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Kohler 300EFOZCS Operation Download Page 1

Commercial Marine Generator Sets

TP-7126 5/20b

Operation

Models:

350/500EOZCS

300/450EFOZCS

Controller:

Decision-Maker

r

3500

Summary of Contents for 300EFOZCS

Page 1: ...Commercial Marine Generator Sets TP 7126 5 20b Operation Models 350 500EOZCS 300 450EFOZCS Controller Decision Makerr 3500...

Page 2: ...tem S Do not idle the engine except as necessary For more information go to www P65warnings ca gov diesel Product Identification Information Product identification numbers determine service parts Reco...

Page 3: ...5 Voltage Selector Switch 26 1 7 6 Paralleling Operation 26 1 7 7 Emissions Information IMO Tier III Models Only 34 1 8 Controller Configuration Menu 34 1 8 1 Controller Configuration Submenu 34 1 8 2...

Page 4: ...1 Impeller Inspection and Replacement Procedure 72 3 6 Exhaust System 73 3 7 Diesel Exhaust Fluid DEF 73 3 8 Storage Procedure 74 3 8 1 Lubricating System 74 3 8 2 Cooling System 74 3 8 3 Fuel System...

Page 5: ...the set disable the generator set as follows 1 Move the generator set master switch to the OFF position 2 Disconnect the power to the battery charger 3 Remove the battery cables negative lead first Re...

Page 6: ...fuel vapors can cause severe injury or death Vaporized fuels are highly explosive Use extreme care when handling and storing fuels Store fuels in a well ventilated area away from spark producing equi...

Page 7: ...nection of the generator set power and shore power Testing live electrical circuits Hazardous voltage or current will cause severe injury or death Have trained and qualified personnel take diagnostic...

Page 8: ...TP 7126 5 20 8 Safety Precautions and Instructions Notes...

Page 9: ...and efficient operation Inspect the parts often and perform required service at the prescribed intervals Obtain service from an authorized service distributor dealer to keep equipment in top condition...

Page 10: ...e Headquarters Europe Middle East Africa EMEA Kohler EMEA Headquarters Netherlands B V Kristallaan 1 4761 ZC Zevenbergen The Netherlands Phone 31 168 331630 Fax 31 168 331631 Asia Pacific Kohler Asia...

Page 11: ...Filter Maintenance Kit Includes both Oil Filters above Seals GM107937 GM107937 but includes only 1 filter GM67211 GM107940 GM107937 but includes only 1 filter GM67211 Seawater Pump Impeller Kit GM106...

Page 12: ...TP 7126 5 20 12 Maintenance and Service Parts Related Literature Notes...

Page 13: ...Filter Coolant Drain Oil Filter Main Coolant Inlet Static Line Main Coolant Outlet Oil Dipstick Oil Drain Connectors for Customer Load Leads Unit Mounting Holes Coolant Bleed Pipe Exhaust Outlet Fuel...

Page 14: ...eawater Outlet Coolant Fill Pressure Cap Seawater Inlet ANTICORROSION ZINC ANODE LOCATIONS QTY 2 Cooling Air Inlets Alternator Air Outlets Expansion Tank Seawater Pump Expansion Tank Heat Exchanger Fi...

Page 15: ...oad Leads Oil Drain Main Coolant Outlet Main Coolant Inlet Static Line Fuel Priming Pump behind knockout in cover Oil Filter Oil Dipstick Coolant Bleed Pipe Centrifugal Oil Filter Oil Fill Fuel Filter...

Page 16: ...hout power box ANTICORROSION ZINC ANODE LOCATIONS QTY 6 Coolant Fill Pressure Cap Seawater Inlet Seawater Outlet Seawater Outlet Cooling Air Inlets Alternator Air Outlets Expansion Tank Heat Exchanger...

Page 17: ...ality profile and application program is supplied in the junction box of the generator set Typically the Kohler authorized distributor dealer passes this disk onto the owner The owner should store thi...

