CUMMINS DFAB, DFBE, DFBF, DFCC, DFCE Operation & Service Manual

Caution: This document contains mixed page sizes (8.5 x 11 or 11 x

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17), which may affect printing. Please adjust your printer settings according to the size of each page you wish to print.

Operation/Service Manual

Redistribution or publication of this document by any means, is strictly prohibited.

Digital Paralleling GenSet Model

DFAA, DFAB, DFAC, DFBC, DFBD, DFBE, DFBF, DFCB, DFCC, DFCE, DFEB, DFEC, DFED, DFFA, DFFB, DFGA, DFGB, DFGC, DFJA, DFJB, DFJC, DFJD, DFLA, DFLB, DFLC, DFLD, DFLE, DFMB, DQAA, DQAB, DQBA, DQBB

with PowerCommand Control PCC3100

Printed in U.S.A.

900-0519D 04-2005

IMPORTANT SAFETY INSTRUCTIONS

Redistribution or publication of this document by any means, is strictly prohibited.

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-15M

iii

ELECTRICAL SHOCK CAN CAUSE

Redistribution or publication of this document by any means, is strictly prohibited.

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 DI-

RECTLY 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.

MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)

•

Medium voltage acts differently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death.

• Do not work on energized equipment. Unauthorized

personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized personnel so that the equipment can be de-energized and safely grounded.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling point

•

than water. DO NOT open a radiator or heat ex-

changer pressure cap while the engine is running. To prevent severe scalding, let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been relieved.

• 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 gener-

ator set.

• Make sure generator set is mounted in a manner to

prevent combustible materials from accumulating under or near 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 system, turbo charger system and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv

1. Introduction

Redistribution or publication of this document by any means, is strictly prohibited.

ABOUT THIS MANUAL

This manual provides troubleshooting and repair information regarding the PowerCommand Control 3100 (PCC) and generators for the generator set (genset) models 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

instructions and precautions in this manual.

and carefully observe all

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)

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 trained and experienced to perform electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv.

Incorrect service or replacement of

1-1

SYSTEM OVERVIEW

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The PCC is a microprocessor-based control for Cummins generator sets. It provides fuel control and engine speed governing, main alternator voltage output regulation, and complete generator set control and monitoring. It also provides controls for automatic and semi-automatic synchronizing and automatic load sharing controls for both isolated bus or utility (mains) paralleling applications.

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.

GENERATOR SET CONTROL FUNCTION

Figure1-1 shows some of the control functions. A more complete block diagram is provided in Section

3. A system schematic is provided in

Section 9

.

The PCC monitors frequency from both the magnetic pick-up (MPU) and the main stator inputs. The control sends a low power pulse-width modulated (PWM) signal to the governor output module, which then sends an amplified signal to the engine fuel control.

The Bus PT module reduces the bus voltage to approximately 18 VAC and provides a signal to the control for reference in synchronizing the generator set to the system bus.

The external PT/CT module reduces generator voltage to approximately 18 VAC, and produces a representative AC voltage from CT output current. The voltage regulation function sends a low power PWM signal to the voltage regulator output module, which then sends an amplified signal to the exciter stator.

Oil, coolant, and exhaust temperatures are sensed by variable resistance element sensors. Oil pressure is sensed by a capacitive element active sensor.

Governor

Output

Regulator

Output

PMG

•

Fuel

Control

NS

•

2 3 4

11234

MPU

Bus PT Module

•

Sensors

Battery

BT1

To

•

Load

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

1-2

2. Control Operation

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GENERAL

The following describes the function and operation of the PowerCommand generator set control. All indicators, displays, meters and control switches are located on the face of the control panel as illustrated in Figure 2-1.

The PCC control cabinet must be opened only by technically qualified personnel.

Normally, generator set configuration options are set at the factory . When a new control is installed on a generator set or when parts are replaced, the control must be configured for that generator set with the use of the “Initial Start Setup” portion of the internal software. Setup and calibration procedures are described in

The automatic voltage regulator (AVR) and governor operation characteristic adjustments are also described in

Section 5

.

SAFETY CONSIDERATIONS

AC power is present when the set is running. Do not open the generator output box while the set is running.

WARNING

nents can cause electrocution, resulting in severe personal injury or death. Do not open the generator output box while the set is running. Read and observe all WARNINGS and CAUTIONS in your generator set manuals.

CAUTION

opened only by technically qualified personnel. Lower level voltages (18 VAC to 24 VDC) are present in PCC control cabinet. These voltages can cause electrical shock, resulting in personal injury.

Even with power removed, improper handling of components can cause electrostatic discharge and damage to circuit components.

Contacting high voltage compo-

The PCC control cabinet must be

2-1

SEQUENCE OF OPERATION

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When the PowerCommand control is in the AUTO mode, it will cause the generator set to start on receiving a signal from a remote device. The PowerCommand control will initiate a starter cranking signal and verify that the engine is rotating. The PowerCommand control will provide sufficient fuel to the engine to accelerate to start disconnect speed. On reaching that speed, the control will ramp the generator set to rated speed and voltage.

On reaching rated speed and voltage, the PowerCommand control checks the system bus voltage. If no bus voltage is present, it will wait for a pulse from a remote Master First Start Sensor. On receiving that pulse, the control will signal the paralleling breaker to close.

If bus voltage is present, the PowerCommand control will check for proper phase rotation, adjust the generator set to the bus voltage and frequency level, and then synchronize the generator set to the system bus. When a synchronous condition is achieved, the control will send a signal to close the paralleling breaker.

When the paralleling breaker is closed, the generator set will assume it’s proportional share of the total load on the system bus.

PCC POWER ON / STANDBY MODE

Standby Mode

In the Standby (sleep) mode (selector switch S5 on the Digital Board is set to the right and the generator set is not running), the control’s operating software is inactive and the LEDs and displays on front panel are all off.

The operating software is initialized and the front panel is turned on in response to a run signal or any

one of eight “wake up” inputs from remote sensing switches.

The wake up signals are:

• Emergency Stop

• Low Coolant Level

• Low Coolant Temperature

• Low Fuel

• Customer Fault Inputs 2 and 3

• Run Selected on Run/Off/Auto Switch

• Remote Start Signal in Auto Mode

• Self Test switch

To activate and view the menu displays, press and release the Self Test switch. The PCC will initialize the operating software and permit operation of the menu display panel. If no menu selections are made, the power to the control panel will shut down after 30 seconds.

Power On Mode

In the Power On (awake) mode (selector switch S5 on the Digital Board is set to the left), the PCC will initialize the operating software and permit operation of the menu display panel. (See Figure 3-1 for S5 location.) Power will stay on until switch (S5) is set to the Standby mode. It is recommended that switch S5 be left in the Power On mode in all applications, except those where auxiliary battery charging is not available.

CAUTION

circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards or socket-mounted ICs and when disconnecting or connecting harness connectors.

Electrostatic discharge will damage

2-2

KILOWATT

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METER

(PERCENT LOAD)

FREQUENCY

METER

AC

VOLTMETER

(DUAL SCALE)

AC AMMETER

(PERCENT AMPS)

MENU

SELECTION

SWITCH

(1 of 4)

ACTIVE SWITCH

INDICATOR

(1 of 6)

ALPHANUMERIC

DISPLAY

UPPER AND LOWER

SCALE INDICATOR

PCC 3100

LABEL

PARALLELING

BREAKER

SWITCHES AND

INDICATORS

RUN/OFF/AUTO

SWITCH

RESET

SWITCH

SELF TEST

SWITCH

NON-AUTOMATIC

WARNING

SHUTDOWN

STATUS INDICATORS

MENU

SWITCH

PANEL LAMP

SWITCH

PHASE SELECTOR

FIGURE 2-1. FRONT PANEL (PCC 3100)

2-3

EMERGENCY

STOP PUSH

BUTTON

SWITCH AND

INDICATORS

FRONT PANEL

Redistribution or publication of this document by any means, is strictly prohibited.

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

AC Voltmeter:

voltage. Measurement scale in use is shown on scale indicator lamp.

AC Ammeter:

maximum rated current. (Percent current is based on .8 PF.)

Kilowatt Meter:

put as percent of rated load.

Dual scale instrument indicates AC

Indicates current output in percent of

Indicates 3-phase AC power out-

Reset Switch:

Press this switch to reset warning and shutdown messages after the condition has been corrected. To reset a shutdown message with the Reset switch, the Run/Off/Auto switch must be in the Off position.

With the Run/Off/Auto switch in the Auto mode, shutdown faults can be reset by removing the remote start input and then cycling the remote reset input.

Self T est Switch:

Press and hold this switch to light all front panel LEDs and cycle through all shutdown and warning messages.

Frequency Meter:

Indicates generator output fre-

quency in hertz.

Upper and Lower Scale Indicator Lamps:

Indi-

cate AC voltmeter scale.

Digital Display:

This two-line, 16-character per line alphanumeric display is used in the menu-driven operating system, in conjunction with the display menu selection switches and the Menu switch. Refer to the menu trees later in this section. The display is also used to show warning and shutdown messages.

Display Menu Selection Switches:

Four momentary switches—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 green arrow adjacent to the switch is lit when the switch can be used (switch is “active”).

Menu Switch:

Press this switch to return the digital display to the MAIN MENU. Refer to the menu trees later in this section.

In the Standby (sleep) mode, with the generator set not running, the control’s operating software is inactive and the LEDs and displays on front panel are all off.

To activate and view the menu displays without starting the generator set, press and hold the Self Test switch until the front panel LEDs light. The PCC will initialize the operating software and permit operation of the menu display panel. If no menu selections are made, a software timer will shut down the power after 30 seconds.

Panel Lights Switch:

Press this switch to turn control panel illumination on and off. The illumination will shut off after about eight minutes.

Phase Selector Switch and Indicators:

Press this momentary switch to select phases of generator output to be measured by the analog AC voltmeter and ammeter. LEDs indicate the selected phase.

Run/Off/Auto Switch:

This switch starts and stops the set locally, or enables start/stop control of the engine from a remote location. (Ground to start.)

2-4

Emergency Stop Button:

Redistribution or publication of this document by any means, is strictly prohibited.

Push the button in for

emergency shutdown of the engine.

Remote Reset switch will not reset emergency stop. Can only be reset at the PCC front panel.

To reset:

1. Pull the button out or turn the button clockwise (button with arrow) and allow it to pop out.

2. Move the Run/Off/Auto switch to Off.

3. Press the front panel Reset switch.

4. Select Run or Auto, as required.

Shutdown Status Indicator:

This red lamp is lit whenever the control detects a shutdown condition. After the condition is corrected, shutdown indicators can be reset by turning the Run/Off/Auto switch to the Off position, and pressing the Reset switch. In Auto mode, shutdowns can be reset by removing the remote start input and then cycling the remote reset input.

Emergency Stop shutdown status (Code 102) can be reset only at the PCC front panel.

Non-Automatic Status Indicator:

This red lamp flashes continuously when the Run/Off/Auto switch is not in the Auto position.

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 Reset switch. (It is not necessary to stop the generator set.)

With the Run/Off/Auto switch in the Auto mode, warnings can also be reset by cycling the remote reset input after the condition is corrected.

Paralleling Breaker Switches and Indicators:

These two switches are used to manually open or close the paralleling breaker of the generator set. The lamps are used to indicate the opened or closed position of the paralleling breaker.

The Breaker Operation switches are operational only when the Run/Off/Auto switch is in the Run position. The breaker will close when the generator set is synchronized with the system bus, or if the system bus is de-energized.

2-5

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

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MENU DISPLAY AND SWITCHES

Figure 2-2 shows the digital display and the menu selection switches. Refer to heading “ which describes the menu display and switches.

In the Standby Mode, to activate and view the menu displays without starting the generator set, press and release the Self Test switch. This will initialize the PCC operating software and permit operation of the menu display panel. If no menu selections are made, a software timer will shut down the power after 30 seconds. In the Power On Mode, power is continuously supplied to the control panel. Display will always remain on.

In the digital display, the “>>” symbol indicates that selecting the adjacent button causes the operating program to branch to the next menu display—as shown in the menu diagrams.

In the digital display, the “<<” symbol indicates that selecting the adjacent button causes the operating program to go back to the previous menu display.

Front Pane

MAIN MENU

The facing page shows the main menu and a block representation of the available submenus.

l”

As shown in the diagram, the main menu can branch into one of four directions.

To display engine parameters, such as oil pressure and temperature, water temperature, engine speed (RPM), and exhaust temperature, press the button next to the word “ENGINE” in the display. Refer to

ENGINE MENU

in this section.

To display generator parameters, such as volts, amps, power (kW), and frequency, press the button next to the word “GEN” in the display. Bus voltage, frequency and a digital synchroscope can also be viewed from this menu branch. Turn to the

MENU

in this section.

GEN

To adjust output voltage and frequency, or start and stop delays, press the button next to the word “ADJUST” in the display. Refer to

Section 5

.

ADJUST MENU

in

To display the selected generator set model and the resident version software, press the button next to the “>>” in the display. Refer to

PLAYS MENUS

in

Section 5

VERSION & DIS-

.

2-6

MAIN MENU

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PAGES 2-8 & 2-9

RPM << EXHAUST

BATTERY << HOURS >>

OIL << COOLANT >>

PAGES 2-10 & 2-11

%GOV / REG << FREQUENCY

POWER << KW HRS >>

VOLTS << AMPS >>

ENGINE GEN

<>

ADJUST >>

<>

RESET MENU >

CLEAR WARNING AND SHUTDOWN MESSAGES

RETURN TO MAIN MENU

⇑ VOLTAGE ⇓ _______ >>

⇑ FREQUENCY ⇓ _______ >>

⇑ START DELAY ⇓ _______ SEC >>

⇑ STOP DELAY ⇓ _______SEC >>

⇑ IDLE SPEED ⇓ _______RPM >>

SECTION 5

INACTIVE BUTTON

< ACTIVE BUTTON

< ACTIVE BUTTON SELECTED

SECTION 5

VERSION SETUP / CAL HISTORY

(ACCESS CODE)

DISPLAY CAL << METERS >>

GOV / REG << PARALLEL SETUP

2-7

ENGINE MENU

Redistribution or publication of this document by any means, is strictly prohibited.

The facing page 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 will appear.

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

OIL/COOLANT submenu:

This is the first submenu. Select OIL for a display of oil pressure and oil temperature. Select COOLANT for a display of coolant temperature. When oil or coolant parameters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the OIL/ COOLANT submenu.

BATTERY/HOURS submenu:

From the OIL/ COOLANT submenu, press the button next to the “>>” in the display to move to the BATTERY/ HOURS submenu. Select BATTERY for a display of battery voltage. Select HOURS for a display of the number of starts and the running hours. When battery or hours parameters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the BATTERY/HOURS submenu.

RPM/EXHAUST submenu:

From the BATTERY/ HOURS submenu, press the button next to the “>>” in the display to move to the RPM/EXHAUST submenu. Select RPM for a display of engine RPM. Select EXHAUST for a display of the (optional) exhaust temperature. When RPM or exhaust parameters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the RPM/EXHAUST submenu.

2-8

ENGINE

Redistribution or publication of this document by any means, is strictly prohibited.

<>

ENGINE GEN ADJUST >>

<>

OIL <<

<>

COOLANT >>

<>

OIL <<

<>

COOLANT >>

___PSI / KPA <<

°F / °C

___

L___

°F / °C<<

°F / °C (or N/A)

R___

BACK

>

BACK

>

<>

OIL <<

<>

COOLANT >>

<>

OIL <<

<>

COOLANT >>

<>

BATTERY <<

<>

HOURS >>

<>

BATTERY <<

<>

HOURS >>

<>

BATTERY <<

<>

HOURS >>

<>

BATTERY <<

<>

HOURS >>

<>

ENGINE GEN

<>

ADJUST >>

BATTERY << ___VDC

STARTS ___ << HOURS ___

<>

OIL <<

<>

COOLANT >>

BACK

>

BACK

>

<>

RPM <<

<

EXHAUST

<>

RPM <<

<

EXHAUST

<>

RPM <<

<

EXHAUST

RPM << ___

L___°F/°C (or N/A) <<

°F/°C (or N/A)

R___

<>

BATTERY <<

<>

HOURS >>

Indicates OR" Condition

2-9

BACK

>

BACK

>

GEN MENU

Redistribution or publication of this document by any means, is strictly prohibited.

