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Generator Service Manual

1. 5 More Options ADJUST 7 E O 5 37 GENSET CURR PROTECTION ENG PROTECTION CT Ratio RRRA H Curr Warning Overspeed 50Hz MPU Enable Yes Threshold 96 Threshold Fly Teetch HHH H Curr Warning Overspeed 60 2 RPM Hz Rato Time Delay Threshold ADJUSTI ADJUST INNEN CLL 5 31 SEE PAGE 5 39 SEE PAGE 5 41 FIGURE 5 13 GENSET SETUP MENUS 5 29 SUBMENUS The Genset submenus are available by pressing the 1 button on the first Genset Setup menu see Figure 5 13 Appendix A provides a block diagram that illustrates the sequence of how the Genset Setup Submenus are displayed Figure 5 14 3 sheets is a block representation of the Genset Submenus Genset Menu The Genset menu is used to set the CT Ratio enable the Magnetic Pickup Unit MPU set the number of teeth pulses per revolution on the Flywheel and set the Speed Frequency Ratio Ratio The CT Ratio value must set to match the CT Ratio of the current transformers on the genset e MPU Enable Displays whether or not the Magnetic Pickup Unit is installed Yes or No e Fly Teeth The total number of teeth pulses per revolution on flywheel used for electronic governed systems can be set from Oto 256 HPM Hz Ratio Allows for setting the Speed Frequency Ratio to
2. 114 10 OPTIONAL RUN RELAY CONNECTION TERMINAL FIGURE 4 1 PCC 1301 COMPONENTS Relay K5 This relay is used by the Base board to control witched battery voltage The relay is energized when the receives a run command Customer Switched is a fused 15 amp circuit F1 SW B quick connect terminal for customer use is located by the engine block ground terminal Wire color is Red Orange stripe Do not use T26 for customer connections not fused K5 is part of the engine harness jumper assembly Relay K4 The Starter Control relay is used by the Base board 4 4 to energize the starter solenoid K4 is part of the engine harness assembly Relay K12 The Fuel Control relay is used by the Base board to control battery to the fuel solenoid s K12 is part of the engine harness assembly Run Relays K10 K11 The optional Run relays are used to control auxiliary equipment such as fans pumps and motorized air dampers The relays are energized when the control receives a run command Hazards present 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 this manual TABLE 4 1 ENGINE DOES NOT CRANK IN MANUAL MODE NO FAULT MESSAGE R
3. RETURN 5 11 FIGURE 5 7 ELECTRONIC GOVERNOR SUBMENUS 5 15 CUSTOMER SUB MENUS The Customer I O submenus are available by pressing the 2 button on the first Genset Service menu see Figure 5 3 Four Customer submenus see Figure 5 8 can be used to define customer input messages and output maps Customer Inputs The Customer Input Text message menus are used to enter an event type and description for two events Enter the event type Warning Shut down or Event e Enter a brief description of the event up to 32 characters Example inputs Low Coolant Level Low Fuel Pressure Ground Fault etc Customer Outputs Two Customer Outputs are configurable to display common warning alarms The two Customer Out put Map menus allow for entering a fault number and fault name to be displayed for the two configurable customer outputs 5 16 Number Enter a code number 0 to 255 for the event Refer to Table 5 3 which provides a list of all warning and shutdown codes The following list contains event codes that not shown Table 5 3 brief description of the event 15 automatically displayed EVENT CODES CODE DESCRIPTION READY TO LOAD UTILITY CONNECTIONS GENSET CONNECTED NOT IN AUTO COMMON ALARM COMMON WARNING COMMON SHUTDOWN CUSTOMER FAULT INPUT 1 CUSTOMER FAULT INPUT 2 ANNUNCIATOR FAULT 1 ANNUNCIATOR FAULT 2 ANNUNCIATOR FAULT 3 CUSTOMER INPU
4. are installed in the Main Terminal Box Refer to the Reconnection Diagram to identify the generator output leads phase that must be routed through each CT and also appropriate transformer post selection for control sensing leads The transformers are labeled CT1 CT2 and CT3 on the reconnection wiring diagram The Reconnection Diagram is located on the control box cover RELAY INSTALLTION CT Installation Requirements The CT s have dual A The CT has a dot on one side This dot must be facing toward the generator reconnection terminal block A dot is also used to indicate pin 1of the CT Route the load lead U V or W through the appropriate CT refer to Reconnection Diagram secondaries 3 pinsmarkedX1 X2 amp X3 Refer to Reconnection Diagram X1 amp X2 for above 300 volts L L X1 amp X3 for below 300 volts L L The PCC 1301 pedestal panel comes fitted with 1 Nos relay module Board 12V 70 Amps Each Relay module consists of two and Half Channel relays Thus PCC 301 uses four Relays whose function is given below Relay 1 RL1 Used for Starter 8 Pull Coil e Relay 2 RL2 Used for fuel solenoid hold Relay 3 Used for Starter Disconnect NOTE The Entire Relay Board has to be replaced if any one of the Relay malfunctions INSIDE VIEW PEDESTAL PANEL RELAY CARD 5 49 e PCC 1301 BASE BOARD e CUSTOMER END CONNECTION TAKEN FROM THIS TERMINAL ST
5. 0 120 220 240 VOLTS 05013 U6 T4 lt lt PHASE 3 WIRE OUTPUT TERMINALS W V CENTER TAP N N N US T3 SENSE W SENSE U SENSE V 8 4 Single Phase Mech Governor WIRING DIAGRAM Ve nml KRTEL MEM Drg 0620 0300 rev1 Sheet 1 2 Ref Pee SSE SIMME RSS Is a NOE pei is S OST F Li VEL FIEL LEVEL ITF TNE TR RFHIF F zzd4H SEMSLE LM WIRING DIAGRAM Ref Drg 0620 0300 rev1 Sheet 2 2 Single Phase Mech Governor ELECTRONIC BATTERY CHARGER OPTIONAL CUSTOMER END CONNECTIONS 230V 110V AC INPUT VOLTAGE FOR ELECTRONIC BATTERY CHARGER TERMINAL amp 14 ON TH2 BATTERY CHARGER OUTPUT 6A 4 COOLANT HEATER OPTIONAL CUSTOMER END CONNECTIONS 230V 110V AC INPUT VOLTAGE FOR WATER HEATER 8 6 WIRING DIAGRAM Three Phase Mech Governor Ref Drg 0620 0302 rev1 Sheet 1 2 4 ppuuap n VOLTAGE SENSING CURRENT SENING CONTROLLER T 155 1 8 8 7 WIRING HARNESS Part Nos Mechanical Governor with PCC 1301 0338 5018 Electronic Governor with PCC 1301 0338 5116 8 8 CUSTOMER CONN
6. Metering Voltage Adjust menu 4 Calibrate voltage reading for L7 so that the reading on the display agrees with the calibrated voltmeter 5 After adjusting press the SAVE button to save the setting 6 Shut the generator set OFF 7 Repeat steps 1 through 6 for 12 and 13 In step1 attach meter to the AC output from L2 to L3to calibrate L2 and L3 to L1 to calibrate L3 Metering Current Adjust Menu The Metering Current Adjust menu allows for adjusting metered amps 1 With the genset OFF attach a calibrated ammeter to L1 2 Start the genset and allow it to reach normal operating speed 3 Display the Metering Current Adjust menu 4 Load the genset to maximum rated kVA at rated voltage 5 Calibrate the reading for L7 current so that the reading on the display agrees with calibrated ammeter 6 After adjusting press the SAVE button to save the setting Shut the generator set OFF 8 Repeat steps 1 through 7 for L2 and L3 In step1 attach meter to L2 to calibrate L2current and L3 to calibrate 3 current N METER CALIB Reg Volt Adj 96 Voltage METER FREQ ADJUST Reg Volt Adj 9 Freq Adj 4 496 Voltage V Frequency 2 ADJUST FREQ ADJUST METERING VOLTAGE ADJUST Freq Adj Li N Frequency Hz SAVE ADJUST METERING METERING VOLTAGE ADJUST CURRENT ADJUST L1 AMPS L2 fitit AMP
7. NOTE Press the button on any of the Operator menus or the Establishing Re establishing communication with control menus If the mode change access code feature is enabled the Mode Change Access Code menu is displayed Enter the mode change access code as described above A menu with alternating arrows is displayed above a second ELTA Symbol Press the second 8979 button The Operator menu that was displayed before Auto mode was selected is re displayed and the Auto indicator is lit To disable auto mode press the button Manual Run mode can also be selected while in Auto mode VDC Battery Eng Temp Oll Press Eng Hours h THIS MENU IS DISPLAYED ONLY IF THE MODE CHANGE ACCESS CODE FEATURE IS ENABLED Mode Change Access Code ALTERNATING ARROWS ARE 4 DISPLAYED Battery 0 Eng Temp F Oil Press PSI Hours h AUTO MODE SELECTED FIGURE 2 10 SELECTING AUTO MODE Selecting Manual Run Mode To switch to Manual Run mode see Figure 2 11 Battery VDC 1 Press the 7 button on any of the Operator Eng Temp menus or if displayed the Establishing Re Oil Press PSI establishing communication with control Eng Hours menus 2 the mode change access code feature is enabled the Mode Change Access Code menu is displayed Enter the mode change access code as described on the previous page
8. 3 A menu with alternating arrows is displayed Mode Change IF above a second symbol Press the Access Code THE MODE CHANGE second button to start the genset ACCESS CODE FEATURE 15 ENABLED The Operator menu that was displayed before Manual Run mode was selected is redisplayed and the Manual Run indicator is lit To disable Manual Run mode press the 9 button ALTERNATING NOTE Auto mode can also be selected while in ARROWS ARE Manual Run mode Switching to Auto mode DISPLAYED may result in the generator set shutting down Aborting the Transition to Auto or Manual Run Mode If the Mode Change Access Code menu or the menu showing alternating arrows above the or buttons is displayed the transition to Auto or MANUAL Manual Run mode is aborted when Oil Press E HUDS RUN MODE SELECTED Either the lt C 0 or button is pressed Eng Hours or button is not pressed within ten seconds If the transition to Auto or Manual Run mode is aborted the Operator menu that was displayed be FIGURE 2 11 SELECTING MANUAL RUN MODE fore Auto or Manual Run mode was selected is re displayed 2 9 OPERATOR MENUS Figures 2 12 and 2 13 show block representations of the following Operator menus Engine Status Alternator Status Line to Line Voltage Line to Neutral Voltage Alternator Amperage To navigate between the Operator menus press the buttons next t
9. Check for the following conditions Coolant heater not connected to power supply Check for blown fuse or disconnected heater cord and correct as required Check for low coolant level and replenish if required Look for possible coolant leakage points and repair as required Open heater element Check current draw of heater Coolant temperature must be below 7OF default setting for one minute to activate warning and be above 7 for five minutes before the warning can be cleared The nature of the fault is an optional configurable selection Example inputs Low Fuel Day Tank Water In Fuel Ground Fault etc Each of the fault functions can be programmed using service tool as follows e Warning or Shutdown Default Warning See fault code 75 76 for Shutdown e Change display name using up to 32 characters Indicates that the control has sensed that the engine coolant temperature sensor output is out of range high or low Check sender connectors wires This fault will only occur if water temperature sensor is equipped on the genset Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation will occur Discharged or defective battery Check the battery charger fuse Recharge or replace the battery Poor battery cable connections Clean the battery cable terminals and tighten all connections Check battery wiring calibration Check engine DC alternator Replace engine DC alternato
10. Generator Service Manual Power _ Generation Our energy working for you Generator Set With Power Command 1 1 Controller C33D5 C38D5 C30D6 C35D6 English 12 2007 961 0518 Issue1 Table of Contents SECTION TITLE IMPORTANT SAFETY INSTRUCTIONS INTRODUCTION About this Manual Generator Set System Overview Test Equipment How to Obtain Service CONTROL OPERATION General Control Panel Power On Off Modes Control Panel System Messages Selecting Auto Manual Run and OFF Modes Operator Menus Service Menus History About Menu Screen Adjust Menu Fault History Menu CIRCUIT BOARD General Base Board TROUBLESHOOTING General InPower Service Tool Network Applications and Customer Inputs Safety Consideration Reading Fault Codes PAGE 1 1 1 1 1 1 1 1 2 5 2 7 2 10 2 14 2 16 2 18 2 20 3 3 4 1 4 1 4 2 4 2 Troubleshooting Procedure CONTROL ADJUSTMENT AND SERVICE General Circuit Board Removal Replacement Setup Menu Genset Setup Menus Genset Service Submenus Automatic Voltage Regulator Submenus Electronic Governor Submenus Customer I O Submenus Metering Submenus Annunciator Submenus Genset Setup Submenus Genset Submenus Voltage Protection Submenus Current Protection Submenus Engine Protection Submenus TB1 Base Board Customer Connections Engine Sensors Magnetic Speed Pickup Unit MPU Installation Current Transformer CT Installation
11. e Fault History see page 2 20 e Status see below e Lamp Test The six LEDs on the control panel should light as long as the 6 button 15 pressed The third Service Menu can be viewed by pressing the selection button on the second Service Menu The third Service Menu provides access to the Network Status menus Status Menu The Status menu is displayed when the 5 button is pressed on the second Service Menu The Status menu shows the following e Voltage regulator drive percentage of duty cycle level In e Governor regulator drive level in percent age of duty cycle This value 15 only displayed if the governor is enabled Network Status Menus The Network Status menus are displayed when the 7 button is pressed on the third Service Menu Two menus are used to display the quantity of the following devices that are connected to the network Auto Mains Failure AMF modules Universal Annunciators Bar graphs Battery chargers Controls I O modules Operator panels any type 2 14 1 api te MENU etup Menus 1ST 2 History About SERVICE 3 Screen Adjust More Options HISTORY ADJUST SETUP wxx Contrast Password Brightness Units PSI ADJUST SETUP MENUS HISTORY ABOUT MENUS SCREEN ADJUST MENU SECTION 5 SEE PAGE 2 16 SEE PAGE 2 18 SERVICE MENU S
12. 2 16 HISTORY starts Hours H Control Hours ABOUT GENSET Model Number AAA MPP Control 1301 ABOUT GENSET KVA Standby Rating ABOUT CONTROL P N SW P N ABHHHHI SW Version 4 ABOUT DISPLAY SW P N HHHHEHHE SW Sern Var 8 FIGURE 2 15 HISTORY ABOUT MENUS 2 17 SCREEN ADJUST MENU Figure 2 16 shows a block representation of the Screen Adjust menu The Screen Adjust sub menu is displayed when the 3 button is pressed in the first Service Menu Adjusting Values Parameters 1 Press the ADJUST selection button to select the first parameter or value to be changed 2 Press the or selection buttons to adjust values or select parameters 3 Press the arrow selection button 7 to navigate to the next or previous adjustable value or parameter 4 After adjusting values selecting parameters press the SAVE button to save your settings NOTE If the Previous Menu button LU is pressed before pressing the SAVE button the changes are not saved 5 Press the LU button to return to the Service Menu Screen Adjust Menu This menu allows for adjusting the screen s contrast and brightness and for selecting the units of measurement SAE or SI to be displayed Contrast and Brightness Press or selection buttons to adjust the screen s contrast and brightness Changi
13. Off and Auto mode Internal adjustment of the control also allows the Sleep mode to be active only during the Off mode Baseboard switch 51 or disabled for both modes installation of jumper When disabled the operating soft ware will always remain active Power On mode 51 switch setting OFF Sleep mode is enabled for Auto and Off modes ON Sleep mode is enabled for Off mode only J1 J2 jumper installation Install jumper between J1 4 and J1 5 to disable sleep mode J1 and J2 are identical either one can be used for jumper 9 ADD JUMPER TO DISABLE SLEEP MODE FOR AUTO AND OFF MODE FIGURE 2 1 SLEEP MODE ACTIVATION SETTINGS 2 1 GRAPHICAL DISPLAY DISPLAY MENU SELECTION BUTTONS LED INDICATORS Om id OFF MODE BUTTON PREVIOUS MENU LEVEL BUTTON FIGURE 2 2 FRONT PANEL WITH DISPLAY CONTROL PANEL Figure 2 2 shows the features of the front panel It includes six LED indicators the graphical display and six buttons used to navigate through the menus and adjust parameters Graphical Display This graphical display is used to view menus of the menu driven operating system The bottom of the graphical display indicates the functions that are available by pressing the four selection buttons Re fer to the menu trees later in this section System messages communication event and fault are also shown on the graphical display For more information see System Messages later this s
14. before the engine shuts down because of a high AC current fault condition If the fault condition is active for the duration of this time delay the engine shuts down and the High AC Current shutdown message fault code 46 is announced CURRENT PROTECTION SUBMENUS CURR PROTECTION H Curr Warning Threshold 96 H Curr Warning Time Delay sec iim CURR PROTECTION CURR PROTECTION H Gurr Warning H Cur Threshold Threshold Warming H Shutdown eee Time Delay a gt CURR PROTECTION H Curr Shutdown Threshold 19 H Curr Shutdown Time Lalay 8 SAVE FIGURE 5 16 CURRENT PROTECTION SUBMENUS 5 39 ENGINE PROTECTION SUBMENUS The Engine Protection submenus are available by pressing the 4 button on the second Genset Setup menu see Figure 5 13 The Engine Protection submenus see Figure 5 17 are used to set thresholds to determine when engine fault conditions exist and time delays to determine how long a fault condition is present before the fault message is announced and if necessary shutdown the engine Engine Protection Overspeed Menu This menu is used to set the value necessary to shutdown the genset and activate an Overspeed shut down message fault code 31 on 50and 60 Hz gensets indicating that the engine has exceeded normal operating speed Overspeed 50Hz Threshold This threshold is used to
15. seconds NOTE When a fault is displayed it can be cleared from the front panel by pressing the A or button When a lt symbol is displayed the selection button can be used to abort the Auto or Manual Run mode and return to the Operator menu that was displayed before the Auto or Manual Run mode was selected When ADJUST is displayed the selection button is used to display an adjustable menu When the ADJUST button is pressed the first adjustable parameter value in the sub menu 15 highlighted When the gt symbol is displayed the selection button is used to navigate to an editable field within a menu When the and symbols are displayed the selection buttons are used to increase or de crease a parameter or value shown on the screen When changing values pressing the button be low the symbol increase the value and pressing the button below the symbol decreases the value When SAVE is displayed the selection button is used to save changes made in a sub menu If the Previous Menu button is pressed before pressing SAVE the changes are not saved Some menus include list of numbered subjects These menus include numbers in parenthesis for example 1 displayed above the selection buttons The selection buttons are then used to display submenus of the subjects included in the list When a black box 55 displayed the selection button has no function Previous Main Menu Button Press
16. 11 12 L1 N THREE PHASE 2 L3 N 11 CURRENT L2 HHHH A SENSE ONLY 13 FIGURE 2 12 OPERATOR MENUS TEXT VERSION 2 11 hrs Hz RPM THREE PHASE ONLY SINGLE PHASE OW 11 12 V THREE PHASE WYE ONLY L1 L2 A L3 CURRENT SENSE ONLY FIGURE 2 13 OPERATOR MENUS SYMBOLIC VERSION 2 12 SERVICE MENUS Figure 2 14 shows a block representation of the menus available from the Service Menus Appendix provides a block diagram that illustrates the sequence of how the Service Menus are dis played The first Service Menu can be viewed from any of the Operator menus by simultaneously pressing the A and and selection buttons for two seconds The first Service Menu provides access to the following menus e Setup Menus Used by Service personnel Adjusting the Setup menus is restricted by a password and is described in Section 5 To view the Setup menus only press the VIEW button on the Setup password menu e History About see page 2 16 e Screen Adjust see page 2 18 To return to the Operator menu that was displayed prior to viewing the Service Menu press the button The second Service Menu can be viewed by pressing the V selection button on the first Service Menu The second Service Menu provides access to the following menus
