Owners Manual
Operator/Installation
Controller
PowerCommand1302
English
Original Instructions 6-2014 900−0661 (Issue 10)
“Intentionally Left Blank”
58
Table of Contents
SECTION TITLE PAGE
Foreword viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Safety Instructions ix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. Introduction 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About This Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Overview 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Certifications 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connector Seal Standards 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit Description 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Equipment 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1302 Control Features 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Requirements 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1302 Control System 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Module 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Run/Off/Auto Switch 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel Connections 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Inputs and Outputs 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Inputs 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Outputs 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Protection and Faults 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Codes 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Protective Functions 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Protection 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Protection 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Draw 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Running Mode 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parade Rest Mode 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleep Mode 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Installation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting Guidelines 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Capability 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1302 Main Control Board 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1302 Operator Panel 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Wiring Information 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guidelines for Current Transformers 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Transformer Selection 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of CT Sizing − Two Lead CT 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Example of CT Sizing − Three Lead CT 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Transformer Setup 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two Lead CT Setup Example: 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Three Lead CT Setup Example 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging Alternator Connections 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Denso Type Charging Alternators 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bosch Type Charging Alternators 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Connections 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series Star 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Series Delta 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parallel Star 3-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Double Delta 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Single Phase 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Guidelines for Engine Sensors 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Coolant Temperature Sensors 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Sensors 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lube Oil Pressure Switch 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Board Connections 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor Connections 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Kit Installation 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup, Trims, and Adjustments 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Control Adjustments 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AVR Enable/Disable Feature 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Output Voltage Regulation 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque-Matched Volts/Hz Overload Control 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battleshort Mode 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Tuning 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
V/Hz Curve 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Tuning 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Startup 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Startup 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup for Gain Tuning 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gain Tuning Parameters 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Calibration 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1302 Control Functions 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Mode 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12/24V Battery 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Starting 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Cranking 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spark Ignition Power/Glow Plug Control 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug Control 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preheat Processing 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug Output Logic 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start and Stop Time Delays (Cool Down) 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Speed Sensing 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed Governor Algorithm and Adjustment 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Real Time Clock 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Excerise Scheduler 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATS Control 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dual Fuel 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battle Short Mode Option 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations With an Operator Panel 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations Without an Operator Panel 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battle Short Mode 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations with an Operator Panel 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations without an Operator Panel 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. Operator Panel Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Status Output Indicator 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Modes 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Run Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auto Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sleep Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations with an Operator Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installations with a Manual Run/Off/Auto Switch 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graphical Display 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Text / Symbolic Versions 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Menu Selection Buttons 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Previous Main Menu Button 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Off Button 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not In Auto Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Start Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Auto Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Run Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Panel System Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Event Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Messages 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Reset / Acknowledgement 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault/Status Codes 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Default Settings 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Saving Your Changes 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operator Menus 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Status Menu 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Status Menu 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Line-to-Line Voltage Menu 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Line-to-Neutral Voltage Menu 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Single Phase Voltage Menu 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Amperage Menu 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Auto, Manual Run, and Off Modes 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Entering the Mode Change Access Code 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Auto Mode 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selecting Manual Run Mode 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aborting the Transition to Auto or Manual Run Mode 4-23. . . . . . . . . . . . . . . . . . . . . .
Selecting Off Mode 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Menus 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status Menu 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Status Menus 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History / About Menus 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
History Submenu 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Genset Submenus 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Control Submenu 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About Display Submenu 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault History Menu 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Adjust Menu 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Values/Parameters 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Screen Adjust Menu 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. 1302 Control Panel Service Menus 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Menus 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup Menus 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Service Menus 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viewing Only 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Navigation 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viewing and Adjusting 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv
SECTION TITLE PAGE
Setup Password Submenu 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Values/Parameters 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Service Submenus 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Menu, Part 1 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Menu, Part 2 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start/Stop Delay Menu 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cycle Crank Menu 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battle Short Menu 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AVR Setup Menu 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governer Menu, Part 1 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governer Menu, Part 2 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Number Menu 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display Setup Menu 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volts and Hertz Menu 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic Voltage Regular Submenus 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Volts/Hz Rolloff Menu 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator Gains Menu 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator Gains Menu 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor Submenus 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Crank Fuel Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor Regulator Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electronic Governor Enable Speed Menu 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer I/O Submenus 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Input Function Selection 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Inputs 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Input Active State Selection 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Customer Outputs 5-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metering Submenus 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Meter Calib Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freq. Adjust Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metering Voltage Adjust Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Metering Current Adjust Menu 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annunciator Submenus 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annunciator Inputs 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Annunciator Outputs 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ModBus Submenus 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ModBus Enable 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ModBus Setup 5-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Setup Submenus 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viewing Only 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Menu Navigation 5-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Viewing and Adjusting 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
v
SECTION TITLE PAGE
Genset Setup Password Submenu 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Values/Parameters 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Menus 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Menu 1 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Menu 2 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Application Rating Select Menu 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standby kVA Rating Menu 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Prime kVA Rating Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Select Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Threshold Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Delay Setup Menu 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Setup Menus 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Select Menu 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Thresholds Menu 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Delay Setup Menu 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil Pressure Setup Menus 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Protection Submenus 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High AC Voltage Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low AC Voltage Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overfrequency Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Underfrequency Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alternator Protection 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Protection Submenus 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High AC Current Menu 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Protection Submenus 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Protection Overspeed Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Protection Speed/Frequency Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure Warning Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Oil Pressure Shutdown Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Coolant Temperature Warning Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Coolant Temperature Shutdown Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Protection Low Coolant Temperature and Battery Charger Menus 5-53. . . .
6. Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Based Service Tool 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Applications and Configurable Inputs 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Considerations 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Fault Codes 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reading Fault Codes Using Optional Operator Panel 6-2. . . . . . . . . . . . . . . . . . . . . . .
Reading Fault Codes Using the Control Switch Indicator 6-2. . . . . . . . . . . . . . . . . . . .
Troubleshooting Procedures 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage/Continuity Testing 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vi
7. Wiring Diagrams 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A. 1302 Menu System Maps A-1
Appendix B. Index B-1
General Information B-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information B-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information B-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
vii
Foreword
The purpose of this manual is to provide the users with general control operation and fault code information.
Refer to the equipment manufacturer’s product support manuals for important safety precautions.
Manufacturers applying this control are respectfully advised that it is their responsibility to employ competent persons to carry out any installation work in the interests of good practice and safety. It is essential that
the utmost care is taken with the application of this control device.
Warranty
Warranty: This manual is published solely for information purposes and should not be considered all inclu-
sive. Sale of product shown or described in this literature is subject to terms and conditions outlined in appropriate Cummins Power Generation selling policies or other contractual agreement between the parties.
This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and
Cummins Power Generation.
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS,
AND DESCRIPTIONS CONTAINED HEREIN.
In no event will Cummins Power Generation be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental, or consequential damage
or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system,
cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the
purchaser or user by its customers resulting from the use of the information, recommendations, and descriptions contained herein.
viii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator and batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.
DANGER
This symbol warns of immediate
hazards which will result in severe personal injury or death.
WARNING
This symbol refers to a hazard or
unsafe practice which can result in severe personal injury or death.
CAUTION
This symbol refers to a hazard or
unsafe practice which can result in personal injury or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from improper practices.
DO NOT fill fuel tanks while engine is running, un-
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential fire hazard.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source
near the generator set or fuel tank.
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be
made with an approved flexible line. Do not use
zinc coated or copper fuel lines with diesel fuel.
Be sure all fuel supplies have a positive shutoff
valve.
Be sure battery area has been well-ventilated prior
to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by
arcing, sparking, smoking, etc.
EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properly
expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are
secured and not warped. Do not use exhaust
gases to heat a compartment.
Be sure the unit is well ventilated.
Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
moving parts.
Before starting work on the generator set, discon-
nect battery charger from its AC source, then disconnect starting batteries, negative (−) cable first.
This will prevent accidental starting.
Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
Do not wear loose clothing or jewelry in the vicinity
of moving parts, or while working on electrical
equipment. Loose clothing and jewelry can become caught in moving parts.
If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed
and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can
be created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power
Generation distributor for more information.
ix
LS-14L
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical contacts and cause shock or burning.
Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical
codes. Have all electrical installations performed
by a qualified licensed electrician. Tag and lock
open switches to avoid accidental closure.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator
set into the utility line. This creates a potential for
electrocution or property damage. Connect only
through an approved isolation switch or an approved paralleling device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling
point than water. DO NOT open a radiator or heat
exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the
system pressure first.
Used engine oils have been identified by some
state or federal agencies as causing cancer or reproductive toxicity. When checking or changing
engine oil, take care not to ingest, breathe the
fumes, or contact used oil.
Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels;
Class C fires, live electrical equipment. (ref. NFPA
No. 10).
Make sure that rags are not left on or near the gen-
erator.
Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under the unit.
Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.
Keep the generator set and the surrounding area
clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.
Do not work on this equipment when mentally or
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment unsafe.
Substances in exhaust gases have been identified
by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
explosion could result.
Wear hearing protection when going near an oper-
ating generator set.
To prevent serious burns, avoid contact with hot
metal parts such as radiator, turbo charger and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
x
LS-14L
1. Introduction
ABOUT THIS MANUAL
This manual provides installation and operation information regarding the 1302 series control. This
manual includes information for the following types
of installations.
Kit 541−1414−01 is for Hydro Mechanical
(HM) engines.
Kit 541−1414−02 is for Full Authority Elec-
tronic (FAE) engines. FAE engines have an
external Electronic Control Module (ECM).
This manual does not have instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is
faulty, replace it. Do not repair it. Attempts to repair
a printed circuit board can lead to costly equipment
damage.
This manual contains basic (generic) wiring diagrams and schematics that are included to help in
troubleshooting. Service personnel must use the
actual wiring diagram and schematic shipped with
each unit. The wiring diagrams and schematics
that are maintained with the unit should be updated
when modifications are made to the unit.
Read Important Safety Precautions and carefully observe all instructions and precautions in this
manual.
SYSTEM OVERVIEW
The 1302 series control is a microprocessor-based
control. All generator set control functions are contained on one circuit board. The circuit board provides engine speed governing (optional, when the
governor output module and appropriate engine
equipment is provided), main alternator voltage
output regulation, and complete generator set control protection and monitoring.
The operating software provides control of the generator set and its performance characteristics, and
displays performance information on an optional
operator panel. It accepts menu-driven control and
setup input from the push button switches on the
operator panel.
CERTIFICATIONS
The 1302 series control meets or exceeds the requirements of the following codes and standards.
NFPA110 for level 2 or 3 systems
ISO 8528−4: 1993 Compliance, Controls
and Switchgear
CE Marking: The control system is suitable
for use on generator sets to be CE−marked
EN 50081−1,2 Residential/Light Industrial
emissions or Industrial Emissions
EN 50082−1,2 Residential/light industrial or
Industrial susceptibility
ISO 7637−2, level 2; DC supply surge volt-
age test
Mil Std 202C, Method 101 and ASTM B117:
Salt Fog test
This control is suitable for use on generator sets
that are UL2200 listed.
Connector Seal Standards
The following standards apply to the connector
seals used with the 1302 series control.
J11, J25, and J20 − AMP 794758-1
J12 − AMP 794275−1 Interface seal and
AMP 794276−1 Wire seal (both are required)
J17 − AMP 794269−1 Interface seal and
AMP 794276−1 Wire seal (both are required)
J18 − AMP 794271−1 Interface seal and
AMP 794276−1 Wire seal (both are required)
HOW TO OBTAIN SERVICE
Contact your generator set manufacturer when
seeking additional service information or replacement parts. Provide model and serial number information.
WARNING
parts can result in severe personal injury or
death, and/or equipment damage. Service personnel must be qualified to perform electrical
and mechanical service. Read and follow Important Safety Precautions, on pages v and vi.
Incorrect service or replacement of
1-1
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1-2
2. Description
FIGURE 2-1. 1302 MAIN CONTROL BOARD AND OPERATOR PANEL (HMI211)
OVERVIEW
The PCC1302 controller is a microprocessor−
based generator set (genset) monitoring, metering, and control system. The control provides a
simple operator interface to the genset’s digital
voltage regulation, engine speed governing, remote start / stop control, and protective functions.
The PCC1302 control is suitable for use on hydro
mechanical or FAE engines. It can be used in nonparalleling applications and it is compatible with reconnectable alternators up to 600VAC. The control
can also be configured for various frequency (50 /
60 Hz operation), voltage, and power connection
configurations from 190−600 VAC L-L.
The control is designed for mounting on the generator set. The 1302 series control is usually powered from the generator set starting batteries and
works over a voltage range from 8 to 30 VDC.
The 1302 series control meets NFPA 110 requirements (with appropriate accessories) and is designed for connection to a 12 or 24 VDC control
system.
An optional operator panel can be used as a user
interface.
KIT DESCRIPTION
The 1302 genset control kits include the 1302 control board (12/24V control assembly with run and
start relay drivers) and the operator panel shown in
Figure 2-1. Also included in these kits are the following sensors and harnesses.
Quantity
Description
Oil Pressure Sensor 1 —
Temperature Sensor 1 —
Coolant Temperature
Sensor Harness
Oil Pressure Sensor
Harness
Control Panel to
PCC1302 Harness
Engine Harness 1 1
Genset AC Harness 1 1
HM Kit
541−1414−01
1 —
1 —
1 1
FAE Kit
541−1414−02
2-1
ADDITIONAL EQUIPMENT
Figure 2-1 shows the 1302 control module (327−
1617−01) and the optional HMI211 digital display
panel (300−6014). If your installation is to include
any additional equipment (see Figure 2-2), the appropriate kit(s) must be purchased separately.
HMI112 LED Bargraph − Kit 541−1319 (In-
cludes Instruction Sheet C697)
HMI113 Universal Annunciator − Kit
300−5929 (Includes Operator’s Manual
900−0301)
AUX101 System I/O Module − Kit 541−1291
(Includes Instruction Sheet C693)
AUX104 External Governor Power Module −
Kit 541−1231 (Includes Instruction Sheet
C689)
HMI112 LED BARGRAPH
(300−6050−02)
AUX101 SYSTEM I/O MODULE
(327−1536)
HMI113 UNIVERSAL ANNUNCIATOR
(300−5929)
FIGURE 2-2. ADDITIONAL EQUIPMENT
AUX104 EXTERNAL GOVERNOR
POWER MODULE (327−1507)
2-2
1302 CONTROL FEATURES
The 1302 series controller includes the following
features.
Operates on 12 or 24 VDC.
Electronic Governor Enable/Disable (via an
external Governor Power Module).
Configurable Inputs and Outputs. Four dis-
crete configurable inputs and two dry contact
relay outputs.
Relay driver output for glow p
controller, switched B+, FSO, Starter, Ready to
Load, Local Status, and Keyswitch control.
lug or spark igniter
Current Requirements
FAE Engine support utilizing partial PGI CAN
protocol support.
Automatic Voltage Regulator (AVR) Enable/
Disable.
PMG or Shunt Excitation methods supported.
PCCNet Communications.
ModBus Communications.
Digital speed governing.
Digital voltage regulation.
Low power sleep mode, with configurable
Wake-In-Auto mode.
Phase voltage and current sensing. Wye and
Delta voltage sensing single phase. Current
sensing with an external 0−5 amp current
transformers.
Engine relay drivers.
Generator set monitoring. Display status of all
critical engine and alternator generator set
functions.
Genset protection – Engine and Alternator
protection features.
The 1302 series control consumes 0.150 Amps of
current while in idle mode. While in the running
mode, it consumes 0.75 Amps of current. This
doesn’t include other application specific devices
such as the optional operator panel, external
actuators, relay coils, or display lamps.
1302 CONTROL SYSTEM
Control Module
The basic control system for the generator set
consists of a single control board with an external
control switch and status indicator.
The control board includes all the functions
necessary to locally or remotely start and stop the
Genset, provide digital voltage regulation, and
protect the Genset.
To use the electronic governor feature, an external
governor power stage may be required to drive the
fuel actuator.
Control Run/Off/Auto Switch
Off Mode − If the control is in the OFF mode, the
generator set is immediately shut down (if running)
and can’t be started. When in OFF mode, all active
faults are reset.
Operator Panel Display (optional). Provides
easy to use operator display of critical genset
parameters and operating history.
Advanced serviceability using a PC based
software service tool.
Environmental protection. The control system
is designed for reliable operation in harsh environments. The core control board is potted
module that is fully protected from the elements.
Run Mode − If the control is in the RUN mode, the
generator set will execute its start sequence and
operate at rated speed and voltage.
Auto Mode − If the control is in AUTO mode, the
generator set can be started with a start signal from
a remote device, such as an automatic transfer
switch by accepting a ground signal.
Fault Reset − Placing the switch in the OFF posi-
tion also resets the active/inactive faults in the control.
2-3
OPERATOR PANEL
The 1302 series control is provided with an optional
operator panel that may be either locally or
remotely mounted. The operator menus are made
up of English or internationally accepted symbols
so translations are not required. The display is
composed of an adjustable contrast backlit LCD
display, with a series of 6 generator status LED
lamps. The display is accompanied by a set of six
tactile feel membrane switches that are used by the
operator to navigate through control menus, and to
make control adjustments. It is configurable for
units of measurement.
The Run/Off/Auto switch function is integrated into
the operator panel; therefore an external switch is
not required when a operator panel is installed. The
operator panel displays current active faults, and a
time-ordered history of previous faults.
Operator Panel Connections
Two connectors (J1 and J2) are located on the
back of the operator panel (see Figure 2-3).
Connections are listed in Table 2-1.
NOTE: J1 and J2 are identical. Either one can be
used for the harness connection between
the main control board and the operator
panel.
PIN 1
J1-4
FIGURE 2-3. 1302 OPERATOR PANEL
TABLE 2-1. OPERATOR PANEL CONNECTIONS
Connector Pin
J1-1 RS-485 Data A Network Data A
J1-2 RS-485 Data B Network Data B
J1-3 B+ Network Supply
J1-4 PCCNet System Wake Up System Wakeup
J1-5 Return Network Supply Return
J1-6 Run Output
J1-7 Auto Output
J1-8
Signal Name Connect To / Comments
J1
J2
1
2
3
4
5
6
7
8
J1 or J2
2-4
CONTROL INPUTS AND OUTPUTS
Control Inputs
Input signals to the main control board are:
Run/Off/Auto switch
Remote start signal
Remote emergency stop
Local emergency stop
Coolant temperature signal
Lube oil pressure signal
Battery voltage signal
PCCNet System Wake Up Input
Magnetic pick up signal
Starter disconnect signal
Single or three-phase current transformers
(CTs)
Single or three phase line-to-neutral voltage
Configurable inputs – The control includes
four inputs that have configurable functions.
Once mapped, each configurable input can be
used as a fault input, remote fault reset input,
battleshort input, or disabled.
Control Outputs
Output signals from the control are:
Control status lamp.
Configurable relay outputs (OUT1_NO and
OUT2_NO) − The control includes two relay
outputs rated at two amps. These outputs can
be configured to activate on any control warning or shutdown fault as well as ready to load,
not in auto, common alarm, common warning,
and common shutdown.
Ready to load (generator set running) signal –
This output pin goes low when the genset is
capable of supporting a load. The genset
speed and voltage output are what determines
the state of this pin.
Communications connections − The control
includes two RS-485 ports.
− PC Tool Interface – This communication
port (TB15) allows the control to communicate with a personal computer running a PC based service tool. This port
also allows the control to communicate
with external devices, such as a Programmable Logic Controller (PLC) via
the ModBus protocol.
− PCCNet − This communications port
(TB1) allows for connection from the
control to the optional operator panel,
universal annunciator, LED bargraph,
and system I/O module.
Local status – Refer to “Local Status Output In-
dicator” on page 4-1.
Battery charging alternator – Alternator flash
connection
Fuel shut-off relay driver
Starter relay driver
Keyswitch relay driver
Glow plug relay driver
Governor drive PWM command
Field coil − AVR PWM command
Excitation source − Input power for field coil
Alternator line voltage sensing − 600 VAC
RMS max
Switched B+ driver
2-5
PROTECTION AND FAULTS
The 1302 series control features genset protection
functions and fault detection.
Upon operation of a protective function, the control
will indicate a fault by flashing the fault code on the
local status lamp driver (J25−1). On systems with
an optional operator panel, the warning or
shutdown LED lights and the fault symbol and code
is displayed on the display. The nature of the fault
and time of occurrence is logged in the control. The
service manual and PC based service tool provide
service keys and procedures based upon the
service codes provided.
Fault Codes
A list of fault/status codes is included in Section 4.
Shutdown faults will shutdown the genset. Warning
faults are issued to notify the genset operator of the
problem but the 1302 series control will not shutdown the genset when they occur.
Genset Protective Functions
The control provides the following system protective functions:
Configurable Alarm and Status Inputs – The
1302 series control accepts up to four alarm or
status inputs (configurable contact closed to
ground or open) to indicate customer-specified conditions. The control is programmable
for warning, shutdown, or status indication,
and for labeling the input.
