900 0661_I10(AG) 0661 Onan Power Command PCC1302 Controller Owners Manual (06 2014)
User Manual: 900-0661 Onan PowerCommand PCC1302 Controller Owners manual (06-2014)
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Owners Manual Operator/Installation Controller PowerCommand1302 English Original Instructions 6-2014 900−0661 (Issue 10) “Intentionally Left Blank” 58 Table of Contents SECTION TITLE PAGE Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . viii Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connector Seal Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-1 1-1 2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Protection and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parade Rest Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-1 2-2 2-3 2-3 2-3 2-3 2-3 2-4 2-4 2-5 2-5 2-5 2-6 2-6 2-6 2-6 2-7 2-7 2-7 2-7 2-7 3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Environmental Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 1302 Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 i SECTION TITLE PAGE 1302 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Control Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Guidelines for Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Current Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Example of CT Sizing − Two Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Example of CT Sizing − Three Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Current Transformer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Two Lead CT Setup Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Three Lead CT Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Battery Charging Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Denso Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Bosch Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Series Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Series Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Parallel Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 Double Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 Guidelines for Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Coolant Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Oil Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 Lube Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 Control Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 Electronic Governor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19 Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20 Setup, Trims, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26 Alternator Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 AVR Enable/Disable Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Digital Output Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Torque-Matched Volts/Hz Overload Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Battleshort Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35 Genset Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 V/Hz Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Governor Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Engine Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Alternator Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Setup for Gain Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Gain Tuning Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-38 Controller Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41 1302 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Remote Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Remote Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 Local Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 ii SECTION TITLE PAGE Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/24V Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Ignition Power/Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preheat Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug Output Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start and Stop Time Delays (Cool Down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Speed Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Governor Algorithm and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Real Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excerise Scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battle Short Mode Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations With an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations Without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battle Short Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46 3-46 3-46 3-46 3-47 3-47 3-47 3-48 3-48 3-48 3-49 3-49 3-50 3-51 3-53 3-55 3-55 3-55 3-57 3-57 3-57 3-58 4. Operator Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Status Output Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with a Manual Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Text / Symbolic Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Menu Selection Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Previous Main Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not In Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutdown Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii 4-1 4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-4 4-5 4-5 4-5 4-5 4-5 SECTION TITLE PAGE Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Manual Run Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Operator Panel System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Communication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Fault Reset / Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Fault/Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Adjusting Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Saving Your Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Engine Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Alternator Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Alternator Line-to-Line Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Alternator Line-to-Neutral Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Alternator Single Phase Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Alternator Amperage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Selecting Auto, Manual Run, and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Entering the Mode Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 Selecting Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Selecting Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Aborting the Transition to Auto or Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . 4-23 Selecting Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 Network Status Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 History / About Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 History Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 About Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 About Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 About Display Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26 Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 5. 1302 Control Panel Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv 5-1 5-3 5-4 5-4 5-4 5-6 SECTION TITLE PAGE Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Genset Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Genset Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Start/Stop Delay Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 Cycle Crank Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Battle Short Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 AVR Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11 Electronic Governer Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Electronic Governer Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Genset Number Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Display Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Volts and Hertz Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15 Automatic Voltage Regular Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Volts/Hz Rolloff Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17 Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Governor Crank Fuel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Electronic Governor Regulator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Electronic Governor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Electronic Governor Enable Speed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Fault Input Function Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Fault Input Active State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21 Customer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Meter Calib Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Freq. Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Metering Voltage Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Metering Current Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Annunciator Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 Annunciator Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 ModBus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 ModBus Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 ModBus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33 Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35 Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-37 v SECTION TITLE PAGE Genset Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Rating Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Threshold Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Thresholds Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High AC Current Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Overspeed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Speed/Frequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Oil Pressure Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Oil Pressure Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Coolant Temperature Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Coolant Temperature Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Low Coolant Temperature and Battery Charger Menus . . . . 5-37 5-37 5-39 5-39 5-39 5-39 5-39 5-41 5-41 5-41 5-43 5-43 5-40 5-40 5-42 5-42 5-45 5-45 5-45 5-45 5-45 5-47 5-47 5-47 5-49 5-49 5-49 5-49 5-51 5-51 5-51 5-53 6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC Based Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Applications and Configurable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes Using Optional Operator Panel . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes Using the Control Switch Indicator . . . . . . . . . . . . . . . . . . . . Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage/Continuity Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi 6-1 6-1 6-1 6-1 6-2 6-2 6-2 6-2 6-2 7. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Appendix A. 1302 Menu System Maps A-1 Appendix B. Index B-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3 vii Foreword The purpose of this manual is to provide the users with general control operation and fault code information. Refer to the equipment manufacturer’s product support manuals for important safety precautions. Manufacturers applying this control are respectfully advised that it is their responsibility to employ competent persons to carry out any installation work in the interests of good practice and safety. It is essential that the utmost care is taken with the application of this control device. Warranty Warranty: This manual is published solely for information purposes and should not be considered all inclusive. Sale of product shown or described in this literature is subject to terms and conditions outlined in appropriate Cummins Power Generation selling policies or other contractual agreement between the parties. This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Cummins Power Generation. NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS CONTAINED HEREIN. In no event will Cummins Power Generation be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental, or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations, and descriptions contained herein. viii IMPORTANT SAFETY INSTRUCTIONS EXHAUST GASES ARE DEADLY SAVE THESE INSTRUCTIONS − This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. 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. Be sure the unit is well ventilated. Engine exhaust and some of its constituents are The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. known to the state of California to cause cancer, birth defects, and other reproductive harm. This symbol warns of immediate hazards which will result in severe personal injury or death. DANGER MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Keep your hands, clothing, and jewelry away from This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death. WARNING moving parts. Before starting work on the generator set, discon- nect battery charger from its AC source, then disconnect starting batteries, negative (−) cable first. This will prevent accidental starting. This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. CAUTION Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. FUEL AND FUMES ARE FLAMMABLE Do not wear loose clothing or jewelry in the vicinity Fire, explosion, and personal injury or death can result from improper practices. of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. 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. If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc. DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. DO NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVIRONMENTS Fuel lines must be adequately secured and free of Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc., unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Power Generation distributor for more information. leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel. Be sure all fuel supplies have a positive shutoff valve. Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc. LS-14L ix ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH 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 generator. Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard. Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath or ingest or come into contact with exhaust gases. Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. Wear hearing protection when going near an operating generator set. To prevent serious burns, avoid contact with hot metal parts such as radiator, turbo charger and exhaust system. Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock or burning. Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. DO NOT CONNECT GENERATOR SET DIRECT- LY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device. GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first. Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE LS-14L x 1. Introduction ABOUT THIS MANUAL This manual provides installation and operation information regarding the 1302 series control. This manual includes information for the following types of installations. CERTIFICATIONS The 1302 series control meets or exceeds the requirements of the following codes and standards. NFPA110 for level 2 or 3 systems ISO 8528−4: 1993 Compliance, Controls and Switchgear CE Marking: The control system is suitable for use on generator sets to be CE−marked EN 50081−1,2 Residential/Light Industrial emissions or Industrial Emissions EN 50082−1,2 Residential/light industrial or Industrial susceptibility ISO 7637−2, level 2; DC supply surge voltage test Mil Std 202C, Method 101 and ASTM B117: Salt Fog test Kit 541−1414−01 is for Hydro Mechanical (HM) engines. Kit 541−1414−02 is for Full Authority Electronic (FAE) engines. FAE engines have an external Electronic Control Module (ECM). 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 equipment damage. 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. This control is suitable for use on generator sets that are UL2200 listed. Connector Seal Standards The following standards apply to the connector seals used with the 1302 series control. J11, J25, and J20 − AMP 794758-1 J12 − AMP 794275−1 Interface seal and AMP 794276−1 Wire seal (both are required) J17 − AMP 794269−1 Interface seal and AMP 794276−1 Wire seal (both are required) J18 − AMP 794271−1 Interface seal and AMP 794276−1 Wire seal (both are required) Read Important Safety Precautions and carefully observe all instructions and precautions in this manual. SYSTEM OVERVIEW The 1302 series control is a microprocessor-based control. All generator set control functions are contained on one circuit board. The circuit board provides engine speed governing (optional, when the governor output module and appropriate engine equipment is provided), main alternator voltage output regulation, and complete generator set control protection and monitoring. The operating software provides control of the generator set and its performance characteristics, and displays performance information on an optional operator panel. It accepts menu-driven control and setup input from the push button switches on the operator panel. HOW TO OBTAIN SERVICE Contact your generator set manufacturer when seeking additional service information or replacement parts. Provide model and serial number information. WARNING Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be qualified to perform electrical and mechanical service. Read and follow Important Safety Precautions, on pages v and vi. 1-1 THIS PAGE LEFT INTENTIONALLY BLANK 1-2 2. Description FIGURE 2-1. 1302 MAIN CONTROL BOARD AND OPERATOR PANEL (HMI211) OVERVIEW The PCC1302 controller is a microprocessor− based generator set (genset) monitoring, metering, and control system. The control provides a simple operator interface to the genset’s digital voltage regulation, engine speed governing, remote start / stop control, and protective functions. The PCC1302 control is suitable for use on hydro mechanical or FAE engines. It can be used in nonparalleling applications and it is compatible with reconnectable alternators up to 600VAC. The control can also be configured for various frequency (50 / 60 Hz operation), voltage, and power connection configurations from 190−600 VAC L-L. KIT DESCRIPTION The 1302 genset control kits include the 1302 control board (12/24V control assembly with run and start relay drivers) and the operator panel shown in Figure 2-1. Also included in these kits are the following sensors and harnesses. Quantity Description The control is designed for mounting on the generator set. The 1302 series control is usually powered from the generator set starting batteries and works over a voltage range from 8 to 30 VDC. The 1302 series control meets NFPA 110 requirements (with appropriate accessories) and is designed for connection to a 12 or 24 VDC control system. An optional operator panel can be used as a user interface. 2-1 HM Kit FAE Kit 541−1414−01 541−1414−02 Oil Pressure Sensor 1 — Temperature Sensor 1 — Coolant Temperature Sensor Harness 1 — Oil Pressure Sensor Harness 1 — Control Panel to PCC1302 Harness 1 1 Engine Harness 1 1 Genset AC Harness 1 1 ADDITIONAL EQUIPMENT HMI113 Universal Annunciator 300−5929 (Includes Operator’s 900−0301) Figure 2-1 shows the 1302 control module (327− 1617−01) and the optional HMI211 digital display panel (300−6014). If your installation is to include any additional equipment (see Figure 2-2), the appropriate kit(s) must be purchased separately. − Kit Manual AUX101 System I/O Module − Kit 541−1291 (Includes Instruction Sheet C693) AUX104 External Governor Power Module − Kit 541−1231 (Includes Instruction Sheet C689) HMI112 LED Bargraph − Kit 541−1319 (Includes Instruction Sheet C697) HMI112 LED BARGRAPH (300−6050−02) AUX101 SYSTEM I/O MODULE (327−1536) HMI113 UNIVERSAL ANNUNCIATOR (300−5929) AUX104 EXTERNAL GOVERNOR POWER MODULE (327−1507) FIGURE 2-2. ADDITIONAL EQUIPMENT 2-2 1302 CONTROL FEATURES Configurable Inputs and Outputs. Four discrete configurable inputs and two dry contact relay outputs. The 1302 series controller includes the following features. Relay driver output for glow plug or spark igniter Operates on 12 or 24 VDC. Electronic Governor Enable/Disable (via an external Governor Power Module). FAE Engine support utilizing partial PGI CAN protocol support. Automatic Voltage Regulator (AVR) Enable/ Disable. PMG or Shunt Excitation methods supported. controller, switched B+, FSO, Starter, Ready to Load, Local Status, and Keyswitch control. Current Requirements The 1302 series control consumes 0.150 Amps of current while in idle mode. While in the running mode, it consumes 0.75 Amps of current. This doesn’t include other application specific devices such as the optional operator panel, external actuators, relay coils, or display lamps. 1302 CONTROL SYSTEM PCCNet Communications. ModBus Communications. Control Module Digital speed governing. The basic control system for the generator set consists of a single control board with an external control switch and status indicator. Digital voltage regulation. Low power sleep mode, with configurable Wake-In-Auto mode. Phase voltage and current sensing. Wye and Delta voltage sensing single phase. Current sensing with an external 0−5 amp current transformers. Engine relay drivers. Generator set monitoring. Display status of all critical engine and alternator generator set functions. The control board includes all the functions necessary to locally or remotely start and stop the Genset, provide digital voltage regulation, and protect the Genset. To use the electronic governor feature, an external governor power stage may be required to drive the fuel actuator. Control Run/Off/Auto Switch Genset protection – Engine and Alternator protection features. Off Mode − If the control is in the OFF mode, the generator set is immediately shut down (if running) and can’t be started. When in OFF mode, all active faults are reset. Operator Panel Display (optional). Provides easy to use operator display of critical genset parameters and operating history. Run Mode − If the control is in the RUN mode, the generator set will execute its start sequence and operate at rated speed and voltage. Advanced serviceability using a PC based software service tool. Auto Mode − If the control is in AUTO mode, the generator set can be started with a start signal from a remote device, such as an automatic transfer switch by accepting a ground signal. Environmental protection. The control system is designed for reliable operation in harsh environments. The core control board is potted module that is fully protected from the elements. Fault Reset − Placing the switch in the OFF position also resets the active/inactive faults in the control. 2-3 OPERATOR PANEL The 1302 series control is provided with an optional operator panel that may be either locally or remotely mounted. The operator menus are made up of English or internationally accepted symbols so translations are not required. The display is composed of an adjustable contrast backlit LCD display, with a series of 6 generator status LED lamps. The display is accompanied by a set of six tactile feel membrane switches that are used by the operator to navigate through control menus, and to make control adjustments. It is configurable for units of measurement. The Run/Off/Auto switch function is integrated into the operator panel; therefore an external switch is not required when a operator panel is installed. The operator panel displays current active faults, and a time-ordered history of previous faults. Operator Panel Connections Two connectors (J1 and J2) are located on the back of the operator panel (see Figure 2-3). Connections are listed in Table 2-1. NOTE: J1 and J2 are identical. Either one can be used for the harness connection between the main control board and the operator panel. PIN 1 1 5 2 6 3 7 4 8 J1 or J2 J2 J1 J1-4 FIGURE 2-3. 1302 OPERATOR PANEL TABLE 2-1. OPERATOR PANEL CONNECTIONS Connector Pin Signal Name Connect To / Comments J1-1 RS-485 Data A Network Data A J1-2 RS-485 Data B Network Data B J1-3 B+ Network Supply J1-4 PCCNet System Wake Up System Wakeup J1-5 Return Network Supply Return J1-6 Run Output J1-7 Auto Output J1-8 2-4 CONTROL INPUTS AND OUTPUTS Ready to load (generator set running) signal – This output pin goes low when the genset is capable of supporting a load. The genset speed and voltage output are what determines the state of this pin. Control Inputs Input signals to the main control board are: Run/Off/Auto switch Communications connections − The control includes two RS-485 ports. Remote start signal Remote emergency stop − PC Tool Interface – This communication port (TB15) allows the control to communicate with a personal computer running a PC based service tool. This port also allows the control to communicate with external devices, such as a Programmable Logic Controller (PLC) via the ModBus protocol. Local emergency stop Coolant temperature signal Lube oil pressure signal Battery voltage signal PCCNet System Wake Up Input Magnetic pick up signal − PCCNet − This communications port (TB1) allows for connection from the control to the optional operator panel, universal annunciator, LED bargraph, and system I/O module. Starter disconnect signal Single or three-phase current transformers (CTs) Single or three phase line-to-neutral voltage Local status – Refer to “Local Status Output Indicator” on page 4-1. Configurable inputs – The control includes four inputs that have configurable functions. Once mapped, each configurable input can be used as a fault input, remote fault reset input, battleshort input, or disabled. Battery charging alternator – Alternator flash connection Fuel shut-off relay driver Starter relay driver Control Outputs Keyswitch relay driver Output signals from the control are: Glow plug relay driver Control status lamp. Governor drive PWM command Configurable relay outputs (OUT1_NO and OUT2_NO) − The control includes two relay outputs rated at two amps. These outputs can be configured to activate on any control warning or shutdown fault as well as ready to load, not in auto, common alarm, common warning, and common shutdown. Field coil − AVR PWM command Excitation source − Input power for field coil Alternator line voltage sensing − 600 VAC RMS max Switched B+ driver 2-5 PROTECTION AND FAULTS PC based service tool or through the display panel menus) to match the capabilities of the engine used. The control includes time delays to prevent nuisance warning/shutdown signals. The 1302 series control features genset protection functions and fault detection. Upon operation of a protective function, the control will indicate a fault by flashing the fault code on the local status lamp driver (J25−1). On systems with an optional operator panel, the warning or shutdown LED lights and the fault symbol and code is displayed on the display. The nature of the fault and time of occurrence is logged in the control. The service manual and PC based service tool provide service keys and procedures based upon the service codes provided. Low Coolant Temperature Warning − This warning indicates that the engine temperature may not be high enough for a 10-second start or proper load pickup. The level is preset (configurable with a PC based service tool or through the display panel menus) to match the capabilities of the engine used. The control includes time delays to prevent nuisance warning signals. Low Battery Voltage Warning − This warning indicates a battery charging system failure by continuously monitoring battery voltage. The control includes time delays to prevent nuisance warning signals. Fault Codes A list of fault/status codes is included in Section 4. Shutdown faults will shutdown the genset. Warning faults are issued to notify the genset operator of the problem but the 1302 series control will not shutdown the genset when they occur. High Battery Voltage Warning – This warning indicates that the battery charging system is of a high level by continuously monitoring battery voltage. The control includes time delays to prevent nuisance warning signals. Genset Protective Functions The control provides the following system protective functions: Weak Battery Voltage Warning − The control system tests the battery bank each time the generator set is signaled to start. A warning is announced if the generator set battery indicates impending failure. The control includes time delays to prevent nuisance warning signals. Configurable Alarm and Status Inputs – The 1302 series control accepts up to four alarm or status inputs (configurable contact closed to ground or open) to indicate customer-specified conditions. The control is programmable for warning, shutdown, or status indication, and for labeling the input. Dead Battery Voltage Shutdown −Indicates battery voltage drop during cranking which resets control for three consecutive times (This feature is available in 1302 calibration version 3.0 onwards ) Emergency Stop − Annunciated whenever the emergency stop signal is received from an external switch. Engine Protection Fail to Start (Overcrank) Shutdown. Fail to Crank Shutdown − This shutdown indicates that the control signaled the starter to crank the engine but the engine did not rotate. Overspeed Shutdown – The engine overspeed default setting is 115% of the rated engine speed nominal. The control includes time delays to prevent nuisance shutdown signals. Cranking Lockout − The control will not allow the starter to attempt to engage or to crank the engine when the engine is rotating (when the control senses the valid engine RPM above the noise threshold value.) Low Lube Oil Pressure Warning/Shutdown − The level is preset (configurable with a PC based service tool or through the display panel menus) to match the capabilities of the engine used. The control includes time delays to prevent nuisance warning/shutdown signals. Sensor Failure Indication – An out-of-range high or low diagnostic logic is provided on the base control to detect analog sensor or interconnecting wiring failures. High Engine Temperature Warning/Shutdown − The level is preset (configurable with 2-6 Under/Overfrequency − The underfrequency default is − 6Hz of the 50 Hz / 60 Hz frequency with a 10 second time delay. The overfrequency default is + 6Hz of the 50 Hz / 60 Hz frequency with a 10 second time delay. Alternator Protection High/Low AC Voltage Shutdown − The high voltage default setting is 110% of the rated voltage with a 10 second time delay. The instantaneous voltage default setting is 130% of the rated voltage. The low AC voltage default setting is 85% of the rated voltage with a 10 second time delay. Loss Of Sensing AC Voltage Shutdown – Loss of sensing AC voltage detects the loss of voltage sensing or senses the loss of zero crosses. This fault will also be the primary way to detect short circuit conditions. Overcurrent Warning/Shutdown − Implementation of the thermal damage curve with an instantaneous trip level is calculated based on the Current Transformer Ratio and the Application Power Rating (see Figure 2-4). Overexcitation Shutdown – Overexcitation is used to detect short circuit alternator faults. CURRENT DRAW Alternator Thermal Damage Curve Overcurrent Protection Curve 10 The current draw information below is for the 1302 series control only. It does not include current draw for other application specific devices, such as the optional operator panel, external actuators, relay coils, or display lamps. Running Mode When in Running mode, the 1302 series control consumes .750 amps of current. Seconds Parade Rest Mode 1 Instantaneous Trip Point Parade Rest mode is when the 1302 series control is waiting for a start command (for example, the genset is not running). During Parade Rest mode, the control consumes 150 milliamps of current. 0.03 Sleep Mode 1 10 Amps (x rated) FIGURE 2-4. ALTERNATOR PROTECTION THERMAL DAMAGE CURVE The 1302 series control enters Sleep mode after five minutes in the Off or Auto mode. During Sleep mode, the control consumes 60 milliamps of current. 2-7 THIS PAGE INTENTIONALLY LEFT BLANK 2-8 3. Installation Read these instructions completely and become familiar with safety warnings, cautions, and procedures before starting the installation. WARNING Incorrect installation, service, or replacement of parts can result in severe personal injury or death and/or equipment damage. Only trained and experienced personnel are to perform the following procedures. A generator set control must be serviced only by technically qualified personnel. High voltages are present. These voltages can cause electrical shock, resulting in personal injury. CAUTION Even with power removed, improper handling of components can cause electrostatic discharge and damage to circuit components. AC voltages and currents present an electrical shock hazard that can cause severe personal injury or death. Incorrect installation, service, or parts replacement can result in severe personal injury, death, and/or equipment damage. WARNING Turn off or remove AC power from the battery charger (if present) and then remove the negative (−) battery cable from the set starting battery. This is to make sure the genset will not start while working on it and to avoid circuit board damage, caused by voltage spikes when removing and replacing circuit board connectors. CAUTION If present, always disconnect a battery charger from its AC source before disconnecting the battery cables. Otherwise, disconnecting the cables can result in voltage spikes high enough to damage the DC control circuits of the generator set. Accidental starting of the generator set while working on it can cause severe personal injury or death. Prevent accidental starting by disconnecting the starting battery cables (negative [−] first). WARNING Make certain the battery area has been wellventilated before servicing the battery—Wear goggles—Stop the genset and disconnect the charger before disconnecting battery cables. Arcing can ignite explosive hydrogen gas given off by batteries, causing severe personal injury. Arcing can occur when a cable is removed or re-attached, or when the negative (−) battery cable is connected and a tool used to connect or disconnect the positive (+) battery cable touches the frame or other grounded metal part of the generator set. Always remove the negative (−) cable first, and reconnect it last. Make certain hydrogen from the battery, engine fuel, and other explosive fumes are fully dissipated. This is especially important if the battery has been connected to a battery charger. Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near a battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. WARNING MOUNTING GUIDELINES The main control board and the optional operator panel are suitable for non-engine mounting. As such, they should not be directly mounted on the engine. The control and operator panel may be mounted on one of the following. A suitable frame on top of the alternator A frame supported from the genset base rail A stand-alone mounting frame isolated from the vibration of the genset Appropriate vibration isolators should be used to make sure that neither the main control board, the operator panel, nor customer wiring are subjected to vibration levels beyond their capability. To prevent the control board and the optional operator panel from being exposed to conditions beyond their specifications, care should be taken not to mount them close to the engine exhaust pipes. Mounting them in a manner that would expose 3-1 them to direct sunlight or rain/snow should also be avoided. Amplitude (Gs) LCD Vibration Profile 10 It is recommended that the control board be mounted with the longer side horizontal and the shorter side vertical so as to allow air to move freely upwards through the heat sink channels. Mounting the control board with the short side horizontal and the longer side vertical should be avoided. 1 ENVIRONMENTAL CAPABILITY 0.1 The control system is specifically designed and tested for resistance to RFI / EMI and to resist the effects of vibration to provide a long reliable life when mounted on a generator set. The control includes transient voltage surge suppression to provide compliance to referenced standards. 0 50 100 150 200 250 Frequency (Hz) FIGURE 3-1. OPERATOR PANEL VIBRATION LIMITS 1302 Main Control Board CONTROL WIRING INFORMATION The main control board is designed to withstand vibration levels of 50 mm / sec in the 20−100 Hz range and of 3.3 G in the 100−2000 Hz range. For connecting the Magnetic Pickup, use minimum 0.8 sq. mm (18 gage), 2 conductors, twisted shielded cable. Connect the shield at J11-8 and leave the shield un-connected at the magnetic pickup side of the cable. The main control board is designed for proper operation without recalibration in ambient temperatures from –40 to +70 Deg C, and for storage from –55 to +80 Deg C. The control is designed to operate with humidity up to 95%, non-condensing, and at an altitude up to 13,000 feet (5000 meters). For connection the ECM CAN, use minimum 0.8 sq. mm (18 gage), 2 conductors, twisted shielded cable. Connect the shield at J11-17and leave the shield un-connected at the ECM side of the cable. The main control board is fully encapsulated to provide resistance to the effects of dust and moisture. For connecting the PCCNet, use minimum 0.8 sq. mm (18 gage), 2 conductors, twisted cable. For connecting the battery supply, use two twisted pair wires (16 AWG). For connecting current transformers, use three twisted pair wires minimum (16 AWG). For all other connections, use minimum 0.8 sq mm (18 gauge) wires. The Electronic Governor feature typically requires an external Governor Output Module Kit. Governor PWM output from the 1302 series control board is connected as input to the Governor Power Module by a minimum 0.8 sq. mm (18 gage), 2 conductors, twisted shielded cable. 1302 Operator Panel The optional operator panel is designed to withstand vibration levels of 40 mm / sec in the 4−100 Hz range and the engine vibration levels shown in Figure 3-1. The operator panel is designed for proper operation in ambient temperatures from −4 to 158 Deg F (–20 to +70 Deg C) and for storage, from −22 to 176 Deg F (–30 to +80 Deg C). The operator panel has a single membrane surface, which is impervious to the effects of dust, moisture, oil, and exhaust fumes. 3-2 GUIDELINES FOR CURRENT TRANSFORMERS All current transformers (CTs) used with a 1302 series control must conform to the following specifications. Continuous rated full load secondary output current: 5 amps at 50 or 60Hz Total burden VA rating: at least 2.5 VA Output terminals between which current is drawn in high and low ranges on tapped CTs. Maximum allowable ratio error at rated output: +/−1% Maximum allowable phase error at rated output: +/−1 10-second overload output current in rated metering load: 10 Amps Maximum allowable ratio error at overload output: +/−1% Ambient temperature rating: −40 to 176 Deg F (−40 to +80 Deg C) System voltage rating − 600VAC NOTE: in PCC1302,if trim parameter Current Multiplier 2X Enable is enabled and only one of the two alternator winding phase cables is routed through CT, then the current measurement calculation will be multiplied by 2 to show the correct reading of the load current. Current Transformer Selection Current transformers (CTs) used in 1302 control applications are ideally sized to produce rated CT secondary amps at twice rated generator (full 200% range) output amperes. In other words, when the generator is producing 100% output amperes, the secondary current of the CTs is 2.5 amperes per phase. This requirement determines a lower bound of the CT ratio. An upper bound is determined by requiring that, at 100% rated output current, the CTs secondary current is at least 1 ampere. The purpose of this is to maintain sufficient metering resolution. The lower and upper bound of the CT limits are prescribed by the following two formulas. Minimum CT Ratio = Maximum CT Ratio = 2 * Max_Rated_Current 5 5 * Min_Rated_Current 5 In non-reconnectable genset applications, the Max_Rated_Current and Min_Rated_Current are the same. In reconnectable genset applications, they are different. Example of CT Sizing − Two Lead CT A 250kVA rated genset application at 240V produces rated output current of 602 amps/phase. This yields a Minimum CT Ratio of 1204:5 and a Maximum CT Ratio of 3010:5. Any CT with a ratio between these two values would be sufficient for this application. 3-3 Example of CT Sizing − Three Lead CT 1. Enter an appropriate value in the CT ratio pa- rameter on the operator panel. A reconnectable generator capable of 208−240/ 416−480V outputs with a 125 kVA 3-phase only rating. You first need to find the current in each phase for each output voltage. This is done using the following formula: Current Current Power (VA ) 3 *Voltage or Power (W ) 3 * Power_ Factor *Voltage Using the above equation, the current in each phase is computed as shown below. Voltage (V) Output Current (A) 208 346.376 240 300.192 416 173.188 480 150.096 The next step is to use the equations on page 3-3 to find the lower and upper bound for the CT ratios for each voltage configuration. For a 208−240 voltage configuration: Maximum CT Ratio 5 * 300.192 1500.96 Minimum CT Ratio 2 * 346.376 692.752 2. Select a feature to be downloaded using the Manufacturing Tool. 3. Program an appropriate value in the Primary CT Current parameter using a PC-based service tool (for example, InPower). NOTE: To check the actual genset output, True (calibrated) RMS meter should be usedThe 1302 series control automatically doubles the entered CT ratio when switching from high nominal voltage (above 300V) to lower nominal voltage (below 300V). When entering a CT ratio the following rules apply: Two Lead CT, above 300V application − Enter CT ratio as read from the CT. Two Lead CT, below 300V applications − Enter HALF of the CT Ratio as read from the CT. Three Lead CT (Center Tapped) – Enter the SMALLER of the two ratios as read from the CT. Two Lead CT Setup Example: For this example, assume a CT with a 1500:5 ratio is being used. Operator Panel Above 300V applications − Enter 1500 into the CT ratio parameter on the operator panel. For a 416−480 voltage configuration: Maximum CT Ratio 5 * 150.096 754.8 Below 300 V applications − Enter 750 into the CR ratio parameter on the operator panel. Manufacturing Tool Minimum CT Ratio 2 * 173.188 346.376 For three-tap CTs, it would be advisable to choose a CT with a 1500/750:5 ratio. For the 208−240 voltage configuration, connect the CT leads to the 1st and 3rd CT connections, leaving the center tap disconnected. For the 416−480 voltage configuration, use the same 1500/750:5 ratio CT, but this time connect the CT leads to the first and second (center-tap) connections on the CT, leaving the third tap unconnected. Above 300V applications − Select a feature corresponding to 1500:5 to download using the Manufacturing Tool. Below 300 V applications − Select a feature corresponding to 750:5 to download using the Manufacturing Tool. PC-Based Service Tool Current Transformer Setup Above 300V applications − Enter 1500 into the Primary CT Current parameter, using the PCbased service tool (e.g. InPower). After the 1302 series control kit has been installed, the controller must be programmed to use the CT by one of the following methods. Below 300V applications − Enter 750 into the Primary CT Current parameter, using the PCbased service tool (e.g. InPower). 