PS0500 Manual

Safety Precautions SAVE THESE INSTRUCTIONS This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries. Before operating the generator set (genset), read the Operators 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

DANGER This symbol warns of immediate hazards which will result in severe personal injury or death. WARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

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

FUEL AND FUMES ARE FLAMMABLE Fire, explosion, and personal injury or death can result from improper practices.

DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard.

DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank.

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

Be sure all fuel supplies have a positive shutoff valve. Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

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

Be sure the unit is well ventilated. Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away from moving parts. Before starting work on the generator set, disconnect battery charger from its

AC source, then disconnect starting batteries, negative () cable first. This will prevent accidental starting. Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

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

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical 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 DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.

MEDIUM VOLTAGE GENERATOR SETS (601V to 15kV)

Medium voltage acts differently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death. Do not work on energized equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized personnel so that the equipment can be deenergized and safely grounded. GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. To prevent severe scalding,

let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been relieved. Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil.

Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10). Make sure that rags or combustible material are not left on or near the generator set. Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under or near the unit. Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard. Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases.

Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the

generator set. A fire or explosion could result. Wear hearing protection when 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

DISPOSE OF THIS UNIT PROPERLY

1. System Overview

Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual. Keep this manual with the other genset and/or controller manuals.

ABOUT THIS MANUAL

You should have a basic understanding of generators and power generation before you read this manual.

This is the Operator Manual for the PowerStart 0500 control. It is not the Operator Manual for the generator set (genset) or any accessories.

DESCRIPTION

The PowerStart 0500 is suitable for non-paralleling generator sets (gensets) in standby or Prime power applications.

The PowerStart 0500 control is shown below.

The PS0500 is a microprocessor-based controller that has these abilities.

Start and stop the genset. Monitor the status of the genset. Warn the operator when unsafe conditions

are occurring Shut down the genset to prevent damage Adjust settings that affect genset behavior. Provide a way for other devices to remotely

start / Stop the genset

Note: other devices that can remotely start / Stop the genset might be as simple as a switch or a push button or as sophisticated as other controllers or computers. This manual introduces the ways the Control can interact with other devices, but this manual cannot identify all of the devices that might be used in every application.

ALTERNATOR CONNECTIONS

This section introduces the connections between the PS0500 and the alternator.

Main Alternator Output

The PS0500 is connected to the main alternator output to measure genset voltage and genset frequency.

The PS0500 is also connected to current transformers (CTs) which reduce the genset current by a known ratio for measuring main alternator output current.

Battery-charging Alternator

The PS0500 may be connected to the battery-charging alternator to make sure the battery-charging alternator is recharging the battery properly.

ENGINE CONNECTIONS

This section introduces the connections between the PS0500 and the engine.

Battery Connections

The battery provides power for the PS0500 and the PS0500 monitors the battery voltage.

Starter The PS0500 is connected to the starter control relay in order to control the starter.

See Sequences of Operation for more information about the behavior of this output.

Fuel Shutoff (FSO) Relay The PS0500 is connected to the fuel shutoff control (FSO) in order to control the fuel shutoff solenoid in the fuel supply line.

See Sequences of Operation for more information about the behavior of this output.

GENSET CONNECTIONS

This section introduces the connections between

the PS0500 and other parts of the genset. Some of these connections are flexible and might be made to many types of devices.

Customer Input

The PS0500 has one customer input that can be configured to invoke a shutdown or Warning response

Battery Charger Failed Switch

The PS0500s Customer Input may be connected to a battery chargers status output (discrete) to monitor the battery charger operation.

Emergency Stop Buttons

The PS0500 may be connected to a push button that shuts the genset down immediately when pressed.

FIGURE 1-2. EMERGENCY STOP BUTTON (EXAMPLE)

Customer Output

The PS0500 has one customer output that can be configured to become active when either a shutdown or Warning fault occurs.

PC-based Service Tools

The PS0500 or the Operator Panel may be connected to a PC-based service tool, such as InPower.

Note: See the PC-based service tool documentation for more information.

The PC-based service tool harness (Figure 1-7) is used to connect the PS0500 to a PC-based service tool.

FIGURE 1-7. PC-BASED SERVICE TOOL HARNESS

Ready to Load

The PS0500 may notify a device when event 1465 (Ready to Load) is active. Typically, the device is a programmable logic controller

Remote Start

The PS0500 may be connected to a device that can generate a remote start signal. Typically, the device is a transfer switch.

CERTIFICATIONS

The PS0500 meets or exceeds the requirements of the following codes and standards.

UL 508 CSA C282 compliant 22.2 compliant NFPA 99 compliant MS 202C, Method 101 compliant IEEE C62.41 compliant IEEE C37.90 compliant BS ISO 85284:2005 BS EN 500811:1992 BS EN 6100062:2001 BS EN 6100063:2001 BS EN 6100064:2001

CE Marking: The control system is suitable for use on generator sets to be CE marked.

2. Control Operation

In this section, italics are used to identify a specific parameter by name.

SAFETY CONSIDERATIONS

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

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

The PS0500 cabinet must be opened only by technically qualified personnel.

WARNING The PS0500 cabinet must be opened only by qualified personnel. High-level voltages (up to 600 VAC) are present in the PS0500 cabinet. These voltages can cause electrical shock, resulting in personal injury or death.

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

Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual.

STARTING AND STOPPING THE GENSET

The buttons related to changing mode of operation are highlighted in figure 2.1 and described in Table 2.1

FIGURE 2-1. CONTROL PANEL BUTTONS

TABLE 2-1 CONTROL PANEL BUTTONS BUTTON(S) DESCRIPTION Manual Puts the control in Manual Mode to

Start the genset Manually. You have to push the Start button in less than ten seconds after you push the Manual button.

Auto Puts the control in Auto Mode. The genset starts and stops when it is told by other devices (such as a transfer switch)

Stop Stops the genset

When the genset starts and stops, it follows a series of steps, called a sequence of operation that is intended to maximize the life of the genset. The genset might not start or stop immediately.

WARNING The genset might not start or stop immediately. Do not attempt to service the genset if it does not appear to respond immediately. Accidental starting of the genset during troubleshooting can cause severe personal injury or death.

CONTROL PANEL

The control panel (Figure 2-2) is the front panel of the PS0500 control.

