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

PowerCommand1302

English

Original Instructions 6-2014 900−0661 (Issue 10)

“Intentionally Left Blank”

Table of Contents

SECTION TITLE PAGE

Foreword viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warranty viii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii

SECTION TITLE PAGE

Emergency Stop 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12/24V Battery 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cycle Cranking 3-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Ignition Power/Glow Plug Control 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Control 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preheat Processing 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Output Logic 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start and Stop Time Delays (Cool Down) 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor 3-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed Sensing 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Governor Algorithm and Adjustment 3-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Real Time Clock 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Excerise Scheduler 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ATS Control 3-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Fuel 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Mode Option 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations With an Operator Panel 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations Without an Operator Panel 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Mode 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with an Operator Panel 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations without an Operator Panel 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Operator Panel Operation 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Status Output Indicator 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Modes 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Run Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sleep Mode 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with an Operator Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with a Manual Run/Off/Auto Switch 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphical Display 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Text / Symbolic Versions 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Menu Selection Buttons 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Previous Main Menu Button 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Button 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not In Auto Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Indicator 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start Indicator 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 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Setup Menus 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Service Menus 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing Only 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Navigation 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing and Adjusting 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION TITLE PAGE

Genset Setup Password Submenu 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Values/Parameters 5-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menus 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu 1 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu 2 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Rating Select Menu 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standby kVA Rating Menu 5-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prime kVA Rating Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Select Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Threshold Menu 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Delay Setup Menu 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Setup Menus 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Select Menu 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Thresholds Menu 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Delay Setup Menu 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Setup Menus 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Protection Submenus 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High AC Voltage Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low AC Voltage Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overfrequency Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Underfrequency Menu 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Protection 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Protection Submenus 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High AC Current Menu 5-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Submenus 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Overspeed Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Speed/Frequency Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Warning Menu 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Shutdown Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Coolant Temperature Warning Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Coolant Temperature Shutdown Menu 5-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Low Coolant Temperature and Battery Charger Menus 5-53. . . .

6. Troubleshooting 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC Based Service Tool 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network Applications and Configurable Inputs 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes Using Optional Operator Panel 6-2. . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes Using the Control Switch Indicator 6-2. . . . . . . . . . . . . . . . . . . .

Troubleshooting Procedures 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage/Continuity Testing 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vii

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

viii

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 compe-

tent 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 inclu-

sive. Sale of product shown or described in this literature is subject to terms and conditions outlined in ap-

propriate 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 govern-

ing 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 PAR-

TICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEAL-

ING 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 (in-

cluding 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 de-

scriptions contained herein.

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual contains

important instructions that should be followed during

installation and maintenance of the generator and bat-

teries.

Before operating the generator set (genset), read the

Operator’s Manual and become familiar with it and the

equipment. Safe and efficient operation can be

achieved only if the equipment is properly operated

and maintained. Many accidents are caused by failure

to follow fundamental rules and precautions.

The following symbols, found throughout this manual,

alert you to potentially dangerous conditions to the oper-

ator, service personnel, or the equipment.

DANGER This symbol warns of immediate

hazards which will result in severe personal in-

jury or death.

WARNING This symbol refers to a hazard or

unsafe practice which can result in severe per-

sonal injury or death.

CAUTION This symbol refers to a hazard or

unsafe practice which can result in personal in-

jury or product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can result

from improper practices.

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

less tanks are outside the engine compartment.

Fuel contact with hot engine or exhaust is a poten-

tial fire hazard.

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

spark, arcing equipment, or other ignition source

near the generator set or fuel tank.

Fuel lines must be adequately secured and free of

leaks. Fuel connection at the engine should be

made with an approved flexible line. Do not use

zinc coated or copper fuel lines with diesel fuel.

Be sure all fuel supplies have a positive shutoff

valve.

Be sure battery area has been well-ventilated prior

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

ly explosive hydrogen gas that can be ignited by

arcing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

Provide an adequate exhaust system to properly

expel discharged gases away from enclosed or

sheltered areas and areas where individuals are

likely to congregate. Visually and audibly inspect

the exhaust daily for leaks per the maintenance

schedule. Make sure that exhaust manifolds are

secured and not warped. Do not use exhaust

gases to heat a compartment.

Be sure the unit is well ventilated.

Engine exhaust and some of its constituents are

known to the state of California to cause cancer,

birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

Keep your hands, clothing, and jewelry away from

moving parts.

Before starting work on the generator set, discon-

nect battery charger from its AC source, then dis-

connect starting batteries, negative (−) cable first.

This will prevent accidental starting.

Make sure that fasteners on the generator set are

secure. Tighten supports and clamps, keep guards

in position over fans, drive belts, etc.

Do not wear loose clothing or jewelry in the vicinity

of moving parts, or while working on electrical

equipment. Loose clothing and jewelry can be-

come caught in moving parts.

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

ning, use extreme caution around hot manifolds,

moving parts, etc.

DO NOT OPERATE IN FLAMMABLE AND

EXPLOSIVE ENVIRONMENTS

Flammable vapor can cause an engine to overspeed

and become difficult to stop, resulting in possible fire, ex-

plosion, severe personal injury and death. Do not oper-

ate a genset where a flammable vapor environment can

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

equipped with an automatic safety device to block the air

intake and stop the engine. The owners and operators of

the genset are solely responsible for operating the gen-

set safely. Contact your authorized Cummins Power

Generation distributor for more information.

LS-14L

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH

Remove electric power before removing protective

shields or touching electrical equipment. Use rub-

ber insulative mats placed on dry wood platforms

over floors that are metal or concrete when around

electrical equipment. Do not wear damp clothing

(particularly wet shoes) or allow skin surface to be

damp when handling electrical equipment. Do not

wear jewelry. Jewelry can short out electrical con-

tacts and cause shock or burning.

Use extreme caution when working on electrical

components. High voltages can cause injury or

death. DO NOT tamper with interlocks.

Follow all applicable state and local electrical

codes. Have all electrical installations performed

by a qualified licensed electrician. Tag and lock

open switches to avoid accidental closure.

DO NOT CONNECT GENERATOR SET DIRECT-

LY TO ANY BUILDING ELECTRICAL SYSTEM.

Hazardous voltages can flow from the generator

set into the utility line. This creates a potential for

electrocution or property damage. Connect only

through an approved isolation switch or an ap-

proved paralleling device.

GENERAL SAFETY PRECAUTIONS

Coolants under pressure have a higher boiling

point than water. DO NOT open a radiator or heat

exchanger pressure cap while the engine is run-

ning. 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 re-

productive toxicity. When checking or changing

engine oil, take care not to ingest, breathe the

fumes, or contact used oil.

Keep multi-class ABC fire extinguishers handy.

Class A fires involve ordinary combustible materi-

als such as wood and cloth; Class B fires, combus-

tible 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 gen-

erator.

Make sure generator set is mounted in a manner to

prevent combustible materials from accumulating

under the unit.

Remove all unnecessary grease and oil from the

unit. Accumulated grease and oil can cause over-

heating and engine damage which present a po-

tential fire hazard.

Keep the generator set and the surrounding area

clean and free from obstructions. Remove any de-

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

Do not work on this equipment when mentally or

physically fatigued, or after consuming any alcohol

or drug that makes the operation of equipment un-

safe.

Substances in exhaust gases have been identified

by some state or federal agencies as causing can-

cer or reproductive toxicity. Take care not to breath

or ingest or come into contact with exhaust gases.

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

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

explosion could result.

Wear hearing protection when going near an oper-

ating generator set.

To prevent serious burns, avoid contact with hot

metal parts such as radiator, turbo charger and ex-

haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

LS-14L

1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides installation and operation in-

formation regarding the 1302 series control. This

manual includes information for the following types

of installations.

Kit 541−1414−01 is for Hydro Mechanical

(HM) engines.

Kit 541−1414−02 is for Full Authority Elec-

tronic (FAE) engines. FAE engines have an

external Electronic Control Module (ECM).

This manual does not have instructions for servic-

ing printed circuit board assemblies. After deter-

mining 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 dia-

grams and schematics that are included to help in

troubleshooting. Service personnel must use the

actual wiring diagram and schematic shipped with

each unit. The wiring diagrams and schematics

that are maintained with the unit should be updated

when modifications are made to the unit.

Read Important Safety Precautions and careful-

ly 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 con-

tained on one circuit board. The circuit board pro-

vides engine speed governing (optional, when the

governor output module and appropriate engine

equipment is provided), main alternator voltage

output regulation, and complete generator set con-

trol protection and monitoring.

The operating software provides control of the gen-

erator 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.

CERTIFICATIONS

The 1302 series control meets or exceeds the re-

quirements 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 volt-

age test

Mil Std 202C, Method 101 and ASTM B117:

Salt Fog test

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 re-

quired)

J17 − AMP 794269−1 Interface seal and

AMP 794276−1 Wire seal (both are re-

quired)

J18 − AMP 794271−1 Interface seal and

AMP 794276−1 Wire seal (both are re-

quired)

HOW TO OBTAIN SERVICE

Contact your generator set manufacturer when

seeking additional service information or replace-

ment parts. Provide model and serial number infor-

mation.

WARNING Incorrect service or replacement of

parts can result in severe personal injury or

death, and/or equipment damage. Service per-

sonnel must be qualified to perform electrical

and mechanical service. Read and follow Im-

portant Safety Precautions, on pages v and vi.

1-2

THIS PAGE LEFT INTENTIONALLY BLANK

2-1

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, meter-

ing, and control system. The control provides a

simple operator interface to the genset’s digital

voltage regulation, engine speed governing, re-

mote start / stop control, and protective functions.

The PCC1302 control is suitable for use on hydro

mechanical or FAE engines. It can be used in non-

paralleling applications and it is compatible with re-

connectable 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.

The control is designed for mounting on the gener-

ator set. The 1302 series control is usually pow-

ered from the generator set starting batteries and

works over a voltage range from 8 to 30 VDC.

The 1302 series control meets NFPA 110 require-

ments (with appropriate accessories) and is de-

signed for connection to a 12 or 24 VDC control

system.

An optional operator panel can be used as a user

interface.

KIT DESCRIPTION

The 1302 genset control kits include the 1302 con-

trol 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 fol-

lowing sensors and harnesses.

Quantity

Description HM Kit

541−1414−01

FAE Kit

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

2-2

ADDITIONAL EQUIPMENT

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 ap-

propriate kit(s) must be purchased separately.

HMI112 LED Bargraph − Kit 541−1319 (In-

cludes Instruction Sheet C697)

HMI113 Universal Annunciator − Kit

300−5929 (Includes Operator’s Manual

900−0301)

AUX101 System I/O Module − Kit 541−1291

(Includes Instruction Sheet C693)

AUX104 External Governor Power Module −

Kit 541−1231 (Includes Instruction Sheet

C689)

HMI113 UNIVERSAL ANNUNCIATOR

(300−5929)

HMI112 LED BARGRAPH

(300−6050−02)

AUX104 EXTERNAL GOVERNOR

POWER MODULE (327−1507)

AUX101 SYSTEM I/O MODULE

(327−1536)

FIGURE 2-2. ADDITIONAL EQUIPMENT

2-3

1302 CONTROL FEATURES

The 1302 series controller includes the following

features.

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.

PCCNet Communications.

ModBus Communications.

Digital speed governing.

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.

Genset protection – Engine and Alternator

protection features.

Operator Panel Display (optional). Provides

easy to use operator display of critical genset

parameters and operating history.

Advanced serviceability using a PC based

software service tool.

Environmental protection. The control system

is designed for reliable operation in harsh en-

vironments. The core control board is potted

module that is fully protected from the ele-

ments.

Configurable Inputs and Outputs. Four dis-

crete configurable inputs and two dry contact

relay outputs.

Relay driver output for glow plug or spark igniter

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

Control Module

The basic control system for the generator set

consists of a single control board with an external

control switch and status indicator.

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

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.

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.

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.

Fault Reset − Placing the switch in the OFF posi-

tion also resets the active/inactive faults in the con-

trol.

2-4

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.

J1-4

PIN 1 J1 or J2

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

2-5

CONTROL INPUTS AND OUTPUTS

Control Inputs

Input signals to the main control board are:

Run/Off/Auto switch

Remote start signal

Remote emergency stop

Local emergency stop

Coolant temperature signal

Lube oil pressure signal

Battery voltage signal

PCCNet System Wake Up Input

Magnetic pick up signal

Starter disconnect signal

Single or three-phase current transformers

(CTs)

Single or three phase line-to-neutral voltage

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.

Control Outputs

Output signals from the control are:

Control status lamp.

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 warn-

ing or shutdown fault as well as ready to load,

not in auto, common alarm, common warning,

and common shutdown.

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.

Communications connections − The control

includes two RS-485 ports.

−PC Tool Interface – This communication

port (TB15) allows the control to com-

municate with a personal computer run-

ning a PC based service tool. This port

also allows the control to communicate

with external devices, such as a Pro-

grammable Logic Controller (PLC) via

the ModBus protocol.

−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.

Local status – Refer to “Local Status Output In-

dicator” on page 4-1.

Battery charging alternator – Alternator flash

connection

Fuel shut-off relay driver

Starter relay driver

Keyswitch relay driver

Glow plug relay driver

Governor drive PWM command

Field coil − AVR PWM command

Excitation source − Input power for field coil

Alternator line voltage sensing − 600 VAC

RMS max

Switched B+ driver

2-6

PROTECTION AND FAULTS

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.

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 shut-

down the genset when they occur.

Genset Protective Functions

The control provides the following system protec-

tive functions:

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-speci-

fied conditions. The control is programmable

for warning, shutdown, or status indication,

and for labeling the input.

Emergency Stop − Annunciated whenever the

emergency stop signal is received from an ex-

ternal switch.

Engine Protection

Overspeed Shutdown – The engine over-

speed default setting is 115% of the rated en-

gine speed nominal. The control includes time

delays to prevent nuisance shutdown signals.

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 pre-

vent nuisance warning/shutdown signals.

High Engine Temperature Warning/Shut-

down − The level is preset (configurable with

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 sig-

nals.

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 (con-

figurable with a PC based service tool or

through the display panel menus) to match the

capabilities of the engine used. The control in-

cludes time delays to prevent nuisance warn-

ing 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 nui-

sance warning signals.

High Battery Voltage Warning – This warn-

ing indicates that the battery charging system

is of a high level by continuously monitoring

battery voltage. The control includes time de-

lays to prevent nuisance warning signals.

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 indi-

cates impending failure. The control includes

time delays to prevent nuisance warning sig-

nals.

Dead Battery Voltage Shutdown −Indicates

battery voltage drop during cranking which re-

sets control for three consecutive times (This

feature is available in 1302 calibration version

3.0 onwards )

Fail to Start (Overcrank) Shutdown.

Fail to Crank Shutdown − This shutdown in-

dicates that the control signaled the starter to

crank the engine but the engine did not rotate.

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.)

Sensor Failure Indication – An out-of-range

high or low diagnostic logic is provided on the

base control to detect analog sensor or inter-

connecting wiring failures.

2-7

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 de-

fault setting is 85% of the rated voltage with a

10 second time delay.

Overcurrent Warning/Shutdown − Imple-

mentation of the thermal damage curve with

an instantaneous trip level is calculated based

on the Current Transformer Ratio and the Ap-

plication Power Rating (see Figure 2-4).

0.03

101

Seconds

Amps (x rated)

Instantaneous

Trip Point

Overcurrent

Protection

Curve

Alternator

Thermal

Damage Curve

FIGURE 2-4. ALTERNATOR PROTECTION

THERMAL DAMAGE CURVE

Under/Overfrequency − The underfrequen-

cy default is − 6Hz of the 50 Hz / 60 Hz frequen-

cy with a 10 second time delay. The overfre-

quency default is + 6Hz of the 50 Hz / 60 Hz fre-

quency 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.

Overexcitation Shutdown – Overexcitation

is used to detect short circuit alternator faults.

CURRENT DRAW

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.

Parade Rest Mode

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.

Sleep Mode

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 cur-

rent.

2-8

THIS PAGE INTENTIONALLY LEFT BLANK

3-1

3. Installation

Read these instructions completely and become

familiar with safety warnings, cautions, and proce-

dures before starting the installation.

WARNING Incorrect installation, service, or

replacement of parts can result in severe per-

sonal injury or death and/or equipment dam-

age. Only trained and experienced personnel

are to perform the following procedures.

CAUTION A generator set control must be

serviced only by technically qualified person-

nel. High voltages are present. These voltages

can cause electrical shock, resulting in person-

al injury.

Even with power removed, improper handling

of components can cause electrostatic dis-

charge and damage to circuit components.

WARNING AC voltages and currents present

an electrical shock hazard that can cause se-

vere personal injury or death. Incorrect instal-

lation, service, or parts replacement can result

in severe personal injury, death, and/or equip-

ment damage.

Turn off or remove AC power from the battery char-

ger (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 bat-

tery charger from its AC source before discon-

necting the battery cables. Otherwise, discon-

necting the cables can result in voltage spikes

high enough to damage the DC control circuits

of the generator set.

WARNING Accidental starting of the genera-

tor set while working on it can cause severe

personal injury or death. Prevent accidental

starting by disconnecting the starting battery

cables (negative [−] first).

Make certain the battery area has been well-

ventilated before servicing the battery—Wear

goggles—Stop the genset and disconnect the

charger before disconnecting battery cables.

Arcing can ignite explosive hydrogen gas giv-

en off by batteries, causing severe personal in-

jury. 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 nega-

tive (−) 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.

WARNING Ignition of explosive battery gases

can cause severe personal injury or death. Arc-

ing at battery terminals, light switch or other

equipment, flame, pilot lights and sparks can

ignite battery gas. Do not smoke, or switch

trouble light ON or OFF near a battery. Dis-

charge static electricity from body before

touching batteries by first touching a grounded

metal surface.

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 oper-

ator panel from being exposed to conditions be-

yond their specifications, care should be taken not

to mount them close to the engine exhaust pipes.

Mounting them in a manner that would expose

3-2

them to direct sunlight or rain/snow should also be

avoided.

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.

ENVIRONMENTAL CAPABILITY

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 in-

cludes transient voltage surge suppression to pro-

vide compliance to referenced standards.

1302 Main Control Board

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.

The main control board is designed for proper op-

eration without recalibration in ambient tempera-

tures from –40 to +70 Deg C, and for storage from

–55 to +80 Deg C. The control is designed to oper-

ate with humidity up to 95%, non-condensing, and

at an altitude up to 13,000 feet (5000 meters).

The main control board is fully encapsulated to pro-

vide resistance to the effects of dust and moisture.

1302 Operator Panel

The optional operator panel is designed to with-

stand 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 opera-

tion 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 sur-

face, which is impervious to the effects of dust,

moisture, oil, and exhaust fumes.

0.1

0 50 100 150 200 250

Frequency (Hz)

Amplitude (Gs) LCD Vibration Profile

FIGURE 3-1. OPERATOR PANEL VIBRATION

LIMITS

CONTROL WIRING INFORMATION

For connecting the Magnetic Pickup, use mini-

mum 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.

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.

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 re-

quires an external Governor Output Module

Kit. Governor PWM output from the 1302 se-

ries 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.

3-3

GUIDELINES FOR CURRENT

TRANSFORMERS

All current transformers (CTs) used with a 1302 se-

ries control must conform to the following specifica-

tions.

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 out-

put: +/−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 cur-

rent measurement calculation will

be multiplied by 2 to show the cor-

rect 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 am-

peres, the secondary current of the CTs is 2.5 am-

peres per phase. This requirement determines a

lower bound of the CT ratio. An upper bound is de-

termined by requiring that, at 100% rated output

current, the CTs secondary current is at least 1 am-

pere. 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 = 2 * Max_Rated_Current

Maximum CT Ratio = 5 * Min_Rated_Current

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 pro-

duces 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.

3-4

Example of CT Sizing − Three Lead CT

A reconnectable generator capable of 208−240/

416−480V outputs with a 125 kVA 3-phase only rat-

ing.

You first need to find the current in each phase for

each output voltage. This is done using the follow-

ing formula:

Voltage

VAPower

Current

)(



VoltageFactorPower

WPower

Current

*_*3

)(



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:

96.1500192.300*5 

Maximum CT Ratio

752.692376.346*2 

Minimum CT Ratio

For a 416−480 voltage configuration:

8.754096.150*5 

Maximum CT Ratio

376.346188.173*2 

Minimum CT Ratio

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 uncon-

nected.

Current Transformer Setup

After the 1302 series control kit has been installed,

the controller must be programmed to use the CT

by one of the following methods.

1. Enter an appropriate value in the CT ratio pa-

rameter on the operator panel.

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 ser-

vice 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 switch-

ing 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.

Below 300 V applications − Enter 750 into the

CR ratio parameter on the operator panel.

Manufacturing Tool

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

Above 300V applications − Enter 1500 into the

Primary CT Current parameter, using the PC-

based service tool (e.g. InPower).

Below 300V applications − Enter 750 into the

Primary CT Current parameter, using the PC-

based service tool (e.g. InPower).

3-5

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 aver-

age voltage. The metering calibration will cali-

brate 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.

2. Regulation Calibration: This calibrates the 3

phase average voltage, which is used for reg-

ulation. Method: Verify the 3 phase average

voltage of the genset matches an external me-

ter’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 be-

cause the PCC regulator is active, and is mak-

ing what the PCC sees be the PCC’s Setpoint.

3. Voltage Adjust: Once both the metering and

voltage calibration is done, you use the volt-

age adjust to modify the PCC’s voltage Set-

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 per-

sonal injury or death. Calibration and adjust-

ment must be performed by technically quali-

fied personnel only. Read and observe all the

Warnings and Cautions in your generator set

manuals.

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 cal-

ibrate 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.

3-6

TABLE 3-1. CALIBRATION

Component to be calibrated Calibration method

PC based service tool Operating panel

Meter Calibration or Voltage mea-

surement 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 Al-

ternator Nominal Voltage is available

at Adjustments −> AC Measurement

Calibrations −> Voltage Measure-

ment for Regulation. Set the Alterna-

tor Nominal Voltage to the voltage

that the genset will generate.

