Decision-Maker® 550 Controller

Welcome to the Kohler Power

Systems Decision-Maker® 550
Service Course
Decision-Maker® 550 Controller
Personality Parameters File
•Each controller has a unique personality
parameter file based on the model and serial
number of the generator application. This file is
stored on a disk and is shipped with the
generator.
•The file contains the engine and alternator
parameters specific to the model application.
•The personality file is required to be downloaded
to a new controller if replacement is required.
 Decision-Maker® 550 Controller
Firmware
•Dec 550 controllers have an operating
firmware loaded into the main control board

•When updating firmware always access the

Kohler Tech Tools website for the latest
firmware release.

•Program Loader software is required to

download new firmware versions or a
personality file to the controller.

•TT-1285 has instructions for using the

Program Loader software. Software is
available on the Tech Tools website.
Decision-Maker® 550 Controller
Communications
•Two communication ports are available RS-232
or RS-485.
•RS-232 is used with Program Loader or local
connection to Monitor III and SiteTech™ software
•The connecting PC needs to have a 9 pin
serial port when connecting to the RS-232
connection port. A 9 pin Null Modem cable is
also required RS-485
•RS-485 connection can be used as a local
connection, but the main use is in a LAN network
with Monitor III or some type of building
management software interpreting Modbus RS-232
registers.
Decision-Maker® 550 Controller
Interconnection Circuit Board
•TB1 Customer connection point for
remote start (3&4) and emergency stop
input ( 1&1A)

•TB2 Customer connection point for the

analog inputs

•TB3 Customer connection point for the

DC control power

•TB4 Customer connection point for the

digital inputs
Decision-Maker® 550 Controller
Interconnection Circuit Board
•Circuit Board Logic
K1, K2 and K4 relays are controlled by main logic
board
•K1 will be energized only during engine crank
•K2 will be energized during crank and run
•K3 relay is controlled by the manual e-stop
•K3 will always be energized unless e-stop
button is activated
•K4 will be energized when Main Logic board
dictates panel lamps to be on
LEDs are built into the circuitry of each relay coil
circuit. If the LED is turned “on,” this implies voltage
is across the corresponding coil, and the relay
should be energized and functioning.
Decision-Maker® 550 Controller
Interconnection Circuit Board
•F1 - provides 5 amp circuit protection to 42A

•F2 - provides 5 amp circuit protection for controllers

12 volt regulator circuit

•F3 - provides 15 amp protection for engine control

circuit. (#70, #71)
Decision-Maker® 550 Controller
Interconnect Circuit Board Operation
•K1 Crank Relay (#71)
•This relay will be energized when cranking
•K2 Run Relay (#70)
•This relay will be energized cranking and running
•K3 E-Stop Relay
•This relay will be energized when not in e-stop
•K4 Panel Lamp Relay (42A)
•This relay will be energized when the main logic board turns on
panel lamps. Touch the keypad to turn on the light. The light
turns off five minutes after the last keypad entry.
•F1 - provides 5-amp circuit protection to 42A
•F2 - provides 5-amp circuit protection for controllers 12-volt
regulator circuit
•F3 - provides 15 amp protection for engine control circuit. (#70,
#71)
Decision-Maker® 550 Controller
Voltage and Current Inputs
Voltage and current inputs enter the controller at P10 of
the main logic board. The inputs are required for
metering calculations, voltage regulation, voltage and
current protection and secondary crank termination
(non-ECM engines).
Decision-Maker® 550 Controller
Voltage Measurement
•The voltage inputs V7, V8, V9 and V0
terminate at generator windings 7, 8, 9 and
neutral for 12-lead alternators.

•For a 4-lead alternator, a transformer

assembly is required to step down the
voltage to input levels acceptable for the
controller (240 or below).

