training manual literature/lit/tp6309...4 this manual covers operation, troubleshooting, and...
TRANSCRIPT
Training Manual
ResidentialGenerator Sets
8.5RES / 12RESG220 ATS
TP-63095/03/04
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Table Of Content
Introduction ................................................................................. 2-6
Safety .......................................................................................... 7-13
System Concept .........................................................................14-19
Specifications..............................................................................20-23
Air Intake .....................................................................................24-25
Fuel System ................................................................................26-30
Governor ..................................................................................... 31
Lube System............................................................................... 32
Ignition System ...........................................................................33-34
Starting System ...........................................................................35-36
Battery Charging ......................................................................... 37
Maintenance ................................................................................ 38
Alternator .....................................................................................39-51
Controller ....................................................................................52-66
Automatic Transfer Switch .......................................................... 67-76
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This manual covers operation, troubleshooting, and features of Kohler Commercial /Residential Generator Sets.
This manual is only intended as a training guide and is to be used as a supplement toclassroom material. This is not a service manual and does not contain all available productinformation. Do not attempt to service generator sets without consulting the servicemanual and following all safety warnings.
Pictures, illustrations, and wiring diagrams in this manual are only representative of thevarious models and may differ slightly even within the same model designation series.
This manual is not intended as an installation or troubleshooting guide.
Introduction
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Kohler Company HistoryFounded by John Michael Kohler on Dec. 3, 1873, Kohler Co.has grown to become the nation�s largest manufacturer ofplumbing and specialty products as well as a major producerof generators and four-cycle engines. In recent years, the com-pany has also acquired two distinguished furniture manufacturersand opened a variety of highly successful hospitality businesses.Headquartered in Kohler, Wis., Kohler Co. is one of the oldestand largest privately held companies in the country and employsmore than 20,000 people.
Power Systems GroupKohler Co., a major producer of engines, generators and electricalproducts, entered the power systems market in the early 1900�s.Its first power systems products included cast iron internal com-bustion engines and Automatic Power and Light, a remarkableimprovement in auxiliary power in its day. Generators, then knownas electrical plants, supplied power during Admiral Richard Byrd�sAntarctic exploration in the late 1920�s. In the post-war years,Kohler expanded its engine and generator product lines andcontinued to improve the durability and performance of all of itspower systems units. Consequently, the number of markets forKohler power systems products grew throughout the United Statesand beyond. Today, Power Systems International, created in 1989and based in Kohler, Wis., is responsible for all Kohler generatorand engine product sales outside of the United States.
Generator DivisionIn use throughout the world, Kohler generators are available forthe marine, home, mobile, commercial, and industrial markets.In addition to generator sets, Kohler also manufactures transferswitches, switchgear and accessories for all product lines. Kohlergenerators are produced in a manufacturing facility located inthe town of Mosel, eight miles north of Kohler, Wis. In 1997 Kohleropened and operates a manufacturing facility in Singapore forthe international product line.
Engine DivisionOne of the world�s major manufacturers of air-cooled, four-cycleengines, Kohler Co. produces models ranging from 4 horsepowersingle-cylinder engines to 26 horsepower twin-cylinder engines.These engines are used by major manufacturers to power lawnand turf, agricultural, industrial construction and recreationalequipment. The Kohler engine is also used in Kohler generatormodels, specifically the residential/ commercial product lines. Kohlerengines are manufactured in Kohler, Wis. and Hattiesburg, Miss.
Kohler de Mexico, S.A. de C.V.Created in 1964 and located in Mexico City, Kohler de Mexicomanufactures four-cycle engines.
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SafetySafety Precautions and Instructions
A generator set, like any other electromechani-cal device, can pose potential dangers to lifeand limb if improperly maintained or imprudentlyoperated. The best way to prevent accidents isto be aware of the potential dangers and toalways use good common sense. In the interestof safety, some general precautions relating tothe operation of a generator set follow. Keepthese in mind. This manual contains severaltypes of safety precautions that are explainedbelow.
DANGER
Danger is used to indicate the presence of ahazard, which will cause severe personalinjury, death, or substantial property damageif the warning is ignored.
WARNING
Warning is used to indicate the presence of ahazard which can cause severe personalinjury, death, or substantial property damageif the warning is ignored.
CAUTION
Caution is used to indicate the presence of ahazard, which will or can cause minor personalinjury or property damage if the warning isignored.
NOTENote is used to notify people of installation,operation, or maintenance information, which isimportant but not hazard-related.
Safety decals are affixed to the generator setin prominent places to advise the operator orservice technician of potentially hazardoussituations. The decals are reproduced here toimprove operator recognition and therebyincrease decal effectiveness.
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Safety
Accidental starting can cause severe Injuryor death. Disconnect battery cables (removenegative lead first and reconnect it last) todisable generator set before working on anyequipment connected to generator. Placecontroller MASTER switch to OFF position. Thegenerator set can be started by remote start/stop switch unless this precaution is followed.
Generator set operation. Carbon monoxidecan cause severe nausea, fainting, or death.Never operate the generator set inside a build-ing unless the exhaust gas is piped safelyoutside. Never operate in any area whereexhaust gas could accumulate and seep backinside a potentially occupied building. Avoidbreathing exhaust fumes when working on ornear the generator set. Carbon monoxide isparticularly dangerous because it is an odorless,colorless, tasteless, nonirritating gas that cancause death if inhaled for even a short period oftime.
Carbon monoxide symptoms. Carbon mon-oxide can cause severe nausea, fainting, ordeath. Carbon monoxide is a poisonous gaswhich is present in exhaust gases. Carbonmonoxide poisoning symptoms include but arenot limited to the following:
� Light-headedness, dizziness
� Physical fatigue, weakness in joints andmuscles
� Sleepiness, mental fatigue, inability toconcentrate or speak clearly, blurred vision
� Stomach ache, vomiting, nausea
If experiencing any of these symptoms andcarbon monoxide poisoning is possible, affectedpersons should seek fresh air immediately.They should remain active. They should not sit,lie down, or fall asleep. Alert others to thepossibility of carbon monoxide poisoning. If thecondition of affected persons does not improvewithin minutes of breathing fresh air, they shouldseek medical attention.
Engine noise. Hazardous noise can causeloss of hearing. Generator sets not equippedwith sound enclosures can produce noise levelsgreater than 105 dBA. Prolonged exposure tonoise levels greater than 85 dBA can causepermanent hearing loss. Wear hearing protec-tion when near an operating generator set.
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Safety
Exposed moving parts can cause severeInjury or death. Keep hands, feet, hair, cloth-ing, and test leads away from belts and pulleyswhen unit is running. Replace guards, covers,and screens before operating generator set.Some scheduled maintenance proceduresrequire the generator set to be running whileperforming service. If the sound shield hasbeen removed leaving belts and pulleys ex-posed, be especially careful of this area.
Flying projectiles can cause severe Injury ordeath. Retorque all crankshaft and rotor hard-ware after servicing. When making adjustmentsor servicing generator set, do not loosen crank-shaft hardware or rotor thru-bolt. If rotatingcrankshaft manually, direction should be clock-wise only. Turning crankshaft bolt or rotor thru-bolt counterclockwise can loosen hardware andresult in serious personal injury from hardwareor pulley flying off engine while unit is running.
A flash fire can cause severe injury or death.Do not Smoke or permit flame or spark to occurnear carburetor, fuel line, fuel filter, fuel pump,or other potential sources of spilled fuel or fuelvapors. When removing fuel line or carburetor,use a proper container to catch all fuel.
A sudden backfire can cause severe Injuryor death. Do not operate with backfire flamearrestor removed. (gasoline models only)
A sudden backfire can cause severe Injuryor death. Do not operate with air cleaner/silencer removed.
A sudden flash fire can cause severe Injuryor death. Do not smoke or permit flame orspark to occur near fuel system. Keep thecompartment and generator set clean and freeof debris to minimize chances of fire. Wipe up
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Safety
Grounding generator set. Hazardous voltagecan cause severe injury or death. Electrocu-tion is possible whenever electricity is present.Open main circuit breakers of all power sourcesbefore servicing equipment. Configure theinstallation to electrically ground the generatorset and electrical circuits when in use. Nevercontact electrical leads or appliances whenstanding in water or on wet ground, as thechance of electrocution increases under suchconditions.
High voltage test. Hazardous voltage cancause severe injury or death. Follow instruc-tions of test equipment manufacturer whenperforming high-voltage test on rotor or stator.An improper test procedure can damage equip-ment or lead to future generator set failures.
