CUMMINS DFAC, DFCC, DFAB, DFGE, DFLB Service Manual

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Service Manual

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PowerCommand Control

2100 Series

Generator Sets

Printed in U.S.A.

Models

DFAB, DFAC, DFBF, DFCB, DFCC, DFCE

DFGB, DFGE, DFLB, DFLC, DFLE

960-0519C 02-2004

IMPORTANT SAFETY INSTRUCTIONS

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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.

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.

LS-14L

iii

ELECTRICAL SHOCK CAN CAUSE

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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. NFP A No. 10).

• Make sure that rags are not left on or near the en-

gine.

• 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

iv

1. Introduction

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ABOUT THIS MANUAL

This manual provides troubleshooting and repair information regarding the PowerCommand Control (PCC) and generators for the gensets listed on the front cover. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator’s Manual.

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 damage to the equipment.

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

Safety Precautions

and carefully observe all

instructions and precautions in this manual.



2100

TEST EQUIPMENT

To perform the test procedures in this manual, the following test equipment must be available

• True RMS meter for accurate measurement of

small AC and DC voltages. Fluke models 87 or 8060A are good choices.

• Grounding wrist strap to prevent circuit board

damage due to electrostatic discharge (ESD).

• Battery Hydrometer

• Jumper Leads

• Tachometer or Frequency Meter

• Wheatstone Bridge or Digital Ohmmeter

• Variac

• Load Test Panel

• Megger or Insulation Resistance Meter

• PCC Service Tool Kit (Harness Tool and Sen-

sor Tool)

• InPower Service Tool (PC based genset ser-

vice tool)

SYSTEM OVERVIEW

The PCC is a microprocessor-based control for Cummins Power Generation generator sets. All generator set control functions are contained on one circuit board (Base board). The Base board provides engine speed governing, main alternator voltage output regulation, and complete generator set control and monitoring.

The operating software provides control of the generator set and its performance characteristics, and displays performance information on a digital display panel. It accepts menu-driven control and setup input from the push button switches on the front panel.

HOW TO OBTAIN SERVICE

Always give the complete Model, Specification and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts. The nameplate is located on the side of the generator output box.

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 Safety Precautions, on pages iii and iv.

Incorrect service or replacement of

1-1

THIS PAGE LEFT INTENTIONALLY BLANK

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1-2

2. Control Operation

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GENERAL

The following describes the function and operation of the PowerCommand 2100 Control (PCC). All indicators, control switches/buttons and digital display are located on the face of the control panel as illustrated in Figure 2-1.

CONTROL PANEL POWER ON/OFF

MODES

The power on/off modes of the control panel and operating software are Power On, Screen Saver and Sleep/Awake.

Power On Mode: In this mode, power is continuously supplied to the control panel. The control’s operating software and control panel LEDs/digital display will remain active until the Screen Saver mode is activated.

Screen Saver Mode: Power to the digital display is removed after 30 minutes (generator set not running or running). The 30 minute timer resets and begins after each control panel action (any button or switch selection) or signal received by the operating software. All LEDs on the control panel operate normally during Screen Saver mode, indicating that the operating software is active (Awake mode).

When a “Warning” signal is sensed by the PCC (for example, low coolant temp), the control displays the warning message.

Sleep/Awake Mode: In the Sleep mode, the control’s operating software is inactive and the LEDs

and the digital display on the control panel are all off. Sleep mode is a feature used to reduce battery power consumption when the control is not being used and the O/Manual/Auto switch is in the O position.

When all conditions are met (i.e., no unacknowledged faults and O/Manual/Auto switch is in the O position) the Sleep mode is activated.

The operating software is initialized and the digital display and control panel LEDs are turned on in response to moving/pressing the following control panel switch/buttons:

• OManual/Auto switch

• Emergency Stop button

• Fault Acknowledge/Reset button

• Panel Lamp/Lamp Test button

To activate the control and view the menu display without starting the generator set, press Fault Acknowledge or Panel Lamp button or move mode switch from O to Manual.

The InPower service tool is required to enable or disable the Sleep mode. When shipped from the factory, the Sleep mode is disabled. When disabled, the operating software will always remain active (Awake mode). (If network and/or power transfer control feature is installed, the sleep mode is not available and should not be enabled − will cause error condition.)

2-1

HOME

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BUTTON

MENU

SELECTION

BUTTON

(1 of 4)

PANEL

LAMP

(1 of 3)

BUTTON

DIGITAL

DISPLAY

SHUTDOWN

AND WARNING

STATUS

INDICATORS

EMERGENCY

STOP PUSH

BUTTON

(Pull to reset)

RUNNING/REMOTE

START/NOT IN AUTO

INDICATORS

CONFIGURABLE

INDICATORS

ANALOG AC

METERING

PANEL

(OPTIONAL)

FAULT

ACKNOWLEDGEMENT/

RESET BUTTON

PANEL LAMP

AND LAMP

TEST

BUTTON

FIGURE 2-1. FRONT PANEL

2-2

OFF/MANUAL/

AUTO SWITCH

MANUAL

RUN/STOP

BUTTON

FRONT PANEL

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Figure 2-1 shows the features of the front panel.

Remote Start Indicator:

This green lamp is lit whenever the control is receiving a remote start signal.

Digital Display:

This two-line, 20-characters per line alphanumeric display is used to view menus of the menu-driven operating system. Refer to the menu trees later in this section. The display is also used to show warning and shutdown messages.

Display Menu Selection Buttons:

Four momentary buttons—two on each side of the digital display window—are used to step through the various menu options and to adjust generator set parame-

ters. A green triangle (

or ), arrow ( , , , or ), >>, or plus/minus sign (+ or −) in the digital display adjacent to the button is shown when the button can be used (button is “active”). Refer to

And Buttons

Home Button:

later in this section.

Press this button ( ) to view the

Menu Display

Home Menu. Refer to the menu trees later in this section.

Previous Main Menu Button:

Press this button ( ) to view the previous Main Menu. All main menus include both types of green triangles (

and ). Refer

to the menu trees later in this section. NOTE: The up and down arrows (

and ) are used

to navigate between submenus.

Emergency Stop Button:

Push this button in for emergency shutdown of the generator set. This will stop the generator set immediately and prevent starting of the set from any location (local and remote).

To reset:

1. Pull the button and allow it to pop out.

2. Turn the O/Manual/Auto switch to O (Off).

3. Press the front panel Fault Acknowledge/Reset button.

4. Select Manual or Auto, as required.

Emergency Stop shutdown can be reset only at the PCC front panel.

Running Indicator:

This green lamp is lit whenever

the generator (local or remote) is running.

Not in Auto Indicator:

This red lamp flashes continuously when the O/Manual/Auto switch is not in the Auto position.

Analog AC Metering Panel (Optional):

This panel simultaneously displays (in percent of genset rated output):

• 3-phase line-to-line AC current (A~)

• Kilowatts (kW)

• Generator output frequency in hertz (Hz)

• 3-phase line-to-line AC volts (V~)

• Power Factor (PF) (shown in 0.2 increments)

Shutdown Status Indicator:

This red lamp is lit whenever the control detects a shutdown condition. The generator set cannot be started when this lamp is on. After the condition is corrected, shutdown indicators can be reset by turning the O/Manual/Auto switch to the O position and pressing the Fault Acknowledge/Reset button.

Warning Status Indicator:

This yellow lamp is lit whenever the control detects a warning condition. After the condition is corrected, warning indicators can be reset by pressing the Fault Acknowledge/ Reset button. (It is not necessary to stop the generator set.) In auto mode, warning indicators can also be reset by cycling the remote reset input after the condition is corrected.

Some warnings remain active after the condition is corrected and the control reset button is pressed. This will require the genset to be shutdown to reset the warning indicator.

Fault Acknowledge/Reset Button:

Press this button to acknowledge warning and shutdown messages after the fault has been corrected. Pressing this button clears the fault from the current fault list.

To acknowledge a Warning message, the O/Manual/Auto switch can be in any position. (It is not necessary to stop the generator set to acknowledge an inactive Warning condition.) To acknowledge a shutdown message with this button, the O/Manual/ Auto switch must be in the O position.

2-3

Panel Lamp and Lamp Test Button:

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Press this button to turn the control panel lamps on or off. The lights will shut of f after about ten minutes. Press and hold this button to test all front panel LEDs and meters. The meters will light one bar at a time.

Manual Run/Stop Button:

This button starts and stops the set locally and will bypass Time Delay to Start and Stop sequences. The O/Manual/Auto switch must be in the Manual position to enable this button.

O/Manual/Auto Switch:

The Manual position en-

ables the use of the Manual Run/Stop button. The Auto position enables start/stop control of the

engine from a remote location. (It disables the use of the Manual Run/Stop button.)

The O (Off) position prevents the starting of the set (local or remote). If the switch is set to O during set operation, the engine will immediately shut down (cool-down timers are bypassed). This hot shutdown should be avoided, if possible, to help prolong the life of the engine.

Configurable Indicators

The following configurable indicators (default values shown) can be changed with the InPower service tool. The configurable items are: change generator event and LED color (green, yellow or red), and enable/disable indicator.

Low Oil Pressure Warning Indicator:

lamp indicates the oil pressure is lower than the normal range of operation.

High Engine Temperature Warning Indicator:

This yellow lamp indicates the engine temperature is higher than the normal range of operation.

Low Oil Pressure Shutdown Indicator:

lamp indicates the engine has shut down because of low oil pressure.

Overspeed Shutdown Indicator:

dicates

speed.

Fail to Start Indicator:

the engine has shut down because of excessive

This red lamp indicates the

engine failed to start.

This yellow

This red

This red lamp in-

2-4

MENU DISPLAY AND BUTTONS

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Figure 2-2 shows the digital display and the menu selection buttons.

Digital Display:

line, digital display is used to view the menus of the menu-driven operating system. Refer to the menu trees later in this section. The display is also used to show fault messages.

Display Menu Selection Buttons:

tary buttons—two on each side of the digital display window—are used to step through the various menu options and to adjust generator set parameters. The button is active when a symbol adjacent to the button is displayed. The displayed symbol indicates the function of the button.

• In the digital display for main menus (Figure 2-3), the the adjacent button causes the operating pro-

gram to go to the selected submenu (e.g., Engine Menu in Figure 2-5).

The two-line, 20 characters per

Four momen-

and symbols indicate that pressing

• In the digital display, the plus or minus symbols (+ or −) indicate that pressing the adjacent button can be used to change a parameter or value shown on the display.

When there is a choice of two parameters, one parameter is associated with the + symbol and the other is associated with the − symbol.

When changing values, pressing the button a d jacent to the + symbol increase the value and pressing the button adjacent to the − symbol decreases the value. Only one numeric character of a field can be changed at a time.

• In the digital display, the

or symbol indicates that pressing the adjacent button causes the operating program to move the cursor to the next numeric character. The selected numeric character can then be changed by pressing the buttons adjacent to the + and − symbols. Only

symbol is displayed when the cursor is on

the the first character of a field that can be changed. Only the

is displayed when the cursor is on the last character. Both symbols are displayed when the cursor is on any other character.

• In the digital display, the More>> symbol indicates that pressing the adjacent button causes the operating program to go to the next main menu, as shown in Figure 2-3.

• In the digital display, the

or symbols indicate that pressing the adjacent button causes the operating program to go to the next or previous submenu, as shown in the menu diagrams. Only the

first submenu. Only the

symbol is displayed in the

is displayed in the last submenu. Both symbols are displayed in the rest of the submenus.

• After adjusting values/parameters, pressing the

symbol results in the changes being

saved. If the Home button or Previous Main

Menu button is pressed before pressing the

symbol, the changes are not saved.

Home Button:

Pressing this button causes the operating system to show Main Menu 1 (Figure 2-3) in the digital display.

Previous Main Menu Button:

Pressing this button causes the operating system to show the previous Main Menu in the digital display . All main menus in-

clude both types of green triangles (

and ).

2-5

2 LINE, 20 CHARACTERS PER LINE

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MENU DISPLAY

DIGITAL DISPLAY

HOME

BUTTON

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION BUTTONS

PREVIOUS MAIN

MENU BUTTON

2-6

MAIN MENUS

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Figure 2-3 shows the three major main menus available to t h e user . Figure 2-3 also includes references to pages in this section where you can find additional information on submenus. When viewing a submenu, you can press the previous main menu button at any time to view its main menu.

Main Menu 1

As shown in the illustration, each main menu can branch into one of four directions. Press the button next to “More>>” in the display to view the next Main menu. Main Menu 1 is redisplayed when you press the button next to “More>>” in the Main Menu 3 display.

PAGE

2-11

PAGE

2-13

Engine Alternator

PAGE

2-17

PAGE

2-19

Adjust More>>

Main Menu 2

Faults System

PAGE

NO TAG

History More>>

PAGE

2-21

Main Menu 3

PAGE

2-23

PAGE

2-25

FIGURE 2-3. MAIN MENUS

About Pwr Tran

2-7

Setup More>>

PAGE

5-5

CONTROLLER CONFIGURATION MENU

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Figure 2-4 shows a block representation of the Controller Configuration menus. These menus are used to change the default language, temperature units, and pressure units to be displayed in menus.

To view the first Controller Configuration menu, make sure Main Menu 1 is displayed and simultaneously press the Home Menu and Previous Main Menu buttons.

As shown in the diagram, the Controller Configuration menu has three submenus.

Press the button next to the symbol in the display until the + and − symbols are displayed.

Press the button next to the + or − symbol to select the desired option.

After selecting option, pressing the

symbol results in the changes being saved. If the Home button or Previous Main Menu button is pressed before pressing the

Language Selected submenu:

symbol, the changes are not saved.

Used to select de-

sired language (default = English).

Temperature Units submenu:

Used to select

Fahrenheit or Centigrade for temperature readings.

Press the buttons next to the

and symbols in the

digital display to navigate between the menus.

Fluid Pressure Units submenu:

PSI or kPA for pressure readings.

Used to select

2-8

CONTROLLER CONFIGURATION MENU

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Main Menu 1

Engine Alternator

Language Selected

English

Temperature Units

Deg F

Adjust More>>

+Language Selected

− English

Back

+Temperature Units

− Deg C

Back

Fluid Pressure Units

PSI

+Fluid Pressure Units

− kPa

FIGURE 2-4. CONTROLLER CONFIGURATION MENU

2-9

Back

ENGINE MENU

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Figure 2-5 shows a block representation of the Engine menu. If you press the button next to the word “Engine” in the display, the first Engine submenu is displayed.

