CUMMINS PowerCommand 3100 Service Manual

Ser

vice Manual

Controller

PowerCommand® 3100

English
Original Instructions

9−2010

A034T570 (Issue 1)

Table of Contents

SECTION

TITLE

PAGE

IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

1

INTRODUCTION

About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

How To Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Generator Set Control Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2

CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

PCC Power On/Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Menu Display and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Engine Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Gen Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

3

CIRCUIT BOARDS AND MODULES

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Digital Board (A32) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Engine Interface Board (A31) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Analog Board (A33) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Digital Display Board (A35) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Customer Interface Board (A34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

PT/CT Board (A36) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Voltage Regulator Output Module (A37) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

Governor Output Module (A38) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

4

TROUBLESHOOTING

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Resetting the Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Warning and Shutdown Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

PCC Oil Pressure Warning and Shutdown Limits . . . . . . . . . . . . . . . . . . . 4-10

i

Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Rack Position Fault/Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46

5

CONTROL SERVICE AND CALIBRATION

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Circuit Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Initial Start Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Setup and Calibration Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

Calibration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

Accessory Box Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20

Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26

Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . . 5-30

Current Transformer (CT) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

ii

IMPORTANT SAFETY INSTRUCTIONS

EXHAUST GASES ARE DEADLY

SAVE THESE INSTRUCTIONS −

This manual contains

important instructions that should be followed during

• Provide an adequate exhaust system to properly

installation and maintenance of the generator and batter-

expel discharged gases away from enclosed or

ies.

sheltered areas and areas where individuals are

Before operating the generator set (genset), read the

likely to congregate. Visually and audibly inspect

Operator’s Manual and become familiar with it and the

the exhaust daily for leaks per the maintenance

equipment. Safe and efficient operation can be

schedule. Make sure that exhaust manifolds are se-

achieved only if the equipment is properly operated

cured and not warped. Do not use exhaust gases to

and maintained. Many accidents are caused by failure

heat a compartment.

to follow fundamental rules and precautions.

• Be sure the unit is well ventilated.

The following symbols, found throughout this manual,

Engine exhaust and some of its constituents are

alert you to potentially dangerous conditions to the op-

known to the state of California to cause cancer,

erator, service personnel, or the equipment.

birth defects, and other reproductive harm.

This symbol warns of immediate

MOVING PARTS CAN CAUSE SEVERE

hazards which will result in severe personal in-

PERSONAL INJURY OR DEATH

jury or death.

This symbol refers to a hazard or un-

moving parts.

safe practice which can result in severe per-

Before starting work on the generator set, discon-

sonal injury or death.

nect battery charger from its AC source, then dis-

connect starting batteries, negative (−) cable first.

This symbol refers to a hazard or un-

This will prevent accidental starting.

safe practice which can result in personal injury

or product or property damage.

secure. Tighten supports and clamps, keep guards

FUEL AND FUMES ARE FLAMMABLE

in position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity of

Fire, explosion, and personal injury or death can result

from improper practices.

moving parts, or while working on electrical equip-

ment. Loose clothing and jewelry can become

caught in moving parts.

less tanks are outside the engine compartment.

Fuel contact with hot engine or exhaust is a potential

ning, use extreme caution around hot manifolds,

fire hazard.

moving parts, etc.

spark, arcing equipment, or other ignition source

DO NOT OPERATE IN FLAMMABLE AND

near the generator set or fuel tank.

EXPLOSIVE ENVIRONMENT S

Flammable vapor can cause an engine to overspeed and

leaks. Fuel connection at the engine should be

become difficult to stop, resulting in possible fire, explo-

made with an approved flexible line. Do not use zinc

sion, severe personal injury and death. Do not operate a

coated or copper fuel lines with diesel fuel.

genset where a flammable vapor environment can be

created by fuel spill, leak, etc., unless the genset is

valve.

equipped with an automatic safety device to block the air

intake and stop the engine. The owners and operators of

to servicing near it. Lead-acid batteries emit a highly

the genset are solely responsible for operating the gen-

explosive hydrogen gas that can be ignited by arc-

set safely. Contact your authorized Cummins Power

ing, sparking, smoking, etc.

Generation distributor for more information.

LS-15M

iii

•

WARNING

CAUTION

• DO NOT fill fuel tanks while engine is running, un-

• DO NOT permit any flame, cigarette, pilot light,

• Fuel lines must be adequately secured and free of

• Keep your hands, clothing, and jewelry away from

•

• Make sure that fasteners on the generator set are

•

• If adjustment must be made while the unit is run-

• Be sure all fuel supplies have a positive shutoff

• Be sure battery area has been well-ventilated prior

ELECTRICAL SHOCK CAN CAUSE

changer pressure cap while the engine is running.

To prevent severe scalding, let engine cool down

SEVERE PERSONAL INJURY OR DEATH

before removing coolant pressure cap. Turn cap

•

Remove electric power before removing protective

slowly, and do not open it fully until the pressure has

shields or touching electrical equipment. Use rub-

been relieved.

ber insulative mats placed on dry wood platforms

Used engine oils have been identified by some state

over floors that are metal or concrete when around

or federal agencies as causing cancer or reproduc-

electrical equipment. Do not wear damp clothing

tive toxicity. When checking or changing engine oil,

(particularly wet shoes) or allow skin surface to be

take care not to ingest, breathe the fumes, or con-

damp when handling electrical equipment. Do not

tact used oil.

wear jewelry. Jewelry can short out electrical con-

tacts and cause shock or burning.

Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible materials

components. High voltages can cause injury or

such as wood and cloth; Class B fires, combustible

death. DO NOT tamper with interlocks.

and flammable liquid fuels and gaseous fuels; Class

C fires, live electrical equipment. (ref. NFPA No. 10).

Follow all applicable state and local electrical

codes. Have all electrical installations performed by

•

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

a qualified licensed electrician. Tag and lock open

ator set.

switches to avoid accidental closure.

Make sure generator set is mounted in a manner to

DO NOT CONNECT GENERATOR SET DI-

prevent combustible materials from accumulating

RECTLY TO ANY BUILDING ELECTRICAL SYS-

under or near the unit.

TEM. Hazardous voltages can flow from the gen-

erator set into the utility line. This creates a potential

Remove all unnecessary grease and oil from the

for electrocution or property damage. Connect only

unit. Accumulated grease and oil can cause over-

through an approved isolation switch or an ap-

heating and engine damage which present a poten-

proved paralleling device.

tial fire hazard.

MEDIUM VOLTAGE GENERATOR SETS

Keep the generator set and the surrounding area

(601V to 15kV)

clean and free from obstructions. Remove any de-

bris from the set and keep the floor clean and dry.

Do not work on this equipment when mentally or

Special equipment and training is required to work

physically fatigued, or after consuming any alcohol

on or around medium voltage equipment. Operation

or drug that makes the operation of equipment un-

and maintenance must be done only by persons

safe.

trained and qualified to work on such devices. Im-

proper use or procedures will result in severe per-

Substances in exhaust gases have been identified

sonal injury or death.

by some state or federal agencies as causing can-

• Do not work on energized equipment. Unauthorized

cer or reproductive toxicity. Take care not to breath

personnel must not be permitted near energized

or ingest or come into contact with exhaust gases.

equipment. Due to the nature of medium voltage

Do not store any flammable liquids, such as fuel,

electrical equipment, induced voltage remains even

cleaners, oil, etc., near the generator set. A fire or

after the equipment is disconnected from the power

explosion could result.

source. Plan the time for maintenance with author-

ized personnel so that the equipment can be de-en-

Wear hearing protection when going near an oper-

ergized and safely grounded.

ating generator set.

GENERAL SAFETY PRECAUTIONS

To prevent serious burns, avoid contact with hot

Coolants under pressure have a higher boiling point

metal parts such as radiator system, turbo charger

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

system and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv

• Use extreme caution when working on electrical

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• Medium voltage acts differently than low voltage.

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1. Introduction

ABOUT THIS MANUAL

TEST EQUIPMENT

To perform the test procedures in this manual, the

This manual provides troubleshooting and repair

following test equipment must be available

information regarding the PowerCommand



Control 3100 (PCC).

True RMS meter for accurate measurement of

small AC and DC voltages.

Engine service instructions are in the

Grounding wrist strap to prevent circuit board

applicable engine service manual. Operating and

damage due to electrostatic discharge (ESD).

maintenance instructions are in the applicable

Battery Hydrometer

Operator’s Manual.

Jumper Leads

This manual does not have instructions for

Tachometer or Frequency Meter

servicing printed circuit board assemblies. After

Wheatstone Bridge or Digital Ohmmeter

determining that a printed circuit board assembly is

Variac

faulty, replace it. Do not repair it. Attempts to repair a

Load Test Panel

printed circuit board can lead to costly damage to

Megger or Insulation Resistance Meter

the equipment.

PCC Service Tool Kit (Harness Tool and Sen-

This manual contains basic (generic) wiring

sor Tool)

diagrams and schematics that are included to help

Timing Light

in troubleshooting. Service personnel must use the

O2 Meter

actual wiring diagram and schematic shipped with

Pyrometer

each unit. The wiring diagrams and schematics that

are maintained with the unit should be updated

0 to 35 PSI Gauge

when modifications are made to the unit.

Manometer (0 to 25 WC)

Read Safety Precautions and carefully observe all

HOW TO OBTAIN SERVICE

instructions and precautions in this manual.

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 Incorrect service or replacement of

parts can result in severe personal injury or

death, and/or equipment damage. Service per-

sonnel must be trained and experienced to per-

form electrical and mechanical service. Read

and follow Safety Precautions, on pages iii and

iv.

Copyright 2001 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.

1-1

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SYSTEM OVERVIEW

more complete block diagram is provided in Section

3. A system schematic is provided in Section 8.

The PCC is a microprocessor-based control for

The PCC monitors frequency from both the mag-

Cummins generator sets. It provides fuel control

netic pick-up (MPU) and the main stator inputs. The

and engine speed governing, main alternator volt-

control sends a low power pulse-width modulated

age output regulation, and complete generator set

(PWM) signal to the fuel control actuator.

control and monitoring.

The external PT/CT module reduces generator volt-

The operating software provides control of the gen-

age to approximately 18 VAC, and produces a rep-

erator set and its performance characteristics, and

resentative AC voltage from CT output current. The

displays performance information on a digital dis-

voltage regulation function sends a low power PWM

play panel. It accepts menu-driven control and set-

signal to the voltage regulator output module, which

up input from the push button switches on the front

then sends an amplified signal to the exciter stator.

panel.

Oil, coolant, and exhaust temperatures are sensed

by variable resistance element sensors. Oil pres-

GENERATOR SET CONTROL FUNCTION

sure is sensed by a capacitive element active sen-

sor.

Figure 1-1 shows some of the control functions. A

Fuel

MPU

Control

Actuator

Regulator

Output

PMG

Sensors

S N

Battery

BT1

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

1-2

2. Control Operation

GENERAL

PCC POWER ON / STANDBY MODE

Standby Mode

The following describes the function and operation

In the Standby (sleep) mode (selector switch S5 on

of the PowerCommand generator set control. All in-

the Digital Board is set to the right and the generator

dicators, displays, meters and control switches are

set is not running), the control’s operating software

located on the face of the control panel as illustrated

is inactive and the LEDs and displays on front panel

in Figure 2-1.

are all off.

The operating software is initialized and the front

Normally, generator set configuration options are

panel is turned on in response to a run signal or any

set at the factory. When a new control is installed on

one of eight “wake up” inputs from remote sensing

a generator set or when parts are replaced, the con-

switches.

trol must be configured for that generator set with

The wake up signals are:

the use of the “Initial Start Setup” portion of the inter-

Emergency Stop

nal software. Setup and calibration procedures are

Low Coolant Level

described in Section 5.

Low Coolant Temperature

The automatic voltage regulator (AVR) and gover-

Low Fuel

nor operation characteristic adjustments are also

Customer Fault Inputs 2 and 3

described in Section 5.

Run Selected on Run/Off/Auto Switch

SAFETY CONSIDERATIONS

Remote Start Signal in Auto Mode

Self Test switch

AC power is present when the set is running. Do not

To activate and view the menu displays, press and

open the generator output box while the set is run-

release the Self Test switch. The PCC will initialize

ning.

the operating software and permit operation of the

menu display panel. If no menu selections are

WARNING

Contacting high voltage compo-

made, the power to the control panel will shut down

nents can cause electrocution, resulting in se-

after 30 seconds.

vere personal injury or death. Do not open the

Power On Mode

generator output box while the set is running.

In the Power On (awake) mode (selector switch S5

Read and observe all WARNINGS and CAU-

on the Digital Board is set to the left), the PCC will

TIONS in your generator set manuals.

initialize the operating software and permit opera-

The PCC control cabinet must be opened only by

tion of the menu display panel. (See Figure 3-1 for

technically qualified personnel.

S5 location.) Power will stay on until switch (S5) is

set to the Standby mode. It is recommended that

The PCC control cabinet must be

switch S5 be left in the Power On mode in all ap-

opened only by technically qualified personnel.

plication, except those where auxiliary battery

Lower level voltages (18 VAC to 24 VDC) are

charging is not available.

present in PCC control cabinet. These voltages

CAUTION

Electrostatic discharge will damage

can cause electrical shock, resulting in person-

circuit boards. To prevent this damage, always

al injury.

wear a grounding wrist strap when touching or

Even with power removed, improper handling

handling circuit boards or socket-mounted ICs

of components can cause electrostatic dis-

and when disconnecting or connecting harness

charge and damage to circuit components.

connectors.

2-1

CAUTION

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KILOWATT METER

FREQUENCY

AC

AC AMMETER

(PERCENT LOAD)

METER

VOLTMETER

(PERCENT AMPS)

(DUAL SCALE)

MENU

UPPER AND

ALPHANUMERIC

ACTIVE SWITCH

SELECTION

LOWER SCALE

DISPLAY

INDICATOR

SWITCH

INDICATOR

(1 of 6)

(1 of 4)

RUN/OFF/AUTO

SELF TEST

RESET

MENU

PANEL LAMP

EMERGENCY

SWITCH

SWITCH

SWITCH SWITCH

SWITCH

STOP PUSH

BUTTON

(Turn CW to reset)

NON-AUTOMATIC

PHASE SELECTOR

WARNING

SWITCH AND

SHUTDOWN

INDICATORS

STATUS INDICATORS

FIGURE 2-1. FRONT PANEL

2-2

FRONT PANEL

operation of the menu display panel. If no menu

selections are made, a software timer will shut

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

down the power after 30 seconds.

Panel Lights Switch: Press this switch to turn con-

AC Voltmeter: Dual scale instrument indicates AC

trol panel illumination on and off. The illumination

voltage. Measurement scale in use is shown on

will shut off after about eight minutes.

scale indicator lamp.

AC Ammeter: Indicates current output in percent of

Phase Selector Switch and Indicators: Press this

maximum rated current. (Percent current is based

momentary switch to select phases of generator

on .8 PF.)

output to be measured by the analog AC voltmeter

and ammeter. LEDs indicate the selected phase.

Kilowatt Meter: Indicates 3-phase AC power out-

put as percent of rated load.

Run/Off/Auto Switch: This switch starts and stops

Frequency Meter: Indicates generator output fre-

the set locally, or enables start/stop control of the

quency in hertz.

engine from a remote location. (Ground to start.)

Upper and Lower Scale Indicator Lamps: Indi-

Note: When the generator set is operating in the Re-

cate AC voltmeter scale.

mote Start mode, removing the Remote Start com-

mand does not shut off the engine if the load is more

Digital Display: This two-line, 16-character per line

than 10 per cent, the cooldown timer is set to zero,

alphanumeric display is used in the menu-driven

and the control is configured for a si n g le unit (not in

operating system, in conjunction with the display

parallel). The generator set continues to operate un-

menu selection switches and the Menu switch. Re-

til it runs out of fuel, the E−stop button is used, or the

fer to the menu trees later in this section. The dis-

load is removed.

play is also used to show warning and shutdown

Emergency Stop Button: Push the switch in for

messages.

emergency shutdown of the engine.

Display Menu Selection Switches: Four momen-

tary switches—two on each side of the digital dis-

Remote Reset switch will not reset emergency stop.

play window—are used to step through the various

Can only be reset at the PCC front panel.

menu options and to adjust generator set parame-

To reset:

ters. The green arrow adjacent to the switch is lit

1. Turn the switch clockwise and allow it to pop

when the switch can be used (switch is “active”).

out.

Menu Switch: Press this switch to return the digital

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

display to the MAIN MENU. Refer to the menu trees

3. Press the front panel Reset switch.

later in this section.

4. Select Run or Auto, as required.

Reset Switch: Press this switch to reset warning

Non-Automatic Status Indicator: This red lamp

and shutdown messages after the condition has

been corrected. To reset a shutdown message with

flashes continuously when the Run/Off/Auto switch

the Reset switch, the Run/Off/Auto switch must be

is not in the Auto position.

in the Off position.

Warning Status Indicator: This yellow lamp is lit

whenever the control detects a warning condition.

With the Run/Off/Auto switch in the Auto mode,

After the condition is corrected, warning indicators

shutdown faults can be reset by removing the re-

can be reset by pressing the Reset switch. (It is not

mote start input and then cycling the remote reset

necessary to stop the generator set.)

input.

Self Test Switch: Press and hold this switch to light

With the Run/Off/Auto switch in the Auto mode,

all front panel LEDs and cycle through all shutdown

warnings can also be reset by cycling the remote re-

and warning messages.

set input after the condition is corrected.

In the Standby (sleep) mode, with the generator set

Shutdown Status Indicator: This red lamp is lit

not running, the control’s operating software is inac-

whenever the control detects a shutdown condition.

tive and the LEDs and displays on front panel are all

After the condition is corrected, shutdown indica-

off.

tors can be reset by turning the Run/Off/Auto switch

To activate and view the menu displays without

to the Off position, and pressing the Reset switch.

starting the generator set, press and hold the Self

In Auto mode, shutdowns can be reset by removing

Test switch until the front panel LEDs light. The

the remote start input and then cycling the remote

PCC will initialize the operating software and permit

reset input.

