900 0520D 0520 Onan DFHA DFHB DFHC DFHD (spec A J) Genset Operators Manual (10 2011)

User Manual: 900-0520 Onan DFHA DFHB DFHC DFHD (spec A-J) Genset Operators manual (10-2011)

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Operator Manual

Generator Set

DFHA (Spec A−J)

DFHB (Spec A−J)

DFHC (Spec A−J)

DFHD (Spec A−J)

with PowerCommandR 3100 Controller

English − Original Instructions 10−2011 900−0520 (Issue 7)

Table of Contents

SECTION TITLE PAGE

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

1 INTRODUCTION

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

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

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

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

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

2 CONTROL OPERATION

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

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

Sequence of Operation 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Front Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Display and Switches 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Menu 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Menu 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gen Menu 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CIRCUIT BOARDS AND MODULES

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

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

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

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

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

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

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

Bus PT Board (A39) 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Communications Module (A41) 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Regulator Output Module (A37) 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Output Module (A38) 3-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Master First Start Sensor 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TROUBLESHOOTING

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

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

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

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

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

PCC Oil Pressure Warning and Shutdown Limits 4-12. . . . . . . . . . . . . . . . . . .

Troubleshooting Procedure 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PCC Fuses 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rack Position Fault/Test Procedure 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Load Sharing Controls Troubleshoot Procedure 4-59. . . . . . . . . . . . . . . . . . . .

SECTION TITLE PAGE

5 CONTROL SERVICE AND CALIBRATION

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

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

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

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

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

Calibration Procedure 5-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Torque Adjustment 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accessory Box Control Components 5-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Sensors 5-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Magnetic Speed Pickup Unit (MPU) Installation 5-45. . . . . . . . . . . . . . . . . . . . .

Current Transformer (CT) Installation 5-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Board (A32) Calibration 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 SERVICING THE GENERATOR

General 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator/PCC Control Isolation Procedure 6-2. . . . . . . . . . . . . . . . . . . . . . . . .

Testing the Generator 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exciter Stator 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exciter Rectifier Bridge (Rotating Rectifier Assembly) 6-6. . . . . . . . . . . . . . . .

Exciter Rotor 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Rotor (Generator Field) 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main Stator 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing the PMG 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bearing Inspection/Removal/Replacement 6-11. . . . . . . . . . . . . . . . . . . . . . . . .

Generator Disassembly 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Reassembly 6-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Aligning Generator with Engine 6-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 DAY TANK FUEL TRANSFER PUMP AND CONTROL

Operation 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring Connections 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Transfer Pump Motor Connections 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Testing the Float Switch Assembly 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 INITIAL SYSTEM STARTUP

General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The Startup Process 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Equipment Application Review 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Individual Generator Set Startup 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual System Operation 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic System Operation 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Black Start Testing 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test Reports and Acceptance 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

On Site Power System Application Review

(Diesel/600VAC and Lower) 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 WIRING DIAGRAMS

General 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LS-14L

iii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual contains

important instructions that should be followed during

installation and maintenance of the generator and batter-

ies.

Before operating the generator set (genset), read the

Operator’s Manual and become familiar with it and the

equipment. Safe and efficient operation can be

achieved only if the equipment is properly operated

and maintained. Many accidents are caused by failure

to follow fundamental rules and precautions.

The following symbols, found throughout this manual,

alert you to potentially dangerous conditions to the oper-

ator, service personnel, or the equipment.

This symbol warns of immediate

hazards which will result in severe personal in-

jury or death.

WARNING This symbol refers to a hazard or un-

safe practice which can result in severe person-

al injury or death.

CAUTION This symbol refers to a hazard or un-

safe practice which can result in personal injury

or product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can result

from improper practices.

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

less tanks are outside the engine compartment.

Fuel contact with hot engine or exhaust is a potential

fire hazard.

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

spark, arcing equipment, or other ignition source

near the generator set or fuel tank.

Fuel lines must be adequately secured and free of

leaks. Fuel connection at the engine should be

made with an approved flexible line. Do not use zinc

coated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoff

valve.

Be sure battery area has been well-ventilated prior

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

explosive hydrogen gas that can be ignited by arc-

ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properly

expel discharged gases away from enclosed or

sheltered areas and areas where individuals are

likely to congregate. Visually and audibly inspect

the exhaust daily for leaks per the maintenance

schedule. Make sure that exhaust manifolds are se-

cured and not warped. Do not use exhaust gases to

heat a compartment.

Be sure the unit is well ventilated.

Engine exhaust and some of its constituents are

known to the state of California to cause cancer,

birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away from

moving parts.

Before starting work on the generator set, discon-

nect battery charger from its AC source, then dis-

connect starting batteries, negative (−) cable first.

This will prevent accidental starting.

Make sure that fasteners on the generator set are

secure. Tighten supports and clamps, keep guards

in position over fans, drive belts, etc.

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

moving parts, or while working on electrical equip-

ment. Loose clothing and jewelry can become

caught in moving parts.

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

ning, use extreme caution around hot manifolds,

moving parts, etc.

DO NOT OPERATE IN FLAMMABLE AND

EXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed and

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

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

genset where a flammable vapor environment can be

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

equipped with an automatic safety device to block the air

intake and stop the engine. The owners and operators of

the genset are solely responsible for operating the gen-

set 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 rub-

ber insulative mats placed on dry wood platforms

over floors that are metal or concrete when around

electrical equipment. Do not wear damp clothing

(particularly wet shoes) or allow skin surface to be

damp when handling electrical equipment. Do not

wear jewelry. Jewelry can short out electrical con-

tacts and cause shock or burning.

Use extreme caution when working on electrical

components. High voltages can cause injury or

death. DO NOT tamper with interlocks.

Follow all applicable state and local electrical

codes. Have all electrical installations performed by

a qualified licensed electrician. Tag and lock open

switches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECT-

LY TO ANY BUILDING ELECTRICAL SYSTEM.

Hazardous voltages can flow from the generator set

into the utility line. This creates a potential for elec-

trocution or property damage. Connect only

through an approved isolation switch or an ap-

proved paralleling device.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling point

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

changer pressure cap while the engine is running.

Allow the generator set to cool and bleed the system

pressure first.

Used engine oils have been identified by some state

or federal agencies as causing cancer or reproduc-

tive toxicity. When checking or changing engine oil,

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

tact used oil.

Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible materials

such as wood and cloth; Class B fires, combustible

and flammable liquid fuels and gaseous fuels; Class

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

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

gine.

Make sure generator set is mounted in a manner to

prevent combustible materials from accumulating

under the unit.

Remove all unnecessary grease and oil from the

unit. Accumulated grease and oil can cause over-

heating and engine damage which present a poten-

tial fire hazard.

Keep the generator set and the surrounding area

clean and free from obstructions. Remove any de-

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

Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol

or drug that makes the operation of equipment un-

safe.

Substances in exhaust gases have been identified

by some state or federal agencies as causing can-

cer or reproductive toxicity. Take care not to breath

or ingest or come into contact with exhaust gases.

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

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

explosion could result.

Wear hearing protection when going near an oper-

ating generator set.

To prevent serious burns, avoid contact with hot

metal parts such as radiator, turbo charger and ex-

haust system.

LS-14L

iii

CONTAINERIZED RENTAL UNITS

POTENTIAL TIPPING PROBLEM

On all containerized rental equipment, there is a potential

problem of having the container tip forward over the land-

ing legs, pulling the axles off the ground when the con-

tainer is fully fueled without a semi-tractor under the king

pin. Jack stands for the front of the container are required

to mitigate this potential problem.

Note: The figure below shows the jack stands and

their placement at the nose of the container.

Jack Stands at Nose of Container

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

THIS PAGE LEFT INTENTIONALLY BLANK

1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides troubleshooting and repair

information regarding the PowerCommand

Control 3100 (PCC) and generators for the

generator set (genset) models listed on the front

cover. Engine service instructions are in the

applicable engine service manual. Operating and

maintenance instructions are in the applicable

Operator’s Manual.

This manual does not have instructions for

servicing printed circuit board assemblies. After

determining that a printed circuit board assembly is

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

printed circuit board can lead to costly damage to

the equipment.

This manual contains basic (generic) wiring

diagrams and schematics that are included to help

in troubleshooting. Service personnel must use the

actual wiring diagram and schematic shipped with

each unit. The wiring diagrams and schematics that

are maintained with the unit should be updated

when modifications are made to the unit.

Read Important Safety Instructions and carefully

observe all instructions and precautions in this

manual.

TEST EQUIPMENT

To perform the test procedures in this manual, the

following test equipment must be available

True RMS meter for accurate measurement of

small AC and DC voltages. Fluke models 87 or

8060A are good choices.

Grounding wrist strap to prevent circuit board

damage due to electrostatic discharge (ESD).

Battery Hydrometer

Jumper Leads

Tachometer or Frequency Meter

Wheatstone Bridge or Digital Ohmmeter

Variac

Load Test Panel

Megger or Insulation Resistance Meter

PCC Service Tool Kit (Harness Tool and Sen-

sor Tool)

HOW TO OBTAIN SERVICE

Always give the complete Model, Specification and

Serial number of the generator set as shown on the

nameplate when seeking additional service

information or replacement parts. The nameplate is

located on the side of the generator output box.

WARNING Incorrect service or replacement of

parts can result in severe personal injury or

death, and/or equipment damage. Service per-

sonnel must be trained and experienced to per-

form electrical and mechanical service. Read

and follow Important Safety Instructions, on

pages iii and iv.

1-2

SYSTEM OVERVIEW

The PCC is a microprocessor-based control for

Onan generator sets. It provides fuel control and

engine speed governing, main alternator voltage

output regulation, and complete generator set

control and monitoring. It also provides controls for

automatic and semi-automatic synchronizing and

automatic load sharing controls for both isolated

bus or utility (mains) paralleling applications.

The operating software provides control of the

generator set and its performance characteristics,

and displays performance information on a digital

display panel. It accepts menu-driven control and

setup input from the push button switches on the

front panel.

GENERATOR SET CONTROL FUNCTION

Figure1-1 shows some of the control functions. A

more complete block diagram is provided in Section

3. A system schematic is provided in Section 9.

The PCC monitors frequency from both the

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

The control sends a low power pulse-width

modulated (PWM) signal to the governor output

module, which then sends an amplified signal to the

engine fuel control.

The Bus PT module reduces the bus voltage to

approximately 18 VAC and provides a signal to the

control for reference in synchronizing the generator

set to the system bus.

The external PT/CT module reduces generator

voltage to approximately 18 VAC, and produces a

representative AC voltage from CT output current.

The voltage regulation function sends a low power

PWM signal to the voltage regulator output module,

which then sends an amplified signal to the exciter

stator.

Oil, coolant, and exhaust temperatures are sensed

by variable resistance element sensors. Oil

pressure is sensed by a capacitive element active

sensor.

Sensors

Governor

Output

MPU

PMG

Battery

BT1

Fuel

Control

Bus PT

Module



Regulator

Load



234

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

2-1

2. Control Operation

GENERAL

The following describes the function and operation

of the PowerCommandgenerator set control. All in-

dicators, displays, meters and control switches are

located on the face of the control panel as illustrated

in Figure 2-1.

The PCC control cabinet must be opened only by

technically qualified personnel.

Normally, generator set configuration options are

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

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

trol must be configured for that generator set with

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

nal software. Setup and calibration procedures are

described in Section 5.

The automatic voltage regulator (AVR) and gover-

nor operation characteristic adjustments are also

described in Section 5.

SAFETY CONSIDERATIONS

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

open the generator output box while the set is run-

ning.

WARNING Contacting high voltage compo-

nents can cause electrocution, resulting in se-

vere personal injury or death. Do not open the

generator output box while the set is running.

Read and observe all WARNINGS and CAU-

TIONS in your generator set manuals.

CAUTION The PCC control cabinet must be

opened only by technically qualified personnel.

Lower level voltages (18 VAC to 24 VDC) are

present in PCC control cabinet. These voltages

can cause electrical shock, resulting in person-

al injury.

Even with power removed, improper handling

of components can cause electrostatic dis-

charge and damage to circuit components.

2-2

SEQUENCE OF OPERATION

When the PowerCommand control is in the AUTO

mode, it will cause the generator set to start on re-

ceiving a signal from a remote device. The Power-

Command control will initiate a starter cranking sig-

nal and verify that the engine is rotating. The Power-

Command control will provide sufficient fuel to the

engine to accelerate to start disconnect speed. On

reaching that speed, the control will ramp the gener-

ator set to rated speed and voltage.

On reaching rated speed and voltage, the Power-

Command control checks the system bus voltage. If

no bus voltage is present, it will wait for a pulse from

a remote Master First Start Sensor. On receiving

that pulse, the control will signal the paralleling

breaker to close.

If bus voltage is present, the PowerCommand con-

trol will check for proper phase rotation, adjust the

generator set to the bus voltage and frequency lev-

el, and then synchronize the generator set to the

system bus. When a synchronous condition is

achieved, the control will send a signal to close the

paralleling breaker.

When the paralleling breaker is closed, the genera-

tor set will assume it’s proportional share of the total

load on the system bus.

PCC POWER ON / STANDBY MODE

Standby Mode

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

the Digital Board is set to the right and the generator

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

is inactive and the LEDs and displays on front panel

are all off.

The operating software is initialized and the front

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

one of eight “wake up” inputs from remote sensing

switches.

The wake up signals are:

Emergency Stop

Low Coolant Level

Low Coolant Temperature

Low Fuel

Customer Fault Inputs 2 and 3

Run Selected on Run/Off/Auto Switch

Remote Start Signal in Auto Mode

Self Test switch

To activate and view the menu displays, press and

release the Self Test switch. The PCC will initialize

the operating software and permit operation of the

menu display panel. If no menu selections are

made, the power to the control panel will shut down

after 30 seconds.

Power On Mode

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

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

initialize the operating software and permit opera-

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

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

set to the Standby mode. It is recommended that

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

plications, except those where auxiliary battery

charging is not available.

CAUTION Electrostatic discharge will damage

circuit boards. Always wear a grounding wrist

strap when touching or handling circuit boards

or socket-mounted ICs and when disconnect-

ing or connecting harness connectors.

2-3

ACTIVE SWITCH

INDICATOR

(1 of 6)

UPPER AND LOWER

SCALE INDICATOR

FREQUENCY

METER

KILOWATT

METER

(PERCENT LOAD)

PHASE SELECTOR

SWITCH AND

INDICATORS

RESET

SWITCH

NON-AUTOMATIC

WARNING

SHUTDOWN

STATUS INDICATORS

EMERGENCY

STOP PUSH

BUTTON

PANEL LAMP

SWITCH

SELF TEST

SWITCH

VOLTMETER

(DUAL SCALE)

AC AMMETER

(PERCENT AMPS)

ALPHANUMERIC

DISPLAY

SELECTION

SWITCH

(1 of 4)

RUN/OFF/AUTO

SWITCH

PARALLELING

BREAKER

SWITCHES AND

INDICATORS

PCC 3100

LABEL

FIGURE 2-1. FRONT PANEL (PCC 3100)

2-4

FRONT PANEL

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

AC Voltmeter: Dual scale instrument indicates AC

voltage. Measurement scale in use is shown on

scale indicator lamp.

AC Ammeter: Indicates current output in percent of

maximum rated current. (Percent current is based

on .8 PF.)

Kilowatt Meter: Indicates 3-phase AC power out-

put as percent of rated load.

Frequency Meter: Indicates generator output fre-

quency in hertz.

Upper and Lower Scale Indicator Lamps: Indi-

cate AC voltmeter scale.

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

alphanumeric display is used in the menu-driven

operating system, in conjunction with the display

menu selection switches and the Menu switch. Re-

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

play is also used to show warning and shutdown

messages.

Display Menu Selection Switches: Four momen-

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

play window—are used to step through the various

menu options and to adjust generator set parame-

ters. The green arrow adjacent to the switch is lit

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

Menu Switch: Press this switch to return the digital

display to the MAIN MENU. Refer to the menu trees

later in this section.

Reset Switch: Press this switch to reset warning

and shutdown messages after the condition has

been corrected. To reset a shutdown message with

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

in the Off position.

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

shutdown faults can be reset by removing the re-

mote start input and then cycling the remote reset

input.

Self Test Switch: Press and hold this switch to light

all front panel LEDs and cycle through all shutdown

and warning messages.

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

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

tive and the LEDs and displays on front panel are all

off.

To activate and view the menu displays without

starting the generator set, press and hold the Self

Test switch until the front panel LEDs light. The

PCC will initialize the operating software and permit

operation of the menu display panel. If no menu

selections are made, a software timer will shut

down the power after 30 seconds.

Panel Lights Switch: Press this switch to turn con-

trol panel illumination on and off. The illumination

will shut off after about eight minutes.

Phase Selector Switch and Indicators: Press this

momentary switch to select phases of generator

output to be measured by the analog AC voltmeter

and ammeter. LEDs indicate the selected phase.

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

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

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

2-5

Emergency Stop Button: Push the switch in for

emergency shutdown of the engine.

Remote Reset switch will not reset emergency stop.

Can only be reset at the PCC front panel.

To reset:

1. Pull the button out or turn the switch clockwise

(button with arrow) and allow it to pop out.

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

3. Press the front panel Reset switch.

4. Select Run or Auto, as required.

Non-Automatic Status Indicator: This red lamp

flashes continuously when the Run/Off/Auto switch

is not in the Auto position.

Warning Status Indicator: This yellow lamp is lit

whenever the control detects a warning condition.

After the condition is corrected, warning indicators

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

necessary to stop the generator set.)

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

warnings can also be reset by cycling the remote re-

set input after the condition is corrected.

Shutdown Status Indicator: This red lamp is lit

whenever the control detects a shutdown condition.

After the condition is corrected, shutdown indica-

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

to the Off position, and pressing the Reset switch.

In Auto mode, shutdowns can be reset by removing

the remote start input and then cycling the remote

reset input.

Emergency Stop shutdown status (Code 102) can be

reset only at the PCC front panel.

Paralleling Breaker Switches and Indicators:

These two switches are used to manually open or

close the paralleling breaker of the generator set.

The lamps are used to indicate the opened or

closed position of the paralleling breaker.

The Breaker Operation switches are operational only

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

The breaker will close when the generator set is syn-

chronized with the system bus, or if the system bus

is de-energized.

2-6

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES

Figure 2-2 shows the digital display and the menu

selection switches. Refer to heading “Front Panel”

which describes the menu display and switches.

In the Standby Mode, to activate and view the menu

displays without starting the generator set, press

and release the Self Test switch. This will initialize

the PCC operating software and permit operation of

the menu display panel. If no menu selections are

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

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

continuously supplied to the control panel. Display

will always remain on.

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

selecting the adjacent button causes the operating

program to branch to the next menu display—as

shown in the menu diagrams.

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

selecting the adjacent button causes the operating

program to go back to the previous menu display.

MAIN MENU

The facing page shows the main menu and a block

representation of the available submenus.

As shown in the diagram, the main menu can

branch into one of four directions.

To display engine parameters, such as oil pressure

and temperature, water temperature, engine speed

(RPM), and exhaust temperature, press the button

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

ENGINE MENU in this section.

To display generator parameters, such as volts,

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

next to the word “GEN” in the display. Bus voltage,

frequency and a digital synchroscope can also be

viewed from this menu branch. Turn to the GEN

MENU in this section.

To adjust output voltage and frequency, or start and

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

JUST” in the display. Refer to ADJUST MENU in

Section 5.

To display the selected generator set model and the

resident version software, press the button next to

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

PLAYS MENUS in Section 5.

2-7

DISPLAY CAL <<

METERS >>

 VOLTAGE

 _______ >>

ENGINE GEN

ADJUST >>

< ACTIVE BUTTON

<ACTIVE BUTTON SELECTED

INACTIVE BUTTON

RESET MENU >

RETURN TO

MAIN MENU

CLEAR WARNING AND

SHUTDOWN MESSAGES

PAGES 2-8 & 2-9

MAIN MENU

(ACCESS CODE)

PAGES 2-10 & 2-11

OIL <<

COOLANT >>

BATTERY <<

HOURS >>

RPM <<

EXHAUST

 FREQUENCY

 _______ >>

 START DELAY

 _______ SEC >>

 STOP DELAY

 _______SEC >>

VOLTS <<

AMPS >>

POWER <<

KW HRS >>

%GOV / REG <<

FREQUENCY

SECTION 5

RACKTEST <<

SECTION 5

 IDLE SPEED

 _______RPM >> GOV / REG <<

PARALLEL SETUP

VERSION

SETUP / CAL

HISTORY

2-8

ENGINE MENU

The facing page shows a block representation of

the ENGINE menu. If you press the button next to

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

submenu will appear.

As shown in the diagram, the ENGINE menu has

three submenus.

OIL/COOLANT submenu: This is the first subme-

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

temperature. Select COOLANT for a display of

coolant temperature. When oil or coolant parame-

ters are displayed, pressing the button next to the

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

COOLANT submenu.

BATTERY/HOURS submenu: From the OIL/

COOLANT submenu, press the button next to the

“>>” in the display to move to the BATTERY/

HOURS submenu. Select BATTERY for a display

of battery voltage. Select HOURS for a display of

the number of starts and the running hours. When

battery or hours parameters are displayed, press-

ing the button next to the “<<” will return the display

(“BACK”) to the BATTERY/HOURS submenu.

RPM/EXHAUST submenu: From the BATTERY/

HOURS submenu, press the button next to the “>>”

in the display to move to the RPM/EXHAUST sub-

menu. Select RPM for a display of engine RPM.

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

haust temperature. When RPM or exhaust param-

eters are displayed, pressing the button next to the

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

HAUST submenu.

2-9

BATTERY <<

___

L___F / C<<

R___F / C (or N/A)

BATTERY <<

HOURS >>

ENGINE GEN

ADJUST >>

OIL <<

COOLANT >>

___PSI / KPA <<

___F / C

ENGINE GEN

ADJUST >>

OIL <<

COOLANT >>

OIL <<

COOLANT >>

OIL <<

COOLANT >>

BATTERY <<

HOURS >>

STARTS ___ <<

HOURS ___

BATTERY <<

HOURS >>

BATTERY <<

HOURS >>

L___F/C (or N/A) <<

R___F/C (or N/A)

RPM <<

EXHAUST

RPM <<

EXHAUST

RPM <<

EXHAUST

RPM <<

___

BATTERY <<

HOURS >>

BACK

ENGINE

OIL <<

COOLANT >>

Indicates OR" Condition

2-10

GEN MENU

The facing page shows a block representation of

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

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

will appear.

As shown in the diagram, the GEN menu has three

submenus.

VOLTS/AMPS submenu: This is the first subme-

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

line-to-neutral selection, or for viewing of the sys-

tem bus line-to-line voltage. Select line-line or line-

neutral for the desired voltage display. Select

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

amps. When voltage or current parameters are dis-

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

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

If DELTA is selected in the Initial Start Setup subme-

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

neutral” submenus will not be displayed, only the

L12, L23, L31 submenu will be displayed.

POWER / KW HOURS submenu: From the

VOLTS/AMPS submenu, press the button next to

the “>>” in the display to move to the POWER/KW

HOURS submenu. Select POWER for a display of

power output in kilowatts and a power factor value.

Select KW HOURS for a display of kilowatt hours.

When power or kW hours parameters are dis-

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

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

HOURS submenu.

The PF reading will contain an asterisk if the power

factor is leading (for example, *.3PF).

Beginning Version 1.06, N/A is displayed in the PF

field when the generator set is not running.

%GOV/REG/FREQUENCY submenu: From the

POWER/KW HOURS submenu, press the button

next to the “>>” in the display to move to the %GOV/

REG/FREQUENCY submenu. Select %GOV/REG

for a display of voltage regulator and governor duty

cycle (drive) levels in percentage of maximum. Se-

lect FREQUENCY for a display of the generator

output frequency the bus frequency, or the digital

synchroscope. When voltage regulator and gover-

nor or frequency parameters are displayed, press-

ing the button next to the “<<” will return the display

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

menu.

Bus Frequency (Digital Synchroscope) subme-

nu: When the bus frequency (digital synchroscope)

information is displayed, the operator can observe

the generator set synchronizing with the system

bus. The display indicates bus frequency and num-

ber of degrees from synchronous condition (+ indi-

cates faster, − indicates slower). When the genera-

tor set is operating within the sync-check window,

an asterisk will indicate that the paralleling breaker

can be closed.

2-11

><>

<<>

ENGINE GEN

ADJUST >>

VOLTS <<

AMPS >>

L − L <<

L − N BUS

L12 L23 L31 <<

___ ___ ___

L1N L2N L3N <<

___ ___ ___

BACK

VOLTS <<

AMPS >>

L1 L2 L3 <<

___ ___ ___

BACK

VOLTS <<

AMPS >>

ENGINE GEN

ADJUST >>

VOLTS <<

AMPS >>

POWER <<

KW HRS >>

___ KW <<

___ PF

BACK

POWER <<

KW HRS >>

KW HRS <<

____________

BACK

POWER <<

KW HRS >>

POWER <<

KW HRS >>

%GOV / REG <<

FREQUENCY

BACK

%GOV / REG <<

FREQUENCY

%GOV / REG <<

FREQUENCY

GOV __ % <<

REG __ %

FREQUENCY <<

___ HZ BUS

BACK

GEN

L − L <<

L − N BUS

L − L <<

L − N BUS

><>

L − L <<

L − N BUS

L12 L23 L31 <<

___ ___ ___

BACK

FREQUENCY <<

___ HZ BUS

BUS FREQUENCY<<

___ HZ ___ DEG

BACK

Indicates OR" Condition

2-12

THIS PAGE LEFT INTENTIONALLY BLANK

3-1

3. Circuit Boards and Modules

GENERAL

This section describes the function of the PCC cir-

cuit boards and modules that are contained in the

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

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

nal and external components of the PCC system.

The system schematics are provided in Section 9 of

this manual.

CAUTION Electrostatic discharge will damage

circuit boards. Always wear a grounding wrist

strap when touching or handling circuit boards

or socket-mounted ICs.

PT/CT

BOARD

A36

VOLTAGE REGULATOR

OUTPUT MODULE

A37

GOVERNOR

OUTPUT MODULE

A38

BUS PT MODULE

A39

CUSTOMER INTERFACE

A34

ENGINE INTERFACE

A31

ANALOG

BOARD

A33

DIGITAL BOARD

A32

DISPLAY BOARD

A35

RUN/OFF/AUTO

SWITCH S12

S5 POWER ON/

STANDBY SWITCH

GENSET

COMM.

BOARD

A41

J1 (FOR INPOWER

SERVICE TOOL)

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

3-2

FIGURE 3-2. BLOCK DIAGRAM

3-3

DIGITAL BOARD (A32)

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

microprocessor and the operational software for the

control. It connects to all other boards inside the

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

tal conversions for the PCC.

Switch

S5 Slide the switch to the left to select the Power

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

ating software will remain on until the switch is

reset to the Standby mode. It is recom-

mended that switch S5 be left in the Power On

mode in all applications, except those where

auxiliary battery charging is not available.

Slide right to put the PCC in the Standby

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

ating software will be initiated by selection of

Run on the front panel, by pressing the Self

Test switch, by a remote start input (in Auto

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

signals from external switches.

Connectors

The digital board has five connectors. They are:

J1 For InPower Service Tool

J2 Connects to J4 on A34 Customer Interface

board

J3 Connects to J2 on A33 Analog board

J4 Connects to J1 on A31 Engine Interface

board

J5 Connects to J5 on A35 Digital Display assem-

bly

LEDs

The digital board has seven LED’s that indicate the

following conditions:

DS1 Spare (Green)

DS2 Spare (Green)

DS3 +18 VDC supply OK (Green)

DS4 +5 VDC supply OK (Green)

DS5 Run (Flashes once per second if software

is running) (Green)

DS6 +24 VDC B+ supply OK (Green)

DS7 +12 VDC supply OK (Green)

Resistors

The three resistors (R36, R37 and R38) are used to

configure the digital board to the generator set mod-

el number. Refer to Digital Board (A32) Calibration

in Section 5, which provides a detailed description

of how to configure this board.

DS1

DS2

DS3

DS4

DS7

DS6

DS5

R36

R37

R38

FIGURE 3-3. DIGITAL BOARD (A32)

3-4

ENGINE INTERFACE BOARD (A31)

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

control inputs, monitors engine, generator and sys-

tem status, and initiates the appropriate action for

normal operating and fault conditions (warning or

shutdown).

This board is connected to the engine sensors, bat-

tery, starter, governor output module, voltage regu-

lator output module, and the magnetic pick-up

(MPU).

The engine interface board can also be connected

to an optional network interface module for network

access.

During a typical start sequence the LED’s light as

follows:

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

ceived and S12 is in the Auto possition, or S12

is moved to the Run position.

2. DS12 lights when the magnetic pick-up voltage

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

gine is cranking, the mag pickup output should

be a minimum of 1 volt.)

3. DS11 extinguishes, DS9 lights and DS10 is

dimly lit when the generator is running.

Connectors

The engine interface board has seven connectors

and one terminal strip. They are:

J1 Connects to J4 on A32 Digital board.

J2 Connects to J1 on A33 Analog board.

J3 Connects to display board, front panel

switches and meters.

J4 Connects to customer connections and to en-

gine harness which includes magnetic pick-

up.

J5 Connects to engine sensors.

J6 Connects to Genset Control module (GCM).

J7 Connects to Genset Control module (GCM).

Fuses

The engine interface board has two replaceable

fuses. They are:

F1 Control B+ (5 Amps)

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

contacts).

LED’s

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

cate the following conditions:

DS1 Low Fuel Alarm input (Red)

DS2 Low Coolant Level Alarm input (Red)

DS3 Low Engine Temperature Alarm input (Red)

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

Off/Auto switch.

DS5 S12 in Auto position (Green)

DS6 Emergency Stop (Red)

DS7 Not configured.

DS8 Not configured.

DS9 Automatic voltage regulator duty cycle

(Green). Brighter indicates larger duty

cycle.

DS10 Governor duty cycle (Green). Brighter indi-

cates larger duty cycle.

DS11 Start pilot relay output (Red)

DS12 Run pilot relay output (Red)

3-5

5A AUX B+

5A CNTRL B+

DS1 - LOW FUEL

DS2 - LO COOL

DS5 - AUTO

DS10 - GOV

DS11 - START

DS3 - LET

DS4 - RUN SW

DS6 - E-STOP

DS9 - REG

DS12 - RUN RLY

FIGURE 3-4. ENGINE INTERFACE BOARD

3-6

ANALOG BOARD (A33)

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

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

are two versions of the analog board that are used

for paralleling and non-paralleling systems.

This board interprets all analog input signals and

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

tal board.

Connectors

The analog board has four connectors with ribbon

cables permanently soldered to them. They are:

J1 Connects to J2 on A31 Engine Interface

board

J2 Connects to J3 on A32 Digital board

J3 Spare analog inputs

J4 Connects to J1 on A34 Customer Interface

board

FIGURE 3-5. ANALOG BOARD

3-7

DIGITAL DISPLAY BOARD (A35)

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

and the LED display.

Connectors

The digital board has three connectors. They are:

J1 Connects to front panel membrane switches

J5 Connects to J2 on A32 Digital board. (With J5

disconnected, the display will be non-func-

tional, but the PCC will continue to operate.)

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

on A31 Engine Interface board

LEDs

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

cate operational status of the generator set and

control panel mode/switch selections.

DS9 Not In Auto (Red)

DS10 Upper Scale (Green)

DS11 Left Top Arrow (Green)

DS12 Right Top Arrow (Green)

DS13 Warning (Amber)

DS14 Lower Scale (Green)

DS15 Shutdown (Red)

DS20 Left Bottom Arrow (Green)

DS21 Right Bottom Arrow (Green)

DS22 Automatic mains failure (AMF) or paralleling

application only: Breaker Closed (Red)

DS23 Phase A (Green)

DS24 Reset Arrow (Green)

DS25 Menu Arrow (Green)

DS26 AMF application only: Breaker Open

(Green)

DS27 Phase B (Green)

DS29 Phase C (Green)

DS36 AMF application: Breaker Closed (Red) − or

− paralleling application: Breaker Open

(Green)

DS37 AMF application only: Breaker Open

(Green)

DS29

DS27

DS23

DS15

DS13

DS9

DS24

DS11

DS20

DS25

DS12

DS21

DS14

DS10

DS26

DS22

DS37

DS36

FIGURE 3-6. DIGITAL DISPLAY BOARD

3-8

CUSTOMER INTERFACE BOARD (A34)

The customer interface board (Figure 3-7) connects

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

also connects to customer inputs and outputs. Note

that there are two versions of this board, for parallel

and non-parallel generator sets.

Connectors

The customer interface board has five connectors.

They are:

J1 Customer connections

J2 Customer connections

J3 A36 PT/CT Board and customer connections

J4 Connects to J2 on A32 Digital board

J5 Connects to J4 on A33 Analog board

LEDs

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

dicate the following conditions:

DS1 Master First Start Input (Green) − paralleling

application only

DS2 Pre low oil pressure output relay K14 (Red)

DS3 Customer Fault #4 Input (Red)

DS4 Customer Fault #1 Input (Red)

DS5 Low oil pressure output relay K15 (Red)

DS6 Fault Reset Input (Red)

DS7 Engine Idle (Green)

DS8 Paralleling Breaker Close Input (Green)

[paralleling function is load demand]

DS9 Paralleling Breaker Open Input (Green)

DS10 Paralleling Breaker Position Input (Green)

DS11 Customer Fault #2 input (Red)

DS12 Low coolant output relay K17 (Red)

DS13 Low Fuel Input (Red)

DS14 Remote Start input (Green)

DS15 Customer Fault #3 input (Red)

DS16 Paralleling Breaker Control input relay ener-

gized from Digital board (Green). This out-

put is activated to close the paralleling

breaker.

DS17 Common Alarm output relay energized from

Digital board (Green)

This output is activated only on a shut-

down condition.

DS18 Spare output relay energized from Digital

board (Green)

This output is activated only on a warn-

ing condition.

DS19 Load Dump output relay energized from

Digital board (Red)

If overload or underfrequency for 5 sec-

onds, this output is activated (before shut-

down).

DS20 Ready to Load output relay energized from

Digital board (Green)

This output is activated when AC voltage

and frequency exceed 90% of nominal.

DS21 Pre high engine temperature output relay

K8 (Red)

DS22 Not in auto output relay K6 (Red)

DS23 High engine temperature output relay K9

(Red)

DS24 Overspeed output relay K10 (Red)

DS25 Overcrank output relay K11 (Red)

DS26 Low engine temperature output relay K12

(Red)

DS27 Low fuel output relay K13 (Red)

3-9

DS1 - MA 1ST START

DS3 - CUST FAULT4

DS4 - CUST FAULT1

DS6 - FAULT RESET

DS7 - ENG IDLE

DS8 - LOAD DEMAND

DS9 - BRKR TRIP/INHBIT

DS10 - BRKR CLOSED

DS11 - CUST FAULT2

DS13 - LOW FUEL

DS14 - RMT START

DS15 - CUST FAULT3

DS2 - [K14] PRE-LOP

DS5 - [K15] LOP

DS12 - [K7]

LOW COOL

DS16 - CLOSE BKR

DS17 - COMMON SHTDN

DS18 - COMMON WARNING

DS19 - LOAD DUMP

DS20 - READY TO LOAD

DS21 - [K8] PRE-HET

DS22 - [K6] NOT IN AUTO

DS23 - [K9] HET

DS24 [K10] OVERSPEED

DS25 - [K11] OVERCRANK

DS26 - [K12] LET

DS27 - [K13] LOW FUEL

FIGURE 3-7. CUSTOMER INTERFACE BOARD

3-10

PT/CT BOARD (A36)

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

accessory box. This board converts generator out-

put voltage to approximately 18 VAC levels for the

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

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

input for the analog board.