As shown in the diagram, the Engine menu has seven submenus. The data in the submenus will vary according to the type and number of sensors provided with the engine.

Press the buttons next to the digital display to navigate between the menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.

and symbols in the

Coolant Temperature submenu:

This submenu displays the engine coolant temperature which can be viewed in degrees Fahrenheit or Centigrade (see

Controller Configuration Menu

Oil Pressure submenu:

This submenu displays

in this section).

the engine oil pressure which can be viewed in PSI or kPA (see

Controller Configuration Menu Menu

in

this section).

Oil Temperature submenu:

This submenu displays the engine oil temperature which can be viewed in degrees Fahrenheit or Centigrade (see

Controller Configuration Menu

Engine Speed submenu:

in this section).

This submenu displays

the engine RPM.

Battery Voltage submenu:

This submenu dis-

plays the engine battery voltage.

Governor Duty Cycle submenu:

This submenu displays the governor duty cycle (drive) levels in percentage of maximum.

Active Time Delay submenu:

This submenu displays the time delay that is currently active: warm− up, cool down, start or stop delays.

2-10

ENGINE MENU

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Main Menu 1

Coolant Temperature

nnn Deg F

Oil Pressure

nnn PSI

Oil Temperature

nn Deg F

Engine Speed

nnnn RPM

Engine Alternator

Adjust More>>

Battery Voltage

nn.n VDC

Governor Duty Cycle

nnn %

Active Time Delay None nnnn Sec

FIGURE 2-5. ENGINE MENU

2-11

ALTERNATOR MENU

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Figure 2-6 shows a block representation of the Alternator menu. If you press the button next to the word “Alternator” in the display, the first Alternator submenu is displayed.

As shown in the diagram, the Alternator menu has eleven submenus.

Press the buttons next to the digital display to navigate between the menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.

and symbols in the

Line-to-Line V oltage submenu:

The voltage Lineto-Line (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to L1, respectively. (Single phase − L1 to L2 only.)

Line-to-Neutral Voltage submenu:

Note that the Line-to -Neutral column will not be displayed for a 3 phase/3 wire system. Single phase − L1 to N and L2 to N.

Amps submenu:

All phases. (Single phase − L1

and L2 only.)

Frequency submenu:

Generator set output fre-

quency.

Total Real Power submenu:

This submenu displays the total amount of real power output, in kilowatts (kW).

Real Power submenu:

This submenu displays the amount of real power output for L1, L2, and L3, in kilowatts (kW). (Single phase − L1 and L2 only.)

Total Apparent Power submenu:

This submenu displays the total amount of apparent power output, in kilovolt amps (kVA).

Apparent Power submenu:

This submenu displays the amount of apparent power output for L1, L2, and L3, in kilovolt amps (kVA). (Single phase − L1 and L2 only.)

Total Power Factor submenu:

This submenu displays the power factor with leading/lagging indication.

The PF reading will contain an asterisk if the power factor is leading (for example, Total PF 0.9 * ).

Power Factor submenu:

This submenu displays a power factor value for L1, L2, and L3. (Single phase − L1 and L2 only.)

The PF reading will contain an asterisk if the power factor is leading (for example, PF L1 0.9*).

AVR Duty Cycle submenu:

This submenu displays the voltage regulator (drive) level in percentage of maximum. (Where maximum is 100% Duty Cycle, software clamps Duty Cycle maximum to 60% for PMG and 90% for shunt.)

2-12

ALTERNATOR MENU

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Main Menu 1

Volts L12 L23 L31

V nnn nnn nnn

Volts L1N L2N

V nnn nnn

Amps L1 L2 L3

nnn nnn nnn

Engine Alternator

Total Power

nn.n kVA

Power L1 L2 L3

kVA nn.n nn.n nn.n

Adjust More>>

Frequency

nn.n Hz

Total Power

nnn kW

Power L1 L2 L3

kW nn.n nn.n nn.n

Total PF

n.nn*

PF L1 L2 L3

*n.nn *n.nn *n.nn

AVR Duty Cycle

nnn %

FIGURE 2-6. ALTERNATOR MENU

2-13

ADJUST MENU

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Figure 2-7 shows a block representation of the Adjust menu. If you press the button next to the word “Adjust” in the display, the first Adjust submenu is displayed.

As shown in the diagram, the Adjust menu has five submenus. Each submenu includes a parameter or value that can be changed.

Press the buttons next to the digital display to navigate between the menus. Press the Home button or the Previous Main Menu button to return to Main Menu 1.

Adjusting Values/Parameters:

and symbols in the

Voltage Adjust submenu:

Voltage can be adjusted to 5 percent of the nominal voltage. For ex- ample, if genset output voltage is 208 volts, the voltage can be adjusted from 198 to 218 volts.

If the displayed value is greater or less than the allowed (5%) range, the control will not except the entry and will return to the previous setting. Retry by entering a smaller change in one volt increments.

Frequency Adjust submenu:

Frequency can be adjusted to 5 percent of the nominal frequency. For example, if the genset frequency is 60.0 Hz, the frequency can be adjusted from 57.0 to 63.0 Hz.

Start Delay submenu:

Start Delay can be set from 0 to 300 seconds (default = 0). This function is bypassed during a manual start/stop sequence.

Stop Delay submenu:

Stop Delay can be set from 0 to 600 seconds (default = 0). This function is bypassed during a manual start/stop sequence and engine shutdown faults.

1.. Press the button next to the symbol in the display until the + and − symbols are displayed.

2.. If necessary , press the button next to the

or symbols to move to the numeric character you wish to change.

3.. Press the button next to the + symbol to increase the value or select parameter; press the button next to the − symbol to decrease the value or select parameter.

4.. After adjusting values/selecting parameters, pressing the

symbol results in the changes being saved. (When adjusting values, make sure the cursor is on the last numeric character

before pressing the

symbol).

If the Home button or Previous Main Menu button is pressed before pressing the

symbol,

the changes are not saved.

Rated To Idle (Beginning Version 2.303):

Rated To Idle delay can be set from 0 to 10 seconds (default = 0). (Enter 1 or more to enable.) Entering a non-zero delay will cause the genset to delay the transition to Cooldown At Idle.

Idle Start submenu (Not available on all mod-

Idle Start can be enabled or disabled (default =

els):

Disable). This function is only enabled when the genset is started in manual mode. Idle Start can also be enabled while the set is running in manual mode.

Enabling Idle Start will cause the genset to run in idle mode until Idle Start is disabled. A warning is displayed if genset is left in idle more than 10 minutes. Long periods of engine idling can eventually affect engine performance and may void engine warranty.

The idle speed can be adjusted from 700 to 1100 RPM (default of 800 RPM). Refer to

up Menu

in Section 5. A countdown timer is used to

Crank/Idle Set-

limit engine idle time. With InPower , idle time can be adjusted from 0 to 60 minutes in 1 minute increments.

2-14

ADJUST MENU

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by any means, is strictly prohibited.

Main Menu 1

Voltage Adjust

nnn V

Frequency Adjust

nn.n Hz

Start Delay

nnn Sec

Engine Alternator

Adjust More>>

+Voltage Adjust

− nnn V

Back

+Frequency Adjust

− nn.n Hz

Back

+Start Delay

− nnn Sec

Back

Stop Delay

nnn Sec

Rated To Idle Delay

nn Sec

Idle Start

Disable

+Stop Delay

− nnn Sec

Back

+Rated To Idle Delay

− nn Sec

Back

+Idle Start

− Enable

Back

FIGURE 2-7. ADJUST MENU

2-15

FAULTS MENU

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by any means, is strictly prohibited.

Figure 2-9 shows a block representation of the Faults menu. Up to 20 of the most recent faults can be viewed. An example of how a fault code is displayed is shown in Figure 2-8.

The available menus are dependent on the number of faults that have occurred.

• If there are word “Faults” is not displayed and no Fault menus are available.

• If

more than one fault

the button next to the word “Fault” in the screen display to view the Faults Main Menu. As shown in the diagram, the Faults Main Menu has two submenus. Press the Previous Main Menu button to return to the Faults Main Menu. Press the Previous Main Menu button a second time to return to Main Menu 2.

Press the Home button at any time to return to Main Menu 1.

no faults

, the symbol next to the

has occurred, press

History submenu:

From the Faults Main Menu, press the button next to the word “History” in the display to view up to twenty of the most recent ac-

knowledged faults. Press the buttons next to the and symbols in the digital display to navigate be-

tween the menus. Press the Previous Main Menu button to return to the Faults Main Menu.

Current Fault submenu:

From the Faults Main Menu, press the button next to the word “Current” in the display to view up to twenty of the most recent unacknowledged faults. Press the Previous Main Menu button to return to the Faults Main Menu.

ASTERISK =

ACTIVE FAULT

W = WARNING S = SHUTDOWN

FIGURE 2-8. HISTORY/CURRENT FAULT SUBMENU

FAULT

CODE

HOUR FAULT

OCCURRED

FAULT

DESCRIPTION

2-16

FAULTS MENU

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by any means, is strictly prohibited.

Main Menu 2

Faults Main Menu

nnnnn @Hr nnnnn.n W xxxxxxxxxxxxxxxxxxxx

Fault 1

History Current

Faults System

nnnnn @Hr nnnnn.n S xxxxxxxxxxxxxxxxxxxx

Fault 1

History More>>

nnnnn @Hr nnnnn.n S xxxxxxxxxxxxxxxxxxxx

Fault 2

nnnnn @Hr nnnnn.n W xxxxxxxxxxxxxxxxxxxx

Fault 20

nnnnn @Hr nnnnn.n W xxxxxxxxxxxxxxxxxxxx

Fault 2

nnnnn @Hr nnnnn.n W xxxxxxxxxxxxxxxxxxxx

Fault 20

FIGURE 2-9. FAULTS MENU

2-17

SYSTEM MENU

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by any means, is strictly prohibited.

Figure 2-10 shows a block representation of the System menu. If you press the button next to the word “System” in the display, the System Main Menu is displayed. This menu is displayed only if the network communications module (NCM) feature is installed. The System Main Menu allows you to view the status and load of other PCC equipment connected on a common network with the PCC 2100 control.

As shown in the diagram, the System Main Menu has three submenus.

When viewing ATS and Genset System submenus, press the buttons next to the digital display to navigate between the menus.

Press the Previous Main Menu button to return to the System Main Menu. Press the Previous Main Menu button a second time to return to Main Menu 2. Press the Home button to return to Main Menu 1.

and symbols in the

ATS System submenus:

From the System Main Menu, press the button next to the word “A TS” in the display to view the first of up to 16 ATS System submenus. An ATS system must be available in the network to display this submenu.

The ATS submenu allows viewing of the transfer switch name (configured with InPower), kW load (if monitored by the ATS system), status (e.g., not in auto), and source connected and availability (ON = source connected, OK = source available, or NA = source not available).

Master System submenu:

From the System Main Menu, press the button next to the word “Master” in the display to view the Master System submenu. A master controller must be available in the network to display this submenu.

The master submenu allows viewing of the master controller name (configured with InPower), kW load and operational state.

Genset System submenus:

From the System Main Menu, press the button next to the word “Genset” in the display to view the first of up to 16 Genset System submenus. One genset must be available in the network to display this submenu.

The genset submenu allows viewing of the genset name (configured with InPower), kW load and operational state.

If a PCC 2100 control genset, in the network, contains the Power Transfer Control (PTC) feature, a genset system submenu will be displayed for the genset and the ATS System submenu will be displayed for the PTC feature.

2-18

SYSTEM MENU

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Main Menu 2

System Main Menu

ATSnameTag01>nnnnkW Non Auto S1=On, S2=On

ATS Menu 1

ATS Master

Genset

Faults System

GensetName01>nnnnkW Warning Fail2Start

History More>>

Genset Menu 1

ATSnameTag02>nnnnkW NonAut o S1=Ok, S2=NA

ATS Menu 2

ATSnameTag16>nnnnkW NonAuto S1=Ok, S2=NA

ATS Menu 16

GensetName02>nnnnkW NonAuto Alarm

Genset Menu 2

GensetName16>nnnnkW NonAuto Alarm

Genset Menu 16

Master>nnnn kW Shutdwn N=On,E=NA

FIGURE 2-10. SYSTEM MENU

2-19

HISTORY MENU

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by any means, is strictly prohibited.

Figure 2-11 shows a block representation of the History menu. If you press the button next to the word “History” in the display, the first History submenu is displayed.

Number of Starts submenu:

This submenu shows

the number of engine starts.

Engine Hours submenu:

This submenu shows

the number of operating hours for the engine.

As shown in the diagram, the History menu has five submenus. This information is stored in non-volatile memory and will not be deleted due to loss of battery power.

Press the buttons next to the

and symbols in the digital display to navigate between the menus. Press the the Previous Main Menu button to return to Main Menu 2. Press the Home button to return to Main Menu 1.

Control Hours submenu:

This submenu shows

the number of operating hours for the control.

Kilowatt Hours submenu:

This submenu shows the number of kilowatt (kW) or megawatt (MW) hours.

Genset Duty Cycle submenu:

This submenu shows the percent of genset operating hours that are less than 30 percent of rated load and percent of hours that are greater than 90 percent.

2-20

HISTORY MENU

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by any means, is strictly prohibited.

Main Menu 2

Faults System

History More>>

Number Starts

nnnnn

Engine Hours nnnnn Hours

Control Hours nnnnn Hours

kW Hours nnnnn kW Hrs

Genset Duty Cycle Hr <30:nn% >90:nn%

FIGURE 2-11. HISTORY MENU

2-21

ABOUT MENU

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by any means, is strictly prohibited.

Figure 2-12 shows a block representation of the About menu. If you press the button next to the word “About” in the display, the first About submenu is displayed.

As shown in the diagram, the About menu has three submenus.

Model submenu:

This submenu shows the genset

model.

Rating submenu:

This submenu shows the rating

(Standby or Prime) and number of kilowatts (kW)).

Press the buttons next to the

and symbols in the digital display to navigate between the menus. Press the the Previous Main Menu button to return to Main Menu 3. Press the Home button to return to Main Menu 1.

Software Version submenu:

This submenu shows the software version level. This information is required to service the generator set.

2-22

ABOUT MENU

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by any means, is strictly prohibited.

Main Menu 3

Model

xxxxxxxxxxxxxxx

Rating

Standby nn.n kW

Software Version

nn.nnn

About Pwr Tran

Setup More>>

FIGURE 2-12. ABOUT MENU

2-23

POWER TRANSFER MENU

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by any means, is strictly prohibited.

