the
the alternator output voltage. Early types of regulators particular application. Each of the individual phase
voltages is available in Menu 11, Voltage Regulator.
sensed the voltage on just one phase of the alternator.
Single-phase sensing is not uncommon today as most

TP-6200 10/12 Appendix 203

Reactive Droop As implied above, the reactive droop is not usually
necessary in stand-alone applications. Therefore,
Reactive droop refers to another compensation some means of disabling the feature is provided. If the
technique used in excitation control systems. Reactive generator set will not be paralleled with other generator
droop means that the generator set voltage droops with sets, the reactive droop feature should be disabled. A
increasing reactive current. Although this sounds like an reactive droop setting of 0 will also effectively disable the
undesirable effect, it is quite beneficial in paralleling reactive droop feature. It should be noted that reactive
applications with multiple generator sets. Because the droop applies strictly to the reactive current or
terminals of the generator set are connected to another volt-ampere-reactive (VAR) loading. Primarily, the
generator set(s), the voltage at the terminals is not solely fueling or speed governing system controls the real
determined by either generator set’s excitation. Rather, current which contributes to watts loading.
it is determined by the combination of the excitation
level, the generated voltage, and the voltage drop The gain of the reactive droop function is determined by
across the armature impedance or armature reactance the voltage droop setting. For most applications, a
for each generator set. droop of 3%--5% of rated voltage at rated load at 0.8 PF
is adequate. Prior to actually connecting the generator
Normally the generated voltage is higher than the sets in parallel, test the droop by applying full rated load
voltage at the terminals because the generator set at 0.8 PF. The system is operating correctly if this test
current causes a drop across the armature impedance. shows a reduction in voltage equal to the voltage droop
In a parallel application, the generated voltage of one setting. If the available load is less than full load, the
generator set may be slightly higher than the generated correct voltage droop should be proportional to the
voltage of another generator set. Differences in applied VAR load as a fraction of the rated VAR output for
potential between the generator sets will cause current the generator set. For instance, a 480-volt generator set
to flow into the lower voltage generator set and will also with a voltage droop setting of 4% should drop 19.2 volts
cause the generator sets to share the load current with full rated (0.8 PF) load applied (480 x 0.04) or
disproportionately. Both results are undesirable. 9.6 volts with half the rated load applied (480 x 0.04 / 2).

By introducing reactive droop, the reactive current can When a generator set will be connected in parallel with
be better predicted and controlled. If the current is the utility, VAR or PF control should be ENABLED. If
measured, the regulator/controller can adjust the there are multiple generator sets in parallel as well, then
excitation up or down accordingly, reducing excitation as reactive droop should be ENABLED also.
more current is supplied or increasing excitation as the
reactive current decreases. If all the parallel generator Example
sets incorporate this type of compensation, the reactive
current can be shared equally based on the proportional Two 100 kilowatt (kW) generator sets are paralleled to
size of the generator sets. For an example, see below. provide 150 kW of power at 0.8 PF and wired for a
277/480-volt wye system.
The stability and accuracy of this technique depends on
several factors. Most important, the regulation point for Total kVA load:
each generator set must be equal. That is, each voltage
adjust setting must be the equal to the other(s). This is a kVA = kW / PF
basic requirement prior to the actual paralleling
connection. Also, the effects of the reactive current in 187.5 = 150 / 0.8
each generator set must be compensated for
KVAR load:
individually, which requires an adjustable droop for each
generator set. This adjustment happens to be the kVAR = kVA * sin (acos [ PF ] )
reactive droop adjust. The reactive droop adjust is
quantified as the droop in operating voltage from the 112.5 = 187.5 * 0.6
adjusted setting when full rated load with 0.8 power
factor (PF) is applied. A droop setting of 4% voltage at Line current:
full rated load is a recommended starting point. If the
reactive current is not shared proportionately in each I = ( VA / 3 ) / VL-N
generator set, the respective droops may need
adjustment. Adjust those generator sets that have 226 amps = (187500 / 3) / 277
proportionately higher current for more droop and those
Reactive current:
generator sets with lower reactive current for less droop.
If the reactive current is not stable in the system, adjust I = (VAR / 3) / VL-N
the droop lower in all generator sets.

