Kirloskar KG645 - User Manual For Genset Controller PDF

KG645 CONTROLLER MANUAL
KG645
Kirloskar
Genset Controller
User Manual
KIRLOSKAR OIL ENGINES LIMITED
A Kirloskar Group Company
Laxmanrao Kirloskar Road, Khadki, Pune-411 003,
India. Tel : +91(20) 2581 0341
Fax: +91(20) 2581 3208/ 2581 0209
www.kirloskar.com
Page 1 of 123
Table of Contents
KG-645 Genset Controller
1 Introduction ..................................................................................................................................... 5
1.1 Key Highlights of the Product ............................................................................................................................ 5
2 Specifications ................................................................................................................................... 6
2.1 Terminals............................................................................................................................................................ 6
2.2 Power Supply Specifications .............................................................................................................................. 7
3 Inputs .............................................................................................................................................. 8
3.1 Generator Voltages And Frequency Measurements.......................................................................................... 8
3.2 Generator Current Measurement ...................................................................................................................... 8
3.3 Mains Voltage And Frequency Measurements .................................................................................................. 8
3.4 Digital Inputs ...................................................................................................................................................... 9
3.5 Analogue Inputs ...............................................................................................................................................10
3.6 Sensor Common...............................................................................................................................................11
3.7 Magnetic Pick Up Input....................................................................................................................................11
3.8 D+ Charge Alt ...................................................................................................................................................12
4 Outputs.......................................................................................................................................... 12
4.1 Digital Outputs .................................................................................................................................................12
4.2 Actuator Outputs .............................................................................................................................................13
5 Communication Ports ..................................................................................................................... 13
6 Installation ..................................................................................................................................... 14
6.1 Dimensions ......................................................................................................................................................14
6.2 Mounting on panel ..........................................................................................................................................15
6.3 Terminal Description ........................................................................................................................................16
6.4 Typical Wiring Diagram ....................................................................................................................................18
7 Module Display .............................................................................................................................. 20
7.1 Power on screen ..............................................................................................................................................20
7.2 Monitoring Mode.............................................................................................................................................20
8 Description of Control keys ............................................................................................................. 27
8.1 Mode Selection diagram ..................................................................................................................................27
8.2 Functions of Control keys.................................................................................................................................28
9 Configuration Mode ....................................................................................................................... 29
9.1 Configurable Parameters .................................................................................................................................30
10 Module Operation in Manual Mode……………………………………………………….…………………………………….46
11 Module Operation in Auto Mode .................................................................................................. 46
11.1 Auto Mains Failure (AMF) ..............................................................................................................................46
11.2 Remote start/stop ..........................................................................................................................................47
12 Paralleling support / Speed bias mode .......................................................................................... 47
12.1 Paralleling concept.........................................................................................................................................47
12.2 Configuration in KG-645.................................................................................................................................48
13 Module Operation In Test Mode ................................................................................................... 49
14 Deep Sleep Mode ......................................................................................................................... 49
15 Alarms ......................................................................................................................................... 49
16 Troubleshooting ........................................................................................................................... 53
Communication Protocol
17 Introduction ................................................................................................................................. 56
18 MODBUS Based Protocol .............................................................................................................. 56
18.1 Connection Details .........................................................................................................................................56
18.2 Supported Functions......................................................................................................................................56
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18.3 Register Map ..................................................................................................................................................56
Expansion Module
19 Introduction ................................................................................................................................. 66
19.1 Expansion Module Integration ......................................................................................................................67
KG-645 – Configuration Utility
20 Introduction ................................................................................................................................. 68
21 Installation Instructions ................................................................................................................ 68
21.1 System Requirements ....................................................................................................................................68
21.2 Installation Process for KG 645 - Configuration Utility...................................................................................68
21.3 Installation Process for USB Driver ................................................................................................................69
22 Usage Instructions ........................................................................................................................ 75
22.1 Starting with KG 645 - Configuration Utility ..................................................................................................75
22.2 Working with KG 645 - Configuration Utility .................................................................................................76
22.3 Establishing Connection with Controller .......................................................................................................76
22.4 Editing Parameters .........................................................................................................................................76
22.5 Tools ...............................................................................................................................................................77
23 Interpretation of Parameters ........................................................................................................ 83
23.1 Module...........................................................................................................................................................83
23.2 Digital Inputs ..................................................................................................................................................85
23.3 Analog Inputs .................................................................................................................................................87
23.4 Outputs ..........................................................................................................................................................94
23.5 Timers ............................................................................................................................................................97
23.6 Generator.....................................................................................................................................................100
23.7 Mains ...........................................................................................................................................................105
23.8 Engine ..........................................................................................................................................................107
23.9 Maintenance ................................................................................................................................................112
23.10 Rotary Actuator..........................................................................................................................................113
23.11 Expansion Module .....................................................................................................................................117
KG-645 – EOL Flashing Utility
24 Menu Bar ................................................................................................................................... 121
25 Writing Configuration To Device.................................................................................................. 122
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Clarification of notation used within this publication.
Highlights an essential element of a procedure to ensure correctness
Indicates a procedure or practice, which, if not strictly observed,

could result in damage or destruction of equipment.
Indicates a procedure or practice, which could result in injury to

personnel or loss of life if not followed correctly.
Page 4 of 123
1 Introduction
This document presents information necessary for operating KOEL's KG-645 genset controller. It also provides
the user with the necessary background for using KG-645 genset controller in an application that involves
communication of the genset controller with an external system such as a server or a remote data
communication system.
KOEL's KG-645 is a modern and feature rich genset controller with user-friendly HMI and full graphics LCD. The
KG-645 controller comes bundled with highly versatile software & extensive I/O's and thereby supports a wide
variety of industry standard features in diesel/gasoline engine gensets. The KG-645 controller's smart software
offers flexibility to configure each individual input and output for a specific function or application. KG-645
controller also offers unique feature such as electronic governing for engines with mechanical fuel systems. With
the Rotary Actuator as an add-on for air/fuel charge control, these controllers can subsume the electronic
governing duty for the engine and offer tight speed governing performance. The KG-645 can be configured
through Windows PC utility (Refer section KG 645 - Configuration Utility). Also, all parameters can be configured
using the keypad of the genset controller.
1.1 Key Highlights of the Product

The KG-645 product is customized for Kirloskar Oil Engines Ltd to offer several key advantages to the end
user such as:
• Auto & manual start/stop modes for 1-ph & 3-ph gensets
• Electronic governor controller integration
• PC connectivity via USB port, RS485
• Expansion module interface
• Real time clock based event logs
• Configurable fuel theft alarm
• RPM sensing using frequency & MPU
• Backlit and full graphics display with power saving feature
Figure 1: Representative drawing of KG-645 genset controller's front
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2 Specifications
2.1 Terminals
The KG-645 hosts two types of terminal blocks as shown in figure 3 and figure 4 below.
2.1.1 5 mm pitch connector suitable for 2 sq mm wire
Figure 3: Representative photograph for 8-pin female (mating) connector of 5 mm pitch
Connector type/ Male (On genset Female (Mating) Male (On genset Female (Mating)
Manufacturer controller) controller)
Degson Phoenix
(Degson Electronics Co. Ltd.) (Phoenix Contact (I) Pvt. Ltd.)
2-Pin 2EDGVC-5.08-02P-14- 2EDGK-5.08-02P-14- 1755516 1754449
00AH 00AH
4-Pin 2EDGVC-5.08-04P-24- 2EDGK-5.08-04P-24- NA NA
00AH 00AH
2.1.2 3.5 mm pitch connector suitable for 0.5 – 1.5 sq mm wire
Figure 4: Representative photograph for 8-pin female (mating) connector of 3.5 mm pitch
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Connector type/ Male (On genset Female (Mating) Male (On genset Female (Mating)
Manufacturer controller) controller)
Degson Phoenix
(Degson Electronics Co. Ltd.) (Phoenix Contact (I) Pvt. Ltd.)
4-Pin 15EDGVC-3.5-04P-14- 15EDGK-3.5-04P-14- 1843622 1840382
00AH 00AH
6-Pin 15EDGVC-3.5-06P-14- 15EDGK-3.5-06P-14- 1843648 1840405
00AH 00AH
8-Pin 15EDGVC-3.5-08P-14- 15EDGK-3.5-08P-14- 1843664 1840421
00AH 00AH
10-Pin 15EDGVC-3.5-10P-14- 15EDGK-3.5-10P-14- 1843680 1840447
00AH 00AH
2.2 Power Supply Specifications

Controller terminal number 1, 2 (Ground and Battery positive respectively)
8 to 32 V-DC continuous
Supply voltage range
(Transient as per ISO 7637-2 test level IV @ 24 V-DC)
Cranking drop out period 50 mS
Maximum reverse voltage -32V DC continuous
Measurement accuracy ±1 % full scale
Resolution 0.1 V
~ 0.2 A @ 12 V-DC (Excluding the current load for the high side driver output's
Maximum current(with all
and rotary Actuator's output)
sensors disconnect)
~ 1.2 A @ 12 V-DC (Excluding the current load for the high side driver output's)
Standby current 60 mA @ 12 V-DC
Deep sleep current 15 mA @ 12 V-DC
3 Inputs
3.1 Generator Voltages And Frequency Measurements

Controller terminal number 27, 28, 29, 30 (N, B, Y, R respectively)
Measurement type True RMS
Sample Rate 5 kHz
Harmonics 10th
Input Impedance 0.3 MΩ
Phase to Neutral voltage 15 to 415 V-AC RMS
Phase to Phase voltage 15 to 750 V-AC RMS
Common mode offset from
100 V-AC
Earth
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Surge L-L and L-E As per CE / IEC requirements

Rate of updation of display 1 sec
Voltage accuracy ±1 % of full scale Phase to Neutral
Voltage resolution 1 V-AC RMS for Phase to Neutral
Frequency range 3 to 75 Hz
Frequency resolution 0.1 Hz
Frequency accuracy 0.25 % of full scale
Minimum voltage level
25 V-RMS
required to measure
For 1 phase genset application, it is mandatory to connect the genset phase and
neutral cables to the genset controller's phase R and Neutral terminals respectively.
3.2 Generator Current Measurement

Controller terminal number 35 and 36 (for phase B), 37 and 38 (for phase Y), 39 and 40 (for phase R)
Sample Rate 5 kHz
Harmonics 10th
Nominal CT secondary 5A
rating
Maximum continuous 6A
current
Overload Measurement 3 X Nominal Range setting
Absolute maximum 50 A for 1 sec. As per the short-circuit overload imposed by a 5 VA
overload
Burden 0.25 VA
Resolution 0.1 A
Accuracy ±1 % of Nominal
Follow the recommended phase sequence while connecting the Current

Transformer (CT).
3.3 Mains Voltage And Frequency Measurements

Controller terminal number 31, 32, 33, 34 (N, B, Y, R respectively)
Sample Rate 5 kHz
Harmonics 10th
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Input Impedance 0.3 MΩ

Phase to Neutral voltage 15 to 415 V- AC RMS
Phase to Phase voltage 15 to 750 V-AC RMS
Common mode offset from 100 V-AC
Earth
Surge L-L and L-E As per CE / IEC requirements
Rate of updation of display 1 sec
Voltage accuracy ±2 % of full scale
Voltage resolution 1 V-AC RMS for Phase to Neutral
Frequency resolution 0.1 Hz
Frequency accuracy 0.25 % of full scale
Minimum voltage level 25 V-RMS
required to measure
For 1 phase application, it is mandatory to connect the mains phase and neutral
cables to the genset controller's phase R and Neutral terminals respectively.
3.4 Digital Inputs

Controller terminal number 10, 11, 12, 21, 22
Number of inputs 5
Type Negative sensing (connect to ground for activation)
Low level threshold 0.8 V-DC maximum (Measured at the genset controller's terminal and battery
ground terminal)
Maximum input voltage VBATT
Minimum input voltage 0 V (BATT-)
Contact wetting current 2.5 mA typical
Open circuit voltage (VBATT – 1) V-DC
Surge As per ISO 7637-3
Protection Level Short circuit to BATT+ and BATT-
Software configurable Lub Oil Pressure Switch, High Temperature Switch and many more. Please refer
options section 43 for more details.
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3.5 Analogue Inputs
3.5.1 I/P: ANLG / DIG F

Controller terminal number 26 (CANOPY_Temp/LOP sensor)
Type Ratio-metric sensing
Arrangement Common mode measurement
Full scale 5 KΩ
Open circuit detection Above 5.5 KΩ or more
Resolution 0.1 Bar
Accuracy 1.5 % of full scale
Maximum common mode 2V
voltage
Display range 0 to 10 Bar
Connection method One should connect the sensor output terminals between the genset
controller's terminal and the battery ground terminal.
This input can be configured to accept input from lube oil pressure sensor or canopy temperature sensor or lube
oil temperature sensor.
3.5.2 I/P: ANLG (0–5V / 4–20 mA)

This input can be configured to accept lube oil pressure current input or analog voltage input.
3.5.2.1 Lube Oil Pressure (4–20 mA)

Controller terminal 23
number
Type Analog current sensing
Maximum input voltage 6 V (for 20 mA)
7.5 V (for 25 mA)
Maximum current limit 25 mA
Accuracy 1.5 % of full scale
Surge As per ISO 7637-3
3.5.2.2 Analog Voltage Input

Controller terminal number 23
Type Analog voltage sensing
Range 0 to 5 V-DC
Accuracy 0.5 % of full scale (5 V-DC)
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While generating genset paralleling application, this input can be configured to accept a 0-5 V-DC speed bias signal
generated by a load sharing module (LSM).
Controller terminal number 24 (Eng_temp sensor)

Full scale 5 KΩ
Open circuit detection Above 5.5 KΩ
Resolution 1 °C
Accuracy 1 % of full scale (for 50 to 1000 Ω)
15 % of measured value (for 2500 Ω)
17 % of measured value (for 5 KΩ)
Display range -5 to 300 °C (23 to 572 °F) depending on sensor
3.5.3 I/P: ANLG TEMP / DIG H
3.5.4 I/P: ANLG FL / DIG G

Controller terminal number 25 (Fuel_Level sensor)
Full scale 5 KΩ
Resolution 1 % of tank capacity
Accuracy ±1.5 % of full scale
Display range 0 to 100 %
3.6 Sensor Common

Controller terminal number 41 (Connection to Sensor Common)
Important Note: The sensor common point (SCP) terminal (Pin # 41) should be directly connected
to the point of engine body which is a common reference point for all the analog sensors. The wire
used for the SCP connection should not be shared with any other connection. The SCP connection
should not be taken from genset control panel ground because this will let sharing of it with other
connections. The connection should be done with a single wire being connected from pin# 41 to
the engine body.
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3.7 Magnetic Pick Up Input

Type Single ended
Input voltage range 200 mV to 70 V-AC RMS
Resolution 1 RPM
Accuracy 0.25 %
Flywheel teeth 1 to 300
The Magnetic Pick Up (MPU) is an inductive sensor fitted on the engine flywheel for the engine speed sensing. The output
of MPU is a sine-wave signal.
3.8 D+ Charge Alt

Voltage range 0 to 35 V
Excitation 2.5 W closed loop
Output power 2.5 W @ 12 V-DC
Resolution 0.1 V
Accuracy 2%
The D+ Charge Alt input is a combined input and output terminal.When the genset starts cranking, this terminal
provides the excitation current to the charge alternator field winding. Excitation will be given for max 2 sec or (Crank
hold time – 1) sec. Once excitation is stopped, after 2 sec, monitoring of D+ Charge Alt pin will begin. When the
charge alternator correctly charges the battery, the voltage of this terminal is close to or greater than the battery
supply voltage. This charging alt voltage is used to detect engine start condition. This detection happens in cranking
and crank rest duration as well. In case of failure of charge alternator, the voltage of this terminal is pulled down to
a low voltage by the charge alternator. This drop in voltage triggers the charge failure alarm in the genset controller.
The level at which this logic operates and whether it triggers a warning or shutdown alarm is configurable.
4 Outputs
4.1 Digital Outputs

Controller terminal number 3, 4, 5, 6, 8, 9
Number of outputs 6
Type High side driver
Rating 0.75 A
Maximum current 1A
Protection Level Overload, Overcurrent, Short circuit to BATT+ and BATT-
Software configurable Start Relay, Fuel Relay, Close Genset Contactor and many more. Please refer
options section 9.1.8 for more details.
Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID”

directly to the controller's output terminals.
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4.2 Actuator Outputs

Controller terminal number 17, 18, 19, 20
Type Stepper motor drive
Maximum current 1 A each coil
Actuator outputs are used only for rotary Actuator, if installed. The rotary Actuator is a 4-wire actuator that is
used for creating an electronic governing application in case of a mechanical fuel system engine. In diesel engines,
the rotary Actuator's shaft output gets mechanically connected to the stop lever or the throttle lever of an in-
line or rotary fuel injection pump. In case of petrol or natural gas engines, the rotary Actuator's shaft output gets
connected to the throttle/charge control valve.
Figure 5: Representing Actuator connector pin out when viewed from the terminal insertion side
The following table provides the connection details while connecting Actuator with KG-645 controller.
Actuator KG-645 Controller