Figure 2-13 shows a block representation of the Power Transfer menu. If you press the button next to the word “Pwr Tran” in the display, the first Power Transfer submenu is displayed. (The Power Transfer Control feature must be installed to display this submenu.)

With this option installed, the control will monitor the utility voltage (mains) and frequency for failure. If power fails, the PTC control will start the generator, open the mains circuit breakers and close the generator circuit breakers.

S1 (Source 1) submenu:

This submenu shows power transfer source voltage. The voltages Lineto-Line (L1, L2 and L3) are measured between L1 to L2, L2 to L3 and L3 to L1, respectively. (Single phase − L1 to L2 only.)

S1 (L-N Source) submenu:

This submenu is displayed only if the control system is configured for line−to−neutral voltage sensing of source 1. Single phase only − L1 to N and L2 to N.

Frequency submenu:

This menu shows power

transfer frequency.

As shown in the diagram, the Power Transfer menu has five submenus.

Press the buttons next to the

and symbols in the digital display to navigate between the menus. Press the the Previous Main Menu button to return to Main Menu 3. Press the Home button to return to Main Menu 1.

Source 1 submenu:

This submenu shows utility status (On, Ok, or NA). “On” means Source 1 is connected and available. “Ok” means Source 1 i s available but not connected. “NA” means Source 1 is not available.

Genset submenu:

This submenu shows generator status (On, Ok, or NA). “On” means the genset is connected and available. “Ok” means the genset is available but not connected. “NA” means the genset is not available.

Active Transfer Timer submenu:

This submenu

shows the time delay, in seconds.

2-24

POWER TRANSFER MENU

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by any means, is strictly prohibited.

Main Menu 3

S1 L12 L23 L31

V nnn nnn nnn

S1 L1N L2N

V nnn nnn

Frequency

nn.n Hz

About Pwr Tran

Setup More>>

S1

On

Genset

On

Active Tran Timer

TD Re-Trans nnn Sec

FIGURE 2-13. POWER TRANSFER MENU

2-25

THIS PAGE LEFT INTENTIONALLY BLANK

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2-26

3. Circuit Boards

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by any means, is strictly prohibited.

GENERAL

WARNING

uninsulated parts inside the control panel box can result in severe personal injury or death. Measurements and adjustments must be done with care to avoid touching hazardous voltage parts.

Stand on a dry wooden platform or rubber insulating mat, make sure your clothing and shoes are dry, remove jewelry and use tools with insulated handles.

HAZARDOUS VOLTAGE. Touching

INDICATOR

BOARD

DISPLAY

BOARD

This section describes the function of the Power-



Command

2100 Control (PCC) base circuit board that is contained in the control panel box (Figure 3-1). The block diagram in Figure 3-2, shows the external connections of the PCC system. The system schematics are provided in

Section 10

of this manu-

al.

CAUTION

Electrostatic discharge will damage circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards.

CONTROL

PANEL BOX

BASE

BOARD

FRONT CONTROL

PANEL ASSEMBLY

(MEMBRANE BUTTONS)

BARGRAPH BOARD

(OPTIONAL)

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

3-1

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by any means, is strictly prohibited.

FIGURE 3-2. BLOCK DIAGRAM

3-2

BASE BOARD

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by any means, is strictly prohibited.

The base circuit board (Figure 3-3) contains all of the electronic circuitry required to operate the generator set. The Base board provides fuel control and engine speed governing, main alternator volt-

J6

NCM

J4

DIGITAL DISPLAY

J1

HARNESS

S12, S13

XX = F5 (PCB P/N 300-5381)

RS1 (PCB P/N 327-1379)

age output regulation, and complete generator set control and monitoring.

The following paragraphs describe each of the connectors (J), fuses (F) and terminal boards (TB) shown in Figure 3-3.

J2

LED BOARD &

BARGRAPH

J9

InPOWER

J3

MEMBRANE

TB2 PTC

F1 F2 F3

TB1

CUSTOMER CONNECTIONS

FIGURE 3-3. BASE BOARD

XX

F4

J7

ENGINE

J8 − AC

GENERATOR

3-3

Connector J1

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by any means, is strictly prohibited.

J1 connects to the Emergency Stop switch (S13) and the O/Manual/Auto control panel switch (S12).

J1

S13

14

WIRE TABULATION

SIGNAL FROM TO

GND S12-4 J1-8

OFF (O) S12-1 J1-7

MANUAL S12-3 J1-6

AUTO S12-5 J1-5 ESTOP-NC1 S13-1 J1-2 ESTOP-NC2 S13-2 J1-1

ESTOP-NO1 S13-3 J1-3 ESTOP-NO2 S13-4 J1-4

S12

PIN 1

PIN 2

BASE

BOARD

32

EMERGENCY STOP

SWITCH

15

3

4

O/MANUAL/AUTO

SWITCH

FIGURE 3-4. CONNECTOR J1 (CONTROL HARNESS)

3-4

Connector J2

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by any means, is strictly prohibited.

J2 connects to LED (indicator) board and bargraph board of front control panel assembly.

CONNECTOR J2

PIN SIGNAL

1 MOSI

PIN 1

BASE

BOARD

J2

PIN 15

FIGURE 3-5. J2 LED/BARGRAPH CONNECTOR

Connector J3

J3 connects to membrane buttons of front control panel assembly.

2, 4, 6, 16 GND

3 SCK 5 SEL_A 7 SEL_B

10, 14, 15 VCC

9 SEL_C 11 SEL_D 13 BAR_ENABLE

CONNECTOR J3

PIN SIGNAL

1 HOME MENU <<

2 PREVIOUS MENU <

BASE

BOARD

J3

PIN 10

FIGURE 3-6. J3 MEMBRANE CONNECTOR

3 UPPER LEFT

4 LOWER LEFT

5 UPPER RIGHT

6 LOWER RIGHT

7 FAULT ACK/RESET

8 PANEL LAMP

9 MANUAL RUN/STOP 10 COMMON (GND)

3-5

Connector J4

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by any means, is strictly prohibited.

J4 connects to display menu of front control panel assembly.

PIN 1

BASE

BOARD

J4

PIN 13

FIGURE 3-7. J4 DISPLAY MENU CONNECTOR

CONNECTOR J4

PIN SIGNAL

1 GND

2 VCC

3 N.U.

4 RS

5 R/W

6 ENABLE DISPLAY

7 D[0]

8 D[1]

9 D[2] 10 D[3] 11 D[4] 12 D[5] 13 D[6] 14 D[7]

3-6

Connector J7

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by any means, is strictly prohibited.

J7 connects to the engine sensors, battery, starter, governor actuator and magnetic pickup.

PIN 36

J7

PIN 1

PIN 4

FIGURE 3-8. J7 ENGINE HARNESS CONNECTOR

BASE

BOARD

CONNECTOR J7

PIN SIGNAL

5, 6, 7, 8 GND 1, 2, 3, 4 B+ IN

9 10

11 12

13 17 21

15 16

GEN SW B+

FUEL SOL B−

CT1

CT1−COM

OIL PRE OUT

OIL PRE COM

OIL PRE 5V

CT2

CT2−COM 18 ALT FLASHOUT 19

20 22

26 23

27 24

28 25

29 33

30 34

31 32 35

COOLANT SNDER

COOLANT SNDER COM

CT3

CT3−COM

OIL TEMP

OIL TEMP COM

GEN SW B+

START SOL B−

ACTUATOR + ACTUATOR −

MAG PICKUP+ MAG PICKUP−

GND

COOL LVL B+

COOL LVL RTN

COOL LVL GND

3-7

Connector J8

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by any means, is strictly prohibited.

J8 connects directly to the generator to monitor and control AC output of the genset.

BASE

BOARD

PIN 24

J8

CONNECTOR J8

PIN SIGNAL COMMENTS

4 12 20

7 13

5 21

22 23

U1 (T1) V2 (T2)

W3 (T3)

N (T4)

FIELD + FIELD −

AC2 (PMG2)

AC3 PMG3)

AC4 (PMG4)

Used for alternator voltage sensing and power factor angle sensing

Excitation drive output

Used for excitation power (Shunt connection − pins 21 & 22 only)

PIN 1

FIGURE 3-9. J8 AC GENERATOR CONNECTOR

REFERENCE

DESIGNATION

F1 10A Customer B+ (to TB1 customer terminal block) F2 5A Customer switched B+ (to TB1 customer terminal block) F3 2A Customer switched B+ (to T26 engine terminal block) F4 5A Base board power supply fuse F5 2A B+ supply to Power Transfer Control (PTC) module (optional) (PCB P/N 300-5381)

RS1 (Fuse/Auto

Reset)

PIN 4

TABLE 3-1. BASE BOARD FUSES

RATING FUNCTION

0.9A B+ supply to Power Transfer Control (PTC) module (optional) (PCB P/N 327-1379)

TB1 Customer Connections

Customer monitor/control connections are attached to terminal board TB1. Optional equipment such as sensing devices used to monitor genset operation, remote start/stop switches and etc. are attached to this terminal. Refer to Customer Connections diagram in

Section 10

for TB1 connections.

TB2 Power Transfer Control (PTC) Connections

TB2 is used to connect the optional PTC module to the control. With this option installed, the control will monitor the utility voltage (mains) and frequency for failure. If power fails, the PTC control will start the generator, open the mains circuit breakers and close the generator circuit breakers. Refer to Customer Connections diagram in

Section 10

connections.

3-8

for TB2

4. Troubleshooting

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by any means, is strictly prohibited.

GENERAL

The PowerCommand 2100 Control (PCC) continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the PCC will light a yellow Warning lamp or a red Shutdown lamp and display a message on the digital display panel.

INPOWER SERVICE TOOL

The InPower service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions. Refer to the InPower User’s Guide, provided with the InPower software for test procedures.

InPower, when used improperly, can cause symptoms like warnings and shutdowns that appear to be a defective base board. When these problems occur, always verify that a self-test or fault simulation (override) have not been left enabled with InPower. If you do not have InPower, or the enabled fault simulation(s) can not be found using InPower, disconnect battery power to disable the test or override condition.

Make sure that parameter adjustments and time delays, related to the fault condition, have been appro-

priately set for the application. It may be necessary to write the initial capture file to the device or update the calibration file.

Updating a calibration file requires the InPower Pro version. Confirm that the installed calibration part number matches the serial plate information.

CAUTION

Using the wrong calibration file can result in equipment damage. Do not swap Base boards from another genset model and only use the calibration file shown on the nameplate.

Some features are not available until the hardware for that feature is installed and InPower Pro is used to update (enable) that feature. Confirm that the feature is installed and enabled prior to troubleshooting the base board for symptoms related to a feature.

NETWORK APPLICATIONS AND

CUSTOMER INPUTS

In applications with networks and remote customer inputs, the genset may start unexpectedly or fail to crank as a result of these inputs. These symptoms may appear to be caused by the base board. Verify that the remote input is not causing the symptom or isolate the control from these inputs before troubleshooting the control.

4-1

SAFETY CONSIDERATIONS

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by any means, is strictly prohibited.

WARNING

nents can cause electrocution, resulting in severe personal injury or death. Keep the output box covers in place during troubleshooting.

Contacting high voltage compo-

CAUTION

Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the genset.

High voltages are present when the genset is running. Do not open the generator output box while the genset is running.

WARNING

Ignition of explosive battery gases 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 battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (−) cable first and reconnect last.

WARNING

Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (−) cable from the battery terminal.

When troubleshooting a generator set that is shut down, make certain the generator set cannot be accidentally restarted as follows:

1. Move the O/Manual/Auto switch on the control panel to the O position.

2. Turn off or remove AC power from the battery charger.

3. Remove the negative (−) battery cable from the generator set starting battery.

4-2

TROUBLESHOOTING PROCEDURE

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by any means, is strictly prohibited.

The following tables are a guide to help you evaluate problems with the generator set. You can save time if you read through the manual ahead of time and understand the system.

Try to think through the problem. Go over what was done during the last service call. The problem could be as simple as a loose wire, an opened fuse or a tripped circuit breaker.

NOTE: Each fault code “warning” can be changed to “shutdown” using InPower. Default settings are used in this manual. It is recommended that all changes to settings be recorded at each site to aid in the troubleshooting of the genset.

This section contains the following information:

• Table 4-1 and 4-2: Describes how to trouble-

shoot a local/remote fail to crank problem when control panel does not indicate fault condition.

• Table 4-3: Describes each status, warning and

shutdown code, warning and shutdown limits where applicable, and basic corrective actions,

such as, checking fluid levels, control reset functions, battery connections, etc.

• Fault Code Tables: Provide detailed trouble-

shooting procedures. In the following tables, the fault codes are used as the table reference number and are arranged in numeric order.

Figure 4-2 shows the location of the components within the control panel that are referenced in the following troubleshooting procedures. Connector locations for each circuit board are provided in

tion 3

. The control wiring and circuit board connec-

tions are shown in

CAUTION

Always set the O/Manual/Auto

Section 10

.

switch to the O position before disconnecting or connecting harness connectors. Otherwise, disconnecting the harness connectors can result in voltage spikes high enough to damage the DC control circuits of the set.

CAUTION

Electrostatic discharge will damage circuit boards. Always wear a wrist strap when handling circuit boards or when disconnecting or connecting harness connectors. See Circuit Board Removal/Replacement in Section 6.

Sec-

4-3

EMERGENCY STOP

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INDICATOR

BOARD

O/MANUAL/AUTO

SWITCH (S12)

BUTTON

DISPLAY

BOARD

BASE

BOARD

CONTROL ALIVE

INDICATOR

FRONT CONTROL PANEL ASSEMBLY

(MEMBRANE BUTTONS)

BARGRAPH BOARD

(OPTIONAL)

FIGURE 4-2. PCC CONTROL COMPONENTS

TB2 (1−6) TB1 (1−22)

CHASSIS GROUND

SCREW

AUX RELAYS

(OPTIONAL)

LOCATION

4-4

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

TABLE 4-1. ENGINE DOES NOT CRANK IN MANUAL MODE

(NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a manual start signal. Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. No power supplied to control. (Control Alive indicator on Base board is not flashing.)

2. Base board not properly calibrated or corrupt calibration. (Control Alive indicator flashes every 1/2 second.)

3. The Emergency Stop switch or wiring is defective.

4. The Manual input is not getting from the Manual select switch (S12) to the Base board indicting that S12, Base board or the harness is bad.

5. The Manual Run/Stop button, harness or the Base board is bad.

1a. Poor battery cable connections. Clean the battery cable terminals

and tighten all connections.