The facing page shows a block representation of the GEN menu. If you press the button next to the word “GEN” in the display, the first GEN submenu will appear.

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

VOLTS/AMPS submenu:

This is the first submenu. Select VOLTS for a display of a line-to-line or line-to-neutral selection, or for viewing of the system bus line-to-line voltage. Select line-line or lineneutral for the desired voltage display. Select AMPS for a display of L1, L2, and L3 current in amps. When voltage or current parameters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the L-L/L-N submenu.

If DELTA is selected in the Initial Start Setup submenu, when selecting VOLTS, the “line-line” or “lineneutral” submenus will not be displayed, only the L12, L23, L31 submenu will be displayed.

POWER / KW HOURS submenu:

From the VOLTS/AMPS submenu, press the button next to the “>>” in the display to move to the POWER/KW HOURS submenu. Select POWER for a display of power output in kilowatts and a power factor value. Select KW HOURS for a display of kilowatt hours. When power or kW hours parameters are displayed, pressing the button next to the “<<” will re-

turn the display (“BACK”) to the POWER/KW HOURS submenu.

The PF reading will contain an asterisk if the power factor is leading (for example, *.3PF).

Beginning Version 1.06, N/A is displayed in the PF field when the generator set is not running.

%GOV/REG/FREQUENCY submenu:

From the POWER/KW HOURS submenu, press the button next to the “>>” in the display to move to the %GOV/ REG/FREQUENCY submenu. Select %GOV/REG for a display of voltage regulator and governor duty cycle (drive) levels in percentage of maximum. Select FREQUENCY for a display of the generator output frequency the bus frequency, or the digital synchroscope. When voltage regulator and governor or frequency parameters are displayed, pressing the button next to the “<<” will return the display (“BACK”) to the %GOV/REG/FREQUENCY submenu.

Bus Frequency (Digital Synchroscope) submenu:

When the bus frequency (digital synchroscope) information is displayed, the operator can observe the generator set synchronizing with the system bus. The display indicates bus frequency and number of degrees from synchronous condition (+ indicates faster, − indicates slower). When the generator set is operating within the sync-check window, an asterisk will indicate that the paralleling breaker can be closed.

2-10

<>

Redistribution or publication of this document by any means, is strictly prohibited.

ENGINE GEN ADJUST >>

<>

VOLTS << AMPS >>

<>

VOLTS <<

<>

AMPS >>

L − L << L − N BUS

<<>

<>

L − L << L − N BUS

<

L − L << L − N BUS

<

L − L <<

<>

L − N BUS

<

L1 L2 L3 << ___ ___ ___

GEN

BACK

>

L12 L23 L31 << ___ ___ ___

L1N L2N L3N << ___ ___ ___

L12 L23 L31 << ___ ___ ___

BACK

><>

BACK

>

BACK

><>

<>

VOLTS <<

<>

AMPS >>

<>

VOLTS <<

<>

AMPS >>

<>

ENGINE GEN ADJUST >>

<>

POWER << KW HRS >>

<>

POWER << KW HRS >>

<>

POWER << KW HRS >>

<>

POWER << KW HRS >>

<>

%GOV / REG << FREQUENCY

<

<>

%GOV / REG << FREQUENCY

<

BACK

___ KW << ___ PF

KW HRS << ____________

<>

%GOV / REG << FREQUENCY

<

GOV__ % << REG__ %

FREQUENCY << ___ HZ BUS

>

BACK

>

BACK

>

BACK

>

Indicates OR" Condition

2-11

FREQUENCY << ___ HZ BUS

BUS FREQUENCY<< ___ HZ ___ DEG

>

BACK

>

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2-12

3. Circuit Boards and Modules

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GENERAL

This section describes the function of the PCC circuit boards and modules that are contained in the control panel (Figure 3-1) and the accessory box. The block diagram in Figure 3-2, shows both internal and external components of the PCC system.

STANDBY SWITCH

DISPLAY BOARD

A35

The system schematics are provided in this manual.

CAUTION

circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards or socket-mounted ICs.

S5 POWER ON/

Section 9

of

Electrostatic discharge will damage

J1 (FOR INPOWER

SERVICE TOOL)

DIGITAL BOARD

A32

GENSET

COMM. BOARD

A41

ANALOG

BOARD

A33

RUN/OFF/AUTO

SWITCH S12

BUS PT MODULE

A39

VOLTAGE REGULATOR

OUTPUT MODULE

A37

ENGINE INTERFACE

A31

ACCESSORY BOX

(HC 4/5)

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

CUSTOMER INTERFACE

A34

GOVERNOR

OUTPUT MODULE

A38

PT/CT

BOARD

A36

3-1

Redistribution or publication of this document by any means, is strictly prohibited.

FIGURE 3-2. BLOCK DIAGRAM

3-2

DIGITAL BOARD (A32)

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Connectors

The digital circuit board (Figure 3-3) contains the microprocessor and the operational software for the control. It connects to all other boards inside the control. This board also provides the analog-to-digital conversions for the PCC.

Switch

S5 Slide the switch to the left to select the Power

On (awake) mode. Control panel power/operating software will remain on until the switch is reset to the Standby mode. It is recommended that switch S5 be left in the Power On mode in all applications, except those where auxiliary battery charging is not available.

Slide right to put the PCC in the Standby (“sleep”) mode. In this mode, the PCC operating software will be initiated by selection of Run on the front panel, by pressing the Self Test switch, by a remote start input (in Auto mode), or by any one of several “wake-up” signals from external switches.

The digital board has five connectors. They are:

J1 For InPower Service Tool J2 Connects to J4 on A34 Customer Interface

board

J3 Connects to J2 on A33 Analog board J4 Connects to J1 on A31 Engine Interface

board

J5 Connects to J5 o n A35 Digital Display assem-

bly

LEDs

The digital board has seven LED’s that indicate the following conditions:

DS1 Spare (Green) DS2 Spare (Green) DS3 +18 VDC supply OK (Green) DS4 +5 VDC supply OK (Green) DS5 Run (Flashes once per second if software

is running) (Green) DS6 +24 VDC B+ supply OK (Green) DS7 +12 VDC supply OK (Green)

DS1 DS2 DS3 DS4

DS7 DS6 DS5

FIGURE 3-3. DIGITAL BOARD

3-3

ENGINE INTERFACE BOARD (A31)

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The engine interface board (Figure 3-4) reads user control inputs, monitors engine, generator and system status, and initiates the appropriate action for normal operating and fault conditions (warning or shutdown).

J4 Connects to customer connections and to en-

gine harness which includes magnetic pick-

up.

J5 Connects to engine sensors. J6 Connects to Genset Control module (GCM). J7 Connects to Genset Control module (GCM).

This board is connected to the engine sensors, battery , starter, governor output module, voltage regulator output module, and the magnetic pick-up (MPU).

The engine interface board can also be connected to an optional network interface module for network access.

During a typical start sequence the LED’s light as follows:

1. DS11 lights when a remote run signal is re- ceived and S12 is in the Auto possition, or S12 is moved to the Run position.

2. DS12 lights when the magnetic pick-up voltage is sensed (engine is cranking). (When the engine is cranking, the mag pickup output should be a minimum of 1 volt.)

3. DS11 extinguishes, DS9 lights and DS10 is dimly lit when the generator is running.

Connectors

The engine interface board has seven connectors and one terminal strip. They are:

J1 Connects to J4 on A32 Digital board. J2 Connects to J1 on A33 Analog board. J3 Connects to display board, front panel

switches and meters.

Fuses

The engine interface board has two replaceable fuses. They are:

F1 Control B+ (5 Amps) F3 Aux. B+ (5 Amps). (Panel lamps and run/start

contacts).

LED’s

The engine interface board has 10 LED’s that indicate the following conditions:

DS1 Low Fuel Alarm input (Red) DS2 Low Coolant Level Alarm input (Red) DS3 Low Engine Temperature Alarm input (Red) DS4 S12 in Run position (Green). S12 is the Run/

Off/Auto switch.

DS5 S12 in Auto position (Green) DS6 Emergency Stop (Red) DS7 Not configured. DS8 Not configured. DS9 Automatic voltage regulator duty cycle

(Green). Brighter indicates larger duty cycle.

DS10 Governor duty cycle (Green). Brighter indi-

cates larger duty cycle.

DS11 Start pilot relay output (Red) DS12 Run pilot relay output (Red)

3-4

DS1 - LOW FUEL

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DS2 - LO COOL

DS3 - LET

DS4 - RUN SW

DS5 - AUTO

DS6 - E-STOP

DS9 - REG

DS10 - GOV

DS11 - START

DS12 - RUN RLY

5A CNTRL B+

5A AUX B+

FIGURE 3-4. ENGINE INTERFACE BOARD

3-5

ANALOG BOARD (A33)

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Connectors

The analog board (Figure 3-5) is the only circuit board inside the control that has no LED’s. There are two versions of the analog board that are used for paralleling and non-paralleling systems.

This board interprets all analog input signals and converts the analog signals to 0−5 VDC for the digital board.

The analog board has four connectors with ribbon cables permanently soldered to them. They are:

J1 Connects to J2 on A31 Engine Interface

board

J2 Connects to J3 on A32 Digital board J3 Spare analog inputs J4 Connects to J1 on A34 Customer Interface

board

FIGURE 3-5. ANALOG BOARD

3-6

DIGITAL DISPLAY BOARD (A35)

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The digital board (Figure 3-6) connects to all meters and the LED display.

Connectors

The digital board has three connectors. They are:

J1 Connects to front panel membrane switches J5 Connects to J2 on A32 Digital board. (With J5

disconnected, the display will be non-functional, but the PCC will continue to operate.)

J6 Connects to meters, Run/Off/Auto switch, J3

on A31 Engine Interface board

LEDs

The digital board has 18 LED’s that are used to indicate operational status of the generator set and control panel mode/switch selections.

DS9 Not In Auto (Red) DS10 Upper Scale (Green) DS11 Left Top Arrow (Green)

DS12 Right Top Arrow (Green) DS13 Warning (Amber) DS14 Lower Scale (Green) DS15 Shutdown (Red) DS20 Left Bottom Arrow (Green) DS21 Right Bottom Arrow (Green) DS22 Automatic mains failure (AMF) or paralleling

application only: Breaker Closed (Red)

DS23 Phase A (Green) DS24 Reset Arrow (Green) DS25 Menu Arrow (Green) DS26 AMF application only: Breaker Open

(Green)

DS27 Phase B (Green) DS29 Phase C (Green) DS36 AMF application: Breaker Closed (Red) − or

− paralleling application: Breaker Open (Green)

DS37 AMF application only: Breaker Open

(Green)

DS9

DS13

DS15

DS22 DS26

DS36 DS37

DS11

DS20

DS24

FIGURE 3-6. DIGITAL DISPLAY BOARD

DS12

DS21

DS25

DS10 DS14

DS23 DS27 DS29

3-7

CUSTOMER INTERFACE BOARD (A34)

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The customer interface board (Figure 3-7) connects to the PT/CT board to bring in voltage and current. It also connects to customer inputs and outputs. Note that there are two versions of this board, for parallel and non-parallel generator sets.

Connectors

The customer interface board has five connectors. They are:

J1 Customer connections J2 Customer connections J3 A36 PT/CT Board and customer connections J4 Connects to J2 on A32 Digital board J5 Connects to J4 on A33 Analog board

LEDs

The customer interface board has 27 LED’s that indicate the following conditions:

DS1 Master First Start Input (Green) − paralleling

application only

DS2 Pre low oil pressure output relay K14 (Red) DS3 Customer Fault #4 Input (Red) DS4 Customer Fault #1 Input (Red) DS5 Low oil pressure output relay K15 (Red) DS6 Fault Reset Input (Red) DS7 Engine Idle (Green) DS8 Paralleling Breaker Close Input (Green)

[paralleling function is load demand]

DS9 Paralleling Breaker Open Input (Green) DS10 Paralleling Breaker Position Input (Green) DS11 Customer Fault #2 input (Red) DS12 Low coolant output relay K17 (Red)

DS13 Low Fuel Input (Red) DS14 Remote Start input (Green) DS15 Customer Fault #3 input (Red) DS16 Paralleling Breaker Control input relay ener-

gized from Digital board (Green). This output is activated to close the paralleling breaker.

DS17 Common Alarm output relay energized from

Digital board (Green)

This output is activated only on a shutdown condition.

DS18 Spare output relay energized from Digital

board (Green)

This output is activated only on a warning condition.

DS19 Load Dump output relay energized from

Digital board (Red) If overload or underfrequency for 5 seconds, this output is activated (before shutdown).

DS20 Ready to Load output relay energized from

Digital board (Green) This output is activated when AC voltage and frequency exceed 90% of nominal.

DS21 Pre high engine temperature output relay

K8 (Red)

DS22 Not in auto output relay K6 (Red) DS23 High engine temperature output relay K9

(Red)

DS24 Overspeed output relay K10 (Red) DS25 Overcrank output relay K11 (Red) DS26 Low engine temperature output relay K12

(Red)

DS27 Low fuel output relay K13 (Red)

3-8

DS1 - MA 1ST START

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DS3 - CUST FAULT4 DS4 - CUST FAULT1 DS6 - FAULT RESET DS7 - ENG IDLE DS8 - LOAD DEMAND DS9 - BKR TRIP / INHIBIT DS10 - BRKR CLOSED DS11 - CUST FAULT2 DS13 - LOW FUEL DS14 - RMT START DS15 - CUST FAULT3

DS2 - [K14] PRE-LOP

DS5 - [K15] LOP

DS12 - [K7] LOW COOL

DS16 - CLOSE BKR

DS17 - COMMON SHTDN

DS18 - COMMON WARNING

DS19 - LOAD DUMP

DS20 - READY TO LOAD

DS21 - [K8] PRE-HET

DS22 - [K6] NOT IN AUTO

DS23 - [K9] HET

DS24 [K10] OVERSPEED

DS25 - [K11] OVERCRANK

DS26 - [K12] LET

DS27 - [K13] LOW FUEL

FIGURE 3-7. CUSTOMER INTERFACE BOARD

3-9

PT/CT BOARD (A36)

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The PT/CT board (Figure 3-8) is mounted inside the accessory box. This board converts generator output voltage to approximately 18 VAC levels for the analog board. It also converts CT .55 amp (at full load) output to approximately 1.65 VAC (at full load) input for the analog board.

There are three versions of this board. For proper operation, the PT/CT board must be correctly matched to the generator set.

In addition, there is a specific set of CTs for each genset. For proper operation, the CTs must also be correctly matched to the genset output current.

Connectors

The PT/CT board has two connectors. They are: J8 Connects to J3 on A34 Customer Interface

board

J9 Connects to AC harness (generator output

voltage and CTs)

J9 wiring connections:

Yellow Gen. A In Orange Gen. B In Red Gen. C In Brown Gen. Common In White CT21 (+) In Gray CT21 (common) In Grn/Ylw CT22 (+) In Black CT22 (common) In Purple CT23 (+) In Blue CT23 (common) In

J9

J8

FIGURE 3-8. PT/CT BOARD

3-10

BUS PT MODULE (A39)

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The bus PT module (Figure 3-9) is mounted inside the accessory box. This module converts the bus output voltage (from the load side of the paralleling breaker) to 18 VAC and provides this to the analog board. It provides a reference signal to the PowerCommand Control for synchronizing the generator set output to a system bus. There are four versions of this module, for primary voltages of 69, 120, 240 or 346 volts AC line to neutral. For proper operation, the correct bus PT module must be installed in the generator set. Correct phasing is also important as the system uses the bus PT module output for both protection and control of the generator set.

