K80EFOZC

Operation
Marine Generator Sets
Pleasure Craft Models:

40-200EOZDJ
33-175EFOZDJ
Commercial Models:
40-200EOZCJ
33-175EFOZCJ
Controller:
Decision Maker® 3500
TP-6861 11/24g
WARNING: This product can expose you to chemicals, including carbon monoxide and
benzene, which are known to the State of California to cause cancer and birth defects or
other reproductive harm. For more information go to www.P65warnings.ca.gov
WARNING: Breathing diesel engine exhaust exposes you to chemicals known to the
State of California to cause cancer and birth defects or other reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel
Product Identification Information
Product identification numbers determine service parts. Record the product identification numbers in the spaces below
immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed
kit numbers after installing the kits.
Generator Set Identification Numbers
Record the product identification numbers from the generator set nameplate(s).
Model Designation _________________________________________________________
Specification Number _______________________________________________________
Serial Number: ____________________________________________________________
Engine Identification
Record the product identification information from the engine nameplate.
Manufacturer_________________________________________________________________
Model Designation___________________________________________________________
Serial Number_______________________________________________________________
Accessory Number Accessory Description Accessory Number Accessory Description
2 TP-6861 11/24
Table of Contents
Safety Precautions and Instructions ........................................................................................................................................ 5

Introduction ................................................................................................................................................................................ 9
Service Assistance................................................................................................................................................................... 10
Maintenance and Service Parts/Related Literature ............................................................................................................... 11
Section 1. Specifications and Features ................................................................................................................. 13
1.1 Introduction ............................................................................................................................................................ 13
1.2 Permanent Magnet Alternator Concept .................................................................................................................. 13
1.3 Short Circuit Performance ...................................................................................................................................... 16
1.4 Service Views ......................................................................................................................................................... 17
1.5 Introduction ............................................................................................................................................................ 21
1.6 Controller Specifications......................................................................................................................................... 21
1.7 Decision-Maker® 3500 Controller Information ....................................................................................................... 21
1.8 Controller Features................................................................................................................................................. 22
1.8.1 Switches and Controls ............................................................................................................................. 23
1.8.2 Annunciator Lamps .................................................................................................................................. 24
1.8.3 Graphical Display ..................................................................................................................................... 24
1.9 Metering Menu ....................................................................................................................................................... 25
1.9.1 Generator Metering Submenu.................................................................................................................. 25
1.9.2 Engine Metering Submenu....................................................................................................................... 25
1.9.3 Overview Submenu.................................................................................................................................. 26
1.9.4 Paralleling Metering Submenu ................................................................................................................. 26
1.10 Generator Information Menu .................................................................................................................................. 27
1.10.1 Generator Information Submenu .............................................................................................................. 27
1.10.2 Event History Submenu ........................................................................................................................... 28
1.10.3 Configuration Submenu ........................................................................................................................... 28
1.10.4 Voltage Regulation Submenu .................................................................................................................. 30
1.10.5 Voltage Selector Switch ........................................................................................................................... 31
1.10.6 Paralleling Operation ............................................................................................................................... 31
1.11 Controller Configuration Menu ............................................................................................................................... 39
1.11.1 Controller Configuration Submenu ........................................................................................................... 39
1.11.2 Communication Setup Submenu ............................................................................................................. 40
1.11.3 Calibration Submenu ............................................................................................................................... 41
1.12 I/O Setup Menu ...................................................................................................................................................... 42
1.12.1 Controller Fault Diagnostics ..................................................................................................................... 43
1.12.2 Main Logic Circuit Board .......................................................................................................................... 47
1.12.3 For Units Equipped with 3rd Party Marine Option .................................................................................... 47
Section 2. Operation ................................................................................................................................................ 49
2.1 Prestart Checklist ................................................................................................................................................... 49
2.2 Marine Inspection ................................................................................................................................................... 50
2.3 Angular Limits During Operation ............................................................................................................................ 51
2.4 Operation in European Union Member Countries .................................................................................................. 51
2.5 Load Profile ............................................................................................................................................................ 51
2.6 Controller Operation ............................................................................................................................................... 52
2.6.1 Emergency Stop ...................................................................................................................................... 54
2.6.2 System Status Lamps .............................................................................................................................. 54
2.6.3 System Fault Warning Lamp with Digital Displays ................................................................................... 55
2.6.4 System Fault Shutdown Lamp with Digital Displays ................................................................................ 58
2.6.5 Status and Notice Digital Displays ........................................................................................................... 60
2.6.6 Controller Resetting (Following System Shutdown or Warning)............................................................... 61
2.7 Menu Displays ........................................................................................................................................................ 61
TP-6861 11/24 3
2.8 Monitoring and Programming Setup ....................................................................................................................... 68
2.8.1 PC Communications ................................................................................................................................ 69
2.8.2 Modbus® Communications ....................................................................................................................... 70
Section 3. Scheduled Maintenance ........................................................................................................................ 71
3.1 Alternator Service ................................................................................................................................................... 71
3.2 Engine Service ....................................................................................................................................................... 71
3.3 Generator Set Service Schedule ............................................................................................................................ 73
3.4 Alternator Bearing Service ..................................................................................................................................... 76
3.4.1 20-300 kW Models ................................................................................................................................... 76
3.5 Diesel Fuel Systems............................................................................................................................................... 76
3.5.1 Bleeding Air from Fuel System................................................................................................................. 76
3.6 Cooling System ...................................................................................................................................................... 76
3.6.1 Cooling System Component Inspection ................................................................................................... 77
3.6.2 Procedure to Drain Cooling System ......................................................................................................... 77
3.6.3 Procedure to Flush and Clean Cooling System ....................................................................................... 77
3.6.4 Procedure to Refill Cooling System ......................................................................................................... 78
3.6.5 Siphon Break ........................................................................................................................................... 79
3.6.6 Impeller Inspection and Replacement Procedure .................................................................................... 80
3.7 Exhaust System ..................................................................................................................................................... 82
3.8 Storage Procedure ................................................................................................................................................. 83
3.8.1 Lubricating System .................................................................................................................................. 83
3.8.2 Cooling System ........................................................................................................................................ 83
3.8.3 Fuel System ............................................................................................................................................. 83
3.8.4 Exterior..................................................................................................................................................... 83
3.8.5 Battery ..................................................................................................................................................... 84
Section 4. Troubleshooting..................................................................................................................................... 85
4.1 Controller Display and Voltage Regulation Troubleshooting Chart ........................................................................ 90
Section 5. Wiring Diagrams .................................................................................................................................... 91
Section 6. Voltage Reconnection ......................................................................................................................... 127
6.1 Introduction .......................................................................................................................................................... 127
Section 7. Accessories .......................................................................................................................................... 129
7.1 Accessories .......................................................................................................................................................... 129
7.2 Accessory Connections ........................................................................................................................................ 129
Appendix A. Abbreviations ....................................................................................................................................... 133
Appendix B. Alternator Protection ........................................................................................................................... 137
Appendix C. Operating Hour Service Log ............................................................................................................... 139
4 TP-6861 11/24
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generator sets, transfer switches, switchgear,
and accessories, can cause bodily harm and pose life-threatening danger when improperly installed, operated, or maintained.
To prevent accidents be aware of potential dangers and act safely. Read and follow all safety precautions and instructions.
SAVE THESE INSTRUCTIONS.
This manual has several types of safety precautions and instructions: Danger, Warning, Caution, and Notice.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
NOTICE is used to address practices not related to physical injury.
Safety decals affixed to the equipment in prominent places alert the operator or service technician to potential hazards and
explain how to act safely. The decals are shown throughout this publication to improve operator recognition. Replace missing or
damaged decals.
Accidental Starting
WARNING Accidental starting.

Can cause severe injury or death.
Disconnect the battery cables before working on the generator set. Remove the
negative (–) lead first when disconnecting the battery. Reconnect the negative (–)
lead last when reconnecting the battery.
Disabling the generator set. Accidental starting can cause severe injury or death. Before working on the generator set or
equipment connected to the set, disable the generator set as follows: (1) Press the generator set off/reset button to shut down
the generator set. (2) Disconnect the power to the battery charger, if equipped. (3) Remove the battery cables, negative (–) lead
first. Reconnect the negative (–) lead last when reconnecting the battery. Follow these precautions to prevent the starting of the
generator set by the remote start/stop switch.
TP-6861 11/24 5
Engine Backfire/Flash Fire
WARNING Risk of fire.

Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the fuel system. A flash fire can cause severe injury or death. Do not smoke or permit flames or sparks near the
fuel injection system, fuel line, fuel filter, fuel pump, or other potential sources of spilled fuels or fuel vapors. Catch fuels in an
approved container when removing the fuel line or fuel system.
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the
air cleaner removed.
Combustible materials. A fire can cause severe injury or death. Generator set engine fuels and fuel vapors are flammable
and explosive. Handle these materials carefully to minimize the risk of fire or explosion. Equip the compartment or nearby area
with a fully charged fire extinguisher. Select a fire extinguisher rated ABC or BC for electrical fires or as recommended by the
local fire code or an authorized agency. Train all personnel on fire extinguisher operation and fire prevention procedures.
Exhaust System
WARNING Carbon monoxide.

Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a
poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
• Light-headedness, dizziness
• Physical fatigue, weakness in joints and muscles
• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
• Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active.
Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the
condition of affected persons does not improve within minutes of breathing fresh air.
Inspecting the exhaust system. Carbon monoxide can cause severe nausea, fainting, or death. For the safety of the craft’s
occupants, install a carbon monoxide detector. Never operate the generator set without a functioning carbon monoxide detector.
Inspect the detector before each generator set use.
Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Be especially careful if
operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the
generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always
be aware of others, making sure your exhaust is directed away from other boats and buildings.
6 TP-6861 11/24
Fuel System
WARNING Explosive fuel vapors.

Can cause fires and severe burns.
If a gaseous odor is detected, ventilate the area and contact an authorized service
technician.
The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme
care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the
reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts
or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines
and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel
line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion.
Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
Hazardous Noise
CAUTION Hazardous noise.

Can cause hearing loss.
Never operate the generator set without a muffler or with a faulty exhaust system.
Hazardous Voltage/Moving Parts
DANGER Hazardous voltage. Moving parts.

Will cause severe injury or death.
Operate the generator set only when all guards and electrical enclosures are in place.
Servicing the generator set when it is operating. Exposed moving parts will cause severe injury or death. Keep hands,
feet, hair, clothing, and test leads away from the belts and pulleys when the generator set is running. Replace guards, screens,
and covers before operating the generator set.
Grounding electrical equipment. Hazardous voltage will cause severe injury or death. Electrocution is possible whenever
electricity is present. Ensure you comply with all applicable codes and standards. Electrically ground the generator set, transfer
switch, and related equipment and electrical circuits. Turn off the main circuit breakers of all power sources before servicing the
equipment. Never contact electrical leads or appliances when standing in water or on wet ground because these conditions
increase the risk of electrocution.
Disconnecting the electrical load. Hazardous voltage will cause severe injury or death. Disconnect the generator set from
the load by turning off the line circuit breaker or by disconnecting the generator set output leads from the transfer switch and
heavily taping the ends of the leads. High voltage transferred to the load during testing may cause personal injury and equipment
damage. Do not use the safeguard circuit breaker in place of the line circuit breaker. The safeguard circuit breaker does not
disconnect the generator set from the load.
TP-6861 11/24 7
Short circuits. Hazardous voltage/current will cause severe injury or death. Short circuits can cause bodily injury and/or
equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments or repairs. Remove all
jewelry before servicing the equipment.
Engine block heater. Hazardous voltage will cause severe injury or death. The engine block heater can cause electrical
shock. Remove the engine block heater plug from the electrical outlet before working on the block heater electrical connections.
Electrical backfeed to the utility. Hazardous backfeed voltage can cause severe injury or death. Connect the generator
set to the building/marina electrical system only through an approved device and after the building/marina main switch is turned
off. Backfeed connections can cause severe injury or death to utility personnel working on power lines and/or personnel near
the work area. Some states and localities prohibit unauthorized connection to the utility electrical system. Install a ship-to-shore
transfer switch to prevent interconnection of the generator set power and shore power.
Testing live electrical circuits. Hazardous voltage or current will cause severe injury or death. Have trained and qualified
personnel take diagnostic measurements of live circuits. Use adequately rated test equipment with electrically insulated probes
and follow the instructions of the test equipment manufacturer when performing voltage tests. Observe the following precautions
when performing voltage tests: (1) Remove all jewelry. (2) Stand on a dry, approved electrically insulated mat. (3) Do not touch
the enclosure or components inside the enclosure. (4) Be prepared for the system to operate automatically. (600 volts and under)
Hot Parts
WARNING Hot coolant and steam.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen
the pressure cap to relieve pressure. Fill system before starting unit.
WARNING Hot engine and exhaust system.

Do not work on the generator set until it cools.
Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and
exhaust system components become extremely hot during operation.
Notice
NOTICE
Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Do not
substitute clear glass-type fuses for ceramic fuses. Refer to the wiring diagram when the ampere rating is unknown or
questionable.
NOTICE
Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt
deposits from metal surfaces.
8 TP-6861 11/24
Introduction
This manual provides operation instructions for 40-200EOZDJ/EOZCJ and 33-175EFOZDJ/EFOZCJ John Deere-powered
marine model generator sets equipped with the following controller:
• Decision-Maker® 3500
Refer to the engine operation manual for generator set engine scheduled maintenance information.
Information in this publication represents data available at the time of print. Discovery Energy, LLC reserves the right to change
this publication and the products represented without notice and without any obligation or liability whatsoever.
Read this manual and carefully follow all procedures and safety precautions to ensure proper equipment operation and to avoid
bodily injury. Read and follow the Safety Precautions and Instructions section at the beginning of this manual. Keep this manual
with the equipment for future reference.
The equipment service requirements are very important to safe and efficient operation. Inspect the parts often and perform
required service at the prescribed intervals. Obtain service from an authorized service distributor/dealer to keep equipment in
top condition.
Before installing a marine generator set, obtain the most current installation manual from your local distributor/dealer.
Only qualified persons should install the generator set.
Abbreviations
This publication makes use of numerous abbreviations. Typically, the word(s) are spelled out along with the abbreviation in
parentheses when shown for the first time in a section. Appendix A, Abbreviations, also includes many abbreviation definitions
Software
Distributors can download the latest software from the Kohler Power Resource Center website including the following topics:
• Software used by generator set controllers including updates and documentation references.
• Network Communications provides basics to terms, protocols, standards, wiring, configurations, and model.
• Engine Electronic Control Module (ECM) has information about electronic devices provided by the engine
manufacturer to manage engine data.
TP-6861 11/24 9
Service Assistance
For professional advice and conscientious service, please China

contact your nearest authorized distributor or dealer. North China Regional Office, Beijing
Phone: (86) 10 6518 7950
• Visit the company website at KOHLEREnergy.com. (86) 10 6518 7951
• Look at the labels and decals on your product or (86) 10 6518 7952
review the appropriate literature or documents Fax: (86) 10 6518 7955
included with the product.
East China Regional Office, Shanghai
• Call toll free in the US and Canada 1-800-544-2444. Phone: (86) 21 6288 0500
• Outside the US and Canada, call the nearest Fax: (86) 21 6288 0550
regional office. India, Bangladesh, Sri Lanka
Headquarters Europe, Middle East, Africa (EMEA) India Regional Office
EMEA Headquarters Bangalore, India
Netherlands B.V. Phone: (91) 80 3366208
Kristallaan 1 (91) 80 3366231
4761 ZC Zevenbergen Fax: (91) 80 3315972
The Netherlands Japan, Korea
Phone: (31) 168 331630
Fax: (31) 168 331631 North Asia Regional Office
Tokyo, Japan
Asia Pacific Phone: (813) 3440-4515
Asia Pacific Headquarters Fax: (813) 3440-2727
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
10 TP-6861 11/24
Maintenance and Service Parts/Related Literature
Maintenance and Service Parts

Figure 1 identifies maintenance and service parts for your generator set. Obtain a complete list of maintenance and service parts
from your authorized generator distributor/dealer.
Models
40EOZDJ/ 55EOZDJ/ 65EOZDJ/

40EOZCJ 55EOZCJ 65EOZCJ
33EFOZDJ/ 40EFOZDJ/ 50EFOZDJ/ 45EFOZDJ/ 55EFOZDJ/

Part Description 33EFOZCJ 40EFOZCJ 50EFOZCJ 45EFOZCJ 55EFOZCJ
Engine 4045DFM70 4045TFM75 4045TFM85
Air Filter Element 226915 GM86446
Belt, Alternator and Seawater Pump GM15402
Fuel Filter Element, Primary GM48727 GM48729
Fuel Filter Element, Secondary GM48728 GM48730
Oil Filter GM32809
Seawater Pump Impeller Kit GM50644
Zinc Anode 352142
Models
80EOZDJ/ 99EOZDJ/ 125EOZDJ/ 150EOZDJ/ 200EOZDJ/

80EOZCJ 99EOZCJ 125EOZCJ 150EOZCJ 200EOZCJ
70EFOZDJ/ 80EFOZDJ/ 100EFOZDJ/ 125EFOZDJ/ 175EFOZDJ/

Part Description 70EFOZCJ 80EFOZCJ 100EFOZCJ 125EFOZCJ 175EFOZCJ
Engine 4045AFM85 6068AFM85 6090AFM85
Air Filter Element GM87479 GM90310 GM98860
Belt, Alternator and Seawater Pump GM88686 GM88686 GM98801
Fuel Filter Element, Primary (Standard) GM48729
Fuel Filter Element, Secondary (Standard) GM48730

GM50263 * GM91974 *
Fuel Filter Element, Primary (with 3rd Party Option)
GM50263 *
Fuel Filter Element, Secondary (with 3rd Party Option)
Oil Filter GM32809 GM32809 GM50200
GM98756
Seawater Pump Impeller Kit GM18793 GM18793
GM117329 †
Zinc Anode 352142 352142 352142

 Includes primary and secondary fuel filter element
† Use with engine beginning at serial number RG6090L133666.
Figure 1 Maintenance and Service Parts
TP-6861 11/24 11
Related Literature
Figure 2 identifies related literature available for the generator sets covered in this manual. Only trained and qualified personnel
should install or service the generator set.
Pleasure Craft Models
40EOZDJ 55EOZDJ 65EOZDJ

40EFOZDJ 50EFOZDJ
33EFOZDJ 45EFOZDJ 55EFOZDJ
Commercial Models
40EOZCJ 55EOZCJ 65EOZCJ

40EFOZCJ 50EFOZCJ
Literature Type 33EFOZCJ 45EFOZCJ 55EFOZCJ
Specification Sheet, Pleasure Craft Models: EOZDJ/EFOZDJ G2-152 G2-159 G2-160 G2-153 G2-154
Specification Sheet, Commercial Models:
G2-161 G2-168 G2-169 G2-162 G2-163
EOZCJ/EFOZCJ
Marine Safety Precautions TP-5620
Installation Manual TP-6862
Service Manual—Generator TP-6863
Parts Catalog * TP-6864
Operation Manual—Engine TP-6444 TP-6889
Service Manual—Engine TP-5854
Service Manual, Fuel System—Engine TP-6829 TP-6830 TP-6454
Modbus® Communications Protocol Operation Manual TP-6113
SiteTech™ Software Operation Manual TP-6701
 Includes the generator and engine information.
Pleasure Craft Models

80EOZDJ 99EOZDJ 125EOZDJ 150EOZDJ 200EOZDJ
70EFOZDJ 80EFOZDJ 100EFOZDJ 125EFOZDJ 175EFOZDJ
Commercial Models
80EOZCJ 99EOZCJ 125EOZCJ 150EOZCJ 200EOZCJ
Literature Type 70EFOZCJ 80EFOZCJ 100EFOZCJ 125EFOZCJ 175EFOZCJ

Specification Sheet, Pleasure Craft Models:
G2-155 G2-156 G2-157 G2-158 G2-170
EOZDJ/EFOZDJ
Specification Sheet, Commercial Models:
G2-164 G2-165 G2-166 G2-167 G2-183
EOZCJ/EFOZCJ
Marine Safety Precautions TP-5620
Installation Manual TP-6862
Service Manual—Generator TP-6863
Parts Catalog * TP-6864
Operation Manual—Engine TP-6889 TP-6972
Service Manual—Engine TP-5854 TP-6458
Service Manual, Fuel System—Engine TP-6456 TP-6459
Modbus® Communications Protocol Operation Manual TP-6113
SiteTech™ Software Operation Manual TP-6701
 Includes the generator and engine information.
Figure 2 Generator Set Literature
12 TP-6861 11/24
Section 1. Specifications and Features
1.1 Introduction
The specification sheets for each generator set provide specific alternator and engine information. Refer to the respective
specification sheet for data not supplied in this manual. Consult the generator set operation manual, installation manual, engine
operation manual, and engine service manual for additional specifications.
A permanent magnet alternator is identified with one of the following designations: 4P_X, 4Q_X, 4R_X, 4S_X, or 4T_X, and
4UA_. Example: Gen. Model 4S12X. The first alpha character (S) identifies the alternator family. If the last character is an X, it
denotes a Fast-Response® X alternator.
The generator set has a rotating-field alternator with a smaller rotating-armature alternator turned by a common shaft. The main
rotating-field alternator supplies current to load circuits while the rotating- armature (exciter) alternator supplies DC to excite the
main alternator’s field.
The generator set has a 4-pole, rotating-field with brushless, permanent magnet (PM) alternator excitation system. The PM
system provides short-circuit excitation current up to 300% at 60 Hz (approximately 275% at 50 Hz) for a minimum of 10 seconds
to allow selective circuit breaker tripping.
Voltage regulation is provided by the generator set controller. Refer to the Service Manual for additional voltage regulator
information.
1.2 Permanent Magnet Alternator Concept

The alternator excitation system uses a permanent, magnet exciter with a silicon controlled rectifier (SCR) assembly which
controls the amount of DC current fed to the alternator field. This type of system uses a voltage regulator (located within the
Decision-Maker® 3500 controller) which provides a signal to control the SCR assembly through an optical coupling. The voltage
regulator monitors engine speed and alternator output voltage to turn a stationary light emitting diode (LED) on or off, according
to engine speed and output voltage. The LED is mounted on the end bracket opposite a photo transistor board which rotates on
the shaft. The photo transistor picks up the signal from the LED and tells the SCR assembly to turn on or off, depending upon
the need, as dictated by the voltage regulator. See Figure 3 or Figure 4.
The voltage recovery period of this type of alternator is several times faster than the conventionally wound field brushless
alternator because it does not have to contend with the inductance of the exciter field. It also has better recovery characteristics
than the static excited machine because it is not dependent upon the generator set output voltage for excitation power. Possibly
the greatest advantage of this type machine is its inherent ability to support short-circuit current and allow system coordination
for tripping downstream branch circuit breakers.
The alternator system delivers exciter current to the main field within 0.05 seconds of a change in load demand.
TP-6861 11/24 13
1
11 10
17
3B 5B
13
15
14 12
N A B C
16
TP-6863-1
1. Rotor shaft 9. FRX activator/photo transistor board

2. Rotor field windings (rotor assembly) 10. Photo transistor
3. Stator main windings (stator assembly) 11. LED optic board
4. Alternator assembly 12. Engine starting battery
5. Exciter assembly 13. Alternator protection (controller)
6. Exciter armature (connected to rotor) 14. Generator set controller
7. Exciter armature windings 15. AC voltage regulator (controller)
8. Exciter field magnets 16. AC output leads
17. Current sensing
Figure 3 Alternator Schematic (For Models 40-150EOZD(C)J/33-125EFOZD(C)J)
14 TP-6861 11/24
1
13
12
6
14 11
7
10
TP-6861-1
1. Field 8. Starting battery

2. Main alternator 9. Alternator protection (controller)
3. RRA (rotating rectifier assembly) 10. AC voltage regulator (controller)
4. Exciter alternator 11. LED board
5. Exciter field magnets 12. Photo transistor board
6. Exciter armature 13. Stator
7. Optical coupling 14. Current sensing
Figure 4 Alternator Schematic (For Models 200EOZD(C)J/175EFOZD(C)J)
TP-6861 11/24 15
1.3 Short Circuit Performance
When a short circuit occurs in the load circuit(s) being served, output voltage drops and amperage momentarily rises to
600%-1000% of the generator set’s rated current until the short is removed. The SCR assembly sends full exciter power to the
main field. The alternator then sustains up to 300% of its rated current. Sustained high current will cause correspondingly rated
load circuit fuses/breakers to trip. The controller alternator protection feature serves to collapse the alternator’s main field in the
event of a sustained heavy overload or short circuit.
16 TP-6861 11/24
1.4 Service Views
8 22
5 9
6 21
7 9
4 4
2 3 6
1 10 23
11
12
20 12
19
17 16 15 14 13 24
18 25
28 29 27
27
26
4 30
ADV-8501C
1. Nameplate 16. Closed crankcase vent filter

2. Controller 17. Oil drain valve
3. Air cleaner 18. Fuel filter
4. Fuel return 19. Cable connector for customer load leads
5. Lifting eye 20. Cooling air inlets (alternator)
6. Fuel inlet 21. Coolant overflow bottle
7. Oil fill 22. Pressure cap
8. Overflow tube 23. Exhaust outlet
9. Water fill 24. Belt guard
10. Seawater pump 25. Coolant drain
11. Oil dipstick (check) 26. Fuel injection pump
12. Seawater inlet 27. Anticorrosion zinc anode (2), one on each end of the heat
exchanger
13. Oil filter 28. Positive battery connection
14. Fuel filter/water separator 29. Heat exchanger
15. Fuel pump 30. Negative battery connection
Figure 5 Service Views, Typical (65EOZD(C)J/55EFOZD(C)J Model Shown)
TP-6861 11/24 17
5
20
4 6 7 19
3 8 9 7
2 10
1 21
11
4
18
11
15 12 9
17 16 14 13
23 22
25
26 27
21
24
29 28
ADV-8506D
1. Nameplate 16. Closed crankcase vent filter

2. Controller 17. Cable connector for customer load leads
3. Air cleaner 18. Cooling air inlets (alternator)
4. Fuel inlet 19. Coolant overflow bottle
5. Lifting eye 20. Pressure cap
6. Overflow tube 21. Exhaust outlet
7. Water fill 22. Coolant drain
8. Fuel filter/water separator 23. Belt guard
9. Oil fill 24. Fuel injection pump
10. Seawater pump 25. Positive battery connection
11. Seawater inlet 26. Heat exchanger
12. Oil filter 27. Anticorrosion zinc anode (2)
13. Oil check 28. Negative battery connection
14. Fuel filter 29. Fuel return
15. Oil drain
18 TP-6861 11/24
4
2 5 6 10
7 8 9 11
1 3 12
16
16
15
23
21 20 19 18 17
22 15
14 13
25 26
12
24
29 28 27
ADV-8508A
1. Nameplate 16. Seawater inlet

2. Controller 17. Oil filter
3. Air filter (inside of tray) 18. Oil check
4. Closed crankcase vent filter 19. Fuel filter
5. Lifting eye 20. Fuel filter/water separator
6. Overflow tube 21. Oil drain
7. Water fill 22. Cable connector for customer load leads
8. Oil fill 23. Cooling air inlets (alternator)
9. Seawater pump 24. Fuel return
10. Coolant overflow bottle 25. Positive battery connection
11. Pressure cap 26. Heat exchanger
12. Exhaust outlet 27. Anticorrosion zinc anode (2)
13. Coolant drain 28. Negative battery connection
14. Belt guard 29. Fuel injection pump
15. Fuel inlet
TP-6861 11/24 19
4
5 6 7 10
11 13
2 8 14
11
1 3 9
12 15
6
17
29
22
21 17 20 19 18
16
25
29
29 23 24 15
28 27 26
ADV-8747-
1. Controller 16. Belt guard

2. Nameplate 17. Fuel inlet
3. Air cleaner 18. Fuel filter
4. Lifting eye 19. Fuel filter/water separator
5. Closed crankcase vent filter 20. Oil drain
6. Fuel return 21. Cable connector for customer load leads
7. Oil filter 22. Cooling air inlets (alternator)
8. Oil fill/oil check 23. Seawater inlet
9. Coolant overflow bottle 24. Positive battery connection
10. Fuel injection pump 25. Aftercooler
11. Water fill 26. Negative battery connection
12. Overflow tube 27. Block drain valve
13. Pressure cap 28. Seawater pump
14. Heat exchanger 29. Anticorrosion zinc anodes (5)
15. Exhaust outlet Heat Exchanger:
1 on service side and 2 on non-service side
Aftercooler:
2 on non-service side, rear
20 TP-6861 11/24
1.5 Introduction
The spec sheets for each generator set provide model-specific generator and engine information. Refer to the respective spec
sheet for data not supplied in this manual. Refer to the generator set service manual, installation manual, engine operation
manual, and engine service manual for additional specifications.
1.6 Controller Specifications

Decision-Maker® 3500
Power source with circuit protection 12- or 24-volt DC
400 milliamps at 12V

