It-manual--pcc 3100.pdf

Table of Contents SECTION

PAGE

TITLE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii 1

INTRODUCTION About this Manual Test Equipment How To Obtain Service System Overview Generator Set Control Function

2

3

4

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1-1 1-1 1-1 1-2 1-2

CONTROL OPERATION General Safety Considerations Sequence of Operation PCC Power On/Standby Mode Front Panel Menu Display and Switches Main Menu Engine Menu Gen Menu CIRCUIT BOARDS AND MODULES General Digital Board (A32) Engine Interface Board (A31) Analog Board (A33) Digital Display Board (A35) Customer lntertace'Board (A34) : PT/CT Board (A36) '. Bus PT Board (A39) Genset Communications Module (A41) Voltage Regulator Output Module (A37) Governor Output Module (A38) Master First .Start'Sensor

2-1

2-1 2-1 2-2 2-2 2-4 2-6 2-6 2-8 2-10

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3-1 3-3 3-4 3-6 3-7 3-8 3-10 3-11 3-12 3-13 3-14 3-15

TROUBLESHOOTING General Safety Considerations Status lndicators Resetting the Control Warning and Shutdown Codes PCC Oil Pressure Warning and Shutdown Limits Troubleshooting Procedure PCC Fuses Load Sharing Controls Troubleshooting Procedure

4-1 4-1 4-2 4-2 4-3 4-12 4-13 4-56 4-57

SECTION

TITLE

PAGE

5

CONTROL SERVICE AND CALIBRATION

6

General Circuit Board Removal/Replacement lnitial Start Setup Menu Adjust Menu Setup and Calibration Menus Calíbration Procedure Accessory Box Control Components Engine Sensors Magnetic Speed Pickup Unit (MPU) lnstallation Current Transformer (CT} lnstallation SERVICING THE GENERATOR

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·

Testing the Generator Generator/PCC Control lsolation Procedure lnsulation Resistance (Megger) & Polarization lndex (PI) Testing Drying the Windings Excitar Stator Exciter Rectifier Bridge (Rotating Rectifier Assembly} Excitar Rotor Main Rotor (Generator Field) Main Stator Test the PMG Bearing I nspection/Removal/Replacement Generator Disassembly Generator Reassembly Aligning Generator with Engine -

5-1 5-1 5-4 5-6 5-8 5-26 5-29 5-42 5-46 5-47 6-1 6-2 6-3 6-5 6-6 6-7 6-8 6-9 6-1 O 6-12 6-13 6-15 6-24 6-28

7

DAY TANK FUEL TRANSFER PUMP ANO CONTROL 7-2 7-4 7-6 7-7

8

Operation ·: Wiring Connections /. Fuel Transfer Pump Motor Connections Testing the Float Switch Assembly INITIAL SYSTEM STARTUP

8-1 8-1 8-2 8-2 8-4 8-7 8-8 8-8

9

General The Startup Procsss Equipment Appllcation Review Individual Generator Set Startup Manual System Operation Automatic System Operation Black Start Testing Test Reports and Acceptance On Site Power System Application Review (Diesel/600VAC and Lower) WIRING DIAGRAMS General

8-9 9-1

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IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries.

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

Before operatingthe generatorset (genset), read the Operator's Manual and become famíliar with it and the equipment. Safe and efficient operation can be achievedonly if the equipmentis properlyoperated and maintained. Many accidents are caused by failure to follow fundamental rules and precautíons.

• Be sure the unit is well ventilated.

The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.

• Engine exhaust and sorne of its constituents are known to the state of California to cause cancer, birth defects, and other reproductiva harm.

tt1•t4UtiJ=l;i This symbo/ warns of immediate hazardswhichwi/1resultin severe personalin­ jury or death.

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

lit.WARNING!

• Keep your hands, clothing, and jewelry away from moving parts.

, . ,.. IA CAUTION I

• Before starting work on the generator set, disconnect battery charger from its AC source, then disconnect starting batteries, negativa (-) cable first. This will prevent accidental starting.

This symbo/refers to a hazard or un­ safe practice which can result in severe per­ sonal injuryor death.

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This symbo/refers to a hazard or un­ sale practicewhich can resultin personalinjury or product or propertydamage.

• Make sure that fasteners on the generator set are secura. 1ighten supports and clamps, keep guards in position over fans, drive belts, etc.

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

• Do not wear loosg clothing or jewelry in the vicinity of moving parts, or while working on electrical equípment. Loose clothing and jewelry can become caught in moving parts.

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

;e lf adjustment must be made while the unit is run-

ning, use extreme caution around hot manifolds, moving parts, etc.

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

DO NOT OPERATE IN FLAMMABLE ANO EXPLOSIVE ENVIRONMENTS

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

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

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

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LS-15M

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

changar pressure cap while the engine is running. To prevent severe scalding, let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully untíl the pressure has been relieved.

• Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over f loors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear jewelry. Jewelry can short out electrical contacts and cause shock or burning. • Use extreme caution when working on electrical components. High voltages can cause injury or death. DO NOT tamper with interlocks. • Follow all applicable state and local electrical codes. Have all electrical installations performed by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. • DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.

MEDIUM VOLTAGE GENERATOR SETS (601 V to 15kV) • Medium voltage acts differently than low voltage. Special equipment and training is required to work on or around medium voltage equipment. Operation and maintenance must be done only by persons trained and qualified to work on such devices. lrnproper use or procedures will result in severe personal injury or death. • Do not work on energizad equipment. Unauthorized personnel must not be permitted near energized equipment. Due to the nature of medium voltage electrical equipment, induced voltage remains even after the equipment is oisconnectedtrom the power source. Plan the time for maintenance with authorized personnel so that the equipment can be de-energized and safely grounded. ·· 1

GENERAL SAFETY PRECAUTIO.NS •

Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat ex-

•

Used engine oils have been identified by sorne state or federal agencies as causing cancer or reproductiva toxicity. When checking or changing engine oíl, take care not to ingest, breathe the fumes, or contact used oil.

•

Keep rnulti-class ABC tire extinguishers handy . Class A tires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 1 O).

•

Make sure that rags are not left on or near the generator set.

•

Make sure generator set is mounted in a manner to prevent combustible materials from accumulating under ornear the unit.

•

Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard.

•

Keep the generator set and the surrounding area clean and free from obstructions. Remove any debris from the set and keep the floor clean and dry.

•

Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe.

•

Substances in exhaust gases have been identified by sorne state or federal agencies as causing cancer or reproductiva 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 tire or explosion could result.

•

Wear hearing protection when going near an operating generator set.

•

To prevent serious burns, avoid contact with hot metal parts such as radiator system, turbo charger system and exhaust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

iv

1. lntroduction ABOUT THIS MANUAL

TEST EQUIPMENT To perform the test procedures in this manual, the following test equipment must be available • True RMS meter for accurate measurement of small AC and DC voltages. Fluke models 87 or 8060A are good choices. • Grounding wrist strap to prevent circuit board damage dueto electrostatic discharge (ESO). • Battery Hydrometer • Jumper Leads • Tachometer or Frequency Meter • Wheatstone Bridge or Digital Ohmmeter • Variac • Load Test Panel • Megger or lnsulation Resistance Meter • PCC Service Tool Kit (Harness Tool and Sensor Tool)

This manual provides troubleshooting and repair information regarding the PowerCommand® Control 3100 (PCC) and generators for the generator set (genset) models listed on the front cover. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator's Manual. This manual does not have instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it. Do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment. This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. Service personnel must use the actual wiring diagram and schematic shipped with each unit. The wiring diagrams and schematics that are maintained with the unit should be updated /::.·:.,. )_. ~t .. .'...·. when modifications are made to the unit. ''·~.~~ Read Safety Precautions and carefully observe ali instructions and precautions in this manual. .:

HOW TO OBTAIN SERVICE Always give the complete Model, Specification and Serial number of the generator set as shown on the nameplate when seeking additional service information or replacement parts. The nameplate is located on the side of the generator output box. LA.WARNING I lncorrectservice or replacement of parts can result Í!J severe personal injury or death, andlor equipmentdamage. Service per­ sonne/ mustbe trainedand experienced to per­ form electrica/and mechanical service. Read end followSafety Precautions, on pages iii and

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iv.

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Copyright@ 2001 Cummins Power Generation. Ali rights reservad. Cummins and PowerCommand are registered trademarks of Cummins lnc .

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SYSTEM OVERVIEW

The PCC monitors frequency from both the magnetic pick-up (MPU) and the main stator inputs. The control sends a low power pulse-width modulated (PWM) signa! to the governor output module, which then sends an amplified signa! to the engine fuel control.

The PCC is a microprocessor-based control for Cummins generator sets. lt provides fuel control and engine speed governing, main alternator voltage output regulation, and complete generator set control and monitoring. lt also provides controls for automatic and semi-automatic synchronizing and automatic load sharing controls for both isolated bus or utility (mains) paralleling applications.

The Bus PT module reduces the bus voltage to approximately 18 VAC and provides a signa! to the control for reference in synchronizing the generator set to the system bus. The externa! PT/CT module reduces generator voltage to approximately 18 VAC, and produces a representativa AC voltage from CT output current. The voltage regulation function sends a low power PWM signal to the voltage regulator output module, which then sends an amplified signal to the excitar stator.

The operating software provides control of the generator set and its performance characteristics, and displays performance information on a digital display panel. lt accepts menu-driven control and setup input from the push button switches on the front panel.

GENERATOR SET CONTROL FUNCTION

Oil, coolant, and exhaust temperatures are sensed by variable resistance element sensors. Oil pressure is sensed by a capacitiva element active sensor.

Figure 1-1 shows sorne of the control functions. A more complete block diagram is provided in Section 3. A system schematic is provided in Section 9.

Governor Output

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Fuel Control . · ..

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FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

1-2

Battery BT1

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2. Control Operation GENERAL

SAFETY CONSIDERATIONS

The following describes the function and operation of the PowerCommand generator set control. Ali indicators, displays, meters and control switches are located on the face of the control panel as illustrated in Figure 2-1.

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

I Contacting high voltage campo­ nents can cause electrocution, resulting in se­ vere personal injury or death. Do not open the generator output box while the set is running. Read and observe ali WARNINGS and CAU· TIONSin your generator set manua/s. LA CAUTION I The PCC control cabinet must be opened only by technical/y qua/ified personnel. Lower leve/ voltages (18 VAC to 24 VDC) are present in PCC control cabinet. These voltages can cause electrica/ shock, resulting in person­ al injury. Even with power removed, improper handling of components can cause electrostatic dls­ charge and damage to circuit components. LAWARNING

The PCC control cabinet must be opened only by technically qualified personnel. Normally, generator set configuration options are set at the factory. When a new control is installed on a generator set or when parts are replaced, the control must be configured for that generator set with the use of the "lnitial Start Setup" portion of the interna! software. Setup and calibration procedures are described in Section 5. The automatic voltage regulator (AVR) and governor operation characteristic adjustments are also described in Section 5.

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2-1

one of eight "wake up" inputs from remote sensing switches.

SEQUENCE OF OPERATION When the PowerCommand control is in the AUTO mode, it will cause the generator set to start on receiving a signal from a remote device. The PowerCommand control will initiate a starter cranking signa! and verify that the engine is rotating. The PowerCommand control will provide sufficient fuel to the engine to accelerate to start disconnect speed. On reaching that speed, the control wíll ramp the generator set to rated speed and voltage.

The wake up signals are: • Emergency Stop • Low Coolant Level • Low Coolant Temperature • Low Fuel • Customer Fault lnputs 2 and 3

On reaching rated speed and voltage, the PowerCommand control checks the system bus voltage. lf no bus voltage is present, it will wait for a pulse from a remote Master First Start Sensor. On receiving that pulse, the control will signal the paralleling breaker to close.

• Run Selected on Run/Off/Auto Switch • Remota Start Signal in Auto Mode • Self Test switch To activate and view the menu displays, press and ralease the Self Test switch. The PCC will initialize the operating software and permit operation of the menu display panel. lf no menu selections are made, the power to the control panel will shut down after 30 seconds.

lf bus voltage is present, the PowerCommand control will check for proper phase rotation, adjust the generator set to the bus voltage and frequency leve!, and then synchronize the generator set to the system bus. When a synchronous condition is achieved, the control will send a signal to close the paralleling breaker.

Power On Mode In the Power On (awake) mode (selector switch 85 on the Digital Board is set to the left), the PCC will initialize the operating software and permit operation of the menu display panel. (See Figure 3-1 for SS location.) Power will stay on until switch (85) is set to the Standby mode. lt is recommended that switch SS be left in the Power On mode in all applications, except tFiose where auxiliary battery charging is not available.

When the paralleling breaker is closed, the generator set will assume it's proportional share of the total load on the system bus.

PCC POWER ON I STANDBY MODE Standby Mode In the Standby (sleep) mode (selector switch 85 on the Digital Board is set to the right and the generator set is not running), the control's operating software is inactiva and the LEDs and displays on front panel are all off.

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IA CAUTION I

Electrostatic discharge wi/1 damage cfrcuit boards. Always wear a grounding wrist strap when touching or handling circuit boards or socket­mounted /Cs and when disconnect­ ing or connecting harness connectors.

The operating software is initialized and the front panel is turned on in response to a run signal or any I

) 2-2

KILOWATT METER (PERCENT LOAD)

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MENU SELECTION SWITCH (1 of 4)

FREQUENCY METER

AC VOLTMETER (DUAL SCALE)

ACAMMETER (PERCENT AMPS)

ALPHANUMERIC DISPLAY

ACTIVE SWITCH INDICATOR (1 of 6)

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NON-AUTOMATIC WARNING SHUTDOWN STATUS INDICATORS

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PANEL LAMP SWITCH

PHASE SELECTOR SWITCH ANO INDICATORS

FIGURE 2~1.FRONT PANEL (PCC 3100)

2-3

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L2 L3

Phase Select

EMERGENCY STOP PUSH BUTTON

FRONT PANEL

Reset Switch: Press this switch to reset warning and shutdown messages after the condition has been corrected. To reset a shutdown message with the Reset switch, the Aun/Off/Auto switch must be in the Off position.

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

AC Voltmeter:Dual scale ínstrument indicates AC voltage. Measurement scale indicator lamp.

scale in use is shown on

With the Aun/Off/Auto switch in the Auto mode, shutdown faults can be reset by removing the remote start input and then cycling the remote reset input.

AC Ammeter: lndicates current output in percent of maximum rated current. (Percent current is based on .8 PF.)

Sel! Test Switch:Press and hold this switch to light all front panel LEDs and cycle through all shutdown and warning messages.

KilowattMeter: lndicates 3-phase AC power output as percent of rated load.

In the Standby (sleep) mode, with the generator set not running, the control's operating software is inactive and the LEDs and displays on front panel are all off.

FrequencyMeter: lndicates generator output frequency in hertz.

Upper and Lower Sea/e lndicatorLamps: lndicate AC voltmeter scale.

To actívate and view the menu displays without starting the generator set, press and hold the Self Test switch until the front panel LEDs light. The PCC will initialize the operating software and permit operation of the menu display panel. lf no menu selections are made, a software timer will shut down the power after 30 seconds.

DigitalDisplay:This two-line, 16-character per line alphanumeric display is used in the menu-driven operating system, in conjunction with the display menu selection switches and the Menu switch. Refer to the menu trees later in this section. The display is also used to show warning and shutdown messages.

PanelLightsSwitch:Press this switch to turn control panel illumination on and off. The illumination will shut off after about eight minutes.

DisplayMenu Selection Switches:Four momentary switches-two on each side of the digital display window-are used to step through the various menu options and to adjust generator set pararneters. The green arrow adjacent to the switch is lit when the switch can be used (switch is "active").

Phase SelectorSwitchand lndicators : Press this momentary switch to select phases of generator output to be measur.ed by the analog AC voltmeter and ammeter. LEDs indicate the selected phase.

Menu Switch: Press this switch to return the digital

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

display to the MAIN MENU. Refer to the menu trees later in this section.

the set locally, or enables startlstop control of the erígine from a remote location. (Ground to start.)

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2-4

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Emergency Stop Button: Push the button in for emergency shutdown of the engine.

Shutdown Status lndicator: This red lamp is lit whenever the control detects a shutdown condition. After the condition is corrected, shutdown indicators can be reset by turning the Aun/Off/Auto switch to the Off position, and pressing the Aeset switch. In Auto mode, shutdowns can be reset by removing the remote start input and then cycling the remete reset input.

Remote Reset switch will not reset emergency stop. Can only be reset at the PCC front panel.

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To reset: 1. Pull the button out or turn the button clockwise (button with arrow) and allow it to pop out. 2. Move the Aun/Off/Auto switch to Off. 3. Press the front panel Aeset switch. 4. Select Aun or Auto, as required.

Emergency Stop shutdown status (Code 102) can be reset only at the PCC front panel.

Non­Autometic Status lndicator: This red lamp flashes continuously when the Aun/Off/Auto switch is not in the Auto position.

Paralleling Breaker Switches and lndicators: These two switches are used to manually open or close the paralleling breaker of the generator set. The lamps are used to indicate the opened or closed position of the paralleling breaker.

Warning Status lndicator: This yellow lamp is lit whenever the control detects a warning condition. After the condition is corrected, warning indicators can be reset by pressing the Aeset switch. (lt is not necessary to stop the generator set.)

The Breaker Operation switches are operational only when the Aun/Off/Auto switch is in the Aun position. The breaker will close when the generator set is synchronized with the system bus, or if the system bus is de-energized.

With the Aun/Off/Auto switch in the Auto mode, warnings can also be reset by cycling the remete reset input after the condition is corrected.

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2-5

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2 UNE, 16 CHARACTER PER UNE MENU DISPLAY

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FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES

MAIN MENU The facing page shows the main menu and a block representation of the available submenus.

Figure 2-2 shows the digital display and the menu selection switches. Refer to heading "Front Panel" which describes the menu display and switches.

As shown in the diagram, the main menu can branch into one of four directions. To display engine parameters, such as oil pressure and temperature, water temperature, engine speed .•.•.• ) (RPM), and exhaust temperature, press the button next to the word "ENGINE" in the display. Refer to ENG/NE MENU in this section.

In the Standby Mode, to actívate and view the menu displays without starting the generator set, press and release the Self Test switch. This will initialize the PCC operating software and permit operation of the menu display panel. lf no menu selections are made, a software timer will shut down the power after 30 seconds. In the Power On Mode, power is continuously supplied to the control panel. Display will always remain on.

To display generator parameters, such as volts, amps, power (kW), and frequency, press the button next to the word "GEN" in the display. Bus voltage, frequency and a digital synchroscope can also be viewed from this menu branch. Turn to the GEN MENU in this section. To adjust output voltage and frequency, or start and stop delays, press the button next to the word "ADJUST' in the display. Refer to ADJUST MENU in Section 5.

In the digital display, the ">>" symbol indicates that selecting the adjacent button causes the operating program to branch to the next menu display-as shown in the menu diagrams. ·· 1

To display the selected generator set model and the resident version software, press the button next to the ">>" in the display. Refer to VERSION & DJS­ PLAYS MENUS in Section 5.

In the digital display, the "<<" symbol indicates that selecting the adjacent button causes the operating program to go back to the previous menu display.

2-6

't

MAIN MENU PAGES 2-8 & 2-9

PAGES 2-10 & 2-11 %GOV J REG FREQUENCY

<<

RPM EXHAUST

<<

BATTERY HOURS

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OIL COOLANT

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VOLTS AMPS

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CLEAR WARNING AND SHUTDOWN MESSAGES

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SECTION 5

VERSION SETUP /CAL HISTORY

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GOV I REG PARALLEL

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SECTION 5

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ACTIVE BUTTON ACTIVE BUTTON SELECTED

2-7

<< SETUP

ENGINE MENU The facing page shows a block representation of the ENGINE menu. lf you press the button next to the word "ENGINE" in the display, the first ENGINE submenu wíll appear.

BATTERY/HOURS submenu: From the OIU COOLANT submenu, press the button next to the ">>" in the display to move to the BATTERY/ HOURS submenu. Select BATTERY for a display of battery voltage. Select HOURS for a display of the number of starts and the running hours. When battery or hours parameters are displayed, pressing the button next to the "<<" will return the display ("BACK") to the BATTERY/HOURS submenu.

As shown in the diagram, the ENGINE menu has three submenus. 0/UCOOLANT submenu: This is the first submenu. Select OIL for a display of oil pressure and oil temperature. Select COOLANT for a display of coolant temperature. When oil or coolant parameters are displayed, pressing the button next to the "<<" wíll return the display ("BACK") to the OIU COOLANT submenu.

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RPMIEXHAUST submenu: From the BATTERY/ HOURS submenu, press the button next to the ">>" in the display to move to the RPM/EXHAUST submenu. Select RPM for a display of engine RPM. Select EXHAUST for a display of the (optional) exhaust temperature. When RPM or exhaust pararneters are displayed, pressing the button next to the "<<" will return the display ("BACK") to the RPM/EXHAUST submenu.

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2-8

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1 - - - - lndicates "OR" Condition I

2-9

GEN MENU The facíng page shows a block representation of the GEN menu. lf you press the button next to the word "GEN" in the display, the first GEN submenu will appear. As shown in the diagram, the GEN menu has three submenus. VOLTS!AMPS submenu: This is the first submenu. Select VOLTS for a display of a line-to-line or line-to-neutral selection, or for viewing of the system bus line-to-line voltage. Select line-line or lineneutral for the desired voltage display. Select AMPS for a display of L 1, L2, and L3 current in amps. When voltage or current parameters are displayed, pressing the button next to the "<<" will return the display ("BACK") to the L-UL-N submenu. lf DELTA is selected in the lnitial Start Setup submenu, when selecting VOLTS, the "line-line" or "lineneutral" submenus will not be displayed, only the L 12, L23, L31 submenu will be displayed.

POWER / KW HOURS submenu: From the VOLTS/AMPS submenu, press the button next to the ">>" in the display to move to the POWER/KW HOURS submenu. Select POWER for a display of power output in kilowatts anda power factor value. Select KW HOURS for a display of kilowatt hours. When power or kW hours parameters are displayed, pressing the button next to the "<<' will re-

I

2-10

turn the display ("BACK") to the POWER/KW HOURS submenu. The PF reading will contain an asterisk if the power factor is leading (for example, *.3PF). Beginning Version 1.06, N/A is displayed in the PF field when the generator set is not running.

%GOV/REG!FREQUENCY submenu: From the POWER/KW HOURS submenu, press the button next to the ">>" in the display to move to the %GOV/ REG/FREQUENCY submenu. Select %GOV/REG for a display of voltage regulator and governor duty cycle (drive) levels in percentage of maximum. Select FREQUENCY for a display of the generator output frequency the bus frequency, or the digital synchroscope. When voltage regulator and governor or frequency parameters are displayed, pressing the button next to the "<<" will return the display ("BACK") to the %GOV/REG/FREQUENCY submenu. Bus Frequency (Digital Synchroscope) subme­ nu: When the bus frequency (digital synchroscope) information is displayed, the operator can observe the generator set synchronizing with the system bus. The display indicates bus frequency and number of degrees from synchronous condition (+ indicates faster, - indicates slower). When the generator set is operating within the sync-check window, an asterisk will índlcate that the paralleling breaker can be closed.

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THIS PAGE LEFT INTENTIONALLY BLANK

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2-12

3. Circuit Boards and Modules GENERAL

The system schematics are provided in Section 9 of this manual.

This section describes the function of the PCC clrcuit boards and modules that are contained in the control panel (Figure 3-1) and the accessory box. The block diagram in Figure 3-2, shows both interna! and externa! components of the PCC system.

LA CAUTION I

Electrostatic discharge wi/1 damage circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards or socket­mounted /Cs.

S5 POWER ON/

J1 (FOR INPOWER

DISPLAY BOARD A35 (O>

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CUSTOMER INTERFACE A34

AUN/OFF/AUTO SWITCH S12

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GOVERNOR OUTPUT MODULE A38

BUS PT MODULE A39

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VOLTAGE REGULATOR OUTPUT MODULE A37

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ACCESSORY BOX (HC 4/5)

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FIGURE 3-1. CIRCUIT BOARD LOCATIONS

3-1

PT/CT BOARD A36

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3-2

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GOVERNOR OUTPUT MODULE (A38)

Fu ses

The governor output module (Figure 3-12) receives a low power pulse-wídth modulated (PWM) signal from the engine interface board and then sends an amplífied signal to drive the governor actuator. The PCC monitors frequency from both the magnetic pick-up (MPU) and the main stator inputs.

The governor output module has three fuses to protect ít from overloads and groundfaults. They are: Network B+ (1 o Amps) Switched B+ (10 Amps)-T26 Gov Act + (1 O Amps)

F1 F2 F3 LEDs

Connectors

The governor output module has two LED's that indicate the following conditions:

The governor output module has one connector: JG

051 OutputDuty Cycle: brighter = longer duty ,. cycle (Amber). The duty cycle range of the PWM signa! is O - 90%. Normal duty cycle is about 30%. 052 Run signal to Governor Controller (Green)

Connects to Governor Actuator, Governor Orive (from Engíne Interface), B+, T26

o

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081 . OUTPUTDUT®E

DS2 • GENSITRUN

.--~~~~~~....;;.._~~__;;==:....___,

FI

F2

Network B+

F3

Switched B+

A38-J6

Governor B+ 98-6909

J6

FIGURE 3-12. GOVERNOR OUTPUT MODULE (A38)

3-14

I• •

J10

VOLTAGE REGULATOR OUTPUT MODULE (A37)

Connects to engine harness (power) J10 wiring connections:

The voltage regulator output module (Figure 3-11) is a power amplifier. This board is used to amplify the pulse-width modulated (PWM) signal from the PCC to drive the exciter windings. Power from the PMG is used by this board to amplify the PWM signa!.

Phase A PMG power

Yellow

Phase B PMG power

Orange Phase C PMG power

X (Field +) Output Brown XX (Field -) Output Red

Connectors

LEDs

The voltage regulator output module has two connectors. They are:

The voltage_regulator output module has 3 LEO's that indicate...the !?llowing conditions.

J7

(

Green

Connects to engine harness (control) J7 wiring connections: Gray Regulator Orive (+) Input White Regulator Orive (-) Input Blue B+ Input (RUN signal) Purple Ground Input Grn/Yel Start in Black Start solenojd

DS1 On when voltage regulator isolated supply is operating (Green) DS2 Output Duty Cycle - Brighter when load increases - larger duty cycle (Amber). The duty cycle range of the PWM signa! is O - 60%. Because the normal duty cycle is less than 10%, the output duty cycle LEO, 082 will normally be very dimly lit. DS3 Backup start disconnect - On when start disconnect is true (Green). The backup start disconnect is initiated at about 850 RPM, when sensed PMG voltage is greater than 105 volts RMS.

..

A37-J7

DS1 - ISOLATED SUPPLY DS2- OUTPUT DUTY CYCLE A37-J10 - A T I NN

r--,r--, CR10

1 J7

11

I

CR11

1

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

3-13

J10

GENSET COMMUNICATIONS (A41)

PCC data such as voltage, oil pressure, current, engine speed, and not in auto status; and provides that information to the network. The GCM also facilitates remate monitoring and limited remate control of the genset that PCC controls. Outputs from the GCM can 'wake up' the PCC when needed, or issue start commands to the genset. The GCM also includes a termínate circuit for use at the end of a network data bus. The GCM module is powered from the genset starting batteries. lt is operational at all times when powered, even if the PCC is asleep. The GCM module is mounted on stand-off mounting legs above the analog board (A33). Refer to the Power Command Network lnstallation and Operator's Manual (900-0366) for information on installation and use of the GCM module.

MODULE

The genset communications module (GCM) is required to connect the PCC to a PowerCommand (LonWorks) network, and communicate with other network modules. The GCM module is an optional feature, and it is available as a field upgrade kit for applications where the feature must be added in the field. The PCC must be operating with firmware version 1.06 or later. For model DFH gensets only, firmware must be version 1.04 or later.) The GCM provides an interface for data transfer between the PowerCommand control and other modules on the network. lt communicates with the PCC through a serial port on the PCC, as well as monitoring various PCC inputs to determine the operating state of the control. For example, the GCM monitors

J7

J7

CJ

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BATTERY VOLTAGE SWITCH S4

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3-12

BUS PT MODULE (A39) The bus PT module (Figure 3-9) is mounted inside the accessory box. This module converts the bus output voltage (from the load side of the paralleling breaker) to 18 VAC and provides this to the analog board. lt provides a reference signal to the PowerCommand Control for synchronizing the generator set output to a system bus. There are tour versions of this module, for primary voltages of 69, 120, 240 or 346 volts AC line to neutral. For proper operation, the correct bus PT module must be installed in the generator set. Correct phasing is also ímportant as the system uses the bus PT module output for both protection and control of the generator set.

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o

o

Connectors The bus PT module has two terminal blocks. They are:

(.

o

TB1 Bus voltage connections. N bus neutral A bus A phase (U) B bus B phase (V) e bus e phase (W) TB2 Bus PT output for PowerCommand control.

re I IJ0JJ0JJ0IJ@I

A B C N

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FIGURE 3-9. BUS PT MODULE

'.·.

3-11

PT/CT BOARD (A36)

Connectors

The PT/CT board (Figure 3-8) is mounted inside the accessory box. This board converts generator output voltage to approximately 18 VAC levels for the analog board. lt also converts CT .55 amp (at full load) output to approximately 1.65 VAC (at full load) input for the analog board.

The PT/CT board has two connectors. They are: J8 Connects to J3 on A34 Customer Interface board J9 Connects to AC harness (generator output voltage and CTs) J9 wiringconnections : Yellow Gen. A In Orange Gen. B In Red Gen. e In Brown Gen. Common In Whiie CT21 (+) In Gray 'CT21 (common) In Grn/Ylw CT22 (+) In Black · CT22 (common) In Purple CT23 (+) In Blue CT23 (common) In

There are three versions of this board. For proper operation, the PT/CT board must be correctly matched to the generator set. In addition, there is a specific set of CTs for each genset. For proper operatíon, the CTs must also be correctly matched to the genset output current.

J8

FIGURE 3-8. PT/CT BOARD

3-10

o

D

~

081 - MA 1ST START 083 - CUST FAULT4

D

084 - CUST FAULT1 086 - FAULT RESET 087-ENGIDLE DS8 - LOAD DEMANO 089 - BKR TRIP / INHIBIT

J1

IBLACKl

0811 - CUST FAULT2 0813- LOW FUEL OS14, - RMT START OS15. - CUST FAULT3

1 3 li 7 9 11 13 15

2

J.4 22

25 27

28

31 33

J2 IORAY>

34

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7 9 11 13 15 17 19 21 23 25 27

J3

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J5

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19

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31 33

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34

o

DS16 - GLOSE BKR DS17- COMMON SHTDN DS18 - COMMON WARNING 0819 - LOAD DUMP DS20 - READY TO LOAD 0821 - [K8] PRE-HET DS22 - [K6] NOT IN AUTO DS23- [K9] HET DS24[K10]0VERSPEEO DS25- [K11] OVERCRANK OS26 - [K12] LET 0827 - [K13] LOW FUEL

FIGURE 3-7. CUSTOMER INTERFACE BOARD

3-9

1

DSS - [K15] LOP

I

0810- BRKR CLOSEO

o

082 - [K14] PRE-LOP

DS12-[K7] LOWCOOL

DS13

Low Fuel Input (Red) DS14 Remote Start input (Green) DS15 Customer Fault #3 input (Red)

CUSTOMER INTERFACE BOARD (A34) The customer interface board (Figure 3-7) connects to the PT/CT board to bring in voltage and current. lt also connects to customer inputs and outputs. Note that there are two versions of this board, for parallel and non-parallel generator sets.

DS16 Paralleling Breaker Control input relay energized from Digital board (Green). This output is activated to close the paralle!ing breaker.

