TP 6929

Service
Industrial and Towable Generator Sets
Models:
30--175 kW
Controller:
Decision-Makerr 3500
TP-6929 1/15
Product Identification Information
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 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.
the numbers are readily available for future reference.
Record field-installed kit numbers after installing the Controller Description
kits.
Engine Identification
Generator Set Identification Numbers
Record the product identification information from the
Record the product identification numbers from the engine nameplate.
generator set nameplate(s).
Manufacturer
Model Designation
Model Designation
Specification Number
Serial Number
Serial Number
Accessory Number Accessory Description
Table of Contents
Product Identification Information 2

Safety Precautions and Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
List of Related Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Service Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Section 1 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 Controller Identification and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.1 Controller Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2 Controller Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.3 Electrical Sensor/Switch Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.1 Electrical Sensors/Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.2 Generator Set Sensor/Switch Part Numbers . . . . . . . . . . . . . . . . . . . . . . . 16
1.3.3 Generator Set Sensor/Switch Warning and Shutdown Setpoints . . . . . 17
1.3.4 Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.5 Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.6 Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.3.7 Temperature Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.3.8 Pressure Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.4 Decision-Makerr 3500 with Integral Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . 19
1.4.1 Specifications and Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.2 Integral Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.4.3 Activator Board GM88453 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Section 2 Controller Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.1 Warning Parameter Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1.2 Fault Parameter Default Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.1.3 Controller Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Section 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.1 General Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.2 Controller Display Troubleshooting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Paralleling Troubleshooting—When Circuit Breaker Does Not Close to Bus . . . . 57
3.3.1 Faults Not Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.3.2 Faults Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
3.4 Paralleling Troubleshooting—When Breaker Does Close to Bus . . . . . . . . . . . . . 59
3.4.1 Faults Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.5 Paralleling Troubleshooting—When Running in AUTO . . . . . . . . . . . . . . . . . . . . . . 63
3.5.1 Faults Shown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.6 Troubleshooting—Protective Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
3.7 Troubleshooting—Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
3.8 Troubleshooting—Genset Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
3.9 Troubleshooting—Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Section 4 General Repair Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.2 SiteTecht Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.3 Controller Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.4 Factory Reserved Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
4.5 Controller Service Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.5.2 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
4.5.3 Installation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.6 Synchronizing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
TP-6929 1/15 Table of Contents 3

Table of Contents, continued
Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

5.1 Controller Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.1.1 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2 Other Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.1 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.2.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
5.3 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.4 Leads/Wires/Wiring Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.5 Crank Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
5.6 Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.6.1 Function and Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.6.2 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.7 Fuel Leak Alarm (FLA) Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
5.8 Engine Pressure and Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8.2 Sensor Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8.3 Switch Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8.4 Sensor Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
5.8.5 Oil Pressure Sensor Testing (OPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.8.6 Water or Coolant Temperature Sensor Testing (CTS) . . . . . . . . . . . . . . . 90
5.9 Coolant Level Sensor (CLS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
5.10 Powering Up the ECU without Cranking the Engine
(John Deere-Powered Models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
5.11 Remote Serial Annunciator (RSA III) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.11.1 RSA III Features and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.11.2 Terminating Resistor and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.12 Fault Warning and Shutdown Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.13 Voltage Selector Switch (Towable Models only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.14 Motor-Operated Circuit Breakers (if equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.14.1 Automatic Closing of the Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.14.2 Automatic Opening of the Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.14.3 Synchronization of the Generator Output to the Paralleling Bus . . . . . . 102
5.14.4 Troubleshooting Non-Operating Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Section 6 Paralleling System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1 Controller Functionality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1.1 Single-Generator Set Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1.2 External Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.1.3 Internal Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
6.2 Choosing an Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2.1 Single Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2.2 External Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.2.3 Internal Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3 Paralleling Configuration Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3.1 Low Wye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3.2 High Wye . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
6.3.3 Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.3.4 Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.4 Functional Operation Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.4.1 PGEN Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.4.2 Generator Set Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.4.3 First-On Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
6.4.4 Synchronizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
6.4.5 System Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.4.6 Real Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
6.4.7 Reactive Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
4 Table of Contents TP-6929 1/15

6.4.8 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

6.4.9 Start Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4.10 Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4.11 Generator Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4.12 Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.4.13 Communication Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
6.5 Calibration and Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.5.1 Voltage Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.5.2 Current Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.5.3 Gains and Settings for Paralleling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6 Parameter Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6.1 PGEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6.2 First-On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
6.6.3 Synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
6.6.4 Load Sharing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
6.6.5 Power Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
6.6.6 Generator Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
6.6.7 Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.6.8 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Section 7 Generator Management Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.1 Generator Management Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.2 Generator Management Basic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.2.1 Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
7.2.2 Control Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
7.2.3 Timing Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.3 Generator Management Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
7.4 Generator Management Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.4.1 Control Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
7.4.2 Enabled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.4.3 Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.4.4 Start Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.4.5 Stop Percentage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
7.4.6 Start Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.4.7 Stop Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.4.8 Stable Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.4.9 Runtime Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.4.10 Fuel Level Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.4.11 Min Gens Online . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.4.12 Min Load Shed Priority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
7.5 Generator Management Detailed Functional Description . . . . . . . . . . . . . . . . . . . . 149
7.5.1 Stability Timer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.5.2 Stop Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
7.5.3 Stop Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.5.4 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.5.5 Order Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.5.6 Start/Stop Threshold Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.5.7 Start/Stop Accumulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.5.8 Availability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.5.9 Preemptive Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
7.6 Generator Management Detailed Functional Sequence . . . . . . . . . . . . . . . . . . . . . 154
7.6.1 Order Selection Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.6.2 Start/Stop kW Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.6.3 Activation Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.6.4 Start/Stop Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
TP-6929 1/15 Table of Contents 5

Section 8 Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

8.1 Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.2 Basic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
8.2.1 Sequence of Operation—Single Generator Set System . . . . . . . . . . . . . 157
8.2.2 Sequence of Operation—Paralleling System . . . . . . . . . . . . . . . . . . . . . . 160
8.3 Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.1 Total Load on the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.2 Load Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.3 Ease of Interrupting Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.4 Criticality of the Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.5 Number of Generator Sets in the System . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.6 Use of Generator Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
8.3.7 Emissions Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4 Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.1 Genset Maximum Percent Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.2 Generator Overloaded Percent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.3 Under Frequency Shed Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.4 Base Load Add Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.5 Base Over Load Shed Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.4.6 Base Under Frequency Shed Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
8.5 Detailed Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.5.1 Activation/Deactivation Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.5.2 Output Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.5.3 Startup Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
8.5.4 Generator Capacity Load Add . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
8.5.5 Overload Shed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
8.5.6 Under Frequency Shed Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Appendix F Electrical Noise and Wiring Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
6 Table of Contents TP-6929 1/15

Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS.

Electromechanical equipment,
Accidental Starting WARNING
including generator sets, transfer
switches, switchgear, and accessories, WARNING
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 safety working on the generator set.
precautions and instructions: Danger, explosive fumes.
Remove the negative (--) lead first
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 cause
DANGER severe injury or death. Battery acid
can cause blindness and burn skin.
Disabling the generator set. 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 substantial
working on the generator set or open a sealed battery or mutilate the
property damage.
equipment connected to the set, battery case. If battery acid splashes in
disable the generator set as follows: the eyes or on the skin, immediately
(1) Press the generator set off/reset flush the affected area for 15 minutes
WARNING button to shut down the generator set. with large quantities of clean water.
(2) Disconnect the power to the battery Seek immediate medical aid in the case
Warning indicates the presence of a charger, if equipped. (3) Remove the of eye contact. Never add acid to a
hazard that can cause severe battery cables, negative (--) lead first. battery after placing the battery in
personal injury, death, or substantial Reconnect the negative (--) lead last service, as this may result in hazardous
property damage. when reconnecting the battery. Follow spattering of battery acid.
these precautions to prevent the
starting of the generator set by the Battery acid cleanup. Battery acid
CAUTION remote start/stop switch. can cause severe injury or death.
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 Battery bicarbonate of soda (baking soda) to a
container with 4 L (1 gal.) of water and
personal injury or property damage.
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
NOTICE WARNING battery acid and continue to add the
Notice communicates installation,
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 Sulfuric acid in batteries.
or service technician to potential Can cause severe injury or death.
hazards and explain how to act safely.
The decals are shown throughout this Wear protective goggles and
publication to improve operator clothing. Battery acid may cause
recognition. Replace missing or blindness and burn skin.
damaged decals.
TP-6929 1/15 Safety Precautions and Instructions 7

Battery gases. Explosion can cause
severe injury or death. Battery gases
Engine Backfire/Flash Exhaust System
can cause an explosion. Do not smoke Fire
or permit flames or sparks to occur near WARNING
a battery at any time, particularly when WARNING
it is charging. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects. Carbon monoxide.
Remove all jewelry before servicing the Fire. Can cause severe nausea,
equipment. Discharge static electricity Can cause severe injury or death. fainting, or death.
from your body before touching
batteries by first touching a grounded Do not smoke or permit flames or The exhaust system must be
metal surface away from the battery. To sparks near fuels or the fuel system. leakproof and routinely inspected.
avoid sparks, do not disturb the battery
charger connections while the battery Servicing the fuel system. A flash Generator set operation. Carbon
is charging. Always turn the battery fire can cause severe injury or death. monoxide can cause severe nausea,
charger off before disconnecting the Do not smoke or permit flames or fainting, or death. Carbon monoxide
battery connections. Ventilate the sparks near the fuel mixer, fuel line, fuel is an odorless, colorless, tasteless,
compartments containing batteries to filter, or other potential sources of fuel nonirritating gas that can cause death if
prevent accumulation of explosive vapors. When removing the fuel line or inhaled for even a short time. Avoid
gases. fuel system be aware that liquid breathing exhaust fumes when working
propane can cause frostbite on contact. on or near the generator set. Never
Battery short circuits. Explosion
(Gas-fueled model) operate the generator set inside a
can cause severe injury or death.
building unless the exhaust gas is
Short circuits can cause bodily injury
Servicing the fuel system. A flash piped safely outside. Never operate
and/or equipment damage.
fire can cause severe injury or death. the generator set where exhaust gas
Disconnect the battery before
Do not smoke or permit flames or could accumulate and seep back inside
generator set installation or
sparks near the fuel injection system, a potentially occupied building.
maintenance. Remove all jewelry
before servicing the equipment. Use fuel line, fuel filter, fuel pump, or other
Carbon monoxide symptoms.
tools with insulated handles. Remove potential sources of spilled fuels or fuel
Carbon monoxide can cause severe
the negative (--) lead first when vapors. Catch fuels in an approved
nausea, fainting, or death. Carbon
disconnecting the battery. Reconnect container when removing the fuel line
monoxide is a poisonous gas present in
the negative (--) lead last when or fuel system.
exhaust gases. Carbon monoxide is an
reconnecting the battery. Never (Diesel-fueled model) odorless, colorless, tasteless,
connect the negative (--) battery cable nonirritating gas that can cause death if
to the positive (+) connection terminal Servicing the air cleaner. A sudden inhaled for even a short time. Carbon
of the starter solenoid. Do not test the backfire can cause severe injury or monoxide poisoning symptoms include
battery condition by shorting the death. Do not operate the generator but are not limited to the following:
terminals together. set with the air cleaner removed. D Light-headedness, dizziness
D Physical fatigue, weakness in
Combustible materials. A fire can
joints and muscles
cause severe injury or death.
D Sleepiness, mental fatigue,
Generator set engine fuels and fuel
inability to concentrate
vapors are flammable and explosive.
or speak clearly, blurred vision
Handle these materials carefully to
D Stomachache, vomiting, nausea
minimize the risk of fire or explosion.
If experiencing any of these symptoms
Equip the compartment or nearby area
and carbon monoxide poisoning is
with a fully charged fire extinguisher.
possible, seek fresh air immediately
Select a fire extinguisher rated ABC or
and remain active. Do not sit, lie down,
BC for electrical fires or as
or fall asleep. Alert others to the
recommended by the local fire code or
possibility of carbon monoxide
an authorized agency. Train all
poisoning. Seek medical attention if
personnel on fire extinguisher
the condition of affected persons does
operation and fire prevention
not improve within minutes of breathing
procedures.
fresh air.
8 Safety Precautions and Instructions TP-6929 1/15

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

Testing the photo transistor circuit Connecting the battery and the
CAUTION board. Hazardous voltage can battery charger. Hazardous voltage
cause severe injury or death. When can cause severe injury or death.
the end cover is removed, do not Reconnect the battery correctly,
expose the photo transistor circuit positive to positive and negative to
board mounted on the generator set negative, to avoid electrical shock and
end bracket to any external light damage to the battery charger and
source, as exposure to light causes battery(ies). Have a qualified
Welding the generator set.
high voltage. Keep foreign sources of electrician install the battery(ies).
Can cause severe electrical
light away from the photo transistor
equipment damage. Short circuits. Hazardous
circuit board during testing. Place
black electrical tape over the LED on voltage/current can cause severe
Never weld components of the injury or death. Short circuits can
generator set without first the circuit board before starting the
generator set. cause bodily injury and/or equipment
disconnecting the battery, controller damage. Do not contact electrical
wiring harness, and engine electronic Installing the photo transistor connections with tools or jewelry while
control module (ECM). circuit board. Hazardous voltage making adjustments or repairs.
can cause severe injury or death. Remove all jewelry before servicing the
Grounding electrical equipment. Ensure that the foil side of the photo equipment.
Hazardous voltage can cause transistor circuit board, the end of the
severe injury or death. Electrocution shaft, and the threaded holes are clean Engine block heater. Hazardous
is possible whenever electricity is and free of metal particles and chips. voltage can cause severe injury or
present. Ensure you comply with all Metal debris may short-circuit the death. The engine block heater can
applicable codes and standards. photo transistor circuit board and cause cause electrical shock. Remove the
Electrically ground the generator set, hazardous voltage in the generator set. engine block heater plug from the
transfer switch, and related equipment Do not reconnect the generator set to electrical outlet before working on the
and electrical circuits. Turn off the main the load until the AC voltmeter shows block heater electrical connections.
circuit breakers of all power sources the correct output. Electrical backfeed to the utility.
before servicing the equipment. Never Hazardous backfeed voltage can
contact electrical leads or appliances Welding on the generator set. Can
cause severe electrical equipment cause severe injury or death. Install
when standing in water or on wet a transfer switch in standby power
ground because these conditions damage. Before welding on the
generator set perform the following installations to prevent the connection
increase the risk of electrocution. of standby and other sources of power.
steps: (1) Remove the battery cables,
Disconnecting the electrical load. negative (--) lead first. (2) Disconnect Electrical backfeed into a utility
Hazardous voltage can cause all engine electronic control module electrical system can cause severe
severe injury or death. Disconnect (ECM) connectors. (3) Disconnect all injury or death to utility personnel
the generator set from the load by generator set controller and voltage working on power lines.
turning off the line circuit breaker or by regulator circuit board connectors. Testing live electrical circuits.
disconnecting the generator set output (4) Disconnect the engine battery- Hazardous voltage or current can
leads from the transfer switch and charging alternator connections. cause severe injury or death. Have
heavily taping the ends of the leads. (5) Attach the weld ground connection trained and qualified personnel take
High voltage transferred to the load close to the weld location. diagnostic measurements of live
during testing may cause personal circuits. Use adequately rated test
injury and equipment damage. Installing the battery charger.
Hazardous voltage can cause equipment with electrically insulated
High voltage test. Hazardous severe injury or death. An probes and follow the instructions of the
voltage can cause severe injury or ungrounded battery charger may test equipment manufacturer when
death. Follow the instructions of the cause electrical shock. Connect the performing voltage tests. Observe the
test equipment manufacturer when battery charger enclosure to the ground following precautions when performing
performing high-voltage tests on the of a permanent wiring system. As an voltage tests: (1) Remove all jewelry.
rotor or stator. An improper test alternative, install an equipment (2) Stand on a dry, approved electrically
procedure can damage equipment or grounding conductor with circuit insulated mat. (3) Do not touch the
lead to generator set failure. conductors and connect it to the enclosure or components inside the
equipment grounding terminal or the enclosure. (4) Be prepared for the
lead on the battery charger. Install the system to operate automatically.
battery charger as prescribed in the (600 volts and under)
equipment manual. Install the battery
charger in compliance with local codes
and ordinances.

Servicing the generator set when it
is operating. Exposed moving parts
Hot Parts Notice
Keep hands, feet, hair, clothing, and WARNING NOTICE
test leads away from the belts and
pulleys when the generator set is This generator set has been
running. Replace guards, screens, and rewired from its nameplate voltage
covers before operating the generator to
set.
Hot coolant and steam.
Can cause severe injury or death.
WARNING
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
Airborne particles. to the generator set after reconnecting
Can cause severe injury or WARNING the set to a voltage different from the
blindness. voltage on the nameplate. Order
voltage reconnection decal 246242
Wear protective goggles and clothing from an authorized service
when using power tools, hand tools, distributor/dealer.
or compressed air.
Hot engine and exhaust system. NOTICE
Can cause severe injury or death. Canadian installations only. For
standby service connect the output of
Heavy Equipment Do not work on the generator set until
the generator set to a suitably rated
it cools.
transfer switch in accordance with
WARNING Servicing the alternator. Hot parts
Canadian Electrical Code, Part 1.

Avoid touching the alternator field or
exciter armature. When shorted, the
alternator field and exciter armature
become hot enough to cause severe
burns.
Unbalanced weight.
Improper lifting can cause severe Servicing the exhaust system. Hot
injury or death and equipment parts can cause severe injury or
damage. death. Do not touch hot engine parts.
The engine and exhaust system
Do not use lifting eyes. components become extremely hot
Lift the generator set using lifting bars during operation.
inserted through the lifting holes on
the skid.

Notes

Introduction
This manual provides troubleshooting and repair Tech Tools

instructions for generator set models using the
Decision-Makerr 3500 controller. Access the TechTools site to find the following topics:
Wiring diagram manuals are available separately. D Software used by generator set controllers including
updates and documentation references.
Refer to the generator set controller operation manual
for operating instructions. Refer to the engine operation D Network Communications provides basics to
manual for generator set engine scheduled terms, protocols, standards, wiring, configurations,
maintenance information. Refer to the engine service and model.
manual for generator set engine repair and overhaul
information. D Engine Electronic Control Module (ECM) has
information about electronic devices provided by the
Note: While this service manual includes engine manufacturer to manage engine data.
troubleshooting information regarding paralleling
applications using motorized circuit breakers, the
motorized circuit breakers are not an available List of Related Materials
option offered by Kohlerr Power Systems on
Industrial and Towable generator sets. Separate literature contains voltage regulator setup
information not provided in this manual. Figure 1 lists
Information in this publication represents data available the available literature part numbers.
at the time of print. Kohler Co. reserves the right to
change this publication and the products represented Manual Description Literature Part No.
without notice and without any obligation or liability
Remote Serial Annunciator III Spec Sheet G6-139
whatsoever.
Remote Serial Annunciator III Installation
TT-1625
Read this manual and carefully follow all procedures Instruction
and safety precautions to ensure proper equipment
Decision-Makerr 3500 Controller
operation and to avoid bodily injury. Read and follow the Operation Manual TP-6914
Safety Precautions and Instructions section at the
REOZT4 Trailer and Decision-Makerr
beginning of this manual. Keep this manual with the 3500 Controller Operation Manual TP-6895
equipment for future reference.
REZGT Trailer and Decision-Makerr 3500
Controller Operation Manual TP-6935
The equipment service requirements are very important
to safe and efficient operation. Inspect the parts often REOZK and REOZK4 Wiring Diagrams
TP-6924
and perform required service at the prescribed intervals. Manual
Maintenance work must be performed by appropriately REOZT4 Wiring Diagrams Manual TP-6913
skilled and suitably trained maintenance personnel
familiar with generator set operation and service. REZGT Wiring Diagrams Manual TP-6936
SiteTecht Software Operation Manual TP-6701

Warranty Startup Procedure Requirements SB-616
Fast Responset X Alternator Service
Manual TP-6783
4D/4E Wound Field Alternator Service

Manual TP-6878
Figure 1 Related Literature
TP-6929 1/15 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
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office. Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Netherlands B.V. Fax: (813) 3440-2727
Kristallaan 1
Latin America
4761 ZC Zevenbergen
Latin America Regional Office
The Netherlands
Lakeland, Florida, USA
Phone: (31) 168 331630
Phone: (863) 619-7568
Fax: (31) 168 331631
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-6929 1/15

Section 1 Specifications
1.1 Introduction D Adjustable Engine Run Speed. Set engine speed

slightly higher or lower than nominal (+49 to --50
The specification sheets for each generator set provide RPM) for passive synchronization.
specific alternator and engine information. Refer to the D Alarm Silence. The controller can be set up to
respective specification sheet for data not supplied in silence the alarm horn only when in the AUTO mode
this manual. Consult the generator set operation for NFPA-110 application or Always for user
manual, installation manual, engine operation manual, convenience.
and engine service manual for additional specifications. D Alternator Protection. The controller provides
generator set overload and short circuit protection
This service manual provides controller and accessory matched to each alternator for the particular
troubleshooting and repair information for the following voltage/phase configuration.
controller:
D Automatic Restart. The controller automatic restart
feature initiates the start routine and recrank after a
1.2 Controller Identification and failed start attempt.
Features D Cyclic Cranking. The controller has programmable
cyclic cranking.
1.2.1 Controller Identification D ECM Diagnostics. The controller displays engine
ECM fault code descriptions to help in engine
Refer to Figure 1-1 for an illustration of the controller
troubleshooting.
and components.
D Engine Start Aid. The configurable starting aid
feature provides customized control for an optional
1.2.2 Controller Features engine starting aid.
D AC Output Voltage Regulator Adjustment. The D Event Logging. The controller keeps a record (up to
voltage adjustment provides a maximum adjustment 1000 entries) for warning and shutdown faults. This
of ±10% of the system voltage. fault information becomes a stored record of system
events and can be reset.
1 2 3 4 5 6
9 8 7
1. Power panel 7. Mini USB connection
2. Emergency stop switch (located on the power panel) 8. Generator set master control,
3. Graphical display OFF/RESET--AUTO--RUN buttons with lamps
4. Annunciator fault lamp 9. Alarm silence button with lamp
5. Pushbutton/rotary selector dial (press and hold for 3 seconds for lamp test)
6. Alarm horn (behind panel)
Figure 1-1 Decision-Makerr 3500 Controller
TP-6929 1/15 Section 1 Specifications 15

D Generator Management. Programmable generator D Voltage Selection Menu. This menu provides the
management based on manual selection, fuel level, capability of quickly switching generator output
or run time to optimize fuel usage, noise, voltage. Requires initial activation using SiteTecht
maintenance, etc. software. NOTE: Generator set output leads may
require reconnection.
D Historical Data Logging. Total number of successful
starts of the generator is recorded and displayed. D Paralleling Functions:
D Integrated Hybrid Voltage Regulator. The voltage d Bus sensing
regulator provides ±0.5% no-load to full-load RMS d First on logic
voltage regulation with three-phase sensing. d Synchronizing
D Lamp Test. Press the alarm silence/lamp test button d Communication based isochronous load sharing
to verify functionality of the indicator lights. d Droop load sharing
D LCD Display. Backlit LCD display with integral heater d External controlled load sharing via analog bias
and adjustable contrast for viewing in varying signals
temperatures and lighting conditions.
D Load Management. Dynamic load add/shed, based 1.3 Electrical Sensor/Switch
on the present load and available capacity based on Specifications
the number of generator sets on the bus.
D Measurement Units. The controller provides 1.3.1 Electrical Sensors/Switches
selection of English or metric displays.
D Power Metering. Controller graphical display Refer to Section 1.3.2 for Generator Set Sensor/Switch
provides voltage, current, power factor, kW, kVA, and Part Numbers for referencing the specific electrical
kVAR. sensors/switches used with each generator set.
Information on testing the sensors/ switches is found
D Programming Access (USB). Provides software later in this manual.
upgrades and diagnostics with PC software tools.
D Remote Reset. The remote reset function supports Some sensors/switches are supplied by the engine
acknowledging and resetting faults and allows manufacturer. Consult the engine literature for engine-
restarting of the generator set without going to the supplied sensors and switches and their testing
master control switch off/reset position. information.
D Run Time Hourmeter. The generator set run time is
displayed. Refer to 1.3.3 Generator Set Sensor/Switch Warning
and Shutdown Setpoints by model.
D Time Delay Engine Cooldown (TDEC). The TDEC
provides a time delay before the generator set shuts Note: The information found in Section 1.3.3 Generator
down.
Set Sensor/Switch Warning and Shutdown
D Time Delay Engine Start (TDES). The TDES Setpoints by Model is also available in publication
provides a time delay before the generator set starts. SB-616.
1.3.2 Generator Set Sensor/Switch Part Numbers

Oil Pressure Sender Coolant Temp. Coolant Level Sensor Fuel Leak Alarm Fuel Level Sensor
(OPS) Sender (CTS) (CLS) (FLA) Switch * (FLS) *
Model (lead 7) (lead 35A) (leads 31A and N1) (leads 64 and N22) (leads 63 and N15)
Gas Models
30REZGT
50REZGT GM39458 (see 1.3.6 GM66270 (see 1.3.4
Engine supplied Not used Not used
70REZGT Temperature Sensors) Coolant Level Sensor)
125REZGT
Diesel Models
30REOZK4 343473 (see 1.3.5
Pressure Sensors)
35REOZT4
Note: Early models 226717 (see 1.3.6 GM66270 (see 1.3.4 GM90154 Assembly
SA24291-3
40REOZK4 may be equipped with Temperature Sensors) Coolant Level Sensor) (255600 Switch)
343474. Service
45REOZT4 replacement is 343473.
* If equipped with diesel subbase fuel tank.
16 Section 1 Specifications TP-6929 1/15

1.3.3 Generator Set Sensor/Switch Warning and Shutdown Setpoints
Refer to the tables in Section 5.12, Fault Warning and Shutdown Testing.
1.3.4 Coolant Level Sensor
Sensor
P/N Input Voltage Value with Fluid Present Value with No Fluid Present
GM66270 12 VDC 12 VDC ±5 VDC Oscillating between 5.5 VDC ±0.5 VDC and 12 VDC ±0.5 VDC @ 6.5 sec.
intervals (minimum)
1.3.5 Pressure Sensors

Sensor
P/N Value A Value B Value C Value D
365624 241 ±16 ohms at 0 psi 152 ±13 ohms at 50 psi 33.5 ohms at 200 psi
264390 240 +17/--15 ohms at 0 psi 153 +12/--15 ohms at 25 psi 33.5 ohms at 100 psi
344538 120 +9/--8 ohms at 0 psi 76.5 +6/--7.5 ohms at 25 psi 16.8 ohms at 100 psi
267408 9 ±4 ohms at 0 psi 48 ±4 ohms at 15 psi 84 ±4 ohms at 30 psi 120 ±5 ohms at 45 psi
267967 9 ±4 ohms at 0 psi 48 ±4 ohms at 15 psi 84 ±4 ohms at 30 psi 120 ±5 ohms at 45 psi
344305 10 ±5 ohms at 0 psi 60 ±5 ohms at 20 psi 115 ±10 ohms at 80 psi
343473 240 +2.5/--10.5 ohms at 0 psi 33.5 +10.5/--7.5 ohms at 100 psi
GM29290 240 +17/--15 ohms at 0 psi 153 +12/--15 ohms at 25 psi 33.5 ohms at 100 psi
1.3.6 Temperature Sensors

Sensor
P/N Value A Value B Value C
226717 123.8 +7.2/--7.8 ohms at 90.6C (195F) 35.6 +3.4/--3.6 ohms at 137.8C (280F)
249287 382 ±40 ohms at 37.7C (100F) 62 ±6 ohms at 93C (200F) 35 ohms at 115.6C (240F)
249348 134 ±10 ohms at 60C (140F) 51.5 ±4 ohms at 90C (194F) 38 ±3 ohms at 100C (212F)
255240 180 ±22 ohms at 54C (130F) 71 ±8 ohms at 82C (180F)
274988 123.8 ±12.3 ohms at 90.6C (195F) 35 ±3.5 ohms at 137.8C (280F)
GM10166 123.8 +7.2/--7.8 ohms at 90.6C (195F) 35.6 +3.4/--3.6 ohms at 137.8C (280F)

1.3.7 Temperature Switches
Switch
P/N Epoxy Color Value A Value B
240976 Red Normally open--to close on temp. rise of 96C ±4C (205F ±7F)
240977 White Normally open--to close on temp. rise of 80C ±4C (190F ±7F)
241308 Black Normally open--to close on temp. rise of 107C ±4C (225F ±7F)
241481 Olive Normally open--to close on temp. rise of 103C ±4C (218F ±7F)
253322 Normally open--to close on temp. rise of 107C ±4C (225F ±7F)
255241 Green Normally open--to close on temp. rise of 103C ±4C (218F ±7F)
255242 Red Normally open--to close on temp. rise of 96C ±4C (205F ±7F)
Normally open--to close on temp.
255264 Brass Normally open--to close on temp. fall of 16C ±3C (60F ±5F)
rise of 27C ±3C (80F ±5F)
326105 Black Normally open--to close on temp. rise of 107C ±4C (225F ±7F)
326733 Red w/blue dot Normally open--to close on temp. rise of 99C ±4C (210F ±7F)
336848 Blue Normally open--to close on temp. rise of 102C ±1.8C (215F ±3F)
336849 Pink Normally open--to close on temp. rise of 106C ±1.8C (222F ±3F)
336923 Black w/white dot Normally open--to close on temp. rise of 111C ±4C (232F ±7F)
343160 Red w/blue dot Normally open--to close on temp. rise of 99C ±4C (210F ±7F)
361956 Brass Normally open--to close on temp. fall of 16C ±3C (60F ±5F)
rise of 27C ±3C (80F ±5F)
GM10061 Brass Normally open--to close on temp. fall of 16C ±3C (60F ±5F)
rise of 27C ±3C (80F ±5F)
rise of 27C ±3C (80F ±5F)
GM19475 Normally open--to close on temp. rise of 103C ±4C (218F ±7F)
rise of 27C ±3C (80F ±5F)
GM24579 Red w/white dot Normally open--to close on temp. rise of 98C ±2C (208F ±4F)
GM24649 Black w/white dot Normally open--to close on temp. rise of 111C ±4C (232F ±7F)
rise of 27C ±3C (80F ±5F)
rise of 27C ±3C (80F ±5F)
GM94597 Normally open--to close on temp. fall of 128C ±4C (263F ±10F)

1.3.8 Pressure Switches 1.4 Decision-Makerr 3500 with
Switch
Integral Voltage Regulator
P/N Value, kPa Value, psi
The voltage regulator is integral to the controller and uses
271425 138 ±14 kPa (20 ±2 psi) patented hybrid voltage regulator design providing 0.5%
255912 234 ±21 kPa (34 ±3 psi)
no-load to full-load regulation using root-mean-square
(RMS) voltage sensing.
255913 262 ±21 kPa (38 ±3 psi)
The voltage regulator features three-phase sensing and
253323 103 ±21 kPa (15 ±3 psi) supports both 12- and 24-volt engine electrical systems.
289282 172 ±14 kPa (25 ±2 psi) D The Decision-Makerr 3500 graphical display and
328308 55 ±17 kPa (8 ±2.5 psi) pushbutton/rotary dial provide access to data. A five-line,
35-characters per line LCD display provides complete
328309 103 ±14 kPa (15 ±2 psi) and concise information include gain, ramp rate, reactive
354564 28 ±10 kPa (4 ±1.5 psi)
droop, VAR control (P, I, D gains), and PF control (P, I, D
gains).
361178 483 ±14 kPa (70 ±2 psi)
D The controller provides ISO 8528-5, Class G3,
364343 200 ±21 kPa (29 ±3 psi) compliance for transient response on some 20--300 kW
364344 234 ±21 kPa (34 ±3 psi) generator set models. The controller also supports
Modbusr.
364345 262 ±21 kPa (38 ±3 psi)
D The controller can control Fast Responset II, Fast
364346 551 ±48 kPa (80 ±7 psi) Responset X, and wound field alternators using the
364353 641 ±48 kPa (93 ±7 psi) GM88453 activator board.
GM10574 276 ±34 kPa (40 ±5 psi) Voltage Regulation Menu
GM10575 379 ±34 kPa
D Voltage adjustment, 10% of system voltage
(55 ±5 psi)
D V/Hz cut-in, 42--62 Hz
GM29292 138 ±14 kPa (20 ±2 psi) D Underfrequency unload slope, 0--10% of system voltage
GM30263 6.9 ±2.1 kPa (1 ±0.3 psi)
D Reactive droop, 0.0--20%
D Voltage regulator gain adjust, 1--255
GM39931 103 ±14 kPa (15 ±2 psi) D Startup ramp rate, 5.0% to 100.0%/sec
GM54744 13.8 ±3.4 kPa (2 ±0.5 psi) Generator Set Calibration Menu
D L1-L2 volts
D L2-L3 volts (3-phase)
D L3-L1 volts (3-phase)
D L1-N volts
D L2-N volts
D L3-N volts (3-phase)
D Gen L1 current
D Gen L2 current
D Gen L3 current (3-phase)
D Bus L1--L2 volts
D Bus L2--L3 volts (3-phase)
D Bus L3--L1 volts (3-phase)
Modbusr is a registered trademark of Schneider Electric.

1.4.1 Specifications and Features
Specification/Feature Voltage Regulator Type Integral with Decision-Makerr 3500
Generator Set Availability 15--1000 kW
Integrated Voltage Regulator Patented Hybrid Design
Status and Shutdown Indicators LEDs and Graphical LCD Display
Operating Temperature --40_C to 70_C (--40_F to 158_F)
Storage Temperature --40_C to 85_C (--40_F to 185_F)
Humidity Withstand 5--95% Condensing
Salt Spray Tolerance 5% Salt Spray per ASTM-B-117-90
Circuit Protection Solid-State, Redundant Software and Fuses
Sensing, Nominal 100--600 V (L-L), 50--60 Hz
Sensing Mode RMS, Single- or 3-Phase
Input Requirements 8--36 VDC
Continuous Output 5 VDC @ 100 mA max. 5.0 ADC with GM88453 Activator Board
Maximum Forcing Output 5 VDC @100 mA max. 7.8 ADC with GM88453 Activator Board
Transition Frequency 42.0--62.0 Hz
Exciter Field Resistance 4--30 Ohms with GM88453 Activator Board
No-Load to Full-Load Voltage Regulation 0.5%
Thermal Drift <0.5% (--40_C to 70_C) [--40_F to 158_F ] Range
Response Time Less than 5mS
System Voltage Adjust Range 10%
Voltage Adjustment Controller Menu Knob
Remote Voltage Adjustment 0.5--4.5 VDC (10%) Bias Input
Paralleling Capability Reactive Droop plus Load Share and Control
VAR/PF Control Input VAR Control Mode, PF Control Mode, System VAR Control, System PF Control
1.4.2 Integral Voltage Regulator

Adjustment Digital Display Range Setting Default Selection
Voltage Adjustment Voltage Adjust 10% of System Voltage System Voltage
V/Hz Cut-in V/Hz Setpoint 42 to 62 Hz 1.0 Hz Below Nominal Frequency
Underfrequency Unload Slope V/Hz Slope 0--10% of System Voltage (Volts per Cycle) 5% of Rated Voltage per Cycle
Volt Droop @
Reactive Droop 0.0% to 20% of System Voltage 1% of System Voltage
100% kVAR
Voltage Regulator Gain Adjust Voltage Gain Adjust 1 to 255 128
Startup Voltage Ramp Rate Startup Ramp Rate 5.0% to 100.0%/Sec 25%/Sec
1.4.3 Activator Board GM88453 D Interfaces between the controller and alternator assembly
using rotor field leads, auxiliary power windings, and
optic board leads.
D Allows the Decision-Makerr controllers the ability to

control a wound-field alternator using the same control
signal as the Fast Responset alternator.
D Permits the generator set controller to control the current

to the exciter field of a wound-field excited alternator.
D Contains two isolated relay driver outputs (RDO) rated at

250 mA. Provides RDO outputs indicating a field over-
excitation condition and that the alternator is supplying
voltage to the activator.

Section 2 Controller Parameters
2.1 Introduction 2.1.1 Warning Parameter Default

Setting
The controller parameters section provides information
regarding the controller firmware. Inhibit Time Delay. The inhibit time delay is the time
period following crank disconnect during which the
Note: Use Kohlerr SiteTecht software and a personal generator set stabilizes and the controller does not
computer connected to the controller’s USB port detect a fault or status event. Select the desired inhibit
to configure the controller parameters. See the time delay from 0 to 60 seconds. A setting of 0 (zero)
SiteTecht Software Operation Manual TP--6701 means the warning is monitored continuously, even if
for instructions. not running.
Section 2.1.1 and Section 2.1.2 contain warnings and Note: The engine ECM may limit the crank cycle even if
faults with ranges and time delays including items that the controller is set to a longer time period.
do not have user adjustments.
TIme Delay (Shutdown or Warning). The time delay
Section 2.1.3 Controller Parameters List is an overview follows the inhibit time delay. The time delay is the time
of the various features and functions of the controller. period between when the controller first detects a fault or
Certain features function only when optional status event and the controller warning or shutdown
accessories are connected. Some generator set/ lamp illuminates. The delay prevents nuisance alarms.
engine models may not support every controller Select the desired time delay from 0 to 60 seconds.
parameter.
Figure 2-1 lists default settings for common warnings.
Fault Sensing Warning When Inhibit Time Display

Condition Mechanism Condition Active Time Delay Cleared On
Low oil Pressure sender Varies by generator Running Crank disconnect 0 sec. Warning
pressure set model (See + 30 sec. removal,
pre-alarm Section 1.3.3) generator off
High coolant Temperature sender Varies by generator ON Crank disconnect 0 sec. Warning
temperature set model (See + 30 sec. removal,
Section 1.3.3) generator off
Low cranking Battery analog input Vbat < 60% of Cranking Cranking. 3 sec. Next good
voltage nominal crank or
system reset
Low battery Battery analog input < 11 V Continuous, 0, Always 60 sec. Warning
voltage (12V) not cranking removed
High battery Battery analog input > 16 V Continuous, 0, Always 60 sec. Warning
Low battery Battery analog input < 22 V Continuous, 0, Always 60 sec. Warning
High battery Battery analog input > 30 V Continuous, 0, Always 60 sec. Warning
Battery charger Digital input from Input closed Continuous 0, Always 1 sec. Warning
fault charger removed
Low fuel Digital input from Input closed Continuous 0, Always 10 sec. Warning
fuel switch removed
Low coolant Digital input Input closed Continuous 0, Always 10 sec. Warning
temperature removed
Not in auto Mode switch Mode not in auto Continuous 0, Always 0 sec. Warning
removed
Figure 2-1 Warning Parameter Default Table
TP-6929 1/15 Section 2 Controller Parameters 21

2.1.2 Fault Parameter Default Setting
Figure 2-2 lists default settings for common faults.
Fault Sensing Fault When Inhibit Time Display
Condition Mechanism Condition Active Time Delay Cleared On
E-Stop E-Stop switch input Input open Continuous 0, Always 1 sec. Fault removal
and reset
Locked rotor ECM No rotation Cranking Cranking 3 sec. Reset
Overcrank Speed sensor or 3 cycles Cranking Cranking 15 sec. Reset
ECM
ECM CAN input No CAN Cranking and 1 sec. 1 sec. Reset
comm. loss communication running
Auxiliary fault Digital input from Input closed Continuous 0, Always 2 sec. Removal of
customer device input and reset
Under frequency Metering software > 1 Hz below nominal ON Crank disconnect 60 sec. Reset
long term + 10 sec.
Under frequency Metering software < 90% of nominal ON Crank disconnect 10 sec. Reset
short term + 10 sec.
Over frequency Metering software > 110% of nominal ON Crank disconnect 10 sec. Reset
+ 10 sec.
Over voltage Metering software > 120% of nominal ON Crank disconnect 2 sec. Reset
Under voltage Metering software < 80% of nominal ON Crank disconnect 10 sec. Reset
Low oil Analog input and/or Varies by generator ON Crank disconnect 5 sec. Reset
pressure ECM set model (See + 30 sec. or ECM or ECM
Section 1.3.3)
Overspeed ECM > 115% of nominal ON Crank disconnect 0.3 sec. Reset
High coolant Analog input and/or Varies by generator ON Crank disconnect 5 sec. Reset
temperature ECM set model (See
Section 1.3.3)
Low coolant Digital input Low coolant level ON 30 sec. 5 sec. Fault removal
level (optional) and reset
Low coolant Analog input Low coolant level Continuous 0, Always 10 sec. Fault removal
level in radiator and reset
(optional)
High oil temp Digital input High temperature ON 30 sec. 5 sec. Fault removal
(optional) (Engine specific) and reset
Low oil level Digital input Low oil level ON 30 sec. 5 sec. Fault removal
(optional) and reset
Fuel leak Digital input Fuel leak ON 30 sec. 5 sec. Fault removal
(optional) and reset
Intake air ECM Engine specific. Running ECM ECM ECM
temperature Consult engine
specifications.
Fuel return ECM 100_C Running ECM ECM ECM
temperature
AC sensing loss Integral voltage No AC voltage at Running 10 sec. 3 sec.
metering controller
Alternator CTs and integral Exceeding alternator Running Crank disconnect
protection metering protection curve
ECM model CAN parameter file ECM comms don’t Prior to crank
mismatch match
Run relay coil Internal hardware Relay coil exceeds Running 0 0 Fault removal
overload and software max. current and reset
Sensor supply CAN (John Deere ECM Running ECM ECM
voltage only)
Starter relay Internal hardware Cranking Cranking
coil overload and software
Figure 2-2 Fault Parameter Default Table
22 Section 2 Controller Parameters TP-6929 1/15
2.1.3 Controller Parameter List
Write Decision-Makerr 3500
SiteTecht Parameter Access Units User Interface Notes
Identity
Vendor None
Product None
Firmware Version None Software Version:
XXXXXXXX
Engine Metering
Engine Speed None R/min Engine Speed: ####RPM The speed at which the engine is
presently running
Engine Oil Pressure None kPa Oil Pressure: ###PSI
Engine Coolant Temperature None _C Coolant Temperature:
###_F
Engine Oil Level None %
Engine Coolant Level None %
Engine Fuel Level None %
Battery Voltage None V Gen Battery Voltage: The battery voltage as measured
##.#VDC by the controller
Fuel Temperature None _C Fuel Temperature: ###_F
Fuel Pressure None kPa Fuel Pressure: ###PSI
Fuel Rate None L/h Fuel Rate: ###GAL/h
Fuel Used Last Run None L Fuel Used Last Run
Coolant Pressure None kPa Coolant Pressure: ###PSI
Lube Oil Temperature None _C Oil Temperature: ###_F
Crankcase Pressure None kPa Crankcase Pressure
Genset Controller Temperature None _C
Battery Voltage From ECM None V ECM Battery Voltage: The battery voltage as reported
##.#VDC by the ECM
Exhaust Temperature None _C Exhaust Temperature
Exhaust Pressure None kPa Exhaust Pressure
Intake Air Temperature None _C Intake Air Temperature:
###_F
Intake Air Pressure None kPa Intake Air Pressure:
###PSI
Engine Low Oil Pressure Switch None
Engine Oil Level Switch None
Engine High Coolant Temperature Switch None
Engine Low Coolant Temperature Switch None
Engine Low Fuel Level Switch None
Engine Seawater Pressure None kPa
Engine Governor Target Speed None R/min
Engine Speed Governor
Engine Speed Adjustment Always The target engine speed setting
Adjusted Engine Run Speed Always Adjusted Engine Run
Speed: ####RPM
Generator Metering
Generator Rotation Actual None Gen Phase Rotation: Metered values for each phase
Disabled/A-B-C/C-B-A
Generator Current Lead/Lag L1 None
Generator Current Total Lead/Lag None
Generator Power Factor L1 None LI PF: #.##
Generator Power Factor L2 None L2 PF: #.##
Generator Power Factor L3 None L3 PF: #.##
Generator Total Power Factor None Total PF: #.##
Generator Apparent Power L1 None VA L1 Apparent Power:
####VA
####VA
####VA
Generator Total Apparent Power None VA Total Apparent Power:
####VA
Generator Percent Of Rated Apparent Power None %

Generator Reactive Power L1 None VAR L1 Reactive Power:
####VAR
####VAR
####VAR
Generator Total Reactive Power None VAR Total Reactive Power:
####VAR
Generator Percent Of Rated Reactive Power None % Gen % of Rated kVA:
###%
Generator Voltage L1-L2 None V L1--L2 Volts: ###V
Generator Voltage Average Line To Line None V AVG Gen Voltage L--L:
###V
Generator Voltage L1-N None V L1--L0 Volts: ###V
Generator Voltage Average Line To Neutral None V AVG Gen Voltage L--N:
###V
Generator Current L1 None A L1 Current: ###A
Generator Current Average None A AVG Current: ###A
Generator Phase Angle AB To L2-L3 None _
Generator Phase Angle AB To L3-L1 None _
Generator Phase Angle Voltage A To Current L1 None _
Generator Phase Angle Voltage B To Current L2 None _
Generator Phase Angle Voltage C To Current L3 None _
AC Frequency None Hz Gen Frequency: ##.#Hz
Generator Percent Of Rated Real Power None % Gen % of Rated kW:
###%
Generator Real Power L1 None W L1 Power: ####W
Generator Total Real Power None W Total Power: ####W
Bus Metering
Bus Voltage L1-L2 None V
Bus Voltage Average Line To Line None V AVG Bus Voltage L--L:
###.#V
Bus Total Real Power None kW
Bus Total Real Power Percentage None %
Bus Total Reactive Power Percentage None %
Bus Frequency None Hz Bus Frequency: ##.##Hz
Bus Rotation Actual None Bus Phase Rotation:
Disabled/A-B-C/C-B-A
Phase Angle Generator Voltage AB Bus Voltage None _ Phase Difference: ###.#_
L1-L2
Speed Bias 2 None
Voltage Bias 2 None
Bus Phase Angle AB To L2-L3 None _
Bus Phase Angle AB To L3-L1 None _
Genset Info
Genset Model Number Locked Genset Model #:
XXXXXXXXX
Genset Spec Number Locked Genset Spec #:
XXXXXXXXX
Genset Serial Number Locked Genset Serial #:
XXXXXXXXX
Alternator Part Number Locked Alternator Part #:
XXXXXXXXX
Genset Controller Serial Number None Controller Serial #:
XXXXXXX
Engine Part Number Locked Engine Part #: XXXXXXX

Engine Model Number Locked Engine Model #:
XXXXXXXXX
Engine Serial Number Engine Serial #:
Locked
XXXXXXX
ECM Serial Number Locked ECM Serial #: XXXXXXX
Genset State None The present state of the genset
Master Switch Position None
Genset Run Time
Genset Controller Clock Time Always Time: ##:## XM The present time on the
Date: ##/##/#### controller system clock
Genset Controller Total Operation Time None h Operating Hours: The total number of hours that
######hrs power has been applied to the
genset controller
Engine Total Run Time None h Total Run Time: #####hrs The total number of hours that
the engine has been running
Engine Total Run Time Loaded None h Hours Loaded: #####hrs The total number of hours that
the engine has been running
Engine Total Run Time Unloaded None h Hours Unloaded: while supplying more than 1% of
#####hrs rated genset load
Engine Total Number Of Starts None Total # of Starts: The total number of times that
######## the engine was started via the
genset controller
Genset Total Energy None kW-h kW Hours: #####kWh The total amount of energy that
the genset has produced
Engine Maintenance Period Hours Always h The number of hours between
engine maintenance requirement
Genset Date Time Of Last Maintenance None Last Maintenance: The time on the controller system
##/##/#### clock when the last maintenance
was performed
Engine Run Time At Reset Maintenance None h The total number of hours that
the engine had been running
when the last maintenance was
performed
Engine Run Time Until Maintenance None h The total number of engine run
hours that remain before engine
maintenance is required
Genset Controller Hours Of Operation Since None h Op Hrs Since Maint: The number of hours that power
Maintenance ####hrs has been applied to the genset
controller since maintenance was
performed
Engine Run Time Since Maintenance None h Eng Hrs Since Maint: The number of hours that the
####hrs engine has been running since
maintenance was performed
Engine Run Time Loaded Since Maintenance None h Loaded Since Maint: The number of hours that the
####hrs engine has been running while
supplying more than 1% of rated
genset load, since maintenance
was performed
Engine Run Time Unloaded Since Maintenance None h Unloaded Since Maint: The total number of hours that
####hrs the engine has been running
while supplying less than 1% of
rated genset load, since
Engine Number Of Starts Since Maintenance None Starts Since Maint: ### The number of times that the
engine was started via the genset
controller, since maintenance
was performed
Genset Energy Since Maintenance None kW-h kW Hrs Since Maint: The amount of energy that
####kWh genset has produced since
Engine Last Start Time None Last Start: ##/##/#### The date and time that the engine
was last started via the genset
controller
Last Run Length None h Last Run Length: ####hrs The length of time that the engine
ran the last time it was started via
the genset controller
Genset Controller Date Format Always Date Format: Month Date
Year/Date Month Year
Genset Controller Time Format Always Time Format: Hr 12/Hr 24