There are three versions of this board. For proper

operation, the PT/CT board must be correctly

matched to the generator set.

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

genset. For proper operation, the CTs must also be

correctly matched to the genset output current.

Connectors

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

J8 Connects to J3 on A34 Customer Interface

board

J9 Connects to AC harness (generator output

voltage and CTs)

J9 wiring connections:

Yellow Gen. A In

Orange Gen. B In

Red Gen. C In

Brown Gen. Common In

White CT21 (+) In

Gray CT21 (common) In

Grn/Ylw CT22 (+) In

Black CT22 (common) In

Purple CT23 (+) In

Blue CT23 (common) In

FIGURE 3-8. PT/CT BOARD

3-11

BUS PT MODULE (A39)

The bus PT module (Figure 3-9) is mounted inside

the accessory box. This module converts the bus

output voltage (from the load side of the paralleling

breaker) to 18 VAC and provides this to the analog

board. It provides a reference signal to the Power-

Command Control for synchronizing the generator

set output to a system bus. There are four versions

of this module, for primary voltages of 69, 120, 240

or 346 volts AC line to neutral. For proper operation,

the correct bus PT module must be installed in the

generator set. Correct phasing is also important as

the system uses the bus PT module output for both

protection and control of the generator set.

Connectors

The bus PT module has two terminal blocks. They

are:

TB1 Bus voltage connections.

N bus neutral

A bus A phase (U)

B bus B phase (V)

C bus C phase (W)

TB2 Bus PT output for PowerCommand control. FIGURE 3-9. BUS PT MODULE

3-12

GENSET COMMUNICATIONS MODULE

(A41)

The genset communications module (GCM) is re-

quired to connect the PCC to a PowerCommand

(LonWorks) network, and communicate with other

network modules. The GCM module is an optional

feature, and it is available as a field upgrade kit for

applications where the feature must be added in the

field. The PC must be operating with firmware ver-

sion 1.06 or later. For model DFH gensets only, firm-

ware must be version 1.04 or later.)

The GCM provides an interface for data transfer be-

tween the PowerCommand control and other mod-

ules on the network. It communicates with the PCC

through a serial port on the PCC, as well as monitor-

ing various PCC inputs to determine the operating

state of the control. For example, the GCM monitors

PCC data such as voltage, oil pressure, current, en-

gine speed, and not in auto status; and provides

that information to the network.

The GCM also facilitates remote monitoring and

limited remote control of the genset that PCC con-

trols. Outputs from the GCM can ’wake up’ the PCC

when needed, or issue start commands to the gen-

set. The GCM also includes a terminate circuit for

use at the end of a network data bus.

The GCM module is powered from the genset start-

ing batteries. It is operational at all times when pow-

ered, even if the PCC is asleep.

The GCM module is mounted on stand-off mount-

ing legs above the analog board (A33).

Refer to the Power Command Network Installation

and Operator’s Manual (900-0366) for information

on installation and use of the GCM module.

TERMINATE

SWITCH S3

SERVICE

SWITCH S1 RESET

SWITCH S2

BATTERY

VOLTAGE

SWITCH S4

J6 J7

FIGURE 3-10. GENSET COMMUNICATIONS MODULE

3-13

VOLTAGE REGULATOR OUTPUT MODULE

(A37)

The voltage regulator output module (Figure 3-11)

is a power amplifier. This board is used to amplify

the pulse-width modulated (PWM) signal from the

PCC to drive the exciter windings. Power from the

PMG is used by this board to amplify the PWM sig-

nal.

Connectors

The voltage regulator output module has two con-

nectors. They are:

J7 Connects to engine harness (control)

J7 wiring connections:

Gray Regulator Drive (+) Input

White Regulator Drive (-) Input

Blue B+ Input (RUN signal)

Purple Ground Input

Grn/Yel Start in

Black Start solenoid

J10 Connects to engine harness (power)

J10 wiring connections:

Green Phase A PMG power

Yellow Phase B PMG power

Orange Phase C PMG power

Red X (Field +) Output

Brown XX (Field −) Output

LEDs

The voltage regulator output module has 3 LED’s

that indicate the following conditions.

DS1 On when voltage regulator isolated supply is

operating (Green)

DS2 Output Duty Cycle − Brighter when load in-

creases − larger duty cycle (Amber). The duty

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

cause the normal duty cycle is less than 10%,

the output duty cycle LED, DS2 will normally

be very dimly lit.

DS3 Backup start disconnect − On when start dis-

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

connect is initiated at about 850 RPM, when

sensed PMG voltage is greater than 105 volts

RMS.

J10J7

DS1 - ISOLATED SUPPLY

DS2 - OUTPUT DUTY CYCLE

DS3 - BACKUP START DISCONNECT

FIGURE 3-11. VOLTAGE REGULATOR OUTPUT MODULE (A37)

3-14

GOVERNOR OUTPUT MODULE (A38)

The governor output module (Figure 3-12) receives

a low power, 3 kHz pulse-width modulated (PWM)

command from the engine interface board (A31).

This module drives the two fuel actuators (right and

left) with a feed back-controlled, 200 Hz PWM pow-

er output stage. The governor module also has both

right and left 0-5 volt actuator position voltages

which are used for actuator diagnostics.

Connectors

The governor output module has two connectors.

They are:

Inputs: Run Signal, B+, Governor Command (from

engine interface board)

Outputs: B+ (fused), SwB+, actuator position volt-

ages (R, L), and Rack Position Fault

J13

Inputs: (R, L) Actuator position sensing signals

Outputs: (R, L) Actuator drive

Fuses

The governor output module has four fuses to pro-

tect it from overloads and groundfaults. They are:

F1 Left Actuator Drive (15 Amps)

F2 Right Actuator Drive (15 Amps)

F3 Switched B+ (10 Amps)

F4 B+ Fused (10 Amps)

LEDs

The governor output module has six LED’s that indi-

cate the following conditions:

DS1 (Green) Run command signaling governor

module is active.

DS2 (Green) 5 volt power supply is active.

DS3 (Green) Left actuator drive is active. The PCC

duty cycle range is 25 - 93%. When running,

the maximum duty cycle is about 63%. Note

that the brighter the LED, the larger the duty

cycle.

DS4 (Green) Right actuator drive is active. See

DS3 description.

DS5 (Red) Left actuator fault indicator. If the actua-

tor is more than 1.5 mm form its commanded

position, the fault indicator will be ON. Note

that the actuator has maximum range of 0 −

21mm. During transients and starting se-

quences, the fault indicator will become ac-

tive for short (200 millisecond) periods.

DS6 (Red) Right actuator fault indicator. See DS5

description.

LOOP

DS3

DS4

DS5 DS6

F1 F2

R54

DS2

K1 K2 F3 F4

R63 R68

DS1

BANK TO

BANK

FIGURE 3-12. GOVERNOR OUTPUT MODULE (A38)

3-15

MASTER FIRST START SENSOR

The First Start Sensor System is an Onan control

sub-system which is used to sense when a genera-

tor set is ready to close to a de-energized system

bus and to prevent more than one generator set

from closing to a dead bus on automatic system

starting. The First Start Sensor System for Power-

Command generator sets is composed of control al-

gorithms within the PowerCommand control and a

Master First Start Sensor, which is usually mounted

in a remote master control panel.

The sequence of operation of the control system is

as follows: On a signal to start, all generator sets in a

system simultaneously start, and accelerate to

rated speed and voltage. The Master First Start

Sensor continuously provides pulses to each Pow-

erCommand control. When the PowerCommand

control receives the pulse from the Master First

Start Sensor, if it is ready to close to the bus, an in-

terlock signal is sent to all other controls to prevent

their respective paralleling breakers from closing. A

close signal is then provided to the generator set

paralleling breaker.

3-16

THIS PAGE LEFT INTENTIONALLY BLANK

4-1

4. Troubleshooting

GENERAL

The PowerCommand Control 3100 (PCC) contin-

uously monitors engine sensors for abnormal con-

ditions, such as low oil pressure and high coolant

temperature. If any of these conditions occur, the

PCC will light a yellow Warning lamp or a red Shut-

down lamp and display a message on the digital dis-

play panel.

In the event of a shutdown fault (red Shutdown

lamp), the PCC will stop the generator set (genset)

and close a set of contacts that can be wired to trip a

circuit breaker. If the genset is stopped for this rea-

son, the operator can restart the genset after mak-

ing adjustments or corrections.

This section contains the following information:

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

cluding the displayed message and status indi-

cator. Also references the page number that

contains a description of each code.

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

down code, warning and shutdown limits

where applicable, and basic corrective actions,

such as, checking fluid levels, control reset

functions, battery connections, etc.

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

and shutdown limits.

Tables 4-4 through 4-36: Provide detailed

troubleshooting procedures.

Table 4-37: Describes the analog circuit board

inputs and outputs.

Table 4-38: Describes the location and func-

tion of each fuse.

SAFETY CONSIDERATIONS

WARNING Contacting high voltage compo-

nents can cause electrocution, resulting in se-

vere personal injury or death. Keep the output

box covers in place during troubleshooting.

High voltages are present when the genset is run-

ning. 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. Arc-

ing at battery terminals, light switch or other

equipment, flame, pilot lights and sparks can ig-

nite battery gas. Do not smoke, or switch

trouble light ON or OFF near battery. Discharge

static electricity from body before touching bat-

teries by first touching a grounded metal sur-

face.

Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-

connect charger before disconnecting battery

cables—Disconnect negative (−) cable first and

reconnect last.

CAUTION Disconnect battery charger from AC

source before disconnecting battery cables.

Otherwise, disconnecting cables can result in

voltage spikes damaging to DC control circuits

of the genset.

WARNING Accidental starting of the generator

set can cause severe personal injury or death.

Prevent accidental starting by disconnecting

the negative (−) cable from the battery terminal.

When troubleshooting a generator set that is shut

down, make certain the generator set cannot be ac-

cidentally restarted as follows:

1. Move the Run/Off/Auto switch on the control

panel to the OFF position.

2. Turn off or remove AC power from the battery

charger.

3. Remove the negative (−) battery cable from the

generator set starting battery.

4-2

STATUS INDICATORS

Non-Automatic Status Indicator: This red lamp

flashes continuously when the Run/Off/Auto switch

is in the Off position.

Warning Status Indicator: This yellow lamp is lit

whenever the control detects a warning condition.

After the condition is corrected, warning indicators

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

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

warning indicators can also be reset by cycling the

remote reset input after the condition is corrected.

Shutdown Status Indicator: This red lamp is lit

whenever the control detects a shutdown condition.

Shutdown faults are latched. After the condition is

corrected, shutdown indicators can be reset by

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

and pressing the Reset switch. In the Auto position,

shutdown faults can be reset by removing the re-

mote start input and then cycling the remote reset

input.

Emergency Stop shutdown status (Code 102) can be

reset only at the PCC front panel.

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

alphanumeric display is used in the menu-driven

operating system and to show shutdown and warn-

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

RESETTING THE CONTROL

Press the momentary Reset Switch to reset warn-

ing and shutdown messages after the condition has

been corrected. To reset a shutdown message with

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

in the Off Position. (The control cannot go into

Standby (sleep) mode until all faults have been

reset.)

In Auto mode, warning indicators can also be reset

by cycling the remote reset input after the condition

is corrected. Shutdown faults can be reset by re-

moving the remote start input and then cycling the

remote reset input.

ALPHANUMERIC

FAULT MESSAGE

DISPLAY

RESET

SWITCH

WARNING AND

SHUTDOWN

STATUS INDICATORS

FIGURE 4-1. CONTROL PANEL (PCC 3100)

4-3

TABLE 4-1. WARNING AND SHUTDOWN CODES

BASIC TROUBLE-

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

Blank LOAD DEMAND none 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

101 IDLE MODE none 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

102 EMERGENCY STOP Shutdown 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200 LOW OIL PRESSURE Warning 4-5 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 LOW OIL PRESSURE Shutdown 4-5 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 OIL PRES SENDER Warning 4-5 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 LOW COOLANT TEMP Warning 4-6 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 HIGH COOLANT TEMP Warning 4-6 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 HIGH COOLANT TEMP Shutdown 4-6 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 COOLANT SENDER Warning 4-6 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214 LOW COOLANT LVL Warning 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 LOW COOLANT LVL Shutdown 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 MAG PICKUP Shutdown 4-7 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221 FAIL TO CRANK Shutdown 4-7 4-15, 4-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222 OVERCRANK Shutdown 4-7 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223 OVERSPEED Shutdown 4-7 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224 FAIL TO SYNCHRONIZE Warning/Shutdown 4-8 4-31. . . . . . . . . . . . . . . . . . . . . . . . . .

226 FAIL TO CLOSE Warning/Shutdown 4-8 4-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 LOW DC VOLTAGE Warning 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231 HIGH DC VOLTAGE Warning 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232 WEAK BATTERY Warning 4-8 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 LOW FUEL − DAY Warning 4-9 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241 LOW FUEL Warning 4-9 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 EEPROM ERROR Shutdown 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251 EEPROM ERROR Warning 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252 EEPROM ERROR Warning 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4

TABLE 4-1. WARNING AND SHUTDOWN CODES

BASIC TROUBLE-

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

260 RACK POSITION Warning/Shutdown 4-9 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

261 GROUND FAULT*Warning/Shutdown 4-9/10 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

262 DAY TANK*Warning/Shutdown 4-9/10 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

263 HIGH GEN TEMP*Warning/Shutdown 4-9/10 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

270 PHASE ROTATION Shutdown 4-10 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

272 FIRST START Warning 4-10 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

301 HIGH AC VOLTAGE Shutdown 4-10 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

303 LOW AC VOLTAGE Shutdown 4-10 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313 UNDER FREQUENCY Shutdown 4-10 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

320 OVERCURRENT Warning 4-10 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

321 OVERCURRENT Shutdown 4-11 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322 SHORT CIRCUIT Shutdown 4-11 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 OVERLOAD Warning 4-11 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

335 REVERSE POWER Shutdown 4-11 4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

337 LOSS OF EXCITATION Shutdown 4-12 4-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

None INVALID SETUP None 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

None INVALID CAL None 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*Default message. Editable for customer site requirements. It is recommended that the bell alarm contacts of the

paralleling breaker be brought back to the control and indicate “Parallel CB Trip” as one customer fault.

4-5

TABLE 4-2. WARNING AND SHUTDOWN CODES

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

MESSAGE:

LOAD DEMAND

The PowerCommand control has received a signal to shut down from a

remote device. This is a normal operation mode, which is typically used in

automatic control system to minimize generator set operation hours and

system fuel consumption. When the load demand signal is removed, the

generator set will automatically start, synchronize, and close to the sys-

tem bus.

MESSAGE:

IDLE MODE

101 − WARNING

Indicates that the engine is operating in idle mode. When the genset is op-

erating in the RUN mode, grounding the engine idle input causes genera-

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

When ground is removed from this input, the genset returns to normal

speed and voltage.When the engine idle function is enabled, the control

automatically gensets lower oil pressure warning and shutdown trip

points to reflect the lower operating speed. When the engine idle function

is removed and the genset reverts to normal operating speed, the control

automatically resets oil pressure warning and shutdown trip points to the

normal settings.

Shutdown lamp lights.

MESSAGE:

EMERGENCY STOP

102 − SHUTDOWN

Indicates local or remote Emergency Stop.

To reset the local/remote Emergency Stop button:

Pull the button out (button with arrow − turn clockwise to allow it to pop

out).

Move the Run/Off/Auto switch to Off.

Press the Reset switch.

Select Run or Auto, as required.

Warning lamp lights.

MESSAGE:

LOW OIL PRESSURE

200 − WARNING

Indicates engine oil pressure has dropped to an unacceptable lev-

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

wait until next shutdown period and then follow 201-SHUTDOWN

procedure.

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

ing the fault.

Shutdown lamp lights.

MESSAGE:

LOW OIL PRESSURE

201 − 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, re-

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

4-3.

Warning lamp lights.

MESSAGE:

OIL PRES SENDER

204 − WARNING

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

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

erly connected.

4-6

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

LOW COOLANT TEMP

210 − WARNING

Set is not operating. Warning occurs

when engine coolant temperature is

70 F (21 C) or lower.

NOTE: In applications where the

ambient temperature falls below

40F (4C), Low Coolant Temp

may be indicated even though the

coolant heaters are operating.

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

ant. Check for the following conditions:

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

or disconnected heater cord and correct as required.

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

sible coolant leakage points and repair as required.

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

Warning lamp lights.

MESSAGE:

HIGH COOLANT TEMP

211 − WARNING

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

mended maximum temperature limit:

215 F (102 C) − standby or 207 F (97 C) − prime.

If generator is powering non-critical and critical loads and cannot be shut

down, use the following:

a. Reduce load if possible by turning off non-critical loads.

b. Check air inlets and outlets and remove any obstructions to airflow.

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

DOWN procedure.

To check coolant temperature, access the coolant temperature

menu prior to clearing the fault.

Shutdown lamp lights.

MESSAGE:

HIGH COOLANT TEMP

212 − SHUTDOWN

Indicates engine has overheated (coolant temperature has risen above

the shutdown trip point:

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

cool down completely before proceeding with the following checks:

a. Check for obstructions to cooling airflow and correct as necessary.

b. Check fan belt and repair or tighten if necessary.

c. Check coolant mixture.

d. Check blower fan and circulation pumps on remote radiator installa-

tions.

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

Warning lamp lights.

MESSAGE:

COOLANT SENDER

213 − WARNING

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

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

2k ohms.

4-7

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

LOW COOLANT LVL

214 − WARNING

LOW COOLANT LVL

215 − SHUTDOWN

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

to cool down completely before proceeding.

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

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

necessary.

b. If radiator level is low and coolant bottle level is correct, defective

coolant bottle hose or radiator cap.

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

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

mode (low coolant warning only).

Shutdown lamp lights.

MESSAGE:

MAG PICKUP

220 − SHUTDOWN

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

match generator set output frequency.

a. Restart and check RPM on the digital display.

Engine will not crank.

Shutdown lamp lights.

MESSAGE:

FAIL TO CRANK

221 − SHUTDOWN

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

lowing conditions:

a. Check fuse F3 on the Engine Interface board.

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

and tighten all connections.

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

Shutdown lamp lights.

Engine stops cranking.

MESSAGE:

OVERCRANK

222 − SHUTDOWN

Indicates possible fuel system problem.

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

rect as required.

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

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

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

Engine runs and then shuts down.

Shutdown lamp lights.

MESSAGE:

OVERSPEED

223 − SHUTDOWN

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

nominal).

4-8

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Warning (or Shutdown) lamp

lights.

MESSAGE:

FAIL TO SYNCHRONIZE

224 − WARNING

FAIL TO SYNCHRONIZE

224

The generator set has not synchronized to the system bus within the al-

lowable time frame.

a. Check the governor system stability. Adjust governing and synchro-

nizer parameters as required.

b. Check for fuel system problems which can cause engine instability.

Synchronizing time can be improved by widening the synchronizing

window and reducing the acceptance time delay.

Warning lamp lights.

MESSAGE:

FAIL TO CLOSE

226 − SHUTDOWN

Indicates that the paralleling breaker has been given a signal to close, but

has not closed properly.

a. Verify that the charging mechanism of the paralleling breaker is func-

tioning properly.

b. Check the close signal to the breaker.

c. Verify that the auxiliary contact signals from the breaker to the Pow-

erCommand control are operational.

Warning lamp lights.

MESSAGE:

LOW DC VOLTAGE

230 − WARNING

Indicates battery voltage is below 10 VDC.

a. Discharged or defective battery.

Check the battery charger fuse.

Recharge or replace the battery.

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

and tighten all connections.

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

battery charging voltage is not obtained.

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

el).

Warning lamp lights.

MESSAGE:

HIGH DC VOLTAGE

231 − WARNING

Indicates battery voltage exceeds 32 VDC.

Check voltage float level on battery charger if applicable (lower float lev-

el).

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

tery charging voltage is not obtained.

Warning lamp lights.

MESSAGE:

WEAK BATTERY

232 − WARNING

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

during starting.

Discharged or defective battery.

See Warning message 230, LOW DC VOLTAGE.

4-9

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

LOW FUEL−DAY

240 − WARNING

LOW FUEL

241 − WARNING

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

plenish as required.

Shutdown lamp lights.

MESSAGE:

EEPROM ERROR

250 − SHUTDOWN

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

eters.

Warning lamp lights.

MESSAGE:

EEPROM ERROR

251 − WARNING

252 − WARNING

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

rameters.

Shutdown lamp lights.

MESSAGE:

RACK POSITION

260 − WARNING

Indicates that one or both of the fuel racks is not at the commanded posi-

tion.

a. Check fuel pump connections.

b. Check left and right actuator fuses (A38-F1 & F2) on the governor

output module.

Shutdown lamp lights.

MESSAGE:

GROUND FAULT

261 − SHUTDOWN

DAY TANK

262 − SHUTDOWN

HIGH GEN TEMP

263 − SHUTDOWN

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

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

tional customer selection. These fault functions can be programmed to

initiate a shutdown or a warning.

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

selected.

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

the code shown (261 thru 263) may have been edited and may not appear

as shown in this table.

4-10

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

GROUND FAULT

261 − WARNING

DAY TANK

262 − WARNING

HIGH GEN TEMP

263 − WARNING

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

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

tional customer selection. These fault functions can be programmed to

initiate a shutdown or a warning.

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

lected.

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

the code shown (261 thru 263) may have been edited and may not appear

as shown in this table.

Shutdown lamp lights.

MESSAGE:

PHASE ROTATION

270 − SHUTDOWN

The phase relationship between the generator set and the system bus is

not matched.

a. Using a phase rotation checker, verify that the generator set phase

rotation matches the phase orientation of the system bus.

b. Verify that control wiring to the bus PT module on the PowerCom-

mand control is properly connected.

Shutdown lamp lights.

MESSAGE:

FIRST START

272 − WARNING

The PowerCommand control is not receiving a proper signal from the sys-

tem master first start sensor. When this occurs, the control reverts to a fall-

back mode in which breaker closure is automatically allowed if bus is de-

energized. If bus voltage is sensed, the control will force the generator set

to synchronize to the system bus before breaker close signal is initiated.

Shutdown lamp lights.

MESSAGE:

HIGH AC VOLTAGE

301 − SHUTDOWN

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

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

Shutdown lamp lights.

MESSAGE:

LOW AC VOLTAGE

303 − SHUTDOWN

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

of nominal for 10 seconds.

Shutdown lamp lights.

MESSAGE:

UNDER FREQUENCY

313 − SHUTDOWN

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

seconds.

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

Check fuel supply, intake air supply and load.

4-11

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Warning lamp lights.

MESSAGE:

OVERCURRENT

320 − WARNING

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

seconds.

Check load and load lead connections.

Shutdown lamp lights.

MESSAGE:

OVERCURRENT

321 − SHUTDOWN

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

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

down.

Check load and load lead connections.

Shutdown lamp lights.

MESSAGE:

SHORT CIRCUIT

322 − SHUTDOWN

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

Check load and load lead connections.

Warning lamp lights.

MESSAGE:

OVERLOAD

330 − WARNING

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

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

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

Check load and load lead connections.

Shutdown lamp lights.

MESSAGE:

REVERSE POWER

335 − SHUTDOWN

Indicates that power is flowing into the generator set, rather than out from

the unit. This can be caused by engine failure, or inability to carry load, or

by a number of control or interconnection problems.

a. If problem occurs at initial startup, verify connection of generator set

CT’s, by applying load to the generator set while it is operating alone

while connected to bus.

b. Verify proper connection of load sharing lines.

c. Verify that the generator set is operating at the correct frequency and

voltage. The no-load voltage of the generator set and other genera-

tor sets should all be the same.

4-12

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

Hazards present in troubleshooting can cause equipment damage, severe personal

injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-

ity, and machinery hazards should perform service procedures. Read Important Safety Instruc-

tions page and observe all instructions and precautions in this manual.

WARNING

SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.

MESSAGE:

LOSS OF EXCITATION

337 − SHUTDOWN

Indicates that the alternator excitation system is improperly adjusted or has

failed. Loss of Excitation failure may also be caused by operation of filters

and power factor correction capacitors in the generator set loads when the

kW load level on the genset is low. The capacitors in the filters and power

factor correction equipment can present a leading power factor load to the

generator set, which (correctly) shuts down the generator set through the

loss of excitation fault. Leading power factor loads can cause the generator

set to lose control of the output voltage of the genset and can cause kVar

load sharing problems. Therefore, it is necessary to protect the genset from

excessive leading power factor and reverse Var conditions.

a. Start the generator set in the RUN mode and check output voltage

with both the control digital meter set and a calibrated meter. Cali-

brate voltage if necessary. Output voltage should be adjusted to the

same level as all other generator sets at no load. Make adjustments

as necessary to correct.

b. Check load sharing lines for proper interconnections.

c. See Section 6 of this manual “Servicing the Generator”, Exciter Rec-

tifier, and exciter Rotor.

MESSAGE:

INVALID SETUP

Indicates that the digital board is not properly calibrated for the generator

set model. Refer to Digital Board (A32) Calibration in Section 5.

MESSAGE:

INVALID CAL

Indicates that the digital board is not properly calibrated for the generator

set model. Refer to Digital Board (A32) Calibration in Section 5.

TABLE 4-3. PCC OIL PRESSURE WARNING & SHUTDOWN LIMITS

QST30 Engine: NORM 45-65 psi (310-448 kPa), IDLE 20 psi (138 kPa)

35 psi (241 kPa) shutdown limit - run mode value

40 psi (276 kPa) warning limit - run mode value

10 psi (69 kPa) shutdown limit - idle mode value

15 psi (103 kPa) warning limit- idle mode value

To check oil pressure or engine temperature during a warning, access the oil pressure or

coolant temperature menu prior to clearing the fault.

4-13

TROUBLESHOOTING PROCEDURE

The following tables are a guide to help you evalu-

ate problems with the generator set. You can save

time if you read through the manual ahead of time

and understand the system.

To determine the appropriate troubleshooting

procedure for the specific problem at hand, be

sure to refer to the “Indicators” column pro-

vided in each troubleshooting table.

Try to think through the problem. Go over what was

done during the last service call. The problem could

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

tripped circuit breaker. (Table 4-38 describes the

location and function of each fuse.)

Figure 4-2 shows the location of the components

within the control panel that are referenced in the

following troubleshooting procedures. Connector,

LED and switch locations for each circuit board and

module are provided in Section 3. The control wiring

and circuit board connections are shown in Section

CAUTION Always set the Run/Off/Auto (S12)

switch to the Off position and the Power On/

Standby (S5) switch to the Standby position be-

fore disconnecting or connecting harness con-

nectors. Otherwise, disconnecting the harness

connectors can result in voltage spikes high

enough to damage the DC control circuits of the

genset.

CAUTION Electrostatic discharge will damage

circuit boards. Always wear a grounding wrist

strap when handling circuit boards or socket-

mounted IC’s and when disconnecting or con-

necting harness connectors.

4-14

ACCESSORY BOX

(A40)

CUSTOMER INTERFACE

A34

ENGINE INTERFACE

A31

ANALOG BOARD

A33

DIGITAL BOARD

A32

DISPLAY BOARD

A35

RUN/OFF/AUTO

SWITCH S12

OPTIONAL RTD

RELAY

OPTIONAL

COMMON ALARM

RELAY K14

OPTIONAL RUN

RELAYS K11, K12 &

K13 OPTIONAL

THERMISTOR

RELAY 160/140 C

TB1-1 THROUGH 60

GOVERNOR

OUTPUT MODULE

A38

PT/CT BOARD A36

VOLTAGE

REGULATOR

OUTPUT MODULE

A37

S5 POWER ON/

STANDBY SWITCH

BUS PT MODULE

A39

FIGURE 4-2. CIRCUIT BOARD LOCATIONS

4-15

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CRANK”

(221)

message

Reset and

attempt to

start:

Start LED

DS11 on the

engine

interface board

turns on.

NOTE:

These two

indications

suggest that

the PCC has

received a

start signal

and has sent a

start command

to the start

output (J4-2)

on the engine

interface

board.

2. Starter could be bad.

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

there may be an open between A37

and A31, an open between A37 and

K4, or A31 may be bad.

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

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

starter could be bad. Test starter (see engine

service manual). Replace the starter.

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

B+ into and out of start solenoid contacts. If

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

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

check ground connection. If ground connection

is good, the start solenoid is bad. Replace the

start solenoid.

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

contacts, check for an open between the start

solenoid contacts and the starter. If there is no

B+, go to the next step.

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

lenoid K4 could be bad.

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

coil (K4), the backup start disconnect

contacts in the regulator output mod-

ule (A37) could be open (indicating

that A37 is bad).

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

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

is no continuity, the regulator output module is

bad. Replace A37.

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

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

A37 P7-5.

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

tween start solenoid coil (K4) and A37. If there

is no B+ at P7-5, check for B+ at J4-2 on the en-

gine interface board (A31) while attempting to

start.

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

tween A37 and A31.

If there is no B+ at A31 J4-2, (and DS11 is on)

the engine interface board is bad. Replace A31.

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

ty for a fully charged battery is approximately

1.260 at 80 F (27 C).

1b. Clean and tighten or replace the battery cable

connectors and cables at the battery and the

set.

1c. Adjust charge rate of battery charging circuit.

1d. Replace engine DC alternator if normal battery

charging voltage is not obtained.

1. Insufficient battery voltage. Check the

following conditions:

a. Batteries not charged.

b. Battery connections loose or

dirty.

c. Insufficient battery charging volt-

age.

d. Engine DC alternator could be

bad.

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

6. The mag pickup signal is not being

sensed.

6. Refer to the mag pickup shutdown message

(220).

4-16

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

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

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

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

If open, replace the fuse with one of the same

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

check the B+ supply from the wiring harness.

1. Fuse F3 on the engine interface board

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

getting to F3.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CRANK”

(221)

message

Reset and

attempt to

start:

Start LED

DS11 on the

engine

interface board

does NOT

turn on.

NOTE:

These two

indications

suggest that

the PCC has

received a

start signal

and has NOT

sent a start

command to

the start output

(J4-2) on the

engine

interface

board.

2. To isolate:

Check for B+ at S13-1 and S13-2.

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

(and S13 is NOT in the emergency stop

position), then S13 is bad. Replace S13.

If there is no B+ at S13-2, disconnect

J3/P3, and check for B+ at A31 J3-2. If

there is no B+, replace A31.

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

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

or replace as necessary.

2. Emergency Stop switch S13 or the

PCC door harness may be bad.

4. Engine interface board (A31) may be

bad.

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

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

bad. Replace A31.

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

the control. Attempt to start, and test for ground

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

A32 is bad. Replace A32.

3. Digital board (A32) may be bad.

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

4-17

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

“FAIL TO

CRANK”

(221)

message

DOES NOT

appear on

digital display

−and:

Auto LED DS5

on the engine

interface board

(A31) is on −

RMT Start

LED DS14 on

the customer

interface board

(A34) is on −

NOTE:

This condition

suggests that

the PCC

processor

(digital board

−A32) has

NOT received

or recognized

a remote start

start signal.

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

for ground output at A32 J4-18.

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

engine interface board A31 is bad. Replace

A31.

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

ceed to the next step.

1. The Auto mode signal is not getting

from engine interface board A31 to

digital board A32, indicating that A31 is

bad.

Indicator(s) Possible Cause Corrective Action

2. The Remote run signal is not getting

from customer interface board A34 to

A32, indicating that A34 is bad.

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

the control. Attempt to remote start, and check

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

put (but A34 DS14 is on) customer interface

board A34 is bad. Replace A34.

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

ceed to the next step.

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

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

at A32 J4-18—and there is no “FAIL TO

CRANK” message—and the set does not

crank; A32 is bad. Replace, A32.

3. Digital board (A32) may be bad.

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

4-18

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CRANK”

(221)

message

DOES NOT

appear on

digital display

−and:

Auto LED DS5

on the engine

interface board

(A31) is off −

RMT Start

LED DS14 on

the customer

interface board

(A34) is on −

NOTE:

This condition

suggests that

the engine

interface board

(A31) is NOT

enabling the

remote start

logic on the

digital board.

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

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

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

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

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

The Auto mode input is not getting from the

Auto select switch (S12) to engine interface

board A31 (indicating that S12, A31, or the

harness is bad.

1. S12 or the wiring harness may be bad. *1. Disconnect A31 J3/P3. Check continuity to

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

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

ground is present, place S12 in Auto and check

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

isolate to switch or wiring harness. Repair as

necessary. If there is continuity, A31 may be

bad. Reconnect J3/P3.

2. Engine interface board A31 may be

bad.

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

J4-16, A32 is bad. Replace A32.

3. Digital board A32 may be bad.

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

4-19

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CRANK”

(221)

message

DOES NOT

appear on

digital display

−and:

Auto LED DS5

on the engine

interface board

(A31) is on −

RMT Start

LED DS14 on

the customer

interface board

(A34) is off

NOTE:

This condition

suggests that

the remote

start input is

NOT passing

through the

customer

interface board

(A34) to

enable the

remote start

logic on the

digital board.

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

DS14 is off, replace A34.

The remote start input is not getting from the

remote start switch to the output of the cus-

tomer interface board (A34) (indicating that

the switch, A34, or the harness is bad.

1. The remote start switch or the

wiring harness may be bad.

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

the control. Attempt remote start and check for

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

ent, isolate to the switch or the wiring harness

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

as necessary.

2. Customer interface board A34

may be bad.

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

4-20

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CRANK”

(221)

message

DOES NOT

appear on

digital display

−and:

Run LED DS4

on the engine

interface board

(A31) is off−

NOTE:

This condition

suggests that

the start input

is NOT getting

from the

Run/Off/ Auto

switch (S12) to

the engine

interface board

(A31) to

enable the

remote start

logic on the

digital board.

The start input is not getting from the Run/

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

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

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

wiring harness may be bad.

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

ground is not present, replace A31. If ground is

present, place S12 in Run and check continuity

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

switch or wiring harness. Repair as necessary.

If there is continuity, A31 may be bad.

2. Engine interface board A31

may be bad.

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

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

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

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

DS5 is off, replace A31.

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

J4-16, replace A32.

3. Digital board A32 may be bad.

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

4-21

TABLE 4-10. ENGINE CRANKS BUT DOES NOT START

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

2. The mechanical fuel linkage could be

binding, loose, or damaged.

2. Inspect the mechanical fuel linkage, and repair

or replace as necessary.

Follow the procedure in the engine repair

manual to check the EFC for binding or dam-

age.

Disconnect the actuator connector, and con-

nect +12 VDC from the battery to the actuator.

The actuator should click upon application and

removal of the voltage.