Installing battery charger. Hazardous voltagecan cause severe injury or death. Electricalshock may occur if battery charger is not electri-cally grounded. Connect battery charger enclo-sure to ground of a permanent wiring system.As an alternative, install an equipment ground-ing conductor with circuit conductors and con-nect to equipment grounding terminal or lead onbattery charger. Perform battery charger instal-lation as prescribed in equipment manual. Installbattery charger in compliance with local codesand ordinances.
Connecting battery and battery charger.Hazardous voltage can cause severe injuryor death. Reconnect battery correctly to avoidelectrical shock and damage to battery chargerand battery(ies). Have a qualified electricianinstall battery(ies).
Testing voltage regulator. Hazardous voltagecan cause severe injury or death. Highvoltage is present at the voltage regulator heatsink. Do not touch voltage regulator heat sinkwhen testing voltage regulator or electricalshock will occur. (PowerBoost-, PowerBoost- ///,and PowerBoost- V voltage regulator modelsonly.)
Engine block heater. Hazardous voltage cancause severe injury or death. Engine blockheater can cause electrical shock. Removeengine block heater plug from electrical outletbefore working on block heater electrical con-nections.
Electrical backfeed to utility. Hazardousbackfeed voltage can cause severe injury ordeath. Install a transfer switch in standby powerinstallations to prevent connection of standbyand other sources of power. Electrical backfeedinto a utility electrical system can cause seriousinjury or death to utility personnel working ontransmission lines.
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Safety
Explosive fuel vapors can cause severeinjury or death. Take additional precautionswhen using the following fuels: Gasoline - Storegasoline only in approved red containers clearlymarked GASOLINE.
Propane (LP)-Adequate ventilation is manda-tory. Propane is heavier than air; installpropane gas detectors low in room. Inspectdetectors often.
Natural Gas-Adequate ventilation is mandatory.Natural gas rises; install natural gas detectorshigh in room. Inspect detectors often.
Gas fuel leaks. Explosive fuel vapors cancause severe injury or death. Fuel leakagecan cause an explosion. Check LP vapor gas ornatural gas fuel system for leakage using asoap-water solution with fuel system test pres-surized to 6-8 ounces per square inch (10-14inches water column). Use a soap solutioncontaining neither ammonia nor chlorine be-cause both prevent bubble formation. A suc-cessful test depends on the ability of the solutionto bubble.
Fuel system. Explosive fuel vapors cancause severe injury or death. All fuels arehighly explosive in a vapor state. Use extremecare when handling and storing fuels. Store fuelin a well-ventilated area away from spark-producing equipment and out of the reach ofchildren. Never add fuel to the tank while theengine is running because spilled fuel may igniteon contact with hot parts or from spark. Do notsmoke or permit flame or spark to occur nearsources of spilled fuel or fuel vapors. Keep fuellines and connections tight and in good condi-tion. Do not replace flexible fuel lines with rigidlines. Use flexible sections to avoid breakagecaused by vibration. Do not operate generatorset in the presence of fuel leaks, fuel accumula-tion, or sparks. Repair systems before resuminggenerator set operation.
LP liquid withdrawal fuel leaks. Explosivefuel vapors can cause severe injury or death.Fuel leakage can cause an explosion. CheckLP liquid withdrawal gas fuel system for leakageusing a soap-water solution with fuel system testpressurized to at least 90 psi (621 kPa). Use asoap solution containing neither ammonia norchlorine because both prevent bubble formation.A successful test depends on the ability of thesolution to bubble.
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Safety
If battery acid is splashed in the eyes or onskin, immediately flush the affected area for15 minutes with large Quantities of cleanwater. In the case of eye contact, seekimmediate medical aid. Never add acid to abattery once the battery has been placed inservice. Doing so may result in hazardousspattering of electrolyte.
Explosion can cause severe Injury or death.Battery gases can cause an explosion. Do notsmoke or permit flame or spark to occur near abattery at any time, particularly when it is beingcharged. Avoid contacting terminals with tools,etc. to prevent bums and to prevent sparks thatcould cause an explosion. Remove wristwatch,rings, and any other jewelry before handlingbattery. Never connect negative (-) batterycable to positive (+) connection terminal ofstarter solenoid. Do not test battery condition byshorting terminals together or sparks couldignite battery gases or fuel vapors. Any com-partment containing batteries must be wellventilated to prevent accumulation of explosivegases. To avoid sparks, do not disturb batterycharger connections while battery is beingcharged and always turn charger off beforedisconnecting battery connections. Whendisconnecting battery, remove negative lead firstand reconnect it last.
Battery acid. Sulferic acid in batteries cancause severe injury or death.
Hot coolant can cause severe Injury or death.Allow engine to cool and release pressurefrom cooling system before opening pressurecap. To release pressure, cover the pressurecap with a thick cloth then turn ft slowly coun-terclockwise to the first stop. After pressurehas been completely released and the enginehas cooled, remove cap. If generator set isequipped with a coolant recovery tank, checkcoolant level in tank.
Hot parts can cause severe Injury or death.Do not touch hot engine parts. An engine getshot while running and exhaust system compo-nents get extremely hot.
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Safety
NOTICEVoltage reconnection! Affix notice to gen-erator set after reconnecting to a voltagedifferent from the nameplate. Order voltagereconnection decal 246242 from authorizedservice distributors/dealers.
NOTICEHardware damage! Engine and generator setmay use both American Standard and metrichardware. Use the correct size tools to preventrounding of bolt heads and nuts.
NOTICEWhen replacing hardware, do not substitutewith inferior grade hardware. Screws andnuts are available in different hardness ratings.American Standard hardware uses a series ofmarkings and metric hardware uses a numericsystem to indicate hardness. Check markingson bolt head and nuts for identification.
NOTICECanadian installations only: For standbyservice connect output of generator set to asuitably rated transfer switch in accordance withCanadian Electrical Code, Part 1.
System Concept
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System Concept
The system concept features a utility (primary) source, generator (backup) source, and anautomatic transfer switch connected to a building load.
The generator is designed to provide a dependable alternate source of electrical power. Whenconnected to an automatic transfer switch (ATS) the generator will be signaled to start and buildingload transferred to the generator if the utility supply fails or falls below a specified level. When utilityreturns the ATS will transfer back to utility and allow the generator to go into a cooldown mode beforeshutting down the generator. The system is designed to require no manual intervention from thehomeowner when operating automatically.
Note: when planning an installation of a home standby generator and ATS the installer must follow allmunicipal codes for the region. Installers must be familiar with and comply to all Natural Gas or LPfuels codes as well as all electrical safety codes.
System Concept
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Essential Loads Panel
Prior to installing a Kohler power system theinstaller should carefully determine the sizegenerator and ATS required. The generator willbe sized to meet one of two electrical designs.Essential loads application (shown above) orWhole House Power. The �essential loads�refers to providing power for those devices that acustomer designates as essential during anemergency utility power outage. Sump pumps,furnaces, air conditioning, refrigerators, freezersand security lighting could all be consideredessential.
During installation these devices are wiredthrough an �essential loads� distribution panel,which in turn is wired to the generator and ATS.
Sizing the generator for �essential loads� allowsthe customer to use a smaller generator to meetthe homes electrical power needs during apower outage.
System Concept
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The majority of newer residential utility serviceentrances in the United States are protected bya 100 or 200 amp circuit breaker. This maindisconnect circuit breaker is generally located ina panel with the distribution circuit breakers.
The Normal 60 Hz. voltage supply from themeter is usually single phase , 3 wire, 220 to240 volts measured line to line and 110 to 120volts line to neutral. The neutral or common istied to a ground lug.
When designing a Standby Power System theEmergency Generator set must match thevoltage and frequency of the Normal source.
The Transfer switch must also have the samevoltage and frequency rating of the Normal andEmergency power supplies for operation of thetransfer mechanism.
If the total load of a 200 amp service isconnected to the transfer switch, the switchmust meet or exceed the 200 amp rating eventhough the generator may only be capable ofsupplying 50 amperes.
Normally not all circuits are considered ascritical loads and therefore need not be poweredby the generator. An emergency supply of 8.5 to12kW in most cases is adequate.
There are various design schemes that anelectrical contractor can offer that can meetcustomers particular needs.
The load applied to the generator can bereduced if required by manually openingdistribution breakers.
System Concept
System Concept
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Whole House Power
When the customer decides that the generatorshould power the whole house, just as if normalutility power is working, the generator and ATSmust be wired directly into the homes electricaldistribution panel (as shown). Care must betaken when sizing the generator and ATS switchfor each application, refer to the specificationsheets of the generator and automatic transferswitch to make sure the current and voltageratings meet the energy needs of the installation.