FIGURE 2-2. CONTROL PANEL (PS0500)

Control Panel DescriptionAlpha-numeric LCD Display

The 2 line 16 Character, Backlit LCD display is used to indicate various genset parameters in several frames. The frames are normally scrolled one after the other for 3 seconds each at a time. The scrolling can be stopped and parameters on a particular frame can be monitored for longer time by pressing the OK button while the frame of interest is being displayed. Pressing the OK button again causes the frames to start scrolling again. The LCD display is also used to present the setup menus during the setup modes. The set up modes are described in detail in a separate section in this manual.

TABLE 2-2. LED INDICATORS AND BUTTONS

LED DESCRIPTION

Genset Running

This green LED is lit when the genset is running at or near rated speed and voltage.

This is not lit while the genset is Stopped.

Remote Start

This green LED is lit when the remote start signal is active. This signal has no effect unless the PS0500 is in Auto mode.

Shutdown This red LED is lit when there is any active shutdown fault. Event 1541 (Common Shutdown) is active.

Warning This amber LED is lit when there is an active warning fault. Event 1540 (Common Warning) is active.

Buttons and LED Indicators

TABLE 2-3. BUTTONS

LED/BUTTON

DESCRIPTION

Manual Press this to put the PS0500 in Manual mode from Stop mode. If you do not press the Start button In ten seconds, the control automatically enters the Stop mode The green LED above this button blinks when the PS0500 is in Manual mode.

Start In Manual mode, press this to initiate a Manual Start sequence. In other modes, this button has no effect.

Auto Press this to put the PS0500 in Auto mode from Stop mode. The green LED above this button blinks when the PS0500 is in Auto mode.

Stop Press this to Stop the running Genset. The Red LED above this button blinks when the PS0500 is in Stop mode. Pressing this button takes the control to STOP mode.

Reset This button is used along with the OK button to enter setup mode. Holding these two buttons pressed continuously for 5 Seconds causes the control to enter in setup mode if the control is in STOP mode. This button also wakes up the control from Power Down Sleep Mode.

OK This button is used mainly in Setup mode to select menu items. It is also used to Pause / Resume the scrolling of the parameter frames.

MODES OF OPERATION

The mode of operation determines the ways the Genset can be started and stopped. The PS0500 runs in one of these modes at any given time.

Table 2-3 explains how to change the mode of operation.

Stop (Off) Mode

Pressing the STOP button will always put the PS0500 in STOP mode and the RED LED above the STOP button will start blinking.

In this mode, the PS0500 does not allow the genset to start / Crank.

If the genset is running (either in Manual or Auto Mode) when the Stop button is pressed, the PS0500 stops the genset and enters in the STOP mode.

Setup Mode

The Setup mode can be entered only from Stop mode when the genset is not running. This is accomplished by holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led flashes faster (double the normal rate) as long as the control is in setup mode. While in setup mode, pressing Start or Stop button has no effect. Exiting from setup mode will return the control to STOP mode.

In the setup mode, a Menu driven setup process is available for making adjustments that are allowed to be made from the control panel. Set up process is described in detail in a separate section later in this manual.

Auto Mode

Pressing the Auto Button while the PS0500 is in the STOP mode will put the PS0500 in AUTO Mode. Pressing Auto Button while the PS0500 is

in Manual Mode (Running or Not Running) has no effect.

WARNING In Auto mode, the genset can start at any time. NEVER service the genset in Auto mode. Accidental starting of the genset during troubleshooting can cause severe personal injury or death. Disable the genset before troubleshooting.

When the remote start signal becomes active, the PS0500 initiates the start sequence to start the genset. The PS0500 continues to run as long as the signal is active. When the Remote Start signal becomes inactive the PS0500 initiates a normal stop sequence.

Pressing the Stop button shall always deactivate the FSO immediately.

Remote Start Signal This signal will start the Genset when these conditions are met.

The PS0500 is in Auto mode There are no active shutdown faults

This signal comes typically from a transfer switch or an external toggle switch.

Manual Mode

Pressing the Manual Button while the PS0500 is in the Stop Mode will put the PS0500 in the Manual Mode.

In this mode, the genset is controlled manually. Pressing the Start button initiates a Manual Start sequence. Remote start signal has no effect.

Note: If you do not press the Start button in ten seconds, the PS0500 changes over to STOP (Off) mode.

Pressing the Stop button initiates a stop sequence.

Power-Down Mode

The PS0500 can enter power-down or sleep mode, to reduce load on batteries when not being used.

PS0500 Power-down Mode Table 2-4 shows how much current the PS0500 control module consumes in normal operation and in power-down mode.

TABLE 2-4. PS0500 CURRENT CONSUMPTION PS0500 MODE CURRENT Normal operation 350 mA Power-down < 5 mA

The PS0500 enters power-down mode when these conditions are met.

The genset is not running. The Power down Mode Time Delay has expired. There is no active communication on the RS-485 communication link. There are no active faults There are no active Wake Up signals present.

In power-down mode, the microprocessor in the control stops, thereby reducing the consumption from battery.

Wake Up Signals

The PS0500 wakes up from power-down mode when any of these wakeup signals becomes active. Tool wakeup input (TB15 pin 5) is grounded. he Reset button on the Control Panel is pressed Remote Start Signal (Typically, to a transfer switch) is low.

SEQUENCES OF OPERATION

Sequences of operation describe the way the PS0500 starts the genset or stops the genset. This is illustrated in Figure 2-7.

Stopped

Start Sequence

Genset Running

Stop Sequence

FIGURE 2-7. Sequence of operation

Start Sequences The PS0500 follows different start sequences depending on its setup and conditions. If a start sequence is interrupted for any reason except a shutdown fault (for example, the remote start signal becomes inactive), the PS0500 aborts the start sequence and initiates a Stop sequence.

Remote Start This sequence begins when these conditions are met.

The PS0500 is in Auto mode. The remote start signal is active, There are no active shutdown faults. This sequence is shown in Figure 2-8.

Stopped

Start Delay and

Preheat if enabled

Start Engine after Start

Delay expires and

Preheat conditions are

met

Wait For the Genset to

reach 90 % of Nominal

Frequency and

Voltage

Genset Running

FIGURE 2-8. Remote Start Sequence

In this sequence, the PS0500 follows these steps to start the engine. 1. The PS0500 waits until Start Time Delay expires.

If the trim Glow Plug Enable is set to Enabled, the PS0500 turns on the Glow Plug Control output. The PS0500 turns off the Glow Plug Output when Glow Plug Timeout Period expires.