Connectors

The bus PT module has two terminal blocks. They are:

TB1 Bus voltage connections.

N bus neutral A bus A phase (U) B bus B phase (V) C bus C phase (W)

TB2 Bus PT output for PowerCommand control.

FIGURE 3-9. BUS PT MODULE

3-11

GENSET COMMUNICATIONS MODULE

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(A41)

The genset communications module (GCM) is required to connect the PCC to a PowerCommand (LonWorks) network, and communicate with other network modules. The GCM module is an optional feature, and it is available as a field upgrade kit for applications where the feature must be added in the field. The PCC must be operating with firmware version 1.06 or later. For model DFH gensets only, firmware must be version 1.04 or later.)

The GCM provides an interface for data transfer between the PowerCommand control and other modules on the network. It communicates with the PCC through a serial port on the PCC, as well as monitoring various PCC inputs to determine the operating state of the control. For example, the GCM monitors

PCC data such as voltage, oil pressure, current, engine speed, and not in auto status; and provides that information to the network.

The GCM also facilitates remote monitoring and limited remote control of the genset that PCC controls. Outputs from the GCM can ’wake up’ the PCC when needed, or issue start commands to the genset. The GCM also includes a terminate circuit for use at the end of a network data bus.

The GCM module is powered from the genset starting batteries. It is operational at all times when powered, even if the PCC is asleep.

The GCM module is mounted on stand-off mounting legs above the analog board (A33).

Refer to the Power Command Network Installation and Operator’s Manual (900-0366) for information on installation and use of the GCM module.

J6

J7

TERMINATE

SWITCH S3

BATTERY VOLTAGE

SWITCH S4

SERVICE

SWITCH S1

FIGURE 3-10. GENSET COMMUNICATIONS MODULE

SWITCH S2

3-12

RESET

VOLTAGE REGULATOR OUTPUT MODULE

Redistribution or publication of this document by any means, is strictly prohibited.

(A37)

The voltage regulator output module (Figure 3-11) is a power amplifier. This board is used to amplify the pulse-width modulated (PWM) signal from the PCC to drive the exciter windings. Power from the PMG is used by this board to amplify the PWM signal.

J10 Connects to engine harness (power)

J10 wiring connections:

Green Phase A PMG power Yellow Phase B PMG power Orange Phase C PMG power Red X (Field +) Output Brown XX (Field −) Output

Connectors

The voltage regulator output module has two connectors. They are:

J7 Connects to engine harness (control)

J7 wiring connections:

Gray Regulator Drive (+) Input White Regulator Drive (-) Input Blue B+ Input (RUN signal) Purple Ground Input Grn/Yel Start in Black Start solenoid

LEDs

The voltage regulator output module has 3 LED’s that indicate the following conditions.

DS1 On when voltage regulator isolated supply is

operating (Green)

DS2 Output Duty Cycle − Brighter when load in-

creases − larger duty cycle (Amber). The duty cycle range of the PWM signal is 0 - 60%. Because the normal duty cycle is less than 10%, the output duty cycle LED, DS2 will normally be very dimly lit.

DS3 Backup start disconnect − On when start dis-

connect is true (Green). The backup start disconnect is initiated at about 850 RPM, when sensed PMG voltage is greater than 105 volts RMS.

DS1 - ISOLATED SUPPLY DS2 - OUTPUT DUTY CYCLE

DS3 - BACKUP START DISCONNECT

J10J7

FIGURE 3-11. VOLTAGE REGULATOR OUTPUT MODULE (A37)

3-13

GOVERNOR OUTPUT MODULE (A38)

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Fuses

The governor output module (Figure 3-12) receives a low power pulse−width modulated (PWM) signal from the engine interface board and then sends an amplified signal to drive the governor actuator. The PCC monitors frequency from both the magnetic pick-up (MPU) and the main stator inputs.

Connectors

The governor output module has one connector: J6 Connects to Governor Actuator, Governor

Drive (from Engine Interface), B+, T26

The governor output module has three fuses to protect it from overloads and groundfaults. They are:

F1 Network B+ (10 Amps) F2 Switched B+ (10 Amps) — T26 F3 Gov Act + (10 Amps)

LEDs

The governor output module has two LED’s that indicate the following conditions:

DS1 Output Duty Cycle: brighter = longer duty

cycle (Amber). The duty cycle range of the PWM signal is 0 - 90%. Normal duty cycle is about 30%.

DS2 Run signal to Governor Controller (Green)

DS1 - OUTPUT DUTY CYCLE

DS2 - GENSET RUN

Network B+ Switched B+ Governor B+

J6

FIGURE 3-12. GOVERNOR OUTPUT MODULE (A38)

3-14

MASTER FIRST START SENSOR

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The First Start Sensor System is an Onan control sub-system which is used to sense when a generator set is ready to close to a de-energized system bus and to prevent more than one generator set from closing to a dead bus on automatic system starting. The First Start Sensor System for PowerCommand generator sets is composed of control algorithms within the PowerCommand control and a Master First Start Sensor , which is usually mounted in a remote master control panel.

The sequence of operation of the control system is as follows:

On a signal to start, all generator sets in a system simultaneously start, and accelerate to rated speed and voltage. The Master First Start Sensor continuously provides pulses to each PowerCommand control. When the PowerCommand control receives the pulse from the Master First Start Sensor, if it is ready to close to the bus, an interlock signal is sent to all other controls to prevent their respective paralleling breakers from closing. A close signal is then provided to the generator set paralleling breaker.

3-15

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3-16

4. Troubleshooting

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GENERAL

The PowerCommand Control 3100 (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.

In the event of a shutdown fault (red Shutdown lamp), the PCC will stop the generator set (genset) and close a set of contacts that can be wired to trip a circuit breaker. If the genset is stopped for this reason, the operator can restart the genset after making adjustments or corrections.

This section contains the following information:

• T able 4 - 1 : Contains a list of all status codes, in-

cluding the displayed message and status indicator. Also references the page number that contains a description of each code.

• Table 4-2: Describes each warning and shut-

down code, warning and shutdown limits where applicable, and basic corrective actions, such as, checking fluid levels, control reset functions, battery connections, etc.

• Table 4-3: Lists the PCC oil pressure warning

and shutdown limits.

• Tables 4-4 through 4-35: Provide detailed

troubleshooting procedures.

• T able 4-36: Describes the analog circuit board

inputs and outputs.

• Table 4-37: Describes the location and func-

tion of each fuse.

SAFETY CONSIDERATIONS

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-

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.

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.

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 Run/Off/Auto switch on the control panel to the OFF position.

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

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

4-1

STATUS INDICATORS

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Non-Automatic Status Indicator:

flashes continuously when the Run/Off/Auto switch is in the Off position.

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 Reset switch. (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.

Shutdown Status Indicator:

whenever the control detects a shutdown condition. Shutdown faults are latched. After the condition is corrected, shutdown indicators can be reset by turning the Run/Off/Auto switch to the Off position, and pressing the Reset switch. In the Auto position, shutdown faults can be reset by removing the remote start input and then cycling the remote reset input.

This red lamp

This red lamp is lit

Emergency Stop shutdown status (Code 102) can be reset only at the PCC front panel.

Digital Display:

This two-line, 16-character per line alphanumeric display is used in the menu-driven operating system and to show shutdown and warning messages. Refer to Tables 4-1 and 4-2.

RESETTING THE CONTROL

Press the momentary ing and shutdown messages after the condition has been corrected. To reset a shutdown message with the Reset switch, the Run/Off/Auto switch must be in the Off Position. (The control cannot go into

Standby (sleep) mode until all faults have been reset.)

In Auto mode, warning indicators can also be reset by cycling the remote reset input after the condition is corrected. Shutdown faults can be reset by removing the remote start input and then cycling the remote reset input.

Reset Switch

to reset warn-

WARNING AND

SHUTDOWN

STATUS INDICATORS

RESET

SWITCH

FIGURE 4-1. CONTROL PANEL

4-2

ALPHANUMERIC FAULT MESSAGE

DISPLAY

TABLE 4-1. WARNING AND SHUTDOWN CODES

Redistribution or publication of this document by any means, is strictly prohibited.

BASIC TROUBLE-

CODE MESSAGE STATUS LED CHECKS SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Blank LOAD DEMAND none 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 IDLE MODE none 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 EMERGENCY STOP Shutdown 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 LOW OIL PRESSURE Warning 4-5 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 LOW OIL PRESSURE Shutdown 4-5 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 OIL PRES SENDER Warning 4-5 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 LOW COOLANT TEMP Warning 4-6 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 HIGH COOLANT TEMP Warning 4-6 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 HIGH COOLANT TEMP Shutdown 4-6 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 COOLANT SENDER Warning 4-6 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214 LOW COOLANT LVL Warning 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 LOW COOLANT LVL Shutdown 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 MAG PICKUP Shutdown 4-7 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221 FAIL TO CRANK Shutdown 4-7 4-15, 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222 OVERCRANK Shutdown 4-7 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223 OVERSPEED Shutdown 4-7 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224 FAIL TO SYNCHRONIZE Warning/Shutdown 4-8 4-31. . . . . . . . . . . . . . . . . . . . . . . . . .

226 FAIL TO CLOSE Shutdown 4-8 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 LOW DC VOLTAGE Warning 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231 HIGH DC VOLTAGE Warning 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232 WEAK BATTERY Warning 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 LOW FUEL − DAY Warning 4-9 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241 LOW FUEL Warning 4-9 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 EEPROM ERROR Shutdown 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251 EEPROM ERROR Warning 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252 EEPROM ERROR Warning 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3

TABLE 4-1. WARNING AND SHUTDOWN CODES

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BASIC TROUBLE-

CODE MESSAGE STATUS LED CHECKS SHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

260 CUSTOMER FAULT 1* Warning/Shutdown 4-9 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . .

261 GROUND FAULT* Warning/Shutdown 4-9 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262 DAY TANK* Warning/Shutdown 4-9 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263 HIGH GEN TEMP* Warning/Shutdown 4-9 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

270 PHASE ROTATION Shutdown 4-10 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

272 FIRST START Warning 4-10 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

301 HIGH AC VOLTAGE Shutdown 4-10 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

303 LOW AC VOLTAGE Shutdown 4-10 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313 UNDER FREQUENCY Shutdown 4-10 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

320 OVERCURRENT Warning 4-10 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

321 OVERCURRENT Shutdown 4-10 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322 SHORT CIRCUIT Shutdown 4-10 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 OVERLOAD Warning 4-11 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

335 REVERSE POWER Shutdown 4-11 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

337 LOSS OF EXCITATION Shutdown 4-11 4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* Default message. Editable for customer site requirements. It is recommended that the bell alarm contacts of the

paralleling breaker be brought back to the control and indicate “Parallel CB Trip” as one customer fault.

4-4

TABLE 4-2. WARNING AND SHUTDOWN CODES

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

MESSAGE:

LOAD DEMAND

MESSAGE:

IDLE MODE 101 − WARNING

The PowerCommand control has received a signal to shut down from a remote device. This is a normal operation mode, which is typically used in automatic control system to minimize generator set operation hours and system fuel consumption. When the load demand signal is removed, the generator set will automatically start, synchronize, and close to the system bus.

Indicates that the engine is operating in idle mode. When the genset is operating in the RUN mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM.

When ground is removed from this input, the genset returns to normal speed and voltage.When the engine idle function is enabled, the control automatically gensets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the genset reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings.

Shutdown lamp lights. MESSAGE:

EMERGENCY STOP 102 − SHUTDOWN

Warning lamp lights.

MESSAGE:

LOW OIL PRESSURE 200 − WARNING

Shutdown lamp lights.

MESSAGE:

LOW OIL PRESSURE 201 − SHUTDOWN

Warning lamp lights.

MESSAGE:

OIL PRES SENDER 204 − WARNING

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

Pull the button out (button with arrow − turn clockwise to allow it to pop out). Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required.

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 201-SHUTDOWN procedure.

T o check oil pressure, access the Oil Pressure menu prior to clearing the fault.

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, re plenish. Reset control and restart. Oil pressure limits are listed in Table 4-3.

Indicates that the control has sensed that the engine oil pressure sender is out of its working range. Check that the engine oil pressure sender is properly connected.

4-5

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

LOW COOLANT TEMP 210 − WARNING

Set is not operating. Warning occurs when engine coolant temperature is

° F (21° C) or lower.

70

NOTE: In applications where the ambient temperature falls below

40

°F (4°C), Low Coolant Temp

may be indicated even though the coolant heaters are operating.

Warning lamp lights.

MESSAGE:

HIGH COOLANT TEMP 211 − WARNING

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 disconnected heater cord and correct as required.

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

sible coolant leakage points and repair as required.

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

Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit:

215°

F (102° C) − standby or 207° F (97° C) − prime.

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 HIGH COOLANT TEMP 212 − SHUT-

DOWN procedure.

Shutdown lamp lights.

MESSAGE:

HIGH COOLANT TEMP 212 − SHUTDOWN

Warning lamp lights.

MESSAGE:

COOLANT SENDER 213 − WARNING

To check coolant temperature, access the coolant temperature menu prior to clearing the fault.

Indicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223° F (106° C) − standby or 215° F (102° C) − prime. Allow engine to cool down completely before proceeding with the following checks:

a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary.

c. Check coolant mixture.

d. Check blower fan and circulation pumps on remote radiator installa-

tions.

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

Indicates that the resistance of the coolant temperature sender is out of range. Check the resistance of the sender. Resistance should be 500 to 2k ohms.

4-6

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

LOW COOLANT LVL 214 − WARNING or LOW COOLANT LVL 215 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

MAG PICKUP 220 − SHUTDOWN

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

a. Check coolant level in both radiator and coolant recovery bottle and

replenish if l o w. Look for possible coolant leakage points and repair if necessary.

b. If radiator level is low and coolant bottle level is correct, defective

coolant bottle hose or radiator cap.

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

LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode (low coolant warning only).

Indicates mag pickup speed indication is not being sensed or does not match generator set output frequency.

a. Restart and check RPM on the digital display.

Engine will not crank. Shutdown lamp lights. MESSAGE:

FAIL TO CRANK 221 − SHUTDOWN

Shutdown lamp lights.

Engine stops cranking. MESSAGE:

OVERCRANK 222 − SHUTDOWN

Engine runs and then shuts down. Shutdown lamp lights. MESSAGE:

OVERSPEED 223 − SHUTDOWN

Indicates possible fault with control or starting system. Check for the following conditions:

a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals

and tighten all connections.

c. Discharged or defective battery. Recharge or replace the battery.

Indicates possible fuel system problem.

a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and cor-

rect as required.

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 has exceeded normal operating speed. (115% ±1% of nominal).

4-7

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Warning (or Shutdown) lamp

lights. MESSAGE:

FAIL TO SYNCHRONIZE 224 − WARNING or FAIL TO SYNCHRONIZE 224

Warning lamp lights.

MESSAGE:

FAIL TO CLOSE 226 − SHUTDOWN

The generator set has not synchronized to the system bus within the allowable time frame.

a. Check the governor system stability. Adjust governing and synchro-

nizer parameters as required.

b. Check for fuel system problems which can cause engine instability.

Synchronizing time can be improved by widening the synchronizing window and reducing the acceptance time delay.

Indicates that the paralleling breaker has been given a signal to close, but has not closed properly.

a. Verify that the charging mechanism of the paralleling breaker is func-

tioning properly.

b. Check the close signal to the breaker.

c. Verify that the auxiliary contact signals from the breaker to the Pow-

erCommand control are operational.

Warning lamp lights. MESSAGE:

LOW DC VOLTAGE 230 − WARNING

Warning lamp lights.

MESSAGE:

HIGH DC VOLTAGE 231 − WARNING

Warning lamp lights.

MESSAGE:

WEAK BATTERY 232 − WARNING

Indicates battery voltage is below 10 VDC.

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 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 lev-

el).

