Kohler KD700 Instruction Manual

Models:
KD700-KD4000
Controller:
APM802
Industrial Generator Sets
TP-7070 11/22g
Operation

2 TP-7070 11/22
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
Engine Identification
Record the product identification numbers from the generator
set nameplate(s).
Record the product identification information from the engine
nameplate.
Model Designation ________________________________
Manufacturer ______________________________________
Specification Number ______________________________
Model Designation _________________________________
Serial Number ____________________________________
Serial Number ____________________________________
Controller Identification
Alternator Identification
Record the controller description from the generator set
operation manual, spec sheet, or sales invoice. Record the
Controller Serial Number from the controller nameplate.
Record the alternator model number from the generator set
nameplate(s).
Controller Description ______________________________
Alternator Model _________________________________
Controller Serial Number ___________________________
Accessory Number
Accessory Description
Accessory Number
Accessory Description

TP-7070 11/22 3
Table of Contents
Safety Precautions and Instructions ........................................................................................................................................5
Introduction ..............................................................................................................................................................................11
Service Assistance...................................................................................................................................................................13
Section 1. Specifications and Features .................................................................................................................15
1.1 Introduction ............................................................................................................................................................15
1.2 Controller Specifications.........................................................................................................................................15
1.2.1 Controller Specifications ..........................................................................................................................15
1.2.2 Display and Touchscreen.........................................................................................................................15
1.3 Controller Features.................................................................................................................................................16
1.3.1 Connections.............................................................................................................................................17
1.3.2 Modbus Connections...............................................................................................................................18
1.3.3 Optional Keyswitch and Manual Start/Stop Button...................................................................................18
1.4 NFPA Requirements ..............................................................................................................................................19
1.5 Parameter Settings.................................................................................................................................................20
1.6 Base Module Inputs and Outputs...........................................................................................................................20
Section 2. Operation................................................................................................................................................23
2.1 Prestart Checklist...................................................................................................................................................23
2.2 Exercising Generator Set.......................................................................................................................................24
2.3 Operation in Cold Weather Climates......................................................................................................................24
2.4 Generator Set Operation........................................................................................................................................24
2.4.1 Start Signal ..............................................................................................................................................24
2.4.2 Stop Signal...............................................................................................................................................25
2.4.3 Engine Cooldown.....................................................................................................................................25
2.4.4 Emergency Stop ......................................................................................................................................25
2.4.5 Idle Mode.................................................................................................................................................25
2.5 Controller Operation Modes...................................................................................................................................26
2.5.1 Out of Service Mode................................................................................................................................27
2.5.2 Manual Mode...........................................................................................................................................28
2.5.3 Auto Mode (Standby or System Ready)...................................................................................................28
2.6 Load Shed..............................................................................................................................................................29
2.7 HMI Screen Layout.................................................................................................................................................31
2.7.1 Home Screen...........................................................................................................................................31
2.7.2 Top Bar....................................................................................................................................................31
2.7.3 Generator View........................................................................................................................................32
2.7.4 Control Panel...........................................................................................................................................32
2.7.5 Custom View Button.................................................................................................................................33
2.8 Operator Login .......................................................................................................................................................34
2.9 Data Displays.........................................................................................................................................................35
2.9.1 Generator Mechanical Values..................................................................................................................35
2.9.2 Generator Electrical Values .....................................................................................................................37
2.9.3 Curve Display...........................................................................................................................................38
2.9.4 Saved Electrical and Mechanical Data.....................................................................................................40
2.10 Events....................................................................................................................................................................41
2.10.1 Faults and Alarms....................................................................................................................................42
2.10.2 Resetting an Alarm ..................................................................................................................................44
2.10.3 Resetting a Fault......................................................................................................................................44
2.10.4 Consulting Status Messages....................................................................................................................45
2.10.5 Full Event Log..........................................................................................................................................47