1b. Remove F4 and check continuity. If open, replace the fuse with one

of the same type and amp rating (5 Amps). If F4 is OK, remove connector P7 and check for B+ at P7-1 through

P7-4 and GND at P7-5 through P7-8. If B+ or ground missing,isolate to harness and TB BAT terminal mounted on engine block.

If B+ and ground check OK, Base board may be defective. Cycle power to Base board by reconnecting P7. If Control Alive indicator does not blink, replace Base board.

2. Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary. (When properly installed, Control Alive indicator flashes every second.)

3. With Emergency Stop push button not activated, remove connector P1 and check for continuity between P1-1 (ESTOP-NC1) and P1-2 (ESTOP-NC2). (If circuit is open, the control will detect a local E-Stop condition but will not display the E-Stop condition.) If circuit is open, isolate to Emergency Stop switch and wiring.

If there is continuity, go to next step.

4. With S12 in Manual, remove connector P1 from the Base board and check for continuity from P1-6 (MAN) to P1-9 (GND). If no continuity, isolate to switch and wiring.

If there is continuity, go to next step.

5. Remove connector P3 from the Base board and check for continuity from P3-9 (MAN RUN/STOP) to P3-10 (GND). If no continuity when pressing the Manual Run/Stop button, replace front membrane panel. If there is continuity, the Base board is bad.

4-5

WARNING

Redistribution or publication of this document, 

by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

TABLE 4-2. ENGINE DOES NOT CRANK IN REMOTE MODE

(NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a remote start signal. Effect: Engine will not start in remote mode, but starts in manual mode.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The remote start switch or customer wiring is faulty.

2. The Auto mode input is not getting from the Auto select switch (S12) to the Base board indicting that S12, Base board or the harness is bad.

1. Reset the control. Attempt to start, and check for ground at TB1-1. If ground level is not present, isolate to the remote switch or customer wiring. Repair as necessary.

If ground is present, go to next step.

2. With S12 in Auto, remove connector P1 from the Base board and check for continuity from P1-5 (AUTO) to P1-9 (GND). If no continuity, isolate to switch or wiring harness. If there is continuity, the Base board is bad.

4-6

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TABLE 4-3. WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

121 SPEED SIGNAL LOST

Lamp: Shutdown

135 OIL PRESSURE SENSOR H

Lamp: Warning

141 OIL PRESSURE SENSOR L

Lamp: Warning

143 PRE-LOW OIL PRES

Lamp: Warning

144 COOL SENSOR HIGH

Lamp: Warning

145 COOL SENSOR LOW

Lamp: Warning

146 PRE-HIGH COOL TMP

Lamp: Warning

Indicates mag pickup speed indication is not being sensed. Restart and check RPM on the digital display.

Indicates that the control has sensed that the engine oil pressure sender signal is shorted high. Check sender/connectors/wires.

Indicates that the control has sensed that the engine oil pressure sender signal is shorted low. Check sender/connectors/wires.

Indicates engine oil pressure has dropped to an unacceptable level. If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow code 415 procedure.

Indicates that the control has sensed that the engine coolant temperature signal is shorted high. Check sender/connectors/wires.

Indicates that the control has sensed that the engine coolant temperature signal is shorted low. Check sender/connectors/wires.

Indicates engine has begun to overheat (coolant temperature has risen to an unacceptable level.

If generator is powering non-critical and critical loads and cannot be shut down, use the following:

151 HIGH COOLANT TEMP

Lamp: Shutdown

197 LOW COOLANT LEVEL

Lamp: Warning (Optional)

a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow.

If engine can be stopped, follow code 151 procedure. Indicates engine has overheated (coolant temperature has risen above the shut-

down trip point). Allow engine to cool down completely before proceeding with the following checks:

a. Check coolant level and replenish if low. Look for possible coolant leakage

points and repair if necessary. b. Check for obstructions to cooling airflow and correct as necessary. c. Check fan belt and repair or tighten if necessary. d. Check blower fan and circulation pumps on remote radiator installations. e. Reset control and restart after locating and correcting problem.

Indicates engine coolant level has fallen below the warning trip point. Allow engine to cool down completely before proceeding.

a. Check coolant level and replenish if low. Look for possible coolant leakage

points and repair if necessary. b. Reset control and restart after locating and correcting problem.

4-7

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TABLE 4-3. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

212 OIL TEMP SENSOR H

Lamp: Warning

213 OIL TEMP SENSOR L

Lamp: Warning

234 OVERSPEED

Lamp: Shutdown

235 LOW COOLANT LEVEL

Lamp: Shutdown

359 FAIL TO START

Lamp: Shutdown

415 LOW OIL PRESSURE

Lamp: Shutdown

421 OIL TEMP

Lamp; Warning (Optional)

Indicates that the control has sensed that the engine oil temperature signal is shorted high. Check sender/connectors/wires.

Indicates that the control has sensed that the engine oil temperature signal is shorted low. Check sender/connectors/wires.

Indicates engine has exceeded normal operating speed. Possible causes are single step large block load removal, flammable vapors drawn into the intake air passage or turbocharger seals leaking oil.

Indicates engine coolant level has fallen below the shutdown trip point. Allow engine to cool down completely before proceeding.

a. Check coolant level and replenish if low. Look for possible coolant leakage

points and repair if necessary.

b. Reset control and restart after locating and correcting problem.

Indicates possible fuel system problem. (Engine cranks but fails to start)

a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as re-

quired. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem.

Indicates engine oil pressure has dropped below the shutdown trip point. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart.

Indicates engine has begun to overheat (oil temperature has risen to an unacceptable level). If generator is powering non-critical and critical loads and cannot be shut down, use the following:

a. Reduce load if possible by turning off non-critical loads. b. Check air inlets and outlets and remove any obstructions to airflow.

If engine can be stopped, follow code 151 procedure and also check engine oil level.

4-8

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TABLE 4-3. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

441 LOW BAT VOLTAGE

Lamp: Warning

442 HIGH BAT VOLTAGE

Lamp: Warning

1123 SHUTDOWN AFTER BS

Lamp: Shutdown

1124 DELAYED SHUTDOWN

Lamp: Warning

1131 BATTLE SHORT ACTIVE

Lamp: Warning

Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation will occur.

a. Discharged or defective battery.

Check the battery charger fuse. Recharge or replace the battery.

b. Poor battery cable connections. Clean the battery cable terminals and tighten all

connections. c. Check battery wiring/calibration. c. Check engine DC alternator. Replace engine DC alternator if normal battery

charging voltage is not obtained. d. Check battery charge voltage float level if applicable (raise float level).

Indicates battery voltage supply to the control is approaching a high level at which damage to the control can occur. Check float level on battery charger if applicable (lower float level). Check battery wiring/calibration.

A shutdown fault occurred while Battle Short was enabled and Battle Short transitioned from enabled to disabled. Review Fault History and perform corrective action.

A shutdown fault became active while the Delayed Shutdown feature was enabled. The shutdown will be delayed by the delayed shutdown time entered. Review Fault History and perform corrective action.

Indicates that the control is in Battle Short mode − used to bypass several critical fault shutdowns for genset operation during emergencies.

1311, 1312, 1317, 1318 CUSTOMER INPUT #1 − #4

Lamp: Warning/Shutdown or none for status message.

1313 − 1316 NETWORK FAULT 1 thru 4

Lamp: Warning/Shutdown or none for status message.

1334 CRIT SCALER OR

Lamp: Shutdown

The nature of the fault is an optional customer selection. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, Low Starting Hydraulic Pressure, Low Starting Air Pressure, etc.

Each of the fault functions can be programmed (using service tool), as follows:

• Enable/disable input (Default: enable)

• Status, Warning or Shutdown (Default: #1−None, #2 thru #4−Warning)

• Active closed or open (Default: closed [ground])

• Change display name using up to 19 characters (Default: #1− Customer Fault 1,

#2−Ground Fault, #3−Low Fuel, #4−Rupture Basin Fault)

Indicates network input (#1−#4) is in an active state. Each of the fault functions can be programmed (using service tool), as follows:

• Status, Warning or Shutdown

• Change display name using up to 19 characters

Incorrect feature or calibration was entered into control.

4-9

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TABLE 4-3. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

1335 NONCRIT SCALER OR

Lamp: Warning

1416 FAIL TO SHUTDOWN

Lamp: Warning

1417 POWER DOWN ERROR

Lamp: Warning

1433 EMERGENCY STOP

Lamp: Shutdown

1434 REMOTE E-STOP

Lamp: Shutdown

1435 LOW COOLANT TEMP

Lamp: Warning Set is not operating. Warning

occurs when engine coolant temperature is 70° F (21° C) or lower. NOTE: In applica-

tions where the ambient temperature falls below 40 F (4° C), Low Coolant Temp may be indicated even though the coolant heaters are operating.

Incorrect feature or calibration was entered into control.

Genset continues to run after receiving shutdown command from the controller. Battle Short feature enabled − used to bypass several critical fault shutdowns for genset operation during emergencies.

Indicates that the controller can not power down because of some unknown condition. Possible drain on battery.

Indicates local Emergency Stop. To reset the local/remote Emergency Stop button:

1. Pull the button out.

2. Move the O/Manual/Auto switch to O.

3. Press the front panel Fault Acknowledge/Reset button.

4. Select Manual or Auto, as required.

Indicates remote Emergency Stop. See code 1433 to reset.

Indicates engine coolant heater is not operating or is not circulating coolant. Check for the following conditions:

a. Coolant heater not connected to power supply. Check for blown fuse or discon-

nected heater cord and correct as required.

b. Check for low coolant level and replenish if required. Look for possible coolant

leakage points and repair as required.

c. Open heater element. Check current draw of heater.

Coolant temperature must be below 70° F (default setting) for one minute to acti-

°

vate warning and be above 70° F for five minutes before the warning can be cleared.

1438 FAIL TO CRANK

Lamp: Shutdown

1442 WEAK BATTERY

Lamp: Warning

1443 BATTERY FAILED

Lamp: Shutdown

Indicates possible fault with control, speed sensing or starting system.

Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time. See code 441 for corrective action.

Dead battery − engine will not start. See code 441 for corrective action.

4-10

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TABLE 4-3. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

1444 KW OVERLOAD

Lamp: Warning

1445 SHORT CIRCUIT

Lamp: Shutdown

1446 HIGH AC VOLTAGE

Lamp: Shutdown

1447 LOW AC VOLTAGE

Lamp: Shutdown

1448 UNDER FREQUENCY

Lamp: Shutdown

1449 OVER FREQUENCY

Lamp: Warning

1452 GEN CB NOT CLOSE

Lamp: Warning

1453 GEN CB NOT OPEN

Lamp: Warning

1459 REVERSE POWER

Lamp: Shutdown

1461 LOSS OF FIELD

Lamp: Shutdown

1466 MODEM FAILURE

Lamp: Warning

1468 NETWORK ERROR

Lamp: Warning

1469 SPEED/HZ MATCH

Lamp: Shutdown

1471 OVER CURRENT

Lamp: Warning

Indicates that generator output power exceeded 105% of genset rating. Check load and load lead connections.

Indicates that generator output current has exceeded 175% of rated. Check load and load lead connections. (Fault may not reset for several minutes.)

Indicates that one or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds.

Indicates that one or more of the phase voltages has dropped below 85% of nominal for 10 seconds.

Indicates that engine speed has dropped below 90% of nominal for 10 seconds. Check fuel supply, intake air supply and load.

Indicates frequency is 10% above base frequency for 20 seconds.

Refer to Section 5.

Indicates improper CT phasing. Check wiring to voltage sense circuit. Refer to CT Installation in

Indicates loss of field (electric) due to reverse kVAR.

Indicates that control can not communicate with the modem. Check for open, short circuit to ground, and loose connections to the modem.

Indicates momentary loss of communication from the LonWorks Network. Refer to the LonWorks Network publications for more specific troubleshooting methods.

Indicates that measured speed and measured AC output frequency do not agree. Check calibration file.

Indicates that generator output current has exceeded 110% of rated for 60 seconds.

Check load and load lead connections.

Section 6

.

4-11

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TABLE 4-3. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

1472 OVER CURRENT

Lamp: Shutdown

2323 − 2326 NETWORK FAULT 5 thru 8

Lamp: Warning/Shutdown or none for status message.

2327 PTC FAULT

Lamp: Warning

2329 LOW S1 FREQUENCY

Lamp: Warning

2331

Lamp: Warning

2335 EXCITATION FAULT

Lamp: Shutdown

2336 MEMORY ERROR

Lamp: Shutdown

2337 PWR TRAN DISABLED

Lamp: Warning

2338 PWR TRAN FAILURE

Lamp: Warning

2339 PWR DOWN ENABLED

Lamp: Warning

2341 HIGH CONTROL TEMP

Lamp: Warning

2342 TOO LONG IN IDLE

Lamp: Warning

2358 HIGH S1 VOLTAGE

Lamp: Warning

2396 S1 CB NOT CLOSE

Lamp: Warning

Indicates that generator output current has exceeded 110% of rated, and that a control time/current calculation has initiated an overcurrent shutdown.

Check load and load lead connections. (Fault may not reset for several minutes.) Indicates network input (#5−#8) is in an active state. See 1313−1316 fault code

corrective action.

Refer to Section 5.

Indicates a loss of all three voltage sense leads or failure in excitation circuit. Check field wiring (X1 and X2) for shorts or opens.

Indicates control memory error. Data corruption of critical operating parameters. Try reloading calibration file.

Refer to Section 5.

Control temperature is above normal (158° F [70° C]) for a time greater than control temperature set time. Check genset room air flow.

Indicates genset has been in Idle mode too long. Exit idle mode.

Refer to Section 5.

4-12

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TABLE 4-3. WARNING AND SHUTDOWN CODES (CONT.)

FAULT CODE CORRECTIVE ACTION

2397 S1 CB NOT OPEN

Lamp: Warning

2966 PTC TIMEOUT

Lamp: Warning

2967 GOVERNOR FAULT

Lamp: Warning

2968 AVR FAULT

Lamp: Warning

2969 LON FAILURE

Lamp: Warning

2971

Lamp: None

2972 FIELD OVERLOAD

Lamp: Shutdown

Refer to Section 5.

Governor hardware drive circuitry contains a fault condition.

Indicates AVR hardware contains a fault condition.

Indicates no communications with LonWorks board.

Refer to Section 5.

AVR Field has been at Max Field for a time greater than the allowed Max Field Time.

4-13

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CODE 121 − SPEED SIGNAL LOST (SHUTDOWN)

Reason: This indicates that the PCC is not sensing the magnetic pickup signal. Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Loose or damaged magnetic pickup (MPU) wires/connector pins.

