CUMMINS PowerCommand 3201 Service Manual
Service Manual
Controller
PowerCommand 3201
Table of Contents
SECTION TITLE PAGE
1. Introduction 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ABOUT THIS MANUAL 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST EQUIPMENT 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HOW TO OBTAIN SERVICE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. Control Operation 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEQUENCE OF OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL POWER ON/OFF MODES 2-1. . . . . . . . . . . . . . . . . . . . .
CONTROL PANEL ASSEMBLY 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
READING FAULT CODES 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MENU DISPLAY AND SWITCHES 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LANGUAGE/UNITS SELECTION MENU 2-8. . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN MENU 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE SUBMENUS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALTERNATOR SUBMENUS 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL SUBMENU 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HISTORY/ABOUT SUBMENUS 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HISTORY/ABOUT SUBMENUS (CONT.) 2-15. . . . . . . . . . . . . . . . . . . . . . . . .
PARALLEL DATA SUBMENU 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRANSFER MAIN/SUBMENUS 2-17. . . . . . . . . . . . . . . . . . . . . . . . .
UTILITY (PWR TRAN) SUBMENUS 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATUS (PWR TRAN) SUBMENUS 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TRANSFER CONTROL (PWR TRAN) SUBMENU 2-21. . . . . . . . . . . . . . . . .
GENSET (PWR TRAN) SUBMENUS 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Control Calibration and Adjustment 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PARALLELING and NON−PARALLELING 3-1. . . . . . . . . . . . . . . . . . . . . . . . .
SOFTWARE CALIBRATIONS 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MODIFYING SETUP/ADJUST SUBMENUS 3-1. . . . . . . . . . . . . . . . . . . . . . . .
SETUP MENUS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GOVERNING/VOLT REG SUBMENU 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUSTOMER FAULTS SUBMENUS 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION SUBMENUS 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ISOLATED BUS SUBMENUS 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UTILITY SUBMENUS 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER TRANSFER CONTROL MAIN MENUS 3-19. . . . . . . . . . . . . . . . . . .
UTILITY SENSORS SUBMENUS 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENSET SENSORS SUBMENUS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIMERS SUBMENU 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST/EXERCISE SUBMENU 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUST SUBMENU 3-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CALIBRATION PROCEDURE 3-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
SECTION TITLE PAGE
CONTROL BOX WIRING 3-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RUN RELAYS (K11, K12, K13) 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ALARM RELAY (K16) 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAGNETIC SPEED PICKUP UNIT (MPU) INSTALLATION 3-35. . . . . . . . .
ii
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS − This manual contains
important instructions that should be followed during
installation and maintenance of the generator set and
batteries.
Before operating the generator set (genset), read the
Operator’s Manual and become familiar with it and the
equipment. Safe and efficient operation can be
achieved only if the equipment is properly operated
and maintained. Many accidents are caused by failure
to follow fundamental rules and precautions.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
ator, service personnel, or the equipment.
This symbol warns of immediate
hazards which will result in severe personal in-
jury or death.
WARNING
This symbol refers to a hazard or un-
safe practice which can result in severe person-
al injury or death.
CAUTION
This symbol refers to a hazard or un-
safe practice which can result in personal injury
or product or property damage.
FUEL AND FUMES ARE FLAMMABLE
Fire, explosion, and personal injury or death can result
from improper practices.
DO NOT fill fuel tanks while engine is running, un-
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential
fire hazard.
DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source
near the generator set or fuel tank.
Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be
made with an approved flexible line. Do not use zinc
coated or copper fuel lines with diesel fuel.
Be sure all fuel supplies have a positive shutoff
valve.
Be sure battery area has been well-ventilated prior
to servicing near it. Lead-acid batteries emit a highly
explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.
EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to properly
expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
likely to congregate. Visually and audibly inspect
the exhaust daily for leaks per the maintenance
schedule. Make sure that exhaust manifolds are se-
cured and not warped. Do not use exhaust gases to
heat a compartment.
Be sure the unit is well ventilated.
Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
birth defects, and other reproductive harm.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
Keep your hands, clothing, and jewelry away from
moving parts.
Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
connect starting batteries, negative (−) cable first.
This will prevent accidental starting.
Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
in position over fans, drive belts, etc.
Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
caught in moving parts.
If adjustment must be made while the unit is run-
ning, use extreme caution around hot manifolds,
moving parts, etc.
DO NOT OPERATE IN FLAMMABLE AND
EXPLOSIVE ENVIRONMENTS
Flammable vapor can cause an engine to overspeed and
become difficult to stop, resulting in possible fire, explo-
sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the genset is
equipped with an automatic safety device to block the air
intake and stop the engine. The owners and operators of
the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power
Generation distributor for more information.
v
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH
Remove electric power before removing protective
shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around
electrical equipment. Do not wear damp clothing
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not
wear jewelry. Jewelry can short out electrical con-
tacts and cause shock or burning.
Use extreme caution when working on electrical
components. High voltages can cause injury or
death. DO NOT tamper with interlocks.
Follow all applicable state and local electrical
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open
switches to avoid accidental closure.
DO NOT CONNECT GENERATOR SET DIRECT-
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set
into the utility line. This creates a potential for elec-
trocution or property damage. Connect only
through an approved isolation switch or an ap-
proved paralleling device.
GENERAL SAFETY PRECAUTIONS
Coolants under pressure have a higher boiling point
than water. DO NOT open a radiator or heat ex-
changer pressure cap while the engine is running.
To prevent severe scalding, let engine cool down
before removing coolant pressure cap. Turn cap
slowly, and do not open it fully until the pressure has
been relieved.
Used engine oils have been identified by some state
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil,
take care not to ingest, breathe the fumes, or con-
tact used oil.
Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
and flammable liquid fuels and gaseous fuels; Class
C fires, live electrical equipment. (ref. NFPA No. 10).
Make sure that rags or combustible material are not
left on or near the generator set.
Make sure generator set is mounted in a manner to
prevent combustible materials from accumulating
under or near the unit.
Remove all unnecessary grease and oil from the
unit. Accumulated grease and oil can cause over-
heating and engine damage which present a poten-
tial fire hazard.
Keep the generator set and the surrounding area
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
physically fatigued, or after consuming any alcohol
or drug that makes the operation of equipment un-
safe.
Substances in exhaust gases have been identified
by some state or federal agencies as causing can-
cer or reproductive toxicity. Take care not to breath
or ingest or come into contact with exhaust gases.
Do not store any flammable liquids, such as fuel,
cleaners, oil, etc., near the generator set. A fire or
explosion could result.
Wear hearing protection when near an operating
generator set.
To prevent serious burns, avoid contact with hot
metal parts such as radiator system, turbo charger
system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
vi
1. Introduction
ABOUT THIS MANUAL
This manual provides PowerCommand Control
3201 (PCC) calibration and adjustment proce-
dures, control operation, alternator test and repair
procedures.
Operating and maintenance instructions are in the
applicable Operator’s Manual.
Read Important Safety Instructions and carefully
observe all instructions and precautions in this
manual.
TEST EQUIPMENT
To perform the test procedures in this manual, the
following test equipment must be available
True RMS meter for accurate measurement of
small AC and DC voltages.
Battery Hydrometer
Jumper Leads
Tachometer or Frequency Meter
Wheatstone Bridge or Digital Ohmmeter
Variac
Load Test Panel
Megger or Insulation Resistance Meter
InPower Service Tool (PC based genset ser-
vice tool)
HOW TO OBTAIN SERVICE
Always give the complete Model, Specification and
Serial number of the generator set as shown on the
nameplate when seeking additional service infor-
mation or replacement parts. The nameplate is lo-
cated on the side of the generator output box.
WARNING
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 Important Safety Instructions, on
pages iii and iv.
Incorrect service or replacement of
1-1
THIS PAGE LEFT INTENTIONALLY BLANK
1-2
2. Control Operation
GENERAL
The following describes the function and operation
of the PowerCommand
dicators, control switches/buttons and graphical
display are located on the face of the control panel
as illustrated in Figure 2-1.
