Download - CUmmins 350 kva and 640 Kva DG Manual

Models

DGBB

DGBC

DGCA

DGCB

DGCC

DGDA

DGDB

DGEA

DGFA

DGFC

Printed U.S.A. 900�0524 12�97

i

Table of Contents

SECTION TITLE PAGE

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

1 INTRODUCTION

About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Overview 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Set Control Function 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 CONTROL OPERATION 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Operation 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Power On/Standby Mode 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Panel 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Switches 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Menu 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gen Menu 2-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CIRCUIT BOARDS AND MODULESGeneral 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Board (A32) 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Interface Board (A31) 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analog Board (A33) 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Display Board (A35) 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Interface Board (A34) 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PT/CT Board (A36) 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bus PT Board (A39) 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Communications Module (A41) 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage Regulator Output Module (A37) 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . Governor Output Module (A38) 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Master First Start Sensor 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 TROUBLESHOOTING

General 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Considerations 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status Indicators 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting the Control 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning and Shutdown Codes 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Oil Pressure Warning and Shutdown Limits 4-13. . . . . . . . . . . . . . . . . . . Troubleshooting Procedure 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PCC Fuses 4-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Load Sharing Controls Troubleshooting Procedure 4-55. . . . . . . . . . . . . . . . . .

ii

5 CONTROL SERVICE AND CALIBRATION

General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit Board Removal/Replacement 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Start Setup Menu 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Menu 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup and Calibration Menus 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accessory Box Control Components 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Sensors 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) Installation 5-40. . . . . . . . . . . . . . . . . . . . . Current Transformer (CT) Installation 5-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 SERVICING THE GENERATOR

Testing the Generator 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 6-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the PMG 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 DAY TANK FUEL TRANSFER PUMP AND CONTROL

Operation 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Connections 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump Motor Connections 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Float Switch Assembly 7-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 INITIAL SYSTEM STARTUP

General 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . The Startup Process 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equipment Application Review 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual Generator Set Startup 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual System Operation 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic System Operation 8-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Black Start Testing 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Reports and Acceptance 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Site Power System Application Review (Diesel/600VAC and Lower) 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 WIRING DIAGRAMS

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

LS-12iii

Safety Precautions

Before operating the generator set, read the Opera-tor’s Manual and become familiar with it and the equip-ment. Safe and efficient operation can be achievedonly if the equipment is properly operated and main-tained. Many accidents are caused by failure to followfundamental rules and precautions.

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

This symbol warns of immediatehazards which will result in severe personal in-jury or death.

WARNING This symbol refers to a hazard or un-safe practice which can result in severe per-sonal injury or death.

CAUTION This symbol refers to a hazard or un-safe practice which can result in personal injuryor product or property damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury or death can resultfrom improper practices.

• DO NOT fill fuel tanks while engine is running, un-less tanks are outside the engine compartment.Fuel contact with hot engine or exhaust is a potentialfire hazard.

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

• Fuel lines must be adequately secured and free ofleaks. Fuel connection at the engine should bemade with an approved flexible line. Do not usecopper piping on flexible lines as copper will be-come brittle if continuously vibrated or repeatedlybent.

• Be sure all fuel supplies have a positive shutoffvalve.

• Be sure battery area has been well-ventilated priorto servicing near it. Lead-acid batteries emit a highlyexplosive hydrogen gas that can be ignited by arc-ing, sparking, smoking, etc.

EXHAUST GASES ARE DEADLY

• Provide an adequate exhaust system to properlyexpel discharged gases away from enclosed orsheltered areas and areas where individuals arelikely to congregate. Visually and audibly inspectthe exhaust daily for leaks per the maintenanceschedule. Make sure that exhaust manifolds are se-cured and not warped. Do not use exhaust gases toheat a compartment.

• Be sure the unit is well ventilated.

• Engine exhaust and some of its constituents areknown to the state of California to cause cancer,birth defects, and other reproductive harm.

MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH

• Keep your hands, clothing, and jewelry away frommoving parts.

• Before starting work on the generator set, discon-nect battery charger from its AC source, then dis-connect starting batteries, negative (-) cable first.This will prevent accidental starting.

• Make sure that fasteners on the generator set aresecure. Tighten supports and clamps, keep guardsin position over fans, drive belts, etc.

• Do not wear loose clothing or jewelry in the vicinity ofmoving parts, or while working on electrical equip-ment. Loose clothing and jewelry can becomecaught in moving parts. Jewelry can short out elec-trical contacts and cause shock or burning.

• If adjustment must be made while the unit is run-ning, use extreme caution around hot manifolds,moving parts, etc.

DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS

Flammable vapor can cause a diesel engine to over-speed and become difficult to stop, resulting in possiblefire, explosion, severe personal injury and death. Do notoperate a diesel-powered genset where a flammable va-por environment can be created by fuel spill, leak, etc.,unless the genset is equipped with an automatic safetydevice to block the air intake and stop the engine. Theowners and operators of the genset are solely responsi-ble for operating the genset safely. Contact your autho-rized Onan/Cummins dealer or distributor for more in-formation.

iv

ELECTRICAL SHOCK CAN CAUSESEVERE PERSONAL INJURY OR DEATH

• Remove electric power before removing protectiveshields or touching electrical equipment. Use rub-ber insulative mats placed on dry wood platformsover floors that are metal or concrete when aroundelectrical equipment. Do not wear damp clothing(particularly wet shoes) or allow skin surface to bedamp when handling electrical equipment.

• Use extreme caution when working on electricalcomponents. High voltages can cause injury ordeath. DO NOT tamper with interlocks.

• Follow all applicable state and local electricalcodes. Have all electrical installations performed bya qualified licensed electrician. Tag and lock openswitches to avoid accidental closure.

• DO NOT CONNECT GENERATOR SET DI-RECTLY TO ANY BUILDING ELECTRICAL SYS-TEM. Hazardous voltages can flow from the gen-erator set into the utility line. This creates a potentialfor electrocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

MEDIUM VOLTAGE GENERATOR SETS(601V to 15kV)

• Medium voltage acts differently than low voltage.Special equipment and training is required to workon or around medium voltage equipment. Operationand maintenance must be done only by personstrained and qualified to work on such devices. Im-proper use or procedures will result in severe per-sonal injury or death.

• Do not work on energized equipment. Unauthorizedpersonnel must not be permitted near energizedequipment. Due to the nature of medium voltageelectrical equipment, induced voltage remains evenafter the equipment is disconnected from the powersource. Plan the time for maintenance with author-ized personnel so that the equipment can be de-en-ergized and safely grounded.

GENERAL SAFETY PRECAUTIONS

• Coolants under pressure have a higher boiling pointthan water. DO NOT open a radiator or heat ex-changer pressure cap while the engine is running.Allow the generator set to cool and bleed the systempressure first.

• Benzene and lead, found in some gasoline, havebeen identified by some state and federal agenciesas causing cancer or reproductive toxicity. Whenchecking, draining or adding gasoline, take care notto ingest, breathe the fumes, or contact gasoline.

• Used engine oils have been identified by some stateor federal agencies as causing cancer or reproduc-tive toxicity. When checking or changing engine oil,take care not to ingest, breathe the fumes, or con-tact used oil.

• Provide appropriate fire extinguishers and installthem in convenient locations. Consult the local firedepartment for the correct type of extinguisher touse. Do not use foam on electrical fires. Use extin-guishers rated ABC by NFPA.

• Make sure that rags are not left on or near the en-gine.

• Remove all unnecessary grease and oil from theunit. Accumulated grease and oil can cause over-heating and engine damage which present a poten-tial fire hazard.

• Keep the generator set and the surrounding areaclean and free from obstructions. Remove any de-bris from the set and keep the floor clean and dry.

• Do not work on this equipment when mentally orphysically fatigued, or after consuming any alcoholor drug that makes the operation of equipment un-safe.

• Substances in exhaust gases have been identifiedby some state or federal agencies as causing can-cer or reproductive toxicity. Take care not to breathor ingest or come into contact with exhaust gases.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides troubleshooting and repairinformation regarding the PowerCommandControl (PCC) and generators used on the DGSeries generator sets. Engine service instructionsare in the applicable engine service manual.Operating and maintenance instructions are in theapplicable Operator’s Manual.This manual does not have instructions forservicing printed circuit board assemblies. Afterdetermining that a printed circuit board assembly isfaulty, replace it. Do not repair it. Attempts to repair aprinted circuit board can lead to costly damage tothe equipment.This manual contains basic (generic) wiringdiagrams and schematics that are included to helpin troubleshooting. Service personnel must use theactual wiring diagram and schematic shipped witheach unit. The wiring diagrams and schematics thatare maintained with the unit should be updatedwhen modifications are made to the unit.Read Safety Precautions and carefully observe allinstructions and precautions in this manual.

TEST EQUIPMENTTo perform the test procedures in this manual, thefollowing test equipment must be available

• True RMS meter for accurate measurement ofsmall AC and DC voltages. Fluke models 87 or8060A are good choices.

• Grounding wrist strap to prevent circuit boarddamage due to electrostatic discharge (ESD).

• Battery Hydrometer• Jumper Leads• Tachometer or Frequency Meter• Wheatstone Bridge or Digital Ohmmeter• Variac• Load Test Panel• Megger or Insulation Resistance Meter• PCC Service Tool Kit (Harness Tool and Sen-

sor Tool)

HOW TO OBTAIN SERVICEAlways give the complete Model, Specification andSerial number of the generator set as shown on thenameplate when seeking additional serviceinformation or replacement parts. The nameplate islocated on the side of the generator output box.

WARNING Incorrect service or replacement ofparts can result in severe personal injury ordeath, and/or equipment damage. Service per-sonnel must be qualified to perform electricaland mechanical service. Read and follow SafetyPrecautions, on pages iii and iv .

1-2

SYSTEM OVERVIEW

The PCC is a microprocessor-based control forOnan generator sets. It provides fuel control andengine speed governing, main alternator voltageoutput regulation, and complete generator setcontrol and monitoring. It also provides controls forautomatic and semi-automatic synchronizing andautomatic load sharing controls for both isolatedbus or utility (mains) paralleling applications.

The operating software provides control of thegenerator set and its performance characteristics,and displays performance information on a digitaldisplay panel. It accepts menu-driven control andsetup input from the push button switches on thefront panel.

GENERATOR SET CONTROL FUNCTION

Figure1-1 shows some of the control functions. Amore complete block diagram is provided in Section3. A system schematic is provided in Section 9.

The PCC monitors frequency from both themagnetic pick-up (MPU) and the main stator inputs.The control sends a low power pulse-widthmodulated (PWM) signal to the governor outputmodule, which then sends an amplified signal to theengine fuel control.

The Bus PT module reduces the bus voltage toapproximately 18 VAC and provides a signal to thecontrol for reference in synchronizing the generatorset to the system bus.

The external PT/CT module reduces generatorvoltage to approximately 18 VAC, and produces arepresentative AC voltage from CT output current.The voltage regulation function sends a low powerPWM signal to the voltage regulator output module,which then sends an amplified signal to the exciterstator.

Oil, coolant, and exhaust temperatures are sensedby variable resistance element sensors. Oilpressure is sensed by a capacitive element activesensor.

Sensors

GovernorOutput

Output

MPU

NS

PMG

BatteryBT1

FuelControl

Bus PTModule

•

•

•

Regulator

LoadTo

••

•

1

1

2 3 4

234

FIGURE 1-1. GENERATOR SET CONTROL FUNCTIONS

2-1

2. Control Operation

GENERAL

The following describes the function and operationof the PowerCommand generator set control. All in-dicators, displays, meters and control switches arelocated on the face of the control panel as illustratedin Figure 2-1.

The PCC control cabinet must be opened only bytechnically qualified personnel.

Normally, generator set configuration options areset at the factory. When a new control is installed ona generator set or when parts are replaced, the con-trol must be configured for that generator set withthe use of the “Initial Start Setup” portion of the inter-nal software. Setup and calibration procedures aredescribed in Section 5.

The automatic voltage regulator (AVR) and gover-nor operation characteristic adjustments are alsodescribed in Section 5.

SAFETY CONSIDERATIONS

AC power is present when the set is running. Do notopen the generator output box while the set is run-ning.

WARNING Contacting high voltage compo-nents can cause electrocution, resulting in se-vere personal injury or death. Do not open thegenerator output box while the set is running.Read and observe all WARNINGS and CAU-TIONS in your generator set manuals.

CAUTION The PCC control cabinet must beopened only by technically qualified personnel.Lower level voltages (18 VAC to 24 VDC) arepresent in PCC control cabinet. These voltagescan cause electrical shock, resulting in per-sonal injury.Even with power removed, improper handlingof components can cause electrostatic dis-charge and damage to circuit components.

2-2

SEQUENCE OF OPERATION

When the PowerCommand control is in the AUTOmode, it will cause the generator set to start on re-ceiving a signal from a remote device. The Power-Command control will initiate a starter cranking sig-nal and verify that the engine is rotating. The Power-Command control will provide sufficient fuel to theengine to accelerate to start disconnect speed. Onreaching that speed, the control will ramp the gener-ator set to rated speed and voltage.

On reaching rated speed and voltage, the Power-Command control checks the system bus voltage. Ifno bus voltage is present, it will wait for a pulse froma remote Master First Start Sensor. On receivingthat pulse, the control will signal the parallelingbreaker to close.

If bus voltage is present, the PowerCommand con-trol will check for proper phase rotation, adjust thegenerator set to the bus voltage and frequency lev-el, and then synchronize the generator set to thesystem bus. When a synchronous condition isachieved, the control will send a signal to close theparalleling breaker.

When the paralleling breaker is closed, the genera-tor set will assume it’s proportional share of the totalload on the system bus.

PCC POWER ON / STANDBY MODE

Standby Mode

In the Standby (sleep) mode (selector switch S5 onthe Digital Board is set to the right and the generatorset is not running), the control’s operating softwareis inactive and the LEDs and displays on front panelare all off.

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

one of eight “wake up” inputs from remote sensingswitches.

The wake up signals are:

• Emergency Stop

• Low Coolant Level

• Low Coolant Temperature

• Low Fuel

• Customer Fault Inputs 2 and 3

• Run Selected on Run/Off/Auto Switch

• Remote Start Signal in Auto Mode

• Self Test switch

To activate and view the menu displays, press andrelease the Self Test switch. The PCC will initializethe operating software and permit operation of themenu display panel. If no menu selections aremade, the power to the control panel will shut downafter 30 seconds.

Power On Mode

In the Power On (awake) mode (selector switch S5on the Digital Board is set to the left), the PCC willinitialize the operating software and permit opera-tion of the menu display panel. (See Figure 3-1 forS5 location.) Power will stay on until switch (S5) isset to the Standby mode. It is recommended thatswitch S5 be left in the Power On mode in all ap-plications, except those where auxiliary batterycharging is not available.

CAUTION Electrostatic discharge will damagecircuit boards. Always wear a grounding wriststrap when touching or handling circuit boardsor socket-mounted ICs and when disconnect-ing or connecting harness connectors.