Connector Pin No. Description Terminal Sr. No. Description
1 ACT 1 (Red coloured wire) 17 E-GOV OUT 1
4 ACT 4 (Yellow coloured wire) 18 E-GOV OUT 4
2 ACT 2 (Orange coloured wire) 19 E-GOV OUT 2
3 ACT 3 (Blue coloured wire) 20 E-GOV OUT 3
5 Communication Ports
Used to flash the firmware
USB USB 2.0 Type B for connection between controller and PC running KG
645 - Configuration Utility
RS485 Used for data communication
Controller terminal number for 15, 16
RS485
Used for communication between controller and the input/output
CAN expansion module* (Refer section 18)
Controller terminal number for CAN 13, 14
For further details please refer section Communication Protocol For KG-645 (section 16).
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6 Installation
6.1 Dimensions
Figure 6: Dimensions of the KG-645 genset controller
Recommended mounting panel cut-out dimensions: 118 mm X 93 mm
Page 14 of 123
6.2 Mounting on panel

To mount the controller into the panel use the fixing clips provided along with the controller. Follow the given
steps.
Figure 7: Representative drawing of Fixing clip and screw supplied along with controller
Figure 8: Representative drawing of controller mounting on the panel using the fixing clips
• Insert the fixing clip into the slot provided on the side of the controller.
• Pull the fixing clips backwards (towards the back of the module). Ensure that the fixing clip is properly
fitted inside the slot provided on the controller.
• Fix the screws and tighten the screw (turn clockwise) to mount the controller properly into the panel.
Ensure that the screw will be always perpendicular to the panel surface. The maximum tightening torque
is 0.19 N-m.
Over tightening of the screws may damage the controller casing.
Page 15 of 123
6.3 Terminal Description

Following figure shows the rear view of module.
Figure 9: Representative drawing of KG-645 genset controller from backside
The following table provides the details of controller's terminals.
Terminal Sr. Degson Female (Mating)

Name Description
No. Connector Part No.
1 BATT - Battery ground
2EDGK-5.08-02P-14-00AH
2 BATT + Battery positive
3 OUT A High side driver output – A
4 OUT B High side driver output – B

15EDGK-3.5-04P-14-00AH
5 OUT C High side driver output – C
6 OUT D High side driver output – D
7 D+ CHARGE ALT Input for charging alternator
8 OUT E High side driver output – E

15EDGK-3.5-04P-14-00AH
9 OUT F High side driver output – F
10 DIG_IN A Input from switch – A
11 DIG_IN B Input from switch – B

12 DIG_IN C Input from switch – C
15EDGK-3.5-06P-14-00AH
13 CAN H CAN high
14 CAN L CAN low
Page 16 of 123
Terminal Sr. Degson Female (Mating)

Name Description
No. Connector Part No.
15 RS485_B RS485 – B
16 RS485_A RS485 – A
17 E-GOV OUT 1 Output for the rotary Actuator
21 DIG_IN D Input from switch – D
22 DIG_IN E Input from switch – E
23 I/P: ANLG (0-5V / 4- Analog (0 to 5V) / (4 to 20mA) input
20mA) 15EDGK-3.5-10P-14-00AH
24 I/P: ANLG TEMP / DIG G Analog input from Engine Temperature
Sensor
25 I/P: ANLG FL / DIG H Analog input from Fuel Level Sensor
26 I/P: ANLG / DIG F Analog input from Canopy Temperature
Sensor / Lube Oil Pressure Sensor
27 GEN_V IN NTRL Voltage input from Gen Neutral
28 GEN_V IN B Voltage input from Gen Phase B

2EDGK-5.08-04P-24-00AH
29 GEN_V IN Y Voltage input from Gen Phase Y
30 GEN_V IN R Voltage input from Gen Phase R

31 MAINS_V IN NTRL Voltage input from Mains Neutral
32 MAINS_V IN B Voltage input from Mains Phase B

2EDGK-5.08-04P-24-00AH
33 MAINS_V IN Y Voltage input from Mains Phase Y
34 MAINS_V IN R Voltage input from Mains Phase R

35 GEN_CT_IN B1 CT input 1 from Gen Phase B
36 GEN_CT_IN B2 CT input 2 from Gen Phase B
37 GEN_CT_IN Y1 CT input 1 from Gen Phase Y
38 GEN_CT_IN Y2 CT input 2 from Gen Phase Y

39 GEN_CT_IN R1 CT input 1 from Gen Phase R 15EDGK-3.5-08P-14-00AH
40 GEN_CT_INR2 CT input 2 from Gen Phase R
41 EBP_IN Sensor Common
42 MPU_IN Input from engine speed sensor

(Inductive)
Page 17 of 123
6.4 Typical Wiring Diagram
6.4.1 Manual Control Application

3-phase Manual Control Application on engine with Analog resistive LOP sensor configuration.
Figure 10: Representative drawing of KG-645 genset controller when used in the 3-phase Manual Control Panel
Page 18 of 123
1-phase Manual Control Application on engine with Analog current LOP sensor configuration and Analog resistive
CANOPY Temperature sensor configuration.
Figure 13: Representative drawing of KG-645 genset controller when used in the 1-phase Manual Control Panel
Page 19 of 123
7 Module Display
Following section describes the layout of screens.
7.1 Power on screen

Screen 2: PRODUCT INFO
Screen 1: LOGO
(This screen displays product id, engine sr no,

date and real time clock)
7.2 Monitoring Mode

In monitoring mode, screens will scroll automatically after a predefined time which can be configured in
configuration menu. Also, “Navigation UP/DOWN Keys” are provided to scroll/browse the screens.
When the controller is displaying any monitoring screen except ALARMS screen, ENGINE STATUS screen will pop-
up when there is change in controller mode or alarm occurs or timer starts/stops.
ALARMS screen will pop-up when a new alarm is generated and then second priority will be for ENGINE STATUS
screen. It shall keep scrolling between ALARMS screen and ENGINE STATUS screen till there are one or more
active alarms unless manually cleared alarms or scrolled screens.
Monitoring mode screens are grouped and identified by different symbols at top left corner of screens. Test
mode and Off mode are also distinguished by different symbols at bottom left corner of screens. Following tables
provides more details.
Symbols for Screen's Group Name of Screen's Group
Status & Info screens
Generator screens
Mains screens
Engine screens
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Symbols for Mode Controller Mode
Test mode
Off mode
7.2.1 Group 1: Status & Info screens
7.2.1.1 Status and Operating Mode

This screen will show engine status or alarms along with the operating mode of the controller.
Screen 3: STATUS Screen 4: STATUS
(These screens will be visible in Manual mode)
(Test mode can be identified by symbol in bottom

(This screen will be visible in Test mode)
left corner)
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(This screen will be visible in Auto mode) (This screen will be visible in Manual mode)
(This screen will be visible in Manual mode) (This screen will be visible in Manual mode)
(Off mode can be identified by symbol in bottom

(This screen will be visible in Off mode) left corner)
Page 22 of 123
Screen 13: CONTACTORS Screen 14: GENERATOR VOLTAGE
(This screen will be visible only if output related to genset (The “Y” and “B” phase will be visible only if config-
and mains contactor are configured) ured for 3 phase genset)
Screen 15: Generator Kw Load Screen 16: Generator KVA Load
(The “Y” and “B” phase will be visible only if configured (The “Y” and “B” phase will be visible only if config-
for 3 phase genset) ured for 3 phase genset)
Screen 17: GENERATOR KVAr LOAD Screen 18: GENERATOR POWER FACTOR
(The “Y” and “B” phase will be visible only if configured (The “Y” and “B” phase will be visible only if config-
for 3 phase genset) ured for 3 phase genset)
Page 23 of 123
Screen 19: GENERATOR OUTPUT Screen 20: GENERATOR ENERGY
(The “Y” and “B” phase will be visible only if config-

ured for 3 phase genset. Minimum frequency out of 3
phases will be displayed on screen)
MAINS SCREENS
Screen 21: MAINS Screen 22: MAINS
(The “Y” & “B” phase will be visible only if configured

for 3 phase mains. This screen will display readings
only if “Mains monitoring” is enabled. Minimum fre-
quency out of 3 phases will be displayed on screen)
Screen 23: MAINS
(This screen will be visible if “Mains monitoring” is enabled and mains is not available or unhealthy. The “Y” &
“B” phase will be visible only if configured for 3 phase mains. )
Page 24 of 123
ENGINE SCREENS
Screen 24: ENGINE BATTERY Screen 25: CANOPY TEMPERATURE
(This screen will be visible only if “Canopy Temperature”

sensor is configured)
Screen 26: ENGINE TEMPERATURE Screen 27: ENGINE LUB OIL PRESSURE
(This screen will be visible only if “Engine tempera- (This screen will be visible only if “Lube Oil Pressure”
ture” sensor is configured) sensor is configured)
Screen 28: ENGINE REMAINING FUEL Screen 29:EXPANSION MODULE ANALO SENSOR 1
(This screen will be visible only if “Fuel Level” sensor (This screen will be visible only if Expansion module is
is configured) enabled and
“AN EX-S1” is configured as “Pressure Sensor”)
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Screen 30: EXT ANALOG SEN 1 Screen 31: ENGINE SPEED
(This screen will be visible only if Expansion module is

enabled and
“AN EX-S1” is configured as “Temperature Sensor”)
Rest of expansion module analog sensor's screens
would look same as above*.
Screen 32:ENGINE RUN TIME Screen 33: ALARM
Screen34 : ENGINE LUB OIL temperature
(This screen will be visible only if “Lube Oil Temperature” sensor is configured)
Page 26 of 123
8 Description of Control keys
Menu
Navigation
UP key
Menu
Navigation AUTO/MANU
DOWN key AL/
TEST mode
select key
STOP key
START key
8.1 Mode Selection diagram
Figure 16: Mode selection using control keys in KG-645
Stop long press 3 secs

Stop + Down long press 2 secs
Up + Down long press 2 secs
Auto long press 2 secs
Up long press 3 secs
Down long press 3 secs
Page 27 of 123
8.2 Functions of Control keys

Following table provides details of control keys in different modes.
# Mode Key input Function
1 Manual/Test Start Starts the engine
2 Auto Enters into Auto mode
3 Auto (long pressed) Enters into Test mode
Manual Immediate stops the engine when

4 Stop (long pressed)
engine is running
Enters into Off mode when engine
5 Stop (long pressed)
is off
Stops the engine and enters into
6 Manual/Auto Stop
Manual mode
7 Manual/Configuration Up/Down Scrolls the parameter
8 Manual/Off Down+Stop (long pressed) Enters into configuration mode
Displays last group's first screen
Up (long pressed) (Refer section 7.2 for more details
9 about screen's group)
Manual/Test/Auto/Off
Down (long pressed) Displays next group's first screen
Up+Down (simultaneously press and
10 Clears the alarms
release while on ALARMS screen)
11 Start Selects/saves the parameter
12 Configuration Up+Down (long pressed) Enters on event log page
13 Down+Stop (long pressed)
14 Auto Auto/stop
15 Deep sleep Any key Back to Manual mode
16 Test Stop
17
Off Auto
18 Stop (long pressed) Programming mode
19 Event log page Up+Down (long pressed) Back to configuration mode
20 Programming Up+Down (long pressed) Reset the controller
Page 28 of 123
9 Configuration Mode
To configure the controller please follow the below mentioned instructions.
Enter into the configuration mode (Refer section 8).
Screen 34: Configuration Mode Screen 35: Configuration mode: Authentication Page
To enter into edit mode press “START” key. If you wish to read the configuration press “STOP” key.
To access the configuration menu, please enter your 4-Digit PIN here using ''Navigation UP/DOWN” keys. Once
you enter into the “EDIT” mode scroll to the parameter that you wish to edit and press “START” key to edit the
parameter. At this moment the parameter will start blinking and you can change the parameter value using “UP”
and “DOWN” keys (Refer section 9.1 for configuring parameters).
After selecting the required value press “START” key to save parameter or “STOP” key to discard the value. After
completion of parameter configuration, exit from configuration mode. Before existing from configuration mode
controller will show you the following screen.
Screen 36: Saving Settings
Page 29 of 123
9.1 Configurable Parameters
9.1.1 Table 1 – List of Configurable Parameters

Level 0 Level 1 (On screen) Level 2 (On screen) Possible Value (On screen)
Module General Profile name (PROFILE NAME) Profile 1
Power on mode (POWER ON MODE) Manual, Auto
Power on lamp test (POWER ON LAMP Disable, Enable
TEST)
Deep sleep mode (DEEP SLEEP MODE) Disable, Enable
Expansion module (EXPANSION Disable, Enable
MODULE)*
Display Contrast (CONTRAST) 0 – 100 %
Power save mode (POWER SAVE MODE) Disable, Enable
RS485 Communication mode (COMM MODE) None, MODBUS
communication
Slave ID (MODBUS SLAVE ID) 1 – 247
(RS485 COMM)
Modbus baud rate (MODBUS BAUDRATE) 1200, 2400, 4800, 9600,
19200, 38400, 57600, 115200
Parity None, Even, Odd
Inputs DIG IN A Source (SOURCE) Refer Table 2
Polarity (POLARITY) Close To Activate, Open To
Activate
Action (ACTION) None, Warning, Electrical Trip,
Shutdown
Activation (ACTIVATION) Never, From Engine Start,
From Monitoring On, Always
Activation delay (ACTIVATION DELAY) 1 – 60 sec
DIG IN B Source (SOURCE) Refer Table 2
Activate
Shutdown
DIG IN C Source (SOURCE) Refer Table 2
Activate
Shutdown
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DIG IN D Source (SOURCE) Refer Table 2
Activate
Shutdown
DIG IN E Source (SOURCE) Refer Table 2
Activate
Shutdown
ENG TEMP/DIG G Sensor selection (SENSOR SELECTION) Not used, Dig In G, Anlg In Eng
Temp
(Digital) Source ((DIG) SOURCE) Refer Table 2
(Digital) Polarity ((DIG) POLARITY) Close To Activate, Open To
Activate
(Digital) Action ((DIG) ACTION) None, Warning, Electrical Trip,
Shutdown
(Digital) Activation ((DIG) ACTIVATION) Never, From Engine Start,
(Digital) Activation delay ((DIG) 1 – 60 sec
ACTIVATION DELAY)
Shutdown (SHUTDOWN) Disable, Enable
Shutdown threshold (SHUTDOWN 26 – 200 °C
THRESHOLD)
Warning (WARNING) Disable, Enable
Warning threshold (WARNING 25 – 199 °C
THRESHOLD)
Open circuit alarm (OPEN CKT ALARM) None, Warning, Electrical Trip,
Shutdown
Engine Temperature Sensor Calibration Refer Table 3
Fuel LVL/DIG H Sensor selection (SENSOR SELECTION) Not used, Dig In H, Anlg In Fuel
LVL
Activate
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Shutdown
ACTIVATION DELAY)
Shutdown threshold (SHUTDOWN 0 – 50 %
THRESHOLD)
Warning threshold (WARNING 2 – 55 %
THRESHOLD)
Fuel tank capacity (FUEL TANK CAPACITY) 0 – 1000 Litres
Fuel theft alarm (FUEL THEFT ALARM) Disable, Enable
Fuel theft threshold (FUEL THEFT 0 – 100 % per hour
THRESHOLD)
Fuel Consumption (FUEL CONSUMPTION) 0.0 – 100.0 Litres per hour
Fuel in liters (FUEL IN LITERS) Disable, Enable
Fuel Level Sensor Calibration Refer Table 4
Analog Sensor S1 Sensor selection (SENSOR SELECTION (pin Not used, LOP Sensor
(AN S1 (4 to 20 23))
mA))
Shutdown threshold (SHUTDOWN 0.0 – 4.8 Bar
THRESHOLD)
Warning threshold (WARNING 0.2 – 5.0 Bar
THRESHOLD)
Circuit fault alarm (CKT FAULT ALARM) None, Warning, Electrical Trip,
Shutdown
LOP (4 to 20mA) Sensor Calibration Refer Table 5
Analog Sensor S2 Sensor selection (SENSOR SELECTION (pin Not used, Dig In F, Anlg In
(AN S2 RES/DIG F) 26)) Canopy Temp, Anlg In Lube Oil
Temp, Anlg In LOP
Activate
Shutdown
ACTIVATION DELAY)
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Shutdown threshold (SHUTDOWN 0.0 – 4.8 Bar (for LOP) /
THRESHOLD) 26 – 200 °C (for Canopy Temp
/ Lube Oil Temp)
Warning threshold (WARNING 0.0 – 5.0 Bar (for LOP) /
THRESHOLD) 25 – 199 °C (for Canopy Temp /
Lube Oil Temp)
Shutdown
Canopy Temp Sensor Calibration/Lube Oil Refer Table 6
Temperature Sensor Calibration
LOP (Resistive) Sensor Calibration Refer Table 7 (for LOP)
Outputs OUT A Source (SOURCE) Refer Table 8
On activation (ON ACTIVATION) De-energise, Energise
OUT B Source (SOURCE) Refer Table 8
OUT C Source (SOURCE) Refer Table 8
OUT D Source (SOURCE) Refer Table 8
OUT E Source (SOURCE) Refer Table 8
OUT F Source (SOURCE) Refer Table 8
Timers Cranking timer Crank hold time (CRANK HOLD TIME) 1 – 15 sec
Crank rest time (CRANK REST TIME) 2 – 60 sec
Crank start delay (CRANK START DELAY) 0 – 30 sec
General timer Safety monitor start delay (SAFETY 10 – 60 sec
MONITOR DELAY)
Mains detect delay (MAINS DETECT 1 – 30 sec
DELAY)
Alternator detect delay (ALT DETECT 1 – 30 sec
DELAY)
Warm up delay (WARM UP DELAY) 0 – 60 sec
Return to mains delay (RETN -TO-MAINS 0 – 600 sec
DELAY)
Engine cooling time (ENG COOL TIME) 0 – 300 sec
Stop action time (STOP ACTION TIME) 10 – 120 sec
Load transfer delay (LOAD TRANSFER 0 – 60 sec
DELAY)
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Power save mode delay (PWR SAVE MODE 5 – 1800 sec
DELAY)
Screen changeover time (SCRN 1 – 1800 sec
CHNGOVER TIME)
Deep sleep mode delay (DEEP SLP MODE 5 – 1800 sec
DELAY)
Sounder alarm timer (SOUNDER ALARM 1 – 300 sec
TIMER)
Test mode timer (TEST MODE TIMER) 1 – 720 Min
Generator Alternator Alternator present (ALT PRESENT) No, Yes