2-3

Emergency

Stop shutdown status (Code 102 ) ca n be

reset only at the PCC front panel.

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES

MAIN MENU

The facing page shows the main menu and a block

representation of the available submenus.

Figure 2-2 shows the digital display and the menu

selection switches. Refer to heading “Front Panel”

As shown in the diagram, the main menu can

branch into one of four directions.

which describes the menu display and switches.

To display engine parameters, such as oil pressure

and temperature, water temperature, engine speed

In the Standby Mode, to activate and view the menu

(RPM), and exhaust temperature, press the button

displays without starting the generator set, press

next to the word “ENGINE” in the display. Refer to

and release the Self Test switch. This will initialize

ENGINE MENU in this section.

the PCC operating software and permit operation of

To display generator parameters, such as volts,

the menu display panel. If no menu selections are

amps, power (kW), and frequency, press the button

made, a software timer will shut down the power af-

next to the word “GEN” in the display. Turn to the

ter 30 seconds. In the Power On Mode, power is

GEN MENU in this section.

continuously supplied to the control panel. Display

To adjust output voltage and frequency, or start and

will always remain on.

stop delays, press the button next to the word “AD-

JUST” in the display. Refer to ADJUST MENU in

In the digital display, the “>>” symbol indicates that

Section 5.

selecting the adjacent button causes the operating

To display the selected generator set model and the

program to branch to the next menu display—as

resident version software, press the button next to

shown in the menu diagrams.

the “>>” in the display. Refer to VERSIO N & DIS-

In the digital display, the “<<” symbol indicates that

PLAYS MENUS in Section 5.

selecting the adjacent button causes the operating

program to go back to the previous menu display.

2-4

MAIN MENU

PAGES 2-6 & 2-7

PAGES 2-8 & 2-9

%GOV / REG

<<

RPM

<<

FREQUENCY

EXHAUST

BATTERY

<<

POWER

<<

HOURS

>>

KW HRS

>>

OIL

<<

VOLTS

<<

COOLANT

>>

AMPS

>>

ENGINE

GEN

< >

ADJUST

>>

< >

RESET MENU

>

CLEAR WARNING AND

RETURN TO

SHUTDOWN

MAIN MENU

MESSAGES

⇑ VOLTAGE

>>

_______

VERSION

SECTION 5

SETUP / CAL

FREQUENCY

HISTORY

>>

_______

(ACCESS CODE)

_______ SEC >>

STOP DELAY

DISPLAYS

<<

SECTION 5

METERS

>>

_______RPM >>

GOV / REG

<<

SECTION 5

SECTION 5

SETUP

>>

INACTIVE BUTTON

<

< ACTIVE BUTTON SELECTED

2-5

⇓

⇑
⇓

⇑ START DELAY
⇓

⇑
⇓ _______SEC >>

⇑ IDLE SPEED
⇓

ACTIVE BUTTON

ENGINE MENU

OIL/COOLANT submenu: This is the first subme-

The facing page shows a block representation of

the ENGINE menu. If you press the button next to

nu. Select OIL for a display of oil pressure and oil

the word “ENGINE” in the display, the first ENGINE

temperature. Select COOLANT for a display of

submenu will appear.

coolant temperature. When oil or coolant parame-

ters are displayed, pressing the button next to the

As shown in the diagram, the ENGINE menu has

“<<” will return the display (“BACK”) to the OIL/

three submenus.

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, press-

ing 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 sub-

menu. Select RPM for a display of engine RPM.

Select EXHAUST for a display of the (optional) ex-

haust temperature. When RPM or exhaust param-

eters are displayed, pressing the button next to the

“<<” will return the display (“BACK”) to the RPM/EX-

HAUST submenu.

2-6

ENGINE

BACK

___PSI / KPA

<<

< >

>

OIL

<<

ENGINE

GEN

< >

___°F / °C

ADJUST

>>

COOLANT

>>

< >

< >

BACK

L___°F / °C <<

< >

>

OIL

<<

R___°F / °C (or

COOLANT

>>

< >

n/a)

<>

GEN

< >

OIL

<<

ENGINE

COOLANT

>>

ADJUST

>>

< >

< >

< >

OIL

<<

COOLANT

>>

< >

BACK

BATTERY

<<

< >

>

BATTERY

<<

___VDC

HOURS

>>

< >

BACK

STARTS ___

<<

< >

>

BATTERY

<<

HOURS ___

HOURS

>>

< >

< >

BATTERY

<<

OIL

<<

< >

HOURS

>>

COOLANT

>>

< >

< >

< >

BATTERY

<<

HOURS

>>

< >

BACK

RPM

<<

< >

>

RPM

<<

___

<

EXHAUST

BACK

L___°F/°C (or n/a) <<

>

< >

RPM

<<

<

EXHAUST

< >

< >

RPM

<<

BATTERY

<<

HOURS

>> < EXHAUST

< >

Indicates “OR” Condition

2-7

R___°F/°C (or n/a)

GEN MENU

VOLTS/AMPS submenu: This is the first subme-

The facing page shows a block representation of

the GEN menu. If you press the button next to the

nu. Select VOLTS for a display of a line-line or line-

word “GEN” in the display, the first GEN submenu

neutral selection. Select line-line (L-L) or line-neu-

will appear.

tral (L-N) for the desired voltage display. Select

AMPS for a display of L1, L2, and L3 current in

As shown in the diagram, the GEN menu has three

amps. When voltage or current parameters are dis-

submenus.

played, pressing the button next to the “<<” will re-

turn the display (“BACK”) to the L-L/L-N submenu.

If DELTA is selected in the Initial Start Setup subme-

nu, when selecting VOLTS, the “line-line” or “line-

neutral” submenus will not be displayed, only the

L1-2, L2-3, L3-1 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 dis-

played, pressing the button next to the “<<” will re-

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

HOURS submenu.

The PF reading will contain an asteri sk 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 n o t running.

%GOV/REG/FREQUENCY submenu: From the

POW ER/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. Se-

lect FREQUENCY for a display of the generator

output frequency. When voltage regulator and gov-

ernor or frequency parameters are displayed,

pressing the button next to the “<<” will return the

display (“BACK”) to the %GOV/REG/FREQUENCY

submenu.

2-8

GEN

ENGINE

GEN

< >

ADJUST

>>

< >

BACK

L − L <<

L1-2 L2-3 L3-1 <<

< >

VOLTS

<<

< >

>

___ ___ ___

AMPS

>>

< >

<

L − N

BACK

<<

L − L <<

L1N L2N L3N

>

< >

___ ___ ___

< L − N

BACK

L − L <<

< >

<

L − N

BACK

L1 L2 L3

>

<> <<

VOLTS

<<

___ ___ ___

AMPS

>>

< >

<>

GEN

VOLTS

<<

ENGINE

< >

AMPS

>>

ADJUST

>>

< >

< >

BACK

___ KW

<<

>

< >

VOLTS

<<

POWER

<<

< >

___ PF

AMPS

>>

KW HRS

>>

< >

< >

BACK

KW HRS

<< > POWER

<<

< >

____________

KW HRS

>>

< >

BACK

POWER

<<

< >

KW HRS

>>

< >

BACK

%GOV / REG

<<

< >

POWER

<<

< >

KW HRS

>>

<

FREQUENCY

< >

BACK

%GOV / REG

<<

GOVERNOR_ % <<

< >

>

REGULATOR_ %

<

FREQUENCY

BACK

%GOV / REG

<<

FREQUENCY

<<

< >

>

___ HZ

<

FREQUENCY

Indicates “OR” Condition

2-9

THIS PAGE LEFT INTENTIONALLY BLANK

2-10

3. Circuit Boards and Modules

GENERAL

The system schematics are provided in Sect ion 9 of

this manual.

This section describes the function of the PCC cir-

cuit boards and modules that are contained in the

CAUTION

Electrostatic discharge will damage

circuit boards. To prevent this damage, always

control panel (Figure 3-1) and the accessory box.

wear a grounding wrist strap when touching or

The block diagram in Figure 3-2, shows both inter-

handling circuit boards or socket-mounted ICs.

nal and external components of the PCC system.

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

DISPLAY

BOARD

ANALOG

A35

BOARD

A33

ENGINE INTERFACE

CUSTOMER

A31

INTERFACE

A34

GOVERNOR

RUN/OFF/AUTO

OUTPUT MODULE

SWITCH S12

A38

PT/CT

BOARD

A36

VOLTAGE REGULATOR

ACCESSORY

OUTPUT MODULE

BOX (HC 4/5)

A37

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

3-1

FIGURE 3-2. BLOCK DIAGRAM

3-2

DIGITAL BOARD (A32)

Connectors

The digital board has five connectors. They are:

The digital circuit board (Figure 3-3) contains the

J1

Serial Interface RS232

microprocessor and the operational software for the

J2

Connects to J4 on A34 Customer Interface

control. It connects to all other boards inside the

board

control. This board also provides the analog-to-digi-

tal conversions for the PCC.

J3

Connects to J2 on A33 Analog board

J4

Connects to J1 on A31 Engine Interface

Switch

board

J5

Connects to J5 on A35 Digital Display assem-

S5

Slide the switch to the left to select the Power

bly

On (awake) mode. Control panel power/oper-

LEDs

ating software will remain on until the switch is

reset to the Standby mode. It is recom-

The digital board has seven LED’s that indicate the

mended that switch S5 be left in the Power On

following conditions:

mode in all applications, except those where

DS1 Spare (Green)

auxiliary battery charging is not available.

DS2 Spare (Green)

Slide right to put the PCC in the Standby

DS3 +18 VDC supply OK (Green)

(“sleep”) mode. In this mode, the PCC oper-

DS4 +5 VDC supply OK (Green)

ating software will be initiated by selection of

DS5 Run (Flashes once per second if software

Run on the front panel, by pressing the Self

is running) (Green)

Test switch, by a remote start input (in Auto

DS6 +24 VDC B+ supply OK (Green)

mode), or by any one of several “wake-up”

DS7 +12 VDC supply OK (Green)

signals from external switches.

DS1

DS2

DS7

DS3

DS6

DS4

DS5

FIGURE 3-3. DIGITAL BOARD

3-3

ENGINE INTERFACE BOARD (A31)

J4

Connects to customer connections and to en-

gine harness which includes magnetic pick-

The engine interface board (Figure 3-4) reads user

up.

control inputs, monitors engine, generator and sys-

J5

Connects to engine sensors.

tem status, and initiates the appropriate action for

J6

Connects to Genset Control module (GCM).

normal operating and fault conditions (warning or

shutdown).

J7

Connects to Genset Control module (GCM).

This board is connected to the engine sensors, bat-

Fuses

tery, starter, governor output module, voltage regu-

The engine interface board has two replaceable

lator output module, and the magnetic pick-up

fuses. They are:

(MPU).

F1

Control B+ (5 Amps)

The engine interface board can also be connected

F3

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

to an optional network interface module for network

contacts).

access.

LED’s

During a typical start sequence the LED’s light as

follows:

The engine interface board has 10 LED’s that indi-

cate the following conditions:

1. DS11 lights when a remote run signal is re-

ceived and S12 is in the Auto position, or S12 is

DS1 Low Fuel Alarm input (Red)

moved to the Run position.

DS2 Low Coolant Level Alarm input (Red)

2. DS12 lights when the magnetic pick-up voltage

DS3 Low Engine Temperature Alarm input (Red)

is sensed (engine is cranking). (When the en-

DS4 S12 in Run position (Green). S12 is the Run/

gine is cranking, the mag pickup output should

Off/Auto switch.

be a minimum of 1 volt.)

DS5 S12 in Auto position (Green)

3. DS11 extinguishes, DS9 lights and DS10 is

DS6 Emergency Stop (Red)

dimly lit when the generator is running.

DS7 Not configured.

Connectors

DS8 Not configured.

The engine interface board has seven connectors

DS9 AVR duty cycle (Green). Brighter indicates

and one terminal strip. They are:

larger duty cycle.

J1

Connects to J4 on A32 Digital board.

DS10 GOV duty cycle (Green). Brighter indicates

larger duty cycle.

J2

Connects to J1 on A33 Analog board.

DS11 Start pilot relay output (Red)

J3

Connects to display board, front panel

DS12 Run pilot relay output (Red)

switches and meters.

3-4

DS1 - LOW FUEL

DS2 - LO COOL

DS3 - LET

DS4 - RUN SW

DS5 - AUTO

DS6 - E-STOP

DS9 - REG

5A CNTRL B+

DS10 - GOV

DS11 - START

DS12 - RUN RLY

5A AUX B+

FIGURE 3-4. ENGINE INTERFACE BOARD

3-5

ANALOG BOARD (A33)

Connectors

The analog board (Figure 3-5) is the only circuit

The analog board has four connectors with ribbon

board inside the control that has no LED’s. There

cables permanently soldered to them. They are:

are two versions of the analog board that are used

J1

Connects to J2 on A31 Engine Interface

for paralleling and non-paralleling systems.

board

This board interprets all analog input signals and

J2

Connects to J3 on A32 Digital board

converts the analog signals to 0−5 VDC for the digi-

J3

Spare analog inputs

tal board.

J4

Connects to J1 on A34 Customer Interface

board

FIGURE 3-5. ANALOG BOARD

3-6

DIGITAL DISPLAY BOARD (A35)

DS13 Warning (Amber)

DS14 Lower Scale (Green)

The digital board (Figure 3-6) connects to all meters

and the LED display.

DS15 Shutdown (Red)

DS20 Left Bottom Arrow (Green)

Connectors

DS21 Right Bottom Arrow (Green)

The digital board has three connectors. They are:

DS22 Automatic mains failure (AMF) for parallel-

J1

Connects to front panel membrane switches

ing application only: Breaker Closed (Red)

J5

Connects to J2 on A32 Digital board. (With J5

DS23 Phase A (Green)

disconnected, the display will be non-func-

DS24 Reset Arrow (Green)

tional, but the PCC will continue to operate.)

DS25 Menu Arrow (Green)

J6

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

on A31 Engine Interface board

DS26 AMF application only: Breaker Open

(Green)

LEDs

DS27 Phase B (Green)

The digital board has 18 LED’s that are used to indi-

DS29 Phase C (Green)

cate operational status of the generator set and

DS36 Automatic mains failure (AMF) for parallel-

control panel mode/switch selections.

ing application only: Breaker Closed (Red) −

DS9 Not In Auto (Red)

or − paralleling application: Breaker Open

DS10 Upper Scale (Green)

(Green)

DS11 Left Top Arrow (Green)

DS37 Automatic mains failure (AMF) for parallel-

DS12 Right Top Arrow (Green)

ing application only: Breaker Open (Green)

DS9

DS11

DS12

DS10

DS13

DS14

DS15

DS20

DS21

DS22

DS23

DS24

DS25

DS26

DS27

DS29

DS36

DS37

FIGURE 3-6. DIGITAL DISPLAY BOARD

3-7

CUSTOMER INTERFACE BOAR D ( A34)

DS14 Remote Start input (Green)

DS15 Customer Fault #3 input (Red)

The customer interface board (Figure 3-7) connects

to the PT/CT board to bring in voltage and current. It

DS16 Breaker Control input relay energized from

also connects to customer inputs and outputs.

Digital board (Green).

In single set application, this output is acti-

Connectors

vated for a breaker trip when there is a shut-

down fault.

The customer interface board has five connectors.

In paralleling application, this output is acti-

They are:

vated to close a breaker

J1

Customer connections

DS17 Common Alarm output relay energized from

J2

Customer connections

Digital board (Green)

J3

A36 PT/CT Board and customer connections

This output is activated only on a shut-

down condition.

J4

Connects to J2 on A32 Digital board

DS18 Spare output relay energized from Digital

J5

Connects to J4 on A33 Analog board

board (Green)

LEDs

This output is activated only on a warn-

ing condition.

The customer interface board has 27 LED’s that in-

dicate the following conditions:

DS19 Load Dump output relay energized from

Digital board (Red)

DS1 Master First Start Input (Green) − paralleling

If overload or underfrequency for 5 sec-

application only

onds, this output is activated (before shut-

DS2 Pre low oil pressure output relay K14 (Red)

down).

DS3 Customer Fault #4 Input (Red)

DS20 Ready to Load output relay energized from

DS4 Customer Fault #1 Input (Red)

Digital board (Green)

DS5 Low oil pressure output relay K15 (Red)

This output is activated when AC voltage

and frequency exceed 90% of nominal.

DS6 Fault Reset Input (Red)

DS21 Pre high engine temperature output relay

DS7 Engine Idle (Green)

K8 (Red)

DS8 Load Demand Input (Green) − paralleling

DS22 Not in auto output relay K6 (Red)

application only

DS23 High engine temperature output relay K9

DS9 Breaker Open/Inhibit Input (Green) − paral-

(Red)

leling application only

DS24 Overspeed output relay K10 (Red)

DS10 Genset Breaker Closed Position (Green) −

paralleling application only

DS25 Overcrank output relay K11 (Red)

DS11 Customer Fault #2 input (Red)

DS26 Low engine temperature output relay K12

(Red)

DS12 Low coolant output relay K17 (Red)

DS27 Low fuel output relay K13 (Red)

DS13 Low Fuel Input (Red)

3-8

DS2 - [K14] PRE-LOP

DS1 - MA 1ST START

DS3 - CUST FAULT4

DS4 - CUST FAULT1

DS5 - [K15] LOP

DS6 - FAULT RESET

DS7 - ENG IDLE

DS8 - BRKR CLOSE

DS9 - BRKR OPEN

DS10 - BRKR POSN

DS12 - [K7]

DS11 - CUST FAULT2

LOW COOL

DS13 - LOW FUEL

DS14 - RMT START

DS15 - CUST FAULT3

DS16 - AC CONTACTOR

DS17 - COMMON ALARM

DS18 - SPARE RELAY

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)

Connectors

The PT/CT board has two connectors. They are:

The PT/CT board (Figure 3-8) is mounted inside the

accessory box. This board converts generator out-

J8

Connects to J3 on A34 Customer Interface

put voltage to approximately 18 VAC levels for the

board

analog board. It also converts CT .55 amp (at full

J9

Connects to AC harness (generator output

load) output to approximately 1.65 VAC (at full load)

voltage and CTs)

input for the analog board.