2-3

ACTIVE SWITCHINDICATOR

(1 of 6)

UPPER AND LOWERSCALE INDICATOR

FREQUENCYMETER

KILOWATTMETER

(PERCENT LOAD)

PHASE SELECTORSWITCH ANDINDICATORS

RESETSWITCH

NON-AUTOMATICWARNING

SHUTDOWNSTATUS INDICATORS

EMERGENCYSTOP PUSH

BUTTON(Turn CW to reset)

PANEL LAMPSWITCH

SELF TESTSWITCH

MENUSWITCH

ACVOLTMETER

(DUAL SCALE)

AC AMMETER(PERCENT AMPS)

ALPHANUMERICDISPLAY

MENUSELECTION

SWITCH(1 of 4)

RUN/OFF/AUTOSWITCH

PARALLELINGBREAKER

SWITCHES ANDINDICATORS

FIGURE 2-1. FRONT PANEL

2-4

FRONT PANEL

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

AC Voltmeter: Dual scale instrument indicates ACvoltage. Measurement scale in use is shown onscale indicator lamp.

AC Ammeter: Indicates current output in percent ofmaximum rated current. (Percent current is basedon .8 PF.)

Kilowatt Meter: Indicates 3-phase AC power out-put as percent of rated load.

Frequency Meter: Indicates generator output fre-quency in hertz.

Upper and Lower Scale Indicator Lamps: Indi-cate AC voltmeter scale.

Digital Display: This two-line, 16-character per linealphanumeric display is used in the menu-drivenoperating system, in conjunction with the displaymenu selection switches and the Menu switch. Re-fer to the menu trees later in this section. The dis-play is also used to show warning and shutdownmessages.

Display Menu Selection Switches: Four momen-tary switches—two on each side of the digital dis-play window—are used to step through the variousmenu options and to adjust generator set parame-ters. The green arrow adjacent to the switch is litwhen the switch can be used (switch is “active”).

Menu Switch: Press this switch to return the digitaldisplay to the MAIN MENU. Refer to the menu treeslater in this section.

Reset Switch: Press this switch to reset warningand shutdown messages after the condition hasbeen corrected. To reset a shutdown message withthe Reset switch, the Run/Off/Auto switch must bein the Off position.

With the Run/Off/Auto switch in the Auto mode,shutdown faults can be reset by removing the re-mote start input and then cycling the remote resetinput.

Self Test Switch: Press and hold this switch to lightall front panel LEDs and cycle through all shutdownand warning messages.

In the Standby (sleep) mode, with the generator setnot running, the control’s operating software is inac-tive and the LEDs and displays on front panel are alloff.

To activate and view the menu displays withoutstarting the generator set, press and hold the SelfTest switch until the front panel LEDs light. ThePCC will initialize the operating software and permitoperation of the menu display panel. If no menu se-lections are made, a software timer will shut downthe power after 30 seconds.

Panel Lights Switch: Press this switch to turn con-trol panel illumination on and off. The illuminationwill shut off after about eight minutes.

Phase Selector Switch and Indicators: Press thismomentary switch to select phases of generatoroutput to be measured by the analog AC voltmeterand ammeter. LEDs indicate the selected phase.

Run/Off/Auto Switch: This switch starts and stopsthe set locally, or enables start/stop control of theengine from a remote location. (Ground to start.)

2-5

Emergency Stop Button: Push the switch in foremergency shutdown of the engine.

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

To reset:1. Turn the switch clockwise and allow it to pop

out.2. Move the Run/Off/Auto switch to Off.3. Press the front panel Reset switch.4. Select Run or Auto, as required.

Non-Automatic Status Indicator: This red lampflashes continuously when the Run/Off/Auto switchis not in the Auto position.

Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Reset switch. (It is notnecessary to stop the generator set.)

With the Run/Off/Auto switch in the Auto mode,warnings can also be reset by cycling the remote re-set input after the condition is corrected.

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.After the condition is corrected, shutdown indica-tors can be reset by turning the Run/Off/Auto switchto the Off position, and pressing the Reset switch.In Auto mode, shutdowns can be reset by removingthe remote start input and then cycling the remotereset input.

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

Paralleling Breaker Switches and Indicators:These two switches are used to manually open orclose the paralleling breaker of the generator set.The lamps are used to indicate the opened orclosed position of the paralleling breaker.

The Breaker Operation switches are operational onlywhen the Run/Off/Auto switch is in the Run position.The breaker will close when the generator set is syn-chronized with the system bus, or if the system busis de-energized.

2-6

FIGURE 2-2. DIGITAL DISPLAY AND MENU SELECTION SWITCHES

MENU DISPLAY AND SWITCHES

Figure 2-2 shows the digital display and the menuselection switches. Refer to heading “Front Panel”which describes the menu display and switches.

In the Standby Mode, to activate and view the menudisplays without starting the generator set, pressand release the Self Test switch. This will initializethe PCC operating software and permit operation ofthe menu display panel. If no menu selections aremade, a software timer will shut down the power af-ter 30 seconds. In the Power On Mode, power iscontinuously supplied to the control panel. Displaywill always remain on.

In the digital display, the “>>” symbol indicates thatselecting the adjacent button causes the operatingprogram to branch to the next menu display—asshown in the menu diagrams.

In the digital display, the “<<” symbol indicates thatselecting the adjacent button causes the operatingprogram to go back to the previous menu display.

MAIN MENUThe facing page shows the main menu and a blockrepresentation of the available submenus.

As shown in the diagram, the main menu canbranch into one of four directions.

To display engine parameters, such as oil pressureand temperature, water temperature, engine speed(RPM), and exhaust temperature, press the buttonnext to the word “ENGINE” in the display. Refer toENGINE MENU in this section.

To display generator parameters, such as volts,amps, power (kW), and frequency, press the buttonnext to the word “GEN” in the display. Bus voltage,frequency and a digital synchroscope can also beviewed from this menu branch. Turn to the GENMENU in this section.

To adjust output voltage and frequency, or start andstop delays, press the button next to the word “AD-JUST” in the display. Refer to ADJUST MENU inSection 5.

To display the selected generator set model and theresident version software, press the button next tothe “>>” in the display. Refer to VERSION & DIS-PLAYS MENUS in Section 5.

2-7

DISPLAYS <<METERS >>

⇑ VOLTAGE⇓ _______ >>

< >

< >

ENGINE GEN

ADJUST >>

< ACTIVE BUTTON

< ACTIVE BUTTON SELECTED

INACTIVE BUTTON

RESET MENU >

RETURN TOMAIN MENU

CLEAR WARNING ANDSHUTDOWN MESSAGES

PAGES 2-8 & 2-9

MAIN MENU

VERSIONSETUP / CALHISTORY

(ACCESS CODE)

PAGES 2-10 & 2-11

OIL <<COOLANT >>

BATTERY <<HOURS >>

RPM <<EXHAUST

⇑ FREQUENCY⇓ _______ >>

⇑ START DELAY⇓ _______ SEC >>

⇑ STOP DELAY⇓ _______SEC >>

VOLTS <<AMPS >>

POWER <<KW HRS >>

%GOV / REG <<FREQUENCY

SECTION 5

SECTION 5

SECTION 5

SECTION 5

⇑ IDLE SPEED⇓ _______RPM >>

GOV / REG <<PARALLEL SETUP

2-8

ENGINE MENU

The facing page shows a block representation ofthe ENGINE menu. If you press the button next tothe word “ENGINE” in the display, the first ENGINEsubmenu will appear.

As shown in the diagram, the ENGINE menu hasthree submenus.

OIL/COOLANT submenu: This is the first sub-menu. Select OIL for a display of oil pressure and oiltemperature. Select COOLANT for a display ofcoolant temperature. When oil or coolant parame-ters are displayed, pressing the button next to the“<<” will return the display (“BACK”) to the OIL/COOLANT submenu.

BATTERY/HOURS submenu: From the OIL/COOLANT submenu, press the button next to the“>>” in the display to move to the BATTERY/HOURS submenu. Select BATTERY for a displayof battery voltage. Select HOURS for a display ofthe number of starts and the running hours. Whenbattery or hours parameters are displayed, press-ing the button next to the “<<” will return the display(“BACK”) to the BATTERY/HOURS submenu.

RPM/EXHAUST submenu: From the BATTERY/HOURS submenu, press the button next to the “>>”in the display to move to the RPM/EXHAUST sub-menu. Select RPM for a display of engine RPM.Select EXHAUST for a display of the (optional) ex-haust temperature. When RPM or exhaust pa-rameters are displayed, pressing the button next tothe “<<” will return the display (“BACK”) to the RPM/EXHAUST submenu.

2-9

BATTERY <<___VDC

< >

< >

< >

< >

>L___°F / °C <<R___°F / °C (or n/a)

>

>

>

< >

< >

< >< >

BATTERY <<HOURS >>

>

< >

< >

< >ENGINE GENADJUST >>

< >< >

OIL <<COOLANT >>

< > ___PSI / KPA <<___°F / °C

ENGINE GENADJUST >>

< >< >

< >OIL <<COOLANT >>

< >

< >OIL <<COOLANT >>

OIL <<COOLANT >>

< >

>

< >BATTERY <<HOURS >>

STARTS ___ <<HOURS ___

< >



L___°F/°C (or n/a) <<R___°F/°C (or n/a)

<RPM <<EXHAUST

< >

<RPM <<EXHAUST

< >

<RPM <<EXHAUST

RPM <<___

BATTERY <<HOURS >>< >

BACK

BACK

BACK

BACK

BACK

BACK

ENGINE

OIL <<COOLANT >>

Indicates “OR” Condition

2-10

GEN MENU

The facing page shows a block representation ofthe GEN menu. If you press the button next to theword “GEN” in the display, the first GEN submenuwill appear.

As shown in the diagram, the GEN menu has threesubmenus.

VOLTS/AMPS submenu: This is the first sub-menu. Select VOLTS for a display of a line-to-line orline-to-neutral selection, or for viewing of the sys-tem bus line-to-line voltage. Select line-line or line-neutral for the desired voltage display. SelectAMPS for a display of L1, L2, and L3 current inamps. When voltage or current parameters are dis-played, pressing the button next to the “<<” will re-turn the display (“BACK”) to the L-L/L-N submenu.

If DELTA is selected in the Initial Start Setup subme-nu, when selecting VOLTS, the “line-line” or “line-neutral” submenus will not be displayed, only theL12, L23, L31 submenu will be displayed.

POWER / KW HOURS submenu: From theVOLTS/AMPS submenu, press the button next tothe “>>” in the display to move to the POWER/KWHOURS submenu. Select POWER for a display ofpower output in kilowatts and a power factor value.Select KW HOURS for a display of kilowatt hours.When power or kW hours parameters are dis-played, pressing the button next to the “<<” will re-

turn the display (“BACK”) to the POWER/KWHOURS submenu.

The PF reading will contain an asterisk if the powerfactor is leading (for example, *.3PF).

Beginning Version 1.06, N/A is displayed in the PFfield when the generator set is not running.

%GOV/REG/FREQUENCY submenu: From thePOWER/KW HOURS submenu, press the buttonnext to the “>>” in the display to move to the %GOV/REG/FREQUENCY submenu. Select %GOV/REGfor a display of voltage regulator and governor dutycycle (drive) levels in percentage of maximum. Se-lect FREQUENCY for a display of the generatoroutput frequency the bus frequency, or the digitalsynchroscope. When voltage regulator and gover-nor or frequency parameters are displayed, press-ing the button next to the “<<” will return the display(“BACK”) to the %GOV/REG/FREQUENCY sub-menu.

Bus Frequency (Digital Synchroscope) subme-nu: When the bus frequency (digital synchroscope)information is displayed, the operator can observethe generator set synchronizing with the systembus. The display indicates bus frequency and num-ber of degrees from synchronous condition (+ indi-cates faster, -- indicates slower). When the genera-tor set is operating within the sync-check window,an asterisk will indicate that the paralleling breakercan be closed.

2-11

<

< >

< >< > < >

< >

< >< >

< >

< >

< > < >

< >

< >

< >

<< >

>< ><< >

ENGINE GENADJUST >>< >

VOLTS <<AMPS >>

L --- L <<L --- N BUS

>

L12 L23 L31 <<___ ___ ___

L1N L2N L3N <<___ ___ ___

BACK

BACK

<

BACK

< >< >

VOLTS <<AMPS >>

>L1 L2 L3 <<___ ___ ___

BACK

VOLTS <<AMPS >>

ENGINE GENADJUST >>< >

VOLTS <<AMPS >>

POWER <<KW HRS >>

>___ KW <<___ PF

BACK

< >< >POWER <<

KW HRS >>>KW HRS <<

____________

BACK

< >POWER <<KW HRS >>

POWER <<KW HRS >>


BACK

< ><


< ><


>GOVERNOR_ % <<REGULATOR_ %

>FREQUENCY <<___ HZ BUS

BACK

BACK

BACK

GEN

L --- L <<L --- N BUS

L --- L <<L --- N BUS

>< ><

L --- L <<L --- N BUS

L12 L23 L31 <<___ ___ ___

BACK

>FREQUENCY <<___ HZ BUS

>BUS FREQUENCY<<___ HZ ___ DEG

BACK


3-1

3. Circuit Boards and Modules

GENERAL

This section describes the function of the PCC cir-cuit boards and modules that are contained in thecontrol panel (Figure 3-1) and the accessory box.The block diagram in Figure 3-2, shows both inter-nal and external components of the PCC system.

The system schematics are provided in Section 9 ofthis manual.

CAUTION Electrostatic discharge will damagecircuit boards. Always wear a grounding wriststrap when touching or handling circuit boardsor socket-mounted ICs.

PT/CTBOARD

A36VOLTAGE REGULATOROUTPUT MODULE

A37

GOVERNOROUTPUT MODULE

A38

CUSTOMER INTERFACEA34

ENGINE INTERFACEA31

ANALOGBOARD

A33

DIGITAL BOARDA32

DISPLAY BOARDA35

RUN/OFF/AUTOSWITCH S12

S5 POWER ON/STANDBY SWITCH

BUS PT MODULEA39

GENSETCOMM.BOARD

A41

FIGURE 3-1. CIRCUIT BOARD LOCATIONS

3-2

FIGURE 3-2. BLOCK DIAGRAM

3-3

DIGITAL BOARD (A32)

The digital circuit board (Figure 3-3) contains themicroprocessor and the operational software for thecontrol. It connects to all other boards inside thecontrol. This board also provides the analog-to-digi-tal conversions for the PCC.

Switch

S5 Slide the switch to the left to select the PowerOn (awake) mode. Control panel power/oper-ating software will remain on until the switch isreset to the Standby mode. It is recom-mended that switch S5 be left in the Power Onmode in all applications, except those whereauxiliary battery charging is not available.

Slide right to put the PCC in the Standby(“sleep”) mode. In this mode, the PCC oper-ating software will be initiated by selection ofRun on the front panel, by pressing the SelfTest switch, by a remote start input (in Automode), or by any one of several “wake-up”signals from external switches.

