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1-8 Specifications

TP-5631 7/96

Emergency
Stop

B+

B-

Emergency
Stop

Remote
Switch

AUX

LOP

HET

Common Fault **

** Common Fault Indicator

Activated By:

HET Fault

LOP Fault

LWT Fault

OC Fault

OS Fault

AUX Fault

Connect A/V Alarm or

Common Fault Relay Kit

LWT

Remove Jumper if

Emergency Stop is

Used.

System Ready

Not In Auto

PHET

PLOP

Low Fuel

Battery Charging Fault

Low Battery

CIRCUIT BOARD TERMINAL IDENTIFICATION (TB1)

1 -

Ground— Emergency Stop Relay (K4)— Connect Emergency Stop Across Terminals TB1-1 and 1A.

1A -

Emergency Stop Relay (K4) Coil; Negative— Connect Emergency Stop Across Terminals TB1-1 and 1A.

56 -

Not Used

42A - Battery Voltage (Fuse #1 Protected)— Accessory Power Supply; Customer may also Provide Separate Accessory Power Source

2 -

Ground Terminal

9 -

Crank Mode Selection (open— cyclic crank; ground— continuous crank) Connect TB1-2 to TB1-9 for Continuous

Cranking; Leave TB1-9 open for cyclic cranking. See Starting Procedure.

48 -

Emergency Stop Indicator *

3 -

Remote Start Ground— Connect Remote Start Switch to TB1-3 and TB1-4

4 -

Remote Start— Connect Remote Start Switch to TB1-3 and TB1-4

26 -

Auxiliary Indicator (Aux.) *

12 -

Overcrank Indicator (OC) *

39 -

Overspeed Indicator (OS) *

38 -

Low Oil Pressure Indicator (LOP) *

36 -

High Engine Temperature Indicator (HET) *

60 -

System Ready Indicator *

80 -

Not In Auto Indicator *

40 -

Prealarm High Engine Temperature Indicator (PHET) *

41 -

Prealarm Low Oil Pressure Indicator (PLOP) *

32 -

Common Fault/Prealarm Line— A/V Alarm or Common Fault Relay Activated by HET, LOP, LWT, OC, OS, and AUX Faults

63 -

Low Fuel— Connect Fuel Level Sensor to TB1-63 to Activate Fault Lamp (If Used)

61 -

Battery Charger Fault— Connect Battery Charger to TB1-61 to Activate Fault Lamp (If Used)

62 -

Low Battery Volts— Connect Battery Charger to TB1-62 to Activate Fault Lamp (If Used)

35 -

Low Water Temperature— Connect LWT Sensor (Prealarm Kit) to TB1-35 to Activate LWT or LWT/AUX Lamp

NOTE: Not all terminal connections are used for all generator sets (see Wiring Diagrams).

* Indicators may be customer supplied lamps and/or alarms or A/V Alarms, Annunciators, Dry Contact Kits, etc.

TB1 Terminal Strip

42A 2 9 48

3 4 26

39 38 36 60 80 40 41 32 63 61 62 35

Figure 1-9. Controller TB1 Terminal Strip Connections

Содержание 6.5RMY

Страница 1: ...Operation Manual Industrial Generator Sets Models 6 5RMY 10 18RY RZ TP 5631 7 96 Controllers Decision Makert 3 5 Light Relay...

Страница 2: ...Engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm WARNING California Proposition 65...

Страница 3: ...r 2 11 Starting 2 11 Stopping 2 11 Fault Shutdowns relay controller 2 11 Circuit Protection relay controller 2 12 Voltage Regulator Fuse 2 12 Controller Resetting Procedure following fault shutdown 2...

Страница 4: ...ANGER Danger indicates the presence of a hazard that will cause severe personal injury death or substantial property damage WARNING Warning indicates the presence of a hazard that can cause severe per...

Страница 5: ...abling generator set Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove negative...

Страница 6: ...e case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid Battery gases Explosion can cause severe injury or dea...

Страница 7: ...ng fuel system A flash fire can cause severe injury or death Do not smoke or permit flame or spark to occur near carburetor fuel line fuel filter fuel pump or other potential sources of spilled fuel o...

Страница 8: ...that it can cause death if inhaled for even a short time Carbon monoxide symptoms Carbon monoxide can cause severe nausea fainting or death Carbon monoxide is a poisonous gas which is present in exha...

Страница 9: ...han air install propane gas detectors low in room Inspect detectors often Natural Gas Adequate ventilation is mandatory Natural gas rises install natural gas detectors high in room Inspect detectors o...

Страница 10: ...TP 5631 7 96 Safety Precautions and Instructions VII Hazardous Noise Hazardous noise Can cause loss of hearing Never operate generator set without a muffler or with a faulty exhaust system CAUTION...

Страница 11: ...ve install an equipment grounding conductor with circuit conductors and connect to equipment grounding terminal or lead on battery charger Perform battery charger installation as prescribed in equipme...