Connectors

DS17 Common Alarm output relay energized from Digital board (Green) This output is activated only on a shutdown condition. DS18 Spare output relay energized from Digital board (Green) This outputis activated only on a warning condition. DS19 Load Dump output relay energized from Digital board (Red) lf overload or underfrequency for 5 seconds, this output is activated (before shutdown). DS20 Ready to Load output relay energized from Digital board (Green) This output is activated when AC voltage and frequency exceed 90% of nominal. DS21 Pre high engine temperature output relay K8 (Red) DS22 Not in auto output relay K6 (Red) DS23 High engine temperature output relay K9 (Red) DS24 Overspeed output relay K1 O (Red) DS25 Overcrank output relay K11 (Red)

The customer interface board has five connectors. They are: J1 J2 J3 J4 J5

Customer connections Customer connections A36 PT/CT Board and customer connections Connects to J2 on A32 Digital board Connects to J4 on A33 Analog board

LEDs The customer interface board has 27 LED's that i~dicate the following conditions: Master First Start Input (Green) - paralleling application only DS2 Pre low oil pressure output relay K14 (Red) DS3 Customer Fault #4 Input (Red) DS4 Customer Fault #1 Input (Red) DSS Low oil pressure output relay K15 (Red) DS6 Fault Reset Input (Red) DS7 Engine ldle (Green) osa Paralleling Breaker Glose Input (Green) [paralleling function is load demand] DS9 Paralleling Breaker Open Input (Green) DS10 Paralleling Breaker Position Input (Green) DS11 Customer Fault #2 input (Red) DS12 Low coolant output relay K17 (Red) DS1

DS26 Low engine temperature output relay K12 (Red) DS27 Low fue! output relay K13 (Red)

3-8

,.

(:"'.) . ...;,~·..::·'

DIGITAL DISPLAY BOARD (A35)

DS12

The digital board (Figure 3-6) connects to all meters and the LEO display.

DS13 DS14 DS15

Connectors

DS20

The digital board has three connectors. They are: J1

J5 JG

DS21

Connects to front panel membrana switches Connects to J2 on A32 Digital board. (With J5 disconnected, the display will be non-functíonal, but the PCC will continue to operate.) Connects to meters, Run/Off/Auto switch, J3 on A31 Engine Interface board

DS22 DS23 DS24 DS25 DS26

LEDs DS27

The digital board has 18 LED's that are used to indicate operational status of the generator set and control panel mode/switch selectíons. !

DS29 DS36

Not In Auto (Red) DS1 O Upper Scale (Green) DS11 Left Top Arrow (Green). DS9

(

c:JD59 [:]D513 0DS15

= =

[:]0522 (:]DS26

=

[:]0536 (:]DS37

= =

DS37

0511

Right Top Arrow (Green) Warning (Amber) Lower Scale (Green) Shutdown (Red} Left Bottom Arrow (Green) Right Bottom Arrow (Green) Automatic mains failure (AMF} or paralleling application only: Breaker Closed (Red) Phase A (Green) Reset Arrow (Green) Men9· Arrow (Green) AMF appücatíon only: Breaker Open (Green) Phase B (Green) Phase C (Green) AMF application: Breaker Closed (Red} - or - paralleling application: Breaker Open (Green} AMF application only: Breaker Open (Green}

o

00512

05200

OS24D

==

==

nuJ6

J1

FIGURE 3-6. DIGITAL DISPLAY BOARD

/

\

3-7

D510 (:] 0514 D

0$23(:] OS27(:] OS29(:]

= = = = = =

ANALOG BOARD (A33)

Connectors

The analog board (Figure 3-5) is the only circuit board inside the control that has no LED's. There are two versions of the analog board that are used for paralleling and non-paralleling systems.

The analog board has tour connectors with ribbon , -. cables permanently soldered to them. They are: (

This board interprets all analog input signals and converts the analog signals to 0-5 VDC for the digital board.

J1

Connects to J2 on A31 Engine Interface board

J2

Connects to J3 on A32 Digital board Spare analog inputs Connects to J1 on A34 Customer Interface board

J3

J4

!

J1

L.!

.....

J2 L.,.._

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.__

__.J3

J4

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FIGURE 3·5. ANALOG BOARD

3-6

·/

o 1 3 5

7

o

7 J2

J5 C0RAYl 21

I

i!8

§ 1~ §

DS1 • LOW FUEL OS2 - LO COOL 083 • LET

J7

33 31 i!9 27

Q)

23 IB 27

DS4· AUN SW 085-AUTO

12

o

086 - E-STOP

(.,:

9 11 13 15

15 11 9 7 !I

2

C)

h

19

J 1 17

3 1

F1

DS9- REG ~ 0810 • GOV 0$11 • START

5A CNTRL B+ J,4 CWHITEI

F3

0812 - AUN RLY

5AAUX B+

TP1

c=:i

FIGURE 3-4. ENGINE INTERFACE BOARD

3-5

ENGINE INTERFACE BOARD (A31)

J4

The engine interface board (Figure 3-4) reads user control inputs, monitors engine, generator and system status, and initiates the appropriate action tor normal operating and fault conditions (warning or shutdown).

J5 J6 J7

Fu ses

This board is connected to the engine sensors, battery, starter, governor output module, voltage regulator output module, and the magnetic pick-up (MPU).

The engine interface board has two replaceable fuses. They are: F1

The engine interface board can also be connected to an optional network interface module for network access.

F3

The engine interface board has 1 O LED's that indlcate the following conditions:

1 . DS11 lights when a remote run signal is r~ceived and 812 is in the Auto possition, or 812 is moved to the Run position.

Low Fuel Alarm input (Red) DS2 t.ow Coolant Level Alarm input (Red) DS3 Low Engine Temperature Alarm input (Red) DS4 812 in Aun position (Green). 812 is the Run/ Off/Auto switch. DS5 812 in Auto position (Green) DS6 Emergency Stop (Red) DS7 Not configured. osa Not configured. DS9 Automatic voltage regulator duty cycle (Green). Brighter indicates larger duty cycle. DS10 Governor duty cycle (Green). Brighter indicates larger duty cycle. DS11 8tart pilot relay output (Red) DS12 Aun pilot relay output (Red) DS1

2. DS12 lights when the magnetic pick-up voltage is sensed (engine is cranKlng). (When the engine is cranking, the mag pickup output should be a mínimum of 1 volt.) 3. DS11 extinguishes, DS9 lights and DS1 O is dimly lit when the generator is running. Connectors The engine interface board has seven connectors and ene terminal strip. They are: J2 J3

Centro). B+ (5 Amps) Aux. Bit- (5 Amps). (Panel lamps and run/start contacts). ··

LED's

During a typical start sequence the LED's light as follows:

J1

Connects to customer connections and to engine harness which includes magnetic pickup. Connects to engine sensors. Connects to Genset Control module (GCM). Connects to Genset Control module (GCM).

Connects to J4 on A32 Digital board. Connects to J1 on A33 Analog board. Connects to display board, front panel switches and meters.

3-4

..

DIGITAL BOARD (A32)

Connectors The digital board has five connectors. They are:

The digital circuit board (Figure 3-3) contains the microprocessor and the operational software tor the control. lt connects to all other boards inside the control. This board also provides the analog-to-digital conversions for the PCC.

J1 J2

J3

J4

Switch S5

JS

Slide the switch to the left to select the Power On (awake) mode. Control panel power/operating software will remain on until the switch is reset to the Standby mode. lt is recommended that switch 85 be left in the Power On mode in all applications, except those where auxiliary battery charging is not available.

LEDs

\·.

I

The digital boardhas seven LED's that indicate the following conditions: OS1 Spare (Green) OS2 Spare (Green)

Slide right to put the PCC in the Standby ("sleep") mode. In this mode, the PCC opsrating software will be initiated by selection of Run on the tront panel, by pressing the Self Test switch, by a remate start input (in Auto mode), or by any one of severa! "wake-up" signals from externa! switches.

(

Far lnPower Service Tool Connects to J4 on A34 Customer Interface board Connects to J2 on A33 Analog board Connects to J1 on A31 Engine Interface board Connects to JS on A35 Digital Display assembly

OS3 +18 VDC supply OK (Green) OS4 +5 VDC supply OK (Green)

OSS Run (Flashes once per second if software is running)(Green) DS6 +24 VDC B+ supply OK (Green) DS7 +12 VDC supply OK (Green)

ü

I SS ol

J2

J4

o

o

o FIGURE 3-3. DIGITAL BOARD

3-3

MASTER FIRST START SENSOR The First Start Sensor System is an Onan control sub-system which is used to sense when a generator set is ready to close to a de-energized system bus and to prevent more than one generator set from closing to a dead bus on automatic system starting. The First Start Sensor System for PowerCommand generator sets is composed of control algorithms within the PowerCommand control and a Master First Start Sensor, whích ís usually mounted ín a remote master control panel.

I

,,

3-15

The sequence of operation of the control system is as follows: On a signal to start, all generator sets in a system simultaneously start, and accelerate to rated speed and voltage. The Master First Start Sensor continuously provides pulses to each PowerCommand control. When the PowerCommand control receives the pulse from the Master First Start Sensor, if it is ready to close to the bus, an interlock sígnal is sent to all other controls to prevent their respective paralleling breakers from closing. A clase signal is then provided to the generator set paralleling breaker.

-, ·\

.!

THIS PAGE LEFT INTENTIONALLY BLANK

.: ·.

:

I

) ,/

4. Troubleshoot ing GENERAL

High voltages are present when the genset is running. Do not open the generator output box while the genset is running.

The PowerCommand® Control 3100 (PCC) continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. lf any of these conditions occur, the PCC will light a yellow Warning lamp or a red Shutdown lamp and display a message on the digital display panel.

I lgnition of exp/osive battery gases can cause severe personal injury or death. Arc­ ing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ig­ nite battery gas. Do not smoke, or switch troub/e light ON or OFF near battery. Discharge static electricity from body before touching bet­ teries by first touching a grounded metal sur­ face.

LA.WARNING

In the event of a shutdown fault (red Shutdown lamp), the PCC will stop the generator set (genset) and close a set of contacts that can be wired to trip a circuit breaker. lf the genset is stopped for this reason, the operator can restart the genset after making adjustments or corrections.

Ventilate battery area befare working on ornear battery­Wear goggles­Stop genset and dis­ connect charger befare disconnecting battery cables­Disconnect negative (­) cable first and reconnect last.

This section contains the following information: • Table 4-1: Contains a list of all status codes, including the displayed message and status indicator. Also references the page number that contains a description of each code. • Table 4-2: Describes each warning and shutdown code, warning and shutdown limits where applicable, and basic corrective actions, such as, checking fluid levels, control reset functions, battery connections, etc. • Table 4-3: Lists the PCC oil pressure warning and shutdown limits. • Tables 4-4 through 4-35: Provide detailed troubleshooting procedures. · • Table 4-36: Describes the analog circuit board inputs and outputs. • Table 4-37: Describes the location and function of each fuse.

IA CAUTION I Disconnect battery charger from AC source befare disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the genset.

!A.WARNING

set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (­) cable from the battery terminal. When troubleshooting a generator set that is shut dówn, make certain the generator set cannot be accidentally restarted as follows: 1. Move the Aun/Off/Auto switch on the control panel to the OFF position.

SAFETY CONSIDERATIONS

,,

I

2. Turn off or remove AC power from the battery charger.

i

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.

!A.WARNING

I Accidental starting of the generator

3. Remove the negativa(-) battery cable from the generator set starting battery.

4-1

Emergency Stop shutdown status (Code 102) can be reset only at the PCC front panel.

STATUS INDICATORS Non­Automatic Status lndicator: This red lamp flashes continuously when the Run/Off/Auto switch is in the Off position.

Digital Display: This two-line, 16-character per line alphanumeric display is used in the menu-driven operating system and to show shutdown and warning messages. Refer to Tables 4-1 and 4-2.

Warning Status lndicator: This yellow lamp is lit whenever the control detects a warning condition. After the condition is corrected, warning indicators can be reset by pressing the Reset switch. (lt is not necessary to stop the generator set.) In auto mode, warning indicators can also be reset by cycling the remote reset input after the condition is corrected.

RESETIING THE CONTROL Press the momentary Reset Switch to reset warning and shutdown messages after the condition has been corrected. To reset a shutdown message with the Reset switch, the Run/Off/Auto switch must be in the Off Position. (The control cannot go into Standby (sleep) mode until all faults have been reset.) In Auto mode, warning indicators can also be reset by cycling the remate reset input after the condition is corrected. Shutdown faults can be reset by removing the remote start input and then cycling the remote reset input.

Shutdown Status lndicator: This red lamp is lit whenever the control detects a shutdown condition. Shutdown faults are latched. After the condition is corrected, shutdown indicators can be reset by turning the Run/Off/Auto switch to the Off position, and pressing the Reset switch. In the Auto position, shutdown faults can be reset by removing the remete start input and then cycling the remota reset input.

. ·.• \': ¡ .

(=>

Non-Automatic

(=>

Warning

(=>

Shutdown

~o ~o ~o

arallel tna Break•r Cloood

=

[I] [o]

Opon

C=> (=>

Upper Scale Lower Scale

Voltage

381

Amps

181

(=> L1·l2

L1·L2

L1

(=> L2·L3 L1·l2

L2

(=> L3-L1

L3

O

Phase Seleet

w

Aun

Off

WARNING ANO SHUTDOWN STATUS INDICATORS

Auto

RES ET SWITCH

FIGURE 4-1. CONTROL PANEL

4-2

ALPHANUMERIC FAULT MESSAGE DISPLAY

,,/

TABLE 4-1. WARNING AND SHUTDOWN CODES

f,.·_­:•._~-·. .i.~.> _j

CODE

MESSAGE

BASIC TROUBLESTATUS LEO . . . . . . . . . CHECKS . . . SHOOTING

Blank

LOAD DEMAND

none . . . . . . . . . . . . . . . . . . . 4-5

101

IDLE MODE

none . . . . . . . . . . . . . . . . . . . 4-5

102

EMERGENCY

200

STOP

Shutdown

4-5

LOW OIL PRESSURE

Warning

4-5

4-24

201

LOW OIL PRESSURE

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

4-24

204

OIL PRES SENDER

Warning

4-5

4-25

21 O

LOW COOLANT TEMP

Warning

4-6

4-26

211

HIGH COOLANT TEMP

Warning

4-6

4-27

212

HIGH COOLANT TEMP

Shutdown

4-6

4-27

213

COOLANT SENDER

Warning

4-6

4-25

214

LOW COOLANT LVL

Warning

4-7

4-28

215

LOW COOLANT LVL

Shutdown

4-7

4-28

220 . . . . . . MAG PICKUP

Shutdown . . . . . . . . . . . . . . . 4- 7

4-29

221

FAIL TO CRANK

Shutdown

4-7

4-15, 4-23

222

OVERCRANK

Shutdown

4-7

4-21

223 224

OVERSPEED FAIL TO SYNCHRONIZE

Shutdown . . . . . . . . . . . . . . . 4-7 Warning/Shutdown 4-8

4-30 4-31

226

FAIL TO CLOSE

Shutdown . . . . . . . . . . . . . . . 4-8

4-33

230

LOW OC VOLTAGE

Warning

4-8

4-35

231

HIGH OC VOLTAGE

Warning

-4-8

4-35

232

WEAK BATTERY

Warning

4-8

4-35

240

LOW FUEL- DAY

Warning

4-9

4-36

241

LOW FUEL

Warning

4-9

4-37

4-9

4-38

250 . . . . . . EEPROM ERROR

J . Shutdown . . . . . . . . . . . . . . .

251

EEPROM ERROR

Warning

4-9

4-38

252

EEPROM ERROR

Warning

. . . . . . . . . . . . . . . . 4-9

4-38

I

4-3

TABLE 4-1. WARNING ANO SHUTDOWN CODES BASIC

TROUBLE-

CODE

MESSAGE

STATUS LEO . . . . . . . . . CHECKS . . . SHOOTING

260

CUSTOMER FAULT 1*

Warning/Shutdown

4-9

4-39

261

GROUND FAULT*

Warning/Shutdown

4-9

4-39

262

DAY TANK*

Warning/Shutdown . . . . . . . 4-9

4-39

263

HIGH GEN TEMP*

Warning/Shutdown . . . . . . . 4-9

4-39

270

PHASE ROTATION

Shutdown . . . . . . . . . . . . . . . 4-1 O

4-40

272

FIRST START

Warning

4-10

4-42

301

HIGH-AC VOLTAGE

Shutdown

4-10

4-43

303

LOW AC VOLTAGE

Shutdown

4-10

4-46

313

UNDER FREQUENCY

Shutdown

4-10

4-48

320

OVERCURRENT

Warning . . . . . . . . . . . . . . . . 4-1 O

4-49

321

OVERCURRENT

Shutdown

4-10

4-49

322

SHORT CIRCUIT

Shutdown

4-10

4-49

330

OVERLOAD

Warning . . . . . . . . . . . . . . . . 4-11

4-49

335

REVERSE POWER

Shutdown . . . . . . . . . . . . . . . 4-11

4-50

337

LOSS OF EXCITATION

Shutdown

4-51

4-11

* Default message. Editable for customer site requirements. lt is recommended that the bell alarm contacts of the paralleling breaker be brought back to the control and indicate "Parallel CB Trip" as one customer fault.

. >) ....

I

4-4

/

TABLE 4-2. WARNING AND SHUTDOWN CODES

IA WARNING I

Hazards presentin troubleshooting can causeequipmentdamage, severe personal injuryor death. Onlytrainedand experienced servicepersonnelwithknowledge of fuels, etectricity, and machineryhazards shouldperformserviceprocedures . Read Safety Precautionspage and observeali instructionsand precautionsin this manual. SYMPTOM

CORRECTIVE ACTION

MESSAGE: LOAD DEMAND

The PowerCommand control has received a signa! to shut down from a remote device. This is a normal operation mode, which is typically used in automatic control system to minimize generator set operation hours and system fuel consumption. When the load demand signa! is removed, the generator set will automatically start, synchronize, and close to the system bus.

MESSAGE: IDLE MODE 101 - WARNING

lndicates that the engine is operating in idle mode. When the genset is operating in the RUN mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at 800 RPM. When ground is removed from this input, the genset returns to normal speed and voltage.When the engine idle function is enabled, the control automatically gensets lower oíl pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the genset reverts to normal operating speed, the control automatically resets oíl pressure warning and shutdown trip points to the normal settings.

/:(·_'.·,·· :'~0":: ..

1,,,,:·.·

····~.

,''

,,

Shutdownlamp lights. MESSAGE: EMERGENCY STOP 102- SHUTOOWN

lndicates local or remote Emergency Stop. To reset the local/remota Emergency Stop button: Pull the button out (button with arrow = turn clockwise to allow it to pop out). Move the Run/Off/Auto switch to Off. Press the Reset switch. Select Run or Auto, as required.

Warninglamp lights. MESSAGE: LOW OIL PRESSURE 200 - WARNING

lndicates engine oil pressure has dropped toan unacceptable level. lf generator is powering critica! loads and cannot be shut down, wait until next shutdown period and then follow 201-SHUTDOWN procedure, Ir

To checkoil pressure, accessthe Oil Pressure menu priorto clearing the fault.

Shutdownlamp lights. MESSAGE: LOW OIL PRESSURE 201 - SHUTDOWN

lndicates engine oil pressure has dropped below the shutdown trip point. Check oíl level, lines and filters. lf oíl system is OK but oíl level is low, replenish. Reset control and restart. Oil pressure limits are listed in Table 4-3.

Warninglamp lights. MESSAGE: OIL PRES SENDER 204 - WARNING

lndicates that the control has sensed that the engine oil pressure sender is out of its working range. Check that the engine oil pressure sender is properly connected.

4-5

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

IA WARNING I

Hazards present in troub/eshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with know/edge of fuels, e/ectric­ ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe ali instructions and precautions in this manual.

SYMPTOM

CORRECTIVE ACTION

Warning lamp lights. MESSAGE: LOW COOLANT TEMP 210-WARNING Set is not operating. Warning occurs when engine coolant temperature is 70° F (21 ° C) or lower. NOTE: In applications where the ambient temperature falls below 40°F (4°C), Low Coolant Temp may be indicated even though the coolant heaters are operating.

lndicates engine coolant heater is not operating or is not circulating coolant. Check far the following conditions:

Warning lamp lights. MESSAGE: HIGH COOLANT TEMP 211 - WARNING

lndicates the engine coolant temperature is getting clase to the recommended maximum temperature limit: 215° F (102º C)- standby or 207° F (97° C)- prime. lf generator is powering non-critica! and critica! loads and cannot be shut down, use the following:

a. Coolant heater not connected to power supply. Check fer blown fuse or disconnected heater cord and correct as required. b. Check for low coolant level and replenish if required. Look for possible coolant leakage points and repair as required. c. Open heater element. Check current draw of heater.

a. Reduce load if possible by turning off non-critica! loads. b. Check air inlets and outlets and remove any obstructions to airflow. lf engine can be stopped, follow HIGH C-OOLANT TEMP 212 - SHUTDOWN procedure. To check coolant temperature, access the coolant temperature menu prior to clear~ng the fault.

lndicates engine has overheated (coolant temperature has risen above the shutdown trip point: 223º F (106° C) - standby or 215º F (102º C)- prime. Allow angina to cool down completely befare proceeding with the following checks:

Shutdown lamp lights. MESSAGE: HIGH COOLANT TEMP 212- SHUTDOWN i

Warning lamp lights. MESSAGE: COOLANT SENDER 213-WARNING

a. b. c. d.

Check fer obstructions to cooling airflow and correctas necessary. Check fan belt and repair or tighten if necessary. Check coolant mixture. Check blower fan and circulation pumps on remete radiator installations. e. Reset control and restart after locating and correcting problem.

lndicates that the resistance of the coolant temperatura sender is out of range. Check the resistance of the sender. Resistance should be 500 to 2k ohms.

4-6

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

IA WARNING I

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with know/edge of fuels, e/ectric­ ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe ali instructions and precautions in this manual. SYMPTOM

CORRECTIVE ACTION

Shutdown lamp lights. MESSAGE: LOW COOLANT LVL 214-WARNING or LOW COOLANT LVL 215-SHUTDOWN

lndicates engine coolant level has fallen below the trip point. Allow engine to cool down completely before proceeding.

Shutdown lamp lights. MESSAGE: MAG PICKUP 220 - SHUTDOWN

lndicates mag pickup speed indication is not being sensed or does not match generator set output frequency.

Engine will not crank. Shutdown lamp lights. MESSAGE: FAIL TO CRANK 221 - SHUTDOWN

lndicates possible fault with control or starting system. Check for the following conditions:

Shutdown lamp lights. Engine stops cranking. MESSAGE: OVERCRANK 222 - SHUTDOWN

lndícates possible fuel system problem.

Engine runs and then shuts down. Shutdown lamp lights. MESSAGE: OVERSPEED 223 - SHUTDOWN

a. Check coolant level in both radiator and coolant recovery bottle and replenish if low. Look for possible coolant leakage points and repair if necessary. b. lf radiator level is low and coolant bottle level is correct, defective coolant bottle hose or radiator cap. c. Reset control and restart after locating and correcting problem. LOW COOLANT LVL Shutdown will not occur if genset is in ldle mode (low coolant warning only).

a. Restart and check RPM on the digital display.

a. Check fuse F3 on the Engine Interface board. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. _ c. Discharged or detective battery. Recharge or replace the battery.

a. Check for ernpty fuel tank, fuel leaks, or plugged fuel lines and correctas required. b. Check for dirty fuel filter and replace if necessary. c. Check for dirty or plugged air filter and replace if necessary. d. Reset the control and restart after correcting the problem. Ir

lndicates engine has exceeded normal operating speed. (115% ±1% of nominal).

4-7

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

LA WARNING I

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electric­ ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe ali instructions and precautions in this manual.

SYMPTOM Warning (or Shutdown) lights. MESSAGE: FAIL TO SYNCHRONIZE 224 - WARNING or FAIL TO SYNCHRONIZE 224

CORRECTIVE ACTION lamp

The generator set has not synchronized to the system bus within the allowable time trame. a. Check the governor system stability. Adjust governing and synchronizer parameters as required. b. Check far fuel system problems which can cause engine instability. Synchronizing time can be lmproved by widening the synchronizing window and reducing the acceptance time delay.

Warning lamp lights. MESSAGE: FAIL TO CLOSE 226 - SHUTDOWN

lndicates that the paralleling breaker has been given a signa! to close, but has not closed properly.

Warning lamp lights. MESSAGE: LOW OC VOLTAGE 230 - WARNING

lndicates battery voltage is below 1 O VDC.

Warning lamp lights. MESSAGE: HIGH OC VOLTAGE 231 -WARNING

lndicates battery voltage exceeds 32 VDC.

a. Verify that the charging mechanism of the paralleling breaker is functioning properly. b. Check the close signa! to the breaker. c. Verify that the auxiliary contact signals from the breaker to the PowerCommand control are operational.

a. Discharged or detective battery. Check the battery charger fuse. Recharge or replace the battery. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections . .. c. Check engine OC alternator. Replace engine OC alternator if normal battery charging_, voltage is not obtained. d. Check battery charge voltage float level if applicable (raise float leve!).

Check voltage float level on battery charger if applicable (lower float lev, el). Check englne OC altemator. Replace engine OC alternator if normal battery charging voltage is not obtained.

Warning lamp lights. MESSAGE: WEAK BATTERY 232 - WARNING

lndicates battery voltage drops below 60% of nominal for two seconds, during starting. Oischarged or detective battery. See Warning message 230, LOW OC VOLTAGE.

4-8

TABLE 4-2. WARNING AND SHUTDOWN CODES (CONT.) WARNING I Hazards present in troub/eshooting can cause equipment damage, severe personal injury or death. On/y trained and experienced service personnel with know/edge of fuels, electric­ ity, and machinery hazards shou/d perform service procedures. Read Safety Precautions page and observe ali instructions and precautions in this manual.

IA

SYMPTOM

.--)

r..

f·: ···.

\~.~~..:·

CORRECTIVE ACTION

Warning lamp lights. MESSAGE: LOW FUEL-DAY 240 - WARNING or LOW FUEL 241 - WARNING

lndícates day tank fuel supply is running low. Check fuel supply and replenísh as required.

Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 - SHUTDOWN

lndícates PCC memory error. Data corruption of critica! operating parameters.

Warning lamp lights. MESSAGE: EEPROM ERROR 251 - WARNING or 252 - WARNING

lndicates PCC memory error. Data corruption of noncritlcal operating parameters.

Shutdown lamp lights. MESSAGE: CUSTOMER FAULT 1 260-SHUTDOWN GROUND FAULT 261 - SHUTDOWN or DAYTANK 262 - SHUTDOWN or HIGH GEN TEMP 263 - SHUTDOWN

When any one of these customer defined ínputs is closed to ground, the corresponding fault message is displayed.. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown ora warning. 'As indicated by the Shutdown lamp, a shutdown response has been preselected. •· Note: Customer fault messages are editable. The message displayed for the code shown (260 thru 263) may have been edited and may not appear as shown in this table. ,·

r

4-9

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

LA WARNING I

Hazards present in troub/eshooting can cause equípment damage, severe personal injury or death. Only trained and experienced service personnel with know/edge of fuels, etectrlc­ ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe al/ instructions and precautions in this manual.

SYMPTOM

CORRECTIVE ACTION

Warning lamp lights. MESSAGE: CUSTOMER FAULT 1 260 - WARNING GROUND FAULT 261 - WARNING or DAYTANK 262 - WARNING or HIGH GEN TEMP 263 - WARNING

When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a shutdown ora warning.

Shutdown lamp lights. MESSAGE: PHASE ROTATION 270 - SHUTDOWN

The phase relationship between the generator set and the system bus is not matched.

Shutdown lamp lights. MESSAGE: FIRST START 272 - WARNING

The PowerCommand control is not receiving a proper signal from the system master first start sensor. When this oocurs, the control reverts to a fallback mode in which breaker closure is automatically allowed if bus is deenergized. lf bus voltage is sensed, the control will force the generator set to synchronize to the system bus befare breaker clase signal is initiated.

Shutdown lamp lights. MESSAGE: HIGH AC VOLTAGE 301 - SHUTDOWN

lndicates that one or rnore of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 1 O seconds.

Shutdown lamp lights. MESSAGE: LOW AC VOLTAGE 303 - SHUTDOWN

, lndicates that one or more of the phase voltages has dropped below 85% .. of nominal far 1 O seconds.

Shutdown lamp lights. MESSAGE: UNDER FREQUENCY 313 - SHUTDOWN

lndicates that engine speed has dropped below 90% of nominal far 1 O seconds. Note: Five seconds befare shutdown, a Load Dump signal is initiated.

As indicated by the Warning lamp, a warning response has been preselected. Note: Customer fault messages are editable. The message displayed for the code shown (260 thru 263) may have been edited and may not appear as shown in this table.

a. Using a phase rotation checker, verify that the generator set phase rotation matches the phase orientation of the system bus. b. Verify that control wiring to the bus PT module on the PowerCommand control is properly connected.

Check fuel supply, intake air supply and load.

4-10

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

IA WARNING I

Hazards present in troub/eshooting can cause equipment damage, severe personal injury or death. On/y trained and experienced service personnel with knowledge of fuels, electrlc­ ity, and machinery hazards should perform service procedures. Read Safety Precautions page and observe ali instructions and precautions in this manual.

SYMPTOM

,:\.·:._)·· :, ..... (.f:7" ,..

''',

CORRECTIVE ACTION

Warning lamp lights. MESSAGE: OVERCURRENT 320 - WARNING

lndicates that generator output current has exceeded 110% of rated for 60 seconds.

Shutdown I amp lights. MESSAGE: OVERCURRENT 321 - SHUTDOWN

lndicates that generator output current has exceeded 110% of rated, and that a PCC time/current calculation has initiated an overcurrent shutdown.

Shutdown lamp lights. MESSAGE: SHORT CIRCUIT 322 - SHUTDOWN

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

Check load and load lead connections.

Check load and load lead connections.

Check load and load lead connections.

Warning lamp lights. MESSAGE: OVERLOAD 330 - WARNING

lndicates that three-phase power output exceeds 105% of standby (or 115% of prime) rating. After five seconds, the Load Dump output is activated. Alter 60 seconds, the OVERLOAD warning is activated. Check load and load lead connections.

I

4-11

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

IA WARNING I

Hazards present in troubleshooting can cause equipment damage, severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, e/ectric­ ity, and machinery hazards shou/d perform service procedures. Read Safety Precautions page and observe al/ instructions and precautions in this manual.

SYMPTOM

CORRECTIVE ACTION

Shutdown lamp lights. MESSAGE: REVERSE POWER 335 - SHUTDOWN

lndicates that power is flowing into the generator set, rather than out from the unit. This can be caused by engine failure, or inability to carry load, or by a number of control or interconnection problems.

Shutdown lamp lights. MESSAGE: LOSS OF EXCITATION 337 - SHUTDOWN

lndicates that the alternator excitation system is improperly adjusted or has failed. Loss of Excitation failure may also be caused by operation of filters and power factor correction capacitors in the generator set loads when the kW load level on the genset is low. The capacitors in the filters and power factor correction equipment can presenta leading power factor load to the generator set, which (correctly) shuts down the generator set through the loss of excitation fault. Leading power factor loads can cause the generator set to lose control of the output voltage of the genset and can cause kVar load sharing problems. Therefore, it is necessary to protect the genset from excessive leading power factor and reverse Var conditions.

a. lf problem occurs at initial startup, verify connection of generator set CT's, by applying load to the generator set while lt is operating alone while connected to bus. b. Verify proper connection of load sharing lines. c. Verify that the generator set is operating at the correct frequency and voltage. The no-load voltage of the generator set and other generator sets should ali be the same.

a. Start the generator set in the RUN mode and check output voltage with both the control digital meter set anda calibrated meter. Calibrate voltage if necessary. Output voltage should be adjusted to the same level as ali other generator sets at no load. Make adjustments as necessary to.correct. b. Check load sha'ring lines for proper interconnections. c. See Section 6 of this manual "Servicing the Generator'', Excitar Rectifier, and exciter Rotor.

I

4-12

.... . .