Indicates battery voltage exceeds 32 VDC. Check voltage float level on battery charger if applicable (lower float lev-

el). Check engine DC alternator. Replace engine DC alternator if normal bat-

tery charging voltage is not obtained.

Indicates battery voltage drops below 60% of nominal for two seconds, during starting.

Discharged or defective battery. See Warning message 230, LOW DC VOLTAGE.

4-8

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

LOW FUEL−DAY 240 − WARNING

or

LOW FUEL 241 − WARNING

Shutdown lamp lights.

MESSAGE:

EEPROM ERROR 250 − SHUTDOWN

Warning lamp lights.

MESSAGE:

EEPROM ERROR 251 − WARNING or 252 − WARNING

Indicates day tank fuel supply is running low. Check fuel supply and replenish as required.

Indicates PCC memory error. Data corruption of critical operating parameters.

Indicates PCC memory error. Data corruption of noncritical operating parameters.

Shutdown lamp lights. MESSAGE:

CUSTOMER FAULT 1 260 − SHUTDOWN GROUND FAULT 261 − SHUTDOWN

or

DAY TANK 262 − SHUTDOWN

or

HIGH GEN TEMP 263 − SHUTDOWN

When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning.

As indicated by the Shutdown lamp, a shutdown response has been preselected.

Note: Customer fault messages are editable. The message displayed for the code shown (260 thru 263) may have been edited and may not appear as shown in this table.

4-9

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

CUSTOMER FAULT 1 260 − WARNING GROUND FAULT 261 − WARNING

or

DAY TANK 262 − WARNING

or

HIGH GEN TEMP 263 − WARNING

Shutdown lamp lights.

MESSAGE:

PHASE ROTATION 270 − SHUTDOWN

When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown or a warning.

As indicated by the Warning lamp, a warning response has been preselected.

Note: Customer fault messages are editable. The message displayed for the code shown (260 thru 263) may have been edited and may not appear as shown in this table.

The phase relationship between the generator set and the system bus is not matched.

a. Using a phase rotation checker, verify that the generator set phase

rotation matches the phase orientation of the system bus.

b. Verify that control wiring to the bus PT module on the PowerCom-

mand control is properly connected.

Shutdown lamp lights. MESSAGE:

FIRST START 272 − WARNING

Shutdown lamp lights.

MESSAGE:

HIGH AC VOLTAGE 301 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

LOW AC VOLTAGE 303 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

UNDER FREQUENCY 313 − SHUTDOWN

The PowerCommand control is not receiving a proper signal from the system master first start sensor . When this occurs, the control reverts to a fallback mode in which breaker closure is automatically allowed if bus is deenergized. If bus voltage is sensed, the control will force the generator set to synchronize to the system bus before breaker close signal is initiated.

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. Note: Five seconds before shutdown, a Load Dump signal is initiated.

Check fuel supply, intake air supply and load.

4-10

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

OVERCURRENT 320 − WARNING

Shutdown lamp lights.

MESSAGE:

OVERCURRENT 321 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

SHORT CIRCUIT 322 − SHUTDOWN

Indicates that generator output current has exceeded 1 10% of rated for 60 seconds.

Check load and load lead connections.

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

Check load and load lead connections.

Indicates that generator output current has exceeded 175% of rated. Check load and load lead connections.

Warning lamp lights. MESSAGE:

OVERLOAD 330 − WARNING

Indicates that three-phase power output exceeds 105% of standby (or 115% of prime) rating. After five seconds, the Load Dump output is activated. After 60 seconds, the OVERLOAD warning is activated.

Check load and load lead connections.

4-11

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

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.

SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

REVERSE POWER 335 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

LOSS OF EXCITATION 337 − SHUTDOWN

Indicates that power is flowing into the generator set, rather than out from the unit. This can be caused by engine failure, or inability to carry load, or by a number of control or interconnection problems.

a. If problem occurs at initial startup, verify connection of generator set

CT’s, by applying load to the generator set while it is operating alone while connected to bus.

b. Verify proper connection of load sharing lines.

c. Verify that the generator set is operating at the correct frequency and

voltage. The no-load voltage of the generator set and other generator sets should all be the same.

Indicates that t he a lternator e xcitation s ystem i s i mproperly a djusted o r h as failed. Loss of Excitation failure may also b e c aused b y o peration of f ilters and power factor c orrection capacitors in the generator s et l oads w hen t he kW load level on the g enset i s l ow. The capacitors in the f ilters and p ower factor correction equipment can p resent a l eading power factor load to the generator set, which (correctly) shuts down the generator set through the loss of e xcitation f ault. L eading p ower f actor l oads c an c ause t he g enerator set to lose control of the output voltage of the genset and can cause kVar load sharing p roblems. T herefore, i t i s n ecessary t o p rotect t he g enset f rom excessive leading power factor and reverse Var conditions.

a. Start the generator set in the RUN mode and check output voltage

with both the control digital meter set and a calibrated meter. Calibrate voltage if necessary . Output voltage should be adjusted to t h e same level as all other generator sets at no load. Make adjustments as necessary to correct.

b. Check load sharing lines for proper interconnections.

c. See

Section 6

tifier, and exciter Rotor.

of this manual “Servicing the Generator”, Exciter Rec-

4-12

TABLE 4-3. PCC OIL PRESSURE WARNING & SHUTDOWN LIMITS

Redistribution or publication of this document by any means, is strictly prohibited.

L10/M11 Engine: NORM 30-50 psi (207-345 kPa), IDLE 15 psi (103 kPa)

20 psi (138 kPa) shutdown limit - run mode value 25 psi (172 kPa) warning limit - run mode value 8 psi (55 kPa) shutdown limit - idle mode value 12 psi (83 kPa) warning limit- idle mode value

NTA 855 Engine: NORM 35-50 psi (241-345 kPa), IDLE 15 psi (103 kPa)

25 psi (172 kPa) shutdown limit - run mode value 30 psi (207 kPa) warning limit - run mode value 8 psi (55 kPa) shutdown limit - idle mode value 12 psi (83 kPa) warning limit- idle mode value

K19 Engine: NORM 50-70 psi (345-482 kPa), IDLE 20 psi (138 kPa)

35 psi (241 kPa) shutdown limit - run mode value 40 psi (276 kPa) warning limit - run mode value 10 psi (69 kPa) shutdown limit - idle mode value 15 psi (103 kPa) warning limit- idle mode value

V28 Engine: NORM 50-90 psi (345-620 kPa), IDLE 20 psi (138 kPa)

35 psi (241 kPa) shutdown limit - run mode value 40 psi (276 kPa) warning limit - run mode value 10 psi (69 kPa) shutdown limit - idle mode value 15 psi (103 kPa) warning limit- idle mode value

K38 Engine: NORM 45-65 psi (310-448 kPa), IDLE 20 psi (138 kPa)

35 psi (241 kPa) shutdown limit - run mode value 40 psi (276 kPa) warning limit - run mode value 10 psi (69 kPa) shutdown limit - idle mode value 15 psi (103 kPa) warning limit- idle mode value

K50 Engine: NORM 50-70 psi (345-482 kPa), IDLE 20 psi (138 kPa)

35 psi (241 kPa) shutdown limit - run mode value 40 psi (276 kPa) warning limit - run mode value 10 psi (69 kPa) shutdown limit - idle mode value 15 psi (103 kPa) warning limit- idle mode value

To check oil pressure or engine temperature during a warning, access the oil pressure or engine temperature menu prior to clearing the fault.

4-13

TROUBLESHOOTING PROCEDURE

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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.

To determine the appropriate troubleshooting procedure for the specific problem at hand, be sure to refer to the “Indicators” column provided in each troubleshooting table.

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. (Table 4-32 describes the location and function of each fuse.)

Figure 4-2 shows the location of the components within the control panel that are referenced in the following troubleshooting procedures. Connector,

LED and switch locations for each circuit board and module are provided in and circuit board connections are shown in

9

.

CAUTION

Always set the Run/Off/Auto (S12)

Section 3

. The control wiring

Section

switch to the Off position and the Power On/ Standby (S5) switch to the Standby 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 socket-mounted IC’s and when disconnecting or connecting harness connectors.

4-14

DISPLAY BOARD

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A35

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

ANALOG BOARD

A33

OPTIONAL

THERMISTOR

RELAY 160

OPTIONAL RUN

RELAYS K11, K12 &

°/140° C

TB1-1

K13

TB1-60

RUN/OFF/AUTO

SWITCH S12

ENGINE INTERFACE

A31

CUSTOMER INTERFACE

A34

BUS PT MODULE

A39

GOVERNOR

OUTPUT MODULE

A38

OPTIONAL

COMMON ALARM

RELAY K14

PT/CT BOARD A36

OPTIONAL RTD

RELAY

VOLTAGE

REGULATOR

OUTPUT MODULE

A37

ACCESSORY BOX

FIGURE 4-2. CIRCUIT BOARD LOCATIONS

4-15

TABLE 4-4. ENGINE DOES NOT CRANK—LOCAL OR REMOTE RUN

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

Reset and attempt to start:

Start LED DS11 on the engine interface board turns on.

NOTE: These two indications suggest that the PCC has received a start signal and has sent a start command to the start output (J4-2) on the engine interface board.

1. Insufficient battery voltage. Check the following conditions:

a. Batteries not charged. b. Battery connections loose or

dirty.

c. Insufficient battery charging volt-

age.

d. Engine DC alternator could be

bad.

2. Starter could be bad.

3. If there is no B+ at the starter, start solenoid K4 could be bad.

4. If there is no B+ at the start solenoid coil (K4), the backup start disconnect contacts in the regulator output module (A37) could be open (indicating that A37 is bad).

1a. Recharge or replace the battery. Specific gravi-

ty for a fully charged battery is approximately

1.260 at 80° F (27° C).

1b. Clean and tighten or replace the battery cable

connectors and cables at the battery and the

set. 1c. Adjust charge rate of battery charging circuit. 1d. Replace engine DC alternator if normal battery

charging voltage is not obtained.

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

3. Reset the control. Attempt to start, and test for B+ into and out of start solenoid contacts. If there is B+ in, but not out, check for B+ at the start solenoid coil. If there is B+ at the coil, check ground connection. If ground connection is good, the start solenoid is bad. Replace the start solenoid.

If there is B+ into and out of the start solenoid contacts, check for an open between the start solenoid contacts and the starter. If there is no B+, go to the next step.

*4. Disconnect J7/P7 at the regulator output mod-

ule. Test for continuity at A37 J7-5/J7-6. If there is no continuity, the regulator output module is bad. Replace A37.

5. If there is continuity at A37 J7-5/J7-6, there may be an open between A37 and A31, an open between A37 and K4, or A31 may be bad.

6. The mag pickup signal is not being sensed.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

*5. If there is continuity at A37 J7-5/J7-6, reset the

control, attempt to start, and check for B+ at A37 P7-5.

If there is B+ at P7-5, there may be an open be-

tween start solenoid coil (K4) and A37. If there is no B+ at P7-5, check for B+ at J4-2 on the engine interface board (A31) while attempting to start.

If there is B+ at A31 J4-2, check for an open between A37 and A31.

If there is no B+ at A31 J4-2, (and DS11 is on) the engine interface board is bad. Replace A31.

6. Refer to the mag pickup shutdown message (220).

4-16

TABLE 4-5. ENGINE DOES NOT CRANK—LOCAL OR REMOTE RUN

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

Reset and attempt to start:

Start LED DS11 on the engine interface board does NOT turn on.

NOTE: These two indications suggest that the PCC has received a start signal and has NOT sent a start command to the start output (J4-2) on the engine interface board.

1. Fuse F3 on the engine interface board (A31) may be open, or B+ may not be getting to F3.

2. Emergency Stop switch S13 or the PCC door harness may be bad.

3. Digital board (A32) may be bad.

4. Engine interface board (A31) may be bad.

*1. Install harness tool between A31 J4/P4. Reset

the control. Attempt to start and check for B+ at J4-2. If no B+, remove F3 and check continuity. If open, replace the fuse with one of the same type and amp rating (5 Amps). If F3 is OK, check the B+ supply from the wiring harness.

2. To isolate:

• Check for B+ at S13-1 and S13-2. If there is B+ at S13-2, but not at S13-1 (and S13 is NOT in the emergency stop position), then S13 is bad. Replace S13.

• If there is no B+ at S13-2, disconnect J3/P3, and check for B+ at A31 J3-2. If there is no B+, replace A31.

• If there is B+ at A31 J3-2, check continuity from P3-2 to P3-6. If no continuity, repair or replace as necessary.

*3. Install harness tool between A32 J4/P4. Reset

the control. Attempt to start, and test for ground output at A32 J4-3. If there is no ground output, A32 is bad. Replace A32.

*4. If there is a ground output at A32 J4-3, and yet

there is no B+ output at A31 J4-2; then A31 is bad. Replace A31.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-17

TABLE 4-6. ENGINE DOES NOT CRANK—REMOTE RUN

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

−and: Auto LED DS5 on the engine interface board (A31) is on − RMT Start LED DS14 on the customer interface board (A34) is on −

NOTE: This condition suggests that the PCC processor (digital board

−A32) has NOT received or recognized a remote start start signal.

1. The Auto mode signal is not getting from engine interface board A31 to digital board A32, indicating that A31 is bad.

2. The Remote run signal is not getting from customer interface board A34 to A32, indicating that A34 is bad.

3. Digital board (A32) may be bad.

*1. Install harness tool between A32 J4/P4. Check

for ground output at A32 J4-18.

If there is no ground output (but A31 DS5 is on)

engine interface board A31 is bad. Replace A31.

If there is a ground output at A31 J1-18, proceed to the next step.

*2. Install harness tool between A32 J4/P4. Reset

the control. Attempt to remote start, and check for ground output at A32 J2-26. If no ground output (but A34 DS14 is on) customer interface board A34 is bad. Replace A34.

If there is a ground output at A32 J2-26, proceed to the next step.

*3. If, when attempting remote start, there is a

ground input at A32 J2-26, and a ground input at A32 J4-18—and there is no “FAIL TO CRANK” message—and the set does not crank; A32 is bad. Replace, A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-18

TABLE 4-7. ENGINE DOES NOT CRANK—REMOTE RUN

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

−and: Auto LED DS5 on the engine interface board (A31) is off − RMT Start LED DS14 on the customer interface board (A34) is on −

The Auto mode input is not getting from the Auto select switch (S12) to engine interface board A31 (indicating that S12, A31, or the harness is bad.

1. S12 or the wiring harness may be bad.

2. Engine interface board A31 may be bad.

*1. Disconnect A31 J3/P3. Check continuity to

ground at A31 J3-11. (J3-11 is ground out to S12. If ground is not present, replace A31. If ground is present, place S12 in Auto and check continuity from P3-11 to P3-13. If no continuity , isolate to switch or wiring harness. Repair as necessary. If there is continuity, A31 may be bad. Reconnect J3/P3.

*2. Install harness tool between A32 J4/P4. Check

the 16 volt (nominal) supply at A32 J4-16.

NOTE: This condition suggests that the engine interface board (A31) is NOT enabling the remote start logic on the digital board.

3. Digital board A32 may be bad.

If the voltage is present at A32 J4-16, and ground is present at A31 P3-13—and yet A31 DS5 is off; then A31 is bad. Replace A31.

3. If there is no +16 volt supply voltage at A32 J4-16, A32 is bad. Replace A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-19

TABLE 4-8. ENGINE DOES NOT CRANK—REMOTE RUN

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

−and: Auto LED DS5 on the engine interface board (A31) is on − RMT Start LED DS14 on the customer interface board (A34) is off

NOTE: This condition suggests that the remote start input is NOT passing through the customer interface board (A34) to enable the remote start logic on the digital board.

The remote start input is not getting from the remote start switch to the output of the customer interface board (A34) (indicating that the switch, A34, or the harness is bad.

1. The remote start switch or the wiring harness may be bad.

2. Customer interface board A34 may be bad.

*1. Install harness tool between A34 J1/P1. Reset

the control. Attempt remote start and check for ground at A34 J1-13. If ground level is not present, isolate to the switch or the wiring harness by checking for a start signal at TB1-5. Repair as necessary.