If the actuator does not click, refer to the engine

manual.

If the actuator clicks, reconnect the wires to the

actuator.

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 ser-

vice manual.

Indicator(s) Possible Cause Corrective Action

“OVERCRANK”

(222)

message

−and

While cranking,

Run LED DS12

on the

engine interface

board (A31)

is on.

and

While cranking,

Run LED DS2

on the

governor output

module (A38)

is on.

NOTE:

These

indications

suggest that the

PCC has sent a

run signal to the

fuel solenoid.

3. Fuel solenoid (K1) on the injection

pump not energized due to:

a. Open in fuel solenoid circuit or

defective governor module.

b. Defective fuel solenoid.

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

B+ at the K1 fuel solenoid coil on the injection

pump and at output of governor module. Check

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

3b. Check wiring continuity of fuel solenoid circuit.

Test fuel solenoid.

Repair or replace as necessary.

5. Engine fuel injection or other engine

problem.

4. Fuel tank solenoid not energized due

to:

a. Open in fuel tank solenoid circuit.

b. Defective fuel tank solenoid.

5. Refer to the engine service manual.

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

cuit.

4b. Test fuel tank solenoid.

Repair or replace as necessary.

Fuel supply or fuel delivery.

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

4-22

TABLE 4-11. ENGINE CRANKS BUT DOES NOT START

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

1. The run signal is not getting out of the

engine interface board (A31). A31

may be bad.

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

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

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

A31.

Indicator(s) Possible Cause Corrective Action

“OVERCRANK”

(222)

message

−and

While cranking,

Run LED DS12

on the

engine interface

board (A31)

is on.

and

While cranking,

Run LED DS2

on the

governor output

module (A38)

is off.

NOTE:

These

indications

suggest that the

PCC has sent a

run signal to the

governor

module, but the

signal is not

getting through

the governor

module to the

fuel solenoid.

The run signal is not getting through the

governor module to the fuel solenoid.

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

at A31 J4-1.

2. There is an open between the engine

interface board (A31) and the gover-

nor output module (A38).

3. The run signal is not getting through

the governor output module (A38).

A38 may be bad.

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

tween A38 J6/P6. Check for B+ at

A38 J6-19, while attempting to crank. If there is

no B+ at A38 J6-19, isolate to connectors and

wiring. Repair or replace as necessary.

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

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

tery ground, if not continuity replace harness, if

continuity, replace A38.

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

4-23

TABLE 4-12. ENGINE CRANKS BUT DOES NOT START

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

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

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

1. The run signal is not getting out of the

digital board (A32). A32 may be bad.

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

A32.

Indicator(s) Possible Cause Corrective Action

“OVERCRANK”

(222)

message

−and

Run LED DS12

on the

engine interface

board (A31)

is off.

NOTE:

These

indications

suggest that the

PCC has NOT

sent a run

signal −

(fuel solenoid

enable signal)

out to the

governor

module and the

fuel solenoid.

The run signal from the digital board (A32)

is not being processed by the engine inter-

face board (A31).

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

A31.

2. The run signal is not being processed

by the engine interface board (A31).

A31 may be bad.

“FAIL TO

CRANK”

(221)

message

NOTE:

The engine is

cranking but

shutting down

on a 221 fault.

The mag pickup signal is not being

sensed.

Refer to the mag pickup shutdown message

(220).

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

4-24

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOW OIL

PRESSURE”

warning

(200) or

shutdown

(201)

message.

1. Low oil level. Clogged lines or filters.

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

the generator set may be shutting

down on another fault.

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

OK but oil level is low, replenish. Oil pressure

limits are listed in Table 4-3.

2. Disconnect the oil pressure sender leads, and

connect an oil pressure sender simulator to the

harness.

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

nect the sender, disconnect the run signal wire

at the fuel solenoid, and crank the engine.

Check the oil pressure reading on the digital

display.

If the display shows an acceptable oil pres-

sure, the problem may not be in the oil or oil

sensing system. The generator set may

be shutting down on another fault (out of

fuel, blown governor fuse, intermittent

connector). Restart the generator set and

monitor the PCC display panel for other

faults.

If the display does not show an acceptable

oil pressure, replace the sender. If the

PCC still doesn’t display an oil pressure

while cranking, the oil pump may be faulty.

Refer to the engine service manual.

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

the PCC or the harness is bad. Install harness

tool between A31 J2/P2.

Check for +5 VDC at the sender (lead marked

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

Check for 5 VDC at A31 J5-18.

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

VDC at A31 J2-24.

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

If there is 5 VDC at the sender, use the sender

simulator to generate a signal to A31 J2-23. If

the pressure signal (.5 to 4.5 VDC) does not get

to A31 J2-23, isolate to the harness or A31. If

the pressure signal does get to A31 J2-23, refer

to the analog/digital troubleshooting procedure

(Table 4-36a/b).

2b. Harness or PCC circuit board could be

bad.

Isolate to the harness, engine inter-

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

or digital board (A32).

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

4-25

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“OIL

PRESSURE

SENDER”

warning

(204)

message.

1. The sender connections could be bad.

2. The sender, the harness, engine inter-

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

or analog board (A33) could be faulty.

1. Check the sender connections.

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

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

board (A32).

Disconnect the oil pressure sender leads, and

connect an oil pressure sender simulator to the

harness.

“OIL PRES SENDER” warning is displayed

after the fault condition is sensed for 10 sec-

onds.

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

place the sender.

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

the PCC or the harness is bad. Install harness

tool between A31 J2/P2.

Check for +5 VDC at the sender (lead marked

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

Check for 5 VDC at A31 J5-18.

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

VDC at A31 J2-24.

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

If there is 5 VDC at the sender, use the sender

simulator to generate a signal to A31 J2-23. If

the pressure signal (.5 to 4.5 VDC) does not get

to A31 J2-23, isolate to the harness or A31. If

the pressure signal does get to A31 J2-23, refer

to the analog/digital troubleshooting procedure

(Table 4-36a/b).

“COOLANT

SENDER”

warning

(213)

message.

1. Check the sender connections.

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

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

board (A32).

Disconnect the sender, and plug in a resistive

sender simulator to isolate the fault.

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

place the sender.

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

lator, refer to the high coolant temp trou-

bleshooting procedure.

1. The sender connections could be bad.

2. The sender, the harness, engine inter-

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

or analog board (A33) could be faulty.

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

4-26

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

“LOW

COOLANT

TEMP”

warning

(210)

message.

Coolant level

is normal.

Heater is OK.

Coolant temp

on front panel

display is OK.

DS3 on the

engine

interface

board, A31,

is on.

Indicator(s) Possible Cause Corrective Action

DS3 / A31 is on, indicating that engine in-

terface board A31 is receiving a low cool-

ant temp from the sender.

The sender, the harness or A31 could be

bad.

Isolate the source of the signal.

Unplug the coolant temperature switch (S1) and re-

set the control.

1. If the 210 warning message drops out and does

not reappear, replace the sender.

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

mains after control reset, disconnect A31 J4

and check continuity from P4−13 to GND.

If there is continuity, replace the harness.

If there is no continuity, replace circuit

board A31.

DS3 / A31 is off, indicating that engine in-

terface board A31 is not receiving a low en-

gine temp signal from the sender—but the

210 message indicates that A32, the digital

board, is responding to a false low engine

temp signal.

A31, the engine interface board, or A32,

the digital board, could be bad.

Isolate the source of the signal.

Check J4−6/P4−6 on A32.

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

2. Open J4−6 and reset the control.

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

place A31.

If fault returns after resetting the control,

replace A32.

“LOW

COOLANT

TEMP”

warning

(210)

message.

Coolant level

is normal.

Heater is OK.

Coolant temp

on front panel

display is OK.

DS3 on the

engine

interface

board, A31,

is off.

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

4-27

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“HIGH

COOLANT

TEMP”

warning

(211) or

shutdown

(212)

message.

Coolant

mixture and

level is normal.

No airflow

obstructions.

Fan belt is OK.

1. Engine problem:

Coolant pump could be faulty.

Thermostat could be faulty.

There could be an obstruction in

the coolant flow.

External coolant pump (with re-

mote radiator) could be faulty.

External radiator fan motor (with

remote radiator) could be faulty.

2. The generator set may have been

overloaded.

3. Sender, harness or PCC circuit board

could be bad.

1. Refer to the engine service manual if there are

any physical indications of overheating.

2. Correct any overload condition.

3. If there are no physical indications of overheat-

ing, check to see if the PCC accurately displays

ambient engine temperature.

If the PCC ambient coolant temperature

reading is accurate, the engine may be

overheating. Refer to the engine service

manual.

If the PCC ambient coolant temperature

reading is not accurate, isolate to the

sender, harness, engine interface board

(A31), analog board, or digital board.

Disconnect the coolant temperature sender

leads, and connect an coolant temperature

sender simulator to the harness.

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

place the sender.

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

lator, install harness tool between A31

J5/P5. Connect the coolant temperature

sender simulator (and B+) to A31 J5.

If the control displays the correct simulated

temperature, replace the harness.

If the control does not display the correct

simulated temperature, install harness

tool at A31 J2/P2, and open lines 18/19

(and 14/15, if applicable). Check for conti-

nuity between A31 J2-18 to 19 (for coolant

temp L), and A31 J2-14 to 15 (for coolant

temp R).

If no continuity, then A31 is bad.

If continuity is OK, then send a simu-

lated temperature signal and mea-

sure the voltage out of A31 (A31

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

If voltage is not OK (refer to the ana-

log board inputs and outputs, Table

4-37), replace A33.

If voltage is OK, refer to the analog/

digital troubleshooting procedure

(Table 4-36a/b).

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

4-28

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOW

COOLANT

LVL” warning

(214) or

shutdown

(215) message

Coolant level

is normal.

DS2 on the

engine

interface

board, A31,

is on.

DS2 on A31 is on, indicating that A31 is re-

ceiving a low coolant signal from the send-

er.

The sender, the harness or the A31 circuit

board could be bad.

If the coolant level is normal, isolate the source of the

low coolant signal. (This is a ground signal.)

Disconnect the signal lead at the sender and reset

the control.

1. If the 215 shutdown message drops out and

does not reappear, replace the sender.

*2. If the 215 shutdown message reappears and

remains after control reset, disconnect J4/A31

and check continuity from P4−7 to GND.

If there is continuity, replace the harness.

If there is no continuity, replace circuit

board A31.

“LOW

COOLANT

LVL” warning

(214) or

shutdown

(215) message

Coolant level

is normal.

DS2 on the

engine

interface

board, A31,

is off.

DS2 on A31 is off, indicating that A31 is not

receiving a low coolant signal from the

sender—but the 215 message indicates

that A32, the digital board, is responding to

a false low coolant signal.

A31, the engine interface board, or A32, the

digital board, could be bad.

If the coolant level is normal, isolate the source of the

low coolant signal.

Check J4−4/P4−4 on A32.

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

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

If the fault drops out and does not return,

replace A31.

If the fault returns after resetting the con-

trol, replace A32.

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

4-29

TABLE 4-18. MAG PICKUP SHUTDOWN (220)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“MAG

PICKUP”

shutdown

message (220)

This indicates that the PCC is not sensing

the mag pickup signal, or the mag pickup

frequency does not correspond (in propor-

tion) to the genset output frequency.

1. Check and correct setting if necessary.

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

essary.

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

tempt to start the set in idle mode.

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

down message, or if the engine starts and idles,

but then shuts down on a MAG PICKUP fault,

the MPU sender could be bad. Remove the

MPU connectors and check for 3.5 to 15 VAC at

the MPU while cranking.

If no output, check for damage or debris.

Also check for improper adjustment of the

MPU. (Refer to Section 5.) If there is still

no output, replace the MPU sender.

If the MPU output is OK, install harness

tool between A32 J4/P4. Check for MPU

voltage at A32 J4-10 to 11, while cranking.

If OK, replace A32. If not OK, use continu-

ity checks to isolate to A31 or harness.

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

play a fault, then there could be a frequency

mismatch problem.

Measure generator output frequency with

a digital multimeter and compare to the fre-

quency on the PCC display.

If they do match, multiply the frequency by

30 and compare this number to the RPM

on the PCC display. If these are not the

same, the MPU sender may be bad. Re-

place the MPU sender

If the multimeter and PCC frequencies do

not match, there is a frequency sensing

problem. Verify the accuracy of the PCC

L1N voltage, and then refer to the analog/

digital troubleshooting procedure (Table

4-36a/b).

1. The PCC may not be set for the correct

generator set.

2. Loose or damaged mag pickup wire.

3. Damaged mag pickup (MPU).

4. The harness, the engine interface

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

the digital board (A32) could be bad.

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

4-30

TABLE 4-19. OVERSPEED SHUTDOWN (223)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“OVERSPEED”

shutdown

message (223)

1. Inspect the mechanical fuel linkage, and repair

or replace as necessary.

Follow the procedure in the engine repair

manual to check the EFC for binding or

damage.

Disconnect the actuator connector, and

connect +12 VDC from the battery to the

actuator. The actuator should click upon

application and removal of the voltage.

If the actuator does not click, refer to the

engine manual.

If the actuator clicks, reconnect the wires

to the actuator.

*2. Reset the control, and start the set while moni-

toring the PCC duty cycle display.

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

set shuts down on overspeed, replace A32.

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

down on overspeed, replace A38.

1. The mechanical fuel linkage could be

binding, loose, or damaged.

2. The governor output module (A38) or

the digital board (A32) could be bad.

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

4-31

TABLE 4-20a. FAIL TO SYNCHRONIZE (224)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

SYNCHRO-

NIZE” warning

(224) or

shutdown

(224)

message.

1. Improper adjustment of bus or genera-

tor set voltage.

1. Verify that the bus voltage is within plus or mi-

nus 5% of the value which is programmed into

the PowerCommand control, and verify that the

generator set is operating at proper voltage and

frequency. Verify that the bus PT module is

properly calibrated. (Refer to Digital Bus Volt-

age Calibration in Section 5). Check the FAIL

TO SYNCHRONIZE time delay. It should be set

for approximately 120 seconds. Check parallel-

ing setup adjustments, particularly PERM WIN -

PHASE and PERM WIN - TIME. They are typi-

cally adjusted to 20 degrees and 0.5 seconds.

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

2. Generator set hunting due to improper

synchronizing adjustments.

3. Unstable or hunting generator set due

to governor component failure or mis-

adjustment.

Continued On Next Page...

2. Check synchronizer adjustments in the Power-

Command control set−up. If you are unsure of

proper adjustment procedure, returning the unit

to it’s default values should result in proper op-

eration. The default values are shown in the test

report which is shipped with the generator set.

In particular, check values for paralleling func-

tions, governing and voltage regulation.

3. Inspect generator set governing system for evi-

dence of binding or sticking linkages or other

components which are not operating correctly.

Verify that water jacket heaters are operational

and properly functioning. Check and adjust

governor settings as required.

4-32

TABLE 4-20b. FAIL TO SYNCHRONIZE (224) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

SYNCHRO-

NIZE” warning

(224) or

shutdown

(224)

message.

4. Unstable or hunting generator set due

to air entrained in the fuel system.

4. This problem is indicated in situations where

the generator set performs properly after the

generator set is up and running with load, but

experiences ”FAIL TO SYNCHRONIZE” alarms

after it has been shut down for several days.

Check the generator set fuel system for leaks or

cracks. If fuel filters have recently been

changed, air may be trapped in the fuel filter

heads. Check to be sure that there is a fuel head

on the engine fuel pump. Check fuel line routing

for overhead loops which could result in the

trapping of air in the system if the system sits

idle for some period of time. Parallel systems

should use option C174, the fuel pump feature

option. This feature is available as an aftermar-

ket accessory kit.

Note: The generator set will synchronize

faster as the synchronize acceptance win-

dow is widened (i.e., the value in the PERM

WIN−PHASE is increased) and as the accep-

tance time is minimized (the value in the

PERM WIN−TIME is minimized). Caution

should be taken in utility (mains) paralleling

applications to avoid damage to the genera-

tor set by inappropriate setting of these pa-

rameters.

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

4-33

TABLE 4-21a. FAIL TO CLOSE (226)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CLOSE”

warning (226)

or shutdown

(226)

message.

1. Check the paralleling breaker for indi-

cation that the breaker is tripped and

locked out from a signal issued from

it’s internal trip unit

1. If the breaker has tripped due to operation of it’s

internal trip unit, the alternator and electrical

distribution system connected to the alternator

should be carefully inspected for evidence of

burning or tracking, which might indicate that an

electrical fault has occurred. If no evidence of a

fault is found, reset the trip unit and verify that

the trip settings of the breaker are appropriate

for the application. Reset the fault on the Pow-

erCommand control and check the system op-

eration to verify that the failure to close fault

problem has been eliminated.

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

2. Breaker charge circuit is not operating

properly. (Power circuit breakers only.)

Continued On Next Page...

2. Check the circuit breaker status indicators and

verify that the breaker status indicates that the

breaker is properly charged. If it is, go on to step

3. If it is not charged, check the charge circuit for

proper operation. Switch the PowerCommand

control RUN/OFF/AUTO switch to OFF and

then manually recharge the paralleling breaker

according to the manufacturer’s instructions.

Switch the PowerCommand control RUN/OFF/

AUTO switch back to RUN. The generator set

should start and accelerate to rated speed and

voltage and the operator should be able to

manually control the circuit breaker from the

pushbuttons on the front panel of the Power-

Command control. In most cases the breaker

should automatically recharge on closing to the

system bus. If this does not occur, problem may

be in the control wiring to the breaker, or the

control power source.

NOTE: Some breakers are not able to be set

up to charge on closing (they will recharge

on opening). If this is the case with your

installation, it is critical that the generator

set be allowed to operate for a cooldown pe-

riod which is long enough for the breaker to

completely charge before the generator set

is shut down. If the generator set is shut

down on a fault condition, the breaker may

require manual recharge before the system

can be put back into automatic operation.

4-34

TABLE 4-21b. FAIL TO CLOSE (226) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FAIL TO

CLOSE”

warning (226)

or shutdown

(226)

message.

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

3. Breaker close signal has been issued

from the PowerCommand control, but

has not reached the breaker.

3. Disconnect breaker control wiring and verify

that the control is sending a close signal to the

breaker. If the breaker signal is present at the

generator set control, reconnect the control wir-

ing at the set, verify that it is present at the

breaker terminals.

Note that in Onan paralleling systems, DC pow-

er for operation of the relay comes from the gen-

erator control. Verify that the 20 amp customer

B+ fuse (F1 − engine harness assembly) is OK

and that the pilot relay operates properly.

4. Breaker status (open/close) signals

are not properly connected to the Pow-

erCommand control, or are not operat-

ing properly.

4. Verify that the breaker auxiliary contact wiring is

properly connected to the generator set. Verify

that the breaker is sending proper condition sig-

nals to the generator set, by disconnecting the

control wiring at the breaker and verifying that

the breaker auxiliary contacts change state

when breaker condition changes. If they are

functioning properly, verify that the signals are

reaching the generator set by reconnecting the

wiring and the breaker and checking for condi-

tion change at the generator set control acces-

sory box.

4-35

TABLE 4-22. DC (BATTERY) WARNINGS (230, 231, 232)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOW DC

VOLTAGE”

(230) or

“WEAK

BATTERY”

(232),

warning

message.

“HIGH DC

VOLTAGE”

(231)

warning

message.

But battery

voltage is OK.

1. Recharge or replace the battery. Specific gravi-

ty for a fully charged battery is approximately

1.260 at 80 F (27 C).

2. Replenish electrolyte and recharge battery.

3. Clean and tighten or replace the battery cable

connectors and cables at the battery and the

set.

4. Adjust charge rate of battery charging circuit,

according to manufacturers instructions.

5. Replace engine DC alternator if normal battery

charging voltage is not obtained.

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

tions are OK, check the battery voltage at A31

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

voltage), disconnect J5 and isolate to the har-

ness or A31.

If the voltage is OK, check battery voltage at

A33 J1-31. If the voltage is not OK, replace

A31. If the voltage at A33 J1-31 is OK, isolate to

A33 or A32 using the analog input troubleshoot-

ing procedure (Table 4-36a/b).

1. Weak or discharged battery.

2. Low electrolyte level in battery.

3. Battery connections loose or dirty.

4. Insufficient battery charging voltage.

5. Engine DC alternator could be bad.

6. If the batteries are OK, the problem

may be the harness, the engine inter-

face board (A31), the digital board

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

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

lem may be the engine interface board

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

analog board (A33).

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

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

connect J5 and isolate to the harness or A31.

If the voltage is OK, check battery voltage at

A33 J1-31. If the voltage is not OK, replace

A31. If the voltage at A33 J1-31 is OK, isolate to

A33 or A32 using the analog input troubleshoot-

ing procedure (Table 4-36a/b).

1. Adjust charge rate of battery charging circuit ac-

cording to manufacturers instructions.

1. Excessive battery charging voltage.

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

2. Replace engne DC alternator if normal battery

charging voltage is not obtained.

2. Engine DC alternator could be bad.

4-36

TABLE 4-23. LOW FUEL −DAY WARNING (240)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOW FUEL−

DAY”

warning

message (240)

Fuel level is

normal.

DS1 on the

engine

interface

board, A31,

is on.

DS1 on A31 is on, indicating that A31 is re-

ceiving a low fuel signal from the sender.

The sender, the harness or the A31 circuit

board could be bad.

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

fuel signal.

Disconnect the signal lead at the sender and reset

the control.

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

appear, replace the sender.

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

ter control reset, disconnect J4/A31 and check

continuity from P4−14 to GND.

If there is continuity, replace the harness.

If there is no continuity, replace circuit

board A31.

DS1 on A31 is off, indicating that the PCC is

not receiving a low fuel signal from the

sender—but the 240 message indicates

that A32, the digital board, is responding to

a false low fuel signal.

A31, the engine interface board, or A32, the

digital board, could be bad.

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

fuel signal.

*1. Install a breakout connector at A32 J4.

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

If the fault drops out and does not return,

replace A31.

If the fault returns after resetting the con-

trol, go to step 3.

3. Install harness tool between A32 J2/P2.

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

If the fault drops out and does not return,

replace A31.

If the fault returns after resetting the con-

trol, replace A32..

“LOW FUEL−

DAY”

warning

message (240)

Fuel level is

normal.

DS1 (A31)

and DS13

(A34) are off.

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

4-37

TABLE 4-24. LOW FUEL WARNING (241)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

DS13 on A34 is on, indicating that A34 is re-

ceiving a low fuel signal from the customer

circuit.

If there is no actual fault, the problem may

be a short to ground in the external wiring or

a bad customer interface board (A34).

Indicator(s) Possible Cause Corrective Action

DS13 on A34 is off, indicating that the PCC

is not receiving a low fuel signal from the

sender—but the 241 message indicates

that A32, the digital board, is responding to

a false low fuel signal.

A34, the customer interface board, or A32,

the digital board, could be bad.

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

fuel signal.

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

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

If the fault drops out and does not return,

replace A34.

If the fault returns after resetting the con-

trol, replace A32.

“LOW FUEL”

warning

message (241)

Fuel level is

normal.

DS13 (A34) is

off.

“LOW FUEL”

warning

message (241)

Fuel level is

normal.

DS13 on the

customer

interface

board, A34, is

on.

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

fuel signal.

Disconnect the signal lead near the control and reset

the control.

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

appear, there is a short to ground in the external

wiring or a faulty sender.

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

ter control reset, disconnect J1/A34 and check

continuity from P1−5 to GND.

If there is continuity, find and repair a short

to ground in the external wiring.

If there is no continuity, replace circuit

board A34.

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

4-38

TABLE 4-25. EEPROM ERROR SHUTDOWN (250) OR WARNING (251, 252)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“EEPROM

ERROR”

shutdown

(250)

message.

The EE memory on the digital board (A32)

may be bad.

1. Perform the initial start setup procedure.

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

the control. Simultaneously press the RESET,

MENU, and PHASE SELECT keys to start the

setup.

Select the correct values, save your choices,

and attempt to start the set.

2. If the set shuts down on the same EEPROM

ERROR message, replace the digital board

(A32).

“EEPROM

ERROR”

warning

(251)

message.

The EE memory on the digital board (A32)

may be bad.

1. Perform the adjustment procedures (described

in Section 5). Save the adjustments.

Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROM

ERROR message, perform the calibration pro-

cedures in Section 5.

Reset the control. Shut off and restart the set.

3. If the control generates the same EEPROM

ERROR message, replace the digital board

(A32).

“EEPROM

ERROR”

warning

(252)

message.

The EE memory on the digital board (A32)

may be bad.

1. If this message occurred during an adjustment,

option selection, or calibration of the PCC,

verify the values or choices selected and repeat

the save operation.

Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROM

ERROR message, replace the digital board

(A32).

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

4-39

TABLE 4-26. RACK POSITION WARNING (260)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“RACK

POSITION”

warning

message (260)

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

PowerCommand control fault or defective

governor control circuitry.

Restart the generator set and monitor the fault LED’s

of the governor output module (A38). Refer to Sec-

tion 3 for LED descriptions.

1 LED’s (DS1 through DS4 are on and DS5 and

DS6 are off) do not indicate a fault, refer to “Cus-

tomer Fault 261, 262 & 263 for corrective ac-

tion.

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

a fault and the generator set shuts down after

restarting − perform the Rack Position Fault/

Test Procedure at the end of this section.

4-40

TABLE 4-27. CUSTOMER FAULTS (261, 262 or 263)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“CUSTOMER

FAULT

(261, 262 or

263) message.

And

corresponding

LED on

customer

interface board

A34 is on.

If the corresponding LED on the customer

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

ceiving a signal from the customer circuit.

If there is no actual fault, the problem may

be a short to ground in the external wiring or

a bad customer interface board (A34).

Isolate the source of the false signal.

Disconnect the signal lead near the control and reset

the control.

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

ground in the external wiring.

2. If the message remains, replace A34.

“CUSTOMER

FAULT

(261, 262 or

263) message.

And

corresponding

LED on

customer

interface board

A34 is off.

Isolate the source of the false signal.

Check J2/P2 on A32.

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

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

or J2-15 and reset the control.

If the fault does not return, replace A34.

If the fault reappears, replace A32.

If the corresponding LED on the customer

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

receiving a signal from the customer circuit.

The message indicates that A32, the digital

board, is responding to a false signal.

A34, the customer interface board, or A32,

the digital board, could be bad.

A 34

LED

A32

CONNECTOR

CUSTOMER

FAULT #

FAULT

CODE

DS4

DS11

DS15

DS3

J2-3

J2-24

J2-9

J2-15

Rack Position

260

261

262

263

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

4-41

TABLE 4-28a. PHASE ROTATION (270)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“PHASE

ROTATION”

shutdown

(270)

message.

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

2. Generator set output power feeders

are improperly connected.

Continued On Next Page...

2. Verify phase rotation of the generator set output

relative to the system bus. Correct wiring of

power output conductors if required. The phase

relationship between the generator set and the

system bus can be checked by either using a

phase rotation checker, or by using synchroniz-

ing lamps or two voltmeters. The procedure for

using voltmeters for checking phase relation-

ship is as follows:

Energize the system bus and start the genera-

tor set in question in the RUN mode, but do not

close the paralleling breaker. Connect each

voltmeter from the line to load side of a single

phase of the paralleling breaker (see Figure

8-1). If the generator set and bus have the same

phase rotation, the voltmeters should rise and

fall in voltage at the same time. If they are not in

phase, one will rise while the other falls.

1. Single phase bus condition. 1. Verify that bus voltage is proper and is not single

phased.

4-42

TABLE 4-28b. PHASE ROTATION (270) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“PHASE

ROTATION”

shutdown

(270)

message.

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

3. Wiring to bus PT module is not correct. 3. If power conductors are properly phased, check

the phase rotation of the wiring to the generator

set CT/PT module (A36) and Bus PT module

(A39). This is done using voltmeters connected

as shown in Figure 8-1. Energize the system

bus and start the generator set being tested in

the RUN mode. Operate the display screen on

the PowerCommand control to show the digital

synchroscope (bus frequency). Observe the

voltmeter(s) and the synchronized indicator (*)

on the PowerCommand screen. When the volt-

age of the meter(s) approaches zero, the *

should be displayed. If the * is on when the volt-

meters are reading their highest value, the Bus

PT module or the genset CT/PT module is in-

correctly wired. If incorrect wiring is indicated,

switch off the power supply to the system bus

and manually close the paralleling breaker by

pushing the breaker close switch on the front of

the PowerCommand control. Check the voltage

between phase L1 of the generator CT/PT mod-

ule (J9-4 yellow) and phase L1 of the Bus PT

module (terminal TB1-1 on the module). If there

is voltage difference between these points, re-

verse the wiring between TB1-1 and TB1-3 on

the Bus PT module. Retest the system to be

certain that the phase relationship problem has

been corrected. If no voltage difference is

sensed at the input to the CT/PT module and

Bus PT module, the problem could be in the wir-

ing between the Bus PT module and the Power-

Command control. Reverse the connections

between terminals TB2-1, 2 with TB2-5, 6. Re-

test the system to make sure that the phase

relationship problem has been corrected.

4-43

TABLE 4-29. FIRST START (272)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“FIRST

START”

warning (272)

message.

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

1. Master First Start Sensor has failed. 1. Verify that the Master First Start Sensor is prop-

erly functioning. This can be accomplished by

connecting a DC voltmeter from ground to the

appropriate terminal on the Master First Start

Sensor to the PowerCommand Control. The

voltmeter should indicate a pulsing voltage

present on the terminal.

2. Interconnection between Master First

Start Sensor and the PowerCommand

control has failed.

2. Verify that the voltage pulse is present at the

PowerCommand Control (terminal TB1−50).

Check and repair any problems in the intercon-

nection wiring between the generator set and

the Master First Start Sensor.

4-44

TABLE 4-30a. HIGH AC VOLTAGE SHUTDOWN (301)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“HIGH AC

VOLTAGE ”

shutdown

(301)

message.

1. The problem may be in the PCC, the

alternator, or the interconnection be-

tween them.

Note 1: The PCC may indicate either

a low AC Voltage or High AC Voltage

shutdown due to the design of the

logic in the control.

You must first determine if the out-

put voltage the control sees is low

or high.

Note 2: Residual voltage is normally

5 to 10% of nominal output voltage.

For example, a genset with a 480

volt output, will have a residual volt-

age of 25 to 50 VAC at normal oper-

ating speed.

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

L-N.

a. Start the genset and observe the voltage

displayed on the digital display.

b. If all phases of voltage are balanced and not

zero, but lower than normal, the alternator

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

lem is in the excitation circuit for the alterna-

tor. Go to step 2.

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

the voltages are unbalanced, the PCC is not

measuring all phases of voltage and is re-

sponding to the low “average” of the three

phases of voltage. Go to step 3.

2. The problem may be the regulator

module (A37), the engine interface

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

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

running, check A31 DS9, the AVR duty cycle

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

2d.

Isolate the genset output from the load. Discon-

nect A37 J10, and place the set in Idle mode. In

Idle mode the excitation circuit is disabled. Start

the set and monitor the AC output voltage with a

digital multimeter.

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

of normal output), go to step 3.

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

DS2 on A37 is off, go to step 4.

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

DS2 on A37 is on, look at DS9 on A31.

If DS9 on A31 is off, replace A37.

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

nector at A32 J4, and open J4-2.

If DS9 goes out, replace A32.

If DS9 stays on replace A31.

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

(Continued)

4-45

TABLE 4-30b. HIGH AC VOLTAGE SHUTDOWN (301) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“HIGH AC

VOLTAGE ”

shutdown

(301)

message.

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

ule (A36) or the interconnecting wiring

to the PT/CT module.

NOTE: To calculate the “expected A36

output” voltage range, do the follow-

ing:

Determine the ratio between the mea-

sured voltage and the expected volt-

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

module will also be reduced by this ra-

tio.

*3. Before starting the generator set, discon-

nect the harness connector from the PT/CT

module (A36) and connect the harness tool

between A36 and its harness connector.

Check the output voltage at the alternator

output terminals and record the voltages.

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

b. If the voltages are balanced, calculate the

expected output voltage from the PT/C mod-

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

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

and 2−1.

If the output voltage is proportional to the

alternator output voltage the A36 module

is OK. Go on to step 4.

If the voltages are not balanced, replace

A36.

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

4. The problem may be in the customer

interface board (A34) or the intercon-

necting wiring.

*4. Disconnect the plugs in the following steps

below with the set off then start the set in the

idle mode, and measure voltages with a digi-

tal multimeter.

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

ness tool. Check the voltage into the cus-

tomer interface board with the harness tool

at J3 terminals 4−6, 5−13, and 7−20. Re-

move the harness tool and reconnect J3 and

P3. These voltages should be the same val-

ues measured in step 3b.

If the voltages are balanced, continue in this

step. If the voltages are unbalanced, repair

the harness between the A36 module and

the A34 board.

b. Disconnect J5/P5 on the customer interface

board and insert the harness tool. Check the

voltage out of the customer interface board

at J5 terminals 24−28, 26−28, and 30−28.

These voltages should be the same values

measured in step 3b.

If the voltages are balanced, go to step 5. If

the voltages are unbalanced, replace the

customer interface board.

(Continued)

4-46

TABLE 4-30c. HIGH AC VOLTAGE SHUTDOWN (301) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“HIGH AC

VOLTAGE ”

shutdown

(301)

message.

5. The problem may be the analog board

(A33).

NOTE: To determine the “3-phase

ave” signal voltage range for Step 3b,

use the following formula:

Vout 3-phase ave = Vin (2.9PT) 5%

Vin = Actual generator output voltage

(phase-to-neutral)

PT = PT primary (120, 240 or 346)

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

ave” signal at A33 J2-18.

If the voltage is within the expected range,

replace A32. If the voltage is not within the

expected range, replace A33. See Note.

6. The problem may be in the generator

set itself.

6. Refer to the generator servicing procedures in

Section 6.

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

4-47

TABLE 4-31a. LOW AC VOLTAGE SHUTDOWN (303)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOW AC

VOLTAGE ”

shutdown

(303)

message.

1. PMG or field wiring could be faulty.

2. The rotating rectifier assembly (diodes

CR1 through CR6) is faulty.

3. Overload.

4. There may be a loose connector in the

control loop.

5a. The problem may be the analog board

(A33) or the digital board (A32).

5b. The problem may be the regulator

module (A37), the engine interface

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

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

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

field wiring.

2. Check each diode according to Servicing the

Generator in Section 6. Service as necessary.

3. Check the load and correct any overload.

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

on A34, and J7 on A37.

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

the control, restart the set, and measure AC

output voltage with a multimeter.

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

shooting section for High AC Voltage Shutdown

(301).

If output voltage is normal, the problem must be

in the voltage sensing circuitry (A32 or A33).

Isolate, using the analog input troubleshooting

procedure (Table 4-36a/b). Check the phase

that shows a low voltage on the PCC display.

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

the output voltage high enough. The problem

could be A37, A31, or A32. Restart the set and

monitor isolated B+ supply LED A37/DS1,

output duty cycle LED A37/DS2, and

AVR duty cycle LED A31/DS10.

If A37/DS1 is not on, disconnect A3 J7/P7

and check for B+ at P7-1. (Control must be in

Run mode for B+ reading.)

If B+ is OK to A37, replace A37.

