1) 4h.083.01.0.00-Genset User Manual For Liquid Cooled R1040 Series

CPCB II
GENSET USER MANUAL
RATING: 20 to 82.5 kVA

TYPE: WATER COOLED (R1040 SERIES ENGINE)
Dear Customer,
Ideas diesel generating sets.
Each Kirloskar Green genset is a result of painstaking research by us over decades. The research takes
into consideration the arduous operating conditions and user practices to create a world class reliable
product.
We have not only designed the genset, but also its major aggregates – Kirloskar Green AC Generator,
Sound Proof Outdoor Enclosure and Control Panel.
This Users Manual of Kirloskar Green Power Ideas genset has been prepared by keeping in mind needs
of most of the users. Thus, the manual only illustrates user serviceable maintenance practices and
parts. In case you desire more detailed information about the genset, its engine, AC generator, or control
panel, please let us know.
We are sure, Kirloskar Green Power ideas genset will serve you well for years as you continue to
maintain it as presented in this manual.
Yours faithfully,
For Kirloskar Oil Engines Ltd.,
Pune, INDIA
Head, Power Generation Business
Enriching Lives
While asking for assistance to our Authorised Service Dealer,
please provide the following information.
Your Name & Phone or Mobile Number.
Engine Serial Number.
Name of the Company.
Engine Location.
General Description of assistance required.
And the service will be on its way.
FOR EMERGENCY CONTACT

In the very unlikely event of you are not receiving the prompt attention
from our eld force, following are the contact details of our Help Desk
and area e for your assistance.
HELP DESK CONTACT NUMBER - +91 880 63 344 33

HELP DESK TOLL FREE NUMBER - 1800 233 3344
KIRLOSKAR OIL ENGINES LTD.

LAXMANRAO KIRLOSKAR ROAD, KHADKI, PUNE - 411 003.
email ID - koel.helpdesk@kirloskar.com
www.koel.co.in
PREFACE
This manual deals with the Kirloskar Green Power Ideas (KGPI) genset operation. The manual also explains
components and parts which a user can service on their own. The maximum performance of the genset
largely depends on its proper maintenance and upkeep. So, please ensure proper Genset maintenance as
per the instructions and schedule given in this manual. This user manual is divided into 6 Sections. These
relate to Genset, Diesel Engine, Alternator, Warranty, Customer Service, Area Office Contacts and Check
Call Cards. Please go through a synopsis of each section.
Section A – Genset Warranty
The Warranty Section is most important for you to understand completely. It gives you description
of all the “ifs and buts” of the warranty clauses and the means to get benefit from KGPI extended
warranty. It also contains a log sheet that you need to fill religiously. Please record the daily running of
the DG set and various parameters.
Section B – Customer Service Package
To ensure maximum life and best performance of your genset, we provide free commissioning
checks and maintenance checks. KOEL Service Dealer will carry out free service checks as mentioned in the
package. Please keep in mind that you would be required to pay for the consumables like lube oil filters,
fuel filters, lube oil, etc.
Section C – Genset User Manual
This Section takes you through to understand each aspect of the genset, its major components and
their operation. Chapter 3 tells you about the installation procedures and subsequent chapter take care of
the electrical control systems and optional equipment that can be used. You must read Chapter 6 and 7
thoroughly to understand the maintenance procedures for genset and batteries.
Section D – Engine User Manual
This part of the manual gives you a complete understanding of the engine operation and
maintenance from a user perspective. All the fluid systems, namely, lube-oil, fuel oil, cooling liquid flows
have been described because the upkeep of these three systems is significant to obtain optimum
performance from the engine. Later in this section, you must go through to comprehend the trouble-
shooting, remedial and engine preservation measures. This section takes care of all the models of engines
used in a KGPI genset. Efforts have been made to highlight those specific areas which are unique to a
particular engine model.
Section E – Alternator
Here we have given you a brief knowledge about the Kirloskar Green (KG) Alternator coupled to the
diesel engine. User needs to read the safety requirements and all the “do’s & don’ts”. In the end, you are
provided with the fault, cause and repair tables so that every time you don’t need to rush to a mechanic.
Section F – Service Network
KGPI takes care of you anywhere everywhere. And this last section contains the information (contact
details) of our zonal offices, area offices and service dealer locations. Each time you run into a problem
with your genset, just look for your nearest office/service dealer location in this section and KGPI will take
care of the rest.
Intimation Card
Please ensure that your manual has the intimation card. We request you to fill the required details
completely in the intimation card and post it to us immediately.
CONVENTIONS
Each warning/most important instruction in the manual succeeds the sign.
All the significant procedures are highlighted in bold letters in the manual.
All the illustrative diagrams in the manual show only the user-serviceable parts. The
numbers in the round boxes for every part are described below the illustration.
The logo displayed at the top corner of each page is the Kirloskar Green Power Ideas
brand logo.
KOEL Area Offices
Service
State Address Telephones Mobiles
Manager
Kirloskar Oil Engines Limited Anil Pandey 011-28715826 +91-
4-C/6, New Rohtak Road, 919910116895
New Delhi Opp. Liberty Cinema,
Karol Bagh,
New Delhi-110005
Kirloskar Oil Engines Limited Ravindra Kain 0161- +91-
Plot No. 12, Sherpur Chowk, 2546667/668/669 9810937556
Punjab N.P.C. Tempo, Union Street,
Near Arun Gas Godown,
Ludhiana – 141 003
Kirloskar Oil Engines Limited Varun Bali Tel :0141- 2370007 / +91-
Rajasthan Plot No. 3, Purohit Ji Ka 2370014 9829205552
Bagh, Off M. I. Road, Jaipur
– 302 001
Kirloskar Oil Engines Limited Kapil Shah/ 0522-2741440 / +91-
498/143 KA, New Faizabad Sudhir 2741441 9918000838
U.P. Road, /7678893875
Near IT College Crossing,
Lucknow – 226007
Kirloskar Oil Engines Limited Manna Arindam 033-22170858 +91-
Poonam Building, /60/61 9674003617
Flat No. 8A and 8B, 8th
West Bengal
Floor,
5/2, Russel Street,
Kolkata – 700071
Kirloskar Oil Engines Limited Mohit 0361-
29, 1st Floor,G.N.B.Road, Choudhary 2131334/2457616
Assam Pan Bazar,
Above Avery India Ltd.,
Guwahati – 781 001
Kirloskar Oil Engines Limited Santanu Das 0674- +91-
No. 178/A, Zone-B, 2588021/2588047 9778477870
Odisha Mancheswar Industrial
Estate,
Bhubaneshwar – 751010
Kirloskar Oil Engines Limited Narendra :+91-
Meena Plaza, South Kumar Roy 9031061077
Museum Road,
Bihar
Budh Marg,
Patna – 800001
Service
State Address Telephones Mobiles
Manager
Kirloskar Oil Engines Limited Kumar 0651- +91-
C/O Shri Ram Logistics Prabhakar 2301197/2211255 9771417061
Services,
Jharkhand 4P, 4th Floor, Shri Gopal
Complex,
Kutchery Road,
Ranchi – 834 001
Kirloskar Oil Engines Limited Kadhirvel 044 - 3744624/625 +91-
Nelson Towers, 1st Floor, /Bharanikumar 7299995717
2nd Wing No. 51, /9444990295
Tamil Nadu
Nelson Manickam Road,
Aminjikarai,
Chennai – 600029
Kirloskar Oil Engines Limited Vardhaman 040- +91-
D No. 5-2-220 To 222 Deepakkumar 27534197/27534176 9550500066
2nd Floor, Sri Padmavathi
Andhra Towers,
Pradesh Hyderbasti, Opp Andhra
Bank, Ranigunj,
Secunderabad – 500003
Kirloskar Oil Engines Limited Vijay T B 080-25587562/ +91-

15, Shri Laxmi Complex, 3rd 30578174 9900021100
Floor, St. Marks Road,
Karnataka
Opposite Bowring Institute,
Adjacent to India Garage,
Bangalore – 560001
Kirloskar Oil Engines Limited Shaji Mathew 0484- +91-
No. 39/2694-A1, Anugraha, 2385756/2385757 9744716767
Kerala
Panthiyil Lane, Warriam
Road, Cochin – 16
Kirloskar Oil Engines Limited Prashant Falke : 0731-3913101/11 :+91-
B-1, Radhakrishna Complex, 9826026463
10/1, Manorama Ganj,
M.P. Geeta Bhawan Square,
AB Road (Agra-Mumbai
Road),
Indore – 452 001
Kirloskar Oil Engines Limited 079-
Ground Floor, ‘D’ Block, 26929687/26929689
Gujarat Pruthvi Complex, Near
Jodhpur Char Rasta,
Ahmedabad – 380015
Kirloskar Oil Engines Limited Malay Amin/ 020- +91-
Maharashtra Laxmanrao Kirloskar Road, Rohit Patil 25810341/25815341 9922431561/
Khadki , Pune – 411003 9881495639
INDEX
Section A - Warranty
Section B - Customer Service
Section C - Genset
Section D - Diesel Engine
Section E - Alternator
Enriching Lives
Operational and Maintenance Manual:
Diesel Genset
Warranty
Important
1. This warranty is applicable for Kirloskar Green Power Ideas (KPIG) gensets
manufactured by/under license from Kirloskar Oil Engines Limited (KOEL). Before
commissioning of the genset, please go through the contents of this Warranty
Section carefully.
2. For details of KOEL Authorised Service Dealer for your genset, please contact KOEL
Helpdesk.
3. For availing the warranty services please ensure following:
a) Produce this warranty booklet to KOEL authorised Service Dealer, when

requested.
b) Carry out first service check (G1) at 50 hours or 30 days from date of
commissioning, whichever is earlier. Carry out second service check (G2) at
250 hours or 6 months from date of commissioning, whichever is earlier.
Thereafter carry out subsequent service checks at every 500 hours or 6
months, whichever is earlier provided KOEL Premium Oil is used in the
engine.
c) Use recommended grade of lube oil and ensure periodic change of lube oil, as
recommended.
d) Use genuine air filter elements, lube oil filter elements, fuel filter elements,
coolant and additives, sourced from KOEL Authorised Service Dealer.
e) Please maintain the log-book for the genset at your end. The suggested
format for log-book is provided on page A-9.
f) Carry out all preventive maintenance and repair work of genset, through KOEL
authorised service dealers only.
g) The performance of genset depends on the quality and grade of lube oil and
periodic preventive maintenance. To ensure the genuinity of oil, KOEL has
launched the lube oil branded as K-Oil Premium. Please use K-Oil Premium
and genuine filters sourced through KOEL authorised parts and service dealer
and avail extended warranty.
A-1
-
Diesel Genset
Please provide following details to our Authorized

Service Dealer for quick restoration of your genset.
- Genset Model and Serial Number.
- Engine serial Number.
- Detailed site address
- Contact Person and Telephone/Mobile Number.
- Number of hours run till date
- Nature of failure
A-2
Diesel Genset
GENSET MODEL AND SERIAL NUMBER

_____________________________________________________
ENGINE MODEL AND SERIAL NUMBER

___________________________________________
KG ALTERNATOR SERIAL NUMBER, MAKE AND TYPE

__________________________________________
PANEL SERIAL NUMBER

__________________________________________
G1 (1ST SERVICE) CHECK CARRIED OUT ON

__________________________________________
G2 (2ND SERVICE) CHECK CARRIED OUT ON

___________________________________________
SERVICE DEALER'S STAMP AND SIGNATURE

__________________________________________
A-3
Diesel Genset
Use K- Oil Premium, Kirloskar Genuine filters, K Cool Super Plus and avail two years warranty
KIRLOSKAR GREEN D.G. SET WARRANTY
For Power Generation Non-Cellular Application Engines -
This warranty is applicable to Kirloskar Green (KG) diesel genset. The warranty is for 2 years from
the date of installation or 5000 operating hours or 30 calendar months from date of dispatch
whichever is earlier as detailed below, subject to use of Kirloskar K-Oil Premium. Kirloskar
genuine filters. K-Cool Super Plus and services sourced through KOEL authorised Service
Dealer.
For Power Generation Non Cellular Application Engines and KG
Alternator -
The warranty is for 2 years from the date of installation or 5000 operating hours or 30 calendar
months from date of dispatch whichever is earlier, subject to use of Kirloskar K-Oil Premium.
Kirloskar genuine filters. K-Cool Super Plus and services sourced through KOEL authorised
Service Dealer.Refer details in pages ahead.
Kirloskar Oil Engines Ltd. hereby warrants that this Kirloskar Green Genset is free from defects in
material, design and workmanship. This warranty shall be limited for repairs and replacement under
normal use, regular check up and maintenance of the Kirloskar Green Genset as per our
maintenance schedule and purchase and servicing of the Kirloskar Green Genset through our
authorised dealer.
This warranty is the only document given by us warranting the Kirloskar Green Genset. No other
document giving any warranty terms conflicting these contents shall be considered and entertained.
Kirloskar Oil Engines Ltd. is not liable to service, or repair of Kirloskar Green Genset free of costs
during the warranty period, for the Kirloskar Green Genset purchased from person other than an
authorised person or DG set Dealer or AGOEM of Kirloskar Oil Engines Ltd.
Kirloskar Oil Engines Ltd. is not liable for any loss or damage, direct or consequential, labour
charges or the effect of any accident resulting from defective material, faulty workmanship or
otherwise. In any case the liability of Kirloskar Oil Engines Ltd. will not exceed the Kirloskar Green
Genset price or the market value of the Kirloskar Green Genset whichever is lower and shall be
without interest.
Use K-Oil Premium for your Gensets.

For details of K-Oil Premium, please contact our Authorised Service Dealer.
A-4
Diesel Genset
This warranty does not apply for the following:

1. The Kirloskar Green Genset or engine failure due to any misuse including improper
shutdown, improper handling and adjustments, negligence, over speeding, alteration
of specification and due to accident or Act. of God.
2. Kirloskar Green Genset or engine if not maintained as per the maintenance schedule
given by Kirloskar Oil Engines Ltd.
3. If K-Cool Super Plus engine coolant is not used for liquid-cooled Genset.
4. Damage due to improper installation of the parts, components and accessories.
5. For the parts supplied under warranty or voluntarily or at special rates or free of charge,
the warranty will be applicable only to the unexpired portion of D G Set warranty.
6. Damage due to use of improper lubricant or the lubricant used other than suggested by
Kirloskar Oil Engines Ltd.
7. Normal wear and tear of the components of Kirloskar Green Genset / Engine.
8. For resale of Kirloskar Green Genset or if the Kirloskar Green Genset purchased is
second hand.
Warranty period for DG set components is as below.
For Power Generation Non Cellular Application
•Proprietary parts not manufactured by Kirloskar Oil Engines Limited like:
•Starter
•Alternator
•Fuel injection pumps
Service Dealer.
•Kirloskar Green Alternators
30 Calendar Months from Date of Despatch or 5000 operating hours or 24 calendar months from
date of installation, whichever occurs first.
•All other Electrical Components supplied along with Genset like:
•Sensors
•Switches
•Engine Safety Units
•Actuator
•Controller card
A-5
Diesel Genset
Service Dealer.
**Warranty is not applicable for fuse & charging bulb.
•Kirloskar Green canopy Components supplied along with Genset like:
•Locks •Hinges •Fuel level gauges •Exhaust fan
Service Dealer.
**Warranty is not applicable for foam,canopy door & panels, bulb, and tubes
•Kirloskar Green Control Panel Components supplied along with Genset like:
•AMF module
•Relay card / board
•LVM / GVM
•Current transformer
•Battery chargers
•Switches
•MCB
•Contactors
Service Dealer.
**Warranty is not applicable for fuse, charging bulb and contactor coil
For Power Generation Cellular Application -

•Proprietary parts not manufactured by Kirloskar Oil engines like:
•Starter
•Alternator
•Fuel injection pumps
•Battery
•Exhaust Fan
A-6
Diesel Genset
For Power Generation Cellular Application - 15 Calendar Months from Date of Dispatch or 2500
operating hours, whichever occurs first. The warranty is subject to analysiis of defect by the
respective authorised dealer of manufacturer.
•All other Electrical Components supplied along with engine like:
•Sensors
•Switches
•Engine Safety Units
•Fuel level gauge
15 Calendar Months from Date of Dispatch or 2500 operating hours, whichever occurs
first.The warranty is subject to analysis of defect by the respective authorised dealer of
manufacturer.
**Warranty is not applicable for fuse and charging bulb.
•Kirloskar Green canopy Components supplied along with Genset like:
•Locks
•Hinges
•AVM
first.The warranty is subject to analysis of defect by the respective authorised dealer
of manufacturer.
**Warranty is not applicable for foam, bulb, and tubes.
•Kirloskar Green Control Panel Components supplied along with Genset like:
•AMF module
•Relay card / board
•LVM / GVM
•Current transformer
•Battery chargers
•Switches
•MCB
•Contactors
first.The warranty is subject to analysis of defect by the respective authorised dealer of
manufacturer.
**Warranty is not applicable for fuse & charging bulb & contactor coil.
Any claim or obligation in connection with the sale or performance of Kirloskar Green Genset shall
be subject to Pune Jurisdiction.
A-7
Diesel Genset
Conditions precedent to Kirloskar Green Genset warranty.

The Kirloskar Green Genset warranty given by the company is subject to the below condition which
are to be observed by every purchaser/user of Kirloskar Green Genset, without which the warranty
claims if any will be rejected.
A. Proper installation of the Kirloskar Green Genset is the sole responsibility of

the owner of the Kirloskar Green Genset.
B. Operation & Maintenance as recommended by the company within the limits
mandated by the specifications.
C. Any defective part claimed, to be returned to Kirloskar Oil Engines Ltd., if such
part is replaced by the company under warranty, the returned part becomes
the property of the company, this transportation charges to be paid by the
customer.
D. In case of interchange of part between Kirloskar Green Gensets / Engine shall
void the warranty. Unauthorised repair work will make the warranty null and
void.
E. For the proprietary parts not manufactured by Kirloskar Oil Engines Ltd., such
as Fuel Injection Equipment, Electrical Equipment and Instruments etc. the
warranty terms of respective supplier will be applicable.
The warranty detailed above is offered for the Kirloskar green power
ideas Diesel Genset consisting of Kirloskar Engine, Kirloskar Green AC
Generator & sound proof enclosure branded Kirloskar Green and
control panel.
To meet specific customer needs, your Genset may not contain

Kirloskar green power ideas AC Generator, soundproof enclosure, or
control panel. If so warranty for such aggregates may please be availed
from the manufacturers of these aggregates. The seller of the Genset
will be happy to provide you the details.
Log Sheet
Please find a sample of Log Sheet on following sheets for your reference. You are requested to
maintain a separate log book registering the following mentioned parameters in the table.
A-8
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-9
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-10
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-11
Diesel Genset
Engine________________________ RPM_________________ HP____________
Date
Daily use in
hours
Hour meter
reading
Coolant
Temp (°C)
Pressure
(Kg/cm2) or
Lube Oil (bar)
Temp
(°C)
Fuel added
(Liters)
Lube oil
added (liters)
Engine
(RPM)
Current
(Amp) 3-
phase or 1-
phase
Voltage (V)
Frequency
(Hz)
PF & kW in
Controller
kWH meter in
Controller
Remarks -
Record
events of
maintenance
/ repairs
A-12
Time FIRST SERVICE CHECK (G1) - ENGINE SIDE Date
D G Set Parameters (Within 30 days from date of commissioning or first 50 hours of Genset run, whichever is earlier.) S. R. Number :
Engine Type : Application Code / Sr. No. :
Radiator Sr. No. : Turbocharger Sr. No. :
FIP Sr. No. : Electronic Governor Sr. No. :
Installation Dt : Commissioning Date:
Hours run and the date of visit :
Make of Alternator : Rating : Sr. No. :
P ha s e : S ingle / T hre e Type : B rus hle s s / B rus h Type F ra me :
Alternator Control Panel : AMF / Non AMF Make : Sr. No. :
Type of Load : Resistive / Inductive / Capactive /
Canopy : Sr. No. :
DG Set Tested on full load for hours.
Current
Lube Oil Pressure : Lube Oil Temp. : Voltage : R: Amp.
Y: Amp.
Water Temp. : Abnormal Noise : Frequency : B: Amp.
Ambient temp. (air temp. near air-cleaner element) :
S a fe tie s : L ow L ube O il P re s s ure – W ork ing / N ot Work ing

H igh L ube O il / W a te r Te mp – W ork ing / N ot Work ing
V B e lt F a ilure – W ork ing / N ot Work ing
Leakages, if any and the corrective action
Overall Performance of DG Set OK / Not OK.
Remarks of the service dealer representative :
Educated Customer on routine maintenance to be carried out :

t Cleaning of Air Cleaner (Dry / Oil Bath), Restriction Indicator operation. Yes / No
t Lube Oil & Oil Filter Change Yes / No
t Fuel / Filter Element Change Yes / No
t Cleaning of Radiator Cooling ns Yes / No
t Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine. Yes / No
Customer Remarks : Customer Name :
Site Address :
Tel. No.
Name, Signature & Designation of AGOEM Name & Address Name, Signature & Designation of
Customer Representative. Service Dealer Representative.
N . B . - P lea s e f ill t he inf orma t ion, a s a pplic a ble. P a ge N o . 1 o f 3

1) KOEL HEAD OFFICE COPY
ALTERNATOR CHECK POINTS - DURING G1 CHECKS
S l N o. S e rvic e P oint R e m a rk
1 Alternator Checks to be carried out during stop condition for
Ma in S ta tor W inding le a ds tig htne s s a t Ma in Te rmina l. O K / NO T O K
All AV R c onne c tions tig htne s s . O K / NO T O K
O utgoing c a ble c onne c tions tig htne s s . O K / NO T O K
2 Check for Seperate Earthing connections for neutral & Genset body,
both s hould be c onne c te d to e a rth pit. O K / NO T O K
P our s uffic ie nt wa te r in to E a rth pit. DO N E / N O T DO N E
C he c k outg oing ma in c a ble c onne c tion a t te rmina l. O K / NO T O K

Observe proper lugs, crimping & glands.
3 Start the Set and observe the following parameter-
C he c k for s ta ble out put volta g e from Alte rna tor. O K / NO T O K
Check for Balance load. ( unbalance should not be more than 10 % of total load ) Balance / Unbalance
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor ( if available )-
4 Connected Load details - Unit - KW/ KVA
Total Motor load connected -
AC / DC Drive ( 3 ,6,12 pulse ) load connected.
UPS connected -
Other load details like fan / lights. -
Total Load connected -
Site Address :
Tel. No.

CHECK FOR CONTROL PANEL - DURING G1 AND G2 CHECKS
Sl No. Service Point Status
1. Check the tightness of crimping of cables -
Ma ins c a ble tightne s s & lugs c rimping & gla nd in c ontrol pa ne l . OK / no t O K
G e ne ra tor c a ble a t c ontrol pa ne l a nd a lte rna tor te rmina l. OK / no t O K
C orre c t c a ble s iz e with c orre c t lugs . OK / no t O K
C onne c tion a re tight. ( All powe r & c ontrol c a ble ) OK / no t O K
2. C he c k the E a rth c onne c tion of c ontrol pa ne l. OK / no t O K
C he c k c ontrol pa ne l is mounte d on AV mounting or c he c k vibra tion. OK / no t O K
3. Accessories -
AMF module type
MCCB ( make & rating )
Mains contactor ( make & rating )
Generator contactor ( make & rating )
4. Check for tightness of following connections -
Connection at main terminal board are tight with proper lugs or solder end Ok / not OK
P owe r c onne c tion a t both C onta c tors a re tight. O K / no t O K
C onne c tion a t a ll fus e s or MC B a re tight. O K / no t O K
Check the proper tightness of all relays at relay base with proper relay locking clips. Ok / not OK
5. C he c k the B a tte ry volta ge a nd e ns ure tha t ba tte ry is fully c ha rge d O K / no t O K
Battery voltage
S pe c ific G ra vity of ba tte ry s olution ( re quire d 1. 270 ) O K / no t O K
Ensure all cells of battery are with electrolyte battery solution to max. level OK / not OK
Ensure charging of battery by charging alternator (if provided) or by Battery charger OK / not OK
C he c k B a tte ry te rmina l for c le a nline s s a nd tightne s s . O K / no t O K
6. Checking of electrical accessories -
C he c k a ll the ga uge s a re work ing. O K / no t O K
C he c k the e xha us t fa n work ing a nd dire c tion of fa n. O K / no t O K
C he c k s ole noid s upply is not more tha n 15-20 s e c . O K / no t O K
7. C he c k a ll the me te rs for work ing on c ontrol pa ne l work ing. O K / no t O K

8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. E ns ure AU T O / MAN U L mode ope ra tion of AMF pa nne l. O K / no t O K
Site Address :
Tel. No.

Time SECOND SERVICE CHECK (G2) - ENGINE SIDE Date
( Within 6 months from commissioning or second oil change) S. R. Number :
1 Application Code & Engine serial no & Type :
2 Customer Name :
3 Date of service check : G1 G1 S. R. Number
4 Installation date : Commissioning date :
5 No. of Hours run :
Service points: Action taken
1 t Change engine lube oil. t Done

(Drain the Engine Oil when the Engine is warm. Top up 0.5 liters more for
t
2,3,4 cylinder engines or as applicable to compensate Lube Oil Filter Capacity.
t Always replace Lube Oil filter element with every oil change. t Done / OK
2 t Incase of oil bath type air cleaner, clean air cleaner & re it with fresh lube oil. t Done / OK
Clean the precleaner bowl if applicable.
t In case of dry type air cleaner element follow the practice mentioned in O & M manual. t Done / OK
3 For Air Cooled Engines :

t Check for proper cowling ment for e ective cooling of the engine. t Done / OK
t Clean the cylinder liner & cylinder heads Clean by removing main cowling & t Done / OK
direct compressed air ow on the s, or clean with brush.
For Liquid Cooled Engines :
t Check up coolant level in radiator, compensatory tank or heat exchanger t Done / OK
& top up if required.
(For initial add Radiator coolant as recommended. Keep the cap
open after topping up & run the engine on low idle speed to remove air pocket.)
(Do not top up cooling system with plain water, use only recommonded coolant.)
t Check whether radiator are choked. Educate customer on how to clean the t Done / OK
radiator externally.
4 t Check button of feed pump. If choked, clean it. (educate customer) Cleaned.
t Drain the water from Water Separator. Cleaned.
t C ha ng e primary and main fue l filte rs a s pe r O & M s c he dule . t Done / OK
hence not
necessary.
5 Check for all External Fasteners as per Spe ed torques. Tightened

(Tighten all foundation bolts)
6 Check battery lead connections, check spe gravity of electrolyte. OK/ corrected
7 Check Belt tension and condition, & adjust /replace if required. Replaced/
Corrected/OK
8 If the engine is turbocharged, check for

t Leakages in air intake/exhaust piping t Done / OK
t Hose connections tightness t Done / OK
SECOND SERVICE CHECK (G2) - ENGINE SIDE
( Within 6 months from installation date or second oil change )
DG Set Tested during inspection for ho urs . C urre nt
Lube Oil Pressure : Lube Oil Temp. : Voltage : R: Amp.

Y: Amp.
Coolant Temp. : Abnormal Noise : Frequency : B: Amp.
Ambient temp. (air temp. near air-cleaner element) :

S a fe tie s : L ow L ube O il P re s s ure – Work ing / N ot W ork ing
H igh L ube O il / C oola nt Te mp – Work ing / N ot W ork ing
V B e lt F a ilure – Work ing / N ot W ork ing
Leakages, if any and the corrective action
Overall Performance of DG Set OK / Not OK.
Remarks of the service dealer representative :
Educated Customer on routine maintenance to be carried out :

t Cleaning of Air Cleaner and checking of r estriction Indicator operation. Yes / No
t Lube Oil & Oil Filter Change Yes / No
t Fuel / Filter Element Change Yes / No
t Cleaning of Radiator Cooling ns Yes / No
t Cleaning of Liner & Cylinder Head Fins in case of Air Cooled Engine. Yes / No
Site Address :
Tel. No.

ALTERNATOR CHECK POINTS - DURING G2 CHECKS
1. C he c k for Abnorma l nois e during running. O K / N ot O K
2. Check the ventilation grill is clean and free from dust for proper cooling . OK / Not OK
3. Check power cables connected at terminal are tight and proper lugs condition. OK / Not OK
4. Check for tightness of External Fastener of Coupling and Adaptor. OK / Not OK
5. P ut wa te r in the E a rth P it. O K / N ot O K
6. C he c k for P rope r E a rthing c onne c tions . O K / N ot O K
C he c k the tig htne s s of AV R c onne c tions . O K / N ot O K
7. Start the Set and observe the following parameter-
C he c k for s ta ble out put volta g e from Alte rna tor. O K / N ot O K
Check for Balance load. Load difference should be less than 10% of load Balance / Unbalance
in phases for 3 phase DG.
Current ( Amp ) - R- Y- B- N- phase respectively
Voltage (Volts ) - RY - YB- BR-
Power factor
8 Canopy Checks
C he c k C a nopy doors for prope r fitme nt a nd a lignme nt O K / N ot O K
C he c k C a nopy for e xte rna l & inte rna l rus ting . O K / N ot O K
C he c k C a nopy loc k s for prope r ope ra tion. O K / N ot O K
Check temperature d erence between canopy inside & outside by closing the Di rence -
doors and running the Genset on full load for atleast 30 minutes.
Site Address :
Tel. No.

CHECK FOR CONTROL PANEL - DURING G1 AND G2 CHECKS
Sl No. Service Point Status
1. Check the tightness of crimping of cables -
Ma ins c a ble tightne s s & lugs c rimping & gla nd in c ontrol pa ne l . OK / no t O K
G e ne ra tor c a ble a t c ontrol pa ne l a nd a lte rna tor te rmina l. OK / no t O K
C orre c t c a ble s iz e with c orre c t lugs as per KOEL specifications. OK / no t O K
C onne c tion a re tight. ( All powe r & c ontrol c a ble ) OK / no t O K
2. C he c k the E a rth c onne c tion of c ontrol pa ne l. OK / no t O K
C he c k c ontrol pa ne l is mounte d on AV mounting or c he c k vibra tion. OK / no t O K
3. Accessories -
AMF module type
MCCB ( make & rating )
Mains contactor ( make & rating )
Generator contactor ( make & rating )
4. Check for tightness of following connections -
Connection at main terminal board are tight with proper lugs or solder end. OK / not OK
P owe r c onne c tion a t both C onta c tors a re tight. O K / no t O K
C onne c tion a t a ll fus e s or MC B a re tight. O K / no t O K
Check the proper tightness of all relays at relay base with proper relay locking clips
5. C he c k the B a tte ry volta ge a nd e ns ure tha t ba tte ry is fully c ha rge d O K / no t O K
Battery voltage
S pe c ific G ra vity of ba tte ry s olution ( re quire d 1. 270 ) O K / no t O K
Ensure all cells of battery are with electrolyte battery solution to max. level OK / not OK
Ensure charging of battery by charging alternator (if provided) or by Battery charger OK / not OK
C he c k B a tte ry te rmina l for c le a nline s s a nd tightne s s . Apply petroleum jelly to battery terminals. O K / no t O K
6. Checking of electrical accessories -
C he c k a ll the ga uge s a re work ing. O K / no t O K
C he c k the e xha us t fa n work ing a nd dire c tion of fa n. O K / no t O K
C he c k s ole noid s upply is not more tha n 15-20 s e c . O K / no t O K
7. Check all indicated parameters on control panel. O K / no t O K

8. Mains voltage ( EB Power ) -
Mains current ( EB Power ) -
9. Generator voltage -
Generator current-
10. E ns ure AU T O / MAN U L mode ope ra tion of AMF pa nne l. O K / no t O K
Site Address :
Tel. No.

Diesel Genset
Genset
C1. About KOEL ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.1 State‐of‐the‐art Manufacturing Setup ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.2 Design and innovation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.3 Kirloskar Green Power Facts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐1
C1.4 Awards and Accolades ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C1.5 Note ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C2. Safety ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐2
C3. Ratings Plate‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐3
C4. Lifting the genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐4
C5. Moving the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐6
C6. Technical Data ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C6.1 Liquid Cooled Gensets with Acoustic Canopy ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐7
C7. Genset with Liquid Cooled Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C7.1 Introduction ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C7.2 Description Of Genset Package ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C7.3 Canopy ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8. Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.1 Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐8
C8.1.1 Liquid Cooled Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9
C8.2 Engine Governor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9
C8.3 Brushless Alternator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐9
C8.4 Vibration Isolation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐10
C8.5 Fuel Tank and Base Frame ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐10
C8.6 Silencer and Exhaust System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.7 Genset Circuit Breaker ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.8 System Protection‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.9 Control Panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.10 Control Panel Power Supply ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C8.11 Control Panel Mounting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐11
C9. Components of genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐12
C9.1 View from Fuel Pump side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐12
C9.2 View from Starter Motor side ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐14
C10. Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐15
C10.1 Location ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐15
C10.2 Foundation‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐17
C10.2.1 Features of Foundations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐18
C10.2.2 Soil Load Bearing Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐18
i
Diesel Genset
C10.2.3 Calculation for Foundation Depth ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19

C10.3 Cooling and Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐19
C10.3.1 Genset installed in a room ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20
C10.3.2 Ventilation check ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20
C10.4 Air Intake Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20
C10.4.1 Air Inlet ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐20
C10.5 Exhaust Installation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐21
C10.5.1 Exhaust piping dimension recommendation ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐22
C10.5.2 Flexible Connections ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26
C10.6 Fire Precautions ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26
C10.7 Electrical Connection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐26
C10.7.1 Earthing/Grounding ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐27
C10.7.2 Protection ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28
C10.7.3 Loading ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28
C10.7.4 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐28
C10.8 Noise Control ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐29
C10.9 Pre‐commissioning Checks ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐29
C10.10 Prior to Starting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐30
C10.10.1 Warning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐31
C10.10.2 Manual Mode (Non‐AMF) Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐32
C10.10.2.1 Starting the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐32
C10.10.2.2 Stopping The Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33
C10.11 AMF Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33
C10.11.1 Activating AMF ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐33
C10.12 Daily Checks ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐34
C11. Battery ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐35
C11.1 Battery Maintenance Schedule ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐35
C11.1.1 Battery Tips ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐36
C12. Optional Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.1 Battery Charger ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2 Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.1 Engine Heater Plug ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.2 Anti‐condensation Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C12.2.3 Electronic Governor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C13. Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐38
C13.1 Daily Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐39
C13.1.1 Maintenance Every Six Months or 250 Hours ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐39
C13.1.2 Alternator Unit Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C13.1.3 Cleaning of Radiator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C13.1.3.1 External Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐40
C13.1.3.2 Internal Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐41
ii
Diesel Genset
C14. Control System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐41
C14.1 Control Panel‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C14.1.1 AMF panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐42
C14.1.2 Non‐AMF panel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐43
C15. Controllers ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐43
C15.1 Kirloskar Green Controller‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ C‐43
C16. Circuit diagrams ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐
iii
Diesel Genset
iv
Diesel Genset
Genset
C1. About KOEL
Incorporated in 1946, Kirloskar Oil Engines Limited (KOEL) is a part of the Kirloskar Group.
KOEL is one of the leading and largest manufacturer of diesel engines ranging from 4 HP to
800 HP and from 2,400 HP to 11,000 HP with the annual manufacturing volumes exceeding
3,20,000 engines.
Branded as 'Kirloskar,' KOEL engines are used as prime movers and are most preferred choice
when powering earthmoving and construction equipment, agro-industrial applications, material
handling equipment, marine applications and equipment used by the defense forces.
Today KOEL is one of the world's leading players in the Diesel Genset market and is committed
to offer best in its class products and services to all customers across the globe.
C1.1 State-of-the-art Manufacturing Setup
The engines are manufactured in a most eco-friendly environment in India at our Pune-Khadki,
Kolhapur- Kagal, Rajkot and Nashik Plants. The Kagal factory has both domestic and export
oriented unit.
The manufacturing plants are well equipped with most advance and high-tech machineries,
having state of the art, cutting edge technology for machining of all the critical components.
C1.2 Design and innovation
KOEL has an ultra modern Research and Engineering facility for Design, Development and up-
gradation of engines, systems, controls and canopy. A team of dedicated and experienced
professionals carry out the proactive cutting edge research to develop innovations that
delight customers in India and abroad to give KOEL the edge over competition.
C1.3 Kirloskar Green Power Facts
•Fully integrated Gensets and Power systems to meet current as well as future needs of
customers.
•Market leader with full range from 5 kVA to 625 kVA.
•Every 2nd Gen-set in the country is a Kirloskar Green Genset.
C-1
-
Diesel Genset
•Over 75,000 Gensets all over the country help to run the Indian Telecom Network.
•More than 15,000 Gensets deployed along the Indian Borders providing reliable power to the
Defence forces.
•More than 100 special containerized Genset packages, supplied for critical Defence
applications.
•Large number of satisfied customers from Manufacturing, Software, Construction,
Infrastructure sector in 320 kVA to 625 kVA range.
C1.4 Awards and Accolades
•KOEL pursues highest quality adherence for zero defect

•Rated “Most Preferred Brand” and “Customer Service Support Leadership” by Frost &
Sullivan.
•Winner of the Rated Best in Class in service by AC Nielsen.
•ISO 9001 certification for Quality Management System since 1992 by ABS QE Inc.
•ISO/TS 16949:2002 for Quality Management System since 2007 by ABS QE Inc.
•ISO 14001 certification for Environment Management System since 1999 by TUV NORD.
•OHSAS 18000:2007 certificate for Health, Safety 6k Environment since 2009 by TUV NORD.
C1.5 Note
•The information provided for this manual is subject to change without notice as we
continuously endeavor to offer the best products to our customers.
•Ensure that the use lube oil, filter filler, coolant, carbon sludge is not thrown away in open
land, gutters and landfills. This could lead to contamination of soil, rivers, streams and ground
water supplies.
•Ensure complete adherence of the local legislation rules of pollution control, electrical
installation, safety, fire hazard, waste treatment and waste disposal.
C2. Safety
KOEL encourages safety as a corporate philosophy.
•It is important that every individual of the team engaged in installation and subsequent
operation is thoroughly aware of the entire process and appreciates the criticality of each
action.
•Ensure that the tools and tackles used are of adequate capacity and are in proper working
conditions.
•Strictly follow all universal and local safety norms.
•Always remember that there are no short cuts in safety.
C-2
Diesel Genset
C3. Ratings Plate

The genset’s model and serial number are stamped on nameplate along with engine rating,
electrical ratings, and referred standards. The name plate details must be given while ordering
spares and asking for service. KOEL gensets are built by the company themselves as well as
by Genset Original Equipment Manufacturers (GOEMs), who produce under license from the
company. The gensets from KOEL or GOEMs carry different ratings plates to identify the
source of manufacture.
Manufactured by
KIRLOSKAR OIL ENGINES LTD.
A Kirloskar Group Company
Khadki, Pune 411 003 I www.kirloskar.com
GENSET MODEL/kVA
PRODUCT CODE
MFG. DATE/SR. NO.
NOISE LIMIT
TYPE APPROVAL
CERTIFICATE NO.
THIS PRODUCT CONFORMS TO THE
ENVIRONMENT (PROTECTION) RULES 1986.
Figure C - 1: Ratings Plate - KOEL manufacture
Manufactured by
XYZ COMPANY LTD.
XYXYXY Road, Pune 411 003. INDIA.
www.xyz.com
GENSET MODEL/kVA
PRODUCT CODE
MFG. DATE/SR. NO.
NOISE LIMIT
TYPE APPROVAL
CERTIFICATE NO.
THIS PRODUCT CONFORMS TO THE ENVIRONMENT (PROTECTION) RULES 1986.
Under License from
Khadki, Pune 411 003 I www.kirloskar.com
Figure C - 2: Ratings Plate - GOEM manufacture
C-3
Diesel Genset
C4. Lifting the genset

The genset is a heavy object that demands great care while lifting and transporting.
•Only trained and qualified personnel should lift the genset.
•All personnel should wear personal protective gear such as safety shoes, helmets etc.
•All equipment used for lifting should be rated for handling the weight of the genset.
•Attach the sling hooks of lifting crane etc. only in the lifting eyes (holes) provided on the base.
•Attaching hooks anywhere else could permanently damage the genset.
Figure C - 3: Unloading the genset
C-4
Diesel Genset
Figure C - 4: Location and use of lifting eyes

•Use spreaders to move straps away from the body of the genset.
•The width of spreader must be greater than the genset’s width.
•Do note use chains or wire rope.
•Use slings of soft material like Nylon rope / flexible belt to avoid damage to the genset.
Figure C - 5: Use of flexible belt for lifting
C-5
Diesel Genset

Figure C - 6: Lifting the genset
C5. Moving the Genset
Figure C - 7: Use of lifting tackle and crane

Moving the genset to its installation location requires extreme vigilance and care.
C-6
Diesel Genset
•Only trained and qualified personnel should lift the genset.