J9 wiring connections:

Yellow Gen. A In

There are three versions of this board. For proper

operation, the PT/CT board must be correctly

Orange Gen. B In

matched to the generator set.

Red

Gen. C In

Brown Gen. Common In

In addition, there is a specific set of CTs for each

White CT21 (+) In

genset. For proper operation, the CTs must also be

Gray

CT21 (common) In

correctly matched to the genset output current.

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

VOLTAGE REGULATOR OUTPUT MODULE

J10 Connects to engine harness (power)

(A37)

J10 wiring connections:

Green Phase A PMG power

The voltage regulator output module (Figure 3-9) is

a power amplifier. This board is used to amplify the

Yellow Phase B PMG power

pulse-width modulated (PWM) signal from the PCC

Orange Phase C PMG power

to drive the exciter windings. Power from the PMG is

Red

X (Field +) Output

used by this board to amplify the PWM signal.

Brown XX (Field −) Output

Connectors

LEDs

The voltage regulator output module has two con-

The voltage regulator output module has 3 LED’s

nectors. They are:

that indicate the following conditions.

J7

Connects to engine harness (control)

DS1 On when voltage regulator isolated supply is

J7 wiring connections:

operating (Green)

Gray

Regulator Drive (+) Input

DS2 Output Duty Cycle − Brighter when load in-

White Regulator Drive (-) Input

creases − larger duty cycle (Amber). The duty

Blue

B+ Input (RUN signal)

cycle range of the PWM signal is 0 - 60%. Be-

cause the normal duty cycle is less than 10%,

Purple Ground Input

the output duty cycle LED, DS2 will normally

Grn/Yel Start in

be very dimly lit.

Black

Start solenoid

DS3 Backup start disconnect − On when start dis-

connect is true (Green). The backup start dis-

connect 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

J7

J10

FIGURE 3-9. VOLTAGE REGULATOR OUTPUT MODULE (A37)

3-11

GOVERNOR OUTPUT MODULE (A38)

Fuses

The governor output module has three fuses to pro-

The governor output module (Figure 3-10) receives

tect it from overloads and groundfaults. They are:

a low power pulse−width modulated (PWM) signal

from the engine interface board and then sends an

F1

Network B+ (10 Amps)

amplified signal to drive the governor actuator. The

F2

Switched B+ (10 Amps) — T26

PCC monitors frequency from both the magnetic

F3

Gov Act + (10 Amps)

pick-up (MPU) and the main stator inputs.

LEDs

Connectors

The governor output module has two LED’s that in-

dicate the following conditions:

The governor output module has one connector:

DS1 Output Duty Cycle: brighter = longer duty

cycle (Amber). The duty cycle range of the

J6

Connects to Governor Actuator, Governor

PWM signal is 0 - 90%. Normal duty cycle is

Drive (from Engine Interface), B+, T26

about 30%.

DS2 Run signal to Governor Controller (Green)

DS1 - OUTPUT DUTY CYCLE

DS2 - GENSET RUN

Network B+

J6

FIGURE 3-10. GOVERNOR OUTPUT MODULE (A38)

3-12

Switched B+ Governor B+

4. Troubleshooting

GENERAL

•

Tables 4-4 through 4-29: Provide detailed

troubleshooting procedures.

The PowerCommand Control continuously moni-

Table 4-30: Describes the analog circuit board

tors engine sensors for abnormal conditions, such

inputs and outputs.

as low oil pressure and high coolant temperature. If

any of these conditions occur, the PCC will light a

Table 4-31: Describes the location and func-

yellow Warning lamp or a red Shutdown lamp and

tion of each fuse.

display a message on the digital display panel.

SAFETY CONSIDERATIONS

In the event of a shutdown fault (red Shutdown

High voltages are present when the set is running.

lamp), the PCC will stop the engine and close a set

Do not open the generator output box while the set

of contacts that can be wired to trip a circuit breaker.

is running.

If the generator set is stopped for this reason, the

operator can restart the set after making adjust-

WARNING Contacting high voltage compo-

ments or corrections.

nents can cause electrocution, resulting in se-

vere personal injury or death. Keep the output

This section contains the following information:

box covers in place during troubleshooting.

When troubleshooting a set that is shut down, make

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

certain the generator set cannot be accidentally re-

cluding the displayed message and status indi-

started. Place the Run/Off/Auto switch in the Off

cator. Also references the page number that

position. Turn off or remove AC power from the bat-

contains a description of each code.

tery charger, MAKE CERTAIN EXPLOSIVE BAT-

TERY GASSES ARE DISPELLED FROM BAT-

Table 4-2: Describes each warning and shut-

TERY COMPARTMENT, and then remove the neg-

down code, warning and shutdown limits

where applicable, and basic corrective actions,

ative (−) battery cable from the set starting battery.

such as, checking fluid levels, control reset

WARNING Accidental starting of the generator

functions, battery connections, etc.

set during troubleshooting can cause severe

personal injury or death. Disable the generator

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

set (see above) before troubleshooting.

and shutdown limits.

4-1

•

•

•

STATUS INDICATORS

Emergency Stop shutdown status (Code 102) can be

reset only at the PCC front panel.

Non-Automatic Status Indicator: This red lamp

Digital Display: This two-line, 16-character per line

flashes continuously when the Run/Off/Auto switch

alphanumeric display is used in the menu-driven

is in the Off position.

operating system and to show shutdown and warn-

Warning Status Indicator: This yellow lamp is lit

ing messages. Refer to Tables 4-1 and 4-2.

whenever the control detects a warning condition.

After the condition is corrected, warning indicators

RESETTING THE CONTROL

can be reset by pressing the Reset switch. (It is not

necessary to stop the generator set.) In auto mode,

Press the momentary Reset Switch to reset warn-

warning indicators can also be reset by cycling the

ing and shutdown messages after the condition has

remote reset input after the condition is corrected.

been corrected. To reset a shutdown message with

the Reset switch, the Run/Off/Auto switch must be

Shutdown Status Indicator: This red lamp is lit

in the Off Position. (The control cannot go into

whenever the control detects a shutdown condition.

Standby [sleep] mode until all faults have been

Shutdown faults are latched. After the condition is

reset.)

corrected, shutdown indicators can be reset by

turning the Run/Off/Auto switch to the Off position,

In Auto mode, warning indicators can also be reset

and pressing the Reset switch. In the Auto position,

by cycling the remote reset input after the condition

shutdown faults can be reset by removing the re-

is corrected. Shutdown faults can be reset by re-

mote start input and then cycling the remote reset

moving the remote start input and then cycling the

input.

remote reset input.

WARNING AND

RESET

ALPHANUMERIC

SHUTDOWN

SWITCH

FAULT MESSAGE

STATUS INDICATORS

DISPLAY

FIGURE 4-1. CONTROL PANEL

4-2

TABL E 4-1. WARNING AND SHUTDOWN CODES

BASIC

TROUBLE-

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

101 . . . . . . IDLE MODE . . . . . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-4

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

200 . . . . . . LOW OIL PRESSURE . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-4 . . . . . . . . 4-22

201 . . . . . . LOW OIL PRESSURE . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-4 . . . . . . . . 4-22

204 . . . . . . OIL PRES SENDER . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-4 . . . . . . . . 4-23

210 . . . . . . LOW COOLANT TEMP . . . . . . . Warning . . . . . . . . . . . . . . . . 4-5 . . . . . . . . 4-24

211 . . . . . . HIGH COOLANT TEMP . . . . . . Warning . . . . . . . . . . . . . . . . 4-5 . . . . . . . . 4-25

212 . . . . . . HIGH COOLANT TEMP . . . . . . Shutdown . . . . . . . . . . . . . . . 4-5 . . . . . . . . 4-25

213 . . . . . . COOLANT SENDER . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-5 . . . . . . . . 4-23

214 . . . . . . LOW COOLANT LVL . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-26

215 . . . . . . LOW COOLANT LVL . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-26

220 . . . . . . MAG PICKUP . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-27

221 . . . . . . FAIL TO CRANK . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-13, 4-21

222 . . . . . . OVERCRANK . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-19

223 . . . . . . OVERSPEED . . . . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-28

230 . . . . . . LOW DC VOLTAGE . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-6 . . . . . . . . 4-29

231 . . . . . . HIGH DC VOLTAGE . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-29

232 . . . . . . WEAK BATTERY . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-29

240 . . . . . . LOW FUEL − DAY . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-30

241 . . . . . . LOW FUEL . . . . . . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-31

250 . . . . . . EEPROM ERROR . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-32

251 . . . . . . EEPROM ERROR . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-32

252 . . . . . . EEPROM ERROR . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-7 . . . . . . . . 4-32

260 . . . . . . CUSTOMER FAULT 1* . . . . . . . Warning/Shutdown . . . . . . . 4-7/8 . . . . . . . 4-33

261 . . . . . . GROUND FAULT* . . . . . . . . . . . Warning/Shutdown . . . . . . . 4-7/8 . . . . . . . 4-33

262 . . . . . . RUPTURE BASIN* . . . . . . . . . . . Warning/Shutdown . . . . . . . 4-7/8 . . . . . . . 4-33

263 . . . . . . HIGH GEN TEMP* . . . . . . . . . . . Warning/Shutdown . . . . . . . 4-7/8 . . . . . . . 4-33

301 . . . . . . HIGH AC VOLTAGE . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-8 . . . . . . . . 4-34

303 . . . . . . LOW AC VOLTAGE . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-8 . . . . . . . . 4-37

313 . . . . . . UNDER FREQUENCY . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-8 . . . . . . . . 4-39

320 . . . . . . OVERCURRENT . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-8 . . . . . . . . 4-40

321 . . . . . . OVERCURRENT . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-8 . . . . . . . . 4-40

322 . . . . . . SHORT CIRCUIT . . . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-8 . . . . . . . . 4-40

330 . . . . . . OVERLOAD . . . . . . . . . . . . . . . . Warning . . . . . . . . . . . . . . . . 4-9 . . . . . . . . 4-40

335 . . . . . . REVERSE POWER . . . . . . . . . . Shutdown . . . . . . . . . . . . . . . 4-9

* Default message. Editable for customer site requirements.

4-3

TABLE 4-2. WARNING AND SHUTDOWN CODES

WARNING Many troubleshooting procedures present hazards which can result in severe per-

sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM

CORRECTIVE ACTION

MESSAGE:

Indicates that the engine is operating in idle mode. When the set is operat-

IDLE MODE

ing in the RUN mode, grounding the engine idle input causes generator

101 − WARNING

build-up to be inhibited and the engine to be governed at 800 RPM. When

ground is removed from this input, the set returns to normal speed and

voltage.When the engine idle function is enabled, the control automatical-

ly sets lower oil pressure warning and shutdown trip points to reflect the

lower operating speed. When the engine idle function is removed and the

set reverts to normal operating speed, the control automatically resets oil

pressure warning and shutdown trip points to the normal settings.

Shutdown lamp lights.

Indicates local or remote Emergency Stop.

MESSAGE:

To reset the local/remote Emergency Stop button:

EMERGENCY STOP

Turn the switch clockwise and allow it to pop out (local only).

102 − SHUTDOWN

Move the Run/Off/Auto switch to Off.

Press the Reset switch.

Select Run or Auto, as required.

Warning lamp lights.

Indicates engine oil pressure has dropped to an unacceptable lev-

MESSAGE:

el. If generator is powering critical loads and cannot be shut down,

LOW OIL PRESSURE

wait until next shutdown period and then follow 201-SHUTDOWN

200 − WARNING

procedure.

To check oil pressure, access the Oil Pressure menu prior to clear-

ing the fault.

Shutdown lamp lights.

Indicates engine oil pressure has dropped below the shutdown trip point.

MESSAGE:

Check oil level, lines and filters. If oil system is OK but oil level is low, re-

LOW OIL PRESSURE

plenish. Reset control and restart. Oil pressure limits are listed in Table

201 − SHUTDOWN

4-3.

Warning lamp lights.

Indicates that the control has sensed that the engine oil pressure sender is

MESSAGE:

out of its working range. Check that the engine oil pressure sender is prop-

OIL PRES SENDER

erly connected.

204 − WARNING

4-4

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

WARNING Many troubleshooting procedures present hazards which can result in severe per-

sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM

CORRECTIVE ACTION

Warning lamp lights.

Indicates engine coolant heater is not operating or is not circulating cool-

MESSAGE:

ant. Check for the following conditions:

LOW COOLANT TEMP

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

210 − WARNING

or disconnected heater cord and correct as required.

Set is not operating. Warning occurs

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

when engine coolant temperature is

sible coolant leakage points and repair as required.

70° F (21° C) or lower

.

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

NOTE: In applications where the

ambient temperature falls below

may be indicated even though the

coolant heaters are operating.

Warning lamp lights.

Indicates the engine coolant temperature is getting close to the recom-

MESSAGE:

mended maximum temperature limit:

HIGH COOLANT TEMP

215

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

211 − WARNING

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.

To check coolant temperature, access the coolant temperature

menu prior to clearing the fault.

Shutdown lamp lights.

Indicates engine has overheated (coolant temperature has risen above

MESSAGE:

the shutdown trip point:

HIGH COOLANT TEMP

215

F (102° C) − standby or 207° F (97° C) − primary. Allow engine to

212 − SHUTDOWN

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.

Warning lamp lights.

Indicates that the resistance of the coolant temperature sender is out of

MESSAGE:

range. Check the resistance of the sender. Resistance should be 500 to

COOLANT SENDER

2k ohms.

213 − WARNING

4-5

40°F (4°C), Low Coolant Temp

°

°

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

WARNING Many troubleshooting procedures present hazards which can result in severe per-

sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM

CORRECTIVE ACTION

Shutdown lamp lights.

Indicates engine coolant level has fallen below the trip point. Allow engine

MESSAGE:

to cool down completely before proceeding.

LOW COOLANT LVL

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

214 − WARNING

replenish if low. Look for possible coolant leakage points and repair if

or

necessary.

LOW COOLANT LVL

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

215 − SHUTDOWN

LOW COOLANT LVL Shutdown will not occur if genset is in Idle

mode (low coolant warning only ).

Shutdown lamp lights.

Indicates mag pickup speed indication is not being sensed or does not

MESSAGE:

match generator set output frequency.

MAG PICKUP

a. Restart and check RPM on the digital display.

220 − SHUTDOWN

Engine will not crank.

Indicates possible fault with control or starting system. Check for the fol-

Shutdown lamp lights.

lowing conditions:

MESSAGE:

a. Check fuse F3 on the Engine Interface board.

FAIL TO CRANK

b. Poor battery cable connections. Clean the battery cable terminals

221 − SHUTDOWN

and tighten all connections.

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

Shutdown lamp lights.

Indicates possible fuel system problem.

Engine stops cranking.

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

MESSAGE:

rect as required.

OVERCRANK

b. Check for dirty fuel filter and replace if necessary.

222 − SHUTDOWN

c. Check for dirty or plugged air filter and replace if necessary.

d. Reset the control and restart after correcting the problem.

Engine runs and then shuts down.

Indicates engine has exceeded normal operating speed. (115% ±1% of

Shutdown lamp lights.

nominal).

MESSAGE:

OVERSPEED

223 − SHUTDOWN

4-6

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

WARNING Many troubleshooting procedures present hazards which can result in severe per-

sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM

CORRECTIVE ACTION

Warning lamp lights.

Indicates battery voltage is below 10 VDC.

MESSAGE:

a. Discharged or defective battery.

LOW DC VOLTAGE

Check the battery charger fuse.

230 − WARNING

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 float level if applicable (raise float level).

Warning lamp lights.

Indicates battery voltage exceeds 32 VDC.

MESSAGE:

Check float level on battery charger if applicable (lower float level).

HIGH DC VOLTAGE

231 − WARNING

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

tery charging voltage is not obtained.

Warning lamp lights.

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

MESSAGE:

during starting.

WEAK BATTERY

Discharged or defective battery.

232 − WARNING

See Warning message 230, LOW DC VOLTAGE.

Warning lamp lights.

Indicates day tank fuel supply is running low. Check fuel supply and re-

MESSAGE:

plenish as required.

LOW FUEL−DAY

240 − WARNING

or

LOW FUEL

241 − WARNING

Shutdown lamp lights.

Indicates PCC memory error. Data corruption of critical operating param-

MESSAGE:

eters.

EEPROM ERROR

250 − SHUTDOWN

Warning lamp lights.

Indicates PCC memory error. Data corruption of noncritical operating pa-

MESSAGE:

rameters.

EEPROM ERROR

251 − WARNING

or

252 − WARNING

4-7

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

WARNING Many troubleshooting procedures present hazards which can result in severe per-

sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM

CORRECTIVE ACTION

Shutdown lamp lights.

When any one of these customer defined inputs is closed to ground, the

MESSAGE:

corresponding fault message is displayed. The nature of the fault is an op-

CUSTOMER FAULT 1

tional customer selection. These fault functions can be programmed to

260 − SHUTDOWN

initiate a shutdown or a warning.

or

As indicated by the Shutdown lamp, a shutdown response has been pre-

GROUND FAULT

selected.

261 − SHUTDOWN

or

Note: Customer fault messages are editable. The message displayed for

RUPTURE BASIN

the code shown (260 thru 263) may have been edited and may not appear

262 − SHUTDOWN

as shown in this table.

or

HIGH GEN TEMP

263 − SHUTDOWN

Warning lamp lights.

