Cummins Power Generation PowerCommand 3100 Series, PowerCommand 3100 DQAF, PowerCommand 3100 DQAD, PowerCommand 3100 DQAE Service Manual

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Service Manual

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PowerCommand Control

3100 Series

Generator Sets

Printed in U.S.A.

Models

DQAD. DQAE. DQAF

960-0516B 2-2004

IMPORTANT SAFETY INSTRUCTIONS

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by any means, is strictly prohibited.

SAVE THESE INSTRUCTIONS − This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.

Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be

achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure

to follow fundamental rules and precautions. The following symbols, found throughout this manual,

alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.

This symbol warns of immediate hazards which will result in severe personal injury or death.

WARNING

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION

This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can result from improper practices.

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

less tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.

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

spark, arcing equipment, or other ignition source near the generator set or fuel tank.

• Fuel lines must be adequately secured and free of

leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel.

• Be sure all fuel supplies have a positive shutoff

valve.

• Be sure battery area has been well-ventilated prior

to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properly

•

expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.

• Be sure the unit is well ventilated.

• Engine exhaust and some of its constituents are

known to the state of California to cause cancer, birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

•

Keep your hands, clothing, and jewelry away from moving parts.

• Before starting work on the generator set, discon-

nect battery charger from its AC source, then disconnect starting batteries, negative (-) cable first. This will prevent accidental starting.

• Make sure that fasteners on the generator set are

secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity of

moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts.

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

ning, use extreme caution around hot manifolds, moving parts, etc.

DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power Generation distributor for more information.

LS-14L

iii

ELECTRICAL SHOCK CAN CAUSE

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SEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protective

•

shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock or burning.

• Use extreme caution when working on electrical

components. High voltages can cause injury or death. DO NOT tamper with interlocks.

• Follow all applicable state and local electrical

codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure.

• DO NOT CONNECT GENERATOR SET DIRECT-

LY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling point

•

than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first.

• Used engine oils have been identified by some state

or federal agencies as causing cancer or reproductive toxicity . When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil.

• Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFP A No. 10).

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

gine.

• Make sure generator set is mounted in a manner to

prevent combustible materials from accumulating under the unit.

• Remove all unnecessary grease and oil from the

unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.

• Keep the generator set and the surrounding area

clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.

• Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe.

• Substances in exhaust gases have been identified

by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases.

• Do not store any flammable liquids, such as fuel,

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

• Wear hearing protection when going near an oper-

ating generator set.

• To prevent serious burns, avoid contact with hot

metal parts such as radiator, turbo charger and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv

1. Introduction

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by any means, is strictly prohibited.

ABOUT THIS MANUAL

This manual covers models produced under the Cummins tion brand names.

This manual provides troubleshooting and repair information regarding the PowerCommand Control 3100 (PCC) and generators for the generator set (genset) models listed on the front cover. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator’s Manual.

This manual does not have instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it. Do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment.

This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. Service personnel must use the actual wiring diagram and schematic shipped with each unit. The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit.

Read instructions and precautions in this manual.



/Onan and Cummins Power Genera-

Safety Precautions

and carefully observe all

TEST EQUIPMENT

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

• True RMS meter for accurate measurement of

small AC and DC voltages. Fluke models 87 or



8060A are good choices.

• Grounding wrist strap to prevent circuit board

damage due to electrostatic discharge (ESD).

• Battery Hydrometer

• Jumper Leads

• Tachometer or Frequency Meter

• Wheatstone Bridge or Digital Ohmmeter

• Variac

• Load Test Panel

• Megger or Insulation Resistance Meter

• PCC Service Tool Kit (Harness Tool and Sen-

sor Tool)

• InSite service tool (required to diagnose the

CM570 engine control module only)

HOW TO OBTAIN SERVICE

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

WARNING

parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. Read and follow Safety Precautions, on pages iii and iv.

Incorrect service or replacement of

1-1

SYSTEM OVERVIEW

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by any means, is strictly prohibited.

The PCC is a microprocessor-based control for Cummins Power Generation generator sets. It provides fuel control and engine speed governing, main alternator voltage output regulation, and complete generator set control and monitoring.

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

GENERATOR SET CONTROL FUNCTION

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

3

. A system schematic is provided in

Section

Section 8

.

The PCC monitors frequency from both the magnetic pick-up (MPU) and the main stator inputs. The control sends a low power pulse-width modulated (PWM) signal (Speed Bias) to the CM570 module to control engine speed.

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

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

Regulator

PMG

CM570

ECM

Output

NS

MPU

Exciter

Sensors

PT/CT

Battery

BT1

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

1-2

2. Control Operation

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GENERAL

The following describes the function and operation



of the PowerCommand dicators, displays, meters and control switches 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 (genset) or when parts are replaced, the control must be configured for that generator set with the use of the “Initial Start Setup” portion of the internal software. Setup and calibration procedures are described in

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

Section 5

Control 3100 (PCC). All in-

Section 5

.

SAFETY CONSIDERATIONS

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

WARNING

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

The PCC control cabinet must be opened only by technically trained and experienced personnel.

CAUTION

opened only by persons trained and experienced in electrical maintenance. Lower level voltages (18 VAC to 24 VDC) are present in PCC control cabinet. These voltages can cause electrical shock, resulting in personal injury.

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

Contacting high voltage compo-

The PCC control cabinet must be

PCC POWER ON / STANDBY MODE

Standby Mode

In the Standby (sleep) mode (selector switch S5 on the Digital Board is set to the right and the generator set is not running), the control’s operating software is inactive and the LEDs and displays on front panel are all off. See Figure 3-1 for S5 location.

The operating software is initialized and the front panel is turned on in response to a run signal or any one of eight “wake up” inputs from remote sensing switches.

The wake up signals are:

• Emergency Stop

• Low Coolant Level

• Low Coolant Temperature

• Low Fuel

• Customer Fault Input 2

• Run Selected on Run/Off/Auto Switch

• Remote Start Signal in Auto Mode

• Self Test switch

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

Power On Mode

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

CAUTION

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

Electrostatic discharge will damage

2-1

KILOWATT

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METER

(PERCENT LOAD)

FREQUENCY

METER

AC

VOLTMETER

AC AMMETER

MENU

SELECTION

SWITCH

(1 of 4)

ACTIVE SWITCH

INDICATOR

(1 of 6)

ALPHANUMERIC

DISPLAY

UPPER AND LOWER

SCALE INDICATOR

PCC 3100

LABEL

RUN/OFF/AUTO

SWITCH

SELF TEST

SWITCH

NON-AUTOMATIC

WARNING

SHUTDOWN

STATUS INDICATORS

RESET

SWITCH

MENU

SWITCH

FIGURE 2-1. FRONT PANEL (PCC 3100)

2-2

PANEL LAMP

SWITCH

PHASE SELECTOR

SWITCH AND

INDICATORS

EMERGENCY

STOP PUSH

BUTTON

FRONT PANEL

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by any means, is strictly prohibited.

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

AC Voltmeter:

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

AC Ammeter:

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

Kilowatt Meter:

put as percent of rated load.

Frequency Meter:

quency in hertz.

Upper and Lower Scale Indicator Lamps:

cate AC voltmeter scale.

Digital Display:

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

Display Menu Selection Switches:

tary switches—two on each side of the digital display window—are used to step through the various menu options and to adjust generator set parameters. The green arrow adjacent to the switch is lit when the switch can be used (switch is “active”).

Menu Switch:

display to the MAIN MENU. Refer to the menu trees later in this section.

Reset Switch:

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

In Auto mode, shutdown faults can be reset by removing the remote start input and then cycling the remote reset input.

Self T est Switch:

all front panel LEDs and cycle through all shutdown and warning messages.

Dual scale instrument indicates AC

Indicates current output in percent of

Indicates 3-phase AC power out-

Indicates generator output fre-

Indi-

This two-line, 16-character per line

Four momen-

Press this switch to return the digital

Press this switch to reset warning

Press and hold this switch to light

Panel Lights Switch:

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

Phase Selector Switch and Indicators:

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

Run/Off/Auto Switch:

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

Emergency Stop Button:

Push the switch in for

emergency shutdown of the genset.

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

To reset:

1. Pull the button out.

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

3. Press the front panel Reset switch.

4. Select Run or Auto, as required.

Non-Automatic Status Indicator:

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

Warning Status Indicator:

This yellow lamp is lit whenever the control detects a warning condition. After the condition is corrected, warning indicators can be reset by pressing the Reset switch. (It is not necessary to stop the generator set.)

In Auto mode, warnings can also be reset by cycling the remote reset input after the condition is corrected.

Shutdown Status Indicator:

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

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

2-3

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

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MENU DISPLAY AND SWITCHES

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

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

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

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

Front Panel”

MAIN MENU

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

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

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

ENGINE MENU

To display generator parameters, such as volts, amps, power (kW), and frequency, press the button next to the word “GEN” in the display. Turn to the

GEN MENU

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

Section 5

.

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

PLAYS MENUS

in this section.

in

Section 5

ADJUST MENU

VERSION & DIS-

.

in

2-4

MAIN MENU

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PAGES 2-6 & 2-7

RPM << EXHAUST

BATTERY << HOURS >>

OIL << COOLANT >>

PAGES 2-8 & 2-9

%GOV / REG << FREQUENCY

POWER << KW HRS >>

VOLTS << AMPS >>

ENGINE GEN

<>

ADJUST >>

<>

RESET MENU >

CLEAR WARNING AND SHUTDOWN MESSAGES

RETURN TO MAIN MENU

⇑ VOLTAGE ⇓ _______ >>

⇑ FREQUENCY ⇓ _______ >>

⇑ START DELAY ⇓ _______ SEC >>

⇑ STOP DELAY ⇓ _______SEC >>

⇑ IDLE SPEED ⇓ _______RPM >>

SECTION 5

INACTIVE BUTTON

< ACTIVE BUTTON

< ACTIVE BUTTON SELECTED

SECTION 5

VERSION SETUP / CAL HISTORY

(ACCESS CODE)

DISPLAYS << METERS >>

GOV / REG << PARALLEL SETUP

2-5

ENGINE MENU

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

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

OIL/COOLANT submenu:

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

BATTERY/HOURS submenu:

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

RPM/EXHAUST submenu:

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

2-6

ENGINE

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<>

ENGINE GEN ADJUST >>

<>

OIL <<

<>

COOLANT >>

<>

OIL <<

<>

COOLANT >>

___PSI / KPA << ___

°F / °C

L___

°F / °C<<

°F / °C (or n/a)

R___

BACK

>

BACK

>

<>

OIL <<

<>

COOLANT >>

<>

OIL <<

<>

COOLANT >>

<>

BATTERY <<

<>

HOURS >>

<>

BATTERY <<

<>

HOURS >>

<>

BATTERY <<

<>

HOURS >>

<>

BATTERY <<

<>

HOURS >>

<>

ENGINE GEN

<>

ADJUST >>

BATTERY << ___VDC

STARTS ___ << HOURS ___

<>

OIL <<

<>

COOLANT >>

BACK

>

BACK

>

<>

RPM <<

<

EXHAUST

<>

RPM <<

<

EXHAUST

<>

RPM <<

<

EXHAUST

RPM << ___

L___°F/°C (or n/a) <<

°F/°C (or n/a)

R___

<>

BATTERY <<

<>

HOURS >>

Indicates OR" Condition

2-7

BACK

>

BACK

>

GEN MENU

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

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

VOLTS/AMPS submenu:

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

If DELTA is selected in the Initial Start Setup submenu, when selecting VOLTS, the “line-line” or “lineneutral” submenus will not be displayed, only the 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 displayed, pressing the button next to the “<<” will return the display (“BACK”) to the POWER/KW HOURS submenu.

The PF reading will contain an asterisk if the power factor is leading (for example, *.3PF). N/A is displayed in the PF field when the generator set is not running.

%GOV/REG/FREQUENCY submenu:

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

2-8

<>

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by any means, is strictly prohibited.