Normally, generator set configuration options are
set at the factory. When a new control is installed on
a generator set or when parts are replaced, the con-
trol must be configured for that generator set. Setup
and calibration procedures are described in Sec-
tion 3.
Control 3200 (PCC). All in-
SEQUENCE OF OPERATION
When the PowerCommand control is in the AUTO
mode, it will cause the generator set to start on re-
ceiving a signal from a remote device. The control
will initiate a starter cranking signal and verify that
the engine is rotating. The control will provide suffi-
cient fuel to the engine to accelerate to start discon-
nect speed. On reaching that speed, the control will
ramp the generator set to idle (warm-up) or rated
speed and voltage.
On reaching rated speed and voltage, the control
checks the system bus voltage. If no bus voltage is
present, it will wait for a pulse from a remote Master
First Start Sensor. On receiving that pulse, the control will signal the paralleling breaker to close.
If bus voltage is present, the control will check for
proper phase rotation, adjust the generator set to
the bus voltage and frequency level, and then syn-
chronize the generator set to the system bus. When
a synchronous condition is achieved, the control will
send a signal to close the paralleling breaker.
When the paralleling breaker is closed, the genera-
tor set will assume it’s proportional share of the total
load on the system bus.
CONTROL PANEL POWER ON/OFF
MODES
The power on/off modes of the control panel and op-
erating software are Power On, Screen Saver and
Sleep/Awake.
Power On Mode: In this mode, power is continu-
ously supplied to the control panel. The control’s
operating software and control panel LEDs/graphi-
cal display will remain active until the Screen Saver
mode is activated.
2-1
Screen Saver Mode: Power to the graphical dis-
play will be removed after 10 minutes (generator set
not running or running). The 10 minute timer resets
and begins after each control panel action (any button or switch selection) or signal received by the operating software. The bottom LEDs of the Analog
AC Metering Panel (bar graphs) may remain on dur-
ing Screen Saver mode, indicating that the operat-
ing software is active (Awake mode).
If these conditions are not met, Sleep mode is disabled in Auto mode.
The graphical display can enter Screen Saver mode
even if Sleep mode is disabled.
If Sleep mode is enabled in Auto mode, Sleep mode
is activated when there are no unacknowledged
faults and Screen Saver mode is active.
When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control will display
the warning message. The control will remain active
until the Fault Acknowledge button is pressed to
clear the warning message and start the 10 minute
timer.
Sleep/Awake Mode: In the Sleep mode, the con-
trol’s operating software is inactive and the LEDs
and the graphical display on the control panel are all
off. Sleep mode is a feature that is used to reduce
battery power consumption when the control is not
being used.
In Off mode, Sleep mode is activated when there
are no unacknowledged faults and Screen Saver
mode is active.
In Auto mode, Sleep mode can be enabled or dis-
abled. When shipped from the factory, it is disabled.
You can enable Sleep mode by making these
changes:
Use InPower service tool to set Auto Sleep En-
able to Sleep in Auto.
Set switch S1 on the Genset/Paralleling Card
to Sleep/Off. This switch is located next to con-
nector J8 and relay K9.
The operating software is initialized and the control
panel LEDs and graphical display are turned on in
response to one of the following:
Moving/pressing any control panel switch/but-
ton. (If Sleep mode is enabled in Auto mode,
the control will remain asleep if Sleep mode
was previously active in Off mode.)
Receiving a remote start input signal (genera-
tor set in Auto mode)
Receiving an active DCD signal on the RS-232
port.
Modem RI latch becoming active.
Digital display waking up.
Lonworks (backplane) wakeup becoming ac-
tive.
Customer fault 2 or 3 only (shutdown or warn-
ing indicator is on).
Dial Out process becoming active.
To activate the control and view the menu display
without starting the generator set, press any button
on the control panel.