3. With the genset OFF, attach a cali-

brated 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 Alter-

nator 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 Alter-

nator L2−N 60Hz Voltage Display

Adjust trim and Alternator L3−N

50Hz Voltage Display Adjust or Alter-

nator L3−N 60Hz Voltage Display

Adjust trim respectively.

8. Save the adjustments by doing a

Save Trims with your PC based ser-

vice 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 ap-

plication. If necessary press the ”Ad-

just” 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 cali-

brated 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 Alter-

nator L2−N 60Hz Voltage Display

Adjust trim and Alternator L3−N

50Hz Voltage Display Adjust or Alter-

nator L3−N 60Hz Voltage Display

Adjust trim respectively.

14. Save the adjustment by pressing

the ”Save” button.

3-7

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 cali-

brated 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 Regula-

tion Calibration 60Hz for your desired

application. The effect of this trim is

Inverse on the regulated voltage. In-

creasing the trim will lower the regu-

lated voltage, and decreasing the

trim will raise the regulated voltage.

The monitored Regulated Voltage

will match with the reading on the at-

tached external calibrated meter and

the Regulated Feedback Voltage (Al-

ternator Voltage) matches the de-

sired Nominal voltage.

6. Shut the generator set OFF.

7. Save the adjustments by doing a

Save Trims with your PC based ser-

vice 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 ap-

plication. If necessary press the ”Ad-

just” 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

PC based service tool.

2. Verify the nominal voltage trim is

set to the desired value.

3. With the genset OFF, attach a cali-

brated 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 Set-

point either in positive direction or in

negative direction as per your re-

quirement.

Not Applicable.

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.

3-8

Three Lead CT Setup Example

For this example, assume that a CT with a

1500/750:5 ratio is being used.

Operator Panel

Enter 750 into the CT Ratio parameter on the

Operator Panel.

Manufacturing Tool

Select a feature corresponding to 750:5 to

download using the Manufacturing Tool.

PC-Based Service Tool

Enter 750 into the Primary CT Current param-

eter using a PC based service tool (e.g. In-

Power).

BATTERY CHARGING ALTERNATOR

CONNECTIONS

The 1302 series control currently supports the fol-

lowing charging alternator types.

Denso Type Charging Alternators

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 dis-

connect signal and to indicate a failed battery

charging alternator.

Bosch Type Charging Alternators

A Bosch charging alternator with D+ (flash input)

connection point is shown in Figure 3-3. This con-

figuration is used to produce a start disconnect sig-

nal and to indicate a failed charging alternator.

Battery Charging

Alternator Input

Denso Type

Charging Alternator

RUN

1302 Series Control

B+

J20−22

J20−11

FIGURE 3-2. DENSO CHARGING ALTERNATOR WIRING DIAGRAM

Bosch Type

Charging Alternator

D+

RUN

1302 Series Control

B+

J20−22

J20−11

Battery Charging

Alternator Input

Approx, 5 Ohm

input impedance

FIGURE 3-3. BOSCH CHARGING ALTERNATOR WIRING DIAGRAM

3-9

ALTERNATOR CONNECTIONS

A fast acting UL certified ceramic fuse with a rating

of ten amperes shall be placed inline with the Ex-

citation Inputs J18-1 and J18-2.

Series Star

Series star connection yields an output voltage of

220−277/380−480 volts. Figure 3-4 shows the cor-

rect series−star alternator connections.

CT3

CT1 CT2

J12-1 J12-4 J12-2 J12-5

V2: J22-2

VN: J22-4

V3: J22-3

V5 (T8)

W6 (T12)

W5 (T9)

W2 (T6)

W1 (T3)

V2 (T5)

V1 (T2)

V6 (T11)

U1 (T1)

U2 (T4)

U5 (T7)

U6 (T10)

J12-3 J12-6

V1: J22-1

FIGURE 3-4. SERIES STAR CONNECTIONS

Series Delta

Series delta provides for an output voltage of

110−120/220−240 volts. Figure 3-5 shows the cor-

rect series delta connections.

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

Parallel star alternator configuration yields an out-

put voltage of 110−139/190−240 volts. Figure 3-6

illustrates the correct parallel star connections.

CT3

CT1

CT2

VN: J22-4

V2: J22-2

V3: J22-3

V1: J22-1

J12-1 J12-4

J12-2 J12-5

J12-3 J12-6

W6 (T12)

W5 (T9)

W2 (T6)

W1 (T3)

U6 (T10)

V5 (T8)

V2 (T5)

V1 (T2)

V6 (T11)

U1 (T1)

U2 (T4)

U5 (T7)

FIGURE 3-5. SERIES DELTA CONNECTIONS

CT3

CT1

CT2

J12-2 J12-5

J12-3 J12-6

J12-1 J12-4

V1: J22-1

V2: J22-2

V3: J22-3

U6 (T10)

V1 (T2)

VN: J22-4

V5 (T8)

V2 (T5)

W1 (T3)

V6 (T11)

U2 (T4)

U5 (T7)

W5 (T9)

W2 (T6)W6 (T12)

U1 (T1)

FIGURE 3-6. PARALLEL STAR CONNECTIONS

3-10

Double Delta

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.

CT1

CT2

VN: J22-4

V2: J22-2

V1: J22-1

J12-1 J12-4

J12-2 J12-5

V1 (T2)

W6 (T12)

W5 (T9)

W1 (T3)

V2 (T5)

U2 (T4)

U5 (T7)

U6 (T10)

V6 (T11) U1 (T1)

V5 (T8)

W2 (T6)

FIGURE 3-7. DOUBLE DELTA CONNECTIONS

Single Phase

Single phase provides for an output voltage of

110−120/220−240 volts. Single phase alternator

connections are shown in Figure 3-8.

CT2

J12-2 J12-5

CT1

J12-1 J12-4

VN: J22-4

V2: J22-2

V1: J22-1

U2 (T4)

U1 (T1)

U5 (T7)

U6 (T10)

FIGURE 3-8. SINGLE PHASE CONNECTIONS

3-11

GUIDELINES FOR ENGINE SENSORS

The engine sensors included in this kit are:

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 avail-

able 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.

Oil Pressure Sensors

The 1302 series control can be programmed for ei-

ther oil pressure sensors or switches. The trim pa-

rameter 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.

For information on setting the oil pressure sender

type using the display panel, see page 5-43.

FIGURE 3-9. THREE-WIRE PRESSURE SENSOR

CONNECTIONS

FIGURE 3-10. TWO-WIRE PRESSURE SENSOR

CONNECTIONS

TABLE 3-1. COOLANT TEMPERATURE SENSORS

CPG P/N 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

CPG P/N Manufacturer Manufacturer P/N Comments

0323−1755 Packard 121621893 Plastic shell with seal

0323−1818 Delphi 12124075 Socket Connector

3-12

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 resis-

tive 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 termi-

nals (Packard 12103881)

309−0641−XX Stewart Warner Pressure Switch (See the following page)

A028X493 Kavlico

P4055−5001−1

3-Wire Active

Sender

(Capacitive)

0−100 PSIG 0−5 VDC Mating Connector

326−1666 (Packard

12065287) includes

323−1667 socket termi-

nals (Packard 12103881)

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 pan-

el. A software setting allows for selection of the ac-

tive state of the switch. The Lube Oil Pressure

Switch Polarity can be set to Active High or Active

Low.

For information on setting the oil pressure switch

polarity using the display panel, see page 5-43.

FIGURE 3-11. PRESSURE SWITCH

TABLE 3-4. AVAILABLE PRESSURE SWITCHES (309−0641)

Part No. 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

3-13

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.

3-14

CONTROL BOARD CONNECTIONS

The 1302 control board includes the following

connectors (see Figure 3-12).

CAUTION Reversing the power supply con-

nections on TB1 and/or TB15 can permanently

damage the control. Refer to drawing 630−3270

for proper connections.

TB1 − Customer connections (see Table 3-5

and sheet 3 of Figure 7-1)

TB15 − Tools interface connections (see Table

3-6 and sheet 3 of Figure 7-1)

J11 − Engine connections (see Table 3-7)

J12 − Genset CT connections (see Table 3-8)

J17 − Field winding connections (see Table

3-9)

J18 − Field power connections (see Table

3-10)

J20 − Genset connections (see Table 3-11)

J22 − Alternator voltage sense connections

(see Table 3-12)

J25 − Display connections (see Table 3-13)

Mating connector and connector pin part numbers

for the control board are listed in Table 3-14.

J25 (DISPLAY

CONNECTIONS)

TB1 (CUSTOMER

CONNECTIONS)

J12 (CT

CONNECTIONS)

J11 (ENGINE

CONNECTIONS)

J18 (FIELD

POWER)

J20 (GENSET

CONNECTIONS)

TB15 (PC BASED

SERVICE TOOL)

J17 (FIELD

POWER)

J22 (ALTERNATOR

VOLTAGE SENSE)

FIGURE 3-12. CONTROL BOARD CONNECTIONS

3-15

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 20ma Low Side Relay Driver

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

TABLE 3-6. TB15 − TOOLS INTERFACE CONNECTIONS

Connector

Signal Name Connect To

TB15-1 Return Network Power Supply Return

TB15-2

TB15-3 RS-485 Data A Network Data A

TB15-4 RS-495 Data B Network Data B

TB15-5 PCCNet System Wakeup

3-16

TABLE 3-7. J11 − ENGINE CONNECTIONS

Connector Pin Signal Name Connect To

J11-1 Oil Pressure Sender (Active) +5V

J11-2 Oil Pressure Sender or Switch Re-

turn

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 Re-

turn

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

Connector Pin Signal Name Connect To

J12-1 CT1

J12-2 CT2

J12-3 CT3

J12-4 CT1 Common

J12-5 CT2 Common

J12-6 CT3 Common

3-17

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 Charging alternator

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

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

3-18

TABLE 3-13. J25 − DISPLAY CONNECTIONS

Connector Pin Signal Name 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 Connector Pins

onnector CPG P/N 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 Amp/Tyco / 770586−1 323−2466 Amp/Tyco / 770904−1/

770988−1/171637−1

3-19

ELECTRONIC GOVERNOR

CONNECTIONS

This section describes the installation of the option-

al Electronic Governor Power Module.

A description of the Governor Power Module con-

nections are listed in Table 3-15. Module connector

pat numbers are listed in Table 3-16.

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 dia-

grams “Applications without FSO” (see Figure

3-13) and “Applications with FSO” (see Figure

3-14) as appropriate.

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 Connector Pins

Ref Internal P/N Man / P/N Internal P/N Man / P/N

P1 0323−2216 Amp/Tyco /

1−480763−0

0323−1200 Amp/Tyco /

770008−3

1302 Series

Control

FSO

PWM

Fuel

Actuator

B+

GND

Governor

Power Stage

Relay

J20−14

J11−5

J11−4

Fuse

E−Stop B+

FIGURE 3-13. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITHOUT FSO

3-20

1302 Series

Control

FSO

PWM

B+

GND

Governor

Power Stage

Relay

J20−14

J11−5

J11−4

E−Stop B+

FSO

FIGURE 3-14. ELECTRONIC GOVERNOR CONNECTIONS FOR APPLICATIONS WITH FSO

KIT INSTALLATION

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 gov-

ernor 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 inter-

feres with your installation.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedMounting hardware for the 1302 con-

trol 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).

b. The battery charger (if equipped) is

turned off and disconnected.

c. The negative (−) cable from the battery is

disconnected to prevent accidental start-

ing.

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.

DIMENSIONS ARE IN MILLIMETERS

FIGURE 3-15. 1302 CONTROL FOOTPRINT

3-21

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 con-

trol 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

3-22

4. Install the genset harness (see Figure 3-18).

a. Make sure the current transformers in-

stalled are appropriate for use with a 1302

series control. Refer to the “Guidelines for

Current Transformers” subsection, start-

ing on page 3-3.

b. Make sure the battery charging alternator

installed is one of the types listed in the

“Battery Charger Alternator Connec-

tions” subsection, starting on page 3-8.

c. Make sure the alternator connections are

appropriate for your installation (see “Al-

ternator Connections” on page 3-9).

d. Connect the six harness CT wires to the

current transformers.

e. Connect the four harness sense wires to

the alternator.

f. Connect the harness X+ and XX− wires to

the generator field windings.

g. Make the connections for the excitiation

source (shunt or PMG). For shunt ap-

plications, connect J18-1 and J18-2 to the

low side of L1 and L2. For PMG applica-

tions, 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 in-

puts.

CAUTION Do not connect J18-1 di-

rectly to L1 in 480V applications. Mak-

ing this connection will blow up the

1302 control board.

h. Connect the harness P12, P17, P18, and

P22 connectors to the mating connectors

on the 1302 control board.

DIMENSIONS ARE IN INCHES

FIGURE 3-18. GENSET HARNESS

3-23

5. Install the engine harness.

a. Connect the engine harness wires

marked P11-2 and P11-3 to the oil pres-

sure harness wires marked J11-5, J11-6,

and J11-17 (see Figure 3-20).

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).

c. If installed, connect the engine harness

wires marked P11-8, P11-9, and P11-10

to the magnetic pickup sensor on the en-

gine. If not installed, tie the wires back.

d. Connect the remaining engine harness

wires to the appropriate locations indi-

cated in Figure 3-19.

NOTE: If your installation does not in-

clude an electronic governor, tie

back the wires marked P11-4 and

P11-5.

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.

a. Install the sensor on the engine.

b. Connect the harness connector to the oil

pressure sensor.

FIGURE 3-19. ENGINE HARNESS

3-24

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.

8. Reconnect the generator starting battery

cables (positive [+] cable first).

9. Connect the battery charger (If equipped).

10. Press any button on the operator panel to

“wake up” the control.

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 parame-

ters.

a. For general information on all available

parameters that can be adjusted, see

“Setup, Trims, and Adjustments” on page

3-26.

3-25

b. Follow the setup procedures for current

transformers listed on page 3-4.

c. For information on alternator control ad-

justments, see page 3-36.

d. For information on genset tuning, see

page 3-36.

e. For information on other control functions,

see page 3-46. These include:

−Remote start mode

−Remote emergency stop

−12V/24V batteries

−Engine starting

−Cycle cranking

−Spark ignition power/Glow plug

control

−Genset cooldown start and stop

time delays

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.

3-26

SETUP, TRIMS, AND ADJUSTMENTS

While applying a 1302 series control to a new ap-

plication, make sure the parameters listed in Table

3-17 have appropriate values. Many of these can

be adjusted using the operator panel but some re-

quire 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 ad-

just 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 Gov-

ernor Gains, CT Ratio, etc have to be assigned ap-

propriate values at manufacturing time.

TABLE 3-17. 1302 CONTROL PARAMETERS

Adjusted Using Limits

Group Parameter Name PC Based

Service Tool

Operator

Panel Lower Limit Upper

Limit

Units

Ref

Adjust- Voltage Adjust X−5 5 % —

ment 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

Adjust- Stop Time Delay X X 0 600 Sec 5-8

ment V/Hz Knee Frequency X X 0 10 Hz 5-17

V/Hz Rolloff Slope X X 0 5 % 5-17

3-27

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup –

Nominal Battery Voltage X X 12 24 VDC 5-41

Genset 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

3-28

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup –

Oil Pressure Sensor Type X X 2 or 3 wire N/A N/A 5-43

Genset

(Contin-

ued)

Electronic Governor Enable XEnable or

Disable

NA NA —

XYes or No N/A N/A 5-11

Glow Plug Enable XEnable or

Disable

N/A N/A —

XYes or No N/A N/A 5-8

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 XEnable or

Disable

None N/A —

XYes 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

Battle Short Enable XEnable or

Disable

NA NA 5-11

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

3-29

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup –

ECM CAN

ECM CAN Enabled XDisable, 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 —

Setup −

Configur-

bl I/O

Configurable Input #1−4

Function

X X Active open or

Active closed

N/A 5-21

able I/O

Configurable I/P #1

AnnActive LED

X NO_ANNUN_M

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

N/A 5-21

Configurable I/P #2

AnnActive LED

X NO_ANNUN_M

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

N/A 5-21

3-30

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Configurable I/P #3

AnnActive LED

X NO_ANNUN_M

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

N/A 5-21

Configurable I/P #4

AnnActive LED

X NO_ANNUN_M

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

N/A 5-21

3-31

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Setup −

Configur-

bl I/O

Configurable Fault Input

#1−4 Active State Select

X X Active open or

Active closed

N/A 5-21

able I/O

Configurable Fault Input

#1−4 Fault Level Response

X X Warning,

Shutdown, or

None

5-21

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

Regulated

Voltage

Adj t

Voltage Regulator

Calibration 50Hz

X X 0.9 1.1 % 5-27

Adjust 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

3-32

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Regulated

Voltage

Adj t

Alternator L1 60Hz Current

Adjust

X X 0.8 1.2 % 5-27

Adjust

(Contin-

ued)

Alternator L2 60Hz Current

Adjust

X X 0.8 1.2 % 5-27

ed)

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 XX 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 XEnable 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

Protection

– Engine

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

3-33

TABLE 3-17. 1302 CONTROL PARAMETERS (CONT.)

Group Pg

Ref

Units

LimitsAdjusted Using

Parameter Name

Group Pg

Ref

Units

Upper

Limit

Lower Limit

Operator

Panel

PC Based

Service Tool

Parameter Name

Protection

– Engine

(Contin-

24V Weak Battery

Threshold

X X 18 21 VDC 5-41

ued) Weak Battery Fault Delay X X 1 5 sec 5-43

Fault

Reset Runs X —

History Reset Start Attempts X —

NFPA 110 Status Logical Bits 1−7, Annunciator

Discrete Signals (Configurable via PCC1302

A universal annunciator connected in a network in-

dicates 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 configur-

able 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) ”Configur-

able I/P# n Ann Active LED” (n = 1,2,3 or 4), where,

”Configurable I/P# 1 Ann Active LED”) is applica-

ble 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

Active Condition (LED#

indication) on Annunciator

Active Fault

Condition

Active

FC#

”Configurable In-

# F i ”

NO_ANNUN_MAPPING No bit set = NONE None 1311

put #1 Function” =

Fault Input and

”

Configurable

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

”C

gura

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

LED

CUSTOMER_FAULT_3 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

3-34

TABLE 3-18. 1302 CONTROL SETUP (CONT.)

Input # Active

FC#

Active Fault

Condition

Active Condition (LED#

indication) on Annunciator

”Configurable I/P# n Ann

Active LED” (n =

1,2,3 or 4) set to one of

the following

”Configurable In-

#1 F i ”

NO_ANNUN_MAPPING No bit set = NONE None 1312

put #1 Function” =

Fault Input and

”

Configurable

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

”C

gura

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

LED

CUSTOMER_FAULT_3 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

”Configurable In-

# F i ”

NO_ANNUN_MAPPING No bit set = NONE None 1317

put #1 Function” =

Fault Input and

”

Configurable

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

”C

gura

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

LED

CUSTOMER_FAULT_3 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

”Configurable In-

#1 F i ”

NO_ANNUN_MAPPING No bit set = NONE None 1318

put #1 Function” =

Fault Input and

”

Configurable

CUSTOMER_FAULT_1 Bit 1 set = LED 1 Annunciator

Fault 1

”C

gura

I/P# 1 Ann Active

LED”

CUSTOMER_FAULT_2 Bit 1 set = LED 2 Annunciator

Fault 2

LED

CUSTOMER_FAULT_3 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 line-

to-line sensing voltage regulation system that is

compatible with shunt or PMG excitation systems.

The voltage regulation system is SCR type. Excita-

tion 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-

3-35

age build up from residual levels is ensured by the

use of efficient semiconductors in the power circuit-

ry.

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.

For information on enabling/disabling the AVR fea-

ture 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 start-

up 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

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 set-

ting (%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 incre-

ment.

For information on adjusting rolloff and knee fre-

quency 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 ser-

vice 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 battle-

short feature using the operator panel, see page

5-11.

3-36

GENSET TUNING

The 1302 series control uses a standard 4 coeffi-

cient 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 adjust-

ments.

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 ad-

justed 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 regula-

tor 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 dur-

ing a load acceptance, and prevent large volt-

age overshoots during offloads and during en-

gine/alternator startup.

The value of K2 should be adjusted to control

the recovery characteristics of the voltage dur-

ing large load acceptance and rejection tran-

sients. Values of K2 which are too high can

cause unstable voltage performance and val-

ues too low can cause slow performance or

steady state voltage offset errors.

In general, K1 increases and K2 decreases in val-

ue 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 dur-

ing 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 fre-

quency 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 frequen-

cy and the actual frequency. For example, a volt-

age set point of 93.4% of nominal would be com-

manded 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 set-

tings per calibration so the values must be

used for both 50 and 60Hz operation. If a

particular application requires vastly differ-

ent V/Hz settings for 50Hz and 60Hz op-

eration, it will be required to create sepa-

rate software features for those applica-

tions.

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

3-37

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 applica-

tion is to start with a set of released gains for an en-

gine 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 over-

shoots during offloads, and during engine/alterna-

tor 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 gover-

nor 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 val-

ues 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 re-

sponse of the governor in transient situations. Ad-

justment of GK3 and the Damping factor is an itera-

tive process started by finding the engine load level

which produces the worst steady state engine per-

formance (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 un-

til the sensed voltage goes above the value of the

AVR Boot Threshold trim and if AVR feature is en-

abled. The regulator will now bring the voltage up to

rated voltage.

The purpose of the AVR Boot Table is to aid alterna-

tor startup whilst preventing overvoltage condi-

tions. 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 de-

termining engine and alternator control parame-

ters.

1. Determine 60Hz governor gains, regulator

gains, and V\Hz curve values with PMG ex-

citation.

a. Start the genset, bring it to rated speed

and temperature, and adjust the GK3 and

damping factor for 60Hz operation to al-

low 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

3-38

levels. Most engines have some load lev-

el which is inherently less stable than oth-

ers and must be found to determine the

correct value for GK3 and the damping

factor.