configuration
Number of poles (NUMBER OF POLES) 2, 4, 6, 8 poles
(ALT CONFIG)
Alternator AC system (ALT AC SYSTEM) 1 Phase, 3 Phase
Minimum healthy voltage (MIN HEALTHY 80 – 450 V Ph-N
VOLT)
Minimum healthy frequency (MIN 0 – 60 Hz
HEALTHY FREQ)
Phase reversal detect (PHASE REVERSAL Disable, Enable
DETECT)
Phase reversal action (PHASE REVERSAL None, Warning, Electrical Trip,
ACTION) Shutdown
Alternator voltage lost shutdown (ALT Disable, Enable
VOLT LOST SHUTDOWN)
Auto load transfer (AUTO LOAD Disable, Enable
TRANSFER)
Voltage monitoring Under voltage shutdown (UNDER VOLT Disable, Enable
(VOLT MONITOR) SHUTDOWN)
Under voltage shutdown threshold (UV 0 – 398 V Ph-N
SHUTDOWN THRESHOLD)
Under voltage warning (UNDER VOLT Disable, Enable
WARNING)
Under voltage warning threshold (UV 2 – 400 V Ph-N
WARNING THRESHOLD)
Over voltage shutdown (OVER VOLT Disable, Enable
SHUTDOWN)
Over voltage shutdown threshold (OV 102– 800 V Ph-N
SHUTDOWN THRESHOLD)
Over voltage warning (OVER VOLT Disable, Enable
WARNING)
Over voltage warning threshold 100 – 798 V Ph-N
(OV WARNING THERSHOLD)
Frequency Under frequency shutdown (UNDER FREQ Disable, Enable
monitoring SHUTDOWN)
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(FREQ MONITOR) Under frequency shutdown threshold (UF 0.0 – 59.0 Hz
SHUTDOWN THRESHOLD)
Under frequency warning (UNDER FREQ Disable, Enable
WARNING)
Under frequency warning threshold (UF 1.0 – 60.0 Hz
WARNING THRESHOLD)
Over frequency shutdown (OVER FREQ Disable, Enable
SHUTDOWN)
Over frequency shutdown threshold (OF 26.0 – 70.0 Hz
SHUTDOWN THRESHOLD)
Over frequency warning (OVER FREQ Disable, Enable
WARNING)
Over frequency warning threshold (OF 25.0 – 69.0 Hz
WARNING THRESHOLD)
Current monitoring CT ratio (CT RATIO) 1 – 8000
(CURR MONITOR)
Over current threshold (OVER CURR 5 – 10000 A
THRESHOLD)
Over current delay (OVER CURR DELAY) 1 – 600 sec
Over current action (OVER CURR ACTION) None, Warning, Electrical Trip,
Shutdown
Unbalanced load action (UNBAL LOAD None, Warning, Electrical trip,
ACTION) Shutdown
Unbalanced load threshold (UNBAL LOAD 5 – 200 %
THRESHOLD)
Unbalanced load delay (UNBAL LOAD 1– 600 sec
DELAY)
RESERVED NA
Load monitoring Generator rating (GEN RATING) 1.0 – 800.0 kW
(LOAD MONITOR)
Over load threshold (OVERLOAD 50 – 150 %
THRESHOLD)
Overload monitoring delay (OVERLOAD 1 – 600 sec
MON DELAY)
Overload action (OVERLOAD ACTION) None, Warning, Electrical trip,
Shutdown
Mains Mains Mains monitoring (MAINS MONITORING) Disable, Enable
Configuration
Mains AC system (MAINS AC SYSTEM) 1 Phase, 3 Phase
(MAINS CONFIG)
Phase reversal detect (PHASE REVERSAL Disable, Enable
DETECT)
Phase reversal action (PHASE REVERSAL None, Notification
ACTION)
Under voltage Enable (ENABLE) No, Yes
monitoring
Trip (TRIP) 48 – 398 V Ph-N
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(UNDER VOLT Return (RETURN) 50 – 400 V Ph-N
MON)
Over voltage Enable (ENABLE) No, Yes
monitoring
Trip (TRIP) 102 – 800 V Ph-N
(OVER VOLT MON)
Return (RETURN) 100 – 798 V Ph-N
Under frequency Enable (ENABLE) No, Yes
monitoring
Trip (TRIP) 27.0 – 67.0 Hz
(UNDER FREQ
MON) Return (RETURN) 28.0 – 68.0 Hz
Over frequency Enable (ENABLE) No, Yes
monitoring
Trip (TRIP) 30.0 – 70.0 Hz
(OVER FREQ MON)
Return (RETURN) 29.0 – 69.0 Hz
Engine Crank disconnect Start attempts (START ATTEMPTS) 1–9
(CRANK
Disconnect on oil pressure (DISCONN ON Disable, Enable
DISCONNECT)
LOP SENS)
Disconnect oil pressure (DISCONN LOP 0.5 – 10.0 Bar
SENS)
Reserved (RESERVED) NA
Disconnect on oil pressure switch Disable, Enable
(DISCONN ON LLOP SW)
LLOP switch transient time (LLOP SW 0.0 – 3.0 Sec
TRANS TIME)
Alternator frequency (ALT FREQUENCY) 0 – 70 Hz
Engine speed (ENGINE SPEED) 0 – 4000 RPM
Disconnect on charging alternator voltage Disable, Enable
(DISCONN ON CHG ALT VOLT)
Charging alternator threshold (CHG ALT 5.0 – 30.0 Volt
THRESHOLD)
Speed monitoring Speed sense source (SPEED SENSE Magnetic pickup, Alternator
(SPEED MONITOR) SOURCE) frequency (Alt Freq)
Flywheel teeth (FLYWHEEL TEETH) 1– 300
Under speed shutdown (UNDER SPEED Disable, Enable
SHUTDOWN)
Under speed threshold (UNDER SPEED 0 – 3600 RPM
THRESHOLD)
Under speed delay (UNDER SPEED DELAY) 1– 60 Sec
Over speed level 1 threshold (OVER SPEED 800 – 4000 RPM
THRESHOLD)
Over speed delay (OVER SPEED DELAY) 1 – 60 Sec
Over speed level 2 threshold (Gross OS 100 – 200 %
THRESHOLD)
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Healthy speed threshold (HEALTHY SPEED 300 – 4000 RPM
THRES)
Battery monitoring Low volt action (LOW VOLT ACTION) None, Warning, Electrical Trip,
(BATTERY Shutdown
MONITOR)
Low volt threshold (LOW VOLT 8.0 – 24.0 V
THRESHOLD)
Low volt delay (LOW VOLT DELAY) 5 – 1800 Sec
High volt action (HIGH VOLT ACTION) None, Warning, Electrical Trip,
Shutdown
High volt threshold (HIGH VOLT 12.0 – 36.0 V
THRESHOLD)
High volt delay (HIGH VOLT DELAY) 5 – 1800 Sec
Charge alternator Fail action (FAIL ACTION) None, Warning, Electrical Trip,
monitoring Shutdown
(CHARGE ALT
Fail threshold (FAIL THRESHOLD) 4.0 – 28.0 V
MON)
Fail delay (FAIL DELAY) 5 – 60 Sec
Preheat Preheat timer (PREHEAT TIMER) 1 – 60 Sec
(PREHEAT)
Engine Temperature limit (ENG TEMP Disable, Enable
LIMIT)
Engine Temperature limit (ENG TEMP 0 – 300 °C
LIMIT)
Maintenan Maintenance Action (ACTION) Notification, Warning
ce alarm (MAINT
Due at engine hours (DUE AT ENGINE 10 – 65000 hrs
ALARM)
HOURS)
Alarm due date Current day onwards
(ALARM DUE DATE)
Rotary General Actuator application (ACTUATOR APPLN) As E-Governor, As Start/Stop
Actuator (GENERAL) Device
}
Actuator speed (ACTUATOR SPEED) 1 – 10 x25 Hz
Actuator direction (ACTUATOR Clockwise, Anti–Clockwise
DIRECTION)
Engine start Cranking steps (CRANKING STEPS) 10 – 5000
strategy (ENG
Reserved parameter NA
START STRGY)
Init low speed delay (INIT LOW SPEED 0 – 180 Sec
DELAY)
Init low speed (INIT LOW SPEED) 500 – 1800 RPM
CRANK SENSE SPEED 20 – 2800 RPM
Ramp up time (RAMP UP TIME) 1 – 180 Sec
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Generator E- Speed set point select (SPEED SET POINT Fixed (0% droop), Speed bias
governor SELECT) Inp (0-5V), Load based droop
configuration
Droop (DROOP) 0–4%
(GEN EGOV CNFG)
Target speed (TARGET SPEED) 500 – 4000 RPM
Proportional gain (PROPORTIONAL GAIN) 0 – 1000
Integral gain (INTEGRAL GAIN) 0 – 2000
Derivative gain (DERIVATIVE GAIN) 0 – 1000
Friction set off (FRICTION SETOFF) 0 – 1000
Gain schedule trigger (GAIN SCHEDULE 0.0 – 100.0 % RPM error
TRIGGER)
Loading factor (LOADING FACTOR) 0 – 1000
Unloading factor (UNLOADING FACTOR) 0 – 1000
Engine E-governor Target speed (TARGET SPEED) 500 – 4000 RPM
configuration
Proportional gain (PROPORTIONAL GAIN) 0 – 1000
(ENG EGOV CNFG)
Integral gain (INTEGRAL GAIN) 0 – 2000
Derivative gain (DERIVATIVE GAIN) 0 – 1000
Friction set off (FRICTION SETOFF) 0 – 1000
Gain schedule trigger (GAIN SCHEDULE 0.0 – 100.0 % RPM error
TRIGGER)
Loading factor (LOADING FACTOR) 0 – 1000
Unloading factor (UNLOADING FACTOR) 0 – 1000
Start/stop device Running steps (RUNNING STEPS) 0 – 500
configuration
(STR/STP DEVICE
CNFG)
Expansion DIG IN EX-A Source (SOURCE) Refer Table 2
digital
inputs (EXP
Activate
DIG
INPUTS) Action (ACTION) None, Warning, Electrical Trip,
Shutdown
DIG IN EX-B Source (SOURCE) Refer Table 2
Activate
Page 38 of 123
Shutdown
DIG IN EX-C Source (SOURCE) Refer Table 2
Activate
Shutdown
DIG IN EX-D Source (SOURCE) Refer Table 2
Activate
Shutdown
DIG IN EX-E Source (SOURCE) Refer Table 2
Activate
Shutdown
Expansion AN EX-S1/DIG EX-F Sensor selection (SENSOR SELECTION) Not used, Dig In EX-F, Pressure
analogue sensor, Temperature sensor
inputs (EXP
ANLG
INPUTS) (Digital) Polarity ((DIG) POLARITY) Close To Activate, Open To
Activate
Shutdown
ACTIVATION DELAY)
Action None, Warning, Electrical Trip,
Shutdown
Threshold (THRESHOLD) 0.0 – 10.0 Bar (for Pressure) /
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-5.0 – 1000.0 °C (for
Temperature)
Threshold type Less Than Threshold, Greater
Than Threshold
Shutdown
Pressure Sensor Calibration / Refer Table 7 (for Pressure) /
Temperature Sensor Calibration Refer Table 9 (for Temperature)
AN EX-S2/DIG EX-G Sensor selection (SENSOR SELECTION) Not used, Dig In EX-G, Pressure
sensor, Temperature sensor
Activate
Shutdown
ACTIVATION DELAY)
Shutdown
-5.0 – 1000.0 °C (for
Temperature)
Than Threshold
Shutdown
AN EX-S3/DIG EX-H Sensor selection (SENSOR SELECTION) Not used, Dig In EX-H, Pressure
Activate
Shutdown
ACTIVATION DELAY)
Page 40 of 123
Shutdown
-5.0 – 1000.0 °C (for
Temperature)
Than Threshold
Shutdown
AN EX-S4/DIG EX-I Sensor selection (SENSOR SELECTION) Not used, Dig In EX-I, Pressure
Activate
Shutdown
(Digital) Activation delay ((DIG) 1– 60 sec
ACTIVATION DELAY)
Shutdown
-5.0 – 1000.0 °C (for
Temperature)
Than Threshold
Shutdown
AN EX-S5/DIG EX-J Sensor selection (SENSOR SELECTION) Not used, Dig In EX-J, Pressure
Activate
Shutdown
Page 41 of 123
ACTIVATION DELAY)
Shutdown
-5.0 – 1000.0 °C (for
Temperature)
Than Threshold
Shutdown
Expansion OUT EX-A Source (SOURCE) Refer Table 8
digital
Polarity (POLARITY) De-energise, Energise
outputs
(EXP OUT EX-B Source (SOURCE) Refer Table 8
OUTPUTS) Polarity (POLARITY) De-energise, Energise
OUT EX-C Source (SOURCE) Refer Table 8
OUT EX-D Source (SOURCE) Refer Table 8
OUT EX-E Source (SOURCE) Refer Table 8
Password Password 1 #### 0 – 9 for each digit
Password 2 #### 0 – 9 for each digit
Page 42 of 123
Table 2 – Digital Input Sources Selection

# Source (On screen)
1 Not used
2 User configured
3 Low fuel level switch (Low fuel LVL Switch)
4 Low lube oil pressure switch (Low Lube Oil Press Switch)
5 High engine temperature switch (High Engine Temp Switch)
6 Water level switch (Water LVL Switch)
7 Emergency stop switch (Emergency Stop)
8 Remote Start / Stop
9 Simulate Start
10 Simulate Stop
11 Simulate Auto
12 Close generator / open mains switch (Close Gen/Open Mains Switch)
13 Close mains / open generator switch (Close Mains/Open Gen Switch)
14 Simulate Mains
15 Reserved
16 High canopy temperature
17 V-Belt broken switch
Table 3 – Engine Temperature Sensor

Resistance (Ω) Temperature° C
0 – 5000 (R1-R10) -25 – 200 °C (T1-T10)
Table 4 – Fuel Level Sensor Calibration

Resistance (Ω) Fuel level (%)
0 – 5000 (R1-R10) 0 – 100 % (L1-L10)
Table 5 – LOP (4 to 20 mA) Sensor Calibration

Current (mA) Pressure (Bar)
4 – 20 (I1-I10) 0.0 – 10.0 Bar (V1-V10)
Table 6 – CANOPY Temperature Sensor Calibration/Lube Oil Temperature Sensor

Calibration
0 – 5000 (R1-R10) -25 – 200 °C (V1-V10)
Page 43 of 123
Table 7 – LOP (Resistive) Sensor Calibration

Resistance (Ω) Pressure (Bar)
0 – 5000 (R1-R10) 0.0 – 10.0 Bar (V1-V10)
Table 8 – Digital Output Source Selection