Power drain
200 milliamps at 24V
Humidity range 5-95%
Operating temperature -40° to 70°C (-40° to 158°F)
Storage temperature -40° to 85°C (-40° to 185°F)
Note:
Have setup and adjustments of the Decision-Maker® 3500 controller performed only by an authorized distributor/dealer. The
setup and adjustments are password protected.
1.7 Decision-Maker® 3500 Controller Information

The following data must be resident for the controller to function.
• Application program contains the software that controls system operation. The application file was preprogrammed
in the original controller at the factory.
• Personality profile is specific to the engine and alternator and was preprogrammed in the original controller at the
factory.
Typically, the authorized distributor/dealer creates a backup of the personality profile and passes this information onto
the owner. Inform the owner to store this information for possible future use such as controller replacement or other
circumstances requiring a backup.
Note:
If the personality profile is NOT available, request a replacement from Kohler Aftermarket Parts Department.
Enter an aftermarket parts order for part number PROFILE. Include in the order notes the generator set model,
specification number, serial number, generator set modifications, and email of recipient.
• User parameters unique to an installation include timer values, setpoints, generator set data such as voltage and
input/output selections. These parameters are typically set up for or by the installer at the time of installation. User
parameters are typically recorded on the personality profile disk, a separate backup disk/drive, or written on a paper
form.
Note:
If the user parameters are included on the personality disk, the disk label should indicate Site Program—Yes.
Note:
After the unit is set up on the vessel, authorized distributor/dealer saves any user parameter changes to an external
medium. Authorized distributor/dealer passes this information onto the owner. The owner should store this information
for possible future use such as controller replacement or other circumstances requiring a backup.
Note:
Controller service replacement kits do not include the three files. The service technician must install the three files into
the replacement controller.
TP-6861 11/24 21
1.8 Controller Features
The controller features include the annunciator lamp, graphical display and pushbutton/rotary selector dial, switches and
controls, and terminal blocks. See Figure 9 for an illustration of the controller front panel. The following paragraphs detail the
features by general topics. The controller provides:
• The backlit LCD (liquid crystal display) for monitoring the generator set functions and output values
• Master control buttons with status lights
• Fault lamp
• Pushbutton/rotary selector dial to navigate the generator set displays
• Alarm horn and alarm silence switch/light
• Mini USB connector for PC setup using SiteTech™ software
The controller features, accessories, and menu displays depend upon the engine electronic control module (ECM) setup and
features. Controller features apply to generator set models with ECM and non-ECM engines unless otherwise noted.
Graphical display Annunciator fault lamp Alarm horn (interior, located

behind controller face)
Pushbutton/rotary
Emergency stop switch selector dial
Mini USB connection
Alarm silence button with lamp (press and hold Generator set master control, OFF/RESET-AUTO-RUN
for 3 seconds for lamp test) buttons with lamps
Figure 9 Decision-Maker® 3500 Controller with Digital Display and Pushbutton/Rotary Selector Dial
Note:
Press the pushbutton/rotary selector dial to turn on the controller lights and display. The backlight turns off 60 minutes after the
last entry when in the AUTO mode.
Note:
After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), the menu is reset to the top of the main menus
and auto-paging activates for the Overview submenus.
Note:
Measurements display in metric or English units. Use the Controller Configuration menu to change the measurement display.
22 TP-6861 11/24
1.8.1 Switches and Controls
Note:
US/Metric Display is selectable in the Controller Configuration Menu section.
Alarm Horn. The alarm horn alerts the operator or other attendants that a warning or shutdown condition exists.
Alarm (Horn) Silence. The alarm silence switch silences the alarm horn at the operator’s discretion. Press the master control
switch AUTO button before pressing the alarm silence button. The alarm horn cannot be silenced unless the master control
switch AUTO button is pressed.
Note:
Additional alarm silencing options are shown in the Controller Configuration Menu section.
Restore alarm horn switches at all locations including those on remote annunciator kits after correcting the fault shutdown to
avoid reactivating the alarm horn. See the Operation, Controller Resetting section for resetting the controller.
Emergency Stop. The operator-activated pushbutton immediately shuts down the generator set in emergency situations. Reset
the emergency stop switch after shutdown by pulling the emergency stop switch outward. Use the emergency stop switch for
emergency shutdowns only. Use the master control switch OFF/RESET button for normal shutdowns.
Generator Set Master Control (OFF/RESET-AUTO-RUN). These buttons reset the controller fault lamps and start/stop the
generator set. Additional information is shown in the Operation section.
Lamp Test. Press and hold the Alarm Silence/Lamp Test button to test the controller indicator lamps, alarm horn, and digital
display.
Pushbutton/Rotary Selector Dial. This control provides access to the menus for monitoring. Press the selector dial to activate
the graphical display and to select choices shown on the display. Rotate the dial to navigate through the menus.
The pushbutton/rotary selector dial has several features and functions:

• Momentarily press the dial to activate the graphical display if dark.
• Rotate the dial to navigate through the main menus—turn counterclockwise to go forward (down) and clockwise to go
back (up). The menus wrap to the beginning.
• Press the dial at a given main menu to access the submenus within the selected main menu.
• When in the submenu, rotate the dial to navigate through the submenu—counterclockwise to go forward (down) and
clockwise to go back (up). The menus wrap to the beginning.
• Momentarily press the dial when in the submenu to make a user selection choice (if available) or to go back to the
respective main menu.
• To return to the previous menu, rotate the dial (counterclockwise or clockwise) until the back arrow appears in the upper
left corner and press the dial.
01:46 PM
GENERATOR METER
11/07/13
► L1-L2 VOLTS ###.#V
L2-L3 VOLTS ###.#V
L3-L1 VOLTS ###.#V
AVG GEN VOLTAGE L-L ####V
Back arrow GEN FREQUENCY ##.#Hz
01:46 PM
GENERATOR METER
11/07/13
L1-L2 VOLTS ###.#V
L2-L3 VOLTS ###.#V
L3-L1 VOLTS ###.#V
AVG GEN VOLTAGE L-L ####V
GEN FREQUENCY ##.#Hz
Figure 10 Back Arrow Location

• After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), the menu resets to the top of the
main menus and auto-paging activates for the Overview submenus.
TP-6861 11/24 23
1.8.2 Annunciator Lamps
The controller has a single annunciator fault lamp providing visual generator set status. In addition, each button has a lamp.
See Figure 11.
Lamp/Button Lamp Color

Yellow (Warning) or Red
Alarm (Fault) Lamp
(Shutdown)
Off/Reset Button Blue
Auto Button Blue (System Ready)
Run Button Blue
Alarm Silence Button Orange
Figure 11 Annunciator Lamps
System Status Lamps (Master Control Switches)
The lamp illuminates on the master control switch AUTO (automatic start) button indicating the system senses no faults and the
unit is ready to start by remote command.
The lamp illuminates on the master control switch OFF/RESET button indicating the generator set is stopped.
The lamp illuminates on the master control switch RUN button indicating the generator set is cranking or running from a local
command.
Only one of the three master control switch lamps will illuminate at any given time.
Alarm Silence Lamp. Orange lamp illuminates indicating the alarm horn was silenced.
Alarm Fault Lamp. Yellow lamp illuminates indicating a warning condition or red lamp illuminates indicating a shutdown
condition. See System Warning Fault Lamp and System Shutdown Fault Lamp following for system fault conditions.
System Warning Fault Lamp. Yellow lamp identifies an existing fault condition that does not shut down the generator set. A
continuing system warning fault condition may cause a system shutdown. Correct all system warnings as soon as practical.
See the System Fault Warning Lamp with Digital Displays section, for definitions of the items listed.
System Shutdown Fault Lamp. Red lamp indicates that the generator set has shut down because of a fault condition. The unit
will not start without resetting the controller, see the Controller Resetting procedure section.
See the System Fault Shutdown Lamp with Digital Displays section, for definitions of the items listed.
1.8.3 Graphical Display
Press the pushbutton/rotary selector dial to turn on the controller lamps and display. The backlight turns off 10 minutes after the
last entry when in the AUTO mode.
The generator set must be running for some displays to indicate values. If the generator set is not running some values will
display zero or N/A (not available).
The 5-line, 35 character per line backlit heated display provides generator set and engine data, system status, and fault
information. See the Decision-Maker® 3500 Controller with Digital Display and Pushbutton/Rotary Selector Dial figure. The
graphical display shows abbreviations in some instances.
Note:
US/Metric Unit Display is selectable in the Controller Configuration menu.
Note:
After about 5 minutes of no user input (pushbutton/rotary selector dial or buttons), the menu resets to the top of the main menus
and auto-paging activates for the Overview submenus.
The main menus are listed below. Within each main menu are multiple submenus with descriptions following.
• Metering (See the Metering Menu section)
• Generator Information (See the Generator Information Menu section)
• Controller Configuration (See the Controller Configuration Menu section)
• I/O Setup (See the I/O Setup Menu section)
• Active Events (See the System Fault Warning Lamp with Digital Displays, System Fault Shutdown Lamp with Digital
Displays, and Status and Notice Digital Display section)
24 TP-6861 11/24
1.9 Metering Menu
1.9.1 Generator Metering Submenu
• Volts displays the alternator output AC voltages. The display shows all line-to-line and line-to-neutral voltage
combinations for three-phase or single-phase configurations. The display also shows the average line-to-line and line-
to-neutral voltages.
Note:
The average line-to-neutral is not listed for the delta connection.
• Current displays the alternator output AC amps. The display shows each line (L1-L2-L3) of three-phase models or L1-
L2 current for single-phase models. The display also shows the average current.
• Frequency (Hz) displays the frequency (Hz) of alternator output voltage.
• Power kW displays the total and the individual L1, L2, and L3 alternator output as actual output values.
• Power Factor displays the total and individual line power factor values.
• % Rated kW displays alternator output as a percentage of the entered rated value.
• Reactive Power kVAR displays the total and individual L1, L2, and L3 kVAR.
• Apparent Power kVA displays the total and individual L1, L2, and L3 kVA.
• % Rated kVA displays alternator kVA as a percentage of the entered rated value.
• Phase Rotation displays the actual generator rotation.
1.9.2 Engine Metering Submenu
Note:
Not all of these engine metering submenus may apply.
• Engine Speed (Tachometer) displays the engine speed (RPM) at which the engine is presently running.
• Oil Pressure displays the engine oil pressure.
• Coolant Temperature displays the engine coolant temperature.
• Fuel Rate displays the calculated fuel consumption rate based on fuel injector outputs (if available from ECM).
• Gen Battery Voltage displays the DC voltage of the generator starting battery(ies) as measured by the controller.
• ECM Battery Voltage displays the DC voltage of the engine starting battery(ies) as reported from the ECM.
• Oil Temperature displays the engine oil temperature.
• Coolant Pressure displays for the engine coolant pressure.
• Fuel Pressure displays the fuel line pressure at the generator set inlet for gas-powered models.
• Fuel Temperature displays the fuel supply temperature.
• Fuel Used Last Run displays the accumulated amount of fuel used since last reset (if available from ECM).
• Crankcase Pressure displays the engine crankcase pressure.
• Intake Air Pressure displays the engine intake manifold air pressure if available.
• Intake Air Temperature displays the engine intake manifold air temperature if available.
TP-6861 11/24 25
1.9.3 Overview Submenu
Generator Status:
• Average Volts Line-to-Line. For three-phase configurations the average line-to-line voltage of L1, L2, and L3 is
displayed. Single-phase configurations show the L1-L2 voltage.
• Average Current value displays as the average for three-phase configurations or the current value for L1-L2 with
single-phase configurations.
• Frequency (Hz) value displays for the output AC voltage.
Engine Status:
• Coolant Temperature displays the engine coolant temperature.
• Oil Pressure displays the engine oil pressure.
• Battery Voltage displays the DC voltage of the engine starting battery(ies).
System Status:
• Fuel Pressure displays fuel injection pressure.
• Total Power displays the generator operating power rating in kW.
• Engine Run Time displays the total run time hours.
1.9.4 Paralleling Metering Submenu
Note:
The paralleling metering is only valid if the Decision-Maker 3500controller is controlling a motor-operated circuit breaker.
• Connected to Bus displays if the generator is connected to the paralleling bus (the output breaker or contactor is
closed).
• Avg Bus Voltage L-L displays the average of the three-phase line-to-line voltage measured by the paralleling bus
sensing.
• Avg Gen Voltage L-L displays the average of the three-phase line-to-line voltage of the generator output.
• Bus Frequency displays the cycle frequency of the paralleling bus.
• Gen Frequency displays the cycle frequency of the generator.
• Bus Total Power displays the real power provided by all the generators in the paralleling system.
• Bus % of Rated kW displays the ratio between the Bus Total Power and the Bus Total Capacity (found in the Generator
Management screen) expressed as a percentage.
• Bus % of Rated kVAR displays the ratio between the reactive load on all generators in the paralleling system and the
bus reactive capacity (the sum of ¾ of the rated kW of all connected generators) expressed as a percentage.
26 TP-6861 11/24
1.10 Generator Information Menu
1.10.1 Generator Information Submenu
• Total Run Time displays the total run time hours.
• Hours Loaded displays the total loaded hours.
• Hours Unloaded displays the total unloaded hours.
• kW Hours displays the total kW hours.
• Operating Hours displays the total operating hours.
• Total Number of Starts displays the total number of times that the engine was started via the generator set controller.
• Last Maintenance displays the date on the controller system clock when the last maintenance was performed.
• Operating Hours Since Maintenance displays the total number of hours of operation since the last maintenance date.
• Starts Since Maintenance displays the total number of generator set startup events since the last maintenance date.
• Engine Hours Since Maintenance displays the total engine hours since last maintenance.
• Loaded Since Maintenance displays the total loaded hour since last maintenance.
• Unloaded Since Maintenance displays the unloaded hours since last maintenance.
• kW Hours Since Maintenance displays the total kW hours since last maintenance.
• Reset Maintenance Records: displays a Yes/No choice for the user to select.
• Last Start displays the date when the generator set last operated.
• Last Run Length displays the length of time that the engine ran the last time it was started via the generator set
controller.
• Controller Serial No. displays the controller serial number.
• Software Version displays the software version number. Use the version number to determine if an upgrade is needed
and/or when troubleshooting the controller.
• ECM Serial No. displays the ECM serial number.
• Genset Model No. displays the generator set model number. Only adjustable from SiteTech™.
• Genset Spec No. displays the generator set specification number. Only adjustable from SiteTech™.
• Genset Serial No. displays the generator set serial number. Only adjustable from SiteTech™.
• Alternator Part No. displays the alternator part number. Only adjustable from SiteTech™.
• Engine Part No. displays the engine part number. Only adjustable from SiteTech™.
• Engine Model No. displays the engine model number. Only adjustable from SiteTech™.
• Engine Serial No. displays the engine serial number. Only adjustable from SiteTech™.
TP-6861 11/24 27
1.10.2 Event History Submenu
Generator Event History:
This menu allows the user to review up to 1000 entries of generator system events including shutdown faults, warning faults,
notices, and status events with date and time stamp. See Controller Fault Diagnostics section for a list of the items that appear
on the Generator Event History.
Engine Event Log:
A message is sent each time there is a change in a monitored engine condition (i.e. fault becomes active, fault is cleared). Upon
broadcast of this message, the controller will request another message that contains the following information for each fault:
• SPN (Suspect Parameter Number) is a four-digit code that represents an engine component.
• FMI (Failure Mode Indicator) is a two-digit code that represents the type of fault that occurred (i.e. short circuit, out of
range).
• Occurrence Count is a count of how many times a fault has occurred.

1.10.3 Configuration Submenu
Generator Configuration
The values in this menu are user-entered for the generator set configuration and are NOT measured values of the generator
set.
Note:
• Operating Mode displays the programmer entered generator set application configuration as Standby or Prime.
• Application Type displays the programmer entered generator set application type as None, Marine, Mobile, Standby
or Prime.
• System Voltage displays the programmer-entered L1-L2-L3 output voltage for three-phase or the L1-L2 output voltage
for single-phase.
• System Frequency displays the programmer-entered L1-L2-L3 output voltage frequency for three-phase or the L1-L2
output voltage frequency for single-phase.
• System Phase displays the programmer-entered configuration as Single Phase, Single Phase Dogleg, Three Phase
Wye, or Three Phase Delta.
• Rated Engine Speed displays the programmer entered engine speed in RPM.
• Adjusted Engine RPM displays the target engine speed setting.
• kW Rating displays the programmer entered kW value for the generator set.
• kVA Rating displays the programmer entered kVA value for the generator set.
• Rated Current displays the programmer entered current value for the generator set.
• Battery Voltage displays the programmer entered battery voltage.
• Engine Start Delay displays the time delay before the generator set starts while the master switch is in AUTO or RUN
positions.
• Starting Aid Delay displays the engine starting aid activation time.
• Crank On Delay displays the time allocated for generator set crank on in seconds.
• Crank Pause Delay displays the time allocated for generator set crank pause in seconds.
• Engine Warmed Up displays the temperature when the engine is warmed up enough to be loaded.
• Engine Cooled Down displays the temperature below which the engine cooldown can be overridden.
28 TP-6861 11/24
• Cooldown Delay displays the time delay for engine cooldown while the master switch is in the AUTO or RUN positions
and not in the idle mode.
• Cooldown Override allows the user to select the Cooldown Temperature Override Mode. If set to ON, the engine will
stop immediately if the coolant temperature is below the engine cooled threshold, but will run for the duration of the
cooldown cycle otherwise. If set to OFF, the engine will always complete the cooldown cycle.
• Fuel Type displays the programmer entered fuel type as NG (Natural Gas), LP (Liquefied Petroleum), Gasoline, Diesel,
or Unknown.
• Crank Cycles Limit displays the programmer entered crank cycle.
• Enable NFPA Defaults: Allows the user to Enable or Disable the NFPA defaults.
• Enable Emergency Battlemode: Allows the user to turn On/Off the emergency battlemode feature.
Note:
Conditional for certain units.
Protection Configuration
Note:
The time delays are user adjustable using SiteTech™. Have setup and adjustments of the Decision-Maker® 3500 controller
performed only by an authorized distributor/dealer. The setup and adjustments are password protected.
• Overvoltage displays the percentage of the system voltage that the generator voltage must exceed for an overvoltage
condition to be indicated.
• Overvoltage Delay displays the time that the generator voltage must be in an overvoltage condition before a fault is
indicated.
• Undervoltage displays the percentage of the system voltage that the generator voltage must drop below for an
undervoltage condition to be indicated.
• Undervoltage Delay displays the time that the generator voltage must be in an undervoltage condition before a fault
is indicated.
• Overfrequency displays the percentage of the system frequency that the generator frequency must exceed for an
overfrequency condition to be indicated.
• Underfrequency displays the percentage of the system frequency that the generator frequency must drop below for
an under frequency condition to be indicated.
• Overspeed displays the engine speed that the engine must exceed for an overspeed condition to be indicated.
• Low Battery Voltage displays the system battery voltage that the battery voltage must drop below for a low battery
voltage condition to be indicated.
• High Battery Voltage displays the system battery voltage that the battery voltage must exceed for a high battery
voltage condition to be indicated.
TP-6861 11/24 29
1.10.4 Voltage Regulation Submenu
Note:
The Decision-Maker® 3500 controller has a built-in voltage regulation function. This means that no external voltage regulator is
necessary. The voltage regulation of the controller uses Root Mean Square (RMS) sensing for fast response to changes in
indicated and regulated voltages resulting in excellent regulation accuracy.
The descriptions of the voltage regulator adjustments and features follow.
Voltage Adjust. The voltage adjust allows the user to enter the desired generator set output level. The voltage regulator controls
the average of the three output phase voltages to this target in a three phase configuration, and L1L2 voltage to this target in a
single phase configuration.
Submenus display the individual line-to-line voltages and the individual phase voltages. These voltages are for reference only
and are relevant in unbalanced load conditions. The voltage adjust setpoint can be changed to accommodate an important
phase in an unbalanced system.
Target Voltage. The voltage that the Decision-Maker® 3500 controller is trying to achieve including droop and parallelling bias.
Volts/Hz. The excitation control system includes an under-frequency unloading feature. This is sometimes referred to as Volts-
per-Hertz or V/Hz. When the frequency drops below a certain value, the output voltage is reduced to decrease engine load,
allowing the engine speed to recover more quickly. The output voltage reduction is based on the frequency.
Volts per Hz Settings. The amount of voltage reduction can be adjusted to achieve the desired transient response of the engine
and alternator system. The V/Hz function will use the following parameter settings:
• V/Hz Setpoint (Hz)
• V/Hz Slope (%/Hz)
• V/Hz reduction limit (fixed at 50% of rated voltage)
Volts per Hz Adjustment. The V/Hz settings can be changed using the PC-based setup program or at the front panel using the
password. The setup program will read current settings to determine a similar function when making changes to alternator
connections, system voltages or operating frequency.
Volts/Hz Setpoint. This adjustment affects the voltage droop (volts per Hz) when load is applied and underfrequency occurs.
The volts/Hz setpoint setting defines the threshold below which the underfrequency unloading is active. Any frequency below
the setpoint causes the voltage to drop thus reducing the load allowing the engine speed to recover according to the volts/Hz
slope setting.
Engine speed recovery depends upon characteristics such as engine make, fuel type, load types, and operating conditions. The
volts/Hz setpoint setting is set at the factory to match the engine speed recovery characteristics for the application.
Volts/Hz Slope. This setting determines how much the voltage drops during an underfrequency condition. The Volts/Hz Slope
setting is set at the factory. Typically, applying a large electrical load causes a dip in engine speed and frequency. The voltage
regulator reduces voltage, allowing engine speed recovery. The volts-per-Hz setting determines the degree of unloading that
occurs for each 1 Hz decrease in frequency.
Voltage Droop at 100% kVAR (Reactive Droop). Reactive droop compensation provides reactive current flow adjustment in
the generator set when connected in paralleling applications. Reactive droop reduces excitation levels with increasing reactive
power. A reduced excitation level reduces generator set reactive power or generated VARs, improving reactive load sharing.
Enter the parameter as a percentage of system voltage when full-rated load with 0.8 power factor is applied. Any loads less than
full load force the voltage to drop by the ratio of reactive volt-amps (VARs) to rated VARs.
30 TP-6861 11/24
Voltage Gain Adjust. Regulator gain refers to the gain of the control system. Generally, the higher the gain the faster the system
responds to changes and the lower the gain, the more stable the system.
If the voltage is slow to recover when loads are applied or removed, increase the regulator gain. If the voltage is unstable,
decrease the regulator gain.
The voltage regulator value is reviewable at all times and provides the ability to fine adjust voltage. Changing the system voltage
or replacing the circuit board typically requires a voltage adjustment.
The user can change the individual value or can select Reset Regulator Defaults?-Yes to reset to the default value. The Reset
Regulator Defaults display will only show if editing is enabled.
Start-Up Ramp Rate. Slowly ramps the voltage to its target to minimize voltage overshoot at startup.
1.10.5 Voltage Selector Switch
The voltage selector switch menu does not apply to the EOZDJ/EFOZDJ and EOZCJ/EFOZCJ models.
1.10.6 Paralleling Operation
Note:
Have paralleling setup performed by appropriately skilled and suitably trained maintenance personnel familiar with generator set
parallel commissioning, operation, service, and troubleshooting.
The Decision-Maker® 3500 controller is a paralleling controller and provides varying degrees of paralleling functionality.
While the Decision-Maker® 3500 controller can also be used with external switchgear controlling the speed, voltage and
paralleling breaker/contactor, the Parallel Operation menu is used to configure settings for parallel operation where the controller
is communicating on a network with other controllers and provides integral paralleling functionality.
Paralleling Setup
The Paralleling Setup menu is intended to configure the basic settings for the parallel operation of the controller. Most of the
settings in this menu are configured during commissioning and do not require user adjustment. There are a few settings that
may be viewed or adjusted after commissioning is complete.
Volts-Hz OK Delay. The time that the voltage and frequency must remain within the acceptable window before the controller
considers them to be stable. The voltage window requires the output voltage of the generator to be within the Voltage OK
Pickup of the system voltage, the frequency window requires the operating frequency of the generator to be within the
Frequency OK Pickup of the system frequency. This delay may need to be increased if the first generator to close to the bus
has not yet reached rated operating parameters or if the speed/voltage is in an overshoot condition when the generator comes
online.
First On Delay. The time that the system will wait before closing the first generator to the bus. This delay should be set as low
as possible, but can be extended to ensure that a different generator will be the first to close. One generator in the system should
have the first on delay set to a low number to minimize the delay before the generator can supply power to the load.
kW Ramp Rate. The generator will load and unload against the other generators at this rate. The default rate (5%/sec) requires
20 sec to accept 100% load. Increasing the ramp rate will allow the generator to disconnect more quickly from the bus when
signal to stop by generator management, but may result in variations in the output voltage or frequency of the generator system.
The ramp rate can be decreased if there is noticeable fluctuation in the voltage or frequency when a generator is loading or
unloading.
Trims Enable. The trims are the mechanism that the paralleling system uses to keep the output voltage and frequency near the
rated values when the generator system is operating. The trims default is enabled on all generators, but they can be disabled
on some generators in the system to improve load sharing. The trims should be enabled on at least one generator in the
paralleling system or the voltage and frequency may drift significantly during the operation of the system.
Load Enable. The generator will unload and trip the circuit breaker/contactor when this setting is set to OFF. This can be used
to force a generator to soft-unload and shut down for service. To keep the breaker/contactor from reclosing, the Sync Mode in
Auto can be set to OFF (see Sync Mode In Auto below). A generator is not considered for generator management when Load
Enable is set to OFF. This parameter should always be returned to ON after the generator has been stopped for service, as it
will keep the generator from sharing load or starting for generator management if it is set to OFF.
TP-6861 11/24 31
Stand Alone Mode. This will tell the controller that it is a paralleling controller, even if it does not see another generator on the
communication lines. This may be required if all other generator controllers are removed from service for a period of time in
which the battery power to this controller will be cycled (the controller remembers that it is in a paralleling system until power is
cycled). If the controller sees another controller on the PGEN communication network, this parameter will not change the
operation of the system in any way.
Sync Mode In Auto. This should be set to Active before leaving the vessel when commissioning or testing is complete, but can
be used to keep the controller from closing the paralleling breaker/contactor to complete a test or to take a generator out of
service. Setting the Sync Mode to OFF will disable the synchronizer, the paralleling breaker/contactor will not close with the
synchronizer disabled. To remove a generator from service manually, set the Sync Mode in Auto to OFF, wait for any additional
generators to start, and set the Load Enable to OFF. When the breaker/contactor trips, stop the generator by pressing the OFF
button, then set the Sync Mode back to Active and the Load Enable back to ON.
Note:
Pressing the OFF button will also disconnect the generator from the paralleling bus, but it will not give the other generators any
opportunity to negotiate an arrangement to support the load. Even if there are enough generators online to support the load, the
voltage and frequency may dip when the other running generators are required to pick up the load formerly supported by this
generator.
Sync Mode In Run. The default setting for this parameter is Check. In Check mode, the controller will close the paralleling
breaker/contactor to a dead bus (no other generators supplying the load) but will hold synchronism with the bus without closing
the paralleling breaker/contactor if it is already supplied by another generator. This allows operational verification of the
synchronizer, but does not allow the generator to supply the load. If the generator system is to be operated with the engine
control switch in Run, the Sync Mode in Run may need to be set to Active.
Note:
System Start (AUTO-RUN) is the preferred method of operating a generator system. RUN is intended for testing or verification
only.
Note:
Sync Mode in Auto and Sync Mode in Run can also be found on the Synchronizing Setup screen.
Synchronizing Setup
This screen is primarily used to configure the synchronizer. There is a lot of metering information that can be accessed on this
screen, but the parameters should be adjusted only during commissioning.
Volts-Hz OK. The voltage and frequency have been within the acceptable window for the Volts-Hz OK Delay.
In Sync. The frequency, voltage and phase rotation of the generator have matched that of the bus and the generator and bus
have been in phase for the duration of the dwell timer. This value is only updated when the controller is synchronizing (Synch
Mode = Active, Passive or Check, breaker/contactor is open, generator is running).
Voltage Matched. The difference between the generator voltage and the bus voltage is within the acceptable window. This
value is only updated when the controller is synchronizing (Synch Mode = Active, Passive or Check, breaker/contactor is open,
generator is running).
AVG Bus Voltage L-L. The average voltage of the paralleling bus.
AVG Gen Voltage L-L. The average voltage of this generator.
Voltage Bias. The amount that the controller is attempting to adjust the output voltage
(100% bias = +10% on the output voltage, -100% = -10% on the output voltage).
The controller adjusts the Voltage Bias to match the generator voltage to the bus voltage
Frequency Matched. The difference between the generator frequency and the bus frequency is within the acceptable window.
This value is only updated when the controller is synchronizing (Synch Mode = Active, Passive or Check, breaker/contactor is
open, generator is running).
Bus Frequency. The operating frequency of the paralleling bus.