The PS0500 does not proceed to crank until both Start Time Delay expires and the Glow Plug Output is turned off.

2. The PS0500 turns on the fuel shutoff (FSO) output and the Starter Output.

Cycle Cranking he starter turns on for Cycle Crank Engage

Time and turns off for Cycle Crank Rest Time. The starter repeats this process up to Crank Attempts times.

The PS0500 turns OFF the Starter Output and keeps it OFF when,

The Genset Frequency is >= Starter Disconnect Speed / Frequency Speed gain,

(Example: Typically the starter disconnect speed is set to 450 RPM. In case off a four pole alternator the value of the Frequency speed gain is set to 30. So the genset frequency at which the starter disengagement happens would be calculated as 450 / 30 = 15Hz)

OR The Battery Charging Alt Voltage >= Start Disconnect threshold

If the genset frequency does not reach the start disconnect threshold (15 Hz in above example) before PS0500 finishes the cranking cycle, then it generates shutdown fault 359 (Fail To start).

The PS0500 waits for the Genset to reach the rated frequency and voltage. If that does not happen within 10 seconds from the starter disconnect, the PS0500 generates Shutdown Fault 2335 (loss of AC Sensing).

Manual Start This sequence begins when these conditions are met. The PS0500 is in Manual mode and the Start button is pressed. There are no active shutdown faults. This sequence is shown in Figure 2-9.

Stopped

Turn ON Glow Plug

Output and Wait for

Preheat conditions to

be met if Glow Plug is

enabled

Start Engine

Wait For the Genset to

reach 90% of Nominal

Frequency and

Voltage

Genset Running

FIGURE 2-9. Manual Start Sequence

In this sequence, the PS0500 follows these steps to start the engine.

1. If the trim Glow Plug Enable is set to Enabled, the PS0500 turns on the Glow Plug Control output. The PS0500 turns off the Glow Plug Output when Glow Plug Timeout Period expires.

The PS0500 does not proceed to crank until the Glow Plug Output is turned off.

2. The PS0500 turns ON the fuel shutoff (FSO) output and the Starter Output.

The cycle cranking process as explained above is followed in Manual Mode also.

Genset Running (Ready to Load)

The PS0500 enters the Genset Running (Ready to Load) state when the genset frequency and voltage are both >= 90 percent of the nominal frequency and nominal voltage respectively.

Meter Calibration

When running in Manual Mode, the control allows meter calibration process to be invoked, when the Genset Running (Ready to Load) state is reached. The Meter Calibration process is invoked by holding the Reset and OK buttons pressed for 5 seconds continuously. The process allows the arrow keys to be used for adjusting the displayed alternator AC Voltage / Current values to actual values (as measured using an independent calibrated instrument) one by one.

The Meter Calibration Process is available when running the genset in Manual Mode only.

Nominal Voltage and Frequency

The PS0500 does not have the control of the genset frequency (speed) and the genset voltage.

The nominal voltage and the nominal frequency set-up parameters are used only for calculation of the over voltage, under voltage, over frequency and under frequency fault thresholds and determining if the Genset Running (Ready to Load) state has been reached as described above.

Stop Sequences

The PS0500 follows different stop sequences depending on its setup and conditions.

Auto Mode In Auto mode the stop sequence begins when these conditions are met. The genset is running at rated speed and voltage The remote start signal is inactive. There are no active shutdown faults.

The Genset will continue to run for the Stop Delay time and then the FSO Output will be deactivated by the PS0500.

Manual Mode

In Manual mode the stop sequence begins when these conditions are met. The genset is running at rated speed and voltage The Stop button has been pressed. There are no active shutdown faults.

The FSO Output will be deactivated by the PS0500 immediately when the Stop button is pressed.

Fault Shutdown

In Manual as well as Auto mode, the FSO Output will be deactivated by the PS0500 immediately when any of the shutdown faults becomes active.

3. Setup and Calibration

Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual.

CAUTION: Only qualified technicians should adjust the parameters described in this section. Failure to follow this may affect genset operation and may cause damage to the genset or to equipment connected to the genset.

In this section, italics are used to identify a specific parameter by name.

PARAMETERS

See Section 4 for more information about parameters that you can adjust in the Operator Panel.

Capture File

Use InPower to save the current settings in a capture file on a PC or network. You can use the capture file to look at the current settings while you are away from the PS0500 or to restore settings if you have to reset the PS0500 for any reason. See the InPower User Guide for more information.

While InPower can be used with the PS0500 for facilitating the setup, it is not essential for carrying out the basic setup operations. The basic setup can be performed directly from the control panel of PS0500. Following paragraphs Describe the process of carrying out basic setup from the control panel.

Entering and leaving the Setup Mode

The Setup mode can be entered only from Stop mode when the genset is not running. This is accomplished by

holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led flashes faster (double the normal rate) as long as the control is in setup mode. Pressing button while in Main Menu exits the setup mode. Navigation through the setup menus is described further in a separate section later.

MENU Description

Tables 3.1 to 3.15 show a summary of the menus offered on the control panel of the PS0500.

Table 3.1 Main Menu Description

Menu Description Alt Setup Use this menu to select

alternator setup parameters like Single / Three phase, 50 / 60 Hz operation, Wye / Delta , Voltage etc.

Units Use this menu to select Metric or US units for Coolant Temperature and Oil Pressure

Oil Pr Input

Use this menu to select the sensor types used with oil pressure

Customer I/O Use this Menu to configure the response to Customer input and to configure usage of the customer output

Flt History Use this menu to view last five faults that are stored in the control

Load Defaults Use this menu to set the default values.