ENGINE GEN ADJUST >>

<>

VOLTS << AMPS >>

<>

VOLTS <<

<>

AMPS >>

L − L << L − N

<<>

<>

L − L << L − N

<

<>

L − L << L − N

<

L1 L2 L3 << ___ ___ ___

GEN

BACK

>

L1-2 L2-3 L3-1 << ___ ___ ___

L1N L2N L3N << ___ ___ ___

BACK

><>

BACK

>

<>

VOLTS <<

<>

AMPS >>

<>

VOLTS <<

<>

AMPS >>

<>

ENGINE GEN ADJUST >>

<>

POWER << KW HRS >>

<>

POWER << KW HRS >>

<>

POWER << KW HRS >>

<>

POWER << KW HRS >>

<>

%GOV / REG << FREQUENCY

<

BACK

___ KW << ___ PF

KW HRS << ____________

<>

%GOV / REG << FREQUENCY

<

GOVERNOR_ % << REGULATOR_ %

>

BACK

>

BACK

>

<>

%GOV / REG << FREQUENCY

<

FREQUENCY << ___ HZ

Indicates OR" Condition

2-9

BACK

>

THIS PAGE LEFT INTENTIONALLY BLANK

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2-10

3. Circuit Boards and Modules

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GENERAL

This section describes the function of the PCC circuit boards and modules that are contained in the control panel (Figure 3-1) and the accessory box. The block diagram in Figure 3-2, shows both internal and external components of the PCC system. The PCC/CM570 interface diagram in Figure 3-3,

DISPLAY BOARD

A35

lists the functional characteristics of the PCC and the CM570 engine control module and shows the interconnecting control signals. The system schematics are provided in

CAUTION

Electrostatic discharge will damage

Section 9

of this manual.

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

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

ANALOG BOARD

A33

RUN/OFF/AUTO

SWITCH S12

VOLTAGE REGULATOR

OUTPUT MODULE

A37

ENGINE INTERFACE

A31

ACCESSORY BOX

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

CUSTOMER INTERFACE

A34

RELAY

ASSEMBLY

PT/CT

BOARD

A36

3-1

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FIGURE 3-2. BLOCK DIAGRAM

3-2

3-3

Speed (Freq) Bias

Fault Acknowledge

Idle/Rated

FIGURE 3-3. PCC/CM570 INTERFACE

DIGITAL BOARD (A32)

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Connectors

The digital circuit board (Figure 3-4) contains the microprocessor and the operational software for the control. It connects to all other boards inside the control. This board also provides the analog-to-digital conversions for the PCC.

Switch

S5 Slide the switch to the left to select the Power

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

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

The digital board has five connectors. They are:

J1 Serial Interface RS232 J2 Connects to J4 on A34 Customer Interface

board

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

board

J5 Connects to J5 o n A35 Digital Display assem-

bly

LEDs

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

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

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

DS1 DS2 DS3 DS4

DS7 DS6 DS5

FIGURE 3-4. DIGITAL BOARD

3-4

ENGINE INTERFACE BOARD (A31)

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by any means, is strictly prohibited.

The engine interface board (Figure 3-5) reads user control inputs, monitors engine, generator and system status, and initiates the appropriate action for normal operating and fault conditions (warning or shutdown).

J4 Connects to customer connections and to en-

gine harness which includes magnetic pick-

up.

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

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

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

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

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

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

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

Connectors

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

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

switches and meters.

Fuses

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

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

contacts).

LED’s

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

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

Off/Auto switch.

DS5 S12 in Auto position (Green) DS6 Emergency Stop (Red) DS7 Not configured. DS8 Not configured. DS9 AVR duty cycle (Green). Brighter indicates

larger duty cycle.

DS10 GOV duty cycle (Green). Brighter indicates

larger duty cycle.

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

3-5

DS1 - LOW FUEL

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DS2 - LO COOL

DS3 - LET

DS4 - RUN SW

DS5 - AUTO

DS6 - E-STOP

DS9 - REG

DS10 - GOV

DS11 - START

DS12 - RUN RLY

5A CNTRL B+

5A AUX B+

FIGURE 3-5. ENGINE INTERFACE BOARD

3-6

ANALOG BOARD (A33)

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Connectors

The analog board (Figure 3-6) is the only circuit board inside the control that has no LED’s. There are two versions of the analog board that are used for paralleling and non-paralleling systems.

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

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

J1 Connects to J2 on A31 Engine Interface

board

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

board

FIGURE 3-6. ANALOG BOARD

3-7

DIGITAL DISPLAY BOARD (A35)

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The digital board (Figure 3-7) connects to all meters and the LED display.

Connectors

The digital board has three connectors. They are:

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

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

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

on A31 Engine Interface board

LEDs

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

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

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

ing application only: Breaker Closed (Red)

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

(Green)

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

− paralleling application: Breaker Open (Green)

DS37 AMF application only: Breaker Open

(Green)

DS9

DS13

DS15

DS22 DS26

DS36 DS37

DS11

DS20

DS24

FIGURE 3-7. DIGITAL DISPLAY BOARD

DS12

DS21

DS25

DS10 DS14

DS23 DS27 DS29

3-8

CUSTOMER INTERFACE BOARD (A34)

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The customer interface board (Figure 3-8) connects to the PT/CT board to bring in voltage and current. It also connects to customer inputs and outputs.

Connectors

The customer interface board has five connectors. They are:

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

LEDs

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

DS1 Master First Start Input (Green) − paralleling

application only

DS2 Pre low oil pressure output relay K14 (Red) DS3 CM570/Engine - Shutdown (Red) DS4 Customer Fault #1 Input (Red) DS5 Low oil pressure output relay K15 (Red) DS6 Fault Reset Input (Red) DS7 Engine Idle (Green) DS8 Load Demand Input (Green) − paralleling

application only

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

leling application only

DS10 Genset Breaker Closed Position (Green) −

paralleling application only

DS11 Customer Fault #2 input (Red) DS12 Low coolant output relay K17 (Red) DS13 Low Fuel Input (Red)

DS14 Remote Start input (Green) DS15 CM570/Engine - Warning (Red) DS16 Breaker Control input relay energized from

Digital board (Green). In single genset application, this output is activated for a breaker trip when there is a shutdown fault. In paralleling application, this output is activated to close a breaker

DS17 Common Alarm output relay energized from

Digital board (Green)

This output is activated only on a shutdown condition.

DS18 Spare output relay energized from Digital

board (Green)

This output is activated only on a warning condition.

DS19 Load Dump output relay energized from

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

DS20 Ready to Load output relay energized from

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

DS21 Pre high engine temperature output relay

K8 (Red)

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

(Red)

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

(Red)

DS27 Low fuel output relay K13 (Red)

3-9

DS1 - MA 1ST START

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DS3 - CM570/ENGINE SHTDWN DS4 - CUST FAULT1 DS6 - FAULT RESET DS7 - ENG IDLE DS8 - BRKR CLOSE DS9 - BRKR OPEN DS10 - BRKR POSN DS11 - CUST FAULT2 DS13 - LOW FUEL DS14 - RMT START DS15 - CM570/ENGINE WRNG

DS2 - [K14] PRE-LOP

DS5 - [K15] LOP

DS12 - [K7] LOW COOL

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 3-8. CUSTOMER INTERFACE BOARD

3-10

PT/CT BOARD (A36)

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by any means, is strictly prohibited.

The PT/CT board (Figure 3-9) is mounted inside the accessory box. This board converts generator output voltage to approximately 18 VAC levels for the analog board. It also converts CT .55 amp (at full load) output to approximately 1.65 V AC (at full load) input for the analog board.

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

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

Connectors

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

board

J9 Connects to AC harness (generator output

voltage and CTs)

J9 wiring connections:

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

J8

J9

FIGURE 3-9. PT/CT BOARD

3-11

VOLTAGE REGULATOR OUTPUT MODULE

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(A37)

The voltage regulator output module (Figure 3-10) is a power amplifier. This board is used to amplify the pulse-width modulated (PWM) signal from the PCC to drive the exciter windings. Power from the PMG is used by this board to amplify the PWM signal.

J10 Connects to engine harness (power)

J10 wiring connections:

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

Connectors

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

J7 Connects to engine harness (control)

J7 wiring connections:

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

LEDs

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

DS1 On when voltage regulator isolated supply is

operating (Green)

DS2 Output Duty Cycle − Brighter when load in-

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

DS3 Backup start disconnect − On when start dis-

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

FIGURE 3-10. VOLTAGE REGULATOR OUTPUT MODULE (A37)

DS1 - ISOLATED SUPPLY DS2 - OUTPUT DUTY CYCLE

DS3 - BACKUP START DISCONNECT

J10J7

3-12

RELAY ASSEMBLY

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by any means, is strictly prohibited.

The relay assembly (Figure 3-11) is mounted inside the accessory box. This assembly contains five relays used to reverse the polarity of the DC voltages

GOVERNOR

GAIN ADJUST

(R1)

K6-SWITCHED

B+ RELAY

K7-CM570

EMERGENCY

STOP RELAY

transferred between the PCC and the engine CM570 module. The relay assembly also contains the governor gain adjust and the 50/60 Hertz selector for the CM570 module.

50/60 HERTZ

SELECTOR

K10-CM570

WARNING

RELAY

K9-CM570

SHUTDOWN

RELAY

K8-CM570 RUN/

STOP RELAY

FIGURE 3-11. RELAY ASSEMBLY

TABLE 3-1. RELAYS K6 THROUGH K10

RELAYS FUNCTION

K6 B+: In the Run mode, relay K6 is energized, which supplies Switched B+ to TB1 customer terminal

block.

K7 CM570 EMERGENCY STOP RELAY: The PCC supplies the keyswitch (enable/disable) signal to

the CM570 module. Pressing the Emergency Stop switch, de-energizes relay K7, which removes the B+ enable signal to the CM570 module.

K8 CM570 RUN/STOP RELAY: The PCC supplies the run/stop signal to the CM570 module. In the

Run mode, relay K8 is energized, which grounds (activates) the input to the CM570 module.

K9 CM570 SHUTDOWN RELAY: When the CM570 detects a shutdown condition, relay K9 is ener-

gized, which grounds (activates) the input to the PCC.

K10 CM570 WARNING RELAY: When the CM570 detects a warning condition, relay K10 is energized,

which gouunds (activates) the input to the PCC

3-13

50/60 Hertz Selector Switch

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by any means, is strictly prohibited.

Used to change the operating parameters of the CM570 module for 50Hz or 60Hz operation. The PCC control menu selections must also be modified if changing genset frequency (refer to

Setup Menu

in

Section 5

).

Initial Start

Governor Gain Adjust

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 and overspeed may result.

If the potentiometer (pot) required replacement or the governor gain requires adjustment, make sure that the resistance of the pot is set to the factory setting (which should provide the best genset performance) as follows.

CAUTION

cable(s), press the the Emergency Stop button and wait at least 30 seconds. Engine performance may be affected (e.g., engine dying or hard starting) if battery cable(s) is removed during the 30 second waiting period. CM570 module may require adjustment using InSite service tool.

WARNING

can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery . Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

Before disconnecting battery

Ignition of explosive battery gases

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

CAUTION

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

WARNING

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

When removing plug C-01, B+ must be removed from the CM570 module by disconnecting the battery cable. Remove battery cable as follows:

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

2. Press the Emergency Stop button and wait at least 30 seconds before completing Step 3.

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

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

Gain Adjustment: Remove plug C-01 from the CM570 module. Measure resistance between C-01-21 and C-01-49 and adjust pot to 1.4k ohms.

(GAIN ADJUST)

R1-3

(RETURN)

TO C-01-49

R1-1

TO C-01-21

FIGURE 3-12. GOVERNOR GAIN POTENTIOMETER (R1)

R1-2

(5VDC SUPPLY)

3-14

4. Troubleshooting

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by any means, is strictly prohibited.

GENERAL

The PowerCommand Control 3100 (PCC) continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the PCC will light a yellow Warning lamp or a red Shutdown lamp and display a message on the digital display panel.

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

This section contains the following information:

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

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

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

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

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

and shutdown limits.

• Tables 4-4 through 4-30: Provide detailed

troubleshooting procedures.

• T able 4-31: Describes the analog circuit board

inputs and outputs.

• Table 4-32: Describes the location and func-

tion of each fuse.