When any one of these customer defined inputs is closed to ground, the

MESSAGE:

corresponding fault message is displayed. The nature of the fault is an op-

CUSTOMER FAULT 1

tional customer selection. These fault functions can be programmed to

260 − WARNING

initiate a shutdown or a warning.

or

As indicated by the Warning lamp, a warning response has been prese-

GROUND FAULT

lected.

261 − WARNING

or

Note: Customer fault messages are editable. The message displayed for

RUPTURE BASIN

the code shown (260 thru 263) may have been edited and may not appear

262 − WARNING

as shown in this table.

or

HIGH GEN TEMP

263 − WARNING

Shutdown lamp lights.

Indicates that one or more of the phase voltages has exceeded 130% of

MESSAGE:

nominal, or has exceeded 110% of nominal for 10 seconds.

HIGH AC VOLTAGE

301 − SHUTDOWN

Shutdown lamp lights.

Indicates that one or more of the phase voltages has dropped below 85%

MESSAGE:

of nominal for 10 seconds.

LOW AC VOLTAGE

303 − SHUTDOWN

Shutdown lamp lights.

Indicates that engine speed has dropped below 90% of nominal for 10

MESSAGE:

seconds.

UNDER FREQUENCY

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

313 − SHUTDOWN

Check fuel supply, intake air supply and load.

4-8

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

WARNING Many troubleshooting procedures present hazards which can result in severe per-

sonal injury or death. Only qualified service personnel with knowledge of fuels, electricity, and

mechanical hazards should perform service procedures. Review safety precautions.

SYMPTOM

CORRECTIVE ACTION

Warning lamp lights.

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

MESSAGE:

seconds.

OVERCURRENT

Check load and load lead connections.

320 − WARNING

Shutdown lamp lights.

Indicates that generator output current has exceeded 110% of rated, and

MESSAGE:

that a PCC time/current calculation has initiated an overcurrent shut-

OVERCURRENT

down.

321 − SHUTDOWN

Check load and load lead connections.

Shutdown lamp lights.

Indicates that generator output current has exceeded 175% of rated.

MESSAGE:

Check load and load lead connections.

SHORT CIRCUIT

322 − SHUTDOWN

Warning lamp lights.

Indicates that three-phase power output exceeds 105% of standby (or

MESSAGE:

115% of prime) rating. After five seconds, the Load Dump output is acti-

OVERLOAD

vated. After 60 seconds, the OVERLOAD warning is activated.

330 − WARNING

Check load and load lead connections.

Shutdown lamp lights.

Indicates improper CT or PT phasing. (Non-parallel units only.)

MESSAGE:

Check CT / PT wiring. Refer to CT Installation in Section 5.

REVERSE POWER

335 − SHUTDOWN

4-9

TABL E 4-3. PCC OIL PRESSURE WARNING & SHUTDOWN LIMITS

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.

4-10

TROUBLESHOOTING PROCEDURE

LED and switch locations for each circuit board and

module are provided in Section 3. The control wiring

The following tables are a guide to help you evalu-

and circuit board connections are shown in Section

ate problems with the generator set. You can save

9.

time if you read through the manual ahead of time

and understand the system.

CAUTION

Always set the Run/Off/Auto (S12)

switch to the Off position and the Power On/

To determine the appropriate troubleshooting pro-

Standby (S5) switch to the Standby position be-

cedure for the specific problem at hand, be sure to

fore disconnecting or connecting harness con-

refer to the “Indicators” column provided in each

troubleshooting table.

nectors. Otherwise, disconnecting the harness

connectors can result in voltage spikes high

Try to think through the problem. Go over what was

enough to damage the DC control circuits of the

done during the last service call. The problem could

set.

be as simple as a loose wire, an opened fuse or a

tripped circuit breaker. (Table 4-31 describes the

Electrostatic discharge will damage

location and function of each fuse.)

circuit boards. Always wear a wrist strap when

handling circuit boards or socket-mounted IC’s

Figure 4-2 shows the location of the components

and when disconnecting or connecting harness

within the control panel that are referenced in the

connectors.

following troubleshooting procedures. Connector,

4-11

CAUTION

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

DISPLAY

BOARD

ANALOG

A35

BOARD

A33

ENGINE INTERFACE

CUSTOMER

A31

INTERFACE

A34

RUN/OFF/AUTO

SWITCH S12

OPTIONAL

THERMISTOR

GOVERNOR

RELAY 160°/140° C

OUTPUT MODULE

A38

TB1-1

OPTIONAL

COMMON ALARM

OPTIONAL RUN

RELAY K14

RELAYS K11, K12 &

K13

TB1-40

PT/CT BOARD A36

OPTIONAL RTD

VOLTAGE

RELAY

REGULATOR

OUTPUT MODULE

A37

ACCESSORY

BOX

FIGURE 4-2. CIRCUIT BOARD LOCATIONS

4-12

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. Insufficient battery voltage. Check the

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

“FAIL TO

following conditions:

ty for a fully charged battery is approximately

CRANK”

1.260 at 80° F (27° C).

a. Batteries not charged.

(221)

1b. Clean and tighten or replace the battery cable

b. Battery connections loose or dirty.

message

connectors and cables at the battery and the

c. Insufficient battery charging volt-

set.

Reset and

age.

attempt to

1c. Adjust charge rate of battery charging circuit.

d. Engine DC alternator could be bad.

start:

1d. Replace engine DC alternator if normal battery

charging voltage is not obtained.

Start LED

DS11 on the

2. Starter could be bad.

2. Reset the control. Attempt to start, and test for

engine

B+ at the starter. If there is B+ at the starter, the

interface board

starter could be bad. Test starter (see engine

turns on.

service manual). Replace the starter.

3. If there is no B+ at the starter, start so-

3. Reset the control. Attempt to start, and test for

NOTE:

lenoid K4 could be bad.

B+ into and out of start solenoid contacts. If

These two

there is B+ in, but not out, check for B+ at the

indications

start solenoid coil. If there is B+ at the coil,

suggest that

check ground connection. If ground connection

the PCC has

is good, the start solenoid is bad. Replace the

received a

start solenoid.

start signal

and has sent a

If there is B+ into and out of the start solenoid

start command

contacts, check for an open between the start

to the start

solenoid contacts and the starter. If there is no

output (J4-2)

B+, go to the next step.

on the engine

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

4. If there is no B+ at the start solenoid

interface

coil (K4), the backup start disconnect

ule. Test for continuity at A37 J7-5/J7-6. If there

board.

contacts in the regulator output mod-

is no continuity, the regulator output module is

ule (A37) could be open (indicating

bad. Replace A37.

that A37 is bad).

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

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

there may be an open between A37

control, attempt to start, and check for B+ at A37

and A31, an open between A37 and

P7-5.

K4, or A31 may be bad.

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 en-

gine interface board (A31) while attempting to

start.

If there is B+ at A31 J4-2, check for an open be-

tween 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. The mag pickup signal is not being

6. Refer to the mag pickup shutdown message

sensed.

(220).

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

4-13

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

WARNING

M any troubl eshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

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

“FAIL TO

1. Fuse F3 on the engine interface board

CRANK”

(A31) may be open, or B+ may not be

the control. Attempt to start and check for B+ at

(221)

getting to F3.

J4-2. If no B+, remove F3 and check continuity.

message

If open, replace the fuse with one of the same

type and amp rating (5 Amps). If F3 is OK, check

Reset and

the B+ supply from the wiring harness.

attempt to

start:

2. To isolate:

2. Emergency Stop switch S13 or the

Start LED

PCC door harness may be bad.

Check for B+ at S13-1 and S13-2.

DS11 on the

If there is B+ at S13-2, but not at S13-1 (and

engine

S13 is NOT in the emergency stop position),

interface board

then S13 is bad. Replace S13.

does NOT

turn on.

and check for B+ at A31 J3-2. If there is no

B+, replace A31.

NOTE:

If there is B+ at A31 J3-2, check continuity

These two

from P3-2 to P3-6. If no continuity, repair or

indications

replace as necessary.

suggest that

the PCC has

received a

start signal

and has NOT

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

3. Digital board (A32) may be bad.

sent a start

the control. Attempt to start, and test for ground

command to

output at A32 J4-3. If there is no ground output,

the start output

A32 is bad. Replace A32.

(J4-2) on the

engine

interface

board.

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

4. Engine interface board (A31) may be

bad.

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.

4-14

•

• If there is no B+ at S13-2, disconnect J3/P3,

•

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“FAIL TO

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

1. The Auto mode signal is not getting

CRANK”

from engine interface board A31 to

for ground output at A32 J4-18.

(221)

digital board A32, indicating that A31 is

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

message

bad.

engine interface board A31 is bad. Replace

DOES NOT

A31.

appear on

If there is a ground output at A31 J1-18, pro-

digital display

ceed to the next step.

−and:

Auto LED DS5

on the engine

interface board

(A31) is on −

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

2. The Remote run signal is not getting

RMT Start

from customer interface board A34 to

the control. Attempt to remote start, and check

LED DS14 on

A32, indicating that A34 is bad.

for ground output at A32 J2-26. If no ground out-

the customer

put (but A34 DS14 is on) customer interface

interface board

board A34 is bad. Replace A34.

(A34) is on −

If there is a ground output at A32 J2-26, pro-

ceed to the next step.

NOTE:

This condition

suggests that

the PCC

processor

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

3. Digital board (A32) may be bad.

(digital board

ground input at A32 J2-26, and a ground input

−A32) has

at A32 J4-18—and there is no “FAIL TO

NOT received

CRANK” message—and the set does not

or recognized

crank; A32 is bad. Replace, A32.

a remote start

start signal.

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

4-15

TABL E 4-7. ENGINE DOES NOT CRANK—REMOTE RUN

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“FAIL TO

The Auto mode input is not getting from the

CRANK”

Auto select switch (S12) to engine interface

(221)

board A31 (indicating that S12, A31, or the

message

harness is bad.

DOES NOT

appear on

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

1. S12 or the wiring harness may be bad.

digital display

ground at A31 J3-11. (J3-11 is ground out to

−and:

S12. If ground is not present, replace A31. If

Auto LED DS5

ground is present, place S12 in Auto and check

on the engine

continuity from P3-11 to P3-13. If no continuity,

interface board

isolate to switch or wiring harness. Repair as

(A31) is off −

necessary. If there is continuity, A31 may be

RMT Start

bad. Reconnect J3/P3.

LED DS14 on

the customer

interface board

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

2. Engine interface board A31 may be

(A34) is on −

bad.

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

If the voltage is present at A32 J4-16, and

NOTE:

ground is present at A31 P3-13—and yet A31

This condition

DS5 is off; then A31 is bad. Replace A31.

suggests that

the engine

interface board

(A31) is NOT

3. Digital board A32 may be bad.

3. If there is no +16 volt supply voltage at A32

enabling the

J4-16, A32 is bad. Replace A32.

remote start

logic on the

digital board.

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

4-16

TABL E 4-8. ENGINE DOES NOT CRANK—REMOTE RUN

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“FAIL TO

The remote start input is not getting from the

CRANK”

remote start switch to the output of the cus-

(221)

tomer interface board (A34) indicating that

message

the switch, A34, or the harness is bad.

DOES NOT

appear on

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

1. The remote start switch or the

digital display

the control. Attempt remote start and check for

wiring harness may be bad.

−and:

ground at A34 J1-13. If ground level is not pres-

Auto LED DS5

ent, isolate to the switch or the wiring harness

on the engine

by checking for a start signal at TB1-5. Repair

interface board

as necessary.

(A31) is on −

RMT Start

LED DS14 on

2. If ground is present at A34 J1-13—and yet A34

2. Customer interface board A34

the customer

DS14 is off, replace A34.

may be bad.

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.

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

4-17

TABL E 4-9. ENGINE DOES NOT CRANK—LOCAL RUN

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“FAIL TO

The start input is not getting from the Run/

CRANK”

Off/ Auto select switch (S12) to A31 (indi-

(221)

cating that S12, A31, or the harness is bad.

message

DOES NOT

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

1. Run/Off/ Auto select switch S12 or the

appear on

ground is not present, replace A31. If ground is

wiring harness may be bad.

digital display

present, place S12 in Run and check continuity

−and:

from P3-11 to P3-12. If no continuity, isolate to

Run LED DS4

switch or wiring harness. Repair as necessary.

on the engine

If there is continuity, A31 may be bad.

interface board

(A31) is off−

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

2. Engine interface board A31

NOTE:

may be bad.

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

This condition

suggests that

If the voltage is present at A32 J4-16, and

the start input

ground is present at A31 J3-12—and yet A31

is NOT getting

DS5 is off, replace A31.

from the

Run/Off/ Auto

switch (S12) to

3. Digital board A32 may be bad.

3. If there is no +16 volt supply voltage at A32

the engine

J4-16, replace A32.

interface board

(A31) to

enable the

remote start

logic on the

digital board.

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

4-18

TABL E 4-10. ENGINE CRANKS BUT DOES NOT START

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“OVERCRANK” Fuel supply or fuel delivery.

(222)

1. Restricted fuel supply due to:

1a. Add fuel if low. Prime the fuel system.

message

a. Fuel level below pickup tube in

1b. Open any closed shutoff valve in the fuel line

tank.

supplying the engine.

−and

b. Closed shutoff valve in supply line.

1c. Refer to engine service manual.

c. Fuel injuectors clogged.

While cranking,

1d. Bleed air from fuel system. Refer to engine ser-

d. Air in fuel system.

Run LED DS12

vice manual.

on the

2. Inspect the mechanical fuel linkage, and repair

engine interface

2. The mechanical fuel linkage could be

binding, loose, or damaged.

or replace as necessary.

board (A31)

is on.

Follow the procedure in the engine repair

manual to check the EFC for binding or dam-

and

age.

Disconnect the actuator connector, and con-

While cranking,

nect +12 VDC from the battery to the actuator.

Run LED DS2

The actuator should click upon application and

on the governor

removal of the voltage.

output module

If the actuator does not click, refer to the engine

(A38) is on.

manual.

If the actuator clicks, reconnect the wires to the ac-

NOTE:

tuator.

These

indications

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

suggest that the

3. Fuel solenoid (K1) on the injuection

pump ot energized due to:

B+ at the K1 fuel solenoid coil on the injection

PCC has sent a

pump and at output of governor module. Check

run signal to the

a. Open in fuel solenoid circuit or de-

continuity from J6-20 and 21 to J6-19.

fuel solenoid.

fective governor module.

3b. Check wiring continuity of fuel solenoid circuit.

b. Defective fuel solenoid.

Test fuel solenoid.

Repair or replace as necessary.

4. Fuel tank solenoid not energized due

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

to:

cuit.

a. Open in fuel solenoid circuit.

4b. Test fuel tank solenoid.

b. Defective fuel solenoid.

4c. Adjust charge rate of battery charging circuit.

4d. Replace engine DC alternator if normal battery

charging voltage (12 to 14 VDC) is not obtained.

Repair or replace as necessary.

5. Engine fuel injection or other engine

5. Service as necessary.

problem.

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

4-19

TABL E 4-11. ENGINE CRANKS BUT DOES NOT START

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“OVERCRANK”

The run signal is not getting through the

Reset the control. Attempt to start and check for B+

at A31 J4-1.

governor module to the fuel solenoid.

(222)

message

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

1. The run signal is not getting out of the

−and

engine interface board (A31). A31

the control. Attempt to start and check for B+ at

may be bad.

A31 J4-1. If there is no B+ at A31 J4-1, replace

While cranking,

A31.

Run LED DS12

on the

2. There is an open between the engine

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

engine interface

interface board (A31) and the gover-

tween A38 J6/P6. Check for B+ at A38 J6-19,

board (A31)

nor output module (A38).

while attempting to crank. If there is no B+ at

is on.

A38 J6-19, isolate to connectors and wiring.

Repair or replace as necessary.

and

3. The run sighnal is not getting through

3. If there is B+ at A31 J4-1, and there is B+ at A38

While cranking,

the governor output module (A38).

J6-19, check continuity from A38 J6-15 to bat-

Run LED DS2

A38 may be bad.

tery ground, if not continuity replace harness, if

on the governor

continuity, replace A38.

output module

(A38) is off.

NOTE:

This indication

suggest that the

PCC has sent a

run signal to

relay K6, but

the signal is not

getting through

to the fuel

control actuator

or fuel solenoid.

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

4-20

TABL E 4-12. ENGINE CRANKS BUT DOES NOT START

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

*Install harness tool between A32 J4/P4. Attempt to

“OVERCRANK” The run signal from the digital board (A32)

start and check for ground signal at A32 J4−8.

(222)

is not being processed by the engine inter-

message

face board (A31).

−and

Run LED DS12

on the

1. The run signal is not getting out of the

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

engine interface

digital board (A32). A32 may be bad.

A32.

board (A31)

is off.

2. The run signal is not being processed

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

by the engine interface board (A31).

A31.

A31 may be bad.

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.

“FAIL TO

The mag pickup signal is not being

Refer to the mag pickup shutdown message

CRANK”

sensed.

(220).

(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.

4-21

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. Low oil level. Clogged lines or filters.

1. Check oil level, lines and filters. If oil system is

“LOW OIL

OK but oil level is low, replenish. Oil pressure

PRESSURE”

limits are listed in Table 4-3.

warning

(200) or

shutdown

(201)

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

2. Disconnect the oil pressure sender leads, and

message.

the generator set may be shutting

connect an oil pressure sender simulator to the

down on another fault.

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 pres-

sure, 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 connec-

tor). 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.

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

2b. Harness or PCC circuit board could be

the PCC or the harness is bad. Install harness

be bad.

tool between A31 J2/P2.

Isolate to the harness, engine inter-

Check for +5 VDC at the sender (lead marked

face board (A31), analog board (A33),

E1-B). If there is no 5 VDC at the sender

or digital board (A32).

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 4-29a/b).