# Output source (On screen)
1 Disable
2 Sounder alarm
3 Battery over voltage
4 Battery under voltage
5 Charge alt shutdown
6 Charge alt warning
7 Close genset contactor (Close Gen Contactor)
8 Close mains contactor
9 Mains failure
10 Common alarm
11 Common electrical trip
12 Common shutdown
13 Common warning
14 Cooling down
15 Digital input A (Dig In A)
16 Digital input B (Dig In B)
17 Digital input C (Dig In C)
18 Digital input D (Dig In D)
19 Digital input E ((Dig In E)
20 Digital input F (Analog Sensor 2 In) (Dig In F (Anlg S2 In))
21 Digital input G (Analog In Engine Temp) (Dig In G (Anlg In Eng Temp))
22 Digital input H (Analog In Fuel Level) (Dig In H (Anlg In Fuel LVL))
23 Emergency stop
24 Stop solenoid
25 Fail to start
26 Fail to stop
27 Fuel relay
28 Generator available (Gen Available)
29 Generator R Phase over voltage shutdown (R Phase OV Shutdown)
30 Generator R Phase under voltage shutdown (R Phase UV Shutdown)
31 Generator Y Phase over voltage shutdown (Y Phase OV Shutdown)
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32 Generator Y Phase under voltage shutdown (Y Phase UV Shutdown)

33 Generator B Phase over voltage shutdown (B Phase OV Shutdown)
34 Generator B Phase under voltage shutdown (B Phase UV Shutdown)
35 Generator over current (Gen Over Current)
36 High engine temperature (High Engine Temp)
37 Low fuel level (Low Fuel LVL)
38 Low lube oil pressure (Low LOP)
39 Main high voltage (Mains High Volt)
40 Mains low voltage (Mains Low Volt)
41 Oil pressure open circuit
42 Open generator contactor (Open Gen Contactor)
43 Open mains contactor
44 Over frequency shutdown (Over Freq Shutdown)
45 Over speed shutdown
46 Gross over speed shutdown
47 Start relay
48 Temperature sensor open circuit (Temp Sensor Open Circuit)
49 Under frequency shutdown (Under Freq Shutdown)
50 Under speed shutdown
51 Maintenance due (Maintenance Due)
52 Stop mode
53 Auto mode
54 Manual mode
55 Reserved
56 Preheat output
57 Dig In EX-A*
58 Dig In EX-B*
59 Dig In EX-C*
60 Dig In EX-D*
61 Dig In EX-E*
62 Dig In EX-F (AN EX-S1 RES)*
63 Dig In EX-G (AN EX-S2 RES)*
64 Dig In EX-H (AN EX-S3 RES)*
65 Dig In EX-I (AN EX-S4 RES)*
66 Dig In EX-J (AN EX-S5 RES)*
67 Expansion module available (Exp Module Available)*
68 Oil Pressure Circuit Open
Page 45 of 123
Table 9 – Temperature Calibration (Expansion Module)*

0 – 5000 (R1-R10) -5 – 1000 °C (V1-V10)
*All the expansion module relevant parameters will be applicable, if KG-645 is connected to expansion module.
10 Module Operation in manual Mode

In this mode if Start key is pressed, genset will be cranked. Once the preconfigured engine alternator voltage or
frequency or RPM or lube oil pressure is detected, then engine will be on. Controller will latch the genset
contactor when genset loading voltage and frequency are above the minimum healthy thresholds. Genset
contactor will get latched only when Auto Load Transfer option is enabled. Engine run hours will start
incrementing when the genset voltage becomes greater than Min Healthy Voltage. During genset running,
if Stop key is pressed, Genset contactor if latched will get open after the Load Transfer Delay and
then Engine Cooling Timewill start. After this, controller will command genset to stop.
When Genset is not running and Mains is healthy and Mains Monitoring is enabled, Mains contacor will get
lached. Similarly, if Mains is found to be unhealthy Mains contactor will be opened.
If Mains Monitoring is disabled, then Mains contactor will not be operated in this mode.
During Crank time, if the Stop key is pressed or warning alarm occurs or shutdown alarm occurs controller will
not issue start command. To start the genset it is necessary to clear all the alarms manually and press the Start
key again.
11 Module Operation in Auto Mode

To enter into Auto mode press “AUTO” key (Refer section 8). The controller can be used in following
configurations while in Auto mode.
• Auto Mains Failure (AMF)
• Remote start/stop
• RS485 start/stop
11.1 Auto Mains Failure (AMF)

When the Mains Monitoring is enabled in the Mains Configuration (Refer section 9.1 and 22.7.1) and the
controller is in the Auto mode, AMF mode gets activated.
In this mode, if the mains healthy condition is present then the genset remains in Stop mode. When the mains
unhealthy condition occurs, mains contactor will get opened and genset will be cranked. Once the preconfigured
engine alternator voltage or frequency or RPM or lube oil pressure is detected, then engine will be on. Once, the
genset loading voltage and frequency are above the minimum healthy thresholds, warm-updelay will start. At
the end of this delay, controller will latch the genset contactor. Engine run hours will start incrementing when
the genset voltage becomes greater than Min Healthy Voltage. During genset running, if the mains voltage
returns, Mains Detect Delay will start first. If the mains is found to be healthy for this delay then Return To Mains
Delay timer will start. After this, genset contactor will get opened and after the Load Transfer Delay, mains
contactor will get latched and controller will command genset to stop after Engine Cooling Time.
When the genset is taking Engine Cooling Time due to electrical trip and if mains healthy condition is detected,
then mains contactor will get latched. In this case, if mains unhealthy condition is detected again, then mains
contacor will get unlatched again.
Page 46 of 123
During Crank Hold Time, if the mains voltage recovers or any stop command or shutdown alarm occurs controller
will not issue start command. To start the genset it is necessary to clear all the alarms manually and put the
controller in Auto mode again.
Once the Mains Monitoring is disabled, then enable option will not appear in configuration menu. To enable the
Mains Monitoring again, enable and configure at least one parameter from mains voltage or frequency
monitoring.
Mains healthy condition will be decided by mains under/over voltage/frequency thresholds. If the Under Voltage
monitoring is disabled, controller will display MAINS HEALTHY condition for Under Voltage condition also.
Controller will detect unhealthy condition of enabled parameters only.
11.2 Remote start/stop

To use the Remote start/stop mode of the controller, first configure one of the digital input as Remote Start/Stop
and put the controller in the Auto mode.
In this mode, once the Remote start/stop input is configured the GCU will enter into Remote start/stop mode
only after pressing the auto key . Also the mains monitoring should be disable. The mains contactor will be
latched or unlatched as per the Remote start/stop input only after entering in the auto mode.
Screenshot configuration utility representing digital input configured as Remote Start/Stop (Refer figure 17).
Figure 17: Digital input configuration screen in KG 645 - Configuration Utility
12 Paralleling support / Speed bias mode

The KG-645 controller offers unique feature of electronic governing for engines with mechanical fuel systems. In
conjunction with the external Load Sharing Module, KG-645 controller can control speed of engine and supports
genset synchronisation and paralleling feature.
Electronic speed governing (E-governor) system is especially applicable to engines used in genset. This system
provides precise, fast-acting control of engine speed. This system can be configured for fixed speed (0% droop)
application or paralleling support mode. In paralleling support mode, the system maintains the speed in
accordance to the speed bias signal provided by supervisory control/Load Sharing Module (LSM).
12.1 Paralleling concept

Paralleling is the operation in which multiple gensets, usually two or more, are synchronized and then connected
to a common bus. The frequency, voltage, phase angle and phase rotation of all the genset must match within
prescribed limits before they can be paralleled. By considering linear relation between speed of the engine and
Page 47 of 123
frequency of the alternator output, the speed must be controlled until the genset is paralleled with the grid or
other genset with the help of electronic governor. A Load Sharing Module controls the speed and the voltage of
the genset by controlling the AVR and E-governor of the gesnet. To control these two devices the LSM provides
the DC analog voltage signal to the both devices. The analog voltage signal is generally in the range of 0-5 V.
Figure 18: Representing Analog Voltage Input terminal of KG-645
12.2 Configuration in KG-645

Following is the stepwise procedure for configuring KG-645 for paralleling operation.
 Select the Actuator Application as a E-Governor (Refer figure 19). Configure Actuator speed and direction.
 Configure generator E-Governor related parameters. Select Set Speed Selection as Speed Bias Input (0-5 V).
Set the Target Speed. Then depending upon the voltage applied at terminal no. 23, the RPM will be decided.
Genset will run at RPM less than 100 by Target RPM when 0V is applied and will run at RPM greater than
100 than Target RPM when the 5V is applied. There will be linear relationship between RPM and applied
voltage (0-5 V).
 Provide 0-5 V analog signal from the LSM to KG-645 controller at terminal no. 23, as a speed bias signal
(Refer figure 18).
Figure 19: Representing Analog Voltage Input terminal of KG-645
Page 48 of 123
13 Module Operation In Test Mode

To enter into Test mode, press and hold “AUTO” key for longer duration (minimum 3 sec), when the engine is off.
Once the controller is in Test mode, “START” key's and “AUTO” key's LED will start blinking. Then, user can start
and test the engine by pressing “START key”. The controller will remain in this mode, for the preconfigured Test
Mode Timer (Refer section 8). If STOP key is pressed while Test Mode Timer is running, controller will stop engine
and will return to Manual mode again.
14 Deep Sleep Mode

Deep Sleep Mode is a useful feature to prolong the battery life.
In this mode, normal functions of the controller are suspended and controller is placed into its lowest power
consumption state. Controller maintains the status and alarms it had before Deep Sleep Mode. When the controller
is waked up, normal operations are resumed automatically.
The controller goes in Deep Sleep Mode if this mode is enabled in controller's configuration and there is no user
interaction for the preset Deep Sleep Mode Delay.
When remote start/stop input is used and mains monitoring is disabled
Device enters into deep sleep mode on enabling in all conditions except:
• Auto Mode
• Any mode with main contactor configured to an output and mains monitoring enabled
• Configuration mode
• Programming mode
• When remote start/stop input is configured and mains monitoring is disabled
Press any key to wake up the controller from Deep Sleep Mode.
15 Alarms
KG-645 controller allows to configure several Shutdown/Electrical trip, Warning and Notification alarms such as
Low Oil Pressure shutdown, Over Load warning and many more.
An alarm condition occurs when the preconfigured parameter is out of preset level. On initiation of an alarm,
the Alarm LED will start blinking and Sounder alarm will be activated if configured. The controller will display
name of alarms along with count on ALARMS screen and the nature of alarm on STATUS screen. For
acknowledging the alarms, press “UP+DOWN” key (in case of sounder alarm). All the alarms will be activated at
the end of Safety Monitoring Delay duration. The controller will not issue the start command if any of alarm left
unacknowledged.
# Alarm Actions Description

Genset is taken off load and immediately stopped by skipping Engine
1 Shutdown
Cooling Time.
Genset is taken off load and engine cooling timer begins, after which
2 Electrical trip
genset is stopped.
Warning alarms serves to draw operator's attention to an undesirable
3 Warning
condition without affecting genset's operation.
4 Notification Controller will display message on the display screen.
Page 49 of 123
Sr. Action
Alarms Causes
No. Options
Indicates that the oil pressure measured is below the
Shutdown
1 Low Oil Pressure preset threshold. This condition is detected only when
Warning
engine is off.
Indicates that the oil pressure measured is below the Shutdown
Low Oil Pressure
2 preset threshold. This condition is detected only when Electrical Trip
(Switch)
engine is off. Warning
Shutdown
3 Oil Pressure Ckt Open The oil pressure sensor is detected as not being present Electrical Trip
Warning
Indicates that the engine temperature is above the preset Shutdown
4 High Eng Temp
threshold. This condition is detected only when engine is on. Warning
Shutdown
High Eng Temp Indicates that the engine temperature is above the preset
5 Electrical Trip
(Switch) threshold. This condition is detected only when engine is on.
Warning
Shutdown
Eng Temp/ pin24-Ckt
6 The temperature sensor is detected as not being present Electrical Trip
Opn
Warning
Indicates that the amount of fuel level is below the preset Shutdown
7 Low Fuel level
threshold. This condition is detected only when engine is on. Warning
Shutdown
Indicates that the amount of fuel level is below the preset
8 Low Fuel level (Switch) Electrical Trip
threshold. This condition is detected only when engine is on.
Warning
9 Fuel Theft The fuel consumption has exceeded the preset threshold Warning
Shutdown
Low Water Level Indicates that radiator water level is below the preset
10 Electrical Trip
Switch threshold
Warning
High Canopy Indicates that canopy temperature is above the preset Shutdown
11
Temperature threshold Warning
Shutdown
High Canopy Indicates that canopy temperature is above the preset
12 Electrical Trip
Temperature (Switch) threshold
Warning
Shutdown
The canopy temperature sensor is detected as not being
13 Canopy Temp Ckt Open Electrical Trip
present
Warning
Shutdown
Anlg S1/ pin23-Ckt Opn
14 Analog sensor S1 is detected as not being present Electrical Trip
/ Gnd
Warning
Shutdown
Anlg S2 / pin26-Ckt
15 Analog sensor S2 is detected as not being present Electrical Trip
Open
Warning
Auxiliary Input (for Shutdown
Configured auxiliary input has triggered longer than preset
16 eg.Aux_A) /user Electrical Trip
duration
defined name Warning
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Sr. Action
Alarms Causes
No. Options
When emergency stop switch is pressed and immediate
17 Emergency Stop shutdown is required. This condition is detected in both Shutdown
conditions- engine on and off.
It is detected that genset is still running after sending stop
18 Fail To Stop Shutdown
command
Indicates that genset has not started after the preset
19 Fail To Start Shutdown
number of Start Attempts
Indicates that genset (R) Phase voltage has exceeded the Shutdown
20 R Phase Over Voltage
preset over voltage threshold. Warning
Indicates that genset (Y) Phase voltage has exceeded the Shutdown
21 Y Phase Over Voltage
preset over voltage threshold Warning
Indicates that genset (B) Phase voltage has exceeded the Shutdown
22 B Phase Over Voltage
preset over voltage threshold Warning
Indicates that geset (R) Phase voltage has fallen below Shutdown
23 R Phase Under Voltage
preset under voltage threshold. Warning
Indicates that geset (Y) Phase voltage has fallen below Shutdown
24 Y Phase Under Voltage
preset under voltage threshold Warning
Indicates that geset (B) Phase voltage has fallen below Shutdown
25 B Phase Under Voltage
preset under voltage threshold Warning
Shutdown
26 DG Phase Reversed Alternator phase sequence (R-Y-B) is not correct Electrical Trip
Warning
27 Mains Phase Reversed Indicates the mains unhealthy condition Notification
Indicates that genset output frequency has exceeded the Shutdown
28 Over Frequency
preset threshold Warning
Indicates that genset output frequency has fallen below the Shutdown
29 Under Frequency
preset threshold Warning
Shutdown
Indicates that genset current has exceeded the preset
30 Over Current Electrical Trip
shutdown threshold
Warning
Shutdown
Anlg S1 / pin23-Over Indicates that analog sensor S1 current input has exceeded
31 Electrical Trip
Curr threshold (25mA)
Warning
Shutdown
Indicates that the measured kW load rating has exceeded
32 Over Load Electrical Trip
the preset threshold
Warning
Shutdown
Load on any phase is greater or less than other phases by a
33 Unbalanced Load Electrical Trip
threshold value
Warning
Indicates that genset speed has exceeded the preset over
34 Over Speed speed threshold. Genset will shutdown after Over Speed Shutdown
Delay.
Indicates that genset speed has exceeded the preset Gross
35 Gross Over Speed Shutdown
Over Speed Threshold. Genset will shutdown immediately
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Sr. Action
Alarms Causes
No. Options
without any delay.
36 Under Speed The engine speed has fallen below the preset RPM Shutdown
Shutdown
The charge alternator voltage has dropped below the preset
37 Charge Fail Electrical Trip
threshold
Warning
38 No Speed Signal Indicates that speed sensor connections are absent Shutdown
Shutdown
Indicates that there is failure of the V-belt, which is driving
39 V Belt Broken Electrical Trip
the charging alternator
Warning
Shutdown
40 Battery Under Voltage The battery voltage has fallen below the preset threshold Electrical Trip
Warning
Shutdown
41 Battery Over Voltage The battery voltage has exceeded the preset threshold Electrical Trip
Warning
This indicates that alternator voltage have not crossed 50 V-
42 Alt Voltage Lost Shutdown
RMS within 2 seconds after crank disconnect event
High Oil Press Lube oil pressure is detected above the crank disconnect
43 Warning
Detected threshold when the engine is off.
This indicates that engine speed have not crossed preset
44 Engine Speed Fault Healthy Speed Threshold within 2 seconds from the crank Shutdown
disconnect event
Controller has detected engine speed even when the start
45 Eng Speed Detected Warning
command is not issued.
Indicates that engine running hours has exceeded the preset
Notification
46 Maintenance Due hours limit or maintenance due date has occurred and filter
Warning
servicing is required.
Indicates that lube oil temperature is above the preset Shutdown
47 High Lube Oil Temp
threshold Warning
Expansion module is enabled in the controller configuration
48 Exp Module Comm but controller is not receiving any response from the Notification
Error* expansion module.
Auxiliary Input* (for Shutdown
The user configured digital input from expansion module is
49 eg.Aux_XA) /user Electrical Trip
activated longer than the preset duration
defined name) Warning
Shutdown
Anx S1/S2/S3/S4/S5 Analog sensor EX-(S1/S2/S3/S4/S5) from expansion module
50 Electrical Trip
Ckt Opn* is detected as not being present
Warning
Note: Only warning alarms will get auto cleared.
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16 Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Sr.
Fault Remedial Actions
No.
Possible Issues in MANUAL Mode
1 The controller does not power ON. • Check the battery voltage.
• Check the fuse on the battery supply.
• Check continuity between battery +ve and
controller terminal # 2.
• Check continuity between battery ground
and controller terminal # 1.
2 The controller fails to crank-start the engine. • Check the battery voltage.
• Enter the “configuration mode” in
controller and verify the configuration for
the “START” output. Also, check that
“START” output is working correctly by
measuring its voltage o/p.
controller and verify the configuration of
“CRANK DISCONNECT” method.
• Verify the configuration of “LLOP SWITCH”
polarity. Also, ensure that the lube oil
pressure switch & sensor are working OK.
Check their wiring.
3 The “Emergency Stop” alarm comes up even • Check if the “Emergency Stop” switch is
when the “Emergency Stop” is not pressed. working OK. Check its wiring also.
controller and verify the configuration of
“EMERGENCY STOP” polarity.
4 The controller generates unnecessary • Check the respective switch/sensor and
“Shutdown Alarms” or “Warning Alarms” wiring.
• Enter the “configuration mode” in the
controller and verify the respective
threshold configuration.
5 The controller reports “Charge Fail” alarm. • To check if the controller's charging
alternator terminal is working or not:
disconnect the charging alternator wiring
to the controller's terminal # 7. Short the
terminal # 7 to the ground through a DC
ammeter. Crank-start the engine. The DC
ammeter should indicate the current in the
range 200 - 400 mA for ~30 seconds. If yes,
the controller's charging alternator
terminal is working OK.
• Disconnect and re-connect the charging
alternator ind connection to the
controller's terminal # 7.
• Check if the charging alternator is working
OK or not.
6 The controller issues unnecessary “crank-start” • Ensure that the controller's o/p terminal is
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Sr.
Fault Remedial Actions
No.
command immediately after power on. not directly connected to the starter relay.
The controller's o/p should be given to an
intermediate relay which should in-turn
power the starter relay. The controller can
get permanently damaged and will need to
be replaced if this precaution is not taken.
• Check start-relay connection with the
suitable controller terminal.
the “START RELAY” o/p polarity.
7 The engine runs, but the controller shows • Check if the MPU signal (if used), and main
genset to be “OFF”. alternator voltage signal (R phase) are
received by the controller terminals.
• Check if the LOP and LLOP are working OK.
Also check their wiring to the controller.
8 The controller displays incorrect PF value or kW • Check wiring of the respective alternator
or load current. phase voltage and the CT to the controller.
• Check the CT ratio (if kW or current
reading is faulty).
9 The controller displays incorrect mains voltage • Check the wiring of the respective phase to
or incorrect main alternator voltage. the controller.
• If the problem is not resolved, replace the
controller and try again.
10 Controller displays incorrect reading for any of • Check respective sensor and its wiring.
LOP, Fuel Level, Temp sensors. • Enter the “configuration mode” in the
controller and verify the calibration for the
respective sensor in configuration.
11 The controller displays incorrect engine RPM. • Check the MPU connection and
configuration (if enabled).
• Check wiring of the main alternator’s R-
phase and neutral to the controller.
12 The controller screen freezes or hangs up. • Reset the controller power.
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Possible Issues in AUTO Mode