Emergency Stop − Annunciated whenever the
emergency stop signal is received from an external switch.
Engine Protection
PC based service tool or through the display
panel menus) to match the capabilities of the
engine used. The control includes time delays
to prevent nuisance warning/shutdown signals.
Low Coolant Temperature Warning − This
warning indicates that the engine temperature
may not be high enough for a 10-second start
or proper load pickup. The level is preset (configurable with a PC based service tool or
through the display panel menus) to match the
capabilities of the engine used. The control includes time delays to prevent nuisance warning signals.
Low Battery Voltage Warning − This warning
indicates a battery charging system failure by
continuously monitoring battery voltage. The
control includes time delays to prevent nuisance warning signals.
High Battery Voltage Warning – This warn-
ing indicates that the battery charging system
is of a high level by continuously monitoring
battery voltage. The control includes time delays to prevent nuisance warning signals.
Weak Battery Voltage Warning − The control
system tests the battery bank each time the
generator set is signaled to start. A warning is
announced if the generator set battery indicates impending failure. The control includes
time delays to prevent nuisance warning signals.
Dead Battery Voltage Shutdown −Indicates
battery voltage drop during cranking which resets control for three consecutive times (This
feature
3.0 onwards )
Fail to Start (Overcrank) Shutdown.
is available in 1302 calibration version
Overspeed Shutdown – The engine over-
speed default setting is 115% of the rated engine speed nominal. The control includes time
delays to prevent nuisance shutdown signals.
Low Lube Oil Pressure Warning/Shutdown
− The level is preset (configurable with a PC
based service tool or through the display panel
menus) to match the capabilities of the engine
used. The control includes time delays to prevent nuisance warning/shutdown signals.
High Engine Temperature Warning/Shut-
down − The level is preset (configurable with
Fail to Crank Shutdown − This shutdown in-
dicates that the control signaled the starter to
crank the engine but the engine did not rotate.
Cranking Lockout − The control will not allow
the starter to attempt to engage or to crank the
engine when the engine is rotating (when the
control senses the valid engine RPM above
the noise threshold value.)
Sensor Failure Indication – An out-of-range
high or low diagnostic logic is provided on the
base control to detect analog sensor or interconnecting wiring failures.
2-6
Alternator Protection
High/Low AC Voltage Shutdown − The high
voltage default setting is 110% of the rated
voltage with a 10 second time delay. The
instantaneous voltage default setting is 130%
of the rated voltage. The low AC voltage default setting is 85% of the rated voltage with a
10 second time delay.
Overcurrent Warning/Shutdown − Imple-
mentation of the thermal damage curve with
an instantaneous trip level is calculated based
on the Current Transformer Ratio and the Application Power Rating (see Figure 2-4).
Alternator
Thermal
Damage Curve
Overcurrent
Protection
Curve
Under/Overfrequency − The underfrequen-
cy default is − 6Hz of the 50 Hz / 60 Hz frequency with a 10 second time delay. The overfrequency default is + 6Hz of the 50 Hz / 60 Hz frequency with a 10 second time delay.
Loss Of Sensing AC Voltage Shutdown –
Loss of sensing AC voltage detects the loss of
voltage sensing or senses the loss of zero
crosses. This fault will also be the primary way
to detect short circuit conditions.
Overexcitation Shutdown – Overexcitation
is used to detect short circuit alternator faults.
CURRENT DRAW
The current draw information below is for the 1302
series control only. It does not include current draw
for other application specific devices, such as the
optional operator panel, external actuators, relay
coils, or display lamps.
Running Mode
10
Seconds
1
Instantaneous
Trip Point
0.03
101
Amps (x rated)
FIGURE 2-4. ALTERNATOR PROTECTION
THERMAL DAMAGE CURVE
When in Running mode, the 1302 series control
consumes .750 amps of current.
Parade Rest Mode
Parade Rest mode is when the 1302 series control
is waiting for a start command (for example, the
genset is not running). During Parade Rest mode,
the control consumes 150 milliamps of current.
Sleep Mode
The 1302 series control enters Sleep mode after
five minutes in the Off or Auto mode. During Sleep
mode, the control consumes 60 milliamps of current.
2-7
THIS PAGE INTENTIONALLY LEFT BLANK
2-8
3. Installation
Read these instructions completely and become
familiar with safety warnings, cautions, and procedures before starting the installation.
WARNING
replacement of parts can result in severe personal injury or death and/or equipment damage. Only trained and experienced personnel
are to perform the following procedures.
CAUTION
serviced only by technically qualified personnel. High voltages are present. These voltages
can cause electrical shock, resulting in personal injury.
Even with power removed, improper handling
of components can cause electrostatic discharge and damage to circuit components.
WARNING
an electrical shock hazard that can cause severe personal injury or death. Incorrect installation, service, or parts replacement can result
in severe personal injury, death, and/or equipment damage.
Turn off or remove AC power from the battery charger (if present) and then remove the negative (−)
battery cable from the set starting battery. This is to
make sure the genset will not start while working on
it and to avoid circuit board damage, caused by
voltage spikes when removing and replacing circuit
board connectors.
CAUTION
tery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes
high enough to damage the DC control circuits
of the generator set.
WARNING
tor set while working on it can cause severe
personal injury or death. Prevent accidental
starting by disconnecting the starting battery
cables (negative [−] first).
Make certain the battery area has been wellventilated before servicing the battery—Wear
goggles—Stop the genset and disconnect the
Incorrect installation, service, or
A generator set control must be
AC voltages and currents present
If present, always disconnect a bat-
Accidental starting of the genera-
charger before disconnecting battery cables.
Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur when a cable is removed
or re-attached, or when the negative (−) battery
cable is connected and a tool used to connect
or disconnect the positive (+) battery cable
touches the frame or other grounded metal part
of the generator set. Always remove the negative (−) cable first, and reconnect it last. Make
certain hydrogen from the battery, engine fuel,
and other explosive fumes are fully dissipated.
This is especially important if the battery has
been connected to a battery charger.
WARNING
can cause severe personal injury or death. Arcing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can
ignite battery gas. Do not smoke, or switch
trouble light ON or OFF near a battery. Discharge static electricity from body before
touching batteries by first touching a grounded
metal surface.
Ignition of explosive battery gases
MOUNTING GUIDELINES
The main control board and the optional operator
panel are suitable for non-engine mounting. As
such, they should not be directly mounted on the
engine.
The control and operator panel may be mounted on
one of the following.
A suitable frame on top of the alternator
A frame supported from the genset base rail
A stand-alone mounting frame isolated from
the vibration of the genset
Appropriate vibration isolators should be used to
make sure that neither the main control board, the
operator panel, nor customer wiring are subjected
to vibration levels beyond their capability.
To prevent the control board and the optional operator panel from being exposed to conditions beyond their specifications, care should be taken not
to mount them close to the engine exhaust pipes.
Mounting them in a manner that would expose
3-1
them to direct sunlight or rain/snow should also be
avoided.
It is recommended that the control board be
mounted with the longer side horizontal and the
shorter side vertical so as to allow air to move freely
upwards through the heat sink channels. Mounting
the control board with the short side horizontal and
the longer side vertical should be avoided.
Amplitude (Gs)
LCD Vibration Profile
10
1
ENVIRONMENTAL CAPABILITY
The control system is specifically designed and
tested for resistance to RFI / EMI and to resist the
effects of vibration to provide a long reliable life
when mounted on a generator set. The control includes transient voltage surge suppression to provide compliance to referenced standards.
1302 Main Control Board
The main control board is designed to withstand
vibration levels of 50 mm / sec in the 20−100 Hz
range and of 3.3 G in the 100−2000 Hz range.
The main control board is designed for proper operation without recalibration in ambient temperatures from –40 to +70 Deg C, and for storage from
–55 to +80 Deg C. The control is designed to operate with humidity up to 95%, non-condensing, and
at an altitude up to 13,000 feet (5000 meters).
The main control board is fully encapsulated to provide resistance to the effects of dust and moisture.
1302 Operator Panel
The optional operator panel is designed to withstand vibration levels of 40 mm / sec in the 4−100
Hz range and the engine vibration levels shown in
Figure 3-1.
The operator panel is designed for proper operation in ambient temperatures from −4 to 158 Deg F
(–20 to +70 Deg C) and for storage, from −22 to 176
Deg F (–30 to +80 Deg C).
The operator panel has a single membrane surface, which is impervious to the effects of dust,
moisture, oil, and exhaust fumes.
0.1
0 50 100 150 200 250
Frequency (Hz)
FIGURE 3-1. OPERATOR PANEL VIBRATION
LIMITS
CONTROL WIRING INFORMATION
For connecting the Magnetic Pickup, use mini-
mum 0.8 sq. mm (18 gage), 2 conductors,
twisted shielded cable. Connect the shield at
J11-8 and leave the shield un-connected at the
magnetic pickup side of the cable.
For connection the ECM CAN, use minimum
0.8 sq. mm (18 gage), 2 conductors, twisted
shielded cable. Connect the shield at
J11-17and leave the shield un-connected at
the ECM side of the cable.
For connecting the PCCNet, use minimum 0.8
sq. mm (18 gage), 2 conductors, twisted
cable.
For connecting the battery supply, use two
twisted pair wires (16 AWG).
For connecting current transformers, use
three twisted pair wires minimum (16 AWG).
For all other connections, use minimum 0.8 sq
mm (18 gauge) wires.
The Electronic Governor feature typically re-
quires an external Governor Output Module
Kit. Governor PWM output from the 1302 series control board is connected as input to the
Governor Power Module by a minimum 0.8 sq.
mm (18 gage), 2 conductors, twisted shielded
cable.
3-2
GUIDELINES FOR CURRENT
TRANSFORMERS
All current transformers (CTs) used with a 1302 series control must conform to the following specifications.
Continuous rated full load secondary output
current: 5 amps at 50 or 60Hz
Total burden VA rating: at least 2.5 VA
Output terminals between which current is
drawn in high and low ranges on tapped CTs.
Maximum allowable ratio error at rated output:
+/−1%
Maximum allowable phase error at rated out-
put: +/−1
10-second overload output current in rated
metering load: 10 Amps
Maximum allowable ratio error at overload
output: +/−1%
Ambient temperature rating: −40 to 176 Deg F
(−40 to +80 Deg C)
System voltage rating − 600VAC
NOTE: in PCC1302,if trim parameter
Current Multiplier 2X Enable is
enabled and only one of the two
alternator winding phase cables
is routed through CT, then the current measurement calculation will
be multiplied by 2 to show the correct reading of the load current.
Current Transformer Selection
Current transformers (CTs) used in 1302 control
applications are ideally sized to produce rated CT
secondary amps at twice rated generator (full
200% range) output amperes. In other words,
when the generator is producing 100% output amperes, the secondary current of the CTs is 2.5 amperes per phase. This requirement determines a
lower bound of the CT ratio. An upper bound is determined by requiring that, at 100% rated output
current, the CTs secondary current is at least 1 ampere. The purpose of this is to maintain sufficient
metering resolution. The lower and upper bound of
the CT limits are prescribed by the following two
formulas.
Minimum CT Ratio =
Maximum CT Ratio =
2 * Max_Rated_Current
5
5 * Min_Rated_Current
5
In non-reconnectable genset applications, the
Max_Rated_Current and Min_Rated_Current are
the same. In reconnectable genset applications,
they are different.
Example of CT Sizing − Two Lead CT
A 250kVA rated genset application at 240V produces rated output current of 602 amps/phase.
This yields a Minimum CT Ratio of 1204:5 and a
Maximum CT Ratio of 3010:5. Any CT with a ratio
between these two values would be sufficient for
this application.
3-3
Example of CT Sizing − Three Lead CT
A reconnectable generator capable of 208−240/
416−480V outputs with a 125 kVA 3-phase only rating.
You first need to find the current in each phase for
each output voltage. This is done using the following formula:
VAPower
Voltage
WPower
)(
)(
VoltageFactorPower
*_*3
*3
or
Current
Current
Using the above equation, the current in each
phase is computed as shown below.
1. Enter an appropriate value in the CT ratio pa-
rameter on the operator panel.
2. Select a feature to be downloaded using the
Manufacturing Tool.
3. Program an appropriate value in the Primary
CT Current parameter using a PC-based service tool (for example, InPower).
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedThe 1302 series control automatically
doubles the entered CT ratio when switching from high nominal voltage (above
300V) to lower nominal voltage (below
300V).
Voltage (V) Output Current (A)
208 346.376
240 300.192
416 173.188
480 150.096
The next step is to use the equations on page 3-3
to find the lower and upper bound for the CT ratios
for each voltage configuration.
For a 208−240 voltage configuration:
Maximum CT Ratio
Minimum CT Ratio
96.1500192.300*5
752.692376.346*2
For a 416−480 voltage configuration:
Maximum CT Ratio
Minimum CT Ratio
8.754096.150*5
376.346188.173*2
For three-tap CTs, it would be advisable to choose
a CT with a 1500/750:5 ratio.
For the 208−240 voltage configuration, connect
the CT leads to the 1
st
and 3rd CT connections,
leaving the center tap disconnected.
For the 416−480 voltage configuration, use the
same 1500/750:5 ratio CT, but this time connect
the CT leads to the first and second (center-tap)
connections on the CT, leaving the third tap unconnected.
Current Transformer Setup
When entering a CT ratio the following rules apply:
Two Lead CT, above 300V application − Enter
CT ratio as read from the CT.
Two Lead CT, below 300V applications − Enter
HALF of the CT Ratio as read from the CT.
Three Lead CT (Center Tapped) – Enter the
SMALLER of the two ratios as read from the
CT.
Two Lead CT Setup Example:
For this example, assume a CT with a 1500:5 ratio
is being used.
Operator Panel
Above 300V applications − Enter 1500 into the
CT ratio parameter on the operator panel.
Below 300 V applications − Enter 750 into the
CR ratio parameter on the operator panel.
Manufacturing Tool
Above 300V applications − Select a feature
corresponding to 1500:5 to download using
the Manufacturing Tool.
Below 300 V applications − Select a feature
corresponding to 750:5 to download using the
Manufacturing Tool.
PC-Based Service Tool
Above 300V applications − Enter 1500 into the
Primary CT Current parameter, using the PCbased service tool (e.g. InPower).
After the 1302 series control kit has been installed,
the controller must be programmed to use the CT
by one of the following methods.
Below 300V applications − Enter 750 into the
Primary CT Current parameter, using the PCbased service tool (e.g. InPower).
3-4
In PCC1302 Control, Voltage Calibration
procedure is divided into three processes
as described below:
1. Meter Calibration: There are two sets of AC in-
puts on the 1302: L1−N, L2−N, and L3−N (or
L1−2, L2−3, L3−1 for delta) AND 3 phase average voltage. The metering calibration will calibrate L1−N, L2−N, L3−N., which is used for
display and diagnostic purposes. Method:
Verify each phase on PCC matches external
calibrated meter. This calibration should be
done first.
2. Regulation Calibration: This calibrates the 3
phase average voltage, which is used for regulation. Method: Verify the 3 phase average
voltage of the genset matches an external meter’s voltage. Special note: When changing
the regulation feedback calibration, the PCC’s
feedback will appear to say the same, and the
external meter’s value will change. This is because the PCC regulator is active, and is making what the PCC sees be the PCC’s Setpoint.
3. Voltage Adjust: Once both the metering and
voltage calibration is done, you use the voltage adjust to modify the PCC’s voltage Set-
point ( i.e. for example: If the user wants the
PCC to output 215VAC instead of 220VAC)
Procedure of calibrating the Alternator
Voltages is as follows:
Safety Precautions:
1. Contacting high voltage components can
cause electrocution, resulting in severe personal injury or death. Calibration and adjustment must be performed by technically qualified personnel only. Read and observe all the
Warnings and Cautions in your generator set
manuals.
2. Improper calibration and adjustment of the
PCC can cause equipment malfunction or
damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
One or more of the PCC’s internal circuits may
need to be calibrated, in which case you should calibrate the internal circuits in the following order
listed in the table shown below:
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be used.
3-5
Component to be calibrated
p
Meter Calibration or Voltage measurement for display
TABLE 3-1. CALIBRATION
Calibration method
PC based service tool Operating panel
1. Connect to the control with your
PC based service tool.
2. Verify the nominal voltage trim is
set to the desired value. The trim Alternator Nominal Voltage is available
at Adjustments −> AC Measurement
Calibrations −> Voltage Measurement for Regulation. Set the Alternator Nominal Voltage to the voltage
that the genset will generate.
3. With the genset OFF, attach a calibrated Voltmeter to the AC Output
from L1 to L2. (L1 to Neutral for
single phase alternators).
4. Start the genset and allow it to
reach normal operating speed.
5. Calibrate voltage reading for L1 by
adjusting the trim Alternator L1−N
50Hz Voltage Display Adjust or Alternator L1−N 60Hz Voltage Display
Adjust trim for your application, so
that the reading on the display
agrees with the calibrated voltmeter.
6. Shut the generator set OFF.
7. Repeat Step 3 to Step 6 for L2
and L3 (In Step 3 attach meter to the
AC output from L2 to L3 to calibrate
L2 and L3 to L1 to calibrate L3) by
adjusting the trims Alternator L2−N
50Hz Voltage Display Adjust or Alternator L2−N 60Hz Voltage Display
Adjust trim and Alternator L3−N
50Hz Voltage Display Adjust or Alternator L3−N 60Hz Voltage Display
Adjust trim respectively.
8. Save the adjustments by doing a
Save Trims with your PC based service tool.
1. View the service menu by holding
down the ”up” and ”down” arrow keys
on any of the operating menus.
2. Select item 1, ”Setup Menu”.
3. Enter Setup menu password
”574”.
4. Select item 1, ”Genset Service”.
5. Select item 1, and verify the ”Volts
AC” setting is correct for your application. If necessary press the ”Adjust” button and change the setting,
and press the ”Save” button.
6. Press the back button to return to
service menu.
7. With the genset OFF, attach a calibrated Voltmeter to the AC Output
from L1 to L2. (L1 to Neutral for
single phase alternators).
8. Start the genset and allow it to
reach normal operating speed.
9. Select item 3, ”Meter Calib”.
10. Press the down arrow twice to
scroll down to the ”Metering Voltage
Adjust”
11. Adjust the three parameters one
by one listed so that the reading on
the display agrees with the calibrated
voltmeter.
12. Shut the generator set OFF.
13. Repeat Step 7 to Step 12 for L2
and L3 (In Step 3 attach meter to the
AC output from L2 to L3 to calibrate
L2 and L3 to L1 to calibrate L3) by
adjusting the trims Alternator L2−N
50Hz Voltage Display Adjust or Alternator L2−N 60Hz Voltage Display
Adjust trim and Alternator L3−N
50Hz Voltage Display Adjust or Alternator L3−N 60Hz Voltage Display
Adjust trim respectively.
14. Save the adjustment by pressing
the ”Save” button.
3-6
Regulation Calibration or Voltage
measurement for regulation
Voltage Setpoint Adjustment 1. Connect to the control with your
NOTE:
1. Meter Calibration is what all the diagnostics use and the display shows, while Regulator Calibration it the
feedback going to the AVR. Thus Meter Calibration and the Regulator calibration shall be done when the
PCC1302 control is initially calibrated or if the boards are swapped / replaced with the new ones.
2.Voltage Setpoint adjustment shall be carried out as and when required to move the voltage Setpoint.
1. Connect to the control with your
PC based service tool.
2. Verify the nominal voltage trim is
set to the desired value.
3. With the genset OFF, attach a calibrated Voltmeter to the AC Output
from L1 to L2.
4. Start the genset and allow it to
reach normal operating speed.
5. Adjust the trim Voltage Regulation
Calibration 50Hz or Voltage Regulation Calibration 60Hz for your desired
application. The effect of this trim is
Inverse on the regulated voltage. Increasing the trim will lower the regulated voltage, and decreasing the
trim will raise the regulated voltage.
The monitored Regulated Voltage
will match with the reading on the attached external calibrated meter and
the Regulated Feedback Voltage (Alternator Voltage) matches the desired Nominal voltage.
6. Shut the generator set OFF.
7. Save the adjustments by doing a
Save Trims with your PC based service tool.
PC based service tool.
2. Verify the nominal voltage trim is
set to the desired value.
3. With the genset OFF, attach a calibrated Voltmeter to the AC Output
from L1 to L2.
4. Start the genset and allow it to
reach normal operating speed.
5. Adjust the trim Voltage Adjust
which shall move the voltage Setpoint either in positive direction or in
negative direction as per your requirement.
1. View the service menu by holding
down the ”up” and ”down” arrow keys
on any of the operating menus.
2. Select item 1, ”Setup Menu”.
3. Enter Setup menu password
”574”.
4. Select item 1, ”Genset Service”.
5. Select item 1, and verify the ”Volts
AC” setting is correct for your application. If necessary press the ”Adjust” button and change the setting,
and press the ”Save” button.
6. Press the back button to return to
service menu.
7. Start the genset and allow it to
reach normal operating speed.