Gen Frequency. The operating frequency of this generator.
32 TP-6861 11/24
Speed Bias. The amount that the controller is attempting to adjust the output frequency of the generator
(100% bias = +5% on the engine speed, -100% = -5% on the engine speed).
The controller adjusts the Speed Bias to match frequency and phase with the paralleling bus.
Phase Matched. The phase between the generator voltage and the bus voltage is within the acceptable window. This value is
only updated when the controller is synchronizing (Synch Mode = Active, Passive or Check, breaker/contactor is open, generator
is running).
Phase Difference. The phase angle between the generator and the bus.
Note:
This value is only accurate if the generator is running and the bus is energized. The phase angle must be established between
two waveforms.
Dwell Time Remaining. The remaining time for the dwell timer in seconds. The generator is considered to be in Sync when the
dwell timer expires. If this value is resetting to the Dwell Time (directly above it), the generator is not holding synchronism. This
value is only updated when the controller is synchronizing (Synch Mode = Active, Passive or Check, breaker/contactor is open,
generator is running).
Sync Time Remaining. The remaining time before the controller issues a Failure to Synchronize warning. The Failure to
Synchronize warning will cause the generator management to consider this generator unreliable and to start another generator
(if available). If the system commissioning has been performed properly, this warning should only occur if the system is
overloaded or if there is a malfunction on this generator. This value is only populated when the generator is actively synchronizing
(Sync Mode = Active, breaker/contactor is open, generator is running).
Note:
Dwell Time Remaining and Sync Time Remaining are not supported on all firmware versions. If the controller firmware does not
support the time remaining parameters, they will be populated with N/A.
Sharing Setup
Bus % of Rated kW. The ratio of the total load on the bus (sum of the loads on all connected generators) to the total bus
capacity (sum of all the connected generator capacities), expressed as a percentage. This value can be monitored to determine
system loading (also found on Bus Metering screen, and Generator Management screen).
Gen % of Rated kW. The ratio of the total load on this generator to its rated capacity, expressed as a percentage. This value
can be compared to the Bus % of Rated kW (directly above it) to determine if the system is sharing load properly. The acceptable
difference between the generator and bus is site-dependent. The adjustment of the parameters on this screen (during
commissioning) will determine how closely the generators share load.
Speed Bias. The amount that the controller is attempting to adjust the output frequency of the generator
(100% bias = +5% on the engine speed, -100% = -5% on the engine speed).
The controller adjusts the speed bias to share load between the generators connected to the paralleling bus.
Bus % of Rated kVAR. The ratio of the total reactive load on the bus (sum of the reactive loads on all connected generators)
to the total bus reactive capacity (sum of all the connected generator reactive capacities), expressed as a percentage. This value
can be monitored to determine system loading (also found on Bus Metering screen). The Reactive Power rating of the generator
is fixed at 3/4 of the rated kW capacity of the generator (even in single-phase applications).
Gen % of Rated kVAR. The ratio of the total reactive load on this generator to its rated reactive capacity, expressed as a
percentage. This value can be compared to the Bus % of Rated kVAR (directly above it) to determine if the system is sharing
reactive load properly. The acceptable difference between the generator and bus is site-dependent. The adjustment of the
parameters on this screen (during commissioning) will determine how closely the generators share reactive load. The Reactive
Power rating of the generator is fixed at 3/4 of the rated kW capacity of the generator (even in single-phase applications).
Voltage Bias. The amount that the controller is attempting to adjust the output voltage of the generator (100% bias = +10% on
the output voltage, -100% = -10% on the output voltage). The controller adjusts the voltage bias to share reactive load between
the generators connected to the paralleling bus.
Note:
The metering values in this screen are populated regardless of the state of the generator system, but the system must be in a
sharing mode before it will attempt to match generator and bus loading.
TP-6861 11/24 33
Protective Relays
The protective relays serve two purposes:
1. To protect the generator from damage
2. To protect the loads supplied by the generator from damage
The protective relays are configured during commissioning and should not be adjusted except by a trained commissioning agent.
These settings are often taken into consideration for breaker trip curves, load control settings, and generator management
settings. The adjustment without careful consideration of the implications may mask a problem in the system and cause another.
Properly-configured protective relays should only trip due to a failure.
Note:
All protective relay events will trip the breaker/contactor, but will not stop the generator until the Trip to Shutdown Delay has
expired. During this time, the protective relay which tripped the breaker/contactor will be listed under the Active Events, the
warning LED will be active, and the generator will remain running. The protective relay can be reset by pressing the AUTO button
(note, if the generator is in Run, the protective relay will have to be cleared by stopping the generator). Pressing OFF/RESET or
removing the remote start signal to the generator system also clears any active protective relays.
Gen Management
Generator Management is intended to minimize wear and tear, fuel consumption, pollutant/sound emissions, and generated
heat. It acts by signaling each generator to stop when it is unneeded. If generator management for a generator is disabled, the
generator will start—generator management failures will result in additional generators running any time the system receives a
start signal (this unit or others).
Generator management sequences the generators off in a predetermined order. The highest order generators stop first (when
load is low enough) and re-start last (when load is too high). The order can be viewed on the front panel of the controller, but
can only be adjusted under certain conditions (see Gen Management Order later in this section).
The time to start a generator (if the load increases) varies with the degree of overload.
The time to stop a generator (if the load is low enough that the generator is no longer needed) varies with the degree of available
capacity.
Note:
Receipt of a start signal will cause all generators to start, synchronize, and close to the bus. Generator management requires
that the generators are available (not faulted) in order to be permitted to stop. If a generator is faulted or manually stopped and
then placed back in Auto, Generator Management will require the generator to start and connect to the bus before it is considered
available (and permitted to stop) again—even if generator management had previously signaled the generator to stop.
Start Capacity. The percent of generator rated kW of the running generators that the system allows before the accumulator to
start this generator begins filling. The Start Capacity is set during commissioning and should not be changed.
Start Delay. The time to decide to start the generator at 10% over capacity. The Start Delay is set during commissioning
and should not be changed.
Stop Capacity. The percent of generator rated kW of the other running generators that the system allows before the accumulator
to stop this generator begins filling. The Stop Capacity is set during commissioning and should not be changed.
Stop Delay. The time to decide to stop the generator at 10% available capacity. The Stop Delay is set during commissioning
and should not be changed.
34 TP-6861 11/24
Gen Management Modes
The method that generator management uses to determine the starting and stopping order of the available generators. All the
generators in the system must have the same setting for this parameter for the generator management to operate. If this
parameter is changed, it will be updated on all the generators which are connected to the PGEN network. This parameter can
be set to one of the following:
• Manual/Fixed. The order of the generators is manually set. In this mode, the order is set once by the user.
Note:
The controllers require that the order be valid. If two nodes share a common order or there is a gap in the order
sequence, the controllers will attempt to re-sort the order until it is valid. If the order is not valid (automatic re-sorting
failed) generator management will be disabled (all generators will run all the time).
• Run Time. The generator management start/stop order is determined by the runtime hours on the generators. In this
mode, the order is determined to ensure that the generator with the fewest runtime hours is the last to stop. Each
subsequent order is assigned to generators with increasing runtime hours.
If a generator is not running, the system will add the Run Time Threshold to the runtime hours for that generator before
it considers it in the order—this allows the generators to avoid starting and stopping continuously. The actual runtime
will have to differ by more than the threshold to force the generator order to switch (the stopped generator will start,
synchronize to the paralleling bus, and begin sharing load—the running generator will soft-unload, disconnect from the
bus, cool down and stop).
The generator management order is not user adjustable in runtime mode.
Note:
If the load on the system requires an additional generator to start, the generator with the most runtime hours will always
be the first one to stop if the load decreases enough to permit it (the threshold is no longer taken into consideration as
soon as the generator is connected to the paralleling bus).
• Fuel Level. The generator management start/stop order of the generators is determined by the level of the fuel in the
tank which supplies each generator. In this mode, the order is determined to ensure that the generator with the most
fuel is the last to stop. Each subsequent order is assigned to generators with decreasing fuel percentage.
If a generator is running, the system will add the Fuel Level Threshold to the measured Fuel Level for that generator
before it considers it in the order. This allows the generators to avoid starting and stopping continuously. The actual
fuel level will have to differ by more than the threshold to force the generator order to switch (the stopped generator will
start, synchronize to the paralleling bus, and begin sharing load and the running generator will soft-unload, disconnect
from the bus, cool down and stop).
The generator management order is not user adjustable in Fuel Level mode.
Note:
Fuel Level Order Selection mode requires separate fuel tanks for the generators and fuel level senders connected to
the controller to operate. Operation of Fuel Level mode without sensors is not defined.
Note:
If the load on the system requires an additional generator to start, the generator with the lowest fuel level will always
be the one to stop (the threshold is no longer taken into consideration as soon as the generator is connected to the
paralleling bus).
Gen Management. Allows permanent disabling of the generator management on this generator. This parameter can be set
individually for each generator and will inhibit the Generator Management Configuration Mismatch Warning for this generator if
set to OFF.
Note:
Disabling the generator management on one generator in a paralleling system will not keep the other generators in the paralleling
system from alarming if the generator management configuration of any of the other nodes differs from the disabled generator.
Note:
Generators with Generator Management disabled are not taking into consideration for generator management on the other
generators. It is not recommended to disable any of the generators in a paralleling system where generator management is
intended to be used, the generator management may operate too many generators in these cases.
Generator management defaults to OFF. It should be enabled on all generators in the system if it is desired.
TP-6861 11/24 35
Gen Management Order. Determines the Start/Stop Order of this generator. Generators with a lower order will start before
generators with a higher order, higher order generators stop before lower order generators.
If the Generator Management Order for a generator changes, generator management will start any generators which were
involved in the order changing process (including automatic re-sort). After the incoming generators connect to the paralleling
bus, the generators with a high enough order to stop will start filling their accumulators to stop.
The generator order is adjustable in Manual/Fixed Order selection mode. It is only adjustable in Runtime or Fuel level mode if
the generators have identical runtime or fuel level.
Total Bus Capacity. The total bus capacity is simply the sum of the kW rating of all generators that are connected to the
paralleling bus (running with paralleling breaker/contactor closed). Generators in Baseload, System Control, or Unload mode
are not taking into consideration for this capacity.
Bus Total Power. The sum of the power output of all generators which are connected to the bus and available for sharing load.
Generators in Baseload, System Control, or Unload mode are not taking into consideration for this level. The Bus Total Power
is compared to the Start kW and Stop kW of the generator to determine if the generator should be started, stopped, or remain
as-is.
Start kW. The threshold of Bus Total Power above which the Start Accumulator for this generator will start filling.
Note:
The Accumulator fill rate is higher for larger differences between Bus Total Power and Start kW.
Stop kW. The threshold of Bus Total Power below which the Stop Accumulator for this generator will start filling.
Note:
The Accumulator fill rate is higher for larger differences between Stop kW and the Bus Total Power.
Preemptive Warnings. A preemptive warning tells the system that a generator may have a problem in the future. If Generator
Management has stopped the generators, it will start one of the unused generators but keep the running generator with the
preemptive fault online. The following conditions are considered preemptive warnings:
• Low Oil Pressure Warning
• Low Fuel Pressure Warning
• High Coolant Temperature Warning
• Failure to Synchronize Warning
• Water in Fuel Warning
• Fuel Tank Leak Warning
• Loss of Fuel Warning
A preemptive warning disables Generator Management on the unit which has the warning. It will run as long as the start signal
is present.
Note:
Most of the preemptive warnings have a shutdown which follows shortly after the warning. The intent of starting another generator
is that it will be able to supply the load when the generator shuts down on a fault.
Start Accumulator. The Start Accumulator fills from 0% to 100% while the Bus Total Load remains above the Start kW. This
generator will be signaled to start when this accumulator reaches 100%.
Note:
The Start Accumulator will reset to 0% if the Bus Total Power drops below the Start kW for one second.
The Start Accumulator may be filling while the engine is running in cooldown. If it reaches 100% before the cooldown is complete,
the generator will synchronize and close to the bus (it will not have to go through a start sequence).
Stop Accumulator. The Stop Accumulator fills from 0% to 100% while the Bus Total Load remains below the Stop kW. This
generator will be signaled to stop when this accumulator reaches 100%.
Note:
The Stop Accumulator will reset to 0% if the Bus Total Power exceeds the Stop kW for one second.
36 TP-6861 11/24
The generator may remain running and connected to the paralleling bus for a few seconds after the Stop Accumulator reaches
0%. During this time, the generator is unloading so that it can trip the circuit breaker/contactor connecting it to the bus with
minimal wear on the contacts in the breaker/contactor and minimal disturbance to the voltage and frequency of the system.
Run Time Threshold. The maximum difference in runtime hours that generator management will accept before it re-sorts the
Start/Stop Order of the generators to equalize hours (see Gen Management Order earlier in this section). All the generators in
the system must have the same setting for the Run Time Threshold for the generator management to operate. If this parameter
is changed on any controller, it will be updated on all the generators which are connected to the PGEN network.
Total Run Time. The actual runtime hours of this generator (to the nearest tenth of an hour). This parameter is also available in
the Generator Information screen, but is rounded to the nearest hour.
Fuel Level Threshold. The maximum difference in fuel level that generator management will accept before it re-sorts the
Start/Stop Order of the generators to equalize fuel level. (See Gen Management Order earlier in this section). All the generators
in the system must have the same setting for the Fuel Level Threshold for the generator management to operate. If this
parameter is changed, it will be updated on all the generators which are connected to the PGEN network.
Fuel Level. The level of the fuel in the tank supplying this generator. This is available in the engine metering section in
SiteTech™, but not elsewhere on the User Interface. If no fuel level sensor is connected, this parameter will display N/A. Do not
use Fuel Level as the Generator Management Mode if there is no fuel level sensor connected—the operation of the system is
not defined in this case.
Stable Delay. The time between the system entering a valid generator management state and the time that generator
management becomes active.
A valid generator management state requires:
• A Start Signal is present (Local start, remote start, or communications start)
• A least one generator is closed to the paralleling bus
• Generator Management is enabled
• The configuration of vital parameters of the system are identical between all controllers
• No generators have recently failed
• Load control has added priorities through the Min Loads Added Threshold
• The generator management order is valid
Once active, generator management will only go inactive if:
• A generator fails (shuts down with either a fault or user input)
• All generators are disconnected from the bus
• The Start Signal is removed
• Generator Management is disabled

• The configuration on any controller on the network is changed by a user
• The order becomes invalid
All the generators in the system must have the same setting for the stable delay for the generator management to operate. If
this parameter is changed, it will be updated on all the generators which are connected to the PGEN network.
Minimum Gens Online. Generator Management will always try to keep this many generators online (even if they are not
needed). All the generators in the system must have the same setting for the Minimum Gens Online for the generator
management to operate. If this parameter is changed, it will be updated on all the generators which are connected to the PGEN
network.
The purpose of this setting is to allow configuration to support large transient loads or potential generator failure
(N+1 redundancy).
Note:
Only 1 and 2 Minimum Gens Online is supported at this time.
TP-6861 11/24 37
Min Loads Added. The Load Shed priority that must be online before generator management will consider stopping a generator.
This is implemented so that generators aren’t stopped prematurely (before all the available load has been applied to the system).
All the generators in the system must have the same setting for Min Loads Added for the generator management to operate. If
this parameter is changed, it will be updated on all the generators which are connected to the PGEN network.
Note:
Min Loads Added should be set up to support the load control outputs which are connected to actual loads. There is no reason
to wait for a load control output to add if no load will be added to the system when it does. At the same time, it is important that
all load which the paralleling system will have to support be supplied by the system before generator management makes the
determination to stop a generator.
The load control outputs should be capable of shedding enough load that a single generator can support what remains (this
should be handled during commissioning, but is included for consideration as loads grow).
Load Control
Load Control drives 6 outputs (Load Priority 1 Shed through Load Priority 6 Shed) to remove loads from the paralleling bus when
the attached generators are unable to support them. See the Load Control Description section following for more information.
The outputs must be tied to programmable outputs in the configuration before they can be used, but they are controlled internally
regardless of output configuration or external connection status.
All generators on the PGEN network initiate load control at the same time and use the same measured values to determine the
Add and Shed timing (Bus % kW and Bus Frequency). If the load control settings are set identically, each load control priority
will add at the same time on all generators in the paralleling system. This allows Priorities 1 and 2 to be connected to one
generator, while Priorities 3 and 4 can be connected to another generator.
Note:
Load Control in a paralleling system operates identically to the load control on a single generator, except that it takes different
metered values into consideration.
Load Control Description
The purpose of Load Control is to permit a generator to support load which may occasionally exceed the rated capacity of the
generator. In paralleling systems, load shed permits the bus to stay at rated voltage and frequency while an additional generator
is synchronizing to it. In single-generator applications, load control may shed unimportant but highly demanding loads when the
generator is overloaded, preventing a power outage caused by the generator going offline.
The Load Control in the Decision-Maker® 3500 controller supports 6 load control priorities. These priorities generate internal
notices for the shed condition. The internal notices are generated any time a load is shed, but they will only operate a load
control relay if they are configured to a digital output.
Only 4 load control priorities can be configured to the RDO outputs on the controller (2 in paralleling applications) but the optional
14 relay dry contact kit will permit all 6 load control priorities to be accessed and configured to disconnect 6 different loads (each
load priority can interrupt several devices).
In paralleling applications, the load shed priorities can be divided between all the generators. For instance, Generator #1 can
support Load Priorities 1 and 4,
Generator #2 can support Priorities 2 and 5 and
Generator #3 can support Priorities 3 and 6. This configuration does not require the 14 relay dry contact kit and permits partial
load shed functionality even if one controller is powered down or fails (redundancy).
Load Priority 1 is shed last and added first, the priorities are added in increasing sequence and shed in decreasing sequence.
All Load Priorities are immediately shed when load control is initiated. Load control is initiated when the system receives a start
signal (a system start, a remote start, or a start by communication). In a paralleling application, the controller can receive a start
signal from any generator which is connected to the PGEN communication network. Pressing RUN on the controller will not
cause the loads to shed.
All loads are added immediately when Load Control is de-activated—this occurs when the start signal is removed.
Load Control adds loads based on the capacity of the system—loads will add more quickly if the available capacity is higher.
Load Control sheds loads based on the degree of overload of the system—loads will shed more quickly as the degree of the
system overload increases.
38 TP-6861 11/24
Note:
The generator management start % should be significantly lower than the Gen Overload Percent so that additional generators
will come online before a load is shed.
An under frequency event will also shed load—the under frequency threshold is not adjustable from the User Interface.
The load control will shed subsequent loads more quickly if shedding a load did not remove the overload or underfrequency
condition.
In a standard application (single generator or generator controlled by external switchgear) the load control logic uses the Gen
% or Rated kW and the Gen Frequency.
In a paralleling application (where the Decision-Maker® 3500 controller is responsible for first-on, synchronizing, load sharing,
and generator management) the load control logic uses the Bus % of Rated kW and Bus Frequency. All generators use the
same start signal, load and frequency values to determine load control timing, hence each controller will shed and add a given
load priority at the same time (provided that the load control settings are identical in each controller).
In a paralleling application where Generator Management is used, some generator sets may be shut down (turned Off) by
Generator Management. Even if the generator set is Off, it may de-activate its Load Control outputs to energize those loads.
This may seem counter-intuitive, but the generator sets are acting as a system. If voltage and frequency of the paralleling bus
are adequate, and Load Add accumulators are met, the loads will be enabled, even if a particular generator set is shut down by
the Generator Management.
Description of User Adjustable Load Control Settings
The Load Control settings are found under GENERATOR INFO -> PARALLEL OPERATION -> LOAD CONTROL. Load control
is active, even if the generator is not operating in a paralleling application.
Gen % Max Cap. The load level on the generator (or paralleling bus, in a paralleling application) that the load control will not
intentionally exceed. If the load is within 15% of this load level, the load control will not add the next priority until the load
decreases (or another generator starts, synchronizes and closes its paralleling breaker/contactor, in a paralleling application).
Gen Overload Percent. The load level on the generator (or paralleling bus, in a paralleling application) above which the load
Control will start to consider shedding loads. Loads will shed more quickly if the generator is heavily overloaded, more slowly if
the generator is barely overloaded. If the load drops below the Gen Overload Percent before a load priority is shed, the
accumulator for shedding load is reset.
Note:
Additional load control settings are provided in SiteTech™, but they are configured during commissioning and should not require
adjustment after commissioning is complete. Have setup and adjustments of the Decision-Maker® 3500 controller performed
only by an authorized distributor/dealer.
1.11 Controller Configuration Menu

1.11.1 Controller Configuration Submenu
• Language displays the user selected language. At this time, English is the only available option.
• Units displays the user selected unit of measure as Metric or English.
• Time Format displays the user selected time format as 12 hours or 24 hours.
• Date Format displays the user selected date format as mm/dd/yyyy or dd/mm/yyyy.
• Contrast displays user selected resolution values to improve digital display clarity.
• Alarm Silence displays the programmer selected alarm silence method Always or Auto Only using SiteTech™ software.
The Always selection activates the alarm horn in any of the OFF/RESET-AUTO-RUN modes. The Auto Only selection
activates the alarm horn only when in the Auto mode.
Note:
Press the Alarm Silence/Lamp Test button to silence the alarm horn.
TP-6861 11/24 39
1.11.2 Communication Setup Submenu
Modbus® Communications
The controller communicates using Modbus®*as a slave connection with the Modbus® master initiating the communication. The
controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus ® master.
In addition, the controller accepts information to alter controller parameters including generator set starting and stopping. See
Figure 12. Refer to the List of Related Materials for available Modbus ® literature.
Note:
Only one Modbus® master can be connected to the controller. Examples include the remote serial annunciator, monitoring
software, and switchgear applications.
RS-485
up to 1220 m (4000 ft.)
Generator Set Controller Modbus® Master
RS-232
up to 15 m (50 ft.)
Figure 12 Modbus® Connections

A controller can communicate directly to a Modbus® master or participate in a network of devices. It can also be used to interface
a local master to a network of devices.
The Modbus® master polls slave devices for data. Controller devices are slaves. Examples of master devices are a personal
computer running monitoring software and the remote serial annunciator
SiteTech Group Parameter Setting

Modbus Address Use a unique network address between 1 and 247 for each unit. Use 1 for a single connection.
Do not use 0 (zero).
Baud rate 9600, 19200, 38400, or 57600.
Must match the master PC and all devices in the system.
Figure 13 Decision-Modbus® 3500 Communication Parameters
Select the baud rate. Choose the same baud rate for the Modbus® master, modems, and connected devices. See Figure 13.
Each generator set controller must have a unique Modbus® address and PGEN node number (1-4).
Note:
The PGEN node number is automatically determined. The number of nodes online should match the number of installed
generators.
Note:
The PGEN baud rate should not be adjusted except under direction from a factory service representative. Different baud rates
between controllers on the network will result in a loss of communication on the network.
Modbus® is a registered trademark of Schneider Electric.
40 TP-6861 11/24
1.11.3 Calibration Submenu
The calibration values are reviewable at all times and provide the calibration of the voltage and current sensing logic. Changing
the system voltage or replacing the circuit board requires a calibration adjustment.
Note:
Have calibration adjustments performed by an authorized distributor/dealer.
To enable calibration, when the line is highlighted, push and hold the pushbutton/rotary selector dial to enable the calibration
capability. The user is prompted with a Yes/No prompt for calibration. The display will show the following:
• Gen L1-L0 Volts
• Gen L2-L0 Volts
• Gen L3-L0 Volts
• Gen L1-L2 Volts
• Gen L2-L3 Volts
• Gen L3-L1 Volts
• Gen L1 Current
• Gen L2 Current
• Gen L3 Current
• Bus L1-L2 Volts
• Bus L2-L3 Volts
• Bus L3-L1 Volts
• Reset Gen Volt Meter: (Yes/No)
• Reset Gen Amp Meter: (Yes/No)
• Reset Bus Volt Meter: (Yes/No)
• Reset All Meters: (Yes/No)
The user can change individual values or can select the individual Reset to reset certain values. The Reset selections will only
show if calibration is enabled. Refer to the requirements shown with Generator Set Calibration in Status and Notice Digital
Displays section.
TP-6861 11/24 41
1.12 I/O Setup Menu
Note:
Have setup and adjustments of the Decision-Maker® 3500 controller performed only by an authorized distributor/dealer. There
is a lot of setup information that can be accessed on this screen, but the parameters should be adjusted only during
commissioning.
Analog and Digital Input Setup
There are three types of inputs setups:
1. Analog Resistive
2. Analog Differential (used in paralleling applications)
3. Digital
Note:
Analog = a sender, variable-resistant device.
Digital = a switch with contacts.
The I/O Setup Menu displays the setup of digital and analog warning and shutdown inputs. These inputs provide choices for
configuring customized auxiliary inputs.
The user must enable the programming mode to edit the display. See the Menu Displays section for changeable settings in this
menu.
Descriptions. Descriptions for user inputs (auxiliary analog or auxiliary digital) may be entered using the SiteTech™ software
accessory where the user determines the descriptions.
Enabled. This menu indicates whether or not the input is enabled. If the input is not enabled, the controller will ignore this input
signal.
Analog inputs have separate warning and shutdown enabled choices.
Inhibit Time Delay. The inhibit time delay is the time period following crank disconnect during which the generator set stabilizes
and the controller does not detect the fault or status event. The controller will ignore the input until the inhibit time expires. If the
inhibit time is set to zero, the input is monitored at all times, even when the generator set is not running. The inhibit time delay
range is from 0 to 60 seconds.
Time Delay (shutdown or warning). The time delay follows the inhibit time delay. The time delay is the time period between
when the controller first detects the fault or status event and the controller warning or shutdown lamp illuminates. The delay
prevents any nuisance alarms. The time delay range is from 0 to 60 seconds.
Additional Analog Input Entries. The analog input selection typically requires entering four values—low warning, high warning,
low shutdown, and high shutdown.
Digital Output and Relay Driver Output Setup
The I/O Setup Menu displays the setup of digital status and fault outputs and relay driver outputs (RDO). These RDO outputs
provide choices for configuring customized auxiliary outputs. Additional individual outputs are available for monitoring,
diagnostics, and control functions. See Optional Dry Contact Kit following.
The user must enable the programming mode to edit the display. See the Menu Displays section for changeable settings in this
menu.
Note:
Changes to the Digital Outputs description requires the use of SiteTech ™ software. The digital output can either open or close
the circuit to activate.
42 TP-6861 11/24
Optional Dry Contact Kit
Dry contact kits provide an isolated interconnection between the generator set controller and optional devices. Up to fourteen
conditions can be specifically identified with this kit.
A relay coil will be energized when the corresponding engine or generator sensing device or switch monitored by the
microprocessor control board is activated.
Each relay provides one set of SPST contacts for field connection of customer supplied indicators or alarms. Contacts are rated
for a maximum resistive load of 10A at 120VAC.
The fifteen-relay dry contact board has four digital inputs and two analog inputs. There are fourteen programmable relay outputs
and one common fault relay output.
The relay contacts (K1 to K14) are rated:
• 10 amp @ 120 VAC
• 10 amp @ 28 VDC (max.)
• 0.01 amp @ 28 VDC (min.)
The common fault relay contact (K15) is rated:
• 500 mA @ 125 VAC
• 2 amp @ 30 VDC
1.12.1 Controller Fault Diagnostics
Figure 15 provides descriptions of possible system events and their types—warning, shutdown, status, and notice.
Warnings show a yellow warning lamp and sound an audible alarm to signal an abnormal condition. A warning does not shut
down the unit but indicates attention is required. Shutdowns show a red fault lamp, sound an audible alarm, and stop the
generator set. Statuses do not require user interaction but are part of the event history. Notices are used for controlling outputs
and notifying the user of the operating status. Notices are NOT part of the event history.
The default selection time delays and digital outputs are factory set and adjustable. Some data entries require using a PC and
SiteTech™ software.
11:44 AM
ACTIVE EVENTS 01/02/13
01/02/2013 11:40:31 AM
Parameter Value Abnormal: Warning
PARAMETER: GEN BATTERY VOLTAGE
FMI: High
Event 4 or 4
PRESS OFF TO RETURN TO MAIN MENU
Figure 14 Event Screen Capture (Example)
TP-6861 11/24 43
FMI
Alarm Fault Programmed Programmed
(Failure Mode Level
Horn Lamp Input Output
Indicator) Event ID/Parameter at Local Display
Protectives
Low Engine Speed Shutdown On Red D
High Engine Speed Shutdown On Red D
Shorted High Engine Oil Pressure * Warning On Yellow AD D
Shorted High Engine Oil Pressure * Shutdown On Red AD D
Shorted Low Engine Oil Pressure * Shutdown On Red D
Low Engine Oil Pressure Warning On Yellow AD D
Low Engine Oil Pressure Shutdown On Red D D
Open Circuit Engine Oil Pressure * Shutdown On Red D
Open Circuit Engine Oil Pressure * Warning On Yellow D
Low Engine Coolant Temperature * Warning On Yellow AD D
Low Engine Coolant Temperature * Shutdown On Red D
High Engine Coolant Temperature * Warning On Yellow AD D
High Engine Coolant Temperature * Shutdown On Red AD D
Open Circuit Engine Coolant Temperature * Shutdown On Red D
Open Circuit Engine Coolant Temperature * Warning On Yellow D
Shorted High (3) Engine Coolant Temperature * Shutdown On Red D
Shorted Low (4) Engine Coolant Temperature * Shutdown On Red D
Open Circuit Exhaust Temperature, if equipped Warning On Yellow D
Open Circuit Exhaust Temperature, if equipped Shutdown On Red D
High Lube Oil Temperature * Warning On Yellow AD
High Lube Oil Temperature * Shutdown On Red D
Low Engine Coolant Level Shutdown On Red D D
Low Engine Fuel Level Warning On Yellow AD D
Low Engine Fuel Level Shutdown On Red D D
High Engine Fuel Level Warning On Yellow D D
Critically High Engine Fuel Level Warning On Yellow D D
Low Fuel Pressure Warning On Yellow AD D
Low Fuel Pressure Shutdown On Red AD D
Low Gen Battery Voltage Warning On Yellow D
High Gen Battery Voltage Warning On Yellow D
Low Cranking Voltage Warning On Yellow D
Low Engine Oil Level Warning On Yellow AD D
Low Engine Oil Level Shutdown On Red D D
Low Generator Voltage L1-L2 Shutdown On Red D
High Generator Voltage L1-L2 Shutdown On Red D
Low Avg Gen Voltage L-L Warning On Yellow D
High Avg Gen Voltage L-L Warning On Yellow D
Low Generator Frequency Warning On Yellow D
44 TP-6861 11/24
FMI
(Failure Mode Level
High Generator Frequency Warning On Yellow D
Low Generator Frequency Shutdown On Red D
High Generator Frequency Shutdown On Red D
Low Total Power (Generator Total Real Power) Warning On Yellow D
High Total Power (Generator Total Real Power) Warning On Yellow D
High Total Power (Generator Total Real Power) Shutdown On Red D
Low Total Reactive Power Warning On Yellow D
High Avg Current Warning On Yellow D
Low Maximum Alternator Current Shutdown On Red D
High Intake Air Temperature Warning On Yellow D
High Intake Air Temperature Shutdown On Red D
High Fuel Temperature Warning On Yellow D
High Fuel Temperature Shutdown On Red D
Low Coolant Pressure Warning On Yellow AD D
AC Sensing Lost Warning On Yellow D
AC Sensing Lost Shutdown On Red D
Alternator Protection Shutdown On Red D
Auxiliary Input Warning On Yellow AD D
Auxiliary Input Shutdown On Red D D
Battery Charger Fault Warning On Yellow AD D
Ecm Communication Loss Shutdown On Red D
Ecm Model Mismatch Shutdown On Red
Emergency Stop Shutdown On Red D
Fuel Tank Leak Warning On Yellow AD D
Fuel Tank Leak Shutdown On Red D D
Ground Fault Input Warning On Yellow AD D
Locked Rotor Shutdown On Red D
Electrical Metering Communication Loss Shutdown On Red
Over Crank Shutdown On Red D
Speed Sensor Fault Warning On Yellow D
Other Alerts
Alarm Horn Silenced Status
Engine Cool Down Active Notice D
Engine Start Aid Active Notice D
Engine Started Status
Engine Stopped Status
Emergency Power System Supplying Load Notice D
Generator Running Notice D
Not In Auto Warning On Yellow D
Option Board 2A Communication Loss Notice
Option Board 2B Communication Loss Notice
Option Board 2C Communication Loss Notice
Remote Start Status
TP-6861 11/24 45
FMI
(Failure Mode Level
Load Priority 1 Shed Notice D
Cabinet Intrusion Alarm Warning On Yellow D D
Reserve Oil Empty Warning On Yellow D D
Stopped By Generator Management Status D
Failure To Synchronize Warning On Yellow D
High Fail To Open Delay Warning On Yellow
High Fail To Close Delay Warning On Yellow
High Max Close Attempts Warning On Yellow
Erroneous Data Generator Management (Invalid Generator
Warning On Yellow
Received Management Enabled)
High Trip To Shutdown Delay Shutdown On Red
Run Relay Coil Overload Shutdown On Red
Starter Relay Coil Overload Shutdown On Red
High System Frequency Warning On Yellow
Low System Frequency Warning On Yellow