CAUTION

Before disconnecting battery cable(s), press the Emergency Stop button and wait at least 30 seconds. Engine performance may be affected (e.g., engine dying or hard starting) if battery cable(s) is removed during the 30 second waiting period. CM570 module may require adjustment using InSite service tool.

WARNING

Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery . Discharge static electricity from body before touching batteries by first touching a grounded metal surface.

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

CAUTION

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

WARNING

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

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

SAFETY CONSIDERATIONS

WARNING

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

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

Contacting high voltage compo-

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

2. Press the Emergency Stop button and wait at least 30 seconds before completing Step 3.

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

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

4-1

STATUS INDICATORS

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by any means, is strictly prohibited.

Non-Automatic Status Indicator:

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

Warning Status Indicator:

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

Shutdown Status Indicator:

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

This red lamp

This red lamp is lit

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

Digital Display:

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

RESETTING THE CONTROL

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

Standby [sleep] mode until all faults have been reset.)

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

Reset Switch

to reset warn-

WARNING AND

SHUTDOWN

STATUS INDICATORS

RESET

SWITCH

ALPHANUMERIC FAULT MESSAGE

DISPLAY

FIGURE 4-1. CONTROL PANEL (PCC 3100)

4-2

TABLE 4-1. WARNING AND SHUTDOWN CODES

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by any means, is strictly prohibited.

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 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 LOW OIL PRESSURE Shutdown 4-4 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 OIL PRES SENDER Warning 4-4 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 LOW COOLANT TEMP Warning 4-5 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 HIGH COOLANT TEMP Warning 4-5 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 HIGH COOLANT TEMP Shutdown 4-5 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 COOLANT SENDER Warning 4-5 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214 LOW COOLANT LVL Warning 4-6 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 LOW COOLANT LVL Shutdown 4-6 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 MAG PICKUP Shutdown 4-6 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221 FAIL TO CRANK Shutdown 4-6 4-13, 4-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222 OVERCRANK Shutdown 4-6 4-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223 OVERSPEED Shutdown 4-6 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 LOW DC VOLTAGE Warning 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231 HIGH DC VOLTAGE Warning 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232 WEAK BATTERY Warning 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 LOW FUEL − DAY Warning 4-7 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241 LOW FUEL Warning 4-7 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 EEPROM ERROR Shutdown 4-7 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251 EEPROM ERROR Warning 4-7 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252 EEPROM ERROR Warning 4-7 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

260 CUSTOMER FAULT 1* Warning/Shutdown 4-8 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . .

261 GROUND FAULT* Warning/Shutdown 4-8 4-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262 CM570/ENGINE Warning 4-8 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263 CM570/ENGINE Shutdown 4-8 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

301 HIGH AC VOLTAGE Shutdown 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

303 LOW AC VOLTAGE Shutdown 4-8 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313 UNDER FREQUENCY Shutdown 4-9 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

320 OVERCURRENT Warning 4-9 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

321 OVERCURRENT Shutdown 4-9 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322 SHORT CIRCUIT Shutdown 4-9 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 OVERLOAD Warning 4-9 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

* Default message. Editable for customer site requirements.

4-3

TABLE 4-2. WARNING AND SHUTDOWN CODES

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by any means, is strictly prohibited.

WARNING

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

SYMPTOM CORRECTIVE ACTION

MESSAGE:

IDLE MODE 101 − WARNING

Shutdown lamp lights.

MESSAGE:

EMERGENCY STOP 102 − SHUTDOWN

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

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

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

Pull the button out. Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required.

Warning lamp lights. MESSAGE:

LOW OIL PRESSURE 200 − WARNING

Shutdown lamp lights.

MESSAGE:

LOW OIL PRESSURE 201 − SHUTDOWN

Warning lamp lights.

MESSAGE:

OIL PRES SENDER 204 − WARNING

Indicates engine oil pressure has dropped to an unacceptable level. If generator is powering critical loads and cannot be shut down, wait until next shutdown period and then follow 201-SHUTDOWN procedure.

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

Indicates engine oil pressure has dropped below the shutdown trip point. Check oil level, lines and filters. If oil system is OK but oil level is low, re plenish. Reset control and restart. Oil pressure limits are listed in Table 4-3.

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

4-4

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

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by any means, is strictly prohibited.

WARNING

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

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

LOW COOLANT TEMP 210 − WARNING

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

° F (21° C) or lower.

70

NOTE: In applications where the ambient temperature falls below

40

°F (4°C), Low Coolant Temp

may be indicated even though the coolant heaters are operating.

Warning lamp lights.

MESSAGE:

HIGH COOLANT TEMP 211 − WARNING

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

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

or disconnected heater cord and correct as required.

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

sible coolant leakage points and repair as required.

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

Indicates the engine coolant temperature is getting close to the recommended maximum temperature limit: 215° F (102° C) − standby or 207° F (97° C) − prime. If generator is powering non-critical and critical loads and cannot be shut down, use the following:

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

If engine can be stopped, follow HIGH COOLANT TEMP 212 − SHUT-

DOWN procedure.

Shutdown lamp lights.

MESSAGE:

HIGH COOLANT TEMP 212 − SHUTDOWN

Warning lamp lights.

MESSAGE:

COOLANT SENDER 213 − WARNING

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

Indicates engine has overheated (coolant temperature has risen above the shutdown trip point:

F (106° C) − standby or 215° F (102° C) − prime. Allow engine to

223°

cool down completely before proceeding with the following checks:

a. Check for obstructions to cooling airflow and correct as necessary. b. Check fan belt and repair or tighten if necessary. c. Check coolant mixture. d. Check blower fan and circulation pumps on remote radiator installa-

tions.

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

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

4-5

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

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by any means, is strictly prohibited.

WARNING

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

SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

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

Shutdown lamp lights.

MESSAGE:

MAG PICKUP 220 − SHUTDOWN

Engine will not crank. Shutdown lamp lights. MESSAGE:

FAIL TO CRANK 221 − SHUTDOWN

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

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

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

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

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

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

a. Restart and check RPM on the digital display.

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

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

and tighten all connections.

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

Shutdown lamp lights. Engine stops cranking. MESSAGE:

OVERCRANK 222 − SHUTDOWN

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

OVERSPEED 223 − SHUTDOWN

Indicates possible fuel system problem.

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

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

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

4-6

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

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WARNING

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

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

LOW DC VOLTAGE 230 − WARNING

Warning lamp lights.

MESSAGE:

HIGH DC VOLTAGE 231 − WARNING

Indicates battery voltage is below 10 VDC.

a. Discharged or defective battery.

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

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

and tighten all connections.

c. Check engine DC alternator. Replace engine DC alternator if normal

battery charging voltage is not obtained.

d. Check battery charge voltage float level if applicable (raise float lev-

el).

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

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

tery charging voltage is not obtained.

Warning lamp lights. MESSAGE:

WEAK BATTERY 232 − WARNING

Warning lamp lights.

MESSAGE:

LOW FUEL−DAY 240 − WARNING

or

LOW FUEL 241 − WARNING

Shutdown lamp lights.

MESSAGE:

EEPROM ERROR 250 − SHUTDOWN

Warning lamp lights.

MESSAGE:

EEPROM ERROR 251 − WARNING or 252 − WARNING

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

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

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

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

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

4-7

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

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SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

CUSTOMER FAULT 1 260 − SHUTDOWN

or

GROUND FAULT 261 − SHUTDOWN

Warning lamp lights.

MESSAGE:

CUSTOMER FAULT 1 260 − WARNING

or

GROUND FAULT 261 − WARNING

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

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

Note: Customer fault messages are editable. The message displayed for the code shown (260 and 261) may have been edited and may not appear as shown in this table.

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

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

Note: Customer fault messages are editable. The message displayed for the code shown (260 and 261) may have been edited and may not appear as shown in this table.

Warning lamp lights. MESSAGE:

CM570/ENGINE 262 − WARNING

Shutdown lamp lights.

MESSAGE:

CM570/ENGINE 263 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

HIGH AC VOLTAGE 301 − SHUTDOWN

Shutdown lamp lights.

MESSAGE:

LOW AC VOLTAGE 303 − SHUTDOWN

Indicates CM570 engine control module error condition. Check CM570 module using InSite service tool.

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

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

4-8

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

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SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

UNDER FREQUENCY 313 − SHUTDOWN

Warning lamp lights.

MESSAGE:

OVERCURRENT 320 − WARNING

Shutdown lamp lights.

MESSAGE:

OVERCURRENT 321 − SHUTDOWN

Indicates that engine speed has dropped below 90% of nominal for 10 seconds. Note: Five seconds before shutdown, a Load Dump signal is initiated.

Check fuel supply, intake air supply and load.

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

Check load and load lead connections.

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

Check load and load lead connections.

Shutdown lamp lights. MESSAGE:

SHORT CIRCUIT 322 − SHUTDOWN

Warning lamp lights.

MESSAGE:

OVERLOAD 330 − WARNING

Shutdown lamp lights.

MESSAGE:

REVERSE POWER 335 − SHUTDOWN

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

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

Check load and load lead connections.

Indicates improper CT or PT phasing. (Non-parallel units only.) Check CT / PT wiring. Refer to

TABLE 4-3. OIL PRESSURE WARNING AND

SHUTDOWN LIMITS

Normal Oil Pressure

Warning Limit Shutdown Limit

Idle Oil Pressure

Warning Limit Shutdown Limit

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

30-50 psi (207-345 kPa)

25 psi (172 kPa) 20 psi (138 kPa)

15 psi (104 kPa)

12 psi (83 kPa) 8 psi (55 kPa)

CT Installation

in

Section 5

.

4-9

TROUBLESHOOTING PROCEDURE

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by any means, is strictly prohibited.

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

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

Try to think through the problem. Go over what was done during the last service call. The problem could be as simple as a loose wire, an opened fuse or a tripped circuit breaker. (Table 4-31 describes the location and function of each fuse.)

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

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

9

.

CAUTION

Always set the Run/Off/Auto (S12)

Section 3

. The control wiring

Section

switch to the Off position and the Power On/ Standby (S5) switch to the Standby position before disconnecting or connecting harness connectors. Otherwise, disconnecting the harness connectors can result in voltage spikes high enough to damage the DC control circuits of the genset.

CAUTION

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

4-10

DISPLAY BOARD

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by any means, is strictly prohibited.

A35

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

ANALOG BOARD

A33

TB1-1

OPTIONAL RUN

RELAYS K11, K12 &

K13

RUN/OFF/AUTO

SWITCH S12

ENGINE INTERFACE

A31

GOVERNOR GAIN

ADJUST

CUSTOMER INTERFACE

A34

50/60HZ SWITCH

RELAY

ASSEMBLY

OPTIONAL

COMMON ALARM

RELAY K14

PT/CT BOARD A36

FB1 − FB7

(SEE TABLE 4-31)

VOLTAGE

REGULATOR

OUTPUT MODULE

A37

ACCESSORY BOX

FIGURE 4-2. CIRCUIT BOARD LOCATIONS

4-11

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

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WARNING

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Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

Reset and attempt to start:

Start LED DS11 on the engine interface board turns on.

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

1. Insufficient battery voltage. Check the following conditions:

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

c. Insufficient battery charging volt-

age.

d. Engine DC alternator could be bad.

2. Starter could be bad.

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

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

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

6. The mag pickup signal is not being sensed.

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

ty for a fully charged battery is approximately

1.260 at 80° F (27° C).

1b. Clean and tighten or replace the battery cable

connectors and cables at the battery and the

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

charging voltage is not obtained.

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

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

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

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

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

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

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

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

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

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

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

6. Refer to the mag pickup shutdown message

(220).

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

4-12

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

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

Reset and attempt to start:

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

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

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

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

3. Digital board (A32) may be bad.

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

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

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

2. To isolate:

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

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

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

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

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

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

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

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

4-13

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

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Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

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

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

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

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

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

3. Digital board (A32) may be bad.

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

for ground output at A32 J4-18.

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

engine interface board A31 is bad. Replace A31.

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

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

the control. Attempt to remote start, and check for ground output at A32 J2-26. If no ground output (but A34 DS14 is on) customer interface board A34 is bad. Replace A31.

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

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

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

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

4-14

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

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Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

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

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

1. S12 or the wiring harness may be bad.

2. Engine interface board A31 may be bad.

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

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

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

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

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

3. Digital board A32 may be bad.

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

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

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

4-15

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

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WARNING

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

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

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

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

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

2. Customer interface board A34 may be bad.

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

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

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

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.