8. Select item 3, ”Meter Calib”.
9. Press the ”Adjust” button and
change the ”Reg Volt Adj” value. The
effect of this trim is Inverse on the
regulated voltage. Increasing the trim
will decrease the regulated voltage.
Decreasing the trim will increase the
regulated voltage.
10. Save the adjustment by pressing
the ”Save” button.
Not Applicable.
3-7
Three Lead CT Setup Example
For this example, assume that a CT with a
1500/750:5 ratio is being used.
Operator Panel
Enter 750 into the CT Ratio parameter on the
Operator Panel.
Manufacturing Tool
Select a feature corresponding to 750:5 to
download using the Manufacturing Tool.
PC-Based Service Tool
Enter 750 into the Primary CT Current parameter using a PC based service tool (e.g. InPower).
BATTERY CHARGING ALTERNATOR
CONNECTIONS
The 1302 series control currently supports the following charging alternator types.
Denso Type Charging Alternators
A Denso charging alternator with IG and L (failure
lamp) connection points is shown in Figure 3-2.
This configuration is used to produce a start disconnect signal and to indicate a failed battery
charging alternator.
Bosch Type Charging Alternators
A Bosch charging alternator with D+ (flash input)
connection point is shown in Figure 3-3. This configuration is used to produce a start disconnect signal and to indicate a failed charging alternator.
Denso Type
Charging Alternator
Bosch Type
Charging Alternator
Approx, 5 Ohm
input impedance
1302 Series Control
L
RUN
IG
FIGURE 3-2. DENSO CHARGING ALTERNATOR WIRING DIAGRAM
D+
B+
RUN
B+
J20−22
J20−11
1302 Series Control
J20−22
J20−11
Battery Charging
Alternator Input
Battery Charging
Alternator Input
FIGURE 3-3. BOSCH CHARGING ALTERNATOR WIRING DIAGRAM
3-8
ALTERNATOR CONNECTIONS
A fast acting UL certified ceramic fuse with a rating
of ten amperes shall be placed inline with the Excitation Inputs J18-1 and J18-2.
U1 (T1)
W6 (T12)
J12-1 J12-4
V1: J22-1
CT1
Series Star
Series star connection yields an output voltage of
220−277/380−480 volts. Figure 3-4 shows the correct series−star alternator connections.
J12-1 J12-4
U1 (T1)
U2 (T4)
U5 (T7)
U6 (T10)
W6 (T12)
CT1
W5 (T9)
W2 (T6)
W1 (T3)
V1: J22-1
V1 (T2)
V6 (T11)
V5 (T8)
J12-3 J12-6
V2 (T5)
VN: J22-4
V3: J22-3
CT3
FIGURE 3-4. SERIES STAR CONNECTIONS
J12-2 J12-5
V2: J22-2
CT2
Series Delta
Series delta provides for an output voltage of
110−120/220−240 volts. Figure 3-5 shows the correct series delta connections.
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedSense N must not be connected in
three phase delta connections.
Parallel Star
Parallel star alternator configuration yields an output voltage of 110−139/190−240 volts. Figure 3-6
illustrates the correct parallel star connections.
U6 (T10)
W5 (T9)
U2 (T4)
U5 (T7)
V1 (T2)
W2 (T6)
W1 (T3)
V6 (T11)
V5 (T8)
V2 (T5)
J12-2 J12-5
CT2
V2: J22-2
VN: J22-4
J12-3
J12-6
CT3
FIGURE 3-5. SERIES DELTA CONNECTIONS
J12-1 J12-4
U1 (T1)
U5 (T7)
U2 (T4)
W5 (T9)
CT1
U6 (T10)
V5 (T8)
V1: J22-1
V6 (T11)
V1 (T2)
W2 (T6)W6 (T12)
W1 (T3)
J12-3 J12-6
CT3
V2 (T5)
J12-2 J12-5
CT2
VN: J22-4
V3: J22-3
FIGURE 3-6. PARALLEL STAR CONNECTIONS
V3: J22-3
V2: J22-2
3-9
Double Delta
Single Phase
The double delta alternator configuration yields an
output voltage of 110−120/220−240 volts. Correct
double delta connections are illustrate in Figure
3-7.
J12-1 J12-4
V1: J22-1
VN: J22-4
V2: J22-2
V5 (T8)
W2 (T6)
V1 (T2)
W6 (T12)
V6 (T11) U1 (T1)
W1 (T3)
V2 (T5)
W5 (T9)
U2 (T4)
U5 (T7)
U6 (T10)
CT1
J12-2 J12-5
CT2
Single phase provides for an output voltage of
110−120/220−240 volts. Single phase alternator
connections are shown in Figure 3-8.
J12-1 J12-4
U5 (T7)
CT1
U6 (T10)
U1 (T1)
J12-2 J12-5
U2 (T4)
CT2
V1: J22-1
VN: J22-4
V2: J22-2
FIGURE 3-7. DOUBLE DELTA CONNECTIONS
FIGURE 3-8. SINGLE PHASE CONNECTIONS
3-10
GUIDELINES FOR ENGINE SENSORS
The engine sensors included in this kit are:
Coolant Temperature Sensor 193−0529−01
Oil Pressure Sensor 193−0444
This section provides information on these plus
additional engine sensors that can be used with
1302 series controllers.
Coolant Temperature Sensors
The coolant temperature sensors that are available from Cummins Power Generation (CPG) are
listed in Table 3-1.
The coolant temperature sensor connectors that
are available from CPG are listed in Table 3-2.
Oil Pressure Sensors
The 1302 series control can be programmed for either oil pressure sensors or switches. The trim parameter for this is: Lube Oil Pressure Sensor Type
= Sensor, Switch. If the type is set to Sensor, the
control can also be programmed for either 3-wire or
2-wire sensors. The trim parameter for this is Oil
Pressure Sender Type = 3-wire, 2-wire. Available
switch and sensors are listed in Table 3-3.
For information on setting the oil pressure sender
type using the display panel, see page 5-43.
FIGURE 3-9. THREE-WIRE PRESSURE SENSOR
CONNECTIONS
FIGURE 3-10. TWO-WIRE PRESSURE SENSOR
CONNECTIONS
TABLE 3-1. COOLANT TEMPERATURE SENSORS
CPG P/N
0193−0529−01 AirPax / 5024−0250 −40 to +230 F 3/8 “NPTF
0193−0529−02 AirPax / 5024−0274 −40 to +230 F M14 X 1.5 with “O” Ring
CPG P/N
0323−1755 Packard 121621893 Plastic shell with seal
0323−1818 Delphi 12124075 Socket Connector
Manufacturer / P/N Resistive Temp Range Threading
TABLE 3-2. TEMPERATURE SENSOR CONNECTORS
Manufacturer Manufacturer P/N Comments
3-11
TABLE 3-3. OIL PRESSURE SENSORS AND SWITCH
CPG P/N
193−0430−02 F.W. Murphy
193−0444 Kavlico
309−0641−XX Stewart Warner Pressure Switch (See the following page)
A028X493 Kavlico
Manufacturer /
P/N
ED2P-100
P165−5110
P4055−5001−1
Sensor Type
2-Wire Standard
Resistive Sender
3-Wire Active
Sender
(Capacitive)
3-Wire Active
Sender
(Capacitive)
Range /
Unit
0−100 PSIG 240−33
0−100 PSIG 0−5 VDC Mating Connector
0−100 PSIG 0−5 VDC Mating Connector
Resistance /
Voltage
Ohms
Comments
Includes 10-32 hex nut
connectors, 1/8” NPTF dry
sealing threading, and a
diaphragm operated resistive sensing element
326−1666 (Packard
12065287) includes
323−1667 socket terminals (Packard 12103881)
326−1666 (Packard
12065287) includes
323−1667 socket terminals (Packard 12103881)
Lube Oil Pressure Switch
The part number for the Lube Oil Pressure Switch
is 309−0641−XX. The XX portion of the number is
dependent the trip pressure point. Refer to Table
3-4 to select an appropriate lube oil pressure
switch.
If an oil pressure switch is used, the active state
(active high or active low) of the switch must be
configured using a PC based service tool or
through the menus available with the operator panel. A software setting allows for selection of the active state of the switch. The Lube Oil Pressure
Switch Polarity can be set to Active High or Active
Low.
TABLE 3-4. AVAILABLE PRESSURE SWITCHES (309−0641)
Part No.
309−0641−01
309−0641−02
309−0641−03
309−0641−04
309−0641−05
309−0641−06
309−0641−07
309−0641−08
309−0641−10
Set Point Contact (At Rest) No. of Terminals
14 2.0 PSI
14 2.0 PSI
14 2.0 PSI
9 1.5 PSI
9 1.5 PSI
10 1.5 PSI
20 2.0 PSI
20 2.0 PSI
20 3.0 PSI
For information on setting the oil pressure switch
polarity using the display panel, see page 5-43.
FIGURE 3-11. PRESSURE SWITCH
Closed 1
Open 2
Closed 2
Open 2
Closed 1
Open 2
Closed 1
Closed 2
Closed 2
3-12
309−0641−13
309−0641−14
309−0641−15
309−0641−16
309−0641−17
309−0641−18
309−0641−19
309−0641−20
All pressure switches have steel base and nipple construction.
30 3.0 PSI
4 1.0 PSI
5 1.0 PSI
5 1.0 PSI
5 1.0 PSI
5 1.0 PSI
14 2.0 PSI
20 2.0 PSI
Closed 1
Open 2
Open/Closed 3
Closed 1
Open 1
Open 2
Closed 2
Closed 1
3-13
CONTROL BOARD CONNECTIONS
J12 − Genset CT connections (see Table 3-8)
The 1302 control board includes the following
connectors (see Figure 3-12).
CAUTION
Reversing the power supply connections on TB1 and/or TB15 can permanently
damage the control. Refer to drawing 630−3270
for proper connections.
TB1 − Customer connections (see Table 3-5
and sheet 3 of Figure 7-1)
TB15 − Tools interface connections (see Table
3-6 and sheet 3 of Figure 7-1)
J11 − Engine connections (see Table 3-7)
J22 (ALTERNATOR
VOLTAGE SENSE)
J17 (FIELD
POWER)
J18 (FIELD
POWER)
J17 − Field winding connections (see Table
3-9)
J18 − Field power connections (see Table
3-10)
J20 − Genset connections (see Table 3-11)
J22 − Alternator voltage sense connections
(see Table 3-12)
J25 − Display connections (see Table 3-13)
Mating connector and connector pin part numbers
for the control board are listed in Table 3-14.
J12 (CT
CONNECTIONS)
TB15 (PC BASED
SERVICE TOOL)
J11 (ENGINE
CONNECTIONS)
TB1 (CUSTOMER
CONNECTIONS)
FIGURE 3-12. CONTROL BOARD CONNECTIONS
J25 (DISPLAY
CONNECTIONS)
J20 (GENSET
CONNECTIONS)
3-14
TABLE 3-5. TB1 − CUSTOMER CONNECTIONS
Pin
TB1-1 PCCNet A Network Data A
TB1-2 PCCNet B Network Data B
TB1-3 PCCNet Shield / B+ Return
TB1-4 Ready to Load 20ma Low Side Relay Driver
TB1-5 B+ Output (5A)
TB1-6 Configurable Relay 1 − A
TB1-7 Configurable Relay 1 − B
TB1-8 Configurable Relay 2 − A
TB1-9 Configurable Relay 2 − B
TB1-10 Remote Start Return
TB1-11 Remote Start
TB1-12 Configurable Input 1 Pull to TB1-13 to activate input. Remove from TB1-13 to
TB1-13 Configurable Input − Common Common for the two fault inputs
TB1-14 Configurable Input 2 Pull to TB1-13 to activate input. Remove from TB1-13 to
TB1-15 Remote E-STOP Return Remote normally closed E-STOP switch
TB1-16 Remote E-STOP Remote normally closed E-STOP switch
Signal Name Connect To
deactivate input.
deactivate input.
TABLE 3-6. TB15 − TOOLS INTERFACE CONNECTIONS
Connector
Pin
TB15-1 Return Network Power Supply Return
TB15-2
TB15-3 RS-485 Data A Network Data A
TB15-4 RS-495 Data B Network Data B
TB15-5 PCCNet System Wakeup
Signal Name Connect To
3-15
TABLE 3-7. J11 − ENGINE CONNECTIONS
Connector Pin
J11-1 Oil Pressure Sender (Active) +5V
J11-2 Oil Pressure Sender or Switch Re-
turn
J11-3 Oil Pressure Sender
J11-4 Governor Drive − Governor PWM low side driver
J11-5 Governor Drive + Governor drive + (for low side driver)
J11-6 Relay Coil B+ Coil for glow plug relay
J11-7 Glow Plug / Ignition Control Relay
Driver
J11-8 Magnetic Pickup Shield
J11-9 Magnetic Pickup Supply
J11-10 Magnetic Pickup Return
J11-11 Coolant Temperature Sender
J11-12 Coolant Temperature Sender Re-
turn
J11-13 NA
J11-14 NA
J11-15 NA
J11-16 NA
J11-17 ECM CAN Shield
J11-18 B+ Return for ECM
J11-19 ECM CAN Low
J11-20 ECM CAN High
J11-21 Keyswitch Low Side Driver Low side of keyswitch relay coil
J11-22 Keyswitch Relay Coil B+ High side of keyswitch relay coil
J11-23 NA
J11-24 NA
Signal Name Connect To
Low side of the relay coil
Connector Pin
J12-1 CT1
J12-2 CT2
J12-3 CT3
J12-4 CT1 Common
J12-5 CT2 Common
J12-6 CT3 Common
TABLE 3-8. J12 − GENSET CT CONNECTIONS
Signal Name Connect To
3-16
TABLE 3-9. J17 − FIELD WINDING CONNECTIONS
Connector Pin
J17-1 Field + X+ (F1)
J17-2 Field − XX− (F2)
Connector Pin
J18-1 PMG 1 / Shunt L1 240 Vmax Excitation Source
J18-2 PMG 2 / Shunt L2 240 Vmax Excitation Source
J18-3 NC
Connector Pin
J20-1 Chassis ground
J20-2 B+ Return
J20-3 Switched B+ Low Side Driver
J20-4 B+ Return
J20-5 Discrete Input Return
J20-6 Discrete Input Return
J20-7 B+ Return
J20-8 Discrete Input Return
J20-9 B+ Input
J20-10 B+ Input
J20-11 Starter Disconnect Input Charging alternator
J20-12 B+ Return
J20-13 Relay Coil B+ Supply Switched B+ (Switched B+ might be connected to
J20-14 FSO Relay Driver Low Side of FSO Relay Coil
J20-15 Starter Relay Driver Low Side of Starter Relay Coil
J20-16 NA
J20-17 Configurable Input #3 Defaulted to Low Coolant Level Switch
J20-18 Configurable Input #4 Defaulted to Low Fuel Level Switch
J20-19 NA
J20-20 B+ Input
J20-21 B+ Input
J20-22 Alt Flash Input
Signal Name Connect To
TABLE 3-10. J18 − FIELD POWER CONNECTIONS
Signal Name Connect To
TABLE 3-11. J20 − GENSET CONNECTIONS
Signal Name Connect To
E−Stop B+ instead)
TABLE 3-12. J22 − GENSET VOLTAGE SENSING CONNECTIONS
Connector Pin
J22-1 L1 600 Vmax L1 Source
J22-2 L2 600 Vmax L2 Source
J22-3 L3 600 Vmax L3 Source
J22-4 LN 600 Vmax LN Source
Signal Name Connect To
3-17
TABLE 3-13. J25 − DISPLAY CONNECTIONS
C
Connector Pin
J25-1 Local Status Low side of local status lamp
J25-2 Local E-Stop Normally closed local E-Stop switch
J25-3 PCCNet B Network Data B
J25-4 PCCNet A Network Data A
J25-5 System wakeup
J25-6 Discrete Input Return
J25-7 Discrete Input Return
J25-8 B+ Return
J25-9 B+ Return / PCCNet
J25-10 Manual
J25-11 Auto
J25-12 B+
onnector
J11 323−2161 Amp/Tyco / 790587−1 323−2466 Amp/Tyco / 770904−1/
J12 323−1932 Amp/Tyco / 1−480704−0 323−1200 Amp/Tyco / 350536−1/350550−1
J17 323−2098 Amp/Tyco / 1−480698−0 323−1200 Amp/Tyco / 350536−1/350550−1
J18 323−2444 Amp/Tyco / 1−480700−0 323−1200 Amp/Tyco / 350536−1/350550−1
J25 323−2445 Amp/Tyco / 770581−1 323−2466 Amp/Tyco / 770904−1/
J22 323−2226−03 Amp/Tyco / 282809−4
J20 323−2466 Amp/Tyco / 770586−1 323−2466 Amp/Tyco / 770904−1/
CPG P/N Man/Man P/N CPG P/N Man/Man P/N
Signal Name Connect To
TABLE 3-14. CONNECTOR PART NUMBERS
Connector Housing Connector Pins
770988−1/171637−1
770988−1/171637−1
770988−1/171637−1
3-18
ELECTRONIC GOVERNOR
CONNECTIONS
This section describes the installation of the optional Electronic Governor Power Module.
A description of the Governor Power Module connections are listed in Table 3-15. Module connector
pat numbers are listed in Table 3-16.
TABLE 3-15. GOVERNOR MODULE CONNECTIONS
Connector Pin Signal Name Comments
P1-1 Gov drive −
P1-2 Gov drive +
P1-3 B+ Battery +
P1-4 Actuator Low side of actuator
P1-5 Return GND
TABLE 3-16. CONNECTOR PART NUMBERS FOR THE GOVERNOR MODULE CONNECTIONS
Connector Housing Connector Pins
Ref Internal P/N Man / P/N Internal P/N Man / P/N
P1 0323−2216 Amp/Tyco /
1−480763−0
The electronic fuel actuator is driven by the output
of the Governor Power Module. Use twisted pair
wires minimum 1 sq mm (16 Gage). Power to the
Governor Power Module is derived from the genset
starting battery but should be connected to the
Governor Power Module as indicated in the diagrams “Applications without FSO” (see Figure
3-13) and “Applications with FSO” (see Figure
3-14) as appropriate.
0323−1200 Amp/Tyco /
770008−3
GND
B+
Fuel
Actuator
1302 Series
Control
PWM
FSO
J20−14
J11−5
J11−4
E−Stop B+
Relay
Fuse
Governor
Power Stage
FIGURE 3-13. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITHOUT FSO
3-19
E−Stop B+
J20−14
FSO
1302 Series
Control
PWM
J11−5
J11−4
FIGURE 3-14. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITH FSO
KIT INSTALLATION
Refer to the control wiring diagram included in
Section 7 when installing the items included in this
kit. This wiring diagram also includes information
on wiring items (annunciator, I/O module, and governor power module) not included in this kit.
While the harnesses included in this kit should be
long enough for all types of installations, it is a good
idea to make sure that the distance between two
connecting parts does not exceed the length of the
harness. Excess wiring may be trimmed if it interferes with your installation.
Relay
FSO
Governor
Power Stage
GND
B+
c. The negative (−) cable from the battery is
disconnected to prevent accidental starting.
2. Select a suitable location (see “Mounting
Guidelines” on page 3-1) and mount the
1302 control board using M4 hardware. Figure
3-15 shows the control board dimensions. The
outside dimensions do not include necessary
clearance for wire connections.
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedMounting hardware for the 1302 con-
trol and the operator panel is not included
in this kit. The instructions below include
suggested hardware sizes.
1. Make sure the generator set is shut down and
disabled:
a. The generator set Run/Off/Auto switch is
in the Off position and the generator is
cool (to the touch).
b. The battery charger (if equipped) is
turned off and disconnected.
DIMENSIONS ARE IN MILLIMETERS
FIGURE 3-15. 1302 CONTROL FOOTPRINT
3-20
3. Install the operator panel and operator panel
harness.
a. Select a suitable location and mount the
panel using #6−32 hardware. Figure 3-16
shows the operator panel dimensions.
The operator panel must be mounted
within 72 inches (1828.8 mm) of the control board.
b. Install the operator panel harness (see
Figure 3-17). Plug the P1 connector into
the display (either J1 or J2) and plug the
P25 connector into the J25 connector on
the control board.
DIMENSIONS ARE IN MILLIMETERS
FIGURE 3-16. OPERATOR PANEL FOOTPRINT
DIMENSIONS ARE IN FEET
FIGURE 3-17. OPERATOR PANEL HARNESS
3-21
4. Install the genset harness (see Figure 3-18).
a. Make sure the current transformers in-
stalled are appropriate for use with a 1302
series control. Refer to the “Guidelines for
Current Transformers” subsection, starting on page 3-3.
b. Make sure the battery charging alternator
installed is one of the types listed in the
“Battery Charger Alternator Connections” subsection, starting on page 3-8.
f. Connect the harness X+ and XX− wires to
the generator field windings.
g. Make the connections for the excitiation
source (shunt or PMG). For shunt applications, connect J18-1 and J18-2 to the
low side of L1 and L2. For PMG applications, connect J18-1, J18-2, and 18-3 to
P2, P3, and P4 on the permanent magnet.