•TB5 is a fuse block for voltage sensing

circuit protection.
Decision-Maker® 550 Controller
Current Measurement
•For generators above 200 kW, a CT Burden Resistor
Board is included with the application of the 550
controller.
•The Burden Resistor Board is located in the junction
box with harnessing between the DEC 550 and CT
Burden Resistor Board.
•CTs with a secondary current of 0.5 amp are mounted
in the junction box and wired to TB11 of the Burden
Resistor Board.
•The CT Burden Resistor Board converts the CT current
input to a voltage output (P26) for the main logic board
for the DEC550 controller.
•The current input and voltage output are proportional,
the greater the current sensing the higher the voltage
out.
•20-200 kW generators will utilize a CT with the resistor
installed as part of the CT so no burden resistor board is
required
Decision-Maker® 550 Controller
Voltage Regulator (Kohler Alternator)
•The controller s voltage regulator provides +/-
0.25% regulation for single-or three-phase
loading.

•The three-phase voltage sensing regulator is

built into the main logic board of the controller
and will be serviced as part of the complete
controller.

•The output of the regulator is a pulse width

modulation (PWM) signal.

•The PWM signal controls how much current

flows through the main rotor field, which in
turn controls how much voltage is present at
the output of the alternator stator leads.
Decision-Maker® 550 Controller
Voltage Regulator (Marathon Alternator)

•The three-phase voltage sensing regulator

is built into the Main Logic Board of the
controller. Additionally, an interface board is
required to provide excitation to the
Marathon alternator.

•The output of the voltage regulator (3B-5B)

is a pulse width modulation (PWM) signal.

•This PWM signal triggers the excitation

circuit of the interface board allowing for DC
field excitation of the Main Rotor.
Decision-Maker® 550 Controller

Dec 500 Programming

•Understand menu navigation
•Calibrate generator voltage and amperage in menu 12
•Set up or verify menu 11 voltage regulator settings
•Understand Time or Temperature-based cooldown
•Program a loadshed output
•Understand menu 7 and system settings
•Understand menu 20 setup
Decision-Maker® 550 Controller

•Menu 1 – Generator Monitoring

Menus
•Menu 2 – Engine Monitoring
•Menu 3 – Analog Monitoring
•Menu 4 – Operational Records
•Menu 5 – Event History
•Menu 6 – Time and Date
•Menu 7 – Generator System
•Menu 8 – Time Delays
•Menu 9 – Input Setup
•Menu 10 – Output Setup
•Menu 11 – Voltage Regulator
•Menu 12 – Calibration
•Menu 13 – Communications
•Menu 14 – Programming Mode
•Menu 15 – Paralleling Features (Must be ordered)
•Menu 20 – Hidden Menu
Decision-Maker® 550 Controller
Menu 7 Generator System

•Menu 7 is used to define the generator system.

•This menu typically does not require any

changes; however, programming is required if
the user wants to redefine pickup and dropout
settings, the alternator is reconfigured, or if the
controller is replaced.
Decision-Maker® 550 Controller
Voltage Regulator Adjustment (Menu 11)
•Voltage Adjust

•The Voltage Adjustment allows the user to enter the desired generator set output level.
•This regulated level setting is the average of the three line-to-line voltages in 3-phase configurations or L1-to-
L2 in single-phase configurations.
•The voltage can be adjusted +/-20% of system voltage
Decision-Maker® 550 Controller
Voltage Regulator Adjustment (Volts per Hz)
•Underfrequency Unload Enable
•This menu is used to turn the Underfrequency Unload on or off.

•When on display shows ENABLED, when off display shows ENABLED NO.

•The Underfrequency Unload defaults to an enabled condition.

•Underfrequency Unload Frequency Setpoint

•This is the cut-in point for the Underfrequency Unloading.

• At any operating frequency below this value, the output voltage will be reduced.

•Underfrequency Unload Slope

•This setting determines how much the voltage drops during an underfrequency condition.