ConnectorsThe digital board has five connectors. They are:

J1 Serial Interface RS232J2 Connects to J4 on A34 Customer Interface

boardJ3 Connects to J2 on A33 Analog boardJ4 Connects to J1 on A31 Engine Interface

boardJ5 Connects to J5 on A35 Digital Display assem-

blyLEDsThe digital board has seven LED’s that indicate thefollowing conditions:

DS1 Spare (Green)DS2 Spare (Green)DS3 +18 VDC supply OK (Green)DS4 +5 VDC supply OK (Green)DS5 Run (Flashes once per second if software

is running) (Green)DS6 +24 VDC B+ supply OK (Green)DS7 +12 VDC supply OK (Green)

DS1DS2DS3DS4

DS7DS6DS5

FIGURE 3-3. DIGITAL BOARD

3-4

ENGINE INTERFACE BOARD (A31)The engine interface board (Figure 3-4) reads usercontrol inputs, monitors engine, generator and sys-tem status, and initiates the appropriate action fornormal operating and fault conditions (warning orshutdown).

This board is connected to the engine sensors, bat-tery, starter, governor output module, voltage regu-lator output module, and the magnetic pick-up(MPU).

The engine interface board can also be connectedto an optional network interface module for networkaccess.

During a typical start sequence the LED’s light asfollows:

1. DS11 lights when a remote run signal is re-ceived and S12 is in the Auto possition, or S12is moved to the Run position.

2. DS12 lights when the magnetic pick-up voltageis sensed (engine is cranking). (When the en-gine is cranking, the mag pickup output shouldbe a minimum of 1 volt.)

3. DS11 extinguishes, DS9 lights and DS10 isdimly lit when the generator is running.

Connectors

The engine interface board has seven connectorsand one terminal strip. They are:

J1 Connects to J4 on A32 Digital board.J2 Connects to J1 on A33 Analog board.J3 Connects to display board, front panel

switches and meters.

J4 Connects to customer connections and to en-gine harness which includes magnetic pick-up.

J5 Connects to engine sensors.J6 Connects to Genset Control module (GCM).J7 Connects to Genset Control module (GCM).

Fuses

The engine interface board has two replaceablefuses. They are:

F1 Control B+ (5 Amps)F3 Aux. B+ (5 Amps). (Panel lamps and run/start

contacts).

LED’s

The engine interface board has 10 LED’s that indi-cate the following conditions:

DS1 Low Fuel Alarm input (Red)DS2 Low Coolant Level Alarm input (Red)DS3 Low Engine Temperature Alarm input (Red)DS4 S12 in Run position (Green). S12 is the Run/

Off/Auto switch.DS5 S12 in Auto position (Green)DS6 Emergency Stop (Red)DS7 Not configured.DS8 Not configured.DS9 Automatic voltage regulator duty cycle

(Green). Brighter indicates larger dutycycle.

DS10 Governor duty cycle (Green). Brighter indi-cates larger duty cycle.

DS11 Start pilot relay output (Red)DS12 Run pilot relay output (Red)

3-5

5A AUX B+

5A CNTRL B+

DS1 - LOW FUEL

DS2 - LO COOL

DS5 - AUTO

DS10 - GOVDS11 - START

DS3 - LET

DS4 - RUN SW

DS6 - E-STOP

DS9 - REG

DS12 - RUN RLY

FIGURE 3-4. ENGINE INTERFACE BOARD

3-6

ANALOG BOARD (A33)The analog board (Figure 3-5) is the only circuitboard inside the control that has no LED’s. Thereare two versions of the analog board that are usedfor paralleling and non-paralleling systems.

This board interprets all analog input signals andconverts the analog signals to 0--5 VDC for the digi-tal board.

Connectors

The analog board has four connectors with ribboncables permanently soldered to them. They are:

J1 Connects to J2 on A31 Engine Interfaceboard

J2 Connects to J3 on A32 Digital boardJ3 Spare analog inputsJ4 Connects to J1 on A34 Customer Interface

board

FIGURE 3-5. ANALOG BOARD

3-7

DIGITAL DISPLAY BOARD (A35)The digital board (Figure 3-6) connects to all metersand the LED display.

Connectors

The digital board has three connectors. They are:

J1 Connects to front panel membrane switchesJ5 Connects to J2 on A32 Digital board. (With J5

disconnected, the display will be non-func-tional, but the PCC will continue to operate.)

J6 Connects to meters, Run/Off/Auto switch, J3on A31 Engine Interface board

LEDs

The digital board has 18 LED’s that are used to indi-cate operational status of the generator set andcontrol panel mode/switch selections.

DS9 Not In Auto (Red)DS10 Upper Scale (Green)DS11 Left Top Arrow (Green)

DS12 Right Top Arrow (Green)DS13 Warning (Amber)DS14 Lower Scale (Green)DS15 Shutdown (Red)DS20 Left Bottom Arrow (Green)DS21 Right Bottom Arrow (Green)DS22 Automatic mains failure (AMF) or paralleling

application only: Breaker Closed (Red)DS23 Phase A (Green)DS24 Reset Arrow (Green)DS25 Menu Arrow (Green)DS26 AMF application only: Breaker Open

(Green)DS27 Phase B (Green)DS29 Phase C (Green)DS36 AMF application: Breaker Closed (Red) -- or

-- paralleling application: Breaker Open(Green)

DS37 AMF application only: Breaker Open(Green)

DS29DS27DS23

DS15

DS13

DS9

DS24

DS11

DS20

DS25

DS12

DS21

DS14DS10

DS26DS22

DS37DS36

FIGURE 3-6. DIGITAL DISPLAY BOARD

3-8

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

Connectors

The customer interface board has five connectors.They are:

J1 Customer connectionsJ2 Customer connectionsJ3 A36 PT/CT Board and customer connectionsJ4 Connects to J2 on A32 Digital boardJ5 Connects to J4 on A33 Analog board

LEDs

The customer interface board has 27 LED’s that in-dicate the following conditions:

DS1 Master First Start Input (Green) -- parallelingapplication only

DS2 Pre low oil pressure output relay K14 (Red)DS3 Customer Fault #4 Input (Red)DS4 Customer Fault #1 Input (Red)DS5 Low oil pressure output relay K15 (Red)DS6 Fault Reset Input (Red)DS7 Engine Idle (Green)DS8 Paralleling Breaker Close Input (Green)

[paralleling function is load demand]DS9 Paralleling Breaker Open Input (Green)DS10 Paralleling Breaker Position Input (Green)DS11 Customer Fault #2 input (Red)DS12 Low coolant output relay K17 (Red)

DS13 Low Fuel Input (Red)DS14 Remote Start input (Green)DS15 Customer Fault #3 input (Red)DS16 Paralleling Breaker Control input relay ener-

gized from Digital board (Green). This out-put is activated to close the parallelingbreaker.

DS17 Common Alarm output relay energized fromDigital board (Green)This output is activated only on a shut-down condition.

DS18 Spare output relay energized from Digitalboard (Green)This output is activated only on a warn-ing condition.

DS19 Load Dump output relay energized fromDigital board (Red)If overload or underfrequency for 5 sec-onds, this output is activated (before shut-down).

DS20 Ready to Load output relay energized fromDigital board (Green)This output is activated when AC voltageand frequency exceed 90% of nominal.

DS21 Pre high engine temperature output relayK8 (Red)

DS22 Not in auto output relay K6 (Red)DS23 High engine temperature output relay K9

(Red)DS24 Overspeed output relay K10 (Red)DS25 Overcrank output relay K11 (Red)DS26 Low engine temperature output relay K12

(Red)DS27 Low fuel output relay K13 (Red)

3-9

DS1 - MA 1ST STARTDS3 - CUST FAULT4DS4 - CUST FAULT1DS6 - FAULT RESETDS7 - ENG IDLEDS8 - LOAD DEMANDDS9 - BRKR TRIP/CLOSE INHIBITDS10 - BRKR CLOSEDDS11 - CUST FAULT2DS13 - LOW FUELDS14 - RMT STARTDS15 - CUST FAULT3

DS2 - [K14] PRE-LOP

DS5 - [K15] LOP

DS12 - [K7]LOW COOL

DS16 - AC CONTACTORDS17 - COMMON ALARM

DS18 - COMMON WARNINGDS19 - LOAD DUMP

DS20 - READY TO LOADDS21 - [K8] PRE-HET

DS22 - [K6] NOT IN AUTODS23 - [K9] HET

DS24 [K10] OVERSPEEDDS25 - [K11] OVERCRANK

DS26 - [K12] LETDS27 - [K13] LOW FUEL

FIGURE 3-7. CUSTOMER INTERFACE BOARD

3-10

PT/CT BOARD (A36)The PT/CT board (Figure 3-8) is mounted inside theaccessory box. This board converts generator out-put voltage to approximately 18 VAC levels for theanalog board. It also converts CT .55 amp (at fullload) output to approximately 1.65 VAC (at full load)input for the analog board.

There are three versions of this board. For properoperation, the PT/CT board must be correctlymatched to the generator set.

In addition, there is a specific set of CTs for eachgenset. For proper operation, the CTs must also becorrectly matched to the genset output current.

ConnectorsThe PT/CT board has two connectors. They are:J8 Connects to J3 on A34 Customer Interface

boardJ9 Connects to AC harness (generator output

voltage and CTs)J9 wiring connections:

Yellow Gen. A InOrange Gen. B InRed Gen. C InBrown Gen. Common InWhite CT21 (+) InGray CT21 (common) InGrn/Ylw CT22 (+) InBlack CT22 (common) InPurple CT23 (+) InBlue CT23 (common) In

J8

J9

FIGURE 3-8. PT/CT BOARD

3-11

BUS PT MODULE (A39)The bus PT module (Figure 3-9) is mounted insidethe accessory box. This module converts the busoutput voltage (from the load side of the parallelingbreaker) to 18 VAC and provides this to the analogboard. It provides a reference signal to the Power-Command Control for synchronizing the generatorset output to a system bus. There are four versionsof this module, for primary voltages of 69, 120, 240or 346 volts AC line to neutral. For proper operation,the correct bus PT module must be installed in thegenerator set. Correct phasing is also important asthe system uses the bus PT module output for bothprotection and control of the generator set.

Connectors

The bus PT module has two terminal blocks. Theyare:

TB1 Bus voltage connections.N bus neutralA bus A phase (U)B bus B phase (V)C bus C phase (W)

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

3-12

GENSET COMMUNICATIONS MODULE(A41)

The GCM (Figure 3-10) is mounted inside the PCChousing. It is required for connection of the PCC tothe PowerCommand Network. Control and monitor-ing of the PCC can be accomplished over the net-work, via the GCM.

The GCM contains a terminate circuit for use at theend of a network data bus.

The GCM provides an interface for data from thePCC to other modules on the network. The GCMcommunicates with the PCC via the engine inter-face board, and it monitors various PCC circuits todetermine the operating state of the control. For ex-

ample, the GCM stores PCC data such as volts, cur-rent, engine speed, and oil temp; and then sends itout on the network when another network node re-quests the data.

Refer to the PowerCommand Network Installationand Operator’s Manual (900-0366) for logical instal-lation and connection of the GCM on the network.

Outputs from the GCM allow it to “wake up” the PCCwhen needed, or to cause an emergency shutdownon command. The GCM also provides some directlocal control and monitoring of the PCC. It monitorsfor Not-In-Auto mode and High and Low batteryvoltage (when the PCC is asleep).The GCM is powered from the genset battery. It re-mains powered even when the PCC is “asleep.”

TERMINATESWITCH S3

SERVICESWITCH S1 RESET

SWITCH S2

BATTERYVOLTAGE

SWITCH S4

J6J7

FIGURE 3-10. GENSET COMMUNICATIONS MODULE

3-13

Block Diagram

Refer to Table 3-1 and Figure 3-11 for a block dia-gram overview of the GCM.

GCMPCC

FIGURE 3-11. BLOCK DIAGRAM: GENSET COMMUNICATIONS MODULE (GCM)

3-14

TABLE 3-1. GCM -- BLOCK DIAGRAM DESCRIPTIONS

Function Description/Specification

B+ Power This is an output from the PCC to the GCM. The digital and analog circuitry onthe GCM is powered from CNTRL B+ from the PCC. The GCM is always pow-ered. It rides through starter dip and crank. The GCM is switch selectable for12V or 24V systems.

Serial Data This is a bidirectional data path between the PCC and GCM. The GCM com-municates with the PCC through the PCC’s serial port. Communication rate is2400 baud. Starting, stopping and exercising of the set, readout of AC data,Engine data, and Set status information are done through this link.NOTE: When the PCC’s service port is connected (serial port) to anexternal device, the GCM cannot communicate with the PCC and thus thePCC state and data cannot be known on the network.

Emergency StopControl

This is an output from the GCM. The GCM can activate the PCC’s EmergencyStop Latching Relay. This allows a remote emergency stop over the network.NOTE: The Emergency Stop condition can only be reset at the PCC frontpanel.

Wake Up Monitorand Control

This is both an output and an input for the GCM. The GCM has the capability towake up the PCC. It would do this for example when a network message wastelling the genset to start. The GCM also has the capability to monitor whetheror not the PCC is awake (i.e. due to some other reason). This helps the GCMdetermine if it can communicate with the PCC.

B+ Voltage Sensing This is an input to the GCM from the PCC. The GCM directly monitors batteryvoltage and determines high and low conditions. This function is needed whenthe PCC is not awake (and thus is not capable of monitoring battery voltageitself). A low or high condition will cause the GCM to wake up the PCC. ThePCC then annunciates the warning. Voltage thresholds are the same as in thePCC. The GCM annunciates to the network a high or low voltage condition.

Not-In-Auto Monitor This is an input to the GCM from the PCC. The GCM monitors the position ofthe front panel Run/Off/Auto switch. When the PCC is not awake, the GCMannunciates to the network a Not-In-Auto condition.

Network Data Transformer Coupled into Category 4 Twisted Pair at 78,000 bits/sec.

3-15

GCM Connections

GCM connections are made at connectors J1, J4,J6, and J7. Refer to Table 3-2.

Switches/Service Points/LEDsThe Service switch is used during installation (whenprompted by the LonMaker program). The Termina-tor switch must be set to the appropriate position atinstallation. Switches are described in Table 3-3.Service points are described in Table 3-4. LEDs aredescribed in Table 3-5.

TABLE 3-2. GCM -- CONNECTIONS

Connector Description

J7 Ribbon cable harness from GCM to A31 engine interface board. Plugs into outermostconnector on engine interface board. Cannot physically mate with any of the other con-nectors. This cable carries all GCM/PCC interface signals except network data.

J6 Twisted pair cable harness from the GCM to the engine interface board. This cable car-ries network data to the engine interface board where it then goes out through the lowerwaterproof connector on its way to the customer connection terminal strip.

J1 26 pin header on the board used for factory test purposes only.

J4 RJ45 connector for network data -- service and Installation use only.

TB1--14 Accessory Box ---- Network Data 1 signal from GCM

TB1--15 Accessory Box ---- Network Data 2 signal from GCM

TABLE 3-3. GCM -- SWITCHES

Ref Name Type Description

S1 SERVICE momentary push Used at time of logical installation to identify device tothe installation software. Pressing S1 will light the DS1LED.