NOTE: It is important to control the

steady state performance of the

engine. Unstable engine perfor-

mance is carried over into the

generator output voltage. Very

fast increases or decreases in en-

gine speed, even if the magnitude

of the increase or decrease is

small, tend to be carried into the

alternator voltage as large in-

creases and decreases in voltage

at the same frequency as the en-

gine speed changes.

b. Do a series of load steps to determine the

transient characteristics of the genset.

Tuning of the governor GK1 and GK2 val-

ues, 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 ad-

justed 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 giv-

en 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 con-

trol 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 re-

cover too quickly and recovers to nominal

speed very poorly. A V/Hz curve too shal-

low causes a very slow engine recovery

from a transient.

c. Re-verify steady state voltage and gover-

nor performance.

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 Al-

gorithm and Adjustment” below).

a. Adjust the Initial Crank Fueling Com-

mand, Initial Crank Fueling Period, Crank

Fueling Ramp Rate, and Max Crank Fuel-

ing 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 Com-

mand parameter should be set to the gov-

ernor duty at which the engine runs when

at rated speed, or to a value slightly high-

er.

Gain Tuning Parameters

This is a list of all of the parameters which affect

genset performance. A correct value should be de-

termined for each of the parameters listed.

NOTE: To check the actual genset output, True

(calibrated) RMS meter should be

usedFor any parameters that have some-

thing listed in the “Value” column, it is

recommended that the parameter stay at

that value during testing. Some parame-

ters should never be changed during test-

ing and are listed as never to be changed.

3-39

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 fre-

quency 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 algo-

rithm in 50Hz applications. Adjust for frequency stability

reasons.

Governor Damping Effect

(50Hz)

Affects high frequency characteristics of the governor algo-

rithm 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 mul-

tiplied against the sum of all previous errors.

GK3 (60Hz) Affects high frequency characteristics of the governor algo-

rithm in 60Hz applications. Adjust for frequency stability

reasons.

Governor Damping Effect

(60Hz)

Affects high frequency characteristics of the governor algo-

rithm in 60Hz applications. Adjust for frequency stability

reasons.

3-40

TABLE 3-21. GAIN TUNING PARAMETERS (CONT.)

Parameter CommentsValue

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 dur-

ing 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

3-41

Controller Calibration

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

Voltage measurement for regulation

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 Calibration Method

Component to be

Calibrated PC Based Service Tool Operator Panel

Voltage Measurement for

Regulation

The goal of this is to cali-

brate the regulation cir-

cuitry so it regulates the

genset to the desired

nominal voltage.

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 Regu-

lation Calibration 60Hz for your

desired application. The effect of

this trim is inverse on the regu-

lated 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 mea-

sured with a known calibrated

voltage meter.

4. 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 operator menus (see Fig-

ure 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. De-

creasing 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 Alterna-

tor Nominal Voltage is available at Ad-

justments  AC Measurement Cal-

ibrations  Voltage Measurement for

Regulation. Set the Alternator Nomi-

nal Voltage to the voltage that the gen-

set 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.

1. View the Service Menu by holding

down the “up” and “down” arrow keys

on any of the operator menus (see Fig-

ure 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 volt-

age being produced by the genset.

8. Save the adjustments by pressing the

“save” button.

3-42

TABLE 3-22. CONTROLLER CALIBRATIONS FOR GENSETS (CONT.)

Component to be

Calibrated

Calibration Method

Component to be

Calibrated Operator PanelPC Based Service Tool

Current Measurement for

Display

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.

4. Adjust the LX 50Hz Current Adjust or

LX 60Hz Current Adjust trim for your

current application so the 1302 series

control measured current matches the

current read by the know current me-

ter. Each of the three lines will have to

be adjusted independently of each

other.

5. 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 operator menus (see Fig-

ure 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 ra-

tios and power rating are correct by

scrolling through the available

screens.

7. Return to the Setup Menu screen by

press the back arrow twice.

8. Select item 1, “Genset Service”.

9. Select item 3, “Meter Calib.”

10. Press the down arrow three times to

scroll down to Metering Current Ad-

just.

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.

3-43

ENTER “574”

ENTER VOLTS

AC VALUE AND

PRESS THE

SAVE BUTTON

ENTER REG

VOLT ADJ VALUE

AND PRESS THE

SAVE BUTTON

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(9)

(5)

NOTE: THE NUMBERS IN PARENTHESIS

MATCH THE STEPS INCLUDED

IN THE PROCEDURE LISTED IN

TABLE 3-22.

FIGURE 3-24. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR REGULA-

TION

3-44

NOTE: THE NUMBERS IN PARENTHESIS

MATCH THE STEPS INCLUDED

IN THE PROCEDURE LISTED IN

TABLE 3-22.

ENTER “574”

ADJUST ALL THREE

PARAMETERS AND

PRESS THE SAVE

BUTTON

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

FIGURE 3-25. OPERATOR PANEL MENUS FOR CALIBRATING VOLTAGE MEASUREMENT FOR DISPLAY

3-45

NOTE: THE NUMBERS IN PARENTHESIS

MATCH THE STEPS INCLUDED

IN THE PROCEDURE LISTED IN

TABLE 3-22.

ENTER

“574”

ENTER

“1209”

ADJUST ALL THREE

PARAMETERS AND

PRESS THE SAVE

BUTTON

(1)

(2)

(3)

(4)

(5)

(6)

(9)

(11)

(6)

(7)

(10)

(8)

(12)

(6)

FIGURE 3-26. OPERATOR PANEL MENUS FOR CALIBRATING CURRENT MEASUREMENT FOR DISPLAY

3-46

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 sec-

ond path is fed directly into the relay drivers, disab-

ling them when an E-stop is present.

Emergency Stop

It is also required that there be a physical interrup-

tion of the FSO and the starter (and, optionally,

switched B+) when an emergency stop is active. In

order to do this, add a second E-stop contact in se-

ries with B+ and the FSO relay coil. Figure 3-27 il-

lustrates 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 con-

nection point is called E−Stop B+.

Referring to wiring diagram: 630−3270 for com-

plete 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 Volt-

age 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.

B+

1302 Series Control

Remote

E−Stop

Contact 1

Remote

E−Stop

Contact 2

Local

E−Stop

Contact 1

Local

E−Stop

Contact 2 E−Stop B+

(To Relay

Contacts)

Local

E−Stop

Switch

Remote

E−Stop

Switch

FIGURE 3-27. EMERGENCY STOP CONTACTS

3-47

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.

FIGURE 3-28. PRE−GLOW MEASUREMENT

Glow Plug Control implemented in PCC1302 con-

sists of the following two processes:

a. Preheat Process (Pre−Glow Process)

b. Total Glow Process

Preheat Glow Time and Total Glow Time are deter-

mined by linear interpolation of Preheat Time and

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 re-

main 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 Name of the

Trims

Default

Value

Range

1Preheat Time

(Trim)(sec)

15 (sec) 0−30 (sec)

Preheat Tem-

perature

(Trim)(_F)

70 (_F) 0−100 (_F)

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 temper-

ature the control defines a non−cold engine. The

glow plugs will not preheat for engine coolant tem-

peratures above the Preheat Temperature.

Total Glow Processing:

Total Glow processing logic has three associated

trims as shown in Table 3−23.

3-48

TABLE 3-24. TOTAL GLOW PROCESSING TRIMS

TABLE

Sr. No Name of the

Trims

Default

Value

Range

Total Glow

Time

(Trim)(sec)

0 (sec) 0−60 (sec)

Total Glow

Temperature

(Trim)(_F)

70 (_F) 0−110 (_F)

Total Glow

Knee Point

(Trim)(_F)

0 (_F) 0−32 (_F)

Glow Plug Output Logic:

In PCC1302, Glow Plug Output depends upon To-

tal Glow Time Value (Mon). The Glow Plug Output

turns on when Fuel System (Trim) = Diesel and To-

tal 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) ex-

pires.

b. When Generator Set Control stops nor-

mally.

c. When Generator Set Control stops during

emergency.

d. When Generator Set Control performs cy-

clical 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 Tempera-

ture. Adjusting both of the trims will allow for tailor-

ing of the glow plug preheat logic for specific en-

gine applications. Setting Glow Plug = Disabled

disables the glow plug preheat logic.

When the trim parameter Fuel Type = Gas, pin

J11-7 can be used to control an external spark igni-

tion control module. Pin J11-7 is turned on simulta-

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 shut-

down command is received, the fuel solenoid is

disabled but the ignition control module driver

stays on until the Fuel Burn Off Time delay timer ex-

pires. 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 sys-

tem 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 gov-

erning capability for a generator set when a elec-

tronic governor option is installed on the genset. It

has a field adjustment trim to enable or disable the

electronic governing feature. It supports isochro-

nous 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 Barber-

Coleman actuators with similar drive charac-

teristics.

It provides speed governor setpoints of 1500

RPM and 1800 RPM. The governor setpoint is

a field adjustment (50 Hz or 60 Hz).

3-49

The optional display allows the operator to ad-

just frequency within plus or minus 5% of rated

speed.

The controller provides ramping at startup and

an ability to program the cranking fueling be-

fore the governor algorithm is enabled.

Engine Speed Sensing

For electronically governed gensets, the 1302 se-

ries control requires an engine speed input from a

magnetic pickup speed sensor. The magnetic pick-

up signal needs to be calibrated for number of en-

gine flywheel teeth. The table shown below lists the

number of flywheel teeth for some common engine

types.

TABLE 3-25. FLYWHEEL TEETH REQUIREMENTS

Engine Type 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

For non-electronically governed gensets, the mag-

netic pickup is optional. If it is not used, engine

speed is calculated from the alternator output fre-

quency.

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 (Proportion-

al−Integral−Derivative).

It allows field tuning of the speed coefficients.

The 1302 series control provides a dither fea-

ture. Dither is a method of introducing small

amounts of noise into the speed governing

system. The purpose of this feature is to pre-

vent the fuel actuators from becoming stuck.

Therefore dither should be used in applica-

tions 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 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 high-

er levels of cranking fuel. Following parameters

should be chosen to make sure the genset starts

up quickly enough but does not overshoot or pro-

duces excessive smoke at startup.

The initial cranking fuel duty cycle can be cho-

sen to suit the engine / application.

The initial cranking fuel period can be chosen

to suit the application.

The cranking fuel is ramped up during crank-

ing after initial cranking fueling period is over.

The rate of ramping up of fueling can be cho-

sen 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 actua-

tor 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 con-

trol of the PWM output to the actuator.

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 ex-

pires, the fuel command is ramped at the Crank

Fueling Ramp Rate until the Maximum Crank Fuel-

ing limit is reached. Upon reaching the Starter Dis-

connect Speed, the fueling command is pulled

back to the Crank Exit Fueling Duty Cycle value un-

til the Governor Enable Engine Speed is reached.

When the Governor Enable Engine Speed is

reached, the governor is enabled, the speed set-

point 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 dia-

gram below illustrated these setpoints.

3-50

Initial Crank Fuel

Duty Cycle

Crank Fuel

Ramp Rate

Initial Crank

Fueling Period

Crank Fuel Duty Cycle

Max Crank Fuel

Duty Cycle

Crank Exit Fuel

Duty Cycle

Closed Loop Operation

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. Un-

der this condition, and with Scheduler Prog x En-

able 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 Day-

light Savings Time Enable needs to be set to En-

abled. To setup DST, specify the values for the fol-

lowing trims. These trims can be set via PCTools or

HMI211 or HMI211RS or via Modbus utility.

3-51

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 Saving Start

Month

Daylight Saving Start

Week Occurrence in Month

Second Occur-

rence

Daylight Saving Time Ad-

justment

NOTE: The software accuracy of real time

clock is +/− hour over a period of 1 cal-

endar 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 automati-

cally starts the genset for exercise. This feature

prevents common problems which result from me-

chanical 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’ condi-

tion. No exceptions can be set in PCC1302.

The exercise program has the following trims

which establish its behavior where currently x al-

ways denotes 1.

3-52

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-

ly,Quarterly,Semi−Annual

Specifies the repeating behavior of Program

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

TABLE 3-29. EXAMPLE TRIM VALUE

Trim Value

Scheduler Prog x Enable Enable

Scheduler Prog Start Minute 12

Scheduler Prog Start Hour 8

Scheduler Prog Start Day Monday

Scheduler Prog Start Period AM

Scheduler Prog Repeat Interval Weekly

Scheduler Prog Duration (Mins) 15

3-53

TABLE 3-30. EXCERISER SCHEDULE

Scheduler

Program

Enable

Scheduler

Program

Start Day

Start Time Scheduler

Program

Duration

Schedular

Program

Start Period

AM/PM

Schedule Re-

peat Interval

Hr Min Min 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 parame-

ters except for the trim ”Scheduler Prog x En-

able”.

5. If the user tries to edit these trims except

”Scheduler Prog x Enable”, following mes-

sage, ”Can Not Edit Exercise On” will be dis-

played on both HMI 211 and HMI 211 RS.

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.

NOTE: The excerise scheduler function is

available from 1320 calibration ver-

sion 2.76 and above and HMI211 cal-

ibration version 6.90 and above.

ATS Control

Automatic Transfer Switch is used to transfer pow-

er 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 transfer-

ring 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 in-

puts 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

Pin Signal Name

TB1−12 Configurable Input 1

TB1−13 Configurable Input 1 − Common

TB1−14 Configurable Input 2

Configurable Input 1 is used for Utility switch posi-

tion 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: When Exercise is active and if Utility

lost condition is received (remote start

signal is active), Genset Control dis-

cards the Exercise and continues with

3-54

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.

GENSET CONTROL

TRANSFER SWITCH

LOAD

SOURCE 2

GENSET

SOURCE 1

UTILITY

GENSET

FEEDBACK

UTILITY

FEEDBACK

Ready to Load/

ATS Output

UTILITY VOLTAGE

MONITORING

SENSOR

REMOTE START

COMMAND

READY TO LOAD

CONDITION

START/STOP

OPERATION

Config I/P 2 Config I/P 1

Remote HMI

TB1−14 TB1−12

TB1−4

TB1−10

FIGURE 3-30. PCC1302 BLOCK DIAGRAM

As per the block diagram shown above,

Genset Control (PCC1302) monitors the sta-

tus of the Utility (Failing and Returning con-

dition) directly through Remote Start Com-

mand (Active or Inactive) condition.

When Utility voltage monitoring sensor

senses that the voltage has gone below

Drop−out Voltage, it will activate the Remote

Start Command input.

When Utility voltage monitoring sensor

senses that the voltage has gone above the

Pickup Voltage, it will de−activate the Re-

mote Start Command input.

When Genset control receives the Remote

Start active input command, the control will

do the following when Control Switch Posi-

tion is in Auto.

a. Genset Control gives the start command

to Genset after the Start Time delay is

completed.

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.

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

3-55

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 speci-

fied 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 Re-

mote Start Inactive Input Command and

Auto Mains Failure Enable is enabled,

Genset Control starts Re−Transfer Delay

(Trim).

b. When Genset Control receives the Re-

mote 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 In-

put 2 Status = Inactive (Genset Open) and

Configurable Input 1 Status = Active (Util-

ity 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 ”Util-

ity 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, Gen-

set Control will declare the Warning fault

”Transfer Switch Status Unknown Position”.

NOTE: In Genset Control, if Auto Mains Fail-

ure Enable = Enabled and Transfer

Switch Feedback Enable = Enabled,

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 En-

able = Disabled, then transferring and

retransferring process depends upon

Ready to Load / ATS Output status

only.

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 sta-

tus 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 con-

trol system has the ability to transfer the fuel source

from Natural Gas to Propane in case a low fuel con-

dition 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

holding down the “up” and “down” arrow keys.

3. Select item 1, “Setup Menus”.

3-56

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.

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.”

NOTE: When Switch Input is set to “Op-

erator Panel”, the “Battle Short:

Active/Inactive” subject is dis-

played. Battle Short should not

be set to “Active” until it is needed

by the customer.

−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.

For more information on the Battle Short feature,

see Section 4.

3-57

Installations Without an Operator Panel

Installations without a operator panel require the

following.

A Manual Run/Off/Auto switch must be con-

nected to the control harness.

A status indicator lamp must be installed to

flash shutdown fault codes.

An external On/Off switch must be con-

nected 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 assis-

tance. For more information on the Battle Short

feature, see Section 4.

Battle Short Mode

Battle Short mode is designed to work only in criti-

cal 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.

WARNING Use of the Battle Short mode fea-

ture can cause a fire or electrical hazard, result-

ing in severe personal injury or death and/or

property and equipment damage. Operation of

the genset must be supervised during Battle

Short operation.

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).

Before the Battle Short feature can be used, it must

first be enabled. Only trained and experienced ser-

vice 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 Ac-

tive or Inactive) using the operator panel.

The PC service tool is required to enable the

Battle Short mode feature. Contact an autho-

rized 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 over-

ridden 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

−Speed Signal Lost (Loss of Speed

Sense) − Fault Code 121

−Excitation Fault (Loss of Voltage

Sense) − Fault Code 2335

Battle Short mode is disabled after an over-

ridden 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.

3-58

Installations without an Operator Panel

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.

The PC service tool is required to enable the

Battle Short mode feature and to enable the ex-

ternal Battle Short switch using one of the two

available customer inputs. Contact an autho-

rized service center for assistance.

When Battle Short mode is enabled and an overrid-

den shutdown fault occurs, the genset continues to

run and the status indicator lamp flashes the shut-

down fault code. See “Local Status Output” on page

4-1 for information on interpreting the status indica-

tor light.

Battle Short is suspended and a shutdown occurs

immediately if:

Any of the following shutdown faults occurs.

−Overspeed − Fault code 234 or 1992 or

3131

−Emergency Stop − Fault code 1433 or

1434

−Speed Signal Lost (Loss of Speed

Sense) − Fault code 121

−Excitation Fault (Loss of Voltage

Sense) − Fault code 2335

The external Battle Short switch is moved to

the OFF position after an active but overrid-

den shutdown fault occurred while in Battle

Short mode. The status indicator lamp then

flashes Fault Code 1123 − Shutdown After

Battle Short.

3-59

ENTER “574”

(2)

(3)

(4)

(5)

(6)

(8)

(7)

NOTE: THE NUMBERS IN PARENTHESIS

MATCH THE STEPS INCLUDED IN THE

PROCEDURE LISTED ON PAGE 3-55.

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”

(7)

FIGURE 3-31. OPERATOR PANEL MENUS FOR CALIBRATING BATTLE SHORT MODE

3-60

THIS PAGE INTENTIONALLY LEFT BLANK

4-1

4. Operator Panel Operation

PREVIOUS MENU

LEVEL BUTTON

GRAPHICAL

DISPLAY

OFF MODE

BUTTON

DISPLAY MENU

SELECTION BUTTONS

LED

INDICATORS

HMI1211

FIGURE 4-1. 1302 OPTIONAL OPERATOR PANEL

INTRODUCTION

This section includes information on the following.

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

LOCAL STATUS OUTPUT INDICATOR

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.

Constant Fast Flashing = This occurs during

preheat (when used) and while the generator

set is starting.

Constant On = The genset is running.

Intermittent Flashing = A genset shutdown

fault condition exists. All of the shutdown

faults described in Table 4-2 can be an-

nounced with a status indicator lamp.

For four-digit shutdown fault codes, the first

digit in the code is flashed, followed by a half-

second 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, fol-

lowed by a two-second pause.

NOTE: Only the last shutdown fault is flashed.

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.

4-2

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 in-

cluded 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 shut-

down sequence. When in Off mode, all active faults

are reset.

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.

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.

When all remote start signals are removed, the

control performs a normal shutdown sequence

which may include a time delay stop.

Emergency Stop Mode

When the optional emergency stop button is used,

it immediately shuts down the generator set, by-

passing any time delay stop. The red Shutdown

LED lights and Fault Code 1433 or 1434 − Emer-

gency Stop is either displayed (installations with a

operator panel) or flashed (installations with a sta-

tus indicator lamp).

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).

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).

TB15

CONNECTOR

FIGURE 4-2. TB15 CONNECTOR WITH JUMPER

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.

Once in sleep mode, the 1302 series control will

wake up when one of the following wakeup signals

are received.

Local E-Stop − Active when switch is open

Remote E-Stop − Active when switch is open

Manual Start

PCCNet System Wakeup

Remote Start

Auto Mode (If Configured)

Configurable Input #3

Configurable Input #4

4-3

Installations with an Operator Panel

Sleep mode is automatically enabled on the opera-

tor panel. To awaken the operator panel, press any

button.

Installations with a Manual Run/Off/Auto

Switch

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.

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.

Graphical Display

This graphical display is used to view menus of the

menu-driven operating system. The bottom of the

graphical display indicates the functions that are

available by pressing the four selection buttons.

Refer to the menu trees later in this section.

System messages (communication, event, status,

and fault) are also shown on the graphical display.

For more information, see page 4-6.

Display Text / Symbolic Versions

Using the Display Setup Service submenu (see

page 5-15), the graphical display can be set up to

show either text or symbolic versions of fault mes-

sages, some Operator menus, and the Mode

Change menu. A description of commonly used

symbols used are included in Table 4-1. Combina-

tions of symbols are used to display some fault con-

ditions. Additional specialized symbols are also

used for some faults (see Table 4-2).

TABLE 4-1. SYMBOLS

SYMBOL DESCRIPTION

Generator Warning Fault

Generator Shutdown Fault

Coolant Temperature

Oil Pressure

Voltage Alternating Current (VAC)

Voltage Direct Current (VDC)

AC Current

Hz Frequency

Battery

Out of Range

High or Pre-High

Low or Pre-Low

Annunciator

4-4

Display Menu Selection Buttons

Four momentary soft-key buttons are used to step

through the various menus and to adjust parame-

ters. 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.