17. Confirm that the installed calibration part number matches the serial plate information A CAUTION Using the wrong calibration file can result in equipment damage Do not swap Baseboards from another genset model and only use the calibration file shown on the nameplate Some features are not available until the hardware for that feature is installed and InPower Pro is used to update enable that feature Confirm that the feature is installed and enabled prior to trouble shooting the base board for symptoms related to a feature NETWORK APPLICATIONS ANDCUSTOMER INPUTS In applications with networks and remote customer inputs the genset may start unexpectedly or fail to crank as a result of these inputs These symptoms may appear to be caused by the base board Verify that the remote input is not causing the symptom or isolate the control from these inputs before trouble shooting the control SAFETY CONSIDERATIONS A WARNING Contacting high voltage components can cause electrocution resulting in severe personal injury or death Keep the output box covers place during troubleshooting High voltages are present when the genset is running Do not open the generator output box while the genset is running WARNING Ignition of explosive battery gases can cause severe personal injury or death Arcing at battery terminals light switch or other equipment flame pilot lights and sparks can ignite battery gas D
18. EXCITER STATOR BOARD FIGURE 6 2 TESTING AND FLASHING THE EXCITER STATOR 6 3 Exciter Rectifier Bridge Rotating Rectifier Assembly The exciter rectifier bridge is mounted on the exciter rotor inboard facing the main rotor It consists of a positive plate and a negative plate split diametrically Each carries three diodes three terminal posts for connecting exciter rotor leads to the diode pig tails and a terminal for the main rotor generator field lead surge suppresser is connected across the two plates to prevent transient voltages that could damage the diodes Testing Diodes Disconnect the diode pigtails from the terminal posts Using an ohmmeter measure electrical resistance between each diode pigtail and the plate on which the diode is mounted Reverse the meter test probes and repeat the tests The electrical resistance across each diode should be high in one direction and low in the other If the resistance is high or low in both directions replace the diode DIODE ONE OF SIX DISCONNECT THE DIODE PIGTAIL FROM THE TERMINAL AND MEASURE ELECTRICAL RESISTANCE BETWEEN THE PIGTAIL AND THE METAL PLATE UNDER THE DIODE DIODE PLATES TWO Replacing Diodes Make sure the replacement diode is of the correct polarity Disconnect the pig tail from the terminal post and unscrew the old diode Apply heat sink compound under the head of the diode Make sure the compound does not get on the threads
19. SERVICING THE GENERATOR General Generator Base Board Isolation Procedure Generator Disassembly Generator Reassembly Generator Specifications Specifications WIRING DIAGRAMS General 5 12 5 14 5 16 5 18 5 20 5 27 5 30 5 36 5 38 5 40 5 46 5 47 5 48 5 49 6 2 6 10 6 12 7 1 8 1 IMPORTANT SAFETY INSTRUCTIONS 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 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 DONOT fill fuel tanks while engine is r
20. VOLTAGE PROTECTION SUBMENUS 5 37 CURRENT PROTECTION SUBMENUS The Current Protection submenus are available by pressing the 3 button on the first Genset Setup menu see Figure 5 13 Figure 5 16 is a block representation of the two Current Protection submenus High AC Current Warning Menu This menu is used to determine when a high AC current warning fault condition exists and for how long the fault condition should be present before the High AC Current warning message is announced Curr Warning Threshold This threshold is used to set the percentage of rated AC cur rent at which the High AC Current warning fault condition becomes active This value can be set from 110 to 130 Curr Warning Time Delay A time delay of10 to 60 seconds must expire before a warning message is announced If the fault condition is active for the duration of this time delay the High AC Current warning message fault code 216 is announced 5 38 High AC Current Shutdown Menu This menu is used to determine when a high AC current shutdown fault condition exists and for how long the fault condition should be present before the engine is shut down e Curr Shutdown Threshold This threshold is used to set the percentage of rated AC current at which the High AC Current shut down fault condition becomes active This value can be set from 130 to 190 e H Curr Shutdown Time Delay A time delay of 2 to 60 seconds must expire
21. W2 and W5 W6 with Wheatstone bridge ohmmeter having at least0 001 ohm precision Replace the stator if the resistance of any winding is not as specified in Table6 1 Alternatively winding resistance can be measured line to line at the generator terminals U V V W W U on star connected generators On a 600 volt generator line to line resistance should be twice the table value two winding elements in series On series star connected generator line to line resistance should be four times the table value four winding elements in series On a parallel star connected generator line to line resistance should be the same as the table value two sets of two winding elements in series Single phase only windings can be measured at W V and should be twice the table value Testing Winding Insulation Resistance Disconnect the AVR completely AT THE AVR before carrying out this test Disconnect any connections from Neutral to Earth The Stator insulation should be checked with an Insulation tester The test instrument should be 500 or 1000 volts for low voltage Generators up to 690V For low voltage machines up to 690V the MINIMUM insulation value is 1 0 Meg Ohm to Earth Ground WINDINGS MUST BE DRIED OUT IF BELOW 1 0 MEG OHM NOTE Faults on the stator winding or cables may also cause noticeable load increase on the engine when excitation is applied Connections shown in Series Star L EARTH
22. WALSAS L3SN39 FIGURE 3 2 BLOCK DIAGRAM 3 2 BASE BOARD The Base board Figure 3 3 contains all of the electronic circuitry required to operate the generator set The Base board provides fuel control main alternator voltage output regulation and complete generator set control and monitoring The following paragraphs describe the connectors J terminal board TB relays R and the LED status indicator Figure 3 3 shows the pin locations for all Base board connectors Refer to Block diagram in Section each connector input output signal TB1 Customer Connections Display panel link and customer monitor control SLEEP MODE SELECTION 5 485 COMMUNICATIONS lt on Pe ee ENGINE HARNESS connections are attached to terminal boardTB1 Optional equipment such as sensing devices used to monitor genset operation remote start stop switches and etc are attached to this terminal Refer to Block Diagram and Customer Connections diagram in Section 8 for TB1 connections DS1 LED Status Indicator The status indicator lamp is illuminated when the Base board is in the Power On mode processor is operating 51 Sleep Mode Selection Refer to Control Panel On Off Modes in Section 2 CUSTOMER CONNECTIONS STATUS INDICATOR VOLTAGE FIELD FIGURE 3 4 BASE BOARD CONNECTOR TERMINAL PIN LOCATIONS 3 3 4 Troubleshooting GENERAL Th
23. and glow plugs 3 The engine fuel system is worn 3 Service according to the engine service manual or malfunctioning or has lost prime fuel lift pump injection pump injectors timing 4 The engine is worn 4 Service according to the engine service manual malfunctioning mechanically 4 20 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 73 FAIL TO START SHUTDOWN ELECTRONIC GOVERNED ENGINE Reason This indicates that the engine failed to start after expiration of last crank time Effect Engine will not start POSSIBLE CAUSE CORRECTIVE ACTION 1 Restricted fuel supply due to 1a Add fuel if low Prime the fuel system Fuel level below pickup tube 16 Open any closed shutoff valve in the fuel line supplying the in tank engine Closed shutoff valve in supply Refer to engine service manual line 1d Bleed air from fuel system Refer to engine service manual Fuel injectors clogged Air in fuel system 2 The governor linkage needs 2 Repair and adjust the linkage as necessary refer to Section 7 adjustment 4 21 CODE 73 FAIL TO START SHUTDOWN CONT ELECTRONIC GOVERNED ENGINE Reason
24. fault simulation overrides 2 Low oil level Clogged lines or Check oil level lines and filters If oil system is OK but filters oil level is low replenish 3 Sensor or oil pump could be bad Disconnect the oil pressure sensor leads and connect Or the generator set may be an oil pressure sensor simulator to the harness shutting down on another fault If the control responds to the simulator reconnect the sensor disconnect signal wire at the fuel solenoid and crank the engine Check the oil pressure reading on the digital display e f the display shows an acceptable oil pressure the problem may not be in the oil or oil sensing system The genset may be shutting down on another fault out of fuel intermittent connector Restart the genset and monitor the display panel for other faults If the display does not show an acceptable oil pressure replace the sensor If the Control still doesn t display an oil pressure while cranking the oil pump may be bad Refer to the engine service manual If the control does not respond to the simulator go to next step 4 Harness or Base board could be f the control does not respond to the simulator bad Base board or the harness is bad Check for 5 VDC at the sensor lead marked 51 If there is no 5 VDC at the sensor Check for 5 VDC at P11 17 If yes harness is bad If no Base board is bad If there is 5 VDC at the sensor use the sensor simulator to
25. frequency fault condition exists and for how long the fault condition should be present before the engine is shut down Under frequency Threshold This threshold is used to set the Hertz number that the alternator line frequency can be under to activate an Under frequency fault condition This value can be set from 2 to 10 Hz e Under frequency Time Delay A time delay of 500 and 2000 half cycles must expire before the engine shuts down because of an under frequency fault condition If the fault condition is active for the duration of this time delay the engine shuts down and the Under frequency shutdown message fault code 15 is announced VOLTAGE PROTECTION SUBMENUS VOLT PROTECTION High AC Voltage Threshold V High AC Voltage Time Delay 8 VOLT PROTECTION ioe High AC Voltage Threshold Threshold High Voltage Low AC Voltage Time Delay s Tma Da au SAVE VOLT PROTECTION VOLT PROTECTION Overfrequency Low AC Voltage Threshold Hz Threshold Overfrequency Low AC Voltage Time Delay Time Delay s save T ADJUST A VOLT PROTECTION VOLT PROTECTION Overfrequen Underfrequency Threshold Hz Hz Underfrequency ih Time Delay Time Delay SAVE ADJUST A VOLT PROTECTION Underfrequen Threshold Hz Underfrequency Time Delay SAVE FIGURE 5 15
26. must have sufficient capacity and be attached properly so that the load cannot shift Before starting disconnect the negative cable from the battery to make sure the set will not start while working on it ZS WARNING ignition of explosive battery gases can cause severe personal injury or death Arc ing 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 A CAUTION Disconnect battery charger from AC source before disconnecting battery cables Otherwise disconnecting cables can result in voltage spikes damaging to DC control circuits of the set WARNING Accidental starting of generator set can cause severe personal injury or death Prevent accidental starting by disconnecting the negative cable from the battery terminal Removing The Generator Control Housing 1 Disconnect the line cables and conduit For reconnections later make sure each cable is clearly marked to indicate the correct terminal 2 Disconnect the remote control wiring and conduit For reconnections later make
27. 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 the generator set can cause severe personal injury or death Prevent accidental starting by disconnecting the negative cable from the battery terminal WRIST 254 o _ LEAD CLIP SETUP MENU The Setup Menus menu Figure 5 2 provides access to genset menus with system parameters that can be viewed and if a password is entered adjusted The Setup Password menu is displayed when the 1 button is pressed on the Service Menu Figure 3 14 Pressing the VIEW button in the Setup Password menu will display the 1 Genset Service menu see Figure 5 3 Note that when viewing the Gen set Service menus the ADJUST button will not be displayed as shown in Figure 5 3 After entering the password from the Setup Pass word menu a second Setup menu is displayed that provides access to t
28. remembered until five minutes of button inactivity has elapsed If five minutes of button inactivity has elapsed you will have to re enter the password to access and change Genset Setup menus Adjusting Values Parameters Once the correct password has been entered on the Genset Setup Password menu the first Genset Setup submenu is displayed 1 Press the buttons above theA and Wsymbols in the digital display to navigate between submenus 2 Press the ADJUST selection button to select the first parameter or value to be changed 3 Press the 4 or selection buttons to adjust values or select parameters 4 Press the arrow selection button gt to navigate to the next or previous adjustable value or parameter 5 After adjusting values selecting parameters press the SAVE button to save your settings NOTE the lt button is pressed before pressing the SAVE button the changes are not saved 6 Press the button 4 to return to genset Setup Menus menu 7 To return to the Service Menu from the genset Setup Menus menu press the button GENSET SETUP MENUS SETUP MENUS 1 Genset Service 2 Genset Setup C 2 GENSET SETUP Password EXXX VIEW AST GENSET SETUP 1 Genset GENSET 2 Volt Protect SETUP 3 Curr Protect MENU More Optlons 1 2 3 VOLT PROTECTION IND GENSET SETUP High AC Voltage Enalne Prote Threshold GENSET 4 Engine Protect as SETUP High AC Voltage
29. scale factor of 0 05 to 10 0 The Integral Gain K2 multiplier can beset from 5 to 100096 e D The Damping adjustment can set from95 to 105 5 12 NOTE hese menus are only available tf RETURN TO the Automatic Voltage Regulator PAGE 5 9 AVR is enabled see page 5 9 V Hz Setup Kree Rolloff amp amp ADJUST Galn Kree 27 Int Bio V Hz Rolloff D REGULATOR GAINS Gan Int HHH D RETURN TO PAGE 5 9 FIGURE 5 6 AUTOMATIC VOLTAGE REGULATOR SUBMENUS 5 13 ELECTRONIC GOVERNOR SUBMENU The Electronic Governor submenus are available only if the governor is enabled see page 5 9 Four Electronic Governor submenus see 5 7 can be used to adjust governor settings Governor Crank Fuel Menu The Governor Crank Fuel menu allows for setting the Initial Crank Fuel Duty Cycle the Initial Crank Fueling Period the Crank Fuel Ramp Rate and the Maximum Crank Fuel Duty Cycle e Initial DC The Initial Crank Fuel Duty Cycle is the initial value assigned to the Governor Duty Cycle parameter when cranking begins This value can be set from 0 to 50 percent e Initial Time The Initial Crank Fueling Period is the amount of time for which the value of Initial Crank Fuel Duty Cycle is assigned to the governor duty cycle after cranking begins This value can be set from 0 to 10 seconds e Ramp Rate The Crank Fuel Ramp Rate is the
30. selection Each event function can be programmed using InPower service tool or access to Setup menu as follows Change display name using up to 32 characters Select active low or high input 171 174 AUX I O MODULE INPUT 9 12 The nature of the Aux I O Module event is an optional Lamp None customer selection Each event function can be programmed using InPower service tool or access to Setup menu as follows Change display name using up to 32 characters Select active low or high input 202 PRE HIGH COOL TMP Indicates engine is operating near cooling system Lamp Warning capacity monitor condition Increase in load or higher ambient temperature may cause High Coolant Temp 1 shutdown Review code 1 correction list for other 4 9 TABLE 4 3 WARNING AND SHUTDOWN CODES FAULT CODE 203 LOW COOLANT TEMP Lamp Warning Set is not operating Warning occurs when engine coolant temperature is 7 21C or lower NOTE In applications where the ambient temperature falls below 40 4C Low Coolant Temp may be indicated even though the coolant heaters are operating 204 205 CONFIGURABLE INPUT 1 2 Lamp Warning 212 COOL SENSOR OOR Lamp Warning 213 LOW BATTERY Lamp Warning 214 HIGH BATTERY Lamp Warning 215 PRE LOW OIL PRESSURE Lamp Warning 216 HIGH AC CURRENT Lamp Warning CORRECTIVE ACTION Indicates engine coolant heater is not operating or is not circulating coolant
31. service tool or access to the Genset Service Menus is required to modify the customer fault inputs TB1 Customer Outputs Available options will vary between PCC1301 control models PCC with or without display X3 3 Genset Models are provided with Display unit Refer to Page 9 6 for typical connections to TB1 Customer Outputs 1 and 2 One set of normally open NO contacts rated for 2 amps at 30 VDC for each of the two output signals The relays can be used to control small devices and indicator lamps The nature of the customer output signal contacts closed is an optional customer selection Example outputs Genset running event warning common shutdown etc Refer to Table 5 3 for the warning and shutdown code listing and page 5 3 for the event code listing Each relay can be independently programmed to energize by entering the a code number 0 through 255 default 0 for the desired event The InPower service tool or access to the Genset Service Menus is required to modify the customer outputs Ready To Load Operates when the generator set has reached 90 of rated speed and voltage and latches until generator set is switched to off mode B signal output FIGURE 5 18 CONTROL BOX 5 46 ENGINE SENSORS Figure 5 19 shows the locations of the coolant temperature and oil pressure sender to which the PCC responds The coolant temperature sender functions by varying the resistance with the coo
32. set the overspeed value necessary to activate an Overspeed shutdown fault condition on 50 Hz gensets This value can beset from 0 to 8192 RPM in 25 RPM increments Overspeed 60Hz Threshold This threshold is used to set the overspeed value necessary to activate an Overspeed shutdown fault condition on 60 Hz gensets This value can beset from 0 to 24 096 RPM in 25 RPM increments 5 40 Engine Protection Speed Frequency Menu This menu is used to determine when a speed frequency conflict shutdown fault condition exists and for how long the fault condition should be present before the engine is shut down Speed Freq Fault Threshold This threshold is used to set the value necessary to activate the speed frequency conflict shutdown fault condition This value can be set from 0 1 to20 0 Hz Speed Freq Fault Time Delay A time delay of 0 2 to 10 0 seconds must expire before the warning message 15 announced because of a speed frequency conflict shutdown fault condition If the fault condition is active for the duration of this time delay the genset is shutdown and the Speed Hz Match shutdown message fault code 71 is announced Low Oil Pressure Warning Menu This menu is used to determine when a low oil pressure warning fault condition exists and for how long the fault condition must be present before the warning message Is announced Warning Threshold This threshold is used to set the pressure value n