Typically when sizing a whole house system, thegenerator current ratings should be equal to themain circuit breaker rating. If not then theinstaller should calculate current draw of allelectrical devices that may be on during anemergency power outage and size the generatoraccordingly. Failure to do so will result in thegenerator being overloaded causing possibleharm to the generator or electrical load.
System Concept
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Residential Power Systems Sizing Chart
Home Appliances Wattage Requirements
This sizing chart is intended to help you estimate the essential wattage requirements for the appli-ances you wish to use during an emergency utility outage. Your total wattage requirement will helpdetermine which Kohler residential generator set system will best serve your needs.
When selecting your essential appliances, please note the following:
1. Wattage loads for appliances are calculated two different ways:
a. Resistive LoadsCircuits that do not have electric motors; ovens, toaster, TV, lighting
b. Inductive LoadsCircuit that have electric motors; AC, dryer, washer, furnace, sump pump
Starting wattage - additional wattage is required to start electric motors used in home appli-ances..
2. These estimates are intended to assist in the specification phase of assessing your generatorset requirements. Actual appliance wattage will vary depending on the appliance manufacturerand application.
3. By staggering when you use specific appliances, the chart allows you to determine practicalusage during an emergency utility failure.
Typical AC Electrical Requirements for Residential Installation
Use the chart on the next page to calculate your estimated wattage. After you have your total estimatedwattage calculated, go back and determine, from a practical standpoint, those appliances you wouldactually run (need) at the same time. Keep in mind you can stagger appliance usage (for example, turnoff an electric range element to run a toaster).
This practical home wattage requirement should be equal to or less than the kilowatt rating of yourselected Kohler generator set.
System Concept
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FEATURES AND SPECIFICATIONS
Models 8.5 and 12RES are powered by V-Twin, Kohler Command CH20 and CH740 air cooled,overhead valve engines.
The generator set can utilize either LP or Natural Gas for the fuel supply. The model designationcorresponds with the full load kW rating of a 60 hertz unit operating on LP gas. Due to the lowerBTU rating of Natural gas approximately 12% less than the LP rating is normal when fueled byNatural gas.
Systems are available for both single phase, 3 wire 120/240 volt, 60 hertz and 110/220 volt, 50 hertzapplications. Both voltage and frequency are field adjustable to closely match the utility supply.
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Alternator Specifications
Compliance with NEMA, IEEE, and ANSIstandards for temperature rise.
Self-ventilation and drip-proof construction.
Vacuum-impregnated windings with fungus-resistant epoxy varnish for dependability andlong life.
Superior voltage waveform and minimumharmonic distortion from skewed alternatorconstruction.
A rotating-field alternator with static exciter forexcellent load response.
Specification
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The 8.5/12RES generator sets are equipped withfour-cycle, twin cylinder, air-cooled Kohlerengines. Some of the engine features include:
One-side serviceability of air cleaner, carburetor,oil fill, dipstick, and oil drain.
Efficient overhead valve design and full pressurelubrication for maximum power, torque, andreliability under all operating conditions.
Electronic governor to ensure AC power outputis maintained at desired frequency.
Overspeed shutdown to prevent governedfrequency from exceeding 70 Hz.
Low oil pressure cutout to prevent failure.
Dependable, maintenance free electronicignition.
Digital Spark Advance Module (DSAM) optimizesengine timing for natural gas or LP fuel (12RESonly)
Parts subject to the most wear and tear madefrom precision formulated cast iron.
Hydraulic valve adjusters to eliminate the needfor valve adjustments.
Fuel systems that allow fuel changeover fromnatural gas to LP vapor (and vice-versa) whilemaintaining CARB certification.
SpecificationEngine Specification
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Advanced Digital ControllerLED display
Run time hoursCrank Cycle StatusDiagnosticsApplication Software Version
LED display faultsHigh Battery VoltageLow Battery VoltageLow Oil PressureOvercrankOverspeedOverfrequencyOvervoltageUndervoltageUnderFrequency
Password ProtectedRun / Off-reset / Auto modeDigital Isochronous GovernorDigital Voltage RegulatorCyclic cranking
SpecificationController Specifications
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The enclosed unit is cooled by a directed airflow system.
Two fans, one attached to the engine flywheeland the other to the alternator rotor draw inambient air to cool the engine, alternator, andcontroller, as well as purge the compartment ofhot air.
The engine fan draws air from the housing inletand forces it across the cylinder cooling fins. Aportion of air is also directed through the control-ler . An opening in the controller shelf providesair flow for the voltage regulator.
The Alternator fan draws cool air into openings inthe end bracket to cool the rotor and stator
Air IntakeCooling
Air Inlet
Exhaust Air
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A portion of the outside ambient air is directedfrom the flywheel fan to the Gas/Air mixer(carburetor) for combustion.
The air is first filtered by an oiled-foamprecleaner and replaceable paper element aircleaner.
It is important that the filters are serviced at therecommended scheduled times and that the unitis not operated with the filters removed. Dirtparticles entering the intake will cause prematureengine wear and failure.
A clogged filter may cause excessive fuelconsumption and a loss of engine power.
Air Cleaner
Air Intake
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Fuel System
The generator set will operate on either Naturalor LP fuel in a gaseous state. Manual shut-offvalves and Primary regulators are installed bythe fuel supplier.
A secondary regulator and 12vdc solenoid valveare located in the front inlet air compartment.The solenoid valve is energized from thecontroller to open at start and deenergize atshutdown. A ½� NPT inlet is provided.
Inlet gas pressure to the regulator should notexceed 6oz. The regulator controls the pressureon engine demand. A plug is provided at theregulator input for installationof a gauge or manometer if apressure check is required.
A fuel lock-off is also locatedin the regulator whichprevents fuel flow when theengine is not operating. Thisis adjusted at the factory andshould not be used in anattempt to adjust fuel mixtureor engine speed.
The fuel system employs the use of a fuel blockwhich allows either natural gas or LP fuels to beused. Fuel changeover is completed byswitching inlet ports and if necessary changingthe ignition timing connection. (see ignitionsystems)
The fuel block has adjustment for optimumengine performance on either NG or LP fuels.The adjustments are set and sealed at thefactory and should not be modified.
Fuel System
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Natural Gas System
The natural gas as supplied from the utility isin a vapor state. The primary regulator for anatural gas system will be the responsibility ofthe utility that supplies the natural gas.
The heating value of Natural gas should be1000BTU per cubic foot. When heatingcontent falls below 1000BTU the set will notproduce rated power and will need to bederated. Always check the specificationsheet for the rating of the generator whilerunning on natural gas, many applicationsrequire derating of the full load power onnatural gas.
When installing or troubleshooting the fuelsystem the following factors must beconsidered.
• Pressure loss due to length of pipe• Pressure loss due to other appliances on
same fuel supply• Pressure loss due to number of fittings
or elbows
Measured pressure at the inlet to thesecondary regulator should be 4 � 6ounces per square inch or 7 � 11 incheswater column. The outlet or carburetor side ofthe secondary regulator should measure 4-5inches water column under load.
Fuel System
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LP Gas
LP gas is supplied as a liquid in pressuretanks, which makes it easily adaptable tostationary generator applications wherecomplete independence of a fuel source isrequired.
LP gas is propane, butane, or a mixture of thetwo gases. The ratio of butane to propane isespecially important when an outdoor tank isused. LP gas suppliers may supply the tank inwarm summer months with a mixture composedmostly of butane, this mixture my work well insummer but may not provide sufficient vaporizedpressure at cold temperatures (below 32°) tostart and run the engine. Check with you LP gassupplier for mixture content when hard startingsymptoms exist.
The heating value for propane is 2,516 BTU percubic foot with a boiling point of -44° F andbutane is 3,264 BTU per cubic foot with a boilingpoint of 32° F.
Inlet pressure into the secondary regulatorshould be 4 � 6 ounces per square inch or 7 � 11inches water column. Outlet pressure to thecarburetor will be a negative pressure of about�11/2 inches water column.
Fuel System
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Pipe Size Requirement for Gaseous System
When installing the generator and laying the pipe for a gaseous system a few things need to beconsidered, the type of fuel, the distance it must travel from gas meter or tank to the fuel shutoffsolenoid, and the amount of fuel consumed by the engine. To figure the correct pipe size for aspecific installation, refer to the chart and follow the procedure outlined.
1. Determine length of pipe between gas meter/tank and fuel shutoff solenoid at generator set.Example: 35ft.
2. Find figure closest to pipe length in �Length of Pipe� column on chart.Example: For 35ft it would be 40ft.
3. Refer to fuel consumption from the generator specification sheet. Note type of fuel, andconsumption of fuel at 100% load. Example: The 8.5RES for natural gas operating at 100%full load uses 132cfh (cubic feet per hour).