J18-1 and J18-2 are 240V maximum inputs.
c. Make sure the alternator connections are
appropriate for your installation (see “Alternator Connections” on page 3-9).
d. Connect the six harness CT wires to the
current transformers.
e. Connect the four harness sense wires to
the alternator.
CAUTION
Do not connect J18-1 directly to L1 in 480V applications. Making this connection will blow up the
1302 control board.
h. Connect the harness P12, P17, P18, and
P22 connectors to the mating connectors
on the 1302 control board.
FIGURE 3-18. GENSET HARNESS
3-22
DIMENSIONS ARE IN INCHES
5. Install the engine harness.
a. Connect the engine harness wires
marked P11-2 and P11-3 to the oil pressure harness wires marked J11-5, J11-6,
and J11-17 (see Figure 3-20).
b. Connect the engine harness wires
marked P11-11 and P11-12 to the coolant
temperature sensor harness wires
marked P11-11 and P11-12 (see Figure
3-21).
wires to the appropriate locations indicated in Figure 3-19.
NOTE: If your installation does not in-
clude an electronic governor, tie
back the wires marked P11-4 and
P11-5.
e. Connect the engine harness P11 and P20
connectors to the 1302 control board J11
and J20 connectors.
c. If installed, connect the engine harness
wires marked P11-8, P11-9, and P11-10
to the magnetic pickup sensor on the engine. If not installed, tie the wires back.
d. Connect the remaining engine harness
6. Install the oil pressure sensor and harness.
a. Install the sensor on the engine.
b. Connect the harness connector to the oil
pressure sensor.
FIGURE 3-19. ENGINE HARNESS
3-23
DIMENSIONS ARE IN FEET
FIGURE 3-21. COOLANT TEMPERATURE SENSOR HARNESS
FIGURE 3-20. OIL PRESSURE SENSOR HARNESS
DIMENSIONS ARE IN FEET
FIGURE 3-22. OIL PRESSURE SENSOR
7.
Install the coolant temperature sensor and
harness.
a. Install the sensor on the radiator.
b. Connect the harness connector to the
temperature sensor.
8. Reconnect the generator starting battery
cables (positive [+] cable first).
9. Connect the battery charger (If equipped).
10. Press any button on the operator panel to
“wake up” the control.
FIGURE 3-23. COOLANT TEMPERATURE SENSOR
Use the operator panel to access the Service
11.
menus (see Section 5) and/or a PC service
tool to adjust the appropriate control parameters.
a. For general information on all available
parameters that can be adjusted, see
“Setup, Trims, and Adjustments” on page
3-26.
3-24
b. Follow the setup procedures for current
transformers listed on page 3-4.
c. For information on alternator control ad-
justments, see page 3-36.
d. For information on genset tuning, see
page 3-36.
e. For information on other control functions,
see page 3-46. These include:
− Remote start mode
− Remote emergency stop
− 12V/24V batteries
− Engine starting
− Cycle cranking
− Spark ignition power/Glow plug
control
− Genset cooldown start and stop
time delays
f. For information on the Battle Short option,
see page 3-55.
12. Place the generator set Run/Off/Auto switch in
the desired position.
3-25
SETUP, TRIMS, AND ADJUSTMENTS
P
j
j
While applying a 1302 series control to a new application, make sure the parameters listed in Table
3-17 have appropriate values. Many of these can
be adjusted using the operator panel but some require use of a genset Manufacturing Tool or a PC
based service tool.
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedSection 5 includes information on all
TABLE 3-17. 1302 CONTROL PARAMETERS
Adjusted Using Limits
Group Parameter Name
Adjustment
Adjustment
Voltage Adjust X −5 5 % —
Start Time Delay (V2.79
and prior with HMI211 7.10
or prior)
Start Time Delay (V2.80
and later with HMI211 7.20
or later)
Stop Time Delay X X 0 600 Sec 5-8
V/Hz Knee Frequency X X 0 10 Hz 5-17
V/Hz Rolloff Slope X X 0 5 % 5-17
PC Based
Service Tool
X X 0 300 Sec 5-8
X X 0 3600 Sec 5−8
of the Service menus that are used to adjust parameters using the 1302 operator
panel. The last column in Table 3-17 lists
the page references in Section 5 where you
can find information on how to adjust each
parameter.
Configurable / Model Specific features like nominal
voltage, frequency, KVA rating, Engine protection
values Alternator Protection values, AVR and Governor Gains, CT Ratio, etc have to be assigned appropriate values at manufacturing time.
Operator
Panel
Lower Limit
Upper
Limit
Units
Ref
g
3-26
Group
p
Group
Setup –
Genset
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
LimitsAdjusted Using
Parameter Name
Parameter Name
Nominal Battery Voltage X X 12 24 VDC 5-41
AVR Enable X X Enable or
Excitation Source X X Shunt or PMG 5-39
Excitation / Line Frequency
Gain
Nominal Voltage X X 190 480 V AC 5-8
Alternator Nominal
Frequency
Single Phase 60Hz Standby
kVA Rating
Three Phase 60Hz Standby
kVA Rating
Single Phase 50Hz Standby
kVA Rating
Three Phase 50Hz Standby
kVA Rating
Single Phase 60Hz Prime
kVA Rating
Three Phase 60Hz Prime
kVA Rating
Single Phase 50Hz Prime
kVA Rating
Three Phase 50Hz Prime
kVA Rating
Frequency to Speed Gain
Select
Oil Pressure Switch Polarity X Active Low or
PC Based
Service Tool
X X 1,2,4 5-39
X X 50 or 60 N/A Hz 5-8
X X 0 2000 KVA 5-39
X X 0 2000 KVA 5-39
X X 0 2000 KVA 5-39
X X 0 2000 KVA 5-39
X X 0 2000 KVA 5-41
X X 0 2000 KVA 5-41
X X 0 2000 KVA 5-41
X X 0 2000 KVA 5-41
X X 20, 30, or 60 N/A RPM/Hz 5-39
Operator
Panel
Lower Limit
Disable
Active High
Upper
Limit
NA NA 5-11
N/A N/A 5-43
Units
Units
Pg
Pg
Ref
Ref
3-27
Group
p
d)
Group
Setup –
Genset
(Continue
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
LimitsAdjusted Using
Parameter Name
Parameter Name
Oil Pressure Sensor Type X X 2 or 3 wire N/A N/A 5-43
Electronic Governor Enable
Glow Plug Enable
Fuel System X X Diesel or Gas N/A N/A 5-8
Fuel Burn Time Delay X X 0 10 Sec 5-8
Magnetic Pickup Enable
Flywheel Teeth X X 0 255 Teeth 5-39
Dither Factor X X 0 30 % 5-19
Maximum Governor Duty
Cycle
AVR Gain Adjust X X 5 1000 % 5-17
AVR K2 Gain Adjust X X 5 1000 % 5-17
AVR D Gain Adjust X X 95 105 % 5-17
K1 (Regulator Gain 50Hz) X 0 65535 NA —
K1 (Regulator Gain 60Hz) X 0 65535 NA —
K2 (Regulator Integral
50Hz)
K2 (Regulator Integral
60Hz)
K3 (Regulator K3 Gain
50Hz)
K3 (Regulator K3 Gain
60Hz)
Damping Effect (60Hz) X 0.2 0.99 NA —
Damping Effect (50Hz) X 0.2 0.99 NA —
Cycle Crank Attempts X X 1 7 Attempts 5-11
Cycle Crank Engage Time X X 3 30 Sec 5-11
Cycle Crank Rest Time X X 0 60 Sec 5-11
Remote / Local Display N/A X Remote or
Battle Short Enable X Enable or
Battle Short Switch Input X X Configurable
Governor Ramp Time X X 0 30 Sec 5-19
PC Based
Service Tool
X Enable or
X Enable or
X Enable or
X X 0 100 % 5-19
X 0 65535 NA —
X 0 65535 NA —
X 0 65535 NA —
X 0 65535 NA —
Operator
Panel
X Yes or No N/A N/A 5-11
X Yes or No N/A N/A 5-8
X Yes or No None N/A 5-13
Lower Limit
Disable
Disable
Disable
Local
Disable
input 1−4 or
operator panel
Upper
Limit
NA NA —
N/A N/A —
None N/A —
N/A N/A 5-15
NA NA 5-11
N/A N/A 5-11
Units
Units
Pg
Pg
Ref
Ref
3-28
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
g
LimitsAdjusted Using
Group
Group
Setup –
ECM CAN
Setup −
Configurable I/O
Parameter Name
Parameter Name
ECM CAN Enabled X Disable, J1939,
Keyswitch Reset Delay X 1 10 Sec —
Keyswitch On Time Delay X 1 10 Sec —
CAN Datalink Failure
Retries
ECM Datasave Time X 30 60 Sec —
Configurable Input #1−4
Function
Configurable I/P #1
AnnActive LED
Configurable I/P #2
AnnActive LED
PC Based
Service Tool
X 0 10 Times —
X X Active open or
X NO_ANNUN_M
X NO_ANNUN_M
Operator
Panel
Lower Limit
PGI
Active closed
APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL
APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL
Upper
Limit
N/A 5-21
N/A 5-21
N/A 5-21
Units
Units
Pg
Pg
Ref
Ref
—
3-29
Group
Group
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
Parameter Name
Parameter Name
Configurable I/P #3
AnnActive LED
Configurable I/P #4
AnnActive LED
PC Based
Service Tool
X NO_ANNUN_M
X NO_ANNUN_M
Operator
Panel
Lower Limit
APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL
APPING,
CUSTOMER_F
AULT_1,
CUSTOMER_F
AULT_2,
CUSTOMER_F
AULT_3,
GEN_SUPPLY
_LOAD,
CHARGER_AC
_FAIL,
LOW_COOLAN
T_LEVEL,
LOW_FUEL_L
EVEL
LimitsAdjusted Using
Units
Upper
Limit
N/A 5-21
N/A 5-21
Units
Pg
Pg
Ref
Ref
3-30
Group
g
g
Group
Setup −
Configurable I/O
Regulated
Voltage
Adjust
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
LimitsAdjusted Using
Parameter Name
Parameter Name
Configurable Fault Input
#1−4 Active State Select
Configurable Fault Input
#1−4 Fault Level Response
Configurable #1−4 Input
Text Line 1
Configurable #1−4 Input
Text Line 2
Customer Output 1/2 Event X X 0 9999 Fault
Voltage Regulator
Calibration 50Hz
Voltage Regulator
Calibration 60Hz
Alternator L1−N 50Hz
Voltage Display Adjust
Alternator L2−N 50Hz
Voltage Display Adjust
Alternator L2−N 50Hz
Voltage Display Adjust
Alternator L1−N 60Hz
Voltage Display Adjust
Alternator L2−N 60Hz
Voltage Display Adjust
Alternator L2−N 60Hz
Voltage Display Adjust
Alternator L1 50Hz Current
Adjust
Alternator L2 50Hz Current
Adjust
Alternator L2 50Hz Current
Adjust
PC Based
Service Tool
X X Active open or
X X Warning,
X X 5-21
X X 5-21
X X 0.9 1.1 % 5-27
X X 0.9 1.1 % 5-27
X X 0.8 1.1 % 5-27
X X 0.8 1.1 % 5-27
X X 0.8 1.1 % 5-27
X X 0.8 1.1 % 5-27
X X 0.8 1.1 % 5-27
X X 0.8 1.1 % 5-27
X X 0.8 1.2 % 5-27
X X 0.8 1.2 % 5-27
X X 0.8 1.2 % 5-27
Operator
Panel
Lower Limit
Active closed
Shutdown, or
None
Upper
Limit
N/A 5-21
5-21
Units
Units
Code
Numbers
Pg
Pg
Ref
Ref
5-25
3-31
Group
g
ed)
g
Group
Regulated
Voltage
Adjust
(Continu
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
LimitsAdjusted Using
Parameter Name
Parameter Name
Alternator L1 60Hz Current
Adjust
Alternator L2 60Hz Current
Adjust
Alternator L2 60Hz Current
Adjust
High AC Voltage Threshold X X 105 125 % 5-45
High AC Voltage Delay X X 1 10 Sec 5-45
Low AC Voltage Threshold X X 50 95 % 5-45
Low AC Voltage Delay X X 2 20 Sec 5-45
Under Frequency Threshold X X 2 10 Hz 5-45
Under Frequency Delay X X 500 2000 1/2
Overfrequency Enable X Enable or
Overfrequency Threshold X X 2 10 Hz 5-45
Overfrequency Delay X X 100 2000 1/2
High AC Current Shutdown
Delay
PC Based
Service Tool
X X 0.8 1.2 % 5-27
X X 0.8 1.2 % 5-27
X X 0.8 1.2 % 5-27
X X 2 60 Sec 5-45
Operator
Panel
Lower Limit
Disable
Upper
Limit
N/A NA —
Units
Units
cycles
cycles
Pg
Pg
Ref
Ref
5-45
5-45
Protection
– Engine
Overspeed Shutdown
Threshold 50Hz
Overspeed Shutdown
Threshold 60Hz
LOP Shutdown Threshold X X 0 100 Psig 5-51
LOP Shutdown Delay X X 2 15 Sec 5-51
LOP Warning Threshold X X 0 100 Psig 5-49
LOP Warning Delay X X 2 15 Sec 5-49
LCT Warning Threshold X X 32 100 deg f 5-53
HCT Shutdown Threshold X X 180 300 deg f 5-51
HCT Shutdown Delay X X 2 10 Sec 5-51
HCT Warning Threshold X X 150 290 deg f 5-51
HCT Warning Delay X X 2 10 sec 5-51
12V Low Battery Threshold X X 11 13 VDC 5-41
24V Low Battery Threshold X X 22 27 VDC 5-41
Low Battery Fault Delay X X 2 60 Sec 5-43
High Battery Fault Delay X X 14 17 VDC 5-41
24V High Battery Threshold X X 28 34 VDC 5-41
12V High Battery Threshold X X 2 60 Sec 5-43
12V Weak Battery
Threshold
X X 0 8192 Rpm 5-49
X X 0 8192 Rpm 5-49
X X 6 10 VDC 5-41
3-32
Group
(Conti
g
”Confi
LED
Group
Protection
– Engine
n-
ued)
Fault
History
TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)
LimitsAdjusted Using
Parameter Name
Parameter Name
24V Weak Battery
Threshold
Weak Battery Fault Delay X X 1 5 sec 5-43
Reset Runs X —
Reset Start Attempts X —
PC Based
Service Tool
X X 18 21 VDC 5-41
Operator
Panel
Lower Limit
Upper
Limit
Units
Units
Pg
Pg
Ref
Ref
NFPA 110 Status Logical Bits 1−7, Annunciator
Discrete Signals (Configurable via PCC1302
A universal annunciator connected in a network indicates and annunciates the active faults received
from the PCC1302. The NFPA 110 Status Logical
bits 1 to 7 (i.e. LEDs) of an annunciator can be
mapped to indicate and annunciate the active
faults corresponding to each of the four configurable inputs of PCC1302 as defined by the user. For
this, the (trim) ”Configurable Input #n Function” (n =
1, 2, 3, or 4) should be set as ”Fault Input” and the
LED should be mapped through (trim) ”Configurable I/P# n Ann Active LED” (n = 1,2,3 or 4), where,
”Configurable I/P# 1 Ann Active LED”) is applicable only for ”Configurable Input #1 Function”.
TABLE 3-18. 1302 CONTROL SETUP
”Configurable I/P# n Ann
Input #
”Configurable Input #1 Function” =
Fault Input and
”
gurable
I/P# 1 Ann Active
LED”
Active LED” (n =
1,2,3 or 4) set to one of
the following
NO_ANNUN_MAPPING No bit set = NONE None
CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
”Configurable I/P# 2 Ann Active LED” is applicable
only for ”Configurable Input #2 Function”.
”Configurable I/P# 3 Ann Active LED” is applicable
only for ”Configurable Input #3 Function”.
”Configurable I/P# 4 Ann Active LED” is applicable
only for ”Configurable Input #4 Trim Function”
Each active fault corresponding to the respective
configurable input of PCC1302 is annunciated and
indicated according to the LEDs mapped by the
user to the ”Configurable Input #n Function” (n = 1,
2, 3, or 4) set as ”Fault Input”:
Refer the table below for more information on setup
and expected observations:
Active Condition (LED#
indication) on Annunciator
Active Fault
Condition
Fault 1
Fault 2
Fault 3
Supplying
Load
Failure
Active
FC#
1311
3-33
Input #
g
”Confi
LED
g
”Confi
LED
g
”Confi
LED
”Configurable Input #1 Function” =
Fault Input and
”
gurable
I/P# 1 Ann Active
LED”
”Configurable Input #1 Function” =
Fault Input and
”
gurable
I/P# 1 Ann Active
LED”
”Configurable Input #1 Function” =
Fault Input and
”
gurable
I/P# 1 Ann Active
LED”
TABLE 3-18. 1302 CONTROL SETUP (CONT.)
”Configurable I/P# n Ann
Active LED” (n =
1,2,3 or 4) set to one of
the following
NO_ANNUN_MAPPING No bit set = NONE None
CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
LOW_COOLANT_LEVEL Bit 1 set = LED 6 Low Coolant
LOW_FUEL_LEVEL Bit 1 set = LED 7 Low Fuel
NO_ANNUN_MAPPING No bit set = NONE None
CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
NO_ANNUN_MAPPING No bit set = NONE None
CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator
CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator
CUSTOMER_FAULT_3 Bit 1 set = LED 3 Annunciator
GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset
CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC
Active Condition (LED#
indication) on Annunciator
Active Fault
Condition
Fault 1
Fault 2
Fault 3
Supplying
Load
Failure
Level
Level
Fault 1
Fault 2
Fault 3
Supplying
Load
Failure
Fault 1
Fault 2
Fault 3
Supplying
Load
Failure
Active
FC#
1312
1317
1318
ALTERNATOR CONTROL ADJUSTMENTS
The 1302 series control includes an integrated lineto-line sensing voltage regulation system that is
compatible with shunt or PMG excitation systems.
The voltage regulation system is SCR type. Excitation power is derived either directly from the genset
terminals or from a PMG stator. Power from either
source is fed into the control thru J18. Positive volt-
3-34
age build up from residual levels is ensured by the
use of efficient semiconductors in the power circuitry.
AVR Enable/Disable Feature
The 1302 series control provides automatic
voltage regulating capability for the generator set
when the AVR feature is enabled on the genset. It
has a field adjustment trim to enable or disable the
AVR feature. The trim parameter for this is AVR
Enable = Enable / Disable.
protection of the excitation system, by reducing the
output voltage proportionally with speed.
The voltage rolloff set point and rate of decay (i.e.,
the slope of the volts/hertz curve) is adjustable in
the control.
Major system features include.
%Volts/Hz rolloff supports the engine speed
recovery under block loading. The slope setting (%volts/Hz) range is 0.0−5.0% of rated
with 0.1% increment.
For information on enabling/disabling the AVR feature using the operator panel, see page 5-11.
Digital Output Voltage Regulation
The 1302 series control supports digital output
voltage regulation as defined below.
Voltage setpoint algorithm sets the level of the
automatic voltage regulation. It is adjustable.
The maximum allowed rated current for the
field coil for the regulation is 4.0 Amps RMS
and maximum 6.0 Amps for 10 seconds.
The control provides voltage ramping at start-
up if the AVR algorithm is enabled, such that
voltage overshoot can be controlled. AVR boot
enable logic supports the step by step voltage
ramping.
A PC based service tool allows the operator to
adjust the output voltage within plus or minus
5.0% of rated voltage.
Torque-Matched Volts/Hz Overload
Control
A frequency measuring circuitry monitors the
generator output and provides output underspeed
The knee frequency range is 0.0−10.0Hz less
than the nominal frequency with 0.1 Hz increment.
For information on adjusting rolloff and knee frequency settings using the operator panel, see page
5-17.
Battleshort Mode
The 1302 series control can be programmed to
work in battleshort mode by loading the battleshort
feature with a manufacturing tool or PC based service tool.
The controller then can accept Configurable Input
1−4 as battle short switch inputs. If an operator
panel is used, it can be also selected as a source of
input by selecting appropriate input source value
for the trim.
Battleshort mode is designed to work only in critical
load circumstances. While in battleshort mode the
1302 series control will ignore most warnings and
shutdowns and will continue to operate as if no fault
or shutdown exists on the system.
For information on enabling/disabling the battleshort feature using the operator panel, see page
5-11.
3-35
GENSET TUNING
The 1302 series control uses a standard 4 coefficient PID algorithm running at an execution rate of
once per zero cross of the generator AC waveform.
Standard values for the K1−K4 and damping terms
for both 60 and 50Hz are listed in Table 3-19.
Consider the following before making any adjustments.
The values of K3, K4, and the damping factor
are set for basic stability reasons and should
not need to be adjusted, but they can be adjusted if necessary.
The useful range of values for K2 is 200 to
1500. The value of 1500 for K2 can be a little
too high or aggressive for some applications
and cause “ringing” upon recovering from a
load acceptance or offload transient situation.