33. sure each wire is clearly marked to indicate the correct terminal 3 Disconnect all engine wiring harness connections in the generator control and output boxes For reconnections later make sure each wire is clearly marked to indicate the correct terminal 4 Disconnect all generator control leads winding taps from connections in the output box For reconnections later make sure each wire is clearly marked to indicate the correct terminal 5 If the set has a mounted line circuit breaker disconnect the cables to the circuit breaker For reconnections later make sure each cable is clearly marked to indicate the correct terminal 6 Attach a hoist to the generator output box loosen the mounting bolts on the sides of the generator and remove the box Withdrawing The Generator From The Set A CAUTION Do not use fan blade to bar over engine That can damage blades and cause property damage and personal injury 1 The rotor will be carried inside the stator when the generator is withdrawn from the engine Bar the engine until one of the four poles of the rotor points straight down so that the rotor will rest on the face of the pole when the generator is withdrawn ZS CAUTION The rotor can be damaged if it rests the edges of the winding slot between two poles 2 Attach lifting eyes and a hoist of sufficient capacity Figure 6 7 3 Take up hoist slack and remove the two through bolts securing the generator to the rubbe
34. 20 30 or 60 RPM Hz Application Rating Select Menu The genset application rating can be set to either Standby or Prime 5 30 Standby Rating Menu The kVA Rating menu displays the kVA rating of single phase or three phase 50 or 60 hertz standby genset systems These values are used by the control to determine what 100 load is The values must match the kVA rating of the genset application and cannot be more than 2000 kVA 3Ph 50Hz The three phase 50 Hertz rating can be set from 0 to 2000 kVA 3Ph 60Hz The three phase 60 Hertz rating can be set from 0 to 2000 kVA 1Ph 50Hz The single phase 50 Hertz rating can e be set from 0 to 2000 kVA 1Ph 60Hz The single phase 60 Hertz rating can be set from 0 to 2000 kVA Prime kVA Rating Menu The kVA Rating menu displays the kVA rating of single phase or three phase 50 or 60 hertz prime genset systems These value are used by the control to determine what is 100 load The values must match the kVA rating of the genset application and cannot be more than 2000 kVA 3Ph 50Hz The three phase 50 Hertz rating can be set from 0 to 2000 kVA 3Ph 60Hz The three phase 60 Hertz rating can be set from 0 to 2000 kVA e 1Ph 50Hz The single phase 50 Hertz rating can be set from 0 to 2000 e 71Ph 60Hz The single phase 60 Hertz rating can be set from 0 to 2000 kVA GENSET SUBMENUS GENSET CT Ratio MPU Enable Yes Fly T
35. 4 Base board or generator is bad 4 Refer to Generator Base Board Isolation Procedure in Section 7 to determine if the Base board is causing the high AC voltage shutdown fault 5 Voltage sense connections set 5 See Section 17 for proper corrective actions up could be incorrect CODE 13 LOW ACE VOLTAGE SHUTDOWN Reason One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage Delay seconds Effect Engine will shut down POSSIBLE CAUSE CORRECTIVE ACTION 1 Fault simulation was enabled 1 With a PC based service tool verify that the related fault with a PC based service tool simulation is not enabled If you do not have a PC based service tool remove battery power from the control to disable fault simulation overrides 2 Fault threshold is not set 2 Reset the threshold to the lowest allowable setting Determine service tool disconnecting load and restarting generator set 4 Improper connections have been 4 Reconnect according to the appropriate reconnection diagram made at the generator output See Section 9 terminals connection could be incorrect the correct voltage 6 The rotating rectifier assembly 6 Check each diode See genset service manual diodes CR1 through CR6 is faulty 7 Repair connections P13 or replace the Base board if is bad necessary could be incorrect 4 15 WARNING Hazards present troubleshooting can cause equipment damage severe p
36. ATING RECTIFIER ASSEMBLY GENERATOR BASE BOARD ISOLATION PROCEDURE The following procedure is used to determine if the generator or the control Base board is causing a high AC voltage shutdown fault 1 Throw the line circuit breaker OFF and shutdown the set CAUTION This test involves unregulated excitation of the generator To prevent dam age to the generator due to over current make sure that all loads have been disconnected and that all faults have been cleared from the power output terminals of the generator WARNING HAZARDOUS VOLTAGE Touching Un insulated parts inside the control housing and power output boxes can result in severe personal injury or death Measurements and adjustments must be done with care to avoid touching hazardous voltage parts Stand on a dry wooden platform or rubber insulating mat make sure your clothing and shoes are dry remove jewelry and use tools with insulated handles 2 Remove the side access cover of the control housing to access the exciter stator leads X and XX Disconnect the X and XX leads from the AC harness quick connect type connectors 3 Prepare to measure output voltage across the generator terminals while the set is running 4 Bring two jumpers from a 12 volt battery for connection to the exciter stator X Field and XX Field leads Connect the jumper from the positive post of the battery to the X lead Be prepared to connect the jumper
37. AUSE CORRECTIVE ACTION 1 Weak or discharged 1 Recharge or replace the battery Specific gravity for a fully battery charged battery is approximately 1 260 at 80F 27 battery loose or dirty cables at the battery and the set charging voltage according to manufactures instructions 5 Engine DC alternator 5 Replace engine DC alternator if normal battery charging voltage could be bad 12 to 14 VDC is not obtained 6 Ifthe batteries are OK 6 Remove connector P11 from Base board and check battery the problem may be the voltage at P11 3 amp 15 B to P11 9 amp 10 GND harness or the Base e voltage at P11 is not the same as the battery voltage the board harness is bad e Ifthe voltage at P11 is OK the Base board is bad 7 Fault threshold could be 7 Check fault threshold against requirement of the application bad CODE 214 HIGH BATTERY VOLTAGE WARNING Reason High voltage has been detected for battery Effect Control damage will occur charging voltage according to manufacturers instructions 2 Replace engine DC alternator if normal battery charging voltage could be bad 12 to 14 VDC is not obtained bad 4 26 WARNING Hazards present 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 an
38. AVR Sensing amp Power supply from Main Stator 6 Neutral 3 Phase Output 1 EARTH FIGURE 6 6 TESTING THE GENERATOR STATOR 6 7 Main Excitation Windings If after establishing and correcting any fault on the rectifier assembly the output is still low when separately excited then the main rotor exciter stator and exciter rotor winding resistances should be checked see Resistance Charts as the fault must be in one of these windings The exciter stator resistance is measured across leads F1 and F2 The exciter rotor is connected to six studs which also carry the diode lead terminals The main rotor winding is connected across the two rectifier plates The respective leads must be disconnected before taking the readings Resistance values should be within 10 of the values given in the table below ALTERNATOR FRAME SIZE Main Rotor Ohms Exciter stator Ohms Exciter Rotor a P044D 0 437 P044F 945 388 08 P044H Main Stator Resistance mh PME Note These Windings referred by the alternator Manufacturer 7311 Winding 6 9 GENERATOR DISASSEMBLY The generator is heavy You will need an assistant and a hoist of sufficient capacity to remove and service the generator WARNING Accidentally dropping the generator can damage it and cause severe personal injury and death The hoist straps and chains
39. C be bad at P11 17 OP OUT and P11 6 OP COM If in range replace Base board 4 27 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 221 WEAK BATTERY WARNING POSSIBLE CAUSE CORRECTIVE ACTION 1 Refer to code 213 1 Refer to code 213 CODE 222 224 CONFIGURABLE INPUT WARNING Reason The nature of the fault is an optional configurable selection Effect Warning POSSIBLE CAUSE CORRECTIVE ACTION 1 there is no actual fault Disconnect the signal lead from TB1 and reset the control the problem may be an Check the following pins These connections are on the external wiring problem Universal Annuciator CONF_ANNUC_IN1 TB1 14 CONF_ANNUC_IN2 TB1 12 If the message drops out the external wiring has a short circuit Grounding of either input activates fault CODE 225 ANNUCIATOR CONFIGURATION ERROR WARNING Reason Indicates that more then one network device is configured to activate one of the Annunciator output relays Effect Warning POSSIBLE CAUSE CORRECTIVE ACTION 1 Network configuration is 1 Check setup of devices on the network against duplicate use bad of the same Annunciator relay output 2 Bad d
40. ECTIONS CUSTOMER INPUTS APPLY GROUND TO ACTIVATE CUSTOMER OUTPUTS REMOTE ESTOP 16 GND 5 SOG FAULT IN 14 GND 13 FAULT IN 2 Zi 12 S REMOTE START gt GND 10 0 1301 BASE BOARD FOR REF ONLY TBI TBI TBI TBI TBI TBI TBI TB1 Connections Terminated 2 inside the Panel OUT2 NO 8 OUT2 COM 1 OUTI NO C 6 OUTI COM READY TO LOAD 1 TERMINALS 2 4 Hd itd GOV Module PCC 1301 Base Board 8 9 Cummins India Limited Power Generation Business Unit 35 A 1 2 Erandawana Pune 411 038 India 91 020 6602 7525 Fax 91 020 6602 8090 www cumminsindia com Cummins the logo and Our energy working for you are trademarks of Cummins Inc 2007 Cummins Power Generation Inc All rights reserved
41. ERVICE MENU 2 latory 7 Network Status 2ND 3RD More Options 6 Lamp Test More Optlons 4 NETWORK STATUS AMF Modules Annunciators Bar Graphs FAULT HISTORY STATUS Batt Charger At Hrs Fault Number AVR Duty Cyc Ss Gov Duty Cyc 96 SOO gt NETWORK STATUS Controls Modules FAULT HISTORY MENUS Op Panels 5 2 20 gt Gece FIGURE 2 14 SERVICE MENUS 2 15 HISTORY ABOUT MENUS Figure 2 15 shows a block representation of the History About menu The first History About sub menu is displayed when the 2 button is pressed on the Service Menu Press the buttons next to the and symbols the graphical display to navigate between the History About submenus Press the LO button to return to the Service Menu History Submenu This submenu displays the number of engine starts hours of operation for the engine and hours of operation for the control About Genset Submenu This submenu displays the generator set model number and rating About Control Submenu This submenu displays the control s part number serial number up to 11 characters software part number and software version About Display Submenu This submenu displays the optional control panel software part number software version screen part number and screen version of the display
42. IVE ACTION 1 The remote start switch or Reset the control Attempt to start and check for ground at configurable wiring is faulty TB1 11 If ground level is not present isolate to the remote switch or configurable wiring Repair as necessary If ground is present go to next step 2 The menu display Auto button Check for continuity between P11 16 AUTO to P11 8 harness or the Base board is bad GND If no continuity when pressing the menu display Auto button isolate to front membrane panel or wiring harness If there is continuity the Base board is bad 4 6 s 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 this manual TABLE 4 3 WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE ACTION 1 Indicates engine has overheated coolant temperature has risen above shutdown trip point Allow engine to cool down completely before proceeding with the following checks a Check coolant level and replenish if low Look for possible coolant HIGH COOLANT TEMP Lamp Shutdown leakage points and repair if necessary b Check for obstructions to cooling airflow and correct as necessary c Check fan belt and repair or tighten if necessary d Check blow
43. RESHOLDS Weak HV Batt TD E 5 24V SAVE ADJUST Low Batt High LL JT P BATT DELAY CONTINUED ON L 5 5 35 TD Tp Wk 4 m SAVE XXI FIGURE 5 14 GENSET SETUP SUBMENUS SHEET 2 OF 3 5 33 Oil Pressure Setup Menus A menu 1 available to set the sensor type If the sensor type is Switch then another menu is available to set the sensor polarity If the sensor type is Sender then another menu is available to set the sender type Sensor Type The sensor type can be set for either Switch or Sender Sensor Polarity This menu is displayed only if the sensor type is set to Switch Sensor polarity can be set to either Active Low or Active High 5 34 Sender This menu is displayed only if the sensor type is set to Sender The sender type can be set to either 2 Wire or 3 Wire Startup Delay This menu is displayed only if the sensor type is set to Sender This menu allows for setting a time delay 0 to 400seconds default 0 seconds that prevents the oil pressure out of range fault warning fault code 217 from being displayed for the specified time period when the genset is starting Setting this time delay is useful with genset s that build up more than 100 psi oil pressure during start up and warm up GENSET SUBMENUS Continued 2 RETURN PAGE 5 33 OIL P
44. RESS SETUP Sensor Type Swltch SWITCH SENDER OIL PRESS SETUP OIL PRESS SETUP Oll Pressure Setup Sensor Type Sensor Polarlty Sender Type Low 3 Wire SAVE ADJUST ADJUST OIL PRESS SETUP OIL PRESS SETUP OOR Startup Sensor Polarlty Sender Type Delay 2 Wire Delay secs SAVET gt gt SAVET gt 1 0000 0000000 Startup Delay Delay EgaaSecs SAVE seen FIGURE 5 14 GENSET SETUP SUBMENUS SHEET 3 OF 3 5 35 VOLTAGE PROTECTION SUBMENUS The Voltage Protection submenus are available by pressing the 2 button on the first Genset Setup menu see Figure 5 13 Figure 5 15 is a block representation of the four Voltage Protection submenus that are available High AC Voltage Menu This menu is used to determine when a high AC voltage fault condition exists and for how long the fault condition should be present before the engine is shut down High AC Voltage Threshold This threshold is used to set the percentage of desired voltage necessary to activate a High AC Voltage fault condition This value can be set from 105 to125 High AC Voltage Time Delay A time delay of1 to 10 seconds must expire before the engine shuts down because of a high AC volt age fault condition If the fault condition is active for the duration of this time delay the engine shuts down and the High AC Voltage shutdown message fault code 12 is announced Low AC Voltage Men
45. RIP PCC 1301 GOV CARD 6 SERVICING THE GENERATOR TESTING THE GENERATOR These tests can be performed without removing the generator Before starting tests disconnect the negative cable from the battery to make sure the engine will not start while performing these tests 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 first touching grounded metal surface Ventilate battery area before working on or near battery Wear STATOR OUTPUT LEADS TERMINALS MAIN STATOR GENERATOR ADAPTOR CASTING COOLING BLOWER 6 1 MAIN ROTOR GENERATOR FIELD goggles Stop genset and disconnect charger before disconnecting battery cables Disconnect negative cable first and reconnect last Disconnect battery charger from AC source before disconnecting battery cables Otherwise disconnecting cables can result in voltage spikes damaging to DC control circuits of the set 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 END EXCITER PLATE STATOR ROTOR SHAFT BEARING EXCITER ROTOR ROT
46. S L3 AMPS SAVE ADJUST METERING CURRENT ADJUST AMPS L2 AMPS L3 AMPS SAVE FIGURE 5 9 METERING SUBMENUS 5 19 ANNUNCIATOR SUBMENUS The Annunciator submenus are available by pressing the 4 button on the second Genset Service menu see Figure 5 3 Seven annunciator submenus see Figure 5 10 can be used to define three Annunciator Fault Text messages and four Annunciator Output Maps 5 20 Inputs The annunciator has three possible customer defined fault conditions that can be shown on the 1301 display The Annunciator Fault Text message menus are used to enter an event type and description for those three customer defined Annunciator faults Enter the event type Warning Shut down or Event e Enter a brief description of the event up to32 characters ANNUNCIATOR FAULT 1 Waning SAVE ANNUNCIATOR FAULT 2 TEXT Type Shutdown b 4 d 0 d i 0 d P b b b b b i ADJUST ANNUNCIATOR FAULT 3 TEXT Type Warnlng CONTINUED ON PAGE 5 23 FIGURE 5 10 ANNUNCIATOR SUBMENUS SHEET 1 OF 2 5 21 Annuciator outputs An annunciator has four custom N O relays that can be controlled by the PCC 1301 When a specified event becomes active a message can be sen
47. SUBMENUS The Genset Service submenus are available by pressing the 1 button on the first Genset Service menu see Figure 5 3 Appendix A provides a block diagram that illustrates the sequence of how the Genset Service Submenus are displayed The Genset Service submenus consist of ten basic menus Genset Part 1 Genset Part 2 Fuel System Start Stop Time Delays Cycle Crank Battle Short Automatic Voltage Regulator Setup Electronic Governor Genset Model and Serial Number Display Setup Genset Menu Part 1 The first genset menu displays the preset AC Voltage genset frequency number of phases and phase type e Volts AC Displays the AC voltage 190 200 208 220 230 240 380 400 416 440 460 or 480 e Hertz Displays genset frequency 50 or60 Hz The control selects limits gains and frequency values based upon this selection e No of Phases Displays the number of phases 1 or 3 e Phase Displays the phase type Delta or Wye Genset Menu Part 2 The second genset menu allows for enabling or disabling charging alternators Charging Alt Enable A starter disconnect will occur whenever anyone of the following three possible signals reaches its disconnect set point The average engine speed if a magnetic pickup unit is installed The average frequency The charging alternator voltage if the Charging Alt feature is enabled The Charging Alt Enable menu is used to enable or disa
48. T 1 TEXT Warning 3 CUSTOMER CUSTOMER INPUT 2 TEXT INPUT 1 TEXT Shutdown XXOOOOOOOOOOOOOUR CUSTOMER MEUSE OUTPUT 1 MAP TEXT Fault Number 29 Loss of AC voltage sense CUSTOMER CUSTOMER OUTPUT 2 MAP OUTPUT 1 MAP Fault Number 29 Fault Number Loss of AC Loss of AC voltage sense voltage sense CUSTOMER OUTPUT 2 MAP Fault Number Loss of AC voltage sense SAVE FIGURE 5 8 CUSTOMER I O SUBMENUS 5 17 METERING SUBMENUS The Metering submenus available by pressing the 3 button on the first Genset Service menu see Figure 5 3 Four Metering submenus see Figure 5 9 can be used to adjust regulated voltage frequency line to neutral voltage and line current settings Meter Calib Menu The Meter Calib menu allows for adjusting the actual output voltage of the genset The percentage can be set from 90 to 110 The alternator voltage is also shown on this menu Freq Adjust Menu The Frequency Adjust menu allows for adjusting the genset frequency The frequency can be adjust from 6 0 to 6 0 Hz The actual frequency is also shown on this menu Metering Voltage Adjust Menu The Metering Voltage Adjust menu allows for adjusting metered genset line voltage 1 With the genset OFF attach a calibrated volt meter to the AC output from L1 to L2 L1 to Neutral for single phase alternators 2 Start the genset and allow it to reach normal operating speed 5 18 3 Display