Genset Personality Profile
ECM Model Locked
Maximum Alternator Current None A Used by thermal protection
algorithm
Engine Number Of Flywheel Teeth Locked The number of teeth on the
engine flywheel
Engine Warmed Up Temperature Locked _C Engine Warmed Up: The engine is warmed up enough
###_F to be loaded
Engine Cooled Down Temperature Locked _C Engine Cooled Down: The engine is cool enough to be
###_F turned off
Engine Crank Disconnect Speed Locked R/min The engine speed that the starter
will be disengaged
Engine Idle Speed Locked R/min The engine speed when in idle
mode
Engine Run Speed Stopped R/min Rated Engine Speed: The normal operating speed of
####RPM the engine
Engine Coolant Temperature Protectives Enabled Locked
Engine Low Coolant Temperature Inhibit Delay Locked s The time, after crank disconnect,
before the protectives are
monitored; if 0, protectives are
Engine High Coolant Temperature Inhibit Delay Locked s monitored even when the engine
is stopped
Engine Low Coolant Temperature Warning Delay Locked s
Engine High Coolant Temperature Warning Delay Locked s
Engine Low Coolant Temperature Shutdown Delay Locked s
Engine High Coolant Temperature Shutdown Delay Locked s
Engine Low Coolant Temperature Warning Limit Locked _C
Engine High Coolant Temperature Warning Limit Locked _C
Engine Low Coolant Temperature Shutdown Limit Locked _C
Engine High Coolant Temperature Shutdown Limit Locked _C
Engine Coolant Temperature Deadband Locked _C
Personality Alternator Manufacturer Locked
Personality Alternator Toc Time Constant Locked s
Personality Alternator Number Of Poles Locked
Personality Alternator Type Locked
Personality Fixed Voltage 50Hz Locked V
Personality Power Rating Single Phase 50Hz 10PF Locked kW
Personality Power Rating Fixed Volt 50Hz Locked kW
Personality Power Rating 50Hz 220 440 Locked kW
Personality Power Rating 50Hz Delta Locked kW
Personality Fixed Voltage 60Hz Locked V
Personality Power Rating Fixed Volt 60Hz Locked kW
Personality Power Rating 60Hz Delta Locked kW
Personality Installed Options Locked
Gen Rating 1 Fuel Type Locked
Gen Rating 1 50HZ 1Ph Locked kW
Gen Rating 1 50HZ Wye 173 346 Locked kW
Gen Rating 1 50Hz Delta Locked kW
Gen Rating 1 Fixed Voltage 50Hz Locked V

Gen Rating 1 Fixed Voltage KW 50Hz Locked kW
Gen Rating 2 Fuel Type Locked
Freq Match P Gain Scaler Locked
Freq Match I Gain Scaler Locked
Freq Match D Gain Scaler Locked
Volt Match P Gain Scaler Locked
Volt Match I Gain Scaler Locked
Volt Match D Gain Scaler Locked
Phase Match P Gain Scaler Locked
Phase Match I Gain Scaler Locked
Phase Match D Gain Scaler Locked
Real Power P Gain Scaler Locked
Real Power I Gain Scaler Locked
Real Power D Gain Scaler Locked
Torque Share P Gain Scaler Locked
Torque Share I Gain Scaler Locked
Torque Share D Gain Scaler Locked
Freq Trim P Gain Scaler Locked
Freq Trim I Gain Scaler Locked
Freq Trim D Gain Scaler Locked
Reactive Power P Gain Scaler Locked
Reactive Power I Gain Scaler Locked
Reactive Power D Gain Scaler Locked
Volt Trim P Gain Scaler Locked
Volt Trim I Gain Scaler Locked
Volt Trim D Gain Scaler Locked
Voltage Selector Switch
Voltage Selector Switch Position Locked
Voltage Selector Switch Max Positions Locked
Voltage Selector Switch Position 1 Voltage Locked V
Voltage Selector Switch Position 1 Frequency Locked Hz
Voltage Selector Switch Position 1 Voltage Phase
Locked
Connection

Locked
Connection
Locked
Connection
Genset System Configuration
Genset System Voltage Stopped V System Voltage L--L: The generator operating voltage
###V
Genset System Frequency Stopped Hz System Frequency: The generator operating
##.#Hz frequency
Genset Voltage Phase Connection Stopped System Phase: Single/ The generator number of phases
Single Dog/Three-Wye/ (single or three)
Three-Delta
Genset Power Rating Locked kW kW Rating: ####kW The generator operating power
rating in kW
Genset Apparent Power Rating Stopped kVA The generator operating apparent
power rating in kVA
Genset Rated Current None A Rated Current: ###A Calculated from power rating,
voltage, and connection
Genset System Battery Voltage Stopped V Battery Voltage: ##V The generator operating battery
voltage
Prime Power Application Locked Operating Mode: Indicates whether the generator
Standby/Prime set is in a prime power
application
Current Transformer Ratio Locked
Local Start Mode None Indicates the last pushbutton that
was pressed on the controller
panel
Measurement System Always Units: Metric/English Indicates whether to use the
English or Metric measurements
system for display of parameter
values and their units
Alarm Silence Always Allowed Always Alarm Silence: Always/Auto When true, the alarm can be
Only silenced when the controller is in
any state; when false, the alarm
can only be silenced in the Auto
state
NFPA 110 Enabled Always NFPA Defaults: On/Off Indicates whether NFPA110
defaults are enabled
Cool Down Temperature Override Always Cooldown Override: Indicates whether the engine’s
On/Off cooled-down parameter should
be overridden during the time
delay
Oil Sensor Type Stopped Indicates the type of oil sensor
Public CAN Protocol Stopped Indicates the public CAN Protocol
Display Contrast Always Contrast: ###
Using Voltage Selector Switch Stopped
Genset System Language Always Language: English
Genset Maximum Percent Capacity Always %
Generator Overloaded Percent Always %
Under Frequency Shed Level Always %
Base Load Add Time Always s
Base Over Load Shed Time Always s
Base Under Frequency Shed Time Always s
Genset Fuel Type Stopped Fuel Type: Natural
Gas/LP/ Gasoline/Diesel/
Unknown
Battle Mode Always Emergency Battlemode:
On/Off
ECM Powered Mode Stopped Indicates whether the ECM
Power is turned on
Genset Application Locked Application Type:
None/Marine/
Mobile/Standby/Prime
Genset Calibration
Calibration Factor Voltage L1-L2 Always Gen L1--L2 Volts: ###.#V

Calibration Factor Voltage L1-N Always Gen L1--L0 Volts: ###.#V
Calibration Factor Voltage L2-N Always Gen L2--L0 Volts: ###.#V
Calibration Factor Voltage L3--N Always Gen L3--L0 Volts: ###.#V
Calibration Factor Current L1 Always Gen L1 Current: ###.#A
Bus Calibration Factor Voltage L1-L2 Always Bus L1--L2 Volts: ###.#V
Voltage Regulator
Voltage Regulator Average Voltage Adjustment Always V Voltage Adjust: ###.#V The target voltage setting
Voltage Regulator Volts Per Hertz Slope Always % V/Hz Slope: ##%/Hz The ratio of volts/hertz ramping
Voltage Regulator Volts Per Hertz Cut In Frequency Always Hz V/Hz Setpoint: ##.#Hz The frequency that the Volts Per
Hertz feature is activated
Voltage Regulator Gain Always Voltage Gain Adjust: ### Provides adjustment to the
sensitivity of the voltage regulator
Voltage Regulator Stability Adjust Always Controls damping to provide
stable voltage during transients
and steady-state operation
Voltage Regulator Firmware Version None
Voltage Regulator Target Voltage None V Target Voltage: ###.#V
Voltage Regulator Normal Ramp Rate Always %/s Start Up Ramp Rate:
###.#%/s
Engine Timing
Engine Idle Duration Always s The length of time for the engine
idle mode
Engine Restart Delay Always s The length of time to wait before
attempting to restart the engine
when engine rotation cannot be
determined
Engine Start Delay Always s Engine Start Delay: ##s The length of time to wait before
attempting to start the engine
after a remote start command is
received
Engine ECM Start Delay Always s The length of time to wait before
engaging the starter after the
ECM has been powered
Engine Cool Down Delay Always s Cooldown Delay: ##s The length of time to wait before
stopping the engine after a
remote stop command is
received (unless the low
temperature delay applies)
Engine Start Aid Delay Always s Starting Aid Delay: ##s The length of time to turn the
starting aid output on before
attempting to start the engine
Engine Crank On Delay Always s Crank On Delay: ##s The length of time for the
on-period of the crank cycle
Engine Crank Pause Delay Always s Crank Pause Delay: ##s The length of time for the
off-period of the crank cycle
Engine Number Of Crank Cycles Stopped Crank Cycles Limit: ## The number of crank cycles
before an over crank fault is
indicated
Genset Protection
After Crank Disconnect Fault Inhibit Delay None s The time, after crank disconnect,
before some protectives are
monitored
Genset Low Battery Voltage Warning Delay None s
Genset High Battery Voltage Warning Delay None s
Genset Low Battery Voltage Warning Limit Always % Percentage of System Battery
Voltage that the battery voltage
must drop below for a Low
Battery voltage condition to be
indicated
Genset High Battery Voltage Warning Limit Always % Percentage of System Battery
must exceed for a High Battery
voltage condition to be indicated
Genset Battery Low Cranking Voltage Warning Delay None s

Genset Battery Low Cranking Voltage Warning Limit None % Percentage of System Battery
must drop below during cranking
for a Low Cranking Battery
condition to be indicated
Engine Protection
Engine Low Coolant Level Shutdown Delay None s
Engine Low Oil Pressure Warning Delay Locked s
Engine Low Oil Pressure Shutdown Delay Locked s
Engine Locked Rotor Shutdown Delay Always s The length of time for the starter
to be engaged with no engine
rotation detected, before a fault is
indicated
ECM Communication Loss Shutdown Delay None s
Genset Low Engine Speed Shutdown Limit Always % Percentage of nominal engine
speed that the engine must drop
below for an under speed
Genset High Engine Speed Shutdown Limit Always % Percentage of nominal engine
speed that the engine must
exceed for an overspeed
Engine Oil Pressure Protectives Enabled Locked
Engine Low Oil Pressure Inhibit Delay Locked s The time, after crank disconnect,
before the protectives are
monitored; if 0, protectives are
monitored even when the engine
is stopped
Engine Low Oil Pressure Warning Limit Locked kPa
Engine Low Oil Pressure Shutdown Limit Locked kPa
Engine Oil Pressure Deadband Locked kPa
Generator Protection
Loss Of AC Sensing Shutdown Delay None s
Genset Low Voltage Shutdown Delay Always s Undervoltage Delay: ##s The time that the generator
voltage must be in an under
voltage condition before a fault is
indicated
Genset High Voltage Shutdown Delay Always s Overvoltage Delay: ##s The time that the generator
voltage must be in an over
voltage condition before a fault is
indicated
Genset Low Voltage Shutdown Limit Always % Undervoltage: ##% Percentage of System Voltage
that the generator voltage must
drop below for an under voltage
Genset High Voltage Shutdown Limit Always % Overvoltage: ##% Percentage of System Voltage
that the generator voltage must
exceed for an over voltage
Genset Short Term Low Frequency Shutdown Delay None s
Genset Long Term Low Frequency Shutdown Delay None s
Genset High Frequency Shutdown Delay None s
Genset Low Frequency Shutdown Limit Always % Underfrequency: ##% Percentage of System Frequency
that the generator frequency
must drop below for an under
frequency condition to be
indicated
Genset High Frequency Shutdown Limit Always % Overfrequency: ##% Percentage of System Frequency
that the generator frequency
must exceed for an over
frequency condition to be
indicated
Programmable Digital Input
Digital Input Board Number None I/O Board Number: X Indicates board number this IO
point is located on
Digital Input Io Number None Indicates the point number, of
this IO type on this board, for this
configuration
Digital Input Status None The current value of the input
(scaled to the units of the
function ID)

Digital Input Enabled Always Enabled: On/Off Indicates whether this input is
enabled
Digital Input Logic Always The type of switch that is
connected to the input, where
“normal” refers to the
non-activated state
Digital Input Function Always Function: Indicates the functionality of this
IO point
Digital Input Event Always Event: The parameter ID defining the
function for this input
Digital Input Delay Always s Delay Time: ##s The time that the input must be
active before a status change is
Digital Input Inhibit Delay Always s Inhibit Time: ##s indicated
Digital Input Description Always Description: A user-defined description of this
IO point
Programmable Digital Output
Digital Output Board Number None I/O Board Number: X Indicates board number this IO
point is located on
Digital Output IO Number Indicates what this configuration
None is for based on the point number
of this IO type on this board
Digital Output Status The value of the input relative to
None
the full range of the input
Digital Output Enabled Indicates whether this input is
Always Enabled On/Off
enabled
Digital Output Logic Logic: Active On/Active Indicates whether shutdown is
Always
Off active for this input
Digital Output Function Indicates what is the functionality
Always Function:
of this IO point
Digital Output Event The parameter ID defining the
Always Event:
Digital Output Description A user defined description of
Always Description:
what this IO point is
Programmable Analog Resistive Input
Analog Resistive Input Board Number Indicates board number this IO
None I/O Board Number X
point is located on
Analog Resistive Input IO Number Indicates what this configuration
None is for based on the point number
of this IO type on this board
Analog Resistive Input Metered Value The current value of the input
Measurement ###.#
None (scaled to the units of the
Ohms
function ID)
Analog Resistive Input Metered Relative Value The value of the input relative to
None
Analog Resistive Input Enabled Indicates whether this input is
Always Input Enabled On/Off
enabled
Analog Resistive Input Switch Logic The type of switch that is
connected to the input where
Always
non-activated state.
Analog Resistive Input Function Indicates whats the functionality
Always
of this IO point
Analog Resistive Input Protectives Enabled Indicates which of the protectives
Always Low Warning On/Off
are active for this input
Analog Resistive Input Event The parameter ID defining the
Always
Analog Resistive Input Sensor The type of sensor connected to
Always Sensor Type
the input
Analog Resistive Input Low Protective Inhibit Delay The time, after crank disconnect,
Always s Low Protect Inhibit: ##s before the protectives for this
input are monitored; if 0
Analog Resistive Input High Protective Inhibit Delay protectives are monitored even
Always s High Protect Inhibit: ##s
when the engine is stopped
Analog Resistive Input Delay Always s The time that the input must be
Analog Resistive Input Inhibit Delay Always s indicated
Analog Resistive Input Normal Delay The time that the input must be
within its normal operating range
Always s
before all protectives are
considered good

Analog Resistive Input Low Warning Delay Always s Low Warning Delay: ##s The time that the input must be
Analog Resistive Input Critically Low Warning Delay Always s within its warning operating range
Analog Resistive Input High Warning Delay Always s High Warning Delay: ##s before a warning protective is
Analog Resistive Input Critically High Warning Delay Always s indicated
Analog Resistive Input Low Shutdown Delay Always s Low Shutdown Delay: ##s The time that the input must be
within its shutdown operating
Analog Resistive Input High Shutdown Delay range before a shutdown
Always s High Shutdown Delay: ##s protective is indicated
Analog Resistive Input Low Warning Limit Always Low Warning Limit The limit that the input must drop
below to enter its low warning
Analog Resistive Input Critically Low Warning Limit Always operating range
Analog Resistive Input Low Shutdown Limit The limit that the input must drop
Always Low Shutdown Limit below to enter its low shutdown
operating range
Analog Resistive Input High Warning Limit Always High Warning Limit The limit that the input must
exceed to enter its high warning
Analog Resistive Input Critically High Warning Limit Always operating range
Analog Resistive Input High Shutdown Limit The limit that the input must
Always High Shutdown Limit exceed to enter its high shutdown
operating range
Analog Resistive Input Deadband A percentage of the parameter
value which defines the
Always
hysteresis for the protective
ranges
Analog Resistive Input Relative Upper Range Limit Indicates the limit in raw form
Always when the input will be considered
shorted high
Analog Resistive Input Relative Lower Range Limit Indicates the limit in raw form
Always when the input will be considered
shorted low
Analog Resistive Input Relative Range Limit Specifies how much the raw
Deadband Always value needs to change by before
no longer considered shorted
Analog Resistive Input Relative Range High Limit Specifies what the inhibit time
Inhibit Time Always should be when the input is
considered shorted high
Analog Resistive Input Relative Range Low Limit Specifies what the inhibit time
Inhibit Time Always should be when the input is
considered shorted low
Analog Resistive Input Relative Range Limit Delay Specifies what the debounce
Always time is on the input after the
inhibit time is met
Analog Resistive Input Description A user defined description of
Always Description:
what this IO point is
Programmable Analog Voltage Input
Analog Voltage Input Board Number None I/O Board Number: X Indicates board number this IO
point is located on
Analog Voltage Input Io Number None Indicates the point number, of
configuration
Analog Voltage Input Metered Value None Measurement: ###.# The current value of the input
Ohms (scaled to the units of the
function ID)
Analog Voltage Input Metered Relative Value None The value of the input relative to
Analog Voltage Input Enabled Always Input Enabled: On/Off Indicates whether this input is
enabled
Analog Voltage Input Switch Logic Always The type of switch that is
Analog Voltage Input Function Always Indicates the functionality of this
IO point
Analog Voltage Input Protectives Enabled Always Low Warning: On/Off Indicates which of the protectives
High Warning: On/Off are active for this input
Low Shutdown: On/Off
High Shutdown: On/Off
Analog Voltage Input Event Always The parameter ID defining the
Analog Voltage Input Sensor Always Sensor Type: The type of sensor connected to
the input

Analog Voltage Input Low Protective Inhibit Delay Always s Low Protect Inhibit: ##s The time, after crank disconnect,
before the protectives for this
input are monitored; if 0,
Analog Voltage Input High Protective Inhibit Delay Always s High Protect Inhibit: ##s protectives are monitored even
Analog Voltage Input Delay Always s The time that the input must be
Analog Voltage Input Inhibit Delay Always s indicated
Analog Voltage Input Normal Delay Always s The time that the input must be
considered good
Analog Voltage Input Low Warning Delay Always s Low Warning Delay: ##s The time that the input must be
Analog Voltage Input Critically Low Warning Delay Always s within its warning operating range
before a warning protective is
Analog Voltage Input High Warning Delay Always s High Warning Delay: ##s
indicated
Analog Voltage Input Critically High Warning Delay Always s
Analog Voltage Input Low Shutdown Delay Always s Low Shutdown Delay: ##s The time that the input must be
Analog Voltage Input High Shutdown Delay Always s High Shutdown Delay: ##s range before a shutdown
protective is indicated
Analog Voltage Input Low Warning Limit Always Low Warning Limit: The limit that the input must drop
Analog Voltage Input Critically Low Warning Limit Always operating range
Analog Voltage Input Low Shutdown Limit Always Low Shutdown Limit: The limit that the input must drop
below to enter its low shutdown
operating range
Analog Voltage Input High Warning Limit Always High Warning Limit: The limit that the input must
operating range
Analog Voltage Input Critically High Warning Limit Always The limit that the input must
operating range
Analog Voltage Input High Shutdown Limit Always High Shutdown Limit: The limit that the input must
exceed to enter its high shutdown
operating range
Analog Voltage Input Deadband Always A percentage of the parameter
value, which defines the
ranges
Analog Voltage Input Relative Upper Range Limit Always Indicates the limit in raw form
when the input will be considered
shorted high
Analog Voltage Input Relative Lower Range Limit Always Indicates the limit in raw form
shorted low
Analog Voltage Input Relative Range Limit Deadband Always Specifies how much the raw
value needs to change by before
Analog Voltage Input Relative Range High Limit Always s Specifies what the inhibit time
Inhibit Time should be when the input is
Analog Voltage Input Relative Range Low Limit Inhibit Always s Specifies what the inhibit time
Time should be when the input is
Analog Voltage Input Relative Range Limit Delay Always s Specifies what the debounce
time is on the input after the
inhibit time is met
Analog Voltage Input Description Always Description: A user-defined description of this
IO
Protective Relays
PR Over Power Trip Always % Over Power Trip: ###.#% Percent of rated power
PR Over Power Time Delay Always s Over Power Delay: ##.#s
PR Reverse Power Trip Always % Reverse Power Trip: Percent of rated power
###.#%
PR Reverse Power Time Delay Always s Reverse Power Delay:
##.#s
PR Over Voltage Trip Always % Over Voltage Trip: ###.#% Percent of rated power
PR Over Voltage Time Delay Always s Over Voltage Delay: ##.#s
PR Under Voltage Trip Always % Under Voltage Trip: Percent of rated power
###.#%

PR Under Voltage Time Delay Always s Under Voltage Delay:
##.#s
PR Over Frequency Trip Always % Over Freq Trip: ###.#% Percent of rated power
PR Over Frequency Time Delay Always s Over Freq Delay: ##.#s
PR Under Frequency Trip Always % Under Freq Trip: ###.#% Percent of rated power
PR Under Frequency Time Delay Always s Under Freq Delay: ##.#s
PR Reverse Var Trip Always % Reverse VAR Trip: Percent of rated reactive power
###.#% (PR Loss Of Field)
PR Reverse Var Time Delay Always s Reverse VAR Delay:
##.#s
PR Over Current VR Trip Always % Over Current Trip: ###.#% Percent of maximum current
PR Over Current VR Time Delay Always s Over Current Delay: ##.#s
Breaker Trip To Shutdown Time Delay Always s Trip to Shtdwn Delay:
#####s
Synchronization Control
Voltage Match Window Always % Voltage Match Window: Percent of rated voltage
##.#%
Sync Frequency Window Always Hz Frequency Window: #.#Hz
Phase Match Window Always _ Phase Match Window:
##.#_
Dwell Time Always s Dwell Time: ##.#s
Fail To Sync Delay Always s Fail to Sync Time: ####s
Breaker Reclose Time Always s Reclose Delay: ##.#s
Breaker Close Attempts Always Max Close Attempts: ###
First On Close Delay Always s First On Delay: ##.#s
Circuit Breaker Current Fault Limit Always % CB Current Fault Limit: 10 = 1.0%
###.#%
Circuit Breaker Current Fault Delay Always s CB Current Fault Delay: 10 = 1.0 Sec
##.#s
Volts Hertz Okay Time Delay Always s Volts-Hz OK Delay: ##.#s
Sync Mode In Auto Always Sync Mode in Auto:
Invalid/Off/Passive/Check/
Active/Dead Field
Sync Mode In Run Always Sync Mode in Run:
Invalid/Off/Passive/Check/
Active/Dead Field
Circuit Breaker Phase Angle Fault Limit Always _ CB Phase Fault Limit:
##.#_
Circuit Breaker Phase Angle Fault Delay Always s CB Phase Fault Delay:
##.#s
Dead Bus Level Always % Dead Bus Level: ##.#%
Pickup Acceptable Voltage Window Always % Voltage OK Pickup: ##.#%
Dropout Acceptable Voltage Window Always % Voltage OK Dropout:
##.#%
Pickup Acceptable Frequency Window Always Hz Frequency OK Pickup:
##.#Hz
Dropout Acceptable Frequency Window Always Hz Frequency OK Dropout:
##.#Hz
Stand Alone Operation Always Stand Alone Mode: On/Off
PGen Baud Rate Always b/s PGEN Baud Rate:
OFF/9600 b/s/19200
b/s/38400 b/s/ 57600
b/s/115200 b/s
PGen Node Id None PGEN Node ID: ##
PGen Nodes Connected None PGEN Nodes Online: ##
PGen Nodes Disconnected None PGEN Nodes Offline: ##
Fail To Open Delay Always s Fail to Open Delay: ##s
Fail To Close Delay Always s Fail to Close Delay: ##s
Voltage Match Proportional Gain Always Voltage Match P Gain:
##.##
Voltage Match Integral Gain Always Voltage Match I Gain:
##.##
Voltage Match Derivative Gain Always Voltage Match D Gain:
##.##
Frequency Match Proportional Gain Always Freq Match P Gain: ##.##
Frequency Match Integral Gain Always Freq Match I Gain: ##.##
Frequency Match Derivative Gain Always Freq Match D Gain: ##.##

Phase Match Proportional Gain Always Phase Match P Gain:
##.##
Phase Match Integral Gain Always Phase Match I Gain:
##.##
Phase Match Derivative Gain Always Phase Match D Gain:
##.##
Generator Paralleling Breaker None
External Bias Inputs Enabled Always
Synchronization Metering
Sync Time Remaining None s Sync Time Remaining: (Sec x 10)
####s
Sync Dwell Time Remaining None s Dwell Time Remaining: (Sec x 10)
##.#s
Sync Status Generator V Hz OK None Volts-Hz OK: True/False Bit 0: Gen_VHz_OK
Sync Status Voltage Matched None Voltage Matched: Bit 1: Synch_V_Matched
True/False
Sync Status Frequency Matched None Frequency Matched: Bit 2: Synch_Freq_Matched
True/False
Sync Status Phase Matched None Phase Matched: Bit 3: Synch_Phase_Matched
True/False
Sync Check Matched Ok None In Sync: True/False
Real Power Load Sharing
Real Power Baseload Setpoint Always % 250 = 25.0%
Real Power Disconnect Level Always % kW Disconnect Level: 100 = 10.0% of rated kW
##.#%
Real Power Ramp Rate Always %/s kW Ramp Rate: ##.#%/s 50 = 5.0% of rated kW/Sec
Real Power Droop Slope Always %@FL 20 = 2.0 % of rated speed @
100% rated kW
Speed Bias None Speed Bias: ###.## 5000 = 50.00 Note: speed bias
is equal to
% speed x 10 (5000 --> 50.00 -->
+5% Voltage)
Load Enable Always Load Enabled: On/Off
Base Load Mode Always
System Load Control Always System Load Control:
On/Off
System Sync Control Always System Sync Control:
On/Off
Trims Enabled Always Trims Enabled: On/Off
Real Power Sharing Proportional Gain Always kW Sharing P Gain: ##.##
Real Power Sharing Integral Gain Always kW Sharing I Gain: ##.##
Real Power Sharing Derivative Gain Always kW Sharing D Gain: ##.##
Torque Sharing Proportional Gain Always
Torque Sharing Integral Gain Always
Torque Sharing Derivative Gain Always
Frequency Trim Proportional Gain Always Freq Trim P Gain: ##.##
Frequency Trim Integral Gain Always Freq Trim I Gain: ##.##
Frequency Trim Derivative Gain Always Freq Trim D Gain: ##.##
Real Power Baseload Proportional Gain Always
Real Power Baseload Integral Gain Always
Real Power Baseload Derivative Gain Always
System Real Load Control Proportional Gain Always
System Real Load Control Integral Gain Always
System Real Load Control Derivative Gain Always
Reactive Power Load Sharing
Reactive Power Baseload Setpoint Always % 600 = 60.0% Rated kVAR
Power Factor Setting Always 80 = 0.80 PF lagging,
--90 = 0.90 PF leading
Reactive Droop Slope Always %@FL 40 = 4.0% rated Volts @ 100%
rated KVAR
Voltage Bias None Voltage Bias: ###.## 5000 = 50.00 Note voltage bias
is equal to % voltage x 10 (5000
--> 50.00 --> +5% Voltage)
Var Control Mode Always
Reactive Power Sharing Proportional Gain Always kVAR Sharing P Gain:
##.##

Reactive Power Sharing Integral Gain Always kVAR Sharing I Gain:
##.##
Reactive Power Sharing Derivative Gain Always kVAR Sharing D Gain:
##.##
Reactive Power Load Sharing
Voltage Trim Proportional Gain Always Volt Trim P Gain: ##.##
Voltage Trim Integral Gain Always Volt Trim I Gain: ##.##
Voltage Trim Derivative Gain Always Volt Trim D Gain: ##.##
Reactive Power Baseload Proportional Gain Always
Reactive Power Baseload Integral Gain Always
Reactive Power Baseload Derivative Gain Always
Power Factor Baseload Proportional Gain Always
Power Factor Baseload Integral Gain Always
Power Factor Baseload Derivative Gain Always
System Reactive Power Control Proportional Gain Always
System Reactive Power Control Integral Gain Always
System Reactive Power Control Derivative Gain Always
System Power Factor Control Proportional Gain Always
System Power Factor Control Integral Gain Always
System Power Factor Control Derivative Gain Always
Generator Management
Gen Management Control Mode Always Gen Management Mode:
Invalid/Manual Fixed/
Run Time/Fuel Level
Gen Management Enabled Always Gen Management: On/Off
Gen Management Order Always Gen Management Order: Only editable if in Manual Mode
#
Gen Management Start Percent Always % Start Capacity: ###.#%
Gen Management Stop Percent Always % Stop Capacity: ###.#%
Gen Management Start Delay Always s Start Delay: ####s
Gen Management Stop Delay Always s Stop Delay: ####s
Gen Management Start Accumulator None Start Accumulator: #####
Gen Management Stop Accumulator None Stop Accumulator: #####
Gen Management Start KW None kW Start kW: #####kW
Gen Management Stop KW None kW Stop kW: #####kW
Gen Management Stable Delay Always s Stable Delay: ####s
Gen Management Run Time Threshold Always h Run Time Threshold: Only if in Run Time Management
###.#hrs
Gen Management Fuel Difference Threshold Always % Fuel Level Threshold: Only if in Fuel Level Management
##.#%
Gen Management Min Gens Online Always Minimum Gens Online: ##
Gen Management Min Load Shed Priority Always Min Loads Added: ##
Gen Management Stopped By Gen Mgmt None Stopped by Gen Mgmt:
True/False
Gen Management Total Bus Capacity None kW Total Bus Capacity:
#####kW
Modbus
Modbus Baud Rate Always b/s Modbus Baud Rate: Mpac DM: 0 = 9600;
OFF/9600 b/s/19200 1 = 19200; 3 = 57600
b/s/38400 b/s/ 57600
b/s/115200 b/s
Modbus Slave Address Always Modbus Address: ##
Programmable Analog Resistive Input 100
Analog Resistive Input Board Number None I/O Board Number: X Indicates board number this IO
point is located on
Analog Resistive Input Io Number None Indicates the point number, of
configuration
Analog Resistive Input Metered Value None Measurement: ###.# The current value of the input
function ID)
Analog Resistive Input Metered Relative Value None The value of the input relative to

Analog Resistive Input Enabled Always Input Enabled: On/Off Indicates whether this input is
enabled
Analog Resistive Input Switch Logic Always The type of switch that is
Analog Resistive Input Function Always Indicates the functionality of this
IO point
Analog Resistive Input Protectives Enabled Always Low Warning: On/Off Indicates which of the protectives
Analog Resistive Input Event Always The parameter ID defining the
Analog Resistive Input Sensor Always Sensor Type: The type of sensor connected to
the input
Analog Resistive Input Low Protective Inhibit Delay Always s Low Protect Inhibit: ##s The time, after crank disconnect,
Analog Resistive Input High Protective Inhibit Delay Always s High Protect Inhibit: ##s protectives are monitored even
Analog Resistive Input Normal Delay Always s The time that the input must be
considered good
within its warning operating range
indicated
Analog Resistive Input Critically Low Warning Delay Always s The time that the input must be
Analog Resistive Input High Warning Delay Always s High Warning Delay: ##s
Analog Resistive Input Critically High Warning Delay Always s indicated
Analog Resistive Input High Shutdown Delay Always s High Shutdown Delay: ##s range before a shutdown
Analog Resistive Input Low Warning Limit Always Low Warning Limit: The limit that the input must drop
Analog Resistive Input Low Shutdown Limit Always Low Shutdown Limit: The limit that the input must drop
operating range
Analog Resistive Input High Warning Limit Always High Warning Limit: The limit that the input must
Analog Resistive Input High Shutdown Limit Always High Shutdown Limit: The limit that the input must
operating range
Analog Resistive Input Deadband Always A percentage of the parameter
ranges
Analog Resistive Input Relative Upper Range Limit Always Indicates the limit in raw form
shorted high
Analog Resistive Input Relative Lower Range Limit Always Indicates the limit in raw form
shorted low
Analog Resistive Input Relative Range Limit Always Specifies how much the raw
Deadband value needs to change by before
Analog Resistive Input Relative Range High Limit Always s Specifies what the inhibit time
Analog Resistive Input Relative Range Low Limit Always s Specifies what the inhibit time

Analog Resistive Input Relative Range Limit Delay Always s Specifies what the debounce
inhibit time is met
Analog Resistive Input Description Always Description: A user-defined description of this
IO
point is located on
configuration
function ID)
enabled
IO point
the input
considered good
Analog Resistive Input Critically Low Warning Delay Always s before a warning protective is
indicated
Analog Resistive Input High Warning Delay Always s High Warning Delay: ##s The time that the input must be
Analog Resistive Input Critically High Warning Delay Always s before a warning protective is
indicated
operating range
operating range

ranges
shorted high
shorted low
inhibit time is met
IO
point is located on
configuration
function ID)
enabled
IO point
the input
considered good
Analog Resistive Input Critically Low Warning Delay Always s
Analog Resistive Input High Warning Delay Always s High Warning Delay: ##s indicated
Analog Resistive Input Critically High Warning Delay Always s The time that the input must be
indicated

range before a shutdown
Analog Resistive Input High Shutdown Delay Always s High Shutdown Delay: ##s The time that the input must be
range before a shutdown
operating range
operating range
ranges
shorted high
shorted low
inhibit time is met
IO
point is located on
configuration
function ID)
enabled
IO point
the input

considered good
indicated
Analog Resistive Input Critically High Warning Delay Always s
operating range
operating range
ranges
shorted high
shorted low
inhibit time is met
IO
point is located on
configuration
function ID)
enabled

IO point
the input
considered good
Analog Resistive Input Critically Low Warning Delay Always s before a warning protective is
indicated
Analog Resistive Input High Warning Delay Always s High Warning Delay: ##s The time that the input must be
Analog Resistive Input Critically High Warning Delay Always s before a warning protective is
indicated
operating range
operating range
ranges
shorted high
shorted low
inhibit time is met

IO
point is located on
configuration
function ID)
enabled
IO point
the input
considered good
indicated
Analog Resistive Input Critically High Warning Delay Always s
operating range
operating range
ranges
shorted high
shorted low

inhibit time is met
IO
Programmable Analog Voltage Input 106
point is located on
configuration
function ID)
enabled
IO point
the input
considered good
indicated
operating range
Analog Voltage Input Critically High Warning Limit Always operating range

operating range
ranges
shorted high
shorted low
inhibit time is met
IO
point is located on
configuration
function ID)
enabled
IO point
the input
considered good
indicated

operating range
operating range
ranges
shorted high
shorted low
inhibit time is met
IO
point is located on
configuration
function ID)
enabled
IO point
the input

considered good
indicated
operating range
operating range
ranges
shorted high
shorted low
inhibit time is met
IO
Programmable Digital Input 109
point is located on
configuration
function ID)
enabled
non-activated state
IO point

IO point
point is located on
configuration
function ID)
enabled
non-activated state
IO point
IO point
point is located on
configuration
function ID)
enabled
non-activated state
IO point
IO point
point is located on
configuration
function ID)
enabled
non-activated state
IO point

IO point
point is located on
configuration
function ID)
enabled
non-activated state
IO point
IO point
point is located on
configuration
function ID)
enabled
non-activated state
IO point
IO point
Programmable Digital Output 115
point is located on
Digital Output Io Number None Indicates the point number, of
configuration
Digital Output Status None The value of the input relative to
Digital Output Enabled Always Enabled: On/Off Indicates whether this input is
enabled
Digital Output Logic Always Logic: Active On/Active Indicates whether shutdown is
Digital Output Function Always Function: Indicates the functionality of this
IO point
Digital Output Event Always Event: The parameter ID defining the

Digital Output Description Always Description: A user-defined description of this
IO point.
point is located on
configuration
enabled
IO point
IO point.
point is located on
configuration
enabled
IO point
IO point.
point is located on
configuration
enabled
IO point
IO point.
Special Parameters
Profile
Saved Date
File Version
Address
Password
* Some functions require optional input sensors or are engine ECM dependent on some generator set models.
[ ECM inputs are engine manufacturer dependent.

Section 3 Troubleshooting
This section contains generator set troubleshooting, Corrective action and testing often require knowledge of
diagnostic, and repair information. electrical and electronic circuits. To avoid additional
problems caused by incorrect repairs, have an
Use the following charts to diagnose and correct authorized service distributor/dealer perform service.
common problems. First check for simple causes such
as a dead engine starting battery or an open circuit NOTICE
breaker. The table groups generator set faults and
Fuse replacement. Replace fuses with fuses of the same
suggests likely causes and remedies. The table also
ampere rating and type (for example: 3AB or 314, ceramic).
refers you to more detailed information including Do not substitute clear glass-type fuses for ceramic fuses.
sections of this manual, the generator set operation Refer to the wiring diagram when the ampere rating is
manual (O/M), the generator set installation manual unknown or questionable.
(I/M), and the engine service manual (Engine S/M) to
correct the indicated problem. Maintain a record of repairs and adjustments performed
on the equipment. If the procedures in this manual do
Note: The paralleling contactor behavior matches the not explain how to correct the problem, contact an
paralleling circuit breaker behavior for all the authorized distributor/dealer. Use the record to help
listed troubleshooting sequences, but the describe the problem and repairs or adjustments made
contactor is controlled by a single maintained to the equipment.
output and defaults to open, so the
troubleshooting procedure for the contactor will
be slightly different.
TP-6929 1/15 Section 3 Troubleshooting 51

52
3.1 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*
Controller and Emergency Stop Switch
x x Controller circuit board(s) inoperative. Replace the controller assembly. Gen. S/M
x x Controller circuit board(s) wiring fault. Check the wiring. W/D
x Controller fault. Troubleshoot the controller.[ Gen. S/M
Controller fuse blown. Check for continuity across the fuse. If fuse is blown, W/D
x x x troubleshoot controller wiring and replace the circuit
board.[
Controller master control buttons Replace the controller master control button circuit —
x
inoperative. board.
Controller master control button in the Press the controller master control RUN or AUTO Gen. O/M
x
OFF/RESET mode. button.
Engine start circuit open. Press the controller master control RUN button to test Gen. O/M, W/D,
x the generator set. Troubleshoot the auto start circuit Gen. S/M
and the time delays.
Emergency stop switch activated, if Reset the emergency stop switch. Gen. O/M
x x
equipped.
Voltage regulator inoperative. Replace the junction box sensing fuses. If the fuse W/D, Gen. S/M
x x
blows again, troubleshoot the controller.
x Controller firmware error. Review the controller display troubleshooting chart. Gen. O/M,
SiteTech 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
[ Have an authorized service distributor/dealer perform this service.
TP-6929 1/15
Trouble Symptoms
TP-6929 1/15
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
Alternator
AC output circuit breaker open. Reset the breaker and check for AC voltage at the —
x
generator set side of the circuit breaker.
Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO ATS O/M
x
position. position.
Transfer switch fails to transfer load. Move the ATS test switch to the AUTO position. ATS O/M, ATS
x
Troubleshoot the transfer circuit and time delays. S/M
Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M, W/D
x
field open.
Main field (rotor) inoperative (open or Test and/or replace the rotor.[ Gen. S/M
x
grounded).
x Stator inoperative (open or grounded). Test and/or replace the stator.[ Gen. S/M
x Vibration excessive. Tighten loose components.[ —
x x Voltage regulator settings incorrect. Adjust voltage regulator.[ SiteTech O/M
Electrical System (DC circuits)
Battery connections loose, corroded, Verify that the battery connections are correct, clean, Gen. O/M
x x
or incorrect. and tight.
Battery weak or dead. Recharge or replace the battery. The spec sheet Gen. O/M, S/S
x x
provides recommended battery CCA rating.
x x Starter/starter solenoid inoperative. Replace the starter or starter solenoid. Eng. S/M
Engine harness connector(s) not Disconnect the engine harness connector(s) then W/D
x x
locked tight. reconnect it to the controller.
x Fault shutdown. Reset the fault switches and troubleshoot the controller. Gen. O/M
53
54
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
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
Engine overload. Reduce the electrical load. See the generator set spec S/S
x x x x x
sheet for wattage specifications.
Exhaust system leak. Inspect the exhaust system. Replace the inoperative I/M
x
exhaust system components.[
Exhaust system not securely installed. Inspect the exhaust system. Tighten the loose exhaust I/M
x
system components.[
x x x x Governor inoperative. Adjust the governor.[ Eng. S/M
x x Valve clearance incorrect. Adjust the valves.[ Eng. O/M
x Vibration excessive. Tighten all loose hardware. —
Engine ECM and/or sensors. Troubleshoot the engine ECM and/or sensors. Eng. O/M,
x x x x x
Eng. S/M
Cooling System
x x Air openings clogged. Clean the air openings. —
High temperature shutdown. Allow the engine to cool down. Then troubleshoot the Gen. O/M,
x
cooling system. Eng. O/M
Low coolant level shutdown, if Restore the coolant to normal operating level. Eng. O/M
x
equipped.
x Coolant level low. Restore the coolant to normal operating level. Eng. O/M
Cooling water pump inoperative. Tighten or replace the belt. Replace the water pump. Eng. O/M or
x
Eng. S/M
x Thermostat inoperative. Replace the thermostat. Eng. S/M
TP-6929 1/15
Trouble Symptoms
TP-6929 1/15
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
Fuel System
x x Fuel tank empty or fuel valve shut off. Add fuel and move the fuel valve to the ON position. —
x x x Air in fuel system (diesel only). Bleed the diesel fuel system. Eng. O/M
x x x x Fuel filter restriction. Clean or replace the fuel filter. Eng. O/M
Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel Eng. S/M
x x x
(diesel only). injector.[
x Fuel solenoid inoperative Troubleshoot the fuel solenoid.[ Eng. S/M
Fuel injection timing out of adjustment Adjust the fuel injection timing.[ Eng. S/M
x x x x
(diesel only).
Fuel feed or injection pump inoperative Rebuild or replace the injection pump.[ Eng. S/M
x x x
(diesel only).
Engine Lubrication System
Oil level low. Restore the oil level. Inspect the generator set for oil Eng. O/M
x x x
leaks.
x Low oil pressure shutdown. Check the oil level. Eng. O/M
Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the Eng. O/M
x x x x
ambient temperature. operating climate.
55
56
3.2 Controller Display Troubleshooting Chart
Section or
Publication
Trouble Symptoms Probable Causes Recommended Actions Reference*
Controller Display and Voltage Regulator
Display is black. No/low battery charge. Recharge/replace battery. Gen. O/M
Display shows single segment. Low battery voltage. Recharge battery. Gen. O/M
Display shows an error message. Controller firmware or pushbutton/ Review the Error Message section. Gen. O/M
rotary selector dial entry error.
Display locks up. No/low battery charge. Recharge/replace battery. Gen. O/M
Output voltage ramps. Defective exciter winding Troubleshoot alternator components.[ Gen. S/M
Output voltage unstable. Voltage regulation calibration incorrect Readjust voltage regulation.[ SiteTech O/M
Unable to change voltage and current calibrations. Calibration not enabled. Enable calibration in Generator Metering section. Gen. O/M
Unable to find volt select menu. Volt select not enabled. Enable volt select in SiteTech. SiteTech 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
TP-6929 1/15
3.3 Paralleling Troubleshooting—When Circuit Breaker Does Not Close to Bus
3.3.1 Faults Not Shown
Step Potential Cause Explanation Troubleshooting
TP-6929 1/15
1 PGEN communication The controller must have seen PGEN communication with at least one other In Controller Config --> Communication Setup, verify the PGEN Nodes Online
not operational node at some time since the last power cycle event before it will close the is at least 2. If so, continue troubleshooting at Step 8 otherwise, continue on
circuit breaker. to Step 2.
2 Single generator set There is only one generator set on site, but the controller is expecting to see Configure a digital input to Standalone mode and assert it, or set
application PGEN communication. The controller supports this scenario if the controller is Standalone mode in Kohler SiteTecht. Note, Standalone mode should
configured in Standalone mode. Standalone mode can be set using the only be asserted if there is only one generator set at the site.
standalone input to the controller or in Kohler SiteTecht.
3 PGEN wiring not PGEN communicates over an RS-485 connection. RS-485 requires that the Verify wiring, all PGEN + connections should be connected with daisy-chain
connected correctly network be connected in a daisy-chain configuration, terminated at 120 Ohms wire (Belden #9841 or equivalent). Verify terminations are at the end of the
at either end of the network and that positive (B) and negative (A) polarity be network. Verify that there are no unintentional or loose connections.
maintained.
4 Baud rate One of the controllers on the network is attempting to communicate at a In Controller Config --> Communication Setup, verify that the baud rate of all
misconfigured different baud rate than the other controllers. This results in collisions on the generator sets on the network matches. Default is 57,600 baud.
communication bus and incorrect interpretation of the data.
5 Interference The PGEN network is seeing noise which makes it difficult for the generator set Verify that PGEN network uses Belden #9841 or equivalent. Verify that the
controllers to communicate. shield drain for the cable is grounded at only one end.
6 Short circuit in The RS-485 communication wires are short-circuited together. In Controller Config --> Communication Setup, verify the PGEN Node ID is
communication wiring less than 16. If not, check the PGEN wiring for short circuits. Otherwise,
continue troubleshooting to Step 7.
7 Intermittent connection Although the generator set controllers can occasionally communicate, the It is not uncommon for small communications wire to not connect directly to
in PGEN wiring connection is unreliable. This can be caused by a short or open circuit. a terminal block well. Verify there are no loose wiring connections or
“whiskers” at the PGEN terminal blocks. Ring or spade connectors are
preferred for terminal block connections.
8 Unable to establish The generator set is trying to close to a dead bus but it is not receiving Cycle power on all generator sets.
first-on lock permission from one of the other nodes to allow it to do so. This can occur if
one of the other nodes has seen a node removed from the network.
3.3.2 Faults Shown