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

4-22

•

•

•

•

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“OIL

1. The sender connections could be bad.

1. Check the sender connections.

PRESSURE

SENDER”

warning

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

2. The sender, the harness, engine inter-

(204)

face board (A31), digital board (A32),

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

message.

or analog board (A33) could be faulty.

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 sec-

onds.

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

place the sender.

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

tor, 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 send-

er 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 har-

ness or A31. If the pressure signal does get

to A31 J2-23, refer to the analog/digital trou-

bleshooting procedure (Table 4-29a/b).

“COOLANT

1. The sender connections could be bad.

1. Check the sender connections.

SENDER”

warning

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

2. The sender, the harness, engine inter-

(213)

face board (A31), digital board (A32),

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

message.

or analog board (A33) could be faulty.

board (A32).

Disconnect the sender, and plug in a resistive

sender simulator to isolate the fault.

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

place the sender.

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

tor, refer to the high coolant temp trouble-

shooting procedure.

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

4-23

•

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“LOW

DS3 / A31 is on, indicating that engine in-

Isolate the source of the signal.

COOLANT

terface board A31 is receiving a low cool-

Unplug the coolant temperature switch (S1) and re-

TEMP”

ant temp from the sender.

set the control.

warning

The sender, the harness or A31 could be

1. If the 210 warning message drops out and does

(210)

bad.

not reappear, replace the sender.

message.

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

Coolant level

mains after control reset, disconnect A31 J4

is normal.

and check continuity from P4−13 to GND.

• If there is continuity, replace the harness.

Heater is OK.

A31.

Coolant temp

on front panel

display is OK.

DS3 on the

engine

interface

board, A31,

is on.

“LOW

DS3 / A31 is off, indicating that engine in-

Isolate the source of the signal.

COOLANT

terface board A31 is not receiving a low en-

Check J4−6/P4−6 on A32.

TEMP”

gine temp signal from the sender—but the

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

warning

210 message indicates that A32, the digital

2. Open J4−6 and reset the control.

(210)

board, is responding to a false low engine

message.

temp signal.

If fault drops out and does not return, re-

place A31.

A31, the engine interface board, or A32,

Coolant level

the digital board, could be bad.

If fault returns after resetting the control,

is normal.

replace A32.

Heater is OK.

Coolant temp

on front panel

display is OK.

DS3 on the

engine

interface

board, A31,

is off.

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

4-24

• If there is no continuity, replace circuit board

•

•

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

WARNING

M any troubl eshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“HIGH

1. Engine problem:

1. Refer to the engine service manual if there are

COOLANT

any physical indications of overheating.

Coolant pump could be faulty.

TEMP”

2. Correct any overload condition.

Thermostat could be faulty.

warning

3. If there are no physical indications of overheat-

There could be an obstruction in

(211) or

the coolant flow.

ing, check to see if the PCC accurately displays

shutdown

ambient engine temperature.

External coolant pump (with re-

(212)

mote radiator) could be faulty.

If the PCC ambient coolant temperature

message.

reading is accurate, the engine may be over-

External radiator fan motor (with re-

Coolant

heating. Refer to the engine service manual.

mote radiator) could be faulty.

mixture and

2. The generator set may have been

If the PCC ambient coolant temperature

level is normal.

reading is not accurate, isolate to the send-

overloaded.

er, harness, engine interface board (A31),

3. Sender, harness or PCC circuit board

No airflow

analog board, or digital board.

could be bad.

obstructions.

Disconnect the coolant temperature sender

leads, and connect a coolant temperature

Fan belt is OK.

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.

lated temperature signal and mea-

sure the voltage out of A31 (A31

J2-18 to 19, and A31 J2-14 to 15).

If voltage is not OK (refer to the ana-

log board inputs and outputs, Table

4-30), replace A33.

If voltage is OK, refer to the analog/

digital troubleshooting procedure

(Table 4-29a/b).

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

4-25

•

•

•

•

•

•

•

•

•

•

• If continuity is OK, then send a simu-

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“LOW

DS2 on A31 is on, indicating that A31 is re- If the coolant level is normal, isolate the source of

COOLANT

ceiving a low coolant signal from the send- the low coolant signal. (This is a ground signal.)

LVL” warning

er.

Disconnect the signal lead at the sender and reset

(214) or

The sender, the harness or the A31 circuit the control.

shutdown

board could be bad.

1. If the 215 shutdown message drops out and

(215) message

does not reappear, replace the sender.

Coolant level

*2. If the 215 shutdown message reappears and

is normal.

remains after control reset, disconnect J4/A31

and check continuity from P4−7 to GND.

DS2 on the

•

If there is continuity, replace the harness.

engine

If there is no continuity, replace circuit board

interface

A31.

board, A31,

is on.

“LOW

DS2 on A31 is off, indicating that A31 is not If the coolant level is normal, isolate the source of

COOLANT

receiving a low coolant signal from the the low coolant signal.

LVL” warning

sender—but the 215 message indicates

(214) or

that A32, the digital board, is responding to

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

shutdown

a false low coolant signal.

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

(215) message

A31, the engine interface board, or A32, the

If the fault drops out and does not return, re-

digital board, could be bad.

Coolant level

place A31.

is normal.

replace A32.

DS2 on the

engine

interface

board, A31,

is off.

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

4-26

•

Check J4−4/P4−4 on A32.

•

• If the fault returns after resetting the control,

TABL E 4-18. MAG PICKUP SHUTDOWN (220)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“MAG

This indicates that the PCC is not sensing

PICKUP”

the mag pickup signal, or the mag pickup

shutdown

frequency does not correspond (in propor-

message (220) tion) to the genset output frequency.

1. Check and correct setting if necessary.

1. The PCC may not be set for the correct

generator set.

2. Inspect the wires, and repair or replace as nec-

2. Loose or damaged mag pickup wire.

essary.

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

3. Damaged mag pickup (MPU).

tempt to start the set in idle mode.

4. The harness, the engine interface

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

board (A31), the analog board (A33) or

down message, or if the engine starts and idles,

the digital board (A32) could be bad.

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 Section 5.) If there is still 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, re-

place 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.

digital multimeter and compare to the fre-

quency 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 (Table

4-29a/b).

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

4-27

• Measure generator output frequency with a

•

•

TABLE 4-19. OVERSPEED SHUTDOWN (223)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. The mechanical fuel linkage could be

1. Inspect the mechanical fuel linkage, and repair

“OVERSPEED”

binding, loose, or damaged.

or replace as necessary.

shutdown

message (223)

• Follow the procedue in the engine repair manu-

al to check the EFC for binding or damage.

• Disconnect the actuator connector, and con-

nect +12 VDC from the battery to the actuator.

The actuator should click upon applicatin 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-

2. The governor output module (A38) or

the digital board (A32) could be bad.

toring the PCC duty cycle display.

If the duty cycle goes high (above 40%) and the

set shuts down on overspeed, replace A32.

down on overspeed, replace A38.

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

4-28

•

• If the duty cycle goes to zero and the set shuts

TABLE 4-20. DC (BATTERY) WARNINGS (230, 231, 232)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. Weak or discharged battery.

1. Recharge or replace the battery. Specific gravi-

“LOW DC

ty for a fully charged battery is approximately

VOLTAGE”

1.260 at 80° F (27° C).

(230) or

“WEAK

2. Low electrolyte level in battery.

2. Replenish electrolyte and recharge battery.

BATTERY”

(232),

warning

3. Battery connections loose or dirty.

3. Clean and tighten or replace the battery cable

message.

connectors and cables at the battery and the

set.

4. Insufficient battery charging voltage.

4. Adjust charge rate of battery charging circuit,

according to manufacturers instructions.

5. Engine DC alternator could be bad.

5. Replace engine DC alternator if normal battery

charging voltage is not obtained.

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

6. If the batteries are OK, the problem

may be the harness, the engine inter-

tions are OK, check the battery voltage at A31

face board (A31), the digital board

J5-17. If the voltage is not OK (same as battery

(A32), or the analog board (A33).

voltage), disconnect J5 and isolate to the har-

ness 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 trouble-

shooting procedure (Table 4-29a/b).

“HIGH DC

1. Excessive battery charging voltage.

1. Adjust charge rate of battery charging circuit ac-

VOLTAGE”

cording to manufacturers instructions.

(231)

warning

2. Engine DC alternator could be bad.

2. Replace engine DC alternator if normal battery

message.

charging voltage is not obtained.

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

3. If the battery voltage is OK, the prob-

But battery

lem may be the engine interface board

voltage is not OK (same as battery voltage), dis-

voltage is OK.

(A31), the digital board (A32), or the

connect J5 and isolate to the harness or A31.

analog board (A33).

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 4-29a/b).

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

4-29

TABL E 4-21 . LOW FUEL −DAY WARNING (240)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“LOW FUEL−

DS1 on A31 is on, indicating that A31 is re- If the fuel level is normal, isolate the source of the

DAY”

ceiving a low fuel signal from the sender.

low fuel signal.

warning

The sender, the harness or thhe A31 circuit Disconnect the signal lead at the sender and reset

message (240)

board could be bad.

the control.

1. If the 240 message drops out and does not re-

Fuel level is

appear, replace the sender.

normal.

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

DS1 on the

ter control reset, disconnect J4/A31 and check

engine

continuity from P4−14 to GND.

interface

•

If there is continuity, replace the harness.

board, A31,

If there is no continuity, replace circuit board

is on.

A31.

“LOW FUEL−

DS1 on A31 is off, indicating that the PCC is If the fuel level is normal, isolate the source of the

DAY”

not receiving a low fuel signal from the low fuel signal.

warning

sender—but the 240 message indicates

*1. Install a breakout connector at A32 J4.

message (240)

that A32, the digital board, is responding to

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

a false low fuel signal.

Fuel level is

If the fault drops out and does not return, re-

A31, the engine interface board, or A32,

normal.

place A31.

the digital board, could be bad.

DS1 (A31) and

go to step 3.

DS13 (A34)

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

are off.

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

If the fault drops out and does not return, re-

place 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.

4-30

•

•

• If the fault returns after resetting the control,

•

•

TABL E 4-22 . LOW FUEL WARNING (241)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

“LOW FUEL”

DS13 on A34 is on, indicating that A34 is re- If the fuel level is normal, isolate the source of the

warning

ceiving a low fuel signal from the customer low fuel signal.

message (241) circuit.

Disconnect the signal lead near the control and reset

If there is no actual fault, the problem may the control.

Fuel level is

be a short to ground in the external wiring

1. If the 241 message drops out and does not re-

normal.

or a bad customer interface board (A34)

.

appear, there is a short to ground in the external

DS13 on the

wiring or a faulty sender.

customer

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

interface

ter control reset, disconnect J1/A34 and check

board, A34, is

continuity from P1−5 to GND.

on.

ground in the external wiring.

If there is no continuity, replace circuit board

A34.

“LOW FUEL”

DS13 on A34 is off, indicating that the PCC If the fuel level is normal, isolate the source of the

warning

is not receiving a low fuel signal from the low fuel signal.

message (241)

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

that A32, the digital board, is responding to

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

Fuel level is

a false low fuel signal.

normal.

If the fault drops out and does not return, re-

A34, the customer interface board, or A32,

place A34.

DS13 (A34) is

the digital board, could be bad.

off.

replace A32.

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

4-31

sender—but the 241 message indicates

• If there is continuity, find and repair a short to

•

•

• If the fault returns after resetting the control,

TABLE 4-23. EEPROM ERROR SHUTDOWN (250) OR WARNING (251, 25 2)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

The EE memory on the digital board (A32)

1. Perform the initial start setup procedure.

“EEPROM

may be bad.

Turn the Run/Off/Auto switch to Off and reset

ERROR”

the control. Simultaneously press the RESET,

shutdown

MENU, and PHASE SELECT keys to start the

(250)

setup.

message.

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).

“EEPROM

The EE memory on the digital board (A32)

1. Perform the adjustment procedures (described

ERROR”

may be bad.

in Section 5). Save the adjustments.

warning

Reset the control. Shut off and restart the set.

(251)

2. If the control generates the same EEPROM

message.

ERROR message, perform the calibration pro-

cedures in Section 5.

Reset the control. Shut off and restart the set.

3. If the control generates the same EEPROM

ERROR message, replace the digital board

(A32).

“EEPROM

The EE memory on the digital board (A32)

1. If this message occurred during an adjustment,

ERROR”

may be bad.

option selection, or calibration of the PCC,

warning

verify the values or choices selected and repeat

(252)

the save operation.

message.

Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROM

ERROR message, replace the digital board

(A32).

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

4-32

TABL E 4-24a. CUSTOMER FAULTS (260**, 261, 262 or 263)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

If the corresponding LED on the customer Isolate the source of the false signal.

“CUSTOMER

interface board (A34) is on, then A34 is re-

Disconnect the signal lead near the control and

FAULT

ceiving a signal from the customer circuit.

(260, 261, 262

reset the control.

or 263)

If there is no actual fault, the problem may

1. If the message drops out, there is a short to

message.

be a short to ground in the external wiring

ground in the external wiring.

or a bad customer interface board (A34).

2. If the message remains, replace A34.

And

corresponding

LED on

customer

interface board

A34 is on.

If the corresponding LED on the customer Isolate the source of the false signal.

“CUSTOMER

interface board (A34) is off, then A34 is not

Check J2/P2 on A32.

FAULT

receiving a signal from the customer circuit.

*

1. Install harness tool between A32 J2/P2.

(260, 261, 262

or 263)

The message indicates that A32, the digital

2. Open the appropriate circuit J2-3, J2-24, J2-9,

message.

board, is responding to a false signal.

or J2-15 and reset the control.

A34, the customer interface board, or A32,

If the fault does not return, replace A34.

And

the digital board, could be bad.

corresponding

If the fault reappears, replace A32.

LED on

customer

interface board

A 34

A32

CUSTOMER FAULT

A34 is off.

LED

CONNECTOR

FAULT #

CODE

DS4

J2-3

1

260

DS11

J2-24

2

261

DS15

J2-9

3

262

DS3

J2-15

4

263

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

4-33

** For generator sets with QST30 Engines, Customer Fault 260 is Rack Position Warning see page 4-34

•

•

TABLE 4-24b. RACK POSITIONING WARNING 260 (QST30 ENGINES)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

PowerCommand control fault or defective

Restart the generator set and monitor the fault

end of this section (Page 4-46).

“RACK

governor control circuitry.

POSITION ”

warning

message

(260)

4-34

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

LED’s of the governor output module (A38). Refer

to Section 3 for LED descriptions.

1 LED’s (DS1 through DS4 are on and DS5
and DS6 are off) do not indicate a fault,
refer to “Customer Fault 261, 262 & 263
for corrective action.

2 LED’s (DS5 or DS6 are on) one or more

indicate a fault and the generator set
shuts down after restarting – perform the

Rack Position Fault/Test Procedure at the

TABLE 4-25a . HIGH AC VOLTAGE SHUTDOWN (301)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. The problem may be in the PCC, the

1. Set the display on the PCC to GEN, VOLTS,

“HIGH AC

L-N.

alternator, or the interconnection be-

VOLTAGE ”

tween them.

a. Start the genset and observe the voltage

shutdown

displayed on the digital display.

(301)

Note 1: The PCC may indicate either

b. If all phases of voltage are balanced and not

message.

a low AC Voltage or High AC Voltage

zero, but lower than normal, the alternator

shutdown due to the design of the

and the input to the PCC are OK. The prob-

logic in the control.

lem is in the excitation circuit for the alterna-

tor. Go to step 2.

You must first determine if the out-

put voltage the control sees is low

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

or high.

the voltages are unbalanced, the PCC is not

measuring all phases of voltage and is re-

Note 2: Residual voltage is normally

sponding to the low “average” of the three

5 to 10% of nominal output voltage.

phases of voltage. Go to step 3.

For example, a genset with a 480

volt output, will have a residual volt-

age of 25 to 50 VAC at normal oper-

ating speed.

2. The problem may be the regulator

2. With DC power to the PCC and with the set not

module (A37), the engine interface

running, check A31 DS9, the AVR duty cycle

board (A31), or the digital board (A32).

LED. this LED should be off. If it si on, go to step

2d.

Isolate the genset output from the load. Discon-

nect 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.

(Continued)

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

4-35

TABLE 4-25b. HIGH AC VOLTAGE SHUTDOWN (301)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

*3. Before starting the generator set, discon-

3. The problem may be the PT/CT mod-

“HIGH AC

ule (A36) or the interconnecting wiring

nect the harness connector from the PT/CT

VOLTAGE ”

to the PT/CT module.

module (A36) and connect the harness tool

shutdown

between A36 and its harness connector.

NOTE: To calculate the “expected A36

(301)

Check the output voltage at the alternator

output” voltage range, do the follow-

message.

output terminals and record the voltages.

ing:

a. If the voltages are not balanced, go to step 5.

Determine the ratio between the mea-

b. If the voltages are balanced, calculate the

sured voltage and the expected volt-

expected output voltage from the PT/C mod-

age. The output (18 VAC) of the PT/CT

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

module will also be reduced by this ra-

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

tio.

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

4. The problem may be in the customer

interface board (A34) or the intercon-

below with the set off then start the set in the

necting wiring.

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.

4-36

TABLE 4-25c . HIGH AC VOLTAGE SHUTDOWN (301)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

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

5. The problem may be the analog board

“HIGH AC

(A33).

ave” signal at A33 J2-18.

VOLTAGE ”

If the voltage is within the expected range,

shutdown

replace A32. If the voltage is not within the

NOTE: To determine the “3-phase

(301)

expected range, replace A33. See Note.

ave” signal voltage range for Step 3b,

message.

use the following formula:

V

out

3-phase ave = Vin (2.9÷PT) ±5%

V

in

= Actual generator output voltage

(phase-to-neutral)

PT = PT primary (120, 240 or 346)

6. The problem may be in the generator

6. Refer to the generator servicing procedures in

set itself.

Section 6.