Table 3.2 Alt Setup Menu

Table 3.3 Frequency Sub Menu

Table 3.4 Phase Type Sub Menu

Menu Items Single 3 Wire 3 Phase Single 2 wire

Table 3.4 Connect Type Sub Menu

Menu Items Star Connect Delta Connect

Table 3.5 CT Ratio Sub Menu

Menu Items 50:5 75:5 100:5 150:5 200:5 250:5 300:5

Table 3.6 Nom LL Voltage Sub Menu

Menu Items 190 200 208 220 230 240 380 400 416 440 460 480 600

Table 3.7 Units Menu

Menu Item

Description

Metric Select this item to choose Metric Units for the display of Coolant Temperature and Oil Pressure

SubMenu Description Phase Type Select this submenu to

choose between single / three phase operation

CT Ratio Select this submenu to choose the CT Ratio

Connect Type Select this submenu to choose between Wye / Delta connection of alternator windings

Nom LL Voltage Select this submenu to choose the alternator nominal voltage

Frequency Select this submenu to choose the frequency of operation

Menu Items 50 Hz 60 Hz

US Select this item to choose US Units for the display of Coolant Temperature and Oil Pressure

Table 3.9 Oil Pr Input

SubMenu Description Sensor Select this if using a Sender Switch Select this if using a Switch

Table 3.10 Oil Pressure Sensor Sub Menu

MenuItems ONAN CIL

Table 3.11 Customer I/O Menu

SubMenu Description Cust I/P Flt Choose the

response to the input when active

Customer O/P1 Choose the function of this output

Customer O/P2 Choose the function of this output

Table 3.12 Cust I/P Flt Submenu

MenuItems ShutDown Warning

Table 3.13 Customer O/P1 menu

MenuItems Glow Plug Warning Shutdown

Table 3.14 Customer O/P2 menu

MenuItems ShutDown Warning Genset Running

Table 3.15 Flt History Menu

MenuItems Description Fault 1 Fault 5 View the last 5

faults stored in the control

Table 3.16 Load Default

MenuItems Description Confirmation Screen

To confirm the action press OK

Navigation

The manual (), Reset ( //), OK () and Auto () buttons are used for navigation during the setup. As long as setup mode is not exited these buttons will only act as arrow keys. The RED Stop lamp flashes at twice the normal rate as long as the setup mode is not exited and the control is not returned to STOP mode.

Navigation Example (Set the nominal LL voltage to 440)

The Fig above shows the basic elements of a Setup Menu.

Line 1 always bears the Menu Name and Line 2 shows items in the Menu.

The symbols , / /, indicate that the buttons bearing those symbols are active and can be used as follows

Main Menu / / /

Alt Setup

Back Button / / () Scroll Down to the next item Select the item shown on line 2

When a menu or submenu containing more choices is selected, the Name of the Menu or Submenu moves to line 1 and the choices in the menu are displayed on line 2. / / () button can then be used to scroll through the choices available in the Menu, and (OK) button can be used to choose the item shown on line 2. The button can be used to go back one level up in the menu.

Here in the current example, pressing will take you to the Alt Setup menu. The Name of the chosen Menu (Alt Setup) will move into the line 1 and the first choice within that menu (phase type) will be shown on line 2.

You can now press / / () button to scroll through the choices available in the Alt Setup Menu one by one. When the choice that you want appears on line 2, pressing will take you into that submenu.

Here in our example, let us say, you pressed / / () until Nom LL Voltage submenu was displayed in line 2.

Pressing will take you into the choices available for nominal line to line voltages. Pressing will take you to the main menu and pressing / / () will take you to the next item within Alt Setup Menu.

Let us say you pressed . The display will now look like this.

Pressing / / () will show all the choices available for nominal LL voltage one by one. Let us say you pressed / / () until 440 was displayed.

Pressing will select that as the Nominal LL Voltage. An asterisk (*) will appear in line 2 indicating that to be the current selection. The at the end of line 2 will change to indicating that the only active buttons now are / / () and .

Pressing button will take you to one level up in the menu tree at a time. You have to press several times to reach the main menu. Pressing button while at the main menu shall exit the setup mode. Following message shall be displayed before leaving the setup mode.

Press to leave setup mode and resume normal operation. The red Stop LED will resume flashing with normal rate (1 Hz).

Nom LL Voltage / / * 440

Current Config Saved

Nom LL Voltage / / 440

Nom LL Voltage / / 190

Alt Setup / / Nom LL Voltage

Alt Setup / / Phase Type

4. Parameters

CAUTION: Parameters (nominal voltage, frequency, CT Ratio etc.) are set to appropriate values at the Genset manufacturing time based on the application requirements. In case of a replacement control, however, the control would have the default values as indicated in the table 4.1 and these would need to be adjusted as required. Use caution while replacing the control the field. Only

qualified technicians should adjust the parameters described in this section. Failure to follow this may affect genset operation and may cause damage to the genset or to equipment connected to the genset

It is intended that there will be only one calibration (0326-7727) for the PS0500 series control.