The function of the four selection buttons varies

with each menu.

When the symbol is displayed, the

selection button can be used to switch to

Auto mode.

When the symbol is displayed, the selec-

tion button can be used to switch to Manual

Run mode.

When the up and down triangles ( and )

are displayed, the selection buttons are used

to navigate between a series of submenus.

NOTE: When any Operator menu is dis-

played, a series of Service menus can

be viewed by simultaneously pressing

the and selection buttons for two

seconds (see page 4-24).

NOTE: When a fault is displayed, it can be

cleared from the front panel by press-

ing the or button.

When a symbol is displayed, the selection

button can be used to abort the Auto or

Manual Run mode and return to the Opera-

tor menu that was displayed before the Auto

or Manual Run mode was selected.

When ADJUST is displayed, the selection

button is used to display an adjustable

menu. When the ADJUST button is pressed,

the first adjustable parameter or value in the

submenu is highlighted.

When the symbol is displayed, the

selection button is used to navigate to an

editable field within a menu.

When the + and − symbols are displayed,

the selection buttons are used to increase or

decrease a parameter or value shown on the

screen.

When changing values, pressing the button

below the + symbol increase the value and

pressing the button below the − symbol de-

creases the value.

When SAVE is displayed, the selection but-

ton is used to save changes made in a sub-

menu. If the Previous Menu button is

pressed before pressing SAVE, the

changes are not saved.

Some menus include a list of numbered sub-

jects. These menus include numbers in pa-

renthesis (for example, (1)) displayed above

the selection buttons. The selection buttons

are then used to display submenus of the

subjects included in the list.

When a black box is displayed, the

selection button has no function.

Previous Main Menu Button

Press the button to view the previous main

menu.

NOTE: In the Screen Adjust menu, settings are not

saved when the button is pressed.

4-5

PREVIOUS MAIN

MENU BUTTON

OFF

BUTTON

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.

If the button is pressed during genset operation

(manual or remote start), the engine immediately

shuts down and the control enters the Off mode. If

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

This red lamp is lit when the control detects a Shut-

down condition. The generator set cannot be

started when this lamp is on. After the condition is

corrected, the lamp can be reset by performing a

fault reset. When Battle Short mode is enabled and

an overridden shutdown fault occurs, the Shut-

down lamp is lit even though the genset continues

to run.

Warning Indicator

This yellow lamp is lit whenever the control detects

a warning condition. This lamp is automatically

shut off when the warning condition no longer ex-

ists.

Remote Start Indicator

This green lamp indicates the control is receiving a

remote start signal.

Auto Indicator

This green lamp indicates the control is in Auto

mode. Auto mode can be selected by pressing the

selection button from any of the Operator me-

nus (see page 4-22).

Manual Run Indicator

This green lamp indicates the control is in the

Manual Run mode. Manual Run mode can be se-

lected by pressing the selection button from any

of the Operator menus (see page 4-22).

4-6

OPERATOR PANEL SYSTEM MESSAGES

A system pop-up message is displayed when the

event it is displaying becomes active. These pop-

up messages remain displayed until pre-empted by

another pop-up message or until the or the

display buttons is pressed or the event has expired.

Once the or the button is pressed, the pre-

vious screen is redisplayed.

Communication Messages

System messages are displayed for initial power-

up or when there is a subsequent loss of commu-

nications. Auto and Manual Run modes can also be

selected when communication messages are dis-

played (for more information, see page 4-22).

Upon initial power-up, the message “Establishing

communication with control” is displayed (see Fig-

ure 4-4). This menu also displays the screen’s soft-

ware number and version.

FIGURE 4-4. ESTABLISHING COMMUNICATIONS

MESSAGE

When the display detects that it is no longer com-

municating with the control, the Shutdown, Warn-

ing, and Remote Start LEDs are turned off.

If communications are lost, the message “Re-es-

tablishing 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 4-5. RE-ESTABLISHING

COMMUNICATIONS MESSAGE

If either communication message remains dis-

played (cannot view other menus), this is an in-

dication that communications between the op-

erator panel and the control logic is lost. Con-

tact 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).

Event = START,

or STOP

FIGURE 4-6. EVENT MESSAGE

Status Messages

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 sta-

tus messages include the event code, a short de-

scription, and the time the event occurred. Symbol-

ic status messages include the event code and

symbols to indicate the type of event that occurred.

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

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

4-7

fault code number, a short description, and when

the fault occurred (see Figure 4-8). Symbolic fault

messages include the fault code number and sym-

bols, 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 = WARNING

or SHUTDOWN

FIGURE 4-8. FAULT MESSAGE − TEXT VERSION

214

EXAMPLE OF

A SYMBOLIC

WARNING

FAULT

EXAMPLE OF

A SYMBOLIC

SHUTDOWN

FAULT

FIGURE 4-9. FAULT MESSAGES − SYMBOLIC

VERSION

Fault Reset / Acknowledgement

Shutdown faults must be acknowledged after the

fault condition has been corrected. Shutdown

faults are usually acknowledged by one of the fol-

lowing methods.

If the control is equipped with an operator

panel, press the button.

If the control is not equipped with and opera-

tor panel, place the Auto/Off/Manual Run

switch in the Off position.

Shutdown faults can also be acknowledged when

in Auto mode by using an external customer-sup-

plied remote fault reset switch. This ability must be

enabled by setting the Remote Fault Reset En-

abled 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.

4-8

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 al-

ternator shutdown faults that require immediate re-

pair by trained and experienced service personnel

(generator set non-operational). The control pre-

vents 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 power-

ing critical loads and cannot be shut down. Catego-

ry B faults require repair by trained and experi-

enced 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 dam-

age can occure without detection.) Continued op-

eration may void the generator set warranty if

damage occures that relates to the fault condi-

tion.

Category D Fault Codes: Consist of faults that are

repairable by site personnel. Service will be re-

quired by trained and experienced service person-

nel 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 LAMP TEXT VERSION SYMBOLIC

VERSION

DESCRIPTION

A 121 Shutdown SPEED SIGNAL

LOST 121

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.

C 135 Warning OIL PRESS

SENSOR OOR

HIGH 135 Indicates the oil pressure sensor output is

out of range (OOR), high.

C 141 Warning OIL PRESS

SENSOR OOR

LOW 141 Indicates the oil pressure sensor output is

out of range (OOR), low.

B143 ** Warning PRE-LOW OIL

PRESSURE 143 Indicates that the engine oil pressure is

approaching an unacceptable level.

C 144 Warning COOLANT

SENSOR OOR

LOW 144

Indicates the coolant temperature sensor

output is out of range (OOR), low.

C 145 Warning COOLANT

SENSOR OOR

HIGH 145

Indicates the coolant temperature sensor

output is out of range (OOR), high.

C146 ** Warning PRE-HIGH

COOLANT TEMP 146 Indicates that the engine has begun to

overheat and the engine coolant tempera-

ture 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).

4-9

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

D151 ** Shutdown HIGH COOLANT

TEMP 151 Indicates that the engine coolant tempera-

ture is above normal and has reached the

shutdown trip point.

C 153 Warning INTAKE

MANIFOLD

TEMP OOR

HIGH 153

Indicates the intake manifold temperature

sensor is out of range (OOR), high.

C 154 Warning INTAKE

MANIFOLD

TEMP OOR LOW 154 Indicates the intake manifold temperature

sensor is out of range (OOR), low.

D 155 Shutdown INTAKE

MANIFOLD

TEMP HIGH 155 Indicates that the intake manifold

temperature is above normal and has

reached the shutdown trip point.

D 195 Warning COOLANT

LEVEL OOR

HIGH 195 Indicates that a sensor on the radiator has

detected that the coolant level is out of

range (OOR), high.

D 196 Warning COOLANT

LEVEL OOR

LOW 196 Indicates that a sensor on the radiator has

detected that the coolant level is out of

range (OOR), low.

D 197 Warning COOLANT

LEVEL LOW 197 Indicates that a sensor on the radiator has

detected that the coolant level is below

normal.

A 234 ** Shutdown OVERSPEED

234

Indicates that the engine has exceeded

normal operating speed. The default

thresholds are 1725 RPM (50 Hz) or 2075

RPM (60 Hz).

A 285 Shutdown ECM PGN

TIMEOUT 285 Datalink failure. PCC control not

responding to the engine control module.

A 286 Shutdown ECM

CONFIGURABLE

ERROR 286 Indicates an engine control module

configuration error − out of calibration.

D 359 Shutdown FAIL TO START

359

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).

A 415 Shutdown LOW OIL

PRESSURE 415

Indicates the engine oil pressure has

dropped below normal and has reached

the shutdown trip point.

C 421^Shutdown OIL TEMP HIGH 421 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).

4-10

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

−− 418 NONE N / A N/A Indicates water in fuel

B 425^Shutdown OIL TEMP OOR 425 Indicates the oil temperature sensor output

is out of range (OOR), high or low. (I/O

Module option)

A 426 Shutdown DATA LINK

ERROR 426 Datalink failure. No communications

between the PCC control and the engine

control module.

A 427 Warning CAN LINK LOST 427 Datalink fault. Indicates that important data

was lost between the PCC control and the

engine control module.

D441 ** Warning LOW BATTERY

441

Indicates battery voltage supply to the con-

trol is approaching a low level at which un-

predictable operation can occur.

D442 ** Warning HIGH BATTERY 442 Indicates battery voltage supply to the con-

trol is approaching a high level at which

damage to the control can occur.

D 488^Shutdown INTAKE

MANIFOLD

TEMP HIGH 488 Indicates the intake manifold temperature

is above normal and has reached the

shutdown trip point. (I/O Module option)

A 689 Shutdown ENGINE SPEED

ERRATIC 689 Indicates a fault condition in the engine

crankshaft sensor circuit.

A 781 Shutdown CAN LINK LOST 781 Datalink failure. No communications

between the PCC control and the engine

control module.

D1117 Warning ECM POWER

LOST 1117 Indicates battery voltage supply to the

engine control module was lost.

B 1123

Shutdown SHUTDOWN

AFTER BS 1123 A shutdown fault occurred while the Battle

Short mode was enabled.

D 1131

Warning BATTLE SHORT

ACTIVE 1131

Indicates that the control is in Battle Short

mode − used to bypass several fault shut-

downs for genset operation during emer-

gencies.

C 1246 Warning GENERIC

ENGINE FAULT 1246 Engine control fault code not recognized

by the PCC control.

E 1311 Configur-

able

Customer Fault

Input 1 1311 The nature of the fault is an optional cus-

tomer selection.

E 1312 Configur-

able

Customer Fault

Input 2 1312 The nature of the fault is an optional cus-

tomer selection.

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.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

E 1317 Configur-

able

Customer Fault

Input 3 1317 The nature of the fault is an optional cus-

tomer selection.

E 1318 Configur-

able

Customer Fault

Input 4 1318 The nature of the fault is an optional cus-

tomer selection.

B 1416

Warning FAIL TO

SHUTDOWN 1416 Indicates that a shutdown fault is active,

but is being bypassed by Battle Short.

A 1417 Shutdown FAILURE TO

POWER DOWN 1417 Indicates the control is powered up after

attempting to go to sleep.

D 1433 Shutdown LOCAL

EMERGENCY

STOP 1433 Indicates a Local Emergency Stop has

been activated.

D 1434 Shutdown REMOTE

EMERGENCY

STOP 1434 Indicates a Remote Emergency Stop has

been activated.

D 1435

Warning LOW COOLANT

TEMP 1435

Indicates that the engine coolant tempera-

ture is below the adjusted setpoint. This

may indicate that the coolant heater is not

operating or is not circulating coolant.

D 1438 Shutdown FAIL TO CRANK

1438

The genset has failed to sense rotation for

two start attempts. This indicates a pos-

sible fault with the control, speed sensing,

or the starting system.

D 1442

Warning WEAK BATTERY 1442

Indicates that the genset battery voltage is

below battery thresholds during cranking.

A 1443 Shutdown DEAD BATTERY

1443

Indicates during cranking battery voltage

has dropped below operating voltage of

control resetting the control for three con-

secutive times.

A 1446

Shutdown HIGH AC

VOLTAGE

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.

A 1447

Shutdown LOW AC

VOLTAGE

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.

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.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

A 1448

Shutdown UNDER

FREQUENCY 1448Hz Indicates that the alternator frequency is 6

hertz under nominal frequency.

A 1449

Shutdown OVER

FREQUENCY 1449Hz Indicates that the alternator frequency is 6

hertz above nominal frequency.

−− 1463 NONE N /A N/A Indicates Not in Auto.

−− 1468 NONE N / A N/A Indicates Ready to Load.

A 1469

Shutdown SPEED HZ

MATCH

Indicates that measured engine speed and

measured alternator AC output frequency

do not agree.

B 1471*

Warning HIGH AC

CURRENT 1471 Indicates that the alternator output current

(one or more phases) has exceeded safe

operating limits.

A 1472

Shutdown HIGH AC

CURRENT 1472 Indicates that alternator output current

(one or more phases) has exceeded the

alternator’s current rating.

−− 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 1845 Indicates the water in fuel sensor is out of

range (OOR), high.

C 1846 Warning WATER IN FUEL

OOR LOW 1846 Indicates the water in fuel sensor is out of

range (OOR), low.

D 1852 Warning WATER IN FUEL 1852 Indicates that the water in fuel is above

normal and has reached the warning trip

point.

E 1853 Configur-

able

Annunciator Fault

21853 The nature of the annunciator fault is an

optional customer selection.

E 1854 Configur-

able

Annunciator Fault

31854 The nature of the annunciator fault is an

optional customer selection.

E 1855 Configur-

able

Annunciator Fault

11855 The nature of the annunciator fault is an

optional customer selection.

E 1944 Warning ANNUNCIATOR

OUTPUT CON-

FIGURATION

ERROR 1944

Indicates a mismatch in the configuration

of one of the annunciator relay outputs.

D 1965

Warning EXHAUST

TEMPERATURE

OOR 1965 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).

4-13

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

B 1992 Warning ENGINE

OVERSPEED 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 Indicates genset is running on secondary

fuel source in dual fuel application.

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 1517 At least One Module of a Multi−module

system has a severe fault.

B 1921 Warning REGEN

MANDATORY

HIGH LEVEL 1921

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).

4-14

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

B 1922 Warning GENSET

CRITICAL CALL

TECHNICIAN 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.

B 175 Warning AIR THROT

DRIVE CCT

OORH 175 Electronic Throttle Control Actuator Driver

Circuit − Voltage Above Normal or Shorted

to High Source.

B 176 Warning AIR THROT

DRIVE CCT

OORH 176 Electronic Throttle Control Actuator Driver

Circuit − Voltage Below Normal or Shorted

to Low Source.

B 177 Warning AIR THROT

DRIVE MECH

SYS ERROR 177 Electronic Throttle Control Actuator −

Mechanical System Not Responding or

Out of Adjustment.

B 3539 Warning AIR THROT

POSN SENSOR

OORH 3539 Engine Intake Throttle Actuator Position

Sensor Circuit − Voltage Above Normal or

Shorted to High Source.

B 3541 Warning AIR THROT

DRIVE CCT

OORL 3541 Engine Intake Throttle Actuator Position

Sensor Circuit − Voltage Below Normal or

Shorted to Low Source.

B 3542 Warning AIR THROT

POSN SENS

DATA INCORR 3542 Engine Intake Throttle Actuator Position

Sensor − Data Erratic, Intermittent, or

Incorrect.

B 5669 Warning ENGINE

COMBUSTION

FAULT 5669 Intake Manifold Over Pressure − Condition

Exists.

C 2224

Warning FUEL LEVEL

OOR 2224 Indicates the fuel level sensor is out of

range (OOR), high or low. (Aux 101 I/O

option).

A 2335 Shutdown EXCITATION

FAULT 2335 Indicates that a loss of voltage or frequen-

cy sensing from the generator has oc-

curred.

C 2398

Warning AMBIENT

TEMPERATURE

OOR 2398 Indicates the ambient temperature sensor

is out of range (OOR), high or low. (Aux

101 I/O option).

C 2542

Warning VOLTAGE BIAS

OOR 2542 Indicates the voltage bias circuit output is

out of range (OOR), high or low. (Aux 101

I/O option).

A 2545 Shutdown KEYSWITCH

RESET

REQUIRED 2545 Indicates a datalink failure. Communica-

tions 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).

4-15

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

E 2619

Diagnos-

tic

AUX101 ANA-

LOG INPUT 1

2619

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-

tic

AUX101 ANA-

LOG INPUT 2 2621 See code 2619.

E 2622

Diagnos-

tic

AUX101 ANA-

LOG INPUT 3 2622 See code 2619.

E 2623

Diagnos-

tic

AUX101 ANA-

LOG INPUT 4 2623 See code 2619.

E 2624

Diagnos-

tic

AUX101 ANA-

LOG INPUT 5 2624 See code 2619.

E 2625

Diagnos-

tic

AUX101 ANA-

LOG INPUT 6 2625 See code 2619.

E 2626

Diagnos-

tic

AUX101 ANA-

LOG INPUT7 2626 See code 2619.

E 2627

Diagnos-

tic

AUX101 ANA-

LOG INPUT 8 2627 See code 2619.

E 2628

Diagnos-

tic

AUX102 DIGITAL

INPUT 9

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-

tic

AUX102 DIGITAL

INPUT 10 2629 See code 2628.

E 2631

Diagnos-

tic

AUX102 DIGITAL

INPUT 11 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).

4-16

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

E 2632

Diagnos-

tic

AUX102 DIGITAL

INPUT 12 2632 See code 2628.

A 2676 Shutdown ALTERNATOR

FREQUENCY

CONFLICT

Indicates the measured alternator line fre-

quency and measured alternator excitation

frequency do not agree.

A 2677 Shutdown FAIL TO STOP 2677 The genset continues to run after receiving

a stop command from the controller.

B 2678

Warning CHARGER

FAILURE

2678

Indicates the battery charging alternator

has not reached a acceptable voltage

range within the selected time period (de-

fault = 120 seconds).

This warning is also displayed if your alter-

nator is a type that does not support the

control’s charging alternator logic function-

ality. If this occurs, this warning can be dis-

abled if the Charging Alt. Enable setting is

set to “No.” See the Genset Service sub-

menus on page 5-8.

C 2693

Warning SPEED BIAS

OOR 2693 Indicates the speed bias circuit output is

out of range (OOR), high or low. (Aux 101

I/O Module option).

C 2694

Warning ALTERNATOR

RTD OOR 2694 Indicates the alternator RTD sensor is out

of range (OOR), high or low. (Aux 101 I/O

Module option).

A 2696

Shutdown ALTERNATOR

RTD TEMP HIGH 2696 Indicates the alternator temperature is

above normal and has reached the

shutdown trip point. (I/O Module option)

C 2729

Warning I/O MODULE

LOST 2729 Indicates an intermittent data link between

the I/O module and the PCC control. (Aux

101 I/O Module option).

C 2731 Shutdown I/O MODULE

LOST 2731 Indicates the data link between the I/O

module and the PCC control is lost. (Aux

101 I/O Module option).

A 2897 Shutdown FACTORY

BLOCK

CORRUPT 2897 Indicates a fatal software error occurred in

the PCC control.

A 2898 Warning PERIODIC/

FAULT

CORRUPT 2898 Indicates a fatal software error occurred in

the PCC control.

A 2899 Shutdown USER BLOCK

CORRUPT 2899 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).

4-17

TABLE 4-2. FAULT AND STATUS CODES (CONT.)

CTG DESCRIPTION

DISPLAYED MESSAGE/SYMBOLS

LAMPCODE

CTG DESCRIPTION

SYMBOLIC

VERSION

TEXT VERSION

LAMPCODE

A 2911 Shutdown TRIM BLOCK

CORRUPT 2911 Indicates a fatal software error occurred in

the PCC control.

D 2964 Warning INTAKE

MANIFOLD

TEMPERATURE

HIGH 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.

A 2972

Shutdown FIELD

OVERLOAD 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 dis-

play 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 execut-

ed, all temporary adjustments are lost.

Adjustments to the following are stored in flash

memory in the optional operator panel.

Contrast

Brightness

Units

Local or remote display

Symbols or text displayed

Access code required for mode change to

Auto or Manual Run

All other adjustments are stored in the control

board.

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

This menu displays the engine starting battery volt-

age, engine coolant temperature, engine oil pres-

sure, and hours of engine operation.

Alternator Status Menu

This menu displays genset load (in kVA), frequen-

cy, and engine speed (RPM).

Alternator Line-to-Line Voltage Menu

This menu displays L1-L2, L2-L3, and L3-L1 line-

to-line voltages for three phase applications only.

4-18

Alternator Line-to-Neutral Voltage Menu

This menu displays line-to-neutral voltages for L1,

L2, and L3 for three phase wye configurations only.

In delta configurations, this menu is not shown.

Alternator Single Phase Voltage Menu

This menu displays L1-N, L2-N, and L1-L2 volt-

ages for single phase applications only.

Alternator Amperage Menu

For applications that include current transformers,

this menu displays L1, L2, and L3 current sense

amperage.

4-19

OPERATOR MENUS − Text Version

THREE PHASE

ONLY

THREE PHASE

WYE ONLY

CURRENT SENSE

AMPERAGE

SINGLE

PHASE

ONLY

FIGURE 4-10. OPERATOR MENUS (TEXT VERSION)

4-20

CURRENT SENSE

AMPERAGE

OPERATOR MENUS − Symbolic Version

THREE PHASE

ONLY

THREE PHASE

WYE ONLY

SINGLE

PHASE

ONLY

FIGURE 4-11. OPERATOR MENUS (SYMBOLIC VERSION)

4-21

SELECTING AUTO, MANUAL RUN, AND

OFF MODES

Auto, Manual Run, and Off modes can be selected:

From any of the Operator menus

When the message “Establishing commu-

nication with control” is displayed

When the message “Re-establishing com-

munication with control” is displayed

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 en-

tered before the mode can be changed. The mode

change access code feature is enabled through the

Display Setup submenu (see page 5-15).