High System Voltage Warning On Yellow
Low System Voltage Warning On Yellow
Erroneous Data
System Phase Warning On Yellow
Received
ECM Diagnostics
Engine Derate Active Warning On Yellow
Injector Wiring Fault Warning On Yellow
Run Relay Coil Overload Warning On Yellow
Sensor Supply Voltage Warning On Yellow
Speed Sensor Fault Warning On Yellow
Starter Relay Coil Overload Warning On Yellow
Water In Fuel Warning On Yellow
Notices Excluded From Display
Common Fault Notice D
Common Warning Notice D
System Ready Notice D
Remote Start Command Issued Notice
Run Button Acknowledged Notice
Contactor Notice D
Close Breaker Notice D
Remove Breaker Trip Notice D
Standalone Operation Status D
Load Enable Status D
Baseload Mode Status D
46 TP-6861 11/24
FMI
(Failure Mode Level
System Control Mode Status D
System Sync Mode Status D
Enable Trims Status D
Note:
 Sensor dependent
A = Analog, D = Digital
Figure 15 System Events Display Message List
1.12.2 Main Logic Circuit Board
The main logic circuit board provides the connection sockets to connect the controller to the engine/generator, input/output
connections, optional I/O module kit, and circuit protection fuses. See the Accessories section for the circuit board connectors.
Circuit Board Connections
P1 (35-Pin) Connector for engine/generator wiring harness.
P2 (14-Pin) Connector for sensor input connections and relay driver output connections.
P3 (8-Pin) Connector for generator set output voltage connection and paralleling bus voltage sensing connections.
P4 (Ethernet) Connector connects to a network communication line.
1.12.3 For Units Equipped with 3rd Party Marine Option
Additional engine sensors are provided to satisfy 3rd party approval requirements. Handling of these redundant sensors is
described below:
• All units will have two oil pressure sensors. If the engine is equipped with an ECM, the primary oil pressure sensor (#1)
will go to the ECM and the primary oil pressure readings are derived from CAN communications. If the engine is not
equipped with an ECM, the primary oil pressure sensor connects to the genset controller at one of the auxiliary analog
inputs and primary oil pressure readings will be measured directly by the controller. On all units, the secondary oil
pressure sensor (#2) connects to the genset controller at one of the auxiliary analog inputs and secondary oil pressure
readings will be measured directly by the controller.
• All units will have a single analog coolant pressure sensor. This sensor connects to the genset controller at one of the
auxiliary analog inputs and coolant pressure readings will be measured directly by the controller.
• All units will have a single analog oil temperature sensor. This sensor connects to the genset controller at one of the
auxiliary analog inputs and oil temperature readings will be measured directly by the controller.
• All units will have two coolant temperature sensors. If the engine is equipped with an ECM, the primary coolant
temperature sensor (#1) will go to the ECM and the primary coolant temperature readings are derived from CAN
communications. If the engine is not equipped with an ECM, the primary coolant temperature sensor connects to the
genset controller at one of the auxiliary analog inputs and primary coolant temperature readings will be measured
directly by the controller. On all units, the secondary coolant temperature sensor (#2) connects to the genset controller
at one of the auxiliary analog inputs and the secondary coolant temperature readings will be measured directly by the
controller.
• When two sensors are installed (oil pressure and coolant temperature), separate warning messages are initiated for
each sensor when a warning limit is exceeded. Should either sensor provide a reading that violates a shutdown limit,
a shutdown occurs regardless of the other sensor reading. If either sensor signal is lost, a Loss of Signal (LOS) warning
will be initiated. If both sensor signals are lost, a Loss of Signal (LOS) shutdown occurs.
• Every ECM handles their respective sensor readings and values independently and the ECM may send warnings or
cause shutdowns on their own. Refer to the respective Engine ECM documentation for unique handling.
• Low coolant pressure and/or loss of coolant pressure readings will cause a warning only (not a shutdown).
All 3rd party marine agency-approved kits include a secondary fuel shut off. A secondary fuel shut off is required for 3rd party
approval. See Figure 16.
TP-6861 11/24 47
Transfer pump (supplied by engine manufacturer)
as part of the filter assembly.
Secondary fuel shut off valve
GM88314-A
Figure 16 Secondary Fuel Shut Off Valve Location Equipped On Agency-Approved Kits (80-99 kW shown)
48 TP-6861 11/24
Section 2. Operation
2.1 Prestart Checklist

To ensure continued satisfactory operation perform the following checks or inspections before or at each startup, as designated,
and at the intervals specified in the service schedule. In addition, some checks require verification after the unit starts.
Air Cleaner. Check for a clean and installed air cleaner element to prevent unfiltered air from entering the engine.
Air Inlets. Check for clean and unobstructed air inlets.
Air Shrouding. Check for securely installed and positioned air shrouding.
Battery. Check for tight battery connections. Consult the battery manufacturer’s instructions regarding battery care and
maintenance.
Coolant Level. Check the coolant level according to the cooling system maintenance information.
Note:
Block Heater Damage. The block heater will fail if the energized heater element is not immersed in coolant. Fill the cooling
system before turning on the block heater. Run the engine until it is warm, and refill the radiator to purge the air from the system
before energizing the block heater.
Drive Belts. Check the belt condition and tension of the water pump and battery charging alternator belt.
Exhaust System. Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust
system connections.
Inspect the exhaust system components (exhaust manifold, mixing elbow, exhaust line, hose clamps, silencer, and exhaust
outlet) for cracks, leaks, and corrosion.
• Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed.
• Check for corroded or broken metal parts and replace them as needed.
• Check for loose, corroded, or missing clamps. Tighten or replace the hose clamps as needed.
• Check that the exhaust outlet is unobstructed.
• Visually inspect for exhaust leaks (blow by). Check for carbon or soot residue on exhaust components. Carbon and
soot residue indicates an exhaust leak. Seal leaks as needed.
• Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the generator
set operates.
For your safety: Never operate the generator set without a functioning carbon monoxide detector(s) for your safety and
the safety of others on your vessel.
Fuel Level. Check the fuel level and keep the tank(s) full to ensure adequate fuel supply.
Oil Level. Maintain the oil level at or near, not over, the full mark on the dipstick.
Operating Area. Check for obstructions that could block the flow of cooling air. Keep the air intake area clean. Do not leave
rags, tools, or debris on or near the generator set.
Seawater Pump Priming. Prime the seawater pump before initial startup. To prime the pump: (1) close the seacock, (2) remove
the hose from the water-filter outlet, (3) fill the hose and seawater pump with clean water, (4) reconnect the hose to the water
filter outlet, and (5) open the seacock. Confirm seawater pump operation on startup as indicated by water discharge from the
exhaust outlet.
TP-6861 11/24 49
2.2 Marine Inspection
Discovery Energy, LLC recommends that all boat owners have their vessels inspected at the start of each boating season by
the US Coast Guard, the local Coast Guard Auxiliary, or local state agency.
Discovery Energy, LLC also recommends having the generator’s exhaust system inspected at the start of each boating season
by an authorized distributor/dealer. Repair any problems identified before operating the generator set.

Carbon monoxide symptoms. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is a
poisonous gas present in exhaust gases. Carbon monoxide is an odorless, colorless, tasteless, nonirritating gas that can cause
death if inhaled for even a short time. Carbon monoxide poisoning symptoms include but are not limited to the following:
• Light-headedness, dizziness
• Physical fatigue, weakness in joints and muscles
• Sleepiness, mental fatigue, inability to concentrate or speak clearly, blurred vision
• Stomachache, vomiting, nausea
If experiencing any of these symptoms and carbon monoxide poisoning is possible, seek fresh air immediately and remain active.
Do not sit, lie down, or fall asleep. Alert others to the possibility of carbon monoxide poisoning. Seek medical attention if the
condition of affected persons does not improve within minutes of breathing fresh air.
Operating the generator set. Carbon monoxide can cause severe nausea, fainting, or death. Be especially careful if
operating the generator set when moored or anchored under calm conditions because gases may accumulate. If operating the
generator set dockside, moor the craft so that the exhaust discharges on the lee side (the side sheltered from the wind). Always
be aware of others, making sure your exhaust is directed away from other boats and buildings.
50 TP-6861 11/24
2.3 Angular Limits During Operation
See Figure 17 for angular operation limits for units covered in this manual.
Model Continuous Intermittent—3 minutes or less
40EOZD(C)J
20° 30°
33EFOZD(C)J
40EFOZD(C)J
50EFOZD(C)J
30° 45°
55/65EOZD(C)J
45/55EFOZD(C)J
80/99EOZD(C)J
35° 45°
70/80EFOZD(C)J
125/150EOZD(C)J
25° 35°
100/125EFOZD(C)J
200EOZD(C)J
20° 30°
175EFOZD(C)J
Maximum value for all directions
Figure 17 Angular Limits During Operation
2.4 Operation in European Union Member Countries

This generator set is specifically intended and approved for operation below the deck in the engine compartment. Operation
above the deck and/or outdoors would constitute a violation of European Union Directive 2000/ 14/EC noise emission standard.
2.5 Load Profile

Whenever operating the generator set, Discovery Energy, LLC recommends maintaining the minimum load profile indicated in
Figure 18. Maintaining the load profile prevents corrosion formation on internal engine components when they’re exposed to the
breakdown of exhaust gases. Extended light loading may result in engine “wet stacking.”
Minimum Load Requirement Ideal Load Requirement
30% load 70% load or more
Figure 18 Load Profile

Unburned Fuel (Wet Stacking) occurs when water/fuel vapor condenses in the exhaust system. At normal combustion
temperatures, water stays vaporized but at low combustion temperatures, it condenses back to a liquid. When running the
generator set under normal loads (30% load or more) for long periods of time, diesel exhaust stays hot enough to prevent
water/fuel vapor from condensing. Conversely, if the generator set is subjected to light loads (30% or less) for long periods of
time, water/fuel vapors accumulate and may result in the following conditions to develop:
• Cylinder wall glazing
• Fuel on water
• Crankcase oil dilution
• Wet stacking
Note:
Consult the engine manufacturer’s guidelines for more details on unburned fuel and wet stacking.
The operator should perform all of the prestart checks. Start the generator set according to the starting procedure in the controller
section of this manual. While the generator set is operating, listen for a smooth-running engine and visually inspect the generator
set for fluid or exhaust leaks.
TP-6861 11/24 51
2.6 Controller Operation
Note:
Opening seacock. Before starting the generator set, open the seacock to allow cooling water passage. Failure to do so could
damage the seawater pump impeller and cause serious engine overheating damage.
Note:
Transfer switch. Check that the marine ship-to-shore transfer switch, if equipped, is in the ship position.
Note:
If the generator set does not start after 3 crank attempts (an overcrank fault occurs):
1) Close the seacock.
2) Completely drain the water from the exhaust system at the silencer’s drain plug.
3) Do not attempt generator set restart.
4) Contact an authorized distributor/dealer. A water-filled exhaust piping and silencer may further hinder generator starting
and cause seawater entry into the engine cylinders through the exhaust valves. Water ingested into the engine may
cause major engine damage that the Discovery Energy, LLC warranty does not cover.
The controller operation includes several types of starting and stopping functions as detailed below. The controller buttons,
lamps, and alarm horn functions are summarized in Figure 19.
There are three primary modes of operation, selected by pressing the respective buttons:
• OFF
• RUN
• AUTO (Standby Mode)
When the OFF button is pressed, the generator set is in OFF or goes to OFF and will not start. When the RUN button is pressed,
the generator set starts and runs until the OFF or AUTO button is pressed or until a fault is received. When the AUTO button is
pressed, the generator set enters the Standby Mode (STANDBY-RUNNING or STANDBY-OFF depending upon the start signal).
• OFF. If the generator set was previously running, pressing the OFF button immediately shuts off the generator set, with no
engine cooldown. The generator set remains off and will not respond to a remote start signal.
• RUN—Local Start. A single generator set starts. No other generator sets in the system will start (or stop).
• AUTO—Standby or System Ready. The generator set is waiting for a start signal. The generator set will start and run
when a start signal is received via a remote start, local auto-start, or communications-based start.
All generator sets in the system (connected by PGEN and in Standby Mode by pressing AUTO) will start when any one of the
generator sets receives a start signal.
Any generator set in the system not in AUTO will not start.
If Generator Management is on, some generator sets may shutdown after a period of time.
With removal of the start signal, all generator sets will shutdown with the appropriate engine cooldown.
• AUTO-RUN (Press AUTO and RUN together for a system start signal). All generator sets in the system start and run, close
to bus, synchronize, parallel, share load, etc. Some generator sets may shut down after a period of time (indicated by
Generator Management) but they remain in Standby Mode ready to start and run if needed.
• AUTO-OFF (Press AUTO and OFF together to remove a system start signal, if AUTO-RUN is active). All generator sets in
the system open their breakers, enter engine cooldown, shut down, and enter Standby Mode. Closing the remote start
contacts has no affect. Generator sets in the system will enter Standby Mode.
Note:
Pressing AUTO and OFF together only stops the generator sets if there are no other system start signals present.
52 TP-6861 11/24
Start Signal
A start signal includes the following:
• Remote start signal via contacts 3 and 4. An ATS (used during a power outage, exercise period, etc.) or a remote panel
used in the vessel take precedence over all other start signals.
• System Start (AUTO-START). Press AUTO and RUN simultaneously to send a start signal.
• Communications-based start message from SiteTech™ or a CAN-based remote panel.
Hardwired contacts (remote start contacts 3 and 4) have priority over all other start signals. If the remote start contacts are
activated, the generator sets in the system that are in AUTO, will start and run. If the generator sets were already running, they
will remain running but the original source of that start signal will be ignored. The contacts now have control.
Note:
The alarm horn sounds and the Not-In-Auto Warning display appears whenever the generator set is not in the AUTO mode.
Note:
The transient start/stop function of the controller prevents accidental cranking of the rotating engine. The generator set stops
and recranks when the OFF/RESET button is momentarily pressed and then the RUN button is pressed.
Note:
The controller provides up to 30 seconds of programmable cyclic cranking and up to 60 seconds rest with up to 6 cycles. The
default setting is 15 seconds cranking and 15 seconds rest for 3 cycles. Make cyclic cranking adjustments using SiteTech™
software.
Stop Signal
A stop signal includes the following:
• Removal of start signal via contacts 3 and 4. An ATS (used during a power outage, exercise period, etc.) or a remote panel
used in the vessel take precedence over all other start signals.
• System Stop (AUTO-OFF). Press AUTO and OFF simultaneously to send a stop signal to cancel the system start.
Note:
This will not do anything if the system start is not active or if the system is receiving a start signal from another source. Press
AUTO and OFF on any controller in the system.
• Communications-based stop message from SiteTech™ or a CAN-based remote panel.
Engine Cooldown
Cooldown is a state where the generator is running at no load to allow hot engine components time to cool slowly before the
engine is stopped. In paralleling applications, this occurs with the circuit breaker open.
When the generator set is running in AUTO mode (AUTO-RUN), an engine cooldown cycle begins when the remote start input
is deactivated. Also, if stopping due to a stop signal, a cooldown cycle begins.
If the Cooldown Override is disabled (OFF) in the Generator Configuration Menu, coolant temperature is ignored. The generator
will enter cooldown when the start signal is removed, only if the engine control switch is in AUTO. The engine will run for a period
of time equal to the Cooldown Delay parameter setting, regardless of the coolant temperature.
If the Cooldown Override is enabled (ON) in the Generator Configuration Menu, coolant temperature will be considered for
cooldown. The generator will enter cooldown when the start signal is removed, only if the engine control switch is in AUTO. The
engine will run until the coolant temperature is below the Engine Cooled Down parameter setting, or until the Cooldown Delay
has expired.
The cooldown cycle lasts for some predetermined amount of time. The cooldown delay is an adjustable parameter. The Engine
Cooled Down temperature is not adjustable.
Note:
No engine cooldown cycle occurs if the OFF button is pressed or if a fault occurs. The shutdown is immediate. If possible, run
the generator set without load for 5 minutes to ensure adequate engine cooldown.
TP-6861 11/24 53
Fault Alarm Alarm Silence Alarm
Button Mode Generator Set Status Lamp Horn Button Horn Lamp Controller Display
Off — Off — — Scrolling Overview Menu
On (or Cranking) — Off — — Only
AUTO
On — —
Running and then Off Red Shutdown Message
Off Pressed Yellow
On — —
OFF/RESET Off Yellow Not In Auto Warning
Off Pressed Yellow
On — —
Off (or Cranking) Yellow Not in Auto Warning
RUN Off Pressed Yellow
(unit fails to start) On — — Locked Rotor Shutdown (or
Off Red
Off Pressed Yellow other shutdown message)
Off (or Cranking) On — —

Yellow Not in Auto Warming
RUN On Off Pressed Yellow
(unit starts) On — —
Running and then Off Red Shutdown Message
Off Pressed Yellow
Figure 19 Button Function Summary
2.6.1 Emergency Stop
Use the controller emergency stop switch for immediate emergency shutdown.
The emergency stop switch bypasses the time delay engine cooldown and immediately shuts down the generator set.
Note:
Use the emergency stop switch(es) for emergency shutdowns only. Use the generator set OFF/RESET button for normal
shutdowns.
The controller fault lamp lights and the unit shuts down when the local emergency stop switch activates.
Use the following procedure to reset the generator set after shutdown by a local or remote emergency stop switch. Refer to the
Controller Resetting (Following System Shutdown or Warning) section, Controller Resetting procedure, to restart the generator
set following a fault shutdown.
1. Investigate and correct the cause of the emergency stop.
2. Reset the controller emergency stop switch by pulling the switch dial outward.
3. Press the generator set OFF/RESET button.
4. After resetting all faults using the controller reset procedure in the Controller Resetting (Following System Shutdown or
Warning) section, press the generator set RUN and/or AUTO button to restart the generator set. The generator set will
not crank until the reset procedure completes.
2.6.2 System Status Lamps
The (OFF/RESET-AUTO-RUN) buttons indicate the status condition with an integrated lamp at the button.
The lamp illuminates on the AUTO (automatic start) button indicating the system senses no faults and the unit is ready to start
by remote command.
The lamp illuminates on the OFF/RESET button indicating the generator set is stopped.
The lamp illuminates on the RUN button indicating the generator set is cranking or running from a local command or is
commanded to run from a local command.
Only one of the three button lamps will illuminate at any given time.
54 TP-6861 11/24
2.6.3 System Fault Warning Lamp with Digital Displays
The system FAULT lamp glows yellow and the alarm horn sounds indicating a warning fault but does not shut down the generator
set. The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel-fueled models approaches
empty. This fault requires an optional low fuel level switch for the lamp to function. See the Controller Resetting (Following
System Shutdown or Warning) section, for instructions on resetting a system warning.
When the system warning lamp is on and no message displays, rotate the dial to the Active Events menu. Press the dial to view
messages. Rotate the dial to view additional messages. Press the OFF button to return to the main menu. When the system
warning continues, it may lead to a fault and cause a system shutdown.
Use the Silence Alarm button to silence the alarm horn at the operator’s discretion.
If the controller is setup for an NFPA 110 application, press the AUTO button before silencing the alarm horn. The alarm horn
cannot be silenced unless the button is in the AUTO mode. See Status and Notice Digital Displays section for more information.
Current Below Normal or Open Circuit Coolant Temperature. The fault lamp illuminates yellow and the alarm horn sounds
when the engine coolant temperature sender circuit is not receiving enough current or is open for more than 5 seconds.
Current Below Normal or Open Circuit Exhaust Temperature. The fault lamp illuminates yellow and the alarm horn sounds
when the exhaust temperature sender circuit is not receiving enough current or is open for more than 5 seconds.
Current Below Normal or Open Circuit Oil Pressure. The fault lamp illuminates yellow and the alarm horn sounds when the
engine oil pressure sender circuit is not receiving enough current or is open for more than 5 seconds.
AC Sensing Lost (controller in RUN or AUTO and voltage was never present). The fault lamp illuminates yellow and the
alarm horn sounds when the controller does not detect the nominal generator set AC output voltage after crank disconnect.
Auxiliary Input. The fault lamp illuminates yellow and the alarm horn sounds when an auxiliary digital or analog input signals
the controller. The digital inputs do not function during the first 30 seconds after startup. Use SiteTech™ software to define
inputs as shutdowns or warnings.
Average Current High. The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters excessive
load or a downstream fault. The output breaker trips. The available sustained fault current of the generator can be obtained from
the per-unit transient reactance of the generator and the system voltage and power.
Average Generator Voltage High. The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters
an over voltage condition. This condition can be caused by a loss of sensing wire, a winding failure, voltage regulator failu re,
etc. The output breaker trips. The generator may continue to produce excessive voltage until it is shut down.
Average Generator Voltage Low. The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters
an under voltage condition. This condition can be caused by a loss of a diode on the rectifier bridge, sensing problem, a winding
failure, voltage regulator failure, etc. The output breaker trips. The generator may continue to produce insufficient voltage until it
is shut down.
Battery Charger Fault. The fault lamp illuminates yellow and the alarm horn sounds when the battery charger malfunctions.
This fault feature requires an optional battery charger with a malfunction output for the lamp to function.
Cabinet Intrusion. The fault lamp illuminates yellow and the alarm horn sounds when the door to the unit was opened.
Common Warning. The fault lamp illuminates yellow and the alarm horn sounds when the controller is signaled by a common
warning. Use SiteTech™ software to activate the common warning. The common warning comprises all of the warnings under
a single alert.
Critically High Fuel Level (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when
the fuel tank level on diesel models approaches full. This fault requires an optional critical high fuel switch and fuel tank for the
lamp to function.
ECM Diagnostics (Multiple Engine Inputs). The fault lamp illuminates yellow and the alarm horn sounds when ECM
diagnostics signals the controller. The specific display (xxxxx) will be a brief message or fault code that is engine manufacturer
dependant. The engine literature provides the fault code description and further information.
Failure to Synchronize. The fault lamp illuminates yellow and the alarm horn sounds when the generator set does not
successfully synchronize to the live bus within the time delay as defined in the synchronizing setup menu. The controller will
continue attempting to synchronize to the bus after the time delay expires and the warning occurs. Generator Management will
start another generator set if this warning occurs.
TP-6861 11/24 55
Fuel Tank Leak. The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank signals a leak of the inner tank.
This fault requires an optional fuel tank leak switch for the lamp to function.
Generator Frequency High. The fault lamp illuminates yellow and the alarm horn sounds when the generator has an
overfrequency condition. The output breaker trips. This condition can be caused by various mechanical failures (loss of speed
signal to ECU, improperly controlled or inadvertent injection of gaseous fuel etc.).
Generator Frequency Low. The fault lamp illuminates yellow and the alarm horn sounds when the generator has an
underfrequency condition. The output breaker trips.
Generator Total Real Power High. The fault lamp illuminates yellow and the alarm horn sounds when the generator encounters
excessive load or a downstream fault. The output breaker trips.
Generator Total Real Power Low. The fault lamp illuminates yellow and the alarm horn sounds when the generator is no longer
producing power (loss of fuel, bearing failure, fuel system failure, ECU problem, or speed bias connection failure on non-ECM
engines). The output breaker trips.
Ground Fault Input. The fault lamp illuminates yellow and the alarm horn sounds when a user-supplied ground fault detector
signals the controller.
High Battery Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage rises above the
preset level for more than 10 seconds. Figure 20 shows high battery voltage specifications. The high battery voltage feature
monitors the battery and battery charging system in the generator set operating and off modes.
Engine Electrical System Voltage High Battery Voltage Range High Battery Voltage Default Setting
12 13.2-16.2 15
24 26.4-32.4 30
Figure 20 High Battery Voltage Specs

High Coolant Temperature. The fault lamp illuminates yellow and the alarm horn sounds when the engine coolant temperature
approaches the shutdown range. The high coolant temperature warning does not function during the preset inhibit time delay
period after startup.
High Fail To Close Delay. The fault lamp illuminates yellow and the alarm horn sounds when the circuit breaker did not close
within the allocated breaker closure time.
High Fail To Open Delay. The fault lamp illuminates yellow and the alarm horn sounds when the circuit breaker did not open
as quickly as the controller expected.
High Fuel Level (diesel-powered models only). The fault lamp illuminates yellow and the alarm horn sounds when the fuel
tank level on diesel models approaches near full. This fault requires an optional high fuel switch and fuel tank for the lamp to
function.
High Genset System Frequency. The fault lamp illuminates yellow and the alarm horn sounds when another generator in the
paralleling system has a lower system frequency than this generator. The local display shows System Frequency, FMI: High.
High Genset System Voltage. The fault lamp illuminates yellow and the alarm horn sounds when another generator in the
paralleling system has a lower system voltage than this generator. The local display shows System Voltage, FMI: High.
High Intake Air Temperature. The fault lamp illuminates yellow and the alarm horn sounds when the engine intake air
temperature approaches the shutdown range.
High Lube Oil Temperature. The fault lamp illuminates yellow and the alarm horn sounds when the engine high oil temperature
approaches the shutdown range.
High Max. Close Attempts The fault lamp illuminates yellow and the alarm horn sounds when the circuit breaker did not close,
even after the controller attempted to close it as many times as specified by the max. close attempts.
Invalid Generator Management Enabled. The fault lamp illuminates yellow and the alarm horn sounds when the generator
management has been disabled because the generator management configuration of this generator does not match the
generator management configuration of another generator that is connected to the same PGEN network. The local display shows
Generator Management.
Invalid Genset Voltage Phase Connection. The fault lamp illuminates yellow and the alarm horn sounds when another
generator in the paralleling system has a different phase connection than this generator. The local display shows System Phase.
56 TP-6861 11/24
Low Battery Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below a
preset level for more than 90 seconds.
Engine Electrical System Voltage Low Battery Voltage Range Low Battery Voltage Default Setting
12 9.6-12.6 12
24 19.2-25.2 24
Figure 21 Low Battery Voltage Specs