2. The magnetic pickup, harness or Base board could be bad.

1. Inspect the wires/connector pins, and repair or replace as necessary.

2. To isolate the problem, reset the control and attempt to start the set in Idle mode (select Idle Mode − Enable menu).

a. If 1438 (Fail To Crank) is displayed, or if the engine starts, but then

shuts down on 121 (Speed Signal Lost), the MPU sender could be bad. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking.

• If no output, check for damage or debris. Also check for improper adjustment of the MPU. (Refer to still no output, replace the MPU sender.

• If the MPU output is OK, check for MPU voltage at P7−25 (MAG PICK+) to P7-29 (MAG PICK−) while cranking. If OK, replace the Base board. If not OK, use continuity checks to isolate connectors/harness.

b. If the engine starts and idles, and does not display a fault, then

there could be a frequency mismatch problem. Measure generator output frequency with a digital multimeter and compare to the frequency on the PCC display.

• If they do match, multiply the frequency by 30 and compare this number to the RPM on the PCC display. If these are not the same, the MPU sender may be bad. Replace the MPU sender.

• If the multimeter and PCC frequencies do not match, there is a frequency sensing problem within the Base board. Replace Base board.

Section 6

.) If there is

4-14

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CODE 135 − OIL PRESSURE SENSOR HIGH (WARNING)

Reason: This indicates that the engine oil pressure sensor signal is shorted high. Effect: No engine protection for oil pressure during genset operation.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. The sensor connections could be bad. 2. Inspect the sensor and engine harness connector pins. Repair or

3. The sensor could be bad. 3. Disconnect the oil pressure sensor leads, and connect an oil pres-

4. The harness could be bad. 4. Remove connector P7 from Base board and connector from sen-

5. The Base board could be bad. 5. With all connectors attached, check pressure signal (.5 to 4.5 VDC)

1. With InPower, verify that the fault simulation is not enabled for the oil pressure sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

replace as necessary.

sure sensor simulator to the harness.

“OIL PRESSURE SENSOR H” warning is displayed after the fault condition is sensed for 10 seconds.

If the control responds to the simulator, replace the sensor. If control does not respond, go to next step.

sor. Check P7-13, 17 & 21 as follows:

• Check for a short circuit from pin to pin (more than 200k ohms OK).

• Check for an open circuit (10 ohms or less OK).

Repair or replace as necessary.

at P7-13 (OP OUT) and P7-17 (OP COM). If in range, replace Base board.

4-15

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CODE 141 − OIL PRESSURE SENSOR LOW (WARNING)

Reason: This indicates that the engine oil pressure sensor signal is shorted low. Effect: No engine protection for oil pressure during genset operation.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. The sensor connections could be bad. 2. Inspect the sensor and engine harness connector pins. Repair or

3. The sensor could be bad. 3. Disconnect the oil pressure sensor leads, and connect an oil pres-

4. The harness could be bad. 4. Remove connector P7 from Base board and connector from sen-

5. The Base board could be bad. 5. With all connectors attached, check pressure signal (.5 to 4.5 VDC)

1. With InPower, verify that the fault simulation is not enabled for the oil pressure sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

replace as necessary.

sure sensor simulator to the harness.

“OIL PRESSURE SENSOR L” warning is displayed after the fault condition is sensed for 10 seconds.

If the control responds to the simulator, replace the sensor. If control does not respond, go to next step.

sor. Check P7-13, 17 & 21 as follows:

• Check for an open circuit (10 ohms or less OK).

• Check for a short circuit to the engine block ground (more than

200k ohms OK).

• Check for a short circuit from pin to pin (more than 200k ohms OK).

Repair or replace as necessary.

at P7-13 (OP OUT) and P7-17 (OP COM). If in range, replace Base board.

4-16

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CODE 143/415 − PRE-LOW OR LOW OIL PRESSURE (WARNING/SHUTDOWN)

Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure. Effect: Calibration-dependent. No action is taken by the PCC for code 143. Engine will shut down for code 415.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Low oil level. Clogged lines or filters. 2. Check oil level, lines and filters. If oil system is OK but oil level is

3. Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault.

4. Harness or Base board could be bad. 4. If the control does not respond to the simulator, the Base board or

1. With InPower, verify that the fault simulation is not enabled for the oil pressure sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

low, replenish.

3. Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness.

a. If the control responds to the simulator, reconnect the sensor, dis-

connect the ACT− signal wire at the fuel pump actuator, and crank the engine. Check the oil pressure reading on the digital display.

• If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The genset may be shutting down on another fault (out of fuel, intermittent connector). Restart the genset and monitor the PCC display panel for other faults.

• If the display does not show an acceptable oil pressure, replace the sensor. If the PCC still doesn’t display an oil pressure while cranking, the oil pump may be bad. Refer to the engine service manual.

If the control does not respond to the simulator, go to next step.

the harness is bad. Check for +5 VDC at the sensor (lead marked E1-A). If there is no 5

VDC at the sensor:

• Check for 5 VDC at P7-21.

• If yes, harness is bad. If no, Base board is bad.

If there is 5 VDC at the sensor, use the sensor simulator to generate a signal to P7-13 (OP OUT) and P7-17 (OP COMM). If the pressure signal (.5 to 4.5 VDC) does not get to P7, isolate to the harness. If the pressure signal does go to P7, the Base board is bad.

4-17

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CODE 144 − COOLANT SENSOR HIGH (WARNING)

Reason: This indicates that the coolant temperature sensor signal is shorted high. Effect: No engine protection for coolant temperature during genset operation. Possible white smoke.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. The sensor connections could be bad. 2. Inspect the sensor and engine harness connector pins. Repair or

3. The sensor could be bad. 3. Disconnect the sensor, and plug in a resistive sensor simulator to

4. The harness or Base board could be bad.

1. With InPower, verify that the fault simulation is not enabled for the coolant sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

replace as necessary.

isolate the fault. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, go to next step.

4. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P7 from Base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

4-18

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CODE 145 − COOLANT SENSOR LOW (WARNING)

Reason: This indicates that the coolant temperature sensor signal is shorted low. Effect: No engine protection for coolant temperature during genset operation. Possible white smoke.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. The sensor connections could be bad. 2. Inspect the sensor and engine harness connector pins. Repair or

3. The sensor could be bad. 3. Disconnect the sensor, and plug in a resistive sensor simulator to

4. The harness or Base board could be bad.

1. With InPower, verify that the fault simulation is not enabled for the coolant sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

replace as necessary.

isolate the fault. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, go to next step.

4a. Remove connector P7 from Base board and disconnect sensor.

Check pins P7-30 (IH20) and P7-34 (IH20 COM) for short circuit as follows:

• Check for a short circuit to the engine block ground (more than 200k ohms OK).

• Check for a short circuit from pin to pin (more than 200k ohms OK).

Repair or replace as necessary.

4b. Measure the resistance of the coolant sensor and reconnect har-

ness to sensor. Remove connector P7 from Base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

4-19

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CODE 146/151 − PRE-HIGH OR HIGH COOLANT TEMPERATURE (WARNING/SHUTDOWN)

Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature. Effect: Calibration-dependent. No action is taken by the PCC for code 146. Engine will shut down for code 151.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Engine or sensor circuitry problem. 2. Isolate to the engine or sensor circuitry.

3. The sensor could be bad. 3. Disconnect the sensor and connect a coolant temperature sensor

4. The harness or Base board could be bad.

1. With InPower, verify that the fault simulation is not enabled for the coolant sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

Check the sensor accuracy with a thermocouple or similar temperature probe.

• If the PCC ambient coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual.

• If the PCC ambient coolant temperature reading is not accurate, go to next step.

simulator to the harness. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, go to next step.

4. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P7 from Base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

4-20

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CODE 197/235 − LOW COOLANT LEVEL (WARNING/SHUTDOWN)

Reason: Engine coolant level has dropped below the warning/shutdown threshold for low/high coolant level. Effect: No action is taken by the PCC for code 197. Engine will shut down for code 235.

POSSIBLE CAUSE CORRECTIVE ACTION

The sensor, harness or Base board could be bad.

If the coolant level is normal, isolate the source of the low coolant signal. (This is a ground signal.)

Disconnect the signal lead at the sender and reset the control.

1. If the 197/235 message drops out and does not reappear, replace the sender.

2. If the 197/235 message reappears and remains after control reset, remove connector P7 from Base board and check continuity from P7-32 to ground.

• If there is continuity, replace the harness.

• If there is not continuity, replace the Base board.

CODE 212 − OIL TEMPERATURE SENSOR HIGH (WARNING)

Reason: This indicates that the oil temperature sensor signal is shorted high. Effect: No engine protection for oil temperature during genset operation. No effect on performance.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The sensor connections could be bad. 1. Inspect the sensor and engine harness connector pins. Repair or replace as necessary.

2. The sensor could be bad. 2. Disconnect the sensor, and plug in the simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, go to next step.

3. The the harness or Base board could be

bad.

3. Measure the resistance of the oil sensor and reconnect harness to sensor. Remove connector P7 from Base board and check resistance between pins P7-22 (OIL TEMP) and P7-26 (OIL TEMP COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

4-21

WARNING

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Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 213 − OIL TEMPERATURE SENSOR LOW (WARNING)

Reason: This indicates that the oil temperature sensor signal is shorted low. Effect: No engine protection for oil temperature during genset operation. No effect on performance.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The sensor connections could be bad. 1. Inspect the sensor and engine harness connector pins. Repair or replace as necessary.

2. The sensor could be bad. 2. Disconnect the sensor, and plug in the simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, go to next step.

3. The harness or Base board could be

bad.

3a. Remove connector P7 from Base board and disconnect sensor.

Check pins P7-22 (OIL TEMP) and P7-26 (OIL TEMP COM) for short circuit as follows:

• Check for a short circuit to the engine block ground (more than 200k ohms OK).

• Check for a short circuit from pin to pin (more than 200k ohms OK).

Repair or replace as necessary.

3b. Measure the resistance of the coolant sensor and reconnect har-

ness to sensor. Remove connector P7 from Base board and check resistance between pins P7-22 (OIL TEMP) and P7-26 (OIL TEMP COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

4-22

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 234 − OVERSPEED (SHUTDOWN)

Reason: Engine speed signal indicates an engine speed greater than shutdown threshold. Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Cold engine (no coolant heaters) 1. Overspeed can occur when starting a vary cold engine. Clear fault and restart genset.

2. Single step large block load removal. 2. Clear fault and restart genset.

1. Fault simulation was enabled with In-

Power.

2. Fault threshold is not set correctly with

InPower.

3. Monitor the engine rpm using InPower. 3. If the RPM is not correct, refer to fault code 121 for corrective ac-

4. The electronic governor actuator could

be bad.

1. With InPower, verify that the fault simulation is not enabled for the coolant sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

2. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

tion.

4. Binding in actuator assembly of injection pump. Disassembly of injection pump may be required to inspect/repair O-rings, pump, etc. Refer to the engine service manual.

CODE 235 − LOW COOLANT LEVEL (SHUTDOWN)

Reason: Effect:

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 197. 1. Refer to code 197.

4-23

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 359 − FAIL TO START (SHUTDOWN)

Reason: This indicates that the engine failed to start after expiration of last crank time. Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Restricted fuel supply due to: a. Fuel level below pickup tube in

tank. b. Closed shutoff valve in supply line. c. Fuel injectors clogged. d. Air in fuel system.

2. Fuel solenoid not energized due to: a. Fuse F1 o f harness assembly may

be opened.

b. Fuse F3 on Base board may be

open. c. Base board is bad. d. K1 Fuel Pilot Relay is bad. e. Fuel solenoid is bad.

1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line supplying the engine. 1c. Refer to engine service manual. 1d. Bleed air from fuel system. Refer to engine service manual.

Isolate to F1, F3, K1 relay, fuel solenoid or Base board.

2a. Remove fuse F1 (located near TB BATT terminal on engine block)

and check continuity. If open, replace the fuse with one of the same type and amp rating (3 Amps.) If fuse reopens, check wiring continuity of fuel solenoid circuit/test fuel solenoid. (Go to step 2e for solenoid test.)

2b. Remove fuse F3 (located on Base board) and check continuity. If

open, replace the fuse with one of the same type and amp rating (2 Amps.) If fuse reopens, check wiring continuity/test K12 fuel pilot relay coil.

2c. Install harness tool between Base board P7 connector. Attempt to

start and check for B+ at P9-9 (GEN SW B+) and P7-10 (FUEL SOL−). (These are the leads to the K1 coil.)

• If there is no B+, the Base board is bad.

• If there is B+, K1 or the harness is bad. Go to step 2d.

2d. Attempt to start and check for B+ IN (K1-30) and OUT (K1-87)

• If there is no B+ IN, check for open circuit.

• If There is B+ IN and not OUT, K1 is bad.

• If there is B+ OU T, fuel solenoid or the harness is bad. Check

circuit between K1-87 and fuel solenoid. Repair as necessary. If OK, go to step 2e.

2e. Disconnect lead to fuel solenoid. Measure the resistance of the fuel

solenoid between fuel solenoid terminal and the engine block. A reading of 30 ohms indicates that the solenoid coil is OK.

If coil resistance is OK, check mechanical operation of solenoid by connecting B+ to solenoid terminal. Solenoid should click when energized.

4-24

WARNING

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CODE 359 − FAIL TO START (SHUTDOWN)(CONT.)

Reason: This indicates that the engine failed to start after expiration of last crank time. Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

3. Injection pump actuator not energized due to the harness, governor actuator or the Base board is bad.

Isolate to harness, governor actuator or Base board.

3a. Display “Governor Duty Cycle” menu. Attempt to start and check

for duty cycle (44% is about average). If percentage of duty cycle is displayed before shutdown, the harness, actuator or output circuit of Base board is bad, go to step 3b. (Duty cycle displayed indicates processor is functioning, but output circuitry of Base board could still be defective.) If the duty cycle is not displayed, the Base board is bad.

3b. Remove connector P7 from Base board and check wiring continu-

ity of actuator circuit. P7-24 (ACT +) and P7-28 (ACT −) to appropriate +/− terminals of governor actuator. Repair as necessary. If continuity is OK, go to step 3c.

3c. Disconnect the two leads attached to the injection pump actuator.

Measure the resistance across the two actuator terminals. A reading of 7.5 ohms indicates that the actuator circuit is OK. (This test only shows that the actuator circuit is not opened or shorted, but not if there is binding.) Replace actuator assembly if open or short is measured. If actuator is OK, go to step 3d.

3d. Attempt to start and check for CNTL B+ at terminal lead ACT + of

governor actuator (use engine block for meter ground). If not present, Base board is bad.