The Auto or Off mode switch status is saved in non-

volatile memory when it changes. When the control

panel powers up (after sleeping or upon battery re-

moval), the switch status is restored to its previous

saved state.

Entering the Mode Change Access Code

If the mode change feature access code is en-

abled, an access code must be entered to switch to

Auto, Manual Run, or Off modes. The text and sym-

bolic versions of the Mode Change menu are

shown in Figure 4-12.

To enter the mode change access code,

1. With the first character highlighted, press the

button below to the + or − symbols until the val-

ue reads “1.”

2. Press the arrow selection button to move

to the next numeric character.

3. Press the button below the + or − symbols until

the value reads “2.”

4. Press the arrow selection button to move

to the next numeric character.

5. Press the button below the + or − symbols until

the value reads “1.”

6. After you have completed entering the pass-

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.

TEXT VERSION

SYMBOLIC VERSION

FIGURE 4-12. MODE CHANGE MENU

4-22

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.

3. A menu with alternating arrows is displayed

above a second symbol. Press the sec-

ond button. The Operator menu that was

displayed before Auto mode was selected is

redisplayed.

To disable Auto mode, press the button.

NOTE: Manual Run mode can also be selected

while in Auto mode.

ALTERNATING

ARROWS ARE

DISPLAYED

AUTO MODE

SELECTED

THIS MENU IS

DISPLAYED ONLY IF

THE MODE CHANGE

ACCESS CODE

FEATURE IS ENABLED

FIGURE 4-13. SELECTING AUTO MODE

4-23

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 me-

nus or the “Establishing/Re-establishing com-

munication 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 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 dis-

played before Manual Run mode was selected

is redisplayed.

To disable Manual Run mode, press the 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

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 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 be-

fore Auto or Manual Run mode was selected is re-

displayed

MANUAL

RUN MODE

SELECTED

ALTERNATING

ARROWS ARE

DISPLAYED

THIS MENU IS

DISPLAYED ONLY IF

THE MODE CHANGE

ACCESS CODE

FEATURE IS ENABLED

FIGURE 4-14. SELECTING MANUAL RUN MODE

Selecting Off Mode

To switch to Off mode, press the button. If the

genset is running and Off mode is selected, a nor-

mal shutdown sequence is initiated. More informa-

tion on the use of the Off button is included on page

4-5.

4-24

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 fol-

lowing 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.

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 press-

ing the selection button on the first Service

Menu. The second Service Menu provides access

to the following menus:

Fault History − see page 4-28

Status − see below

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.

Status Menu

The Status menu is displayed when the (5) button

is pressed on the second Service Menu. The Sta-

tus menu shows the following:

Voltage regulator (drive) level, in percentage

of duty cycle.

Governor regulator (drive) level, in percent-

age of duty cycle. This value is only dis-

played if the governor is enabled.

Network Status Menus

The Network Status menus are displayed when the

(7) button is pressed on the third Service Menu.

Two menu are used to display the quantity of the

following devices that are connected to the net-

work.

Universal Annunciators

Bar graphs

Battery chargers

Controls

I/O modules

Operator panels (any type)

4-25

FAULT HISTORY MENUS

SEE PAGE 4-28

HISTORY / ABOUT MENUS

SEE PAGE 4-26

SETUP MENUS

SEE PAGE 5-4

SCREEN ADJUST MENU

SEE PAGE 4-30

1ST

SERVICE

2ND

SERVICE

3RD

SERVICE

FIGURE 4-15. SERVICE MENUS

4-26

HISTORY / ABOUT MENUS

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).

Press the buttons next to the and symbols in

the graphical display to navigate between the His-

tory / About submenus. Press the button to re-

turn to the Service Menu.

History Submenu

This submenu displays the number of engine

starts, hours of operation for the engine, and hours

of operation for the control.

About Genset Submenus

Two submenus display the generator set model

number, control number, and genset application

frequency rating.

About Control Submenu

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 Display Submenu

This submenu displays the optional control panel

software part number, software version, screen

part number, and screen version of the display.

4-27

HISTORY / ABOUT MENUS

FIGURE 4-16. HISTORY / ABOUT MENUS

4-28

FAULT HISTORY MENU

Figure 4-18 shows a block representation of the

Fault History menu. The first Fault menu is dis-

played when the (4) button is pressed on the sec-

ond Service Menu (see Figure 4-15). If there are

any active fault submenus, an “Active Fault” head-

ing 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 dis-

played is shown in Figure 4-17.

Press the buttons next to the and symbols in

the graphical display to navigate between menus.

Press the button to return to the Service Menu.

Information on faults is included in Table 4-2 on

page 4-8.

FAULT

CODE

FAULT

DESCRIPTION

TIME FAULT

OCCURRED

FIGURE 4-17. FAULT HISTORY MENU EXAMPLE

4-29

FAULT HISTORY MENU

Fault 1

Fault 2

Oldest Fault

(Maximum of 5)

Active Fault

FIGURE 4-18. FAULT HISTORY MENU

4-30

SCREEN ADJUST MENU

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).

Adjusting Values/Parameters

1. Press the ADJUST selection button to select

the first parameter or value to be changed.

2. Press the + or − selection buttons to adjust val-

ues or select parameters.

3. Press the arrow selection button to navi-

gate to the next or previous adjustable value or

parameter.

4. After adjusting values/selecting parameters,

press the SAVE button to save your settings.

NOTE: If the Previous Menu button is

pressed before pressing the SAVE

button, the changes are not saved.

5. Press the button to return to the Service

Menu.

Screen Adjust Menu

This menu allows for adjusting the screen’s con-

trast 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 con-

trast and brightness. Changing the bright-

ness setting also affects the brightness of

the LEDs on the operator panel.

Units: Press the + or − selection buttons to

select SAE (_F, PSI) or SI (C, kPa) units of

measurement to be displayed.

SCREEN ADJUST MENU

FIGURE 4-19. SCREEN ADJUST MENU

5-1

5. 1302 Control Panel Service Menus

SERVICE MENUS

NOTE: When using any PCCNet device on a gen-

set 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).

CAUTION Incorrect settings can result in

equipment malfunction and damage. Only

trained and experienced personnel should be

authorized to change the settings.

The Service Menus shown in this section can be

viewed and, if the correct password(s) are entered,

modified. Changing the settings should be re-

stricted to trained and experienced installation and

service personnel.

Figure 5-1 shows a block representation of the me-

nus 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 fol-

lowing menus:

Setup Menus − See page 5-3

History / About − See page 4-27

Screen Adjust − See page 4-30

Changes can be made to Adjust submenus without

entering a password. However, a password is re-

quired to change any of the Setup submenus.

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 press-

ing 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

Bar graphs

Battery chargers

Controls

I/O modules

Operator panels

5-2

FAULT HISTORY MENUS

SEE PAGE 4-28

HISTORY / ABOUT MENUS

SEE PAGE 4-26

SETUP MENUS

SEE PAGE 5-4

SCREEN ADJUST MENU

SEE PAGE 4-30

STATUS MENU

SEE PAGE 4-24

NETWORK STATUS MENUS

SEE PAGE 4-24

1ST

SERVICE

2ND

SERVICE

3RD

SERVICE

FIGURE 5-1. SERVICE MENUS

5-3

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) but-

ton is pressed on the Service Menu. From the Set-

up Password menu, a second Setup menu is dis-

played 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

5-4

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.

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.

The first Genset Service Menu provides access to

the following menus:

Genset

Customer I/O

Meter Calibration

The second Genset Service Menu provides access

to the following menus:

Annunciator

ModBus

The Genset Service menus can be viewed by se-

lecting 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 me-

nus; therefore, no adjustments can be made.

Menu Navigation

1. Press the buttons above the and sym-

bols in the digital display to navigate between

submenus.

2. To return to the genset Setup Menus menu

from any of the submenus, press the but-

ton.

3. To return to the Service Menu from the genset

Setup Menus menu, press the button.

5-5

GENSET SERVICE MENUS (Viewing Only)

SEE PAGE 5-8

SEE PAGE 5-21

SEE PAGE 5-27 SEE PAGE 5-29

NOTE: When the VIEW button is selected

from the Setup Password menu with-

out entering a password, the AD-

JUST button is not available on any of

the menus shown in Figures 5-5 thru

5-14.

1ST VIEW

GENSET

SERVICE

2ND VIEW

GENSET

SERVICE

SEE PAGE 5-34

FIGURE 5-3. VIEWING GENSET SERVICE MENUS WITHOUT ENTERING A PASSWORD

5-6

Viewing and Adjusting

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 al-

lowed.

The first Genset Service Menu provides access to

the following menus:

Genset

Customer I/O

Meter Calibration

The second Genset Service Menu provides access

to the following menus:

Annunciator

ModBus

Setup Password Submenu

Adjusting the Genset Service menus is restricted to

service personnel and a password must be entered

to modify these menus.

When the Password menu is displayed, the first nu-

meric character (0) is highlighted (see Figure 5-4).

NOTE: When selected (highlighted), each charac-

ter initially turns to “0” and the remaining

characters turn to “X”.

NOTE: Make sure that each numeric character is

correct before you move to the next char-

acter. If a wrong character is entered, you

will not be able to go back and correct it. If

the wrong password is entered, you will be

able to view the Genset Service menus but

you won’t be able to change them.

To enter the password:

1. With the first character highlighted, press the

button below to the + or − symbols until the val-

ue reads “5.”

2. Press the arrow selection button to move

to the next numeric character.

3. Press the button below the + or − symbols until

the value reads “7.”

4. Press the arrow selection button to move

to the next numeric character.

5. Press the button below the + or − symbols until

the value reads “4.”

6. After you have completed entering the pass-

word, press the arrow selection button .

The first main Setup menu is displayed.

After the correct password is entered, it will be re-

membered 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.

Adjusting Values/Parameters

Once the correct password has been entered and

Genset Service (1) is selected on the Setup Menus

menu, the first Genset Service submenu is dis-

played.

1. Press the buttons above the and sym-

bols in the digital display to navigate between

submenus.

2. Press the ADJUST selection button to select

the first parameter or value to be changed.

3. Press the + or − selection buttons to adjust val-

ues or select parameters.

4. Press the arrow selection button to navi-

gate to the next or previous adjustable value

or parameter.

5. After adjusting values/selecting parameters,

press the SAVE button to save your settings.

NOTE: If the button is pressed before

pressing the SAVE button, the

changes are not saved.

6. Press the button to return to the Service

Menu.

5-7

GENSET SERVICE MENUS (Viewing and Adjusting)

SEE PAGE 5-8

SEE PAGE 5-21

SEE PAGE 5-27 SEE PAGE 5-29

1ST

GENSET

SERVICE

2ND

GENSET

SERVICE

SEE PAGE 5-34

FIGURE 5-4. GENSET SERVICE MENUS

5-8

Genset Service Submenus

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 Genset Service submenus consist of ten basic

submenus.

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 Gov-

ernor has five additional submenus.

Genset Menu, Part 1

The first genset menu displays the preset AC Volt-

age, 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).

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.

Charging Alt. Enable:

A starter disconnect will occur whenever any

one of the following three possible signals

reaches its disconnect setpoint.

−The average engine speed (if a mag-

netic pickup unit is installed)

−The average frequency

−The charging alternator voltage (if the

Charging Alt feature is enabled)

The Charging Alt. Enable menu is used to en-

able or disable the Charging Alt feature. While

the default setting is “Yes,” this menu provides

a means to disable the control’s charging alter-

nator logic if it is not supported by your alterna-

tor. 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 sig-

nal is based only on the average engine speed

or frequency and the Charger Failure warning

is disabled.

Fuel System

The Fuel System menu allows for selecting fuel

type and, depending on the type selected, enab-

ling/disabling glow plugs or setting a fuel burn time

delay.

Fuel System: Allows for selecting the fuel

type (Diesel or Gas, default = Diesel).

If Fuel System is set to “Diesel”

Glow Plug Enable: Allows control of Glow

Plugs for a particular genset (Yes or No, de-

fault = 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 in-

take manifold is burned.

Start/Stop Delay Menu

The time delay after receiving a valid start signal,

until the genset starts, can be adjusted. The time

delay that the genset is allowed to 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 ad-

justed 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.

5-9

Stop: The genset stop time delay can be

adjusted from 0 to 600 seconds (default = 0

seconds).

5-10

CONTINUED ON

PAGE 5-12

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.

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 1 OF 4)

5-11

Cycle Crank Menu

The Cycle Crank menu allows for configuring the

generator for all starting modes (manual and re-

mote), 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.

Rest: The minimum amount of time between

crank attempts can be set from 0 to 60 sec-

onds (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

(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 se-

lected. 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 Inac-

tive), (default = Inactive). This subject will

only be displayed if the switch input is set to

“Operator Panel.”

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).

5-12

GENSET SERVICE SUBMENUS (Continued)

RETURN TO

PAGE 5-10

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”

YES NO

GO TO AVR

SETUP MENUS

ON PAGE 5-18

CONTINUED

ON PAGE 5-14

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 2 OF 4)

5-13

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 per-

centage of governor duty cycle that is first used

when exiting cranking.

Genset Number Menu

The Genset Number menu is used to enter the gen-

set’s model and serial numbers. Each allow up to

16 characters to be entered.

5-14

GENSET SERVICE SUBMENUS (Continued)

YES NO

GO TO

GOVERNOR

SETUP MENUS

ON PAGE 5-20

GO TO

PAGE 5-18

IF AVR IS NOT

ENABLED

IF AVR IS

ENABLED

RETURN TO

PAGE 5-12

CONTINUED

ON PAGE 5-16

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 3 OF 4)

5-15

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 op-

erator 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 re-

quire or not require entering the mode (Auto,

Manual Run, or Off) change access code

(default = No).

Symbols: A display can be set up to display

international symbols on the Operator me-

nus (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).

5-16

GENSET SERVICE SUBMENUS (Continued)

RETURN TO

PAGE 5-14

FIGURE 5-5. GENSET SERVICE SUBMENUS (SHEET 4 OF 4)

5-17

Automatic Voltage Regulator Submenus

The Automatic Voltage Regulator (AVR) subme-

nus are available only if the AVR is enabled (see

page 5-12).

Two Automatic Voltage Regulator (AVR) subme-

nus (see Figure 5-7) can be used to adjust Volts/Hz

Rolloff and Regulator Gains settings.

Volts/Hz Rolloff Menu

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 be-

low 55 Hz.

Slope refers to how fast the voltage is rolled off be-

low 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.

FREQUENCY

NOMINAL

VOLTAGE

SLOPE

KNEE FREQUENCY

VOLTAGE

NOMINAL

(100%) VOLTAGE SET-

POINT CURVE

NOMINAL

FREQUENCY

FIGURE 5-6. KNEE FREQUENCY AND SLOPE

V/Hz Knee: The Knee Frequency can be ad-

justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-

ments (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.

V/Hz Rolloff: The Rolloff setting can be ad-

justed from 0.0 to 5.0 percent of rated volt-

age, 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.

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%).

5-18

AUTOMATIC VOLTAGE REGULATOR SUBMENUS

RETURN TO

PAGE 5-12

NOTE: These menus are only available if

the Automatic Voltage Regulator

(AVR) is enabled (see page 5-12).

RETURN TO

PAGE 5-12

FIGURE 5-7. AUTOMATIC VOLTAGE REGULATOR SUBMENUS

5-19

Electronic Governor Submenus

The Electronic Governor submenus are available

only if the governor is enabled (see page 5-12).

Four Electronic Governor submenus (see Figure

5-8) can be used to adjust governor settings.

Governor Crank Fuel Menu

The Governor Crank Fuel menu allows for setting

the Initial Crank Fuel Duty Cycle, the Initial Crank

Fueling Period, the Crank Fuel Ramp Rate, and the

Maximum Crank Fuel Duty Cycle.

Initial DC: The Initial Crank Fuel Duty Cycle

is the initial value assigned to the Governor

Duty Cycle parameter when cranking be-

gins. This value can be set from 0 to 50 per-

cent (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 be-

gins. This value can be set from 0 to 10 sec-

onds (default = 2 seconds).

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.

Gain: The proportional governor gain (K1)

multiplier can be set from 5 to 1000% (de-

fault = 100%). This allows for a scale factor

of 0.05 to 10.0.

Int: The integral governor gain (K2) multiplier

can be set from 5 to 1000% (default =

100%).

D: The governor Damping adjustment can

be set from 95 to 105% (default = 100%).

Electronic Governor Menu

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 Gov-

ernor Enable menu.

Crank Exit Fuel DC: The Crank Exit Fuel

Duty Cycle is the value at which the gover-

nor duty cycle is held after disengaging the

starter until the governor is enabled. This

value can be set from 0 to 100% (default =

25%).

Dither Factor: Dither is a signal that is super-

imposed on the PWM (pulse with modula-

tion) 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% (de-

fault = 15%). The dither function is disabled

when the dither factor is set to 0%.

Ramp Time: This feature is used to set the

minimum governor speed reference ramp

rate. The governor Ramp Time can be set

from 0.00 to 30.0 seconds, in 0.01 second

increments (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%).

Max. Gov DC: The Maximum Governor Duty

Cycle (with dithered value) can be set from 0

to 100% (default = 95%).

5-20

ELECTRONIC GOVERNOR SUBMENUS

DRETURN TO

PAGE 5-14

NOTE: These menus are only available

if the governor is enabled (see

page 5-12).

RETURN TO

PAGE 5-14

FIGURE 5-8. ELECTRONIC GOVERNOR SUBMENUS

5-21

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 mes-

sages and output maps. The Customer I/O menus

consist of four Fault Input Function Selection me-

nus, 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, Shut-

down 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.

5-22

FAULT INPUT FUNCTION SELECTION SUBMENUS

GO TO

CUSTOMER

INPUT MENUS

ON PAGE 5-23

FIGURE 5-9. CUSTOMER I/O SUBMENUS (SHEET 1 OF 4)

5-23

CUSTOMER INPUT SUBMENUS

RETURN TO

PAGE 5-22

GO TO FAULT

INPUT ACTIVE

STATE MENUS ON

PAGE 5-24

FIGURE 5-10. CUSTOMER I/O SUBMENUS (SHEET 2 OF 4)

5-24

FAULT INPUT ACTIVE STATE SELECTION SUBMENUS

RETURN TO

PAGE 5-23

GO TO

CUSTOMER

OUTPUT MENUS

ON PAGE 5-26

FIGURE 5-11. CUSTOMER I/O SUBMENUS (SHEET 3 OF 4)

5-25

Customer Outputs

Two Customer Outputs are configurable to display

common warning alarms. The two Customer Out-

put Map menus allow for entering a fault number

and fault name to be displayed for the two configur-

able customer outputs. See Figure 5-12.

Number: Enter a valid code number

(0−65535, default = 0) for the event.

A brief description of the event is automati-

cally displayed.

5-26

CUSTOMER OUTPUT SUBMENUS

RETURN TO

PAGE 5-24

FIGURE 5-12. CUSTOMER I/O SUBMENUS (SHEET 4 OF 4)

5-27

Metering Submenus

The Metering submenus are available by pressing

the (3) button on the first Genset Service menu

(see Figure 5-3 or Figure 5-4).

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 ac-

tual 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.

Freq. Adjust Menu

The Frequency Adjust menu allows for adjusting

the genset frequency. The frequency can be adjust

from −6.0 to +6.0 Hz (default = 0.0 Hz). The actual

frequency is also shown on this menu.

Metering Voltage Adjust Menu

The Metering Voltage Adjust menu allows for ad-

justing metered line voltage.

Metering Current Adjust Menu

The Metering Current Adjust menu allows for ad-

justing metered amps.

5-28

METERING SUBMENUS

FIGURE 5-13. METERING SUBMENUS

5-29

Annunciator Submenus

The Annunciator submenus are available by press-

ing 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-de-

fined 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-de-

fined annunciator faults.

Type: Enter the event type (Warning, Shut-

down, or Event, default = Warning).

Enter a brief description of the event (up to

32 characters).

5-30

ANNUNCIATOR SUBMENUS

CONTINUED ON

PAGE 5-32

FIGURE 5-14. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2)

5-31

Annunciator Outputs

An annunciator has four custom (N.O.) relays that

can be controlled by the PCC 1302. When a speci-

fied 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 warn-

ing alarms. The four Annunciator Output Map me-

nus allow for entering a fault number and fault

name to be displayed for the configurable annun-

ciator outputs.

Number: Enter a valid code number

(0−65535, default = 0) for the event.

A brief description of the event is automati-

cally displayed.

NOTE: Output relays can be configured for events

that are not displayed by the operator pan-

el. 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

5-32

ANNUNCIATOR SUBMENUS (Continued)

RETURN TO PAGE 5-30

FIGURE 5-14. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2)

5-33

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 Enable

The ModBus menu is used to enable or disable the

ModBus feature (default = No).

ModBus Setup

The ModBus Setup menu is used to set the ad-

dress, baud rate, and parity.

Address: Enter the address of the control on

the ModBus register (default = 1).

Baud Rate: Enter the appropriate baud rate

− 2400, 4800, 9600, or 19200 (default =

9600).

Parity: The parity can be set to either odd or

even (default = even).

5-34

MODBUS SUBMENUS

FIGURE 5-15. MODBUS SUBMENUS

5-35

GENSET SETUP SUBMENUS

The first Setup menu is displayed when the (1) but-

ton is pressed on the Service Menu. From the Set-

up Password menu, a Setup Menus menu is dis-

played that provides access to the following two

categories of genset menus.

Genset Service menus − Go to page 5-3

Genset Setup menus

This section covers Genset Setup menus only. A

password does not need to be entered on the Set-

up 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 Pass-

word, the settings in the Genset Setup menus can

be adjusted. However, if a password is not entered,

these menus can still be viewed.