49. This indicates that the engine failed to start after expiration of last crank time Effect Engine will not start POSSIBLE CAUSE CORRECTIVE ACTION 3 Injection pump Isolate to harness governor actuator or Base board actuator not energized 3a Display Governor Duty Cycle menu Attempt to start and check for duty cycle due to the harness 44 is about average If percentage of duty cycle is displayed before shutdown governor actuator the harness actuator governor or output circuit of control is bad go to step 4b governor module or Duty cycle displayed indicates processor is functioning but output circuitry of the base board is bad Base board could still be defective If the duty cycle is not displayed the control is bad or is configured incorrectly Check configuration 3b Remove connector P11 from control and check wiring continuity of actuator circuit P11 14 GOV DR and P11 7 GOV DR to appropriate terminals of governor module and between J1 4 on governor module and actuator If continuity is OK go to step 4c 3c Disconnect the two leads attached to the injection pump actuator Measure the resistance across the two actuator terminals A reading of 2 3 ohms indicates that the actuator circuit is OK This test only shows that the actuator circuit is not opened or shorted but not if there is binding Replace actuator assembly if open or short is measured If actuator is OK go to step 4d 3d Remov
50. Threshold Lid V Charger Falled Time Delay 5 SAVE FIGURE 5 17 ENGINE PROTECTION SUBMENUS SHEET 3 OF 3 5 45 1 BASE BOARD CUSTOMER CONNECTIONS The PCC Base board Figure 5 18 provides connection points 1 for remote control and monitor options TB1 Customer Inputs Available options will vary between PCC1301 control models PCC with or without display X3 3 Genset Models are provided with Display unit Refer to Page 9 6 for typical connections to TB1 Remote Start When the control is in Auto Remote mode 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 The remote stop is actually the removal of the remote start signal to the control Local 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 anyone of these inputs activates the corresponding warning or shutdown sequence External sensing equipment must be connected to the designated digital input The nature of the fault is an optional customer selection Example inputs Low Coolant Level Low Fuel Pressure Ground Fault etc Each of the two fault functions can be programmed as follows e Status Warning or Shutdown Default Warning e Enter a brief description of the event up to 32characters The InPower
51. Torque the diodes to 36 to 42 in lbs 4 to 4 8Nm and the pigtail terminals to 24 in Ibs 2 7 Nm when reassembling Surge Suppresser Testing and Replacement Remove the suppresser Replace the suppresser if it appears to have overheated or if ohmmeter readings indicate less than infinite resistance end of scale in both directions Torque the terminals to 24in lbs 27 when reassembling CAUTION Layers of dust can cause diodes to overheat and fail Brush dust off regularly TERMINAL ONE OF SIX SURGE SUPPRESSER REMOVE TO TEST FIGURE 6 3 TESTING THE ROTATING RECTIFIER ASSEMBLY Exciter Rotor Testing Winding Resistance Disconnect the six rotor winding leads from the terminal posts on the rectifier assembly With a Wheatstone bridge mea sure electrical resistance across each pair of rotor windings U CR1 or CR4 and CR2 or 5 V CR2 or CR5 and W CR3 or CR6 W CR3 orCR6 and U CR1 or CR4 See the winding schematic MEASURE WINDING INSULATION RESISTANCE BETWEEN ANY LEAD OR THE TERMINAL TO WHICH 5 CONNECTED AND THE ROTOR LAMINATIONS Replace the whole rotor shaft assembly if the resistance of any winding is not as specified in Table 6 1 Testing Winding Insulation Resistance Using an ohmmeter measure the resistance between any rotor winding lead or the terminal to which it is connected and the rotor laminations Replace the whole rotor shaft assembly if insulation resistance is l
52. and a password must be entered to modify these menus When the Password menu is displayed the first numeric character 0 is highlighted see Figure 5 3 NOTE selected highlighted each character initially turns to 0 and the remaining characters turn to X NOTE Make sure that each numeric character is correct before you move to the next character If a wrong character is entered you will not be able to go back and correct it If the wrong password is entered you will be able to view the Genset Service menus but you won t be able to change them To enter the Genset Service Menus password 574 5 4 1 With the first character highlighted press the button below to the or symbols until the value reads 5 2 Press the arrow selection button to move to the next numeric character 3 Press the button below or symbols until the value reads 7 4 Press the arrow selection button to move to the next numeric character 5 Press the button below or symbols until the value reads 4 6 After you have completed entering the password press the arrow selection button The first main Setup menu is displayed After the correct password is entered it will be remembered until five minutes of button inactivity has elapsed If five minutes of button inactivity has elapsed you will have to re enter the password to access and change the Genset Service submenus Adjusting Values Para
53. ation with control is displayed see Figure 2 4 When the display detects that it is no longer communicating with the control the Shutdown Warning and Remote Start LEDs are turned off If communications are lost the message Re establishing communication with control 16 displayed until communications have been re established see Figure 2 5 The LEDs then return to the state determined by the control If either communication message remains displayed cannot view other menus this indicates that communications between the control panel and the control logic is lost This menu also displays the screen s software number and version Establishing communication wiih control 3266219 Vi FIGURE 2 4 ESTABLISHING COMMUNICATION WITH CONTROL He establishing communication with control FIGURE 2 5 RE ESTABLISHING COMMUNICATION WITH CONTROL Event Messages When pre set events time delay to start or stop are activated Event messages are displayed showing the time remaining until the event occurs see Figure 2 6 Fault Messages A Fault message is an indicator of a Warning or Shutdown condition It includes the fault number a short description and when the fault occurred see Figure 2 7 Symbolic fault messages include the fault code number and symbols indicating the type of fault see Figure 2 8 With the symbolic versions of fault messages the D and EJ symbols flash Se
54. ator set its performance characteristics and displays performance information on digital display panel It accepts menu driven control and set up input from the push button switches on the front panel 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 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 Load Test Panel Megger or Insulation Resistance Meter InPower Service Tool based genset service tool PCC1301 Interface Kit Used with InPower Service Tool HOW TO OBTAIN SERVICE Always give the complete Model Specification and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts The nameplate is located on the front of the control panel WARNING Incorrect service or replacement of 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 follow Important Safety Instructions on pages ili 2 Control Operation GENERAL The followi
55. authorized personnel If a control panel is set up with the mode change access code feature enabled an access code must first be entered before the mode can be changed The InPower service tool or access to the Genset Service submenu is required enable disable the mode change Access Code feature Refer to Section 5 Entering the Mode Change Access Code If the mode change access code feature is enabled an access code must be entered to switch to Auto Manual Run or Off mode The text and symbolic versions of the Mode Change menu are shown in Figure 2 9 To enter the mode change access code 1 With the first character highlighted press the button below to the or symbols until the value reads 1 2 Press the arrow selection button to move to the next numeric character 3 Press the button below or symbols until the value reads 2 4 Press the arrow selection button to move to the next numeric character 5 Press the button below the or symbols until the value reads 1 6 After you have completed entering the password press the arrow selection button NOTE If an incorrect password is entered the Operator menu that was displayed before Auto Manual Run or Off mode was selected is redisplayed Mode Change Access Code TEXT VERSION SYMBOLIC VERSI N FIGURE 2 9 MODE CHANGE MENU Selecting Auto Mode To switch to Auto mode see Figure 2 10 3
56. ble the Charging Alt feature This menu provides a means to disable the 8 charging alternator logic if it is not supported by the alternator If the alternator does not support this functionality the Charger Failure warning fault code 219 will constantly be displayed un less this setting is changed to No When disabled set to No the start disconnect signal is based only on the average engine speed or frequency and the Charger Failure warning is disabled Fuel System The Fuel System menu allows for selecting fuel type and depending on the type selected enabling disabling glow plugs or setting a fuel burn time delay e Fuel System Allows for selecting fuel type Diesel or Gas If Fuel System is set to Diesel o Glow Plug Enable Allows control of Glow Plugs for a particular genset Yes or No o X3 3 Gensets are not provided with Glow Plug If Fuel System is set to Gas e Fuel Burn Delay After the genset receives a stop signal this feature allows for setting a fuel time delay from O to 10 seconds in which the ignition remains on so that any fuel downstream of the intake manifold is burned Start Stop Delay Menu The time delay after receiving a valid start signal until the genset starts can be adjusted The time delay that the genset is allowed to run at rated speed after receiving a stop signal until the genset stops can also be adjusted These time delays do not apply to manual start r
57. check for open circuit between K7 COM and battery If B is present reconnect lead COM to K7 Remove lead from K7 N O Attempt to start and check for at terminal K7 N O lf B is present check for open circuit between K7 N O and SW terminal of starter If B is not present the Base 7 relay is bad 3 The Emergency Stop With Emergency Stop push button not activated remove switch or wiring is configurable leads from TB1 15 and TB1 16 and check for defective continuity between these two leads If circuit is open isolate to Emergency Stop switch and wiring If there is continuity go to next step 4 Base board 5 Referto Code 45 instructions is bad 4 19 s 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 CODE 73 FAIL TO START SHUTDOWN MECHANICAL GOVERNED ENGINE Reason This indicates that the engine failed to start after expiration of last crank time Effect Engine will not start POSSIBLE FAULT CORRECTIVE ACTION 1 Restricted fuel supply due to 1a Add fuel if low Prime the fuel system Fuel level below pickup tube 1b Open any closed shutoff valve in the fuel line supplying the in tan
58. correct if necessary Connections or CT setup Refer to Current Transformer Setup in Section 6 6 4 The problem may be the 4 Remove connector P12 from Base board Check Base board or harness continuity from P12 to CTs connections P12 1 CT1 to P12 4 CT1 COM P12 2 CT2 to P12 5 CT2 COM P12 3 CT3 to P12 6 CT3 COM Repair connections 5 Incorrect rating setup 5 Check rating setup in control Correct if necessary 4 18 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 CODE 72 FAIL TO CRANK SHUTDOWN LOCAL OR REMOTE Reason This indicates that the engine failed to crank after the control received a start signal Effect Engine will not start POSSIBLE CAUSE CORRECTIVE ACTION 1 Starter is bad 1 Reset the control Attempt to start and test for B at the starter If there is B at the starter the starter could be bad Test starter see engine service manual Replace the starter If B is not present at the starter go to next step 2 Base board K7 Starter Check wiring continuity test relay Relay is bad Remove lead from K7 COM and check for at lead COM directly connected to battery B If there is no
59. ction 4 provides a list of fault codes fault types messages displayed and descriptions of the faults Five of the most recent faults are placed in a fault history file that can be viewed using the Fault History Menus see Figure 2 18 Fault Acknowledgement Shutdown faults must be acknowledged after the faults have been corrected If in Auto or Manual Run mode the control must be set to O off Also faults are acknowledged when in Auto and the Remote Start command is removed Faults are cleared from the control panel display by pressing 4 button Faults are re announced if they are detected again after being acknowledged TIME REMAINING UNTIL Event Event TIME DELAY START or STOP Seconds ENEEEEEEESSEN FIGURE 2 5 EVENT MESSAGE At Hrs Fault Number Fault WARNING SHUTDOWN EXAMPLE OF A SYMBOLIC WARNING FAULT EXAMPLE OF A SYMBOLIC SHUTDOWN FAULT JOU FIGURE 2 8 FAULT MESSAGES SYMBOLIC VERSION SELECTING AUTO MANUAL RUN AND OFF MODES Auto Manual Run and Off modes can be selected From any of the Operator menus When the message Establishing communication with control is displayed When the message Re establishing communication with control is displayed Switching to Auto Manual Run or Off mode can be restricted to
60. d be bad reconnect harness to sensor Remove connector P11 from Base board and check resistance between pins P11 18 H20 and P11 6 H20 COM resistance is not the same harness 15 bad resistance is the same Base board is bad 4 24 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 204 205 CONFIGURABLE INPUT WARNING Reason The nature of the fault is an optional configurable selection Effect Warning POSSIBLE CAUSE CORRECTIVE ACTION If there is no actual fault Disconnect the signal lead from 1 and reset the control Check the the problem may be an following pins external wiring problem CUST IN1 TB1 14 CUST IN2 TB1 12 If the message drops out the external wiring has a short circuit Grounding of either input activates fault CODE 212 COOLANT SENSOR OOR HIGH LOW WARNING Reason This indicates that the coolant temperature sensor signal is out of range shorted high or low Effect No engine protection for coolant temperature during genset operation Possible white smoke POSSIBLE CAUSE CORRECTIVE ACTION The sensor 1 Inspect the sensor and engine harness connector pins Repair or connections could
61. d observe all instructions and precautions in this manual CODE 215 PRE LOW OIL PRESSURE WARNING POSSIBLE CAUSE CORRECTIVE ACTION 1 Refer to code 2 for oil 1 Refer to code 2 for oil pressure sender pressure sender CODE 216 HIGH AC CURRENT WARNING POSSIBLE CAUSE CORRECTIVE ACTION 1 Refer to code 46 1 Refer to code 46 CODE 217 OIL PRESSURE SENSOR OOR HIGH LOW WARNING Reason This indicates that the engine oil pressure sensor signal is out of range shorted high or low Effect No engine protection for oil pressure during genset operation POSSIBLE CAUSE CORRECTIVE ACTION 1 The sensor connections 1 Inspect the sensor and engine harness connector pins Repair or could be bad replace as necessary 2 sensor could be 3 Disconnect the oil pressure sensor leads and connect an oil bad pressure sensor simulator to the harness OIL PRESSURE SENSOR warning is displayed after the fault condition is sensed for 10 seconds If the control responds to the simulator replace the sensor If control does not respond go to next step 3 The harness could be 3 Remove connector P7 from Base board and connector from bad sensor Check P11 6 17 amp 21 as follows e Check for a short circuit from pin to pin more than 200k ohms Check for an open circuit 10 ohms or less OK Repair or replace as necessary 4 The Base board could 4 all connectors attached check pressure signal 5 to 4 5 VD
62. d starts to recover This menu allows for adjusting the knee frequency and voltage set point slope parameters The knee frequency is the value below nominal frequency at which the roll off function begins For example if the knee frequency is set to 5 Hz on a 60 Hz genset this function begins when the frequency drops below 55Hz Slope refers to how fast the voltage is rolled off below the knee frequency The voltage is rolled off the slope percent setting for every 1 Hz below the knee For example on a 60 Hz genset if the slope is set to 5 and the knee frequency is set to 5 Hz then if the frequency drops to 54 Hz the voltage set point is reduced 5 If the frequency drops to 53 Hz the volt age set point is reduced 109 etc NOMINAL KNEE FREQUENCY NOMINAL 10055 VOLTAGE SET POINT CURVE FREQUENCY FIGURE 5 5 KNEE FREQUENCY AND SLOPE SLOPE VOLTAGE V Hz Knee The Knee Frequency can be adjusted from 0 0 to 10 0Hertz in 0 1 2 increments When generator set speed decreases by more than the value of the knee frequency the generator set voltage decreases by the Hz value V Hz off The Roll off setting can be adjusted from 0 0 to 5 0 percent of rated voltage in 0 1 increments Regulator Gains Menu The Regulator menu allows for setting proportional Gain Integral Gain and Damping values e Gain The proportional Gain multiplier be set from 5 to 100096 This allows for a
63. down fault condition This value can be set from 200 to 230 degrees F e Shutdown Time Delay A time delay of 2to 10 seconds must expire before the engine shuts down because of a high coolant temperature fault condition If the fault condition is active for the duration of this time delay the engine shuts down and the High Coolant Temperature shutdown message fault code1 is announced LOP SETUP LOP Shutdown Threshold psi LOP Shutdown Time Delay SETUP SETUP Shutdown Warning Threshold Threshold F LOP Shutdown HCT Warning Time Delay oe Time Delay sec SAVE ADJUST SETUP SETUP HCT Warnin HCT Shutdown Threshold Threshold F HCT Warning Shutdown Time Delay sec Time Delay sec SAVE ADJUST 5 Shutdown CONTINUED Threshold 5 45 Shutdown mici L FIGURE 5 17 ENGINE PROTECTION SUBMENUS SHEET 2 OF 3 5 43 Engine Protection Low Coolant Temperature and Battery Charger Menus The low coolant temperature menu is used to determine when the genset s coolant temperature is too low and a Low Coolant Temperature warning message fault code 203 is announced This warning message is not announced unless the coolant temperature has been determined to be low for one minute e LCT Warning Threshold This threshold is u
64. dy Class fires involve ordinary combustible materials such as wood and cloth Class fires combustible and flammable liquid fuels and gaseous fuels Class C fires live electrical equipment ref NFPA No 10 Make sure that rags are not left on or near the generator set Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under or near the unit Remove all unnecessary grease and oil from the unit Accumulated grease and oil can cause over heating and engine damage which present a 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 operating generator set To prevent serious burns avoid contact with hot metal parts such as radiator system turbo charger system and exhaust system KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE Int
65. e Shutdown fault condition This value can be set from O to100 psi e Shutdown Time Delay time delay of 2 to 15 seconds must expire before the engine shuts down because of a low oil pressure fault condition If the fault condition is active for the duration of this time delay the engine shuts down and the Low Oil Pressure shut down message fault code 2 is announced High Coolant Temperature Warning Menu This menu is used to determine when a high coolant temperature warning fault condition exists and for how long the fault condition should be present be fore the warning message is announced Warning Threshold This threshold is used to set the temperature value necessary to activate a High Coolant Temperature Warning fault condition This 5 42 value can be from 180 to 220 degrees Warning Time Delay time delay of 2to 10 seconds must expire before the warning message is announced If the fault condition is active for the duration of this time delay the High Coolant Temperature warning message fault code 202 is announced High Coolant Temperature Shutdown Menu This menu is used to determine when a high coolant temperature shutdown fault condition exists and for how long the fault condition should be present be fore the engine is shut down Shutdown Threshold This threshold is used to set the temperature value necessary to activate a High Coolant Temperature Shut