Page 18: ...ler features apply to generator set models with ECM and non ECM engines unless otherwise noted Note Press the pushbutton rotary selector dial to turn on the controller lights and display The backlight...

Page 19: ...ay Pushbutton Rotary Selector Dial This control provides access to the menus for monitoring Press the selector dial to activate the graphical display and to select choices shown on the display Rotate...

Page 20: ...e a system shutdown Correct all system warnings as soon as practical See Section 2 6 3 System Fault Warning Lamp with Digital Displays for definitions of the items listed System Shutdown Fault Lamp Re...

Page 21: ...ion displays the actual generator rotation 1 6 2 Engine Metering Submenu Note Not all of these engine metering submenus may apply D Engine Speed Tachometer displays the engine speed RPM at which the e...

Page 22: ...ency displays the cycle frequency of the generator D Bus Total Power displays the real power provided by all the generators in the paralleling system D Bus of Rated kW displays the ratio between the B...

Page 23: ...oller will request another message that contains the following information for each fault D SPN Suspect Parameter Number is a four digit code that represents an engine component D FMI Failure Mode Ind...

Page 24: ...ecision Makerr 3500 controller performed only by an authorized Kohler distributor dealer The setup and adjustments are password protected D Overvoltage displays the percentage of the system voltage th...

Page 25: ...the password The setup program will read current settings to determine a similar function when making changes to alternator connections system voltages or operating frequency Volts Hz Setpoint This ad...

Page 26: ...the delay before the generator can supply power to the load kW Ramp Rate The generator will load and unload against the other generators at this rate The default rate 5 sec requires 20 sec to accept...

Page 27: ...control switch in Run the Sync Mode in Run may need to be set to Active Note System Start AUTO RUN is the preferred method of operating a generator system RUN is intended for testing or verification o...

Page 28: ...loads on all connected generators to the total bus capacity sum of all the connected generator capacities expressed as a percentage This value can be monitored to determine system loading also found...

Page 29: ...Management Order later in this section The time to start a generator if the load increases varies with the degree of overload The time to stop a generator if the load is low enough that the generator...

Page 30: ...not user adjustable in Fuel Level mode Note Fuel Level Order Selection mode requires separate fuel tanks for the generators and fuel level senders connected to the controller to operate Operation of...

Page 31: ...tart kW This generator will be signaled to start when this accumulator reaches 100 Note The Start Accumulator will reset to 0 if the Bus Total Power drops below the Start kW for one second The Start A...

Page 32: ...ted at this time Min Loads Added The Load Shed priority that must be online before generator management will consider stopping a generator This is implemented so that generators aren t stopped prematu...

Page 33: ...loads based on the degree of overload of the system loads will shed more quickly as the degree of the system overload increases Note The generator management start should be significantly lower than t...

Page 34: ...nt emissions related messages are received they will be indicated on the generator set controller through the use of special symbols for IMO Tier III engines These symbols are shown in Figure 1 8 When...

Page 35: ...interface a local master to a network of devices The Modbusr master polls slave devices for data Controller devices are slaves Examples of master devices are a personal computer running monitoring sof...

Page 36: ...pability The user is prompted with a Yes No prompt for calibration The display will show the following D Gen L1 L0 Volts D Gen L2 L0 Volts D Gen L3 L0 Volts D Gen L1 L2 Volts D Gen L2 L3 Volts D Gen L...

Page 37: ...e delay The time delay is the time period between when the controller first detects the fault or status event and the controller warning or shutdown lamp illuminates The delay prevents any nuisance al...

Page 38: ...Event Screen Capture Example Engine Specific Events FMI Failure Mode Indicator Event ID Parameter at Local Display Level Alarm Horn Fault Lamp Programmed Input Programmed Output Protectives Low After...

Page 39: ...D Shorted High Coolant Pressure Shutdown On Red AD D Shorted High Coolant Pressure Warning On Yellow AD D Shorted Low Coolant Pressure Shutdown On Red AD D Shorted Low Coolant Pressure Warning On Yel...