204 Appendix TP-6200 10/12

135 amps = ( 112500 / 3) / 277 for a linear load may be calculated as the cosine of the
angle between voltage and current. This relationship is
Where: acos is arccosine or inverse cosine based on the power triangle. Using this power triangle
W is Watt concept, it can be shown that the reactive power for a
L-N is line-to-neutral linear load is equal to the sine of the power angle. Then,
using these trigonomic functions, it can be shown that for
PF is power factor
a PF of 0.8, the VARs are related similarly to the VA by a
VA is volt-ampere factor of 0.6. More explicitly, the power angle is equal to
k is kilo ( = 1000 ) the inverse cosine (arccosine) of the PF. For a PF of 0.8,
the power angle is 36.9 degrees (0.2 radians). The sine
Therefore, each generator set in this case should carry of this angle, sine (36.9 degrees) is 0.6. This is the factor
113 amps per phase or half the 226 calculated line for calculating rated VARs from the rated VA. The ratio of
amps. The 113 amps includes 67.5 amps of reactive these two factors is 0.75 (0.6 / 0.8), which can be used to
current, half of the calculated reactive current of calculate rated VARs directly from the rated kW; rated
135 amps. The reactive droop should be adjusted until VARs equals rated watts * 0.75.
each generator set carries equal reactive current. The
load sharing control should be adjusted so that real When a generator set will be connected in parallel with
current and/or watts are shared equally as well. the utility, VAR or PF control should be ENABLED. If
multiple generator sets are in parallel as well, then
If one generator set is larger than the other, it should be reactive droop should be ENABLED also. Additionally,
adjusted to carry proportionate current. For this note that VAR control should be used only when the
example, if a 150 kW generator set is paralleled to a generator set is connected in parallel with the utility.
75 kW generator set, the larger generator set would Parallel connection with the utility requires the logical
carry 90 amps reactive (135 * 2 / 3) and the other would indication that the circuit breakers tying the generator
carry 45 amps reactive (135 * 1 / 3). Adjust the reactive set bus to the utility bus are closed. This indication is
droop based on the ratio of the actual measured made by use of the programmable digital input for
currents, not the calculated values. VAR/PF mode. If this input function is activated, the
excitation control changes to the selected VAR or PF
VAR Control control. If the logical indicator is not present and the VAR
or PF control is not enabled, the control will not switch to
VAR control is analogous to the reactive droop function VAR or PF control. Because the active state for the
described above. It differs in that it applies to utility digital input is a HI or open connection, the default for the
paralleling applications. Because the utility represents a digital input (VAR/PF Mode) is DISABLED (displays
nearly infinite bus, the voltage at the load terminals is not ENABLED NO). If the input is ENABLED by the user, it
controlled at all by the generator set, and it is impossible should be held low by a contact or jumper until the actual
to compare the ratio of the generator set current to the closing of the connecting circuit breaker(s). The proper
utility based on its rated output. In this situation, the control method, VAR or PF, must be ENABLED within
excitation control changes from voltage feedback to the regulator’s configuration menu.
VAR feedback. More specifically, the excitation is
controlled to maintain a certain VAR output rather than a
voltage output. This is called VAR control and again is
Power Factor Control
used only in utility paralleling applications. PF control is much like the VAR control above. PF
control is used only when the generator set is paralleled
The VAR adjust can be set to any value within the
to the utility grid. The difference is that the PF of the
generator set’s rated capability. Because the VARs
generator set current is held constant. The setting for
cause heating in the armature, any value beyond the
the PF adjust determines the relationship of the current
generator set’s rating could damage the alternator. In
and voltage from the generator set. The PF is a term that
most cases, the generator set will be adjusted to
defines the ratio of real watts to the volt-ampere (VA)
generate VAR (lagging PF) but could absorb VARs
product. For linear loads, a trigonomic relationship can
(leading PF) as well. However, the VAR setting is
describe the PF. The PF equals the cosine of the angle
maintained regardless of the relative PF. If the particular
between the current and voltage. PF is further defined
load requires more VARs than the generator set setting,
as leading or lagging. That is to say, if the current lags
the excess is derived from the utility bus.
the voltage (i.e., is later in time), the PF is lagging; if the
The term rated VARs is a bit obscure. In essence, it is a current leads the voltage (i.e., is earlier in time), the PF is
value derived from the rated kW of the generator set. For leading. Inductive loads have lagging PF while
a typical standby rating, the full load of the generator set capacitive loads have leading PF. The current in a
is defined to have 0.8 PF. This means that the kW load is purely resistive load is in phase with the voltage (not
eight-tenths of the VA load. As described earlier, the PF leading or lagging) and the PF is 1.0 (cos. [0]).

