Alpha Technologies AlphaGen 3.5_5.0kW Kohler COM5 - Manual (Page 58)

TP-6482 8/06 58 Section 6 Controller Operation and Test
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
Moving rotor.
WARNING
Servicing the generator set when it is operating. Exposed
moving parts can 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.
Short circuits. Hazardous voltage/current can 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.
6.4.1 Low Oil Pressure (LOP) Shutdown
The low oil pressure (LOP) switch closes 5 seconds
after the oil pressure drops below 5 psi, shutting down
the generator set and lighting LED4.
The low oil
pressure shutdown does not function during the first
30 seconds after startup.
To test the operation of the LOP shutdown, connect a
jumper wire from pin J4-13 of the controller-to-engine
wiring harness to the generator set ground. Start the
generator set.
After approximately 35 seconds the
generator set shuts down and the fault lamp lights. If the
generator set does not shut down, replace the control
board.
6.4.2 High Engine Temperature (HET)
Shutdown
The high engine temperature (HET) switch closes
5 seconds after the generator set temperature reaches
305
°F, shutting down the generator set and lighting
LED2 on the control board. The high engine
temperature shutdown does not function during the first
30 seconds after startup.
To test the HET shutdown, connect a jumper from the
HET switch (lead ) to the generator set ground. Start the
generator set.
After approximately 35 seconds the
generator set shuts down and the fault lamp lights.
Five seconds after the jumper is removed, the fault lamp
goes out and the generator set restarts. If the generator
set does not shut down and restart as described,
replace the control board.
6.4.3 Overcrank Shutdown
The generator set shuts down and LED5 lights after
approximately 70 seconds of cyclic cranking (three
attempts to start). The manufacturer sets the circuit
board for three cranking attempts: crank 20 seconds,
rest 5 seconds, crank 20 seconds, rest 5 seconds,
crank 20 seconds, shutdown.
Use the following
procedure to test the overcrank shutdown operation.
Overcrank Shutdown Test Procedure
1. Turn off the fuel supply to prevent flooding and
remove the coil wire from the ignition module.
2. Move the generator set master switch to the RUN
position.
3. Verify that the generator set shuts down and the
fault lamp lights after the third crank/rest cycle.
6.4.4 Overspeed Shutdown
The generator set shuts down and LED1 lights when the
engine speed exceeds 3750 rpm.
Use the following procedure to test the operation of the
overspeed shutdown.
Overspeed Shutdown Test Procedure
Note: Do not increase engine speed above 3950 rpm.
Increasing the engine speed above 3950 rpm
can raise the output voltage high enough to
damage generator and connected equipment.
1. Disconnect the load from the generator set.
2. Connect a tachometer to the engine spark plug
lead to measure the engine speed during the test.
Note: If a tachometer is not available, connect a
frequency meter across terminals C and E
on the AC side of the voltage rectifier.
Increase the engine speed as instructed in
step 3. The generator set should shut down
when the output frequency reaches 750 Hz.
Do not exceed 790 Hz.
3. With the generator set running, carefully move the
throttle linkage to increase the engine speed.
Watch the tachometer and note the speed when
the generator set shuts down.
4. Reset the controller by moving the master switch to
the OFF position and then back to AUTO.
If the generator set does not shut down when the engine
speed exceeds 3750 rpm, replace the control board.