S2 RESET momentary push Resets the Neuron Chip processor. Not normally used,except for troubleshooting.

S3 TERMINATOR slide Switch is set to position opposite of text “TERM” fromfactory. The two devices at ends of network data musthave their switches set to “TERM”.

S4 12/24V SENSING slide Selects whether high/low battery sensing is for a 24VDCor 12VDC system. It is set to 24V position from thefactory.

TABLE 3-4. GCM -- SERVICE POINTS

Ref Name Description

TP1 GCM VCC This is the 5.0VDC that supplies the logic on the GCM. It is measuredwith respect to TP2. This test point is for troubleshooting use only.

TP2 GND Reference point for TP1.

3-16

TABLE 3-5. GCM -- LED INDICATORS

Ref Color Name Description

DS1 Amber SERVICE Indicates various states of the GCM node. It will be ON if S1 is pressedand held. States without S1 pressed:OFF = All OK. GCM has application image and is installed in a network.ON= GCM is applicationless or has experienced a error that preventsNeuron Chip from executing application code.1/2 Hz BLINKING (1 second on / 1 second off) =GCM has an applica-tion, but has not been logically installed in a network.FLASHING (momentarily) once every 2--3 seconds=GCM is experienc-ing an error condition, causing a watchdog timeout reset.

DS2 Green RXD Indicates Serial Data output from the GCM to the PCC. If the PCC isawake and no service tool is connected, this LED should be flickeringregularly. RXD may be steady ON if the PCC is not awake.

DS3 Green DTR ON indicates that the PCC is capable of communicating with the GCM(i.e. PCC is awake and no service tool is connected).

DS4 Green TXD Indicates Serial Data input to the GCM from the PCC. Should be flicker-ing regularly if the PCC is awake. If the service tool is connected, flicker-ing will indicate responses from the PCC to the service tool. TXD may besteady ON if the PCC is not awake.

DS5 Green RTS ON indicates that the PCC has new information for the GCM to retrieve.(May not be used.)

DS6 Green WAKE UP ON when the GCM has turned on the PCC.

DS7 Green STATUS Approx. 1/2 Hz Blinking (1 second on / 1 second off) indicates thatthe GCM’s processor is executing the application code. In the future,may be used to indicate other conditions for troubleshooting purposes.

DS8 Red E--STOP ON when a network emergency stop is active.

DS9 Red HIGH B+ ON for a high battery condition sensed by GCM.

DS10 Red LOW B+ ON for a low battery condition sensed by GCM.

DS13 Green WREN ON (normal state) indicates that the off-chip EEPROM can be written to.Indicator must be ON if device is to be logically installed in a network.OFF could be caused by:1) PCC CNTRL B+ is below 10VDC.2) RESET switch being pressed and held.3) Problem with board or connectors.

3-17

VOLTAGE REGULATOR OUTPUT MODULE(A37)The voltage regulator output module (Figure 3-12)is a power amplifier. This board is used to amplifythe pulse-width modulated (PWM) signal from thePCC to drive the exciter windings. Power from thePMG is used by this board to amplify the PWM sig-nal.

Connectors

The voltage regulator output module has two con-nectors. They are:

J7 Connects to engine harness (control)J7 wiring connections:

Gray Regulator Drive (+) InputWhite Regulator Drive (-) InputBlue B+ Input (RUN signal)Purple Ground InputGrn/Yel Start inBlack Start solenoid

J10 Connects to engine harness (power)J10 wiring connections:

Green Phase A PMG powerYellow Phase B PMG powerOrange Phase C PMG powerRed X (Field +) OutputBrown XX (Field --) Output

LEDs

The voltage regulator output module has 3 LED’sthat indicate the following conditions.

DS1 On when voltage regulator isolated supply isoperating (Green)

DS2 Output Duty Cycle -- Brighter when load in-creases -- larger duty cycle (Amber). The dutycycle range of the PWM signal is 0 - 60%. Be-cause the normal duty cycle is less than 10%,the output duty cycle LED, DS2 will normallybe very dimly lit.

DS3 Backup start disconnect -- On when start dis-connect is true (Green). The backup start dis-connect is initiated at about 850 RPM, whensensed PMG voltage is greater than 105 voltsRMS.

J10J7

DS1 - ISOLATED SUPPLYDS2 - OUTPUT DUTY CYCLEDS3 - BACKUP START DISCONNECT

FIGURE 3-12. VOLTAGE REGULATOR OUTPUT MODULE (A37)

3-18

GOVERNOR OUTPUT MODULE (A38)

The governor output module (Figure 3-13) receivesa low power pulse--width modulated (PWM) signalfrom the engine interface board and then sends anamplified signal to drive the governor actuator. ThePCC monitors frequency from both the magneticpick-up (MPU) and the main stator inputs.

Connectors

The governor output module has one connector:

J6 Connects to Governor Actuator, GovernorDrive (from Engine Interface), B+, T26

Fuses

The governor output module has three fuses to pro-tect it from overloads and groundfaults. They are:

F1 Network B+ (10 Amps)F2 Switched B+ (10 Amps) — T26F3 Gov Act + (10 Amps)

LEDs

The governor output module has two LED’s that in-dicate the following conditions:

DS1 Output Duty Cycle: brighter = longer duty cy-cle (Amber). The duty cycle range of thePWM signal is 0 - 90%. Normal duty cycle isabout 30%.

DS2 Run signal to Governor Controller (Green)

J6

DS1 - OUTPUT DUTY CYCLE

DS2 - GENSET RUN

Network B+ Switched B+ Governor B+

FIGURE 3-13. GOVERNOR OUTPUT MODULE (A38)

3-19

MASTER FIRST START SENSORThe First Start Sensor System is an Onan controlsub-system which is used to sense when a genera-tor set is ready to close to a de-energized systembus and to prevent more than one generator setfrom closing to a dead bus on automatic systemstarting. The First Start Sensor System for Power-Command generator sets is composed of control al-gorithms within the PowerCommand control and aMaster First Start Sensor, which is usually mountedin a remote master control panel.

The sequence of operation of the control system isas follows:On a signal to start, all generator sets in a systemsimultaneously start, and accelerate to rated speedand voltage. The Master First Start Sensor continu-ously provides pulses to each PowerCommandcontrol. When the PowerCommand control re-ceives the pulse from the Master First Start Sensor,if it is ready to close to the bus, an interlock signal issent to all other controls to prevent their respectiveparalleling breakers from closing. A close signal isthen provided to the generator set parallelingbreaker.

4-1

4. Troubleshooting

GENERAL

The PowerCommand�Control continuously moni-tors engine sensors for abnormal conditions, suchas low oil pressure and high coolant temperature. Ifany of these conditions occur, the PCC will light ayellow Warning lamp or a red Shutdown lamp anddisplay a message on the digital display panel.

In the event of a shutdown fault (red Shutdownlamp), the PCC will stop the engine and operate aset of contacts which will trip the paralleling circuitbreaker. If the generator set is stopped for this rea-son, the operator can restart the set after makingadjustments or repairs to remove the fault condi-tion. If the generator set is receiving a remote startsignal, and the control switch is in the Auto position,the generator set will automatically restart, and theparalleling breaker will automatically re-close aftersynchronizing.

This section contains the following information:

� Table 4-1: Contains a list of all status codes,including the displayed message and statusindicator. Also references the page numberthat contains a description of each code.

� Table 4-2: Describes each warning and shut-down code, warning and shutdown limitswhere applicable, and basic corrective actions,such as, checking fluid levels, control resetfunctions, battery connections, etc.

� Table 4-3: Lists the PCC oil pressure warningand shutdown limits.

� Tables 4-4 through 4-35: Provide detailedtroubleshooting procedures.

� Table 4-36: Describes the analog circuit boardinputs and outputs.

� Table 4-37: Describes the location and func-tion of each fuse.

SAFETY CONSIDERATIONS

WARNING The control system and accessorybox for this generator set can contain danger-ous high voltages, even when the generator setis shut down.Donot attempt to service thisgen-erator set unless you have been trained in prop-er service techniques for the control system.

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

WARNING Contacting high voltage compo-nents can cause electrocution, resulting insevere personal injury or death. Keep the out-put box covers in place during troubleshooting.

When troubleshooting a set that is shut down,makecertain the generator set cannot be accidentally re-started. Place the Run/Off/Auto switch in the Offposition. Turn off or remove AC power from thebattery charger, MAKE CERTAIN EXPLOSIVEBATTERY GASSES ARE DISPELLED FROMBATTERY COMPARTMENT, and then remove thenegative (--) battery cable from the set starting bat-tery.

WARNING Accidental startingof the generatorset during troubleshooting can cause severepersonal injury or death. Disable the generatorset (see above) before troubleshooting.

4-2

STATUS INDICATORS

Non-Automatic Status Indicator: This red lampflashes continuously when the Run/Off/Auto switchis in the Off position.

Warning Status Indicator: This yellow lamp is litwhenever the control detects a warning condition.After the condition is corrected, warning indicatorscan be reset by pressing the Reset switch. (It is notnecessary to stop the generator set.) In automode,warning indicators can also be reset by cycling theremote reset input after the condition is corrected.

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdowncondition.Shutdown faults are latched. After the condition iscorrected, shutdown indicators can be reset byturning the Run/Off/Auto switch to the Off position,and pressing theReset switch. In the Auto position,shutdown faults can be reset by removing the re-mote start input and then cycling the remote resetinput.

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

DigitalDisplay:This two-line, 16-character per linealphanumeric display is used in the menu-drivenoperating system and to show shutdown and warn-ing messages. Refer to Tables 4-1 and 4-2.

RESETTING THE CONTROL

Press the momentary Reset Switch to reset warn-ing and shutdownmessages after the condition hasbeen corrected. To reset a shutdown message withthe Reset switch, the Run/Off/Auto switch must bein the Off Position. (The control cannot go intoStandby (sleep) mode until all faults have beenreset.)In Auto mode, warning indicators can also be resetby cycling the remote reset input after the conditionis corrected. Shutdown faults can be reset by re-moving the remote start input and then cycling theremote reset input.

ALPHANUMERICFAULT MESSAGE

DISPLAY

RESETSWITCH

WARNING ANDSHUTDOWN

STATUS INDICATORS

FIGURE 4-1. CONTROL PANEL

4-3

TABLE 4-1. WARNING AND SHUTDOWN CODES

BASIC TROUBLE-

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

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

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

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

200 LOW OIL PRESSURE Warning 4-5 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

201 LOW OIL PRESSURE Shutdown 4-6 4-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

204 OIL PRES SENDER Warning 4-6 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

210 LOW COOLANT TEMP Warning 4-6 4-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 HIGH COOLANT TEMP Warning 4-6 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

212 HIGH COOLANT TEMP Shutdown 4-7 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

213 COOLANT SENDER Warning 4-7 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

214 LOW COOLANT LVL Warning 4-7 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 LOW COOLANT LVL Shutdown 4-7 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 MAG PICKUP Shutdown 4-7 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

221 FAIL TO CRANK Shutdown 4-7 4-16, 4-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

222 OVERCRANK Shutdown 4-8 4-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

223 OVERSPEED Shutdown 4-8 4-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224 FAIL TO SYNCHRONIZE Warning/Shutdown 4-8 4-32. . . . . . . . . . . . . . . . . . . . . . . . . .

226 FAIL TO CLOSE Warning/Shutdown 4-8 4-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

230 LOW DC VOLTAGE Warning 4-9 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

231 HIGH DC VOLTAGE Warning 4-9 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

232 WEAK BATTERY Warning 4-9 4-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

240 LOW FUEL -- DAY Warning 4-9 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

241 LOW FUEL Warning 4-9 4-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

250 EEPROM ERROR Shutdown 4-10 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

251 EEPROM ERROR Warning 4-10 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

252 EEPROM ERROR Warning 4-10 4-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-4


BASIC TROUBLE-

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

260 CUSTOMER FAULT 1* Warning/Shutdown 4-10 4-40. . . . . . . . . . . . . . . . . . . . . . . . . .

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

262 RUPTURE BASIN* Warning/Shutdown 4-10 4-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

270 PHASE ROTATION Warning 4-11 4-41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

272 FIRST START Warning 4-11 4-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

301 HIGH AC VOLTAGE Shutdown 4-11 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

303 LOW AC VOLTAGE Shutdown 4-11 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

313 UNDER FREQUENCY Shutdown 4-11 4-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

320 OVERCURRENT Warning 4-11 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

321 OVERCURRENT Shutdown 4-11 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

322 SHORT CIRCUIT Shutdown 4-12 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

330 OVERLOAD Warning 4-12 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

335 REVERSE POWER Shutdown 4-12 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

337 LOSS OF EXCITATION Shutdown 4-12 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* Defaultmessage.Editable for customer site requirements. It is recommended that the bell alarmcontacts of theparalleling breaker be brought back to the control and indicate “Parallel CB Trip” as one customer fault.

4-5

Indicates local or remote Emergency Stop.To reset the local/remote Emergency Stop button :

Turn the switch clockwise and allow it to pop out(local only).Move the Run/Off/Auto switch to Off.Press the Reset switch.Select Run or Auto, as required.

Indicates that the engine is operating in idle mode.When the set is operating in the RUNmode, ground-ing the engine idle input causes generator build-up tobe inhibited and the engine to be governed at 800RPM. When ground is removed from this input, theset returns to normal speed and voltage.When the engine idle function is enabled, the controlautomatically sets lower oil pressure warning andshutdown trip points to reflect the lower operatingspeed.When the engine idle function is removedandthe set reverts to normal operating speed, the controlautomatically resets oil pressure warning and shut-down trip points to the normal settings.


SYMPTOM CORRECTIVE ACTION

Shutdown lamp lights.MESSAGE:EMERGENCY STOP102 -- SHUTDOWN

Warning lamp lights.MESSAGE:LOW OIL PRESSURE200 -- WARNING

Indicates engine oil pressure has dropped to anunac-ceptable level. If generator is powering critical loadsandcannot beshut down,wait until next shutdownpe-riod and then follow 201-SHUTDOWN procedure.

To check oil pressure during a warning, access the oilpressure menu prior to clearing the fault.

Many troubleshooting procedures present hazardswhich can result in severe personalinjury or death. Only qualified service personnel with knowledge of fuels, electricity, andmechanical hazards should perform service procedures. Review safety precautions.

WARNING

MESSAGE:IDLE MODE101 -- WARNING

The PowerCommand control has received a signalto shut down from a remote device. This is a normaloperation mode, which is typically used in automaticcontrol system to minimize generator set operationhours and system fuel consumption. When the loaddemand signal is removed, the generator set will au-tomatically start, synchronize, and close to the sys-tem bus.

MESSAGE:LOAD DEMAND

4-6

Warning lamp lights.MESSAGE:LOW COOLANT TEMP210 -- WARNINGSet is not operating. Warning occurswhen engine coolant temperature is 70�F (21� C) or lower. NOTE: In applica-tionswhere the ambient temperaturefalls below 40�F (4�C), Low CoolantTemp may be indicated even thoughthe coolant heaters are operating.

SYMPTOM

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

CORRECTIVE ACTION

Indicates engine coolant heater is not operating or isnot circulating coolant. Check for the followingcondi-tions: Note: this signal wakes up the PCC.