4-16

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

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WARNING

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

Indicator(s) Possible Cause Corrective Action

“FAIL TO CRANK” (221) message

DOES NOT

appear on digital display

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

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

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

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

2. Engine interface board A31 may be bad.

3. Digital board A32 may be bad.

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

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

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

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

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

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

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

4-17

TABLE 4-10. ENGINE CRANKS BUT DOES NOT START

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WARNING

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

Indicator(s) Possible Cause Corrective Action

“OVERCRANK” (222) message

−and While cranking,

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

NOTE: This indication suggest that the PCC has sent a run signal to the CM570 module.

Fuel supply or fuel delivery.

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

tank.

b. Closed shutoff valve in supply line.

c. Air in fuel system.

2. Fuel tank solenoid not energized due

to: a. Open in fuel solenoid circuit. b. Defective fuel solenoid.

3. Engine fuel system or other engine problem.

1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line

supplying the engine.

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

vice manual.

2a. Check wiring continuity of fuel tank solenoid cir-

cuit.

2b. Test fuel tank solenoid.

Repair or replace as necessary.

3. Refer to engine service manual.

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

4-18

TABLE 4-11. ENGINE CRANKS BUT DOES NOT START

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Indicator(s) Possible Cause Corrective Action

“OVERCRANK” (222) message

−and While cranking,

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

NOTE: This indication suggest that the PCC has sent a run signal, but the signal is not getting through to the CM570 module or the CM570 enable signal is not getting through.

The run signal is not getting from engine interface board (A31) to the CM570 module.

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

2. There is an open between the engine interface board (A31) and relay K8.

3. Relay K8 is defective.

4. CM570 module is defective. 4. Check CM570 module using InSite service tool.

The keyswitch signal is not getting from customer interface board (A32) to the CM570 module.

1. The keyswitch signal is not getting out of the customer interface board (A32). A32 may be bad.

2. There is an open between the customer interface board (A32) and relay K7.

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

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

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

2. If there is B+ at A31 J4-1, check for B+ at K8-86, while attempting to crank. If there is no B+ at K8-86, isolate to connectors and wiring. Repair or replace as necessary.

3. If there is B+ at K8-86, check for ground signal at K8-30. If open, replace K8.

Reset the control. Check for ground at A32 P3-10. (Control panel switch set to Off position.)

*1. Install harness tool between A32 J3/P3. Check

for ground at A32 J3-10. If no ground output at A32 J3-10, replace A32.

2. If there is ground at A32 J3-10, isolate to connectors and wires between A32 J3-10 to TB1-19 to K7-85.

3. Relay K7 is defective. 3. B+ must be present at relay K7-30 for the

4. CM570 module is defective. 4a. Check fuses FB3 and FB4 which supply B+ to

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

CM570 module to be operational. If B+ is not present, isolate to defective K7 relay/wiring. (K7-30 B+ is present during stop or run mode. Disabled only for emergency stop.)

the CM570 module.

4b. Check CM570 module using InSite service tool.

4-19

TABLE 4-12. ENGINE CRANKS BUT DOES NOT START

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Indicator(s) Possible Cause Corrective Action

“OVERCRANK” (222) message

−and Run LED DS12

on the engine interface board (A31) is off.

NOTE: These indications suggest that the PCC has NOT sent a run signal.

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

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

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

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

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

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

“FAIL TO CRANK” (221) message

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

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

The mag pickup signal is not being sensed.

Refer to the mag pickup shutdown message (220).

4-20

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

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Indicator(s) Possible Cause Corrective Action

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

1. Low oil level. Clogged lines or filters.

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

the generator set may be shutting down on another fault.

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

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

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

nect the sender, disconnect the run signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display.

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

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

Table 4-3.

2b. Harness or PCC circuit board could be

bad. Isolate to the harness, engine inter-

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

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

4-21

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

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

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

• Check for 5 VDC at A31 J5-18.

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

VDC at A31 J2-24.

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

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

Table 4-30a/b

(

).

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

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Indicator(s) Possible Cause Corrective Action

“OIL PRESSURE SENDER” warning (204) message.

1. The sender connections could be bad.

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

1. Check the sender connections.

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

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

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

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

a. If the control responds to the simulator, 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 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 4-30a/b

).

“COOLANT SENDER” warning (213) message.

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

1. The sender connections could be bad.

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

1. Check the sender connections.

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

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

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

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

place the sender.

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

tor, refer to the high coolant temp troubleshooting procedure.

4-22

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

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Indicator(s) Possible Cause Corrective Action

“LOW COOLANT TEMP” warning (210) message.

Coolant level is normal.

Heater is OK. Coolant temp

on front panel display is OK.

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

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

The sender, the harness or A31 could be bad.

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

set the control.

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

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

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

• If there is continuity, replace the harness.

• If there is no continuity, replace circuit board

A31.

“LOW COOLANT TEMP” warning (210) message.

Coolant level is normal.

Heater is OK. Coolant temp

on front panel display is OK.

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

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

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

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

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

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

2. Open J4−6 and reset the control.

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

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

4-23

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

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Indicator(s) Possible Cause Corrective Action

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

Coolant mixture and level is normal.

No airflow obstructions.

Fan belt is OK.

1. Engine problem:

• Coolant pump could be faulty.

• Thermostat could be faulty.

• There could be an obstruction in

the coolant flow.

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

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

2. The generator set may have been overloaded.

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

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

2. Correct any overload condition.

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

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

• If the PCC ambient coolant temperature reading is not accurate, isolate to the sender, harness, engine interface board (A31), analog board, or digital board.

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

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

place the sender.

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

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

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

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

• If no continuity, then A31 is bad.

• If continuity is OK, then send a simu-

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

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

), replace A33.

4-31

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

Table 4-30a/b

).

Table

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

4-24

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

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Indicator(s) Possible Cause Corrective Action

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

Coolant level is normal.

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

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

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

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

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

1. If the 215 shutdown message drops out and does not reappear, replace the sender.

*2. If the 215 shutdown message reappears and

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

• If there is continuity, replace the harness.

• If there is no continuity, replace circuit board

A31.

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

Coolant level is normal.

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

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

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

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

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

Check J4−4/P4−4 on A32.

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

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

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

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

4-25

TABLE 4-18. MAG PICKUP SHUTDOWN (220)

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Indicator(s) Possible Cause Corrective Action

“MAG PICKUP” shutdown message (220)

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

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

2. Loose or damaged mag pickup wire.

3. Damaged mag pickup (MPU).

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

1. Check and correct setting if necessary.

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

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

tempt to start the genset in idle mode.

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

down message, or if the engine starts and idles, but then shuts down on a MAG PICKUP fault, the MPU sender could be bad. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking.

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

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

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

play a fault, then there could be a frequency mismatch problem.

• Measure generator output frequency with a digital multimeter and compare to the frequency on the PCC display.

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

• If the multimeter and PCC frequencies do not match, there is a frequency sensing problem. Verify the accuracy of the PCC L1N voltage, and then refer to the analog/ digital troubleshooting procedure (

4-30a/b

).

Section 5

.) If there is still no

Table

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

4-26

TABLE 4-19. OVERSPEED SHUTDOWN (223)

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Indicator(s) Possible Cause Corrective Action

“OVERSPEED” shutdown message (223)

1. Fuel system or CM570 module is bad.

the digital board (A32) could be bad.

1a. Refer to the engine service manual to trouble-

shoot fuel system.

1b. Use InSite service tool to troubleshoot CM570

module.

*2. Replace A31. If fault reappears, replace A32.2. The engine interface board (A31) or

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

4-27

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

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Indicator(s) Possible Cause Corrective Action

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

1. Weak or discharged battery.

2. Low electrolyte level in battery.

3. Battery connections loose or dirty.

4. Insufficient battery charging voltage.

5. Engine DC alternator could be bad.

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

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

1.260 at 80° F (27° C).

2. Replenish electrolyte and recharge battery.

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

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

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

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

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

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

Table 4-30a/b

).

“HIGH DC VOLTAGE” (231) warning message.

But battery voltage is OK.

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

1. Excessive battery charging voltage.

2. Engine DC alternator could be bad.

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

4-28

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

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

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

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

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

Table 4-30a/b

).

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

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Indicator(s) Possible Cause Corrective Action

“LOW FUEL− DAY” warning message (240)

Fuel level is normal.

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

“LOW FUEL− DAY” warning message (240)

Fuel level is normal.

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

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

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

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

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

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

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

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

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

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

• If there is continuity, replace the harness.

• If there is no continuity, replace circuit board

A31.

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

*1. Install a breakout connector at A32 J4.

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

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

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

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

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

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

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

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

4-29

TABLE 4-22. LOW FUEL WARNING (241)

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Indicator(s) Possible Cause Corrective Action

“LOW FUEL” warning message (241)

Fuel level is normal.

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

DS13 on A34 is on, indicating that A34 is receiving a low fuel signal from the customer circuit.

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

.

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

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

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

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

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

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

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

“LOW FUEL” warning message (241)

Fuel level is normal.

DS13 (A34) is off.

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

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

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

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

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

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

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

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

4-30

TABLE 4-23. EEPROM ERROR SHUTDOWN (250) OR WARNING (251, 252)

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Indicator(s) Possible Cause Corrective Action

“EEPROM ERROR” shutdown (250) message.

“EEPROM ERROR” warning (251) message.

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

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

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

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

1. Perform the adjustment procedures (described in

Section 5

Reset the control. Shut off and restart the genset.

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

Reset the control. Shut off and restart the genset.

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

). Save the adjustments.

Section 5

.

“EEPROM ERROR” warning (252) message.

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

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

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

Reset the control. Shut off and restart the genset.

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

4-31

TABLE 4-24. CUSTOMER FAULTS (260 or 261)

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Indicator(s) Possible Cause Corrective Action

“CUSTOMER FAULT (260 or 261) message.

And corresponding LED on customer interface board A34 is on.

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

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

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

the control.

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

2. If the message remains, replace A34.

“CUSTOMER FAULT (260 or 261) message.

And corresponding LED on customer interface board A34 is off.

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

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

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

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

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

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

• If the fault does not return, replace A34.

• If the fault reappears, replace A32.

A 34

LED

DS4 DS11

A32

CONNECTOR

J2-3 J2-24

CUSTOMER

FAULT #

1 2

FAULT

CODE

260 261

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

4-32

TABLE 4-25a. CM570/ENGINE WARNING (262) OR SHUTDOWN (263)

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“CM570/ ENGINE” warning (262) message.

And corresponding LED on customer interface board A34 is on.

1. Low B+ to CM570 module during cranking. Check the following conditions:

a. Batteries not charged. b. Battery connections loose or dirty. c. Insufficient battery charging volt-

age.

d. Engine DC alternator could be bad.

problem.

3. If there is no actual fault from the CM570 module, the problem may be a short to ground in the K10 relay circuit, defective K10 relay, or a bad customer interface board (A34).

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

ty for a fully charged battery is approximately

1.260 at 80° F (27° C).

1b. Clean and tighten or replace the battery cable

connectors and cables at the battery and the

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

charging voltage is not obtained.

2. Check CM570 module using InSite service tool.2. Defective CM570 module or engine

3. Isolate the source of the false signal. Disconnect the signal lead at TB1-P4B-21 and reset the control.

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

ground in the K10 relay circuit or relay K10 is defective.

b. If the message remains, replace A34.

“CM570/ ENGINE” shutdown (263) message.

And corresponding LED on customer interface board A34 is on.

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

problem.

2. If there is no actual fault from the CM570 module, the problem may be a short to ground in the K9 relay circuit, defective K9 relay, or a bad customer interface board (A34).

1. Check CM570 module using InSite service tool.1. Defective CM570 module or engine

2. Isolate the source of the false signal. Disconnect the signal lead at TB1-P4B-22 and reset the control.

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

ground in the K9 relay circuit or relay K9 is defective.

b. If the message remains, replace A34.

4-33

TABLE 4-25b. CM570/ENGINE WARNING (262) OR SHUTDOWN (263)

Redistribution or publication of this document, 

by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“CM570/ ENGINE” (262 or 263) message.