If A37/DS1 is on, check A31/DS10 (with the

set running).

If A31/DS10 is not on with set running, check

for continuity: A31 J1-2 to J4-10 and A31

J1-1 to J4-11 (270 ohms). If no continuity, re-

place A31.

If A31is OK, replace A32.

If A31/DS10 is on with set running and

A37/DS2 is not on, check the harness.

If the harness is OK, replace A37.

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

(Continued)

4-48

TABLE 4-31b. LOW AC VOLTAGE SHUTDOWN (303) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOW AC

VOLTAGE ”

shutdown

(303)

message.

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

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

customer interface board (A34), or the

digital board (A32).

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

must have lost AC sensing. Check PTs (primary

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

sensing harness wires, generator output con-

nections, and the customer interface board for

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

log and digital boards, using the analog input

troubleshooting procedure (Table 4-36a/b).

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

4-49

TABLE 4-32. UNDER FREQUENCY SHUTDOWN (313)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“UNDER

FREQUENCY”

shutdown

(313)

message.

1. Improper setup.

2. Overload.

3. Fuel or air delivery problem.

4. The governor output module (A38),

the digital board (A32), or the engine

interface board (A31) could be bad.

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

essary.

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

essary.

Disconnect the load. Reset the control and at-

tempt to restart the generator set.

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

fuel/air delivery service procedures.

*4. Disconnect the wire to the fuel solenoid, reset

the control, and crank the set. DS2 on the gov-

ernor output module A38 should light.

If the duty cycle LED (DS1) on the governor out-

put module (A38) slowly becomes bright, the

governor output module(A38), the digital board

(A32), and the engine interface board (A31) are

functioning properly.

If DS1 does not light or instantly becomes

bright, A31, A32 or A38 may be bad.

A38 - Crank the set, and check the gover-

nor duty cycle on the PCC display. If the

duty cycle is OK (60% max), replace gov-

ernor output module (A38).

If the duty cycle is not OK, the digital board

(A32) or the engine interface board (A31)

may be bad.

A31 - Check for continuity: A31 J1-13 to

A31 J4-19 and A31 J1-14 to A31 J4-12. If

no continuity, replace A31.

A32 - If A31 is OK, replace A32

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

4-50

TABLE 4-33. OVERCURRENT WARNING (320) OR SHUTDOWN (321),

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

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“OVER-

CURRENT”

warning (320)

or shutdown

(321),

“SHORT

CIRCUIT”

shutdown

(322), or

OVERLOAD

warning (330)

message.

1. Short or Overload.

2. Incorrect CTs or CT connections.

3. The problem may be a bad PT/CT

module (A36).

4. The problem may be the customer in-

terface board (A34) or connections.

5. The problem may be the analog board

(A33) or the digital board (A32).

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

essary.

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

essary. Refer to Current Transfer Installation in

Section 5.

3. Disconnect the PT/CT module and check the

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

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

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

A33. Repair the connection or replace A34 if

necessary. Refer to Section 9 for pin reference.

5. Isolate, using the analog input troubleshooting

procedure (Table 4-36a/b). Check the bad

phase or phases.

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

4-51

TABLE 4-34. REVERSE POWER (335)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“REVERSE

POWER”

shutdown

(335)

message.

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

1. If this shutdown condition occurs when

a non-paralleled generator set is

loaded, it indicates that the generator

set output CT’s or PT’s are incorrectly

installed.

1. Verify proper CT orientation, wiring and con-

nections on the control system. Refer to Current

Transformer (CT) Installation in Section 5.

Make sure that the no load frequency matches

the bus frequency. Check metering calibration

for both generator set and bus.

2. Verify that the generator set is operat-

ing at the correct frequency and volt-

age. The bus voltage and frequency

should be the same as the no-load

generator set frequency and voltage.

2. Make adjustments as required for proper op-

eration.

3. The load sharing line connections and

orientation must be correctly accom-

plished for proper load sharing.

3. Verify that load sharing connections are made

as noted in the drawings and that there are no

damaged or disconnected wires.

4. If the alarm occurs when a large load is

added or shed, dissimilar transient re-

sponse of the generator sets in the

system may cause the reverse power

condition.

4. Apply various load steps to each generator set

in the system, noting the voltage and frequency

dips/surges and recovery times. The generator

sets should be adjusted so that transient load

performance is approximately the same in all

machines in the system.

5. Reverse power alarm can also indi-

cate that the generator set is unable to

carry load properly.

5. Verify that the generator set can pick up and

carry loads properly, up to the rated capacity of

the machine. Inability to carry load can be re-

lated to engine misadjustments, component

failures, or poor fuel quality. Check governing

system for binding or sticking. Check fuel filters

and fuel lines for cracks, leaks or dents. Check

air cleaner(s) for obstructions.

4-52

TABLE 4-35. LOSS OF EXCITATION (337)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOSS OF

EXCITATION”

shutdown

(337)

message.

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

1. Improper voltage adjustment of the

generator set relative to the system

bus.

1. Verify that the no load voltage of the generator

set matches the bus voltage. Check generator

set metering calibration for both generator set

and bus readings. If no problems are found,

check the paralleling adjustments in the Power-

Command control, to see if they match the de-

fault settings in the generator set test report.

2. Load sharing line mis-connection or

damage.

2. Verify load sharing line connections and condi-

tion. Make corrections as required.

3. If condition occurs when the generator

set is lightly loaded, leading power fac-

tor loads may cause this condition.

3. Loss of Excitation failure may also be caused by

operation of filters and power factor correction

capacitors in the generator set loads when the

kW load level on the genset is low. The capaci-

tors in the filters and power factor correction

equipment can present a leading power factor

load to the generator set, which (correctly)

shuts down the generator set through the loss

of excitation fault. Leading power factor loads

can cause the generator set to lose control of

the output voltage of the genset, and can cause

kVar load sharing problems, so it is necessary

to protect the genset from excessive leading

power factor and reverse var conditions.

For generator sets prior to the release of

version 2.0 firmware:

Check the load for devices which may apply

leading power factor loads to the generator set.

These include power factor correction capaci-

tors, input filter and some non-linear load de-

vices with internal voltage waveform correction

provisions. These devices may need to be dis-

connected from the bus until other loads are

added to the system.

For generator sets with version 2.0 and

higher firmware:

If there is a loss of excitation fault that cannot be

explained by genset component failures or mis-

adjustments, perform the following steps:

(Continued)

4-53

TABLE 4-35. LOSS OF EXCITATION (337) (Continued)

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

Indicator(s) Possible Cause Corrective Action

“LOSS OF

EXCITATION”

shutdown

(337)

message.

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

4. The generator set may be incapable of

carrying full reactive load due to com-

ponent failures.

4. See section 6 of this manual, “Servicing the

Generator, Exciter Rectifier and Exciter Rotor”.

See also repair and diagnosis process for ”Low

AC Voltage” in this section.

3. (continued) a. Start the generator set and apply system

loads in their normal operation sequence.

Observe the output voltage, power factor,

and % voltage regulation of the generator

set as the loads are applied. (This may

take more than one test.)

b. If the voltage does not rise and the % volt-

age regulation is greater than 0 as the sys-

tem loads are applied, extend the time

delay on loss of excitation shutdown and

repeat the load addition test.

c. If the increase in time delay does not re-

solve the shutdown condition, contact the

factory for the maximum permissible set-

ting of the loss of excitation shutdown set

points.

d. If the voltage rises or the % voltage regula-

tion value drops to 0 and does not rise as

load is applied, investigate means to re-

move leading power factor loads from the

genset bus.

5. If transient conditions result in this

alarm condition, the PowerCommand

control internal set points may need

adjustment.

5. Consult factory.

4-54

TABLE 4-36a. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL

BOARDS

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

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

board (A33) or to the digital board (A32). You must have schematics and wiring

diagrams to identify the various inputs and outputs.

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

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

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

voltage across the + and − inputs at A33 J1 using harness tool. (This assumes that you have verified

that the harness and the engine interface board is good.)

If the input voltage to the analog board is correct (refer to Table 4-36), go to step 2.

If the input voltage to the analog board is incorrect, check for 12 VDC at A32 J3-20 and 5 VDC at

A32 J3-12. Do this with the analog board connected to the digital (A32).

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

If the 12 VDC and 5 VDC voltages are not OK, disconnect A32 J3 and recheck for 12 VDC at

A32 J3-20 and 5 VDC at A32 J3-12.

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

If the 12 VDC and 5 VDC voltages are still not OK, replace the digital board.

1b. To check the AC inputs into the analog board, drive the PT/CT inputs (voltage or current) and verify

that the input is correct.

If the input to the analog board is correct, go to step 2.

If the input to the analog board is incorrect, disconnect the ribbon cable at A34 J5 and check the volt-

age at A34 J5 again (Customer Interface).

If the voltage is now correct, replace the analog board.

If the voltage is still not correct, the problem is not on the analog or digital boards.

2. If the input to the analog board is correct, determine whether the signal is multiplexed (refer to Table

4-36). If the signal is not multiplexed, go to step 2a. If the signal is multiplexed, go to step 2b.

2a. This step is for non-multiplexed AC signals. Drive the input to the analog board with an AC source,

and test the signal level out of the analog board. You must calculate what the analog output voltage

should be (Table 4-36), assuming the analog board transfer function is linear.

If the signal level into the digital board is correct, the problem must be on the digital board. Replace

the digital board.

If the signal level into the digital board is incorrect, remove the ribbon cable connector at A32 J3, and

check the front panel digital display of the bad analog value.

If the display reads 0, replace the analog board.

If the display reads a value other than 0, replace the digital board.

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

4-55

TABLE 4-36b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND

DIGITAL BOARDS

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

ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and

machinery hazards should perform service procedures. Review Important Safety Instructions page.

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

board (A33) or to the digital board (A32). You must have schematics and wiring

diagrams to identify the various inputs and outputs.

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

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

the analog board.

Yes. If more than one multiplexed signal reading is bad, remove the ribbon cable connector at

A32 J3 and check the front panel digital display of the bad inputs. It should read 0 for all inputs ex-

cept the temperature inputs (which should read less than 32 F or less than 0 C) and power factor

(which should read “NA”).

If any values read incorrectly, replace the digital board.

If they all read correctly, measure voltages on the multiplexer control lines (with A32-J3 discon-

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

A32-J3-23: 3.0 0.25 VDC

A32-J3-24: 2.4 0.25 VDC

A32-J3-27: 1.4 0.25 VDC

A32-J3-33: 3.0 0.25 VDC

A32-J3-34: 3.0 0.25 VDC

If these control (select) line voltages are not correct, replace the digital board.

If these control (select) line voltages are correct (and the input to the analog board is correct),

reconnect the ribbon cable connector (through harness tool) at A32 J3 and check the 5 VDC

reference at A32 J3-12 and the 12 VDC supply at A32 J3-20.

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

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

voltages again (measured from Digital board side).

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

analog board.

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

the digital board.

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

4-56

TABLE 4−37. ANALOG CIRCUIT BOARD (A33) INPUTS AND OUTPUTS

Input Name Input

Connection

Input Signal

Range

Output Name1Output

Connection2

Output

Signal Range

L1 (0 to nominal) J4-24 to J4-28 0 to 18 VAC L10 (ACH1) J2-4 0 to 3.0 VDC

L2 (0 to nominal) J4-26 to J4-28 0 to 18 VAC L20 (ACH2) J2-13 0 to 3.0 VDC

L3 (0 to nominal) J4-37 to J4-28 0 to 18 VAC L30 (ACH3) J2-1 0 to 3.0 VDC

3PH ave (ACH0) J2-18 0 to 2.9 VDC

Line freq. (HSI.1) J2-21 0-5V sq wave @ L1 Hz

CT21 (0 to full load) J4-33 to J4-34 0 to 1.65 VAC C1 fltrd (ACH4) J2-3 0 to 1.0 VDC

CT22 (0 to full load) J4-32 to J4-34 0 to 1.65 VAC C2 fltrd (ACH5) J2-9 0 to 1.0 VDC

CT23 (0 to full load) J4-31 to J4-34 0 to 1.65 VAC C3 fltrd (ACH6) J2-17 0 to 1.0 VDC

C1 (ACH7) J2-7 0 to 1.0 VDC

C2 (ACH7) J2-7 0 to 1.0 VDC

C3 (ACH7) J2-7 0 to 1.0 VDC

(1 to 0.8 pf) Phase angle 1 (ACH7)3J2-7 0 to 1.0 VDC

(1 to 0.8 pf) Phase angle 2 (ACH7)3J2-7 0 to 1.0 VDC

(1 to 0.8 pf) Phase angle 3 (ACH7)3J2-7 0 to 1.0 VDC

(L1 vs CT21) Lead lag (P2A.1)) 3J2-29 0 or 5 VDC (digital)

Bus L1 (0 to nominal) 6J4-15 to J4-18 0 to 18 VAC Bus L1 (ACH7) J2-7 0 to 3.0 VDC

Bus L2 (0 to nominal) 6J4-16 to J4-18 0 to 18 VAC Bus L2 (ACH7) J2-7 0 to 3.0 VDC

Bus L3 (0 to nominal) 6J4-17 to J4-18 0 to 18 VAC Bus L3 (ACH7) J2-7 0 to 3.0 VDC

Bus freq (HS1.3) J2-22 0-5V sq wave @ Bus L1 Hz

Phase rot (P2A.0)5J2-26 0 or 5 VDC (digital)

Bus/gen phase dif (ACH7)5J2-7 0 to 5.0 VDC

Bus/gen phase (HS1.2)5J2-19 0-5V 120 Hz 0 to 100% DC

Synch (ACH7)5J2-7

Battery voltage J1-31 (+) to J1-30(−)0 to 32 VDC Battery voltage (ACH7) J2-7 0 to 2.9 VDC

Oil press (0 to 100 psi) (See note 4 )0.5 to 4.5 VDC Oil press (ACH7) J2-7 0.5 to 4.5 VDC

H2O 1 (6 to 230 F) J1-19/20 to J1-17/18 700 to 1800 H2O 1 (ACH7) J2-7 1.4 to 3.7 VDC

H2O 2 (6 to 230 F) J1-15/16 to J1-14/15 700 to 1800 H2O 2 (ACH7) J2-7 1.4 to 3.7 VDC

Oil temp (6 to 230 F) J1-11/12 to J1-9/10 700 to 1800 Oil temp (ACH7) J2-7 1.4 to 3.7 VDC

Exh temp 1 (32 to 1471 F) J1-7/8 to J1-5/6 100 to 376 Exh temp 1 (ACH7) J2-7 0.8 to 3.0 VDC

Exh temp 2 (32 to 1471 F) J1-3/4 to J1-1/2 100 to 376 Exh temp 2 (ACH7) J2-7 0.8 to 3.0 VDC

Notes:

1. All output signals on ACH7 are multiplexed.

2. All output voltages on A33 J2 are referenced to ground (J2-15 and J2-16).

3. Must have L1, L2, L3, CT21, CT22, and CT23 for these phase angle outputs.

4. J1-24 (5VDC), J1-23 (signal), J1-18 (return).

5. Must have L1, L2, L3, Bus L1, Bus L2, and Bus L3 for these outputs.

6. L1, L2, and L3 can be 0 to 180out of phase with Bus L1, Bus L2, and Bus L3, respectively.

4-57

TABLE 4-38. PCC FUSES

LOCATION

REFERENCE

DESIGNATION RATING FUNCTION

Engine Interface A31-F1 5 Amp PCC control B+

Engine Interface A31-F3 5 Amp Auxiliary B+ (for panel lights, run and start relays)

Governor Output

Module

A38-F4 10 Amp Network B+ (to TB1 customer terminal block)

Governor Output

Module

A38-F3 10 Amp Switched B+ (to TB1 customer terminal block)

Governor Output

Module

A38-F1 15 Amp Left actuator

TB-Bat (Engine

Harness Assembly)

F1 20 Amp Customer B+ (to TB1 customer terminal block)

Governor Output

Module

A38-F2 15 Amp Right actuator

4-58

RACK POSITION FAULT/TEST

PROCEDURE

The rack position fault/test procedure is a trouble-

shooting tool for the Rack Position (260) warning

message. This test will isolate the fault to one of

these components; fuel pump, governor output

module (A38), or the PowerCommand control.

Use a calibrated RMS multimeter for accurate mea-

surements. Fluke models 87 or 8060A are good

choices.

1. Move the Run/Off/Auto switch to the Off posi-

tion.

2. At the engine interface board (A31), place a

jumper wire from A31-TP1 to A31-TP2 (see

Figure 3-4 for test point location).

3. Select RACK TEST from the Setup Menu

(page 5-17) to initiate the fuel rack test. This will

apply power to the governor output module.

4. Are A38 DS1 (RUN) and A38 DS2 (VCC) LED’s

on?

Yes: Go to next step.

No: Possible control problem. Remove jum-

ber wires (Step 2). Restart set and follow

proper troubleshooting procedure.

5. Are fuses A38 F1 and F2 blown?

Yes: Replace blown fuse and restart set.

No: Go to next step.

6. Move both racks from 0mm to 19mm from the

“POS MM” menu (see Setup Menu). Periodi-

cally read the DC voltages from J11-B (left

position voltage) to J11-A and J11-C (right

position voltage) to J11-A. (J11 engine harness

connector is located at the bottom of the acces-

sory box.)

7. Do these voltages correspond to the voltage on

the display (  .25 VDC) ?

Yes: Test OK. Restart set and monitor

A38-DS5 (left position fault) and

A38-DS6 (right position fault).

No: Go to next step.

8. Are both left and right voltages out of toler-

ance?

Yes: Possible control or governor output mod-

ule problem. Check PWM signal (refer to

Step 4 of error Code 313 in Trouble-

shooting section).

No: Go to next step.

9. Move the racks to 0mm from the “POS MM”

menu. Monitor the position voltage of the side

that has the incorrect voltage.

10. Disconnect the fuel pump connector at the fuel

pump. Does the voltage rise up from approxi-

mately 1.3  .25 VDC to 4.5  .25 VDC ?

Yes: Replace defective fuel pump (refer to en-

gine service manual).

No: Replace defective governor output mod-

ule.

Engine Torque Adjustment procedure must be

performed after replacement of fuel pump or

governor output module. Refer to Section 5.

4-59

LOAD SHARING CONTROLS

TROUBLESHOOT PROCEDURE

The generator set load sharing settings in the Pow-

erCommand control are factory set and normally do

not require adjustment. The controls are designed

to cause generator sets in the paralleling system to

share load proportionally, based on the standby rat-

ings of the generator sets in the system.

When the system is operating normally, the genera-

tor sets in an isolated bus (not utility/mains paral-

leled) paralleling system will share both real (kW)

and reactive (amps) load equally, within plus or mi-

nus 5%. For example, if two 1000 kW generator

sets are paralleled and serving a 2000 kW load, the

generator sets should each carry between 950 and

1050 kW.

In actual practice, load sharing may be much more

precise than plus or minus 5%, but you should not

be concerned about operational problems unless

the load sharing is in error by more than 5%. If dis-

similar generator sets are used in a system, there

may be load sharing inequities for a short time when

loads are applied, but the steady state load sharing

should perform to the plus or minus 5% standard.

If the generator set is paralleled to a utility (mains)

gird, the amount of load on the generator set is pro-

grammed into the control in the setup mode or set

from a remote device. It is NOT a function of the load

sharing control system. See Section 5 for more in-

formation on load sharing set−up functions, and util-

ity (mains) paralleling set−up.

If the generator set is not sharing load properly, the

following procedure can be used to diagnose and

solve the problem:

1. The no load speed and voltage of the generator

set must be the same as the system bus. Mea-

sure the bus voltage and frequency, and the

generator set voltage and frequency with a true

RMS digital meter. Calibrate the voltage and

current sensing circuits of the control, and

make required adjustments to voltage and fre-

quency to match bus conditions. Adjusting the

voltage and frequency after the generator set is

paralleled to the bus will cause load sharing to

be unequal between generator sets.

2. Check to make sure that the load sharing con-

trol wiring is properly connected.

3. Check to make sure that each generator set in

the system is capable of carrying its rated load.

4. Fine adjustment to the amount of load carried

by each generator set can be made by adjust-

ing the KW BALANCE and KVAR BALANCE

settings under the paralleling setup menu

(Section 5).

5. If the generator sets share load approximately

equally, but there is an oscillating load circulat-

ing between the generator sets, the governor

gain may be set too high. Reduce the governor

gain (see Setup Menu, Section 5).

6. Consult factory for any other load sharing prob-

lems.

4-60

THIS PAGE LEFT INTENTIONALLY BLANK

5-1

5. Control Service and Calibration

GENERAL

This section contains circuit board removal and re-

placement procedures, calibration procedures for

the generator set control and test procedures for the

generator and engine components. Refer to the fig-

ures included with this information and also the Wir-

ing Diagrams section when instructed.

Before servicing the PCC, it is recommended that all

settings be recorded. This will make sure of correct

and complete readjustment of the PCC in the event

that all previous entries are lost during servicing.

CIRCUIT BOARD

REMOVAL/REPLACEMENT

No special tools (other than a grounding wrist strap)

are required to remove a circuit board from inside

the control panel or the accessory box.

There are several circuit boards, that when re-

placed, require you to recalibrate the control panel

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

appropriate procedure to perform to recalibrate the

control panel. The circuit board locations are shown

in Figure 5-1.

Before you attempt to remove a circuit board, read

the Circuit Board Removal Safety Precautions in

this section.

TABLE 5-1. CONTROL PANEL RECALIBRATION

CIRCUIT BOARD/

DEVICE

Analog Board (A33)

ADJUSTMENT PROCEDURE / PAGE

1. Voltage, Current and PF.

2. Coolant Temperature L & R

Digital Board (A32) Must recalibrate all values, starting with

the Initial Start Setup procedure.

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

2. Adjust Menu (Page 5-6).

3. Setup and Calibration Menus (Page

5-8).

PT/CT Board (A36) Voltage, Current and PF.

Setup and Calibration Menus (Page 5-8)

Governor Output

Module (A38)

Torque Adjustment % DC Engine Torque Adjustment (Page 5-30)

Fuel Pump Torque Adjustment % DC Engine Torque Adjustment (Page 5-30)

5-2

CUSTOMER INTERFACE

A34

ENGINE INTERFACE

A31

ANALOG BOARD

A33

DIGITAL BOARD

A32

DISPLAY BOARD

A35

RUN/OFF/AUTO

SWITCH S12

S5 POWER ON/

STANDBY SWITCH

ACCESSORY BOX

(A40)

GOVERNOR

OUTPUT MODULE

A38

PT/CT BOARD A36

VOLTAGE

REGULATOR

OUTPUT MODULE

A37

BUS PT MODULE

A39

FIGURE 5-1. CIRCUIT BOARD LOCATIONS

5-3

Circuit Board Removal Safety Precautions

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 megohm to ground.)

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

trol 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.

Turn off or remove AC power from the battery char-

ger 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.

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 ig-

nite battery gas. Do not smoke, or switch

trouble light ON or OFF near battery. Discharge

static electricity from body before touching bat-

teries by first touching a grounded metal sur-

face.

Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-

connect 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 set.

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.

GROUND LEAD CLIP

WRIST STRAP

NON-PAINTED

SURFACE

FIGURE 5-2. WRIST STRAP

5-4

INITIAL START SETUP MENU

The facing page shows a block representation of

the INITIAL START SETUP menu.

CAUTION Selecting this menu resets all oper-

ating parameters to the default values for the

selected set. All previously selected setup and

adjustment settings will be lost. Therefore, this

procedure must be performed by technically

qualified personnel only.

This menu appears on the digital display when the

PCC has not been set up for use with a generator

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

placed in the PCC.

When this display is showing, you must go through

the Initial Start Setup menu to select the operating

parameters for the generator set. These include

whether the set will be used for Prime Power or

Standby use, the Model Number of the generator

set, and its operating frequency and output voltage.

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

only memory before the PCC will accept changes

made to other menus.

If the PCC is already set up to operate with a specific

generator set, this menu will not appear when power

is applied. To reset the control and display the Initial

Start Setup menu, you can press RESET, MENU, and

PHASE SELECT buttons at the same time.

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

justments and the setup options will be reset to the

default settings (including the editable customer

fault messages). Display calibrations (volts, amps,

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

To make sure correct and complete readjustment of

the PCC, it is suggested that all settings be recorded

before you perform the reset function.

CAUTION Improper setup, calibration, or ad-

justments can cause equipment malfunction or

damage. Setup, calibration, and adjustment

must be performed by technically qualified per-

sonnel only.

STANDBY/PRIME submenu: Use the buttons next

to the “” symbols to toggle the standby/prime op-

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

to move to the model select submenu.

MODEL select submenu: Use the buttons next to

the “” and “” symbols to select the correct genera-

tor set model number, frequency and power rating.

VOLTAGE SELECT submenu: Use the buttons

next to the “” and “” symbols to select the correct

generator set nominal line-to-line output voltage.

DELTA / WYE submenu: Use the buttons next to

the “” and “” symbols to select the delta or wye op-

tion.

SAVE submenu: From the model select submenu,

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

move to the SAVE submenu. Select SAVE to save

your changes. The MAIN MENU will then be dis-

played.

If “INVALID SETUP” or “INVALID CAL” is displayed

after saving your changes, refer to Digital Board

(A32) Calibration at the end of this section.

5-5

 STANDBY/PRIME

 _______ >>

 MODEL

 (kw mod# freq) >>

SAVE >> <>

INITIAL START SETUP

(It can be invoked by simultaneously pressing

the Reset, Menu, and Phase Select keys.)

ENGINE GEN

ADJUST >>

SAVE >> <>

 STANDBY/PRIME

 _______ >>

TO LOOP BACK & CHECK:

< VOLTAGE SELECT

 (vac) L-L VAC >>

 DELTA / WYE

 _______ >>

Indicates OR" Condition

5-6

ADJUST MENU

The ADJUST submenus permit adjustment of the

output voltage and frequency and the start and stop

delay times of the generator set.

The complete calibration procedure is described in

the Calibration Procedure in this section.

The facing page shows a block representation of

the ADJUST menu. If you press the button next to

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

AGE ADJUST submenu will appear.

As shown in the diagram, the ADJUST menu has

five submenus, including a save/exit procedure.

Voltage and frequency can be adjusted only when

the generator set is running under normal operating

parameters (not in idle mode). For example, if volt-

age adjustment is selected when the set is in Idle

mode or not running, the digital display will be:

“ VOLTAGE ”

“ N/A >>”

VOLTAGE submenu: This is the first submenu.

Use the buttons next to the “” and “” symbols to

adjust output voltage 5%.

FREQUENCY submenu: From the VOLTAGE sub-

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

play to move to the FREQUENCY submenu. Use

the buttons next to the “” and “” symbols to adjust

output frequency 5%.

START DELAY submenu: This delay applies only

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

QUENCY submenu, press the button next to the

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

submenu. Use the buttons next to the “” and “”

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

justment range is 0 to 300 seconds.

STOP DELAY submenu: This delay applies only

to remote stopping in the Auto mode. From the

START DELAY submenu, press the button next to

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

submenu. Use the buttons next to the “” and “”

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

justment range is 0 to 600 seconds.

IDLE SPEED submenu: From the STOP DELAY

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

display to move to the IDLE SPEED submenu. Use

the buttons next to the “” and “” symbols to set the

idle speed. The idle speed adjustment range is 800

RPM 100 RPM. (Default value is 800 RPM.)

The idle speed can be adjusted only when the gener-

ator set is running in the idle mode. When not in idle

mode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAY

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

display to move to the SAVE/EXIT submenu. Select

SAVE to save your changes. At the CHANGES

SAVED submenu, select EXIT to return to the main

menu.

If you select SAVE, the adjustments will be retained

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

restarted. If you select EXIT without saving first, the

adjustments will remain in effect until the generator

set is shut down, but will be reset (and will not be in

effect) when the set is restarted.

5-7

<><>

ENGINE GEN

ADJUST >>

 VOLTAGE

 _______ >>

 FREQUENCY

 _______ >>

 START DELAY

 _______ SEC >>

 STOP DELAY

 _______SEC >>

<SAVE

EXIT >>

<SAVE

EXIT >>

<SAVE

EXIT >>

CHANGES SAVED

EXIT >>

CHANGES SAVED

EXIT >>

< VOLTAGE

 _______ >>

ENGINE GEN

ADJUST >>

< VOLTAGE

 _______ >>

ENGINE GEN

ADJUST >>

ADJUST

< IDLE SPEED

 _______RPM >>

Indicates OR" Condition

5-8

SETUP AND CALIBRATION MENUS

The setup and calibration menus allow you to cali-

brate the PCC with the reading from a calibrated

meter. There are four setup and calibration menus

that are selectable from the SETUP/CAL menu:

VERSION AND DISPLAYS

METERS

GOVERNOR/REGULATOR

SETUP

These four menus are intended for qualified service

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

code must be entered before you can proceed to

those menus.

ENTER CODE submenu:

The access code for your PCC is: 5 7 4.

To enter the code:

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

first digit.

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

second digit.

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

second digit.

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

third digit.

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

third digit.

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

the DISPLAYS/METERS submenu. (Pro-

vided, of course, that you have correctly en-

tered the access code.)

The following sub-sections describe how to select

and make changes to the setup and calibration me-

nus and save the changes made to these menus.

Version Menu

The VERSION menu allows you to verify the model

number and frequency of the generator set, the

date and version of the operating software and gen-

erator set configuration options. From the VER-

SION menu you can also review a History file, that

can contain up to 20 error messages.

The complete calibration procedure is described in

the Calibration Procedure in this section.

The facing page shows a block representation of

the VERSION submenus. If you press the button

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

SION/SETUP/CAL menu will appear.

CAUTION Improper calibration or adjustment

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

and adjustment must be performed by techni-

cally qualified personnel only.

VERSION submenu: If you select VERSION, the

display will show the generator set model number,

frequency, and kW rating, and the date and version

of the operating software.

To display the generator set configuration options,

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

displays the model number, frequency and etc. This

menu provides the following information:

Generator set voltage

WYE or DELTA

Standby or Prime

Parallel or Single

HISTORY: From the VERSION, SETUP/CAL

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

play to move to the HISTORY submenu. Press the

button next to “HISTORY” to display the last (latest)

recorded error message.

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

sages. The last error detected will always be dis-

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

est error recorded after 20 will be deleted.

To view the generator set runtime at which the error

occurred and to scroll through the remaining re-

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

the error message menu to display the RUNTIME,

NEWER/OLDER menu.

The buttons next to NEWER and OLDER are used

to scroll up and down through the error messages.

For example, pressing OLDER will display the next

oldest recorded error message. When pressing

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

played, or OLDER and oldest error is displayed, the

display will return to the HISTORY menu.

5-9

ENGINE GEN

ADJUST >>

<  ENTER CODE

__ __ __>>

VERSION MENUS

VERSION <<

SETUP/CAL >>

(kW) (model) (hz) <<

______ V___.__ >>

BACK

ENGINE GEN

ADJUST >>

VERSION <<

SETUP/CAL >>

VERSION <<

SETUP/CAL >>

(kW) (model) (hz) <<

______ V___.__ >>

_______ V ______<<

_______ ______

BACK

VERSION <<

SETUP/CAL >>

HISTORY <<

BACK

HISTORY << >

_________________

_________________ >>

RUNTIME _________

NEWER OLDER

REFER TO FOLLOWING

MENUS IN THIS SECTION

DISPLAYS ERROR

MESSAGE AND CODE

DISPLAYS VOLTAGE & GEN

SET CONFIGURATION

Indicates OR" Condition

5-10

Displays Menu

The DISPLAYS submenus permit calibration of the

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

ant temperature displays. Calibration is accom-

plished by using this section of the menu software to

adjust the display so that it matches the reading tak-

en on an accurate, recently calibrated meter.

The complete calibration procedure is described in

the Calibration Procedure in this section.

The facing page shows a block representation of

the DISPLAYS submenus, which is the first of four

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

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

SETUP/CAL menu will appear.

CAUTION Improper calibration or adjustment

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

and adjustment must be performed by techni-

cally qualified personnel only.

DISPLAYS submenus: The DISPLAYS submenus

are intended for qualified service personnel only.

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

entered before you can proceed to those menus.

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

TER CODE submenu. Enter access code (574) as

previously described in this section.

Select DISPLAYS to proceed to the DISPLAYS sub-

menus. Use the buttons next to the “” and “” sym-

bols to calibrate the selected voltage, current, PF or

coolant temperature reading. Press the button next

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

ment.

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

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

L3 to L1, respectively. Note that the system includes

bus voltage reading provisions (“BUS VOLTS L12,”

“BUS VOLTS L23,” and “BUS VOLTS L31”), which

must be calibrated separately from the generator

set voltage settings.

“PF1, PF2 and PF3” will display N/A when the gen-

erator set is not running.

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

has only one sensor. To calibrate coolant tempera-

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

gine sensor tool) must be temporally substituted for

the temperature sender. Refer to Calibration Proce-

dure in this section.

SAVE/EXIT submenu: From the AMPS L3 subme-

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

move to the SAVE/EXIT submenu. Select SAVE to

save your changes. At the CHANGES SAVED sub-

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

TERS submenu.

If you select SAVE, the adjustments will be retained

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

restarted. If you select EXIT without saving first, the

adjustments will remain in effect until the genset is

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

when the set is restarted.

5-11

DISPLAYS MENU

 PF3

 _______ >>

COOLANT TEMP R

 _______F>>

 COOLANT TEMP L

 _______F>>

DISPLAY CAL <<

METERS >>

 VOLTS L12

 _______ >>

 VOLTS L23

 _______ >>

 VOLTS L31

 _______ >>

 AMPS L1

 _______ >>

 AMPS L2

 _______ >>

<SAVE

EXIT >> <>

CHANGES SAVED

EXIT >>

<><>

CHANGES SAVED

EXIT >>

< VOLTS L12

 _______ >>

<SAVE

EXIT >> <>

< VOLTS L12

 _______ >>

<SAVE

EXIT >> <>

DISPLAY CAL <<

METERS >>

DISPLAY CAL <<

METERS >>

 PF1

 _______ >>

 PF2

 _______ >>

 AMPS L3

 _______ >>

<  ENTER CODE

__ __ __>>

<>VERSION <<

SETUP/CAL >>

 BUS VOLTS L31

 _______ >>

 BUS VOLTS L23

 _______ >>

 BUS VOLTS L12

 _______ >>

Indicates OR" Condition

5-12

Meters Menu

The METERS submenus permit calibration of the

control’s analog meters to match the calibrated digi-

tal values. (Calibrate the digital display before cali-

brating the analog meters.) This calibration is ac-

complished by using this section of the menu soft-

ware to adjust the selected meter reading so that it

matches the reading provided on the digital display.

The complete calibration procedure is described in

the Calibration Procedure in this section.

The facing page shows a block representation of

the METERS submenus, which is the second of

four SETUP/CAL menus. If you press the button

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

SION/SETUP/CAL submenu will appear.

CAUTION Improper calibration or adjustment

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

and adjustment must be performed by techni-

cally qualified personnel only.

METERS submenu: The METERS submenus are

intended for qualified service personnel only. For

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

tered before you can proceed to those menus.

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

TER CODE submenu. Enter access code (574) as

previously described in this section.