4 TP-7070 11/22
2.11 Applications............................................................................................................................................................48
2.11.1 Reference ................................................................................................................................................49
2.11.2 Region Settings........................................................................................................................................50
2.11.3 HMI Settings ............................................................................................................................................52
2.11.4 Restart.....................................................................................................................................................54
2.11.5 Display Cleaning......................................................................................................................................54
2.11.6 Firmware Update .....................................................................................................................................55
2.11.7 Screenshot...............................................................................................................................................56
2.11.8 Ladder Tools............................................................................................................................................57
2.11.9 Save Parameters.....................................................................................................................................59
2.11.10 Upload Parameters..................................................................................................................................59
2.12 Menus ....................................................................................................................................................................60
2.12.1 Menu 1-Settings.......................................................................................................................................62
2.12.2 Menu 2-Measurements............................................................................................................................64
2.12.3 Menu 3-History.........................................................................................................................................66
2.12.4 Menu 4-Diagnosis....................................................................................................................................67
2.12.5 Menus 5 and 6.........................................................................................................................................71
2.12.6 Menu 6.5-Communication........................................................................................................................71
Section 3. Troubleshooting.....................................................................................................................................73
3.1 Introduction ............................................................................................................................................................73
3.2 Generator Set and Controller.................................................................................................................................73
3.3 Engine....................................................................................................................................................................73
3.4 Transfer Switch......................................................................................................................................................73
3.5 General Troubleshooting Chart..............................................................................................................................74
Section 4. Accessories............................................................................................................................................79
4.1 Accessories and Connections................................................................................................................................79
4.2 Accessory Connections..........................................................................................................................................79
4.3 Battery Chargers....................................................................................................................................................80
4.4 Input and Output Modules......................................................................................................................................80
4.4.1 Analog Input/Output Module ....................................................................................................................81
4.4.2 Digital Input/Output Module......................................................................................................................82
4.4.3 Thermocouple Input Module ....................................................................................................................85
4.5 Remote Emergency Stop Kit..................................................................................................................................86
4.5.1 Remote Emergency Stop Kit....................................................................................................................87
4.5.2 Lockable Emergency Stop Switch............................................................................................................87
4.6 Remote Serial Annunciator ....................................................................................................................................88
Appendix A. Abbreviations.........................................................................................................................................91
Appendix B. Operating Hours and Service Log........................................................................................................95

TP-7070 11/22 5
Safety Precautions and Instructions
IMPORTANT SAFETY INSTRUCTIONS. Electromechanical equipment, including generatorsets, 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) Shut down the generator set. (2) Place the controller
in Out of Service mode. (3) Press the emergency stop button. (4) Disconnect the power to the battery charger, if equipped. (5)
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.

6 TP-7070 11/22
Battery
WARNING
Sulfuric acid in batteries.
Can cause severe injury or death.
Wear protective goggles and clothing. Battery acid may cause blindness and burn skin.
WARNING
Explosion.
Can cause severe injury or death.
Relays in the battery charger cause arcs or sparks.
Locate the battery in a well‐ventilated area. Isolate the battery charger from explosive
fumes.
Battery electrolyte is a diluted sulfuric acid. Battery acid can cause severe injury or death. Battery acid can cause
blindness and burn skin. Always wear splashproof safety goggles, rubber gloves, and boots when servicing the battery. Do not
open a sealed battery or mutilate the battery case. If battery acid splashes in the eyes or on the skin, immediately flush the
affected area for 15 minutes with large quantities of clean water. Seek immediate medical aid in the case of eye contact. Never
add acid to a battery after placing the battery in service, as this may result in hazardous spattering of battery acid.
Battery acid cleanup. Battery acid can cause severe injury or death. Battery acid is electrically conductive and corrosive.
Add 500 g (1 lb.) of bicarbonate of soda (baking soda) to a container with 4 L (1 gal.) of water and mix the neutralizing solution.
Pour the neutralizing solution on the spilled battery acid and continue to add the neutralizing solution to the spilled battery acid
until all evidence of a chemical reaction (foaming) has ceased. Flush the resulting liquid with water and dry the area.
Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit
flames or sparks to occur near a battery at any time, particularly when it is charging. Do not dispose of a battery in a fire. To
prevent burns and sparks that could cause an explosion, avoid touching the battery terminals with tools or other metal objects.
Remove all jewelry before servicing the equipment. Discharge static electricity from your body before touching batteries by first
touching a grounded metal surface away from the battery. To avoid sparks, do not disturb the battery charger connections while
the battery is charging. Always turn the battery charger off before disconnecting the battery connections. Ventilate the
compartments containing batteries to prevent accumulation of explosive gases.
Battery short circuits. Explosion can cause severe injury or death. Short circuits can cause bodily injury and/or equipment
damage. Disconnect the battery before generator set installation or maintenance. Remove all jewelry before servicing the
equipment. Use tools with insulated handles. Remove the negative (–) lead first when disconnecting the battery. Reconnect the
negative (–) lead last when reconnecting the battery. Never connect the negative (–) battery cable to the positive (+) connection
terminal of the starter solenoid. Do not test the battery condition by shorting the terminals together.