13 The controller does not start the engine even • Check the wiring of the “Remote Start”
when a “Remote Start” command is sent from signal to the controller's respective digital
an external device. i/p terminal.
the “Remote Start” digital i/p terminal.
• Check that the controller is in “Auto”
mode.
14 Controller does not stop engine even when a • Check the wiring of the “Remote Stop”
“Remote Stop” command is sent from an signal to the controller's respective digital
external device. i/p terminal.
the “Simulate Stop” digital i/p terminal.
• Check that the controller is in “Auto”
mode.
15 While in Auto mode, controller issues “Start” • Check the wiring of the mains R, Y and B
command even if the mains present. phase to the controller's respective i/p
terminal.
the “MAINS MONITORING”.
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Communication Protocol for KG-645

17 Introduction
The KG-645 genset controller implement a custom protocol based on the standard MODBUS protocol.
18 MODBUS Based Protocol

KG-645 genset controller operates in a slave mode and responds to commands received from an external
MODBUS master. Genset controller can send alarm messages and receive operational commands over MODBUS
communication.
18.1 Connection Details

The transmission mode used by KG-645 genset controller is MODBUS RTU (not MODBUS ASCII). The byte format
for communication is 1 start bit, 8 data bits, with/without parity bit and 1 stop bit. The baud rate is selectable
between 1200 kbps to 115200 kbps through the configuration options. Please refer the sections KG 645 -
Configuration Utility in this document, for more details on how the baud rate can be set. Similarly, the slave ID
can be selected through the genset controller configuration options.
18.2 Supported Functions

KG-645 genset or Diesel Genset (DG) controllers operates as a MODBUS slave that responds to certain commands
(or functions, as defined by MODBUS standard) received from the MOSBUS master in appropriate format.
Supported functions and respective command-response structure is as shown below. If the command received
from the MODBUS master is other than the three functions mentioned below, an exception message is generated.
18.2.1 Function 4 (0x04): Read Input Registers

This function is used to read measurement parameters and status from the KG-645 genset controller. The
command-response pattern is as shown in Table 10 and Table 11.
Table 10: Command from MODBUS master for Function 4

Byte Field Remarks
0 Slave address As configured in KG-645
1 Function code (0x04)
2 First register address – high byte 16-bit register address, register address map is
3 First register address – low byte described in Table 16
4 Number of registers to read – high byte Number of registers to read must be between
5 Number of registers to read – low byte 1 to 255
6/7 Error check CRC
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Table 11: Normal response from KG-645 slave for Function 4

Byte Field Remarks
Equals to number of registers to be read times
2 Byte count (n)
two. 8-bit even number between 2 to 250
3 First register – high byte
4 First register – low byte
. .
. .
. .
1+n Last register – high byte
2+n Last register – low byte
3+n/4+n Error check CRC
18.2.2 Function 16 (0x10): Write Holding Registers

This function is used to issue certain commands to the controller. The command-response pattern is as shown in
Table 12 and Table 13.

Byte Field Remarks
4 Number of registers to write – high byte Number of registers to write must be between
5 Number of registers to write – low byte 1 to 255
6 Number of data bytes to follow (n)
7 Value at first register
. .
. .
. .
6+n Value at last register

Byte Field Remarks
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Byte Field Remarks

4 Number of registers written – high byte Number of registers that have been written
5 Number of registers written – low byte
6/7 Error check CRC
18.2.3 Function 3 (0x03): Read Holding Registers

This function is used to read holding registers that is the commands that have been issued to the controller. The
command-response pattern is as shown in Table 14 and Table 15.

Byte Field Remarks
4 Number of registers to read – high byte Number of registers to read must be between
5 Number of registers to read – low byte 1 to 255
6/7 Error check CRC
Byte Field Remarks

Equals to number of registers to be read times
2 Byte count (n)
two. 8-bit even number between 2 to 250
3 First register – high byte
4 First register – low byte
. .
. .
. .
1+n Last register – high byte
2+n Last register – low byte
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18.3 Register Map

The register map for input registers is as shown in Table 16.
Table 16: Register map for input registers

Register Scale
Value Unit/Interpretation Bits/ Sign
Offset Factor
0 Protocol revision 1 -- Unsigned
1 Analog Sensor S1 0.01 Bar Unsigned
Analog Sensor S2(Canopy Temperature)** 1 Deg C Unsigned
2 Analog Sensor S2(Lube Oil Temperature)** 1 Deg C Unsigned
Analog Sensor S2(Lube Oil Pressure)** 0.01 Bar Unsigned
3 Coolant temperature 1 Deg C Unsigned
4 Fuel level 1 % Unsigned
5 Charge alternator voltage 0.1 V Unsigned
6 Battery voltage 0.1 V Unsigned
7 Number of starts 1 -- Unsigned
8 Number of trips 1 -- Unsigned
9 Engine run Hours 1 Hrs Unsigned
10 Engine run Minutes 1 Min Unsigned
11 Engine speed 1 RPM Unsigned
12 Generator R frequency 0.1 Hz Unsigned
13 Generator Y frequency 0.1 Hz Unsigned
14 Generator B frequency 0.1 Hz Unsigned
15 Generator R-N voltage 0.1 V Unsigned
16 Generator Y-N voltage 0.1 V Unsigned
17 Generator B-N voltage 0.1 V Unsigned
18 Generator R-Y voltage 0.1 V Unsigned
19 Generator Y-B voltage 0.1 V Unsigned
20 Generator B-R voltage 0.1 V Unsigned
21 Generator R current 0.1 A Unsigned
22 Generator Y current 0.1 A Unsigned
23 Generator B current 0.1 A Unsigned
24 Generator R power 0.1 KW Unsigned
25 Generator Y power 0.1 KW Unsigned
26 Generator B power 0.1 KW Unsigned
27 Generator total power 0.1 KW Unsigned
28 Generator R apparent power 0.1 KVA Unsigned
29 Generator Y apparent power 0.1 KVA Unsigned
Page 59 of 123
Register Scale
Offset Factor
30 Generator B apparent power 0.1 KVA Unsigned
31 Generator total apparent power 0.1 KVA Unsigned
32 Generator R reactive power 0.1 KVAr Unsigned
33 Generator Y reactive power 0.1 KVAr Unsigned
34 Generator B reactive power 0.1 KVAr Unsigned
35 Generator total reactive power 0.1 KVAr Unsigned
36 Generator power factor R 0.01 -- Unsigned
37 Generator power factor Y 0.01 -- Unsigned
38 Generator power factor B 0.01 -- Unsigned
39 Generator average power factor 0.01 -- Unsigned
40– 41 Generator cumulative energy 0.1 KWh Unsigned
42 – 43 Generator cumulative apparent energy 0.1 KVAh Unsigned
44 – 45 Generator cumulative reactive energy 0.1 KVArh Unsigned
46 Mains R-N voltage 0.1 V Unsigned
47 Mains Y-N voltage 0.1 V Unsigned
48 Mains B-N voltage 0.1 V Unsigned
49 Mains R-Y voltage 0.1 V Unsigned
50 Mains Y-B voltage 0.1 V Unsigned
51 Mains B-R voltage 0.1 V Unsigned
52 Mains R frequency 0.1 Hz Unsigned
53 Mains Y frequency 0.1 Hz Unsigned
54 Mains B frequency 0.1 Hz Unsigned
55 Alarm 1 -- --
Low oil pressure -- -- 13/16-16/16
High coolant temperature -- -- 9/16-12/16
Low fuel level -- -- 5/16-8/16
Radiator Water level -- -- 1/16-4/16
56 Alarm 2 -- --
Under speed -- -- 13/16-16/16
Over speed -- -- 9/16-12/16
Fail to start -- -- 5/16-8/16
Fail to stop -- -- 1/16-4/16
57 Alarm 3 -- --
Reserved -- -- 13/16-16/16
Reserved -- -- 9/16-12/16
Generator low frequency -- -- 5/16-8/16
Page 60 of 123
Register Scale
Offset Factor
Generator high frequency -- -- 1/16-4/16
58 Alarm 4 -- --
Generator high current -- -- 13/16-16/16
Generator overload -- -- 9/16-12/16
Unbalanced load -- -- 5/16-8/16
Emergency stop -- -- 1/16-4/16
59 Alarm 5 -- --
Charge fail -- -- 13/16-16/16
Filter maintenance -- -- 9/16-12/16
Reserved -- -- 5/16-8/16
Reserved -- -- 1/16-4/16
60 Alarm 6 -- --
Battery low voltage -- -- 13/16-16/16
Battery high voltage -- --
Analog sensor 1/ pin23 circuit open -- -- 5/16-8/16
Engine temperature circuit open -- -- 1/16-4/16
61 Alarm 7 -- --
Fuel theft -- -- 13/16-16/16
No speed signal -- -- 9/16-12/16
Analog sensor 2/ pin26 circuit open -- -- 5/16-8/16
Analog sensor 1 over current -- -- 1/16-4/16
62 Alarm 8 -- --
Auxiliary Input A -- -- 13/16-16/16
Auxiliary Input B -- -- 9/16-12/16
Auxiliary Input C -- -- 5/16-8/16
Auxiliary Input D -- -- 1/16-4/16
63 Alarm 9 -- --
Auxiliary Input E -- -- 13/16-16/16
Auxiliary Input F -- -- 9/16-12/16
Auxiliary Input G -- -- 5/16-8/16
Auxiliary Input H -- -- 1/16-4/16
64 Alarm 10 -- --
Gen R phase low volt -- -- 13/16-16/16
Gen R phase high volt -- -- 9/16-12/16
Gen Y phase low volt -- -- 5/16-8/16
Gen Y phase high volt -- -- 1/16-4/16
Page 61 of 123
Register Scale
Offset Factor
65 Alarm 11 -- --
Gen B phase low volt -- -- 13/16-16/16
Gen B phase high volt -- -- 9/16-12/16
DG phase rotation -- -- 5/16-8/16
Mains phase rotation -- -- 1/16-4/16
66 Alarm 12 -- --
High canopy temperature -- -- 13/16-16/16
V belt broken -- -- 9/16-12/16
Analogue EX-S1 circuit open* -- -- 5/16-8/16
67 Alarm 13 -- --
Auxiliary Input EX-A* -- -- 1/16-4/16
68 Alarm 14 -- --
Auxiliary Input EX-B* -- -- 13/16-16/16
Auxiliary Input EX-XC* -- -- 9/16-12/16
Auxiliary Input EX-XD* -- -- 5/16-8/16
Auxiliary Input EX-XE* -- -- 1/16-4/16
69 Alarm 15 -- --
Auxiliary Input EX-F* -- -- 13/16-16/16
Auxiliary Input EX-G* -- -- 9/16-12/16
Auxiliary Input EX-H* -- -- 5/16-8/16
Auxiliary Input EX-I* -- -- 1/16-4/16
70 Alarm 16 -- --
Auxiliary Input EX-J* -- -- 13/16-16/16
Analog sensor 1/pin23 circuit ground -- -- 9/16-12/16
Alternator voltage lost -- -- 5/16-8/16
Engine Speed detected -- -- 1/16-4/16
71 Exp Module I/O Diagnostics* -- --
Digital Input EX-A* -- -- 16/16
Digital Input EX-B* -- -- 15/16
Digital Input EX-C* -- -- 14/16
Digital Input EX-D* -- -- 13/16
Digital Input EX-E* -- -- 12/16
Page 62 of 123
Register Scale
Offset Factor
Digital Input EX-F* -- -- 11/16
Digital Input EX-G* -- -- 10/16
Digital Input EX-H* -- -- 9/16
Digital Input EX-I* -- -- 8/16
Digital Input EX-J* -- -- 7/16
Digital Output A* -- -- 6/16
Digital Output B* -- -- 5/16
Digital Output C* -- -- 4/16
Digital Output D* -- -- 3/16
Digital Output E* -- -- 2/16
Expansion module comm error* -- -- 1/16
72 Input Output Diagnostics -- --
Digital Input A -- -- 16/16
Digital Input B -- -- 15/16
Digital Input C -- -- 14/16
Digital Input D -- -- 13/16
Digital Input E -- -- 12/16
Digital Input F -- -- 11/16
Digital Input G -- -- 10/16
Digital Input H -- -- 9/16
Digital Output A -- -- 8/16
Digital Output B -- -- 7/16
Digital Output C -- -- 6/16
Digital Output D -- -- 5/16
Digital Output E -- -- 4/16
Digital Output F -- -- 3/16
Unimplemented -- -- 2/16
Unimplemented -- -- 1/16
73 DG Status -- --
Load on DG -- TRUE (1), FALSE (0) 16/16
Running (1), Stopped
Current DG Status -- 15/16
(0)
DG Stopped normally -- TRUE (1), FALSE (0) 14/16
DG Stopped with fault -- TRUE (1), FALSE (0) 13/16
DG Mode -- Auto (1), Manual(0) 12/16
Common shutdown -- 11/16
Common electric trip -- 10/16
Page 63 of 123
Register Scale
Offset Factor
Common warning -- 9/16
Common notification -- 8/16
Unimplemented -- -- 7/16-1/16
One of the following:
DG Started (1)
DG Stopped (2)
DG already On (3)
74 Command Status -- Unsigned
DG already Off (4)
DG in manual mode
(5)
DG Not started (6)
75 Alarm 17 -- --
High oil pressure detected -- -- 13/16-16/16
Engine Speed Fault -- -- 9/16-12/16
Lube Oil Temperature -- -- 5/16-8/16
Reserved -- -- 1/16-4/16
Actual value = Observed value on MODBUS interface multiplied with scale factor.
Actual value ** Value of the configured sensor will be shown at a time from Analog Sensor S2.
Page 64 of 123
The register map for holding registers is as shown in Table 17.
Table 17: Register map for holding registers