The low battery voltage feature monitors the battery and battery charging system in the generator set operating and off modes.
The controller logic inhibits the low battery voltage warning during the crank cycle.
Low Coolant Temperature. The fault lamp illuminates yellow and the alarm horn sounds when the engine coolant temperature
is low. The low coolant temperature warning does not function during the preset inhibit time delay period after startup.
Low Cranking Voltage. The fault lamp illuminates yellow and the alarm horn sounds when the battery voltage drops below 60%
of the nominal voltage (12 VDC or 24 VDC) for more than 6 seconds during the crank cycle.
Low Engine Oil Level. The fault lamp illuminates yellow and the alarm horn sounds because of low engine oil level. This fault
feature requires an optional low engine oil level sensor for the lamp to function.
Low Fuel Level. The fault lamp illuminates yellow and the alarm horn sounds when the fuel tank level on diesel-fueled models
approaches empty. This fault requires an optional low fuel level switch for the lamp to function.
Low Fuel Pressure. The fault lamp illuminates yellow and the alarm horn sounds when low fuel pressure occurs. This fault
requires an optional low fuel pressure switch for the lamp to function.
Low Genset System Frequency. The fault lamp illuminates yellow and the alarm horn sounds when another generator in the
paralleling system has a higher system frequency than this generator. The local display shows System Frequency, FMI: Low.
Low Genset System Voltage. The fault lamp illuminates yellow and the alarm horn sounds when another generator in the
paralleling system has a higher system voltage than this generator. The local display shows System Voltage, FMI: Low.
Low Oil Pressure. The fault lamp illuminates yellow and the alarm horn sounds when the engine oil pressure approaches the
shutdown range. The low oil pressure warning does not function during first the 30 seconds after startup.
Not in Auto (Generator Master Control Switches). The fault lamp illuminates yellow and the alarm horn sounds when the
generator set button is in the RUN or OFF/RESET mode.
Option Board 2X Communication Loss. The fault lamp illuminates yellow and the alarm horn sounds when the communication
with option board 2X (A, B, or C) has been lost.
Reserve Oil Empty. The fault lamp illuminates yellow and the alarm horn sounds when the oil makeup kit level has dropped
below a threshold.
Speed Sensor Fault. The fault lamp illuminates yellow and the alarm horn sounds when the speed signal is absent for one
second while the generator set runs.
Total Reactive Power Low. The fault lamp illuminates yellow and the alarm horn sounds when the generator has a loss of field
condition due to insufficient reactive load production to support real load. The output breaker trips.
TP-6861 11/24 57
2.6.4 System Fault Shutdown Lamp with Digital Displays
The system FAULT lamp glows red, the alarm horn sounds, and the unit shuts down to indicate a fault shutdown under the
following conditions. See the Controller Resetting (Following System Shutdown or Warning) section, Controller Resetting
procedure, for information on resetting a system shutdown.
When the system shutdown lamp is on and no message displays, rotate the dial to the Active Events menu. Press the dial to
view messages. Rotate the dial to view additional messages. Press the OFF button to return to the main menu.
Use the Alarm Off button to silence the alarm horn at the operator’s discretion. If the controller is setup for an NFPA 110
application, press the AUTO button before silencing the alarm horn. The alarm horn cannot be silenced unless the button is in
the AUTO mode. See Status and Notice Digital Displays for more information.
AC Sensing Lost (controller in AUTO and voltage was previously present). The fault lamp illuminates red, the alarm horn
sounds, and the unit shuts down when the controller does not detect the nominal generator set AC output voltage for more than
3 seconds after crank disconnect.
Alternator Protection. The fault lamp illuminates red and the unit shuts down because of an alternator overload or short circuit.
See Appendix D, Alternator Protection for more information.
Auxiliary Input (Shutdown). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when an auxiliary
digital or analog inputs signals the controller. The digital inputs do not function during the first 30 seconds after startup. Use
SiteTech™ software to define inputs as shutdowns or warnings.
Common Fault. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller is signaled
by a common fault. Use SiteTech™ software to activate the common fault shutdown. The common fault comprises of any
combination of the fault shutdowns under a single alert.
Current Below Normal or Open Circuit Coolant Temperature. The fault lamp illuminates red, the alarm horn sounds, and the
unit shuts down when the engine coolant temperature sender circuit is not receiving enough current or is open for more than 5
seconds.
Current Below Normal or Open Circuit Exhaust Temperature. The fault lamp illuminates red, the alarm horn sounds, and
the unit shuts down when the exhaust temperature sender circuit is not receiving enough current or is open for more than 5
seconds.
Current Below Normal or Open Circuit Oil Pressure. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts
down when the engine oil pressure sender circuit is not receiving enough current or is open for more than 5 seconds.
ECM Communications Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the ECM
communication link is disrupted.
ECM Diagnostics (Multiple Engine Inputs). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when ECM diagnostics signals the controller. The specific display (xxxxx) will be a brief message or fault code that is engine
manufacturer dependant. The engine literature provides the fault code description and further information.
ECM Model Mismatch. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the controller
detects an error with the ECM model.
Electrical Metering Communication Loss. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when the metering to the controller communication link is disrupted.
Emergency Stop. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the local or optional
remote emergency stop switch activates.
Fuel Tank Leak. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the fuel tank signals a
leak of the inner tank. This fault requires an optional fuel tank leak switch for the lamp to function.
Generator Total Real Power High. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the
generator set supplies more than 102% of the rated standby output kW (or 112% of the rated prime power output kW) for more
than 60 seconds.
High Coolant Temperature. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of high
engine coolant temperature. The high coolant temperature shutdown does not function during the preset inhibit time delay period
after startup.
58 TP-6861 11/24
Note:
The high engine temperature shutdown function and the low coolant level shutdown function are independent. A low coolant
level condition may not activate the high engine temperature switch.
High Engine Speed. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down immediately when the
governed frequency on 50 and 60 Hz models exceeds the over speed setting.
High Intake Air Temperature. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of high
intake air temperature. The shutdown occurs 5 seconds after the engine intake air reaches the temperature shutdown range.
The engine intake air temperature shutdown does not function during the first 30 seconds after startup.
High Generator Frequency. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the frequency
is above the overfrequency setting. See Figure 22.
Overfrequency Setting Range Time Delay Overfrequency Default Setting
102%-140% of nominal 10 sec. 110% of nominal
Figure 22 Overfrequency Specs

High Generator Voltage (Each Phase). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when
the voltage exceeds the overvoltage setting for the preset time delay period. See Figure 23 for overvoltage specifications.
Note:
Overvoltage can damage sensitive equipment in less than one second. Install separate overvoltage protection on online
equipment requiring faster than 2-second shutdown.
Overvoltage Setting Range Time Delay Range Overvoltage Default Setting
105%-135% of nominal 2-10 sec. 120% at 2 sec.
Figure 23 Overvoltage Specs

High Lube Oil Temperature. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of high
engine oil temperature. The shutdown occurs 5 seconds after the engine oil reaches the temperature shutdown range. The high
engine oil temperature shutdown does not function during the first 30 seconds after startup.
Locked Rotor (failed to crank). If none of the speed sensing inputs show engine rotation within the preset time delay of initiating
engine cranking, the ignition and crank circuits turn off for the preset period and the cycle repeats. The fault lamp illuminates
red, the alarm horn sounds, and the unit shuts down after the second cycle of the preset period of cranking.
Low Coolant Level. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low coolant
level. Shutdown occurs 5 seconds after low coolant level is detected.
Low Engine Oil Level. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low engine
oil level. This fault feature requires an optional low engine oil level sensor for the lamp to function.
Low Engine Speed. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down immediately when the
governed frequency on 50 and 60 Hz models drops below the under speed setting.
Low Fuel Level (diesel-powered models only). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down
when the fuel tank level on diesel-fueled models approaches empty. This fault requires an optional low fuel level switch for the
lamp to function.
Low Fuel Pressure. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when low fuel pressure
occurs. This fault requires an optional low fuel pressure switch for the lamp to function.
Low Generator Frequency. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the frequency
drops below the underfrequency setting. See Figure 24 for underfrequency specifications.
Underfreq. Setting Range Time Delay Underfrequency Default Setting
10 sec. (short term)

80%-95% of nominal 90% of nominal
60 sec. (long term)
Figure 24 Underfrequency Specs
TP-6861 11/24 59
Low Generator Voltage (Each Phase). The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when
the voltage drops below the undervoltage setting for the time delay period. See Figure 25 for undervoltage specifications.
Undervoltage Setting Range Time Delay Range Undervoltage Default Setting
70%-95% of nominal 5-30 sec. 80% of nominal at 10 sec.
Figure 25 Undervoltage Specs

Low Oil Pressure. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down because of low oil pressure.
The shutdown occurs 5 seconds after the low pressure condition is detected. The low oil pressure shutdown does not function
during first the 30 seconds after startup.
Max. Alternator Current Low. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when Alternator
Protection Configuration in the personality profile is not correct. If the settings are correct for the application, the controller may
need a new or updated personality profile. Consult your local authorized distributor.
Overcrank. The fault lamp illuminates red, the alarm horn sounds, and cranking stops when the unit does not start within the
defined cranking period. See the Controller Operation section for cyclic crank specifications.
Run Relay Coil Overload. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the current
draw on the 70 wire from the controller has exceeded 40 amps or has exceeded 10 amps for at least 10 ms.
Starter Relay Coil Overload. The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the current
draw on the 71 wire from the controller has exceeded 40 amps or has exceeded 10 amps for at least 10 ms.
Trip to Shutdown Delay The fault lamp illuminates red, the alarm horn sounds, and the unit shuts down when the generator is
stopped if the circuit breaker has tripped for a Protective Relay function, and the trip to shutdown time delay has expired. This
delay allows mitigation of problem conditions without engine shutdown. If the delay expires, it is presumed no successful action
was taken in the allotted time.
2.6.5 Status and Notice Digital Displays
Warnings and shutdown faults appear on the digital display under the Active Events menu and become part of the event history.
Beyond the warnings and shutdowns there are several events which also appear on the digital display under the Active Events
menu. Status is an event that is not an alert but is part of the event history. Notice is an alert that is not part of the event history.
The controller allows a selected number of changes by the user for setting up the controller application which are covered in this
section.
Alarm Horn Silence. This status message indicates whether the alarm horn can be silenced in any button mode (OFF/RESET-
AUTO-RUN) or requires the AUTO button be pressed first compliant per NFPA 110. Use SiteTech™ software to change this
setting. See the Controller Resetting (Following System Shutdown or Warning) section, Controller Resetting procedure, for
information on resetting the system.
The local display shows Alarm Silence: Always when the alarm horn can be silenced with the master control buttons in any
position (default setting).
The local display shows Alarm Silence: Auto Only when the alarm horn can be silenced only when in the AUTO mode. The
correct reset sequence requires pressing the OFF/RESET button, then pressing the AUTO button, and then pressing the ALARM
SILENCE button.
Close Breaker. This notice message indicates that the controller is attempting to close the circuit breaker (a close command is
being sent to the circuit breaker). This notice only appears in paralleling applications (where the bus sensing is connected to the
bus side of the paralleling breaker).
Contactor. This notice message indicates that the controller wants to be connected to the paralleling bus. If a contactor is used
for paralleling, this output controls it. This notice only appears in paralleling applications (where the bus sensing is connected to
the bus side of the paralleling breaker).
Emergency Power System (EPS) Supplying Load. This notice message indicates when the generator set supplies more than
1% of the rated standby output current.
Engine Cooldown (Delay) Active. This notice message indicates that the delay for engine cooldown is active where the
generator set will continue to run after the OFF/RESET button is pressed. The unit will continue to run until the time delay times
out.
Engine Start Aid Active. This notice message indicates that the start aid is active and will energize an engine equipped preheat
or ether system during the crank cycle. Use SiteTech™ software to set up this feature.
Engine Started. This status indicates that the generator set start circuit is closed allowing the engine to crank and run.
60 TP-6861 11/24
Engine Stopped. This status indicates that the generator set start circuit is open causing the engine to shut down.
Generator Running. This notice indicates that the generator set has started and is running.
Load Priority # Shed. This status message indicates the digital output for load priority # (1, 2, 3, 4, 5, or 6) shed is active
(contacts closed), indicating the 1st, 2nd, 3rd, 4th, 5th, or 6th priority load shed has been activated.
Remote Start. This notice indicates that the generator set start circuit was closed from a remote location allowing the engine to
crank and run. The remote location is typically a set of contacts on a transfer switch or remote start switch.
Remove Breaker Trip. This notice message indicates that the controller considers the breaker to be safe to close. The breaker
may be closed or preparing to close when this notice is displayed. This notice only appears in paralleling applications (where
the bus sensing is connected to the bus side of the paralleling breaker).
Run Button Acknowledged. This notice message indicates that the RUN button on the controller has been pushed.
System Ready. This status indicates that the generator set is in the AUTO mode and available to start if the start circuit is
closed.
2.6.6 Controller Resetting (Following System Shutdown or Warning)
Use the following procedure to restart the generator set after a system shutdown or to clear a warning lamp condition. This
procedure includes the resetting of the optional remote annunciator.
Refer to the Emergency Stop section, to reset the generator set after an emergency stop.
1. Disconnect the generator set load using the line circuit breaker or automatic transfer switch.
2. Correct the cause of the fault shutdown or warning. See the Safety Precautions and Instructions section of this manual
before proceeding.
3. Reset the fault by pressing the OFF/RESET button.
4. Start the generator set by pressing the generator set OFF/RESET button and then press the RUN button.
When equipped, the remote annunciator alarm horn sounds. Press the ALARM SILENCE/LAMP TEST button to stop
the alarm horn. The alarm silenced lamp turns on if the alarm is silenced.
5. Test operate the generator set to verify correction of the shutdown cause by pressing the RUN button.
6. Press the generator set OFF/RESET button to stop the generator set.
7. Press the generator set AUTO button.
8. Silence the controller alarm horn by pressing the ALARM SILENCE button.
9. Reconnect the generator set load via the line circuit breaker or automatic transfer switch.
10. When equipped, the remote annunciator alarm horn sounds. Press the ALARM SILENCE/LAMP TEST button to stop
the alarm horn. The alarm silenced lamp turns on if the alarm is silenced.
2.7 Menu Displays

Use the Menu Summary List and Figure 26 after reading and understanding the features of the pushbutton/rotary selector dial.
See the Graphical Display section.
The Menu Summary List and Figure 26 provide a quick reference to the digital display data. Some digital display data may not
be identical to your display due to generator set application differences. The closed bullet items represent main level data and
the open bullet items are sub-level data. The Menu Summary List indicates items that are user selectable. Use SiteTech ™
software for changing programmable information.
TP-6861 11/24 61
Menu Summary List (Legend: ● First level submenu, ○ second level submenu, ◊ third level submenu)
Metering Menu Metering Menu (Continued) Generator Information Menu (Continued)
• Generator Metering o FUEL RATE: ###GAL/h o LAST MAINTENANCE:

o L1-L2 VOLTS: ###V (shown if available from ECM) ##/##/####
o L2-L3 VOLTS: ###V o FUEL USED LAST RUN: ###GAL o OP HRS SINCE MAINT: ####hrs
o L3-L1 VOLTS: ###V (shown if available from ECM) o STARTS SINCE MAINT: ###
o AVG GEN VOLTAGE L-L: ###V o CRANKCASE PRESSURE: ###PSI o ENG HRS SINCE MAINT:
o GEN FREQUENCY: ##.#Hz o INTAKE AIR PRESSURE: ###PSI ####hrs
o L1-L0 VOLTS: ###V o INTAKE AIR TEMP: ###°F o LOADED SINCE MAINT: ####hrs
o L2-L0 VOLTS: ###V • Battery X Meter o UNLOADED SINCE MAINT:
o L3-L0 VOLTS: ###V Note: ####hrs
o AVG GEN VOLTAGE L-N: This menu option does not apply o kW HRS SINCE MAINT:
###V to marine generator sets. ####kWh
o GEN FREQUENCY: ##.#Hz o STATUS: (IDLING/STANDBY/ o RESET MAINT RECORDS:
o L1 CURRENT: ###A CHARGING/ BATT FAIL/CHRGR YES/NO*
o L2 CURRENT: ###A FAIL/ NOT AVAILABLE) o LAST START: ##/##/####
o L3 CURRENT: ###A o OUTPUT VOLTAGE: ##.#VDC o LAST RUN LENGTH: ####hrs
o AVG CURRENT: ###A o OUTPUT CURRENT: ##.#A o CTRL SERIAL #: XXXXXXXXX
o GEN FREQUENCY: ##.#Hz o CHARGER STATE: IDLE/BULK/ o SOFTWARE VER.: XXXXXXXXX
o L1 POWER: ####W ABSORB/FLOAT/EQUAL/ o ECM SERIAL #: XXXXXXXXX
o L2 POWER: ####W REFRESH/ RECOVER/NA o GENSET MODEL #:
o L3 POWER: ####W o CHARGER TEMP: ###°F XXXXXXXXX
o TOTAL POWER: ####.#kW o REDUCED OUTPUT ACTIVE: o GENSET SPEC. #: XXXXXXXXX
o GEN % OF RATED kW: ###% YES/NO o GENSET SERIAL #:
o L1 REACTIVE POWER: o TEMP COMPENSATION ACTIVE: XXXXXXXXX
####VAR YES/NO o ALT. PART #: XXXXXXXXX
o L2 REACTIVE POWER: o SOFTWARE VER.: o ENGINE PART #: XXXXXXXXX
####VAR XXXXXXXXXXXX o ENGINE MODEL #: XXXXXXXXX
o L3 REACTIVE POWER: • Overview o ENGINE SERIAL #: XXXXXXXXX
####VAR o GENERATOR STATUS • Event History
o TOTAL REACTIVE POWER: ◊ AVG GEN VOLTAGE L-L: ##V o GENERATOR EVENT HISTORY
####VAR ◊ AVG CURRENT: ###A ##/##/#### (Date) ##:##.##XX
o L1 APPARENT POWER: ◊ GEN FREQUENCY: ##.#Hz (Time) DEVICE EVENT: ###
####VA o ENGINE STATUS STATUS/FAULT/NOTICE/
o L2 APPARENT POWER: ◊ COOLANT TEMPERATURE: WARNING EVENT X OF Y
####VA ###°F o ENGINE EVENT LOG
o L3 APPARENT POWER: ◊ OIL PRESSURE: ###PSI SPN: ####
####VA ◊ GEN BATTERY VOLTAGE: FMI: ##
o TOTAL APPARENT PWR: ##.#V OCCURRENCE COUNT: ###
####VA o SYSTEM STATUS EVENT X OF Y
o GEN % OF RATED kVA: ###% ◊ FUEL PRESSURE: ###PSI • Configuration
o L1 PF: #.## ◊ TOTAL POWER: ####kW o GENERATOR CONFIGURATION
o L2 PF: #.## ◊ TOTAL RUN TIME: #####.#hrs ◊ OPERATING MODE:
o L3 PF: #.## • Paralleling Metering (STANDBY/PRIME)
o TOTAL PF: #.## o CONNECTED TO BUS: ◊ APPLICATION TYPE:
o GEN PHASE ROTATION: ### TRUE/FALSE (NONE/MARINE/
• Engine Metering o AVG BUS VOLTAGE L-L: ###.#V MOBILE/STANDBY/PRIME)
o ENGINE SPEED: ####RPM o AVG GEN VOLTAGE L-L: ###.#V ◊ SYSTEM VOLTAGE L-L:
o ECM BATTERY VOLTAGE: o BUS FREQUENCY: ##.##Hz ###V*
##.#VDC o GEN FREQUENCY: ##.##Hz ◊ SYSTEM FREQUENCY:
o GEN BATTERY VOLTAGE: o BUS TOTAL POWER: #####.#kW ##.#Hz*
##.#VDC o BUS % OF RATED kW: ###% ◊ SYSTEM PHASE:
o GENSET CONTROLLER o BUS % OF RATED kVAR: ###% (SINGLE/SINGLE
TEMP: ###°F DOG/THREE-WYE/THREE-
o OIL PRESSURE: ###PSI Generator Information Menu DELTA)*
o OIL TEMPERATURE: ###°F ◊ RATED ENGINE SPEED:
o COOLANT TEMPERATURE: • Generator Information ####RPM
###°F o TOTAL RUN TIME: #####.#hrs ◊ ENGINE SPEED
o COOLANT PRESSURE: o HOURS LOADED: #####hrs ADJUSTMENT: *
###PSI o HOURS UNLOADED: #####hrs ◊ ADJUSTED ENGINE RUN
o FUEL LEVEL: ###% o kW HOURS: #####kWh SPEED:
o FUEL PRESSURE: ###PSI o OPERATING HOURS: ######hrs ####RPM
o FUEL TEMPERATURE: ###°F o TOTAL # OF STARTS: ########
* User-Defined (changeable) Menu Displays. Use SiteTech™ software to change other settings including User-Defined Menu Displays.
62 TP-6861 11/24
Generator Information Menu Generator Information Menu (Continued) Generator Information Menu (Continued)
(Continued)
◊ kW RATING: ####kW ◊ CHARGER SYSTEM ◊ LOAD ENABLE: ON/OFF*
◊ kVA RATING: #####kVA VOLTAGE: 12VDC/24VDC ◊ SYSTEM LOAD CONTROL:
◊ RATED CURRENT: ###A ◊ AUTO EQUALIZE ENABLED: ON/OFF*
◊ BATTERY VOLTAGE: ON/OFF* ◊ SYSTEM SYNC CONTROL:
##VDC* ◊ TEMP COMPENSATION ON/OFF*
◊ POWER ECM: ON/OFF* ENABLED: ON/OFF* ◊ STAND ALONE MODE:
◊ ENGINE START DELAY: ◊ ABSORPTION TERMINATION: ON/OFF*
##s* #.##A ◊ SYNC MODE IN AUTO:
◊ STARTING AID DELAY: (+/- 0.05)* (INVALID/OFF/PASSIVE/
##s* ◊ BULK VOLTAGE: ##.##VDC CHECK/ ACTIVE/DEAD
◊ CRANK ON DELAY: ##s* (+/- 0.05)* FIELD)*
◊ CRANK PAUSE DELAY: ◊ ABSORPTION VOLTAGE: ◊ SYNC MODE IN RUN:
##s* ##.##VDC (+/- 0.05) * (INVALID/OFF/PASSIVE/
◊ ENGINE WARMED UP: ◊ FLOAT VOLTAGE: ##.##VDC CHECK/ ACTIVE/DEAD
###°F (+/- 0.05)* FIELD)*
◊ ENGINE COOLED DOWN: ◊ MANUAL EQUALIZE ACTIVE: o SYNCHRONIZING SETUP
###°F YES/NO* ◊ SYNC MODE IN RUN:
◊ COOLDOWN DELAY: ##s* ◊ CUSTOM PROFILE ENABLED: (INVALID/OFF/PASSIVE/
◊ COOLDOWN OVERRIDE: ON/OFF* CHECK/ ACTIVE/DEAD
ON/OFF* ◊ TEMP COMPENSATION FIELD)*
◊ FUEL TYPE: (NATURAL SLOPE: ##mV/C* ◊ SYNC MODE IN AUTO:
GAS/LP/GASOLINE/ ◊ EQUALIZE VOLTAGE: (INVALID/OFF/PASSIVE/
DIESEL/ UNKNOWN)* ##.##VDC (+/- 0.05)* CHECK/ ACTIVE/DEAD
◊ CRANK CYCLES LIMIT:##* ◊ MAX ABSORPTION TIME: FIELD)*
◊ NFPA DEFAULTS: ###MIN* ◊ CONNECTED TO BUS:
ON/OFF* ◊ MAX BULK TIME: ###MIN* TRUE/FALSE
◊ EMERGENCY ◊ BULK STATE RETURN: ##.##V ◊ VOLTS-Hz OK: TRUE/FALSE
BATTLEMODE: ON/OFF* (+/- 0.05)* ◊ IN SYNC: TRUE/FALSE
o PROTECTION • Voltage Regulation ◊ VOLTAGE MATCHED:
CONFIGURATION o AVG GEN VOLTAGE L-L: ###.#V TRUE/FALSE
◊ OVERVOLTAGE: ###%* o VOLTAGE ADJUST: ###.#V* ◊ VOLTAGE MATCH WINDOW:
◊ OVERVOLTAGE: ###.#V o TARGET VOLTAGE: ###.#V ##.#%*
◊ OVERVOLTAGE DELAY: o L1-L2 VOLTS: ###.#V ◊ AVG BUS VOLTAGE L-L:
##s* o L2-L3 VOLTS: ###.#V ###.#V
◊ UNDERVOLTAGE: ##%* o L3-L1 VOLTS: ###.#V ◊ AVG GEN VOLTAGE L-L:
◊ UNDERVOLTAGE: ##.#V o GEN FREQUENCY: ##.#Hz ###.#V
◊ UNDERVOLTAGE DELAY: o V/Hz SETPOINT: ##.#Hz* ◊ VOLTAGE MATCH P GAIN:
##s* o V/Hz SLOPE: ##%/Hz* ##.##*
◊ OVERFREQUENCY: ##%* o VOLT DROOP AT 100% kVAR: ◊ VOLTAGE MATCH I GAIN:
◊ OVERFREQUENCY: ##.#%* ##.##*
##.#Hz o VOLTAGE GAIN ADJUST: ###* ◊ VOLTAGE MATCH D GAIN:
◊ UNDERFREQUENCY: o START UP RAMP RATE: ###.#%/s* ##.##*
##%* o RESET REG. DEFAULTS:YES/NO* ◊ VOLTAGE BIAS: ###.##
◊ UNDERFREQUENCY: • Paralleling Operation ◊ FREQUENCY MATCHED:
##.#Hz o PARALLELING SETUP TRUE/FALSE
◊ OVERSPEED: ##.#%* ◊ DEAD BUS LEVEL: ##.#%* ◊ FREQUENCY WINDOW:
◊ OVERSPEED: ##.#Hz ◊ VOLTAGE OK PICKUP: ##.#%* #.#Hz*
◊ OVERSPEED: ####RPM ◊ VOLTAGE OK DROPOUT: ◊ BUS FREQUENCY: ##.##Hz
◊ LOW BATTERY VOLTAGE: ##.#%* ◊ GEN FREQUENCY: ##.##Hz
###%* ◊ FREQUENCY OK PICKUP: ◊ FREQ MATCH P GAIN:##.##*
◊ LOW BATTERY VOLTAGE: ##.#Hz* ◊ FREQ MATCH I GAIN: ##.##*
##.#VDC ◊ FREQUENCY OK DROPOUT: ◊ FREQ MATCH D GAIN:##.##*
◊ HIGH BATTERY ##.#Hz* ◊ SPEED BIAS: ###.##
VOLTAGE: ###%* ◊ VOLTS-Hz OK DELAY: ##.#s* ◊ PHASE MATCHED:
◊ HIGH BATTERY ◊ FIRST ON DELAY: ##.#s* TRUE/FALSE
VOLTAGE: ##.#VDC ◊ FAIL TO OPEN DELAY: ##s* ◊ PHASE MATCH WINDOW:
o BATT X BASIC CONFIG ◊ FAIL TO CLOSE DELAY: ##s* ##.#°*
Note: ◊ RECLOSE DELAY: ##.#s* ◊ PHASE DIFFERENCE: ###.#°
This menu option does not ◊ MAX CLOSE ATTEMPTS: ###* ◊ PHASE MATCH P GAIN:
apply to marine generator sets. ◊ CB CRNT FAULT LIMIT: ##.##*
◊ BATTERY TOPOLOGY: ###.#%* ◊ PHASE MATCH I GAIN:
(DEFAULT/ ◊ CB CRNT FAULT DELAY: ##.##*
VRLA/ AGM/GEL/NiCd* ##.#s* ◊ PHASE MATCH D GAIN:
◊ CB PHASE FAULT LIMIT: ##.##*
##.#_* ◊ SPEED BIAS: ###.##
◊ CB PHASE FAULT DELAY: ◊ DWELL TIME: ##.#s*
##.#s* ◊ DWELL TIME REMAINING:
◊ kW RAMP RATE: ##.#%/s* ##.#s
◊ kW DISCONNECT LEVEL: ◊ FAIL TO SYNC TIME: ####s*
##.#%* ◊ SYNC TIME REMAINING:
◊ TRIMS ENABLE: ON/OFF* ####s
TP-6861 11/24 63
Generator Information Menu Generator Information Menu (Continued) Controller Configuration Menu
(Continued)
◊ BUS PHASE ROTATION: ◊ UNDER FREQ DELAY: ##.#s* • Controller Configuration
DISABLED/A-B-C/C-B-A ◊ REVERSE VAR TRIP: ###.#%* o LANGUAGE: English*
◊ GEN PHASE ROTATION: ◊ REVERSE VAR DELAY: ##.#s* o UNITS: Metric/English*
DISABLED/A-B-C/C-B-A ◊ OVER CURRENT TRIP: o TIME FORMAT: Hr 12/Hr 24*
o SHARING SETUP ###.#%* o DATE FORMAT: Month Date
◊ BUS % OF RATED kW: ◊ OVER CURRENT DELAY: Year/
###.##% ##.#s* Date Month Year*
◊ GEN % OF RATED kW: ◊ TRIP TO SHTDWN DELAY: o DATE: ##/##/####*
###.##% #####s* o TIME: ##:## XM*
◊ kW SHARING P GAIN: o GENERATOR MANAGEMENT o CONTRAST: ###*
##.##* ◊ GEN MANAGEMENT MODE: o ALARM SILENCE:
◊ kW SHARING I GAIN: (INVALID/MANUAL ALWAYS/AUTO ONLY*
##.##* FIXED/RUN TIME/FUEL • Communication Setup
◊ kW SHARING D GAIN: LEVEL)* o MODBUS BAUD RATE:
##.##* ◊ GEN MANAGEMENT: OFF/9600 b/s/
◊ SPEED BIAS: ###.## ON/OFF* 19200 b/s/38400 b/s/57600 b/s/
◊ SYSTEM FREQUENCY: ◊ GEN MANAGEMENT ORDER: 115200 b/s*
##.#Hz #* o MODBUS ADDRESS: ##*
◊ GEN FREQUENCY: ##.#Hz will revert to previous setting in o PGEN BAUD RATE: OFF/9600
◊ FREQ TRIM P GAIN: ##.##* run time or fuel level mode. b/s/
◊ FREQ TRIM I GAIN: ##.##* ◊ START CAPACITY: ###.#%* 19200 b/s/38400 b/s/57600 b/s/
◊ FREQ TRIM D GAIN: ◊ START DELAY: ####s* 115200 b/s
##.##* ◊ STOP CAPACITY: ###.#%* o PGEN NODE ID: ##
◊ SPEED BIAS: ###.## ◊ STOP DELAY: ####s* o PGEN NODES ONLINE: ##
◊ FREQ DROOP AT 100% ◊ TOTAL BUS CAPACITY: o PGEN NODES OFFLINE: ##
kW: ##.#%* #####kW • Calibration
◊ BUS % OF RATED kVAR: ◊ BUS TOTAL POWER: When the line is highlighted, hold the
###.##% #####kW knob down to enable the calibration
◊ GEN % OF RATED kVAR: ◊ START kW: #####kW capability.
###.##% ◊ STOP kW: #####kW o GEN L1-L0 VOLTS: ###.#V*
◊ kVAR SHARING P GAIN: ◊ START ACCUMULATOR: o GEN L2-L0 VOLTS: ###.#V*
##.##* ##### o GEN L3-L0 VOLTS: ###.#V*
◊ kVAR SHARING I GAIN: ◊ STOP ACCUMULATOR: ##### o GEN L1-L2 VOLTS: ###.#V*
##.##* ◊ RUN TIME THRESHOLD: o GEN L2-L3 VOLTS: ###.#V*
◊ kVAR SHARING D GAIN: ###.#hrs* o GEN L3-L1 VOLTS: ###.#V*
##.##* only if in Run Time o GEN L1 CURRENT: ###.#A*
◊ VOLTAGE BIAS: ###.## Management o GEN L2 CURRENT: ###.#A*
◊ SYSTEM VOLTAGE L-L: ◊ TOTAL RUN TIME: o GEN L3 CURRENT: ###.#A*
###.#V #######.#hrs o BUS L1-L2 VOLTS: ###.#V*
◊ AVG GEN VOLTAGE L-L: ◊ FUEL LEVEL THRESHOLD: o BUS L2-L3 VOLTS: ###.#V*
###.#V ##.#%* o BUS L3-L1 VOLTS: ###.#V*
◊ VOLT TRIM P GAIN: ##.##* only if in Fuel Level o RESET GEN VOLT METER:
◊ VOLT TRIM I GAIN: ##.##* Management YES/NO*
◊ VOLT TRIM D GAIN: ##.##* ◊ FUEL LEVEL: ###.#% o RESET GEN AMP METER:
◊ VOLTAGE BIAS: ###.## ◊ STABLE DELAY: ####s* YES/NO*
◊ VOLT DROOP AT 100% ◊ MINIMUM GENS ONLINE: ##* o RESET BUS VOLT METER:
kVAR: ##.#%* ◊ MIN LOADS ADDED: ##* YES/NO*
o PROTECTIVE RELAY SETUP ◊ STOPPED BY GEN MGMT: o RESET ALL METERS: YES/NO*
◊ OVER POWER TRIP: TRUE/FALSE
###.#%* o LOAD CONTROL
◊ OVER POWER DELAY: ◊ GEN MAX % CAP: ###.#%*
##.#s* ◊ GEN OVERLOAD %: ###.#%*
◊ REVERSE POWER TRIP:
###.#%*
◊ REVERSE POWER
DELAY: ##.#s*
◊ OVER VOLTAGE TRIP:
###.#%*
◊ OVER VOLTAGE DELAY:
##.#s*
◊ UNDER VOLTAGE TRIP:
###.#%*
◊ UNDER VOLTAGE DELAY:
##.#s*
◊ OVER FREQ TRIP:
###.#%*
◊ OVER FREQ DELAY:
##.#s*
◊ UNDER FREQ TRIP:
###.#%*
64 TP-6861 11/24
I/O Menu I/O Menu (Continued) Active Events Menu
• Resistive Input • Digital Input Rotate the dial to view Active Events:
Analog Input 0:1 Digital Input 0:1 Warnings
Analog Input 0:2 Digital Input 0:2 Shutdowns
Analog Input 0:3 Digital Input 0:3 Statuses
Analog Input 0:4 Digital Input 0:4 Notices
Analog Input 0:5 Digital Input 0:5
Analog Input 0:6 Digital Input 0:6 See the System Fault Warning Lamp with
o DESCRIPTION: (function by o DESCRIPTION: (function by default Digital Displays, System Fault Shutdown
default unless modified via unless modified via SiteTech) Lamp With Digital Displays, and Status
SiteTech) o STATUS: ACTIVE/INACTIVE and Notice Digital Displays sections for
o MEASUREMENT: ###.#Ohms o FUNCTION: * descriptions.
o EVENT: * o EVENT: *
o INPUT ENABLED: ON/OFF* o LOGIC: ACTIVE ON/ACTIVE OFF * Press the OFF button to return to the
o SENSOR TYPE: * o ENABLED: ON/OFF* main menu.
o LOW PROTECTIVE INHIBIT: o INHIBIT TIME: ##s*
##s* o DELAY TIME: ##s*
o LOW WARNING: ON/OFF* • Digital Output
o LOW WARNING LIMIT: * Digital Output 0:1
o LOW WARNING DELAY: ##s* Digital Output 0:2
o LOW SHUTDOWN: ON/OFF* Digital Output 0:3
o LOW SHUTDOWN LIMIT: * Digital Output 0:4
o LOW SHUTDOWN DELAY: Digital Output 1:1
##s* (Note:
o HIGH PROTECTIVE INHIBIT: Only displayed if the 15-Relay
##s* Dry Contact Kit is installed.)
o HIGH WARNING: ON/OFF*
o HIGH WARNING LIMIT: * o DESCRIPTION: (function by default
o HIGH WARNING DELAY: ##s* unless modified via SiteTech)
o HIGH SHUTDOWN: ON/OFF* o STATUS: ACTIVE/INACTIVE
o HIGH SHUTDOWN LIMIT: * o FUNCTION: *
o HIGH SHUTDOWN DELAY: o EVENT: *
##s* o LOGIC: ACTIVE ON/ACTIVE OFF*
TP-6861 11/24 65
From Controller Power-Up From Controller Sleep/Idle Operation
Alternates Alternates
every every
8 seconds 8 seconds
°F
Changes after 3 seconds