Table 4.1 Adjustable Parameters

Group Parameter

Name InPower

PS0500 Control Panel

Possible Values

Default value

Units Lo High

Genset

Nominal Voltage (L-

L) Yes Yes 190 600 416 V AC

Nominal Frequency

Yes Yes

50 or 60

50 Hz

Connection type

Yes Yes

Delta or WYE

WYE -

Phase type

Yes

Yes

Single or Three

Three

-

CT ratio Yes

Yes 10/15/20/30/

40/50/60 20

Engine Oil Pressure

Input Type

Yes

Yes

Sensor or switch

Sensor

N/A

Cycle Crank

Attempts

Yes

1 7

3 Attempt

s

Cycle Crank time

Yes 3 30

5 Sec

Cycle Crank

Rest time

Yes

0 60

5

Sec

Battle Short

Enable

Yes

Enable or Disable

Disable

NA

Start Time Delay

Yes 0 300

0 Sec

Group Parameter

Name InPower

PS0500 Control Panel

Possible Values

Default value

Units

Stop Time Delay

Yes

0 600

120

Sec

Configurable I/O

Customer Input

Function

Yes

Yes Warning,

Shutdown,

Shutdown

Customer output

Function

Yes

Yes

Turn on if any shutdown fault is active/ Turn

On if any warning fault

is active/ /Turn on when

genset running

Turn on if any

shutdown fault is active,

Alternator Protection

High AC Voltage

Threshold

Yes

105 125

110 %

%

High AC Voltage Delay

Yes

1 10

5

Sec

Low AC Voltage

Threshold

Yes

50 95

85%

%

Low AC Voltage Delay

Yes

2 20

5

Sec

Under Frequency Threshold

Yes

2 10

5

Hz

Under Frequency

Delay

Yes

500 2000

1000

cycles

Over Frequency Threshold

Yes

2 10

5

Hz

Over Frequency

Delay

Yes

100 2000

1000 1/2

cycles

Protection Engine

Low Oil Pressure Shutdown Threshold

Yes

10 100

25

Psig

Low Oil Pressure Shutdown

Delay

Yes

2 15

5

Sec

Low Oil Pressure Warning

Threshold

Yes

10 100

30

Psig

Group Parameter

Name InPower

PS0500 Control Panel

Possible Values

Default value

Units

Low Oil Pressure Warning

Delay

Yes

2 15

5

Sec

High Coolant

Temperature

Shutdown Threshold

Yes

180 300

212

deg f

High Coolant

Temperature

Shutdown Delay

Yes

2 10

5

Sec

High Coolant

Temperature Warning Threshold

Yes

150 290

200

deg f

High Coolant

Temperature Warning

Delay

Yes

2 10

5

Sec

Low Battery Voltage

Threshold Yes 11 13

11

VDC

Low Battery Delay

Yes

2 60

30

Sec

High Battery Voltage

Threshold

Yes

14 17

16

VDC

High Battery Delay

Yes

2 60

30

Sec

Weak Battery Voltage

Threshold

Yes

6 10

8

VDC

Weak Battery Delay

Yes

1 5

3

sec

5. Hardware

J22 Voltage connector Arrow at Pin 1

TB2 Customer TB Arrow at Pin 1

TB15 Tool Connector Arrow at Pin 1

J16 Engine connector Arrow at Pin 1

J12 CT connector Arrow at Pin 1

J12 Pin 4

J16 Pin 7

The dot designates pin 1 on the connectors,

TB15 Tools Interface Connector

J22 Alternator Voltage Sense inputs and Field Output

J12 CT Connections

PS0500 CONTROL BOARD

J16 Engine Connections Coolant Sensor, Lube Oil Pressure sensor, Run / OFF / Auto Switch, FSO, Starter, Battery, Mag Pick Up, Starter Disconnect Feed Back, Battery Charger D+, Chassis GND. Governor PWM

TB2 Customer Terminal Block Customer fault input, Customer output, Glow Plug, Remote Start, Remote E-stop.

Control Inputs and Outputs

Engine Connector The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). A possible supplier is Molex; their part number is 39299123. The Cummins part number for this connector is 0323-2589. The PCB outline drawing shows where the connector is located as above .Each signal is described as below

Connector Pin Signal Name J16-1 Coolant temperature sensor J16-2 Battery charging alternator

(WL) J16-3 Starter Relay Driver (Low

Side) J16-4 Fuel shutoff relay Driver (Low

Side) J16-5 BAT- J16-6 Chassis GND J16-7 NC J16-8 NC J16-9 Oil Pressure Sensor

J16-10 Starter Disconnect Input J16-11 Sensor Common J16-12 BAT +

CT Connector The CT connector is a 6- pin MATE-N-LOCK connector. The possible manufacturer is Tyco, and the supplier part number for the part is 643749-1. The Cummins part number for this connector is 0323-2154. Connector details are as follows

Connector pin Signal J12-1 CT1_input J12-2 CT2_input J12-3 CT3_input J12-4 CT1_COM J12-5 CT2_COM J12-6 CT3_COM

Voltage Connector The voltage connection is via a 4 pin header with alternate spaces between the pins. The possible supplier is Tyco with the supplier part number as 282828-4. The Cummins part number for the same is 0323-2225-03.

Connector pin Signal J22-1 Gen_V1 J22-2 Gen_V2 J22-3 Gen_V3 J22-4 Gen_N

Customer Connection TB The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum: The terminal pins details are as shown below-

Terminal pins

Signal

TB2-1 Remote start Switch Input TB2-2 Glow Plug Output Relay

Driver (Low Side) TB2-3 Customer Output Relay

Driver (Low Side) TB2-4 Customer Input TB2-5 E-Stop TB2-6 NC

All the inputs are active GND. And outputs are low side drivers. Remote E-Stop switch should have two independent potential free contacts. One NC contact for cutting out the Battery supply to the Fuel Solenoid and another NC contact to disconnect controllers E-Stop input from GND to indicate to the control when the E-Stop is pushed in active state.

Battery Positive is not provided on the Customer terminal block (TB2). External provision needs to be made in the harness to provide fused B+ via a 1 amp fuse for wiring up external relays. External Relays of suitable contact ratings must be used for controlling FSO, Starter, Customer Output and Glow plug.

PC Tool Connector The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is Tyco, with the supplier part numbers are 796643-5. The Cummins part number for the same is 0323-2191-04.

Terminal pins

Signal

TB15-1 GND

TB15-2 NC TB15-3 RS485_DATA_A TB15-4 RS485_DATA_B TB15-5 TOOL_WAKEUP

Connector Part Numbers

Quantity Name Description Manufacturer Manufacturers part number Cummins

part no

Remarks

1 J22 Alt Voltage Connector TYCO 282828-4 0323-2225-03

1 J12 CT Connector TYCO 643749-1 0323-2154

1 J16 Engine Connector MOLEX 39299123 0323-2589

1 TB2 Customer TB MAGNUM EM257506VC 0323-1677-05

1 TB15 Tool Connector TYCO 796643-5

0323-2191-04

All these connectors

are PCB mounted

connectors

Quantity Name Description Manufacturer Manufacturers part number Cummins

part no

Remarks

1 J22 Alt Voltage Connector TYCO 282809-4 0323-2226-03

CT Connector 1-480704-0 0323-1932 1 J12 Crimp

Terminals TYCO

350551-1 0323-1200

Engine Connector 39012120 0323-2602

1 J16 Crimp

terminals

MOLEX 39000038 0323-2603

1 TB2 Customer TB MAGNUM EM256506H

0323-1678-05

All these connectors are used in the harness

1 TB15 Tool Connector TYCO Communication cable Kit 0541-1199 is used for

the tool interface

6. Troubleshooting

GENERAL The PS0500 control continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control will light a yellow warning lamp or a red shutdown lamp and display a message on the LCD display.

PC BASED SERVICE TOOL The PC based service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions.

When used improperly, a PC based service tool can cause symptoms like warnings and shutdowns that appear to be a defective control. When these problems occur, always verify that a self-test or fault simulation (override) have not been left enabled with the tool. If you do not have a PC based service tool, or the enabled fault simulation(s) can not be found using the tool, disconnect battery power to disable the test or override condition.

Make sure that parameter adjustments and time delays, 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 a Pro version of many of PC based service tools. Confirm that the installed calibration part number matches the serial plate information.

CAUTION Using the wrong capture file can result in equipment damage. Do not swap Controls from another genset model and only use the calibration file shown on the nameplate.