66. e PowerCommand 1301 Control PCC continuously monitors engine sensors for abnormal con ditions when genset is operating such as low oil pressure and high coolant temperature If any of these conditions occur the control with graphical display will light a yellow Warning lamp or a red Shutdown lamp and display a message on the graphical display A control without the graphical display indicates shutdown condition by intermittent flashing of the status indicator INPOWER SERVICE TOOL The InPower service tool Interface Kit can be used in troubleshooting to perform tests verify control inputs and outputs and test protective functions Refer to the InPower User s Guide pro vided with the InPower software for test procedures InPower when used improperly can cause symptoms like warnings and shutdowns that appear to be a defective base board When these problems occur always verify that self test simulation override have not been left enabled with InPower If you do not have InPower or the enabled fault simulation s can not be found using InPower disconnect battery power to disable the test or override condition 4 1 Make sure that parameter adjustments and time de lays related to the fault condition have been appropriately set for the application It may be necessary to write the initial capture file to the device or update the calibration file Updating a calibration file requires the InPower Proversion
67. e power from control for one minute Put power back on the control and check for B at J11 14 If not present control is bad If present go to step 4e Attempt to start and check for CNTL at terminal lead ACT of governor actuator use engine block for metering ground If not present check wiring or SW B control function and J1 3 of governor module If CNTL B is present attempt to start and check for GOV PWM pulse wide modulated signal measure across terminals of actuator and across J1 2 to J1 1 of governor module If not present on J1 control is bad If not present on actuator governor module is bad 4 22 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 73 FAIL TO START SHUTDOWN CONT ELECTRONIC GOVERNED ENGINE Reason This indicates that the engine failed to start after expiration of last crank time Effect Engine will not start POSSIBLE CAUSE CORRECTIVE ACTION 4 The engine fuel system is worn or 4 Service according to the engine service manual malfunctioning or has lost prime fuel lift pump injection pump injectors timing 5 he engine is worn or malfunctioning 5 Service according to the e
68. eason This indicates that the control has not received or recognized a manual start signal Effect Engine will not start POSSIBLE CAUSE CORRECTIVE ACTION 1 No power supplied to control a Poor battery cable connections Clean the battery cable terminals and tighten all connections Remove connector P11 and check for B at P11 3 amp 15 and GND at P11 9 amp 10 If B or ground missing isolate to harness and TB BAT terminal mounted on engine block If B and ground check OK cycle power to base board by reconnecting P11 and retry operation 2 No power supplied to front Check for at TB1 1 and GND at TB1 4 If B or ground membrane panel missing the base board is bad If B and ground check OK remove P1 from back of front membrane panel Check for at P1 3 and ground at P1 5 If B or ground missing repair harness 3 Base board not properly Confirm that the installed calibration part number matches calibrated or corrupt the serial plate information Re enter calibration file if calibration necessary 4 The Emergency Stop switch or With Emergency Stop push button not activated switch wiring is defective closed remove configurable leads from TB1 15 and TB1 16 and check for continuity between these two leads If circuit is open isolate to Emergency Stop switch and wiring If there is continuity go to next step o Base board not properly Confirm that the installed calibration part number matches calibrated or co
69. ecessary to activate a Pre Low Oil Pressure warning fault condition This value can be set from Oto 100 psi e Warning Time Delay A time delay of 2to 15 seconds must expire before the warning message is announced because of a low oil pressure warning fault condition If the fault condition is active for the duration of this time delay the Pre Low Oil Pressure warning message fault code 215 is announced ENGINE PROTECTION SUBMENUS Continued LOP SETUP LOP Shutdown Threshold LOP Shutdown Time Delay 91 124 Warnln Threshold HCT Warning Time Be SAVE SETUP Shutdown Threshold Shutdown Time Delay sec SAVE RETURN TO PAGE 5 41 LOP SETUP LOP Shutdown Threshold psl LOP Shutdown Time Delay ADJUST SETUP HCT Warning Threshold F HCT Warning Time Delay sec ADJUST SETUP HOT Shutdown Threshold Shutdown Time Delay sec ADJUST CONTINUED ON PAGE 5 45 FIGURE 5 17 ENGINE PROTECTION SUBMENUS SHEET 1 OF 3 5 41 Low Pressure Shutdown Menu This menu is used to determine when a low oil pressure shutdown fault condition exists and for how long the fault condition should be present before the engine is shut down e Shutdown Threshold This threshold is used to set the oil pressure value necessary to activate a Low Oil Pressur
70. ection Display Text Symbolic Versions This graphical display can be set up to show either text or symbolic versions for fault messages some Operator menus and the Mode Change menu A description of commonly used symbols used are included in Table 2 1 Combinations of symbols are used to display some fault conditions Additional specialized symbols are also used for some 2 2 faults see Section 4 When shipped from the factory symbolic display is selected Refer to Setup menu in Section 5 to change to text or symbolic display TABLE 2 1 SYMBOLS DESCRIPTION Generator VVarnindg Fault Display Menu Selection Buttons Four momentary soft key buttons are used to step through the various menus and to adjust parameters These selection buttons are active when a word or symbol in the graphical display 15 shown above the button Some submenus do not include any active buttons The function of the four selection buttons varies with each menu When the symbol is displayed the selection button can be used to switch to Auto mode When the symbol is displayed the selection button can be used to switch to Manual Run mode When the up and down triangles and are displayed the selection buttons are used to navigate between a series of submenus NOTE When any Operator menu Figure 2 12 is displayed a series of Service menu scan be viewed by simultaneously pressing the A and selection buttons for two
71. eetch RPM Hz Ratio GENSET CT Ratlo MPU Enable Fly Teetch HH RPM Hz Ratio APPLICATION RATING SELECT Application Ratlng Prime kVA STANDBY 3Ph 60Hz gt Application pe 1 50 2 888 8 Rating 1Ph SOHz SAVE ADJUST APPLICATION kVA STANDBY 3Ph 60Hz 3Ph 60Hz 8 1Ph 5O0Hz 1Ph 50Hz PRIME 3Ph 60Hz Jd 3Ph 60Hz 1Ph 50Hz HHHH H 1Ph 50Hz ADJUSTI PRIME 3Ph 60Hz SPh 60Hz BH 1Ph 5O0Hz AH 1 Hz CONTINUED ON PAGE 5 33 SAVE FIGURE 5 14 GENSET SETUP SUBMENUS SHEET 1 3 5 31 Battery Select Menu The Battery Select menu is used to set the nominal battery voltage Nominal Battery Voltage Allows for setting the nominal battery voltage 12 or 24 Battery Thresholds Menus The Battery Thresholds menu is used to set the low and high voltage values to determine when the battery voltage is out of the set range during normal operation This menu is also used to determine when the battery voltage is below weak battery thresholds during cranking The Battery Thresholds menu that is displayed is dependent upon the battery voltage entered in the Battery Select menu e low Bait The low battery voltage threshold can be set from 11 0 to 13 0 VDC for 12 volt batter
72. efault 120 seconds Refer Lamp Warning to engine service manual if this fault occurs If not failed check wiring 220 Genset continues to run after receiving shutdown command from the FAIL TO SHUTDOWN controller Battle Short feature enabled used to bypass several critical Lamp Warning fault shutdowns for genset operation during emergencies 221 Indicates that during cranking the battery voltage is at or below the WEAK BATTERY weak battery warning trip point for a time greater than or equal to the Lamp Warning weak battery set time See code 213 for corrective action 222 223 224 The nature of the annunciator fault is an optional configurable selection ANNUNCIATOR FAULT 1 2 3 Lamp Warning 225 Indicates a mismatch in the configuration of one of the annunciator ANNUNCIATOR OUTPUT relay outputs CONFIGURATION ERROR Lamp Warning 226 233 The nature of the Base I O Module fault is an optional customer Base I O Module Input selection Example inputs Low Fuel Day Tank Water in Fuel Ground 1 8 Fault etc Lamp Warning Each of the fault functions can be programmed using InPower service tool or access to Setup menu as follows e Warning Shutdown or Event Default Warning See fault code 84 91 for shutdown and code 163 170 for Event e Change display name using up to 32 characters 234 237 The nature of the Aux Module fault is an optional customer AUX I O MODULE INPUT selection Example inputs Low Fuel Day Tank Water i
73. er fan and circulation pumps on remote radiator installations e Reset control and restart after locating and correcting problem 2 Indicates engine oil pressure has dropped below the shutdown trip point LOW OIL PRESSURE Check oil level lines and filters If oil system is OK but oil level is low Lamp Shutdown replenish Reset control and restart If oil switch is used check switch performance 12 Indicates that one or more of the phase voltages has exceeded 130 of HIGH AC VOLTAGE nominal for O second or has exceeded high ac voltage threshold of nominal Lamp Shutdown for time delay seconds 13 Indicates that one or more of the phase voltages has dropped below low ac LOW AC VOLTAGE voltage threshold for time delay seconds Lamp Shutdown 14 Indicates frequency is 1090 above base frequency for approximately 10 OVER FREQUENCY seconds Lamp Shutdown 15 Indicates that engine speed has dropped below 90 of nominal for UNDER FREQUENCY approximately 10 seconds Lamp Shutdown Check fuel supply intake air supply and load 27 Indicates a loss of all three voltage sense leads or failure in excitation circuit EXCITATION FAULT Check field wiring X1 and X2 for shorts or opens Refer to Section 7 Lamp Shutdown 31 Indicates engine has exceeded normal operating speed The default OVERSPEED thresholds are 1725 RPM 50 Hz or 2075 RPM 60 Hz Lamp Shutdown Possible causes are single step large block load removal or flammable vapo
74. ersonal 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 this manual CODE 14 OVER FREQUENCY SHUTDOWN Reason Generator AC output frequency is high Effect Generator set will shut down POSSIBLE CAUSE CORRECTIVE ACTION 1 Fault threshold is not set 1 Reset the threshold to the highest allowable setting correctly with based Determine the required operating range before adjusting the service tool threshold 2 Fuel or air delivery problem 2 Refer to the engine service manual 3 Governor fault 3 Check governor frequency adjustment Refer to Section 7 4 Loose connector or Base 4 Repair connections P12 P13 or replace the Base board if board is bad necessary CODE 15 UNDER FREQUENCY SHUTDOWN Reason Generator AC output frequency is low Effect Generator set will shut down POSSIBLE CAUSE CORRECTIVE ACTION 1 Fault threshold is not set 1 Reset the threshold to the lowest allowable setting correctly with PC based Determine the required operating range before adjusting the service tool threshold 2 Overload 2 Check the load and correct any overload Check operation by disconnecting load and restarting generator set 3 Fuel or air delivery problem 3 Refer to the engine service manual 4 Governor fault 4 Check
75. ery System Alternator specifications Torque match shunt standard EBS optional EBS Excitation Boost System lt 5 no load to full linear load lt 3 for any single harmonic Available voltages 60 Hz line neutral line line 50 Hz line neutral line line Std Voltage 127 220 230 400 STD 120 208 133 230 138 240 STD 240 416 220 380 127 220 138 240 277 480 220 380 240 416 255 440 265 460 254 440 265 460 277 480 120 208 133 230 Generator set options and accessories 1105 C Temp Rise Alternator 1 208 240 480 Volt coolant 125 C Temp Rise Alternator O Shunt Trip Heavy Duty Air Cleaner heater 150 C Temp Rise Alternator Auxiliary Contacts 0 Electronic Governing OEBS Excitation Boost System H Earth Fault Relay Battery Charger I 120 240 V 25 anti 1500 3000 hours Maintenance Kit condensation heater Exhaust system 1 Standard Residential grade exhaust silencer 8 WIRING DIAGRAMS GENERAL This section consists of the schematic and connection wiring diagrams referenced in the text The following drawings are included Page 8 2 AC Reconnect Wiring Diagram Page 8 3 amp 8 4 Block Diagram Page 8 5 AC Harness Page 8 6 Engine Harness Electronic Mechanical Governor 8 7 Engine Harness Jumper PCC2100 to PCC1301 Page 8 8 Customer Connections NOTE P1 Alternators for X3 3 have Winding 311 for 3 phase for 50 and 60 Hz and 05 06 Windin
76. ess than 1 megohm ROTOR LEADS DISCONNECT THE SIX ROTOR WINDING LEADS FROM THEIR TERMINALS AND MEASURE FLECTRICAL RESISTANCE ACROSS EACH PAIR OF WINDINGS U V V W W U FIGURE 6 4 TESTING THE EXCITER ROTER 6 5 Main Rotor Generator Field Testing Winding Resistance Disconnect the two leads of the main rotor from the terminals on the rotating rectifier assembly See Figure 6 4 Measure electrical resistance between the two leads with a Wheatstone bridge or digital ohmmeter Replace the rotor if the resistance is not as specified in Table 6 1 Connect the rotor leads and torque the terminals to 24 in Ibs 2 7 Nm when reassembling Testing Winding Insulation Resistance Using an ohmmeter measure the resistance between either lead of the main rotor windings or the terminal to which it is connected and the main rotor laminations Replace the rotor if insulation resistance is less than 1 mega ohm NOTE Incorrect resistances indicate faulty windings and component replacement is necessary MEASURE WINDING INSULATION RESISTANCE BETWEEN EITHER ROTOR LEAD AND THE ROTOR _ j 119 UU DISCONNECT THE MAIN ROTOR LEADS FROM THE ROTATING RECTIFIER ASSEMBLY AND MEASURE THE WINDING RESISTANCE BETWEEN THEM FIGURE 6 5 TESTING THE MAIN ROTOR Main Stator Testing Winding Resistance Measure electrical resistance across each pair of stator leads 01 02 05 06 VI V2 V5 V6 W1
77. etects a Shut down condition The generator set cannot be started when this lamp is on After the condition is corrected the lamp can be reset by pressing the off button Warning Indicator This yellow lamp is lit whenever the control detects a warning condition This lamp is automatically shutoff when the warning condition no longer exists Remote Start Indicator This green lamp indicates the control is receiving are mote run signal Auto Indicator This green lamp indicates the control is in Auto mode Auto mode can be selected by pressing the selection button from any of the Operator menus see Figure 2 12 Manual Run Indicator This green lamp indicates the control is in the Manual Run mode Manual Run mode can be selected by pressing the selection button from any of the Operator menus see Figure 2 12 SYSTEM MESSAGES A system pop up message is displayed when the event it is displaying becomes active These pop up messages remain displayed until pre empted by another pop up message or until the V or display button is pressed Once the W button is pressed the previous screen 15 redisplayed Communication Messages System messages are displayed for initial power up or when there is subsequent loss of communications Note that the Auto and Manual Run modes can be selected when communication messages are displayed Upon initial power up the message Establishing communic
78. evice on network 2 Troubleshoot network for malfunctioning devices 4 28 5 CONTROL ADJUSTMENTS AND SERVICE GENERAL This section contains circuit board removal and re placement procedures and system parameter adjustment procedures for the genset control This section also describes the function and operation of engine sensors genset options and other special features of the genset control system such as customer connection points magnetic speed pickup unit and current transformers Installation in formation is also provided for these items where necessary WARNING Incorrect service or replacement of parts can result in severe personal injury or death and or equipment damage Service personnel must be trained and experienced to per form electrical and mechanical service CS WARNING HAZARDOUS VOLTAGE The PCC1301 control box must be opened only by technically qualified personnel Voltages of upto600 VAC are present in the PCC box These voltages can cause electrical shock resulting in personal injury CIRCUIT BOARD REMOVAL REPLACEMENT No special tools other than a grounding wrist strap and InPower Service tool with PCC1301 Interface Kit are required to remove a circuit board from in side the control box The InPower Service tool is required when replacing the Base board Before replacing the Base board make sure that a capture file of the genset s parameter values has been created using InPower D
79. from the negative post oft he battery to the XX leads If one of the 12 volt cranking batteries is used bring the jumpers from the battery connected on the grounded side of the system to avoid inadvertently imposing 24 volts on the system 5 Check polarity again Polarity must be corrector this test will be inconclusive because the induced residual magnetic polarities in the exciter stator will be opposed Genset may shut down on a fault condition with in5to15 seconds due to the exciter stator leads being disconnected from the Base board Clear fault and start genset to check next phase 6 Start the set and connect the jumper from the battery negative terminal to the XX lead 7 The generator circuitry is probably okay if rated output voltage or higher is obtained and the voltages for all phases are balanced when the exciter is powered by a 12 volt battery Refer to Section 4to troubleshoot the PCC control circuitry Normal excitation voltage ranges from approximately 10 VDC at no load to approximately 40 VDC at full load 8 the voltages are unbalanced trouble shoot the main stator first If the voltages are uniformly low troubleshoot the exciter and field circuits first 6 2 Exciter Stator Testing Winding Resistance Measure winding resistance with a stone bridge or digital ohm meter Replace the stator if winding resistance is not as specified by Table6 1 Testing Winding Insulation Resi
80. fuel shutoff solenoid adjustment 5 Loose connector or Base 5 Repair connections P13 or replace the Base board if board is bad necessary 4 16 Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 31 OVERSPEED SHUTDOWN Reason Engine speed signal indicates an engine speed greater than shutdown threshold Effect Engine will shut down 22 POSSIBLECAUSE CAUSE engine coolant can occur when starting a very cold engine Clear fault and heaters restart genset Single step large block load Clear fault and restart BEBE eeecccec removal 3 Fault simulation was enabled 3 With PC based service tool BEEN 11 111 that the fault simulation is not enabled for with a PC based service tool the coolant sensor If you do not have PC based service tool remove battery power from the control to disable fault simulation overrides 4 Fault threshold is set 4 Reset the threshold to the highest allowable setting Determine the required correctly with PC based service operating range before adjusting the threshold tool PC based service tool 6b Replace defective injection pu