3-4 In PCC1302 Control, Voltage Calibration procedure is divided into three processes as described below: 1. Meter Calibration: There are two sets of AC in- puts on the 1302: L1−N, L2−N, and L3−N (or L1−2, L2−3, L3−1 for delta) AND 3 phase average voltage. The metering calibration will calibrate L1−N, L2−N, L3−N., which is used for display and diagnostic purposes. Method: Verify each phase on PCC matches external calibrated meter. This calibration should be done first. point ( i.e. for example: If the user wants the PCC to output 215VAC instead of 220VAC) Procedure of calibrating the Alternator Voltages is as follows: Safety Precautions: 1. Contacting high voltage components can cause electrocution, resulting in severe personal injury or death. Calibration and adjustment must be performed by technically qualified personnel only. Read and observe all the Warnings and Cautions in your generator set manuals. 2. Regulation Calibration: This calibrates the 3 phase average voltage, which is used for regulation. Method: Verify the 3 phase average voltage of the genset matches an external meter’s voltage. Special note: When changing the regulation feedback calibration, the PCC’s feedback will appear to say the same, and the external meter’s value will change. This is because the PCC regulator is active, and is making what the PCC sees be the PCC’s Setpoint. 3. Voltage Adjust: Once both the metering and voltage calibration is done, you use the voltage adjust to modify the PCC’s voltage Set- 2. Improper calibration and adjustment of the PCC can cause equipment malfunction or damage. Calibration and adjustment must be performed by technically qualified personnel only. One or more of the PCC’s internal circuits may need to be calibrated, in which case you should calibrate the internal circuits in the following order listed in the table shown below: NOTE: To check the actual genset output, True (calibrated) RMS meter should be used. 3-5 Component to be calibrated p TABLE 3-1. CALIBRATION Calibration method PC based service tool Meter Calibration or Voltage mea- 1. Connect to the control with your surement for display PC based service tool. 2. Verify the nominal voltage trim is set to the desired value. The trim Alternator Nominal Voltage is available at Adjustments −> AC Measurement Calibrations −> Voltage Measurement for Regulation. Set the Alternator Nominal Voltage to the voltage that the genset will generate. 3. With the genset OFF, attach a calibrated Voltmeter to the AC Output from L1 to L2. (L1 to Neutral for single phase alternators). 4. Start the genset and allow it to reach normal operating speed. 5. Calibrate voltage reading for L1 by adjusting the trim Alternator L1−N 50Hz Voltage Display Adjust or Alternator L1−N 60Hz Voltage Display Adjust trim for your application, so that the reading on the display agrees with the calibrated voltmeter. 6. Shut the generator set OFF. 7. Repeat Step 3 to Step 6 for L2 and L3 (In Step 3 attach meter to the AC output from L2 to L3 to calibrate L2 and L3 to L1 to calibrate L3) by adjusting the trims Alternator L2−N 50Hz Voltage Display Adjust or Alternator L2−N 60Hz Voltage Display Adjust trim and Alternator L3−N 50Hz Voltage Display Adjust or Alternator L3−N 60Hz Voltage Display Adjust trim respectively. 8. Save the adjustments by doing a Save Trims with your PC based service tool. 3-6 Operating panel 1. View the service menu by holding down the ”up” and ”down” arrow keys on any of the operating menus. 2. Select item 1, ”Setup Menu”. 3. Enter Setup menu password ”574”. 4. Select item 1, ”Genset Service”. 5. Select item 1, and verify the ”Volts AC” setting is correct for your application. If necessary press the ”Adjust” button and change the setting, and press the ”Save” button. 6. Press the back button to return to service menu. 7. With the genset OFF, attach a calibrated Voltmeter to the AC Output from L1 to L2. (L1 to Neutral for single phase alternators). 8. Start the genset and allow it to reach normal operating speed. 9. Select item 3, ”Meter Calib”. 10. Press the down arrow twice to scroll down to the ”Metering Voltage Adjust” 11. Adjust the three parameters one by one listed so that the reading on the display agrees with the calibrated voltmeter. 12. Shut the generator set OFF. 13. Repeat Step 7 to Step 12 for L2 and L3 (In Step 3 attach meter to the AC output from L2 to L3 to calibrate L2 and L3 to L1 to calibrate L3) by adjusting the trims Alternator L2−N 50Hz Voltage Display Adjust or Alternator L2−N 60Hz Voltage Display Adjust trim and Alternator L3−N 50Hz Voltage Display Adjust or Alternator L3−N 60Hz Voltage Display Adjust trim respectively. 14. Save the adjustment by pressing the ”Save” button. Regulation Calibration or Voltage measurement for regulation 1. Connect to the control with your PC based service tool. 2. Verify the nominal voltage trim is set to the desired value. 3. With the genset OFF, attach a calibrated Voltmeter to the AC Output from L1 to L2. 4. Start the genset and allow it to reach normal operating speed. 5. Adjust the trim Voltage Regulation Calibration 50Hz or Voltage Regulation Calibration 60Hz for your desired application. The effect of this trim is Inverse on the regulated voltage. Increasing the trim will lower the regulated voltage, and decreasing the trim will raise the regulated voltage. The monitored Regulated Voltage will match with the reading on the attached external calibrated meter and the Regulated Feedback Voltage (Alternator Voltage) matches the desired Nominal voltage. 6. Shut the generator set OFF. 7. Save the adjustments by doing a Save Trims with your PC based service tool. 1. View the service menu by holding down the ”up” and ”down” arrow keys on any of the operating menus. 2. Select item 1, ”Setup Menu”. 3. Enter Setup menu password ”574”. 4. Select item 1, ”Genset Service”. 5. Select item 1, and verify the ”Volts AC” setting is correct for your application. If necessary press the ”Adjust” button and change the setting, and press the ”Save” button. 6. Press the back button to return to service menu. 7. Start the genset and allow it to reach normal operating speed. 8. Select item 3, ”Meter Calib”. 9. Press the ”Adjust” button and change the ”Reg Volt Adj” value. The effect of this trim is Inverse on the regulated voltage. Increasing the trim will decrease the regulated voltage. Decreasing the trim will increase the regulated voltage. 10. Save the adjustment by pressing the ”Save” button. Voltage Setpoint Adjustment 1. Connect to the control with your Not Applicable. PC based service tool. 2. Verify the nominal voltage trim is set to the desired value. 3. With the genset OFF, attach a calibrated Voltmeter to the AC Output from L1 to L2. 4. Start the genset and allow it to reach normal operating speed. 5. Adjust the trim Voltage Adjust which shall move the voltage Setpoint either in positive direction or in negative direction as per your requirement. NOTE: 1. Meter Calibration is what all the diagnostics use and the display shows, while Regulator Calibration it the feedback going to the AVR. Thus Meter Calibration and the Regulator calibration shall be done when the PCC1302 control is initially calibrated or if the boards are swapped / replaced with the new ones. 2.Voltage Setpoint adjustment shall be carried out as and when required to move the voltage Setpoint. 3-7 BATTERY CHARGING ALTERNATOR CONNECTIONS Three Lead CT Setup Example For this example, assume that a CT with a 1500/750:5 ratio is being used. The 1302 series control currently supports the following charging alternator types. Operator Panel Denso Type Charging Alternators Enter 750 into the CT Ratio parameter on the Operator Panel. A Denso charging alternator with IG and L (failure lamp) connection points is shown in Figure 3-2. This configuration is used to produce a start disconnect signal and to indicate a failed battery charging alternator. Manufacturing Tool Select a feature corresponding to 750:5 to download using the Manufacturing Tool. Bosch Type Charging Alternators PC-Based Service Tool A Bosch charging alternator with D+ (flash input) connection point is shown in Figure 3-3. This configuration is used to produce a start disconnect signal and to indicate a failed charging alternator. Enter 750 into the Primary CT Current parameter using a PC based service tool (e.g. InPower). 1302 Series Control Denso Type Charging Alternator Battery Charging Alternator Input J20−22 L RUN IG J20−11 B+ FIGURE 3-2. DENSO CHARGING ALTERNATOR WIRING DIAGRAM 1302 Series Control Bosch Type Charging Alternator J20−22 D+ Approx, 5 Ohm input impedance RUN B+ J20−11 FIGURE 3-3. BOSCH CHARGING ALTERNATOR WIRING DIAGRAM 3-8 Battery Charging Alternator Input ALTERNATOR CONNECTIONS J12-1 J12-4 A fast acting UL certified ceramic fuse with a rating of ten amperes shall be placed inline with the Excitation Inputs J18-1 and J18-2. V1: J22-1 W6 (T12) CT1 U1 (T1) Series Star W5 (T9) W2 (T6) Series star connection yields an output voltage of 220−277/380−480 volts. Figure 3-4 shows the correct series−star alternator connections. VN: J22-4 J12-3 J12-6 W1 (T3) U2 (T4) V3: J22-3 V6 (T11) CT3 U5 (T7) J12-1 J12-2 J12-4 V1: J22-1 V2 (T5) CT1 U1 (T1) U2 (T4) J12-5 V2: J22-2 V5 (T8) CT2 V2 (T5) V1 (T2) J12-2 J12-5 V6 (T11) U5 (T7) U6 (T10) U6 (T10) V1 (T2) V2: J22-2 CT2 V5 (T8) VN: J22-4 W6 (T12) FIGURE 3-5. SERIES DELTA CONNECTIONS W5 (T9) W2 (T6) W1 (T3) J12-3 J12-6 V3: J22-3 J12-1 J12-4 CT3 V1: J22-1 CT1 FIGURE 3-4. SERIES STAR CONNECTIONS U5 (T7) Series Delta Series delta provides for an output voltage of 110−120/220−240 volts. Figure 3-5 shows the correct series delta connections. U1 (T1) V2: J22-2 V2 (T5) U6 (T10) V5 (T8) U2 (T4) J12-2 J12-5 V6 (T11) CT2 V1 (T2) VN: J22-4 NOTE: To check the actual genset output, True (calibrated) RMS meter should be usedSense N must not be connected in three phase delta connections. Parallel Star W6 (T12) W2 (T6) W5 (T9) W1 (T3) J12-3 J12-6 V3: J22-3 CT3 Parallel star alternator configuration yields an output voltage of 110−139/190−240 volts. Figure 3-6 illustrates the correct parallel star connections. FIGURE 3-6. PARALLEL STAR CONNECTIONS 3-9 Double Delta Single Phase The double delta alternator configuration yields an output voltage of 110−120/220−240 volts. Correct double delta connections are illustrate in Figure 3-7. Single phase provides for an output voltage of 110−120/220−240 volts. Single phase alternator connections are shown in Figure 3-8. J12-1 J12-4 V6 (T11) U1 (T1) J12-1 J12-4 V1: J22-1 CT1 U5 (T7) V1: J22-1 CT1 V5 (T8) W2 (T6) W1 (T3) V2 (T5) U2 (T4) U6 (T10) VN: J22-4 VN: J22-4 U1 (T1) U5 (T7) V1 (T2) W6 (T12) J12-2 J12-5 W5 (T9) J12-2 J12-5 U6 (T10) U2 (T4) V2: J22-2 V2: J22-2 CT2 CT2 FIGURE 3-7. DOUBLE DELTA CONNECTIONS FIGURE 3-8. SINGLE PHASE CONNECTIONS 3-10 GUIDELINES FOR ENGINE SENSORS The engine sensors included in this kit are: For information on setting the oil pressure sender type using the display panel, see page 5-43. Coolant Temperature Sensor 193−0529−01 Oil Pressure Sensor 193−0444 This section provides information on these plus additional engine sensors that can be used with 1302 series controllers. Coolant Temperature Sensors The coolant temperature sensors that are available from Cummins Power Generation (CPG) are listed in Table 3-1. The coolant temperature sensor connectors that are available from CPG are listed in Table 3-2. FIGURE 3-9. THREE-WIRE PRESSURE SENSOR CONNECTIONS Oil Pressure Sensors The 1302 series control can be programmed for either oil pressure sensors or switches. The trim parameter for this is: Lube Oil Pressure Sensor Type = Sensor, Switch. If the type is set to Sensor, the control can also be programmed for either 3-wire or 2-wire sensors. The trim parameter for this is Oil Pressure Sender Type = 3-wire, 2-wire. Available switch and sensors are listed in Table 3-3. CPG P/N FIGURE 3-10. TWO-WIRE PRESSURE SENSOR CONNECTIONS TABLE 3-1. COOLANT TEMPERATURE SENSORS Manufacturer / P/N Resistive Temp Range Threading 0193−0529−01 AirPax / 5024−0250 −40 to +230 F 3/8 “NPTF 0193−0529−02 AirPax / 5024−0274 −40 to +230 F M14 X 1.5 with “O” Ring TABLE 3-2. TEMPERATURE SENSOR CONNECTORS Manufacturer CPG P/N Manufacturer P/N Comments 0323−1755 Packard 121621893 Plastic shell with seal 0323−1818 Delphi 12124075 Socket Connector 3-11 TABLE 3-3. OIL PRESSURE SENSORS AND SWITCH CPG P/N Manufacturer / P/N Sensor Type Range / Unit Resistance / Voltage Comments 193−0430−02 F.W. Murphy ED2P-100 2-Wire Standard Resistive Sender 0−100 PSIG 240−33 Ohms Includes 10-32 hex nut connectors, 1/8” NPTF dry sealing threading, and a diaphragm operated resistive sensing element 193−0444 Kavlico P165−5110 3-Wire Active Sender (Capacitive) 0−100 PSIG 0−5 VDC Mating Connector 326−1666 (Packard 12065287) includes 323−1667 socket terminals (Packard 12103881) 309−0641−XX Stewart Warner Pressure Switch A028X493 3-Wire Active Sender (Capacitive) Kavlico P4055−5001−1 (See the following page) 0−100 PSIG 0−5 VDC Mating Connector 326−1666 (Packard 12065287) includes 323−1667 socket terminals (Packard 12103881) For information on setting the oil pressure switch polarity using the display panel, see page 5-43. Lube Oil Pressure Switch The part number for the Lube Oil Pressure Switch is 309−0641−XX. The XX portion of the number is dependent the trip pressure point. Refer to Table 3-4 to select an appropriate lube oil pressure switch. If an oil pressure switch is used, the active state (active high or active low) of the switch must be configured using a PC based service tool or through the menus available with the operator panel. A software setting allows for selection of the active state of the switch. The Lube Oil Pressure Switch Polarity can be set to Active High or Active Low. FIGURE 3-11. PRESSURE SWITCH TABLE 3-4. AVAILABLE PRESSURE SWITCHES (309−0641) Set Point Contact (At Rest) No. of Terminals 309−0641−01 14 2.0 PSI Closed 1 309−0641−02 14 2.0 PSI Open 2 309−0641−03 14 2.0 PSI Closed 2 309−0641−04 9 1.5 PSI Open 2 309−0641−05 9 1.5 PSI Closed 1 309−0641−06 10 1.5 PSI Open 2 309−0641−07 20 2.0 PSI Closed 1 309−0641−08 20 2.0 PSI Closed 2 309−0641−10 20 3.0 PSI Closed 2 Part No. 3-12 309−0641−13 30 3.0 PSI Closed 1 309−0641−14 4 1.0 PSI Open 2 309−0641−15 5 1.0 PSI Open/Closed 3 309−0641−16 5 1.0 PSI Closed 1 309−0641−17 5 1.0 PSI Open 1 309−0641−18 5 1.0 PSI Open 2 309−0641−19 14 2.0 PSI Closed 2 309−0641−20 20 2.0 PSI Closed 1 All pressure switches have steel base and nipple construction. 3-13 CONTROL BOARD CONNECTIONS J12 − Genset CT connections (see Table 3-8) The 1302 control board includes the following connectors (see Figure 3-12). J17 − Field winding connections (see Table 3-9) CAUTION Reversing the power supply connections on TB1 and/or TB15 can permanently damage the control. Refer to drawing 630−3270 for proper connections. J18 − Field power connections (see Table 3-10) TB1 − Customer connections (see Table 3-5 and sheet 3 of Figure 7-1) J22 − Alternator voltage sense connections (see Table 3-12) TB15 − Tools interface connections (see Table 3-6 and sheet 3 of Figure 7-1) J25 − Display connections (see Table 3-13) J11 − Engine connections (see Table 3-7) J22 (ALTERNATOR VOLTAGE SENSE) J20 − Genset connections (see Table 3-11) Mating connector and connector pin part numbers for the control board are listed in Table 3-14. J12 (CT CONNECTIONS) TB15 (PC BASED SERVICE TOOL) J17 (FIELD POWER) J11 (ENGINE CONNECTIONS) J18 (FIELD POWER) J20 (GENSET CONNECTIONS) J25 (DISPLAY CONNECTIONS) TB1 (CUSTOMER CONNECTIONS) FIGURE 3-12. CONTROL BOARD CONNECTIONS 3-14 TABLE 3-5. TB1 − CUSTOMER CONNECTIONS Pin Signal Name Connect To TB1-1 PCCNet A Network Data A TB1-2 PCCNet B Network Data B TB1-3 PCCNet Shield / B+ Return TB1-4 Ready to Load TB1-5 B+ Output (5A) TB1-6 Configurable Relay 1 − A TB1-7 Configurable Relay 1 − B TB1-8 Configurable Relay 2 − A TB1-9 Configurable Relay 2 − B TB1-10 Remote Start Return TB1-11 Remote Start TB1-12 Configurable Input 1 Pull to TB1-13 to activate input. Remove from TB1-13 to deactivate input. TB1-13 Configurable Input − Common Common for the two fault inputs TB1-14 Configurable Input 2 Pull to TB1-13 to activate input. Remove from TB1-13 to deactivate input. TB1-15 Remote E-STOP Return Remote normally closed E-STOP switch TB1-16 Remote E-STOP Remote normally closed E-STOP switch 20ma Low Side Relay Driver TABLE 3-6. TB15 − TOOLS INTERFACE CONNECTIONS Connector Pin TB15-1 Signal Name Connect To Return Network Power Supply Return TB15-3 RS-485 Data A Network Data A TB15-4 RS-495 Data B Network Data B TB15-5 PCCNet System Wakeup TB15-2 3-15 TABLE 3-7. J11 − ENGINE CONNECTIONS Signal Name Connector Pin Connect To J11-1 Oil Pressure Sender (Active) +5V J11-2 Oil Pressure Sender or Switch Return J11-3 Oil Pressure Sender J11-4 Governor Drive − Governor PWM low side driver J11-5 Governor Drive + Governor drive + (for low side driver) J11-6 Relay Coil B+ Coil for glow plug relay J11-7 Glow Plug / Ignition Control Relay Driver Low side of the relay coil J11-8 Magnetic Pickup Shield J11-9 Magnetic Pickup Supply J11-10 Magnetic Pickup Return J11-11 Coolant Temperature Sender J11-12 Coolant Temperature Sender Return J11-13 NA J11-14 NA J11-15 NA J11-16 NA J11-17 ECM CAN Shield J11-18 B+ Return for ECM J11-19 ECM CAN Low J11-20 ECM CAN High J11-21 Keyswitch Low Side Driver Low side of keyswitch relay coil J11-22 Keyswitch Relay Coil B+ High side of keyswitch relay coil J11-23 NA J11-24 NA TABLE 3-8. J12 − GENSET CT CONNECTIONS Signal Name Connector Pin J12-1 CT1 J12-2 CT2 J12-3 CT3 J12-4 CT1 Common J12-5 CT2 Common J12-6 CT3 Common Connect To 3-16 TABLE 3-9. J17 − FIELD WINDING CONNECTIONS Connector Pin Signal Name Connect To J17-1 Field + X+ (F1) J17-2 Field − XX− (F2) TABLE 3-10. J18 − FIELD POWER CONNECTIONS Connector Pin Signal Name Connect To J18-1 PMG 1 / Shunt L1 240 Vmax Excitation Source J18-2 PMG 2 / Shunt L2 240 Vmax Excitation Source J18-3 NC TABLE 3-11. J20 − GENSET CONNECTIONS Connector Pin Signal Name Connect To J20-1 Chassis ground J20-2 B+ Return J20-3 Switched B+ Low Side Driver J20-4 B+ Return J20-5 Discrete Input Return J20-6 Discrete Input Return J20-7 B+ Return J20-8 Discrete Input Return J20-9 B+ Input J20-10 B+ Input J20-11 Starter Disconnect Input J20-12 B+ Return J20-13 Relay Coil B+ Supply Switched B+ (Switched B+ might be connected to E−Stop B+ instead) J20-14 FSO Relay Driver Low Side of FSO Relay Coil J20-15 Starter Relay Driver Low Side of Starter Relay Coil J20-16 NA J20-17 Configurable Input #3 Defaulted to Low Coolant Level Switch J20-18 Configurable Input #4 Defaulted to Low Fuel Level Switch J20-19 NA J20-20 B+ Input J20-21 B+ Input J20-22 Alt Flash Input Charging alternator TABLE 3-12. J22 − GENSET VOLTAGE SENSING CONNECTIONS Connector Pin Signal Name Connect To J22-1 L1 600 Vmax L1 Source J22-2 L2 600 Vmax L2 Source J22-3 L3 600 Vmax L3 Source J22-4 LN 600 Vmax LN Source 3-17 TABLE 3-13. J25 − DISPLAY CONNECTIONS Signal Name Connector Pin Connect To J25-1 Local Status Low side of local status lamp J25-2 Local E-Stop Normally closed local E-Stop switch J25-3 PCCNet B Network Data B J25-4 PCCNet A Network Data A J25-5 System wakeup J25-6 Discrete Input Return J25-7 Discrete Input Return J25-8 B+ Return J25-9 B+ Return / PCCNet J25-10 Manual J25-11 Auto J25-12 B+ TABLE 3-14. CONNECTOR PART NUMBERS Connector Connector Housing CPG P/N Connector Pins Man/Man P/N CPG P/N Man/Man P/N J11 323−2161 Amp/Tyco / 790587−1 323−2466 Amp/Tyco / 770904−1/ 770988−1/171637−1 J12 323−1932 Amp/Tyco / 1−480704−0 323−1200 Amp/Tyco / 350536−1/350550−1 J17 323−2098 Amp/Tyco / 1−480698−0 323−1200 Amp/Tyco / 350536−1/350550−1 J18 323−2444 Amp/Tyco / 1−480700−0 323−1200 Amp/Tyco / 350536−1/350550−1 J25 323−2445 Amp/Tyco / 770581−1 323−2466 Amp/Tyco / 770904−1/ 770988−1/171637−1 J22 323−2226−03 Amp/Tyco / 282809−4 J20 323−2466 323−2466 Amp/Tyco / 770904−1/ 770988−1/171637−1 Amp/Tyco / 770586−1 3-18 ELECTRONIC GOVERNOR CONNECTIONS The electronic fuel actuator is driven by the output of the Governor Power Module. Use twisted pair wires minimum 1 sq mm (16 Gage). Power to the Governor Power Module is derived from the genset starting battery but should be connected to the Governor Power Module as indicated in the diagrams “Applications without FSO” (see Figure 3-13) and “Applications with FSO” (see Figure 3-14) as appropriate. This section describes the installation of the optional Electronic Governor Power Module. A description of the Governor Power Module connections are listed in Table 3-15. Module connector pat numbers are listed in Table 3-16. TABLE 3-15. GOVERNOR MODULE CONNECTIONS Connector Pin Signal Name Comments P1-1 Gov drive − P1-2 Gov drive + P1-3 B+ Battery + P1-4 Actuator Low side of actuator P1-5 Return GND TABLE 3-16. CONNECTOR PART NUMBERS FOR THE GOVERNOR MODULE CONNECTIONS Connector Housing Ref P1 Internal P/N 0323−2216 Connector Pins Man / P/N Internal P/N Amp/Tyco / 1−480763−0 Man / P/N 0323−1200 Amp/Tyco / 770008−3 B+ E−Stop B+ Fuse FSO J20−14 Relay Governor Power Stage 1302 Series Control PWM Fuel Actuator J11−5 J11−4 GND FIGURE 3-13. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITHOUT FSO 3-19 E−Stop B+ FSO FSO B+ J20−14 Relay Governor Power Stage 1302 Series Control PWM J11−5 J11−4 GND FIGURE 3-14. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITH FSO KIT INSTALLATION c. The negative (−) cable from the battery is disconnected to prevent accidental starting. Refer to the control wiring diagram included in Section 7 when installing the items included in this kit. This wiring diagram also includes information on wiring items (annunciator, I/O module, and governor power module) not included in this kit. While the harnesses included in this kit should be long enough for all types of installations, it is a good idea to make sure that the distance between two connecting parts does not exceed the length of the harness. Excess wiring may be trimmed if it interferes with your installation. 2. Select a suitable location (see “Mounting Guidelines” on page 3-1) and mount the 1302 control board using M4 hardware. Figure 3-15 shows the control board dimensions. The outside dimensions do not include necessary clearance for wire connections. NOTE: To check the actual genset output, True (calibrated) RMS meter should be usedMounting hardware for the 1302 control and the operator panel is not included in this kit. The instructions below include suggested hardware sizes. 1. Make sure the generator set is shut down and disabled: a. The generator set Run/Off/Auto switch is in the Off position and the generator is cool (to the touch). DIMENSIONS ARE IN MILLIMETERS b. The battery charger (if equipped) is turned off and disconnected. FIGURE 3-15. 1302 CONTROL FOOTPRINT 3-20 3. Install the operator panel and operator panel harness. a. Select a suitable location and mount the panel using #6−32 hardware. Figure 3-16 shows the operator panel dimensions. The operator panel must be mounted within 72 inches (1828.8 mm) of the control board. b. Install the operator panel harness (see Figure 3-17). Plug the P1 connector into the display (either J1 or J2) and plug the P25 connector into the J25 connector on the control board. DIMENSIONS ARE IN MILLIMETERS FIGURE 3-16. OPERATOR PANEL FOOTPRINT DIMENSIONS ARE IN FEET FIGURE 3-17. OPERATOR PANEL HARNESS 3-21 4. Install the genset harness (see Figure 3-18). f. Connect the harness X+ and XX− wires to the generator field windings. a. Make sure the current transformers installed are appropriate for use with a 1302 series control. Refer to the “Guidelines for Current Transformers” subsection, starting on page 3-3. g. Make the connections for the excitiation source (shunt or PMG). For shunt applications, connect J18-1 and J18-2 to the low side of L1 and L2. For PMG applications, connect J18-1, J18-2, and 18-3 to P2, P3, and P4 on the permanent magnet. J18-1 and J18-2 are 240V maximum inputs. b. Make sure the battery charging alternator installed is one of the types listed in the “Battery Charger Alternator Connections” subsection, starting on page 3-8. c. Make sure the alternator connections are appropriate for your installation (see “Alternator Connections” on page 3-9). CAUTION Do not connect J18-1 directly to L1 in 480V applications. Making this connection will blow up the 1302 control board. d. Connect the six harness CT wires to the current transformers. h. Connect the harness P12, P17, P18, and P22 connectors to the mating connectors on the 1302 control board. e. Connect the four harness sense wires to the alternator. DIMENSIONS ARE IN INCHES FIGURE 3-18. GENSET HARNESS 3-22 wires to the appropriate locations indicated in Figure 3-19. 5. Install the engine harness. a. Connect the engine harness wires marked P11-2 and P11-3 to the oil pressure harness wires marked J11-5, J11-6, and J11-17 (see Figure 3-20). NOTE: If your installation does not include an electronic governor, tie back the wires marked P11-4 and P11-5. b. Connect the engine harness wires marked P11-11 and P11-12 to the coolant temperature sensor harness wires marked P11-11 and P11-12 (see Figure 3-21). e. Connect the engine harness P11 and P20 connectors to the 1302 control board J11 and J20 connectors. 6. Install the oil pressure sensor and harness. c. If installed, connect the engine harness wires marked P11-8, P11-9, and P11-10 to the magnetic pickup sensor on the engine. If not installed, tie the wires back. a. Install the sensor on the engine. b. Connect the harness connector to the oil pressure sensor. d. Connect the remaining engine harness FIGURE 3-19. ENGINE HARNESS 3-23 DIMENSIONS ARE IN FEET FIGURE 3-20. OIL PRESSURE SENSOR HARNESS DIMENSIONS ARE IN FEET FIGURE 3-21. COOLANT TEMPERATURE SENSOR HARNESS FIGURE 3-22. OIL PRESSURE SENSOR 7. Install the coolant temperature sensor and harness. a. Install the sensor on the radiator. b. Connect the harness connector to the temperature sensor. FIGURE 3-23. COOLANT TEMPERATURE SENSOR 11. Use the operator panel to access the Service menus (see Section 5) and/or a PC service tool to adjust the appropriate control parameters. 8. Reconnect the generator starting battery cables (positive [+] cable first). a. For general information on all available parameters that can be adjusted, see “Setup, Trims, and Adjustments” on page 3-26. 9. Connect the battery charger (If equipped). 10. Press any button on the operator panel to “wake up” the control. 3-24 b. Follow the setup procedures for current transformers listed on page 3-4. − 12V/24V batteries c. For information on alternator control adjustments, see page 3-36. − Cycle cranking − Engine starting − Spark ignition power/Glow plug control d. For information on genset tuning, see page 3-36. − Genset cooldown start and stop time delays e. For information on other control functions, see page 3-46. These include: − Remote start mode − Remote emergency stop f. For information on the Battle Short option, see page 3-55. 12. Place the generator set Run/Off/Auto switch in the desired position. 3-25 SETUP, TRIMS, AND ADJUSTMENTS While applying a 1302 series control to a new application, make sure the parameters listed in Table 3-17 have appropriate values. Many of these can be adjusted using the operator panel but some require use of a genset Manufacturing Tool or a PC based service tool. NOTE: To check the actual genset output, True (calibrated) RMS meter should be usedSection 5 includes information on all of the Service menus that are used to adjust parameters using the 1302 operator panel. The last column in Table 3-17 lists the page references in Section 5 where you can find information on how to adjust each parameter. Configurable / Model Specific features like nominal voltage, frequency, KVA rating, Engine protection values Alternator Protection values, AVR and Governor Gains, CT Ratio, etc have to be assigned appropriate values at manufacturing time. TABLE 3-17. 1302 CONTROL PARAMETERS Adjusted Using Group Adjustj ment Adjustj ment Parameter Name Limits PC Based Operator Service Tool Panel Lower Limit Units Upper Limit Pg Ref Voltage Adjust X −5 5 % — Start Time Delay (V2.79 and prior with HMI211 7.10 or prior) X X 0 300 Sec 5-8 Start Time Delay (V2.80 and later with HMI211 7.20 or later) X X 0 3600 Sec 5−8 Stop Time Delay X X 0 600 Sec 5-8 V/Hz Knee Frequency X X 0 10 Hz 5-17 V/Hz Rolloff Slope X X 0 5 % 5-17 3-26 TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Group Setup p– G Genset Parameter Name Limits PC Based Operator Service Tool Panel Lower Limit Upper Limit Units Pg Ref Nominal Battery Voltage X X 12 24 VDC 5-41 AVR Enable X X Enable or Disable NA NA 5-11 Excitation Source X X Shunt or PMG 5-39 Excitation / Line Frequency Gain X X 1,2,4 5-39 Nominal Voltage X X 190 480 V AC 5-8 Alternator Nominal Frequency X X 50 or 60 N/A Hz 5-8 Single Phase 60Hz Standby kVA Rating X X 0 2000 KVA 5-39 Three Phase 60Hz Standby kVA Rating X X 0 2000 KVA 5-39 Single Phase 50Hz Standby kVA Rating X X 0 2000 KVA 5-39 Three Phase 50Hz Standby kVA Rating X X 0 2000 KVA 5-39 Single Phase 60Hz Prime kVA Rating X X 0 2000 KVA 5-41 Three Phase 60Hz Prime kVA Rating X X 0 2000 KVA 5-41 Single Phase 50Hz Prime kVA Rating X X 0 2000 KVA 5-41 Three Phase 50Hz Prime kVA Rating X X 0 2000 KVA 5-41 Frequency to Speed Gain Select X X 20, 30, or 60 N/A RPM/Hz 5-39 Oil Pressure Switch Polarity X Active Low or Active High N/A N/A 5-43 3-27 TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Group Setup p– G Genset (Continued) Parameter Name PC Based Operator Service Tool Panel Oil Pressure Sensor Type X Electronic Governor Enable X X Lower Limit Units Upper Limit Pg Ref 2 or 3 wire N/A N/A 5-43 Enable or Disable NA NA — Yes or No N/A N/A 5-11 Enable or Disable N/A N/A — X Yes or No N/A N/A 5-8 X Glow Plug Enable Limits X Fuel System X X Diesel or Gas N/A N/A 5-8 Fuel Burn Time Delay X X 0 10 Sec 5-8 Magnetic Pickup Enable X Enable or Disable None N/A — X Yes or No None N/A 5-13 Flywheel Teeth X X 0 255 Teeth 5-39 Dither Factor X X 0 30 % 5-19 Maximum Governor Duty Cycle X X 0 100 % 5-19 AVR Gain Adjust X X 5 1000 % 5-17 AVR K2 Gain Adjust X X 5 1000 % 5-17 AVR D Gain Adjust X X 95 105 % 5-17 K1 (Regulator Gain 50Hz) X 0 65535 NA — K1 (Regulator Gain 60Hz) X 0 65535 NA — K2 (Regulator Integral 50Hz) X 0 65535 NA — K2 (Regulator Integral 60Hz) X 0 65535 NA — K3 (Regulator K3 Gain 50Hz) X 0 65535 NA — K3 (Regulator K3 Gain 60Hz) X 0 65535 NA — Damping Effect (60Hz) X 0.2 0.99 NA — Damping Effect (50Hz) X 0.2 0.99 NA — Cycle Crank Attempts X X 1 7 Attempts 5-11 Cycle Crank Engage Time X X 3 30 Sec 5-11 Cycle Crank Rest Time X X 0 60 Sec 5-11 Remote / Local Display N/A X Remote or Local N/A N/A 5-15 X Enable or Disable NA NA 5-11 Battle Short Enable Battle Short Switch Input X X Configurable input 1−4 or operator panel N/A N/A 5-11 Governor Ramp Time X X 0 30 Sec 5-19 3-28 TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Group Setup – ECM CAN Setup − Configurg able bl I/O Parameter Name Limits PC Based Operator Service Tool Panel Lower Limit Upper Limit Units Pg Ref ECM CAN Enabled X Disable, J1939, PGI Keyswitch Reset Delay X 1 10 Sec — Keyswitch On Time Delay X 1 10 Sec — CAN Datalink Failure Retries X 0 10 Times — ECM Datasave Time X 30 60 Sec — Configurable Input #1−4 Function X Active open or Active closed N/A 5-21 Configurable I/P #1 AnnActive LED X NO_ANNUN_M N/A APPING, CUSTOMER_F AULT_1, CUSTOMER_F AULT_2, CUSTOMER_F AULT_3, GEN_SUPPLY _LOAD, CHARGER_AC _FAIL, LOW_COOLAN T_LEVEL, LOW_FUEL_L EVEL 5-21 Configurable I/P #2 AnnActive LED X NO_ANNUN_M N/A APPING, CUSTOMER_F AULT_1, CUSTOMER_F AULT_2, CUSTOMER_F AULT_3, GEN_SUPPLY _LOAD, CHARGER_AC _FAIL, LOW_COOLAN T_LEVEL, LOW_FUEL_L EVEL 5-21 X 3-29 — TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Group Parameter Name PC Based Operator Service Tool Panel Limits Lower Limit Upper Limit Units Pg Ref Configurable I/P #3 AnnActive LED X NO_ANNUN_M N/A APPING, CUSTOMER_F AULT_1, CUSTOMER_F AULT_2, CUSTOMER_F AULT_3, GEN_SUPPLY _LOAD, CHARGER_AC _FAIL, LOW_COOLAN T_LEVEL, LOW_FUEL_L EVEL 5-21 Configurable I/P #4 AnnActive LED X NO_ANNUN_M N/A APPING, CUSTOMER_F AULT_1, CUSTOMER_F AULT_2, CUSTOMER_F AULT_3, GEN_SUPPLY _LOAD, CHARGER_AC _FAIL, LOW_COOLAN T_LEVEL, LOW_FUEL_L EVEL 5-21 3-30 TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Group Setup − Configurg bl I/O able Regulated Voltage g Adj t Adjust Parameter Name Limits PC Based Operator Service Tool Panel Lower Limit Units Upper Limit Configurable Fault Input #1−4 Active State Select X X Active open or Active closed Configurable Fault Input #1−4 Fault Level Response X X Warning, Shutdown, or None Configurable #1−4 Input Text Line 1 X X 5-21 Configurable #1−4 Input Text Line 2 X X 5-21 Customer Output 1/2 Event X X 0 9999 Fault Code Numbers 5-25 Voltage Regulator Calibration 50Hz X X 0.9 1.1 % 5-27 Voltage Regulator Calibration 60Hz X X 0.9 1.1 % 5-27 Alternator L1−N 50Hz Voltage Display Adjust X X 0.8 1.1 % 5-27 Alternator L2−N 50Hz Voltage Display Adjust X X 0.8 1.1 % 5-27 Alternator L2−N 50Hz Voltage Display Adjust X X 0.8 1.1 % 5-27 Alternator L1−N 60Hz Voltage Display Adjust X X 0.8 1.1 % 5-27 Alternator L2−N 60Hz Voltage Display Adjust X X 0.8 1.1 % 5-27 Alternator L2−N 60Hz Voltage Display Adjust X X 0.8 1.1 % 5-27 Alternator L1 50Hz Current Adjust X X 0.8 1.2 % 5-27 Alternator L2 50Hz Current Adjust X X 0.8 1.2 % 5-27 Alternator L2 50Hz Current Adjust X X 0.8 1.2 % 5-27 3-31 N/A Pg Ref 5-21 5-21 TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Group Regulated Voltage g Adj t Adjust (Continued) Protection – Engine g Parameter Name Limits PC Based Operator Service Tool Panel Lower Limit Units Upper Limit Pg Ref Alternator L1 60Hz Current Adjust X X 0.8 1.2 % 5-27 Alternator L2 60Hz Current Adjust X X 0.8 1.2 % 5-27 Alternator L2 60Hz Current Adjust X X 0.8 1.2 % 5-27 High AC Voltage Threshold X X 105 125 % 5-45 High AC Voltage Delay X X 1 10 Sec 5-45 Low AC Voltage Threshold X X 50 95 % 5-45 Low AC Voltage Delay X X 2 20 Sec 5-45 Under Frequency Threshold X X 2 10 Hz 5-45 Under Frequency Delay X X 500 2000 1/2 cycles 5-45 Overfrequency Enable X Enable or Disable N/A NA Overfrequency Threshold X X 2 10 Hz 5-45 Overfrequency Delay X X 100 2000 1/2 cycles 5-45 High AC Current Shutdown Delay X X 2 60 Sec 5-45 Overspeed Shutdown Threshold 50Hz X X 0 8192 Rpm 5-49 Overspeed Shutdown Threshold 60Hz X X 0 8192 Rpm 5-49 LOP Shutdown Threshold X X 0 100 Psig 5-51 LOP Shutdown Delay X X 2 15 Sec 5-51 LOP Warning Threshold X X 0 100 Psig 5-49 LOP Warning Delay X X 2 15 Sec 5-49 LCT Warning Threshold X X 32 100 deg f 5-53 HCT Shutdown Threshold X X 180 300 deg f 5-51 HCT Shutdown Delay X X 2 10 Sec 5-51 HCT Warning Threshold X X 150 290 deg f 5-51 HCT Warning Delay X X 2 10 sec 5-51 12V Low Battery Threshold X X 11 13 VDC 5-41 24V Low Battery Threshold X X 22 27 VDC 5-41 Low Battery Fault Delay X X 2 60 Sec 5-43 High Battery Fault Delay X X 14 17 VDC 5-41 24V High Battery Threshold X X 28 34 VDC 5-41 12V High Battery Threshold X X 2 60 Sec 5-43 12V Weak Battery Threshold X X 6 10 VDC 5-41 3-32 — TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.) Adjusted Using Parameter Name Group Limits PC Based Operator Service Tool Panel Lower Limit Units Upper Limit Pg Ref Protection – Engine (Continued) 24V Weak Battery Threshold X X 18 21 VDC 5-41 Weak Battery Fault Delay X X 1 5 sec 5-43 Fault Hi History Reset Runs X — Reset Start Attempts X — NFPA 110 Status Logical Bits 1−7, Annunciator Discrete Signals (Configurable via PCC1302 A universal annunciator connected in a network indicates and annunciates the active faults received from the PCC1302. The NFPA 110 Status Logical bits 1 to 7 (i.e. LEDs) of an annunciator can be mapped to indicate and annunciate the active faults corresponding to each of the four configurable inputs of PCC1302 as defined by the user. For this, the (trim) ”Configurable Input #n Function” (n = 1, 2, 3, or 4) should be set as ”Fault Input” and the LED should be mapped through (trim) ”Configurable I/P# n Ann Active LED” (n = 1,2,3 or 4), where, ”Configurable I/P# 1 Ann Active LED”) is applicable only for ”Configurable Input #1 Function”. ”Configurable I/P# 2 Ann Active LED” is applicable only for ”Configurable Input #2 Function”. ”Configurable I/P# 3 Ann Active LED” is applicable only for ”Configurable Input #3 Function”. ”Configurable I/P# 4 Ann Active LED” is applicable only for ”Configurable Input #4 Trim Function” Each active fault corresponding to the respective configurable input of PCC1302 is annunciated and indicated according to the LEDs mapped by the user to the ”Configurable Input #n Function” (n = 1, 2, 3, or 4) set as ”Fault Input”: Refer the table below for more information on setup and expected observations: TABLE 3-18. 1302 CONTROL SETUP Input # ”Configurable I/P# n Ann Active LED” (n = 1,2,3 or 4) set to one of the following NO_ANNUN_MAPPING ”Configurable g Input #1 # Function” F i ” = CUSTOMER_FAULT_1 Fault Input and ”Configurable I/P# 1 Ann Active CUSTOMER_FAULT_2 LED” LED CUSTOMER_FAULT_3 Active Condition (LED# indication) on Annunciator No bit set = NONE Active Fault Condition None Bit 1 set = LED 1 Annunciator Fault 1 Bit 1 set = LED 2 Annunciator Fault 2 Bit 1 set = LED 3 Annunciator Fault 3 GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset Supplying Load CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC Failure 3-33 Active FC# 1311 TABLE 3-18. 1302 CONTROL SETUP (CONT.) Input # ”Configurable I/P# n Ann Active LED” (n = 1,2,3 or 4) set to one of the following Active Condition (LED# indication) on Annunciator NO_ANNUN_MAPPING ”Configurable Ing F i ” = CUSTOMER_FAULT_1 put #1 Function” Fault Input and ”Configurable I/P# 1 Ann Active CUSTOMER_FAULT_2 LED LED” CUSTOMER_FAULT_3 No bit set = NONE Active Fault Condition None Bit 1 set = LED 1 Annunciator Fault 1 Bit 1 set = LED 2 Annunciator Fault 2 Bit 1 set = LED 3 Annunciator Fault 3 GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset Supplying Load CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC Failure LOW_COOLANT_LEVEL Bit 1 set = LED 6 Low Coolant Level LOW_FUEL_LEVEL Bit 1 set = LED 7 Low Fuel Level NO_ANNUN_MAPPING ”Configurable g Input #1 # Function” F i ” = CUSTOMER_FAULT_1 Fault Input and ”Configurable I/P# 1 Ann Active CUSTOMER_FAULT_2 LED” LED CUSTOMER_FAULT_3 No bit set = NONE None Bit 1 set = LED 1 Annunciator Fault 1 Bit 1 set = LED 2 Annunciator Fault 2 Bit 1 set = LED 3 Annunciator Fault 3 GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset Supplying Load CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC Failure NO_ANNUN_MAPPING ”Configurable g Input #1 Function” F i ” = CUSTOMER_FAULT_1 Fault Input and ”Configurable I/P# 1 Ann Active CUSTOMER_FAULT_2 LED LED” CUSTOMER_FAULT_3 No bit set = NONE None Bit 1 set = LED 1 Annunciator Fault 1 Bit 1 set = LED 2 Annunciator Fault 2 Bit 1 set = LED 3 Annunciator Fault 3 GEN_SUPPLY_LOAD Bit 1 set = LED 4 Genset Supplying Load CHARGER_AC_FAIL Bit 1 set = LED 5 Charger AC Failure ALTERNATOR CONTROL ADJUSTMENTS The 1302 series control includes an integrated lineto-line sensing voltage regulation system that is compatible with shunt or PMG excitation systems. Active FC# 1312 1317 1318 The voltage regulation system is SCR type. Excitation power is derived either directly from the genset terminals or from a PMG stator. Power from either source is fed into the control thru J18. Positive volt- 3-34 age build up from residual levels is ensured by the use of efficient semiconductors in the power circuitry. AVR Enable/Disable Feature The 1302 series control provides automatic voltage regulating capability for the generator set when the AVR feature is enabled on the genset. It has a field adjustment trim to enable or disable the AVR feature. The trim parameter for this is AVR Enable = Enable / Disable. protection of the excitation system, by reducing the output voltage proportionally with speed. The voltage rolloff set point and rate of decay (i.e., the slope of the volts/hertz curve) is adjustable in the control. Major system features include. %Volts/Hz rolloff supports the engine speed recovery under block loading. The slope setting (%volts/Hz) range is 0.0−5.0% of rated with 0.1% increment. The knee frequency range is 0.0−10.0Hz less than the nominal frequency with 0.1 Hz increment. For information on enabling/disabling the AVR feature using the operator panel, see page 5-11. Digital Output Voltage Regulation The 1302 series control supports digital output voltage regulation as defined below. Voltage setpoint algorithm sets the level of the automatic voltage regulation. It is adjustable. The maximum allowed rated current for the field coil for the regulation is 4.0 Amps RMS and maximum 6.0 Amps for 10 seconds. The control provides voltage ramping at startup if the AVR algorithm is enabled, such that voltage overshoot can be controlled. AVR boot enable logic supports the step by step voltage ramping. A PC based service tool allows the operator to adjust the output voltage within plus or minus 5.0% of rated voltage. Torque-Matched Volts/Hz Overload Control A frequency measuring circuitry monitors the generator output and provides output underspeed For information on adjusting rolloff and knee frequency settings using the operator panel, see page 5-17. Battleshort Mode The 1302 series control can be programmed to work in battleshort mode by loading the battleshort feature with a manufacturing tool or PC based service tool. The controller then can accept Configurable Input 1−4 as battle short switch inputs. If an operator panel is used, it can be also selected as a source of input by selecting appropriate input source value for the trim. Battleshort mode is designed to work only in critical load circumstances. While in battleshort mode the 1302 series control will ignore most warnings and shutdowns and will continue to operate as if no fault or shutdown exists on the system. For information on enabling/disabling the battleshort feature using the operator panel, see page 5-11. 