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

b. Check for low coolant level and replenish if re-quired. Look for possible coolant leakage pointsand repair as required.

c. Open heater element. Check current draw ofheater.

Warning lamp lights.MESSAGE:HIGH COOLANT TEMP211 -- WARNING

Indicates engine has begun to overheat (coolanttemperature has risen to an unacceptable level:215� F -- standby / 207� F -- primary).If generator is powering non-critical and critical loadsand cannot be shut down, use the following:a. Reduce load if possible by turning off non-critical

loads.b. Check air inlets and outlets and remove any ob-

structions to airflow.If engine can be stopped, follow HIGH COOLANTTEMP 212 -- SHUTDOWN procedure.

To check coolant temperature during a warning, ac-cess coolant termperature menu prior to clearing thefault.


WARNING

Shutdown lamp lights.MESSAGE:LOW OIL PRESSURE201 -- SHUTDOWN

Indicates engine oil pressure has dropped below theshutdown trip point. Checkoil level, lines and filters. Ifoil system is OK but oil level is low, replenish. Resetcontrol and restart. Oil pressure limits are listed in Ta-ble 4-3.

Warning lamp lights.MESSAGE:OIL PRES SENDER204 -- WARNING

Indicates that the control has sensed that the engineoil pressure sender is out of its working range. Checkthat the engine oil pressure sender is properly con-nected.

4-7

Shutdown lamp lights.MESSAGE:LOW COOLANT LVL214 -- WARNINGorLOW COOLANT LVL215 -- SHUTDOWN

SYMPTOM


CORRECTIVE ACTION

Shutdown lamp lights.MESSAGE:MAG PICKUP220 -- SHUTDOWN

Indicates engine coolant level has fallen below thetrip point. Allow engine to cool down completely be-fore proceeding. Note: this signal wakes up the PCC.a. Check coolant level and replenish if low. Look

for possible coolant leakage points and repair ifnecessary.

b. Reset control and restart after locating and cor-recting problem.LOW COOLANT LVL Shutdown will not occur ifgenset is in Idlemode (low coolant warning only).

Indicates mag pickup speed indication is not beingsensed or does not match generator set output fre-quency.a. Restart and check RPM on the digital display.

Engine will not crank.Shutdown lamp lights.MESSAGE:FAIL TO CRANK221 -- SHUTDOWN

Indicates possible fault with control or starting sys-tem. Check for the following conditions:a. Check fuse F3 on the Engine Interface board.b. Poor battery cable connections. Clean the bat-

tery cable terminals and tighten all connections.c. Discharged or defective battery. Recharge orreplace the battery.


WARNING

Warning lamp lights.MESSAGE:COOLANT SENDER213 -- WARNING

Shutdown lamp lights.MESSAGE:HIGH COOLANT TEMP212 -- SHUTDOWN

Indicates engine has overheated (coolant tempera-ture has risen above the shutdown trip point:223�F -- standby / 215�F -- primary). Allow engineto cool down completely before proceeding with thefollowing checks:a. Check for obstructions to cooling airflow and

correct as necessary.b. Check fan belt and repair or tighten if necessary.c. Reset control and restart after locating and cor-recting problem.

d. Check blower fan and circulation pumps on re-mote radiator installations.

Indicates that the resistance of the coolant tempera-ture sender is out of range. Check the resistance ofthe sender. Resistance should be 500 to 2k ohms.

4-8

Warning (or Shutdown) lamp lights.MESSAGE:FAIL TO SYNCHRONIZE224 -- WARNINGorFAIL TO SYNCHRONIZE224 -- SHUTDOWN

SYMPTOM


CORRECTIVE ACTION

Shutdown lamp lights.MESSAGE:FAIL TO CLOSE226 -- WARNINGorFAIL TO CLOSE226 -- SHUTDOWN

The generator set has not synchronized to the sys-tem bus within the allowable time frame.a. Check the governor system stability. Adjust gov-

erning and synchronizer parameters as re-quired.

b. Check for fuel system problems which cancause engine instability.Synchronizing time can be improved by widen-ing the synchronizing window and reducing theacceptance time delay.

Indicates that the paralleling breaker has been givena signal to close, but has not closed properly.a. Verify that the charging mechanism of the paral-

leling breaker is functioning properly.b. Check the close signal to the breaker.c. Verify that the auxiliary contact signals from thebreaker to the PowerCommand control are op-erational.


WARNING

Engine runs and then shuts down,Shutdown lamp lights.MESSAGE:OVERSPEED223 -- SHUTDOWN

Indicates possible fuel system problem.a. Check for empty fuel tank, fuel leaks, or plugged

fuel lines and correct as required.b. Check for dirty fuel filter and replace if neces-

sary.c. Check for dirty or plugged air filter and replace ifnecessary.

d. Reset the control and restart after correcting theproblem.

Shutdown lamp lights.Engine stops cranking.MESSAGE:OVERCRANK222 -- SHUTDOWN

Indicates engine has exceeded normal operatingspeed. (115% �1% of nominal)

4-9

Warning lamp lights.MESSAGE:HIGH DC VOLTAGE231 -- WARNING

SYMPTOM


CORRECTIVE ACTION

Warning lamp lights.MESSAGE:LOW DC VOLTAGE230 -- WARNING

Warning lamp lights.MESSAGE:WEAK BATTERY232 -- WARNING

Indicates battery voltage exceeds 32 VDC.Check float level on battery charger if applicable(lower float level).

Indicates battery voltage is below 24 VDC.

a. Discharged or defective battery.Check the battery charger fuse.Recharge or replace the battery.

b. Poor battery cable connections. Clean the bat-tery cable terminals and tighten all connections.

c. Check float level if applicable (raise float level).

Indicates battery voltage drops below 60% of nomi-nal for two seconds, during starting.Discharged or defective battery.See Warning message 230, LOW DC VOLTAGE.

Warning lamp lights.MESSAGE:LOW FUEL--DAY240 -- WARNING

Indicates day tank fuel supply is running low. Checkfuel supply and replenish as required.


WARNING

Warning lamp lights.MESSAGE:LOW FUEL241 -- WARNING

Indicates fuel supply is running low. Check fuel sup-ply and replenish as required.

4-10


Shutdown lamp lights.MESSAGE:CUSTOMER FAULT 1260 -- SHUTDOWNorGROUND FAULT261 -- SHUTDOWNorDAY TANK262 -- SHUTDOWNorHIGH GEN TEMP263 -- SHUTDOWN


SYMPTOM

When any one of these customer defined inputs isclosed to ground, the corresponding fault message isdisplayed. The nature of the fault is an optional cus-tomer selection. These fault functions can be pro-grammed to initiate a shutdown or a warning. Cus-tomer fault 261 or 262 input can “wakeup” the controlif it is not operating.As indicated by the Shutdown lamp, a shutdown re-sponse has been preselected.Note: Customer fault messages are editable. Themessage displayed for the code shown (260 thru263) may have been edited and may not appear asshown in this table.

CORRECTIVE ACTION

WARNING

When any one of these customer defined inputs isclosed to ground, the corresponding fault message isdisplayed. The nature of the fault is an optional cus-tomer selection. These fault functions can be pro-grammed to initiate a shutdown or a warning. Cus-tomer fault 261 or 262 input can “wakeup” the controlif it is not operating.As indicated by the Warning lamp, a warning re-sponse has been preselected.Note: Customer fault messages are editable. Themessage displayed for the code shown (260 thru263) may have been edited and may not appear asshown in this table.

Warning lamp lights.MESSAGE:CUSTOMER FAULT 1260 -- WARNINGorGROUND FAULT261 -- WARNINGorRUPTURE BASIN262 -- WARNINGorHIGH GEN TEMP263 -- WARNING

IndicatesPCCmemoryerror. Datacorruptionof non-critical operating parameters.

Warning lamp lights.MESSAGE:EEPROM ERROR251 -- WARNINGor252 -- WARNING

Shutdown lamp lights.MESSAGE:EEPROM ERROR250 -- SHUTDOWN

IndicatesPCCmemory error. Data corruption of criti-cal operating parameters.

4-11




WARNING

Shutdown lamp lights.MESSAGE:HIGH AC VOLTAGE301 -- SHUTDOWN

Indicates that one or more of the phase voltages hasexceeded 130% of nominal, or has exceeded 110%of nominal for 10 seconds.

Shutdown lamp lights.MESSAGE:LOW AC VOLTAGE303 -- SHUTDOWN

Indicates that one or more of the phase voltages hasdropped below 85% of nominal for 10 seconds.

Warning lamp lights.MESSAGE:FIRST START272 -- WARNING

The PowerCommand control is not receiving a prop-er signal from the system master first start sensor.When this occurs, the control reverts to a fallbackmode in which breaker closure is automatically al-lowed if bus is de-energized. If bus voltage is sensed,the control will force the generator set to synchronizeto the system bus before breaker close signal is initi-ated.

Warning lamp lights.MESSAGE:OVERCURRENT320 -- WARNING

Indicates that generator output current has ex-ceeded 110% of rated for 60 seconds.

Check load and load lead connections.

Indicates that engine speed has dropped below 90%of nominal for 10 seconds.NOTE: Five seconds before shutdown, a LoadDumpsignal is initiated.

Check fuel supply, intake air supply and load.

Shutdown lamp lights.MESSAGE:UNDER FREQUENCY313 -- SHUTDOWN

Shutdown lamp lights.MESSAGE:OVERCURRENT321 -- SHUTDOWN

Indicates that generator output current has ex-ceeded 110% of rated, and that a PCC time/currentcalculation has initiated an overcurrent shutdown.


Warning lamp lights.MESSAGE:PHASE ROTATION270 -- SHUTDOWN

The phase relationship between the generator setand the system bus is not matched.a. Using a phase rotation checker, verify that the

generator set phase rotationmatches the phaseorientation of the system bus.

b. Verify that controlwiring to the busPTmoduleonthe PowerCommand control is properly con-nected.

4-12

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


Shutdown lamp lights.MESSAGE:SHORT CIRCUIT322 -- SHUTDOWN

Indicates that generator output current has ex-ceeded 175% of rated.


Warning lamp lights.MESSAGE:OVERLOAD330 -- WARNING

Indicates that three-phase power output exceeds105% of standby (or 115% of prime) rating. After fiveseconds, theLoadDumpoutput is activated. After 60seconds, the OVERLOAD warning is activated.



WARNING

Shutdown lamp lights.MESSAGE:REVERSE POWER335 -- SHUTDOWN

Indicates that power is flowing into the generator set,rather than out from the unit. This can be caused byengine failure, or inability to carry load, or by a num-ber of control or interconnection problems.a. If problemoccurs at initial startup, verify connec-

tion of generator set CT’s, by applying load to thegenerator set while it is operating alone whileconnected to bus.

b. Verify proper connection of load sharing lines.c. Verify that the generator set is operating at thecorrect frequency and voltage. The no-load volt-age of the generator set and other generatorsets should all be the same.

Shutdown lamp lights.MESSAGE:LOSS OF EXCITATION337 -- SHUTDOWN

Indicates that the alternator excitation system is im-properly adjusted or has failed.a. Start the generator set in the RUN mode and

check output voltage with both the control digitalmeter set and a calibrated meter. Calibrate volt-age if necessary. Output voltage should be ad-justed to the same level as all other generatorsets at no load. Make adjustments as necessaryto correct.

b. Check load sharing lines for proper interconnec-tions.

c. SeeSection 6of thismanual “Servicing theGen-erator”, Exciter Rectifier, and exciter Rotor.

4-13

TABLE 4-3. OIL PRESSURE WARNING/SHUTDOWN LIMITS

ENGINE MODEL 4B/6B/6C

Normal Oil PressureWarning LimitShutdown Limit

40 - 70 psi (276 - 483 kPa20 psi (138 kPa)15 psi (103 kPa)

Idle Oil PressureWarning LimitShutdown Limit

10-30 psi (69-207 kPa)12 psi (83 kPa)8 psi (55 kPa)

To check oil pressure or engine temperature during a warning, access the oil pres-sure or engine temperature menu prior to clearing the fault.

4-14

TROUBLESHOOTING PROCEDURE

The following tables are a guide to help you evalu-ate problems with the generator set. You can savetime if you read through the manual ahead of timeand understand the system.

To determine the appropriate troubleshootingprocedure for the specific problem at hand, besure to refer to the “Indicators” column pro-vided in each troubleshooting table.

Try to think through the problem. Go over what wasdoneduring the last service call. The problemcouldbe as simple as a loose wire, an opened fuse or atripped circuit breaker. (Table 4-32 describes thelocation and function of each fuse.)

Figure 4-2 shows the location of the componentswithin the control panel that are referenced in thefollowing troubleshooting procedures. Connector,

LED and switch locations for each circuit board andmodule are provided inSection 3. The controlwiringand circuit board connections are shown in Section9.

CAUTION Always set the Run/Off/Auto (S12)switch to the Off position and the Power On/Standby (S5) switch to the Standby position be-fore disconnecting or connecting harness con-nectors. Otherwise, disconnecting the harnessconnectors can result in voltage spikes highenough todamage theDCcontrol circuits of theset.

CAUTION Electrostaticdischargewill damagecircuit boards. Always wear a wrist strap whenhandling circuit boardsor socket-mounted IC’sandwhendisconnectingor connectingharnessconnectors.

4-15


ENGINE INTERFACEA31

ANALOG BOARDA33

DIGITAL BOARDA32

DISPLAY BOARDA35

RUN/OFF/AUTOSWITCH S12

OPTIONALCOMMON ALARM

RELAY K14OPTIONAL RUNRELAYS K11, K12 &

K13

TB1-1

TB1-60


A38

PT/CT BOARD A36

VOLTAGEREGULATOR

OUTPUT MODULEA37


BUS PT MODULEA39


4-16

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

WARNING Many troubleshooting procedures present hazards that can result in severe personal in-jury or death. Only qualified service personnel with knowledge of fuels, electricity, and machineryhazards should perform service procedures. Review safety precautions on pages iii and iv.

Indicator(s) Possible Cause Corrective Action

“FAIL TOCRANK”(221)

message

Reset andattempt tostart:

Start LEDDS11 on theengineinterface boardturns on.

NOTE:These twoindicationssuggest thatthe PCC hasreceived astart signaland has sent astart commandto the startoutput (J4-2)on the engineinterfaceboard.

2. Starter could be bad.

5. If there is continuity at A37 J7-5/J7-6,there may be an open between A37and A31, an open between A37 andK4, or A31 may be bad.

2. Reset the control. Attempt to start, and test forB+ at the starter. If there is B+ at the starter, thestarter could be bad. Test starter (see engineservice manual). Replace the starter.

3. Reset the control. Attempt to start, and test forB+ into and out of start solenoid contacts. Ifthere is B+ in, but not out, check for B+ at thestart solenoid coil. If there is B+ at the coil,check ground connection. If ground connectionis good, the start solenoid is bad. Replace thestart solenoid.If there is B+ into and out of the start solenoidcontacts, check for an open between the startsolenoid contacts and the starter. If there is noB+, go to the next step.