4. Refer to correction factors below. Locate factor for specific gravity of fuel used. Example: natural gas specific gravity - .65, correction factor - .962.
5. Divide consumption figure (132cfh) by the correction factor (.962).
132÷.962= 137cfh.
6. Move vertically across page to determined point in �length of pipe� column (40ft) go downcolumn and stop at first figure equal to or greater then corrected consumption figure(137cfh).
7. Move to left column from figure (137cfh) to determine correct pipe size. The correct pipe size fora 8.5RMY with a pipe run of 35 ft. should be 3/4 inch.
Fuel System
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Maximum capacity of Pipe in Cubic Feet of gas per Hour for a Gas pressure of 0.5Psig or less
A pressure drop of 0.5 inch water column has been calculated into the chart to make allowances fora nominal number of fittings.
Fuel System
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Governor System
The frequency of the alternator output isdetermined by the speed of the engine. A 2-pole alternator must be driven at 3600 RPMto provide 60 hertz. (3000 rpm/50 Hz)
The engine speed is maintained by an electronicgovernor system consisting of a magneticpickup, electric actuator and electronic controlassembly.
The microprocessor based ADC controllermaintains generator speed based on the magpick-up input. The magnetic pick-up, whichmonitors the flywheel ring gear, provides thespeed reference signal to the ADC controller
The ADC provides regulated power to the bi-directional stepper motor actuator, which islinked, to the carburetor throttle arm.
Failure or loss of the input speed signal from thepick-up will result in a low or idle speedcondition.
At cranking speed of a properly adjusted pick-upshould produce a minimum of 1.75vac. Air gap isfactory set at 0.040 in. (1.02mm).
Engine speed is adjustable to +/- 5% which allowsa range of speed adjustment between 3420 rpmand 3776 rpm. This adjustment is made throughthe advance programming menu of the ADCcontroller.
Speed Gain has an adjustment of +/- 5% .Adjustments are made through the advancedsetting menu in the ADC program.
Governor
ADC2100
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Lube System
The Kohler Command engine features apressurized oil lubrication system.
The gear driven pump is located in the sumpand supplies approximately 25-35 psi oflubricant to the internal components at nominalengine speed. Pressure is limited by a reliefvalve.
A dipstick is provided for periodic oil levelchecks. As with any engine do not operate withthe level below or above the designated markings.
It is also very important to adhere to a goodmaintenance program. Replace the oil and filterat the recommended intervals.
To aid in operating under high ambient conditionsan oil cooler is provided, Heat is transferred to thefins and dissipated in the air flow.
The engine operates with a partial vacuum inthe crankcase. This is controlled by a�breather� assembly consisting of a reedvalve. A pressurized crankcase due to a faultyor clogged valve could cause oil leaks at sealsand gaskets.
A hose attached to the valve vents the crankcasefumes to the mixer air intake for ingestion into thecombustion chambers.
A pressure switch is installed in an oil passage inthe breather cover to protect the engine in theevent of a fault which would cause oil pressureto drop to an unsafe operating level. Contacts inthe switch will close when the pressure dropsbelow 3 to 5 psi and will initiate an engine shut-down.
Lube System
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Ignition System CH20
The CH20 engine feature dual capacitordischarge ignition modules to fire the twosparkplugs. They are installed on the cylindersin close proximity to the flywheel.
A permanent magnet is located on the flywheelwhich is keyed to the crankshaft providing a fixedtimed ignition. (CH20)
As the magnet approaches the L1 coil a potentialis generated which is rectified by the D1 diodeand stored in the C1 capacitor.
Further rotation of the flywheel causes a currentto be induced in the L2 coil which triggers theSCR discharging the capacitor to the primary ofthe T1 ignition coil.
This rapid flow of current in the primary inducesa very high voltage in the T1 secondary windingssufficient to jump the spark plug gap and ignitethe cylinder fuel mixture.
This firing occurs on every revolution of theflywheel.
Ignition is terminated by shorting the high side ofthe primary circuit to ground. This isaccomplished by the K5 relay contacts.
Air gap between the core of the modules and themagnet is .010 in. (0.25mm)
This magneto type ignition requires no externalbattery supply or timing adjustments.
Ignition System
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Ignition System CH740
The CH25/CH740 engine features a �SMARTSPARK� or DSAM module mounted externally atthe rear cylinder shroud. Operation is similar tothe capacitive discharge ignition except a sparkadvance circuit is provided to the triggeringcircuit and a battery voltage supply is required.(70a)
The CH20 CD ignition module relies on the fixedtiming circuit based on the L2 coil to trigger theSCR circuit. The CH25/CH740 uses amicroprocessor based circuit (DSAM) to triggerthe SCR circuit. This change allows for betterengine timing in relation to fuels used.
The timing of spark is controlled by the locationof the flywheel magnet as referenced to theengine TDC and the delay created by the Sparkadvanced module
Previous CH25 engines used a SAM or analogspark advance module, this module has sincebeen upgraded with a mocroprocessorcontrolled spark advance or DSAM.
Ignition Timing
Ignition Timing Connection
There is an ignition timing connection locatednear the secondary gas regulator. Thisconnection needs to be made when usingnatural gas to run the 12RES generators. Thisconnection should be open when running LPwith the 12RES.
The conection should be open on the 8.5RESwhen running either NG or LP.
Ignition System
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Starting SystemStarting System
The generator set can be started locally byplacing the start selector switch in the �RUN�position.
When placed in the �AUTO� position thegenerator set can be started from a remotelocation (automatic transfer switch) by contactclosure between wires 3 & 4 on the ADC controller.A 10 amp fuse (F2) protects the Crank/Run circuit.
The electric starting system requires a 12 voltlead acid battery with a minimum 675 coldcranking amp rating.
The unit is designed for negative groundconnections . The controller will not allow anengine crank with a reversed battery connection,and system damage may occur.
The Starter Solenoid (SS) contains contacts thatconnect the battery to the starter brushes and aspring loaded drive mechanism which engagesthe starter motor pinion to the flywheel ring gear.
To insure a successful start-up the battery mustbe properly maintained and kept fully charged.
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Cyclic Cranking
A cyclic cranking feature is provided whichallows the starter to be energized for a presettime followed by a preset rest time. This cyclewill repeat until the total time allocated by thecontroller has lapsed or a successful startoccurs.
Cranking time (ON) is factory set for 15 sec.,Rest period (OFF) is set for 15 sec. This is amicroprocessor based setting and cannot bechanged.
If the engine does not start within the totalcyclic time the starting attempt will beterminated and an indication of �overcrank�(OC) will result. The selector switch must beplaced in the �Reset/Off� position prior toattempting another start cycle.
Cyclic cranking provides the startingcomponents a rest or reset period to preventoverheating and allows more efficient use ofavailable battery power before it is depleted.This is important especially for remote startingof an unattended unit.
When a start signal is provided, voltage is appliedto the cyclic cranking circuit. During the �crank�cycle the Start relay contacts will closeenergizing the cranking control relay SR. Whenthe SR contacts close the starter solenoid andStarter Motor will be energized.
If the engine starts within the cranking time of thecycle the Start relay will deenergize removingpower from the coil of the SR relay and terminateengine cranking.
The Gas valve and Run relay will also beenergized during the cranking cycle.
Starting System
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Battery Charger6-Amp Battery charger
The 8.5 and 12RES generator sets are equippedwith a factory installed battery charger. Thebattery charger is powered by a 120vac source.The 120vac source must be available wheneither utility or generator power is available.
The 6-amp charger has 3 modes of operation,bulk rate, absorption rate, and float.
Bulk rate indicates the battery is discharged andthe charger rate is 6 amps.
Absorption rate is when the charger is at a rateof 1.5 to 5 amps. This mode of charging tops offthe battery and reduces harmful sulfating.
Float rate is when the charger rate has droppedbelow 1.5 amps. At 1.5 amps the battery is at90% charge, the charger rate will drop to .1amps as the battery approaches 100% charge.The charger will maintain this float rate withoutovercharging the battery.
The 6-amp charger has 2 LED�s (Red, Green) toindicate battery charger mode.Bulk charge mode - Red on, Green offAbsorption mode - Red on, Green onFloat mode - Red off, Green on
LED indicating lights
10 amp fuseprotection
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Scheduled Maintenance
Alternator
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Alternator Design
Mechanical alternators or generators thatproduce an AC output are either the rotatingarmature or the rotating field design andrequire 3 basic things.