3-35 GENSET TUNING The 1302 series control uses a standard 4 coefficient PID algorithm running at an execution rate of once per zero cross of the generator AC waveform. Standard values for the K1−K4 and damping terms for both 60 and 50Hz are listed in Table 3-19. Consider the following before making any adjustments. The values of K3, K4, and the damping factor are set for basic stability reasons and should not need to be adjusted, but they can be adjusted if necessary. The useful range of values for K2 is 200 to 1500. The value of 1500 for K2 can be a little too high or aggressive for some applications and cause “ringing” upon recovering from a load acceptance or offload transient situation. A value of K2 below 200 can cause the regulator to hit an integrator windup limit and should be avoided if possible. Set the correct value for the application. The value of K1 should be adjusted to meet the specification for percent off rated voltage during a load acceptance, and prevent large voltage overshoots during offloads and during engine/alternator startup. The value of K2 should be adjusted to control the recovery characteristics of the voltage during large load acceptance and rejection transients. Values of K2 which are too high can cause unstable voltage performance and values too low can cause slow performance or steady state voltage offset errors. In general, K1 increases and K2 decreases in value with increasing generator size, but can vary in different applications. V/Hz Curve The 1302 series control uses a simple breakpoint and slope approach to the V/Hz curve to allow for the matching of the torque curve of the engine during a large transient load acceptance. The two ad- justment points are the V/Hz Knee Frequency which set the point at which the V/Hz curve starts, and the V/Hz Roll−off Slope which sets the roll−off slope of the voltage setpoint as a function of frequency error. The default V/Hz settings are: Parameter Default Value V/Hz Knee Frequency 0.5 Hz V/Hz Roll-off Slope 2.2 %V/Hz The voltage set point command is calculated from the frequency error between commanded frequency and the actual frequency. For example, a voltage set point of 93.4% of nominal would be commanded if there is a frequency error of 3.5Hz under nominal. There is no offset to voltage for errors above nominal frequency. NOTE: To check the actual genset output, True (calibrated) RMS meter should be usedNote: There are only one V/Hz settings per calibration so the values must be used for both 50 and 60Hz operation. If a particular application requires vastly different V/Hz settings for 50Hz and 60Hz operation, it will be required to create separate software features for those applications. For information on how to adjust the slope and knee frequency using the operator panel, see page 5-17. TABLE 3-19. GOVERNOR GAINS FOR SMALL ENGINES Newage BC/UC Generators Under 200Kw 60Hz 50Hz K1 = 1000 K1 = 1000 K2 = 650 K2 = 650 K3 = 10000 K3 = 10000 K4 = 36429 K4 = 36429 Damping = 0.8 Damping = 0.8 3-36 Governor The 1302 series control’s governor also uses the 4 coefficient PID algorithm. There are gains for use at 50 and 60Hz operation. Standard values for the K1−K4 and damping terms for both 60 and 50 Hz for engines in the Cummins 4B3.9 and 6B5.9 range are listed in Table 3-20. TABLE 3-20. GOVERNOR GAINS FOR SMALL ENGINES 60Hz 50Hz GK1 = 1696 GK1 = 1200 GK2 = 240 GK2 = 300 GK3 = 28,800 GK3 = 28,800 GK4 (calc) = 7424 GK4 (calc) = 7424 Governor Damping = 0.936 Governor Damping = 0.936 Governor Tuning A good starting point for any new engine application is to start with a set of released gains for an engine of a similar type and size should they already exist. If a set of pre−developed gains are not available, the gains listed above should work well enough to start most engines and to allow them to run smoothly. The value of GK1 should be adjusted to meet the specification for percent off rated voltage during a load acceptance, to prevent large voltage overshoots during offloads, and during engine/alternator startup. The value of GK2 should be adjusted to control the recovery characteristics of the engine during large load acceptance and rejection transients. GK2 is a true integral type gain and is applied to the governor output as GK2 times the sum of all the previous governor error. Values of GK2 which are too high can cause unstable voltage performance and values too low can cause slow performance or steady state voltage offset errors. The values of GK3, GK4 and the Damping factor are used to set the basic steady state stability of the engine, but also influence the overall speed of response of the governor in transient situations. Adjustment of GK3 and the Damping factor is an iterative process started by finding the engine load level which produces the worst steady state engine performance (note: GK1 and GK2 may have to be ad- justed first to allow the engine to be transitioned smoothly into this) and adjusting GK3 until the best performance is observed, then doing the same for the Damping factor. Repeat this process at least once to ensure that the best possible values for GK3 and the Damping term have been determined. For information on how to adjust the GK1and GK2 values and the damping factor using the operator panel, see page 5-17. Engine Startup The 1302 series control applies fuel to the engine as described in the Speed Governor Algorithm and Adjustment section. Alternator Startup The alternator will be started up and brought to rated voltage when the engine speed reaches rated speed. The PWM command to the field coil will now be stepped through an AVR Boot Table until the sensed voltage goes above the value of the AVR Boot Threshold trim and if AVR feature is enabled. The regulator will now bring the voltage up to rated voltage. The purpose of the AVR Boot Table is to aid alternator startup whilst preventing overvoltage conditions. The value of the AVR Boot Table and the AVR Boot Threshold can be set to bring the voltage up both as quickly and as smoothly as possible, but should already be set in the calibration to their ideal values. The AVR Boot Table has different values depending on value of the Excitation Source trim. Setup for Gain Tuning In order to properly set up engine and alternator control parameters it is convenient to setup the PC based service tool to be used to monitor. The following are step-by-step procedures for determining engine and alternator control parameters. 1. Determine 60Hz governor gains, regulator gains, and V\Hz curve values with PMG excitation. a. Start the genset, bring it to rated speed and temperature, and adjust the GK3 and damping factor for 60Hz operation to allow the engine to run smoothly in steady state operation. NOTE: GK1 and/or GK2 may need to be adjusted to allow this to happen. Apply various loads up to 100% rated and verify the steady state operation at all load 3-37 speed very poorly. A V/Hz curve too shallow causes a very slow engine recovery from a transient. levels. Most engines have some load level which is inherently less stable than others and must be found to determine the correct value for GK3 and the damping factor. c. Re-verify steady state voltage and governor performance. NOTE: It is important to control the steady state performance of the engine. Unstable engine performance is carried over into the generator output voltage. Very fast increases or decreases in engine speed, even if the magnitude of the increase or decrease is small, tend to be carried into the alternator voltage as large increases and decreases in voltage at the same frequency as the engine speed changes. b. Do a series of load steps to determine the transient characteristics of the genset. Tuning of the governor GK1 and GK2 values, the settings of the V/Hz curve, and the values of K1 and K2 (mostly K1) for the regulator must be done concurrently. In general, these values should be adjusted to achieve the maximum possible performance from both the engine and the alternator. A production test spec (if available) should give the full load step transient performance levels for any given genset model. This is a very iterative process and many require some time to find the best combination of gains to fit the application. In general, adjust GK1 to control the peak frequency during transients and adjust GK2 to control the recovery shape of the frequency transient. A V/Hz slope too steep causes the engine to recover too quickly and recovers to nominal 2. Determine 50Hz governor gains, Regulator gains, and V/Hz curve values. Follow the same process as used at 60Hz. The order of 50Hz vs 60Hz testing can be reversed. 3. Determine the correct values for the governor startup parameters (see “Speed Governor Algorithm and Adjustment” below). a. Adjust the Initial Crank Fueling Command, Initial Crank Fueling Period, Crank Fueling Ramp Rate, and Max Crank Fueling Command parameters to control the way the engine transitions through the cranking stage of the engine startup. The controls default values should work well. b. The value of the Crank Exit Fueling Command parameter should be set to the governor duty at which the engine runs when at rated speed, or to a value slightly higher. Gain Tuning Parameters This is a list of all of the parameters which affect genset performance. A correct value should be determined for each of the parameters listed. NOTE: To check the actual genset output, True (calibrated) RMS meter should be usedFor any parameters that have something listed in the “Value” column, it is recommended that the parameter stay at that value during testing. Some parameters should never be changed during testing and are listed as never to be changed. 3-38 TABLE 3-21. GAIN TUNING PARAMETERS Parameter Value Comments AVR Parameters K1 (50Hz) Sets overall AVR gain in 50Hz applications. This is a true proportional gain which is multiplied against the voltage error signal. K2 (50Hz) Controls the recovery shape of voltage transients in 50Hz applications. This is a true integral gain which is multiplied against the sum of all previous errors. K3 (50Hz) Affects high frequency characteristics of the AVR algorithm in 50Hz applications. Adjust for voltage stability reasons. Damping Effect (50Hz) Affects high frequency characteristics of the AVR algorithm in 50Hz applications. Adjust for voltage stability reasons. K1 (60Hz) Sets overall AVR gain in 60Hz applications. This is a true proportional gain which is multiplied against the voltage error signal. K2 (60Hz) Controls the recovery shape of voltage transients in 60Hz applications. This is a true integral gain which is multiplied against the sum of all previous errors. K3 (60Hz) Affects high frequency characteristics of the AVR algorithm in 60Hz applications. Adjust for voltage stability reasons. Damping Effect (60Hz) Affects high frequency characteristics of the AVR algorithm in 60Hz applications. Adjust for voltage stability reasons. Engine Governing Parameters GK1 (50Hz) Sets overall governor gain in 50Hz applications. This is a true proportional gain which is multiplied against the frequency error signal. GK2 (50Hz) Controls the recovery shape of speed transients in 50Hz applications. This is a true integral gain which is multiplied against the sum of all previous errors. GK3 (50Hz) Affects high frequency characteristics of the governor algorithm in 50Hz applications. Adjust for frequency stability reasons. Governor Damping Effect (50Hz) Affects high frequency characteristics of the governor algorithm in 50Hz applications. Adjust for frequency stability reasons. GK1 (60Hz) Sets overall governor gain in 60Hz applications. This is a true proportional gain which is multiplied against the speed error signal. GK2 (60Hz) Controls the recovery shape of frequency transients in 60Hz applications. This is a true integral gain which is multiplied against the sum of all previous errors. GK3 (60Hz) Affects high frequency characteristics of the governor algorithm in 60Hz applications. Adjust for frequency stability reasons. Governor Damping Effect (60Hz) Affects high frequency characteristics of the governor algorithm in 60Hz applications. Adjust for frequency stability reasons. 3-39 TABLE 3-21. GAIN TUNING PARAMETERS (CONT.) Parameter Value Comments Engine Starting Parameters Initial Crank Fueling Duty Cycle The initial value assigned to Governor Duty Cycle at entry in Crank State Initial Crank Fueling Period The period for which the value of Initial Crank Fuel Duty Cycle is assigned to Governor Duty Cycle after entry in Crank State Crank Fueling Ramp Rate The Rate at which the value of Governor Duty Cycle is ramped up by during Crank State after expiration of the Initial Crank Fueling Period Maximum Crank Fueling The level to which the Governor Duty Cycle is limited during Crank State Crank Exit Fueling Command The Value at which the Governor Duty Cycle is held after disengaging the starter until the Governor is enabled. Governor Enable Speed The Value of speed above which the electronic governor starts controlling the value of Governor Duty Cycle Governor Ramp Time Sets the minimum governor speed reference ramp rate 3-40 Controller Calibration Voltage measurement for regulation The internal circuitry of the 1302 series control may need to be calibrated. There are three different components which may need this. They are: Voltage measurement for display Current measurement for display The internal circuits must be calibrated in the order listed in Table 3-22. TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS Component to be Calibrated Voltage Measurement for Regulation The goal of this is to calibrate the regulation circuitry so it regulates the genset to the desired nominal voltage. Calibration Method PC Based Service Tool 1. Connect to the control with your PC based service tool. 2. Verify the Nominal Voltage Trim is set to the desired value. 3. Adjust the trim Voltage Regulation Calibration 50Hz or Voltage Regulation Calibration 60Hz for your desired application. The effect of this trim is inverse on the regulated voltage. Increasing the trim, well lower the regulated voltage, and decreasing the trim will raise the regulated voltage. Adjust the trim so regulated voltage matches the desired nominal voltage measured with a known calibrated voltage meter. 4. Save the adjustments by doing a Save Trims with your PC based service tool. Operator Panel 1. View the Service Menu by holding down the “up” and “down” arrow keys on any of the operator menus (see Figure 3-24). 2. Select item 1, “Setup Menus”. 3. Enter setup menu password 574. 4. Select item 1, “Genset Service”. 5. Select item 1, and verify the “Volts AC” setting is correct for your application. If necessary, press the “Adjust” button and change the setting. and press the “Save” button. 6. Press the back button to return to the service menu. 7. Select item 3, “Meter Calib.” 8. Press the “Adjust” button and change the “Reg Volt Adj:” value. The effect of this trim is inverse on the regulated voltage. Increasing the percentage will decrease the regulated voltage. Decreasing the percentage will increase the regulated voltage. 9. Save the adjustments by pressing the “Save” button. Voltage Measurement for Display 1. Connect to the control with your PC based service tool. 2. Verify the Nominal Voltage Trim is set to the desired value. The trim Alternator Nominal Voltage is available at Adjustments AC Measurement Calibrations Voltage Measurement for Regulation. Set the Alternator Nominal Voltage to the voltage that the genset will generate. 3. Adjust the trim Alternator LX−N 50Hz Voltage Display Adjust or Alternator LX−N 60Hz Voltage Display Adjust trim for your application. Each line will need to be adjusted independently. The goal is to have the value read by the PC based service tool correspond to the actual voltage being produced. 4. Save the adjustments by doing a Save Trims with your PC based service tool. 3-41 1. View the Service Menu by holding down the “up” and “down” arrow keys on any of the operator menus (see Figure 3-25). 2. Select item 1, “Setup Menus”. 3. Enter setup menu password 574. 4. Select item 1, “Genset Service”. 5. Select item 3, “Meter Calib.” 6. Press the down arrow twice to scroll down to the “Metering Voltage Adjust” 7. Adjust the three parameters listed so the display voltage matches the voltage being produced by the genset. 8. Save the adjustments by pressing the “save” button. TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS (CONT.) Component to be Calibrated Current Measurement for Display Calibration Method PC Based Service Tool 1. Apply a load to the genset and monitor the current with a calibrated current meter. 2. Connect to the control with your PC based service tool. 3. Verify the CT ratio settings and power ratings are correct for your application. The Power Rating of the alternator is configurable with the trims located in Genset Power Ratings menu. The CT ratio adjustable trim is available at Features Genset Setup. Operator Panel 1. View the Service Menu by holding down the “up” and “down” arrow keys on any of the operator menus (see Figure 3-26). 2. Select item 1, “Setup Menus”. 3. Enter service menu password 574. 4. Select item 2, “Genset Setup”. 5. Enter the setup menu password 1209. 6. Verify with the display that the CT ratios and power rating are correct by scrolling through the available screens. 4. Adjust the LX 50Hz Current Adjust or LX 60Hz Current Adjust trim for your 7. Return to the Setup Menu screen by current application so the 1302 series press the back arrow twice. control measured current matches the current read by the know current me- 8. Select item 1, “Genset Service”. ter. Each of the three lines will have to 9. Select item 3, “Meter Calib.” be adjusted independently of each 10. Press the down arrow three times to other. scroll down to Metering Current Adjust. 5. Save the adjustments by doing a save trims with your PC based service tool. 11. Adjust the three parameters to match the current being displayed by the known current meter. 12. Save the adjustments by pressing the “Save” button. 3-42 NOTE: THE NUMBERS IN PARENTHESIS MATCH THE STEPS INCLUDED IN THE PROCEDURE LISTED IN TABLE 3-22. (1) (2) (3) ENTER “574” (4) (5) (5) (7) (6) (5) (8) ENTER VOLTS AC VALUE AND PRESS THE SAVE BUTTON ENTER REG VOLT ADJ VALUE AND PRESS THE SAVE BUTTON (9) (5) FIGURE 3-24. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR REGULATION 3-43 NOTE: THE NUMBERS IN PARENTHESIS MATCH THE STEPS INCLUDED IN THE PROCEDURE LISTED IN TABLE 3-22. (1) (2) (3) ENTER “574” (4) (5) (7) (6) (6) (7) ADJUST ALL THREE PARAMETERS AND PRESS THE SAVE BUTTON (8) FIGURE 3-25. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR DISPLAY 3-44 NOTE: THE NUMBERS IN PARENTHESIS MATCH THE STEPS INCLUDED IN THE PROCEDURE LISTED IN TABLE 3-22. (1) (2) (9) (3) ENTER “574” (10) (4) (8) (7) (6) (10) (5) ENTER “1209” (6) (10) (6) (10) (6) (6) (6) (11) (12) ADJUST ALL THREE PARAMETERS AND PRESS THE SAVE BUTTON FIGURE 3-26. OPERATOR PANEL MENUS FOR CALIBRATING CURRENT MEASUREMENT FOR DISPLAY 3-45 1302 CONTROL FUNCTIONS Remote Start Mode The 1302 series control accepts a ground signal from remote devices to automatically start the generator set and immediately accelerate to rated speed and voltage. The control can incorporate a time delay start. For information on how to set a start time delay using the operator panel, see page 5-8. Remote Emergency Stop For operation of the genset, a closed relay contact between TB1-15 and TB1-16 must be present. The control enters an emergency stop mode when the short is removed. Before the genset can be restarted, the control must be manually reset by re-applying the short and acknowledging the fault. The E-stop circuit contains two parallel paths. One path is fed into the micro-processor for status processing. The second path is fed directly into the relay drivers, disabling them when an E-stop is present. Local Emergency Stop For operation of the genset, a short between J25-2 and J25-6 must be present. The control enters an emergency stop mode when the short is removed. Before the genset can be restarted, the control must be manually reset by re-applying the short and acknowledging the fault. The E-stop circuit contains two parallel paths. One path is fed into the micro-processor for status processing. The second path is fed directly into the relay drivers, disabling them when an E-stop is present. Emergency Stop It is also required that there be a physical interruption of the FSO and the starter (and, optionally, Local E−Stop Contact 1 Local E−Stop Switch switched B+) when an emergency stop is active. In order to do this, add a second E-stop contact in series with B+ and the FSO relay coil. Figure 3-27 illustrates one possible way to do this. Power to the fuel shutoff valve is provided serially through one contact of the two contact E-stop switch. The connection point is called E−Stop B+. Referring to wiring diagram: 630−3270 for complete illustration. 12/24V Battery The 1302 series control provides 12 and 24 VDC battery operation capability for genset system. It requires battery voltage input from the genset starter batteries. The control system provides a field adjustable trim to select either 12V/24V battery operations for selection of the internal thresholds to this feature. The trim parameter for this is Nominal Battery Voltage and the default trim is set at 12 VDC. For information on how to set the nominal battery voltage using the operator panel, see page 5-41. Engine Starting The control system supports automatic engine starting. Primary and backup start disconnects are achieved by one of the following three methods: magnetic pickup, battery charging alternator feedback, or main alternator output frequency. Cycle Cranking The 1302 series control can be configured for the number of starting cycles (1 to 7) and duration of crank and rest periods. The control includes starter protection algorithms to prevent the operator from specifying a starting sequence that might be damaging. Remote E−Stop Contact 1 Remote E−Stop Switch B+ Local E−Stop Contact 2 1302 Series Control E−Stop B+ (To Relay Contacts) Remote E−Stop Contact 2 FIGURE 3-27. EMERGENCY STOP CONTACTS 3-46 For information on how to set the cycle crank attempts using the operator panel, see page 5-11. Spark Ignition Power/Glow Plug Control Pin J11-7 on the 1302 series control is dual purpose. Glow Plug Control Glow plug is used as a Cold starting aid. Glow plugs heat up the air going in for combustion for Diesel Engine. Glow plug is used to improve the starting ability of engines and to reduce the white smoke during cold start. In PCC1302 when Glow Plug Enable = Enabled and Fuel System = Diesel the Glow Plug Function is enabled and control will preheat the engine starting glow plugs. Pin J11−7 on the PCC1302 control can be used to drive Glow Plugs via external Relay. Setting Glow Plug Enable = Disabled or Fuel System = Gas, disables the Glow Plug Function. Total Glow Time respectively based on reading of Engine Coolant Temperature as shown in the graph above. Cranking will start after the Preheat Time has expired. The Glow Plug Output will remain on until the Total Glow Time has expired. The Control commands the glow plugs to enable when the control. a. Detects that the genset has received a valid start command. b. Determines teh preheat time and total glow times as the function of the Engine Coolant Temperature. c. Turns off the glow plug during the normal stop or during the fault shutdown or during the cyclical crank attempts or if the total glow time has expired. Preheat Processing Preheat processing logic has three associated trims as shown in Table 3−22 TABLE 3-23. PREHEAT PROCESSING TRIMS TABLE Sr. No FIGURE 3-28. PRE−GLOW MEASUREMENT Glow Plug Control implemented in PCC1302 consists of the following two processes: a. Preheat Process (Pre−Glow Process) b. Total Glow Process Preheat Glow Time and Total Glow Time are determined by linear interpolation of Preheat Time and Name of the Trims Default Value Range 1 Preheat Time (Trim)(sec) 15 (sec) 0−30 (sec) 2 Preheat Temperature (Trim)(_F) 70 (_F) 0−100 (_F) 3 Preheat Knee Point (Trim)(_F) 0 (_F) 0−70 (_F) Preheat Time = controls how many seconds the glow plug will preheat before cranking the engine. Preheat Temperature = controls at which temperature the control defines a non−cold engine. The glow plugs will not preheat for engine coolant temperatures above the Preheat Temperature. Total Glow Processing: Total Glow processing logic has three associated trims as shown in Table 3−23. 3-47 TABLE 3-24. TOTAL GLOW PROCESSING TRIMS TABLE Sr. No Name of the Trims Default Value Range 1 Total Glow Time (Trim)(sec) 0 (sec) 0−60 (sec) 2 Total Glow Temperature (Trim)(_F) 70 (_F) 0−110 (_F) 3 Total Glow Knee Point (Trim)(_F) 0 (_F) 0−32 (_F) Glow Plug Output Logic: In PCC1302, Glow Plug Output depends upon Total Glow Time Value (Mon). The Glow Plug Output turns on when Fuel System (Trim) = Diesel and Total Glow Time Value (Mon) > 0. Glow Plug Driver Command remains on until the Total Glow Time Value (Mon) has expired. Glow Plug Output turns off, if any of the following conditions is valid: a. When Total Glow Tiem Value (Mon) expires. b. When Generator Set Control stops normally. c. When Generator Set Control stops during emergency. d. When Generator Set Control performs cyclical crank process. When the trim parameter Fuel Type is set to Diesel and Glow Plug is Enabled, the control preheats the engine starting glow plugs. Two trim parameters may need to be adjusted in order for the glow plug preheat control logic to work effectively. The trim parameter Preheat Time = seconds controls how many seconds the glow plugs will preheat before cranking the engine. The trim parameter Preheat Temperature = degrees Fahrenheit controls at which temperature the control defines a non-cold engine. The glow plugs will not preheat for engine coolant temperatures above the Preheat Temperature. Adjusting both of the trims will allow for tailoring of the glow plug preheat logic for specific engine applications. Setting Glow Plug = Disabled disables the glow plug preheat logic. neously with the fuel solenoid and held on as long as the genset is running. Both drivers stay on while the engine speed is above 150 RPM. When a shutdown command is received, the fuel solenoid is disabled but the ignition control module driver stays on until the Fuel Burn Off Time delay timer expires. By running the ignition system off of this delayed output, all of the fuel downstream of the fuel solenoid is burned following a genset stop / shutdown. This removes the occasional fuel flash in the exhaust system after a stop / shutdown. Refer to the wiring diagram for more information on how to configure the Remote Emergency Stop Switch for gas gensets to interrupt the ignition system power. For information on how to set the Fuel Type, enable a Glow Plug, and set a Fuel Burn Time Delay using the operator panel, see page 5-8. Start and Stop Time Delays (Cool Down) The 1302 series control is configurable for a time delay of 0−300 seconds prior to starting after receiving a remote start signal, and for a time delay of 0−600 seconds prior to shut down after signal to stop in normal operation modes. The default for both time delay periods is 0. 0−3600 seconds (fron 1302 calibration version 2.80 and HMI211 calibration version 7.20). Earlier versions have 0−300 seconds. For information on how to set a start or stop time delay using the operator panel, see page 5-8. Electronic Governor The 1302 series control provides electronic governing capability for a generator set when a electronic governor option is installed on the genset. It has a field adjustment trim to enable or disable the electronic governing feature. It supports isochronous speed governing as defined below. The maximum allowed rated current for the actuator drive for the governor power stage is 6.0A continuous max; 10 Amps for 1 second. The governing system is suitable for use with Gensets using Cummins EFC normally closed actuators, Woodward, FORD Gas, or BarberColeman actuators with similar drive characteristics. When the trim parameter Fuel Type = Gas, pin J11-7 can be used to control an external spark ignition control module. Pin J11-7 is turned on simulta- It provides speed governor setpoints of 1500 RPM and 1800 RPM. The governor setpoint is a field adjustment (50 Hz or 60 Hz). 3-48 vent the fuel actuators from becoming stuck. Therefore dither should be used in applications where the fuel actuators are prone to sticking. This feature has adjustable dither amplitude (0% to 30% of governor duty cycle). The dither function is enabled by selecting a dither factor. The dither function is disabled by setting the dither factor to 0%. The optional display allows the operator to adjust frequency within plus or minus 5% of rated speed. The controller provides ramping at startup and an ability to program the cranking fueling before the governor algorithm is enabled. Engine Speed Sensing For electronically governed gensets, the 1302 series control requires an engine speed input from a magnetic pickup speed sensor. The magnetic pickup signal needs to be calibrated for number of engine flywheel teeth. The table shown below lists the number of flywheel teeth for some common engine types. The following cranking fuel control characteristics are also provided to “tune up” the genset startup to suit the application. Cold weather applications might need a longer cranking period and/OR higher levels of cranking fuel. Following parameters should be chosen to make sure the genset starts up quickly enough but does not overshoot or produces excessive smoke at startup. TABLE 3-25. FLYWHEEL TEETH REQUIREMENTS Engine Type The initial cranking fuel duty cycle can be chosen to suit the engine / application. Number of Flywheel Teeth Cummins 4B, 6B 159 Cummins 4C 138 Ford 4cycl Gas 104 Kubota Engines 105 Cummins L10, NT855 118 Komatsu 3.3L 110 Cummins V28, K19, K38, K50 142 Ford V6 and V10 gas 133 The initial cranking fuel period can be chosen to suit the application. The cranking fuel is ramped up during cranking after initial cranking fueling period is over. The rate of ramping up of fueling can be chosen to suit the application. The maximum crank fuel duty cycle can be chosen to suit the application. During cranking the duty cycle of the PWM, output to the actuator will be limited to this value. The crank exit fuel duty cycle can be chosen to suit the application. After the engine fires, the fueling level will return to this value before the 4 coefficient algorithm takes over the control of the PWM output to the actuator. For non-electronically governed gensets, the magnetic pickup is optional. If it is not used, engine speed is calculated from the alternator output frequency. Speed Governor Algorithm and Adjustment The 1302 series control supports the following speed governor algorithm characteristics: It uses a four-coefficient field adjustable closed loop PID control algorithm (Proportional−Integral−Derivative). It allows field tuning of the speed coefficients. The 1302 series control provides a dither feature. Dither is a method of introducing small amounts of noise into the speed governing system. The purpose of this feature is to pre- Fueling is initially set to the Initial Crank Fueling Duty Cycle value and remains at that value for the Initial Crank Fueling Period. After this period expires, the fuel command is ramped at the Crank Fueling Ramp Rate until the Maximum Crank Fueling limit is reached. Upon reaching the Starter Disconnect Speed, the fueling command is pulled back to the Crank Exit Fueling Duty Cycle value until the Governor Enable Engine Speed is reached. When the Governor Enable Engine Speed is reached, the governor is enabled, the speed setpoint is set to the sensed engine speed value at this point, and the setpoint is ramped to rated speed in a time equal to the Governor Ramp Time. The diagram below illustrated these setpoints. 3-49 Crank Fuel Duty Cycle Closed Loop Operation Max Crank Fuel Duty Cycle Initial Crank Fuel Duty Cycle Crank Exit Fuel Duty Cycle Initial Crank Fueling Period Crank Fuel Ramp Rate FIGURE 3-29. GOVERNOR RAMP TIME SETPOINTS REAL TIME CLOCK The PCC1302 control system includes a Real Time Clock (RTC) function used for automatic scheduler (exercise scheduler) feature. The Real Time Clock (RTC) in PCC1302 is NOT used for calculating controller on time, or for recording fault occurrence times, or for supporting factory test. Once PCC1302 is programmed and given a power cycle, the user should enter the correct time, date and clock cycle (AM/PM). Based on the time and date saved by the user, the real time clock accurately* calculates seconds, minutes, hours, date of the month, month, day of the week, and year with leap year compensation. The clock operates in 12 hour format with support for AM/PM. When battery power is removed or the PCC1302 controller goes in sleep mode, the RTC parameters get reset to 00:00 (HH:MM) for Time and 00/00/00 (MM/DD/YY) for Date and AM for Clock Cycle. Under this condition, and with Scheduler Prog x Enable trim Enabled and Clock Diagnostic Enable trim Enabled, FC 1689 (Clock Not Set) will become active indicating that the date, time and AM/PM needs to be set by the user. The RTC also supports Daylight Savings Time (DST), which is a convention used to advance the time by one hour so that afternoons have more daylight than mornings. The DST logic adds the DST Adjustment time to the current time when the current time is equal to the DST Start Time. The DST logic subtracts the DST Adjustment time from the current time when the current time is equal to the DST End Time. To enable DST, the trim Daylight Savings Time Enable needs to be set to Enabled. To setup DST, specify the values for the following trims. These trims can be set via PCTools or HMI211 or HMI211RS or via Modbus utility. 3-50 TABLE 3-26. TRIM RANGE VALUES Trim Range Meaning Daylight Savings End Day Monday − Sunday Calendar Day in which DST Ends Daylight Savings End Hour 01− 12 hours (it is always AM) Hour (12 Hr) in which DST Ends Daylight Savings End Month 1 − 12 months Month in which DST Ends Daylight Savings End Week Occ Month Default − Fifth Occurrence Occurrence of Daylight Savings End Day in which DST Ends Daylight Savings End Day Monday − Sunday Calendar Day in which DST Starts Daylight Savings End Hour 01− 12 hours (it is always AM) Hour (12 Hr) in which DST Ends Daylight Savings Start Month 1 − 12 months Month in which DST Starts Daylight Savings Start Week Occ Month Default − Fifth Occurrence Occurrence of Daylight Savings End Day in which DST Starts Daylight Savings Time Adjustmenty 0 − 120 minutes Amount of time to be added or subtracted from current time for DST adjustment. For Example: If DST Ends on the 1st Wednesday in April at 02:00 AM every year, and DST Starts on the 2nd Thursday in September at 3:00 AM every year, and DST Adjusts the clock by 1 hour each time, the parameters should be set to the following values. TABLE 3-27. TRIM VALUES Trim Value Daylight Saving End Day Wednesday Daylight Saving End Hour 02 Daylight Saving End Month 4 Daylight Saving End Week Occurrence in Month First Occurrence Daylight Saving Start Day Thursday Daylight Saving Start Hour 3 Daylight Month 9 Saving Start Daylight Saving Start Week Occurrence in Month Second Occurrence Daylight Saving Time Adjustment 60 NOTE: The software accuracy of real time clock is +/− hour over a period of 1 calendar year. The real time clock func- tion is available from 1320 calibration version 2.76 and above and HMI211 calibration version 6.90 and above. EXERCISE SCHEDULER The exercise scheduler is a feature that automatically starts the genset for exercise. This feature prevents common problems which result from mechanical equipment being not in operation for long periods of time. In order for the automatic exerciser to work, the PCC1302 control system needs to be in ’Auto’ mode, the RTC needs to be set (Fault 1689 is not active), and the trim Scheduler Prog x Enable needs to be set to Enable. SLEEP mode will be disabled if the user enables the exercise scheduler. This is because sleep mode will reset the clock (RTC) in PCC 1302 and exercise function will not work. The PCC1302 can be programmed to run only 1 program, which is a repeating event. Furthermore, the program can be programmed to exercise the genset at rated condition and at ’No Load’ condition. No exceptions can be set in PCC1302. The exercise program has the following trims which establish its behavior where currently x always denotes 1. 3-51 TABLE 3-28. TRIM SCHEDULE VALUE Trim Value Meaning Scheduler Prog x Enable Enable − Disable Enables or Disables Schedule x=1 Scheduler Prog Start Minute 0 − 59 Specifies at what minute Program with start Scheduler Prog Start Hour 1 − 12 Specifies at what hour Program will start Scheduler Prog Start Day Monday − Sunday Specifies at what day Program will start Scheduler Prog Start Period AM − PM Specifies at what period Program will start Scheduler Prog Repeat Interval Weekly,Bi_Monthly,Month- Specifies the repeating behavior of Program ly,Quarterly,Semi−Annual Scheduler Prog Duration (Mins) 5 − 15 Specifies how many minutes Program will run For example, if it was desired to have a Program that ran on every Monday at 8:12 AM for 15 Minutes, the trims should be defined in Table 3−28 Scheduler Prog Start Minute 12 Scheduler Prog Start Hour 8 Scheduler Prog Start Day Monday TABLE 3-29. EXAMPLE TRIM VALUE Scheduler Prog Start Period Trim Scheduler Prog x Enable AM Value Scheduler Prog Repeat Interval Weekly Enable Scheduler Prog Duration (Mins) 15 3-52 TABLE 3-30. EXCERISER SCHEDULE Scheduler Scheduler Program Program Enable Start Day Start Time Hr Min Scheduler Program Duration Min Schedular Program Start Period AM/PM Schedule Repeat Interval Weekly Bi− monthy, Monthly, Quarterly Semi−Annual Program 1 The following are the set of rules for exercise scheduler 1. While in Exercise mode, genset will start if in AUTO mode, and run at rated condition and at ’No Load’ 2. While in Exercise mode, ’Exercise Scheduler On’ message will be displayed on both HMI 211 and HMI 211 RS. 3. This message screen will be displayed for 1 sec when in Info screens of the HMI and will toggle with the Info screens at a frequency of 3 sec. 4. While in Exercise mode, the user cannot edit the Clock parameters, the Exercise Scheduler parameters and the Daylight Savings parameters except for the trim ”Scheduler Prog x Enable”. ATS Control Automatic Transfer Switch is used to transfer power from Utility to Genset and vice−versa. A trim Auto Mains Failure Enable is provided to enable/ disable the ATS functionality in PCC1302. There are settable delay timers incorporated for transferring and re−transferring the load from Utility to Genset and vice−versa. In addition, diagnostic faults of ATS functionality and its corresponding FCs/ symbols are supported in HMI211 and HMI211RS. PCC 1302 has four configurable inputs, out of which two Configurable Inputs can be used for checking the feedback of the switch positions i.e. on Genset side or Utility side. The configurable inputs will remain locked for ATS functionality when AMF feature is enabled and the trim Transfer Switch Feedback Enable is enabled. TABLE 3-31. CONFIGURABLE INPUTS 5. If the user tries to edit these trims except ”Scheduler Prog x Enable”, following message, ”Can Not Edit Exercise On” will be displayed on both HMI 211 and HMI 211 RS. Pin Signal Name TB1−12 Configurable Input 1 TB1−13 Configurable Input 1 − Common TB1−14 Configurable Input 2 While in exercise scheduler mode, i.e. a scheduled program is active and control system is in ’Auto’ mode, if the PC1.1 control system receives a remote start command via HMI or from PCTools or from external transfer switch, the exercise scheduler mode will be terminated and the Scheduler Prog Duration (Mins) timer will become 0. However, the genset will continue to run in ’Auto’ mode and will follow ATS operation if ATS functionality is enabled. If remote start command is removed then the genset will stop running. Configurable Input 1 is used for Utility switch position status and Configurable Input 2 is used for Genset switch position status. For transferring the load from Utility to Genset or vice−versa, PCC1302 will use low side driver Ready to Load/ ATS Output only. ATS functionality will only be enabled when Auto Mains Failure Enable is enabled with the condition that Genset control is running in Auto mode. NOTE: The excerise scheduler function is available from 1320 calibration version 2.76 and above and HMI211 calibration version 6.90 and above. NOTE: When Exercise is active and if Utility lost condition is received (remote start signal is active), Genset Control discards the Exercise and continues with 3-53 the ATS functionality. The excerise scheduler function is available from 1320 calibration version 2.76 and above and HMI211 calibration version 6.90 and above. LOAD SOURCE 2 GENSET SOURCE 1 UTILITY TRANSFER SWITCH READY TO LOAD CONDITION START/STOP OPERATION GENSET FEEDBACK UTILITY FEEDBACK Config I/P 2 Config I/P 1 TB1−14 TB1−12 Ready to Load/ ATS Output UTILITY VOLTAGE MONITORING SENSOR TB1−4 REMOTE START COMMAND TB1−10 GENSET CONTROL Remote HMI FIGURE 3-30. PCC1302 BLOCK DIAGRAM As per the block diagram shown above, Genset Control (PCC1302) monitors the status of the Utility (Failing and Returning condition) directly through Remote Start Command (Active or Inactive) condition. do the following when Control Switch Position is in Auto. a. Genset Control gives the start command to Genset after the Start Time delay is completed. When Utility voltage monitoring sensor senses that the voltage has gone below Drop−out Voltage, it will activate the Remote Start Command input. b. After starting the Genset, when Genset Control reaches the ”Running” condition, it starts the Transfer Delay (trim) if Auto Mains Failure Enable is enabled. When Utility voltage monitoring sensor senses that the voltage has gone above the Pickup Voltage, it will de−activate the Remote Start Command input. c. When Genset Control reaches the Ready to Load condition and Auto Mains Failure Enable is enabled and Transfer Delay is completed, Genset Control will activate the Ready to Load/ATS output (Customer Ready to load driver output) to initiate the When Genset control receives the Remote Start active input command, the control will 3-54 then transferring and retransferring process depends upon Feedback Logic and Ready to Load/ ATS Output automatically. In Genset Control, if Auto Mains Failure Enable = Enabled and Transfer Switch Feedback Enable = Disabled, then transferring and retransferring process depends upon Ready to Load / ATS Output status only. transfer process of the load from Utility source to Genset source. d. After activating the Ready to Load/ATS output, Genset Control starts Transfer Delay Timer. Genset control will check for Configurable Input 1 Status = Inactive (Utility Open) and Configurable Input 2 Status = Active (Genset Close) feedback. If the feedback is not received for specified period of time (Transfer to Genset Delay Timer), Genset Control will declare the Shutdown fault ”Genset Failed To Close”. When Genset Control receives the Remote Start Inactive Input Command, the Control will do the following a. When Genset Control receives the Remote Start Inactive Input Command and Auto Mains Failure Enable is enabled, Genset Control starts Re−Transfer Delay (Trim). b. When Genset Control receives the Remote Start Inactive Input Command and Auto Mains Failure Enable is enabled, Genset Control starts Re−Transfer Delay (Trim). c. After de−activating the output and Auto Mains Failure Enable is enabled, Genset Control will check for the Configurable Input 2 Status = Inactive (Genset Open) and Configurable Input 1 Status = Active (Utility Close) feedback. If the feedback is not received for specified period of time (Re− Transfer to Utility Delay Timer), Genset Control will declare the Warning fault ”Utility Failed To Close”. d. Genset Control will initiate the Stop Time delay only when the feedback is received otherwise Genset will continue to be in running state. After the completion of the Stop Time delay, Genset Control will give the command to stop the Genset. If Transfer Switch is at unknown position, Genset Control will declare the Warning fault ”Transfer Switch Status Unknown Position”. NOTE: The ATS control function is available from 1320 calibration version 2.76 and above and HMI211 calibration version 6.90 and above. Dual Fuel The PCC1302 has the ability to determine the status of the Fuel System and notify the user and the ECM. When Fuel Type = Gas and Engine Application Type = FAE (ECM CAN Enable = Enabled), user will be able to set the trim parameter Gas Fuel Type as Natural Gas (Default) or Propane or Dual. When Gas Fuel Type is selected as Dual, the control system has the ability to transfer the fuel source from Natural Gas to Propane in case a low fuel condition is sensed for Natural Gas. BATTLE SHORT MODE OPTION The 1302 series control can be programmed to work in battle short mode. The PC service tool is required to enable the Battle Short feature. If the operator panel is not installed, the PC service tool is also required to enable the external Battle Short switch. The controller then can accept Configurable Input 1 as battle short switch inputs. If an operator panel is used, it can be also selected as a source of input by selecting the appropriate input source value for the trim. Installations With an Operator Panel To activate the Battle Short feature for installations that include the operator panel (see Figure 3-31), 1. Use the PC service tool to enable the Battle Short mode feature. Contact an authorized service center for assistance. 