Fault: System Voltage Mismatch Between Generator Sets
1 System voltage is not One of the controllers on the network is configured differently than the other Verify the system voltage of all the generator sets match the requirements
equivalent controllers. This will inhibit any of the generator sets from closing to the bus. of the site.
Fault: System Frequency Mismatch Between Generator Sets
1 System frequency is One of the controllers on the network is configured differently than the other Verify the system frequency of all the generator sets match the
not equivalent controllers. This will inhibit any of the generator sets from closing to the bus. requirements of the site.
Fault: Phase Connection Mismatch Between Generator Sets
1 Phase connection is One of the controllers on the network is configured differently than the other Verify the phase connection of all the generator sets match the
not equivalent controllers. This will inhibit any of the generator sets from closing to the bus. requirements of the site.
Fault: Live Bus Sensed When Dead Bus Expected
1 Bus is considered to The controller is measuring voltage on the paralleling bus. This will inhibit the Check bus for residual voltage (sometimes induced by large transformers or
be live circuit breaker from closing. motors). Possibly, adjust the Dead Bus Threshold to accommodate the
residual voltage.
2 Bus sensing is not The controller may see voltage on the paralleling bus when the generator set is Verify the bus sensing wiring is connected to the load side of the
connected operating and the bus sensing is disconnected. motor-operated circuit breaker for this generator set.
57
58
Fault: Close Attempt
Fault: Fail to Close
1 Circuit breaker is The controller is attempting to close the circuit breaker but the circuit breaker is Watch the ready flag on the motor operator of the circuit breaker. If it
unable to close not closing. indicates not ready when the engine is stopped and toggles to the ready
state when the generator set is trying to close the circuit breaker, the trip
coil is acting correctly. Continue at Step 5 otherwise, continue on to Step 2.
2 Trip is not removed The controller is attempting to close the circuit breaker but the circuit breaker is If the ready flag of the motor operator indicates ready when the engine is
from the circuit breaker not closing because the trip coil is still energized. stopped, continue at Step 3 otherwise, continue on to Step 4.
3 CB trip relay is wired The controller is expecting that the trip on the circuit breaker is a Verify the CB trip relay is wired to hold a trip on the circuit breaker when the
as normally open normally-closed contact. This is intentional as it holds a trip on the circuit relay is not energized.
breaker if the controller is removed.
4 Incorrect wiring The CB trip relay is operating correctly but the trip coil on the circuit breaker is Verify the wiring to the circuit breaker.
between the CB trip remaining energized. This could be due to incorrect wiring between the
relay and the trip coil generator set controller and the circuit breaker.
on the circuit breaker
5 Close is not applied to The circuit breaker trip is removed but the controller is not able to close the Verify the wiring between the generator set controller and the circuit breaker
the circuit breaker circuit breaker. close coil. Check the close coil to ensure that it is not defective.
6 Circuit breaker is not The circuit breaker is receiving the signal to close but the energizing spring is Verify the motor operator is receiving voltage at the appropriate contacts to
charged not charged. allow it to wind the spring.
7 Circuit breaker is not The 24V electronics on the circuit breaker require an external 24V source on a Verify the 24V input which exists on paralleling generator sets is receiving
powered 12V generator set. 24VDC in the correct polarity.
8 Wiring to power is not There is no voltage to the CB close relay on this circuit breaker. Connect the supply to the CB close relay to either 24V from wire #70 or an
complete external 24VDC supply (with battery storage).
9 Circuit breaker status The circuit breaker closes but the controller does not see a change in status. Verify the wiring on the circuit breaker to ensure that it is connected
feedback is not valid, The controller cannot see the bus is energized as the bus sensing is not correctly. Verify bus wiring for all nodes. Verify the generator set output is
no bus sensing connected correctly on any generator sets on the network. connected to the line side of the generator set circuit breaker.
Fault: CB Status
Warning: Bus Sensing Not Connected
feedback is not valid, The controller cannot see the bus is energized as the bus sensing is not correctly. Verify bus wiring for this generator set.
no bus sensing connected correctly on this generator set, but another generator set is
connected.
Fault: CB Status
feedback is not valid The controller sees the bus is now live. correctly.
TP-6929 1/15
3.4 Paralleling Troubleshooting—When Breaker Does Close to Bus
3.4.1 Faults Shown
TP-6929 1/15
Fault: Close Attempt
Fault: Fail to Close
feedback is not valid, The controller cannot see the bus is energized as the bus sensing is not correctly. Verify bus wiring for all nodes. Verify the generator set output is
no bus sensing connected correctly on any generator sets on the network. connected to the line side of the generator set circuit breaker.
Fault: CB Status
feedback is not The controller sees the bus is now live. correctly.
connected
2 Circuit breaker status The controller sees the circuit breaker is closed even when it is not trying to Verify connection of the breaker status wiring at the circuit breaker.
is short circuited open it.
3 Circuit breaker status The controller sees open status for the circuit breaker after telling it to close, The controller is expecting the circuit breaker status to be an “A” contact.
feedback is connected closed status after telling it to open. Verify the circuit breaker auxiliary contacts are either:
to the wrong contacts 11 and 14
21 and 24
31 and 34 or
41 and 44.
4 Circuit breaker status The circuit breaker status indicated that it closed when it was triggered to close Verify the circuit breaker status input to the controller is connected directly
feedback is connected but it did not indicate that it was open when the circuit breaker opened. This to an auxiliary contact on the circuit breaker.
to a latching contact fault will only occur if the bus sensing is connected correctly (the controller sees
the voltage go to 0 when the circuit breaker is triggered to open).
Fault: Bus Phase Rotation Mismatch
1 All of the bus sensing The bus sensing wires must be connected to phase A, phase B, and phase C Verify the bus metering connections.
wires are incorrectly of the bus. If any two connections are reversed, the controller can detect the
connected reversed connections. This fault will only occur if all three wires are incorrectly
connected.
2 The phase connections The power leads from the generator set to the paralleling circuit breaker must Verify the output cable connections.
on the paralleling be connected consistently. Phase A from the generator set must go to phase A
circuit breaker are of the line side of the paralleling (motor operated) circuit breaker, phase B from
inconsistent with the the generator set to phase B of the circuit breaker and phase C of the generator
generator set set to phase C of the circuit breaker.
3 Generator set sensing The controller measurement leads are not connected to the appropriate output Verify the sensing leads from the controller are connected to the
is connected phases or the phases are incorrectly labeled. appropriate output leads from the generator. L1 should connect to phase A,
incorrectly L2 to phase B, L3 to phase C, L0 to neutral.
4 Circuit breaker to bus In applications where the bus sensing is taken from a location other than the load Verify the cable connections from the paralleling breaker to the paralleling
wiring is inconsistent side of the paralleling circuit breaker, it is possible to connect the wiring bus.
incorrectly between the load side of the output circuit breaker and the paralleling
bus.
Fault: Bus Voltage Amplitude Mismatch--Phase A
1 The phase A voltage of The voltage measured on the bus sensing for phase A does not match the Verify the bus sensing wire for phase A is connected to phase A of the load
the bus does not voltage measured on phase A of the generator set. side of the paralleling breaker and there are no breaks in the wire.
match the generator
set
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Fault: Bus Voltage Amplitude Mismatch--Phase B
1 The phase B voltage of The voltage measured on the bus sensing for phase B does not match the Verify the bus sensing wire for phase B is connected to phase B of the load
the bus does not voltage measured on phase B of the generator set. side of the paralleling circuit breaker and there are no breaks in the wire.
match the generator
set
Fault: Bus Voltage Amplitude Mismatch--Phase C
1 The phase C voltage of The voltage measured on the bus sensing for phase C does not match the Verify the bus sensing wire for phase C is connected to phase C of the load
the bus does not voltage measured on phase C of the generator set. side of the paralleling circuit breaker and there are no breaks in the wire.
match the generator
set
Fault: Bus Voltage Amplitude Mismatch
1 The bus metering is The bus metering is not connected to the appropriate lugs of the load side of Verify the bus sensing wire for all three phases is connected to the
not connected correctly the paralleling circuit breaker (but there is some voltage present). appropriate lugs on the load side of the paralleling circuit breaker and there
are no breaks in any of the wires.
2 The generator set The generator set metering is not connected to the output of the generator set. Verify the generator set metering is sensed at the output of the generator
metering is not sets. A common mistake is to connect the metering to the center tap
connected correctly voltages V7, V8, V9.
Fault: Phase Angle Mismatch
1 All of the bus sensing The bus sensing wires must be connected to phase A, phase B, and phase C Verify the bus metering connections.
wires are incorrectly of the bus. If any two connections are reversed, the controller can detect the
connected reversed connections. This fault will only occur if all three wires are incorrectly
connected.
2 The phase connections The power leads from the generator set to the paralleling circuit breaker must Verify the output cable connections.
on the paralleling be connected consistently. Phase A from the generator set must go to phase A
circuit breaker are of the line side of the paralleling (motor operated) circuit breaker, phase B from
inconsistent with the the generator set to phase B of the breaker, and phase C of the generator set to
generator set phase C of the circuit breaker.
3 Generator set sensing The controller measurement leads are not connected to the appropriate output Verify sensing leads from the controller are connected to the appropriate
is connected phases or the phases are incorrectly labeled. output leads from the generator set. L1 should connect to phase A, L2 to
incorrectly phase B, L3 to phase C, L0 to neutral.
4 Circuit breaker to bus In applications where the bus sensing is taken from a location other than the Verify cable connections from the paralleling circuit breaker to the
wiring is inconsistent load side of the paralleling circuit breaker, it is possible to connect the wiring paralleling bus.
incorrectly between the load side of the output circuit breaker and the
paralleling bus.
Fault: Bus Frequency Mismatch
1 Abnormal condition Bus frequency is not similar to generator set frequency with circuit breaker Verify bus metering is connected correctly. Reset the controller.
closed.
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Fault: Bus Sensing Phases A and B are Reversed
1 The bus sensing for Phase angle from generator set to bus is about 180_ and bus rotation is Verify wiring between bus sensing inputs and load side of paralleling circuit
phase A is connected backwards. breaker.
TP-6929 1/15
to phase B of the
paralleling bus and
vice versa
2 The wiring between the Phase angle from generator set to bus is about 180_ and bus rotation is Verify wiring between generator set and paralleling circuit breaker.
generator set and the backwards.
paralleling circuit
breaker is incorrect
3 The generator set Phase angle from generator set to bus is about 180_ and bus rotation is Verify metering connections on the generator set. L1 should connect to the
metering is not backwards. phase A output lead. L2 to phase B, L3 to phase C, L0 to neutral.
connected correctly
Fault: Bus Sensing Phases B and C are Reversed
1 The bus sensing for Phase angle from generator set to bus is about --120_ and bus rotation is Verify wiring between bus sensing inputs and load side of paralleling circuit
phase B is connected backwards. breaker.
to phase C of the
paralleling bus and
vice versa
2 The wiring between the Phase angle from generator set to bus is about --120_ and bus rotation is Verify wiring between generator set and paralleling circuit breaker.
paralleling circuit
3 The generator set Phase angle from generator set to bus is about --120_ and bus rotation is Verify metering connections on the generator set. L1 should connect to the
connected correctly
Fault: Bus Sensing Phases C and A are Reversed
1 The bus sensing for Phase angle from generator set to bus is about 120_ and bus rotation is Verify wiring between bus sensing inputs and load side of paralleling circuit
phase A is connected backwards. breaker.
to phase C of the
paralleling bus and
vice versa
2 The wiring between the Phase angle from generator set to bus is about 120_ and bus rotation is Verify wiring between generator set and paralleling circuit breaker.
paralleling circuit
3 The generator set Phase angle from generator set to bus is about 120_ and bus rotation is Verify metering connections on the generator set. L1 should connect to the
connected correctly
Fault: Bus Sensing Not Connected
1 No wires connect the Wiring not connected between load side of the paralleling circuit breaker and Verify that the bus sensing is connected.
bus sensing on the the bus metering.
generator set to the
load side of the
paralleling circuit
breaker
2 No leads connect the The leads connecting the output of the generator set to the paralleling circuit Verify that the leads connecting the generator set to the paralleling circuit
generator set output to breaker are not connected. breaker are connected.
the line side of the
paralleling circuit
breaker
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3 The line circuit breaker The line circuit breaker (at the generator set) is open, disconnecting the output Verify that the line circuit breaker is closed.
is open from the generator set from the line side of the paralleling circuit breaker.
Fault: Bus Sensing Connected to Generator Side of Circuit Breaker
1 Bus metering is The controller sees the bus voltage always matches the generator set voltage, Verify the bus metering is connected on the load side of the paralleling
connected to the even when the circuit breaker contacts indicate that the circuit breaker is open. circuit breaker.
wrong side of the
paralleling circuit
breaker
2 Circuit breaker is The controller sees that the bus voltage always matches the generator set Verify the paralleling circuit breaker control wiring is connected correctly
closed and status voltage, even when the circuit breaker contacts indicate that the circuit breaker and the status feedback is connected to an “A” contact.
feedback is not is open.
connected
Fault: Failure to Open
1 Wiring between CB trip The CB trip relay is releasing, but the coil in the circuit breaker is not Verify wiring to the trip coil (A4) is connected correctly.
relay and trip coil is not energizing, hence the circuit breaker is not opening.
connected
2 CB trip relay is not The CB trip relay is releasing, but there is no voltage to apply to the trip coil. Verify the CB trip relay has a 24VDC supply which is common to the CB
receiving 24V power This is most likely to occur when the generator set has a 12V battery and there close relay and charge motor.
is an external battery bank to operate the circuit breaker.
TP-6929 1/15
3.5 Paralleling Troubleshooting—When Running in AUTO
3.5.1 Faults Shown
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Fault: Generator Set Phase Rotation Mismatch
1 This generator set is The controller has validated that the bus metering is accurate relative to this Verify wiring between this generator set and the paralleling circuit breaker. It
wired with the opposite generator set, if the bus phase rotation is backwards to the generator set, the may be necessary to reverse two phases between the generator set and
phase rotation of all phase rotation must really be different. the paralleling circuit breaker and then to reverse the sensing at the bus to
the other generator match. This generator set should be started and closed to a dead bus again
sets on the paralleling to validate the changes.
bus
2 The wiring between the Voltage from other generator sets comes into this generator set as incorrect Verify wiring between the paralleling circuit breaker and the paralleling bus.
paralleling circuit phase rotation because the wiring connections to the paralleling bus are It may be necessary to reverse the connection of two of the leads. This
breaker and the reversed, even though the rotation of the other generator sets is identical to the generator set should be started and closed to a dead bus again to validate
paralleling bus is rotation of this generator set. the changes.
incorrectly connected
(two phases are
reversed)
3 The generator set Voltage from the other generator set comes into this generator set as incorrect Verify wiring between the paralleling circuit breaker and the paralleling bus
which is connected to phase rotation because the wiring connections from the other generator set to of the other generator set. It may be necessary to reverse two phases
the paralleling bus has the paralleling bus are reversed, even though the rotation of the other generator between the paralleling circuit breaker and the paralleling bus on the other
the opposite phase sets is identical to the rotation of this generator set. generator set. The other generator set should be started and closed to a
rotation of this dead bus again to validate the changes.
generator set and all
others
Fault: Dead Bus Sensed When Live Bus Expected
1 The wiring was not This generator set controller observed accurate bus voltage when it closed the Verify wiring between the paralleling circuit breaker and the paralleling bus
connected between the circuit breaker, the other generator set controller did the same, but the bus of of this generator set .
load side of the this generator set is not connected to the bus of the other generator set. The
paralleling circuit other generator set is energizing the load, this generator set cannot energize
breaker for this the load as there is a disconnected wiring between this generator set and the
generator set and the paralleling bus.
paralleling bus
2 The wiring was not This generator set controller observed accurate bus voltage when it closed the Verify wiring between the paralleling circuit breaker and the paralleling bus
connected between the circuit breaker, the other generator set controller did the same, but the bus of of the other generator set.
load side of the this generator set is not connected to the bus of the other generator set. The
paralleling circuit other generator set is not energizing the load because it is not connected to
breaker for the other it—this generator set may be able to energize the load, but there is no simple
generator set and the way of telling this without connecting the output of the other generator set.
paralleling bus
Fault: Bus Voltage Out of Spec
1 The generator sets When the generator sets which are supplying a load are overloaded, their Verify the load requirements are met by a single generator set. If not, it may
which are connected to engine speed will decrease, resulting in a decrease in output voltage. be necessary to connect several low priority loads to load shed outputs
the paralleling bus are Sometimes this decrease in output voltage is sufficient to allow the generator from the paralleling generator sets to avoid overloading a single generator
overloaded sets to recover. set.
2 Excessive cable Although a single generator set can handle the load, the cables which connect Increase wire size on the generator set connection leads.
lengths from generator the generator set to the paralleling bus are too long or too small of gauge,
sets to paralleling bus resulting in insufficient bus voltage.
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Fault: Bus Voltage Out of Spec
2 Excessive cable Although a single generator set can handle the load, the cables which connect Increase wire size on the generator set connection leads.
lengths from generator the generator set to the paralleling bus are too long or too small of gauge,
sets to paralleling bus resulting in insufficient bus voltage.
Fault: Bus Frequency Out of Spec
Fault: Failure to Synchronize
1 Varying load Heavy variations in the load on a generator set will cause the speed of the Adjustment of synchronizing dwell time or synchronizing gains may improve
requirements drive generator set to vary significantly. It can be difficult to synchronize with a ability to synchronize.
generator set generator set with continuously changing frequency.
frequency unstable
2 Fuel variations or other When the frequency regulation is impeded by atmospheric conditions or fuel It may be necessary to adjust the synchronizing gains.
environmental factors quality, the ability to synchronize may be affected. Not only is the bus varying
cause the generator more than normal, but it is more difficult for the generator set to control speed
set frequency while synching.
regulation to suffer
3 Different sized units or The factory synchronizing gains were calibrated for equal-sized units. The It may be necessary to adjust the synchronizing gains.
units of different fuel response of a large unit to a small one is slightly different than two small units. A
types diesel generator set has significantly better frequency regulation than a natural gas
generator set.
Fault: Generator Set is Disabled Due to High Voltage
1 Metering calibration All the generator sets on the paralleling bus attempt to control to the same Verify the controller is measuring voltage accurately. If not, re-calibrate it.
issue voltage. If one has incorrect calibration, it may see this voltage as a much
higher level than the other generator sets, resulting in a protective relay trip.
2 Voltage drop on If the generator set is sourcing high current through too small of output leads, Install oversized connecting leads for the generator set to minimize voltage
generator set the voltage drop in these cables may require the generator set to run at an drop between the generator set and the paralleling bus.
connection leads increased voltage to supply the necessary current to the paralleling bus.
3 Attempting to operate The speed bias and voltage bias control real and reactive load in base-load Install contacts in series with the base-load mode input to the controller
a generator set in mode against a source with a nearly constant frequency and voltage (such as a which are disconnected when the utility source is disconnected from the
base-load mode while utility source). If the generator set is disconnected from the utility source, the paralleling bus.
it is connected to a speed and voltage will deviate to either extreme of the bias range, depending
variable load on the target load and the actual load.
Fault: Generator Set is Disabled Due to Low Voltage
1 Metering calibration All the generator sets on the paralleling bus attempt to control to the same Verify the controller is measuring voltage accurately. If not, re-calibrate it.
issue voltage. If one has incorrect calibration, it may see this voltage as a much lower
level than the other generator sets, resulting in a protective relay trip.
TP-6929 1/15
Fault: Generator Set is Disabled Due to High Frequency
TP-6929 1/15
Fault: Generator Set is Disabled Due to Low Frequency
Fault: Generator Set is Disabled Due to Over Power
1 Continuous overload The generator set circuit breaker will trip to protect the generator set from Ensure that the load is low enough for a single generator set to support it.
damage due to excessive loads.
Fault: Generator Set is Disabled Due to Reverse Power
1 Loss of fuel pressure The generator set circuit breaker will trip to prevent generator set operation. Ensure that the generator set has sufficient fuel to support load. Connect a
Otherwise, power could be absorbed from other generator sets causing fuel level sensor and place Generator Management in Fuel Level
potential damage to the fuel system by operating without lubrication. Equalization mode.
2 Quick ramp rate The real power may overshoot when in a real power control situation such as It may be necessary to adjust the load control gains.
settings base load or system control.
3 Different sized units or The real power may overshoot when in a real power control situation such as a It may be necessary to adjust the kW load sharing gains.
units of different fuel load ramp or a quickly changing customer load.
types.
4 Different engine speed Setting the Engine Speed Adjust parameter high on a generator set will result in Set the engine speed adjustment similarly on all generator sets.
adjust settings that generator set providing more real power than the other generator sets. It is
possible to drive the other generator sets offline in light loading conditions.
Fault: Generator Set is Disabled Due to Over Current
1 Excessive reactive The generator set circuit breaker will trip to prevent the generator set from Ensure that the load is low enough for a single generator set to support it.
load damage due to excessive stator current. Note, the controller also has a
heat-model-based alternator protection algorithm (which will shut the generator
set down).
Fault: Generator Set is Disabled Due to Reverse VARs
1 Different sized units The reactive power may overshoot when in a power control situation such as a It may be necessary to adjust the kVAR load sharing gains.
load ramp or a quickly changing customer load.
2 Different automatic Setting the Engine Speed Adjust parameter high on a generator set will result in Set the voltage regulator average voltage adjustment to the same value on
voltage regulator that generator set providing more real power than the other generator sets. It is all connected generator sets.
settings possible to drive the other generator sets offline in light loading conditions.
3 Different voltage Because each generator set will attempt to match the target output voltage, Verify the controller is measuring voltage accurately, If not, re-calibrate.
calibrations generator sets with incorrect calibration may be targeting a different output
voltage, thus generating or absorbing VARs.
4 Failure in voltage The generator set circuit breaker will trip to prevent the generator set from Verify the voltage regulator and activator are okay. Perform load tests to
regulator or activator absorbing VARs from the other generator sets. Providing power while absorbing verify.
board VARs may cause that alternator to slip a pole—potentially damaging the rotor or
crankshaft.
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Fault: Generator Set is Management Config Mismatch
1 Two generators sets Generator set management will not operate if any generator sets on the PGEN Adjust the Order Selection mode on any generator set on the network to set
that are network have different Order Selection modes. the Order Selection mode in all controllers.
communicating on the
network have different
Order Selection modes
2 Two generator sets Generator set management will not operate if any generator sets on the PGEN Adjust the Order Selection mode on any generator set on the network to set
that are network have different Stability delays. the Stability delay in all controllers.
Stability delays
that are network have different Redundancy Requirements. the Redundancy Requirements in all controllers.
Redundancy
Requirements
that are network have different Maximum Run Time Hour Difference Thresholds. the Maximum Run Time Hour Difference Threshold in all controllers.
Maximum Run Time
Hour Difference
Thresholds
that are network have different Maximum Fuel Level Difference Thresholds. the Maximum Fuel Level Difference Threshold in all controllers.
Maximum Fuel Level
Difference Thresholds
TP-6929 1/15
3.6 Troubleshooting—Protective Relays
Protective Relay Intended Function Potential Causes Troubleshooting
Reverse Power To trip the paralleling Incorrect Real Load Sharing The engine should be able to provide power individually. If so, the Real Load Sharing configuration is
circuit breaker if a configuration. probably incorrect.
TP-6929 1/15
generator set is not A paralleled unit in a fixed power Check modes on other controllers. Baseload mode on one generator set may result in reverse power
producing absorbing real mode (Baseload), set to a value on the other generator sets. Check Baseload setting is less than actual load.
power. A generator set higher than required for actual
should always produce load.
power while running. If
the generator set is not Incorrect wiring to the CTs on one Load bank each generator set individually. Power should read positive and accurately. Make sure that
producing power, the or more units on the paralleling the generator set controller reads a unity power factor into a resistive load bank. If a load bank is
protective relay will trip bus (not necessarily the unit that unavailable, make sure that phase powers are all positive and that phase power factors make sense.
the paralleling circuit tripped on reverse power).
breaker, removing the Incorrect current meter calibration Check current meter calibration according to the manual
generator set from the for one or more generator sets in
paralleling bus, as it is the system.
not contributing to the
Loss of fuel (run out of fuel, a The failed generator set should be easily detected as it will shut down for underspeed or
power output.
failed suction line, or failed fuel underfrequency after the circuit breaker trips. There will be no fuel pressure.
supply component such as Check the fuel reservoir, fuel supply lines, and fuel supply components on the engine.
injectors, carburetor, throttle Check for related diagnostic messages (DTCs) from the ECU.
control, etc.).
Electrical failure in the engine The generator set will shut down for underspeed or underfrequency after the circuit breaker trips. Fuel
ECU. pressure will be normal.
Check for related diagnostic messages (DTCs) from the ECU.
Mechanical problem in the engine. The generator set will shut down for underspeed or underfrequency after the circuit breaker trips. The
crankshaft may be very difficult to turn.
Check for related diagnostic messages (DTCs) from the ECU.
Incorrect protective relay setting. Ensure that protective relay settings are determined by a comprehensive coordination study using
recent and accurate system data.
No speed control through, Check ECU calibration file.
replacement ECU not configured
correctly to accept CAN speed
commands, engine derates active.
Over Power To protect the generator Incorrect Load Management setup. Verify critical load is less than a single generator set capacity. Load Management should be able to
set from overload remove enough load to allow a single generator set to support it.
conditions that may Verify correct wiring between load shed outputs and switching components.
result in damage to the Verify distributed loads and ratings are consistent with Load Management configuration/settings.
generator set. Failure of another generator set. Check Load Management settings to ensure that all loads are shed quickly enough in the event of a
generator set failure.
Check Generator Management settings to ensure the desired minimum number of generator sets is
selected.
Load growth in application. Verify that Load Management can shed enough load for a single generator set to support it.
Incorrect protective relay setting. Ensure that protective relay settings are determined by a comprehensive coordination study using
recent and accurate system data with consideration for Load Management configuration.
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Reverse VARs Protect the generator set Incorrect Reactive Load Sharing Check that the engine is able to supply load and maintain normal voltage when running alone. If so,
from slipping a pole due configuration. the Reactive Load Sharing configuration is probably incorrect.
to a low excitation A paralleled unit in a fixed power Check modes on other controllers. Baseload mode on one generator set may result in reverse VARs
condition in the mode (Baseload or System Load on the other generator sets.
alternator. Control) or KVAR setting is higher Verify KVAR setting is less than the actual load requires, consider PF sharing.
than the actual load.
Incorrect wiring to the CTs on one Load bank each generator set individually. Power should read positive and accurately. Make sure that
or more units on the paralleling the generator set controller reads a unity power factor into a resistive load bank. If a load bank is
bus (not necessarily the unit that unavailable, make sure that phase powers are all positive and that phase power factors make sense.
tripped on reverse power).
Incorrect current meter calibration Check the current meter calibration according to the manual.
for one or more generator sets in
the system.
Loose or broken wiring between The failed generator set should be easily detected as it will shut down on undervoltage after the
controller and LED board or wound protective relay trips the circuit breaker.
field activator. Voltage may be unusually unstable.
Check wires and connectors for any failures, intermittent or open connections.
Activator board failure on Perform flashlight test per the respective alternator service manual (Fast-Responset II or
alternator. Fast-Responset X alternators only).
If alternator produces no voltage, look for bad wires or connections. If no bad connections are found,
continue with alternator troubleshooting in the alternator service manual.
Visually inspect the activator board for damage or failure.
Broken wire or failed winding in Perform flashlight test per the respective alternator service manual (Fast-Responset II or
alternator. Fast-Responset X alternators only).
If alternator produces no voltage, look for bad wires or connections. If no bad connections are found,
Capacitive load. Verify that the load is not capacitive. If a single generator set (with the CTs connected properly) is
reading a leading power factor, the load is capacitive. If multiple generator sets are supplying the load,
check for the total system load under bus metering to determine if the reactive power is leading (-).
Incorrect Protective Relay setting. Ensure that protective relay settings are determined by a comprehensive coordination study using
recent and accurate system data. Note: Setting the Reverse VARs protective relay above 20% is not
recommended as it may result in slipping a pole under high real loads.
Loss of sensing on a voltage The controller uses three-phase sensing to regulate voltage (in a three-phase application). The loss of
phase. a single phase may cause either an overvoltage or undervoltage event. Start the generator set to
ensure that all three line voltages are metered accurately.
TP-6929 1/15
Over Current To protect the alternator Undersized generator set for Ensure that the load demand is not greater than a single generator can support. This may require
from excessive heating application. ensuring more than one generator set is online before attempting to start a motor load.
due to stator current. Verify Generator Management and Load Management are appropriately configured and system wiring
is correct for operation as determined by a comprehensive coordination study.
TP-6929 1/15
Incorrect Soft Start configuration Some Soft Starters transfer the motor to line voltage before it has time to reach rated speed. This will
for motor. cause a large current spike on the alternator. Monitor current into the motor with a current clamp and
multimeter to trace the root cause.
Verify appropriate soft starter configuration for the generator set supplied application.
Simultaneous starting of switching If multiple motors exist in the application, try ensuring that they all start simultaneously to repeat the
motor loads. condition. If the condition repeats, it may be necessary to inhibit some motors from starting until others
are up to speed.
Verify Generator Management and Load Management are appropriately configured and system wiring
is correct for operation as determined by a comprehensive coordination study.
Under Voltage To protect the user loads System Control mode. System Control mode will force all generator sets in the system to control reactive power to a target set
from poor quality power. by the voltage bias. If the actual reactive power is lower than the target, the voltage will increase. If the
actual reactive power is higher than the target, the voltage will decrease. Make sure that no controllers
are receiving a system load control input. Make sure that no controllers are configured for System
Control mode in software.
System Sync mode. System Sync mode will force all generator sets in the system to match voltage to a bias level set by
the voltage bias (which could be from 90% to 110% of rated voltage). Make sure that no controllers
are receiving a system sync control input. Make sure that no controllers are configured for System
Baseload. Baseload mode on a controller may decrease the voltage of the paralleling bus if attempting to unload
reactive power when the other generator sets as configured are not able to support the load. Check for
other nodes configured in Baseload mode. Check if this node is configured for Baseload.
Excessive motor load. Very heavy motor loads may cause the voltage to remain low for long enough to trip the undervoltage
relay. Make sure that the voltage on the generator set recovers to rated voltage within 1/2 of the time
specified for the undervoltage protective relay when all motors are started together with a reasonable
preload. If not, it may be necessary to reconsider the coordination study for the system.
Loose wiring between controller Failure of any alternator in the paralleling system can cause an undervoltage condition (although it
and LED board or wound field should be detected by a reverse VAR condition, that time delay is often longer). The failed generator
activator. set should be easily detected as it will shut down on undervoltage after the protective relay trips the
circuit breaker.
Activator board failure on Failure of any alternator in the paralleling system can cause an undervoltage condition (although it
alternator. should be detected by a reverse VAR condition, that time delay is often longer).
Broken wire or failed winding in Failure of any alternator in the paralleling system can cause an undervoltage condition (although it
alternator. should be detected by a reverse VAR condition, that time delay is often longer).
Voltage Trim disabled. The Voltage Trim corrects the generator set output voltage to a nominal level under normal operation.
If it is disabled, the generator set voltage could fall anywhere between 90% and 110% of nominal.
Make sure that Trims are enabled on at least 1 of the paralleling generator sets.
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Over Voltage To protect the loads from System Control mode. System Control mode will force all generator sets in the system to control reactive power to a target set
potential damage from by the voltage bias. If the actual reactive power is lower than the target, the voltage will increase. If the
high voltage conditions. actual reactive power is higher than the target, the voltage will decrease. Make sure that no controllers
are receiving a system load control input. Make sure that no controllers are configured for System
System Sync mode. System Sync mode will force all generator sets in the system to match voltage to a bias level set by
the voltage bias (which could be from 90% to 110% of rated voltage). Make sure that no controllers
are receiving a system sync control input. Make sure that no controllers are configured for System
Baseload. Baseload mode on a controller may decrease the voltage of the paralleling bus if attempting to unload
reactive power when the other generator sets as configured are not able to support the load. Check for
other nodes configured in Baseload mode. Check if this node is configured for Baseload.
Excessive motor load. If a large motor load is removed from the generator, the voltage will spike momentarily. The voltage
should recover to the nominal value very quickly, but could trip the protective relay if the time delay is
sufficiently short.
Activator board failure on Failure of any alternator in the paralleling system can cause an overvoltage condition (although it may
alternator. also show up as reverse VARs on properly-functioning generator sets).
Voltage Trim disabled. The Voltage Trim corrects the generator set output voltage to a nominal level under normal operation.
If it is disabled, the generator set voltage could fall anywhere between 90% and 110% of nominal.
Make sure that Trims are enabled on at least 1 of the paralleling generator sets.
Under Frequency To protect the loads from Failure of another generator. Check Load Management settings to ensure that all loads are shed quickly enough in the event of a
poor quality power. generator failure.
Load growth in application. Verify that Load Management can shed enough load for a single generator set to support it.
Dirty air cleaner. Check air cleaner element.
Poor fuel supply. Verify fuel line size and installation. Verify fuel pressure at unit under full load.
System Control mode. System Control mode will force all generator sets in the system to control real power to a target set by
the speed bias. If the actual power is lower than the target, the speed will increase. If the actual power
is higher than the target, the speed will decrease. Make sure that no controllers are receiving a system
load control input. Make sure that no controllers are configured for System Control Mode in software.
System Sync mode. System Sync mode will force all generator sets in the system to match frequency to a bias level set by
the speed bias (which could be from 95% to 105% of rated speed). Make sure that no controllers are
receiving a system sync control input. Make sure that no controllers are configured for System Control
Mode in software.
Baseload. Baseload mode on a controller may decrease the frequency of the paralleling bus if attempting to
unload real power when the other generator sets are not able to support the load. Check for other
nodes configured in Baseload mode. Check if this node is configured for Baseload.
Frequency Trim disabled. The Frequency Trim corrects the generator set output frequency to a nominal level under normal
operation. If it is disabled, the generator set frequency could fall anywhere between 95% and 105% of
nominal. Make sure that Trims are enabled on at least 1 of the paralleling generator sets.
TP-6929 1/15
Over Frequency To protect the loads from System Control mode. System Control mode will force all generator sets in the system to control real power to a target set by
poor quality power. the speed bias. If the actual power is lower than the target, the speed will increase. If the actual power
is higher than the target, the speed will decrease. Make sure that no controllers are receiving a system
load control input. Make sure that no controllers are configured for System Control mode in software.
TP-6929 1/15
System Sync mode. System Sync mode will force all generator sets in the system to match frequency to a bias level set by
the speed bias (which could be from 95% to 105% of rated speed). Make sure that no controllers are
receiving a system sync control input. Make sure that no controllers are configured for System Control
Mode in software.
Baseload. Baseload mode on a controller may decrease the frequency of the paralleling bus if attempting to
unload real power when the other generator sets are not able to support the load. Check for other
nodes configured in Baseload mode. Check if this node is configured for Baseload.
Excessive restriction on return On certain units, excessive restriction on the return line will cause seals to fail in the injector pump
line. which may supply unwanted fuel to the engine causing it to ’run away’ (accelerate without being
commanded to do so by the ECM or governor). Verify backpressure at the return line. Ensure that no
valves exist in the return line that can be accidentally closed (without knowledge of the implications).
Frequency Trim disabled. The Frequency Trim corrects the generator set output frequency to a nominal level under normal
operation. If it is disabled, the generator set frequency could fall anywhere between 95% and 105% of
nominal. Make sure that Trims are enabled on at least 1 of the paralleling generator sets.
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3.7 Troubleshooting—Voltage Regulator
Symptom Potential Causes Troubleshooting
No voltage Circuit breaker status is indicating Ensure that Connected to Bus under Parallel Metering is set to False. (Note: This condition will have similar results in a
closed. paralleling or standalone application). If shown as True, verify that BSN and BSP wires are not connected.
Loose wiring between controller and Check wiring between controller and LED board. Perform flashlight test per the respective alternator service manual
LED board or wound field activator. (Fast-Responset II or Fast-Responset X alternators only).
If alternator produces no voltage, look for bad wires or connections. If no bad connections are found, continue with alternator
troubleshooting in the alternator service manual.
Activator board failure on alternator. Perform flashlight test per the respective alternator service manual (Fast-Responset II or Fast-Responset X alternators
only).
Broken wire or failed winding in Perform flashlight test per the respective alternator service manual (Fast-Responset II or Fast-Responset X alternators
alternator. only).
If alternator produces no voltage, look for bad wires or connections in the alternator. If no bad connections are found,
Speed sensor. Verify that the controller is seeing speed above the crank disconnect level. The voltage regulator is not enabled until the
engine speed exceeds the crank disconnect level.
No ECM communications. If the engine speed is received from the engine ECM, the voltage regulator requires a CAN message listing the speed as
above the crank disconnect speed before the voltage regulator is enabled.
Open circuit breaker. A tripped circuit breaker on the generator set will result in no voltage to the load without a failure on the generator set. If the
generator set controller is measuring voltage, the circuit breaker is probably tripped.
Irregular voltage Loose wiring between controller and Check the wiring between the controller and the LED board. Perform flashlight test per the respective alternator service
output LED board or wound field activator. manual (Fast-Responset II or Fast-Responset X alternators only).
Broken wire or failed winding in Perform flashlight test per the respective alternator service manual (Fast-Responset II or Fast-Responset X alternators
alternator. only).
If alternator produces no voltage, look for bad wires or connections in the alternator. If no bad connections are found,
Loose voltage sensing wiring to Verify wiring to voltage sensing of controller.
controller.
Incorrect Personality Profile in Check Alternator Manufacturer setting:
controller. FRII or FRX alternators should use Alternator Manufacturer = Kohler,
4D Alternators should use Alternator Manufacturer = Kohler Wound Field
Incorrect voltage regulation gains. Verify voltage regulator gains:
Normal Gain = 128,
Stability = 128
Incorrect Volts/Hz settings. Verify that Volts/Hz Cut-In (knee) frequency is at least 0.5Hz below full-load operating frequency.
Engine hunting problem. Verify that engine is operating stably. Verify fuel supply, pressure regulator (if equipped) fuel filters (if equipped), water in fuel
indicator (if equipped).
Voltage decreases as Reactive droop is set too high. Reactive droop should be set between 0.0% and 1.0% in single-generator set applications.
load increases and Reactive Droop should be set between 1.0% and 4.0% in paralleling applications.
does not recover Voltage regulator gain is set too low. Voltage regulator gain should be set to at least 16.
Missing wiring between alternator The activator on FRX and 4D alternators requires 3-phase input (all three wires should be connected).
and activator board.
TP-6929 1/15
Voltage dips when Normal operation. Sudden increases in reactive load on the generator set will cause the voltage to dip momentarily. Large increases in load on
load is applied, but the engine (real load) will cause the frequency to dip, resulting in voltage dip from underfrequency unload in voltage
recovers relatively regulator.
quickly
TP-6929 1/15
Excessive motor loading. Large motor loads will cause the voltage on the generator set to dip significantly. To determine the motor lock-rotor kVA that a
generator set will support at a given voltage dip, consult the data sheet for the alternator.
Large transformers, lighting ballasts, Many non-linear devices will demand very large inrush currents until an internal power bus is charged.
UPS battery chargers, or VFDs
powering up.
Voltage overshoots Normal operation. Sudden decrease in reactive load on a generator set will result in short-duration voltage spikes on the alternator. The spike
when load is removed duration and magnitude is minimized by the alternator.
Large motor tripping off while Ensure that the motor is within the capability of the generator set. Compare the motor locked-rotor kVA with the appropriate
attempting to start. voltage dip on the alternator data sheet. It is not recommended to attempt to start a motor with a locked-rotor kVA that is
greater than what would cause a 35% voltage dip.
Large transformers or lighting Lighting controllers and other ’smart’ devices can cause strange loading scenarios on generator sets. It may be necessary to
ballasts disconnecting from the reconfigure the devices in order to get the system to operate as intended.
generator.
Excessive voltage Incorrect connection of voltage Voltage sensing leads on the controller should be connected to L1, L2 and L3 of the generator set. Center Taps V7, V8 and
sensing leads. V9 are not to be used with this controller.
Missing/disconnected voltage The controller regulates the average of the three line voltages to the target. If a single phase is lost, the controller will attempt
sensing lead. to bring the average back to match the target.
Incorrect controller configuration. If the alternator is wired for single-phase and the controller is configured for three-phase, the generator set will output
excessive voltage.
If the controller is configured for too high of voltage, the generator set will output excessive voltage.
Damaged activator board. If the activator board fails to a full-on condition, the alternator will probably produce excessive voltage.
Damaged controller. If the controller fails to request a full-on condition from the activator board, the alternator will probably produce excessive
voltage.
Damaged alternator. If the alternator develops an internal short circuit on one of the windings, the other windings may generate excessive voltage.
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3.8 Troubleshooting—Genset Controller
Engine does not A fault is active. Verify that E-Stop, auxiliary fault, and other latching faults are inactive before attempting to start the generator set.
crank Low battery condition. The generator set controller may reset when a crank sequence is initiated. If not, monitor the battery voltage while cranking
to ensure that it remains above 10V.
Missing, damaged, incorrect wiring Verify that the starter is receiving battery voltage to the large post on the solenoid. Verify that the 71 wire to the starter
to the starter. solenoid is activating when the engine is signaled to start.
Start relay is damaged or Most applications drive the starter solenoid with a pilot relay. Verify that the pilot relay is supplied with battery voltage and
inoperative. that it is activating when the 71 wire output from the controller turns on.
Note: The 71 wire will appear to be supplying battery voltage if all that is connected to it is a multimeter. The multimeter must
be connected across the coil of the relay while the relay is plugged in.
Starter is damaged or inoperative. If the starter is receiving the appropriate signals, but the engine is not rotating, the starter or solenoid may be inoperative.
Engine is unable to turn. In some cases, the engine may be experiencing mechanical interference or damage that will not let it turn. Verify that the
engine will turn with a breaker bar or ratchet on the bolt in the front pulley.
Engine cranks but Controller fault. The generator set controller is stopping the engine due to a fault before the engine is able to start. Additional troubleshooting
does not start will vary based on the fault that occurs.
Loss of fuel prime (diesel-fueled If the engine progresses through a full crank cycle without starting, it is entirely possible that it is not receiving fuel. Manual
models only). priming may be required to get the engine to start.
Air in fuel. A pinhole in a fuel line or a trapped air pocket from assembly can inhibit an engine from starting. Manual priming and
bleeding the system may be required to clear the air pocket and start the engine.
Missing, damaged, incorrect wiring If the ECM or fuel solenoid is not powered up while cranking, the engine will not be able to start. The fuel solenoid power can
to the fuel solenoid or ECM. be verified with a multimeter and it should click when the engine is signaled to start. The ECM is powered if the controller is
able to sense engine speed while cranking.
ECM fault code. If the ECM has a fault, it may not permit the engine to start. Further troubleshooting will depend on the fault that is present.
Damaged or inoperative component A fuel pump failure, pressure regulator failure, fuel solenoid failure, or electrical problem in a control system may prevent the
in fuel system. engine from starting. Refer to the engine service manual for expected fuel pressures and component checkout procedures.
Damaged or inoperative run relay. If the ECM or fuel solenoid is not receiving power, the run relay may not be activating or making contact.
Run relay overload Damaged or inoperative run relay. Run Relay Overload means that the current on the Run Relay has exceeded 10A for 10ms. If the coil on the run relay is
shorted, it will draw more than 10A.
Faulty component fed by 70 wire. If additional components (other than the run relay) are fed by the 70 wire from the controller, any of them could have
developed an internal short-circuit that will draw more than 10A.
Short circuit in wiring of 70 wire The 70 wire may be short-circuited to ground. A multimeter between the 70 wire in P1 to the controller and ground should
from controller. indicate if a short circuit is present.
Too many devices on 70 wire. Field-installed devices that are activated by the 70 wire from the controller may cause the current draw to exceed 10A.
These devices should be powered through a pilot relay in this case.
Over Crank Loss of fuel prime. If the engine progresses through a full crank cycle without starting, it is entirely possible that it is not receiving fuel. Manual
priming may be required to get the engine to start.
Air in fuel. A pinhole in a fuel line or a trapped air pocket from assembly can inhibit an engine from starting. Manual priming and
bleeding the system may be required to clear the air pocket and start the engine.
Missing, damaged, incorrect wiring If the ECM or fuel solenoid is not powered up while cranking, the engine will not be able to start. The fuel solenoid power can
to the fuel solenoid or ECM. be verified with a multimeter and it should click when the engine is signaled to start. The ECM is powered if the controller is
able to sense engine speed while cranking.
ECM fault code. If the ECM has a fault, it may not permit the engine to start. Further troubleshooting will depend on the fault that is present.
Damaged or inoperative component A fuel pump failure, pressure regulator failure, fuel solenoid failure, or electrical problem in a control system may prevent the
in the fuel system. engine from starting. Refer to the engine service manual for expected fuel pressures and component checkout procedures.
Weak or damaged battery. A weak battery or battery with a shorted cell may result in a crank speed too slow for the engine to start.
Starter is damaged or inoperative. The engine may not be able to start if it turns too slowly. A weak starter may result in slow rotating speed.
TP-6929 1/15
Start Relay Overload Damaged or inoperative crank relay. Start Relay Overload means that the current on the Start Relay has exceeded 10A for 10ms. In systems where the 71 output
from the controller drives a pilot relay to operate the starter solenoid, the coil on the relay may be short-circuited, causing the
current draw on the 71 wire to exceed 10A.
TP-6929 1/15
Damaged or inoperative starter In systems where the 71 wire from the controller directly drives the starter solenoid, an inoperative solenoid may draw more
solenoid. than 10A. It may be sufficient to add a pilot relay to drive the starter solenoid.
Magnetic pickup wiring damaged. The controller requires a speed signal from a magnetic pickup in non-ECM applications. Without a signal from the magnetic
pickup, the controller does not know that the engine is turning. The wiring from the mag pickup may have been damaged to
interrupt the signal.
Magnetic pickup damaged or If the magnetic pickup is damaged, misaligned or maladjusted, the controller will not be able to detect engine rotation and will
maladjusted. fault for a locked rotor condition.
Low battery charge, weak battery, If the crank relay is dropping out as soon as the starter engages, the engine will not turn, but the controller may remain
or corroded battery terminals. powered up throughout the event. The start relay and solenoid will make a chattering noise in this condition.
Missing, damaged, incorrect wiring If the engine is not turning, Verify that the starter is receiving battery voltage to the large post on the solenoid. Verify that the
to the starter. 71 wire to the starter solenoid is activating when the engine is signaled to start.
Start Relay is damaged or Most applications drive the starter solenoid with a pilot relay. Verify that the pilot relay is supplied with battery voltage and
inoperative. that it is activating when the 71 output from the controller turns on.
Note: The 71 wire will appear to be supplying battery voltage if all that is connected to it is a multimeter. The multimeter must
be connected across the coil of the relay while the relay is plugged in.
Starter is damaged or inoperative. If the starter is receiving the appropriate signals, but the engine is not rotating, the starter or solenoid may be inoperative.
Engine is unable to turn. In some cases, the engine may be experiencing mechanical interference or damage that will not let it turn. Verify that the
engine will turn with a breaker bar or ratchet on the bolt in the front pulley.
ECM Communication Damaged or inoperative Run Relay. The fault requires that the ECM establishes communications and then loses it. It is possible that the Run Relay is dropping
Loss out or has an intermittent connection. Verify that the ECM is retaining power until the shutdown occurs.
Intermittent CAN wiring connection. Loose wiring will often vibrate on startup and cause an intermittent connection. Check connections on CAN wiring to ensure
that they are tight and all crimps are well formed and making good electrical connections.
Missing, damaged or incorrect The ECM communication may drop out if the power supply to the ECM is intermittent. Verify wiring through all connectors to
wiring to supply power to ECM. the ECM.
Connection of additional devices to Additional devices include CAN analysis tools, 3rd-party data logging solutions, ECM diagnostic software, etc. Any of these
engine CAN. devices may cause additional traffic on the CAN lines that may cause the controller to lose communication with the ECM.
Speed Sensor Fault Engine stalled unintentionally. The engine stopped rotating without the controller telling it to stop. This could be caused by a loss of fuel, an external stop
signal, or an unannounced ECM fault.
Magnetic pickup wiring intermittent. On non-ECM engines, this fault may indicate that the signal from the mag pickup was lost unexpectedly (which could be
caused by bad wiring to the magnetic pickup).
Review the wiring to the mag pickup, checking for loose connections on terminals and crimp joints.
Magnetic pickup maladjusted. A maladjusted magnetic pickup can work intermittently, it may also provide a temperature-related signal (as parts expand).
Verify that the magnetic pickup is adjusted per the factory specifications.
ECM Mismatch Error Incorrect configuration. This error indicates that the ECM reported a different model type than the generator set controller was expecting. The
controller may have an incorrect personality profile loaded in it.
Incorrect part replacement. If the ECM was recently replaced, verify that it is the correct part and that it has the correct calibration in it. If it is a newer
revision, check for an updated personality or firmware for the generator set controller.
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3.9 Troubleshooting—Paralleling
System voltage high A generator set in the system is Verify that all generator sets in the system are configured so that their system voltage matches the site requirements.
configured to an incorrect, lower
voltage setting.
This generator set is configured to Verify that all generator sets in the system are configured so that their system voltage matches the site requirements.
an incorrect, higher voltage setting.
System voltage low A generator set in the system is Verify that all generator sets in the system are configured so that their system voltage matches the site requirements.
configured to an incorrect, higher
voltage setting.
This generator set is configured to Verify that all generator sets in the system are configured so that their system voltage matches the site requirements.
an incorrect, lower voltage setting.
System frequency A generator set in the system is Verify that all generator sets in the system are configured so that their system frequency matches the site requirements. It is
high configured to 50 Hz in a 60 Hz possible that one of the generator sets will have to be reconfigured to operate at a different speed.
application.
This generator set is configured to Verify that all generator sets in the system are configured so that their system frequency matches the site requirements. It is
60 Hz in a 50 Hz application. possible that one of the generator sets will have to be reconfigured to operate at a different speed.
System frequency low A generator set in the system is Verify that all generator sets in the system are configured so that their system frequency matches the site requirements. It is
configured to 60 Hz in a 50 Hz possible that one of the generator sets will have to be reconfigured to operate at a different speed.
application.
This generator set is configured to Verify that all generator sets in the system are configured so that their system frequency matches the site requirements. It is
50 Hz in a 60 Hz application. possible that one of the generator sets will have to be reconfigured to operate at a different speed.
System phase A generator set in the system is Ensure that all generator sets in the system have an identical phase connection and that the connection matches the site
connection mismatch configured to an incorrect phase requirements. Note: Single-phase dog-leg should not be used as a phase connection type.
connection (single-phase, delta, or
wye).
This generator set is configured to Ensure that all generator sets in the system have an identical phase connection and that the connection matches the site
an incorrect phase connection requirements. Note: Single-phase dog-leg should not be used as a phase connection type.
(single-phase, delta, or wye).
Generator The Generator Management Stable Either change the Generator Management Stable Delay on one generator set in the paralleling system (which will update all
Management Delay is different on at least one of of them) or check each generator set to determine the one that doesn’t match.
mismatch the nodes in the system.
The Generator Management Min Either change the Generator Management Min Gens Online parameter on one generator in the paralleling system (which will
Gens Online parameter is different update all of them) or check each generator set to determine the one that doesn’t match.
on at least one of the nodes in the
system.
The Generator Management Either change the Generator Management Minimum Load Shed Priority parameter on one generator in the paralleling
Minimum Load Shed Priority system (which will update all of them) or check each generator set to determine the one that doesn’t match.
parameter is different on at least
one of the nodes in the system.
The Generator Management Either change the Generator Management Runtime Threshold on one generator in the paralleling system (which will update
Runtime Threshold is different on at all of them) or check each generator set to determine the one that doesn’t match.
least one of the nodes in the
system.
The Generator Management Fuel Either change the Generator Management Fuel Difference Threshold on one generator in the paralleling system (which will
Difference Threshold is different on update all of them) or check each generator set to determine the one that doesn’t match.
at least one of the nodes in the
system
TP-6929 1/15
Phase angle fault The bus wiring is not connected Verify bus measurement wiring.
correctly on the load side of the
generator paralleling circuit breaker.
TP-6929 1/15
The paralleling circuit\ breaker is Verify circuit breaker status accuracy by watching the status on the screen and manually operating the circuit breaker while
indicating closed when it is actually no generator sets in the paralleling system are running.
open.
Circuit breaker The generator has loads that are All loads fed by the generator set should be connected downstream of the paralleling circuit breaker. If a fire pump circuit
current fault attached on the generator side of breaker is required, the current fault should be adjusted to accommodate the fire pump current.
the paralleling circuit breaker.
The generator set circuit breaker is Verify circuit breaker status accuracy by watching the status on the screen and manually operating the circuit breaker while
closed, but is indicating open. no generator sets in the paralleling system are running.
Failure to synchronize The load is changing too frequently Observe the frequency and voltage of the paralleling bus to ensure that they are are not changing too quickly. If so, try to find
to synchronize. which load are causing the problem and inhibit them from receiving power until more generator sets are online (if possible).
The synchronizing gains are not Some application may require adjustment of the paralleling gains.
calibrated correctly.
Close attempt fault First-On close delay or Dwell Time Ensure that the trip relay is energizing enough before the close relay energized to remove any inhibiting mechanism tied to
(Fail to Close Delay: is too short. the trip coil.
Device Out of Order) External protection inhibiting circuit If 3rd-party protective relays are used for permissive functions, ensure that the window on the protective relays is wider than
but no Failure to breaker closure. the window on the controller. If the protective relay is not changeable, adjust the controller to be tighter than the protective
Close relay.
Intermittent wiring to circuit breaker. Check wiring to circuit breaker to ensure that all connections are tight.
Failure to Close (Max Remove Breaker Trip not configured Verify configuration in SiteTech for Digital output 115.
Close Attempts: High) to Digital Output 115 or Digital
Output 115 not enabled.
Close Breaker not configured to Verify configuration in SiteTech for Digital output 116.
Digital Output 116 or Digital Output
116 not enabled.
No power supply to circuit breaker. Verify that charge motor operates on motor-operated circuit breaker.
Incorrect wiring between terminal Make sure that trip and close relays operate properly. Changing the event for digital output 115 and 116 to not in auto will
block and circuit breaker relays. allow for simpler troubleshooting, as pressing the off button will signal the breaker to close and pressing the auto button will
signal the circuit breaker to trip.
Note: Make sure that Digital outputs 115 and 116 are set back to remove circuit breaker trip and close the circuit breaker
with troubleshooting is complete.
Incorrect wiring between terminal Verify the wiring between the circuit breaker and the circuit breaker close relay.
block and circuit breaker.
No status feedback from circuit Verify that bus sensing is connected to load side of the circuit breaker. Verify the circuit breaker status wiring is connected
breaker and no bus sensing correctly.
connected.
SDE contact not installed correctly. Some circuit breakers require a contact in the SDE position of the circuit breaker in order for the motor operator to operate
correctly. Verify that the SDE contact is installed per the wiring diagram for the circuit breaker.
Failure To Open (Fail Trip wiring not installed or Verify the wiring between the circuit breaker and the circuit breaker trip relay.
to Open Delay: connected incorrectly.
Device Out of Order) Circuit breaker status wired to The circuit breaker status feedback (BSP and BSN) should be connected to terminals 1 and 4 (11 and 14) of the circuit
incorrect terminals. breaker.
Continued circuit No circuit breaker status feedback Verify the circuit breaker status wiring is connected correctly.
breaker cycling with bus sensing connected.
Remove circuit breaker trip is not Verify that the circuit breaker trip relay is wired per the wiring diagram.
wired to the normally closed contact
on the relay.
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78
Circuit breaker will not Synch Mode is set to check or off. Verify that Synch Mode in Run is set to Active if operating the generator set using the run button on the front panel. Verify
close to a live bus that Synch Mode in Auto is set to Active if operating the generator set using the remote start signal.
(but no fault is issued) Synch disabled is on. Verify that the Disable Synchronization is not active.
Bus phase rotation does not match Verify that Bus phase rotation and generator set phase rotation match (using SiteTech or the controller UI). If they don’t,
generator set. close the generator set circuit breaker to a dead bus to ensure that the generator set bus sensing is connected correctly.
Phase rotation should match and phase angle should read between --5_and 5_ when the generator set is running and the
circuit breaker is closed.
Bus load is varying too quickly. Observe the frequency and voltage of the paralleling bus to ensure that they are are not changing too quickly. If so, try to find
which load are causing the problem and inhibit them from receiving power until more generator sets are online (if possible).
Synchronizing gains are incorrectly Some application may require adjustment of the paralleling gains.
calibrated.
Bus voltage and/or frequency is out Make sure that enough load is connected to load management outputs that the system can reduce the load to a level that a
of the normal operating range. single generator set can handle.
Circuit breaker will not Synch Mode is set to off. Verify that Synch Mode in Run is set to Check or Active if operating the generator set using the run button on the front panel.
close to a dead bus Verify that Synch Mode in Auto is set to Check or Active if operating the generator set using the remote start signal.
(but no fault is issued) Synch Disabled is on. Verify that the Disable Synchronization is not active.
No communications with other Check if the number of PGEN nodes is >1 (found under Controller Config -> Communication Setup on UI, or under
generator sets. Synchronization Control in SiteTech).
Generator set perceives bus as not Check bus metering. Must be below the dead bus level as a percentage of system voltage. Check for loose connections and
being dead. stray voltage on bus. Verify that bus is truly dead. If bus has stray voltage on it, it may be necessary to adjust the dead bus
percentage up to accommodate the stray voltage.
Another generator set is indicating Make sure that all other generator sets in the paralleling system are disconnected from the paralleling bus and are reporting
that it is closed to the bus. circuit breaker position correctly.
TP-6929 1/15
Section 4 General Repair Information
4.1 Introduction D TP-6701 SiteTecht Software Operation Manual

available by accessing TechTools.
This section contains controller repair information.
Refer to the parts catalog for service part numbers. No D USB Cable with male USB-A and mini-B connectors.
other replacement service parts are available. See TP-6701.Request and Error Messages
Before replacing the controller, remove all external Request and Status Messages
accessories and other electrical connections to verify
that these items are not the cause of the controller Display messages require the user to enter additional
problems. Verify that the accessories and connections data, confirm the previous entry or require time to
are functioning correctly before reconnecting them to process as described below.
the new controller.
Entry Accepted appears for several seconds after
Electrical noise can affect the controller operation, refer pressing the Enter key during the programming mode.
to the Appendices for Electrical Noise and Wiring The display then shows the new data.
Practices.
Reset Complete indicates the user has successfully:
The controller receives input signals from several
D Reset the maintenance records,
senders/sensors that provide fault warnings and
shutdowns that can be tested for proper function. D Restored the AC analog inputs to the default settings,
Simulating these conditions may be helpful in or
troubleshooting the generator set. Refer to D Restored voltage regulator settings to the defaults.
Section 5—Component Testing, Fault Warning and
Shutdown Testing. Right Arrow  directs the user to the next menu. The
menus loop; press the right arrow key to move to the
Go to the Overview Menu and verify that the Software next menu.
(SW) Version is correct for the generator set model and
alternator voltage. Use the operation manual for details
regarding accessing the Overview Menu. 4.3 Controller Functional Test
Use SiteTecht software for updating the controller The controller operation includes several types of
application code. starting and stopping functions as detailed in the
operation manual.
4.2 SiteTecht Software 4.4 Factory Reserved Inputs