DIAL CLICK
MAIN MENU 12:00 AM
12/12/12
METERING
GENERATOR INFO
CONTROLLER CONFIG
I/O
ACTIVE EVENTS
DIAL TURN
DIAL PUSH at METERING. Go to the Figure 27.

DIAL PUSH at GENERATOR INFO. Go to the Figure 28.
DIAL PUSH at CONTROLLER CONFIG. Go to the
Figure 29.
DIAL PUSH at I/O. Go to the Figure 30.
Figure 26 Decision-Maker 3500 Controller Information Menu Structure

12:00 AM
METERING
12/12/12
GENERATOR METERING
ENGINE METERING
Note:
BATTERY CHARGER METERING - - > Battery Charger Metering menu options appear but do not apply to these models.
OVERVIEW
PARALLELING METERING
DIAL TURN
DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH
12:00 AM 12:00 AM 12:00 AM 12:00 AM
GENERATOR METER ENGINE METERING ENGINE STATUS PARALLEL METERING
12/12/12 12/12/12 12/12/12 12/12/12
L1-L2 VOLTS: ###V ENGINE SPEED: ####RPM CONNECTED TO BUS: TRUE/FALSE
COOLANT OIL PRESSURE GEN BATTERY
L2-L3 VOLTS: ###V ECM BATTERY VOLTAGE: ##.#VDC AVG BUS VOLTAGE L-L: ###.#V
TEMPERATURE VOLTAGE
L3-L1 VOLTS: ###V GEN BATTERY VOLTAGE: ##.#VDC AVG GEN VOLTAGE L-L: ###.#V
AVG GEN VOLTAGE L-L: ###V GENSET CONTROLLER TEMP:###°F BUS FREQUENCY: ##.##Hz
GEN FREQUENCY: ##.#Hz OIL PRESSURE: ###PSI GEN FREQUENCY: ##.##Hz
L1-L0 VOLTS: ###V OIL TEMPERATURE: ###°F BUS TOTAL POWER: #####.#kW
L2-L0 VOLTS: ###V COOLANT TEMPERATURE: ###°F BUS % OF RATED kW: ###%
L3-L0 VOLTS: ###V COOLANT PRESSURE: ###PSI ###°F ###PSI ##.#Hz BUS % OF RATED kVAR: ###%
AVG GEN VOLTAGE L-N: ###V FUEL LEVEL: ###%
GEN FREQUENCY: ##.#Hz FUEL PRESSURE: ###PSI
L1 CURRENT: ###A FUEL TEMPERATURE: ###°F Alternates every
L2 CURRENT: ###A FUEL RATE: ###GAL/h 8 seconds
L3 CURRENT: ###A FUEL USED LAST RUN: ###GAL
AVG CURRENT: ###A CRANKCASE PRESSURE: ###PSI
GEN FREQUENCY: ##.#Hz INTAKE AIR PRESSURE: ###PSI 12:00 AM
GENERATOR STATUS
L1 POWER: ####W INTAKE AIR TEMPERATURE: ###°F 12/12/12
L2 POWER: ####W
AVGGEN AVG CURRENT GEN
L3 POWER: ####W
VOLTAGE L-L FREQUENCY
TOTAL POWER: ####.#kW
GEN % OF RATED kW: ###%
L1 REACTIVE POWER: ####VAR
L2 REACTIVE POWER: ####VAR
L3 REACTIVE POWER: ###VAR
TOTAL REACTIVE POWER: ####VAR ###V ###A ##.#Hz
L1 APPARENT POWER: ####VA 12:00 AM
BATTERY X METER
L2 APPARENT POWER: ####VA 12/12/12
L3 APPARENT POWER: ####VA STATUS:
TOTAL APPARENT POWER: ####VA OUTPUT VOLTAGE: ##.#VDC Alternates every
GEN % OF RATED kVA: ###% OUTPUT CURRENT: ##.#A 8 seconds
L1 PF: #.## CHARGER STATE:
L2 PF: #.## CHARGER TEMP: ###°F 12:00 AM
REDUCED OUTPUT ACTIVE: YES/NO SYSTEM STATUS
L3 PF: #.## 12/12/12
TOTAL PF: #.## TEMP COMPENSATION ACTIVE: YES/NO
SOFTWARE VERSION: ########### FUEL TOTAL POWER TOTAL RUN
GEN PHASE ROTATION: ###
PRESSURE TIME
###PSI ####Kw ####HRS
Figure 27 Metering Menu
66 TP-6861 11/24
12:00 AM
GENERATOR INFO
12/12/12
GENERATOR INFO
EVENT HISTORY Note:
CONFIGURATION --> Battery Charger Configuration menu options appear but do not apply. to these models.
VOLTAGE REGULATOR Note:
VOLTAGE SELECTOR SWITCH --> Voltage Selector Switch menu options do not apply to these models.
PARALLELING OPERATION
EMISSIONS INFO - - > Note:
Emissions Info menu options do not apply to these models.
DIAL TURN
Go
To
A
DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH

12:00 AM 12:00 AM 12:00 AM 12:00 AM
GENERATOR INFO EVENT HISTORY CONFIGURATION VOLT REG CONFIG
12/12/12 12/12/12 12/12/12 12/12/12
TOTAL RUN TIME: #####hrs GENERATOR EVENT HISTORY GENERATOR CONFIG AVG GEN VOLTAGE L-L: ###.#V
HOURS LOADED: #####hrs ENGINE EVENT LOG PROTECTIVE CONFIG VOLTAGE ADJUST: ###.#V
HOURS UNLOADED: #####hrs BATTERY CHARGER CONFIG TARGET VOLTAGE: ###.#V
kW HOURS: #####kWh L1-L2 VOLTS: ###.#V
OPERATING HOURS: ######hrs L2-L3 VOLTS: ###.#V
TOTAL # OF STARTS: ######## L3-L1 VOLTS: ###.#V
LAST MAINTENANCE: ##/##/#### GEN FREQUENCY: ##.#Hz
OP HRS SINCE MAINT: ####hrs V/Hz SETPOINT: ##.#Hz
STARTS SINCE MAINT:
ENG HRS SINCE MAINT:
###
####hrs
DIAL TURN DIAL TURN V/Hz SLOPE: ##%/Hz
VOLT DROOP AT 100% kVAR: ##.#%
LOADED SINCE MAINT: ####hrs VOLTAGE GAIN ADJUST: ###
UNLOADED SINCE MAINT: ####hrs
kW HRS SINCE MAINT: ####kWh DIAL PUSH DIAL PUSH START UP RAMP RATE:
RESET REG DEFAULTS:
###.#%/s
YES/NO
RESET MAINT RECORDS: YES/NO* 12:00 AM 12:00 AM
EVENT HISTORY ENGINE EVENT
LAST START: ##/##/#### 12/12/12 12/12/12
LAST RUN LENGTH: ####hrs 12/12/2012 10:17:37 AM SPN: ####
CONTROLLERSERIAL#: XXXXXXXXX (EVENT INFORMATION) FMI: ## (DESCRIPTION)
SOFTWARE VERSION: XXXXXXXXX
ECM SERIAL #: XXXXXXXXX EVENT X OF Y OCCURRENCE COUNT: ###
GENSET MODEL #: XXXXXXXXX PRESS (STATE) TO RETURN TO MAIN EVENT X OF Y
GENSET SPEC. #: XXXXXXXXX PRESS (STATE) TO RETURN TO MAIN
GENSET SERIAL #: XXXXXXXXX
ALTERNATOR PART #: XXXXXXXXX
ENGINE PART #: XXXXXXXXX
ENGINE MODEL #: XXXXXXXXX
ENGINE SERIAL #: XXXXXXXX
DIAL PUSH DIAL PUSH DIAL PUSH
12:00 AM 12:00 AM 12:00 AM
GENERATOR CONFIG PROTECTION CONFIG BATT X BASIC CONFIG
12/12/12 12/12/12 12/12/12
OPERATING MODE: (MODE) OVERVOLTAGE: ###%* BATTERY TOPOLOGY: *
APPLICATION TYPE: (APP TYPE) OVERVOLTAGE: ###.#V CHARGER SYSTEMVOLTAGE: 12VDC/24VDC*
SYSTEM VOLTAGE L-L: ###V* OVERVOLTAGE DELAY: ##s* AUTO EQUALIZE ENABLED: ON/OFF*
SYSTEM FREQUENCY: ##.#Hz* UNDERVOLTAGE: ##%* TEMP COMPENSATION-ENABLED: ON/OFF*
SYSTEM PHASE: (PHASE)* UNDERVOLTAGE: ##.#V ABSORPTION TERMINATION: ##.#A*
RATED ENGINESPEED: ####RPM* UNDERVOLTAGE DELAY: ##s*
ENGINE SPEED ADJUSTMENT: * OVERFREQUENCY: ##%*
ADJUSTED ENG RUN SPEED: ##RPM
kW RATING: ####Kw
OVERFREQUENCY:
UNDERFREQUENCY:
##.#Hz
##%*
DIAL PUSH
kVA RATING: #####kVA UNDERFREQUENCY: ###Hz 12:00 AM
BATT X ADV CONFIG
RATED CURRENT: ###A OVERSPEED: ##.#%* 12/12/12
BATTERY VOLTAGE: ##VDC* OVERSPEED: ##.#Hz BULK VOLTAGE: ##.##VDC*
POWER ECM: ON/OFF* OVERSPEED: ####RPM ABSORPTION VOLTAGE: ##.##VDC*
ENGINE START DELAY: ##s* LOW BATTERY VOLTAGE: ###%* FLOAT VOLTAGE: ##.##VDC*
STARTING AID DELAY: ##s* LOW BATTERY VOLTAGE: ##.#VDC MANUAL EQUALIZE ACTIVE: YES/NO*
CRANK ON DELAY: ##s* HIGH BATTERY VOLTAGE: ###%* CUSTOM PROFILE ENABLED: ON/OFF*
CRANK PAUSE DELAY: ##s* HIGH BATTERY VOLTAGE: ##.#VDC TEMPCOMPENSATION SLOPE: ##mV/C*
ENGINE WARMED UP: ###°F EQUALIZE VOLTAGE: ##.##VDC*
ENGINE COOLED DOWN: ###°F MAX ABSORPTION TIME: ###MIN*
COOLDOWN DELAY: ##s* MAX BULK TIME: ###MIN*
COOLDOWN OVERRIDE: ON/OFF* BULK STATE RETURN: ##.##V
FUEL TYPE: (FUEL TYPE)
CRANK CYCLES LIMIT: ##*
NFPA DEFAULTS: ON/OFF*
EMERGENCY BATTLEMODE: ON/OFF*
POWER UP IN AUTO: ON/OFF*
NOT INAUTO WARNENABLE: ON/OFF*
AUX FAULT DELAY: #s*
AUX FAULT INHIBIT DELAY: #s*
A
DIAL PUSH
12:00 AM
PARALLEL OPERATION
12/12/12
PARALLELING SETUP
SYNCHRONIZING SETUP
SHARING SETUP
PROTECTIVE RELAY SETUP
GENERATOR MANAGEMENT
LOAD CONTROL
DIAL TURN
DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH
12:00 AM 12:00 AM 12:00 AM PROTECTIVE 12:00 AM 12:00 AM
PARALLELING SETUP SYNCHRONING SETUP SHARING SETUP GEN MANAGEMENT
12/12/12 12/12/12 12/12/12 RELAYS 12/12/12 12/12/12
DEAD BUS LEVEL: ##.#%* SYNC MODE IN RUN: (MODE)* BUS % OF RATED kW: ###.##% OVER POWER TRIP: ###.#%* GEN MANAGEMENT MODE: {MODE}*
VOLTAGE OK PICKUP: ##.#%* SYNC MODE IN AUTO: (MODE)* GEN % OF RATED kW: ###.##% OVER POWER DELAY: ##.#s* GEN MANAGEMENT: ON/OFF*
VOLTAGE OK DROPOUT: ##.#%* CONNECTED TO BUS: TRUE/FALSE kW SHARING P GAIN: ##.##* REVERSE POWER TRIP: ###.#%* GEN MANAGEMENT ORDER: #*
FREQUENCY OK PICKUP: ##.#Hz* VOLTS-Hz OK: TRUE/FALSE kW SHARING I GAIN: ##.##* REVERSE POWER DELAY: ##.#s* START CAPACITY: ###.#%*
FREQUENCY OK DROPOUT: ##.#Hz* IN SYNC: TRUE/FALSE kW SHARING D GAIN: ##.##* OVER VOLTAGE TRIP: ###.#%* START DELAY: ####s*
VOLTS-Hz OK DELAY: ##.#s* VOLTAGE MATCHED: TRUE/FALSE SPEED BIAS: ###.## OVER VOLTAGE DELAY: ##.#s* STOP CAPACITY: ###.#%*
FIRST ON DELAY: ##.#s* VOLTAGE MATCH WINDOW: ##.#%* SYSTEM FREQUENCY: ##.#Hz UNDER VOLTAGE TRIP: ###.#%* STOP DELAY: ####s*
FAIL TO OPEN DELAY: ##s* AVG BUS VOLTAGE L-L: ###.#V GEN FREQUENCY: ##.#Hz UNDER VOLTAGE DELAY: ##.#s* TOTAL BUS CAPACITY: #####kW
FAIL TO CLOSE DELAY: ##s* AVG GEN VOLTAGE L-L: ###.#V FREQ TRIM P GAIN: ##.##* OVER FREQ TRIP: ###.#%* BUS TOTAL POWER: #####kW
RECLOSE DELAY: ##.#s* VOLTAGE MATCH P GAIN: ##.##* FREQ TRIM I GAIN: ##.##* OVER FREQ DELAY: ##.#s* START kW: #####kW
MAX CLOSE ATTEMPTS: ###* VOLTAGE MATCH I GAIN: ##.##* FREQ TRIM D GAIN: ##.##* UNDER FREQ TRIP: ###.#%* STOP kW: #####kW
CB CURRENT FAULT LIMIT: ###.#%* VOLTAGE MATCH D GAIN: ##.##* SPEED BIAS: ###.## UNDER FREQ DELAY: ##.#s* START ACCUMULATOR: #####
CB CURRENT FAULT DELAY: ##.#s* VOLTAGE BIAS: ###.## FREQ DROOPAT 100% kW: ##.#%* REVERSE VAR TRIP: ###.#%* STOP ACCUMULATOR: #####
CB PHASE FAULT LIMIT: ##.#°* FREQUENCYMATCHED:TRUE/FALSE BUS % OF RATED kVAR: ###.##% REVERSE VAR DELAY: ##.#s* RUN TIME THRESHOLD: ###.#hrs*
CB PHASE FAULT DELAY: ##.#s* FREQUENCY WINDOW: #.#Hz* GEN % OF RATED kVAR: ###.##% OVER CURRENT TRIP: ###.#%* TOTAL RUN TIME: #######.#hrs
kW RAMP RATE: ##.#%/s* BUS FREQUENCY: ##.##Hz kVAR SHARING P GAIN: ##.##* OVER CURRENT DELAY: ##.#s* FUEL LEVEL THRESHOLD: ##.#%*
kW DISCONNECT LEVEL: ##.#%* GEN FREQUENCY: ##.##Hz kVAR SHARING I GAIN: ##.##* TRIP TO SHTDWN DELAY: #####s* FUEL LEVEL: ###.#%
TRIMS ENABLE: ON/OFF* FREQ MATCH P GAIN: ##.##* kVAR SHARING D GAIN: ##.##* STABLE DELAY: ####s*
LOAD ENABLE: ON/OFF* FREQ MATCH I GAIN: ##.##* VOLTAGE BIAS: ###.## MINIMUM GENS ONLINE: ##*
SYSTEM LOAD CONTROL: ON/OFF* FREQ MATCH D GAIN: ##.##* SYSTEM VOLTAGE L-L: ###.#V MIN LOADS ADDED: ##*
SYSTEM SYNC CONTROL: ON/OFF* SPEED BIAS: ###.## AVG GEN VOLTAGE L-L: ###.#V STOPPED BY GEN MGMT:
STAND ALONE MODE: ON/OFF* PHASE MATCHED: TRUE/FALSE VOLT TRIM P GAIN: ##.##* TRUE/FALSE
SYNC MODE IN AUTO: {MODE}* PHASE MATCH WINDOW: ##.#°* VOLT TRIM I GAIN: ##.##*
SYNC MODE IN RUN: {MODE}* PHASE DIFFERENCE: ###.#° VOLT TRIM D GAIN: ##.##*
PHASE MATCH P GAIN: ##.##* VOLTAGE BIAS: ###.##
PHASE MATCH I GAIN: ##.##* VOLT DROOP AT 100% kVAR:
PHASE MATCH D GAIN: ##.##* ##.#%*
SPEED BIAS: ###.## 12:00 AM
DWELL TIME: ##.#s* LOAD CONTROL
12/12/12
DWELL TIME REMAINING: ##.#s GEN MAX % CAP: ###.#%*
FAIL TO SYNC TIME: ####s* GEN OVERLOAD %: ###.#%*
SYNC TIME REMAINING: ####s
BUS PHASE ROTATION: {ROTATION}
GEN PHASE ROTATION: {ROTATION}
Figure 28 Generator Information Menu
TP-6861 11/24 67
12:00 AM
CONTROLLER CONFIG
12/12/12
CONFIGURATION
COMMUNICATION SETUP
CALIBRATION
LANGUAGE: DIAL TURN

ENGLISH
UNITS:
METRIC
ENGLISH DIAL PUSH DIAL PUSH DIAL PUSH
12:00 AM
TIME FORMAT: CONTROL CONFIG
12:00 AM
12/12/12
COMM SETUP
12:00 AM
12/12/12
CALIBRATION
12/12/12
GEN L1-L0 VOLTS: ###.#V*
12hr LANGUAGE:
UNITS:
{LANGUAGE}*
{UNITS}*
MODBUS BAUD RATE:
MODBUS ADDRESS:
{M RATE}*
##* GEN L2-L0 VOLTS: ###.#V*
24hr TIME FORMAT:
DATE FORMAT:
{TIME FORMAT}*
{DATE FORMAT}*
PGEN BAUD RATE:
PGEN NODE ID:
{P RATE}
## GEN L1-L2 VOLTS: ###.#V*
DATE FORMAT: DATE:
TIME:
##/##/####*
##:## XM*
PGEN NODES ONLINE:
PGEN NODES OFFLINE:
##
## GEN L3-L1 VOLTS: ###.#V*
GEN L1 CURRENT: ###.#A*
mm/dd/yyyy CONTRAST:
ALARM SILENCE:
###*
{ALARM}* GEN L2 CURRENT: ###.#A*
GEN L3 CURRENT: ###.#A*
dd/mm/yyyy BUS L1-L2 VOLTS: ###.#V*
BUS L2-L3 VOLTS: ###.#V*
ALARM: BUS L3-L1 VOLTS: ###.#V*
RESET GEN VOLT METER: YES/NO*
ALWAYS RESET GEN AMP METER: YES/NO*
RESET BUS VOLT METER: YES/NO*
AUTO ONLY RESET ALL METERS: YES/NO*
Figure 29 Controller Configuration Menu

12:00 AM
I/O
12/12/12
RESISTIVE INPUT SETUP
DIGITAL INPUT SETUP
DIGITAL OUTPUT SETUP
DIAL TURN
DIAL PUSH DIAL PUSH DIAL PUSH

12:00 AM 12:00 AM 12:00 AM
RESISTIVE INPUT SETUP DIGITAL INPUT SETUP DIGITAL OUTPUT SETUP
12/12/12 12/12/12 12/12/12
Analog Input 0:1 Digital Input 0:1 Digital Output 0:1
Analog Input 0:2 Digital Input 0:2 Digital Output 0:2
: : :
Analog Input X:X Digital Input X:X Digital Output X:X
DIAL TURN DIAL TURN DIAL TURN
DIAL PUSH DIAL PUSH DIAL PUSH DIAL PUSH