:,.,

)

TABLE 4-3. PCC OIL PRESSURE

WARNING & SHUTDOWN LIMITS

L10/M11 Engine: NORM 30-50 psi (207-345 kPa), IDLE 15 psi (103 kPa) 20 psi 25 psi 8 psi 12 psi

(138 kPa) (172 kPa) (55 kPa) (83 kPa)

shutdown limit - run mode value warning limit - run mode value shutdown limit - idle mode value warning limit- idle mode value

NTA 855 Engine: NORM 35-50 psi (241-345 kPa), IDLE 15 psi (103 kPa) 25 psi 30 psi 8 psi 12 psi

(172 kPa) (207 kPa) (55 kPa) (83 kPa)

shutdown limit - run mode value warning limit - run mode value shutdown limit - idle mode value warning limtt- idle mode value

K19 Engine: NORM 50-70 psi (345-482 kPa), IDLE 20 psi (138 kPa) 35 psi 40 psi 10 psi 15 psi

(241 kPa) (276 kPa) (69 kPa) (103 kPa)

shutdown limit - run mode value warning limit - run mode value shutdown limit - idle mode value warning ürnit- idle mode value

V28 Engine: NORM 50-90 psi (345-620 kPa), IDLE 20 psi (138 kPa) 35 psi 40 psi 10 psi 15 psi

(241 kPa) (276 kPa) (69 kPa) (103 kPa)

shutdown limit - run mode value warning limit - run mode value shutdown limit - idle mode value warning ümit- idle mode value

K38 Engine: NORM 45-65 psi (310-448 kPa), IDLE 20 psi (138 kPa) 35 psi 40 psi 10 psi 15 psi

(241 kPa) (276 kPa) (69 kPa) (103 kPa)

shutdown limit - run mode value warning limit - run mode value shutdown limit - idle mode value warning llmlt- idle mode value

K50 Engine: NORM 50-70 psi (345-482 kPa), IDLE 20 psi (138 kPa) 35 psi 40 psi 10 psi 15 psi

(241 kPa) (276 kPa) (69 kPa) (103 kPa)

shutdown limif run mode value warning limit - run mode value shutdown limit - idle mode value warning lirnit- idle mode value

.. To check oil pressure or en6ine temperature during a warning, access the oil pressure or engine temperature menÍ.J prior to clearing the fault.

4-13

TROUBLESHOOTING

PROCEDURE

LED and switch locations for each circuit board and module are provided in Section 3. The control wiring and circuit board connections are shown in Section

The following tables are a guide to help you evaluate problems with the generator set. You can save time if you read through the manual ahead of time and understand the system.

9.

LA CAUTION I

Always set the Run/Off/Auto (512) switch to the Off position and the Power Onl Standby (SS) switch to the Standby position be­ fare disconnecting or connecting harness con­ nectors. Otherwise, disconnecting the harness connectors can result in voltage spikes high enough to damage the DC control circuits of the set.

To determine the appropriate troubleshooting procedure for the specific problem at hand, be sure to refer to the "lndicators" column provided in each troubleshooting table. Try to think through the problem. Go over what was done during the last service call. The problem could be as simple as a loose wire, an opened fuse or a tripped circuit breaker. (Table 4-32 describes the location and function of each fuse.)

LA CAUTION I

E/ectrostatic discharge wi/1 damage circuit boards. Always wear a wrist strap when handling circuit boards or socket­mounted IC's and when disconnecting or connecting harness connectors.

Figure 4-2 shows the location of the components within the control panel that are referenced in the following troubleshooting procedures. Connector,

I

4-14

S5 POWER ON/ STANDBY SWITCH

@

DISPLAYBOARD A35 @

ANALOG BOARD A33

AUN/OFF/AUTO SWITCH 812 BUS PT MODULE A39

OPTIONAL THERMISTOR RELAY 160°/140° C

GOVERNOR OUTPUT MODULE A38 OPTIONAL COMMON ALARM RELAY K14

PT/CT BOARD A36

:, 'y--~~~', •.

OPTIONAL RTD RELAY

t

J

ACCESSORY BOX

------..

I

1 1

\

lg_

FIGURE 4-2. CIRCUIT BOARD LOCATIONS

4-15

VOLTAGE REGULATOR OUTPUT MODULE A37

TABLE 4-4. ENGINE DOES NOT CRANK-LOCAL OR REMOTE AUN

I

Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and ma­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s)

Possible Cause

Corrective Action

"FAIL TO CRANK" (221) message

1. lnsufficient battery voltage. Check the following conditions: a. Batteríes not charged. b. Battery connections loose or dirty. c. lnsufficient battery charging voltage. d. Engine DC alternator could be bad.

1 a. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80º F (27º C). 1 b. Clean and tighten or replace the battery cable connectors and cables at the battery and the set. 1 c. Adjust charge rate of battery charging circuit. 1 d. Replace engine DC alternator if normal battery charging voltage is not obtained.

Reset and attempt to start: Start LEO DS11 on the engine interface board turns on. NOTE: These two indications suggest that the PCC has received a start signal and has sent a start command to the start output (J4-2) on the engine interface board.

2. Starter could be bad.

2. Reset the control. Attempt to start, and test for B+ at the starter. lf there is B+ at the starter, the starter could be bad. Test starter (see engine service manual). Replace the starter.

3. lf there is no B+ at the starter, start solenoid K4 could be bad.

3. Reset the control. Attempt to start, and test for B+ into and out of start solenoid contacts. lf there is B+ in, but not out, check for B+ at the start solenoid coil. lf there is B+ at the coil, check ground connection. lf ground connection is good, the start solenoid is bad. Replace the start solenoid. lf there is B+ into and out of the start solenoid contacts, check for an open between the start solenoid contacts and the starter. lf there is no B+, go to the ne~t step.

4. lf there is no B+ at the start solenoid coil (K4), the backup start disconnect contacts in the regulator output module (A37) could be open (indicating that A37 is bad).

*4. Disconnect J7/P7 at the regulator output module. Testfor continuity at A37 J7-5/J7-6. lf there is no continuity, the regulator output module is ; bad. Replace A37.

5. lf there is contínuity at A37 J7-5/J7-6, there may be an open between A37 and A31, an open between A37 and K4, or A31 may be bad. r

*5. lf there is continuity at A37 J7-5/J7-6, reset the control, attempt to start, and check for B+ at A37 P7-5. lf there is B+ at P7-5, there may be an open between start solenoid coil (K4) and A37. lf there is no B+ at P7-5, check for B+ at J4-2 on the engine interface board (A31) while attempting to start. lf there is B+ at A31 J4-2, check for an open between A37 and A31 . lf there is no B+ at A31 J4-2, (and 0811 is on) the engine interface board is bad, Replace A31.

6. The mag pickup signal is not being sensed.

6. Refer to the mag pickup shutdown message (220}.

*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to 5tandby before connecting/disconnecting

4-16

harness plugs.

TABLE 4-5. ENGINE DOES NOT CRANK-LOCAL OR REMOTE RUN Many troub/eshootíng procedures present hazards that can result in severe personal ínju­ ry or death. Only traíned experienced service personnel with knowledge of fuels, electricity, and me­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

IAWARNING!

lndicator( s)

Possible Cause

"FAIL TO CRANK" (221) message

1. Fuse F3 on the engine interface board (A31) may be open, or B+ may not be getting to F3.

*1. lnstall harness tool between A31 J4/P4. Reset the control. Attempt to start and check for B+ at J4-2. lf no B+, remove F3 and check continuity. lf open, replace the fuse with one of the same type and amp rating (5 Amps). lf F3 is OK, check the B+ supply from the wiring harness.

2. Emergency Stop switch S13 or the PCC door harness may be bad.

2. To isolate: • Check for B+ at S13-1 and S 13-2. lf there is B+ at S 13-2, but not at S 13-1 (and S13 is NOT in the emergency stop position), then S13 is bad. Replace S13. • lf there is no B+ at S13-2, disconnect J3/P3, and check for B+ at A31 J3-2. lf there is no B+, replace A31. • lf there is B+ at A31 J3-2, check continuity from P3-2 to P3-6. lf no continuity, repair or replace as necessary.

Corrective Action

Reset and attempt to start: Start LEO DS11 on the engine interface board does NOT turn on. NOTE: These two indications suggest that the PCC has received a start signal and has NOT sent a start command to the start output (J4-2) on the engine interface board.

3. Digital board (A32) may be bad.

*3. lnstall harness tool between A32 J4/P4. Reset the control. Attempt to start, and test for ground output at A32 J4-3. lf there is no ground output, A32 is bad. ~place A32.

4. Engine interface board (A31) may be bad.

j

*4. lf there is a ground output at A32 J4-3, and yet there is no B+ output at A31 J4-2; then A31 is bad. Replace A31.

I

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

4-17

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

I

Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and ma­ chinery hazards should perform service procedures. Review safety precautions on pages lli and iv.

!A.WARNING

lndicator(s)

Possible Cause

"FAIL TO CRANK" (221) message DOES NOT appearon digital display -and: Auto LEO 085 on the engine interface board (A31) is on RMT 8tart LEO 0814 on the customer interface board (A34) is on -

1. The Auto mode signal is not getting from engine interface board A31 to digital board A32, indicating that A31 is bad.

*1. lnstall harness tool between A32 J4/P4. Check far ground output at A32 J4-18. lf there is no ground output (but A31 085 is on) engine interface board A31 is bad. Replace A31. lf there is a ground output at A31 J1 -18, proceed to the next step.

2. The Remota run signal is not getting from customer interface board A34 to A32, indicating that A34 is bad.

*2. lnstall harness tool between A32 J4/P4. Reset the control. Attempt to remote start, and check for ground output at A32 J2-26. lf no ground output (but A34 0814 is on) customer interface board A34 is bad. Replace A34. lf there is a ground output at A32 J2-26, proceed to the next step.

3. Digital board (A32) may be bad.

*3. lf, when attempting remate start, there is a ground input at A32 J2-26, and a ground input at A32 J4-18=-and there is no "FAIL TO CRANK" message-and the set does not crank; A32 is bad. Replace, A32.

NOTE: This condition suggests that the PCC processor (digital board -A32)has NOT received or recognized a remete start start signal.

Corrective Action

I

*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to Standby before connecting/disconnecting harness plugs.

4-18

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

I

Many troubleshooting procedures present hazards that can result in severo personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and me­ chinery hazards shou/d perform servíce procedures. Review safety precautíons on pages iii and iv.

LA.WARNING

lndicator(s) "FAIL TO CRANK" (221) message DOES NOT appearon digital display -and: Auto LED 085 on the engine interface board (A31) is off RMT 8tart LED 0814 on the customer interface board (A34) is on NOTE: This condition suggests that the engine interface board (A31) is NOT enabling the remote start logic on the digital board.

Possible Cause

Corrective Action

The Auto mode input is not getting from the Auto select switch (812) to engine interface board A31 (indicating that 812, A31, or the harness is bad. 1. 812 or the wiring hamess may be bad.

*1. Disconnect A31 J3/P3. Check continuity to ground at A31 J3-11. (J3-11 is ground out to S12. lf ground is not present, replace A31. lf ground is present, place 812 in Auto and check continuity from P3-11 to P3-13. lf no continuity, isolate to switch or wiring harness. Repair as necessary. lf there is continuity, A31 may be bad. Reconnect J3/P3.

2. Engine interface board A31 may be bad.

*2. lnstall harness tool between A32 J4/P4. Check the 16 volt (nominal) supply at A32 J4-16. lf the voltage is present at A32 J4-16, and ground is present at A31 P3-13-and yet A31 DS5 is off; then A31 is bad. Replace A31.

3. Digital board A32 may be bad.

3. lf there is no + 16 volt supply voltage at A32 J4-16, A32 is bad. Replace A32.

I

*CAUTJON: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting

4-19

harness plugs.

TABLE 4-8. ENGINE DOES NOT CRANK-REMOTE RUN Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of tuets, electricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING!

lndicator(s)

Possible Cause

Corrective Action

"FA!L TO The remote start input is not getting from the CRANK" remete start switch to the output of the cus(221) tomer interface board (A34) (indicating that message the switch, A34, or the harness is bad. DOES NOT appearon digital display 1 . The remete start switch or the -and: wiring harness may be bad. Auto LED DSS on the engine interface board (A31) is on RMT Start LED DS14 on 2. Customer interface board A34 the customer may be bad. interface board (A34) is off NOTE: This condition suggests that the remote start input is NOT passing through the customer interface board (A34) to enab!e the remote start logic on the digital board.

*1. !nsta!I harness too! between A34 J1 /P1. Reset the control. Attempt remote start and check for ground at A34 J1 -13. lf ground level is not present, iso!ate to the switch or the wiring harness by checking for a start signa! at TB1-5. Repair as necessary. 2. lf ground is present at A34 J1 -13-and yet A34 DS14 is off, rep!ace A34.

;

i

I

..

*CAUTION: Wearing wrist strap, set 812 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-20

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

I

Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!A.WARNING

lndicator(s) "FAIL TO CRANK" (221) message DOES NOT appearon digital display -and: Run LEO 084 on the engine interface board (A31) is off-

7\ ({j

NOTE: This condition suggests that the start input is NOT getting from the Run/Off/ Auto switch (812) to the engine interface board (A31) to enable the remate start logic on the digital board.

Possible Cause

Corrective Action

The start input is not getting from the Run/ Off/ Auto select switch (812) to A31 (indicating that 812, A31, or the harness is bad. 1 . Run/Off/ Auto select switch 812 or the wiring harness may be bad.

*1. Check continuity to ground at A31 J3-11. lf ground is not present, replace A31. lf ground is present, place 812 in Run and check continuity from P3-11 to P3-12. lf no continuity, isolate to switch or wiring harness. Repair as necessary. lf there is continuity, A31 may be bad.

2. Engine interface board A31 may be bad.

*2. Instan harness tool between A32 J4/P4. Check the 16 volt (nominal) supply at A32 J4-16. lf the voltage is present at A32 J4-16, and ground is present at A31 J3-12-and yet A31 085 is off, replace A31.

3. lf there is no + 16 volt supply voltage at A32 J4-16, replace A32.

3. Digital board A32 may be bad.

; i

•'

¡

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

4-21

TABLE 4-10. ENGINE CRANKS BUT DOES NOT START

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and machinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!A.WARNING

lndicator(s)

Possible Cause

Corrective Action

"OVERCRANK" Fuel supply or fuel delivery. (222) 1 . Restricted fuel supply due to: message a. Fuel level below pickup tube in tank. -and b. Closed shutoff valve in supply line. While cranking, c. Fuel injectors clogged. Run LED DS12 d. Air in fuel system. on the engine interface board (A31) 2. The mechanical fuel linkage could be is on. binding, loase, or damaged. and While cranking, Run LED DS2 onthe governor output module (A38) is on. NOTE: These indications suggest that the PCC has sent a run signal to the fuel solenoid.

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

2. lnspect the mechanical fuel linkage, and repair or replace as necessary. Follow the procedure in the engine repair manual to check the EFC for binding or damage. Disconnect the actuator connector, and connect + 12 VDC from the battery to the actuator. The actuator should click upon application and removal of the voltage. lf the actuator does not click, refer to the engine manual. lf the actuator clicks, reconnect the wires to the actuator.

3. Fuel solenoid (K1) on the injection pump not energizad due to: a. Open in fuel sólenoid circuit or detective governor module. b. Detective fuel solenoid.

3a. Reset the control. Attempt to start and check for B+ at the K1 fuel solenoid coil on the injection pump and at output of governor module. Check , continuity from J6-20 and 21 to J6-19. 1 3b. Check wiring continuity of fuel solenoid circuit. Test fuel solenoid. Repair or replace as necessary.

4. Fuel tank solenoid not' energizad due to: a. Open in fuel tank solenoid circuit. b. Detective fuel tank solenoid.

4a. Check wiring continuity of fuel tank solenoid oírcuit. 4b. Test fuel tank solenoid. Repair or replace as necessary.

5. Engine fuel injection or other engine problem.

5. Refer to the engine service manual.

*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnecting

4-22

harness plugs.

TABLE 4-11.

ENGINE CRANKS BUT DOES NOT START

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity,and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s)

Possible Cause

Corrective Action

"OVERCRANK" The run signal is not getting through the governor module to the fuel solenoid. (222) message 1. The run signal is not getting out of the -and engine interface board (A31 ). A31 may be bad. While cranking, Run LEO 0812 2. There is an open between the engine on the interface board (A31) and the goverengine interface nor output module (A38). board (A31) is on. and While cranking, Run LEO 082 on the governor output module (A38) is off.

Reset the control. Attempt to start and check for B+ at A31 J4-1. *1. lnstall harness tool between A31 J4/P4. Reset the control. Attempt to start and check far B+ at A31 J4-1. lf there is no B+ at A31 J4-1, replace A31. *2. lf there is B+ at A31 J4-1, install harness tool between A38 J6/P6. Check far B+ at A38 JG-19, while attempting to crank. lf there is no B+ at A38 J6-19, isolate to connectors and wiring. Repair or replace as necessary.

3. The run signal is not getting through the governor output module (A38). A38 may be bad.

NOTE: These indications suggest that the PCC has sent a run signal to the governor module, but the signal is not getting through the governor module to the fuel solenoid.

3. lf there is B+ at A31 J4-1, and there is B+ at A38 JG-19, check continuity from A38 J6-15 to battery ground, if not continuity replace harness, if continuity, replace A38.

;

;

I

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

4-23

TABLE 4-12. ENGINE CRANKS BUT DOES NOT START

I

Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

Corrective Action

"OVERCRANK" The run signal from the digital board (A32) is not being processed by the engine lnter(222) tace board (A31). message

*lnstall harness tool between A32 J4/P4. Attempt to start and check for ground signal at A32 J4-8.

-and Run LEO DS12 the engine interface board (A31) is off.

Oíl

NOTE: These indications suggest that the PCC has NOT sent a run signal(fuel solenoid enable signal) out to the governor module and the fuel solenoid.

1 . The run signal is not getting out of the digital board (A32). A32 may be bad.

1 . lf there is no ground signal at A32 J4-8, replace A32.

2. The run signal is not being processed by the engine interface board (A31 ). A31 may be bad.

2. lf there is a ground signal at A32 J4-8, replace A31.

i

"FAIL TO CRANK" (221) message

The mag pickup signa! is not being sensed.

Refer to the mag pickup shutdown message (220).

,. I

NOTE: The engine is cranking but shutting down on a 221 fault.

,.

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

4-24

TABLE 4-13. LOW OIL PRESSURE WARNING (200) OR SHUTDOWN (201) Many troub/eshooting procedures present hazardsthat can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

1AWARNINGl

lndicator(s)

Possible Cause

"LOWOIL PRESSURE" warning (200) or shutdown (201) message.

1. Low oíl level. Clogged lines ar fílters.

1. Check oíl level, lines and filters. lf oil system is OK but oil level is low, replenish. Oil pressure limits are lísted in Table 4­3.

2a. Sender or oíl pump could be bad. Or the generator set may be shuttíng down on another fault.

2. Disconnect the ali pressure sender leads, and connect an oil pressure sender símulator to the harness. a. lf the control responds to the símulator, reconnect the sender, disconnect the run sígnal wíre at the fuel solenoid, and crank the engine. Check the oíl pressure reading on the digital display. • lf the display shows an acceptable oíl pressure, the problem may not be in the oil or oil sensing system. The generator set may be shuttíng down on another fault (out of fuel, blown governor fuse, intermíttent connector). Restart the generator set and monitor the PCC display panel for other faults. • lf the display does not show an acceptable oíl pressure, replace the sender. lf the PCC sti(( doesn't display an oíl pressure while crankíng, the oil pump may be faulty. Refer to tlie engine servíce manual.

Corrective Action

2b. Harness or PCC circuit board could be bad. *b. lf the control does not respond to the simulator, lsolate to the harness, engine inter- / the PCC or the harness is bad. lnstall harness tace board (A31), analog board (A33), tool between A31 J2/P2. or digital board (A32). Check far +5 VDC at the sender (lead marked E1-B}. lf there is no 5 VDC at the sender • Check for 5 VDC at A31 J5-18. • lf yes, harness is bad. lf no, check far 5 I VDC at A31 J2-24. • lf yes, A31 is bad. lf no, A33 is bad. lf there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. lf the pressure signa! (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness ar A31. lf the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshootíng procedure (Table 4­35alb).

*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to 5tandby before connecting/disconnecting harness plugs.

4-25

TABLE 4-14. SENDER WARNING$ (204 or 213)

I Many troub/eshooting procedures present hazards that can result in severe personal lnju­ ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

"OIL PRESSURE SENDER" warning (204) message.

1. The sender connections could be bad.

"COOLANT SENDER" warning (213) message.

Corrective Action

2. The sender, the harness, engine interface board (A31 ), digital board (A32), or analog board (A33) could be faulty.

1 . The sender connections could be bad.

1 . Check the sender connections.

*2. lsolate to the sender, harness, engine interface board (A31 ), analog board (A33), or digital board (A32). Disconnect the oíl pressure sender leads, and connect an oíl pressure sender simulator to the harness. "OIL PRES SENDER" warning is displayed after the fault condition is sensed for 1 O seconds. a. lf the control responds to the simulator, replace the sender. *b. lf the control does not respond to the simulator, the PCC or the harness is bad. lnstall harness tool between A31 J2/P2. Check for +5 VDC at the sender (lead marked E1-B). lf there is no 5 VDC at the sender • Check for 5 VDC at A31 JS-18. • lf yes, harness is bad. lf no, check for 5 VDC at A31 J2-24. • lf yes, A31 is bad. lf no, A33 is bad. lf there is 5 VDC at the sender, use the sender simulator to generate a signal to A31 J2-23. lf the pressure signal (.5 to 4.5 VDC) does not get to A31 J2-23, isolate to the harness or A31. lf the pressure signal does get to A31 J2-23, refer to the analog/digital troubleshooting procedure (Table4­35a/b).

1. Check the sender connections.

¡

2. The sender, the harness, engine interface board (A31 ), digital board (A32), or analog board (A33) could be faulty.

*2. lsolate to the sender, harness, engine interface board (A31 ), analog board (A33), or digital board (A32). Disconnect the sender, and plug in a resistive sender simulator to isolate the fault. a. lf the control responds to the simulator, replace the sender. b. lf the control does not respond to the simulator, refer to the high coolant temp troubleshooting procedure.

*CAUTION: Wearing wrist strap, set 512 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-26

TABLE 4-15. LOW ENGINE TEMPERATURE

WARNING (21 O)

Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING!

lndicator(s) "LOW COOLANT TEMP" warning (210} message.

Possible Cause

Corrective Action

DS3 / A31 is on, índícating that engine interface board A31 is receiving a low coolant temp from the sender. The sender, the harness or A31 could be bad.

lsolate the source of the signa!. Unplug the coolant temperature switch (S1) and reset the control. 1 . lf the 21 O warning message drops out and does not reappear, replace the sender. *2. lf the 21 o warning message reappears and remains after control reset, disconnect A31 J4 and check continuity from P4-13 to G N D. • lf there is continuity, replace the harness. • lf there is no continuity, replace circuit board A31.

DS3 / A31 is off, indicating that engine interface board A31 is not receiving a low engine temp signa! from the sender-but the 21 O message indicates that A32, the digital board, is responding to a false low engine temp signa!. A31, the engine interface board, or A32, the digital board, could be bad.

lsolate the source of the signal. Check J4-6/P4-6 on A32. *1. lnstall harness'tool between A32 J4/P4. 2. Open J4-6 and reset the control. • lf fault drops out and does not return, replace A31. • lf fault returns after resetting the control, replace A32.

Coolant level is normal. Heater is OK. Coolant temp on f ront panel display is OK.

/.7',,.

DS3 on the engine interface board, A31, is on.

{L.J)

"LOW COOLANT TEMP" warning (210) message. Coolant level is normal. Heater is OK. Coolant temp on front panel display is OK.

,-

DS3 on the engine interface board, A31, is off.

*CAUTION: Wearina wrist strao. set 812 to Off and A32 85 to 8tandbv before connectinci/disconnectina harness oluas.

4-27

TABLE 4-16. HIGH ENGINE TEMPERATURE

WARNING (211) OR SHUTDOWN (212)

I

Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fue/s, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

"HIGH COOLANT TEMP" warning (211) or shutdown (212) message.

1. Engine problem: • Coolant pump could be faulty. • Thermostat could be faulty. • There could be an obstruction in the coolant flow. • Externa! coolant pump (with remate radiator) could be faulty. • Externa! radiator tan motor (with remote radiator) could be faulty. 2. The generator set may have been overloaded. 3. Sender, harness or PCC circuit board could be bad.

Coolant mixture and level is normal. No airflow obstructions.

Corrective Action

Fan belt is OK.

I

1. Refer to the engine service manual if there are any physical indications of overheating. 2. Correct any overload condition. 3. lf there are no physical indications of overheating, check to see if the PCC accurately displays ambient engine temperature. • lf the PCC ambient coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. • lf the PCC ambient coolant temperature reading is not accurate, isolate to the sender, harness, engine interface board (A31 ), analog board, or digital board. Disconnect the coolant temperature sender leads, and connect a coolant temperature sender simulator to the harness. a. lf the control responds to the simulator, replace the sender. *b. lf the control does not respond to the sírnulator, install harness tool between A31 J5/P5. Connect the coolant temperature sender simulator (and B+) to A31 J5. • lf the control displays the correct simulated temperature, replace the harness. • lf the control does not display the correct simulated temperature, install harness tool at A31 J2/P2, and open lines 18/19 (and 14/15, if applicable). Check for continuity between A31 J2-18 to 19 (far coolant temp L), and A31 J2-14 to 15 (far coolant temp R). • lf no continuity, then A31 is bad. • lf continuity is OK, then send a simulated temperature signal and measure the voltage out of A3i (A31 J2-18 to 19, and A31 J2-14 to 15). lf voltage is not OK (refer to the analog board inputs and outputs, Table 4­36), replace A33. lf voltage is OK, refer to the analog/ digital troubleshooting procedure (Table 4­35a/b).

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

4-28

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

I Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s) "LOW COOLANT LVL" warning (214) or shutdown (215) message

Possible Cause

Corrective Action

DS2 on A31 is on, indicating that A31 is receiving a low coolant signa! from the sender. The sender, the harness or the A31 circuit board could be bad.

Coolant level is normal. DS2 on the engine interiace board, A31, is on.

lf the coolant leve! is normal, isolate the source of the low coolant signal. (This is a ground signal.) Disconnect the signa! lead at the sender and reset the control. 1. lf the 215 shutdown message drops out and does not reappear, replace the sender. *2. lf the 215 shutdown message reappears and remains after control reset, disconnect J4/A31 and check continuity from P4-7 to GND. • lf there is continuity, replace the harness. • lf there is no continuity, replace circuit board A31.

(r) 1------+------+-----------, "LOW COOLANT LVL" warning (214) or shutdown (215) message Coolant level is normal. DS2 on the engine interface board, A31, is off.

DS2 on A31 is off, indicating that A31 is not receiving a low coolant signal from the sender-but the 215 message indicates that A32, the digital board, is responding to a false low coolant signar. A31, the engine interface board, or A32, the digital board, could be bad.

lf the coolant leve! is normal, isolate the source of the low coolant signal. Check J4-4/P4-4 en A32. *1. lnstall harness tool between A32 J4/P4. 2. Open the J4-4 circuit and reset the control. • lf the fault drops out and does not return, replace A31. • lf the fault returns after resetting the control, replace A32.

r

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

4-29

harness plugs.

TABLE 4-18. MAG PICKUP SHUTDOWN (220)

I Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LAWARNING

lndicator(s) "MAG PICKUP" shutdown message (220)

Possible Cause

Corrective Action

This indicates that the PCC is not sensing the mag pickup signa!, or the mag pickup frequency does not correspond (in proportion) to the genset output frequency. 1. The PCC may not be set for the correct generator set. 2. Loose or damaged mag pickup wire.

3. Damaged mag pickup (MPU).

4. The harness, the engine interface board (A31 ), the analog board (A33) or the digital board (A32) could be bad.

,·

r ,.

1. Check and correct setting if necessary.

2. lnspect the wires, and repair or replace as necessary.

*3/4 To isolate the problem, reset the control and attempt to start the set in idle mode. a. lf the engine displays a "FAIL TO CRANK" shutdown message, or if the engine starts and idles, but then shuts down on a MAG PICKUP fault, the MPU sender could be bad. Remove the MPU connectors and check for 3.5 to 15 VAC at the MPU while cranking. • lf no output, check for damage or debris . Also check for improper adjustment of the MPU. (Refer to Section 5.) lf there is still no output, replace the MPU sender. • lf the MPU output is OK, install harness tool between A32 J4/P4. Check for MPU voltage atA32 J4-10 to 11, while cranking. lf OK, replace A32. lf not OK, use continuity checks to isolate to A31 or harness. b. lf the engine starts and idles, and does not dis; j play a fault, then there could be a frequency mismatch problem. • Measure generator output frequency with a digital multimeter and compare to the frequency on the PCC display. • lf they do match, multiply the frequency by 30 and compare this number to the RPM on the PCC display. lf these are not the same, the MPU sender may be bad. Replace the MPU sender • lf the multimeter and PCC frequencies do not match, there is a frequency sensing problem. Verify the accuracy of the PCC L1 N voltage, and then refer to the analog/ digital troubleshooting procedure (Table 4­35a/b).

~cAUTION: Wearing wrist strap, set 812 to Off and A32 SS to Standby befare connecting/disconnecting harness plugs.

4-30

TABLE 4-19. OVERSPEED SHUTDOWN {223)

I Many troub/eshooting procedures present hazards that can result in severe personal iniu­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

Corrective Action

"OVERSPEED" shutdown message (223)

1 . The mechanical fuel linkage could be binding, loose, or damaged.

1. lnspect the mechanical fuel linkage, and repair or replace as necessary. • Follow the procedure in the engine repair manual to check the EFC for binding or damage. • Disconnect the actuator connector, and connect +12 VDC from the battery to the actuator. The actuator should click upon application and removal of the voltage. lf the actuator does not click, refer to the engine manual. lf the actuator clicks, reconnect the wires to the actuator.

2. The governor output module (A38) or the digital board (A32) could be bad.

*2. Reset the control, and start the set while monitoring the PCC duty cycle display. • lf the duty cycle goes high (above 40%) and the set shuts down on overspeed, replace A32. • lf the duty cycle goes to zero and the set shuts down on overspeed, replace A38.

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*CAUTION: Wearing wrist strap, set 812 to Off and A32 SS to Standby before connecting/disconnecting harness plugs.

4-31

TABLE 4-20a. FAIL TO SYNCHRONIZE

(224)

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Onty trained experienced service personnel with knowledge of fuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!A.WARNING

lndicator(s)

Possible Cause

"FAIL TO SYNCHRONIZE" warning (224) or shutdown (224) message.

1. lmproper adjustment of bus or genera- . tor set voltage.

1. Verify that the bus voltage is within plus or minus 5% of the value which is programmed into the PowerCommand control, and verify that the generator set is operating at proper voltage and frequency. Verify that the bus PT module is properly calibrated. (Refer to Digital Bus Volt­ age Calibration in Section 5). Check the FAIL TO SYNCHRONIZE time delay. lt should be set far approximately 120 seconds. Check paralleling setup adjustments, particularly PERM WIN PHASE and PERM WIN - TIME. They are typically adjusted to 20 degrees and 0.5 seconds.

2. Generator set hunting due to improper synchronizing adjustments.

2. Check synchronizer adjustments in the PowerCommand control set-up. lf you are unsure of proper adjustment procedure, returning the unit to it's default values should result in proper operation. The default values are shown in the test report which is shipped with the generator set. In particular, check values far paraüelínq functions, governing and voltage regulation.

Corrective Action

3. Unstable or hunting generator set due to governor component failure or misadjustment.

..

3. lnspect generator set governing system for evidence of binding or sticking linkages or other ; components which are not operating correctly. ; Verify that water jacket heaters are operational and properly functioning. Check and adjust governor settings as required .

I

Continued On Next Piige••.

*CAUTION: Wearing wrist strap, set 812 to Off and A32 85 to 8tandby before connecting/disconnecting harness plugs.

4-32

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

I

Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and me­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

"FAIL TO SYNCHRONIZE" warning (224) or shutdown (224) message.