The following items are necessary PC requirements for Available user inputs are dependent on
using the SiteTecht software. factory-reserved inputs for specific engine types, engine
controls, and paralleling applications. See Figure 4-1
D SiteTecht Software Version 3.6 or higher by and Figure 4-2 for analog and digital inputs that are not
accessing TechTools to download on your PC hard user-selectable.
drive or disk if not already installed on your PC.
TP-6929 1/15 Section 4 General Repair Information 79

Analog Resistive Input P1 Main Connector (35-Pin) (continued)
A1 Oil Pressure (Resistive Sensor 1) 19 Fuel Level (Resistive Sensor 3) A3
(wire 63, diesel) (wire 63C, gas)
A2 Coolant Temperature (Resistive Sensor 2)
A3 Fuel Level (Resistive Sensor 3) 20 Common Return for all Digital Inputs
D1--D6
A4 Voltage Selector Switch SS1 (Analog Input 4)
21 Spare Digital Input (Digital Input 4) D4
22 Spare Digital Input (Digital Input 2) D2
23 Isolated RS-485 2 A
Analog Differential Input
24 Controller Power (+) (wire P2)
V1P Circuit Breaker Status P (Diff. Volt Input 1P) * (Battery +)
V1N Circuit Breaker Status N Diff. Volt Input 1N 25 Low Coolant Level Switch (wire 31A) D1
V2P Voltage Bias P (Diff. Volt Input 2P) * 26 E-Stop (wire 1A)
V2N Voltage Bias N Diff. Volt Input 2N 27 Aux Shutdown/EOV Marathon Alternator
V3P Speed Bias P (Diff. Volt Input 3P) * 28 CT l3 (P7--3)
V3N Speed Bias N Diff. Volt Input 3N 29 CT I1 (P7--1)
Digital Input 30 Coolant Temperature (Resistive A2
D1 Low Coolant Level Switch (Digital Input 1) Sensor 2) (wire 35A)
D2 Spare Digital Input (Digital Input 2) 31 Isolated Ground. Analog Return

(wire BGA) (Common for all resistive
D3 Fuel Leak Switch (diesel) (Digital Input 3) inputs A1--A6)
D4 Spare Digital Input (Digital Input 4) 32 Spare Digital Input (Digital Input 5) D5
D5 Spare Digital Input (Digital Input 5) 33 Fuel Leak Switch (diesel) (wire 64) D3
D6 Spare Digital Input (Digital Input 6) 34 Fuel Selection Switch (gas) (wire LP)
Relay Driver Output 35 Isolated RS-485 2 B
RDO1 Circuit Breaker Open (RDO1) * P2 Options Connector (14-Pin)
RDO2 Circuit Breaker Close (RDO2) * 1 Spare Digital Input (Digital Input 6) D6
RDO3 Spare RDO3 2 Diff Volt Input 1P (CB Status *) V1P
RDO4 Air Heater Relay (diesel) RDO4 3 Diff Volt Input 2P (Voltage Bias *) V2P
* Paralleling application only
4 Diff Volt Input 3P (Speed Bias *) V3P
Figure 4-1 User Inputs/Factory-Reserved Inputs 5 RDO1 (CB Open *) RDO1
6 Diff Volt Input 1N V1N
Pin
No. Analog Digital 7 Diff Volt Input 2N V2N
P1 Main Connector (35-Pin) 8 Diff Volt Input 3N V3N
1 Crank Output (wire 71) 9 RDO2 (CB Close *) RDO2
2 RTC Power (Battery +) 10 SS3 Voltage Selector Switch A6

(Analog Input 6)
3 Controller Ground (wire N10) (Battery --)
11 SS 2 Voltage Selector Switch A5
4 Alternator Excitation Output (Analog Input 5)
5 Non Isolated CAN (+) (CAN 1) (yellow) 12 SS1Voltage Selector Switch A4
6 Non Isolated CAN (--) (green) (CAN 1) (Analog Input 4)
7 Open (Speed Sensor Input 1) 13 Air Heater Relay (diesel) (wire AHN) RDO4
8 Open (Speed Sensor Input 2) 14 Spare RDO RDO3
9 Isolated CAN (+) (CAN 2) (yellow) P3 AC Sensing Connector (7-Pin)
10 Isolated CAN (--) (green) CAN 2 1 Gen Voltage Sensing L1 (A)
11 Open (Isolated RS-485 1 A) 2 Gen Voltage Sensing L2 (B)
12 Open(Isolated RS-485 1 B) 3 Open
13 Run (Battery +) (wire 70) 4 Bus Voltage Sensing * L3
14 E-Stop (wire 1) 5 Gen Voltage Sensing L3 (C)
15 Remote Start/Stop (wire 3) 6 Gen Voltage Sensing L0 (NEU)
16 IR (P7--4) CT Return (common for all 7 Bus Voltage Sensing * L1
CTs) 8 Bus Voltage Sensing * L2
17 CT I2 (P7--2) * Paralleling application only
18 Oil Pressure (Resistive Sensor 1) A1 Figure 4-2 Connector (P1, P2, & P3) Designations
(wire 7)
80 Section 4 General Repair Information TP-6929 1/15

4.5 Controller Service A backup disk of the personality profile and
application program is supplied with the literature
Replacement packet shipped with the generator set. Typically, the
Adapted from TT-1642. distributor stores this disk for possible future use such
as controller replacement or other circumstances
requiring a backup.
4.5.1 Introduction
Note: If the personality disk is NOT available, request
Use the following procedure to install a replacement
a replacement from the manufacturer using the
controller. See Figure 4-3 for controller identification. generator set serial number or order number.
For features and operation of the controller, see the
respective operation manual. D User parameters unique to an installation include
timer values, setpoints, generator set data such as
voltage and input/output selections. These
parameters are typically set up for or by the installer at
the time of installation. User parameters are typically
recorded on the personality profile disk, a separate
backup disk/drive, or written on a paper form.
Note: If the user parameters are included on the

personality disk, the disk label should indicate
Site Program—Yes.
Read the entire installation procedure. Perform the

steps in the order shown.
1 TP-6914 Always observe applicable local and national electrical

1. Mini USB connection codes.
Figure 4-3 Decision-Makerr 3500 Controller
Note: The following service procedure changes only
the controller. If the generator set requires
Note: Do not use this controller replacement installation voltage reconnection and/or frequency
instruction for upgrading software. adjustment, see the respective operation
manual.
When replacing the controller, the following data must
be resident for the controller to function. Controller
service replacements do not include the three files 4.5.2 Installation Requirements
installed at the factory. The service technician must The following items are necessary PC requirements for
install the following three files into the replacement installing the controller service replacement.
controller.
D SiteTecht Software Version 3.6 or higher from the
D Application program contains the software that Kohler Power Resource Center website using the
controls system operation. The application file was TechTools button to download on your PC hard drive
preprogrammed in the original controller at the or disk if not already installed on your PC.
factory.
D TP-6701 SiteTecht Software Operation Manual
D Personality profile is specific to the engine and available from the Kohler Power Resource Center
alternator and was preprogrammed in the original website using the TechTools button.
controller at the factory.
D USB Cable with male USB-A and mini-B connectors.
See TP-6701 for more information.

4.5.3 Installation Procedure 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
WARNING connections with tools or jewelry while making adjustments or
repairs. Remove all jewelry before servicing the equipment.
1. Acquire the user parameters.

a. Choose one of the following methods to
retrieve the user parameters:
Accidental starting.
Can cause severe injury or death. D Backup disk. If a backup disk/file was previously
Disconnect the battery cables before made, obtain the parameters from this disk/file. If a
working on the generator set. disk/file was not previously made, create a backup if
Remove the negative (--) lead first possible using the SiteTecht software. The
when disconnecting the battery. existing controller must function enough to connect
Reconnect the negative (--) lead last to SiteTecht in order to create the file.
when reconnecting the battery.
D Paper form. Parameters may have been
previously recorded on a User-Defined Settings
Disabling the generator set. Accidental starting can
form or other similar form. If the parameters have
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the not been saved to a backup disk/file, and if
generator set as follows: (1) Press the generator set off/reset SiteTecht is not available, record the pertinent
button to shut down the generator set. (2) Disconnect the parameter values for manual entry (below) in the
power to the battery charger, if equipped. (3) Remove the replacement controller.
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these D Controller menu. Manually review the controller
precautions to prevent the starting of the generator set by the menu displays if possible and enter the parameter
remote start/stop switch. information in the respective controller operation
manual.
WARNING
b. Save the user parameter data for step 6c.
2. Remove the generator set from service.
a. Press the generator set master control

Hazardous voltage. Moving parts. OFF/RESET button.
b. Disconnect the power to the battery charger, if
Operate the generator set only when equipped.
all guards and electrical enclosures
are in place.
c. Use the battery disconnect switch (if equipped)
to disconnect the battery or disconnect the
Grounding electrical equipment. Hazardous voltage can generator set engine starting battery(ies),
cause severe injury or death. Electrocution is possible
negative (--) lead first.
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
d. Disconnect the generator set from the load by
generator set, transfer switch, and related equipment and
electrical circuits. Turn off the main circuit breakers of all opening the line circuit breaker.
power sources before servicing the equipment. Never contact
electrical leads or appliances when standing in water or on wet 3. Remove the existing controller and disconnect the
ground because these conditions increase the risk of electrical connections.
electrocution.
a. Remove the junction box panels as needed to
Connecting the battery and the battery charger. access the wiring.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and b. Remove the four controller panel screws.
negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified Note: Clearly mark all disconnected leads/
electrician install the battery(ies). connectors from the controller with tape
to simplify reconnection.

c. Disconnect the controller harness connectors, 6. Set the device profile.
see Figure 4-4.
a. Connect the PC to the Decision-Makerr 3500
P1 (35-Pin) Connector for engine/generator controller using a USB cable. See Figure 4-3
wiring harness. for the location of the USB connection port.
P2 (14-Pin) Connector for sensor input b. Insert the personality profile backup disk/drive
connections and relay driver output and load the data. Refer to the Tech
connections. Tools—Software and the SiteTecht Software
Operation Manual for details.
P3 (8-Pin) Connector for generator set output
c. Choose one of the following methods to load
voltage sensing and paralleling bus voltage
the user parameters.
sensing connections.
D Backup disk/drive. Use a PC with SiteTecht
P4 (Ethernet) Connector connects to a software to load the data from the user parameter
network communication line. backup disk/drive.
Note: These connections are typical and may D Paper form. Use a PC with SiteTech to enter the
not apply to all applications. See the user parameter data from a filled-out form.
corresponding wiring diagram found in
the respective wiring diagrams manual. d. If any changes are made using SiteTecht
create a new user parameter data backup
1 2 3
disk/drive. Refer to TP-6701 SiteTecht
Software Operation Manual for details.
e. Disconnect the USB cable.
f. Power down the unit by using the battery

disconnect (if equipped) or by disconnecting
the battery negative (--) terminal.
g. Wait at least 15 seconds and then power up the

GM90275-
unit by using the battery disconnect switch (if
1. P3 (8-pin) connector 4 equipped) or by reconnecting the battery
2. P2 (14-pin) connector
3. P1 (35-pin) connector negative (--) terminal.
4. P4 Ethernet connector
h. Refer to the respective controller operation
Figure 4-4 Main Circuit Board Connectors manual. Calibrate the generator set as
instructed in the Calibration submenu.
4. Reconnect the electrical connections and install
the replacement controller. i. Press the RUN button to start the generator set.
a. Reconnect all of the electrical connections
disconnected in step 3.c. j. Test the functionality of the controller by
reviewing the menus and observing the system
b. Align the controller panel with the mounting status lamps. Use the respective operation
holes and install four screws. manual as needed.
c. Replace the junction box panels if previously k. Press the OFF button to stop the generator set
removed. after completing the test.
5. Restore power to the generator set. l. Reconnect the generator set to load by closing
the line circuit breaker.
a. Use the battery disconnect switch (if equipped)
to reconnect the battery or reconnect the m. Press the generator set master control AUTO
generator set engine starting battery, negative button for startup by remote transfer switch or
(--) lead last. remote start/stop switch.
b. Reconnect power to the battery charger, if

equipped.

4.6 Synchronizing Test 5. Provide the generator set with a start signal
(AUTO-RUN).
Synchronizing is the action of matching the RMS voltage
amplitude, cycle frequency and phase of the generator 6. Allow another generator set to start and close to
with the paralleling bus. The paralleling logic contains a bus.
synchronizer which controls the engine speed and
7. Press the AUTO button to start, watch the screen
voltage regulator RMS target to actively match the
until the phase difference is at 30 degrees, press
frequency, voltage and phase of the generator to the
the RUN button to observe sync behavior. Make
bus. The decision to close the paralleling breaker is
any necessary adjustments.
determined by a synchronism check function (ANSI
relay 25C). The synchronization check function also 8. Press the AUTO button again, watch the screen
includes a dwell timer. If the frequency, voltage and until the phase difference is at 60 degrees, press
phase of the generator do not match the frequency, the RUN button to observe sync behavior. Make
voltage and phase of the paralleling bus, closing the any necessary adjustments.
generator breaker may cause damage to the generator
due to large circulating fault currents and mechanical 9. Repeat steps 7 and 8 above for 30, 60, 90, 120,
stress generated by the power angle between the two 150, 180, --150, --120, --90,--60, --30, and 0
generators. Follow the Synchronizing Test below. degrees. Verify minimal overshoot in all cases,.
Synchronizing Test Sequence 10. If overshoot is observed, try increasing the P

(Proportional) Gain first.
1. Navigate to the Synchronizing Setup Menu
(under the Paralleling Operation Menu). 11. If overshoot does not improve, set the P
(Proportional) Gain to 1.00 and try decreasing the I
2. Place the Sync Mode in Auto to OFF. (Integral) Gain. If the phase difference does not
stay within the window, it may be necessary to
3. Place the Sync Mode in Run to CHECK.
decrease to P (Proportional) Gain slightly.
4. Scroll down until the Phase Difference, Phase
Match P (Proportional) Gain, Phase Match I
(Integral) Gain, Phase Match D (Derivative) Gain,
and Speed Bias are highlighted.

Section 5 Component Testing and Adjustment
This section provides testing and troubleshooting Short circuits. Hazardous voltage/current can cause
information on select controller and generator set severe injury or death. Short circuits can cause bodily injury
accessories. and/or equipment damage. Do not contact electrical
connections with tools or jewelry while making adjustments or
The components and tests in this section apply to all repairs. Remove all jewelry before servicing the equipment.
controllers unless otherwise stated. Servicing the generator set when it is operating. Exposed
moving parts can cause severe injury or death. Keep
hands, feet, hair, clothing, and test leads away from the belts
WARNING and pulleys when the generator set is running. Replace
guards, screens, and covers before operating the generator
set.
WARNING
Accidental starting.
Disconnect the battery cables before
working on the generator set.
Hot coolant and steam.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last Before removing the pressure cap,
when reconnecting the battery. stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
Disabling the generator set. Accidental starting can
cause severe injury or death. Before working on the
generator set or equipment connected to the set, disable the
generator set as follows: (1) Press the generator set off/reset WARNING
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch. Hot engine and exhaust system.
WARNING Do not work on the generator set until

it cools.
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
Hazardous voltage. Moving parts. hot during operation.
Operate the generator set only when WARNING
all guards and electrical enclosures
are in place.
Disconnecting the electrical load. Hazardous voltage can

cause severe injury or death. Disconnect the generator set
from the load by turning off the line circuit breaker or by Carbon monoxide.
disconnecting the generator set output leads from the transfer Can cause severe nausea,
switch and heavily taping the ends of the leads. High voltage fainting, or death.
transferred to the load during testing may cause personal
The exhaust system must be
injury and equipment damage. Do not use the safeguard
leakproof and routinely inspected.
circuit breaker in place of the line circuit breaker. The
safeguard circuit breaker does not disconnect the generator
set from the load.
TP-6929 1/15 Section 5 Component Testing and Adjustment 85

Carbon monoxide symptoms. Carbon monoxide can
cause severe nausea, fainting, or death. Carbon monoxide
5.2 Other Service Parts
is a poisonous gas present in exhaust gases. Carbon The removal and installation of service parts other than
monoxide is an odorless, colorless, tasteless, nonirritating gas
the controller is covered by the following generic
that can cause death if inhaled for even a short time. Carbon
monoxide poisoning symptoms include but are not limited to procedure. Service parts include plug-in relays,
the following: switches, lamps, meters, gauges, brackets, and other
D Light-headedness, dizziness hardware.
D Physical fatigue, weakness in
joints and muscles
D Sleepiness, mental fatigue, 5.2.1 Removal
inability to concentrate
or speak clearly, blurred vision 1. Disconnect wiring from the part(s), noting the
D Stomachache, vomiting, nausea locations from which wiring was removed for later
If experiencing any of these symptoms and carbon monoxide reconnection. Tape and label the wires as needed.
poisoning is possible, seek fresh air immediately and remain
active. Do not sit, lie down, or fall asleep. Alert others to the 2. Note the position of the part(s) and loosen or
possibility of carbon monoxide poisoning. Seek medical remove hardware that holds the part(s) in place. If
attention if the condition of affected persons does not improve the removal is complex or will span several days,
within minutes of breathing fresh air. make sketches or use a video recorder or digital
camera to help capture the detail.
5.1 Controller Handling Note the location, type, and condition of the
The controller contains an electronic printed circuit hardware removed and compare it with the parts
board (PCBs) that is sensitive to a variety of elements list. Replace damaged or missing hardware.
and can be damaged during removal, installation,
3. Carefully remove the part(s) from the unit. Gently
transportation, or storage. Observe the following when
rock plug-in parts, such as relays, from side to side
working with the controller.
while pulling straight out to remove them without
using excessive force.
5.1.1 Handling
D Don’t bend or drop the controller or any of its 5.2.2 Installation
components.
1. Position the part(s) in place in the same manner
D Don’t strike the controller or any of its components that the old part was installed. Support the back of
with a hard object. the socket when installing plug-in parts, such as
relays and wiring harness plugs.
D Clean a dusty or dirty controller only with a vacuum
cleaner, dry brush, and/or aerosol spray cans 2. Tighten or reinstall hardware that holds the part(s)
specifically for electronic equipment and in place to the general torque specifications in
components. Aerosol spray cans are typically found Appendix C, General Torque Specifications,
with computer supplies. unless otherwise noted.
D Never attempt component-level circuit repairs as this If the torque specifications do not cover the
may void third party certification. application or do not seem appropriate let common
sense prevail. Avoid overtorquing hardware in
D Never remove or install a controller with the power sheet metal and non-metallic composites.
connected.
3. Reconnect wiring to the same location from which it
D Label wiring when disconnecting it for reconnection was removed, torquing terminals to the
later. specifications given in Section 1, Specifications.
D Remove wiring harnesses with plug connectors by

pressing the locking tab(s) and pulling on the plug
straight out to remove the wiring harness plug from
the controller socket.
86 Section 5 Component Testing and Adjustment TP-6929 1/15

5.3 General Information 5.5 Crank Relay
Use the respective parts catalog to determine the The test procedure for the following crank relay
appropriate replacement part. Sometimes service kits (Figure 5-1) applies to other applications of the same
replace a given part where additional components in the type relay including:
kit are necessary to provide the functional component D Crank relay
equivalent. The parts catalog illustrations may serve as
a guide for replacement but be aware that multiple D Flash relay
models are generally illustrated in a single view and D Heater relay
details may not represent the specific application. D Run relay
5.4 Leads/Wires/Wiring Harnesses

Repair/replace wiring when there is any doubt about its
condition. Tape minor control circuit wire insulation cuts
or abrasions less than 1 mm (0.04 in.) across by
wrapping the section tightly with three layers of electrical
tape.
GM14230B-D
Repair moderately damaged leads, where conductors
are cut or insulation is damaged over sections shorter Figure 5-1 Crank Relay Contacts
than about 100 mm (4 in.) or less than about 25% of the
length of the wire by cutting out the damaged section The relay is a single-pole, double-throw relay. Contacts
and splicing in wire of the same type. 85 and 86 are the relay coil. See Figure 5-2 for
specifications by relay part number. If replacement is
Replace extensively damaged or deteriorated leads necessary, do not substitute part numbers.
completely. If the leads are part of a wiring harness,
replace entire wiring harness. Fabricate replacement Coil Coil
leads using the same type of wire as the old leads. Add Relay Part Voltage Resistance, NO/NC Contacts
Number VDC ohms Rating, Amp
terminals and lead markers at each end of the new load.
GM49746* 12 90 10 50/30
GM49747* 24 360 10 20/15
* These relays contain an integrated diode that may affect
ohmmeter values when checking coil resistance. Be sure to
check coil resistance with the ohmmeter leads connected both
ways to help verify relay functionality and prevent unnecessary
replacement.
Figure 5-2 Relay Specifications

5.6 Current Transformers Two styles of current transformers are used. Round
(doughnut) styles have black/white leads with no
5.6.1 Function and Application mounting provisions. The square styles have two #8-32
studs/nuts for connecting the leads and four notches in
The current transformers provide several generator set the base for mounting.
functions including sensing for:
D Sensing of alternator AC current
A current transformer contains a coil of wire that induces
a secondary voltage/current from the primary or stator
D Voltage selector switch (if equipped) lead passing through the center. The number of coil
The controller uses one set of current transformers turns inside the current transformer determines the
while the voltage selector switch (if equipped) uses a ratio. Replacement current transformers must have the
separate set of current transformers. same ratio as the original.
See Figure 5-3. The generator set junction box contains

5.6.2 Testing
the stator leads and the current transformers.
Use an ohmmeter to check the current transformer.
Perform this test with the current transformer
disconnected from the generator set. A resistance
reading of infinity or 0 ohms suggests an open or shorted
current transformer that needs replacement. Consider
any other resistance reading acceptable.
5.7 Fuel Leak Alarm (FLA) Switch

The fuel leak alarm switch can be tested using an
ohmmeter. Set to the R x 1 range and attach the test
leads to the FLA leads. The ohmmeter should show
high resistance (open) with the float in the “down”
position and no resistance (closed) with the float in the
“up” position. Use the switch position markings to
properly install the FLA switch in the fuel tank port.
1
ADV-8632B-
Figure 5-3 Current Transformers
When replacing the current transformer or stator

assembly, install the current transformer according to 2 3
the generator reconnection decal on the generator set,
or see the wiring diagrams manual. Observe the correct
current transformer position when installing the stator
GM90154
leads. The current transformer dot or HI mark position 1. Normally closed contact position
and the stator lead direction are essential for correct 2. Normally open contact position
3. Switch position markings
component function. The dot or HI mark should face
toward the stator. Figure 5-4 Fuel Leak Alarm (FLA) Switch

5.8 Engine Pressure and 5.8.3 Switch Testing
Temperature Sensors Before testing switch, disconnect the switch lead(s).
5.8.1 General
Pressure Switch
Use this section to test engine sensors (switches or
Some pressure switches make contact on falling
sensors) installed by the generator set manufacturer on
pressure and some on rising pressure; refer to the
the engine. Refer to the respective engine service
respective drawing for contact style. Connect an
manual for testing sensors installed by the engine
ohmmeter to the switch terminals. Switches with one
manufacturer.
terminal require connection to ground on the switch
Use the following tests to determine if the sensor is metal body. Apply the pressure value shown in
functional. All sensors should have part numbers Section 1, Pressure Switches, and observe the
stamped on the metal housing. In cases where the ohmmeter before and after values to determine if the
number is illegible or missing, refer to the respective switch contacts open and close per specifications.
generator set parts catalog for the corresponding part
number. The user must determine the sensor part Temperature Switch
number in order to determine the sensor specifications
which are found in Section 1, Specifications. High water temperature switches make contact on rising
temperature. Low water temperature switches make
The sensors can be installed on the generator set contact on falling temperature. Refer to the respective
provided the leads are disconnected and a temperature drawing for contact style. Connect an ohmmeter to the
or pressure gauge is available to determine the engine switch terminals. Switches with one terminal require
values. Otherwise, remove the sensor after draining the connection to ground on the switch metal body. Apply
respective engine fluid (oil or coolant) and test using a the temperature value shown in Section 1, Temperature
separate pressure or temperature source. Switches, and observe the ohmmeter before and after
values to determine if the switch contacts open and
The resistance of the oil pressure and water close per specifications.
temperature sensor output signals varies as the
respective pressure and temperature change. Use the
resistance change for verification of sensor function. 5.8.4 Sensor Testing
Disconnect all leads from the sensor before checking Before testing sensor, disconnect the sensor lead(s).
resistance. If the sensor functions and the display does
not function, check the engine wiring harness, leads,
and connectors before replacing the display board. Pressure Sensor
Some generator sets may have sensors/switches Pressure sensors change resistance values as
pressure changes. Connect an ohmmeter to the sensor
incorporated with the engine ECM (electronic control
module). Identify engine ECM sensors/switches by lead terminals. Sensors with one terminal require
designations listed in the following testing information. connection to ground on the switch metal body. Apply
Refer to the wiring diagrams manual for additional lead pressure values shown in Section 1, Pressure Sensors,
and observe the ohmmeter values to determine if the
identification information. Use the engine service
manual for troubleshooting ECM sensors/switches. sensor changes resistance per specifications.
5.8.2 Sensor Types Temperature Sensor
The sensors referenced in this section typically provide Temperature sensors change resistance values as
the following controller inputs: temperature changes. Connect an ohmmeter to the
sensor terminals. Sensors with one terminal require
D High engine temperature shutdown switch
connection to ground on the switch metal body. Apply
D High engine temperature warning (prealarm) switch temperature values shown in Section 1, Temperature
D Low oil pressure shutdown switch Sensors, and observe the ohmmeter values to
D Low oil pressure warning (prealarm) switch determine if the sensor changes resistance per
specifications.
D Low water temperature warning switch
D Oil pressure display sensor (see Section 5.8.5)
D Water temperature display sensor (see Section 5.8.6)

5.8.5 Oil Pressure Sensor Testing 5.9 Coolant Level Sensor (CLS)
(OPS)
The coolant level sensor (CLS) changes output voltage
Disconnect the oil pressure sensor lead 7C. See as the probe tips are exposed to coolant/antifreeze. Use
Figure 5-5. Check the sensor resistance with an the following procedure for testing the CLS switch
ohmmeter. Compare the resistance values when the (Figure 5-7).
generator set is shut down and when it is running at
operating temperature to the values shown in Section 1, (--)
Specifications.
Use a mechanical oil pressure gauge to further verify

correct readings.
Lead 7C GM66270-A
Figure 5-7 Coolant Level Sensor
Testing the coolant level sensor.

1. Setup the test connections as shown in Figure 5-8
TP-5353-7 but do not connect the battery (+) connection at this
Figure 5-5 Oil Pressure Sensor, Typical time.
2. Be sure to isolate the connections at the CLS so

5.8.6 Water or Coolant Temperature that the (+) and (--) connections do not short
Sensor Testing (CTS) together.
The water temperature sensor has three configurations: 3. With the CLS probe tips dry with no coolant
(1) a single function, single-terminal type, (2) a single contacting them, complete the circuit at the battery
function, two-terminal type, and (3) a dual function, two (+) connection.
-terminal type with temperature sensor and low coolant
temperature switch. See Figure 5-6. The sensor is okay if the voltage oscillates between
5 volts +/--1 volt and 9 volts +/-- 1 volt every 10--12
seconds when the probe tips are not immersed in
Type 1 Type 2 Type 3
coolant.
Lead 5 5 5 35A CLS
(+) (--)
TP-5353-7
Figure 5-6 Water Temperature Sensor, Typical
Sensor type 3 has lead 5 connected to water 560 Ohm

temperature sensor terminal with a 6-32 screw and Resistor
lead 35A connected to the low water coolant
temperature switch terminal with an 8-32 screw. 5 Amp
DC Voltmeter
Fuse
Disconnect the water temperature sensor lead 5 (and
Battery (+) Battery (--)
lead N with type 2 configurations). Check the sensor Connection Connection
resistances with an ohmmeter. Compare the resistance SB-000
values when the generator set is shut down and when it
Figure 5-8 CLS Testing
is running at operating temperature to the values listed
in Section 1, Specifications.

4. Disconnect the battery (+) connection. Note: If the RUN button is pressed or the controller is
powered down, the parameter will change back
5. Place the CLS probe tips in a glass or plastic to “OFF” automatically.
container with coolant. Coolant previously drained
from the radiator is acceptable.
1
Note: Do not use water as the test results may not
be accurate.
6. Be sure to isolate the connections at the CLS so

that the (+) and (--) connections do not short
together.
7. With the CLS probe tips immersed in coolant,

complete the circuit at the battery (+) connection. 2
The sensor is okay if the voltage remains steady at

9 volts +/--1 volt when the probe tips are immersed
in coolant.
1. ECU diagnostic port
8. Disconnect the battery (+) connection.
2. USB connector
9. If the CLS passes both tests the CLS is considered Figure 5-9 ECU Diagnostic Port and USB
functional. Replace the CLS if it fails either or both Connector Locations
tests.
5.10 Powering Up the ECU without

Cranking the Engine (John
Deere-Powered Models only)
If connecting to John Deere’s Service Advisor for
troubleshooting in the field or reprogramming the engine
ECU, use the following procedure.
1. Connect a USB cable from a Laptop (equipped with

SiteTecht) to the Decision-Makerr 3500
controller. See Figure 5-9 for the USB connection
at the Decision-Makerr 3500 controller.
2. Connect the John Deere Electronic Data (EDL)

from a Laptop (equipped with John Deere Service
Advisor) to the ECU Diagnostic port on the
generator. See Figure 5-9 for the port location.
3. Open SiteTecht after connection to the

Decision-Makerr 3500 controller is established.
Under the GENSET SYSTEM CONFIGURATION

parameter, change ECM Powered Mode from
“OFF” to “ON”. See Figure 5-10
4. When opening the John Deere Service Advisor

Program on the laptop, it should now power the
LEDs on the EDL and attempt to establish
connection with the ECU.
Figure 5-10 Genset System Configuration Parameter
(in SiteTecht)

5.11 Remote Serial Annunciator
(RSA III)
Adapted from Instruction TT-1625 9/14.
The following information summarizes the setup items

when troubleshooting the remote serial annunciator.
Refer to the RSA installation instructions for operation
and function.
5.11.1 RSA III Features and Connections

RSA III is an annunciator panel offered in several kit
configurations to support Kohler power equipment. The
RSA III is a remote serial annunciator that monitors the
condition of the generator set and/or ATS from a remote
location. The RSA III alerts the operator through visual
and audible signals using LED indication and a horn. An Figure 5-11 Remote Serial Annunciator (RSA III)
alarm silence and lamp test switch are included.
An RSA III annunciator can be used for a single
generator set (Figure 5-11) or with a combination of a
generator set and automatic transfer switch(es)
(Figure 5-12 or Figure 5-13). In systems using more
than a single RSA III, one must be designated as the
master device to broadcast to additional RSA III
annunciators, designated as slave devices. Up to five
RSA III slave devices can be used with an RSA III
master device. All RSA III annunciators are factory set
as the master device, but can be changed to a slave
device using a PC and SiteTecht software that
connects to the RSA III front panel via a universal serial
bus (USB) connection.
The RSA II can be connected with the RSA III provided
that the master remote annunciator is an RSA III.
A PC with SiteTecht software is required to make Figure 5-12 RSA III with Single ATS Control
the RSA III functional. Use your SecurID to access
KOHLERnet, click on the TechTools button, and follow
the instructions to download the files. See SiteTecht
Software Settings and refer to TP-6701 SiteTecht
Software Operation Manual for more information.
RSA III annunciators used with DEC 3+ controllers
require a separate communication module that can be
provided with RSA III kit selection.
If a fault occurs, the RSA III horn activates and the
corresponding LED illuminates. The following paragraphs
describe specific features of the RSA III.
If the RSA III 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.
Figure 5-13 RSA III with Four ATS Controls

If the RSA III is used with a DEC 3+ controller, it will Communication between RSA III Master and RSA III
require a communication module board; refer to Slave. Select and connect the RS-485 wiring from the
TT-1285 Program Loader Software instructions for RSA III master to the RSA III slave(s) in a daisy chain
downloading firmware version 1.23 and higher. wiring configuration using Belden #9841 or equivalent.
Figure 5-15 shows the master/slave RS-485
If there is only one RSA III, it is the master. If several connections and Figure 5-16 shows the RSA III with
RSA III are installed, choose either the RSA III closest to P27 location.
the generator set or determine which RSA III is more
practical for use as a master and use a daisy chain wiring P27 RS-485 Connections (from Master to Slave)
configuration for the remaining RSAs. The RSA III P27-1 (--) Black (from master or previous slave)
connected to controller MUST be assigned as the
P27-2 (+) White (from master or previous slave)
RSA III master.
P27-3 Shield (from master or previous slave)
Note: When an RSA III is installed into a system with P27-4 (--) Black (to next slave or terminating resistor)
existing older RSAs, the RSA III must be P27-5 (+) White (to next slave or terminating resistor)
configured as the master. P27-6 Shield (to next slave or open)
Note: When using RS-485 communication cable, connect the
Note: Should any communication issues occur when “shield” wire at either end but not at both ends.
adding RSA III slaves and/or transfer switches to
Figure 5-15 P27 Connection on RSA III Slave
the system, be sure to power down the RSA III
master and then power up the RSA III master so
Top View
that the RSA III master can recognize the
changes.
Use the SiteTecht software to select either that the

generator set controller activates EPS Supplying Load
LED or the transfer switch activates LED or local EPS
supplying load.
Use the SiteTecht software to select the high speed

mode for direct connection to the DEC 550 and DEC
6000 controllers. Select lower speed for network
connection with the Modbusr/ Ethernet converter. The
lower speed allows network functionality reducing loss
of communication faults.
Bottom View
5.11.2 Terminating Resistor and Wiring
For communication between the controller and RSA III 1
master, see Figure 5-14. For communication between
RSA III Master and RSA III Slave, see Figure 5-15.
Place the terminating resistor on the last RSA III slave in
the daisy chain connection. 2
Note: When using RS-485 communication cable,
connect the “shield” wire at either end but not at 3
both ends.
P27 RS-485 Connections (from Controller to Master ) 4

P27-1 (--) Black (from controller)
P27-2 (+) White (from controller) 7 6 5 GM86125-
P27-3 Shield (from controller) 1. P39, 3-pin Isolated/non-isolated jumper
2. P27, 6-pin RS-485 connections
P27-4 (--) Black (to slave or terminating resistor)
3. P34, 3-pin RS-485 termination resistor for last device
P27-5 (+) White (to slave or terminating resistor) 4. P41, 8-pin Input (EPS/User) connections
P27-6 Shield (to slave or open) 5. P42, 4-pin Input user 4 & 5 connections
6. P40, 6-pin Common fault and horn dry contacts
Note: When using RS-485 communication cable, connect the 7. P37, 3-pin Power/CAN connections
“shield” wire at either end but not at both ends.
Figure 5-14 P27 Connector on Master RSA III Figure 5-16 RSA III Circuit Board GM86125
Connectors
5.12 Fault Warning and Shutdown Test Method 1
Testing Remove the sensor lead and ground the lead to the
engine block ground or connect a jumper wire from the
Adapted from Service Bulletin SB-616 5/14o.
sensor terminal to the engine block ground.
Some generator set models with electronic control
modules (ECM) may limit or prohibit adjusting the Test Method 2
engine speed or testing the warning and shutdown
faults. This type of testing is typically required by the Test faults using a 5 kOhm, 10-turn, 3-watt
NFPA 110 standard for emergency power supply potentiometer (part no. X-6136-36) and the illustration
systems or by other governing agencies and is also shown in Figure 5-17. Before starting the generator set,
useful in troubleshooting the generator set engine and turn the potentiometer fully counterclockwise. While the
controller. Figure 5-19 shows if the fault warning or fault generator set is running, turn the potentiometer
shutdown tests are feasible. clockwise until the unit shuts down.
The engine ECM or other generator set controls may Wiring Harness Connector Terminals
impact the following shutdowns and warnings. The B LT GRN/RED
letter (A or B) in parentheses identifies the fault category
in Figure 5-19. 5 kOhm C LT BLU
Pot.
D Overspeed (governor control) shutdown *
D Overcrank shutdown [
A BLK/LT GRN
D High coolant temperature shutdown (A)
SB616
D High coolant temperature warning (A)
D Low coolant temperature warning (A) Figure 5-17 Coolant Temp. and Oil Pressure Test
D Low oil pressure shutdown (A)
D Low oil pressure warning (A)
Test Method 3
D Battery charger fault warning (B)
D Low battery voltage warning (B) Test coolant temperature faults using a 500 ohm,
D Low fuel (level or pressure) warning (B) 10-turn, 3-watt potentiometer (part no. X-6136-37) and
* Manually overspeed the engine if it is not ECM controlled. the illustration shown in Figure 5-18. Turn
[ To test overcrank (and cyclic engine cranking) on gas-fueled potentiometer fully counterclockwise before starting the
models, temporarily disconnect the ignition system. On generator set. While the generator set is running, turn
diesel-fueled models, temporarily disconnect the fuel injection the potentiometer clockwise until the unit shuts down.
pump wire harness.
The mating connector to the engine wiring harness
Use the information in Figure 5-19 to Figure 5-22 to test connector is a Packard Electrical Division part no.
the engine sensor/switch faults during troubleshooting 12066016.
of the generator set.
Wiring Harness Connector Terminals
500 Ohm A TAN/WHT

Pot.
B BLK/LT GRN
SB616
Figure 5-18 Coolant Temperature Test

Fault Warning and Shutdown Tests
Model Engine Governor Type Overspeed Overcrank Engine Sensors (A) External Sensors (B)
Gas
25--150REZG GM/PSI Electronic, E-Controls No Yes Yes* Yes
Diesel
30/40REOZK4 Kohler
ECM Control Yes Yes Yes* Yes
35/45REOZT4 KDI
* Units with Decision-Makerr 3500 controller may require user-supplied potentiometers to simulate sensor function.
The potentiometer value and connector vary by engine manufacturer/model.
Figure 5-19 Feasibility of Fault Warning and Shutdown Tests
High Coolant High Coolant Low Oil Pressure Low Oil Pressure
Temperature Temperature Shutdown, Warning,
Model Engine Freq. Shutdown, C (F) Warning, C (F) kPa (psi) kPa (psi)
Gas
25--150REZG GM/PSI 60 111 (232) 103 (218) 55 (8) 104 (15)
Diesel
30/40REOZK4
Kohler KDI 60 110 (230) 107 (225) 83 (12) 138 (20)
35/45REOZT4
Figure 5-20 Factory Shutdown and Warning Setpoints
High Coolant Temp. Low Coolant Temp. Low Oil Pressure

Governor Fault Warning Fault Warning Fault Warning
Model Engine Type Test Connections Test Connections Test Connections
Gas
A--Black/Lt. Green
ECM A--Tan/White
30--125REZGT GM/PSI 3 1 Lead 35A 2 B--Lt. Green/Red
Control B--Black/Lt. Green
C--Lt. Blue
Diesel
30/40REOZK4 Kohler ECM
1 Lead 35A 1 Lead 35A 1 Lead 7
35/45REOZT4 KDI Control
BLK Black; BLU Blue; BRN Brown; GRY Gray; GRN Green; ORG Orange; PNK Pink; WHT White
Figure 5-21 Fault Warning Test Method and Connections
High Coolant Temp. Low Oil Pressure

Fault Shutdown Fault Shutdown
Model Engine Governor Type Test Connections Test Connections
Gas
A--Black/Lt. Green
A--Tan/White
30--125REZGT GM/PSI ECM Control 3 2 B--Lt. Green/Red
B--BLK/Lt. Green
C--Lt. Blue
Diesel
30/40REOZK4
Kohler KDI ECM Control 1 Lead 35A 1 Lead 7
35/45REOZT4
BLK Black; BLU Blue; BRN Brown; GRY Gray; GRN Green; ORG Orange; PNK Pink; WHT White
Figure 5-22 Fault Shutdown Test Method and Connections

5.13 Voltage Selector Switch
(Towable Models only) 120/208V
277/480V 3 PH 120/240V
3 PH 1 PH
See Figure 5-23 and Figure 5-24 for the electrical
NOTE: Blank denotes
connections of the voltage selector switch used with contacts open.
selected models. Refer to Figure 5-25, Figure 5-26,
“C” denotes contact closed.
and Figure 5-27 for electrical connections of the
generator set output windings and the auxiliary switch.
Use this information to help troubleshoot the voltage ADV-6670A-B
selector switch when the wiring and/or voltage selector

Switch 277/480 V 120/208 V 120/240 V Switch
switch contacts are in question. Refer the the respective
Terminal 3 Phase 3 Phase 1 Phase Terminal
wiring diagram manual for actual connections.
1 C C 2
3 C 4
5 6
A T7 B
T10 C T9 D
T3
E
T8 AUXILIARY
SWITCH 7 C C 8
9 C C 10
11 C C 12
13 C 14
15 C 16
17 C 18
19 C 20
A B T12 C B D E 21 C C 22
23 C 24
T2 T6 T1 25 C C 26
AUXILIARY
SWITCH 27 C 28
Auxiliary Auxiliary
Terminal Terminal
1 C 2
3 C 4
5 C 6
7 C C 8
T5 T11 T4
9 C C 10
11 C C 12
ALTERNATOR
FACTORY
JUMPER
OUTPUT FACTORY
JUMPER
Figure 5-24 Voltage Selector Switch Internal
WINDING
GM87956-A Connections
Figure 5-23 Voltage Selector Switch

277/480V, 3 (Y) L1 3 AUXILIARY SWITCH
FACTORY JUMPER
ALT. OUTPUT WINDING 1 3 5
T1 Y YY Z
2 4 6
7 9 11
T4 YY YY YY
8
Z 10 Z 12 Z
1 3
YY 7 YY
Y
Z 2 4 Z
8
T7
T10
L0
12
11
YY
Y
T12 T11 20
Z YY
YY
10 19
9 15
14 28 23 Z
Y T9 16 T8 Y
T6 24
Z T5
13 27
18
17 YY
T3 26 T2
YY 25
Y YY
22 Z
21
L2 3
L3 3
TP-6929-5
Figure 5-25 Voltage Selector Switch with Auxiliary Switch Connections, 277/480 Volt, 3-Phase

120/208V, 3 (YY) L1 3 AUXILIARY SWITCH
FACTORY JUMPER
ALT. OUTPUT WINDING L1 1 1 3 5
Y YY Z
T1 2 4 6
7 9 11
YY YY YY
8
Z 10 Z 12 Z
T4
1 3
YY 7 YY
Y
Z 2 4 Z
8
T7
120V
240V
T10
L0
12
11
YY
Y
T12 T11 20
Z YY
YY
10 19
9 15
14 28 23 Z
Y T9 16 T8 Y
T6 24
Z T5
13 27
18
17 YY
T3 26 T2
YY 25
Y YY
22 Z
21
L2 3
L2 1
L3 3 TP-6929-5

120/240V, 1 (Z) L1 3 AUXILIARY SWITCH
FACTORY JUMPER
L1 1
ALT. OUTPUT WINDING 1 3 5
Y YY Z
T1 2 4 6
7 9 11
YY YY YY
T4 8
Z 10 Z 12 Z
1 3
YY 7 YY
Y
Z 2 4 Z
8
T7
120V
240V
T10
L0
12
11
YY
Y
T12 T11 20
Z YY
YY
10 19
9 15
14 28 23 Z
Y T9 16 T8 Y
T6 24
Z T5
13 27
18
17 YY
T3 26 T2
YY 25
Y YY
22 Z
21
L2 3
L2 1
L3 3
TP-6929-5

5.14 Motor-Operated Circuit D The voltage and frequency of the generator set.
There is no benefit to closing the paralleling breaker
Breakers (if equipped) to a dead bus if the generator set is not producing
The Decision-Makerr 3500 controller provides rated voltage and frequency. The breaker will not
close until the generator set output is within spec to
automatic operation of a motor-operated circuit breaker
avoid providing power that is out of certain
including opening and closing of the breaker and
specifications.
synchronization of the generator set output to the
paralleling bus. D Permission from other generator sets. Only one
generator set is permitted to close to the paralleling
5.14.1 Automatic Closing of the Breaker bus when it is dead. This generator set will be
selected from among the running generator sets
Note: The Decision-Makerr 3500 controller will only based on the following:
close the breaker if it receives a signal to run.
D The first generator set to start.
Note: In paralleling applications (two or more generator D The generator set controller with the lowest serial
sets), the PGEN connection is required to close number (if they are both running at the same time).
the breaker. Refer to the respective Wiring
Diagram manual. No controller will signal the motor-operated breaker
to close until all the other generator sets have
Note: In a single generator application with no PGEN conceded that it will be the first to close.
connection, set the Stand Alone Operation
parameter to ON in the Synchronization Control D System configuration parameters:
Menu in order to close the breaker. D Synch Mode in Auto
Dead Bus Closure: If the generator is operating in Auto Mode (the LED
above the Auto button is illuminated), this
The Decision-Makerr 3500 controller monitors the parameter must be set to one of the following for
following to determine if it is safe to close the paralleling the controller to signal the breaker to close to a
breaker to a dead bus: dead bus:
d Check
D Voltage on the paralleling bus sensing
d Passive
connections to the controller. The paralleling bus
d Active
voltage must be below the dead bus threshold.
D Synch Mode in Run
D The status of the paralleling breakers of the other
generator sets on the paralleling bus. All the other If the generator set is operating in Run Mode (the
generator sets in the system must have open LED above the Run button is illuminated), this
breakers if the bus is perceived to be dead for the parameter must be set to one of the following for
following reasons: the controller to signal the breaker to close to a
dead bus:
D It is potentially harmful to provide voltage to the
d Check
stator of a stopped generator set.
d Passive
D If the other generator set is running but the bus d Active
sensing does not indicate bus voltage, the bus
sensing for the controller may not be connected Note: The “Check” Synch Mode will only close the
and it may close out of phase to a live paralleling paralleling breaker to a dead bus, not a live one.
bus.