SETUP

PASSWORD

GENSET SETUP

PASSWORD

SETUP

MENUS

FIGURE 5-16. SETUP PASSWORD MENUS

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

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 se-

lecting the VIEW button on the Genset Setup Pass-

word menu. When the VIEW button is selected

without entering the correct password, the AD-

JUST button is not displayed on any of the Genset

Setup menus; therefore, no adjustments can be

made.

Menu Navigation

1. Press the buttons above the and sym-

bols in the digital display to navigate between

submenus.

2. To return to the genset Setup Menus menu

from any of the submenus, press the but-

ton.

3. To return to the Service Menu from the genset

Setup Menus menu, press the button.

5-36

GENSET SETUP MENUS (Viewing Only)

NOTE: When the VIEW button is selected from

the Genset Setup Password menu with-

out entering a password, the ADJUST

button is not available on any of the me-

nus shown in Figures 5-19 thru 5-22.

SEE PAGE 5-40

SEE PAGE 5-46

SEE PAGE 5-50SEE PAGE 5-48

1ST

GENSET

SETUP

2ND

GENSET

SETUP

AVAILABLE ONLY IF THE ECM

CAN FEATURE IS DISABLED

FIGURE 5-17. GENSET SETUP MENUS (VIEWING ONLY)

5-37

Viewing and Adjusting

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 set-

tings is allowed.

The first Genset Setup Menu provides access to

the following menus:

Genset

Voltage Protection

Current Protection

The second Genset Setup Menu provides access

to the following menu:

Engine Protection

Genset Setup Password Submenu

Adjusting the Genset Setup menus is restricted to

service personnel and a password must be entered

to modify these menus.

Once the Genset Setup button (2) is selected on

the Setup Menus menu, the Genset Setup Pass-

word menu is displayed.

When the Genset Setup Password menu is dis-

played, the first numeric character (0) is highlighted

(see Figure 5-18).

NOTE: When selected (highlighted), each charac-

ter initially turns to “0” and the remaining

characters turn to “X”.

NOTE: Make sure that each numeric character is

correct before you move to the next char-

acter. If a wrong character is entered, you

will not be able to go back and correct it. If

the wrong password is entered, you will be

able to view the Genset Setup menus but

you won’t be able to change them.

To enter the password:

1. With the first character highlighted, press the

button below to the + or − symbols until the val-

ue reads “1.”

2. Press the arrow selection button to move

to the next numeric character.

3. Press the button below the + or − symbols until

the value reads “2.”

4. Press the arrow selection button to move

to the next numeric character.

5. Press the button below the + or − symbols until

the value reads “0.”

6. Press the arrow selection button to move

to the next numeric character.

7. Press the button below the + or − symbols until

the value reads “9.”

8. After you have completed entering the pass-

word, press the arrow selection button .

The first main Setup menu is displayed.

After the correct password is entered, it will be re-

membered until five minutes of button inactivity has

elapsed. If five minutes of button inactivity has

elapsed, you will have to re-enter the password to

access and change Genset Setup menus.

Adjusting Values/Parameters

Once the correct password has been entered on

the Genset Setup Password menu, the first Genset

Setup submenu is displayed.

1. Press the buttons above the and sym-

bols in the digital display to navigate between

submenus.

2. Press the ADJUST selection button to select

the first parameter or value to be changed.

3. Press the + or − selection buttons to adjust val-

ues or select parameters.

4. Press the arrow selection button to navi-

gate to the next or previous adjustable value

or parameter.

5. After adjusting values/selecting parameters,

press the SAVE button to save your settings.

NOTE: If the button is pressed before

pressing the SAVE button, the

changes are not saved.

6. Press the button to return to the genset

Setup Menus menu.

7. To return to the Service Menu from the genset

Setup Menus menu, press the button.

5-38

GENSET SETUP MENUS (Viewing and Adjusting)

SEE PAGE 5-40

SEE PAGE 5-46

SEE PAGE 5-50SEE PAGE 5-48

1ST

GENSET

SETUP

2ND

GENSET

SETUP

AVAILABLE ONLY IF THE ECM

CAN FEATURE IS DISABLED

FIGURE 5-18. GENSET SETUP MENUS (VIEWING AND ADJUSTING)

5-39

Genset Menus

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 transform-

ers 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 elec-

tronic governed systems) can be set from 0

to 256 (default = 110).

RPM/Hz Ratio: Allows for setting the Speed/

Frequency Ratio to 20, 30, or 60 RPM/Hz

(default = 30).

Genset Menu 2

The second Genset Setup menu is used to set the

excitation source and the excitation/line frequency

gain.

Excitation Source: Select Shunt or PMG Ex-

citation, depending upon your application.

Excitation/Line Freq. Gain: If the excitation

source is set to “Shunt,” this value is auto-

matically set to 1. If the excitation source is

set to “PMG,” the value that should be en-

tered 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).

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 stand-

by 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).

3Ph/60Hz: The three phase, 60 Hertz rating

can be set from 0 to 2000 kVA (default = 25

kVA).

1Ph/50Hz: The single phase, 50 Hertz rating

can be set from 0 to 2000 kVA (default = 25

kVA).

1Ph/60Hz: The single phase, 60 Hertz rating

can be set from 0 to 2000 kVA (default = 25

kVA).

5-40

GENSET SETUP SUBMENUS

CONTINUED ON

PAGE 5-42

FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 1 OF 3)

5-41

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 con-

trol 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).

3Ph/60Hz: The three phase, 60 Hertz rating

can be set from 0 to 2000 kVA (default = 25

kVA).

1Ph/50Hz: The single phase, 50 Hertz rating

can be set from 0 to 2000 kVA (default = 25

kVA).

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.

Nominal Battery Voltage: Allows for setting

the nominal battery voltage (12 or 24V, de-

fault = 12V).

Battery Thresholds Menu

The Battery Thresholds menu is used to set the low

and high voltage values to determine when the bat-

tery 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 Thresh-

olds menu that is displayed is dependent upon the

battery voltage entered in the Battery Select menu.

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.

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.

Weak Batt: The weak battery voltage thresh-

old 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 (de-

fault = 14.4 VDC), in 0.1 VDC increments.

5-42

GENSET SETUP SUBMENUS (Continued)

RETURN TO PAGE 5-40

CONTINUED ON

PAGE 5-44

D D

12V 24V

FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 2 OF 3)

5-43

Battery Delay Setup Menu

This menu is used to determine when, after deter-

mining that the battery condition is out of the preset

operating range, a warning message is an-

nounced.

L. Batt TD: A time delay from 2 to 60 sec-

onds (default = 60 seconds) can be set be-

fore the Low Battery warning message

(Fault Code 441) is announced.

H. Batt TD: A time delay from 2 to 60 sec-

onds (default = 60 seconds) can be set be-

fore the High Battery warning message

(Fault Code 442) is announced.

Wk Batt TD: A time delay from 1 to 5 sec-

onds (default = 2 seconds) can be set before

the Weak Battery warning message (Fault

Code 1442) is announced.

Oil Pressure Setup Menus

NOTE: The following menus are only available if

the the ECM CAN feature is disabled.

A menu is available to set the sensor type. If the

sensor type is Switch, then another menu is avail-

able 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).

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).

5-44

GENSET SETUP SUBMENUS (Continued)

RETURN TO PAGE 5-42

SWITCH SENDER

NOTE: These menus are available only

if the the ECM CAN feature is

disabled.

FIGURE 5-19. GENSET SETUP SUBMENUS (SHEET 3 OF 3)

5-45

Voltage Protection Submenus

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).

Figure 5-20 is a block representation of the four

Voltage Protection submenus that are available.

High AC Voltage Menu

This menu is used to determine when a high AC

voltage fault condition exists and for how long the

fault condition should be present before the engine

is shut down.

High AC Voltage Threshold: This threshold

is used to set the percentage of desired volt-

age 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 be-

cause 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.

Low AC Voltage Menu

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 volt-

age necessary to activate a Low AC Voltage

fault condition. This value can be set from 50

to 95% (default = 85%).

Low AC Voltage Time Delay: A time delay of

2 to 20 seconds (default = 10 seconds) must

expire before the engine shuts down be-

cause 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.

Overfrequency Menu

This menu is used to determine when an overfre-

quency fault condition exists and for how long the

fault condition should be present before the engine

is shut down.

Overfrequency Threshold: This threshold is

used to set the amount of Hertz that the al-

ternator line frequency can be over to acti-

vate an Overfrequency fault condition. This

value can be set from 2 to 10 Hz (default = 6

Hz).

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.

Underfrequency Menu

This menu is used to determine when an underfre-

quency fault condition exists and for how long the

fault condition should be present before the engine

is shut down.

Underfrequency Threshold: This threshold is

used to set the Hertz number that the alter-

nator line frequency can be under to activate

an Underfrequency fault condition. This val-

ue can be set from 2 to 10 Hz (default = 6

Hz).

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 shut-

down message (Fault Code 1448) is an-

nounced.

5-46

VOLTAGE PROTECTION SUBMENUS

FIGURE 5-20. VOLTAGE PROTECTION SUBMENUS

5-47

Alternator Protection

The alternator protection feature protects the alter-

nator as well as connected loads from conditions of

High AC Voltage, Low AC Voltage, Loss of AC

Sense, Field Overcurrent, Overfrequency, Under-

frequency, and High AC Current.

Current Protection Submenus

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).

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

condition should be present before the warning

message is displayed and, if necessary, the shut-

down 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.

H. Curr Shutdown Time Delay: The High

Current Shutdown Time Delay sets how long

before the fault is greater than the instanta-

neous threshold. If the fault condition is ac-

tive for the duration of this time delay (2 to

60 seconds, default = 10 seconds), the en-

gine shuts down and the High AC Current

shutdown message (Fault Code 1472) is

announced.

5-48

CURRENT PROTECTION SUBMENUS

FIGURE 5-21. CURRENT PROTECTION SUBMENUS

5-49

Engine Protection Submenus

The Engine Protection submenus are available by

pressing the (4) button on the second Genset Set-

up menu (see Figure 5-17 or Figure 5-18).

The Engine Protection submenus (see Figure

5-22) are used to set thresholds to determine when

engine fault conditions exist and time delays to de-

termine how long a fault condition is present before

the fault message is announced and, if necessary,

shut down the engine.

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 exceed-

ed normal operating speed.

Overspeed (50Hz) Threshold: This threshold

is used to set the overspeed value neces-

sary 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).

Overspeed (60Hz) Threshold: This threshold

is used to set the overspeed value neces-

sary 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).

Engine Protection Speed/Frequency Menu

This menu is used to determine when a speed/fre-

quency conflict shutdown fault condition exists and

for how long the fault condition should be present

before the engine is shut down.

Speed/Freq Fault Threshold: This threshold

is used to set the value necessary to acti-

vate the speed/frequency conflict shutdown

fault condition. This value can be set from

0.1 to 20.0 Hz (default = 2.0 Hz).

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.

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).

LOP Warning Time Delay: A time delay of 2

to 15 seconds (default = 8 seconds) must

expire before the warning message is an-

nounced because of a low oil pressure warn-

ing fault condition. If the fault condition is ac-

tive for the duration of this time delay, the

Pre-Low Oil Pressure warning message

(Fault Code 143) is announced.

5-50

ENGINE PROTECTION SUBMENUS

CONTINUED ON

PAGE 5-52

NOTE: These menus are available only

if the the ECM CAN feature is

disabled.

FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3)

5-51

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 be-

fore 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 be-

cause 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.

High Coolant Temperature Warning Menu

This menu is used to determine when a high cool-

ant 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

set from 150 to 290 degrees F (default = 215

degrees F).

HCT Warning Time Delay: A time delay of 2

to 10 seconds (default = 2 seconds) must

expire before the warning message is an-

nounced. 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 cool-

ant temperature shutdown fault condition exists

and for how long the fault condition should be pres-

ent 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).

HCT Shutdown Time Delay: A time delay of

2 to 10 seconds (default = 2 seconds) must

expire before the engine shuts down be-

cause 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 Tempera-

ture shutdown message (Fault Code 151) is

announced.

5-52

ENGINE PROTECTION SUBMENUS (Continued)

RETURN TO PAGE 5-50

CONTINUED ON

PAGE 5-54

NOTE: These menus are available only

if the the ECM CAN feature is

disabled.

FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 2 OF 3)

5-53

Engine Protection Low Coolant Temperature

and Battery Charger Menus

The low coolant temperature menu is used to de-

termine 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.

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).

The battery charger menu is used to determine

when the alternator charger failure condition exists

and when the warning message should be an-

nounced. The fault condition exists when either the

low or high threshold is reached.

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 (de-

fault = 32.0 VDC) for 24V units.

Charger Failed L Threshold: This threshold

is used to set the low charging alternator

voltage value. This value can be set from 2.0

to 13.0 VDC (default = 5.0 VDC) for 12V

units and from 2.0 to 25.0 VDC (default =

10.0 VDC) for 24V units.

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.

5-54

ENGINE PROTECTION SUBMENUS (Continued)

RETURN TO PAGE 5-52

NOTE: These menus are available only

if the the ECM CAN feature is

disabled.

FIGURE 5-22. ENGINE PROTECTION SUBMENUS (SHEET 3 OF 3)

6-1

6. Troubleshooting

INTRODUCTION

The 1302 series control continuously monitors en-

gine 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 intermit-

tent 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 re-

lated 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 trouble-

shooting 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 en-

abled 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 ap-

propriately set for the application. It may be neces-

sary 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.

CAUTION 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.

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 symp-

toms related to a feature.

NETWORK APPLICATIONS AND

CONFIGURABLE INPUTS

In applications with networks and remote configur-

able 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 in-

puts before troubleshooting the control.

SAFETY CONSIDERATIONS

WARNING Contacting high voltage compo-

nents can cause electrocution, resulting in se-

vere personal injury or death. Keep the output

box covers in place during troubleshooting.

WARNING Ignition of explosive battery gases

can cause severe personal injury or death. Arc-

ing at battery terminals, light switch or other

equipment, flame, pilot lights and sparks can

ignite battery gas. Do not smoke, or switch

trouble light ON or OFF near battery. Discharge

static electricity from body before touching

batteries by first touching a grounded metal

surface.

Ventilate battery area before working on or

near battery—Wear goggles—Stop genset and

disconnect charger before disconnecting bat-

tery 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 genera-

tor set can cause severe personal injury or

death. Prevent accidental starting by discon-

necting 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:

6-2

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 con-

trol into the Off mode.

3. Turn off or remove AC power from the battery

charger.

4. Remove the negative (−) battery cable from

the generator set starting battery.

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 dis-

play. 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.)

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 posi-

tion before interpreting the fault code. Moving

the switch to OFF will clear the fault indication.

Constant Rate Flashing = Engine preheat

/genset starting.

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.

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, fol-

lowed 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 evalu-

ate 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 fol-

lowing tables. In some cases, it is necessary to re-

move a plug to complete the test. Where required,

the corrective action will mention when it is neces-

sary 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 per-

formed by inserting a narrow meter probe into the

back of the plug.

6-3

TABLE 6-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM FAE Engines HM Engines

No power supplied to the

control due to poor bat-

tery cable connections.

Clean the battery cable

terminals and tighten all

connections.

1. Check wakeup conditions.

2. Check for poor battery cable connec-

tions. Clean the battery cable termi-

nals 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 re-

connecting P20 and retry operation.

1. Check wakeup conditions.

2. Check for poor battery cable connec-

tions. Clean the battery cable termi-

nals and tighten all connections.

3. Remove connector P20 and check for

B+ at P20 and P20-10 and GND at

P20-2. If B+ or ground missing, iso-

late 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.

1302 series control

with display: No power

supplied to front mem-

brane panel.

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, re-

move 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, re-

pair the harness.

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, re-

move 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, re-

pair the harness.

Base board not properly

calibrated or corrupt cal-

ibration.

Confirm that the installed calibration part

number matches the serial plate informa-

tion. Re-enter the calibration file if neces-

sary.

Confirm that the installed calibration part

number matches the serial plate informa-

tion. Re-enter the calibration file if neces-

sary.

The Remote Emergency

Stop switch or wiring is

defective.

With Emergency Stop push button not ac-

tivated (switch closed), remove configur-

able leads from TB1-15 and TB1-16 and

check for continuity between these two

leads. If circuit is open, isolate to Emer-

gency Stop switch and wiring. If there is

continuity, go to the next step.

With Emergency Stop push button not ac-

tivated (switch closed), remove configur-

able leads from TB1-15 and TB1-16 and

check for continuity between these two

leads. If circuit is open, isolate to Emer-

gency Stop switch and wiring. If there is

continuity, go to the next step.

6-4

TABLE 6-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE Engines

The Local Emergency

Stop switch or wiring is

defective.

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.

1302 series control

with display: The menu

display Manual Run but-

ton, harness, or the Base

board is defective.

With the Emergency Stop push button not

activated (switch closed), check for conti-

nuity between J25-2 and J25-6. If the cir-

cuit is open, isolate to the Emergency

Stop switch and wiring. If there is continu-

ity, go to the next step.

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 re-

placed.

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 re-

placed.

With the Emergency Stop push button not

activated (switch closed), check for conti-

nuity between J25-2 and J25-6. If the cir-

cuit is open, isolate to the Emergency

Stop switch and wiring. If there is continu-

ity, go to the next step.

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 re-

placed.

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 re-

placed.

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, set-

up 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.

6-5

TABLE 6-2. ENGINE DOES NOT CRANK IN REMOTE MODE (NO FAULT MESSAGE)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

The remote start switch or confi-

gurable wiring is defective.

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, indict-

ing that S12, the Base board, or

the harness is defective.

1. Remove connector P11 from the Base board.

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.

1302 series control with dis-

play: 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. If there is no continuity when pressing the menu display Auto button, iso-

late to the front membrane panel or the wiring harness. If there is continu-

ity, the Base board is defective and must be replaced.

For more information, see Table 6-1, Will Not Crank in Manual Mode.

6-6

TABLE 6-2. WARNING AND SHUTDOWN CODES

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

FAULT CODE CORRECTIVE ACTION

ENGINE PLATFORM 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 sen-

sor 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 pro-

grammed 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 tempera-

ture 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.

6-7

TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

FAULT CODE CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE 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 con-

troller).

Allow the engine to cool down completely

before proceeding with the following

checks:

1. Consult the engine service manual

and reset the PCC1302.

2. Restart the generator after locating

and correcting the problem.

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. Check the coolant level and replenish

if low. Look for possible coolant leak-

age points and repair if necessary.

2. Check for obstructions to the cooling

airflow and correct as necessary.

3. Check the fan belt and repair or tight-

en if necessary.

4. Check the blower fan and circulation

pumps on remote radiator installa-

tions.

5. Reset the control and restart the gen-

erator 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 gen-

set.

4. If an oil switch is used, check switch

performance.

234

OVERSPEED

Lamp: Shutdown

Indicates the engine has exceeded nor-

mal operating speed. The default thresh-

olds 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.

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.

6-8

TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

FAULT CODE CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE Engines

359

FAIL TO START

Lamp: Shutdown

Indicates a possible fuel system or air in-

duction problem. (Engine cranks but fails

to start)

Consult the engine service manual for

possible causes / solutions.

Indicates a possible fuel system or air in-

duction problem. (Engine cranks but fails

to start)

1. Check for an empty fuel tank, fuel

leaks, or plugged fuel lines and cor-

rect as required.

2. Check for a dirty fuel filter and re-

place 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 bat-

tery 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 appli-

cable (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 shut-

downs, therefore allowing genset operation during emergencies.

1311, 1312, 1317, 1318

CONFIGURABLE INPUT

1, 2, 3, 4

Lamp: Configurable

The nature of the fault is an optional configurable selection. Example inputs: Low Fuel

Day Tank, Water In Fuel, Ground Fault, etc.

Each of the fault functions can be programmed (using a service tool or the operator

panel), as follows:

Event or Warning or Shutdown level if Function Select = Fault Input

Change the display name using up to 32 characters.

6-9

TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

FAULT CODE CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE 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 shut-

downs, 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 en-

gine coolant temperature

is 70_F (21_C) or lower.

NOTE: In applications

where the ambient tem-

perature falls below

40_F (4_C), Low Cool-

ant Temp may be indi-

cated even though the

coolant heaters are op-

erating.

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.

Check for an open heater element. Check the heater’s current draw.

The coolant temperature must be below 70_F (default setting) for one minute to acti-

vate a warning and must be above 70_F for one minute before the warning is cleared.

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 diag-

nostic. See Fault Code 427 or 781 for

datalink health diagnostic.

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.

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.

6-10

TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

FAULT CODE CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE 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 approxi-

mately 10 seconds.

Check the fuel supply, intake air supply, and load.

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. Indicates that the measured speed and

the measured AC output frequency do not

agree.

Check the genset setup for number of fly-

wheel 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.

Check the load and load lead connections.

1853, 1854, 1855

ANNUNCIATOR

FAULT 1, 2, 3

Lamp: Configurable

The nature of the annunciator fault is an optional configurable selection.

1944

ANNUNCIATOR OUT-

PUT 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 FRE-

QUENCY CONFLICT

Lamp: Shutdown

Indicates the alternator line frequency and alternator excitation frequency do not

match.

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 fre-

quency and alternator excitation frequency are also viewable with InPower.

3. Check voltage sense leads and excitator power lead for open or shorts.

6-11

TABLE 6-2. WARNING AND SHUTDOWN CODES (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

FAULT CODE CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE Engines

2677

FAIL TO STOP

Lamp: Shutdown

Genset continues to run after receiving

shutdown command from the controller.

The keyswitch relay is the what the

PCC1302 uses to tell the engine control-

ler to stop. Check the keyswitch relay op-

eration 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.

Genset continues to run after receiving a

shutdown command from the controller.

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 manu-

al 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 sec-

onds.

6-12

TABLE 6-3. CODE 121 − SPEED SIGNAL LOST (SHUTDOWN) − GENSETS WITH MPU

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

Reason: This indicates that the control is not sensing the magnetic pickup signal.

Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. There are loose or

damaged magnetic

pickup (MPU) wires/

connector pins.