SAFETY CONSIDERATIONS WARNING Contacting high voltage components can cause electrocution,

resulting in severe personal injury or death.

Keep the output box covers in place during Trouble shooting.

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

Ventilate battery area before working on or near batteryWear gogglesStop genset and disconnect charger before disconnecting battery cablesDisconnect negative (-) cable first and reconnect last.

CAUTION Disconnect battery charger from AC source before disconnecting battery cables.

READING FAULT CODES The fault code and message can be viewed on the display. 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. A PC based service tool is required to view this data log.

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.

Voltage/Continuity Testing Voltage and continuity tests are required in the following tables. In some cases, it is necessary to remove a plug to complete the test. Where required, the corrective action

will mention when it is necessary to remove a plug for testing. In other cases, the plug cannot 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.

TABLE 20-1. ENGINE DOES NOT CRANK IN MANUAL MODE

Reason: 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

Check if the control is in Manual mode and when the Start button is pressed, and that there are no shutdown faults present.

Poor battery cable connections. Clean the battery cable terminals and tighten all connections.

Check for blown fuses.

Remove connector P16 and check for B+ at P16-12 and GND at P16-5. If B+ or ground missing, check the harness. If B+ and ground check OK, cycle power to control by reconnecting P16. Press Reset Button to wake the control up. And retry operation.

2. Control not properly calibrated or corrupt calibration.

Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary.

3. The Emergency Stop switch or wiring is defective.

With Emergency Stop push button not activated (switch closed), remove leads from TB2-5 and B- 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.

5. Oil Pressure switch or wiring is defective

Remove P16 connection and check wiring between P16-9 and P16-11 to the switch. Verify control is configured for the type of sensor installed. Verify proper operation of the switch

6. Oil Pressure sender, setup on wiring is defective.

Remove P16 connection and check wiring between P16-9, P16-11 to the sender. Verify control is configured for the type of sender. Verify operation of the sender

TABLE 20-2. ENGINE DOES NOT CRANK IN REMOTE MODE Reason: This indicates that the PS0500 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

CORRECTIVE ACTION

1. The remote start switch or wiring is faulty.

Check if the control is in Auto mode and there are no shutdown faults present. Attempt to start, and check for ground at TB2-1. If ground level is not present, isolate to the remote switch or wiring. Repair as necessary.

If ground level is present then the control is bad. Replace the control

TABLE 20-3. WARNING AND SHUTDOWN CODES FAULT CODE CORRECTIVE

ACTION 151 HIGH COOLANT TEMP Lamp: Shutdown

Indicates engine has overheated (coolant temperature has risen above the 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 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 blower fan and circulation pumps on remote radiator installations.

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

415 LOW OIL PRESSURE Lamp: Shutdown

Indicates engine oil pressure has dropped below the shutdown trip point. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. If oil switch is used, check switch performance.

1446 HIGH AC

Indicates that one or more of the phase

VOLTAGE Lamp: Shutdown

voltages has exceeded 130% of nominal for 0 second, or has exceeded high ac voltage threshold for High AC Voltage time delay seconds.

1447 LOW AC VOLTAGE Lamp: Shutdown

Indicates that one or more of the phase voltages has dropped below low ac voltage threshold for low ac voltage time delay seconds.

1449 OVER FREQUENCY Lamp: Shutdown

Indicates frequency is 10% above base frequency for approximately 10 seconds.

1448 UNDER FREQUENCY Lamp: Shutdown

Indicates that Frequency had dropped below 90% of nominal for approximately 10 seconds. Check fuel supply, intake air supply and load.

1434 EMERGENCY STOP Lamp: Shutdown

Indicates remote Emergency Stop. To reset the remote Emergency Stop button:

1. Open (disable) remote emergency stop button.

2. Press the OFF button.

3. Select the desired operating mode (manual or auto).

359 FAIL TO START Lamp: Shutdown

Indicates possible fuel system or air induction problem. (Engine cranks but fails to start)

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.

2677 FAIL TO STOP Lamp: Shutdown

Genset continues to run after receiving shutdown command from the controller. Check the FSO Relay and related wiring. Check that the FSO is not mechanically stuck

1123 SHUTDOWN AFTER BS Lamp: Shutdown

A shutdown fault occurred while the Battle Short mode was enabled. Check fault history for faults that may have been bypassed.

146 HIGH COOL TEMP. Lamp: Warning

Indicates engine is operating near cooling system capacity. Increase in load or higher ambient temperature may cause High Coolant Temp (151) shutdown. Review code 151 correction list for other possible causes.

1435 LOW COOLANT TEMP Lamp: Warning Set is not operating. Warning occurs when engine coolant temperature is 70F (21C)

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

a. Coolant heater not connected to power supply. Check for blown fuse or disconnected heater cord and correct as required.

b. Check for low coolant level and

or lower. NOTE: In applications where the ambient temperature falls below 40F (4C), Low Coolant Temp may be indicated even though the coolant heaters are operating.

replenish if required. Look for possible coolant leakage points and repair as required.

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

Coolant temperature must be below 70F (default setting) for one minute to activate warning and be above 70F for five minutes before the warning can be cleared.

1312 CUSOMER INPUT FAULT Lamp: Warning Or Shutdown Depending on the setup

Indicates the Customer Input is active.

Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.

If multiple of these are connected in parallel, check if any one of them is active.

144 COOL SENSOR OOR Lamp: Warning

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.

441 LOW BATTERY Lamp: Warning

Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation will occur.

a. Discharged or defective battery.

Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable

connections. Clean the battery cable terminals and tighten all connections.

c. Check battery wiring/calibration.

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

e. Check battery charge voltage float level if applicable (raise float level).

442 HIGH BATTERY Lamp: Warning

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.

141 OIL PRESS SENSOR OOR Lamp: Warning

Indicates that the control has sensed that the engine oil pressure sensor output is out of range (high or low). Check sender/connectors/wires. This warning will only occur if genset is equipped with an oil pressure sender.

1131 BATTLE SHORT ACTIVE Lamp: Warning

Indicates that the control is in Battle Short mode - used to bypass several fault shutdowns for genset operation during emergencies.

2678 CHARGER FAILURE Lamp: Warning

Indicates the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120 seconds). Refer to engine service manual if this fault occurs. If not failed, check wiring.