Select METERS to proceed to the METERS sub-

menus. Use the buttons next to the “” and “” sym-

bols to calibrate the selected meter to match the

“CAL TO:” value provided on the digital display.

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

move to the next calibration.

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

erence the phase that is indicated on the phase

selection LED’s.

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

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

rent at 0.8 PF.)

SAVE/EXIT submenu: From the HERTZ subme-

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

move to the SAVE/EXIT submenu. Select SAVE to

save your changes. At the CHANGES SAVED sub-

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

TERS submenu.

If you select SAVE, the adjustments will be retained

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

restarted. If you select EXIT without saving first, the

adjustments will remain in effect until the generator

set is shut down, but will be reset (and will not be in

effect) when the set is restarted.

5-13

DISPLAY CAL <<

METERS >>

METERS MENU

<>VERSION <<

SETUP/CAL >>

AC VOLTS

CAL TO: ___ >>

 % AMPERES

CAL TO: ___ >>

 % LOAD

CAL TO: ___ >>

 HERTZ

 CAL TO: ___ >>

<SAVE

EXIT >> <>

CHANGES SAVED

EXIT >> <>

DISPLAY CAL <<

METERS >>

<><>

CHANGES SAVED

EXIT >>

<SAVE

EXIT >> <>

<SAVE

EXIT >> <>

DISPLAY CAL <<

METERS >>

DISPLAY CAL <<

METERS >> <>

ENTER CODE

__ __ __>>

 ENTER CODE

__ __ __>>

AC VOLTS

 CAL TO: ___ >>

AC VOLTS

 CAL TO: ___ >>

Indicates OR" Condition

5-14

Governor / Regulator Menu

The GOV/REG submenus permit adjustment of

voltage regulator and governor parameters.

All GOV/REG menu values, except for REG VHZ and

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

“100%” represents the factory setting (default value)

for the selected set. When increasing or decreasing

the value, you are increasing or decreasing from the

factory default value. (For example, entering “200%”

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

by one half.)

Default values are preset by the factory. Due to site

variables, the default values may need to be adjusted

to attain peak performance.

The facing page shows a block representation of

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

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

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

SETUP/CAL submenu will appear.

CAUTION Improper calibration or adjustment

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

and adjustment must be performed by techni-

cally qualified personnel only.

GOV/REG submenu: The GOV/REG submenus

are intended for qualified service personnel only.

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

entered before you can proceed to those menus.

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

TER CODE submenu. Enter the access code (574)

as previously described in this section.

From the DISPLAYS/METERS submenu, press the

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

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

proceed to the GOV/REG submenus.

Use the buttons next to the “” and “” symbols to

adjust the selected governor and regulator parame-

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

to move to the next adjustment.

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

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

low, the engine will respond too slowly to changes in

load—overspeed may result.

For paralleling applications, the default value for

governor gain is 70.

GOV INTEGRAL: If this adjustment is set too low,

the engine will respond too slowly to changes in

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

stable.

GOV RAMP: This adjustment sets the time for the

engine to ramp to full operating speed. This adjust-

ment applies only to set start up and does not affect

the transient response. (Adjustable range: 0

through 10 seconds.)

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

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

the output voltage will respond sluggishly to

changes in load—overshoot may result.

REG INTEGRAL: If this adjustment is set too low,

the output voltage will respond sluggishly to

changes in load, resulting in a droop-type response

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

REG VHZ: This underfrequency roll-off adjustment

controls how much excitation is reduced in re-

sponse to underfrequency. If the value is set too

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

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

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

(Adjustable range: 1 through 50; normal range 7

through 21.)

SAVE/EXIT submenu: From the REG VHZ subme-

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

move to the SAVE/EXIT submenu. Select SAVE to

save your changes. At the CHANGES SAVED sub-

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

TERS submenu.

If you select SAVE, the adjustments will be retained

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

restarted. If you select EXIT without saving first, the

adjustments will remain in effect until the generator

set is shut down, but will be reset (and will not be in

effect) when the set is restarted.

5-15

DISPLAY CAL <<

METERS >>

GOVERNOR/REGULATOR MENU

GOV / REG <<

SETUP >>

 GOV GAIN

 _______% >>

 GOV INTEGRAL

 _______% >>

 GOV RAMP

 _______ >>

<SAVE

EXIT >> <>

CHANGES SAVED

EXIT >> <>

DISPLAY CAL <<

METERS >>

<><>

CHANGES SAVED

EXIT >>

<SAVE

EXIT >> <>

<SAVE

EXIT >> <>

DISPLAY CAL <<

METERS >>

 REG GAIN

 _______% >>

 REG INTEGRAL

 _______% >>

 REG VHZ

 _______ >>

 GOV GAIN

 _______% >>

 GOV GAIN

 _______% >>

GOV / REG <<

SETUP >>

DISPLAY CAL <<

METERS >>

<>VERSION <<

SETUP/CAL >>

 ENTER CODE

__ __ __>>

Indicates OR" Condition

5-16

Setup Menu

The SETUP submenus permit selection of several

configuration and operation options. Setup option

defaults are listed in Table 5-2.

TABLE 5-2. SETUP DEFAULTS

SELECTION DEFAULT

CYCLE CRANK ON

SYSTEM OF UNITS IMPERIAL

*RACK POSITION (CF1) WARN

*GRND FAULT (CF2) WARN

*DAY TANK (CF3) WARN

*HIGH GEN TEMP (CF4) WARN

EGT L NO

EGT R NO

LOW COOLANT SHTD

LANGUAGE ENGLISH

*Default display messages for customer faults (CF) 1

through 4. To change the customer fault mes-

sage(s) or select the desired fault condition (WARN

or SHTD), refer to heading Edit Customer Fault

Messages.

The facing page shows a block representation of

the SETUP submenus, which is the fourth of four

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

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

SETUP/CAL submenu will appear.

CAUTION Improper calibration or adjustment

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

and adjustment must be performed by techni-

cally qualified personnel only.

SETUP submenu: The SETUP submenus are in-

tended for qualified service personnel only. For this

reason, a three-digit access code must be entered

before you can proceed to those menus.

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

TER CODE submenu. Enter the access code (574)

as previously described in this section.

From the DISPLAYS/METERS submenu, press the

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

GOV/REG/SETUP submenu. Select SETUP to

proceed to the SETUP submenus or “>>” to pro-

ceed to the RACK TEST submenus.

Use the buttons next to the “” symbols to toggle

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

in the display to move to the next adjustment.

If the cycle cranking option is selected, the menu will

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

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

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

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

EGT R.

RACK TEST submenu: The RACK TEST subme-

nu is used to initiate the rack position diagnostic

test. This test is used to determine if the PCC is

properly controlling the rack position of the actua-

tors. To initiate this test, the Run/Off/Auto switch

must be set to the Off position.

When exiting this test or if the Run/Off/Auto switch

is moved to either the Run or Auto position, the PCC

software will re-initialize the governor duty cycle to 2

(0%) and allow the engine starting sequence to pro-

ceed as normal.

To perform the rack test, refer to the Rack Position

Fault/Test Procedure in Section 4.

TORQUE ADJ %DC submenu: This submenu is

used to adjust the engine torque through the digital

display to compensate for engine/electronic varia-

tions. If the generator set is not providing the name

plate kilowatt rating, the torque limit can be adjusted

at this menu. Refer to Engine Torque Adjustment in

this section for a detailed description of how to per-

form this adjustment.

5-17

<><>

< REST TIME−SEC

 (7 to 20) >>

DISPLAY CAL <<

METERS >>

< ENTER CODE

__ __ __>>

SETUP MENU

CYCLE CRANK

 ON / OFF >>

SYSTEM OF UNITS

 MET or IMP>>

<>VERSION <<

SETUP/CAL >>

 # OF CYCLE S

 (3, 4, 5 or 6) >>

CYCLE CRANK

 ON / OFF >><>

 CRANK TIME−SEC

 (7 to 20) >>

IF CYCLE CRANK ON :

GOV / REG <<

SETUP >>

GOV / REG <<

SETUP >>

RACK TEST <<

TORQUE

CONTINUED

Indicates OR" Condition

 ___ POS_MM <<

 ___ POS_VOLT

RACK TEST <<

TORQUE

TORQUE ADJ %DC<<

 ___ % DC

5-18

Setup Menu (Cont.)

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

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

able. Customer Fault 1 is reserved for the RACK

POSITION fault. Do not modify this fault name or

change the fault condition (WARN to SHTD).

To enter the desired customer fault message, press

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

the customer fault message to be changed, Cus-

tomer Fault 2, 3 or 4.

Press the upper-left button by the display to select

the desired character. Press the upper-right button

to move the cursor to the next character to be

changed. (Holding this button down will return the

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

to 16 characters. The fault code number will remain

the same, this code cannot be edited.

If these messages are changed, you should note

these changes in the Troubleshooting section of the

Operator’s manual for this generator set.

SAVE/EXIT submenu: From the LANGUAGE sub-

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

play to move to the SAVE/EXIT submenu. Select

SAVE to save your changes. At the CHANGES

SAVED submenu, select EXIT to return to the DIS-

PLAYS/METERS submenu.

If you select SAVE, the adjustments will be retained

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

restarted. If you select EXIT without saving first, the

adjustments will remain in effect until the generator

set is shut down, but will be reset (and will not be in

effect) when the set is restarted.

5-19

< LANGUAGE

_______________>>

SETUP MENU (Cont.)

<SAVE

EXIT >> <>

CHANGES SAVED

EXIT >> <>

DISPLAY CAL <<

METERS >>

<><>

CHANGES SAVED

EXIT >>

<SAVE

EXIT >> <>

<SAVE

EXIT >> <>

DISPLAY CAL <<

METERS >>

LOW COOLANT LVL

 SHTD or WARN

EGT L

 YES / NO >>

EGT R

 YES / NO >>

CYCLE CRANK

 ON / OFF >>

CYCLE CRANK

 ON / OFF >>

HIGH GEN TEMP

 SHTD / WARN >>

CONTINUED

RACK POSITION

 SHTD / WARN >>

RUPTURE BASIN

 SHTD / WARN >>

GROUND FAULT

 SHTD / WARN >>

Indicates OR" Condition

5-20

Paralleling Setup Menu

The PARALLELING SETUP submenus adjust the

control parameters for generator set protection,

synchronizing and load sharing for both isolated

bus and utility (mains) paralleling applications. Util-

ity (mains) parallel applications may require adjust-

ment of both the “isolated bus” and “utility” branch

submenus.

The sync check (permissive) function is operational

in both automatic and manual (RUN) modes. The

control will make sure that the generator set is at

proper voltage, within the defined sync check win-

dow for the defined period of time and that phase

rotation is correct. When all criteria are met, the par-

alleling breaker is closed automatically by the con-

trol (auto mode), or by operation of the breaker

close switch by the operator (run mode).

The synchronizing function of the PowerCommand

control is enabled when the control has brought the

generator set to rated speed and voltage, and has

sensed that bus voltage is available. The control au-

tomatically adjusts the generator set speed and

voltage to match the bus frequency and voltage.

The control can force the generator set to match a

bus voltage and frequency in a range of minus 40%

to plus 10% of normal bus conditions. When the

paralleling breaker has closed, the control will bring

the generator set back to normal voltage and fre-

quency.

When the generator set is paralleled to another

generator set, the control provides automatic load

sharing functions for both real (kW) and reactive

(kVAR) loads. Load sharing is proportional between

generator sets based on their standby ratings. If two

generator sets of different sizes are paralleled, they

will assume the same percentage of the system

load automatically. This can easily be verified on the

analog % Load meters on the front of the Power-

Command control panel.

When the utility paralleling mode is enabled and the

generator set paralleling breaker is closed, the gen-

erator set will assume load based on external ana-

log input signal. The input signal must be calibrated

from 0−5 VDC. When the signal is at 0.5 to 1 VDC,

the control will operate the generator at no load in

parallel with the utility (mains) source. At 4.5 VDC

and greater, the control will operate the generator

set at 110% of the generator set base load setting.

When the load govern signal is between 1 VDC and

4.5 VDC the control will operate the generator set at

a load level which is determined by a linear relation-

ship between the kW reference and the load govern

signal.

ISOLATED BUS ADJUSTMENTS

SYNC TIME LIMIT: This parameter adjusts the time

delay in seconds before the Fail To Synchronize

alarm will operate.

− PWR LIMIT (%): Adjusts the reverse power set

point. For PowerCommand generator sets, a typical

set point is 10-15%.

− PWR LIMIT (TIME): Adjusts the reverse power

function time delay. A typical time delay which is

suitable for PowerCommand generator sets is 3

seconds.

Lower reverse power set points can result in nui-

sance reverse power shutdown faults.

PERM WIN-PHASE: Adjusts the width of the per-

missive (sync-check) acceptance window. The ad-

justment range is from five to twenty electrical de-

grees. Recommended set point is 20 degrees for

isolated bus applications, and 15 degrees for utility

(mains) paralleling applications.

PERM WIN-TIME: Adjusts the time period (in sec-

onds) for which the generator set must be synchro-

nized with the system bus, before a breaker close

signal is issued by the PowerCommand control.

Available range is 0.5 to 5 seconds. Recommended

value for PowerCommand generator sets is 0.5

seconds for isolated bus applications.

Adjusting the control for a smaller sync-check win-

dow or longer time delay will cause synchronizing

time to be extended.

SYNC GAIN: The sync gain adjustment controls

how quickly the governor will respond to try to mini-

mize the bus/generator phase difference. Increas-

ing the gain speeds up the response. If the gain is

too high instability can result.

SYNC INTEGRAL: The sync integral adjustment

controls the rate at which the governor will be ad-

justed to try to minimize the bus/generator phase

difference. The lower the number the slower the re-

sponse.

5-21

DISPLAY CAL <<

METERS >>

< ENTER CODE

__ __ __>>

PARALLELING SETUP MENU

GOV / REG <<

PARALLEL SETUP

ISO BUS <<

UTILITY

<>VERSION <<

SETUP/CAL >>

ISO BUS <<

UTILITY

< SYNC TIME LMT

 120 >><>

< -PWR LMT (%)

 10 >><>

< -PWR LMT (TIME)

 3 >><>

< PERM WIN-PHASE

 20 >>

< PERM WIN-TIME

 .5 >><>

< SYNC GAIN

 95 >><>

B (CONTINUED)

< SYNC INTEGRAL

 12 >><>

A (CONTINUED)

Indicates OR" Condition

5-22

ISOLATED BUS ADJUSTMENTS (Cont.) (A)

KW BALANCE: This function adjusts the kW load

sharing function of the generator set. Before adjust-

ing this value, all generator set calibrations should

be performed. If the total load on the system is not

shared proportionately, the kW Balance can be

used to adjust the generator set for more precise

load sharing. Increasing the kW Balance value will

cause the generator set to reduce the percentage of

the total kW load on that set.

KVAR BALANCE: This function adjusts the kVAR

load sharing function of the generator set. Before

adjusting this value, all generator set calibrations

should be performed. If the total load on the system

is not shared proportionately, the kVAR balance can

be used to adjust the generator set for more precise

load sharing. Increasing the kVAR balance value

will cause the generator set to reduce the percent-

age of the total kVAR load on that set.

KW GAIN: Adjusts the rate of change of kW load on

the generator set. With a constant load on the sys-

tem, if the generator set load is constantly chang-

ing, reduce the gain adjustment on the generator

set. This also allows modification of the rate of load

assumption on transient load change.

KVAR GAIN: Adjusts the rate of change of kVAR

load on the generator set. With a constant load on

the system, if the generator set load is constantly

changing, reduce the gain adjustment on the gener-

ator set. This also allows modification of the rate of

load assumption on transient load change.

1ST START FAIL: Time delay in seconds after a

signal from the first start master is not sensed by the

PCC that a FIRST START FAIL warning is dis-

played.

RAMP UNLD TIME: When a load demand stop in-

put is sensed the load is ramped down from the

present load level on the set to the ramp unload lev-

el in the time specified in seconds.

RAMP UNLD LEVEL: The load demand ramp un-

load function will ramp the load down from the pres-

ent level on the set to this level before opening the

set circuit breaker. Value shown is in % of genset

standby rating.

RAMP LOAD TIME: When the load demand stop

signal is removed the load is ramped from 0kW to

the load share level in the specified time after the

circuit breaker closes.

LOSS FIELD (LOSS OF EXCITATION) TIME and

LEVEL: Adjusts the time delay on the Loss of Ex-

citation fault. Generator sets with version 1.07 and

higher (9−26−96 and later) firmware may be ad-

justed for time delay on this condition. the default

value is 2 seconds.

Generator sets with version 2.0 and higher firmware

allow adjustment of both time delay and reverse

VAR set point. Default values are 10 seconds and

20%.

5-23

PARALLELING SETUP MENU (Cont.)

<SAVE

EXIT >>

<SAVE

EXIT >> <>

DISPLAY CAL <<

METERS >>

< KW BALANCE

 165 + ___% >><>

< KVAR BALANCE

 0 + ___% >><>

< KW GAIN

 6 >>

< KVAR GAIN

 300 >><>

A (CONTINUED)

< 1ST START FAIL

 10 >>

< RAMP UNLD TIME

 10 >><>

< RAMP UNLD LEVEL

 20 >><>

< RAMP LOAD TIME

 10 >><>

Indicates OR" Condition

< LOSS FIELD TIME

 2 >><>

< LOSS FLD LEVEL

 20 >>

GOV / REG <<

PARALLEL SETUP

5-24

UTILITY (MAINS) ADJUSTMENTS (B)

BASE LOAD (%): Controls the maximum kW load

level that the generator set will operate at when par-

alleled with the utility (mains). The value shown indi-

cates the steady state load on the generator as a

percent of the generator set standby rating.

Check generator set ratings for maximum load level

at which the generator set should operate when

paralleled with the utility (mains). Extended opera-

tion at load levels in excess of the generator set rat-

ing can cause abnormal engine wear or premature

engine failure.

PF LEVEL: Adjusts the power factor that the gener-

ator set will run at when paralleled to the utility

(mains). Recommended setting is 1.0.

KW GOVERN GAIN: Controls the rate that the gen-

erator set kW load is increased after the generator

set has closed to the system bus when utility

(mains) paralleled. Decreasing this value will result

in slower loading of the generator set.

KW INTEGRAL: The kW integral adjustment is

used to control the response of the generator set to

large load changes when utility (mains) paralleled.

Use of a higher integral value will result in slower re-

sponse, and reduced kW overshoot on load as-

sumption or rejection, especially on large system

load changes. Decreased integral values will also

result in slower load acquisition and rejection.

KVAR GOVERN GAIN: Controls the rate that the

generator set kVAR load is increased after the gen-

erator set has closed to the system bus when utility

(mains) paralleled. Decreasing this value will result

in slower loading of the generator set.

KVAR INTEGRAL: The kVAR integral adjustment

is used to control the response of the generator set

to large load changes when utility (mains) paral-

leled. Use of a higher integral value will result in

slower response and reduced kVAR overshoot on

load assumption or rejection, especially on large

system load changes. Decreased integral values

will also result in slower load acquisition and rejec-

tion.

RAMP LOAD TIME: This is the ramp time from

present set load to level determined by the load set

analog input. This is active when the control first en-

ters the load govern mode.

RAMP UNLD TIME: This is the ramp time from

present set load to the 0 kW. This ramp is active

when the load set analog input is less than 0.5 volts.

MULTIPLE/SINGLE: This selection modifies the se-

quence of operation and functions of the inputs and

outputs of the control on TB1 to allow for application

of the control in multiple generator set applications

(“Multiple” selection), where generator sets are par-

alleled to each other and may also be paralleled to a

utility (mains) service; or for applications where a

single generator set is used with a breaker pair for

closed transition power transfer functions (“Single”

selection). See Table 5-3 for a description of the op-

eration and use of TB1-51 input.

5-25

Multiple − In the MULTIPLE configuration, the con-

trol is set up for proper operation in a system where

the gensets are configured similar to that shown in

Figure 5-3 or 5-4. In these illustrations, 52-Gn are

the paralleling circuit breakers and 52-Fn are feeder

circuit breakers that provide generator set power to

load transfer devices. 52-U is a utility (mains) circuit

breaker and 52-GM is a generator bus main break-

er. 52-U and 52-GM provide power transfer func-

tions in the system.

Upon receiving a start signal, the gensets automati-

cally start, select one generator set in the system to

be the first one to close to the bus using the First

Start Sensor system, synchronize, and load share.

Upon receiving a signal to the control that the gen-

erator sets are closed to the utility (mains), the gen-

erator sets automatically ramp to their preset base

load level.

52-G1

52-G2

52-G3

SWITCHGEAR

TO LOADS

52-F1 52-F1 52-F1

PCC PCC PCC BUS VOLT

SENSE

FIGURE 5-3. TYPICAL MULTIPLE CONFIGURATION

TO LOADS

52-G1

52-G2

52-G3

SWITCHGEAR

52-F1 52-F1 52-F1

TO LOADS

52-GM 52-U

FROM

UTILITY (MAINS)

PCC PCC PCC BUS VOLT

SENSE

FIGURE 5-4. TYPICAL MULTIPLE CONFIGURATION

5-26

Single − The SINGLE configuration (limited to

ONLY the electrical configuration shown in Figure

5-5) allows for incorporation of a single PowerCom-

mand generator set in a power system that provides

load transfer functions and various utility paralleling

functions. In the SINGLE configuration, Power-

Command provides all the generator set control

functions including synchronizing, load govern (im-

port/export control and var/PF control), and genset

breaker control functions; equipment provided by

others provides utility (mains) breaker control, utility

source sensing, and other functions.

The PCC monitors the position of the generator set

breaker (52-G1) and the utility (mains) breaker

(52-U). In a black start condition, the generator set

receives a start signal from a remote device. If the

PCC senses no voltage available on the bus volt-

age connection and the utility (mains) breaker is

open, it closes the generator set breaker.

When utility (mains) power returns, the remote de-

vice turns on the synchronizer in the PCC, the PCC

synchronizes the genset-to-utility (mains) service,

and the remote device closes the utility (mains)

breaker (52-U). When the PCC senses that 52-U is

closed, it checks the voltage on the external load set

terminals (TB1-59 and 60) and ramps to the com-

manded load level. The remote device control sys-

tem determines when to open the genset breaker

by removing the start signal from the genset control.

When it is removed, the genset ramps down to zero

load and opens the genset breaker (52-G1).

If the generator set receives a start signal when the

utility (mains) service is available, the generator set

starts and accelerates to rated voltage and frequen-

cy. It automatically synchronizes and closes its

breaker. When the generator breaker is closed, the

generator set ramps to the load level commanded

by the signal on the external load set terminals

(TB1-59 and 60).

52-G1

SWITCHGEAR

52-F1 52-F1 52-F1

TO LOAD(S)

(# LOADS OPTIONAL)

52-U

FROM

UTILITY (MAINS)

PCC

BUS VOLT

SENSE

FIGURE 5-5. UTILITY-SINGLE CONFIGURATION

5-27

PARALLELING SETUP MENU (Cont.)

<SAVE

EXIT >>

DISPLAY CAL <<

METERS >>

< BASE LOAD %

 80 >><>

< PF LEVEL

 1.00 >><>

< KW GOVERN GAIN

 100 >>

< KW INTEGRAL

 4 >><>

< KVAR GOVERN GAIN

 300 >>

< KVAR INTEGRAL

 200 >><>

B (CONTINUED)

< RAMP LOAD TIME

 10 >><>

< RAMP UNLD TIME

 10 >>

< MULTIPLE/SINGLE

 SINGLE>><>

Indicates OR" Condition

<SAVE

EXIT >>

GOV / REG <<

PARALLEL SETUP

5-28

CALIBRATION PROCEDURE

WARNING Contacting high voltage compo-

nents can cause electrocution, resulting in se-

vere personal injury or death. Calibration and

adjustment must be performed by technically

qualified personnel only. Read and observe all

WARNINGS and CAUTIONS in your generator

set manuals.

CAUTION Improper calibration or adjustment

of the PowerCommand control can cause

equipment malfunction or damage. Calibration

and adjustment must be performed by techni-

cally qualified personnel only.

The calibration procedure is divided into 7 subsec-

tions, with the subsections arranged in a specified

order. If two or more of the following subsections are

required to calibrate the PCC, they must be com-

pleted in the order shown.

When removing and replacing a defective circuit

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

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

calibration) provides a list of the circuit boards that

require calibration when replaced and the calibra-

tion procedure(s) that must be performed.

Use a calibrated RMS multimeter for accurate mea-

surements. Fluke models 87 or 8060A are good

choices.

Initial Start Setup

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

when you should perform this procedure.

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

cific generator set, refer to the VERSION menu

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

set model number, frequency, and kW rating. If

any of these values are incorrect, you must per-

form the Initial Start Setup procedure.

Voltage and Frequency Adjustment

2. With the generator set OFF, attach a calibrated

frequency/voltmeter to the AC output from L1

to L2.

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

to display the VOLTAGE adjust menu.

4. Start the generator set and allow the generator

set to reach normal operating speed.

5. Adjust VOLTAGE (generator set output volt-

age) so that the calibrated voltmeter reads the

desired voltage. (Use a calibrated voltmeter

because the value displayed on the PCC digital

display may not be calibrated at this time;

therefore, its accuracy is unknown.)

6 Select the Frequency adjust menu.

7. Verify that the frequency displayed on the cali-

brated meter is the desired frequency. If not,

adjust to the desired frequency. (Note: If the

frequency reading on the digital display is not

the same as frequency shown on calibrated

meter, there is an equipment malfunction.)

8. If no frequency or voltage adjustment was

made, select EXIT. If an adjustment was made,

SAVE, then EXIT.

Digital Voltage Display Calibration

The paralleling bus must be de-energized while

voltage calibrations are performed. If this is not

possible, disconnect and isolate bus voltage in-

puts to the Bus PT Module (A39) before attempt-

ing voltage calibration.

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

From this menu proceed to the VOLTS L12

menu (Page 5-11).

10. With the generator set OFF, attach a calibrated

frequency/voltmeter to the AC output from L1

to L2.

11. Start the generator set and allow it to reach

normal operating speed.

12. Calibrate voltage reading for VOLTS L12 so

that the reading on the digital display agrees

with the calibrated voltmeter.

13. Shut the generator set OFF.

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

(In step 10 attach meter to the AC output from

L2 to L3 to calibrate VOLTS L23 and then L3 to

L1 to calibrate VOLTS L31.)

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

ibration was made, SAVE, then EXIT.

Digital Ammeter Display Calibration

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

From this menu proceed to the AMPS L1 menu

(Page 5-11).

17. With the generator set OFF, attach a calibrated

ammeter to L1.

5-29

18. Start the generator set and allow it to reach

normal operating speed.

19. Load the generator set to maximum rated kVA

at rated voltage.

20. Calibrate the reading for AMPS L1 so that the

reading on the digital display agrees with cali-

brated ammeter.

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

step 17, attach meter to L2 to calibrate AMPS

L2 and then L3 to calibrate AMPS L3.)

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

ibration was made, SAVE, then EXIT.

Digital Power Factor Display Calibration

Power factor calibration is not required except in ap-

plications requiring a higher accuracy than 5%. If

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

tion will require reactive load sufficient to reach 0.8

PF at rated load, and calibrated instruments with

1% accuracy or better. Typical load rack instru-

ments are not accurate enough to perform this pro-

cedure.

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

From this menu proceed to the PF1 menu

(Page 5-11).

24. With the generator set OFF, attach the power

factor meter to L1.

25. Start the generator set and allow it to reach

normal operating speed.

26. Load the generator set to maximum rated kVA

at rated voltage.

27. Calibrate the reading for PF1 so that the read-

ing on the digital display agrees with power fac-

tor meter.

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

step 24, attach meter to L2 to calibrate PF2 and

then L3 to calibrate PF3.)

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

ibration was made, SAVE, then EXIT.

Digital Coolant Temperature Display

Calibration

An engine sensor calibration tool is required to per-

form this procedure.

30. With the generator set OFF, replace the coolant

temperature sender with the precision resistor

provided in the calibration tool.

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

From this menu proceed to the COOLANT

TEMP L menu (5-11).

32. Calibrate the temperature reading to match the

temperature indicated on the calibration tool.

33. Repeat step 32 for COOLANT TEMP R if the

engine uses two sensors.

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

ibration was made, SAVE, then EXIT.

Digital Bus Voltage Calibration

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

From this menu proceed to the Bus Volts L12

menu (Page 5-11).

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

quency/voltmeter to the alternator AC output

from L1 to L2.

The paralleling bus must be de-energized while

voltage calibrations are performed. If this is not

possible, disconnect and isolate bus voltage in-

puts to the Bus PT Module (A39) before attempt-

ing voltage calibration.

37. Start the genset and allow it to reach normal

operating speed and voltage.

38. Push the breaker close switch on the front of

the PowerCommand control and verify that the

paralleling breaker has closed by observing the

closed lamp on the control panel and physical

check of the breaker.

39. Calibrate the voltage reading for Bus Volts L12

so that the reading on the digital display

matches the reading on the calibrated meter.

40. Shut the generator set OFF.

41. Repeat steps 36 through 40 for Bus Volts L23

and Bus Volts L31.

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

ibration was made, SAVE, then EXIT.

Analog meter calibration

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

From this menu proceed to the A−C VOLTS

ADJ TO menu (Page 5-13).

44. Start the generator set and allow the generator

set to reach normal operating speed.

45. Calibrate the analog Voltmeter to the digitally

displayed value.

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

tally displayed value.

47. Calibrate the analog % Load meter to the digi-

tally displayed value.

48. Calibrate the analog Frequency meter to the

digitally displayed value.

49. SAVE, then EXIT.

5-30

ENGINE TORQUE ADJUSTMENT

The engine torque fuel limit is set in the PowerCom-

mand control. This limit is adjustable (0% to +1% of

duty cycle units, which corresponds approximately

to 0% to +2% engine horsepower) through the digi-

tal display to compensate for engine/electronic vari-

ation. If the generator set is not providing the name-

plate kilowatt rating, the torque limit can be adjusted

with the following procedure.

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

From this menu proceed to the Torque Adjust

%DC menu (Page 5-17).

2. Start the generator set and allow it to reach nor-

mal operating speed.

3. Load the generator set to maximum rated kVA

at rated voltage.

4. Adjust the torque limit up or down to achieve

the proper generator set frequency, under

maximum load.

If you select SAVE, the adjustments will be retained

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

restarted. If you select EXIT without saving first, the

adjustments will remain in effect until the generator

set is shut down, but will be reset (and will not be in

effect) when the set is restarted.

5-31

ACCESSORY BOX CONTROL

COMPONENTS

The generator set accessory box (Figure 5-6) which

is located on the backside of the control housing,

contains components that provide connection

points for remote control and monitor options. The

set can be equipped with one or more of the follow-

ing components (customer terminal block TB1 is

standard). Refer to Page 9-6 for typical connections

to TB1.

OPTIONAL RTD

RELAY

OPTIONAL RUN RELAYS

K11, K12 & K13

OPTIONAL

COMMON ALARM

RELAY K14

OPTIONAL

THERMISTOR

RELAY 160/140 C

TB1-1

TB1-40

GOVERNOR

OUTPUT MODULE

A38

PT/CT BOARD A36

VOLTAGE

REGULATOR

OUTPUT MODULE

A37

FIGURE 5-6. ACCESSORY BOX COMPONENTS

5-32

1, 2, 3, 4

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS

A39/A40 TB1

TERMINAL # FUNCTION DESCRIPTION

Bus PT Input (On

Bus PT Module)

Phase to Neutral input voltages from system bus (load side of paralleling

breaker.

5Remote Start Close to ground to start generator set. (RUN/OFF AUTO switch must be

in AUTO position.)

41, 42 Common Alarm

Warning

Form C output contact for remote indication of warning condition on

generator set.

50 Master First

Start/Synchronizer

Enable

For isolated bus or multiple generator set utility (mains) applications, a

B+ signal from a remote Master First Start Sensor is applied on this

terminal. For single generator set utility (mains) parallel applications,

apply 24VDC to this terminal to enable synchronizer function in control.

16 − 19 Customer Fault Grounding these terminals initiates an alarm or shutdown condition in

the control.

20 Fault Reset Applying a momentary ground signal to this terminal clears warning or

shutdown faults in the control. (Except Emergency Stop.)

21 Engine Idle

Grounding this input activates the Low Fuel warning.

35 Rupture Basin

Alarm

Applying a ground signal to this point will cause the generator set to

annunciate a Rupture Basin Alarm.

46 Utility Parallel

Signal

Apply a 24VDC signal to terminal 46 to indicate to the control that it is

operating in parallel with a utility (mains) service.

47 Utility Parallel

Signal

Apply a ground signal to terminal 47 to indicate to the control that it is

operating in parallel with a utility (mains) service.

A39

A40

CONTINUED

6 Remote

Emergency Stop

Grounding this input causes an immediate shutdown.

22 Low Fuel

Applying a ground signal at this terminal will cause engine to run at

recommended idle speed. Voltage will be disabled.

5-33

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS (Cont.)

A39/A40 TB1

TERMINAL # FUNCTION DESCRIPTION

51 Load Demand Close to ground to initiate load demand mode in PowerCommand

control. (Select “Multiple” in Paralleling Setup Menu to enable load

demand mode.)

52 Breaker Open /

Inhibit

Close to ground to manually open the paralleling breaker or inhibit

breaker closure.

53 Breaker Position Close to ground to indicate breaker closed.

54, 55 kVAR Load

Load Sharing Lines. Connect to load sharing lines in other generator

sets in the system.

56, 57 kW Load Share Load Sharing Lines. Connect to load sharing lines in other generator

sets in the system.

59, 60 External Load

Set

Analog 0 − 5 VDC input to control kW load level on generator set when

the generator set is paralleled to utility.

51 Utility Single

Verify

For single generator set utility (mains) applications (“SINGLE” selected

in the Paralleling Setup Menu), this terminal must be connected

[strapped] to ground to enable breaker closure. (Version 1.07, beginning

9-26-96 only.)

A40

Remote Start: When the Run/Off/Auto switch is in

the Auto position, grounding this input initiates the

engine cranking and start sequence. This circuit

must be opened to permit resetting a shutdown con-

dition with the Reset input.

Low Fuel: Grounding this input actuates the Low

Fuel warning. This input can be connected to a local

day tank or to a main fuel tank that is located on site.

When the switch grounds this designated input, the

input will “wake up” the control, if it is not operating,

and then initiate the fault.

Customer Fault Inputs 1 through 4: Grounding

any one of these inputs activates the corresponding

warning or shutdown sequence. Warning or shut-

down status is selected in the setup menu.

External sensing equipment must be connected to

the designated digital input.

The four customer fault messages can be separate-

ly edited in the setup menu to display any desired

message. This allows each customer “default” fault

message to be customized to represent the type of

device that is attached the the fault input.

Customer Fault 1 (A40 TB1-16) is reserved for the

RACK POSITION fault. Do not modify this fault name

or change the fault condition (Warning to Shut-

down).

The “default” message that is displayed, when

ground is applied to the input, is as follows:

Fault 1 = RACK POSITION

Fault 2 = GRND FAULT

Fault 3 = DAY TANK

Fault 4 = HIGH GEN TEMP

If Fault 2 or 3 input is grounded, the control will

“wake up” if it is not operating, and then initiate the

fault.