2. View the Service Menu by simultaneously NOTE: In Genset Control, if Auto Mains Failure Enable = Enabled and Transfer Switch Feedback Enable = Enabled, holding down the “up” and “down” arrow keys. 3. Select item 1, “Setup Menus”. 3-55 NOTE: When Switch Input is set to “Operator Panel”, the “Battle Short: Active/Inactive” subject is displayed. Battle Short should not be set to “Active” until it is needed by the customer. 4. Enter setup menu password 574. 5. Select item 1, “Genset Service”. 6. Select item 1, “Genset”. 7. Press the selection button five times to view the “Battleshort” menu. − If you want a customer input to be the activation source of this feature, change the “Switch Input:” setting to “Customer Input 1” or “Customer Input 2.” Refer to page 5-21 for information on setting up customer inputs. 9. Save the adjustments by pressing the “Save” button. NOTE: This menu is displayed only if the Battle Short mode feature has been enabled with the PC service tool. 8. Press the ADJUST button. − If you want the operator panel to be the activation source of this feature, change the “Switch Input:” setting to “Operator Panel.” For more information on the Battle Short feature, see Section 4. 3-56 Installations Without an Operator Panel Installations without a operator panel require the following. A Manual Run/Off/Auto switch must be connected to the control harness. A status indicator lamp must be installed to flash shutdown fault codes. An external On/Off switch must be connected to one of the customer configured inputs on the control board. The PC service tool must be used to enable the Battle Short mode feature. The PC service tool must be used to enable the external Battle Short On/Off switch. Contact an authorized service center for assistance. For more information on the Battle Short feature, see Section 4. Battle Short Mode Battle Short mode is designed to work only in critical load circumstances and is used to satisfy local code requirements, where necessary. This feature can only be used if the necessary software was installed at the factory when the 1302 control was purchased or if it was installed by an authorized customer service representative. Battle Short mode prevents the genset from being shutdown by all but a select few critical shutdown faults. All shutdown faults, including those overridden by Battle Short, must be acted upon immediately to ensure the safety and well being of the operator and the genset. Before the Battle Short feature can be used, it must first be enabled. Only trained and experienced service personnel should enable this feature. When shipped from the factory, this feature is disabled. Installations with an Operator Panel Battle Short can be enabled or disabled (set to Active or Inactive) using the operator panel. The PC service tool is required to enable the Battle Short mode feature. Contact an authorized service center for assistance. Before Battle Short can be used on installations with the operator panel, the Switch Input setting on the Battle Short submenu must be set to “Operator Panel” (see page 5-12). In addition, Battle Short mode must be enabled (set to Active) in the Battle Short submenu (see page 5-12). When Battle Short mode is enabled, the Warning status indicator lights, and Fault Code 1131 − Battle Short Active is displayed. When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp remains lit even though the genset continues to run. Fault Code 1416 − Fail to Shut Down is displayed. If the , , or button is pressed to acknowledge the fault, the fault message is cleared from the display but remains in the Fault History file with an asterisk sign (* indicates an active fault) as long as Battle Short mode is enabled. Battle Short is suspended and a shutdown occurs immediately if: Any of the following shutdown faults occurs. − Overspeed − Fault Code 234, Fault Code 1992 and Fault Code 3131 − Emergency Stop − Fault Code 1433 or 1434 Use of the Battle Short mode feature can cause a fire or electrical hazard, resulting in severe personal injury or death and/or property and equipment damage. Operation of the genset must be supervised during Battle Short operation. WARNING − Speed Signal Lost (Loss of Speed Sense) − Fault Code 121 − Excitation Fault (Loss of Voltage Sense) − Fault Code 2335 This feature must only be used during supervised, temporary operation of the genset. The faults that are overridden when in Battle Short mode are faults that can affect genset performance or cause permanent engine, alternator, or connected equipment damage. Operation may void the generator set warranty if damage occurs that relates to the fault condition(s). Battle Short mode is disabled after an overridden shutdown fault occurred while in Battle Short mode. To disable Battle Short mode, navigate to the Battle Short submenu (see page 5-12) and select “Inactive.” Fault Code 1123 − Shutdown After Battle Short is then displayed. 3-57 Installations without an Operator Panel Battle Short is suspended and a shutdown occurs immediately if: A Manual Run/Off/Auto switch must be installed in installations that do not include a operator panel. Battle Short can be turned on or off with a customer installed external switch connected to one of the two customer configured inputs. Any of the following shutdown faults occurs. − Overspeed − Fault code 234 or 1992 or 3131 − Emergency Stop − Fault code 1433 or 1434 The PC service tool is required to enable the Battle Short mode feature and to enable the external Battle Short switch using one of the two available customer inputs. Contact an authorized service center for assistance. − Speed Signal Lost (Loss of Speed Sense) − Fault code 121 − Excitation Fault (Loss of Voltage Sense) − Fault code 2335 When Battle Short mode is enabled and an overridden shutdown fault occurs, the genset continues to run and the status indicator lamp flashes the shutdown fault code. See “Local Status Output” on page 4-1 for information on interpreting the status indicator light. The external Battle Short switch is moved to the OFF position after an active but overridden shutdown fault occurred while in Battle Short mode. The status indicator lamp then flashes Fault Code 1123 − Shutdown After Battle Short. 3-58 (2) (7) (3) (7) (4) ENTER “574” (7) (5) (7) (6) (7) (7) “BATTLE SHORT: ACTIVE / INACTIVE” IS ONLY DISPLAYED IF THE SWITCH INPUT IS SET TO “OPERATOR PANEL” (8) THIS SUBMENU IS ONLY DISPLAYED IF THE BATTLE SHORT FEATURE HAS BEEN ENABLED USING THE PC SERVICE TOOL NOTE: THE NUMBERS IN PARENTHESIS MATCH THE STEPS INCLUDED IN THE PROCEDURE LISTED ON PAGE 3-55. FIGURE 3-31. OPERATOR PANEL MENUS FOR CALIBRATING BATTLE SHORT MODE 3-59 THIS PAGE INTENTIONALLY LEFT BLANK 3-60 4. Operator Panel Operation LED INDICATORS GRAPHICAL DISPLAY OFF MODE BUTTON HMI1211 DISPLAY MENU SELECTION BUTTONS PREVIOUS MENU LEVEL BUTTON FIGURE 4-1. 1302 OPTIONAL OPERATOR PANEL INTRODUCTION preheat (when used) and while the generator set is starting. This section includes information on the following. Constant On = The genset is running. Local Status Output Indicator Operating Modes Operator Panel Description Operator Panel System Messages Description of Fault and Status Codes Adjusting Values and Saving the Changes Basic Operator Menus Selecting Auto, Manual Run, and Off Modes Service Menus History/About Menus Fault History Menu Screen Adjust Menu Intermittent Flashing = A genset shutdown fault condition exists. All of the shutdown faults described in Table 4-2 can be announced with a status indicator lamp. For four-digit shutdown fault codes, the first digit in the code is flashed, followed by a halfsecond pause, then the second digit is flashed, followed by a half-second pause, then the third digit is flashed, followed by a half-second pause, and then the fourth digit is flashed, followed by a two-second pause. LOCAL STATUS OUTPUT INDICATOR NOTE: Only the last shutdown fault is flashed. If your installation includes a status indicator lamp that flashes genset status and shutdown fault codes, the following describes how to interpret the status indicator light. When a fault is corrected, the Manual Run/Off/ Auto switch must be placed in the Off position to reset the control. Under all other indications, the status lamp is off. Constant Fast Flashing = This occurs during 4-1 OPERATING MODES The 1302 control works with a Manual Run/Off/Auto switch, used to control genset operating modes. This capability is located either in the harness (switch) or is integrated into the operator panel included in this kit. Off Mode When in Off mode, the control does not allow the genset to start. If the genset is already running and the control is set to Off, it initiates a normal shutdown sequence. When in Off mode, all active faults are reset. Sleep Mode The 1302 series control enters a low power (sleep) mode of operation where the current draw is not greater than 60 milliamps (DC) at normal battery voltage levels. The control is set to enter sleep mode after five minutes in the Off or Auto mode (configurable). Sleep mode can only be disabled by installing a jumper between TB15-1 and TB15-5 (the TB15 connector is shown in Figure 4-2). Manual Run Mode When in Manual Run mode, the genset starts and continues to run until the control is put into the Off mode. While in Manual Run mode, any remote start signal is ignored. Auto Mode When in Auto mode, the control allows the genset to be started with a remote start signal only. TB15 CONNECTOR When in Auto mode, the genset can start at any time. When a remote start signal is received, the genset starts after the time delay start and time delay preheat (if programmed) are completed. If the genset is running in Auto mode and the Off button is pressed, the control immediately stops the genset and the control transitions to the Off mode. FIGURE 4-2. TB15 CONNECTOR WITH JUMPER When all remote start signals are removed, the control performs a normal shutdown sequence which may include a time delay stop. The control will not enter the sleep mode if there are any active, unacknowledged shutdown faults, if the control is in the Manual Run mode. Emergency Stop Mode Once in sleep mode, the 1302 series control will wake up when one of the following wakeup signals are received. When the optional emergency stop button is used, it immediately shuts down the generator set, bypassing any time delay stop. The red Shutdown LED lights and Fault Code 1433 or 1434 − Emergency Stop is either displayed (installations with a operator panel) or flashed (installations with a status indicator lamp). Local E-Stop − Active when switch is open Remote E-Stop − Active when switch is open Manual Start PCCNet System Wakeup Remote Start To reset the control, close (disable) the emergency stop button and either press the (Off) button (installations that include a operator panel) or move the control switch to the OFF position (installations with a Manual Run/Off/Auto switch). Auto Mode (If Configured) Configurable Input #3 Configurable Input #4 4-2 Installations with an Operator Panel Sleep mode is automatically enabled on the operator panel. To awaken the operator panel, press any button. Installations with a Manual Run/Off/Auto Switch show either text or symbolic versions of fault messages, some Operator menus, and the Mode Change menu. A description of commonly used symbols used are included in Table 4-1. Combinations of symbols are used to display some fault conditions. Additional specialized symbols are also used for some faults (see Table 4-2). TABLE 4-1. SYMBOLS For installations that utilize an Manual Run/Off/Auto switch located in the harness, the control awakes from sleep mode if Manual Run or Auto mode (if configured) is selected. SYMBOL DESCRIPTION Generator Warning Fault Generator Shutdown Fault OPERATOR PANEL Figure 4-1 shows the front of the optional operator panel. It includes six LED indicators, the graphical display, and six buttons used to navigate through the menus and adjust parameters. Coolant Temperature Oil Pressure Voltage Alternating Current (VAC) Graphical Display Voltage Direct Current (VDC) This graphical display is used to view menus of the menu-driven operating system. The bottom of the graphical display indicates the functions that are available by pressing the four selection buttons. Refer to the menu trees later in this section. AC Current Hz Frequency Battery System messages (communication, event, status, and fault) are also shown on the graphical display. For more information, see page 4-6. Out of Range High or Pre-High Display Text / Symbolic Versions Low or Pre-Low Using the Display Setup Service submenu (see page 5-15), the graphical display can be set up to Annunciator 4-3 Display Menu Selection Buttons When ADJUST is displayed, the selection button is used to display an adjustable menu. When the ADJUST button is pressed, the first adjustable parameter or value in the submenu is highlighted. Four momentary soft-key buttons are used to step through the various menus and to adjust parameters. These selection buttons are “active” when a word or symbol in the graphical display is shown above the button. Some submenus do not include any active buttons. symbol is displayed, the When the selection button is used to navigate to an editable field within a menu. The function of the four selection buttons varies with each menu. When the + and − symbols are displayed, the selection buttons are used to increase or decrease a parameter or value shown on the screen. symbol is displayed, the When the selection button can be used to switch to Auto mode. When changing values, pressing the button below the + symbol increase the value and pressing the button below the − symbol decreases the value. When the symbol is displayed, the selection button can be used to switch to Manual Run mode. When SAVE is displayed, the selection button is used to save changes made in a submenu. If the Previous Menu button is pressed before pressing SAVE, the changes are not saved. When the up and down triangles ( and ) are displayed, the selection buttons are used to navigate between a series of submenus. NOTE: When any Operator menu is displayed, a series of Service menus can be viewed by simultaneously pressing and selection buttons for two the seconds (see page 4-24). Some menus include a list of numbered subjects. These menus include numbers in parenthesis (for example, (1)) displayed above the selection buttons. The selection buttons are then used to display submenus of the subjects included in the list. NOTE: When a fault is displayed, it can be cleared from the front panel by pressing the or button. is displayed, the When a black box selection button has no function. When a symbol is displayed, the selection button can be used to abort the Auto or Manual Run mode and return to the Operator menu that was displayed before the Auto or Manual Run mode was selected. Previous Main Menu Button Press the menu. button to view the previous main NOTE: In the Screen Adjust menu, settings are not button is pressed. saved when the 4-4 possible, this hot shutdown should be avoided to help prolong the reliability of the genset. Not In Auto Indicator This red lamp is lit when the control is not in the Auto mode. Shutdown Indicator OFF BUTTON This red lamp is lit when the control detects a Shutdown condition. The generator set cannot be started when this lamp is on. After the condition is corrected, the lamp can be reset by performing a fault reset. When Battle Short mode is enabled and an overridden shutdown fault occurs, the Shutdown lamp is lit even though the genset continues to run. Warning Indicator PREVIOUS MAIN MENU BUTTON This yellow lamp is lit whenever the control detects a warning condition. This lamp is automatically shut off when the warning condition no longer exists. Remote Start Indicator This green lamp indicates the control is receiving a remote start signal. FIGURE 4-3. PREVIOUS MAIN MENU AND OFF BUTTONS Off Button Press the button to switch to the Off mode. The Off mode disables the control Auto or Manual Run modes. button is pressed during genset operation If the (manual or remote start), the engine immediately shuts down and the control enters the Off mode. If Auto Indicator This green lamp indicates the control is in Auto mode. Auto mode can be selected by pressing the selection button from any of the Operator menus (see page 4-22). Manual Run Indicator This green lamp indicates the control is in the Manual Run mode. Manual Run mode can be selected by pressing the selection button from any of the Operator menus (see page 4-22). 4-5 OPERATOR PANEL SYSTEM MESSAGES A system pop-up message is displayed when the event it is displaying becomes active. These popup messages remain displayed until pre-empted by or the another pop-up message or until the display buttons is pressed or the event has expired. or the button is pressed, the preOnce the vious screen is redisplayed. Communication Messages If either communication message remains displayed (cannot view other menus), this is an indication that communications between the operator panel and the control logic is lost. Contact an authorized service center for service. Event Messages When pre-set events (start or stop) are activated, Event messages are displayed showing the time remaining until the event occurs (see Figure 4-6). System messages are displayed for initial powerup or when there is a subsequent loss of communications. Auto and Manual Run modes can also be selected when communication messages are displayed (for more information, see page 4-22). Event = START, or STOP Upon initial power-up, the message “Establishing communication with control” is displayed (see Figure 4-4). This menu also displays the screen’s software number and version. FIGURE 4-6. EVENT MESSAGE Status Messages FIGURE 4-4. ESTABLISHING COMMUNICATIONS MESSAGE Status messages for some events are displayed on the optional control panel with a code number but are not announced with a lamp indicator. Text status messages include the event code, a short description, and the time the event occurred. Symbolic status messages include the event code and symbols to indicate the type of event that occurred. When the display detects that it is no longer communicating with the control, the Shutdown, Warning, and Remote Start LEDs are turned off. If communications are lost, the message “Re-establishing communication with control” is displayed until communications have been re-established (see Figure 4-5). The LEDs then return to the state determined by the control. FIGURE 4-7. DATASAVE STATUS MESSAGE On Full Authority Electronic engines, the engine controller saves data after each run. During this time, the display displays the message shown in Figure 4-7. The generator can still be started while the ECM Datasave is in progress. Fault Messages FIGURE 4-5. RE-ESTABLISHING COMMUNICATIONS MESSAGE A Fault message is an indicator of a Warning or Shutdown condition that is also announced with a lamp indicator. Text fault messages include the 4-6 fault code number, a short description, and when the fault occurred (see Figure 4-8). Symbolic fault messages include the fault code number and symbols, indicating the type of fault (see Figure 4-9). With the symbolic versions of fault messages, the and symbols flash. Five of the most recent faults are saved in a file and can be viewed using the Fault History Menus (see page 4-28). Fault Reset / Acknowledgement Shutdown faults must be acknowledged after the fault condition has been corrected. Shutdown faults are usually acknowledged by one of the following methods. If the control is equipped with an operator panel, press the button. If the control is not equipped with and operator panel, place the Auto/Off/Manual Run switch in the Off position. Fault = WARNING or SHUTDOWN FIGURE 4-8. FAULT MESSAGE − TEXT VERSION EXAMPLE OF A SYMBOLIC WARNING FAULT EXAMPLE OF A SYMBOLIC SHUTDOWN FAULT 214 1 FIGURE 4-9. FAULT MESSAGES − SYMBOLIC VERSION Shutdown faults can also be acknowledged when in Auto mode by using an external customer-supplied remote fault reset switch. This ability must be enabled by setting the Remote Fault Reset Enabled trim to “Enabled” (disabled by default) using InPower. The remote fault reset switch must be wired into one of the four configurable inputs. The chosen configurable input should have its function mapped to the “Fault Reset” function. To reset the fault, the remote start command must be removed prior to the remote fault reset switch being activated. Faults are removed from the display when they are cleared. NOTE: Pressing the or button also clears the fault from the front panel display. Faults are re-announced if they are detected again after being acknowledged. 4-7 FAULT/STATUS CODES Table 4-2 provides a list of fault and status codes, types, displayed messages/symbols, descriptions, and fault categories (CTG). Category A Fault Codes: Pertain to engine or alternator shutdown faults that require immediate repair by trained and experienced service personnel (generator set non-operational). The control prevents the generator set from being restarted if a shutdown fault is not corrected. Category B Fault Codes: Consist of faults that can affect generator set performance or can cause engine, alternator, or connected equipment damage. Operate the genset only when it is powering critical loads and cannot be shut down. Category B faults require repair by trained and experienced service personnel. Category C Fault Codes: Consist of faults that do not affect generator set performance but require qualified service personnel to repair. These codes indicate a defective harness or wiring problem. These codes can also indicate a defective engine sensor, leaving no ingine protection. (Engine damage can occure without detection.) Continued operation may void the generator set warranty if damage occures that relates to the fault condition. Category D Fault Codes: Consist of faults that are repairable by site personnel. Service will be required by trained and experienced service personnel if site personnel cannot resolve the problem. Category E Fault Codes: Indicates non-critical operational status of generator set, external faults, or customer fault inputs. These faults require repair by trained and experienced service personnel. TABLE 4-2. FAULT AND STATUS CODES DISPLAYED MESSAGE/SYMBOLS CTG CODE A 121 LAMP TEXT VERSION Shutdown SPEED SIGNAL LOST C 135 Warning OIL PRESS SENSOR OOR HIGH C 141 Warning OIL PRESS SENSOR OOR LOW B 143 ** Warning PRE-LOW OIL PRESSURE C 144 Warning COOLANT SENSOR OOR LOW C 145 Warning COOLANT SENSOR OOR HIGH C 146 ** Warning PRE-HIGH COOLANT TEMP SYMBOLIC VERSION 121 135 141 143 144 145 146 DESCRIPTION Indicates that no magnetic pickup pulses were sensed for a Loss of Speed delay. If a magnetic pickup is disabled, this fault is not activated. Indicates the oil pressure sensor output is out of range (OOR), high. Indicates the oil pressure sensor output is out of range (OOR), low. Indicates that the engine oil pressure is approaching an unacceptable level. Indicates the coolant temperature sensor output is out of range (OOR), low. Indicates the coolant temperature sensor output is out of range (OOR), high. Indicates that the engine has begun to overheat and the engine coolant temperature has risen to an unacceptable level. NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-8 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE D C LAMP TEXT VERSION 151 ** Shutdown HIGH COOLANT TEMP 153 Warning INTAKE MANIFOLD TEMP OOR HIGH Warning INTAKE MANIFOLD TEMP OOR LOW C 154 D 155 D 195 Warning COOLANT LEVEL OOR HIGH D 196 Warning COOLANT LEVEL OOR LOW D 197 Warning COOLANT LEVEL LOW A SYMBOLIC VERSION Shutdown INTAKE MANIFOLD TEMP HIGH 151 153 154 Shutdown ECM PGN A 286 Shutdown ECM D 359 Shutdown FAIL TO START A 415 Shutdown LOW OIL C 421^ Shutdown OIL TEMP HIGH TIMEOUT CONFIGURABLE ERROR Indicates the intake manifold temperature sensor is out of range (OOR), high. Indicates the intake manifold temperature sensor is out of range (OOR), low. 155 195 Indicates that a sensor on the radiator has detected that the coolant level is out of range (OOR), high. 196 Indicates that a sensor on the radiator has detected that the coolant level is out of range (OOR), low. 197 Indicates that a sensor on the radiator has detected that the coolant level is below normal. 234 285 Indicates that the engine coolant temperature is above normal and has reached the shutdown trip point. Indicates that the intake manifold temperature is above normal and has reached the shutdown trip point. 234 ** Shutdown OVERSPEED A DESCRIPTION 285 286 359 415 PRESSURE 421 Indicates that the engine has exceeded normal operating speed. The default thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz). Datalink failure. PCC control not responding to the engine control module. Indicates an engine control module configuration error − out of calibration. The genset has failed to start after a set number of crank attempts. This indicates a possible fuel system problem (engine cranks but fails to start). Indicates the engine oil pressure has dropped below normal and has reached the shutdown trip point. Indicates that the engine oil temperature is above normal and has reached the shutdown trip point. (I/O Module option) NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-9 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE LAMP NONE SYMBOLIC VERSION TEXT VERSION −− 418 N/A B 425^ Shutdown OIL TEMP OOR A 426 Shutdown DATA LINK A 427 Warning CAN LINK LOST D 441 ** Warning LOW BATTERY D 442 ** Warning HIGH BATTERY D 488^ Shutdown INTAKE A 689 Shutdown ENGINE SPEED A 781 Shutdown CAN LINK LOST D 1117 B 1123 * D 1131 * Warning C 1246 Warning E 1311 E 1312 ERROR DESCRIPTION Indicates water in fuel N/A 425 Indicates the oil temperature sensor output is out of range (OOR), high or low. (I/O Module option) 426 Datalink failure. No communications between the PCC control and the engine control module. 427 Datalink fault. Indicates that important data was lost between the PCC control and the engine control module. 441 Indicates battery voltage supply to the control is approaching a low level at which unpredictable operation can occur. 442 Indicates battery voltage supply to the control is approaching a high level at which damage to the control can occur. 488 Indicates the intake manifold temperature is above normal and has reached the shutdown trip point. (I/O Module option) 689 Indicates a fault condition in the engine crankshaft sensor circuit. 781 Datalink failure. No communications between the PCC control and the engine control module. 1117 Indicates battery voltage supply to the engine control module was lost. 1123 A shutdown fault occurred while the Battle Short mode was enabled. 1131 Indicates that the control is in Battle Short mode − used to bypass several fault shutdowns for genset operation during emergencies. 1246 Engine control fault code not recognized by the PCC control. Configur- Customer Fault Input 1 able 1311 The nature of the fault is an optional customer selection. Configur- Customer Fault Input 2 able 1312 The nature of the fault is an optional customer selection. MANIFOLD TEMP HIGH ERRATIC Warning ECM POWER LOST Shutdown SHUTDOWN AFTER BS BATTLE SHORT ACTIVE GENERIC ENGINE FAULT NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-10 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE LAMP TEXT VERSION SYMBOLIC VERSION DESCRIPTION E 1317 Configur- Customer Fault Input 3 able 1317 The nature of the fault is an optional customer selection. E 1318 Configur- Customer Fault Input 4 able 1318 The nature of the fault is an optional customer selection. B 1416 * Warning 1416 Indicates that a shutdown fault is active, but is being bypassed by Battle Short. A 1417 Shutdown FAILURE TO 1417 Indicates the control is powered up after attempting to go to sleep. D 1433 Shutdown LOCAL 1433 Indicates a Local Emergency Stop has been activated. D 1434 Shutdown REMOTE 1434 Indicates a Remote Emergency Stop has been activated. D 1435 ** D 1438 D 1442 ** A 1443 A A 1446 ** 1447 ** FAIL TO SHUTDOWN POWER DOWN EMERGENCY STOP EMERGENCY STOP Warning LOW COOLANT TEMP Shutdown FAIL TO CRANK Warning WEAK BATTERY 1435 Indicates that the engine coolant temperature is below the adjusted setpoint. This may indicate that the coolant heater is not operating or is not circulating coolant. 1438 The genset has failed to sense rotation for two start attempts. This indicates a possible fault with the control, speed sensing, or the starting system. 1442 Indicates that the genset battery voltage is below battery thresholds during cranking. 1443 Indicates during cranking battery voltage has dropped below operating voltage of control resetting the control for three consecutive times. Shutdown DEAD BATTERY Shutdown HIGH AC 1446 Indicates that the one or more measured AC output voltages has exceeded the threshold for longer than a specified time limit. The threshold and time limits are 130% of nominal for 0 seconds or 110% of nominal for 10 seconds. 1447 Indicates that the measured AC output voltage is below the threshold for longer than a specified time limit. The threshold and time limits are 85% of nominal for 10 seconds. VOLTAGE Shutdown LOW AC VOLTAGE NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-11 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE LAMP SYMBOLIC VERSION DESCRIPTION Indicates that the alternator frequency is 6 hertz under nominal frequency. FREQUENCY Hz 1448 Hz 1449 TEXT VERSION A 1448 ** Shutdown UNDER A 1449 ** Shutdown OVER −− 1463 NONE N /A N/A Indicates Not in Auto. −− 1468 NONE N/A N/A Indicates Ready to Load. A 1469 ** B 1471* * A 1472 ** −− 1483 NONE N/ A N/A Indicates Common Alarm. −− 1540 NONE N/ A N/A Indicates Common Warning. −− 1541 NONE N/ A N/A Indicates Common Shutdown. C 1845 Warning WATER IN FUEL OOR HIGH C 1846 Warning WATER IN FUEL OOR LOW D 1852 Warning WATER IN FUEL E 1853 Configur- Annunciator Fault 2 able E 1854 E E D FREQUENCY Shutdown SPEED HZ Indicates that measured engine speed and measured alternator AC output frequency do not agree. MATCH Warning Indicates that the alternator frequency is 6 hertz above nominal frequency. HIGH AC CURRENT Shutdown HIGH AC CURRENT 1471 Indicates that the alternator output current (one or more phases) has exceeded safe operating limits. 1472 Indicates that alternator output current (one or more phases) has exceeded the alternator’s current rating. 1845 Indicates the water in fuel sensor is out of range (OOR), high. 1846 Indicates the water in fuel sensor is out of range (OOR), low. 1852 Indicates that the water in fuel is above normal and has reached the warning trip point. The nature of the annunciator fault is an optional customer selection. Configur- Annunciator Fault 3 able 1853 1854 1855 Configur- Annunciator Fault 1 able 1855 The nature of the annunciator fault is an optional customer selection. 1944 Warning ANNUNCIATOR OUTPUT CONFIGURATION ERROR Warning EXHAUST TEMPERATURE OOR 1965 ^ 1944 1965 The nature of the annunciator fault is an optional customer selection. Indicates a mismatch in the configuration of one of the annunciator relay outputs. Indicates the exhaust temperature sensor is out of range (OOR), high or low. (Aux 101 I/O option). NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-12 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE B 1992 LAMP TEXT VERSION Warning ENGINE OVERSPEED SYMBOLIC VERSION DESCRIPTION 1992 Indicates that the engine has exceeded normal operating speed. The default thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz). (ECM fault code). B 1689 Warning CLOCK NOT SET 1689 Indicates real time clock is not set with exercise scheduler function enabled. B 5186 Warning GENSET FAILED TO CLOSE 5186 Indicates transfer switch has failed to close on generator side. B 5187 Warning UTILITY FAILED TO CLOSE 5187 Indicates transfer switch has failed to close on utility side. B 5188 Warning TRANSFER SWITCH STATUS UNKNOW POSITION 5188 Indicates transfer switch position is not known. B 5365 Warning ON SECONDARY SOURCE 5365 B 2118 Warning LOW FUEL PRESSURE 2118 Indicates low fuel pressure sensed for gaseous application. B 5134 Warning UNKNOWN SHUTDOWN AT IIDLE 5134 Indicates genset having ECM has shutdown with unknown fault before reaching rated condition. B 254 Warning FSO DRIVER FAILED 254 Engine Fuel Shutoff Valve Driver Circuit − Voltage Below Normal or Shorted. B 1847 Warning HIGH TEMPERATURE FAULT 1847 Indicates that engine coolant temperature is above normal and has reached the shutdown trip point. B 1517 Warning FAILED MODULE SHUTDOWN B 1921 Warning REGEN MANDATORY HIGH LEVEL 1517 1921 Indicates genset is running on secondary fuel source in dual fuel application. At least One Module of a Multi−module system has a severe fault. Aftertreatment Diesel Particulate Filter Differential Pressure − Data Valid But Above Normal Operating Range − Moderately Severe Level. Need to initiate DPFprocess. NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-13 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE B 1922 LAMP Warning TEXT VERSION GENSET CRITICAL CALL TECHNICIAN B 175 Warning AIR THROT DRIVE CCT OORH B 176 Warning AIR THROT DRIVE CCT OORH B 177 Warning AIR THROT DRIVE MECH SYS ERROR B 3539 Warning AIR THROT POSN SENSOR OORH B 3541 Warning AIR THROT DRIVE CCT OORL B 3542 Warning AIR THROT POSN SENS DATA INCORR B 5669 Warning ENGINE COMBUSTION FAULT C 2224 ^ Warning FUEL LEVEL OOR A 2335 C 2398 ^ Warning AMBIENT TEMPERATURE OOR C 2542 ^ Warning VOLTAGE BIAS OOR A 2545 Shutdown EXCITATION FAULT Shutdown KEYSWITCH RESET REQUIRED SYMBOLIC VERSION DESCRIPTION 1922 Aftertreatment Diesel Particulate Filter Differential Pressure − Data Valid But Above Normal Operating Range − Most Severe Level. Need to call Cummins technician to clear the fault. 175 Electronic Throttle Control Actuator Driver Circuit − Voltage Above Normal or Shorted to High Source. 176 Electronic Throttle Control Actuator Driver Circuit − Voltage Below Normal or Shorted to Low Source. 177 Electronic Throttle Control Actuator − Mechanical System Not Responding or Out of Adjustment. 3539 Engine Intake Throttle Actuator Position Sensor Circuit − Voltage Above Normal or Shorted to High Source. 3541 Engine Intake Throttle Actuator Position Sensor Circuit − Voltage Below Normal or Shorted to Low Source. 3542 Engine Intake Throttle Actuator Position Sensor − Data Erratic, Intermittent, or Incorrect. 5669 Intake Manifold Over Pressure − Condition Exists. 2224 Indicates the fuel level sensor is out of range (OOR), high or low. (Aux 101 I/O option). 2335 Indicates that a loss of voltage or frequency sensing from the generator has occurred. 2398 Indicates the ambient temperature sensor is out of range (OOR), high or low. (Aux 101 I/O option). 2542 Indicates the voltage bias circuit output is out of range (OOR), high or low. (Aux 101 I/O option). 2545 Indicates a datalink failure. Communications are lost between the PCC control and the engine control module. NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-14 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE E 2619 ^ LAMP TEXT VERSION SYMBOLIC VERSION Diagnos- AUX101 ANALOG INPUT 1 tic 2619 DESCRIPTION The nature of the Base I/O Module event is an optional customer selection. (Aux101 I/O Module option) Each event function can be programmed (using InPower service tool or access to the Setup menu), as follows: Change display name using up to 32 characters. Select active low or high input. E 2621 ^ Diagnos- AUX101 ANALOG INPUT 2 tic 2621 See code 2619. E 2622 ^ Diagnos- AUX101 ANALOG INPUT 3 tic 2622 See code 2619. E 2623 ^ Diagnos- AUX101 ANALOG INPUT 4 tic 2623 See code 2619. E 2624 ^ Diagnos- AUX101 ANALOG INPUT 5 tic 2624 See code 2619. E 2625 ^ Diagnos- AUX101 ANALOG INPUT 6 tic 2625 See code 2619. E 2626 ^ Diagnos- AUX101 ANALOG INPUT7 tic 2626 See code 2619. E 2627 ^ Diagnos- AUX101 ANALOG INPUT 8 tic 2627 See code 2619. E 2628 ^ Diagnos- AUX102 DIGITAL INPUT 9 tic 2628 The nature of the Aux I/O Module event is an optional customer selection. (Aux102 I/O Module option) Each event function can be programmed (using InPower service tool or access to the Setup menu), as follows: Change display name using up to 32 characters. Select active low or high input. E 2629 ^ Diagnos- AUX102 DIGITAL INPUT 10 tic 2629 See code 2628. E 2631 ^ Diagnos- AUX102 DIGITAL INPUT 11 tic 2631 See code 2628. NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-15 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE LAMP TEXT VERSION E 2632 ^ Diagnos- AUX102 DIGITAL INPUT 12 tic A 2676 Shutdown ALTERNATOR A 2677 Shutdown FAIL TO STOP B 2678 ** SYMBOLIC VERSION 2632 2693 ^ Warning SPEED BIAS OOR C 2694 ^ Warning ALTERNATOR RTD OOR A 2696 ^ C 2729 ^ C 2731 Shutdown I/O MODULE A 2897 Shutdown FACTORY A 2898 A 2899 Shutdown ALTERNATOR RTD TEMP HIGH Warning I/O MODULE LOST LOST BLOCK CORRUPT Warning 2677 The genset continues to run after receiving a stop command from the controller. 2678 Indicates the battery charging alternator has not reached a acceptable voltage range within the selected time period (default = 120 seconds). This warning is also displayed if your alternator is a type that does not support the control’s charging alternator logic functionality. If this occurs, this warning can be disabled if the Charging Alt. Enable setting is set to “No.” See the Genset Service submenus on page 5-8. 2693 Indicates the speed bias circuit output is out of range (OOR), high or low. (Aux 101 I/O Module option). 2694 Indicates the alternator RTD sensor is out of range (OOR), high or low. (Aux 101 I/O Module option). 2696 Indicates the alternator temperature is above normal and has reached the shutdown trip point. (I/O Module option) 2729 Indicates an intermittent data link between the I/O module and the PCC control. (Aux 101 I/O Module option). 2731 Indicates the data link between the I/O module and the PCC control is lost. (Aux 101 I/O Module option). CHARGER FAILURE C PERIODIC/ FAULT CORRUPT Shutdown USER BLOCK CORRUPT See code 2628. Indicates the measured alternator line frequency and measured alternator excitation frequency do not agree. FREQUENCY CONFLICT Warning DESCRIPTION 2897 2898 2899 Indicates a fatal software error occurred in the PCC control. Indicates a fatal software error occurred in the PCC control. Indicates a fatal software error occurred in the PCC control. NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). 4-16 TABLE 4-2. FAULT AND STATUS CODES (CONT.) DISPLAYED MESSAGE/SYMBOLS CTG CODE A 2911 D 2964 A 2972 ** LAMP TEXT VERSION SYMBOLIC VERSION Shutdown TRIM BLOCK CORRUPT Warning INTAKE MANIFOLD TEMPERATURE HIGH Shutdown FIELD OVERLOAD DESCRIPTION 2911 Indicates a fatal software error occurred in the PCC control. 