•All personnel should wear personal protective gear such as gloves, safety shoes, helmets
etc.
•All equipment used for lifting genset should be rated for handling the weight of the genset.
• Attach the sling hooks of lifting crane etc. only in the lifting eyes (holes) provided on the
base.Use correctly rated equipment for lifting the genset.
•Use specially designed tackles with spreaders to lift genset.
•Use flexible belt to prevent damage to genset.
•Travel at a slow speed while transporting the genset,
•Ensure that the genset does not sway while moving, if required, stabilize with extra belts held
by personnel.
•Personnel should stand at the corners of genset to ensure that the moving object does not
foul any structure.
•Ensure that the moving genset does not touch any personnel.
•Ensure no personnel puts their body appendages (hands, feet) below a suspended genset at
low height or walk below a suspended genset at a higher height.
C6. Technical Data
C6.1 Liquid Cooled Gensets with Acoustic Canopy
Table 1: Liquid Cooled Gensets*
Genset Model Engine Model Rated Maximum Representative Genset

Output at Recommended Dimension Approximate
1500 rpm Genset rating at ( L x W x H) Weight
0.8 pf (kVA)
(BHP) Continuous (mm) (Kg)
KG1‐20WSE1 2R1040 G1 25.5 20 2205X950X1295 930
KG1‐25WSE 3R1040T G1 42 25 2500X950X1295 1090
KG1‐30WSE 3R1040T G1 42 30 2500X950X1295 1090
KG1‐40WSE 3R1040TA G1 56 40 2750X1050X1495 1215
KG1‐45WSE 3R1040TA G1 56 45 2750X1050X1495 1215
KG1‐82.5WS 4R1040TA G1 102 82.5 3200X1100X2000 1710
* = All ratings at Normal Temperature and Pressure (NTP) conditions.
C-7
Diesel Genset
C7. Genset with Liquid Cooled Engine
C7.1 Introduction
KOEL genset is carefully designed to provide optimum performance and reliability with great
economy and minimum maintenance. This genset package is a result of over 55 years of
actual site experience to deliver a comprehensive system built with advanced engineering
concepts and backed by an efficient service network.
Please read this manual to understand operation and maintenance of the genset. By following
instructions in the manual and proper care, the genset will be always ready to respond to any
emergency standby or prime power needs.
C7.2 Description Of Genset Package
Gensets consist of an alternator driven by a diesel engine. The engine has systems such as
fuel, exhaust, cooling, electrical and control. These topics are covered in detail elsewhere in
this manual.
The engine has a governor that maintains the engine speed within a set tolerance to deliver
rated power and frequency as per ISO 3046, DIN 6271 AND BS 5514. The alternator produces
output with correct voltage, optimum wave form, fast response and precise voltage regulation.
C7.3 Canopy
KOEL gensets are housed in a canopy. Use of canopy has the following advantages:
•Reduces the noise produced by genset during operation.

•Allows installation of genset outdoors without needing a shade.
•Protects the genset from weather and vermin.
•Prevents pilferage of fuel etc.
•Creates a comprehensive ‘ready to use’ package that can be easily transported to another
location.
C8. Engine
The engine of the genset has proven reliability and is specifically designed to operate in
conjunction with an alternator. The heavy duty engine is an industrial type 4-stroke,
compression ignition prime mover fitted with all accessories necessary for reliable operation.
C8.1 Cooling System
KOEL offers gensets with air cooled as well as liquid cooled engines. This manual covers only
liquid cooled engines. Air cooled engines are covered under an independent manual.
C-8
Diesel Genset
C8.1.1 Liquid Cooled Engine
The engine uses coolant liquid that circulates around cavities in engine to reduce temperature
of cylinders and cylinder head. The coolant is circulated by an engine driven pump. The hot
coolant is further circulated through a radiator, which exchanges heat with air flowing through
its core. The air is pushed through the radiator core by an engine driven fan, that is driven by V-
Belts.
The radiator has a pressurized cap that allows higher pressure inside the cooling system and
prevents coolant from boiling away. The expansion of the coolant due to heat and pressure
forces the excess liquid to move to a Coolant Compensatory Tank. The same tank refills the
radiator after reduction in temperature creates a vacuum inside the cooling system.
The radiator fan also ensures a draught through the canopy. The hot air leaving engine leaves
canopy through grill in front of radiator. For enclosed gensets, good ventilation is achieved by
using special fans to remove radiated heat from engine and alternator and ensuring that there
is no hot air recirculation.
All genset installations require careful attention to air flow. The notes provided in the Installation
Section of this manual should be consulted before selecting a location for your genset.
C8.2 Engine Governor
The primary function of the governor system is to maintain engine speed in relation to varied
load requirements. This is accomplished by the governor which senses engine speed and
controls the engine fuel rate, in order to maintain practically constant speed. The engine speed
governor maintains engine speed within limits regardless of the steady load. As the alternator
load increases, the engine speed is reduced.
Because the speed must remain relatively constant, the governor, sensing engine speed, will
increase fuel flow to the engine, thus adjusting horsepower to a point sufficient to maintain
engine speed and compensate for the load change. The same principle is applied when the
load decreases. As the load is reduced the speed would increase, the governor will then
reduce fuel delivery thus decreasing the horsepower to maintain the proper speed.
C8.3 Brushless Alternator
The alternator is coupled to the engine with a flexible coupling.

Brushless excitation type alternator eliminates the maintenance associated with slip rings and
brushes. The internal components of the alternator are designed so as to assure efficient and
economical operation.
The control system consists of an automatic voltage regulator (within the alternator), protective
circuits and the necessary instruments to allow you to monitor the operation of genset. On most
models current is supplied through twelve leads enabling the operator to reconnect the genset
to obtain a variety of three phase voltages up to 480 volts. Single phase units supply current
through a two or three lead connection offering a variety of voltages from 120-250V. Units can
be supplied in 50 Hz outputs. See Alternator Section for further details of connections
available.
C-9
Diesel Genset
A brushless alternator is a synchronous rotating field type unit, which produces alternating
current. This alternator unit is completely self-contained and is designed and constructed to
provided trouble free operation, ease of maintenance and long service life.
C8.4 Vibration Isolation
All gensets are fitted with anti vibration mountings which are designed to reduce vibration being
transmitted from the rotating mass of the genset to the foundation on which the genset is
mounted. Vibration isolators are selected to suit the particular duty and are fitted between the
engine, alternator feet and the base frame. On some of the models the vibration isolators are
fitted between the base frame and the foundation depending on the system requirement.
C8.5 Fuel Tank and Base Frame
The design of the base frame incorporates removable fuel tank with a capacity of
approximately 8 hours operation. The tank is provided with fittings to facilitate either manual or
automatic filling. The base frame is manufactured from heavy gauge sheet steel and welded to
form a rigid assembly.
Figure C - 8: Tank Unit

The top surface of fuel tank has a ‘tank unit’ to interface with the engine. The tank unit contains
features such as fuel level gauge, fuel level sensor, fuel level switch, fuel line connection and
return line connection.
C-10
Diesel Genset
C8.6 Silencer and Exhaust System
Exhaust silencer is provided to reduce noise emission from the engine and designed to direct
exhaust gases to areas where they will not be objectionable.
On ‘stand alone’ open gensets, the exhaust silencer is generally placed outside the Genset
room, with suitable extension piping from engine. Stainless steel expansion bellow is provided
on the engine, to facilitate the exhaust piping. For generating sets with acoustic canopy,
residential type silencer is fitted inside or outside the canopy with flange fitting at the outlet to
enable discharge of exhaust gases at desired location, through extension piping, as required.
C8.7 Genset Circuit Breaker
To protect the alternator winding, a suitably rated moulded case circuit breaker or miniature
circuit breaker (depending on the genset model) is supplied mounted in a strong fabricated
steel enclosure.
Current transformers are fitted on each of the phases on the cabling to the circuit breaker
enclosure for current measurement. In some configurations the main circuit breaker may be
incorporated in the automatic transfer panel.
C8.8 System Protection
Control system provides protection of the engine against faults such as high temperature, low
oil pressure, over speed, low fuel level or other conditions. The system also prevents damage
to the cranking motor by automatically disengaging the motor after engine starts and deep
discharge of the starting battery by avoiding cranks if engine fails to start.
C8.9 Control Panel
All control panels are mounted in welded steel enclosures equipped with a sealed hinged door
for easy access and servicing. The control panel is available in several variations to suit the
requirement of the installation.
C8.10 Control Panel Power Supply
Engine instruments and the control panel are supplied from the battery fitted to the genset. This
battery also provides power for operation of the cranking motor to start the engine and for the
stop solenoid.
C8.11 Control Panel Mounting
The control panel and main circuit breaker are normally located on a separate stand that is
mounted on the base frame to ensure vibration free running. More complex control systems
have floor standing control panels. For gensets with acoustical canopy, the control panel is
fitted inside the enclosure. Suitable glass cover opening is provided on the enclosure to view
the instruments.
C-11
Diesel Genset
C9. Components of genset

The following drawings show the view of genset from fuel pump side and starter motor side.
The engine shown in the image is only illustrative, your genset may have a different engine.
19 7
13
18
14
20
12
6
11
17
10
16
15
9 8
2
5
Figure C - 9: View from Fuel Pump side
C9.1 View from Fuel Pump side
Various components are visible in this view. Only components relevant to genset operation or
maintenance are listed here. More details of other details are available in the engine section.
1.Base Frame
The genset is mounted on this is the frame.
2.Lifting Eye
Use the four lifting eyes spaced around the base frame to lift the genset The holes in the eye
should be used to attach a suitably rated lifting hook of a crane.
C-12
Diesel Genset
3.Canopy
This is the sound and weather proofing cover fitted over the base frame. Vents in the canopy
permit the airflow through the interiors. Access sections of genset for operation and
maintenance through lockable doors on sides.
4.Fuel Tank
Located in the base frame, this tank stores diesel fuel for the engine.
5.Fuel Filling Spout
Fill diesel in the tank through this spout, accessible only after unlocking the left hand side door.
6.Fuel Pump
Injects precisely timed and metered amounts of fuel into engine for combustion.
7.Diesel Engine
Prime mover that drives the alternator.
8.Alternator
Generates AC electrical power when rotated by the engine.
9.Anti-Vibration Mount
Four Anti-Vibration Mounts help isolate the engine and alternator vibrations from reaching the
canopy.
10.Control Panel
Contains switchgear, gauges, controls and engine termination.
11.Air Cleaner
Cleans air meant for combustion of dirt and air-borne particles.
12. Air Intake
Pipe to channel cool air into the air cleaner.
13.Exhaust Silencer
Reduces noise borne in the engine exhaust.
14.Exhaust Bellows
Flexible portion to match vibrating exhaust pipe with rigidly mounted silencer.
15.Lube Oil Filter
Cleans lube oil as it circulates through the engine.
16.Fuel Filters
Diesel passes through two fuel filters that trap different sizes of dirt particles.
17.Radiator
Reduces temperature of circulating engine coolant by passing air through radiator core.
18.Radiator Pressure Cap
Keeps the cooling system pressurized to set value.
19.Radiator FIlling Port
Fill radiator from outside of canopy through this opening.
20.Compensatory Bottle
Stores coolant expelled or sucked in by the radiator during operation. During normal use, top
up coolant in this bottle and not the radiator.
C-13
Diesel Genset
21.Radiator Drain
Used to conveniently drain radiator coolant during maintenance.
C9.2 View from Starter Motor side
Various components are visible in this view. Only components relevant to genset operation or
maintenance are listed here. More details of other details are available in the engine section.
Several items covered in the previous section are not listed here.
10 6
3
9
14
7
12
15 13
8 11
5 4 2
Figure C - 10: View from Starter Motor side
1.Base Frame
The genset is mounted on this is the frame.
2.Lifting Eye
Use the four lifting eyes spaced around the base frame to lift the genset The holes in the eye
should be used to attach a suitably rated lifting hook of a crane.
3.Canopy
This is the sound and weather proofing cover fitted over the base frame. Vents in the canopy
permit the airflow through the interiors. Access sections of genset for operation and
maintenance through lockable doors on sides.
C-14
Diesel Genset
4.Fuel Tank
Located in the base frame, this tank stores diesel fuel for the engine.
5.Battery
Provides DC electrical energy to start the engine and operate controls.
6.Diesel Engine
Prime mover that drives the alternator.
7.Alternator
Generates AC electrical power when rotated by the engine.
8.Anti-Vibration Mount
Four Anti-Vibration Mounts help isolate the engine and alternator vibrations from reaching the
canopy.
9.Control Panel
Contains switchgear, gauges, controls and engine termination.
10.Air Cleaner
Cleans air meant for combustion of dirt and air-borne particles.
11. Exhaust Silencer
Reduces noise borne in the engine exhaust.
12.Exhaust Bellows
Flexible portion to match vibrating exhaust pipe with rigidly mounted silencer.
13.Radiator
Acts as a heat exchanger between cooling air blowing over radiator fins and hot engine coolant
circulating through radiator core circulating through rthe coolant.
14.Radiator FIlling Port
Fill radiator from outside of canopy through this opening.
15.Starter Motor
Rotates the crankshaft to start the engine.
C10. Installation
C10.1 Location
Selecting a location for the genset is very important part of any installation procedure. Locate
the genset in an area that will provide adequate ventilation and physical protection for the unit.
Place the genset to allow easy movement all around for maintenance and replenishment of fuel
etc. Ensure 1 to 2 meters space all around the genset.
C-15
Diesel Genset

Figure C - 11: Space around a genset

In case two gensets are installed next to each other, ensure a minimum of 2 meters space in
between their sides. This is to ensure easy access even if doors of both gensets are open.

Figure C - 12: Space between two gensets

•Adequate fire fighting facilities suitable for diesel, oil and electrical fires should be available at
location.
•The location should be clean, dry and have good drainage capabilities.
•The space around the gensets should be adequate to undertake major overhaul or service
operations. In some cases it may be necessary to remove major components.
C-16
Diesel Genset
•The location must allow free ventilation of inlet air and exhaust.
•Ideally the genset should be in open air. In case genset is to be mounted in side the building,
ensure proper ventilation around the genset.
•Choose the direction of placement such that natural wind helps in air flow of the genset.
•Locate the genset as near as possible to the load.
•Place the genset at one end of the site in the direction of wind to avoid dust entry into the
genset.
•In case the site’s atmosphere contains extra suspended particles like at Cement or Textile
factories, stone quarry, the genset may be placed at some distance.
• For highly dusty sites refer to the supplier representative for recommendation.
•The site selection should be complete before the genset reaches to location.
•Ensure sufficient illumination at the installation site. The interiors of acoustic canopy should
be clearly visible without help of any extra lighting.
•Provide suitable, safe access to elevated items.
•Standard tool kit (not supplied with genset) should be available easily and quickly. It should be
protected from corrosion and stored in a dry place.
•If spares are supplied along with the equipment, they should be protected from corrosion and
stored in a dry place.
•While designing the layout, provision should be made for:
-Proper laying of cables.
-Free access to fuel lines and filters.
-Sufficient space in front of the breather vent.
-Space for draining of coolant and lube oil.
-Adequate oil storage space.
-Space for safe storage of spares.
C10.2 Foundation
The foundation provides a leveled platform to seat and seal the Genset.
•Supports 1.5 times of the total dead weight of the single genset and 2 times of the total dead
weight for multiple gensets.
•Support the dynamic load of genset while in running. For dynamic load of the genset, please
refer to manual or contact the supplier.
•Isolate the surrounding structures by absorbing the vibration of genset while running.
C-17
Diesel Genset
C10.2.1 Features of Foundations
•Provide a reinforced concrete foundation for the genset. Do not install acoustic canopy on
loose sand or clay.
•The foundation should have sufficient mass in proportion to the size of the genset to provide
the rigid support necessary for minimizing deflection and vibration.
•Before easing the genset on the foundation, ensure that no hard material such as stones or
steel objects remain on the mounting surface as this may damage fuel tank at the bottom.
•Design the foundation while considering safe load bearing capacity of soil.
•The length and breadth of foundation should be at least 150-300 mm more on each side than
length and breadth of the acoustic canopy.
•Ensure sufficient space for personnel to walk all around the foundation.
•Check the level of foundation diagonally as well as across length for even flatness.
•In case surface is rough, lay nitrile rubber strips, 15mm thick and equal to the width of the
base frame, under the genset, along the periphery of the base frame.
•It is recommended to raise foundation height about 150 to 200 mm above ground level, to
helps maintain cleanliness and avoid flooding.
•Ensure that concrete is completely set and cured before positioning the canopy.
•Consult a qualified structural engineer when seismic events are in consideration.
•The foundation may be located on soil, structural steel, building floors etc., provided the total
weight of the foundation and genset package does not exceed the allowable bearing load of
the support.
•Allowable bearing loads of structural steel can be obtained from Engineering Handbooks
while local building codes will provide the allowable bearing loads for different types of soil.
C10.2.2 Soil Load Bearing Capacity
Table 2: Soil Load Bearing Capacity
Nature of the load bearing material Safe bearing capacity kg/sq. meter
Hard rock granite 2,44,100-9.76.400
Medium rock shell 97,600- 1.46.400
Hard pan 78.100-97.600
Soft rock 48,800 58.600
Hard clay 39.000 - 48.800
Gravel and coarse sand 39.000 - 48.800
Loose, medium coarse and compact fine sand 29.300-39.000
Medium clay 19.500 39.000
Loose fine sand 9.750 - 39.500
C-18
Diesel Genset
Table 2: Soil Load Bearing Capacity (Continued)
Nature of the load bearing material Safe bearing capacity kg/sq. meter
Soft clay 9,750
C10.2.3 Calculation for Foundation Depth
1.5  W
Depth = --------------------------------------
2400  B  L
Where:
• Foundation Depth is in Meters

•W = Total wet weight of Genset in Kgs.
•2400 = Density of concrete (Kg/cubic meter)
•B= Foundation width in meters
•L= Foundation length in meters
C10.3 Cooling and Ventilation
Cool, clean and fresh air should flow the alternator end to the engine end. The exhaust should
also flow in the direction of cooling airflow.
•Incoming cold air enters openings behind the alternator.

•The cold air first passes over the alternator, then the engine, picking up radiant heat as it
passes.
•It then passes through the radiator and is discharged through a duct to the outside of the
genset room.
Figure C - 13: Airflow through genset

•A temperature rise of 5-15 Deg C (9-27 Deg F) in the cooling air can be expected at full load.
C-19
Diesel Genset
•The radiated heat given off by the engine, generator and exhaust piping can result in a
temperature high enough to adversely affect operating and maintenance personal or the
performance of the genset.
•Locate the genset in a room or area that will provide or allow sufficient ventilation to remove
this heat as well as the heat radiated from the engine cooling liquid by the radiator. Preferably
provide exhaust fans to drive hot air outside.
•If acoustic canopy is placed in an enclosed place, ensure that it is well ventilated and exhaust
gases are driven out of the enclosure.
•Ensure that hot air is positively discharged from the building by fitting a flexible connection
between the radiator and the duct.
•The size of the openings should be calculated to ensure that excessive restriction is not
imposed on the flow of cooling air. Openings should at least be as big as the radiator core
area but, as a guide, an area on 150% of the core area of the radiator should be allowed for.
•For weather protection, louvers should be fitted to the intake and exhaust openings. These
can be either of the fixed or movable type.
•Manually operated movable louvers may be acceptable in some cases, but they are not
acceptable for automatic standby units.
•Radiator air should not be depended upon to open/close the louver vanes.
•Ensure that the exhaust releases in the direction of wind flow.
C10.3.1 Genset installed in a room
For basement installations, forced ventilation through air ducts is required. Contact supplier
representative for recommendation of values of air required and fan flows for various gensets
rated at 1500 rpm. Ensure the values are with lagged exhaust piping in the room and silencer
fitted outside the room.
C10.3.2 Ventilation check
Maximum allowed temperature rise above ambient in genset canopy air intake is 7°C.
•Measure the ambient air temperature outside the canopy in shade.
•Measure the temperature inside the canopy near air cleaner inlet of engine.
•Calculate temperature difference between canopy temperature and ambient i.e. delta T.
•It may be necessary to measure actual airflow using an anemometer.
C10.4 Air Intake Installation
C10.4.1 Air Inlet
•Engine inlet air must be clean, dry and as cool as possible. These conditions will drastically
effect both engine life and performance.
C-20
Diesel Genset
•Air temperature near air cleaner should not be more than 5°C above ambient. Sufficient
window openings are required to maintain air inlet temperature within the limit.
•Normally the inlet can be taken from the area surrounding the installation site. However, in
some cases the condition of the air surrounding the machine may warrant ducting the air from
outside or another room.
•When it does become necessary to duct air in, the air cleaner should remain mounted to the
engine as opposed to a remote mounting (such as on a roof or in another room). This will
eliminate the possibility of dirt leaking through the duct work upstream of the air cleaner.
C10.5 Exhaust Installation
The exhaust system is used to direct exhaust gases to non-confined areas and reduce the
noise to tolerable levels. When designing a system the main objective is to minimize back
pressure. Excessive back pressure in an exhaust system will create horsepower loss and
increase the engine operating temperature, and emissions.
•Exhaust pipe outside the canopy should be lagged with aluminum sheet cladding. Typical
thickness of lagging - 50mm.
• If exhaust pipe length is more than 7 meter, add additional flexible bellows.
• Higher back pressure in exhaust system than specified limit will lead to:
-Higher fuel consumption
-Poor performance
-Engine component failure due to higher exhaust temperature
-Reduced engine life
C-21
Diesel Genset
 
Figure C - 14: ERW and GI pipes

•Use of 'B class' MS ERW pipes or prefabricated stainless steel pipe and long bend elbows is
recommended for exhaust piping.
•Never use galvanized water pipes (GI pipes) for exhaust piping as they are heavy and costly.
C10.5.1 Exhaust piping dimension recommendation
•A maximum of 4 bends is acceptable in the exhaust pipe.

•Increase the pipe diameter by approximately 12.2 mm (0.5 inch) after every 5 meters length
above silencer.
•Curve the pipe. Do not use right angle bends.
Figure C - 15: Use Curved Pipe for Exhaust

C-22
Diesel Genset
Figure C - 16: Do not use Angle Pipe for Exhaust

•Provide a rain cap to avoid entry of rain water into the engine. Add a slope to the horizontal
run of the exhaust piping downwards, away from engine to the condensate trap. Silencer
should be installed with drain plug at bottom.
Figure C - 17: Rain-cap

•If the exhaust pipe cannot be bent at 90 degree, provide a rain cap over the pipe’s mouth, as
shown. In such case, the distance between exhaust pipe end, and the rain cap should be
higher than at least twice the diameter of the pipe.
C-23
Diesel Genset
Figure C - 18: Rain-cap on straight Exhaust Pipe

•Fit a loose grill over the end of the exhaust to prevent birds or small animals entering the pipe.
•For installations in the basement or inside a room, the exhaust piping should be directed
outside through the wall or the ceiling.
•For installations in populated areas, direct the exhaust above roof height of adjacent
buildings, as per statutory requirements.
•When bends are required in an exhaust system, always make the radius at least 150% of the
inside diameter of the pipe.
•As most exhaust system designs are governed by the physical characteristics of the building
or room in which they are located, it is of the utmost importance that the exhaust pipe be
routed in a path offering the least amount of turns or bends so not to increase back pressure
more than 50 mm of Mercury Column.
•Generating sets with acoustic canopy are provided with exhaust outlets having connecting
flanges. Exhaust gases from the outlet can be routed away to desired location.
•For up to 3 meter distance exhaust pipe size same as provided on the outlet can be used. For
longer lengths total exhaust system assessment should be done by competent person.
•In no case, exhaust back pressure should exceed 50 mm of Mercury Column when measured
at exhaust manifold of engine, at rated load.
•Be sure that all pipes are well supported and that springs or other dampers are used at points
of high vibration.
•Due to the heat radiation of the exhaust pipes it is recommended that all pipes be located at
least 250 mm from any combustible material.
•Wrapping the exhaust pipes with high temperature insulation or installing fitted insulated
sections will aid in preventing excessive heat radiation within the room.
•At points where the piping passes through a wall or roof, a metal thimble guard 300 mm in
diameter slightly larger than the pipe should be installed.
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Diesel Genset
•Bevel the end of the pipe at a 30 - 45 degree angle. Should the pipe end be horizontal, bevel
the pipe from the top back to the bottom. This will not only reduce the noise levels at the outlet
but will also minimize entrance of precipitation on horizontal pipes.

Figure C - 19: End of Exhaust Pipe

•The level or height at which the outlet is situated should be sufficient to prevent fumes and
odours from becoming an annoyance or potential hazard. Also, an exhaust pressure actuated
rain-cap is recommended for use on vertical outlet pipes.
•Any long horizontal or vertical piping should include water legs and drain traps at their lowest
points so that water does not reach either the silencer or the engine. It is also recommended
that a slight slope downward from the silencer to the water leg or rain trap be added to assure
the proper removal of water.
•By locating the silencer as close to the engine as possible you will be able to minimize the
noise level in the exhaust piping.
•Each genset installation should have it’s own exhaust system and should not be connected to
a system accommodating more than one genset as the possibility of exhaust gas and
condensation backflow may cause permanent damage to an idle engine.
Health Warning
•Inhalation of exhaust fumes is potentially lethal.
•The correct installation of exhaust systems to prevent accumulation of exhaust gas cannot be
overemphasized.
•Additionally, prolonged exposure to engine exhaust noise can be damaging to hearing.
•A genset should never be operated without a fully installed exhaust system and all personnel
in close vicinity should wear ear protection.
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Diesel Genset
C10.5.2 Flexible Connections
The exhaust piping should be connected via a flexible joint located on the engine exhaust
outlet.
This connection serves three purposes.
-It relieves some of the weight of the exhaust piping from the engine.
-It isolates the exhaust system from vibration.
-It allows for some movement of either the genset or exhaust system components.
Long piping runs should be divided into sections separated by additional flexible connections.
This will also compensate for the expansion and contraction of the piping itself due to
temperature change. Any insulation material used for a flexible connection should allow for the
expansion and contraction of the connections, due to temperature changes.
C10.6 Fire Precautions
Note the following points when designing a genset installation:

•The room should be designed so that there is an easy escape route for operating personnel in
the event of fire within the room.
•A recommended type of fire extinguisher or fire extinguishing system should be provided to
fight the fire.
•Personnel manning the genset should be trained in identifying and fighting various types of
fires.
•Gravity operated fire valves operated by fusible links, mounted above the engine, can be
installed in the fuel lines.
•The room should be kept clean and free from accumulated rubbish which can be a fire
hazard.
C10.7 Electrical Connection
Only fully qualified and experienced electrical technicians should be allowed to carry out
electrical installation work.
Warning: Never attempt to work on live wiring. Always stop the genset and open
the circuit breaker on the load cables before working on the alternator or it’s
connectors. Disable starting of engine while working on genset.
•All electrical work should be carried out in accordance with any applicable National, Local
Standards, Codes or Regulations.
•The electrical connection to the genset should be made with flexible cable to prevent the
transmission of vibration and possible damage to the alternator or circuit breaker terminals.
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Diesel Genset
•If it is not convenient to use flexible cable throughout then a link box can be installed close to
the set with a flexible connection between it and the set.
•The cable may be laid in a duct or on cable tray. When bending cable reference must be
made to the recommended minimum bending radius. No rigid connection should be made
between the set and the cable support system, eg, cable tray.
•When single core cables are used the gland plates must be of non-ferrous material, eg,
aluminum, brass or a non- metallic material such as teflon.
•The cable must be suitable for the voltage being used and adequately sized to carry the rated
current with allowances made for ambient temperature, method of installation, proximity of
other cables, etc.
•All connections should be carefully checked for integrity. Phase rotation must be checked for
compatibility with the installation. This is vitally important when connection is made to an auto
transfer switch, or if the machine is to be paralleled.
C10.7.1 Earthing/Grounding
Earthing/Grounding should be done in accordance with applicable National, Local Code or

Regulation. These regulations vary and advice should be sought from the local supply utility to
comply with their requirements. The factory connects the frame of the alternator to the frame of
the genset therefore the complete mass of the genset is at the same potential. The connection
if required of the generator winding star point / neutral to earth is the responsibility of the
installation technicians.
Figure C - 20: Typical Earth Pit

•Any leakages in current will be earthed through the shortest route in the link.
•The size of the link used for the main earth connection should be adequate size as shown in
table.
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Diesel Genset
Table 3: Recommended Size of Earthing Conductor
Genset Rating Recommended Earth Strip /Cable
5-82.5 kVA 8 SWG - Copper
100-250 kVA 25x3mm CU / 25x6mm GI
320 - 500 kVA 50x6mm CU / 50x6mm GI 2 runs
625 - 750 kVA 50x6mm CU / 50x6mm GI 2 runs
•The generating set and all associated equipment must be earthed before the set is put into
operation.
•4 earth pits are required as per Indian electricity rule / local electricity regulations.
•2 earthing pits for genset / control panel body.
•2 earthing pits for neutral,
•Check the Resistance between 2 earth pits.
•Earthing in Rocks and Rocky area to done using grounding Transformers / Zig Zag
Transformers or Use soil conditioning agents - Marconite conductive aggregate and bentonite
moisture retaining clay on Earth electrode back fill.
•Each earth pit to be separated by five times of its depth.
•Earthing resistance must be less than 3 ohms.
C10.7.2 Protection
The cables connecting the genset with the distribution system should be protected by means of
a circuit breaker or fuses to disconnect the output in case of overload or short circuit.
C10.7.3 Loading
When planning the distribution system it is important to ensure that the genset has a balanced
load. Loading one phase excessively as compared to other two phases this will cause
overheating in the alternator windings, imbalance in the phase to phase voltage output and
possible damage to sensitive 3 phase equipment connected to the system. Ensure that no
phase current exceeds that of the current rating of the genset.
It may be necessary to reorganize the electrical distribution system if a genset is to be
connected to an existing installation.
C10.7.4 Power Factor
Determine the power factor (cos phi) of the connected loads while ordering the genset. Power
factors below 0.8 will overload the generator. The genset will provide its kilowatt rating and will
operate satisfactorily from 0.8 to unity power factor. Particular attention must be given to
installation with automatic or manual power factor correction equipment to ensure that a
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Diesel Genset
leading power factor is not present under any conditions. This will lead to voltage instability on
the generator output and may result in damaging overvoltages.
C10.8 Noise Control
The genset is available with accessories and components that reduce noise emissions. These
include residential and super critical silencers, acoustic louvers, splitter vents, fan silencers
and acoustically treated canopies.
The requirements for each site vary enormously and for any critical installation KOEL
recommends a consultation with the dealer at an early stage. The information needed to select
acoustic equipment is:
•The model and capacity of genset

•The designed noise level at a fixed distance, normally 1m or 7m.
• Environmental conditions, ambient temperature etc.
•The location and overall site plan.
Noise emissions from diesel gensets (without acoustic treatment) are at sound pressure levels
of between 100 dB(A) and 110 dB (A) at 1m. Kirloskar Gensets with acoustic canopies have a
typical noise pressure level of 75 dB(A) or less (average) at a distance of 1 meter from the
canopy.
Intermediate levels of treatment will prove more economic and are often satisfactory depending
only on the nature and type of installation. Hospital Care Areas will require more attention than
the normal commercial / industrial installation.
C10.9 Pre-commissioning Checks
Pre - commissioning checks will be conducted by the supplier’s commissioning team.

•Before starting the DG set, ensure that it is positioned on a level surface so that proper liquid
levels can be obtained. This is especially important for mobile or vehicle mounted gensets.
•Ensure that the top of the canopy does not accumulate rain water. If the foundation is
absolutely flat, a 1o slope is built into the design of canopy to ensure water drainage.
•Hardware:
-Open the doors of the genset on both sides and check the tightness of all the fixing
hardware of the various systems.
-Tighten, if found loose.
-Check all hardware on engine- alternator coupling, mountings, fan and radiator mounting.
•Hose check:
-Check proper fitting of Fuel hose. Air hose and Exhaust hose.
•Bellow alignment:
-Check correct alignment of the expansion joint or bellow on the exhaust line.
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Diesel Genset
•Leakage:
-Check for damage on the canopy and for openings on canopy roof which might lead to
water and sound leakage.
-Repair the damages (if any) and close the openings.
•Power cables:
-Check the proper termination power cables are terminated properly and are without
damage.
•Control cables:
-Check that the control cables are terminated properly and are without damage.
•Lube Oil level:
-Check that the lube oil is filled up to marked level.
•Coolant level check (for Liquid-cooled engines):
-For filling coolant do not step on or climb on engine its components.
-A ladder is provided for the easy accessibility of radiator cap for filling the coolant.
-Ensure proper coolant level in the Compensatory Bottle.
•Battery:
-Ensure that the battery used is of correct rating and is connected with the right polarity.
•Cable routing:
-Check whether the power and the control cables are properly routed and secured with
cable ties.
•Cleanliness:
-Ensure that the inside and outside of the genset is dry and clean.
-Remove stains with diesel oil and clean up any oil spillage mark on the floor of the
canopy.
-Ensure that no debris is left inside the canopy which could clog moving parts or become a
fire hazard.
C10.10 Prior to Starting
•Study and familiarize the aspects of genset.

•Get trained by the seller or authorized service dealer before starting the generator.
•Maintain a log book to record all electrical and mechanical parameters with starts and stop
timing.
•Carefully follow all the instructions mentioned in the Pre-commissioning checks.
•Check the Lube oil level, Coolant level and Fuel level. Top up if necessary.
•Check that the restriction indicator of the air cleaner is in the healthy zone.
•Ensure that the load change over switch or the breaker is in off position.
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Diesel Genset
C10.10.1 Warning
•Please read, understand and comply with the following warnings to avoid fire hazard and
damage to the genset.
•Prolonged inhalation of exhaust fumes may result in serious illness or death.
•Prolonged exposure to the noise levels of a diesel engine can impair hearing unless proper
ear protection is worn.Check levels of engine oil, radiator coolant, battery electrolyte and fuel.
Top up as necessary.
•Ensure that the Genset is operated in a well ventilated area with all exhaust fumes piped
away.
•In case the controller fails to start the engine, investigate the reasons before trying to restart.
Checks during commissioning.
•Always shut the genset prior to connecting, or disconnecting, load cables. Only restart after
proper connections has been made.
•If at any time the generator stops because of a fault, the fault should be rectified before trying
to restart the generator.
•Before connecting batteries, ensure control panel is switched off.
•Before starting the genset, ensure that engine and alternator are earthed correctly.
•Adhere to the local and national regulations for the grounding of gensets.
•Confirm following of regulations that describe methods of connection and minimum sizes of
grounding conductors based on the size of the load cables.
•Adequate grounding of the genset is necessary for both stationary and wheel mounted units
to prevent the possibility of injury or death in the event of electrical fault.
•Do not smoke or use naked flame in vicinity when filling the fuel tank.
•Fill the fuel tank only when Genset is switched off and the engine is cold.
•Spilled or vaporized fuel ignites easily.
•Do not connect or disconnect load connection or perform maintenance while the Genset is in
operation.
•To avoid an accidental start of the engine, always disconnect the battery when performing
major operations.
•As the battery system is negative earth, disconnect negative connection first and reconnect
negative connection last.
•The door of the control panel and alternator connections should not be removed while the
genset is in operation. The cover, when removed, exposes live electrical connections.
•Maintenance on the control panel should only be carried out by a trained and qualified
personnel.
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Diesel Genset
•Always shut down the genset and switch off circuit breaker prior to connecting, or
disconnecting load cables. Restart only after making firm connections.
C10.10.2 Manual Mode (Non-AMF) Operation
C10.10.2.1 Starting the Genset
•In this mode, the user starts and stops the engine. The user also transfers the load from
mains to genset and back, as required.
•Before starting, ensure load is disconnected from genset. Ensure people and material/tools
are clear of the engine.
•Check if Manual Mode is selected on the EMS controller by the lit state of lamp on the top left
of the MAN button. If not, operate MAN button once and verify the lighting of the lamp.
MAN
•To start the engine operate the Manual Start button once.
I
•The controller will initiate cranking to start the engine. If the engine fails to start, the controller
will try again. If the engine does not start despite several attempts, the controller indicates a
Start Failure condition and inhibit further cranking. See Controller section for more details.
•After engine starts:
-Check for any leakages.
-Allow engine to idle for 3 minutes and then start connecting load in steps.
-Check engine parameters like Oil pressure, coolant temperature and battery changing
rate at regular intervals, while the genset is in operation.
-Maintain log book.
-Check for exhaust smoke.
-Check for any abnormal sounds.
-Check for alternator parameters, like voltage, ampere, kW and Power Factor on all
phases.
-During commissioning, cross check the meter readings with a calibrated multimeter or
clamp - on meter.
-Ensure that the load is balanced in all phases and within rated output of the genset.
-Check that all gauges and meter provided in control panel are working.
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Diesel Genset
C10.10.2.2 Stopping The Genset
•Disconnect the load from the genset.
0
•Operate the Stop Button once. STOP
•The controller will keep the engine running for several seconds through Cool down timer to
ventilate the engine and alternator.
•After engine stops, check for any leakages.
•Top up fuel tank.
•Close the canopy securely.
•Switch off the Control Panel.
C10.11 AMF Operation
•Unlike Manual Mode operation, AMF (Automatic Mains Failure) panel is active all the time.
•If mains supply is in limits, the panel connects that feeder to load through mains contactors.
•If mains supply is out of limits (or failed), the AMF panel deselect the mains supply and starts
the genset.
•Once the genset is running, the AMF panel connects the load to alternator through the genset
contactors.
•While the genset feeds the load, the AMF panel monitors mains supply for a return back to
normalcy.
•Once the mains supply restores, the genset transfers load back to mains feeder and shuts the
genset after elapsing of cool down timing.
•AMF panel also monitors engine safety parameters for genset.
C10.11.1 Activating AMF
•Before activating, ensure people and material/tools are clear of the engine. Ensure that no
mishap will occur once the load gets charged from either mains or genset supplies.
•Check if Auto Mode is selected on the EMS 934 controller by the lit state of lamp on the top
left of the AUTO button. If not, operate AUTO button once and verify the lighting of the lamp.
AUTO
AUTO
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Diesel Genset
•Now the controller will automatically decide the operation of engine and selection of supply
(mains or genset).
•Switch on panel and all circuit breakers. Ensure that the load is connected to mains supply.
•Switch off mains supply, the controller will start the engine and transfer load to genset supply.
•While engine is running, check engine parameters like Oil pressure, coolant temperature and
battery changing rate at regular intervals.
•Maintain log book.
•Check for exhaust smoke.
•Check for any abnormal sounds.
•Check for alternator parameters, like voltage, ampere, kW and Power Factor on all phases.
•During commissioning, cross check the meter readings with a calibrated multimeter or clamp
- on meter.
•Ensure that the load is balanced in all phases and within rated output of the genset.
•Check that all engine and alternator parameters indications on the controller are working.
•Reconnect mains supply, the controller will transfer load back to mains supply and stop
engine after a cool time timer delay.
•Ensure battery charger inside panel working when load is on mains by observing rising
battery terminal voltage.
•At any time of genset operation operate STOP button to stop the engine including the delay of
0
cool down time. STOP
•In case genset is to be stopped immediately, use the Emergency Stop switch on the panel
and canopy. This is not recommended unless there is a situation that demands the engine to
stop immediately.
C10.12 Daily Checks
Perform these checks daily before starting. If the genset runs infrequently except for standby
duties, these checks may be performed at a weekly interval.
•Visually check entire genset. Watch for potential leaks of fuel, coolant and lubrication oil.
seals.
•Check the alternator for obstructions in the cooling air ventilation screens.
•Check the alternator and control box for accumulation of dirt and dust.
•Clean any dirt/dust accumulations to avoid electrical hazard and cooling problems.
•Check the air cleaner. Clean or replace if necessary.
C-34
Diesel Genset
•Check the fuel level.

•Check the engine coolant level.
•Check the engine oil level.
•Ensure no obstruction to the radiator/cooling air flow.
•Check the condition of the fan, alternator belts and their tension.
•Check hose condition and connections.
•Check battery terminals for corrosion.
•Check the battery electrolyte level, top-up with distilled water if necessary.
•Refer to the engine maintenance section for specific engine maintenance requirements.
•Replace and secure all parts removed for inspection and maintenance before starting the
genset.
•Drain condensate traps in the exhaust system, if fitted.
•Check for exhaust leaks.
•Check for any abnormal noise or vibration.
•Check for fluid leakage or high temperature.
•Dispose of any unnecessary items in the vicinity of genset that may inhibit operation or
represent cause of potential injury.
•Check the control panel for readings within set limits.
C11. Battery
Resistance in starting circuit has a significant effect on the cranking of the engine. Locate the
batteries as close as possible to the genset.
The batteries should be accessible for easy servicing. Maintenance procedures should be
carried out rigorously since the batteries have to be in perfect condition to start the diesel
engine.
Note: Batteries emit inflammable gas. Do not smoke or create sparks or naked flames adjacent
to batteries.
C11.1 Battery Maintenance Schedule
Table 4: Battery Maintenance Schedule
Checking
No. Description Result
Frequency
1. Check battery electrolyte level after Monthly Electrolyte level to match MAX line on

removing the vent caps battery. Don’t cross over MAX line
2. In case of low level, top up the same As & when Top up the level up to MAX by DM

with Battery Grade DM Water only ( found Water only
Don’t use Acid )
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Diesel Genset
Table 4: Battery Maintenance Schedule
3. Keep battery terminals sufficient Monthly Clean & Dust / corrosion free terminal

tight & clean & Dry joints
4. Don’t hammer on terminals while As required Terminals should be gently tighten

fitment with clamps
5 Always ensure the vent plugs are Monthly Vent holes on plugs are clean & vent

Clean & hold tightly on battery top plugs are always in intact position on
cover battery top
6. Clean the battery top cover by wet Monthly Clean & dust free battery top

cloth& Dry it with dry cloth
7. Avoid any physical short circuit As required No short circuit / Accident hazards

between the battery terminals while
checking / Maintaining the batteries
8. Ensure proper fitment of battery in Monthly Battery fit properly in battery box /

cradle cradle
9. Don’t use the battery for other than Every day Good battery life

Engine cranking
11. In case of DG Set remains Idle ( As required Good battery life

without operation ) for more than 3
weeks, please ensure followings :‐
∙ Remove Negative cable of
battery.
∙ Ensure battery in adequate
charge condition before
removal.
∙ In case of not charge,
remove the battery & get the
bench charged
12. In case of any battery problem, As required Fast decision on battery claim & less

report immediately to KOEL Service resolution time
Department
C11.1.1 Battery Tips
Follow the tips to get the maximum life from your battery.
•The top of the battery must be kept clean and dry.