TP-7070 11/22 7
Engine Backfire/Flash Fire
WARNING
Risk of fire.
Can cause severe injury or death.
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 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.
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.
Exhaust System
WARNING
Carbon monoxide.
Can cause severe nausea, fainting, or death.
The exhaust system must be leakproof and routinely inspected.
Generator set operation. Carbon monoxide can cause severe nausea, fainting, or death. Carbon monoxide is an odorless,
colorless, tasteless, nonirritating gas that can cause death if inhaled for even a short time. Avoid breathing exhaust fumes when
working on or near the generator set. Never operate the generator set inside a building unless the exhaust gas is piped safely
outside. Never operate the generator set where exhaust gas could accumulate and seep back inside a potentially occupied
building.
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.

8 TP-7070 11/22
Fuel System
WARNING
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling, storing, and using fuels.
The fuel system. Explosive fuel vapors can causesevere 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.
Fuel tanks. Explosive fuel vapors can cause severe injury or death. Gasoline and other volatile fuels stored in day tanks or
subbase fuel tanks can cause an explosion. Store only diesel fuel in tanks.
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.
Engine noise. Hazardous noise can cause hearing loss. Generator sets not equipped with sound enclosures can produce
noise levels greater than 105 dBA. Prolonged exposure to noise levels greater than 85 dBA can cause permanent hearing loss.
Wear hearing protection when near an operating generator set.

TP-7070 11/22 9
Hazardous Voltage/Moving Parts
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
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.
WARNING
Hazardous voltage. Backfeed to the utility system.
Can cause property damage, severe injury, or death.
If the generator set is used for standby power, install an automatic transfer switch to
prevent inadvertent interconnection of standby and normal sources of supply.
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.
Installing the battery charger. Hazardous voltage will cause severe injury or death. An ungrounded battery charger may
cause electrical shock. Connect the battery charger enclosure to the ground of a permanent wiring system. As an alternative,
install an equipment grounding conductor with circuit conductors and connect it to the equipment grounding terminal or the lead
on the battery charger. Install the battery charger as prescribed in the equipment manual. Install the battery charger in
compliance with local codes and ordinances.
Connecting the battery and the battery charger. Hazardous voltage will cause severe injury or death. Reconnect the
battery correctly, positive to positive and negative to negative, to avoid electrical shock and damage to the battery charger and
battery(ies). Have a qualified electrician install the battery(ies).
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. Install a transfer switch
in standby power installations to prevent the connection of standby and other sources of power. Electrical backfeed into a utility
electrical system can cause severe injury or death to utility personnel working on power lines.
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 orcomponents inside the enclosure. (4)Be prepared forthe systemto operate automatically.(600volts andunder)
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.

10 TP-7070 11/22
Heavy Equipment
WARNING
Unbalanced and elevated weight.
Improper lifting can cause severe injury or death and equipment damage
Do not lift the generator set from the engine or alternator eyes. Never stand under a unit
being lifted. Always maintain a safe distance from the unit being lifted.
See the lifting instructions in the installation manual that was provided with the unit.
Hot Parts
WARNING
Hot coolant and steam.
Can cause severe injury or death.
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.
Can cause severe injury or death.
Do not work on the generator set until it cools.
Servicing the alternator. Hot parts can cause severe injury or death. Avoid touching thealternator field or exciter armature.
When shorted, the alternator field and exciter armature become hot enough to cause severe burns.
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
Parallel Operation. This product includes features intended tosupport operation in parallel with the utility grid, but these features
have not been evaluated for compliance with specific utility interconnection protection standards or requirements.
NOTICE
Canadian installations only. For standby service connect the output of the generator set to a suitably rated transfer switch in
accordance with Canadian Electrical Code, Part 1.