1. Conductors2. A magnetic field3. Movement between the two.
1. The conductors are copper wires woundin slots of laminated steel referred to asthe armature and provide the generatedoutput voltage.
2. The field is the invisible magnetic forceproduced by electro-magnetic pole pieces.
3. Movement between the field and conductorsis necessary to create current flow in thearmature windings and is usually providedby a gas or diesel engine.
Kohler residential generators are of therotating field design.
Rotating Field Generators
Alternators used on most generator sets todayare of the rotating field design. The magneticpoles of the rotor rotate past the armaturewindings of the stator. The rotor is energizedwith a DC field by some type of excitation. Asthe field rotates the magnetic flux lines cut theconductors, which are distributed so as toinduce a sinusoidal voltage in the stator.
The stationary stator also allows for easyreconnection of the windings to permit variousthree phase or single phase voltages.
Alternator
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The Alternator is of the Rotating Field design andconsists of two major components, the Rotorand Stator.
The Rotor which is located within the Stator is ofthe 2 pole design and is directly coupled to thetapered engine crankshaft stub with athru-bolt.
Excitation slip rings are mounted outboard of theend bearing and accessible from the exterior ofthe end bracket. The fan is permanentlymounted to the rotor shaft
The Stator contains the copper windingswhich provide the load current and is assembledto the engine adapter with an end bracket andoverbolts.
The 4 lead stator is wound for single phaseapplications only and is factory connected toprovide a 3 wire 110/220 to 120/240 volt supply.
The DC excitation to the rotor slip rings issupplied by an adjustable static exciter/regulator.
Alternator
Alternator
41
Stator
120 / 240 v 3 Wire.110 / 220 v 3 Wire.
The 4 lead stator is factory connected to providetwo low voltage (110-120) circuits and one high(220-240) voltage circuit. The rated load ampscan be divided between these three circuits.
A 2 pole circuit breaker is provided for loaddisconnect. Customer load connections aremade at the breaker.
Most Standby applications require a 240 voltcircuit including the G120 Automatic TransferSwitch.
120 v 3 Wire.110 v 3 Wire.
The Stator can be reconnected to a straightsingle voltage 2 wire or 3 wire configuration ifrequired. A jumper is placed on the line side ofthe circuit breaker to balance the load betweenthe two windings.
Stator leads 11, 44 are common to statorleads 1 and 4 and provide the voltage sensingfor the voltage regulator circuit. Leads 55 and66 provide the excitation power for voltageregulation.
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Rotor
The rotor is a powerful electromagnet whichwhen rotating induces current flow in thestator windings.
The rotor windings (field coils) are energized bya DC supply from the Exciter/Regulator viabrushes and slip rings and magnetize the twolaminated iron pole pieces.
The DC supply is increased or decreaseddepending on load demand applied to thegenerator and is automatically controlled orregulated by the voltage regulating portion of theADC contrioller logic.
The rotating speed of the rotor determines thefrequency of the alternator output. A two polerotor must rotate at 3600 RPM to produce 60Hz.(3000 RPM / 50Hz)
The rotor, which is directly coupled to the enginetapered stub shaft, is supported by a bearing inthe end bracket assembly.
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Field Excitation
The rotor field windings are energized throughfield excitation. Field excitation comes from avariable DC source called an exciter. By varyingthe exciter voltage we can control the voltageand current induced into the rotor thus controllingthe voltage generated in the stator.To control the exciter voltage a voltage regulatoris incorporated into the alternator design and itsselection is based on the type of excitation usedon the alternator and the application of thegenerator.
Static Excited (Brush Type)
This system rectifies AC power from the outputof the generator and sends a controlled DCcurrent to the rotating field through brushes/collector rings. This exciter is typically an SCRbridge controlled by a solid state voltageregulator circuit. This system can be designed tohave excellent load response and voltageregulation.
The disadvantages of static excited designs arefound in the brushes and collector rings. Thesecomponents are subject to routine maintenancesuch as inspections of brush wear and buildupof dirt and carbon on the collector rings.
(PowerBoostTM)
The Kohler version of static excited generatorsfeature a patented PowerBoostTM exciterregulator. It employs a separate auxiliary statorwinding (independent of the main output) topower the field during fluctuations caused byload-on load-off situations.
This system provides excellent motor startingability and maintains virtually constant voltage.
Alternator
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SCR Rectification
SCR�s (silicon controlled rectifiers) are used torectify the AC output voltage to a DC inputvoltage for rotor excitation.
A sensing circuit in the voltage regulatormonitors the generator output voltage andprovides a signal for controlled gating orconduction of the SCR�s.
The regulation circuit will provide a DC output tothe rotor whenever the voltage monitored isbelow the nominal setting. A voltage above thesetting will turn the regulator (DC output) off. Theregulator circuit is constantly turning on and off inits attempt to maintain its nominal setting.
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Digital Voltage Regulator
The rotor provides the magnetic field flux. The DC supply required to produce the magnetic field isprovided to the rotor from the PowerBoostTM exciter/regulator.
Initial excitation at engine start-up (field flash) is supplied to the rotor bush and slip ringassembly from the starting battery via relay contacts (Flash Relay).
On sensing a successful engine start and alternator build-up (app. 30 vac from PowerboostTM
winding) the battery supply is disconnected and excitation is provided from regulated rectified outputfrom the SCR module to rotor via the FP, FN leads and brushes.
The Digital Voltage Regulation circuit is packaged in the ADC controller. The SCR module isseparate and is located at the rear of the stator.
The excitation component (SCR) rectifies AC from the auxiliary power coil (55-66) of the stator.The voltage regulator circuit monitors the alternator AC output (11 � 44) and controls the firing (Fielddrive +/- ) of the SCR gate circuit providing regulated DC to the rotor slip rings.
The digital regulator provides ± 1.5% RMS Regulation.
Course and Fine Voltage adjustments can be made using the Dynamic settings in the ADCcontroller (see controller dynamics settings)
The regulator can also be field adjusted for minimum voltage fluctuation and light flicker using theADC dynamic settings. (see controller dynamic settings)
A Volts per Hertz feature automatically reduces the voltage if an overload causes the frequency todrop below a preset level. (factory set at 58hertz)
A 10-amp fuse (F1) is provided to protect the power input circuit.
Alternator
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Alternator
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General Troubleshooting
Follow the troubleshooting flowchart todetermine the cause of no or low ACoutput from the generator.
Disconnect generator starting batterybefore testing any parts of thealternator assembly!!!!
This section will cover general trouble-shooting fundamentals used whendiagnosing alternator problems. Whenservicing a generator use specifiedservice manual and follow all safetyprecautions.
Alternator
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Separate Excitation
To determine the cause of no or low AC output,separately excite the generator. The generatorfield (rotor) may be magnetized using analternative DC power source (12-volt automotivebattery) and following the procedure below.While separately exciting the generator todetermine the presence of a faulty voltageregulator, it is possible to determine if a runningfault exists in the rotor and/or stator. A generatorcomponent that appears good while static(stationary) may exhibit a running open or shortwhile dynamic (moving). This fault can becaused by centrifugal forces acting on thewindings while rotating or insulation breakdownas temperatures increase.
Procedure for separate excitation:
1. Disconnect all leads from voltage regulator.
2. Connect an ammeter and a 12-volt automotivebattery to the (+) and (-) brush leads. Include a10amp fuse in the circuit in case of a shortedrotor.
3. The appropriate ammeter reading should bebattery voltage divided by specified rotorresistance. Consult service manual forresistance specifications.
4. Start generator and check that ammeterremains stable. An increase indicates a shortedrotor. A decreasing or erratic meter readingindicates a running open.
5. If Ammeter reading is stable compare thestator winding output results with thespecifications for the specific alternator found inthe service manual. If output readings vary fromspecification the stator is likely to be at fault.
6. If the rotor and stator test good the voltageregulator is probably defective.
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Testing Stator
The stator consists of a series of wire coilsplaced in a laminated steel frame. The statorleads can supply voltage to the AC load, voltageregulator, or controller depending on the functionof that output coil. Prior to testing, inspect thestator for heat discoloration and visible damageto housing, exposed coil windings and exposedvarnished areas of frame laminations. If visibledamage exists the stator will need to be repairedor replaced.
Checking Stator Continuity and Resistance
Tools required: Ohmmeter, MeggerThe example illustrates a single phase alternator.
Note: Refer to service manual for allspecifications with reguards to windingresistance values.
Continuity1. To check stator continuity, set ohm meter to alow resistance setting. This test will check if anycoils are shorted to each other or there is ashort to ground.