Страница 12: ...and Instructions IX Heavy Equipment WARNING Unbalanced weight Improper lift can cause severe injury or death and or equipment damage Do not use lifting eyes Lift generator set using lifting bars inse...

Страница 13: ...eld and exciter armature when shorted become hot enough to cause severe burns Checking coolant level Hot coolant can cause severe injury or death Allow engine to cool Release pressure from cooling sys...

Страница 14: ...d rotor hardware after servicing Do not loosencrankshaft hardware or rotor thrubolt when making adjustments or servicing generator set Rotate crankshaft manually in a clockwise direction only Turning...

Страница 15: ...e both American Standard and metric hardware Use the correct size tools to prevent rounding of bolt heads and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws...

Страница 16: ...eration therefore inspect parts often and perform required service at the prescribed intervals An authorized service distributor dealer should perform required service to keep equipment in top conditi...

Страница 17: ...address or number KOHLER CO Kohler Wisconsin 53044 U S A Phone 414 565 3381 Fax 414 459 1646 U S A Sales 414 459 1614 International To ensure supply of correct parts or information make note of the fo...

Страница 18: ...ual installation manual engine operation manual and engine service manual for additional specifications Generator The generator is equipped with Kohler s PowerBoostt voltage regulation system which pr...

Страница 19: ...engine water liquid cooled models only d Voltmeter DC only D Analog meters 3 5 in 89 mm d AC ammeter 2 full scale accuracy d AC voltmeter 2 full scale accuracy d Frequency meter 0 5 full scale accurac...

Страница 20: ...roprocessor controller The overvoltage circuit immediately shuts down the engine when triggered by a DC signal from an overvoltage shutdown option The generator set automatically shuts down if output...

Страница 21: ...ten relay dry contact kit is included with this kit See Figure 1 3 The remote annunciator includes alarm horn alarm silence switch lamp test and the same lamp indicators as the 5 light microprocessor...

Страница 22: ...common fault lamp See Figure 1 4 NOTE Connect a maximum of three remote annunciators and or A V alarms in any combination to the generator set controller A 292887 Figure 1 4 Audio Visual Alarm Line C...

Страница 23: ...6 Emergency Stop Kit Single Relay Dry Contact Kit microprocessor controller The single relay dry contact kit uses one set of relay contacts to trigger customer provided warning devices if a fault con...

Страница 24: ...ontroller circuit board is equipped with a terminal strip TB1 for easy connection of generator set accessories Do not direct connect accessories to the controller terminal strip Connect all accessorie...

Страница 25: ...Start Switch to TB1 3 and TB1 4 4 Remote Start Connect Remote Start Switch to TB1 3 and TB1 4 26 Auxiliary Indicator Aux 12 Overcrank Indicator OC 39 Overspeed Indicator OS 38 Low Oil Pressure Indicat...

Страница 26: ...on manual for engine coolant specifications Do not add coolant to a hot engine Wait until engine has cooled Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack Do not...

Страница 27: ...liary light 7 Alarm horn 8 DC voltmeter 9 Voltage adjustment potentiometer 10 Oil pressure gauge 11 Engine water temperature gauge not used on 6 5 kW 12 Hourmeter 13 15 amp engine and accessories fuse...

Страница 28: ...lts occur if so equipped These conditions are inhibited during first 30 seconds after crank disconnect D The auxiliary lamp lights and engine shuts down immediately if an overvoltage condition occurs...

Страница 29: ...itched to a position with three circuit lead labels amperage is measured on the upper lead and voltage is measured between the lower two leads AC ammeter and voltmeter do no register with switch in th...

Страница 30: ...art Switch to TB1 3 and TB1 4 4 Remote Start Connect Remote Start Switch to TB1 3 and TB1 4 26 Auxiliary Indicator Aux 12 Overcrank Indicator OC 39 Overspeed Indicator OS 38 Low Oil Pressure Indicator...

Страница 31: ...s cranking or 75 seconds of cyclic cranking crank 15 seconds rest 15 seconds crank 15 seconds etc before overcrank shutdown Make the cranking mode cyclic or continuous selection on the controller circ...

Страница 32: ...ories will not work and the battery connections appear okay one of these fuses may be blown Fuses V7 V8 and V9 on the AC terminal block TB2 protect the controller meters and lights If the controller l...

Страница 33: ...fter 45 seconds of continuous cranking Shutdown occurs after 75 seconds of cyclic cranking crank 15 seconds reset 15 seconds crank 15 seconds etc for a total of 75 seconds Shutdown occurs after 15 sec...

Страница 34: ...5 Verify that cause of shutdown has been corrected by test operating generator set 6 Reconnect generator set to load via line circuit breaker or automatic transfer switch 7 Place generator set master...

Страница 35: ...lit after generator set shuts down Fault lamp lights as fault occurs Hourmeter Hourmeter records generator set operating hours for reference in maintenance scheduling Generator Master Switch Run Off...

Страница 36: ...adequate cooling of the set 2 Place controller or remote start stop switch in the OFF RESET position The generator set shuts down Fault Shutdowns relay controller The generator set shuts down automati...