TP-6200 10/12 Appendix 205

Set the PF adjust according to the requirements of the or remote communications. If voltage adjustment
application. When a generator set will be connected in occurs, the new value will be displayed accordingly in
parallel with the utility, VAR or PF control should be the voltage adjust menu.
ENABLED. If there are multiple generator sets in
parallel as well, then reactive droop should be
ENABLED also. Additionally, note that PF control
Underfrequency Unload Enable
should be used only while the generator set is connected The underfrequency unload enable menu is used to turn
in parallel with the utility. Parallel connection with the the underfrequency unload on or off. A YES entry will
utility requires the logical indication that the circuit turn the feature on and the display will show ENABLED
breakers tying the generator set bus to the utility bus are YES. A NO entry will turn the feature off and the display
closed. This indication is made by use of the will show ENABLED NO. The underfrequency unload
programmable digital input for VAR/PF mode. If this defaults to an enabled (ON) condition.
input function is activated, the excitation control
changes to the selected VAR or PF control. If the logical
indicator is not present and the VAR or PF control is not Frequency Setpoint
enabled, the control will not switch to VAR or PF control.
Because the active state for the digital input is a HI or The frequency setpoint is the cut-in point for
underfrequency unloading. At any operating frequency
open connection, the default for the digital input
below the frequency setpoint, the output voltage will be
(VAR/PF mode) is DISABLED (displays ENABLED NO).
reduced. The frequency may be entered with resolution
If the input is ENABLED by the user, it should be held low
to tenths of a Hz. The range of acceptable entries is 30 to
by a contact or jumper until the actual closing of the
connecting circuit breaker(s). The proper control 70 Hz. Any entry beyond these limits causes a RANGE
ERROR display and the setting will not change. The
method, VAR or PF must be ENABLED within the
default value is one cycle-per-second (or two for
regulator’s configuration menu.
non-ECM engines) below the normal system frequency.
The frequency setpoint changes to the default value if
Adjustment and Setting the system frequency changes. A setting of 30 Hz
essentially disables the underfrequency unload feature
Specifications because most engines do not normally drop to speeds
this low, even during load applications.
Voltage Adjust
The voltage adjust is entered as the rated or otherwise Underfrequency Unload Slope
desired line-to-line voltage. The average of the
The slope determines how much voltage is reduced
line-to-line voltages is then regulated to the
during an unloading condition. The line-to-line voltage is
corresponding value as previously described. The
regulated to a value less than the voltage adjust setting
setting may be as fine as tenths of volts. The voltage
by this amount for every cycle below the frequency
adjust defaults to the rated system voltage whenever the
setpoint. The voltage may be entered with resolution as
system voltage is changed. The voltage adjust may be
fine as one-tenth of one volt. The default value is 2.0
set to any value within ±10% of the system voltage. The
volts per-cycle-per-second. A zero entry for the slope in
upper limit is ±10% above the system voltage and the
effect turns the underfrequency unload feature off.
lower limit is ±10% below the system voltage. If a value
beyond these limits is entered, a RANGE ERROR
message will be displayed. Reactive Droop Enable
As a reference, the present voltage adjust setting is This menu allows the user to enable the reactive droop
displayed as well as the average value of the line-to-line feature. A YES entry turns the feature on and the display
voltages. The individual line-to-line voltages are also shows ENABLED YES. A NO entry turns the feature off
displayed on the subsequent menu screens. This allows and the display shows ENABLED NO. Reactive droop is
the user to monitor any individual phase, if desired. intended to be used in a generator set-to-generator set
paralleling application.
The voltage adjust setting may be changed by means
other than the menu including user-defined digital input