TP-7070 11/22 11
Introduction
This manual provides generator set operation, maintenance, and basic troubleshooting instructions. A separate controller
operation manual contains detailed controller operation information.
Wiring diagram manuals are available separately. 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. Kohler Co. 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. Maintenance work must be performed by appropriately skilled and suitably trained
maintenance personnel familiar with generator set operation and service.
List of Related Materials
Separate literature contains controller operation instructions, engine and alternator maintenance, and accessory information not
provided in this manual. Figure 1 lists the available literature part numbers.
Several engine manufacturers provide engines with electronic controls. These electronic controls indicate engine fault codes in
addition to the generator set controller. The engine operation and service literature provide information for identifying engine
fault codes. For the latest literature part numbers, see the respective generator set parts catalog.
Manual Description
Literature Part No.
APM802 Controller Spec Sheet
G6-152
Generator Set Installation Manual, KD Models
TP-7153
Generator Set Maintenance Manual, KD Models
TP-7143
Controller and Generator Set Service Manual
TP-7079
Engine Operation and Maintenance Manual, KD18L06, KD700-KD750
33521059301
Engine Operation and Maintenance Manual, KD27V12, KD800-KD1000
33521029401
Engine Operation and Maintenance Manual, KD36V16, KD1250-KD1350
33521029701
Engine Operation and Maintenance Manual, KD45V20, KD1250-KD1750
33521030001
Engine Operation and Maintenance Manual, KD62V12, KD2000-KD2500
33521030301
Engine Operation and Maintenance Manual, KD83V16, KD2800-KD3250
33521030601
Engine Operation and Maintenance Manual, KD103V20, KD3500-KD4000
33521030901
Alternator, Voltage Regulator, KD700
TP-7271
Alternator, Voltage Regulator, KD700-KD1750 Wye/600 V
TP-7073
Alternator, Voltage Regulator, KD1250-KD3250 Wye/600 V/4160 V
TP-7075
Alternator, Voltage Regulator, KD2000-KD4000 6600-13800 V
TP-7076
Alternator, Voltage Regulator, KD2000-KD2500 Wye/600 V
TP-7078
Generator Set/Controller Wiring Diagram Manual w/APM802
Original
With Updated Digital
8 I/O Module
KD700-KD750 (APM603)
KD700-KD750 (APM802)
KD800-KD1000
KD1250A-KD1350 (single starter)
KD1250A-KD1350 (redundant starter)
KD1500-KD1750 (single starter)
KD1500-KD1750(redundant starter)
KD2000-KD2500(single starter)
KD2000-KD2500(redundant starter)
KD2800-KD3250 (single starter)
KD2800-KD3250 (redundant starter)
KD3500-KD4000
NA
NA
TP-7106
TP-7117
TP-7117
TP-7071
TP-7071
TP-7107
TP-7107
TP-7108
TP-7108
TP-7169
TP-7262
TP-7263
TP-7242
TP-7243
TP-7244
TP-7245
TP-7246
TP-7247
TP-7248
TP-7249
TP-7250
TP-7251
Remote Serial Annunciator III (RSA III)
TT-1625
Figure 1 Related Literature

12 TP-7070 11/22
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.
Nameplate Location
Generator sets and their components (engine, alternator) are identified with decals or nameplates. For future reference during
routine maintenance or to order service parts, copy the model number, serial number, and specification number from the
generator set nameplate into the spaces provided in the product information section on the inside front cover of this manual. The
generator set nameplate is typically located on the alternator assembly as shown below.
Figure 2 Generator Set Nameplate and Location, Typical
Nameplate location,
typical
11811000100-GR1

TP-7070 11/22 13
Service Assistance
For professional advice and conscientious service, please
contact your nearest Kohler distributor or dealer.
•Visit the Kohler Co. website at KOHLERPower.com.
•Look at the labels and decals on your Kohler product
or review the appropriate literature or documents
included with the product.
•Call toll free in the US and Canada 1-800-544-2444.
•Outside the US and Canada, call the nearest
regional office.
Headquarters Europe, Middle East, Africa (EMEA)
Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
Asia Pacific
Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]