2-2
OPERATOR PANEL SWITCH PANEL
REMOTE START,
NOT IN AUTO,
SHUTDOWN,
WARNING
STATUS INDICATORS
ANALOG AC
METERING
PANEL
PANEL LAMP/
LAMP TEST
BUTTON
FAULT
ACKNOWLEDGE
BUTTON
EMERGENCY
STOP PUSH
BUTTON
GRAPHICAL
DISPLAY
0
DISPLAY MENU
SELECTION BUTTONS
(1 of 6)
EXERCISE
BUTTON &
INDICATOR
MANUAL RUN/
STOP BUTTON
& INDICATOR
FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)
2-3
0/MANUAL/AUTO
SWITCH
CONTROL PANEL ASSEMBLY
The control panel assembly (Figure 2-1) consist of
two panels, the Operator Panel and the Switch Pan-
el.
Dependent on site requirements, the Operator Pan-
el is either mounted on the control panel assembly
(full-featured) as shown in Figure 2-1 or contained
in a separate enclosure and mounted remotely of
the control panel assembly.
The function of several buttons on the control panel
will vary dependent on the location of the control
panel (remote or local of the control panel assem-
bly). If the function differs, it is noted as either “re-
mote” or “local operator panel” in the button de-
scription.
Operator Panel
The operator panel contains the following compo-
nents:
Analog AC Metering Panel: This panel simulta-
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency.
The meter panel is composed of a series of LEDs,
that are configured in bar graphs for each function.
The LEDs are color coded, with green indicating
normal range values, amber for warning levels and
red for shutdown conditions.
Scales for each function are in % of nominal values.
Resolution is 1% for values close to nominal, and increases at values further from nominal.
Graphical Display: The graphical display is capable of displaying up to 9-lines of data with approximately 27 characters per line. The display is used to
view the menus of the menu-driven operating sys-
tem.
The top three lines of the graphical display contain
the following control information in the order de-
scribed:
State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At
Idle, etc. (see Figure 2-2), and paralleling op-
erations, such as Standby, Dead BUS Close,
Synchronize, Load Share and Load Govern.
Action Line − system actions, such as Warning,
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
Description Line − Fault code messages.
Display Menu Selection Buttons: Six momentary
buttons—three on each side of the graphical dis-
play window—are used to navigate through the sys-
tem control menus and to adjust generator set pa-
rameters. The button is active when the message
adjacent to the button is highlighted (displayed in in-
verse video).
2-4
Switch Panel
The switch panel contains the following components:
Emergency Stop Button: Push the button in for
emergency shutdown of the engine. If the engine is
not running, pushing the button in will prevent the
starting of the engine, regardless of the start signal
source (local or remote).
Fault Acknowledge: Press this button to acknowledge warning and shutdown messages after the
fault has been corrected.
To acknowledge a Warning message, the 0/Manual/Auto switch can be in any position. (It is not nec-
essary to stop the generator set to acknowledge an
inactive Warning condition.) To acknowledge a
shutdown message with this button, the 0/Manual/
Auto switch must be in the 0 (Off) position.
To reset:
1. Pull the button out.
2. Move the 0/Manual/Auto switch to 0.
3. Press the front panel Fault Acknowledge
button.
4. Select Manual or Auto, as required.
Remote Start Indicator: This green lamp is lit
whenever the control is receiving a remote run sig-
nal. When flashing, it indicates a load demand stop
mode.
Not in Auto Indicator: This red lamp flashes con-
tinuously when the 0/Manual/Auto switch is not in
the Auto position. (If in Auto position and lamp is
flashing, service is required.)
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
The generator set can not be started when this lamp
is on. After the condition is corrected, shutdown in-
dicators can be reset by turning the 0/Manual/Auto
switch to the 0 position, and pressing the Fault Ac-
knowledge button.
Dependent upon the specific fault that occurs, the
engine may or may not shut down immediately. A
fault that could cause engine damage, causes an
immediate engine shutdown (bypasses engine
cool-down sequence). All other faults would allow
the engine to run during the cool-down sequence
before engine shutdown. In this case, the Shutdown
Status Indicator blinks during the cooldown period.