Fault Reset: When the Run/Off/Auto switch is in

the Auto position and the remote start switch is

open, grounding this input resets any warning and

latched shutdown fault (except Emergency Stop,

which must be reset at the front panel.)

5-34

Engine Idle: When the set is operating in the RUN

mode, grounding this input causes generator build

up to be inhibited and the engine to be governed at

800 RPM. When ground is removed from this input,

the set returns to normal speed and voltage.

Engine idle operation is applicable only in the RUN

mode. The PCC operating program does not permit

engine idle operation when the set is operating in

AUTO mode.

When the engine idle function is enabled, the con-

trol automatically sets lower oil pressure warning

and shutdown trip points to reflect the lower operat-

ing speed. When the engine idle function is re-

moved and the set reverts to normal operating

speed, the control automatically resets oil pressure

warning and shutdown trip points to the normal set-

tings.

Remote Emergency Stop: Grounding this input

causes an immediate shutdown. Emergency stop

must be reset at the front panel.

Master First Start/Synchronizer Enable: This in-

put is received from a Master First Start Sensor,

which is mounted remotely from the PowerCom-

mand control. The input is a pulsed signal which is

used by the PowerCommand control to enable safe

closing of the paralleling breaker when the system

bus is de-energized. the control will receive a pulse

from the Master First Start Sensor approximately

once per second. If the PowerCommand control

does not receive a pulse within the programmable

time delay (default is 10 seconds), the FIRST

START warning is displayed by the control and a

backup system is enabled by the control.

When the system is set up for paralleling a single

generator set with a utility (mains) bus, this input is

used to enable the synchronizer in the PowerCom-

mand control. (See Paralleling Setup Menu, path

B.) A 24VDC signal applied to the terminal will

cause the generator set to synchronize with the

voltage reference signal applied to the bus PT mod-

ule (A39).

All PCC’s in a system should be programmed to a dif-

ferent first start fail time. This will help prevent simul-

taneous closure of breakers in the event of a failure

of the master first start module

Load Demand: On receipt of a signal on the Load

Demand terminals (normally open, close to

ground), the generator set will ramp down to a mini-

mum load level and the paralleling breaker will

open. The generator set will run for a cool-down pe-

riod and shut down. LOAD DEMAND SHUTDOWN

will be displayed on the PowerCommand panel.

When the Load Demand input is removed, the gen-

erator set will start, synchronize and close to the

system bus and accept it’s proportional share of the

total load on the bus.

The Load Demand function of the PowerCommand

control is only active when the RUN/OFF/AUTO

switch is in the AUTO position and “PARALLEL” is

selected in the Paralleling Setup Menu.

Utility Single Verify: For single generator set utility

(mains) applications, this input must be strapped to

ground before the generator set breaker will close

when the utility breaker is opened.

The Load Demand function of the PowerCommand

control is only active when the RUN/OFF/AUTO

switch is in the AUTO position and “SINGLE” is se-

lected in the Paralleling Setup Menu.

5-35

Utility (Mains) Parallel Input: Closure of a normal-

ly open contact to ground on terminal 47 and apply-

ing a 24VDC signal to terminal 46 will cause the

PowerCommand control to begin operation in a util-

ity (mains) paralleling mode. The ground signal is

usually applied by operation of auxiliary contacts in

the utility paralleling breaker. In this operation

mode, the control will ignore inputs from the load

sharing lines and operate at the load level which is

determined by the magnitude of the Load Govern

signal and the base load adjustment in the control

setup.

Load Govern: This input is enabled when the con-

trol has received a utility (mains) parallel input. A

0−5V signal applied to terminals 59 and 60 will di-

rect the control to operate the genset at a fraction of

the preset base load (%). Operating load level is de-

termined by the formula:

31.4 * (Load Set Voltage – 1) = % kW load

For Load Set Voltage of 1.0 volts and lower, the gen-

set will ramp to no load. For Load Set Voltage levels

4.5 volts and higher, the genset will be controlled to

the preset base load.

A change in the Load Set Voltage will cause the

genset to ramp to the new commanded kW level.

Ramp rate is controlled by Ramp Load Time and

Ramp Unload Time. (See Utility (Mains) Adjust-

ments elsewhere in this section.) In the load govern

state, kVar load is always a function of the preset

power factor and the % kW load.

Parallel Breaker Open/Close Inhibit: This func-

tion is operational only when the RUN/OFF/AUTO

switch is in the AUTO position. Closing a normally

open contact to ground on this contact will cause

the paralleling breaker to open if it is closed, or pre-

vent it from closing if it is open. Removing the

ground signal will cause the PowerCommand con-

trol to return to normal operation.

5-36

Operating PowerCommand in Droop Mode

The PowerCommand control is designed to operate

isochronously (with no intended droop) so that volt-

age and frequency are as constant as possible

when the generator set is paralleled to other Power-

Command generator sets. In certain situations,

however, such as paralleling with other generators

that are operating in droop mode, it may be neces-

sary to operate the control in a droop mode for fre-

quency, voltage, or both.

Note that when the generator set is paralleled to a

utility (mains) service it is recommended that the

control be operated in its utility parallel mode, rather

than in droop, even if other generator sets in the

system operate in droop for that function. The droop

mode in PowerCommand will only work when all the

other generator sets in the system are operating in

droop and the system bus voltage and frequency

change with load.

PowerCommand controls that are set up to operate

in droop mode must include the paralleling option

(H532). The generator set should be set up for mul-

tiple unit paralleling, but load sharing interconnect-

ing wiring is not used. Connect a 5K resistor across

terminal A40-TB1-54 and 55 (KVAR) to cause volt-

age to droop. A 5K resistor across terminal

A40-TB1-56 and 57 (KW) will cause frequency to

droop. Resistors can be used on one or both of the

load sharing terminal connections, depending on

the needs of the application.

Complete all start up procedures as described in

Section 8 of this manual up to the point that you are

ready to make load sharing adjustments. To set the

governor and voltage regulation system droop lev-

el:

1. Set the no load speed and voltage at the de-

sired level. Bus must be de-energized when

this setting is made, or disconnect Bus PT

module.

2. Apply 100% load to the generator set, and ad-

just the KW load sharing gain to obtain the de-

sired full load operating frequency. Adjust the

KVAR load sharing gain to obtain the desired

full load operating voltage. Refer to Figure 5-7

for typical gain settings for specific droop lev-

els.

3. Repeat the process for other generator sets in

the system.

4. When initial settings have been made, test the

system with all available load, and verify that

the generator sets share load approximately

equally at no load and maximum available

load.

Proper adjustment of load sharing in droop opera-

tion requires use of both real and reactive load

banks. It is possible that precise load sharing will not

be possible with all generator sets in the system at all

load levels, due to the non-linearity of the droop

characteristic of some generator sets. In that case, it

is generally best to set up the system so that avail-

able load is equally shared at the maximum load level

expected on the system. Note also that the synchro-

nizer is active and functional in PowerCommand

even when the system is set up for droop load shar-

ing. Manual paralleling and system synchronizing

should be performed by the PowerCommand con-

trol. It is recommended that paralleling breakers be

electrically operated by the PowerCommand con-

trol.

5-37

9.00

8.00

7.00

6.00

5.00

3.00

2.00

1.00

0.00

4.00

12345

LOAD SHARE GAIN

% DROOP

% DROOP @1800 RPM

% DROOP @1500 RPM

7689101112 13 14 15 16 17 18 19

FIGURE 5-7. PERCENT SPEED DROOP VERSUS KW LOAD SHARE GAIN

5-38

TB1 Customer Outputs

Refer to Page 9-9 for typical connections to TB1.

TABLE 5-4. TB1 CUSTOMER OUTPUTS

TB1

TERMINAL # FUNCTION DESCRIPTION

B+ Auxiliary Power 24 VDC control power supply, fused at 20 amps.

2Switched B+

Auxiliary Power

24 VDC control power available when genset is running, fused at 10

amps.

3, 4 Ground

7, 8, 9 Common

Shutdown

Form C contact set to indicate to a remote device that a generator set

shutdown fault has occurred.

10, 11

N-K20

Parallel Breaker

Close Signal

Normally open contact which closes to close a remote paralleling

breaker.

14, 15 Network Data Terminations for network data twisted pair, operational when generator

set is equipped with generator control module (GCM).

38, 40 Ready to Load Indicates that the generator set is at rated frequency and voltage and is

ready to accept load. Normally open contact between 38 and 40, which

is common.

39, 40 Load Dump Normally open contact which closes to indicate that the generator set is

overloaded.

41, 42 Common Warning Normally open contact that closes to indicate a warning condition on the

generator set.

43, 44 Common Warning Normally closed contact that opens to indicate a warning condition on

the generator set

48, 49

N-K21

Parallel Breaker

Open Signal

Normally closed contact which opens to close the paralleling breaker.

23−32, 33 NFPA Fault

Contacts

Normally open contact which closes to indicate that a specific fault has

occurred in the generator set. Common is terminal 33.

5-39

Paralleling Breaker Control: Contacts are pro-

vided to allow the PowerCommand control to oper-

ate a remote paralleling circuit breaker. A normally

open contact will close to signal the paralleling

breaker to close. A normally closed contact will

open to open the paralleling breaker.

When the RUN/OFF/AUTO switch is in the RUN

position the breaker signals will be initiated on op-

eration of the paralleling breaker control switches

on the front panel of the PowerCommand control.

The breaker control switches on the front panel of

the control are not operational in other control op-

eration modes.

When the RUN/OFF/AUTO switch is in the AUTO

position, the PowerCommand control will automati-

cally close the paralleling breaker if the system bus

is de-energized and the master first start sensor

pulse is received, or if synchronous condition with

the bus is achieved.

Warning Alarm: One set of normally open (NO)

and one set of normally closed (NC), rated for 2

amps at 30 VDC. Any warning causes the warning

alarm relay (labeled Spare Relay on Customer In-

terface board) to be energized. This output is often

used to energize an audible alarm.

Common Alarm: One set of form-C contacts, rated

for 2 amps at 30 VDC. Any shutdown causes the

common alarm relay to be energized. This output is

often used to energize an audible alarm.

Load Dump: One set of normally open (NO) con-

tacts, rated for 2 amps at 30 VDC. If an overload oc-

curs which causes generator set frequency to drop

more than 3 hertz below nominal for more than 3

seconds, or a load of more than 105% of the stand-

by rating is applied to the generator set for more

than 60 seconds, the normally open load dump con-

tacts are closed. This relay is energized before

shutdown (for overload or underfrequency) occurs.

Ready To Load: One set of normally open (NO)

contacts, rated for 2 amps at 30 VDC. This output is

activated whenever AC voltage and frequency ex-

ceed 90% of nominal.

Switched B+: This is a fused 10 amp, 24 volt

switched output. This output is activated by the run

pilot signal, at the governor output module. (Fuse is

located on Governor Output Module.)

B+: This is a fused 20 amp, 24 volt output. (Fuse is

located on TB-BAT terminal block of the engine har-

ness.)

5-40

Run Relays (K11, K12, 13)

The optional run relays are rail mounted inside the

accessory box (Figure 5-6). The rail mount allows

you to easily remove and replace the snap-on re-

lays. The generator set can be equipped with one,

two or three run relays.

The three-pole, double-throw run relays (Figure

5-8) are used to control auxiliary equipment such as

fans, pumps and motorized air dampers. The run

relays are energized when the generator set reach-

es operating speed.

The contacts are rated:

10 amps at 28 VDC or 120 VAC, 80%PF

6 amps at 240 VAC, 80%PF

3 amps at 480/600 VAC, 80%PF

CUSTOMER

CONNECTIONS

A40-TB1-4

(B-)

A40-TB1-2

(SWITCHED B+)

COIL

COM

K11, K12, K13

K11

RUN RELAY

K11, K12, K13

K12

RUN RELAY

K13

RUN RELAY

FIGURE 5-8. OPTIONAL RUN RELAYS (K11, K12, K13)

5-41

Shutdown Alarm Relay (K14)

The optional shutdown alarm relay is rail mounted

inside the accessory box (Figure 5-6). The rail

mount allows you to easily remove and replace the

snap-on relay.

The three-pole, double-throw shutdown alarm relay

(Figure 5-9) is often used to energize warning de-

vices such as audible alarms. Any generator set

shutdown will energize the alarm relay.

The contacts are rated:

10 amps at 28 VDC or 120 VAC, 80%PF

6 amps at 240 VAC, 80%PF

3 amps at 480/600 VAC, 80%PF

CUSTOMER

CONNECTIONS

A40-TB1-7

(COMMON SHUTDOWN

ALARM)

A40-TB1-1

(B+)

COIL

COM

K14

COMMON SHUTDOWN

ALARM

A40-TB1-4

A40-TB1-8

JUMPER WIRE

REQUIRED FOR K14

RELAY OPTION

(GND)

(COMMON

SHUTDOWN ALARM)

FIGURE 5-9. OPTIONAL SHUTDOWN ALARM RELAY (K14)

5-42

RTD Relay (Optional)

The optional RTD relay is rail mounted inside the

accessory box (Figure 5-6). This relay is used to

monitor six separate temperature zones in the gen-

erator windings using resistive temperature detec-

tors (RTDs). The relay determines the sensed tem-

perature and acts to isolate, alarm, or initiate cor-

rective action.

The RTD relay (Figure 5-10) compares the six in-

puts to the predetermined setpoint (temperature

setpoint is factory adjusted). If one or more of the in-

puts exceed the setpoint, the output relay is ener-

gized. LED’s indicate the state of the output relay

(green for normal, red for tripped). Additional red

LED’s are used to indicate which inputs exceed the

setpoint.

The relay terminals 11, 12 and 14 are for customer

connection. These terminals can be attached to any

one of the four Customer Fault inputs on TB1 to pro-

vide a warning/shutdown condition or to other cus-

tomer warning devices. (Refer to Setup Menu in

Section 7, which describes how to modify the cus-

tomer fault message and to select a warning or

shutdown condition.)

The contacts are rated:

240 VAC, 5 amps non-inductive

24 VDC, 25 amps resistive

OUTPUT RELAY

(CUSTOMER USE)

A40TB1-4

(GROUND)

WHITE

TO RTD TERMINAL

BLOCK

TEMPERATURE RELAY CONNECTIONS

(+) PWR (−)

A40TB1-2

(SWITCHED B+)

24 VDC

FIGURE 5-10. RTD RELAY (OPTIONAL)

5-43

Thermistor Relay (Optional)

The optional thermistor relays are rail mounted in-

side the accessory box (Figure 5-6). Each relay

monitors three thermistors (one per phase) that are

connected in series inside the generator. One se-

ries or chain of thermistors are rated at 140 C and

the other at 160 C. The 140 C relay is commonly

used in a pre-alarm circuit and the 160 C relay in a

shut-down circuit. The relay will energize (trip)

when the thermistor chain resistance reaches 3000

500 ohms.

The relay terminals 1, 2 and 3 are for customer con-

nection and are normally connected to a breaker

shunt trip or a load shed circuit (Figure 5-11).

The contacts are rated:

3 amps at 250 VAC

1 amp at 480 VAC

A40-TB1-4

(GROUND)

WHITE/RED

THERMISTORS A BC

A40-TB1-2

(SWITCHED B+)

BLUE

FAULT CHANNELS

(CUSTOMER

CONNECTIONS)

RELAY CONTACTS

FIGURE 5-11. THERMISTOR RELAY (OPTIONAL)

5-44

ENGINE SENSORS

Figures 5-12 shows the locations of the oil and cool-

ant temperature and oil pressure senders to which

the PCC responds. The switches function by clos-

ing the fault or warning circuit to the engine chassis

ground (battery negative [−]). The low coolant level

switch has its own ground wire.

LOW COOLANT

LEVEL SWITCH

LOW COOLANT

TEMPERATURE

SWITCH

COOLANT TEMPERATURE

SENDER

OIL TEMPERATURE

SENDER (FAR SIDE)

OIL PRESSURE

SENDER (FAR SIDE)

FIGURE 5-12. ENGINE SENSOR LOCATIONS

5-45

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 locknut.

CAUTION Do not use fan blade to bar over en-

gine. That can damage blades and cause prop-

erty damage and personal injury.

MPU

SENSOR

ENGINE

FLYWHEEL

RING GEAR

FIGURE 5-13. MPU SENSOR

5-46

CURRENT TRANSFORMER (CT)

INSTALLATION

Current transformers (CT’s) are required on gener-

ator sets that contain AC meters. The CT’s must be

installed as noted in the following CT Installation

Requirements. Improper installation of CT’s will

cause a “335 Reverse Power” shutdown error.

Refer to the Reconnection Diagram to identify the

output leads/phase that must be routed through

each CT, and also appropriate transformer post

selection for meter sensing leads. The transformers

are labeled CT21, CT22 and CT23 on the recon-

nection wiring diagram. (The Reconnection Dia-

gram is located on the upper side cover of the con-

trol housing.)

CT Installation Requirements

A. The CT has a dot on one side. This dot must be

facing toward the generator (conventional cur-

rent flowing into the dot). A dot is also used to

indicate pin 1 of the CT.

B. CT21 − U load leads (A phase)

CT22 − V load leads (B phase)

CT23 − W load leads (C phase)

C. Route the appropriate leads through each CT.

6 lead generator sets − generator output

leads are routed through the CT’s.

12 lead generator sets − load wires are

routed through the CT’s.

D. Reconnectable generator sets (12 leads) have

dual secondary CT’s (3 pins). The CT secon-

dary wire marked 1 is connected to pin 1 of the

CT. CT secondary wire marked 2/3 is con-

nected to pin 2 for high voltage generator sets

or to pin 3 for low voltage generator sets. (Refer

to Reconnection Diagram.)

Non-reconnectable generator sets (6 leads)

have single secondary CT’s (2 pins).

The lead from CT terminal #1 connects to

the metering circuitry.

The lead from CT terminal #2/3 connects

to ground.

5-47

DIGITAL BOARD (A32) CALIBRATION

The digital board (Figure 5-14) contains three resis-

tors that are used to calibrate the digital board for

different generator set models. One of these resis-

tors may need to be removed in order to calibrate/

initialize the PowerCommand control to the genera-

tor set model. Table 5-5 provides the necessary in-

formation to determine which resistor that may

need to be cut to select the desired generator set

model.

To find the exact genset model, spec. level and en-

gine rating, refer to the engine data tag on the left

bank intake manifold.

After the appropriate resistor selection is made, the

PowerCommand control must be re-initialized. Re-

fer to Initial Start Setup Menu in this section to initial-

ize the PowerCommand control. When the initial

setup save button is pushed, the PowerCommand

control will compare the calibration selection (cut

resistor) to the initial setup and perform one of the

following:

1. If the model numbers corresponding to the cut

resistor and the initial setup are compatible, ac-

cording to Table 5-5, the calibration is vali-

dated. The control will store the appropriate in-

formation based on calibration and initial setup

data in EEProm. The initial setup is now com-

plete and the control can start the engine.

2. If the model number corresponding to the cut

resistor and the initial setup are not compatible

the control will display the fault “INVALID SET-

UP” (fault code 401). No initial setup data is

saved and the control will not leave the initial

setup menu until this fault condition is cor-

rected.

3. If the control senses that more than one resis-

tor has been cut, the control will display the

fault “INVALID CAL” (fault code 402). No initial

setup data is saved and the control will not

leave the initial setup menu until this fault con-

dition is corrected.

TABLE 5-5. DIGITAL BOARD (A32) CALIBRATION

STANDBY MODEL

ENGINE RATING

EPROM KIT P/N RESISTOR

STANDBY MODEL

NUMBERS

ENGINE RATING

SINGLE PARALLEL

RESISTOR

REMOVED

1000DFHD-60/900DFHD-50 QST30-G4 0300-4721-04 0300-4721-16 R38

1000DFHD-60/900DFHD-50 QST30-G5-NR1 0300-4721-04 0300-4721-16 R38

900DFHC-60/800DFHC-50 SPEC A-C QST30-G3 0300-4721-35 0300-4721-40 NONE

900DFHC-60/800DFHC-50 SPEC D QST30-G3 0300-4721-35 0300-4721-40 R38

800DFHB-60/700DFHB-50 SPEC A-D QST30-G2 0300-4721-04 0300-4721-16 R36

800DFHB-60/700DFHB-50 SPEC E QST30-G2 0300-4721-35 0300-4721-40 R37

800DFHB-60/700DFHB-50 SPEC E QST30-G2-NR1 0300-4721-35 0300-4721-40 R37 & R38

750DFHA-60/620DFHA-50 SPEC A-D QST30-G1 0300-4721-04 0300-4721-16 NONE

750DFHA-60/620DFHA-50 SPEC E QST30-G1 0300-4721-35 0300-4721-40 R36

750DFHA-60/620DFHA-50 SPEC E QST30-G1-NR1 0300-4721-35 0300-4721-40 R36 & R37

5-48

DS1

DS2

DS3

DS4

DS7

DS6

DS5

R36

R37

R38

FIGURE 5-14. DIGITAL BOARD (A32)

6-1

6. Servicing the Generator

GENERAL

This section describes how to isolate a high AC volt-

age fault to the PCC control circuitry or generator,

and the procedures to test, disassemble and re-

assemble the generator (Figure 6-1).

WARNING Incorrect service or replacement of

parts can result in severe personal injury or

death, and/or equipment damage. Service per-

sonnel must be trained and experienced to per-

form electrical and mechanical service.

WARNING HAZARDOUS VOLTAGE. The

PCC1301 control box must be opened only by

technically qualified personnel. Voltages of up

to 600 VAC are present in the PCC box. These

voltages can cause electrical shock, resulting

in personal injury.

RECONNECTION

TERMINALS

STATOR

BLOWER

COUPLING

DRIVE

DISCS

ROTOR

SHAFT

AIR DISCHARGE

COVERS

FRAME

ROTATING

RECTIFIER

ASSEMBLY

PMG

STATOR

EXCITER

ROTOR

END BRACKET

PMG

ROTOR

EXCITER

STATOR

END BRACKET/ENGINE

ADAPTOR

ROTOR

END

BEARING

PRESSURE

PLATE

FIGURE 6-1. TYPICAL GENERATOR

6-2

GENERATOR/PCC CONTROL ISOLATION

PROCEDURE

The following procedure is used to determine if the

generator or the PCC control circuitry is causing a

high AC voltage shutdown fault.

1. Throw the line circuit breaker OFF and shut

down the set.

CAUTION This test involves unregulated ex-

citation of the generator. To prevent damage to

the generator due to overcurrent, make sure

that all loads have been disconnected and that

all faults have been cleared from the power out-

put terminals of the generator.

2. Remove the housing cover of the accessory

box and remove plug P10 from connector J10

of the voltage regulator output module (A37).

See Figure 3-9.

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 X (Field +) and XX (Field −)

pins of plug P10.

X = Red wire of P10-6

XX = Brown wire of P10-3

Connect the jumper from the positive (+) post

of the battery to the X pin (red wire) of P10-6.

Be prepared to connect the jumper from the

negative (−) post of the battery to the XX pin

(brown wire) of P10-3. 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 im-

posing 24 volts on the system.

5. Check polarity again. Polarity must be correct

or this test will be inconclusive because the in-

duced and residual magnetic polarities in the

exciter stator will be opposed.

WARNING HAZARDOUS VOLTAGE. Touching

uninsulated high voltage parts inside the con-

trol box can result in severe personal injury or

death. Measurements and adjustments must be

done with care to avoid touching hazardous

voltage parts.

For your protection, stand on a clean dry wood-

en platform or clean rubber insulating mat,

make sure your clothing and shoes are dry, re-

move jewelry and use tools with insulated han-

dles.

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 4 to troubleshoot the PCC control cir-

cuitry. (Normal excitation voltage ranges from

approximately 10 VDC at no-load to approxi-

mately 40 VDC at full−load.)

8. If the voltages are unbalanced, troubleshoot

the main stator first. If the voltages are uniform-

ly low, troubleshoot the exciter and field circuits

first. Perform the Winding Resistance Test pro-

cedure for the desired windings as noted in this

section.

6-3

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.

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 ig-

nite battery gas. Do not smoke, or switch

trouble light ON or OFF near battery. Discharge

static electricity from body before touching bat-

teries by first touching a grounded metal sur-

face.

Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-

connect 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 set.

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.

Insulation Resistance Testing

The insulation resistance test should be performed

before the initial start-up of the generator set or

when low insulation is suspected, e.g. damp or wet

windings.

A 500 VAC megger is recommended for insulation

testing. A test consists of applying the test potential

between the winding and ground (winding lamina-

tions).

The highest resistance values shown in Table 6-1

should be obtained for a new generator with dry

windings. For a set that has been in service, the re-

sistance reading should not be less than the lower

value shown.

If low readings are obtained, the cause should be in-

vestigated and corrected before the generator set is

returned to service.

If moisture is determined to be the cause of low test

readings, a winding drying process will be required.

1. Disconnect plug J10 from the voltage regulator

output stage module.

2. Disconnect the AC control input leads from the

generator output terminals. The AC control

leads are marked 5, 6, 7 and 8. Refer to the ap-

propriate Reconnection Diagram in Section 8.

3. If the RTD (resistive thermal device) option is

installed, ground all six RTD temperature

leads. Each RTD has three leads, one red and

two white leads. Total of 18 leads must be

grounded.

4. Perform the Insulation Resistance Test proce-

dure for the desired windings as noted in this

section.

TABLE 6-1. GENERATOR INSULATION RESISTANCE

FRAME

GENERATOR

MEGGER MINIMUM RESISTANCE (MEG)

FRAME

SIZE

GENERATOR

VOLTAGE

MEGGER

VDC

SETTING

MAIN

STATOR MAIN ROTOR PMG EXCITER

STATOR

P7 600 VAC or

less

500 10.0 − 1.0 10.0 − 1.0 10.0 − 1.0 10.0 − 1.0

HC6 600 VAC or

less

500 5.0 − 1.0 5.0 − 1.0 5.0 − 1.0 5.0 − 1.0

6-4

Drying the Windings

If low readings are obtained and moisture is deter-

mined to be the problem, the windings should be

dried out and the test repeated. Use the generator

heaters or blow warm air through the generator with

a fan. A more effective way is to use a bolted

3-phase short across the generator terminals. This

procedure must be done as described or equipment

damage can result. To do this:

1. Bolt the generator three phase output termi-

nals together. See the reconnection diagrams

in Section 8.

2. Remove the housing cover of the accessory

box and remove plug P10 from connector J10

of the voltage regulator output module (A37).

See Figure 3-11.

3. Connect the positive and negative leads of a

variable 12 VDC source to P10 as follows:

Positive lead − Red wire of P10-6 (X)

Negative lead − Brown wire of P10-3 (XX)

CAUTION Voltage must begin at zero

volts and be gradually increased or equip-

ment damage will result. The current will in-

crease rapidly and it must be monitored to

prevent exceeding the generator rating.

4. Attach a clamp-on ammeter to the generator

leads to measure generator current, adjust the

12 VDC source for zero voltage, start the set

and very slowly increase the excitation voltage.

Obtain the highest current possible without ex-

ceeding generator rating.

5. Run the genset for approximately one hour,

then repeat the insulation resistance tests. If

further drying time is indicated, continue the

drying process.

6-5

EXCITER STATOR

Testing Winding Resistance: Measure winding

resistance with a Wheatstone bridge or digital ohm-

meter. Replace the stator if winding resistance is

not as specified by Table 6-2.

Before performing the following insulation resist-

ance test, refer to the Insulation Resistance Test pro-

cedure at the beginning of this section.

Testing Winding Insulation Resistance: Discon-

nect exciter stator leads F1 and F2 from their con-

nectors in the AC generator wiring harness and iso-

late them from ground.

Connect the megger between one of the leads and

ground and conduct the test as instructed under In-

sulation Resistance testing.

MEASURE WINDING

INSULATION RESISTANCE

BETWEEN EITHER LEAD

AND THE STATOR

LAMINATIONS

MEASURE WINDING RESISTANCE

BETWEEN THE TWO STATOR

LEADS, F1 (X) AND F2 (XX)

FIGURE 6-2. TESTING THE EXCITER STATOR

TABLE 6-2. WINDING RESISTANCE VALUES*

FRAME

EXCITER

MAIN

MAIN STATOR

FRAME

SIZE

EXCITER

STATOR

EXCITER

ROTOR

MAIN

ROTOR WINDING

WINDING

P7B 17.5 0.048 1.67 N/A 0.0016 N/A 0.0026

P7C 17.5 0.048 1.85 N/A 0.00126 N/A 0.002

6G 17 0.158 1.44 0.0037 0.0148 N/A 0.011

6H 17 0.158 1.54 0.0027 0.0108 N/A 0.0072

6J 17 0.158 1.73 0.0024 0.0096 N/A 0.006

6K 17 0.158 1.95 0.0019 0.0076 N/A 0.0052

* Resistance figures are approximates, at 68 F (20C) + 10%.

6-6

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 diametrical-

ly. 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. A 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 re-

sistance is high or low in both directions, replace the

diode.

Replacing Diodes: Make sure the replacement

diode is of the correct polarity. Disconnect the pigtail

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. Torque the diodes to 36 to 42 in-lbs (4 to 4.8

Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm)

when reassembling.

Surge Suppresser Testing and Replacement:

Remove the suppresser. Replace the suppresser if

it appears to have overheated or if ohmmeter read-

ings indicate less than infinite resistance (end of

scale) in both directions. Torque the terminals to 24

in-lbs (2.7 Nm) when reassembling.

CAUTION Layers of dust can cause diodes to

overheat and fail. Brush dust off regularly.

TERMINAL

(ONE OF SIX)

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

SURGE SUPPRESSER

REMOVE TO TEST

DIODE PLATES

(TWO)

FIGURE 6-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

6-7

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 V (CR2 or CR5), V

(CR2 or CR5) and W (CR3 or CR6), W (CR3 or

CR6) and U (CR1 or CR4). See the winding sche-

matic. Replace the whole rotor shaft assembly if the

resistance of any winding is not as specified in Table

6-2.

Before performing the following insulation resist-

ance test, refer to the Insulation Resistance Test pro-

cedure at the beginning of this section.

Testing Winding Insulation Resistance: Discon-

nect all six exciter rotor leads from diode terminals

CR1 through CR6 and isolate them from ground.

Connect the megger between one of the leads and

ground and conduct the test as instructed under In-

sulation Resistance testing.

WINDING SCHEMATIC

MEASURE WINDING INSULATION

RESISTANCE BETWEEN ANY LEAD

OR THE TERMINAL TO WHICH IT IS

CONNECTED AND THE ROTOR

LAMINATIONS

DISCONNECT THE SIX ROTOR WINDING

LEADS FROM THEIR TERMINALS AND

MEASURE ELECTRICAL RESISTANCE

ACROSS EACH PAIR OF WINDINGS: U-V,

V-W, W-U

MAIN ROTOR

LEADS

FIGURE 6-4. TESTING THE EXCITER ROTOR

6-8

MAIN ROTOR (GENERATOR FIELD)

Testing Winding Resistance: Disconnect the two

leads of the main rotor from the terminals on the ro-

tating rectifier assembly. See Figure 6-5. 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

6-2. Connect the rotor leads and torque the termi-

nals to 23 in-lbs (3.3 Nm) when reassembling.

Before performing the following insulation resist-

ance test, refer to the Insulation Resistance Test pro-

cedure at the beginning of this section.

Insulation Resistance and PI Test: Disconnect

the main rotor and voltage suppressor leads from

terminals F1+ and F2− on the rotating rectifier as-

semblies and isolate them from ground. Tag and

mark each lead with its terminal number (F1+ or

F2−).

Connect the megger between one of the rotor leads

and ground and conduct the test as instructed un-

der Insulation Resistance testing.

DISCONNECT THE MAIN ROTOR LEADS

FROM THE ROTATING RECTIFIER ASSEMBLY

AND MEASURE THE WINDING RESISTANCE

BETWEEN THEM

MEASURE WINDING INSULATION

RESISTANCE BETWEEN EITHER ROTOR

LEAD AND THE ROTOR LAMINATIONS

FIGURE 6-5. TESTING THE MAIN ROTOR

6-9

MAIN STATOR

Testing Main Stator Winding Resistance: Dis-

connect all stator leads from the terminals to which

they are connected. Using a Wheatstone bridge

having at least 0.001 ohm precision, measure elec-

trical resistance across each pair of stator leads:

U1-U2, V1-V2, W1-W2, U5-U6, V5-V6 and W5-W6.

Replace the stator if the resistance of any winding is

not as specified in Table 6-2.

Before performing the following insulation resist-

ance test, refer to the Insulation Resistance Test pro-

cedure at the beginning of this section.

Insulation Resistance and PI Test: Remove and

separate all leads of the generator from the genera-

tor load terminal block. Number of neutral leads

(three or six) to remove will vary between low and

medium voltage generators.

Connect the megger between one phase of the sta-

tor and ground while grounding the other two

phases and conduct the test as instructed under In-

sulation Resistance testing.

Repeat this step in turn for the other two phases.

WHEATSTONE

BRIDGE

FIGURE 6-6. TESTING THE GENERATOR STATOR

6-10

TESTING THE PMG

WARNING HAZARDOUS VOLTAGE. Touching

uninsulated high voltage parts inside the con-

trol box can result in severe personal injury or

death. Measurements and adjustments must be

done with care to avoid touching hazardous

voltage parts.

For your protection, stand on a clean dry wood-

en platform or clean rubber insulating mat,

make sure your clothing and shoes are dry, re-

move jewelry and use tools with insulated han-

dles.

1. Disconnect plug J10 from the voltage regulator

output stage module.

2. Start the engine at the set and let the speed sta-

bilize.

3. Measure voltage across lead pairs J10-1 &

J10-4, J10-4 & J10-5, and J10-5 & J10-1. Volt-

age should be at least 150 VAC for 50 Hz sets

and at least 180 VAC for 60 Hz sets, and should

be approximately the same for each set of

leads. If the voltages are low or uneven, check

all the leads and connections between the volt-

age regulator output stage module and the

PMG and repair as necessary before disas-

sembling the PMG.

4. Stop the set and measure electrical resistance

across lead pairs J10-1 & J10-4, J10-4 &

J10-5, and J10-5 & J10-1 with a Wheatstone

bridge or digital ohmmeter. The resistance

should be 2.6 10% ohms for frame size P7

and HC6.

6-11

BEARING

INSPECTION/REMOVAL/REPLACEMENT

The end bearing is enclosed in a pre-packed ma-

chined cartridge.

Bearing Inspection: If a situation occurs which al-

lows an opportunity to visually inspect the end bear-

ing with it installed, check the color of the grease.

The color of the grease is the only indication that

can be used to determine if the bearing is defective.

New grease is a whitish-beige color but some mild

discoloration will occur with use. If the grease

shows signs of gross discoloration, the bearing

should be replaced.

Bearing Removal: The bearing is press fitted onto

the shaft and can be removed with standard work-

shop tools (i.e., two or three legged manual or hy-

draulic bearing pullers). The bearing should only be

removed for replacement (bearing is destroyed dur-

ing removal and must be replaced).

The end bearing is enclosed in a pre-packed car-

tridge housing and must only be dismantled as nec-

essary for relubrication, replacement, or when a

major overhaul is carried out on the generator set.