Inspect the wires/connector pins and repair or replace as necessary.

2. The magnetic pickup,

harness or Base

board is defective.

To isolate the problem, reset the control and attempt to start the genset.

If Fault Code 1438 (Fail To Crank) is displayed, or if the engine starts, but then shuts

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 adjust-

ment 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 fre-

quency 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 Fig-

ure 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. Re-

place 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 sup-

ply. The engine may

fire once during

cranking which could

cause the engine to

speed up past the

starter disconnect

speed. Due to the re-

stricted fuel supply,

the engine will not

turn over anymore

and the 1302 control

panel will display

fault code 121 once

the engine stops

spinning.

In order to fix the problem, you need to make sure that there is an adequate fuel sup-

ply that is free of clogs or leaks.

6-13

TABLE 6-4. CODE 135/141 − OIL PRESSURE SENSOR OOR HIGH/LOW (WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM 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 nec-

essary.

The sensor could be de-

fective.

Consult the engine service manual. Disconnect the oil pressure sensor leads

and connect an oil pressure sensor simu-

lator 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

defective.

Consult the engine service manual. 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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.

6-14

TABLE 6-6. CODE 143/415 − LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM FAE Engines HM Engines

Fault simulation was en-

abled with a PC based

service tool.

With a PC based service tool, verify that the fault simulation is not enabled for the oil

pressure sensor.

If you do not have a PC based service tool, remove battery power from the control to

disable the fault simulation overrides.

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, re-

plenish.

The sensor or oil pump

could be defective. Or

the generator set may be

shutting down on another

fault.

Consult the engine service manual. Disconnect the oil pressure sensor leads

and connect an oil pressure sensor simu-

lator to the harness.

1. If the control responds to the simula-

tor, 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 accept-

able oil pressure, the problem

may not be in the oil or oil sens-

ing system. The genset may be

shutting down on another fault

(out of fuel, intermittent connec-

tor). Restart the genset and

monitor the display panel for oth-

er 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.

6-15

TABLE 6-6. CODE 143/415 − LOW OR PRE-LOW OIL PRESSURE (WARNING/SHUTDOWN) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE Engines

Harness or Base board

could be defective.

Consult the engine service manual. If the control does not respond to the sim-

ulator, 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 re-

placed.

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 incor-

rect.

Consult the engine service manual. Verify set points against the normal oper-

ating pressures of the engine. Refer to

the engine service manual.

TABLE 6-7. CODE 145/144 − COOLANT SENSOR OOR HIGH/LOW (WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM 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 nec-

essary.

6-16

TABLE 6-7. CODE 145/144 − COOLANT SENSOR OOR HIGH/LOW (WARNING) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE Engines

The sensor could be de-

fective.

Consult the engine service manual. Disconnect the sensor and plug in a resis-

tive sensor simulator to isolate the fault.

If the control responds to the simulator,

replace the sensor. If control does not re-

spond, go to the next step.

The harness or Base

board could be defective.

Consult the engine service manual. 1. Remove connector P11 from the

Base board and disconnect the sen-

sor. 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 re-

sistance 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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.

6-17

TABLE 6-9. CODE 146/151 − HIGH OR PRE-HIGH COOLANT TEMPERATURE

(WARNING/SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 CORRECTIVE ACTION

ENGINE PLATFORM FAE Engines HM Engines

Fault simulation was en-

abled with a PC based

service tool.

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

problem.

Refer to the engine service manual. Check sensor accuracy with a thermocou-

ple or similar temperature probe.

If the coolant temperature reading is

accurate, the engine may be over-

heating. Refer to the engine service

manual.

If the coolant temperature reading is

not accurate, go to the next step.

The sensor could be de-

fective.

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

board could be defective.

Not applicable. Measure the resistance of the coolant

sensor and reconnect the harness to the

sensor. Remove connector J11 from the

Base board and check resistance be-

tween pins P11-11 (H20) and P11-12

(H20 COM).

If resistance is not the same, the har-

ness is defective and must be re-

placed.

If resistance is the same, the Base

board is defective and must be re-

placed.

6-18

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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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, or Warning

POSSIBLE CAUSE CORRECTIVE ACTION

Consult the engine

service manual.

Consult the engine service manual.

TABLE 6-11. CODE 234 − OVERSPEED (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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.

If you do not have PC based service tool, remove battery power from the control to

disable fault simulation overrides.

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.

Monitor the engine RPM

using a PC based service

tool.

If the RPM is not correct, refer to Fault Code 121 for corrective action.

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 require-

ments and Figure 5-19, sheet 1 for information on how to adjust the flywheel tooth

setting using the operator panel.

The mechanical fuel sys-

tem setup is incorrect.

Verify that the fuel stop settings are correct for your application.

6-19

TABLE 6-12. CODE 359 − FAIL TO START (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 be-

cause:

1. The fuel level is be-

low the pickup tube

in the tank.

2. There is a closed

shutoff valve in the

supply line.

3. The fuel injectors are

clogged.

4. There is air in the

fuel system.

1. Add fuel if low. Prime the fuel system.

2. Open any closed shutoff valve in the fuel line supplying the engine.

3. Refer to the engine service manual.

4. Bleed air from fuel system. Refer to the engine service manual.

Glow plugs are not heat-

ing because:

1. The glow plug(s) is

defective.

2. The Base board is

defective.

3. The glow plug relay

is defective.

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 sec-

onds) is linear between −5_F and 77_F.

With the coolant temperature colder than 77_F (25_C):

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 re-

placed.

If B+ / GND is present, go to step 3.

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 con-

tact and the glow plugs.

6-20

TABLE 6-12. CODE 359 − FAIL TO START (SHUTDOWN) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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

The fuel solenoid on the

injection pump is not en-

ergized because:

1. The fuse is open.

2. The fuel solenoid is

defective.

3. The Base board/K8

fuel relay is defec-

tive.

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. 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. 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.

6-21

TABLE 6-12. CODE 359 − FAIL TO START (SHUTDOWN) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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

The injection pump ac-

tuator is not energized

due to the harness, gov-

ernor actuator, governor

module, or the Base

board is defective.

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 defec-

tive 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 con-

figuration.

2. Remove connector P11 from the control and check wiring continuity of the actua-

tor 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 re-

placed. 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 wir-

ing 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

worn or malfunctioning or

it has lost prime (fuel lift

pump, injection pump, in-

jectors, timing).

Service according to the engine service manual.

The engine is worn or is

malfunctioning mechani-

cally.

Service according to the engine service manual.

6-22

TABLE 6-13. CODE 427/781 − CAN DATALINK LOST (WARNING/SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

The networking harness

is defective.

1. Check the datalink between the ECM and the GCS. Check for open or shorts be-

tween 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

Weak or discharged bat-

tery.

Recharge or replace the battery. Specific gravity for a fully charged battery is approxi-

mately 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-

ing voltage.

Adjust the charge rate of the AC powered battery charging circuit, according to

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.

6-23

TABLE 6-14. CODE 441 − LOW BATTERY (WARNING) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

If the batteries are OK,

the problem may be with

the harness or the Base

board.

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 defec-

tive 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

Reason: High voltage has been detected for the battery.

Effect: Control damage will occur.

POSSIBLE CAUSE CORRECTIVE ACTION

Excessive battery charg-

ing 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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.

6-24

TABLE 6-17. CODE 1426 − GENERIC ENGINE FAULT (WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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

broadcasted a fault that

the PCC1302 control

doesn’t recognize.

Use an engine service tool (Insite or InPower) to view the active fault messages being

sent by the engine controller. Consult the engine service manual for a Fault Code

mapping and a procedure to cure the problem.

TABLE 6-18. CODE 1443 − DEAD BATTERY

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

Reason: Indicates during cranking battery voltage has dropped below operating voltage of control resetting the con-

trol for three consecutive times.

Effect: Shutdown.

POSSIBLE CAUSE CORRECTIVE ACTION

Weak or discharged bat-

tery.

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-

ing voltage.

Ensure external battery charger is charging the battery at an acceptable rate. Adjust

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 alter-

nator.

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 mea-

sure 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.

6-25

TABLE 6-19. CODE 1435 − LOW COOLANT TEMPERATURE (WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM 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.

If you do not have a based service tool, remove battery power from the control to dis-

able the fault simulation overrides.

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 heat-

er could be defective.

(Radiant heat should be

felt when your hand is

held close to the outlet

hose.)

The coolant heater is not operating because:

The coolant heater is not connected to power. Check for a blown fuse, or discon-

nected 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 min-

utes 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 neces-

sary.

The sensor could be de-

fective.

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 re-

spond, the harness or Base board are defective and must be replaced.

6-26

TABLE 6-19. CODE 1435 − LOW COOLANT TEMPERATURE (WARNING) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

ENGINE PLATFORM HM EnginesFAE Engines

The harness or Base

board could be defective.

Measure the resistance of the coolant temperature sensor and reconnect the harness

to the sensor. Remove connector P11 from the Base board and check resistance be-

tween 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

Reason: This indicates that the engine failed to crank after the control received a start signal.

Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

ENGINE PLATFORM FAE Engines HM Engines

1. The starter is defec-

tive.

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 (di-

rectly 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 start-

er 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 Emergen-

cy 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 cir-

cuit is open, isolate to the Emergency Stop switch and wiring. With the Local Emer-

gency 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 defec-

tive.

Refer to the engine service manual. Refer to the Fault Code 121 instructions.

6-27

TABLE 6-21. CODE 1442 − WEAK BATTERY (WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 en-

abled with a PC based

service tool.

With a PC based service tool, verify that the related fault simulation is not enabled.

If you do not have a PC based service tool, remove battery power from the control to

disable the fault simulation overrides.

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 gen-

erator is defective.

Refer to the Generator/Base Board Isolation Procedure in the Service Manual to de-

termine if the Base board is causing the high AC voltage shutdown fault.

The voltage sense con-

nections/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.

TABLE 6-23. CODE 3539, 3541,3542, 5669 − ENGINE FAULTS ANNOUNCED BY PCC1302

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

Consult Engine Service

Manual.

Consult Engine Service Manual.

6-28

TABLE 6-24. CODE 1447 − LOW AC VOLTAGE (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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.

If you do not have a PC based service tool, remove battery power from the control to

disable fault simulation overrides.

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 termi-

nals.

Reconnect according to the appropriate reconnection diagram.

The voltage sense or set-

up wiring connection

could be incorrect.

Verify that excitation inputs P18-1 and P18-2 are connected to the correct generator

outputs.

The rotating rectifier as-

sembly (diodes CR1

through CR6) is faulty.

Check each diode. See the genset service manual

There is a loose connec-

tor or the Base board is

defective.

Repair connections (P18) or replace the Base board if necessary.

The voltage sense con-

nections/setup could be

incorrect.

See Section 7 for proper connections.

TABLE 6-25. CODE 1448 − UNDER FREQUENCY (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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

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 de-

livery problem

Refer to the engine service manual.

6-29

TABLE 6-25. CODE 1448 − UNDER FREQUENCY (SHUTDOWN) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 connec-

tor 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)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 de-

livery problem.

Refer to the engine service manual.

There us a loose connec-

tor or the Base board is

defective.

Repair connections (P22/P18) or replace the Base board if necessary.

TABLE 6-27. CODE 1471/1472 − HIGH AC CURRENT (SHUTDOWN/WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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. Short or Overload Check the load and load cables. Repair if necessary. Check operation by disconnect-

ing 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.

6-30

TABLE 6-27. CODE 1471/1472 − HIGH AC CURRENT (SHUTDOWN/WARNING) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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

the Base board or

harness connections.

Remove connector P12 from the Base board. Check continuity from P12 to the CTs.

P12-1 (CT1) to P12-4 (CT1-COM)

P12-2 (CT2) to P12-5 (CT2-COM)

P12-3 (CT3) to P12-6 (CT3-COM)

Repair connections.

2. There may be an in-

correct rating setup.

Check the rating setup in the control. Correct if necessary.

TABLE 6-28. CODE 1689 − CLOCK NOT SET

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 ser-

vice tool.

If exercise scheduler function is required, set and save the real time clock.

RTC not set after enab-

ling exercise function.

Set and save the real time clock.

TABLE 6-29. CODE 1944 − ANNUNCIATOR OUTPUT CONFIGURATION ERROR (WARNING)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

Reason: Indicates that more then one network device is configured to activate one of the Annunciator output relays.

Effect: Warning

POSSIBLE CAUSE CORRECTIVE ACTION

Network configuration is

incorrect.

Check setup of the devices on the network against duplicate use of the same Annun-

ciator relay output.

There is a defective de-

vice on the network.

Troubleshoot the network for malfunctioning devices.

6-31

TABLE 6-30. CODE 2118 − LOW FUEL PRESSURE

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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.

If refill is required, stop the genset, and refill.

Fuel Pressure switch is

faulty.

Refer engine manual for pressure switch check. Replace if faulty.

TABLE 6-31. CODE 2335 − LOSS OF AC SENSE (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

1. There may be prob-

lems 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)

6-32

TABLE 6-31. CODE 2335 − LOSS OF AC SENSE (SHUTDOWN) (CONT.)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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 CORRECTIVE ACTION

3. The excitation coil

isn’t charged.

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 sup-

ply.

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-

up.

Verify that the genset is capable of reaching rated speed by manually running the

genset. Some potential problems could be: clogged fuel filter, incorrect fuel stop posi-

tion, 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.

6-33

TABLE 6-32. CODE 2545 − KEYSWITCH RESET REQUIRED (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 be-

tween 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.

Using InPower, increase the keyswitch reset time delay to the highest possible value.

Reset the fault.

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.

Use InPower to increase this number to the highest possible setting.

TABLE 6-33. CODE 2972 − OVER EXCITATION (SHUTDOWN)

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 / har-

ness 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.

6-34

TABLE 6-34. CODE 5134 − UNKNOWN SHUTDOWN AT IDLE

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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

rated conditions and

shutdown because of un-

known reasons.

Check engine service manual.

TABLE 6-35. CODE 5186 − GENERATOR SET FAILED TO CLOSE

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

Reason: Transfer switch has failed to close on generator side.

Effect: Shutdown.

POSSIBLE CAUSE CORRECTIVE ACTION

Mechanical failure of

transfer switch.

Check the transfer switch manual.

Transfer switch transi-

tioned to genset side, but

feedback is lost.

Check for loose connection of the feedback wire connected to TB1−14 from auxiliary

contact of transfer switch. Tighten the same.

Faulty auxiliary contact. Check and replace the auxiliary contact of transfer switch.

TABLE 6-36. CODE 5187 − UTILITY FAILED TO CLOSE

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions pages and observe all instructions and precautions in this manual.

WARNING

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 transi-

tioned 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.

6-35

TABLE 6-37. CODE 5365 − ON SECONDARY SOURCE

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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.

If refill is required, stop the genset, and refill.

Fuel Pressure switch is

faulty.

Refer engine manual for pressure switch check. Replace if faulty.

TABLE 6-38. CODE 5188 − TRANSFER SWITCH UNKNOWN POSITION

Hazards present in troubleshooting can cause equipment damage, severe person-

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

tricity, and machinery hazards should perform service procedures. Read Important Safety In-

structions 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

transfer switch. Feed-

back indicating as, it is

neither at utility side nor

at genset side OR feed-

back is indicating it is at

genset as well as at utility

side at the same time.

Check the transfer switch manual.

Transfer switch is either

at genset side or utility

side, but respective feed-

back is lost or both side

feedbacks are available.

Check for loose connection of the feedback wire connected to TB1−12 from auxiliary

contact of transfer switch. Tighten the same.

Faulty auxiliary contact. Check and replace the auxiliary contact of transfer switch.

6-36

THIS PAGE LEFT INTENTIONALLY BLANK

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 de-

scribed 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 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop 3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12/24V Battery 3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Starting 3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cycle Cranking 3-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spark Ignition Power/Glow Plug Control 3-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Control 3-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Preheat Processing 3-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total Glow Processing: 3-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow Plug Output Logic: 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Start and Stop Time Delays (Cool Down) 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor 3-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Speed Sensing 3-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Speed Governor Algorithm and Adjustment 3-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

real time clock 3-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

exercise scheduler 3-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

The following are the set of rules for exercise scheduler 3-53 . . . . . . . . . . . . . . . . .

ATS Control 3-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual Fuel 3-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Mode Option 3-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations With an Operator Panel 3-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations Without an Operator Panel 3-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battle Short Mode 3-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with an Operator Panel 3-57 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations without an Operator Panel 3-58 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. Operator Panel Operation 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Status Output Indicator 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating Modes 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Mode 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Manual Run Mode 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auto Mode 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop Mode 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sleep Mode 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with an Operator Panel 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installations with a Manual Run/Off/Auto Switch 4-3 . . . . . . . . . . . . . . . . . . . . . . . .

Operator Panel 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graphical Display 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Text / Symbolic Versions 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Menu Selection Buttons 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Previous Main Menu Button 4-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Off Button 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Not In Auto Indicator 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Shutdown Indicator 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Warning Indicator 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start Indicator 4-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Entering the Mode Change Access Code 4-21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Selecting Auto Mode 4-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Setup Menus 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Service Menus 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing Only 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Menu Navigation 5-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Viewing and Adjusting 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 Governor Menu, Part 1 5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electronic Governor Menu, Part 2 5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Number Menu 5-13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Display Setup Menu 5-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volts and Hertz Menu 5-15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Voltage Regulator Submenus 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Volts/Hz Rolloff Menu 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulator Gains Menu 5-17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Setup Password Submenu 5-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjusting Values/Parameters 5-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menus 5-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu 1 5-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Menu 2 5-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Application Rating Select Menu 5-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Standby kVA Rating Menu 5-39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Prime kVA Rating Menu 5-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Select Menu 5-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Thresholds Menu 5-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Delay Setup Menu 5-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Setup Menus 5-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Protection Submenus 5-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High AC Voltage Menu 5-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low AC Voltage Menu 5-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Overfrequency Menu 5-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Underfrequency Menu 5-45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator Protection 5-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Current Protection Submenus 5-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High AC Current Menu 5-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Submenus 5-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Overspeed Menu 5-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Speed/Frequency Menu 5-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Warning Menu 5-49 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Oil Pressure Shutdown Menu 5-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Coolant Temperature Warning Menu 5-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Coolant Temperature Shutdown Menu 5-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Protection Low Coolant Temperature and Battery Charger Menus 5-53 . .

6. Troubleshooting 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PC Based Service Tool 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Network Applications and Configurable Inputs 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Considerations 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes Using Optional Operator Panel 6-2 . . . . . . . . . . . . . . . . . . . .

Reading Fault Codes Using the Control Switch Indicator 6-2 . . . . . . . . . . . . . . . . .

Troubleshooting Procedures 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage/Continuity Testing 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1

7. Wiring Diagrams

GENERAL

This section consists of the schematic and connec-

tion wiring diagrams referenced in the text. The fol-

lowing drawings are included.

SPage 7-3, 1302 Control Wiring Diagram

7-2

THIS PAGE INTENTIONALLY LEFT BLANK

7-3

No. 630-3270 Sh 1 of 4

Rev. − Sys: ProE

Modified

PCC1302 Baseboard

Alternator

Terminal Block

PMG

(optional)

L1 L2 L3 LN

Shunt Applications

PMG Applications

−

L−L 600 Volt Max

Field Winding

20 Amp

Configurable Input

#4, Fuel Level Switch

(Wake−up)

PCC 1302 OEM Genset

ECM Engine Connection

Use alternator center taps

or a transformer

if LL voltage > 240 VAC

J25 − Display

Battery

−+

Fused B+

B+ Return

Switches OEM

connected OR

Terminal blocks for

customer connections

FSO

Control

E−stop B+

Power

J20 − 14

Pilot Relay

Starter

Control

E−stop B+

Power

J20 − 15

Switched B+

(Run) Control

E−stop B+

Power

J20 − 3

J20 − 1

Chassis Ground

Battery

Charging

Alternator

(IC Regulator

Type/

Kubota)

Battery Charger

Alternator

Flash/ Failed

J20−22

Lamp

Failed

Output

Regulator

Power

Battery

Charging

Alternator

(Non−IC Regulator

Type/

Bosch)

Battery Charger

Alternator

Flash/ Failed

J20 − 22

Field

Flash

J20 − Genset

J20 − 9

J20 − 10

J20 − 20

J20 − 21

J20 − 2

J20 − 4

J20 − 7

J20 − 12

J18 − 1

J18 − 2

J18 − 3

10 Amp

J17 −2

J17 −1

J12 − 1

J12 − 4

J12 − 2

J12 − 5

J12 − 3

J12 − 6

J22 − 1

J22 − 2

J22 − 3

J22 − 4

J12 − Genset Current

J22 − Genset Voltage

CT s,

Switched

B+

J20 − 11

J20 −18

J20 − 6

Input

Return

Configurable Input

#3, Coolant Level

Switch

(Wake−up)

J20 −17

J20 − 5

Input

Return

Keyswitch

Control

J11 − 21

Pilot Relay

E−stop B+

Power

LS Out

J11 − Engine

J17 − AVR Control

J18 −AVR Power

Switched

B+

LS Out

Driver

Rating:

4 Amps

Peak: 6

Amps

Relay B+ internally

fused at 1.85A

B.C. Alt. Flash

internally fused at

1.5A

ECM

(PGI

Compliant)

Keyswitch

(FSO

optionally)

Some ECM s integrate

the FSO with the

Keyswitch operation.

Use a dedicated FSO if

application s ECM does

not provide FSO

operation.