This button is also used to blink a fault code if the
Shutdown or Warning Status Indicator is lit. (This
function is used when the control does not contain a
graphical display.) Refer to Reading Fault Codes in
this section, which describes how to use this button
for interpreting fault codes.
Panel Lamp/Lamp Test Button: Press this button
to turn on or off the panel lamp. Press and hold
down this button for three seconds or more to turn
all control panel LEDs on to make sure all lamps illu-
minate. The illumination will shut off after releasing
the button.
Exercise Button: Press this button to initiate a pre-
programmed exercise sequence. To start the exer-
cise sequence, press and hold down the Exercise
button and move the O/Manual/Auto switch from
Auto to Manual and back to Auto or from Manual to
Auto.
Manual Run/Stop Button: This button starts and
stops the set locally and will bypass Time Delay to
Start and Stop sequences. The 0/Manual/Auto
switch must be in the Manual position to enable this
button.
0/Manual/Auto Switch: Manual position enables
the use of the switch panel Manual Run/Stop but-
ton.
Auto position enables start/stop control of the en-
gine from a remote location. (Disables the use of the
switch panel Manual Run/Stop button.)
Warning Status Indicator: This yellow lamp is lit
whenever the control detects a warning condition.
After the condition is corrected, warning indicators
can be reset by pressing the Fault Acknowledge
button. (It is not necessary to stop the generator set
if the fault becomes inactive during genset opera-
tion.)
0 (Off) position prevents the starting of the set (local
or remote). If moved to 0 during set operation, will
cause an immediate engine shutdown (bypasses
cool-down timers). This hot shutdown should be
avoided, if possible, to help prolong the life of the
engine. Hot shutdowns are logged by the system
software.
2-5
READING FAULT CODES
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be
displayed in the display Description Line (Figure
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and
Shutdown status indicators.
A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
set corresponds to the hundreds position, the second to the tens position and the third to the ones digit. Example for Code No. 213:
Shutdown LED:
blink-blink-pause-blink-pause-blink-blink-blink
Reading Fault codes Using Warning/Shutdown
Indicators: If the Warning or Shutdown status indi-
cator is lit, press and hold the Fault Acknowledge
button and release after one second or more. After
one second, the Shutdown lamp will begin to blink
the active fault code(s) as follows.
The Warning lamp is used to indicate the start of a
new code. The Warning lamp will remain on for 2
seconds, followed by the Shutdown lamp blinking
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in-
dicates the beginning of the second fault code.
There are distinct pauses between repetitions of the
code blink transmissions of the Shutdown lamp.
Warning LED:
blink (2 seconds)
The light will display the fault codes (active or inac-
tive) in succession, starting with the most recent. Up
to 32 (unacknowledged) fault codes can be stored
in control panel memory.
To return the control to the most recent fault code,
press and release the Fault Acknowledge button
(less than one second) and repeat procedure.
When the fault code is acknowledged and cor-
rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
tains a fault code history. (The InPower service tool
is required to view this data log.)
2-6
MENU DISPLAY AND SWITCHES
Figure 2-2 shows the graphical display and the
menu selection buttons.
Graphical Display: The graphical display is capable of displaying up to 9-lines of data with approximately 27 characters per line. The display is used to
view the menus of the menu-driven operating sys-
tem. Refer to the menu trees later in this section.
The display is also used to show the following sys-
tem information:
State Line − modes of operation, such as
Stopped, Time Delay To Start, Warm Up At
Idle, etc., and paralleling operations, such as
Standby, Dead BUS Close, Synchronize, etc.
Action Line − system actions, such as Warning,
Derate, Shutdown Cool-down and Shutdown,
and fault codes.
Description Line − Fault code/status mes-
sages.
Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
used to navigate through the system control menus
and to adjust generator set parameters. The button
is active when the message or symbol adjacent to
the switch is highlighted (displayed in inverse video). The displayed message or symbol indicates
the function of the button.