2. Dissconnect all stator leads prior toperforming measurements.
Leads1, 2, 3, and 4 are the generator outputleads. Leads 11, 44, are the voltage regulatorsensing. Leads 55-66 are control power for theexcitation.
3. Check continuity of all windings, the metershould show continuity when checking betweenleads 1-2, 3-4, 55-66.
4. Check for continuity between coil groups,meter should show no continuity. If the meterindicates continuity this means the two coilgroups are shorted together.
5. Check continuity between each coil group andthe frame of the stator, meter should show nocontinuity. If the meter shows continuity thisindicated the coil is shorted to ground.
ResistanceMost ohmmeters will not provide accuratereadings when measuring less then 1 ohm,which is typical for a stator winding. The statorcan be considered good if a low resistancereading is obtained in each coil group and thereis no evidence of an internally shorted winding(heat discoloration).
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Megger Testing
The purpose of insulation is to prevent shortingbetween the windings, lamination slots and anyconductive material used in the generatorconstruction. If this insulation deteriorates orbreaks down a current path can be createdbetween the copper windings and the framestructure. This breakdown may not be detectedwhen performing a continuity test.
Dirt, grease, chemical fumes, aging andmoisture are some of the contributing factorsthat can lead to the insulation breaking down.
A megger can be used to test for possiblecurrent leakage to ground that was not detectedduring continuity testing. Meggers apply a voltagebetween the insulated conductor and thematerial they are insulated from, usually ground.They determine the resistance flow across theinsulation of the conductor. These resistancevalues are very high, in the millions of ohms.
1. Prior to operating a megger disconnect allstator leads
2. You can keep the load leads connectedtogether but it is recommended that youdisconnect all individual coils and test eachone individually.
3. The positive lead of the megger should beattached to the lead coil being tested on thealternator and the ground lead attached to theframe.
4. Perform the megger test following theinstrument instructions.
5. As a general guideline if the insulation resis- tance is greater then 1.5 megohms theinsulation leakage is considered acceptable. If itis below 1.5 megohms the stator needs to beserviced. Always refer to instrumentinstruction or generator specification whendetermining when insulation leakage is suffcientto warrant repair or replacement.
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Testing Rotor (Brush Type)
Prior to testing the rotor, inspect exposed coilwindings, brushes and collector ring surfaces.Check rotor bearing for noisy operation,excessive wear, and heat discoloration. Replaceor repair if needed.
To check the rotor for continuity place the meterleads on the two collector rings. Set meter tolowest setting for measuring resistance. If a highresistance reading is found this indicates anopen winding. Typical measurement readingscan be found in the specification section of theservice manual for the particular rotor beingtested.
To test for a grounded rotor place one meter leadto a collector ring and the other lead to the rotorshaft. Meter should register no continuity.
Megger readings can also be taken by placingone lead of the megger to a collector ring and theother to the rotor shaft. If reading is above .5megohms the insulation leakage is acceptable. Ifreading is below .5 megohms this indicatesthere may be current leakage to ground andservicing is needed. The rotor may havemoisture and needs to be dried out or theinsulation is weak and the rotor will need to beserviced or replaced.
Note: Make sure when taking resistancereadings or performing a megger test that thebrushes are not in contact with the slip rings.
When performing inspection on brushes it isimportant to note the brushes are not sticking,have good surface contact with the rings, andthe brushes are centered and riding completelyon the rings. Severe arching on the brushes maycause regulator to fail and also damage the sliprings.Collector rings acquire a glossy brown finish innormal operation and cleaning to maintain abright machined surface is unnecessary. Ifgrooves have developed on the collector rings acommuter stone should be used to level thesurface. Never use emery cloth or carborundumpaper to level or clean collector rings.
Brush / Collector Ring Maintenance
Controller
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ADC 2100 Controller
The ADC 2100 is a microprocessor-basedcontroller. The controller allows for manualand automatic operation. The controllerhas built in diagnostics with the ability todisplay both generator warnings andshutdowns. The controller keypad allowsaccess to system configuration andvoltage and frequency adjustment.
The LED display indicates generatorset status. When operating normallythe generator total run hours will bedisplayed. The LED display will alsoshow active faults or warnings.
System Faults:Auxiliary Fault � AFHigh Engine Temperature � HELow Oil Pressure � LOPOvercrank � OCOverfrequency � OFOverspeed � OSOvervoltage � OUUnderfrequency � UFUndervoltage � UU
System WarningsHigh Battery � HBLow Battery � LB
The start selector switch is a three-positiondevice. The generator can be started locally byplacing the switch to RUN.
When an Automatic Transfer Switch or remotestart is utilized the generator will be signaled tostart when the selector switch is in the AUTOposition and a contact closure occurs acrossleads 3 and 4.
The generator will shutdown when the switch isplaced in the OFF/RESET position.
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ADC Interface
The ADC controller utilizes 3 plug connections tocontrol the interface between the controller,engine, and alternator.
The P-1 plug is the termination point for allDC connections. The DC inputs include LowOil Pressure, Coolant Temperature, RemoteStart, Battery positive and negative, and themag pick-up input.The DC outputs include the 71N (starterrelay), 70N (run relay), and DC output to thegovernor stepper motor.
The P-15 plug is the input connection for ACsensing. The ADC controller uses this input forvoltage regulation and a secondary means ofcrank disconnect.
The P-16 plug connections are for thePowerBoostTM winding input, and the field driveoutputs to control excitation. The P-16 plug alsohas the FL output which controls the FieldFlashing relay.
Relay Control Board
The ADC controller does not have relaysmounted internally to the controller. A relay boardis required to interface controller logic to thegenerator start and stop functions. Mounted onthe relay board are 3 relays, Crank, Run, and theField Flash Relay. There are LED�s on the relayboard that illuminate when the functioning relayis energized.
Crank Relay is energized when the control logicis in the crank modeRun Relay is energized when cranking orrunningFlash Relay is energized during crank and runand is disconnected when the aux windingoutput has reached 30 vac
A 10 amp fuse powers the relay board and relayoutputs contacts.
An optional relay board is available with anauxiliary run relay and common fault relay forcustomer connections.
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The CIRCUIT BREAKER is a two-pole devicewith trip elements in each pole and is used as acircuit disconnect between the load and alternator.The toggles are tied together. Moving the togglewill open or close both poles. An over currentfault exceeding the trip rating of the breaker willalso trip both poles. Current and trip ratings arelocated on the terminal side of the breaker.
8.5RES - 40 amp breaker
12RES - 50 amp breaker
Circuit protection
The wiring harness has 3 in-line fuses installed.F1, F2, and F3
F1 - 20 amp fuse, protects the PowerBoostwinding. The Power Boost winding is respon-sible for the excitation of the rotor.
F2 - 10 amp fuse, circuit protection for relayboard, fuel solenoid, SR relay, and ignitionmodule.
F3 - 10 amp fuse, circuit protection for theADC controller
Controller
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Controller
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Understanding the Schematic
1. Fused battery power enters what pin connections to the relay control board?
2. Field flashing is controlled by which relay?
3. The Field flashing is required when?
4. Fuse F1 protects the voltage regulator circuitry. T or F
5. When is wire #70A energized?
6. When is wire #71A energized?
7. What is the purpose of the Magnetic Pickup?
8. Which stator winding is responsible for excitation?
9. What is the CTS, ?
10. What symptoms will be observed if the Gas Valve coil electrically opens?
11. What symptom will be seen if the Magnetic pick-up loses output?
12. What symptom will be seen if the F2 fuse opens?
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Controller
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To read the point to point diagram start at any device in the diagram. The wire at the component willhave a wire number followed in parentheses by the component the wire goes to and to where itterminates.
Reading the Diagram
1. You want to check the control voltage to the Start Relay (SR), what termination points shouldyour meter leads be on?
2. Field flashing leads terminate at RIB-T1 and T2, What is RIB
3. Looking at the P14 connector plug, where does wire #71A terminate. List the starting and endingpoint.
4. You need to check the magnetic pick-up voltage. How would you do this? What voltage shouldbe measured during crank?
5. What wire energizes the FV?
6. What is the point to point connection for LOP, list the starting and ending points.
7. At what pin location does positive voltage enter the relay control board? Is this a fused input?
8. What does the F1 fuse provide protection for?
9. To change the ignition timing of the CH740 engine when running on natural gas the 65 wireshould be connected to ground? T or F
10. Is wire 14P a fused power source? What is the purpose of 14P?
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Shipped with application program, this meanstypically you will never have to enter the systemconfiguration menu of the ADC controller.
Reasons to go into the systems configurationmay be controller replacement, voltage orfrequency adjustments, gain adjustment,reconfigure stator output voltage.