206 Appendix TP-6200 10/12

Voltage Droop Generating/Absorbing
The amount of reactive droop is entered here. The While operating in the VAR control mode, the reactive
droop is entered as a percentage of system voltage load on the generator set may be specified to be out of
when a fully rated load at 0.8 PF is applied. The entry GENERATING or into ABSORBING the generator set.
may be made with resolution as fine as one-tenth of one Specifying the VAR type or direction is done through the
volt. This entry determines how much the voltage will GENERATING/ABSORBING menu. Because the
droop when the alternator provides reactive current. normal flow of reactive current is out of the generator set,
The actual amount the voltage changes is equal to the the default value is GENERATING. If ABSORBING is
voltage droop setting times the VAR load as a fraction of desired, a NO entry at this menu will change the control
the rated VARs (at 0.8 PF). If the generator set were mode to ABSORBING. When ABSORBING is selected,
providing full rated load (at 0.8 PF), the expected voltage another NO entry will revert the control mode back to
change would equal the voltage droop setting as a GENERATING. It is assumed that this mode will not be
percentage of system voltage. A voltage droop setting changed when the generator set is running. An attempt
of zero in effect disables the reactive droop feature. The to change the mode while running will return a RANGE
default value is 4% droop at full rated load at 0.8 PF. ERROR message. The generator set will need to be
shut down in order to change this setting.
The present voltage droop setting is displayed for
reference. The display may change if this value is
changed via remote communication. PF Adjust
Use the PF adjust to set the desired operating
VAR Control Enable relationship for the generator set’s output voltage and
current when the generator set is connected in parallel
In order for the VAR control function to operate, it must with the utility. The excitation is regulated to maintain a
be enabled. Entering YES at this menu will turn the PF equal to the entered value. The value entered may
feature on. Because the function is designed to operate be as low as 0.7 for leading PFs or as low as 0.6 for
while the generator set is in parallel with the utility, VAR lagging PFs. Any entries below these limits will cause a
control also requires the proper indication that all tying RANGE ERROR message to display.
circuit breakers are closed. This is done through the
user-programmable digital inputs. The upper limit for PF adjust is 1.0 and the default value
is 0.8 lagging. Each time the system’s rated kW is
Because VAR control cannot be enabled at the same changed, the PF adjust will revert to this default value.
time that PF control is enabled, turning VAR control on The PF adjust display setting may change if the PF
(ENABLED) when PF control is enabled turns the PF adjust is changed via other inputs.
control off (DISABLED).

Lagging/Leading
KVAR Adjust
It is possible to select either a leading or lagging PF for
Using the kVAR adjust sets the desired operating value utility parallel applications. The selected mode is
for the generator set’s reactive load when the generator displayed. A NO entry switches the controller to use the
set operates in a utility paralleling application. The other reference. Because the most common mode of
desired generator set load is entered directly as kVARs. operation will be with a lagging PF, LAGGING is the
The value entered may be as low as zero or as high as default value. Because this mode should not be
the rated value (rated kW x 0.75). Any entry beyond the changed while the generator set is running, attempting
rated value will not be accepted, and a RANGE ERROR to change this mode during operation will return a
message will be displayed. RANGE ERROR message. Always shut down the
generator set to change the lagging/leading mode
The default value for kVAR adjust is zero. Each time the setting.
system’s rated kW is changed, the kVAR adjust will
revert to zero. The displayed kVAR setting may change
if the kVAR setting is changed via other inputs.

TP-6200 10/12 Appendix 207

Appendix D Alternator Protection

The 550 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

208 Appendix TP-6200 10/12

 Appendix E Inputs and System Events by Application

The controller inputs and system events are typically engine ECMs provide additional items that the controller
driven by the engine manufacturer’s ECM. NFPA 110 will display. The following table illustrates the available
guidelines provide specific requirements that all alternator and engine outputs for monitoring and factory
controllers must have for compliance. While the reserved connections.
controller displays all NFPA 110 required data, some
NFPA 110 Paralleling DD/MTU Engines Waukesha
Controller Inputs and System Events Applications Applications with MDEC/ADEC Engines 125RZG
AC Sensing Loss Warning
Air Damper Control (if engine equipped) X
Air Damper Indicator Shutdown (see D20) (if engine
equipped) X

Air/Fuel Module Engine Start Delay X

Air/Fuel Module Remote Start X
Air/Fuel Module Shutdown (see D11) X
Alternator Protection Shutdown
Analog Aux. Input 0 Local Battery VDC
Analog Aux. Inputs A01--A07 (Warning or Shutdown)
Analog Aux. Input A01 Coolant Temperature (non-ECM)
Analog Aux. Input A02 Oil Pressure (non-ECM)
Analog Aux. Input A03 Intake Air Temperature X
Analog Aux. Input A04 Fuel Level
Analog Aux. Input A04 Oil Temperature Warning X
Analog Aux. Input A06 VSG (Volvo, GM, Doosan only)
Analog Aux. Input A07 Analog Volt Adjust
Battery Charger Fault Warning (see D01) X
Battle Switch Warning
Block Heater Control X
Breaker Closed Warning (see D05) X
Breaker Trip Warning X
Common Protective Relay Warning X
Critical Overvoltage Shutdown
Cyclic Cranking
Defined Common Faults (Warning or Shutdown)
Detonation Shutdown (see D13) X
Detonation Warning (see D12) X
Digital Aux. Inputs D01--D21 (Warning or Shutdown)
Digital Aux. Input D01 Battery Charger Fault Warning X
Digital Aux. Input D02 Low Fuel (Level or Pressure) Warning X
Digital Aux. Input D03 Low Coolant Temperature Warning X
Digital Aux. Input D04 Field Overvoltage Shutdown
Digital Aux. Input D05 Breaker Closed Warning X
Digital Aux. Input D06 Enable Synch X
Digital Aux. Input D09 Low Fuel Pressure Shutdown X
Digital Aux. Input D11 Air/Fuel Module (AFM) Shutdown X
Digital Aux. Input D12 Detonation Warning X
Digital Aux. Input D13 Detonation Shutdown X
Digital Aux. Input D13 Knock Shutdown X
Digital Aux. Input D14 Low Coolant Level Warning X
Digital Aux. Input D15 Remote Shutdown
Digital Aux. Input D16 Remote Reset