A value of K2 below 200 can cause the regulator to hit an integrator windup limit and should
be avoided if possible. Set the correct value for
the application.
The value of K1 should be adjusted to meet the
specification for percent off rated voltage during a load acceptance, and prevent large voltage overshoots during offloads and during engine/alternator startup.
The value of K2 should be adjusted to control
the recovery characteristics of the voltage during large load acceptance and rejection transients. Values of K2 which are too high can
cause unstable voltage performance and values too low can cause slow performance or
steady state voltage offset errors.
In general, K1 increases and K2 decreases in value with increasing generator size, but can vary in
different applications.
V/Hz Curve
The 1302 series control uses a simple breakpoint
and slope approach to the V/Hz curve to allow for
the matching of the torque curve of the engine during a large transient load acceptance. The two ad-
justment points are the V/Hz Knee Frequency
which set the point at which the V/Hz curve starts,
and the V/Hz Roll−off Slope which sets the roll−off
slope of the voltage setpoint as a function of frequency error.
The default V/Hz settings are:
Parameter Default Value
V/Hz Knee Frequency 0.5 Hz
V/Hz Roll-off Slope 2.2 %V/Hz
The voltage set point command is calculated from
the frequency error between commanded frequency and the actual frequency. For example, a voltage set point of 93.4% of nominal would be commanded if there is a frequency error of 3.5Hz under
nominal. There is no offset to voltage for errors
above nominal frequency.
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedNote: There are only one V/Hz set-
tings per calibration so the values must be
used for both 50 and 60Hz operation. If a
particular application requires vastly different V/Hz settings for 50Hz and 60Hz operation, it will be required to create separate software features for those applications.
For information on how to adjust the slope and
knee frequency using the operator panel, see page
5-17.
TABLE 3-19. GOVERNOR GAINS FOR SMALL
ENGINES
Newage BC/UC Generators Under 200Kw
60Hz 50Hz
K1 = 1000 K1 = 1000
K2 = 650 K2 = 650
K3 = 10000 K3 = 10000
K4 = 36429 K4 = 36429
Damping = 0.8 Damping = 0.8
3-36
Governor
The 1302 series control’s governor also uses the 4
coefficient PID algorithm. There are gains for use
at 50 and 60Hz operation. Standard values for the
K1−K4 and damping terms for both 60 and 50 Hz
for engines in the Cummins 4B3.9 and 6B5.9 range
are listed in Table 3-20.
TABLE 3-20. GOVERNOR GAINS FOR SMALL
ENGINES
60Hz
GK1 = 1696 GK1 = 1200
GK2 = 240 GK2 = 300
GK3 = 28,800 GK3 = 28,800
GK4 (calc) = 7424 GK4 (calc) = 7424
Governor Damping =
0.936
Governor Damping =
0.936
Governor Tuning
A good starting point for any new engine application is to start with a set of released gains for an engine of a similar type and size should they already
exist.
If a set of pre−developed gains are not available,
the gains listed above should work well enough to
start most engines and to allow them to run
smoothly.
The value of GK1 should be adjusted to meet the
specification for percent off rated voltage during a
load acceptance, to prevent large voltage overshoots during offloads, and during engine/alternator startup.
The value of GK2 should be adjusted to control the
recovery characteristics of the engine during large
load acceptance and rejection transients. GK2 is a
true integral type gain and is applied to the governor output as GK2 times the sum of all the previous
governor error. Values of GK2 which are too high
can cause unstable voltage performance and values too low can cause slow performance or steady
state voltage offset errors.
The values of GK3, GK4 and the Damping factor
are used to set the basic steady state stability of the
engine, but also influence the overall speed of response of the governor in transient situations. Adjustment of GK3 and the Damping factor is an iterative process started by finding the engine load level
which produces the worst steady state engine performance (note: GK1 and GK2 may have to be ad-
50Hz
justed first to allow the engine to be transitioned
smoothly into this) and adjusting GK3 until the best
performance is observed, then doing the same for
the Damping factor. Repeat this process at least
once to ensure that the best possible values for
GK3 and the Damping term have been determined.
For information on how to adjust the GK1and GK2
values and the damping factor using the operator
panel, see page 5-17.
Engine Startup
The 1302 series control applies fuel to the engine
as described in the Speed Governor Algorithm and
Adjustment section.
Alternator Startup
The alternator will be started up and brought to
rated voltage when the engine speed reaches
rated speed. The PWM command to the field coil
will now be stepped through an AVR Boot Table until the sensed voltage goes above the value of the
AVR Boot Threshold trim and if AVR feature is enabled. The regulator will now bring the voltage up to
rated voltage.
The purpose of the AVR Boot Table is to aid alternator startup whilst preventing overvoltage conditions. The value of the AVR Boot Table and the AVR
Boot Threshold can be set to bring the voltage up
both as quickly and as smoothly as possible, but
should already be set in the calibration to their ideal
values. The AVR Boot Table has different values
depending on value of the Excitation Source trim.
Setup for Gain Tuning
In order to properly set up engine and alternator
control parameters it is convenient to setup the PC
based service tool to be used to monitor.
The following are step-by-step procedures for determining engine and alternator control parameters.
1. Determine 60Hz governor gains, regulator
gains, and V\Hz curve values with PMG excitation.
a. Start the genset, bring it to rated speed
and temperature, and adjust the GK3 and
damping factor for 60Hz operation to allow the engine to run smoothly in steady
state operation.
NOTE: GK1 and/or GK2 may need to be
adjusted to allow this to happen.
Apply various loads up to 100% rated and
verify the steady state operation at all load
3-37
levels. Most engines have some load level which is inherently less stable than others and must be found to determine the
correct value for GK3 and the damping
factor.
speed very poorly. A V/Hz curve too shallow causes a very slow engine recovery
from a transient.
c. Re-verify steady state voltage and gover-
nor performance.
NOTE: It is important to control the
steady state performance of the
engine. Unstable engine performance is carried over into the
generator output voltage. Very
fast increases or decreases in engine speed, even if the magnitude
of the increase or decrease is
small, tend to be carried into the
alternator voltage as large increases and decreases in voltage
at the same frequency as the engine speed changes.
b. Do a series of load steps to determine the
transient characteristics of the genset.
Tuning of the governor GK1 and GK2 values, the settings of the V/Hz curve, and
the values of K1 and K2 (mostly K1) for
the regulator must be done concurrently.
In general, these values should be adjusted to achieve the maximum possible
performance from both the engine and
the alternator. A production test spec (if
available) should give the full load step
transient performance levels for any given genset model. This is a very iterative
process and many require some time to
find the best combination of gains to fit the
application. In general, adjust GK1 to control the peak frequency during transients
and adjust GK2 to control the recovery
shape of the frequency transient. A V/Hz
slope too steep causes the engine to recover too quickly and recovers to nominal
2. Determine 50Hz governor gains, Regulator
gains, and V/Hz curve values. Follow the
same process as used at 60Hz. The order of
50Hz vs 60Hz testing can be reversed.
3. Determine the correct values for the governor
startup parameters (see “Speed Governor Algorithm and Adjustment” below).
a. Adjust the Initial Crank Fueling Com-
mand, Initial Crank Fueling Period, Crank
Fueling Ramp Rate, and Max Crank Fueling Command parameters to control the
way the engine transitions through the
cranking stage of the engine startup. The
controls default values should work well.
b. The value of the Crank Exit Fueling Com-
mand parameter should be set to the governor duty at which the engine runs when
at rated speed, or to a value slightly higher.
Gain Tuning Parameters
This is a list of all of the parameters which affect
genset performance. A correct value should be determined for each of the parameters listed.
NOTE: To check the actual genset output, True
(calibrated) RMS meter should be
usedFor any parameters that have some-
thing listed in the “Value” column, it is
recommended that the parameter stay at
that value during testing. Some parameters should never be changed during testing and are listed as never to be changed.
3-38
TABLE 3-21. GAIN TUNING PARAMETERS
Parameter
K1 (50Hz) Sets overall AVR gain in 50Hz applications. This is a true
K2 (50Hz) Controls the recovery shape of voltage transients in 50Hz
K3 (50Hz) Affects high frequency characteristics of the AVR algorithm
Damping Effect (50Hz) Affects high frequency characteristics of the AVR algorithm
K1 (60Hz) Sets overall AVR gain in 60Hz applications. This is a true
K2 (60Hz) Controls the recovery shape of voltage transients in 60Hz
K3 (60Hz) Affects high frequency characteristics of the AVR algorithm
Damping Effect (60Hz) Affects high frequency characteristics of the AVR algorithm
Value Comments
AVR Parameters
proportional gain which is multiplied against the voltage
error signal.
applications. This is a true integral gain which is multiplied
against the sum of all previous errors.
in 50Hz applications. Adjust for voltage stability reasons.
in 50Hz applications. Adjust for voltage stability reasons.
proportional gain which is multiplied against the voltage
error signal.
applications. This is a true integral gain which is multiplied
against the sum of all previous errors.
in 60Hz applications. Adjust for voltage stability reasons.
in 60Hz applications. Adjust for voltage stability reasons.
Engine Governing Parameters
GK1 (50Hz) Sets overall governor gain in 50Hz applications. This is a
true proportional gain which is multiplied against the frequency error signal.
GK2 (50Hz) Controls the recovery shape of speed transients in 50Hz
applications. This is a true integral gain which is multiplied
against the sum of all previous errors.
GK3 (50Hz) Affects high frequency characteristics of the governor algo-
rithm in 50Hz applications. Adjust for frequency stability
reasons.
Governor Damping Effect
(50Hz)
GK1 (60Hz) Sets overall governor gain in 60Hz applications. This is a
GK2 (60Hz) Controls the recovery shape of frequency transients in
GK3 (60Hz) Affects high frequency characteristics of the governor algo-
Affects high frequency characteristics of the governor algorithm in 50Hz applications. Adjust for frequency stability
reasons.
true proportional gain which is multiplied against the speed
error signal.
60Hz applications. This is a true integral gain which is multiplied against the sum of all previous errors.
rithm in 60Hz applications. Adjust for frequency stability
reasons.
Governor Damping Effect
(60Hz)
Affects high frequency characteristics of the governor algorithm in 60Hz applications. Adjust for frequency stability
reasons.
3-39
TABLE 3-21. GAIN TUNING PARAMETERS (CONT.)
Parameter CommentsValue
Engine Starting Parameters
Initial Crank Fueling Duty
Cycle
Initial Crank Fueling Period The period for which the value of Initial Crank Fuel Duty
Crank Fueling Ramp Rate The Rate at which the value of Governor Duty Cycle is
Maximum Crank Fueling The level to which the Governor Duty Cycle is limited dur-
Crank Exit Fueling
Command
Governor Enable Speed The Value of speed above which the electronic governor
Governor Ramp Time Sets the minimum governor speed reference ramp rate
The initial value assigned to Governor Duty Cycle at entry
in Crank State
Cycle is assigned to Governor Duty Cycle after entry in
Crank State
ramped up by during Crank State after expiration of the
Initial Crank Fueling Period
ing Crank State
The Value at which the Governor Duty Cycle is held after
disengaging the starter until the Governor is enabled.
starts controlling the value of Governor Duty Cycle
3-40
Controller Calibration
Component to be
Voltage measurement for regulation
The internal circuitry of the 1302 series control may
need to be calibrated. There are three different
components which may need this. They are:
Voltage measurement for display
TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS
Component to be
Calibrated
Voltage Measurement for
Regulation
The goal of this is to calibrate the regulation circuitry so it regulates the
genset to the desired
nominal voltage.
1. Connect to the control with your PC
PC Based Service Tool Operator Panel
based service tool.
2.
Verify the Nominal Voltage Trim is
set to the desired value.
3. Adjust the trim Voltage Regulation
Calibration 50Hz or Voltage Regulation Calibration 60Hz for your
desired application. The effect of
this trim is inverse on the regulated voltage. Increasing the trim,
well lower the regulated voltage,
and decreasing the trim will raise
the regulated voltage. Adjust the
trim so regulated voltage matches
the desired nominal voltage measured with a known calibrated
voltage meter.
4. Save the adjustments by doing a
Save Trims with your PC based
service tool.
Voltage Measurement for
Display
1. Connect to the control with your PC
based service tool.
2. Verify the Nominal Voltage Trim is set
to the desired value. The trim Alternator Nominal Voltage is available at Adjustments AC Measurement Cal-
ibrations Voltage Measurement for
Regulation. Set the Alternator Nominal Voltage to the voltage that the genset will generate.
3. Adjust the trim Alternator LX−N 50Hz
Voltage Display Adjust or Alternator
LX−N 60Hz Voltage Display Adjust
trim for your application. Each line will
need to be adjusted independently.
The goal is to have the value read by
the PC based service tool correspond
to the actual voltage being produced.
4. Save the adjustments by doing a Save
Trims with your PC based service tool.
Current measurement for display
The internal circuits must be calibrated in the order
listed in Table 3-22.
Calibration Method
1. View the Service Menu by holding
down the “up” and “down” arrow keys
on any of the operator menus (see Figure 3-24).
2. Select item 1, “Setup Menus”.
3. Enter setup menu password 574.
4. Select item 1, “Genset Service”.
5. Select item 1, and verify the “Volts AC”
setting is correct for your application.
If necessary, press the “Adjust” button
and change the setting. and press the
“Save” button.
6. Press the back button to return to the
service menu.
7. Select item 3, “Meter Calib.”
8. Press the “Adjust” button and change
the “Reg Volt Adj:” value. The effect of
this trim is inverse on the regulated
voltage. Increasing the percentage will
decrease the regulated voltage. Decreasing the percentage will increase
the regulated voltage.
9. Save the adjustments by pressing the
“Save” button.
1. View the Service Menu by holding
down the “up” and “down” arrow keys
on any of the operator menus (see Figure 3-25).
2. Select item 1, “Setup Menus”.
3. Enter setup menu password 574.
4. Select item 1, “Genset Service”.
5. Select item 3, “Meter Calib.”
6. Press the down arrow twice to scroll
down to the “Metering Voltage Adjust”
7. Adjust the three parameters listed so
the display voltage matches the voltage being produced by the genset.
8. Save the adjustments by pressing the
“save” button.
3-41
TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS (CONT.)
Component to be
Component to be
Calibrated
Calibrated
Current Measurement for
Display
Calibration Method
1. Apply a load to the genset and monitor
the current with a calibrated current
meter.
2. Connect to the control with your PC
based service tool.
3. Verify the CT ratio settings and power
ratings are correct for your application.
The Power Rating of the alternator is
configurable with the trims located in
Genset Power Ratings menu. The CT
ratio adjustable trim is available at
Features Genset Setup.
4. Adjust the LX 50Hz Current Adjust or
LX 60Hz Current Adjust trim for your
current application so the 1302 series
control measured current matches the
current read by the know current meter. Each of the three lines will have to
be adjusted independently of each
other.
5. Save the adjustments by doing a save
trims with your PC based service tool.
Operator PanelPC Based Service Tool
1. View the Service Menu by holding
down the “up” and “down” arrow keys
on any of the operator menus (see Figure 3-26).
2. Select item 1, “Setup Menus”.
3. Enter service menu password 574.
4. Select item 2, “Genset Setup”.
5. Enter the setup menu password 1209.
6. Verify with the display that the CT ratios and power rating are correct by
scrolling through the available
screens.
7. Return to the Setup Menu screen by
press the back arrow twice.
8. Select item 1, “Genset Service”.
9. Select item 3, “Meter Calib.”
10. Press the down arrow three times to
scroll down to Metering Current Adjust.
11. Adjust the three parameters to match
the current being displayed by the
known current meter.
12. Save the adjustments by pressing the
“Save” button.
3-42
NOTE: THE NUMBERS IN PARENTHESIS
MATCH THE STEPS INCLUDED
IN THE PROCEDURE LISTED IN
TABLE 3-22.
(1)
(2)
(3)
ENTER “574”
(4)
(5)
(5)
(5)
(5)
ENTER VOLTS
AC VALUE AND
PRESS THE
SAVE BUTTON
(7)
(6)
(8)
ENTER REG
VOLT ADJ VALUE
AND PRESS THE
SAVE BUTTON
(9)
FIGURE 3-24. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR REGULA-
TION
3-43
(3)
(4)
(1)
NOTE: THE NUMBERS IN PARENTHESIS
MATCH THE STEPS INCLUDED
IN THE PROCEDURE LISTED IN
TABLE 3-22.
(2)
ENTER “574”
(5)
(6)
(6)
(7)
(7)
ADJUST ALL THREE
PARAMETERS AND
PRESS THE SAVE
BUTTON
(8)
FIGURE 3-25. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR DISPLAY
3-44
(1)
NOTE: THE NUMBERS IN PARENTHESIS
MATCH THE STEPS INCLUDED
IN THE PROCEDURE LISTED IN
TABLE 3-22.
(2)
(9)
(10)
(10)
(10)
(5)
(6)
(3)
(4)
(8)
ENTER
“574”
ENTER
“1209”
(7)
(6)
(6)
(11)
(12)
(10)
(6)
ADJUST ALL THREE
PARAMETERS AND
PRESS THE SAVE
BUTTON
(6)
(6)
FIGURE 3-26. OPERATOR PANEL MENUS FOR CALIBRATING CURRENT MEASUREMENT FOR DISPLAY
3-45
1302 CONTROL FUNCTIONS
Remote Start Mode
The 1302 series control accepts a ground signal
from remote devices to automatically start the
generator set and immediately accelerate to rated
speed and voltage. The control can incorporate a
time delay start.
For information on how to set a start time delay
using the operator panel, see page 5-8.
Remote Emergency Stop
For operation of the genset, a closed relay contact
between TB1-15 and TB1-16 must be present. The
control enters an emergency stop mode when the
short is removed. Before the genset can be
restarted, the control must be manually reset by
re-applying the short and acknowledging the fault.
The E-stop circuit contains two parallel paths. One
path is fed into the micro-processor for status
processing. The second path is fed directly into the
relay drivers, disabling them when an E-stop is
present.
Local Emergency Stop
For operation of the genset, a short between J25-2
and J25-6 must be present. The control enters an
emergency stop mode when the short is removed.
Before the genset can be restarted, the control
must be manually reset by re-applying the short
and acknowledging the fault. The E-stop circuit
contains two parallel paths. One path is fed into the
micro-processor for status processing. The second path is fed directly into the relay drivers, disabling them when an E-stop is present.
Emergency Stop
It is also required that there be a physical interruption of the FSO and the starter (and, optionally,
switched B+) when an emergency stop is active. In
order to do this, add a second E-stop contact in series with B+ and the FSO relay coil. Figure 3-27 illustrates one possible way to do this. Power to the
fuel shutoff valve is provided serially through one
contact of the two contact E-stop switch. The connection point is called E−Stop B+.
Referring to wiring diagram: 630−3270 for complete illustration.
12/24V Battery
The 1302 series control provides 12 and 24 VDC
battery operation capability for genset system. It
requires battery voltage input from the genset
starter batteries.
The control system provides a field adjustable trim
to select either 12V/24V battery operations for
selection of the internal thresholds to this feature.
The trim parameter for this is Nominal Battery Voltage and the default trim is set at 12 VDC.
For information on how to set the nominal battery
voltage using the operator panel, see page 5-41.
Engine Starting
The control system supports automatic engine
starting. Primary and backup start disconnects are
achieved by one of the following three methods:
magnetic pickup, battery charging alternator
feedback, or main alternator output frequency.
Cycle Cranking
The 1302 series control can be configured for the
number of starting cycles (1 to 7) and duration of
crank and rest periods. The control includes starter
protection algorithms to prevent the operator from
specifying a starting sequence that might be
damaging.
B+
Local
E−Stop
Contact 1
Local
E−Stop
Contact 2
Local
E−Stop
Switch
FIGURE 3-27. EMERGENCY STOP CONTACTS
Remote
E−Stop
Contact 1
Remote
E−Stop
Switch
Remote
E−Stop
Contact 2
3-46
1302 Series Control
E−Stop B+
(To Relay
Contacts)
For information on how to set the cycle crank
attempts using the operator panel, see page 5-11.
Spark Ignition Power/Glow Plug Control
Pin J11-7 on the 1302 series control is dual
purpose.
Glow Plug Control
Glow plug is used as a Cold starting aid. Glow plugs
heat up the air going in for combustion for Diesel
Engine. Glow plug is used to improve the starting
ability of engines and to reduce the white smoke
during cold start.
In PCC1302 when Glow Plug Enable = Enabled
and Fuel System = Diesel the Glow Plug Function
is enabled and control will preheat the engine
starting glow plugs. Pin J11−7 on the PCC1302
control can be used to drive Glow Plugs via
external Relay.
Setting Glow Plug Enable = Disabled or Fuel
System = Gas, disables the Glow Plug Function.
Total Glow Time respectively based on reading of
Engine Coolant Temperature as shown in the
graph above. Cranking will start after the Preheat
Time has expired. The Glow Plug Output will remain on until the Total Glow Time has expired. The
Control commands the glow plugs to enable when
the control.
a. Detects that the genset has received a
valid start command.
b. Determines teh preheat time and total
glow times as the function of the Engine
Coolant Temperature.
c. Turns off the glow plug during the normal
stop or during the fault shutdown or during
the cyclical crank attempts or if the total
glow time has expired.