Live Bus Closure: D System configuration parameters:
The Decision-Makerr 3500 controller monitors the D Synch Mode in Auto

following to determine if it is safe to close the paralleling
breaker to a live bus: If the generator set is operating in Auto Mode (the
LED above the Auto button is illuminated), this
D Voltage and frequency of the paralleling bus as parameter must be set to one of the following for
measured by the paralleling bus sensing the controller to signal the breaker to close:
connections to the controller. The paralleling bus d Passive
voltage must be within the validity window (same as
the generator set). The controller is not changing
the speed or voltage bias for
D The difference between the RMS voltage of the the generator set but will signal
parallelling bus and the RMS voltage of the the breaker to close if the
generator. The controller will not signal the breaker voltage, frequency, phase,
to close while the generator set differs from the bus and phase rotation all match
voltage by more than the Voltage Match Window the paralleling bus.
threshold.
d Active
D The difference between the frequency of the
paralleling bus and the frequency of the
The controller controls the
generator set. The controller will not signal the
speed and voltage of the
breaker to close unless the generator set frequency is
generator set to match phase,
within the Frequency Match Window of the frequency
voltage and frequency with the
of the paralleling bus.
parallelling bus, the breaker is
D The Phase Difference between the generator set signaled to close if the voltage,
and the paralleling bus. The controller will not frequency, phase, and phase
signal the breaker to close unless the phase angle rotation all match the
between the generator set output and the bus output parallelling bus.
is within the Phase Match Window (positive or D Synch Mode in Run
negative).
If the generator set is operating in the Run Mode
D The Phase Rotation of the generator set and the (the LED above the Run button is illuminated), this
paralleling bus. The phase rotation (ABC or CBA) of parameter must be set to one of the following for
the generator set must match the phase rotation of the controller to signal the breaker to close:
the paralleling bus in order for the controller to initiate d Passive
active synchronization or to signal the paralleling
breaker to close. The controller is not changing
the speed or voltage bias for
the generator but will signal
the breaker to close if the
voltage, frequency, phase,
and phase rotation all match
the paralleling bus.
d Active
The controller controls the

speed and voltage of the
generator to match phase,
voltage and frequency with the
paralleling bus, the breaker is
signaled to close if the voltage,
frequency, phase, and phase
rotation all match the
paralleling bus.

5.14.2 Automatic Opening of the Breaker The synchronizing function operates under the following
conditions:
The Decision-Makerr 3500 controller opens the
paralleling breaker for any of the following conditions: D Accurate bus sensing connection (to load side of
motor-operated breaker).
D Generator set fault
D Synchronization Mode set to Active or Check. If the
D Emergency stop synch mode is set to passive, synchronization is
monitored but not controlled.
D Start signal removed
D Generator set voltage within tolerance of rated
D Generator Management signals the generator to stop quantities (all phases).
and the generator set is unloaded
D Bus voltage within tolerance of rated quantities (all
D OFF button pressed. Load enable input is removed phases).
and the generator set is unloaded
D Generator set phase rotation matches that of
D Output voltage too high paralleling bus (ignored for single phase) alternator
connections.
D Output voltage too low
The Decision-Makerr 3500 controller controls the
D Output frequency too high
speed and voltage as follows:
D Output frequency too low
D The average single- or three-phase RMS amplitude
D Output power too high of the generator set voltage is controlled to match the
average single- or three-phase RMS amplitude of the
D Generator set absorbing power paralleling bus.
D Output current too high D The cycle frequency of the generator set is controlled
to match the cycle frequency of the paralleling bus.
D Generator set absorbing reactive power (excitation is
lost) D The phase angle between the output waveform of the
generator set and the measured waveform from the
paralleling bus is controlled to 0 electrical degrees.
5.14.3 Synchronization of the Generator
Output to the Paralleling Bus The generator set is considered to be in 0 electrical
degree synchronism when none of these quantities
The synchronizing features of the controller require a differ by more than the allowable threshold (window).
three-phase bus metering connection to ensure that the
line voltage on all three phases can be monitored (to The breaker is signaled to close (in auto mode) after the
avoid high reactive power flow due to phase imbalance generator set has maintained synchronism with the
immediately prior to breaker closure and to ensure paralleling bus for the Dwell Time.
identical phase rotation).

5.14.4 Troubleshooting Non-Operating Breaker
Unable to control
motor operated
breaker
Is switch on motor Place switch in

operator in Auto?
No Auto
Yes
Does the Is the charge Verify wiring

indicator on the motor receiving feeding the
motor operator No 24VDC between No
breaker
show charged? A1 (--) and B4(+)?
Yes
Is the charge Are the green Connect green and

motor receiving Is the breaker black wires to pins
No tripped (handle in No and black No
24VDC between A1 (--) wires 1 and 2 of the SDE
and B2(+)? center position)? switch
connected
incorrectly?
Verify that the

contact block for
Yes SDE is positioned
correctly
Yes
Reset the breaker by

manually moving the
Yes handle or by winding
the motor operator by
hand and pressing
Yes the off button
Is the breaker Open the breaker

No to allow recharge
open?
Yes
Is the motor
operator Reseat the motor
properly seated No operator on the
on the breaker? breaker
It may be necessary
to contact Factory
Yes Service for additional
Go to A troubleshooting steps

Go back to
A previous
page
Set the breaker mode

to manual, close the
breaker by pressing
the On button and open
the breaker by pressing
the Off button
Does the
breaker No
recharge if
placed in Auto?
Yes
Set the Event for both

Digital Output 115 and
Digital Output 116 to
Not In Auto on the
DEC3500
Does the Is the Verify wiring between

breaker close when breaker close relay the controller and the
the Off button is No being energized when No breaker close relay
pressed on the the Off button is (P to pin 86,
DEC3500? pressed? CBC to pin 85)
Yes
Is 24VDC Verify wiring

present between between
pin 30 of the close No terminal 24V+ and
relay (+) and pin 30 of the
24V--(--)? breaker close relay
Verify wiring between

Yes pin 87 of the breaker
Yes close relay and pin A2
of the motor operator
Does the Is the Verify wiring between

breaker open when breaker open relay the controller and the
the auto button is No being energized when No breaker open relay
pressed on the the Off button (P to pin 86,
DEC3500? is pressed? CBO to pin 85)
Yes Yes
Set the Event for
Digital Output 115 to
Remove Breaker Trip Is 24VDC Verify wiring
and Digital Output 116 present between between
to Close Breaker on pin 30 of the No terminal 24V+ and
the DEC3500 close relay (+) pin 30 of the
and24V--(--)? breaker open relay
Verify wiring
between pin 87a of
Yes the breaker trip
Go to B relay and pin A4 of
the motor operator

B
Navigate to
Controller Config -->
Communication Setup
on the UI or open the Note: UI = User Interface at the controller.
Synchronization Control
section in SiteTech
Enable Stand Alone

Are at least 2 Mode (Gen Info -->
Are at least 2 Parallel Operation -->
PGEN nodes No generators installed at No
available? Parallel Ctrl on UI or
the site? Synchronization
Control in SiteTech
Yes
Navigate to
Controller Info --> Parallel Verify PGEN connections
Operation--> Synchronizing between the generators
Setup on the UI or open Yes (wire must be Belden
the Bus Metering section in 9841 or equivalent, 120
SiteTech termination resistor
may be required)
Start the
generator
by pressing run
Verify that the

Is the bus bus metering is
voltage < 10%* of connected to the
the generator voltage No
line side of the
with the generator motor operated
running? breaker
Yes
Does the Follow

controller have troubleshooting for
any active faults Yes
active faults
or warnings?
No
Are any other Open breaker on

generators in the system Yes all connected
indicating a closed generators
breaker?
No
Is the
Sync Mode in Run Set the Sync
set to Check, Active No Mode in Run to
or Passive? Check
It may be necessary
to contact Factory
Service for
Yes additional
troubleshooting
* The bus is considered dead when the bus voltage is below the Dead Bus Threshold. Factory Default is 10% steps

Generator is
not producing
voltage when
running
Navigate to Metering -->

Parallel Metering on
UI or Synchronization Note: UI = User Interface at the controller.
Control in SiteTech
(look at Generator
Paralleling Breaker)
Controller indicates
Failure to Open
(High Fail To Open Delay) Does the
controller indicate
that the generator is Continue with
No alternator
connected to the
paralleling bus? troubleshooting
Yes
Does the Verify that BSP and

indicator on the BSN are connected to
motor operator No an ‘A’ contact (the
show that it is contact tracks the
closed? breaker contacts)
Continue with
“Unable to control
Yes motor operated
breaker”
troubleshooting
Controller indicates Failure to Close

(High Fail To Close Delay or
High Breaker Close Attempts)
Continue with
Does the “Unable to control
indicator on the motor
operator show No motor operated
breaker”
that it is closed? troubleshooting
Verify that BSP and

BSN are connected to
Yes an ‘A’ contact (the
contact tracks the
breaker contacts)

Section 6 Paralleling System Information
6.1 Controller Functionality With the external bias enabled, the output voltage is set
based on the voltage between VBP and VBN:
The Decision-Makerr 3500 controller is intended for
single-generator set applications, applications where D Voltage < 0.5V: Voltage Regulator Average Voltage
the generator set speed and voltage is controlled by Adjustment.
external gear to parallel the generator sets (External
Paralleling), and applications where the controller D Voltage = 0.5V: 90% of Voltage Regulator Average
performs the synchronization, load sharing, and Voltage Adjustment.
generator set management (Internal Paralleling).
D Voltage = 2.5V: Voltage Regulator Average Voltage
Adjustment.
6.1.1 Single-Generator Set Operation
D Voltage = 4.5V: 110% of Voltage Regulator Average
No configuration is necessary for the controller to Voltage Adjustment.
support single-generator set operation, the personality
profile that is loaded at the factory will support this mode. D Voltage > 4.5V: Voltage Regulator Average Voltage
Adjustment.
The controller sets the engine speed to the target speed,
which is determined by the engine run speed from the The controller reads the voltage on the speed and
personality profile and the engine speed adjustment voltage bias inputs every 50 ms (20 times per second)
(which will adjust the speed down 50 rpm and up 49 and passes the new target to the voltage regulator and
rpm). the ECM.
On a non-ECM engine, the controller does not control Reactive droop should be enabled on the controller
the target speed, it is set at the governor (unless the when paralleling with another generator set (either in
engine is fitted with an electronic governor). external or internal paralleling). The slope should be
identical on all generator sets in the paralleling system
The output voltage of the generator set is controlled to (the default is 1.0%). Reactive Droop is configured
the voltage regulator target voltage (which can be under Reactive Power Load Sharing in SiteTecht and
adjusted on the user interface). in the Generator Info -> Voltage Regulation Menu and
the Generator Info -> Paralleling Operation -> Sharing
Setup Menu on the controller user interface.
6.1.2 External Paralleling
External paralleling requires the external speed and Note: Non-ECM engines will require an electronic
voltage bias inputs to be enabled (External Bias Inputs governor and an appropriate governor calibration
Enabled under Synchronization Control in SiteTecht). in order to permit speed adjustment.
With the external bias enabled, the engine speed is set 6.1.3 Internal Paralleling
based on the voltage between SBP and SBN:
The speed and voltage bias are ignored after the
D Voltage < 0.5V: Engine Run Speed. breaker is closed in internal paralleling operation mode
except in System Sync mode and System Load Control
D Voltage = 0.5V: 95% of Engine Run Speed.
mode (described separately). The bias inputs are
D Voltage = 2.5V: Engine Run Speed.
accepted in passive synchronization mode or when
synchronization is disabled (set to off or sync disabled
D Voltage = 4.5V: 105% of Engine Run Speed. input is on). Enabling these inputs will have no effect on
the operation of the generator set in normal operating
D Voltage > 4.5V: Engine Run Speed modes.
The controller will enter internal paralleling mode

automatically if the PGEN communication wires are
connected to another controller (if External Paralleling is
desired, do not connect the communication wires
between two controllers).
TP-6929 1/15 Section 6 Paralleling System Information 107

To force a controller to Internal Paralleling mode without Synchronization is achieved by controlling the speed
PGEN communication, set the Stand Alone Operation bias to the ECM and the voltage bias to the Voltage
parameter to true (Under Synchronization Control in Regulator. These biases are internally derived and are
SiteTecht, in Generator Info -> Paralleling Operation -> not related to the speed and voltage bias inputs.
Paralleling Setup Menu on the controller). This will
make the controller behave like a paralleling controller Passive synch mode does allow external control of the
even if it doesn’t see another generator set on the speed and voltage bias, but closes the breaker only when
communication lines. This is intended for an application the generator set is in synchronism with the paralleling
where the controller is controlling a motor-operated bus.
breaker on the output of the generator set, but there are
no other generator sets on the paralleling bus. Load Sharing
In Internal Paralleling mode, all the controllers that are The controller will attempt to equalize the percent
communicating over PGEN will behave as a loading of each of the generator sets that is connected to
system—they are aware of the status of the other the bus in the paralleling system. This is the normal
generator sets in the system. A start signal to any mode of operation in parallel.
generator set in the system will start all generator sets in
the system. Other paralleling modes should only be used in
applications with additional controls that operate in
Breaker Control parallel with the utility, but are listed below for reference:
In Internal Paralleling mode, the controller sends signals D Baseload Mode. The controller adjusts speed and
to a motor-operated breaker to open and close. These voltage in an effort to maintain the power output to an
signals are provided as Relay Drivers, and must be adjustable parameter. This mode can be used for
connected to pilot relays to operate the circuit breaker. testing, but increases risk of reverse power or reverse
VARs when used in a paralleling system.
Bus Sensing D System Sync Mode. All generator sets in the
paralleling system will respond to the speed and
The controller measures three-phase, line-to-line voltage
voltage bias input of the generator set with this mode
on the paralleling bus, allowing for loss of phase
enabled. This is intended to allow external gear to
detection, phase rotation verification, and accurate
bring the entire generator set bus into synchronism
voltage matching with imbalanced load.
with the utility.
The bus sensing must be connected on the opposite side D System Load Control Mode. All generator sets in
of the motor-operated circuit breaker from the generator the paralleling system adjust speed and voltage in an
set connections to allow the generator set to measure effort to maintain the power output to a target set by
and control the phase relationship across the circuit the speed and voltage bias from an external system
breaker. load control device.
First-On Logic Generator Management

The controller uses dynamic first-on logic. The first The controller contains integral Generator
generator set to reach rated speed and voltage will be Management. This functionality is disabled by default,
given permission to close the paralleling breaker. If two but can be enabled to manage fuel consumption, wear
units reach rated speed and voltage at the same time, and tear, and sound levels.
the one that was powered up first or that has the lower
controller serial number will be permitted to close first. All generator set controllers in the system need to have
First-On negotiation is performed over the PGEN the same settings for the following parameters before
communication lines. Generator Management will be active:
Synchronization D Gen Management Control Mode.

D Gen Management Run Time Threshold.
The controller can actively synchronize the generator
set to the paralleling bus. The personality profile for the D Gen Management Fuel Difference Threshold.
generator set will have default synchronizing settings D Gen Management Stable Delay.
that will permit successful synchronization under normal D Gen Management Min Gens Online.
conditions. D Gen Management Min Load Shed Priority.
A warning is displayed when Generator Management is

disabled because of a parameter mismatch.
108 Section 6 Paralleling System Information TP-6929 1/15

Load Management 6.3 Paralleling Configuration
Paralleling is not required for load management Considerations
(add/shed) to function, but in Internal Paralleling
applications, the load shed priorities can be distributed The controller requires that all units connected to a
between controllers, as a generator set does not have to communications network for paralleling (PGEN) need to
be running to operate load shed priorities based on the match in the following key areas:
bus load and frequency.
D System Voltage
D System Frequency
6.2 Choosing an Application
Because the controller supports different operational D Voltage Phase Connection
modes, it is important that the mode is matched to the
If any controller on the network is different, none of the
application where the generator set will be used.
attached generator sets will close their circuit breakers
(the system is unsure which of the generator sets are
6.2.1 Single Generator Set configured correctly).
Single generator set applications require no setup and Most controlled generator sets will ship with 12-lead,
are by far the simplest. This mode is for applications reconfigurable alternators. The connection of the output
where a single generator set is connected to loads of the alternator will change the effective voltage range,
though a manually-operated circuit breaker, where neutral connection, and relationship between the
there will be no chance of paralleling with the utility and phases.
there is no external gear provided for generator set
control.
6.3.1 Low Wye
This application can be used even when multiple
The controller supports paralleling in a low wye
generator sets are included in a given power network, as
configuration. This connection is the simplest and the
long as the two generator sets feed different distribution
least likely to cause confusion. In low wye configuration,
busses. This application is not recommended with
the sensing leads (L1, L2, L3) are connected to the
paralleling-capable generator sets, as a failure on either
same points as the previous sensing leads (V7, V8, V9)
generator set will put a portion of the load out of power
from legacy product. The output leads from the
(regardless of the load on the other generator set) and
alternator pass through the CTs only once, which is also
there is no simple way to prioritize loads.
identical to legacy product.
6.2.2 External Paralleling 6.3.2 High Wye

Many applications require paralleling with existing
The controller is a direct sensing controller—high wye
generator sets. Because the controller is intended to
voltage is measured at L1, L2, L3 and Neutral. Legacy
parallel only with generator sets which are also running
product measured ~½ of the output voltage using the V7,
Decision-Makerr 3500 controllers, external gear is
V8 and V9 taps—the taps are not used for the generator
required to coordinate operation with another generator
set Decision-Makerr 3500 controller (which may cause
set.
confusion for those that are accustomed to using the
Certain applications require unique Generator center taps for voltage metering). The generator set
Management scenarios or paralleling requirements (such current that the controller measures is intended to be the
as dead-field paralleling). These applications will require actual generator set current (each phase makes a single
external gear to provide support for the unique features. wrap through the CT) where legacy product wrapped
the output leads through the CTs twice in the high-wye
configuration. The bus sensing is also intended to be
6.2.3 Internal Paralleling connected directly to L1, L2, and L3 of the paralleling
bus (opposite side of the motor-operated paralleling
Any multi-generator set application where the generator breaker), where legacy product typically used a
sets are all operated by Decision-Makerr 3500 transformer or contactor.
controllers and the standard controller functionality is
sufficient for the application. This includes most standby
and prime power applications where the standard
Generator Management and load management are
sufficient to support the customer requirements.

6.3.3 Delta 6.4.2 Generator Set Startup
The controller supports paralleling in a delta Crank Disconnect: When the engine speed exceeds
configuration, but it is important to note that the neutral the crank disconnect speed, the engine is considered to
of each generator set needs to be bonded to the same be started/running. The paralleling logic is only solved
phase (or a point between the same two phases). The while the engine is running.
controller does not verify line-neutral voltage between
the generator set and the paralleling bus (neutral of the Voltage Ramp: After the engine is running, the voltage
bus is not measured) so it is possible to close the regulator begins ramping the target voltage up at the
paralleling breaker into a short circuit. Floating delta rate specified by the Normal Voltage Ramp Rate
connections are also supported. parameter. The voltage ramp will follow the Volts/Hz
curve if the engine speed takes longer to reach the
Sensing should be connected to the L1, L2, and L3 target than the voltage does.
outputs of the generator set, no sensing taps or
transformers are needed or desirable. Output leads Voltage and Frequency OK: The Voltage and
should pass through the CTs only once, just as they do in Frequency OK timer starts timing as soon as the
wye configurations. 240 and 440 delta configurations frequency and voltage of the generator set are within the
are accepted. range specified by the Acceptable Voltage Pickup and
the Acceptable Frequency Pickup parameters. The
voltage and frequency for the generator set are
6.3.4 Single Phase considered to be acceptable after the Voltage and
The controller supports paralleling in a single-phase Frequency OK delay has expired.
configuration, but it is important that the metering inputs
are connected appropriately for accurate power 6.4.3 First-On Logic
metering. L1 current should be connected to the I1 input
to the controller, L2 current should be connected to the The First-On Logic is responsible to ensure that only one
I2 input to the controller, L1, L2, and L0 should also be generator set closes its paralleling breaker to the dead
connected to the appropriate inputs to the controller. bus. If two controllers close simultaneously, their
Bus metering should also be connected to L1 and L2. voltage waveforms may be out of sync with each other,
Bus L3, Gen L3, and I3 are unused in a single-phase potentially resulting in damage to the equipment. After
configuration. one generator set closes to the paralleling bus, the
others are able to ensure synchronism with it before
Although the synchronizing logic will synchronize and closing their breakers.
allow the generator set breakers to close, single-phase
connection type should never be used for an alternator Permission Request: When a generator set voltage
that is wired for three-phase, as there is no phase rotation and frequency are considered acceptable, the controller
check in single-phase mode. will broadcast a message to the PGEN network
requesting permission to close. Each of the other nodes
must grant permission to a generator set controller
6.4 Functional Operation before it will initiate closing the circuit breaker to a dead
Description bus.
Arbitration: If another node with higher priority (lower

6.4.1 PGEN Communication node ID, determined by serial number and power-up
order) also requests permission in the same bus scan
PGEN is a proprietary scheduled broadcast (50 ms) the first node must concede the right to close to
communications protocol. Each node (controller) on the the higher-priority node. Each node grants permission
network has a time slice to broadcast a packet only to a single node, which will be the lowest node ID that
containing pertinent generator set information, other it has seen a request from. All units must grant
time is spent listening for packets from the other nodes. permission to the same node for it to be permitted to
All nodes on the PGEN network will send out at least one close.
packet every 50 ms.
Permission Receipt: If all connected PGEN nodes
have granted permission to close through a full PGEN
bus scan, a generator set is permitted to close to the
dead bus and removes the trip command from the circuit
breaker (as it is safe for the breaker to close).

First-On Close Delay: The First-On Close Delay is
intended to give the trip coil on the breaker time to
retract, permitting the next close command to be
successful on breakers that have a close inhibit in place
when the trip is active.
Breaker Close Signal: After the First-On Close Delay

has elapsed, the breaker will be signaled to close. The
close signal is held until the breaker status indicates that
it is closed or until the fail to close time delay expires.
Fault Handling: If the breaker has a close attempt fault

(is unable to close within the Fail To Close Time Delay)
the controller will renounce its claim to first-on status.
This allows another controller to request permission to Figure 6-1 Synchronizing Amplitude, Frequency,
close to the dead bus. A generator set is available to and Phase
close again until the close attempts fault has expired, but
will fall in the priority order according to the node ID and Frequency Match: The synchronizer matches
will be delayed by the reclose delay until it is available to frequency before attempting to match voltage or phase.
close again (which will allow several other nodes to try to The phase angle varies at a rate that is related to the
close to the dead bus). difference in frequency, hence it is difficult to control
phase if the frequency is dramatically different.
After the generator set controller has attempted to close
the circuit breaker for the number of close attempts, the In addition, the controller possesses underfrequency
controller will issue a close attempts fault, indicate that it unload (Volts/Hz) so the bus voltage may be significantly
is unavailable to the other nodes, and start the breaker lower than rated voltage if the load on the bus exceeds
trip to shutdown time delay (default of 5 minutes). If the the generating capacity of the online generator sets and
time delay expires without the fault being cleared, the the bus frequency has drooped (which is a very
controller will shutdown the generator set (as it is not important time for an additional generator set to be able
capable of providing power to the customer with the to synchronize and connect to the bus), hence matching
breaker open, so there is no reason to remain running). frequency with the bus will cause the synchronizing
The circuit breaker fault can be reset by sending a generator set to follow the same volts/Hz curve,
remote reset command through Modbus or SiteTecht, resulting in a much closer initial voltage match.
by stopping the controller and pressing OFF a second
The Frequency Match Control is only initiated if the
time, or by pressing the AUTO button while the controller
generator set frequency differs by more than the
is already in ’Auto’ mode.
Frequency Window from the bus frequency (typically
only occurs on startup and when the bus is overloaded).
6.4.4 Synchronizing The Frequency Match Control adjusts the speed bias to
control generator set frequency to within 10% of the
Synchronizing is the process by which the output of a frequency window of the bus frequency before
generator set is matched to the output of a paralleling Frequency Match Control is disabled and Phase and
bus. See Figure 6-1. Voltage Control are enabled. Phase Match Control and
Frequency Match Control are not active simultaneously.
Because the generator set voltage and the paralleling
bus voltage are AC signals, they have to match in three Note: The Speed Bias has an effective range of 5% of
quantities in order to be identical, amplitude, frequency, nominal speed. The controller can’t synchronize
and phase. The controller adjusts the voltage regulator a generator set to the paralleling bus if the
target and engine speed to match the generator set and frequency is below 95% of nominal (57 Hz on a 60
bus voltage in all three quantities. Hz system, 47.5 Hz on a 50 Hz system).
Voltage Match: The Voltage Match Control adjusts the

target voltage of the voltage regulator on the generator
set to match the measured RMS voltage of the bus using
the voltage bias. The Voltage Matching Control is not
typically active in a standby system unless the bus is
heavily loaded or one or more of the generator sets in
the system has a different voltage regulator target, does
not have the trims enabled, or is not calibrated correctly.

Voltage matching is more common when synchronizing The generator set will continue to run until the CB trip to
to a utility source that may have up to 10% variation in Shutdown time delay expires, at which time it will stop.
the voltage amplitude depending on load on the system. The circuit breaker fault can be reset by sending a
remote reset command through Modbus or SiteTecht,
Phase Match: The Phase Match Control adjusts the by stopping the controller and pressing OFF a second
target speed of the engine in the engine speed governor time, or by pressing the AUTO button while the controller
using the speed bias. The engine speed is increased if is already in ’Auto’ mode.
the generator set voltage lags the bus voltage,
decreased if the generator set voltage leads the bus
voltage. This technique is call bi-directional 6.4.5 System Synchronization
synchronization. Enabling System Synchronization mode in any
The Phase Match Control is active nearly every time that controller on a paralleling bus will make all the generator
a generator set synchronizes to the paralleling bus, so it sets on that paralleling bus respond to the speed and
is very important that it works correctly. In addition, the voltage bias that is provided to that generator set.
generator set may stabilize speed with the phase Note: External bias must be enabled.
difference between the output of the generator set and
the paralleling bus within the entire possible range of The Speed and Voltage Bias both respond with identical
phase angles (-180_ to 180_), so the phase matching range to their action on a single generator set.
sequence may be different with each start of the
generator set. This mode allows external controls to synchronize a
generator set bus to another source (such as an older
In Synchronism: After the voltage amplitude, generator set or a utility) while retaining individual
frequency, and phase of the generator set matches that generator set control within each generator set
of the bus, the controller considers the generator set to controller.
be ’In Synchronism’ with the paralleling bus.
Generator Management, kW and kVAR Sharing, and
When in Synchronism, the controller considers it to be Load Management are still active in system
safe to close the paralleling breaker. The Trip signal to synchronization mode. System Control Mode can be
the generator set circuit breaker is removed when the used while the generator sets on the paralleling bus are
breaker is ok to close, this allows the trip coil time to clear in a variety of operating states, including synchronizing
so that the breaker will be ready to close when it is to the paralleling bus or soft-unloading.
signaled to do so.
Dwell Timer: The Dwell Timer becomes active as soon 6.4.6 Real Power Control
as the generator set is in synchronism with the
paralleling bus. It elapses time until it expires unless the The real power output of a generator set is related to
generator set falls out of synchronism with the how much mechanical power the engine is making.
paralleling bus, when it is reset. When a generator set is operating as a single unit, there
is no good way to control the power output of the
Breaker Close Signal: When the Dwell Timer expires, generator set without controlling the power
the controller will signal the paralleling circuit breaker to requirements of the load. In a parallel system, there is
close. The Contactor output from the controller is also more than one source that can supply the load—hence
energized at the time that the controller signals the the power can be shared between the sources, allowing
breaker to close (some applications may use the it to be controlled.
contactor output for breaker status annunciation).
Because the output of the generator sets is tied together,
The Breaker Close Signal is maintained until the breaker the speed of the generator sets will remain essentially
status indicates closed, the close command is removed, identical, regardless of the mechanical torque that a
or the failure to close time delay expires. single engine provides (providing that the load requires
enough mechanical power that the single engine isn’t
Fault Handling: If the breaker status does not indicate overpowering the other engines on the bus and forcing
closed within the Failure to Close time delay, the them to accelerate and that it doesn’t require more than
controller will issue a close attempt fault. After the Close the other generator sets can handle).
Retry Delay expires, the controller will try to close the
breaker again until the maximum number of close If the speed bias is increased, the engine governor will
attempts is reached, than the controller will issue the try to increase the air/fuel flow to the engine to cause it to
Failure to Close Fault and start the CB Trip to Shutdown accelerate. If the engine speed is unable to change, the
delay. engine torque will steadily increase as long as the target
speed remains higher than the actual speed. This

allows the Power Control logic to increase the load on a Real Power Baseload mode is not responsive to
paralleled generator set. changes in the load requirement on the paralleling bus,
so placing a generator set in Baseload mode on an
If the speed bias is decreased, the engine governor will islanded system may very well cause the other
try to decrease the air/fuel flow to the engine to cause it generator sets in the system to experience a reverse
to decelerate. If the engine speed is unable to change, power condition if the load decreases. Baseload mode
the engine torque will steadily decrease as long as the can be used as a testing mode under supervision, but
target speed remains lower than the actual speed. This should not be used long-term in an islanded application.
allows the Power Control logic to decrease the load on a
paralleled generator set. Frequency Trim is not active in Baseload mode.
kW Sharing The Real Power Controller uses the Real Power

Baseload gains for operation in Baseload mode.
While the controller is operating as part of a standby
power system or a prime power system that is not in System Control
parallel with another source, the primary (and default)
real power control mode is kW sharing. In this mode, System Control mode controls the power level of all
each generator set tries to control output power to the generator sets on a paralleling bus to a target level that
percentage of the bus capacity (the ratio between the is determined by the speed bias input. The bias input
total load on the bus and the total capacity of all online only needs to be supplied to a single generator set on
generator sets). the communication bus in order to control all the
generator sets on that bus. The generator set that is
Generator sets that are making too much power will receiving the signal does not have to be running or
adjust their speed bias down, while generator sets that paralleled to the other generator sets, but it does need to
are not making enough power will adjust their speed have the system control mode and external bias
bias up. The result is that there is no net change in the enabled. If the signal is sent to multiple generator sets in
bus frequency. the system, only one of them will control the bus (the
others will be ignored). The preference order of the
If the bus frequency does drift away from nominal (due to generator set controllers is based on the controller serial
soft loading, soft unloading, or possible fuel supply number.
issues) there is a frequency trim feature in the controller
that constantly drives the frequency toward the nominal System Control mode provides an interface that allows
frequency to correct for such errors. Trims must be the generator sets to be controlled by an external
enabled to allow the frequency trim to adjust the speed controller for soft-unloading/loading and peak shaving
bias to maintain constant frequency. Trim should only against a distant or uncontrolled source (such as the
be disabled on an islanded (not connected to the utility utility grid). The power output increases with increasing
grid) system if the system is having trouble sharing load, speed bias, as described in the following table:
and then only as a troubleshooting step.
Speed Bias < 0.5V = 50% of rated power
Frequency Trim is unnecessary in synchronism with the Speed Bias = 0.5V = 0% of rated power
utility grid.
Speed Bias = 2.5V = 50% of rated power
Note: Frequency and Voltage Trim are enabled and
Speed Bias = 4.5V = 100% of rated power
disabled with a common parameter (Enable
Trims). To disable one individually, the P, I, and D Speed Bias > 4.5V = 50% of rated power
gains must be set to 0.
Frequency Trim is not active in System Control mode.
The Real Power Controller uses the Real Power Sharing
The Real Power Controller uses the System Real Load
gains for operation in kW Sharing mode.
Control gains for operation in System Control mode.
Baseload
Soft Load/Unload
Real Power Baseload mode operates similarly to kW
The Real Power Control references a ramping target
sharing mode except that the target power level is a
(according to the Real Power Ramp Rate) from 0 kW to
stored controller parameter instead of an average bus
the mode-related target for the Real Power Control
load. Baseload mode is intended for use when in
when soft-loading. The target ramps from the target to 0
parallel with a distant or uncontrolled source (such as
according to the same ramp rate in soft-unload mode.
the utility grid).

A generator set will soft-load any time that it The VAR Control mode parameter allows selection
synchronizes to a live paralleling bus. Soft-unloading is between the kVAR and Power Factor control modes.
triggered by the removal of the load enable signal to the VAR control is always used when in load sharing mode.
controller or by Generator Management. In both cases,
the breaker will be signaled to trip when the real power These modes are listed below.
drops below the disconnect level.
D kVAR sharing
6.4.7 Reactive Power Control While the controller is operating as part of a standby
power system or a prime power system that is not in
The reactive power output of a generator set is related to parallel with another source, the primary (and default)
the magnetization energy in the alternator. When a reactive power control mode is kVAR sharing. In this
generator set is operating as a single unit, there is no mode, each generator set tries to control output
good way to control the magnetization energy in the reactive power to the percentage of the bus capacity
alternator without changing the output voltage of the (the ratio between the total reactive load on the bus
generator set. In a parallel system, there is more than and the total reactive power capacity of all online
one source than can supply reactive power to the generator sets).
load—hence the reactive power can be shared between
the sources, allowing it to be controlled. Generator sets that are making too much reactive
power will adjust their voltage bias down, while
Because the output of the generator sets is tied together, generator sets that are not making enough power will
the voltage amplitude of the generator sets will remain adjust their voltage bias up. The result is that there is
essentially identical, regardless of the magnetization no net change in the bus voltage.
energy that a single alternator provides (providing that
the load requires enough magnetization energy that the If the bus voltage does drift away from nominal (due to
single alternator isn’t overpowering the other alternators soft loading, soft unloading, or reactive droop) there is
on the bus and forcing them to increase output voltage a voltage trim feature in the controller that constantly
and that it doesn’t require more than the other drives the voltage toward the nominal voltage to
alternators can handle). correct for such errors. Trims must be enabled to
allow the voltage trim to adjust the voltage bias to
If the voltage bias is increased, the voltage regulator will maintain constant output voltage. Trim should only be
try to increase the field current to the alternator rotor to disabled on an islanded (not connected to the utility
cause the magnetic energy in the alternator to increase, grid) system if the system is having trouble sharing
increasing the voltage output of the alternator. If the load, and then only as a troubleshooting step.
alternator voltage output is unable to change, the field
current will steadily increase as long as the target Voltage Trim is unnecessary in synchronism with the
voltage remains higher than the actual voltage. This utility grid.
allows the Power Control logic to increase the reactive
load on a paralleled generator set. Note: Voltage and Frequency Trim are enabled
and disabled with a common parameter
If the voltage bias is decreased, the voltage regulator will (Enable Trims). To disable one individually,
try to decrease the field current to the alternator to the P, I, and D gains must be set to 0.
decrease the magnetization energy in the alternator and
to cause the output voltage to decrease. If the alternator D Baseload
voltage output is unable to change, the field current will
steadily decrease as long as the target voltage remains Reactive Power Baseload mode operates similarly to
lower than the actual voltage. This allows the Power kVAR sharing mode except that the target reactive
Control logic to decrease the reactive load on a power level is a stored controller parameter instead of
paralleled generator set. an average bus load. Baseload mode is intended for
use when in parallel with a distant or uncontrolled
source (such as the utility grid).
kVAR Control
The reactive power controller measures and controls Reactive Power Baseload is enabled when Real
reactive power (kVAR). Some modes allow direct control Power Baseload is enabled (if the VAR control mode
of the kVAR to a target that is independent of the real is set to VAR control). Baseload mode is not
power supplied by the generator set or generator set responsive to changes in the reactive load
system. requirement on the paralleling bus, so placing a
generator set in baseload mode on an islanded
system may very well cause the other generator sets
in the system to experience an apparent loss of field

condition if the reactive load decreases. Baseload The VAR Control mode parameter allows selection
mode can be used as a testing mode under between the kVAR and Power Factor control modes.
supervision, but should not be used long-term in an VAR control is always used when in load sharing mode.
islanded application.
Note: It is possible to control power factor directly, but
Voltage Trim is not active in Baseload mode. the effect of reactive power variations on the
resultant power factor is very non-linear, making
The Reactive Power Controller uses the Reactive it difficult to provide consistent power factor
Power Baseload gains for operation in Reactive regulation over a broad range of power factor
Power Baseload mode. targets with a single set of gains. The power
factor control modes are listed below.
D System Control
D Baseload
System Control mode controls the reactive power
level of all generator sets on a paralleling bus to a Power Factor Baseload mode operates very similarly
target level that is determined by the voltage bias to baseload kVAR mode except that the target
input. The bias input only needs to be supplied to a reactive power is related to the real load on the
single generator set on the communication bus in generator set by a ratio that is determined from the
order to control all the generator sets on that bus. The Power Factor Baseload Setpoint.
generator set that is receiving the signal does not
have to be running or paralleled to the other generator Power Factor Baseload mode is probably the
sets, but it does need to have the system control simplest way of controlling reactive power when a
mode and external bias enabled. If the signal is sent generator set is operating at a fixed real power.
to multiple generator sets in the system, only one of
them will control the bus (the others will be ignored). Power Factor Baseload is enabled when Real Power
The preference order of the generator set controllers Baseload is enabled (if the VAR control mode is set to
is based on the controller serial number. power factor control). Baseload mode can be used as
a testing mode under supervision, but should not be
System Control mode provides an interface that used long-term in an islanded application.
allows the generator sets to be controlled by an
external controller for soft-unloading/loading and Voltage Trim is not active in Baseload mode.
peak shaving against a distant or uncontrolled source
(such as the utility grid). The power output increases The Reactive Power Controller uses the Power
with increasing voltage bias, as described in the Factor Baseload gains for operation in Power Factor
following: Baseload mode.
Voltage Bias < 0.5V = 50% of rated reactive power D System Control
Voltage Bias = 0.5V = 0% of rated reactive power System Power Factor Control mode controls the
Voltage Bias = 2.5V = 50% of rated reactive power power factor level of all generator sets on a paralleling
bus to a target level that is determined by the voltage
Voltage Bias = 4.5V = 100% of rated reactive power bias input. The individual generator sets calculate
Voltage Bias > 4.5V = 50% of rated reactive power their individual reactive power requirement to meet
the power factor target and control the reactive power
Voltage Trim is not active in System Control mode. to that requirement.
The Reactive Power Controller uses the System
The bias input only needs to be supplied to a single
Reactive Load Control gains for operation in System
generator set on the communication bus in order to
Control mode.
control all the generator sets on that bus. The
generator set that is receiving the signal does not
Power Factor Control have to be running or paralleled to the other generator
sets, but it does need to have the system control
The reactive power controller measures and controls
mode and external bias enabled. If the signal is sent
reactive power (kVAR). Power factor is the ratio of the
to multiple generator sets in the system, only one of
generator set real power to the generator set apparent
them will control the bus (the others will be ignored).
power (which is the geometric sum of the real and
The preference order of the generator set controllers
reactive power). To control power factor, the reactive
is based on the controller serial number.
power target must vary with changing real power.

System Power Factor Control mode provides an D CB Status Fault (shutdown—intended to prevent the
interface that allows the generator sets to be system from running with incorrect breaker status, as
controlled by an external controller for it could be a dangerous condition).
soft-unloading/loading and peak shaving against a
distant or uncontrolled source (such as the utility D Gen to Bus Phase Angle Mismatch (the generator set
grid). The target Power Factor decreases with and bus should have 0_ phase angle when the
increasing voltage bias, as described in the following: breaker is closed. If all three wires are connected to
incorrect phases, the measurement will show 120_
Voltage Bias < 0.5V = 0.75 power factor out of phase with the breaker closed.).
Voltage Bias = 0.5V = 1.00 power factor
D Bus Sensing Phases A and B are Reversed (phase C
Voltage Bias = 2.5V = 0.75 power factor is connected correctly).
Voltage Bias = 4.5V = 0.50 power factor D Bus Sensing Phases B and C are Reversed (phase A
Voltage Bias > 4.5V = 0.75 power factor is connected correctly).
Voltage Trim is not active in System Power Factor D Bus Sensing Phases C and A are Reversed (phase B
Control mode. is connected correctly).
The Reactive Power Controller uses the System
D Bus Sensing Phase A Connection Error (the
Power Factor Control gains for operation in System
Control mode. measured voltage indicates that Phase A is not
connected).
Soft Load/Unload D Bus Sensing Phase B Connection Error (the
The Reactive Power Control runs in power factor mode measured voltage indicates that Phase B is not
any time that the system is soft unloading or loading. connected).
The power factor is set to the final target when soft
D Bus Sensing Phase C Connection Error (the
loading and to the initial power factor when unloading.
measured voltage indicates that Phase C is not
connected).
6.4.8 Faults
D Bus Sensing Connection Error (the Bus sensing is
The controller supports a variety of faults and warnings reading incorrectly, but none of the phases are
to make troubleshooting and diagnostics more reading as expected—probably more than one wire is
transparent and streamlined. Some of the faults have disconnected).
an effect on the operation of the system, some indicate a
malfunction in the operation of the system, others are D Bus Sensing Not Connected (none of the bus
provided only to provide the operator with status sensing wires are connected).
information.
D Breaker Outputs Not Configured (the Breaker
outputs are driven by programmable I/O. They will not
Auto-Validation
work unless they have been configured).
Auto-Validation is a function that verifies the bus
metering connections, breaker control functions, and D Breaker Status Input Not Configured (the breaker
breaker status feedback once per power cycle of the status is a programmable input in later firmware
generator set controller. The function is intended to versions, if it is not configured, the system will get no
detect problems in the wiring and to alert the operator status indication from the circuit breaker).
with easily-understood faults that allow easy
Note: Not all Auto-Validation warnings are supported in
troubleshooting and repair of the fault, while protecting
all applications and in all firmware versions.
the generator set controller from damage due to
incorrect connections.
Failure to Synchronize
Auto-Validation supports the following messages:
A Failure to Synchronize indicates that the generator set
D Bus Sensing Connected to Wrong Side of Paralleling controller has been attempting to match frequency,
Breaker (bus is live anytime the generator set is phase, and voltage with the paralleling bus for longer
running and turns off with the generator set). than the Fail to Sync Delay without being able to
maintain synchronism for the duration of the dwell timer
D Live Bus Sensed when Dead Bus Expected (inhibited to allow the breaker to close.
in Baseload or System Control Mode).

Note: Failure to Synchronize does not stop the Protective Relays
controller from continuing to synchronize. The
Failure to Synchronize Warning is reset when The controller will trip the circuit breaker and issue a
synchronizing stops because the breaker closes, warning if any of the following conditions persist beyond
or the synchronization is canceled. the associated time delay:
D Over Voltage. This protective function is intended to

Fail to Open protect the alternator from over excitation, but
A failure to open indicates that the controller attempted primarily is used to protect the customer loads from a
to open the breaker, but that the breaker status didn’t potentially damaging condition.
indicate open within the Fail to Open Delay. This
D Under Voltage. This protective function is intended
typically indicates a wiring issue, but non-standard to protect electric motors and sensitive electronics
breakers may take longer than the default 1.0 second from damage due to undervoltage. The low voltage
Fail to Open Delay to respond to a trip signal. If the condition may also indicate a failure in the alternator
breaker opens shortly after the warning occurs, it may or in the sensing to the controller.
be possible to extend the time delay to make it work, but
only after considering that a delay in breaker tripping D Over Frequency. This protective function is intended
may decrease the effectiveness of the generator set to protect any motors that are fed by the generator set
protective relays. from overspeeding and potentially damaging the
equipment that they drive.
Close Attempt Fault
D Under Frequency. This protective function is
A Close Attempt Fault indicates that the breaker intended to protect any motors or transformers that
attempted to close and that the breaker did not close are fed by the generator set from potential
within the Fail to Close Delay. The controller will remove overheating and winding damage.
the close signal after the Fail to Close Delay has expired,
so the breaker will probably not close. D Over Power. This protective function can be used to
protect the generator set. The generator set
A failure to close can be caused by external protective controller also has an overpower shutdown, which is
relays inhibiting closure, wiring errors, incorrect voltage set to 102% for standby applications and 112% for
for the motor operator, discharged charge spring in the prime power applications. A practical solution to the
breaker, etc. use of this protective relay is to connect the load
management connections.
Fail to Close
D Reverse Power. This protective function is intended
A Fail to Close fault indicates that the controller has tried to protect the generator set system from motoring
to close the breaker for the Number of Close Attempts generator sets and to protect the fuel system of the
without a successful closure. The failure to close fault generator set from operation in a dry state. This
will start the Circuit Breaker Trip to Shutdown time delay, condition is most commonly caused by a loss of fuel
which will cause the generator set to stop after it times prime or damage to a fuel line. A reverse power
out. condition does not otherwise damage the generator
set.
Configuration Mismatch
D Over Current. This protective function can be used to
The paralleling system will not permit any generator set protect the alternator of the generator set from
to connect to the paralleling bus if the system voltage, overload conditions. The controller also contains
system frequency, and phase connection are different internal alternator protection that prevents thermal
on any of the connected generator sets. The generator damage to the alternator by stopping the engine.
sets can’t safely parallel with each other if these
parameters are different and the paralleling system D Reverse VARs (Loss of Field). This protective
does not know which of the generator sets is correct and function is required to avoid potential damage to the
which is not. generator set caused by the alternator slipping a pole.
Pole slipping can occur when the generator set is
providing real power (Watts) and is absorbing
reactive power (VARs). Slipping a pole can cause
damage to the engine crankshaft or the alternator and
typically causes voltage spikes on the generator set
output—the condition should be avoided.

Note: The alternator can absorb VARs without damage baseload mode, the controller will start, synchronize,
if the real power output of the generator set is very connect to the paralleling bus, and ramp the power
low, but the protective relay does not take the real control target to the baseload setpoint.
power into account, so it needs to be set to a low
enough threshold to protect against pole slipping. Note: The baseload input takes priority over the System
The default of 20% protects the alternator in most control and System Sync input. Baseload mode
conditions, but the stability curve of the alternator will not ramp to the target if load enable is off.
should be considered when adjusting the Baseload can be used to exercise generator sets
parameters to a higher value than 20%. against the utility with a fixed load, it should not be
used in an islanded paralleling system except for
troubleshooting purposes.
6.4.9 Start Modes
D System Control Mode. This function puts the
The generator set controller supports a system start generator set in a power control mode where the
(Auto-Run, remote start contacts, CAN gauge start power level for all generator sets on the paralleling bus
signal, SiteTecht start signal) and local start (pressing is controlled by an external device using the speed and
the run button). The paralleling system behaves voltage bias (speed bias controls real power, voltage
differently depending on which start command is bias controls reactive power or power factor,
received. depending on the VAR control mode). This mode
A system start command to any generator set in the takes priority over the System Sync Mode and requires
system will start all generator sets that are in auto. If a load enable to be active in order to ramp output power
to the system control target. Once the load ramp
generator set is placed in auto after the start signal is
applied to any generator set, that generator set will start. reaches the target, the generator set will try to match
A generator set does not have to be in auto to accept a the power target with the output power. This mode is
start signal, but it does have to be in auto to start. The not to be used in an islanded system, but will allow
external switchgear to control the entire generator set
synchronizer uses the Sync Mode in Auto parameter to
determine the synchronizing settings during a system bus to soft load and unload against the utility. The
start event. Generator Management and load speed and voltage bias can be applied to any number
management are only active during a system start. of generator sets in the system, as only one will have
control of the bus. System Control Mode must be
A local start command to a generator set will result in enabled on generator sets receiving the speed and
only that generator set starting. The synchronizer uses voltage bias.
the Sync Mode in Run parameter to determine the
D System Sync Mode. This function causes all the
synchronizing settings during a local start event.
Generator Management will not consider a generator running generator sets in a paralleling system to
set that is operating in local start mode as available, adjust their target speed and voltage to match the
even if it is running. speed and voltage bias applied to the external bias
inputs on the controller set to system sync mode. This
bias can be applied to multiple units, but only one will
6.4.10 Control Inputs have control of the paralleling bus. System sync
mode is intended to allow external switchgear to
The Paralleling logic accepts the following Control synchronize the generator set paralleling bus to the
Inputs, configurable for a digital input: utility.
D Disable Synchronization. This function will prevent
the controller from synchronizing or closing the 6.4.11 Generator Management
breaker to a dead bus, but will not cause the breaker See Section 7.
to trip if it is closed. This input is commonly used to
coordinate controller generator sets with the first-on 6.4.12 Load Management
logic of older, existing generator sets.
See Section 8.
D Load Enable. This function allows the generator set
to take load. If disabled, the generator set speed will 6.4.13 Communication Failure
drop if load is present on the paralleling bus and no
other nodes are connected to support the load. If When a PGEN node fails to reply for 30 consecutive
other nodes exist, the generator set will control its frames (about one second) the other nodes will detect a
output power to no load. loss of communication with it and will default to droop
sharing and time slice based first-on logic. Not all
D Baseload Mode. This function puts the generator set applications are configured or able to use this functionality.
into baseload mode. If a start signal is received in

6.5 Calibration and Commissioning have an identical baud rate for the network to
communicate effectively.
6.5.1 Voltage Calibration
Range: 9600/19200/38400/57600/115200
The controller is a factory-calibrated direct-sensing Default: 57600
paralleling controller. It is capable of reading up to
800VAC (RMS) accurately, allowing it to directly sense PGEN Node ID. The Node ID is an address (allocated
the output voltage in most low-voltage applications. time slice) that has been assigned to this node. The
node ID is typically indicative of power up sequence, but
The voltage sensing is calibrated in the factory—no not always. All node IDs behave identically on the
calibration is required unless a personality profile from a network, the address only determines the order of
different controller is loaded over the factory calibration communication.
values.
Range: 1–8 or 255 (indicates short circuit on PGEN Wires)
If a personality profile is updated, the calibration factors Default: **STATUS**
for all 9 voltages (L1-L2, L2-L3, L3-L1, L1-L0, L2-L0,
PGEN Nodes Connected. The number of PGEN nodes
L3-L0, Bus L1-L2, Bus L2-L3, Bus L3-L1) should be
that this node has seen communicating on the network
recorded from the new controller so that they can be
in the last second.
restored after the personality is loaded.
Range: 1–8
Calibration is possible in-application, but should only be Default: **STATUS**
necessary if the factory defaults are lost or overwritten.
PGEN Nodes Disconnected. The number of PGEN
6.5.2 Current Calibration nodes that have stopped replying at the appropriate
time. If a node with the same controller serial number as
The current metering is calibrated at the factory for a a disconnected one begins communicating again after
given generator set. It is performed at full load at the being counted as disconnected, the disconnected node
factory. There is a small variation in the output ratio of a count will decrease again.
CT over its supported measurement range, so this
reading may vary slightly at lower loads. Note: Removing battery power from a controller is not
the same as losing communication with that
If a controller is replaced, the current metering will have controller—the disconnected node count does
to be calibrated in order to guarantee power metering not increase in the case of removal of the battery
accuracy. from one controller on the network.
Range: 0–7
6.5.3 Gains and Settings for Paralleling Default: **STATUS**
The controller is preset with factory defaults for each

generator set model number in the personality profile. 6.6.2 First-On
These gains should perform adequately for most
The First-On logic ensures that two generator sets won’t
applications, but it may be necessary to perform
close to the paralleling bus simultaneously. Because the
adjustment of advanced settings.
synchronizing is performed relative to the paralleling bus,
it is impossible to verify synchronism between generator
6.6 Parameter Descriptions sets until one of them is connected to the paralleling bus.
If two generator sets close simultaneously, they may be
Individual descriptions of the functionality of each coupled together out-of phase (which is potentially
parameter within the paralleling logic. damaging to the alternator or engine crankshaft).
First-On Parameters are found under the Synchronization

6.6.1 PGEN Control heading in SiteTecht and under the Generator
Info -> Paralleling Operation -> Paralleling Setup menu on
PGEN is an auto-discovering, scheduled protocol that
the user interface of the controller.
provides the infrastructure for time-critical
inter-controller communication. PGEN stands for First-On Close Delay. The time between
Paralleled Generator. acknowledgement of victory in the first-on race and
breaker closure. This time delay is intended to ensure
PGEN Baud Rate. The PGEN Baud rate is set at the
that the trip signal has time to be removed from the
factory to 57,600. It should only be changed under
circuit breaker before the close signal is applied. Setting
instruction from a factory representative. All nodes must
this delay higher will only delay the system’s ability to
provide power in a timely fashion and should only be set Dropout Acceptable Voltage Window. Once the
to a longer delay if the breaker is failing to close. voltage and frequency are considered to be acceptable,
the voltage has to be outside the Dropout window before
Range: 0.1 – 10.0 sec it is considered to be unacceptable again. See
Default: 0.5 sec Figure 6-3.
Volts Hertz Okay Time Delay. The time after the
voltage and frequency falls within the acceptable
window that the controller waits before the generator set
is considered to be within an acceptable operating
range. Extending this delay may be necessary if a Dropout Window
generator set has significant voltage or speed overshoot
(although resolving the source of the overshoot would Output Voltage (%)
be preferred, such as decreasing the voltage ramp rate).