1416 FAIL TO SHUTDOWN Lamp: Warning

Genset continues to run after receiving shutdown command from the controller. Battle Short feature enabled - used to bypass several critical fault shutdowns for genset operation during

emergencies. 1442 WEAK BATTERY Lamp: Warning

Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time. See code 441 for corrective action.

CODE 151/146 - HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/SHUTDOWN) Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature. Effect: 146 . Warning Lamp lights , Faul code pops up. 151.- Engine will shut down 1. Fault simulation was enabled with a PC based service tool.

1. With a PC based service tool, verify that the fault 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.

2. Engine or sensor circuitry problem.

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.

3. The sensor could be bad.

Disconnect the sensor and connect a 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.

4. The harness or Control

4. Measure the resistance of the coolant sensor and

could be bad. reconnect harness to sensor. Remove connector P16 from Control and check resistance between pins P16-1 and P16-11.

If resistance is not the same, harness is bad.

If resistance is the same, Control is bad.

CODE 143/ 415 - LOW OIL OR PRE-LOW PRESSURE (WARNING/SHUTDOWN) Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure. Effect: 143. Warning Lamp lights, Engine will shut down for code 415. Engine shuts down

POSSIBLE CAUSE

CORRECTIVE ACTION

1. Fault simulation was enabled with a PC based service tool.

With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides.

2. Low oil level. Clogged lines or filters.

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

3. Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault.

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

a. If the control responds to the simulator, reconnect the sensor, disconnect the + signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display.

If the display shows an acceptable oil pressure, the

problem may not be in the oil or oil sensing system. The 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 doesnt display an oil pressure while cranking, the oil pump may be bad. Refer to the engine service manual.

b. If the control does not respond to the simulator, go to next step.

4. Harness or Control could be bad.

If the control does not respond to the simulator, the Control or the harness is bad. Check the resistance in P16-9 and P16-11 (Sensor COMM). If the resistance signal (100 to 33 Ohm) does not get to P16, isolate to the harness. If the resistance does go to P16, the Control is bad.

5. Low Oil Pressure fault set points could be incorrect.

Verify set points against the normal operating pressures of the engine. Refer to engine manual.

CODE 1446 - 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 with a PC based service tool.

1. With a PC based service tool, verify that the related fault 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. Single step large block load removal.

2. Clear fault and restart genset.

3. Fault threshold is not set correctly with InPower.

3. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

4. AVR or generator is bad.

4. Refer to Generator AVR Board Isolation Procedure in Alternator manual to determine if the AVR board is causing the high AC voltage shutdown fault.

5. Voltage sense connections/set up could be incorrect.

See Section 17 for proper corrective actions.

CODE 1447 - LOW AC 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 with a PC based service tool.

1. With a PC based service tool, verify that the related fault 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 correctly with

2. Reset the threshold to the lowest allowable setting. Determine the

a PC based service tool.

required operating range before adjusting the threshold.

3. Overload. 3. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set.

4. Improper connections have been made at the generator output terminals.

4. Reconnect according to the appropriate reconnection diagram. See Section 17.

5. Voltage sense or setup wiring connection could be incorrect.

5. Check that Voltage senses inputs P22-1 to 4 are connected to the correct voltage sensing point at alternator.

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

6. Check each diode. See genset service manual

7. Loose connector or Control is bad.

8. Repair connections (P22) or replace the Control if necessary.

8. AVR or Alternator is bad.

4. Refer to Alternator / AVR Board Isolation Procedure in Alternator manual to determine if the AVR board is causing the Low AC voltage shutdown fault.

9. Voltage sense connections/setup could be incorrect

See section 17 for proper connections

CODE 1449 - 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 correctly with PC based service tool.

2. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

2. Fuel or air delivery

3. Refer to the engine service manual.

problem. 3. Loose connector or Control is bad.

4. Repair connections (P22 1 to 4) or replace the Control if necessary.

CODE 1448 - 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 correctly with PC based service tool.

2. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold.

2. Overload. 3. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set.

3. Fuel or air delivery problem.

4. Refer to the engine service manual.

4. Governor fault.

5. Check fuel shutoff solenoid adjustment (refer to Section 8).

5. Loose connector or Control is bad.

6. Repair connections (P22 1 to 4) or replace the Control if necessary.

CODE 234 - OVERSPEED (SHUTDOWN) Reason: Engine speed signal indicates an engine speed greater than shutdown threshold. Effect: Engine will shut down. POSSIBLE CAUSE

CORRECTIVE ACTION

1. Cold engine (no coolant heaters)

1. Overspeed can occur when starting a very cold engine. Clear fault and restart genset.

2. Single step large block load removal.

2. Clear fault and restart genset.

3. Fault simulation was enabled with a PC

3. With PC based service tool, verify that the fault simulation is not enabled for the coolant sensor.

based service tool.

If you do not have PC based service tool, remove battery power from the control to disable fault simulation overrides.

4. Fault threshold is not set correctly with PC based service tool.

4. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold.

5. Monitor the engine rpm using InPower.

5. If the RPM is not correct, refer to fault code 1449 for corrective action.

6. Governor fault.

6a. Check fuel shutoff solenoid adjustment (refer to Section 8). 6b. Replace defective injection pump unit.

7. Mechanical Fuel system setup could be incorrect.

Verify fuel stop settings for the application.

CODE 359 - 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 CAUSE

CORRECTIVE ACTION

1. Restricted fuel supply due to:

a. Fuel level below pickup tube in tank.

b. Closed shutoff valve in supply line.

c. Fuel injectors clogged.

d. Air in fuel system.

1a. Add fuel if low. Prime the fuel system. 1b. Open any closed shutoff valve in the fuel line supplying the engine. 1c. Refer to engine service manual. 1d. Bleed air from fuel system. Refer to engine service manual.

2. Glow plugs are The Control

not heating due to: a. Glow

plug(s) is bad.

b. Control is bad.

c. Glow Plug Relay is bad.

determines at what temperature and duration of time that the glow plugs will be energized. Using sensed coolant temperature, the glow plugs are energized at 77F (25C) and colder. The glow plugs are energized for up to 15 seconds when the coolant temperature is -5F (-20.5C) or colder. Time duration (15-0 seconds) is linear between -5F and 77F.

With coolant temperature colder than 77F (25C):

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. Attempt to start and check for if Glow plug relay energizes. TB2-2 should be at GND potential. If the TB2-2 is at GND and K2 relay is not working check relay coil.