3. If there is no B+ at the starter, start so-lenoid K4 could be bad.

4. If there is no B+ at the start solenoidcoil (K4), the backup start disconnectcontacts in the regulator output mod-ule (A37) could be open (indicatingthat A37 is bad).

*4. Disconnect J7/P7 at the regulator output mod-ule. Test for continuity at A37 J7-5/J7-6. If thereis no continuity, the regulator output module isbad. Replace A37.

*5. If there is continuity at A37 J7-5/J7-6, reset thecontrol, attempt to start, and check for B+ atA37 P7-5.If there is B+ at P7-5, there may be an open be-tween start solenoid coil (K4) and A37. If thereis no B+ at P7-5, check for B+ at J4-2 on the en-gine interface board (A31) while attempting tostart.If there is B+ at A31 J4-2, check for an open be-tween A37 and A31.If there is no B+ at A31 J4-2, (and DS11 is on)the engine interface board is bad. Replace A31.

1a. Recharge or replace the battery. Specific grav-ity for a fully charged battery is approximately1.260 at 80� F (27� C).

1b. Clean and tighten or replace the battery cableconnectors and cables at the battery and theset.

1c. Adjust charge rate of battery charging circuit.

1. Insufficient battery voltage. Check thefollowing conditions:a. Batteries not charged.b. Battery connections loose or

dirty.c. Insufficient battery charging volt-

age.

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

6. The mag pickup signal is not beingsensed.

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

4-17

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


*1. Install harness tool between A31 J4/P4. Resetthe control. Attempt to start and check for B+ atJ4-2. If no B+, remove F3 and check continuity.If open, replace the fuse with one of the sametype and amp rating (5 Amps). If F3 is OK,check the B+ supply from the wiring harness.

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



message

Reset andattempt tostart:

Start LEDDS11 on theengineinterface boarddoes NOTturn on.

NOTE:These twoindicationssuggest thatthe PCC hasreceived astart signaland has NOTsent a startcommand tothe start output(J4-2) on theengineinterfaceboard.

2. To isolate:� Check for B+ at S13-1 and S13-2.If there is B+ at S13-2, but not at S13-1(and S13 is NOT in the emergency stopposition), then S13 is bad. Replace S13.

� If there is no B+ at S13-2, disconnectJ3/P3, and check for B+ at A31 J3-2. Ifthere is no B+, replace A31.

� If there is B+ at A31 J3-2, check continuityfrom P3-2 to P3-6. If no continuity, repairor replace as necessary.

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

4. Engine interface board (A31) may bebad.

*4. If there is a ground output at A32 J4-3, and yetthere is no B+ output at A31 J4-2; then A31 isbad. Replace A31.

*3. Install harness tool between A32 J4/P4. Resetthe control. Attempt to start, and test for groundoutput at A32 J4-3. If there is no ground output,A32 is bad. Replace A32.

3. Digital board (A32) may be bad.


4-18

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



messageDOES NOTappear ondigital display--and:Auto LED DS5on the engineinterface board(A31) is on --RMT StartLED DS14 onthe customerinterface board(A34) is on --

NOTE:This conditionsuggests thatthe PCCprocessor(digital board--A32) hasNOT receivedor recognizeda remote startstart signal.

*1. Install harness tool between A32 J4/P4. Checkfor ground output at A32 J4-18.If there is no ground output (but A31 DS5 is on)engine interface board A31 is bad. ReplaceA31.If there is a ground output at A31 J1-18, pro-ceed to the next step.

1. The Auto mode signal is not gettingfrom engine interface board A31 todigital board A32, indicating that A31 isbad.


2. The Remote run signal is not gettingfrom customer interface board A34 toA32, indicating that A34 is bad.

*2. Install harness tool between A32 J4/P4. Resetthe control. Attempt to remote start, and checkfor ground output at A32 J2-26. If no ground out-put (but A34 DS14 is on) customer interfaceboard A34 is bad. Replace A31.If there is a ground output at A32 J2-26, pro-ceed to the next step.

*3. If, when attempting remote start, there is aground input at A32 J2-26, and a ground inputat A32 J4-18—and there is no “FAIL TOCRANK” message—and the set does notcrank; A32 is bad. Replace, A32.

3. Digital board (A32) may be bad.


4-19





messageDOES NOTappear ondigital display--and:Auto LED DS5on the engineinterface board(A31) is off --RMT StartLED DS14 onthe customerinterface board(A34) is on --

NOTE:This conditionsuggests thatthe engineinterface board(A31) is NOTenabling theremote startlogic on thedigital board.

*2. Install harness tool between A32 J4/P4. Checkthe 16 volt (nominal) supply at A32 J4-16.

If the voltage is present at A32 J4-16, andground is present at A31 P3-13—and yet A31DS5 is off; then A31 is bad. Replace A31.

The Auto mode input is not getting from theAuto select switch (S12) to engine interfaceboard A31 (indicating that S12, A31, or theharness is bad.

1. S12 or the wiring harness may be bad. *1. Disconnect A31 J3/P3. Check continuity toground at A31 J3-11. (J3-11 is ground out toS12. If ground is not present, replace A31. Ifground is present, place S12 in Auto and checkcontinuity from P3-11 to P3-13. If no continuity,isolate to switch or wiring harness. Repair asnecessary. If there is continuity, A31 may bebad. Reconnect J3/P3.

2. Engine interface board A31 may bebad.

3. If there is no +16 volt supply voltage at A32J4-16, A32 is bad. Replace A32.

3. Digital board A32 may be bad.


4-20





messageDOES NOTappear ondigital display--and:Auto LED DS5on the engineinterface board(A31) is on --RMT StartLED DS14 onthe customerinterface board(A34) is off

NOTE:This conditionsuggests thatthe remotestart input isNOT passingthrough thecustomerinterface board(A34) toenable theremote startlogic on thedigital board.

2. If ground is present at A34 J1-13—and yet A34DS14 is off, replace A34.

The remote start input is not getting from theremote start switch to the output of the cus-tomer interface board (A34) (indicating thatthe switch, A34, or the harness is bad.

1. The remote start switch or thewiring harness may be bad.

*1. Install harness tool between A34 J1/P1. Resetthe control. Attempt remote start and check forground at A34 J1-13. If ground level is not pres-ent, isolate to the switch or the wiring harnessby checking for a start signal at TB1-5. Repairas necessary.

2. Customer interface board A34may be bad.


4-21

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




messageDOES NOTappear ondigital display--and:Run LED DS4on the engineinterface board(A31) is off--

NOTE:This conditionsuggests thatthe start inputis NOT gettingfrom theRun/Off/ Autoswitch (S12) tothe engineinterface board(A31) toenable theremote startlogic on thedigital board.

The start input is not getting from the Run/Off/ Auto select switch (S12) to A31 (indi-cating that S12, A31, or the harness is bad.

1. Run/Off/ Auto select switch S12 or thewiring harness may be bad.

*1. Check continuity to ground at A31 J3-11. Ifground is not present, replace A31. If ground ispresent, place S12 in Run and check continuityfrom P3-11 to P3-12. If no continuity, isolate toswitch or wiring harness. Repair as necessary.If there is continuity, A31 may be bad.

2. Engine interface board A31may be bad.

*2. Install harness tool between A32 J4/P4. Checkthe 16 volt (nominal) supply at A32 J4-16.

If the voltage is present at A32 J4-16, andground is present at A31 J3-12—and yet A31DS5 is off, replace A31.

3. If there is no +16 volt supply voltage at A32J4-16, replace A32.

3. Digital board A32 may be bad.


4-22

TABLE 4-10. ENGINE CRANKS BUT DOES NOT START


2. The mechanical fuel linkage could bebinding, loose, or damaged.

2. Inspect the mechanical fuel linkage, and repairor replace as necessary.Follow the procedure in the engine repairmanual to check the EFC for binding or dam-age.Disconnect the actuator connector, and con-nect +12 VDC from the battery to the actuator.The actuator should click upon application andremoval of the voltage.If the actuator does not click, refer to the enginemanual.If the actuator clicks, reconnect the wires to theactuator.

1. Restricted fuel supply due to:a. Fuel level below pickup tube in

tank.b. Closed shutoff valve in supply

line.c. Fuel injectors clogged.d. Air in fuel system.

1a. Add fuel if low. Prime the fuel system.1b. Open any closed shutoff valve in the fuel line

supplying the engine.1c. Refer to engine service manual.1d. Bleed air from fuel system. Refer to engine

service manual.


“OVERCRANK”(222)

message

--and

While cranking,Run LED DS12on theengine interfaceboard (A31)is on.

and

While cranking,Run LED DS2on thegovernor outputmodule (A38)is on.

NOTE:Theseindicationssuggest that thePCC has sent arun signal to thefuel solenoid.

3. Fuel solenoid (K1) on the injectionpump not energized due to:a. Open in fuel solenoid circuit or

defective governor module.b. Defective fuel solenoid.

3a. Reset the control. Attempt to start and check forB+ at the K1 fuel solenoid coil on the injectionpump and at output of governor module. Checkcontinuity from J6-20 and 21 to J6-19.

3b. Check wiring continuity of fuel solenoid circuit.Test fuel solenoid.

Repair or replace as necessary.

5. Engine fuel injection or other engineproblem.

4. Fuel tank solenoid not energized dueto:a. Open in fuel tank solenoid circuit.b. Defective fuel tank solenoid.

5. Refer to the engine service manual.

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

4b. Test fuel tank solenoid.Repair or replace as necessary.

Fuel supply or fuel delivery.


4-23



1. The run signal is not getting out of theengine interface board (A31). A31may be bad.

*1. Install harness tool between A31 J4/P4. Resetthe control. Attempt to start and check for B+ atA31 J4-1. If there is no B+ at A31 J4-1, replaceA31.



message

--and

While cranking,Run LED DS12on theengine interfaceboard (A31)is on.

and

While cranking,Run LED DS2on thegovernor outputmodule (A38)is off.

NOTE:Theseindicationssuggest that thePCC has sent arun signal to thegovernormodule, but thesignal is notgetting throughthe governormodule to thefuel solenoid.

The run signal is not getting through thegovernor module to the fuel solenoid.

Reset the control. Attempt to start and check for B+at A31 J4-1.

2. There is an open between the engineinterface board (A31) and the gover-nor output module (A38).

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

*2. If there is B+at A31 J4-1, install harness tool be-tween A38 J6/P6. Check for B+ atA38 J6-19, while attempting to crank. If there isno B+ at A38 J6-19, isolate to connectors andwiring. Repair or replace as necessary.

3. If there is B+ at A31 J4-1, and there is B+ at A38J6-19, check continuity from A38 J6-15 to bat-tery ground, if not continuity replace harness, ifcontinuity, replace A38.


4-24



*Install harness tool between A32 J4/P4. Attempt tostart and check for ground signal at A32 J4--8.

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

1. If there is no ground signal at A32 J4--8, replaceA32.



message

--and

Run LED DS12on theengine interfaceboard (A31)is off.

NOTE:Theseindicationssuggest that thePCC has NOTsent a runsignal --(fuel solenoidenable signal)out to thegovernormodule and thefuel solenoid.

The run signal from the digital board (A32)is not being processed by the engine inter-face board (A31).

2. If there is a ground signal at A32 J4--8, replaceA31.

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


message

NOTE:The engine iscranking butshutting downon a 221 fault.

The mag pickup signal is not beingsensed.

Refer to the mag pickup shutdown message(220).


4-25

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



“LOW OILPRESSURE”warning(200) orshutdown(201)message.

1. Low oil level. Clogged lines or filters.

2a. Sender or oil pump could be bad. Orthe generator set may be shuttingdown on another fault.

1. Check oil level, lines and filters. If oil system isOK but oil level is low, replenish. Oil pressurelimits are listed in Table 4-3.

2. Disconnect the oil pressure sender leads, andconnect an oil pressure sender simulator to theharness.

a. If the control responds to the simulator, recon-nect the sender, disconnect the run signal wireat the fuel solenoid, and crank the engine.Check the oil pressure reading on the digitaldisplay.� If the display shows anacceptable oil pres-sure, the problemmay not be in the oil or oilsensing system. The generator set maybe shutting down on another fault (out offuel, blown governor fuse, intermittentconnector). Restart the generator set andmonitor the PCC display panel for otherfaults.

� If the display does not show an acceptableoil pressure, replace the sender. If thePCC still doesn’t display an oil pressurewhile cranking, the oil pumpmay be faulty.Refer to the engine service manual.

*b. If the control does not respond to the simulator,the PCC or the harness is bad. Install harnesstool between A31 J2/P2.Check for +5 VDC at the sender (lead markedE1-B). If there is no 5 VDC at the sender� Check for 5 VDC at A31 J5-18.� If yes, harness is bad. If no, check for 5VDC at A31 J2-24.

� If yes, A31 is bad. If no, A33 is bad.If there is 5 VDC at the sender, use the sendersimulator to generate a signal to A31 J2-23. Ifthe pressure signal (.5 to 4.5 VDC) does not getto A31 J2-23, isolate to the harness or A31. Ifthe pressure signal does get to A31 J2-23, referto the analog/digital troubleshooting procedure(Table 4-35a/b).

2b. Harness or PCC circuit board could bebad.Isolate to the harness, engine inter-face board (A31), analog board (A33),or digital board (A32).


4-26

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



“OILPRESSURESENDER”warning(204)message.

1. The sender connections could be bad.

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

1. Check the sender connections.

*2. Isolate to the sender, harness, engine interfaceboard (A31), analog board (A33), or digitalboard (A32).Disconnect the oil pressure sender leads, andconnect an oil pressure sender simulator to theharness.“OIL PRES SENDER” warning is displayedafter the fault condition is sensed for 10 se-conds.a. If the control responds to the simulator, re-

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

the PCC or the harness is bad. Install harnesstool between A31 J2/P2.Check for +5 VDC at the sender (lead markedE1-B). If there is no 5 VDC at the sender� Check for 5 VDC at A31 J5-18.� If yes, harness is bad. If no, check for 5VDC at A31 J2-24.

� If yes, A31 is bad. If no, A33 is bad.If there is 5 VDC at the sender, use the sendersimulator to generate a signal to A31 J2-23. Ifthe pressure signal (.5 to 4.5 VDC) does not getto A31 J2-23, isolate to the harness or A31. Ifthe pressure signal does get to A31 J2-23, referto the analog/digital troubleshooting procedure(Table 4-35a/b).

“COOLANTSENDER”warning(213)message.

1. Check the sender connections.

*2. Isolate to the sender, harness, engine interfaceboard (A31), analog board (A33), or digitalboard (A32).Disconnect the sender, and plug in a resistivesender simulator to isolate the fault.a. If the control responds to the simulator, re-

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

lator, refer to the high coolant temptroubleshooting procedure.

1. The sender connections could be bad.

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


4-27

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


“LOWCOOLANTTEMP”warning(210)message.

Coolant levelis normal.

Heater is OK.

Coolant tempon front paneldisplay is OK.

DS3 on theengineinterfaceboard, A31,is on.


DS3 / A31 is on, indicating that engine in-terface board A31 is receiving a low cool-ant temp from the sender.The sender, the harness or A31 could bebad.