12:00 AM 12:00 AM 12:00 AM 12:00 AM
RESISTIVE INPUT 0:1 RESISTIVE INPUT X:X DIGITAL INPUT 0:1 DIGITAL INPUT X:X
12/12/12 12/12/12 12/12/12 12/12/12
DESCRIPTION: {MODE} DESCRIPTION: {MODE} DESCRIPTION: {MODE} DESCRIPTION: {MODE}
MEASUREMENT: ###.#Ohms MEASUREMENT: ###.#Ohms STATUS: ACTIVE/INACTIVE STATUS: ACTIVE/INACTIVE
EVENT: NONE?* EVENT: NONE?* FUNCTION: {FUNCTION}* FUNCTION: {FUNCTION}*
INPUT ENABLED: ON/OFF* INPUT ENABLED: ON/OFF* EVENT: * EVENT: *
SENSOR TYPE: {SENSOR}* SENSOR TYPE: {SENSOR}* LOGIC: ACTIVE ON/ACTIVE OFF* LOGIC: ACTIVE ON/ACTIVE OFF*
LOW PROTECTIVE INHIBIT: ##s* LOW PROTECTIVE INHIBIT: ##s* ENABLED: ON/OFF* ENABLED: ON/OFF*
LOW WARNING: ON/OFF* LOW WARNING: ON/OFF* INHIBIT TIME: ##s* INHIBIT TIME: ##s*
LOW WARNING LIMIT: * LOW WARNING LIMIT: * DELAY TIME: ##s* DELAY TIME: ##s*
LOW WARNING DELAY: ##s* LOW WARNING DELAY: ##s*
LOW SHUTDOWN: ON/OFF* LOW SHUTDOWN: ON/OFF*
LOW SHUTDOWN LIMIT: * LOW SHUTDOWN LIMIT: *
LOW SHUTDOWN DELAY:
HIGH PROTECTIVE INHIBIT:
##s*
##s*
LOW SHUTDOWN DELAY:
HIGH PROTECTIVE INHIBIT:
##s*
##s* DIAL PUSH DIAL PUSH
HIGH WARNING: ON/OFF* HIGH WARNING: ON/OFF* 12:00 AM 12:00 AM
DIGITAL OUTPUT 0:1 DIGITAL OUTPUT X:X
HIGH WARNING LIMIT: * HIGH WARNING LIMIT: * 12/12/12 12/12/12
HIGH WARNING DELAY: ##s* HIGH WARNING DELAY: ##s* DESCRIPTION: {MODE} DESCRIPTION: {MODE}
HIGH SHUTDOWN: ON/OFF* HIGH SHUTDOWN: ON/OFF* STATUS: ACTIVE/INACTIVE STATUS: ACTIVE/INACTIVE
HIGH SHUTDOWN LIMIT: * HIGH SHUTDOWN LIMIT: * FUNCTION: {FUNCTION}* FUNCTION: {FUNCTION}*
HIGH SHUTDOWN DELAY: ##s* HIGH SHUTDOWN DELAY: ##s* EVENT: * EVENT: *
LOGIC: ACTIVE ON/ACTIVE OFF* * LOGIC: ACTIVE ON/ACTIVE OFF*
Figure 30 I/O Menu
2.8 Monitoring and Programming Setup

The user programmer can access the controller data with the controller digital display or a personal computer (PC) with optional
SiteTech™ software to monitor and/or program. Access the controller system with a PC using a USB cable with a mini USB
plug. Refer to the Introduction, List of Related Materials for related software literature.
While this manual focuses on data access through the controller pushbutton/rotary selector dial and display, most data entries
require input using a PC for initial setup. The PC entries typically include alpha characters such as digital input descriptions.
68 TP-6861 11/24
2.8.1 PC Communications
Communicate between a PC and the generator set controller logic using USB communication protocol. The PC connections
require optional SiteTech™ software. Contact your authorized distributor/dealer for assistance.
Local Single Connection
A PC connects to the USB port of the generator set controller using a mini USB connector. See Figure 31.
Generator Set Controller
USB Cable
Personal Computer
Figure 31 Local Single Connection
Remote Single Connection

A modem connects a PC to a single device. The PC communicates with the device via telephone line or an Ethernet network.
See Figure 32.
Ethernet Modbus®/
Network Ethernet
Network
Personal Computer Generator Set
with NIC Controller or
OR Transfer Switch
Control
Remote
Network
(Modem)
Telephone lines
Personal Computer
Ethernet Modbus®/
Network Ethernet
Network
Personal Computer Generator Set
with NIC Controller or
OR Transfer Switch
Control
Remote RS-232 to
Network RS-485 Port
(Modem) Converter
Personal Computer Telephone lines RS-485 up to 1220 m (4000 ft.)
Figure 32 Remote Single Connection
TP-6861 11/24 69
2.8.2 Modbus® Communications
The controller communicates using Modbus ® as a slave connection with the Modbus® master initiating the communication. The
controller seeks the system and alternator parameters and diagnostic information then responds back to the Modbus® master.
In addition, the controller accepts information to alter controller parameters including generator set starting and stopping. See
Figure 33. Refer to the List of Related Materials for available Modbus® literature.
Note:
Only one Modbus® master can be connected to the controller. Examples include the remote serial annunciator and switchgear
applications
RS-485
up to 1220 m (4000 ft.)
Generator Set Modbus® Master

Controller
Figure 33 Modbus® Connections
Modbus® is a registered trademark of Schneider Electric.
70 TP-6861 11/24
Section 3. Scheduled Maintenance
Under normal operating conditions, the generator set’s alternator requires no routine service. Consult the Prestart Checklist
section, for a list of routine checks.
3.1 Alternator Service

When operating the generator set under dusty or dirty conditions, use dry compressed air to blow dust out of the alternator while
the generator set is running. Direct the stream of air through openings in the generator set end bracket.
3.2 Engine Service
WARNING Explosive fuel vapors.

Can cause fires and severe burns.
If a gaseous odor is detected, ventilate the area and contact an authorized service
technician.
The fuel system. Explosive fuel vapors can cause severe injury or death. Vaporized fuels are highly explosive. Use extreme
care when handling and storing fuels. Store fuels in a well-ventilated area away from spark-producing equipment and out of the
reach of children. Never add fuel to the tank while the engine is running because spilled fuel may ignite on contact with hot parts
or from sparks. Do not smoke or permit flames or sparks to occur near sources of spilled fuel or fuel vapors. Keep the fuel lines
and connections tight and in good condition. Do not replace flexible fuel lines with rigid lines. Use flexible sections to avoid fuel
line breakage caused by vibration. Do not operate the generator set in the presence of fuel leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming generator set operation.
Draining the fuel system. Explosive fuel vapors can cause severe injury or death. Spilled fuel can cause an explosion.
Use a container to catch fuel when draining the fuel system. Wipe up spilled fuel after draining the system.
WARNING Risk of fire.

Do not smoke or permit flames or sparks near fuels or the fuel system.
Servicing the air cleaner. A sudden backfire can cause severe injury or death. Do not operate the generator set with the
air cleaner/silencer removed.
NOTICE
Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and remove salt
deposits from metal surfaces.
TP-6861 11/24 71
WARNING Hot engine and exhaust system.

Do not work on the generator set until it cools.
Servicing the exhaust system. Hot parts can cause severe injury or death. Do not touch hot engine parts. The engine and
exhaust system components become extremely hot during operation.

Perform engine service at the intervals specified in the engine manufacturer’s service literature. Contact an authorized service
distributor/dealer to obtain service literature.
Note:
Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance
personnel familiar with generator set operation and service.
See the Safety Precautions and Instructions at the beginning of this manual before attempting to service, repair, or operate the
generator set. Have an authorized distributor/dealer perform generator set service.
Routine Maintenance. Refer to the following generator set service schedule, the engine service schedule, and the hourmeter
located on the generator set controller to determine when to schedule routine maintenance. Service more frequently generator
sets that are subject to extreme weather or dusty or dirty conditions.
Service Log. Use the Operating Hour Service Log located in the back of this manual to document performed services.
Service Schedule. Perform maintenance on each item in the service schedule at the designated intervals for the life of the
generator set. For example, an item requiring service every 100 hours or 3 months also requires service after 200 hours or 6
months, 300 hours or 9 months, and so on.
72 TP-6861 11/24
3.3 Generator Set Service Schedule
Note:
Have maintenance work, including battery service, performed by appropriately skilled and suitably trained maintenance
personnel familiar with generator set operation and service.
TP-6861 11/24 73
Action
Visually
Check Change Clean Test
System—Component Inspect Interval
Fuel System
Drain water from fuel filter • • Before operation
Flexible lines and connections X R Weekly
Solenoid valve operation X X Weekly
Transfer pump operation X X Weekly
Replace fuel filter elements • Yearly or 500 Hrs.
Fuel piping X Yearly
Return lines for obstructions X Yearly
Bleed fuel system R As required
Lubrication System
Check oil level • • Before operation
Change oil • First 50 Hrs., Then
Every 250 Hrs. or 6
Replace filter(s)* • months
Crankcase breather • • Quarterly
Replace crankcase vent filter, if equipped • Yearly or 500 Hrs.
Clean crankcase ventilation system, if equipped • Yearly or 500 Hrs.
Cooling System
Check the seawater outlet and clean as necessary X X Daily
Check coolant level • • Before operation
Check seawater strainer and seawater pump • • Before operation
Block heater operation, if equipped X Weekly
Flexible hoses and connectors X X Weekly
Water pump(s) • Weekly
Check the function of the siphon break, if equipped X 3 Months or 100 Hrs.
Inspect and replace zinc plugs • • 6 Months or 250 Hrs.
Check the seawater pump impeller X 6 Months or 250 Hrs.
Coolant temperature protection level • 6 Months or 250 Hrs.
Check cooling system • • Yearly or 500 Hrs.
Inspect and clean heat exchanger core and aftercoolor
• • Yearly or 500 Hrs.
core, if equipped
Replace the seawater pump impeller R Yearly or 500 Hrs.
Pressure test cooling system • 2 years or 2000 Hrs.
Test thermostats • 2 years or 2000 Hrs.
Flush and refill cooling system • 2 years or 2000 Hrs.
Inspect and repair seawater pump • • 2 years or 2000 Hrs.
Add coolant • R As required
Exhaust System
Inspect the exhaust system components X Before operation
Check the exhaust gas condition. If the exhaust is blue
X During operation
or black, contact your local distributor/dealer
Clean the exhaust/water mixing elbow X 6 Months or 250 Hrs.
Inspect the complete exhaust system ‡ X Yearly or 500 Hrs.
Excessive back pressure X Yearly
Hangers and supports X Yearly
• Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow this service
schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action
 Service more frequently if operated in dusty areas.
‡ Should be performed by your local distributor/dealer.
§ Consult the battery manufacturer’s instructions.
74 TP-6861 11/24
Service Schedule, continued
Action
Visually
Check Change Clean Test
System—Component Inspect Interval
DC Electrical System
Keep the battery charged and in good condition § X Before operation
Check and tighten the electrical connections X Monthly or 50 Hrs.
Clean the battery cables X Yearly or 500 Hrs.
AC Electrical System
Controller lamp test X R Weekly
General Inspection X Weekly
Circuit breakers, fuses † X X R X X Monthly
Wire abrasions where subject to motion X X Quarterly
Safety and alarm operation X X 6 Months
Tighten control and power wiring connections X Yearly
Transfer switch main contacts † X X Yearly
Voltage-sensing device/relay adjustment † • • Yearly
Wire-cable insulation breakdown X X 3 Years
Engine and Mounting
Check air cleaner dust unloader valve • • Before operation
General inspection • Before operation
Governor operation, lubricate moving parts (33-40 kW) • • Monthly
Check belt • • R Monthly
Check engine mounts • • 6 Months or 250 Hrs.
Inspect the air cleaner element and clean or replace as 6 Months or 250 Hrs.
• •
necessary
Check air intake hoses, connections, and system • • Yearly or 500 Hrs.
Check engine speeds • Yearly or 500 Hrs.
Check engine electrical ground • Yearly or 500 Hrs.
Governor oil (mechanical governor only) (33-40 kW) • Yearly
Ignition components • • Yearly
Injector pump & injector flow rate, pressure, spray pattern • • Yearly
Check and adjust valve clearance • • 2 Years or 2000 Hrs.
Check crankshaft vibration damper (100-200 kW) • 2 Years or 2000 Hrs.
Bolt torque • • 3 Years
Check front PTO, if equipped • • As required
Remote Control System, etc.
Compartment condition X X Weekly
Remote control X Monthly
Run generator set X Monthly
Alternator
Rotor and stator X X Yearly
Bearing condition X X R Yearly
Exciter X X X Yearly
Voltage regulator X X X Yearly
Measure and record resistance readings of windings with Yearly
insulation tester (Megger®‡, with SCR assembly or rectifier X
disconnected)
Blow dust out of alternator* X • 2 Years
General Condition of Equipment
Visual walkaround general inspection X Before operation
Any condition of vibration, leakage, noise, temperature, or Weekly
X X X
deterioration
• Follow procedures and frequencies indicated in the engine manufacturer’s maintenance manual. If not indicated, follow this service
schedule. Some items may not apply to all generator sets.
R Replace as necessary.
X Action.
 Service more frequently if operated in dusty areas.
† Do not break manufacturer’s seals or internally inspect these devices.
Megger® is a registered trademark of Biddle Instruments.
TP-6861 11/24 75
3.4 Alternator Bearing Service
Have an authorized service distributor/dealer perform service.
3.4.1 20-300 kW Models
Replace the end bracket bearing every 10,000 hours of operation in prime power applications. Service the bearing more
frequently if the annual inspection indicates excessive rotor end play or bearing damage. The sealed end bracket bearing
requires no additional lubrication.
3.5 Diesel Fuel Systems

3.5.1 Bleeding Air from Fuel System
Bleed air from the fuel system after fuel system maintenance, such as replacing the fuel filter(s). Use the information provided
in the engine operation manual.
3.6 Cooling System


WARNING Hot coolant and steam.

Before removing the pressure cap, stop the generator set and allow it to cool. Then loosen
the pressure cap to relieve pressure. Fill system before starting unit.
76 TP-6861 11/24
Allow the engine to cool. Release pressure from the cooling system before removing the pressure cap. To release pressure,
cover the pressure cap with a thick cloth and then slowly turn the cap counterclockwise to the first stop. Remove the cap after
pressure has been completely released and the engine has cooled. Check the coolant level at the tank if the generator set has
a coolant recovery tank.
3.6.1 Cooling System Component Inspection
To prevent generator set shutdown or damage caused by overheating:
• Keep the cooling air inlets clean and unobstructed.
• Inspect the radiator’s exterior for obstructions. Remove dirt and foreign material using a soft brush or cloth to avoid
damaging the radiator fins.
• Check the hoses and connections for leaks. Replace any cracked, frayed, or spongy hoses.
• Check the condition and tension of the radiator fan and water pump belt(s). Follow the belt tension procedure in this
manual and/or the engine operation manual.
• Check the pressure cap seal and replace a cracked or deteriorated cap. Remove dirt and other debris from the pressure
cap and filler neck. The pressure cap raises the boiling point of the coolant, enabling higher operating temperatures.
Replace a leaking pressure cap with one rated for the same pressure. The pressure cap rating usually appears on the
pressure cap.
3.6.2 Procedure to Drain Cooling System
For optimum protection, drain, flush, and refill the cooling system at the intervals listed in the service schedule.
Note:
Dispose of all waste materials (engine oil, fuel, filter, etc.) in an environmentally safe manner and in accordance with all applicable
laws.
1. Press the generator set OFF/RESET button to shut down the generator set.
2. Disconnect the power to the battery charger, if equipped.
3. Disconnect the generator set engine starting battery, negative (-) lead first.
4. Deenergize the block heater, if equipped.
5. Remove the pressure cap to allow the entire system to drain and prevent air pockets from restricting coolant flow
through the engine block.
6. Open the radiator and/or engine block coolant drain valve(s) and allow the system to drain.
7. If the inside of the radiator has mineral deposits or the used coolant contains dirt or grease, refer to the Procedure to
Flush and Clean the Cooling System section. If the cooling system does not have mineral deposits, go to the Procedure
to Refill the Cooling System section.
3.6.3 Procedure to Flush and Clean Cooling System
Use the instructions in the engine operation manual when available to flush and clean the cooling system. Otherwise, use the
following procedure and the cooling system cleaner manufacturer’s instructions.
1. Flush the cooling system with clean water.
2. If the inside of the radiator still has mineral deposits, use a radiator cleaner to remove the remaining deposits following
the manufacturer’s instructions.
3. Drain, clean, and flush the coolant recovery tank.
TP-6861 11/24 77
3.6.4 Procedure to Refill Cooling System
See the generator set spec sheet for coolant capacity.
Note:
Do not add coolant to a hot engine. Adding coolant to a hot engine can cause the cylinder block or cylinder head to crack. Wait
until the engine has cooled.
1. Remove the pressure cap.
2. Close the radiator and/or engine block coolant drain valve(s) and tighten the cooling system hose clamps.
3. Open the air-bleed petcocks, if equipped. Close the air-bleed petcocks when coolant begins to flow from them.
4. Add coolant additives or water pump lubricants according to the engine manufacturer’s recommendations in the engine
operation manual.
5. Fill the cooling system with the recommended coolant/antifreeze mixture of 50% ethylene glycol and 50% clean,
softened water to inhibit rust/corrosion and prevent freezing.
A coolant solution of 50% ethylene glycol provides freezing protection to -37°C (-34°F) and overheating protection to
129°C (265°F). A coolant solution containing less than 50% ethylene glycol may not provide adequate freezing and
overheating protection. A coolant solution containing more than 50% ethylene glycol can cause engine or component
damage. Do not use alcohol or methanol antifreeze or mix them with the specified coolant. Refer to the engine operation
manual for recommendations regarding the coolant mixture to use in extreme temperatures.
6. Replace the pressure cap.
7. Fill the coolant recovery tank to the low mark.
8. Check that the generator set is OFF.
9. Reconnect the generator set engine starting battery, negative (-) lead last.
10. Reconnect the power to the battery charger, if equipped.
11. Operate generator set until the thermostat opens when the upper cooling system hose warms.
12. Stop the engine and allow it to cool.
13. Check and repair any coolant leaks.
14. Remove the pressure cap.
15. Add coolant to bring the coolant level to just below the overflow tube opening of the filler neck.
16. Replace the pressure cap.
17. Maintain the coolant level in the coolant recovery tank between the high and low marks. Air pockets often form in the
engine water jacket when the coolant system is refilled. Check the coolant level in the coolant recovery tank after each
generator set operation and add coolant as necessary until the coolant level stabilizes. Then check the coolant at the
interval specified in the service schedule.
18. Reenergize the block heater, if equipped.
78 TP-6861 11/24
3.6.5 Siphon Break
A siphon break prevents seawater entry into the generator set’s engine when the engine exhaust manifold outlet is less than
230 mm (9 in.) above the waterline of a fully loaded, docked or stationary craft. The siphon break may malfunction when the
generator set operates while the craft is in contaminated waters or saltwater. Use the following procedure to inspect the siphon
break at the intervals listed in the service schedule.
Cap
Reed valve
Mounting base
Figure 34 Siphon Break
Siphon Break Inspection
4. Remove the retaining cap and remove the reed valve for inspection. See Figure 34.
5. Use a mild detergent to remove residue and oxidation from the reed valve.
6. Clear blockage from the reed valve opening.
7. Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated.
8. Install the reed valve into the mounting base with the valve downward. See Figure 34.
9. Install and only finger tighten the retaining cap. Do not overtighten it.
TP-6861 11/24 79
3.6.6 Impeller Inspection and Replacement Procedure
The gear driven seawater pump is located on the service side of the generator set. Check and change the seawater pump
impeller at the interval specified in the service schedule. Follow the instructions included with the impeller kit. If the instructions
are not included with the kit, use the following procedure:
Impeller Inspection and Replacement Procedure:
4. Close the seacock.
5. Remove the seawater pump cover plate. See Figure 35.
Cover plate
Gasket
Impeller
Bearing
Nut
Housing
Pulley
Washer Drive shaft
TP-6053
Figure 35 Seawater Pump, Typical

6. Remove the impeller.
7. Inspect the impeller for damaged, cracked, broken, missing or flattened vanes. The impeller vanes should be straight
and flexible. See Figure 36. Replace the impeller if it is damaged.
80 TP-6861 11/24
Flattened vane
Crack
Broken vane
TP-6053
Figure 36 Worn Impeller

8. Lubricate the impeller with soapy water before installation.
9. Install the impeller.
Note:
During installation push and rotate the impeller in the same direction as the engine rotation until it is thoroughly seated
in the impeller housing.
10. Inspect the cover plate and gasket for corrosion and/or damage. Replace components as necessary.
11. Lubricate the gasket with silicon grease and attach the gasket and cover plate to the seawater pump housing.
12. Open the seacock.

16. Start the generator set and check for leaks.
17. Stop the generator set and repair leaks or replace damaged or worn components.
TP-6861 11/24 81
3.7 Exhaust System


At the interval specified in the service schedule, inspect the exhaust system components (exhaust manifold, mixing elbow,
exhaust hose, hose clamps, silencer, and outlet flapper) for cracks, leaks, and corrosion.
Ensure that the carbon monoxide detector(s) is (1) in the craft, (2) functional, and (3) energized whenever the generator set
operates.
For your safety: Never operate the generator set without a functioning carbon monoxide detector(s) for your safety and
the safety of others on your vessel.
Exhaust System Inspection Points
Check for exhaust leaks and blockages. Check the silencer and piping condition and check for tight exhaust system connections.
• Check the hoses for softness, cracks, leaks, or dents. Replace the hoses as needed.
• Check for corroded or broken metal parts and replace them as needed.
• Check for loose, corroded, or missing clamps. Tighten or replace the hose clamps and/or hangers as needed.
• Check that the exhaust outlet is unobstructed.
• Visually inspect the exhaust system for exhaust leaks (blowby). Check for carbon or soot residue on exhaust
components. Carbon and soot residue indicates an exhaust leak. Seal leaks as needed.
82 TP-6861 11/24
3.8 Storage Procedure
Perform the following storage procedure before taking a generator set out of service for three months or longer. Follow the
engine manufacturer’s recommendations, if available, for fuel system and internal engine component storage.
3.8.1 Lubricating System
Prepare the engine lubricating system for storage as follows:
1. Run the generator set for a minimum of 30 minutes to bring it to normal operating temperature.
2. Stop the generator set.
3. With the engine still warm, drain the oil from the crankcase.
4. Remove and replace the oil filter.
5. Refill the crankcase with oil suited to the climate.
6. Run the generator set for two minutes to distribute the clean oil.
7. Stop the generator set.
8. Check the oil level and adjust, if needed.
3.8.2 Cooling System
Prepare the cooling system for storage as follows:
1. Check the coolant freeze protection using a coolant tester.
2. Add or replace coolant as necessary to ensure adequate freezing protection. Use the guidelines included in the engine
operation manual.
3. Run the generator set for 30 minutes to redistribute added coolant.
3.8.3 Fuel System
Prepare the fuel system for storage as follows:
Diesel-Fueled Engines
1. Fill the fuel tank with #2 diesel fuel.
2. Condition the fuel system with compatible additives to control microbial growth.
3. Change the fuel filter/separator and bleed the fuel system. See the service manual.
3.8.4 Exterior
Prepare the exterior for storage as follows:
1. Clean the exterior surface of the generator set.
2. Seal all engine openings except for the air intake with nonabsorbent adhesive tape.
3. To prevent impurities from entering the air intake and to allow moisture to escape from the engine, secure a cloth over
the air intake.
4. Mask electrical connections.
5. Spread a light film of oil over unpainted metallic surfaces to inhibit rust and corrosion.
TP-6861 11/24 83
3.8.5 Battery
Perform battery storage after all other storage procedures.
1. Place the generator set master switch in the OFF/ RESET position.
2. Disconnect the battery(ies), negative (-) lead first.
3. Clean the battery. Refer to the battery manufacturer’s instructions for the battery cleaning procedure.
4. Place the battery in a cool, dry location.
5. Connect the battery to a float/equalize battery charger or charge it monthly with a trickle battery charger. Refer to the
battery charger manufacturer’s recommendations.
6. Maintain a full charge to extend battery life.
84 TP-6861 11/24
Section 4. Troubleshooting
This section contains generator set troubleshooting, diagnostic, and repair information.
Use the following charts as a quick troubleshooting reference. The table groups generator set faults and suggests likely causes
and remedies. The table also refers you to more detailed information including sections of this manual, the generator set service
manual (S/M), the generator set installation manual (I/M), and the engine service manual (Engine S/M) to correct the indicated
problem.
Corrective action and testing often require knowledge of electrical and electronic circuits. To avoid additional problems caused
by incorrect repairs, have an authorized service distributor/dealer perform service.
NOTICE
Fuse replacement. Replace fuses with fuses of the same ampere rating and type (for example: 3AB or 314, ceramic). Do not
substitute clear glass-type fuses for ceramic fuses. Refer to the wiring diagram when the ampere rating is unknown or
questionable.
Maintain a record of repairs and adjustments performed on the equipment. If the procedures in this manual do not explain how
to correct the problem, contact an authorized distributor/dealer. Use the record to help describe the problem and repairs or
adjustments made to the equipment.
TP-6861 11/24 85
86
Trouble Symptoms
start
noise
Overheats
Starts hard
inoperative
Lacks power
Displays error
Does not crank

Stops suddenly
Low oil pressure
Exercise run time
message/locks up
Section or
Cranks but does not

and/or event records
Publication
High fuel consumption

Excessive or abnormal
No or low output voltage

Probable Causes Recommended Actions Reference*
Controller
Controller circuit board(s)

X X Replace the controller. Gen. S/M
inoperative.
X X Controller circuit board(s) wiring fault. Check the wiring. W/D
X Controller fault. Troubleshoot the controller.† Gen. S/M
Controller master control button in Press the controller master control RUN or AUTO Operation
X
the OFF/RESET mode. button. Section
Press the controller master control RUN button to Operation

X Engine start circuit open. test the generator set. Troubleshoot the auto start Section, W/D,
circuit and the time delays. Gen. S/M
Emergency stop switch activated, if Operation

X X Reset the emergency stop switch.
equipped. Section
Controller
Display and
Voltage
X Controller firmware error. Review the controller display troubleshooting chart.
Regulation
Troubleshooting
Chart Section
 ATS - Automatic Transfer Switch; Eng. - Engine; Gen. - Generator Set; I/M - Installation Manual; O/M - Operation Manual; M/M – Maintenance Manual; S/M - Service Manual;
S/S - Spec Sheet; W/D - Wiring Diagram Manual
† Have an authorized service distributor/dealer perform this service.
TP-6861
11/24
Trouble Symptoms
TP-6861
up
voltage
records
not start
High fuel
Overheats
Starts hard
inoperative
and/or event
Section or
Lacks power
Excessive or
consumption
11/24
Displays error
message/locks
Does not crank

Publication
Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Exercise run time
Alternator
X AC output circuit breaker open. Reset the breaker and check for AC voltage at the —
generator set side of the circuit breaker.
X Transfer switch test switch in the OFF Move the transfer switch test switch to the AUTO —
position. position.
X Wiring, terminals, or pin in the exciter Check for continuity. Gen. S/M or
field open. W/D
X Main field (rotor) inoperative (open or Test and/or replace the rotor. † Gen. S/M
grounded).
X Stator inoperative (open or grounded). Test and/or replace the stator.† Gen. S/M
X Vibration excessive. Tighten loose components.† —
X X Voltage regulator settings incorrect. Adjust the voltage regulator. SiteTech O/M
Electrical System (DC Circuits)
X X Battery connections loose, corroded, Verify that the battery connections are correct, clean, —
or incorrect. and tight.
X X Battery weak or dead. Recharge or replace the battery. The spec sheet Eng. O/M, S/S
provides recommended battery CCA rating.
X X Starter/starter solenoid inoperative. Replace the starter or starter solenoid. Eng. S/M
X X Engine harness connector(s) not Disconnect the engine harness connector(s) then W/D
locked tight. reconnect it to the controller.
Operation
X Fault shutdown. IReset the fault switches and troubleshoot the controller.
Section
High exhaust temperature switch Replace the inoperative switch. Gen. S/M or W/D
X
inoperative.
87
88
Trouble Symptoms
up
voltage
not start
High fuel
Overheats
Starts hard
inoperative
Section or
time and/or
Exercise run
Lacks power
Excessive or
consumption
event records
Publication
Displays error
message/locks
Does not crank

Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Engine
X X X X Air cleaner/backfire flame arrestor Clean or replace the filter element. Eng. O/M
clogged.
X X X X X Compression weak. Check the compression.† Eng. S/M
Reduce the electrical load. See the generator set
X X X X X Engine overload. I/M
installation manual for wattage specifications.
Inspect the exhaust system. Replace the Scheduled

X Exhaust system leak. Maintenance Section,
inoperative exhaust system components.†
I/M
Exhaust system not securely Inspect the exhaust system. Tighten the loose Scheduled
X Maintenance Section,
installed. exhaust system components.†
I/M
X X X X Governor inoperative. Adjust the governor.† Gen. S/M
X X Valve clearance incorrect. Adjust the valves † Eng. O/M
X Vibration excessive. Tighten all loose hardware. —
X X X X X Engine ECM and/or sensors. Troubleshoot the engine ECM and/or sensors. Eng. O/M , Eng. S/M
Cooling System
X X Air openings clogged. Clean the air openings. —
Impeller inoperative. Replace the impeller. Scheduled