System configuration includes:genset modelphasefrequencyvoltageunit utilization (marine, mobile, standby)unit data (analog inputs, digital inputs, magneticpick-up)battery voltage (12- or 24-VDC)communication settingDynamic settings
voltage adjustfrequency adjustgain adjustmentsvolts/Hz adjustment
Password ProtectionThe ADC configuration menu can only beentered with the use of a password.
Using the password1. Hold the select button and toggle the startswitch to run - the generator will not start. Afterapproximately 5 seconds the software versionwill be displayed.2. Continue to hold the select button and pressthe down arrow, then the up arrow, do this 3times.3. If performed correctly 4 LED segments willbe displayed. This display is the first menu forconfiguration setup.
Note: The display will revert to run time hoursafter 1 minute of non-use and only savedsettings will remain.
System Configuration
Select
Down
Up
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Uu0X = Unit utilization (phase, frequency, voltage)Uc0X = Unit configuration (marine, mobile, residential)EcXX = Engine configuration (generator model)Adnc = Advanced Configuration Level
EdXX = Engine data (Advanced Config. Level)Bt12 or Bt24 = Battery voltage (Adv. Config. Level)Cn0X = Communication Setting (Adv. Config. Level)
SAVE
X=numeric value
To navigate the menu�s
Configuration Menu�s
Once in a menu use the UP arrow to togglethrough the menu settings, if you pass over adata selection use the DOWN arrow to go back.
When you find the data selection in a particularmenu press the SELECT button this willadvance you to the next menu. Whatever dataselection you had displayed is what will now beprogrammed into your system configuration.
Use the SELECT button to navigate througheach menu and the UP and DOWN buttons tonavigate within each menu.
The final menu will be SAVE. To save all yoursettings press the UP arrow.
If you fail to save setting the configuration willrevert back to original settings.
Once you have saved your settings the controllertakes you out of the system configurationmenus. You will need to use the password to goback into the configuration menu.
Select
Down
Up
Press the UP button to save settings
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Uc00=MarineUc01=StandbyUc02=Mobile
System Set-Up
Phase, Frequency, VoltageThe first configuration code youwant to select is for the systemphase, voltage and frequency.Press the UP button to find thecorrect code for your system.Once this code is selected pressthe SELECT button to advance tothe next menu.
ApplicationNext you need to select the generator application(marine, standby, mobile). Choose the correctcode. Press Select to advance to the next menu.
Generator ModelChoose the correct code forthe generator model. As theproduct lines advance moremodels will be listed. Whenmodels are listed the softwareversion will change toaccommodate the new data inthe software. If you arechanging out a controller andthe model is not found you willneed to upgrade the softwarein the controller. Press theSELECT button to advance tothe next menu.
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Adnc (Advance Configuration)
The advance menu has three sub menus.Engine Data, Battery Voltage, andCommunication. The advance menu is typicallyan area you will not have to go into unless youare make a generator modification in the fieldsuch as installing the remote gauge package forour marine product line. To bypass this selectionpress SELECT to go to the SAVE menu.
Adnc, Engine Data
The engine data is automatically loaded into thesystem configuration when you choose themodel number. The only time you may have tomodify the data selection is if an option senderdevice is added. Press the SELECT button toadvance to next Adnc sub menu.
Adnc, Battery VoltageThe battery voltage data is automatically loadedwhen you enter the model number code thedefault setting should be left as is. PressSELECT button to advance to next sub-menu
Bt12 (12 VDC)Bt24 (24 VDC)
Adnc, CommunicationsCommunication setting will need to be changedif you add optional equipment which requiresJ1939 can communications. This is not requiredfor the 8.5 and 12RES product .
Cn00 = No CommCn01 = SAE J1939*Cn02 = Future
SAVEThe SAVE menu is the final menu, press the UParrow to save all previous settings.
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Dynamic adjustments
The generator must be running to make dynamicadjustments such as voltage raise and lower orspeed raise and lower.
To enter the dynamic adjustments menu:1. Start the generator and press the SELECTbutton until the software version is displayed.2. Continue to hold the SELECT button andpress the down button and then the UP button,repeat this 3 times.3. If done correctly you will enter the first menuVoltage adjust.
Voltage Adjust (coarse)The course voltage adjustment is your firstsetting. When in the menu you will notice thethird digit flashing. Adjusting the number up willraise the output voltage. Adjusting down willlower the output voltage. Before making anyadjustments you should have a calibrated VOMmeasuring output voltage. Each increment willchange the output between 5-7 vac. Press theSELECT button to advance to the fine voltageadjust.
Voltage Adjust (fine)when in the fine voltage adjust mode the fourthdigit will flash. In fine adjust each increment willchange the output voltage between .5 and .7volts. Press SELECT button to advance toRegulator Gain menu.
Regulator Gain
1PXX = Voltage adjust2PXX = Regulator gain (GainAdjust)3PXX = Under-frequency VoltageDroop (Volts/Hz)4PXX = Governor speed adjust5PXX = Governor gain adjust
Dynamic adjustment menu�s
When in course voltage adjust the thirddigit will flash. When in fine adjust thefourth digit will flash.
When in course Regulator Gain adjustthe third digit will flash. When in fineadjust the fourth digit will flash.
Gain adjustment may need to be done if thegenerator output voltage responds slowly to loadchanges, (gain set to low) or the generator hasvoltage instability or light flicker (gain set to high).
To set gain adjustments an analog meter shouldbe used to monitor the output voltage. Adjust thegain UP until the analog meter reading showsinstability, turn DOWN the gain setting until voltagebecomes stable. Cycle load on the generatoroutput to make sure voltage response isacceptable. SELECT both course and fine adjustthe press SELECT to advance to Volts/Hz.
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0=No droop1=0.5% of nominal2=1.0% of nominal3=1.5% of nominal4=2.0% of nominal5=2.5% of nominal6=3.0% of nominal7=3.5% of nominal8=4.0% of nominal9=4.5% of nominal
Volts/Hz
The Volts/Hz adjustment for the voltage regulatorcomes preset from the factory and typically noadjustments should or need to be made. Thedefault setting is 4.(2% voltage droop)
The programmed roll-off point for 60Hzapplications is 58Hz, for 50Hz applications it is48Hz.
When in the Volts/Hz menu the fourth digit willrepresent the percentage of nominal voltagedroop.
Example:system voltage = 240 vsystem frequency = 60 Hz - roll-off is 58HzVolts/Hz setting is 4 (2% of nominal) = 4.8v percycle
If the generator frequency would drop to 50Hz,that would be a 8Hz drop after roll-off. 58-50.8Hz x 4.8 V per cycle = 38.4 vNominal voltage 240 - 38.4 = 201.6 v @50Hz
The Volts/Hz setting allows the generator torespond quicker to heavy load changes. Shouldthe frequency drop due to an increased load thevoltage regulator will automatically decreasevoltage thus shedding kW and allowing thegenerator to recover to the proper frequency andvoltage output. When the Volts/Hz is setincorrectly response to load changes will takelonger then desired.
When set-point is selected press SELECT toadvance to the Governor Speed menu.
Nominal setting
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Gain adjustment may need to be done if theEngine responds slowly to load changes, (gainset to low) or the engine has voltage instability orhunting (gain set to high).
To set gain adjustments adjust the gain UP untilthe engine starts hunting (similar to a dog barking)then turn DOWN the gain setting until the enginebecomes stable. Cycle load on the generatoroutput to make sure engine response isacceptable. The final test would be to allow thegenerator to cool then start the generator, this willverify that the engine does not respond to slowlycausing the engine to overspeed.
When speed gain is set press SELECT buttonuntil the SAVE menu is displayed, press the UPbutton to save all settings.
Governor Gain Adjust
Governor Speed (Coarse adjustment)
The course Speed adjustment is your firstsetting. When in the menu you will notice thethird digit flashing. Adjusting the number up willraise the speed. Adjusting down will lower thespeed. Before making any adjustments youshould have a calibrated VOM measuring outputFrequency. Speed adjust range is +/- 5%
Fine Speed Adjustmentwhen in the fine speed adjust mode the fourthdigit will flash. Press SELECT button to advanceto Governor Gain menu.
When in course Speed adjust the thirddigit will flash. When in fine adjust thefourth digit will flash.
When in course Governor Gain adjustthe third digit will flash. When in fineadjust the fourth digit will flash.