•The underfrequency unload is set at the factory and typically does not need adjustment. If the generator application is not
responding to large incremental load changes, this could be a possible area of adjustment
 Decision-Maker® 550 Controller
Voltage Regulator Adjustment (Gain)
•Regulator Gain
•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.
•Regulator gain is active only while not in
the VAR/PF mode.
•Reset Regulator Defaults
This setting, when YES is entered, will
reset regulator setting to factory defaults.
Decision-Maker® 550 Controller
Calibration: Voltage and Amperage (Menu 12)
Decision-Maker® 550 Controller
Menu 20
•Menu 20 provides generator set, alternator, controller
and engine identification information.
•The user can use this menu to determine the
generator set operating days and identify the
controller software (code) version.
•The temperature sensor setup applies to non-ECM
engines
•This menu is typically locked, and no settings can be
changed.
•The controller can be unlocked but this should only
be done if the controller requires reinitialization based
on a software upgrade or if the controller is replaced.
•TT-1285 and TT-1310 are used when updating the
controller software or controller replacement.
 Decision-Maker® 550 Controller
Digital Inputs
•Digital inputs are used to monitor external components. These
inputs may come from a battery charger, fuel tank, pressure switch
or other device.
•The controller allows for 21 digital inputs. If the controller has been
set to NFPA (menu 7), some inputs will be predefined and can not
be changed.
•All inputs are based on signal switching to ground.
• The 21 inputs are factory assigned. The user can redefine inputs
using SiteTech™ software, Monitor III software or locally through the
keypad interface.
•Menu 9 is used to program digital inputs locally.
•When wiring the digital inputs to TB4, terminals 1 thru 21 are the
programmed input, terminals 22 thru 42 are ground return.
Decision-Maker® 550 Controller
Defining Digital Inputs
• The Group A list has predefined events. The programmed event activates a function in the controller. Some of the selected
events only work for specific genset applications.
•The user must enable the input before the controller acknowledges the function is active.
• 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 inhibit time delay range is from 0 to 60 seconds. If the
inhibit time is set to zero, the input is monitored at all times, even when the generator is not running.
• 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.
Decision-Maker® 550 Controller
Defining Digital Input Display
• When the digital input is active, the controller will display the event. If the user wants to customize the display they can do so
using SiteTech™ or Monitor III software.

•In the example of the Rupture Basin alarm, when this input is active, the controller display would show “WARNING DO5.”
•If the user wanted to customize this input they could define Input 5 to display “Rupture Basin.”
Decision-Maker® 550 Controller
Analog Inputs
•The Dec 550 controller provides the end user to
install up to 7 analog warning and shutdown
devices based on a 0-5 VDC scale.

•ECM engines have analog inputs 1-7 available for

user-defined applications.

•Non-ECM engines have analog inputs 3-7

available for optional applications

•1and 2 are reserved for Oil Pressure and

Coolant Temperature as standard inputs.

•Analoginputs are typically a 3 wire device utilizing

a 5 VDC voltage and a signal return voltage.

•Menu 3 is used for monitoring the analog devices.

Decision-Maker® 550 Controller
Installing an Analog Input
•When installing an analog signal the device will typically be a 3 wire sensor. The
TB2 terminal block provides the termination points for analog device.
•Refer to the generator model wiring diagram to determine landing locations for the
analog device.
• In the diagram shown the sensor is wired to analog channel 3
•TB2-5 is the 5 VDC to the sensor
•TB2-20 is the sensor return or ground

•TB2-6 is the analog signal input

Decision-Maker® 550 Controller
Analog Input Calibration
•Using the analog input requires a sender or
device that is scaled based on a 0-5vdc signal with
a calibrated output.
•Example: Temperature sender
•.50 VDC @ 50°F
•4.5vdc @ 275°F
•Calibration requires scaling of sender between
two known values to allow the controller to create
a linear scale that represents the device being
used
•The technician must enter menu 12 “Scale Aux
Analog Inputs” to calibrate each analog device.
Decision-Maker® 550 Controller
Analog Input Calibration (step 1)
•Prior to installing any analog sender the controller needs to know what the zero
value is for calibration.
•During the calibration process for analog inputs, the sender inputs need to be
zeroed out. To accomplish this, the P2 ribbon cable must be disconnected prior
to zeroing out.
•After P2 has been disconnected, answer “yes” to the question ZERO AUX.
ANALOG INPUTS? Then reconnect the P2 connector to complete calibration of
sender.
Decision-Maker® 550 Controller
Analog Input Calibration (step 2)
•In this example we will set up an ambient temperature sensor located in
the generator equipment room. After installing the sensor you will to ramp
the analog sender to two different values and then enter these values into
menu 12.

