73Section 5 Decision-Makerr 550 ControllerTP-6356 4/12
5.3 Controller Service
Replacement Kits
(GM20722-1, GM20722-1S, GM20722-2,
and GM20722-2S)
Adapted from Installation Instruction TT-1310.
5.3.1 Introduction
The controller service replacement kit is available to
replace a non-functional controller. Use the following
procedure to install the replacement controller. See
Figure 5-3 for typical controller identification. For
features and operation of the controller, see the
operation manual in the literature kit.
Note: Do not use this controller replacement installation
instruction for upgrading software.
GM17028-A
1. Light bulbs
1
Figure 5-3 Controller Front Panel
When replacing the controller, the personality profile
must be installed in order for the controller to function.
Controller service replacement kits do not include the
personality profile file installed on the generator set
controller at the factory. The service technician must
install the personality profile on the controller service
replacement kit.
D Application program contains the software that
controls system operation. The application file is
preprogrammed on the controller service
replacement kit at the factory.
Note: The application program is not backwards
compatible. Do not attempt to load an application
program that is an older version than the
application program version already installed.
D Personality profile is specific to the engine and
alternator and is preprogrammed on the generator
set controller at the factory.
A backup disk of the personality profile and
application program is supplied with the literature
packet shipped with the generator set. Typically, the
distributor stores this disk for possible future use such
as controller replacement or other circumstances
requiring a backup.
Note: If the personality profile disk is NOT available,
request a replacement from the manufacturer
using the generator set serial number or order
number.
D User parameters unique to an installation include
timer values, setpoints, generator set data such as
kW and voltage, and input/output selections. These
parameters are typically set up for or by the installer at
the time of installation. Created user parameters are
typically documented and stored on the personality
profile disk, a separate backup disk, or written in the
User-Defined Settings appendix in the controller
operation manual. A copy of the User-Defined
Settings form is included in Section 5.3.6.
Note: If the user parameters are included on the
personality disk, the disk label should indicate
Site Program—Yes.
Read the entire installation procedure and perform the
steps in the order shown. Always observe applicable
local and national electrical codes.
Note: The following service kit procedure changes only
the controller. If the generator set requires
voltage reconnection and/or frequency
adjustment, see the controller operation manual.
TP-6083 for code versions prior to 2.10.
TP-6200 for code versions 2.10 or higher.
5.3.2 Installation Requirements
The following items are necessary PC requirements for
installing the controller service replacement kits.
D Controller Application Program Software Version
2.10 or higher from KOHLERnet using the TechTools
button to download on your PC hard drive or disk.
D Program Loader Software Version 2.2.2 or higher
from KOHLERnet using the TechTools button to
download on your PC hard drive or disk if not already
installed on your PC.
D Monitor II Software PA-361725 or PA-365196,
Version 4.0.0 or higher. Add the user parameters
from a backup disk and/or enter alphanumeric data.
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