P7 Bearing Removal

1. Remove the endbracket (complete steps 1

through 16 of the Main Stator and Rotor Re-

moval (P7) procedure.

2. Remove the four screws holding bearing cap.

3. Remove cap.

4. Remove circlip.

5. Remove bearing cartridge housing complete

with bearing.

P7 Bearing Replacement

The instruction sheet provided with the bearing kit is

required to complete the following procedure.

P7 generator component parts cannot be ordered

from Cummins. Refer to the Newage nameplate

and supply all available information. Contact your

nearest Newage distributor for assistance in order-

ing component parts.

1. Lift slightly on end of rotor shaft and install

wooden shims to hold rotor on center with sta-

tor.

2. Install bearing onto rotor shaft. Refer to bearing

kit instruction sheet.

3. Install two threaded studs into end bearing car-

tridge to aid subsequent procedures. Position

the end bearing cartridge assembly close to

proper position for hole alignment with end-

bracket.

4. Install endbracket to the stator frame using the

proper screws and lock washers, but do not

tighten securely as yet.

5. Insert and start the threads of the bearing car-

tridge fasteners, and remove threaded align-

ment studs, through the endbracket into the

cartridge housing.

6. Lift slightly on endbracket and remove wooden

shims holding rotor on center with stator.

7. Securely tighten the endbracket fasteners.

8. Tighten the bearing cartridge fasteners to 4.5

ft-lbs. (6 Nm) torque.

9. Install the PMG assembly. Refer to Permanent

Magnet (PMG) Installation procedure.

P7 Bearing Lubrication

A grease fitting is provided to allow re-greasing of

the bearing with a grease gun (see Operator’s

manual for grease quantities/type, maintenance in-

tervals, and procedure).

6-12

HC6 Bearing Removal

1. Remove the endbracket (complete steps 1

through 16 of the Main Stator and Rotor Re-

moval (P7) procedure.

2. Remove the four screws holding bearing cap

3. Remove cap.

4. Remove circlip.

5. Remove bearing cartridge housing complete

with bearing.

HC6 Bearing Replacement

When replacing bearing onto rotor shaft, be sure to

apply pressing force to the inner face of the bearing

only.

HC6 Bearing Lubrication

Bearing Lubrication: When re-lubricating or re-

placing the bearing, review the following.

Recommended Lubricant: Lithium based

grease, Mobilux No. 2 or Shell Alvania R3.

Temperature Range: -22F to +248F (-30C to

+120C).

Quantity: 2.74 oz. (81 ml). The grease should

be equally divided between the bearing, the

bearing cap cavity, and the bearing cartridge

cavity.

6-13

GENERATOR DISASSEMBLY

The following procedures provide information for

removal and reassembly of the generator PMG ex-

citer, control housing, and stator/rotor assemblies.

Be sure to read through this section first, before per-

forming procedures listed, to determine the steps

most appropriate for the service attention required.

Two types of generators (P7 or HC6) are used with

these generator set models. The major difference

between these two generators is the lifting eye loca-

tions on the generator and the type of control hous-

ing. The control housing for the HC6 generator is

shown in Figure 6-7 and the control housing for the

P7 generator is shown in Figure 6-8. In the following

procedures, if the step only applies to a particular

control housing or generator, it will be noted at the

beginning of the step (e.g., HC6 control housing, P7

generator, etc.)

Permanent Magnet (PMG) Removal

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 ig-

nite battery gas. Do not smoke, or switch

trouble light ON or OFF near battery. Discharge

static electricity from body before touching bat-

teries by first touching a grounded metal sur-

face.

Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-

connect 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 set.

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.

1. Disconnect the negative (-) battery cable to

prevent accidental starting of the generator set

while servicing.

2. HC6 Control Housing: Remove the control

housing grille and access covers (see Figure

6-7).

3. Remove the three M5X12mm capscrews and

lockwashers from the PMG cover, and remove

cover.

4. Disconnect the PMG wiring harness connector.

5. Remove the four bolts and clamps retaining the

exciter stator housing to the endbracket.

6. Tap the stator housing out of its spigot, and

carefully remove from generator endbracket.

The highly magnetic rotor will attract the stator

core; care must be taken to avoid any contact

which may damage the windings.

7. Remove the hex head through-bolt from the ro-

tor shaft and firmly pull the complete rotor as-

sembly from its location. Keep the rotor clean

by avoiding contact with metal dust or particles.

CAUTION The rotor assembly must not be

dismantled, or the magnetic properties will

be destroyed.

Permanent Magnet (PMG) Installation

1. Install the complete rotor assembly to the end

of the main rotor shaft using the hex head

through-bolt. Keep the rotor clean by avoiding

contact with metal dust or particles.

2. Carefully locate the stator housing to position

on the generator endbracket. Fasten in place

using the 4 bolts and clamps, and tighten se-

curely.

The highly magnetic rotor will attract the stator

core, care must be taken to avoid any contact

which may damage the windings.

3. Connect the PMG wiring harness connector.

4. Install the PMG assembly cover using the three

M5x12mm capscrews and lockwashers, and

tighten securely.

5. HC6 Control Housing: Install the control hous-

ing grille and access covers (see Figure 6-7).

6-14

CONTROL HOUSING

ACCESS COVERS

(BOTH SIDES)

GENERATOR

AIR DISCHARGE

COVERS

CONTROL HOUSING

PMG ASSEMBLY

CONTROL HOUSING

GRILLE

GENERATOR AIR INLET

COVER (ROTATING

RECTIFIER ACCESS)

FIGURE 6-7. HC6 GENERATOR AND CONTROL HOUSING ASSEMBLY

CONTROL HOUSING

ACCESS COVERS

(BOTH SIDES)

GENERATOR

AIR DISCHARGE

COVERS

CONTROL HOUSING

PMG

ASSEMBLY

GENERATOR AIR INLET

COVER (ROTATING

RECTIFIER ACCESS)

FIGURE 6-8. P7 GENERATOR AND CONTROL HOUSING ASSEMBLY

6-15

Main Stator and Rotor Removal

1. Remove the PMG, refer to Permanent Magnet

PMG Removal, earlier this section.

2. Remove the air inlet and discharge panels and

access covers from control housing and gener-

ator (see Figure 6-7 or 6-8).

3. Disconnect all load wires from the reconnec-

tion terminal block assembly. If equipped with

the circuit breaker option, disconnect load

wires from circuit breaker. Check that all leads

are labeled to ease reassembly.

4. Disconnect the remote control wiring and con-

duit from the accessory box. For reconnections

later, make sure each wire is clearly marked to

indicate the correct terminal.

5. Disconnect the engine harness connectors

and remove harness assembly from the control

housing:

P4 and P5 from the back side of the control

panel box.

PMG2 through PMG4, F1 and F2 genera-

tor leads located inside the control hous-

ing assembly.

P6 (Governor Output Module), P7 and

P10 (Voltage Regulator OUtput Module)

and J12 (from P12 of the rail assembly), lo-

cated inside the accessory box.

6. Use a hoist or similar lifting device to support

the control housing assembly (see Figure 6-9).

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

7. HC6 Control Housing Removal:

a. Loosen the fasteners that secure the con-

trol housing side and bottom panels to

generator. Make sure that hoisting device

is controlling weight of control housing as-

sembly.

b. Remove control housing fasteners, and

remove the control housing assembly

from the generator. Replace panel fasten-

ers to their respectable positions for safe

keeping, and tighten finger-tight.

c. Remove control housing mounting brack-

ets from both sides of generator, and as-

semble lifting eyes to generator.

8. P7 Control Housing Removal:

a. Loosen the fasteners that secure the con-

trol housing side panels to generator.

Make sure that hoisting device is control-

ling weight of control housing assembly.

b. Remove control housing fasteners, and

remove the control housing assembly

from the generator. Replace panel fasten-

ers to their respectable positions for safe

keeping, and tighten finger-tight.

PLACE SLING STRAPS

THROUGH HOUSING

(P7 OR HC6 HOUSING)

RECONNECTION

TERMINALS

ACCESSORY

BOX

FIGURE 6-9. REMOVING CONTROL HOUSING

6-16

9. Remove as necessary, air intake components

to engine that may interfere with disassembly

and reassembly of generator.

CAUTION Do not use fan blade to bar over

engine. That can damage blades and cause

property damage and personal injury.

10. Crank or bar the engine/generator to position

the rotor such that a full pole face is at the bot-

tom of the main stator core. Proper positioning

can be viewed through the generator access

openings. Refer to engine service manual for

proper cranking or barring procedure.

To remove the stator and rotor at the same time, refer

to step 28. To remove the stator and rotor individual-

ly, continue with step 11.

11. Remove the four bolts retaining the bearing

cartridge housing in the endbracket (outer four

bolts).

12. Remove the eight bolts holding the endbracket

to the generator housing.

13. Insert two bolts (M10) in the two holes provided

for “jacking” purposes, on the endbracket cen-

ter line. Screw bolts in until endbracket spigot

is clear of locating recess.

14. Carefully tap the whole assembly off the bear-

ing cartridge housing, ensuring the endbracket

is supported to prevent the exciter stator from

damaging the windings on the exciter rotor.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

15. The exciter stator is now accessible for inspec-

tion and removal from endbracket/engine

adaptor.

16. The end bearing can now be removed if re-

quired. Refer to Bearing Inspection/Removal/

Replacement in this section.

17. Remove the fasteners from the two generator

mounting feet brackets.

18. Attach cables of lifting device to generator lift-

ing points (Figures 6-10 or 6-11).

GENERATOR

LIFTING

POSITIONS

MOUNTING FEET

BRACKETS

FIGURE 6-10. HC6 GENERATOR LIFTING

POSITIONS

GENERATOR

LIFTING EYE

LOCATION

MOUNTING FEET

BRACKET

FIGURE 6-11. P7 LIFTING POSITION

6-17

19. Using an adequate lifting device, lift the gener-

ator (at lifting eyes provided, and main stator

housing) until the mounting feet brackets are

clear of the frame member (see Figure 6-12 or

6-13).

20. Disconnect the grounding strap from the fly-

wheel housing.

21. Using a forklift, position a lifting bar of the forklift

(inside and inline with the generator) under the

rotor shaft. Lift the rotor shaft slightly so that ro-

tor is not resting on inside of stator assembly.

See Figure 6-12 or 6-13.

STATOR

ASSEMBLY

LIFT

ROTOR

ASSEMBLY

LIFT

STATOR

ASSEMBLY ROTOR

ASSEMBLY

USE FORKLIFT OR

OTHER ADEQUATE

LIFTING DEVICE TO

SLIGHTLY LIFT ROTOR

SHAFT UNTIL ROTOR

CAN BE SUPPORTED

BY HOIST/SLING.

FIGURE 6-12. REMOVING HC6 STATOR ASSEMBLY

6-18

STATOR

ASSEMBLY

LIFT

ROTOR

ASSEMBLY

LIFT

STATOR

ASSEMBLY

ROTOR

ASSEMBLY

USE FORKLIFT OR

OTHER ADEQUATE

LIFTING DEVICE TO

SLIGHTLY LIFT ROTOR

SHAFT UNTIL ROTOR

CAN BE SUPPORTED

BY HOIST/SLING.

FIGURE 6-13. REMOVING P7 STATOR ASSEMBLY

6-19

22. Verify that the stator is adequately supported

and then carefully remove the capscrews from

the stator attachment ring.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

CAUTION Improper stator assembly rig-

ging and handling can result in damage to

stator and rotor assemblies. Lifting eyes

may not be at center-of-gravity position of

stator assembly. Therefore, lifting and mov-

ing the stator assembly alone, by hoisting

at lifting eyes only, presents the hazard of

load imbalance; allowing one end to drop

and other end to rise. Make sure the stator

is adequately hooked/strapped to maintain

level control of stator assembly while lifting

and moving.

23. Being careful not to drag the windings on the

rotor, move the stator assembly sufficiently

away from engine to sling and support the rotor

assembly. Do not allow rotor assembly to hang

on engine flywheel.

CAUTION Drive disc damage can be

caused by allowing the rotor assembly to

hang on flywheel. Use adequate hoist and

sling to support the rotor assembly.

24. Reposition or add hoist and sling support for

the main rotor, and remove the forklift. See Fig-

ure 6-14, Rotor Lift detail.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

25. Remove the stator assembly, being careful not

to drag the windings on the rotor. Place stator

assembly away from the chassis in the horizon-

tal position.

26. Using the hoist and sling to support the rotor,

carefully remove the capscrews and flat wash-

ers that secure the drive discs to the engine fly-

wheel.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

27. Remove the rotor assembly and place it on

wood blocks in the horizontal position. To avoid

possible distortion, do not allow the drive discs

and fan to rest on anything.

6-20

ROTOR LIFT

(EXAMPLE)

STATOR LIFT

(EXAMPLE)

RECONNECTION

TERMINALS

STATOR

BLOWER

COUPLING

DRIVE

DISCS

ROTOR

SHAFT

AIR DISCHARGE

COVERS

FRAME

ROTATING

RECTIFIER

ASSEMBLY

PMG

STATOR

EXCITER

ROTOR

ENDBRACKET

PMG

ROTOR

EXCITER

STATOR

ENDBRACKET/ENGINE

ADAPTOR

ROTOR

END

BEARING

PRESSURE

PLATE

FIGURE 6-14. TYPICAL GENERATOR ASSEMBLY

6-21

Generator Assembly Removal

28. Remove the fasteners from the two generator

mounting feet brackets.

29. Attach cables of lifting device to generator lift-

ing points (Figures 6-10 or 6-11).

30. Using an adequate lifting device, lift the gener-

ator (at lifting eyes provided, and main stator

housing) until the mounting feet brackets are

clear of the frame member.

31. Disconnect the grounding strap from the fly-

wheel housing.

32. Carefully remove the capscrews and flat wash-

ers that secure the drive discs to the engine fly-

wheel.

33. Verify that the generator assembly is ade-

quately supported. Carefully remove the caps-

crews securing the engine adaptor endbracket

to the engine flywheel housing.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

CAUTION Improper generator assembly

rigging and handling can result in damage

to stator and rotor assemblies. Lifting eyes

may not be at center-of-gravity position of

stator assembly. Therefore, lifting and mov-

ing the generator by hoisting at lifting eyes

only, presents the hazard of load imbal-

ance; allowing one end to drop and other

end to rise. Make sure the generator is ade-

quately hooked/strapped to maintain level

control of assembly while lifting and mov-

ing.

34. Remove the generator assembly away from

engine. Place generator assembly on floor with

a piece of wood beneath the stator housing (to-

ward PMG end) to allow for endbracket remov-

al, if desired.

6-22

GENERATOR REASSEMBLY

Generator reassembly is the reverse of disassem-

bly procedure.

To assemble the stator and rotor at the same time,

continue with step 1. To assemble the stator and ro-

tor individually, skip to step 16.

1. Using an adequate lifting device, locate the

generator assembly into position near the en-

gine flywheel housing. Align the holes of the ro-

tor drive discs with the holes of the engine fly-

wheel. Install the capscrews and flat washers

that secure the drive discs to the engine fly-

wheel, hand tighten.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

CAUTION Improper generator assembly

rigging and handling can result in damage

to stator and rotor assemblies. Lifting eyes

may not be at center-of-gravity position of

stator assembly. Therefore, lifting and mov-

ing the generator by hoisting at lifting eyes

only, presents the hazard of load imbal-

ance; allowing one end to drop and other

end to rise. Make sure the generator is ade-

quately hooked/strapped to maintain level

control of assembly while lifting and mov-

ing.

2. Align the holes of the engine adaptor endbrack-

et with the holes in the flywheel housing and

install the capscrews and lock washers. Tight-

en fasteners to 95−105 ft-lbs. (129−142 Nm).

3. Secure the rotor assembly to the flywheel.

Tighten fasteners to 150−180 ft-lbs.

(204−245Nm).

4. Connect the grounding strap to the flywheel

housing using a capscrew and EIT locking

washer; and tighten securely.

5. Install the mounting feet bracket fasteners; and

tighten securely.

If endbracket has been removed, continue with

step 6, otherwise skip to step 15.

6. Lift slightly on end of rotor shaft and install

wooden shims to hold rotor on center with sta-

tor.

7. If removed, install end bearing. Refer to Bear-

ing Inspection/Removal/Replacement proce-

dure in this section.

8. Install two threaded studs into end bearing car-

tridge to aid subsequent procedures. Position

the end bearing cartridge assembly close to

proper position for hole alignment with end-

bracket.

9. Assemble exciter stator, if removed, to inside of

endbracket. Tighten fasteners to 4.5 ft-lbs. (6

Nm) torque.

10. Install endbracket to the stator frame using the

proper capscrews and lock washers, but do not

tighten securely as yet.

11. Insert and start the threads of the bearing car-

tridge fasteners, and remove threaded align-

ment studs, through the endbracket into the

cartridge housing.

12. Lift slightly on endbracket and remove wooden

shims holding rotor on center with stator.

13. Securely tighten the endbracket fasteners.

14. Tighten the bearing cartridge fasteners to 4.5

ft-lbs. (6 Nm) torque.

6-23

15. Install the PMG assembly, if removed. Refer to

Permanent Magnet (PMG) Installation.

Perform the ‘Aligning Generator with Engine’

procedures, later in this section, then return to

the following steps.

To assemble the control housing, skip to step

35.

To assemble the stator and rotor individually be-

gin here.

16. If removed, replace exciter rotor and rotating

rectifier assembly to main rotor shaft. Recon-

nect main rotor wire leads to positive and nega-

tive terminals of rectifier assembly.

17. If removed, install the drive disk spacer, drive

disc and pressure plate on the rotor shaft.

Install the cap screws and flat washers and

tighten to 607 ft-lbs. (822 Nm).

18. Using a hoist and sling to support the rotor,

align the holes in the drive disc with the corre-

sponding holes in the flywheel.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

19. Secure the rotor assembly drive disc to the fly-

wheel using appropriate capscrews and flat

washers. Tighten fasteners to 150−180 ft-lbs.

(204−245Nm) Do not allow rotor assembly to

hang on engine flywheel.

CAUTION Drive disc damage can be

caused by allowing the rotor assembly to

hang on flywheel. Use adequate hoist and

sling to support the rotor assembly.

20. Reassemble engine adaptor endbracket to

stator frame if removed. Using an adequate lift-

ing device, carefully move the stator into posi-

tion over the rotor assembly, being careful not

to drag the windings on the rotor.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

CAUTION Improper stator assembly rig-

ging and handling can result in damage to

stator and rotor assemblies. Lifting eyes

may not be at center-of-gravity position of

stator assembly. Therefore, lifting and mov-

ing the stator assembly alone, by hoisting

at lifting eyes only, presents the hazard of

load imbalance; allowing one end to drop

and other end to rise. Make sure the stator

is adequately hooked/strapped to maintain

level control of stator assembly while lifting

and moving.

21. Using a forklift, position a lifting bar of the forklift

(inside and inline with the generator) under the

rotor shaft. Lift the rotor shaft slightly so that ro-

tor is not resting on inside of stator assembly.

22. Remove the hoist/sling support of the rotor as-

sembly. Align the holes of the engine adaptor

endbracket with the holes in the flywheel hous-

ing and install the capscrews and lock wash-

ers. Tighten fasteners to 95−105 ft-lbs.

(129−142 Nm).

6-24

23. Connect the grounding strap to the flywheel

housing using a capscrew and EIT locking

washer; and tighten securely.

24. Install the mounting feet bracket fasteners; and

tighten securely.

25. Lift slightly on end of rotor shaft and install

wooden shims to hold rotor on center with sta-

tor.

26. If removed, install end bearing. Refer to Bear-

ing Inspection/Removal/Replacement proce-

dure in this section.

27. Install two threaded studs into end bearing car-

tridge to aid subsequent procedures. Position

the end bearing cartridge assembly close to

proper position for hole alignment with end-

bracket.

28. Assemble exciter stator, if removed, to inside of

endbracket. Tighten fasteners to 4.5 ft-lbs. (6

Nm) torque.

29. Install endbracket to the stator frame using the

proper capscrews and lock washers, but do not

tighten securely as yet.

30. Insert and start the threads of the bearing car-

tridge fasteners, and remove threaded align-

ment studs, through the endbracket into the

cartridge housing.

31. Lift slightly on endbracket and remove wooden

shims holding rotor on center with stator.

32. Securely tighten the endbracket fasteners.

33. Tighten the bearing cartridge fasteners to 4.5

ft-lbs. (6 Nm) torque.

34. Install the PMG assembly, if removed. Refer to

Permanent Magnet (PMG) Installation.

Perform the ‘Aligning Generator with Engine’

procedures, later in this section, then return to

step 35.

35. HC6 Control Housing: Remove generator lift-

ing eyes. Reassemble control housing mount-

ing brackets to sides of generator and fasten

securely.

WARNING To prevent personal injury, use

adequate lifting devices to support heavy

components. Keep hands and feet clear

while lifting.

36. Use an adequate lifting device to lift the control

housing in position for mounting to the stator

frame. Replace the capscrews and lock wash-

ers and tighten to 20 ft-lbs. (27 Nm) torque.

37. Connect all control wires and generator leads

using the proper generator set AC and DC wir-

ing diagram/schematic.

38. Reassemble any engine air intake compo-

nents removed during generator disassembly.

39. Reassemble the covers over the generator air

discharge openings and fasten securely.

40. Refer to Permanent Magnet (PMG) Installation

procedure in this section.

41. If equipped with the circuit breaker option, re-

connect load wires to circuit breaker. Recon-

nect all lead wires to the terminal block assem-

bly using proper reconnection diagram in Sec-

tion 9.

42. Verify that all connections are proper and se-

cure and then install the air inlet panel and ac-

cess covers to control housing.

43. Connect the negative (-) battery cable and test

the generator set for operation.

6-25

ALIGNING GENERATOR WITH ENGINE

Proper alignment of the generator and engine as-

semblies is necessary to avoid premature wear and

improper operation of the genset. Review the fol-

lowing alignment conditions and procedures for

aligning the generator assembly to engine flywheel

housing.

Angular Misalignment: Is the result of the genera-

tor bearing center axis not aligning with axis of the

engine crankshaft. This condition creates an angle

between the generator shaft axis and the crank-

shaft axis. The cause of this type of misalignment is

usually shimming error.

Axial Misalignment: Is the result of the generator

shaft axis not aligning with engine crankshaft axis.

The tolerances in the bolted flywheel and drive disc

connection may add up to displace the generator

axially relative to the crankshaft axis.

Misalignment Symptoms: If the assembly is al-

lowed to run under these conditions, the discs must

flex in alternate directions twice for each engine rev-

olution. It is important to minimize the amount of

disc flexing since, if it is excessive, the drive disc will

crack. Although perfect bearing alignment is desir-

able, it is more important to keep disc deflection to

the minimum possible. This procedure assumes

that the pilot bore of the drive discs are in the exact

center and the flywheel counterbore (pilot) has no

practical runout. Under these conditions, perfect

Angular alignment will be attained when no deflec-

tion of the disks is measured.

Excessive Axial misalignment will cause more gen-

erator vibration than Angular misalignment.

Axial misalignment needs to be checked only when

an objectionable vibration is present.

Either type of misalignment may be present in a

generator set assembly, with angular misalignment

being the most common problem. Angular align-

ment may also be effected by set installation condi-

tions and/or mishandling during shipping of the gen-

set.

6-26

Angular Alignment Procedure

WARNING Accidental starting of the generator

set during this procedure presents the hazard

of severe personal injury or death. Make sure to

disconnect the negative (-) battery cable(s) be-

fore beginning.

Fasten a dial indicator to either the generator shaft

or the cooling fan with the sensing point resting on

the capscrew head or the flat surface of the drive

disc at the bolt circle diameter, see Figure 6-15. Bar

the engine over in a clockwise rotation as viewed

from engine flywheel. Do not allow it to roll back on

compression at the end of the travel of each read-

ing. It is unnecessary to zero the indicator since the

total indicator reading (T.I.R.) of the deflection mea-

surement to the bolt heads is what is required. T.I.R.

will be the sum of the maximum positive and nega-

tive dial indicator readings as the engine completes

one revolution.

MOUNTING BOLT

TO DISC

MEASUREMENT

SEE DETAIL A

CLAMP DIAL

INDICATOR

FLEX

DISCS

AXIAL

ALIGNMENT, SEE

FIGURE 6-17

GENERATOR AND

ENGINE

CRANKSHAFT

CENTERLINE

SHIMS

DETAIL A

FIGURE 6-15. ANGULAR ALIGNMENT MEASUREMENT

6-27

Sample Generator Runout Readings

When taking the deflection readings described,

make a diagram similar to the example shown in

Figure 6-16, where a total indicator reading of .025”.

(The highest positive value of +.010 and the largest

negative value of -.015”.) The indicator is closer to

the top and further away at the bottom. This exam-

ple indicates that the generator bearing is high.

Since the side readings are equal, the generator is

centered side to side. To lower the generator, re-

move equal shims from under both generator

mounting feet. To approximate the amount of shims

to remove or add:

1. Measure the distance between the center of

the generator shaft to the point the indicator is

measuring at. (For example; a SAE 18 Disc

coupling distance is 10.7”).

2. Measure the distance from the generator side

of the flex discs to the center of the generator

mounting bolt, refer to Figure 6-15. (For exam-

ple; a HC6 Frame’s distance is 28.4”.)

3. Compare the distance measured in steps 1 and

2. (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply

this ratio times one half the T.I.R. (In our exam-

ple, .025” divided by 2 is .0125”. This, times

2.65 equals .033”. Therefore, remove .033” of

shims from under both mounting feet.)

In general, the T.I.R. should not be more than .001”

for each inch of radius (center of shaft to indicator

axis). If we use our example of 10.7”, then the maxi-

mum T.I.R. would be .011”. This would only require

a correction of .014” from the T.I.R. of .025”. (A read-

ing of +.002 at the top and -.009 at the bottom would

fall within the satisfactory range.)

+.010 +.010

-.002

MEASURED AT

BOLT CIRCLE

DIAMETER

-.010

10.7 IN.

-.015

-.010

-.004

FIGURE 6-16. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

6-28

HC6 Axial Alignment Procedure

Axial misalignment needs to be checked only when

an objectionable vibration is present.

If excessive vibration remains after the angular

alignment, check for concentric alignment of the

generator shaft/engine crankshaft axes.

Fasten dial indicator holding device to skid base,

engine block, or generator shell with a magnetic

base or clamp and position so the sensor point of in-

dicator rests on the generator shaft hub, see Figure

6-15. Bar the engine over in a clockwise rotation as

viewed from engine flywheel, through a couple of

rotations. Record indicator readings in eight equally

spaced points around the shaft diameter. This will

provide a T.I.R. for Axial shaft misalignment.

The maximum allowable T.I.R. runout is subjective,

the optimal T.I.R. for runout would be .000”, howev-

er, that may not be attainable. The recommendation

of this procedure will be to reduce the measured

T.I.R. runout by one half. Specific out-of-tolerance

runout levels are difficult to establish due to the

varying surface quality of the generator shaft’s drive

disc mountain hub.

The goal of the Axial realignment is to reduce the

vibration level of the genset while it is operating. A

small improvement in the T.I.R. runout may have

dramatic effects in the mechanically measured or

physically observed vibration levels.

To correct for an out of tolerance T.I.R. indication,

remove the capscrews connecting drive discs and

flywheel. Mark the drive discs and flywheel with re-

spect to each other. Rotate either the engine or gen-

erator so that drive discs holes are repositioned

180 degrees from their original location. Put the

drive discs capscrews back in and retorque. Re-

check shaft alignment as before. If shaft T.I.R. run-

out remains unchanged then the discs should be ro-

tated to either 30, 60, or 90 degrees from original

location to correct the out of tolerance condition. If

the T.I.R. does not improve after repositioning, a

closer inspection of the flywheel pilot and drive disc

runouts is required. This will help determine the

cause of the Axial misalignment.

GENERATOR

AND ENGINE

CRANKSHAFT

CENTERLINE

ANGULAR ALIGNMENT,

SEE FIGURE 6-15

DETAIL A

SEE DETAIL A FAN HOUSING

CLAMP

GENERATOR

SHAFT HUB

DIAL

INDICATOR

FIGURE 6-17. HC6 AXIAL ALIGNMENT MEASUREMENT

6-29

P7 Axial Alignment Procedure

Axial misalignment needs to be checked only when

an objectionable vibration is present.

If excessive vibration remains after the angular

alignment, concentric alignment of the generator

shaft/engine crankshaft axes may be at fault.

The goal of the axial realignment is to reduce the

vibration level of the genset while it is operating. A

small improvement in the axial alignment may have

dramatic effects in the measured or physically ob-

served vibration levels.

To correct for possible axial misalignment, remove

the capscrews connecting drive discs and flywheel.

Mark the drive discs and flywheel with respect to

each other. Rotate either the engine or generator so

that drive discs holes are repositioned two bolt

holes from their original location. Put the drive discs

capscrews back in and retorque. Recheck/record

vibration levels as before. Repeat this test until the

drive discs holes are repositioned 180 degrees from

their original location.

Review vibration data and position drive disc in low-

est recorded level location.

6-30

THIS PAGE LEFT INTENTIONALLY BLANK

7-1

7. Day Tank Fuel Transfer Pump and Control

A fuel transfer pump and control are available when

a sub-base or in-skid day tank are provided. the au-

tomatic control operates the fuel pump to maintain a

reservoir of fuel in the day tank.

WARNING Diesel fuel is highly combustible.

Improper installation of this kit can lead to spill-

age of large quantities of fuel and loss of life and

property if the fuel is accidentally ignited. Instal-

lation and service must be performed by quali-

fied persons in accordance with the applicable

codes, including environmental regulations.

Do not smoke near fuel and keep flames, sparks

and other sources of ignition well away.

CONTROL

FUEL

GAUGE

FLEXIBLE FUEL

SUPPLY LINE

FLEXIBLE FUEL

RETURN LINE

DAY

TANK

FLOAT SWITCH

ASSEMBLY

FUEL FILL

CAP

FUEL PUMP

AND MOTOR

FIGURE 7-1. TYPICAL IN-SKID DAY TANK INSTALLATION

7-2

OPERATION

1. Push the control switch to the ON position for

automatic operation. The green SYSTEM

READY light will come on and the pump will fill

the tank if AC power is available for pumping

and DC power is available for the internal logic

circuits. The level of fuel in the tank will be auto-

matically kept between a set of pump-on and

pump-off float switches.

When filling an empty tank, the red LO SHUT-

DOWN and LO FUEL lights will come on when

the control switch is pushed to the ON position.

This is normal. Push the panel RESET switch to

turn off the red lights after the tank has been

filled.

If the SYSTEM READY light does not come on,

check for correct AC and DC power connec-

tions. See Wiring Connections and Fuel Pump

Motor Connections below.

2. The green PUMP ON light indicates when the

pump is running. It will come on and go off as

fuel is pumped to maintain the proper level in

the tank.

3. Push the control switch to the EMERGENCY

RUN position (momentary contact) to pump

fuel into the tank if the control fails to operate

the pump automatically.

The green PUMP ON light does not come on

when the switch is in the EMERGENCY RUN

position.

4. The red lights indicate fault conditions and the

need for service. The control panel includes the

following lights:

A. HI FUEL: The fuel in the tank has reached

an abnormally high level, indicating pos-

sible failure of the pump-off float switch.

The high-fuel float switch takes over as the

automatic pump-off switch. The HI FUEL

light stays on. The light can be RESET with

the panel switch when the fuel level drops

to normal, but will come back on again dur-

ing the next pumping cycle if the fault re-

mains.

WARNING Continued operation with a

HI FUEL fault present can lead to spill-

age of large quantities of fuel if the

high-fuel float switch fails. Spilled fuel

can cause loss of life and property if it

is accidentally ignited, or environmen-

tal damage.

HI FUEL (RED)

LO FUEL (RED)

LO SHUTDOWN (RED)

BASIN (RED)

BLANK (RED)

SYSTEM READY (GREEN)

PUMP ON (GREEN)

FIGURE 7-2. FUEL PUMP CONTROL PANEL

7-3

B. LO FUEL: The fuel in the tank has

dropped to an abnormally low level, indi-

cating possible failure of the pump-on float

switch. The lo-fuel float switch takes over

as the automatic pump-on switch. The LO

FUEL light stays on. The light can be RE-

SET with the panel switch when the fuel

level rises to normal, but will come back on

again during the next pumping cycle if the

fault remains.

C. LO SHUTDOWN: The fuel has dropped to

a level near the bottom of the tank, indicat-

ing an empty main fuel tank, pump failure

or possible failure of both the pump-on and

low-fuel level float switches. Further op-

eration will allow air to enter the engine fuel

unit, causing shutdown and the necessity

to bleed the fuel unit to start up the engine

again. Connections should have been

made to Terminals TB1-14 and TB1-15 to

shut down the engine automatically (to

ground one of four customer fault inputs

on terminals A40-TB1-16, 17, 18, or 19). If

the light comes on, check the fuel level in

the main fuel tank and fill it if necessary. As

the day tank is refilling, RESET the light

with the panel switch.

To restore engine operation following this

fault, both the pump control and the PCC

have to be RESET.

D.BASIN: Fuel has overflowed into the rup-

ture basin (if provided), indicating possible

failure of both the pump-off and hi-fuel lev-

el float switches, or a leak in the day tank.

RESET the control after the fuel in the ba-

sin has been safely disposed of and the

cause of the overflow corrected.

E.BLANK: For customer use.

The control fault circuits will trip and latch,

requiring RESET, even if AC power is lost.

5. Press the TEST switch to test the indicator

lights and pump operating circuits. Replace

any light that does not come on. The pump will

stop automatically after it has filled the tank to

the normal pump-off fuel level.

6. Press the reset button of the AC or DC circuit

breaker if either has tripped.

7-4

WIRING CONNECTIONS

See Day Tank Pump Control Wiring diagram in Sec-

tion 8 when making connections at the control box

terminal board. The following should be noted.

1. The control can be powered by 120 VAC or 240

VAC. The control is set up at the factory for con-

nection to 240 VAC.

To convert the day tank controller from 240

VAC to 120 VAC, perform the following steps.

A. Remove the two jumpers between termi-

nals TB1-6 and TB1-7 in the control box

and connect one between terminals

TB1-5 and TB1-6 and the other between

terminals TB1-7 and TB1-8.

B. Move selector switch S103 on the control

PCB to the up position for 120V.

C. If the control is equipped with a transform-

er, remove the two jumpers between ter-

minals H2 and H3 and connect one

between H1 and H3 and the other be-

tween H2 and H4.

To convert the day tank controller from 120

VAC to 240 VAC, perform the following steps.

A. Remove the jumpers between terminals

TB1-5 and TB1-6, and TB1-7 and TB1-8

in the control box and connect the two

jumpers between terminals TB1-6 and

TB1-7.

B. Move selector switch S103 on the control

PCB to the down position for 240 VAC.

C. If the control is equipped with a transform-

er, remove the jumpers between terminals

H1 and H3, and H2 and H4 and connect

the two jumpers between H2 and H3.

2. Attach a tag to the control box indicating the

supply voltage.

3. If a two lead wiring harness is provided, the

control does not include a power transformer.

To provide 24 VDC for the control circuit, con-

nect terminal TB1-19 to the positive (+) termi-

nal of the 24 V starter motor solenoid and

terminal TB-20 to the negative (-) terminal.