•Vaseline should be applied to cable clamps and terminals, Never apply
grease.
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Diesel Genset
•Terminal corrosion dirt and moisture cause loss of power and make the battery weak.
•Battery open circuit voltage checked regularly and recorded in the service record.
•A faulty electrical system will damage the battery.
•The charging voltage setting measured across the battery terminals shall be maintained at
14.00+ 0.20 volts for 12V System and 28.0 V + 0.4 Volts for 24Vsystem.
•The recommended Specific Gravity of a fully charged battery is 1.270+ 0.005 at 27 oC. Take
immediate corrective action if case of any deviation.
•Electrolyte level must always be maintained in line with the bottom of the vent hole In case of
any drop in the electrolyte level, add pure distilled water. NEVER ADD ACID!
•. Keep battery away from places near fire as hydrogen gas generated from the battery may
cause fire and explosion.
•Shorting the battery terminals with a wire etc. will lead to fire and explosion.
•To prevent potential of harm, keep battery away from the reach of children and personnel who
do not have knowledge of battery.
•Wear the protection goggle and hand gloves while I handling the battery, since battery liquid
may cause blindness and severe burns.
•Do not add excess distilled water above the barrel level. Excess flow may cause damage and
burns.
•Do not drop and shake the battery, as it may cause injuries/damages.
•Care should be taken while handling the battery, as sulphuric acid may cause blindness and
severe burns.
•If battery liquid gets in the eyes, flush eyes thoroughly with clean water and seek medical
attention.
•When battery liquid gets in mouth, rinse immediately with plenty of water and seek medical
attention.
•When battery liquid gets into contact with skin, wash thoroughly with soap and water and
seek medical attention.
•IT IS STRONGLY RECOMMENDED NOT TO USE BATTERY ADDITIVES OR DOPES.
•Social Responsibility and Govt of India Notification:
-Lead acid batteries contain Lead and Sulphuric Acid, which are highly toxic and extremely
hazardous to health and environment
-Lead poisoning affects the Central Nervous System, causing irreversible retardation and
subsequent death.
-As per the notification of the Govt of India, "It shall be the responsibility of the consumer to
ensure that used batteries are not disposed off in any manner other than depositing with
the dealer, manufacturer or at the designated collection centers”.
-It is mandatory for our authorized dealers to accept a used battery and provide
corresponding rebate on purchase of a new battery
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Diesel Genset
•Please note that violations of these guidelines may lead to legal action & prosecution by
Government Authorities
C12. Optional Equipment
C12.1 Battery Charger
A mains powered battery charger is recommended for gensets meant for Non-AMF standby
duty. This is especially important if the genset does not run often. The battery charger will
ensure that the battery is kept in the peak condition for quickly starting the genset when
required. The battery charger has automatic charge control, thus avoiding overcharging of the
battery.
In case of AMF genset, a mains powered battery charger is usually built in the panel.
C12.2 Heater
C12.2.1 Engine Heater Plug
To ease cold weather starting, a 12 VDC heater plug is fitted to the inlet manifold. This heater
plug is energized for a preset interval before cranking the engine. The passage of electrical
current through the heater plug heats the device and the air inside the inlet manifold. The 12
VDC supply to the heater plug should be switched off during cranking to ensure maximum
battery capacity for the starter motor. Ensure that the heater plug is not energized when the
engine is running.
C12.2.2 Anti-condensation Heater
Alternators are offered with heaters to prevent condensation, These heaters are fitted to the
alternator stator winding. These operate at a relatively low temperature and do not require a
thermostat. These heaters should be switched off when the genset is running. An external AC
power supply is required to power these heaters.
C12.2.3 Electronic Governor
Genset engines are available with Electronic Governors to closely regulate engine speeds and
therefore output frequency. Electronic Governor is recommended for gensets powering critical
loads and also when two or more gensets are required to run in synchronisation.
C13. Maintenance
A good maintenance programme is essential for long genset life. Please find a program that
should keep your machine in top running condition. Also included in this programme are
routine maintenance operations required for the engine and alternator (see Engine
Maintenance and Alternator Maintenance Sections).
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Diesel Genset
It is good practice to have all of the maintenance and service operations performed by trained
personnel familiar with genset maintenance. This, along with a good service records system,
should aid in developing an efficient maintenance program. The service records of each genset
should include information such as complete nameplate data with model and serial numbers,
all drawing and wiring diagrams, spare parts stock lists, as well as a service schedule and a
copy of this manual. These records will allow quick reference and may help to diagnose a
problem in the future.
C13.1 Daily Maintenance
Perform this maintenance before every start up. If the genset is used for standby applications
with little running, these procedures may be required after longer periods like every weekly.
to weekly.
•Make a visual check of the entire genset. Watch for signs of potential leaks from the engine
fuel system, cooling system or lubrication seals.
•Check the alternator for obstructions in the cooling air ventilation screens.
•Check the alternator and control box for heavy accumulation of dust and dirt. Clean any
heavy accumulations as electrical hazards, as well as cooling problems could arise.
•Check the air cleaner. Clean or replace if necessary.
•Check the fuel level.
•Check the engine coolant level (in case of Liquid cooled engines).
•Be sure that the radiator air flow or blower air flow is not obstructed.
•Check the condition of the blower, fan and alternator belts and their tension.
•Check all hose connections and hose conditions.
•Check the engine oil level. Maintain the level at ‘H’ mark, top up if level is low.
•Check the battery terminals for corrosion.
•Check the battery electrolyte level and fill with distilled water if necessary.
•Ensure cleanliness around genset. Dispose of any unnecessary items in the vicinity of the
genset that may inhibit operation or represent cause of potential injury.
•Refer to the engine maintenance section for specific engine maintenance requirements.
•Start the genset after all checks have been made.
•Drain condensate traps in the exhaust system, if so equipped, and check for exhaust leaks.
•Check for any abnormal noise or vibration.
•Check for leakage of air, fuel, oil or coolant.
•Check all parameters in the control panel for operation within normal limits.
C13.1.1 Maintenance Every Six Months or 250 Hours
•Repeat the daily maintenance checks.
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Diesel Genset
•Check all safety devices by electrically simulating a fault to ensure that all systems will
function properly in the event of a fault.
•Clean all battery cap vents.
•Start the genset and observe all parameters are within limits.
•Tighten all exhaust connections.
•Tighten all electrical connections.
•Refer to the engine maintenance section, for further details.
C13.1.2 Alternator Unit Cleaning
The alternator unit should be cleaned inside and out on a regular basis. The frequency of such
cleaning depends on the environmental conditions of the operating site. The following
procedure should be applied when cleaning is necessary:-
•Disconnect all power.
•Wipe dust, oil, water or any other liquids from the external surfaces of the alternator unit. All of
these materials can work their way into the windings and may cause overheating or insulation
breakdown.
•Remove these same materials from the ventilation screens around the circumferences of the
unit. Do not permit such material to accumulate on these screens as this will obstruct air flow.
Such debris is best removed with a vacuum cleaner to avoid redepositing of these materials
on other parts of the equipment.
•DO NOT USE COMPRESSED AIR, STEAM OR A HIGH PRESSURE WATER CLEANER.
•Use a vacuum cleaner to clean the windings of the alternator unit. This will remove dust from
the coils that cannot be reached with a wiping cloth.
C13.1.3 Cleaning of Radiator
C13.1.3.1 External Cleaning
Figure C - 21: Cleaning Radiator Fins

•Cleaning the radiator fins:
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Diesel Genset
-Clean the radiator fins after every 400 hours. (Under very dusty conditions, increase fins
cleaning frequency.)
-For cleaning, blow pressurized air through radiator fins in reverse direction that of radiator
fan flow.
-Do not spill water on radiator fins.
-Clean cooling system after every 5000 hours while replacing coolant.
C13.1.3.2 Internal Cleaning
•The internal cleaning of radiator is done using ‘K Clean’ chemical.

-K Clean is designed to remove contaminants like scale, oil, grease, rust, loose material
that are present in the engine cooling systems.
-Add K Clean in the ratio of 375 ml. for every 16 litre capacity of radiator. Top up the
radiator with clean water (mineral or similar).
-Run the engine for minimum of 20-30 minutes.
-Stop the engine and allow the water to completely cool down.
-Drain coolant system completely.
-Refill the cooling system with plain clean water and run the engine for another 15-20
minutes for flushing the system.
-Allow the water to cool down and then drain the cooling system completely.
-Observe the drained water; if it still contents rust, scale and dirt, repeat the above
procedure for one more time.
-After cleaning, fill the system with K-Cool Super Plus.
-Use of K-Cool Super Plus has benefits such maximizing engine life and providing
optimum performance.
C14. Control System

Most diesel gensets work fully or partially without continuous human supervision. This
necessitates an electrical and electronic control system that ensures safe operation for the
genset all the time.
The Control System has several design objectives, some or all of which may be present on a
particular genset:
• Means of starting and stopping the Generator Set on user’s command.

•Detect various conditions like failure of mains or restoration of main for starting or stopping
genset automatically.
•Monitor and display engine and genset parameters.
C-41
Diesel Genset
•Compare engine and genset parameters against set levels to ensure operation within safe
limits.
•If the parameters deviate from the set levels, generate alarms to warn the operator.
•If the parameters exceed another set of levels, automatically trip (shut down) the genset to
protect the installation, load and personnel.
•Typical conditions for alarm and trip condition are low oil pressure, high coolant temperature,
over speed, under speed, low coolant level, low fuel level etc.
C14.1 Control Panel
The genset are provided with a control panel with the following typical components:
•Electronic unit that provide logic to control genset,

•Gauges for displaying engine and genset parameters.
•Termination for sensor wires from engine.
•Termination for solenoid and relay outputs to engine.
•Termination for altenator incoming supply.
•Termination for load.
•Fuses and circuit breakers
•Alternator Circuit Breaker for connecting the generator output to load and automatically
disconnecting the load in case of overload or short circuit.
•Mains and Genset contactors.
•Battery charger.
C14.1.1 AMF panel
Auto Mains Failure (AMF) panel contains electronic logic for automating genset operation
including transferring power from mains to genset and vice-versa without human intervention.
AMF logic performs the following functions:
•Senses mains supply parameters for operation within set parameters.

•If mains supply is acceptable, the AMF logic selects the mains contactor and the load is
charged from mains feeder.
•If the mains supply goes out of set parameter limits, the AMF logic deselects the mains
contactor and starts the genset.
•Once the genset is running and the parameters are within set limits, the AMF logic selects
genset contactor to charge load from genset feeder.
•AMF logic displays the engine and electrical parameters while the genset is running.
•The AMF logic monitors genset safety to ensure operation within limits
C-42
Diesel Genset
•The AMF logic also monitors mains feeder for a return back to normalcy.
•Once mains restores, the AMF logic deselects the genset contactor and selects the mains
contactor to charge load from mains feeder.
•The AMF logic shuts the genset down in the prescribed sequence and restarts the monitoring
of mains feeder for operation within safe limits.
•The AMF logic offer several timers that add delays necessary for correct operation.
C14.1.2 Non-AMF panel
Non-AMF panel provides basic genset safety and display functions. The task of starting,
stopping of genset as well as selecting between mains and genset feeder is done by the
operator.
C14.2 KG EMSController
This electronic controller provides all the logic for AMF and Non-AMF panels, for single phase
as well as three phase gensets.
KG
C-43
KG645 CONTROLLER MANUAL
KG645
Kirloskar
Genset Controller
User Manual
KIRLOSKAR OIL ENGINES LIMITED
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
Page 2 of 123
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
Page 3 of 123
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
Page 5 of 123
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
Page 6 of 123
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
Page 7 of 123
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

Sample Rate 5 kHz
Harmonics 10th
Page 8 of 123
Input Impedance 0.3 MΩ

Phase to Neutral voltage 15 to 415 V- AC RMS
Common mode offset from 100 V-AC
Earth
Voltage accuracy ±2 % 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.
Page 9 of 123
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
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)
Page 10 of 123
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.
Page 11 of 123
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.
Page 12 of 123
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).
Page 13 of 123
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
37 GEN_CT_IN Y1 CT input 1 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
Page 20 of 123
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)
Page 21 of 123
(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”)
Page 25 of 123
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)
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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
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
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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)
Page 32 of 123
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)
Page 33 of 123
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
Page 35 of 123
(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)
Page 36 of 123
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
Page 37 of 123
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) /
Page 39 of 123
-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)
Page 44 of 123
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
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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
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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.
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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
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.
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

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

2 Byte count (n)
. .
. .
. .
Page 58 of 123
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
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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
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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.
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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
Page 86 of 123
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
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
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.
Page 93 of 123
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 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
Page 100 of 123

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
Page 101 of 123

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
Page 102 of 123

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
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

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

KG640
Kirloskar
Genset Controller
User Manual
Laxmanrao Kirloskar Road, Khadki, Pune-411 003, India.
Tel : +91(20) 2581 0341
Fax: +91(20) 2581 3208/ 2581 0209
www.kirloskar.com
Safety Instructions
General Instructions
 This document includes important instructions that should be followed during installation and maintenance
of the generator set controller.
 For safety reasons, the manufacturer recommends that this equipment be installed and serviced by an
Authorized Service personnel. Follow all applicable state and local electrical codes.
 Efficient and safe operation of the controller can be acquired only if the equipment is correctly operated,
configured and maintained. Many accidents arise due to ignorance or illiteracy towards the elemental rules
of safety and precautions.
The following safety notations found throughout this document indicate potentially hazardous conditions to
the operator, service personnel or the equipment.
• Highlights an essential element of a procedure to ensure correctness
• Indicates a procedure or practice, which could result in damage or

destruction of equipment, if not strictly observed
• Indicates a procedure or practice, which could result in injuring personnel or

loss of life, if not followed correctly
Electrical safety
 Electric shock can cause severe personal injury or death.
 Ensure the generator set must be grounded before performing any installation or service.
 Generators produce high electrical voltages, direct contact with it can cause fatal electrical shock. Prevent
contact with terminals, bare wires, connections, etc., while the generator and related equipment are
running. Do not tamper with interlocks.
 To handle the maximum electrical current, sizes of wire gauge used for electrical connections and wirings
must be appropriate to which they will be subjected to.
In operation safety
 Before installing genset controller, ensure that all power voltage supplies are positively turned off at their
source. Disconnect the generator’s battery cables and remove panel fuse to prevent accidental start up.
Disconnect the cable from the battery post, indicated by a NEGATIVE, NEG, or (–) first. Reconnect the
negative cable last. Failure to do so will result in hazardous and possibly fatal electrical shock.
 Remove electric power supply before removing controller or touching other electrical parts.
 Use extreme caution when working on electrical components. High voltage can cause injury or death.
 Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when
working near generator set or other electrical equipment.
 Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling
electrical equipment.
Page | i
 Do not operate any electrical device or wires while standing in water, while barefoot, or while hands or feet
are wet. It may result in severe electrical shock.
 Do not wear jewellery. Jewellery can cause a short circuit within electrical contacts and cause shock or
burning.
 In case of an accident caused by electric shock, immediately shut down the electrical power source. If this
is not possible, try to release the victim from the live conductor. Avoid direct contact with the victim.
Use a nonconducting object, like, a rope or wooden stick, to release the victim from the live conductor. If
the victim is unconscious, apply first aid and get immediate medical help.
Page | ii
List of Abbreviation
This list contains the list of acronyms used in this document and it can be used to refer their respective
description. This list does not contain units of measure.
Acronym Description
AC Alternating Current
ACK Acknowledge
ALT Alternator
AMF Auto Mains Failure
AUX Auxiliary
BTS Base Transceiver Station
CHG Charging
CKT Circuit
CT Current Transformer
DC Direct Current
DG Diesel Generator
DIG IN Digital Input
ENG TEMP Engine Temperature
GCU Genset Control Unit
Genset Generator Set
GND Ground
HMI Human Machine Interface
HSD High Side Driver
HWT High Water Temperature
LCD Liquid Crystal Display
LED Light Emitting Diode
LLOP Low Lube Oil Pressure
LOP Lube Oil Pressure
LVL Level
MCP Manual Control Panel
MPU Magnetic Pickup Unit
NC Normally Closed
NO Normally Open
OV Over Voltage
PFC Potential Free Contacts
PID Proportional Integral Derivative
PWM Pulse Width Modulation
RMS Root Mean Square
RPM Revolutions Per Minute
R-Y-B Red-Yellow-Blue
SCP Sensor Common Point
SMD State Machine Diagram
SMPS Switched Mode Power Supply
TEMP Temperature
USB Universal Serial Bus
UV Under Voltage
Page | iii
Table of Contents
Introduction .......................................................................................................................... 1
1.1 Key Highlights of the Product .......................................................................................... 1
Specifications ...................................................................................................................... 2
2.1 Terminals ........................................................................................................................ 2
2.2 Power Supply Specifications ........................................................................................... 3
2.3 Genset Voltages and Frequency Measurements ............................................................ 3
2.4 Genset Current Measurement ......................................................................................... 4
2.5 Mains Voltage and Frequency Measurements ................................................................ 4
2.6 Digital Inputs ................................................................................................................... 5
2.7 Analog Inputs .................................................................................................................. 5
2.8 Sensor Common ............................................................................................................. 6
2.9 D+ Charge Alt ................................................................................................................. 6
2.10 Digital Outputs................................................................................................................. 7
2.11 Deep Sleep Mode ........................................................................................................... 7
Communication Ports ......................................................................................................... 8
Installation ............................................................................................................................ 8
4.1 Dimensions ..................................................................................................................... 8
4.2 Mounting on panel........................................................................................................... 9
4.3 Terminal Description ..................................................................................................... 10
4.4 Typical Wiring Diagram ................................................................................................. 12
Module Display .................................................................................................................. 13
5.1 Power on Screen........................................................................................................... 13
5.2 Monitoring Mode ........................................................................................................... 13
5.3 Status & Info screens .................................................................................................... 14
Description of Control Keys ............................................................................................. 17
6.1 Mode Selection diagram ............................................................................................... 18
6.2 Functions of Control keys .............................................................................................. 18
Configuration Mode ........................................................................................................... 19
7.1 Configurable Parameters .............................................................................................. 20
Module Operation .............................................................................................................. 31
8.1 Manual Mode ................................................................................................................ 31
8.2 Auto Mode ..................................................................................................................... 31
8.3 Semi – Auto Mode......................................................................................................... 31
Alarms ................................................................................................................................ 32
Troubleshooting ................................................................................................................ 36
Introduction to Communication Protocol ........................................................................ 38
MODBUS Based Protocol ................................................................................................. 38
12.1 Connection Details ........................................................................................................ 38
12.2 Supported Functions ..................................................................................................... 38
Page | iv
12.3 Register Map ................................................................................................................. 40

Introduction to KOEL Configuration Utility ..................................................................... 46
Installation Instructions .................................................................................................... 46
14.1 System Requirements ................................................................................................... 46
14.2 Installation Process for KOEL Configuration Utility ....................................................... 46
14.3 Installation Process for USB Driver ............................................................................... 47
Usage Instruction .............................................................................................................. 51
15.1 Starting with KOEL Configuration Utility ........................................................................ 51
15.2 Working with KOEL Configuration Utility ....................................................................... 52
15.3 Establishing Connection with Controller ........................................................................ 52
15.4 Editing Parameters........................................................................................................ 53
15.5 Tools ............................................................................................................................. 53
Interpretation of Parameters ............................................................................................. 57
16.1 Module .......................................................................................................................... 57
16.2 Digital Inputs ................................................................................................................. 59
16.3 Analog Inputs ................................................................................................................ 61
16.4 Outputs ......................................................................................................................... 65
16.5 Timers ........................................................................................................................... 67
16.6 Generator ...................................................................................................................... 69
16.7 Mains ............................................................................................................................ 74
16.8 Engine ........................................................................................................................... 76
16.9 Maintenance.................................................................................................................. 81
Notes ......................................................................................................................................... 82
Page | v
List of Figures
Figure 1: KG640 genset controller's front fascia .............................................................................................. 1
Figure 2: Connectors of 10.16 mm pitch.......................................................................................................... 2
Figure 3: Connectors of 5.08 mm pitch ........................................................................................................... 2
Figure 4: Connectors of 3.5 mm pitch ............................................................................................................. 2
Figure 5: Dimensions of the KG640 genset controller ..................................................................................... 8
Figure 6: Fixing clip and screw supplied along with controller ......................................................................... 9
Figure 7: Controller mounting on the panel using the fixing clips ..................................................................... 9
Figure 8: KG640 genset controller from backside.......................................................................................... 10
Figure 9: KG640 genset controller when used in the 3-phase manual control panel ..................................... 12
Figure 10: Control keys function .................................................................................................................... 17
Figure 11: Mode selection using control keys in KG640 ................................................................................ 18
Figure 12: Saving settings ............................................................................................................................. 19
Figure 13: Remote start/stop digital input configuration screen ..................................................................... 31
Figure 14: Semi-auto mode digital input configuration screen ....................................................................... 32
Figure 15: Semi-auto mode SMD .................................................................................................................. 32
Figure 16: Configuration utility setup ............................................................................................................. 46
Figure 17: Configuration utility setup completion ........................................................................................... 47
Figure 18: Programming mode screen .......................................................................................................... 47
Figure 19: Device manager screen ............................................................................................................... 48
Figure 20: Update driver software screen...................................................................................................... 49
Figure 21: Browse for driver software screen ................................................................................................ 49
Figure 22: Saving location selection screen .................................................................................................. 50
Figure 23: SEDEMAC controller screen ........................................................................................................ 50
Figure 24: Driver installation successful screen............................................................................................. 51
Figure 25: Configuration utility screen ........................................................................................................... 51
Figure 26: Start screen.................................................................................................................................. 52
Figure 27: File menu ..................................................................................................................................... 52
Figure 28: Options available for editing parameters screen ........................................................................... 53
Figure 29: Tools menu .................................................................................................................................. 53
Figure 30: Write configuration to device screen............................................................................................. 54
Figure 31: Device configuration screen ......................................................................................................... 54
Figure 32: Configuration utility completion screen ......................................................................................... 54
Figure 33: Read configuration from device screen ........................................................................................ 55
Figure 34: Successful reading of configuration screen .................................................................................. 55
Figure 35: Preview configuration summary screen ........................................................................................ 55
Figure 36: Save as PDF screen .................................................................................................................... 56
Figure 37: Event log saved screen ................................................................................................................ 56
Figure 38: Version information screen........................................................................................................... 56
Figure 39: Menu ribbon- module selection .................................................................................................... 57
Figure 40: General module screen ................................................................................................................ 57
Figure 41: Display module screen ................................................................................................................. 58
Figure 42: RS485 communication module screen ......................................................................................... 58
Figure 43: Master password module screen.................................................................................................. 59
Figure 44: Menu ribbon- digital inputs selection ............................................................................................ 59
Figure 45: Digital inputs selection screen ...................................................................................................... 59
Figure 46: Menu ribbon- Analog inputs selection........................................................................................... 61
Figure 47: Lube oil pressure sensor .............................................................................................................. 61
Figure 48: Engine temperature sensing (resistive) screen............................................................................. 62
Figure 49: Fuel level sensing screen as fuel level sensor.............................................................................. 63
Page | vi
Figure 50: Fuel level sensing screen as digital input ..................................................................................... 64

Figure 51: Menu ribbon- outputs selection .................................................................................................... 65
Figure 52: Outputs screen ............................................................................................................................. 65
Figure 53: Menu ribbon- timers selection ...................................................................................................... 67
Figure 54: Cranking timers screen ................................................................................................................ 68
Figure 55: General timers screen .................................................................................................................. 68
Figure 56: Menu ribbon- generator selection ................................................................................................. 69
Figure 57: Alternator configuration generator screen .................................................................................... 70
Figure 58: Voltage monitoring generator screen............................................................................................ 71
Figure 59: Frequency monitoring generator screen ....................................................................................... 72
Figure 60: Current monitoring generator screen ............................................................................................ 73
Figure 61: Load monitoring generator screen ................................................................................................ 74
Figure 62: Menu ribbon- mains selection....................................................................................................... 74
Figure 63: Mains configuration mains screen ................................................................................................ 75
Figure 64: Voltage monitoring mains screen ................................................................................................. 75
Figure 65: Frequency monitoring mains screen............................................................................................. 76
Figure 66: Menu ribbon- engine selection ..................................................................................................... 76
Figure 67: Crank disconnect engine screen .................................................................................................. 77
Figure 68: Speed monitoring engine screen .................................................................................................. 78
Figure 69: Battery monitoring engine screen ................................................................................................. 79
Figure 70: Charging alternator monitoring engine screen .............................................................................. 80
Figure 71: Preheat engine screen ................................................................................................................. 80
Figure 72: Menu ribbon- maintenance selection ............................................................................................ 81
Figure 73: Maintenance screen ..................................................................................................................... 81
Page | vii
List of Table
Table 1: 10.16 mm pitch connector details ...................................................................................................... 2
Table 2: 5.08 mm pitch connectors details ...................................................................................................... 2
Table 3: 3.5 mm pitch connector details .......................................................................................................... 3
Table 4: Power supply specifications .............................................................................................................. 3
Table 5: Genset voltages and frequency measurements................................................................................. 3
Table 6: Genset current measurement ............................................................................................................ 4
Table 7: Mains voltage and frequency measurement ...................................................................................... 4
Table 8: Digital inputs...................................................................................................................................... 5
Table 9: I/P: ANLG/DIG F ............................................................................................................................... 5
Table 10: I/P: ANLG TEMP / DIG H ................................................................................................................ 5
Table 11: I/P: ANLG FL / DIG G ...................................................................................................................... 6
Table 12: D+ charge alt ................................................................................................................................... 6
Table 13: Digital outputs ................................................................................................................................. 7
Table 14: Communication ports ...................................................................................................................... 8
Table 15: Details of KG640 terminals ............................................................................................................ 10
Table 16: Power on screen ........................................................................................................................... 13
Table 17: Symbols & name of screen's group ............................................................................................... 13
Table 18: Screens of genset status and operating mode............................................................................... 14
Table 19: Control keys in different modes ..................................................................................................... 18
Table 20: Configuration mode ....................................................................................................................... 19
Table 21: List of configurable parameters ..................................................................................................... 20
Table 22: Digital input sources selection ....................................................................................................... 28
Table 23: LOP sensor calibration .................................................................................................................. 28
Table 24: Engine temperature sensor calibration .......................................................................................... 28
Table 25: Fuel level sensor calibration .......................................................................................................... 28
Table 26: Digital output source selection ....................................................................................................... 28
Table 27: Alarm actions ................................................................................................................................ 33
Table 28: Alarms and their actions ................................................................................................................ 33
Table 29: Troubleshooting ............................................................................................................................ 36
Table 30: Command from MODBUS master for Function 4 ........................................................................... 38
Table 31: Normal response from KG640 slave for Function 4 ....................................................................... 38
Table 32: Command from MODBUS master for Function 16 ......................................................................... 39
Table 33: Normal response from KG640 slave for Function 16 ..................................................................... 39
Table 34: Command from MODBUS master for Function 3 ........................................................................... 39
Table 35: Normal response from KG640 slave for Function 3 ....................................................................... 40
Table 36: Register map for input registers..................................................................................................... 40
Table 37: Register map for holding registers ................................................................................................. 45
Table 38: Interpretation of alarm status results.............................................................................................. 45
Table 39: General parameters & their interpretations .................................................................................... 57
Table 40: Display parameters & their interpretations ..................................................................................... 58
Table 41: RS 485 communication parameters & their interpretations ............................................................ 58
Table 42: Master password parameters & their interpretation ....................................................................... 59
Table 43: Digital inputs parameters & their interpretations ............................................................................ 60
Table 44: Digital input sources & their interpretations.................................................................................... 60
Table 45: LOP sensor parameters & their interpretations .............................................................................. 62
Table 46: Engine temperature sensing (resistive) parameters & their interpretations .................................... 62
Table 47: Fuel level parameters & their interpretations ................................................................................. 64
Table 48: Output parameters & their interpretations ...................................................................................... 65
Table 49: Digital output sources & their interpretations ................................................................................. 65
Page | viii
Table 50: Cranking parameters & their interpretations .................................................................................. 68

Table 51: General timers’ parameters & their interpretations......................................................................... 68
Table 52: Alternator configuration parameters & their interpretations ............................................................ 70
Table 53: Voltage monitoring parameters & their interpretations ................................................................... 71
Table 54: Frequency monitoring parameters & their interpretations .............................................................. 72
Table 55: Current monitoring parameters & their interpretations ................................................................... 73
Table 56: Load monitoring parameters & their interpretations ....................................................................... 74
Table 57: Mains configuration parameters and their interpretations .............................................................. 75
Table 58: Voltage monitoring parameters and their interpretations................................................................ 75
Table 59: Frequency monitoring parameters and their interpretations ........................................................... 76
Table 60: Crank disconnect parameters & their interpretations ..................................................................... 77
Table 61: Speed monitoring parameters & their interpretations ..................................................................... 78
Table 62: Battery monitoring parameters & their interpretations .................................................................... 79
Table 63: Charging alternator monitoring parameters & their interpretations ................................................. 80
Table 64: Preheat parameters & their interpretations .................................................................................... 80
Table 65: Maintenance parameters & their interpretations ............................................................................ 81
Page | ix
Introduction
This document presents information necessary for operating KOEL's KG640 genset controller. It also
provides the user with the necessary background for using KG640 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 KG640 is a modern and feature rich genset controller with user-friendly HMI and full graphics LCD.
The KG640 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 KG640 controller's smart
software offers flexibility to configure each individual input and output for a specific function or application.
The KG640 can be configured through Windows PC utility (refer section 13, Introduction to KOEL
Configuration Utility & 14, Installation Instructions). Also, all parameters can be configured using the keypad
of the genset controller.
Key Highlights of the Product

The KG640 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
• PC connectivity via USB port, RS485
• Configurable fuel theft alarm
• RPM sensing using alternator frequency
• Backlit and full graphics display with power saving feature
Figure 1: KG640 genset controller's front fascia
Page | 1
Specifications
Terminals
The KG640 hosts three types of terminal blocks as shown in Figure 2, Figure 3 and Figure 4 below.
2.1.1 10.16 mm pitch connector suitable for 2 sq. mm wire
Figure 2: Connectors of 10.16 mm pitch

Table 1: 10.16 mm pitch connector details
Connector Male (On SM Part Female (Mating)* SM Part Quantity
type controller) * Number Number (Nos)
4-Pin 5474274 SM0003195 5453499 SM0001163 1
*Phoenix (Phoenix Contact (I) Pvt. Ltd.)
2.1.2 5.08 mm pitch connectors suitable for 2 sq. mm wire

Table 2: 5.08 mm pitch connectors details
Connector Male (On SM Part Female (Mating)* SM Part Quantity
2-Pin 5447353 SM0000281 5441980 SM0001164 1
*Phoenix (Phoenix Contact (I) Pvt. Ltd.)
2.1.3 3.5 mm pitch connector suitable for 0.5 – 1.5 sq. mm wire
Page | 2
Table 3: 3.5 mm pitch connector details

Connector Male (On SM Part SM Part Quantity
Female (Mating)*
4-Pin 5441294 SM0000278 5441430 SM0003731 2
6-Pin 5441317 SM0003346 5449283 SM0003732 1
8-Pin 5441320 SM0003348 5441456 SM0003733 1
10-Pin 5443962 SM0003349 5449306 SM0003734 1
* Phoenix (Phoenix Contact (I) Pvt. Ltd.)
Power Supply Specifications

Table 4: 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
Maximum current (with all ~ 0.2 A @ 12 V-DC (excluding the current load for the high side
sensors disconnect) driver output's)
Standby current 60 mA @ 12 V-DC
Deep sleep current 15 mA @ 12 V-DC
Genset Voltages and Frequency Measurements

Table 5: Genset voltages and frequency measurements
Sample Rate 5 kHz
Harmonics 10th
Phase to Neutral voltage 15 to 350 V-AC RMS
Common mode offset from Earth 100 V-AC
Rate of updating of display 1 sec
Voltage accuracy ±1 % of full-scale Phase to Neutral
Minimum voltage level required
25 V-RMS
to measure
Page | 3
For 1 phase genset application, it is mandatory to connect the genset phase and neutral
Genset Current Measurement

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

Following table gives a brief overview of Mains voltage and frequency measurement
Table 7: Mains voltage and frequency measurement
Sample Rate 5 kHz
Harmonics 10th
Phase to Neutral voltage 15 to 360 V- AC RMS
Common mode offset from Earth 100 V-AC
Voltage accuracy ±2 % of full scale
Page | 4
For single phase application, it is mandatory to connect the mains phase and neutral
Digital Inputs
Table 8: Digital inputs
Controller terminal number 10, 11, 12, 21, 22
Number of inputs 5
Type Negative sensing (connect to ground for activation)
0.8 V-DC maximum (measured at the genset controller's terminal
Low level threshold
and battery ground terminal)
Maximum input voltage VBATT
Minimum input voltage 0 V (BATT-)
Contact wetting current 2.5 mA typical
Protection Level Short circuit to BATT+ and BATT-
Lube Oil Pressure Switch, High Temperature Switch and many
Software configurable options
more. Please refer Table 22 for more details.
Analog Inputs
2.7.1 I/P: ANLG / DIG F

Table 9: I/P: ANLG/DIG F
Controller terminal number 26 (LOP sensor)
Full scale 1 kΩ
Open circuit detection Above 5.5 KΩ or more
Resolution 0.1 Bar
Maximum common mode voltage 2V
Display range 0 to 10 Bar
One should connect the sensor output terminals between the
Connection method
genset controller's terminal and the battery ground terminal.
2.7.2 I/P: ANLG TEMP / DIG H

Table 10: I/P: ANLG TEMP / DIG H
Controller terminal number 24 (Eng temp sensor)
Full scale 5 kΩ
Open circuit detection Above 5.5 KΩ
Resolution 1 °C
Page | 5
1 % of full scale (for 50 to 1000 Ω)

Accuracy 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
2.7.3 I/P: ANLG FL / DIG G

Table 11: I/P: ANLG FL / DIG G
Controller terminal number 25 (Fuel Level sensor)
Full scale 1 kΩ
Resolution 1 % of tank capacity
Accuracy ±1.5 % of full scale
Display range 0 to 100 %
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.
D+ Charge Alt
Table 12: 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.
Page | 6
Digital Outputs
Table 13: 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-
Start Relay, Fuel Relay, Close Genset Contactor and many more.
Software configurable options
Please refer Table 26 for more details.
Genset & mains contactor latching relays should be compiled against 4kVA surge as
per IEC-61000-4-5 standard.
Do not connect “STARTER MOTOR RELAY” and “STOP SOLENOID” directly to the
controller's output terminals.
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 pre-set Deep Sleep Mode Delay.
When remote start/stop input is used, and mains monitoring is disabled
Device enters 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.
Page | 7
Communication Ports
Table 14: Communication ports
Used to flash the firmware
USB USB 2.0 Type B for connection between controller and PC running
KG640 - Configuration Utility
RS485 Used for data communication
Controller terminal number 15, 16 (RS485 A and RS485 B)
For further details please refer section Communication Protocol for KG640 (section 11, Introduction to
Communication Protocol).
Installation
Dimensions
Figure 5: Dimensions of the KG640 genset controller
Page | 8
Recommended mounting panel cut-out dimensions: 118 mm X 93 mm
Mounting on panel
To mount the controller into the panel, use the fixing clips provided along with the controller. Follow the given
steps.
• 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.
Figure 6: Fixing clip and screw supplied along with controller
Figure 7: Controller mounting on the panel using the fixing clips
Over tightening of the screws may damage the controller casing.
Page | 9
Terminal Description
Following figure shows the rear view of module.
Figure 8: KG640 genset controller from backside

The following table provides the details of controller's terminals.
Table 15: Details of KG640 terminals
Terminal
Name Description
Sr. No.
1 BATT - Battery ground
2 BATT + Battery positive
3 OUT A High side driver output – A
4 OUT B High side driver output – B
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
9 OUT F High side driver output – F
10 DIG_IN A Input from switch – A
11 DIG_IN B Input from switch – B
Page | 10
Terminal
Name Description
Sr. No.
12 DIG_IN C Input from switch – C
13 Reserved Not used (reserved)
14 Reserved Not used (reserved)
15 RS485_B RS485 – B
16 RS485_A RS485 – A
17 Reserved Reserved
21 DIG_IN D Input from switch – D
22 DIG_IN E Input from switch – E
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 LOP / DIG F Analog input from 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
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
33 MAINS_V IN Y Voltage input from Mains Phase Y
34 MAINS_V IN R Voltage input from Mains Phase R
39 GEN_CT_IN R1 CT input 1 from Gen Phase R
40 GEN_CT_INR2 CT input 2 from Gen Phase R
41 SCP Sensor Common
Page | 11
Typical Wiring Diagram
4.4.1 Manual Control Application
Figure 9: KG640 genset controller when used in the 3-phase manual control panel
1) Wiring drawing is for representation purpose only. Please refer wiring as per
given genset application drawing.
2) Relay cards that used with controller should have protection against reverse
battery voltages.
Page | 12
Module Display
Following section describes the layout of screens.
Power on Screen
Table 16: Power on screen
SCREEN LOGO PRODUCT INFO
(This screen displays product ID, engine sr no)
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.
Table 17: Symbols & name of screen's group
Symbols for Screen's Group Name of Screen's Group
Generator screens
Engine screens
Test mode
Off mode
Page | 13

This screen will show genset status or alarms along with the operating mode of the controller.
Table 18: Screens of genset status and operating mode
MANUAL MODE ENGINE OFF MANUAL MODE
(These screens will be visible in Manual mode) (These screens will be visible in Manual mode)
TEST MODE ENGINE OFF TEST MODE
(Test mode can be identified by symbol in bottom

(This screen will be visible in Test mode)
left corner)
AUTO MODE MANUAL MODE WARNING ALARM
(This screen will be visible in Auto mode) (This screen will be visible in Manual mode)
MANUAL MODE SHUTDOWN ALARM MANUAL MODE ELECTRIC TRIP
(This screen will be visible in Manual mode) (This screen will be visible in Manual mode)
Page | 14
OFF MODE ENGINE OFF GEN kW LOAD IN OFF MODE
(Off mode can be identified by symbol in bottom

(This screen will be visible in Off mode)
left corner)
CONTACTORS GENERATOR VOLTAGE
(This screen will be visible only if output related to (The “Y” and “B” phase will be visible only if
genset and mains contactor are configured) configured for 3 phase genset)
GENERATOR kW LOAD GENERATOR kVA LOAD
(The “Y” and “B” phase will be visible only if (The “Y” and “B” phase will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
GENERATOR kVAr LOAD GENERATOR POWER FACTOR
(The “Y” and “B” phase will be visible only if (The “Y” and “B” phase will be visible only if
configured for 3 phase genset) configured for 3 phase genset)
Page | 15
GENERATOR OUTPUT GENERATOR ENERGY
(The “Y” and “B” phase will be visible only if

configured for 3 phase genset. Minimum frequency
out of 3 phases will be displayed on screen)
ENGINE SCREENS
ENGINE BATTERY LUBE OIL TEMP
(This screen will be visible only if “Lube Oil

Temperature” sensor is configured)
ENGINE TEMPERATURE ENGINE LUB OIL PRESSURE
(This screen will be visible only if “Engine (This screen will be visible only if “Lube Oil
temperature” sensor is configured) Pressure” sensor is configured)
ENGINE REMAINING FUEL ENGINE SPEED
(This screen will be visible only if “Fuel Level”

sensor is configured)
Page | 16
ENGINE RUN TIME ALARM
Description of Control Keys
1
6
2
5
4
3
Figure 10: Control keys function

1. Navigation UP key
2. Navigation DOWN key
3. Stop/Off key
4. Auto/Manual/Test mode selection key
5. Start/Select key
6. Screen
Page | 17
Mode Selection diagram
Figure 11: Mode selection using control keys in KG640

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
Functions of Control keys

Following table provides details of control keys in different modes.
Table 19: Control keys in different modes
1 Manual/Test Start Starts the engine
2 Auto Enters Auto mode
3 Auto (long pressed) Enters Test mode
Manual Immediate stops the engine when engine
is running
5 Stop (long pressed) Enters Off mode when engine is off
6 Manual/Auto Stop Stops the engine and enters Manual mode
7 Manual/Configuration Up/Down Scrolls the parameter
8 Manual/Off Down+Stop (long pressed) Enters configuration mode
Page | 18