Preheat Processing
Preheat processing logic has three associated
trims as shown in Table 3−22
FIGURE 3-28. PRE−GLOW MEASUREMENT
Glow Plug Control implemented in PCC1302 consists of the following two processes:
a. Preheat Process (Pre−Glow Process)
b. Total Glow Process
Preheat Glow Time and Total Glow Time are determined by linear interpolation of Preheat Time and
TABLE 3-23. PREHEAT PROCESSING TRIMS
TABLE
Sr. No Name of the
Trims
1
2
3
Preheat Time
(Trim)(sec)
Preheat Temperature
(Trim)(_F)
Preheat Knee
Point
(Trim)(_F)
Default
Range
Value
15 (sec) 0−30 (sec)
70 (_F) 0−100 (_F)
0 (_F) 0−70 (_F)
Preheat Time = controls how many seconds the
glow plug will preheat before cranking the engine.
Preheat Temperature = controls at which temperature the control defines a non−cold engine. The
glow plugs will not preheat for engine coolant temperatures above the Preheat Temperature.
Total Glow Processing:
Total Glow processing logic has three associated
trims as shown in Table 3−23.
3-47
TABLE 3-24. TOTAL GLOW PROCESSING TRIMS
TABLE
Sr. No Name of the
Trims
Total Glow
1
2
3
Time
(Trim)(sec)
Total Glow
Temperature
(Trim)(_F)
Total Glow
Knee Point
(Trim)(_F)
Default
Range
Value
0 (sec) 0−60 (sec)
70 (_F) 0−110 (_F)
0 (_F) 0−32 (_F)
Glow Plug Output Logic:
In PCC1302, Glow Plug Output depends upon Total Glow Time Value (Mon). The Glow Plug Output
turns on when Fuel System (Trim) = Diesel and Total Glow Time Value (Mon) > 0. Glow Plug Driver
Command remains on until the Total Glow Time
Value (Mon) has expired. Glow Plug Output turns
off, if any of the following conditions is valid:
a. When Total Glow Tiem Value (Mon) ex-
pires.
b. When Generator Set Control stops nor-
mally.
c. When Generator Set Control stops during
emergency.
d. When Generator Set Control performs cy-
clical crank process.
When the trim parameter Fuel Type is set to Diesel
and Glow Plug is Enabled, the control preheats the
engine starting glow plugs. Two trim parameters
may need to be adjusted in order for the glow plug
preheat control logic to work effectively. The trim
parameter Preheat Time = seconds controls how
many seconds the glow plugs will preheat before
cranking the engine. The trim parameter Preheat
Temperature = degrees Fahrenheit controls at
which temperature the control defines a non-cold
engine. The glow plugs will not preheat for engine
coolant temperatures above the Preheat Temperature. Adjusting both of the trims will allow for tailoring of the glow plug preheat logic for specific engine applications. Setting Glow Plug = Disabled
disables the glow plug preheat logic.
When the trim parameter Fuel Type = Gas, pin
J11-7 can be used to control an external spark ignition control module. Pin J11-7 is turned on simulta-
neously with the fuel solenoid and held on as long
as the genset is running. Both drivers stay on while
the engine speed is above 150 RPM. When a shutdown command is received, the fuel solenoid is
disabled but the ignition control module driver
stays on until the Fuel Burn Off Time delay timer expires. By running the ignition system off of this
delayed output, all of the fuel downstream of the
fuel solenoid is burned following a genset stop /
shutdown. This removes the occasional fuel flash
in the exhaust system after a stop / shutdown.
Refer to the wiring diagram for more information on
how to configure the Remote Emergency Stop
Switch for gas gensets to interrupt the ignition system power.
For information on how to set the Fuel Type, enable
a Glow Plug, and set a Fuel Burn Time Delay using
the operator panel, see page 5-8.
Start and Stop Time Delays (Cool Down)
The 1302 series control is configurable for a time
delay of 0−300 seconds prior to starting after
receiving a remote start signal, and for a time delay
of 0−600 seconds prior to shut down after signal to
stop in normal operation modes. The default for
both time delay periods is 0.
0−3600 seconds (fron 1302 calibration version
2.80 and HMI211 calibration version 7.20). Earlier
versions have 0−300 seconds.
For information on how to set a start or stop time
delay using the operator panel, see page 5-8.
Electronic Governor
The 1302 series control provides electronic governing capability for a generator set when a electronic governor option is installed on the genset. It
has a field adjustment trim to enable or disable the
electronic governing feature. It supports isochronous speed governing as defined below.
The maximum allowed rated current for the
actuator drive for the governor power stage is
6.0A continuous max; 10 Amps for 1 second.
The governing system is suitable for use with
Gensets using Cummins EFC normally closed
actuators, Woodward, FORD Gas, or BarberColeman actuators with similar drive characteristics.
It provides speed governor setpoints of 1500
RPM and 1800 RPM. The governor setpoint is
a field adjustment (50 Hz or 60 Hz).
3-48
The optional display allows the operator to ad-
just frequency within plus or minus 5% of rated
speed.
The controller provides ramping at startup and
an ability to program the cranking fueling before the governor algorithm is enabled.
Engine Speed Sensing
For electronically governed gensets, the 1302 series control requires an engine speed input from a
magnetic pickup speed sensor. The magnetic pickup signal needs to be calibrated for number of engine flywheel teeth. The table shown below lists the
number of flywheel teeth for some common engine
types.
vent the fuel actuators from becoming stuck.
Therefore dither should be used in applications where the fuel actuators are prone to
sticking. This feature has adjustable dither
amplitude (0% to 30% of governor duty cycle).
The dither function is enabled by selecting a
dither factor. The dither function is disabled by
setting the dither factor to 0%.
The following cranking fuel control characteristics
are also provided to “tune up” the genset startup to
suit the application. Cold weather applications
might need a longer cranking period and/OR higher levels of cranking fuel. Following parameters
should be chosen to make sure the genset starts
up quickly enough but does not overshoot or produces excessive smoke at startup.
TABLE 3-25. FLYWHEEL TEETH REQUIREMENTS
Engine Type
Cummins 4B, 6B 159
Cummins 4C 138
Ford 4cycl Gas 104
Kubota Engines 105
Cummins L10, NT855 118
Komatsu 3.3L 110
Cummins V28, K19,
K38, K50
Ford V6 and V10 gas 133
For non-electronically governed gensets, the magnetic pickup is optional. If it is not used, engine
speed is calculated from the alternator output frequency.
Number of
Flywheel Teeth
142
Speed Governor Algorithm and
Adjustment
The 1302 series control supports the following
speed governor algorithm characteristics:
It uses a four-coefficient field adjustable
closed loop PID control algorithm (Proportional−Integral−Derivative).
It allows field tuning of the speed coefficients.
The 1302 series control provides a dither fea-
ture. Dither is a method of introducing small
amounts of noise into the speed governing
system. The purpose of this feature is to pre-
The initial cranking fuel duty cycle can be cho-
sen to suit the engine / application.
The initial cranking fuel period can be chosen
to suit the application.
The cranking fuel is ramped up during crank-
ing after initial cranking fueling period is over.
The rate of ramping up of fueling can be chosen to suit the application.
The maximum crank fuel duty cycle can be
chosen to suit the application. During cranking
the duty cycle of the PWM, output to the actuator will be limited to this value.
The crank exit fuel duty cycle can be chosen
to suit the application. After the engine fires,
the fueling level will return to this value before
the 4 coefficient algorithm takes over the control of the PWM output to the actuator.
Fueling is initially set to the Initial Crank Fueling
Duty Cycle value and remains at that value for the
Initial Crank Fueling Period. After this period expires, the fuel command is ramped at the Crank
Fueling Ramp Rate until the Maximum Crank Fueling limit is reached. Upon reaching the Starter Disconnect Speed, the fueling command is pulled
back to the Crank Exit Fueling Duty Cycle value until the Governor Enable Engine Speed is reached.
When the Governor Enable Engine Speed is
reached, the governor is enabled, the speed setpoint is set to the sensed engine speed value at this
point, and the setpoint is ramped to rated speed in
a time equal to the Governor Ramp Time. The diagram below illustrated these setpoints.
3-49
Crank Fuel Duty Cycle
Initial Crank Fuel
Cycle
Duty
Initial Crank
Fueling Period
FIGURE 3-29. GOVERNOR RAMP TIME SETPOINTS
REAL TIME CLOCK
The PCC1302 control system includes a Real Time
Clock (RTC) function used for automatic scheduler
(exercise scheduler) feature. The Real Time Clock
(RTC) in PCC1302 is NOT used for calculating
controller on time, or for recording fault occurrence
times, or for supporting factory test. Once
PCC1302 is programmed and given a power cycle,
the user should enter the correct time, date and
clock cycle (AM/PM). Based on the time and date
saved by the user, the real time clock accurately*
calculates seconds, minutes, hours, date of the
month, month, day of the week, and year with leap
year compensation. The clock operates in 12 hour
format with support for AM/PM.
When battery power is removed or the PCC1302
controller goes in sleep mode, the RTC parameters
get reset to 00:00 (HH:MM) for Time and 00/00/00
Closed Loop Operation
Max Crank Fuel
Duty Cycle
Crank Exit Fuel
Duty Cycle
Crank Fuel
Ramp Rate
(MM/DD/YY) for Date and AM for Clock Cycle. Under this condition, and with Scheduler Prog x Enable trim Enabled and Clock Diagnostic Enable
trim Enabled, FC 1689 (Clock Not Set) will become
active indicating that the date, time and AM/PM
needs to be set by the user.
The RTC also supports Daylight Savings Time
(DST), which is a convention used to advance the
time by one hour so that afternoons have more
daylight than mornings. The DST logic adds the
DST Adjustment time to the current time when the
current time is equal to the DST Start Time. The
DST logic subtracts the DST Adjustment time from
the current time when the current time is equal to
the DST End Time. To enable DST, the trim Daylight Savings Time Enable needs to be set to Enabled. To setup DST, specify the values for the following trims. These trims can be set via PCTools or
HMI211 or HMI211RS or via Modbus utility.
3-50
TABLE 3-26. TRIM RANGE VALUES
Trim
Daylight Savings End Day Monday − Sunday Calendar Day in which DST Ends
Daylight Savings End Hour 01− 12 hours (it is always
AM)
Daylight Savings End Month 1 − 12 months Month in which DST Ends
Daylight Savings End Week Occ
Month
Daylight Savings End Day Monday − Sunday Calendar Day in which DST Starts
Daylight Savings End Hour 01− 12 hours (it is always
Daylight Savings Start Month 1 − 12 months Month in which DST Starts
Daylight Savings Start Week Occ
Month
Daylight Savings Time Adjustmenty 0 − 120 minutes Amount of time to be added or subtracted
Default − Fifth Occurrence Occurrence of Daylight Savings End Day in
AM)
Default − Fifth Occurrence Occurrence of Daylight Savings End Day in
Range Meaning
Hour (12 Hr) in which DST Ends
which DST Ends
Hour (12 Hr) in which DST Ends
which DST Starts
from current time for DST adjustment.
For Example: If DST Ends on the 1st Wednesday in
April at 02:00 AM every year, and DST Starts on the
2nd Thursday in September at 3:00 AM every year,
and DST Adjusts the clock by 1 hour each time, the
parameters should be set to the following values.
TABLE 3-27. TRIM VALUES
Trim Value
Daylight Saving End Day Wednesday
Daylight Saving End Hour 02
Daylight Saving End Month 4
Daylight Saving End Week
First Occurrence
Occurrence in Month
Daylight Saving Start Day Thursday
Daylight Saving Start Hour 3
Daylight Saving Start
9
Month
Daylight Saving Start
Week Occurrence in Month
Daylight Saving Time Ad-
Second Occur-
rence
60
justment
NOTE: The software accuracy of real time
clock is +/− hour over a period of 1 cal-
endar year. The real time clock func-
tion is available from 1320 calibration
version 2.76 and above and HMI211
calibration version 6.90 and above.
EXERCISE SCHEDULER
The exercise scheduler is a feature that automatically starts the genset for exercise. This feature
prevents common problems which result from mechanical equipment being not in operation for long
periods of time. In order for the automatic exerciser
to work, the PCC1302 control system needs to be
in ’Auto’ mode, the RTC needs to be set (Fault 1689
is not active), and the trim Scheduler Prog x Enable
needs to be set to Enable.
SLEEP mode will be disabled if the user enables
the exercise scheduler. This is because sleep
mode will reset the clock (RTC) in PCC 1302 and
exercise function will not work.
The PCC1302 can be programmed to run only 1
program, which is a repeating event. Furthermore,
the program can be programmed to exercise the
genset at rated condition and at ’No Load’ condition. No exceptions can be set in PCC1302.
The exercise program has the following trims
which establish its behavior where currently x always denotes 1.
3-51
TABLE 3-28. TRIM SCHEDULE VALUE
Trim
Scheduler Prog x Enable Enable − Disable Enables or Disables Schedule x=1
Scheduler Prog Start Minute 0 − 59 Specifies at what minute Program with start
Scheduler Prog Start Hour 1 − 12 Specifies at what hour Program will start
Scheduler Prog Start Day Monday − Sunday Specifies at what day Program will start
Scheduler Prog Start Period AM − PM Specifies at what period Program will start
Scheduler Prog Repeat Interval Weekly,Bi_Monthly,Month-
ly,Quarterly,Semi−Annual
Scheduler Prog Duration (Mins) 5 − 15 Specifies how many minutes Program will run
Value Meaning
Specifies the repeating behavior of Program
For example, if it was desired to have a Program
that ran on every Monday at 8:12 AM for 15
Minutes, the trims should be defined in Table 3−28
TABLE 3-29. EXAMPLE TRIM VALUE
Trim Value
Scheduler Prog x Enable Enable
Scheduler Prog Start Minute 12
Scheduler Prog Start Hour 8
Scheduler Prog Start Day Monday
Scheduler Prog Start Period AM
Scheduler Prog Repeat Interval Weekly
Scheduler Prog Duration (Mins) 15
3-52
Program 1
Scheduler
Program
Enable
TABLE 3-30. EXCERISER SCHEDULE
Scheduler
Program
Start Day
Start Time Scheduler
Program
Duration
Hr Min Min Weekly Bi−
Schedular
Program
Start Period
AM/PM
Schedule Re-
peat Interval
monthy,
Monthly,
Quarterly
Semi−Annual
The following are the set of rules for
exercise scheduler
1. While in Exercise mode, genset will start if in
AUTO mode, and run at rated condition and at
’No Load’
2. While in Exercise mode, ’Exercise Scheduler
On’ message will be displayed on both HMI
211 and HMI 211 RS.
3. This message screen will be displayed for 1
sec when in Info screens of the HMI and will
toggle with the Info screens at a frequency of
3 sec.
4. While in Exercise mode, the user cannot edit
the Clock parameters, the Exercise Scheduler
parameters and the Daylight Savings parameters except for the trim ”Scheduler Prog x Enable”.
5. If the user tries to edit these trims except
”Scheduler Prog x Enable”, following message, ”Can Not Edit Exercise On” will be displayed on both HMI 211 and HMI 211 RS.
While in exercise scheduler mode, i.e. a scheduled
program is active and control system is in ’Auto’
mode, if the PC1.1 control system receives a
remote start command via HMI or from PCTools or
from external transfer switch, the exercise
scheduler mode will be terminated and the
Scheduler Prog Duration (Mins) timer will become
0. However, the genset will continue to run in ’Auto’
mode and will follow ATS operation if ATS
functionality is enabled. If remote start command is
removed then the genset will stop running.
ATS Control
Automatic Transfer Switch is used to transfer power from Utility to Genset and vice−versa. A trim
Auto Mains Failure Enable is provided to enable/
disable the ATS functionality in PCC1302. There
are settable delay timers incorporated for transferring and re−transferring the load from Utility to
Genset and vice−versa. In addition, diagnostic
faults of ATS functionality and its corresponding
FCs/ symbols are supported in HMI211 and
HMI211RS.
PCC 1302 has four configurable inputs, out of
which two Configurable Inputs can be used for
checking the feedback of the switch positions i.e.
on Genset side or Utility side. The configurable inputs will remain locked for ATS functionality when
AMF feature is enabled and the trim Transfer
Switch Feedback Enable is enabled.
TABLE 3-31. CONFIGURABLE INPUTS
Pin Signal Name
TB1−12 Configurable Input 1
TB1−13 Configurable Input 1 − Common
TB1−14 Configurable Input 2
Configurable Input 1 is used for Utility switch position status and Configurable Input 2 is used for
Genset switch position status.
For transferring the load from Utility to Genset or
vice−versa, PCC1302 will use low side driver
Ready to Load/ ATS Output only.
ATS functionality will only be enabled when Auto
Mains Failure Enable is enabled with the condition
that Genset control is running in Auto mode.
NOTE: The excerise scheduler function is
available from 1320 calibration version 2.76 and above and HMI211 calibration version 6.90 and above.
NOTE: When Exercise is active and if Utility
lost condition is received (remote start
signal is active), Genset Control discards the Exercise and continues with
3-53
the ATS functionality. The excerise
scheduler function is available from
1320 calibration version 2.76 and
above and HMI211 calibration version
6.90 and above.
LOAD
START/STOP
OPERATION
SOURCE 2
GENSET
READY TO LOAD
CONDITION
TRANSFER SWITCH
GENSET
FEEDBACK
Config I/P 2 Config I/P 1
TB1−14 TB1−12
GENSET CONTROL
UTILITY
FEEDBACK
TB1−4
TB1−10
Ready to Load/
ATS Output
Remote HMI
SOURCE 1
UTILITY
UTILITY VOLTAGE
MONITORING
SENSOR
REMOTE START
COMMAND
FIGURE 3-30. PCC1302 BLOCK DIAGRAM
As per the block diagram shown above,
Genset Control (PCC1302) monitors the status of the Utility (Failing and Returning condition) directly through Remote Start Command (Active or Inactive) condition.
When Utility voltage monitoring sensor
senses that the voltage has gone below
Drop−out Voltage, it will activate the Remote
Start Command input.
When Utility voltage monitoring sensor
senses that the voltage has gone above the
Pickup Voltage, it will de−activate the Remote Start Command input.
When Genset control receives the Remote
Start active input command, the control will
do the following when Control Switch Position is in Auto.
a. Genset Control gives the start command
to Genset after the Start Time delay is
completed.
b. After starting the Genset, when Genset
Control reaches the ”Running” condition,
it starts the Transfer Delay (trim) if Auto
Mains Failure Enable is enabled.
c. When Genset Control reaches the Ready
to Load condition and Auto Mains Failure
Enable is enabled and Transfer Delay is
completed, Genset Control will activate
the Ready to Load/ATS output (Customer
Ready to load driver output) to initiate the
3-54
transfer process of the load from Utility
source to Genset source.
d. After activating the Ready to Load/ATS
output, Genset Control starts Transfer
Delay Timer. Genset control will check for
Configurable Input 1 Status = Inactive
(Utility Open) and Configurable Input 2
Status = Active (Genset Close) feedback.
If the feedback is not received for specified period of time (Transfer to Genset
Delay Timer), Genset Control will declare
the Shutdown fault ”Genset Failed To
Close”.
When Genset Control receives the Remote
Start Inactive Input Command, the Control will
do the following
a. When Genset Control receives the Re-
mote Start Inactive Input Command and
Auto Mains Failure Enable is enabled,
Genset Control starts Re−Transfer Delay
(Trim).
b. When Genset Control receives the Re-
mote Start Inactive Input Command and
Auto Mains Failure Enable is enabled,
Genset Control starts Re−Transfer Delay
(Trim).
then transferring and retransferring
process depends upon Feedback
Logic and Ready to Load/ ATS Output
automatically. In Genset Control, if
Auto Mains Failure Enable = Enabled
and Transfer Switch Feedback Enable = Disabled, then transferring and
retransferring process depends upon
Ready to Load / ATS Output status
only.
NOTE: The ATS control function is available
from 1320 calibration version 2.76 and
above and HMI211 calibration version
6.90 and above.
Dual Fuel
The PCC1302 has the ability to determine the status of the Fuel System and notify the user and the
ECM.
When Fuel Type = Gas and Engine Application
Type = FAE (ECM CAN Enable = Enabled), user
will be able to set the trim parameter Gas Fuel Type
as Natural Gas (Default) or Propane or Dual.
When Gas Fuel Type is selected as Dual, the control system has the ability to transfer the fuel source
from Natural Gas to Propane in case a low fuel condition is sensed for Natural Gas.
c. After de−activating the output and Auto
Mains Failure Enable is enabled, Genset
Control will check for the Configurable Input 2 Status = Inactive (Genset Open) and
Configurable Input 1 Status = Active (Utility Close) feedback. If the feedback is not
received for specified period of time (Re−
Transfer to Utility Delay Timer), Genset
Control will declare the Warning fault ”Utility Failed To Close”.
d. Genset Control will initiate the Stop Time
delay only when the feedback is received
otherwise Genset will continue to be in
running state. After the completion of the
Stop Time delay, Genset Control will give
the command to stop the Genset.