If CNTL B+ is present, attempt to start and check for GOV PWM (pulse width modulated) signal (measure across terminals of actuator). If not present, Base board is bad.

If GOV PWM signal is present, governor actuator is bad (binding in actuator assembly of injection pump). Disassembly of injection pump may be required to inspect/repair O-rings, pump, etc. (Refer to engine service manual.)

4-25

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 415 − LOW OIL PRESSURE (SHUTDOWN)

Reason: Engine oil pressure has dropped below the shutdown threshold for high oil pressure. Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 143. 1. Refer to code 143.

CODE 421 − OIL TEMPERATURE (WARNING)

Reason: Engine oil temperature has exceeded the warning threshold for high oil temperature. Effect: No action is taken by the PCC. Possible loss of performance.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault threshold is not set correctly with InPower.

2. Engine or sensor circuitry problem. 2. Isolate to the engine or sensor circuitry.

3. The sensor could be bad. 3. Disconnect the sensor and connect an oil temperature sensor sim-

4. The harness or Base board could be bad.

1. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

Check the sensor accuracy with a thermocouple or similar temperature probe.

• If the PCC ambient oil temperature reading is accurate, the engine may be overheating. Refer to the engine service manual.

• If the PCC ambient oil temperature reading is not accurate, go to next step.

ulator to the harness. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, go to next step.

4. Measure the resistance of the oil sensor and reconnect harness to sensor. Remove connector P7 from Base board and check resistance between pins P7-22 (OIL TEMP) and P7-26 (OIL TEMP COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

4-26

WARNING

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Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 441 − LOW BATTERY VOLTAGE (WARNING)

Reason: Low voltage has been detected for battery. Effect: PCC voltage supply approaching level at which unpredictable operation may occur.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Weak or discharged battery. 1. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C).

2. Low electrolyte level in battery. 2. Replenish electrolyte and recharge battery.

3. Battery connections loose or dirty. 3. Clean and tighten or replace the battery cable connectors and cables at the battery and the set.

4. Wrong battery voltage. 4. Verify that battery voltage 12 or 24 matches calibration.

5. Insufficient battery charging voltage. 5. Adjust charge rate of battery charging circuit, according to manufactures instructions.

6. Engine DC alternator could be bad. 6. Replace engine DC alternator if normal battery charging voltage (12 to 14 or 24 to 26 VDC) is not obtained.

7. If the batteries are OK, the problem may

be the harness or the Base board.

7. Remove connector P7 from Base board and check battery voltage at P7−3 (B+) to P7-7 (GND) and P7−4 (B+) to P7-8 (GND).

• If the voltage at P7 is not the same as the battery voltage, the harness is bad.

• If the voltage at P7 is OK, the Base board is bad.

CODE 442 − HIGH BATTERY VOLTAGE (WARNING)

Reason: High voltage has been detected for battery. Effect: PCC damage will occur.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Excessive battery charging voltage. 1. Adjust charge rate of battery charging circuit according to manufacturers instructions.

2. Engine DC alternator could be bad. 2. Replace engine DC alternator if normal battery charging voltage (12 to 14 or 24 to 26 VDC) is not obtained.

3. Wrong battery voltage. 3. Verify that battery voltage 12 or 24 matches calibration.

4-27

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1311, 1312, 1317, 1318 − CUSTOMER INPUT (WARNING/SHUTDOWN)

Reason: The nature of the fault is an optional customer selection. Effect: Status, warning or shutdown.

POSSIBLE CAUSE CORRECTIVE ACTION

If there is no actual fault, the problem may be an external wiring problem, active input (closed or open) selection is incorrect.

Disconnect the signal lead from TB1 and reset the control.

• CUST_IN1 − TB1-4

• CUST_IN2 − TB1-5

• CUST_IN3 − TB1-6

• CUST_IN4 − TB1-7

If the message drops out, the external wiring has a short or open circuit, or the active input selection (closed/open) is not correct for customer input (use service tool to check selection).

4-28

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1435 − LOW COOLANT TEMPERATURE (WARNING)

Reason: Engine coolant temperature has dropped below the warning threshold for low coolant temperature. Effect: No action is taken by the PCC. Engine may not start due to slow cranking speed.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Fault threshold is not set correctly with InPower.

3. The engine coolant heater could be bad. (Radiant heat should be felt with hand held close to outlet hose.)

4. The sensor connections could be bad. 4. Inspect the sensor and engine harness connector pins. Repair or

5. The sensor could be bad. 5. Disconnect the sensor, and plug in a resistive sensor simulator to

6. The harness or Base board could be bad.

1. With InPower, verify that the fault simulation is not enabled for the coolant sensor.

If you do not have InPower, remove battery power from the control to disable fault simulation overrides.

2. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold.

3. Coolant heater not operating due to:

• Coolant heater not connected to power. Check for blown fuse, or disconnected heater cord and correct as required.

• Low coolant level. Look for possible coolant leakage points and repair as required.

• Defective heater element/thermostat. With coolant heater removed from engine and power disconnected, flush with cold tap water for two minutes to close internal heater thermostat (opens at 100 across input power leads: a. Open − replace coolant heater. b. Closed − coolant heater OK (coil resistance of 10 to 60

replace as necessary.

isolate the fault. If the control responds to the simulator, replace the sensor. If con-

trol does not respond, harness or Base board is bad.

6. Measure the resistance of the coolant temperature sensor and reconnect harness to sensor. Remove connector P7 from Base board and check resistance between pins P7-30 (IH20) and P7-34 (IH20 COM).

• If resistance is not the same, harness is bad.

• If resistance is the same, Base board is bad.

° F and closes at 80° F). Check resistance

ohms)

4-29

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1438 − FAIL TO CRANK (SHUTDOWN) (LOCAL OR REMOTE)

Reason: This indicates that the engine failed to crank after the PCC received a start signal. Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Starter is bad. 1. Reset the control. Attempt to start, and test for B+ at the starter. If there is B+ a t the starter, the starter could be bad. Test starter (see engine service manual). Replace the starter.

If B+ is not present at the starter, go to next step.

2. Base board is bad or fuse F3 on the

Base board may be open.

3. Start Pilot Relay K4 or starter circuitry

could be bad.

4. The Emergency Stop switch or wiring is

defective.

5. MPU/circuit is bad. 5. Refer to Code 121 instructions.

2. Remove F3 and check continuity. If open, replace the fuse with one of the same type and amp rating (2 Amps).

If F3 is OK, install harness tool between Base board P7 connector. Attempt to start and check for B+ at P7-23 (GEN SW B+) and P7-27 (START SOL−). (These are leads to the K4 coil.)

• If there is no B+ signal, the Base board is bad.

• If there is a B+ signal, the Start Pilot Relay K4 or starter circuit-

ry is bad. Go to next step.

3. Check for B+ IN at K4-1 (directly connected to battery B+). If not present, check for open circuit.

If there is B+ IN, attempt to start and test for B+ OUT at K4-4.

• If there is no B+ OUT at K4-4, K4 is bad.

• If there is B+ OUT at K4-4, check for open circuit between

K4-4 and starter.

4. With Emergency Stop push button not activated, remove connector P1 and check for continuity between P1-1 (ESTOP-NC1) and P1-2 (ESTOP-NC2). (If circuit is open, the control will detect a local E-Stop condition but will not display the E-Stop condition.) If circuit is open, isolate to Emergency Stop switch and wiring.

If there is continuity, go to next step.

4-30

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1442 − WEAK BATTERY (WARNING)

Reason: Battery is weak. Effect: No action is taken by the PCC.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Weak or discharged battery. 1. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C).

2. Low electrolyte level in battery. 2. Replenish electrolyte and recharge battery.

3. Battery connections loose or dirty. 3. Clean and tighten or replace the battery cable connectors and cables at the battery and the set.

4. Insufficient battery charging voltage. 4. Adjust charge rate of battery charging circuit, according to manufacturers instructions.

5. If the batteries are OK, the problem may

be the harness.

5. Remove connector P7 from Base board. Check battery voltage at: P7-3 (CNTL) to P7-7 (GND) and

P7-4 (CNTL) to P7-8 (GND) If voltage is not OK, repair defective harness.

CODE 1443 − BATTERY FAILED (SHUTDOWN)

Reason: Battery is dead. Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 1438. 1. Refer to code 1438 instructions.

4-31

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1444 − KW OVERLOAD (WARNING)

Reason: The kW has reached overload. The threshold for kW overload is 3 seconds at 110 percent of rated power

output.

Effect: No action taken by the PCC.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault threshold is not set correctly with InPower.

2. Short or overload. 2. Check the load and load cables. Repair if necessary. Check opera-

3. Incorrect CTs or CT connections. 3. Check CTs and CT connections. Correct if necessary. Refer to

4. The problem may be the Base board or harness connections.

1. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

tion by disconnecting load and restarting generator set.

rent Transformer Installation

4. Remove connector P7 from Base board. Check continuity from P7 to CTs.

P7-11 (CT1) to P7-12 (CT1-COM) P7-15 (CT2) to P7-16 (CT2-COM) P7-19 (CT3) to P7-20 (CT3-COM)

Repair connections.

in

Section 6

.

CODE 1445 − SHORT CIRCUIT (SHUTDOWN)

Reason: This indicates that the generator output current has exceeded 175% of rated. Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 1444. 1. Refer to code 1444.

Cur-

CODE 1471/1472 − OVER CURRENT (WARNING/SHUTDOWN)

Reason: This indicates that the generator output current has exceeded 110% of rated. Effect: No action is taken by the PCC for code 1471. Engine will shut down for code 1472.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 1444. 1. Refer to code 1444.

4-32

WARNING

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Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1446 − HIGH AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for

10 seconds.

Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Single step large block load removal. 2. Clear fault and restart genset.

3. Fault threshold is not set correctly with InPower.

4. Base board or generator is bad. 4. Refer to

1. With InPower, verify that the related fault simulation is not enabled. If you do not have InPower, remove battery power from the control

to disable fault simulation overrides.

3. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

Generator/Base Board Isolation Procedure

determine if the generator or the Base board is causing the high A C voltage shutdown fault.

in

Section 7

to

4-33

WARNING

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by any means, is strictly prohibited.

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1447 − LOW AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has dropped below 85% of nominal for 10 seconds. Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Fault threshold is not set correctly with InPower.

3. Overload. 3. Check the load and correct any overload. Check operation by dis-

4. Improper connections have been made at the generator output terminals.

5. PMG or field wiring could be bad. 5. Check and repair the PMG or field wiring (

6. Shunt wiring connection could be incorrect.

7. The rotating rectifier assembly (diodes CR1 through CR6) is faulty.

8. Loose connector or Base board is bad. 8. Repair connections (P8) or replace the Base board if necessary.

1. With InPower, verify that the related fault simulation is not enabled. If you do not have InPower, remove battery power from the control

to disable fault simulation overrides.

2. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold.

connecting load and restarting generator set.

4. Reconnect according to the appropriate reconnection diagram. See

Section 10

6. Check that excitation inputs P8-21 and P8-22 are connected to the correct voltage. If misconnected to a high voltage, the AVR fault will shut down excitation and cause Low AC Voltage condition. (

Section 10

7. Check each diode (

.

refer to Section 10

).

refer to

).

refer to Section 7

).

Reason: Generator AC output frequency is low. Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Fault threshold is not set correctly with InPower.

3. Overload. 3. Check the load and correct any overload. Check operation by dis-

4. Fuel or air delivery problem. 4. Refer to the engine service manual.

5. Loose connector or Base board is bad. 5. Repair connections (P8) or replace the Base board if necessary.

CODE 1448 − UNDER FREQUENCY (SHUTDOWN)

1. With InPower, verify that the related fault simulation is not enabled. If you do not have InPower, remove battery power from the control

to disable fault simulation overrides.

2. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold.

connecting load and restarting generator set.

4-34

WARNING

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Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe all instructions and precautions in this manual.

CODE 1449 − OVER FREQUENCY (WARNING)

Reason: Generator AC output frequency is high. Effect: No action taken by the PCC.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with InPower.

2. Fault threshold is not set correctly with InPower.

3. Fuel or air delivery problem. 3. Refer to the engine service manual.

4. Loose connector or Base board is bad. 4. Repair connections (P7/P8) or replace the Base board if neces-

1. With InPower, verify that the related fault simulation is not enabled. If you do not have InPower, remove battery power from the control

to disable fault simulation overrides.

2. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

sary.

4-35

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4-36

5. PTC Troubleshooting

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GENERAL

This section describes the optional Power Transfer Control (PTC module) and the related Fault Codes and troubleshooting procedures.

The PTC troubleshooting procedures use fault codes, from the PCC 2100 diagnostics, and symptoms. Conditional schematics are used with the symptoms to help diagnose problems, including those not covered by the fault codes.

WARNING

Improper operation of the generator set presents a hazard that can cause severe personal injury or death. Observe all safety precautions in your generator set manuals.

WARNING

AC power at the PTC Module or at the breakers or contactors present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts with body, tools, jewelry, hair, clothes, etc. Remove power from both source 1 and source 2 before removing and replacing components. The following procedures are to be performed only by technically qualified personnel.

PTC MODULE

cluding the genset start signal and network port), the RS-232 communications port for the service tool, and drivers for the control panel indicators, switches, and meters.

Utility voltage is monitored by the PCC 2100 control via voltage sensing transformers on the PTC module. The PTC module contains relays that are used to drive external relays (K20 thru K23) to perform the transfer function.

Two versions of the PTC module are available based on the application voltage. Four optional external power relays are also required. The relays must be selected based on the power rating of the switching mechanism (circuit breaker or contactor), coil voltage and mounting type. Refer to the PTC kit instructions for relay selection.

SEQUENCE OF EVENTS

The control executes a prescribed sequence of events for all PTC operations. The genset must set to the Auto position for the following sequence of events to occur. The operations for a typical loss of S1 utility power and a return of S1 utility power are:

Transfer from Source 1 (Utility) to Source 2 (Genset)

The optional PTC module is used to transfer the customer load between Source 1 (S1 utility) and Source 2 (S2 genset) as needed in the event that the utility power is unstable. The PTC module measures source 1 (Utility) voltage and frequency. The value of S1 voltage and frequency is monitored by the base board where the PCC 2100 control determines if the voltage and frequency are within limits. The system, controlled by the PCC 2100, attempts to maintain a power source for the customer load.

The PCC 2100 actively performs monitoring and control of the power source to the customer load. The PCC 2100 contains the logic and timing circuits that control the transfer sequence. This control also contains many of the customer interface circuits (in-

This sequence of events includes a programmed transition and begins with Source 1 (utility) available and connected. The sequence ends with Source 2 (generator) assuming the load. (See Figure 2.)

