Alpha Technologies AlphaGen 3.5_5.0kW Kohler COM5 - Manual (Page 57)

TP-6482 8/06 57 Section 6 Controller Operation and Test
Fault Description Fault Condition/Possible Cause
High engine
temperature Shuts down 5 seconds after the fault. When the engine cools, the fault clears
and allows the generator set to be started without resetting the controller. The
high engine temperature shutdown is inhibited (does not function) during the
first 30 seconds after startup.
D
Engine reaches shutdown
temperature
D
Very low oil level
D
Air inlet or outlets blocked
D
Cooling system malfunction
Low oil pressure Shuts down 5 seconds after the fault. The low oil pressure shutdown does not
function during the first 30 seconds after startup.
Note: The low oil pressure shutdown does not protect against low oil level.
D
Engine oil pressure drops below
low oil pressure limit
D
Very low oil level
Overcrank Shuts down after 70 seconds of cyclic cranking. The factory sets the circuit
board for three starting attempts: crank 20 sec., rest 5 sec., crank 20 sec., rest
5 sec., crank 20 sec., overcrank fault.
Overcrank shutdown also occurs in the case of a locked rotor.
D
Starting problem
D
Locked rotor (2 seconds without
rotation or no AC speed sensor
input)
Overspeed Shuts down immediately if the engine speed exceeds 3750 rpm.
D
Engine rpm exceeds 3750
D
Loss of speed (AC) sensing
Figure 6-5 Fault Shutdowns
6.3.1 Control Resetting Procedure
(Following Fault Shutdown)
Use the following procedure to restart the generator set
after a fault shutdown.
1. Move either the generator set master switch or the
remote switch to the STOP position.
2. Correct the cause of the fault shutdown. See the
safety precautions at the beginning of this section
before proceeding.
3. Start the generator set locally by moving the
generator set master switch to the RUN position, or
move the master switch to the AUTO position and
start the generator set using the remote start
switch. Run the generator set to verify that the
cause of the shutdown has been corrected.
4. Move the generator set master switch to the STOP
position to stop the generator set.
5. Move the generator set master switch to the AUTO
position to return to standby operation.
6.4 Fault Shutdown Tests
Verify operation of the controller overspeed, overcrank,
low coolant level, low oil pressure, and high engine
temperature shutdowns by performing the following
tests with the generator set running. Observe the LEDs
on the controller circuit board during the tests. Refer to
the service views in Section 1.4 for component
locations.
Remove the generator set from the enclosure to gain
access to the components in the following tests. See
Section 5.1 for instructions to remove the generator set
and run it using the service fixtures.
Note: If you run the generator set outside the enclosure,
place the cover over the top of the generator to
prevent contact with rotating parts. The cover
has an opening in the center to allow cooling air
flow.
Check the continuity of the wiring harness leads before
replacing the control board.
Refer to the wiring
diagrams in Section 8 for the lead codes and connecting
terminals.
If these tests are inconclusive, test the individual
shutdown
circuit components as described in
Section 6.5.
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
DANGER