2. If ground is present at A34 J1-13—and yet A34 DS14 is off, replace A34.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-20

TABLE 4-9. ENGINE DOES NOT CRANK—LOCAL RUN

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

−and: Run LED DS4 on the engine interface board (A31) is off−

NOTE: This condition suggests that the start input is NOT getting from the Run/Off/ Auto switch (S12) to the engine interface board (A31) to enable the remote start logic on the digital board.

The start input is not getting from the Run/ Off/ Auto select switch (S12) to A31 (indicating that S12, A31, or the harness is bad.

1. Run/Off/ Auto select switch S12 or the wiring harness may be bad.

2. Engine interface board A31 may be bad.

3. Digital board A32 may be bad.

*1. Check continuity to ground at A31 J3-11. If

ground is not present, replace A31. If ground is present, place S12 in Run and check continuity from P3-11 to P3-12. If no continuity, isolate to switch or wiring harness. Repair as necessary . If there is continuity, A31 may be bad.

*2. Install harness tool between A32 J4/P4. Check

the 16 volt (nominal) supply at A32 J4-16. If the voltage is present at A32 J4-16, and

ground is present at A31 J3-12—and yet A31 DS5 is off, replace A31.

3. If there is no +16 volt supply voltage at A32 J4-16, replace A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-21

TABLE 4-10. ENGINE CRANKS BUT DOES NOT START

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“OVERCRANK” (222) message

−and While cranking,

Run LED DS12 on the engine interface board (A31) is on.

and While cranking,

Run LED DS2 on the governor output module (A38) is on.

NOTE: These indications suggest that the PCC has sent a run signal to the fuel solenoid.

Fuel supply or fuel delivery.

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. The mechanical fuel linkage could be

binding, loose, or damaged.

3. Fuel solenoid (K1) on the injection

pump not energized due to:

a. Open in fuel solenoid circuit or

defective governor module.

b. Defective fuel solenoid.

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 ser-

vice manual.

2. Inspect the mechanical fuel linkage, and repair or replace as necessary.

Follow the procedure in the engine repair manual to check the EFC for binding or damage.

Disconnect the actuator connector, and connect +12 VDC from the battery to the actuator. The actuator should click upon application and removal of the voltage.

If the actuator does not click, refer to the engine manual.

If the actuator clicks, reconnect the wires to the actuator.

3a. Reset the control. Attempt to start and check for

B+ at the K1 fuel solenoid coil on the injection pump and at output of governor module. Check continuity from J6-20 and 21 to J6-19.

3b. Check wiring continuity of fuel solenoid circuit.

Test fuel solenoid.

Repair or replace as necessary.

4. Fuel tank solenoid not energized due to:

5. Engine fuel injection or other engine problem.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

a. Open in fuel tank solenoid circuit. b. Defective fuel tank solenoid.

4-22

4a. Check wiring continuity of fuel tank solenoid cir-

cuit.

4b. Test fuel tank solenoid.

Repair or replace as necessary.

5. Refer to the engine service manual.

TABLE 4-11. ENGINE CRANKS BUT DOES NOT START

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“OVERCRANK” (222) message

−and While cranking,

Run LED DS12 on the engine interface board (A31) is on.

and While cranking,

Run LED DS2 on the governor output module (A38) is off.

The run signal is not getting through the governor module to the fuel solenoid.

1. The run signal is not getting out of the engine interface board (A31). A31 may be bad.

2. There is an open between the engine interface board (A31) and the governor output module (A38).

3. The run signal is not getting through the governor output module (A38). A38 may be bad.

Reset the control. Attempt to start and check for B+ at A31 J4-1.

*1. Install harness tool between A31 J4/P4. Reset

the control. Attempt to start and check for B+ at A31 J4-1. If there is no B+ at A31 J4-1, replace A31.

*2. If there is B+ at A31 J4-1, install harness tool be-

tween A38 J6/P6. Check for B+ at A38 J6-19, while attempting to crank. If there is no B+ at A38 J6-19, isolate to connectors and wiring. Repair or replace as necessary.

3. If there is B+ at A31 J4-1, and there is B+ at A38 J6-19, check continuity from A38 J6-15 to battery ground, if not continuity replace harness, if continuity, replace A38.

NOTE: These indications suggest that the PCC has sent a run signal to the governor module, but the signal is not getting through the governor module to the fuel solenoid.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-23

TABLE 4-12. ENGINE CRANKS BUT DOES NOT START

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“OVERCRANK” (222) message

−and Run LED DS12

on the engine interface board (A31) is off.

NOTE: These indications suggest that the PCC has NOT sent a run signal − (fuel solenoid enable signal) out to the governor module and the fuel solenoid.

The run signal from the digital board (A32) is not being processed by the engine interface board (A31).

1. The run signal is not getting out of the digital board (A32). A32 may be bad.

2. The run signal is not being processed by the engine interface board (A31). A31 may be bad.

*Install harness tool between A32 J4/P4. Attempt to start and check for ground signal at A32 J4−8.

1. If there is no ground signal at A32 J4−8, replace A32.

2. If there is a ground signal at A32 J4−8, replace A31.

“FAIL TO CRANK” (221) message

NOTE: The engine is cranking but shutting down on a 221 fault.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

The mag pickup signal is not being sensed.

Refer to the mag pickup shutdown message (220).

4-24

TABLE 4-13. LOW OIL PRESSURE WARNING (200) OR SHUTDOWN (201)

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WARNING

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Indicator(s) Possible Cause Corrective Action

“LOW OIL PRESSURE” warning (200) or shutdown (201) message.

1. Low oil level. Clogged lines or filters.

2a. Sender or oil pump could be bad. Or

the generator set may be shutting down on another fault.

1. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Oil pressure limits are listed in

2. Disconnect the oil pressure sender leads, and connect an oil pressure sender simulator to the harness.

a. If the control responds to the simulator, recon-

nect the sender, disconnect the run signal wire at the fuel solenoid, 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 generator set may be shutting down on another fault (out of fuel, blown governor fuse, intermittent connector). Restart the generator set and monitor the PCC display panel for other faults.

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

Table 4-3.

2b. Harness or PCC circuit board could be

bad. Isolate to the harness, engine inter-

face board (A31), analog board (A33), or digital board (A32).

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-25

*b. If the control does not respond to the simulator,

the PCC or the harness is bad. Install harness tool between A31 J2/P2.

Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender

• Check for 5 VDC at A31 J5-18.

• If yes, harness is bad. If no, check for 5

VDC at A31 J2-24.

• If yes, A31 is bad. If no, A33 is bad.

If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (

Table 4-35a/b

).

TABLE 4-14. SENDER WARNINGS (204 or 213)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“OIL PRESSURE SENDER” warning (204) message.

1. The sender connections could be bad.

2. The sender, the harness, engine interface board (A31), digital board (A32), or analog board (A33) could be faulty.

1. Check the sender connections.

*2. Isolate to the sender, harness, engine interface

board (A31), analog board (A33), or digital board (A32).

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

“OIL PRES SENDER” warning is displayed after the fault condition is sensed for 10 seconds.

a. If the control responds to the simulator, r e -

place the sender.

*b. If the control does not respond to the simulator,

the PCC or the harness is bad. Install harness tool between A31 J2/P2.

Check for +5 VDC at the sender (lead marked E1-B). If there is no 5 VDC at the sender

• Check for 5 VDC at A31 J5-18.

• If yes, harness is bad. If no, check for 5

VDC at A31 J2-24.

• If yes, A31 is bad. If no, A33 is bad.

If there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. If the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. If the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (

Table 4-35a/b

).

“COOLANT SENDER” warning (213) message.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

1. The sender connections could be bad.

2. The sender, the harness, engine interface board (A31), digital board (A32), or analog board (A33) could be faulty.

1. Check the sender connections.

*2. Isolate to the sender, harness, engine interface

board (A31), analog board (A33), or digital board (A32).

Disconnect the sender, and plug in a resistive sender simulator to isolate the fault.

a. If the control responds to the simulator, r e -

place the sender.

b. If the control does not respond to the simu-

lator, refer to the high coolant temp troubleshooting procedure.

4-26

TABLE 4-15. LOW ENGINE TEMPERATURE WARNING (210)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW COOLANT TEMP” warning (210) message.

Coolant level is normal.

Heater is OK. Coolant temp

on front panel display is OK.

DS3 on the engine interface board, A31, is on.

DS3 / A31 is on, indicating that engine interface board A31 is receiving a low coolant temp from the sender.

The sender, the harness or A31 could be bad.

Isolate the source of the signal. Unplug the coolant temperature switch (S1) and re-

set the control.

1. If the 210 warning message drops out and does not reappear, replace the sender.

*2. If the 210 warning message reappears and re-

mains after control reset, disconnect A31 J4 and check continuity from P4−13 to GND.

• If there is continuity, replace the harness.

• If there is no continuity, replace circuit

board A31.

“LOW COOLANT TEMP” warning (210) message.

Coolant level is normal.

Heater is OK. Coolant temp

on front panel display is OK.

DS3 on the engine interface board, A31, is off.

DS3 / A31 is off, indicating that engine interface board A31 is not receiving a low en gine temp signal from the sender—but the 210 message indicates that A32, the digital board, is responding to a false low engine temp signal.

A31, the engine interface board, or A32, the digital board, could be bad.

Isolate the source of the signal. Check J4−6/P4−6 on A32.

*1. Install harness tool between A32 J4/P4.

2. Open J4−6 and reset the control.

• If fault drops out and does not return, replace A31.

• If fault returns after resetting the control, replace A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-27

TABLE 4-16. HIGH ENGINE TEMPERATURE WARNING (211) OR SHUTDOWN (212)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“HIGH COOLANT TEMP” warning (211) or shutdown (212) message.

Coolant mixture and level is normal.

No airflow obstructions.

Fan belt is OK.

1. Engine problem:

• Coolant pump could be faulty.

• Thermostat could be faulty.

• There could be an obstruction in

the coolant flow.

• External coolant pump (with remote radiator) could be faulty.

• External radiator fan motor (with remote radiator) could be faulty.

2. The generator set may have been overloaded.

3. Sender, harness or PCC circuit board could be bad.

1. Refer to the engine service manual if there are any physical indications of overheating.

2. Correct any overload condition.

3. If there are no physical indications of overheating, check to see if the PCC accurately displays ambient engine temperature.

• 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, isolate to the sender, harness, engine interface board (A31), analog board, or digital board.

Disconnect the coolant temperature sender leads, and connect a coolant temperature sender simulator to the harness.

a. If the control responds to the simulator, re-

place the sender.

*b. If the control does not respond to the simu-

lator, install harness tool between A31 J5/P5. Connect the coolant temperature sender simulator (and B+) to A31 J5.

• If the control displays the correct simulated temperature, replace the harness.

• If the control does not display the correct simulated temperature, install harness tool at A31 J2/P2, and open lines 18/19 (and 14/15, if applicable). Check for continuity between A31 J2-18 to 19 (for coolant temp L), and A31 J2-14 to 15 (for coolant temp R).

• If no continuity, then A31 is bad.

• If continuity is OK, then send a simu-

lated temperature signal and measure the voltage out of A31 (A31 J2-18 to 19, and A31 J2-14 to 15).

If voltage is not OK (refer to the analog board inputs and outputs,

), replace A33.

4-36

If voltage is OK, refer to the analog/ digital troubleshooting procedure

Table 4-35a/b

(

).

Table

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-28

TABLE 4-17. LOW COOLANT WARNING OR SHUTDOWN (214 / 215)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW COOLANT LVL” warning (214) or shutdown (215) message

Coolant level is normal.

DS2 on the engine interface board, A31, is on.

DS2 on A31 is on, indicating that A31 is receiving a low coolant signal from the sender.

The sender, the harness or the A31 circuit 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 215 shutdown message drops out and does not reappear, replace the sender.

*2. If the 215 shutdown message reappears and

remains after control reset, disconnect J4/A31 and check continuity from P4−7 to GND.

• If there is continuity, replace the harness.

• If there is no continuity, replace circuit

board A31.

“LOW COOLANT LVL” warning (214) or shutdown (215) message

Coolant level is normal.

DS2 on the engine interface board, A31, is off.

DS2 on A31 is off, indicating that A31 is not receiving a low coolant signal from the sender—but the 215 message indicates that A32, the digital board, is responding to a false low coolant signal.

A31, the engine interface board, or A32, the digital board, could be bad.

If the coolant level is normal, isolate the source of the low coolant signal.

Check J4−4/P4−4 on A32.

*1. Install harness tool between A32 J4/P4.

2. Open the J4-4 circuit and reset the control.

• If the fault drops out and does not return, replace A31.

• If the fault returns after resetting the control, replace A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-29

TABLE 4-18. MAG PICKUP SHUTDOWN (220)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“MAG PICKUP” shutdown message (220)

This indicates that the PCC is not sensing the mag pickup signal, or the mag pickup frequency does not correspond (in proportion) to the genset output frequency.

1. The PCC may not be set for the correct generator set.

2. Loose or damaged mag pickup wire.

3. Damaged mag pickup (MPU).

4. The harness, the engine interface board (A31), the analog board (A33) o r the digital board (A32) could be bad.

1. Check and correct setting if necessary.

2. Inspect the wires, and repair or replace as necessary.

*3/4 To isolate the problem, reset the control and at-

tempt to start the set in idle mode.

a. If the engine displays a “FAIL TO CRANK” shut-

down message, or if the engine starts and idles, but then shuts down on a MAG PICKUP fault, 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 no output, replace the MPU sender.

• If the MPU output is OK, install harness tool between A32 J4/P4. Check for MPU voltage at A32 J4-10 to 11, while cranking. If OK, replace A32. If not OK, use continuity checks to isolate to A31 or harness.

b. If the engine starts and idles, and does not dis-

play 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. Verify the accuracy of the PCC L1N voltage, and then refer to the analog/ digital troubleshooting procedure (

4-35a/b

).

Section 5

.) If there is still

Table

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-30

TABLE 4-19. OVERSPEED SHUTDOWN (223)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“OVERSPEED” shutdown message (223)

1. The mechanical fuel linkage could be binding, loose, or damaged.

2. The governor output module (A38) or the digital board (A32) could be bad.

1. Inspect the mechanical fuel linkage, and repair or replace as necessary.

• Follow the procedure in the engine repair manual to check the EFC for binding or damage.

• Disconnect the actuator connector, and connect +12 VDC from the battery to the actuator. The actuator should click upon application and removal of the voltage.

If the actuator does not click, refer to the engine manual.

If the actuator clicks, reconnect the wires to the actuator.

*2. Reset the control, and start the set while moni-

toring the PCC duty cycle display.

• If the duty cycle goes high (above 40%) and the set shuts down on overspeed, replace A32.

• If the duty cycle goes to zero and the set shuts down on overspeed, replace A38.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-31

TABLE 4-20a. FAIL TO SYNCHRONIZE (224)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO SYNCHRONIZE” warning (224) or shutdown (224) message.

1. Improper adjustment of bus or generator set voltage.

2. Generator set hunting due to improper synchronizing adjustments.

1. Verify that the bus voltage is within plus or minus 5% of the value which is programmed into the PowerCommand control, and verify that the generator set is operating at proper voltage and frequency. Verify that the bus PT module is properly calibrated. (Refer to

in

age Calibration

TO SYNCHRONIZE time delay. I t should be set for approximately 120 seconds. Check paralleling setup adjustments, particularly PERM WIN PHASE and PERM WIN - TIME. They are typically adjusted to 20 degrees and 0.5 seconds.

2. Check synchronizer adjustments in the PowerCommand control set−up. If you are unsure of proper adjustment procedure, returning the unit to it’s default values should result in proper operation. The default values are shown in the test report which is shipped with the generator set. In particular, check values for paralleling functions, governing and voltage regulation.

Section 5

Digital Bus Volt-

). Check the FAIL

3. Unstable or hunting generator set due to governor component failure or misadjustment.

Continued On Next Page...