Register
Description Note Bits/ Sign
Offset
Send (0x01) to Start DG.
0 Command Register Send (0x02) to Stop DG. Unsigned
Command Status is updated in Status register.
Send (0x01) to toggle Current mode of operation between
Operating Mode the Auto mode and the Manual mode.
1 Unsigned
Auto Mode is to operate DG remotely.
Manual is to operate DG with through key-press events.
The interpretation of alarm status (registers 54-69 and 74 in Table 16) is as shown in Table 18.
Table 18: Interpretation of alarm status results

Value of Register Interpretation
0 Alarm disabled
1 Alarm not active
2 Warning alarm active
3 Shutdown alarm active
4 Electrical trip alarm active
5 Notification alarm active
6 – 14 Reserved
15 Unimplemented
Page 65 of 123
Expansion Module
19 Introduction
The input/output expansion module can be used in conjunction with KG-645 genset controller to provide additional 5
digital inputs, 5 analog inputs and 5 digital outputs. These inputs/outputs have the same specification as given in
sections 3.4 , 3.5 and 4.1.
Expansion module have two diagnostic LED's as shown in figure 20. Green LED indicates power status of the module
and red LED blinks when data communication between KG-645 controller and expansion module is active. Refer
section 9.1 and 22.11 for configuration details of module.
Figure 20: expansion module
The following figure shows the expansion module connector.
Figure 21: Representing the expansion module connector when viewed from the terminal insertion side
The following table provides the details for connecting expansion module with KG-645 genset controller.
Expansion module KG-645 controller

Connector Pin No. Description Terminal Sr. No. Description
3 CAN L 14 CAN L
16 CAN H 13 CAN H
Page 66 of 123
19.1 Expansion Module Integration

The following table provides the pin out description of expansion module connector.
Pin # Name Description

1 ANLG_IN_EX-S1 Analog input from sensor S1
3 CAN L CAN low
5 DIG_IN EX-D Input from switch – D
6 DIG_IN EX-E Input from switch – E
7 Not used NA
8 OUT EX-E High side driver output – E
9 OUT EX-D High side driver output – D
10 OUT EX-C High side driver output – C
11 OUT EX-B High side driver output – B

12 OUT EX-A High side driver output – A
13 BATTERY - Battery ground
15 SENSOR COMMON Connection to Sensor Common
16 CAN H CAN high
18 DIG_IN EX-C Input from switch – C
19 DIG_IN EX-B Input from switch – B
20 DIG_IN EX-A Input from switch – A
21 Not used NA
22 Not used NA
23 Not used NA
24 Not used NA
25 BATTERY + Battery positive
26 BATTERY + Battery positive
Page 67 of 123
KG 645 - Configuration Utility

20 Introduction
KOEL's KG 645 - Configuration Utility offers greater flexibility to configure each individual input and output,
engine and alternator operating parameters, timers and alarms threshold setting for a specific function or
application. This configuration utility can be installed on Windows operating system and allows the KG-645
controller to be connected to a laptop/computer via USB.
21 Installation Instructions
21.1 System Requirements

Operating System: Windows 7, Windows 8 with Microsoft .Net 4.5 framework
Communication: USB 2.0 Type B required for connection between controller and PC running KG 645 -
Configuration Utility.
21.2 Installation Process for KG 645 - Configuration Utility

Following is the stepwise procedure for installation of configuration utility.
I. Locate the installer on your system and double-click the setup.
II. The installation process starts with the following window. Click Install to continue.
Page 68 of 123
A progress bar will show installation completion progress. On completion of installation, a window will be shown as
below. Click Finish.
21.3 Installation Process for USB Driver

For connecting the KG-645 genset controller with PC or laptop, USB driver needs to be installed on the laptop.
Following is the stepwise procedure for USB driver installation.
I. Connect a USB cable between the KG-645 controller and laptop. Put the controller in Programming mode
(Refer section 8). Ensure that the controller is in Programming mode which is indicated on LCD screen of
the controller as shown below.
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Once the controller enters into the Programming mode, go to Device Manager→Other devices→GCUSMPL.
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II. Right click on “GCUSMPL” and select “Update Driver Software”.
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III. Choose “Browse my computer for driver software” to select the correct driver software.
IV. For driver installation on 64-bit Windows system, choose a driver path as “C:\Program Files(x86)\KG-645
Configuration Utility\USB Driver” and then click Next.
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Please refer following links for Installing Unsigned Drivers in Windows 8.

Disabling Driver Signature Verification on 64-Bit Windows 8:
http://www.howtogeek.com/167723/how-to-disable-driver-signature-verification-on-64-bit-windows-8.1-so-that-you-can-install-
unsigned-drivers/
Installing Unsigned Drivers in Windows 8:

http://my.okidata.com/idocs2.nsf/f7f729f023d5f3b785257706006556ac/49724794617ca7c885257acb005c2851/$FILE/Installing%20Uns
igned%20Drivers%20in%20Windows%208.pdf
V. On successful installation of USB driver, a confirmation screen will be shown as below. Click Close.
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VI. Ensure the successful driver installation by checking the entry of “GCxx” under the “Ports” option in Device
Manager.
After successful installation of configuration utility and USB driver, if KG-645 controller is not
detected at PC port, then disable serial or virtual serial port (if any used) of PC.
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22 Usage Instructions
22.1 Starting with KG 645 - Configuration Utility

Run configuration utility installed on your system. Start up screen will be displayed as shown below.
The screen prompts the user to select between two options as follows.
• Open a config file: Editing a configuration previously saved to disk by clicking “Open a config file” and
browsing to the file.
• Other options: Creating a new configuration. Click on text “START” on next screen, to start with
configuration.
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22.2 Working with KG 645 - Configuration Utility

A configuration is a set of parameter values that determines behaviour of the controller. To create a new
configuration file, click on File→New. To save the current set of parameter values as a configuration, click on
File→Save To File. To open a previously saved configuration file from disk, click on File→Open.
Screenshot of configuration utility representing File dropdown menu.
22.3 Establishing Connection with Controller

For establishing a connection with the KG-645 genset controller, first connect a USB cable between the controller
and laptop, then put the controller in Programming mode (Refer section 8). A connection status message will be
displayed at bottom left corner of screen. It is possible to open, create and modify configurations without an
active connection with the controller. However, for read and write operations of the controller, an active
connection is required.
22.4 Editing Parameters

Configuration utility allows to edit parameter values for intended application of the genset controller. Following
are the options available for editing parameters.
Increment/Decrement
Arrows
Text
entry
Box Slider
Check Box
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• Check box
Check box is typically used to enable/disable a feature.
• Text entry box
A value can be directly entered in a text entry box.
• Increment/Decrement arrows
Increment/Decrement arrows can be used to progressively increase/decrease the corresponding value.
• Slider
A slider can be dragged to change the corresponding parameter value.
22.5 Tools
KG 645 - Configuration Utility allows a set of actions to be performed in addition to editing and saving the
configurations. These actions can be accessed under the Tools menu as shown in following screenshot. These
actions are enabled only if an active connection with a controller is detected.
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22.5.1 Write Configuration To Device

This action writes the currently chosen configuration to the controller. On selecting this action, pop-up window
will be shown as below, which summarizes existing values of the parameters.
The user can confirm that these values of parameters are correct. To modify these values, Edit Configuration option
should be chosen to go back to the parameter editing page. To write the values, choose Write Configuration To
Device option. Following pop-up window will be shown.
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A confirmation window will be shown when writing is complete.
22.5.2Read Configuration From Device

This action reads the configuration of controller and accordingly populates the chosen configuration file.
Select Read From Device option. The configuration will be read from the controller and appropriately populated
in the uility. A confirmation window will be shown as below.
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22.5.3 Preview Configuration From Device

This action previews the configuration of controller. On selecting this action, pop-up window will be shown as
below, which summarizes existing values from the controller.
22.5.4 Update Firmware On Device

This action updates the firmware in the controller without affecting configuration of the controller. First select
firmware image from the file system of computer by clicking on browse Browse option.
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Then click Update. The firmware on the controller will be updated. A progress bar will show status of updation.
A confirmation window will be shown as below.
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22.5.5 Read Event Log From Device

This action reads and displays event logs in the connected controller. The pop-up window will be shown as below.
After clicking ‘’Save As PDF’’ this window will be shown.
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22.5.6 Update Time On Device

This action updates date and time in the controller using the system's date and time.
It is necessary, first to check date and time of your computer system are correct. On selecting Yes option,
computer system's current date and time will be updated in the controller.
22.5.7 Get Version Information From Device
23 Interpretation of Parameters
This section describes interpretation of parameters which are accessed via configuration utility.
23.1 Module
The Module allows configuration of a set of module-wide parameters.
Select Module to start GCU
configuration
Then select appropriate tab

to configure parameters
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23.1.1 General
Parameter Interpretation
Allows to enter a text string to identify configuration as a Profile. This ID will be
Profile Name
displayed on Active Profile screen of the controller.
The controller enters into this mode, on application of battery supply. Available
Power On Mode
options are Manual and Auto mode.
Enables or disables lamp test sequence. If enabled, all LEDs on front fascia of the
Power On Lamp Test
controller will illuminate for 3 seconds.
Enables or disables Deep Sleep mode. If enabled, the controller enters into low-
Deep Sleep Mode power mode after Deep Sleep Mode Delay duration (Refer section 22.5.2 for delay
setting).
Enables or disables Expansion module. This enables the Expansion Box option
Expansion Mode*
(Refer section 22.11) to configure expansion module parameters.
Table 19: General
23.1.2Display
Contrast Decides the percentage contrast of LCD display.
Enables or disables power save feature for LCD display backlit. If enabled, the
Power Save Mode backlit of LCD display will be switched OFF after Power Save Mode Delay duration
(Refer section 22.5.2 for delay setting).
Table 20: Display
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23.1.3RS485 Communication
Decides the communication function to be performed by the controller.
Available options:
None: No communication function will be performed.
Communication Mode
MODBUS: The controller will communicate through the RS485 port using
MODBUS protocol. The relevant parameters such as MODBUS Slave ID and
Baudrate will be activated.
MODBUS Slave ID MODBUS slave ID you wish to communicate with.
MODBUS Baudrate MODBUS baudrate (bits per second) you wish to connect at.
Parity bit provides the simple error checking for transmitted data. The available
Parity Bit types of parity checking are as follows:
None, Even, Odd
Table 21: RS485 Communication
23.2 Digital Inputs

The Digital Inputs allows configuration of digital inputs.
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Following is an example showing configuration of Digital Input A as User configured.
Decides how the digital input will be interpreted by the controller. The input
Source
can be assigned as one of a set of Digital Input Source (Refer section 22.2.1).
It is enabled only if the Source is selected as User configured. The text string
entered here will be displayed on LCD screen when corresponding user
Name
configured input is activated. The text string is also used as the event
description for the corresponding input event in the event log.
Allows to select polarity of the digital input. Available options:
Close to Activate: The input will be interpreted as active if the input is
Polarity grounded.
Open to Activate: The input will be interpreted as active if the input is not
grounded.
It is enabled if the Source is selected as User configured or switch or High
Canopy Temperature. Allows to select the action taken by the controller when
the input is found to be active. Available options:
None: No action will be taken.
Action
Warning: A warning will be displayed without affecting the operation of genset.
Electric Trip: The genset will be first unloaded by deactivating the contactor
before genset being stopped.
Shutdown: Genset will be shutdown.
It is enabled only if the Source is selected as User configured or switch or High
Canopy Temperature. Decides when to start monitoring of the digital input.
Available options:
Never: The input will never monitored.
Activation
From Engine Start: The input will be monitored from the start of genset.
From Monitoring On: The input will be monitored when the engine and
alternator safety monitoring begins.
Always: The input will always monitored.
Allows to select duration in seconds, for which the input active condition
Activation Delay
should persist before which preconfigured action will be taken.
Table 22: Digital Input A
Refer Table 22 for configuration of Digital Input A, Digital Input B, Digital Input C, Digital Input D and Digital Input
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23.2.1 List of Digital Input Source

Digital Input Source Interpretation
Not used The digital input will not be used.
User configured Allows to enter a text string to identify the digital input.
Low Fuel Level Switch Engine low fuel level switch input – used for low Fuel Level alarm.
High Engine Temperature
Engine high temperature switch input – used for High Eng Temp alarm.
Switch
Low Lube Oil Pressure
Engine oil pressure switch – used for Low Oil Pressure alarm.
switch
Low Water Level Switch Radiator water level switch – used for Radiator Water Level alarm.
Emergency Stop Emergency stop input.
In Remote start/stop mode, the genset can be commanded to start/stop by
Remote Start/Stop
activating/deactivating this input.
Simulate Start Simulates the “START” button on fascia.
Simulate Stop Simulates the “STOP” button on fascia.
Simulate Auto Simulates the “AUTO” button on fascia.
Close Gen/Open Mains Command to manually transfer the load to genset. (To be used in manual
Switch mode. Not recommended to use in auto mode)
Close Mains/Open Gen Command to manually transfer the load to mains. (To be used in manual mode.
Switch Not recommended to use in auto mode)
This input allows the controller to act as if mains is healthy, irrespective of
Simulate Mains actual mains voltage/frequency. This input can be used to over-ride genset
starting based on mains monitoring in Auto Mains Failure (AMF) mode.
Reserved NA
High Canopy Temp Switch Canopy temperature switch – used for High Canopy Temperature alarm.
V-Belt Broken Switch V-Belt Broken switch – used for V-Belt Broken alarm.
Table 23: Digital Input Source
23.3 Analog Inputs

Analog Inputs can be configured as Analog Input or Digital Input.
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23.3.1 Analog Sensor S1 (4 – 20mA)

This allows to configure Analog Sensor S1 as LOP (4 – 20mA) sensor.
Decides how the input will be interpreted. Available options:
Use Input As Not used: The input will not be used.
Lube Oil Pressure Sensor: The input will be used as LOP (4 – 20 mA) sensor.
Low Level Shutdown Enables or disables low oil pressure shutdown detection.
Low Level Shutdown Allows to select the threshold on the oil pressure value below which selected
Threshold action for Low Oil Pressure condition will be triggered.
Low Level Warning Enables or disables low oil pressure warning detection.
Low Level Warning Allows to select the threshold on the oil pressure value below which selected
Threshold action for Low Oil Pressure condition will be triggered.
Allows to select alarm action on detection of following fault conditions:
1. Oil pressure open circuit/ground (Anlg S1 / pin23 - Ckt Opn/Gnd)
2. Analog sensor S1 over current (Anlg S1 / pin23 - Overcurrent)
When any of these conditions is detected, an alarm will be triggered. Available
options:
Oil Pressure Circuit Fault
A table that defines relation between the sensor value and corresponding
Sensor Calibration Table
physical quantity.
Table 24: Analog Sensor S1 (4–20 mA)
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At any given time, user can select either Lube Oil Pressure (4-20mA) current sensor
Lube Oil Pressure resistive sensor or Speed bias input (0-5 V) in Generator Egov Configura-
tion.
23.3.2 Analog Sensor S2 (Resistive)