4. Unstable or hunting generator set due to air entrained in the fuel system.

Corrective Action 4. This problem is indicated in situations where the generator set performs properly after the generator set is up and running with load, but experiences "FAIL TO SYNCHRONIZE" alarms after it has been shut down for severa! days. Check the generator set fuel system for leaks or cracks. lf fuel filters have recently been changed, air may be trapped in the fuel filter heads. Check to be sure that there is a f uel head on the engine fuel pump. Check fuel line routing for overhead loops which could result in the trapping of air in the system if the system sits idle for sorne period of time. Parallel systems should use option C174, the fuel pump feature option. This feature is available as an aftermarket accessory kit. Note: The generator set will synchronize faster as the synchronize acceptance window is widened (i.e., the value in the PERM WIN-PHASE is increased) and as the acceptance time is minimized (the value in the PERM WIN-TIME is minimized). Caution should be taken in utility (mains) paralleling applications to avoid damage to the generator set by inappropriate setting of these parameters.

I

*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnectinQ harness pluQs.

4-33

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

I Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of tuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iil and iv.

LAWARNING

lndicator(s) "FAIL TO CLOSE" warning (226) or shutdown (226) message.

Possible Cause

Corrective Action

1 . Check the paralleling breaker for lndication that the breaker is tripped and locked out from a signa! issued from it's interna! trip unit

1. lf the breaker has tripped due to operation of it's interna! trip unit, the alternator and electrical distribution system connected to the alternator should be carefully inspected for evidence of burning or tracking, which might indicate that an electrical fault has occurred. lf no evidence of a fault is found, reset the trip unit and verify that the trip settings of the breaker are appropriate for the application. Reset the fault on the PowerCommand control and check the system operation to verify that the failure to close fault problem has been eliminated.

2. Breaker charge circuit is not operating properly. (Power circuit breakers only.)

2. Check the circuit breaker status indicators and verify that the breaker status indicates that the breaker is properly charged. lf it is, go on to step 3. lf it is not charged, check the charge circuit for proper operation. Switch the PowerCommand control RUN/OFF/AUTO switch to OFF and then manually recharge the paralleling breaker according to the manufacturer's instructions. Switch the PowerCommand control RUN/OFF/ AUTO switch back to RUN. The generator set should start and accelerate to rated speed and voltage and the operator should be able to manually control the circuit breaker from the pushbuttons on the front panel of the PowerCommand control. In most cases the breaker should automatically recharge on closing to the ; system bus. lf this does not occur, problem may j be in the control wiring to the breaker, or the control power source.

Continued On Next Page ...

..

NOTE: Sorne breakers are notable to be set up to charge on closing (they will recharge on opening). lf this is the case with your installation, it is critica! that the generator set be allowed to operate for a cooldown period which is long enough for the breaker to completely charge befare the generator set is shut down. lf the generator set is shut down on a fault condition, the breaker may require manual recharge before the system can be put back into automatic operation.

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*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnectina

4-34

harness olugs.

TABLE 4-21 b. FAIL TO CLOSE {226)

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iil and iv.

!.AWARNING

lndicator(s)

Possible Cause

Corrective Action

"FAIL TO CLOSE" warning (226) or shutdown (226) message.

3. Breaker close signal has been issued from the PowerCommand control, but has not reached the breaker.

4. Breaker status (open/close) signals are not properly connected to the PowerCommand control, orare not operating properly.

3. Disconnect breaker control wiring and verify that the control is sending a close signa! to the breaker. lf the breaker signal is present at the generator set control, reconnect the control wiring at the set, verify that it is present at the breaker terminals. Note that in Onan paralleling systems, DC power for operation of the relay comes from the generator control. Verify that the 20 amp customer B+ fuse (F1 - engine harness assembly) is OK and that the pilot relay operates properly.

4. Verify that the breaker auxiliary contact wiring is properly connected to the generator set. Verify that the breaker is sending proper condition signals to the generator set, by disconnecting the control wiring at the breaker and verifying that the breaker auxiliary contacts changa state when breaker condition changes. lf they are functioning properly, verify that the signals are reaching the generator set by reconnecting the wiring and the breaker and checking for condition change at the generator set control accessory box. -

i

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

4-35

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

I

Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and machinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s) "LOWOC VOLTAGE" (230) or "WEAK BATTERY" (232), warning message.

"HIGH OC VOLTAGE" (231) warning message. But battery voltage is OK.

Possible Cause

Corrective Action

1. Weak or discharged battery.

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

2. Low electrolyte level in battery.

2. Replenish electrolyte and recharge battery.

3. Battery connections loose or dirty.

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

4. lnsufficient battery charging voltage.

4. Adjust charge rate of battery charging circuit, according to manufacturers instructions.

5. Engine OC alternator could be bad.

5. Replace engine oc alternator if normal battery charging voltage is not obtained.

6. lf the batteries are OK, the problem may be the harness, the engine ínterface board (A31 ), the digital board (A32), or the analog board (A33).

*6. lf the battery voltage, electrolyte, and connections are OK, check the battery voltage at A31 J5-17. lf the voltage is not OK (same as battery voltage), disconnect J5 and isolate to the harness or A31. lf the voltage is OK, check battery voltage at A33 J1-31. lf the voltage is not OK, replace A31. lf the voltage at A33 J1-31 is OK, isolate to A33 or A32 using the analog input troubleshooting procesure (Table 4­35a/b).

1. Excessive battery charqínq voltage. ;

2. Engien OC alternator could be bad.

3. lf the battery voltage is OK, the problem may be the en,gine interface board (A31 ), the digital .board (A32), or the analog board (A33).

j

1. Adjust charge rate of battery charging circuit according to manufacturers instructions. 2. Replace engine OC alternator if normal battery charging voltage is not obtained. *3. Check the battery voltage at A31 J5-17. lf the voltage is not OK (same as battery voltage), disconnect JS and isolate to the harness or A31. lf the voltage is OK, check battery voltage at A33 J1-31. lf the voltage is not OK, replace A31. lf the voltage at A33 J1 -31 is OK, isolate to A33 or A32 using the analog input troubleshooting procedure (Table 4­35a/b).

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

4-36

harness plugs.

.)

TABLE 4-23. LOW FUEL -DAY WARNING (240) Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages ;;; and iv.

!Ji.WARNING!

lndicator(s)

Possible Cause

Corrective Action

"LOW FUEL081 on A31 is on, indicating that A31 is reOAY" ceiving a low fuel signa! from the sender. warning The sender, the harness or the A31 circuit message (240) board could be bad.

lf the fuel leve! is normal, isolate the source of the low fuel signa!. Disconnect the signal lead at the sender and reset the control. 1. lf the 240 message drops out and does not reappear, replace the sender. *2. lf the 240 message reappears and remains atter control reset, disconnect J4/A31 and check continuity from P4-14 to GND. • lf there is continuity, replace the harness. • lf there is no continuity, replace circuit board A31.

Fuel leve! is normal. 081 on the engine interface board, A31, is on. "LOW FUELDAY" warning message (240) Fuel leve! is normal.

081 on A31 is off, indicating that the PCC is not receiving a low fuel signa! from the sender-but the 240 message indicates that A32, the digital board, is responding to a false low fuel signa!. A31, the engine interface board, or A32, the digital board, could be bad.

081 (A31) and 0813 (A34) are off.

;

lf the fuel leve! is normal, isolate the source of the low fuel signa!. *1. lnstall a breakout connector at A32 J4. 2. Open the J4-15 circuit and reset the control. • lf the fault drops out and does not return, replace A31 . • lf the fault returns after resetting the control, go to step 3. 3. lnstall harness tool between A32 J2/P2. 4. Opern the J2-19 circuit and reset the control. • lf the faulf drops out and does not return, replace A31. • lf the fault returns after resetting the control, replace A32.

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*CAUTION: Wearinq wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnectinq harness pluqs.

4-37

TABLE 4-24. LOW FUEL WARNING (241) Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel wíth know/edge of fuels, electricity,and ma­ chínery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!.A.WARNING!

lndicator(s)

Possible Cause

Corrective Action

"LOW FUEL" DS13 on A34 is on, indicating that A34 is rewarning ceiving a low fuel signa! from the customer message (241) circuit. lf there is no actual fault, the problem may Fuel level is be a short to ground in the externa! wiring or normal. abad customer interface board (A34}.

lf the fuel level is normal, isolate the source of the low fuel signal. Disconnect the signal lead near the control and reset the control. 1 . lf the 241 message drops out and does not reappear, there is a short to ground in the externa! wiring ora faulty sender. *2. lf the 241 message reappears and remains after control reset, disconnect J1/A34 and check continuity from P1-5 to GND. • lf there is continuity, find and repair a short to ground in the externa! wiring. • lf there is no continuity, replace circuit

DS13 on the customer interface board, A34, is Oíl.

i--,...,,, rrl

"LOW FUEL" warning message (241 ) Fuel level is normal. DS13 (A34) is off.

DS13 on A34 is off, indicating that the PCC is not receiving a low fuel signal from the sender-but the 241 message indicates that A32, the digital board, is responding to a false low f uel signal. A34, the customer interface board, or A32, the digital board, could be bad.

/\ ".l A

lf the fuel level is normal, isolate the source of the low fuel signal. *1 . lnstall harness tool between A32 J2/P2. 2. Open the J2-19 circuit and reset the control. • lf the fault drops out and does not return, replace A34. • lf the fault returns after resetting the control, replace A32.

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*CAUTION: Wearing wrist strap, set 812 to Off and A32 SS to Standby before connecting/disconnecting harness plugs.

4-38

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

I Many troub/eshooting procedures present hazards that can result in severe personal lnju­ ry or death. Only trained experienced service personnel with know/edge of fuels, electricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages ;;; and iv.

LA.WARNING

lndicator(s)

Possible Cause

Corrective Action

"EEPROM ERROR" shutdown (250) message.

The EE memory on the digital board (A32) may be bad.

1. Perform the initial start setup procedure. Turn the Run/Off/Auto switch to Off and reset the control. Simultaneously press the RESET, MENU, and PHASE SELECT keys to start the setup. Select the correct values, save your choices, and attempt to start the set. 2. lf the set shuts down on the same EEPROM ERROR message, replace the digital board (A32).

"EEPROM ERROR" warning (251) message.

The EE memory on the digital board (A32) may be bad.

1. Perform the adjustment procedures (described in Sectíon 5). Save the adjustments. Reset the control. Shut off and restart the set. 2. lf the control generates the same EEPROM ERROR message, perform the calibration procedures in Section 5. Reset the control. Shut off and restart the set. 3. lf the control generates the same EEPROM ERROR rnessaqe, replace the digital board (A32).

;

"EEPROM ERROR" warning (252) message.

The EE memory on the digital board (A32) may be bad.

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i

1. lf this message occurred during an adjustment, option selection, or calibration of the PCC, verify the values or choices selected and repeat the save operation. Reset the control. Shut off and restart the set. 2. lf the control generates the same EEPROM ERROR message, replace the digital board (A32).

*CAUTION: Wearing wrist strap, set S12 lo Off and A32 SS to Standby befare connecting/disconnecling harness plugs.

4-39

TABLE 4-26. CUSTOMER FAULTS (260, 261, 262 or 263)

I

Many troub/eshooting procedures present hazards that can result in severe personal lnju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s) "CUSTOMER FAULT (260, 261, 262 or 263) message. And corresponding LEOon customer interface board A34 is on.

"CUSTOMER FAULT (260, 261, 262 or 263) message. And corresponding LEO on customer interface board A34 is off.

Possible Cause

Corrective Action

lf the corresponding LEO on the customer interface board (A34) is on, then A34 is receiving a signa! from the customer circuit. lf there is no actual fault, the problem may be a short to ground in the externa! wiring or abad customer interface board (A34).

lsolate the source of the false signa!. Disconnect the signa! lead near the control and reset the control. 1. lf the message drops out, there is a short to ground in the externa! wiring. 2. lf the message remains, replace A34.

lf the corresponding LED on the customer lsolate the source of the false signa!. interface board (A34) is off, then A34 is not Check J2/P2 on A32. receiving a signal from the customer circuit. *1. lnstall harness tool between A32 J2/P2. The message indicates that A32, the digital 2. Open the appropriate circuit J2-3, J2-24, J2-9, board, is responding to a false signa!. or J2-15 and reset the control. A34, the customer interface board, or A32, • lf the fault does not return, replace A34. the digital board, could be bad. • lf the fault reappears, replace A32.

r

A 34 LED

A32 CONNECTOR

CUSTOMER FAULT #

FAULT CODE

DS4 DS11 DS15 DS3

J2-3 J2-24 J2-9 J2-15

1 2 3 4

260 261 262 263

¡

*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnecting

4-40

harness plugs.

.

···)·~ · .:

TABLE 4-27a. PHASE ROTATION (270)

I Many troub/eshooting procedures present hazards that can result in severe personal iniury or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s)

Possible Cause

Corrective Action

"PHASE ROTATlON" shutdown (270) message.

1. Single phase bus condition.

1. Verify that bus voltage is proper and is not single phased.

2. Generator set output power feeders are improperly connected.

2. Verify phase rotation of the generator set output relativa to the system bus. Correct wiring of power output conductors if required. The phase relationship between the generator set and the system bus can be checked by either using a phase rotation checker, or by using synchronizing lamps or two voltmeters. The procedure for using voltmeters for checking phase relationship is as follows: Energiza the system bus and start the generator set in question in the RUN mode, but do not close the paralleling breaker. Connect each voltmeter from the line to load side of a single phase of the paralleling breaker (see Figure 8-1). lf the generator set and bus have the same phase rotation, the voltmeters should rise and fall in voltage at the same time. lf they are not in phase, one will ríse while the other falls.

Continued On Next Page ...

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*CAUTION: Wearinci wrist strap, set 512 to Off and A32 SS to Standby before ccnnecting/disconnectlnq

4-41

harness pluqs,

TABLE 4-27b. PHASE ROTATION (270)

I

Many troub/eshootíng procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, electricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s)

Possible Cause

Corrective Action

"PHASE ROTATION" shutdown (270) message.

3. Wiring to bus PT module is not correct.

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3. lf power conductors are properly phased, check the phase rotation of the wiring to the generator set CT/PT module (A36) and Bus PT module (A39). This is done using voltmeters connected as shown in Figure 8-1. Energize the system bus and start the generator set being tested in the RUN mode. Operate the display screen on the PowerCommand control to show the digital synchroscope (bus frequency). Observe the voltmeter(s) and the synchronized indicator (*) on the PowerCommand screen. When the voltage of the meter(s) approaches zero, the * should be displayed. lf the * is on when the voltmeters are reading their highest value, the Bus PT module or the genset CT/PT module is incorrectly wired. lf incorrect wiring is indicated, switch off the power supply to the system bus and manually close the paralleling breaker by pushing the breaker clase switch on the front of the PowerCommand control. Check the voltage between phase L1 of the generator CT/PT module (J9-4 yellow) and phase L 1 of the Bus PT module (terminal TB1-1 on the module). lf there is voltage difference between these points, reverse the wiring between TB1-1 and TB1-3 on the Bus PT module. Retest the system to be certain that the phase relationship problem has been corrected. lf no voltage difference is sensed at the input to the CT/PT module and Bus PT module, the problem could be in the wiring between the Bus PT module and the PowerCommand control. Reverse the connections between terminals TB2-1, 2 with TB2-5, 6. Retest the system to make sure that the phase relationship problem has been corrected.

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*CAUTION: Wearing wrist strap, set 512 to Off and A32 S5 to Standby before connecting/disconnecting harness plugs.

4-42

...

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)

TABLE 4-28. FIRST START (272)

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of tuets, etectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

"FIRST START" warning (272) message.

1. Master First Start Sensor has failed.

1 . Verify that the Master First Start Sensor is properly functioning. This can be accomplished by connecting a OC voltmeter from ground to the appropriate terminal on the Master First Start Sensor··to the PowerCommand Control. The voltmeter should indicate a pulsing voltage present on the terminal.

2. lnterconnection between Master First Start Sensor and the PowerCornmand control has failed.

2. Verify that the voltage pulse is present at the PowerCommand Control (terminal TB 1-50). Check and repair any problems in the intercannection wiring between the generator set and the Master First Start Sensor.

Corrective Action

-

*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting

4-43

harness pluqs,

TABLE 4·29a. HIGH AC VOLTAGE SHUTDOWN (301) !AWARNING! Many troubleshooting procedures present hazards thatcan result in severe personal inju­

ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv. lndicator(s)

Possible Cause

"HIGH AC VOLTAGE" shutdown (301) message.

1 . The problem may be in the PCC, the alternator, or the interconnection between them.

Corrective Action

Note 1 : The PCC may indicate either a low AC Voltage or High AC Voltage shutdown due to the design of the logic in the control. You must first determine if the output voltage the control sees is low or high. !

I

Note 2: Residual voltage is normaíly 5 to 10% of nominal output voltage. For example, a genset with a 480 volt output, will have a residual voltage of 25 ío 50 VAC at normal operating speed. 2. The problem may be the regulator module (A37), the engine interface board (A31 ), or the digital board (A32).

1. Set the display on the PCC to GEN, VOLTS, L-N. a. Start the genset and observe the voltage displayed on the digital display. b. lf all phases of voltage are balanced and not zero, óut lower than normal, the alternator and the input to the PCC are OK. The problem is in the excitation circuit for the alternator. Go to step 2. c. lf one or more phases of voltage are high or the voltages are unbalanced, the PCC is not measuring al! phases of voltage and is respondinq to the low "average" of the three phases of voltage. Go to step 3.

2. With OC power to the PCC and with the set not running, check A31 OS9, the AVR duty cycle LEO. this LEO should be off. lf it si on, go to step 2d. lsolate the genset output from the load. Oisconnect A37 J1 O, and place the set in ldle mode. In ldle mode the excitation circuit is disabled. Start the set and monitor the AC output voltage with a digital multimeter. a. lf output voltage is greater than residual (5% of normal output), go to step 3. b. lf output voltage stays at O (or residual), and OS2 on A37 is off, go to step 4. c. lf output voltage stays at O (or residual), and 082 on A37 is on, look at DS9 on A31. lf DS9 on A31 is off, replace A37. d. lf OS9 on A31 is on, connect a breakout connector at A32 J4, and open J4-2. lf 089 goes out, replace A32. lf 089 stays on replace A31.

(Continued)

*CAUTION: Wearinq wrist strap, set 512 to Off and A32 S5 to Standby befare connecting/disconnecting harness pJugs.

4-44

TABLE 4-29b. HIGH AC VOL TA GE SHUTDOWN (301)

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of tuels, electricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s) "HIGH AC VOLTAGE shutdown (301) message.

II

Possible Cause

Corrective Action

3. The problem may be the PT/CT module (A36) or the interconnecting wiring to the PT/CT module. NOTE: To calculate the "expected A36 output" voltage range, do the following: Determine the ratio between the measured voltage and the expected voltage. The output (18 VAC) of the PT/CT module will also be reduced by this ratio. !

!

4. The problem may be in the customer interface board (A34} or the interconnecting wiring.

*3. Before starting the generator set, disconnect the harness connector from the PT/CT module (A36) and connect the harness tool between A36 and its harness connector. Check the output voltage at the alternator outp4t terminals and record the voltages. a. lf the volta{j"es are not balanced, go to step 5. b. lf the voltages are balanced, calculate the expected output voltage from the PT/C rnodule (see Note to the left). Measure and record the outputs from A36 J8 pins 6-5, 4-3, and 2-1. _lf the output voltage is proportional to the álternator output voltage the A36 module is OK. Go on to step 4. lf the voltages are not balanced, replace A36. *4. Disconnect the plugs in the following steps below with the set off then start the set in the idle mode, and measure voltages with a digital multimeter. a. Disconnect J3/P3 (blue} and insert the harness tool. Check the voltage into the customer interface board with the harness tool at J3 terminals 4-6, 5-13, and 7-20. Remove the harness tool and reconnect J3 and P3. These voltages should be the same values measured in step 3b. lf the voltages are balanced, continua in this step. lf the voltages are unbalanced, repair the harness between the A36 module and the A34 board. b. Disconnect J5/P5 on the customer interface board and insert the harness tool. Check the voltage out of the customer interface board at J5 terminals 24-28, 26-28, and 30-28. These voltages should be the same values measured in step 3b. lf the voltages are balanced, go to step 5. lf the voltages are unbalanced, replace the customer interface board.

(Continued)

*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby before connecting/disconnecting harness pluqs,

4-45

TABLE 4-29c. HIGH AC VOLTAGE SHUTDOWN (301) Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fue/s, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING!

lndicator(s) "HIGHAC VOLTAGE" shutdown (301) message.

Possible Cause

Corrective Action

5. The problem may be the analog board (A33). NOTE: To determine the "3-phase ave" signal voltage range for Step 3b, use the following formula:

*5. Using the harness tool, check the "3-phase ave" signal at A33 J2-18. lf the voltage is within the expected range, replace A32. lf the voltage is not within the expected range, replace A33. See Note. I

Vout 3-phase ave= V¡n (2.9+PT) ±5%

= Actual generator output voltage (phase-to-neutral) PT = PT primary (120, 240 or ~~6)

V¡n

6. The problem may be in the generator set itself. -

6. Refer to the generator servicing procedures in Section 6.

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

4-46

harness plugs.

TABLE 4-30b.

LOW AC VOLTAGE SHUTDOWN (303)

Many troub/eshooting procedures present hazards thatcan result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LAWARNING!

lndicator(s) "LOWAC VOLTAGE" shutdown (303) message.

Possible Cause

Corrective Action

5c. The problem may be the PT/CT rnodule (A36), the analog board (A33), the customer interface board (A34), or the digital board (A32).

c. lf the measured AC voltage is hígh, the control must have lost AC sensing. Check PTs (primary 1 K-2.5K ohms; secondary 140-225 ohms), sensing harness wires, generator output connectíons·, and the customer interface board for contínuify. lf tírese are OK, then check the analog and digital boards, using the analog input troubleshooting procedure ( Table 4­36a/b).

! !

-

(~i.;} .._

. . ·~

*CAUTION: Wearing wrist strap, set 512 to Off and A32 SS to Standby befare connecting/disconnecting harness pluqs.

4-48

TABLE 4-31. UNDER FREQUENCY SHUTDOWN (313)

I Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

lndicator(s) "UNDER FREQUENCY" shutdown (313) message.

Possible Cause

Corrective Action

1. lmproper setup.

1. Check lnitial Setup (set size) and correct, if necessary.

2. Overload.

2. Check_Jhe load and correct any overload, if necessa!)¡ Disconnect"the load. Reset the control and attempt to restart the generator set.

3. Fuel or air delivery problem.

3. lf the engine starts and runs, refer to the engine fuel/air delivery service procedures.

,! 4. The governor output module (A38), the digital board (A32), or the engine interface board (A31) could be bad.

(_ \'..

*4. Disconnect the wire to the fuel solenoid, reset the control, and crank the set. 082 on the governor output module A38 should light. lf the duty cycle LEO (DS1) on the governor output module (A38) slowly becomes bright, the governor output module(A38), the digital board (A32), and the engine interface board (A31) are functioning properly. lf DS1 does not light or instantly becomes bright, A31, A32 or A38 may be bad. A38 - Crank the set, and check the governor duty cycle on the PCC display. lf the duty cycle is OK (60% max), replace gov­ ernor output module (A38). lf the duty cycle is not OK, the digital board (A32) or the engine interface board (A31) may be bad. • A31 - Check for continuity: A31 J1-13 to A31 J4-19 and A31 J1-14 to A31 J4-12. lf no continuity, replace A31. • A32 - lf A31 is OK, replace A32

*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting

4-49

harness plugs.

TABLE 4-32. OVERCURRENT WARNING (320) OR SHUTDOWN (321), SHORT CIRCUIT SHUTDOWN (322), OR OVERLOAD WARNING (330)

I Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and ma­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LAWARNING

lndicator(s) "OVERCURRENT" warning (320) or shutdown (321 ), or "SHORT CIRCUIT" shutdown (322), or OVERLOAD warning (330) message.

Possible Cause

Corrective Action

1. Short or Overload.

1. Check the load and load cables. Repair if necessary.

2. lncorrect CTs or CT connections.

2. Check¡::;Ts and CT connections. Correct if necessary. Refer to Current Transfer lnstallation in Sectíon 5. 3. Disconnect the PT/CT module and check the 3-ohm resistors {J8-15 to 14, J8-22 to 23, J8-7 to 8). Replace the module if necessary.

3. The problem may be a bad PT/CT module (A36). '

..

4. The problem may be the customer interface board (A34) or connections.

*4. Check continuity from A36-through A34-to A33. · Repair the connection or replace A34 if necessary. Ref er to Section 9 for pin reference.

5. The problem may be the analog board (A33) or the digital board {A32).

5. lsolate, using the analog input troubleshooting procedure (Table 4­35a/b). Check the bad phase or phases.

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

4-50

TABLE 4-33. REVERSE POWER (335)

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

!A.WARNING

lndicator(s)

Possible Cause

"REVERSE POWER"

1. lf this shutdown condition occurs when a non-paralleled generator set is loaded, it indicates that the generator set output CT's or PT's are incorrectly installed.

1. Verify proper CT orientation, wiring and connections on the control system. Refer to Current Transformer (CT} lnstallation in Section 5. Make sure that the no load frequency matches the bus frequency. Check metering catíbratlon for both generator set and bus.

2. Verify that the generator set is operating at the correct frequency and voltage. The bus voltaqe and frequency should be the same as the no-load generator set frequency and voltage.

2. Make adjustments as required for proper operation.

3. The load sharing line connections and orientation must be correctly accomplished for proper load sharing.

3. Verify that load sharing connections are made as noted in the drawings and that there are no damaged or disconnected wires.

4. lf the alarm occurs when a large load is added or shed, dissimilar transient response of the generator sets in the system may cause the reverse power condition.

4. Apply various load steps to each generator set in the system, noting the voltage and frequency dips/surges and recovery times. The generator sets should be adjusted so that transient load performance is approximately the same in all machines in the system.

5. Reverse power alarm can also indicate that the generator set is unable to carry load properly.

5. Verify that the generator set can pick up and carry loads properly, up to the rated capacity of the machi ne. lnability to carry load can be related to engine misadjustments, component failures, or poor fuel quality. Check governing system for binding or sticking. Check fuel filters and fuel lines for cracks, leaks or dents. Check air cleaner(s) for obstructions.

shutdown (335)

message.

Corrective Action

-

..

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

4-51

TABLE 4-34. LOSS OF EXCITATION (337) Many troubleshooting procedures present hazards that can result in severe personal lnju­ ry or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING!

lndicator(s)

Possible Cause

Corrective Action

"LOSS OF EXCITATION" shutdown (337) message.

1. lmproper voltage adjustment of the generator set relative to the system bus.

1. Verify that the no load voltage of the generator set matches the bus voltage. Check generator set metering calibration for both generator set and bus readings. lf no problems are found, check t~e paralleling adjus:ments in the PowerCommand control, to see 1f they match the default settings in the generator set test report.

2. Load sharing line mis-connection or dama ge.

2. Verify load sharing line connections and condition. Make corrections as required.

3. lf condition occurs when the geherator set is lightly Joaded, Jeading power tac­ tor Joads may cause this condition.

3. Loss 9f Excitation failure may also be caused by operation of filters and power factor correction capacitors in the generator set loads when the kW load leve! on the genset is low. The capacitors in the filters and power factor correction equipment can present a leading power factor load to the generator set, which (correctly) shuts down the generator set through the loss of excitation fault. Leading power factor loads can cause the generator set to lose control of the output voltage of the genset, and can cause kVar load sharing problems, so it is necessary to protect the genset f rom excessive leading power factor and reverse var conditions.

!

-

For generator sets prior to the release of version 2.0 firmware: Check the load for devices which may apply leading power factor loads to the generator set. These include power factor correction capacitors, input filter and sorne non-linear load devices with interna! voltage waveform correction provisions. These devices may need to be disconnected from the bus until other loads are added to the system. For generator sets with version 2.0 and higher firmware: lf there is a Joss of excitation fault that cannot be explained by genset component failures or misadjustments, perform the following steps: (Continued)

*CAUTION: Wearing wrist strap, set 812 to Off and A32 S5 to Standby before connecting/disconnecting

4-52

harness plugs.

TABLE 4-34. LOSS OF EXCITATION (337) (Continued)

I Many troubleshooting procedures present hazards that can result in severe personal Inju­ ry or death. Only trained and experienced service personnel with knowledge of fuels, e/ectricity, and machinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

IAWARNING

lndicator(s)

Possible Cause

"LOSS OF EXCITATION" shutdown (337) message.

3. (continued)

Corrective Action a. Start the generator set and apply system loads in their normal operation sequence. Observe the output voltage, power factor, and % voltage regulation of the generator se.t as the loads are applied. (This may · take more than one test.) b. lf the voltage does not rise and the % voltage regulation is greater than O as the system loads are applied, extend the time delay on loss of excitation shutdown and repeat the load addition test. c. lf the increase in time delay does not resalve the shutdown condition, contact the factory far the maximum permissible setting of the loss of excitation shutdown set points. d. lf the voltage rises or the % voltage regulation value drops to O and does not rise as load is applied, investigate means to remove leading power factor loads from the genset bus.

!

!

(

4. The generator set may be incapable of carrying full reactive load due to component failures.

4. See section 6 of this manual, "Servicing the Generator, Exciter Rectifier and Exciter Rotor''. See also repair and diagnosis process for "Low AC Voltage" in this section.

5. lf transient conditions result in this alarm condition, the PowerCommand control interna! set points may need adjustment.

5. Consult factory.

*CAUTION: WearinQ wrist strap, set S12 to Off and A32 S5 to Standby before connecting/disconnecting

4-53

harness pluqs.

TABLE 4-35a. TROUBLESHOOTING

ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL BOARDS

I

Many troubleshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with knowledge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

LA.WARNING

NOTE: Perform this procedure after you have isolated the problem to either the analog board (A33) or to the digital board (A32). You must have schematics and wiring diagrams to identify the various inputs and outputs .

..

*1. Check that the input to the analog board is correct. There are a few ¡,ignals (e.g.: 3PH Ave, Une Freq, Phase Angle 1 to 3, Lead Lag) that are derived from one or more input slqnals. 1 a. To check the sensor input voltages into the analog board, connect the sender simulator and test the voltage across the + and - inputs at A33 J1 using harness tool. (This assumes that you have verified that the harness and the engine interface board is good.) • lf the input voltage to the analog board i&borrect (refer to Table 4-36), go to step 2. • lf the input voltage to the analog board is incorrect, check for 12 VDC at A32 J3-20 and 5 VDC at A32 J3-12. Do this with the analog board connected to the digital (A32). lf the 12 VDC and 5 VDC voltages are OK, replace the analog board. lf the 12 VDC añd 5 VDC voltages are not OK, disconnect A32 J3 and recheck for 12 VDC at A32 J3-20 and 5 VDC at A32 J3-12. lf the 12 VDC and 5 VDC voltages are now OK, replace the analog board. lf the 12 VDC and 5 VDC voltages are still not OK, replace the digital board. 1 b. To check the AC inputs into the analog board, drive the PT/CT inputs (voltage or current) and verify that the input is correct. • lf the input to the analog board is correct, go to step 2. • lf the input to the analog board is incorrect, disconnect the ribbon cable at A34 JS and check the voltage at A34 JS again (Customer Interface). lf the voltage is now correct, replace the analog board. lf the voltage is still not correct, the problem is not on the analog or digital boards. 2. lf the input to the analog board is correct, determine whether the signal is multiplexed (refer to Table 4-36). lf the signal is not multiplexed, go to step 2a. lf the signal is multiplexed, go to step 2b. 2a. This step is for non-multiplexed AC signals. Drive the input to the analog board with an AC source, and test the signal level out of the analog board. You must calculate what the analog output voltage should be (Table 4-36), assuming the analog board transfer function is linear. • lf the signal leve! into the digital board is correct, the problem must be on the digital board. Replace the digital board. • lf the signal leve! into the digital board is incorrect, remove the ribbon cable connector at A32 J3, and check the front panel digital display of the bad analog value. lf the display reads O, replace the analog board. lf the display reads a value other than O, replace the digital board.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 SS to Standby before connecting/disconnecting

4-54

harness plugs.