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

3. Inspect generator set governing system for evidence of binding or sticking linkages or other components which are not operating correctly. Verify that water jacket heaters are operational and properly functioning. Check and adjust governor settings as required.

4-32

TABLE 4-20b. FAIL TO SYNCHRONIZE (224)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO SYNCHRONIZE” warning (224) or shutdown (224) message.

4. Unstable or hunting generator set due to air entrained in the fuel system.

4. This problem is indicated in situations where the generator set performs properly after the generator set is up and running with load, but experiences ”FAIL TO SYNCHRONIZE” alarms after it has been shut down for several days. Check the generator set fuel system for leaks or cracks. If fuel filters have recently been changed, air may be trapped in the fuel filter heads. Check to be sure that there is a fuel head on the engine fuel pump. Check fuel line routing for overhead loops which could result in the trapping of air in the system if the system sits idle for some period of time. Parallel systems should use option C174, the fuel pump feature option. This feature is available as an aftermarket accessory kit.

Note: The generator set will synchronize faster as the synchronize acceptance window is widened (i.e., the value in the PERM WIN−PHASE is increased) and as the acceptance time is minimized (the value in the PERM WIN−TIME is minimized). Caution should be taken in utility (mains) paralleling applications to avoid damage to the generator set by inappropriate setting of these parameters.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-33

TABLE 4-21a. FAIL TO CLOSE (226)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CLOSE” warning (226) or shutdown (226) message.

1. Check the paralleling breaker for indication that the breaker is tripped and locked out from a signal issued from it’s internal trip unit

2. Breaker charge circuit is not operating properly. (Power circuit breakers only .)

Continued On Next Page...

1. If the breaker has tripped due to operation of it’s internal trip unit, the alternator and electrical distribution system connected to the alternator should be carefully inspected for evidence of burning or tracking, which might indicate that an electrical fault has occurred. If no evidence of a fault is found, reset the trip unit and verify that the trip settings of the breaker are appropriate for the application. Reset the fault on the PowerCommand control and check the system operation to verify that the failure to close fault problem has been eliminated.

2. Check the circuit breaker status indicators and verify that the breaker status indicates that the breaker is properly charged. If it is, go on to step

3. If it is not charged, check the charge circuit for proper operation. Switch the PowerCommand control RUN/OFF/AUTO switch to OFF and then manually recharge the paralleling breaker according to the manufacturer’s instructions. Switch the PowerCommand control RUN/OFF/ AUTO switch back to RUN. The generator set should start and accelerate to rated speed and voltage and the operator should be able to manually control the circuit breaker from the pushbuttons on the front panel of the PowerCommand control. In most cases the breaker should automatically recharge on closing to the system bus. If this does not occur , problem may be in the control wiring to the breaker, or the control power source.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

NOTE: Some breakers are not able to be set up to charge on closing (they will recharge on opening). If this is the case with your installation, it is critical that the generator set be allowed to operate for a cooldown period which is long enough for the breaker to completely charge before the generator set is shut down. If the generator set is shut down on a fault condition, the breaker may require manual recharge before the system can be put back into automatic operation.

4-34

TABLE 4-21b. FAIL TO CLOSE (226)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TO CLOSE” warning (226) or shutdown (226) message.

3. Breaker close signal has been issued from the PowerCommand control, but has not reached the breaker.

4. Breaker status (open/close) signals are not properly connected to the PowerCommand control, or are not operating properly.

3. Disconnect breaker control wiring and verify that the control is sending a close signal to the breaker. If the breaker signal is present at the generator set control, reconnect the control wiring at the set, verify that it is present at the breaker terminals. Note that in Onan paralleling systems, DC power for operation of the relay comes from the generator control. Verify that the 20 amp customer B+ fuse (F1 − engine harness assembly) is OK and that the pilot relay operates properly.

4. Verify that the breaker auxiliary contact wiring is properly connected to the generator set. Verify that the breaker is sending proper condition signals to the generator set, by disconnecting the control wiring at the breaker and verifying that the breaker auxiliary contacts change state when breaker condition changes. If they are functioning properly, verify that the signals are reaching the generator set by reconnecting the wiring and the breaker and checking for condition change at the generator set control accessory box.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-35

TABLE 4-22. DC (BATTERY) WARNINGS (230, 231, 232)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW DC VOLTAGE” (230) or “WEAK BATTERY” (232), warning message.

1. Weak or discharged battery.

2. Low electrolyte level in battery.

3. Battery connections loose or dirty.

4. Insufficient battery charging voltage.

5. Engine DC alternator could be bad.

6. If the batteries are OK, the problem may be the harness, the engine interface board (A31), the digital board (A32), or the analog board (A33).

1. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately

1.260 at 80° F (27° C).

2. Replenish electrolyte and recharge battery.

3. Clean and tighten or replace the battery cable connectors and cables at the battery and the set.

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

5. Replace engine DC alternator if normal battery charging voltage is not obtained.

*6. If the battery voltage, electrolyte, and connec-

tions are OK, check the battery voltage at A31 J5-17. If the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31.

If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (

Table 4-35a/b

).

“HIGH DC VOLTAGE” (231) warning message.

But battery voltage is OK.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

1. Excessive battery charging voltage.

2. Engien DC alternator could be bad.

3. If the battery voltage is OK, the problem may be the engine interface board (A31), the digital board (A32), or the analog board (A33).

4-36

1. Adjust charge rate of battery charging circuit ac cording to manufacturers instructions.

2. Replace engine DC alternator if normal battery charging voltage is not obtained.

*3. Check the battery voltage at A31 J5-17. If the

voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31.

If the voltage is OK, check battery voltage at A33 J1-31. If the voltage is not OK, replace A31. If the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (

Table 4-35a/b

).

TABLE 4-23. LOW FUEL −DAY WARNING (240)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW FUEL− DAY” warning message (240)

Fuel level is normal.

DS1 on the engine interface board, A31, is on.

“LOW FUEL− DAY” warning message (240)

Fuel level is normal.

DS1 (A31) and DS13 (A34) are off.

DS1 on A31 is on, indicating that A31 is receiving a low fuel signal from the sender.

The sender, the harness or the A31 circuit board could be bad.

DS1 on A31 is off, indicating that the PCC is not receiving a low fuel signal from the sender—but the 240 message indicates that A32, the digital board, is responding to a false low fuel signal.

A31, the engine interface board, or A32, the digital board, could be bad.

If the fuel level is normal, isolate the source of the low fuel signal.

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

1. If the 240 message drops out and does not reappear, replace the sender.

*2. If the 240 message reappears and remains af-

ter control reset, disconnect J4/A31 and check continuity from P4−14 to GND.

• If there is continuity, replace the harness.

• If there is no continuity, replace circuit

board A31.

If the fuel level is normal, isolate the source of the low fuel signal.

*1. Install a breakout connector at A32 J4.

2. Open the J4-15 circuit and reset the control.

• If the fault drops out and does not return, replace A31.

• If the fault returns after resetting the control, go to step 3.

3. Install harness tool between A32 J2/P2.

4. Opern the J2-19 circuit and reset the control.

• If the fault drops out and does not return, replace A31.

• If the fault returns after resetting the control, replace A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-37

TABLE 4-24. LOW FUEL WARNING (241)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW FUEL” warning message (241)

Fuel level is normal.

DS13 on the customer interface board, A34, is on.

“LOW FUEL” warning message (241)

Fuel level is normal.

DS13 (A34) is off.

DS13 on A34 is on, indicating that A34 is receiving a low fuel signal from the customer circuit. If there is no actual fault, the problem may be a short to ground in the external wiring or a bad customer interface board (A34)

DS13 on A34 is of f, indicating that the PCC is not receiving a low fuel signal from the sender—but the 241 message indicates that A32, the digital board, is responding to a false low fuel signal.

A34, the customer interface board, or A32, the digital board, could be bad.

.

If the fuel level is normal, isolate the source of the low fuel signal.

Disconnect the signal lead near the control and reset the control.

1. If the 241 message drops out and does not reappear, there is a short to ground in the external wiring or a faulty sender.

*2. If the 241 message reappears and remains af-

ter control reset, disconnect J1/A34 and check continuity from P1−5 to GND.

• If there is continuity, find and repair a short to ground in the external wiring.

• If there is no continuity, replace circuit board A34.

If the fuel level is normal, isolate the source of the low fuel signal.

*1. Install harness tool between A32 J2/P2.

2. Open the J2-19 circuit and reset the control.

• If the fault drops out and does not return, replace A34.

• If the fault returns after resetting the control, replace A32.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-38

TABLE 4-25. EEPROM ERROR SHUTDOWN (250) OR WARNING (251, 252)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“EEPROM ERROR” shutdown (250) message.

“EEPROM ERROR” warning (251) message.

The EE memory on the digital board (A32) may be bad.

1. Perform the initial start setup procedure. Turn the Run/Off/Auto switch to Off and reset the control. Simultaneously press the RESET, MENU, and PHASE SELECT keys to start the setup.

Select the correct values, save your choices, and attempt to start the set.

2. If the set shuts down on the same EEPROM ERROR message, replace the digital board (A32).

1. Perform the adjustment procedures (described

Section 5

in Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROM ERROR message, perform the calibration procedures in

Reset the control. Shut off and restart the set.

3. If the control generates the same EEPROM ERROR message, replace the digital board (A32).

). Save the adjustments.

Section 5

.

“EEPROM ERROR” warning (252) message.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

The EE memory on the digital board (A32) may be bad.

1. If this message occurred during an adjustment, option selection, or calibration of the PCC, verify the values or choices selected and repeat the save operation.

Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROM ERROR message, replace the digital board (A32).

4-39

TABLE 4-26. CUSTOMER FAULTS (260, 261, 262 or 263)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“CUSTOMER FAULT (260, 261, 262 or 263) message.

And corresponding LED on customer interface board A34 is on.

If the corresponding LED on the customer interface board (A34) is on, then A34 is receiving a signal from the customer circuit.

If there is no actual fault, the problem may be a short to ground in the external wiring or a bad customer interface board (A34).

Isolate the source of the false signal. Disconnect the signal lead near the control and reset

the control.

1. If the message drops out, there is a short to ground in the external wiring.

2. If the message remains, replace A34.

“CUSTOMER FAULT (260, 261, 262 or 263) message.

And corresponding LED on customer interface board A34 is off.

If the corresponding LED on the customer interface board (A34) is off, then A34 is not receiving a signal from the customer circuit.

The message indicates that A32, the digital board, is responding to a false signal.

A34, the customer interface board, or A32, the digital board, could be bad.

Isolate the source of the false signal. Check J2/P2 on A32.

*1. Install harness tool between A32 J2/P2.

2. Open the appropriate circuit J2-3, J2-24, J2-9, or J2-15 and reset the control.

• If the fault does not return, replace A34.

• If the fault reappears, replace A32.

A 34

LED

DS4 DS11 DS15 DS3

A32

CONNECTOR

J2-3 J2-24 J2-9 J2-15

CUSTOMER

FAULT #

1 2 3 4

FAULT

CODE

260 261 262 263

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-40

TABLE 4-27a. PHASE ROTATION (270)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“PHASE ROTATION” shutdown (270) message.

1. Single phase bus condition.

2. Generator set output power feeders are improperly connected.

1. Verify that bus voltage is proper and is not single phased.

2. Verify phase rotation of the generator set output relative to the system bus. Correct wiring of power output conductors if required. The phase relationship between the generator set and the system bus can be checked by either using a phase rotation checker, o r b y using synchronizing lamps or two voltmeters. The procedure for using voltmeters for checking phase relationship is as follows:

Energize the system bus and start the generator set in question in the RUN mode, but do not close the paralleling breaker. Connect each voltmeter from the line to load side of a single phase of the paralleling breaker (see Figure 8-1). If the generator set and bus have the same phase rotation, the voltmeters should rise and fall in voltage at the same time. If they are not in phase, one will rise while the other falls.

Continued On Next Page...

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-41

TABLE 4-27b. PHASE ROTATION (270)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“PHASE ROTATION” shutdown (270) message.

3. Wiring to bus PT module is not correct.

3. If power conductors are properly phased, check the phase rotation of the wiring to the generator set CT/PT module (A36) and Bus PT module (A39). This is done using voltmeters connected as shown in Figure 8-1. Energize the system bus and start the generator set being tested in the RUN mode. Operate the display screen on the PowerCommand control to show the digital synchroscope (bus frequency). Observe the voltmeter(s) and the synchronized indicator (*) on the PowerCommand screen. When the voltage of the meter(s) approaches zero, the * should be displayed. If the * is on when the voltmeters are reading their highest value, the Bus PT module or the genset CT/PT module is incorrectly wired. If incorrect wiring is indicated, switch off the power supply to the system bus and manually close the paralleling breaker by pushing the breaker close switch on the front of the PowerCommand control. Check the voltage between phase L1 of the generator CT/PT module (J9-4 yellow) and phase L1 of the Bus PT module (terminal TB1-1 on the module). If there is voltage difference between these points, reverse the wiring between TB1-1 and TB1-3 on the Bus PT module. Retest the system to be certain that the phase relationship problem has been corrected. If no voltage difference is sensed at the input to the CT/PT module and Bus PT module, the problem could be in the wiring between the Bus PT module and the PowerCommand control. Reverse the connections between terminals TB2-1, 2 with TB2-5, 6. Retest the system to make sure that the phase relationship problem has been corrected.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-42

TABLE 4-28. FIRST START (272)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FIRST START” warning (272) message.

1. Master First Start Sensor has failed.

2. Interconnection between Master First Start Sensor and the PowerCommand control has failed.

1. Verify that the Master First Start Sensor is properly functioning. This can be accomplished by connecting a DC voltmeter from ground to the appropriate terminal on the Master First Start Sensor to the PowerCommand Control. The voltmeter should indicate a pulsing voltage present on the terminal.

2. Verify that the voltage pulse is present at the PowerCommand Control (terminal TB1−50). Check and repair any problems in the interconnection wiring between the generator set and the Master First Start Sensor.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-43

TABLE 4-29a. HIGH AC VOLTAGE SHUTDOWN (301)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“HIGH AC VOLTAGE ” shutdown (301) message.

1. The problem may be in the PCC, the alternator, or the interconnection between them.

Note 1: The PCC may indicate either a low AC Voltage or High AC Voltage shutdown due to the design of the logic in the control.

You must first determine if the output voltage the control sees is low or high.

Note 2: Residual voltage is normally 5 to 10% of nominal output voltage. For example, a genset with a 480 volt outpu t , will have a residual voltage of 25 to 50 VAC at normal operating speed.

1. Set the display on the PCC to GEN, VOLTS, L-N.

a. Start the genset and observe the voltage

displayed on the digital display.

b. If all phases of voltage are balanced and not

zero, but lower than normal, the alternator and the input to the PCC are OK. The problem is in the excitation circuit for the alternator. Go to step 2.

c. If one or more phases of voltage are high or

the voltages are unbalanced, the PCC is not measuring all phases of voltage and is responding to the low “average” of the three phases of voltage. Go to step 3.

(Continued)

2. The problem may be the regulator module (A37), the engine interface board (A31), or the digital board (A32).

2. With DC power to the PCC and with the set not running, check A31 DS9, the AVR duty cycle LED. this LED should be off. If it si on, go to step 2d.

Isolate the genset output from the load. Disconnect A37 J10, and place the set in Idle mode. In Idle mode the excitation circuit is disabled. Start the set and monitor the AC output voltage with a digital multimeter.

a. If output voltage is greater than residual (5%

of normal output), go to step 3.

b. If output voltage stays at 0 (or residual), and

DS2 on A37 is off, go to step 4.

c. If output voltage stays at 0 (or residual), and

DS2 on A37 is on, look at DS9 on A31. If DS9 on A31 is off, replace A37.

d. If DS9 on A31 is on, connect a breakout con-

nector at A32 J4, and open J4-2. If DS9 goes out, replace A32. If DS9 stays on replace A31.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-44

TABLE 4-29b. HIGH AC VOLTAGE SHUTDOWN (301)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“HIGH AC VOLTAGE ” shutdown (301) message.