Following is an example showing Analog Sensor S2 (Resistive) configured as Canopy Temperature Sensor.
Not used: The input will not be used.
Digital Input F: The selected sensor input will be used as digital input. The
parameters identical to digital inputs will be displayed and the input can
configured in the same way as that of digital input being configured (Refer
section 22.2.1).
Use Input As
Canopy Temperature Sensor: The input will be used as analog input for canopy
temperature sensor (resistive).
Lube Oil Temperature Sensor: The input will be used as analog input for lube
oil temperature sensor (resistive).
Lube Oil Pressure Sensor: The input will be used as analog input for lube oil
pressure sensor (resistive).
High Level Shutdown Enables or disables shutdown for high canopy temperature value
Threshold on canopy temperature value above which shutdown will be
Shutdown Threshold
triggered
High Level Warning Enables or disables warning for high canopy temperature value
Warning Threshold Threshold on canopy temperature value above which warning will be triggered
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When the S2 sensor circuit open condition is detected, an alarm will be
triggered. Available options:
Warning: A warning will be displayed without affecting the operation of
S2 Sensor Circuit Fault
genset.
physical quantity.
Table 25: Analog Sensor S2 (Resistive)
Analog Sensor S2 (Resistive) can be configured as Lube Oil Pressure Sensor (resistive) on enabling in all
conditions except:
• If the Lube Oil Pressure sensor is configured to Analog Sensor S1 (4-20 mA)
• Speed Bias Input (0-5 V) is configured in Generator Egov Configuration
Following is an example showing, Analog Sensor S2 (Resistive) configured as Lube Oil Pressure Sensor(resistive).
Following is an example showing, Analog Sensor S2 (Resistive) configured as Lube Oil Temperature
Sensor(resistive).
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23.3.3 Engine Temperature Sensing (Resistive)
Digital Input G: The selected sensor input will be used as digital input. The
Use Input As
section 22.2.1).
Engine Temperature Sensor: The input will be used as analog sensor
(resistive).
High Temp Shutdown Enables or disables shutdown for high engine temperature value
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Threshold Threshold on engine temperature value above which shutdown will be triggered
High Temp Warning Enables or disables warning for high engine temperature value
Threshold Threshold on engine temperature value above which warning will be triggered
Allows to select the action taken by the controller if engine temperature sensor is
detected as open circuit (Eng Temp / pin24 - Ckt Opn). Available options:
Engine Temp Circuit Fault Warning: A warning will be displayed without affecting the operation of genset.
physical quantity.
Table 26: Engine Temperature Sensing (Resistive)
23.3.4 Fuel Level Sensing (Resistive)
Not Used: The input will not be used.
Digital Input H: The selected sensor input will be used as digital input. The
Use Input As parameters identical to digital inputs will be displayed and the input can
section 22.2.1).
Fuel Level Sensor: The input will be used as analog sensor (resistive).
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Enables or disables an engine shutdown by the controller if Low Fuel Level
Low Fuel Level Shutdown
condition is detected.
Allows to select the threshold on fuel level value below which Low Fuel
Shutdown Threshold
Level shutdown alarm will be triggered.
Enables or disables warning generation by the controller if Low Fuel Level
Low Fuel Level Warning
condition is detected.
Allows to select the threshold on fuel level value below which Low Fuel
Warning Threshold
Level warning will be triggered.
Fuel Theft Warning Enables or disables Fuel Theft warning alarm.
Allows to select the threshold on percentage fuel consumption per hour,
Fuel Theft Threshold
above which Fuel Theft alarm will be triggered.
Fuel Consumption Fuel consumption in litres per hour.
Display Fuel in Liters If enabled, fuel level will be displayed in liters on screen.
physical quantity.
Table 27: Fuel Level Sensing (Resistive)
Analog Sensor S2, Engine Temperature Sensing and Fuel Level Sensing can be configured as Digital Inputs (Refer
section 22.2 and 22.2.1).
Following is the screenshot of configuration utility representing configuration of Fuel Level sensor as a digital
switch.
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23.4 Outputs
The Outputs allows configuration of digital outputs.
Allows to select the output as one of the set of Digital Output Source (Refer
Source
section 22.4.1). Alternatively, the outputs can be disabled.
Allows to select activation polarity of selected output. Available options:
De-energise: The output will be disconnected from battery positive supply if the
On Activation corresponding source condition is active.
Energise: The output will be connected to battery positive supply if the
corresponding source condition is active.
Table 28: Outputs
23.4.1 List of Digital Output Source

Interpretation
Digital Output Source
Active when... Inactive when...
Sounder Alarm An audible alarm is pending. No audible alarm is pending.
Battery Over Voltage alarm is not
Battery Over Voltage Battery Over Voltage alarm is pending.
pending.
Battery Under Voltage alarm is not
Battery Under Voltage Battery Under Voltage alarm is pending.
pending.
Charge Fail shutdown alarm is not
Charge Alt Shutdown Charge Fail shutdown alarm is pending.
pending.
Charge Fail warning alarm is not
Charge Alt Warning Charge Fail warning alarm is pending.
pending.
Close Gen Contactor Genset contactor is to be closed. Genset contactor is not to be closed.
Close Mains Contactor Mains contactor is to be closed. Mains contactor is not to be closed.
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Interpretation
Mains is detected as healthy or mains
Mains Failure Mains is detected as not healthy.
monitoring is disabled.
Any warning or shutdown or electric
Common Alarm No alarm is pending.
trip alarm is pending.
Common Electric Trip Any electric trip alarm is pending. No electric trip alarm is pending.
Common Shutdown Any shutdown alarm is pending. No shutdown alarm is pending.
Common Warning Any warning alarm is pending. No warning alarm is pending.
Cooling Down Cooling down timer is active. Cooling down timer is not active.
Digital Input A Digital Input A is active. Digital Input A is not active.
Digital Input B Digital Input B is active. Digital Input B is not active.
Digital Input C Digital Input C is active. Digital Input C is not active.
Digital Input D Digital Input D is active. Digital Input D is not active.
Digital Input E Digital Input E is active. Digital Input E is not active.
Digital Input F (Analog S2
Digital Input F is active. Digital Input F is not active.
Input)
Digital Input G (Analog
Digital Input G is active. Digital Input G is not active.
Input Eng Temp)
Digital Input H (Analog
Digital Input H is active. Digital Input H is not active.
Input Fuel LVL)
Emergency stop input is active. This
Emergency Stop output will be active (if configured) in Emergency stop input is not active.
both conditions- engine on and off.
An engine stop command is being An engine stop command is not being
Stop Solenoid
issued. issued.
Fail To Start Fail To Start alarm is pending. Fail To Start alarm is not pending.
Fail To Stop Fail To Stop alarm is pending. Fail To Stop alarm is not pending.
Fuel Relay Engine needs to be running. Engine need not to be running.
Genset voltage and frequency are Genset voltage and frequency are not
Gen Available
within acceptable limits. within acceptable limits.
Genset R Phase Over Voltage shutdown Genset R Phase Over Voltage
R Phase OV Shutdown
alarm is pending. shutdown alarm is not pending.
Genset R Phase Under Voltage Genset R Phase Under Voltage
R Phase UV Shutdown
shutdown alarm is pending. shutdown alarm is not pending.
Genset Y Phase Over Voltage shutdown Genset Y Phase Over Voltage
Y Phase OV Shutdown
Genset Y Phase Under Voltage Genset Y Phase Under Voltage
Y Phase UV Shutdown
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Interpretation
Genset B Phase Over Voltage shutdown Genset B Phase Over Voltage
B Phase OV Shutdown
Genset B Phase Under Voltage Genset B Phase Over Voltage
B Phase UV Shutdown
Genset Over Current alarm is not
Gen Over Current Genset Over Current alarm is pending.
pending.
High Engine Temperature output is High Engine Temperature output is
High Engine Temperature
active. not active.
Low Fuel LVL Low Fuel level alarm is pending. Low Fuel level alarm is not pending.
Low Oil Pressure alarm is not
Low LOP Low Oil Pressure alarm is pending.
pending.
Mains voltage is not detected to be
Mains High Volt Mains voltage is detected to be high.
high.
Mains voltage is not detected to be
Mains Low Volt Mains voltage is detected to be low.
low.
Oil pressure circuit is detected to be Oil pressure circuit is not detected to
Oil Pressure Open Circuit
open. be open.
Open Gen Contactor Genset contactor is to be open. Genset contactor is not to be open.
Open Mains Contactor Mains contactor is to be open. Mains contactor is not to be open.
Over Frequency shutdown alarm is Over Frequency shutdown alarm is
Over Freq Shutdown
pending. not pending.
Over Speed shutdown alarm is not
Over Speed Shutdown Over Speed shutdown alarm is pending.
pending.
Gross Over Speed Gross Over Speed Shutdown alarm is Gross Over Speed Shutdown alarm is
Shutdown pending. not pending.
Start Relay Cranking command is active. Cranking command is not active.
Temperature circuit is detected to be Temperature circuit is not detected to
Temp Sensor Open Circuit
open. be open.
Under Frequency shutdown alarm is Under Frequency shutdown alarm is
Under Freq Shutdown
pending. not pending.
Under Speed shutdown alarm is Under Speed shutdown alarm is not
Under Speed Shutdown
pending. pending.
Maintenance Due alarm is not
Maintenance Due Maintenance Due alarm is pending.
pending.
Stop Mode Controller is in Stop mode. Controller is not in Stop mode.
Auto Mode Controller is in Auto mode. Controller is not in Auto mode.
Manual Mode Controller is in Manual mode. Controller is not in Manual mode.
Reserved NA NA
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Interpretation
Preheat output is to be active as per Preheat output is not to be active as
Preheat Output
preheating setting. per preheating setting.
Digital Input XA* Digital Input XA is active. Digital Input XA is not active.
Digital Input XB* Digital Input XB is active. Digital Input XB is not active.
Digital Input XC* Digital Input XC is active. Digital Input XC is not active.
Digital Input XD* Digital Input XD is active. Digital Input XD is not active.
Digital Input XE* Digital Input XE is active. Digital Input XE is not active.
Digital Input XF (ANX S1
Digital Input XF is active. Digital Input XF is not active.
RES)*
Digital Input XG (ANX S2
Digital Input XG is active. Digital Input XG is not active.
RES)*
Digital Input XH (ANX S3
Digital Input XH is active. Digital Input XH is not active.
RES)*
Digital Input XI (ANX S4
Digital Input XI is active. Digital Input XI is not active.
RES)*
Digital Input XJ (ANX S5
Digital Input XJ is active. Digital Input XJ is not active.
RES)*
Communication between genset Communication between genset
Expansion Module
controller and expansion module is controller and expansion module is
Available*
active. not active.
Table 29: Digital Output Source
23.5 Timers
23.5.1 Cranking
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Crank Hold Time The crank output will be active upto this time during cranking.
Crank Rest Time The time between two crank commands.
Crank Start Delay Gets executed only when no output is configured for the engine preheat function.
Table 30: Cranking
23.5.2 General
Decides the time from engine on for which engine and alternator safety
parameters will be ignored. This timer should be selected sufficiently large so
Safety Monitoring Delay
that no false alarms will be triggered due to transient during genset start-up
procedure.
The time in which a deviation in mains parameters (voltage, frequency) outside
Mains Detect Delay the preconfigured range is allowed before corresponding alarm being
triggered.
The time in which a deviation in genset parameters (voltage, frequency)
Alternator Detect Delay outside the preconfigured range is allowed before corresponding alarm being
triggered.
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The delay between (1) Alternator's developing healthy voltage and frequency,
Warm-Up delay and (2) the load being transferred onto the alternator by suitably actuating
contactors.
A delay between the detection of healthy mains return and issuing genset Stop
Return To Mains Delay
command in Auto mode operation of genset.
The time between issuing Stop command and the beginning of actual stopping
Engine Cooling Time sequence. This timer will be skipped in case of shutdown alarms, emergency
stop and repeated “STOP” key input
This timer will start after receiving stop command. After completion of this
Stop Action Time timer, if LOP or engine speed is detected below threshold, then genset will
declared as completely off, otherwise Fail To Stop alarm will be triggered.
The time between one of the genset or mains contactor being opened and the
Load Transfer Delay other contactor being closed during a power transfer event between the
genset and mains.
The time in which, if no activity is detected and engine is OFF, the backlit of
Power Save Mode Delay LCD display will be switched OFF. Go on page Module to enable Power Save
Mode (Refer section 22.1.2).
The time after which a display screen will shift to the next screen. When this
time is set to 0, then screen will not scroll automatically. User will have to scroll
Screen Changeover Time
all the screens excluding ALARMS screen using “UP”/“DOWN” keys. ALARMS
screen will pop up on detection of any alarm.
The time in which, if no activity is detected and engine is OFF, the controller
Deep Sleep Mode Delay enters into Deep Sleep mode. Go on page Module to enable Deep Sleep Mode
(Refer section 22.1.1).
On initiation of an alarm, audible alarm will sound (if configured) upto this
Sounder Alarm Timer
time.
The controller will remain in Test mode, for the preconfigured Test Mode
Test Mode Timer Duration. This timer expires only when engine is running, otherwise controller
remains in this mode for infinite time.
Table 31: General
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23.6 Generator
The genset specific parameters are divided into sections as shown below.
23.6.1Alternator Configuration
Allows to select engine operation with or without the alternator. If the
Alternator Present alternator is not fitted, all the relevant parameters will be ignored and disabled.
This will be considered as an engine-only operation.
Number Of Poles Allows to select the number of poles of alternator.
AC System Allows to select AC System as 3 Phase or 1 Phase.
Min Healthy Voltage A threshold above which genset is considered healthy for taking electrical load.
Min Healthy Frequency A threshold above which genset is considered healthy for taking electrical load.
If enabled, the alternator phase sequence (R-Y-B) will be checked. This option
Phase Reversal Detection
will be enabled if AC System is configured as 3 Phase.
Allows to select the action taken by the controller if the alternator phase
reversal condition occurs. Available options:
Phase Reversal Action Warning: A warning will be displayed.
before the genset being stopped.
This alarm will generate if alternator voltage does not cross 50 V-RMS within 2
Alt Voltage Lost Shutdown
seconds after crank disconnect event
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An option to actuate genset and mains contactors if configured as outputs in
Auto Load Transfer the manual mode. If disabled, it is necessary to manually put the load on
genset.
Table 32: Alternator Configuration
23.6.2 Voltage Monitoring

These parameters will be enabled, if the Alternator Present parameter is selected as Yes (Refer section 22.6.1).
Under-voltage Shutdown Enables or disables Under Voltage shutdown alarm.
Under Voltage Shutdown The voltage value below which the Under Voltage shutdown alarm will be
Threshold triggered.
Under-voltage Warning Enables or disables Under Voltage warning alarm.
Under Voltage Warning The voltage value below which the Under Voltage warning alarm will be
Over-voltage Shutdown Enables or disables Over Voltage shutdown alarm.
Over Voltage Shutdown The voltage value above which the Over Voltage shutdown alarm will be
Over-voltage Warning Enables or disables Over Voltage warning alarm.
Over Voltage Warning The voltage value above which the Over Voltage warning alarm will be
Table 33: Voltage Monitoring
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23.6.3Frequency Monitoring
Under-frequency Shutdown Enables or disables Under Frequency shutdown alarm.
Under Frequency Shutdown The frequency value below which the Under Frequency shutdown alarm will be
Under-frequency Warning Enables or disables Under Frequency warning alarm.
Under Frequency Warning The frequency value below which the Under Frequency warning alarm will be
Over-frequency Shutdown Enables or disables Over Frequency shutdown alarm.
Over Frequency Shutdown The frequency value above which the Over Frequency shutdown alarm will be
Over-frequency Warning Enables or disables Over Frequency warning alarm.
Over Frequency Warning The frequency value above which the Over Frequency warning alarm will be
Table 34: Frequency Monitoring
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23.6.4 Current Monitoring

The primary-side factor for interpretation of CT ratio. The controller assumes
CT Ratio
that the secondary-side factor is 5.
Over-current Threshold The current value above which the Over Current alarm will be triggered.
The time for which a value higher than the preset Over Current Threshold value
Over-current Delay
is allowed before the Over Current alarm being triggered.
Allows to select the action when Over Current condition is detected.
Available options:
Over-current Action Warning: A warning will be displayed without affecting the operation of genset.
Allows to select the action if an unbalanced load is detected in AC System
configured as 3 Phase. Available options:
Unbalanced Load Action Warning: A warning will be displayed without affecting the operation of genset.
The threshold on load unbalance, in percentage of per-phase full load. The
unbalance load action will be triggered when
Unbalanced Load Threshold {[(Max kW from R, Y, B)– (Min kW from R, Y, B)] / [Max kW load allowed per
phase assuming 100 % rated load]} * 100 is greater than configured unbalanced
load threshold
The time for which an unbalanced load condition is monitored before the
Unbalanced Load Delay
corresponding action will be taken.
Table 35: Current Monitoring
Page 103 of 123

23.6.5 Load Monitoring

These parameters will be enabled, if Alternator Present parameter is selected as Yes (Refer section 22.6.1).
Decides the genset rating in kW.
This value must be specified as a total load rating
Generator Rating and NOT as per phase load rating.
The load value (as a percentage of full load) above which the selected action for
Over-load Threshold
Over Load alarm will be triggered.
The time for which a value higher than the preset Overload Threshold value is
Over-load Mon Delay
allowed before the Over Load alarm being triggered.
Allows to select the action when Over Load alarm is detected.
Available options:
Over-load Action Warning: A warning will be displayed without affecting the operation of genset.
Table 36: Load Monitoring
Page 104 of 123

23.7 Mains
The Mains configuration is divided into sections as shown below.
23.7.1Mains Configuration
When enabled it displays status of mains on the Mains monitoring screen.
Mains Monitoring
Enables or disables Auto Mains Failure (AMF) mode.
Mains AC System Allows to select Mains AC system as 1 Phase or 3 Phase.
Phase Reversal If enabled, the mains phase sequence (R-Y-B) will be checked.
Allows to select the action taken by the controller. In AMF mode, if the mains
phase reversal condition occurs then genset will start. Available options:
Phase Reversal Action
Notification: A notification text will be displayed.
Table 37: Mains Configuration
23.7.2Voltage Monitoring
Page 105 of 123