Min Pickup Threshold
Max Pickup Threshold
This delay can also be used to delay first-on availability Min Dropout Threshold
Max Dropout Threshold
for a generator set that should not close to the bus first
(such as a smaller generator set).
Range: 0.1 – 10.0 sec

Default: 0.5 sec
Pickup Acceptable Voltage Window. The Voltage

must remain within this percentage of the system Range: 1.00 – 50.00%
voltage for the duration of the Volts Hertz Okay Time Default: 30.00%
Delay in order for the voltage to be considered Figure 6-3 Dropout Acceptable Voltage Window
acceptable to supply a customer’s load. See Figure 6-2.
Pickup Acceptable Frequency Window. The
Note: The Volts Hertz Timer does not run unless both generator set frequency must remain within this window
voltage and frequency are within the window. for the duration of the Volts Hertz Okay Time Delay
before it is considered to be acceptable. See Figure 6-4.
Note: The Volts Hertz Timer does not run unless both
voltage and frequency are within the window.
Pickup Window
Output Voltage (%)

Min Dropout Threshold
Pickup Window
Frequency

Range: 1.00 – 50.00%
Default: 10.00%
Figure 6-2 Pickup Acceptable Voltage Window

Range: 1.00 – 50.00Hz
Default: 2.50Hz
Figure 6-4 Pickup Acceptable Frequency Window

Dropout Acceptable Frequency Window. Once the Sync Mode in Auto
Voltage and Frequency are considered to be
acceptable, the frequency has to be outside the Dropout The Sync Mode in Auto is the mode that the paralleling
window before it is considered to be unacceptable logic uses for synchronization control when the
again. See Figure 6-5. generator set is operating in Auto. The controller
supports the following Sync Modes:
Note: Transient Loading may cause the bus frequency
to dip significantly—the paralleling breaker may D Off
trip if the voltage or frequency is perceived to be
Synchronizing is disabled—the breaker will not close,
outside the dropout window for very long. The
even to a dead bus.
dropout frequency should be set to a large
number to avoid unintended operation of the D Passive
system.
The controller will not attempt to control the speed
and voltage of the generator set (although that can be
controlled remotely), but will close the breaker if the
voltage, frequency, and phase are all matched for the
Dropout Window Dwell Time. After breaker closure, the controller will
assume control of the speed and voltage bias to share
load. The breaker will close to a dead bus in Passive
Frequency
mode.
Max Dropout Threshold D Check
The controller activates the auto-synchronizer, but

does not close the breaker to a live bus (even if the
voltage, frequency, and phase are all matched for the
dwell time). The breaker will close to a dead bus in
check mode.
Range: 1.00 – 50.00% D Active

Default: 30.00Hz
Figure 6-5 Dropout Acceptable Frequency Window The controller activates the auto-synchronizer, and
will close the breaker to a live bus if the voltage,
Dead Bus Level. The threshold (in percent of rated frequency, and phase are all matched for the dwell
voltage) below which the bus is considered to be dead time.
(allowing closure without synchronization). If the bus
voltage is measured to be above this threshold, but it is D Dead Field
not within the pickup acceptable voltage window of the
rated bus voltage, the generator set will not synchronize The Synch mode cannot be set to this value in
or connect to the bus. standard applications.
Range: 1.00 – 25.00% Setting Dead Field Synch mode will cause this unit to
Default: 10.00% start, close the breaker at a given engine RPM, and
soft-ramp the voltage to the final target. All generator
sets that start with this synch mode configuration will
6.6.3 Synchronization reach rated voltage and frequency in parallel.
Synchronizing parameters are found under the Note: Dead Field Paralleling is not supported in
Synchronization Control heading in SiteTecht and standard applications, the DFP voltage
under the Generator Info -> Paralleling Operation -> ramp rate, DFP breaker close RPM, and
Synchronizing Setup menu on the user interface of the DFP fail RPM are not available as
controller. The Synchronizing Status parameters can be user-adjustable parameters.
found under the Synchronization Metering heading in
SiteTecht. Note: Synchronization will not occur if the bus is live and
has different phase rotation than the generator
set.
Range: 1 – 4 (Off – Active)

Default: 4 (Active)

Sync Mode in Run Phase Match Window
The Sync Mode in Run is the mode that the paralleling The Phase Angle Window defines the threshold that the
logic uses for synchronization control when the phase angle between the L1-L2 generator set voltage
generator set is operating in Run. Available modes are and the L1-L2 paralleling bus voltage must remain
the same as the Sync Mode in Auto. below for the phase of the generator set to be
considered to be matched with the paralleling bus. The
Range: 1 – 4 (Off – Active)
generator set voltage may either lead or lag the bus
Default: 3 (Check)
voltage, but must be within the Phase Match Window to
be considered to be matched.
Voltage Match Window
Large phase angle differences between the generator
The voltage match window defines the maximum
set and the paralleling bus when the paralleling breaker
difference between the average line-line voltage of the
closes will result in large current spikes as the alternator
generator set and the average line-line voltage of the
field is forced to align between the generator sets.
paralleling bus which will allow the generator set voltage
Phase Match Windows above 15_ are not
to be considered as matching the bus voltage. The
recommended.
generator set voltage can be above or below the bus
voltage, but must be within the Voltage Match Window of Range: 1.0_ – 20.0_
the bus to be considered to be matched. Default: 5.0_
This parameter is intended to avoid excessive current

Dwell Time
due to reactive power transfer. A large voltage difference
may cause reactive power to transfer between generator The Dwell Time is the time duration that the
sets when the paralleling breaker is closed. synchronizer requires the voltage, frequency, rotation
Range: 1 – 10% and phase of the generator set to match that of the
Default: 1% paralleling bus before it will signal the paralleling
breaker to close.
Sync Frequency Window Setting the dwell time too short may cause the breaker to
The Frequency Window is the maximum difference in close when the generator set frequency does not match
output frequency between the bus and the generator set the bus frequency very closely (resulting in a small real
at which the frequency is considered to be matched. The power discrepancy when the breaker first closes). Short
generator set frequency can be above or below the bus dwell times are occasionally required in applications
frequency, but must be within the Sync Frequency where the engine frequency regulation is loose (such as
Window of the bus to be considered as matched. spark-ignited engines).
There is a slight delay in the activation of the paralleling Setting the dwell time too long will only delay breaker
breaker (typically between 50 and 100ms). If the closure and will not improve the real power discrepancy
frequency difference is too high, the breaker may close when the breaker closes. Dwell times longer than
out of phase, even though it was in phase when the 2 seconds are only required in very special applications.
close signal was activated. Range: 0.1 – 30.0 sec
Default: 0.3 sec
Note: The frequency matching controller is active until
the generator set frequency is within 1/10 of the
frequency window of the bus frequency. Once Voltage Match Proportional Gain
within this window, the frequency matching The Voltage Match Proportional Gain adjusts the
controller is de-activated and the phase matching Voltage Bias by an amount that is directly related to the
controller is activated. The phase matching difference between the average generator set line
controller is de-activated and the frequency voltage and the average bus line voltage. The voltage
matching controller is activated if the frequency of bias is adjusted in the direction that should decrease the
the generator set differs by more than the difference between the generator set and the paralleling
Frequency Match Window from the bus bus.
frequency.
Range: 0.01 – 100.00
Setting the frequency window too wide may make it Default: 1.00
difficult for the phase matching controller to work correctly.
Range: 0.1 – 5.0Hz
Default: 2.0Hz

Voltage Match Integral Gain Note: This gain is set very low from the factory, but may
be needed to track the bus if the load on the bus is
The Voltage Match Integral Gain adjusts the Voltage changing often.
Bias at a rate that is related to the difference between the
average generator set line voltage and the average bus Range: 0.01 – 100.00
line voltage. The voltage bias is adjusted in the direction Default: 1.00
that should decrease the difference between the
generator set and the paralleling bus. Phase Match Proportional Gain
Range: 0.01 – 100.00 The Phase Match Proportional Gain adjusts the Speed
Default: 1.00 Bias by an amount that is directly related to the phase
difference between the generator set L1-L2 voltage and
Voltage Match Derivative Gain the bus L1-L2 voltage. The speed bias is adjusted in the
direction that should decrease phase angle between the
The Voltage Match Derivative Gain adjusts the Voltage
generator set and the paralleling bus.
Bias by an amount that is related to the rate of change of
the difference between the average generator set line Range: 0.01 – 100.00
voltage and the average bus line voltage. The voltage Default: 1.00
bias is adjusted in the direction that should decrease the
rate of change of the difference between the generator Phase Match Integral Gain
set and the paralleling bus.
The Phase Match Integral Gain adjusts the Speed Bias
Note: This gain is set very low from the factory, but may at a rate that is related to the phase difference between
be needed to track the bus voltage if the load on the generator set L1-L2 voltage and the bus L1-L2
the bus is changing often. voltage. The speed bias is adjusted in the direction that
Range: 0.01 – 100.00 should decrease the phase angle between the
Default: 1.00 generator set and the paralleling bus.
Range: 0.01 – 100.00

Frequency Match Proportional Gain
Default: 1.00
The Frequency Match Proportional Gain adjusts the
Speed Bias by an amount that is directly related to the Phase Match Derivative Gain
difference between the generator set frequency and the
The Phase Match Derivative Gain adjusts the Speed
bus frequency. The speed bias is adjusted in the
Bias by an amount that is related to the rate of change of
direction that should decrease the difference between
the phase difference between the generator set L1-L2
the generator set and the paralleling bus.
voltage and the bus L1-L2 voltage. The speed bias is
Range: 0.01 – 100.00 adjusted in the direction that should decrease the rate of
Default: 1.00 change of the phase difference between the generator
set and the paralleling bus.
Frequency Match Integral Gain
Range: 0.01 – 100.00
The Frequency Match Integral Gain adjusts the Speed Default: 1.00
Bias at a rate that is related to the difference between the
generator set frequency and the bus frequency. The Fail to Sync Delay
speed bias is adjusted in the direction that should
decrease the difference between the generator set and The Failure to Synchronize merely indicates that a
the paralleling bus. generator set was not able to synchronize within the
expected synchronizing time. This warning on a
Range: 0.01 – 100.00 generator set in Generator Management will cause
Default: 1.00 another generator set to start if it is available, but will not
cause the first generator set to stop synchronizing.
Frequency Match Derivative Gain
Range: 10 – 600 sec
The Frequency Match Derivative Gain adjusts the
Default: 300 sec
Speed Bias by an amount that is related to the rate of
change of the difference between the generator set
frequency and the bus frequency. The speed bias is
adjusted in the direction that should decrease the rate of
change of the difference between the generator set and
the paralleling bus.

Dwell Time Remaining Sync Status Frequency Matched
This parameter displays the remaining time for the dwell This parameter indicates that the frequency of this
timer in seconds. The generator set is considered to be generator set is within the Frequency Match Window of
in Sync when the dwell timer expires. If this value is the bus frequency. This must be true before the
resetting to the Dwell Time (directly above it in generator set will attempt to connect to the paralleling
SiteTecht), the generator set is not holding bus.
synchronism. This value is only updated when the
controller is synchronizing (Synch Mode = Active, This parameter is only updated if the generator set is
Passive or Check, breaker is open, generator set is synchronizing (in either active or check mode).
running).
Range: False-True
Note: Early firmware versions for the controller do not Default: False
support this parameter (there is no value
populated for it). Sync Status Phase Matched
Sync Time Remaining This parameter indicates that the phase angle between
this generator set and the paralleling bus is within the
The remaining time before the controller issues a fail to Phase Match Window. This must be true before the
sync warning. The fail to sync warning will cause the generator set will attempt to connect to the paralleling
Generator Management to consider this generator set bus.
unreliable and to start another generator set (if
available). If the system commissioning has been This parameter is only updated if the generator set is
performed properly, this warning should only occur if the synchronizing (in either active or check mode).
system is overloaded or if there is a malfunction on this
generator set. This value is only populated when the Range: False-True
generator set is actively synchronizing (Sync Mode = Default: False
Active, breaker is open, generator set is running).
Sync Check Matched OK
Note: Early firmware versions for the controller do not
support this parameter (there is no value This parameter indicates that the voltage, frequency,
populated for it). and phase of the generator set are all within their
respective windows of the paralleling bus. This must be
Sync Status Generator V Hz OK true before the dwell timer will start timing. If this
This parameter indicates that the voltage and frequency parameter goes false while the dwell timer is timing, the
of this generator set are considered to be acceptable. dwell timer will be reset.
This must be true before the generator set will attempt to
This parameter is only updated if the generator set is
synchronize to the paralleling bus.
synchronizing (in either active or check mode).
This parameter is updated every 50ms, regardless of
the state of the paralleling controls. Range: False-True
Default: False
Range: False-True
Default: False
6.6.4 Load Sharing
Sync Status Voltage Matched Load Sharing Parameters are found under the Real
Power Load Sharing heading in SiteTecht and under
This parameter indicates that the average line voltage of the Generator Info -> Paralleling Operation -> Sharing
this generator set is within the Voltage Match window of Setup menu on the user interface of the controller.
the average line voltage of paralleling bus. This must be
true before the generator set will attempt to connect to
the paralleling bus. Real Load Sharing
D Real Power Droop Slope
This parameter is only updated if the generator set is
synchronizing (in either active or check mode). This controls the rate at which the target speed of the
engine decreases with increasing load. Real Power
Range: False-True
Droop is intended to permit generator sets to share
Default: False
load in paralleled applications when there is no
communication between the generator set
controllers. See Figure 6-6.

If the load on a given generator set increases, the The Real Power Sharing Derivative Gain determines
target speed will decrease, resulting in a decrease in the contribution of the real power sharing derivative
throttle, causing a decrease in load. The remaining term to the speed bias. The derivative term is directly
load will be supplied by other generator sets in the related to the rate of change in the difference between
paralleling system, which will cause their target speed the average percent electrical loading of all gens on
to decrease slightly. The generator set system will the bus and the percent electrical loading of this
share load relatively evenly if they operate in droop individual generator set. The derivative term
mode, but the system frequency will vary with load. increases the speed bias when the difference
between the average bus load and the average
generator set load increases.
Range: 0.01 – 100.00
Default: 1.00
3Hz (5%) @ 100%
D Torque Sharing Proportional Gain
5% Droop @ 60Hz
5% Droop @ 50Hz
The Torque Sharing Proportional Gain determines
the contribution of the torque sharing proportional
term to the speed bias. The proportional term is
2.5Hz (5%) @ 100% directly related to the difference between the average
percent mechanical loading of all gens on the bus and
the percent mechanical loading of this individual
Generator Load (% of rated capacity)
generator set. The proportional term increases the
speed bias when the average bus load is greater than
Range: 0.0% – 10.0% the generator set load.
Default: 1.0%
Figure 6-6 Real Power Droop Slope Range: 0.01 – 100.00
Default: 1.00
D Real Power Sharing Proportional Gain
D Torque Sharing Integral Gain
The Real Power Sharing Proportional Gain
determines the contribution of the real power sharing The Torque Sharing Integral Gain determines the
proportional term to the speed bias. The proportional contribution of the torque sharing integral term to the
term is directly related to the difference between the speed bias. The integral term ramps at a rate directly
average percent electrical loading of all gens on the related to the difference between the average percent
bus and the percent electrical loading of this mechanical loading of all gens on the bus and the
individual generator set. The proportional term percent mechanical loading of this individual
increases the speed bias when the average bus load generator set. The integral term ramps the speed bias
is greater than the generator set load. up when the average bus load is greater than the
generator set load.
Range: 0.01 – 100.00 Range: 0.01 – 100.00
Default: 1.00 Default: 1.00
D Real Power Sharing Integral Gain D Torque Sharing Derivative Gain
The Real Power Sharing Integral Gain determines The Torque Sharing Derivative Gain determines the
the contribution of the real power sharing integral contribution of the torque sharing derivative term to the
term to the speed bias. The integral term ramps at a speed bias. The derivative term is directly related to
rate directly related to the difference between the the rate of change in the difference between the
average percent electrical loading of all gens on the average percent mechanical loading of all gens on the
bus and the percent electrical loading of this bus and the percent mechanical loading of this
individual generator set. The integral term ramps the individual generator set. The derivative term increases
speed bias up when the average bus load is greater the speed bias when the difference between the
than the generator set load. average bus load and the average generator set load
increases.
Range: 0.01 – 100.00
Default: 1.00 Range: 0.01 – 100.00
Default: 1.00
D Real Power Sharing Derivative Gain

D Frequency Trim Proportional Gain Note: Paralleling systems typically require
reactive droop to remain stable, as the
The Frequency Trim Proportional Gain determines voltage reacts much more quickly than the
the contribution of the frequency trim proportional engine speed. The Voltage Trim is equipped
term to the speed bias. The proportional term is to compensate for the reactive droop over
directly related to the difference between the target time.
speed bias (typically 0) and the actual speed bias.
The proportional term increases the speed bias when
the speed bias is negative.
Range: 0.01 – 100.00

Default: 1.00
D Frequency Trim Integral Gain
The Frequency Trim Integral Gain determines the

1% Droop @ 240V
contribution of the frequency trim integral term to the 2.4V = 1%
speed bias. The integral term ramps at a rate directly

related to the difference between the target speed
bias (typically 0) and the actual speed bias. The
integral term increases the speed bias when the
speed bias is negative. Generator Reactive Load (% of rated capacity)

Range: 0.01 – 100.00
Range: 0.0% – 20.0%
Default: 1.00
Default: 1.0%
D Frequency Trim Derivative Gain Figure 6-7 Reactive Droop Slope
The Frequency Trim Derivative Gain determines the D Reactive Power Sharing Proportional Gain
contribution of the frequency trim derivative term to
The Reactive Power Sharing Proportional Gain
the speed bias. The derivative term is related to the
determines the contribution of the reactive power
rate of change of the difference between the target
sharing proportional term to the voltage bias. The
speed bias (typically 0) and the actual speed bias.
proportional term is directly related to the difference
The derivative term increases the speed bias when
between the average percent reactive loading of all
the speed bias decreases.
gens on the bus and the percent reactive loading of
Range: 0.01 – 100.00 this individual generator set. The proportional term
Default: 1.00 increases the voltage bias when the average bus
reactive load is greater than the generator set
reactive load.
Reactive Load Sharing
Range: 0.01 – 100.00
D Reactive Droop Slope
Default: 1.00
This controls the rate at which the target voltage of the
D Reactive Power Sharing Integral Gain
voltage regulator decreases with increasing reactive
load. Reactive Droop is intended to permit alternators The Reactive Power Sharing Integral Gain
to share reactive load in paralleled applications when determines the contribution of the reactive power
there is no communication between the generator set sharing proportional term to the voltage bias. The
controllers. See Figure 6-7. integral term ramps at a rate related to the difference
between the average percent reactive loading of all
If the reactive load on a given generator set
gens on the bus and the percent reactive loading of
decreases, the target voltage will increase, resulting in
this individual generator set. The integral term
a decrease in field current, causing a decrease in
increases the voltage bias when the average bus
reactive power output. The remaining reactive load will
reactive load is greater than the generator set
be supplied by other generator sets in the paralleling
reactive load.
system, which will cause their target voltage to
decrease slightly. The generator set system will share Range: 0.01 – 100.00
reactive load relatively evenly if they operate in droop Default: 1.00
mode, but the system voltage will vary with reactive
load.

D Reactive Power Sharing Derivative Gain 6.6.5 Power Control
The Reactive Power Sharing Derivative Gain Real Power Disconnect Level
sharing derivative term to the voltage bias. The The Real Power Disconnect Level is the real power
derivative term is related to the rate of change of the threshold below which the generator set circuit breaker
difference between the average percent reactive will be signaled to trip when the generator set is signaled
loading of all gens on the bus and the percent reactive to unload (the load enable signal is removed or the
loading of this individual generator set. The derivative parameter is set to off).
term increases the voltage bias when the generator
set reactive load decreases relative to the bus Range: 0.0% – 25.0%
reactive load. Default: 5.0%
Range: 0.01 – 100.00 Real Power Ramp Rate

Default: 1.00
The Real Power Ramp Rate determines the rate that the
D Voltage Trim Proportional Gain generator set will attempt to take and remove load. The
ramp rate is used in soft-loading (when a generator set
The Voltage Trim Proportional Gain determines the closes to a live bus) and soft-unloading (when a
contribution of the voltage trim proportional term to generator set is signaled to stop by Generator
the voltage bias. The proportional term is directly Management or the load enable signal is removed.
related to the difference between the target voltage
bias (which offsets the reactive droop) and the actual Range: 0.1%/sec – 25.0%/sec
voltage bias. The proportional term increases the Default: 10.0%/sec
voltage bias when the voltage bias is lower than the
target. Real Power Baseload Setpoint
Range: 0.01 – 100.00 The Real Power Baseload Setpoint is the final target for
Default: 1.00 the load ramp when entering baseload mode and is the
target for the real power controller as long as baseload is
D Voltage Trim Integral Gain
active. The setpoint could be adjusted remotely via
The Voltage Trim Integral Gain determines the communications, but the system is intended to operate
contribution of the voltage trim integral term to the in system control mode when paralleling with the utility
voltage bias. The integral term ramps at a rate related using external switchgear controls.
to the difference between the target voltage bias Range: 0.0% – 100.0%
(which offsets the reactive droop) and the actual Default: 50.0%
voltage bias. The integral term increases the voltage
bias when the voltage bias is lower than the target.
Real Power Baseload Proportional Gain
Range: 0.01 – 100.00
The Real Power Baseload Proportional Gain
Default: 1.00
determines the contribution of the real power control
D Voltage Trim Derivative Gain proportional term to the speed bias. The proportional
term is directly related to the difference between the
The Voltage Trim Derivative Gain determines the baseload setpoint and the percent electrical loading of
contribution of the voltage trim derivative term to the this individual generator set. The proportional term
voltage bias. The derivative term is directly related to increases the speed bias when the baseload setpoint is
the rate of change of the difference between the greater than the generator set load.
target voltage bias (which offsets the reactive droop)
and the actual voltage bias. The derivative term Range: 0.01 – 100.00
increases the voltage bias when the voltage bias Default: 1.00
decreases.
Range: 0.01 – 100.00

Default: 1.00

Real Power Baseload Integral Gain System Real Load Control Derivative Gain
The Real Power Baseload Integral Gain determines the The System Real Load Control Derivative Gain
contribution of the real power control integral term to the determines the contribution of the real power control
speed bias. The integral term ramps at a rate directly derivative term to the speed bias. The derivative term is
related to the difference between the baseload setpoint directly related to the rate of change in the difference
and the percent electrical loading of this individual between the system control target set by the speed bias
generator set. The integral term ramps the speed bias and the percent electrical loading of this individual
up when the baseload setpoint is greater than the generator set. The derivative term increases the speed
generator set load. bias when the difference between the system control
target and the generator set load increases.
Range: 0.01 – 100.00
Default: 1.00 Range: 0.01 – 100.00
Default: 1.00
Real Power Baseload Derivative Gain
Reactive Power Baseload Setpoint
The Real Power Baseload Derivative Gain determines
the contribution of the real power control derivative term The Reactive Power Baseload Setpoint is the final target
to the speed bias. The derivative term is directly related for the load ramp when entering baseload mode and is
to the rate of change in the difference between the the target for the reactive power controller as long as
baseload setpoint and the percent electrical loading of baseload is active. The setpoint could be adjusted
this individual generator set. The derivative term remotely via communications, but the system is
increases the speed bias when the difference between intended to operate in system control mode when
the baseload setpoint and the generator set load paralleling with the utility using external switchgear
increases. controls.
Range: 0.01 – 100.00 Range: 0.0% – 100.0%

Default: 1.00 Default: 50.0%
System Real Load Control Proportional Gain Reactive Power Baseload Proportional Gain
The System Real Load Control Proportional Gain The Reactive Power Baseload Proportional Gain
determines the contribution of the real power control determines the contribution of the reactive power
proportional term to the speed bias. The proportional control proportional term to the voltage bias. The
term is directly related to the difference between the proportional term is directly related to the difference
system control target set by the speed bias and the between the baseload setpoint and the percent reactive
percent electrical loading of this individual generator loading of this individual generator set. The proportional
set. The proportional term increases the speed bias term increases the voltage bias when the baseload
when the system control target is greater than the setpoint is greater than the generator set reactive load.
generator set load.
Range: 0.01 – 100.00
Range: 0.01 – 100.00 Default: 1.00
Default: 1.00
Reactive Power Baseload Integral Gain
System Real Load Control Integral Gain
The Reactive Power Baseload Integral Gain determines
The System Real Load Control Integral Gain the contribution of the reactive power control integral
determines the contribution of the real power control term to the speed bias. The integral term ramps at a rate
integral term to the speed bias. The integral term ramps directly related to the difference between the baseload
at a rate directly related to the difference between the setpoint and the percent reactive loading of this
system control target set by the speed bias and the individual generator set. The integral term ramps the
percent electrical loading of this individual generator voltage bias up when the baseload setpoint is greater
set. The integral term ramps the speed bias up when the than the generator set reactive load.
system control target is greater than the generator set
load. Range: 0.01 – 100.00
Default: 1.00
Range: 0.01 – 100.00
Default: 1.00

Reactive Power Baseload Derivative Gain Power Factor Baseload Derivative Gain
The Reactive Power Baseload Derivative Gain The Power Factor Baseload Derivative Gain determines
determines the contribution of the reactive power the contribution of the reactive power control derivative
control derivative term to the speed bias. The derivative term to the voltage bias. The derivative term is directly
term is directly related to the rate of change in the related to the rate of change in the difference between
difference between the baseload setpoint and the the reactive power target calculated from the real power
percent reactive loading of this individual generator set. and the power factor baseload setpoint and the percent
The derivative term increases the speed bias when the reactive loading of this individual generator set. The
difference between the baseload setpoint and the derivative term increases the voltage bias when the
generator set reactive load increases. difference between the baseload setpoint and the
generator set load increases.
Range: 0.01 – 100.00
Default: 1.00 Range: 0.01 – 100.00
Default: 1.00
Power Factor Baseload Setpoint
System Reactive Load Control Proportional Gain
The Power Factor Baseload Setpoint is the final target
for the load ramp when entering baseload mode and The System Reactive Load Control Proportional Gain
allows computation of the target for the reactive power determines the contribution of the reactive power
controller as long as baseload is active. The setpoint control proportional term to the voltage bias. The
could be adjusted remotely via communications, but the proportional term is directly related to the difference
system is intended to operate in system control mode between the system control target set by the external
when paralleling with the utility using external voltage bias and the percent reactive loading of this
switchgear controls. individual generator set. The proportional term
increases the voltage bias when the system control
Range: 0.50% – 1.00% target is greater than the generator set reactive load.
Default: 0.80%
Range: 0.01 – 100.00
Default: 1.00
Power Factor Baseload Proportional Gain
The Power Factor Baseload Proportional Gain System Reactive Load Control Integral Gain
control proportional term to the voltage bias. The The System Reactive Load Control Integral Gain
proportional term is directly related to the difference determines the contribution of the reactive power
between the reactive power target calculated from the control integral term to the voltage bias. The integral
real power and the power factor baseload setpoint and term ramps at a rate directly related to the difference
the percent reactive loading of this individual generator between the system control target set by the external
set. The proportional term increases the voltage bias voltage bias and the percent reactive loading of this
when the reactive power target is greater than the individual generator set. The integral term ramps the
generator set load. voltage bias up when the system control target is greater
than the generator set reactive load.
Range: 0.01 – 100.00
Default: 1.00 Range: 0.01 – 100.00
Default: 1.00
Power Factor Baseload Integral Gain
System Reactive Load Control Derivative Gain
The Power Factor Baseload Integral Gain determines
the contribution of the reactive power control integral The System Reactive Load Control Derivative Gain
term to the voltage bias. The integral term ramps at a determines the contribution of the reactive power control
rate directly related to the difference between the derivative term to the voltage bias. The derivative term is
reactive power target calculated from the real power and directly related to the rate of change in the difference
the power factor baseload setpoint and the percent between the system control target set by the external
electrical loading of this individual generator set. The voltage bias and the percent reactive loading of this
integral term ramps the speed bias up when the individual generator set. The derivative term increases
baseload setpoint is greater than the generator set load. the voltage bias when the difference between the system
control target and the generator set reactive load
Range: 0.01 – 100.00 increases.
Default: 1.00
Range: 0.01 – 100.00
Default: 1.00
System Power Factor Baseload Proportional Gain Control Mode
The System Power Factor Baseload Proportional Gain The Control Mode parameter controls the Order
determines the contribution of the reactive power Selection Method for Generator Management. The
control proportional term to the voltage bias. The available Methods are:
proportional term is directly related to the difference
between the reactive power target calculated from the D Manual/Fixed
real power and the power factor target set by the
external voltage bias and the percent reactive loading of The Generator Start/Stop Order is manually
this individual generator set. The proportional term selected. In this mode, the user sets the order of each
increases the voltage bias when the reactive power generator set at the controller and Generator
target is greater than the generator set reactive load. Management retains the order (there is no automatic
re-sort during operation).
Range: 0.01 – 100.00
Default: 1.00 Note: All generator sets must have different
orders. If two or more generator sets have
the same order, Generator Management is
System Power Factor Baseload Integral Gain disabled (all available generator sets will
The System Power Factor Baseload Integral Gain run, but no fault will be displayed on the
determines the contribution of the reactive power controller). The system will attempt to
control integral term to the voltage bias. The integral resolve order conflicts, but this may require
term ramps at a rate directly related to the difference manual intervention, especially if more than
between the reactive power target calculated from the one order is changed simultaneously (using
real power and the power factor target set by the SiteTecht). If generator sets are added to
external voltage bias and the percent reactive loading of or subtracted from the paralleling system,
this individual generator set. The integral term ramps the system may see an order
the voltage bias up when the reactive power target is conflict—resulting in a reassignment of the
greater than the generator set reactive load. orders in the system (the order for any
generator set could change from the
Range: 0.01 – 100.00 previous setting).
Default: 1.00
Manual mode can be used in a scenario where
certain generator sets are preferred to run more
System Power Factor Baseload Derivative Gain
frequently for any reason (such as position, sound
The System Power Factor Baseload Derivative Gain level, fuel efficiency, fuel type, etc.)
control derivative term to the voltage bias. The The need for manual mode should decrease as
derivative term is directly related to the rate of change in additional automatic modes are added.
the difference between the reactive power target
D Runtime
calculated from the real power and the power factor
target set by the external voltage bias and the percent The Generator Start/Stop Order is selected
reactive loading of this individual generator set. The automatically by the controller based on the runtime
derivative term increases the voltage bias when the hours on each generator set. In this mode, the
difference between the baseload setpoint and the generator set with the lowest runtime hours will be
generator set reactive load increases. assigned the lowest order (starting first, stopping
last), with each sequential order number being
Range: 0.01 – 100.00
assigned to generator sets of increasing runtime
Default: 1.00
hours. The intent is to equalize runtime hours
between the units.
6.6.6 Generator Management
If the generator set system is supplying the load,
Generator Management provides logic to determine Generator Management implements a Runtime
how many generator sets are required to support the Threshold to avoid starting and stopping generator
load on the generator set system and which generator sets every 0.1 hours. The Runtime Threshold is
sets are the most desirable to run. If Generator added to the runtime hours of generator sets that are
Management is disabled, all available generator sets not running (for the purpose of comparison),
will run as long as a start signal is received. preventing excessively frequent starting and
stopping of generator sets.

If all the generator sets are running, the Order re-sorts Enabled
automatically any time the runtime hours of a higher
order generator set drops below the hours on a lower This permits disabling all Generator Management
order generator set. This will not typically occur while features. When Generator Management is disabled, a
all generator sets are running, as they will all be generator set will not alert the user of a Generator
acquiring runtime hours at the same rate. Management configuration mismatch. Any generator
sets in the paralleling system with Generator
If a generator set starts because the load increases, Management disabled will run if they are in auto and are
the Order may re-sort as soon as it connects to the receiving a start signal (they will not stop if they are not
paralleling bus, hence the runtime hours will be needed).
equalized before the difference reaches the
threshold. Nodes with Generator Management enabled may still
see a configuration mismatch if a disabled node is
Runtime control mode is intended for application configured differently.
where the generator sets require wear-leveling, such
as a prime-power application. Range: False-True
Default: False
D Fuel Level
Order
The Generator Start/Stop Order is selected
automatically by the controller based on the fuel level The Order that a generator set will start and stop in the
measured by each generator set. In this mode, the Generator Management sequence—Higher orders
generator set with the highest fuel level (as measured start last and stop first. This parameter is only adjustable
in percentage) will be assigned the lowest order in Manual Mode.
(starting first, stopping last), with each sequential
order number being assigned to generator sets of The Order of each of the generator sets in the paralleling
decreasing fuel level. The intent is to equalize fuel system must be different for Generator Management to
level between the units. function. Generator Management will attempt to correct
an order conflict, but can only do so to a limited extent.
If the generator set system is supplying the load,
Generator Management implements a Fuel Level If a generator set controller is powered down or
Threshold to avoid starting and stopping generator disconnected from the communications network, the
sets every time the fuel level changes (which could remaining controllers will attempt to re-sort the order so
happen frequently if the fuel is moving). The Fuel that each generator set has a unique and sequential
Level Threshold is added to the fuel level of generator Order—the re-sort is not always successful in manual
sets that are running (for the purpose of comparison), mode.
preventing excessively frequent starting and
stopping of generator sets. It is important to verify the Start/Stop Order of each
generator set if power is cycled to one or more generator
If all the generator sets are running, the Order re-sorts sets in a paralleling system where Generator
automatically any time the fuel level of a lower order Management is used in manual mode.
generator set drops below the fuel level on a higher
order generator set. This will not typically occur while Range: 1-8
all generator sets are running, as they will all be using Default: *Depends on Power-up sequence and Ser #
fuel at the same relative rate (if the tanks are sized
appropriately for each generator set). Start Percentage
If a generator set starts because the load increases, The Percentage of Rated Capacity on the paralleling
the Order may re-sort as soon as it connects to the system (the generator sets that are running and are
paralleling bus, hence the fuel level will be equalized active in Generator Management) above which a
before the difference reaches the threshold. generator set is considered for starting.
Fuel Level Control mode is intended to equalize fuel Only a generator set which is available, not running and
level in a system of generator sets where each is enabled for Generator Management can be started by
generator set has a separate fuel tank—it is intended Generator Management.
to prevent the case where one generator set runs out
of fuel while the others have plenty. Generator Management uses the start percentage to
calculate the Start kW for this generator set.
Range: Invalid = 0, Manual Fixed = 1, Runtime = 2,
Fuel Level = 3
Default: Runtime
The Start Percentage should be set so that the The Start Delay should be configured to ensure that
generator set system starts enough generator sets that reasonable load spikes are handled without starting an
any transient loading can be supported by the running additional generator set, while allowing a generator set
generator sets, or to keep an additional generator set to start if the increased load persists.
running for redundancy. The default (80%) works for
most applications, but applications with large switching Range: 1 sec - 600 sec
loads may require a lower setting for the Start Default: 30 sec
Percentage.
Stop Delay
The Start Percentage should always be at least 10%
higher than the stop percentage. A time factor that represents the time that Generator
Management will wait to stop a generator set if the load
Range: 0.00% - 100.00% on the lower-order running generator sets drops below
Default: 80.00% the Stop Percentage of this generator set by 10% and all
higher-order generator sets are already stopped.
Stop Percentage
The Stop Delay should be configured to allow generator
The Percentage of Rated Capacity on the other sets to stop quickly if they will not be needed, but to
generator sets in the paralleling system (the other prevent generator sets from stopping during a
generator sets that are running and are active in short-duration light load on the paralleling system.
Generator Management) below which a generator set is
considered for stopping. Range: 0 sec - 7200 sec
Default: 300 sec
Only a generator set which is running (in auto) and is
enabled for Generator Management can be stopped by Stable Delay
Generator Management. Generator sets running in
RUN (pressing the run button on the front panel) are not The Stable Delay is the delay between the system
considered for Generator Management (their capacity is reaching a typical loading scenario and Generator
not counted toward supplying the load and they are not Management becoming active. This delay is intended to
stopped when not needed). allow any loads connected to the system to reach a
typical load level before Generator Management stops
Generator Management uses the stop percentage to any generator sets.
calculate the Stop kW for this generator set.
The Stable delay should be configured to allow the
Note: The calculation is based on the capacity of the Generator Management to become active when the
other generator sets on the paralleling bus, as system load has reached a nominal level (all abnormal
this generator set will not be providing power after load conditions due to a loss of power have been
it stops. removed).
The Stop Percentage should be set so that the Range: 0 sec - 3600 sec
generator set system keeps enough generator sets Default: 300sec
online to supply any transient loading that the
application may demand (such as large chillers, air Runtime Threshold
conditioners, pumps, or bow thrusters), while allowing
unneeded generator sets to stop. The Runtime Threshold is the maximum Runtime Hour
difference that Generator Management will allow before
The Stop Percentage should always be at least 10% starting the lower-hour generator set and stopping the
lower than the start percentage. higher-hour generator set. This parameter is only
considered with the order selection mode (control
Range: 0.00% - 100.00% mode) set to Runtime Hours. The Threshold should be
Default: 60.00% set based on the intended start/stop frequency of the
generator sets (understanding that changing load may
Start Delay cause additional start/stop cycles).
A time factor that represents the time that Generator Range: 0.1 h - 2400.0 h
Management will wait to start this generator set if the Default: 24.0 h
load on the running generator sets exceeds the Start
Percentage of this generator set by 10% and all
available lower-order generator sets are running.

Fuel Level Threshold 6.6.7 Load Management
The Fuel Level Threshold is the maximum Fuel Level Load Management allows the temporary removal of
difference that Generator Management will allow before loads from a paralleling generator set system during
starting the generator set with more fuel and stopping startup (as as single generator set will close to the dead
the generator set with less fuel. This parameter is only paralleling bus and must be able to maintain rated
considered with the order selection mode (control voltage and frequency so that the other node can
mode) set to Fuel Level. The Threshold should be set synchronize to it). It also removes loads in the event of a
based on the intended start/stop frequency of the generator set overload in order to maintain power to
generator sets (understanding that changing load may more important loads.
cause additional start/stop cycles).
All load priorities are shed on receipt of a system start
Range: 0.5% - 50.0%
command, but no loads are shed during a local start.
Default: 10.0%
Load Management has 6 priorities that add in sequence.
Min Gens Online Priority 1 adds first and priority 6 adds last. The priorities
shed in reverse order, priority 6 sheds first and priority 1
This parameter indicates how many generator sets the
sheds last.
system will run with no load on the system. It can be
used to keep an additional generator set online, but is The timing for a priority to add is related to the available
not intended to convert a system to N+1 Redundancy. capacity of the generator set system (more capacity will
N+1 Redundancy can be accomplished by setting the result in quicker load adding).
start and stop percentages considerably lower.
Range: 1 - 2 The timing for a priority to shed is related to the degree of
Default: 1 system overload (except for initial shed, which is
instant). More overload results in quicker load shedding.
Min Load Shed Priority
Genset Maximum Percent Capacity
Generator Management will be disabled any time the
load control sheds a priority below this level. Setting the The Genset Maximum Percent Capacity is the
Min Load Shed Priority to 0 will disable the link between maximum level that the load management system will
Load Control and Generator Management. Minimum automatically place on the generator set. Each priority is
Load Shed Priority should only be set to 0 if no Load expected to provide 15% load on the generator set
Control priorities are connected to interrupt a load. system, so load management will ensure that the
generator set load is below 15% less than the Genset
If loads are shed below this threshold, Generator Maximum Percent Capacity before permitting another
Management will be disabled (resulting in all available load to add.
generator sets starting).
Range: 0.0% - 120.0%
Any connected Load Control priorities should disable Default: 70.0%
Generator Management when they are shed, to avoid
Generator Management stopping generator sets while Generator Overloaded Percent
loads are still adding, to allow Generator Management
to start additional generator sets to support shed loads, The Generator Overloaded Percent is the output power
and to allow extended underfrequency events to start threshold above which the load management system
additional generator sets. considers a generator set or generator set system to be
overloaded. Loads will start shedding in their priority
Range: 0 - 6 order if the generator set system output power exceeds
Default: 0 this level for long enough. Loads will continue to shed in
decreasing intervals until the output power of the
generator set system drops below this level.
Range: 0.0% - 120.0%

Default: 85.0%

Under Frequency Shed Level 6.6.8 Miscellaneous
The Under Frequency Shed Level is the degree of
frequency droop (operation below the nominal value) Fail to Open Delay
that is permitted on the generator set system before the The Fail to Open Delay is the time that the controller will
load management system considers a generator set or wait after applying a trip signal to the circuit breaker to
generator set system to be overloaded. Loads will start see the breaker status indicate open. If the breaker
shedding in their priority order if the generator set status does not indicate open within this time, the
system frequency droop exceeds this level for long controller will issue a Failure to Open warning. The
enough. Loads will continue to shed in decreasing controller continues to apply the trip signal to the circuit
intervals until the frequency of the generator set system breaker and if the breaker opens at a later time, the
recovers to the point where the droop drops below this warning will be cleared automatically (but still stored in
level. the event log). If this warning recurs frequently in the
event log of a generator set, it may indicate that the Fail
Range: 0.00Hz - 5.00Hz to Open Delay is set for too short of a time and that the
Default: 0.50Hz breaker is not able to respond quickly enough to match
the Fail to Open Delay. In this case, the Fail to Open
Base Load Add Time delay can be lengthened, but consideration of the
protective relay functionality and timing should be
The Base Load Add Time is the time required to add a
considered when lengthening the timing, as it may be
load with 25% available capacity (generator set system
preferred to troubleshoot the breaker for slow operation
power output is 40% below the Genset Maximum
first.
Percent Capacity). The load will add more quickly with
lower load and take longer as the load increases, but the Range: 0.1 sec - 30.0 sec
time is relative to the base load add time. Default: 1.0 sec
Range: 10.0 sec - 2400.0 sec
Default: 60.0 sec Fail to Close Delay
The Fail to Close Delay determines the time that the
Base Overload Shed Time controller will hold the close signal on during a close
attempt. If the breaker status does not indicate that it is
The Base Overload Shed Time is the time required to
closed within the time allocated by the Fail to Close
shed a load with 10% overload on the generator set
Delay, the controller will remove the close signal and
system (generator set system power output is 10%
issue a Breaker Close Attempt Fault. After the controller
above the Generator Overloaded Percent). The load will
has seen a number of close attempt faults equal to the
shed more quickly with higher load and take longer as
breaker close attempts, the controller will issue a Failure
the load decreases, but the time is relative to the base
to Close. Failures to Close may be caused because the
overload shed time.
breaker requires an abnormally long time to close, but
Range: 2.0 sec - 30.0 sec they are typically caused by wiring errors, external
Default: 30.0 sec protective relay settings, or incorrect motor operator
specifications/operating voltage.
Base Under Frequency Shed Time Range: 0.1 sec - 30.0 sec
The Base Under Frequency Shed Time is the time Default: 0.3 sec
required to shed a load with 1Hz of frequency droop
(frequency is 1Hz below the Under Frequency Shed Breaker Reclose Time
Level less than the rated frequency of the generator
The Breaker Reclose Time controls the time delay
set). The load will shed more quickly with lower
between close attempts on the breaker. This is intended
frequency and take longer as the frequency increases,
to allow the breaker to reset to a normal state and to
but the time is relative to the Base Under Frequency
operate properly on the subsequent reclose attempt.
Shed Time.
Range: 0.5 sec - 30.0 sec
Range: 1.0 sec - 20.0 sec
Default: 2.0 sec
Default: 5.0 sec

Breaker Close Attempts
The Breaker Close Attempts indicates how many failed
attempts to close the breaker the controller will accept
before issuing a Fail to Close fault and requiring a fault
reset to re-attempt breaker closure.
Range: 1 - 100
Default: 3.0 sec
Generator Paralleling Breaker

The Generator Paralleling Breaker is a Status
parameter that indicates the internal measured position
of the paralleling breaker. The parameter is displayed
under Metering -> Paralleling Metering and under
Generator Info -> Parallel Operation -> Synchronization
Setup as Connected to Bus.
Range: False - True

Default: **STATUS** Range: -100.00% – 100.00%
Default: 0.00% **Not Writable**
Figure 6-8 Speed Bias
Speed Bias
The amount that the controller is attempting to adjust the Voltage Bias
output frequency of the generator set (100% bias = +5%
on the engine speed, -100% = -5% on the engine The amount that the controller is attempting to adjust the
speed). The controller adjusts the Speed bias to match output voltage (100% bias = +10% on the output
frequency and phase with the paralleling bus. voltage, -100% = -10% on the output voltage). The
controller adjusts the voltage bias to match the
Note: The Speed Bias can also be controlled by an generator set voltage to the bus voltage.
external device if the External Bias Inputs
Enabled parameter is true, the Stand Alone Note: The Voltage Bias can also be controlled by an
Operation parameter is false, no generator sets external device if the External Bias Inputs
are visible on the PGEN communications Enabled parameter is true, the Stand Alone
channel, and the voltage applied to the speed Operation parameter is false, no generator sets
bias input is between 0.5V and 4.5V. are visible on the PGEN communications
channel, and the voltage applied to the voltage
The External Speed Bias Input (SBP and SBN) is a bias input is between 0.5V and 4.5V.
voltage measuring channel capable of reading from
-10V to 30V DC. The input is normally pulled down to The External Voltage Bias Input (VBP and VBN) is a
-3.3V, but can be overridden by applying a voltage to the voltage measuring channel capable of reading from
input. -10V to 30V DC. The input is normally pulled down to
-3.3V, but can be overridden by applying a voltage to the
The voltage that the controller sees on the voltage input.
measuring channels is visible in the Analog Voltage
Input Metered Relative Value under the Programmable The voltage that the controller sees on the voltage
Analog Voltage Input I08 heading. The input is polarity measuring channels is visible in the Analog Voltage
sensitive. Input Metered Relative Value under the Programmable
Analog Voltage Input I07 heading. The input is polarity
The Speed Bias is interpreted by the controller as sensitive.
illustrated in Figure 6-8.

