Training Manual Fast-Response™ Il Standby Generator Sets Models: 20-300 kW KOHLER. POVVER SYSTEMS‘TABLE OF CONTENTS ‘SUBJECT PAGE INTRODUCTION. é ‘SAFETY PRECAUTIONS. a FAST RESPONSE ALTERNATOR DESIGN BASICS. iv FIELD EXCITATION DESIGNS. v FAST RESPONSE DESIGN vi ALTERNATOR ASSEMBLY FRI ALTERNATOR COMPONENTS A FRII ALTERNATOR COMPONENTS: ‘a2 STATOR CODE SIZE a3 ‘STATOR WINDING CONNECTIONS. aa ‘STATOR LOAD BALANCE re ‘STATOR INSULATION a8 STATOR RESISTANCE. ar EXCITER FIELD (PM), a8 ROTOR - Main Field rn EXCITER ARMATURE A10 ‘SCR MODULE ant PHOTO TRANSISTOR BOARD. a2 LED BOARD As VOLTAGE REGULATOR. ae GENERATOR ENCLOSURE, ANS ‘SAFEGUARD BREAKER TERMINAL STRIP... A18 (CURRENT TRANSFORMERS (CT) Aa ‘AURILIARY RELAYS, At Governor relay KS at ‘AirDamper Relay K6. Aa ‘CONTROLLER, CONTROLLER CABINETS. 1 Manual Contr Gia, c22 7 Light microcomputer Cia, 623, 16 Light microcomputer Cia 16 Light microcomputer, expanded. Cra Parateing engine gauge box. Cia DEC 1 Controler Cia c2e Decision-Maker™300 car -c29 AG METERS, G2 ‘Wattmeter. 2a METER SELECTOR SWITCH 3 Meter scale indicator, 3a Meter terminal stip and fuses 3a EMERGENCY STOP SWITCH. ce VOLTAGE ADJUST RHEOSTAT. cs HOURMETER, cs PANEL LAMPS os ENGINE GAUGES & SENDERS cs Oil temp. Ba Tachometer se CONTROL STATUS INDICATOR PANEL...C7 ‘Control switch, Rur-OffResetAut cr Lamp Test Sw cr Alarm Horn cr ‘Alarm Silence Switch cr Plug connectas. Cra STATUS PANEL INDICATORS, ce Engine tems. pressure senders. 3 DIAGRAM, DEC 3+ Fauitincicator senders....8 DEC 3 Fault indicator senders. 3a SUBJECT PAGE MICROPROCESSOR CIRCUIT BOARD (OEC 3)C12 ‘TBI TERMINAL STRIP (DEC 3) C2 Remote staristop, C28 Emergency Stop C2 rank mode C28 ‘Tet TERMINAL STRIP. rr Indicator output termina, C13 ‘SPEED SENSOR 13. ‘Overcrank cs Overspeed os Locked Rotor. ca CIRCUIT BOARD CONNECTORS (DEC3)....C14 CIRCUIT BOARD RELAYS & FUSES... 15 Diagram, relay & fuses cs. DIAGRAM FR System, Schemate (GEC 3)... C16 DIAGRAM -FR System, Line (DEC 3). C16 MICROPROCESSOR CIRCUIT BOARD (EC 33)G17 ‘TBt TERMINAL STRIP (DEC 34), Cita (Output terminals cs Remote etastep. C18 Crank Moge ‘C18a Prime Power mode. ‘C18 CIRCUIT BOARD CONNECTORS (OEC 33)... C19 CIRCUIT BOARD FUSES AND RELAYS (DEC 54)C20 ‘Overvoiage shutdown ‘C208 CIRCUIT DIAGRAM (DEC 3), ‘cat CIRACUIT BOARD (DEC #). casa CIRCUIT DIAGRAM (DEC 1) nn C28 CIRCUIT BOARDS (Decision Maker™s40) C30 -C34 "ACCESSORIES & OPTIONS LINE CIRCUIT BREAKER aie ‘Thotmal tp, Ais Magnetic tip aN Shunt tp ‘Aisa ‘Thermal Magnetic. ‘aga SAFEGUARD BREAKER a REACTIVE DROOP COMPENSATOR a20 RUN RELAY. 922 (CUSTOMER CONNECTION TERMINAL STRIP. -A23 OVERVOLTAGE KIT (DEC 3) Act REMOTE EMERGENCY STOP SW. (Break glass)AC2 AUDIONVISUAL ALARM KIT. ‘ACA ‘COMMON FAULT RELAY KIT ‘ACS 1 RELAY DRY CONTACT KIT. ‘AC8 10 RELAY ORY CONTACT KIT. ‘AC? 14 RELAY ORY CONTACT KIT. ‘ACB REMOTE ANNUNCIATOR PANEL ‘Aco Faulk inciators. ‘aco, REMOTE ANNUNCIATOR PANEL. ‘Ac10 Interconnection "ACO DIAGRAM - Accessory connections ACIt DIAGRAM - Accessory interconnections ‘Aci2 OVERIUNDER FREQUENCY MODULE ACIS ENGINE MANAGEMENT MODULE ACIS GLOSSARY - stINTRODUCTION ‘This manual covers operation and features of KOHLER FAST RESPONSE Generator sets. Itis only intended as a training guide and does not necessarily contain all available service information. Pictures, Illustrations and wiring diagrams in this manual are only representative of the various models. ‘and may differ slightly even within the same model designation series. This manual is not to be used as an installation manual For complete service, parts, and installation information the following manuals are available from Kohler Co. Generator Division, Service Parts Department. FR GENERATOR SET MANUALS ‘TP-5044 - FAST RESPONSE SERVICE MANUAL (Early FR Generators wimother-daughter board and uniboard controller.) ‘TP-6149 - FRI GENERATOR SERVICE MANUAL (Early FRII Generators with Dec Il Controllers) ‘TP-6262 - FRIl GENERATOR SERVICE MANUAL (FRII Generators with Relay Controllers, DEC 3 controllers and split activators.) ‘TP-8353 - FRIl GENERATOR SERVICE MANUAL (FRII Generators with DEC 3 Enhanced controller.) “TP-5823 - Decision-Maker™ 340 SOFTWARE OPERATION ‘TP-5829 - Decision-Maker™ 340 OPERATION ‘TP-5061 - Parts list- FAST RESPONSE GENERATORS. (Early FR generators with Mother/daughter or uniboard controller) ‘TP-5160 - Parts list - RFll GENERATORS. (Early FRI! Generators with DEC II controller.) ‘TP-5276 - Parts list - FRI GENERATORS. (FRI Generators manufactured after 1/87. DEC 3 Controller and split Activator. ‘TP-5408 - Parts list - FRI] GENERATORS, (FRI Generators with DEC 3 Enhanced controllers, Split Activator, 20-180ROZJ, JD powered.) ‘TP-5354 - Parts list- FRIl GENERATORS. (FRI Generators with DEC 3 Enhanced controller, Split Activator, 200-300ROZD, DD powered.) “TP-6543 - Parts list - FRI! (20 - 30KW Ford Powered with DEC 3 Enhanced Controller) ‘TP-5613 - Parts list -FRIl (33 - 45KW Ford Powered with DEC 3 Enhanced Controller) TP-5614 - Parts list - FRI (50 - 100KW Ford Powered with DEC 3 Enhanced Controller. ‘TP-5400 - DESIGN & APPLICATION INFORMATION. (Technical and Application Guide Book) ‘TP-5700 - INSTALLATION GUIDE. (Stationary Duty.)