14 TP-7070 11/22
Notes

TP-7070 11/22 15
Section 1. Specifications and Features
1.1 Introduction
The spec sheets for each generator set provide model specific generator and engine information. The controller spec sheet
provides specifications for the controller. 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.
1.2 Controller Specifications
1.2.1 Controller Specifications
•Power Supply Requirements:
oNominal voltage: 24 VDC, reverse polarity protected
o240 VAC/60Hz customer-supplied; factory wiring to basic electrical package available
•Operating Temperature: - 40°C to 70°C (- 104°F to 158°F)
•Storage Temperature: - 40°C to 70°C (- 104°F to 158°F)
•Humidity: 5% to 95% non-condensing
•Protection Index:
oIP65 Front
oIP20 Rear
•Standards:
oNFPA 99
oNFPA 110, Level 1
oCSA 282-09
oUL 508
oIEC/EN60068-2-52 (salt spray)
oCE Directive
1.2.2 Display and Touchscreen
•Type: XGA TFT LED LCD
•Screen Size: 305 mm (12 inches)
•Viewing Angle: 140° horizontal and vertical
•Languages: English, French
Note:
Have setup and adjustments of the controller performed only by an authorized Kohler distributor. The setup and adjustments
are password protected.

16 TP-7070 11/22
1.3 Controller Features
The controller features include a 307 mm (12.1 inch) touchscreen with backlight and wide viewing angle (140° horizontal and
vertical) and terminal blocks for input and output connections. See Figure 3 for an illustration of the controller front panel and
the customer connection area. Controller features include:
•12-inch touchscreen with backlight and wide viewing angle for easy local access to data.
•System settings are password-protected.
•Measurements selectable in metric or English units.
•User language is selectable (English or French).
•Graphic displays showgenerator set mechanical values including operating hours, fuellevel (where applicable), battery
voltage, coolant temperature, oil pressure, and oil temperature.
•Meter displays provide a visual representation of generator electrical values including power (kW), power factor,
reactive power (kVAR), frequency, voltage, and current (amps).
•Two USB ports allow connection of a flash drive, mouse, or keypad.
•Electrical data, mechanical data, and system settings can be saved to a flash drive.
•Recording feature allows data collection of key values.
•Ethernet port allows connection to a PC type computer and/or Ethernet switch.
•Serial (RS-485) port.
•The controller supports Modbus®RTU and TCP protocols.
•Real time clock with battery back-up.
•See the controller specification sheet or operation manual for input and output specifications.
Figure 3 APM802 Controller and Customer Connection Box
Modbus®is a registered trademark of Schneider Electric.
Emergency stop
switch
Controller
touchscreen
11601000945
Note:
Covers have been removed for illustration.
APM802 controller human-
machine interface (HMI)
USB ports, qty.
2 (on the back
of the HMI)
Wiring harness
connection
Key switch
Manual start/stop
button
Generator set
mechanical data
240 VAC/60 Hz
power supply
connection
(required)
Terminal block TB10 for accessory
connections
Fault indicator/display
button
Mode selection
switch
Generator set electrical values
Human-Machine Interface (HMI)

TP-7070 11/22 17
1.3.1 Connections
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before opening the enclosure.
Inputs and outputs from the controller base module are brought out to TB10 in the connection box. See the figure titled: APM802
Controller and Customer Connection Box for the terminal block location. Do not connect directly to the controller base module
(except for the Ethernet 3 connection).
TB10 Terminal Strip for input and output connections. See thegenerator set wiring diagram for connections. Inputs and outputs
are factory-set; the default settings are shown in the Base Module Inputs and Outputs Section.
240 VAC Power Connection. The installer must connect a 240 VAC power source for the controller heater. See Controller
Features Section and the wiring diagram for the 240 VAC power connections to TB10.
Mini USB Connectors for connection to a PC for firmware updates orsaving data files. Two USB ports are located on the back
of the controller’s human-machine interface (HMI). See Figure 4. Lift the hinged panel to access the USB ports.
Ethernet 3 port on the base module can be connected to a personal computer or network to allow remote monitoring using
VNC.
Additional input and output connections are available with optional module kits. See the Accessories section for accessory
connection details.
Figure 4 USB Ports (back of HMI)
USB Ports