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

4-37

TABLE 4-26a. LOW AC VOLTAGE SHUTDOWN (303)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. If output voltage is low and both A37/DS2 and

1. PMG or field wiring could be faulty.

“LOW AC

A31/DS10 are on, check and repair the PMG or

VOLTAGE ”

field wiring.

shutdown

(303)

2. The rotating rectifier assembly (diodes

2. Check each diode according to Servicing the

message.

CR1 through CR6) is faulty.

Generator in Section 6. Service as necessary.

3. Overload.

3. Check the load and correct any overload.

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

4. There may be a loose connector in the

control loop.

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-

5a. The problem may be the analog board

(A33) or the digital board (A32).

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

5b. The problem may be the regulator

procedure (Table 4-29a/b). Check the phase

module (A37), the engine interface

board (A31), or the digital board (A32).

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, re-

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.

(Continued)

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

4-38

•

•

•

•

•

•

TABL E 4-26 b. LOW AC VOLTAGE SHUTDOWN (303)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

5c. The problem may be the PT/CT mod-

c. If the measured AC voltage is high, the control

“LOW AC

ule (A36), the analog board (A33), the

must have lost AC sensing. Check PTs (primary

VOLTAGE ”

customer interface board (A34), or the

1K−2.5K ohms; secondary 140−225 ohms),

shutdown

digital board (A32).

sensing harness wires, generator output con-

(303)

nections, and the customer interface board for

message.

continuity. If these are OK, then check the ana-

log and digital boards, using the analog input

troubleshooting procedure (Table 4-29a/b).

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

4-39

TABL E 4-27. UNDER FREQUENCY SHUTDOWN (313)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. Improper setup.

1. Check Initial Setup (set size) and correct, if nec-

“UNDER

essary.

FREQUENCY”

shutdown

(313)

2. Overload.

2. Check the load and correct any overload, if nec-

message.

essary.

Disconnect the load. Reset the control and at-

tempt to restart the generator set.

3. Fuel or air delivery problem.

3. If the engine starts and runs, refer to the engine

fuel/air delivery service procedures.

*4. Crank the set, and check the governor duty

4. The fuel control actuator, the digital

board (A32), or the engine interface

cycle on the PCC display. If the duty cycle is OK

board (A31) could be bad.

(70% max), replace the fuel control actuator.

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 con-

tinuity, 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.

4-40

•

TABL E 4-28. OVERCURRENT WA RNING (320) OR SHUTDOWN (321),

SHORT CIRCUIT SHUTDOWN (322), OR OVERLOAD WARNING (330)

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s)

Possible Cause

Corrective Action

1. Short or Overload.

1. Check the load and load cables. Repair if nec-

“OVER-

essary.

CURRENT”

warning (320)

or shutdown

2. Incorrect CTs or CT connections.

2. Check CTs and CT connections. Correct if nec-

(321),

essary. Refer to Current Transformer Installa-

or

tion in Section 5.

“SHORT

3. Disconnect the PT/CT module and check the

3. The problem may be a bad PT/CT

CIRCUIT”

3-ohm resistors (J8-15 to 14, J8-22 to 23,

module (A36).

shutdown

J8-7 to 8). Replace the module if necessary.

(322), or

OVERLOAD

*4. Check continuity from A36—through A34—to

4. The problem may be the customer in-

warning (330)

A33. Repair the connection or replace A34 if

terface board (A34) or connections.

message.

necessary. Refer to Section 9 for pin reference.

5. Isolate, using the analog input troubleshooting

5. The problem may be the analog board

procedure (Table 4-29a/b). Check the bad

(A33) or the digital board (A32).

phase or phases.

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

4-41

TABL E 4-29a. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL

BOARDS

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards 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 i n p u ts 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 4-30), 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

4-30). 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 4-30), 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.

4-42

•

•

•

•

TABL E 4-29b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL

BOARDS

WARNING Many troubleshooting procedures present hazards that can result in severe personal inju-

ry or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery haz-

ards 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 i n p u ts 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 ex-

cept 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 s trap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-43

•

TABLE 4−30. ANALOG CIRCUIT BOARD (A33) INPUTS AND OUTPUTS

Input Name

Input

Input Signal

Output Name

1

Output

Output

Connection

Range

Connection

2

Signal Range

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

3PH ave (ACH0)

Line freq. (HSI.1)

J2-21

0-5V sq wave @ L1 Hz

34

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

C1 (ACH7)

J2-7

0 to 1.0 VDC

C3 (ACH7)

J2-7

0 to 1.0 VDC

(1 to 0.8 pf)

Phase angle 1 (ACH7)

3

J2-7

0 to 1.0 VDC

(1 to 0.8 pf)

Phase angle 2 (ACH7)

3

J2-7

0 to 1.0 VDC

(1 to 0.8 pf)

Phase angle 3 (ACH7)

3

J2-7

0 to 1.0 VDC

(L1 vs CT21)

Lead lag (P2A.1))

3

J2-29

0 or 5 VDC (digital)

Bus L1 (0 to nominal)

6

J4-15 to J4-18

0 to 18 VAC

Bus L1 (ACH7)

J2-7

0 to 3.0 VDC

Bus L2 (0 to nominal)

6

J4-16 to J4-18

0 to 18 VAC

Bus L2 (ACH7)

J2-7

0 to 3.0 VDC

Bus L3 (0 to nominal)

6

J4-17 to J4-18

0 to 18 VAC

Bus L3 (ACH7)

J2-7

0 to 3.0 VDC

Bus freq (HS1.3)

J2-22

0-5V sq wave @ Bus L1 Hz

Phase rot (P2A.0)

5

J2-26

0 or 5 VDC (digital)

Bus/gen phase dif (ACH7)

J2-7

0 to 5.0 VDC

5

J2-19

0-5V 120 Hz 0 to 100% DC

Synch (ACH7)

Battery voltage

J1-31 (+) to J1-30(−)

0 to 32 VDC

Battery voltage (ACH7)

J2-7

0 to 2.9 VDC

(See note

F)

J2-7

1.4 to 3.7 VDC

F)

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

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.

4-44

J2-18

0 to 2.9 VDC

CT21 (0 to full load)

J4-33 to J4-

0 to 1.65 VAC C1 fltrd (ACH4)

C2 (ACH7)

Bus/gen phase (HS1.2)

J2-3

J2-7

5

5

J2-7

0 to 1.0 VDC

0 to 1.0 VDC

Oil press (0 to 100 psi)

H2O 1 (6 to 230°

H2O 2 (6 to 230°

J1-19/20 to J1-17/18 700 to 1800 Ω H2O 1 (ACH7)

J1-15/16 to J1-14/15 700 to 1800 Ω H2O 2 (ACH7)

4 )

0.5 to 4.5 VDC Oil press (ACH7)

J2-7

J2-7

0.5 to 4.5 VDC

1.4 to 3.7 VDC

TABLE 4-31. PCC FUSES

REFERENCE

LOCATION

RATING

FUNCTION

DESIGNA-

TION

Engine Interface

A31-F1

5 Amp

PCC control B+

Engine Interface

A31-F3

5 Amp

Auxiliary B+ (for panel lights, run and start relays)

Governor Output

A38-F1

10 Amp

Network B+ (to TB1 customer terminal block)

Module

Governor Output

A38-F2

10 Amp

Switched B+ (to TB1 customer terminal block)

Module

Governor Output

A38-F3

10 Amp

Governor B+ )power for governor output module and actuator)

Module

TB-Bat (Engine

F1

20 Amp

Customer B+ (to TB1 customer terminal block)

Harness Assembly

4-45

4-46

The r ack pos ition f ault/test pr ocedure i s a t rouble-
shooting tool f or t he R ack P osition ( 260) warning

of

these c omponents; f uel pum p, gov ernor o utput

Use a c alibrated R MS multimeter f or ac curate
measurements. F luke models 8 7 or 80 60A ar e

Move t he R un/Off/Auto s witch t o t he O ff

ine i nterface boar d ( A31), pl ace

TP2

Select R ACK T EST from t he S etup M enu

17) t o i nitiate t he f uel r ack t est.

This will apply power to the governor output

S1 ( RUN) and A38 D S2 ( VCC)

Possible control problem. Remove
jumper w ires ( Step 2) . R estart s et
and f ollow proper t roubleshooting

Move both racks from 0mm to 19mm from

RACK POSITION FAULT/TEST

Periodically read the DC voltages from J11-

PROCEDURE

message. T his t est w ill isolate t he f ault t o o ne

module (A38), or the PowerCommand control.

good choices.

1.
position.

2. At t he en g
a j umper w ire f rom A 31-TP1 t o A31-
(see Figure 3-4 for test point location).

3.
(page 5 -

module.

4. Are A38 D
LED’s on?

Yes: Go to next step.
No:

procedure.

5. Are fuses A38 F1 and F2 blown?
Yes: Replace blown fuse and restart set.
No: Go to next step.

6.
the “POS MM” menu (see Setup Menu).

B (left position voltage) to J11-A and J11-C
(right position voltage) to J11-A. (J11
engines harness connector is located at the
bottom of the accessory box.)

7. Do these voltages correspond to the voltage
on the display ( ± .25 VDC)?

Yes: Test OK. Restart set and monitor A38-

DS5 (left position fault) and A38-DS6
(right position fault).

No: Go to next step.

8. Are both left and right voltages out of
tolerance?

Yes: Possible control or governor output

module problem. Check PWM signal
(refer to Step 4 of error Code 313 in
Troubleshooting section).

No: Go to next step.

9. Move the racks to 0mm from the “POS MM”
menu. Monitor the position voltage of the
side that has the incorrect voltage.

10. Disconnect the fuel pump connector at the
fuel pump. Does the voltage rise up from
approximately 1.3 ± .25 VDC to 4.5 ± .25
VDC?

Yes: Replace defective fuel pump (refer to

engine service manual).

No: Replace defective governor output

module.

Engine Torque Adjustment procedure must be
performed after replacement of fuel pump or
governor output module. Refer to Section 5.

5. Control Service and Calibration

GENERAL

CIRCUIT BOARD

REMOVAL/REPLACEMENT

This section contains circuit board removal and re-

No special tools (other than a grounding wrist strap)

placement procedures, calibration procedures for

are required to remove a circuit board from inside

the genset control and test procedures for the gen-

the control panel or the accessory box.

erator and engine components. Refer to the figures

included with this information and also the Wiring

There are several circuit boards, that when re-

Diagrams section when instructed.

placed, require you to recalibrate the control panel

functions. Table 5-1 lists the circuit boards and the

Before servicing the PCC, it is recommended that all

appropriate procedure to perform to recalibrate the

settings be recorded. This will make sure of correct

control panel. The circuit board locations are shown

and complete readjustment of the PCC in th e event

in Figure 5-1.

that all previous entries are lost during servicing.

Before you attempt to remove a circuit board, read

the Circuit Board Removal Safety Precautions in

this section.

TABLE 5-1. CONTROL PANEL RECALIBRATION

CIRCUIT BOARD

ADJUSTMENT

PROCEDURE / PAGE

Analog Board (A33)

1. Voltage, Current and PF.

Setup and Calibration Menus (Page 5-8)

2. Coolant Temperature L & R

1. Initial Start Setup (Page 5-4).

Digital Board (A32)

Must recalibrate all values, starting with

the Initial Start Setup procedure.

2. Adjust Menu (Page 5-6).

3. Setup and Calibration Menus (Page

5-8).

PT/CT Board (A36)

Voltage, Current and PF.

Setup and Calibration Menus (Page 5-8)

5-1

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

DISPLAY

BOARD

ANALOG

A35

BOARD

A33

ENGINE INTERFACE

CUSTOMER

A31

INTERFACE

A34

GOVERNOR

OUTPUT MODULE

A38

PT/CT BOARD

A36

VOLTAGE REGULATOR

ACCESSORY

OUTPUT MODULE

BOX (HC 4/5)

A37

FIGURE 5-1. CIRCUIT BOARD LOCATIONS

5-2

Circuit Board Removal Safety Precautions

Always disconnect a battery char-

ger from its AC source before disconnecting the

battery cables. Otherwise, disconnecting the

To prevent circuit board damage due to electrostatic

cables can result in voltage spikes high enough

discharge (ESD), a grounding wrist strap must be

to damage the DC control circuits of the set.

worn when handling circuit boards or socket-

mounted IC’s. (The wrist strap does not provide a

WARNING Accidental starting of the generator

direct short to ground, but is typically rated at

set while working on it can cause severe per-

approximately 1 megohm to ground.)

sonal injury or death. Prevent accidental start-

ing by disconnecting the starting battery cables

Attach the clip to a non -painted surface of the con-

(negative [−] first).

trol box and place the strap around your wrist before

handling a circuit board.

Make certain battery area has been well-venti-

lated before servicing battery. Arcing can ignite

CAUTION

Electrostatic discharge will damage

explosive hydrogen gas given off by batteries,

circuit boards. To prevent this damage, always

causing severe personal injury. Arcing can oc-

wear a grounding wrist strap when handling cir-

cur when cable is removed or re-attached, or

cuit boards or socket-mounted IC’s.

when negative (−) battery cable is connected

and a tool used to connect or disconnect posi-

tive (+) battery cable touches frame or other

Turn off or remove AC power from the battery char-

grounded metal part of the set. Always remove

ger and then remove the negative (−) battery cable

negative (−) cable first, and reconnect it last.

from the set starting battery. This is to make sure

Make certain hydrogen from battery, engine

that the set will not start while working on it and to

fuel, and other explosive fumes are fully dissi-

avoid circuit board damage, caused by voltage

pated. This is especially important if battery has

spikes when removing and replacing circuit board

been connected to battery charger.

connectors.

WRIST STRAP

NON-PAINTED

SURFACE

GROUND LEAD CLIP

FIGURE 5-2. WRIST STRAP

5-3

CAUTION

INITIAL START SETUP MENU

STANDBY/PRIME submenu: Use the buttons next

The facing page shows a block representation of

the INITIAL START SETUP menu.

to the “⇑⇓” symbols to toggle the standby/prime op-

tion. Press the button next to the “>>” in the display

CAUTION

Selecting this menu resets all oper-

to move to the model select submenu.

ating 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

MODEL select submenu: Use the buttons next to

PCC has not been set up for use with a generator

the “⇑” and “⇓” symbols to select the correct genera-

set during factory test, or the digital board was re-

tor set model number, frequency and power rating.

placed 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

VOLTAGE SELECT submenu: Use the buttons

set, and its operating frequency and output voltage.

next to the “⇑” and “⇓” symbols to select the correct

These choices must be saved into the PCC’s read-

only memory before the PCC will accept changes

generator set nominal line-to-line output voltage.

made to other menus.

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.

DELTA / WYE submenu: Use the buttons next to

If you choose to do this, the governor/regulator ad-

justments and the setup options will be reset to the

the “⇑” and “⇓” symbols to select the delta or wye op-

default settings (including the editable customer

tion.

fault messages). Display calibrations (volts, amps,

PF and coolant temperature) are retained (not reset).

Before you perform the reset function, it is recom-

mended that all settings be recorded. This will make

sure of correct and complete readjustment of the

PCC.

SAVE submenu: From the model select submenu,

Improper setup, calibration, or ad-

press the button next to the “>>” in the display to

justments can cause equipment malfunction or

move to the SAVE submenu. Select SAVE to save

damage. Setup, calibration, and adjustment

your changes. The MAIN MENU will then be dis-

must be performed by technically qualified per-

sonnel only.

played.

5-4

CAUTION

INITIAL START SETUP

(It can be invoked by simultaneously pressing

the Reset, Menu, and Phase Select keys.)

STANDBY/PRIME

>>

⇓⇑ _______

< >

<

(kw mod# freq) >>

< >

<

(vac) L-L VAC >>

< >

DELTA / WYE

>>

_______

< >

< >

ENGINE

GEN

SAVE

>>

ADJUST

>>

< >

< >

TO LOOP BACK & CHECK:

STANDBY/PRIME

>>

SAVE

>> ⇓⇑ _______

< >

< >

Indicates “OR” Condition

5-5

⇑ MODEL
⇓

⇑ VOLTAGE SELECT
⇓

⇓⇑

ADJUST MENU

VOLTAGE submenu: This is the first submenu.

The ADJUST submenus permit adjustment of the

output voltage and frequency and the start and stop

Use the buttons next to the “⇑” and “⇓” symbols to

delay times of the generator set.

adjust output voltage

5%.

The complete calibration procedure is described in

FREQUENCY submenu: From the VOLTAGE sub-

the Calibration Procedure in this section.

menu, press the button next to the “>>” in the dis-

The facing page shows a block representation of

play to move to the FREQUENCY submenu. Use

the ADJUST menu. If you press the button next to

the buttons next to the “⇑” and “⇓” symbols to adjust

the word “ADJUST” in the Main menu, the VOLT-

output frequency

±

5%.

AGE ADJUST submenu will appear.

START DELAY submenu: This delay applies only

As shown in the diagram, the ADJUST menu has

to remote starting in the Auto mode. From the FRE-

five submenus, including a save/exit procedure.

QUENCY submenu, press the button next to the

Voltage and frequency can be adjusted only when

“>>” in the display to move to the START DELAY

the generator set is running under no rmal operating

submenu. Use the buttons next to the “⇑” and “⇓”

parameters (not in idle mode). For e xam p le, if volt-

symbols to set the start delay. The start delay ad-

age adjustment is selected when the set is in Idle

justment range is 0 to 300 seconds.

mode or not running, the digital display will be:

STOP DELAY submenu: This delay applies only

“⇑ VOLTAGE ”

to remote stopping in the Auto mode. From the

“⇓ N/A >>”

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 ad-

justment 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. When not in idle

mode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAY

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

±

ADJUST

< >

ENGINE

GEN

ADJUST

>>

< >

<

< >

>>

FREQUENCY

< >

>>

_______

START DELAY

< >

_______ SEC >>

< >

_______SEC >>

BEGIN VERSION 1.06

< ⇑ IDLE SPEED

⇓

< >

<

SAVE

CHANGES SAVED

< >

ENGINE

GEN

EXIT

>>

EXIT

<> >>

< >

ADJUST

>>

< >

VOLTAGE

CHANGES SAVED

EXIT

>>

< >

< >

>>

_______

<

SAVE

< >

ENGINE

GEN

EXIT

>>

< >

ADJUST

>>

< >

<

SAVE

EXIT

>>

<>

>>

< >

⇓

Indicates “OR” Condition

5-7

⇑ VOLTAGE
⇓ _______

<

⇑
⇓

<

⇑
⇓

<

⇑ STOP DELAY
⇓

_______RPM >>

< ⇑ VOLTAGE

_______

<

⇑
⇓

SETUP AND CALIBRATION MENUS

adjust the display so that it matches the reading tak-

en on an accurate, recently calibrated meter.