And corresponding LED on customer interface board A34 is off.

If the corresponding LED on the customer interface board (A34) is off, then A34 is not receiving a signal from the CM570 module.

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

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

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

• If the fault does not return, replace A34.

• If the fault reappears, replace A32.

A 34 LED

DS15 DS3

A32

CONNECTOR

J2-9 J2-15

FAULT

CODE

262 263

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

4-34

TABLE 4-26a. HIGH AC VOLTAGE SHUTDOWN (301)

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“HIGH AC VOLTAGE ” shutdown (301) message.

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

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

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

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

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

a. Start the genset and observe the voltage

displayed on the digital display.

b. If all phases of voltage are balanced and not

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

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

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

(Continued)

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

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

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

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

of normal output), go to step 3.

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

DS2 on A37 is off, go to step 4.

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

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

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

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

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

4-35

TABLE 4-26b. HIGH AC VOLTAGE SHUTDOWN (301)

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“HIGH AC VOLTAGE ” shutdown (301) message.

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

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

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

*3. Before starting the generator set, discon-

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

Check the output voltage at the alternator

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

expected output voltage from the PT/C mod-

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

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

and 2−1.

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

If the voltages are not balanced, replace A36.

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

*4. Disconnect the plugs in the following steps

below with the genset off then start the genset in the idle mode, and measure voltages with a digital multimeter.

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

ness tool. Check the voltage into the customer interface board with the harness tool at J3 terminals 4−6, 5−13, and 7−20. Remove the harness tool and reconnect J3 and P3. These voltages should be the same values 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 4-26c. HIGH AC VOLTAGE SHUTDOWN (301)

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“HIGH AC VOLTAGE ” shutdown (301) message.

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

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

3-phase ave = Vin (2.9÷PT) ±5%

V

out

V

= Actual generator output voltage

in

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

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

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

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

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

6. Refer to the generator servicing procedures in

Section 6

.

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

4-37

TABLE 4-27a. LOW AC VOLTAGE SHUTDOWN (303)

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“LOW AC VOLTAGE ” shutdown (303) message.

1. PMG or field wiring could be faulty.

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

3. Overload.

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

5a. The problem may be the analog board

(A33) or the digital board (A32).

5b. The problem may be the regulator

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

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

2. Check each diode according to

Generator in Section 6

3. Check the load and correct any overload.

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

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

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

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

shooting section for High AC Voltage Shutdown (301).

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

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

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

the output voltage high enough. The problem could be A37, A31, or A32. Restart the genset 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

genset running).

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

• If A31is OK, replace A32.

• If A31/DS10 is on with genset running and

A37/DS2 is not on, check the harness.

• If the harness is OK, replace A37.

Table 4-30a/b

. Service as necessary.

). Check the phase

Servicing the

(Continued)

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

4-38

TABLE 4-27b. LOW AC VOLTAGE SHUTDOWN (303)

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by any means, is strictly prohibited.

WARNING

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

Indicator(s) Possible Cause Corrective Action

“LOW AC VOLTAGE ” shutdown (303) message.

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

ule (A36), the analog board (A33), the customer interface board (A34), or the digital board (A32).

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

must have lost AC sensing. Check PTs (primary 1K−2.5K ohms; secondary 140−225 ohms), sensing harness wires, generator output connections, and the customer interface board for continuity . If these are OK, then check the analog and digital boards, using the analog input troubleshooting procedure (

Table 4-30a/b

).

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

4-39

TABLE 4-28. UNDER FREQUENCY SHUTDOWN (313)

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WARNING

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Indicator(s) Possible Cause Corrective Action

“UNDER FREQUENCY” shutdown (313) message.

1. Improper setup.

2. Overload.

3. Fuel or air delivery problem.

4. Fuse FB3 or FB4 in the accessory box may be open, or B+ may not be getting to the fuses.

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

2. Check the load and correct any overload, if necessary.

Disconnect the load. Reset the control and attempt to restart the generator set.

3. If the engine starts and runs, refer to the engine fuel/air delivery service procedures in the engine service manual.

4. Check fuses FB3 and FB4 which supply B+ to the CM570 module. If open, replace the fuse with one of the same type and amp rating (10 Amps). If fuses are OK, check B+ supply back to TB2-7 and 8.

5. The CM570 module, the digital board (A32), or the engine interface board (A31) could be bad.

*5. Crank the genset, and check the governor duty

cycle on the PCC display. If the duty cycle is OK (70%), indicates that the

CM570 module may be bad (use InSite service tool).

If the duty cycle is not OK, the digital board (A32) or the engine interface board (A31) may be bad.

• A31 - Check for continuity: A31 J1-13 to A31 J4-19 and A31 J1-14 to A31 J4-12. If no continuity, replace A31.

• A32 - If A31 is OK, replace A32

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

4-40

TABLE 4-29. OVERCURRENT WARNING (320) OR SHUTDOWN (321),

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by any means, is strictly prohibited.

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

WARNING

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

Indicator(s) Possible Cause Corrective Action

“OVERCURRENT” warning (320) or shutdown (321), or “SHORT CIRCUIT” shutdown (322), or OVERLOAD warning (330) message.

1. Short or Overload.

2. Incorrect CTs or CT connections.

3. The problem may be a bad PT/CT module (A36).

4. The problem may be the customer interface board (A34) or connections.

5. The problem may be the analog board (A33) or the digital board (A32).

1. Check the load and load cables. Repair if necessary.

2. Check CTs and CT connections. Correct if necessary. Refer to

in

Section 5

tion

3. Disconnect the PT/CT module and check the 3-ohm resistors (J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary.

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

A33. Repair the connection or replace A34 if necessary. Refer to

5. Isolate, using the analog input troubleshooting procedure ( phase or phases.

Current Transformer Installa-

.

Section 9

Table 4-30a/b

for pin reference.

). Check the bad

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

4-41

TABLE 4-30a. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL

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BOARDS

WARNING

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

NOTE: Perform this procedure after you have isolated the problem to either the analog

board (A33) or to the digital board (A32). You must have schematics and wiring diagrams to identify the various inputs and outputs.

*1. Check that the input to the analog board is correct. There are a few signals (e.g.: 3PH Ave, Line Freq,

Phase Angle 1 to 3, Lead Lag) that are derived from one or more input signals.

1a. To check the sensor input voltages into the analog board, connect the sender simulator and test the

voltage across the + and − inputs at A33 J1 using harness tool. (This assumes that you have verified that the harness and the engine interface board is good.)

• If the input voltage to the analog board is correct (refer to Table 4-31), 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 4-31). 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 4-31), 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

TABLE 4-30b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL

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BOARDS

WARNING

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

NOTE: Perform this procedure after you have isolated the problem to either the analog

board (A33) or to the digital board (A32). You must have schematics and wiring diagrams to identify the various inputs and outputs.

2b. This step is for multiplexed signals. Is more than one multiplexed signal reading bad?

• No. If the input to the analog board is correct and only one multiplexed signal is reading bad, replace the analog board.

• Yes. If more than one multiplexed signal reading is bad, remove the ribbon cable connector at A32 J3 and check the front panel digital display of the bad inputs. It should read 0 for all inputs except the temperature inputs (which should read less than 32° F or less than 0° C) and power factor (which should read “NA”).

If any values read incorrectly, replace the digital board. If they all read correctly, measure voltages on the multiplexer control lines (with A32-J3 discon-

nected, measure from Digital board connector J3). Voltages should be:

A32-J3-23: 3.0 ±0.25 VDC A32-J3-24: 2.4 ±0.25 VDC A32-J3-27: 1.4 ±0.25 VDC A32-J3-33: 3.0 ±0.25 VDC

A32-J3-34: 3.0 ±0.25 VDC If these control (select) line voltages are not correct, replace the digital board. If these control (select) line voltages are correct (and the input to the analog board is correct),

reconnect the ribbon cable connector (through harness tool) at A32 J3 and check the 5 VDC reference at A32 J3-12 and the 12 VDC supply at A32 J3-20.

If the 5 VDC and the 12 VDC voltages are OK, replace the analog board.

If the 5 VDC and the 12 VDC voltages are not OK, disconnect A32 J3 and check the

voltages again (measured from Digital board side).

If the 5 VDC and the 12 VDC voltages are OK with A32 J3 disconnected, replace the analog board.

If the 5 VDC and the 12 VDC voltages are not OK with A32 J3 disconnected, replace the digital board.

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

4-43

TABLE 4−31. ANALOG CIRCUIT BOARD (A33) INPUTS AND OUTPUTS

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by any means, is strictly prohibited.

Input Name Input

Connection

L1 (0 to nominal) J4-24 to J4-28 0 to 18 VAC L10 (ACH1) J2-4 0 to 3.0 VDC L2 (0 to nominal) J4-26 to J4-28 0 to 18 VAC L20 (ACH2) J2-13 0 to 3.0 VDC L3 (0 to nominal) J4-30 to J4-28 0 to 18 VAC L30 (ACH3) J2-1 0 to 3.0 VDC

CT21 (0 to full load) J4-33 to J4-34 0 to 1.65 VAC C1 fltrd (ACH4) J2-3 0 to 1.0 VDC CT22 (0 to full load) J4-32 to J4-34 0 to 1.65 VAC C2 fltrd (ACH5) J2-9 0 to 1.0 VDC CT23 (0 to full load) J4-31 to J4-34 0 to 1.65 VAC C3 fltrd (ACH6) J2-17 0 to 1.0 VDC

(1 to 0.8 pf) Phase angle 1 (ACH7) (1 to 0.8 pf) Phase angle 2 (ACH7) (1 to 0.8 pf) Phase angle 3 (ACH7)

(L1 vs CT21) Lead lag (P2A.1)) Bus L1 (0 to nominal) Bus L2 (0 to nominal) Bus L3 (0 to nominal)

6

J4-15 to J4-18 0 to 18 VAC Bus L1 (ACH7) J2-7 0 to 3.0 VDC J4-16 to J4-18 0 to 18 VAC Bus L2 (ACH7) J2-7 0 to 3.0 VDC J4-17 to J4-18 0 to 18 VAC Bus L3 (ACH7) J2-7 0 to 3.0 VDC

Input Signal

Range

Output Name

3PH ave (ACH0) J2-18 0 to 2.9 VDC Line freq. (HSI.1) J2-21 0-5V sq wave @ L1 Hz

C1 (ACH7) J2-7 0 to 1.0 VDC C2 (ACH7) J2-7 0 to 1.0 VDC C3 (ACH7) J2-7 0 to 1.0 VDC

1

3

Output

Connection

J2-7 0 to 1.0 VDC J2-7 0 to 1.0 VDC J2-7 0 to 1.0 VDC

J2-29 0 or 5 VDC (digital)

2

Output

Signal Range

Bus freq (HS1.3) J2-22 0-5V sq wave @ Bus L1 Hz Phase rot (P2A.0) Bus/gen phase dif (ACH7) Bus/gen phase (HS1.2)

Synch (ACH7) Battery voltage J1-31 (+) to J1-30(−) 0 to 32 VDC Battery voltage (ACH7) J2-7 0 to 2.9 VDC Oil press (0 to 100 psi) (See note H2O 1 (6 to 230° F) J1-19/20 to J1-17/18 700 to 1800 Ω H2O 1 (ACH7) J2-7 1.4 to 3.7 VDC H2O 2 (6 to 230° F) J1-15/16 to J1-14/15 700 to 1800 Ω H2O 2 (ACH7) J2-7 1.4 to 3.7 VDC Oil temp (6 to 230° F) J1-11/12 to J1-9/10 700 to 1800 Ω Oil temp (ACH7) J2-7 1.4 to 3.7 VDC Exh temp 1 (32 to 1471° F) J1-7/8 to J1-5/6 100 to 376 Ω Exh temp 1 (ACH7) J2-7 0.8 to 3.0 VDC Exh temp 2 (32 to 1471° F) J1-3/4 to J1-1/2 100 to 376 Ω Exh temp 2 (ACH7) J2-7 0.8 to 3.0 VDC

4 )

0.5 to 4.5 VDC Oil press (ACH7) J2-7 0.5 to 4.5 VDC

5

J2-26 0 or 5 VDC (digital)

5

J2-7 0 to 5.0 VDC

J2-19 0-5V 120 Hz 0 to 100% DC

J2-7

Notes:

1. All output signals on ACH7 are multiplexed.

2. All output voltages on A33 J2 are referenced to ground (J2-15 and J2-16).

3. Must have L1, L2, L3, CT21, CT22, and CT23 for these phase angle outputs.

4. J1-24 (5VDC), J1-23 (signal), J1-18 (return).

5. Must have L1, L2, L3, Bus L1, Bus L2, and Bus L3 for these outputs.

6. L1, L2, and L3 can be 0 to 180° out of phase with Bus L1, Bus L2, and Bus L3, respectively.

4-44

TABLE 4-32. PCC FUSES

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by any means, is strictly prohibited.