3. The problem may be the PT/CT module (A36) or the interconnecting wiring to the PT/CT module.

NOTE: To calculate the “expected A36 output” voltage range, do the following:

Determine the ratio between the measured voltage and the expected voltage. The output (18 VAC) of the PT/CT module will also be reduced by this ratio.

4. The problem may be in the customer interface board (A34) or the interconnecting wiring.

*3. Before starting the generator set, discon-

nect the harness connector from the PT/CT module (A36) and connect the harness tool between A36 and its harness connector.

Check the output voltage at the alternator

output terminals and record the voltages. a. If the voltages are not balanced, go to step 5. b. If the voltages are balanced, calculate the

expected output voltage from the PT/C mod-

ule (see Note to the left). Measure and re-

cord the outputs from A36 J8 pins 6−5, 4−3,

and 2−1.

If the output voltage is proportional to the alternator output voltage the A36 module is OK. Go on to step 4.

If the voltages are not balanced, replace A36.

*4. Disconnect the plugs in the following steps

below with the set off then start the set in the

idle mode, and measure voltages with a digi-

tal multimeter. a. Disconnect J3/P3 (blue) and insert the har-

ness tool. Check the voltage into the cus-

tomer interface board with the harness tool

at J3 terminals 4−6, 5−13, and 7−20. Re-

move the harness tool and reconnect J3 and

P3. These voltages should be the same val-

ues measured in step 3b.

If the voltages are balanced, continue in this

step. If the voltages are unbalanced, repair

the harness between the A36 module and

the A34 board. b. Disconnect J5/P5 on the customer interface

board and insert the harness tool. Check the

voltage out of the customer interface board

at J5 terminals 24−28, 26−28, and 30−28.

These voltages should be the same values

measured in step 3b.

If the voltages are balanced, go to step 5. If

the voltages are unbalanced, replace the

customer interface board.

(Continued)

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-45

TABLE 4-29c. HIGH AC VOLTAGE SHUTDOWN (301)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“HIGH AC VOLTAGE ” shutdown (301) message.

5. The problem may be the analog board (A33).

NOTE: To determine the “3-phase ave” signal voltage range for Step 3b, use the following formula:

V

3-phase ave = Vin (2.9÷PT) ±5%

out

V

= Actual generator output voltage

in

(phase-to-neutral) PT = PT primary (120, 240 or 346)

6. The problem may be in the generator set itself.

*5. Using the harness tool, check the “3-phase

ave” signal at A33 J2-18. If the voltage is within the expected range,

replace A32. If the voltage is not within the expected range, replace A33. See Note.

6. Refer to the generator servicing procedures in

Section 6

.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-46

TABLE 4-30a. LOW AC VOLTAGE SHUTDOWN (303)

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WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW AC VOLTAGE ” shutdown (303) message.

1. PMG or field wiring could be faulty.

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

3. Overload.

4. There may be a loose connector in the control loop.

5a. The problem may be the analog board

(A33) or the digital board (A32).

5b. The problem may be the regulator

module (A37), the engine interface board (A31), or the digital board (A32).

1. If output voltage is low and both A37/DS2 and A31/DS10 are on, check and repair the PMG or field wiring.

2. Check each diode according to

Generator

3. Check the load and correct any overload.

4. Check connectors J8 and J9 on A36, J3 and J5 on A34, and J7 on A37.

*5. Isolate the genset output from the load. Reset

the control, restart the set, and measure AC output voltage with a multimeter.

a. If output voltage is high, refer to the trouble-

shooting section for High AC Voltage Shutdown (301).

If output voltage is normal, the problem must be in the voltage sensing circuitry (A32 or A33).

Isolate, using the analog input troubleshooting procedure ( that shows a low voltage on the PCC display.

*b. If output voltage is low, the control cannot drive

the output voltage high enough. The problem could be A37, A31, or A32. Restart the set and monitor isolated B+ supply LED A37/DS1, output duty cycle LED A37/DS2, and AVR duty cycle LED A31/DS10.

• If A37/DS1 is not on, disconnect A3 J7/P7 and check for B+ at P7-1. (Control must be in Run mode for B+ reading.)

• If B+ is OK to A37, replace A37.

• If A37/DS1 is on, check A31/DS10 (with the

set running).

• If A31/DS10 is not on with set running, check for continuity: A31 J1-2 to J4-10 and A31 J1-1 to J4-11 (270 ohms). If no continuity, r e place A31.

• If A31is OK, replace A32.

• If A31/DS10 is on with set running and

A37/DS2 is not on, check the harness.

• If the harness is OK, replace A37.

in

Section 6

Table 4-36a/b

. Service as necessary.

). Check the phase

Servicing the

(Continued)

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-47

TABLE 4-30b. LOW AC VOLTAGE SHUTDOWN (303)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“LOW AC VOLTAGE ” shutdown (303) message.

5c. The problem may be the PT/CT mod-

ule (A36), the analog board (A33), the customer interface board (A34), or the digital board (A32).

c. If the measured AC voltage is high, the control

must have lost AC sensing. Check PTs (primary 1K−2.5K ohms; secondary 140−225 ohms), sensing harness wires, generator output connections, and the customer interface board for continuity . If these are OK, then check the analog and digital boards, using the analog input troubleshooting procedure (

Table 4-36a/b

).

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-48

TABLE 4-31. UNDER FREQUENCY SHUTDOWN (313)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“UNDER FREQUENCY” shutdown (313) message.

1. Improper setup.

2. Overload.

3. Fuel or air delivery problem.

4. The governor output module (A38), the digital board (A32), or the engine interface board (A31) could be bad.

1. Check Initial Setup (set size) and correct, if necessary.

2. Check the load and correct any overload, if necessary.

Disconnect the load. Reset the control and attempt to restart the generator set.

3. If the engine starts and runs, refer to the engine fuel/air delivery service procedures.

*4. Disconnect the wire to the fuel solenoid, reset

the control, and crank the set. DS2 on the governor output module A38 should light.

If the duty cycle LED (DS1) on the governor output module (A38) slowly becomes bright, the governor output module(A38), the digital board (A32), and the engine interface board (A31) are functioning properly.

If DS1 does not light or instantly becomes bright, A31, A32 or A38 may be bad.

A38 - Crank the set, and check the governor duty cycle on the PCC display. If the duty cycle is OK (60% max), replace governor output module (A38).

If the duty cycle is not OK, the digital board (A32) or the engine interface board (A31) may be bad.

• A31 - Check for continuity: A31 J1-13 to A31 J4-19 and A31 J1-14 to A31 J4-12. If no continuity, replace A31.

• A32 - If A31 is OK, replace A32

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-49

TABLE 4-32. OVERCURRENT WARNING (320) OR SHUTDOWN (321),

Redistribution or publication of this document by any means, is strictly prohibited.

SHORT CIRCUIT SHUTDOWN (322), OR OVERLOAD WARNING (330)

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“OVERCURRENT” warning (320) or shutdown (321), or “SHORT CIRCUIT” shutdown (322), or OVERLOAD warning (330) message.

1. Short or Overload.

2. Incorrect CTs or CT connections.

3. The problem may be a bad PT/CT module (A36).

4. The problem may be the customer interface board (A34) or connections.

5. The problem may be the analog board (A33) or the digital board (A32).

1. Check the load and load cables. Repair if necessary.

2. Check CTs and CT connections. Correct if necessary . R efer to

Section 5

3. Disconnect the PT/CT module and check the 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary.

*4. Check continuity from A36—through A34—to

A33. Repair the connection or replace A34 if necessary. Refer to

5. Isolate, using the analog input troubleshooting procedure ( phase or phases.

Current Transfer Installation

.

Table 4-35a/b

Section 9

). Check the bad

in

for pin reference.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-50

TABLE 4-33. REVERSE POWER (335)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“REVERSE POWER” shutdown (335) message.

1. If this shutdown condition occurs when a non-paralleled generator set is loaded, it indicates that the generator set output CT’s or PT’s are incorrectly installed.

1. Verify proper CT orientation, wiring and connections on the control system. Refer to

Current Transformer (CT) Installation Section 5

. Make sure that the no load fre-

in

quency matches the bus frequency . Check metering calibration for both generator set and bus.

2. Verify that the generator set is operating at the correct frequency

2. Make adjustments as required for proper operation.

and voltage. The bus voltage and frequency should be the same as the no-load generator set frequency and voltage.

3. The load sharing line connections and orientation must be correctly accomplished for proper load sharing.

3. Verify that load sharing connections are made as noted in the drawings and that there are no damaged or disconnected wires.

4. If the alarm occurs when a large load is added or shed, dissimilar transient response of the generator sets in the system may cause the reverse power condition.

5. Reverse power alarm can also indicate that the generator set is unable to carry load properly.

4. Apply various load steps to each generator set in the system, noting the voltage and frequency dips/surges and recovery times. The generator sets should be adjusted so that transient load performance is approximately the same in all machines in the system.

5. Verify that the generator set can pick up and carry loads properly, up t o the rated capacity of the machine. Inability to carry load can be related to engine misadjustments, component failures, or poor fuel quality. Check governing system for binding or sticking. Check fuel filters and fuel lines for cracks, leaks or dents. Check air cleaner(s) for obstructions.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-51

TABLE 4-34. LOSS OF EXCITATION (337)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv .

Indicator(s) Possible Cause Corrective Action

“LOSS OF EXCITATION” shutdown (337) message.

1. Improper voltage adjustment of the generator set relative to the system bus.

2. Load sharing line mis-connection or damage.

3. If condition occurs when the generator set is lightly loaded, leading power factor loads may cause this condition.

1. Verify that the no load voltage of the generator set matches the bus voltage. Check generator set metering calibration for both generator set and bus readings. If no problems are found, check the paralleling adjustments in the PowerCommand control, to see if they match the default settings in the generator set test report.

2. Verify load sharing line connections and condition. Make corrections as required.

3. Loss of Excitation failure may also be caused by operation of filters and power factor correction capacitors in the generator set loads when the kW load level on the genset is low. The capacitors in the filters and power factor correction equipment can present a leading power factor load to the generator set, which (correctly) shuts down the generator set through the loss of excitation fault. Leading power factor loads can cause the generator set to lose control of the output voltage of the genset, and can cause kVar load sharing problems, so it is necessary to protect the genset from excessive leading power factor and reverse var conditions.

For generator sets prior to the release of version 2.0 firmware:

Check the load for devices which may apply leading power factor loads to the generator set. These include power factor correction capacitors, input filter and some non-linear load devices with internal voltage waveform correction provisions. These devices may need to be disconnected from the bus until other loads are added to the system.

For generator sets with version 2.0 and higher firmware:

(Continued)

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

If there is a loss of excitation fault that cannot be explained by genset component failures or misadjustments, perform the following steps:

4-52

TABLE 4-34. LOSS OF EXCITATION (337) (Continued)

Redistribution or publication of this document by any means, is strictly prohibited.

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv .

Indicator(s) Possible Cause Corrective Action

“LOSS OF EXCITATION” shutdown (337) message.

3. (continued)

a. Start the generator set and apply system

loads in their normal operation sequence. Observe the output voltage, power factor, and % voltage regulation of the generator set as the loads are applied. (This may take more than one test.)

b. If the voltage does not rise and the % volt-

age regulation is greater than 0 as the system loads are applied, extend the time delay on loss of excitation shutdown and repeat the load addition test.

c. If the increase in time delay does not re-

solve the shutdown condition, contact the factory for the maximum permissible setting of the loss of excitation shutdown set points.

d. If the voltage rises or the % voltage regula-

tion value drops to 0 and does not rise as load is applied, investigate means to remove leading power factor loads from the genset bus.

4. The generator set may be incapable of carrying full reactive load due to component failures.

5. If transient conditions result in this alarm condition, the PowerCommand control internal set points may need adjustment.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4. See section 6 of this manual, “Servicing the Generator, Exciter Rectifier and Exciter Rotor”. See also repair and diagnosis process for ”Low AC Voltage” in this section.

5. Consult factory.

4-53

TABLE 4-35a. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL

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BOARDS

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

NOTE: Perform this procedure after you have isolated the problem to either the analog

board (A33) or to the digital board (A32). You must have schematics and wiring diagrams to identify the various inputs and outputs.

*1. Check that the input to the analog board is correct. There are a few signals (e.g.: 3PH Ave, Line Freq,

Phase Angle 1 to 3, Lead Lag) that are derived from one or more input signals.

1a. To check the sensor input voltages into the analog board, connect the sender simulator and test the

voltage across the + and − inputs at A33 J1 using harness tool. (This assumes that you have verified that the harness and the engine interface board is good.)

• If the input voltage to the analog board is correct (refer to Table 4-36), go to step 2.

• If the input voltage to the analog board is incorrect, check for 12 VDC at A32 J3-20 and 5 VDC at

A32 J3-12. Do this with the analog board connected to the digital (A32).

If the 12 VDC and 5 VDC voltages are OK, replace the analog board. If the 12 VDC and 5 VDC voltages are not OK, disconnect A32 J3 and recheck for 12 VDC at

A32 J3-20 and 5 VDC at A32 J3-12.

If the 12 VDC and 5 VDC voltages are now OK, replace the analog board. If the 12 VDC and 5 VDC voltages are still not OK, replace the digital board.

1b. To check the AC inputs into the analog board, drive the PT/CT inputs (voltage or current) and verify

that the input is correct.

• If the input to the analog board is correct, go to step 2.

• If the input to the analog board is incorrect, disconnect the ribbon cable at A34 J5 and check the volt-

age at A34 J5 again (Customer Interface).

If the voltage is now correct, replace the analog board. If the voltage is still not correct, the problem is not on the analog or digital boards.

2. If the input to the analog board is correct, determine whether the signal is multiplexed (refer to Table 4-36). If the signal is not multiplexed, go to step 2a. If the signal is multiplexed, go to step 2b.

2a. This step is for non-multiplexed AC signals. Drive the input to the analog board with an AC source,

and test the signal level out of the analog board. You must calculate what the analog output voltage should be (Table 4-36), assuming the analog board transfer function is linear.

• If the signal level into the digital board is correct, the problem must be on the digital board. Replace the digital board.

• If the signal level into the digital board is incorrect, remove the ribbon cable connector at A32 J3, and check the front panel digital display of the bad analog value.

If the display reads 0, replace the analog board. If the display reads a value other than 0, replace the digital board.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-54

TABLE 4-35b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND

Redistribution or publication of this document by any means, is strictly prohibited.

DIGITAL BOARDS

WARNING

Many troubleshooting procedures present hazards that can result in severe personal injury or death. Only trained experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

NOTE: Perform this procedure after you have isolated the problem to either the analog

board (A33) or to the digital board (A32). You must have schematics and wiring diagrams to identify the various inputs and outputs.

2b. This step is for multiplexed signals. Is more than one multiplexed signal reading bad?

• No. If the input to the analog board is correct and only one multiplexed signal is reading bad, replace the analog board.

• Yes. If more than one multiplexed signal reading is bad, remove the ribbon cable connector at A32 J3 and check the front panel digital display of the bad inputs. It should read 0 for all inputs except the temperature inputs (which should read less than 32° F or less than 0° C) and power factor (which should read “NA”).

If any values read incorrectly, replace the digital board. If they all read correctly, measure voltages on the multiplexer control lines (with A32-J3 discon-

nected, measure from Digital board connector J3). Voltages should be:

A32-J3-23: 3.0 ±0.25 VDC A32-J3-24: 2.4 ±0.25 VDC A32-J3-27: 1.4 ±0.25 VDC A32-J3-33: 3.0 ±0.25 VDC

A32-J3-34: 3.0 ±0.25 VDC If these control (select) line voltages are not correct, replace the digital board. If these control (select) line voltages are correct (and the input to the analog board is correct),

reconnect the ribbon cable connector (through harness tool) at A32 J3 and check the 5 VDC reference at A32 J3-12 and the 12 VDC supply at A32 J3-20.