4. To immediately shut down the engine when the

LO SHUTDOWN light comes on, connect ter-

minal TB1-14 to a good grounding point on the

engine block and terminal TB1-15 to terminal

A40-TB2-16, 17, 18, or 19 (Customer Fault in-

puts). The customer fault input selected, must

be set for a shutdown operation (refer to SET-

UP MENU in Section 5).

5. Terminals TB1-10 through TB1-17 and TB2-23

through TB2-27 are available for connections

to remote annunciators or to any one of the four

customer fault inputs of the PCC.

6. Terminal TB2-22 is available for connection of

a grounding signal to activate the blank red

light.

7. Terminals TB1-8 and TB1-5 are available for

connection of a 120 or 240 VAC electric fuel

shutoff valve rated not more than 0.5 amps.

The voltage rating of the valve must corre-

spond with the voltage utilized for the pump.

See Item 2 above.

7-5

GND

TO A40-TB1-22 (LOW FUEL)

TO A40-TB1-16,17,18, or 19 (RUPTURE BASIN)

USE WITH PCC,

SEE DETAIL A

DETAIL A

FIGURE 7-3. FUEL PUMP CONTROL TERMINAL BOARD

7-6

FUEL TRANSFER PUMP MOTOR

CONNECTIONS

Connect a replacement fuel transfer pump motor as

follows.

1. Remove the end bell cover for access to the

motor wiring terminals.

2. Disconnect the brown lead from motor terminal

P103-3 and connect it to terminal P103-6. (Ter-

minal P103-6 is an insulated receptacle for se-

curing the end of the lead so that it cannot move

and touch the motor frame or a live terminal

and cause a short circuit.)

3. Disconnect the red lead from motor terminal

P103-2. It will be connected to the piggy-back

terminal on the lead connected at motor termi-

nal P103-3.

4. Cut the white lead from its ring connector at

motor terminal P103-4. Strip 1/2 inch (12 mm)

of insulation from the end of the white motor

lead for splicing to the wire harness lead

marked P103-WHITE.

5. Connect each lead of the five-lead wiring har-

ness to the motor terminal or lead marked on it.

6. Connect the red motor lead to the piggy-back

terminal at motor terminal P103-3.

7. Secure the end bell cover.

FIGURE 7-4. FUEL TRANSFER PUMP MOTOR CONNECTIONS

7-7

TESTING THE FLOAT SWITCH ASSEMBLY

The float switch assembly consists of 5 switches.

Each switch has a pair of color coded leads con-

nected to a common jack.

To test the float switches, remove the fuel pump

control cover, disconnect the wiring jack and un-

screw the assembly from the top of the day tank.

Test as follows:

1. With an ohmmeter, test for electrical continuity

(switch closed) between each pair of colored

leads, while holding the assembly vertical. Re-

place the assembly if any switch is open (all the

readings should be zero).

2. Lift each float, in turn, to 1/8 inch (3 mm) below

the C-clip stop above it (use a feeler gauge)

and test for electrical continuity. Replace the

assembly if any switch does not open (all the

readings should be infinity).

3. Use pipe thread sealant when replacing the as-

sembly.

SWITCH 1 − SHUTDOWN

SWITCH 2 − LOW FUEL

SWITCH 3 − PUMP ON

SWITCH 4 − PUMP OFF

SWITCH 5 − HI FUEL

SWITCH 5

SWITCH 4

SWITCH 3

SWITCH 1

SWITCH 2

FIGURE 7-5. FLOAT SWITCH ASSEMBLY

7-8

THIS PAGE LEFT INTENTIONALLY BLANK

8-1

8. Initial System Startup

GENERAL

Do not perform any procedure in

this section on medimum voltage (601 through

15,000 volts) generator sets. 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.

This section describes a process which can be used

in the initial startup and test of generator sets which

are paralleled using PowerCommand Digital Paral-

leling controls. PowerCommand Digital Paralleling

systems have many functions which are common to

traditional paralleling systems, but they are com-

pletely different in the way that these functions are

supplied in the system. The intent of this section is

to provide you with guidance in the initial running of

the equipment, so that you can perform this function

with as safe and efficient procedures as possible.

The accessory box of the Power-

Command Control contains high voltages when

the generator set is running. It can be energized

from the system bus and contain high voltages

even when the generator set is not running.

Contacting these high voltage components will

cause severe injury or death. Do not attempt to

service, operate or adjust the control unless

you have been trained in proper service tech-

niques.

THE STARTUP PROCESS

The startup process described in this section is typi-

cal for paralleling systems which utilize PowerCom-

mand Digital Paralleling equipment. Every parallel-

ing system is different in its design and application,

so portions of the recommended procedures may

be inappropriate for your application, or some pro-

cedures may be needed which are not described in

this section. Use your experience as the best guide

for enhancing these general guidelines to provide

the best process for the specific site which you are

servicing.

In general, the startup process contains these ma-

jor steps:

Installation design review, including mechani-

cal and electrical support systems for the gen-

erator sets and paralleling equipment.

Individual generator set preparation, operation

and performance review.

Manual system operation.

Automatic system operation and adjustments.

Black start testing of system.

Customer acceptance testing.

Customer training.

Issuing an installation report showing the work

done, system performance and customer ac-

ceptance.

EQUIPMENT APPLICATION REVIEW

The purpose of the equipment application review is

to visually inspect the installation to confirm that the

equipment has been installed within specified pa-

rameters and that the equipment can be started as

specified. Cummins technical application manuals

T-030 Liquid-Cooled Generator Sets and T-016

Paralleling and Paralleling Switchgear provide

guidance in evaluating installation requirements. It

is recommended that you use an installation review

report form, included at the end of this section, to

avoid missing any major points in the equipment re-

view and simplify reporting of problem areas to the

installer or customer.

The system startup process should not proceed un-

til the inspection and review are complete and all is-

sues resolved.

8-2

INDIVIDUAL GENERATOR SET STARTUP

The generator set should be properly serviced, with

proper levels of coolant and lubricants in the sys-

tem. Care should be taken to remove all shipping

blocks and braces from the equipment. Complete

all pre-start service and checks as for a standard

non-paralleled generator set.

Equipment needed to perform the startup:

Two properly calibrated hand-held digital me-

ters.

Be certain that the meters are rated for use on a

circuit operating at proper voltage.

Phase rotation meter.

PowerCommand service tool kit.

Individual generator set and system drawings,

specific to the project being installed. Opera-

tor’s manual, including PC program documen-

tation, if available.

A two channel strip chart recorder with voltage and

frequency modules is helpful, but not required for

the startup.

Operate the generator set RUN/OFF/AUTO switch

to the OFF position. Connect the generator set

starting and control batteries at their proper loca-

tions and verify that no fuses are blown (indicating

improper connections in the system). Verify that the

stationary battery chargers are properly installed

and wired and turn them on.

If the system includes a master control panel, verify

that control power is present in the master control

and operate the system mode select switch to the

manual operation position, so that the system does

not inadvertently receive a start signal. If the system

includes a touchscreen, PLC bridge/MUX or net-

work interconnections, verify that these are all func-

tional.

Check the settings of the paralleling control func-

tions. Typical values for these functions are shown

in Table 8-1. If the generator set was tested in paral-

lel at the factory, do not modify these adjustments at

this time. Check the factory test report to verify that

the settings of the control match the test report.

For paralleling applications, the default value of the

governor gain should be set to 70. See Section 5 −

Governor/Regulator menu for more information.

Generator sets that are shipped from the factory

without Cummins parallel gear are set up as single

units. For multiple unit paralleling applications you

must reconfigure the control. See Section 5 − Paral-

leling Setup menu.

TABLE 8-1. TYPICAL PARALLEL SET-UP

PARAMETERS

FUNCTION TYPICAL SETTING

ISOLATED BUS PARAMETERS

SYNC TIME LIMIT 120 seconds

− PWR LIMIT 10 percent

− PWR LIMIT (TIME) 3 seconds

PERM WIN-PHASE  20 degrees (ISO bus)

 15 degrees (utility)

PERM WIN-TIME 0.5 seconds

SYNC GAIN 95

SYNC INTEGRAL 12

KW BALANCE 165

KVAR BALANCE 0

KW GAIN 6

KVAR GAIN 300

1ST START FAIL 10 seconds

RAMP UNLD TIME 30 seconds

RAMP UNLD LEVEL 20 percent

RAMP LOAD TIME 30 seconds

LOSS FIELD TIME 2 seconds

UTILITY PARAMETERS

BASE LOAD % 80 percent

PF LEVEL 1.00

KW GOVERN GAIN 100

KW INTEGRAL 4

KVAR GOVERN GAIN 300

KVAR INTEGRAL 200

RAMP LOAD TIME 10 seconds

RAMP UNLD TIME 10 seconds

8-3

Connect a jumper to the idle terminals of the gener-

ator set in the accessory box, so that it will start and

run initially at idle speed.

Verify that starting the generator set and energizing

the system bus will not cause hazards to other per-

sons working in the vicinity of the equipment, or di-

rectly on the equipment or anything electrically con-

nected to the equipment. Notify responsible per-

sons in the building that the equipment may be en-

ergized and operating at any time.

Start the generator set by operating the RUN/OFF/

AUTO switch to the RUN position. The generator

set should start and accelerate to idle speed. An idle

mode alarm should appear on the generator set dig-

ital display panel. Allow the generator set to run at

idle, taking care to note unusual noises or vibration

from the engine or alternator, leaking fluids or ex-

haust connections. Run the generator set at idle un-

til the coolant temperature is greater than 100 de-

grees F (40 degrees C) Make any corrections nec-

essary prior to continuing with the startup process.

Stop the generator set and remove the idle speed

jumper from the accessory box interconnection ter-

minal block. Start the generator set by operating the

RUN/OFF/AUTO switch to the RUN position and

observe it accelerating to rated frequency and volt-

age. Calibrate and adjust all generator set metering

(if necessary) using the hand-held digital meter and

the procedure in Section 5 of this manual. Adjust the

generator set to proper voltage and frequency. Re-

cord the values of voltage and frequency so that all

units can be adjusted to the same values. Remem-

ber to save all changes and adjustments prior to

switching off the generator set.

Make sure that the paralleling breaker is charged

and ready to close (power circuit breakers only) and

that the paralleling bus is de-energized. If the break-

er is not charged, manually charge the breaker.

Manually close the paralleling breaker for the gen-

erator set. Most paralleling breakers will automati-

cally re-charge on closing (power circuit breakers

only). When the charging cycle is complete, electri-

cally open the breaker using the breaker open con-

trol switch on the front of the PowerCommand con-

trol. Close the breaker using the breaker close

switch on the front of the PowerCommand control.

Verify proper functioning of the breaker open and

close lamps on the PowerCommand Control and

proper operation of the manual breaker control

switches on the PowerCommand control.

Use extreme caution when perform-

ing phase relationship testing. The system is

energized and dangerous voltages are present

in many locations. Contact with energized parts

will cause serious injury or death. Do not at-

tempt these tests unless you have proper

equipment for testing and are trained in its safe

use.

Verify that the phase rotation of the generator set

matches the phase rotation of the utility service at

each transfer switch or breaker power transfer pair.

Correct generator set phase rotation to match utility

condition, if required, by reversing the phase L1 (A

or U) and L2 (C or W) connections on the generator

set output.

Note: The purpose of this procedure is to make sure

that the generator set output matches the bus phase

relationship. Later in the startup process the wiring

and interconnection of the bus and generator set PT

modules will be verified. Note that the PT/CT module

phases must be matched to the generator set phase

changes, or a FAIL TO SYNCHRONIZE alarm will oc-

cur.

If a master control is used in the system, make sure

that the main bus metering is functioning and prop-

erly calibrated.

Using the load bank or available load on the system,

check the generator set load carrying ability and the

transient performance of the generator set. Adjust

as necessary for proper generator set operation.

Disconnect the load from the system.

Make sure that all alarm and shutdown circuits in

the generator set are functioning properly. Shut

down the generator set by switching the RUN/OFF/

AUTO switch to OFF.

Repeat the process described in this section for

each generator set in the system before moving on

to the next step of the startup process.

8-4

MANUAL SYSTEM OPERATION

Once all generator sets in the system have been

successfully run individually, the generator sets are

ready for verification of manual paralleling capabili-

ty.

Make sure that all generator set RUN/OFF/AUTO

control switches are placed in the OFF position and

that the master control switch (if used) is also in the

manual mode position.

Operate the control switch of one generator set to

the RUN position and allow the generator set to

start and accelerate to rated speed and voltage.

Manually close the paralleling breaker on this gen-

erator set by pushing the breaker close pushbutton

on the front face of the PowerCommand control. Al-

low the generator set to run at no load for the first

phase of the manual paralleling test.

Use extreme caution when perform-

ing phase relationship testing. The system is

energized and dangerous voltages are present

in many locations. Contact with energized parts

will cause serious injury or death. Do not at-

tempt these tests unless you have proper

equipment for testing and are trained in its safe

use.

Check the phase relationship of the generator set

output to its Bus PT module. The voltage difference

between the L1 phase on the input to the Bus PT

board and the generator set PT/CT board should be

zero. Repeat this process for each generator set in

the system.

Make sure that all generator set RUN/OFF/AUTO

control switches are placed in the OFF position and

that the master control switch (if used) is also in the

manual mode position.

Operate the control switch of one generator set to

the RUN position and allow the generator set to

start and accelerate to rated speed and voltage.

Manually close the paralleling breaker on this gen-

erator set by pushing the breaker close pushbutton

on the front face of the PowerCommand control.

Check the phase relationship of the generator set

which is closed to the bus, with each individual gen-

erator set. This can be accomplished by starting the

second generator set in the system by operating the

RUN/OFF/AUTO control switch to the RUN position

and allow the generator set to start and accelerate

to rated speed and voltage. When generator set fre-

quency and voltage have stabilized, operate the

display screen of the PowerCommand control to the

voltage and frequency screens and use the digital

display to verify that the generator set voltage and

frequency matches the bus voltage and frequency.

Switch the display screen to the digital synchro-

scope (bus frequency) screen and observe the con-

trol phase relationship between the generator set

and the bus. When the phase relationship of the on-

coming generator set is within the acceptance pa-

rameters programmed into the control, an asterisk

(*) will be displayed on the screen next to the phase

difference display.

When the asterisk is displayed on the control panel,

check the phase relationship between the genera-

tor set and the bus. With the hand-held digital volt-

meter, check the voltage from the line side to the

load side for each phase of the open paralleling

breaker on two phases simultaneously (Figure 8-1).

If the phase relationship is proper, the voltage

across the breaker (with the breaker open) should

be zero, or nearly zero on both phases when the

”synchronized” indicator lamp is on. The voltage of

the two meters should rise and fall at approximately

the same time.

Note: If the generator set output phase rotation

matches the bus and a PHASE ROTATION warning

appears when you attempt to close the paralleling

breaker, you should check the generator set and Bus

PT boards for proper wiring and interconnection.

Both the primary and secondary wiring in the Bus PT

board should be checked. See Table 4-28.

8-5

Power Command Control

Accessory Box

Bus PT

Board (A39)

PT/CT

Board (A36)

VM2

VM1

(Open)

To Load Bus

FIGURE 8-1. CHECKING PHASE RELATIONSHIP BETWEEN GENERATOR SET AND SYSTEM BUS

Note: For applications where a wye connected gen-

erator set is paralleled to a delta connected bus, the

generator neutral bus must be floating and the neu-

tral connection to the bus PT module must not be

used.

8-6

Make sure that the “charged” flag is present on the

paralleling breaker and push the breaker close

pushbutton on the PowerCommand Control to

manually close the oncoming set paralleling break-

er and paralleling the generator set to the system

bus.

Note: The breaker close function operates through a

permissive relay function in the PowerCommand

Control, so the paralleling breaker will not close un-

less the generator set is properly synchronized with

the system bus.

Perform the phase rotation verification on each

generator set in the system, prior to attempting to

close it to the live parallel bus for the first time.

When all generator sets have been closed to the

bus, observe the voltage, frequency, amp load and

kilowatt load on each generator set metering set.

The metering should indicate identical voltage and

frequency readings on all generator sets in the sys-

tem. Amp and kilowatt readings should all be zero.

With no load on the system, a positive amp load

reading on generator sets indicates a voltage differ-

ence between the generator sets in the system. A

positive kilowatt reading on any generator set indi-

cates a frequency misadjustment on at least one

generator set. Perform adjustments necessary to

eliminate circulating currents and kilowatt loads.

Save the generator set adjustments made prior to

switching off the generator set.

With all generator sets running in parallel in manual

(RUN) mode, apply available load to the system.

Observe load sharing levels on the generator sets.

The units should share load proportionally. (The

%load and %amps meters on the PowerCommand

control should all read within plus or minus 5% of

each other.)

Adjust load sharing parameters within control sys-

tem to achieve proper load sharing. Save all

changes.

If possible, operate the system at various load lev-

els and verify proper operation at each level.

Remove all load from the system and return the

generator sets to their normal automatic mode by

placing the RUN/OFF/AUTO switch in the AUTO

position.

8-7

AUTOMATIC SYSTEM OPERATION

If the system includes a master control panel, move

the mode selection switch on that panel to the full

automatic position. Operate the test switch to cause

the system to automatically start and parallel all

generator sets.

The generator sets should automatically start, ac-

celerate to rated speed and voltage, synchronize

and parallel on the system bus. As the generator

sets synchronize and close to the system bus, ob-

serve the operation of the load adding (priority) con-

trol relays in the master control. (If load add control

relays are provided.) Observe and record the time

to synchronize for each generator set.

With all the generator sets running and closed to the

system bus, apply load to the running generator

sets, but at a low enough level that all the generator

sets need not be running in order to carry the bus

load. On one generator set, ground the Load De-

mand contact in the accessory box. The following

sequence should then occur:

The ”LOAD DEMAND” shutdown message

should be displayed on the PowerCommand

digital display panel.

The load should ramp down on the generator

set to its minimum set point level.

The generator set paralleling breaker should

open.

The generator should run for its normal cool-

down period and then shut down.

When the unit has shut down, remove the ground

signal on the Load Demand termination point. The

generator set should start, build up to rated frequen-

cy and voltage, synchronize and parallel to the sys-

tem bus. When it has closed to the bus, it should

ramp up to its proportional share of the total bus

load.

Repeat the load demand test for each of the gener-

ator sets in the system.

Switch off the test switch in the master control. All

the paralleling breakers should simultaneously

open and the generator sets should run for a cool-

down period and shut down.

Simulate a remote start in the master control. The

generator sets should automatically start, acceler-

ate to rated speed and voltage, synchronize and

parallel on the system bus. Remove the remote

start jumper on the master control. The generator

set paralleling breakers should all open and the

generator sets should run for a cooldown period

and shut down.

At this point the various control functions of the

master control can be tested and verified. Consult

the project drawings and specifications or approved

submittal documents for details on master control

functions and requirements.

8-8

BLACK START TESTING

The black start testing process is designed to dem-

onstrate that the entire on-site power system is

installed correctly and that system support equip-

ment, such as day tanks, fuel pumps, or supple-

mental ventilation equipment, is designed and

installed correctly. It is primarily used in applications

where the paralleling system is intended to provide

emergency power in the event of a normal utility

(mains) power failure. The black start testing pro-

cess is performed after the entire on-site power sys-

tem is installed. This testing process is often per-

formed in conjunction with the customer approval

testing, since it may be disruptive to the operation of

the facility and demand special arrangements to

avoid potentially dangerous or costly power failures

in the facility.

The specific details of this testing process are very

dependent on the design of the electrical and me-

chanical systems of the facility. In general the steps

in this process are as follows:

A power failure is simulated in the facility by

opening the main power feeder in the building.

It is desirable to do this to be certain that critical

loads such as fuel pumps are fed from both the

generator and utility (mains) bus.

The generator sets start and parallel. The time

required for the generator sets to start and par-

allel should be recorded and noted on the final

test report for the system.

Observe operation of all power transfer de-

vices, noting the time required to transfer.

The generator sets should be run in parallel

with all available load in the building, at a mini-

mum of approximately 30% of their standby

KW rating. The duration of the test should be

sufficient for the generator sets to reach their

normal operating temperatures. The load de-

mand system (if provided in the system master

control) should be shut down until all generator

sets in the system have reached normal opera-

tion temperatures and their operation tempera-

tures have stabilized. During this process, data

should be gathered to demonstrate the load

applied and the operational performance of the

system. It is customary to document the gener-

ator set performance during this period, by re-

cording all values on all meters and engine

monitors every 15 minutes.

When all required customer testing and verifi-

cations have been performed, return the sys-

tem to normal power by restoring utility (mains)

power at the point where it was disconnected.

Verify that the generator sets and power trans-

fer devices all return to their normal ready-to-

start states.

TEST REPORTS AND ACCEPTANCE

The technician performing the system startup

should issue a start up and test report to document

the work performed and demonstrate that the sys-

tem is functional and operational. The exact re-

quirements of this report will vary depending on

customer requirements, but should include, as a

minimum:

The application and review and evaluation. A

copy of the site review checklist performed at

the start of the testing process might be in-

cluded to document this step of the process.

A copy of the startup check list (a typical check

list is included at the end of this section), docu-

menting the functions tested and that each

function performed properly.

Test data sheets documenting results of load

testing.

List of all the settings of each generator set

control.

Black start test results.

Certification that the system is operational and

ready to run.

It is customary for an owner’s representative to

review and sign all test documents, indicating

acceptance of the test data and system perfor-

mance.

8-9

ON SITE POWER SYSTEM APPLICATION REVIEW (DIESEL/600VAC AND LOWER)

Date: ___________ Location: __________________________________________________________

Owner/Operator: ______________________________________________________________________

Generator Set Model: ____________________ Serial Number: ____________________

Transfer Switch Model: ____________________ Serial Number: ____________________

Project/Order Number: ________________________________________

Review Performed By: _____________________________

Mounting/Noise/Isolation

[ ] Flexible power output conduit, supported by bldg.

[ ] Isolators/pad (integral to set)

[ ] Isolators/pad (external to set)

[ ] Isolators/spring-pad, adjusted correctly

[ ] Flexible stainless steel exhaust connection

[ ] Flexible fuel lines (supply& return), secured

[ ] Flexible power output conduit, supported by bldg.

[ ] Flexible auxiliary power connections

[ ] Flexible control connections

[ ] Flexible exhaust air duct

[ ] Seismic restraints (where required)

[ ] Provisions for draining oil/coolant

[ ] Clearance around genset (3ft/1 meter min.)

[ ] Fire alarm provisions

[ ] System covers/shields all in place

Exhaust

[ ] Silencer close to genset

[ ] Exhaust connections sealed

[ ] Exhaust insulated

[ ] Proper personnel protection provided

[ ] Exhaust run slopes away from genset

[ ] Condensate trap with valve on exhaust silencer

[ ] Provisions for thermal expansion

[ ] Raincap/birdscreen on exterior of building

[ ] Exhaust thimble

[ ] Correct pipe size, supported by building

[ ] Facility vent air intake, windows, doors not close to

exhaust outlet

[ ] No combustible materials, or fire system

components near uninsulated pipe

Cooling System

[ ] Filled with soft water/E.G./DCA mixture

[ ] Jacket water heater provided

[ ] Valves to isolate jacket water heater

[ ] Power supply to heater from normal power

Ventilation System

[ ] Inlet air duct properly sized (approx. 1.5x radiator)

[ ] Exhaust air duct properly sized (effective open area

not less than radiator area)

[ ] Heat sources in room insulated

[ ] Recirculation of radiator exhaust air unlikely

[ ] Access door to room opens in (or vented)

[ ] Vent dampers powered from emergency power

supply

[ ] Direction of prevailing winds

Fuel System

[ ] Piping is not galvanized or copper

[ ] Manual shut-off valve

[ ] Solenoid valve on fuel supply, power from set

[ ] Fuel returns to main tank

[ ] Fuel line size adequate

[ ] Fuel line high loops

[ ] Day tank/vent at highest point

[ ] Day tank/location below return lines

[ ] Day tank/strainer-filter

[ ] Day tank/level alarms

[ ] Main fuel tank below set

[ ] Fuel transfer pump/power from genset

[ ] Main fuel tank above set

[ ] Solenoid valve

[ ] Sub-base tank

[ ] Level gage

[ ] Vent

Electrical System

[ ] Control connections isolated from power

[ ] Control connections use stranded wire

[ ] Conductor size OK (power & control)

[ ] Proper battery size/filled with electrolyte

[ ] Battery rack isolated from floor

[ ] Battery charger/power from utility

[ ] Start signal wired to ATS

[ ] Generator frame grounded (bonded)

[ ] Neutral connection (where/how)

[ ] Power/control conductors torqued

[ ] Wiring accuracy/matches drawings

Other

[ ] Oil installed in engine

[ ] Posted operating instructions

[ ] Generator/ATS manuals, drawings provided

[ ] Generator room/control boxes cleaned

8-10

THIS PAGE LEFT INTENTIONALLY BLANK

9-1

9. Wiring Diagrams

GENERAL

This section consists of the schematic and connec-

tion wiring diagrams referenced in the text. The fol-

lowing drawings are included.

Page 9-2 and 9-3, AC Reconnect Wiring Dia-

gram

Page 9-4, Block Diagram (12 Lead)

Page 9-5, Block Diagram (6 Lead)

Page 9-6, Customer Connections

Page 9-7, Engine Interface Board (A31)

Page 9-8, Digital board (A32)

Page 9-9, Analog board (A33)

Page 9-10, Customer Interface Board (A34)

Page 9-11, Display Board (A35)

Page 9-12, PC/CT Board (A36)

Page 9-13,Voltage Regulator Output Module

(A37)

Page 9-14, Governor Output Board (A38)

Page 9-15, PT/CT Wiring Harness

Page 9-16, Engine Wiring Harness

Page 9-17, Accessory Box Interconnection

Harness Diagram

Page 9-18, Day Tank Pump Control Wiring

Page 9-19 Accessory Interconnect Diagram

Page 9-20, Sequence of Operation (Local Start

and Run)

Page 9-21, Sequence of Operation (Local

Stop)

Page 9-22, Sequence of Operation (Local

Emergency Stop)

9-2

THIS PAGE LEFT INTENTIONALLY BLANK

AC RECONNECT WIRING DIAGRAM (SHEET 1 OF 2)

9-2

No. 625−3100 sh1 of 2

Rev. H Sys:CADAM

Modified 2/2011

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

AC RECONNECT WIRING DIAGRAM (SHEET 2 OF 2)

9-3

No. 625−3100 sh 2 of 2

Rev. H Sys:CADAM

Modified 2/2011

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-4

BLOCK DIAGRAM (12 LEAD)

No. 612−6701 sh 1of 3

Rev. B Sys: HP

Modified 12/1996

BLOCK DIAGRAM (6 LEAD)

9-5

No. 612−6701 sh 2of 3

Rev. B Sys: HP

Modified 12/1996

9-6

PCC CUSTOMER CONNECTIONS

No. 612−6701 sh 3of 3

Rev. B Sys: hp

Modified 12/1996

ENGINE INTERFACE BOARD (31)

9-7

NO. 300-4819 sht 1 of 4

REV. B

MODIFIED 8/2008

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-8

DIGITAL BOARD (A32)

NO. 300−4079

REV. N

MODIFIED 4/2006

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

ANALOG BOARD (A33)

9-9

NO. 300−4080

REV.e

MODIFIED 11/2000

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-10

CUSTOMER INTERFACE BOARD (A34)

NO. 300−4462 sh1

REV. J

MODIFIED 8/2008

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-11

DISPLAY BOARD (A35)

NO. 300−4286 sh 1

REV. M Sys. HP

MODIFIED 1/2008

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

DWG

QTY

BA12

BA2

BA3

BA4

BA5

BAD2

BAD3

BAD4

BAD5

BAD6

BAD7

BA1

BA2

BA3

BA4

BA5

BA6

BA7

BA8

BA9

BA10

BA11

BA12

BWR

BRD

BCS7

BAD0 BA0

BAD1

BCS7

BWRBWRBWRBWR

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BWR BWR BWR BWR

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

SELF_TEST

DISPLAY(RT_BOTTOM)

DISPLAY(RT_TOP)

DISPLAY(LF_BOTTOM)

DISPLAY(LF_TOP)

CB_OPEN

CB_CLOSED

PHASE_SELECT

GND

VCC

RESET_

BRD

BWR

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BAD7

BRD

BWR

BA0

BA1

BAD0

BAD1

BAD2

BAD3

BAD4

BAD5

BAD6

BAD7

SELF_TEST

ARROW_RIGHT_BOTTOM

NON−AUTO

WARNING

ARROW_MENU

ARROW_RIGHT_TOP

ARROW_RESET

ARROW_LEFT_BOTTOM

ARROW_LEFT_TOP

SHUTDOWN

GENERATOR_CLOSED

UTILITY_CLOSED

PHASE_C

PHASE_B

PHASE_A

LOWER_SCALE

UPPER_SCALE

B+

10K

@VCC

220

VCC

GND

VCC

GND

DS21 Green

.1uF

VCC

C13

.1uF

U25

74HC154

CS1

CS2

Y01

Y12

Y23

Y34

Y45

Y56

Y67

Y78

Y89

Y910

Y1011

Y1113

Y1214

Y1315

Y1416

Y1517

U12

10K

@VCC

U12

10K

@VCC

R14

220

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

DS25 Green

R13

220

C17

.01uF

+5V_BAT

DS10 Green

220

10K

@VCC

CLR

U12

10K

@VCC

U14

.1uF

CLR

R10

220

GND

+5V_BAT

GND

R19

220

VCC

DS11 Green

CR6

R12

220

VCC

U20

8255

PA3

1PA2

2PA1

3PA0

‘RD 5

‘CS 6

A1 8

A0 9

PC7

10 PC6

11 PC5

12 PC4

PC0

PC1

PC2

PC3

PB0

PB1

PB2

PB3

PB4

PB5

PB6

PB7

D7 27

D6 28

D5 29

D4 30

D3 31

D2 32

D1 33

D0 34

RESET 35

‘WR 36

PA7

37 PA6

38 PA5

39 PA4

VCC

R24

220

GND

U10

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

DS27 Green

R35

220

GND

C12

.1uF

R18

220

U15

C15

.1uF

U26

GND

DS21 Green

C22

22uF

R30

220

R20

220

U13

2803A

CLAMP

GND

9R1

220

DS20 Green

.1uF

U11

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

DS11 Green

R15

220

CR2

GND

DS27 Green

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

R34

10K

U24

7555

B−

TRIG

2OUT

RST

5THOLD

DISC

B+8

R51

4.7K

U14

DS12 Green

GND

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

.1uF

CLR

GND

U12

10K

@VCC

DS29 Green

12 R21

220

R49

1.8M

VCC

LP_OFF

DS24 Green

.1uF

U15

DS23 Green

R41

220

SELF_TEST

U23

2803A

CLAMP

GND

CLR

R23

220

U12

10K

@VCC

CR3

VCC

U12

10K

@VCC

DS36 Green

CLR

DS10 Green

R47

4.7M

VCC

GND

CLR

R31

220

U21

2803A

CLAMP

GND

RESET

DS23 Green

U22

8255

PA3 1

PA2 2

PA1 3

PA0 4

‘RD

5‘CS

8A0

PC7 10

PC6 11

PC5 12

PC4 13

PC0 14

PC1 15

PC2 16

PC3 17

PB0 18

PB1 19

PB2 20

PB3 21

PB4 22

PB5 23

PB6 24

PB7 25

27 D6

28 D5

29 D4

30 D3

31 D2

32 D1

33 D0

RESET

35 ‘WR

36 PA7 37

PA6 38

PA5 39

PA4 40

U15

CLR

10K

@VCC

U12

10K

@VCC

DS25 Green

R39

10K

GND

R17

220

10K

@VCC

.1uF

220

U12

10K

@VCC

220

U12

10K

@VCC

C18

.1uF

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

+5V_BAT

GND

10K

@VCC

R32

100K

DS14 Green

U26

R40

220

R29

220

DS24 Green

GND

220

CLR

U15

U14

RESET

VCC

C11

22uF

220

GND

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

DS12 Green

VCC

DS36 Green

GND

DLG2416

CE1

CE2

CLR

CUE

A08

A17

D011

D112

D213

D314

D417

D516

D615

R28

220

VCC

C10

.1uF

220

R16

220

R22

220

U14

+5V_REF

DS20 Green

C20

.1uF

GND

SELF_TEST

C19

.1uF

DS29 Green

U16

3302

−

+12V

CLR

10K

@VCC

R11

220

R37

100K

GND

DS14 Green

VCC

R36

220

R50

100

R25

4.7K

DS13 Amber

DS22 Red

DS15 Red

DS9 Red

DS22 Red

DS9 Red

DIGITAL BOARD

MEMBRANE SWITCH

RUN/STOP/REMOTE

SWITCH

9-12

PC/CT BOARD (A36)

NO. 300−4250 sh1

REV. C SYS. HP

MODIFIED 1/24/95

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

VOLTAGE REGULATOR OUTPUT MODULE (A37)

9-13

NO. 300−4085 sh1

REV. L

MODIFIED 10/2002

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-14

GOVERNOR OUTPUT BOARD (A38)

NO.300-4724 sh1

REV. J

MODIFIED 9/2005

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

PT/CT WIRING HARNESS

9-15

NO. 338−3019 sh1

REV. T

MODIFIED 9/2011

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-16

ENGINE WIRING HARNESS

No. 338−3377 sh 2of 2

Rev. J Sys: revisio

Modified 4/2002

9-17

ACCESSORY BOX INTERCONNECTION HARNESS DIAGRAM

No. 338−3199 sh1

Rev. M Sys:CADAM

Modified 8/2003

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-18

DAY TANK PUMP CONTROL WIRING

NO. 625-2141

REV. R

MODIFIED 3/2006

ACCESSORY INTERCONNECT DIAGRAM

9-19

NO.630−1345 sh1

REV. j

MODIFIED 11/1996

THIS IS A REPRESENTATIVE (GENERIC)

SCHEMATIC/WIRING DIAGRAM. FOR

TROUBLESHOOTING, REFER TO THE

WIRING DIAGRAM PACKAGE THAT WAS

INCLUDED WITH YOUR GENSET.

9-20

SEQUENCE OF OPERATION (LOCAL START AND RUN)

No. 612-6679 sh 1 of 2

Rev. B Sys: HP

Modified 11/21/95

SEQUENCE OF OPERATION (LOCAL STOP)

9-21

No. 612-6679 sh 2 of 2

Rev. B Sys: HP

Modified 11/21/95

9-22

SEQUENCE OF OPERATION (LOCAL EMERGENCY STOP)

NO.612−6680 sh10f1

REV. A

MODIFIED 8/25/94

Cummins Power Generation

1400 73rd Ave. NE

Minneapolis, MN 55432 USA

Phone 1 763 574 5000

Toll-free 1 800 888 6626

Fax 1 763 574 5298

Email ask.powergen@cummins.com

www.cumminspower.com

CumminsR, the “C” logo, and “Our energy working for you.”

are trademarks of Cummins Inc.

900 0520D 0520 Onan DFHA DFHB DFHC DFHD (spec A J) Genset Operators Manual (10 2011)

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