REFERENCE

LOCATION

DESIGNA-

RATING FUNCTION

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) Accessory Box FB1 20 Amp Main B+ feed (to TB2) Accessory Box FB2 20 Amp Customer B+ (to TP1 customer terminal block) Accessory Box FB3 10 Amp CM570 B+ power (to CM570 module) Accessory Box FB4 10 Amp CM570 B+ power (to CM570 module) Accessory Box FB5 10 Amp NET B+ (to TB1 customer terminal block) Accessory Box FB6 10 Amp Heater B+ (to engine block heaters) Accessory Box FB7 10 Amp Switched B+ (to TB1 customer terminal block)

4-45

THIS PAGE LEFT INTENTIONALLY BLANK

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4-46

5. Control Service and Calibration

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GENERAL

This section contains circuit board removal and replacement procedures, calibration procedures for the generator set (genset) control and test procedures for the generator and engine components. Refer to the figures included with this information and also the

Wiring Diagrams

instructed.

Before servicing the PCC, all settings should be recorded. This will enable correct and complete readjustment of the PCC in the event that all previous entries are lost during servicing.

CIRCUIT BOARD

Analog Board (A33)

1. Voltage, Current and PF.

2. Coolant Temperature L & R

section when

TABLE 5-1. CONTROL PANEL RECALIBRATION

ADJUSTMENT PROCEDURE / PAGE

CIRCUIT BOARD

REMOVAL/REPLACEMENT

No special tools (other than a grounding wrist strap) are required to remove a circuit board from inside the control panel or the accessory box.

There are several circuit boards, that when replaced, require you to recalibrate the control panel functions. Table 5-1 lists the circuit boards and the appropriate procedure to perform to recalibrate the control panel. The circuit board locations are shown in Figure 5-1.

Before you attempt to remove a circuit board, read the

Circuit Board Removal Safety Precautions

this section.

Setup and Calibration Menus

(Page 5-8)

in

Digital Board (A32) Must recalibrate all values, starting with

the

Initial Start Setup

PT/CT Board (A36) Voltage, Current and PF.

procedure.

1.

Initial Start Setup

2.

Adjust Menu

3.

Setup and Calibration Menus

5-8).

Setup and Calibration Menus

(Page 5-4).

(Page 5-6).

(Page

(Page 5-8)

5-1

DISPLAY BOARD

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by any means, is strictly prohibited.

A35

S5 POWER ON/

STANDBY SWITCH

DIGITAL BOARD

A32

ANALOG BOARD

A33

GOVERNOR GAIN

ADJUST (R1)

VOLTAGE REGULATOR

OUTPUT MODULE

A37

ENGINE INTERFACE

A31

ACCESSORY BOX

FIGURE 5-1. CIRCUIT BOARD LOCATIONS

CUSTOMER INTERFACE

A34

50/60HZ

SELECTOR

RELAY

ASSEMBLY

PT/CT

BOARD

A36

5-2

Circuit Board Removal Safety Precautions

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by any means, is strictly prohibited.

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

Attach the clip to a non -painted surface of the control box and place the strap around your wrist before handling a circuit board.

CAUTION

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

Turn off or remove AC power from the battery charger and then remove the negative (−) battery cable from the genset starting battery. This is to make sure that the genset will not start while working on it and to avoid circuit board damage, caused by volt-

Electrostatic discharge will damage

age spikes when removing and replacing circuit board connectors.

WARNING

Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas causing severe personal injury.

Ventilate battery area before working on or near battery—Wear safety glasses—Do not smoke— Switch trouble light ON or OFF away from battery—Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (−) cable first and reconnect last.

CAUTION

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

WARNING

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

WRIST STRAP

NON-PAINTED

SURFACE

GROUND LEAD CLIP

FIGURE 5-2. WRIST STRAP

5-3

INITIAL START SETUP MENU

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by any means, is strictly prohibited.

The facing page shows a block representation of the INITIAL START SETUP menu.

coolant temperature) are retained (not reset). To ensure correct and complete readjustment of the PCC, it is suggested that all settings be recorded before you perform the reset function.

CAUTION

Selecting this menu resets all operating parameters to the default values for the selected genset. All previously selected setup and adjustment settings will be lost. Therefore, this procedure must be performed by technically qualified personnel only.

This menu appears on the digital display when the PCC has not been set up for use with a generator set during factory test, or the digital board was replaced in the PCC.

When this display is showing, you must go through the Initial Start Setup menu to select the operating parameters for the generator set. These include whether the genset will be used for Prime Power or Standby use, the Model Number of the generator set, and its operating frequency and output voltage. These choices must be saved into the PCC’s readonly memory before the PCC will accept changes made to other menus.

If the PCC is already set up to operate with a specific generator set, this menu will not appear when power is applied. To reset the control and display the Initial Start Setup menu, you can press RESET, MENU, and PHASE SELECT buttons at the same time.

If you choose to do this, the regulator adjustments and the setup options will be reset to the default settings (including the editable customer fault messages). Display calibrations (volts, amps, PF and

CAUTION

Improper setup, calibration, or adjustments can cause equipment malfunction or damage. Setup, calibration, and adjustment must be performed by technically qualified personnel only.

STANDBY/PRIME submenu:

to the “

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

Use the buttons next

tion. Press the button next to the “>>” in the display to move to the model select submenu.

MODEL select submenu:

the “

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

Use the buttons next to

tor set model number, frequency and power rating.

Make sure that the 50/60Hz selector switch located on the Relay Assembly (Figure 5-1) is set to the desired frequency.

VOLTAGE SELECT submenu:

next to the “

⇑” and “⇓” symbols to select the correct

Use the buttons

generator set nominal line-to-line output voltage.

DELTA / WYE submenu:

the “

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

Use the buttons next to

tion.

SAVE submenu:

From the model select submenu, press the button next to the “>>” in the display to move to the SAVE submenu. Select SAVE to save your changes. The MAIN MENU will then be displayed.

5-4

INITIAL START SETUP

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(It can be invoked by simultaneously pressing

the Reset, Menu, and Phase Select keys.)

STANDBY/PRIME

⇓⇑ _______ >>

<>

⇑ MODEL

<

⇓ (kw mod# freq) >>

<>

⇑ VOLTAGE SELECT

<

⇓ (vac) L-L VAC >>

<>

DELTA / WYE

⇓⇑ _______ >>

<>

TO LOOP BACK & CHECK:

<>

SAVE >>

<>

ENGINE GEN ADJUST >>

<>

STANDBY/PRIME

⇓⇑ _______ >>

<>

Indicates OR" Condition

5-5

ADJUST MENU

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by any means, is strictly prohibited.

The ADJUST submenus permit adjustment of the output voltage and frequency and the start and stop delay times of the generator set.

The complete calibration procedure is described in

Calibration Procedure

the

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

As shown in the diagram, the ADJUST menu has five submenus, including a save/exit procedure.

Voltage and frequency can be adjusted only when the generator set is running under normal operating parameters (not in idle mode). For example, if voltage adjustment is selected when the genset is in Idle mode or not running, the digital display will be:

“⇑ VOLTAGE ” “

⇓ N/A >>”

in this section.

QUENCY submenu, press the button next to the “>>” in the display to move to the START DELAY submenu. Use the buttons next to the “

⇑” and “⇓”

symbols to set the start delay. The start delay adjustment range is 0 to 300 seconds.

STOP DELAY submenu:

This delay applies only to remote stopping in the Auto mode. From the START DELAY submenu, press the button next to the “>>” in the display to move to the STOP DELAY submenu. Use the buttons next to the “

⇑” and “⇓”

symbols to set the stop delay. The stop delay adjustment range is 0 to 600 seconds.

IDLE SPEED submenu:

From the STOP DELAY submenu, press the button next to the “>>” in the display to move to the IDLE SPEED submenu. Use the buttons next to the “

⇑” and “⇓” symbols to set the

idle speed. The idle speed adjustment range is 800 RPM

±100 RPM. (Default value is 800 RPM.)

The idle speed can be adjusted only when the generator set is running in the idle mode. When not in idle mode, N/A is displayed in RPM field.

VOLTAGE submenu:

Use the buttons next to the “ adjust output voltage

FREQUENCY submenu:

This is the first submenu.

⇑” and “⇓” symbols to

± 5%.

From the VOL TAGE submenu, press the button next to the “>>” in the display to move to the FREQUENCY submenu. Use the buttons next to the “ output frequency

± 5%.

START DELAY submenu:

⇑” and “⇓” symbols to adjust

This delay applies only

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

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 genset 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 genset is restarted.

5-6

ADJUST

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by any means, is strictly prohibited.

<>

ENGINE GEN ADJUST >>

<>

<

⇑ VOLTAGE

<>

⇓ _______ >>

<

⇑ FREQUENCY

<>

⇓ _______ >>

<

⇑ START DELAY

<>

⇓ _______ SEC >>

<

⇑ STOP DELAY

<>

⇓ _______SEC >>

⇑ IDLE SPEED

<

⇓ _______RPM >>

<>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

CHANGES SAVED EXIT >>

<>

CHANGES SAVED EXIT >>

<>

ENGINE GEN ADJUST >>

<>

<

⇑ VOLTAGE

<>

⇓ _______ >>

<>

ENGINE GEN ADJUST >>

<>

<

⇑ VOLTAGE

<><>

⇓ _______ >>

Indicates OR" Condition

5-7

SETUP AND CALIBRATION MENUS

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by any means, is strictly prohibited.

The setup and calibration menus allow you to calibrate the PCC with the reading from a calibrated meter. There are four setup and calibration menus that are selectable from the SETUP/CAL menu:

• VERSION AND DISPLAYS

• METERS

• GOVERNOR/REGULATOR

adjust the display so that it matches the reading taken on an accurate, recently calibrated meter.

The complete calibration procedure is described in the

Calibration Procedure

in this section.

The facing page shows a block representation of the VERSION and DISPLAYS submenus, which is the first of four SETUP/CAL menus. If you press the button next to the “>>” in the Main menu display, the VERSION/SETUP/CAL menu will appear.

• SETUP

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

ENTER CODE submenu:

The access code for your PCC is: 5 7 4. To enter the code:

1. Press the button next to the “ first digit.

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

3. Press the button next to the “ second digit.

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

5. Press the button next to the “ third digit.

6. Press the button next to the “>>” to proceed to the DISPLAYS/METERS submenu. (Provided, of course, that you have correctly entered the access code.)

The following sub-sections describe how to select and make changes to the setup and calibration menus and save the changes made to these menus.

⇑” to increment the

CAUTION

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

VERSION submenu:

If you select VERSION, the display will show the generator set model number, frequency, and kW rating, and the date and version of the operating software.

To display the generator set configuration options, press the button next to the “>>” in the submenu that displays the model number , frequency and etc. This menu provides the following information:

• Generator set voltage

• WYE or DELTA

• Standby or Prime

• Parallel or Single

HISTORY:

menu, press the button next to the “>>” in the display to move to the HISTORY submenu. Press the button next to “HISTORY” to display the last (latest) recorded error message.

The software will record (save) up to 20 error messages. The last error detected will always be displayed first. As each new error is detected, the oldest error recorded after 20 will be deleted.

From the VERSION, SETUP/CAL

Version and Displays Menus

The VERSION menu allows you to verify the model number and frequency of the generator set, the date and version of the operating software and generator set configuration options. From the VERSION menu you can also review a History file, that can contain up to 20 error messages.