If the 5 VDC and the 12 VDC voltages are OK, replace the analog board.

If the 5 VDC and the 12 VDC voltages are not OK, disconnect A32 J3 and check the

voltages again (measured from Digital board side).

If the 5 VDC and the 12 VDC voltages are OK with A32 J3 disconnected, replace the analog board.

If the 5 VDC and the 12 VDC voltages are not OK with A32 J3 disconnected, replace the digital board.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-55

TABLE 4−36. ANALOG CIRCUIT BOARD (A33) INPUTS AND OUTPUTS

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Input Name Input

Connection

L1 (0 to nominal) J4-24 to J4-28 0 to 18 VAC L10 (ACH1) J2-4 0 to 3.0 VDC L2 (0 to nominal) J4-26 to J4-28 0 to 18 VAC L20 (ACH2) J2-13 0 to 3.0 VDC L3 (0 to nominal) J4-30 to J4-28 0 to 18 VAC L30 (ACH3) J2-1 0 to 3.0 VDC

CT21 (0 to full load) J4-33 to J4-34 0 to 1.65 VAC C1 fltrd (ACH4) J2-3 0 to 1.0 VDC CT22 (0 to full load) J4-32 to J4-34 0 to 1.65 VAC C2 fltrd (ACH5) J2-9 0 to 1.0 VDC CT23 (0 to full load) J4-31 to J4-34 0 to 1.65 VAC C3 fltrd (ACH6) J2-17 0 to 1.0 VDC

(1 to 0.8 pf) Phase angle 1 (ACH7) (1 to 0.8 pf) Phase angle 2 (ACH7) (1 to 0.8 pf) Phase angle 3 (ACH7)

(L1 vs CT21) Lead lag (P2A.1)) Bus L1 (0 to nominal) Bus L2 (0 to nominal) Bus L3 (0 to nominal)

6

J4-15 to J4-18 0 to 18 VAC Bus L1 (ACH7) J2-7 0 to 3.0 VDC J4-16 to J4-18 0 to 18 VAC Bus L2 (ACH7) J2-7 0 to 3.0 VDC J4-17 to J4-18 0 to 18 VAC Bus L3 (ACH7) J2-7 0 to 3.0 VDC

Input Signal

Range

Output Name

3PH ave (ACH0) J2-18 0 to 2.9 VDC Line freq. (HSI.1) J2-21 0-5V sq wave @ L1 Hz

C1 (ACH7) J2-7 0 to 1.0 VDC C2 (ACH7) J2-7 0 to 1.0 VDC C3 (ACH7) J2-7 0 to 1.0 VDC

1

3

Output

Connection

J2-7 0 to 1.0 VDC J2-7 0 to 1.0 VDC J2-7 0 to 1.0 VDC

J2-29 0 or 5 VDC (digital)

2

Output

Signal Range

Bus freq (HS1.3) J2-22 0-5V sq wave @ Bus L1 Hz Phase rot (P2A.0) Bus/gen phase dif (ACH7) Bus/gen phase (HS1.2)

Synch (ACH7) Battery voltage J1-31 (+) to J1-30(−) 0 to 32 VDC Battery voltage (ACH7) J2-7 0 to 2.9 VDC Oil press (0 to 100 psi) (See note H2O 1 (6 to 230° F) J1-19/20 to J1-17/18 700 to 1800 Ω H2O 1 (ACH7) J2-7 1.4 to 3.7 VDC H2O 2 (6 to 230° F) J1-15/16 to J1-14/15 700 to 1800 Ω H2O 2 (ACH7) J2-7 1.4 to 3.7 VDC Oil temp (6 to 230° F) J1-11/12 to J1-9/10 700 to 1800 Ω Oil temp (ACH7) J2-7 1.4 to 3.7 VDC Exh temp 1 (32 to 1471° F) J1-7/8 to J1-5/6 100 to 376 Ω Exh temp 1 (ACH7) J2-7 0.8 to 3.0 VDC Exh temp 2 (32 to 1471° F) J1-3/4 to J1-1/2 100 to 376 Ω Exh temp 2 (ACH7) J2-7 0.8 to 3.0 VDC

4 )

0.5 to 4.5 VDC Oil press (ACH7) J2-7 0.5 to 4.5 VDC

5

J2-26 0 or 5 VDC (digital)

5

J2-7 0 to 5.0 VDC

J2-19 0-5V 120 Hz 0 to 100% DC

J2-7

Notes:

1. All output signals on ACH7 are multiplexed.

2. All output voltages on A33 J2 are referenced to ground (J2-15 and J2-16).

3. Must have L1, L2, L3, CT21, CT22, and CT23 for these phase angle outputs.

4. J1-24 (5VDC), J1-23 (signal), J1-18 (return).

5. Must have L1, L2, L3, Bus L1, Bus L2, and Bus L3 for these outputs.

6. L1, L2, and L3 can be 0 to 180° out of phase with Bus L1, Bus L2, and Bus L3, respectively.

4-56

TABLE 4-37. PCC FUSES

Redistribution or publication of this document by any means, is strictly prohibited.

REFERENCE

LOCATION

Engine Interface A31-F1 5 Amp PCC control B+ Engine Interface A31-F3 5 Amp Auxiliary B+ (for panel lights, run and start relays)

DESIGNATION

RATING FUNCTION

Governor Output Module

TB-Bat (Engine Harness Assembly)

A38-F1 10 Amp Network B+ (to TB1 customer terminal block)

A38-F2 10 Amp Switched B+ (to TB1 customer terminal block)

A38-F3 10 Amp Governor B+ (power for governor output module and

actuator)

F1 20 Amp Customer B+ (to TB1 customer terminal block)

4-57

LOAD SHARING CONTROLS

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TROUBLESHOOTING PROCEDURE

The generator set load sharing settings in the PowerCommand control are factory set and normally do not require adjustment. The controls are designed to cause generator sets in the paralleling system to share load proportionally , based on the standby ratings of the generator sets in the system.

When the system is operating normally, the generator sets in an isolated bus (not utility/mains paralleled) paralleling system will share both real (kW) and reactive (amps) load equally, within plus or minus 5%. For example, if two 1000 kW generator sets are paralleled and serving a 2000 kW load, the generator sets should each carry between 950 and 1050 kW.

If the generator set is not sharing load properly, the following procedure can be used to diagnose and solve the problem:

1. The no load speed and voltage of the generator set must be the same as the system bus. Measure the bus voltage and frequency, and the generator set voltage and frequency with a true RMS digital meter. Calibrate the voltage and current sensing circuits of the control, and make required adjustments to voltage and frequency to match bus conditions. Adjusting the voltage and frequency after the generator set is paralleled to the bus will cause load sharing to be unequal between generator sets.

2. Check to make sure that the load sharing control wiring is properly connected.

In actual practice, load sharing may be much more precise than plus or minus 5%, but you should not be concerned about operational problems unless the load sharing is in error by more than 5%. If dissimilar generator sets are used in a system, there may be load sharing inequities for a short time when loads are applied, but the steady state load sharing should perform to the plus or minus 5% standard.

If the generator set is paralleled to a utility (mains) gird, the amount of load on the generator set is programmed into the control in the setup mode or set from a remote device. It is NOT a function of the load sharing control system. See

Section 5

for more information on load sharing set−up functions, and utility (mains) paralleling set−up.

3. Check to make sure that each generator set in the system is capable of carrying its rated load.

4. Fine adjustment to the amount of load carried by each generator set can be made by adjusting the KW BALANCE and KVAR BALANCE settings under the paralleling setup menu (

Section 5

).

5. If the generator sets share load approximately

equally , but there is an oscillating load circulating between the generator sets, the governor gain may be set too high. Reduce the governor gain (see

Setup Menu, Section 5

).

6. Consult factory for any other load sharing prob-

lems.

4-58

5. Control Service and Calibration

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GENERAL

This section contains circuit board removal and replacement procedures, calibration procedures for the genset control and test procedures for the generator and engine components. Refer to the figures included with this information and also the

Diagrams

Before servicing the PCC, all settings should be recorded. This will enable correct and complete readjustment of the PCC in the event that all previous entries are lost during servicing.

section when instructed.

CIRCUIT BOARD

Analog Board (A33)

TABLE 5-1. CONTROL PANEL RECALIBRATION

1. Voltage, Current and PF.

2. Coolant Temperature L & R

Wiring

ADJUSTMENT PROCEDURE / PAGE

CIRCUIT BOARD

REMOVAL/REPLACEMENT

No special tools (other than a grounding wrist strap) are required to remove a circuit board from inside the control panel or the accessory box.

There are several circuit boards that, when replaced, require you to recalibrate the control panel functions. Table 5-1 lists the circuit boards and the appropriate procedure to perform to recalibrate the control panel. The circuit board locations are shown in Figure 5-1.

Before you attempt to remove a circuit board, read the

Circuit Board Removal Safety Precautions

this section.

Setup and Calibration Menus

(Page 5-8)

in

Digital Board (A32) Must recalibrate all values, starting with

the

Initial Start Setup

PT/CT Board (A36) Voltage, Current and PF.

Bus PT Module (A39) Voltage

procedure.

1.

Initial Start Setup

2.

Adjust Menu

3.

Setup and Calibration Menus

5-8).

Setup and Calibration Menus

(Page 5-4).

(Page 5-6).

(Page

(Page 5-8)

5-1

DISPLAY BOARD

Redistribution or publication of this document by any means, is strictly prohibited.

A35

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

ANALOG BOARD

A33

BUS PT MODULE

A39

VOLTAGE REGULATOR

OUTPUT MODULE

A37

ENGINE INTERFACE

A31

ACCESSORY BOX

(HC 4/5)

FIGURE 5-1. CIRCUIT BOARD LOCATIONS

CUSTOMER INTERFACE

A34

GOVERNOR

OUTPUT MODULE

A38

PT/CT BOARD

A36

5-2

Circuit Board Removal Safety Precautions

Redistribution or publication of this document by any means, is strictly prohibited.

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.)

Attach the clip to a non -painted surface of the control box and place the strap around your wrist before handling a circuit board.

CAUTION

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.

Electrostatic discharge will damage

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.

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.

WRIST STRAP

NON-PAINTED

SURFACE

GROUND LEAD CLIP

FIGURE 5-2. WRIST STRAP

5-3

INITIAL START SETUP MENU

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The facing page shows a block representation of the INITIAL START SETUP menu.

CAUTION

Selecting this menu resets all operating parameters to the default values for the selected set. All previously selected setup and adjustment settings will be lost. Therefore, this procedure must be performed by technically qualified personnel only.

This menu appears on the digital display when the PCC has not been set up for use with a generator set during factory test, or the digital board was replaced in the PCC.

When this display is showing, you must go through the Initial Start Setup menu to select the operating parameters for the generator set. These include whether the set will be used for Prime Power or Standby use, the Model Number of the generator set, and its operating frequency and output voltage. These choices must be saved into the PCC’s readonly memory before the PCC will accept changes made to other menus.

STANDBY/PRIME submenu:

Use the buttons next to the “⇑⇓” symbols to toggle the standby/prime option. Press the button next to the “>>” in the display to move to the model select submenu.

MODEL select submenu:

the “

⇑” and “⇓” symbols to select the correct genera-

Use the buttons next to

tor set model number, frequency and power rating.

VOLTAGE SELECT submenu:

Use the buttons next to the “⇑” and “⇓” symbols to select the correct generator set nominal line-to-line output voltage.

If the PCC is already set up to operate with a specific generator set, this menu will not appear when power is applied. To reset the control and display the Initial Start Setup menu, you can press RESET, MENU, and PHASE SELECT buttons at the same time.

If you choose to do this, the governor/regulator adjustments and the setup options will be reset to the default settings (including the editable customer fault messages). Display calibrations (volts, amps, PF and coolant temperature) are retained (not reset). To ensure correct and complete readjustment of the PCC, it is suggested that all settings be recorded before you perform the reset function.

CAUTION

Improper setup, calibration, or adjustments can cause equipment malfunction or damage. Setup, calibration, and adjustment must be performed by technically qualified personnel only.

DELTA / WYE submenu:

the “

⇑” and “⇓” symbols to select the delta or wye op-

Use the buttons next to

tion.

SAVE submenu:

From the model select submenu, press the button next to the “>>” in the display to move to the SAVE submenu. Select SAVE to save your changes. The MAIN MENU will then be displayed.

5-4

INITIAL START SETUP

Redistribution or publication of this document by any means, is strictly prohibited.

(It can be invoked by simultaneously pressing

the Reset, Menu, and Phase Select keys.)

STANDBY/PRIME

⇓⇑ _______ >>

<>

⇑ MODEL

<

⇓ (kw mod# freq) >>

<>

⇑ VOLTAGE SELECT

<

⇓ (vac) L-L VAC >>

<>

DELTA / WYE

⇓⇑ _______ >>

<>

TO LOOP BACK & CHECK:

<>

SAVE >>

<>

ENGINE GEN ADJUST >>

<>

STANDBY/PRIME

⇓⇑ _______ >>

<>

Indicates OR" Condition

5-5

ADJUST MENU

Redistribution or publication of this document by any means, is strictly prohibited.

The ADJUST submenus permit adjustment of the output voltage and frequency and the start and stop delay times of the generator set.

The complete calibration procedure is described in the

Calibration Procedure

in this section.

The facing page shows a block representation of the ADJUST menu. If you press the button next to the word “ADJUST” in the Main menu, the VOLTAGE ADJUST submenu will appear.

As shown in the diagram, the ADJUST menu has five submenus, including a save/exit procedure.

Voltage and frequency can be adjusted only when the generator set is running under normal operating parameters (not in idle mode). For example, if voltage adjustment is selected when the set is in Idle mode or not running, the digital display will be:

“⇑ VOLTAGE ”

⇓ N/A >>”

“

VOLTAGE submenu:

Use the buttons next to the “ adjust output voltage

FREQUENCY submenu:

This is the first submenu.

⇑” and “⇓” symbols to

± 5%.

From the VOL TAGE submenu, press the button next to the “>>” in the display to move to the FREQUENCY submenu. Use the buttons next to the “ output frequency

START DELAY submenu:

⇑” and “⇓” symbols to adjust

± 5%.

This delay applies only to remote starting in the Auto mode. From the FREQUENCY submenu, press the button next to the “>>” in the display to move to the START DELAY submenu. Use the buttons next to the “

⇑” and “⇓”

symbols to set the start delay. The start delay adjustment range is 0 to 300 seconds.

STOP DELAY submenu:

This delay applies only to remote stopping in the Auto mode. From the START DELAY submenu, press the button next to the “>>” in the display to move to the STOP DELAY submenu. Use the buttons next to the “

⇑” and “⇓”

symbols to set the stop delay. The stop delay adjustment range is 0 to 600 seconds.

IDLE SPEED submenu:

From the STOP DELAY submenu, press the button next to the “>>” in the display to move to the IDLE SPEED submenu. Use the buttons next to the “

⇑” and “⇓” symbols to set the

idle speed. The idle speed adjustment range is 800 RPM

±100 RPM. (Default value is 800 RPM.)

The idle speed can be adjusted only when the gener-

.

ator set is running in the idle mode mode, N/A is displayed in RPM field.

SAVE/EXIT submenu:

From the STOP DELAY

When not in idle

submenu, press the button next to the “>>” in the display to move to the SAVE/EXIT submenu. Select SAVE to save your changes. At the CHANGES SAVED submenu, select EXIT to return to the main menu.

If you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the set is restarted. If you select EXIT without saving first, the adjustments will remain in effect until the genset is shut down, but will be reset (and will not be in effect) when the set is restarted.

5-6

CUMMINS DFAB, DFBE, DFBF, DFCC, DFCE Operation & Service Manual

Table of Contents

IMPORTANT SAFETY INSTRUCTIONS

1. Introduction

2. Control Operation

3. Circuit Boards and Modules

4. Troubleshooting

5. Control Service and Calibration