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INSTALLATION INSTRUCTIONS
Original Issue Date:
Models:
Market:
Subject:
1/01
Microprocessor-Based Generator Set Controllers and ATS Controllers
All
Program Loader Software
Introduction
The controller application program is a set of
instructions that tell the controller how to operate
(similar to the operating system on a computer). Use
Program Loader software and a personal computer to
update the application program on the following
controllers:
D Model 550 generator set controllers
D Advanced Digital Control (ADC 2100) generator set
controllers
D 16-light microprocessor generator set controllers *
D Series 1000 ATS controllers
D Series 500 ATS controllers
D MPACt 550 ATS controllers
D Modbus/KBUS converters for Series 340 controllers
System Requirements
D 100% IBMr PC compatible with a 133 MHz or higher
Pentiumr-compatible CPU.
D Microsoftr Windowsr 98, Windows NTr Workstation
running
Windowsr
2000
and
communicating through USB ports may require a
serial adapter card to connect the PC to the ATS
controller. (The Sockett PCMCIA Serial Adapter
card is one example).
Safety Precautions
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 connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
Version Required
2.2.1 or higher
2.3.0 or higher
2.4.0 or higher
2.5.0 or higher
Converter, Modbus/KBUS
2.6.0 or higher
2.7.0 or higher
Figure 1
DANGER
Hazardous voltage.
Will cause severe injury or death.
Only authorized personnel should
open the enclosure.
Figure 2
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
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Figure 3
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Figure 4
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FACTORY SETUP
FACTORY SETUP
FINAL ASSEMBLY
CLOCK NO.
00000
OPERATING DAYS
ENTER CODE
(UNLOCKS SETUP)
ENTER CODE
(UNLOCKS SETUP)
FINAL ASSEMBLY
CLOCK NO ?
OPERATING DAYS
MODEL NO
SPEC NO
GENSET SERIAL NO
ALTERNATOR PART NO
ENGINE PART NO
SERIAL NO
MODEL NO.
(26 CHARACTERS MAX)
SPEC NO.
(16 CHARACTERS MAX)
SERIAL NO.
?
CONTROLLER SERIAL NO
CONTROLLER SERIAL NO.
?
CODE VERSION
COPYRIGHT
#
XXXX
CODE VERSION
COPYRIGHT
#
XXXX
INITIALIZE BLOCK?
Y/N
(data block failure code)
INITIALIZE EEPROM? Y/N
SETUP LOCK
Figure 5
Y/N
SETUP LOCKED
Figure 6
YES
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Install and
Install and
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3
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4
1.
2.
3.
4.
5.
Figure 7
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Figure 8
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10
GM28707A-C
3
1. LED display
2. Up and down arrow buttons (use for setup and
adjustment only)
3. Generator set master switch
4. Select button (use for setup and adjustment only)
Figure 9
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3 16-Light Microprocessor
Controllers
Use the Program Loader software version 2.4.0 or
higher to load controller application program onto
16-light controllers with red main logic boards (shipped
November, 2003 or later).
Note: Version 2.4.0 or higher of the Program Loader
software is required to load programs onto the
16-light microprocessor controller.
tp6214
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1. TB5 connector
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11
RS-232 to
RS-485
Converter
TB5 connector
TD (A)
TD (B)
-+
GND
-+
GND
GND
GND
+12 V
Connect A to --,
B to +, and
GND to shield
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1. RS-232 to RS-485 converter GM29361. Connect to the PCs serial port. Do not connect to the +12V terminal on the converter. (The
converter is powered through the PCs serial port.)
2. Twisted-pair shielded cable, Belden #9841 or equivalent, customer-supplied. Use a maximum cable length of 1219.2 m (4000 ft.)
from the RS-485 converter to the controller.
3. Terminal strip TB5 on controllers main logic board
12
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13
OR
GM39556
14
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RS-232
port
TT1285
RS-232 to
RS-485
Converter
Belden #9841
or equivalent
GND
+
-TB1 connector
Connect A to --,
B to +, and
GND to shield
TT1285
1. RS-232 to RS-485 converter GM29361. Connect to the PCs serial port. Do not connect to the +12V terminal on the converter. (The
converter is powered through the PCs serial port.)
2. Twisted-pair shielded cable, Belden #9841 or equivalent, customer-supplied. Use a maximum cable length of 1219.2 m (4000 ft.)
from the RS-485 converter to the controller.
3. Terminal strip TB1 on converter module PCB
Figure 16 Converter Module-to-Personal Computer RS-485 Connection (Note: RS-232 connection is also
possible)
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15
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16
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DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
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GM211077A
17
18
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19
DANGER
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
R6 C3
R7 C4
R8 C5
R9 C6
R10 C7
R11 C8
R12 C9
Y1
C16 C20 U3
C23
V2
V3
7
V4
P1
V1
L2
D19
12
C55
D18
C37
C42
K5
D17
C28R38
D11
K4
D15
Q3
D16
D10
R42 R54
R43R55
C35 C40R60 R70
R44 R56
C36C41 C47 C52
R45 R57R61 R71
D14
D8
R37
R69
+
+
5 4P2
3 2
Z5
R68
R32
D7
C32
R36
C27
R34
K3
C34 R35C29
Z2
C26 C31
VR2
R33
D5
Z1
R16
P7
C30
D9
C15
D6
R65
Q2
Q1
C39
L1
K2
Z4
R30
U1
R31 C19
D4
K1
R50
D12 D13
Z3
R29
R28
R15
D3
BARCODE
C24
C25
R27
R26
R25
R24
R22
R21
R20
R4
D2
C13
C43 C48
C44 C49
C33
R39 R46
U5
R40 R47
R48
R49
C50
C1812 C22 22
R14
R13
C12
P6
23
11
12
D1
GND +3.3V
4
3
33
U2
R19
+
C14
R18
+
C10
C1 R2
R1
R3
6
1
34
P3
34
+12V
C11
VR1
C21
C17 44
P4
P5
C2
R23
R5
R17
50
60
FREQUENCY
GM35950
1. Test button
2. Exercise button
20
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21
22
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D Belden
cable or
DANGER
GM50446
1. TB1 Connector
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23
TB1
Connections:
A to 1,
B to 2.
shield to GND
1
2
--24 VDC 3
+24 VDC 4
Connector GM40557;
connects to TB1 on
MPAC 550 controller
TD (A)
TD (B)
GND
GND
+12 V
Belden #9841
or equivalent
RS-232 to RS-485
converter connects to
serial port on the PC
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24
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25
26
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8 Online Help
Use the programs online help system to help you
diagnose error messages or problems encountered
while running the program. Figure 28 lists the error
codes. Refer to the online help system for more
information about error codes and suggestions for
correcting the errors.
Error Code
Description
2000
2001
2002
2003
2004
2005
2006
2007
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27
Notes
28
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