2964 Indicates engine has begun to overheat (intake manifold temperature has risen to an unacceptable level). Increase in load or higher ambient temperature may cause Intake Manifold Temp High (code 155) shutdown. 2972 Indicates that the Field Voltage has been above 70V for 8 seconds. NOTE: Shutdown fault codes can also be announced with a local status lamp indicator. * For more information on these events, refer to the Battle Short Mode description on page 3-57. ** Any values listed in the Description column for these faults are default values. If authorized, these values can be changed using the Genset Setup menus (see page 5-37). ^ These faults are available only if your installation includes the optional I/O Module (Kit 541−1291). ADJUSTING DEFAULT SETTINGS The optional operator panel can be set up to display with SAE or SI units of measurement. For more information, see the Adjust Screen menu shown on page 4-30. SAVING YOUR CHANGES All adjustments made to menus are temporary until the SAVE button is pressed. If the SAVE button is pressed and the engine is running, the adjustments are not saved until after the engine speed is zero. If power is lost to the control before a SAVE is executed, all temporary adjustments are lost. Adjustments to the following are stored in flash memory in the optional operator panel. Contrast When the SAVE button is pressed, the previous menu is redisplayed. OPERATOR MENUS Figures 4-10 and 4-11 show block representations of the following Operator menus. Engine Status Alternator Status Line-to-Line Voltage Line-to-Neutral Voltage Alternator Amperage To navigate between the Operator menus, press the buttons next to the and symbols in the graphical display. The Operator menus can be used to select Auto or Manual Run modes (see page 4-22). Engine Status Menu Units This menu displays the engine starting battery voltage, engine coolant temperature, engine oil pressure, and hours of engine operation. Local or remote display Alternator Status Menu Symbols or text displayed This menu displays genset load (in kVA), frequency, and engine speed (RPM). Brightness Access code required for mode change to Auto or Manual Run All other adjustments are stored in the control board. Alternator Line-to-Line Voltage Menu This menu displays L1-L2, L2-L3, and L3-L1 lineto-line voltages for three phase applications only. 4-17 Alternator Line-to-Neutral Voltage Menu ages for single phase applications only. This menu displays line-to-neutral voltages for L1, L2, and L3 for three phase wye configurations only. In delta configurations, this menu is not shown. Alternator Amperage Menu Alternator Single Phase Voltage Menu This menu displays L1-N, L2-N, and L1-L2 volt- For applications that include current transformers, this menu displays L1, L2, and L3 current sense amperage. 4-18 OPERATOR MENUS − Text Version THREE PHASE ONLY SINGLE PHASE ONLY THREE PHASE WYE ONLY CURRENT SENSE AMPERAGE FIGURE 4-10. OPERATOR MENUS (TEXT VERSION) 4-19 OPERATOR MENUS − Symbolic Version THREE PHASE ONLY SINGLE PHASE ONLY THREE PHASE WYE ONLY CURRENT SENSE AMPERAGE FIGURE 4-11. OPERATOR MENUS (SYMBOLIC VERSION) 4-20 SELECTING AUTO, MANUAL RUN, AND OFF MODES 2. Press the arrow selection button to the next numeric character. to move 3. Press the button below the + or − symbols until Auto, Manual Run, and Off modes can be selected: the value reads “2.” From any of the Operator menus 4. Press the arrow selection button When the message “Establishing communication with control” is displayed to the next numeric character. to move 5. Press the button below the + or − symbols until When the message “Re-establishing communication with control” is displayed the value reads “1.” 6. After you have completed entering the pass- Switching to Auto, Manual Run, or Off mode can be restricted to authorized personnel. If a operator panel is set up with the mode change access code feature enabled, an access code must first be entered before the mode can be changed. The mode change access code feature is enabled through the Display Setup submenu (see page 5-15). word, press the arrow selection button . NOTE: If an incorrect password is entered, the Operator menu that was displayed before Auto, Manual Run, or Off mode was selected is redisplayed. The Auto or Off mode switch status is saved in nonvolatile memory when it changes. When the control panel powers up (after sleeping or upon battery removal), the switch status is restored to its previous saved state. TEXT VERSION Entering the Mode Change Access Code If the mode change feature access code is enabled, an access code must be entered to switch to Auto, Manual Run, or Off modes. The text and symbolic versions of the Mode Change menu are shown in Figure 4-12. SYMBOLIC VERSION To enter the mode change access code, 1. With the first character highlighted, press the button below to the + or − symbols until the value reads “1.” FIGURE 4-12. MODE CHANGE MENU 4-21 Selecting Auto Mode To switch to Auto mode (see Figure 4-13), 1. Press the button on any of the Operator menus or the “Establishing/Re-establishing communication with control” menus. 2. If the mode change access code feature is en- abled, the Mode Change Access Code menu is displayed. Enter the mode change access code as described above. THIS MENU IS DISPLAYED ONLY IF THE MODE CHANGE ACCESS CODE FEATURE IS ENABLED 3. A menu with alternating arrows is displayed symbol. Press the secabove a second button. The Operator menu that was ond displayed before Auto mode was selected is redisplayed. To disable Auto mode, press the button. ALTERNATING ARROWS ARE DISPLAYED NOTE: Manual Run mode can also be selected while in Auto mode. AUTO MODE SELECTED FIGURE 4-13. SELECTING AUTO MODE 4-22 Selecting Manual Run Mode To switch to Manual Run mode (see Figure 4-14), To switch to Manual Run mode, 1. Press the button on any of the Operator menus or the “Establishing/Re-establishing communication with control” menus. THIS MENU IS DISPLAYED ONLY IF THE MODE CHANGE ACCESS CODE FEATURE IS ENABLED 2. If the mode change access code feature is en- abled, the Mode Change Access Code menu is displayed. Enter the mode change access code as described on the previous page. 3. A menu with alternating arrows is displayed above a second symbol. Press the second button. The Operator menu that was displayed before Manual Run mode was selected is redisplayed. To disable Manual Run mode, press the ALTERNATING ARROWS ARE DISPLAYED button. NOTE: Auto mode can also be selected while in Manual Run mode. Switching to Auto mode may result in the generator set shutting down. Aborting the Transition to Auto or Manual Run Mode MANUAL RUN MODE SELECTED If the Mode Change Access Code menu or the menu showing alternating arrows above the or buttons is displayed, the transition to Auto or Manual Run mode is aborted when: Either the , , or FIGURE 4-14. SELECTING MANUAL RUN MODE button is pressed. A selection button is not pressed within ten seconds. If the transition to Auto or Manual Run mode is aborted, the Operator menu that was displayed before Auto or Manual Run mode was selected is redisplayed Selecting Off Mode To switch to Off mode, press the button. If the genset is running and Off mode is selected, a normal shutdown sequence is initiated. More information on the use of the Off button is included on page 4-5. 4-23 SERVICE MENUS Figure 4-15 shows a block representation of the menus available from the Service Menus. The first Service Menu can be viewed from any of the Operator menus by simultaneously pressing the and selection buttons for two seconds. The first Service Menu provides access to the following menus: Setup Menus − Used by Service personnel. Adjusting the Setup menus is restricted by a password and is described in the Control Service section. To view the Setup menus only, press the VIEW button on the Setup password menu. The third Service Menu can be viewed by pressing selection button on the second Service the Menu. The third Service Menu provides access to the Network Status menus. Status Menu The Status menu is displayed when the (5) button is pressed on the second Service Menu. The Status menu shows the following: Voltage regulator (drive) level, in percentage of duty cycle. Governor regulator (drive) level, in percentage of duty cycle. This value is only displayed if the governor is enabled. History / About − see page 4-26 Screen Adjust − see page 4-30 To return to the Operator menu that was displayed prior to viewing the Service Menu, press the button. The second Service Menu can be viewed by pressselection button on the first Service ing the Menu. The second Service Menu provides access to the following menus: Network Status Menus The Network Status menus are displayed when the (7) button is pressed on the third Service Menu. Two menu are used to display the quantity of the following devices that are connected to the network. Universal Annunciators Bar graphs Fault History − see page 4-28 Battery chargers Status − see below Controls Lamp Test − The six LEDs on the control panel should light as long as the button (6) is pressed. I/O modules Operator panels (any type) 4-24 1ST SERVICE MENU SETUP MENUS SEE PAGE 5-4 HISTORY / ABOUT MENUS SEE PAGE 4-26 2ND SERVICE MENU SCREEN ADJUST MENU SEE PAGE 4-30 3RD SERVICE MENU FAULT HISTORY MENUS SEE PAGE 4-28 FIGURE 4-15. SERVICE MENUS 4-25 HISTORY / ABOUT MENUS About Genset Submenus Figure 4-16 shows a block representation of the History / About menus. The first History / About submenu is displayed when the (2) button is pressed on the Service Menu (see Figure 4-15). Two submenus display the generator set model number, control number, and genset application frequency rating. Press the buttons next to the and symbols in the graphical display to navigate between the Hisbutton to retory / About submenus. Press the turn to the Service Menu. This submenu displays the control’s part number, serial number (up to 11 characters), software part number (up to 9 characters), and software version. About Control Submenu History Submenu About Display Submenu This submenu displays the number of engine starts, hours of operation for the engine, and hours of operation for the control. This submenu displays the optional control panel software part number, software version, screen part number, and screen version of the display. 4-26 HISTORY / ABOUT MENUS FIGURE 4-16. HISTORY / ABOUT MENUS 4-27 FAULT HISTORY MENU Figure 4-18 shows a block representation of the Fault History menu. The first Fault menu is displayed when the (4) button is pressed on the second Service Menu (see Figure 4-15). If there are any active fault submenus, an “Active Fault” heading is displayed for the most recent active fault. All other fault submenus display a “Fault History” heading. Five of the most recent faults can be viewed. An example of how a fault code is displayed is shown in Figure 4-17. Information on faults is included in Table 4-2 on page 4-8. TIME FAULT OCCURRED FAULT CODE FAULT DESCRIPTION and symbols in Press the buttons next to the the graphical display to navigate between menus. Press the button to return to the Service Menu. FIGURE 4-17. FAULT HISTORY MENU EXAMPLE 4-28 FAULT HISTORY MENU Active Fault Fault 1 OR Fault 2 Oldest Fault (Maximum of 5) FIGURE 4-18. FAULT HISTORY MENU 4-29 SCREEN ADJUST MENU NOTE: If the Previous Menu button is pressed before pressing the SAVE button, the changes are not saved. Figure 4-19 shows a block representation of the Screen Adjust menu. The Screen Adjust menu is displayed when the (3) button is pressed in the first Service Menu (see Figure 4-15). 5. Press the Menu. button to return to the Service Screen Adjust Menu Adjusting Values/Parameters 1. Press the ADJUST selection button to select the first parameter or value to be changed. This menu allows for adjusting the screen’s contrast and brightness and for selecting the units of measurement (SAE or SI) to be displayed. Contrast and Brightness: Press the + or − selection buttons to adjust the screen’s contrast and brightness. Changing the brightness setting also affects the brightness of the LEDs on the operator panel. 2. Press the + or − selection buttons to adjust val- ues or select parameters. 3. Press the arrow selection button to navigate to the next or previous adjustable value or parameter. Units: Press the + or − selection buttons to select SAE (_F, PSI) or SI (C, kPa) units of measurement to be displayed. 4. After adjusting values/selecting parameters, press the SAVE button to save your settings. SCREEN ADJUST MENU FIGURE 4-19. SCREEN ADJUST MENU 4-30 5. 1302 Control Panel Service Menus SERVICE MENUS NOTE: When using any PCCNet device on a genset control application, the wiring used to connected ALL devices in the network must be Belden 9729 Two Pair, Stranded, Shielded Twisted Pair Cable (24 AWG). Incorrect settings can result in equipment malfunction and damage. Only trained and experienced personnel should be authorized to change the settings. CAUTION The Service Menus shown in this section can be viewed and, if the correct password(s) are entered, modified. Changing the settings should be restricted to trained and experienced installation and service personnel. Figure 5-1 shows a block representation of the menus available from the Service Menu. The first Service Menu can be viewed from any of the Operator menus by simultaneously pressing the and selection buttons for two seconds. The first Service Menu provides access to the following menus: To return to the Operator menu that was displayed prior to viewing the Service Menu, press the button. The second Service Menu can be viewed by pressing the selection button on the first Service Menu. The second Service Menu provides access to the following menus: Fault History Status Lamp Test − The six LEDs on the control panel should light as long as the button (6) is pressed. The third Service Menu can be viewed by pressing the selection button on the second Service Menu. The third Service Menu provides access to the Network Status menus. The Network Status menus are displayed when the (7) button is pressed on the third Service Menu. Two menu are used to display the quantity of the following devices that are connected to the network. Universal Annunciators Setup Menus − See page 5-3 Bar graphs History / About − See page 4-27 Battery chargers Screen Adjust − See page 4-30 Controls Changes can be made to Adjust submenus without entering a password. However, a password is required to change any of the Setup submenus. I/O modules Operator panels 5-1 1ST SERVICE MENU SETUP MENUS SEE PAGE 5-4 HISTORY / ABOUT MENUS SEE PAGE 4-26 2ND SERVICE MENU FAULT HISTORY MENUS SEE PAGE 4-28 SCREEN ADJUST MENU SEE PAGE 4-30 3RD SERVICE MENU STATUS MENU SEE PAGE 4-24 NETWORK STATUS MENUS SEE PAGE 4-24 FIGURE 5-1. SERVICE MENUS 5-2 SETUP MENUS The Setup menus are available by pressing the (1) button on the first Service menu (see Figure 5-1). The Setup Menus (see Figure 5-2) provide access to genset menus with settings that can be viewed and, if a password is entered, adjusted. The first Setup menu is displayed when the (1) button is pressed on the Service Menu. From the Setup Password menu, a second Setup menu is displayed that provides access to the following two categories of genset menus. Genset Service menus Genset Setup menus − Go to page 5-35 FIGURE 5-2. SETUP MENUS 5-3 GENSET SERVICE MENUS The first Genset Service menu is available by pressing the (1) button on the Setup Menus menu (see Figure 5-2). This section covers Genset Service menus only. For information on Genset Setup menus, go to page 5-35. If a password is entered, the settings in the Genset Service menus can be adjusted. However, if a password is not entered, these menus can still be viewed. The Genset Service menus can be viewed by selecting the VIEW button on the Setup Password menu and then selecting (1) on the second Setup menu. When the VIEW button is selected without entering the correct password, the ADJUST button is not displayed on any of the Genset Service menus; therefore, no adjustments can be made. Menu Navigation 1. Press the buttons above the and symbols in the digital display to navigate between submenus. Viewing Only Figure 5-3 is a block representation of the Genset Service menus that are available when a password is not entered (or an incorrect password is entered) in the Setup Password menu. 2. To return to the genset Setup Menus menu from any of the submenus, press the button. The first Genset Service Menu provides access to the following menus: 3. To return to the Service Menu from the genset Setup Menus menu, press the button. Genset Customer I/O Meter Calibration The second Genset Service Menu provides access to the following menus: Annunciator ModBus 5-4 GENSET SERVICE MENUS (Viewing Only) NOTE: When the VIEW button is selected from the Setup Password menu without entering a password, the ADJUST button is not available on any of the menus shown in Figures 5-5 thru 5-14. 1ST VIEW GENSET SERVICE MENU 2ND VIEW GENSET SERVICE MENU SEE PAGE 5-21 SEE PAGE 5-8 SEE PAGE 5-27 SEE PAGE 5-29 SEE PAGE 5-34 FIGURE 5-3. VIEWING GENSET SERVICE MENUS WITHOUT ENTERING A PASSWORD 5-5 Viewing and Adjusting 2. Press the arrow selection button to the next numeric character. Figure 5-4 is a block representation of the Genset Service menus that are available from the Setup Menus menu after the correct password has been entered. The ADJUST button is available on these submenus; therefore, adjusting the settings is allowed. 3. Press the button below the + or − symbols until the value reads “7.” 4. Press the arrow selection button to the next numeric character. 6. After you have completed entering the password, press the arrow selection button . The first main Setup menu is displayed. Genset Meter Calibration The second Genset Service Menu provides access to the following menus: to move 5. Press the button below the + or − symbols until the value reads “4.” The first Genset Service Menu provides access to the following menus: Customer I/O to move After the correct password is entered, it will be remembered until five minutes of button inactivity has elapsed. If five minutes of button inactivity has elapsed, you will have to re-enter the password to access and change Setup menus. Annunciator Adjusting Values/Parameters ModBus Once the correct password has been entered and Genset Service (1) is selected on the Setup Menus menu, the first Genset Service submenu is displayed. Setup Password Submenu Adjusting the Genset Service menus is restricted to service personnel and a password must be entered to modify these menus. and sym1. Press the buttons above the bols in the digital display to navigate between submenus. When the Password menu is displayed, the first numeric character (0) is highlighted (see Figure 5-4). 2. Press the ADJUST selection button to select the first parameter or value to be changed. NOTE: When selected (highlighted), each character initially turns to “0” and the remaining characters turn to “X”. 3. Press the + or − selection buttons to adjust values or select parameters. to navi4. Press the arrow selection button gate to the next or previous adjustable value or parameter. NOTE: Make sure that each numeric character is correct before you move to the next character. If a wrong character is entered, you will not be able to go back and correct it. If the wrong password is entered, you will be able to view the Genset Service menus but you won’t be able to change them. 5. After adjusting values/selecting parameters, press the SAVE button to save your settings. NOTE: If the button is pressed before pressing the SAVE button, the changes are not saved. To enter the password: 1. With the first character highlighted, press the button below to the + or − symbols until the value reads “5.” 6. Press the Menu. 5-6 button to return to the Service GENSET SERVICE MENUS (Viewing and Adjusting) 1ST GENSET SERVICE MENU 2ND GENSET SERVICE MENU SEE PAGE 5-21 SEE PAGE 5-8 SEE PAGE 5-27 SEE PAGE 5-29 FIGURE 5-4. GENSET SERVICE MENUS 5-7 SEE PAGE 5-34 Genset Service Submenus − The average engine speed (if a magnetic pickup unit is installed) − The average frequency The Genset Service submenus are available by pressing the (1) button on the first Genset Service menu (see Figure 5-3 or Figure 5-4). − The charging alternator voltage (if the Charging Alt feature is enabled) The Genset Service submenus consist of ten basic submenus. The Charging Alt. Enable menu is used to enable or disable the Charging Alt feature. While the default setting is “Yes,” this menu provides a means to disable the control’s charging alternator logic if it is not supported by your alternator. If your alternator does not support this functionality, the Charger Failure warning (fault code 2678) will constantly be displayed unless this setting is changed to “No.” When disabled (set to “No”), the start disconnect signal is based only on the average engine speed or frequency and the Charger Failure warning is disabled. Genset, Part 1 Genset, Part 2 Fuel System Start/Stop Time Delays Cycle Crank Battle Short (if enabled) Automatic Voltage Regulator Setup* Electronic Governor* Genset Model and Serial Number Display Setup Volts and Hz Password * If enabled, the Automatic Voltage Regulator has two additional submenus and the Electronic Governor has five additional submenus. Fuel System The Fuel System menu allows for selecting fuel type and, depending on the type selected, enabling/disabling glow plugs or setting a fuel burn time delay. Fuel System: Allows for selecting the fuel type (Diesel or Gas, default = Diesel). Genset Menu, Part 1 The first genset menu displays the preset AC Voltage, genset frequency, number of phases, and phase type. Volts AC: Displays the AC voltage (190, 200, 208, 220, 230, 240, 380, 400, 416, 440, 460, 480, or 600 VAC, default = 208). If Fuel System is set to “Diesel” Glow Plug Enable: Allows control of Glow Plugs for a particular genset (Yes or No, default = No). If Fuel System is set to “Gas” Fuel Burn Delay: After the genset receives a stop signal, this feature allows for setting a fuel time delay from 0 to 10 seconds (default = 5 seconds) in which the ignition remains on so that any fuel down stream of the intake manifold is burned. Hertz: Displays the genset frequency (50 or 60 Hz, default = 60 Hz). The control selects limits, gains, and frequency values based upon this selection. No. of Phases: Displays the number of phases (1 or 3, default = 3). Phase: Displays the phase type (Delta or Wye default = Wye). Genset Menu, Part 2 The second genset menu allows for enabling or disabling charging alternators. Start/Stop Delay Menu The time delay after receiving a valid start signal, until the genset starts, can be adjusted. The time delay that the genset is allowed to ruin at rated speed after receiving a stop signal, until the genset stops, can also be adjusted. These time delays do not apply to manual start/runs. Start: The genset start time delay can be adjusted from 0 to 300 seconds (default = 0 seconds) or 0 to 3600 seconds from 1320 calibration version 2.80, HMI211 calibration version 7.20 onwards. Charging Alt. Enable: A starter disconnect will occur whenever any one of the following three possible signals reaches its disconnect setpoint. 5-8 Stop: The genset stop time delay can be adjusted from 0 to 600 seconds (default = 0 seconds). 5-9 GENSET SERVICE SUBMENUS WHEN FUEL SYSTEM IS SET TO DIESEL, THE “GLOW PLUG ENABLE” SUBJECT IS DISPLAYED. WHEN FUEL SYSTEM IS SET TO GAS, THE “FUEL BURN DELAY” SUBJECT IS DISPLAYED. B A CONTINUED ON PAGE 5-12 FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 1 OF 4) 5-10 Cycle Crank Menu The Cycle Crank menu allows for configuring the generator for all starting modes (manual and remote), as follows: Crank: The cranking period can be set from 3 to 30 seconds (default = 15 seconds). This time limit is used to determine a Fail to Start status. (see page 3-57 for more Battle Short information). Before the Battle Short feature can be used, one of three available activation sources must be selected. If the activation source switch input is set to “Operator Panel,” then Battle Short functionality can be enabled or disabled with this menu. Switch Input: The Switch Input can be set for Configurable Input 1, Configurable Input 2, Operator Panel, or None (default = None). Battle Short: Battle Short functionality can be enabled or disabled (set to Active or Inactive), (default = Inactive). This subject will only be displayed if the switch input is set to “Operator Panel.” Rest: The minimum amount of time between crank attempts can be set from 0 to 60 seconds (default = 30 seconds). Attempts: The maximum number of times the starter can be engaged when attempting to start the engine with cycle cranking can be set from 1 to 7 attempts (default = 3). Battle Short Menu This menu is displayed only if the PC service tool has been used to enable the Battle Short feature AVR Setup Menu The AVR Setup menu is used to enable or disable the automatic voltage regulator (default = Yes). If enabled, two additional menus are displayed that can be used to adjust the AVR settings (see page 5-18). 5-11 GENSET SERVICE SUBMENUS (Continued) RETURN TO PAGE 5-10 A B THIS SUBMENU IS ONLY DISPLAYED IF THE BATTLE SHORT FEATURE HAS BEEN ENABLED USING THE PC SERVICE TOOL “BATTLE SHORT: ACTIVE / INACTIVE” IS ONLY DISPLAYED IF THE SWITCH INPUT IS SET TO “OPERATOR PANEL” F YES NO K OR C E GO TO AVR SETUP MENUS ON PAGE 5-18 CONTINUED ON PAGE 5-14 FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 2 OF 4) 5-12 Electronic Governor Menu, Part 1 The engine Electronic Governor Enable menu is used to enable or disable the electronic governor on gensets with electronic governors and magnetic pickup sensors (default = Yes). If enabled (set to “Yes”), four additional menus are displayed that can be used to adjust governor settings (see page 5-20). Electronic Governor Menu, Part 2 The Pre-Load Offset menu is used to enter a percentage of governor duty cycle that is first used when exiting cranking. Genset Number Menu The Genset Number menu is used to enter the genset’s model and serial numbers. Each allow up to 16 characters to be entered. 5-13 GENSET SERVICE SUBMENUS (Continued) RETURN TO PAGE 5-12 E F G IF AVR IS NOT ENABLED OR YES IF AVR IS ENABLED NO OR H GO TO PAGE 5-18 D GO TO GOVERNOR SETUP MENUS ON PAGE 5-20 M L CONTINUED ON PAGE 5-16 FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 3 OF 4) 5-14 Manual Run, or Off) change access code (default = No). Display Setup Menu The Display Setup menu is used to set the display for Local (Auto/Off/Manual Run switch functions on the operator panel are turned on) or Remote (Auto/Off/Manual Run switch functions on the operator panel are turned off). Connection: A display can be set up to be Local or Remote (default = Local). Access Code: A display can be set up to require or not require entering the mode (Auto, Symbols: A display can be set up to display international symbols on the Operator menus (default = Yes). Volts and Hertz Menu The Volts and Hertz menu is used to select whether or not a password is required in order to change voltage and hertz settings outside of the Genset Service menus (default = Required). 5-15 GENSET SERVICE SUBMENUS (Continued) RETURN TO PAGE 5-14 L M FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 4 OF 4) 5-16 Automatic Voltage Regulator Submenus NOMINAL VOLTAGE The Automatic Voltage Regulator (AVR) submenus are available only if the AVR is enabled (see page 5-12). NOMINAL (100%) VOLTAGE SLOPE VOLTAGE SETPOINT CURVE FREQUENCY Two Automatic Voltage Regulator (AVR) submenus (see Figure 5-7) can be used to adjust Volts/Hz Rolloff and Regulator Gains settings. NOMINAL FREQUENCY FIGURE 5-6. KNEE FREQUENCY AND SLOPE Volts/Hz Rolloff Menu V/Hz Knee: The Knee Frequency can be adjusted from 0.0 to 10.0 Hertz in 0.1 Hz increments (default = 1.0 Hz). When generator set speed decreases by more than the value of the knee frequency, the generator set voltage decreases by the %/Hz value. The Volts/Hz Rolloff function helps optimize the genset’s response to added load. If the engine speed drops below nominal frequency, the control automatically drops the voltage until the engine speed starts to recover. This menu allows for adjusting the knee frequency and voltage setpoint slope parameters. The knee frequency is the value below nominal frequency at which the rolloff function begins. For example, if the knee frequency is set to 5 Hz on a 60 Hz genset, this function begins when the frequency drops below 55 Hz. KNEE FREQUENCY V/Hz Rolloff: The Rolloff setting can be adjusted from 0.0 to 5.0 percent of rated voltage, in 0.1% increments (default = 2.0%). Regulator Gains Menu The Regulator menu allows for setting proportional Gain, Integral Gain, and Damping values. Gain: The proportional Gain (K1) multiplier can be set from 5 to 1000% (default = 100%). This allows for a scale factor of 0.05 to 10.0. Slope refers to how fast the voltage is rolled off below the knee frequency. The voltage is rolled off the slope percent setting for every 1 Hz below the knee. For example, on a 60 Hz genset, if the slope is set to 5% and the knee frequency is set to 5 Hz, then if the frequency drops to 54 Hz, the voltage set point is reduced 5%. If the frequency drops to 53 Hz, the voltage set point is reduced 10%, etc. Int: The Integral Gain (K2) multiplier can be set from 5 to 1000% (default = 100%). D: The Damping adjustment can be set from 95 to 105% (default = 100%). 5-17 AUTOMATIC VOLTAGE REGULATOR SUBMENUS NOTE: These menus are only available if the Automatic Voltage Regulator (AVR) is enabled (see page 5-12). RETURN TO PAGE 5-12 F C H K RETURN TO PAGE 5-12 FIGURE 5-7. AUTOMATIC VOLTAGE REGULATOR SUBMENUS 5-18 Electronic Governor Submenus Int: The integral governor gain (K2) multiplier can be set from 5 to 1000% (default = 100%). The Electronic Governor submenus are available only if the governor is enabled (see page 5-12). D: The governor Damping adjustment can be set from 95 to 105% (default = 100%). Four Electronic Governor submenus (see Figure 5-8) can be used to adjust governor settings. Governor Crank Fuel Menu Electronic Governor Menu The Governor Crank Fuel menu allows for setting the Initial Crank Fuel Duty Cycle, the Initial Crank Fueling Period, the Crank Fuel Ramp Rate, and the Maximum Crank Fuel Duty Cycle. The Electronic Governor menu allows for setting Crank Exit Fuel DC, Dither Factor, and Damping values. This menu is displayed only if the governor has been enabled with the Engine Electronic Governor Enable menu. Initial DC: The Initial Crank Fuel Duty Cycle is the initial value assigned to the Governor Duty Cycle parameter when cranking begins. This value can be set from 0 to 50 percent (default = 25%). Crank Exit Fuel DC: The Crank Exit Fuel Duty Cycle is the value at which the governor duty cycle is held after disengaging the starter until the governor is enabled. This value can be set from 0 to 100% (default = 25%). Initial Time: The Initial Crank Fueling Period is the amount of time for which the value of Initial Crank Fuel Duty Cycle is assigned to the governor duty cycle after cranking begins. This value can be set from 0 to 10 seconds (default = 2 seconds). Dither Factor: Dither is a signal that is superimposed on the PWM (pulse with modulation) duty cycle to prevent the actuator valve from sticking. The Dither Factor is the dither percent added to the current duty cycle. The Dither Factor can be set from 0 to 30% (default = 15%). The dither function is disabled when the dither factor is set to 0%. Ramp Rate: The Crank Fuel Ramp Rate is the rate at which the value of the Governor Duty Cycle is ramped up by during the Crank State, after expiration of the Initial Crank Fueling Period. This value can be set from 5 to 100 (default = 25). Max DC: The Maximum Crank Fuel Duty Cycle is the maximum level to which the Governor Duty Cycle should be limited to during a crank state. This value can be set from 50 to 100% (default = 100%). Electronic Governor Regulator Menu The Electronic Governor Regulator menu allows for setting proportional Gain, Integral Gain, and Damping values. Ramp Time: This feature is used to set the minimum governor speed reference ramp rate. The governor Ramp Time can be set from 0.00 to 30.0 seconds, in 0.01 second increments (default = 0.25 seconds). Electronic Governor Enable Speed Menu These menus allow for setting the minimum and maximum governor duty cycle. Min. Gov DC: The Minimum Governor Duty Cycle can be set from 0 to 100% (default = 5%). Gain: The proportional governor gain (K1) multiplier can be set from 5 to 1000% (default = 100%). This allows for a scale factor of 0.05 to 10.0. Max. Gov DC: The Maximum Governor Duty Cycle (with dithered value) can be set from 0 to 100% (default = 95%). 5-19 ELECTRONIC GOVERNOR SUBMENUS NOTE: These menus are only available if the governor is enabled (see page 5-12). D RETURN TO PAGE 5-14 G E RETURN TO PAGE 5-14 FIGURE 5-8. ELECTRONIC GOVERNOR SUBMENUS 5-20 Customer I/O Submenus The Customer I/O menus are available by pressing the (2) button on the first Genset Service menu (see Figure 5-3 or Figure 5-4). The Customer I/O menus (see Figures 5-9 thru 5-12) can be used to define customer input messages and output maps. The Customer I/O menus consist of four Fault Input Function Selection menus, four Customer Input Test message menus, four Fault Input Active State Selection menus, and two Customer Output Map menus. Fault Input Function Selection Each of the four configurable input functions can be set to Disabled, Fault Input, Fault Reset or Battle Short (the default is different for each input). See Figure 5-9. Customer Inputs The Customer Input Text message menus are used to enter an event type and description for up to four events. See Figure 5-10. Type: Enter the event type (Warning, Shutdown or Event, default = Warning). Enter a brief description of the event (up to 32 characters). Fault Input Active State Selection Each of the four fault input active states can be set to Active Closed or Active Open, (default = Active Open). See Figure 5-11. 5-21 FAULT INPUT FUNCTION SELECTION SUBMENUS B A GO TO CUSTOMER INPUT MENUS ON PAGE 5-23 FIGURE 5-9. CUSTOMER I/O SUBMENUS (SHEET 1 OF 4) 5-22 CUSTOMER INPUT SUBMENUS A B RETURN TO PAGE 5-22 D C GO TO FAULT INPUT ACTIVE STATE MENUS ON PAGE 5-24 FIGURE 5-10. CUSTOMER I/O SUBMENUS (SHEET 2 OF 4) 5-23 FAULT INPUT ACTIVE STATE SELECTION SUBMENUS C D RETURN TO PAGE 5-23 F E GO TO CUSTOMER OUTPUT MENUS ON PAGE 5-26 FIGURE 5-11. CUSTOMER I/O SUBMENUS (SHEET 3 OF 4) 5-24 Customer Outputs able customer outputs. See Figure 5-12. Number: Enter a valid code number (0−65535, default = 0) for the event. Two Customer Outputs are configurable to display common warning alarms. The two Customer Output Map menus allow for entering a fault number and fault name to be displayed for the two configur- A brief description of the event is automatically displayed. 5-25 CUSTOMER OUTPUT SUBMENUS RETURN TO PAGE 5-24 E F FIGURE 5-12. CUSTOMER I/O SUBMENUS (SHEET 4 OF 4) 5-26 Metering Submenus Freq. Adjust Menu The Metering submenus are available by pressing the (3) button on the first Genset Service menu (see Figure 5-3 or Figure 5-4). The Frequency Adjust menu allows for adjusting the genset frequency. The frequency can be adjust from −6.0 to +6.0 Hz (default = 0.0 Hz). The actual frequency is also shown on this menu. Three Metering submenus (see Figure 5-13) can be used to adjust regulated voltage, frequency, line-to-neutral voltage, and line current settings. Meter Calib Menu The Meter Calib menu allows for adjusting the actual output voltage of the genset. The percentage can be set from 90 to 110% (default = 100%). The alternator voltage is also shown on this menu. Metering Voltage Adjust Menu The Metering Voltage Adjust menu allows for adjusting metered line voltage. Metering Current Adjust Menu The Metering Current Adjust menu allows for adjusting metered amps. 5-27 METERING SUBMENUS FIGURE 5-13. METERING SUBMENUS 5-28 Annunciator Submenus The Annunciator submenus are available by pressing the (4) button on the second Genset Service menu (see Figure 5-3 or Figure 5-4). Seven annunciator submenus (see Figure 5-14) can be used to define three Annunciator Fault Text messages and four Annunciator Output Maps. Annunciator Inputs The annunciator has three possible customer-defined fault conditions that can be shown on the 1302 series control display. The Annunciator Fault Text message menus are used to enter an event type and description for those three customer-defined annunciator faults. Type: Enter the event type (Warning, Shutdown, or Event, default = Warning). Enter a brief description of the event (up to 32 characters). 5-29 ANNUNCIATOR SUBMENUS B A CONTINUED ON PAGE 5-32 FIGURE 5-14. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2) 5-30 Annunciator Outputs An annunciator has four custom (N.O.) relays that can be controlled by the PCC 1302. When a specified event becomes active, a message can be sent by the PCC 1302 to the annunciator to turn the relay on or off. Only one event per relay is allowed. The four annunciator outputs of the 1302 series control are configurable to display common warning alarms. The four Annunciator Output Map menus allow for entering a fault number and fault name to be displayed for the configurable annunciator outputs. Number: Enter a valid code number (0−65535, default = 0) for the event. A brief description of the event is automatically displayed. NOTE: Output relays can be configured for events that are not displayed by the operator panel. If one of the events listed in the following table is configured, it will activate the relay when the event occurs. TABLE 5-1. EVENT AND CODES EVENT CODE Water In Fuel 418 Not In Auto 1463 Ready to Load 1468 Common Alarm 1483 Common Warning 1540 Common Shutdown 1541 5-31 ANNUNCIATOR SUBMENUS (Continued) RETURN TO PAGE 5-30 A B FIGURE 5-14. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2) 5-32 ModBus Submenus The ModBus submenus are available by pressing the (5) button on the second Genset Service menu (see Figure 5-3 or Figure 5-4). ModBus Setup The ModBus Setup menu is used to set the address, baud rate, and parity. Address: Enter the address of the control on the ModBus register (default = 1). ModBus Enable Baud Rate: Enter the appropriate baud rate − 2400, 4800, 9600, or 19200 (default = 9600). The ModBus menu is used to enable or disable the ModBus feature (default = No). Parity: The parity can be set to either odd or even (default = even). 5-33 MODBUS SUBMENUS FIGURE 5-15. MODBUS SUBMENUS 5-34 GENSET SETUP SUBMENUS The first Setup menu is displayed when the (1) button is pressed on the Service Menu. From the Setup Password menu, a Setup Menus menu is displayed that provides access to the following two categories of genset menus. Genset Service menus − Go to page 5-3 Viewing Only Figure 5-17 is a block representation of the Genset Setup menus that are available when a password is not entered (or an incorrect password is entered) in the Genset Setup Password menu. The first Genset Setup Menu provides access to the following menus: Genset Genset Setup menus This section covers Genset Setup menus only. A password does not need to be entered on the Setup Password menu in order to view or adjust the Genset Setup submenus. When the (2) button is selected to access Genset Setup menus, a second password menu (Genset Setup Password) is displayed (see Figure 5-16). If a password is entered on the Genset Setup Password, the settings in the Genset Setup menus can be adjusted. However, if a password is not entered, these menus can still be viewed. Voltage Protection Current Protection The second Genset Setup Menu provides access to the following menu: Engine Protection The Genset Setup submenus can be viewed by selecting the VIEW button on the Genset Setup Password menu. When the VIEW button is selected without entering the correct password, the ADJUST button is not displayed on any of the Genset Setup menus; therefore, no adjustments can be made. Menu Navigation SETUP PASSWORD MENU 1. Press the buttons above the and symbols in the digital display to navigate between submenus. 2. To return to the genset Setup Menus menu butfrom any of the submenus, press the ton. 3. To return to the Service Menu from the genset Setup Menus menu, press the button. SETUP MENUS MENU GENSET SETUP PASSWORD MENU FIGURE 5-16. SETUP PASSWORD MENUS 5-35 GENSET SETUP MENUS (Viewing Only) NOTE: When the VIEW button is selected from the Genset Setup Password menu without entering a password, the ADJUST button is not available on any of the menus shown in Figures 5-19 thru 5-22. 1ST GENSET SETUP MENU AVAILABLE ONLY IF THE ECM CAN FEATURE IS DISABLED 2ND GENSET SETUP MENU SEE PAGE 5-46 SEE PAGE 5-40 SEE PAGE 5-48 SEE PAGE 5-50 FIGURE 5-17. GENSET SETUP MENUS (VIEWING ONLY) 5-36 Viewing and Adjusting 3. Press the button below the + or − symbols until the value reads “2.” Figure 5-18 is a block representation of the Genset Setup menus that are available after the correct password has been entered in the Genset Setup Password menu. The ADJUST button is available on these submenus; therefore, adjusting the settings is allowed. 4. Press the arrow selection button to the next numeric character. to move 5. Press the button below the + or − symbols until the value reads “0.” 6. Press the arrow selection button to the next numeric character. The first Genset Setup Menu provides access to the following menus: to move 7. Press the button below the + or − symbols until the value reads “9.” Genset 8. After you have completed entering the password, press the arrow selection button . The first main Setup menu is displayed. Voltage Protection Current Protection The second Genset Setup Menu provides access to the following menu: Engine Protection Genset Setup Password Submenu After the correct password is entered, it will be remembered until five minutes of button inactivity has elapsed. If five minutes of button inactivity has elapsed, you will have to re-enter the password to access and change Genset Setup menus. Adjusting Values/Parameters Adjusting the Genset Setup menus is restricted to service personnel and a password must be entered to modify these menus. Once the correct password has been entered on the Genset Setup Password menu, the first Genset Setup submenu is displayed. Once the Genset Setup button (2) is selected on the Setup Menus menu, the Genset Setup Password menu is displayed. 