Страница 37: ...heck the controller fuse if the generator set will not crank and the battery and or connections appear correct Replace fuse If fuse blows again see Section 4 Troubleshooting for possible causes Voltag...

Страница 38: ...rator set master switch in the OFF RESET position until the fault lamp goes out See Safety Precautions before proceeding 2 Disconnect generator set from load with line circuit breaker or automatic tra...

Страница 39: ...t last WARNING Disabling generator set Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cabl...

Страница 40: ...djust the carburetor run the generator set at approximately half load Rotate engine fuel mixture screw clockwise or counterclockwise until the engine runs smoothly See Figure 3 2 Applyvarying loadsand...

Страница 41: ...tly connected and terminals are tight Battery Charging Systems 6 5 kW The battery charging circuit incorporates a winding in the generator set alternator and a rectifying module protected by a self re...

Страница 42: ...d reconnect it last Sulfuric acid in batteries can cause severe injury or death Sulfuric acid in batteries can cause permanent damage to eyes burn skin and eat holes in clothing Always wear splash pro...

Страница 43: ...tween specific gravities of each cell should not exceed 0 01 The battery should be charged if the specific gravity is below 1 215 at an electrolyte temperature of 80 F 26 7 C 10 20 30 40 50 60 70 80 9...

Страница 44: ...oil having a viscosity appropriate for the particular climate 5 Run the generator set for a few minutes to distribute the clean oil 6 Stop the generator set Fuel gasoline fueled engines 1 To remove f...

Страница 45: ...uel filter gasoline models only Replace fuel filter lacks power or operates erratically Air cleaner lever in the wrong temperature position 6 5 kW models only Place air cleaner lever in correct positi...

Страница 46: ...r connections Check connections High output voltage or high frequency Governor misadjusted high frequency Check governor Faulty voltage regulator Check voltage regulator adjustment and or test voltage...

Страница 47: ...NG Disabling generator set Accidental starting can cause severe injury or death Turn generator set master switch to OFF position disconnect power to battery charger and remove battery cables remove ne...

Страница 48: ...e circuit breaker are not to be connected together when a factory two pole circuit breaker is used see Figure 5 2 If the installation requires a 100 120 volt 2 wire system use a single pole circuit br...

Страница 49: ...L0 L1 L0 L2 L1 L2 60 Hz 100 120 volt 100 120 volt 200 240 volt 50 Hz 100 120 volt 100 120 volt 200 240 volt 4 3 2 1 Stator Leads LO GRD L2 L1 LO Neutral Line Side Factory Two Pole Circuit Breaker Grou...

Страница 50: ...ltage CT1 L1 7 10 12 9 11 8 CT2 L2 5 2 3 6 L0 1 4 60 HZ 120 240V 1PH 3 WIRE 50 HZ 110 220V 1 PH 3 WIRE USED ON GENERATORS 20 100 KW ONLY L3 CT3 3 6 L0 10 7 L1 CT3 NOT USED TB2 METER SCALE LAMP JUMPER...

Страница 51: ...ler cover and reposition meter scale lamp jumper if necessary to match meter scale lamps with desired voltage See Figure 5 8 5 The jumper J1 must be in place on the overvoltage circuit board if the ge...

Страница 52: ...ator Reconnection TP 5631 7 96 N VO C3 C2 C1 CO UPV7F LOW 1 TP 5631 5 1 Lamp jumper Figure 5 8 Meter Scale Lamp Jumper TP 5631 5 PH PH 1 1 Voltage adjustment potentiometer Figure 5 9 Voltage Adjustmen...

Страница 53: ...r Requirements The generator set requires correct air flow for cooling and combustion The louvers on the upper portion of the weather housing and the cutouts in the skid provide the cooling and combus...

Страница 54: ...engine Emission certified engines may be fitted with carburetors that have no possible adjustments The generator set can be fueled by gasoline LP gas or natural gas Gasoline requires a different fuel...

Страница 55: ...Section 1 Accessories and an authorized service distributor dealer for a list of available accessories Most of the accessories operate on 12 volts DC and some may require AC line voltage Do not direc...

Страница 56: ...l Code NEC and is done by a licensed electrician All applicable local and state codes must be followed See Wiring Diagram manual for more information regarding generator set electrical connections 1 C...

Страница 57: ...before top dead center Btu British thermal unit _ C Celsius degree cc cubic centimeter CCA cold cranking amps CEC Canadian Electrical Code cfh cubic feet per hour cfm cubic feet per minute CID cubic...

Страница 58: ...l Electrical Manufacturers Association NFPA National Fire Protection Association Nm Newton meter s N O normally open no nos number numbers NPT National Standard taper pipe thread per general use N R n...

Страница 59: ...hler Wisconsin 53044 Phone 414 565 3381 Fax 414 459 1646 U S A Sales Fax 414 459 1614 International For the nearest sales and service outlet in U S A and Canada Phone 1 800 544 2444 PRINTED IN U S A T...

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