X
Maintenance Section
Scheduled
X X Seawater strainer clogged or Clean the strainer. Maintenance Section
restricted.
Allow the engine to cool down. Then troubleshoot
X High temperature shutdown. Eng. O/M
the cooling system.
Low coolant level shutdown, if
X Restore the coolant to normal operating level. Eng. O/M
equipped.
TP-6861
X Coolant level low. Restore the coolant to normal operating level. Eng. O/M
11/24
Trouble Symptoms
TP-6861
voltage
not start
High fuel
Overheats
Starts hard
and/or event
Lacks power
Excessive or
consumption
11/24
Displays error
Section or
Does not crank

Stops suddenly
abnormal noise
Cranks but does

No or low output
Low oil pressure
Publication
Exercise run time
message/locks up
records inoperative
Cooling System
X Cooling water pump inoperative. Tighten or replace the belt. Replace the water pump. Eng. O/M or
Eng. S/M
X Thermostat inoperative. Replace the thermostat. Eng. S/M
Fuel System
X X Fuel tank empty or fuel valve shut off. Add fuel and move the fuel valve to the ON position. —
X X X Air in fuel system (diesel only). Bleed the diesel fuel system. Eng. O/M
X X X Fuel or fuel injectors dirty or faulty Clean, test, and/or replace the inoperative fuel Eng. S/M
(diesel only). injector.†
X X X X Fuel injection timing out of adjustment Adjust the fuel injection timing.† Eng. S/M
(diesel only).
X X X Fuel feed or injection pump Rebuild or replace the injection pump.† Eng. S/M
inoperative (diesel only).
X X X X Fuel filter restriction. Clean or replace the fuel filter.† Eng. O/M
Engine Lubrication System
X X X Oil level low. Restore the oil level. Inspect the generator set for oil Eng. O/M
leaks.
X Low oil pressure shutdown. Check the oil level. Eng. O/M
X X X X Crankcase oil type incorrect for Change the oil. Use oil with a viscosity suitable for the Eng. O/M
ambient temperature. operating climate.
 ATS - Automatic Transfer Switch; Eng. - Engine; Gen. - Generator Set; I/M - Installation Manual; O/M - Operation Manual; M/M – Maintenance Manual: S/M - Service Manual;
89
90
Section or
4.1
Publication
Trouble Symptoms Probable Causes Recommended Actions Reference*
Controller Display and Voltage Regulator
Display is black. No/low battery charge. Recharge/replace battery. —
Display shows single segment. Low battery voltage. Recharge battery. —
Display shows an error message. Controller firmware fault has occurred or pushbutton/ Review the Error Message section. —
rotary selector dial entry error.
Display locks up. No/low battery charge. Recharge/replace battery. —
Output voltage ramps. Defective exciter winding. Voltage ramp on startup is Troubleshoot alternator components. † Generator Service
normal, but ramping past the target without recovering Manual
may indicate additional failures in the alternator or
excitation circuit.
Output voltage unstable. Voltage regulation calibration incorrect. Readjust voltage regulation. † SiteTech O/M
Unable to change voltage and current calibrations. Calibration not enabled. Enable calibration in Generator Metering Graphical Display
section. section
• ATS—Automatic Transfer Switch; Eng.—Engine; Gen.—Generator Set; Alt.—Alternator; I/M—Installation Manual; O/M—Operation Manual; S/M—Service Manual;
S/S—Spec Sheet; O/S/M—Operation/Service Manual; W/D—Wiring Diagram
Controller Display and Voltage Regulation Troubleshooting Chart
TP-6861
11/24
Section 5. Wiring Diagrams


TP-6861 11/24 91
Wiring Voltage
Model Diagram Figure Schematic Figure Reconnection Figure Controller
40EOZD(C)J Figure 37
33EFOZD(C)J Figure 40
GM93788-F Figure 38 ADV-8717-G
Figure 41
Figure 39
Figure 45
GM93789-H Figure 43 ADV-8718-G
Figure 44
55EOZD(C)J
Figure 50
GM93790-G Figure 48 ADV-8719-H
Figure 49 Wiring Diagram,
55EFOZD(C)J Alternator
Reconnections, 12 Decision-Maker®
80EOZD(C)J ADV-5875F-AE
Lead, Sheet 1 of 1 3500
Figure 55 (ADV-5875F-AE)
GM93791-H Figure 53 ADV-8720-H
99EOZD(C)J Figure 56 figure
Figure 54
80EFOZD(C)J
125EOZD(C)J
Figure 60
GM93792-F Figure 58 ADV-8721-G
Figure 59
125EFOZD(C)J
GM95013-F Figure 63 ADV-8757-F
Figure 66
Figure 64
DWG.GM35943, Wiring Diagram GM35943-D Figure 67

®
Interconnection Diagram for Decision-Maker 3500 GM88254-C Figure 68
Figure 69
92 TP-6861 11/24
GM93788A-F
Figure 37 40EOZD(C)J and 33EFOZD(C)J Wiring Diagram, Decision-Maker® 3500, Sheet 1 of 3
TP-6861 11/24 93
GM93788B-F
94 TP-6861 11/24
GM93788C-F
TP-6861 11/24 95
ADV-8717A-G
Figure 40 40EOZD(C)J and 33EFOZD(C)J Schematic, Decision-Maker® 3500, Sheet 1 of 2
96 TP-6861 11/24
ADV-8717B-G
TP-6861 11/24 97
GM93789A-H
Figure 42 40EFOZD(C)J and 50EFOZD(C)J Wiring Diagram, Decision-Maker® 3500, Sheet 1 of 3
98 TP-6861 11/24
GM93789B-H
TP-6861 11/24 99
GM93789C-H
100 TP-6861 11/24

ADV-8718A-G
Figure 45 40EFOZD(C)J and 50EFOZD(C)J Schematic, Decision-Maker® 3500, Sheet 1 of 2
TP-6861 11/24 101

ADV-8718B-G
Figure 46 40EFOZD(C)J and 50EFOZD(C)J Schematic, Decision-Maker® 3500, Sheet 2 of 2
102 TP-6861 11/24

GM93790A-G
Figure 47 55/65EOZD(C)J and 45/55EFOZD(C)J Wiring Diagram, Decision-Maker® 3500, Sheet 1 of 3
TP-6861 11/24 103

GM93790B-G
104 TP-6861 11/24

GM93790C-G
TP-6861 11/24 105

ADV-8719A-H
Figure 50 55/65EOZD(C)J and 45/55EFOZD(C)J Schematic, Decision-Maker® 3500, Sheet 1 of 2
106 TP-6861 11/24

ADV-8719B-H
TP-6861 11/24 107

GM93791A-H
108 TP-6861 11/24

GM93791B-H
TP-6861 11/24 109

GM93791C-H
110 TP-6861 11/24

ADV-8720A-H
TP-6861 11/24 111

ADV-8720B-H
112 TP-6861 11/24

GM93792A-F
TP-6861 11/24 113

GM93792B-F
114 TP-6861 11/24

GM93792C-F
TP-6861 11/24 115

ADV-8721A-G
116 TP-6861 11/24

ADV-8721B-G
®
Figure 61 125/150EOZD(C)J and 100/125EFOZD(C)J Schematic, Decision-Maker 3500, Sheet 2 of 2
TP-6861 11/24 117

GM95013A-F
118 TP-6861 11/24

GM95013B-F
TP-6861 11/24 119

GM95013C-F
120 TP-6861 11/24

ADV-8757A-F
TP-6861 11/24 121

ADV-8757B-F
122 TP-6861 11/24

GM35943-D
Figure 67 DWG. GM35943, Wiring Diagram Drawing
TP-6861 11/24 123

GM88254A-C
Figure 68 Interconnection Diagram for Decision-Maker® 3500 (Sheet 1 of 2)
124 TP-6861 11/24

GM88254B-C
Figure 69 Interconnection Diagram for Decision-Maker® 3500 (Sheet 2 of 2)
TP-6861 11/24 125

Notes
126 TP-6861 11/24

Section 6. Voltage Reconnection
6.1 Introduction
Use the following voltage reconnection schematic to change the voltage of 12-lead generator sets. Frequency changes require
voltage regulator and governor adjustments. Refer to the respective spec sheet to determine if frequency is fixed or field-
convertible. If frequency is adjustable, refer to the engine service manual and/or governor literature for conversion information.
Refer to the following connection schematics. Follow the safety precautions at the front of this manual and in the procedure text
and observe National Electrical Code (NEC) guidelines.
NOTICE
This generator set has been rewired
from its nameplate voltage to:
246242
NOTICE
Voltage reconnection. Affix a notice to the generator set after reconnecting the set to a voltage different from the voltage on
the nameplate. Order voltage reconnection decal 246242 from an authorized service distributor/dealer.
Note:
Equipment damage. Verify that the voltage ratings of the transfer switch, line circuit breakers, and other accessories match the
selected line voltage.


TP-6861 11/24 127

Figure 70 Wiring Diagram, Alternator Reconnections, 12 Lead, Sheet 1 of 1 (ADV-5875F-AE)
128 TP-6861 11/24

Section 7. Accessories
7.1 Accessories
Several accessories help finalize installation, add convenience to operation and service, and establish state and local code
compliance.
Accessories vary with each generator set model and controller. Select factory-installed and/or shipped- loose accessories.
Obtain the most current accessory information from your local authorized service distributor/dealer.
Accessory kits generally include installation instructions. See the wiring diagrams for electrical connections not shown in this
section. See the installation instructions and drawings supplied with the kit for information on kit mounting location.
The instructions provided with the accessory kit supersede these instructions where there are differences. In general, run AC
and DC wiring in separate conduit. Use shielded cable for all analog inputs. Observe all applicable national, state, and local
electrical codes during accessory installation.
See Accessory Connections section for terminal identification.
7.2 Accessory Connections

The controller contains a circuit board equipped with connectors for use in connecting external optional accessories including
alarms, battery chargers, and remote switches. The optional fifteen relay dry contact board provides an additional four digital
inputs and two analog inputs.
For specific information on accessory connections, refer to the accessory wiring diagrams in the wiring diagram manual and the
instruction sheet accompanying the kit. See Figure 74 for controller circuit board connections.
Circuit Board Connections (see Figure 71). Consult the wiring diagrams in Wiring Diagrams section for more detail and model-
specific information.
• P1 (35-Pin) Connector for engine/generator wiring harness.
• P2 (14-Pin) Connector for sensor input connections and relay driver output connections.
• P3 (8-Pin) Connector for generator set output voltage connection and paralleling bus voltage sensing connections.
• P4 (Ethernet) RG 45 Connector connects to a network communication line.
DEC 3500 Controller Front Panel (see Figure 72).
• Mini USB Connector for connection of a PC with SiteTech™ software programming or for firmware updates.
TB12 Terminal Strip (see Figure 73) for CAN, PGEN, remote emergency stop, and remote start connections. Consult the wiring
diagrams in Wiring Diagrams section for more detail and model-specific information.
TP-6861 11/24 129

GM85936A-E
Figure 71 Main Circuit Board Connectors, Typical (Back of DEC 3500 Controller)
Mini USB connector
Figure 72 DEC 3500 Controller Front Panel
130 TP-6861 11/24

See Wiring Diagrams in Wiring
Diagrams section.

Diagrams section.

Diagrams section.
GM93790A-D
Figure 73 TB12 Terminal Strip, Typical (located inside the Junction Box)
TP-6861 11/24 131

P1 35-Pin Connector, Engine/Generator Wiring Harness
P2 14-Pin Connector, Analog/Digital Input and Relay
Terminal Description Connection Driver Output Connections
Terminal Description Connection
P1-1 71 P23-1 (71)
P1-2 Open - P2-1 87 P1B-20
P2-2 BSP TB13-BSP
P1-3 N P1B-31 Circuit Breaker
P1-4 3B P6-2 (3B) Status (+)
P2-3 VBP TB13-VBP
P1-5 YEL P1B-34 (YEL) Voltage Bias (+)
P1-6 GRN P1B-33 (GRN) P2-4 SBP TB13-SBP
Speed Bias (+)
P1-7 Open or BLU - or P1B-28 (Blue)
(40EOZD(C)J/ (40EOZD(C)J/ P2-5 CBO TB13-CBO
33EFOZD(C)J) 33EFOZD(C)J) Circuit Breaker
Open
P1-8 Open or GRN - or P1B-29 (Green)
(40EOZD(C)J/ (40EOZD(C)J/ P2-6 BSN TB13-BSN
33EFOZD(C)J) 33EFOZD(C)J) Circuit Breaker
Status (-)
P1-9 YEL TB12-CAN(+)
P2-7 VBN TB13-VBN
P1-10 GRN TB12-CAN(-) Voltage Bias (-)
P1-11 BLK TB12-COM (-) P2-8 SBN TB13-SBN
P1-12 RED TB12-COM (+) Speed Bias (-)
P1-13 70 P30-3 (70) P2-9 CBC TB13-CBC
P1-14 1 TB12-1 (1) Circuit Breaker
Close
P1-15 3 TB12-3 (3)
P2-10 5P P1B-7
P1-16 IR P26-2 (IR)
P2-11 Open -
P1-17 I2 P26-3 (I2)
P2-12 7 P1B-18
P1-18 Open or 7 - or P1B-13 (7)
(40EOZD(C)J/ (40EOZD(C)J/ P2-13 RD3 TB13-12
33EFOZD(C)J) 33EFOZD(C)J) Relay Driver 3
P1-19 69 P1B-8 (69) P2-14 RD4 TB13-13

Relay Driver 4
P1-20 Open -
P3 8-Pin Connector, Output Voltage and Paralleling Bus
P1-21 37 P1B-5 (37) Voltage Sensing Connections
P1-22 25 P1B-2 (25)
Terminal Description Connection
P1-23 YEL TB12-PGEN (-) (YEL)
P1-24 P1 P1B-4 (P1) P3-1 A INSA* (without C/B)
P1-25 31A P1B-25 (31A) CBRK*-Line A (with C/B)
P1-26 1A TB12-1A (1A) P3-2 B INSB* (without C/B)
P1-27 30 TB12-AUX (30) CBRK*-Line B (with C/B)
P1-28 I3 P26-5 (I3) P3-3 Open -
P1-29 I1 P26-1 (I1) P3-4 L3 Bus Voltage TB13-L3
P1-30 Open or 5 - or P1B-17 (5) Sense
(40EOZD(C)J/ (40EOZD(C)J/ P3-5 C INSC* (without C/B)
33EFOZD(C)J) 33EFOZD(C)J) CBRK*-Line C (with
P1-31 BGA P1B-27 (BGA) C/B)
P1-32 Open - P3-6 NEU INSLO*
P1-33 64 P1B-1 (64)
P3-7 L1 Bus Voltage TB13-L1
P1-34 31 P1B-3 (31) Sense
P1-35 ORG TB12-PGEN (+) (ORG) P3-8 L2 Bus Voltage TB13-L2
Sense
Figure 74 Controller Connections
P4 Connector, RJ45 Ethernet
Open Network communications
 INSA, INSB, INSC, INSLO = Insulated Standoff
CBRK = Circuit Breaker
132 TP-6861 11/24

Appendix A. Abbreviations
The following list contains abbreviations that may appear in this publication.
A, amp ampere blk. htr. block heater DAC digital to analog converter
ABDC after bottom dead center BMEP brake mean effective pressure dB decibel
AC alternating current bps bits per second dB(A) decibel (A weighted)
A/D analog to digital br. Brass DC direct current
ADC advanced digital control; BTDC before top dead center DCR direct current resistance
analog to digital converter
adj. adjust, adjustment Btu British thermal unit DEF diesel exhaust fluid
ADV advertising dimensional drawing Btu/min. British thermal units per minute deg., ° degree
AGM absorbent glass mat C Celsius, centigrade dept. department
Ah amp-hour cal. Calorie dia. Diameter
AHWT anticipatory high water CAN controller area network DI/EO dual inlet/end outlet
temperature
AISI American Iron and Steel Institute CARB California Air Resources Board DIN Deutsches Institut fur Normung e.
V. (also Deutsche Industrie
Normenausschuss)
ALOP anticipatory low oil pressure CAT5 Category 5 (network cable) DIP dual inline package
alt. alternator CB circuit breaker DPDT double-pole, double-throw
Al aluminum CC crank cycle DPST double-pole, single-throw
ANSI American National Standards cc cubic centimeter DS disconnect switch
Institute (formerly American
Standards Association, ASA)
AO anticipatory only CCA cold cranking amps DVR digital voltage regulator
APDC Air Pollution Control District ccw. Counterclockwise E2PROM, electrically-erasable
EEPROM programmable read-only memory
API American Petroleum Institute CEC Canadian Electrical Code E, emer. emergency (power source)
approx. approximate, approximately cert. certificate, certification, certified EATS Exhaust Aftertreatment System
APU Auxiliary Power Unit cfh cubic feet per hour ECM electronic control module, engine
control module
AQMD Air Quality Management District cfm cubic feet per minute EDI electronic data interchange
AR as required, as requested CG center of gravity EFR emergency frequency relay
AS as supplied, as stated, as CID cubic inch displacement e.g. for example (exempli gratia)
suggested
ASE American Society of Engineers CL centerline EG electronic governor
ASME American Society of Mechanical cm centimeter EGSA Electrical Generating Systems
Engineers Association
assy. Assembly CMOS complementary metal oxide EIA Electronic Industries Association
substrate (semiconductor)
ASTM American Society for Testing com communications (port) EI/EO end inlet/end outlet
Materials
ATDC after top dead center coml commercial EMI electromagnetic interference
ATS automatic transfer switch Coml/Rec Commercial/Recreational emiss. Emission
auto. Automatic conn. Connection eng. Engine
aux. auxiliary cont. continued EPA Environmental Protection Agency
avg. average CPVC chlorinated polyvinyl chloride EPS emergency power system
AVR automatic voltage regulator crit. Critical ER emergency relay
AWG American Wire Gauge CRM Common Rail Manifold ES engineering special, engineered
special
AWM appliance wiring material CSA Canadian Standards Association
bat. Battery CT current transformer ESD electrostatic discharge
BBDC before bottom dead center Cu copper est. estimated
BC battery charger, battery charging cUL Canadian Underwriter’s E-Stop emergency stop
Laboratories
BCA battery charging alternator cu. in. cubic inch etc. et cetera (and so forth)
BCI Battery Council International cw. Clockwise exh. exhaust
BDC before dead center CWC city water-cooled ext. external
BHP brake horsepower cyl. Cylinder F Fahrenheit, female
blk. black (paint color), block (engine) D/A digital to analog FDS Fluid Dosing System
TP-6861 11/24 133

FHM flat head machine (screw) in. inch Lpm liters per minute
fl. oz. fluid ounce in. H2O inches of water LOP low oil pressure
flex. flexible in. Hg inches of mercury LP liquefied petroleum
freq. frequency in. Lb. inch pounds LPG liquefied petroleum gas
FS full scale Inc. incorporated LS left side
ft. foot, feet ind. Industrial Lwa sound power level, A weighted
ft. lb. foot pounds (torque) int. internal LWL low water level
ft./min. feet per minute int./ext. internal/external LWT low water temperature
ftp file transfer protocol I/O input/output m meter, milli (1/1000)
g gram IP internet protocol M mega (106 when used with SI
units), male
ga. gauge (meters, wire size) ISO International Organization for m3 cubic meter
Standardization
gal. gallon J joule m3/hr. cubic meters per hour
gen. generator JIS Japanese Industry Standard m3/min. cubic meters per minute
genset generator set k kilo (1000) mA milliampere
GFI ground fault interrupter K kelvin man. manual
GND, ground kA kiloampere max. maximum
gov. governor KB kilobyte (210 bytes) MB megabyte (220 bytes)

gph gallons per hour KBus Kohler communication protocol MCCB molded-case circuit breaker
gpm gallons per minute kg kilogram MCM one thousand circular mils
gr. grade, gross kg/cm2 kilograms per square meggar megohmmeter
centimeter
GRD equipment ground kgm kilogram-meter MHz megahertz
gr. wt. gross weight kg/m3 kilograms per cubic meter mi. mile
HxWx height by width by depth kHz kilohertz mil one one-thousandth of an inch
D
HC hex cap kJ kilojoule min. minimum, minute
HCHT high cylinder head temperature km kilometer misc. miscellaneous
HD heavy duty kOhm, kilo-ohm MJ megajoule
kΩ
HET high exhaust temp., high kPa kilopascal mJ millijoule
engine temp.
hex hexagon kph kilometers per hour mm millimeter
Hg mercury (element) kV kilovolt mOhm, milliohm
mΩ
HH hex head kVA kilovolt ampere MOhm, megohm
MΩ
HHC hex head cap kVAR kilovolt ampere reactive MOV metal oxide varistor
HP horsepower kW kilowatt MPa megapascal
hr. hour kWh kilowatt-hour mpg miles per gallon
HS heat shrink kWm kilowatt mechanical mph miles per hour
hsg. Housing kWth kilowatt-thermal MS military standard
HVAC heating, ventilation, and air L liter ms millisecond
conditioning
HWT high water temperature LAN local area network m/sec. meters per second
Hz hertz (cycles per second) LxWx length by width by height mtg. mounting
H
IBC International Building Code lb. pound, pounds MTU Motoren-und Turbinen-Union
IC integrated circuit lbm/ft3 pounds mass per cubic feet MW megawatt
ID inside diameter, identification LCB line circuit breaker mW milliwatt
IEC International Electrotechnical LCD liquid crystal display µF microfarad
Commission
IEEE Institute of Electrical and LED light emitting diode µF microfarad
Electronics Engineers
IMS improved motor starting Lph liters per hour
134 TP-6861 11/24

N, norm. normal (power source) PMG permanent magnet generator SCR silicon controlled rectifier
(electrical), selective catalytic
reduction (exhaust emissions)
NA not available, not applicable pot potentiometer, potential s, sec. second
nat. gas natural gas ppm parts per million SI Systeme international d’unites,
International System of Units
NBS National Bureau of Standards PROM programmable read-only SI/EO side in/end out
memory
NC normally closed psi pounds per square inch sil. Silencer
NEC National Electrical Code psig pounds per square inch gauge SMTP simple mail transfer protocol
NEMA National Electrical pt. pint SN serial number
Manufacturers Association
NiCd nickel cadmium PTC positive temperature coefficient SNMP simple network management
protocol
NFPA National Fire Protection PTO power takeoff SPDT single-pole, double-throw
Association
Nm newton meter PVC polyvinyl chloride SPST single-pole, single-throw
NO normally open PVC polyvinyl chloride spec specification
no., nos. number, numbers PWM pulse width modulated, pulse specs specification(s)
width modulation
NPS National Pipe, Straight qt. quart, quarts sq. square
NPSC National Pipe, Straight-coupling qty. quantity sq. cm square centimeter
NPT National Standard taper pipe R replacement (emergency) sq. in. square inch
thread per general use power source
NPTF National Pipe, Taper-Fine rad. radiator, radius SMS short message service
NR not required, normal relay RAM random access memory SS stainless steel
Ns nanosecond RDO relay driver output std. standard
OC overcrank ref. reference stl. Steel
OD outside diameter rem. Remote tach. Tachometer
OEM original equipment Res/Co Residential/Commercial TB terminal block
manufacturer ml
OF overfrequency RFI radio frequency interference TCP transmission control protocol
opt. option, optional RH round head TD time delay
OS oversize, overspeed RHM round head machine (screw) TDC top dead center
OSHA Occupational Safety and Health rly. Relay TDEC time delay engine cooldown
Administration
OSHPD Office of Statewide Health rms root mean square TDEN time delay emergency to
Planning and Development normal
(California)
OV overvoltage rnd. Round TDES time delay engine start
oz. ounce RO read only TDNE time delay normal to
emergency
p., pp. page, pages ROM read only memory TDOE time delay off to emergency
PC personal computer rot. rotate, rotating TDON time delay off to normal
PCB printed circuit board rpm revolutions per minute temp. temperature
pF picofarad RS right side term. Terminal
PF power factor RTDs resistance temperature THD total harmonic distortion
detectors
ph., ø phase RTU remote terminal unit TIF telephone influence factor
PHC Phillips® head Crimptiter RTV room temperature vulcanization tol. Tolerance
(screw)
PHH Phillips® hex head (screw) RW read/write turbo. Turbocharger
PHM pan head machine (screw) SAE Society of Automotive typ. typical (same in multiple
Engineers locations)
PLC programmable logic control scfm standard cubic feet per minute UF underfrequency
TP-6861 11/24 135

UHF ultrahigh frequency
UIF user interface
UL Underwriter’s Laboratories, Inc.
UNC unified coarse thread (was NC)
UNF unified fine thread (was NF)
univ. universal
URL uniform resource locator (web
address)
US undersize, underspeed
UV ultraviolet, undervoltage
V volt
VAC volts alternating current
VAR voltampere reactive
VDC volts direct current
VFD vacuum fluorescent display
VGA video graphics adapter
VHF very high frequency
W watt
WCR withstand and closing rating
w/ with
WO write only
w/o without
wt. weight
xfmr transformer
136 TP-6861 11/24

Appendix B. Alternator Protection
The controller has built-in thermal protection for the alternator. This feature functions similarly to a thermal circuit breaker. When
the output current exceeds the nominal rating for a short period of time the condition causes the fault shutdown. The amount of
time at which current is over the rating is inversely related to the amount of current above the nominal rating. In other words, the
higher the current, the shorter the acceptable time.
The current and time limits are defined by actual test data and are maintained in the personality parameter file. Although the
equation for detecting a fault is proprietary, some of the important limits are shown below for informational purposes.
Rated Current Time Delay

200% 40 seconds
300% 10 seconds
425% 5 seconds
950% 1 second
TP-6861 11/24 137

Notes
138 TP-6861 11/24

Appendix C. Operating Hour Service Log
Use the log below to keep a cumulative record of operating hours on your generator set and the dates required services were
performed. Enter hours to the nearest quarter hour.
Operating Hours Service Record
Date Hours Total Service

Run Run Hours Date Service
TP-6861 11/24 139

TP-6861 11/24g Discovery Energy, LLC
200 Twin Oaks Road, Kohler, WI 53044 USA
Original Instructions (English) For the nearest sales and service outlet in the
US and Canada, phone 1-800-544-2444
© 2024 Discovery Energy, LLC - All rights reserved. KOHLEREnergy.com

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Operation

Marine Generator Sets

Pleasure Craft Models:

Decision Maker® 3500

Product Identification Information

Generator Set Identification Numbers

Model Designation _________________________________________________________

Specification Number _______________________________________________________

Serial Number: ____________________________________________________________

Record the product identification information from the engine nameplate.

Accessory Number Accessory Description Accessory Number Accessory Description

Safety Precautions and Instructions ........................................................................................................................................ 5

WARNING Accidental starting.

WARNING Risk of fire.

WARNING Carbon monoxide.

WARNING Explosive fuel vapors.

CAUTION Hazardous noise.

Hazardous Voltage/Moving Parts

DANGER Hazardous voltage. Moving parts.

WARNING Hot coolant and steam.

WARNING Hot engine and exhaust system.

For professional advice and conscientious service, please China

Maintenance and Service Parts

40EOZDJ/ 55EOZDJ/ 65EOZDJ/

33EFOZDJ/ 40EFOZDJ/ 50EFOZDJ/ 45EFOZDJ/ 55EFOZDJ/

Engine 4045DFM70 4045TFM75 4045TFM85

Air Filter Element 226915 GM86446

Belt, Alternator and Seawater Pump GM15402

Fuel Filter Element, Primary GM48727 GM48729

Fuel Filter Element, Secondary GM48728 GM48730

Oil Filter GM32809

Seawater Pump Impeller Kit GM50644

Zinc Anode 352142

80EOZDJ/ 99EOZDJ/ 125EOZDJ/ 150EOZDJ/ 200EOZDJ/

70EFOZDJ/ 80EFOZDJ/ 100EFOZDJ/ 125EFOZDJ/ 175EFOZDJ/

Engine 4045AFM85 6068AFM85 6090AFM85

Air Filter Element GM87479 GM90310 GM98860

Belt, Alternator and Seawater Pump GM88686 GM88686 GM98801

Fuel Filter Element, Primary (Standard) GM48729

Fuel Filter Element, Secondary (Standard) GM48730

Oil Filter GM32809 GM32809 GM50200

Zinc Anode 352142 352142 352142

Pleasure Craft Models

40EOZDJ 55EOZDJ 65EOZDJ

40EOZCJ 55EOZCJ 65EOZCJ

Installation Manual TP-6862

Service Manual—Generator TP-6863

Parts Catalog * TP-6864

Operation Manual—Engine TP-6444 TP-6889

Service Manual—Engine TP-5854

Service Manual, Fuel System—Engine TP-6829 TP-6830 TP-6454

Modbus® Communications Protocol Operation Manual TP-6113

SiteTech™ Software Operation Manual TP-6701

 Includes the generator and engine information.

Pleasure Craft Models

Literature Type 70EFOZCJ 80EFOZCJ 100EFOZCJ 125EFOZCJ 175EFOZCJ

Figure 2 Generator Set Literature

1.2 Permanent Magnet Alternator Concept

1. Rotor shaft 9. FRX activator/photo transistor board