The DISPLA YS submenus permit calibration of the digital voltage, current, power factor (PF) and coolant temperature displays. Calibration is accomplished by using this section of the menu software to

To view the generator set runtime at which the error occurred and to scroll through the remaining recorded errors, press the button next to the “>>” in the error message menu to display the RUNTIME, NEWER/OLDER menu.

The buttons next to NEWER and OLDER are used to scroll up and down through the error messages. For example, pressing OLDER will display the next oldest recorded error message. When pressing NEWER and the last (newest) error message is displayed, or OLDER and oldest error is displayed, the display will return to the HISTORY menu.

5-8

VERSION & DISPLAYS MENUS

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by any means, is strictly prohibited.

<>

ENGINE GEN ADJUST >>

<>

VERSION <<

<>

SETUP/CAL >>

(kW) (model) __ __ __ V:___.__ >>

(hz) <<

BACK

> >

DISPLAYS VOLTAGE & GEN SET CONFIGURATION

_______ V ______<< _______ ______

BACK

>

<>

VERSION <<

<>

SETUP/CAL >>

<>

VERSION <<

<>

SETUP/CAL >>

<>

VERSION <<

<>

SETUP/CAL >>

⇑ ENTER CODE

<

⇓ __ __ __ >>

<>

CONTINUED

<>

ENGINE GEN ADJUST >>

<>

HISTORY <<

<>

HISTORY <<

BACK

DISPLAYS ERROR MESSAGE AND CODE

_________________ _________________ >>

RUNTIME _________

NEWER OLDER

<>

PRESS MENU" TO RETURN

TO THE ENGINE MENU

>

Indicates OR" Condition

5-9

Version and Displays Menus (Cont.)

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by any means, is strictly prohibited.

DISPLAYS submenus:

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

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter access code (574) as previously described in this section.

Select DISPLAYS to proceed to the DISPLA YS submenus. Use the buttons next to the “ bols to calibrate the selected voltage, current, PF or coolant temperature reading. Press the button next to the “>>” in the display to move to the next adjustment.

“VOLTS L12,” “VOLTS L23,” and “VOL TS L31” refer to voltages measured from L1 to L2, L2 to L3, and L3 to L1, respectively.

The DISPLA YS submenus

⇑” and “⇓” sym-

“PF1, PF2 and PF3” will display N/A when the generator set is not running.

“COOLANT TEMP R” will display “N/A” if the genset has only one sensor. To calibrate coolant temperature display, a precision resistor (provided in the engine sensor tool) must be temporally substituted for the temperature sender. Refer to

in this section.

dure

SAVE/EXIT submenu:

From the AMPS L3 subme-

Calibration Proce-

nu, 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 DISPLAYS/METERS submenu.

If you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the genset 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 genset is restarted.

5-10

VERSION & DISPLAYS MENUS (Cont.)

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by any means, is strictly prohibited.

CONTINUED

⇑ ENTER CODE

<

⇓ __ __ __ >>

<>

DISPLAYS << METERS >>

<>

<

⇑ VOLTS L12

<>

⇓ _______ >>

<

⇑ VOLTS L23

<>

⇓ _______ >>

<

⇑ VOLTS L31

<>

⇓ _______ >>

<

⇑ AMPS L1

<>

⇓ _______ >>

<

⇑ AMPS L2

<>

⇓ _______ >>

<

⇑ AMPS L3

<>

⇓ _______ >>

<

⇑ PF1

<>

⇓ _______ >>

<

⇑ PF2

<>

⇓ _______ >>

<

⇑ PF3

<>

⇓ _______ >>

<

⇑ COOLANT TEMP L

<>

⇓ _______ >>

<

⇑ COOLANT TEMP R

<>

⇓ _______ >>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

<

⇑ VOLTS L12

<>

⇓ _______ >>

CHANGES SAVED EXIT >>

<>

CHANGES SAVED EXIT >>

<>

DISPLAYS << METERS >>

<>

DISPLAYS << METERS >>

<>

<

⇑ VOLTS L12

<><>

⇓ _______ >>

Indicates OR" Condition

5-11

Meters Menu

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by any means, is strictly prohibited.

The METERS submenus permit calibration of the control’s analog meters to match the calibrated digital values. (Calibrate the digital display before calibrating the analog meters.) This calibration is accomplished by using this section of the menu software to adjust the selected meter reading so that it matches the reading provided on the digital display.

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter access code (574) as previously described in this section.

Select METERS to proceed to the METERS submenus. Use the buttons next to the “

⇑” and “⇓” sym-

bols to calibrate the selected meter to match the “CAL TO” value provided on the digital display. Press the button next to the “>>” in the display to move to the next calibration.

The complete calibration procedure is described in the

Calibration Procedure

in this section.

The facing page shows a block representation of the METERS submenus, which is the second of four SETUP/CAL menus. If you press the button next to the “>>” in the Main menu display, the VERSION/SETUP/CAL submenu will appear.

CAUTION

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

METERS submenu:

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

“VOL T METER” and “% AMPERES” calibration reference the phase that is indicated on the phase selection LED’s.

NOTE: The % AMPERES meter scale is based on a 0. 8 power factor. (100% of rated current is full load current at 0.8 PF.)

SAVE/EXIT submenu:

From the HERTZ 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 DISPLAYS/METERS submenu.

If you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the genset 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 genset is restarted.

5-12

METERS MENU

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by any means, is strictly prohibited.

<>VERSION <<

SETUP/CAL >>

<>

⇑ ENTER CODE

<

⇓ __ __ __ >>

<>

DISPLAYS << METERS >>

<>

DISPLAYS << METERS >>

<>

<

⇑ A−C VOLTS

<>

⇓ CALTO: ___ >>

<

⇑ % AMPERES

<>

⇓ CALTO: ___ >>

ENTER CODE

⇑ __ __ __ >>

<>

<

⇑ % LOAD

<>

⇓ CALTO: ___ >>

<

⇑ HERTZ

<>

⇓ CALTO: ___ >>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

CHANGES SAVED EXIT >>

<>

CHANGES SAVED EXIT >>

<>

DISPLAYS << METERS >>

<>

<

⇑ A−C VOLTS

<>

⇓ ADJ TO: ___ >>

<>

DISPLAYS << METERS >>

<>

<

⇑ A−C VOLTS

<><>

⇓ ADJ TO: ___ >>

Indicates OR" Condition

5-13

Governor / Regulator Menu

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by any means, is strictly prohibited.

The REGULA TOR submenus permit adjustment of voltage regulator. The Governor submenus are not used for this engine model except for GOV RAMP. Governor control is provided by the CM570 module and the Governor Gain Adjust potentiometer.

All GOV/REG menu values, except for REG VHZ and GOV RAMP, will display “100%”. The expression “100%” represents the factory setting (default value) for the selected set. When increasing or decreasing the value, you are increasing or decreasing from the factory default value. (For example, entering “200%” will double the value; “50%” will decrease the value by one half.)

Use the buttons next to the “

⇑” and “⇓” symbols to

adjust the selected governor and regulator parameters. Press the button next to the “>>” in the display to move to the next adjustment.

GOV RAMP:

This adjustment sets the time for the engine to ramp to full operating speed. This adjustment applies only to set start up and does not affect the transient response. (Adjustable range: 0 through 10 seconds.)

REG GAIN:

If the gain adjustment is set too high, output voltage will be unstable. If gain is set too low, the output voltage will respond sluggishly to changes in load—overshoot may result.

Default values are preset by the factory. Due to site variables, the default values may need to be adjusted to attain peak performance.

The facing page shows a block representation of the GOV/REG submenus, which is the third of four SETUP/CAL menus. If you press the button next to the “>>” in the Main menu display, the VERSION/ SETUP/CAL submenu will appear.

CAUTION

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

GOV/REG submenu:

The GOV/REG submenus are intended for qualified service personnel only. For this reason, a three-digit access code must be entered before you can proceed to those menus.

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter the access code (574) as previously described in this section.

From the DISPLAYS/METERS submenu, press the button next to the “>>” in the display to move to the GOV/REG/SETUP submenu. Select GOV/REG to proceed to the GOV/REG submenus.

REG INTEGRAL:

If this adjustment is set too low, the output voltage will respond sluggishly to changes in load, resulting in a droop-type response If it is set too high, output voltage will be unstable.

REG VHZ:

This underfrequency roll-off adjustment controls how much excitation is reduced in response to underfrequency. If the value is set too low, excitation will be cut too fast, and the voltage will drop too much. If set too high, the generator set may not be able to pick up rated load in one step. (Adjustable range: 1 through 50; normal range 7 through 21.)

SAVE/EXIT submenu:

From the REG VHZ 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 DISPLAYS/METERS submenu.

If you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the genset 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 genset is restarted.

5-14

GOVERNOR/REGULATOR MENU

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by any means, is strictly prohibited.

⇑ ENTER CODE

<>VERSION <<

SETUP/CAL >>

<>

DISPLAYS << METERS >>

<>

<

⇓ __ __ __ >>

<>

GOV / REG <<

SETUP

<>

GOV / REG <<

SETUP

⇑ GOV RAMP

<

⇓ _______ >>

<>

⇑ REG GAIN

<

⇓ _______% >>

<>

⇑ REG INTEGRAL

<

⇓ _______% >>

<>

⇑ REG VHZ

<

⇓ _______ >>

<>

<

SAVE EXIT >>

<>

>

<>

DISPLAYS << METERS >>

<>

CHANGES SAVED EXIT >>

<>

DISPLAYS << METERS >>

<>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

<

CHANGES SAVED EXIT >>

<>

DISPLAYS << METERS >>

<>

⇑ GOV GAIN

<

⇓ _______% >>

<>

⇑ GOV GAIN

<><>

⇓ _______% >>

Indicates OR" Condition

5-15

Setup Menu

Redistribution or publication of this document, 

by any means, is strictly prohibited.

The SETUP submenus permit selection of several configuration and operation options. Setup option defaults are listed in Table 5-2.

TABLE 5-2. SETUP DEFAULTS

SELECTION DEFAULT

CYCLE CRANK ON SYSTEM OF UNITS IMPERIAL

*

CUSTOMER FAULT 1 GRND FAULT

*

EGT L NO EGT R NO LOW COOLANT SHTD LANGUAGE ENGLISH

* Default display messages for customer faults 1 and

2. To change the customer fault message(s), to display the desired fault condition, refer to heading

Customer Fault Messages

The facing page shows a block representation of the SETUP submenus, which is the fourth of four SETUP/CAL menus. If you press the button next to the “>>” in the Main menu display, the VERSION/ SETUP/CAL submenu will appear.

CAUTION

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

SETUP submenu:

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

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter the access code (574) as previously described in this section.

WARN WARN

Edit

.

From the DISPLAYS/METERS submenu, press the button next to the “>>” in the display to move to the GOV/REG/SETUP submenu. Select SETUP to proceed to the SETUP submenus.

Use the buttons next to the “

⇑⇓” symbols to toggle

the setup options. Press the button next to the “>>” in the display to move to the next adjustment.

If the cycle cranking option is selected, the menu will prompt for the selection of cycle number (3, 4, or 5) and crank and rest times (7 to 20 seconds).

An in-line engine that has the EGT (exhaust gas temp.) option, select “YES” for EGT L and ’NO” for EGT R.

Edit Customer Fault Message(s):

The two cus-

tomer fault messages shown in Table 5-2 are editable. To enter the desired customer fault message, press the button next to the “>>” in the display to display the customer fault message to be changed.

Press the upper-left button by the display to select the desired character. Press the upper-right button to move the cursor to the next character to be changed. (Holding this button down will return the cursor to the first position.) The message can be up to 16 characters. The fault code number will remain the same, this code cannot be edited.

If these messages are changed, you should note these changes in the Operator’s manual for this generator set.

SAVE/EXIT submenu:

Troubleshooting

section of the

From the LANGUAGE 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 SA VED submenu, select EXIT to return to the DISPLAYS/METERS submenu.

If you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the genset 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 genset is restarted.

5-16

SETUP MENU

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by any means, is strictly prohibited.