In the graphical display, the “B” symbol indicates
that selecting the adjacent button causes the operat-
ing program to go to the next menu display—as
shown in the menu diagrams.
In the graphical display, the “Y” symbol indicates
that selecting the adjacent button causes the operat-
ing program to go back to the previous menu display.
In the graphical display, the “
that selecting the adjacent button causes the operat-
ing program to go back to Main Menu A (Figure 2-4).
” symbol indicates
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU
BUTTONS
FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS
MENU
BUTTONS
2-7
LANGUAGE/UNITS SELECTION MENU
During any control panel operation, you can select
one of three languages and change how units are
displayed by pressing the two lower menu buttons
(one on each side of display). When pressing these
two buttons simultaneously, the language/units
menu will appear (Figure 2-3). After making desired
selections, press the ENTER button in this menu to
change and save the selections.
Use the + buttons to select the desired option for
each field. Use the arrow (
next field. Selected field is highlighted.
Language: Used to select desired language (de-
fault = English).
Location: This selection must be set to Local when
the graphical display is mounted on the generator
set front control panel or Remote when mounted re-
motely from the generator set.
The Local/Remote selection determines which but-
tons in the Control submenu (page 2-13) are active
(displayed).
) button to move to the
Temp: Used to select F or C for temperature read-
ings.
Pressure Fluid: Used to select PSI, KPA, BAR or
IN for pressure readings.
Pressure Gas: Used to select INHG or MMHG for
pressure readings.
Flow Air: Used to select CFM or CMM for air flow
readings.
LANGUAGEENGLISH
LOCATIONLOCAL
+
TEMP F
PRESS FLDPSI
PRESS GASINHG
FLOW AIRCFM
ENTER
FIGURE 2-3. LANGUAGE/UNITS MENU
2-8
MAIN MENU
_\_ Button (Paralleling Applications Only)
Figure 2-4 shows the main menus (Menu A and
Menu B) of the system control. The two main menus
are used to divide the system submenus into major
categories, such as, Engine Data, Alternator Data,
Control, etc.
To view system data, simply press the appropriate
menu button to select the category. After pressing
the desired menu button, refer to the page number
shown in Figure 2-4 for detailed information related
to the selected category.
In the following figures, the boxed/highlighted field
indicates that the adjacent menu button is active.
Also, the submenus are shown in the order in which
they are displayed when scrolling up
Y or down B.
Adjust Button
The Adjust submenu is intended for qualified site
personnel only. Note that a password may be as-
signed to allow only authorized operators to modify
this data. (Password is not required if not assigned.)
Setup Button
When displayed, indicates that the feature for generator set paralleling applications is installed. This
button is used to open and close the generator set
circuit breaker (CB). The symbol indicates if the CB
is opened or closed. Opened _\_, push to close.
Closed _−_, push to open.
With the control panel 0/Manual/Auto switch in the
Auto position, the opening and closing of the CB is
controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
button will be inactive when the control is in Auto.
In the Manual position, the CB can only be closed
by using this button. When manually closed and the
CB opens, it must be closed again by using this but-
ton. To close the CB, press and hold the button until
the symbol indicates a closed CB. (CB close will oc-
cur only when setup conditions allow − dead bus or
generator synchronized with bus.)
Power Trans Button (Power Transfer
Control Applications Only)
The Setup submenu is described in Section 3.
The “Adjust” and “Setup” submenus can be viewed,
but not modified without entering the correct pass-
words.
When displayed, indicates that the Power Transfer
Control (PTC) feature is installed. Refer to page
2-17 for PTC Data submenu description. The PTC
setup submenu is described in Section 3.
2-9
MENU
BUTTONS
PAGE
2-11
MENU A
MENU
B
MENU
BUTTONS
PAGE
2-12
PAGE
2-13
Section
3
ENGINE
ALTERNATOR
CONTROL
SETUP
POWER TRAN or _\_
HISTORY/ABOUT
MENU B
PARALLEL DATA
GRAPHICAL
DISPLAY
MORE>>
ADJUST
BACK<<
FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B
Page
2-9
PAGE
2-14
Section
3
PAGE
2-16
MENU
A
2-10
ENGINE SUBMENUS
If you press the “ENGINE” button in Menu A, the Engine submenus will appear (Figure 2-5).