TP-6200 10/12 Appendix 209

 NFPA 110 Paralleling DD/MTU Engines Waukesha
Controller Inputs and System Events Applications Applications with MDEC/ADEC Engines 125RZG
Digital Aux. Input D17 VAR/PF mode
Digital Aux. Input D18 Voltage Lower
Digital Aux. Input D19 Voltage Raise
Digital Aux. Input D20 Air Damper Indicator Shutdown
(if engine equipped) X

Digital Aux. Input D21 Idle (Speed) Mode Warning

ECM Yellow Alarm Warning X
ECM Red Alarm Shutdown X
EEPROM Write Failure Shutdown
Emergency Stop Shutdown
Engine Derate Active
(Engine) J1939 CAN Engine Shutdown (ECM only)
Engine Stalled (ECM only)
EPS (Emergency Power System) Supplying Load Warning
Field Overvoltage Shutdown
(M4, M5, M7, M10 alternator only) (see D04)
Fuel Level (units with subbase fuel tanks) (see A04)
Fuel Valve Relay X
Generator Set Running
Ground Fault Detected Warning
High Battery Voltage Warning
High Coolant Temperature Shutdown
High Coolant Temperature Warning
High Oil Temperature Shutdown
High Oil Temperature Warning X X
Idle Speed Mode Function Warning
Intake Air Temperature Shutdown X
Intake Air Temperature Warning X
Intake Air Temperature Warning (see A03) X
Internal Fault Shutdown
Knock Shutdown (see D13) X
Load Shed kW Overload Warning (FAA only)
Load Shed Over Temperature (activated by HCT shutdown) X
Load Shed Underfrequency Warning
Locked Rotor Shutdown
Loss of ECM Communication Shutdown (ECM engines only)
Loss of Field Shutdown (Reverse VARs) X
Low Battery Voltage Warning
Low Coolant Level Shutdown
Low Coolant Level Warning (see D14) X
Low Coolant Temperature Shutdown X
Low Coolant Temperature Warning (see D03) X
Low Fuel (Level or Pressure) Warning, (see D02) X
Low Fuel (Pressure) Shutdown (see D09) X
(Low) Oil Pressure Shutdown
(Low) Oil Pressure Warning
Maintenance Due
Master Not In Auto (Generator Set Switch)
Master Switch Error Shutdown
Master Switch to Off Shutdown
Master Switch Open Shutdown

210 Appendix TP-6200 10/12

 NFPA 110 Paralleling DD/MTU Engines Waukesha
Controller Inputs and System Events Applications Applications with MDEC/ADEC Engines 125RZG
NFPA 110 Fault (Warning or Shutdown) X
No Air Temperature Signal Warning X
No Coolant Temperature Signal Shutdown
No Oil Pressure Signal Shutdown
No Oil Temperature Signal Warning X
Overcrank Shutdown
Over Current Voltage Restraint Shutdown X
Over Current Warning
Over Frequency Shutdown
Over Power Shutdown X
Over Speed Shutdown
Overvoltage Shutdown
Pre Lube Relay X
Remote Reset (see D16)
Remote Shutdown (see D15)
Synch Enable (see D06) X
VAR/PF Mode (see D17)
Voltage Lower (see D18)
Voltage Raise (see D19)
Reverse Power Shutdown X
Speed Sensor Fault Warning
System Ready
Time Delay Engine Cooldown (TDEC)
Time Delay Engine Start (TDES)
Time Delay Starting Aid
Underfrequency Shutdown
Undervoltage Shutdown
Variable Speed Governor (VSG) (see A06)
VAR/PF Mode (see D17)
Voltage Lower (see D18)
Voltage Raise (see D19)
Weak Battery Warning

TP-6200 10/12 Appendix 211

 Notes

212 Appendix TP-6200 10/12

 Notes

TP-6200 10/12 213

 Notes

214 TP-6200 10/12

 KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
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TP-6200 10/12i 7 Jurong Pier Road
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