Displays last group's first screen (refer
Up (long pressed) section 5.2, Monitoring Mode for more
9 details about screen's group)
Manual/Test/Auto/Off Down (long pressed) Displays next group's first screen
Up+Down (simultaneously
10 press and release while on Clears the alarms
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
Back to Manual mode
15 Deep sleep Any key
16 Test Stop
17 Event log page Up+Down (long pressed) Back to configuration mode
18 Programming Up+Down (long pressed) Reset the controller
Configuration Mode
To configure the controller please follow the below mentioned instructions.
Enter the configuration mode (refer section 6, Description of Control Keys).
Table 20: Configuration mode
CONFIGURATION MODE ENTER PASSWORD
To enter 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 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 7.1, Configurable 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.
Figure 12: Saving settings
Page | 19
Configurable Parameters
Table 21: List of configurable parameters
Level 1 (On
Level 0 Level 2 (On screen) Possible Value (On screen)
screen)
Profile Name
Profile 1
(PROFILE NAME)
Power On Mode
Manual/Auto
General (POWER ON MODE)
(GENERAL) Power On Lamp Test
Disable/Enable
(POWER ON LAMP TEST)
Deep Sleep Mode
Disable/Enable
(DEEP SLEEP MODE)
Contrast
0 – 100 %
Module Display (CONTRAST)
(MODULE) (DISPLAY) Power Save Mode
Disable/Enable
(POWER SAVE MODE)
Communication Mode
MODBUS
(COMM MODE)
MODBUS Slave ID
RS485 1 – 247
(MODBUS SLAVE ID)
Communication
(RS485 COMM) MODBUS Baudrate 1200/2400/4800/9600/19200/
(MODBUS BAUDRATE) 38400/57600/115200
Parity Bit
None/Even/Odd
(PARITY)
Source
Refer Table 22
(SOURCE)
Polarity Close to Activate/Open to
(POLARITY) Activate
Digital Input X
Action None/Warning/
(DIG IN X)
(ACTION) Electrical Trip/Shutdown
X= A/B/C/D/E
Activation Never/From Engine Start/
(ACTIVATION) From Monitoring On/Always
Activation Delay
1 – 60 sec
(ACTIVATION DELAY)
Inputs
Use Input As Not used/Digital Input F/
(INPUTS)
(SENSOR SELECT (pin 26)) Anlg In LOP
(Digital) Source
Refer Table 22
((DIG) SOURCE)
Lube Oil (Digital) Polarity Close to Activate/Open to
Pressure ((DIG) POLARITY) Activate
(LOP/DIG F) (Digital) Action None/Warning/
((DIG) ACTION) Electrical Trip/Shutdown
(Digital) Activation Never/From Engine Start/
((DIG) ACTIVATION) From Monitoring On/Always
(Digital) Activation Delay 1 – 60 sec
Page | 20
Level 1 (On
screen)
((DIG) ACTIVATION DELAY)
(LOP) High Level Shutdown
Disable/Enable
(SHUTDOWN)
(LOP) High Level Shutdown
Threshold 0.0 – 4.8 Bar
(SHUTDOWN THRESHOLD)
(LOP) High Level Warning
Disable/Enable
(WARNING)
(LOP) High Level Warning
Threshold 0.2 – 5.0 Bar
(WARNING THRESHOLD)
(LOP) Sensor Circuit Fault None/Warning/
(OPEN CKT ALARM) Electrical Trip/Shutdown
Lube Oil Pressure Sensor
Refer Table 23
Calibration
Use Input As Not used/Digital Input G/
(SENSOR SELECTION) Anlg In Eng Temp
(Digital) Source
Refer Table 22
((DIG) SOURCE)
(Digital) Polarity Close to Activate/Open to
((DIG) POLARITY) Activate
(Digital) Action None/Warning/
Engine (Digital) Activation Delay
1 – 60 sec
Temperature ((DIG) ACTIVATION DELAY)
Sensing (ETS) High Temp Shutdown
(Resistive) Disable/Enable
(SHUTDOWN)
(ENG TEMP/DIG
G) (ETS) High Temp Shutdown
Threshold 26 – 200 °C
(ETS) High Temp Warning
Disable/Enable
(WARNING)
(ETS) High Temp Warning
Threshold 25 – 199 °C
(WARNING THRESHOLD)
(ETS) Engine Temp Circuit Fault None/Warning/
(OPEN CKT ALARM) Electrical Trip/Shutdown
(ETS) Engine Temperature
Refer Table 24
Sensor Calibration
Fuel Level Use Input As Not used/Digital Input H/
Sensing (SENSOR SELECTION) Anlg In Fuel LVL
(Resistive) (Digital) Source
Refer Table 22
((DIG) SOURCE)
Page | 21
Level 1 (On
screen)
(FUEL LVL/DIG (Digital) Polarity Close to Activate/Open to
H) ((DIG) POLARITY) Activate
(Digital) Action None/Warning/
(Digital) Activation Delay
1 – 60 sec
((DIG) ACTIVATION DELAY)
(FLS) Low Fuel Level Shutdown
Disable/Enable
(SHUTDOWN)
(FLS) Low Fuel Level Shutdown
Threshold 0 – 50 %
(FLS) Low Fuel Level Warning
Disable/Enable
(WARNING)
(FLS) Low Fuel Level Warning
Threshold 2 – 55 %
(WARNING THRESHOLD)
(FLS) Fuel Tank Capacity
0 – 1000 Litre
(FUEL TANK CAPACITY)
(FLS) Fuel Theft Warning
Disable/Enable
(FUEL THEFT ALARM)
(FLS) Fuel Theft Threshold
0 – 100 %/Hour
(FUEL THEFT THRESHOLD)
(FLS) Fuel Consumption
0.0 – 100.0 Ltr/Hour
(FUEL CONSUMPTION)
(FLS) Display Fuel in Liters
Disable/Enable
(FUEL IN LITERS)
(FLS) Fuel Sensor Reference Engine Body/
(FUEL REFERENCE) Battery Negative
(FLS) Fuel Level Sensor
Refer Table 25
Calibration Table
Source
Output X Refer Table 26
Outputs (SOURCE)
(OUT X)
(OUTPUTS) On Activation
X= A/B/C/D/E/F De-energise/Energise
(ON ACTIVATION)
Crank Hold Time
1 – 15 sec
(CRANK HOLD TIME)
Cranking
Crank Rest Time
(CRANKING 2 – 60 sec
Timers (CRANK REST TIME)
TIMER)
(TIMERS) Crank Start Delay
0 – 30 sec
(CRANK START DELAY)
General Safety Monitoring Delay
1 – 60 sec
(GENERAL (SAFETY MONITOR DELAY)
Page | 22
Level 1 (On
screen)
TIMER) Mains Detect Delay
1 – 30 sec
(MAINS DETECT DELAY)
Alternator Detect Delay
1 – 30 sec
(ALT DETECT DELAY)
Warm-Up Delay
0 – 60 sec
(WARM UP DELAY)
Return to Mains Delay
0 – 600 sec
(RETN-TO-MAINS DELAY)
Engine Cooling Time
0 – 300 sec
(ENG COOL TIME)
Stop Action Time
10 – 120 sec
(STOP ACTION TIME)
Load Transfer Delay
0 – 60 sec
(LOAD TRANSFER DELAY)
Power Save Mode Delay
5 – 1800 sec
(PWR SAVE MODE DELAY)
Screen Changeover Time
5 – 1800 sec
(SCRN CHNGOVER TIME)
Deep Sleep Mode Delay
5 – 1800 sec
(DEEP SLP MODE DELAY)
Sounder Alarm Timer
1 – 300 sec
(SOUNDER ALARM TIMER)
Test Mode Timer
1 – 720 Min
(TEST MODE TIMER)
Alternator Present
No/Yes
(ALT PRESENT)
Number Of Poles
2/4/6/8
(NUMBER OF POLES)
AC system
1 Phase/3 Phase
(ALT AC SYSTEM)
Min Healthy Voltage
80 – 350 V Ph-N
(MIN HEALTHY VOLT)
Min Healthy Frequency
Alternator 0 – 60 Hz
Generator (MIN HEALTHY FREQ)
Configuration
(GENERATOR) Phase Reversal Detection
(ALT CONFIG) Disable/Enable
(PHASE REV DETECT)
Phase Reversal Action None/Warning/
(PHASE REV ACTION) Electrical Trip/Shutdown
Alt Voltage Lost Shutdown
Disable/Enable
(ALT VOLT LOST SHUTDN)
Alt Voltage Lost Threshold
0 – 100 Volt
(ALT VOLT LOST THRESH)
Alt Voltage Lost Delay
0 – 30 sec
(ALT VOLT LOST DELAY)
Page | 23
Level 1 (On
screen)
Auto Load Transfer
Disable/Enable
(AUTO LOAD TRANSFER)
Under-voltage Shutdown
Disable/Enable
(UNDER VOLT SHUTDOWN)
Under-voltage Shutdown
Threshold 0 – 338 Volt Ph-N
(UV SHUTDOWN THRESH)
Under-voltage Warning
Disable/Enable
(UNDER VOLT WARNING)
Under-voltage Warning
Voltage Threshold 2 – 340 Volt Ph-N
Monitoring (UV WARNING THRESHOLD)
(VOLT
MONITOR) Over-voltage Shutdown
Disable/Enable
(OVER VOLT SHUTDOWN)
Over-voltage Shutdown
Threshold 102 – 350 Volt Ph-N
(OV SHUTDOWN THRESH)
Over-voltage Warning
Disable/Enable
(OVER VOLT WARNING)
Over-voltage Warning Threshold
100 – 345 Volt Ph-N
(OV WARNING THERSHOLD)
Under-frequency Shutdown
Disable/Enable
(UNDER FREQ SHUTDOWN)
Under-frequency Shutdown
Threshold 0.0 – 59.0 Hz
(UF SHUTDOWN THRESH)
Under-frequency Warning
Disable/Enable
(UNDER FREQ WARNING)
Under-frequency Warning
Frequency Threshold 1.0 – 60.0 Hz
Monitoring (UF WARNING THRESH)
(FREQ Over-frequency Shutdown
MONITOR) Disable/Enable
(OVER FREQ SHUTDOWN)
Over-frequency Shutdown
(OF SHUTDOWN THRESH)
Over-frequency Warning
Disable/Enable
(OVER FREQ WARNING)
Over-frequency Warning
(OF WARNING THRESH)
Current CT Ratio
1 – 8000/5
Monitoring (CT RATIO)
(CURRENT Over-current Threshold
MONITOR) 5 – 10000 A
(OVER CURR THRESHOLD)
Page | 24
Level 1 (On
screen)
Over-current Delay
1 – 600 sec
(OVER CURR DELAY)
Over-current Action None/Warning/
(OVER CURR ACTION) Electrical Trip/Shutdown
Unbalanced Load Action None/Warning/
(UNBAL LOAD ACTION) Electrical Trip/Shutdown
Unbalanced Load Threshold
5 – 200 %
(UNBAL LOAD THRESHOLD)
Unbalanced Load Delay
1– 600 sec
(UNBAL LOAD DELAY)
(RESERVED) NA
CT Correction Factor 0.900 – 1.100
Generator Rating
1.0 – 800.0 kW
(GEN RATING)
Over-load Threshold
Load Monitoring 50 – 150 %
(OVERLOAD THRESHOLD)
(LOAD
MONITOR) Over-load Monitoring Delay
1 – 600 sec
(OVERLOAD MON DELAY)
Over-load Action None/Warning/
(OVERLOAD ACTION) Electrical Trip/Shutdown
Mains Monitoring
Disable/Enable
(MAINS MONITORING)
Mains Mains AC System
1 Phase/3 Phase
Configuration (MAINS AC SYSTEM)
(MAINS Phase Reversal Detect
Disable/Enable
CONFIG) (PHASE REVERSAL DETECT)
Phase Reversal Action
None/Notification
(PHASE REVERSAL ACTION)
Enable
No/Yes
Under Voltage (ENABLE)
Monitoring Trip
(UNDER VOLT 48 – 398 V Ph-N
Mains (TRIP)
(MAINS) MON)
Return
50 – 400 V Ph-N
(RETURN)
Enable
No/Yes
Over Voltage (ENABLE)
Monitoring Trip
(OVER VOLT 102 – 800 V Ph-N
(TRIP)
MON)
Return
100 – 798 V Ph-N
(RETURN)
Under Frequency Enable
No/Yes
Monitoring (ENABLE)
(UNDER FREQ Trip
MON) 27.0 – 67.0 Hz
(TRIP)
Page | 25
Level 1 (On
screen)
Return
28.0 – 68.0 Hz
(RETURN)
Enable
No/Yes
Over Frequency (ENABLE)
Monitoring Trip
(OVER FREQ 30.0 – 70.0 Hz
(TRIP)
MON)
Return
29.0 – 69.0 Hz
(RETURN)
Start Attempts
1–9
(START ATTEMPTS)
Disconnect on LOP Sensor
Disable/Enable
(DISCONN ON LOP SENS)
Disconnect Pressure Threshold
0.5 – 10.0 Bar
(DISCON LOP THRESH)
Reserved
NA
(RESERVED)
Disconnect on LLOP Switch
Crank Disable/Enable
(DISCONN ON LLOP SW)
Disconnect
(CRANK LLOP Switch Transient Time
0.0 – 3.0 Sec
DISCON) (LLOP SW TRANS TIME)
Alternator Frequency Threshold
0 – 70 Hz
(ALT FREQ THRESH)
Engine Speed Threshold
0 – 4000 RPM
(ENG SPEED THRESH)
Disconnect On Charging Alt
Engine Voltage Disable/Enable
(ENGINE) (DISCONN CHG ALT VOLT)
Charging Alt Threshold
5.0 – 30.0 Volt
(CHG ALT THRESHOLD)
Engine Speed Sense Source Alternator frequency (Alt
(SPEED SENSE SOURCE) Freq)
Under-speed Shutdown Enable
Disable/Enable
(UNDER SPEED SHUTDOWN)
Under-speed Threshold
0 – 3600 RPM
(UNDER SPEED THRESH)
Speed Under-speed Delay
Monitoring 1– 60 Sec
(UNDER SPEED DELAY)
(SPEED
MONITOR) Over-speed Threshold
800 – 4000 RPM
(OVER SPEED THRESHOLD)
Over-speed Delay
1 – 60 sec
(OVER SPEED DELAY)
Gross Over-speed Threshold
100 – 200 %
(GROSS OS THRESHOLD)
Engine Speed Fault Disable/Enable
Page | 26
Level 1 (On
screen)
(ENGINE SPEED FAULT)
Healthy-speed Threshold
300 – 4000 RPM
(HEALTHY SPEED THRES)
Healthy-speed Delay
1 – 10 sec
(SPEED FLT DETECT DLY)
Low Battery Voltage Action None/Warning/
(LOW VOLT ACTION) Notification/Shutdown
Low Battery Voltage Threshold
8.0 – 24.0 Volt
(LOW VOLT THRESHOLD)
Battery Low Battery Voltage Delay
5 – 1800 sec
Monitoring (LOW VOLT DELAY)
(BATTERY High Battery Voltage Action None/Warning/
MONITOR) (HIGH VOLT ACTION) Notification/Shutdown
High Battery Voltage Threshold
12.0 – 36.0 Volt
(HIGH VOLT THRESHOLD)
High Battery Voltage Delay
5 – 1800 sec
(HIGH VOLT DELAY)
Charging Alternator Fail Action None/Warning/Electrical
(FAIL ACTION) Trip/Shutdown/Notification
Charging
Alternator Charging Alternator Fail
Monitoring Threshold 4.0 – 28.0 Volt
(CHARGE ALT (FAIL THRESHOLD)
MON) Charging Alternator Fail Delay
5 – 60 sec
(FAIL DELAY)
Preheat Timer
0 – 60 Sec
(PREHEAT TIMER)
Engine Temperature Limit
Disable/Enable
Preheat (ENG TEMP LIMIT)
(PREHEAT) Engine Temperature Limit
0 – 300 °C
(ENG TEMP LIMIT)
Cold Start
Disable/Enable
(COLD START)
Maintenance Alarm
Disable/Enable
(ALARM)
Maintenance Maintenance Action
Notification/Warning
(MAINTENANCE) (MAINT ALARM) (ACTION)
Due At Engine Hours
10 – 65000 hrs
(DUE AT ENGINE HOURS)
Password X
Password
(PASSWORD X) #### 0 – 9 for each digit
(PASSWORD)
X= 1/2
(ENGIN RUN TIME) (In Numbers) Hrs
(RESET DG RESET
(NO OF STARTS) (In Numbers)
COUNTERS) COUNT
(NO OF TRIPS) (In Numbers)
Page | 27
Level 1 (On
screen)
(ENG kWh) (In Numbers) kWh
(ENG kVAh) (In Numbers) kVAh
(ENG kVArh) (In Numbers) kVArh
*2 level password (configurable through product UI and KG configuration utility)
Table 22: Digital input sources selection
# Source (On screen)
0 Not Used
1 User Configured
2 Low Fuel LVL Switch
3 Low Lube Oil Press Switch
4 High Engine Temp Switch
5 Low Water LVL Switch
6 Emergency Stop
7 Remote Start/Stop
8 Simulate Start
9 Simulate Stop
10 Simulate Auto
11 Close Gen/Open Mains SW
12 Close Mains/Open Gen SW
13 Simulate Mains
14 High Canopy Temp Switch
15 V-Belt Broken Switch
16 Semi-Auto Mode
Table 23: LOP sensor calibration

Resistance (Ω) Pressure (Bar)
0 – 1000 (R1-R10) 0.0 – 10.0 Bar (V1-V10)
Table 24: Engine temperature sensor calibration

0 – 5000 (R1-R10) -25 – 200 °C (T1-T10)
Table 25: Fuel level sensor calibration

Resistance (Ω) Fuel level (%)
0 – 1000 (R1-R10) 0 – 100 % (L1-L10)
Table 26: Digital output source selection

# Output Source (On Screen)
1 Disable
2 Sounder Alarm
3 Battery Over Volt
4 Battery Under Volt
Page | 28

5 Charge Alt Shutdown
6 Charge Alt Warning
7 Close Gen Contactor
8 Close Mains Contactor
9 Mains Failure
10 Common Alarm
11 Common Electric Trip
12 Common Shutdown
13 Common Warning
14 Cooling Down
15 Digital Input A
16 Digital Input B
17 Digital Input C
18 Digital Input D
19 Digital Input E
20 Digital Input F (Dig In F (Anlg In LOP))
21 Digital Input G (Dig In G (Anlg In Eng Temp))
22 Digital Input H (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 Gen Available
29 R Phase OV Shutdown
30 R Phase UV Shutdown
31 Y Phase OV Shutdown
32 Y Phase UV Shutdown
33 B Phase OV Shutdown
34 B Phase UV Shutdown
35 Gen Over Current
36 High Engine Temp
37 Low Fuel LVL
38 Low LOP
39 Mains High Volt
40 Mains Low Volt
41 Oil Pressure Open Circuit
42 Open Gen Contactor
43 Open Mains Contactor
44 Over Freq Shutdown
45 Over Speed Shutdown
Page | 29

46 Gross Over Speed Shutdown
47 Start Relay
48 Temp Sensor Open Circuit
49 Under Freq Shutdown
50 Under Speed Shutdown
51 Maintenance Due
52 Stop Mode
53 Auto Mode
54 Manual Mode
55 Preheat Output
Page | 30
Module Operation
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 Time will start. After this, controller will command genset to stop.
When Genset is not running and Mains is healthy, and Mains Monitoring is enabled, Mains contactor will get
latched. 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.
Auto Mode
To enter Auto mode press “AUTO” key (refer section 6, Description of Control Keys). The controller can be
used in following configurations while in Auto mode.
• Remote start/stop
8.2.1 Remote start/stop

To use the Remote start/stop mode of the controller, first configure one of the digital inputs 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 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 13).
Figure 13: Remote start/stop digital input configuration screen
Semi – Auto Mode

The semi-Auto mode provide the feasibility to the operator to start the Genset as and when he wants
manually in case of Mains failures. In this mode, the genset is powered OFF automatically when the Mains
is restored. To use the Semi-Auto mode of the controller, first configure one of the digital inputs as “Semi-
Page | 31
Auto Mode”, enable the Mains monitoring parameters and put the controller in Manual mode. In this mode,
the Genset contactor will be latched in Genset healthy condition and Mains unhealthy.
Figure 14: Semi-auto mode digital input configuration screen
Figure 15: Semi-auto mode SMD
Alarms
KG640 controller allows to configure several Shutdown/Electrical trip, Warning and Notification alarms such
as Low Oil Pressure shutdown, Overload warning and many more.
An alarm condition occurs when the preconfigured parameter is out of pre-set 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
Page | 32
activated at the end of Safety Monitoring Delay duration. The controller will not issue the start command if
any of alarm left unacknowledged.
Table 27: Alarm actions
# 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 begin, after which genset
2 Electrical trip
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.
If warning / shutdown / notification / Electric trip alarm appears, the screen doesn’t not scroll automatically.
Table 28: Alarms and their actions
Sr. Action
Alarms Causes
No. Options
Indicates that the oil pressure measured is below the pre-set Shutdown/
1 Low Oil Pressure
threshold. This condition is detected only when engine is off. Warning
Shutdown/
Low Oil Pressure Indicates that the oil pressure measured is below the pre-set
2 Electrical Trip/
(Switch) threshold. This condition is detected only when engine is off.
Warning
Shutdown/
Oil Pressure Ckt
3 The oil pressure sensor is detected as not being present Electrical Trip/
Open
Warning
Indicates that the engine temperature is above the pre-set Shutdown/
4 High Eng Temp
Shutdown/
High Eng Temp Indicates that the engine temperature is above the pre-set
5 Electrical Trip/
Warning
Shutdown/
Eng Temp/
6 The temperature sensor is detected as not being present Electrical Trip/
pin24-Ckt Opn
Warning
Indicates that the amount of fuel level is below the pre-set Shutdown/
7 Low Fuel level
Shutdown/
Low Fuel level Indicates that the amount of fuel level is below the pre-set
8 Electrical Trip/
Warning
9 Fuel Theft The fuel consumption has exceeded the pre-set threshold Warning
Shutdown/
Low Water Level Indicates that radiator water level is below the pre-set
10 Electrical Trip/
Switch threshold
Warning
Auxiliary Input Shutdown/
(for eg. Aux_A) Configured auxiliary input has triggered longer than pre-set
11 Electrical Trip/
/user defined duration
name Warning
12 Emergency Stop When emergency stop switch is pressed and immediate Shutdown
shutdown is required. This condition is detected in both
Page | 33
Sr. Action
Alarms Causes
No. Options
conditions- engine on and off.
It is detected that genset is still running after sending stop
13 Fail To Stop Shutdown
command
Indicates that genset has not started after the pre-set number
14 Fail To Start Shutdown
of Start Attempts
R Phase Over Indicates that genset (R) Phase voltage has exceeded the Shutdown/
15
Voltage pre-set over voltage threshold. Warning
Y Phase Over Indicates that genset (Y) Phase voltage has exceeded the Shutdown/
16
Voltage pre-set over voltage threshold Warning
B Phase Over Indicates that genset (B) Phase voltage has exceeded the Shutdown/
17
Voltage pre-set over voltage threshold Warning
R Phase Under Indicates that genset (R) Phase voltage has fallen below pre- Shutdown/
18
Voltage set under voltage threshold. Warning
Y Phase Under Indicates that genset (Y) Phase voltage has fallen below pre- Shutdown/
19
Voltage set under voltage threshold Warning
B Phase Under Indicates that genset (B) Phase voltage has fallen below pre- Shutdown/
20
Voltage set under voltage threshold Warning
Shutdown/
DG Phase
21 Alternator phase sequence (R-Y-B) is not correct Electrical Trip/
Reversed
Warning
Indicates that genset output frequency has exceeded the pre- Shutdown/
22 Over Frequency
set threshold Warning
Indicates that genset output frequency has fallen below the Shutdown/
23 Under Frequency
pre-set threshold Warning
Shutdown/
Indicates that genset current has exceeded the pre-set
24 Over Current Electrical Trip/
shutdown threshold
Warning
Shutdown/
Indicates that the measured kW load rating has exceeded the
25 Over Load Electrical Trip/
pre-set threshold
Warning
Shutdown/
Unbalanced Load on any phase is greater or less than other phases by a
26 Electrical Trip/
Load threshold value
Warning
Indicates that genset speed has exceeded the pre-set over
27 Over Speed speed threshold. Genset will shut down after Over Speed Shutdown
Delay.
Indicates that genset speed has exceeded the pre-set Gross
Gross Over
28 Over Speed Threshold. Genset will shut down immediately Shutdown
Speed
without any delay.
29 Under Speed The engine speed has fallen below the pre-set RPM Shutdown
Shutdown/
The charge alternator voltage has dropped below the pre-set
30 Charge Fail Electrical Trip/
threshold
Warning
31 No Speed Signal Indicates that speed sensor connections are absent Shutdown
32 V Belt Broken Indicates that there is failure of the V-belt, which is driving the Shutdown/
Page | 34
Sr. Action
Alarms Causes
No. Options
charging alternator Electrical Trip/
Warning
Shutdown/
Battery Under
33 The battery voltage has fallen below the pre-set threshold Electrical Trip/
Voltage
Warning
Shutdown/
Battery Over
34 The battery voltage has exceeded the pre-set threshold Electrical Trip/
Voltage
Warning
This indicates that alternator voltage has not crossed 50 V-
35 Alt Voltage Lost Shutdown
RMS within 2 seconds after crank disconnect event
High Oil Press Lube oil pressure is detected above the crank disconnect
36 Warning
Detected threshold when the engine is off.
This indicates that engine speed has not crossed pre-set
Engine Speed
37 Healthy Speed Threshold within 2 seconds from the crank Shutdown
Fault
disconnect event
Eng Speed Controller has detected engine speed even when the start
38 Warning
Detected command is not issued.
Indicates that engine running hours has exceeded the pre-set Notification/
Maintenance
39 hours limit or expansion module due date has occurred and
Due Warning
filter servicing is required.
High Lube Oil Indicates that lube oil temperature is above the pre-set Shutdown/
40
Temp threshold Warning
Page | 35
Troubleshooting
This section explains the common faults, their possible causes and remedial actions.
Table 29: Troubleshooting
Sr.
No.
Possible Issues in MANUAL Mode
1 The controller does not • Check the battery voltage.
power ON. • 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 • Check the battery voltage.
crank-start the engine. • 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.
• Enter the “configuration mode” in 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” • Check if the “Emergency Stop” switch is working OK. Check its
alarm comes up even wiring also.
when the “Emergency • Enter the “configuration mode” in controller and verify the
Stop” is not pressed. configuration of “EMERGENCY STOP” polarity.
4 The controller • Check the respective switch/sensor and wiring.
generates unnecessary • Enter the “configuration mode” in the controller and verify the
“Shutdown Alarms” or respective threshold configuration.
“Warning Alarms”
5 The controller reports • To check if the controller's charging alternator terminal is working or
“Charge Fail” alarm. 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 • Ensure that the controller's o/p terminal is not directly connected to
unnecessary “crank- the starter relay. The controller's o/p should be given to an
start” command intermediate relay which should in-turn power the starter relay. The
immediately after controller can get permanently damaged and will need to be
power on. replaced if this precaution is not taken.
• Check start-relay connection with the suitable controller terminal.
• Enter the “configuration mode” in the controller and verify the
configuration for the “START RELAY” o/p polarity.
7 The engine runs, but • Check if the MPU signal (if used), and main alternator voltage signal
the controller shows (R phase) are received by the controller terminals.
genset to be “OFF”. • Check if the LOP and LLOP are working OK. Also check their wiring
to the controller.
8 The controller displays • Check wiring of the respective alternator phase voltage and the CT
incorrect PF value or to the controller.
Page | 36
Sr.
No.
kW or load current. • Check the CT ratio (if kW or current reading is faulty).
9 The controller displays • Check the wiring of the respective phase to the controller.
incorrect mains voltage • If the problem is not resolved, replace the controller and try again.
or incorrect main
alternator voltage.
10 Controller displays • Check respective sensor and its wiring.
incorrect reading for • Enter the “configuration mode” in the controller and verify the
any of LOP, Fuel Level, calibration for the respective sensor in configuration.
Temp sensors.
11 The controller displays • Check the MPU connection and configuration (if enabled).
incorrect engine RPM. • Check wiring of the main alternator’s R-phase and neutral to the
controller.
12 The controller screen • Reset the controller power.
freezes or hangs up.
13 The controller does not • Check the wiring of the “Remote Start” signal to the controller's
start the engine even respective digital i/p terminal.
when a “Remote Start” • Enter the “configuration mode” in the controller and verify the
command is sent from configuration for the “Remote Start” digital i/p terminal.
an external device. Check that the controller is in “Auto” mode.
•
14 Controller does not • Check the wiring of the “Remote Stop” signal to the controller's
stop engine even when respective digital i/p terminal.
a “Remote Stop” • Enter the “configuration mode” in the controller and verify the
command is sent from configuration for the “Simulate Stop” digital i/p terminal.
an external device. • Check that the controller is in “Auto” mode.
15 While in Auto mode, • Check the wiring of the mains R, Y and B phase to the controller's
controller issues “Start” respective i/p terminal.
command even if the • Enter the “configuration mode” in the controller and verify the
mains present. configuration for the “MAINS MONITORING”.
Page | 37
Communication Protocol for KG640

Introduction to Communication Protocol
The KG640 genset controller implement a custom protocol based on the standard MODBUS protocol.
MODBUS Based Protocol

KG640 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.
Connection Details
The transmission mode used by KG640 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
KG640 - 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.
Supported Functions
KG640 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.
12.2.1 Function 4 (0x04): Read Input Registers

This function is used to read measurement parameters and status from the KG640 genset controller. The
Byte Field Remarks
0 Slave address As configured in KG640
2 First register address – high byte 16-bit register address register address map is
4 Number of registers to read – high byte Number of registers to read must be between 1
5 Number of registers to read – low byte to 255
6/7 Error check CRC
Table 31: Normal response from KG640 slave for Function 4

Byte Field Remarks
2 Byte count (n)
. .
. .
Page | 38
Byte Field Remarks

. .
12.2.2 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 32 and Table 33.
Byte Field Remarks
4 Number of registers to write – high byte Number of registers to write must be between 1
5 Number of registers to write – low byte to 255
6 Number of data bytes to follow (n)
7 Value at first register
. .
. .
. .
6+n Value at last register

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
12.2.3 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 34 and Table 35.
Byte Field Remarks
Page | 39
Byte Field Remarks

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

Byte Field Remarks
2 Byte count (n)
. .
. .
. .
Register Map
The register map for input registers is as shown in Table 36.
Table 36: Register map for input registers
Reg Offset Value Scale Factor Measuring Unit Bits/Sign
0 Protocol version 1 Unsigned
1 Reserved NA NA NA
2 Lub. Oil pressure 0.1 Bar/Deg C Unsigned
3 Coolant temperature 0.1 Deg C Unsigned
4 Fuel level 1 % Unsigned
5 Charge alternator voltage 1 V Unsigned
6 Battery voltage 0.1 V Unsigned
7 No of Starts 1 - Unsigned
8 No of Trips 1 - Unsigned
9 Engine run time (Hours) 1 Hours Unsigned
10 Engine run time (Minutes) 1 Minutes 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 L1-N voltage 0.1 V Unsigned
Page | 40

18 Generator L1-L2 voltage 0.1 V Unsigned
19 Generator L2-L3 voltage 0.1 V Unsigned
20 Generator L3- L1 voltage 0.1 V Unsigned
21 Generator L1 current 0.1 A Unsigned
24 Generator L1 power 0.1 KW Unsigned
27 Generator total power 0.1 KW Unsigned
28 Generator L1 apparent power 0.1 KVA Unsigned
31 Generator total apparent power 0.1 KVA Unsigned
32 Generator L1 reactive power 0.1 KVAr Unsigned
35 Generator total reactive power 0.1 KVAr Unsigned
36 Generator power factor L1 0.01 Unsigned
37 Generator power factor L2 0.01 Unsigned
38 – 39 Generator power factor L3 0.01 Unsigned
40 – 41 Generator average power factor 0.01 Unsigned
42 – 43 Generator cumulative energy 0.1 KWH Unsigned
44 Generator cumulative apparent 0.1 KVA Unsigned
energy
45 Generator Cumulative reactive 0.1 KVAr Unsigned
energy
46 Mains L1-N voltage 0.1 V Unsigned
49 Mains L1-L2 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
Page | 41

Low fuel level 5/16-8/16
Low water level Switch 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
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 alternator failure 13/16-16/16
Maintenance alarm 9/16-12/16
60 Alarm 6
Battery low voltage 13/16-16/16
Battery high voltage 9/16-12/16
Reserved 5/16-8/16
Engine temperature circuit open 1/16-4/16
61 Alarm 7
Fuel theft 13/16-16/16
Reserved 9/16-12/16
Analogue sensor 2 circuit open 5/16-8/16
Reserved 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
Page | 42

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
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
Reserved 5/16-8/16
Reserved 1/16-4/16
67 Alarm 13
Reserved 9/16-12/16
Reserved 5/16-8/16
Reserved 1/16-4/16
68 Alarm 14
Reserved 9/16-12/16
Reserved 5/16-8/16
Reserved 1/16-4/16
69 Alarm 15
Reserved 9/16-12/16
Reserved 5/16-8/16
Reserved 1/16-4/16
70 Alarm 16
Reserved 9/16-12/16
Alternator Vtg Lost 5/16-8/16
Speed detected 1/16-4/16
71 Reserved
Reserved 16/16
Reserved 15/16
Reserved 14/16
Reserved 13/16
Reserved Dec-16
Page | 43

Reserved Nov-16
Reserved Oct-16
Reserved Sep-16
Reserved Aug-16
Reserved Jul-16
Reserved Jun-16
Reserved May-16
Reserved Apr-16
Reserved Mar-16
Reserved Feb-16
Reserved Jan-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 Dec-16
Digital Input F Nov-16
Digital Input G Oct-16
Digital Input H Sep-16
Digital Output A Aug-16
Digital Output B Jul-16
Digital Output C Jun-16
Digital Output D May-16
Digital Output E Apr-16
Digital Output F Mar-16
Unimplemented Feb-16
Unimplemented Jan-16
73 DG Status
Load on DG TRUE (1), FALSE (0) 16/16
Current DG Status Running (1), Stopped (0) 15/16
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) Dec-16
Common shutdown TRUE (1), FALSE (0) 11/16-1/16
Common electrical trip TRUE (1), FALSE (0)
Common warning TRUE (1), FALSE (0)
Common Notification TRUE (1), FALSE (0)
Load On Mains TRUE (1), FALSE (0)
Unimplemented TRUE (1), FALSE (0)
Page | 44

74 Command Status Unsigned
Write command DG Started (1)
Write command DG Stopped (2)
Read command DG already On (3)
Read command DG already Off (4)
Read command DG in manual mode (5)
Read command DG Not started (6)
75 Alarm 17
High Oil Pressure detected 13/16-16/16
WARNING
Speed Fault 9/16-12/16
Reserved 5/16-8/16
Reserved 1/16-4/16
Actual value = Observed value on MODBUS interface multiplied with scale factor.
The register map for holding registers is as shown in Table 37.

Table 37: Register map for holding registers
Register
Description Note Bits/ Sign
Offset
0 Command Send (0x01) to Start DG. Unsigned
Register Send (0x02) to Stop DG.
Command Status is updated in Status register.
1 Operating Mode Send (0x01) to toggle Current mode 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 36) is as shown in Table 38.
Table 38: 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 | 45
KOEL Configuration Utility

Introduction to KOEL Configuration Utility
KOEL 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 KG640 controller to
be connected to a laptop/computer via USB.
Installation Instructions
System Requirements
Operating System: Windows 8, Windows 10 with Microsoft .Net 4.5 framework
Communication: USB 2.0 Type B required for connection between controller and PC running KOEL
Configuration Utility.
Installation Process for KOEL 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.
Figure 16: Configuration utility setup

A progress bar will show installation completion progress. On completion of installation, a window will be
shown as below. Click Finish.
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Figure 17: Configuration utility setup completion
Installation Process for USB Driver

For connecting the KG640 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 KG640 controller and laptop. Put the controller in Programming
mode (refer section 6, Description of Control Keys). Ensure that the controller is in Programming
mode which is indicated on LCD screen of the controller as shown below.
Figure 18: Programming mode screen

Once the controller enters the Programming mode, go to Device Manager→Other devices→GCUSMPL.
Page | 47
Figure 19: Device manager screen
Page | 48
II. Right click on “GCUSMPL” and select “Update Driver Software”.
Figure 20: Update driver software screen

III. Choose “Browse my computer for driver software” to select the correct driver software.
Figure 21: Browse for driver software screen

IV. For driver installation on 64-bit Windows system, choose a driver path as “C:\Program
Files(x86)\KG640 Configuration Utility\USB Driver” and then click Next.
Page | 49
Figure 22: Saving location selection screen

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/49724794617ca7c885257acb005c28
51/$FILE/Installing%20Unsigned%20Drivers%20in%20Windows%208.pdf
V. On successful installation of USB driver, a confirmation screen will be shown as below. Click Close.
Figure 23: SEDEMAC controller screen
Page | 50
VI. Ensure the successful driver installation by checking the entry of “GCxx” under the “Ports” option in
Device Manager.
Figure 24: Driver installation successful screen
After successful installation of configuration utility and USB driver, if KG640 controller
is not detected at PC port, then disable serial or virtual serial port (if any used) of PC.
Usage Instruction
Starting with KOEL Configuration Utility
Run configuration utility installed on your system. Start-up screen will be displayed as shown below.
Figure 25: Configuration utility screen
Page | 51
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.
Figure 26: Start screen
Working with KOEL 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.
Figure 27: File menu
Establishing Connection with Controller

For establishing a connection with the KG640 genset controller, first connect a USB cable between the
controller and laptop, then put the controller in Programming mode (refer section 6, Description of Control
Keys). A connection status message will be displayed at bottom left corner of screen. It is possible to open,
Page | 52
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.
Editing Parameters
Configuration utility allows to edit parameter values for intended application of the genset controller.
Following are the options available for editing parameters.
4
1
3
2
Figure 28: Options available for editing parameters screen

1. Text box - A value can be directly entered in a text entry box
2. Check box - Check box is typically used to enable/disable a feature
3. Slider - A slider can be dragged to change the corresponding parameter value
4. Increment/Decrement Arrows - Increment/Decrement arrows can be used to progressively
increase/decrease the corresponding value
Tools
KOEL 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.
Figure 29: Tools menu
15.5.1 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.
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Figure 30: Write configuration to device screen

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.
Figure 31: Device configuration screen
Figure 32: Configuration utility completion screen
Page | 54
A confirmation window will be shown when writing is complete.
15.5.2 Read Configuration from Device

This action reads the configuration of controller and accordingly populates the chosen configuration file.
Figure 33: Read configuration from device screen

Select Read From Device option. The configuration will be read from the controller and appropriately
populated in the utility. A confirmation window will be shown as below.
Figure 34: Successful reading of configuration screen
15.5.3 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.
Figure 35: Preview configuration summary screen
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15.5.4 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.
Figure 36: Save as PDF screen

Click the ‘’Save As PDF’’ button and the even log will be saved to PC on user defined location in PDF format
and following window appears.
Figure 37: Event log saved screen
15.5.5 Get Version Information from Device
Figure 38: Version information screen
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Interpretation of Parameters
This section describes interpretation of parameters which are accessed via configuration utility.
Module
The Module allows configuration of a set of module-wide parameters.
Select Module to start GCU
configuration
Figure 39: Menu ribbon- module selection

Then select appropriate tab to configure
parameters
16.1.1 General
Figure 40: General module screen

Table 39: General parameters & their interpretations
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 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
Power On Lamp Test
the controller will illuminate for 3 seconds.
Enables or disables Deep Sleep mode. If enabled, the controller enters
Deep Sleep Mode low-power mode after Deep Sleep Mode Delay duration (refer section 16.5.2,
General for delay setting).
Page | 57
16.1.2 Display
Figure 41: Display module screen

Table 40: Display parameters & their interpretations
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 16.5.2, General for delay setting).
16.1.3 RS485 Communication
Figure 42: RS485 communication module screen

Table 41: RS 485 communication parameters & their interpretations
Decides the communication function to be performed by the controller.
Available options:
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
Page | 58
16.1.4 Master Password
Figure 43: Master password module screen

Table 42: Master password parameters & their interpretation
Master Password Level 1 Password that can be used to change all the parameters and master
password of the controller.
Digital Inputs
The Digital Inputs allows configuration of digital inputs.
Figure 44: Menu ribbon- digital inputs selection

Following is an example showing configuration of Digital Input A as User configured.
Figure 45: Digital inputs selection screen
Page | 59
Table 43: Digital inputs parameters & their interpretations

Decides how the digital input will be interpreted by the controller. The input can
Source be assigned as one of a set of Digital Input Source (refer section 16.2.1, List of
Digital Input Source).
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 grounded.
Polarity
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:
Action
Shutdown: Genset will shut down.
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 have 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 begin.
Always: The input will always have monitored.
Allows to select duration in seconds, for which the input active condition should
Activation Delay
persist before which preconfigured action will be taken.
Refer Table 43 for configuration of Digital Input A, Digital Input B, Digital Input C, Digital Input D and Digital
Input E.
16.2.1 List of Digital Input Source

Table 44: Digital input sources & their interpretations
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
Engine low fuel level switch input – used for low Fuel Level alarm.
Switch
Low Lube Oil
Engine oil pressure switch – used for Low Oil Pressure alarm.
Pressure switch
High Engine
Engine high temperature switch input – used for High Eng Temp alarm.
Temperature Switch
Low Water Level
Radiator water level switch – used for Radiator Water Level alarm.
Switch
Emergency Stop Emergency stop input.
Page | 60

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 Command to manually transfer the load to genset. (To be used in manual mode.
Mains Switch Not recommended to use in auto mode)
Close Mains/Open Command to manually transfer the load to mains. (To be used in manual mode.
Gen Switch Not recommended to use in auto mode)
This input allows the controller to act as if mains is healthy, irrespective of actual
Simulate Mains mains voltage/frequency. This input can be used to over-ride genset starting
based on mains monitoring in Auto Mains Failure (AMF) mode.
High Canopy
Used for high canopy temperature alarm
Temperature Switch
V-Belt Broken Switch V-Belt Broken switch – used for V-Belt Broken alarm.
The semi-Auto mode provide the feasibility to the operator to start the Genset
Semi-Auto Mode as and when he wants manually in case of Mains failures. In this mode, the
genset is powered OFF automatically when the Mains is restored
Analog Inputs
Figure 46: Menu ribbon- Analog inputs selection
16.3.1 Lube Oil Pressure Sensing

This allows to configure LOP sensor.
Figure 47: Lube oil pressure sensor
Page | 61
Table 45: LOP sensor parameters & their interpretations

Digital Input F: 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 be
configured in the same way as that of digital input being configured (refer
section 16.2.1, List of Digital Input Source).
Lube Oil Pressure Sensor: The input will be used as LOP 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
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
Allows to select alarm action on detection of following fault condition:
1. Oil pressure open circuit/ground
When the following conditions is detected, an alarm will be triggered. Available
options:
Oil Pressure Circuit
Fault
Sensor Calibration A table that defines relation between the sensor value and corresponding
Table physical quantity.
16.3.2 Engine Temperature Sensing (Resistive)
Figure 48: Engine temperature sensing (resistive) screen

Table 46: Engine temperature sensing (resistive) parameters & their interpretations
Use Input As Not used: The input will not be used.
Digital Input G: The selected sensor input will be used as digital input. The
Page | 62
parameters identical to digital inputs will be displayed and the input can be
Engine Temperature Sensor: The input will be used as analog sensor
(resistive).
High Temp Shutdown Enables or disables shutdown for high engine temperature value
Threshold on engine temperature value above which shutdown will be
Threshold
triggered
High Temp Warning Enables or disables warning for high engine temperature value
Threshold on engine temperature value above which warning will be
Threshold
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
genset.
16.3.3 Fuel Level Sensing (Resistive)
Figure 49: Fuel level sensing screen as fuel level sensor
Page | 63
Table 47: Fuel level parameters & their interpretations

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 be
Fuel Level Sensor: The input will be used as analog sensor (resistive).
Low Fuel Level Enables or disables an engine shutdown by the controller if Low Fuel Level
Shutdown condition is detected.
Allows to select the threshold on fuel level value below which Low Fuel Level
Shutdown Threshold
shutdown alarm will be triggered.
Low Fuel Level Enables or disables warning generation by the controller if Low Fuel Level
Warning condition is detected.
Allows to select the threshold on fuel level value below which Low Fuel Level
Warning Threshold
warning will be triggered.
Fuel Tank Capacity Allows to select fuel tank capacity in litres
Fuel Theft Warning Enables or disables Fuel Theft warning alarm.
Allows to select the threshold on percentage fuel consumption per hour, above
Fuel Theft Threshold
which Fuel Theft alarm will be triggered.
Fuel Consumption Fuel consumption in litres per hour.
Display Fuel in Litres If enabled, fuel level will be displayed in litres on screen.
Fuel Sensor
Allows to select between Engine body and Battery Negative.
Reference
LOP, Engine Temperature Sensing and Fuel Level Sensing can be configured as Digital Inputs (refer section
16.2.1, List of Digital Input Source and 16.3, Analog Inputs).
Following is the screenshot of configuration utility representing configuration of Fuel Level sensor as a digital
switch.
Figure 50: Fuel level sensing screen as digital input
Page | 64
Outputs
The Outputs allows configuration of digital outputs.
Figure 51: Menu ribbon- outputs selection
Figure 52: Outputs screen