<>VERSION <<

SETUP/CAL >>

<>

⇑ ENTER CODE

<

⇓ __ __ __ >>

<>

DISPLAYS << METERS >>

<>

GOV / REG <<

<>

CYCLE CRANK

<>

⇑⇓ ON / OFF >>

SYSTEM OF UNITS

⇑⇓ MET/ IMP >>

<>

SETUP

IF CYCLE CRANK ON :

⇑ # OF CYCLE S

<

⇓ (3, 4, or 5) >>

<>

RESET MENU >

<

⇑ CRANK TIME − SEC

CYCLE CRANK

<>

⇑⇓ ON / OFF >>

⇓ (7 to 20) >>

RESET MENU >

⇑ REST TIME − SEC

<

⇓ (7 to 20) >>

<><>

RESET MENU >RESET MENU >

<>

CUSTOMER FAULT1

<>

⇑⇓ SHTD / WARN >>

<>

GRND FAULT

<>

⇑⇓ SHTD / WARN >>

<

SAVE EXIT >>

<>

CHANGES SAVED EXIT >>

<>

CHANGES SAVED EXIT >>

EGT L

⇑⇓ YES / NO >>

<>

EGT R

⇑⇓ YES / NO >>

<>

LOW COOLANT

⇑⇓ SHTD / WARN >>

<>

⇑ LANGUAGE

< <>

⇓ _______________>>

<>

DISPLAYS << METERS >>

<>

CYCLE CRANK

⇑⇓ ON / OFF >>

<><>

<

SAVE EXIT >>

<>

<

SAVE EXIT >>

<>

DISPLAYS << METERS >>

<>

CYCLE CRANK

<>

⇑⇓ ON / OFF >>

Indicates OR" Condition

5-17

CALIBRATION PROCEDURE

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by any means, is strictly prohibited.

WARNING

nents can cause electrocution, resulting in severe personal injury or death. Calibration and adjustment must be performed by technically qualified personnel only. Read and observe all WARNINGS and CAUTIONS in your generator set manuals.

CAUTION

of the PowerCommand control can cause equipment malfunction or damage. Calibration and adjustment must be performed by technically qualified personnel only.

The calibration procedure is divided into 7 subsections, with the subsections arranged in a specified order. I f two or more of the following subsections are required to calibrate the PCC, they must be completed in the order shown.

When removing and replacing a defective circuit board, you may have to perform one or more of the following subsections. Table 5-1 (Control Panel Recalibration) provides a list of the circuit boards that require calibration when replaced and the calibration procedure(s) that must be performed.

Use a calibrated RMS multimeter for accurate measurements. Fluke models 87 or 8060A are good choices.

Contacting high voltage compo-

Improper calibration or adjustment

Initial Start Setup

1. Refer to Page 5-4, which describes how and when you should perform this procedure.

To verify if the PCC is set to operate with a specific generator set, refer to the

VERSION

menu (Page 5-9). This menu will show the generator set model number, frequency , and kW rating. If any of these values are incorrect, you must perform the Initial Start Setup procedure.

Voltage and Frequency Adjustment

2. With the genset OFF, attach a calibrated frequency/voltmeter to the AC output from L1 to L2.

3. Select to display the

ADJUST

from the Main Menu (page 5-7)

VOLTAGE

adjust menu.

4. Start the genset and allow the genset to reach normal operating speed.

5. Adjust

VOLTAGE

(genset output voltage) so that the calibrated voltmeter reads the desired voltage. (Use a calibrated voltmeter because the value displayed on the PCC digital display may not be calibrated at this time; therefore, its accuracy is unknown.)

6 Select the Frequency adjust menu.

7. Verify that the frequency displayed on the calibrated meter is the desired frequency. If not, adjust to the desired frequency. (Note: If the frequency reading on the digital display is not the same as frequency shown on calibrated meter, there is an equipment malfunction.)

8. If no frequency or voltage adjustment was made, select EXIT. If an adjustment was made, SAVE, then EXIT.

Digital Voltage Display Calibration

9. Select “>>” from the Main Menu (Page 5-9). From this menu proceed to the menu (Page 5-11).

10. With the genset OFF, attach a calibrated frequency/voltmeter to the AC output from L1 to L2.

11. Start the genset and allow it to reach normal operating speed.

12. Calibrate voltage reading for that the reading on the digital display agrees with the calibrated voltmeter.

13. Shut the genset OFF.

14. Repeat steps 10 through 13 for L23 and L31. (In step 10 attach meter to the AC output from L2 to L3 to calibrate calibrate

VOLTS L31

VOLTS L23

.)

15. If no calibration was made, select EXIT. If a calibration was made, SAVE, then EXIT.

VOLTS L12

and L3 to L1 to

so

5-18

Digital Ammeter Display Calibration

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by any means, is strictly prohibited.

16. Select “>>” from the Main Menu (Page 5-9). From this menu proceed t o the (Page 5-11).

17. With the genset OFF, attach a calibrated ammeter to L1.

18. Start the genset and allow it to reach normal operating speed.

19. Load the genset to maximum rated kVA at rated voltage.

20. Calibrate the reading for reading on the digital display agrees with calibrated ammeter.

21. Repeat steps 17 through 20 for step 17, attach meter to L2 to calibrate

and L3 to calibrate

L2

22. If no calibration was made, select EXIT. If a calibration was made, SAVE, then EXIT.

AMPS L3

AMPS L1

L2

.)

menu

so that the

and L3. (In

AMPS

Digital Power Factor Display Calibration

Power factor calibration is not required except in applications requiring a higher accuracy than ±5%. If the ±5% accuracy is not acceptable, further calibra- tion will require reactive load sufficient to reach 0.8 PF at rated load, and calibrated instruments with ±1% accuracy or better. Typical load rack instruments are not accurate enough to perform this procedure.

23. Select “>>” from the Main Menu (Page 5-9). From this menu proceed to the (Page 5-11).

24. With the genset OFF, attach the power factor meter to L1.

25. Start the genset and allow it to reach normal operating speed.

26. Load the genset to maximum rated kVA at rated voltage.

27. Calibrate the reading for PF1 so that the reading on the digital display agrees with power factor meter.

PF1

menu

28. Repeat steps 24 through 27 for L2 and L3. (In step 24, attach meter to L2 to calibrate

PF3

L3 to calibrate

29. If no calibration was made, select EXIT. If a calibration was made, SAVE, then EXIT.

.)

PF2

and

Digital Coolant Temperature Display Calibration

An engine sensor calibration tool is required to perform this procedure.

30. With the genset OFF, replace the coolant temperature sender with the precision resistor provided in the calibration tool.

31. Select “>>” from the Main Menu (Page 5-9). From this menu proceed to the

TEMP L

32. Calibrate the temperature reading to match the temperature indicated on the calibration tool.

33. Repeat step 32 for engine uses two sensors.

34. If no calibration was made, select EXIT. If a calibration was made, SAVE, then EXIT.

menu (5-11).

COOLANT TEMP R

COOLANT

if the

Analog meter calibration

35. Select “>>” from the Main Menu (Page 5-9). From this menu proceed to the

CAL TO

36. Start the genset and allow the genset to reach normal operating speed.

37. Calibrate the analog Voltmeter to the digitally displayed value.

38. Calibrate the analog % Amps meter to the digitally displayed value.

39. Calibrate the analog % Load meter to the digitally displayed value.

40. Calibrate the analog Frequency meter to the digitally displayed value.

41. SAVE, then EXIT.

menu (Page 5-13).

A−C VOLTS

5-19

ACCESSORY BOX CONTROL

Redistribution or publication of this document, 

by any means, is strictly prohibited.

COMPONENTS

The generator set accessory box (Figure 5-3) which is located on the backside of the control housing,

OPTIONAL RUN

RELAYS K11, K12

& K13

CUSTOMER

TERMINAL

BLOCK (TB1)

contains components that provide connection points for remote control and monitor options. The genset can be equipped with one or more of the following components (customer terminal block TB1 is standard).

OPTIONAL

COMMON

ALARM RELAY

K14

FIGURE 5-3. ACCESSORY BOX COMPONENTS

5-20

TB1 Customer Inputs

Redistribution or publication of this document, 

by any means, is strictly prohibited.

Refer to Page 8-7 for typical connections to TB1.

Remote Start:

the Auto position, grounding this input initiates the engine cranking and start sequence. This circuit must be opened to permit resetting a shutdown condition with the Reset input.

Low Fuel:

Fuel warning. This input can be connected to a local day tank or to a main fuel tank that is located on site. When the switch grounds this designated input, the input will “wake up” the control, if it is not operating, and then initiate the fault.

When the Run/Off/Auto switch is in

Grounding this input actuates the Low

Engine idle operation is applicable only in the RUN mode. The PCC operating program does not permit engine idle operation when the genset is operating in AUTO mode.

When the engine idle function is enabled, the control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the genset reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings.

Remote Emergency Stop:

Grounding this input causes an immediate shutdown. Emergency stop must be reset at the front panel.

Customer Fault Inputs 1 and 2:

Grounding any one of these inputs activates the corresponding warning or shutdown sequence. Warning or shutdown status is selected in the setup menu. Refer to the menu descriptions in this section.

External sensing equipment must be connected to the designated digital input.

The two customer fault messages can be separately edited in the setup menu to display any desired message. This allows each customer “default” fault message to be customized to represent the type of device that is attached the the fault input.

The “default” message that is displayed, when ground is applied to the input, is as follows:

Fault 1 = CUSTOMER FAULT1 Fault 2 = GRND FAULT

Fault Reset:

When the Run/Off/Auto switch is in the Auto position and the remote start switch is open, grounding this input resets any warning and latched shutdown fault (except Emergency Stop, which must be reset at the front panel.)

Engine Idle:

When the genset is operating in the RUN mode, grounding this input causes generator build up to be inhibited and the engine to be governed at 800 RPM. When ground is removed from this input, the genset returns to normal speed and voltage.

TB1 Customer Outputs

Refer to Page 8-9 for typical connections to TB1.

Breaker Control:

contacts, rated for 5 amps at 30 VDC. A shutdown fault will cause the relay to energize and operate a shunt trip circuit on a circuit breaker. The relay will stay energized until reset.

Common Alarm:

for 2 amps at 30 VDC. Any warning or shutdown causes the common alarm relay to be energized. This output is often used to energize an audible alarm.

Load Dump:

tacts, rated for 2 amps at 30 VDC. If an overload or underfrequency condition exists for 5 seconds, the NO load dump contacts are closed. This relay is energized before shutdown (for overload or underfrequency) occurs.

Ready To Load:

contacts, rated for 2 amps at 30 VDC. This output i s activated whenever AC voltage and frequency exceed 90% of nominal.

Switched B+:

switched output. This output is activated by the run pilot signal, at the governor output module. (Fuse FB7 is located in accessory box.)

B+:

This is a fused 20 amp, 24 volt output. (Fuse

FB1 is located in accessory box.)

One set of normally open (NO)

One set of form-C contacts, rated

One set of normally open (NO) con-

One set of normally open (NO)

This is a fused 10 amp, 24 volt

5-21

Run Relays (K11, K12, 13)

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by any means, is strictly prohibited.

The optional run relays are rail mounted inside the accessory box (Figure 5-3). The rail mount allows you to easily remove and replace the snap-on relays. The generator set can be equipped with one, two or three run relays.

The three-pole, double-throw run relays (Figure 5-4) are used to control auxiliary equipment such as

K11, K12, K13

fans, pumps and motorized air dampers. The run relays are energized when the generator set control receives a start signal.

The contacts are rated:

• 10 amps at 28 VDC or 120 VAC, 80%PF

• 6 amps at 240 VAC, 80%PF

• 3 amps at 480/600 VAC, 80%PF

A40-TB1-8

(SWITCHED B+)

K11, K12, K13

K11

RUN RELAY

NO NC

COIL

COM

A40-TB1-12

(B-)

CUSTOMER

CONNECTIONS

K12

RUN RELAY

NO NC

K13

RUN RELAY

NO

NC

FIGURE 5-4. OPTIONAL RUN RELAYS (K11, K12, K13)

5-22

Cummins Power Generation PowerCommand 3100 Series, PowerCommand 3100 DQAF, PowerCommand 3100 DQAD, PowerCommand 3100 DQAE Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

IMPORTANT SAFETY INSTRUCTIONS

1. Introduction

2. Control Operation

3. Circuit Boards and Modules

4. Troubleshooting

5. Control Service and Calibration