Enables or disables mains under voltage monitoring. If enabled, the controller
Under Voltage
monitors the mains under voltage condition.
The voltage value below which an under voltage condition for mains is
Under Voltage Trip
detected.
The minimum voltage which must be reached for the mains voltage to be
Under Voltage Return considered healthy. This value is used when an unhealthy mains condition has
been detected.
Enables or disables mains over voltage monitoring. If enabled, the controller
Over Voltage
monitors the mains over voltage condition.
The maximum value for the mains voltage to be considered healthy. This value
Over Voltage Return
is used when an unhealthy mains condition has been detected.
Over Voltage Trip The voltage value above which an over voltage condition for mains is detected.
Table 38: Voltage Monitoring
23.7.3Frequency Monitoring
Enables or disables mains under frequency monitoring. If enabled, the
Under Frequency
controller monitors the mains under frequency condition.
The frequency value below which an under frequency condition for mains is
Under Frequency Trip
detected.
The minimum frequency which must be reached for the mains frequency to be
Under Frequency Return considered healthy. This value is used when an unhealthy mains condition has
been detected.
Enables or disables mains over frequency monitoring. If enabled, the controller
Over Frequency
monitors the mains over frequency condition.
The maximum value for the mains frequency to be considered healthy. This
Over Frequency Return
value is used when an unhealthy mains condition has been detected.
Page 106 of 123

The frequency value above which an over frequency condition for mains is
Over Frequency Trip
detected.
Table 39: Frequency Monitoring
23.8 Engine
The engine specific parameters are divided into sections as shown below.
23.8.1 Crank Disconnect
Allows to select maximum number of start sequences before Fail To Start alarm is
Start Attempts
triggered.
Decides if the oil pressure value is used for crank disconnect operation. If enabled,
Disconnect on LOP Sensor
crank will be disconnected if oil pressure is sensed to be more than a threshold.
The threshold value for the oil pressure above which the cranking command will
Disconnect Pressure Threshold
be withdrawn. This parameter is relevant only if Disconnect on LOP is enabled.
Decides if the oil pressure switch condition is used for withdrawing the crank
Disconnect on LOP Switch command. If enabled, the crank command will be withdrawn as soon as oil
pressure switch stops indicating that oil pressure is low.
Page 107 of 123

The time for which the oil pressure switch condition should be consistently shown
as Low Oil Pressure before the corresponding crank command withdrawal. Note
LLOP Switch Transient Time that if some other source for crank command withdrawal (such as engine speed
more than Engine Speed Threshold) is reached before this time, then crank is
withdrawn before this time.
Alternator Frequency Threshold on alternator frequency above which the crank command will be
Threshold withdrawn.
Allows to select the engine speed above which crank command will be
withdrawn.
The controller will not issue Start command if any of

Engine Speed Threshold the enabled crank withdrawal condition is detected.
Decides whether the charging alternator voltage is to be used for crank

Disconnect on Charging Alt
disconnect operation. If enabled, crank will be disconnected if charging
Voltage
alternator voltage is sensed to be more than threshold.
Threshold on charging alternator voltage. Above this threshold, cranking
Charging Alt Threshold command will be withdrawn. This parameter is relevant only if Disconnect on
Charging Alt Voltage is enabled.
Table 40: Crank Disconnect
Page 108 of 123

23.8.2 Speed Monitoring
Allows to select electrical signal to be use for measurement of engine speed.
Available options:
Engine Speed Sense Source Magnetic pickup: Engine speed will be sensed from Magnetic Pickup Unit
(MPU).
Alternator frequency: Engine speed will be sensed from alternator frequency.
Allows to select the number of teeth on flywheel ring gear. This option is
Flywheel Teeth
enabled, if Engine Speed Sense Source is selected as MPU.
Under-speed Shutdown Enables or disables Under Speed shutdown alarm.
Under-speed Threshold The engine speed below which Under Speed alarm will be triggered.
The time for which an engine speed value lower than Under Speed Threshold is
Under-speed Delay
allowed before Under Speed shutdown alarm being triggered.
Over-speed Threshold The engine speed in RPM above which Over Speed alarm will be triggered.
The time for which an engine speed value higher than the preset Over Speed
Over-speed Delay
Threshold is allowed before Over Speed shutdown alarm being triggered.
The percentage speed above Over Speed Threshold to sense the speed very
Gross Over-speed Threshold fast, especially during ramp up and to trip the engine on detecting high speed.
It will shutdown engine immediately.
Minimum engine speed that the genset must achieve within 2 seconds from
Healthy-speed Threshold
crank disconnect event.
Table 41: Speed Monitoring
23.8.3Battery Monitoring
Page 109 of 123

Allows to select the action if the Low Battery Voltage condition is detected.
Available options:
Low Battery Voltage Action Warning: A warning will be displayed without affecting the operation of genset.
Low Battery Voltage The value of battery voltage below which the Battery Under Voltage alarm will
Threshold be triggered.
The time for which battery voltage value lower than Low Battery Voltage
Low Battery Voltage Delay
Threshold is allowed before the Battery Under Voltage alarm being triggered.
Allows to select the action if the High Battery Voltage condition is detected.
Available options:
High Battery Voltage Action Warning: A warning will be displayed without affecting the operation of genset.
High Battery Voltage The value of battery voltage above which the Battery Over Voltage alarm will
Threshold be triggered.
The time for which battery voltage value higher than High Battery Voltage
High Battery Voltage Delay
Threshold is allowed before the Battery Over Voltage alarm being triggered.
Table 42: Battery Monitoring
Page 110 of 123

23.8.4 Charging Alternator Monitoring
Allows to select the action if the charging alternator fail (Charge Fail) condition is
detected. Available options:
Charging Alternator Fail
Action
Charging Alternator Fail The voltage at the charge alternator fail input terminal, below which the Charge
Threshold Fail alarm will be triggered.
The time for which voltage value (at charge alternator fail input terminal) lower
Charging Alternator Fail
than Charging Alternator Fail Threshold is allowed before the Charge Fail alarm
Delay
being triggered.
Table 43: Charging Alternator Monitoring
23.8.5 Preheat
To enable the Preheat, configure one of the digital output as the Preheat Output (Refer section 22.4).
Page 111 of 123

Preheat Timer is used for engine smoke reduction and better cold start. The
Preheat Timer Preheat Output will be active for this duration. If this timer is configured, Crank
Start Delay will not considered.
Engine Temperature Limit Temperature Enable decides whether the coolant temperature is used for
controlling the Preheat Output. If enabled, the Preheat output is deactivated
Engine Temperature when the coolant temperature is sensed to be higher than the Temperature
Limit.
Table 44: Preheat
23.9 Maintenance
Alarm action on logged engine hours or service due date, which ever occurs
first. Available options:
Alarm Action
Notification: Notification text will be displayed on LCD screen.
genset.
Due At Engine Hours Maintenance Due alarm will be triggered when the engine has run for more
than specified number of hours or if maintenance service due date
Alarm Due Date occurred, whichever happens first.
Table 45: Maintenance
Page 112 of 123

23.10 Rotary Actuator

Rotary actuator can be configured as start/stop device or as E-governor.
23.10.1 General
Allows to select the Actuator application. Available options:
Actuator Application
As E-Governor or As Start/Stop Device
Actuator frequency multiplying factor. The frequency at which Actuator
Actuator Speed
controls the engine.
Allows to select the Actuator direction to stop the engine. This direction
depends on the engine design. The Actuator is viewed from the shaft side.
Available options:
Actuator Direction
Clockwise: Actuator will rotate in clockwise direction to stop the engine.
Anti clockwise: Actuator will rotate in anti-clockwise direction to stop the
engine.
Table 46: General
23.10.2 Engine Start Strategy
Page 113 of 123

Cranking Steps Number of pulses issued to the Actuator.
Time for which engine stays at low idle speed (used for ramping-for smoke
Initial Low Speed Delay
reduction)
Initial Low Speed Low Idle Speed
The speed governor recognizes that the engine cranking action is initiated once
the
Crank Sense Speed
engine speed exceeds this value. Upon recognition, the governor executes the
Cranking Steps and then initiates the low speed governing phase.
Ramp Up Time Time taken by the engine to ramp the speed from initial low to target speed
Table 47: Engine Start Strategy
If Actuator Application is configured As Start/Stop Device, then following tab will popup.
23.10.3 Start/Stop Device Configuration
Number of pulses issued to the Actuator during normal engine running.
Page 114 of 123

If Actuator Application is configured As E-Governor, then following tabs will popup.
23.10.4 Generator EGov Configuration

This section allows configuration of Generator EGov Configuration whenever alternator is fitted to engine.
Allows to select speed governing type. Available options:
Fixed Speed (0 % Droop): Fixed speed application.
Set Speed Selection
Speed Bias Input (0-5 V): Paralleling support application
Load Based Droop: Configurable droop application
Droop The percentage drop in the speed of engine from no load speed.
Target Speed Decides the target governing speed.
Proportional Gain (Kp) Decides the response of the controller in terms of the responsiveness of the
Integral Gain (Ki) controller to an error, the degree of speed oscillations and the degree to which
Derivative Gain (Kd) the controller overshoots or undershoots the target governing speed.
Friction Setoff To ensure wear and tear free operation of linkage and Actuator.
Gain Schedule Trigger Percentage RPM that triggers the engine overshoot/undershoot condition.
Loading Factor
To scale the PID control loop parameters.
Unloading Factor
Table 48: Generator EGov Configuration
Page 115 of 123

23.10.5 Engine EGov Configuration

This section allows configuration of Engine EGov Configuration for engine-only application.
Target Speed Decides the target governing speed.
Proportional Gain (Kp)
Decides the response of the controller in terms of the responsiveness of the
Integral Gain (Ki) controller to an error, the degree of speed oscillations and the degree to which the
controller overshoots or undershoots the target governing speed.
Derivative Gain (Kd)
Friction Setoff To ensure wear and tear free operation of linkage and Actuator.
Gain Schedule Trigger Percentage RPM that triggers the engine overshoot/undershoot condition.
Loading Factor
To scale the PID control loop parameters.
Unloading Factor
Table 49: Engine EGov Configuration
Electronic Governor parameters are relevant only if a actuator is used for

electronic governing of the engine.
Electronic Governor parameters are not intended to be changed in the field without
consulting experts.
Page 116 of 123

23.11 Expansion Module
Expansion module parameters will be enabled if the Expansion Module is enabled (Refer section 22.1).
23.11.1 Digital Inputs

Digital Inputs (EX-A, EX-B, EX-C, EX-D, EX-E) of expansion module can be configured same as that of Digital Input
A of controller. Refer section 22.2 and 22.2.1 for configuration details.
Screenshot of configuration utility representing configuration of extended Digital Input EX-A as a User configured
input.
23.11.2 Analog Inputs

Analog Inputs can be configured as Analog Input or Digital Input.
Following is an example showing configuration of Analog Input EX-S1 as a Pressure sensor (resistive).
Page 117 of 123

Digital Input XF: The selected sensor input will be used as digital input. The
Use Input As
section 22.2 and 22.2.1).
Pressure Sensor: The input will be used as analog input for pressure sensor
(resistive).
Temperature Sensor: The input will be used as analog input for temperature
sensor (resistive).
Allows to select the action taken by the controller if undesirable condition is
detected. Available options:
Action
genset.
The text string entered here will distinguish the corresponding sensor from the
Name
sensors on other terminal.
Allows to select alarm generation condition. Available options:
Less Than Threshold: Alarm will be generated if measured sensor value is less
Threshold Type than selected threshold.
Greater Than Threshold: Alarm will be generated if measured sensor value is
greater than selected threshold.
Allows to select the threshold on the measured sensor value above/below
Threshold
which selected action for undesirable condition will be triggered.
Allows to select alarm generation condition, when the selected sensor circuit
open condition is detected. Available options:
Circuit Open Fault
genset.
physical quantity.
Page 118 of 123

Table 50: Analog Input EX-S1 Sensor

Following is an example showing Analog Input EX-S1 configured as Temperature sensor (resistive).
Analog Input EX-S1, Analog Input EX-S2, Analog Input EX-S3, Analog Input EX-S4 and Analog Input EX-S5 can be
configured as Digital Inputs. Refer section 22.2 and 22.2.1 for configuration details.
Page 119 of 123

23.11.3 Digital Outputs
Extended Digital Outputs can be configured same as that of controller Digital Outputs (Refer section 22.4 and
22.4.1).
*Expansion Module parameters are relevant only if a input/output

Expansion Module is connected to KG-645 genset controller.
Page 120 of 123

KG 645 – EOL Flashing Utility

KG 645 – EOL Flashing Utility allows flashing of KG-645 controller.
24 Menu Bar
Toolbar is located at the top of the screen.
Following options can be accessed under different Menus.
Menu Available options Description

File Exit Exit the flashing utility
Tools Get Device Information Reads product id and engine serial number from
device (Refer window below this table)
Help Mode Selection Displays diagram of mode selection in device (Refer
section Error: Reference source not found)
About Information about flashing utility
On selecting Get Device Information option following window will be shown:
Page 121 of 123

25 Writing Configuration To Device

Following is the stepwise procedure for flashing KG-645.
• Locate the installer on PC and double-click the setup.
• Connect KG-645 controller to PC. Put the controller in Programming mode (Refer section 8).
• Now, enter the Engine Serial No (optional).
Page 122 of 123

• Browse and select configuration file. On selecting this file, profile name will be read from file and
displayed on screen of the flashing utility.
• Now, select Write To Device. This tab will be active only when connection between KG -645 controller and
PC is active. Once the configuration is written to device, confirmation window will be shown.
Disclaimer: Due to continuous development, the details provided in this document are subject to change
without any prior notice.
Page 123 of 123

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KG645 CONTROLLER MANUAL

KIRLOSKAR OIL ENGINES LIMITED

A Kirloskar Group Company

Laxmanrao Kirloskar Road, Khadki, Pune-411 003,

India. Tel : +91(20) 2581 0341

Fax: +91(20) 2581 3208/ 2581 0209

18.3 Register Map ..................................................................................................................................................56

Clarification of notation used within this publication.

Highlights an essential element of a procedure to ensure correctness

Indicates a procedure or practice, which, if not strictly observed,

Indicates a procedure or practice, which could result in injury to

1.1 Key Highlights of the Product

Figure 1: Representative drawing of KG-645 genset controller's front

2.1.1 5 mm pitch connector suitable for 2 sq mm wire

Figure 3: Representative photograph for 8-pin female (mating) connector of 5 mm pitch

2.1.2 3.5 mm pitch connector suitable for 0.5 – 1.5 sq mm wire

2.2 Power Supply Specifications

3.1 Generator Voltages And Frequency Measurements

Surge L-L and L-E As per CE / IEC requirements

3.2 Generator Current Measurement

Follow the recommended phase sequence while connecting the Current

3.3 Mains Voltage And Frequency Measurements

Input Impedance 0.3 MΩ

3.4 Digital Inputs

3.5 Analogue Inputs

3.5.1 I/P: ANLG / DIG F

3.5.2 I/P: ANLG (0–5V / 4–20 mA)

3.5.2.1 Lube Oil Pressure (4–20 mA)

3.5.2.2 Analog Voltage Input

Controller terminal number 24 (Eng_temp sensor)

3.5.3 I/P: ANLG TEMP / DIG H

3.5.4 I/P: ANLG FL / DIG G

3.6 Sensor Common

3.7 Magnetic Pick Up Input

3.8 D+ Charge Alt

4.1 Digital Outputs

Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID”

4.2 Actuator Outputs

Actuator KG-645 Controller

6.2 Mounting on panel

Over tightening of the screws may damage the controller casing.

6.3 Terminal Description

Figure 9: Representative drawing of KG-645 genset controller from backside

The following table provides the details of controller's terminals.

Terminal Sr. Degson Female (Mating)

4 OUT B High side driver output – B

6 OUT D High side driver output – D

7 D+ CHARGE ALT Input for charging alternator

8 OUT E High side driver output – E

10 DIG_IN A Input from switch – A

11 DIG_IN B Input from switch – B

Terminal Sr. Degson Female (Mating)

28 GEN_V IN B Voltage input from Gen Phase B

30 GEN_V IN R Voltage input from Gen Phase R

32 MAINS_V IN B Voltage input from Mains Phase B

34 MAINS_V IN R Voltage input from Mains Phase R

36 GEN_CT_IN B2 CT input 2 from Gen Phase B

37 GEN_CT_IN Y1 CT input 1 from Gen Phase Y

38 GEN_CT_IN Y2 CT input 2 from Gen Phase Y

40 GEN_CT_INR2 CT input 2 from Gen Phase R

41 EBP_IN Sensor Common

42 MPU_IN Input from engine speed sensor