Table 48: Output parameters & their interpretations
Allows to select the output as one of the set of Digital Output Source (refer
Source section 16.4.1, List of Digital Output Source). 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.
16.4.1 List of Digital Output Source

Table 49: Digital output sources & their interpretations
Interpretation
Active when Inactive when
Sounder Alarm An audible alarm is pending. No audible alarm is pending.
Battery Over Voltage alarm is Battery Over Voltage alarm is not
Battery Over Voltage
pending. pending.
Battery Under Voltage alarm is Battery Under Voltage alarm is not
Battery Under Voltage
pending. pending.
Charge Fail shutdown alarm is Charge Fail shutdown alarm is not
Charge Alt Shutdown
pending. pending.
Charge Fail warning alarm is Charge Fail warning alarm is not
Charge Alt Warning
pending. pending.
Page | 65
Interpretation
Close Gen Contactor Genset contactor is to be closed. Genset contactor is not to be closed.
Close Mains
Mains contactor is to be closed. Mains contactor is not to be closed.
Contactor
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
Digital Input F is active. Digital Input F is not active.
(Analog Input LOP)
Digital Input G
(Analog Input Eng Digital Input G is active. Digital Input G is not active.
Temp)
Digital Input H
(Analog Input Fuel Digital Input H is active. Digital Input H is not active.
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.
R Phase OV Genset R Phase Over Voltage Genset R Phase Over Voltage
Shutdown shutdown alarm is pending. shutdown alarm is not pending.
R Phase UV Genset R Phase Under Voltage Genset R Phase Under Voltage
Y Phase OV Genset Y Phase Over Voltage Genset Y Phase Over Voltage shutdown
Shutdown shutdown alarm is pending. alarm is not pending.
Y Phase UV Genset Y Phase Under Voltage Genset Y Phase Under Voltage
B Phase OV Genset B Phase Over Voltage Genset B Phase Over Voltage
B Phase UV Genset B Phase Under Voltage Genset B Phase Over Voltage
Page | 66
Interpretation
Genset Over Current alarm is Genset Over Current alarm is not
Gen Over Current
pending. pending.
High Engine High Engine Temperature output is High Engine Temperature output is not
Temperature active. active.
Low Fuel LVL Low Fuel level alarm is pending. Low Fuel level alarm is not pending.
Low LOP Low Oil Pressure alarm is pending. Low Oil Pressure alarm is not pending.
Mains High Volt Mains voltage is detected to be high.
high.
Mains Low Volt Mains voltage is detected to be low. Mains voltage is not detected to be low.
Oil Pressure Open Oil pressure circuit is detected to be Oil pressure circuit is not detected to be
Circuit open. open.
Open Gen Contactor Genset contactor is to be open. Genset contactor is not to be open.
Open Mains
Mains contactor is to be open. Mains contactor is not to be open.
Contactor
Over Frequency shutdown alarm is Over Frequency shutdown alarm is not
Over Freq Shutdown
pending. pending.
Over Speed Over Speed shutdown alarm is Over Speed shutdown alarm is not
Shutdown pending. pending.
Gross Over Speed Gross Over Speed Shutdown alarm Gross Over Speed Shutdown alarm is
Shutdown is pending. not pending.
Start Relay Cranking command is active. Cranking command is not active.
Temp Sensor Open Temperature circuit is detected to be Temperature circuit is not detected to be
Circuit open. open.
Under Frequency shutdown alarm is Under Frequency shutdown alarm is not
Under Freq Shutdown
pending. pending.
Under Speed Under Speed shutdown alarm is Under Speed shutdown alarm is not
Shutdown pending. pending.
Maintenance Due Maintenance Due alarm is pending. Maintenance Due alarm is not 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.
Preheat output is to be active as per Preheat output is not to be active as per
Preheat Output
preheating setting. preheating setting.
Timers
Figure 53: Menu ribbon- timers selection
Page | 67
16.5.1 Cranking
Figure 54: Cranking timers screen

Table 50: Cranking parameters & their interpretations
Crank Hold Time The crank output will be active up to 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.
16.5.2 General
Figure 55: General timers screen

Table 51: General timers’ parameters & their interpretations
Safety Monitoring Decides the time from engine on for which engine and alternator safety
Delay parameters will be ignored. This timer should be selected sufficiently large so
Page | 68
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.
Alternator Detect The time in which a deviation in genset parameters (voltage, frequency) outside
Delay the preconfigured range is allowed before corresponding alarm being triggered.
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.
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 timer,
Stop Action Time 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
LCD display will be switched OFF. Go on page Module to enable Power Save
Delay
Mode (refer section 16.1.1, General).
The time after which a display screen will shift to the next screen. When this
Screen Changeover time is set to 0, then screen will not scroll automatically. User will have to scroll
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
enters Deep Sleep mode. Go on page Module to enable Deep Sleep Mode
Delay
(refer section 16.1.1, General).
Sounder Alarm Timer On initiation of an alarm, audible alarm will sound (if configured) up to this 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.
Generator
The genset specific parameters are divided into sections as shown below.
Figure 56: Menu ribbon- generator selection
Page | 69
16.6.1 Alternator Configuration
Figure 57: Alternator configuration generator screen

Table 52: Alternator configuration parameters & their interpretations
Allows to select engine operation with or without the alternator. If the alternator
Alternator Present 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
A threshold above which genset is considered healthy for taking electrical load.
Frequency
Phase Reversal If enabled, the alternator phase sequence (R-Y-B) will be checked. This option
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
Warning: A warning will be displayed.
Action
Alt Voltage Lost This alarm will generate if alternator voltage does not cross 50 V-RMS within 2
Shutdown seconds after crank disconnect event
Alt Voltage Lost
This sets the threshold for alternator voltage lost alarm
Threshold
Alt Voltage Lost This is the delay for which the controller monitors the alternator voltage before
Delay declaring an alternator voltage lost alarm
An option to actuate genset and mains contactors if configured as outputs in the
Auto Load Transfer
manual mode. If disabled, it is necessary to manually put the load on genset.
Page | 70

These parameters will be enabled, if the Alternator Present parameter is selected as Yes (refer section
16.6.1, Alternator Configuration).
Figure 58: Voltage monitoring generator screen

Table 53: Voltage monitoring parameters & their interpretations
Under-voltage
Enables or disables Under Voltage shutdown alarm.
Shutdown
Under Voltage The voltage value below which the Under-Voltage shutdown alarm will be
Shutdown Threshold triggered.
Under-voltage
Enables or disables Under Voltage warning alarm.
Warning
Under Voltage The voltage value below which the Under-Voltage warning alarm will be
Warning Threshold triggered.
Over-voltage
Enables or disables Over Voltage shutdown alarm.
Shutdown
Over Voltage 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
16.6.3 Frequency Monitoring

These parameters will be enabled, if the Alternator Present parameter is selected as Yes (refer section 16.6.1,
Alternator Configuration).
Page | 71
Figure 59: Frequency monitoring generator screen

Table 54: Frequency monitoring parameters & their interpretations
Under-frequency
Enables or disables Under Frequency shutdown alarm.
Shutdown
Under Frequency The frequency value below which the Under-Frequency shutdown alarm will be
Under-frequency
Enables or disables Under Frequency warning alarm.
Warning
Under Frequency The frequency value below which the Under-Frequency warning alarm will be
Over-frequency
Enables or disables Over Frequency shutdown alarm.
Shutdown
Over Frequency The frequency value above which the Over Frequency shutdown alarm will be
Over-frequency
Enables or disables Over Frequency warning alarm.
Warning
Over Frequency The frequency value above which the Over Frequency warning alarm will be
16.6.4 Current Monitoring

These parameters will be enabled, if the Alternator Present parameter is selected as Yes (refer section 16.6.1,
Page | 72
Figure 60: Current monitoring generator screen

Table 55: Current monitoring parameters & their interpretations
The primary-side factor for interpretation of CT ratio. The controller assumes
CT Ratio
that the secondary-side factor is 5.
Over-current
The current value above which the Over Current alarm will be triggered.
Threshold
The time for which a value higher than the pre-set Over Current Threshold
Over-current Delay
value 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
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
Unbalanced Load The time for which an unbalanced load condition is monitored before the
Delay corresponding action will be taken.
16.6.5 Load Monitoring

These parameters will be enabled, if Alternator Present parameter is selected as Yes (refer section 16.6.1,
Page | 73
Figure 61: Load monitoring generator screen

Table 56: Load monitoring parameters & their interpretations
Generator Rating Decides the genset rating in kW.
The load value (as a percentage of full load) above which the selected action for
Over-load Threshold
Overload alarm will be triggered.
The time for which a value higher than the pre-set Overload Threshold value is
Over-load Mon Delay
allowed before the Overload alarm being triggered.
Allows to select the action when Overload alarm is detected.
Available options:
Over-load Action Warning: A warning will be displayed without affecting the operation of genset.
The generator rating in kW value must be specified as a total load rating and NOT as per
phase load rating.
Mains
The Mains configuration is divided into sections as shown below.
Figure 62: Menu ribbon- mains selection
Page | 74
16.7.1 Mains Configuration
Figure 63: Mains configuration mains screen

Table 57: Mains configuration parameters and their interpretations
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 phase reversal condition occurs then genset will start. Available options:
Action None: No action will be taken.
Notification: A notification text will be displayed.
Figure 64: Voltage monitoring mains screen

Table 58: Voltage monitoring parameters and their interpretations
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.
Over Voltage Enables or disables mains over voltage monitoring. If enabled, the controller
Page | 75
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.
16.7.3 Frequency Monitoring
Figure 65: Frequency monitoring mains screen

Table 59: Frequency monitoring parameters and their interpretations
Enables or disables mains under frequency monitoring. If enabled, the controller
Under Frequency
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
considered healthy. This value is used when an unhealthy mains condition has
Return
been detected.
Enables or disables mains over frequency monitoring. If enabled, the controller
Over Frequency
monitors the mains over frequency condition.
Over Frequency The maximum value for the mains frequency to be considered healthy. This
Return value is used when an unhealthy mains condition has been detected.
The frequency value above which an over frequency condition for mains is
Over Frequency Trip
detected.
Engine
The engine specific parameters are divided into sections as shown below.
Figure 66: Menu ribbon- engine selection
Page | 76
16.8.1 Crank Disconnect
Figure 67: Crank disconnect engine screen

Table 60: Crank disconnect parameters & their interpretations
Allows to select maximum number of start sequences before Fail To Start alarm
Start Attempts
is triggered.
Decides if the oil pressure value is used for crank disconnect operation. If
Disconnect on LOP
enabled, crank will be disconnected if oil pressure is sensed to be more than a
Sensor
threshold.
Disconnect Pressure The threshold value for the oil pressure above which the cranking command will
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
command. If enabled, the crank command will be withdrawn as soon as oil
Switch
pressure switch stops indicating that oil pressure is low.
The time for which the oil pressure switch condition should be consistently
shown as Low Oil Pressure before the corresponding crank command
LLOP Switch
withdrawal. Note that if some other source for crank command withdrawal (such
Transient Time
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
Engine Speed Allows to select the engine speed above which crank command will be
Decides whether the charging alternator voltage is to be used for crank
Disconnect on
disconnect operation. If enabled, crank will be disconnected if charging
Charging Alt Voltage
alternator voltage is sensed to be more than threshold.
Threshold on charging alternator voltage. Above this threshold, cranking
Charging Alt
command will be withdrawn. This parameter is relevant only if Disconnect on
Threshold
Charging Alt Voltage is enabled.
The controller will not issue Start command if any of the enabled crank withdrawal
Page | 77
16.8.2 Speed Monitoring
Figure 68: Speed monitoring engine screen

Table 61: Speed monitoring parameters & their interpretations
Engine Speed Sense Allows to select electrical signal to be use for measurement of engine speed.
Source Alternator frequency: Engine speed will be sensed from alternator frequency.
Under-speed
Enables or disables Under Speed shutdown alarm.
Shutdown Enable
Under-speed
The engine speed below which Under Speed alarm will be triggered.
Threshold
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
The engine speed in RPM above which Over Speed alarm will be triggered.
Threshold
The time for which an engine speed value higher than the pre-set 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
fast, especially during ramp up and to trip the engine on detecting high speed. It
Threshold
will shut down engine immediately.
If enabled, the controller monitors the engine speed and if it is found lower than
Engine Speed Fault
the set threshold, the engine will be shut down and an alarm will be raised
Healthy-speed Minimum engine speed that the genset must achieve within 2 seconds from
Threshold crank disconnect event.
Page | 78
16.8.3 Battery Monitoring
Figure 69: Battery monitoring engine screen

Table 62: Battery monitoring parameters & their interpretations
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
Low Battery Voltage The time for which battery voltage value lower than 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 be
High Battery Voltage The time for which battery voltage value higher than High Battery Voltage
Delay Threshold is allowed before the Battery Over Voltage alarm being triggered.
Page | 79
16.8.4 Charging Alternator Monitoring
Figure 70: Charging alternator monitoring engine screen

Table 63: Charging alternator monitoring parameters & their interpretations
Allows to select the action if the charging alternator fail (Charge Fail) condition
is detected. Available options:
Charging Alternator
Fail Action
Charging Alternator The voltage at the charge alternator fail input terminal, below which the Charge
Fail Threshold Fail alarm will be triggered.
The time for which voltage value (at charge alternator fail input terminal) lower
Charging Alternator
than Charging Alternator Fail Threshold is allowed before the Charge Fail alarm
Fail Delay
being triggered.
16.8.5 Preheat
To enable the Preheat, configure one of the digital output as the Preheat Output (refer section 16.4, Outputs).
Figure 71: Preheat engine screen

Table 64: Preheat parameters & their interpretations
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 be considered.
Engine Temperature Temperature Enable decides whether the coolant temperature is used for
Limit 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 Limit.
Page | 80
If the preheat output is selected with enabling the “cold start” parameter and if
“Engine temperature limit” is also enabled. The KG640 will start the engine once
Cold Start
the set temperature is reached, the start delay will be considered in the starting
sequence
Maintenance
Figure 72: Menu ribbon- maintenance selection
Figure 73: Maintenance screen

Table 65: Maintenance parameters & their interpretations
Maintenance Alarm Enables or Disables Maintenance Alarm
Alarm action on logged engine hours or service due date, whichever occurs
Alarm Action first. Available options:
Notification: Notification text will be displayed on LCD screen.
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 occurred,
Alarm Due Date whichever happens first.
Page | 81
Notes
Page | 82
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
100/5A,2.5VA
230VAC,50Hz,1PH.
SUPPLY TO LOAD
R2(40)
1 GY
R1(39)
1 GY
9.6 9.6
CT CONNECTIONS TO CONTROLLER
INSULATED BUTT SPLICE CONNECTOR
RG3
12 UN
RG4
12 UN
NG3
12 UN
NG4
12 UN
1 3 5 7
-7F1
50A/4P,06KA
2 4 6 8
1PH.GENSET SUPPLY
(BEFORE MCB ON)
-X1 -X1
TO CONTROLLER
CHARGER & TO CONTROLLER

MAINS SUPPLY
1 2
RG1 RG2 MR MR1
/ 9.2 / 9.5
1 RD 1 RD 1 RD 1 RD
FUSE 6A FUSE 6A
NG1 MN MN
/ 9.2 / 9.4
1 BK 1 BK 1 BK
RG1
10 RD/12 UN
RG2
10 RD/12 UN
NG1
10 BK/12 UN
NG2
10 BK/12 UN
CONTROL CKT
TO BATTERY
MR1
/ 11.5
1 RD
MN
/ 11.6
1 BK
-R -R -N -N -X2 1 2
25A,600V -X1 = 230V AC FUSE TERMINALS
FUSE TERMINAL,MAKE-CONNECTWELL/WAGO, TYPE NO - CF4UL110-240V
230VAC,50Hz,1PH. -X2 = CONTROL TERMINAL FOR LOP SENSOR/SWITCH
SUPPLY FROM MAINS CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE
SUPPLY FROM DG ALT.
-XPTB1 =POWER TERMINALS FOR LOAD
POWER TERMINAL BOARD EVEREST/REPUTED MAKE 2 WAY 10 MM STUD
MODIFICATION Mounting : PNL1

REV DESCRIPTION DATE INITIAL ECN NO.
SHEET NO.
DRN DATE 03.05.2019 TITLE : Main Incoming Supply KIRLOSKAR OIL ENGINES LTD.,
00 NEW RELEASE 03.05.2019 SUPRIYA DRN BY SUPRIYA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
CHD BY SA PROJECT : CONTROL PANEL FOR 30KVA 1 PH GENSET REV NO.
KOEL DRAWING NO:
APROV. BY SRN ENGINE MODEL : 2R Page : 7 / 41
SCALE 4.00mm 2H.764.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
ENGINE SIDE PANEL SIDE

1
-VE +VE
G CHARGING
-8ALTR1
1 ALTERNATOR
-IND1
-XC11 -XC1
7 5 5 7
0.75 GY
/ 10.5 IND
-8VBFS1
14 13 V BELT TEMP SW(OPTIONAL)/ WATER LEVEL SW 21 3 3 21(D)
0.75 GY
/ 10.6 V BELT TEMP FAIL/WATER LEVEL SW
-8TS1
13 14 TEMP. SENSOR 24 10 10 24
0.75 GY
/ 10.5 TEMP SENSOR
-8CHTS1
14 13 CYL. HEAD TEMP SW 26 9 9 26
0.75 GY
/ 10.5 CYL.HEAD TEMP SW
-8LLOPS1
12 11 LLOP SWITCH 12 4 4 12(C)
0.75 GY
/ 10.5 LLOP SWITCH
CONTROL ON/OFF SW
-8S1
2A 2 2 2A 4 3 2A
1 GY 1 GY
/ 10.4 TO CONTROLLER +VE
1A 1 1 1A
1 GY
/ 10.3 BATT. -VE (1A)
1
1 11 11 1
2.5 GY
/ 10.3 BATT. -VE(1)
-8FLS1
13 14 FUEL LEVEL SENSOR 25 7 7 25
0.75 GY
/ 10.4 FUEL LEVEL SENSOR
6 6
12 12
1B 8 8 1B
0.75 GY
/ 10.5 LLOP -VE(1B)
-8SS1
13 13
A2 A1 STOP SOLENOID 6
4 GY
14 14
1
15 15
-8BATT.1
BC +VE
+VE -VE
11.5
BATTERY
12VDC
2B
1.5 GY
-8STA1 -XC12 -XC2
STARTER 1 1 6
/ 10.1 STOP SOLENOID
-VE M +VE 4 GY
2 2
-8F2 2 1
2 2 2B
-SOL1
4 GY 4 GY
/ 10.1 BATTERY +VE
32A/1P,06KA
3 3 3 3
2.5 GY
/ 10.2 STARTER
-8S1
4 4 2B/4 14 13 2E
4 GY 1 GY
/ 10.3 DC INTERFACE CARD
2B/4
-XC11 =15 PIN CONNECTOR TYCO MAKE (FEMALE) TYPE- 85113.-1

-XC1 = 15PIN CONNECTOR HOUSING TYCO MAKE (MALE) TYPE- 85114-1
ENGINE WIRING HARNESS CONNECTOR(ENGINE SIDE)
ENGINE WIRING HARNESS CONNECTOR
-XC12 =4 PIN CONNECTOR TYCO MAKE (FEMALE) HOUSING TYPE - 235305-1 -XC2 = 4PIN CONNECTOR HOUSING TYCO MAKE (MALE) TYPE-235304-1
ENGINE WIRING HARNESS CONNECTOR(ENGINE SIDE) ENGINE WIRING HARNESS CONNECTOR

SHEET NO.
DRN DATE 03.05.2019 TITLE : Engine Wiring harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
CT CONNECTION
SENSOR GND
7.2 7.2
MAINS
GENSET 1PH SUPPLY
1PH SUPPLY INSULATED BUTT
7.5 7.5
SPLICE CONNECTOR
7.3 7.3 9.7
B1 B2 Y1 Y2 R1 R2
MN
1 BK
MR1
1 RD
B1
1 BU
B2
1 BU
Y1
1 YE
Y2
1 YE
R1
1 RD
R2
1 RD
1
1 GY
NG
1 BK
RG2
1 RD
-J6 1 2 3 4 -J7 1 2 3 4 1 2 3 4 5 6 7 8
-J8
-9GCU1
02.026.18.0.PR 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
GENSET CONTROL
UNIT
N B Y R N B Y R B1 B2 Y1 Y2 R1 R2
SENSOR COMMON POINT
RESERVED
GENSET I/P MAINS I/P CT I/P
GENSET CONTROL UNIT

USB
(KG 640 UNIT)
I/P:ANLG TEMP/DIG G
I/P:ANLGFL/DIG H
I/P:ANLG/DIG F
D+CHARGE ALT
DIGITAL O/P D
DIGITAL O/P C
DIGITAL O/P A
DIGITAL O/P B
DIGITAL O/P E
DIGITAL O/P F
DIGITAL I/P D
DIGITAL I/P C
DIGITAL I/P A
DIGITAL I/P B
DIGITAL I/P E
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
BATTERY
RS 485_A
RS 485_B
12/24V
+VE -VE
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-J5 1 2 3 4 5 6 7 8 9 10 -J4 1 2 3 4 5 6 -J3 1 2 3 4 -J2 1 2 3 4 -J1 1 2

26
0.75 GY
25
0.75 GY
24
0.75 GY
23
0.75 GY
22(E)
0.75 GY
21(D)
0.75 GY
12(C)
0.75 GY
11(B)
0.75 GY
10(A)
0.75 GY
9(F)
0.75 GY
8(E)
0.75 GY
7
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
3(A)
0.75 GY
2
1 GY
1
1 GY
1
1 GY
10.5 10.4 10.5 10.6 12.5 10.6 10.6 10.6 10.6 12.4 12.3 10.5 10.3 10.3 10.3 10.4 10.4 9.7
CYL.HEAD TEMP SW
FUEL LEVEL SENSOR
TEMP SENSOR
4-20mA SENSOR
SEMI AUTO
V BELT FAIL/WATER LEVEL SW
LLOP SWITCH
EMG
AUTO START
GENSET RELAY
MAINS RELAY
IND
STOP
START
FAULT
DC SUPPLY +VE
DC SUPPLY -VE
SENSOR GND
SPARE O/P
-J1 = 2PIN CONNECTOR PHOENIX MAKE (TYPE -2EDGK-5.08-02P-14-00AH) WITH FEMALE PINS
-J2 = 4PIN CONNECTOR PHOENIX MAKE (TYPE - 15EDGK-3.5-04P-14-00AH) WITH FEMALE PINS
-J4 = 6PIN CONNECTOR PHOENIX MAKE (TYPE-15EDGK-3.5-06P-14-00AH)WITH FEMALE PINS
-J5 = 10PIN CONNECTOR PHOENIX MAKE (TYPE -15EDGK-3.5-10P-14-00AH ) WITH FEMALE PINS
-J6 = 4PIN CONNECTOR PHOENIX MAKE (TYPE-2EDGK-506-04P-24-00AH) WITH FEMALE PINS
-J7 = 4PIN CONNECTOR PHOENIX MAKE (TYPE-2EDGK-506-04P-24-00AH) WITH FEMALE PIN
-J8 = 8 PIN CONNECTOR PHOENIX MAKE (TYPE-15EDGK-3.5-08P-14-00AH) WITH FEMALE PINS

SHEET NO.
DRN DATE 03.05.2019 TITLE : KG640 Controller Diagram KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
-C2 = 4 PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 04R) WITH FEMALE PINS
R1- START RELAY (70A) -C4 = 10 PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 010R) WITH FEMALE PINS
R2- STOP RELAY (70A) -C5 = 6 PIN FEMALE CONNECTOR PHONIX MAKE(TYPE-MVSTBW 2.5/ 6-ST-5.08)
R3- COMMON FAULT RELAY (6A)
V BELT FAIL/ WATER LEVEL SW

R4- AUTO START RELAY (6A)
-C8 = 2PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 02R) WITH FEMALE PINS
-C9 = 8PIN MALE CONNECTOR POWERMATE MAKE-(TE/AMP) PART NO.:-640582-1
FUEL LEVEL SENSOR
CYL.HEAD TEMP SW
4-20mA SENSOR
DC SUPPLY +VE
DC SUPPLY -VE
TEMP SENSOR
-VE
LLOP SWITCH
AUTO START
10.4
START
FAULT
STOP
IND
EMG
10.1
9.6
9.6
9.6
9.5
9.7
9.7
9.2
9.2
9.1
9.5
9.4
9.2
9.2
9.4
OUTPUT
3(A)
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
SPARE
2
1 GY
1
1 GY
1
1 GY
7
0.75 GY
10(A)
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
1
1 GY
1
1 GY
1
1 GY
-C9 1 2 3 4 5 6 7 8 -C8 1
2
-C7 1
2 3 4 5 6 -C6 1 2 3 4 5 6 7 8
-10GC1 C9:1 C9:2 C9:3 C9:4 C9:5 C9:6 C9:7 C9:8 C8:1 C8:2 C7:1 C7:2 C7:3 C7:4 C7:5 C7:6 C6:1 C6:2 C6:3 C6:4 C6:5 C6:6 C6:7 C6:8
+VE -VE
R4
A1 A1 A1
R1 R2 R3 F3
A2 A2 A2 500mA
F1 F2 A1
3.75A 3.75A R4 R3
A2
R2 R1
DC INTERFACE CARD
C1:1 C1:2 C1:3 C1:4 C2:1 C2:2 C2:3 C2:4 C3:1 C3:2 C3:3 C3:4 C3:5 C3:6 C4:1 C4:2 C4:3 C4:4 C4:5 C4:6 C4:7 C4:8 C4:9 C4:10 C5:1 C5:2 C5:3 C5:4 C5:5 C5:6
-C2 1 2 3 4 -C3 2 3 4 5 6 -C4 2 3 4 5 6 7 8 9 10 -C5 1 2 3 4 5 6

1 1
COMMON SPARE
+VE SPARE
FAULT OUTPUT
-VE SPARE
SPARE
25
0.75 GY
24
0.75 GY
26
0.75 GY
12(C)
0.75 GY
2E
1 GY
1A
1 GY
2A
1 GY
1A
1 GY
7
0.75 GY
21(D)
0.75 GY
11(B)
0.75 GY
11(B)
0.75 GY
2F
0.75 GY
1H
0.75 GY
23
0.75 GY
6
4 GY
2B
4 GY
3
2.5 GY
8.7 8.7 8.7 8.7 8.7 8.7 8.7 8.7 12.1 12.2 12.5
IND
CANOPY EMG.
CANOPY LAMP
AUTO START
FROM GC/MC-IC
STOP SOLENOID
STARTER
CONTROLLER +VE
FUEL LEVEL SENSOR
TEMP SENSOR
CYL.HEAD TEMP SW
3
10S2
EMG. STOP
OPTIONAL
BATT. +VE / 8.7
-X3
1
12(C) 12(C)
LLOP SWITCH / 8.7
0.75 GY 0.75 GY
1A
1 GY
2
1B 1
-VE(1A) / 8.7
0.75 GY 1 GY
3
23
0.75 GY
4
2E 2E
1 GY 1 GY
/ 11.2 TO RMS
2E
CONTROL ON +VE / 8.7
1 GY
1 1
-VE(1) / 8.7
2.5 GY 1 GY
/ 11.2 -VE(1)
1A 1A
-VE(1A) / 8.7
1 GY 1 GY
/ 12.3 -VE(1A)
-X3 = CONTROL TERMINAL FOR LOP SENSOR/SWITCH
CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE

SHEET NO.
DRN DATE 03.05.2019 TITLE : DC Interfacing Card KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
2E 2E
BATT. +VE 10.7
1 GY 1 GY
12.5 BATT. +VE
1 1
BATT. -VE 10.7
1 GY 1 GY
12.1 BATT. -VE
1
1 GY
BATT. +VE
BATT. -VE
11.6
/ 11.4
/ 8.5
BATT. -VE
1
1 GY
2E
1 GY
1 2
-XC3
2B
1.5 GY
1
1 GY
-11KRM1 1 2
-11BC1
9 to 36V 12V,2Amp
KOEL PART NO.:-
DV2.858.04.0.PR
BATTERY CHARGER
+VE -VE
x2
BC
x1
RMS MODULE
RMS MODULE P N E
MR1
1 RD
MN
1 BK
7.5 7.5
-XC3 = MSSL MAKE CONNECTOR 250 SERIES 2PIN FEMALE CONNECTOR WITH FEMALE PINS(TERMINALS 82404140) (FOR PANEL)
RMS UNIT CONNECTOR

SHEET NO.
DRN DATE 03.05.2019 TITLE : Batter Charger & RMS KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
1
BATT. -VE 11.4
1 GY
GENSET RELAY
MAINS RELAY
AUTO START
TO CONTROLLER
SEMI AUTO
BATT +VE
CANOPY LAMP
BATT. -VE
ON/OFF SW
EMG. STOP
/ 10.7
/ 10.7
/ 11.4
/ 9.5
/ 9.5
/ 9.2
/ 10.7
/ 10.7
8(E)
0.75 GY
9(F)
0.75 GY
2E
1.5 GY
-12S2 3
1 2
-X5 1 -X5 2 -X5 3

4 FUSE 300MA FUSE 300MA FUSE 6A
LDM
0.75 GY
LDG
0.75 GY
1A
1 GY
1H
0.75 GY
22(E)
0.75 GY
1
1 GY
11(B)
0.75 GY
1
1 GY
23
0.75 GY
1
1 GY
2E1
1.5 GY
1 2 3 4 1 2 3
-XC4 -XC5 -X4 1 2 3 4
-XC14 -XC15
1 2 3 4 1 2 3
FROM EXTERNAL
11
PANEL
1
23
1A
-LDM -COMMON -LDG
13 x1
-EMG1 -H1 EMERGENCY STOP ILP
14 x2 (ON CANOPY)
EMERGENCY CANOPY LAMP

(ON CANOPY) QTY AS PER
CANOPY DESIGN
-X4 = CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE

CONTROL TERMINAL FOR AMF PANEL
-X5 = FUSE TERMINAL S/F 12V GLASS FUSE MAKE - CONNECTWELL
-XC4 = 4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONECTOR MALE PINS) FUSE TERMINAL
CANOPY WIRING HARNESS CONNECTOR -XC14 =4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONECTOR MALE PINS)
-XC5 = 3 POLE MALE(110) TYPE-TTP-13MN,TT MAK
EMG STOP ILP CONNECTOR -XC15 =3 POLE FEMALE(110) TYPE-TTP-13FN,TT MAKE

SHEET NO.
DRN DATE 03.05.2019 TITLE : Canopy Wiring Harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
RG3
14 UN
-7V2
50/5A,2.5VA S1 S2 2
YG3
14 UN 415VAC,50Hz,3PH.
-7V3 SUPPLY TO LOAD
50/5A,2.5VA 3
S1 S2 BG3
14 UN
50/5A,2.5VA 4
NG2
18 UN
R2(40)
1 GY
R1(39)
1 GY
Y2(38)
1 GY
Y1(37)
1 GY
B2(34)
1 GY
B1(35)
1 GY
9.6 9.6 9.6 9.6 9.6 9.6
RG2
14 UN
YG2
14 UN
BG2
14 UN
NG1
18 UN
1 3 5
-7F1 -7NL1
40A/3P,06KA 20A
2 4 6
RG
6 RD
YG
6 YE
BG
6 BU
NG
6 BK
-X1 -X1
1 4
RG RG1 MR MR1
3PH.GENSET SUPPLY
/ 9.2 / 9.5
(BEFORE MCB ON)
1 RD 1 RD 1 RD 1 RD
TO CONTROLLER
TO CONTROLLER
FUSE 6A FUSE 6A
MAINS SUPPLY
2 5
YG YG1 MY MY1
/ 9.2 / 9.5
1 YL FUSE 2A 1 YL 1 YE 1 YE
FUSE 2A
3 6
BG BG1 MB MB1
/ 9.2 / 9.4
1 BL FUSE 2A 1 BL 1 BU FUSE 2A 1 BU
NG NG MN
/ 9.2 / 9.4
1 BK 1 BK 1 BK
CONTROL CKT
TO BATTERY
CHARGER &
MR1
/ 11.5
1 RD
-R -Y -B -N -X2 1 2 3 4
MN
/ 11.6
25A,600V 1 BK -X1 = 230V AC FUSE TERMINALS
SUPPLY FROM DG ALT. SUPPLY FROM MAINS CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE
POWER TERMINAL BOARD 125 AMP. EVEREST/REPUTED MAKE 4 WAY 8 MM STUD

SHEET NO.
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.60.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
150/5A,2.5VA
230VAC,50Hz,1PH.
SUPPLY TO LOAD
NEUTRAL (N) BUSBAR AL 15X10MM 2

NG3
6 UN
R2(40)
1 GY
R1(39)
1 GY
9.6 9.6
RG3
12 UN
RG4
12 UN
RG5
12 UN
1 3 5
-7F1
50A/3P,06KA
2 4 6
1PH.GENSET SUPPLY
-X1 -X1
(BEFORE MCB ON)
TO CONTROLLER
-7NL1
CHARGER & TO CONTROLLER

MAINS SUPPLY
1 2
RG1 RG2 MR MR1
/ 9.2 / 9.5
1 RD 1 RD 1 RD 1 RD
FUSE 6A FUSE 6A
NG1 MN MN
/ 9.2 / 9.4
1 BK 1 BK 1 BK
RG1
10 RD/12 UN
RG2
10 RD/12 UN
RG3
10 RD/12 UN
NG1
25 BK/10 UN
NG2
25 BK/10 UN
CONTROL CKT
TO BATTERY
MR1
/ 11.5
1 RD
MN
/ 11.6
1 BK
-R -R -R -N -N -X2 1 2
25A,600V -X1 = 230V AC FUSE TERMINALS
POWER TERMINAL BOARD EVEREST/REPUTED MAKE 2 WAY 10 MM STUD

SHEET NO.
00 NEW RELEASE 03.05.2019 SUPRIYA 23290 23290 DRN BY SUPRIYA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
KOEL DRAWING NO:
APROV. BY SRN ENGINE MODEL : 3RT Page : 7 / 41
SCALE 4.00mm 3H.471.60.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
RG3
12 UN
-7V2
50/5A,2.5VA S1 S2 2
YG3
-7V3 SUPPLY TO LOAD
50/5A,2.5VA 3
S1 S2 BG3
12 UN
50/5A,2.5VA 4
NG2
14 UN
R2(40)
1 GY
R1(39)
1 GY
Y2(38)
1 GY
Y1(37)
1 GY
B2(34)
1 GY
B1(35)
1 GY
9.6 9.6 9.6 9.6 9.6 9.6
RG2
12 UN
YG2
12 UN
BG2
12 UN
NG1
14 UN
1 3 5
-7F1 -7NL1
50A/3P,06KA 40A
2 4 6
RG
10 RD/12 UN
YG
10 YE/12 UN
BG
10 BU/12 UN
NG
10 BK/14 UN
-X1 -X1
1 4
RG RG1 MR MR1
3PH.GENSET SUPPLY
/ 9.2 / 9.5
(BEFORE MCB ON)
1 RD FUSE 6A1 RD 1 RD 1 RD
TO CONTROLLER
TO CONTROLLER
FUSE 6A
MAINS SUPPLY
2 5
YG YG1 MY MY1
/ 9.2 / 9.5
1 YE FUSE 2A 1 YE 1 YE 1 YE
FUSE 2A
3 6
BG BG1 MB MB1
/ 9.2 / 9.4
1 BU FUSE 2A1 BU 1 BU FUSE 2A 1 BU
NG MN
/ 9.2 / 9.4
1 BK 1 BK
CONTROL CKT
TO BATTERY
CHARGER &
MR1
/ 11.5
1 RD
-R -Y -B -N -X2 1 2 3 4
MN
/ 11.6
25A,600V 1 BK -X1 = 230V AC FUSE TERMINALS

SHEET NO.
00 NEW RELEASE 03.05.2019 SUPRIYA 23290 23290 DRN BY SUPRIYA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
KOEL DRAWING NO:
SCALE 4.00mm 3H.469.80.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S2 S1 1
RG3
10 UN
-7V2
100/5A,2.5VA S2 S1 2
YG3
-7V3 SUPPLY TO LOAD
100/5A,2.5VA 3
S2 S1 BG3
10 UN
100/5A,2.5VA 4
NG2
14 UN
R2(40)
1 GY
R1(39)
1 GY
Y2(38)
1 GY
Y1(37)
1 GY
B2(34)
1 GY
B1(35)
1 GY
9.6 9.6 9.6 9.6 9.6 9.6
RG2
10 UN
YG2
10 UN
BG2
10 UN
NG2
14 UN
1 3 5
-7Q1
75A/3P,10KA
MCCB
-7NL1
40A
I> I> I>
2 4 6
RG
YG
BG
NG
-X1 -X1
1 4
RG RG1 MR MR1
3PH.GENSET SUPPLY
/ 9.2 / 9.5
(BEFORE MCB ON)
1 RD 1 RD 1 RD 1 RD
TO CONTROLLER
TO CONTROLLER
FUSE 6A FUSE 6A
MAINS SUPPLY
2 5
YG YG1 MY MY1
/ 9.2 / 9.5
FUSE 2A
3 6
BG BG1 MB MB1
/ 9.2 / 9.4
1 BU FUSE 2A 1 BU 1 BU FUSE 2A 1 BU
NG MN
/ 9.2 / 9.4
1 BK 1 BK
CONTROL CKT
TO BATTERY
CHARGER &
MR1
/ 11.5
1 RD
-X2 1 2 3 4
MN
/ 11.6
-R -Y -B -N 25A,600V 1 BK
-X1 = 230V AC FUSE TERMINALS
SHEET NO.
00 ---- ---- DRN BY SUPRIYA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
CHD BY SA PROJECT : CONTROL PANEL FOR 45KVA 3RTA REV NO.
KOEL DRAWING NO:
APROV. BY SRN ENGINE MODEL : 3RTA Page : 7 / 41
SCALE 4.00mm 3H.465.40.0.PR 00
0 1 2 3 4 5 6 7 8 9

1
-VE +VE
G CHARGING
-8ALTR1
1 ALTERNATOR
-IND1
-XC11 -XC1
7 5 5 7
0.75 GY
/ 10.5 IND
-8VBFS1
0.75 GY
-8CHTS1
14 13 CYL.HEAD TEMP SW/WATER TEMP SEN. 24 9 9 24
-8WTS1 0.75 GY
/ 10.5 CYL.HEAD TEMP SW/ WATER TEMP SENSOR
13 14
-8OTS1
13 14 LUBE OIL TEMP.SENSOR (OPTIONAL) 26 10 10 26
0.75 GY
/ 10.5 LUBE OIL TEMP.SENSOR (OPTIONAL)
-8LLOPS1
12 11 LLOP SWITCH 12 4 4 12(C)
0.75 GY
/ 10.5 LLOP SWITCH
CONTROL ON/OFF SW
-8S1
2A 2 2 2A 4 3 2A
1 GY 1 GY
1A 1 1 1A
1 GY
/ 10.3 BATT. -VE (1A)
1
1 11 11 1
2.5 GY
/ 10.3 BATT. -VE(1)
-8FLS1
13 14 FUEL LEVEL SENSOR 25 7 7 25
0.75 GY
/ 10.4 FUEL LEVEL SENSOR
6 6
12 12
1B 8 8 1B
0.75 GY
/ 10.5 LLOP -VE(1B)
-8SS1
13 13
A2 A1 STOP SOLENOID 6
4 GY
14 14
1
15 15
-8BATT.1
BC +VE
+VE -VE
11.5
BATTERY
12VDC
2B
1.5 GY
-8STA1 -XC12 -XC2
STARTER 1 1 6
-VE M +VE 4 GY
2 2
-8F2 2 1
2 2 2B
-SOL1
4 GY 4 GY
/ 10.1 BATTERY +VE
32A/1P,06KA
3 3 3 3
2.5 GY
/ 10.2 STARTER
-8S1
4 4 2B/4 14 13 2E
4 GY 1 GY
2B/4


SHEET NO.
DRN DATE 03.05.2019 TITLE : Engine Wiring harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.40.0.PR 00
0 1 2 3 4 5 6 7 8 9
CT CONNECTION
SENSOR GND
7.3 7.3 7.3 7.2 7.2 7.2
GENSET MAINS
3PH SUPPLY 3PH SUPPLY
INSULATED BUTT
7.3 7.3 7.3 7.3 7.5 7.5 7.5 7.5 9.7
SPLICE CONNECTOR
B1 B2 Y1 Y2 R1 R2
NG
1 BK
BG1
1 BU
YG1
1 YE
RG1
1 RD
MN
1 BK
MB1
1 BU
MY1
1 YE
MR1
1 RD
B1
1 BU
B2
1 BU
Y1
1 YE
Y21
1 YE
R1
1 RD
R2
1 RD
1
1 GY
-J6 1 2 3 4 -J7 1 2 3 4 1 2 3 4 5 6 7 8
-J8
-9GCU1
02.026.09.0.00 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
GENSET CONTROL
UNIT
GENSET I/P MAINS I/P CT I/P MPU I/P
GENSET CONTROL UNIT

USB
(KG 645 UNIT)
I/P:ANLG (0-5V / 4-20mA)
I/P:ANLG TEMP/DIG G
I/P:ANLGFL/DIG H
D+CHARGE ALT
I/P:ANLG/DIG F
DIGITAL O/P D
DIGITAL O/P C
DIGITAL O/P A
DIGITAL O/P B
DIGITAL O/P E
DIGITAL O/P F
DIGITAL I/P D
DIGITAL I/P C
DIGITAL I/P A
DIGITAL I/P B
DIGITAL I/P E
E-GOV OUT 3
E-GOV OUT 2
E-GOV OUT 4
E-GOV OUT 1 BATTERY
CAN HIGH
CAN LOW
RS 485_A
RS 485_B
12/24V
+VE -VE
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-J5 1 2 3 4 5 6 7 8 9 10 -J4 1 2 3 4 5 6 -J3 1 2 3 4 -J2 1 2 3 4 -J1 1 2

26
0.75 GY
25
0.75 GY
24
0.75 GY
23
0.75 GY
22(E)
0.75 GY
21(D)
0.75 GY
12(C)
0.75 GY
11(B)
0.75 GY
10(A)
0.75 GY
9(F)
0.75 GY
8(E)
0.75 GY
7
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
3(A)
0.75 GY
2
1 GY
1
1 GY
1
1 GY
10.5 10.4 10.5 10.6 12.5 10.6 10.6 10.6 10.6 12.4 12.3 10.5 10.3 10.3 10.3 10.4 10.4 9.7
LUBE OIL TEMP SENSOR
FUEL LEVEL SENSOR

CYL.HEAD TEMP SW/
WATER TEMP SENSOR
4-20mA SENSOR
SEMI AUTO
LLOP SWITCH
EMG
AUTO START
GENSET RELAY
MAINS RELAY
IND
STOP
START
FAULT
DC SUPPLY +VE
DC SUPPLY -VE
SENSOR GND
SPARE O/P

SHEET NO.
DRN DATE 03.05.2019 TITLE : KG645 Controller Diagram KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.40.0.PR 00
0 1 2 3 4 5 6 7 8 9
R2- STOP RELAY (70A) -C5 = 6 PIN FEMALE CONNECTOR PHONIX MAKE(TYPE-MVSTBW 2.5/ 6-ST-5.08)
R3- COMMON FAULT RELAY (6A)

R4- AUTO START RELAY (6A)
CYL.HEAD TEMP SW/
LUBE OIL TEMP SEN.