TABLE 4-35b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITAL BOARDS

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personnel with know/edge of fuels, e/ectricity, and me­ chinery hazards should perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

NOTE: Perform this procedure after you have isolated the problem to either the analog board (A33) or to the digital board (A32). You must have schematics and wiring diagrams to identify the various inputs and outputs. 2b. This step is for multiplexed signals. Is more than one rnultíplexed signa! reading bad? • No. lf the input to the analog board is correct and only one mujtiplexed signal is reading bad, replace the analog board. ·· • Yes. lf more than one multiplexed signa! reading is bad, remove the ribbon cable connector at A32 J3 and check the front panel digital display of the bad ínputs. lt should read O for ali inputs except the temperature inputs (which should read less than 32° F or less than Oº C) and power factor (which should read "NA"). lf any values read incorrectly, replacs the digital board. lf they ali read correctly, measure voltaqes on the multipJexer control lines (with A32-J3 disconnected, measure from Digital board connector J3). voltaqes should be: A32-J3-23..:. A32-J3-24: A32-J3-27: A32-J3-33: A32-J3-34:

3.0 ±0.25 2.4 ±0.25 1 .4 ±0.25 3.0 ±0.25 3.0 ±0.25

VDC VDC VDC VDC VDC

lf these control (select) line voltages are not correct, replace the digital board. lf these control (select) line voltages are correct (and the input to the analog board is correct), reconnect the ribbon cable connector (through harness tool) at A32 J3 and check the 5 VDC reference at A32 J3-12 and the 12 VDC supply at A32 J3-20. lf the 5 VDC and the 12 VDC voltages are OK, replace the analog board. lf the 5 VDC and the 12 VDC voltages are not OK, disconnect A32 J3 and check the voltages again (measured from Digital board side). lf the 5 VDC and the 12 VDC voltages are OK with A32 J3 disconnected, replace the analog board. lf the 5 VDC and the 12 VDC voltages are not OK with A32 J3 disconnected, replace the digital board.

*CAUTION: Wearing wrist strap, set S12 to Off and A32 55 to Standby before connecting/disconnecting

4-55

harness plugs.

TABLE 4-36. ANALOG CIRCUIT BOARD (A33) INPUTS AND OUTPUTS Input Name

Input Connection

Input Signal Range

L 1 (O to nominal)

J4-24 to J4-28

Oto18VAC

L2 (O to nominal)

J4-26 to J4-28

L3 (O to nominal)

J4-30 to J4-28

CT21 (O to ful! load)

J4-33 to J4-34

Output Name 1

Output Connectionf

Output Signa! Range

L10 (ACH1)

J2-4

Oto3.0VOC

Oto18VAC

L20 (ACH2)

J2-13

Oto 3.0 VDC

Oto18VAC

L30 (ACH3)

J2-1

Oto 3.0 VDC

3PH ave (ACHO)

J2-18

Oto 2.9 VDC

Une freq. (HSl.1)

J2-21

0-5V sq wave @ L 1 Hz

J2-3

Oto 1.0VDC

J2-9

O to 1.0 VDC

O to 1.65 VAC

C1 fltrd (ACH4)

.. I

CT22 (O to full load)

J4-32 to J4-34

O to 1.65 VAC

C2 fltrd (ACH5)

CT23 (O to full load)

J4-31 to J4-34

O to 1.65 VAC

C3 fltrd (ACH6)

J2-17

O to 1.0 VDC

C1 (ACH7)

J2-7

O to 1.0 VDC

C2 (ACH7)

J2-7

O to 1.0 VDC

C3 (ACH7)

J2-7

O to 1.0VDC

(1 to 0.8 pf)

Phase angle 1 (ACH7)3

J2-7

O to 1.0VDC

(1 to 0.8 pf)

Phase angla 2 (ACH7)3

J2-7

O to 1.0VDC

Phase angla 3 (ACH7)3

J2-7

O to 1.0 VDC

Lead lag (P2A.1)) 3

J2-29

!

!

(1 to 0.8 pf)

-

(L1 vsCT21)

,•

o or 5 VDC

(digital)

Bus L1 (O to nominal) 6

J4-15 to J4-18

Oto18VAC

Bus L1 (ACH7)

J2-7

Oto 3.0 VDC

Bus L2 (O to nominal) 6

J4-16 to J4-18

Oto 18 VAC

Bus L2 (ACH7)

J2-7

O to 3.0 VDC

Bus L3 (O to nominal) 6

J4-17 to J4-18

Oto18VAC

Bus L3 (ACH7)

J2-7

O to 3.0 VDC

Bus freq (HS1 .3)

J2-22

0­SV sq wave @ Bus L1 Hz

Phase rot (P2A.o)s

J2-26

O or 5 VDC (digital)

Bus/gen phase dif (ACH7)5

J2-7

o io s.o voc

Bus/gen phase (HS1 .2)5

J2-19

0-SV 120 Hz O to 100% OC

Synch (ACH7)5

J2-7

Battery voltage (ACH7)

J2-7

O to 2.9VDC

Oil press (ACH7)

J2-7

0.5 to 4.5 VDC

Battery voltage Oil press (O to 100 psi)

J1-31 (+) to J1-30(-)

O to 32 VDC

(See note 4l

0.5 to 4.5 VDC

H20 1 (6 to 230° F)

J1-19/20 to J1-17/18

700 to 1800

n

H201 (ACH7)

J2-7

1.4 to 3.7 VDC

H20 2 (6 to 230º F)

J1-15/16 to J1-14/15

700 to 1800 Q

H202 (ACH7)

J2-7

1.4 to 3.7 VDC

Oil temp (ACH7)

J2-7

1.4 to 3.7 VDC

Oil temp (6 to 230° F)

J1-11/12 to J1-9/10

100 to 1800

n

Exh temp 1 (32 to 1471° F)

J1-7/8 to J1-5/6

100 to376Q

Exh temp 1 (ACH7)

J2-7

0.8 to 3.0 VDC

Exh temp 2 (32 to 1471º F)

J1-3/4 to J1-1/2

100 to376Q

Exh temp 2 (ACH7)

J2-7

0.8 to 3.0 VDC

Notes: 1. AII output signals on ACH7 are multiplexed. 2. AII output voltages on A33 J2 are referenced to ground (J2-15 and J2-16). 3. Must have L 1, L2, L3, CT21 , CT22, and CT23 for these phase angle outputs. 4. J1-24 {SVDC), J1-23 (signal), J1-18 (retum). 5. Must have L1, L2, L3, Bus L1, Bus L2, and Bus L3 for these outputs. 6. L1, L2, and L3 can be O to 180º out of phase with Bus L 1, Bus L2, and Bus L3, respectively.

4-56

TABLE 4-37. PCC FUSES LOCATION

\

-,

RATING

FUNCTION

Engine Interface

A31-F1

5Amp

PCC control B+

Engine Interface

A31-F3

5Amp

Auxiliary B+ (for panel lights, run and start relays)

Governor Output Module

A38-F1

10Amp

Network B+ (to TB1 customer termlnal block)

Governor Output Module

A38-F2

10Amp

Switched B+ (to TB1 customer terminal block)

Governor Output Module

A38-F3

10Amp

Governor B+ (power for governor output module and actuator)

F1

20Amp

Customer B+ (to TB1 customer terminal block)

TB-Bat (Engine Harness Assembly)

(

REFERENCE DESIGNATION

I

.

4-57

,.,

LOAD SHARING CONTROLS TROUBLESHOOTING PROCEDURE

lf the generator set is not sharing load properly, the following procedure can be used to diagnose and solve the problem:

The generator set load sharing settings in the PowerCommand control are factory set and normally do not require adjustment. The controls are designad to cause generator sets in the paralleling system to share load proportionally, based on the standby ratings of the generator sets in the system.

1 . The no load speed and voltage of the generator set must be the same as the system bus. Measure the bus voltage and frequency, and the generator set voltage and frequency with a true RMS digital meter. Calibrate the voltage and current sensing circuits of the control, and make required adjustments to voltage and frequency to match bus conditions. Adjusting the voltage and frequency after the generator set is paralleleíí to the bus will cause load sharing to be unequal between generator sets.

When the system is operating normally, the generator sets in an isolated bus (not utility/mains paralleled) paralleling system will share both real (kW) and reactive (amps) load equally, within plus or minus 5%. For example, if two 1000 kW generator sets are paralleled and serving a 2000 kW load, the generator sets should each carry between 950 and 1050 kW.

2. Check to make sure that the load sharing control wiring is properly connected.

In actual practice, load sharing may be much more precise than plus or minus 5%, but you should nót be concerned about operational problems unless the load sharing is in error by more than 5%. lf dissimilar generator sets are useq in a system, there may be load sharing inequities for a short time when loads are applied, but the steady state load sharing should perform to the plus or minus 5% standard.

3. Check to make sure that each generator set in the system is capable of carrying its rated load. 4. Fine adjustment to the amount of load carried by each generator set can be made by adjusting the KW BALANCE and KVAR BALANCE settings under the paralleling setup menu ( Sectíon 5). 5. lf the generator sets share load approximately equally, but there is an oscillating load circulating between the generator sets, the governor gain may be set too high. Reduce the governor gain (see Setup Menu, Sectíon 5).

lf the generator set is paralleled to a utility (mains) gird, the amount of load on the generator set is programmed into the control in the setup mode or set f rom a remote device. lt is NOT a function of the load sharing control system. See Sectíon 5 for more information on load sharing set-up functions, and utility (mains) paralleling set-up.

6. Consult factory for any other load sharing problems.

4-58

@)

5. Control Service and Calibration GENERAL

CIRCUIT BOARD REMOVALJREPLACEMENT

This section contains circuit board removal and replacement procedures, calibration procedures for the genset control and test procedures for the generator and engine components. Refer to the figures included with this information and also the Wiring Diagrams section when instructed.

No special tools (other than a grounding wrist strap) are required to remove a circuit board from inside the control panel or the accessory box. There are severa! circuit boards that, when replaced, require you to recalibrate the control panel functions. Table 5-1 lists the circuit boards and the appropriate procedure to perform to recalibrate the control panel. The circuit board locations are shown in Figure 5-1.

Before servicing the PCC, ali settings should be recorded. This will enable correct and complete readjustment of the PCC in the event that all previous entries are lost during servicing.

Before you attempt to remove a circuit board, read the Circuit Board Removal Safety Precautions in this section.

TABLE 5-1. CONTROL PANEL RECALIBRATION CIRCUIT BOARD

ADJUSTMENT

PROCEDURE/PAGE

,. ...

( .. ...

Analog Board (A33)

1. Voltage, Current and PF. 2. Coolant Temperature L & R

Digital Board (A32)

Must recalibrate all values, starting with the lnitial Start Setup procedure.

PT/CT Board (A36)

Voltage, Current and PF.

Setup and Calibration Menus (Page 5-8)

Voltage

Setup and Calibration Menus (Page 5-8)

Bus PT Module (A39)

5-1

Setup and Calibration Menus (Page 5-8) 1. lnitial Start Setup (Page 5-4). 2. Adjust Menu (Page 5-6). 3. Setup and Calibration Menus (Page 5-8).

85 POWER ON/ STANDBY SWITCH

@

DISPLAY BOARD

A35

©>

·· ANALOG BOARD

'

A33

o GOVERNOR OUTPUT MODULE

A38

BUS PT MODULE

A39

·. j <: ~~1 . L.J l:J ,,-··-..,

~

•

•

1

O

VOLTAGE REGULATOR OUTPUT MODULE

A37

ACCESSORY BOX

·1

(HC 4/5)

FIGURE 5-1. CIRCUIT BOARD LOCATIONS

5-2

PT/CTBOARD

A36

I lgnitian of expiosive battery gases can cause severe personal injury or death. Arc­ ing at battery terminals, light switch ar other equipment, flame, pitot lights and sparks can ig­ nite battery gas. Do not smoke, ar switch troúble light ON ar OFF near battery. Discharge static electricity trom bady befare tauching bat­ teries by first tauching a graunded metal sur­ face.

Circuit Board Removal Safety Precautions

!AWARNING

To prevent circuit board damage dueto electrostatic discharge (ESO), a grounding wrist strap must be worn when handling circuit boards or socketmounted IC's. (The wrist strap does not provide a direct short to ground, but is typically rated at approximately 1 megohm to ground.) Attach the clip to a non -painted surface of the control box and place the strap around your wrist before handling a circuit board.

Ventilate battery area befare warking on ar near battery­Wear gaggles­Stap genset and dis­ cannect charger before discannecting battery cebtes=Disconnect negative (­) cable first and recannect last.

LA CAUTION I

Electrostatic discharge will damage circuit boards. Always wear a graunding wrist strap when handling circuit baards ar socket­ maunted IC's.

I Discannect battery charger trom AC source befare discannecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set ..

!A CAUTlON

Turn off or remove AC power from the battery charger and then remove the negative (-) battery cabte from the set starting battery. This is to make sure that the set will not start while working on it and to avoid circuit board damage_caused by voltage spikes when removing and replacing circuit board connectors.

I Accidental starting of the generator set can cause severe personal injury ar death. Prevent accidental starting by disconnecting the negative (­) cable from the battery terminal.

LA.WARNING

(

1,,,

[]]

o

7

NON-PAINTED SURFACE

GROUND LEAD CLIP

FIGURE 5-2. WRIST STRAP

WRISTSTRAP

INITIAL START SETUP MENU The facing page shows a block representation of the INITIAL START SETUP menu.

STANDBYIPRIME submenu: Use the buttons next to the "íl' .U" symbols to toggle the standby/prime option. Press the button next to the ">>" in the display to move to the model select submenu.

I Se/ecting this menu resets ali oper­ ating parameters to the default va/ues for the se/ected set. Al/ previous/y se/ected setup and adjustment settings wi/1 be /ost. Therefore, this procedure must be performed by technical/y qua/ified personnel only.

!A CAUTION

This menu appears on the digital display when the PCC has not been set up for use with a generator set during factory test, or the digital board was replaced in the PCC.

MODEL se/ect submenu: Use the buttons next to ... the "1l" and ".U." symbols to select the correct generator set model number, frequency and power rating.

When this display is showing, you must go through the lnitial Start Setup menu to select the operating parameters for the generator set. These include whether the set will be used for Prime Power or Standby use, the Model Number of the generator set, and its operating frequency and output voltage. These choices must be saved ínto the PCC's readonly memory befare the PCC will accept changes made to other menus.

VOLTAGE SELECT submenu: Use the buttons next to the "1l" and ".!.!" symbols to select the correct generator set nominal line-to-line output voltage.

lf the PCC is already set up to operate with a specific generator set, this menu will not appear when power is applied. To reset the control and display the lnitial Start Setup menu, you can press RESET, MENU, and PHASE SELECT buttons at the same time.

DELTA/ WYE submenu: Use the buttons next to the "ft" and ".!.!" symbols to select the delta or wye option.

lf you choose to do this, the governor/regulator adjustments and the setup options will be reset to the default settings (including the editable customer fault messages). Display calibrations (volts, amps, PF and coolant temperature) are retained (not reset). To ensure correct and complete readjustment of the PCC, it is suggested that ali settings be recorded before you perform the reset function.

SAVE submenu: From the model select submenu, press the button next to the ">>" in the display to move to the SAVE submenu. Select SAVE to save your changes. The MAIN MENU will then be displayed.

l

lmproper setup, calibration, orad­ justments can cause equipment malfunction or damage. Setup, calibration, and adjustment must be performed by technical/y qua/ified per­ sonnel only. !ACAUTION

5-4

INITIAL START SETUP (lt can be invoked by simultaneously pressing the Reset, Menu, and Phase Select keys.)

O

D< .U.1l

O< D<

STANDBY/PRIME

>>

MODEL

(kw mmitt f@Q) > >

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VOLTAGE SELECT (vac) L-L VAC >>

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SAVE

DELTA/WYE

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ENGINE ADJUST

GEN

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! TO LOOP BACK & CHECK:

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SAVE

0

0

1

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STANDBY/PRIME

>>

1 - - - -

5-5

lndicates "OR'' Condition

I

ADJUST MENU

The ADJUST submenus permit adjustment of the output voltage and frequency and the start and stop delay times of the generator set.

VOLTAGE submenu: This is the first submenu. Use the buttons next to the "ll" and ".()." symbols to adjust output voltage ± 5%.

The complete calibration procedure is described in the Calibration Procedure in this section.

FREQUENCY submenu: From the VOLTAGEsubmenu, press the button next to the ">>" in the display to move to the FREQUENCY submenu. Use the buttons nsxt to the "11'" and ".U." symbols to adjust output frequency '± 5%.

The facing page shows a block representation of the ADJUST menu. lf you press the button next to the word "ADJUST" in the Main menu, the VOLTAGE ADJUST submenu will appear.

START DELA Y submenu: This dela y applies only to remote starting in the Auto mode. From the FREQUENCY submenu, press the button next to the ">>" in the display to move to the START DELAY submenu. -Use the buttons next to the "'ft" and ".()." symbols to set the start delay. The start delay adjustment range is O to 300 seconds.

As shown in the diagram, the ADJUST menu has five submenus, including a save/exit procedure. Voltage and frequency can be adjusted only whe.h the generator set is running under normal operating parameters (not in idle mode). For example, if voltage adjustment is selected when the set is in ldle mode or not running, the digital display will be:

"lf VOLTAGE" ".U. N/A >>"

STOP DELA Y submenu: This delay applies only to remote stopping in the Auto mode. From the START DELAY submenu, press the button next to the ">>" in the display to move to the STOP DELAY submenu. Use the buttons next to the "1l'" and ".U." symbols to set the stop delay. The stop delay adjustment range is O to 600 seconds. IDLE SPEED submenu: From the STOP DELAY submenu, press the button next to the ">>" in the display to move to the IDLE SPEED submenu. Use the buttons next to the "11'" and ".U." symbols to set the idle speed. The idle speed adjustment range is 800 RPM ±100 RPM. (Default value is 800 RPM.) The idle speed can be adjusted only when the generator set is running in the idle mode. When not in idle mode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAY submenu, press the button next to the ">>" in the display to move to the SAVE/EXIT submenu. Select SAVE to save your changes. At the CHANGES SAVED submenu, select EXIT to return to the main menu. lf you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the set is restarted. Jf you select EXIT without saving first, the adjustments will remain in effect until the genset is shut down, but will be reset (and will not be in effect) when the set is restarted.

5-6

I ADJUST I

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ENGINE ADJUST

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>>

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>>

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VOLTAGE

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11' STOP DELAY

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SEC

>>

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IDLE SPEED RPM

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START DELAY SEC >>

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ENGINE ADJUST

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VOLTAGE

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1 - - - - lndicates "OR" Condition I 5-7

The facing page shows a block representation of the VERSION submenus. lf you press the button next to the ">>" in the Main menu display, the VERSION/SETUP/CAL menu will appear.

SETUP AND CALIBRATION MENUS The setup and calibration menus allow you to calibrate the PCC with the reading from a calibrated meter. There are tour setup and calibration menus that are selectable from the SETUP/CAL menu:

IA. CAUTION I

lmproper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage. Calibration and adjustment must be performed by techni­ cal/y qualified personnel only.

• VERSION ANO DISPLAYS • METERS • GOVERNOR/REGULATOR • SETUP

VERSIONsubmenu: lf you select VERSION, the display wi)I stíow the generator set model number, frequency, and kW rating, and the date and version of the operating software.

These tour menus are intended for qualified service personnel only. For this reason, a three-digit access code must be entered before you can proceed to those menus.

To display the generator set configuration options, press the button next to the ">>" in the submenu that displays the model number, frequency and etc. This menu provídes the following information:

ENTER CODE submenu: The access code for your PCC is: 5 7 4. To enter the code: 1. Press the button next to the."11" to increment the first digit.

• Generator set voltage • WYE or DELTA

2. Press the button next to the ">>" to select the second digit.

• Standby or Prime

3. Press the button next to the "11" to increment the second digit.

• Parallel or Single HISTORY: From the VERSION, SETUP/CAL menu, press the button next to the ">>" in the display to move to the HISTORY submenu. Press the button next to "HISTORY" to display the last (latest) recorded error message.

4. Press the button next to the ">>" to select the third digit. 5. Press the button next to the "11" to increment the third digit. 6. Press the button next to the ">>" to proceed to the DISPLAYS/METERS submenu. (Provided, of course, that you have correctly entered the access code.)

The software will record (save) up to 20 error messages. The last error detected will always be displayed first. As each new error is detectad, the oldest error recorded after 20 will be deleted.

The following sub-sections describe how to select and make changes to the setup and calibration menus and save the changes made to these menus.

To view the generator set runtime at which the error occurred and to scroll through the remaining recorded errors, press the button next to the ">>" in the error message menu to display the RUNTIME, NEWER/OLDER menu.

Version Menu The VERSION menu allows you to verify the model number and frequency of the generator set, the date and version of the operating software and generator set configuration options. From the VERSION menu you can also review a History file, that can contain up to 20 error messages.

The buttons next to NEWER and OLDER are used to scroll up and down through the error messages. For example, pressing OLDER will display the next oldest recorded error message. When pressing NEWER and the last (newest) error message is displayed, or OLDER and oldest error is displayed, the display will return to the HISTORY menu.

The complete calibration procedure is described in the Calibration Procedure in this section.

5-8

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..

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I VERSION MENUS I O< 0< .< O<

ENGINE ADJUST

GEN >>

VERSION SETUP/CAL

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(model) (hz) << V:_._>>

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VERSION SETUP/CAL

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DISPLAY$ VOLTAGE & GEN SET CONFIGURATION

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DISPLAYS ERROR MESSAGE AND CODE

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REFER TO FOLLOWING MENUS IN THIS SECTION

1 - - - - lndicates "OR" Condition

5-9

I

bols to calibrate the selected voltage, current, PF or coolant temperature reading. Press the button next to the ">>" in the display to move to the next adjustment. "VOLTS L 12," "VOLTS L23," and "VOLTS L31" refer to voltages measured from L 1 to L2, L2 to L3, and L3 to L1, respectively. Note that the system includes bus voltage reading provisions ("BUS VOLTS L 12," "BUS VOLTS L23," and "BUS VOLTS L31"), which must be calibrated separately from the generator set voltage settings.

Displays Menu The DISPLAYS submenus permit calibration of the digital voltage, current, power factor (PF) and coolant temperature displays. Calibration is accomplished by using this section of the menu software to adjust the display so that it matches the reading taken on an accurate, recently calibrated meter. The complete calibration procedure is described in the Calibration Procedure in this section.

The facing page shows a block representation of the DISPLAYS submenus, which is the first of tour SETUP/CAL menus. lf you press the button next to the ">>" in the Main menu display, the VERSION/ SETUP/CAL menu will appear.

"PF1, PF2 and PF3" will display N/A when the generator set is not runnínq.

!A CAUTION !

"COOLANT TEMP R" will display "N/A'' if the genset has only one sensor. To calibrate coolant temperature display, a precislon resistor (provided in the engine sensor tool) must be temporally substituted for the temperature sender. Refer to Calibration Proce­ dure in this section.

DISPLAYSsubmenus: The DlSPLAYS submenus are intended for qualified service personnel only. For this reason, a three-digit access code must be entered before you can proceed to those menus.

SAVEIEX/t submenu: From the AMPS L3 submenu, press the button next to the ">>" in the display to move to the SAVE/EXIT submenu. Select SAVE to save your changes. At the CHANGES SAVED submenu, select EXIT to return to the DISPLAYS/METERS submenu. lf you select SAVE, the adjustments will be retained

lmproper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage. Calibratian and adjustment must be performed by tecbni­ cally qua/ified personnel only.

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter access code (574) as previously described in this section. Select DISPLAYS to proceed to the DISPLAYS submenus. Use the buttons next to the "1l" and ".U." sym-

after shutdown, and will be in effect when the set is restarted. lf you select EXIT without saving first, the adjustments will remain in effect until the genset is shut down, but will be reset (and wlll not be in effect) when the set is restarted.

5-10

ftt.:­.

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I DISPLAYS MENU I >O >O

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DISPLAYCAL METERS

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VERSION SETUP/CAL

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>O >O 1 - - - - lndicates "OR" Condition

5-11

I

Meters Menu

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter access code (574) as previously described in this section.

The METERS submenus permit calibration of the control's analog meters to match the calibrated digital values. (Calibrate the digital display before calibrating the analog meters.) This calibration is accomplished by using this section of the menu software to adjust the selected meter reading so that it matches the reading provided on the digital display.

Select METERS to proceed to the METERS submenus. Use the buttons next to the "ll" and ".U." symbols to calibrate the selected meter to match the "CAL TO:" value provided on the digital display. Press the button next to the ">>" in the display to move to the next calibration. "VOLT METER" and "% AMPERES" calibration reterence the phase that is indicated on the phase selection LE9's.

The complete calibration procedure is described in the Calibration Procedure in this section. The facing page shows a block representation of the METERS submenus, which is the second of tour SETUP/CAL menus. lf you press the button next to the ">>" in the Main menu display, the VERSION/SETUP/CAL submenu will appear.

LA CAUTION I

NOTE: The o/o AMPERES meter scale is based on a 0.8 power factor. (100% of rated current is full load current at 0.8 PF.) ·

SAVEIEXITsubmenu: From the HERTZ subme-

'

lmproper calibration or eajustment of the PowerCommand control can cause equipment malfunction or damage. Calibration and adjustment must be performed by techni­ cally qualified personnel only. METERS submenu: The METERS submenus are

intended for qualified service personnel only. For this reason, a three-digit access code must be entered before you can proceed to those menus.

5-12

nu, press the button next to the ">>" in the display to move to the SAVE/EXIT submenu. Select SAVE to save your changes. At the CHANGES SAVED submenu, select EXIT to return to the DISPLAYS/METERS submenu. lf you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the set is restarted. lf you select EXIT without saving first, the adjustments will !emain in effect ~ntil the !;!enset is @\:,1 shut down, but w1II be reset (and will not be m effect) \(_,,/ when the set is restarted. -

f O< .<

VERSION SETUP/CAL

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>>

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ENTER CODE

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DISPLAY CAL METERS

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<< >>

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%LOAD CAL TO:

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AC VOLTS .U CAL TO:

% AMPERES .U CAL TO:

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DISPLAY CAL METERS

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DISPLAY CAL METERS

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DISPLAY CAL METERS

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11' ACVOLTS CAL TO:

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1 - - - -

5-13

lndicates "OR'' Condition

I

Governor I Regulator Menu

GOV GAIN: lf the gain adjustment is set too high, engine speed will "hunt'' or oscillate. lf gain is set too low, the engine will respond too slowly to changes in load-overspeed may result.

The GOV/REG submenus permit adjustment of voltage regulator and governor parameters.

For paralleling applications the default value for governor gain is 70.

AII GOV/REG menu values, except for REG VHZ and GOV RAMP, will display "100%". The expression "100%" represents the factory setting (default value) for the selected set. When increasing or decreasing the value, you are increasing or decreasing from the factory default value. (For example, entering "200%" will double the value; "50%" will decrease the value by one half.)

GOV INTEGRAL: lf this adjustment is set too low, the engine will respond too slowly to changes in load. lf it is set too high, engine response will be unstable. GOV RAMP:·This adjustment sets the time for the engine to rarñp to.full operating speed. This adjustment applies only to set start up and does not affect the transient response. (Adjustable range: O through 1 O seconds.)

Default values are preset by the factory. Due to site variables, the default values may need to be adjusted to attain peak performance.

REG GAIN: lf the gain adjustment is set too high, output voltage will be unstable. lf gain is set too low, the output voltage will respond sluggishly to changes in load-overshoot may result.

The facing page shows a block representation <:Íf the GOV/REG submenus, which is the third of tour SETUP/CAL menus. lf you press the button next to the ">>" in the Main menu display, the VERSION/ SETUP/CAL submenu will appear,

REG INTEGRAL: lf this adjustment is set too low, the output voltage will respond sluggishly to changes in load, resulting in a droop-type response lf it is set too high, output voltage will be unstable.

LA CAUTION I

lmproper calíbration or adjustment of the PowerCommand control can cause equipment malfunction or damage. Calibration and adjustment must be performed by techni­ cally qualified personnel only.

REG VHZ: This underfrequency roll-off adjustment controls how much excitation is reduced in response to underfrequency. lf the value is set too low, excitation will be cut too fast, and the voltage will drop too much. lf set too high, the generator set may not be able to pick up rated load in one step. (Adjustable range: 1 through 50; normal range 7 through 21.)

GOVIREG submenu: The GOV/REG submenus are intended for qualified service personnel only. For this reason, a three-digit access code must be entered before you can proceed to those menus. Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter the access code (574) as previously described in this section.

SAVE/EXIT submenu: From the REG VHZ submenu, press the button next to the ">>" in the display to move to the SAVE/EXIT submenu. Select SAVE to save your changes. At the CHANGES SAVED submenu, select EXIT to return to the DISPLAYS/METERS submenu.

From the DISPLAYS/METERS submenu, press the button next to the ">>" in the display to move to the GOV/REG/SETUP submenu. Select GOV/REG to proceed to the GOV/REG submenus.

lf you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the set is restarted. lf you select EXIT without saving first, the adjustments will remain in effect until the genset is shut down, but will be reset (and will not be in effect) when the set is restarted.

Use the buttons next to the "1l" and "JJ." symbols to adjust the selected governor and regulator parameters. Press the button next to the ">>" in the display to move to the next adjustment.

5-14

.<

I GOVERNOR/REGULATOR

0< VERSION SETUP/CAL

O< DISPLAY CAL O< METERS O< GOV/REG

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PARALLEL

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SETUP

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ENTER CODE

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GOVGAIN % 1 - - - -

5-15

lndicates "OR" Condition

I

Setup Menu The SETUP submenus permít selectíon of several configuration and operation options. Setup option defaults are listed in Table 5-2.

From the DISPLAYS/METERS submenu, press the button next to the ">>" in the display to move to the GOV/REG/SETUP submenu. Select SETUP to proceed to the SETUP submenus. Use the buttons next to the "'ft.!J!' symbols to toggle the setup options. Press the button next to the ">>" in the display to move to the next adjustment.

TABLE 5-2. SETUP DEFAULTS SELECTION

DEFAULT

CYCLE CRANK SYSTEM OF UNITS *CUSTOMER FAULT 1 *GRNDFAULT *DAYTANK *HIGH GEN TEMP EGTL EGTR LOWCOOLANT LANGUAGE

ON IMPERIAL WARN WARN WARN WARN NO NO SHTD ENGLISH

lf the cycle cranking option is selected, the menu will prompt for the selection of cycle number (3, 4, or 5) and crank a~d rest times (7 to 20 seconds).

..

An in-line engine that has the EGT (exhaust gas temp.) option, select "YES" for EGT L and 'NO" for EGTR.

Edit Customer Fault Message(s): The tour customer fault messages shown in Table 2-1 are editable. To enter the desired customer fault message, press the button next to the ">>" in the display to display the customer fault message to be changed.

! !

* Default display messages for customer faults 1 through 4. To change the customer fault message(s), to display the desirea fault condition, refer to heading Edit Customer Fault Messages.

Press the upper-left button by the display to select the desired character. Press the upper-right button to move the cursor to the next character to be changed. (Holding this button down will return the cursor to the first position.) The message can be up to 16 characters. The fault code number will remain the same, this code cannot be edited.

The facing page shows a block representation of the SETUP submenus, which is the fourth of four S ETU P/CAL menus. lf you press the button next to the ">>" ín the Main menu display, the VERSION/ SETUP/CAL submenu will appear.

LA CAUTION I

lmproper calibration or adjustment of the PowerCommand control can cause equipment malfunction or damage. Calibration and adjustment must be performed by techni­ ca/ly qualified personnel only.

SETUP submenu: The SETUP submenus are intended for qualified service personnel only. For this reason, a three-digit access code must be entered before you can proceed to those menus.

lf these messages are changed, you should note these changes in the Troub/eshootingsection of the Operator's manual for this generator set.

SAVEIEXITsubmenu: From the LANGUAGE submenu, press the button next to the ">>" in the display to move to the SAVE/EXIT submenu. Select SAVE to save your changes. At the CHANGES SAVED submenu, select EXIT to return to the DISPLAYS/METERS submenu. lf you select SAVE, the adjustments will be retained after shutdown, and will be in effect when the set is restarted. lf you select EXIT without saving first, the adjustments will remain in effect until the genset is shut down, but will be reset (and will not be in effect) when the set is restarted.

Select SETUP/CAL. The display will show the ENTER CODE submenu. Enter the access code (574) as previously described in this section.