The setup and calibration menus allow you to cali-

The complete calibration procedure is described in

brate the PCC with the reading from a calibrated

the Calibration Procedure in this section.

meter. There are four setup and calibration menus

that are selectable from the SETUP/CAL menu:

The facing page shows a block representation of

the VERSION and DISPLAYS submenus, which is

•

VERSION AND DISPLAYS

the first of four SETUP/CAL menus. If you press the

METERS

button next to the “>>” in the Main menu display, the

VERSION/SETUP/CAL menu will appear.

TOR

SETUP

Improper calibration or adjustment

of the PowerCommand control can cause

These four menus are intended for qualified service

equipment malfunction or damage. Calibration

personnel only. For this reason, a three-digit access

and adjustment must be performed by techni-

code must be entered before you can proceed to

cally qualified personnel only.

those menus.

VERSION submenu: If you select VERSION, the

ENTER CODE submenu:

display will show the generator set model number,

The access code for your PCC is: 5 7 4

frequency, and kW rating, and the date and version

.

of the operating software.

To enter the code:

1. Press the button next to the “⇑” to increment the

To display the generator set configuration options,

first digit.

press the button next to the “>>” in the submenu that

displays the model number, frequency and etc. This

2. Press the button next to the “>>” to select the

menu provides the following information:

second digit.

Generator set voltage

3. Press the button next to the “⇑” to increment the

second digit.

WYE or DELTA

4. Press the button next to the “>>” to select the

third digit.

• Parallel or Single

5. Press the button next to the “⇑” to increment the

HISTORY: (Beginning Version 1.06) From the VER-

third digit.

SION, SETUP/CAL menu, press the button next to

6. Press the button next to the “>>” to proceed to

the “>>” in the display to move to the HISTORY sub-

the DISPLAYS/METERS submenu. (Pro-

menu. Press the button next to “HISTORY” to dis-

vided, of course, that you have correctly en-

play the last (latest) recorded error message.

tered the access code.)

The software will record (save) up to 20 error mes-

The following sub-sections describe how to select

sages. The last error detected will always be dis-

and make changes to the setup and calibration me-

played first. As each new error is detected, the old-

nus and save the changes made to these menus.

est error recorded after 20 will be deleted.

Version and Displays Menus

To view the generator set runtime at which the error

occurred and to scroll through the remaining re-

The VERSION menu allows you to verify the model

corded errors, press the button next to the “>>” in

number and frequency of the generator set, the

the error message menu to display the RUNTIME,

date and version of the operating software and gen-

NEWER/OLDER menu.

erator set configuration options. From the VER-

The buttons next to NEWER and OLDER are used

SION menu you can also review a History file, that

to scroll up and down through the error messages.

can contain up to 20 error messages.

For example, pressing OLDER will display the next

oldest recorded error message. When pressing

The DISPLAYS submenus permit calibration of the

NEWER and the last (newest) error message is dis-

digital voltage, current, power factor (PF) and cool-

played, or OLDER and oldest error is displayed, the

ant temperature displays. Calibration is accom-

display will return to the HISTORY menu.

plished by using this section of the menu software to

5-8

•

• GOVERNOR/REGULA

•

CAUTION

•

•

• Standby or Prime

VERSION & DISPLAYS MENUS

< >

ENGINE

GEN

ADJUST

>>

< >

BACK

< >

(kW)

(model) (hz) <<

>

DISPLAYS VOLTAGE &

VERSION

<<

__ __ __ V:___.__ >>

GENSET CONFIGURATION

< >

>

SETUP/CAL

>>

BEGIN VERSION 1.06

BACK

(kW)

(model) (hz) <<

>

_______ V ______<< >

__ __ __ V:___.__ >>

_______ ______

>

<>

GEN

< >

ENGINE

VERSION

<<

< >

ADJUST

>>

< >

SETUP/CAL

>>

BEGIN VERSION 1.06

BACK

<<

< >

VERSION

<<

HISTORY

< >

SETUP/CAL

>>

DISPLAYS ERROR

CODE

<>

<<

< >

_________________

VERSION

<<

HISTORY

_________________ > >

< >

SETUP/CAL

>>

>

< ⇑ ENTER CODE

RUNTIME _________

>>

NEWER

OLDER ⇓ __ __ __

< >

< >

CONTINUED

Indicates “OR” Condition

5-9

<>

MESSAGE AND

Version and Displays Menus (Cont.)

“PF1, PF2 and PF3” (beginning Version 1.06) will

display N/A when the generator set is not running.

DISPLAYS submenus: The DISPLAYS submenus

“COOLANT TEMP R” will display “N/A” if the genset

are intended for qualified service personnel only.

has only one sensor. To calibrate coolant tempera-

For this reason, a three-digit access code must be

ture display, a precision resistor (provided in the en-

entered before you can proceed to those menus.

gine sensor tool) must be temporally substituted for

the temperature sender. Refer to Calibration Proce-

Select SETUP/CAL. The display will show the EN-

dure in this section.

TER CODE submenu. Enter access code (574) as

SAVE/EXIT submenu: From the AMPS L3 subme-

previously described in this section.

nu, press the button next to the “>>” in the display to

move to the SAVE/EXIT submenu. Select SAVE to

Select DISPLAYS to proceed to the DISPLAYS sub-

save your changes. At the CHANGES SAVED sub-

menus. Use the buttons next to the “⇑” and “⇓” sym-

menu, select EXIT to return to the DISPLAYS/ME-

bols to calibrate the selected voltage, current, PF or

TERS submenu.

coolant temperature reading. Press the button next

to the “>>” in the display to move to the next adjust-

If you select SAVE, the adjustments will be retained

after shutdown, and will be in effect when the set is

ment.

restarted. If you select EXIT without saving first, the

“VOLTS L12,” “VOLTS L23,” and “VOLTS L31” refer

adjustments will remain in effect until the genset is

to voltages measured from L1 to L2, L2 to L3, and

shut down, but will be reset (and will not be in effect)

L3 to L1, respectively.

when the set is restarted.

5-10

VERSION & DISPLAYS MENUS (Cont.)

CONTINUED

< ⇑ ENTER CODE

>>

⇓

__ __ __

< >

<>

AMPS L3

<

DISPLAYS

<<

METERS

>>

_______

< >

>>

<

VOLTS L12

<

PF1

_______

< >

>>

>>

PF2

_______

< >

>>

>>

VOLTS L31

<>

_______

>>

_______

< >

>>

AMPS L1

COOLANT TEMP L

_______

>>

_______

< >

>>

< ⇑ AMPS L2

COOLANT TEMP R

_______

>>

_______

< >

>>

<

SAVE

< ⇑ VOLTS L12

EXIT

>>

< >

< >

>>

_______

<

SAVE

CHANGES SAVED

< >

DISPLAYS

<<

EXIT

>>

EXIT

<> >>

< >

METERS

>>

< >

VOLTS L12

CHANGES SAVED

EXIT

>>

< >

< >

>>

_______

<

SAVE

< >

DISPLAYS

<<

EXIT

>>

METERS

<> >>

< >

Indicates “OR” Condition

5-11

<>

⇑
⇓

⇑

<>

⇓ _______

<

⇑ VOLTS L23

<>

⇓ _______

<

⇑

<

<

⇓

<

⇑

<>

⇓

<>

⇓

<

<

⇓

⇑
⇓

⇑
⇓

⇑ PF3
⇓

⇑
⇓

⇑
⇓

<

⇑
⇓

Meters Menu

Select SETUP/CAL. The display will show the EN-

TER CODE submenu. Enter access code (574) as

previously described in this section.

The METERS submenus permit calibration of the

control’s analog meters to match the calibrated digi-

Select METERS to proceed to the METERS sub-

tal values. (Calibrate the digital display before cali-

menus. Use the buttons next to the “⇑” and “⇓” sym-

brating the analog meters.) This calibration is ac-

bols to calibrate the selected meter to match the

complished by using this section of the menu soft-

“CAL TO” value provided on the digital display.

ware to adjust the selected meter reading so that it

Press the button next to the “>>” in the display to

matches the reading provided on the digital display.

move to the next calibration. (Beginning with Ver-

sion 1.06, CAL replaces ADJ in menu.)

The complete calibration procedure is described in

“VOLT METER” and “% AMPERES” calibration ref-

the Calibration Procedure in this section.

erence the phase that is indicated on the phase

selection LED’s.

The facing page shows a block representation of

NOTE: The % AMPERES meter scale is based on a 0.8

the METERS submenus, which is the second of

power factor. (100% of rated current is full load cur-

four SETUP/CAL menus. If you press the button

rent at 0.8 PF.)

next to the “>>” in the Main menu display, the VER-

SION/SETUP/CAL submenu will appear.

SAVE/EXIT submenu: From the HERTZ subme-

nu, press the button next to the “>>” in the display to

move to the SAVE/EXIT submenu. Select SAVE to

CAUTION

Improper calibration or adjustment

of the PowerCommand control can cause

save your changes. At the CHANGES SAVED sub-

equipment malfunction or damage. Calibration

menu, select EXIT to return to the DISPLAYS/ME-

and adjustment must be performed by techni-

TERS submenu.

cally qualified personnel only.

If you select SAVE, the adjustments will be retained

after shutdown, and will be in effect when the set is

METERS submenu: The METERS submenus are

restarted. If you select EXIT without saving first, the

intended for qualified service personnel only. For

adjustments will remain in effect until the genset is

this reason, a three-digit access code must be en-

shut down, but will be reset (and will not be in effect)

tered before you can proceed to those menus.

when the set is restarted.

5-12

METERS MENU

< >

VERSION

<<

SETUP/CAL

>>

< >

< ⇑ ENTER CODE

__ __ __

>>

⇓

< >

ENTER CODE

< >

DISPLAYS

<<

METERS

>>

>>

< >

< >

DISPLAYS

<<

METERS

>>

< >

A−C VOLTS

< >

CAL*TO: ___ >>

% AMPERES

< >

*

% LOAD

< >

*

<

HERTZ

< >

>>

CAL*TO: ___

<

SAVE

< >

CHANGES SAVED

DISPLAYS

<<

EXIT

>>

EXIT

METERS

>>

<> >>

< >

< >

A−C VOLTS

CHANGES SAVED

EXIT

>>

< >

< >

>>

ADJ TO: ___

<

SAVE

< >

DISPLAYS

<<

EXIT

>>

METERS

<> >>

< >

<

SAVE

<

A−C VOLTS

EXIT

>>

< >

< >

>>

O: ___

* Begin Version 1.06

Indicates “OR” Condition

5-13

<

<

<

⇑
⇓

⇑
⇓ CAL

⇑
⇓ CAL

⇑
⇓

TO: ___ >>

TO: ___ >>

<>

⇑ __ __ __

⇑
⇓ ADJ T

<

⇑
⇓

Governor / Regulator Menu

GOV GAIN: If the gain adjustment is set too high,

engine speed will “hunt” or oscillate. If gain is set too

low, the engine will respond too slowly to changes in

load—overspeed may result.

The GOV/REG submenus permit adjustment of

voltage regulator and governor parameters.

GOV INTEGRAL: If this adjustment is set too low,

the engine will respond too slowly to changes in

All GOV/REG menu values, except for REG VHZ a nd

load. If it is set too high, engine response will be un-

GOV RAMP, will display “100%”. The expression

stable.

“100%” represents the factory settin g (d efault value)

for the selected set. When increasi n g o r decreasing

GOV RAMP: This adjustment sets the time for the

the value, you are increasing or decreasing from the

engine to ramp to full operating speed. This adjust-

factory default value. (For exam p le, entering “200%”

ment applies only to set start up and does not affect

will double the value; “50%” will decrease the value

by one half.)

the transient response. (Adjustable range: 0

through 10 seconds.)

Default values are preset by the factory. Due to site

variables, the default values may need to be adjusted

REG GAIN: If the gain adjustment is set too high,

to attain peak performance.

output voltage will be unstable. If gain is set too low,

the output voltage will respond sluggishly to

The facing page shows a block representation of

changes in load—overshoot may result.

the GOV/REG submenus, which is the third of four

SETUP/CAL menus. If you press the button next to

REG INTEGRAL: If this adjustment is set too low,

the “>>” in the Main menu display, the VERSION/

the output voltage will respond sluggishly to

SETUP/CAL submenu will appear.

changes in load, resulting in a droop-type response

If it is set too high, output voltage will be unstable.

CAUTION

Improper calibration or adjustment

of the PowerCommand control can cause

REG VHZ: This underfrequency roll-off adjustment

equipment malfunction or damage. Calibration

controls how much excitation is reduced in re-

and adjustment must be performed by techni-

sponse to underfrequency. If the value is set too

cally qualified personnel only.

low, excitation will be cut too fast, and the voltage

will drop too much. If set too high, the generator set

GOV/REG submenu: The GOV/REG submenus

may not be able to pick up rated load in one step.

are intended for qualified service personnel only.

(Adjustable range: 1 through 50; normal range 7

For this reason, a three-digit access code must be

through 21.)

entered before you can proceed to those menus.

SAVE/EXIT submenu: From the REG VHZ subme-

Select SETUP/CAL. The display will show the EN-

nu, press the button next to the “>>” in the display to

TER CODE submenu. Enter the access code (574)

move to the SAVE/EXIT submenu. Select SAVE to

as previously described in this section.

save your changes. At the CHANGES SAVED sub-

From the DISPLAYS/METERS submenu, press the

menu, select EXIT to return to the DISPLAYS/ME-

button

next to the “>>” in the display to move to the

TERS submenu.

GOV/REG/SETUP submenu. Select GOV/REG to

proceed to the GOV/REG submenus.

If you select SAVE, the adjustments will be retained

after shutdown, and will be in effect when the set is

Use the buttons next to the “⇑” and “⇓” symbols to

restarted. If you select EXIT without saving first, the

adjust the selected governor and regulator parame-

adjustments will remain in effect until the genset is

ters. Press the button next to the “>>” in the display

shut down, but will be reset (and will not be in effect)

to move to the next adjustment.

when the set is restarted.

5-14

GOVERNOR/REGULATOR MENU

< >

VERSION

<<

< ⇑ ENTER CODE

SETUP/CAL

>>

__ __ __

<> >>

< >

< >

DISPLAYS

<<

METERS

>>

< >

<>

<<

< >

GOV / REG

<<

DISPLAYS

SETUP

METERS

>> > < >

< >

GOV / REG

<<

SETUP

>

< ⇑ GOV GAIN

>>

⇓

_______%

< >

< ⇑ GOV INTEGRAL

>>

⇓

< >

>>

_______

< >

< ⇑ REG GAIN

>>

_______%

< >

REG INTEGRAL

<

>>

_______%

< >

< ⇑ REG VHZ

>>

_______

< >

<

< >

CHANGES SAVED

DISPLAYS

<<

EXIT

>>

EXIT

METERS

>>

<> >>

< >

< >

⇑

CHANGES SAVED

EXIT

>>

< >

< >

>>

_______%

<

< >

DISPLAYS

<<

EXIT

>>

METERS

<> >>

< >

GOV GAIN

<

<

>>

EXIT

>>

< >

< >

Indicates “OR” Condition

5-15

_______%

< ⇑ GOV RAMP

⇓

⇓

⇓

⇑
⇓

⇓

SAVE

SAVE

SAVE

⇑
⇓ _______%

<

GOV GAIN

⇓

Setup Menu

The SETUP submenus permit selection of several

From the DISPLAYS/METERS submenu, press the

configuration and operation options. Setup option

button next to the “>>” in the display to move to the

defaults are listed in Table 5-2.

GOV/REG/SETUP submenu. Select SETUP to

proceed to the SETUP submenus.

Use the buttons next to the “⇑⇓” symbols to toggle

TABLE 5-2. SETUP DEFAULTS

the setup options. Press the button next to the “>>”

SELECTION

DEFAULT

in the display to move to the next adjustment.

If the cycle cranking option is selected, the menu will

CYCLE CRANK

ON

SYSTEM OF UNITS

IMPERIAL

prompt for the selection of cycle number (3, 4, or 5)

*CUSTOMER FAULT 1

WARN

and crank and rest times (7 to 20 seconds).

*GRND FAULT

WARN

*DAY TANK

An in-line engine that has the EGT (exhaust gas

WARN

*HIGH GEN TEMP

temp.) option, select “YES” for EGT L and ’NO” for

WARN

EGT R.

EGT L

NO

EGT R

NO

Edit Customer Fault Message(s): The four cus-

LOW COOLANT

SHTD

tomer fault messages shown in Table 5-2 are edit-

LANGUAGE

ENGLISH

able. To enter the desired customer fault message,

press the button next to the “>>” in the display to dis-

*

Default display messages for customer faults 1

play the customer fault message to be changed.

through 4. To change the customer fault mes-

sage(s), to display the desired fault condition, refer

Press the upper-left button by the display to select

to heading Edit Customer Fault Messages.

the desired character. Press the upper-right button

to move the cursor to the next character to be

The facing page shows a block representation of

changed. (Holding this button down will return the

the SETUP submenus, which is the fourth of four

cursor to the first position.) The message can be up

SETUP/CAL menus. If you press the button next to

to 16 characters. The fault code number will remain

the “>>” in the Main menu display, the VERSION/

the same, this code cannot be edited.