Press the UP button to save settings
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Upgrading ADC Software
To upgrade the ADC 2100 requires:1. Program Loader (version 2.3 or higher)2. Null modem cable3. TT-1285, instructions for downloadingsoftware to ADC controller4. ADC 2100 Application Program5. Service Manual: TT-6196 (RES)6. Access to controller DB9 port (RS 232)
Once the ADC software has been upgraded theADC controller will require configuration andadjustment of parameters specific to generator
Distributors have access to Program Loadersoftware and the ADC application software viathe internet.
Controller Replacement
ADC has no replaceable assembliesPotting does not allow component changesOrder kit: GM33159Includes TT-1364 for setup
The ADC as a replacement controller requiresthat it be configured for the application. It is notshipped from the factory ready for operation.Programming systems menus will be requiredbefore the generator can be operated.
Automatic Transfer Switch
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The Transfer Switch is a required componentof an emergency or standby electrical powersystem. It not only serves to transfer the loadbetween electrical supplies but also to preventthe sources from being connected togetherresulting in destruction of the system.
An Automatic Transfer Switch (ATS) consistsof three major components.
1. Stationary and movable heavy dutyCONTACT ASSEMBLIES.
2. An OPERATING MECHANISM for themoveable contacts.
3. A CONTROLLER to monitor the systemand provide signals for engine start andcontact transfer.
The controller logic constantly monitors thecondition of the utility or normal powersupply. A signal for an engine start will begive when the voltage or frequency is not ata predetermined level or fails completely.
When the Generator voltage and frequencyare acceptable to the monitoring circuit, thetransfer operating mechanism will be ener-gized, causing a Load (L) transfer from theNormal (N) to the Emergency (E) source.
The controller will seek the primary sourceand on return of acceptable power willretransfer the load back to the normal sourceand initiate an engine shutdown.
Concept
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Contactor
The contact assemblies are not identical forthe 100-amp and 200-amp contactors. Referto the Service manual when performing ser-vice work.
The 2-pole, G220 Series contactor is availablefor 100 and 200 amp Standby Systems.
This contactor is designed for use on line to line220 - 240 volt single phase utility systems asprovided to the majority of residences. Theemergency source or generator set must alsoprovide this same power.
A diagram is provided inside the ATS enclosureto aid installation of line power connections.push-on tab terminals are provided at each ofthese terminals for controller voltage sensingand the transfer operator coil supply.
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These contactors are electrically operateddouble throw switching devices. The Normaland Emergency power sources are connectedto stationary contacts and the movable Loadcontacts assembled to a pivot shaft. Thisprovides a mechanical interlock to assure bothpower sources cannot be connectedsimultaneously.
Two electric solenoids operate the linkage toflip the moveable contact between the powersources. A complete transfer occurs within 50milliseconds.
The solenoid is powered by 120 vac rectified linevoltage from the source to which the load will betransferred. (Normal or Emergency)
A full wave bridge assembly rectifies the AC linevoltage to DC. Input is to terminals labeled AC.There is no polarity preference of the solenoid tothe + and - rectifier output terminals.
The DC Voltage to the solenoid coil is suppliedonly momentarily. The circuit is disrupted by camactuated limit switches after full travel of thesolenoid plunger.
Coil, varistor, and bridge rectifier are assembledas one piece. Disassemble/unsolder thecomponents before testing for an open or shortedcircuit.
Contactor
L
E
N
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When the contactor is in the Normal position theoperating lever allow limit contacts SCN to beopen and SCE to beclosed. The oppositeoccurs when in theEmergency position.
The contactor isalways mechanically latched in position after atransfer.
During installation or when servicing thecontactor a manual transfer can be performedby using the manual operating handle provided.
The limit switchassemblies are factoryset and nonadjustable.They are wired inseries with controlrelay contacts NR andER.
ELECTRICAL POWER MUSTBE DISCONNECTED FROMTHE CONTACTOR WHENMANUALLY TRANSFERRING
Contactor
SCN SCE
Operating Lever
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The contactor assembly is interconnected to thecontroller by a harness and plug connector.
Connections at the contactor assembly aremade with push-on tab terminals. A 15 pin plugconnector designated as J1 is attached at thecontroller end of the harness .
Use caution when testing for voltage or continuitybetween plug pins. Any voltage present onthe normal or emergency contacts is alsopreset at the connector pins.
Harness
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G220 Controller
The decision making process of the automatictransfer switch is performed by the Controller.
The controller monitors the systems electricalsources and logically energizes control relays forengine starting and switch transfer. Voltagesupply to the transfer mechanism is provided bythe source to which the switch is transferring.
The Utility is the NORMAL or Primary sourceand the control circuit will always seek thenormal source.
The controller is sensitive to the system voltage.Transformers reduce the line voltage to lowmore manageable voltage for the sensing andcontrol circuits. Logic circuitry is both relay andsolid state.
STANDARD FEATURES
Normal and Emergency voltage sensing isfactory set at 160 vac drop-out and 190 vac pick-up.
DROP-OUT :If the Normal utility voltage fails completely ordrops below 160 volts (line to line) a signal foran engine start would be initiated.
PICK-UP:When the Emergency Generator voltagereaches 190 vac A transfer to the Emergencysource will be initiated.
The same specifications apply for pick-up onreturn of the Normal source voltage. (190 vac )
TDES: 3 second time delay on engine start.
This feature prevents nuisance engine startattempts if only a momentary (under 3 seconds)loss of power occurs.
TDNE:2 second time delay on a Normal to Emergencytransfer.
After a successful engine start a delay of 2seconds is provided to allow the engine toattain operating speed and stabilize prior toapplying load.
TDEN:12 second time delay on an Emergency toNormal transfer.
When Normal power returns to the Pick-upvoltage (190 vac) a delay of 12 seconds willcommence before allowing a transfer back to theNormal Source. This is to allow the Utility powerto stabilized. If Normal power fails within thistiming period, timing will be terminated and reset.
TDEC:2 minute time delay for Engine cooldown.
On a successful retransfer back to the Utility theengine will operate for two minutes unloaded toallow a cooldown period prior to shutting down.
If the Normal source returns prior to completionof the timing no engine start will be attemptedand the timer will reset.
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The main control board contains the intelligencelogic as well as transformers, relays, jumpersand terminal strips. Not all terminals and com-ponents are used in this application.
Circuit Board
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+ 5VDC5v. logic voltage test point.
P2Plant exerciser selector switch harness connec-tor.
TB5Power supply and relay status terminal strip.
TB4Transfer disable option jumper terminal strip.
TB2Test switch option terminals.
TB13 phase sensing module terminal strip.
JP2Test switch jumper.
TB3Connections to the engine start circuit aremade to terminals 1&3 . A dry set of K1 relaycontacts will close between terminals 1&3when an engine start is required.
(ES) LEDThe ES LED will light when the K1 is ener-gized.
(NR) LEDThe NR LED will light when the NR relay coil isenergized.
(ER) LEDThe ER LED will light when the ER relay coil isenergized.
(NA) LEDThe NA LED will light when the Normal sourcevoltage is at the acceptable level.
(EA) LEDThe EA LED will light when the Emergencysource voltage is at the acceptable level.
NRNormal source control relay
EREmergency source control relay.
(R20) EUV
Emergency source voltage pick-up adjust.(Factory set)
(R15) NUVNormal source voltage pick-up adjust. (Fac-tory set)
Circuit Board
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Engine Exerciser Feature
To insure the generator set will start and performwhen needed, a circuit is provided which allowsthe engine to automatically start and run for 20minutes a week. The engine will run unloaded.The switch will not transfer unless a powerfailure occurs during the exercise period.
The day and time of day that the feature was setwill be the day and time the exercise will occureach week until reset or disabled.
A 3-position switch provides the setting anddisabling functions.
The internal exercise clock requires either theNormal or Emergency source to be present tomaintain its memory.
If both sources are absent for longer than 90seconds the time and day selected will be lostand automatically reset to the time and daypower was restored.
Transfer Test Switch
The complete system can be tested by remov-ing the JP2 jumper and installing an optionaltoggle switch between terminals 2 (TEST) and3 (GRD) of the TB2 terminal strip on the Con-troller board. A normally closed push button ormomentary toggle is recommended. Openingthe switch contacts will simulate a loss of theUtility power and initiate an engine start-up andtransfer of load to the Generator set.
SET
Placing the switch in this momentary positionwill set the start time as well as the day of weekthe exercise will occur.
RUN
The switch will return to this position whenreleased from setting. This is the normalposition when the weekly exercise option isselected.
DISABLEIf the exercise option is not desired it can beturned off when left in this position. The disableposition effects the exercise option only. It hasno effect on transfer switch operation.
Neutral / Ground
An equipment ground terminal and Neutral busis provided in the enclosure.
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