Page 40: ...Warning On Yellow AD D Engine Speed Shutdown On Red D Exhaust Gas Temp High Shutdown On Red D High Exhaust Temperature if equipped Shutdown On Red AD D High Exhaust Temperature if equipped Warning On...

Page 41: ...ing On Yellow D PR Over Frequency Trip Warning On Yellow D PR Over Power Trip Warning On Yellow D PR Over Voltage Trip Warning On Yellow D PR Reverse Power Trip Warning On Yellow D PR Reverse Var Trip...

Page 42: ...on 234 Software Identification 636 Engine Position Sensor 641 Engine Variable Geometry Turbocharger Actuator 1 645 Engine Tachometer Signal Output 651 Engine Injector Cylinder 01 652 Engine Injector C...

Page 43: ...auxiliary analog inputs and secondary oil pressure readings will be measured directly by the controller D All units will have a single coolant pressure sensor This sensor connects to the genset contr...

Page 44: ...TP 7126 5 20 44 Section 1 Specifications Notes...

Page 45: ...tion and check for tight exhaust system connections Inspect the exhaust system components exhaust manifold mixing elbow exhaust line hose clamps silencer and exhaust outlet for cracks leaks and corros...

Page 46: ...a fainting or death Be especially careful if operating the generator set when moored or anchored under calm conditions because gases may accumulate If operating the generator set dockside moor the cra...

Page 47: ...unburned fuel and wet stacking The operator should perform all of the prestart checks Start the generator set according to the starting procedure in the controller section of this manual While the ge...

Page 48: ...Some generator sets may shut down after a period of time indicated by Generator Management but they remain in Standby Mode ready to start and run if needed D AUTO OFF Press AUTO and OFF together to re...

Page 49: ...rature If the Cooldown Override is enabled ON in the Generator Configuration Menu coolant temperature will be considered for cooldown The generator will enter cooldown when the start signal is removed...

Page 50: ...rgency stop 2 Reset the controller emergency stop switch by pulling the switch dial outward 3 Press the generator set OFF RESET button 4 After resetting all faults using the controller reset procedure...

Page 51: ...oltage regulator failure etc The output breaker trips The generator may continue to produce insufficient voltage until it is shut down Battery Charger Fault The fault lamp illuminates yellow and the a...

Page 52: ...e Default Setting 24 26 4 32 4 30 Figure 2 4 High Battery Voltage Specs High Coolant Temperature The fault lamp illuminates yellow and the alarm horn sounds when the engine coolant temperature approac...

Page 53: ...yellow and the alarm horn sounds to inform the user that they need to refill the DEF tank Low Engine Oil Level The fault lamp illuminates yellow and the alarm horn sounds because of low engine oil le...

Page 54: ...the alarm horn sounds and the unit shuts down when ECM diagnostics signals the controller The specific display will be a brief message or fault code that is engine manufacturer dependant ECM Model Mi...

Page 55: ...lant level is detected Low Engine Oil Level The fault lamp illuminates red the alarm horn sounds and the unit shuts down because of low engine oil level This fault feature requires an optional low eng...

Page 56: ...e Section 2 6 for cyclic crank specifications Run Relay Coil Overload The fault lamp illuminates red the alarm horn sounds and the unit shuts down when the current draw on the 70 wire from the control...

Page 57: ...the paralleling breaker Emergency Power System EPS Supplying Load This notice message indicates when the generator set supplies more than 1 of the rated standby output current Engine Cooldown Delay Ac...

Page 58: ...st operate the generator set to verify correction of the shutdown cause by pressing the RUN button 6 Press the generator set OFF RESET button to stop the generator set 7 Press the generator set AUTO b...

Page 59: ...ENSET CONTROLLER TEMP _F d OIL PRESSURE PSI d OIL TEMPERATURE _F d COOLANT TEMPERATURE _F d COOLANT PRESSURE PSI d FUEL LEVEL d FUEL PRESSURE PSI d FUEL TEMPERATURE _F d FUEL RATE GAL h shown if avail...