The Voltage Bias is interpreted by the controller as Load Enable
illustrated in Figure 6-9.
Load Enable allows the generator set controller to ramp
to a target load in any of the power control modes. A
controller will attempt to control load to 0% load when
load enable is false, resulting in decreasing bus
frequency when a single generator set is supplying the
load and severe load disparities when in parallel with
other generator sets.
If Load Enable is removed after having been applied, the

generator set will soft-unload and trip its circuit breaker
when the output power reaches the kW Disconnect
Level.
Load Enable should remain on except when being used

for testing, as it can cause loss of functionality that can
be rather difficult to troubleshoot.
Load Enable can be configured to be a digital input to the

controller, allowing external gear to signal the generator
set to unload and trip its breaker.
Range: False - True
Range: --100.00% – 100.00% Default: True
Default: 0.00% **Not Writable**
Figure 6-9 Voltage Bias
Disable Synchronization
Stand Alone Operation The Disable Synchronization parameter allows blocking

the controller from closing the paralleling breaker, but
This Parameter forces the controller to solve paralleling does not trip the breaker if asserted while the breaker is
logic, even when it is not seeing PGEN communications closed. This input can be used by external gear to inhibit
with another generator set. This is intended for the generator set from closing to a bus. This allows
applications where the generator set is equipped with a integration with existing first-on systems and allows the
motor operator that is controlled by the generator set generator set to be unloaded and tripped without
controller, but that the generator set is equipped with a immediate re-synchronization and breaker closure.
motor-operated breaker (either for disconnection
means, baseload capability, or to allow for the This parameter can be configured to a digital input to
installation of additional units in the future). Standalone allow it to be controlled by external gear.
mode is not necessary and should not be enabled in
Range: False - True
applications where multiple generator sets are in
Default: False
communication over PGEN or in applications where the
generator set is controlled by external gear that also
controls the circuit breaker. Baseload Mode
Baseload Mode is intended for use in parallel with a utility
Standalone Operation can be configured as a digital
source. Setting this input to true will place the controller in
input, allowing the ability to turn paralleling functionality
baseload mode, which will attempt to control the output
on remotely.
real and reactive power to a setpoint parameter. Only the
Range: False - True controller receiving the baseload mode signal will
Default: False operate in baseload, other modes will continue to operate
normally. Baseload mode takes priority over System
Control mode and System Sync mode.
Baseload mode should only be used in parallel with the

utility except as a troubleshooting tool. Baseload Mode
is configurable as a digital input.
Range: False - True
Default: False

System Load Control kW Control Mode
System Load Control mode is intended for use in parallel Determines the method of controlling generator set real
with a utility source. Setting this input to true will place all power between the following modes:
the controllers in the paralleling system in system D Electrical Power Control Mode. The generator set
control mode (unless baseload mode is also asserted controller controls power based on the electrical
on the controllers). System control mode controls the power that is produced by the alternator. This is the
real and reactive power of each generator set to targets normal mode of operation.
set by the external speed and voltage bias, which is 50%
(2.5V equivalent) when the external bias inputs are D Engine Torque Control Mode. The generator set
disabled. System Load Control mode can be controller controls power based on the mechanical
configurable as a digital input. torque as measured or calculated by the engine ECM.
This mode is typically used if one of the generator sets
Range: False - True in a paralleling system has a mechanical load which is
Default: False also coupled to the engine.
System Sync Control Note: Not all applications support this parameter.
System Sync Control mode is intended for use in Range: Invalid = 0, kWe mode = 1, kWm mode = 2
applications where it is necessary to synchronize a Default: kWe mode
paralleling bus containing multiple generator sets to a
utility source. System Sync mode causes all generator VAR Control Mode
sets in a paralleling system to accept a speed and
voltage bias from the external inputs of a single The VAR Control mode parameters set the means that
generator set (as long as external bias is enabled). This the controller uses to control reactive power in baseload
allows external gear to synchronize an entire bus of and system control mode. This parameter has no effect
generator sets as if it were a single generator set. when the generator sets are islanded and are merely
System Sync Control mode can be configurable as a sharing the power supplied to the load between them.
digital input. The modes are:
Range: False - True D PF Control Mode = 0. Power Factor Control mode

Default: False indicates that the reactive power target is related to
the real power output level.
Enable Trims
D VAR Control Mode = 1. VAR Control mode indicates
Enable Trims allows activating/de-activating of the that the reactive power target is not related to the real
frequency and voltage trim functions that are available power output.
while in load sharing mode. There are few applications
where the trims should be disabled, but it provides a Range: PF Control Mode = 0, VAR Control Mode = 1
good interface for troubleshooting. Default: PF Control Mode
Range: False - True External Bias Inputs Enabled

Default: True
The external speed and voltage bias are set to 0
internally unless they are enabled. When enabled, they
are controlled by the voltage applied to the external bias
inputs. If there are no wires connected to the inputs, the
biases will still read 0, as the inputs are pulled down to
-3.3V, which is outside the normal range (0.5 to 4.5V). If
a wire feeding the speed or voltage bias loses
connection, the input should also revert to -3.3V (0 bias).
Range: False - True

Default: False

Notes

Section 7 Generator Management Information
7.1 Generator Management 7.2.1 Sequence of Operation

Purpose This sequence follows the operation of a normal
paralleling system which uses Generator Management.
Generator Management is intended to decrease fuel
consumption, environmental emissions, and sound When a start signal is applied to any of the generator
emissions while improving generator life and sets in the paralleling system, all the generator sets that
serviceability. are in auto and have no shutdown faults will start.
Figure 7-1 illustrates the system after the first generator

7.2 Generator Management Basic set has reached rated voltage and frequency and has
Function closed to the paralleling bus (any of the generator sets
can be the first to close, depending on which generator
Generator Management supplies a stop signal to a set reaches rated voltage and frequency first). The Total
generator. If Generator Management fails or is turned System Capacity is that of a single generator set and the
off, the stop signal is removed, resulting in the generator load is low enough to be supported by a single generator
starting. Most faults relating to Generator Management set because non-critical loads have been shed by a
will cause it to be disabled, causing the generator to Load Add/Shed (Load Control) system (not shown).
start.
Generator Management is disabled when the start

signal to the system is removed, and must go through a
stability delay before it will stop generator sets.
Figure 7-1 A Generator Set Energizes the Bus
TP-6929 1/15 Section 7 Generator Management Information 139

As the other generator sets were synchronizing and In Figure 7-2, the system capacity is at a maximum for
connecting to the paralleling bus, the Load Add/Shed all generator sets in the paralleling system, as the
system added a load priority, increasing the load on the generator sets are all connected to and supplying the
system beyond what a single generator set can handle. load.
Figure 7-2 All Generator Sets are Connected to the Paralleling Bus
Figure 7-3 is representative of the system after all load generator sets can be stopped. The load must stabilize
priorities have been added. With no load intentionally before such determination will be accurate, so the
de-activated, Generator Management is able to assess stability delay begins.
the load on the system accurately to determine if any
Figure 7-3 All Loads Have Been Added
140 Section 7 Generator Management Information TP-6929 1/15

By the time the Generator Management Stability Delay start timing to stop Generator Set #4 because the
has expired (see Figure 7-4), the load has settled down system load is below the stop kW of Generator Set #4.
to a steady-state level. Generator Management can
Figure 7-4 The Stability Timer has Expired
When its Stop Delay is complete, Generator Set #4 will system continues to feed the load with Generator Sets
soft-unload (gently transfer load to the other generator #1, #2 and #3 as illustrated in Figure 7-5. The load has
sets) and disconnect from the paralleling bus, either decreased further from the peak loading which occurred
stopping or going into engine cooldown after right after startup.
disconnecting. After Generator Set #4 has stopped, the
Figure 7-5 Generator Set #4 is Stopped by Generator Management

When the load decreases below the Stop Load Level for Set #3 will soft unload and disconnect from the
Generator Set #3, Generator Management will begin paralleling bus, leaving only Generator Sets #1 and #2
the stop delay. When the stop delay expires, Generator to supply the load (see Figure 7-6).
Figure 7-6 Generator Sets #3 and #4 are Stopped by Generator Management
The load increases to a level above the Stop Load Level the load increase until the load exceeds the Start Load
for Generator Set #3, but the system will not respond to Level of Generator Set #3 (see Figure 7-7).
Figure 7-7 Load Increases After Generator Set #3 Stops

In Figure 7-8, the load increases well past the start kW
for Generator Set #3, causing the generator set to start,
synchronize, and connect to the bus.
Figure 7-8 Generator Set #3 Restarts Due to Increase in Load
When the Start signal goes away, all generator sets

disconnect from the paralleling bus and stop (see
Figure 7-9).
Figure 7-9 Paralleling Generator Set System has Returned to Standby State

Note: The generator set order in the examples above sets is required for load sharing and first-on logic.
matches the generator set numbers for simplicity, Centralized Generator Management requires
but it is not required or even customary for the connection of Start and Unload signals to the generator
Start/Stop order of managed generator sets to set controllers, interruption of the external start signal,
match their generator set numbers. and an additional module.
Figure 7-10 outlines the differences between these two

7.2.2 Control Approach types of Generator Management.
The controller uses Individual Generator Management. The two systems operate very similarly, but the
This means that each generator set controller manages individual approach has no single point of failure for the
only the generator set that it controls. Individual system. The centralized system relies on the Generator
Generator Management allows for improved scalability, Management Controller to issue the start signal to each
more seamless redundancy, and more comprehensive generator set—hence, a failure in the Generator
fault handling than centralized Generator Management. Management Controller could prevent the system from
Individual Generator Management controls each responding to a start signal. The individual approach will
generator set without need for additional signal only lose one generator set if a controller fails.
routing—the communication between the generator
Figure 7-10 Comparison of Generator Management Topologies

7.2.3 Timing Approach
The Generator Management in the controller uses
Overload-Based Start Timing and Capacity-Based Stop
Timing. This means that the time to start or stop a
generator set depends on the loading on the system.
Start Timing
The Start Timing is inversely related to the system
load—increasing system load will decrease the time to
start a generator set. This allows the Generator
Management system to start additional generator sets
when needed while providing ride-through capability for
transient loads.
Figure 7-12 Capacity-Based Stop Timing
The Start Delay and Start Percentage are adjustable, Stop Percentage = 60%,
but the curve shape is hard-coded for the controller. Stop Delay = 300s
Figure 7-12 illustrates that Generator Management

would require only 9 seconds to stop a generator set if
the generator set system were completely unloaded, but
that the generator set would take 1200 seconds (20
minutes) to stop a generator set if the load on the other
generator sets would be 55% after that generator set
stopped. This technique helps to ensure that the system
can handle the load without a particular generator set
before stopping that generator set.
7.3 Generator Management

Considerations
Generator Management is disabled by default on the
Figure 7-11 Overload-Based Start Timing controller. It is important to consider the following before
Start Percentage = 80%, enabling Generator Management:
Start Delay = 10s
D Application of the Generator Set System. In
Figure 7-11 illustrates that the system load would have applications where the generator sets run for
to remain at 85% of running capacity for about extended durations and for extended time intervals,
40 seconds before an additional generator set would Generator Management will provide a significant
start, but the generator set will start within 2.5 seconds if improvement in the life and fuel efficiency of the
the system load reaches 100% of running capacity. The generator sets. Standby applications that run only
curve shape is intended to approximate the capability of occasionally are less dependent on Generator
the generator sets. Management.
Stop Timing D Load Types. In applications where the load varies

quickly and significantly, it is more difficult to manage
The Stop Timing is directly related to the system the generator sets, as a large increase in load may
load—increasing system load will increase the time to overload the generator set system before Generator
stop a generator set. This allows the Generator Management can start another generator set.
Management system to stop unneeded generator sets Although Generator Management can be used in
while maintaining enough capacity online to support these applications, the system needs to be
transient loading. configured to keep enough generator sets online to
support the transient load.
The Stop Percentage and the Stop Delay are
adjustable, but the shape of the curve is hard-coded in
the controller.

D Generator Set Sizing. If the generator sets are sized D Runtime: The Generator Start/Stop Order is
such that any of them can support the entirety of the selected automatically by the controller based on the
load, Generator Management provides the function runtime hours on each generator set. In this mode,
of stopping unneeded generator sets while permitting the generator set with the lowest runtime hours will be
them to be available in case of a failure. assigned the lowest order (starting first, stopping
last), with each sequential order number being
D Criticality of the Application. Highly critical assigned to generator sets of increasing runtime
applications typically require one or more generator hours. The intent is to equalize runtime hours
sets in spinning reserve. Although, it is possible to between the units.
configure Generator Management to keep an
additional generator set running, this might not meet If the generator set system is supplying the load,
the needs of the application. Generator Management implements a Runtime
Threshold to avoid starting and stopping generator
D Complexity of Operation. Many facilities prefer sets every 0.1 hours. The Runtime Threshold is
simple, understandable system operation (all added to the runtime hours of generator sets that are
generator sets running when the utility is not not running (for the purpose of comparison),
available) which allows for easier troubleshooting (if a preventing excessively frequent starting and
generator set is not running, something is wrong). stopping of generator sets.
If all the generator sets are running, the order re-sorts

7.4 Generator Management Setup automatically any time the runtime hours of a higher
order generator set drop below the hours on a lower
Generator Management requires consideration of order generator set. This will not typically occur while
several factors as each parameter is configured. The all generator sets are running, as they will all be
default settings will only work in certain scenarios. acquiring runtime hours at the same rate.
7.4.1 Control Mode If a generator set starts because the load increases,
the order may re-sort as soon as it connects to the
The Control Mode Parameter controls the Order paralleling bus, hence the runtime hours will be
Selection Method for Generator Management. The equalized before the difference reaches the
available Methods are: threshold.
D Manual/Fixed: The Generator Start/Stop Order is Runtime control mode is intended for applications
manually selected. In this mode, the user sets the where the generator sets require wear-leveling, such
order of each generator set at the controller and as a prime-power application.
Generator Management retains the order (there is no
automatic re-sort during operation). D Fuel Level: The Generator Start/Stop Order is
selected automatically by the controller based on the
Note: All generator sets must have different orders. If fuel level measured by each generator set. In this
two or more generator sets have the same order, mode, the generator set with the highest fuel level (as
Generator Management is disabled (all available measured in percentage) will be assigned the lowest
generator sets will run, but no fault will be order (starting first, stopping last), with each
displayed on the controller). The system will sequential order number being assigned to generator
attempt to resolve order conflicts, but this may sets of decreasing fuel level. The intent is to equalize
require manual intervention, especially if more fuel level between the units.
than one order is changed simultaneously (using
SiteTecht). If generator sets are added to or If the generator set system is supplying the load,
subtracted from the paralleling system, the Generator Management implements a Fuel Level
system may see an order conflict – resulting in a Threshold to avoid starting and stopping generator
reassignment of the orders in the system (the sets every time the fuel level changes (which could
order for any generator set could change from the happen frequently if the fuel is moving). The Fuel
previous setting). Level Threshold is added to the fuel level of generator
sets that are running (for the purpose of comparison),
Manual mode can be used in a scenario where preventing excessively frequent starting and
certain generator sets are preferred to run more stopping of generator sets.
frequently for any reason (such as position, sound
level, fuel efficiency, fuel type, etc.). If all the generator sets are running, the order re-sorts
automatically any time the fuel level of a lower order
The need for manual mode should decrease as generator set drops below the fuel level on a higher
additional automatic modes are added.
order generator set. This will not typically occur while 7.4.4 Start Percentage
all generator sets are running, as they will all be using
fuel at the same relative rate (if the tanks are sized The Percentage of Rated Capacity on the paralleling
appropriately for each generator set). system (the generator sets that are running and are
active in Generator Management) above which a
If a generator set starts because the load increases, generator set is considered for starting.
the order may re-sort as soon as it connects to the
paralleling bus, hence the fuel level will be equalized Only a generator set which is available, not running, and
before the difference reaches the threshold. is enabled for Generator Management can be started by
Generator Management.
Fuel Level Control mode is intended to equalize fuel
Generator Management uses the start percentage to
level in a system of generator sets where each
calculate the Start kW for this generator set.
generator set has a separate fuel tank—it is intended
to prevent the case where one generator set runs out The Start Percentage should be set so that the
of fuel while the others have plenty. generator set system starts enough generator sets that
any transient loading can be supported by the running
7.4.2 Enabled generator sets, or to keep an additional generator set
running for redundancy. The default (80%) works for
This permits disabling all Generator Management most applications, but applications with large switching
features. When Generator Management is disabled, a loads may require a lower setting for the Start
generator set will not alert the user of a Generator Percentage.
Management configuration mismatch. Any generator
sets in the paralleling system with Generator The Start Percentage should always be at least 10%
Management disabled will run if they are in auto and are higher than the stop percentage.
receiving a start signal (they will not stop if they are not
needed).
7.4.5 Stop Percentage
Nodes with Generator Management enabled may still The Percentage of Rated Capacity on the other
see a configuration mismatch if a disabled node is generator sets in the paralleling system (the other
configured differently. generator sets that are running and are active in
Generator Management) below which a generator set is
7.4.3 Order considered for stopping.
The order that a generator set will start and stop in the Only a generator set which is running (in auto) and is
Generator Management sequence—higher orders start enabled for Generator Management can be stopped by
last and stop first. This parameter is only adjustable in Generator Management. Generator sets running in
Manual Mode. The order of each of the generator sets in RUN (pressing the run button on the front panel) are not
the paralleling system must be different for Generator considered for Generator Management (their capacity is
Management to function. Generator Management will not counted toward supplying the load and they are not
attempt to correct an order conflict, but can only do so to stopped when not needed).
a limited extent.
Generator Management uses the stop percentage to
If a generator set controller is powered down or calculate the Stop kW for this generator set.
disconnected from the communications network, the
remaining controllers will attempt to re-sort the order so Note: The calculation is based on the capacity of the
that each generator set has a unique and sequential other generator sets on the paralleling bus, as
order—the re-sort is not always successful in manual this generator set will not be providing power after
mode. it stops.
It is important to verify the Start/Stop Order of each The Stop Percentage should be set so that the
generator set if power is cycled to one or more generator generator set system keeps enough generator sets
sets in a paralleling system where Generator online to supply any transient loading that the
Management is used in manual mode. application may demand (such as large chillers, air
conditioners, pumps, or bow thrusters), while allowing
unneeded generator sets to stop.
The Stop Percentage should always be at least 10%

lower than the start percentage.

7.4.6 Start Delay considered with the order selection mode (control
mode) set to Runtime Hours. The Threshold should be
A time factor that represents the time that Generator set based on the intended start/stop frequency of the
Management will wait to start this generator set if the generator sets (understanding that changing load may
load on the running generator sets exceeds the Start cause additional start/stop cycles).
Percentage of this generator set by 10% and all
available lower-order generator sets are running.
7.4.10 Fuel Level Threshold
The Start Delay should be configured to ensure that
reasonable load spikes are handled without starting an The Fuel Level Threshold is the maximum Fuel Level
additional generator set, while allowing a generator set difference that Generator Management will allow before
to start if the increased load persists. starting the generator set with more fuel and stopping
the generator set with less fuel. This parameter is only
considered with the order selection mode (control
7.4.7 Stop Delay mode) set to Fuel Level. The Threshold should be set
based on the intended start/stop frequency of the
A time factor that represents the time that Generator generator sets (understanding that changing load may
Management will wait to stop a generator set if the load cause additional start/stop cycles).
on the lower-order running generator sets drops below
the Stop Percentage of this generator set by 10% and all
higher-order generator sets are already stopped. 7.4.11 Min Gens Online
The Stop Delay should be configured to allow generator This parameter indicates how many generator sets the
sets to stop quickly if they will not be needed, but to system will run with no load on the system. It can be
prevent generator sets from stopping during a used to keep an additional generator set online, but is
short-duration light load on the paralleling system. not intended to convert a system to N+1 redundancy.
N+1 Redundancy can be accomplished by setting the
start and stop percentages considerably lower.
7.4.8 Stable Delay
The Stable Delay is the delay between the system 7.4.12 Min Load Shed Priority
reaching a typical loading scenario and Generator
Management becoming active. This delay is intended to Generator Management will be disabled any time the
allow any loads connected to the system to reach a load control sheds a priority below this level. Setting the
typical load level before Generator Management stops Min Load Shed Priority to 0 will disable the link between
any generator sets. Load Control and Generator Management. Minimum
Load Shed Priority should only be set to 0 if no Load
The Stable Delay should be configured to allow the Control priorities are connected to interrupt a load.
Generator Management to become active when the
system load has reached a nominal level (all abnormal If loads are shed below this threshold, Generator
load conditions due to a loss of power have been Management will be disabled (resulting in all available
removed). generator sets starting).
Any connected Load Control priorities should disable

7.4.9 Runtime Threshold Generator Management when they are shed, to avoid
Generator Management stopping generator sets while
The Runtime Threshold is the maximum Runtime Hour loads are still adding, to allow Generator Management
difference that Generator Management will allow before to start additional generator sets to support shed loads,
starting the lower-hour generator set and stopping the and to allow extended underfrequency events to start
higher-hour generator set. This parameter is only additional generator sets.

7.5 Generator Management 7.5.2 Stop Signal
Detailed Functional Generator Management is supplemental to a paralleling
Description generator set system. The paralleling functionality of the
system is not effected by or dependent on Generator
Management. While Generator Management must
7.5.1 Stability Timer coordinate with Load Add/Shed, Load Add/Shed is not
The Stability Timer must timeout before Generator dependant on Generator Management to function.
Management becomes functional. The Stability Delay is
adjustable as a parameter, but is a fixed amount of time
(does not depend on any variables). If the timer restarts,
the delay will be measured from the time of restart.
Requirements to run stability timer (all must be

true):
D Start Signal is being received on at least one
generator set in the paralleling system (the generator
set that is receiving the start signal does not need to
be in auto, as long as some generator sets in the
system are available, they will start).
D At least 2 generator sets are connected to the

paralleling bus.
D Load Priorities have added past the Minimum Load

Shed Priority.
D Generator Set Order is Valid (unique and sequential).
D Configuration of Generator Management matches on

all nodes. Figure 7-13 Generator Management Interaction
D Generator Management is Enabled. In effect, the function of Generator Management is

limited to a single signal to the paralleling logic, telling
Conditions to cause a restart of the stability timer: the generator set that it is no longer needed. If Generator
Management is disabled, that signal is not sent, and the
D Start Signal is removed from all generator sets in the generator set will run as long as it has a start signal, fuel,
paralleling system. and no faults. Generator Management does not directly
control any system outputs (a programmable IO can be
D No generator sets are connected to the paralleling set to track the internal Stopped by Generator
bus. Management signal, allowing annunciation of this
condition).
D The Load Priority specified by Minimum Load Shed
Priority is shed. Generator Management requires status from the Load
Add/Shed in order to coordinate with it.
D Generator Set Order remains invalid for 10 seconds.
Setting the Min Priority Added Parameter to 0 for
D Configuration of Generator Management is changed Generator Management effectively disables any
on a node or a node is added to the system with a influence that the Load Add/Shed can have over
different configuration. Generator Management (both functions are still
considering the same parameters, so they can still be
D Generator Management is Disabled.
coordinated without a direct tie).
D A generator set disconnects from the paralleling bus
when it has not been told to do so by Generator
Management (a user forces the generator set to stop
by pressing off, the circuit breaker trips due to a fault,
the generator set has a shutdown, etc.).

7.5.3 Stop Behavior ramp rate, and disconnect from the paralleling bus any
time that load enable is removed. If the synchronizer is
Because the paralleling system is not dependent on enabled, the paralleling logic will immediately start
Generator Management, the Paralleling Logic behavior synchronizing to the paralleling bus and will connect
is also independent from Generator Management. again to the bus when synchronized.
Generator Management only controls the internal
signals to the logic to override the normal inputs. To avoid unintended reclosing, the synchronizer is
disabled during the unloading process, once the stop
signal is sent to the Generator Control Logic, the unload
signal is removed, re-enabling the Synchronizer and
reverting Load Enable to the previously commanded
state.
Note: If Load Enable is set to false externally (by digital

input, SiteTecht, or the user interface),
Generator Management is disabled for this
generator set. Unloading and disconnecting will
only occur when load enable is removed (it
changes from true to false).
Stop Signal
The Stop signal is sent to the Generator Control Logic. If
this input is set, the controller will ignore any start signal
that it is receiving. The stop signal is sent if the generator
set is disconnected from the paralleling bus and
receiving a Generator Management stop signal.
Note: The Stop signal requires Generator Management

to be active, if Generator Management is
disabled (by user selection, configuration
mismatch, order mismatch, preemptive warning,
shutdown, or incorrect setting (like synchronizer
set to off, load enable set to off, Baseload mode,
etc.), the stop signal will be removed.
Network Data
The following information is read from the PGEN
Figure 7-14 Detailed Generator Management communications network for Order Selection:
Interaction
D Order of all generator sets.
Figure 7-14 illustrates a more complete diagram of the D Runtime Hours of all generator sets (for Runtime
interactions within the paralleling controller. To stop a mode).
generator set, Generator Management provides a D Fuel Level of all generator sets (for Fuel Level mode).
signal to the Unload/Stop Logic, which sends either an
unload signal, or a stop signal, based on the generator The following information is read from the PGEN
set connection status to the paralleling bus. communication network for Start/Stop Threshold
Calculation:
Unload Signal D Availability of all generator sets (able to start if
requested).
The unload signal sets the Load Enable input to the
paralleling logic to false and turns the synchronizer off. D Connection Status with paralleling bus.
The paralleling logic will go into power control mode, D Order of all generator sets.
unload a generator set according to the load/unload

Activation Logic: is greater than the fuel level of this generator set
(including the Fuel Level Difference if only one of the
D Runtime Threshold of all generator sets.
generator sets is stopped) or if the fuel level of a
D Fuel Level Threshold of all generator sets. lower-order generator set is less than the fuel level of
D Order Selection Method of all generator sets. this generator set (including the Fuel Level Difference if
D Minimum Gens Online for all generator sets. only one of the generator sets is stopped).
D Min Load Shed Priority for all generator sets. All Modes: More than one generator set has the same
D Stable Delay for all generator sets. order.
D Order of all generator sets.
When the need for a change is detected, the order will
Bus Metering attempt to re-sort such that all generator sets have a
unique and sequential order and that the order matches
Bus Total Real Power (sum of the power supplied by all the order selection mode criteria (depending on mode).
generator sets which are connected to the paralleling If there is no valid configuration to be found after
bus). 10 seconds of trying, Generator Management will be
disabled until the order conflict can be resolved (this
7.5.4 Parameters may happen automatically by fuel level or runtime
changing, or may require user intervention).
The following parameters are used for Order Selection:
D Generator Management Control Mode. Note: It is very unlikely that an order conflict will not be
resolved in runtime or fuel level mode. Manual
D Runtime Hour Difference (for Runtime Mode).
mode presents additional challenges in
D Runtime Hours (for Runtime Mode). re-sorting that may cause an un-negotiable
D Fuel Level Difference (for Fuel Level Mode). conflict in order numbers.
D Fuel Level Percentage (for Fuel Level Mode).
7.5.6 Start/Stop Threshold Calculation
D Generator Management Order (for Manual Mode).
The following parameters are used for Start/Stop The determination to start or stop a generator set
Threshold Calculation: involves the comparison of the actual load on the
paralleling bus with the Start Threshold (called the Start
D Generator Management Start Percentage. kW) and the Stop Threshold (called the Stop kW) for the
D Generator Management Stop Percentage. generator set. These thresholds are computed based
D Generator Management Order.
on the order of the generator set, the kW rating of any
lower-order generator sets, and the availability of any
D Generator Management Total Bus Capacity. lower-order generator sets.
7.5.5 Order Selection The Start kW is computed as:
The Start/Stop Order only changes when the need for a
change is detected. The detection of a need to change is Start kW = Capacity of lower order generators X Start Percentage
dependent on the order selection mode.
Manual Mode: The order is only automatically re-sorted The Capacity of lower order generator sets is simply the
if the Generator Management orders of all generator sum of all available generator sets with a lower
sets on the PGEN network are not unique and Generator Management Order than this generator set.
sequential.
If the Minimum Gens Online is set to 2, the lowest 2
Runtime Mode: The order is only automatically available generator sets will have a start kW of 0.
re-sorted if the runtime hours of a higher-order
generator set are less than the runtime hours of this The Stop kW is computed as:
generator set (including the Runtime Hour Difference if
only one of the generator sets is stopped) or if the Stop kW = Capacity of lower order generators X Stop Percentage
runtime hours of a lower-order generator set are greater
than the runtime hours of this generator set (including
the Runtime Hour Difference if only one of the generator The Capacity of lower order generator sets is simply the
sets is stopped). sum of all available generator sets with a lower
Generator Management Order than this generator set.
Fuel Level Mode: The order is only automatically
re-sorted if the fuel level of a higher-order generator set If the Minimum Gens Online is set to 2, the lowest 2
available generator sets will have a stop kW of 0.

7.5.7 Start/Stop Accumulators The Time before a generator set stops is the time
required to reach 100% at the given fill rate, or:
The Start/Stop Accumulators fill at a rate which is related
to the load on the system. The accumulators are full 100
when they reach 100%. When the start accumulator for Time To Stop =
Stop Accumulator Fill Rate
a generator set is full (100%) the generator set will start,
synchronize, and connect to the paralleling bus
(supplying the load). When the Stop Accumulator is full
(100%) the generator set will soft-unload, disconnect 7.5.8 Availability
from the paralleling bus, and stop (a cooldown cycle is An available generator set needs to be able to supply
optional). power to the load if Generator Management requires
additional capacity.
Start Accumulator
A generator set is considered available if:
The Start Accumulator fills at the following rate:
D It does not have a preemptive warning or shutdown.
Percent Difference 2
Start Accumulator Fill Rate (%/s) =
Start Delay ∗ 100 D The Engine Control Switch is in Auto.
D The Synch Mode in Auto is either Passive, Active, or

The Percent Difference is computed as: Dead Field.
(System Load -- Start kW) D The breaker can close (no faults or protective relays
Percent Difference =
Total Capacity of Paralleling Bus if the active).
system load is greater than the start kW.
D The generator set is sharing load (not in System
Control or Baseload mode, Load Enable is True).
0 if the system load is less than or equal to the start kW.
D Generator Management is Enabled.
(The Total Capacity of Paralleling Bus is the sum of the
kW ratings of all the generator sets that are connected to
the paralleling bus). 7.5.9 Preemptive Warning
A preemptive warning is a warning that indicates the
The Time before a generator set starts is the time
potential of an impending failure before it actually
required to reach 100% at the given fill rate, or:
happens. The intent of preemptive warnings is to avoid
unintended overload conditions caused by a generator
100
Time To Start = set tripping offline. Generator Management no longer
Start Accumulator Fill Rate
considers a generator set available if it has a preemptive
warning (causing an additional generator set to start if it
is available and necessary).
Stop Accumulator
The Stop Accumulator Fills at the following rate: The following warnings are considered to be
preemptive:
Percent Difference 2
Stop Accumulator Fill Rate (%/s) = D Low Engine Oil Pressure Warning (This indicates that
Stop Delay ∗ 100
the engine oil pressure is lower than normal. Possible
causes: bearing failure, bearing wear, oil pump wear,
The Percent Difference is computed as: oil temperature too high). Low Oil Pressure Shutdown
may occur shortly after this warning.
(Stop kW -- System Load)
Percent Difference =
(Total Capacity of Paralleling Bus -- Capacity of This Gen.) Note: If the low oil pressure warning is caused by over
if the system load is less than the stop kW. temperature of the oil, starting an additional
engine may decrease the load on this generator
set enough to lower the oil temperature to a
0 if the system load is greater than or equal to the stop kW. reasonable level.
(The Total Capacity of Paralleling Bus is the sum of the

kW ratings of all the generator sets that are connected to
the paralleling bus).

D Low Engine Fuel Pressure Warning (This indicates D Water in Fuel Warning (This indicates that the fuel
that the engine is not receiving enough fuel. Possible supply has enough water in it to potentially cause
causes: day tank transfer pump failure, dip-tube improper operation of the engine. Possible causes:
failure, lift pump failure, high pressure pump failure). filters in need of replacement, contaminated fuel
The engine may run out of fuel and disconnect on the received, water leaked into fuel supply due to
reverse power protective relay if this condition improperly installed fill caps, etc.). This generator set
continues. may stall if the water gets past the separator.
D High Engine Coolant Temperature (This indicates Note: Starting another generator set may cause water
that the engine is not able to cool properly. Possible to infiltrate the fuel system of all generator sets,
causes: low coolant level, water pump failure, but the water stored in the fuel/water separator
thermostat failure, radiator fin corrosion, high will be distributed across more engines, possibly
temperature exchange fluid, exchange fluid path avoiding the stalling of all generator sets
obstruction, etc.). High Coolant Temperature supplying the load.
Shutdown may occur if the condition continues.
D Fuel Tank Leak Warning (There is liquid in some
Note: If an additional generator set starts, the load on interstitial space between two bulkheads of the fuel
this generator set may decrease enough for the supply tank. Possible causes: rain infiltration, snow
warning condition to go away. melt, fuel spill, etc.). This generator set may be
stopping due to a fuel tank leak shutdown, so
D Failure to Synchronize Warning (This indicates that a automatically start another generator set to
generator set is trying to connect to the paralleling compensate for this one.
bus, but is unable to hold synchronism long enough to
connect. Possible causes: erratic load on bus, engine D Loss of Fuel Warning (This generator set has had a
malfunction, incorrect synchronizing settings, etc.). significant loss of fuel over a short period of time.
This generator set may not be able to supply load, so Possible causes: sticking fuel float, vibration of fuel
automatically start another one. If this one comes on tank, actual leak, etc.). This generator set may shut
later, the other one can stop. down due to the Loss of Fuel Shutdown, so
automatically start another generator set to
compensate.

7.6 Generator Management Detailed Functional Sequence
Figure 7-15 Generator Management Functional Sequence
Generator Management has four basic functional Manual Mode Order Update Required Logic
modules which fit the architecture illustrated in
Figure 7-15. Each module has minimal interaction with The order will attempt to re-negotiate if any of the
other modules, to allow simplified interaction scenarios following conditions come true:
and functional descriptions.
D The order is not valid (unique and sequential). This
can be caused by changing the number of generator
7.6.1 Order Selection Logic sets connected to the PGEN network, or by changing
settings in a single controller while it was not
The order is only changed if a change is required. The connected to the PGEN network.
criterion to determine if a change is required depends on
the order selection method of the Generator D A user has manually adjusted the order.
Management system.

Manual Mode Order Update Logic Fuel Level Mode Order Update Logic
Generator Management looks for two orders that are the The order is computed by adding the fuel level threshold
same, if they are, it finds the first available sequential to all units that are connected to the paralleling bus to get
order and adjusts all generator sets with orders between effective fuel level (including the fuel level threshold).
the conflicting order and the available order except any Each controller determines where it should fall in the
units with a lock. A lock has the following requirements: sequence and sets the order to that value.
D Has a conflict with another node and Conflicts in order are resolved the same way as they are
in manual and runtime mode.
D was manually written, or
D has the lowest controller serial number of the 7.6.2 Start/Stop kW Calculation
conflicting controllers.
The Start kW for a generator set is determined by
If the available position is higher than the conflicting summing the total capacity of all available generator
order, all generator set controllers with orders between sets with a lower order number than this one and
the conflicting and available order are incremented, multiplying it by the Start Percentage.
otherwise the orders are decremented on the other
generator set controllers. The Stop kW for a generator set is determined by
summing the total capacity of all available generator
sets with a lower order number than this one and
Runtime Mode Order Update Required Logic multiplying it by the Stop Percentage.
To determine if the order needs to re-sort, the order
Note: The Start and Stop kW for Order 1 are always set
selection logic will compute a minimum valid order and a
to 0kW (never stop, always start). Order 2 is set to
maximum valid order for this generator set. If the
0kW if the Minimum Gens Online is set to 2.
existing order is between the minimum and maximum,
there is no re-sort required. Otherwise, a re-sort is
initiated. 7.6.3 Activation Logic
The Stable Timer is latched to run if all of the start
Runtime Mode Order Update Logic
conditions are true, the timer will continue to run even if
The order is computed by adding the runtime threshold some of the start conditions become false, as long as
to all units that are not connected to the paralleling bus to none of the reset conditions are true.
get effective runtime (including the runtime hour
threshold). Each controller determines where it should 7.6.4 Start/Stop Logic
fall in the sequence and sets the order to that value.
The Generator Management Stop Logic is very simple,
Conflicts in order are resolved the same way as they are a Generator Management stop is sent if all of the
in manual mode. following conditions are true:
D The Stop Accumulator is full.
Fuel Level Mode Order Update Required Logic
D The Start Accumulator is empty.
To determine if the order needs to re-sort, the order
selection logic will compute a minimum valid order and a D Generator Management is stable (the stable timer
maximum valid order for this generator set. If the has expired).
existing order is between the minimum and maximum,
there is no re-sort required. Otherwise, a re-sort is D All lower order generator sets are either connected to
initiated. the paralleling bus or not available.

Notes

Section 8 Load Management
8.1 Purpose
Load Management is intended to disconnect
low-importance loads from the generator set system in 25kW
Load
Shed
Panel
order to allow the generator set system to continue to Generator
supply important loads. Load Management will permit (99kW rating)
low-importance loads to receive power as long as the

generator set system has adequate capacity to supply 25kW 18kW 8kW 3kW 10kW 12kW 5kW
them, only removing them if the system is operating in a Load

Shed
Critical Most
loads important
Least
important
Panel
state of reduced or insufficient power to supply all the non-
critical
Additional
non-critical
non-
critical
loads loads loads
loads.
8.2 Basic Function

Load Management is available in the controller, but is Figure 8-1 A Single Generator Set System Using
only active when the controller is receiving a remote Load Management
start signal.
Load Management controls six priority shed outputs.

The priorities add and shed in a fixed order. Priority 6
sheds first and re-adds last. Priority 1 sheds last and
re-adds first. The outputs are controlled with notices in
the controller, but they have to be assigned to digital
outputs or Relay Driver Outputs (RDOs) on the
controller in order to be available to connect to
low-importance loads.
Note: Load Management uses the load on a single

generator set and the frequency of that generator
set to determine load priority status if there is only
a single generator set in the paralleling system. Figure 8-2 Load Add Timing Based on Generator
Load Management uses the total generator set Set Output Power
system load and the frequency of the paralleling (Genset Max. Percent Capacity = 70%,
bus to determine load priority status if there are Base Load Add Time = 60 seconds)
multiple generator sets in the paralleling system
(hence all generator sets in the system add and The time required to add the first load is dependent
shed priorities simultaneously (as long as the on the Genset Maximum Percent Capacity, the
settings are identical). Base Load Add Time, and the actual real power
output of the generator set.
8.2.1 Sequence of Operation—Single Each priority will add after a time delay as specified
Generator Set System in the curve above.
1. Startup Shed. When a remote start signal is applied
to the generator set, the generator set will start and In the example system illustrated in Figure 8-1, the
all the load priorities will shed to ensure that the 99 kW generator set is loaded to 25% of capacity
generator set has enough capacity to handle the when it is supplying the critical load. Referencing
inrush load. Figure 8-2, the time required to add priority 1 will be
approximately 42 seconds.
2. Load Add. After the generator set starts and
reaches rated voltage and frequency, Load After the first priority adds, the generator set power
Management will become active. If the load on the output may increase, resulting in an increase in the
generator set is more than 15% (the expected load delay for subsequent loads to add.
demand per priority) below the Genset Maximum
Percent Capacity, Load Management will begin
timing to add the first load.
TP-6929 1/15 Section 8 Load Management 157

Load Load
43kW Shed 57kW Shed
Panel Panel
Generator Generator
(99kW rating) (99kW rating)
25kW 18kW 8kW 3kW 10kW 12kW 5kW 12kW 7kW 8kW 3kW 10kW 12kW 5kW
Load Critical Most Least Load Critical Most Least
Shed loads important important Shed loads important important
Panel non- non- Panel non- Additional non-
Additional
critical non-critical critical critical non-critical critical
loads loads loads loads loads loads
Figure 8-3 Example System After Priority 1 Has Figure 8-4 Example System After All Priorities Have
Been Added Been Added
In the example system illustrated in Figure 8-3, the 3. Overload Shed. When the load on the generator
99 kW generator set is loaded to 43% of capacity set is too high to allow the generator set to support
when it is supplying both the critical load and the sudden increases in load without undesirable
load that is interrupted by load shed priority 1. voltage and/or frequency dips, the Load
Figure 8-2 indicates that load shed priority 2 will Management system will remove unimportant
add in about 240 seconds (4 minutes) after load loads so that the critical loads continue to receive
priority 1 is added. high quality power.
The 51 kW that will be supplied by the generator set In the Example system illustrated in Figure 8-1,
with priorities 1 and 2 added will extend the time to Figure 8-3, and Figure 8-4, the generator set can
add priority 3 to about 2400 seconds (40 minutes), become overloaded if the power requirements of
although the time delay may be shortened if the the critical load and the priority 1 load increase.
load on the generator set decreases and may
extend if the load increases.
The time to add priority 4 will be greatly extended

by the generator set output power being so close to Load
94kW Shed
the threshold to add load without exceeding the Panel
Genset Maximum Percent Capacity that it will take Generator

(99kW rating)
37,500 seconds (10 hours and 25 minutes) to add.
Note: In a real-world application, the requirements Load

35kW 21kW 8kW 3kW 10kW 12kW 5kW
Critical Most Least
of the load vary enough that priority 4 would Shed
Panel
loads important
non- Additional
important
non-
critical critical
never add, as all that is required to reset the loads
non-critical
loads loads
timer is to exceed the 55 kW (Genset

Maximum Percent Capacity -15%)
threshold for a moment.
If the power requirement of the critical and priority

1 load dropped to 12 and 7 kW, respectively, the Figure 8-5 Example System With Increased Critical
total load on the generator set would be 30 kW, Load and Increase Priority 1 Load
which would result in priority 4 adding in 60
Although the 99 kW generator set is only producing
seconds. After priority 4 is added, the generator set
94 kW, this lies dangerously close to the maximum
will be providing 40 kW, which will increase the time
capacity of the generator set. Any sudden
delay for priority 5 to about 170 seconds (nearly 3
increases in load may result in the generator set
minutes). The generator set will be providing 52 kW
being overloaded, potentially causing the critical
of load after priority 5 is added, extending the delay
load to receive voltage and frequency that are
for priority 6 to add to about 4200 seconds (1 hour
outside of normal operating parameters.
and 10 minutes). Once priority 6 is added, the
generator set will be supplying 57 kW.
158 Section 8 Load Management TP-6929 1/15

The Generator Overloaded Percent for the shed. This can occur if the engine has a dirty fuel
example system is set to the default (85%) while filter or air filter, the intake air temperature is
the generator set is actually producing 95% of its significantly warmer than the generator set
rated capacity. At this difference, Load operating temperature, the generator set is located
Management will begin counting to shed priority 6. at a high elevation, the fuel system has a restriction
or improperly sized lines, or the engine is damaged
or near end of life.
Even without a failure on the engine, the

Underfrequency Shed logic is active any time the
generator set frequency is less than the
Underfrequency Shed Level below the generator
set nominal operating frequency. Depending on
the configuration of the engine, the
Underfrequency Shed timing may cause a priority
to shed before the Overload Shed timing.
Figure 8-6 Load Shed Timing Based on Generator

Set Output Power
(Generator Overload Percent = 85%,
Base Over Load Shed Time = 30 seconds)
Figure 8-6 indicates that at 95% of rated capacity,

Load Management will wait for 30 seconds before
shedding a priority. Because priority 6 is the first
priority to shed from a stable state, the shed timing
is identical to what is indicated by Figure 8-6.
Shedding priority 6 decreases the load on the Figure 8-7 Load Shed Timing Based on Generator
generator set by 5 kW, but it is still at 90% of rated Set Frequency
capacity. Figure 8-6 provides a time reference for (Underfrequency Shed Level = 0.50 Hz,
90% load at 120 seconds (2 minutes), but Load Base Underfrequency Shed Time = 5 sec.)
Management will accelerate the shed timing as the
overload condition was already present and was If the generator set was overloaded to 110% of
not cleared by priority 6 shedding. The acceleration capacity and this caused the generator set
factor for overload shed is 0.4, hence priority 5 will frequency to dip to 58 Hz, Underfrequency Shed
shed in 120 – (120* 0.40) = 72 seconds. would cause priority 6 to shed in 2 seconds
(Overload Shed would also be active, but would
The generator set output power will drop to 78 kW require 5 seconds to shed, so it would only be 40%
(79% capacity) when priority 5 sheds, allowing shed).
sufficient margin above the working load of the
generator set that small increases/fluctuations in When removing priority 6 decreases the load to
the requirements of the load should be easily 105% and causes the frequency to recover to
handled by the generator set. 58.5 Hz, the curve in Figure 8-7 would indicate that
priority 5 would shed in 5 seconds, but
Priorities 5 and 6 will not add again until the Underfrequency Shed has acceleration of 0.56,
generator set output power drops below 55 kW for meaning that each priority sheds in half as much
long enough for the loads to add. time as the previous priority if the condition is not
cleared, hence priority 5 would actually shed in
4. Underfrequency Shed. In order to maintain 2.5 seconds (Overload Shed would have a total
acceptable power quality, loads must be shed if the time of 7.5 seconds, meaning that another 33%
frequency of the generator set dips, even if the would be added to the 40% shed condition, making
generator set is not producing enough power to priority 4 73% shed due to overload).
indicate that it is overloaded and cause an overload

When removing priority 5 decreases the load to curve indicates approximately 1500 seconds (25
93% and allows the frequency to recover to 59.2 Hz minutes) before priority 1 will add.
in the next two seconds, the curve in Figure 8-7
would indicate that the time to shed would be about After synchronizing to the paralleling bus, generator
60 seconds, but the acceleration drops it to sets #1 and #3 will close their paralleling breakers,
0.25* 60 = 15 seconds. Even at that load, the providing a total of 150 kW of capacity to the paralleling
generator set is allowed to recover to rated bus. The 25 kW load is only 17% of the capacity of the
frequency by the underfrequency shed logic, but bus with all three generator sets supplying it, hence the
the overload shed logic will still cause the priority 4 time to add a priority drops to 26 seconds.
to shed in another 15 seconds (45 sec time to shed
at 93% load, and shed already 67% complete). When priority 1 adds, the output from generator set #1
that drives the load shed priority will de-energize.
8.2.2 Sequence of Operation—

Paralleling System
This sequence follows the operation of a normal
paralleling system which uses Load Management. The Load
Shed
14kW 15kW 14kW
Load Management logic uses the paralleling bus Panel
Generator #1 Generator #2 Generator #3
frequency and the paralleling bus percentage of rated (50kW rating) (50kW rating) (50kW rating)
capacity to determine a need to add or shed load. A

generator set does not have to be running to support 25kW 18kW 8kW 3kW 10kW 12kW 5kW
Load Critical Most Least
Load Management. Shed
Panel
loads important
non- Additional
important
non-
critical non-critical critical
loads loads loads
When a start signal is applied to any of the generator
sets in the paralleling system, all the generator sets that
are in auto and have no shutdown faults will start and all
the load priorities will shed. This shed is intended to
remove excess load from the system so that a single
Figure 8-9 All Generator Sets Supplying the
generator set can support it.
Paralleling Bus, Priority 1 Added
Figure 8-8 illustrates the system after the first generator
With load priority 1 added, the total system load is
set has reached rated voltage and frequency and has
43 kW, shared between the three generator sets. This
closed to the paralleling bus (any of the generator sets
amounts to 29% of the rated capacity of the system,
can be the first to close, depending on which generator
increasing the time delay to add priority 2 to 55 seconds.
set reaches rated voltage and frequency first).
With priority 2 online, the system load is 34%, requiring
85 seconds to add priority 3.

25kW
Load
Shed 104 seconds to add priority 4.
Panel
(50kW rating) (50kW rating) (50kW rating) With priority 4 online, the system load is 43%, requiring
260 seconds (just over 4 minutes) to add priority 5.
Load Critical Most Least
Shed
Panel
loads important
non-
important
non-
Additional
critical
loads
non-critical
loads
critical
loads 2400 seconds (40 minutes) to add priority 6.
After all load priorities are added, Generator

Management may elect to stop a generator set (see
Figure 8-10), but only if the stop percentage is above
81% (the load on two generator sets). If a generator set
Figure 8-8 One Generator Set Energizes the
is stopped, no loads will shed, as the percent of system
Paralleling Bus
capacity is below the Generator Overloaded Percent
The load on the first generator set to connect to the (85%).
paralleling bus is merely that of the critical loads.
The time to Add Priority 1 can be determined from

Figure 8-9 based on a 50% generator set load. The

be configured and connected to be used. It is important
to consider the following when using Load
Management:
Load
40kW 41kW 0kW Shed
Panel
8.3.1 Total Load on the System
(50kW rating) (50kW rating) (50kW rating)
If the power requirements of the load will never exceed
the capacity of the generator set, there is no need or
Load
Critical Most Least
reason to connect and configure Load Management for
Shed
Panel
loads important
non- Additional
important
non- the application. If the load is high enough to overload a
critical non-critical critical
loads loads loads single generator set or one of the generator sets in a
paralleling system, it should be prioritized and
connected to Load Management controls.
8.3.2 Load Types

Figure 8-10 Generator Set #3 Stopped, All Priorities
Added Applications where the loads are occasional will allow
for generator set capacity below the sum of all
Note: Priorities 3 and 6 will remain added unless the connected loads, but the generator set can be
system is overloaded, even though they are overloaded if all the occasional loads were to demand
controlled by the generator set #3 controller, as power simultaneously.
the Load Management logic in the generator set
#3 controller looks at bus frequency and bus
loading to make Load Management 8.3.3 Ease of Interrupting Loads
determinations.
Many loads are easily controlled with a simple relay
Note: The case above is unlikely, as Generator (such as HVAC systems, VFDs and Soft Starters), such
Management will not typically be configured to loads can be tied to Load Management outputs with very
stop a generator set above 80%, as this does not little difficulty and will allow temporary power
leave very much available capacity for changing interruptions without serious loss of function.
loads.
8.3.4 Criticality of the Loads
If the Stop Percentage for Generator Management is
changed, it should not be configured to be above the The generator set must be sized to support at least the
Generator Overloaded Percent, as Generator critical loads in the application. A generator set that is
Management may force a priority to shed when a able to support the critical loads may be significantly
generator set is stopped, nor should the Start smaller than the entire load requires.
Percentage for Generator Management be above the
Generator Overloaded Percent, as this may result in Some applications have loads that can be easily
loads being shed while an available generator set does categorized and prioritized. In this case, Load
not start to supply the loads. Management would be helpful to prevent loss of power
to critical loads. If all loads are of similar importance,
If the Minimum Load Priority Online for Generator Load Management will be difficult to apply.
Management is set to 6, the third generator set will start
as soon as Load Management sheds priority 6. This 8.3.5 Number of Generator Sets in the
would result in priority 6 re-adding and the generator set System
stopping again, establishing a repeating cycle.
Multi-generator set systems should typically utilize Load
Overload Shed and Underfrequency Shed use identical Management unless they have multiple generator sets
timing and thresholds to the single generator set case, simply for redundancy (any generator set can handle
but use the bus % kW and the bus frequency to make the entire load).
Load Management determinations.
8.3.6 Use of Generator Management
8.3 Considerations If Generator Management is used, the Load
Management outputs should be connected to some
Load Management is not required or desired in all
loads to allow an additional generator set time to start if
applications. Although it is active any time that the
the load increases suddenly past the level that the
generator set is receiving a system start signal, it must
running generator sets can support.