5-16

I SETUP MENU I O< .<

VERSION SETUP/CAL

(

>O >O

>>

>O

<< >>

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<< SETUP

>O >.

o

ENTER CODE

O< O<

---

O< O<

DISPLAY CAL METERS

O< O<

GOV I REG PARALLEL

D D<

<< >>

CYCLE CRANK ON /OFF >>

1l u.

IF CYCLE CRANK ON :

o O< D<

o

O< O<

o

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------------------

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#OFCYCLE S (3, 4, 5 or 6) >> RES ET

1l CRANK TIME Jj.

(7 to 20)

RESET

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MENU

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- SEG >>

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MENU

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REST TIME - SEG (7 to 20) >> MENU

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SYSTEM OF UNITS METor IMP>>

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CUSTOMEA FAULT1 1l!J. SHTD / WARN >>

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GROUND FAULT 1l U SHTD / WARN

>>

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'fl'Jj. SHTD / WARN

>>

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>>

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SAVE EXIT

>>

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RUPTURE BASIN

HIGH GEN TEMP

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SAVE EXIT

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EGTR YES/ NO

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DISPLAY CAL METE AS

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CHANGES SAVED EXIT >>

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DISPLAY CAL METE AS

<< >>

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CYCLE CRANK ON /OFF >>

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5-17

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LOW COOLANT LVL D SHTD /WARN >> >.

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:_o_ >>

>>

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SAVE EXIT

EGTL YES/ NO

CHANGES SAVED EXIT >>

1

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1----

>>

D >.

<< >>

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CYCLE CRANK ON /OFF >>

o

>O

lndicates "OR'' Condition

j

set at 110% of the generator set base load setting. When the load govern signa! is between 1 VDC and 4.5 VDC the control will operate the generator set at a load level which is determined by a linear relationship between the kW reference and the load govern signal.

Paralleling Setup Menu The PARALLELING SETUP submenus adjust the control parameters for generator set protection, synchronizing and load sharing for both isolated bus and utility (mains) paralleling applications. Utility (mains) parallel applications may require adjustment of both the "isolated bus" and "utility'' branch submenus.

ISOLATED BUS ADJUSTMENTS SYNC TIME LIMIT:This parameter adjusts the time delay in seconds before the Fail To Synchronize alarm will operate.

The sync check (permissive) function ís operational in both automatic and manual (RUN) modes. The control will make sure that the generator set is at proper voltage, within the defined sync check window for the defined period of time and that phase rotation is correct. When ali criteria are met, the paralleling breaker is closed automatically by the control (auto mode), or by operation of the breaker close switch by the operator (run mode). i

­ PWR LIMl'T (%): Adjusts the reverse power set point. For PowerCommand generator sets, a typical set point is 10-15%. ­ PWR LIMIT (TIME): Adjusts the reverse power function time delay. A typical time delay which is suitable for PowerCommand generator sets is 3 seconds. ·.

The synchronizing function of the PowerCommand control is enabled when the control has brought the generator set to rated speed and voltage, and has sensed that bus voltage is available. The control automatically adjusts the generator set speed and voltage to match the bus frequency and voltage. The control can force the generator set to match a bus voltage and frequency in a range of minus 40% to plus 10% of normal bus conditions. When the paralleling breaker has closed, the control will bring the generator set back to normal voltage and frequency.

Lower reverse power set points can result in nuísance reverse power shutdown faults.

PERM WIN­PHASE: Adjusts the width of the permissive (sync-check) acceptance window. The adjustment range is from five to _tw~nty electrical de- (''\ grees. Recommended set point rs 20 degrees for \;¿,/ isolated bus applications, and 15 degrees for utility (mains) paralleling applications. PERM WIN­TIME: Adjusts the time period (in seconds) for which the generator set must be synchronized with the system bus, before a breaker clase signa! is issued by the PowerCommand control. Available range is 0.5 to 5 seconds. Recommended value for PowerCommand generator sets is 0.5 seconds for isolated bus applications.

When the generator set is paralleled to another generator set, the control provides automatic load sharing functions for both real (kW) and reactive (kVAR) loads. Load sharing is proportional between generator sets based on their standby ratings. lf two generator sets of different sizes are paralleled, they will assume the same percentage of the system load automatically. This can easily be verified on the analog % Load meters on the front of the PowerCommand control panel.

Adjusting the control for a smaller sync-check window or longer time delay will cause synchronizing time to be extended.

SYNC GAIN: The sync gain adjustment controls how quickly the governor will respond to try to minimize the bus/generator phase difference. lncreasing the gain speeds up the response. lf the gain is too high instability can result.

When the utility paralleling mode is enabled and the generator set paralleling breaker is closed, the generator set will assume load based on externa! analog input signal. The input signal must be calibrated from 0-5 VDC. When the signal is at 0.5 to 1 VDC, the control wíll operate the generator at no load in parallel with the utility (mains) source. At 4.5 VDC and greater, the control will operate the generator

SYNC INTEGRAL: The sync integral adjustment controls the rate at which the governor will be adjusted to try to minimize the bus/generator phase difference. The lower the number the slower the response.

5-18

I PARALLELING O< .<

>O >D

>>

>D

<< >>

>O >.

<<

>O >O

ENTER CODE

O< O<

('.;:..

<< >>

VERSION SETUP/CAL

--DISPLAY CAL METERS

O< .<

GOV / REG PARALLEL

O< .<

ISO BUS UTILITY

<<

>O

.< O<

ISO BUS UTILITY

<<

>O

>>

>.

>>

>.

D< 1t O< J.l O< fi O< J.l

SYNC TIME LMT

120 -PWR LMT (%)

10

D< O<

fi J.l

-PWR LMT (TIME)

D< O<

fi

PERM WIN-PHASE

D< O<

1t

D< O<

fi J.l

SYNCGAIN

D< O<

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SYNC INTEGRAL

J.l

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3

20

>>

.5

95

12

A

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I

I

B

(CONTINUED)

1

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o o

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>>

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>>

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PERM WIN-TIME

I

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SETUP

SETUP MENU

o

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(CONTINUED)

1 - - - -

5-19

lndicates "OR" Condition

I

ISOLATED BUS ADJUSTMENTS

ator set. This also allows modification of the rate of load assumption on transient load change. 1 ST START FAIL: Time dela y in seconds after a signal from the first start master is not sensed by the PCC that a FIRST START FAIL warning is displayed. RAMP UNLD TIME: When a load demand stop input is sensed the load is ramped down from the present load level on the set to the ramp unload level in the time specified in seconds. RAMP UNLD LEVEL: The load demand ramp unload function _vvill ramp the load down from the present level on t.,he set to this level before opening the set circuit breake'r. Value shown is in % of genset standby rating. RAMP LOAD TIME: When the load demand stop signal is removed the load is ramped from OkW to the load share level in the specified time after the circuit breaker closes. LOSS FIELD (LOSS OF EXCITATION) TIME and LEVEL: Adjusts the time delay on the Loss of Excitation fault. Generator sets with version 1.07 and higher (9-26-96 and later) firmware may be adjusted for time delay on this condition. the default value is 2 seconds. Generator sets with version 2.0 and higher firmware allow adjustment of both time delay and reverse ~;'.>, (·.:· ..'·.':·:.} VAR set point. Default values are 1 o seconds and <:. . .>····' 20%.

(Cont.) (A)

KW BALANCE: This function adjusts the kW load sharing function of the generator set. Before adjusting this value, all generator set calibratíons should be performed. lf the total load on the system is not shared proportionately, the kW Balance can be used to adjust the generator set for more precise load sharing. lncreasing the kW Balance value will cause the generator set to reduce the percentage of the total kW load on that set. KVAR BALANCE: This function adjusts the kVAR load sharing function of the generator set. Before adjusting this value, all generator set calibrations should be performed. lf the total load on the system is not shared proportionately, the kVAR balance can be used to adjust the generator set for more precise load sharing. lncreasing the kVAR balance value will cause the generator set to reduce the percentage of the total kVAR load on that set. · KW GAIN: Adjusts the rate of change of kW load on the generator set. With a constant load on the system, if the generator set load is constantly changing, reduce the gain adjustmeTlt on the generator set. This also allows modification of the rate of load assumption on transient load change. KVAR GAIN: Adjusts the rate of change of kVAR load on the generator set. With a constant load on the system, if the generator set load is constantly changing, reduce the gain adjustment on the gener-

5-20

I PARALLELING SETUP MENU (Cont.) 1

A (CONTINUED)

O< 11' O< .u.

l<:­N BALANCE 165 + _%

O< 11' O< .u.

KVAR BALANCE

O< O<

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11' l<:­N GAIN 6

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11' RAMP UNLD LEVEL >> 20

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KVAR GAIN

300

RAMP UNLD TIME

10

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RAMP LOAD TIME

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LOSS FIELD TIME

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LOSS FLD LEVEL

10

2

20

>> >>

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SAVE EXIT

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SAVE EXIT

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DISPLAY CAL METERS

GOV/REG PARALLEL

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SETUP

1 - - - -

5-21

lndicates "OR'' Condition

I

UTILITY (MAINS) ADJUSTMENTS (B) BASE LOAD (%): Controls the maxímum kW load level that the generator set will operate at when paralleled with the utility (mains). The value shown indicates the steady state load on the generator as a percent of the generator set standby rating. Check generator set ratings for maximum load level at which the generator set should operate when paralleled with the utility (maíns). Extended operation at load levels in excess of the generator set rating can cause abnormal engine wear or premature engine faílure. PF LEVEL: Adjusts the power factor that the generator set will run at when paralleled to the utility (mains). Recommended setting is 1.0. KW GOVERN GAIN: Controls the rate that the generator set kW load is increased after the generator set has closed to the system bus when utility (maíns) paralleled. Decreasíng this value wíll result in slower loading of the generator set. KW INTEGRAL: The kW integral adjustment is used to control the response of the generator set to large load changes when utility' (mains) paralleled. Use of a higher integral value will result in slower response, and reduced kW overshoot on load assumption or rejection, especially on large system load changes. Decreased integral values will also result in slower load acquisition and rejection. KVAR GOVERN GAIN: Controls the rate that the generator set kVAR load is increased after the gen-

erator set has closed to the system bus when utility (mains) paralleled. Decreasing this value will result in slower loading of the generator set. KVAR INTEGRAL: The kVAR integral adjustment is used to control the response of the generator set to large load changes when utility (mains) paralleled. Use of a higher integral value will result in slower response and reduced kVAR overshoot on load assumption or rejection, especíally on large system load changes. Decreased integral values will also result in slower load acquisition and rejectíon. RAMP LOAP TIME: This is the ramp time from present set load to level determined by the load set analog input. This is active when the control fírst enters the load govern mode. RAMP UNLD TIME: This is the ramp time from present set load to the O kW. This ramp is active when the load set analog input is less than 0.5 volts. MULTIPLEISINGLE: This selection modifies the sequence of operation and functions of the inputs and outputs of the control on TB 1 to allow for application of the control in multiple generator set applications ("Multiple" selection), where generator sets are paralleled to each other and may also be paralleled to a utility (mains) service; or for applications where a single generator set is used with a breaker pair for closed transition power transfer functions ("Single" selection). See Table5­3for a description of the operation and use of TB1-51 input.

5-22

i,¡;

Multiple - In the MULTIPLE configuration, the control is set up for proper operation in a system where the gensets are configured similar to that shown in Figure 5-3 or 5-4. In these illustrations, 52-Gn are the paralleling circuit breakers and 52-Fn are feeder circuit breakers that provide generator set power to load transfer devices. 52-U is a utility (mains) circuit breaker and 52-GM is a generator bus main breaker. 52-U and 52-GM provide power transfer tune-

tíons in the system. U pon receiving a start signa!, the gensets automatically start, select one generator set in the system to be the first one to close to the bus using the Fírst Start Sensor system, synchronize, and load share. Upon receiving a signal to the control that the generator sets are closed to the utility (mains), the generator sets automatically ramp to their preset base load level.

..

B~SVOLT

SENSE

52-G1

52·G2

52-G3

52-F1 •

.

52-F1

------

SWITCHGEAR

52-F1

-------

-------·

TO LOADS

( ... -."

FIGURE 5-3. TYPICAL MULTIPLE CONFIGURATION

BUS VOLT

SENSE

FROM UTILITY (MAINS)

52-G1

52-G2

52-G3

52-GM

52-U

TO LOADS 52-F1 ,

52-F1

SWITCHGEAR

-----------------------------------•

52-F1

------

-------

TO LOADS

FIGURE 5-4. TYPICAL MULTIPLE CONFIGURATION

5-23

-------

Single - The SINGLE configuration

(limited to ONLY the electrical configuration shown ín Figure 5-5) allows for incorporation of a single PowerCommand generator set in a power system that provides load transfer functions and various utility paralleling functions. In the SINGLE configuration, PowerCommand provides all the generator set control functions including synchronizing, load govern (import/export control and var/PF control), and genset breaker control functions; equipment provided by others provides utility (mains) breaker control, utility source sensing, and other functions.

When utility (mains) power returns, the remote device tums on the synchronizer in the PCC, the PCC synchronizes the genset-to-utility (mains) service, and the remote device closes the utility (mains) breaker (52-U). When the PCC senses that 52-U is closed, it checks the voltage on the externa! load set terminals (TB 1-59 and 60) and ramps to the cornmanded load level. The remete device control system determines when to open the genset breaker by removing the start signar from the genset control. When it is removed, the genset ramps down to zero load and opens the genset breaker (52-G 1 ). lf the generator set receives a start signa! when the utility (mains) servlce is available, the generator set starts and accelerates to rated voltage and frequency. lt automatically synchronizes and clases its breaker. When the generator breaker is closed, the generator set ramps to the load level commanded by the signal on the externa! load set terminals (TB1-59 and 60).

The PCC monitors the position of the generator set breaker (52-G1) and the utility (mains) breaker (52-U). In a black start condition, the generator set receives a start signal from a remote device. lf the PCC senses no voltage available on the bus voltage connection and the utility (mains) breaker ¡s open, it closes the generator set breaker. ·

FROM UTILITY (MAINS) BUS VOLT

SENSE

- - - 1

,,....•.•..

(

::·:.:. :·.\ ·

....:..,,;: /

52·G1

52-U

52·F1 '

'L -

52-F1

52-F1

SWITCHGEAR - - - - -

-

- - -

- - -

- - -

-

- ... • -

• •

-

- -

- - - -

-

- - - - -

TO LOAD(S)

(# LOADS OPTIONAL)

FIGURE 5-5. UTILITY-SINGLE CONFIGURATION

5-24

-•

~

I PARALLELING SETUP MENU (Cont.) 1

B (CONTINUED)

s-

(

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O< O<

11' BASE LOAD%

O< O<

11' PF LEVEL

u.

80

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>>

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>>

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O< O<

11' KW GOVERN GAIN .u. 100 >>

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11' KWINTEGRAL 4

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11' i>

O< O<

11' KVAR INTEGRAL >>

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O< O<

11' RAMP LOAD TIME .u. 10 >>

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O< O<

11' RAMP UNLD TIME .u. 10 >>

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11' MULTIPLE/SINGLE .u. SINGLE>>

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SAVE

EXIT

>>

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O< O<

SAVE EXIT

>>

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.u.

1.00

u.

>>

200

I

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u. JJ

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o

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DISPLAY CAL METERS

O< O<

GOV /REG PARALLEL

<< >>

>O >O

<< SETUP

>O

1 - - - -

5-25

o

lndicates "OR" Condition

I

CALIBRATION

4. Start the genset and allow the genset to reach normal operating speed.

PROCEDURE

Contacting high voltage compo­ nents can cause e/ectrocution, resulting in se­ vere personal injury or death. Calibration and adjustment must be performed by technical/y qualified personnel on/y. Read and observe ali WARNINGSand CAUT/ONS in your generator set manua/s.

!A.WARNING!

5. Adjust VOLTAGE (genset output voltage) so that the calibrated voltmeter reads the desired voltage. (Use a calibrated voltmeter because the value displayed on the PCC digital display may not be calibrated at this time; therefore, its accuracy is unknown.)

LA CAUTION I

6 Select the Frequency adjust menu.

lmproper calibration or adjustment of the PowerCommand control can cause equipment ma/function or damage. Calibration and adjustment must be performed by techni­ cal/y qua/ified personnel only.

7. Verify that the frequency displayed on the calibrated meter is the desired frequency. lf not, adjust tothe desired frequency. (Note: lf the frequen6y reading on the digital display is not the same as frequency shown on calibrated meter, there is an equipment malfunction.)

The calíbration procedure is divided into 7 subsections, with the subsections arranged in a specified order. lf two or more of the following subsections are required to calibrate the PCC, they must be cornpleted in the order shown. ·

8. lf no frequency or voltage adjustment was made, select EXIT. lf an adjustment was made, SAVE, then EXIT.

Digital Voltage Display Calibration

When removing and replacing a defective circuit board, you may have to perform one or more of the following subsections. Table 5-1 (Control Panel Recalibration) provides a list of the circuit boards that require calibration when replaced and the calibration procedure(s) that must be performed.

The paralleling bus must be de-energized while voltage calibrations are performed. lf this is not possible, disconnect and isolate bus voltage inputs to the Bus PT Module (A39) before attempting voltage calibration.

Use a calibrated RMS multimeter for accurate measurements. Fluke models 87 or 8060A are good choices.

9. Select ">>" from the Main Menu (Page 5-9). () From this menu proceed to the VOLTS L 12 menu (Page 5-11).

lnitial Start Setup 1. Refer to Page 5-4, which describes how and when you should perform this procedure. To verify if the PCC is set to operate with a specific generator set, refer to the VERSIONmenu (Page 5-9). This menu will show the generator set model number, frequency, and kW rating. lf any of these values are incorrect, you must perform the lnitial Start Setup procedure.

Voltage and Frequency Adjustment

1 O. With the genset OFF, attach a calibrated frequency/voltmeter to the AC output from L 1 to

L2.

11 . Start the genset and allow it to reach normal operating speed. 12. Calibrate voltage reading for VOLTS L 12 so that the reading on the digital display agrees with the calibrated voltmeter. 13. Shut the generator set OFF. 14. Repeat steps 1 O through 13 for L23 and L31. (In step 1 O attach meter to the AC output from L2 to L3 to calibrate VOLTS L23and then L3 to L 1 to calibrate VOLTS L31.)

2. With the generator set OFF, attach a calibrated frequency/voltmeter to the AC output from L 1 to L2. 3. SelectADJUSTtrom the Main Menu (page 5-7) to display the VOLTAGEadjust menu.

15. lf no calibration was made, select EXIT. lf a calibration was made, SAVE, then EXIT.

5-26

Digital Ammeter Display Calibration

27. Calíbrate the reading for PF1 so that the reading on the digital display agrees with power factor meter.

16. Select ">>" from the Main Menu (Page 5-9). From thís menu proceed to the AMPS L 1 menu (Page 5-11 ). 17. With the genset OFF, attach a calibrated ammeter to L 1.

28. Repeat steps 24 through 27 for L2 and L3. (In step 24, attach meter to L2 to calibrate PF2 and then L3 to calibrate PF3.)

18. Start the genset and allow it to reach normal operating speed.

29. lf no calibration was made, select EXIT. lf a calibration was made, SAVE, then EXIT.

19. Load the genset to maximum rated voltage.

Digital Bus Voltage Calibration

rated kVA at

20. Calibrate the reading for AMPS L 1 so that the reading on the digital display agrees with calibrated ammeter.

30. Select ">>" from the Main Menu (Page 5-9). From thJs menu proceed to the Bus Volts L12 menu (Page ·5-11).

21. Repeat steps 17 through 20 for L2 and L3. (In step 17, attach meter to L2 to calibrate AMPS L2 and then L3 to calibrate AMPS L3.)

31. With the genset OFF, attach a calibrated frequency/voltmeter to the alternator AC output from L 1 to L2.

22. lf no calibration was made, select EXIT. lf a calibration was made, SAVE, then EXIT. !

The paralleling bus must be de-energized while voltage calibrations are performed. lf this is not possíble, disconnect and isolate bus voltage inputs to the Bus PT Module (A39) before attempting voltage calibration.

Digital Power Factor Display Calibration Power factor calibration is not r:equired except in applications requiring a hígher accuracy than ±5%. lf the ±5% accuracy is not acceptable, further calibration will require reactive load sufficient to reach 0.8 PF at rated load, and calibrated instruments with ±1 % accuracy or better. Typical load rack instruments are not accurate enough to perform this procedure.

32. Start the genset and allow it to reach normal operating speed and voltage. 33. Push the breaker close switch on the front of the PowerCommand control and verify that the paralleling breaker has closed by observing the closed lamp on the control panel and physical check of the breaker.

23. Select ">>" from the Main Menu (Page 5-9). From this menu proceed to the PF1 menu (Page 5-11).

34. Calibrate the voltage reading for Bus Volts L 12 so that the reading on the digital display matches the reading on the calibrated meter.

24. With the genset OFF, attach the power factor meter to L 1.

35. Shut the generator set OFF.

25. Start the genset and allow it to reach normal operating speed.

36. Repeat steps 31 through 35 for Bus Volts L23 and Bus Volts L31.

26. Load the genset to maximum rated voltage.

37. lf no calibration was made, select EXIT. lf a calibration was made, SAVE, then EXIT.

rated kVA at

5-27

Digital Coolant Temperature Display Calibration

Analog meter calibration 35. Select ">>" from the Main Menu (Page 5-9). From this menu proceed to the A­C VOLTS CAL TO; menu {Page 5-13).

A engine sensor calibration too! is required to perform this procedure. 30. With the genset OFF, replace the coolant temperature sender with the precision resistor provided in the calibration too!. 31. Select ">>" from the Main Menu {Page 5-9). From this menu proceed to the COOLANT TEMP L menu {5-11). 32. Calibrate the temperatura reading to match the temperature indicated on the calibration too!. 33. Repeat step 32 for COOLANT TEMP R if the engine uses two sensors. 34. lf no calibration was made, select EXIT. lf a calibration was made, SAVE, then EXIT.

36. Start the genset and allow the genset to reach normal operating speed. 37. Calibrate the analog Voltmeter to the digitally displayed value. 38. Calibrate the analog % Amps meter to the digitally displayed value. 39. Oallbrate the analog % Load meter to the digitally displayed value. 40. Calibrate the analog Frequency meter to the digitally displayed value. 41. SAVE, then EXIT.

5-28

ACCESSORY BOX CONTROL COMPONENTS

contains components that provide connection points for remote control and monitor options. The set can be equipped with one or more of the following components (customer terminal block TB1 is standard}.

The generator set accessory box (Figure 5-6} which is located on the backside of the control housing,

OPTIONAL RUN RELAYS K11,K12&K13

CUSTOMER TERMINAL BLOCK (TB1)

OPTIONAL RTD RELAY

OPTIONAL THERMISTOR RELAY 160/140° C

r=:-. ...__ __ __., I

I

o

o OPTIONAL COMMON ALARM RELAY K14

//

IHC6/71 (/ o

OPTIONAL THERMISTOR RELAY 160/140° C

OPTIONAL RUN RELAYS K11, K12 & K13

o

OPTIONAL COMMON ALARM RELAY K14

-.: : : ~tfflH~J~LJ~-'-~-º ®o

o

OPTIONAL RTD RELAY

!HC 4/5!

FIGURE 5-6. ACCESSORY BOX COMPONENTS

5-29

TB1 Customer lnputs Refer to Page 9-9 for typical connections to TB1. TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS A39/A40 TB1 TERMINAL# A39

1, 2, 3, 4

A40

FUNCTION

DESCRIPTION

Bus PT Input (On Bus PT Module)

Phase to Neutral input voltages from system bus (load side of paralleling breaker.

5

Remate Start

Clase to ground to start generator set. (RUN/OFF AUTO switch must be in AUTO posítion.) ..

6

Re mote Emergency Stop

Grounding this input causes a~ imfnediate shutdown.

16 -19

Customer Fault

Grounding these terminals initiates an alarm or shutdown condítíon in the control.

20

Fault Reset

Applying a rnornentary ground signa! to this terminal clears warning or shutdown faults in the control. (Except Emergency Stop.)

21

Engine ldle

Applying a ground signa! at this terminal will cause engine to run at recommended idle speed. Voltage will be disabled.

22

Low Fuel

35

Rupture Basin Alarm

Applying a ground signal to this point will cause the generator set to annunciate a Rupture Basin Alarm.

Common Alarm Warning

Form C output contact for remate indication of warning condition on generator set.

46

Utility Parallel Signa!

Apply a 24VDC sígnal to terminal 46 to indicate to the control that it is operating in parallel with a utility (mains) service.

47

Utility Parallel Signa!

Apply a ground signa! to terminal 47 to indicate to the control that it is operating in parallel with a utility (mains) service.

50

Master First Start/Synchronizer Enable

For isolated bus or multiple generator set utility (mains) applications, a B+ signa! from a remate Master First Start Sensor is applied on this terminal. For single generator set utility (mains) parallel applications, apply 24VDC to this terminal to enable synchronizer function in control.

41,42

-

Grounding this input activates the Low Fue! warning.

CONTINUED

5-30

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS (Cont.) A39/A40 TB1 TERMINAL# A40

51

FUNCTION Load Demand

1-------· -------------

(,':

DESCRIPTION Clase to ground to initiate load demand mode in PowerCommand control. (Select "Multiple" in Paralleling Setup Menu to enable load demand mode.)

--------------------------------------------------

51

Utility Single Verify

52

Breaker Open / lnhibit

Glose to ground to manually operr'the paralleling breaker or inhibit breaker closure.

53

Breaker Position

Glose to ground to indicate breaker closed.

54, 55

kVAR Load Share

Load Sharin.g Unes. Connect to load sharing lines in other generator sets in the system,

56, 57

kW Load Share

Load Sharing Unes. Connect to load sharing lines in other generator sets in the system.

59,60

Externa! Load Set

Analog O - 5 VDC input to control kW load level on generator set when the generator set is paralleled to utility.

For single generator set utility (mains) applications ("SINGLE" selected in the Paralleling Setup Menu), this terminal must be connected [strapped] to ground to enable breaker closure. (Version 1.06, beginning 9-26-96 only.) -·

Remote Start: When the Aun/Off/Auto switch is in - the Auto position, grounding this input initiates the engine cranking and start sequence. This circuit must be opened to permit resetting a shutdown condition with the Reset input.

message. This allows each customer "default'' fault message to be customized to represent the type of device that is attached the the fault input. The "default" message that is displayed, when ground is applied to the input, is as follows:

Low Fue/: Grounding this input actuates the Low Fuel warning. This input can be connected to a local day tank orto a main fuel tank that is located on site. When the switch grounds this designated input, the input will "wake up" the control, if it is not operating, and then initiate the fault.

Fault 1 = CUSTOMER FAULT1 Fault 2 = GRND FAULT Fault 3 = DAY TANK Fault 4 = HIGH GEN TEMP

Customer Fault lnputs 1 through 4: Grounding any one of these inputs activates the corresponding warning or shutdown sequence. Warning or shutdown status is selected in the setup menu.

lf Fault 2 or 3 input is grounded, the control will "wake up" if it is not operating, and then initiate the fault.

Externa! sensing equipment must be connected to the designated digital input.

Fault Reset: When the Aun/Off/Auto switch is in the Auto position and the remote start switch is open, grounding this input resets any warning and latched shutdown fault (except Emergency Stop, which must be reset at the front panel.)

The tour customer fault messages can be sepárately edited in the setup menu to display any desired

5-31

Engine /die: When the set is operating in the RUN mode, grounding this input causes generator build up to be inhibited and the engine to be governed at 800 RPM. When ground is removed from this input, the set returns to normal speed and voltage.

used to enable the synchronizer in the PowerCommand control. (See Paralleling Setup Menu, path B.) A 24VDC signal applied to the terminal will cause the generator set to synchronize with the voltage reference signa! applied to the bus PT module (A39).

Engine idle operation is applicable only in the AUN mode. The PCC operating program does not permit engine idle operation when the set is operating in AUTO mode.

Ali PCC's in a system should be programmed to a different first start fail time. This will help prevent simultaneous closure of breakers in the event of a failure of the master first start module

When the engine idle function is enabled, the control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed. When the engine idle function is removed and the set reverts to normal operating speed, the control automatically resets oil pressure warning and shutdown trip points to the normal settings.

Load Demend: On receipt of a signal on the Load Demand tepninats (normally open, close to ground), the genefator set will ramp down to a minimum load level and the paralleling breaker will open. The generator set will run for a cool-down period and shut down. LOAD DEMAND SHUTDOWN will be displayed on the PowerCommand panel.

Remate Emergency Stop: Grounding this input causes an immediate shutdown. Emergency stóp must be reset at the front panel.

When the Load Demand input is removed, the generator set will start, synchronize and close to the system bus and accept it's proportional share of the total load on the bus.

Master First Start/Synchronizer Enab/e: This input is received from a Master First Start Sensor, which is mounted remotely from the PowerCommand control. The input is a pulsed signal which is used by the PowerCommand control to enable safe closing of the paralleling breaker when the system bus is de-energized. the control will receive a pulse from the Master First Start Sensor approximately once per second. lf the PowerCommand control does not receive a pulse within the programmable time delay (default is 10 seconds), the FIRST START warning is displayed by the control and a backup system is enabled by the control.

The Load Demand function of the PowerCommand control is only active when the RUN/OFF/AUTO switch is in the AUTO position and "PARALLEL" is selected in the Paralleling Setup Menu. Utility Single Verify: For single generator set utility (mains) applications, this input must be strapped to ground before the generator set breaker will close when the utility breaker is opened. The Load Demand function of the PowerCommand control is only active when the RUN/OFF/AUTO switch is in the AUTO position and "SINGLE" is selected in the Paralleling Setup Menu.

When the system is set up for paralleling a single generator set with a utility (mains) bus, this input is

5-32

(~~>) l."

Utility (Mains) Para/le/ Input: Closure of a normal-

!Y open contact ~o ground on terminal 47 and apply-

mg a 24VDC s1gnal to terminal 46 will cause the PowerCommand control to begin operation in a utility (mains) paralleling mode. The ground signa! is usually applied by operation of auxiliary contacts in the utility paralleling breaker. In this operation mode, the control will ignore inputs from the load sharing lines and operate at the load level which is determined by the magnitude of the Load Govern signa! and the base load adjustment in the control setup. Load Govern: This input is enabled when the con-

trol has received a utility (mains) parallel input. A 0-5V signal applied to terminals 59 and 60 will direct the control to operate the genset at a fraction of the preset base load(%}. Operating load level is determined by the formula: ! 31.4 * (Load Set Voltage - 1) = % kW load ~

( 5-33

For Load Set Voltage of 1.0 volts and lower, the genset will ramp to no load. For Load Set Voltage levels 4.5 volts and higher, the genset will be controlled to the preset base load. A change in the Load Set Voltage will cause the genset to ramp to the new commanded kW level. Ramp rate is controlled by Ramp Load Time and Ramp Unload Time. (See Utílíty (Mains) Adjust­ ments elsewhere in this section.) In the load govern state, kVar load is always a function of the preset power factor and the % kW load. Para/le/ Brijaker Open/C/ose lnhibit: This function is operational only when the AUN/OFF/AUTO switch is in the AUTO position. Closing a normally open contact to ground on this contact will cause the paralleling breaker to open if it is closed, or prevent it from closing if it is open. Removing the ground signal will cause the PowerCommand control to return to normal operation.