Page 60: ...G D GAIN Z VOLTAGE BIAS Z SYSTEM VOLTAGE L L V Z AVG GEN VOLTAGE L L V Z VOLT TRIM P GAIN Z VOLT TRIM I GAIN Z VOLT TRIM D GAIN Z VOLTAGE BIAS Z VOLT DROOP AT 100 kVAR d PROTECTIVE RELAY SETUP Z OVER...

Page 61: ...nput 0 3 Digital Input 0 4 Digital Input 0 5 Digital Input 0 6 d DESCRIPTION function by default unless modified via SiteTech d STATUS ACTIVE INACTIVE d FUNCTION d EVENT d LOGIC ACTIVE ON ACTIVE OFF d...

Page 62: ...WER W TOTAL POWER kW GEN OF RATED kW L1 REACTIVE POWER VAR L2 REACTIVE POWER VAR L3 REACTIVE POWER VAR TOTAL REACTIVE POWER VAR L1 APPARENT POWER VA L2 APPARENT POWER VA L3 APPARENT POWER VA TOTAL APP...

Page 63: ...EN VOLTAGE L L V VOLT TRIM P GAIN VOLT TRIM I GAIN VOLT TRIM D GAIN VOLTAGE BIAS VOLT DROOP AT 100 kVAR OVER POWER TRIP OVER POWER DELAY s REVERSE POWER TRIP REVERSE POWER DELAY s OVER VOLTAGE TRIP OV...

Page 64: ...CTIVE ON ACTIVE OFF DESCRIPTION MODE STATUS ACTIVE INACTIVE FUNCTION FUNCTION EVENT LOGIC ACTIVE ON ACTIVE OFF DESCRIPTION MODE STATUS ACTIVE INACTIVE FUNCTION FUNCTION EVENT LOGIC ACTIVE ON ACTIVE OF...

Page 65: ...EF system has lost its prime and engine performance is reduced Engine emissions outside of normal operating range Engine emissions system fault Exhaust gas temperature is high Exhaust cleaning is in p...

Page 66: ...PC to a single device The PC communicates with the device via telephone line or an ethernet network See Figure 2 17 Personal Computer with NIC Ethernet Network Remote Network Modem Modbusr Ethernet C...

Page 67: ...d around the generator set and remove salt deposits from metal surfaces The engine and generator set may use both American Standard and metric hardware Use the correct size tools to prevent rounding o...

Page 68: ...ine breakage caused by vibration Do not operate the generator set in the presence of fuel leaks fuel accumulation or sparks Repair fuel systems before resuming generator set operation Draining the fue...

Page 69: ...reakers of all power sources before servicing the equipment Never contact electrical leads or appliances when standing in water or on wet ground because these conditions increase the risk of electrocu...

Page 70: ...coolant and clean the cooling system Eng O M X Every 6000 hrs Minimum every 5 yrs Fuel System Check the fuel level Eng O M X Drain the water separating prefilter Eng O M X Every 500 hrs Change the fu...

Page 71: ...exterior and interior Alt O S M X Every 15 days General cleaning Alt O S M X Every 400 hrs Visual inspection Alt O S M X Every 2500 hrs Verify winding state w Alt O S M X Every 2500 hrs Verify correct...

Page 72: ...tions included with the impeller kit If the instructions are not included with the kit use the following procedure Impeller Inspection and Replacement Procedure Note Always keep a spare impeller on bo...

Page 73: ...due on exhaust components Carbon and soot residue indicates an exhaust leak Seal leaks as needed D Check the thermal insulation wraps and secure if needed 3 7 Diesel Exhaust Fluid DEF Some models are...

Page 74: ...generator set for 30 minutes to redistribute added coolant 3 8 3 Fuel System Prepare the fuel system for storage as follows Diesel Fueled Engines 1 Fill the fuel tank with 2 diesel fuel 2 Condition th...

Page 75: ...the indicated problem Corrective action and testing often require knowledge of electrical and electronic circuits To avoid additional problems caused by incorrect repairs have an authorized service d...

Page 76: ...stop switch activated if equipped Reset the emergency stop switch Section 2 x Controller firmware error Review the controller display troubleshooting chart Section 4 1 Alternator x AC output circuit b...