81. g for 50 60 Hz Single phase respectively NOTE The Wiring Drawings are REPRESENTATIVE DRAWINGS FOR SERVICE USE DRAWING SUPPLIED WITH GENSET PASTED ON THE BACKSIDE OF THE DOOR OF THE PEDESTAL PANEL The Drawings can be downloaded from the PGBU Engineering Database 3 Phase Reconnect able 12 Lead CT Secondary Connection XI X3 X3 RANGE RANGE 110 120 220 240 VOLTS 10 139 190 240 VOLTS or LE V UICTI USLTTI VICT2 UBCTIO SERIES DELTA PARALLEL STAR 3 PHASE 4 WIRE 3 PHASE 4 WIRE OUTPUT TERMINALS OUTPUT TERMINALS W5CT9 5 8 USCTT U2CT4 NOTE Sense Lead N is Not Used Tape End and Tie Back 8 2 lt mo m oo am 001 104 004 SENSE U 3 Phase Reconnect able 12 Lead CT Secondary Connection x Xu x RANGE 220 211 380 480 VOLTS RANGE 10 120 220 240 VOLTS LICUJ 12 74 WI T3 UB TIO vores WEI TI2 5 79 6 W6 TI 2 5179 I MINE DOUBLE DELTA PHASE 3 WIRE T eee OUTPUT TERMINALS U W CENTER SENSE W W5CT9 18 15 USCTT U2 14 SENSE U omom m H 2 2 HM lt 8 3 1 Phase NON Reconnect able 4 Lead CT Secondary Connection X3 RANGE
82. generate a signal to P11 17 OP OUT and P11 5 OP COMM If the pressure signal 5 to 4 5 VDC does not get to P11 isolate to the harness If the pressure signal does go to P11 the Base board is bad 5 Low Oil Pressure fault set points Verify set points against the normal operating pressures of the could be incorrect engine Refer to engine manual 4 14 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 12 HIGH AC VOLTAGE SHUTDOWN Reason One or more of the phase voltages has exceeded 130 of nominal for 1 seconds or has exceeded the High AC Voltage Threshold for the High AC Voltage Delay seconds Effect Engine will shut down POSSIBLE CAUSE CORRECTIVE ACTION 1 Fault simulation was enabled 1 With a PC based service tool verify that the related fault with a PC based service tool simulation is not enabled If you do not have a PC based service tool remove battery power from the control to disable fault simulation overrides removal 3 Fault threshold is set 3 Reset the threshold to the highest allowable setting Determine correctly with PC based service the required operating range before adjusting the threshold tool
83. h magnetic pickup installed and enabled 73 Indicates possible fuel system or air induction problem Engine cranks FAIL TO START fails to start Lamp Shutdown a Check for empty fuel tank fuel leaks or plugged fuel lines and correct 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 74 Genset continues to run after receiving shutdown command from the FAIL TO STOP controller Lamp Shutdown 75 76 The nature of the fault is an optional configurable selection Example CONFIGURABLE inputs Low INPUT 1 amp 2 Fuel Day Tank Water In Fuel Ground Fault etc Lamp Shutdown Each of the fault functions can be programmed using service tool or operator panel as follows e Warning or Shutdown Default Warning See fault code 204 205 for Warning e Change display name using up to 32 characters 77 A shutdown fault occurred while the Battle Short mode was enabled Check SHUTDOWN AFTER fault history for faults that may have been bypassed BS Lamp Shutdown 81 82 83 The nature of the annunciator fault is optional configurable selection ANNUNCIATOR FAULT 1 2 3 Lamp Shutdown 202 Indicates engine 1 operating near cooling system capacity Increase in PRE HIGH COOL TMP load or higher ambient temperature may cause High Coolant Temp 1 Lamp Warning shutdown Review code 1 correctio
84. he following two categories of genset adjust menus Genset Service menus Go to page 5 4 e Genset Setup menus Go to page 5 27 5 3 SETUP Menus Password SETUP MENUS 1 Gensat Service 2 Genset Setup FIGURE 5 2 SETUP MENUS GENSET SERVICE MENUS In the following menu entry descriptions the default parameter value is not shown because the default value is subject to change by model Always create and refer to the initial capture file for factory default settings system parameters values The Genset Service menus are available by pressing the 1 button in the Setup menu see Figure5 3 This section covers Genset Service menus only For information on Genset Setup menus go to 5 27 a password is entered the settings in the Genset Service menus can be adjusted However if a password is not entered these menus can still be viewed Viewing and Adjusting Figure 5 3 is a block representation of the two Gen set Service menus that are available from the Setup menu after the correct password has been entered The Genset Service menus provide access to the following categories The first Genset Service Menu provides access to the following menus Genset Customer I O e Meter Calibration The second Genset Service Menu provides access to the following menu Annunciator Setup Password Menu Adjusting the Genset Service submenus is restricted to service personnel
85. ical equipment Do not wear damp clothing particularly wet shoes or allow skin surface to be damp when handling electrical equipment Do not wear jewelry Jewelry can short out electrical contacts and cause shock or burning Use extreme caution when working on electrical components High voltages can cause injury or death DO NOT tamper with interlocks Follow all applicable state and local electrical codes Have all electrical installations performed by a qualified licensed electrician Tag and lock open switches to avoid accidental closure DO NOT CONNECT GENERATOR SET DI RECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous voltages can flow from the generator set into the utility line This creates a potential for electrocution or property damage Connect only through an approved isolation switch or an approved paralleling device GENERAL SAFETY PRECAUTIONS Coolants sunder pressure have a higher boiling point than water DO NOT open a radiator or heat ex changer pressure cap while the engine is running To prevent severe scalding let engine cool down before removing coolant pressure cap Turn cap slowly and do not open it fully until the pressure has been relieved Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity When checking or changing engine oil take care not to ingest breathe the fumes or con tact used oil Keep multi class ABC fire extinguishers han
86. ies and from 22 0 to 2 0 VDC for 24volt batteries in 0 1 VDC increments e High Batt The high battery voltage threshold can be set from 14 0 to 17 0 5 32 VDC for 12 volt batteries and from 28 0 to 34 0 VDC for 24volt batteries in 0 1 VDC increments e Weak Batt The weak battery voltage thresh old can be set from 6 0 to 10 0 VDC for 12volt batteries and from 12 0 to 16 0 VDC for24 volt batteries in 0 1 VDC increments Battery Delay Setup Menu This menu is used to determine when after determining that the battery condition is out of the preset operating range a warning message is announced Batt TD A time delay from 2 to 60 seconds can be set before the Low Battery warning message fault code 213 15 announced e H Batt TD A time delay from 2 to 60 seconds can be set before the High Battery warning message fault code 214 is announced e Wk Batt TD A time delay from 1 to 5 seconds can be set before the Weak Battery warning message fault code 221 IS announced GENSET SUBMENUS Continued RETURN TO PAGE 5 31 BATTERY SELECT Nominal Battery Voltage V BATTERY SELECT BATT THRESHOLDS BATT THRESHOLDS 12V 24V Nominal Battery Low fff Low V Voltage High Batt V High ev Weak Batt Weak 4 4 V ADJUST BATT THRESHOLDS BATT DELAY SETUP 12V L Batt 5 Low Batt High V Batt 5 TH
87. k engine Closed shutoff valve in 1c Refer to engine service manual supply line 1d Bleed air from fuel system Refer to engine service manual Fuel injectors clogged Air in fuel system 2 Glow plugs are not heating due The Base board determines at what temperature and duration of to time that the glow plugs will be energized Using sensed coolant a Glow plug s is bad temperature the glow plugs are energized at 77 F 25 C and b Base board is bad colder The glow plugs are energized for up to 15 seconds when the c Glow Plug Relay is bad coolant temperature is 5 F 20 5 C or colder Time duration 15 0 seconds is linear between 5 F and 77 F With coolant temperature colder than 77 F 25 C 2a Each glow plug should be warm to the touch if the engine has just been cranking First clean and tighten the terminal of any cold glow plug and then replace it if necessary 2b Install harness tool between Base board P11 connector Attempt to start and check for B at P11 2 RELAY COIL B and P11 19 GLOW PLUG SOL These are leads to K2 coil f B is not present the Base board is bad If B is present go to step 2c Check for B at glow plug relay If not present check for open circuit If there is B at glow plug relay attempt to start and test for B at other end of glow plug relay If B is not present glow plug relay is bad If B is present check for open circuit between glow plug relay contact
88. lant and temperature With 5VDC supplied to the sensor the output signal which varies with temperature is supplied to the Base board The coolant sender enables the Base board to detect low pre high and high coolant temperatures Coolant Sender The oil pressure sender functions by converting the sensed oil pressure to voltage which varies the supplied 5 VDC to the sender The output signal of the sender is approximately 0 5 VDC at psi and4 5 VDC at 100 psi The low coolant level switch functions by closing the circuit to the engine chassis ground battery negative The low coolant level switch is not shown in Figure 5 9 this switch is located on the Top Tank of the radiator Oil pressure sender 5 47 MAGNETIC SPEED PICKUP UNIT MPU INSTALLATION To install the MPU sensor bar the engine until a gear tooth on the flywheel lines up in the center of the mounting hole Thread the sensor in gently by hand until it just touches the gear tooth Back it out one quarter turn and set the lock nut To troubleshoot the MPU refer to fault code 45 in Section 4 CAUTION Do not use fan blade to bar over engine That can damage blades and cause property damage and personal injury 5 48 SENSOR 7 ENGINE FLYWHEEL RING GEAR FIGURE 5 20 MPU SENSOR CURRENT TRANSFORMER INSTALLATION The current transformers are used to display genset load in KVA and alternator amperage The
89. m socket head box screw driver 17mm socket 17mm socket x 60mm long non standard 17mm socket x 75mm long STD 8 mm socket 8mm open type spanner amm socket head box screw driver or 8mm Socket amm socket with Allen key bit type wrench with extension rod and 13mm socket type wrench with extension rod and 13mm socket 6 13 Torque value Nm 2 8 3 6 5 5 Oo 2 0 51 51 2 8 3 6 2 8 3 6 2 8 3 6 2 8 3 6 19 26 26 7 GENSET SPECIFICATIONS 3 Phase Ratings kW kVA kW kVA kW kVA kW kVA C33D5 7 26 4 33 2 2430 Standby rating Model C38D5 30 4 38 28 35 C30D6 30 37 5 270375 C35D6 35 43 75 220 1 Phase Ratings Standby rating kW kVA kW kVA kW kVA kVA kW C33D5 12 6 Pf 19 23 8 c38Db5 24 30 6 22272 3006 30 375 2490 3506 94 29364 7 1 Generator set specifications Governor regulation class 1508528 Part 1 Class G2 Voltage regulation no load to full load Random voltage variation Engine specifications Single element Spin on fuel filter cum Water Separator Filtration efficiency Fuel filter 25 micron 99 min Water Separation efficiency 90 min Air cleaner type Dry replaceable element Lube oil filter type s Spin on full flow filter Filtration efficiency 25 micron 99 min Standard cooling system 122 F 50 C ambient radiator with coolant Recov
90. meters Once the correct password has been entered after Genset Service 1 is selected on the Setup Menus menu the first Genset Service menu is displayed 1 Press the buttons above the Aand Wsymbols in the digital display to navigate between submenus 2 Press the ADJUST selection button to select the first parameter or value to be changed 3 Press the or selection buttons to adjust values or select parameters 4 Press the arrow selection gt button to navigate to the next or previous adjustable value or parameter 5 After adjusting values selecting parameters press the SAVE button to save your settings NOTE If the button 4 is pressed before pressing the SAVE button the changes are not saved 6 Press the button 4 to return to the Service Menu GENSET SERVICE MENUS SETUP Manus SETUP MENUS 1 Genet Service 2 Gange Setup GENSET SERVICE 1 Genzet 2 Customer Lich 2 Meter GENSET SERVICE Options 4 Annunclator mor 5 Modbus B Module Mare INPUT TET MODBUS ENABLE Modbus Enable AD ST SEE PAGE 5 16 SEE PAGE 5 24 ANNUNCIATOR Module 0 1 REGULATED METER CALIB 1 Inputs Warning 2 Outputs Senders ADJUST REFER INSTRUCTION PAGE 5 0 SEE PAGE 5 18 SEE PAGE 5 20 SHEET 2693 FIGURE 5 3 GENSET SERVICE MENUS 5 5 GENSET SERVICE
91. mp unit 6 For gensets with magnetic pickup installed verify flywheel tooth count is correct for the engine type Refer to section 7 11 1 for a table could be incorrect CODE 45 SPEED SIGNAL LOST SHUTDOWN GENSET WITH MPU Reason This indicates that the control is not sensing the magnetic pickup signal Effect Engine will shut down POSSIBLE CAUSE CORRECTIVE ACTION 1 Loose or damaged magnetic Inspect the wires connector pins and repair or replace as necessary pickup MPU wires connector pins 2 The magnetic pickup harness To isolate the problem reset the control and attempt to start the set or Base board could be bad If 72 Fail To Crank is displayed or if the engine starts but then shuts down on 45 Speed Signal Lost the MPU sender could be bad Remove the MPU connectors and check for 3 5 to 15 VAC at the MPU while cranking If no output check for damage or debris Also check for improper adjustment of the MPU Refer to Section 7 11 If there is still no output replace the MPU sender If the MPU output is OK check for MPU voltage at P11 12 MAG to P11 24 MAG PICK while cranking If OK replace the Base board If not OK use continuity checks to isolate connectors harness If the engine starts and idles and does not display a fault then there could be a frequency mismatch problem Measure generator output frequency with a digital Multimeter and compare to the frequency on the operator panel or PC based
92. n Fuel Ground 9 12 Fault etc Lamp Warning Each of the fault functions can be programmed using InPower service tool or access to Setup menu as follows e Warning Shutdown or Event Default Warning See fault code 92 95 for shutdown and code 171 174 for Event e Change display name using up to 32 characters 238 Indicates engine has begun to overheat oil temperature has risen to an OIL TEMP HIGH unacceptable level Increase in load or higher ambient temperature Lamp Warning may cause High Oil Temp code 96 shutdown I O Module Option 239 Indicates the oil temperature sensor output is out of range OOR high OIL TEMP OOR or low Module option Lamp Warning 4 11 FAULT CODE CORRECTIVE ACTION TABLE 4 3 WARNING AND SHUTDOWN CODES CONT 242 AMBIENT TEMP HIGH Lamp Warning 243 AMBIENT TEMP OOR Lamp Warning 244 FUEL LEVEL LOW Lamp Warning 245 FUEL LEVEL OOR Lamp Warning 252 MODULE LOST Lamp Warning Indicates the ambient temperature has exceeded the warning threshold for genset room temperature Increase in load may cause Ambient Temp High code 98 shutdown I O Module Option Indicates the ambient temperature sensor output is out of range OOR high or low I O Module Option Indicates that the fuel has dropped below the low fuel level trip point Allows time to refill before fuel level low code 99 shutdown occurs I O Module Option Indicates the fuel level sen
93. n list for other possible causes 4 8 TABLE 4 3 WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE ACTION ACTION 92 95 AUX I O MODULE INPUT 9 12 Lamp Shutdown The nature of the Aux I O Module fault is an optional customer selection Example inputs Low Fuel Day Tank Water In Fuel Ground Fault etc Each of the fault functions can be programmed using InPower service tool or access to Setup menu as follows Warning Shutdown or Event Default Warning See fault code 234 237 for Warning and code 171 174 for Event Change display name using up to 32 characters Indicates that the engine oil temperature is above normal and has reached the shutdown trip point I O Module option 98 AMBIENT TEMP HIGH Indicates ambient temperature is above normal and has Lamp Shutdown reached the shutdown trip point I O Module option 960IL TEMP HIGH Lamp Shutdown 99 FUEL LEVEL ee Indicates that fuel level has reached the shutdown trip ee Shutdown point I O Module option 102 VOLTAGE BIAS OOR Indicates the voltage bias circuit output is out of range Lamp Shutdown high or low I O Module option 103 SPEED BIAS OOR Indicates the speed bias circuit output is out of range Lamp Shutdown OOR high or low I O Module option Lamp Shutdown Base board is lost 163 170 BASE I O MODULE INPUT 1 8 The nature of the Base I O Module event is an optional Lamp None customer
94. ng describes the function and operation of the Power Command 1301 Control All indicators control buttons and graphical display are located on the face of the control panel as illustrated in Figure 2 2 CONTROL PANEL POWER ON OFF MODES The power on off modes of the control panel and operating software are Power On and Sleep Power On Mode In this mode power is continuously supplied to the control panel The control s operating software and control panel LEDs graphical display will remain active until the Sleep mode 15 activated Sleep Mode In the Sleep mode the control s operating software is inactive and the LEDs and the graphical display on the control panel are all off Sleep mode is a feature used to reduce battery power consumption when the control is not being used and is in either the Off or Auto mode When conditions are met unacknowledged faults and the control is in the 51 SLEEP MODE SELECTION SWITCH m a 1 Jei iar ce a d d 28 Wer ck ee Fi a L LI BASE BOARD Off or Auto mode the Sleep mode is activated after five minutes of keypad in activity To activate the control and view the menu display without starting the generator set press any control button When shipped from the factory Sleep mode is enabled for both modes
95. ng the brightness setting also affects the brightness of the LEDs on the control panel Units Press the or selection buttons to select SAE F PSI or SI C kPa units of measurement to be displayed SCREEN ADJUST MENU ADJUST SCREEN Contrast Brightness Units F PSI es EN DU iii ADJUST SCREEN Brightness Units C kPa EN FIGURE 2 16 SCREEN ADJUST MENU 2 18 FAULT HISTORY MENU Figure 2 18 shows a block representation of the TIME FAULT Fault History menu The first Fault menu is OCCURRED displayed when the 4 button is pressed on the FAULT second Service Menu If there are any active fault FAULT HISTORY CODE At 1755 3 Hrs ue sub menus an Active Fault heading is displayed Fault Number 27 for the most recent active fault All other fault Loss of AC submenus display a Fault History heading Five of FAS voltage sense the most recent faults can be viewed An example of how a fault code is displayed is shown in Figure 2 17 DESCRIPTION LXX Press the buttons next to the and symbols in the graphical display to navigate between menus Press the button to return to the Service Menu FIGURE 2 17 FAULT HISTORY MENU EXAMPLE Information on faults is found in Section 4 2 20 FAULT HISTORY MENU Active Fault Fault 1 ACTIVE FAULT FAULT HISTORY At Hrs At Hrs Fault Numbe
96. ngine service manual mechanically CODE 75 76 CONFIGURABLE INPUT SHUTDOWN Reason The nature of the fault is an optional configurable selection Effect Shutdown POSSIBLE CAUSE CORRECTIVE ACTION If there is no actual fault the Disconnect the signal lead from TB1 and reset the control Check the problem may be an external following two points wiring problem CUST IN1 TB1 14 CUST IN2 TB1 12 If the message drops out the external wiring has a short circuit Grounding of either input activates fault CODE 202 PRE HIGH COOLANT TEMP WARNING 1 Refer to code 1 1 Refer to code 1 POSSIBLE CAUSE CORRECTIVE ACTION 4 23 WARNING Hazards present 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 this manual CODE 203 LOW COOLANT TEMPERATURE WARNING Reason Engine coolant temperature has dropped below the warning threshold for low coolant temperature Effect No action is taken by the control Engine may not start due to slow cranking speed POSSIBLE CAUSE ORRECTIVE ACTION 1 Fault simulation was 1 With PC based service tool verify that the fault simulation is enabled with PC based not enabled for the coolant sensor service If you do no