If Transfer Switch is at unknown position, Gen-
set Control will declare the Warning fault
”Transfer Switch Status Unknown Position”.
NOTE: In Genset Control, if Auto Mains Fail-
ure Enable = Enabled and Transfer
Switch Feedback Enable = Enabled,
BATTLE SHORT MODE OPTION
The 1302 series control can be programmed to
work in battle short mode.
The PC service tool is required to enable the Battle
Short feature. If the operator panel is not installed,
the PC service tool is also required to enable the
external Battle Short switch.
The controller then can accept Configurable Input
1 as battle short switch inputs. If an operator panel
is used, it can be also selected as a source of input
by selecting the appropriate input source value for
the trim.
Installations With an Operator Panel
To activate the Battle Short feature for installations
that include the operator panel (see Figure 3-31),
1. Use the PC service tool to enable the Battle
Short mode feature. Contact an authorized
service center for assistance.
2. View the Service Menu by simultaneously
holding down the “up” and “down” arrow keys.
3. Select item 1, “Setup Menus”.
3-55
4. Enter setup menu password 574.
5. Select item 1, “Genset Service”.
6. Select item 1, “Genset”.
7. Press the selection button five times to
view the “Battleshort” menu.
NOTE: This menu is displayed only if the
Battle Short mode feature has been
enabled with the PC service tool.
8. Press the ADJUST button.
− If you want the operator panel to be the
activation source of this feature, change
the “Switch Input:” setting to “Operator
Panel.”
NOTE: When Switch Input is set to “Op-
erator Panel”, the “Battle Short:
Active/Inactive” subject is displayed. Battle Short should not
be set to “Active” until it is needed
by the customer.
− If you want a customer input to be the
activation source of this feature, change
the “Switch Input:” setting to “Customer
Input 1” or “Customer Input 2.” Refer to
page 5-21 for information on setting up
customer inputs.
9. Save the adjustments by pressing the “Save”
button.
For more information on the Battle Short feature,
see Section 4.
3-56
Installations Without an Operator Panel
Installations without a operator panel require the
following.
Before the Battle Short feature can be used, it must
first be enabled. Only trained and experienced service personnel should enable this feature. When
shipped from the factory, this feature is disabled.
A Manual Run/Off/Auto switch must be con-
nected to the control harness.
A status indicator lamp must be installed to
flash shutdown fault codes.
An external On/Off switch must be con-
nected to one of the customer configured
inputs on the control board.
The PC service tool must be used to enable
the Battle Short mode feature.
The PC service tool must be used to enable
the external Battle Short On/Off switch.
Contact an authorized service center for assistance. For more information on the Battle Short
feature, see Section 4.
Battle Short Mode
Battle Short mode is designed to work only in critical load circumstances and is used to satisfy local
code requirements, where necessary. This feature
can only be used if the necessary software was
installed at the factory when the 1302 control was
purchased or if it was installed by an authorized
customer service representative.
Battle Short mode prevents the genset from being
shutdown by all but a select few critical shutdown
faults. All shutdown faults, including those
overridden by Battle Short, must be acted upon
immediately to ensure the safety and well being
of the operator and the genset.
WARNING
ture can cause a fire or electrical hazard, resulting in severe personal injury or death and/or
property and equipment damage. Operation of
the genset must be supervised during Battle
Short operation.
This feature must only be used during supervised,
temporary operation of the genset. The faults that
are overridden when in Battle Short mode are
faults that can affect genset performance or cause
permanent engine, alternator, or connected
equipment damage. Operation may void the
generator set warranty if damage occurs that
relates to the fault condition(s).
Use of the Battle Short mode fea-
Installations with an Operator Panel
Battle Short can be enabled or disabled (set to Active or Inactive) using the operator panel.
The PC service tool is required to enable the
Battle Short mode feature. Contact an authorized service center for assistance.
Before Battle Short can be used on installations
with the operator panel, the Switch Input setting on
the Battle Short submenu must be set to “Operator
Panel” (see page 5-12). In addition, Battle Short
mode must be enabled (set to Active) in the Battle
Short submenu (see page 5-12).
When Battle Short mode is enabled, the Warning
status indicator lights, and Fault Code 1131 −
Battle Short Active is displayed.
When Battle Short mode is enabled and an over-
ridden shutdown fault occurs, the shutdown
lamp remains lit even though the genset continues
to run. Fault Code 1416 − Fail to Shut Down is
displayed. If the
acknowledge the fault, the fault message is cleared
from the display but remains in the Fault History file
with an asterisk sign (* indicates an active fault) as
long as Battle Short mode is enabled.
Battle Short is suspended and a shutdown occurs
immediately if:
Any of the following shutdown faults occurs.
− Overspeed − Fault Code 234, Fault Code
1992 and Fault Code 3131
− Emergency Stop − Fault Code 1433 or
1434
− Speed Signal Lost (Loss of Speed
Sense) − Fault Code 121
− Excitation Fault (Loss of Voltage
Sense) − Fault Code 2335
Battle Short mode is disabled after an over-
ridden shutdown fault occurred while in
Battle Short mode. To disable Battle Short
mode, navigate to the Battle Short submenu
(see page 5-12) and select “Inactive.” Fault
Code 1123 − Shutdown After Battle Short
is then displayed.
, , or button is pressed to
3-57
Installations without an Operator Panel
A Manual Run/Off/Auto switch must be installed in
installations that do not include a operator panel.
Battle Short can be turned on or off with a customer
installed external switch connected to one of the
two customer configured inputs.
The PC service tool is required to enable the
Battle Short mode feature and to enable the external Battle Short switch using one of the two
available customer inputs. Contact an authorized service center for assistance.
When Battle Short mode is enabled and an overridden shutdown fault occurs, the genset continues to
run and the status indicator lamp flashes the shutdown fault code. See “Local Status Output” on page
4-1 for information on interpreting the status indicator light.
Battle Short is suspended and a shutdown occurs
immediately if:
Any of the following shutdown faults occurs.
− Overspeed − Fault code 234 or 1992 or
3131
− Emergency Stop − Fault code 1433 or
1434
− Speed Signal Lost (Loss of Speed
Sense) − Fault code 121
− Excitation Fault (Loss of Voltage
Sense) − Fault code 2335
The external Battle Short switch is moved to
the OFF position after an active but overridden shutdown fault occurred while in Battle
Short mode. The status indicator lamp then
flashes Fault Code 1123 − Shutdown After
Battle Short.
3-58
(4)
(2)
(7)
(3)
(7)
(7)
(6)
(5)
ENTER “574”
“BATTLE SHORT:
ACTIVE / INACTIVE”
IS ONLY DISPLAYED
IF THE SWITCH
INPUT IS SET TO
“OPERATOR PANEL”
(8)
(7)
(7)
(7)
THIS SUBMENU IS ONLY
DISPLAYED IF THE
BATTLE SHORT FEATURE
HAS BEEN ENABLED
USING THE PC SERVICE
TOOL
NOTE: THE NUMBERS IN PARENTHESIS
MATCH THE STEPS INCLUDED IN THE
PROCEDURE LISTED ON PAGE 3-55.
FIGURE 3-31. OPERATOR PANEL MENUS FOR CALIBRATING BATTLE SHORT MODE
3-59
THIS PAGE INTENTIONALLY LEFT BLANK
3-60
4. Operator Panel Operation
GRAPHICAL
DISPLAY
LED
INDICATORS
OFF MODE
BUTTON
HMI1211
DISPLAY MENU
SELECTION BUTTONS
FIGURE 4-1. 1302 OPTIONAL OPERATOR PANEL
INTRODUCTION
This section includes information on the following.
Local Status Output Indicator
Operating Modes
Operator Panel Description
Operator Panel System Messages
Description of Fault and Status Codes
Adjusting Values and Saving the Changes
Basic Operator Menus
Selecting Auto, Manual Run, and Off Modes
Service Menus
History/About Menus
Fault History Menu
Screen Adjust Menu
LOCAL STATUS OUTPUT INDICATOR
PREVIOUS MENU
LEVEL BUTTON
preheat (when used) and while the generator
set is starting.
Constant On = The genset is running.
Intermittent Flashing = A genset shutdown
fault condition exists. All of the shutdown
faults described in Table 4-2 can be announced with a status indicator lamp.
For four-digit shutdown fault codes, the first
digit in the code is flashed, followed by a halfsecond pause, then the second digit is flashed,
followed by a half-second pause, then the third
digit is flashed, followed by a half-second
pause, and then the fourth digit is flashed, followed by a two-second pause.
NOTE: Only the last shutdown fault is flashed.
If your installation includes a status indicator lamp
that flashes genset status and shutdown fault
codes, the following describes how to interpret the
status indicator light.
Constant Fast Flashing = This occurs during
When a fault is corrected, the Manual Run/Off/
Auto switch must be placed in the Off position
to reset the control.
Under all other indications, the status lamp is
off.
4-1
OPERATING MODES
Sleep Mode
The 1302 control works with a Manual Run/Off/Auto
switch, used to control genset operating modes.
This capability is located either in the harness
(switch) or is integrated into the operator panel included in this kit.
Off Mode
When in Off mode, the control does not allow the
genset to start. If the genset is already running and
the control is set to Off, it initiates a normal shutdown sequence. When in Off mode, all active faults
are reset.
Manual Run Mode
When in Manual Run mode, the genset starts and
continues to run until the control is put into the Off
mode. While in Manual Run mode, any remote start
signal is ignored.
Auto Mode
When in Auto mode, the control allows the genset
to be started with a remote start signal only.
The 1302 series control enters a low power (sleep)
mode of operation where the current draw is not
greater than 60 milliamps (DC) at normal battery
voltage levels. The control is set to enter sleep
mode after five minutes in the Off or Auto mode
(configurable).
Sleep mode can only be disabled by installing a
jumper between TB15-1 and TB15-5 (the TB15
connector is shown in Figure 4-2).
TB15
CONNECTOR
When in Auto mode, the genset can start at any
time. When a remote start signal is received, the
genset starts after the time delay start and time
delay preheat (if programmed) are completed.
If the genset is running in Auto mode and the Off
button is pressed, the control immediately stops
the genset and the control transitions to the Off
mode.
When all remote start signals are removed, the
control performs a normal shutdown sequence
which may include a time delay stop.
Emergency Stop Mode
When the optional emergency stop button is used,
it immediately shuts down the generator set, bypassing any time delay stop. The red Shutdown
LED lights and Fault Code 1433 or 1434 − Emer-
gency Stop is either displayed (installations with a
operator panel) or flashed (installations with a status indicator lamp).
To reset the control, close (disable) the emergency
stop button and either press the
(installations that include a operator panel) or move
the control switch to the OFF position (installations
with a Manual Run/Off/Auto switch).
(Off) button
FIGURE 4-2. TB15 CONNECTOR WITH JUMPER
The control will not enter the sleep mode if there are
any active, unacknowledged shutdown faults, if the
control is in the Manual Run mode.
Once in sleep mode, the 1302 series control will
wake up when one of the following wakeup signals
are received.
Local E-Stop − Active when switch is open
Remote E-Stop − Active when switch is open
Manual Start
PCCNet System Wakeup
Remote Start
Auto Mode (If Configured)
Configurable Input #3
Configurable Input #4
4-2
Installations with an Operator Panel
Sleep mode is automatically enabled on the operator panel. To awaken the operator panel, press any
button.
Installations with a Manual Run/Off/Auto
Switch
For installations that utilize an Manual Run/Off/Auto
switch located in the harness, the control awakes
from sleep mode if Manual Run or Auto mode (if
configured) is selected.
show either text or symbolic versions of fault messages, some Operator menus, and the Mode
Change menu. A description of commonly used
symbols used are included in Table 4-1. Combinations of symbols are used to display some fault conditions. Additional specialized symbols are also
used for some faults (see Table 4-2).
TABLE 4-1. SYMBOLS
SYMBOL
Generator Warning Fault
DESCRIPTION
OPERATOR PANEL
Figure 4-1 shows the front of the optional operator
panel. It includes six LED indicators, the graphical
display, and six buttons used to navigate through
the menus and adjust parameters.
Graphical Display
This graphical display is used to view menus of the
menu-driven operating system. The bottom of the
graphical display indicates the functions that are
available by pressing the four selection buttons.
Refer to the menu trees later in this section.
System messages (communication, event, status,
and fault) are also shown on the graphical display.
For more information, see page 4-6.
Display Text / Symbolic Versions
Using the Display Setup Service submenu (see
page 5-15), the graphical display can be set up to
Hz
Generator Shutdown Fault
Coolant Temperature
Oil Pressure
Voltage Alternating Current (VAC)
Voltage Direct Current (VDC)
AC Current
Frequency
Battery
Out of Range
High or Pre-High
Low or Pre-Low
Annunciator
4-3
Display Menu Selection Buttons
Four momentary soft-key buttons are used to step
through the various menus and to adjust parameters. These selection buttons are “active” when a
word or symbol in the graphical display is shown
above the button. Some submenus do not include
any active buttons.
The function of the four selection buttons varies
with each menu.
When the
selection button can be used to switch to
Auto mode.
When the
tion button can be used to switch to Manual
Run mode.
When the up and down triangles (
are displayed, the selection buttons are used
to navigate between a series of submenus.
symbol is displayed, the
symbol is displayed, the selec-
and )
When ADJUST is displayed, the selection
button is used to display an adjustable
menu. When the ADJUST button is pressed,
the first adjustable parameter or value in the
submenu is highlighted.
When the
selection button is used to navigate to an
editable field within a menu.
When the + and − symbols are displayed,
the selection buttons are used to increase or
decrease a parameter or value shown on the
screen.
When changing values, pressing the button
below the + symbol increase the value and
pressing the button below the − symbol de-
creases the value.
When SAVE is displayed, the selection but-
ton is used to save changes made in a submenu. If the Previous Menu button is
pressed before pressing SAVE, the
changes are not saved.
symbol is displayed, the
NOTE: When any Operator menu is dis-
played, a series of Service menus can
be viewed by simultaneously pressing
and selection buttons for two
the
seconds (see page 4-24).
NOTE: When a fault is displayed, it can be
cleared from the front panel by pressing the
When a
button can be used to abort the Auto or
Manual Run mode and return to the Operator menu that was displayed before the Auto
or Manual Run mode was selected.
symbol is displayed, the selection
or button.
Some menus include a list of numbered sub-
jects. These menus include numbers in parenthesis (for example, (1)) displayed above
the selection buttons. The selection buttons
are then used to display submenus of the
subjects included in the list.
When a black box
selection button has no function.
is displayed, the
Previous Main Menu Button
Press the button to view the previous main
menu.
NOTE: In the Screen Adjust menu, settings are not
saved when the
button is pressed.
4-4
OFF
BUTTON
PREVIOUS MAIN
MENU BUTTON
possible, this hot shutdown should be avoided to
help prolong the reliability of the genset.
Not In Auto Indicator
This red lamp is lit when the control is not in the
Auto mode.
Shutdown Indicator
This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be
started when this lamp is on. After the condition is
corrected, the lamp can be reset by performing a
fault reset. When Battle Short mode is enabled and
an overridden shutdown fault occurs, the Shutdown lamp is lit even though the genset continues
to run.
Warning Indicator
This yellow lamp is lit whenever the control detects
a warning condition. This lamp is automatically
shut off when the warning condition no longer exists.
FIGURE 4-3. PREVIOUS MAIN MENU AND OFF
BUTTONS
Off Button
Press the button to switch to the Off mode. The
Off mode disables the control Auto or Manual Run
modes.
If the
(manual or remote start), the engine immediately
shuts down and the control enters the Off mode. If
button is pressed during genset operation
Remote Start Indicator
This green lamp indicates the control is receiving a
remote start signal.
Auto Indicator
This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
selection button from any of the Operator me-
nus (see page 4-22).
Manual Run Indicator
This green lamp indicates the control is in the
Manual Run mode. Manual Run mode can be selected by pressing the
of the Operator menus (see page 4-22).
selection button from any
4-5
OPERATOR PANEL SYSTEM MESSAGES
A system pop-up message is displayed when the
event it is displaying becomes active. These popup messages remain displayed until pre-empted by
another pop-up message or until the
or the
display buttons is pressed or the event has expired.
Once the
or the button is pressed, the pre-
vious screen is redisplayed.
Communication Messages
System messages are displayed for initial powerup or when there is a subsequent loss of communications. Auto and Manual Run modes can also be
selected when communication messages are displayed (for more information, see page 4-22).
Upon initial power-up, the message “Establishing
communication with control” is displayed (see Figure 4-4). This menu also displays the screen’s software number and version.
If either communication message remains displayed (cannot view other menus), this is an indication that communications between the operator panel and the control logic is lost. Contact an authorized service center for service.
Event Messages
When pre-set events (start or stop) are activated,
Event messages are displayed showing the time
remaining until the event occurs (see Figure 4-6).
Event = START,
or STOP
FIGURE 4-6. EVENT MESSAGE
Status Messages
FIGURE 4-4. ESTABLISHING COMMUNICATIONS
MESSAGE
When the display detects that it is no longer communicating with the control, the Shutdown, Warning, and Remote Start LEDs are turned off.
If communications are lost, the message “Re-establishing communication with control” is displayed
until communications have been re-established
(see Figure 4-5). The LEDs then return to the state
determined by the control.
Status messages for some events are displayed on
the optional control panel with a code number but
are not announced with a lamp indicator. Text status messages include the event code, a short description, and the time the event occurred. Symbolic status messages include the event code and
symbols to indicate the type of event that occurred.
FIGURE 4-7. DATASAVE STATUS MESSAGE
On Full Authority Electronic engines, the engine
controller saves data after each run. During this
time, the display displays the message shown in
Figure 4-7. The generator can still be started while
the ECM Datasave is in progress.
FIGURE 4-5. RE-ESTABLISHING
COMMUNICATIONS MESSAGE
Fault Messages
A Fault message is an indicator of a Warning or
Shutdown condition that is also announced with a
lamp indicator. Text fault messages include the
4-6
fault code number, a short description, and when
the fault occurred (see Figure 4-8). Symbolic fault
messages include the fault code number and symbols, indicating the type of fault (see Figure 4-9).
With the symbolic versions of fault messages, the
and symbols flash.
Five of the most recent faults are saved in a file and
can be viewed using the Fault History Menus (see
page 4-28).
Fault = WARNING
or SHUTDOWN
FIGURE 4-8. FAULT MESSAGE − TEXT VERSION
Fault Reset / Acknowledgement
Shutdown faults must be acknowledged after the
fault condition has been corrected. Shutdown
faults are usually acknowledged by one of the following methods.
If the control is equipped with an operator
panel, press the
If the control is not equipped with and opera-
tor panel, place the Auto/Off/Manual Run
switch in the Off position.
Shutdown faults can also be acknowledged when
in Auto mode by using an external customer-supplied remote fault reset switch. This ability must be
enabled by setting the Remote Fault Reset Enabled trim to “Enabled” (disabled by default) using
InPower.
button.
EXAMPLE OF
A SYMBOLIC
WARNING
FAULT
EXAMPLE OF
A SYMBOLIC
SHUTDOWN
FAULT
FIGURE 4-9. FAULT MESSAGES − SYMBOLIC
VERSION
214
1
The remote fault reset switch must be wired into
one of the four configurable inputs. The chosen
configurable input should have its function mapped
to the “Fault Reset” function. To reset the fault, the
remote start command must be removed prior to
the remote fault reset switch being activated.
Faults are removed from the display when they are
cleared.
NOTE: Pressing the
or button also clears the
fault from the front panel display.
Faults are re-announced if they are detected again
after being acknowledged.
4-7
FAULT/STATUS CODES
Table 4-2 provides a list of fault and status codes,
types, displayed messages/symbols, descriptions,
and fault categories (CTG).
Category A Fault Codes: Pertain to engine or alternator shutdown faults that require immediate repair by trained and experienced service personnel
(generator set non-operational). The control prevents the generator set from being restarted if a
shutdown fault is not corrected.
Category B Fault Codes: Consist of faults that
can affect generator set performance or can cause
engine, alternator, or connected equipment
damage. Operate the genset only when it is power-
ing critical loads and cannot be shut down. Category B faults require repair by trained and experienced service personnel.
TABLE 4-2. FAULT AND STATUS CODES
DISPLAYED MESSAGE/SYMBOLS
CTG CODE LAMP
A 121
C 135
C 141
B 143 **
C 144
C 145
C 146 **
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Shutdown
Warning
Warning
Warning
Warning
Warning
Warning
TEXT VERSION
SPEED SIGNAL
LOST
OIL PRESS
SENSOR OOR
HIGH
OIL PRESS
SENSOR OOR
LOW
PRE-LOW OIL
PRESSURE
COOLANT
SENSOR OOR
LOW
COOLANT
SENSOR OOR
HIGH
PRE-HIGH
COOLANT TEMP
Category C Fault Codes: Consist of faults that do
not affect generator set performance but require
qualified service personnel to repair. These codes
indicate a defective harness or wiring problem.