1. Press the buttons above the and symbols in the digital display to navigate between submenus. When the Genset Setup Password menu is displayed, the first numeric character (0) is highlighted (see Figure 5-18). 2. Press the ADJUST selection button to select the first parameter or value to be changed. 3. Press the + or − selection buttons to adjust values or select parameters. NOTE: When selected (highlighted), each character initially turns to “0” and the remaining characters turn to “X”. 4. Press the arrow selection button to navigate to the next or previous adjustable value or parameter. NOTE: Make sure that each numeric character is correct before you move to the next character. If a wrong character is entered, you will not be able to go back and correct it. If the wrong password is entered, you will be able to view the Genset Setup menus but you won’t be able to change them. 5. After adjusting values/selecting parameters, press the SAVE button to save your settings. NOTE: If the button is pressed before pressing the SAVE button, the changes are not saved. To enter the password: 1. With the first character highlighted, press the button below to the + or − symbols until the value reads “1.” button to return to the genset 6. Press the Setup Menus menu. 2. Press the arrow selection button to the next numeric character. 7. To return to the Service Menu from the genset Setup Menus menu, press the button. to move 5-37 GENSET SETUP MENUS (Viewing and Adjusting) 1ST GENSET SETUP MENU AVAILABLE ONLY IF THE ECM CAN FEATURE IS DISABLED 2ND GENSET SETUP MENU SEE PAGE 5-46 SEE PAGE 5-40 SEE PAGE 5-48 SEE PAGE 5-50 FIGURE 5-18. GENSET SETUP MENUS (VIEWING AND ADJUSTING) 5-38 Genset Menus Excitation/Line Freq. Gain: If the excitation source is set to “Shunt,” this value is automatically set to 1. If the excitation source is set to “PMG,” the value that should be entered is the excitation frequency multiplier of the PMG system. For example, enter a “2” if the PMG output is twice the main generator frequency (120 Hz excitation frequency). The Genset submenus are available by pressing the (1) button on the first Genset Setup menu (see Figure 5-17 or Figure 5-18). Genset Menu 1 The first Genset Setup menu is used to set the CT Ratio, enable the Magnetic Pickup Unit (MPU), set the number of teeth pulses per revolution on the Flywheel, and set the Speed/Frequency Ratio. CT Ratio: The CT Ratio value must be set to match the CT Ratio of the current transformers on the genset (default = 150:5). MPU Enable: Displays whether or not the Magnetic Pickup Unit is installed (Yes or No, default = No). Fly. Teeth: The total number of teeth pulses per revolution on the flywheel (used for electronic governed systems) can be set from 0 to 256 (default = 110). Application Rating Select Menu The genset application rating can be set to either Standby or Prime (default = Standby). Standby kVA Rating Menu The kVA Rating menu displays the kVA rating of single-phase or three-phase, 50 or 60 hertz standby genset systems. These value are used by the control to determine what is 100% load. The values must match the kVA rating of the genset application and cannot be more than 2000 kVA. 3Ph/50Hz: The three phase, 50 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). RPM/Hz Ratio: Allows for setting the Speed/ Frequency Ratio to 20, 30, or 60 RPM/Hz (default = 30). 3Ph/60Hz: The three phase, 60 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). Genset Menu 2 1Ph/50Hz: The single phase, 50 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). The second Genset Setup menu is used to set the excitation source and the excitation/line frequency gain. 1Ph/60Hz: The single phase, 60 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). Excitation Source: Select Shunt or PMG Excitation, depending upon your application. 5-39 GENSET SETUP SUBMENUS B A CONTINUED ON PAGE 5-42 FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 1 OF 3) 5-40 Prime kVA Rating Menu The kVA Rating menu displays the kVA rating of single-phase or three-phase, 50 or 60 hertz prime genset systems. These value are used by the control to determine what is 100% load. The values must match the kVA rating of the genset application and cannot be more than 2000 kVA. 3Ph/50Hz: The three phase, 50 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). Battery Thresholds Menu The Battery Thresholds menu is used to set the low and high voltage values to determine when the battery voltage is out of the set range during normal operation. This menu is also used to determine when the battery voltage is below weak battery thresholds during cranking. The Battery Thresholds menu that is displayed is dependent upon the battery voltage entered in the Battery Select menu. 3Ph/60Hz: The three phase, 60 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). Low Batt: The low battery voltage threshold can be set from 11.0 to 13.0 VDC for 12 volt batteries (default = 12.0 VDC) and from 22.0 to 27.0 VDC for 24 volt batteries (default = 24.0 VDC), in 0.1 VDC increments. 1Ph/50Hz: The single phase, 50 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). High Batt: The high battery voltage threshold can be set from 14.0 to 17.0 VDC for 12 volt batteries (default = 16.0 VDC) and from 28.0 to 34.0 VDC for 24 volt batteries (default = 32.0 VDC), in 0.1 VDC increments. 1Ph/60Hz: The single phase, 60 Hertz rating can be set from 0 to 2000 kVA (default = 25 kVA). Battery Select Menu The Battery Select menu is used to set the nominal battery voltage. Weak Batt: The weak battery voltage threshold can be set from 6.0 to 10.0 VDC for 12 volt batteries (default = 8.0 VDC) and from 12.0 to 16.0 VDC for 24 volt batteries (default = 14.4 VDC), in 0.1 VDC increments. Nominal Battery Voltage: Allows for setting the nominal battery voltage (12 or 24V, default = 12V). 5-41 GENSET SETUP SUBMENUS (Continued) RETURN TO PAGE 5-40 A B 12V 24V OR D C CONTINUED ON PAGE 5-44 FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 2 OF 3) 5-42 D Battery Delay Setup Menu Oil Pressure Setup Menus This menu is used to determine when, after determining that the battery condition is out of the preset operating range, a warning message is announced. NOTE: The following menus are only available if the the ECM CAN feature is disabled. L. Batt TD: A time delay from 2 to 60 seconds (default = 60 seconds) can be set before the Low Battery warning message (Fault Code 441) is announced. A menu is available to set the sensor type. If the sensor type is Switch, then another menu is available to set the sensor polarity. If the sensor type is Sender, then another menu is available to set the sender type. Sensor Type: The sensor type can be set for either Switch or Sender (default = Switch). H. Batt TD: A time delay from 2 to 60 seconds (default = 60 seconds) can be set before the High Battery warning message (Fault Code 442) is announced. Sensor Polarity: This menu is displayed only if the sensor type is set to Switch. Sensor polarity can be set to either Active Low or Active High (default = Active Low). Sender Type: This menu is displayed only if the sensor type is set to Sender. The sender type can be set to either 2 Wire or 3 Wire (default = 2 Wire). Wk Batt TD: A time delay from 1 to 5 seconds (default = 2 seconds) can be set before the Weak Battery warning message (Fault Code 1442) is announced. 5-43 GENSET SETUP SUBMENUS (Continued) RETURN TO PAGE 5-42 C D NOTE: These menus are available only if the the ECM CAN feature is disabled. SWITCH SENDER OR FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 3 OF 3) 5-44 Voltage Protection Submenus Overfrequency Menu The Voltage Protection submenus are available by pressing the (2) button on the first Genset Setup menu (see Figure 5-17 or Figure 5-18). This menu is used to determine when an overfrequency fault condition exists and for how long the fault condition should be present before the engine is shut down. Figure 5-20 is a block representation of the four Voltage Protection submenus that are available. Overfrequency Threshold: This threshold is used to set the amount of Hertz that the alternator line frequency can be over to activate an Overfrequency fault condition. This value can be set from 2 to 10 Hz (default = 6 Hz). High AC Voltage Menu This menu is used to determine when a high AC voltage fault condition exists and for how long the fault condition should be present before the engine is shut down. Overfrequency Delay: A time delay of 100 to 2000 half cycles (default = 1100 half cycles) must expire before the engine shuts down because of an overfrequency fault condition. If the fault condition is active for the duration of this time delay, the engine shuts down and the Overfrequency shutdown message (Fault Code 1449) is announced. High AC Voltage Threshold: This threshold is used to set the percentage of desired voltage necessary to activate a High AC Voltage fault condition. This value can be set from 105 to 125% (default = 110%). High AC Voltage Time Delay: A time delay of 1 to 10 seconds (default = 10 seconds) must expire before the engine shuts down because of a high AC voltage fault condition. If the fault condition is active for the duration of this time delay, the engine shuts down and the High AC Voltage shutdown message (Fault Code 1446) is announced. Underfrequency Menu This menu is used to determine when an underfrequency fault condition exists and for how long the fault condition should be present before the engine is shut down. Low AC Voltage Menu Underfrequency Threshold: This threshold is used to set the Hertz number that the alternator line frequency can be under to activate an Underfrequency fault condition. This value can be set from 2 to 10 Hz (default = 6 Hz). This menu is used to determine when a low AC voltage fault condition exists and for how long the fault condition should be present before the engine is shut down. Low AC Voltage Threshold: This threshold is used to set the percentage of desired voltage necessary to activate a Low AC Voltage fault condition. This value can be set from 50 to 95% (default = 85%). Underfrequency Time Delay: A time delay of 500 and 2000 half cycles (default = 1100 half cycles) must expire before the engine shuts down because of an underfrequency fault condition. If the fault condition is active for the duration of this time delay, the engine shuts down and the Underfrequency shutdown message (Fault Code 1448) is announced. Low AC Voltage Time Delay: A time delay of 2 to 20 seconds (default = 10 seconds) must expire before the engine shuts down because of a low AC voltage fault condition. If the fault condition is active for the duration of this time delay, the engine shuts down and the Low AC Voltage shutdown message (Fault Code 1447) is announced. 5-45 VOLTAGE PROTECTION SUBMENUS FIGURE 5-20. VOLTAGE PROTECTION SUBMENUS 5-46 Alternator Protection The alternator protection feature protects the alternator as well as connected loads from conditions of High AC Voltage, Low AC Voltage, Loss of AC Sense, Field Overcurrent, Overfrequency, Underfrequency, and High AC Current. Current Protection Submenus condition should be present before the warning message is displayed and, if necessary, the shutdown message is displayed and the engine is shut down. NOTE: If both the High Current Warning and High Current Shutdown faults are active at the same time, the High Current Shutdown fault is displayed. The Current Protection submenus are available by pressing the (3) button on the first Genset Setup menu (see Figure 5-17 or Figure 5-18). H. Curr Shutdown Time Delay: The High Current Shutdown Time Delay sets how long before the fault is greater than the instantaneous threshold. If the fault condition is active for the duration of this time delay (2 to 60 seconds, default = 10 seconds), the engine shuts down and the High AC Current shutdown message (Fault Code 1472) is announced. Figure 5-21 is a block representation of the Current Protection submenu. High AC Current Menu This menu is used to determine how long the fault 5-47 CURRENT PROTECTION SUBMENUS FIGURE 5-21. CURRENT PROTECTION SUBMENUS 5-48 Engine Protection Submenus The Engine Protection submenus are available by pressing the (4) button on the second Genset Setup menu (see Figure 5-17 or Figure 5-18). for how long the fault condition should be present before the engine is shut down. Speed/Freq Fault Threshold: This threshold is used to set the value necessary to activate the speed/frequency conflict shutdown fault condition. This value can be set from 0.1 to 20.0 Hz (default = 2.0 Hz). The Engine Protection submenus (see Figure 5-22) are used to set thresholds to determine when engine fault conditions exist and time delays to determine how long a fault condition is present before the fault message is announced and, if necessary, shut down the engine. Speed/Freq Fault Time Delay: A time delay of 0.2 to 10.0 seconds (default = 1 second) must expire before the warning message is announced because of a speed/frequency conflict shutdown fault condition. If the fault condition is active for the duration of this time delay, the genset is shut down and the Speed Hz Match shutdown message (Fault Code 1469) is announced. Engine Protection Overspeed Menu This menu is used to set the value necessary to shut down the genset and activate an Overspeed shutdown message (Fault Code 234) on 50 and 60 Hz gensets, indicating that the engine has exceeded normal operating speed. Overspeed (50Hz) Threshold: This threshold is used to set the overspeed value necessary to activate an Overspeed shutdown fault condition on 50 Hz gensets. This value can be set from 0 to 8192 RPM, in 25 RPM increments (default = 1725 RPM). Low Oil Pressure Warning Menu This menu is used to determine when a low oil pressure warning fault condition exists and for how long the fault condition must be present before the warning message is announced. LOP Warning Threshold: This threshold is used to set the oil pressure value necessary to activate a Pre-Low Oil Pressure warning fault condition. This value can be set from 0 to 100 PSig (default = 35 PSig). Overspeed (60Hz) Threshold: This threshold is used to set the overspeed value necessary to activate an Overspeed shutdown fault condition on 60 Hz gensets. This value can be set from 0 to 24,096 RPM, in 25 RPM increments (default = 2075 RPM). LOP Warning Time Delay: A time delay of 2 to 15 seconds (default = 8 seconds) must expire before the warning message is announced because of a low oil pressure warning fault condition. If the fault condition is active for the duration of this time delay, the Pre-Low Oil Pressure warning message (Fault Code 143) is announced. Engine Protection Speed/Frequency Menu This menu is used to determine when a speed/frequency conflict shutdown fault condition exists and 5-49 ENGINE PROTECTION SUBMENUS NOTE: These menus are available only if the the ECM CAN feature is disabled. B A CONTINUED ON PAGE 5-52 FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3) 5-50 set from 150 to 290 degrees F (default = 215 degrees F). Low Oil Pressure Shutdown Menu This menu is used to determine when a low oil pressure shutdown fault condition exists and for how long the fault condition should be present before the engine is shut down. LOP Shutdown Threshold: This threshold is used to set the oil pressure value necessary to activate a Low Oil Pressure Shutdown fault condition. This value can be set from 0 to 100 PSig (default = 30 PSig). LOP Shutdown Time Delay: A time delay of 2 to 15 seconds (default = 8 seconds) must expire before the engine shuts down because of a low oil pressure fault condition. If the fault condition is active for the duration of this time delay, the engine shuts down and the Low Oil Pressure shutdown message (Fault Code 415) is announced. HCT Warning Time Delay: A time delay of 2 to 10 seconds (default = 2 seconds) must expire before the warning message is announced. If the fault condition is active for the duration of this time delay, the High Coolant Temperature warning message (Fault Code 146) is announced. High Coolant Temperature Shutdown Menu This menu is used to determine when a high coolant temperature shutdown fault condition exists and for how long the fault condition should be present before the engine is shut down. HCT Shutdown Threshold: This threshold is used to set the temperature value necessary to activate a High Coolant Temperature Shutdown fault condition. This value can be set from 180 to 300 degrees F (default = 223 degrees F). High Coolant Temperature Warning Menu HCT Shutdown Time Delay: A time delay of 2 to 10 seconds (default = 2 seconds) must expire before the engine shuts down because of a high coolant temperature fault condition. If the fault condition is active for the duration of this time delay, the engine shuts down and the High Coolant Temperature shutdown message (Fault Code 151) is announced. This menu is used to determine when a high coolant temperature warning fault condition exists and for how long the fault condition should be present before the warning message is announced. HCT Warning Threshold: This threshold is used to set the temperature value necessary to activate a High Coolant Temperature Warning fault condition. This value can be 5-51 ENGINE PROTECTION SUBMENUS (Continued) NOTE: These menus are available only if the the ECM CAN feature is disabled. RETURN TO PAGE 5-50 A B D C CONTINUED ON PAGE 5-54 FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 2 OF 3) 5-52 Charger Failed H Threshold: This threshold is used to set the high charging alternator voltage value. This value can be set from 13.0 to 20.0 VDC (default = 18.0 VDC) for 12V units and from 25.0 to 40.0 VDC (default = 32.0 VDC) for 24V units. Engine Protection Low Coolant Temperature and Battery Charger Menus The low coolant temperature menu is used to determine when the genset’s coolant temperature is too low and a Low Coolant Temperature warning message (Fault Code 1435) is announced. This warning message is not announced unless the coolant temperature has been determined to be low for one minute. Charger Failed L Threshold: This threshold is used to set the low charging alternator voltage value. This value can be set from 2.0 to 13.0 VDC (default = 5.0 VDC) for 12V units and from 2.0 to 25.0 VDC (default = 10.0 VDC) for 24V units. LCT Warning Threshold: This threshold is used to set the temperature value necessary to activate a Low Coolant Temperature Warning fault condition. This value can be set from 32 to 100 degrees F (default = 70 degrees F). Charger Failed Time Delay: A time delay of 2 to 300 seconds (default = 120 seconds) must expire before the warning message is announced. If the fault condition is active for the duration of this time delay, the Charger Failure warning message (Fault Code 2678) is announced. The battery charger menu is used to determine when the alternator charger failure condition exists and when the warning message should be announced. The fault condition exists when either the low or high threshold is reached. 5-53 ENGINE PROTECTION SUBMENUS (Continued) NOTE: These menus are available only if the the ECM CAN feature is disabled. C RETURN TO PAGE 5-52 D FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 3 OF 3) 5-54 6. Troubleshooting INTRODUCTION The 1302 series control continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these conditions occur, the control (with graphical display) will light a yellow warning lamp or a red shutdown lamp and display a message on the graphical display. A control without the graphical display indicates a shutdown condition by intermittent flashing of the status indicator. When the control is paired with a Cummins ECM on Full Authority Electronic the local engine inputs are ignored. Instead, the control receives all engine related faults and messages from the ECM. Fault codes are still shown on the HMI or status indicator as if they were local to the PCC1302 controller. PC BASED SERVICE TOOL The PC based service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions. When used improperly, a PC based service tool can cause symptoms like warnings and shutdowns that appear to be a defective base board. When these problems occur, always verify that a self-test or fault simulation (override) have not been left enabled with the tool. If you do not have a PC based service tool, or the enabled fault simulation(s) can not be found using the tool, disconnect battery power to disable the test or override condition. Make sure that parameter adjustments and time delays, related to the fault condition, have been appropriately set for the application. It may be necessary to write the initial capture file to the device or update the calibration file. Updating a calibration file requires the a pro version of many of PC based service tools. Confirm that the installed calibration part number matches the serial plate information. Using the wrong calibration file can result in equipment damage. Do not swap Base boards from another genset model and only use the calibration file shown on the nameplate. CAUTION Some features are not available until the hardware for that feature is installed and the PC based ser- vice tool is used to update (enable) that feature. Confirm that the feature is installed and enabled prior to troubleshooting the base board for symptoms related to a feature. NETWORK APPLICATIONS AND CONFIGURABLE INPUTS In applications with networks and remote configurable inputs, the genset may start unexpectedly or fail to crank as a result of these inputs. These symptoms may appear to be caused by the base board. Verify that the remote input is not causing the symptom or isolate the control from these inputs before troubleshooting the control. SAFETY CONSIDERATIONS Contacting high voltage components can cause electrocution, resulting in severe personal injury or death. Keep the output box covers in place during troubleshooting. WARNING WARNING Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables—Disconnect negative (−) cable first and reconnect last. CAUTION Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the genset. WARNING Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (−) cable from the battery terminal. When troubleshooting a generator set that is shut down, make certain the generator set cannot be accidentally restarted as follows: 6-1 1. For installations without the optional operator panel: Move the Start/Off/Auto switch on the control panel to the OFF position. 2. For installations with the optional operator panel: Press the button (0) to switch the control into the Off mode. 3. Turn off or remove AC power from the battery charger. Warning fault codes are not displayed by the status indicator lamp. A PC based service tool is needed to read warning fault codes. The following describes how to interpret the status indicator light. Do not move the control switch to the OFF position before interpreting the fault code. Moving the switch to OFF will clear the fault indication. Constant Rate Flashing = Engine preheat /genset starting. 4. Remove the negative (−) battery cable from the generator set starting battery. Constant On = Genset running. Variable Rate Flashing = A genset Shutdown fault condition exists (Warning conditions are not displayed). All of the Shutdown faults described in section 14 can be announced with the status indicator lamp. READING FAULT CODES If the genset contains the graphical display and a fault occurs, the fault code/message can be viewed in the display. If the control does not contain the graphical display, the fault code is read from the control switch indicator. After the fault is acknowledged and corrected, the recorded fault will be deleted from the control panel memory, but will remain in a data log to maintain a fault code history and fault code occurrence table. A PC-based service tool is required to view this data log. Reading Fault Codes Using Optional Operator Panel The warning or shutdown LED will light and the fault symbol, and code will be displayed on the display. Refer to the Fault Code List in the Protection and Faults section for the exact name of the fault. Reading Fault Codes Using the Control Switch Indicator 1302 series control without display): The control panel rocker switch contains a status indicator lamp. This lamp is used to flash genset status and shutdown fault codes. (Only the last shutdown fault code is flashed.) An example of a four digit fault code − first digit in the code is flashed, followed by a half−second pause, and then the second digit is flashed, followed by a half−second pause, followed by a half− second pause, and then the third digit is flashed, followed by a half−second pause, and then the fourth digit is flashed, followed by a one second pause. TROUBLESHOOTING PROCEDURES The following tables are a guide to help you evaluate problems with the generator set. You can save time if you read through the manual ahead of time and understand the system. Voltage/Continuity Testing Voltage and continuity tests are required in the following tables. In some cases, it is necessary to remove a plug to complete the test. Where required, the corrective action will mention when it is necessary to remove a plug for testing. In other cases, the plug cannot be removed for testing. When plug removal is not mentioned, testing must be performed by inserting a narrow meter probe into the back of the plug. 6-2 TABLE 6-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: This indicates that the control has not received or recognized a manual start signal. Effect: Engine will not start. POSSIBLE CAUSE ENGINE PLATFORM No power supplied to the control due to poor battery cable connections. Clean the battery cable terminals and tighten all connections. CORRECTIVE ACTION FAE Engines HM Engines 1. Check wakeup conditions. 1. Check wakeup conditions. 2. Check for poor battery cable connections. Clean the battery cable terminals and tighten all connections. 2. Check for poor battery cable connections. Clean the battery cable terminals and tighten all connections. 3. Remove connector P20 and check for B+ at P20-9 and P20-10 and GND at P20-2 and P20-4. If B+ or ground is missing, isolate to the harness and the TB BAT terminal mounted on the engine block. If B+ and ground check OK, cycle power to Base board by reconnecting P20 and retry operation. 3. Remove connector P20 and check for B+ at P20 and P20-10 and GND at P20-2. If B+ or ground missing, isolate to harness and TB BAT terminal mounted on engine block. If B+ and ground check OK, cycle power to Base board by reconnecting P20 and retry operation. Check for B+ at TB1-5 and GND at TB1-3. If ground is missing, the Base board is defective and must be replaced. If B+ is missing, then: Check for B+ at TB1-5 and GND at TB1-3. If ground is missing, the Base board is defective and must be replaced. If B+ is missing, then: 1. If B+ and ground check are OK, remove P1 from the back of the front membrane panel. 1. If B+ and ground check are OK, remove P1 from the back of the front membrane panel. 2. Check for B+ at P1-3 and ground at P1-5. If B+ or ground is missing, repair the harness. 2. Check for B+ at P1-3 and ground at P1-5. If B+ or ground is missing, repair the harness. Base board not properly calibrated or corrupt calibration. Confirm that the installed calibration part number matches the serial plate information. Re-enter the calibration file if necessary. Confirm that the installed calibration part number matches the serial plate information. Re-enter the calibration file if necessary. The Remote Emergency Stop switch or wiring is defective. With Emergency Stop push button not activated (switch closed), remove configurable leads from TB1-15 and TB1-16 and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to the next step. With Emergency Stop push button not activated (switch closed), remove configurable leads from TB1-15 and TB1-16 and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to the next step. 1302 series control with display: No power supplied to front membrane panel. 6-3 TABLE 6-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the control has not received or recognized a manual start signal. Effect: Engine will not start. POSSIBLE CAUSE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines The Local Emergency Stop switch or wiring is defective. With the Emergency Stop push button not activated (switch closed), check for continuity between J25-2 and J25-6. If the circuit is open, isolate to the Emergency Stop switch and wiring. If there is continuity, go to the next step. With the Emergency Stop push button not activated (switch closed), check for continuity between J25-2 and J25-6. If the circuit is open, isolate to the Emergency Stop switch and wiring. If there is continuity, go to the next step. 1302 series control without display: The Manual input signal is not getting from the Manual select switch (S12) to the Base board, indicting that the S12, Base board, or the harness is defective. Remove connector P25 from the Base board. With Start switch in the Manual position, check for continuity between P25-10 (RUN) to P25-8 (GND). If there is no continuity, isolate to the switch and wiring. If there is continuity, the Base board is defective and needs to be replaced. Remove connector P25 from the Base board. With the Start switch in the Manual position, check for continuity between P25-10 (RUN) to P25-8 (GND). If there is no continuity, isolate to the switch and wiring. If there is continuity, the Base board is defective and needs to be replaced. 1302 series control with display: The menu display Manual Run button, harness, or the Base board is defective. Check for continuity between P25-10 (RUN) to P25-8. If there is no continuity when pressing the Manual Run button, isolate to the front membrane panel and wiring. If there is continuity, the Base board is defective and needs to be replaced. Check for continuity between P25-10 (RUN) to P25-8. If there is no continuity when pressing the Manual Run button, isolate to the front membrane panel and wiring. If there is continuity, the Base board is defective and needs to be replaced. Oil Pressure switch or wiring is defective 1. Remove the P11 connection and check wiring between P11-2 and P11-3 to the switch. 2. Verify control is configured for the type of switch installed. 3. Verify proper operation of the switch. Oil Pressure sender, setup on wiring is defective. 1. Remove the P11 connection and check wiring between P11-1, P11-2, and P11-3 (for 3-wire sender) to the sender. 2. Verify that the control is configured for the correct type of sender (see Figure 5-19, sheet 3). 3. Verify operation of the sender. CAN Datalink Failed Refer to Fault Code 427 or 781. 6-4 TABLE 6-2. ENGINE DOES NOT CRANK IN REMOTE MODE (NO FAULT MESSAGE) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the 1302 series control has not received or recognized a remote start signal. Effect: Engine will not start in Remote mode, but starts in manual mode. POSSIBLE CAUSE The remote start switch or configurable wiring is defective. CORRECTIVE ACTION 1. Reset the control. Attempt to start the engine and check for ground at TB1-11. 2. If ground level is not present, isolate to the remote switch or configurable wiring. Repair as necessary. 3. If ground is present, go to the next step. 1302 series control without display: The Auto mode input is not getting from the Auto Select switch to the Base board, indicting that S12, the Base board, or the harness is defective. 1. Remove connector P11 from the Base board. 1302 series control with display: The menu display Auto button, harness, or the Base board is defective. 1. Check for continuity between P25-11 (AUTO) and P25-8 (GND). 2. With S12 in Auto position, check for continuity from P25-11 (AUTO) to P25-8 (GND). 3. If there is no continuity, isolate to the switch or the wiring harness. If there is continuity, the Base board is defective and must be replaced. 2. If there is no continuity when pressing the menu display Auto button, isolate to the front membrane panel or the wiring harness. If there is continuity, the Base board is defective and must be replaced. For more information, see Table 6-1, Will Not Crank in Manual Mode. 6-5 TABLE 6-2. 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, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING FAULT CODE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines 121 SPEED SIGNAL LOST Lamp: Shutdown Not applicable on FAE engines. Indicates that no magnetic pickup pulses are sensed for a Loss of Speed delay. If a magnetic pickup is not installed, then speed sensing is performed by monitoring AC line frequency and this fault cannot occur. 141. 135 OIL PRESS SENSOR OOR L/H Lamp: Warning Indicates that the engine controller has sensed that the engine oil pressure sensor output is out of range (high or low). Consult the engine service manual and check the sender/connectors/wires. Indicates that the control has sensed that the engine oil pressure sensor output is out of range (high or low). Check the sender/connectors/wires. This warning will only occur if the genset is equipped with an oil pressure sender. 143 PRE-LOW OIL PRESSURE Lamp: Warning Indicates the engine oil pressure has dropped below the warning trip point programmed into the engine controller. If the generator is powering critical loads and cannot be shut down, wait until the next shutdown period and then follow the Fault Code 415 procedure. Indicates the engine oil pressure has dropped below the warning trip point. If the generator is powering critical loads and cannot be shut down, wait until the next shutdown period and then follow the Fault Code 415 procedure. This warning will only occur if the genset is equipped with an oil pressure sender. 144, 145 COOL SENSOR OOR LOW/HIGH Lamp: Warning Indicates that the engine controller has sensed that the engine coolant temperature sensor output is out of range (high or low). Consult the engine service manual and check the sender/connectors/wires. Indicates that the control has sensed that the engine coolant temperature sensor output is out of range (high or low). Check the sender/connectors/wires. 146 PRE-HIGH COOL TMP Lamp: Warning Indicates the engine is operating near its cooling system capacity. An increase in load or higher ambient temperature may cause a High Coolant Temp shutdown. Review Fault Code 151 correction list for other possible causes. Indicates the engine is operating near its cooling system capacity. An increase in load or higher ambient temperature may cause a High Coolant Temp shutdown. Review Fault Code 151 correction list for other possible causes. 6-6 TABLE 6-2. 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, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING FAULT CODE CORRECTIVE ACTION ENGINE PLATFORM FAE Engines HM Engines 151 HIGH COOLANT TEMP Lamp: Shutdown Indicates the engine has overheated (coolant temperature has risen above the shutdown trip point set at the engine controller). Allow the engine to cool down completely before proceeding with the following checks: Indicates the engine has overheated (coolant temperature has risen above the shutdown trip point). Allow the engine to cool down completely before proceeding with the following checks: 1. Consult the engine service manual and reset the PCC1302. 1. Check the coolant level and replenish if low. Look for possible coolant leakage points and repair if necessary. 2. Restart the generator after locating and correcting the problem. 2. Check for obstructions to the cooling airflow and correct as necessary. 3. Check the fan belt and repair or tighten if necessary. 4. Check the blower fan and circulation pumps on remote radiator installations. 5. Reset the control and restart the generator after locating and correcting the problem. 415 LOW OIL PRESSURE Lamp: Shutdown Indicates the engine oil pressure has dropped below the shutdown trip point programmed into the engine controller. 1. Consult the engine service manual and reset the control. 2. Restart the generator after locating and correcting the problem. Indicates the engine oil pressure has dropped below the shutdown trip point. 1. Check the oil level, lines, and filters. 2. If the oil system is OK but the oil level is low, replenish. 3. Reset the control and restart the genset. 4. If an oil switch is used, check switch performance. 234 OVERSPEED Lamp: Shutdown Indicates the engine has exceeded normal operating speed. The default thresholds are preprogrammed in the engine controller. An engine service tool such as Insite or CalTerm III is required to change threshold settings. Possible causes are single step large block load removal or flammable vapors drawn into the intake air passage. Reset the control and restart after locating and correcting the problem. 6-7 Indicates engine has exceeded normal operating speed. The default thresholds are 1725 RPM (50 Hz) or 2075 RPM (60 Hz). Possible causes are single step large block load removal or flammable vapors drawn into the intake air passage. Reset the control and restart after locating and correcting the problem. TABLE 6-2. 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, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING FAULT CODE ENGINE PLATFORM 359 FAIL TO START Lamp: Shutdown CORRECTIVE ACTION FAE Engines HM Engines Indicates a possible fuel system or air induction problem. (Engine cranks but fails to start) Indicates a possible fuel system or air induction problem. (Engine cranks but fails to start) Consult the engine service manual for possible causes / solutions. 1. Check for an empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. 2. Check for a dirty fuel filter and replace if necessary. 3. Check for a dirty or plugged air filter and replace if necessary. 4. Reset the control and restart after correcting the problem. 441 LOW BATTERY Lamp: Warning Indicates the battery voltage supply to the control is approaching a low level at which an unpredictable operation will occur. 1. Discharged or defective battery. Check the battery charger fuse. Recharge or replace the battery. 2. Check for poor battery cable connections. Clean the battery cable terminals and tighten all connections. 3. Check the battery wiring/calibration. 4. Check the engine DC alternator. Replace the engine DC alternator if normal battery charging voltage is not obtained. 5. Check the battery charge voltage float level if applicable (raise float level). 442 HIGH BATTERY Lamp: Warning Indicates the battery voltage supply to the control is approaching a high level at which damage to the control can occur. Check the float level on the battery charger if applicable (lower float level). Check battery wiring/calibration. 1123 SHUTDOWN AFTER BATTLESHORT Lamp: Shutdown A shutdown fault occurred while the Battle Short mode was enabled. Check the fault history (see Figure 4-18) for faults that may have been bypassed. 1131 BATTLE SHORT ACTIVE Lamp: Warning Indicates that the control is in Battle Short mode − used to bypass several fault shutdowns, therefore allowing genset operation during emergencies. The nature of the fault is an optional configurable selection. Example inputs: Low Fuel 1311, 1312, 1317, 1318 CONFIGURABLE INPUT Day Tank, Water In Fuel, Ground Fault, etc. 1, 2, 3, 4 Each of the fault functions can be programmed (using a service tool or the operator Lamp: Configurable panel), as follows: Event or Warning or Shutdown level if Function Select = Fault Input Change the display name using up to 32 characters. 6-8 TABLE 6-2. 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, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING FAULT CODE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines 1416 FAIL TO SHUTDOWN Lamp: Warning The genset continues to run after receiving a shutdown command from the controller. The Battle Short feature is enabled − this is used to bypass several critical fault shutdowns, therefore allowing genset operation during emergencies. 1433 REMOTE EMERGENCY STOP Lamp: Shutdown Indicates a Remote Emergency Stop. To reset the Remote Emergency Stop button: 1. Close (disable) the remote Emergency Stop button. 2. Move the control switch to the OFF position or press the OFF button. 3. Select the desired operating mode (Manual or Auto). If the application has a remote fault reset, the fault can also be reset by closing the fault reset switch. 1434 LOCAL EMERGENCY STOP Lamp: Shutdown Indicates a Local Emergency Stop. To reset the Local Emergency Stop button: 1. Close (disable) Local Emergency Stop button. 2. Move the control switch to the OFF position or press the OFF button. 3. Select the desired operating mode (Manual or Auto). If the application has a remote fault reset, the fault can also be reset by closing the fault reset switch. 1435 LOW COOLANT TEMP Lamp: Warning Set is not operating. Warning occurs when engine coolant temperature is 70_F (21_C) or lower. Indicates the engine coolant heater is not operating or is not circulating coolant. Check for the following conditions: The coolant heater is not connected to the power supply. Check for a blown fuse or a disconnected heater cord and correct as required. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. NOTE: In applications Check for an open heater element. Check the heater’s current draw. where the ambient temThe coolant temperature must be below 70_F (default setting) for one minute to actiperature falls below vate a warning and must be above 70_F for one minute before the warning is cleared. 40_F (4_C), Low Coolant Temp may be indicated even though the coolant heaters are operating. 1438 FAIL TO CRANK Lamp: Shutdown The control has failed to receive engine speed from ECM during cranking. Consult the engine service manual for MPU diagnostic. See Fault Code 427 or 781 for datalink health diagnostic. 1442 WEAK BATTERY Lamp: Warning Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time. 1446 HIGH AC VOLTAGE Lamp: Shutdown Indicates that one or more of the line-to-neutral phase voltages has exceeded 130% of nominal for 0 second, or has exceeded high AC voltage threshold of nominal for time delay seconds. 