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro-
vided with the engine.
ENGINE
COOLANT TEMP 180 F
OIL PRESSURE 75PSI
ENGINE SPEED 1800RPM
BATTERY 29.1VDC
MANF TEMP 75 F
MANF PRESS ABS 180INHG
RAIL PRESS ABS 180PSI
PUMP PRESS ABS 291PSI
FUEL INLET TEMP 172 F
COOLANT PRESSURE 59PSI
Y
B
Y
B
BLOWBY FLOW 25CFM
TIMING PRESS 50PSI
AFTERCOOLER TEMP 76 F
AMBIENT PRESS 88INHG
FIGURE 2-5. ENGINE SUBMENUS
Y
2-11
ALTERNATOR SUBMENUS
If you press the “ALTERNATOR” button in Menu A,
the Alternator Data submenus will appear (Figure
2-6).
Voltage L-L and L-N: Indicates voltage Line-to
Line and Line-to-Neutral. Note that the Line-to-Neu-
tral column will not be displayed for a 3 phase/3 wire
system. Accuracy 1%.
The voltage Line-to-Line (L1, L2 and L3) are mea-
sured between L1 to L2, L2 to L3 and L3 to L1, re-
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.
ALTERNATOR
V L-L L-NAMPS
L1 480 2771340
L2 480 2771290
L3 480 2771260
FREQUENCY60.0 HZ
AVR DUTY CYCLE10.3 %
Y
B
AVR DUTY CYCLE: Displays voltage regulator
(drive) level in percentage of maximum.
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
The PF reading will contain an asterisk if the power
factor is leading (for example,
*.30).
kW kVA PF
L1 350 500 .80
L2 350 500 .80
L3 350 500 .80
TOT1050 1500 .80
FIGURE 2-6. ALTERNATOR SUBMENUS
Y
2-12
CONTROL SUBMENU
If you press the “CONTROL” button in Menu A, the
Control submenu will appear (Figure 2-7).
Local CONTROL Submenu Function
When the operator panel is mounted on the control
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this but-
ton is not displayed in remote applications.
The shaded area in Figure 2-7 displays the se-
lected/active mode of operation, either IDLE or
RATED.
Remote CONTROL Submenu Functions
When the operator panel (Figure 2-1) is mounted
remotely of the control panel assembly, the menu
buttons in the Control submenu are used to perform
the following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)
The 0/Manual/Auto switch must be in the Auto posi-
tion to activate the Remote Menu Buttons of the Con-
trol submenu.
Enable Sync: Displayed in paralleling applications
only. Intended for service personnel to turn off the
synchronizer for troubleshooting/testing purposes.
CONTROL
(Local)
+ RUN MODE IDLE
ENABLE SYNC
BARGRAPH TEST
YYY
B
Y
Remote START or STOP Button: This button is
used to start and stop the generator set when the
operator panel is mounted in a remote location.
When the generator set is operating, Stop will be
displayed for this button and Start will be displayed
when not operating.
When the generator set is operating in the Remote
Start mode, removing the Remote Start command
does not shut off the engine if the load is 10 per cent,
the cooldown timer is set to zero, and the control is
configured for a single unit (not in parallel). The gen-
erator set continues to operate until it runs out of
fuel, the E−stop button is used, or the load is re-
moved.
Fault Acknowledge Button: Used to reset inactive
Warning messages, not Shutdown messages.
Local/Remote CONTROL Submenu
Function
Bargraph Test: The function of this button remains
the same and is not dependent on operator panel
location. This button sequentially lights the LEDs to
test the bar graph display.
CONTROL
(Remote)
START GENSET
FAULT ACKNOWLEDGE
ENABLE SYNC
BARGRAPH TEST
FIGURE 2-7. CONTROL SUBMENU
B
Y
2-13
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