Isolate the source of the signal.Unplug the coolant temperature switch (S1) and re-set the control.1. If the 210 warningmessage drops out and does

not reappear, replace the sender.*2. If the 210 warning message reappears and re-

mains after control reset, disconnect A31 J4and check continuity from P4--13 to GND.� If there is continuity, replace the harness.� If there is no continuity, replace circuitboard A31.

DS3 / A31 is off, indicating that engine in-terface board A31 is not receiving a lowen-gine temp signal from the sender—but the210message indicates that A32, the digitalboard, is responding to a false low enginetemp signal.A31, the engine interface board, or A32,the digital board, could be bad.

Isolate the source of the signal.Check J4--6/P4--6 on A32.*1. Install harness tool between A32 J4/P4.2. Open J4--6 and reset the control.

� If fault drops out and does not return, re-place A31.

� If fault returns after resetting the control,replace A32.

“LOWCOOLANTTEMP”warning(210)message.


Heater is OK.

Coolant tempon front paneldisplay is OK.

DS3 on theengineinterfaceboard, A31,is off.


4-28

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



“HIGHCOOLANTTEMP”warning(211) orshutdown(212)message.


No airflowobstructions.

Fan belt is OK.

1. Engine problem:� Coolant pump could be faulty.� Thermostat could be faulty.� There could be an obstruction inthe coolant flow.

� External coolant pump (with re-mote radiator) could be faulty.

� External radiator fan motor (withremote radiator) could be faulty.

2. The generator set may have beenoverloaded.

3. Sender, harness or PCC circuit boardcould be bad.

1. Refer to the engine service manual if there areany physical indications of overheating.

2. Correct any overload condition.3. If there are no physical indications of overheat-

ing, check to see if the PCC accurately displaysambient engine temperature.� If the PCC ambient coolant temperaturereading is accurate, the engine may beoverheating. Refer to the engine servicemanual.

� If the PCC ambient coolant temperaturereading is not accurate, isolate to thesender, harness, engine interface board(A31), analog board, or digital board.

Disconnect the coolant temperature senderleads, and connect a coolant temperaturesender simulator to the harness.a. If the control responds to the simulator, re-

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

lator, install harness tool between A31J5/P5. Connect the coolant temperaturesender simulator (and B+) to A31 J5.

� If the control displays the correct simulatedtemperature, replace the harness.

� If the control does not display the correctsimulated temperature, install harnesstool at A31 J2/P2, and open lines 18/19(and 14/15, if applicable). Check for conti-nuity between A31 J2-18 to 19 (for coolanttemp L), and A31 J2-14 to 15 (for coolanttemp R).� If no continuity, then A31 is bad.� If continuity is OK, then send a simu-lated temperature signal and mea-sure the voltage out of A31 (A31J2-18 to 19, and A31 J2-14 to 15).If voltage is not OK (refer to the ana-log board inputs and outputs, Table4-36), replace A33.If voltage is OK, refer to the analog/digital troubleshooting procedure(Table 4-35a/b).


4-29

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



“LOWCOOLANTLVL” warning(214) orshutdown(215) message



DS2 on A31 is on, indicating that A31 is re-ceiving a low coolant signal from the send-er.The sender, the harness or the A31 circuitboard could be bad.

If the coolant level is normal, isolate the source of thelow coolant signal. (This is a ground signal.)Disconnect the signal lead at the sender and resetthe control.1. If the 215 shutdown message drops out and

does not reappear, replace the sender.*2. If the 215 shutdown message reappears and

remains after control reset, disconnect J4/A31and check continuity from P4--7 to GND.� If there is continuity, replace the harness.� If there is no continuity, replace circuitboard A31.

“LOWCOOLANTLVL” warning(214) orshutdown(215) message


DS2 on theengineinterfaceboard, A31,is off.

DS2 on A31 is off, indicating that A31 is notreceiving a low coolant signal from thesender—but the 215 message indicatesthat A32, the digital board, is responding toa false low coolant signal.A31, the engine interface board, or A32, thedigital board, could be bad.

If the coolant level is normal, isolate the source of thelow coolant signal.Check J4--4/P4--4 on A32.*1. Install harness tool between A32 J4/P4.2. Open the J4-4 circuit and reset the control.

� If the fault drops out and does not return,replace A31.

� If the fault returns after resetting the con-trol, replace A32.


4-30

TABLE 4-18. MAG PICKUP SHUTDOWN (220)



“MAGPICKUP”shutdownmessage (220)

This indicates that the PCC is not sensingthe mag pickup signal, or the mag pickupfrequency does not correspond (in propor-tion) to the genset output frequency.

1. Check and correct setting if necessary.

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

*3/4 To isolate the problem, reset the control and at-tempt to start the set in idle mode.

a. If the engine displays a “FAIL TO CRANK” shut-downmessage, or if the engine starts and idles,but then shuts down on a MAG PICKUP fault,the MPU sender could be bad. Remove theMPU connectors and check for 3.5 to 15 VAC atthe MPU while cranking.� If no output, check for damage or debris.Also check for improper adjustment of theMPU. (Refer to Section 5.) If there is stillno output, replace the MPU sender.

� If the MPU output is OK, install harnesstool between A32 J4/P4. Check for MPUvoltage at A32 J4-10 to 11, while cranking.If OK, replace A32. If not OK, use continu-ity checks to isolate to A31 or harness.

b. If the engine starts and idles, and does not dis-play a fault, then there could be a frequencymismatch problem.� Measure generator output frequency witha digital multimeter and compare to the fre-quency on the PCC display.

� If they do match, multiply the frequency by30 and compare this number to the RPMon the PCC display. If these are not thesame, the MPU sender may be bad. Re-place the MPU sender

� If the multimeter and PCC frequencies donot match, there is a frequency sensingproblem. Verify the accuracy of the PCCL1N voltage, and then refer to the analog/digital troubleshooting procedure (Table4-35a/b).

1. ThePCCmay not be set for the correctgenerator set.

2. Loose or damaged mag pickup wire.

3. Damaged mag pickup (MPU).

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


4-31

TABLE 4-19. OVERSPEED SHUTDOWN (223)



“OVERSPEED”shutdownmessage (223)

1. Inspect the mechanical fuel linkage, and repairor replace as necessary.� Follow the procedure in the engine repairmanual to check the EFC for binding ordamage.

� Disconnect the actuator connector, andconnect +12 VDC from the battery to theactuator. The actuator should click uponapplication and removal of the voltage.If the actuator does not click, refer to theengine manual.If the actuator clicks, reconnect the wiresto the actuator.

*2. Reset the control, and start the set while moni-toring the PCC duty cycle display.

� If the duty cycle goes high (above 40%) and theset shuts down on overspeed, replace A32.

� If the duty cycle goes to zero and the set shutsdown on overspeed, replace A38.

1. The mechanical fuel linkage could bebinding, loose, or damaged.

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


4-32

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



“FAIL TOSYNCHRO-NIZE” warning(224) orshutdown(224)message.

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

1. Verify that the bus voltage is within plus or mi-nus 5% of the value which is programmed intothe PowerCommand control, and verify that thegenerator set is operating at proper voltage andfrequency. Verify that the bus PT module isproperly calibrated. (Refer to Digital Bus Volt-age Calibration in Section 5). Check the FAILTOSYNCHRONIZE time delay. It should be setfor approximately 120 seconds. Check parallel-ing setup adjustments, particularly PERMWIN -PHASE and PERM WIN - TIME. They are typi-cally adjusted to 20 degrees and 0.5 seconds.


2. Generator set hunting due to impropersynchronizing adjustments.

3. Unstable or hunting generator set dueto governor component failure or mis-adjustment.

Continued On Next Page...

2. Check synchronizer adjustments in the Power-Command control set--up. If you are unsure ofproper adjustment procedure, returning the unitto it’s default values should result in proper op-eration. The default values are shown in the testreport which is shipped with the generator set.In particular, check values for paralleling func-tions, governing and voltage regulation.

3. Inspect generator set governing system for evi-dence of binding or sticking linkages or othercomponents which are not operating correctly.Verify that water jacket heaters are operationaland properly functioning. Check and adjustgovernor settings as required.

4-33

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



“FAIL TOSYNCHRO-NIZE” warning(224) orshutdown(224)message.

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

4. This problem is indicated in situations wherethe generator set performs properly after thegenerator set is up and running with load, butexperiences ”FAIL TOSYNCHRONIZE” alarmsafter it has been shut down for several days.Check the generator set fuel system for leaks orcracks. If fuel filters have recently beenchanged, air may be trapped in the fuel filterheads.Check to be sure that there is a fuel headon the engine fuel pump. Check fuel line routingfor overhead loops which could result in thetrapping of air in the system if the system sitsidle for some period of time. Parallel systemsshould use option C174, the fuel pump featureoption. This feature is available as an aftermar-ket accessory kit.

Note: The generator set will synchronizefaster as the synchronize acceptance win-dow is widened (i.e., the value in the PERMWIN--PHASE is increased) and as the accep-tance time is minimized (the value in thePERM WIN--TIME is minimized). Cautionshould be taken in utility (mains) parallelingapplications to avoid damage to the genera-tor set by inappropriate setting of these pa-rameters.


4-34

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



“FAIL TOCLOSE”warning (226)or shutdown(226)message.

1. Check the paralleling breaker for in-dication that the breaker is tripped andlocked out from a signal issued fromit’s internal trip unit

1. If the breaker has tripped due to operation of it’sinternal trip unit, the alternator and electricaldistribution system connected to the alternatorshould be carefully inspected for evidence ofburning or tracking, whichmight indicate that anelectrical fault has occurred. If no evidence of afault is found, reset the trip unit and verify thatthe trip settings of the breaker are appropriatefor the application. Reset the fault on the Pow-erCommand control and check the system op-eration to verify that the failure to close faultproblem has been eliminated.


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


2. Check the circuit breaker status indicators andverify that the breaker status indicates that thebreaker is properly charged. If it is, go on to step3. If it is not charged, check the charge circuit forproper operation. Switch the PowerCommandcontrol RUN/OFF/AUTO switch to OFF andthen manually recharge the paralleling breakeraccording to the manufacturer’s instructions.Switch the PowerCommand control RUN/OFF/AUTO switch back to RUN. The generator setshould start and accelerate to rated speed andvoltage and the operator should be able tomanually control the circuit breaker from thepushbuttons on the front panel of the Power-Command control. In most cases the breakershould automatically recharge on closing to thesystem bus. If this does not occur, problemmaybe in the control wiring to the breaker, or thecontrol power source.

NOTE: Some breakers are not able to be setup to charge on closing (they will rechargeon opening). If this is the case with yourinstallation, it is critical that the generatorset be allowed to operate for a cooldown pe-riod which is long enough for the breaker tocompletely charge before the generator setis shut down. If the generator set is shutdown on a fault condition, the breaker mayrequire manual recharge before the systemcan be put back into automatic operation.

4-35

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



“FAIL TOCLOSE”warning (226)or shutdown(226)message.


3. Breaker close signal has been issuedfrom the PowerCommand control, buthas not reached the breaker.

3. Disconnect breaker control wiring and verifythat the control is sending a close signal to thebreaker. If the breaker signal is present at thegenerator set control, reconnect the control wir-ing at the set, verify that it is present at thebreaker terminals.Note that in Onan paralleling systems, DC pow-er for operation of the relay comes from the gen-erator control. Verify that the 20 amp customerB+ fuse (F1 -- engine harness assembly) is OKand that the pilot relay operates properly.

4. Breaker status (open/close) signalsare not properly connected to thePow-erCommand control, or are not operat-ing properly.

4. Verify that the breaker auxiliary contact wiring isproperly connected to the generator set. Verifythat the breaker is sending proper condition sig-nals to the generator set, by disconnecting thecontrol wiring at the breaker and verifying thatthe breaker auxiliary contacts change statewhen breaker condition changes. If they arefunctioning properly, verify that the signals arereaching the generator set by reconnecting thewiring and the breaker and checking for condi-tion change at the generator set control acces-sory box.

4-36

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



5. If the batteries are OK, the problemmay be the harness, the engine inter-face board (A31), the digital board(A32), or the analog board (A33).

*5. If the battery voltage, electrolyte, and connec-tions are OK, check the battery voltage at A31J5-17. If the voltage is not OK (same as batteryvoltage), disconnect J5 and isolate to the har-ness or A31.If the voltage is OK, check battery voltage atA33 J1-31. If the voltage is not OK, replaceA31. If the voltage at A33 J1-31 isOK, isolate toA33 or A32 using the analog input trouble-shooting procedure (Table 4-35a/b).

“LOW DCVOLTAGE”(230) or“WEAKBATTERY”(232),warningmessage.

“HIGH DCVOLTAGE”(231)warningmessage.

But batteryvoltage is OK.

1. Recharge or replace the battery. Specific grav-ity for a fully charged battery is approximately1.260 at 80� F (27� C).

2. Replenish electrolyte and recharge battery.

3. Clean and tighten or replace the battery cableconnectors and cables at the battery and theset.

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

1. Weak or discharged battery.

2. Low electrolyte level in battery.

3. Battery connections loose or dirty.

4. Insufficient battery charging voltage.

2. If the battery voltage is OK, the prob-lemmay be the engine interface board(A31), the digital board (A32), or theanalog board (A33).

*2. Check the battery voltage at A31 J5-17. If thevoltage is notOK (sameas battery voltage), dis-connect J5 and isolate to the harness or A31.If the voltage is OK, check battery voltage atA33 J1-31. If the voltage is not OK, replaceA31. If the voltage at A33 J1-31 is OK, isolate toA33 or A32 using the analog input troubleshoot-ing procedure (Table 4-35a/b).

1. Adjust charge rate of battery charging circuit ac-cording to manufacturers instructions.

1. Excessive battery charging voltage.


4-37

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



“LOW FUEL--DAY”warningmessage (240)

Fuel level isnormal.


DS1 on A31 is on, indicating that A31 is re-ceiving a low fuel signal from the sender.The sender, the harness or the A31 circuitboard could be bad.

If the fuel level is normal, isolate the source of the lowfuel signal.Disconnect the signal lead at the sender and resetthe control.1. If the 240 message drops out and does not

reappear, replace the sender.*2. If the 240 message reappears and remains af-

ter control reset, disconnect J4/A31 and checkcontinuity from P4--14 to GND.� If there is continuity, replace the harness.� If there is no continuity, replace circuitboard A31.

DS1 on A31 is off, indicating that the PCC isnot receiving a low fuel signal from thesender—but the 240 message indicatesthat A32, the digital board, is responding toa false low fuel signal.A31, the engine interface board, or A32, thedigital board, could be bad.

If the fuel level is normal, isolate the source of the lowfuel signal.*1. Install a breakout connector at A32 J4.2. Open the J4-15 circuit and reset the control.


� If the fault returns after resetting the con-trol, go to step 3.

“LOW FUEL--DAY”warningmessage (240)


DS1 (A31)and DS13(A34) are off.


4-38

TABLE 4-24. LOW FUEL WARNING (241)


DS13 on A34 is on, indicating that A34 is re-ceiving a low fuel signal from the customercircuit.If there is no actual fault, the problem maybe a short to ground in the external wiring ora bad customer interface board (A34).