FUEL LEVEL SENSOR
WATER TEMP.SEN
4-20mA SENSOR
DC SUPPLY +VE
DC SUPPLY -VE
-VE
LLOP SWITCH
AUTO START
10.4
START
FAULT
STOP
EMG
IND
10.1
9.6
9.6
9.6
9.7
9.7
9.2
9.2
9.1
9.5
9.5
9.4
9.2
9.2
9.4
OUTPUT
3(A)
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
SPARE
2
1 GY
1
1 GY
1
1 GY
7
0.75 GY
10(A)
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
1
1 GY
1
1 GY
1
1 GY
-C9 1 2 3 4 5 6 7 8 -C8 1
2
-C7 1
2 3 4 5 6 -C6 1 2 3 4 5 6 7 8
+VE -VE
R4
A1 A1 A1
R1 R2 R3 F3
A2 A2 A2 500mA
F1 F2 A1
3.75A 3.75A R4 R3
A2
R2 R1
DC INTERFACE CARD
-C2 1 2 3 4 -C3 2 3 4 5 6 -C4 2 3 4 5 6 7 8 9 10 -C5 1 2 3 4 5 6

1 1
COMMON SPARE
+VE SPARE
FAULT OUTPUT
-VE SPARE
2E
1 GY
1A
1 GY
2A
1 GY
1A
1 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
7
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
11(B)
0.75 GY
2F
0.75 GY
1H
0.75 GY
SPARE
6
4 GY
2B
4 GY
3
2.5 GY
8.7 8.7 8.7 8.7 8.7 8.7 8.7 8.7 12.1 12.2 12.5
IND
CANOPY EMG.
CANOPY LAMP
AUTO START
FROM GC/MC-IC
STOP SOLENOID
STARTER
CONTROLLER +VE
FUEL LEVEL SENSOR

CYL.HEAD TEMP SW/
WATER TEMP.SEN
LUBE OIL TEMP SEN.
3
10S2
EMG. STOP
OPTIONAL
BATT. +VE / 8.7
-X3
1
12(C) 12(C)
LLOP SWITCH / 8.7
0.75 GY 0.75 GY
1A
1 GY
2
1B 1
-VE(1A) / 8.7
0.75 GY 1 GY
3
23
0.75 GY
4
2E 2E
1 GY 1 GY
/ 11.2 BATT. +VE
2E
CONTROL ON +VE / 8.7
1 GY
1 1
-VE(1) / 8.7
2.5 GY 1 GY
/ 11.2 -VE(1)
1A 1A
-VE(1A) / 8.7
1 GY 1 GY
/ 12.3 -VE(1A)
CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE

SHEET NO.
DRN DATE 03.05.2019 TITLE : DC Interfacing Card KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.40.0.PR 00
0 1 2 3 4 5 6 7 8 9
2E 2E
BATT. +VE 10.7
1 GY 1 GY
12.5 BATT. +VE
1 1
BATT. -VE 10.7
1 GY 1 GY
12.1 BATT. -VE
1
1 GY
BATT. +VE
BATT. -VE
11.6
/ 11.4
/ 8.5
BATT. -VE
1
1 GY
2E
1 GY
1 2
-XC3
2B
1.5 GY
1
1 GY
-11KRM1 1 2
-11BC1
9 to 36V 12V,2Amp
KOEL PART NO.:-
DV2.858.04.0.PR
BATTERY CHARGER
+VE -VE
x2
BC
x1
RMS MODULE
RMS MODULE P N E
MR1
1 RD
MN
1 BK
7.5 7.5
RMS UNIT CONNECTOR

SHEET NO.
DRN DATE 03.05.2019 TITLE : Batter Charger & RMS KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.40.0.PR 00
0 1 2 3 4 5 6 7 8 9
1
BATT. -VE 11.4
1 GY
GENSET RELAY
MAINS RELAY
AUTO START
TO CONTROLLER
SEMI AUTO
BATT +VE
CANOPY LAMP
BATT. -VE
ON/OFF SW
EMG. STOP
/ 10.7
/ 10.7
/ 11.4
/ 9.5
/ 9.5
/ 9.2
/ 10.7
/ 10.7
8(E)
0.75 GY
9(F)
0.75 GY
2E
1.5 GY
-12S2 3
1 2
-X5 1 -X5 2 -X5 3

4 FUSE 300MA FUSE 300MA FUSE 6A
LDM
0.75 GY
LDG
0.75 GY
1A
1 GY
1H
0.75 GY
22(E)
0.75 GY
1
1 GY
11(B)
0.75 GY
1
1 GY
23
0.75 GY
1
1 GY
2E1
1.5 GY
1 2 3 4 1 2 3
-XC4 -XC5 -X4 1 2 3 4
-XC14 -XC15
1 2 3 4 1 2 3
FROM EXTERNAL
11
PANEL
1
23
1A
-LDM -COMMON -LDG
13 x1
14 x2 (ON CANOPY)

CANOPY DESIGN
-X4 = CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE

-X5 = FUSE TERMINAL S/F 12V GLASS FUSE MAKE - CONNECTWELL
-XC4 = 4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONECTOR MALE PINS) FUSE TERMINAL
CANOPY WIRING HARNESS CONNECTOR -XC14 =4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONECTOR MALE PINS)

SHEET NO.
DRN DATE 03.05.2019 TITLE : Canopy Wiring Harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.40.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1
R PHASE BUS BAR 15X10 MM AL
S1 S2
-7R1
-7V2
150/5A,2.5VA Y PHASE BUS BAR 15X10 MM AL
S1 S2
-7Y1 415VAC,50Hz,3PH.
-7V3 SUPPLY TO LOAD
150/5A,2.5VA B PHASE BUS BAR 15X10 MM AL
S1 S2
-7B1
150/5A,2.5VA N NEUTRAL BUS BAR 15X5 MM AL

-7NL1
R2(40)
1 GY
R1(39)
1 GY
Y2(38)
1 GY
Y1(37)
1 GY
B2(34)
1 GY
B1(35)
1 GY
9.6 9.6 9.6 9.6 9.6 9.6
1 3 5
-7Q1
125A/3P,37KA
MCCB
I> I> I>
2 4 6
RG
50 RD/UN 6
YG
50 YE/UN 6
BG
50 BU/UN 6
NG
50 BK/UN 6
-X1 -X1
1 4
RG RG1 MR MR1
3PH.GENSET SUPPLY
/ 9.2 / 9.5
(BEFORE MCB ON)
1 RD 1 RD 1 RD 1 RD
TO CONTROLLER
TO CONTROLLER
FUSE 6A FUSE 6A
MAINS SUPPLY
2 5
YG YG1 MY MY1
/ 9.2 / 9.5
FUSE 2A
3 6
BG BG1 MB MB1
/ 9.2 / 9.4
1 BU FUSE 2A 1 BU 1 BU FUSE 2A 1 BU
NG MN
/ 9.2 / 9.4
1 BK 1 BK
CONTROL CKT
TO BATTERY
CHARGER &
MR1
/ 11.5
1 RD
-R -Y -B -7NL1 -X2 1 2 3 4
MN
/ 11.6
25A,600V 1 BK
415VAC,50Hz,3PH.
SUPPLY FROM MAINS -X2 = CONTROL TERMINAL FOR LOP SENSOR/SWITCH
SUPPLY FROM DG ALT. CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE
SHEET NO.
CHD BY SA PROJECT : CONTROL PANEL FOR 82.5KVA 3PH 4R1040 REV NO.
KOEL DRAWING NO:
APROV. BY SRN ENGINE MODEL : 4R1040 Page : 7 / 41
SCALE 4.00mm 4H.1696.80.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S2 S1 1
RG4
8 UN
100/5A,2.5VA
230VAC,50Hz,1PH.
SUPPLY TO LOAD
2
NG
8 UN
J5/1
1 GY
J5/2
1 GY
NG
8 UN
RG3
8 UN
RM2
8 UN
NM
8 UN
10.6 10.6
S1 S2 CT CONNECTIONS S5 S6
SHORTLINKS SHORTLINKS
TO CONTROLLER
1 3 5 7 1 3 5 7
-8K1 -8K2
/8.7 /8.2
50A 2 4 6 8 50A 2 4 6 8
GENSET MAINS
CONTACTOR CONTACTOR
S3 S4 S7 S8
RM
NM
8 UN
8 UN
RG2
12 UN
RG1
12 UN
NG
12 UN
NG1
12 UN
1 3 5 7
-7F1
50A/4P,06KA
2 4 6 8
-X1
2
RG
RG1
NG
NG1
10 RD/12 UN
10 YE/12 UN
10 BU/12 UN
10 BK/12 UN
RM RM1
/ 10.5
1 RD FUSE 6A 1 RD
TO CONTROLLER
MAINS SUPPLY
-X1
1
RG RG1
1PH.GENSET SUPPLY
/ 8.6
(BEFORE MCB ON)
1 RD 1 RD
TO CONTROLLER
FUSE 6A
NM NM
/ 10.4
1 BK 1 BK
CONTROL CKT
TO BATTERY
CHARGER &
NG NG MR2
/ 8.6 / 8.1
1 BK 1 BK 1 RD
NM
/ 8.1
1 BK
-R -Y -B -7N1
-XPTB2 1 2
230VAC,50Hz,1PH. -XPTB1 =POWER TERMINALS FOR LOAD
INCOMING FROM DG ALT. INCOMING FROM MAINS POWER TERMINAL BOARD EVEREST/REPUTED MAKE 2 WAY 150 AMP 10 MM STUD
POWER TERMINAL BOARD EVEREST/REPUTED MAKE 2 WAY 150 AMP 10 MM STUD

SHEET NO.
DRN DATE 07/05/2019 TITLE : Main Incoming Supply KIRLOSKAR OIL ENGINES LTD.,
00 NEW RELEASE 07/05/2019 URMILA ----- ----- DRN BY URMILA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
CHD BY SA PROJECT : CONTROL PANEL FOR 20KVA 1PH 2RT REV NO.
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
MR2 RG1
FROM MAINS R PHASE 7.6 / /12.8 TO BATTERY CHARGER FROM GENSET R PHASE 7.3 / /10.2 TO CONTROLLER
1 RD 1 RD
C1
-11RB2-RL1
/12.6
13.6
P1
MAINS FAIL
MR3A
1 GY
1 GY
1H
-S2 -S3 -S4
/7.1 /7.1 /7.1
MANUAL AUTO MANUAL AUTO MANUAL AUTO
1 GY
RG3
1 GY
1 GY
1 GY
MR3
MR4
RG4
1 GY
1H1
-8S3
-8S3 /8.3
/8.6
GENSET CONT. ON
MAINS CONT. ON
11.7
O1 O1
-11RB1-RL1 -11RB1-RL2
/12.3 P1 /12.4 P1
1 GY
RG5
MC RELAY GC RELAY
1 GY
MR5
RG5
1 GY
MR5
1 GY
11 11
-8K1 -8K2
/8.7 12 /8.2 12
GENSET CONTACT MAINS CONTACT
1 GY
MR6
1 GY
RG6
MR6 RG6
1 GY 1 GY
A1 x1 A1 x1
-8K2 -8H1 -8K1 -8H2

50A,240VAC RED x2 50A,240VAC RED x2
A2 240VAC A2 240VAC
MAINS CONTACTOR GENSET CONTACTOR
LOAD ON MAINS LOAD ON GENSET
NM NM NG NG
MAINS NEUTRAL 7.6 / / 12.9 TO BATTERY CHARGER GENSET NEUTRAL 7.3 / 1 BK /10.2 TO CONTROLLER
1 BK 1 BK 1 BK
MAINS LOAD ON GENSET LOAD ON
CONTACTOR MAINS CONTACTOR GENSET
1 2 /7.4 1 2 /7.1
3 4 /7.4 3 4 /7.1
5 6 /7.5 5 6 /7.1
7 8 /7.5 7 8 /7.1
11 12 /8.7 11 12 /8.2
13 14 /13.4 13 14 /13.5

SHEET NO.
DRN DATE 07/05/2019 TITLE : Control drawing KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
1
-VE +VE
G CHARGING
-8ALTR1
1 ALTERNATOR
-IND1
-XC11 -XC1
7 5 5 7
0.75 GY
/ 11.6 IND
-8VBFS1
0.75 GY
-8CHTS1
-8WTS1 0.75 GY
13 14
-8CHTS1
14 13 TEMP.SWITCH (OPTIONAL) 26 9 9 26
0.75 GY
/ 11.5 TEMP.SWITCH (OPTIONAL)
-8LLOPS1
12 11 LLOP SWITCH 12 4 4 12(C) LLOP SWITCH
/ 11.5
0.75 GY
CONTROL ON/OFF SW
-8S1
2A 2 2 2A 4 3 2A
1 GY 1 GY
1A 1 1 1A
1 GY
/ 11.3 BATT. -VE (1A)
1
1 11 11 1
2.5 GY
/ 11.3 BATT. -VE(1)
-8FLS1
13 14 FUEL LEVEL SENSOR 25 7 7 25 FUEL LEVEL SENSOR
/ 11.5
0.75 GY
6 6
12 12
1B 8 8 1B
0.75 GY
/ 11.5 LLOP -VE(1B)
-8SS1
STOP SOLENOID
A2 A1 6 13 13
4 GY
-8BATT.1 14 14
1
+VE -VE
BATTERY 15 15
12VDC
BC +VE
-8STA1
STARTER 12.8
-VE M +VE
2B
1.5 GY
-SOL1
-XC12 -XC2
1 1 6
4 GY
2 2
-8F1 2 1
2 2 2B BATTERY +VE
/ 11.1
4 GY 4 GY
32A/1P,06KA
3 3 3 3
2.5 GY
/ 11.2 STARTER
-8S1
2B/4 4 4 2B/4 14 13 2E
4 GY 1 GY
SHEET NO.
DRN DATE 07/05/2019 TITLE : Engine Wiring Harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
CT CONNECTION
7.2 7.2
SENSOR GND
GENSET MAINS
INSULATED BUTT
1PH SUPPLY 1PH SUPPLY
SPLICE CONNECTOR
8.8 8.8 7.7 7.7 10.7

B1 B2 Y1 Y2 R1 R2
B1
1 BU
B2
1 BU
Y1
1 YE
Y2
1 YE
R1
1 RD
R2
1 RD
1
1 GY
NG
1 BK
RG1
1 RD
NM
1 BK
RM1
1 RD
-J6 1 2 3 4 -J7 1 2 3 4 1 2 3 4 5 6 7 8
-J8
-GCU1
02.026.18.0.PR 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
GENSET CONTROL
UNIT
SENSOR COMMON POINT
RESERVED
GENSET I/P MAINS I/P CT I/P
GENSET CONTROL UNIT

USB
(KG 640 UNIT)
I/P:ANLG TEMP/DIG G
I/P:ANLGFL/DIG H
I/P:ANLG/DIG F
D+CHARGE ALT
DIGITAL O/P D
DIGITAL O/P C
DIGITAL O/P A
DIGITAL O/P B
DIGITAL O/P E
DIGITAL O/P F
DIGITAL I/P D
DIGITAL I/P C
DIGITAL I/P A
DIGITAL I/P B
DIGITAL I/P E
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
RESERVED
BATTERY
RS 485_A
RS 485_B
12/24V
+VE -VE
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-J5 1 2 3 4 5 6 7 8 9 10 -J4 1 2 3 4 5 6 -J3 1 2 3 4 -J2 1 2 3 4 -J1 1 2

26
0.75 GY
25
0.75 GY
24
0.75 GY
23
0.75 GY
21(D)
0.75 GY
10(A)
0.75 GY
9(F)
0.75 GY
8(E)
0.75 GY
7
0.75 GY
5(A)
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
3(A)
0.75 GY
2
1 GY
1
1 GY
1
1 GY
22
0.75 GY
12(C)
0.75 GY
11(B)
0.75 GY
11.5 11.5 11.5 11.6 13.7 11.6 11.6 12.4 12.3 11.6 12.6 11.3 11.3 11.3 11.4 11.4 10.7
SENSOR GND
MAINS FAIL
IND
DC SUPPLY +VE
DC SUPPLY -VE
WATER TEMP SENSOR
START
4-20mA SENSOR
MAINS RELAY
AUTO START
TEMP SWITCH (OPTIONAL)
GENSET RELAY
FAULT
FUEL LEVEL SENSOR
STOP
SEMI AUTO
CYL.HEAD TEMP SW/
11.6 11.6
LLOP SWITCH
EMG

SHEET NO.
DRN DATE 07/05/2019 TITLE : KG640 Controller Diagram KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
R2- STOP RELAY (70A) -C4 = 10 PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 010R) WITH FEMALE PINS
R3- COMMON FAULT RELAY (6A) -C5 = 6 PIN FEMALE CONNECTOR PHONIX MAKE(TYPE-MVSTBW 2.5/ 6-ST-5.08)
R4- AUTO START RELAY (6A) -C6 = 8 PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 08R) WITH FEMALE PINS

-VE
CYL.HEAD TEMP SW/

FUEL LEVEL SENSOR
WATER TEMP.SEN
4-20mA SENSOR
DC SUPPLY +VE
DC SUPPLY -VE
LLOP SWITCH
/ 11.4
AUTO START
START
FAULT
STOP
EMG
IND
/ 10.6
/ 10.6
/ 10.6
/ 10.5
/ 10.7
/ 11.1
/ 10.7
/ 10.2
/ 10.2
/ 10.1
/ 10.5
/ 10.4
/ 10.2
/ 10.2
/ 10.4
OUTPUT
3(A)
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
2
1 GY
1
1 GY
1
1 GY
7
0.75 GY
10(A)
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
SPARE
1
1 GY
1
1 GY
1
1 GY
-C9 1 2 3 4 5 6 7 8 -C8 1
2
-C7 1
2 3 4 5 6 -C6 1 2 3 4 5 6 7 8
+VE -VE
R4
A1 A1 A1
R1 R2 R3 F3
A2 A2 A2 500mA
F1 F2 A1
3.75A 3.75A R4 R3
A2
R2 R1
DC INTERFACE CARD
-C2 1 2 3 4 -C3 2 3 4 5 6 -C4 2 3 4 5 6 7 8 9 10 -C5 1 2 3 4 5 6

1 1
COMMON SPARE
-VE SPARE
+VE SPARE
FAULT OUTPUT
SPARE
2E
1 GY
1A
1 GY
2A
1 GY
1A
1 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
7
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
11(B)
0.75 GY
2F
0.75 GY
1H1
1 GY
6
4 GY
3
2.5 GY
2B
4 GY
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
CANOPY EMG. 13.1 /
CANOPY LAMP 13.2 /
8.9 /
AUTO START
IND
STOP SOLENOID
CONTROLLER +VE
CYL.HEAD TEMP SW/

STARTER
FUEL LEVEL SENSOR
WATER TEMP.SEN
3
BATTERY +VE 9.7 / 4
10S2
EMG. STOP
OPTIONAL
-X2
1
LLOP SWITCH 12(C) 12(C)
9.7 /
0.75 GY 0.75 GY
2
1B 1
-VE(1A) 9.7 /
0.75 GY 1 GY
3
23
1A
1 GY
0.75 GY
4
2E 2E RMS MODULE
/ 12.0
1 GY 1 GY
2E
CONTROL ON +VE 9.7 /
1 GY
1 1
-VE(1) 9.7 / / 12.0 -VE(1)
2.5 GY 1 GY
CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE -VE(1A) 1A 1A
9.7 / / 13.4 -VE(1A)
1 GY 1 GY

SHEET NO.
DRN DATE 07/05/2019 TITLE : DC Interface Card Diagram KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
2E /13.1
BATT. +VE 11.7 /
1 GY BATT. +VE
1 1
BATT. -VE 11.7 /
1 GY 1 GY
/ 13.1 BATT. -VE
1
1 GY
MAINS FAIL RELAY
BATT. +VE
BATT. -VE
GENSET RELAY
MAINS RELAY
12.9 /
BATT. -VE
/ 12.2
/ 9.5
2E
1 GY
1
1 GY
1
1 GY
1
1 GY
1
1 GY
/ 10.5
/ 10.5
/ 10.6
2B
1.5 GY
1
1 GY
1 2
8(E)
0.75 GY
9(F)
0.75 GY
5(A)-2
0.75 GY
-XC5
-11RB1 -11RB2
-11KRM1 1 2 RELAY BOARD RELAY BOARD
9 to 36V 2CH. 2C/O 12V DC RL1:1(+) RL1:1(-) RL2:2(+) RL2:2(-) 1CH. 2C/O 12V DC RL1:1(+) RL1:1(-)
UL MAKE UL MAKE
2H.226.33.0.00 RELAY COIL SUPPLY RELAY COIL SUPPLY RELAY COIL SUPPLY
-11BC1
RL1 RL2 RL1 12V,2Amp
BATTERY CHARGER
5A 5A 5A
+VE -VE
C1 O1 P1 C2 O2 P2 C1 O1 P1 C2 O2 P2 C1 O1 P1 C2 O2 P2
C1:1 O1:1 P1:1 C2:1 O2:1 P2:1 C1:2 O1:2 P1:2 C2:2 O2:2 P2:2 C1:1 O1:1 P1:1 C2:1 O2:1 P2:1
x2
RMS MODULE O1 P1 /8.4 O1 P1 /8.8 C1 P1 /8.3

BC
x1
RMS MODULE
P N E
MR2
1 RD
NM
1 BK
8.4 /
8.4 /
RMS UNIT CONNECTOR

SHEET NO.
DRN DATE 07/05/2019 TITLE : Gc&Mc Relay KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
BATT. +VE 2E
12.3 /
1 GY
1
BATT. -VE 12.8 /
1 GY
TO CONTROLLER
CANOPY LAMP
ON/OFF SW
/ 10.2 SEMI AUTO

EMG. STOP
/ 11.7 BATT. -VE
START
AUTO
2E
1 GY
2E
1 GY
/ 11.7
/ 11.7
/ 8.9
13 13
-8K2 -8K1
/8.2 14 /8.7 14
LDM1 LDG1
2F
0.75 GY
2E
1 GY
2E1
1 GY
2E1
1 GY
-12S2 -X4 1
3
1 2 6A
-X5 1 -X5 2 FUSE
300MA 300MA
4 FUSE
FUSE
11(B)
0.75 GY
1
1 GY
23
0.75 GY
1
1 GY
1H
1 GY
2E(A)
1 GY
22(D)
0.75 GY
1
1 GY
LDM
0.75 GY
1A
1 GY
LDG
0.75 GY
1 2 3 4 1 2 3
-XC3 -XC4 -X3 1 2 3 4
-XC13 -XC14
1 2 3 4 1 2 3
FROM EXTERNAL PANEL

11
23
1A
-LDM -COMMON -LDG
13 x1
14 x2 (ON CANOPY)

CANOPY DESIGN

-X3 = CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE FUSE TERMINAL,MAKE-CONNECTWELL/WAGO, TYPE NO - CF4UL110-240V
-XC3 = 4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONNECTOR MALE PINS) -X5 = 230V AC FUSE TERMINALS
CANOPY WIRING HARNESS CONNECTOR
-XC13 =4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONECTOR MALE PINS)

SHEET NO.
DRN DATE 07/05/2019 TITLE : Canopy Wiring Harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.70.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
RG4
14 UN
-7V2
50/5A,2.5VA S1 S2 2
YG4
-7V3 SUPPLY TO LOAD
50/5A,2.5VA 3
S1 S2 BG4
14 UN
50/5A,2.5VA 4
NG4
18 UN
R1(39)
1 GY
R2(40)
1 GY
Y1(37)
1 GY
Y2(38)
1 GY
B1(35)
1 GY
B2(36)
1 GY
RG3
14 UN
YG3
14 UN
BG3
14 UN
NG
18 UN
RM2
14 UN
YM2
14 UN
BM2
14 UN
NM
18 UN
10.6 10.6 10.6 10.6 10.6 10.6
1 3 5 7 1 3 5 7
-8K1 -8K2
/8.7 /8.2
40A 2 4 6 8 40A 2 4 6 8
GENSET MAINS
CONTACTOR CONTACTOR
RG2
14 UN
YG2
14 UN
BG2
14 UN
NG
18 UN
1 3 5
1
-7NL1
RM
YM
BM
NM
20A
14 UN
14 UN
14 UN
18 UN
-7F1
40A/3P,06KA
2 4 6
-X1
4
RG
YG
BG
NG
6 RD/14 UN
6 YE/14 UN
6 BU/14 UN
6 BK/18 UN
RM RM1
/ 10.5
1 RD FUSE 6A 1 RD
TO CONTROLLER
MAINS SUPPLY
5
-X1 YM YM1
/ 10.4
1 YE FUSE 2A 1 YE
1
RG RG1 6
3PH.GENSET SUPPLY
/ 8.6 BM BM1
(BEFORE MCB ON)
1 RD 1 RD
TO CONTROLLER
FUSE 6A / 10.4
1 BU FUSE 2A 1 BU
2
YG YG1
/ 10.2 NM NM
1 YE FUSE 2A 1 YE / 10.4
1 BK 1 BK
3
BG BG1
/ 10.2
1 BU FUSE 2A 1 BU
CONTROL CKT
TO BATTERY
CHARGER &
NG NG MR2
/ 8.6 / 8.1
1 BK 1 BK 1 RD
NM
/ 8.1
1 BK
-R -Y -B -7N1
-XPTB2 1 2 3 4
INCOMING FROM DG ALT. INCOMING FROM MAINS POWER TERMINAL BOARD 125 AMP. EVEREST/REPUTED MAKE 4 WAY 8 MM STUD

SHEET NO.
KOEL DRAWING NO:
SCALE 4.00mm 2H.764.80.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
RG4
12 UN
-7V2
50/5A,2.5VA S1 S2 2
YG4
-7V3 SUPPLY TO LOAD
50/5A,2.5VA 3
S1 S2 BG4
12 UN
50/5A,2.5VA 4
NG4
14 UN
R1(39)
1 GY
R2(40)
1 GY
Y1(37)
1 GY
Y2(38)
1 GY
B1(35)
1 GY
B2(36)
1 GY
RG3
12 UN
YG3
12 UN
BG3
12 UN
NG
14 UN
RM2
12 UN
YM2
12 UN
BM2
12 UN
NM
14 UN
10.6 10.6 10.6 10.6 10.6 10.6
1 3 5 7 1 3 5 7
-8K1 -8K2
/8.7 /8.2
50A,240VAC 2 4 6 8 50A,240VAC 2 4 6 8
GENSET MAINS
CONTACTOR CONTACTOR
RG2
12 UN
YG2
12 UN
BG2
12 UN
NG
14 UN
1 3 5
1
-7NL1
RM
YM
BM
NM
40A
12 UN
12 UN
12 UN
14 UN
-7F1
50A/3P,06KA
2 4 6
-X1
4
RG
YG
BG
NG
10 RD/12 UN
10 YE/12 UN
10 BU/12 UN
6 BK/14 UN
RM RM1
/ 10.5
1 RD FUSE 6A 1 RD
TO CONTROLLER
MAINS SUPPLY
5
-X1 YM YM1
/ 10.4
1 YE FUSE 2A 1 YE
1
RG RG1 6
3PH.GENSET SUPPLY
/ 8.6 BM BM1
(BEFORE MCB ON)
1 RD 1 RD
TO CONTROLLER
FUSE 6A / 10.4
1 BU FUSE 2A 1 BU
2
YG YG1
/ 10.2 NM NM
1 YE FUSE 2A 1 YE / 10.4
1 BK 1 BK
3
BG BG1
/ 10.2
1 BU FUSE 2A 1 BU
CONTROL CKT
TO BATTERY
CHARGER &
NG NG MR2
/ 8.6 / 8.1
1 BK 1 BK 1 RD
NM
/ 8.1
1 BK
-R -Y -B -7N1
-XPTB2 1 2 3 4

SHEET NO.
00 NEW RELEASE 03/05/2019 URMILA 23290 23290 DRN BY URMILA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
KOEL DRAWING NO:
SCALE 4.00mm 3H.470.80.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S1 S2 1
RG4
6 UN
150/5A,2.5VA
230VAC,50Hz,1PH.
SUPPLY TO LOAD
2
NG
6 UN
J5/1
1 GY
J5/2
1 GY
NG
UN 6
RG3
6 UN
RM2
6 UN
NM
6 UN
10.6 10.6 S5 S6
S1 S2 SHORTLINKS
SHORTLINKS
CT CONNECTIONS
TO CONTROLLER
1 3 5 7 1 3 5 7
-8K1 -8K2
/8.7 /8.2
80A,240VAC 2 4 6 8 80A,240VAC 2 4 6 8
GENSET MAINS
CONTACTOR CONTACTOR
S3 S4 S7 S8
RG2
12 UN
YG2
12 UN
BG2
12 UN
NG
6 UN
NEUTRAL (N) BUSBAR AL 15X10MM

1 3 5
-7F1 -7NL1
50A/3P,06KA
2 4 6
RG
16 RD
YG
16 YE
BG
16 BU
NG1
25 BK
NG2
25 BK
RM
UN 6
NM
UN 6
-X1 -X1
1 4
RG RG1 RM RM1
/ 10.5
1PH.GENSET SUPPLY
/ 8.6 1 RD 1 RD
TO CONTROLLER
(BEFORE MCB ON)
1 RD 1 RD FUSE 6A
TO CONTROLLER
MAINS SUPPLY
FUSE 6A
NG NG NM NM
/ 8.6 / 10.4
1 BK 1 BK 1 BK 1 BK
CONTROL CKT
TO BATTERY
CHARGER &
MR2
/ 8.1
1 RD
-R -Y -B -7NL1-7NL2 NM FUSE TERMINAL,MAKE-CONNECTWELL/WAGO, TYPE NO - CF4UL110-240V
-XPTB2 1 2
1 BK
/ 8.1

INCOMING FROM DG ALT. INCOMING FROM MAINS POWER TERMINAL BOARD EVEREST/REPUTED MAKE 2 WAY 150 AMP 10 MM STUD
POWER TERMINAL BOARD EVEREST/REPUTED MAKE 2 WAY 150 AMP 10 MM STUD

SHEET NO.
00 NEW RELEASE 07/05/2019 URMILA 23290 23290 DRN BY URMILA APPLICATION : POWER GENERATION Laxmanrao Kirloskar Road, Khadki, Pune - 411 003, (INDIA) Doc.Type : SCH
KOEL DRAWING NO:
SCALE 4.00mm 3H.471.90.0.PR 00
0 1 2 3 4 5 6 7 8 9
-7V1 -XPTB1
S2 S1 1
RG4
10 UN
-7V2
100/5A,2.5VA S2 S1 2
YG4
-7V3 SUPPLY TO LOAD
100/5A,2.5VA 3
S2 S1 BG4
10 UN
100/5A,2.5VA 4
NG4
14 UN
R1(39)
1 GY
R2(40)
1 GY
Y1(37)
1 GY
Y2(38)
1 GY
B1(35)
1 GY
B2(36)
1 GY
RG3
10 UN
YG3
10 UN
BG3
10 UN
NG
14 UN
RM2
10 UN
YM2
10 UN
BM2
10 UN
NM
14 UN
10.6 10.6 10.6 10.6 10.6 10.6
1 3 5 7 1 3 5 7
-8K1 -8K2
/8.7 /8.2
80A 2 4 6 8 80A 2 4 6 8
GENSET MAINS
CONTACTOR CONTACTOR
RG2
10 UN
YG2
10 UN
BG2
10 UN
NG
14 UN
RM
YM
BM
NM
10 UN
10 UN
10 UN
14 UN
1 3 5
-7Q1
75A/3P,10KA
MCCB
-7NL1
40A
I> I> I>
2 4 6
-X1
4
RG
YG
BG
NG
10 UN
10 UN
10 UN
14 UN
RM RM1
/ 10.5
1 RD FUSE 6A 1 RD
TO CONTROLLER
MAINS SUPPLY
5
-X1 YM YM1
/ 10.4
1 YE FUSE 2A 1 YE
1
RG RG1 6
3PH.GENSET SUPPLY
/ 8.6 BM BM1
(BEFORE MCB ON)
1 RD 1 RD
TO CONTROLLER
FUSE 6A / 10.4
1 BU FUSE 2A 1 BU
2
YG YG1
/ 10.2 NM NM
1 YE FUSE 2A 1 YE / 10.4
1 BK 1 BK
3
BG BG1
/ 10.2
1 BU FUSE 2A 1 BU
CONTROL CKT
TO BATTERY
CHARGER &
NG NG MR1
/ 8.6 / 8.1
1 BK 1 BK 1 RD
NM
/ 8.1
1 BK
-R -Y -B -7N1
-XPTB2 1 2 3 4

SHEET NO.
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
MR1 RG1
FROM MAINS R PHASE 7.6 / /12.8 TO BATTERY CHARGER FROM GENSET R PHASE 7.3 / /10.2 TO CONTROLLER
1 RD 1 RD
C1
-11RB2-RL1
/12.6
13.6
P1
MAINS FAIL
MR3A
1 GY
1 GY
1H
-S2 -S3 -S4
MANUAL AUTO MANUAL AUTO MANUAL AUTO
1 GY
RG3
1 GY
1 GY
1 GY
MR3
MR4
RG4
1 GY
1H1
-8S3
-8S3 /8.3
/8.6
GENSET CONT. ON
MAINS CONT. ON
11.7
O1 O1
-11RB1-RL1 -11RB1-RL2
/12.3 P1 /12.4 P1
1 GY
RG5
MC RELAY GC RELAY
1 GY
MR5
RG5
1 GY
MR5
1 GY
11 11
-8K1 -8K2
/8.7 12 /8.2 12
GENSET CONTACT MAINS CONTACT
1 GY
MR6
1 GY
RG6
MR6 RG6
1 GY 1 GY
A1 x1 A1 x1
-8K2 -8H1 -8K1 -8H2

80A,240VAC RED x2 80A,240VAC RED x2
A2 240VAC A2 240VAC
MAINS CONTACTOR GENSET CONTACTOR
LOAD ON MAINS LOAD ON GENSET
NM NM NG NG
MAINS NEUTRAL 7.6 /
1 BK 1 BK
/ 12.9 TO BATTERY CHARGER GENSET NEUTRAL 7.3 / 1 BK 1BK
/ 10.2 TO CONTROLLER
MAINS LOAD ON GENSET LOAD ON
CONTACTOR MAINS CONTACTOR GENSET
1 2 /7.4 1 2 /7.1
3 4 /7.5 3 4 /7.1
5 6 /7.5 5 6 /7.1
7 8 /7.5 7 8 /7.1
11 12 /8.7 11 12 /8.2
13 14 /13.4 13 14 /13.5

SHEET NO.
DRN DATE 09/05/2019 TITLE : Control drawing KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
1
-VE +VE
G CHARGING
-8ALTR1
1 ALTERNATOR
-IND1
-XC11 -XC1
7 5 5 7
0.75 GY
/ 11.6 IND
-8VBFS1
0.75 GY
-8CHTS1
-8WTS1 0.75 GY
13 14
-8FLS1
13 14 WATER SENSOR (OPTIONAL) 26 10 10 26
0.75 GY
/ 11.5 LUBE OIL TEMP.SENSOR
-8LLOPS1
12 11 LLOP SWITCH 12 4 4 12(C) LLOP SWITCH
/ 11.5
0.75 GY
CONTROL ON/OFF SW
-8S1
2A 2 2 2A 4 3 2A
1 GY 1 GY
1A 1 1 1A
1 GY
/ 11.3 BATT. -VE (1A)
1
1 11 11 1
2.5 GY
/ 11.3 BATT. -VE(1)
-8FLS1
13 14 FUEL LEVEL SENSOR 25 7 7 25 FUEL LEVEL SENSOR
/ 11.5
0.75 GY
6 6
12 12
1B 8 8 1B
0.75 GY
/ 11.5 LLOP -VE(1B)
-8SS1
STOP SOLENOID
A2 A1 6 13 13
4 GY
-8BATT.1 14 14
1
+VE -VE
BATTERY 15 15
12VDC
BC +VE
-8STA1
STARTER 12.8
-VE M +VE
2B
1.5 GY
-SOL1
-XC12 -XC2
1 1 6
4 GY
2 2
-8F1 2 1
2 2 2B BATTERY +VE
/ 11.1
4 GY 4 GY
32A/1P,06KA
3 3 3 3
2.5 GY
/ 11.2 STARTER
-8S1
2B/4 4 4 2B/4 14 13 2E
4 GY 1 GY
SHEET NO.
DRN DATE 09/05/2019 TITLE : Engine Wiring Harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
CT CONNECTION
7.3 7.3 7.2 7.3 7.2 7.2
SENSOR GND
GENSET MAINS
INSULATED BUTT
3PH SUPPLY 3PH SUPPLY SPLICE CONNECTOR
8.8 7.3 7.3 8.8 7.7 7.7 7.7 7.7 10.7

B1 B2 Y1 Y2 R1 R2
B1
1 BU
B2
1 BU
Y1
1 YE
Y2
1 YE
R1
1 RD
R2
1 RD
1
1 GY
NG
1 BK
BG
1 BU
YG
1 YE
RG1
1 RD
NM
1 BK
BM1
1 BU
YM1
1 YE
RM1
1 RD
-J6 1 2 3 4 -J7 1 2 3 4 1 2 3 4 5 6 7 8
-J8
-10GCU1
GENSET CONTROL 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
UNIT
GENSET I/P MAINS I/P CT I/P MPU I/P
GENSET CONTROL UNIT

USB
(KG 645 UNIT)
I/P:ANLG (0-5V / 4-20mA)
I/P:ANLG TEMP/DIG G
I/P:ANLGFL/DIG H
D+CHARGE ALT
I/P:ANLG/DIG F
DIGITAL O/P D
DIGITAL O/P C
DIGITAL O/P A
DIGITAL O/P B
DIGITAL O/P E
DIGITAL O/P F
DIGITAL I/P D
DIGITAL I/P C
DIGITAL I/P A
DIGITAL I/P B
DIGITAL I/P E
E-GOV OUT 3
E-GOV OUT 2
E-GOV OUT 4
E-GOV OUT 1
BATTERY
CAN HIGH
CAN LOW
RS 485_A
RS 485_B
12/24V
+VE -VE
26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
-J5 1 2 3 4 5 6 7 8 9 10 -J4 1 2 3 4 5 6 -J3 1 2 3 4 -J2 1 2 3 4 -J1 1 2

26
0.75 GY
25
0.75 GY
24
0.75 GY
23
0.75 GY
21(D)
0.75 GY
10(A)
0.75 GY
9(F)
0.75 GY
8(E)
0.75 GY
7
0.75 GY
5(A)
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
3(A)
0.75 GY
2
1 GY
1
1 GY
1
1 GY
22
0.75 GY
12(C)
0.75 GY
11(B)
0.75 GY
11.5 11.5 11.5 11.6 13.7 11.6 11.6 12.4 12.3 11.6 12.6 11.3 11.3 11.3 11.4 11.4 10.7
SENSOR GND
MAINS FAIL
IND
DC SUPPLY +VE
DC SUPPLY -VE
WATER TEMP SENSOR
START
4-20mA SENSOR
MAINS RELAY
AUTO START
GENSET RELAY
FAULT
FUEL LEVEL SENSOR
STOP
SEMI AUTO
CYL.HEAD TEMP SW/
11.6 11.6
LUBE OIL TEMP.SENSOR
LLOP SWITCH
EMG

SHEET NO.
DRN DATE 09/05/2019 TITLE : KG645 Controller Diagram KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
R2- STOP RELAY (70A) -C4 = 10 PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 010R) WITH FEMALE PINS
R3- COMMON FAULT RELAY (6A) -C5 = 6 PIN FEMALE CONNECTOR PHONIX MAKE(TYPE-MVSTBW 2.5/ 6-ST-5.08)
R4- AUTO START RELAY (6A) -C6 = 8 PIN CONNECTOR MOLEX MAKE (TYPE MOLEX 5557- 08R) WITH FEMALE PINS