18 TP-7070 11/22
1.3.2 Modbus Connections
Use RS-485 cable for Modbus RTU connections. Belden #9841 or equivalent shielded, twisted-pair cable is recommended. See
Figure 5. See the generator set wiring diagram for the Modbus connection location on TB10.
The controller also supports Modbus TCP over Ethernet. Connect to the RJ45 port labeled Ethernet 3 on the controller’s base
module.
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.
Note:
Only one Modbus®master can be connected to the controller. Examples include the remote serial annunciator and switchgear
applications.
Figure 5 Modbus®Connections
1.3.3 Optional Keyswitch and Manual Start/Stop Button
Some controllers are equipped with the optional keyswitch and manual start/stop button shown in Figure 6. See the Controller
Features Section for the location on the controller assembly.
Figure 6 Optional Keyswitch and Manual Start/Stop Button
Keyswitch. The keyswitch disables the mode pushbutton on the controller touchscreen. The touchscreen will display the
operation mode, but the mode cannot be changed using the touchscreen if the controller is equipped with the keyswitch. The
keyswitch positions are described in Figure 7. See the Controller Operation Modes section for more information on controller
operation modes.
Manual Start/Stop Button. When the keyswitch is in the Manual position, pressing the Start/Stop button will start and stop the
generator set.
Note:
Pressing the manual stop buttonshuts down the generator set immediately, without running the engine cooldown cycle. Running
the generator set without load for 5 minutes before stopping manually is recommended.
Position
Description
Manual
Allows generator set start and stop using the manual pushbutton.
Off
Places the generator set in OFF/Out of Service mode. The generator set will not start, even if a remote start command is
received or the Start button is pressed.
Auto
Automatic operation allows a remote switch or automatic transfer switch to start and stop the generator set.
Figure 7 Keyswitch Positions
Generator Set
Controller
Modbus®Master
RS-485
up to 1220 m (4000 ft.)

TP-7070 11/22 19
1.4 NFPA Requirements
In order to meet NFPA 110, Level 1 requirements, the generator set controller monitors theengine/generator functions and faults
shown below.
Engine functions:
•Overcrank
•Low coolant temperature warning
•High coolant temperature warning
•High coolant temperature shutdown
•Low oil pressure shutdown
•Low oil pressure warning
•Overspeed
•Low fuel level
*
•Low coolant level
•EPS supplying load
•High battery voltage
•Low battery voltage
•Air damper indicator
General functions:
•Master switch not in auto
•Battery charger fault †
•Contacts for local and remote common alarm
•Audible alarm silence switch
•Remote emergency stop
*
Function requires optional input sensors or kits.

20 TP-7070 11/22
1.5 Parameter Settings
Controller parameter settings are factory-set and password-protected. Selected settings are shown in Figure 8. If changes are
required, contact your distributor.
Parameter
Setting
Preheat duration*
0 s
Air-preheater maximum delay (at each start attempt)*
30 s
Number of starting attempts
3
Time between starting attempts
15 s
Fault inhibition time in starting phase
10 s
Auxiliaries start time
5 s
Generators starting maximum delay
(Dead Bus synchronizing)
5 s
Generator cooling time
300 s (5 min.)
Generator immobilization time
5 s
Ventilation time after generator stopped
10 s
Parameter settings not applicable for KD2000-KD4000
Figure 8 Factory Settings
1.6 Base Module Inputs and Outputs
The inputs and outputs on the base module are factoryset. See Figure 9 and Figure 10 for base module input and output factory
settings. For optional input/output module settings, see the Accessories section.
Note:
Make customer connections to TB10 in the connection box. See the generator set wiring diagram for details.
Inputs
Factory Setting
Digital Inputs
DI0
Remote Start
DI1
Low Fuel Level Switch
DI2
Breaker Open Status
DI3
Remote Reset
DI4
Aux Shutdown
DI5
High Fuel Level Switch
DI6
Aux Warning
DI7
Low Oil Level
DI8
Battery Charger Fault
DI9
Fuel Leak Alarm
DI10
Idle Mode
DI11
GFCI Tripped
DI12
Remote Speed Adjust Enable
DI13
Key Switch Enable
DI14
Load Shed Enable
DI15
Overcrank Test
DI16
Reserved for Factory Use
DI17
Emergency Stop
Analog Input
AI0-
Remote Speed Adjust
(+/- 10 VDC)
AI0+
Resistive Input
RES0-
Ambient Air Temperature
RES0+
Figure 9 APM802 Base Module Input Factory Settings