If TB2-2 is not at GND potential replace the Control.

If B+ is present, check for open circuit between glow plug relay contact and glow plugs.

3. Fuel solenoid on the injection pump not energized due to:

Isolate to fuse, K7 relay, fuel solenoid or Control.

3a. Remove fuse (if

a. Fuse may be open.

b. Fuel solenoid is bad.

c. Control/K7 Fuel Relay is bad.

installed) and check continuity. If open, replace the fuse with one of the same type and amp rating. If fuse reopens, check wiring continuity of fuel solenoid circuit/test fuel solenoid.

Binding in the solenoid linkage can prevent activation of the hold coil circuitry in the solenoid. Make sure solenoid shaft moves completely in and out freely. (Applies to solenoids with both Pull and Hold coils.)

3b. Attempt to start and check for B+ at the fuel solenoid coil.

If B+ is present, fuel solenoid is bad.

If B+ is not present, go to step c.

3c. Check wiring continuity/test K7 relay or fuel pilot: Remove lead from K7-COM (fuel pilot). Attempt to start and check for GND at lead COM.

If there is no GND, check for open circuit between K7-COM and Base card.

If GND is present, reconnect lead COM to relay. Remove lead from N/O connection. Attempt to start and check for B+

at terminal N/O connection.

If B+ is present, check for open circuit between N/O connection and fuel solenoid(+).

If B+ is not present, check for relay contacts.

5. The engine fuel system is worn or malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing).

4. Service according to the engine service manual.

6. The engine is worn or malfunctioning mechanically.

5. Service according to the engine service manual.

CODE 1312 - 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 problem may be an external wiring problem.

Disconnect the signal lead from TB2 and reset the control. Check the following two points.

Customer Input TB2-4

If the message drops out, the external wiring has a short circuit. Grounding of the input activates fault.

CODE 146 - HIGH COOLANT TEMP (WARNING) Reason: Effect: POSSIBLE CAUSE

CORRECTIVE ACTION

1. Refer to 1. Refer to code 151.

code 151. CODE 1435 - 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

CORRECTIVE ACTION

1. Fault simulation was enabled with PC based service.

1. With PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a based service tool, remove battery power from the control to disable fault simulation overrides.

2. Fault threshold is not set correctly with a PC based service tool.

2. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold.

3. The engine coolant heater could be bad. (Radiant heat should be felt with hand held close to outlet hose.)

3. Coolant heater not operating due to:

Coolant heater not connected to power. Check for blown fuse, or disconnected heater cord and correct as required.

Low coolant level. Look for possible coolant leakage points and repair as required.

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 100F 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. The sensor connections could be bad.

4. Inspect the sensor and engine harness connector pins. Repair 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. If control does not respond, harness or Control are bad.

6. The harness or Control could be bad.

6. Measure the resistance of the coolant temperature sensor and reconnect harness to sensor. Remove connector P16 from Control and check resistance between pins P16-1 and P16-11 (Sensor Common).

If resistance is not the same, harness is bad.

If resistance is the same, Control is bad.

CODE 1312 - 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, the problem may be an external wiring problem.

Disconnect the signal lead from TB2 and reset the control. Check the following pins.

Customer Input TB2-4

If the message drops out, the external wiring has a short circuit. Grounding of

the nput activates fault.

CODE 144 - 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

1. The sensor connections could be bad.

2. Inspect the sensor and engine harness connector pins. Repair or replace as necessary.

2. The sensor could be bad.

3. Disconnect the sensor, and plug in a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step.

3. The harness or Control could be bad.

4a. Remove connector P16 from Control and disconnect sensor. Check pins P16-1 and P16-11 (Sensor common) for short circuit as follows:

Check for a short circuit to the engine block ground (more than 200k ohms OK).

Check for a short circuit from pin to pin (more than 200k ohms OK).

Repair or replace as necessary.

4b. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P16 from Control and check resistance between pins P16-1 and P16-11 (Sensor Common).

If resistance is not the same, harness is bad.

If resistance is the

same, Control is bad.

CODE 441 - LOW BATTERY (WARNING) Reason: Low voltage has been detected for battery. Effect: The controls voltage supply approaching level at which unpredictable operation may occur. POSSIBLE CAUSE

CORRECTIVE ACTION

1. Weak or discharged battery.

1. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80F (27C).

2. Low electrolyte level in battery.

2. Replenish electrolyte and recharge battery.

3. Battery connections loose or dirty.

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

4. Insufficient battery charging voltage.

4. Adjust charge rate of AC powered battery charging circuit, according to manufactures instructions.

5. Engine DC alternator could be bad.

5. Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained.

6. If the batteries are OK, the problem may be the harness or the Control.

6. Remove connector P16 from Control and check battery voltage at P16-12 (B+) to P16-5 (GND).

If the voltage at P16 is not the same as the battery voltage, the harness is bad.

If the voltage at P16 is OK, the Control is bad.

7. Fault threshold could be bad.

7. Check fault threshold against requirement of the application.

CODE 442 - HIGH BATTERY VOLTAGE (WARNING) Reason: High voltage has been detected for battery. Effect: Control damage will occur. POSSIBLE CAUSE

CORRECTIVE ACTION

1. Excessive battery charging voltage.

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

2. Engine DC alternator could be bad.

2. Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained.

3. Fault threshold could be bad.

3. Check fault threshold against requirement of the application.

CODE 143 - LOW OIL PRESSURE (WARNING) Reason: Effect: POSSIBLE CAUSE CORRECTIVE

ACTION 1. Refer to code 415.

1. Refer to code 415.

CODE 141 - 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 could be bad.

2. Inspect the sensor and engine harness connector pins. Repair or replace as necessary.

2. The sensor could be bad.

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

OIL PRESSURE SENSOR OOR 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 bad.

4. Remove connector P7 from Control and connector from sensor. Check P16-9 and P16-11 as follows:

Check for a short circuit from pin to pin (more than 200k ohms OK).

Check for an open circuit (10 ohms or less OK).

Repair or replace as necessary.

4. The Control could be bad.

5. With all connectors attached, check pressure signal (.500 to .033 VDC)

at P16-9 and P16-11 (Sensor Common). If in range, replace Control.

CODE 1442 - WEAK BATTERY (WARNING) Reason: Effect: POSSIBLE CAUSE

CORRECTIVE ACTION

1. Refer to code 441

1. Refer to code 441.