-VE
CYL.HEAD TEMP SW/

FUEL LEVEL SENSOR
WATER TEMP.SEN
4-20mA SENSOR
DC SUPPLY +VE
DC SUPPLY -VE
LLOP SWITCH
/ 11.4
AUTO START
START
FAULT
STOP
EMG
IND
/ 10.6
/ 10.6
/ 10.6
/ 10.5
/ 10.7
/ 11.1
/ 10.7
/ 10.2
/ 10.2
/ 10.1
/ 10.5
/ 10.4
/ 10.2
/ 10.2
/ 10.4
OUTPUT
3(A)
0.75 GY
5(C)
0.75 GY
4(B)
0.75 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
2
1 GY
1
1 GY
1
1 GY
7
0.75 GY
10(A)
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
SPARE
1
1 GY
1
1 GY
1
1 GY
-C9 1 2 3 4 5 6 7 8 -C8 1
2
-C7 1
2 3 4 5 6 -C6 1 2 3 4 5 6 7 8
+VE -VE
R4
A1 A1 A1
R1 R2 R3 F3
A2 A2 A2 500mA
F1 F2 A1
3.75A 3.75A R4 R3
A2
R2 R1
DC INTERFACE CARD
-C2 1 2 3 4 -C3 2 3 4 5 6 -C4 2 3 4 5 6 7 8 9 10 -C5 1 2 3 4 5 6

1 1
COMMON SPARE
-VE SPARE
+VE SPARE
FAULT OUTPUT
SPARE
2E
1 GY
1A
1 GY
2A
1 GY
1A
1 GY
25
0.75 GY
24
0.75 GY
26
0.75 GY
7
0.75 GY
12(C)
0.75 GY
21(D)
0.75 GY
23
0.75 GY
11(B)
0.75 GY
11(B)
0.75 GY
2F
0.75 GY
1H1
1 GY
6
4 GY
3
2.5 GY
2B
4 GY
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
9.7 /
CANOPY EMG. 13.1 /
CANOPY LAMP 13.2 /
8.9 /
AUTO START
IND
STOP SOLENOID
CONTROLLER +VE
CYL.HEAD TEMP SW/

STARTER
FUEL LEVEL SENSOR
WATER TEMP.SEN

3
BATTERY +VE 9.7 / 4
10S2
EMG. STOP
OPTIONAL
-X2
1
LLOP SWITCH 12(C) 12(C)
9.7 /
0.75 GY 0.75 GY
2
1B 1
-VE(1A) 9.7 /
0.75 GY 1 GY
3
1A
1 GY
23
0.75 GY
4
2E 2E RMS MODULE
/ 12.0
1 GY 1 GY
2E
CONTROL ON +VE 9.7 /
1 GY
1 1
-VE(1) 9.7 / / 12.0 -VE(1)
2.5 GY 1 GY
CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE -VE(1A) 1A 1A
9.7 / / 13.4 -VE(1A)
1 GY 1 GY

SHEET NO.
DRN DATE 09/05/2019 TITLE : DC Interface Card Diagram KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
2E /13.1
BATT. +VE 11.7 /
1 GY BATT. +VE
1 1
BATT. -VE 11.7 /
1 GY 1 GY
/ 13.1 BATT. -VE
1
1 GY
MAINS FAIL RELAY
BATT. +VE
BATT. -VE
GENSET RELAY
MAINS RELAY
12.9 /
BATT. -VE
/ 12.2
/ 9.5
2E
1 GY
1
1 GY
1
1 GY
1
1 GY
1
1 GY
/ 10.5
/ 10.5
/ 10.6
2B
1.5 GY
1
1 GY
1 2
8(E)
0.75 GY
9(F)
0.75 GY
5(A)
0.75 GY
-XC5
-11RB1 -11RB2
-11KRM1 1 2 RELAY BOARD RELAY BOARD
9 to 36V 2CH. 2C/O 12V DC RL1:1(+) RL1:1(-) RL2:2(+) RL2:2(-) 1CH. 2C/O 12V DC RL1:1(+) RL1:1(-)
UL MAKE UL MAKE
2H.226.33.0.00 RELAY COIL SUPPLY RELAY COIL SUPPLY RELAY COIL SUPPLY
-11BC1
RL1 RL2 RL1 12V,2Amp
BATTERY CHARGER
5A 5A 5A
+VE -VE
C1 O1 P1 C2 O2 P2 C1 O1 P1 C2 O2 P2 C1 O1 P1 C2 O2 P2
C1:1 O1:1 P1:1 C2:1 O2:1 P2:1 C1:2 O1:2 P1:2 C2:2 O2:2 P2:2 C1:1 O1:1 P1:1 C2:1 O2:1 P2:1
x2
RMS MODULE O1 P1 /8.4 O1 P1 /8.8 C1 P1 /8.3

BC
x1
RMS MODULE
P N E
MR1
1 RD
NM
1 BK
8.4 /
8.4 /
RMS UNIT CONNECTOR

SHEET NO.
DRN DATE 09/05/2019 TITLE : Gc&Mc Relay KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
0 1 2 3 4 5 6 7 8 9
BATT. +VE 2E
12.3 /
1 GY
1
BATT. -VE 12.8 /
1 GY
TO CONTROLLER
CANOPY LAMP
ON/OFF SW
/ 10.2 SEMI AUTO

EMG. STOP
/ 11.7 BATT. -VE

2E
1 GY
2E
1 GY
START
AUTO
/ 11.7
/ 11.7
/ 8.9
13 13
-8K2 -8K1
/8.2 14 /8.7 14
LDM1 LDG1
2F
0.75 GY
2E
1 GY
2E1
1 GY
2E1
1 GY
-12S2 -X4 1
3
1 2 6A
-X5 1 -X5 2 FUSE
300MA 300MA
4 FUSE
FUSE
11(B)
0.75 GY
1
1 GY
23
0.75 GY
1
1 GY
1H
1 GY
2E(A)
1 GY
22(D)
0.75 GY
1
1 GY
LDM
0.75 GY
1A
1 GY
LDG
0.75 GY
1 2 3 4 1 2 3
-XC3 -XC4 -X3 1 2 3 4
-XC13 -XC14
1 2 3 4 1 2 3
FROM EXTERNAL PANEL

11
23
1A
-LDM -COMMON -LDG
13 x1
14 x2 (ON CANOPY)

CANOPY DESIGN

-X3 = CONTROL TERMINAL 4 SQ.MM.,600V,25A,TYPE-CTS4UN,CONNECTWELL MAKE FUSE TERMINAL,MAKE-CONNECTWELL/WAGO, TYPE NO - CF4UL110-240V
-XC3 = 4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONNECTOR MALE PINS) -X5 = 230V AC FUSE TERMINALS
CANOPY WIRING HARNESS CONNECTOR
-XC13 =4 PIN CONNECTOR POWERMAT/MOLEX MAKE (FEMALE CONECTOR MALE PINS)

SHEET NO.
DRN DATE 09/05/2019 TITLE : Canopy Wiring Harness KIRLOSKAR OIL ENGINES LTD.,
KOEL DRAWING NO:
SCALE 4.00mm 3H.465.50.0.PR 00
Diesel Genset
R1040 series Diesel Engine

D1. Engine Description ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.1 Engine numbering system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.1.1 Engine name plate ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.1.2 Engine number system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐1
D1.1.3 Model designation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐2
D2. General ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.1 Your engine needs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.2 Service and Maintenance‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.3 Maintenance and Repairs‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D2.4 Safety ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐3
D3. Engine Illustration ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐4
D3.0.1 Air Inlet Manifold Side, 2R1040 G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐4
D3.0.2 Exhaust Side, 2R1040 G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐5
D3.0.3 Air Inlet Manifold Side, 3R 1040T G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐6
D3.0.4 Exhaust Side, 3R 1040T G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐7
D3.0.5 Air Inlet Manifold side, 3R1040TA G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐8
D3.0.6 Exhaust side, 3R1040TA G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐9
D3.0.7 Air Inlet Manifold side, 4R 1040TA G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐10
D3.0.8 Exhaust Side, 4R 1040TA G1 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐11
D3.1 Engine lifting device ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12
D3.1.1 For bare engine – R1040 ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12
D3.2 Lube Oil System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12
D3.2.1 Lube oil circuit ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12
D3.2.2 Lube oil pump ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐12
D3.2.3 Lubrication System for R Series Engines ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐13
D3.2.4 Lube Oil Pressure ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐14
D3.2.5 Lube oil temperature ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐14
D3.2.6 Lube Oil Sump Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐14
D3.2.7 Using Lube Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐15
D3.2.8 Quality Grade ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐16
D3.2.9 Viscosity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐16
D3.3 Fuel System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17
D3.3.1 Fuel Circuit ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17
D3.3.2 Fuel Specifications ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐17
D3.3.2.1 Winter Grade Fuel ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐18
D3.3.3 Storing Fuel Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐18
D3.4 Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐18
D3.4.1 Radiator type cooling system ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐18
D3.4.2 Coolant ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐19
i
Diesel Genset
D3.4.2.1 Coolant Recommendation. ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐19
D3.5 Electrical System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐19
D3.5.1 Electrical Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐19
D3.5.2 Battery Cable ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐20
D3.5.2.1 Recommended Battery Capacity ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐20
D4. Engine Operation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐20
D4.1 Commissioning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐20
D4.1.1 Filling Engine Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐20
D4.1.2 Filling Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐21
D4.1.3 Checking V‐Belts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.1.4 Checking Valve Clearance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.1.5 Other Preparations ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.2 Starting and Stopping ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.2.1 Lubrication System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐22
D4.2.2 Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.3 Electrical System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.4 Mechanical ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.5 Procedure of Starting and Stopping ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.5.1 Starting the Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐23
D4.2.5.2 Stopping The Genset ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3 Running in period‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3.1 After first 50 hours running ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.3.2 After first 100 hours running ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐25
D4.4 Engine Cleaning and Preservation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D5. Routine Maintenance‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐26
D5.1 Maintenance Schedule ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐27
D5.2 Maintenance Log ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐29
D5.2.1 Period of Top Overhaul and Major Overhaul ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐30
D6. Service & Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐30
D6.1 Maintenance of Lube System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐30
D6.1.1 Checking Oil Level ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐30
D6.1.2 Draining Engine Oil ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐31
D6.1.3 Oil Drain Plug ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐32
D6.1.4 Removing Lube Oil Filter ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐32
D6.1.5 Changing Lube Oil Filter ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D6.1.6 Assembling Lube Oil Filter ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐33
D6.2 Maintenance of Fuel System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐34
D6.2.1 Changing Fuel Filter ‐ Spin On Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐34
D6.2.2 Changing Fuel Filter ‐ Element Type ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐35
D6.2.3 Fuel Strainer / Button Filter ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐36
D6.3 Maintenance of Cooling System ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37
ii
Diesel Genset
D6.3.1 Radiator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37

D6.3.2 Cleaning of Radiator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37
D6.3.2.1 External Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐37
D6.3.2.2 Internal Cleaning ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐38
D6.3.3 Thermostat ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐38
D6.4 Maintenance of Dry Type Air Cleaner ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐39
D6.4.1 Introduction of Dry Type Air Cleaner ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐39
D6.4.2 Maintenance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐40
D6.4.2.1 Discharging Vaccuator Valve ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D6.4.2.2 Removing Air Cleaner Housing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D6.4.2.3 Cleaning Procedure ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐41
D6.4.2.4 Cleaning of Filter Element ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐42
D6.4.2.5 Inspection of Air Cleaner Element ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐42
D6.4.2.6 Assembling Rubber Sealing Ring ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐43
D6.4.3 Checking V‐belt Tension ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐43
D6.4.4 Valve Clearance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐44
D6.4.5 Checking Valve Clearance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐44
D6.4.6 Adjusting Valve Clearance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45
D6.5 Maintenance of Electrical Equipment ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45
D6.5.1 Battery Charging Alternator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐45
D6.5.2 Checking Battery and Cable Connectors ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46
D6.5.3 Checking Electrolyte Level ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐46
D6.5.4 Checking Electrolyte Density ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐47
D6.6 Additional Jobs ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48
D6.6.1 Exhaust Silencer ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48
D6.6.2 Checking of Fasteners ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐48
D7. Engine Specifications ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐49
D8. Faults, Causes and Remedies ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐49
D8.1 Diagnosis Chart ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐49
D9. Tightening Torque ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐51
D9.1 Table for Fasteners ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐52
D9.2 Tightening Torque Sequence ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐52
D9.2.1 Torque Sequence for Cylinder Head Bolts ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐52
D9.2.1.1 2R1040 G1 Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐52
D9.2.1.2 3R1040T G1 Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐53
D9.2.1.3 4R1040 G1 Engine ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ D‐54
iii
Diesel Genset
R 1040 series Diesel Engine

D1. Engine Description
D1.1 Engine numbering system
D1.1.1 Engine name plate
Engine number is punched on the Name Plate which is fixed on the engine crankcase.
Figure D - 1: Engine Rating Plate
D1.1.2 Engine number system
Please furnish the complete engine number, so that matter concerning Customer Service and
Spare Parts can be more easily dealt with.
D-1
-
Diesel Genset
4H 3002 / 10 00001
Engine Serial Number
Year of Manufacture
Application Code (Build of the engine)
3H - 3R1040
4H - 4R1040
5H - 4R1190
6H - 6R1080
Figure D - 2: Engine Number System
D1.1.3 Model designation
The engine model is punched on nameplate in column =TYPE‘. The information about engine
series, No of cylinders, Piston displacement in liter per cylinder and Aspiration is mentioned.
The examples are stated above will clarify the matter.
D-2
Diesel Genset
D2. General
D2.1 Your engine needs
•Clean high speed diesel oil.
•Lubricating oil of specified quality and viscosity grade.
-KOEL recommends use of K-Oil Premium.
•Fresh air for combustion of fuel, for cooling of genset / radiator.
•Genuine spare parts for its maintenance.
•K - Cool Super Plus Coolant to avoid rust formation.
D2.2 Service and Maintenance
•Sound service and maintenance practices will ensure that the engine continues to meet your
requirements.
•Recommended preventive maintenance at regular intervals must be observed. The service

and maintenance work should be carried out conscientiously.
•Special care should be taken under abnormally demanding operating conditions.
D2.3 Maintenance and Repairs
•Shut down the engine before carrying out maintenance or repair work.
•When the work is complete, be sure to install safety devices that may have been removed.
•If you have to work on a running engine, ensure that all clothing is tight fitting and cannot
entrap the moving parts.
•Observe all industrial safety regulations when engine are operating in enclosed spaces or
underground.
•Please contact your KOEL dealer for spare parts enquiry. Use only genuine spare parts.
D2.4 Safety
• All Safety instructions (for both engine and operator) in this manual are designed by the
accompanying symbol. Please follow them carefully.
•The attention of operating personnel should be drawn to these instructions.
•General safety and accident prevention regulations laid down by law must also be observed.
D-3
Diesel Genset
D3. Engine Illustration
D3.0.1 Air Inlet Manifold Side, 2R1040 G1

Figure D - 3: Air Inlet Manifold Side, 2R1040 G1
Table 1: Air Inlet Manifold Side, 2R1040 G1
Number Item
1 Rocker Cover
2 Air Inlet Manifold
3 Fuel Injection Pump
4 Fuel Filter
5 Gear End Mounting Foot
6 Lube Oil Filter
7 Flywheel End Mounting Foot
8 Flywheel
9 Flywheel Housing
D-4
Diesel Genset
D3.0.2 Exhaust Side, 2R1040 G1

Figure D - 4: Exhaust Side, 2R1040 G1
Table 2: Exhaust Side, 2R1040 G1
Number Item
10 Air Cleaner
11 Breather Pipe
12 Starter
13 Crankcase
14 Lube Oil Drain Plug
15 Lube Oil Sump
16 Crank Pulley
17 Belt
18 Charging Alternator
19 Thermostat
20 Exhaust Manifold
21 Lifting Hook
D-5
Diesel Genset
D3.0.3 Air Inlet Manifold Side, 3R 1040T G1
Figure D - 5: Air Inlet Manifold Side, 3R 1040T G1
Table 3: Air Inlet Manifold Side, 3R 1040T G1
Number Item
1 Crankcase
2 Flywheel
3 Flywheel Housing
4 Lube Oil Sump
5 Lube Oil Filter
8 Fuel Filter
11 Lifting Hook
12 High Pressure Pipes
13 Rocker cover
14 Dipstick
D-6
Diesel Genset
D3.0.4 Exhaust Side, 3R 1040T G1
Figure D - 6: Exhaust Side, 3R 1040T G1
Table 4: Exhaust Side, 3R 1040T G1
Number Item
15 Air Cleaner
16 Air Cleaner Hose
17 Starter
18 Breather Pipe
19 Air Pipe
20 Thermostat
21 Water Pump
23 Belt
24 Crank Pulley
25 Gear Casing
26 Exhaust Manifold
27 Turbo Charger
D-7
Diesel Genset
D3.0.5 Air Inlet Manifold side, 3R1040TA G1
Figure D - 7: Air Inlet Manifold side, 3R1040TA G1
Table 5: Air Inlet Manifold side, 3R1040TA G1
Number Item
1 Crankcase
2 Flywheel
3 Flywheel Housing
4 Lifting Hook
6 Rocker Cover
7 Fuel Filter
9 Lube Oil Filter
10 Lube Oil sump
11 CAC Pipe
12 High Pressure pipes
13 Dipstick
D-8
Diesel Genset
D3.0.6 Exhaust side, 3R1040TA G1
Figure D - 8: Exhaust side,3R1040TA G1
Table 6: Exhaust side, 3R1040TA G1
Number Item
16 Gear casing
17 Crank Pulley
18 Belt
19 Water Pump
20 Thermostat
21 Exhaust Manifold
22 Turbocharger
23 Air Cleaner
24 Air Cleaner Hose
25 Starter
26 Breather Pipe
D-9
Diesel Genset
D3.0.7 Air Inlet Manifold side, 4R 1040TA G1
Figure D - 9: Air Inlet Manifold side, 4R 1040TA G1
Table 7: Air Inlet Manifold side, 4R 1040TA G1
Number Item
1 Crankcase
2 Flywheel
3 Flywheel Housing
4 Air Cleaner
5 Dipstick
6 Lube Oil Sump
11 High Pressure Pipes
12 Lube Oil Filter
13 CAC PIPE
14 Rocker Cover
15 Lifting Hook.
D-10
Diesel Genset
D3.0.8 Exhaust Side, 4R 1040TA G1
Figure D - 10: Exhaust Side, 4R 1040TA G1
Table 8: Exhaust Side, 4R 1040TA G1
Number Item
16 Gear casing
17 Crank Pulley
18 Belt
19 Thermostat
20 Water pump
22 Exhaust Manifold
23 Air Cleaner Hose
24 Turbocharger
25 Starter
26 Breather Pipe
D-11
Diesel Genset
D3.1 Engine lifting device
D3.1.1 For bare engine – R1040
Figure D - 11: Recommended Lifting Device

Before lifting the engine first fix the lifting hooks on the engine and then lift the engine. The
lifting hooks provided on the engine are meant for lifting only the bare engine. Avoid lifting
engine + equipment with only the engine lifting hooks as it could damage the engine or
equipment and cause breakage.
D3.2 Lube Oil System
D3.2.1 Lube oil circuit
Force feed lubrication is provided by a Gerotor type pump to main bearings, large end
bearings, camshaft journals, valve gear etc.
Other components like connecting rod small end bushes, cylinder liners and gear train are
splash lubricated. Oil supply to valve gear is achieved through rocker shaft core hole; the oil
supply is controlled to the valves and rocker arm by oil metering screw, which results into lower
oil consumption and lower carbon deposition.
The system includes adequate filtering by replaceable ‘Spin-on‘ filter cartridge. The water-
cooled lube oil cooler is provided to maintain the oil temperature within limits. A relief valve
controls the maximum oil pressure, which is provided on delivery side of the lube oil pump.
D3.2.2 Lube oil pump
Table 9: Lube oil pump delivery
3R1040T G1 & 3R1030TA G1

Engine type 2R1040 G1
/ 4R1040TA G1
Engine rpm 1500
Lube oil pump rpm 1680
Delivery liters/minutes at 4kg/cm2 pressure 21 30
D-12
Diesel Genset
D3.2.3 Lubrication System for R Series Engines
A schematic diagram shows the lubricating oil circuit of a typical R1040 / R1080 series engines
Figure D - 12: Lubrication System for R1040 Engine
Table 10: Lubrication System for R Series Engines
Number Item
1 Lube oil sump
2 Suction tube
3 Lube oil pump
4 Pressure relief valve
5 Delivery pipe
6 Delivery body
7 Plate type oil cooler
8 Lube oil filter
9 Safety valve (not shown) (In-built in lube oil filter)
10 Oil gallery (Main)
11 Main bearing
12 Large end bearing
D-13
Diesel Genset
Table 10: Lubrication System for R Series Engines (Continued)
Number Item
13 Camshaft bearing
14 Tappet
15 Push rod
16 Rocker arm bearing
17 Metering plug
18 Rocker shaft
19 Oil passage in cylinder head
Oil spray nozzle for piston cooling (Not shown)

20
(Used on Turbo charged & Turbo charged after cooled engines
21 Fuel pump connected to lube oil
D3.2.4 Lube Oil Pressure
Table 11: Lube Oil Pressure
Engine Speed Oil Pressure
At low idling speed Minimum 1.5 Kg/cm2
At loaded condition in operating range 2.5 to 5.5 Kg/cm2
If the lube oil pressure at any time drops below 1.5 kg/cm2 at operating speed of 1500 rpm,
under loaded condition, then replace the lube oil filter cartridge and check the pressure. If the
pressure is still low, then contact your KOEL Dealer.
D3.2.5 Lube oil temperature
The maximum lube oil temperature for R1040 series engines is ambient temperature plus 80
0C. For example if ambient temperature is 40 0C, the maximum lube oil temperature should
be 120 0C. Note :- During the running in period of first 50 hours, never exceed ‘full load‘ even
for a short duration; this is applicable for stationary applications like power generation
application.
D3.2.6 Lube Oil Sump Capacity
The lube oil sump capacities of R1040 series engines are as below. These capacities are for
the standard sheet metal sumps.
D-14
Diesel Genset
Table 12: Lube Oil Sump Capacity
Engine type 2R1040 G1 3R1040T G1 /TA G1 4R1040TA G1
Oil sump type Sheet Metal
First fill (lit.) 6 9 11.5
Max (lit.) 5.5 8 10
Min (lit.) 3 6 8
D3.2.7 Using Lube Oil
The oil must be changed at least once in a year. This is applicable to the engines which are
running for standby duty application.
Note:
•Initial Fill = Sump capacity + Gallery capacity + Lube oil filter capacity.
•Fill the Lube oil filter with oil before fitting on the engine.
•Whenever Lube oil filter is drained off, add approximately 0.5 litre to 1 liter extra lube oil (as
per the size of the Spin-on filter cartridge) in the sump to maintain the correct oil level.)
•The oil level in the sump should be checked at room temperature by using dipstick.
•Top up with fresh oil when the level reaches the low level mark on dip stick, fill till it increases
to top level mark. Avoid over filling.
•The engine should be lubricated only with the specified oil. This specially blended engine oil
designed for the best performance of your genset.
•Using the specified oil has the following advantages:
-Extra protection against corrosion and rusting.
-Excellent performance at both high and low temperatures.
-Reduced fuel consumption.
•Usage of improper lube oil could result in:
-Overheating of the engine.
-Sluggish performance.
-Excessive fuel consumption.
-Increased wear of bearings and other parts.
•The specified K-Oil Premium oil is available only through KOEL’s authorized service dealers
in suitable packing.
D-15
Diesel Genset
D3.2.8 Quality Grade
K-Oil Premium lube oil is recommended to use in the engine. It has the correct viscosity and
detergency grades for the best all round performance..
Warranty is applicable on use of ‘K-Oil Premium’ engine oil only.
D3.2.9 Viscosity
Multi-grade oil should be used. As the viscosity of lube oil is dependent on temperature, the
choice of SAE grade should be governed by the ambient temperature prevailing at the engine
operating site. Optimum operating behavior will be attained if you take the accompanying oil
viscosity diagram as a guide. Should be temperature fall temporarily below the limits of the
SAE grade selected, cold starting may be affected but the engine will not be damaged.
In order to keep wear to a minimum, do not exceed application limits for extended period of
time.
Figure D - 13: Viscosity
D-16
Diesel Genset
D3.3 Fuel System
D3.3.1 Fuel Circuit
NON RETURN VALVE

INJECTOR OVER FLOW
FUEL
FUEL PUMP OVER FLOW

INJECTORS TANK
HAND PRIMING DRAIN

PUMP PLUG
FUEL
MICRO FILTER PRE-FILTER PUMP
FEED PUMP
WATER SEPARATOR
PRE-FILTER
Figure D - 14: Fuel Circuit

Fuel is supplied to the block type fuel pump by a fuel lift pump (feed pump) incorporated in the
fuel pump itself. A dual type spin-on fuel filter consisting of efficient pre and micro paper filter
cartridges ensures the supply of clean fuel to the fuel pump. The schematic diagram above
shows the fuel circuit of the engine.
•It the fuel tank is to be installed below the fuel pump level, and then the bottom level of the
fuel tank should be less than 1 meter below the feed pump inlet.
•Fuel pipe from fuel tank to feed pump should be of 9 mm I.D.
D3.3.2 Fuel Specifications
The performance of the engine depends upon supply of clean and correct grade of fuel. The
fuel injection equipment is manufactured to very close tolerances and slightest amount of dirt in
fuel can cause wear on the injection equipment. Following points are important in use of fuel on
KOEL R1040 series engines.
The following specifications are approved: -
•IS:1460 - 2005
•ASTM D975-88:1-D & 2-D

D-17
Diesel Genset
D3.3.2.1 Winter Grade Fuel
At low temperatures, waxing may occur and clog the fuel system, thus causing operational
troubles.
In the case of ambient temperature below 10°C, use ‘Winter Grade‘ diesel fuel, mixed with
Kerosene. Proportion of Kerosene to be mixed in Diesel, depends on the ambient temperature
as shown in the graph. (Maximum proportion limited to 50%).
PREPARE THE BLEND IN THE TANK ITSELF. FILL IN THE NECESSARY AMOUNT OF
KEROSENE FIRST, THEN ADD DIESEL FUEL.
Figure D - 15: Winter Grade Fuel
D3.3.3 Storing Fuel Oil
•The storage of fuel oil is of utmost importance since many engine problems are traced to dirty
fuel or fuel stored for too long a period.
•Store fuel in a convenient place outside the building.
•It is recommended that the fuel tank should be filled in at the end of the day‘s work. This
keeps moisture out of the tank.
•To eliminate water from the fuel, drain out small quantity of fuel from fuel tank through a drain
plug every day before starting the engine.
D3.4 Cooling System
D3.4.1 Radiator type cooling system
The radiator type cooling system is used in R1040 / R1080 series engines.
D-18
Diesel Genset
The schematic diagram, of the typical coolant circuit with radiator type cooling system is shown
in the figure below.

Figure D - 16: Coolant Circuit
D3.4.2 Coolant
The engine uses a specially formulated coolant ‘K-Cool Super Plus.’ with demineralized water
and glycol. Use only K-Cool Super Plus coolant. Do not use ordinary water. K-Cool Super Plus
is available only through KOEL’s authorized dealer in suitable packing.
D3.4.2.1 Coolant Recommendation.
Use K-Cool Super Plus coolant in the cooling system.
D3.5 Electrical System
Standard engines are equipped with 12V, negative earth electrical starting system.
D3.5.1 Electrical Equipment
Table 13: Electrical Equipment for R series
12 V Electrical system
12V DC, 35 Amp

Alternator
12V DC, 55 Amp
12V DC, 2.0 KW
Starter 12V DC, 2.7 KW
12V DC, 3.0 KW
D-19
Diesel Genset
D3.5.2 Battery Cable
Battery Cable (Copper) = 35mm2
D3.5.2.1 Recommended Battery Capacity
Table 14: Battery Capacity
Genset with
Recommended Battery
Water Cooled Engine Series
2R 12 V, 75 AH
3R 12 V, 75 AH
4R 12 V, 100 AH
D4. Engine Operation
D4.1 Commissioning
Before you start a new or overhauled engine, attend following points:
D4.1.1 Filling Engine Oil
Fill the engine with Lube oil through oil filler as shown in figure below. For Quantity, refer to
“Lube Oil Sump Capacity” in D3.2.6 For Lube Oil grade, refer to “Quality Grade” in D3.2.8. For
Lube Oil Viscosity, refer to “Viscosity” in D3.2.9.
D-20
Diesel Genset

Figure D - 17: Engine Oil Filler
D4.1.2 Filling Cooling System
Figure D - 18: Initial filling of radiator
Add coolant only in Compensatory Bottle, do not open the radiator cap to fill coolant.
•Fill the cooling system with recommended K-Cool Super Plus.

D-21
Diesel Genset
•Fill the coolant through neck of radiator till it runs out through the radiator over flow pipe and
then connect the pipe to Compensatory Bottle.
•Coolant filling through radiator neck is recommended only for initial fill.
•For regular coolant top up, add coolant to the Compensatory Bottle.
•Do not open the radiator cap while engine is running or hot.
•The cooling system is under pressure hence danger of burning body skin.
•Add coolant when the coolant system is cold. The temperature difference between the
coolant in the engine and the coolant being added must not exceed 50oC.
D4.1.3 Checking V-Belts
Check that belts are in position and the belt tension is proper. If the belt tension is not proper
adjust the same as described in D6.4.3.
D4.1.4 Checking Valve Clearance
It is not necessary to check / adjust the valve clearance on a new engine as it is already
adjusted at its required value in factory. However after overhauling the engine, it is necessary
to recheck and adjust the valve clearance before starting the engine. Refer D6.4.6 for
adjustments.
D4.1.5 Other Preparations
Check battery and lead connections. Also check the cable connections at the starter and
alternator. Loose connections lead to improper contact and damage to the terminals.
•Remove lifting hooks after engine installation.
•After completing the preparations, run the engine for a short period of 10 minutes without
load.
-Check the engine for oil and water leakages. Rectify reasons for leakages, if any.
•After stopping the engine check following.
-With engine stationary, check the oil level. Top up the oil if necessary.
-Retighten the V belts.
D4.2 Starting and Stopping
D4.2.1 Lubrication System
Observe these precautions.
•Fill recommended grade of fresh oil in the sump up to the high mark of the dipstick.
•Add an additional 1/2 liter or 1 liter oil to compensate for the extra volume of the lube oil filter.
D-22
Diesel Genset
•Check and top up lube oil level in the oil sump after initial starting and stopping the engine.
D4.2.2 Cooling System
For Liquid Cooled Engines, observe the following points.
•Fill the radiator only with K-Cool Super Plus coolant.
•After starting the engine recheck the coolant level in the radiator and top up if required.
•The Compensatory Bottle on the radiator should also be filled as per the specified marking.
D4.2.3 Electrical System
•Check the battery for correct voltage and current capacity.
•Check that the battery cables are correctly connected and secure.
•Ensure correct polarity.
•Apply petroleum jelly on battery terminals.
•Ensure that all electrical wiring of the alternator is intact.
D4.2.4 Mechanical
•Ensure that all the fasteners in the foundation, couplings etc. are properly secured.
D4.2.5 Procedure of Starting and Stopping
•Before starting:
-Check the oil and coolant levels - top up if required.
-Ensure that there is sufficient fuel in fuel tank.
-Check the restriction indicator of air cleaner is indicating clear status.
-Clean the engine with a dry cloth.
-The engine’s control panel has a electronic controller that handles starting, running
and stopping the engine.
D4.2.5.1 Starting the Genset
•In this mode, the user starts and stops the engine. The user also transfers the load from
mains to genset and back, as required.
•Before starting, ensure load is disconnected from genset. Ensure people and material/tools
are clear of the engine.
D-23
Diesel Genset
•Check if Manual Mode is selected on the EMS controller by the lit state of lamp on the top left
of the MAN button. If not, operate MAN button once and verify the lighting of the lamp.
MAN
•To start the engine operate the Manual Start button once.
I
•The controller will initiate cranking to start the engine. If the engine fails to start, the controller
will try again. If the engine does not start despite several attempts, the controller indicates a
Start Failure condition and inhibit further cranking. See Controller section for more details.
•If engine fails to start, investigate the reasons before trying again.
•After engine starts:
-Check for leakages of fuel, oil and coolant.
-Allow engine to idle for 3 minutes and then start connecting load in steps.
-Check engine parameters like Oil pressure, coolant temperature and battery changing
rate at regular intervals, while the genset is in operation.
-Maintain log book.
-Check for exhaust smoke.
-Check for any abnormal sounds.
-Check for alternator parameters, like voltage, ampere, kW and Power Factor on all
phases.
-During commissioning, cross check the meter readings with a calibrated multimeter or
clamp - on meter.
-Ensure that the load is balanced in all phases and within rated output of the genset.
-Check that all gauges and meter provided in control panel are working.
•After starting:
-Allow the engine to run idle for about 3 minutes before loading the engine in steps.
-While the engine is running, check values of oil pressure, coolant temperature and
battery charging rate regularly.
-Check for alternator outputs like voltage and amps on all three phases for nearly equal
readings.
-Check the electrical parameters like Kilowatts, Power Factor and the Frequency.
•Before stopping:
-Unload the engine and let it run at idling speed for about 5 minutes.
D-24
Diesel Genset
-Check if lube oil pressure and coolant temperature have stabilized.
- The engine’s control panel has a electronic controller that handles starting, running
and stopping the engine.
-If engine fails to stop, investigate the reasons before trying again.
D4.2.5.2 Stopping The Genset
•Disconnect the load from the genset.
0
•Operate the Stop Button once. STOP
•The controller will keep the engine running for several minutes through Cool down timer to
ventilate the engine and alternator.
•After engine stops, check for any leakages.
•Top up fuel tank.
•Close the canopy securely.
•Switch off the Control Panel.
After stopping:
-Check for any fuel, oil and coolant leakages.
-Check the oil level 30 minutes after stopping and top up if required.
D4.3 Running in period
D4.3.1 After first 50 hours running
Change engine oil. For more details, see D6.1.2.
D4.3.2 After first 100 hours running
•Change the lube oil filter cartridge / element see D6.1.4.
•Check and retighten fasteners for lube oil sump if necessary.
•Check V belt tension and retighten if necessary see D4.1.3.
•Check engine for leakages of lube oil, fuel, water.
•Check the engine mounting bolts, retighten if necessary. See D6.6.2
•Retighten intake and exhaust manifold fasteners at cylinder heads.
•Check battery electrolyte level, top up if required.

D-25
Diesel Genset
D4.4 Engine Cleaning and Preservation
Remove the dust deposit from the engine and radiator fins with compressed air. Cleaning with
diesel fuel or kerosene or water may cause dust to deposit again on the cleaned parts.
Cleaning should be done from the side opposite to the normal air flow.
When deposits are hard, scrape and clean with a water jet. Run the engine after such cleaning
till all the water has evaporated.
When the engine is not used for some time, it should be protected from atmospheric moisture
and condensates that could damage the engine parts such as bearings, piston crankshaft, etc.
D5. Routine Maintenance
D-26
Diesel Genset
D5.1 Maintenance Schedule
Table 15: Maintenance Schedule
Every In Running Hours

10th Refer
Job
Hour/ 1st section
250 500 750 1000 2500 5000
Daily 50
* Engine oil level D6.1.1
* Coolant level in radiator

and compensatory tank
D6.3.1
* Restriction indicator of dry

type air cleaner
D6.4.1
* Rubber hose & clips of dry

type air cleaner/radiator
—
Engine oil (Every 500

X X X X X Hrs.)
D6.1.1
Lube oil filter cartridge

X X X X X (Every 500 Hrs.)
D6.1.5
Battery and lead

* connections (Every 50
Hrs.)
D3.5.2
V Belt condition and

* * * * tension (adjust / replace if
required)
D4.1.3
Radiator fins (depends on

+ + + + site condition) externally
D6.3.2.1
+ Radiator tubes internally D6.3.2.2
Fuel filter cartridge - Pre

filter (First change at 500
X Hrs., then after every 500
D6.2.1
Hrs.)
Fuel filter cartridge - Micro

filter (First change at 500
X Hrs., then after every 500
D6.2.2
Hrs.)
* * Injector —
+ + + + + + Fuel strainer (Button filter) D6.2.3
* Thermostat element
(change if necessary)
D6.3.3
D-27
Diesel Genset
Table 15: Maintenance Schedule (Continued)
Every In Running Hours

10th Refer
Job
Hour/ 1st section
250 500 750 1000 2500 5000
Daily 50
* * Valve clearance (adjust if

necessary)
D4.1.4
* * Starter / Alternator —
* * Fasteners —
* Exhaust silencer —
* = Check / Adjust, X = Change, + = Clean
D-28
Diesel Genset
D5.2 Maintenance Log
Table 16: Maintenance Log
Hour Date Remark Signature / Stamp
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
4250
4500
4750
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
D-29
Diesel Genset
Table 16: Maintenance Log (Continued)
Hour Date Remark Signature / Stamp
7500
7750
8000
8250
8500
8750
9000
D5.2.1 Period of Top Overhaul and Major Overhaul
The duration of the operating period before overhaul is dependant entirely on the quality of
maintenance and service given to the engine and also type of environment and engine load
cycle.
However, after about 5000 running hours engine will need top overhaul (servicing of
combustions system) and after about 9000 running hours engine will need major overhaul.
These periods are based on assumption that engine is maintained properly as per the
instructions given in this manual. Hence the above estimated overhaul periods are to be
referred as general guide lines.
Get the engine top overhauled or major overhauled from KOEL authorised service dealer. Use
genuine spare parts for top and major overhaul of the engine.
D6. Service & Maintenance
D6.1 Maintenance of Lube System
D6.1.1 Checking Oil Level
Figure D - 19: Checking Oil Level

D-30
Diesel Genset
•Stop thfe engine and wait for a while (Approximately 30 to 45 minutes) till oil level in the sump
is settled.
•Ensure that engine is in horizontal position.
•Pull out dipstick, wipe it with a non-fraying cloth and push it in as far as it will go and then
withdraw again.
•The film of oil left on the dipstick should extend to the upper (max.) mark.
•If the level approaches near to the lower mark, the oil should be topped-up without delay.
Failure to attend to low lube oil may result in serious damage to the engine (piston and
bearing seizure).
D6.1.2 Draining Engine Oil
Figure D - 20: Draining Engine Oil

•Run engine until it gets warm, (lube oil temp, approximately 80°C),
•Stop the engine, remove battery connections.
•Place oil tray under the engine.
•Unscrew oil drain plug on the end of drain pipe and drain the oil completely.
•Wait until last drop of oil exits the engine.
•Collect used oil in suitable receptacle ready for proper disposal to prevent environmental
pollution.
•Refit oil drain plug with new joint washer and tighten firmly.
D-31
Diesel Genset
D6.1.3 Oil Drain Plug
Filling Fresh Lube Oil

•Lube oil specifications – Use K-Oil Premium
•Lube oil sump capacity, refer “Lube Oil Sump Capacity” on page D-14.
•Do not flush the lube oil system with diesel or kerosene.
Take care when draining off hot oil: Danger of scalding!
D6.1.4 Removing Lube Oil Filter
Figure D - 21: Removing Lube Oil Filter

Replace =Spin-on‘ lube oil filter cartridge for every oil change.
•Release lube oil filter cartridge with special tool and spin off as shown in figure above.
D-32
Diesel Genset
D6.1.5 Changing Lube Oil Filter
Figure D - 22: Changing Lube Oil Filter

•Clean sealing surface of filter carrier.
•Fit the filter cartridge in dry condition. Do not fill oil in the filter before assembly.
•Apply light film of oil to rubber seal of new cartridge.
•Screw cartridge into place by hand until seal is evenly seated.
•Use genuine KOEL lube oil filter.
D6.1.6 Assembling Lube Oil Filter
•Tighten lube oil filter cartridge firmly by giving a final half turn as shown in figure below.
•Check oil level and lube oil pressure.
•Check seal of lube oil filter cartridge for leaks.
Figure D - 23: Assembling Lube Oil Filter
D-33
Diesel Genset
D6.2 Maintenance of Fuel System
D6.2.1 Changing Fuel Filter - Spin On Type
Figure D - 24: Removing Spin On Fuel Filter

•Removing the Fuel Filter.
-Remove the cartridge by rotating in anti-clockwise using commercial tool.
-Collect dripping fuel in a tray.
-Destroy the removed cartridge.
-Replace with a genuine KOEL fuel filter.
Keep naked flames away when working on they fuel system. Do not smoke!
Figure D - 25: Installing new Spin On Fuel Filter

•Installing the Fuel Filter.
-Clean the sealing surface of filter.
-Apply light film of oil or diesel fuel to the rubber gasket of the new fuel filter cartridge.
D-34
Diesel Genset
-Screw in the new cartridge finger tight against the gasket.
Figure D - 26: Tighten new Spin On Fuel Filter

•Tighten the Fuel Filter.
-Tighten the fuel filter cartridge with a final half turn using commercial tool.
-Open fuel stopcock.
-Check for leaks.
D6.2.2 Changing Fuel Filter - Element Type
Figure D - 27: Removing Element type Fuel Filter

•Removing the Fuel Filter.
-Close fuel valve.
-Unscrew the plug at bottom of bowls and collect the fuel in a tray.
-Unscrew the center bolt of bowls and remove bowls and fuel inserts.
-Clean the bowl with diesel.
-Change Pre-filter insert at 500 hours.
-Follow a similar process to change Micro-filter insert at 750 hours.
D-35
Diesel Genset
-Do not change Pre-filter insert and Micro filter insert at a time.
-Discard the removed insert.
-Change the sealing ring.
-Assemble the bowls and tighten centre bolts firmly.
-Bleed the fuel system before starting engine.
•No naked flames when working on the fuel system. No smoking!
•Do not clean and refit older fuel filter inserts. Always install a new insert at recommended
intervals.
•Do not change both the filter elements at a time.
D6.2.3 Fuel Strainer / Button Filter
Figure D - 28: Fuel Strainer / Button Filter

•Cleaning of Fuel Strainer/Button Filter:
-Remove banjo bolt at inlet of feed pump.
-Unscrew the strainer fitted inside the banjo bolt.
-Clean the fuel strainer in fuel and blow it with compressed air.
-Replace if necessary.
-Refit the fuel strainer in banjo bolt.
-Refit the banjo bolt to feed pump with new copper washer.
-Bleed the fuel system.