Operating PowerCommand

in Droop Mode

The PowerCommand control is designed to operate isochronously (with no intended droop) so that voltage and frequency are as constant as possible when the generator set is paralleled to other PowerCommand generator sets. In certain situations, however, such as paralleling with other generators that are operating in droop mode, it may be necessary to operate the control in a droop mode for frequency, voltage, or both. Note that when the generator set is paralleled to a utility (mains) service it is recommended that the control be operated in its utility parallel mode, rather than in droop, even if other generator sets in the system operate in droop for that function. The droop mode in PowerCommand will only work when all the other generator sets in the system are operating ir;1 droop and the system bus voltage and frequency change with load. PowerCommand controls that are set up to operate in droop mode must include the paralleling option (H532). The generator set should be set up for multiple unit paralleling, but load sharing interconnecting wiring is not used. Connect a 5K resistor across terminal A40-TB1-54 and 55 (KVAR) to cause voltage to droop. A 5K resistor across terminal A40-TB1-56 and 57 (KW) will cause frequency to droop. Resistors can be used on one or both of the load sharing terminal connections, depending on the needs of the application. Complete all start up procedures as described in Section 8 of this manual up to the point that you are ready to make load sharing adjustments. To set the

5-34

governor and voltage regulation system droop level: 1. Set the no load speed and voltage at the desired level. Bus must be de-energized when this setting is made, or disconnect Bus PT module. 2. Apply 100% load to the generator set, and adjust the KW load sharing gain to obtain the desired full load operating frequency. Adjust the KVAR load sharing gain to obtain the desired full load operating voltage. Refer to Figure 5-7 for typical gain settings for specific droop levels. .1 3. Repeat the process for other generator sets in the system. 4. When initial settings have been made, test the system with all available load, and verify that the generator sets share load approximately equally at no load and maximum available load. · Proper adjustment of load sharing in droop operation requires use of both real and reactive load banks. lt is possible that precise load sharing will not be possible with all generator sets in the system at all load levels, due to the non-linearity of the droop characteristic of some generator sets. In that case, it P... •··.··_....· ,·•·.·..,.·.,,·-.·•,··,.·'. is generally best to set up the system so that avail- \ .. :.:_ . , able load is equally shared at the maximum load leve! expected on the system. Note also that the synchronizer is active and functional in PowerCommand even when the system is set up for droop load sharing. Manual paralleling and system synchronizing should be performed by the PowerCommand control. lt is recommended that paralleling breakers be electrically operated by the PowerCommand control.

%DROOP 9.00 8.00

--%DROOP @1800 RPM - - - - - % DROOP @1500 RPM

7.00 6.00 5.00 4.00 3.00 2.00

.!

1.00 O.DO 2

3

4

5

6

7

8

9

10 11

12 13 14 15

16 17 18

19

LOAD SHARE GAIN '

FIGURE 5~7. PERCENT SPEED DROOP VERSUS KW LOAD SHARE GAIN

(.

5-35

TB 1 Customer Outputs Refer to Page 9-9 for typical connections to TB1. TABLE 5-4. TB1 CUSTOMER OUTPUTS TB1 TERMINAL#

FUNCTION

DESCRIPTION

1

B+ Auxiliary Power 24 VDC control power supply, fused at 20 amps.

2

Switched B+ Auxiliary Power

3,4

24 VDC control power available when genset is running, fused at 1 O amps.

..

Ground

I

.

7,8,9

Common Shutdown

Form C contact set to indicate to a remate device that a generator set shutdown fault has occurred.

10, 11 N-K20

Parallel Breaker Clase Signal

Normally open contact which clases to clase a remate paralleling breaker.

14, 15 23-32,33

.

I

Network Data

Terminationé far network data twisted pair, operational when generator set is equipped with generator cornmunicatlons module (GCM).

NFPA Fault Contacts

Normally open contact which clases to indicate that a specific fault has occurred in the generator set. Common is terminal 33.

-

38,40

Ready to Load

lndicates that the generator set is at rated frequency and voltage and is ready to accept load. Normally open contact between 38 and 40, which is common.

39,40

Load Dump

Normally open contact which clases to indicate that the generator set is overloaded.

41, 42

Common Warning

Normally open contact that clases to indicate a warning condition on the generator set.

43,44

Common Warning

Normally closed contact that opens to indicate a warning condition on the generator set

48,49 N-K21

Parallel Breaker Open Signal

Normally closed contact which opens to clase the paralleling breaker.

5-36

Paralleling Breaker Control: Contacts are provided to allow the PowerCommand control to operate a remote paralleling circuit breaker. A normally open contact will close to signa! the paralleling breaker to close. A normally closed contact will open to open the paralleling breaker.

When the RUN/OFF/AUTO switch is in the RUN position the breaker signals will be initiated on operation of the paralleling breaker control switches on the front panel of the PowerCommand control. The breaker control switches on the front panel of the control are not operational in other control operation modes.

Common Alarm: One set of form-C contacts, rated for 2 amps at 30 VDC. Any shutdown causes the common alarm relay to be energized. This output is often used to energize an audible alarm. Load Dump: One set of normally open (NO) contacts, rated for 2 amps at 30 VDC. lf an overload occurs which causes generator set frequency to drop more than 3 hertz below nominal for more than 3 seconds, or a load of more than 105% of the standby rating is applied to the generator set for more than 60 seconds, the normally open load dump contacts are closed. This relay is energized befare shutdown (ter overload or underfrequency) occurs. Ready To Load: One set of normally open (NO) contacts, rated for 2 amps at 30 VDC. This output is activated whenever AC voltage and frequency exceed 90% of nominal.

When the RUN/OFF/AUTO switch is in the AUTO position, the PowerCommand control will automatically close the paralleling breaker if the system bus is de-energized and the master first start sensor pulse is received, or if synchronous condition wíth the bus is achieved.

Switched B+: This is a fused 1 O amp, 24 volt switched output. This output is activated by the run pilot signa!, at the governor output module. (Fuse is located on Governor Output Module.)

Warning Alarm: One set of _[lOrmally open (NO) and one set of normally closed (NC), rated for 2 amps at 30 VDC. Any warning causes the warning alarm relay (labeled Spare Relay on Customer Interface board) to be energized. This output is often used to energize an audible alarm.

B+: This is a fused 20 amp, 24 volt output. (Fuse is located on TB-BAT terminal block of the engine harness.)

5-37

Run Relays (K11, K12, 13)

fans, pumps and motorízed air dampers. The run relays are energized when the generator set reaches operating speed.

The optional run relays are raíl mounted insíde the accessory box (Figure 5-6). The raíl mount allows you to easily remove and replace the snap-on relays. The generator set can be equipped with one, two or three run relays.

The contacts are rated: • 10 amps at 28 VDC or 120 VAC, 80%PF • 6 amps at 240 VAC, 80%PF

The three-pole, double-throw run relays (Figure 5-8) are used to control auxiliary equipment such as

K11, K12,K13

• 3 amps at 480/600 VAC, 80%PF

~~

-c..__,:. 4 2

K11, K12, K13 ~ T

;;>-

8 5

CUSTOMEA CONNECTIONS

3 K11, K12, K13 ~ T

9

"'

6

K11 AUN AELAY

K12 AUN RELAY

K13 AUN RELAY

@@@

NO

NO

@@@

NO

@®CD

@@@

NC

@®CD

NC

@®CD

NC

ll-h_c_o_,_L_ A40-TB1 -4 COM (B-)

FIGURE 5-8. OPTIONAL RUN RELAYS (K11, K12, K13)

5-38

Shutdown Alarm Relay (K14)

vices such as audible alarms. Any generator set shutdown will energize the alarm relay.

The optional shutdown alarm relay is rail mounted inside the accessory box (Figure 5-6). The rail mount allows you to easily remove and replace the snap-on relay.

The contacts are rated: • 10 amps at 28 VDC or 120 VAC, 80%PF • 6 amps at 240 VAC, 80%PF

The three-pole, double-throw shutdown alarm relay (Figure 5-9) is often used to energize warning de-

• 3 amps at 480/600 VAC, 80%PF

_,

K14

CU.STOMER CONNECTIONS

K14

K14

(.

J ./" "

K14 COMMON SHUTDOWN ALARM

JUMPERWIRE REQUIRED FOR K14 RELAY OPTION

A40-TB1-4 (GND)

~

@@@

NO

@®CD

NC

A40-TB1-8 (COMMON SHUTDOWN ALARM) A40-TB1-1

(B+)

®®

G)

FIGURE 5·9. OPTIONAL SHUTDOWN ALARM RELAY (K14)

5-39

A40-TB1-7 (COMMON SHUTDOWN ALARM)

RTD Relay (Optional)

LED's are used to indicate which inputs exceed the setpoint.

The optional RTD relay is raíl mounted inside the accessory box (Figure 5-6). This relay is used to monitor six separata temperature zones in the generator windings using resistive temperature detectors (RTDs). The relay determines the sensed temperature and acts to isolate, alarm, or initiate correctiva action.

The relay terminals 11, 12 and 14 are for customer connection. These terminals can be attached to any one of the tour Customer Fault inputs on TB 1 to provide a warning/shutdown condition or to other customer warning devices. (Refer to Setup Menu in this section, which describes how to modify the customer fault message and to select a warning or shutdown condition.)

The RTD relay (Figure 5-1 O) compares the six inputs to the predeterminad setpoint (temperature setpoint is factory adjusted). lf one or more of the inputs exceed the setpoint, the output relay is energized. LED's indicate the state of the output relay (green for normal, red for tripped). Additional red

The contacts..are rated: • 240 VAé, 5 amps non-inductiva • 24 VDC, 25 amps resistive

TEMPERATURE RELAY CONNECTIONS

1 1 2 3

tJJ tJJ tJJ tJJ tJJ 2 3

1

2

1

3

2

1

1

e

B

A

3

2

3

1

o

1

REO WHITE WHITE REO WHITE WHITE RED WHITE WHITE REO WHITE WHITE REO WHITE WHITE

RED

• 1 1 1

E

R T

SET

e

•

rr .

12 1

11

e

ALARM

14

o F

(+)

PWR

1

(-)

1

OUTPUT RELAY (CUSTOMER USE)

-

SAFE

24VDC

L

3

A40TB1-4 (GROUND)

1

2

L

A40TB1-2 (SWITCHED B+)

FIGURE 5-10. RTD RELAY (OPTIONAL)

5-40

WHITE WHITE

TO RTD TERMINAL BLOCK

Thermistor Relay (Optional)

when the thermistor chain resistance reaches 3000 ±500 ohms.

The optional thermistor relays are raíl mounted inside the accessory box (Figure 5-6). Each relay monitors three thermistors (one per phase) that are connected in series inside the generator. One series or chain of thermistors are rated at 140º e and the other at 160º C. The 140º C relay is commonly used in a pre-alarm circuit and the 160º C relay in a shut-down circuit. The relay will energize (trip)

The relay terminals 1, 2 and 3 are for customer connection and are normally connected to a breaker shunt trip ora load shed circuit (Figure 5-11). The contacts are rated: • 3 amps at 250 VAC • 1 amp at 480 VAC

I

THERMISTORS

BLUE

----------...

0 A

WHITE/RED B0C~

/'

~

FAULT CHANNELS (CUSTOMER CONNECTIONS)

A40-TB1-4 (GROUND) A40-TB1-2 (SWITCHED B+) RELAY CONTACTS

FIGURE 5·11. THERMISTOR RELAY (OPTIONAL}

5-41

ENGINE SENSORS

ers to which the PCC responds. The switches function by closing the fault or warning circuit to the engine chassis ground (battery negative [-]). The low coolant leve! switch has its own ground wire.

Figures 5-12 through 5-15 show the locations of the oil and coolant temperature and oil pressure send-

L10 & M11 SERIES

LOWCOOLANT LEVEL SWITCH

COOLANT TEMPERATURE SENDER

D

¡_

o

o OIL PRESSURE SENDER (FAR SIDE)

OIL TEMPERATURE SENDER (FAR SIDE)

NT855 & N14 SERIES

D OIL PRESSURE SENDER (FAR SIDE)

OIL TEMPERATURE SENDER (FAR SIDE)

FIGURE 5-12. ENGINE SENSOR LOCATIONS (L10 & M11 / NT855 & N14 SERIES ENGINES)

5-42

LOWCOOLANT TEMPERATURE SWITCH

COOLANT TEMPERATURE SENDER (1WO)

KT19 SERIES

/

LOW COOLANT LEVEL SWITCH

D

t-------,---L_J

D ..._______

•

__

~_·

-\--

OIL TEMPERATURE SENDER (FAR SIDE)

....-_:·.

( ..

VTA28 SERIES

LOW COOLANT TEMPERATURE (FAR SIDE)

OIL PRESSURE SENDER (FAR SIDE)

COOLANT TEMPERATURE GAUGE SENDER

LOW COOLANT LEVEL SWITCH

\

D l"·-

OIL PRESSURE SENDER

OIL TEMPERATURE SENDER

...

FIGURE 5M13. ENGINE SENSOR LOCATIONS (KT19 /VTA28 SERIES ENGINES)

5-43

TABLE 4-30a. LOW AC VOLTAGE SHUTDOWN (303)

I Many troub/eshooting procedures present hazards that can result in severe personal inju­ ry or death. Only trained experienced service personne/ with know/edge of fuels, e/ectricity, and me­ chinery hazards shou/d perform service procedures. Review safety precautions on pages iii and iv.

!AWARNING

lndicator(s)

Possible Cause

Corrective Action

"LOWAC VOLTAGE" shutdown (303) message.

1. PMG or field wiring could be faulty.

1. lf output voltage is low and both A37/DS2 and A31/DS1 O are on, check and repair the PMG or field wiring. 2. Check each diode according to Servicing the Generiitor in Section 6. Service as necessary. I 3. Check the load and correct any overload. 4. Check connectors J8 and J9 on A36, J3 and JS on A34, and J7 on A37. *5. lsolate the genset output from the load. Reset the control, restart the set, and measure AC output voltage with a multimeter. a. lf output voltage is high, refer to the troubleshooting section for High AC Voltage Shutdown (301 ). lf output voltage is normal, the problem must be in the voltage sensing circuitry (A32 or A33}. lsolate, using the analog input troubleshooting procedure ( Table 4­36a/b). Check the phase that shows a low voltage on the PCC display. *b. lf output voltage is low, the control cannot drive the output voltage high enough. The problem could be A37, A31, or A32. Restart the set and monitor isolated B+ supply LED A37 /DS 1 , output duty cycle LED A37/DS2, and AVR duty cycle LEO A31/DS10. • If A37/DS1 is not on, disconnect A3 J7/P7 and check far B+ at P7-1. (Control must be in Run mode for B+ reading.) • lf B+ is OK to A37, replace A37 . • lf A37/DS1 is on, check A31/DS10 (with the set running). • lf A31/DS1 O is not on with set running, check far continuity: A31 J1-2 to J4-10 and A31 J1-1 to J4-11 (270 ohms). lf no continuity, replace A31. • lf A31 is OK, replace A32 . • lf A31 /DS1o is on with set running and A37/DS2 is not on, check the harness. • lf the harness is OK, replace A37.

2. The rotating rectifier assembly (diodes CR1 through CR6} is faulty. 3. Overload. 4. There may be a loose connector in the control loop.

!

!

Sa. The problem may be the analog board (A33) or the digital board (A32).

Sb. The problem may be the regulator module (A37), the engine interface board (A31 ), or the digital board (A32).

(. . .....

(Continued)

*CAUTION: Wearing wrist strap, set 512 to Off and A32 55 to Standby before connecting/disconnecting harness plugs.

4-47

COOLANT TEMPEAATURE SENDERS (TWO)

KT38 SERIES

D

o OIL PRESSURE SENDER (FAR SIDE)

OIL TEMPERATURE SENDER (FAR SIDE)

FIGURE 5-14. ENGINE SENSOR LOCATIONS (KT38 SERIES ENGINE)

5-44

('"..:"··~\ ,- ./ ..,·... , ..

se ,ce ,He GENERATORS 3 PHASE RECONNECTABLE VOLTAGE CONNECTION

VOLTAGE CONNECTION CURRENT

CURRENT TRANSFORMER SECONDARY CONN 1-J 100/200V. 50HZ 110/220V, 50HZ 115/2JOV, 50HZ 120/240V, SOHZ

268/460V, 60 HZ (R027) 260/450V, 50;60 HZ (R109) 277/480V, 60 HZ (R002) 200/J46V, 50 HZ {R068)

DFAA DFAB DFAC DFBF DFCB DFCC DFCE DFEB DFEC DFED DFFB DFGA .DFGB bFJA DFJB DFJC DFJD DFLB DFLC DFLD DFMB DQAA DQAB DQBA DQBB

• RANGE • 220 - 277/380 - 480V

• RANGE • 110 - 139/190 - 240V

• RANGE • 100 - 120/200 - 240V

THIS DRAWING APPLIES TO: MODEL BEGIN SPEC LETTER

SECONDARY CONN 1-2

220/380V. 50 ;80 HZ (R099) 2J0/400V. 50 HZ (R029) 240/416V. 50 HZ (ROOJ) 255/440V, 50;60 HZ (R023)

110/190V. 50HZ {R004) 115/200V, SOHZ (ROSO) 120/208V. 50;60 HZ (R098) 1J3/2JOV, 50;60 HZ (R057) 127/220V. 50;60HZ (R020) 139/240V, 60HZ (R067) 115/220V , 50HZ

(R79) (R028) (R071) (R106)

TRANSFORMER

CT21

CT21

LI (U)

L2(V)

UI (T1}

LJ(W) LO(N)

V5(T8) V2(T5) U5(T7) U2(T4)

FRAME 4

l .

5

•

w

W1 T3 6 V6fT11) V1 T2) U6 (T1 O) 7 U 1 (T 1 ) W6(T12)8

V

u

U2r4 V2 T5 ,_ W2 T6 6 W5(T9) 7 V5(T8) 8 U5 (T7)

/

N

.....

w "'-

...

V

Wl {T3)

v

6

V6fT1 V1 T2 U6(T10)1 ui (T1 ) W6 (T 12 )8

ºj

W5 (T9)

V2(T5)

V5 (TB)

U2(T4)

U5(T7)

u

(r t )

V1 (T2)

NOTES:

U 1 (Tl )

1.

FRAME 5 ,6 ,& 7

AC RECONNECT WIRING DIAGRAM (SHEET 3 OF 4)

9-5

V

7 N

U6~T1 V6 T11 W6 T12 W2(T6)

W6r12~ V6 T11 U6 T10 W1 (T3)

w

V1 (T2) U1

4

N

U6 {TT11 1 V6 W6 T12 W1 (T3)

u

O!

N

FRAME

,'-

FRAME 5,6,&

FRAME 5 ,6 ,& 7

W5 W2 ~T9} T6 V5 T8 V2 {T5) U5 (T7) U2 {T 4)

U .V .W .N.

U .V .W .N.

FRAME 4 W5(T9) W2(T6)

SERIES STAP 3 PHASE 4 WIRE OUTPUT TERMINALS

PARALLEL STAR 3 PHASE 4 WIRE OUTPUT TERMINALS

SERIES DELTA 3 PHASE 4 WIRE OUTPUT TERMINALS U .V .W .N.

~-.r---5

5 W1 (T3) 6 Vl (T2) 7 Ul (Tl ) 8

W5(T9)

5.------1--

W2 (T 6) V5(T8) 7 V2{T5) U5 (T7) 8

U2(T4)

W6{T121 V6 Tl 1 U6 T10 Wl (T3) V1

(T2)

U1

(T1 )

E E E L L L A K D A L E E L L L D L

L

L L A A A A

UVW PHASE SEQUENCE WITH C.W. FACING DRIVE END. 2. TIE BACK UNUSED LEADS.

ROTATION

3. WHEN RECONNECTING GENERATOR LEADS, SHOULD BE TORQUED AT 68 ~6 FT-LBS. FOR FRAMES 5, 6 AND 7.

BOLTS

4-. WHEN RECONNECTING

BOLTS

GENERATOR LEADS, SHOULD BE TORQUED AT 22 ~2 FT-LBS. FOR FRAMES 4- •

5. NEUTRAL FLOATED FOR DELTA CONFIGURATION. TIE LEAD 5 BACK INTO HARNESS. 6. The dot on the side of the current transformer (Cl) must face the generator. A dot is also used to mark terminal 1. CT terminal 1 connects to the meteñng circuit Terminal 213 connects to ground.

No. 625-3100 sh 1 of 2 Rev. F Sys: Revisio Modified 4/3/97

THIS DRAWJNG APPLIES TO: BEGIN MODEL SPEC LETTER

se ,ce ,He GENERATORS 3 PHASE NON-RECONNECTABLE

MEDIUM VOLTAGE CURRENT TRANSFORMER SECONDARY CONN 1 - 2

CURRENT TRANSFORMER SECONDARY CONN 1 - 2 2400/4160V, 60 HZ {R107) 1905/JJOOV, 50;60HZ {R108) 13800V, 60 HZ

~

UI (TI)

346/600V, 60HZ (R114)

1905V, 50HZ {R120) 2400V, 60 HZ (R121)

L1 (U)

CT21

CT I L 1 (U)

.--------"'""'**:f--

PU2

CURRENT TRANSFORMER SECONDARY CONN 1 - 2 220/380V, 240/416V, 277/480V, 347/&00V, 120/208V , 127/220V,

50 ;60 80 HZ 60 HZ 60 HZ 80 HZ 80 HZ

HZ {R099) (ROOJ) (R002) (R114) (R098) (R020)

230/400V, 50 HZ (R029) 254/440V, 50HZ (R023)

220/440V, 50 HZ (R019) 240/480V, 60 HZ (R119)

SPECIAL WINOINC SPECIAL WINOINC SPECIAL WINOING

CT21 .......,,,:-,:,"T"'""--L.Jl-i+

LO(N)

U1 (TI );------'"'=k,J-

CT21

L1 (U ) _,

L1 {U)

CT22

L2(V) CT23

LO{N)

L3(W)

CT23

~-----

~~q~~ --e• u2h4j W1 {TJ)

---+,.

FRAME 4 ,5

,&

LJ (W)

L2(V) CT23

6

FRAME 5,6, & 7

Vl (T2) ----

PRIMARY JUMPERS WYE CONNECTIONS; PV1 - PW1 - PU1

W5(T9) W2(T6) V5(T8) V2(T5) U5(T7) U2(T4)

(-NEWAGE-) TRANSFORMER PTU

PU2--PU1

~-----"L-l--1+ L3 {W) '-------LO(N)

l3(W)

FRAME 5,6,&

N W2(T6) V2(T5) U2(H)

7

W5(T9) W2(T6) V5{T8) V2(T5) U5(T7) U2(H)

W5(T9) W2(T6)

~---..;~~~ 7 -----'-''--'--<--

L

A K

D A

L

E E

L L L

D L

L

L

L

A A A A

FRAME 4

N

W1 (TJ) 6 V1 {T2) 7 U1 (T1) 8

E E E L L

DFAA DFAB DFAC DFBF DFCB DFCC DFCE DFEB DFEC DFED DFFB DFGA DFGB DFJA DFJB DFJC DFJD DFLB DFLC DFLD DFMB DQAA DQAB DQBA DQBB

8

V5(T8} V2(T5) U5(T7} U2(T4)

W1 T3 6 V6 T11) V1 T2 U6 T10) 7 U1 T1 W6(T12) 8

!~­ AUX-'Z ------7B

A - 4160 VOLT WYE B - 3300 VOLT WYE PV1

PW1

N

PRIMARY JUMPERS DELTA PV1 PWl PUl

CONNECTIONS; - PU2 - PV2 - PW2

A - 2400 VOLT DELTA

No. 625-3100 sh 2 of 2 Rev. F Sys: Revisio Modified 4/3/97

AC RECONNECT WIRING DIAGRAM (SHEET 4 OF 4)

9-6

ll.lSTll'ICR COtN:CTIOf'5(5[[

S!fiT 3) A.'HKIATOR QJSHKR C<JKCTICJIS(S[[

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RON ouT •••• DIGITAL DISPLAY ASSEMBL Y 300-~0BI 1--~R~... e:..,ou,,,.T_""'·-·I.L.1·./l,.,-Jl~'~"~'-~·~v~•""~T~)~J~·~-~·~~-------,r------a..a.a........a=.-------,,---------1 tSTOP SET ••••

1

512

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No. 612-6675 sh 1of 3 Rev. B Sys: HP Modified 11 /7/96

BLOCK DIAGRAM (12 LEAD)

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No. 612-6675 sh 2 of 3 Rev. B Sys: HP Modified 11 /7/96

BLOCK DIAGRAM (6 LEAD)

9~8

CUSTOMER TERMINAL BLOCK (PARALLELING) ..

TBI

TB BAT-Fl

1

Pl2-2

2

A34-Pl-l3 A3'1-Pl-7

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4

4

s

5

í1:

6

A3'1-P2-IO

7

A34-P2-9 A3'1-P2-'1

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11

P12-S

12 13

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A3
1 1 1 1

A3'1-P3-17

1 1 1 1 1 1 1 1

I

A34-Pl-20 A3<1-P3-19

25 27

28

A34-P3-18 A34-PJ-19

24 26

A3<1-P3-16

A3<1-Pl-2

21 23

A3'1-P3-JO A3<1-P3-12

20 22

A34-P3-2 A3<1-P3-J

16

19

A34-PJ-2

1 1 1 1

15

18

A3'1-Pl-16

1 1

14

17

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1 1

9 lo

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29 30 31 32 33

6

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10

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l

NET DATA 2 FAULT

CUSTOMER

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CUSTOMER

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3

CUSTOMER

FAULT

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IY I

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A34-P2-16 A34-P2-2

A34-Pl-l

l

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LOW FUEL

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NOT ON AUTO ENGINE

A34-Pl-15CWHITEl

TEMP

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TEMP

A34-P2-IS A34-P2-23

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REMO TE »; ANNUNCIATOR ill

LOW FUEL LOW COOLANT PRE-LOW

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1

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1

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HIGH ENGINE 26 ,._ OVERSPEED 27 ,_ OVERCRANK 28 ,_ 29 ,_ 30 ,_ 31 ,_ 32 ,._

~:

1

SI-IJTOOHN

1

CONT HTR 2

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(N/0)

FAULT

CONT HTR

COMMON

11 ,_ CN/0)

12 ,_ 13 ,_ J 4 ,_ 15 ,_ 16 ,_ 17 ,_ 18 ,_ 19 ,_ 20 ,_ 21 ,_ 22 ,_ 23 ,_ 24 ,._ 25 ,_

P12-9

FUSED>

GROUND REMOTE REMOTE

TBI

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1 ,..._ B+C20A

OIL PRESSURE

LOW OIL PRESSURE 33 ,._ COMMON

-

34

3<1

35

35

36

36

,-

37

37

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38

38 ,._ CN/0)

39

39

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40 41

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44

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<15

45

46

46

47

48

47 ,- UTILITY 48 ,- C N/C)

49

49

50

,-

,-

RETURN RUPTURE

CONTROL !>c.. } BOX HEATER ~

12 O OR 24 OVAC READY

C N/0 l LOAD

TO LOAD~ DUMP

&

NOTES:

8

CN/0)

}WARNING,¡}, ALARM O

CN/CJ

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52

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53

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57

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58

58

59

59

60

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PULSEO INPUT TO ENABLE GENSET AS íIRST ON LINE íOR MUL TIPLE UNITS. [N snr..1.E/UTILITY PARALLEL HOOC, APPLY 24VOC TO ENABLE SYNCHRONIZER. IN HULTIPLE UNIT OPERAT!ON HOOC APPLY GROUNO TO CAUSE LOAD DEMAND STOP. IN SIN"ol.E 1'.00C, GROUND TERMINAL TO ENABLE BREAKER CLOSURL

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THIS IS A REPRESENTATIVE (GENERIC) SCHEMATIC/WIRING DIAGRAM. FOR TROUBLESHOOTING, REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET.

MPS2222A

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GND

NO. 300-4084 sh1 REV. D MODIFIED 6/7/94

GOVERNOR OUTPUT BOARD (A38)

9-18

(·-·-~·

THIS IS A REPRESENTATIVE (GENERIC) SCHEMATIC/WIRING DIAGRAM. FOR TROUBLESHOOTING, REFER TO THE WIRING DIAGRAM PACKAGE THAT WAS INCLUDED WITH YOUR GENSET.

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TABULATION FROH TO STATION STATION A36-P9-1 I CT22-I A36-P9-10 CT22-2/3 A36-P9-9 CT21-I A36-P9-6 CT21-2/3 A36-P9-7 CT23-I A36-P9·6 CT23-2/3 A36-P9-4 6 A36-P9-3 7 A36-P9-2 6 A36-P9-I 5

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NO. 338-3019 sh1 REV. C MODIFIED 6/9194

PT/CT WIRING HARNESS

9-19

A38

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(SEE IJETAIL"A")

CGOV)

A37 PlO

----

(AVR)

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(CHHJll)

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(AVR)

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E2-6 11'11-111 PIHH 1'11-7

E6-A E6-II

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PIC>-1 PIC>-4

THIS DRAWING APPLI ES TO: MODEL THROUGH SPEC LETTER E DFAA DFAB E DFAC E

--

181-1

...... ....... l'IH7

fn+ 81-IIAT ------'

Al2IIIMIKR

NO. 338-2938

REV.E

DETAIL "A"

MODIFIED 8/15/94

L10 ENGINE HARNESS DIAGRAM

9-20

A38

TB-BAT

P6

(GOV)

(SEE DETAil

"A")

A37 P10

----

(AVR)

TB1-3

DETAIL

(GND-DICI)

"A"

TB1-1

A37

(TIHIAT)

P7

57-SIG

(AVR)

(P4-7)

K4-S1

(P7-6) I

P1 MAG PICK-UP

j

P4

~

S7(+)

{TB-BAT)

A------

Et-A

(PS-2)

57(-) {GNO-ENG)

E4

P5

ACT-+ (P6-6)

LEAD TABULATION TO FROM STATION STATION P4-6 TB-BAT P4-16 GND-ENG P4-5 TB-BAT P4-15 GND-ENG S7-SIG P4-7 P4-1 TB-BAT P4-3 GND-ENG P4-4 P4-2 P7-5 P6-19 P4-1 4- 4 P4-22 P4-21 P4-9 P4-19 12 6-3 P4-10 P7-3 P4-11 P7-4 J12-5 P6-7 GND-ENG J12-6 P4-1 J12-7 P4-18 P4-18 E2-A PS-.S E2-B PS-11 PS-2 El-A P5-18 Et-B P5-1 E1-C P5-21 ES-A P5-7 E6-B TB-BAT TB1-1 1GN - N P5-5 E4-A P5-13 E4-B P5-17 TB-BAT P5-9 GND-ENG

VR21 59 58 57 PS-15 PS-23 P6-6 P6-8 1-BAT GND-ENG 81-GND TB-BAT GND-ENG K4-BA K4 + TB-BAT GND-ENG P10-1 P10-4 P10-5 P10-6 P10-3 J12-2

K4-S2 S9 GND

L10 & M11 ENGINE HARNESS DIAGRAM

9-21

ACT (-) (P6-8)

T26

LEAD TABULATION ,. FROM TO STATION STATION

VOLTAGE REGULATOR RUPTURE BASIN LOW FUEL LOW COOLANT LEVEL

(LCL)

SS S5 54 53 52

THERM05TAT (PRE-HET) SWITCH-PRE55 (PRE-LOP) SWITCH LOW ENGIHE TEMP (LET) SWITCH-OVERSPEEO {OS) THERM05TAT (HET)

51 P1 K4 K2 K1

SWITCH-OIL PRE55 (LOP) MAG PICKUP 5TARTER PILOT 50LENOID PREHEAT 50LENOIO (GLOW PLUG5) FUEL SOLENOIO

HTR G1 E7 E6 ES

ENGINE HEATER ALTERNATOR EXH TEMP fRIGHT) EXH TEMP LEFT) TACHOMETER

BT1

5ENDER-OIL TEMP 5ENOER-WATER TEMP fRIGHT) 5ENDER-WATER TEMP LEFT) 5ENDER-OIL PRE5SURE BATTERY-5TORAGE

81 A12

STARTER & 50LENOID GOVERNOR

E4

E3 E2 El

THIS DRAWING APPLIES TO: MODEL BEGIN SPECLETTER DFAA F DFAB F DFAC F DOAA A A DOAB

NO. 338-3393 REV.8 MODIFIED 4/15/97

HTRl-1 (1261

Jl2

V

HTRl-2

S8

(CH>-EIGI

(p.i-1,1

S9

(J12-9J

A38 P6

SEE DETAIL "A"

(GOVJ

TB-BAT

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GI-GtO

CAVR)

UH>-E«ll

S7-SIG

GHlJT

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(81-eAT)

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P4-16 P4"" P4-18

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(1'15-7)

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Pll-21 Plt-7

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E6

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GND-ENG

PI-A CP4-22l PI-B (P4-21 l PI-SHIELD (P4-9J

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12 11

PI IU IC2 1(1 GI

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1..111 R.E. 1..111 IDUMT I..E'll1. ILa.l lKJINDSl'AT(PAE~I tlm'OH'IIEN IPAE-IJPI IIIITQI 1..111 -9IIITQHMSISUD

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DETAIL "A"

THIS DRAWING APPLIES TO: MODEL THROUGH SPEC LETTER L DFBF

DFCB DFCC

L

L NO . 338-2604 REV. E MODIFIED 8/12/94

NT855 ENGINE HARNESS DIAGRAM

9-22

1)..,38

TBl-1

TB-BAT

{c~)

SEE DETAIL "A"

DETAIL "A" A37 PtO (AVR)

A37 P7

(AVR)

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" i\

.:.:<":l

LEAD TABULATION FROM TO STATION STATION TB-BAT P4-6 P4-16 GND-ENG TB-BAT P4-5 GND-ENG P4-15 P4-7 S7-SIG 4-1 S4 P4-3 TB-BAT P4-4 GND-ENG P7-5 P4-2 P4-1 P6-19 4-14 P4-22 PI-A ~MAG PUl P4-21 Pt-8 MAG PU P4-9 PI (SHIELD) P4-19 P6-2 P4-12 6-3 P4-10 P7-3 P7-4 P4-11 P6-7 J12-5 GND-ENG J12-6 P4-1 J12-7 P4-t8 P4-18 E2-A P5-3 P5-11 E2-B P5-2 El-A PS-18 E1-B P5-1 Et-C PS-21 E6-A E6-8 P5-7 TBl-1 TB-BAT GND-ENG T81-3 P5-5 E4-A E4-B P5-13 TB-BAT PS-17 GND-ENG P5-9

(P5-11)

LEAD TABULATION FROM TO STATION STATION TB-BAT TB-BAT K1 P7-1 Gl-0+ GND-ENG GND-ENG ACT+ ACTG1-B+ G1-GND GND-ENG S7+ S781-BAT 81-SW 81-BAT P7-2 PMGP2 PMGP3 PMGP4 X+ XXP6-12 -1 P5-4 P3-A P3-B P3-C P7-6 GND-ENG J12-9 GND-ENG

P6-1 P6-16 P6-20 P6-21 P6-22 P6-4 P6-15 P6-23 P6-6 P6-8 81-BAT GND-ENG 81-GND TB-BAT GND-ENG K4-BAT K4 + TB-BAT GND-ENG PI0-1 Pl0-4 P10-5 P10-6 P10-3 J12-2 P5-12 G1-B+ T26 G1-GND K4-S1 K4-S2 S9 GND

NT855 & N14 ENGINE HARNESS DIAGRAM

9-23

GND-ENG

Pt

VR21 SB S7

VOLTAGE REGULATOR LOW FUEL LOW COOLANT LEVEL (LCL)

56 SS S4 S3 S2

THERMOSTAT (PRE-HET) SWITCH-PRESS (PRE-LOP) SWITCH LOW ENGINE TEMP (LET) SWITCH-OVERSPEED (OS) THERMOST AT (HET)

S1 Pl K4 K2 KI

SWITCH-OIL PRESS (LOP) MAG PICKUP STARTER PILOT SOLENOID PREHEAT SOLENOID (GLOW PLUGS) FUEL SOLENOID

HTR GI E7 E6 ES

ENGINE HEATER ALTERNATOR EXH TEMP RIGHT) EXH TEMP LEFT) TACHOMETER

E4 E3 E2 Et BT1

SENDER-OIL TEMP SENDER-WATER TEMP ~RIGHT) SENDER-WATER TEMP LEFT) SENDER-OIL PRESSURE BATTERY-STORAGE

81

A12

T26

f

STARTER & SOLENOID GOVERNOR

THIS DRAWING APPLIES TO: MODEL BEGIN SPEC LETTER M DFBF DFCB M DFCC M DFCE A DQBA A DQBB A

NO. 338-3392 REV.C MODIFIED 4/15/97

A38 P6

HTRl-1

(GOVl

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(1'26)

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(CH>-ell)

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P4 E6

P5

IIJ.OCI ------------

f>IG>2(PIO-I)

PIG>3(PI0-4)

PMGP4(PIO-!S)

X+(PI0-6) XX-CPI0-3) PI-A

(P4-22) Pl-8 (P4-21 l PI-SHIE.D CP4-9l

P4-16 P4-t5 P4-IIJ

o EI-C (l~-11

89

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DETAIL "A"

IATIDIY8TMITTR•DDmD

N0.338-2605 REV. E MODIFIED 8/12/94

K19 ENGINE HARNESS DIAGRAM

9-24

( ..'. . ·.·

..