These codes can also indicate a defective engine
sensor, leaving no ingine protection. (Engine damage can occure without detection.) Continued op-
eration may void the generator set warranty if
damage occures that relates to the fault condition.
Category D Fault Codes: Consist of faults that are
repairable by site personnel. Service will be required by trained and experienced service personnel if site personnel cannot resolve the problem.
Category E Fault Codes: Indicates non-critical
operational status of generator set, external faults,
or customer fault inputs. These faults require repair
by trained and experienced service personnel.
SYMBOLIC
VERSION
121
135
141
143
144
145
146
Indicates that no magnetic pickup pulses
were sensed for a Loss of Speed delay. If
a magnetic pickup is disabled, this fault is
not activated.
Indicates the oil pressure sensor output is
out of range (OOR), high.
Indicates the oil pressure sensor output is
out of range (OOR), low.
Indicates that the engine oil pressure is
approaching an unacceptable level.
Indicates the coolant temperature sensor
output is out of range (OOR), low.
Indicates the coolant temperature sensor
output is out of range (OOR), high.
Indicates that the engine has begun to
overheat and the engine coolant temperature has risen to an unacceptable level.
DESCRIPTION
4-8
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
D 151 **
C 153
LAMPCODE
LAMPCODE
Shutdown
Warning
TEXT VERSION
HIGH COOLANT
TEMP
INTAKE
MANIFOLD
TEMP OOR
HIGH
SYMBOLIC
VERSION
151
153
Indicates that the engine coolant temperature is above normal and has reached the
shutdown trip point.
Indicates the intake manifold temperature
sensor is out of range (OOR), high.
C 154
D 155
D 195
D 196
D 197
A 234 **
A 285
A 286
D 359
Warning
Shutdown
Warning
Warning
Warning
Shutdown
Shutdown
Shutdown
Shutdown
INTAKE
MANIFOLD
TEMP OOR LOW
INTAKE
MANIFOLD
TEMP HIGH
COOLANT
LEVEL OOR
HIGH
COOLANT
LEVEL OOR
LOW
COOLANT
LEVEL LOW
OVERSPEED
ECM PGN
TIMEOUT
ECM
CONFIGURABLE
ERROR
FAIL TO START
154
155
195
196
197
234
285
286
359
Indicates the intake manifold temperature
sensor is out of range (OOR), low.
Indicates that the intake manifold
temperature is above normal and has
reached the shutdown trip point.
Indicates that a sensor on the radiator has
detected that the coolant level is out of
range (OOR), high.
Indicates that a sensor on the radiator has
detected that the coolant level is out of
range (OOR), low.
Indicates that a sensor on the radiator has
detected that the coolant level is below
normal.
Indicates that the engine has exceeded
normal operating speed. The default
thresholds are 1725 RPM (50 Hz) or 2075
RPM (60 Hz).
Datalink failure. PCC control not
responding to the engine control module.
Indicates an engine control module
configuration error − out of calibration.
The genset has failed to start after a set
number of crank attempts. This indicates a
possible fuel system problem (engine
cranks but fails to start).
A 415
C 421^
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Shutdown
Shutdown
LOW OIL
PRESSURE
OIL TEMP HIGH
415
421
Indicates the engine oil pressure has
dropped below normal and has reached
the shutdown trip point.
Indicates that the engine oil temperature is
above normal and has reached the
shutdown trip point. (I/O Module option)
4-9
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
−− 418
B 425^
A 426
A 427
D 441 **
D 442 **
D 488^
A 689
LAMPCODE
LAMPCODE
NONE
Shutdown
Shutdown
Warning
Warning
Warning
Shutdown
Shutdown
TEXT VERSION
N / A
OIL TEMP OOR
DATA LINK
ERROR
CAN LINK LOST
LOW BATTERY
HIGH BATTERY
INTAKE
MANIFOLD
TEMP HIGH
ENGINE SPEED
ERRATIC
SYMBOLIC
VERSION
N/A
425
426
427
441
442
488
689
Indicates water in fuel
Indicates the oil temperature sensor output
is out of range (OOR), high or low. (I/O
Module option)
Datalink failure. No communications
between the PCC control and the engine
control module.
Datalink fault. Indicates that important data
was lost between the PCC control and the
engine control module.
Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation can occur.
Indicates battery voltage supply to the control is approaching a high level at which
damage to the control can occur.
Indicates the intake manifold temperature
is above normal and has reached the
shutdown trip point. (I/O Module option)
Indicates a fault condition in the engine
crankshaft sensor circuit.
A 781
D 1117
B 1123
D 1131
C 1246
E 1311
E 1312
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Shutdown
Warning
Shutdown
*
Warning
*
Warning
Configur-
able
Configur-
able
CAN LINK LOST
ECM POWER
LOST
SHUTDOWN
AFTER BS
BATTLE SHORT
ACTIVE
GENERIC
ENGINE FAULT
Customer Fault
Input 1
Customer Fault
Input 2
781
1117
1123
1131
1246
1311
1312
Datalink failure. No communications
between the PCC control and the engine
control module.
Indicates battery voltage supply to the
engine control module was lost.
A shutdown fault occurred while the Battle
Short mode was enabled.
Indicates that the control is in Battle Short
mode − used to bypass several fault shutdowns for genset operation during emergencies.
Engine control fault code not recognized
by the PCC control.
The nature of the fault is an optional customer selection.
The nature of the fault is an optional customer selection.
4-10
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
E 1317
LAMPCODE
LAMPCODE
Configur-
able
TEXT VERSION
Customer Fault
Input 3
SYMBOLIC
VERSION
1317
The nature of the fault is an optional customer selection.
E 1318
B 1416
*
A 1417
D 1433
D 1434
D 1435
**
D 1438
D 1442
**
Configur-
able
Warning
Shutdown
Shutdown
Shutdown
Warning
Shutdown
Warning
Customer Fault
Input 4
FAIL TO
SHUTDOWN
FAILURE TO
POWER DOWN
LOCAL
EMERGENCY
STOP
REMOTE
EMERGENCY
STOP
LOW COOLANT
TEMP
FAIL TO CRANK
WEAK BATTERY
The nature of the fault is an optional cus-
1318
1416
1417
1433
1434
1435
1438
1442
tomer selection.
Indicates that a shutdown fault is active,
but is being bypassed by Battle Short.
Indicates the control is powered up after
attempting to go to sleep.
Indicates a Local Emergency Stop has
been activated.
Indicates a Remote Emergency Stop has
been activated.
Indicates that the engine coolant temperature is below the adjusted setpoint. This
may indicate that the coolant heater is not
operating or is not circulating coolant.
The genset has failed to sense rotation for
two start attempts. This indicates a possible fault with the control, speed sensing,
or the starting system.
Indicates that the genset battery voltage is
below battery thresholds during cranking.
A 1443
A 1446
A 1447
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Shutdown
Shutdown
**
Shutdown
**
DEAD BATTERY
HIGH AC
VOLTAGE
LOW AC
VOLTAGE
1443
1446
1447
Indicates during cranking battery voltage
has dropped below operating voltage of
control resetting the control for three consecutive times.
Indicates that the one or more measured
AC output voltages has exceeded the
threshold for longer than a specified time
limit. The threshold and time limits are
130% of nominal for 0 seconds or 110% of
nominal for 10 seconds.
Indicates that the measured AC output
voltage is below the threshold for longer
than a specified time limit. The threshold
and time limits are 85% of nominal for 10
seconds.
4-11
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
A 1448
**
A 1449
**
−− 1463
−− 1468
A 1469
**
B 1471*
*
A 1472
**
−− 1483
−− 1540
−− 1541
C 1845
LAMPCODE
LAMPCODE
Shutdown
Shutdown
NONE
NONE
Shutdown
Warning
Shutdown
NONE
NONE
NONE
Warning
TEXT VERSION
UNDER
FREQUENCY
OVER
FREQUENCY
N /A
N / A
SPEED HZ
MATCH
HIGH AC
CURRENT
HIGH AC
CURRENT
N/ A
N/ A
N/ A
WATER IN FUEL
OOR HIGH
SYMBOLIC
VERSION
N/A
N/A
N/A
N/A
N/A
1448Hz
1449Hz
1471
1472
1845
Indicates that the alternator frequency is 6
hertz under nominal frequency.
Indicates that the alternator frequency is 6
hertz above nominal frequency.
Indicates Not in Auto.
Indicates Ready to Load.
Indicates that measured engine speed and
measured alternator AC output frequency
do not agree.
Indicates that the alternator output current
(one or more phases) has exceeded safe
operating limits.
Indicates that alternator output current
(one or more phases) has exceeded the
alternator’s current rating.
Indicates Common Alarm.
Indicates Common Warning.
Indicates Common Shutdown.
Indicates the water in fuel sensor is out of
range (OOR), high.
C 1846
D 1852
E 1853
E 1854
E 1855
E 1944
D 1965
^
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Warning
Warning
Configur-
able
Configur-
able
Configur-
able
Warning
Warning
WATER IN FUEL
OOR LOW
WATER IN FUEL
Annunciator Fault
2
Annunciator Fault
3
Annunciator Fault
1
ANNUNCIATOR
OUTPUT CONFIGURATION
ERROR
EXHAUST
TEMPERATURE
OOR
1846
1852
1853
1854
1855
1944
1965
Indicates the water in fuel sensor is out of
range (OOR), low.
Indicates that the water in fuel is above
normal and has reached the warning trip
point.
The nature of the annunciator fault is an
optional customer selection.
The nature of the annunciator fault is an
optional customer selection.
The nature of the annunciator fault is an
optional customer selection.
Indicates a mismatch in the configuration
of one of the annunciator relay outputs.
Indicates the exhaust temperature sensor
is out of range (OOR), high or low. (Aux
101 I/O option).
4-12
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
B 1992
B 1689
LAMPCODE
LAMPCODE
Warning
Warning
TEXT VERSION
ENGINE
OVERSPEED
CLOCK NOT
SET
SYMBOLIC
VERSION
1992
1689
Indicates that the engine has exceeded
normal operating speed. The default
thresholds are 1725 RPM (50 Hz) or 2075
RPM (60 Hz). (ECM fault code).
Indicates real time clock is not set with
exercise scheduler function enabled.
B 5186
B 5187
B 5188
B 5365
B 2118
B 5134
B 254
B 1847
B 1517
B 1921
Warning
Warning
Warning
Warning
Warning
Warning
Warning
Warning
Warning
Warning
GENSET FAILED
TO CLOSE
UTILITY FAILED
TO CLOSE
TRANSFER
SWITCH
STATUS
UNKNOW
POSITION
ON
SECONDARY
SOURCE
LOW FUEL
PRESSURE
UNKNOWN
SHUTDOWN AT
IIDLE
FSO DRIVER
FAILED
HIGH
TEMPERATURE
FAULT
FAILED
MODULE
SHUTDOWN
REGEN
MANDATORY
HIGH LEVEL
5186
5187
5188
5365
2118
5134
254
1847
1517
1921
Indicates transfer switch has failed to close
on generator side.
Indicates transfer switch has failed to close
on utility side.
Indicates transfer switch position is not
known.
Indicates genset is running on secondary
fuel source in dual fuel application.
Indicates low fuel pressure sensed for
gaseous application.
Indicates genset having ECM has
shutdown with unknown fault before
reaching rated condition.
Engine Fuel Shutoff Valve Driver Circuit −
Voltage Below Normal or Shorted.
Indicates that engine coolant temperature
is above normal and has reached the
shutdown trip point.
At least One Module of a Multi−module
system has a severe fault.
Aftertreatment Diesel Particulate Filter
Differential Pressure − Data Valid But
Above Normal Operating Range −
Moderately Severe Level. Need to initiate
DPFprocess.
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
4-13
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
B 1922
LAMPCODE
LAMPCODE
Warning
TEXT VERSION
GENSET
CRITICAL CALL
TECHNICIAN
SYMBOLIC
VERSION
1922
Aftertreatment Diesel Particulate Filter
Differential Pressure − Data Valid But
Above Normal Operating Range − Most
Severe Level. Need to call Cummins
technician to clear the fault.
B 175
B 176
B 177
B 3539
B 3541
B 3542
B 5669
C 2224
^
Warning
Warning
Warning
Warning
Warning
Warning
Warning
Warning
AIR THROT
DRIVE CCT
OORH
AIR THROT
DRIVE CCT
OORH
AIR THROT
DRIVE MECH
SYS ERROR
AIR THROT
POSN SENSOR
OORH
AIR THROT
DRIVE CCT
OORL
AIR THROT
POSN SENS
DATA INCORR
ENGINE
COMBUSTION
FAULT
FUEL LEVEL
OOR
175
176
177
3539
3541
3542
5669
2224
Electronic Throttle Control Actuator Driver
Circuit − Voltage Above Normal or Shorted
to High Source.
Electronic Throttle Control Actuator Driver
Circuit − Voltage Below Normal or Shorted
to Low Source.
Electronic Throttle Control Actuator −
Mechanical System Not Responding or
Out of Adjustment.
Engine Intake Throttle Actuator Position
Sensor Circuit − Voltage Above Normal or
Shorted to High Source.
Engine Intake Throttle Actuator Position
Sensor Circuit − Voltage Below Normal or
Shorted to Low Source.
Engine Intake Throttle Actuator Position
Sensor − Data Erratic, Intermittent, or
Incorrect.
Intake Manifold Over Pressure − Condition
Exists.
Indicates the fuel level sensor is out of
range (OOR), high or low. (Aux 101 I/O
option).
A 2335
C 2398
C 2542
A 2545
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Shutdown
Warning
^
Warning
^
Shutdown
EXCITATION
FAULT
AMBIENT
TEMPERATURE
OOR
VOLTAGE BIAS
OOR
KEYSWITCH
RESET
REQUIRED
2335
2398
2542
2545
Indicates that a loss of voltage or frequency sensing from the generator has occurred.
Indicates the ambient temperature sensor
is out of range (OOR), high or low. (Aux
101 I/O option).
Indicates the voltage bias circuit output is
out of range (OOR), high or low. (Aux 101
I/O option).
Indicates a datalink failure. Communications are lost between the PCC control and
the engine control module.
4-14
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
E 2619
^
LAMPCODE
LAMPCODE
Diagnos-
tic
TEXT VERSION
AUX101 ANALOG INPUT 1
SYMBOLIC
VERSION
2619
The nature of the Base I/O Module event
is an optional customer selection. (Aux101
I/O Module option)
Each event function can be programmed
(using InPower service tool or access to
the Setup menu), as follows:
Change display name using up to 32
characters.
Select active low or high input.
E 2621
^
E 2622
^
E 2623
^
E 2624
^
E 2625
^
E 2626
^
E 2627
^
E 2628
^
Diagnos-
tic
Diagnos-
tic
Diagnos-
tic
Diagnos-
tic
Diagnos-
tic
Diagnos-
tic
Diagnos-
tic
Diagnos-
tic
AUX101 ANALOG INPUT 2
AUX101 ANALOG INPUT 3
AUX101 ANALOG INPUT 4
AUX101 ANALOG INPUT 5
AUX101 ANALOG INPUT 6
AUX101 ANALOG INPUT7
AUX101 ANALOG INPUT 8
AUX102 DIGITAL
INPUT 9
2621
2622
2623
2624
2625
2626
2627
2628
See code 2619.
See code 2619.
See code 2619.
See code 2619.
See code 2619.
See code 2619.
See code 2619.
The nature of the Aux I/O Module event is
an optional customer selection. (Aux102
I/O Module option)
Each event function can be programmed
(using InPower service tool or access to
the Setup menu), as follows:
Change display name using up to 32
characters.
Select active low or high input.
E 2629
E 2631
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
^
^
Diagnos-
tic
Diagnos-
tic
AUX102 DIGITAL
INPUT 10
AUX102 DIGITAL
INPUT 11
See code 2628.
2629
See code 2628.
2631
4-15
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
E 2632
^
LAMPCODE
LAMPCODE
Diagnos-
tic
TEXT VERSION
AUX102 DIGITAL
INPUT 12
SYMBOLIC
VERSION
See code 2628.
2632
A 2676
A 2677
B 2678
**
C 2693
^
C 2694
^
A 2696
^
C 2729
^
C 2731
A 2897
A 2898
A 2899
Shutdown
Shutdown
Warning
Warning
Warning
Shutdown
Warning
Shutdown
Shutdown
Warning
Shutdown
ALTERNATOR
FREQUENCY
CONFLICT
FAIL TO STOP
CHARGER
FAILURE
SPEED BIAS
OOR
ALTERNATOR
RTD OOR
ALTERNATOR
RTD TEMP HIGH
I/O MODULE
LOST
I/O MODULE
LOST
FACTORY
BLOCK
CORRUPT
PERIODIC/
FAULT
CORRUPT
USER BLOCK
CORRUPT
2677
2678
2693
2694
2696
2729
2731
2897
2898
2899
Indicates the measured alternator line frequency and measured alternator excitation
frequency do not agree.
The genset continues to run after receiving
a stop command from the controller.
Indicates the battery charging alternator
has not reached a acceptable voltage
range within the selected time period (default = 120 seconds).
This warning is also displayed if your alternator is a type that does not support the
control’s charging alternator logic functionality. If this occurs, this warning can be disabled if the Charging Alt. Enable setting is
set to “No.” See the Genset Service submenus on page 5-8.
Indicates the speed bias circuit output is
out of range (OOR), high or low. (Aux 101
I/O Module option).
Indicates the alternator RTD sensor is out
of range (OOR), high or low. (Aux 101 I/O
Module option).
Indicates the alternator temperature is
above normal and has reached the
shutdown trip point. (I/O Module option)
Indicates an intermittent data link between
the I/O module and the PCC control. (Aux
101 I/O Module option).
Indicates the data link between the I/O
module and the PCC control is lost. (Aux
101 I/O Module option).
Indicates a fatal software error occurred in
the PCC control.
Indicates a fatal software error occurred in
the PCC control.
Indicates a fatal software error occurred in
the PCC control.
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
4-16
TABLE 4-2. FAULT AND STATUS CODES (CONT.)
DISPLAYED MESSAGE/SYMBOLS
CTG DESCRIPTION
CTG DESCRIPTION
A 2911
LAMPCODE
LAMPCODE
Shutdown
TEXT VERSION
TRIM BLOCK
CORRUPT
SYMBOLIC
VERSION
2911
Indicates a fatal software error occurred in
the PCC control.
D 2964
A 2972
**
NOTE: Shutdown fault codes can also be announced with a local status lamp indicator.
* For more information on these events, refer to the Battle Short Mode description on page 3-57.
** Any values listed in the Description column for these faults are default values. If authorized, these values
can be changed using the Genset Setup menus (see page 5-37).
^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291).
Warning
Shutdown
ADJUSTING DEFAULT SETTINGS
The optional operator panel can be set up to display with SAE or SI units of measurement.
For more information, see the Adjust Screen menu
shown on page 4-30.
SAVING YOUR CHANGES
All adjustments made to menus are temporary until
the SAVE button is pressed. If the SAVE button is
pressed and the engine is running, the adjustments
are not saved until after the engine speed is zero. If
power is lost to the control before a SAVE is executed, all temporary adjustments are lost.
Adjustments to the following are stored in flash
memory in the optional operator panel.
Contrast
Brightness
Units
Local or remote display
Symbols or text displayed
Access code required for mode change to
Auto or Manual Run
All other adjustments are stored in the control
board.
INTAKE
MANIFOLD
TEMPERATURE
HIGH
FIELD
OVERLOAD
Indicates engine has begun to overheat
(intake manifold temperature has risen to
an unacceptable level). Increase in load or
2964
2972
When the SAVE button is pressed, the previous
menu is redisplayed.
higher ambient temperature may cause
Intake Manifold Temp High (
shutdown.
Indicates that the Field Voltage has been
above 70V for 8 seconds.
code 155)
OPERATOR MENUS
Figures 4-10 and 4-11 show block representations
of the following Operator menus.
Engine Status
Alternator Status
Line-to-Line Voltage
Line-to-Neutral Voltage
Alternator Amperage
To navigate between the Operator menus, press
the buttons next to the
graphical display.
The Operator menus can be used to select Auto or
Manual Run modes (see page 4-22).
and symbols in the
Engine Status Menu
This menu displays the engine starting battery voltage, engine coolant temperature, engine oil pressure, and hours of engine operation.
Alternator Status Menu
This menu displays genset load (in kVA), frequency, and engine speed (RPM).
Alternator Line-to-Line Voltage Menu
This menu displays L1-L2, L2-L3, and L3-L1 lineto-line voltages for three phase applications only.
4-17
Alternator Line-to-Neutral Voltage Menu
This menu displays line-to-neutral voltages for L1,
L2, and L3 for three phase wye configurations only.
In delta configurations, this menu is not shown.
Alternator Single Phase Voltage Menu
This menu displays L1-N, L2-N, and L1-L2 volt-
ages for single phase applications only.
Alternator Amperage Menu
For applications that include current transformers,
this menu displays L1, L2, and L3 current sense
amperage.
4-18
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