97. nu a Setup Menus menu is displayed that provides access to the following two categories of genset adjust menus e Genset Service menus Go to page 5 4 e Genset Setup menus This section covers Genset Setup menus only To access the Genset Setup menus 1 Enter the password into the Setup Password Menu Refer to page 5 4 to enter password 2 Press the 2 button in the Setup Menus to display the Genset Setup Password Menu 3 Enter the password into the Genset Setup menu go to page 5 28 or press the View only button 5 27 SETUP Menus SETUP PASSWORD MENU Password xx VIEW SETUP MENUS 1 Genset Service 2 Genset Setup 1 2 GENSET SETUP GENSET SETUP PASSWORD MENU Password FIGURE 5 12 SETUP PASSWORD MENUS Viewing and Adjusting Figure 5 13 is a block representation of the two Genset Setup menus that are available after the correct password has been entered or the View but ton is pressed in the Genset Setup Password menu The Genset Setup menus provide access to the following categories The first Genset Setup Menu provides access to the following menus Genset e Voltage Protection e Current Protection The second Genset Setup Menu provides access to the following menu e Engine Protection Genset Setup Password Menu Adjusting the Genset Setup menus is restricted to service personnel and a password must be entered to modify these menus Once the Gense
98. nu in Section 3 which describes how to view fault codes 4 2 TROUBLESHOOTING PROCEDURE The following tables are a guide to help you evaluate problems with the generator set You can save time if you read through the manual ahead of time and understand the system Try to think through the problem Go over what was done during the last service call The problem could be as simple as a loose wire an opened fuse or a tripped circuit breaker NOTE Each fault code warning can be changed to shutdown using InPower Default settings are used in this manual It is recommended that all changes to settings be recorded at each site to aid the troubleshooting of the genset This section contains the following information e Table 4 1 and 4 2 Describes how to trouble shoot a local remote fail to crank problem when control panel does indicate fault condition e Table 4 3 Describes how to troubleshoot engine problems that are not within the detectable range of the PCC control Table4 4 Describes each status warning and shutdown code warning and shutdown limits where applicable and basic corrective actions such as checking fluid levels control reset functions battery connections etc Fault Code Tables Provide detailed trouble shooting procedures In the following tables the fault codes are used as the table reference number and arranged in numeric order Figure 4 1 shows the loca
99. o 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 disconnect charger before disconnecting battery cables Disconnect negative cable first and reconnect last N 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 shutdown make certain the generator set cannot be accidentally restarted as follows Press the button to switch to the Off mode Turnoff or remove AC power from the battery charger Remove the negative battery cable from the generator set starting battery READING FAULT CODES When fault occurs the graphical display will display the fault code message After the fault is acknowledged and corrected the recorded fault will be deleted from the control panel memory but will remain in a data log to maintain a fault code history The InPower service tool is required to view this data log Refer to Fault History Me
100. o the A and V symbols in the graphical display The Operator menus can be used to select Auto or Manual Run modes Appendix provides a block diagram that illustrates the sequence of how the Operator Menus are displayed Engine Status Menu This menu displays the engine starting battery volt age engine coolant temperature engine oil pres sure and hours of engine operation Oil pressure only available on some models Alternator Status Menu This menu displays genset power kVA frequency and engine speed RPM applications with out current transformers the kVA is not shown Alternator Line to Line Voltage Menu This menu displays L1 L2 L2 L3 and L2 L1 line to line voltages for three phase applications only Alternator Line to Neutral Voltage Menu This menu displays line to neutral voltages for L1 L2 and L3 for three phase wye configurations only In delta configurations this menu is not shown Alternator Single Phase Voltage Menu This menu displays L1 N L2 N and L1 L2 voltages for single phase applications only Alternator Amperage Menu This menu displays L1 L2 and L3 amperage In applications without current transformers this menu is not shown 2 10 OPERATOR MENUS Text Version Battery 4VDC Eng Temp F Oll Press PSI Eng Hours h Power kVA Freq HH H Hz Speed RPM THREE PHASE ONLY SINGLE PHASE L1 N 8S L2 N
101. or and connect coolant temperature sensor simulator to the harness If the control responds to the simulator replace the sensor If control does not respond go to next step The harness or Base board could be Measure the resistance of the coolant sensor and bad reconnect harness to sensor Remove connector P11 from Base board and check resistance between pins P11 18 H20 and P11 6 H20 COM If resistance is not the same harness is bad If resistance is the same Base board is bad 4 13 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 2 215 LOW OIL OR PRE LOW PRESSURE WARNING SHUTDOWN OIL PRESSURE SENSOR TYPE SENDER Reason Engine oil pressure has dropped below the warning shutdown threshold for low high oil pressure Effect Calibration dependent No action is taken by the Control for code 215 Engine will shut down for code 2 POSSIBLE FAULT CORRECTIVE ACTION 1 Fault simulation was enabled with 1 With a PC based service tool verify that the fault a PC based service tool simulation is not enabled for the oil pressure sensor If you do not have PC based service tool remove battery power from the control to disable
102. oss of AC voltage sense SAVE FIGURE 5 10 ANNUNCIATOR SUBMENUS SHEET 2 OF 2 5 23 Modbus Submenus The Modbus submenus are available by pressing the 5 button on the second Genset Service menu see Figure 5 3 Modbus Enable Menu The Modbus Enable menu allows for enabling or disabling the Modbus feature If set to Yes the Modbus Setup menu is made available 5 24 Modbus Setup Menu The Modbus Setup menu allows for setting a numeric address and a baud rate The parity value is automatically displayed e Address Enter a numerical value up to three digits for the address e Baud Rate Select one of the four available baud rates 2400 4800 9600 or 19200 Parity This value is automatically displayed MODBUS SUBMENUS MODBUS ENABLE Modbus Enable No ADJUST MODBUS ENABLE Modbus Enable MODBUS SETUP Address BH Baud Rate Parity DJUST MODBUS SETUP Address DII Baud Rate HGH Parity FIGURE 11 MODBUS SUBMENUS 5 25 GENSET SETUP SUBMENUS In the following menu entry descriptions the default parameter value is not shown because the default value is subject to change by model Always create and refer to the initial capture file for factory default settings of system parameters values The first Setup Password menu is displayed when the 1 button is pressed on the Service Menu From the Setup Password me
103. quire or not require entering the mode change access code If enabled access code must be entered to change genset mode of operation Auto Manual Run or Off Symbols A display can be set up to display international symbols the Operator menus GENSET SERVICE SUBMENUS Continued RETURN TO PAGE 5 9 ELECT GOVERNOR Gov Enable No ADJUST IF AVR IS NOT ENABLED OR IF AVR 15 ENABLED ELECT GOVERNOR Gov Enabl GENSET NUMBER Enable RA Model No SAVE T GOVERNOR Serlal Mo PAGE 5 13 SETUP MENUS ADJUST 5 15 DISPLAY SETUP GENSET NUMBER Connection Model Local Access Code Mo Serla No SSHRBEHESSEHH Symbols DISPLAY SETUP Connection Access Code No Symbols No SAVE gt FIGURE 5 4 GENSET SERVICE SUBMENUS SHEET 3 OF 3 5 11 AUTOMATIC VOLTAGE REGULATOR SUBMENUS The Automatic Voltage Regulator AVR sub menus are available only if the AVR is enabled see page5 9 Two Automatic Voltage Regulator AVR submenus see Figure 5 6 can be used to adjust Volts Hz Roll off and Regulator Gains settings Volts Hz Roll off Menu The Volts Hz Roll off function helps optimize the gensets response to added load If the engine speed drops below nominal frequency the control automatically drops the voltage until the engine spee
104. r Fault Number Fault 2 FAULT HISTORY At Hrs Fault Number XXXXX Oldest Fault Maximum of 5 FAULT HISTORY At E Hrs Fault Number FIGURE 2 18 FAULT HISTORY MENU 2 21 3 Circuit Board GENERAL WARNING HAZARDOUS VOLTAGE Touching uninsulated parts inside the control box can result in severe personal injury or death Measurements and adjustments must be done with care to avoid touching hazardous voltage parts Stand on a dry wooden platform or rubber insulating mat make sure your clothing and shoes are dry remove jewelry and use tools with insulated handles ro TERM INA S TR 4 9 am am uw dg 159 RELAY MODULE This section describes the function of the Power Command 41301 Control PCC Base board is contained in the control box Figure 3 1 The block diagram in Figure 3 2 shows the external connections of the PCC system The system schematics are provided in Section 8 of this manual WARNING Electrostatic discharge will damage circuit boards Always wear grounding wrist strap when touching or handling circuit boards GOVERNOR CARD BASE BOARD 40 _ HOIVn LOV amoo 8 5 SAV HH SH3U0N3Ss HAWOLSND AYNLOALIHOYV
105. r isolation mounts 4 Raise the generator end approximately one inch 12 mm and securely block the engine under the flywheel housing Lower the generator slightly so that the blocks carry most of the weight o Remove the bolts securing the generator drive discs to the flywheel 6 Loosen all the bolts securing the generator adapter casting to the flywheel housing Adjust the hoist to carry the full weight of the generator remove the bolts and pull the generator away Never withdraw the generator leaving the rotor to hang by the drive discs The weight of the rotor will damage the drive discs rear screen plastic NDE casting with bearing housing AVR cover AS480 AVR NDE bearing o ring terminal block exciter stator frame main stator standard terminal box 25 standard terminal box lid 6 11 With drawing Rotor From The Generator 1 Remove the generator adaptor casting on the drive disc end and the end plate on the bearing end Using a hoist of sufficient capacity cinch a lifting strap on the drive end of the rotor Lift the bearing end of the rotor by a Eye Bolt and push it towards the drive end of the generator until half the width of the rotor core protrudes from stator Release the weight of the rotor and recinch the lifting strap around the middle of the rotor core Withdraw the rotor until it is free of the stator guiding it by hand on both ends to prevent con
106. r if normal battery charging voltage is not obtained Check battery charge voltage float level if applicable raise float level Indicates battery voltage supply to the control is approaching a high level at which damage to the control can occur Check float level on battery charger if applicable lower float level Check battery wiring calibration Indicates engine oil pressure has dropped below the warning trip point If generator is powering critical loads and cannot be shut down wait until next shutdown period and then follow code 2 procedure This warning will only occur if genset is equipped with an oil pressure sender Indicates that one or more of the phase currents has exceeded high ac warning threshold for time delay seconds Check load and load lead connections 4 10 TABLE 4 3 WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE CODE 217 Indicates that the control has sensed that the engine oil pressure OIL PRESS SENSOR sensor output is out of range high low Check Lamp Warning sender connectors wires This warning will only occur if genset is equipped with an oil pressure sender 218 Indicates that the control is in Battle Short mode used to bypass BATTLE SHORT ACTIVE several fault shutdowns for genset operation during emergencies Lamp Warning 219 Indicates the battery charging alternator has not reached an acceptable CHARGER FAILURE voltage range within the selected period d
107. rate at which the value of the Governor Duty Cycle is ramped up by during the Crank State after expiration of the Initial Crank Fueling Period This value can be set from 5 to 100 e Max DC The Maximum Crank Fuel Duty Cycle is the maximum level to which the Governor Duty Cycle should be limited to during a crank state This value can be set from 50to 100 Electronic Governor Regulator Menu The Electronic Governor Regulator menu allows for setting proportional Gain Integral Gain and Damping values e Gain The proportional governor gain K1 multiplier can be set from 5 to 1000 This allows for a scale factor of 0 05 to 10 0 5 14 Int The integral governor gain multiplier can be set from 5 to 1000 D The governor Damping adjustment can beset from 95 to 105 K2 Electronic Governor Menu Electronic Governor menu allows for setting Crank Exit Fuel DC Dither Factor and Damping values This menu is displayed only if the governor has been enabled with the Engine Electronic Governor Enable menu e Crank Exit Fuel DC The Crank Exit Fuel Duty Cycle is the value at which the governor duty cycle is held after disengaging the starter until the governor is enabled This value can be set from 0 to 100 e Dither Factor Dither is a signal that is super imposed on the PWM pulse width modulation duty cycle to prevent the actuator valve from sticking The Dither Factor is the dither percent added to the cur
108. rent duty cycle The Dither Factor can be set from 0 to 30 The dither function is disabled when the dither factor is set to 0 Ramp Time This feature is used to set the minimum governor speed reference ramp rate The governor Ramp Time can be set from 0 00 to 30 0 seconds in 0 01 second increments Electronic Governor Enable Speed Menu The Electronic Governor Enable Speed menu allows for setting the minimum and maximum governor duty cycle e Min Gov DC The Minimum Governor Duty Cycle can be set from 0 to 100 e Max Gov DC The Maximum Governor Duty Cycle with dithered value can be set from Oto 100 RETURN 5 9 ELECTRONIC GOVERNOR SUBMENUS b NOTE These menus are only available if the governor is enabled see page 5 9 GOV CRANK FUEL Initial DC Initial Time s Ramp Rate DC ADJUST GOV CRANK FUEL ELECT GOVERNOR Initial DC 1 Time 5 Int Ramp Rate ELECT GOVERNOR ELECT GOVERNOR Crank Fuel Int Dither Factor D Ramp Time 4 ADJUST ELECT GOVERNOR ELECT GOVERNOR Enable Speed Crank RPM Fuel 1 Min Gov 96 Dither Factor Max Gov 95 Ramp Time ADJUST ELECT GOVERNOR Enable Speed RPM Min Gov DC Max Gov DC 3 SAVE
109. replace as necessary be bad 2 he sensor could 2 Disconnect the sensor and plug in a resistive sensor simulator to be bad isolate the fault If the control responds to the simulator replace the sensor If control does not respond go to next step 3 harness or 3a Remove connector P11 from Base board and disconnect sensor Base board could Check pins P11 18 H20 and P11 6 H20 COM for short circuit as be bad follows Check for a short circuit to the engine block ground more than 200k ohms OK e Check for a short circuit from pin to pin more than 200k ohms Repair or replace as necessary 3b Measure the resistance of the coolant sensor and reconnect harness to sensor Remove connector P11 from Base board and check resistance between pins P11 18 H20 and P11 6 H20 COM e lf resistance is not the same harness is bad resistance is the same Base board is bad 4 25 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 213 LOW BATTERY WARNING Reason Low voltage has been detected for battery Effect The control s voltage supply approaching level at which unpredictable operation may occur POSSIBLE C
110. roduction ABOUT THIS MANUAL This manual provides troubleshooting and repair information regarding the PowerCommand 1301Control PCC and generators for the generator sets gensets listed on the front cover Engine service instructions are in the applicable engine service manual Operating and maintenance instructions are in the applicable Operator s Manual This manual does not have instructions for servicing printed circuit board assemblies After determining that a printed circuit board assembly is faulty replace it do not repair it Attempts to repair a printed circuit board can lead to costly damage to the equipment This manual contains basic generic wiring diagrams and schematics that are included to help in troubleshooting Service personnel must use the actual wiring diagram and schematic shipped with each unit The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit Read Important Safety Instructions and carefully observe all instructions and precautions in this manual SYSTEM OVERVIEW The PCC is a microprocessor based control for Cummins Power Generation generator sets All generator set control functions contained on one circuit board Base board The Base board provides fuel control main alternator voltage output regulation and complete generator set control and monitoring The operating software provides control of the gener
111. rrupt the serial plate information Re enter calibration file if calibration necessary 6 The menu display manual Run Check for continuity between P11 4 RUN to P11 8 GND button harness or the Base If no continuity when pressing the manual Run button board is bad isolate to front membrane panel and wiring If there is continuity the Base board is bad 7 Oil Pressure switch or wiring is Remove P11 connection and check wiring between P11 6 defective and P11 7 to the switch Verify control is configured for the type of switch installed Verify proper operation of the switch 8 Oil Pressure sender setup Remove P11 connection and check wiring between 11 6 wiring is defective P11 17 and P11 5 for 3 wire sender to the sender Verify control is configured for the type of sender Verify operation of the sender 4 5 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 TABLE 4 2 ENGINE DOES NOT CRANK IN REMOTE MODE NO FAULT MESSAGE Reason This indicates that the 1301 series control has not received or recognized a remote start signal Effect Engine will not start in remote mode but starts in manual mode POSSIBLE CAUSE CORRECT
112. rs drawn into the intake air passage Reset control and restart after locating and correcting problem 38 Indicates that the Field AVR Duty Cycle has been at the maximum for at FIELD OVERLOAD least 15 seconds Lamp Shutdown 45 Indicates that no magnetic pickup pulses are sensed for a Loss of Speed SPEED SIGNAL LOST delay If a magnetic pickup is not installed then speed sensing is performed Lamp Shutdown by monitoring AC line frequency this fault cannot occur 4 7 TABLE 4 3 WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE ACTION 46 Indicates that an individual phase of alternator output current has exceeded HIGH AC CURRENT high current threshold of the rated output current continuously for more Lamp Shutdown than time delay seconds Check load and load lead connections 61 Indicates remote Emergency Stop To reset the remote Emergency Stop EMERGENCY STOP button Lamp Shutdown 1 Open disable remote emergency stop button 2 Move the rocker switch to the OFF position or press the OFF button 3 Select the desired operating mode manual or remote 71 Indicates that measured speed and measured AC output frequency do SPEED HZ MATCH agree Lamp Shutdown Check genset setup for number of flywheel teeth 72 The genset has failed to sense rotation for two start attempts Indicates FAIL TO CRANK possible fault with control speed sensing or starting system Can only Lamp Shutdown occur in gensets wit