Page 77: ...shoot the controller Section 2 x High exhaust temperature switch inoperative Replace the inoperative switch Gen S M or W D Engine x x x x Air cleaner backfire flame arrestor clogged Clean or replace t...

Page 78: ...ative Replace the thermostat Eng S M 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 fu...

Page 79: ...Defective exciter winding Voltage ramp on startup is normal but ramping past the target without recovering may indicate additional failures in the alternator or excitation circuit Troubleshoot alterna...

Page 80: ...TP 7126 5 20 80 Section 4 Troubleshooting Notes...

Page 81: ...t stop switch or engine start command from a remote computer Hazardous voltage Moving parts Will cause severe injury or death Operate the generator set only when all guards and electrical enclosures a...

Page 82: ...A GM105387C A GM105387D A GM105387E A Figure 5 1 Figure 5 2 Figure 5 3 Figure 5 4 Figure 5 5 ADV 9061A A ADV 9061B A ADV 9061C A ADV 9061D A ADV 9061E A ADV 9061F A ADV 9061G A Figure 5 6 Figure 5 7...

Page 83: ...TP 7126 5 20 83 Section 5 Wiring Diagrams GM105387A A Figure 5 1 Wiring Diagram Sheet 1 of 5 GM105387A...

Page 84: ...TP 7126 5 20 84 Section 5 Wiring Diagrams GM105387B A Figure 5 2 Wiring Diagram Sheet 2 of 5 GM105387B...

Page 85: ...TP 7126 5 20 85 Section 5 Wiring Diagrams GM105387C A Figure 5 3 Wiring Diagram Sheet 3 of 5 GM105387C...

Page 86: ...TP 7126 5 20 86 Section 5 Wiring Diagrams GM105387D A Figure 5 4 Wiring Diagram Sheet 4 of 5 GM105387D...

Page 87: ...TP 7126 5 20 87 Section 5 Wiring Diagrams GM105387E A Figure 5 5 Wiring Diagram Sheet 5 of 5 GM105387E...

Page 88: ...TP 7126 5 20 88 Section 5 Wiring Diagrams ADV9061A A Figure 5 6 Schematic Sheet 1 of 7 ADV9061A...

Page 89: ...TP 7126 5 20 89 Section 5 Wiring Diagrams ADV9061B A Figure 5 7 Schematic Sheet 2 of 7 ADV9061B...

Page 90: ...TP 7126 5 20 90 Section 5 Wiring Diagrams ADV9061C A Figure 5 8 Schematic Sheet 3 of 7 ADV9061C...

Page 91: ...TP 7126 5 20 91 Section 5 Wiring Diagrams ADV9061D A Figure 5 9 Schematic Sheet 4 of 7 ADV9061D...

Page 92: ...TP 7126 5 20 92 Section 5 Wiring Diagrams ADV9061E A Figure 5 10 Schematic Sheet 5 of 7 ADV9061E...

Page 93: ...TP 7126 5 20 93 Section 5 Wiring Diagrams ADV9061F A Figure 5 11 Schematic Sheet 6 of 7 ADV9061F...

Page 94: ...TP 7126 5 20 94 Section 5 Wiring Diagrams ADV9061G A Figure 5 12 Schematic Sheet 7 of 7 ADV9061G...

Page 95: ...TP 7126 5 20 95 Section 5 Wiring Diagrams ADV5875 AB Figure 5 13 Reconnection Diagram ADV 5875...

Page 96: ...TP 7126 5 20 96 Section 5 Wiring Diagrams Notes...

Page 97: ...inch cw clockwise CWC city water cooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree...

Page 98: ...ize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Philli...

Page 99: ...Log Use the log below to keep a cumulative record ofoperating hours on your generator set and the dates required services were performed Enter hours to the nearest quarter hour Operating Hours Service...

Page 100: ...TP 7126 5 20 100 Appendix Notes...

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Page 104: ...ights reserved TP 7126 5 20b 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 Origina...

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