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1

1

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8

.;

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'IIHIAT HIR2-I

Al2

HTll2-2

VTA28 ENGINE HARNESS DIAGRAM

9-25

'iOLTACIE -.a..ATIIR

Lllll F\El. Lllll aD..NIT I.E't'EL (La..) 11EMlSTAT IPAE-fETl 8lfI10H'IIEllS IPAE-1.!Pl 1EII' ILETl <mJ 11EMlSTAT(IET)

lllrlDI Lllll U1:DE IIIIITDHMRIHm

IIIITOHIJI. PIIEIIII IUPl IWI PJtlCII' trTAlrTER PlUIT ll1.EJIJJD PAEIEATll1.EJIJJD ICUIII PUJlll) RE. 9CLElllID .11.,-TDR ElCH 1EII' (RIIHT) ElCH 1EII' (L.EFT) TACIDEUI !IDIEHDL 1EII'

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Tlll-1

P!i--17 1'6-1

P6-16 'IO+

111-IIAT --------'

DETAIL "A" NO. 338-3015 RE'I. D MODIFIED 8/16/94

(SEE NJTE 6)

HTRl-1

HTRl-2

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8

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NO. 338-2606

REV.D

MODIFIED 8/15/94

KT38 ENGINE HARNESS DIAGRAM

9-26

(

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HTRl-1

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1 1

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P4-2 P4-J

P7-G P&-19

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1(4-92

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Pll-11 Pll-4 Pll-12

--

Pll-2 Pll-18 Pll-1 1'26 Pll-21 1'5-7 1'26

PII-US

~

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BTMTER,..__ &IMJNR

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1111-1

1'6-1 1'6-16 87+

91-eAT -------'

DETAIL "A" NO. 338-2607 REV. O MODIFIED B/16/94

KT50 ENGINE HARNESS DIAGRAM

9-27

TB BAT

(SEE DETAil

VR21 S8 S7 S6 S5 S4 S3 S2 SI PI K4 K2 KI HTR GI

"A")

E7 [6

~~8

[5

(GOV)

[4

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A37 PIO

(AVR)

VOLTAGE REGULATOR LOI FU[L LOI COOLANT LEYEL ILCLl THERMOSTAT CPRE-HETJ SWITCH-PRESS IPRE-LOPl SWITCH LOW ENGINE TEMP
BI-SWI (81-Sll2l

A37

BI-SW2

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S4

p

(P4-l 3)

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EI

PI

!MAG PICK-UP rel="nofollow">

E6

ci~:~ >

GND-ENG

CSEE

LEAD TABULATIOH FROM TO STATIOH STATION Pl-2 GND-ENG PMGP2 PI0-1 PMGP3 PI0-4 PMGP4 PI0-5 X+ PI0-6 XXPI0-3 P6-12 Jl2-2 TB-BAT TBl-1 GND-[NG TBl-3 81-BAT TB-BAT TEST S7-A

NOTE 7l

DETAil "A" TB-BAT

./

LEAD TABULATIOH FROM TO STATION STATIOH P4-6 TB-BAT P4-16 GHD-ENG P4-5 16-BAT P4-15 GND-EKG P4-7 S7-D P4-13 S4 P4-3 TB-BAT P4-4 GND-ENG P4-2 P7-5 P4-I P6-19 GHD [HG U-S2 P4-22 PI-A IMAG PU) P4-21 PI-B IMAG PU) P4-9 PI (SHIELDl PH9 P6-2 P4-12 P6-3 PHO P7-3 P4- II P7-4 P6-7 Jl2-5 Jl2-6 GND-ENG PH 7 ISEE Jl2-7 !SEE "4-18 NOTE 8l Jl2-8 NOTE 8l P5-3 E2-A PS-11 E2-B P5-4 [3-A PS-12 E3-B PS-2 El·A [1·8 PS-18 P5·1 EI-C GI-B+ P3-A BI-SWI BI-SW2 [6-A P5·21 [6-8 P5-7 T26 P3-8 GI-GND P3-C PS-15 El-A [7-8 PS-22 P5-5 E4-A [4-8 PS-13 PS-17 TB-BAT PS-9 GKD-ENG TB-BAT P6-I P6·16 TB·BAT KI P6·20 P7-I P6-21 GI-D+ P6-22 T26 P6-4 GHD·ENG P6-15 GHD-[NG P6-23 P6-6 ACT+ P6·8 ACTGl-8+ 81-BAT GI -GND GND-EHG GND-ENG BI-GND S7-C TB-BAT GHD·ENG Sl-8 81 ·BAT K4-8AT K4 + 81-SW P7-6 K4-SI

No. 338-4321 sh 2 of 2 Rev. D Modified 7-04

K50 ENGINE HARNESS DIAGRAM (DFLB-SPEC T, DFLC-SPEC W, DFLE-SPEC F)

9-28

,~" '" , (¿.) ¡.t'

LEAD TABtLATION FROM

STATION Pl2-I Pl2-2 Pl-13

TO

STATION

SEE NOTE 8 ra1-2 ra1-5

Pl-7 P2-IO P2-9 P2-I I P2-4

rar-s

P2-3 Pl2-5 Pl2-6 Pl2-7 RED Pl2-8 8U< Pl-9 Pl-12 Pl-6 Pl-16 Pl-2

TBl-11 ra1-12 ra1-13 rnl-14 RED ra1-15 BU< TBl-16 TBl-17 TBl-18 TBl-19 TBl-20

Pl-10 Pl-5 P3-2 P3-IO P3-I I

TBl-21 TBl-22 TBl-23 TBl-24 TBl-25

P3-12 P3-16 P3-17 P3-18 Pl-21 Pl-19 Pl-20 P3-19 Pl-18 Pl2-9

TBl-26 TBl-27 TBl-28 TBl-29 TBl-30 TBl-31 TBl-32 TBl-33 ra1-35

HTR I HTR 2 P2-14 P2-13 P2-12

ra1-36 ra1-37 TBl-38 TBl-39 TBl-40

TBI

TBl-7 TBl-8 TBl-9 TBl-10

P

P3-20 ,P3-7 P3-13 P3-5 P3-6

P8-6 P8-7 P8-8

P3-4 P3-23 P3-8

P8-14 P8-15 P8-22 P8-23

P3-14 P3-22 P3-15 P3-21

P2-8 P2-7 P2-5 P2-6

TBl-41 ra1-,2 TBl-43 TBI-«

P3-9 P3-I P2-16 P2-2 Pl-17

TBl-46 TBl-47 TBl-48 TBl-49 TBl-50

Pl-3 Pl-11 Pl-4 Pl-22 Pl-23

TBl-51 TBl-52 TBl-53 TBl-54 TBl-55

Pl-8 Pl-15 Pl-1 P2-15 P2-23

TBl-56 TBl-57 TBl-58 TBl-59 TBl-60

P2-21 P2-17 P2-22 P2-18 P2-20

TB2-6 TB2-5 T82-4 TB2-3 TB2-2

P2-19

TB2-I

(BLACK)

P2 (GRAY) P3 BLUE

TIU-34

P8-I P8-2 P8-3 P8-4 P8-5

1

!

A39-TB2-I A39-TB2-2 A39-TB2-3 A39-TB2-4 A39-TB2-5 A39-TB2-6

A39

\ 1

tj

P8 (GRAY)

Pl2

No. 338-3200 sh 1 of 1 Rev. B Sys: HP Modified 2-96

ACCESSORY BOX INERCONNECTION HARNESS DIAGRAM (HC 4 AND 5)

9-29

PI

CBLACK)

(

(·

',

\•

P2 (GRAY) P3 BLUE

---::..,~~..... ,',

' ' \

\\

\ 1

I

\

'\

J \

\

I

tÍ :

t1

P8 (GRAY)

Pl2 LEAD T. FROM

STATION

ll..ATION TO STATION

LEAD li FROM

STATION

1.1..ATION TO

STATION

HTR 2 P2-14 P2-13 P2-12

TBl-31 TBl-32 TBl-33 lBl-34 TBl-35 TBl-36 TBl-37 TBl-38 lBl-39 TBl-40

TBl-11 TBl-12 TBl-13 lBl-14 RED lBl-15 BU<

P8-I P8-2 P8-3 PS-4 PS-5

Pl-9 Pl-12 Pl-6 Pl-16 Pl-2

TBl-16 TBl-17 TBl-18 lBl-19 TBl-20

Pl-10 Pl-5 P3-2 P3-IO P3-I I P3-12 P3-16 P3-l7 P3-18 Pl-21

TBl-21 TBl-22 TBl-23 lBl-24 TBl-25 lBl-26 TBl-27 TBl-28 lBl-29 TBl-30

Pl2-2 Pl2-I

TBl-2 TBl-16

Pl-13

TBl-5

Pl-7 P2-IO P2-9 P2-I I P2-4

TBl-6 TBl-7 lBl-8 TBl-9 lBl-10

P2-3 Pl2-5 Pl2-6 P12-7 (RED) Pl2-8 (BLK)

Pl-19 Pl-20 P3-19 Pl-18 Pl2-9

LEAD TABI.LATION TO STATION STATION P2-8 lBl-41 P2-7 TBl-42 P2-5 lBl-43 lBl-44 P2-6 P3-9 P3-I P2-16 P2-2 Pl-17

lBl-46 lBl-47 lBl-48 TBl-49 lBl-50

P3-20 P3-7 P3-13 P3-5 P3-6

Pl-3 Pl-11 Pl-4 Pl-22 Pl-23

lBl-51 TBl-52 lBl-53 TBl-54 lBl-55

P8-6 PS-7 P8-8

P3-4 P3-23 P3-8

Pl-8 Pl-15 Pl-1 P2-15 P2-23

lBl-56 TBl-57 TBl-58 lBl-59 lBl-60

P8-14 P8-15 P8-22 P8-23

P3-14 P3-22 P3-15 P3-21

P2-21 P2-17 P2-22 P2-18 P2-20 P2-19

TB2-6 TB2-5 TB2-4 TB2-3 1B2-2 TB2-I

lfTR I

e?:\

FROM

'

.

. . !

~.~ ..:. ./

A39-Til2-6 A39-TD2~ A39-lll2-.( A39-TB2-3 A39-11l2-2 A39-lB2-I

No. 338-3202 sh 1 of 2 Rev. B Sys: HP Modified 2-96

ACCESSORY BOX INTERCONNECTION HARNESS DIAGRAM (HC 6 AND 7)

9-30

(

"'

·~_,- .·

SCHEMATIC

PLW

DESIGNATION

ENml IRllO

B+ } USED W/0

01

CBIOl-2 POLE AC CIRCUIT BREAKER, 15 AMP, 7.5 AMP

02 03

5102-2 POI...E SWITCH PI03 - 120/240V PUMP MOTOR

04

1<104 - SYSTEM REAOY INTERLOCK 17

05

TI05 - 120/240V TRANSFORMER

..----Gt,OTRANSFORMER

J4

06

----,.,0

...--+---~·

1

1 1

1 1

1 1 1 1

1 Lr-1 l~-1---

1111-19

08 09 10 11

12 13 14 15 16 17 18

CRI06- RECTIFIER BRIDGE

J6-I

EHERGENCY RlM

II

2~º0FF

J6-2

ON

3

20

SI 11

1

.--------------<>--OOFF J6-7 3

TEST

K

4

30

DSl21-BASIN K

9

K

08

DSl27-HIGH R 129

1111-21

-Wa_-Gl------~---"--.JVV....._ __ - Kl306- -

K 12

t--Yt- ...... -+---o.iiJ---+--4~-o,ro-.-~!--'--.-=-:~~~ JJ-10 JJ-7 ~ ~

~m =;

>- -

a.

DSl32

FlEL

K109

Kll3 KI08

HIGH

K109 TBl-12--f l-

TBl-13

LOW FUEL FAULT CONTACTS

KI 10 TBl-14--f l-

TBl-15

LOW SHJTOOWN FAULT CONTACTS

TBl-17

BASIN FAll..T CONTACTS

TB2-27

SYSTEM READY CONTACTS

TB2-24

OPTIONAL FAlLT CONTACTS

1<112

J-

1<118 TB2-26--f JKll3 TB2-23~

0

44

FRONT VIEW DAY TANK PUMP CONTROL WIRING

9-31

1112-22

TBl-11

KI 13

TB2-25

F1JEL

@

27, 38

LAMP

1<109-LOW A.EL SET@ SET

23.39

@.

KI 12-BASIN FAll..T SET@

J-

TBl-16--f

RUN

K 108-HIGH FUEL SET

K 1 1 O-LO SKITOOWN

TBl-10--f

42

F1JEL FAULT LAMP

DSl32-PI.W ~

JHILOV

37

EJ.ERGEOCY

CR MATERIAi.

FAULT LAMP

Kl30-PI.J4> RB.AY 03, 30

r'­­..­­­'­­­~

PUi>

36

RESET

CONTROL BOX llOtSIIPTIXN

DSl23-LOW FUEL FAULT LAMP

35

DC

2 1

DSl25-LO st-UTDOWN FAULT LAMP

34

o

3

nDC

33

[®] [®]OFF

CIRCUIT BOARD ASS Y. CIRCUIT BREAKER 2 POLE CIRCUIT BREAKER I POLE SWITCH-ROCKER SWITCH-ROCKER LAMP ASSY.-7 LITE RELAY-2PST COVER-CONTROL

4

KI 12

32

CIROJIT 8REAl<ER PI.Si TO RESET

9

5

DS 1 17-SYSTEM READY LAMP 1<118-SYSTEM READY RELAY 42

31

ON

HARIESS-CONTROL.

8 7 6

'

Rll7

11

10

DS 1 15-0PTIONAL FAUL T LAMP

22

29

TEST

14 13 12

K 108-HIGH FUEL RESET 27. 138 K 109-LOW FUEL RESET 23 ,134), KI 10-LO st-UTDOWN RESET ~. ,40 SIII-SINGLE POI...E SWITCH KI 12-BASIN FAlLT RESET 21~,41,~ KI 13-CPTIGIAI... FA\l.T RESET 15,@)43,4!

RESET

21

CBI07

o

15

C8107 - 2 AMP CIRCUIT BREAl<ER ~

oa•-----.

S 1021

23 24 25 26 27 28

AC

COIINECTOR-KNOCKOU T CCNIECTOR-ROEX JJMPER-TERMINAL

18 17 16

19

1

o

0

TRANSFORIER

19

07

~J---

23 22 21 20

1111-:!0

o-

o~

2. Tag the control box to indicate supply voltage.

B+

F8+f#I o 22 23 24 215 26 27 28

1

1. ltem 23, transformer, is not included for kits where battery connections will be made at TB1-19 and TB1-20•

llll-:S.

~-----PI03-GND ------, .-----PI03-4 ~---P 103-WHITE ---PI03-3 PI03-I

1B2

NOTES:

COLUMN I

(REF)

FAULT CONTACTS

'::'

25 ,40 21,41,,;s,Q

KI 13-0PTIOOAI.. FAULT SET@

15,43,M

SCI-EMATIC KEY, EACH CQl4)0NENT IS LOCATEO BY PART N.JeER. ON THE RIGHT HMO SIDE, A DESCRIPTION IS GIVEN OF THE PART At,O ITS Fl..N:TIOOAI.. LOCATIONS.

í¡

~~.IN RELAY

FAlLT RESET 21

L,41

~T~~~ Lv con.. SET tt1 LDE 36

NIO CCNTACTS ttl LnES 21 ANl 41

ITIEN OESCRIPTim.

NO. 625-2141

REV. H

MODIFIED

POhER COMMAND CONTROL

r---------------------------, ¡ \~? ¡ 1

~NE

r------------A32-------------, :

1

:

DIGITAL

301>-'1079

1 1 1 Kl.3 CHTAL 8+ a+ >-"T""-----t-------------~~~~------~~-;11 >-----~,~~---------------r---"-'-'co.i~>--------:if'-i;;,¡"'----,--~vv\r-------=-,1v=5----,

-·· ,----a..L~~-~:; 1

,

AlB

GoVERNOR OUTl'UT STAGE 301>-'1307

Sl3

DIER STOP

t

2

-IN

04 o-c-~==~~~~~.13=-~1.a,i,~)----i QCI)

:

ZJ r3

---=

.

330

¡¡; u

~

-

1

~

4

lu

R11 ESTO!'SET L--------=~~~------~.13=-5~~~·>----------------r----'VV\r--750

I

-

-OUT 4-

NOTES: THE FOLLOHING IS THE SEQUENCE OF EVENTS FOR LOCAL START AND RUN.

IUll'l.TIIII

STMT 5N CHTAL 8+

;;:

"'u

N

5N DmlL

8+

3 TP2

l'SI

G).

n­

+18V

B+IIIIIT>

512

AIWOIT MSTO 5N -

K4.J STMT

KI

"lE.. SOi.

RD.AY 8+

-

STMT

STMT

TONICRO-CONTROU..Dl

"'1TO

TO NICRO-CONTROU..Dl

~---"'1Ta=:=º----------_:;n~-~·"il1:4>-------.....--------1-----1

+

-=-an

1

o.a.7 __

_..-=------------"...._._:

r----il-i------------'CHTAL==..::RTN=..-"'IN::,_

-=-•T2

l--------~--------'------'-------'----_...-------------------'------f--t-----------~-:,:::~RTN:e.:..:,~I~N,.__

DSt

..,u;-c.,_q¡I>--:::i.. : ~

~4~-4~1>--:::i.. 1 -~QCII 1 -

-

OPTO

... ...._"""ll>>--------(flE"'1'--"'3._J __

ISO

: ......... '-JI,)

DS5 c:reon

RDIOTE Gr.. n

'------------=='------------~.13~-~·~·!)>-.......----..~--3-4---a;-"1. DS& 1

t1AG PICKUP

,.....,-=..c•::._---lf---------------------------~4-=,!li1

...... ~.u..;;~~·'-ll,

~

1 ¡t-¡~

I

CGROUND

.

:·

L...--------------------------J

1 1 1

TONICRO-CONTROU..Dl

.:a:_=-----•1r-•

lO NICIIO-CllNTIIOU.

:

7---=EST=OP'----•• (~IE.., .... -... -·lO

: 1 1

9._tl!Y---,,_=,-:-:::-----tr----------------------------=-~>-----------------------------"-31'--..,¡~¡~ ~~

8+

-

1 1

Slll.

•••v

+18V

nrCIIO-COMTIIOU..

: 1 1

~

1

~

dEr4-lO

IW. +

.ffl.

o

d,t•­¡¡

tlAG -

,,,,.

O TO

TO nICRO-CONTROU..Dt

NICIIO-COltTlKIU.

• • 1

L...--------------------------J

l. 512 IS SET TO THE RUN POSITION. 2. RUN PILOT RELAY Kl ON DIGITAL BOARD (A32> IS ENERGIZED. 3. B+ IS NOH APPLIED TO THE POHER SUPPLY SECTION OF ENGINE INTERFACE BOARD IS ENERGIZED. 7. B+ IS NOH APPLIED TO THE STARTER SOLENOID. 8. ENGINE HOULD CRANK. 9. THE DIGITAL BOARD (A32) MONITORS THE MAG PICKUP ANO INITIATES A RUN DRIVE. 10. RUN RELAY K3 ON ENGINE INTERFACE BOARD (A31) IS ENERGIZED. 11. B+ IS NOH APPLIED TO THE FUEL SOLENOID,ALTERNATOR Gl,REGULATOR OUTPUT STAGE (A37>. 12. LEDS DS1 ON REGULATOR OUTPUT STAGE (A37) AND 052 ON GOVERNOR OUTPUT STAGE (A38) ARE ON. 13. RELAY Kl ON THE GOVERNOR OUTPUT STAGE
!_No. 612-6679 sh 1 of 2 Rev. B Sys: HP

Modified 11/21/95

SEQUENCE OF OPERATION (LOCAL START ANO RUN)

9-32

POWER COMMAND CONTROL

A3B GOVERNOR

OUTPUT STAGE 3011-4307

-o--<

....

~

-1

"'u

"'

B+(IIAT)

u

-~

·'

Rl'I' 750 RDI ESTOP

NOTES: THE FOLLOHING IS THE CONDITION OF THE POHER COMMAND CONTROL IN THE "OFF" POSITION.

RI.N l'LT IIR

A3?

REGULATOR OUTPtJT STAGE 3011-4306 Kl.3

STMT

8

l. 512 IS SET TO THE OFF POSITION. 2. RUN PILOT RELAY Kl ON DIGITAL BOARD CA32) IS DE-ENERGIZED. TP2

SM CHTRL 8+

"'3

PSI

8+

8HIIAT rel="nofollow">

Sl2 RIWOIT MITO

KI ntEl.. SOL

¡l;J

I I

:

~l~,....:SM:::..:Rllll:::::::_,AEl.,,,,,~~Y,_,,8+"'--~DL-4;;:..;~~>--~---~...L.--'V\/\,~,---~ST~MT!>.!.......al.Jl.=.t~>-----<1~:::.L-~ST~MT~----+TONlCRO-COHTIIOU.DI

K4.I STMT SOt.

2

__&~_,,_

+ ...=.BTI

1

,---

...,,

05

MITO

J3-13;J')----~-----1.----I

07

RI.N

J3-1~>-------11--~---'----I

I .....+------~CHTRL,:::.,.::::,~RTM~~I~N---'~4~-~·>---i_

1

.=.BT2

~

t------'------'-----'-----'----'----------.....l..---l---l:.,_-----~-~~RTN.!.!!,.~I~N---~4~--4~1>-----:i... I

1

A1!1C""GND

-

DS4

OPTO

AUN DSSGr-Hft

GrHft

IIDIOTE

ISO

:Jl-311):,-----(1:~~'71---3-I RUN=----t ..-+t TO NICRO-<XINTROU..E 1 1 1 1 :, ­1 :) (1'~Ll4::;;-;.:.7 _ __.EST=OP,:;..._ ....,_ _.., TO "ICRO-<XINTROU.DI

l 1 1

: 1 1

L------~GNll::.:::c------~J3~-..,t~l~i,~--:r~-....L~-K2-34--EST-OP--DS-6----i~~:,~1~~2~4~>----~

1 ,....IIAG=e....::;.+ __ --='-~--'

-l---------------...:L:t::5~l)

'---t--!Y----.::,,w;=-------t---------------"-='-'''lil) SHIELO

~

1 1 ~ :11-11'~ ,J,:,4- 10 "';V>-----<~

31-llf>

:L.--------------------------J ~ :

&ez4-ll

IIAG +

.nn.

Ir TO NICRO-<XIHT'ROLLE

IIAG -

'W'

..

TO NICRO-<XINTROU.DI

¡L.--------------------------J ..No. 612-6679 sh 2 of 2 Rev. B Sys: HP Modified 11/21/95

SEQUENCE OF OPERATION (LOCAL STOP)

9-33

POWER COMMAND CONTROL

r------------A3i-------------,

1

r------------A3z-------------,

1

1

1

ENCIHE INTERf"ACE

I

l

301>-'1083

l

l

DIGITAL.

11

;,

30Cl-4079

l

I Fl 1 1 >--r------t------------------OITlll..~~a,.~--------=Z4~-i;~l~----------~--:!.!.:~D-----------i:tf'.i=!Si!.---~--JIJ\I\,------"'~~.,__----, l l F3

Dt-CIIAT> A3B

GOVERNOR

OIITPUT STAGE

~~:._.~· . ,.:h 1

30Cl-4307

­u­<

1

~oo--2---==---a,.:.IN

-1

B+CIIATJ

4

-~

c:,m

n-1 ·~ 1

1

1

ESTOP SET

... "'u

...

__.Gtj-':=4

3

I

~ Rl1

>---------------~--.....,,""'~--750

-

RUN OUT

ROt ESTO#'

-

A31 REGIA.ATOR

PLT III

0UTPUT STAGE 30Cl-4306

Kl.3

&

START

·:1r . : c:a,c,A u: r-.., ---.--:

11,NI

SINlf

11

1

•

,..

-

~:

--

L----=°-1

SN OITIII..

a,.

"'

e I

1¡¡¡~~1:l ll+CIIATI

~

,~.

e

u

TPZ

PSI

B+

NOTES:

1

THE FOLLOHING 15 THE SEQUENCE OF EVENTS FOR LOCAL EHERGENCY STOP. SlZ RlJIVOfT IAIITO

K4. t

K4.Z

1

START SOL

KI

+

FIJD.

SOL

-=.en

1

..:...--~11 1 '"'-'-'º'------------n==--~11;4~~--------~-------+----1

-IIC

1

0"-1-----"-=------------n""---_.l"-ll: >---------1-----,--DS_.4-----I ..------ll---f-----------~CHTAL.,,,.,,:,.;RTM"-"''-"'IN::....

-=.BT2

.,g;4-;;.ui~I~ :

~

RUN D5S Cnen

1--------....L--------.L..----L..----...l------'-------------------.L..----l-+-----------~MJX~RTM~~IN:!.------"!.:l.=L-,lil~ 1

KEY

°"'1i- NIO CONTACT G_OSED .nn.

HAG PICK-t.P SIGWL

~

DIGIT~ SIGWL

..._

COltiON POtER COtH:CTION

..,,c:ND:=

n=-...1~•

,w¡

-

M.DC~QGJ

-

t.ÑD

Z4-21 1)

'----~--1=~--ft-----1-----------------------------..U::24ii·~ - 1 CGRUlNII

ISO

1 1-7 :,

l

9 1

C.r••n

!, ~ ~:·

I .....-'tw.=..;+::....-----11-----------------------------"=-,q¡I) __ .=,~-'

T

II010TE I

:)>--------<{Er~4~-3~1~~-=-----t ..-••TO"ICRO-COHIROI..LE

OPTO

l

u.,w -

l

1 (~~Z::.4"'--7,__...EST::.:.Of'=----1 ..-••TO KICIIO-CONJROI.LE

e l

1

I

1

~

l\-1~

dz4-to

,w¡

Zl-11:b

(kZ4-1l

tw. -

L.--------------------------~

:l

+

.nn. • TO KICIIO-CONJROI.LE 'W'

a TO KICRO-COHtROl.1.E

:l

L.--------------------------~

l. Sl3 IS SET TO THE EHERGENCY STOP POSITION. 2. B+ IS NOH REHOVED FROH THE FUEL SOLENOID,THE GOVERNOR OUTPUT STAGE CA39) AND THE REGULATOR OUTPUT STAGE C A37 ) • RUN LED D512 ON INTERFACE BOARD CA31) IS OFF. LED D52 ON GOVERNOR OUTPUT STAGE CA39) IS Off, LED DSl ON REGULATOR OUTPUT STAGE CA37) IS Off. 3. RELAY Kl ON THE GOVERNOR OUTPUT STAGE CA39) IS DE-ENERGIZED. 4. SH B+ IS NOW REMOVED FROH TERHINAL 26 AND CUSTOHER CONNECTIONS. S. EHERGENCY STOP RELAY K2 <SET> ON THE ENGINE INTERFACE BOARD (A31) IS ENERGIZED AND LATCHED. 6, RELAY CONTACT K2,3 ON THE ENGINE INTERFACE BOARD CA31) IS NOH OPEN, REHOVING B+ TO THE EHERGENCY STOP SHITCH (513>. 7, RELAY CONTACT K2,4 ON THE ENGINE INTERFACE BOARD CA31) IS NOW CLOSED, GROUNDING THE ESTOP LINE TO THE DIGITAL BOARD CA32). e. ESTOP LED D56 ON ENGINE INTERFACE BOARD CA3l) IS ON. 9. THE ENGINE HOULD STOP RUNNING.

N0.612-6680 sh10t1 REV.A MODIFIED 8/25/94

SEQUENCE OF OPERATION (LOCAL EMERGENCY STOP)

9-34