113. s used to enable or disable the automatic voltage regulator If enabled two additional menus are displayed that can be used to adjust the AVR settings see page 5 13 GENSET SERVICE SUBMENUS Continued RETURN TO PAGE 5 CYCLE CRANK Crank Sec Rest Sec Attempts 8 ADJUST CYCLE CRANK Crank Rest Sec Attempts cave AVA Setup AVR Enable Yes ADJUST Setup AVR Enable SAVET 1 GOTO AVR CONTINUED SETUP MENUS ON PAGE 5 11 m ON PAGE 5 13 FIGURE 5 4 GENSET SERVICE SUBMENUS SHEET 2 OF 3 5 9 Electronic Governor Menu The engine Electronic Governor Enable menu is used to enable or disable the electronic governor on gensets with electronic governors and magnetic pickup sensors If enabled set to Yes four additional menus are displayed that can be used to ad just governor settings see page 5 15 Genset Number Menu The Genset Number menu is used to enter the gensets model and serial numbers Each allows up to 16 characters to be entered Display Setup Menu The Display Setup menu is the Auto Off Manual Run switch functions on the used to set display for gt Local 5 10 operator panel are turned on or Remote Auto Off Manual Run switch functions on the operator panel are turned off Connection A display can be set up to be local or remote Access Code A display can be set up to re
114. sed to set the temperature value necessary to activate a Low Coolant Temperature Warning fault condition This value can be set from32 to 100 degrees F The battery charger menu is used to determine when the alternator charger failure condition exists and when the warning message should be 5 44 announced The fault condition exists when either the low or high threshold is reached Charger Failed Threshold This threshold is used to set the high charging alternator voltage value This value can be set from13 0 to 20 0 VDC for 12V units and from 25 0to 40 0 VDC for 24V units Charger Failed L Threshold This threshold is used to set the low charging alternator voltage value This value can be set from 2 0 to 13 0 VDC for 12V units and from 2 0 to 25 0VDC for 24V units e Charger Failed Time Delay A time delay of2 to 300 seconds must expire before the warming message is announced If the fault condition is active for the duration of this time delay the Charger Failure warning message fault code 219 is announced ENGINE PROTECTION SUBMENUS Continued RETURN TO PAGE 5 43 ENG PROTECTION LCT Warnin Threshold F Charger Failed H Threshold AWUSTH a ENG PROTECTION ENG PROTECTION Warning Charger Failed L Threshold Threshold v Charger Failed H Charger Falled Threshold Time Delay 5 SAVE gt I DS gt PROTECTION Charger Falled L
115. service tool e Verify number of flywheel teeth has been correctly configured see Section 7 11 1 If they do match multiply the frequency by 30 and compare this number to the RPM on the operator panel or PC based service tool If these are not the same the MPU sender may be bad Replace the MPU sender If the Multimeter and control frequencies do not match there is a frequency sensing problem within the Base board Replace Base board 4 17 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 46 216 HIGH AC CURRENT SHUTDOWN WARNING Reason This indicates that the indicated generator output current has exceeded 110 of rated Effect No action is taken by the control for code 216 Engine will shut down for code 46 POSSIBLE FAULT CORRECTIVE ACTION 1 Fault threshold are not set 1 Reset the threshold to the desired or correct setting correctly with PC based Determine the required operating range before service tool adjusting the threshold 2 Short or Overload 2 Check the load and load cables Repair if necessary Check operation by disconnection load and restarting generator set 3 Incorrect CTs CT 3 Check CTs CT connections
116. sor output is out of range high or low I O Module Option Indicates an intermittent data link between the I O module and the Base board 4 12 WARNING Hazards present troubleshooting can cause equipment damage severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform service procedures Read Safety Precautions page and observe all instructions and precautions in this manual CODE 1 202 HIGH OR PRE HIGH COOLANT TEMPERATURE SHUTDOWN SHUTDOWN Reason Engine coolant temperature has exceeded the warning threshold for pre high high coolant temperature Effect Calibration dependent No action is taken by the Control for code 202 Engine will shut down for code 1 POSSIBLE CAUSE CORRECTIVE ACTION 1 Fault simulation was enabled with a 1 With a PC based service tool verify that the fault PC based service tool simulation is not enabled for the coolant sensor If you do not have a PC based service tool remove battery power from the control to disable fault simulation overrides Engine or sensor circuitry problem 4 Check the sensor accuracy with a thermocouple or similar temperature probe If the coolant temperature reading is accurate the engine may be overheating Refer to the engine service manual If the coolant temperature reading is not accurate go to next step The sensor could be bad Disconnect the sens
117. stance Disconnect the exciter stator leads X and XX from their connectors in AC harness and isolate them from ground Using an ohmmeter measure resistance between either lead and the stator laminations Re place the stator if insulation resistance is less than 1megohm 1 000 000 ohms MEASURE WINDING INSULATION RESISTANCE BETWEEN EITHER LEAD AND THE STATOR LAMINATIONS Flashing the Field Self Excited Generators Only If necessary flash the exciter field before or after installation Apply 110 to 220 VAC for one to two seconds to the X and XX leads of the exciter stator The generator must be shut down the Baseboard disconnected a diode used to establish correct polarity and a 3 amp fuse to prevent over excitation See the diagram Alternatively while the set is running and disconnected from all loads apply a 12 VDC battery for one to two seconds as shown in the diagram Polarity must be correct to X to XX MEASURE WINDING RESISTANCE BETWEEN THE TWO STATOR LEADS X AND XX FLASHING THE FIELD SELF EXCITED GENERATORS ONLY APPLY 110 TO 220 VAC TO THE EXCITER STATOR FOR 1 TO 2 SECONDS WITH THE BASE BOARD DISCONNECTED AND THE SET NOT RUNNING X DIODE FUSE 110 to 220 Ve STATOR 4 EXCITER DIODE 12 VDC BATTERY ALTERNATIVELY APPLY 12 VDC FROM A BATTERY THE EXCITER STATOR FOR 1 2 SECONDS WITH THE AVR CONNECTED AND THE SET RUNNING WITHOUT LOAD x
118. t disconnect battery charger from its source then disconnect starting batteries negative cable first This will prevent accidental starting sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans drive belts etc e 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 f adjustment must be made while the unit is running use extreme caution around hot manifolds moving parts etc DO NOT OPERATE IN ANDEXPLOSIVE 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 FLAMMABLE ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Remove electric power before removing protective shields touching electrical equipment Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electr
119. t Setup button 2 is selected on the Setup Menus menu see Figure 5 12 the Genset Setup Password menu is displayed When the Genset Setup Password menu is displayed the first numeric character 0 is highlighted see Figure 5 13 NOTE When selected highlighted each character initially turns to 0 and the remaining characters turn to X NOTE Make sure that each numeric character is correct before you move to next character If a wrong character is entered you will not be able to go back and correct it If the wrong password is entered you will be able to view the Genset Setup menus but you won t be able to change them To enter the Genset Setup password 1209 1 With the first character highlighted press the button below to the or symbols until the value reads 1 5 28 2 Press arrow selection button gt to move to the next numeric character 3 Press the button below the or symbols until the value reads 2 4 Press the arrow selection button gt to move to the next numeric character 5 Press the button below the or symbols until the value reads 0 6 Press the arrow selection button to move to the next numeric character 7 Press the button below or symbols until the value reads 79 8 After you have completed entering the password press the arrow selection button The first main Setup menu is displayed After the correct password is entered it will be
120. t by the PCC 1301 to the annunciator to turn the relay on or off Only one event per relay is allowed The four annunciator outputs of the PCC 1301 are configurable to display common warning alarms The four Annunciator Output Map menus allow for entering a fault number and fault name to be displayed for the configurable outputs e Number Enter a code number 0 to 255 for the event Refer to Table 5 3 which provides a list of all warning and shutdown codes The following list contains event codes that are not shown in Table 5 3 Description brief description of the event is automatically displayed 5 22 EVENT CODES READY TO LOAD UTILITY CONNECTIONS GENSET CONNECTED NOT IN AUTO COMMON ALARM COMMON WARNING COMMON SHUTDOWN CUSTOMER FAULT INPUT 1 CUSTOMER FAULT INPUT 2 ANNUNCIATOR FAULT 1 ANNUNCIATOR FAULT 2 ANNUNCIATOR FAULT 3 ANNUNCIATOR OUTPUT 1 MAP Fault Number 29 Loss of AC voltage sense a ANNUNCIATOR ANNUNCIATOR OUTPUT 1 MAP OUTPUT 2 MAP Fault Number Fault Number 29 Loss of AC Loss of AC voltage sense voltage sense SAVE T ADJUST ANNUNCIATOR ANNUNCIATOR OUTPUT2M OUTPUT 3 MAP Fault Number Fault Number 29 Loss of AC Loss of AC voltage sense voltage sense SAVE E ADJUST ANNUNCIATOR OUTPUT 4 MAP OUTPUT MAP Fault Number 29 ioe o opar E voltage sense voltage sense ADJUST SAVE ANNUNCIATOR OUTPUT 4 MAP Fault Number L
121. t have a based service tool remove battery power from the control to disable fault simulation overrides 2 Fault threshold is not set 2 Reset the threshold to the lowest allowable setting Determine correctly with a PC based the required operating range before adjusting the threshold service tool 3 The engine coolant heater 3 Coolant heater not operating due to could be bad Radiant e Coolant heater not connected to power Check for blown fuse heat should be felt with or disconnected heater cord and correct as required hand held close to outlet Low coolant level Look for possible coolant leakage points hose and repair as required e Defective heater element thermostat With coolant heater removed from engine and power disconnected flush with cold tap water for two minutes to close internal heater thermostat opens at 100 F and closes at 80F Check resistance across input power leads a Open replace coolant heater b Closed coolant heater OK coil resistance of 10 to 60 ohms 4 Inspect the sensor and engine harness connector pins Repair could be bad or replace as necessary 5 The sensor could be bad 5 Disconnect the sensor and plug in a resistive sensor simulator to isolate the fault If the control responds to the simulator replace the sensor control does not respond harness or Base board are bad 6 The harness or Base Measure the resistance of the coolant temperature sensor and board coul
122. tact with the stator windings 3 Rest the rotor in a cradle solidly supporting it on two pole faces not on the drive discs blower or exciter 4 Remove the retaining clip if the rotor shaft bearing is to be removed GENERATOR REASSEMBLY Reassembling is the reverse of disassembling Note the following The Assembly Torques are specified in the succeeding page Main rotor dismantling procedure Position of alternator Y after main rotor dismantling Main rotor dismantling 6 12 Generator Assembly Tools and Torque Values Part Description Earth lead to NDE bracket EBG Str Hsg to NDE bracket EBG Str to EBG Str Hsg Excitor stator to NDE bracket Stator Lead to terminal studs Diode fitting Small Terminal box to NDE bracket Rtr to shaft Coupling disc to flywheel DE Adaptor to Flywheel housing Clamping spacer to rectifier hub Rectifier hub to excitor rotor Rotor leads to Clamping spacer EBG Housing cover to housing Terminal block to NDE bracket Varistor to rectifier hub AVR cover to NDE bracket AVR to NDE bracket Axial air inlet cover to NDE bracket DE Air outlet cover Fan to fan hub 290 and 344 Radial Inlet cover to bracket Terminal box lid to terminal box Coupling disc to shaft DE Adaptor to frame blocks NDE bracket to Frame blocks 10mm socket head box screw driver or 10mm Socket 11mm socket head box screw driver Crimping Tool 150mm long x 8mm socket or 8m
123. the 4 button to view the previous main menu NOTE In the Screen Adjust menu settings are not saved when the 4 button is pressed The button lt is also used to acknowledge warning and shutdown messages after the fault has been corrected Pressing this button clears the fault from the front panel display and the previous menu is redisplayed NOTE Pressing the A or button also clears the fault from the front panel display SERVICE MENU 1 Setup Menus 2 History About 3 Screen Adjust More Optlons malar HISTORY HAERERE Starts Hours Control Hours ABOUT GENSET Model Number NONE GE Control 1301 PREVIOUS MAIN MENU BUTTON FIGURE 2 3 PREVIOUS MAIN MENU AND OFF BUTTONS 2 4 Off Button Press the button to switch to the Off mode The Off mode will disable the control Auto or Manual modes the OJ button is pressed during generator set Operation manual or remote start the engine will immediately shut down If possible hot shutdown under load should be avoided to help prolong the reliability of the generator set The Q button is also used to acknowledge warning and shutdown messages after the fault has been corrected Pressing this button clears the fault from the front panel and resets the control Not in Auto Indicator This red lamp is lit when the control is not in the Auto mode Shutdown Status Indicator This red lamp is lit when the control d
124. tion of the components within the control panel that are referenced in the following troubleshooting procedures Connector locations for the Base board are provided in Section3 The control wiring and circuit board connections are shown in Section 8 N CAUTION Always make sure that the PCC is in the OFF mode before disconnecting or connecting harness connectors Otherwise disconnecting the harness connectors can result in voltage spikes high enough to damage the DC control circuits of the set CAUTION Electrostatic discharge will damage circuit boards Always wear a wrist strap when handling circuit boards or when disconnecting Or connecting harness connectors See Circuit Board Removal Replacement in Section Voltage Continuity Testing Voltage and continuity tests are required in the following tables In some cases it is necessary to re move a plug to complete the test The following corrective actions will mention when it is necessary to remove a plug for testing In other cases the plug must not be removed for testing When plug removal is not mentioned testing must be performed by inserting a narrow meter probe into the back of the plug 4 3 RELAYS MOUNTED ON STARTER CONTROL T26 CONTROL SWITCHED B LIE iia BACK OF CONTROL FUEL CONTROL a RELAY K12 K5 SWITCHED B Fi 1 K10 K11 OPTIONAL RUN RELAYS SE EN
125. u This menu is used to determine when a low AC volt age fault condition exists and for how long the fault condition should be present before the engine is shut down e Low AC Voltage Threshold This threshold is used to set the percentage of desired voltage necessary to activate a Low AC Voltage fault condition This value can be set from 50 to 9590 Low AC Voltage Time Delay time delay of2 to 20 seconds must expire before the engine shuts down because of a low AC voltage fault condition If fault condition is active for the duration of this time delay the engine shuts down and the 5 36 Low AC Voltage shut down message fault code 13 is announced Over frequency Menu This menu is used to determine when an over frequency fault condition exists and for how long the fault condition should be present before the engine is shut down e Over frequency Threshold This threshold is used to set the amount of Hertz that the alternator line frequency can be over to activate an Over frequency fault condition This value can be set from 2 to 10 Hz e Over frequency Delay A time delay of 100 to2000 half cycles must expire before the engine shuts down because of an over frequency fault condition If the fault condition is active for the duration of this time delay the engine shuts down and the Over frequency shutdown message fault code 14 is announced Under frequency Menu This menu is used to determine when an under
126. unning unless tanks are outside the engine compartment Fuel contact with hot engine or exhaust is a potential fire hazard e DO NOT permit any flame cigarette pilot light spark arcing equipment or other ignition source near the generator set or fuel tank e 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 e Be sure all fuel supplies have a positive shutoff valve e 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 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 e Before starting work on the generator se
127. uns e Start The genset start time delay can adjusted from 0 to 300 seconds Stop The genset stop time delay can be adjusted from 0 to 600 seconds GENSET Volts Hertz Wit No of Phases Phase Delta ADJUST GENSET GENSET Volts AC Charglng Alt Hertz of Phases Enable Yes Phase Delta SAVE GENSET Fuel System Charging Alt Diesel Enable Glow Plug Enable WHEN FUEL SYSTEM IS Fuel System START STOP DELAY GLOW PLUG ENABLE Start Sec SUBJECT IS DISPLAYED Fuel Burn Delay Stop Sec WHEN FUEL SYSTEM IS sec SET TO GAS THE FUEL ADJUST ADJUST ill BURN DELAY SUBJECT IS DISPLAYED START STOP DELAY Start CONTINUED ON stop Sec PAGE 5 9 SAVE E FIGURE 5 4 GENSET SERVICE SUBMENUS SHEET 1 OF 3 5 7 Cycle Crank Menu The Cycle Crank menu allows for configuring the generator for all starting modes manual and remote as follows e Crank The cranking period can be set from 3 to 30 seconds This time limit is used to determine a Fail to Start status e Rest The minimum amount of time between crank attempts can be set from 0 to 60 seconds e Attempts The maximum number of times the starter can be engaged when attempting to start the engine with cycle cranking can be set from 1 to 7 attempts AVR Setup Menu The AVR Setup menu i
128. uring genset installation it was suggested that a capture file be made before and after changes were made to the genset operating parameters After replacing the Base board use the capture file as a template to write the previous settings to the new Base board software Refer to INPOWER User s Guide for specifics Circuit Board Removal Safety Precautions Turn off or remove AC power from the battery charger and then remove the negative battery cable from the set starting battery This is to make sure that the set will not start while working on it and to avoid circuit board damage caused by voltage spikes when removing and replacing circuit board connectors To prevent circuit board damage due to electrostatic discharge ESD a grounding wrist strap must be worn when handling circuit boards or socket mounted IC s The wrist strap does not provide a direct short to ground but is typically rated at approximately 1 mega ohm to ground Attach the clip to the chassis ground screw in the control box and place the strap around your wrist before handling a circuit board CAUTION Electrostatic discharge will damage circuit boards Always wear a grounding wrist strap when handling circuit boards or socket mounted IC s 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

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