8.3.7 Emissions Requirements capacity is the difference between the power output
level of the generator set and 15% below the Genset
Some facilities require minimum load while operating. Maximum Percent Capacity level. The timing of the load
The Load Management can also be used to control loads add curve is adjusted by changing the Base Load Add
on a load bank, maintaining the generator set at or above Time. The entire curve is shifted by a factor related to the
a given load level. Other application require the generator new Base Load Add Time. A priority will take
set to undergo a de-rate for a DPF regeneration cycle. 1500 seconds to add with 50% load and a 70% Genset
Maximum Percent Capacity with the default Base Load
Add Time of 60 seconds, but will only take 250 seconds
8.4 Setup with a Base Load Add Time of 10 seconds.
Load Management requires consideration of several Range: 10.0 sec – 2400.0 sec
factors as each parameter is configured. The default Default: 60.0 sec
settings will work in most scenarios, but many
applications will require additional configuration.
8.4.5 Base Over Load Shed Time
8.4.1 Genset Maximum Percent Capacity The Base Over Load Shed Time defines the time to shed
a load if the generator set has a 10% overload condition.
The Genset Maximum Percent Capacity is the threshold The overload condition is the difference between the
above which the Load Management logic will not measured power output percentage of the generator set
intentionally load the generator set. Each load priority is and the Generator Overloaded Percent. The timing of
expected to add 15% load to the generator set system, so the over load shed curve is adjusted by changing the
load priorities will not add if the load on the system is more Base Over Load Shed Time. The entire curve is shifted
than 15% below the Genset Maximum Percent Capacity. by a factor related to the new Base Over Load Shed
Range: 0.0% – 120.0% Time. A priority will take 120 seconds to shed with
Default: 70.0% 90% load and a 85% Generator Overloaded Percent
with the default Base Over Load Shed Time of
30 seconds, but will only take 12 seconds with a Base
8.4.2 Generator Overloaded Percent Over Load Shed Time of 3 seconds.
The Generator Overloaded Percent is the threshold Range: Range: 2.0 sec – 30.0 sec
above which Load Management considers the Default: 30.0 sec
generator set system to be overloaded. When the
generator set output is above the generator set
overloaded percent, Load Management will start filling
8.4.6 Base Under Frequency Shed Time
the accumulator to shed the highest added priority. The Base Under Frequency Shed Time defines the time
Range: 0.0% – 120.0% to shed a load if the generator set has a 1 Hz
Default: 85.0% underfrequency condition. The underfrequency
condition is the difference between the measured
frequency of the generator set and the Under Frequency
8.4.3 Under Frequency Shed Level Shed Level less than the nominal (rated) frequency. The
timing of the under frequency shed curve is adjusted by
The amount of frequency dip from the nominal changing the Base Under Frequency Shed Time. The
frequency below which the underfrequency shed starts entire curve is shifted by a factor related to the new Base
timing. This level should be configured to avoid Under Frequency Shed Time. A priority will take
underfrequency shutdown or protective relay trips due 20 seconds to shed with the frequency drooped to 59 Hz
to underfrequency. Because the controller has an with a 0.50 Hz Under Frequency Shed Level, a nominal
extended underfrequency shutdown (1 minute at 1 Hz frequency of 60 Hz with the default Base Under
below rated speed) it is not recommended to adjust the Frequency Shed Time of 5 seconds, but will only take
underfrequency shed level below 59 Hz (as the 4 seconds with a Base Under Frequency Shed Time of
generator set will shut down before shedding load). 1 second.
Range: 0.00 Hz – 5.00 Hz Range: 1.0 sec – 20.0 sec
Default: 0.50 Hz Default: 5.0 sec
8.4.4 Base Load Add Time

The Base Load Add Time defines the time to add a load if
the generator set has 25% available capacity. Available

8.5 Detailed Functional Note: Load Management is deactivated when the
system start signal is removed (even if the
Description generator set continues running because the
individual generator set is in RUN mode).
8.5.1 Activation/Deactivation Logic
Load Management is only active when the generator set 8.5.2 Output Configuration
system is receiving a system start signal. A generator
Although Load Shed notices can be seen in SiteTecht
set does not have to be in AUTO in order to activate Load
and on the display of the controller, the load shed notices
Management (but it does to start). The system start
only drive external relays (using RDOs or the CAN
signal can be provided in a variety of ways:
option board) if they are configured to do so.
D Manual System Start (press AUTO+Run on any
Note: Although each generator set has a separate Load
controller)
Management system, all Load Management logic
D Remote Start Signal (3, 4 contacts)
in a paralleling system uses the same power
metering and frequency (bus frequency) to make
D Remote Start via SiteTecht Load Management decisions, hence the priorities
are universal between controllers using identical
D Remote Start via ModbusR firmware and Load Management configuration. If
multiple generator set controllers exist in the
D Remote Start via CAN paralleling system, the Load Management priorities
should be spread between the controllers and not
Starting a generator set in RUN does not cause Load connected to a single controller — this provides a
Management to become active, although it will remain limited measure of redundancy.
active with the generator set in RUN if receiving a
system start signal. Load Management is not activated
when one or more of the generator sets in the generator 8.5.3 Startup Shed
set system are receiving a local start and none are
Startup Shed occurs when Load Management is
receiving a remote start.
activated. The startup shed level for the controller is
The generator set will receive a local start signal under fixed at 0, meaning that all load priorities are shed when
the following condition: the Load Management system is activated.
D Manual Start (pressing RUN on a generator set All loads are added when the Load Management system
controller to start that generator set) is deactivated.

8.5.4 Generator Capacity Load Add The Add Accumulator fills at a rate that is dependent on
the Reserve Capacity and the Base Load Add Time
Generator Capacity Load Add uses the percent loading such that the time to add a priority is defined as:
of the generator set system and the Genset Maximum
Percent Capacity to compute an Available Capacity.
The percent loading of the generator set system is
taking from the generator set metering in a
single-generator set application and from the total bus
The Base Load Add Time sets the add time at 25%
percent loading in a paralleling application.
reserve capacity, while the timing increases with
Available Capacity is computed according to the additional reserve capacity (lower generator set load).
following formula: See Figure 8-11.
Available Capacity = (Genset Maximum Percent Note: The add function is performed by an accumulator
Capacity – Generator System % load) and the timing is determined by the rate that the
accumulator fills, hence a varying load will fill the
The expected kW for the next load is hard-coded at 15%, accumulator at varying rates, causing the load to
so the reserve capacity is calculated as follows: add at a time that can’t be calculated directly with
Reserve Capacity = (Available Capacity – 15) the equation above, but can be estimated by it.
Figure 8-11 Generator Capacity Load Add Timing With Default Configuration

8.5.5 Overload Shed The Base Over Load Shed Time sets the shed time at a
10% degree of overload, while the time decreases with
Overload Shed uses the percent loading of the additional generator set load. See Figure 8-12.
generator set system and the Generator Overloaded
Percent to compute a Degree of Overload. The percent The time to shed subsequent priorities decreases by a
loading of the generator set system is taking from the fixed 0.4 acceleration factor for each priority shed,
generator set metering in a single-generator set hence if the first priority shed in 10 seconds, the second
application and from the total bus percent loading in a priority will shed in 6 seconds, while the third priority will
paralleling application. shed in 3.6 seconds and the fourth priority in
2.2 seconds with the same load on the generator set
Degree of Overload is computed according to the system.
following formula:
Degree of Overload = (Generator Overloaded Percent – Note: The shed function is performed by an
accumulator and the timing is determined by the
Generator System % load)
rate that the accumulator fills, hence a varying
The kW Shed Accumulator fills at a rate that is dependent load will fill the accumulator at varying rates,
on the Degree of Overload and the Base Over Load Shed causing the load to shed at a time that can’t be
Time such that the time to shed the first priority after the calculated directly with the equation above, but
overload condition occurred is defined as: can be estimated by it.
Figure 8-12 Generator Over Load Shed Timing With Default Configuration

8.5.6 Under Frequency Shed Logic
Under Frequency Shed uses the output frequency of the
generator set system and the under Frequency Shed
Level to compute a Frequency Droop. The output The Base Under Frequency Shed Time sets the shed
frequency of the generator set system is taking from the time at a 1 Hz frequency droop, while the time decreases
generator set metering in a single-generator set as the frequency decreases (indicating additional
application and from the bus metering in a paralleling generator set load). See Figure 8-13.
application.
The time to shed subsequent priorities decreases by a
Frequency Droop is computed according to the fixed 0.5 acceleration factor for each priority shed,
following formula: hence if the first priority shed in 10 seconds, the second
Frequency Droop = (Generator Rated Frequency – priority will shed in 5 seconds, while the third priority will
(Generator System Frequency + Under Frequency shed in 2.5 seconds and the fourth priority in
Shed Level)) 1.3 seconds with the same maintained frequency.
The under Frequency Shed Accumulator fills at a rate Note: The shed function is performed by an
that is dependent on the Frequency Droop and the Base accumulator and the timing is determined by the
Under Frequency Shed Time such that the time to shed rate that the accumulator fills, hence a varying
the first priority after the overload condition occurred is load will fill the accumulator at varying rates,
defined as: causing the load to shed at a time that can’t be
calculated directly with the equation above, but
can be estimated by it.
Figure 8-13 Generator Under Frequency Shed Timing With Default Configuration

Appendix A Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere cfm cubic feet per minute exh. exhaust
ABDC after bottom dead center CG center of gravity ext. external
AC alternating current CID cubic inch displacement F Fahrenheit, female
A/D analog to digital CL centerline FHM flat head machine (screw)
ADC advanced digital control; cm centimeter fl. oz. fluid ounce
analog to digital converter CMOS complementary metal oxide flex. flexible
adj. adjust, adjustment substrate (semiconductor) freq. frequency
ADV advertising dimensional com communications (port) FS full scale
drawing coml commercial ft. foot, feet
Ah amp-hour Coml/Rec Commercial/Recreational ft. lb. foot pounds (torque)
AHWT anticipatory high water conn. connection ft./min. feet per minute
temperature cont. continued ftp file transfer protocol
AISI American Iron and Steel CPVC chlorinated polyvinyl chloride g gram
Institute crit. critical ga. gauge (meters, wire size)
ALOP anticipatory low oil pressure CSA Canadian Standards gal. gallon
alt. alternator Association gen. generator
Al aluminum CT current transformer genset generator set
ANSI American National Standards Cu copper
Institute (formerly American GFI ground fault interrupter
cUL Canadian Underwriter’s
Standards Association, ASA) Laboratories GND, ground
AO anticipatory only CUL Canadian Underwriter’s gov. governor
APDC Air Pollution Control District Laboratories gph gallons per hour
API American Petroleum Institute cu. in. cubic inch gpm gallons per minute
approx. approximate, approximately cw. clockwise gr. grade, gross
APU Auxiliary Power Unit CWC city water-cooled GRD equipment ground
AQMD Air Quality Management District cyl. cylinder gr. wt. gross weight
AR as required, as requested D/A digital to analog HxWxD height by width by depth
AS as supplied, as stated, as DAC digital to analog converter HC hex cap
suggested dB decibel HCHT high cylinder head temperature
ASE American Society of Engineers dB(A) decibel (A weighted) HD heavy duty
ASME American Society of DC direct current HET high exhaust temp., high
Mechanical Engineers engine temp.
DCR direct current resistance
assy. assembly hex hexagon
deg.,  degree
ASTM American Society for Testing Hg mercury (element)
Materials dept. department
dia. diameter HH hex head
ATDC after top dead center HHC hex head cap
ATS automatic transfer switch DI/EO dual inlet/end outlet
DIN Deutsches Institut fur Normung HP horsepower
auto. automatic hr. hour
e. V. (also Deutsche Industrie
aux. auxiliary Normenausschuss) HS heat shrink
avg. average DIP dual inline package hsg. housing
AVR automatic voltage regulator DPDT double-pole, double-throw HVAC heating, ventilation, and air
AWG American Wire Gauge DPST double-pole, single-throw conditioning
AWM appliance wiring material DS disconnect switch HWT high water temperature
bat. battery DVR digital voltage regulator Hz hertz (cycles per second)
BBDC before bottom dead center E2PROM, EEPROM IBC International Building Code
BC battery charger, battery electrically-erasable IC integrated circuit
charging programmable read-only ID inside diameter, identification
BCA battery charging alternator memory IEC International Electrotechnical
BCI Battery Council International E, emer. emergency (power source) Commission
BDC before dead center ECM electronic control module, IEEE Institute of Electrical and
BHP brake horsepower engine control module Electronics Engineers
blk. black (paint color), block EDI electronic data interchange IMS improved motor starting
(engine) EFR emergency frequency relay in. inch
blk. htr. block heater e.g. for example (exempli gratia) in. H2O inches of water
BMEP brake mean effective pressure EG electronic governor in. Hg inches of mercury
bps bits per second EGSA Electrical Generating Systems in. lb. inch pounds
br. brass Association Inc. incorporated
BTDC before top dead center EIA Electronic Industries ind. industrial
Btu British thermal unit Association int. internal
Btu/min. British thermal units per minute EI/EO end inlet/end outlet int./ext. internal/external
C Celsius, centigrade EMI electromagnetic interference I/O input/output
cal. calorie emiss. emission IP internet protocol
CAN controller area network eng. engine ISO International Organization for
CARB California Air Resources Board EPA Environmental Protection Standardization
CAT5 Category 5 (network cable) Agency J joule
CB circuit breaker EPS emergency power system JIS Japanese Industry Standard
CC crank cycle ER emergency relay k kilo (1000)
cc cubic centimeter ES engineering special, K kelvin
CCA cold cranking amps engineered special kA kiloampere
ccw. counterclockwise ESD electrostatic discharge KB kilobyte (210 bytes)
CEC Canadian Electrical Code est. estimated KBus Kohler communication protocol
cert. certificate, certification, certified E-Stop emergency stop kg kilogram
cfh cubic feet per hour etc. et cetera (and so forth)
TP-6929 1/15 Appendix 167

kg/cm2 kilograms per square NBS National Bureau of Standards RTU remote terminal unit
centimeter NC normally closed RTV room temperature vulcanization
kgm kilogram-meter NEC National Electrical Code RW read/write
kg/m3 kilograms per cubic meter NEMA National Electrical SAE Society of Automotive
kHz kilohertz Manufacturers Association Engineers
kJ kilojoule NFPA National Fire Protection scfm standard cubic feet per minute
km kilometer Association SCR silicon controlled rectifier
kOhm, k kilo-ohm Nm newton meter s, sec. second
kPa kilopascal NO normally open SI Systeme international d’unites,
kph kilometers per hour no., nos. number, numbers International System of Units
kV kilovolt NPS National Pipe, Straight SI/EO side in/end out
kVA kilovolt ampere NPSC National Pipe, Straight-coupling sil. silencer
kVAR kilovolt ampere reactive NPT National Standard taper pipe SMTP simple mail transfer protocol
kW kilowatt thread per general use SN serial number
kWh kilowatt-hour NPTF National Pipe, Taper-Fine SNMP simple network management
kWm kilowatt mechanical NR not required, normal relay protocol
kWth kilowatt-thermal ns nanosecond SPDT single-pole, double-throw
L liter OC overcrank SPST single-pole, single-throw
LAN local area network OD outside diameter spec specification
L x W x H length by width by height OEM original equipment specs specification(s)
lb. pound, pounds manufacturer sq. square
lbm/ft3 pounds mass per cubic feet OF overfrequency sq. cm square centimeter
LCB line circuit breaker opt. option, optional sq. in. square inch
LCD liquid crystal display OS oversize, overspeed SMS short message service
LED light emitting diode OSHA Occupational Safety and Health SS stainless steel
Administration std. standard
Lph liters per hour
OV overvoltage stl. steel
Lpm liters per minute
oz. ounce tach. tachometer
LOP low oil pressure
p., pp. page, pages TB terminal block
LP liquefied petroleum
PC personal computer TCP transmission control protocol
LPG liquefied petroleum gas
PCB printed circuit board TD time delay
LS left side
pF picofarad TDC top dead center
Lwa sound power level, A weighted
PF power factor TDEC time delay engine cooldown
LWL low water level
ph.,  phase TDEN time delay emergency to
LWT low water temperature
PHC Phillipsr head Crimptiter normal
m meter, milli (1/1000) (screw)
M mega (106 when used with SI TDES time delay engine start
PHH Phillipsr hex head (screw) TDNE time delay normal to
units), male
PHM pan head machine (screw) emergency
m3 cubic meter
PLC programmable logic control TDOE time delay off to emergency
m3/hr. cubic meters per hour
PMG permanent magnet generator TDON time delay off to normal
m3/min. cubic meters per minute
pot potentiometer, potential temp. temperature
mA milliampere
ppm parts per million term. terminal
man. manual
PROM programmable read-only THD total harmonic distortion
max. maximum memory
MB megabyte (220 bytes) TIF telephone influence factor
psi pounds per square inch tol. tolerance
MCCB molded-case circuit breaker psig pounds per square inch gauge
MCM one thousand circular mils turbo. turbocharger
pt. pint typ. typical (same in multiple
meggar megohmmeter PTC positive temperature coefficient locations)
MHz megahertz PTO power takeoff UF underfrequency
mi. mile PVC polyvinyl chloride UHF ultrahigh frequency
mil one one-thousandth of an inch qt. quart, quarts UIF user interface
min. minimum, minute qty. quantity UL Underwriter’s Laboratories, Inc.
misc. miscellaneous R replacement (emergency) UNC unified coarse thread (was NC)
MJ megajoule power source UNF unified fine thread (was NF)
mJ millijoule rad. radiator, radius univ. universal
mm millimeter RAM random access memory URL uniform resource locator
mOhm, mmilliohm RDO relay driver output (web address)
MOhm, Mmegohm ref. reference US undersize, underspeed
MOV metal oxide varistor rem. remote UV ultraviolet, undervoltage
MPa megapascal Res/Coml Residential/Commercial V volt
mpg miles per gallon RFI radio frequency interference VAC volts alternating current
mph miles per hour RH round head VAR voltampere reactive
MS military standard RHM round head machine (screw) VDC volts direct current
ms millisecond rly. relay VFD vacuum fluorescent display
m/sec. meters per second rms root mean square VGA video graphics adapter
mtg. mounting rnd. round VHF very high frequency
MTU Motoren-und Turbinen-Union RO read only W watt
MW megawatt ROM read only memory WCR withstand and closing rating
mW milliwatt rot. rotate, rotating w/ with
F microfarad rpm revolutions per minute WO write only
N, norm. normal (power source) RS right side w/o without
NA not available, not applicable RTDs Resistance Temperature wt. weight
nat. gas natural gas Detectors xfmr transformer
168 Appendix TP-6929 1/15

Appendix B Common Hardware Application Guidelines
Use the information below and on the following pages to Steps for common hardware application:
identify proper fastening techniques when no specific
reference for reassembly is made. 1. Determine entry hole type: round or slotted.
Bolt/Screw Length: When bolt/screw length is not given, 2. Determine exit hole type: fixed female thread
use Figure 1 as a guide. As a general rule, a minimum (weld nut), round, or slotted.
length of one thread beyond the nut and a maximum
length of 1/2 the bolt/screw diameter beyond the nut is For round and slotted exit holes, determine if
the preferred method. hardware is greater than 1/2 inch in diameter, or
1/2 inch in diameter or less. Hardware that is
Washers and Nuts: Use split lock washers as a bolt greater than 1/2 inch in diameter takes a standard
locking device where specified. Use SAE flat washers nut and SAE washer. Hardware 1/2 inch or less in
with whiz nuts, spiralock nuts, or standard nuts and diameter can take a properly torqued whiz nut or
preloading (torque) of the bolt in all other applications. spiralock nut. See Figure 2.
See Appendix C, General Torque Specifications, and 3. Follow these SAE washer rules after determining
other torque specifications in the service literature. exit hole type:
a. Always use a washer between hardware and a

Preferred Nut/Bolt Clearance slot.
1 2 b. Always use a washer under a nut (see 2 above
for exception).
c. Use a washer under a bolt when the female

thread is fixed (weld nut).
4. Refer to Figure 2, which depicts the preceding

hardware configuration possibilities.
Unacceptable Nut/Bolt Clearance
3 2
1
3
G-585
1. 1/2 of bolt diameter

2. Min. 1 full thread beyond top of nut
3. Below top of nut
Figure 1 Acceptable Bolt Lengths
5
4
6
G-585
1. Cap screw
2. Entry hole types
3. Standard nut and SAE washer
4. Whiz nut or spiralock: up to 1/2 in. dia. hardware
5. Weld nuts: above 1/2 in. dia. hardware
6. Exit hole types
Figure 2 Acceptable Hardware Combinations

Appendix C General Torque Specifications
American Standard Fasteners Torque Specifications

Assembled into
Assembled into Cast Iron or Steel
Torque Aluminum
Size Measurement Grade 2 Grade 5 Grade 8 Grade 2 or 5
8-32 Nm (in. lb.) 1.8 (16) 2.3 (20) —
10-24 Nm (in. lb.) 2.9 (26) 3.6 (32) —
10-32 Nm (in. lb.) 2.9 (26) 3.6 (32) —
1/4-20 Nm (in. lb.) 6.8 (60) 10.8 (96) 14.9 (132)
1/4-28 Nm (in. lb.) 8.1 (72) 12.2 (108) 16.3 (144)
5/16-18 Nm (in. lb.) 13.6 (120) 21.7 (192) 29.8 (264)
5/16-24 Nm (in. lb.) 14.9 (132) 23.1 (204) 32.5 (288)
3/8-16 Nm (ft. lb.) 24 (18) 38 (28) 53 (39)
3/8-24 Nm (ft. lb.) 27 (20) 42 (31) 60 (44)
7/16-14 Nm (ft. lb.) 39 (29) 60 (44) 85 (63)
7/16-20 Nm (ft. lb.) 43 (32) 68 (50) 95 (70) See Note 3
1/2-13 Nm (ft. lb.) 60 (44) 92 (68) 130 (96)
1/2-20 Nm (ft. lb.) 66 (49) 103 (76) 146 (108)
9/16-12 Nm (ft. lb.) 81 (60) 133 (98) 187 (138)
9/16-18 Nm (ft. lb.) 91 (67) 148 (109) 209 (154)
5/8-11 Nm (ft. lb.) 113 (83) 183 (135) 259 (191)
5/8-18 Nm (ft. lb.) 128 (94) 208 (153) 293 (216)
3/4-10 Nm (ft. lb.) 199 (147) 325 (240) 458 (338)
3/4-16 Nm (ft. lb.) 222 (164) 363 (268) 513 (378)
1-8 Nm (ft. lb.) 259 (191) 721 (532) 1109 (818)
1-12 Nm (ft. lb.) 283 (209) 789 (582) 1214 (895)
Metric Fasteners Torque Specifications, Measured in Nm (ft. lb.)

Assembled into
Assembled into Cast Iron or Steel
Aluminum
Size (mm) Grade 5.8 Grade 8.8 Grade 10.9 Grade 5.8 or 8.8
M6 x 1.00 6.2 (4.6) 9.5 (7) 13.6 (10)
M8 x 1.25 15 (11) 23 (17) 33 (24)
M8 x 1.00 16 (11) 24 (18) 34 (25)
M10 x 1.50 30 (22) 45 (34) 65 (48)
M10 x 1.25 31 (23) 47 (35) 68 (50)
M12 x 1.75 53 (39) 80 (59) 115 (85)
M12 x 1.50 56 (41) 85 (63) 122 (90)
M14 x 2.00 83 (61) 126 (93) 180 (133)
M14 x 1.50 87 (64) 133 (98) 190 (140)
M16 x 2.00 127 (94) 194 (143) 278 (205)
M16 x 1.50 132 (97) 201 (148) 287 (212)
M18 x 2.50 179 (132) 273 (201) 390 (288) See Note 3
M18 x 1.50 189 (140) 289 (213) 413 (305)
M20 x 2.50 245 (181) 374 (276) 535 (395)
M20 x 1.50 264 (195) 402 (297) 576 (425)
M22 x 2.50 332 (245) 507 (374) 725 (535)
M22 x 1.50 351 (259) 535 (395) 766 (565)
M24 x 3.00 425 (314) 649 (479) 928 (685)
M24 x 2.00 447 (330) 682 (503) 976 (720)
M27 x 3.00 — 937 (692) 1341 (990)
M27 x 2.00 — 985 (727) 1409 (1040)
M30 x 3.50 — 1278 (943) 1829 (1350)
M30 x 2.00 — 1349 (996) 1931 (1425)
Notes:
1. The torque values above are general guidelines. Always use the torque values specified in the service manuals and/or assembly drawings
when they differ from the above torque values.
2. The torque values above are based on new plated threads. Increase torque values by 15% if non-plated threads are used.
3. Hardware threaded into aluminum must have either two diameters of thread engagement or a 30% or more reduction in the torque to
prevent stripped threads.
4. Torque values are calculated as equivalent stress loading on American hardware with an approximate preload of 90% of the yield strength
and a friction coefficient of 0.125.

Appendix D Common Hardware Identification
Screw/Bolts/Studs Nuts Hardness Grades

Head Styles Nut Styles American Standard
Hex Head or Machine Head Hex Head Grade 2
Hex Head or Machine Head

Lock or Elastic Grade 5
with Washer
Flat Head (FHM) Square Grade 8
Grade 8/9 (Hex Socket

Round Head (RHM) Cap or Acorn
Head)
Metric
Pan Head Wing
Number stamped on
5.8
Hex Socket Head Cap or Washers hardware; 5.8 shown
Allent Head Cap
Washer Styles
Hex Socket Head or Allent
Head Shoulder Bolt Plain
Sheet Metal Screw Split Lock or Spring
Stud Spring or Wave
Drive Styles
External Tooth Lock
Hex
Internal Tooth Lock
Hex and Slotted
Internal-External Tooth Lock
Phillipsr
Slotted
Hex Socket
Allent head screw is a trademark of Holo-Krome Co.

Phillipsr screw is a registered trademark of Phillips Screw Company.
Sample Dimensions
American Standard (Screws, Bolts, Studs, and Nuts) Plain Washers
1/4-20 x 1 9/32 x 5/8 x 1/16
Length In Inches (Screws and Bolts) Thickness
Threads Per Inch External Dimension
Major Thread Diameter In Fractional Inches Or Screw Number Size Internal Dimension
Metric (Screws, Bolts, Studs, and Nuts)
M8-1.25 x 20 Lock Washers
Length In Millimeters (Screws and Bolts) 5/8
Distance Between Threads In Millimeters Internal Dimension
Major Thread Diameter In Millimeters

Appendix E Common Hardware List
The Common Hardware List lists part numbers and dimensions for common hardware items.
American Standard
Part No. Dimensions Part No. Dimensions Part No. Dimensions Type
Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts
X-465-17 1/4-20 x .38 X-6238-14 3/8-24 x .75 X-6009-1 1-8 Standard
X-465-6 1/4-20 x .50 X-6238-16 3/8-24 x 1.25
X-465-2 1/4-20 x .62 X-6238-21 3/8-24 x 4.00 X-6210-3 6-32 Whiz
X-465-16 1/4-20 x .75 X-6238-22 3/8-24 x 4.50 X-6210-4 8-32 Whiz
X-465-18 1/4-20 x .88 X-6210-5 10-24 Whiz
X-465-7 1/4-20 x 1.00 X-6024-5 7/16-14 x .75
X-6024-2 7/16-14 x 1.00 X-6210-1 10-32 Whiz
X-465-8 1/4-20 x 1.25
X-465-9 1/4-20 x 1.50 X-6024-8 7/16-14 x 1.25 X-6210-2 1/4-20 Spiralock
X-465-10 1/4-20 x 1.75 X-6024-3 7/16-14 x 1.50 X-6210-6 1/4-28 Spiralock
X-465-11 1/4-20 x 2.00 X-6024-4 7/16-14 x 2.00 X-6210-7 5/16-18 Spiralock
X-465-12 1/4-20 x 2.25 X-6024-11 7/16-14 x 2.75 X-6210-8 5/16-24 Spiralock
X-465-14 1/4-20 x 2.75 X-6024-12 7/16-14 x 6.50
X-6210-9 3/8-16 Spiralock
X-465-21 1/4-20 x 5.00 X-129-15 1/2-13 x .75 X-6210-10 3/8-24 Spiralock
X-465-25 1/4-28 x .38 X-129-17 1/2-13 x 1.00 X-6210-11 7/16-14 Spiralock
X-465-20 1/4-28 x 1.00 X-129-18 1/2-13 x 1.25 X-6210-12 1/2-13 Spiralock
X-125-33 5/16-18 x .50 X-129-19 1/2-13 x 1.50 X-6210-15 7/16-20 Spiralock
X-125-23 5/16-18 x .62 X-129-20 1/2-13 x 1.75 X-6210-14 1/2-20 Spiralock
X-125-3 5/16-18 x .75 X-129-21 1/2-13 x 2.00
X-129-22 1/2-13 x 2.25 X-85-3 5/8-11 Standard
X-125-31 5/16-18 x .88 X-88-12 3/4-10 Standard
X-125-5 5/16-18 x 1.00 X-129-23 1/2-13 x 2.50
X-129-24 1/2-13 x 2.75 X-89-2 1/2-20 Standard
X-125-24 5/16-18 x 1.25
X-125-34 5/16-18 x 1.50 X-129-25 1/2-13 x 3.00
X-125-25 5/16-18 x 1.75 X-129-27 1/2-13 x 3.50
X-125-26 5/16-18 x 2.00 X-129-29 1/2-13 x 4.00 Washers
230578 5/16-18 x 2.25 X-129-30 1/2-13 x 4.50 Bolt/
X-125-29 5/16-18 x 2.50 X-463-9 1/2-13 x 5.50
X-129-44 1/2-13 x 6.00 Part No. ID OD Thick. Screw
X-125-27 5/16-18 x 2.75
X-125-28 5/16-18 x 3.00 X-129-51 1/2-20 x .75 X-25-46 .125 .250 .022 #4
X-125-22 5/16-18 x 4.50 X-129-45 1/2-20 x 1.25 X-25-9 .156 .375 .049 #6
X-125-32 5/16-18 x 5.00 X-129-52 1/2-20 x 1.50 X-25-48 .188 .438 .049 #8
X-125-35 5/16-18 x 5.50 X-25-36 .219 .500 .049 #10
X-125-36 5/16-18 x 6.00 X-6021-3 5/8-11 x 1.00 X-25-40 .281 .625 .065 1/4
X-125-40 5/16-18 x 6.50 X-6021-4 5/8-11 x 1.25 X-25-85 .344 .687 .065 5/16
X-6021-2 5/8-11 x 1.50 X-25-37 .406 .812 .065 3/8
X-125-43 5/16-24 x 1.75 X-6021-1 5/8-11 x 1.75 X-25-34 .469 .922 .065 7/16
X-125-44 5/16-24 x 2.50 273049 5/8-11 x 2.00
X-125-30 5/16-24 x .75 X-25-26 .531 1.062 .095 1/2
X-6021-5 5/8-11 x 2.25 X-25-15 .656 1.312 .095 5/8
X-125-39 5/16-24 x 2.00 X-6021-6 5/8-11 x 2.50
X-125-38 5/16-24 x 2.75 X-25-29 .812 1.469 .134 3/4
X-6021-7 5/8-11 x 2.75
X-25-127 1.062 2.000 .134 1
X-6238-2 3/8-16 x .62 X-6021-12 5/8-11 x 3.75
X-6238-10 3/8-16 x .75 X-6021-11 5/8-11 x 4.50
X-6238-3 3/8-16 x .88 X-6021-10 5/8-11 x 6.00
X-6238-11 3/8-16 x 1.00 X-6021-9 5/8-18 x 2.50
X-6238-4 3/8-16 x 1.25
X-6238-5 3/8-16 x 1.50 X-6239-1 3/4-10 x 1.00
X-6238-1 3/8-16 x 1.75 X-6239-8 3/4-10 x 1.25
X-6238-6 3/8-16 x 2.00 X-6239-2 3/4-10 x 1.50
X-6238-17 3/8-16 x 2.25 X-6239-3 3/4-10 x 2.00
X-6238-7 3/8-16 x 2.50 X-6239-4 3/4-10 x 2.50
X-6238-8 3/8-16 x 2.75 X-6239-5 3/4-10 x 3.00
X-6238-9 3/8-16 x 3.00 X-6239-6 3/4-10 x 3.50
X-6238-19 3/8-16 x 3.25 X-792-1 1-8 x 2.25
X-6238-12 3/8-16 x 3.50 X-792-5 1-8 x 3.00
X-6238-20 3/8-16 x 3.75 X-792-8 1-8 x 5.00
X-6238-13 3/8-16 x 4.50
X-6238-18 3/8-16 x 5.50
X-6238-25 3/8-16 x 6.50

Metric
Hex head bolts are hardness grade 8.8 unless noted.
Part No. Dimensions Part No. Dimensions Part No. Dimensions

Hex Head Bolts (Partial Thread) Hex Head Bolts (Partial Thread), Hex Head Bolts (Full Thread),
M931-05055-60 M5-0.80 x 55 continued continued
M931-06040-60 M6-1.00 x 40 M960-16090-60 M16-1.50 x 90 M933-12016-60 M12-1.75 x 16
M931-06055-60 M6-1.00 x 55 M931-16090-60 M16-2.00 x 90 M933-12020-60 M12-1.75 x 20
M931-06060-60 M6-1.00 x 60 M931-16100-60 M16-2.00 x 100 M961-12020-60F M12-1.50 x 20
M931-06060-SS M6-1.00 x 60 M931-16100-82 M16-2.00 x 100* M933-12025-60 M12-1.75 x 25
M931-06070-60 M6-1.00 x 70 M931-16120-60 M16-2.00 x 120 M933-12025-82 M12-1.75 x 25*
M931-06070-SS M6-1.00 x 70 M931-16150-60 M16-2.00 x 150 M961-12030-60 M12-1.25 x 30
M931-06075-60 M6-1.00 x 75 M933-12030-82 M12-1.75 x 30*
M931-06090-60 M6-1.00 x 90 M931-20065-60 M20-2.50 x 65 M961-12030-82F M12-1.50 x 30*
M931-06145-60 M6-1.00 x 145 M931-20090-60 M20-2.50 x 90 M933-12030-60 M12-1.75 x 30
M931-06150-60 M6-1.00 x 150 M931-20100-60 M20-2.50 x 100 M933-12035-60 M12-1.75 x 35
M931-20120-60 M20-2.50 x 120 M961-12040-82 M12-1.25 x 40*
M931-08035-60 M8-1.25 x 35 M931-20140-60 M20-2.50 x 140 M933-12040-60 M12-1.75 x 40
M931-08040-60 M8-1.25 x 40 M931-20160-60 M20-2.50 x 160 M933-12040-82 M12-1.75 x 40*
M931-08045-60 M8-1.25 x 45
M931-08050-60 M8-1.25 x 50 M931-22090-60 M22-2.50 x 90 M961-14025-60 M14-1.50 x 25
M931-08055-60 M8-1.25 x 55 M931-22120-60 M22-2.50 x 120 M933-14025-60 M14-2.00 x 25
M931-08055-82 M8-1.25 x 55* M931-22160-60 M22-2.50 x 160 M961-14050-82 M14-1.50 x 50*
M931-08060-60 M8-1.25 x 60 M931-24090-60 M24-3.00 x 90
M931-08070-60 M8-1.25 x 70 M961-16025-60 M16-1.50 x 25
M931-24120-60 M24-3.00 x 120 M933-16025-60 M16-2.00 x 25
M931-08070-82 M8-1.25 x 70* M931-24160-60 M24-3.00 x 160
M931-08075-60 M8-1.25 x 75 M961-16030-82 M16-1.50 x 30*
M931-24200-60 M24-3.00 x 200 M933-16030-82 M16-2.00 x 30*
M931-08080-60 M8-1.25 x 80
M931-08090-60 M8-1.25 x 90 M933-16035-60 M16-2.00 x 35
M931-08095-60 M8-1.25 x 95 Hex Head Bolts (Full Thread) M961-16040-60 M16-1.50 x 40
M931-08100-60 M8-1.25 x 100 M933-16040-60 M16-2.00 x 40
M933-04006-60 M4-0.70 x 6 M961-16045-82 M16-1.50 x 45*
M931-08110-60 M8-1.25 x 110
M931-08120-60 M8-1.25 x 120 M933-05030-60 M5-0.80 x 30 M933-16045-82 M16-2.00 x 45*
M931-08130-60 M8-1.25 x 130 M933-05035-60 M5-0.80 x 35 M933-16050-60 M16-2.00 x 50
M931-08140-60 M8-1.25 x 140 M933-05050-60 M5-0.80 x 50 M933-16050-82 M16-2.00 x 50*
M931-08150-60 M8-1.25 x 150 M933-16060-60 M16-2.00 x 60
M933-06010-60 M6-1.00 x 10 M933-16070-60 M16-2.00 x 70
M931-08200-60 M8-1.25 x 200 M933-06012-60 M6-1.00 x 12
M931-10040-82 M10-1.25 x 40* M933-06014-60 M6-1.00 x 14 M933-18035-60 M18-2.50 x 35
M931-10040-60 M10-1.50 x 40 M933-06016-60 M6-1.00 x 16 M933-18050-60 M18-2.50 x 50
M931-10045-60 M10-1.50 x 45 M933-06020-60 M6-1.00 x 20 M933-18060-60 M18-2.50 x 60
M931-10050-60 M10-1.50 x 50 M933-06025-60 M6-1.00 x 25 M933-20050-60 M20-2.50 x 50
M931-10050-82 M10-1.25 x 50* M933-06030-60 M6-1.00 x 30 M933-20055-60 M20-2.50 x 55
M931-10055-60 M10-1.50 x 55 M933-06040-60 M6-1.00 x 40
M931-10060-60 M10-1.50 x 60 M933-06050-60 M6-1.00 x 50 M933-24060-60 M24-3.00 x 60
M931-10065-60 M10-1.50 x 65 M933-24065-60 M24-3.00 x 65
M933-07025-60 M7-1.00 x 25 M933-24070-60 M24-3.00 x 70
M931-10070-60 M10-1.50 x 70
M931-10080-60 M10-1.50 x 80 M933-08010-60 M8-1.25 x 10
M931-10080-82 M10-1.25 x 80* M933-08012-60 M8-1.25 x 12 Pan Head Machine Screws
M931-10090-60 M10-1.50 x 90 M933-08016-60 M8-1.25 x 16
M931-10090-82 M10-1.50 x 90* M933-08020-60 M8-1.25 x 20 M7985A-03010-20 M3-0.50 x 10
M931-10100-60 M10-1.50 x 100 M933-08025-60 M8-1.25 x 25 M7985A-03012-20 M3-0.50 x 12
M931-10110-60 M10-1.50 x 110 M933-08030-60 M8-1.25 x 30 M7985A-04010-20 M4-0.70 x 10
M931-10120-60 M10-1.50 x 120 M933-08030-82 M8-1.25 x 30* M7985A-04016-20 M4-0.70 x 16
M931-10130-60 M10-1.50 x 130 M7985A-04020-20 M4-0.70 x 20
M931-10140-60 M10-1.50 x 140 M933-10012-60 M10-1.50 x 12
M961-10020-60 M10-1.25 x 20 M7985A-04050-20 M4-0.70 x 50
M931-10180-60 M10-1.50 x 180 M7985A-04100-20 M4-0.70 x 100
M931-10235-60 M10-1.50 x 235 M933-10020-60 M10-1.50 x 20
M933-10025-60 M10-1.50 x 25 M7985A-05010-20 M5-0.80 x 10
M931-10260-60 M10-1.50 x 260
M961-10025-60 M10-1.25 x 25 M7985A-05012-20 M5-0.80 x 12
M960-10330-60 M10-1.25 x 330
M933-10025-82 M10-1.50 x 25* M7985A-05016-20 M5-0.80 x 16
M931-12045-60 M12-1.75 x 45 M961-10030-60 M10-1.25 x 30 M7985A-05020-20 M5-0.80 x 20
M960-12050-60 M12-1.25 x 50 M933-10030-60 M10-1.50 x 30 M7985A-05025-20 M5-0.80 x 25
M960-12050-82 M12-1.25 x 50* M933-10030-82 M10-1.50 x 30* M7985A-05030-20 M5-0.80 x 30
M931-12050-60 M12-1.75 x 50 M961-10035-60 M10-1.25 x 35 M7985A-05080-20 M5-0.80 x 80
M931-12050-82 M12-1.75 x 50* M933-10035-60 M10-1.50 x 35 M7985A-05100-20 M5-0.80 x 100
M931-12055-60 M12-1.75 x 55 M933-10035-82 M10-1.50 x 35*
M931-12060-60 M12-1.75 x 60 M961-10040-60 M10-1.25 x 40 M7985A-06100-20 M6-1.00 x 100
M931-12060-82 M12-1.75 x 60*
M931-12065-60 M12-1.75 x 65 Flat Head Machine Screws
M931-12075-60 M12-1.75 x 75
M931-12080-60 M12-1.75 x 80 M965A-04012-SS M4-0.70 x 12
M931-12090-60 M12-1.75 x 90 M965A-05012-SS M5-0.80 x 12
M931-12100-60 M12-1.75 x 100 M965A-05016-20 M5-0.80 x 16
M931-12110-60 M12-1.75 x 110 M965A-06012-20 M6-1.00 x 12
* This metric hex bolt’s hardness is grade 10.9.

Metric, continued
Part No. Dimensions Type
Hex Nuts
M934-03-50 M3-0.50 Standard
M934-04-50 M4-0.70 Standard
M934-04-B M4-0.70 Brass
M934-05-50 M5-0.80 Standard
M934-06-60 M6-1.00 Standard
M934-06-64 M6-1.00 Std. (green)
M6923-06-80 M6-1.00 Spiralock
M982-06-80 M6-1.00 Elastic Stop
M934-08-60 M8-1.25 Standard
M6923-08-80 M8-1.25 Spiralock
M934-10-60 M10-1.50 Standard
M934-10-60F M10-1.25 Standard
M6923-10-80 M10-1.50 Spiralock
M6923-10-62 M10-1.50 Spiralock[
M934-12-60 M12-1.75 Standard
M934-12-60F M12-1.25 Standard
M6923-12-80 M12-1.75 Spiralock
M6923-16-80 M16-2.00 Spiralock
M934-18-80 M18-2.5 Standard
M934-20-80 M20-2.50 Standard
M934-22-60 M22-2.50 Standard
M934-24-80 M24-3.00 Standard
M934-30-80 M30-3.50 Standard
Washers
Bolt/
Part No. ID OD Thick. Screw
M125A-03-80 3.2 7.0 0.5 M3
M125A-04-80 4.3 9.0 0.8 M4
M125A-05-80 5.3 10.0 1.0 M5
M125A-06-80 6.4 12.0 1.6 M6
M125A-08-80 8.4 16.0 1.6 M8
M125A-10-80 10.5 20.0 2.0 M10
M125A-12-80 13.0 24.0 2.5 M12
M125A-14-80 15.0 28.0 2.5 M14
M125A-16-80 17.0 30.0 3.0 M16
M125A-18-80 19.0 34.0 3.0 M18
M125A-20-80 21.0 37.0 3.0 M20
M125A-24-80 25.0 44.0 4.0 M24
[ This metric hex nut’s hardness is grade 8.

Appendix F Electrical Noise and Wiring Practices
Adapted from Service Bulletin SB-640 4/04. D General Purpose Power Distribution. Circuits to
medium-power loads such as lighting, offices, light-
Electrical noise is an unwanted electrical signal that can duty equipment, and small motors such as fans and
cause errors in measurement, loss of control, pumps can emit transient, medium levels of broad-
malfunctions in microprocessor-based control systems, spectrum noise. Some electronic equipment, such as
errors in data transfer between systems over computers, emits constant levels of broad-spectrum
communication links, or reductions in system noise in addition to transient broad-spectrum noise.
performance. Loads on general-purpose circuits, except for
sensitive electronic equipment, are nearly immune to
Good system design and wiring practices can minimize noise.
noise levels and the effects of noise.
D Control. Control circuits include DC circuits and
Noise, because of its random nature, is typically 120 VAC maximum AC circuits that operate at a low
characterized by frequency distribution. Many noise power level (less than 1 W). Typical circuits include
sources are broad-spectrum, that is, they produce many circuits to switches, actuators, and dry-contact relays,
frequencies distributed over a wide range. Broad- including the generator engine-start circuit. Control
spectrum noise is particularly troublesome because it circuits emit transient low levels of broad-spectrum
cannot be removed easily by filtering and because it can noise and are fairly immune to noise.
affect a variety of systems in unpredictable ways. One
common source of broad-spectrum noise is a switch, D Analog. Analog circuits are low-voltage DC circuits
which can produce voltage and current changes when that convey measurement information as relatively
an electrical circuit is connected and disconnected. small changes in current or voltage. Typical circuits
include those connected to the controller’s analog
Coupling is the transfer of signals between separate inputs. Analog circuits create the lowest noise levels
circuits. Signals from one circuit become noise in and are the most sensitive to noise.
another. The amount of coupling is cumulative and is a
function of the proximity of the circuits, their orientation, D Communication and Signaling. Communication
exposed area, and length of run. Minimize coupling by and signaling circuits are low-voltage circuits that
the following: convey information. Typical circuits include RS-232
and RS-485 serial communication lines, telephone
D Isolating circuits from each other by using separate lines, and computer network lines. These circuits
raceways or conduit for AC and DC circuits create noise with frequencies related to the
communication signaling rate. These circuits have
D Separating circuits from each other by locating them
some level of built-in noise immunity. Typical systems
as far apart as possible
will detect or correct errors caused by noise below
D Enclosing circuits with a grounded metallic shield certain levels, but with a corresponding reduction in
such as an enclosure, metallic conduit, or cable shield the data transfer rate.
D Running conductors perpendicular, rather than When planning an installation, separate all of these
parallel, to each other types of circuits as much as possible to minimize the
hazards of insulation failure, accidental miswiring, and
D Running wires loosely and randomly rather than noise coupling. For best results, install control circuits,
bundling them tightly together analog circuits, and communication and signaling
circuits separately. Combining circuit types is
D Twisting a circuit’s wires together in pairs unavoidable in the controller’s enclosure and some
other areas.
In an industrial environment, there are typically five
types of circuits with different noise emission and Note: It is very important to isolate high- and medium-
rejection capabilities. The five types of circuits are as power circuits in raceways or conduit separate
follows: from the other types of circuits.
D High-Power Distribution. Circuits to high-power

loads such as large electric motors and heaters can
emit transient high levels of broad-spectrum noise.
Loads on high-power distribution circuits are nearly
immune to noise.

Notes

Notes
TP-6929 1/15 177

Notes
178 TP-6929 1/15

TP-6929 1/15 179
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
Asia Pacific Headquarters
TP-6929 1/15 7 Jurong Pier Road
Singapore 619159
E 2015 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455

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Service

Industrial and Towable Generator Sets

Product identification numbers determine service parts. Controller Identification

Product Identification Information 2

TP-6929 1/15 Table of Contents 3

Section 5 Component Testing and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4 Table of Contents TP-6929 1/15

6.4.8 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

TP-6929 1/15 Table of Contents 5

Section 8 Load Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

6 Table of Contents TP-6929 1/15

IMPORTANT SAFETY INSTRUCTIONS.

TP-6929 1/15 Safety Precautions and Instructions 7

8 Safety Precautions and Instructions TP-6929 1/15

TP-6929 1/15 Safety Precautions and Instructions 9

10 Safety Precautions and Instructions TP-6929 1/15

can cause severe injury or death.

TP-6929 1/15 Safety Precautions and Instructions 11

12 Safety Precautions and Instructions TP-6929 1/15

This manual provides troubleshooting and repair Tech Tools

SiteTecht Software Operation Manual TP-6701

4D/4E Wound Field Alternator Service

Figure 1 Related Literature

TP-6929 1/15 Introduction 13

For professional advice on generator set power China

14 Service Assistance TP-6929 1/15

1.1 Introduction D Adjustable Engine Run Speed. Set engine speed

Figure 1-1 Decision-Makerr 3500 Controller

TP-6929 1/15 Section 1 Specifications 15

1.3.2 Generator Set Sensor/Switch Part Numbers

16 Section 1 Specifications TP-6929 1/15

1.3.5 Pressure Sensors

1.3.6 Temperature Sensors

TP-6929 1/15 Section 1 Specifications 17

18 Section 1 Specifications TP-6929 1/15

TP-6929 1/15 Section 1 Specifications 19

1.4.2 Integral Voltage Regulator

D Allows the Decision-Makerr controllers the ability to

D Permits the generator set controller to control the current

D Contains two isolated relay driver outputs (RDO) rated at

20 Section 1 Specifications TP-6929 1/15

2.1 Introduction 2.1.1 Warning Parameter Default

Fault Sensing Warning When Inhibit Time Display

TP-6929 1/15 Section 2 Controller Parameters 21

TP-6929 1/15 Section 2 Controller Parameters 23

24 Section 2 Controller Parameters TP-6929 1/15

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TP-6929 1/15 Section 2 Controller Parameters 41