J1939 (+)

J1939 (−)

J1939 (+)

J1939 (−)

J1939 (Shield)

120

Ohm

120 ohm terminated

Only terminate shield

on one end

J11 − 20

J11 − 19

J11 − 17

Use L1/L2/N

for 1 phase

applications

Don t connect

N in Delta

configuration

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

J11 Mate: 0323−2161

Sockets: 0323−2466

Part numbers

J25 Mate: 0323−2445

Sockets: 0323−2466

Part numbers

J20 Mate: 0323−2446

Sockets: 0323−2466

Part numbers

J22 Mate: 0323−2226−03

Part numbers

J12 Mate: 0323−1932

Sockets: 0323−1200

Part numbers

J17 Mate: 0323−2098

Sockets: 0323−1200

Part numbers

J18 Mate: 0323−2444

Sockets: 0323−1200

Part numbers

PCC 1302: 0327−1617−01

Fused B+

These signals

go to the

display but

don t go

through the

PCC controller.

Terminal

Block

J20

Harness

Remote E−stop

PB (B)

Basic

Customer

Fused B+

These signals

go to the

engine but

don t go

through the

PCC controller.

Terminal

Block

J20

Harness

Fused B+

These signals

go to the

genset but

don t go

through the

PCC controller.

Terminal

Block

J11, J25

Harness

Basic

Customer

E−stop B+ Power

Fused B+

Local

E−stop

Input (Wake−up on open)

Return

J25 − 2

J25 − 6

Remote E−stop PB (B)

Fused B+

HMI2xx

or HMI3xx

Display

HMI Fuse B+

B+ Return

PCC Net A (+)

PCC Net B (−)

Run (Wake−up)

Auto

(Configurable Wake−up)

System Wake−up

J25−10

J25−11

J25−4

J25−3

J25−5

J25−12

J25−8

Use Shielded Twisted Pair for PCC Net

Only terminate shield on one end

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

J29 − 1

J29 − 2

J29 − 3

J28 − 1

J28 − 2

HMI 114

Bargraph

HMI Fuse B+

B+ Return

PCC Net A(+)

PCC Net B (−)

System Wake−up

J25−4

J25−3

J25−5

J25−12

J25−8

Part numbers

HMI 114:

0300−????

J1 & J6 Mate:

0323−2011

Sockets: 0323−2466

J1 − 3

J1 − 4

J1 − 5

J6 − 1

J6 − 2

Locate near

mounting screw

chassis.

HMI211

Display

HMI Fuse B+

B+ Return

PCC Net A (+)

PCC Net B (−)

Manual (Wake−up)

Auto (Configurable Wake−up)

J1 −6

J1 −7

System Wake−up

J1 − 1

J1 − 2

J1 − 4

J1 − 3

J1 − 5

J25−10

J25−11

J25−4

J25−3

J25−5

J25−12

J25−8

Part numbers

HMI211:

0300−6014

Local

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM

(SHEET 1 OF 4)

7-4

No. 630-3270 Sh 2 of 4

Rev. − Sys: ProE

Modified

Local

E−stop

PCC1302 Baseboard

Alternator

Terminal Block

PMG

(optional)

L1 L2 L3 LN

Shunt Applications

PMG Applications

−

L−L600 Volt Max

Field Winding

AUX 104

GOVERNOR POWER STAGE

Active Oil

Pressure Sender

Use Shielded Twisted Pair for Mag PU

20 Amp

Configurable Input

#4, Fuel Level Switch

(Wake−up)

PCC 1302 OEM Genset

Hydro−mechanical Engine

Connection

Use alternator center taps

or a transformer

if LL voltage > 240 VAC

J25 − Display

Input (Wake−up on open)

Return

J25 −2

J25 −6

Remote E−stop PB (B)

Battery

−+

Fused B+

B+ Return

Switches OEM

connected OR

Terminal blocks for

customer connections

FSO

Control

E−stop B+

Power

J20 − 14

Pilot Relay

Starter

Control

E−stop B+

Power

J20 − 15

Switched B+

(Run) Control

E−stop B+

Power

J20 − 3

J20 − 1

Chassis Ground

Battery

Charging

Alternator

(IC Regulator

Type/

Kubota)

Battery Charger

Alternator

Flash/ Failed

J20−22

Lamp

Failed

Output

Regulator

Power

Battery

Charging

Alternator

(Non−IC Regulator

Type/

Bosch)

Battery Charger

Alternator

Flash/ Failed

J20 − 22

Field

Flash

J20 − Genset

J20 − 9

J20 − 10

J20 − 20

J20 − 21

J20 − 2

J20 − 4

J20 − 7

J20 − 12

J18 − 1

J18 − 2

J18 − 3

10 Amp

J17 −2

J17 −1

J12 − 1

J12 − 4

J12 − 2

J12 − 5

J12 − 3

J12 − 6

J22 − 1

J22 − 2

J22 − 3

J22 − 4

J12 − Genset Current

J22 − Genset Voltage

CT s,

Switched

B+

J20 − 11

J20 −18

J20 − 6

Input

Return

Configurable Input

#3, Coolant Level

Switch

(Wake−up)

J20 −17

J20 − 5

Input

Return

J11 − 1

+5V

J11 −3

Sense

J11 −2

Return

Passive Oil

Pressure Sender

J11 −3

Sense

J11 −2

Return

Coolant

Temperature

Sensor

(Onan Type)

J11 −11

Sense

J11 −12

Return

Glow Plug

Control

J11 − 7

Pilot Relay

Ignition

Module

Control

J11 − 7

J11 − 6

Relay B+

LS Out

J11 − 9

J11 − 10

−

J11 − 8

Shield

Mag

Pick−up

J11 − Engine

J11 − 4

J11 − 5

Governor PWM +

Governor PWM −

3rd Party

Fuel Actuator

Module

(20mA Max)

J11 − 4

J11 −5Governor PWM +

Governor PWM −

J1 − 2

J1 − 1 J1 −4Act. LS Driver

Fuel

Actuator

(6 Amps Max)

J1 −3

J1 −5

Gov PS Power

J1−Gov PS

J17 − AVR Control

J18 −AVR Power

Switched

B+

LS Out

Driver

Rating:

4 Amps

Peak: 6

Amps

Relay B+ internally

fused at 1.85A

Low Oil Pressure

Switch

J11 − 3

J11 − 2

Input

Return

Relay B+ internally

fused at 1.85A

B.C. Alt. Flash

internally fused at

1.5A

Use L1/L2/N

for 1 phase

applications

Don tconnect

N in Delta

configuration

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

J11 Mate: 0323−2161

Sockets: 0323−2466

Part numbers

J20 Mate: 0323−2446

Sockets: 0323−2466

Part numbers

J12 Mate: 0323−1932

Sockets: 0323−1200

Part numbers

J22 Mate: 0323−2226−03

Part numbers

J17 Mate: 0323−2098

Sockets: 0323−1200

Part numbers

J18 Mate: 0323−2444

Sockets: 0323−1200

Part numbers

PCC 1302: 0327−1617−01

Part numbers

Aux 104: 0327−1507

J1 Mate: 0323−2216 : Sockets: 0323−1200

Fused B+

These signals

go to the

display but

don tgo

through the

PCC controller.

Terminal

Block

J20

Harness

Remote E−stop

PB (B)

Basic

Customer

Fused B+

These signals

go to the

engine but

don t go

through the

PCC controller.

Terminal

Block

J20

Harness

B+ Return J20

Harness

Fused B+

B+ Return

Gov PS Power

Fused B+

These signals

go to the

genset but

don t go

through the

PCC controller.

Terminal

Block

J11

Harness

B+ Return

J11, J25

Harness

Basic

Customer

E−stop B+ Power

HMI2xx

or HMI3xx

Display

HMI Fuse B+

B+ Return

PCC Net A (+)

PCC Net B (−)

Run (Wake−up)

Auto

(Configurable Wake−up)

System Wake−up

J25−10

J25−11

J25−4

J25−3

J25−5

J25−12

J25−8

Use Shielded Twisted Pair for PCC Net

Only terminate shield on one end

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

J29 −1

J29 −2

J29 −3

J28 −1

J28 −2

HMI 112

Bargraph

HMI Fuse B+

B+ Return

PCC Net A (+)

PCC Net B (−)

System Wake−up

J25−4

J25−3

J25−5

J25−12

J25−8

Part numbers

HMI 112:

0300−6050−02

J1 & J6 Mate:

0323−2011

Sockets: 0323−2466

J1 − 3

J1 − 4

J1 − 5

J6 − 1

J6 − 2

Locate near

mounting screw

chassis.

HMI211

Display

HMI Fuse B+

B+ Return

PCC Net A (+)

PCC Net B (−)

Manual (Wake−up)

Auto (Configurable Wake−up)

J1 − 6

J1 − 7

System Wake−up

J1 − 1

J1 − 2

J1 − 4

J1 − 3

J1 − 5

J25−10

J25−11

J25−4

J25−3

J25−5

J25−12

J25−8

Part numbers

HMI211:

0300−6014

Local

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 2 OF 4)

7-5

No. 630-3270 Sh 3 of 4

Rev. − Sys: ProE

Modified

PCC1302

Baseboard

Battery

Charger

Customer Fused B+

B+ Return

Customer Fused B+

B+ Return

PCC Net A (+)

PCC Net B (−)

System Wake−up

PCC Net A (+)

PCC Net B (−)

System Wake−up

PCC 1302 Customer Connections:

PCC Net Devices

TB1 −1

TB1 −2

TB15 −5

TB1 −5

TB1 −3

TB1 −1

TB1 − 2

TB15 − 5

TB1 − 5

TB1 − 3

TB 1

HMI2xx

and

HMI3xx

Display

Customer Fused B+

B+ Return

PCC Net A (+)

PCC Net B (−)

System Wake−up

TB1 −1

TB1 −2

TB15 −5

TB1 −5

TB1 −3

Use Shielded Twisted Pair for PCC Net

Only terminate shield on one end, to

prevent ground loops

J1 −3

J1 −4

J1 −5

J14 − 1

J14 − 2

Discrete Input (Sense)

Return

Aux 101

Relay 1

Output

J2 − 1

J2 − 3

Relay NO

J2 − 2 Relay Com

Relay NC

Aux 101

Relay 2

Output

J2 − 4

J2 − 6

Relay NO

J2 − 5 Relay Com

Relay NC

Aux 101

Relay 3

Output

J2 − 7

J2 − 9

Relay NO

J2 − 8 Relay Com

Relay NC

Aux 101

Relay 4

Output

J2 − 10

J2 − 12

Relay NO

J2 − 11 Relay Com

Relay NC

Aux 101

Relay 5

Output

J3 − 1

J3 − 3

Relay NO

J3 − 2 Relay Com

Relay NC

Aux 101

Relay 6

Output

J3 − 4

J3 − 6

Relay NO

J3 − 5 Relay Com

Relay NC

Aux 101

Relay 7

Output

J4 − 1

J4 − 3

Relay NO

J4 − 2 Relay Com

Relay NC

Aux 101

Relay 8

Output

J4 − 4

J4 − 6

Relay NO

J4 − 5 Relay Com

Relay NC

J11 − 1

J11 − 2

AND/

J11 − 3

J11 − 4

Input #1 Input #2

+/−5V Analog

Input

Sense

Return

Oil

Temperature

RTD

Sensor

J11 − 5

Sense

J10 − 3

Current source

AND

/OR

J11 −7

J10 − 4

Input #3 Input #4

J11 −9

J10 − 5

Input #5

J11 −11

J10 − 6

Input #6

J10 − 9

Current return

J11 − 6

Sense return

J10 − 10

J11 − 8

J10 − 11

J11 − 10

J10 − 12

J11 − 12

Exhaust Stack

Temperature #1

RTD

Sensor

Sense

Current source

Current return

Sense return

Ambient

Temperature

RTD

Sensor

Sense

Current source

Current return

Sense return

Fuel Level

Sensor

RTD

Sensor

Sense

Current source

Current return

Sense return

Intake Manifold

Temperature

RTD

Sensor

Sense

Current source

Current return

Sense return

0−5VAnalog Input

Sense

Sense return

0−38V Analog

Input

J11 −13

Sense

J11 − 14

Return

AND

/OR

J11 − 15

J11 − 16

Input #7 Input #8

Gnd must be

wired in

Customer

Fused B+

Discrete Input (Sense)

Return

Gnd must be

wired in

Discrete Input (Sense)

Return

Gnd must be

wired in

Customer

Fused B+

Discrete Input (Sense)

Return

Gnd must be

wired in

Discrete Input (Sense)

Return

Gnd must be

wired in

Customer

Fused B+

Discrete Input (Sense)

Return

Gnd must be

wired in

Aux 102

Remote I/O

Aux 102

Relay 9

Output

J1 − 1

J3 − 1

Relay NO

J2 − 1 Relay Com

Relay NC

Aux 102

Relay 10

Output

J1 − 2

J3 − 2

Relay NO

J2 − 2 Relay Com

Relay NC

Aux 102

Relay 11

Output

J1 − 3

J3 − 3

Relay NO

J2 − 3 Relay Com

Relay NC

Aux 102

Relay 12

Output

J1 − 4

J3 − 4

Relay NO

J2 − 4 Relay Com

Relay NC

Aux 102

Relay 13

Output

J1 − 5

J3 − 5

Relay NO

J2 − 5 Relay Com

Relay NC

Aux 102

Relay 14

Output

J1 − 6

J3 − 6

Relay NO

J2 − 6 Relay Com

Relay NC

Aux 102

Relay 15

Output

J1 − 7

J3 − 7

Relay NO

J2 − 7 Relay Com

Relay NC

Aux 102

Relay 16

Output

J1 − 8

J3 − 8

Relay NO

J2 − 8 Relay Com

Relay NC

Chassis Ground

Mounting screw

Maximum

of 2 Aux

101 &

102’s can

be used

per

genset

J11

J10

TB1

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

PCC Net must use a daisy chain

topology only

HMI 113

Annunciator Customer Fused B+

B+ Return

PCC Net A (+)

PCC Net B (−)

TB1 −1

TB1 −2

TB1 −5

TB1 −3

HMI 112

Bargraph Customer Fused B+

B+ Return

PCC Net A (+)

PCC Net B (−)

System Wake−up

TB1 −1

TB1 −2

TB15 −5

TB1 −5

TB1 −3

J2−3

J2−4

TB1−16

TB1−15

J1−5

J1−3

J1−4

J6−1

J6−2

J4 −1

J4 − 2

Input

Return

Input #9

J4 −3

J4 − 4

Return

Input #10

Input

J4 −5

J4 − 6

Return

Input #11

Input

J4 −7

J4 − 8

Return

Input #12

Input

J10 − 7

J10 − 9

5VDC Supply #1

(20 mA max)

Return

J10 −8

J10 − 10

5VDC Supply #2

(20 mA max)

Return

J10

Part numbers

Aux 102:

0327−1265

Part numbers

w/o enclosure:

300−5929−01

w/ enclosure:

300−5929−02

Part numbers

HMI 112: 0300−6050−02

Aux 102

Relay Output

Ratings:

2 A,

30VDC,

250VAC

Aux 101

Relay Output

Ratings:

30VDC,

250VAC

NO: 5A

NC: 3A

AND

/OR

AND

/OR

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

Refer to the PCCNet Spec Sheet for

further details on PCCNet

HMI211

Customer Fused B+

B+ Return

PCC Net A (+)

PCC Net B (−)

System Wake−up

TB1 − 1

TB1 − 2

TB15 − 5

TB1 − 5

TB1 − 3

Remote Start TB1−10

J1 − 7

J1 − 4

J1 − 1

J1 − 2

J1 − 3

J1 − 5

Remote

Part numbers

HMI211:

0300−6014

J29 − 3

J29 − 1

J29 − 2

J28 − 1

J28 − 2

Aux 101

Remote I/O

Part numbers

Aux 101:

0327−1536

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM

(SHEET 3 OF 4)

7-6

No. 630-3270 Sh 4 of 4

Rev. − Sys: ProE

Modified

PCC 1302 Baseboard

CCS WD

PCC 1302 Customer Connections:

Relay Output

Ratings:

3.5 A,

30VDC,

250VAC

Customer

Output #1

TB1 − 6 Relay NO

TB1 − 7 Relay Com

See Application Notes

section for high level

E−stop circuit

TB1 −Basic

TB1 − 11

TB1 − 10

Input

Return

Remote

Start

(Wake−up)

TB1 − 12

TB1 − 13

Return

Customer

Input #1

Input

TB1 − 14

TB1 − 15

Return

Customer

Input #2

Input

TB1 − 5

TB1 −10

Customer fused

Battery Supply

(3A max)

Return

Customer

Output #2

TB1 −8Relay NO

TB1 −9Relay Com

Battery

+−

Remote

E−stop

(Remove jumper

if not used)

Input (Wake−up on open)

Return

TB1 − 16

TB1 − 15

E−stop B+ Power

Local E−stop PB (B)

PCC Net

Devices

(See Customer −

PCC Net page)

PCC Net A (+) −RS485

PCC Net B (−)−RS485

TB1 −1

TB1 −2

PCC Net B Shield

TB1 −3

TB1 − 4 Ready To

Load Output

Low Side Driver

Items in dashed lines

represent internal

PCC circuitry.

System Wake−up

TB15 − 5

TB15 − Modbus/PC Tool

Modbus

System Wakeup:

Ground if the PCC

control system is to

always stay awake.

(+)

(−)

RS485 (+)

RS485 (−)

Shield

120

Ohm

120 ohm terminated

Only terminate shield

on one end

TB15 − 3

TB15 − 4

TB15 − 1

PCC Net

Devices

(See Customer −

PCC Net page)

PC Tool Harness PC Tool

Part numbers

TB 15 Mate: 0323−2192−04

Part numbers

TB 8 Mate: 0323−2325−03

Part numbers

TB 1 Mate: 0323−2434

Part numbers

PC Tool Harness kit: 0541−1199

E−stop B+ Power

These signals

go to the

customer but

don t go

through the

PCC controller.

Terminal

Block

J20

Harness

Local E−stop PB

(B)

J25

Harness

0630−3270 WD−CONTROL

(WD−CONTROL 1302)

FRD24967

FIGURE 7-1. 1302 CONTROL WIRING DIAGRAM (SHEET 4 OF 4)

A-1

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 ac-

cess it.

The first illustration shows the basic Operator Me-

nus. The remaining two illustrations show the Ser-

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.

A-2

THREE

PHASE

ONLY

THREE

PHASE

WYE ONLY

CURRENT

SENSE

AMPERAGE

SINGLE

PHASE

ONLY

OPERATOR MENUS

TEXT VERSION

AUTO MODE

SELECTED

MANUAL

RUN MODE

SELECTED

A-3

YES NO

IF AVR IS

NOT

ENABLED

IF AVR IS

ENABLED

GO TO GENSET

SETUP AND

SERVICE MENUS

ON PAGE A-4

GENSET SERVICE MENUS

VIEWING ONLY VIEWING AND

ADJUSTING

*ONLY ONE OF THE FOUR

AVAILABLE INPUT MENUS

IS SHOWN.

A-4

GENSET SETUP AND SERVICE MENUS

12V 24V

SWITCH SENDER

GO TO GENSET

SERVICE MENUS

ON PAGE A-3

VIEWING ONLY

VIEWING AND

ADJUSTING

THESE MENUS ARE AVAILABLE ONLY

IF ECM CAN FEATURE IS DISABLED

B-1

Appendix B. Index

GENERAL INFORMATION

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

Auto Mode, 2-3, 4-2

Battery Selection, 3-37

Battle Short

Installations with Operator Panel, 3-40

Installations without Operator Panel, 3-41

Mode, 3-41

Battleshort Mode, 3-26

Control

Inputs, 2-5

Outputs, 2-5

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

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

Cycle Cranking, 3-37

Electronic Governor

Connections, 3-15

Module Connections, 3-15

Part Numbers, 3-15

Emergency Stop

Local, 3-37

Remote, 3-37

Emergency Stop Mode, 4-2

Engine Speed Sensing, 3-39

Engine Starting, Automatic, 3-37

Environment Information, 3-2

Equipment

Basic, 2-1

Optional, 2-2

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

B-2

GENERAL INFORMATION

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

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

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-3

Engine Protection, 2-6

Genset Protection, 2-6

Genset

Adjustments

Alternator Startup, 3-28

Gain Tuning, 3-28

Governor, 3-28

Voltage/Frequency, 3-27

Engine Startup, 3-28

GENERAL INFORMATION

Tuning, 3-27

Glow Plug, 3-38

Governor

Algorithm and Adjustment, 3-39

Electronic, 3-38

Harness

Coolant Temperature Sensor, 3-20

Engine, 3-19

Genset, 3-18

Oil Pressure Sensor, 3-20

Operator Panel, 3-17

Local Emergency Stop, 3-37

Local Status Output Indicator, 4-1

Manual Run Mode, 4-2

Module, Control, 2-3

Mounting Installation, 3-1

Off Mode, 2-3, 4-2

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

Operator Panel, 2-4

Connections, 2-4

Footprint, 3-17

General Information, 3-2

Harness, 3-17

Parade Rest Mode, 2-7

Remote Emergency Stop, 3-37

Remote Start, 3-37

Run Mode, 2-3

Run/Off/Auto Switch, 2-3

Running Mode, 2-7

Sensor

Coolant Temperature, 3-20

Oil Pressure, 3-20

Sensors

Coolant Temperature, 3-8

Lube Oil Pressure Switch, 3-9

Oil Pressure, 3-8

Setup, Trims, and Adjustments, 3-22

Sleep Mode, 2-7, 4-3

Spark Ignition, 3-38

Time Delay

Preheat, 4-2

Start, 3-38, 4-2

Stop, 3-38, 4-2

Wiring Diagram, 7-3

Wiring Information, 3-2

B-4

THIS PAGE INTENTIONALLY LEFT BLANK

“Intentionally Left Blank”

Cummins Power Generation

1400 73rd Ave. NE

Minneapolis, MN 55432 USA

Phone 1 763 574 5000

Toll-free 1 800 888 6626

Fax 1 763 574 5298

Email ask.powergen@cummins.com

www.cumminspower.com

CumminsR, the “C” logo, and “Our energy working for you.”

are trademarks of Cummins Inc.

900 0661_I10(AG) 0661 Onan Power Command PCC1302 Controller Owners Manual (06 2014)

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