1. Source 1 fails. The control senses that Source 1 voltage and frequency are not within the specified limits with the under-voltage, over-voltage, or frequency.

2. Source 1 (Utility) is no longer within specified limits (high or low voltage, or low frequency).

3. The control initiates an engine start time delay (TDES), that delays engine start up for Source 2.

5-1

4. If TDES expires without a return to acceptable

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Source 1 power, the control energizes the K4 genset start pilot relay.

5. As soon as the control senses that the generator output reaches 90% (ready to load), it initiates a Transfer Time Delay (Source 1 to Source 2 transfer) to give the genset time to stabilize. The transfer time delay counts down.

6. When the transfer time delay expires, the control momentarily energizes the K22 Open Utility Relay. The K22 relay contacts close energizing S1-1, the S1 Open Coil. The S1 breaker (or contactor) opens and the S1-3 auxiliary contact opens to indicate that S1 is open.

7. The control verifies that the Source 1 breaker (or contactor) is open.

10. Source 1 is restored and within specified voltage and frequency limits.

11. The control senses when Source 1 output is within the specified voltage and frequency limits. The status changes to Source 1

Available

.

Utility

12. The control initiates a Retransfer Time Delay (Source 2 to Source 1) to give Source 1 time to stabilize. The Retransfer time counts down.

13. When the Retransfer time expires, the control momentarily energizes the K20 Open Genset Relay. The K20 relay contacts close energizing S1-2, the S2 Open Coil. The S2 breaker (or contactor) opens and the S2-3 contacts opens to indicate that S2 is open.

8. The control initiates a programmed transition time delay (or recharge delay), so that residual voltage from an inductive load can decay. The delay counts down.

9. When the delay expires, the control momentarily energizes K21, the Close Genset Relay. K21 contacts close energizing S2-2, the S2 Close Coil. The S2 breaker (or contactor) closes and the S2-3 contacts close to indicate that S2 is closed. The generator assumes the load. The status changes to

Genset

Con-

nected.

Transfer from Source 2 to Source 1

This sequence of events includes a programmed transition and begins with Source 2 (generator) available and connected. The sequence ends with Source 1 assuming the load and the generator cooling down.

14. The control verifies that the Source 2 breaker (or contactor) is open.

15. The control initiates programmed transition time delay (or recharge delay), so that residual voltage from an inductive load can decay. The delay time counts down.

16. When the delay expires, the control momentarily energizes K23, the Close Utility Relay. K23 contacts close, energizing S2-1, the S1 Close Coil. The S1 breaker (or contactor) closes and the S1-3 contacts close to indicate that S1 is closed. The utiltiy assumes the load. The status changes to

S1 (Utility)

Connected.

17. The control initiates a TDEC (time delay, engine cool-down) to allow the engine to cool down under no load conditions. When the time delay ends the engine shuts down.

5-2

TROUBLESHOOTING USING FAULT

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CODES

TABLE 5-1. PTC FAULT CODES AND MESSAGES

The Digital Display shows only fault events (warnings and shutdowns). The last 20 faults can be viewed with the Digital Display. You can also read the events in the event history file by using the PC Service Tool.

Fault Events

1452 Genset CB Not Closed 1453 Genset CB Not Open 2327 PTC Fault 2329 Low S1 Frequency 2331 Low S1 Voltage 2337 PWR Tran Disabled

Fault events should be considered alarms for the genset operator. They indicate that one of the power sources or the PTC is not operating correctly.

2338 PWR Tran Failure 2339 PWR Down Enabled

Table 5-1 lists the fault codes and fault message and Table 5-2 gives corrective actions for each fault code.

The controller displays the fault message on the Digital Display and flashes the asterisk indicator.

2358 High S1 Voltage 2396 S1 CB Not Close 2397 S1 CB Not Open 2966 PTC Timeout

Y ou must press the Reset button on the control panel to acknowledge a fault and clear the display.

TABLE 5-2. PTC FAULT CODE TROUBLESHOOTING

WARNING

Some PTC service procedures present hazards that can result in severe person-

2971 No message (PTC Test Mode Active)

al injury or death. Only qualified service personnel with knowledge of electricity and machinery hazards should perform service. See Safety Precautions.

GENSET CB NOT CLOSED (1452)

The genset circuit breaker (S2) failed to close when PTC is enabled.

Corrective Action:

1. Refer to Toubleshooting Chart 5-4 for a listing of all the possible causes.

GENSET CB NOT OPEN (1453)

The genset circuit breaker (S2) failed to open when PTC is enabled.

Corrective Action:

1. Refer to Toubleshooting Chart 5-5 for a listing of all the possible causes.

5-3

TABLE 5-2. PTC FAULT CODE TROUBLESHOOTING (CONT.)

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by any means, is strictly prohibited.

WARNING

Some PTC service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of electricity and machinery hazards should perform service. See Safety Precautions.

PTC FAULT (2327)

The PTC module or the communication link to the PTC module is not working properly

when PTC is enabled.

Corrective Action:

1. Check for blinking light on the PTC module to indicate that it has power (Figure 5-1). If off, check for B+ between TB3-3 and TB3-4. Check PTC status voltage between TB3-5 and TB3-6, 0.2 VDC, if not present, see steps 2 and 3.

2. Check to make sure cable ground shield, on the cable from the PTC module is properly grounded at the PCC2100.

3. Repower the PCC2100 control to see if fault clears. (Remove power from the control for 5 seconds, then repower).

LOW S1 FREQUENCY (2329)

Low utility (S1) frequency.

Corrective Action:

1. Check S1 AC inputs and wiring to PTC at TB5.

2. Check sensor set points at PCC 2100 control.

LOW S1 VOLTAGE (2331)

Low utility (S1) voltage.

Corrective Action:

1. Utility (S1) low voltage. This is a common fault at initial startup due to a delay in sending the S1 voltage status from the PTC module, via the network connection, to the control. Clear the fault and it should not reoccur until the next S1 failure.

1. Check S1 AC inputs and wiring to PTC at TB5.

2. Check S1 pickup and dropout set points at PCC 2100 control.

POWER TRAN DISABLED (2337)

The PTC module is available, but the PTC feature is not enabled.

Corrective Action:

1. Use the InPower service tool to enable the PTC feature. After enabling the feature, cycle power off at the control for 5 seconds, then repower control.

5-4

TABLE 5-2. PTC FAULT CODE TROUBLESHOOTING (CONT.)

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WARNING

Some PTC service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of electricity and machinery hazards should perform service. See Safety Precautions.

POWER TRAN FAILURE (2338)

The PTC module trim is enabled, but the control could not communicate with the PTC module.

Corrective Action:

1. PTC module does not have power or is not installed. Check for blinking light on the PTC module to indicate that it has power (Figure 5−1). If off, check for B+ between TB3-3 and TB3-4. Check PTC status voltage between TB3-5 and TB3-6, 0.2 VDC.

2. Reverse battery connections.

3. Cycle power off at the PCC 2100 control for 5 seconds, then repower control.

POWER DOWN ENABLED (2339)

The Power Down Mode (sleep) function is enabled, but either the PTC module or the network board is

active.

Corrective Action: None required, the message indicates that the control will not go to sleep under these conditions.

HIGH S1 VOLTAGE (2358)

Indicates utility (S1) voltage has increased above the over voltage threshold.

Corrective Action:

1. Meaure S1 AC inputs at PTC module. Compare with value read using InPower. Check utility nominal voltage matches measured value.

2. Check sensor set points at PCC 2100 control.

S1 CB NOT CLOSE (2396)

Utility contact (S1) fail to close, with PTC enabled.

Corrective Action:

1. Refer to Toubleshooting Chart 5-5 for a listing of all the possible causes.

S1 CB NOT OPEN (2397)

Utility contact (S1) fail to open with PTC enabled.

Corrective Action:

1. Refer to Toubleshooting Chart 5-4 for a listing of all the possible causes.

5-5

TABLE 5-2. PTC FAULT CODE TROUBLESHOOTING (CONT.)

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by any means, is strictly prohibited.

WARNING

Some PTC service procedures present hazards that can result in severe personal injury or death. Only qualified service personnel with knowledge of electricity and machinery hazards should perform service. See Safety Precautions.

PTC TIMEOUT (2966)

PTC module is not responding. PTC Status may be okay, but the PTC module is no

longer communicating.

Corrective Action:

1. Check PTC status light, if not flashing see steps two and three.

2. Check cable connections between PTC module and PCC 2100 control.

3. Cycle power off at the PCC 2100 control for 5 seconds, then repower control.

(2971) NO MESSAGE

PTC Test Mode active. (Fault code only displayed in InPower)

Corrective Action:None required

5-6

TROUBLESHOOTING WITH SYMPTOMS

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• Start at rated speed with load

Use the following troubleshooting guide to help diagnose PTC module problems. It is divided into sections based on the symptom. Common problems are listed with their possible causes. Refer to the corrective action column for the appropriate test or adjustment procedure.

Conditional schematics are used to highlight the circuit that is energized during the sequence of the events. Always refer to the schematic and wiring diagram package that was shipped with the equipment for specific information about its configuration.

Make a thorough inspection of the PTC installationwiring to make sure that good wire harness and ground connections are made. Correct any wiring problems before performing tests or replacing any components.

Test Settings

The Test mode can be set to one of four different settings for use with the PTC module:

• Start at idle without load

• Start at idle with load

• Start at rated speed without load

During an actual power outage the genset will start and run at rated speed with load.

Circuit Breaker Applications

When using circuit breakers as a transfer pair , make sure you find out the recharge time and enter it into the Gen. CB and S1 CB recharge delay time settings.

Troubleshooting Warnings

WARNING

set presents a hazard that can cause severe personal injury or death. Observe all safety precautions in your generator set manuals.

WARNING

the breakers or contactors present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts with body, tools, jewelry, hair, clothes, etc. Remove power from both source 1 and source 2 before removing and replacing components. The following procedures are to be performed only by technically qualified personnel.

Improper operation of the generator

AC power at the PTC Module or at

STATUS

INDICATOR

FIGURE 5-1. PTC STATUS LIGHT

5-7

5-8

CONDITION: UTILITY POWER FAILURE BASE BOARD SENSES UTILITY VOLT-

AGE/FREQUENCY OUT OF LIMITS AND ENERGIZES K4, GENSET

START RELAY GENSET CRANKS AND STARTS AFTER TRANSFER TIME DELAY EX-

PIRES, PTC MODULE MOMENTARILY

ENERGIZES K22 RELAY, ACTIVAT-

ING THE S1 OPEN COIL (S1.1) S1 OPENS, S1.3 POSITION CONTACT

OPENS

PCC 2100

BASEBOARD

J7-23(B+)

OPEN

12 OR 24 VDC (24 VAC IN SOME APPLICATIONS)

J7-27(−)

Genset Start Pilot Relay

CLOSE

OPEN

FIGURE 5-2. CONDITIONAL SCHEMATIC - LOSS OF SOURCE 1 POWER (UTILITY), GENSET STARTS, S1 OPENS

MOMENTARY

WARNING

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by any means, is strictly prohibited.

AC power at the PTC Module or at the breakers (or contactors) present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts with body, tools, jewelry, hair, clothes, etc. Remove power from both source 1 and source 2 before removing and replacing components. The following procedures are to be performed only by technically qualified personnel.

TABLE 5-3. SOURCE 1 (UTILITY) POWER FAILS, BUT GENSET DOES NOT START

Trouble and/or Fault Code Possible Cause Corrective Action

PTC Fault − 2327, 2338 1. The PTC module or the com-

munication link to the PTC module is not working properly.

Not in Auto 1. Selector Switch on genset

Not in Auto position.

Start/TDES mode 1. Engine start time delay ac-

tive.

Genset cranks but does not start 1. Genset problem. 1. Check fuel system. Refer to genset trou-

Genset does not crank 1. Wiring, Battery, or Genset

problem

No Genset Start Signal (TDES expired)

Fault − 1438 (Fail to Crank)

1. No genset start signal. 1. Check for start signal to the genset start

1. Check for blinking light on PTC module to indicate that it has power. If not, check for B+ between TB3-3 and TB3-4, if present, check PTC status voltage between TB3-5 and TB3-6 of approx. 0.2 VDC. If no status voltage see steps 2 and 3.

2. Make sure cable ground shield, on the cable from the PTC module is properly grounded at the PCC 2100.

3. Cycle PCC 2100 control power off for 5 seconds.

1. Set selector switch on genset to Auto position. (The PTC is disabled when the switch is in the Manual position).

1. Wait for engine start time delay to expire.

bleshooting section.

1a.Select Manual start on genset control. If

genset starts, check wiring between the PTC module and the PCC control. If it is OK, go to next possible cause −

set start signal

1b.If it does not crank, check batteries and

cable connections.

1c.If it cranks but does not start, check fuel

supply and refer to genset troubleshooting section.

pilot relay K4. Attach a voltmeter across the K4 coil and check for B+. If voltage is present, check relay K4.

2. If voltage is not present, check continuity between J7-23 and the K4 coil and between J7-27 and the K4 coil.

3. Check fuse on base board.

4. Check for open or poor wire connection to E−Stop switch on PCC 2100.

5. If the wiring and connections are good, the base board is defective.

.

No gen-

5-9

5-10

CONDITION: UTILITY FAILURE, GEN-

SET VOLTAGE/FREQUENCY WITHIN LIMITS, S1 AND S2 OPEN

AFTER PROGRAM TRANSITION TIME

OR RECHARGE DELAY EXPIRES, PTC MODULE MOMENTARILY ENERGIZES K21 RELAY, ACTIVATING THE S2 CLOSE COIL (S2.2)

S2 CLOSES, S2.3 POSITION CON-

TACT CLOSES

CLOSE

PCC 2100

BASEBOARD

MOMENTARY

CLOSE

FIGURE 5-3. CONDITIONAL SCHEMATIC - GENSET AVAILABLE, S2 CLOSES

WARNING

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by any means, is strictly prohibited.

AC power at the PTC Module or at the breakers (or contactors) present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts with body, tools, jewelry, hair, clothes, etc. Remove power from both source 1 and source 2 before removing and replacing components. The following procedures are to be performed only by technically qualified personnel.

TABLE 5-4. GENSET STARTS, BUT DOES NOT ASSUME LOAD

Trouble and/or Fault Code Possible Cause Corrective Action

No S2 (Genset) Available status. 1. Genset output voltage not ac-

ceptable or Source 2 voltage settings do not match the application.