D-36
Diesel Genset
D6.3 Maintenance of Cooling System
Engine cooling system consists of radiator, fan, water pump and a thermostat. The electronic
engine controller stops the engine if the coolant temperature exceeds a preset level.
Check coolant level in the Compensatory Bottle every day before starting the engine. If
required add the coolant in Compensatory Bottle. Do not add coolant level beyond the Max.
mark on the Compensatory Bottle.
D6.3.1 Radiator
Figure D - 29: Initial filling of Radiator

Add coolant only when the engine is cold. The temperature difference between the coolant in
the engine and the coolant being added must not exceed 50 °C. Top up coolant in only in the
Compensatory Bottle. Top coolant through the radiator cap only at the time of commissioning.
Do not open radiator cap while the engine is running. Do not open radiator cap when
engine is hot, even if not running. The cooling system is under pressure. Danger of burning
skin!
D6.3.2 Cleaning of Radiator
D6.3.2.1 External Cleaning
D-37
Diesel Genset
Figure D - 30: Cleaning Radiator Fins

•Cleaning the radiator fins:
-Clean the radiator fins after every 400 hours. (Under very dusty conditions, increase
fins cleaning frequency.)
•For cleaning, blow pressurized air through radiator fins in reverse direction that of radiator fan
flow.
-Do not spill water on radiator fins.
-Clean cooling system after every 5000 hours while replacing coolant.
D6.3.2.2 Internal Cleaning
•The internal cleaning of radiator is done using ‘K Clean’ chemical.

-K Clean is designed to remove contaminants like scale, oil, grease, rust, loose
material that are present in the engine cooling systems.
-Add K Clean in the ratio of 375 ml. for every 16 litre capacity of radiator. Top up the
radiator with clean water (mineral or similar).
-Run the engine for minimum of 20-30 minutes.
-Stop the engine and allow the water to completely cool down.
-Drain coolant system completely.
-Refill the cooling system with plain clean water and run the engine for another 15-20
minutes for flushing the system.
-Allow the water to cool down and then drain the cooling system completely.
-Observe the drained water; if it still contents rust, scale and dirt, repeat the above
procedure for one more time.
-After cleaning, fill the system with K Cool Super Plus.
-Use of K Cool Super Plus has benefits such maximizing engine life and providing
optimum performance.
D6.3.3 Thermostat
Figure D - 31: Inspection of Thermostat

The cooling circuit uses a single element thermostat. Thermostat helps quickly attain working
temperature during warm-up period and maintains desired temperature of coolant during
D-38
Diesel Genset
running of the engine. Normally thermostat does not require regular maintenance. Its operation
should be checked only on occurrence of deviations from the specified coolant temperature. A
visual inspection is necessary to ensure proper seating of element. Replace the element if
seating is improper.
D6.4 Maintenance of Dry Type Air Cleaner
D6.4.1 Introduction of Dry Type Air Cleaner
Dry type air cleaner is available with plastic housing or sheet housing. The two types are
illustrated in the images below. Inlet cap or pre-cleaner attached ahead of air intake inlet
prevents ingress of rain and heavy particles.
Two filter elements are fitted coaxially in the air cleaner housing. The outer element is the main
filter element, with a built in cyclone separator that gives a swirling motion to incoming air, and
separate heavy dust particles by centrifugal action.
This dust is collected in the removable end cover. The vacuator valve at the bottom of cover
helps in expelling the accumulated dust. This is achieved by opening / closing of vacuator valve
outlet due to the airflow fluctuations inside the air cleaner. Inner element is a ‘Safety Element’
to prevent ingress of dust into the engine, when the outer (main) element is removed for
cleaning or replacement.
Figure D - 32: Dry Type Air Cleaner with Plastic Housing
D-39
Diesel Genset
Figure D - 33: Dry Type Air Cleaner with Sheet Metal Housing
D6.4.2 Maintenance
Regular check up and maintenance of the air cleaner is essential to ensure maximum
protection to the engine from the dust.
•Damaged hose / clips must be replaced immediately. Any bypassing of unfiltered air through
cracks in the hose / loose hose will quickly lead to serious damage to the engine.
•The pre-cleaner (if provided) should be cleaned, to remove the accumulated dust, after each
day‘s work, when the engine is stopped. This cleaning can be done by removing the top cover
of pre-cleaner.
•The restriction indicator, mounted on air cleaner near the hose, indicates the condition of the
air cleaner element, when the air element is in good condition, a red signal will be seen
through the transparent window on the indicator when the engine is running and will
disappear when engine is stopped. However, if the element is choked, then the red signal will
remain =ON‘ even after engine is stopped. This is an indication that the main filter element
must be removed, cleaned or replaced.
-Do not clean the air cleaner element if restriction indicator does not show red band.
-If engine performance is poor, but restriction is still within limits, do not change the
element. The air cleaner is probably not at fault.
-To get extra service hours out of air cleaner element, make sure the air inlet is away
from any heavy dust clouds caused by operation. Make sure that exhaust carbon
cannot enter the air cleaner.
This is a dry type air cleaner. Ensure that not even a single drop of oil comes in
contract with the air cleaner. Protect air cleaner from ingress of rain / moisture.
D-40
Diesel Genset
D6.4.2.1 Discharging Vaccuator Valve
Figure D - 34: Discharging Vaccuator Valve

•Discharge the dust vaccuator valve by squeezing the lips of ejection slot, as shown above.
•Clean the vacuation slot periodically.
•Remove any dust caked on the valve by pressing together the upper part of the valve.
•Ensure that vacuator valve is not damaged, if required, change the part.
D6.4.2.2 Removing Air Cleaner Housing
Figure D - 35: Removing Air Cleaner Housing

Cleaning of filter element is to be done only when a restriction indicator shows a red signal
even after the engine is stopped.
D6.4.2.3 Cleaning Procedure
•Loosen the mounting band of the dust cup, remove outer element for checking and cleaning
as shown in Refer to Figure D - 38 on page D41.
•Do not remove inner element which is the safety element.
•Use a damp cloth to wipe all visible dust in the air cleaner.
•Thorough cleaning of the fitter element with compressed air is recommended.
D-41
Diesel Genset
D6.4.2.4 Cleaning of Filter Element
Figure D - 36: Cleaning Air Filter Element with Compressed Air

•Clean the element from inside towards outside by blowing compressed air as shown in above
figure.
•Replace the main element after two cleaning intervals.
•Avoid rapping, tapping or pounding the dust out of element as it will result in severe damage
to the filter element.
An excessive air pressure can tear the filter paper and destroy the element. (Maximum
Air Pressure is 3.0 kg/cm2)
D6.4.2.5 Inspection of Air Cleaner Element
Figure D - 37: Inspection of Air Cleaner Element

•Conducting a ‘Light’ test:
-Carefully check new or properly cleaned element for damage before installing.
-Conduct a light test by passing the light through element as shown in figure above.
-If there is any crack in the element, the light will pass through it.
-Replace a cracked element with a new part.

D-42
Diesel Genset
D6.4.2.6 Assembling Rubber Sealing Ring
Figure D - 38: Assembling Rubber Sealing Ring

•Inspect the rubber-sealing ring at the end cover of the element.
•Replace sealing ring in case of any cracks or damage.
•The inner element (Safety element) is not to be removed, when the main element is removed
for cleaning / replacement. A new safety element should be replaced every time the main
element is changed.
•Assemble the cleaned or new element in the air cleaner body and reinstall the end cover,
making sure it seals all around the air cleaner body.
•Reset the restriction indicator by operating the button at the top.
•For certain application involving extremely dusty environment, we recommend use of series
air cleaner systems, i.e. dry type air cleaner in series with oil bath air cleaner.
D6.4.3 Checking V-belt Tension
A single V belt of NPA/XPA section or Poly V belt is used to drive engine water pump, radiator
fan and battery charging alternator for R1040 engines.
•Inspect V-belts over whole length for damage or cracks. Renew damaged or cracked v-belt.
•Check the tension by pressing midway between the pulleys to see whether the belt deflects
inwards by a maximum of 10 to 15 mm as shown below.
Figure D - 39: Checking V-belt tension

D-43
Diesel Genset
•If necessary re-tension V-belt by loosening and re-tightening the battery charging alternator.
•Never check / re-tension / renew V- belt while engine is running.
•Refit V-belt guard, if provided.
D6.4.4 Valve Clearance

Figure D - 40: Valve Clearance

The valve clearance is the requisite gap between the rocker arm toe and valve stem end. See
figure above. Engine performance and power output depend on its correct setting, which can
be done by a skilled mechanic according to the instructions in D6.4.6.
D6.4.5 Checking Valve Clearance
•Check clearance when engine is cold, at room temperature.

•Remove the rocker cover.
•Turn crankshaft until the valves of the cylinder (on which the clearance is being checked) are
overlapping. (exhaust valve about to close, inlet valve about to open).
•Then continue turning the crankshaft through 360 degrees (one complete revolution). At this
position both valves are closed.
•Insert a feeler gauge of 0.25mm in the gap between rocker arm toe and valve for inlet.
•The valve clearance is correct when the filler gauge can be inserted with a slight drag.
•Failing this, the valve clearance must be readjusted as mentioned in D6.4.6.
D-44
Diesel Genset
D6.4.6 Adjusting Valve Clearance
Figure D - 41: Adjusting Valve Clearance
Table 17: Tappet Clearance (in cold condition only)
Inlet Exhaust
0.25mm 0.3 mm
•Loosen lock nut of adjusting screw through one or two turns.
•Adjust the screw with screwdriver so that, when locknut is retightened, the feeler gauge of
0.25 mm can be inserted and withdrawn with slight drag.
•Similarly, check the valve clearance of exhaust valve with 0.3 mm feeler gauge.
•Readjust if necessary.
•Check the valve clearances of each of the remaining cylinders at their respective TDC and
readjust, if necessary.
•Do not change the setting of oil metering screw unless required.
•With hot engine running at idling, an oil flow to pad at rocker arm must be just noticeable. An
excess oil flow can lead to higher oil consumption.
D6.5 Maintenance of Electrical Equipment
D6.5.1 Battery Charging Alternator
•Check belt tension, readjust if necessary.
•Check the battery condition.
•Keep the alternator clean and ensure that ventilation slots are clear and unobstructed.
•Check mounting bolts for tightness.
•Contact KOEL authorised service dealer for any work involving repairs / replacement of
components of alternator.
D-45
Diesel Genset
A slack belt will rapidly wear and because of slip may not drive the alternator at the
required speed. Too tight a belt will impose severe side thrust on the bearings and seriously
shorten their life.
D6.5.2 Checking Battery and Cable Connectors
Figure D - 42: Battery and Terminations

•Keep the battery clean and dry.
•Ensure the cable terminals tightly fitted on the battery posts.
•Secure the battery firmly on the cradle.
•Ensure battery earth. Use rubber or wooden strip between battery & cradle.
•Clean the terminals (+ve and -ve) and clamps with ammonia solution. Mix in the ratio of 115
grams of ammonia for 1 litre of water.
•Apply petroleum jelly / vaseline on terminals & posts. Never apply grease.
•Ensure good contacts of terminals.
D6.5.3 Checking Electrolyte Level
Figure D - 43: Removing Battery Vent Caps

•Remove cell caps.
D-46
Diesel Genset
•Top up only with distilled water.

•Maintain level corresponding to the maximum level.
•Do not add Acid.
•Keep vent plugs tightly closed.
•Ensure the holes in battery caps are open. Choked vent holes could lead to bursting of the
battery.
D6.5.4 Checking Electrolyte Density
Figure D - 44: Checking Electrolyte Density

•Check the specific gravity of individual cell with hydrometer.
•Check specific gravity if battery has been topped up with distilled water. Check 5 minutes
after topping up.
•The measured values indicate state of charge of battery.
•Charge the battery if necessary.
•Avoid measuring specific gravity when battery is warm.
Table 18: Specific Gravity of a Battery
Specific Gravity (kg/1) State of Charge
Normal Tropics
1.28 1.23 Fully charged
1.20 1.12 Half charged, Recharge
1.12 1.08 Discharged, Charge up immediately.
-The gases emitted by the battery are explosive!

-Keep spark and naked flames away from the battery.
-Do not allow battery acid to come into contact with skin or clothing.
D-47
Diesel Genset
-Wear protective goggles.

-Do not rest tools on the battery
D6.6 Additional Jobs
D6.6.1 Exhaust Silencer
•Knock out soot from exhaust silencer and clean the exhaust piping after every 1200 hours.
•The time span of exhaust silencer chocking depends entirely on the working conditions,
maintenance and operating practices, so the time span will be vary accordingly.
D6.6.2 Checking of Fasteners
•Check & tighten-up the fasteners for following:

-Air intake and exhaust manifolds, exhaust piping
-Radiator hose connections
-Engine and radiator mountings
-Lube oil sump
-Front cover
-Hose clip for air cleaner
-Lube oil filter mounting
-Engine mountings
-Fuel connections
-All external nuts and bolts
Do not overtighten the fasteners.
D-48
D8.
D7.
D8.1
Sr. No. Parameters Unit Engine Model
2R1040 G1 3R1040T G1 3R1040TA G1 4R1040TA G1
1. Bore x Stroke Millimeters 105 x120
2. Firing order 1-2 1-2-3 1-3-4-2
Cubic
3. Displacement 2080 3120 4160
Centimeters
Diagnosis Chart
4. Direction of Rotation Anticlockwise
Naturally Turbocharged Turbocharged
5. Aspiration Turbocharged
Aspirated After-cooled After-cooled
Engine Specifications
6. Compression Ratio 18:1 18:1 18:1 18:1

7. Starting arrangement Electric Start
8. Governor Type Mechanical
Faults, Causes and Remedies

9. Class of Governing M3 as per ISO 3046
10. Lube Oil Consumption Grams/hour 4.9 7 11 20
11. Lube Oil Sump Capacity Liters 5.5 8 8 10
Rated Output as per
12. HP 25.5 42 56 102
ISO 3046
13. Rated Speed RPM 1500
14. Rating Standard ISO 3046
B.M.E.P. at Rated
15. Bar 7.4 8.1 10.8 14.7
Output
B.M.E.P. at rated
16. Bar 8.1 8.9 11.9 16.2
Output, Standby Rating
Dry Engine weight with
17. Flywheel and Flywheel Kgs 316 342 352 447
Housing Assembly
A comprehensive diagnosis chart overleaf lists the remedies to most common problems.
18. Noise Level at 1 meter Less than 75 dBA at 75% load at 1 meter as per CPCB regulations.
Diesel Genset
D-49
time
wear
speed
starting
constant
Complaints
Diesel knock
Bearing wear
Engine overheat
Mechanical knock
Excessive vibration
Engine lacks power
Engine will not start
Engine fails to rotate
Low lube oil pressure
Breaking of valve springs

Excessive oil consumption
Excessive smoke at no load
Excessive fuel consumption

Mixing of diesel with lube oil
Excessive smoke at full load
Engine has starting difficulty
Engine gives out blue smoke
Battery runs down frequently

Engine gives out white smoke
Engine speed does not remain
Engine does not reach governed

Engine misfires during operation
Engine rotates very slowly during

Excessive liner & piston ring wear
Engine starts but stops after some
Excessive fuel injection equipment

Excessive valve & valve guide wear
•
•
•
•
•
•
•
•
•
Dust entry in air inlet system

•
•
•
•
•
•
•
•
•
•
•
•
Dirty / clogged air cleaner

•
•
•
•
High exhaust back pressure

Derating due to altitude
System
Air /Exhaust
• •
• • •
Derating due to temperature

•
No fuel
•
•
•
•
•
•
•
• •
Poor quality of fuel

•
•
Air in the fuel line

•
•
•
• •
Choked fuel line

•
•
External / Internal fuel leakage

•
•
• • • •
Choked fuel injector holes

•
• •
•
• •
• •
• • •
Damaged or dribbling nozzle

Loose HR pipe connections
Fuel System
•
•
•
Dirty / Choked fuel filter

•
• •
• • •
• • •
Control lever settings wrong

•
•
•
•
•
•
•
•
Faulty fuel pump
•
•
• •
• •
• •
Water mixed with fuel

•
•
•
•
•
•
Wrong grade of lube oil used

•
Dirty / Choked suction tube strainer

Lube oil dilution
•
•
•
Dirty / Clogged lube oil filter
•
Clogged oil passage

•
Excessive oil in the sump

• •
External / internal leakages
Lubricating System
•
•
•
Faulty oil pump
Radiator fins choked
• •
• •
Loose V - Belt
• • •
Air leakages through radiator &
System
Cooling
•
•
No coolant in radiator/Coolant level
• •
•
•
• •
• •
• Engine overloading
•
•
•
•
•
Engine used after a long time
•
•
•
•
•
•
Wrongly adjusted valve clearances

Maint.
• •
•
•
•
• •
• •
Operation
Prolonged oil change period

•
Blown cylinder head gasket
• •
• •
Valve leakages
•
•
•
• • •
•
• • •
• •
Broken / worn out piston rings
Excessive end play in crankshaft
• • •
•
•
•
•
•
• • •
• • •
•
•
Worn out cylinder liner & piston
Incorrect bearing clearances
• •
• •
• •
• •
•
•
Damaged main & connecting rod
•
•
•
•
• • •
Worn out valves & valve guides
•
•
•
Incorrect valve & fuel timing
• •
• •
• •
•
•
• •
• •
Injector needs adjustment
•
•
•
•
•
•
Engine seized
Faulty governor setting
Mechanical System
•
•
• •
• •
•
• •
•
One or more cylinders not working
Loose mounting bolts
• •
• •
Loose flywheel / wrong alignment
•
•
•
•
•
•
•
•
•
•
Engine needs overhauling
Fuel pump rack stuck in stop
Battery run down / under rated
Faulty starter
• • •
• • •
• • •
• • • •
Battery of wrong capacity
System
•
•
•
•
Electrical
Loose or dislodged wiring
Diesel Genset
D9. Tightening Torque

To prevent faulty assembly, following information on tightening of high tensile bolts is important.
The bolts are to be tightened in stages as specified in the table below. For connecting rod bolt
and main bearing cap bolt use angle torque method with the help of goniometer. The tightening
angles for these two bolts are particularly important, hence figure below indicates the various
angles can be readily obtained by comparison with a clock face.
Figure D - 45: Tightening Torque Angles

Tommy bar is to be clamped in the tool slot and specified angle is to be turned with reference to
the initial graduation on outer dial of the tool or a relation of hex head of bolt can be referred.
NOTE:
1.Lubricate threads and seating face of bolt with engine oil before it is assembled.
2.Screw the bolt by hand till it is engaged up to the seating face.
3.Apply initial torque and tighten the bolts according to the angles/torques in stages as specified
in the “Tightening Table.”
4.In case of replacing main and big end bearings/overhaul/piston seizures, fit new bolts for main
bearing cap, connecting rod cap, balance weight & cylinder head.
5.1 Nm = 0.102 kgm = 0.74 Ib.ft.
D-51
Diesel Genset
D9.1 Table for Fasteners
Sr. Initial Tightening Method Total

No. Description Torque Angle/kgm Angle
kgm Torque
Stage l Stage2 Stage3
Bolt for balance weight
1. 3 30° 30° - 60°
(M12x1.75x60mm long, 10.9 grade)
Bolt for main bearing cap
2. 3 60° 45° - 105°
(M14x2x128 mm long, 10.9 grade)
Bolt for Connecting rod
3. 3 30° 60° - 90°
Bolt for Crank pulley
(M24x2x100 mm long, 10.9 5 25 kgm 48 kgm 48 kgm
4.
grade)without power take off. 3 5 kgm 9 kgm 9 kgm
M14x1xl00 long — 5 nos
Bolt for flywheel
5. 3 30° 30° - 60°
(M10x1x45mm long, 10.9 grade)
Bolt for flywheel housing
6. 5 - - - 5 kgm
7. Nut for injector stud M10 3 - - - 3 kgm
8. Nut for fuel pump hub M14 3 5kgm 8kgm - 8 kgm
Bolt for cylinder head, (M12x1.75) for

9. sequence of tightening torque refer 3 3° 90° 62° 152°
Para D9.2.1.
10. All M8x1.25 screws & bolts 8.8 2.5 - - - 2.5 kgm
3.5 kgm
11. All M10x1.5 screws & bolts 8.8 3.5
12. H.P. PIPE NUT (M14X1.5, M12X1.5) 2.5 2.5 kgm
High Tensile Fasteners for Exhaust

13. system 4 4 kgm
(M8 x1.25, 10.9 grade)
D9.2 Tightening Torque Sequence
D9.2.1 Torque Sequence for Cylinder Head Bolts
D9.2.1.1 2R1040 G1 Engine
D-52

Figure D - 46: Torque Sequence for cylinder head bolts of 2R1040 G1
D9.2.1.2 3R1040T G1 Engine

Figure D - 47: Torque Sequence for cylinder head bolts of 3R1040T G1

Diesel Genset
D9.2.1.3 4R1040 G1 Engine
Exhaust Side
18 14 12 16
Inlet Side
Figure D - 48: Torque Sequence for cylinder head bolts of 4R1040 G1
D-54
Diesel Genset
Kirloskar Green AC Alternator

E1. General ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.1 Introduction ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.2 Standards ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E1.3 Enclosures and Mounting ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E2. Design of AC Generator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E2.1 Stator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐1
E2.2 Rotor‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.3 Exciter Stator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.4 Exciter Rotor‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.5 Rotating Rectifier Assembly‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.6 Impregnation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.7 Balancing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐2
E2.8 Terminal Box‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.9 Bearings ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.10 Ventilation ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.11 Earthing ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.12 Space Heater ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.13 Voltage Regulator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐3
E2.14 Optional Accessories‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3. Operating Principle ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3.1 Standard Brushless AC Generator‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐4
E3.2 Brushless AC Generator with PMG ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐5
E3.3 Advantages Of PMG Excitation System: ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐5
E4. Kirloskar Green (KG) AC Generators ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6
E4.1 Electrical Performance ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6
E4.2 Process‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐6
E5. Automatic Voltage Regulator ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7
E5.1 Features ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7
E5.2 AVR Models ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐7
E6. Derating Factors ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8
E6.1 Temperature‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8
E6.2 Altitude ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐8
E6.3 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9
E7. Selection of AC Generators ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9
E7.1 Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐9
E7.2 Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
E7.3 Power Factor ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
i
Diesel Genset
E7.4 Motor Loads‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐10
E7.5 Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
E7.6 Characteristics of Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
E7.7 Effects Of Non Linear Loads‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
E7.8 Deration for Non Linear Loads ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ ‐ E‐11
ii
Diesel Genset
Brushless A C Generators
E1. General
E1.1 Introduction
Kirloskar Green (KG) Brushless AC Generators are of salient pole, revolving field, brushless,
horizontally foot mounted, and single/double bearing type. These AC Generators are available
with and without PMG generators Standard Voltage of operation i.e., 415/460 V at 50/60 Hz for
3Ø and 230/240 V at 50/60 Hz for 1Ø.
E1.2 Standards
The Kirloskar Green (KG) AC Generators generally comply with various national and
international standards such as IS: 4722, IS: 13364, BS: 5000 Part3 and IEC 6034-1 (34-1)
and specifications mutually agreed upon at the time of order.
E1.3 Enclosures and Mounting
The AC Generators have degree of protection of IP 23 with B15(SB)/B3(DB) type of Mounting.

Other types of protection and mounting can also be offered on request.
Figure E - 1: Alternator Designation
E2. Design of AC Generator
E2.1 Stator
Stator of the AC Generator is made of high quality, low loss high permeability steel stamping
built rigidly to with stand all types of forces due to static, dynamic and transient loading
conditions. The armature coils are made up of enameled high conductivity copper wires with
E-1
-
Diesel Genset
class ‘H’ insulation, 2/3 pitch winding to eliminate triple and its multiple harmonics in the
generated output voltage. Windings are subjected to vacuum pressure impregnation for better
consolidation and the overhangs are provided with epoxy gel coating to protect against ingress
of dust, moisture and others. The winding leads themselves form the output terminals directly
from the armature without any joints on the overhang. All the 6/12 leads are brought out
sleeved and terminated with suitable crimping sockets.
E2.2 Rotor
The main rotor is made of low loss high permeability steel stamping, built directly on to the
shaft, which is then wound with field coils using high conductivity enameled copper for Class
‘H’ insulation. A set of completely interconnected damper winding cage is provided in the rotor
for compensation for any unbalance and during transient condition. Coil support blocks are
provided for adequate supporting of the coils from high centrifugal forces.
E2.3 Exciter Stator
Exciter stator built up of high quality laminated steel stampings carries the field coils mounted
on the Non- Driving End shield of the machine. The coils are made up of high conductivity
enameled copper with class ‘H’ insulation. The coils are firmly supported by suitable epoxy
wedges inserted in between the pole shoes.
E2.4 Exciter Rotor
Exciter rotor built up of thin laminations in the form of riveted core carries three phase armature
windings and is mounted on to the shaft. The winding is made of high conductivity enabled
copper with class ‘H’ Insulation. The output winding leads are terminated at the rotating rectifier
assembly.
E2.5 Rotating Rectifier Assembly
Rotating Rectifier Assembly is a three-phase bridge rectifier mounted on two Aluminum heat
sinks. Provisions are made in the rectifier assembly for connecting the main rotor leads and
surge suppressor provided to protect the diodes from surge voltages.
E2.6 Impregnation
All the windings are impregnated with Class ‘H’ resin and taken through the temperature curing
cycle to form a rigid winding. The overhangs are protected with a coat of epoxy gel application
against ingress of dust, moisture and others particles.
E2.7 Balancing
All generators rotors are dynamically balanced to better than Grade 2.5 (BS 6861: Part 1) for
minimum vibration in operation.
E-2
Diesel Genset
E2.8 Terminal Box
The sheet metal/cast Aluminum terminal box having ample space is fixed on the top of the NDE
end shield. 6/12 output terminals are terminated. It is possible to terminate the customer cables
on either side, depending on the customer’s choice. The Voltage Regulator is also mounted
inside the terminal box and terminated.
E2.9 Bearings
Two nos. of anti-friction double shielded ball bearings are provided one each at NDE and DE in
double bearing machine and only one at NDE in case of Single/double Bearing machine.
Adequate care is taken in the design of the Single/double Bearing machine to accommodate
for possible axial differences in the close coupling system.
E2.10 Ventilation
The AC Generators are self-cooled. The centrifugal Aluminum/Steel fan fitted on the shaft at
the driving end of the rotor draws the fresh air through the opening provided at the NDE cover
and discharges through ventilating ducts provided in the DE End Shield in double bearing
machines and adaptor in Single Bearing machines. The method of cooling is IC 01 as per
IS:6362.
E2.11 Earthing
Two earthling screws provided on the feet ribs are used for grounding of the AC Generator.
E2.12 Space Heater
Two space heaters (optional) suitable for 230 V / 24 V, single phase/ DC are provided on each
overhang of the main stator winding of AC Generator on request.
E2.13 Voltage Regulator
Automatic Voltage Regulator provided is compact, high performance encapsulated unit

mounted inside the terminal box. This unit senses the voltage between lines and controls the
generator output voltage automatically to be with in the specified regulation band. AVR consists
of separate potentiometers for adjusting the voltage, stability, frequency roll off and quadrature
droop adjustment (Optional).
The following are the features of the AVR.
•Build up from a very low residual voltage -about 2.5 V (L-N).

•Voltage regulation within +/- 0.8%of pre-set value.
•Fast response to the load changes.
•Remote V-trim pot for voltage adjustment up to ± 10%of nominal terminal voltage.
E- 3
Diesel Genset
•QDC pot for Quadrature droop adjustment during parallel operation (Optional).
•Stability pot for adjustment of the response.
•Frequency-Roll-Off pot to set the frequency range.
•Over excitation limit pot to set the excitation limit
E2.14 Optional Accessories
These optional accessories are provided on the customer requirement. These are basically for
the protection of the machine while working on the extreme conditions. The following
accessories are provided.
•Winding temperature detectors (RTD/Thermistor).

•Bearing temperature detectors (BTD).
•Current transformers for differential protection.
•Permanent magnet generator.
•Auxiliary winding facility.
•Filters for dusty environment.
•Filters for harmonics.
E3. Operating Principle
E3.1 Standard Brushless AC Generator
1.In this generator there is a separate source to AVR from a small permanent magnet A.C.
generator mounted on the same shaft as the main machine. Refer Figure E - 2 on page 5.
2.The permanent magnet produces an output voltage that is only dependent on speed and is
independent of load conditions. This constant output voltage is fed to the exciter field winding
through the AVR.
3.By comparing the main output ‘sensed’ voltage with the ‘set reference’ voltage, the AVR
decides on the proportion of permanent magnet machine output to rectify and feed to the exciter
field.
4.The exciter rotor output would then increase, established a strong main field and therefore a
marked increase in main output voltage.
5.The AVR senses and compares voltages and adjusts exciter field excitation until desired
output voltage is developed. In this way the main stator voltage is progressively built up until the
‘sensed’ voltage is the same as the ‘set reference’ voltage.
E-4
Diesel Genset
Figure E - 2: Standard Alternator
E3.2 Brushless AC Generator with PMG
PMG = Permanent Magnet Generator
Figure E - 3: PMG Alternator
E3.3 Advantages Of PMG Excitation System:
E- 5
Diesel Genset
•Better motor starting characteristics with lower transient voltage dips.

•Better co-ordination with relay under sustained short circuit condition.
•Since the Power to AVR is supplied from the PMG, isolation from AC Generator output
terminals, harmonic currents from the load are prevented from passing to the AVR. This
reduces output voltage distortion.
•The process of initial voltage build up is very positive in this system, as residual magnetism is
no longer continually depended upon.
E4. Kirloskar Green (KG) AC Generators
E4.1 Electrical Performance
1.AVR used on the machine is of proven design, reliability and performance. These are unique
encapsulated against moisture, sand, salt, humidity and corrosive atmosphere ensuring trouble
free operations under the most demanding conditions. The voltage regulation offered is +/-
0.8%.
•Transient voltage dips are lower.
•Wave-form distortion on no-load is less than 1.8%. Total harmonic distortion and the
telephonic interference is less than 4% in distorting balanced linear load.
•All stators are wound to 2/3rd pitch, which along with PMG excitation system as optional and
2 line sensed as standard AVR and 3 line sensing as optional to provide better system
performance.
•Damper winding on poles ensure smooth parallel operation with similar and dissimilar
machines and with the grid. Power factor controller is recommended when balancing with
gird.
•Liberally rated diode used in rotating rectifier assembly ensures high reliability.
•The rotating diodes are protected by a surge suppresser which has the ability to chop the
transients.
•Short Circuit Current with stand capability is up to 3 times the rated current for 3 seconds.
•Excellent motor starting capacity 2.5 times rated kVA.
E4.2 Process
•Gel coat application is a standard feature which enhances the mechanical strength of the
winding overhang and ensures trouble free performance in humid and corrosive atmosphere.
•Burr free stamping pack construction and file free winding results in excellent quality of
winding and also better machine life.
•Hammer free assembly and sealed bearing increase bearing life.
•Dynamically balanced rotor to minimize vibration.
E-6
Diesel Genset
E5. Automatic Voltage Regulator

Kirloskar Green (KG) regulators are in wide range for wide application. Our regulators have the
following specifications.
•Encapsulated components for weather protection.
•Compact and rugged construction.
•Solid state.
•Fast response to the load changes.
•Build up from a very low residual voltage – about 2.5 V (L-N)
E5.1 Features
•Voltage adjustment: The V trimmer is provided in the AVR for voltage adjustment up to +/-
10% of rated voltage.
•Stability Adjustment: The AVR include stability circuit to provide the good steady state and
transient performance of the generator.
•Under frequency Roll off (UFRO): The AVR incorporates an under speed protect circuit which
gives a Volts/ Hz characteristics when the generator speed falls below a presentable value
the red LED gives indication that the UFRO circuit is operating.
•Droop Adjustment: Generator intended for parallel operation are fitted with a quadrature
droop CT. CT is connected to Q1, Q2 on the AVR with ratios of rated current: 5Amps, 1%
accuracy, 5/2.5 VA burden.
•Accessory Input: for 250 kVA and above AC Generators
•An analog input (A1& A2 is provided to connect to the DC current source device. It is
designed to accept DC signal up to +/- 4.5 Volts.
E5.2 AVR Models
Table 1: AVR Models

Number Parameter TAVR -20 TAVR -30 TAVR -18 (PMG) DSR
1 Voltage adjustment Yes Yes Yes Yes
Stability Yes Yes Yes Yes

2
adjustment
Under frequency No Yes Yes Yes

3
roll off adjustment
Remote voltage Yes Yes Yes Yes

4
adjustment
Over Excitation Yes Yes Yes Yes

5
adjustment
Accessory ( DC No Yes No Yes

6
input)
E- 7
Diesel Genset
Table 1: AVR Models
Number Parameter TAVR -20 TAVR -30 TAVR -18 (PMG) DSR
7 Quadrature Droop No Yes Yes Yes

Sense Loss Yes Yes Yes No
8
indication
Over excitation Yes Yes Yes No
9
indication
Under frequency Yes Yes Yes Yes

10
roll off
Frequency roll of Yes Yes Yes Yes
11
indicator
12 Used on frames KG 164 - 254 KG 284 - 354 KG 284 - 354 KG3-28-32-34
13 Ratings 5 - 200 kVA 250 - 750 kVA 250 - 750 kVA 5 - 160 kVA
E6. Derating Factors
E6.1 Temperature
These AC Generators are designed for an ambient temperature of 40°C. For other applications
where the ambient temperature is greater than 40°C, the AC Generators must be de-rated to
ensure that the actual temperature does not exceed the specified limit.
Outputs are normally quoted at 40°C. These outputs must be multiplied by the following factors
for higher ambient temperatures.
Table 2: Derating for Temperature
TEMPERATURE (°C) MULTIPLIER
45 0.97
50 0.94
55 0.91
60 0.88
E6.2 Altitude
Above 1000 m the effectiveness of the air is reduced sufficiently to make de-rating necessary.
For altitudes above 1000 m outputs must be multiplied by the following factors.
Table 3: Derating for Altitude
Altitudes Multiplier
1500 0.97
2000 0.94
E-8
Diesel Genset
Table 3: Derating for Altitude
Altitudes Multiplier
2500 0.91
3000 0.88
3500 0.85
4000 0.82
E6.3 Power Factor
Standard AC Generators are suitable for 0.8 pf lag to UPF loads. Power factor below 0.8 lag
causes heating of the AC Generator. The A C Generator output must be multiplied by the
following factors for lower PF.
Table 4: Multiplier for Power Factor
P.f(Lag) Multiplier
0.7 0.95
0.6 0.91
0.5 0.88
0.4 0.86
0.3 0.85
0.2 0.84
0.1 0.84
0.0 0.84
Leading pf loads cause rise in terminal voltage which may subsequently harm the AVR and the
loads. Please refer to works in case of leading pf loads.
E7. Selection of AC Generators

This section deals with selection of AC Generators to suit various loads.
The different types of load encountered by an AC Generators can be broadly classified as

a) Linear Loads.
b) Motor Loads (part of linear loads, considered separately).
c) Non-linear Loads.
E7.1 Linear Loads
•Constant load impedance regardless of applied voltage.
E- 9
Diesel Genset
•he load current increases proportionately as the voltage increases and decreases as the
voltage decreases.
Examples of linear loads are motor, incandescent lamp and heating loads.
E7.2 Linear Loads
To select the rating of AC Generator for linear loads the maximum connected load and the
base load which is always connected has to be considered. In arriving at a total load figure is
always wise to select the standard rating larger than that estimated. This despite the fact that
all the loads may not be operating at the same time hence a smaller machine could have been
selected. Future operating conditions and future growth are very difficult to estimate. An
allowance of 15% to 20% excess capacity designed into a set now is a small price to pay
compared with the cost of completely new larger unit that may be required to drive additional
loads in a few years time.
E7.3 Power Factor
It is the nature of the applied load that dictates the system power factor.
1.The loads which operate at or very close to unity (1.0) power factor include most forms of
lighting, all heating elements, rectifier and thyristor type loads & all domestic loads which are
fractional hp motors (washing machine, refrigerator, etc.).
2.For all remaining load types, some knowledge of operating power factor is required, which for
motors depends a great deal on their size and power rating.
Kirloskar Green (KG) A C Generators perform satisfactorily at any power factor in the range of
0.8 p.f lag to unity. For p.f operation at leading low power factor Please refer back to works.
E7.4 Motor Loads
During the starting of an induction motor, a very large current is demanded from the power
source, which is known as the starting or locked rotor current. For better sizing of AC
Generators, the following guidelines can be referred to.
Table 5: Motor Loads
Method Of Starting Current Starting Current as I rated times full load
Direct On Line 6-7
Star Delta 3-3.5
Rotor Resistance 1.5-2
Auto Transformer: At 40% Tapping 1.1
At 60% Tapping 2.5
At 80% Tapping 4.5
E - 10
Diesel Genset
For motor applications the following information should be furnished:
a) Rating of the motor/ motors.

b) Type of the motor (slip ring / squirrel cage).
c) Method of starting.
d) Rated full load current.
e) Starting power factor.
f) Any restriction on Transient Voltage Dip? (Details of the same).
g) Frequency at starting.
h) Base load at the time of starting induction motor.
i) Any other load apart from the motor loads? (Details there of).
j) Sequence of starting of motors.
E7.5 Non Linear Loads
Over a period of time the loads applied to AC generators have become more complex and
more care has to be exercised in the sizing of the generators to ensure satisfactory
performance.
E7.6 Characteristics of Non Linear Loads
a) A non linear load is one in which the load current is not proportional to the instantaneous
voltage. Often the load current is not continuous.
b) These are essentially electronic loads such as computers, UPS equipments and variable
speed motor drives.
E7.7 Effects Of Non Linear Loads
a) Non linear loads generate harmonics in their current waveform which in turn leads to
distortion of the AC generator waveform. Depending upon the degree of voltage waveform
distortion this can lead to instability of the excitation systems and impact on other loads being
supplied by the generator.
b) Odd order harmonics cause heating of neutral conductors.
E7.8 Deration for Non Linear Loads
The above percentage figures are guidelines. There may be a problem with electronic load,
trying to cope with distorted waveform if distortion levels are unacceptable to the load.
Table 6: Non Linear Loads
Loads Derating Factors
Fluorescent lighting load No derate required.
UPS & Telecom load controlled by a 12 Non linear load should not exceed 90% of AC Generator
pulse Thyristor bridge plus a filter. rating
E- 11
Diesel Genset
Table 6: Non Linear Loads
Loads Derating Factors
UPS & Telecom load controlled by 6 pulse Non linear load should not exceed 60% of AC Generator
Thyristor Bridge plus a filter. rating
UPS & Telecom load controlled by3 pulse Non linear should not exceed 50% of AC Generator rating.
thyristor bridge pulse a filter
Variable speed 6 pulse thyristor Non linear load should not exceed 35% of AC
controlled drive. Generator rating
Better sizing of machine is possible on furnishing following information:

a) Number of pulses of Thyristor drive: 3, 6, or 12.
b) Level of harmonic distortion produced by the non-linear load.
c) What is the maximum acceptable level of voltage distortion the Non-linear load can accept?
d) Operating voltage and frequency.
e) If Non-linear load power requirement is stated in kW, then some guidance regarding
operating power factor & system efficiency is required to establish the AC Generator load.
With the information, guidance should be sought from the factory regarding AC Generator
sizing for compatible equipment operation.
E - 12
HELP DESK CONTACT NUMBER - +91 880 63 344 33

HELP DESK TOLL FREE NUMBER - 1800 233 3344
email ID - koel.helpdesk@kirloskar.com Drawing: 4H.083.01.0.00
www.koel.co.in

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CPCB II

GENSET USER MANUAL

RATING: 20 to 82.5 kVA

Ideas diesel generating sets.

For Kirloskar Oil Engines Ltd.,

Head, Power Generation Business

Your Name & Phone or Mobile Number.

Engine Serial Number.

Name of the Company.

General Description of assistance required.

And the service will be on its way.

FOR EMERGENCY CONTACT

HELP DESK CONTACT NUMBER - +91 880 63 344 33

KIRLOSKAR OIL ENGINES LTD.

Section A – Genset Warranty

Section B – Customer Service Package

Section C – Genset User Manual

Section D – Engine User Manual

Section F – Service Network

Each warning/most important instruction in the manual succeeds the sign.

Kirloskar Oil Engines Limited Vijay T B 080-25587562/ +91-

Section B - Customer Service

Section D - Diesel Engine

3. For availing the warranty services please ensure following:

a) Produce this warranty booklet to KOEL authorised Service Dealer, when

Please provide following details to our Authorized

- Genset Model and Serial Number.

- Engine serial Number.

- Detailed site address

- Contact Person and Telephone/Mobile Number.

- Number of hours run till date

GENSET MODEL AND SERIAL NUMBER

ENGINE MODEL AND SERIAL NUMBER

KG ALTERNATOR SERIAL NUMBER, MAKE AND TYPE

PANEL SERIAL NUMBER

G1 (1ST SERVICE) CHECK CARRIED OUT ON

G2 (2ND SERVICE) CHECK CARRIED OUT ON

SERVICE DEALER'S STAMP AND SIGNATURE

KIRLOSKAR GREEN D.G. SET WARRANTY

For Power Generation Non-Cellular Application Engines -

For Power Generation Non Cellular Application Engines and KG

Use K-Oil Premium for your Gensets.

This warranty does not apply for the following:

Warranty period for DG set components is as below.

For Power Generation Non Cellular Application

•Proprietary parts not manufactured by Kirloskar Oil Engines Limited like:

•Kirloskar Green Alternators

•All other Electrical Components supplied along with Genset like:

•Kirloskar Green canopy Components supplied along with Genset like:

•Locks •Hinges •Fuel level gauges •Exhaust fan

For Power Generation Cellular Application -

•All other Electrical Components supplied along with engine like:

•Kirloskar Green canopy Components supplied along with Genset like:

Conditions precedent to Kirloskar Green Genset warranty.

A. Proper installation of the Kirloskar Green Genset is the sole responsibility of

To meet specific customer needs, your Genset may not contain

Engine________________________ RPM_________________ HP____________

Engine________________________ RPM_________________ HP____________

Engine________________________ RPM_________________ HP____________

Engine________________________ RPM_________________ HP____________

Ambient temp. (air temp. near air-cleaner element) :

S a fe tie s : L ow L ube O il P re s s ure – W ork ing / N ot Work ing

Engine________________ RPM_ HP____

Engine________________ RPM_ HP____

Engine________________ RPM_ HP____

Engine________________ RPM_ HP____