SETUP/CAL submenu will appear.

If these messages are changed, you should note

these changes in the Troubleshooting section of the

Improper calibration or adjustment

Operator’s manual for this generator set.

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

SAVE/EXIT submenu: From the LANGUAGE sub-

and adjustment must be performed by techni-

menu, press the button next to the “>>” in the dis-

cally qualified personnel only.

play to move to the SAVE/EXIT submenu. Select

SAVE to save your changes. At the CHANGES

SETUP submenu: The SETUP submenus are in-

SAVED submenu, select EXIT to return to the DIS-

tended for qualified service personnel only. For this

PLAYS/METERS submenu.

reason, a three-digit access code must be entered

If you select SAVE, the adjustments will be retained

before you can proceed to those menus.

after shutdown, and will be in effect when the set is

restarted. If you select EXIT without saving first, the

Select SETUP/CAL. The display will show the EN-

adjustments will remain in effect until the genset is

TER CODE submenu. Enter the access code (574)

shut down, but will be reset (and will not be in effect)

as previously described in this section.

when the set is restarted.

5-16

CAUTION

SETUP MENU

< >

VERSION

<<

SETUP/CAL

>>

< >

IF CYCLE CRANK ON :

< ⇑ ENTER CODE

>>

⇓ __ __ __

< >

# OF CYCLE S

< >

DISPLAYS

<<

>>

⇓

(3, 4, or 5)

< >

METERS

>>

< >

RESET

MENU >

<

CYCLE CRANK

CRANK TIME − SEC

< >

GOV / REG

<<

< >

>>

(7 to 20)

SETUP

< >

RESET

MENU >

< ⇑ REST TIME − SEC

CYCLE CRANK

>>

(7 to 20)

< >

< >

>>

RESET

MENU >

SYSTEM OF UNITS

MET/ IMP >>

< >

EGT L

< >

CUSTOMER FAULT1

>>

YES / NO

< >

< >

SHTD / WARN >>

EGT R

< >

GRND FAULT

>>

YES / NO

< >

< >

SHTD / WARN >>

LOW COOLANT

< >

DAY TANK

SHTD / WARN >>

< >

< >

SHTD / WARN >>

< >

HIGH GEN TEMP

LANGUAGE

< >

< >

_______________>>

<

SAVE

< >

CHANGES SAVED

DISPLAYS

<<

EXIT

>>

EXIT

METERS

>>

<>

>>

< >

< >

CYCLE CRANK

CHANGES SAVED

>>

ON / OFF

EXIT

>>

< >

< >

<

SAVE

< >

DISPLAYS

<<

EXIT

>>

METERS

<>

>>

< >

<

SAVE

CYCLE CRANK

EXIT

>>

<> >>

< >

⇑⇓ ON / OFF

Indicates “OR” Condition

5-17

⇑

<

⇑
⇑⇓ ON / OFF

⇓

⇑⇓ ON / OFF

⇑⇓

⇑⇓

⇑⇓

⇑⇓

⇑⇓ SHTD / WARN >>

⇓

⇑⇓

⇑⇓

⇑⇓

< ⇑

⇓

⇑⇓

CALIBRATION PROCEDURE

3. Select ADJUST from the Main Menu (page 5-7)

to display the VOLTAGE adjust menu.

WARNING Contacting high voltage compo-

4. Start the genset and allow the genset to reach

nents can cause electrocution, resulting in se-

normal operating speed.

vere personal injury or death. Calibration and

adjustment must be performed by technically

5. Adjust VOLTAGE (genset output voltage) so

qualified personnel only. Read and observe all

that the calibrated voltmeter reads the desired

WARNINGS and CAUTIONS in your generator

voltage. (Use a calibrated voltmeter because

set manuals.

the value displayed on the PCC digital display

may not be calibrated at this time; therefore, its

CAUTION

Improper calibration or adjustment

accuracy is unknown.)

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

6 Select the Frequency adjust menu.

and adjustment must be performed by techni-

7. Verify that the frequency displayed on the cali-

cally qualified personnel only.

brated meter is the desired frequency. If not,

The calibration procedure is divided into 7 subsec-

adjust to the desired frequency. (Note: If the

tions, with the subsections arranged in a specified

frequency reading on the digital display is not

order. If two or more of the following subsections are

the same as frequency shown on calibrated

required to calibrate the PCC, they must be com-

meter, there is an equipment malfunction.)

pleted in the order shown.

8. If no frequency or voltage adjustment was

When removing and replacing a defective circuit

made, select EXIT. If an adjustment was made,

board, you may have to perform one or more of the

SAVE, then EXIT.

following subsections. Table 5-1 (Control Panel Re-

Digital Voltage Display Calibration

calibration) provides a list of the circuit boards that

require calibration when replaced and the calibra-

9. Select “>>” from the Main Menu (Page 5-9).

tion procedure(s) that must be performed.

From this menu proceed to the VOLTS L12

Use a calibrated RMS multimeter for accurate mea-

menu (Page 5-11).

surements. Fluke models 87 or 8060A are good

10. With the genset OFF, attach a calibrated fre-

choices.

quency/voltmeter to the AC output from L1 to

L2.

Initial Start Setup

11. Start the genset and allow it to reach normal

1. Refer to Page 5-4, which describes how and

operating speed.

when you should perform this procedure.

12. Calibrate voltage reading for VOLTS L12 so

To verify if the PCC is set to operate with a spe-

that the reading on the digital display agrees

cific generator set, refer to the VERSION menu

with the calibrated voltmeter.

(Page 5-9). This menu will show the generator

set model number, frequency, and kW rating. If

13. Shut the genset OFF.

any of these values are incorrect, you must per-

14. Repeat steps 10 through 13 for L23 and L31.

form the Initial Start Setup procedure.

(In step 10 attach meter to the AC output from

Voltage and Frequency Adjustment

L2 to L3 to calibrate VOLTS L23 and then L3 to

L1 to calibrate VOLTS L31.)

2. With the genset OFF, attach a calibrated fre-

quency/voltmeter to the AC output from L1 to

15. If no calibration was made, select EXIT. If a cal-

L2.

ibration was made, SAVE, then EXIT.

5-18

Digital Ammeter Display Calibration

28. Repeat steps 24 through 27 for L2 and L3. (In

step 24, attach meter to L2 to calibrate PF2 and

16. Select “>>” from the Main Menu (Page 5-9).

then L3 to calibrate PF3.)

From this menu proceed to the AMPS L1 menu

29. If no calibration was made, select EXIT. If a cal-

(Page 5-11).

ibration was made, SAVE, then EXIT.

17. With the genset OFF, attach a calibrated am-

meter to L1.

Digital Coolant Temperature Display

18. Start the genset and allow it to reach normal

Calibration

operating speed.

An engine sensor calibration tool is required to per-

19. Load the genset to maximum rated kVA at

form this procedure.

rated voltage.

20. Calibrate the reading for AMPS L1 so that the

30. With the genset OFF, replace the coolant tem-

reading on the digital display agrees with cali-

perature sender with the precision resistor pro-

brated ammeter.

vided in the calibration tool.

21. Repeat steps 17 through 20 for L2 and L3. (In

31. Select “>>” from the Main Menu (Page 5-9).

step 17, attach meter to L2 to calibrate AMPS

From this menu proceed to the COOLANT

L2 and then L3 to calibrate AMPS L3.)

TEMP L menu (5-11).

22. If no calibration was made, select EXIT. If a cal-

32. Calibrate the temperature reading to match the

ibration was made, SAVE, then EXIT.

temperature indicated on the calibration tool.

Digital Power Factor Display Calibration

33. Repeat step 32 for COOLANT TEMP R if the

engine uses two sensors.

Power factor calibration is not required except in ap-

34. If no calibration was made, select EXIT. If a cal-

plications requiring a higher accuracy than ±5%. If

ibration was made, SAVE, then EXIT.

the ±5% accuracy is not acceptable, further calibra-

tion will require reactive load sufficient to reach 0.8

Analog meter calibration

PF at rated load, and calibrated instruments with

±

1% accuracy or better. Typical load rack instru-

35. Select “>>” from the Main Menu (Page 5-9).

ments are not accurate enough to perform this pro-

From this menu proceed to the A−C VOLTS

cedure.

CAL TO menu (Page 5-13).

23. Select “>>” from the Main Menu (Page 5-9).

36. Start the genset and allow the genset to reach

From this menu proceed to the PF1 menu

normal operating speed.

(Page 5-11).

37. Calibrate the analog Voltmeter to the digitally

24. With the genset OFF, attach the power factor

displayed value.

meter to L1.

38. Calibrate the analog % Amps meter to the digi-

25. Start the genset and allow it to reach normal

tally displayed value.

operating speed.

39. Calibrate the analog % Load meter to the digi-

26. Load the genset to maximum rated kVA at

tally displayed value.

rated voltage.

40. Calibrate the analog Frequency meter to the

27. Calibrate the reading for PF1 so that the read-

digitally displayed value.

ing on the digital display agrees with power fac-

tor meter.

41. SAVE, then EXIT.

5-19

ACCESSORY BOX CONTROL

contains components that provide connection

points for remote control and monitor options. The

COMPONENTS

set can be equipped with one or more of the follow-

ing components (customer terminal block TB1 is

The generator set accessory box (Figure 5-3) which

standard).

is located on the backside of the control housing,

CUSTOMER

OPTIONAL RUN

TERMINAL

RELAYS K11, K12

BLOCK (TB1)

& K13

OPTIONAL RTD

OPTIONAL

RELAY

THERMISTOR

RELAY 160/140° C

OPTIONAL

COMMON ALARM

RELAY K14

HC 6/7

OPTIONAL

THERMISTOR

RELAY 160/140

C

OPTIONAL

COMMON

OPTIONAL RUN

ALARM RELAY

RELAYS K11, K12

K14

& K13

CUSTOMER

TERMINAL

BLOCK (TB1)

OPTIONAL RTD

RELAY

HC 4/5

FIGURE 5-3. ACCESSORY BOX COMPONENTS

5-20

°

TB1 Customer Inputs

Engine idle operation is applicable only in the RUN

mode. The PCC operating program does not permit

Refer to Page 8-7 for typical connections to TB1.

engine idle operation when the set is operating in

AUTO mode.

Remote Start: When the Run/Off/Auto switch is in

When the engine idle function is enabled, the con-

the Auto position, grounding this input initiates the

trol automatically sets lower oil pressure warning

engine cranking and start sequence. This circuit

and shutdown trip points to reflect the lower operat-

must be opened to permit resetting a shutdown con-

ing speed. When the engine idle function is re-

dition with the Reset input.

moved and the set reverts to normal operating

Low Fuel: Grounding this input actuates the Low

speed, the control automatically resets oil pressure

Fuel warning. This input can be connected to a local

warning and shutdown trip points to the normal set-

day tank or to a main fuel tank that is located on site.

tings.

When the switch grounds this designated input, the

Remote Emergency Stop: Grounding this input

input will “wake up” the control, if it is not operating,

causes an immediate shutdown. Emergency stop

and then initiate the fault.

must be reset at the front panel.

Customer Fault Inputs 1 through 4: Grounding

any one of these inputs activates the corresponding

TB1 Customer Outputs

warning or shutdown sequence. Warning or shut-

Refer to Page 8-9 for typical connections to TB1.

down status is selected in the setup menu. Refer to

the menu descriptions later in this section.

Breaker Control: One set of normally open (NO)

External sensing equipment must be connected to

contacts, rated for 5 amps at 30 VDC. A shutdown

the designated digital input.

fault will cause the relay to energize and operate a

shunt trip circuit on a circuit breaker. The relay will

The four customer fault messages can be separate-

stay energized until reset.

ly edited in the setup menu to display any desired

message. This allows each customer “default” fault

Common Alarm: One set of form-C contacts, rated

message to be customized to represent the type of

for 2 amps at 30 VDC. Any warning or shutdown

device that is attached the the fault input.

causes the common alarm relay to be energized.

This output is often used to energize an audible

The “default” message that is displayed, when

alarm.

ground is applied to the input, is as follows:

Load Dump: One set of normally open (NO) con-

Fault 1 = CUSTOMER FAULT1

tacts, rated for 2 amps at 30 VDC. If an overload or

Fault 2 = GRND FAULT

underfrequency condition exists for 5 seconds, the

Fault 3 = DAY TANK

NO load dump contacts are closed. This relay is en-

Fault 4 = HIGH GEN TEMP

ergized before shutdown (for overload or underfre-

If Fault 2 or 3 input is grounded, the control will

quency) occurs.

“wake up” if it is not operating, and then initiate the

Ready To Load: One set of normally open (NO)

fault.

contacts, rated for 2 amps at 30 VDC. This output is

Fault Reset: When the Run/Off/Auto switch is in

activated whenever AC voltage and frequency ex-

the Auto position and the remote start switch is

ceed 90% of nominal.

open, grounding this input resets any warning and

Switched B+: This is a fused 10 amp, 24 volt

latched shutdown fault (except Emergency Stop,

switched output. This output is activated by the run

which must be reset at the front panel.)

pilot signal, at the governor output module. (Fuse is

Engine Idle: When the set is operating in the RUN

located on Governor Output Module.)

mode, grounding this input causes generator build

B+: This is a fused 20 amp, 24 volt output. (Fuse is

up to be inhibited and the engine to be governed at

800 RPM. When ground is removed from this input,

located on TB-BAT terminal block of the engine har-

the set returns to normal speed and voltage.

ness.)

5-21

Run Relays (K11, K12, 13)

fans, pumps and motorized air dampers. The run

relays are energized when the generator set control

The optional run relays are rail mounted inside the

receives a start signal.

accessory box (Figure 5-3). The rail mount allows

you to easily remove and replace the snap-on re-

The contacts are rated:

lays. The generator set can be equipped with one,

•

10 amps at 28 VDC or 120 VAC, 80%PF

two or three run relays.

6 amps at 240 VAC, 80%PF

The three-pole, double-throw run relays (Figure

5-4) are used to control auxiliary equipment such as

K11, K12, K13

CUSTOMER

K11, K12, K13

CONNECTIONS

K11, K12, K13

K11

K12

K13

RUN RELAY

RUN RELAY

RUN RELAY

NO

NO

NO

NC

NC

NC

COIL

A40-TB1-4

A40-TB1-2

(B-)

(SWITCHED B+)

COM

FIGURE 5-4. OPTIONAL RUN RELAYS (K11, K12, K13)

5-22

•

• 3 amps at 480/600 VAC, 80%PF

Shutdown Relay (K14)

such as audible alarms. Any generator set shut-

down will energize the alarm relay.

The optional alarm relay is rail mounted inside the

The contacts are rated:

accessory box (Figure 5-3). The rail mount allows

you to easily remove and replace the snap-on relay.

•

10 amps at 28 VDC or 120 VAC, 80%PF

6 amps at 240 VAC, 80%PF

The three-pole, double-throw shutdown relay (Fig-

ure 5-5) is often used to energize warning devices

3 amps at 480/600 VAC, 80%PF

K14

CUSTOMER

K14

CONNECTIONS

K14

K14

COMMON SHUTDOWN

NO

NC

COIL

A40-TB1-4

A40-TB1-8

(B-)

(COM SHUTDOWN)

COM

FIGURE 5-5. OPTIONAL ALARM RELAY (K14)

5-23

•

•

RTD Relay (Optional)

for normal, red for tripped). Additional red LED’s are

used to indicate which inputs exceed the setpoint.

The optional RTD relay is rail mounted inside the

The relay terminals 11, 12 and 14 are for customer

accessory box (Figure 5-3). This relay is used to

connection. These terminals can be attached to any

monitor six separate temperature zones in the gen-

one of the four Customer Fault inputs on TB1 to pro-

erator windings using resistive temperature detec-

vide a warning/shutdown condition or to other cus-

tors (RTDs). The relay determines the sensed tem-

tomer warning devices. (Refer to Setup Menu in this

perature and acts to isolate, alarm, or initiate cor-

section, which describes how to modify the custom-

rective action.

er fault message and to select a warning or shut-

down condition.)

The RTD relay (Figure 5-6) compares the six inputs

to the predetermined setpoint (temperature set-

The contacts are rated:

point is factory adjusted). If one or more of the inputs

•

240 VAC, 5 amps non-inductive

exceed the setpoint, the output relay is energized.

LED’s indicate the state of the output relay (green

TEMPERATURE RELAY CONNECTIONS

TO RTD TERMINAL

BLOCK

(+) PWR (−)

WHITE

A40TB1-4

OUTPUT RELAY

WHITE

(GROUND)

24 VDC

(CUSTOMER USE)

A40TB1-2

(SWITCHED B+)

FIGURE 5-6. RTD RELAY (OPTIONAL)

5-24

• 24 VDC, 25 amps resistive

Thermistor Relay (Optional)

when the thermistor chain resistance reaches 3000

±

500 ohms.

The optional thermistor relays are rail mounted in-

The relay terminals 1, 2 and 3 are for customer con-

side the accessory box (Figure 5-3). Each relay

nection and are normally connected to a breaker

monitors three thermistors (one per phase) that are

shunt trip or a load shed circuit (Figure 5-7).

connected in series inside the generator. One se-

ries or chain of thermistors are rated at 140° C and

The contacts are rated:

the other at 160° C. The 140° C relay is commonly

3 amps at 250 VAC

used in a

pre-alarm circuit and the 160º

C relay in a

shut-down circuit. The relay will energize (trip)

1 amp at 480 VAC

THERMISTORS

WHITE/RED

A∅ B∅ C∅

BLUE

FAULT CHANNELS

A40-TB1-4

(CUSTOMER

(GROUND)

CONNECTIONS)

A40-TB1-2

(SWITCHED B+)

RELAY CONTACTS

FIGURE 5-7. THERMISTOR RELAY (OPTIONAL)

5-25

•

•