2. Genset is running at idle.

S2 (Genset) Available status displayed but genset does not assume load.

S2 (Genset) Available, S1 (Utility) remains connected “S1 CB Not Open”

(Fault 2397) Refer to Figure 5-2

S2 Genset, not connected to load. “Genset CB Not Closed”

(Fault 1452)

Refer to Figure 5-4

1. Transfer time delay active.

2. Program transition time delay active.

1. No S1 Open utility signal. K22 Open Utility external relay not energized or defective.

2. S1-1 Open coil not energized or defective.

3. S1-3 Position indicator auxiliary contacts defective.

1. No S2 Close genset signal. K21 Close Genset external relay not energized or defective.

2. S2-2 Close coil not energized or defective.

3. S2-3 Position indicator auxiliary contacts defective.

1a.Measure genset output voltage and fre-

quency.

1b.Verify voltage settings in control display

or service tool. Verify that genset ready to load status is active.

1c.Start genset manually and verify Ready

to Load status goes active.

2. Verify Source 2 voltage input to base board. If input to base board matches voltage settings, base board is not calibrated correctly or is defective.

1. Wait for transfer time delay to expire.

2. Wait for program transition time to expire.

1. Check for momentary voltage pulse at K22 relay coil between TB4-8 and ground.

2. Check for momentary source 2 voltage at S1-1 coil. If not present, check K22 contacts (should be closed during transfer). If present, check breaker or contactor.

3. Check S1-3 auxiliary contact (TB4-6 to TB4-7), with the utility breaker or contactor open, S1-3 should be open.

1. Check for momentary voltage pulse at K22 relay coil. If voltage is available between TB4-3 and ground, but not at K22 coil, check K23 NC contacts that are in series with K21 coil.

2. Check for momentary source 2 voltage at S2-2 coil. If not present, check S1-4 and K22 contacts (should be closed during transfer). If present, check breaker or contactor.

3. Check S2-3 auxiliary contact (TB4-5 to TB4-6), with the genset breaker or contactor closed, S2-3 should be closed.

Note: Transfer signals have a very short duration of 10- to 20-milliseconds. Voltage to the relay may be difficult to measure with some meters. The relays make an audible click when momentarily energized by a transfer signal.

5-11

5-12

CONDITION: UTILITY RETURNS

WITHIN VOLTAGE/FREQUENCY LIMITS

AFTER RETRANSFER TIME DELAY

DELAY EXPIRES, PTC MODULE MOMENTARILY ENERGIZES K20 RELAY, ACTIVATING THE S2 OPEN COIL (S2.1)

S2 OPENS, S2.3 POSITION CONTACT

OPENS

OPEN

PCC 2100

BASEBOARD

MOMENTARY

OPEN

CLOSE

FIGURE 5-4. CONDITIONAL SCHEMATIC - SOURCE 1 AVAILABLE, S2 OPENS

WARNING

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by any means, is strictly prohibited.

AC power at the PTC Module or at the breakers (or contactors) present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts with body, tools, jewelry, hair, clothes, etc. Remove power from both source 1 and source 2 before removing and replacing components. The following procedures are to be performed only by technically qualified personnel.

TABLE 5-5. PTC MODULE DOES NOT RETRANSFER WHEN SOURCE 1 UTILITY POWER IS RESTORED

AFTER A POWER FAILURE OR ON INITIAL INSTALLATION

Trouble and/or Fault Code Possible Cause Corrective Action

No S1 (Utility) Available status. 1. Not in Auto.

2. Utility output voltage not acceptable or Source 1 voltage settings do not match the application.

3. Defective PTC module.

S1 (Utility) Available status displayed but utility does not assume load.

1. Transfer time delay active.

2. Program transition time delay active.

1. Set selector switch on genset to Auto position.

2a.Measure utiltiy output voltage. 2b.Verify voltage settings in control with digi-

tal display or service tool.

3. Verify Source 1 voltage input to PTC module. If input to PTC module matches voltage settings, PTC module is defective.

1. Wait for transfer time delay to expire.

2. Wait for program transition time to expire.

S1 (Utility) Available, Genset remains connected “CB Not Open”

(Fault 1453) Refer to Figure 5-4

S1 (Utility) Available, S1 open, S2 Genset, not connected to load. “S1 CB Not Closed”

(Fault 2396) Refer to Figure 5-5

Test with Load Active 1. Test with load active. 1. Wait for Test to complete or deactivate

Note: Transfer signals have a very short duration of 10- to 20-milliseconds. Voltage to the relay may be difficult to measure with some meters. The relays make an audible click when momentarily energized by a transfer signal.

1. No S2 Open genset signal. K20 Open Genset external relay not energized or defective.

2. S2-1 Open coil not energized or defective.

3. S2-3 Position indicator auxiliary contacts defective.

1. No S1 Close utility signal. K23 Close Utility external relay not energized or defective.

2. S1-2 Close coil not energized or defective.

3. S1-3 Position indicator auxiliary contacts defective.

1. Check for momentary voltage pulse at K20 relay coil between TB4-10 and ground.

2. Check for momentary source 1 voltage at S2-1 coil. If not present, check K20 contacts (should be closed during transfer). If present, check breaker or contactor.

3. Check S2-3 auxiliary contact (TB4-5 to TB4-6), with the genset breaker or contactor open, S2-3 should be open.

1. Check for momentary voltage pulse at K23 relay coil. If voltage is available between TB4-1 and ground, but not at K22 coil, check K21 NC contacts that are in series with K21 coil.

2. Check for momentary source 1 voltage at S1-2 coil. If not present, check S2-4 and K23 contacts (should be closed during transfer). If present, check breaker or contactor.

3. Check S1-3 auxiliary contact (TB4-6 to TB4-7), with the utility breaker or contactor closed, S2-3 should be closed.

remote start to end test.

5-13

5-14

CONDITION: UTILITY RETURNS

WITHIN VOLTAGE/FREQUENCY LIMITS

AFTER PROGRAM TRANSITION TIME

OR RECHARGE DELAY EXPIRES, PTC MODULE MOMENTARILY ENERGIZES K23 RELAY, ACTIVATING THE S1 CLOSE COIL (S1.2)

S1 CLOSES, S1.3 POSITION CON-

TACT CLOSES

GENSET SHUTS DOWN AFTER

COOLDOWN TIME DELAY

CLOSE

PCC 2100

BASEBOARD

MOMENTARY CLOSE

FIGURE 5-5. CONDITIONAL SCHEMATIC - SOURCE 1 AVAILABLE, S1 CLOSES

WARNING

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by any means, is strictly prohibited.

AC power at the PTC Module or at the breakers (or contactors) present a shock hazard that can cause severe personal injury or death. Use extreme caution to avoid touching electrical contacts with body, tools, jewelry, hair, clothes, etc. Remove power from both source 1 and source 2 before removing and replacing components. The following procedures are to be performed only by technically qualified personnel.

TABLE 5-6. GENSET CONTINUES TO RUN AFTER RETRANSFER OF LOAD TO S1 UTILITY

Trouble Possible Cause Corrective Action

Genset continues to operate after retransfer

Remote Start Active 1. RMT signal still active. 1. Measure voltage between TB1-1 and

TABLE 5-7. GENSET STARTS DURING NORMAL POWER SERVICE

1. Time Delay Engine Cool-down (TDEC) still active.

2. Cool down idle running

1. Wait for TDEC to expire.

2. Wait for cool down idle to expire.

TB1-20 (GND.). Zero VDC indicates an active RMT signal that holds the genset ON.

Trouble

Genset starts during normal power service.

TABLE 5-8. GENERATOR TEST RUNS BUT GENSET DOES NOT ASSUME LOAD

Trouble Possible Cause Corrective Action

Genset test runs but does not assume load.

Possible Cause Corrective Action

1. Remote test customer input.

2. Momentary source 1 utility voltage dip.

3. Customer supplied exercise clock active.

4. PTC Module no longer sensing Source 1 voltage.

1. Control programmed to test without load.

1. Check for remote test input at J4-5.

2. Check undervoltage settings, adjust if needed.

3. Refer to customer supplied exerciser clock settings.

4. Verify Source 1 voltage input to PTC Module.

1. Check or change program with Digital Display or PC Service tool to Test with load.

5-15

THIS PAGE LEFT INTENTIONALLY BLANK

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by any means, is strictly prohibited.

5-16

6. Control Adjustment and Service

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by any means, is strictly prohibited.

GENERAL

This section contains circuit board removal and replacement procedures and adjustment procedures for the genset control.

This section also describes the function and operation of engine sensors, genset options, and other special features of the genset control system, such as, customer connection points, optional run relays, etc. Installation information is also provided for these items where necessary.

WARNING

parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service.

WARNING

PCC2100 control box must be opened only by technically qualified personnel. Voltages of up to 600 VAC are present in the PCC box. These voltages can cause electrical shock, resulting in personal injury.

Incorrect service or replacement of

HAZARDOUS VOLTAGE. The

6-1

CIRCUIT BOARD

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by any means, is strictly prohibited.

REMOVAL/REPLACEMENT

No special tools (other than a grounding wrist strap and InPower Service tool ) are required to remove a circuit board from inside the control box. The InPower Service tool is required when replacing the Base board.

WARNING

Ignition of explosive battery gases 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 battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Before replacing the Base board, make sure that a capture file of the genset’s parameter values has been created using InPower. (During genset installation, it was suggested that a capture file be made before and after changes were made to the genset operating parameters.)

After replacing the Base board, use the capture file as a template to write the previous settings to the new Base board software.

Refer to INPOWER User’s Guide for specifics.

Circuit Board Removal Safety Precautions

To prevent circuit board damage due to electrostatic discharge (ESD), a grounding wrist strap must be worn when handling circuit boards or socketmounted IC’s. (The wrist strap does not provide a direct short to ground, but is typically rated at approximately 1 megohm to ground.)

Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (−) cable first and reconnect last.

CAUTION

Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set.

WARNING

Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (−) cable from the battery terminal.

Attach the clip to the chassis ground screw in the control box and place the strap around your wrist before handling a circuit board.

CAUTION

Electrostatic discharge will damage circuit boards. Always wear a grounding wrist strap when handling circuit boards or socketmounted IC’s.

Turn off or remove AC power from the battery charger and then remove the negative (−) battery cable from the set starting battery. This is to make sure that the set will not start while working on it and to avoid circuit board damage, caused by voltage spikes when removing and replacing circuit board connectors.

6-2

CHASSIS

GROUND

SCREW

GROUND

LEAD CLIP

FIGURE 6-1. WRIST STRAP

WRIST

STRAP

MODIFYING SETUP SUBMENUS

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by any means, is strictly prohibited.

The Setup submenus allow you to adjust system parameters.

There are three setup menus that are selectable from the Setup Main Menu:

• Crank/Idle Setup Menu

• Governor/Regulator Setup Menu

• Power Transfer Setup Menu

These three menus are intended for qualified service personnel only. For this reason, a three-digit access code (password) must be entered before you can proceed to those menus.

CAUTION

Improper adjustment of the control can cause equipment malfunction or damage. Adjustment must be performed by technically qualified personnel only.

6-3

PASSWORD SUBMENU

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by any means, is strictly prohibited.

Figure 6-2 shows a block representation of the Setup Main menu. If you press the button next to the word “Setup” in the display, the Setup Password submenu is displayed. Use of Setup menus is restricted to service personnel.

Press the Previous Main Menu button to return to Main Menu 3. Press the Home button to return to Main Menu 1.

Password submenu:

word, the Setup Main Menu is displayed. When the Password submenu is displayed, the first numeric character (0 PCC is: 574

) is flashing. The access code for your . To enter the password:

1.. Press the button next to the + symbol until the value reads “5.”

If you enter the correct pass-

2.. Press the button next to the symbol to move to the next numeric character.

3.. Press the button next to the + symbol until the value reads “7.”

4.. Press the button next to the

symbol to move

to the next numeric character.

5.. Press the button next to the + symbol until the value reads “4.”

6.. After you have completed entering the password, press the button next to the symbol. The Setup Main Menu is displayed.

If a wrong number is entered into any of the numeric character fields, use the buttons next to the and

symbols until the correct value is entered. If the wrong character field is selected, use the but-

tons next to the and symbols to move to the character field you wish to change.

6-4

Main Menu 3

Redistribution or publication of this document, 

by any means, is strictly prohibited.

SETUP MAIN MENU

About Pwr Tran

Setup More>>

+Password

− nnn

Setup Main Menu

Crank/Idle Gov/Reg

FIGURE 6-2. SETUP MAIN MENU

6-5

Pwr Tran

CRANK/IDLE SETUP MENU

Redistribution or publication of this document, 

by any means, is strictly prohibited.

Figure 6-3 shows a block representation of the Crank/Idle Setup menu. If you press the button next to the word “Crank/Idle” in the display, the first Crank/Idle Setup submenu is displayed.

As shown in the diagram, the Crank/Idle menu has five submenus. Each submenu includes a parameter or value that can be changed.

Press the buttons next to the graphical display to navigate between the menus. Press the Previous Main Menu button to return to the Setup Main Menu. Press the Previous Main Menu button again to return to Main Menu 3. Press the Home button to return to Main Menu 1.

Adjusting Values/Parameters:

1.. Press the button next to the symbol in the display until the + and − symbols are displayed.

2.. If necessary , press the button next to the or symbols to move to the numeric character you wish to change.

3.. Press the button next to the + symbol to increase the value or select parameter; press the button next to the − symbol to decrease the value or select parameter.

4.. After adjusting values/selecting parameters, pressing the

symbol results in the changes being saved. (When adjusting values, make sure the cursor is on the last numeric character before pressing the

If the Home button or Previous Main Menu button is pressed before pressing the the changes are not saved.

and symbols in the

symbol).

symbol,

Cycle Crank submenu:

Cycle Crank can be en-

abled or disabled (default = Disable).

Number of Crank Attempts submenu:

This value can be adjusted from 2 to 7 attempts (default = 3 a t tempts).

Crank Time submenu:

This value can be adjusted

from 2 to 20 seconds (default = 15 seconds).

Rest Time submenu:

This value can be adjusted

from 7 to 40 seconds (default = 15 seconds).

Idle Speed Adjust submenu:

This value can be adjusted from 700 to 1100 RPM (default = 800 RPM).

6-6

CUMMINS DFAC, DFCC, DFAB, DFGE, DFLB Service Manual

Table of Contents

IMPORTANT SAFETY INSTRUCTIONS

1. Introduction

2. Control Operation

3. Circuit Boards

4. Troubleshooting

5. PTC Troubleshooting

6. Control Adjustment and Service