6-9 The genset has failed to sense rotation for two start attempts. This indicates a possible fault with the control, speed sensing, or starting system. This fault can only occur in gensets with a magnetic pickup installed and enabled. TABLE 6-2. 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, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING FAULT CODE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines 1447 LOW AC VOLTAGE Lamp: Shutdown Indicates that one or more of the line-to-neutral phase voltages has dropped below low the AC voltage threshold for time delay seconds. 1448 UNDER FREQUENCY Lamp: Shutdown Indicates that the genset frequency has dropped below 90% of nominal for approximately 10 seconds. 1449 OVER FREQUENCY Lamp: Shutdown Indicates frequency is 10% above base frequency for approximately 10 seconds. 1469 SPEED HZ MATCH Lamp: Shutdown Not Applicable on FAE engines. Check the fuel supply, intake air supply, and load. Indicates that the measured speed and the measured AC output frequency do not agree. Check the genset setup for number of flywheel teeth (see Figure 5-19, sheet 1). 1471 HIGH AC CURRENT Lamp: Shutdown Indicates that an individual phase of alternator output current has exceeded the high current threshold of the rated output current continuously for more than the set time delay. Check the load and load lead connections. 1472 HIGH AC CURRENT Lamp: Warning Indicates that one or more of the phase currents has exceeded the high AC warning threshold for the set time delay seconds. 1853, 1854, 1855 ANNUNCIATOR FAULT 1, 2, 3 Lamp: Configurable The nature of the annunciator fault is an optional configurable selection. 1944 ANNUNCIATOR OUTPUT CONFIGURATION ERROR Lamp: Warning Indicates a mismatch in the configuration of one of the annunciator relay outputs. 2335 LOSS OF AC SENSE Lamp: Shutdown Indicates a loss of zero cross detection. Check alternator voltage sense and excitation leads for shorts or opens. Check load for shorts. 2676 ALTERNATOR FREQUENCY CONFLICT Lamp: Shutdown Indicates the alternator line frequency and alternator excitation frequency do not match. Check the load and load lead connections. 1. Check the Alternator Frequency Gain trim using the Operator Panel (see Figure 5-19, sheet 1) or InPower. 2. Measure the alternator line frequency (J22-1 to J22-4). Measure the alternator excitation frequency (J18-1 to J18-2). The alternator line frequency * Alternator Frequency Gain should equal the excitation frequency. The alternator line frequency and alternator excitation frequency are also viewable with InPower. 3. Check voltage sense leads and excitator power lead for open or shorts. 6-10 TABLE 6-2. 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, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING FAULT CODE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines 2677 FAIL TO STOP Lamp: Shutdown Genset continues to run after receiving shutdown command from the controller. Genset continues to run after receiving a shutdown command from the controller. The keyswitch relay is the what the PCC1302 uses to tell the engine controller to stop. Check the keyswitch relay operation and make sure it isn’t stuck closed. Activating either emergency stop switch should open the keyswitch relay. Consult the engine service manual for other possible causes / solutions. Check for a stuck fuel actuator and fuel shutoff valve. 2678 CHARGER FAILURE Lamp: Warning Indicates the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120 seconds). Refer to the engine service manual if this fault occurs. If not failed, check wiring. 2972 FIELD OVERLOAD Lamp: Shutdown Indicates that the Field AVR Duty Cycle has been at the maximum for at least 15 seconds. 6-11 TABLE 6-3. CODE 121 − SPEED SIGNAL LOST (SHUTDOWN) − GENSETS WITH MPU WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: This indicates that the control is not sensing the magnetic pickup signal. Effect: Engine will shut down. POSSIBLE CAUSE 1. There are loose or damaged magnetic pickup (MPU) wires/ connector pins. CORRECTIVE ACTION Inspect the wires/connector pins and repair or replace as necessary. 2. The magnetic pickup, To isolate the problem, reset the control and attempt to start the genset. harness or Base If Fault Code 1438 (Fail To Crank) is displayed, or if the engine starts, but then shuts board is defective. down on Fault Code 121 (Speed Signal Lost), the MPU sender could be defective. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking. If there is no output, check for damage or debris. Also check for improper adjustment of the MPU. If there is still no output, replace the MPU sender. If the MPU output is OK, check for MPU voltage at P11-9 (MAG PICK+) to P11 10 (MAG PICK−) while cranking. If OK, replace the Base board. If not OK, use continuity checks to isolate connectors/harness. If the engine starts and idles, and does not display a fault, then there could be a frequency mismatch problem. Measure the generator output frequency with a digital multimeter and compare to the frequency shown on the operator panel or the PC based service tool. Verify that the number of flywheel teeth has been correctly configured (see Figure 5-19, sheet 1 for information on how to adjust the flywheel tooth setting using the operator panel). If they do match, multiply the frequency by Speed/Freq Gain Select trim (typically 30) and compare this number to the RPM on the operator panel or PC based service tool. If these are not the same, the MPU sender may be defective. Replace the MPU sender. If the multimeter and control frequencies do not match, there is a frequency sensing problem within the Base board. Replace the Base board. 3. Restricted fuel supIn order to fix the problem, you need to make sure that there is an adequate fuel supply. The engine may ply that is free of clogs or leaks. fire once during cranking which could cause the engine to speed up past the starter disconnect speed. Due to the restricted fuel supply, the engine will not turn over anymore and the 1302 control panel will display fault code 121 once the engine stops spinning. 6-12 TABLE 6-4. CODE 135/141 − OIL PRESSURE SENSOR OOR HIGH/LOW (WARNING) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the engine oil pressure sensor signal is out of range − shorted high or low. Effect: There is no engine protection for oil pressure during genset operation. POSSIBLE CAUSE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines The sensor connections could be defective. Consult the engine service manual. Inspect the sensor and engine harness connector pins. Repair or replace as necessary. The sensor could be defective. Consult the engine service manual. Disconnect the oil pressure sensor leads and connect an oil pressure sensor simulator to the harness. An “OIL PRESSURE SENSOR OOR” warning is displayed after the fault condition is sensed for 10 seconds. If the control responds to the simulator, replace the sensor. If the control does not respond, go to the next step. The harness could be defective. Consult the engine service manual. 1. Remove connector P11 from the Base board and the connector from the sensor. 2. Check P11-1, 2 & 3 as follows: Check for a short circuit from pin to pin (more than 200k ohms is OK). Check for an open circuit (10 ohms or less is OK). 3. Repair or replace as necessary. The Base board could be Consult the engine service manual. defective. With all connectors attached, check the pressure signal (.5 to 4.5 VDC) at P11-3 (OP OUT) and P11-2 (OP COM). If within range, replace the Base board. TABLE 6-5. CODE 143 − PRE-LOW OIL PRESSURE (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: The engine oil pressure has dropped below the warning/shutdown threshold for pre-low oil pressure. Effect: No action is taken by the control. POSSIBLE CAUSE CORRECTIVE ACTION Refer to Fault Code 415. Refer to Fault Code 415. 6-13 TABLE 6-6. CODE 143/415 − LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure. Effect: Calibration-dependent. No action is taken by the Control for Fault Code 143. Engine will shut down for Fault Code 415. POSSIBLE CAUSE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines Fault simulation was enabled with a PC based service tool. With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor. Low oil level. Clogged lines or filters. Check the oil level, lines, and filters. If the oil system is OK but the oil level is low, replenish. If you do not have a PC based service tool, remove battery power from the control to disable the fault simulation overrides. The sensor or oil pump Consult the engine service manual. could be defective. Or the generator set may be shutting down on another fault. Disconnect the oil pressure sensor leads and connect an oil pressure sensor simulator to the harness. 1. If the control responds to the simulator, reconnect the sensor, disconnect the + signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The genset may be shutting down on another fault (out of fuel, intermittent connector). Restart the genset and monitor the display panel for other faults. If the display does not show an acceptable oil pressure, replace the sensor. If the Control still doesn’t display an oil pressure while cranking, the oil pump may be defective. Refer to the engine service manual. 2. If the control does not respond to the simulator, go to the next step. 6-14 TABLE 6-6. CODE 143/415 − LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure. Effect: Calibration-dependent. No action is taken by the Control for Fault Code 143. Engine will shut down for Fault Code 415. POSSIBLE CAUSE ENGINE PLATFORM Harness or Base board could be defective. CORRECTIVE ACTION FAE Engines HM Engines Consult the engine service manual. If the control does not respond to the simulator, the Base board or the harness is defective. Check for +5 VDC at the sensor (lead marked S1). If there is no 5 VDC at the sensor: Check for 5 VDC at P11-1. If present, the harness is defective and must be replaced. If not present, the Base board is defective and must be replaced. If there is 5 VDC at the sensor, use the sensor simulator to generate a signal to P11-3 (Oil Sense) and P11-2 (Oil Comm.). If the pressure signal (0.5 to 4.5 VDC) does not get to P11, isolate to the harness. If the pressure signal does go to P11, the Base board is defective and must be replaced. Low Oil Pressure fault set points could be incorrect. Consult the engine service manual. Verify set points against the normal operating pressures of the engine. Refer to the engine service manual. TABLE 6-7. CODE 145/144 − COOLANT SENSOR OOR HIGH/LOW (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: This indicates that the coolant temperature sensor signal is out of range − shorted high or low. Effect: No engine protection for coolant temperature during genset operation. Possible white smoke. POSSIBLE CAUSE ENGINE PLATFORM The sensor connections could be defective. CORRECTIVE ACTION FAE Engines HM Engines Consult the engine service manual. 6-15 Inspect the sensor and engine harness connector pins. Repair or replace as necessary. TABLE 6-7. CODE 145/144 − COOLANT SENSOR OOR HIGH/LOW (WARNING) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the coolant temperature sensor signal is out of range − shorted high or low. Effect: No engine protection for coolant temperature during genset operation. Possible white smoke. POSSIBLE CAUSE ENGINE PLATFORM The sensor could be defective. CORRECTIVE ACTION FAE Engines HM Engines Consult the engine service manual. Disconnect the sensor and plug in a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, go to the next step. The harness or Base Consult the engine service manual. board could be defective. 1. Remove connector P11 from the Base board and disconnect the sensor. Check pins P11-11 (H20) and P11-12 (H20 COM) for a short circuit as follows: Check for a short circuit to the engine block ground (more than 200k is ohms OK). Check for a short circuit from pin to pin (more than 200k ohms is OK). Repair or replace as necessary. 2. Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector P11 from the Base board and check resistance between pins P11-11 (H20) and P11-12 (H20 COM). If resistance is not the same, the harness is defective and must be replaced. If resistance is the same, the Base board is defective and must be replaced. TABLE 6-8. CODE 146 − PRE-HIGH COOLANT TEMP (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: The engine coolant temperature has exceeded the warning threshold for pre-high coolant temperature. Effect: No action is taken by the control. POSSIBLE CAUSE CORRECTIVE ACTION Refer to Fault Code 151. Refer to Fault Code 151. 6-16 TABLE 6-9. CODE 146/151 − HIGH OR PRE-HIGH COOLANT TEMPERATURE (WARNING/SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature. Effect: Calibration-dependent. No action is taken by the Control for Fault Code 146. Engine will shut down for Fault Code 151. POSSIBLE CAUSE ENGINE PLATFORM Fault simulation was enabled with a PC based service tool. CORRECTIVE ACTION FAE Engines HM Engines With a PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. Engine or sensor circuitry Refer to the engine service manual. problem. Check sensor accuracy with a thermocouple or similar temperature probe. If the coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. If the coolant temperature reading is not accurate, go to the next step. The sensor could be defective. Refer to engine service manual. Disconnect the sensor and connect a coolant temperature sensor simulator to the harness. If the control responds to the simulator, replace the sensor. If the control does not respond, go to the next step. The harness or Base Not applicable. board could be defective. Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector J11 from the Base board and check resistance between pins P11-11 (H20) and P11-12 (H20 COM). If resistance is not the same, the harness is defective and must be replaced. If resistance is the same, the Base board is defective and must be replaced. 6-17 TABLE 6-10. CODE 153, 154, 155, 195, 196, 197, 285, 286, 418, 426, 1845, 1846, 1852, 1992, 2964 − ENGINE FAULTS ANNOUNCED BY THE PCC1302 (EVENT/WARNING/SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: The engine controller has sensed a fault condition and is broadcasting the fault message. The PCC1302 is uniquely announcing the fault code. Effect: Event, Shutdown, or Warning POSSIBLE CAUSE Consult the engine service manual. CORRECTIVE ACTION Consult the engine service manual. TABLE 6-11. CODE 234 − OVERSPEED (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Engine speed signal indicates an engine speed greater than shutdown threshold. Effect: Engine will shut down. POSSIBLE CAUSE CORRECTIVE ACTION The engine is cold (no coolant heaters) Overspeed can occur when starting a very cold engine. Clear the fault and restart the genset. There is a single step large block load removal. Clear the fault and restart the genset. A fault simulation was enabled with a PC based service tool. With a PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. The fault threshold is not set correctly with the PC based service tool. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. If you do not have PC based service tool, remove battery power from the control to disable fault simulation overrides. Monitor the engine RPM If the RPM is not correct, refer to Fault Code 121 for corrective action. using a PC based service tool. There is a governor fault. 1. Check the fuel shutoff solenoid adjustment. 2. Replace the defective injection pump unit. The flywheel tooth count is incorrect. For gensets with a magnetic pickup installed, verify that the flywheel tooth count is correct for the engine type. Refer to Table 3-25 for a list of flywheel teeth requirements and Figure 5-19, sheet 1 for information on how to adjust the flywheel tooth setting using the operator panel. The mechanical fuel system setup is incorrect. Verify that the fuel stop settings are correct for your application. 6-18 TABLE 6-12. CODE 359 − FAIL TO START (SHUTDOWN) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the engine failed to start after expiration of the last crank time. Effect: Engine will not start. POSSIBLE CAUSE CORRECTIVE ACTION Restricted fuel supply because: 1. The fuel level is below the pickup tube in the tank. 1. Add fuel if low. Prime the fuel system. 2. There is a closed shutoff valve in the supply line. 2. Open any closed shutoff valve in the fuel line supplying the engine. 3. The fuel injectors are clogged. 3. Refer to the engine service manual. 4. There is air in the fuel system. 4. Bleed air from fuel system. Refer to the engine service manual. Glow plugs are not heating because: The Base board determines at what temperature and duration of time that the glow plugs are energized. Using sensed coolant temperature, the glow plugs are energized at 77_F (25_C) and colder. The glow plugs are energized for up to 15 seconds when the coolant temperature is −5_F (−20.5_C) or colder. The time duration (15−0 seconds) is linear between −5_F and 77_F. With the coolant temperature colder than 77_F (25_C): 1. The glow plug(s) is defective. 2. The Base board is defective. 1. Each glow plug should be warm to the touch if the engine has just been cranking. First clean and tighten the terminal of any cold glow plug and then replace it if necessary. 2. Install a harness tool between the Base board P11 connector. Attempt to start the engine and check for B+ at P11-6 (RELAY COIL B+) and GND at P11-7 (GLOW PLUG SOL). If B+ / GND is not present, the Base board is defective and must be replaced. If B+ / GND is present, go to step 3. 3. The glow plug relay is defective. 3. Check for B+ at the glow plug relay. If not present, check for an open circuit. If there is B+ at the glow plug relay, attempt to start and test for B+ at the other end of the glow plug relay. If B+ is not present, the glow plug relay is defective and must be replaced. If B+ is present, check for an open circuit between the glow plug relay contact and the glow plugs. 6-19 TABLE 6-12. CODE 359 − FAIL TO START (SHUTDOWN) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the engine failed to start after expiration of the last crank time. Effect: Engine will not start. POSSIBLE CAUSE The fuel solenoid on the injection pump is not energized because: 1. The fuse is open. CORRECTIVE ACTION Isolate to the fuse, fuel relay, fuel solenoid, or the Base board. 1. Remove the fuse (if installed) and check continuity. If open, replace the fuse with one of the same type and amp rating. If the fuse reopens, check wiring continuity of the fuel solenoid circuit/test fuel solenoid. Binding in the solenoid linkage can prevent activation of the hold coil circuitry in the solenoid. Make sure the solenoid shaft moves completely in and out freely. (Applies to solenoids with both Pull and Hold coils.) 2. The fuel solenoid is defective. 2. Attempt to start the engine and check for B+ at the fuel solenoid coil. If B+ is present, the fuel solenoid is defective and must be replaced. If B+ is not present, go to step 3. 3. The Base board/K8 fuel relay is defective. 3. Check wiring continuity/test K8 relay or fuel pilot: Remove the lead from FUEL RELAY−COM (fuel pilot). Attempt to start the engine and check for B+ at lead COM. If there is no B+, check for an open circuit between K8-COM and fuse. If B+ is present, reconnect lead COM to the relay. Remove the lead from the N/O connection. Attempt to start the engine and check for B+ at the terminal N/O connection. If B+ is present, check for an open circuit between the N/O connection and the fuel solenoid (+). If B+ is not present, check to make sure the E-stop switches are inactive, then check for a ground signal at J11-14. If not, the Base board is defective and must be replaced. 6-20 TABLE 6-12. CODE 359 − FAIL TO START (SHUTDOWN) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the engine failed to start after expiration of the last crank time. Effect: Engine will not start. POSSIBLE CAUSE The injection pump actuator is not energized due to the harness, governor actuator, governor module, or the Base board is defective. CORRECTIVE ACTION Isolate to the harness, governor actuator, or the Base board. 1. Display the “Governor Duty Cycle” menu. Attempt to start and check for duty cycle (44% is about average). If the percentage of duty cycle is displayed before a shutdown, the harness, actuator governor, or output circuit of the control is defective Go to step 2. (Duty cycle displayed indicates the processor is functioning, but the output circuitry of the Base board could still be defective.) If the duty cycle is not displayed, the control is defective or is configured incorrectly. Check the configuration. 2. Remove connector P11 from the control and check wiring continuity of the actuator circuit. Check P11 5 (GOV−DR+) and P11-4 (GOV−DR−) to the appropriate +/− terminals of the governor module and between J1-4 on the governor module and the actuator. If continuity is OK, go to step c. 3. Disconnect the two leads attached to the injection pump actuator. Measure the resistance across the two actuator terminals. A reading of 2.3 ohms indicates that the actuator circuit is OK. (This test only shows that the actuator circuit is not opened or shorted, but not if there is binding.) Replace the actuator assembly if an open or short is measured. If the actuator is OK, go to step 4. 4. Remove power from the control for one minute. Put power back on the control and check for B+ at P11-5. If not present, the control is defective and must be replaced. If present, go to step 5. 5. Attempt to start and check for CNTL B+ at terminal lead ACT + of the governor actuator (use the engine block for metering ground). If not present, check the wiring or SW B+ control function and J1-3 of the governor module. 6. If CNTL B+ is present, attempt to start the engine and check for a GOV PWM (pulse wide modulated) signal (measure across the terminals of the actuator and across J1-2 to J1-1 of the governor module). If not present on J1, the control is defective and must be replaced. 7. If not present on the actuator, governor module is defective and must be replaced. The engine fuel system is Service according to the engine service manual. worn or malfunctioning or it has lost prime (fuel lift pump, injection pump, injectors, timing). The engine is worn or is malfunctioning mechanically. Service according to the engine service manual. 6-21 TABLE 6-13. CODE 427/781 − CAN DATALINK LOST (WARNING/SHUTDOWN) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Indicates that the communication link between the engine controller and genset controller is lost. Effect: Warning – The control issues a warning level fault if the CAN datalink is lost and while there is no engine speed or no start command. Shutdown – The control issues a shutdown level fault if the CAN datalink is lost while there is a non-zero engine speed or a start command is active. POSSIBLE CAUSE The networking harness is defective. CORRECTIVE ACTION 1. Check the datalink between the ECM and the GCS. Check for open or shorts between the following: J11-20 (CANH) J11-19 (CANL) J11-17 (CAN Shield) 2. Also check to make sure that there is 60 Ohms resistance between J11-20 and J11-19. If not, the harness is defective; repair the harness. The ECM is powered down. 1. With the control powered, check for the B+ on the positive side of the keyswitch pilot relay coil. Check for GND on the negative side of the keyswitch relay coil. 2. If B+ doesn’t exist, the harness is defective. If GND doesn’t exist, check for GND on P11-21 (Keyswitch LS Out). If GND does exist, the harness is defective, repair harness. If GND doesn’t exist, the Base board is defective and must be replaced. TABLE 6-14. CODE 441 − LOW BATTERY (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Low voltage has been detected for the battery. Effect: The control’s voltage supply approaches a level at which unpredictable operation may occur. POSSIBLE CAUSE CORRECTIVE ACTION Weak or discharged battery. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80_F (27_C). Low electrolyte level in the battery. Replenish electrolyte and recharge the battery. Battery connections are loose or dirty. Clean and tighten or replace the battery cable connectors and cables at the battery and the genset. Insufficient battery charg- Adjust the charge rate of the AC powered battery charging circuit, according to ing voltage. manufactures instructions. Engine DC alternator could be defective. Replace the engine DC alternator if the normal battery charging voltage (12 to 14 VDC for 12VDC system, 24 to 27 VDC for 24VDC system) is not obtained. 6-22 TABLE 6-14. CODE 441 − LOW BATTERY (WARNING) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Low voltage has been detected for the battery. Effect: The control’s voltage supply approaches a level at which unpredictable operation may occur. POSSIBLE CAUSE If the batteries are OK, the problem may be with the harness or the Base board. CORRECTIVE ACTION Remove connector P11 from the Base board and check battery voltage at P20-9,10,20,21 (B+) to P20-10 2,4,7,12(GND). If the voltage at P11 is not the same as the battery voltage, the harness is defective and must be replaced. If the voltage at P11 is OK, the Base board is defective and must be replaced. Fault threshold could be incorrect. Check the fault threshold against the requirement of the application. TABLE 6-15. CODE 442 − HIGH BATTERY VOLTAGE (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: High voltage has been detected for the battery. Effect: Control damage will occur. POSSIBLE CAUSE CORRECTIVE ACTION Excessive battery charging voltage. Adjust the charge rate of the AC powered battery charging circuit according to the manufacturer’s instructions. Engine DC alternator could be defective. Replace the engine DC alternator if the normal battery charging voltage (12 to 14 VDC) is not obtained. Fault threshold could be incorrect. Check the fault threshold against the requirement of the application. TABLE 6-16. CODE 1311, 1312, 1317, 1318 − CONFIGURABLE INPUT (WARNING/SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: The nature of the fault is an optional configurable selection. Effect: Shutdown. POSSIBLE CAUSE CORRECTIVE ACTION If there is no actual fault, the problem may be an external wiring problem. If the Fault Input Active State select is set to active close, check to see if GND is at the fault input terminal. If GND is at the fault input terminal, check the external wiring. If the Fault Input Active State select is set to active open, check to see if GND is not at the fault input terminal. If GND is not at the fault input terminal, check the external wiring. 6-23 TABLE 6-17. CODE 1426 − GENERIC ENGINE FAULT (WARNING) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: The PCC1302 has received a fault code from the engine control module that it doesn’t uniquely recognize. Effect: Warning. POSSIBLE CAUSE CORRECTIVE ACTION The engine controller has Use an engine service tool (Insite or InPower) to view the active fault messages being broadcasted a fault that sent by the engine controller. Consult the engine service manual for a Fault Code the PCC1302 control mapping and a procedure to cure the problem. doesn’t recognize. TABLE 6-18. CODE 1443 − DEAD BATTERY WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Indicates during cranking battery voltage has dropped below operating voltage of control resetting the control for three consecutive times. Effect: Shutdown. POSSIBLE CAUSE Weak or discharged battery. CORRECTIVE ACTION Measure the voltage of battery with voltmeter. Battery voltage should be 12VDC or greater for 12 VDC system and 24VDC or greater for 24VDC system. If battery voltage is low, check the electrolyte level. Replenish electrolyte level if low and recharge the battery ( specific gravity of fully charged lead acid battery is approximately 1.26 at 80 F ( 27 C). If battery cannot hold adequate voltage, replace battery. Battery connections are loose or dirty. Clean and tighten battery terminals and battery cable connector. If battery cable connectors are cracked or worn out then replace. Insufficient battery charg- Ensure external battery charger is charging the battery at an acceptable rate. Adjust ing voltage. the rate if the rate is below the recommendation of the manufacturer. If battery is located at a far distance from the battery charger, ensure that adequate wire gauge is used to compensate the voltage drop. Faulty engine DC alternator. Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC for 12VDC system , 24 to 27 VDC for 24VDC system) is not obtained. Faulty Harness. Measure the battery voltage at battery terminals when genset is cranking. Then measure battery voltage at base board input while genset is cranking ( at J20−9, J20−10, J20−20,J20−21 for B+ve and J20−2, J20−4, J20−7, J20−12 for B−ve). If voltage at battery terminals and control is not the same, check harness and replace if necessary. 6-24 TABLE 6-19. CODE 1435 − LOW COOLANT TEMPERATURE (WARNING) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: The engine coolant temperature has dropped below the warning threshold for low coolant temperature. Effect: No action is taken by the control. The engine may not start because of a slow cranking speed. POSSIBLE CAUSE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines A fault simulation was enabled with a PC based service. With the PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. The fault threshold was not set correctly with a PC based service tool. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. The engine coolant heater could be defective. The coolant heater is not operating because: (Radiant heat should be felt when your hand is held close to the outlet hose.) If you do not have a based service tool, remove battery power from the control to disable the fault simulation overrides. The coolant heater is not connected to power. Check for a blown fuse, or disconnected the heater cord and correct as required. There is a low coolant level. Look for possible coolant leakage points and repair as required. There is a defective heater element/thermostat. With the coolant heater removed from the engine and power disconnected, flush with cold tap water for two minutes to close the internal heater thermostat (opens at 100_F and closes at 80_F). Check resistance across the input power leads: a. Open − replace the coolant heater. b. Closed − coolant heater OK (coil resistance of 10 to 60 ohms) The sensor connections could be defective. Inspect the sensor and engine harness connector pins. Repair or replace as necessary. The sensor could be defective. Disconnect the sensor and plug in a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, the harness or Base board are defective and must be replaced. 6-25 TABLE 6-19. CODE 1435 − LOW COOLANT TEMPERATURE (WARNING) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: The engine coolant temperature has dropped below the warning threshold for low coolant temperature. Effect: No action is taken by the control. The engine may not start because of a slow cranking speed. POSSIBLE CAUSE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines The harness or Base Measure the resistance of the coolant temperature sensor and reconnect the harness board could be defective. to the sensor. Remove connector P11 from the Base board and check resistance between pins P11-11 (H20) and P11-12 (H20 COM). If resistance is not the same, the harness is defective and must be replaced. If resistance is the same, the Base board is defective and must be replaced. TABLE 6-20. CODE 1438 − FAIL TO CRANK (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: This indicates that the engine failed to crank after the control received a start signal. Effect: Engine will not start. POSSIBLE CAUSE ENGINE PLATFORM CORRECTIVE ACTION FAE Engines HM Engines 1. The starter is defective. Refer to the engine service manual. Reset the control. Attempt to start and test for B+ at the starter. If there is B+ at the starter, the starter could be defective. Test the starter (see the engine service manual) and, if necessary, replace the starter. If B+ is not present at the starter, go to the next step. 2. The starter relay is defective. Check wiring continuity/test starter relay. Remove the lead from the starter relay−COM and check for B+ at the lead COM (directly connected to battery B+). If there is no B+, check for an open circuit between starter relay−COM and the battery B+. If B+ is present, reconnect the lead COM to the starter relay. Remove the lead from the starter relay−N/O. Attempt to start and check for B+ at the terminal starter relay−N/O. If B+ is present, check for an open circuit between starter relay−N/O and the SW terminal of the starter. If B+ is not present, the Base board/starter relay is defective. 3. Either the Emergency Stop switch or the wiring is defective. With the Emergency Stop push button not activated, remove the configurable leads from TB1-15 and TB1-16 and check for continuity between these two leads. If the circuit is open, isolate to the Emergency Stop switch and wiring. With the Local Emergency Stop push button not activated, remove P25 from the Base board. Check for continuity between J25-2 and J25-6. If there is continuity, go to the next step. 4. The MPU/circuit or Base board is defective. Refer to the engine service manual. 6-26 Refer to the Fault Code 121 instructions. TABLE 6-21. CODE 1442 − WEAK BATTERY (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Low voltage has been detected for the battery. Effect: The control’s voltage supply is approaching a level at which unpredictable operation may occur. POSSIBLE CAUSE CORRECTIVE ACTION Refer to Fault Code 441. Refer to Fault Code 441. TABLE 6-22. CODE 1446 − HIGH AC VOLTAGE (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: One or more of the phase voltages has exceeded 130% of nominal for 1 seconds, or has exceeded the High AC Voltage Threshold for the High AC Voltage Delay seconds. Effect: Engine will shut down. POSSIBLE CAUSE CORRECTIVE ACTION Fault simulation was enabled with a PC based service tool. With a PC based service tool, verify that the related fault simulation is not enabled. Single step large block load removal. Clear the fault and restart the genset. Fault threshold is not set correctly with the PC based service tool. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. The Base board or generator is defective. Refer to the Generator/Base Board Isolation Procedure in the Service Manual to determine if the Base board is causing the high AC voltage shutdown fault. The voltage sense connections/set up could be incorrect. Refer to the Generator/Base Board Isolation Procedure in the generator Service Manual to determine if the Base board is causing the high AC voltage shutdown fault. If you do not have a PC based service tool, remove battery power from the control to disable the fault simulation overrides. TABLE 6-23. CODE 3539, 3541,3542, 5669 − ENGINE FAULTS ANNOUNCED BY PCC1302 Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: The engine controller has sensed a fault condition and is broadcasting the fault message. The PCC1302 is uniquely announcing the fault code. Effect: Event,Shutdown,Warning. POSSIBLE CAUSE Consult Engine Service Manual. CORRECTIVE ACTION Consult Engine Service Manual. 6-27 TABLE 6-24. CODE 1447 − LOW AC VOLTAGE (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage Delay seconds. Effect: Engine will shut down. POSSIBLE CAUSE CORRECTIVE ACTION A fault simulation was enabled with a PC based service tool. With a PC based service tool, verify that the related fault simulation is not enabled. The fault threshold is not set correctly with a PC based service tool. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. There is an overload. Check the load and correct any overload. Check operation by disconnecting the load and restarting the generator set. Improper connections have been made at the generator output terminals. Reconnect according to the appropriate reconnection diagram. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. The voltage sense or set- Verify that excitation inputs P18-1 and P18-2 are connected to the correct generator up wiring connection outputs. could be incorrect. The rotating rectifier assembly (diodes CR1 through CR6) is faulty. Check each diode. See the genset service manual There is a loose connector or the Base board is defective. Repair connections (P18) or replace the Base board if necessary. The voltage sense connections/setup could be incorrect. See Section 7 for proper connections. TABLE 6-25. CODE 1448 − UNDER FREQUENCY (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Generator AC output frequency is low. Effect: Generator set will shut down. POSSIBLE CAUSE CORRECTIVE ACTION The fault threshold is not set correctly with PC based service tool. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. There is an overload. Check the load and correct any overload. Check operation by disconnecting the load and restarting the generator set. There is a fuel or air delivery problem Refer to the engine service manual. 6-28 TABLE 6-25. CODE 1448 − UNDER FREQUENCY (SHUTDOWN) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Generator AC output frequency is low. Effect: Generator set will shut down. POSSIBLE CAUSE CORRECTIVE ACTION There is a governor fault Check the fuel shutoff solenoid adjustment. There is a loose connector or the Base board is defective Repair connections (P22/P18) or replace the Base board if necessary. TABLE 6-26. CODE 1449 − OVER FREQUENCY (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Generator AC output frequency is high. Effect: Generator set will shut down. POSSIBLE CAUSE CORRECTIVE ACTION The fault threshold is not set correctly with PC based service tool. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. There is a fuel or air delivery problem. Refer to the engine service manual. There us a loose connec- Repair connections (P22/P18) or replace the Base board if necessary. tor or the Base board is defective. TABLE 6-27. CODE 1471/1472 − HIGH AC CURRENT (SHUTDOWN/WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: This indicates that the indicated generator output current has exceeded at least110% of rated current. Effect: No action is taken by the control for Fault Code 1472. Engine will shut down for Fault Code 147. POSSIBLE CAUSE CORRECTIVE ACTION 1. Short or Overload Check the load and load cables. Repair if necessary. Check operation by disconnecting the load and restarting the generator set. 2. Incorrect CTs, CT connections, or CT setup. Check CTs and CT connections. Correct if necessary. Refer to Current Transformer Setup on page 3-4. 6-29 TABLE 6-27. CODE 1471/1472 − HIGH AC CURRENT (SHUTDOWN/WARNING) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the indicated generator output current has exceeded at least110% of rated current. Effect: No action is taken by the control for Fault Code 1472. Engine will shut down for Fault Code 147. POSSIBLE CAUSE CORRECTIVE ACTION 1. The problem may be Remove connector P12 from the Base board. Check continuity from P12 to the CTs. the Base board or P12-1 (CT1) to P12-4 (CT1-COM) harness connections. P12-2 (CT2) to P12-5 (CT2-COM) P12-3 (CT3) to P12-6 (CT3-COM) Repair connections. 2. There may be an incorrect rating setup. Check the rating setup in the control. Correct if necessary. TABLE 6-28. CODE 1689 − CLOCK NOT SET WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: ’Exercise Scheduler’ function is enabled and real time clock (RTC) is not set. Effect: Warning. Exercise function will not work. POSSIBLE CAUSE CORRECTIVE ACTION Battery power recycled with ’Exercise Scheduler’ function enabled. If exercise scheduler function is not required, disable the function via HMI211 or service tool. RTC not set after enabling exercise function. Set and save the real time clock. If exercise scheduler function is required, set and save the real time clock. TABLE 6-29. CODE 1944 − ANNUNCIATOR OUTPUT CONFIGURATION ERROR (WARNING) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Indicates that more then one network device is configured to activate one of the Annunciator output relays. Effect: Warning POSSIBLE CAUSE CORRECTIVE ACTION Network configuration is incorrect. Check setup of the devices on the network against duplicate use of the same Annunciator relay output. There is a defective device on the network. Troubleshoot the network for malfunctioning devices. 6-30 TABLE 6-30. CODE 2118 − LOW FUEL PRESSURE Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Low pressure sensed for gaseous fuel application. Effect: Warning ( configurable to shutdown ) POSSIBLE CAUSE CORRECTIVE ACTION Fuel source level is low or exhausted. Check primary fuel source level. Fuel Pressure switch is faulty. Refer engine manual for pressure switch check. Replace if faulty. If refill is required, stop the genset, and refill. TABLE 6-31. CODE 2335 − LOSS OF AC SENSE (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: This indicates that the control has loss voltage sensing or it has lost zero cross sensing. Effect: Generator set will shutdown. POSSIBLE CAUSE CORRECTIVE ACTION 1. There may be problems with the load. Verify that the load contains no shorts. Using a DMM check for shorts between each of the J22 pins. It also may be helpful to disconnect all load lines and start the genset. If the genset runs with no load, that could be load lines are shorted. Refer to the reconnection drawings in Section 7 as a reference. 2. The wire harness is defective. Remove the AC Sense harness (J22) and check continuity of all wires. Repair the harness as needed, reset the control, and restart the genset. Check continuity between the following leads. If resistance is greater than 200 Ohms, repair the harness. J22 Pin 4 and VN terminal J22 Pin 3 and V3 terminal J22 Pin 2 and V2 terminal J22 Pin 1 and V1 terminal Check continuity between the following leads. If resistance is greater than 200 Ohms, repair the harness. J17 Pin 1 and Field Coil +. J17 Pin 2 and Field Coil −. Check continuity between the following leads, if resistance is greater than 200 Ohms, repair the harness: J18 Pin 1 and V1 terminal (shunt) or PMG 1 terminal (PMG) J18 Pin 2 and V2 terminal (shunt) or PMG 2 terminal (PMG) 6-31 TABLE 6-31. CODE 2335 − LOSS OF AC SENSE (SHUTDOWN) (CONT.) Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: This indicates that the control has loss voltage sensing or it has lost zero cross sensing. Effect: Generator set will shutdown. POSSIBLE CAUSE 3. The excitation coil isn’t charged. CORRECTIVE ACTION The excitation coil may need to be flashed: 1.. Remove the Field Coil + and Field Coil – leads from the alternator. 2.. Using a 12 VDC power supply, touch the positive supply terminal to the Field Coil + and the negative supply terminal to the Field Coil −. Remove after brief contact. Repeat this procedure three times. 3.. Reconnect the Field Coil + and the Field Coil – leads to the alternator. 4.. Reset the control, and restart the genset. 5.. If the genset fails to operate correctly, repeat steps 1−4 with a 24 VDC power supply. 4. The excitation coil is defective. Remove the Field Coil + and the Field Coil – leads from the alternator. Check continuity between Field Coil + and Field Coil −. Verify that the reading is within alternator specifications. If so, continue to step 4. 5. Verify the genset set- Verify that the genset is capable of reaching rated speed by manually running the up. genset. Some potential problems could be: clogged fuel filter, incorrect fuel stop position, malfunctioning fuel actuators, etc. If the genset is not capable of reaching rated speed: correct the problem, reset the control, and restart the genset. 6. The control board is defective. Replace the control board module. 6-32 TABLE 6-32. CODE 2545 − KEYSWITCH RESET REQUIRED (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: After sensing a CAN datalink failed condition (Fault Code 781), the PCC1302 has tried unsuccessfully to restore communications by toggling power to the ECM. Effect: Shutdown. POSSIBLE CAUSE CORRECTIVE ACTION The networking harness is defective. 1. Check the datalink between the ECM and the GCS. Check for open or shorts between the following: J11-20 (CANH) J11-19 (CANL) J11-17 (CAN Shield) 2. Also check to make sure that there is 60 ohms resistance between J11-20 and J11-19. If not, the harness is defective; repair the harness. The ECM is powered down. With the control powered, check for B+ on the positive side of the keyswitch pilot relay coil. Check for GND on the negative side of the keyswitch relay coil. If B+ doesn’t exist, the harness is defective. If GND doesn’t exist, check for GND on P11-21 (Keyswitch LS Out). If GND does exist, the harness is defective; repair the harness. If GND doesn’t exist, the Base board is defective and must be replaced. The keyswitch minimum on-time is set too short. This time delay sets how long the control waits for the ECM to come online during a power cycle before it determines that the datalink is down and does another power cycle. Using InPower, increase the keyswitch minimum on-time trim to the highest possible value. Reset the fault. the keyswitch reset time is set too short. This time delay sets how long it takes for the keyswitch circuits to turn off. The number of CAN datalink retries is set too low. This sets how many times the control power cycles the ECM before it declares Fault Code 2545. Using InPower, increase the keyswitch reset time delay to the highest possible value. Reset the fault. Use InPower to increase this number to the highest possible setting. TABLE 6-33. CODE 2972 − OVER EXCITATION (SHUTDOWN) WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: The control has sensed an over-excitation caused by an AVR duty cycle greater then 46% (60 Hz) for 8 seconds, or 55% (50 Hz) for 8 seconds. Effect: Shutdown. POSSIBLE CAUSE CORRECTIVE ACTION The load is too large Check to make sure load is with genset capabilities. The load is faulty. Check for shorts in the load. The field winding / harness may be faulty 1. Check for shorts or opens between the two field coils (J18-1 and J18-2) leads. If resistance is less then 20 Ohm or greater then 200 Ohms, the field winding or field winding harness may be defective. 2. Check both 10 amp fuses on J17-1 and J17-2. 6-33 TABLE 6-34. CODE 5134 − UNKNOWN SHUTDOWN AT IDLE WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Genset has shutdown with unknown fault before reaching rated conditions ( for engines with ECM only). Effect: Shutdown. POSSIBLE CAUSE CORRECTIVE ACTION Genset failed to reach Check engine service manual. rated conditions and shutdown because of unknown reasons. TABLE 6-35. CODE 5186 − GENERATOR SET FAILED TO CLOSE WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Transfer switch has failed to close on generator side. Effect: Shutdown. POSSIBLE CAUSE Mechanical failure of transfer switch. CORRECTIVE ACTION Check the transfer switch manual. Transfer switch transiCheck for loose connection of the feedback wire connected to TB1−14 from auxiliary tioned to genset side, but contact of transfer switch. Tighten the same. feedback is lost. Faulty auxiliary contact. Check and replace the auxiliary contact of transfer switch. TABLE 6-36. CODE 5187 − UTILITY FAILED TO CLOSE WARNING Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. Reason: Transfer switch has failed to close on utility side. Effect: Warning. POSSIBLE CAUSE CORRECTIVE ACTION Mechanical failure of transfer switch. Check the transfer switch manual. Transfer switch transitioned to utility side, but feedback is lost. Check for loose connection of the feedback wires connected to TB1−12 and TB1−14 from auxiliary contact of transfer switch. Tighten the same. Faulty auxiliary contacts. Check and replace the auxiliary contact of transfer switch. 6-34 TABLE 6-37. CODE 5365 − ON SECONDARY SOURCE Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Genset is running on secondary fuel source in dual fuel application. Effect: Warning. POSSIBLE CAUSE CORRECTIVE ACTION Primary fuel source level is low or exhausted and genset is transitioned to run on secondary fuel source. Check primary fuel source level. Fuel Pressure switch is faulty. Refer engine manual for pressure switch check. Replace if faulty. If refill is required, stop the genset, and refill. TABLE 6-38. CODE 5188 − TRANSFER SWITCH UNKNOWN POSITION Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures. Read Important Safety Instructions pages and observe all instructions and precautions in this manual. WARNING Reason: Transfer switch position is not known. Effect: Warning. POSSIBLE CAUSE CORRECTIVE ACTION Mechanical failure of Check the transfer switch manual. transfer switch. Feedback indicating as, it is neither at utility side nor at genset side OR feedback is indicating it is at genset as well as at utility side at the same time. Transfer switch is either Check for loose connection of the feedback wire connected to TB1−12 from auxiliary at genset side or utility contact of transfer switch. Tighten the same. side, but respective feedFaulty auxiliary contact. Check and replace the auxiliary contact of transfer switch. back is lost or both side feedbacks are available. 6-35 THIS PAGE LEFT INTENTIONALLY BLANK 6-36 Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii Important Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix 1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Certifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Connector Seal Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Kit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Additional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 1302 Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Current Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 1302 Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Control Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Operator Panel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Control Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Control Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Protection and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Genset Protective Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Current Draw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Running Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Parade Rest Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 3. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Mounting Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Environmental Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 1302 Main Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 1302 Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Control Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Guidelines for Current Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Current Transformer Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Example of CT Sizing − Two Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Example of CT Sizing − Three Lead CT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Current Transformer Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Two Lead CT Setup Example: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 In PCC1302 Control, Voltage Calibration procedure is divided into three processes as described below: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Procedure of calibrating the Alternator Voltages is as follows: . . . . . . . . . . . . 3-5 Safety Precautions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 Three Lead CT Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Battery Charging Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Denso Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bosch Type Charging Alternators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Series Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Series Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Star . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Double Delta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guidelines for Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lube Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup, Trims, and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Control Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AVR Enable/Disable Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Output Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Torque-Matched Volts/Hz Overload Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battleshort Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V/Hz Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup for Gain Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gain Tuning Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controller Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1302 Control Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Start Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12/24V Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle Cranking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spark Ignition Power/Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preheat Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total Glow Processing: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glow Plug Output Logic: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start and Stop Time Delays (Cool Down) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Speed Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Governor Algorithm and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . real time clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . exercise scheduler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The following are the set of rules for exercise scheduler . . . . . . . . . . . . . . . . . 3-8 3-8 3-8 3-9 3-9 3-9 3-9 3-10 3-10 3-11 3-11 3-11 3-12 3-14 3-19 3-20 3-26 3-34 3-35 3-35 3-35 3-35 3-36 3-36 3-37 3-37 3-37 3-37 3-37 3-38 3-41 3-46 3-46 3-46 3-46 3-46 3-46 3-46 3-46 3-47 3-47 3-47 3-47 3-48 3-48 3-48 3-49 3-49 3-50 3-51 3-53 ATS Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battle Short Mode Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations With an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations Without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battle Short Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations without an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4. Operator Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Status Output Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleep Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with an Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installations with a Manual Run/Off/Auto Switch . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Text / Symbolic Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Menu Selection Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Previous Main Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Not In Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shutdown Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Run Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Panel System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Communication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Reset / Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault/Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Default Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saving Your Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Line-to-Line Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Line-to-Neutral Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Single Phase Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Amperage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Auto, Manual Run, and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . Entering the Mode Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Selecting Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 3-55 3-55 3-55 3-57 3-57 3-57 3-58 4-1 4-1 4-1 4-2 4-2 4-2 4-2 4-2 4-2 4-3 4-3 4-3 4-3 4-3 4-4 4-4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-6 4-6 4-6 4-6 4-6 4-7 4-8 4-17 4-17 4-17 4-17 4-17 4-17 4-18 4-18 4-18 4-21 4-21 4-22 4-23 Aborting the Transition to Auto or Manual Run Mode . . . . . . . . . . . . . . . . . . . . Selecting Off Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Status Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History / About Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About Display Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. 1302 Control Panel Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Start/Stop Delay Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle Crank Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battle Short Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AVR Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Number Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Display Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts and Hertz Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Voltage Regulator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Volts/Hz Rolloff Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Crank Fuel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Regulator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Governor Enable Speed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Input Function Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fault Input Active State Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Meter Calib Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4-23 4-24 4-24 4-24 4-26 4-26 4-26 4-26 4-26 4-28 4-30 4-30 4-30 5-1 5-1 5-3 5-4 5-4 5-4 5-6 5-6 5-6 5-8 5-8 5-8 5-8 5-8 5-11 5-11 5-11 5-13 5-13 5-13 5-15 5-15 5-17 5-17 5-17 5-19 5-19 5-19 5-19 5-19 5-21 5-21 5-21 5-21 5-25 5-27 5-27 Freq. Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Voltage Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Metering Current Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annunciator Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Annunciator Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ModBus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ModBus Enable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ModBus Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Navigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Setup Password Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menu 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Menu 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Application Rating Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Standby kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Prime kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Thresholds Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Underfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High AC Current Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Overspeed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Speed/Frequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Oil Pressure Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Oil Pressure Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Coolant Temperature Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Coolant Temperature Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Protection Low Coolant Temperature and Battery Charger Menus . . 6. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PC Based Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Network Applications and Configurable Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes Using Optional Operator Panel . . . . . . . . . . . . . . . . . . . . Reading Fault Codes Using the Control Switch Indicator . . . . . . . . . . . . . . . . . Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage/Continuity Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27 5-27 5-27 5-29 5-29 5-31 5-33 5-33 5-33 5-35 5-35 5-35 5-37 5-37 5-37 5-39 5-39 5-39 5-39 5-39 5-41 5-41 5-41 5-43 5-43 5-45 5-45 5-45 5-45 5-45 5-47 5-47 5-47 5-49 5-49 5-49 5-49 5-51 5-51 5-51 5-53 6-1 6-1 6-1 6-1 6-1 6-2 6-2 6-2 6-2 6-2 7. Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 Appendix A. 1302 Menu System Maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 B-1 Appendix B. Index . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 B-2 B-3 7. Wiring Diagrams GENERAL S Page 7-3, 1302 Control Wiring Diagram This section consists of the schematic and connection wiring diagrams referenced in the text. The following drawings are included. 7-1 THIS PAGE INTENTIONALLY LEFT BLANK 7-2 HMI2xx or HMI3xx Display Part numbers HMI 220: 0300−6314 HMI 320: 0300−6315 J28 Mate: 0323−2091 J29 Mate: 0323−2456 Sockets: 0323−2466 J29 −6 J29 −4 Run (Wake−up) J25−10 PCC 1302 OEM Genset ECM Engine Connection Auto J25−11 (Configurable Wake−up) J29 −1 PCC Net A (+) J25−4 J29 −2 PCC Net B J25−3 J29 −3 System Wake−up J25−5 J28 −1 HMI Fuse B+ J25−12 J28 −2 B+ Return J25−8 (−) Use Shielded Twisted Pair for PCC Net Only terminate shield on one end Local HMI211 Display J1 − 1 J1 − 2 J1 − 4 HMI Fused B+ and Customer Fused B+ share a common 4.5A fuse. HMI Fused B+ is assumed to consume no more than 1.5A Part numbers J25 Mate: 0323−2445 Sockets: 0323−2466 Part numbers HMI211: 0300−6014 HMI Fuse B+ J25−12 B+ Return J25−8 J6 − 1 HMI Fuse B+ J6 − 2 B+ Return These signals go to the display but don t go through the PCC controller. J25−5 PCC Net A (+) PCC Net B (−) System Wake−up J1 − 3 J1 − 4 J1 − 5 Part numbers HMI 114: 0300−???? J1 & J6 Mate: 0323−2011 Sockets: 0323−2466 J25−3 System Wake−up J1 − 3 J1 − 5 HMI 114 Bargraph J25−4 (−) Fused B+ J25−11 PCC Net B Configurable Input #4, Fuel Level Switch (Wake−up) Input Terminal Block Remote E−stop PB (B) J11, J25 Harness J20 Harness Basic Customer Basic Customer Terminal Block Local E−stop PB Fused B+ E−stop B+ Power PCC1302 Baseboard Part numbers PCC 1302: 0327−1617−01 −1 These signals go to the genset but don t go through the PCC controller. Lamp Failed Output These signals go to the engine but don t go through the PCC controller. −6 Remote E−stop PB (B) J20 − 6 J20 J20 − 10 J20 − 20 J20 − 21 Fused B+ J20 −2 B+ Return J20 −4 J20 −7 20 Amp + − Switched B+ Pilot Relay E−stop B+ Power Battery Charger Alternator J20−22 Flash/ Failed J20 − 14 J20 − 15 LS Out FSO Control LS Out Starter Control LS Out Switched B+ (Run) Control Field Flash E−stop B+ Power Switched B+ J20 − 3 J20 − 11 Battery Charger Alternator J20 − 22 Flash/ Failed Relay B+ internally fused at 1.85A B.C. Alt. Flash internally fused at 1.5A Field Winding + J22 − Genset Voltage Part numbers J11 Mate: 0323−2161 Sockets: 0323−2466 Locate near mounting screw chassis. −9 E−stop B+ Power Battery Charging Alternator J25−8 −2 Return OR Part numbers J12 Mate: 0323−1932 Sockets: 0323−1200 J25−12 J20 − 18 Battery (IC Regulator Type/ IC Kubota) Regulator Power (Non−IC Regulator Type/ Bosch) Fused B+ B J20 J20 − 12 Battery Charging Alternator J12 − Genset Current A J20 − 5 J20 − Genset J25−4 J25−3 J25−5 Input (Wake−up on open) J25 Return J25 J20 − 17 Return Switches OEM connected OR Terminal blocks for customer connections Part numbers J20 Mate: 0323−2446 Sockets: 0323−2466 J25 − Display J25−10 PCC Net A (+) Input Chassis Ground OR Manual (Wake−up) J1 − 6 Auto (Configurable Wake−up) J1 − 7 Configurable Input #3, Coolant Level Switch (Wake−up) Alternator Peak: 6 Amps Part numbers J22 Mate: 0323−2226−03 − J11 − Engine Fused B+ Terminal Block J12 − 1 J20 Harness Terminal Block L1 L2 L3 LN J12 − 4 J12 − 2 Fused B+ 5A CT s, J12 − 5 J12 − 3 J11 − 21 J11 − 17 Keyswitch Control LS Out J1939 (+) J11 − 20 J11 − 19 Don t connect N in Delta configuration Pilot Relay E−stop B+ Power 120 Ohm Keyswitch (FSO optionally) Driver Rating: 4 Amps ECM Use L1/L2/N for 1 phase applications (PGI Compliant) J12 − 6 J22 − 1 J22 − 2 J22 − 3 J22 − 4 J1939 (+) 120 ohm terminated J1939 (−) J1939 (Shield) Only terminate shield on one end J1939 (−) Some ECM s integrate the FSO with the Keyswitch operation. Use a dedicated FSO if application s ECM does not provide FSO operation. Use alternator center taps or a transformer if LL voltage > 240 VAC L−L 600 Volt Max Shunt Applications J18 − AVR Power Part numbers J18 Mate: 0323−2444 Sockets: 0323−1200 J18 − 1 J18 − 2 10 Amp OR PMG Applications P2 J18 − 3 PMG (optional) Part numbers J17 Mate: 0323−2098 Sockets: 0323−1200 J17 − AVR Control P4 P3 J17 − 2 J17 − 1 No. 630-3270 Sh 1 of 4 Rev. − Sys: ProE Modified FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 1 OF 4) 7-3 Run (Wake−up) J29 − 6 HMI2xx or HMI3xx Display J29 − 4 J29 − 1 Part numbers HMI 220: 0300−6314 HMI 320: 0300−6315 J28 Mate: 0323−2091 J29 Mate: 0323−2456 Sockets: 0323−2466 J25−10 Auto J25−11 (Configurable Wake−up) J29 − 2 PCC Net A (+) J25−4 PCC Net B J25−3 (−) System Wake−up J29 − 3 PCC 1302 OEM Genset Hydro−mechanical Engine Connection HMI Fuse B+ J25−12 J28 − 2 B+ Return J25−8 HMI Fused B+ and Customer Fused B+ share a common 4.5A fuse. HMI Fused B+ is assumed to consume no more than 1.5A Use Shielded Twisted Pair for PCC Net Only terminate shield on one end Part numbers J25 Mate: 0323−2445 Sockets: 0323−2466 J1 − 6 Auto (Configurable Wake−up) J1 − 7 Local HMI211 Display J1 − 1 J1 − 2 J1 − 4 Part numbers HMI211: 0300−6014 J25−4 PCC Net B (−) J25−3 System Wake−up J25−5 HMI Fuse B+ J25−12 B+ Return J25−8 PCC Net A (+) PCC Net B (−) System Wa ke−up J1 − 3 J1 − 4 J1 − 5 Part numbers HMI 112: 0300−6050−02 J1 & J6 Mate: 0323−2011 Sockets: 0323−2466 Fused B+ J25−11 PCC Net A (+) J1 − 3 J1 − 5 HMI 112 Bargraph J25−10 These signals go to the display but don tgo through the PCC controller. Terminal Block Remote E−stop PB (B) HMI Fuse B+ J25−12 J6 − 2 B+ Return J25−8 Terminal Block J20 Harness J11, J25 Harness Basic Customer J11 Harness B+ Return Basic Customer E−stop B+ Power PCC1302 Baseboard Part numbers PCC 1302: 0327−1617−01 Fused B+ These signals go to the genset but don t go through the PCC controller. Battery Charging Alternator A Lamp Failed Output E−stop PB Fused B+ B Active Oil Pressure Sender Remote E−stop PB (B) J11 Sense J11 − 3 Return J11 − 2 Sense J11 − 3 Return J11 − 2 OR Coolant Temperature Sensor (Onan Type) Mag Pick−up Input J11 − 3 Return J11 − 2 J11 −6 Relay B+ Pilot Relay LS Out −7 J11 −6 Relay B+ J11 −7 LS Out Locate near mounting screw chassis. −9 J20 − 10 J20 − 20 J20 − 21 Fused B+ J20 −2 B+ Return J20 −4 J20 −7 20 Amp + − Switched B+ Pilot Relay E−stop B+ Power Battery Charger Alternator J20−22 Flash/ Failed J20 − 14 J20 − 15 Field Flash LS Out FSO Control LS Out Starter Control LS Out Switched B+ (Run) Control E−stop B+ Power Switched B+ J20 − 3 J20 − 11 Relay B+ internally fused at 1.85A Battery Charger Alternator J20 − 22 Flash/ Failed B.C. Alt. Flash internally fused at 1.5A Field Winding + Alternator Terminal Block − J12 − 1 J20 Harness J12 − 4 J20 Harness J12 − 5 Governor PWM + Return J11 − 12 J11 −4 Governor PWM − −9 J11 − 5 Governor PWM + J1 −2 J11 − 10 J11 − 4 Governor PWM − J1 −1 OR Fused B+ Gov PS Power J1 − 3 B+ Return Gov PS Power J1 − 5 Terminal Block L3 LN L2 5A CT s, J12 − 3 J12 − 6 Don tconnect N in Delta configuration J22 − 1 Use L1/L2/N for 1 phase applications Fused B+ J1 − 4 Act. LS Driver J1 − Gov PS −8 Use Shielded Twisted Pair for Mag PU L1 J12 − 2 3 rd Party Fuel Actuator Module (20mA Max) −5 Driver Rating: 4 Amps Peak: 6 Amps Part numbers J22 Mate: 0323−2226−03 Ignition Module Control J11 J11 J20 E−stop B+ Power Battery Charging Alternator OR 11 Shield B+ Return Glow Plug Control − − Part numbers J11 Mate: 0323−2161 Sockets: 0323−2466 Fused B+ J11 J11 J20 − 6 J22 − Genset Voltage Relay B+ internally fused at 1.85A Sense + Return −1 J11 Low Oil Pressure Switch J20 −18 J11 − Engine +5V OR Passive Oil Pressure Sender Input OR Part numbers J12 Mate: 0323−1932 Sockets: 0323−1200 These signals go to the engine but don t go through the PCC controller. −1 Battery (IC Regulator Type/ IC Kubota) Regulator Power J12 − Genset Current Local J20 J20 − 12 (Non−IC Regulator Type/ Bosch) Input (Wake−up on open) J25 − 2 Return J25 − 6 J20 − 5 J20 − Genset J25−4 J25−3 J25−5 J6 − 1 J20 − 17 Return Switches OEM connected OR Terminal blocks for customer connections Part numbers J20 Mate: 0323−2446 Sockets: 0323−2466 J25 − Display OR Input Chassis Ground Configurable Input #4, Fuel Level Switch (Wake−up) J25−5 J28 − 1 Manual (Wake−up) Configurable Input #3, Coolant Level Switch (Wake−up) AUX 104 GOVERNOR POWER STAGE Part numbers Aux 104: 0327−1507 J1 Mate: 0323−2216 : Sockets: 0323−1200 J22 − 2 J22 − 3 J22 − 4 Use alternator center taps or a transformer if LL voltage > 240 VAC Fuel Actuator (6 Amps Max) L−L 600 Volt Max Shunt Applications J18 − AVR Power Part numbers J18 Mate: 0323−2444 Sockets: 0323−1200 J18 − 1 J18 − 2 10 Amp OR PMG Applications P2 J18 − 3 PMG (optional) Part numbers J17 Mate: 0323−2098 Sockets: 0323−1200 J17 − AVR Control P4 P3 J17 − 2 J17 − 1 No. 630-3270 Sh 2 of 4 Rev. − Sys: ProE Modified FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 2 OF 4) 7-4 Input #3 Oil Temperature RTD Sensor Input #4 Input #5 Input #6 Sense J11 − 5 J11 7 J11 − 9 J11 − 11 Current source J10 J10 − 4 J10 − 5 J10 − 6 −3 − Current return J10 −9 J10 − 10 J10 − 11 J10 − 12 Sense return J11 −6 J11 − 8 J11 − 10 J11 − 12 J11 − 2 Return OR Current source Discrete Input (Sense) Gnd must be wired in Current return AND/ OR OR 0−5V Analog Input Input #7 Input #8 Sense J11 − 13 J11 − 15 Return J11 − 14 J11 − 16 Current source 0−38V Analog Input Sense return OR Sense Sense return OR Discrete Input (Sense) Return Customer Fused B+ Return Discrete Input (Sense) Gnd must be wired in Customer Fused B+ AND /OR OR PCC Net Devices TB1 − 3 J29 − 3 System Wake−up TB15 − 5 J29 − 1 PCC Net A (+) TB1 − 1 PCC Net B TB1 − 2 (−) J28 − 1 Customer Fused B+ TB1 − 5 J28 − 2 B+ Return TB1 − 3 System Wake−up TB15 − 5 PCC Net A (+) TB1 − 1 PCC Net B TB1 − 2 (−) Customer Fused B+ TB1 − 5 B+ Return TB1 − 3 J1−5 System Wake−up TB15 − 5 J1−3 PCC Net A (+) TB1 − 1 J1−4 J6−1 PCC Net B TB1 − 2 Customer Fused B+ TB1 − 5 J6−2 B+ Return TB1 − 3 J2−3 PCC Net A (+) TB1 − 1 (−) PCC Net B (−) J2−4 TB1−16 Customer Fused B+ B+ Return TB1−15 PCC Net must use a daisy chain topology only Use Shielded Twisted Pair for PCC Net Only terminate shield on one end, to prevent ground loops AND /OR PCC1302 Baseboard Use a local, floating (non−grounded) DC power supply if B+ line has high resistance (>1 ohm) due to long runs, to prevent brief power outages during genset starts TB1 − 2 TB1 − 5 TB1 − 3 Refer to the PCCNet Spec Sheet for further details on PCCNet TB 1 AND J11 /OR J10 J4 J3 J2 Return AND /OR Part numbers w/o enclosure: 300−5929−01 w/ enclosure: 300−5929−02 Return OR Discrete Input (Sense) HMI 113 Annunciator OR Discrete Input (Sense) Gnd must be wired in Part numbers HMI 112: 0300−6050−02 TB1 − 2 B+ Return J29 − 2 HMI 112 Bargraph TB1 − 1 PCC Net B (−) PCC 1302 Customer Connections: −5 PCC Net A (+) TB1 − 5 Return Sense return Current return OR TB15 Customer Fused B+ Battery Charger Customer Fused B+ Sense return System Wake−up J1 − 4 J1 − 1 J1 − 2 J1 − 3 J1 − 5 HMI2xx and HMI3xx Display OR Discrete Input (Sense) Gnd must be wired in Current return Intake Manifold Temperature RTD Sensor Remote HMI211 Part numbers HMI211: 0300−6014 OR Sense Gnd must be wired in −3 −4 Sense return Sense Gnd must be wired in J11 J11 Current return Current source Fuel Level Sensor RTD Sensor Return J11 − 1 Current source Sense Ambient Temperature RTD Sensor Sense +/−5V Analog Input TB1−10 Remote Start J1 − 7 Input #2 OR Sense Exhaust Stack Temperature #1 RTD Sensor Input #1 Aux 101 J1 − 5 Remote I/O J1 − 3 J1 − 4 Part numbers Aux 101: 0327−1536 J14 J14 −1 −2 System Wake−up TB15 PCC Net A (+) PCC Net B (−) −5 TB1 − 1 TB1 − 2 Customer Fused B+ TB1 B+ Return TB1 TB 15 −5 −3 Mounting screw J5 Chassis Ground J6 J2 −1 Relay NO J2 −2 Relay Com J2 −3 Relay NC J2 −4 Relay NO J2 −5 Relay Com J2 −6 Relay NC J2 −7 Relay NO J2 −8 Relay Com J2 −9 Relay NC J2 − 10 Relay NO J2 − 11 Relay Com J2 − 12 Relay NC Relay NO Relay Com J3 − 3 Relay NC J3 − 4 Relay NO J3 − 5 Relay Com J3 − 6 Relay NC Aux 101 Relay 2 Output Aux 101 Relay 3 Output Aux 101 Relay 4 Output Aux 101 Relay 5 Output Aux 101 Relay 6 Output J10 J10 − 7 J10 − 9 J10 − 8 J10 − 10 + Return + Return 5VDC Supply #1 (20 mA max) 5VDC Supply #2 (20 mA max) Maximum of 2 Aux 101 & 102’s can be used per genset J4 − 1 Relay NO Relay Com J4 − 3 Relay NC J4 − 4 Relay NO J4 − 5 Relay Com J4 − 6 Relay NC Aux 101 Relay 7 Output Aux 101 Relay 8 Output Part numbers Aux 102: 0327−1265 Input #9 Input #10 Input #12 Input J4 − 1 Return J4 − 2 Input J4 − 3 Return J4 − 4 J1 J2 J3 Aux 101 Relay Output Ratings: 30VDC, 250VAC NO: 5A NC: 3A Input #11 J4 − 2 Aux 102 Remote I/O J4 J3 − 1 J3 − 2 Aux 101 Relay 1 Output J1 −1 Relay NO J2 −1 Relay Com J3 −1 Relay NC J1 −2 Relay NO J2 −2 Relay Com J3 −2 Relay NC J1 −3 Relay NO J2 −3 Relay Com J3 −3 Relay NC J1 −4 Relay NO J2 −4 Relay Com J3 −4 Relay NC J1 − 5 Relay NO J2 − 5 Relay Com J3 − 5 Relay NC J1 − 6 Relay NO J2 − 6 Relay Com J3 − 6 Relay NC Input J4 − 5 J1 − 7 Relay NO Return J4 − 6 J2 − 7 Relay Com J3 − 7 Relay NC Input J4 − 7 Return J4 − 8 J1 − 8 Relay NO J2 − 8 Relay Com J3 − 8 Relay NC Aux 102 Relay 9 Output Aux 102 Relay 10 Output Aux 102 Relay 11 Output Aux 102 Relay 12 Output Aux 102 Relay Output Ratings: 2 A, 30VDC, 250VAC Part numbers Aux 101 mates: J1: 0323−2192−04 J14: 0323−1678−02 Others: come w/ board Aux 102 mates: J1, J2, J3: 0323−1678−08 J4: 0323−1678−07 Others: come w/ board Aux 102 Relay 13 Output Aux 102 Relay 14 Output Aux 102 Relay 15 Output Aux 102 Relay 16 Output No. 630-3270 Sh 3 of 4 Rev. − Sys: ProE Modified FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 3 OF 4) 7-5 PCC 1302 Customer Connections: E−stop B+ Power Remote A Input (Wake−up on open) TB1 − 16 Return TB1 − 15 E−stop PB TB1 − 1 PCC Net A (+) − RS485 TB1 − 2 PCC Net B − RS485 TB1 − 3 (−) PCC Net B Shield Local E−stop PB (B) B (Remove jumper if not used) See Application Notes section for high level E−stop circuit These signals go to the customer but don t go through the PCC controller. PCC Net Devices Terminal Block Local E−stop PB (B) 0630−3270 WD−CONTROL (WD−CONTROL 1302) FRD24967 Part numbers TB 1 Mate: 0323−2434 TB1 − Basic CCS WD J20 Harness J25 Harness PCC 1302 Baseboard (See Customer − PCC Net page) E−stop B+ Power Remote Start (Wake−up) Customer Input #1 Customer Input #2 Input TB1 − 11 TB1 − 6 Relay NO Return TB1 − 10 TB1 − 7 Relay Com Input TB1 − 12 Return TB1 − 13 Input TB1 − 14 Return TB1 − 15 TB1 − 8 Relay NO TB1 − 9 Relay Com TB1 − 4 Low Side Driver + TB1 −5 TB1 − 10 Customer Output #1 Relay Output Ratings: 3.5 A, 30VDC, 250VAC Customer Output #2 Ready To Load Output + Return Customer fused Battery Supply (3A max) − Battery Items in dashed lines represent internal PCC circuitry. Part numbers TB 8 Mate: 0323−2325−03 TB15 − Modbus/PC Tool Part numbers TB 15 Mate: 0323−2192−04 System Wakeup: Ground if the PCC control system is to always stay awake. TB15 System Wake−up −5 RS485 (+) TB15 − 3 TB15 − 4 TB15 − 1 PCC Net Devices 120 Ohm (See Customer − PCC Net page) (+) Modbus 120 ohm terminated RS485 (−) Shield (−) Only terminate shield on one end OR PC Tool Harness PC Tool No. 630-3270 Sh 4 of 4 Rev. − Sys: ProE Modified Part numbers PC Tool Harness kit: 0541−1199 FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 4 OF 4) 7-6 Appendix A. 1302 Menu System Maps The illustrations in this section show an overview of menu navigation. These illustrations can also be used to locate a submenu and determine how to access it. vice, Genset Setup, and Genset Service menus. The illustrations only show the text versions of the menus. In addition, the menus shown in the setup and service menus reflect what is displayed if the appropriate passwords are entered for viewing and changing the menus. The first illustration shows the basic Operator Menus. The remaining two illustrations show the Ser- A-1 OPERATOR MENUS TEXT VERSION THREE PHASE ONLY SINGLE PHASE ONLY THREE PHASE WYE ONLY CURRENT SENSE AMPERAGE MANUAL RUN MODE SELECTED AUTO MODE SELECTED A-2 OR YES OR NO * * * * VIEWING ONLY YES OR NO ONLY ONE OF THE FOUR AVAILABLE INPUT MENUS IS SHOWN. GENSET SERVICE MENUS A-3 IF AVR IS ENABLED IF AVR IS NOT ENABLED OR OR VIEWING AND ADJUSTING GO TO GENSET SETUP AND SERVICE MENUS ON PAGE A-4 12V VIEWING ONLY GO TO GENSET SERVICE MENUS ON PAGE A-3 OR OR 24V OR SWITCH OR SENDER VIEWING AND ADJUSTING A-4 THESE MENUS ARE AVAILABLE ONLY IF ECM CAN FEATURE IS DISABLED OR GENSET SETUP AND SERVICE MENUS Appendix B. Index GENERAL INFORMATION A Current Transformers, 3-3 Selection, 3-3 Setup, 3-4 Three Lead, 3-5 Two Lead, 3-4 Sizing Three Lead, 3-4 Two Lead, 3-3 Alternator Adjustments, 3-26 AVR Enable/Disable, 3-26 Bosch Type, 3-5 Connections Double Delta, 3-7 Parallel Star, 3-6 Series Delta, 3-6 Series Star, 3-6 Single Phase, 3-7 Denso Type, 3-5 Digital Output Voltage Regulation, 3-26 Torque−Matched Volts/Hz Overload Control, 3-26 Cycle Cranking, 3-37 E Electronic Governor Connections, 3-15 Module Connections, 3-15 Part Numbers, 3-15 Auto Mode, 2-3, 4-2 Emergency Stop Local, 3-37 Remote, 3-37 B Battery Selection, 3-37 Emergency Stop Mode, 4-2 Battle Short Installations with Operator Panel, 3-40 Installations without Operator Panel, 3-41 Mode, 3-41 Engine Speed Sensing, 3-39 Engine Starting, Automatic, 3-37 Environment Information, 3-2 Equipment Basic, 2-1 Optional, 2-2 Battleshort Mode, 3-26 C F Control Inputs, 2-5 Outputs, 2-5 Fault, No Message, 6-3 Fault Code 1117 − ECM Power Lost, Warning, 4-10 1123 − Shutdown After Battleshort, Shutdown, 3-41, 3-42, 4-10, 6-8 1131 − Battle Short Active, Warning, 3-41, 4-10, 6-8 121 − Speed Signal Lost, Shutdown, 3-41, 3-42, 4-8, 6-6, 6-12 1246 − Generic Engine Fault, Warning, 4-10 1311 and 1312 − Configurable Input 1, 2, Warning/ Shutdown, 4-10, 6-8, 6-23 1317 and 1318 − Configurable Input 3, 4, Warning/ Shutdown, 4-11, 6-8, 6-23 135 − Oil Pressure Sensor OOR High, Warning, 4-8 141 − Oil Pressure Sensor OOR Low, Warning, 4-8, 6-6, 6-13 1416 − Failure to Shutdown, Warning, 3-41, 4-11, 6-9 1417 − Failure to Power Down, Shutdown, 4-11 142 − Oil Pressure Sensor OOR High, Warning, 6-6, 6-13 Control Board Connections, 3-10 J11 (Engine), 3-12 J12 (Genset CT), 3-12 J17 (Field Windings), 3-13 J18 (Field Power), 3-13 J20 (Genset), 3-13 J22 (Genset Voltage Sensing), 3-13 J25 (Display), 3-14 TB1 (Customer), 3-11 TB15 (Tools Interface), 3-11 Connector Part Numbers, 3-14 Footprint, 3-16 General Information, 3-2 Current Draw Parade Rest Mode, 2-7 Running Mode, 2-7 Sleep Mode, 2-7 B-1 GENERAL INFORMATION 2542 − Voltage Bias OOR, Warning, 4-13 2545 − Keyswitch Reset Required, Shutdown, 6-31 2619, 2621, 2622, 2623, 2624, 2625, 2626, and 2628 − AUX101 Analog Inputs 1−8, Diagnostic, 4-13 2628, 2629, 2631, and 2632 − AUX101 Digital Inputs 1−4, Diagnostic, 4-14 2676 − Alternator Frequency Conflict, Shutdown, 4-14, 6-10 2677 − Fail to Stop, Shutdown, 4-14, 6-11 2678 − Battery Charging Failure, Warning, 4-14, 5-8, 5-52 2693 − Speed Bias OOR, Warning, 4-14 2694 − Alternator RTD Temp OOR, Warning, 4-14 2696 − Alternator RTD Temp High, Shutdown, 4-14 2729 − I/O Module Lost, Warning, 4-15 2731 − I/O Module Lost, Warning, 4-15 285, and 286 − Engine Fault, Event, Warning, or Shutdown, 4-9, 6-18 2897 − Factory Block Corrupt, Shutdown, 4-15 2898 − Periodic Fault Corrupt, Warning, 4-15 2899 − User Block Corrupt, Shutdown, 4-15 2911 − Trim Block Corrupt, Shutdown, 4-15 2964 − Engine Fault, Event, Warning, or Shutdown, 4-15, 6-18 2972 − Field Overload, Shutdown, 4-15, 6-11, 6-31 359 − Fail to Start, Shutdown, 4-9, 6-8, 6-19 415 − Low Oil Pressure, Shutdown, 4-9, 5-50, 6-7, 6-14 418 − Engine Fault, Event, Warning, or Shutdown, (Not Displayed), 6-18 421 − Oil Temperature High, Shutdown, 4-9 424 − Oil Temperature OOR, Shutdown, 4-10 426 − Engine Fault, Event, Warning, or Shutdown, 4-10, 6-18 427 − CAN Datalink Lost, Warning, 6-22 427 − CAN Link Lost, Warning, 4-10 441 − Low Battery, Warning, 4-10, 5-42, 6-8, 6-22 442 − High Battery, Warning, 4-10, 5-42, 6-8, 6-23 488 − Intake Manifold Temperature High, Shutdown, 4-10 689 − Engine Speed Erratic, Shutdown, 4-10 781 − CAN Datalink Lost, Shutdown, 4-10, 6-22 5134 − Unknown Shutdown at Iidle, Warning, 4-13, 6-34 5186 − Genset Failed to Close, Warning, 4-13, 6-34 5187 − Utility Failed to Close, Warning, 4-13, 6-34 5188 − Transfer Switch Status Unknown Position, Warning, 4-13, 6-35 5365 − On Secondary Source, Warning, 4-13, 6-35 1426 − Generic Engine Fault, Warning, 6-24 143 − Pre−Low Oil Pressure, Warning, 4-8, 5-48, 6-6, 6-13, 6-14 1433 − Remote Emergency Stop, Shutdown, 3-41, 3-42, 4-11, 6-9 1434 − Local Emergency Stop, Shutdown, 3-41, 3-42, 4-11, 6-9 1435 − Low Coolant Temperature, Warning, 4-11, 5-52, 6-9, 6-24 1438 − Fail to Crank, Shutdown, 4-11, 6-9, 6-25 144 − Coolant Sensor OOR Low, Warning, 4-8, 6-6, 6-15 1442 − Weak Battery, Warning, 4-11, 5-42, 6-9, 6-26 1443 − Dead Battery, Warning, 4-11, 6-24 1446 − High AC Voltage, Shutdown, 4-11, 5-44, 6-9, 6-26 1447 − Low AC Voltage, Shutdown, 4-11, 5-44, 6-10, 6-27 1448 − Under Frequency, Shutdown, 4-11, 5-44, 6-10, 6-27 1449 − Over Frequency, Shutdown, 4-11, 5-44, 6-10, 6-28 145 − Coolant Sensor OOR High, Warning, 4-8, 6-6, 6-15 146 − Pre−High Coolant Temperature, Warning, 4-8, 5-50, 6-6, 6-16, 6-17 1469 − Speed Hz Match, Shutdown, 4-12, 5-48, 6-10 1471 − High AC Current, Shutdown, 4-12, 6-10, 6-28 1472 − High AC Current, Warning, 4-12, 5-46, 6-10, 6-28 151 − High Coolant Temp, 4-9, 5-50, 6-7, 6-17 1517 − Failed Module Shutdown, Warning 4-13 153, 154, and 155 − Engine Fault, Event, Warning, or Shutdown, 4-9, 6-18 1678 − Charger Failure, Warning, 6-11 1689 − Clock Not Set, Warning, 4-13, 6-30 1845 and 1846 − Engine Fault, Event, Warning, or Shutdown, 4-12, 6-18 1847 − High Temperature Fault, Warning, 4-13 1852 − Engine Fault, Event, Warning, or Shutdown, 4-12, 6-18 1853, 1854, and 1855 − Configurable Annunciator Fault 3, 4, Warning/Shutdown, 4-12, 6-10 1944 − Annunciator Output Configuration Error, Warning, 4-12, 6-10, 6-29 195, 196, and 197 − Engine Fault, Event, Warning, or Shutdown, 4-9, 6-18 1965 − Exhaust Temperature OOR, Warning, 4-12 1992 − Engine Fault, Event, Warning, or Shutdown, 4-12, 6-18 2118 − Low Fuel Pressure, Warning, 4-13, 6-31 2224 − Fuel Level OOR, Warning, 4-13 2335 − Loss of AC Sense, Shutdown, 3-41, 3-42, 4-13, 6-10, 6-30 234 −Overspeed, Shutdown, 3-41, 3-42, 4-9, 5-48, 6-7, 6-18 2398 − Ambient Temperature OOR, Warning, 4-13 Fault Codes Reading Using the Control Switch Indicator, 6-2 Reading Using the Operator Panel, 6-2 Fault Reset, 2-3 Faults Alternator Protection, 2-7 B-2 Alternator Startup, 3-28 Gain Tuning, 3-28 Governor, 3-28 Voltage/Frequency, 3-27 Engine Startup, 3-28 Engine Protection, 2-6 Genset Protection, 2-6 G Genset Adjustments GENERAL INFORMATION General Information, 3-2 Harness, 3-17 Tuning, 3-27 Glow Plug, 3-38 P Governor Algorithm and Adjustment, 3-39 Electronic, 3-38 Parade Rest Mode, 2-7 H R Harness Coolant Temperature Sensor, 3-20 Engine, 3-19 Genset, 3-18 Oil Pressure Sensor, 3-20 Operator Panel, 3-17 Remote Emergency Stop, 3-37 Remote Start, 3-37 Run Mode, 2-3 Run/Off/Auto Switch, 2-3 Running Mode, 2-7 L S Local Emergency Stop, 3-37 Sensor Coolant Temperature, 3-20 Oil Pressure, 3-20 Local Status Output Indicator, 4-1 M Sensors Coolant Temperature, 3-8 Lube Oil Pressure Switch, 3-9 Oil Pressure, 3-8 Manual Run Mode, 4-2 Module, Control, 2-3 Mounting Installation, 3-1 Setup, Trims, and Adjustments, 3-22 O Sleep Mode, 2-7, 4-3 Spark Ignition, 3-38 Off Mode, 2-3, 4-2 T Operating Modes Auto Mode, 2-3, 4-2 Battle Short, 3-41 Emergency Stop Mode, 4-2 Manual Run Mode, 4-2 Off Mode, 2-3, 4-2 Run Mode, 2-3 Sleep Mode, 4-3 Time Delay Preheat, 4-2 Start, 3-38, 4-2 Stop, 3-38, 4-2 Operator Panel, 2-4 Connections, 2-4 Footprint, 3-17 Wiring Diagram, 7-3 W Wiring Information, 3-2 B-3 THIS PAGE INTENTIONALLY LEFT BLANK B-4 “Intentionally Left Blank” 58 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. E2014 Cummins Power Generation, Inc. All rights reserved.
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File Type : PDF File Type Extension : pdf MIME Type : application/pdf PDF Version : 1.6 Linearized : Yes Encryption : Standard V2.3 (128-bit) User Access : Print, Annotate, Fill forms, Extract, Print high-res Author : gh414 Create Date : 2014:07:01 09:21:58-05:00 Modify Date : 2014:07:08 08:58:54-05:00 Has XFA : No XMP Toolkit : Adobe XMP Core 4.2.1-c041 52.342996, 2008/05/07-20:48:00 Creator Tool : BroadVision, Inc. Metadata Date : 2014:07:08 08:58:54-05:00 Format : application/pdf Title : 900-0661_I10(AG) Creator : gh414 Producer : Acrobat Distiller 9.0.0 (Windows) Document ID : uuid:4b0aa248-a288-49e8-a98e-1894b28507f4 Instance ID : uuid:b4daaa2c-1269-4123-b60e-a55d848f5202 Page Count : 224EXIF Metadata provided by EXIF.tools