•To dynamically calibrate the analog input you will need to know either the
exact temperature when setting this value or know the calibration data
.50
based on the voltage input. 50
•If you have the calibration data then allow the sender to reach a
temperature that displays .50 VDC and enter 50 for value 1 and
press “enter.” 4.50
275
•Ramp the temperature up till the value reaches 4.5 VDC and enter
275 for value 2 and press “enter.”

•If
you do not have the calibration data then you will need to have
some means of measuring the temperature and then based on 2
know temps enter this data for value 1 and 2
 Decision-Maker® 550 Controller
Analog Input Calibration (step 3)
•To verify analog device has been installed and calibrated correctly reference Menu 3
Analog Monitoring.
•Scroll to the analog channel that was installed and verify the display has correct
readings.
•The displayed text for an installed analog input can be modified using SiteTech™ or
Monitor III software.
Decision-Maker® 550 Controller
Define Analog Input (step 1)
•After calibration of analog input ,the user may define the analog input as a warning and/or shutdown device, or the analog input can be used
for data information purposes only.

•To program desired function, the user needs to define variables in menu 9.

•After entering the analog input, the user needs to enable the input as a warning and/or shutdown.
Decision-Maker® 550 Controller
Define Analog Input (step 2)
•After the input is activated, an inhibit time can be programmed. This would be a time delay inhibiting an action until the generator set is running.
•A time delay can be programmed to function after the inhibit time delay has elapsed. This time delay is the time period between when the
controller first detects the fault and when the controller indicates a warning or shutdown.
•Values need to be entered to initiate the controller action as a warning or shutdown. These values are determined by the application required.
Decision-Maker® 550 Controller
Define Analog Input (step 3)
•Values need to be entered to initiate a Dec 550 controller action as a warning or shutdown. These values are determined by the application required.
•For example if you wanted to set the Air Temp sender to display a warning when the room gets too cold or too hot you would;
1. Enable the warning function
2. Set inhibit time to zero
3. Set warning to 5 sec.
4. Enter 40 as a low warning value
5. Enter 180 as high warning value

Based on these settings a warning will trigger at any time the room temperature goes below 40⁰ F or above 180⁰ F
Decision-Maker® 550 Controller
Programming RDOs (Relay Driver Output)
•Up to 31 RDOs are available to define using three categories
•System events, digital inputs, and analog inputs
•A Relay Driver Output is an assigned output used to trigger a relay to operate based on:
•A system event such as High Engine Temperature Warning or Engine Running
•A programmed Digital Input such as DO3 Warning

•A programmed Analog input such as AO3 Warning

•Menu 10 allows access to RDO programming
•If the controller is programmed with NFPA -enabled (menu 7), the controller will automatically define 15 of the RDOs as defaults, and the user cannot
reset these defaults. If the user attempts to reassign the default a message displays, Cannot Change NFPA is Enabled.
Decision-Maker® 550 Controller
Installing RDO’s (Relay Driver Outputs)
•When installing RDO circuits reference interconnect diagrams GM16088 or GM78247. These interconnection drawings can be found in wiring
diagram manuals that support generators using the Dec 550 controller
•RDOs provide only the relay driver, not the relay. To wire an RDO circuit, a customer connection kit and relay board are required.
•Relay boards are available in single,10 and14 relay configurations.

Customer Connection Board

10 Relay Board

14 Relay Board
Decision-Maker® 550 Controller
Customer-Defined Common Fault
The user can program a single common fault from the list of system events (group B), digital inputs (group C), and
analog inputs (group D). To define the common fault, the user will go through the submenus and enter yes to any item
that is to be included under common fault. The user then designates an RDO to drive the common fault relay output.