DS13 on A34 is off, indicating that the PCCis not receiving a low fuel signal from thesender—but the 241 message indicatesthat A32, the digital board, is responding toa false low fuel signal.A34, the customer interface board, or A32,the digital board, could be bad.

If the fuel level is normal, isolate the source of the lowfuel signal.*1. Install harness tool between A32 J2/P2.2. Open the J2-19 circuit and reset the control.


� If the fault returns after resetting the con-trol, replace A32.

“LOW FUEL”warningmessage (241)


DS13 (A34) isoff.

“LOW FUEL”warningmessage (241)


DS13 on thecustomerinterfaceboard, A34, ison.

If the fuel level is normal, isolate the source of the lowfuel signal.Disconnect the signal lead near the control and resetthe control.1. If the 241 message drops out and does not

reappear, there is a short to ground in the exter-nal wiring or a faulty sender.

*2. If the 241 message reappears and remains af-ter control reset, disconnect J1/A34 and checkcontinuity from P1--5 to GND.� If there is continuity, find and repair a shortto ground in the external wiring.

� If there is no continuity, replace circuitboard A34.


4-39

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



“EEPROMERROR”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 resetthe control. Simultaneously press the RESET,MENU, and PHASE SELECT keys to start thesetup.Select the correct values, save your choices,and attempt to start the set.

2. If the set shuts down on the same EEPROMERROR message, replace the digital board(A32).

“EEPROMERROR”warning(251)message.


1. Perform the adjustment procedures (describedin Section 5). Save the adjustments.Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROMERROR message, perform the calibration pro-cedures in Section 5.Reset the control. Shut off and restart the set.

3. If the control generates the same EEPROMERROR message, replace the digital board(A32).

“EEPROMERROR”warning(252)message.


1. If this message occurred during an adjustment,option selection, or calibration of the PCC,verify the values or choices selected and repeatthe save operation.Reset the control. Shut off and restart the set.

2. If the control generates the same EEPROMERROR message, replace the digital board(A32).


4-40

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



“CUSTOMERFAULT(260, 261, 262or 263)message.

AndcorrespondingLED oncustomerinterface boardA34 is on.

If the corresponding LED on the customerinterface board (A34) is on, then A34 is re-ceiving a signal from the customer circuit.If there is no actual fault, the problem maybe a short to ground in the external wiring ora bad customer interface board (A34).

Isolate the source of the false signal.Disconnect the signal lead near the control and resetthe control.1. If the message drops out, there is a short to

ground in the external wiring.2. If the message remains, replace A34.

“CUSTOMERFAULT(260, 261, 262or 263)message.

AndcorrespondingLED oncustomerinterface boardA34 is off.

Isolate the source of the false signal.Check J2/P2 on A32.*1. Install harness tool between A32 J2/P2.2. Open the appropriate circuit J2-3, J2-24, J2-9,

or J2-15 and reset the control.� If the fault does not return, replace A34.� If the fault reappears, replace A32.

If the corresponding LED on the customerinterface board (A34) is off, then A34 is notreceiving a signal from the customer circuit.The message indicates that A32, the digitalboard, is responding to a false signal.A34, the customer interface board, or A32,the digital board, could be bad.

A 34LED

A32CONNECTOR

CUSTOMERFAULT #

FAULTCODE

DS4DS11DS15DS3

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

1234

260261262263


4-41

TABLE 4-27a. PHASE ROTATION (270)



“PHASEROTATION”warning (270)message.


2. Generator set output power feedersare improperly connected.


2. Verify phase rotation of the generator set outputrelative to the system bus. Correct wiring ofpower output conductors if required. The phaserelationship between the generator set and thesystem bus can be checked by either using aphase rotation checker, or by using synchroniz-ing lamps or two voltmeters. The procedure forusing voltmeters for checking phase relation-ship is as follows:Energize the system bus and start the genera-tor set in question in the RUN mode, but do notclose the paralleling breaker. Connect eachvoltmeter from the line to load side of a singlephase of the paralleling breaker (see Figure8-1). If the generator set and bus have the samephase rotation, the voltmeters should rise andfall in voltage at the same time. If they are not inphase, one will rise while the other falls.

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

4-42

TABLE 4-27b. PHASE ROTATION (270)



“PHASEROTATION”shutdown(270)message.


3. Wiring to bus PTmodule is not correct. 3. If power conductors are properly phased, checkthe phase rotation of the wiring to the generatorset CT/PT module (A36) and Bus PT module(A39). This is done using voltmeters connectedas shown in Figure 8-1. Energize the systembus and start the generator set being tested inthe RUN mode. Operate the display screen onthe PowerCommand control to show the digitalsynchroscope (bus frequency). Observe thevoltmeter(s) and the synchronized indicator (*)on the PowerCommand screen. When the volt-age of the meter(s) approaches zero, the *should be displayed. If the * is on when the volt-meters are reading their highest value, the BusPT module or the genset CT/PT module is in-correctly wired. If incorrect wiring is indicated,switch off the power supply to the system busand manually close the paralleling breaker bypushing the breaker close switch on the front ofthe PowerCommand control. Check the voltagebetweenphase L1 of the generator CT/PTmod-ule (J9-4 yellow) and phase L1 of the Bus PTmodule (terminal TB1-1 on themodule). If thereis voltage difference between these points, re-verse the wiring between TB1-1 and TB1-3 onthe Bus PT module. Retest the system to becertain that the phase relationship problem hasbeen corrected. If no voltage difference issensed at the input to the CT/PT module andBus PTmodule, the problem could be in thewir-ing between the Bus PTmodule and the Power-Command control. Reverse the connectionsbetween terminals TB2-1, 2 with TB2-5, 6. Re-test the system to make sure that the phaserelationship problem has been corrected.

4-43

TABLE 4-28. FIRST START (272)



“FIRSTSTART”warning (272)message.


1. Master First Start Sensor has failed. 1. Verify that the Master First Start Sensor is prop-erly functioning. This can be accomplished byconnecting a DC voltmeter from ground to theappropriate terminal on the Master First StartSensor to the PowerCommand Control. Thevoltmeter should indicate a pulsing voltagepresent on the terminal.

2. Interconnection between Master FirstStart Sensor and the PowerCommandcontrol has failed.

2. Verify that the voltage pulse is present at thePowerCommand Control (terminal TB1--50).Check and repair any problems in the intercon-nection wiring between the generator set andthe Master First Start Sensor.

4-44

TABLE 4-29a. HIGH AC VOLTAGE SHUTDOWN (301)



“HIGH ACVOLTAGE ”shutdown(301)message.

1. The problem may be the regulatormodule (A37), the engine interfaceboard (A31), or the digital board (A32).

1. With power to the PCC and with the set not run-ning, check A31 DS9, the AVR duty cycle LED.This LED should be off. If it is on, go to step 1d.Isolate the genset output from the load. Discon-nect A37 J10, and place the set in Idle mode.Start the set and monitor the AC output voltagewith a digital multimeter.a. If output voltage is greater than residual,

go to step 2.b. If output voltage stays at 0 (or residual),

and DS2 on A37 is off, go to step 3.c. If output voltage stays at 0 (or residual),

and DS2 on A37 is on, look at DS9 on A31.If DS9 on A31 is off, replace A37.

d. If DS9 on A31 is on, connect a breakoutconnector at A32 J4, and open J4-2.If DS9 goes out, replace A32.If DS9 stays on, replace A31.

2. The problem may be in the PMG orfield wiring.

3. The problem may be an open in asensing wire into the PT/CT, or in theharness or ribbon cables that connectthe circuit boardsThe problem may be the PT/CT mod-ule (A36), the analog board (A33), thecustomer interface board (A34), or thedigital board (A32).


2. If output voltage goes high in the idle mode withA37 J10 disconnect, check and repair the PMGor field wiring. Shut down the set and reconnectaccording to the appropriate reconnection dia-gram.

3. If operation is normal (i.e., output voltage staysat 0 or residual, and DS2 on A37 is off) in theidlemode, the controlmay have a sensing prob-lem or the generator is defective.Start the set in the idle mode, and measure allthree line-to-neutral voltages with a digitalmultimeter (measured voltage must be 30% orhigher of nominal VAC to complete this test).

NOTE: If youmeasure less than 30%of nom-inal VAC, stop the set. Using the proceduredescribed inSection 6, separately excite thefield windings and restart the set in the idlemode.

Whenmeasured at the AC output, are the threeline-to-neutral voltages balanced?If the voltages are balanced, go to step 3a onthe next page.If the voltages are not balanced, go to step 4 onthe next page.



4-45

TABLE 4-29b. HIGH AC VOLTAGE SHUTDOWN (301)



“HIGH ACVOLTAGE ”shutdown(301)message.

3. (Continued)The problem may be an open in asensing wire into the PT/CT, or in theharness or ribbon cables that connectthe circuit boardsThe problem may be the PT/CT mod-ule (A36), the analog board (A33), thecustomer interface board (A34), or thedigital board (A32).

NOTE: To determine the “3-phaseave” signal voltage range for Step 3b,use the following formula:

Vout 3-phase ave = Vin (2.9�PT) �5%

Vin = Actual generator output voltage(phase-to-neutral)

PT = PT primary (120, 240 or 346)

3a. Check all three line-to-neutral voltages onthe PCC display panel.If the voltages are balanced, the problemis in the analog or digital board.Go to step 3b.If the voltages are not balanced, there is anopen on one of the circuit boards or in theharnesses or ribbon cables.Go to step 3c.

b. *Using the harness tool, check the“3-phase ave” signal at A33 J2-18.If the voltage is within the expected range,replace A32. If the voltage is not within theexpected range, replace A33. See Note.

c. Looking for balanced levels, check allthree line-to-neutral voltages into andthrough the PCC as follows:

� Check the residual AC voltages at A36J9-2, 3, and 4).If these voltages are not balanced, theproblem is in the voltage sensing wires orA36, the PT/CT module. Disconnect A36J9 and remeasure to isolate the problem.

� *If the A36 J9 voltages are balanced,check the PT/CT transformer output ACvoltages at A34 J3-4, 5, and 7 using har-ness tool.If these voltages are not balanced, theproblem is in A36, A34, or the harness be-tween them. Disconnect A34 J3 and re-measure to isolate the problem.

� *If the A34 J3 voltages are balanced,check the A34 output AC voltages at A34J5-24, 26, and 30 using harness tool.If these voltages are not balanced, theproblem is in A34 or A33. Disconnect A34J5 and remeasure to isolate the problem.

� *If the A34 J5 voltages are balanced,check the A33 output DC voltages at A33J3-4, 13, and 1 using harness tool.If these voltages are not balanced, theproblem is in A33, A32, or the ribbon cablebetween them. Disconnect A33 J3 and re-measure to isolate the problem.

4. The problem may be in the generatorset itself.

4. Refer to the generator servicing procedures inSection 6.


4-46

TABLE 4-30. LOW AC VOLTAGE SHUTDOWN (303)



“LOW ACVOLTAGE ”shutdown(303)message.

1. PMG or field wiring could be faulty.

2. The rotating rectifier assembly (diodesCR1 through CR6) is faulty.

3. Overload.4. There may be a loose connector in the

control loop.

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

5b. The problem may be the regulatormodule (A37), the engine interfaceboard (A31), or the digital board (A32).

1. If output voltage is low and both A37/DS2 andA31/DS10 are on, check and repair the PMG orfield wiring.

2. Check each diode according to Servicing theGenerator in Section 6. Service as necessary.

3. Check the load and correct any overload.4. Check connectors J8 and J9 on A36, J3 and J5

on A34, and J7 on A37.*5. Isolate the genset output from the load. Reset

the control, restart the set, and measure ACoutput voltage with a multimeter.

a. If output voltage is normal, the problemmust bein the voltage sensing circuitry (A32 or A33).Isolate, using the analog input troubleshootingprocedure (Table 4-35a/b). Check the phasethat shows a low voltage on the PCC display.

*b. If output voltage is low, the control cannot drivethe output voltage high enough. The problemcould be A37, A31, or A32. Restart the set andmonitor isolated B+ supply LED A37/DS1,output duty cycle LED A37/DS2, andAVR duty cycle LED A31/DS10.� If A37/DS1 is not on, disconnect A3 J7/P7and check for B+ at P7-1. (Control must bein Run mode for B+ reading.)

� If B+ is OK to A37, replace A37.� If A37/DS1 is on, check A31/DS10 (withthe set running).

� If A31/DS10 is not on with set running,check for continuity: A31 J1-2 to J4-10 andA31 J1-1 to J4-11 (270 ohms). If no conti-nuity, replace A31.

� If A31is OK, replace A32.� If A31/DS10 is on with set running andA37/DS2 is not on, check the harness.

� If the harness is OK, replace A37.5c. The problem may be the PT/CT mod-

ule (A36), the analog board (A33), thecustomer interface board (A34), or thedigital board (A32).

c. If the measured AC voltage is high, the controlmust have lost ACsensing. CheckPTs (primary1K--2.5K ohms; secondary 140--225 ohms),sensing harness wires, generator output con-nections, and the customer interface board forcontinuity. If these are OK, then check the ana-log and digital boards, using the analog inputtroubleshooting procedure (Table 4-35a/b).


4-47

TABLE 4-31. UNDER FREQUENCY SHUTDOWN (313)



“UNDERFREQUENCY”shutdown(313)message.

1. Improper setup.

2. Overload.

3. Fuel or air delivery problem.

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

1. Check Initial Setup (set size) and correct, if nec-essary.

2. Check the load and correct any overload, if nec-essary.Disconnect the load. Reset the control and at-tempt to restart the generator set.

3. If the engine starts and runs, refer to the enginefuel/air delivery service procedures.

*4. Disconnect the wire to the fuel solenoid, resetthe control, and crank the set. DS2 on the gov-ernor output module A38 should light.If the duty cycle LED (DS1) on the governor out-put module (A38) slowly becomes bright, thegovernor output module(A38), the digital board(A32), and the engine interface board (A31) arefunctioning properly.If DS1 does not light or instantly becomesbright, A31, A32 or A38 may be bad.

A38 - Crank the set, and check the gover-nor duty cycle on the PCC display. If theduty cycle is OK (60% max), replace gov-ernor output module (A38).If the duty cycle is not OK, the digital board(A32) or the engine interface board (A31)may be bad.

� A31 - Check for continuity: A31 J1-13 toA31 J4-19 and A31 J1-14 to A31 J4-12. Ifno continuity, replace A31.

� A32 - If A31 is OK, replace A32


4-48

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



“OVER-CURRENT”warning (320)or shutdown(321),or“SHORTCIRCUIT”shutdown(322), orOVERLOADwarning (330)message.

1. Short or Overload.

2. Incorrect CTs or CT connections.

3. The problem may be a bad PT/CTmodule (A36).

4. The problem may be the customer in-terface board (A34) or connections.

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

1. Check the load and load cables. Repair if nec-essary.

2. Check CTs andCT connections. Correct if nec-essary. Refer to Current Transfer Installation inSection 5.

3. Disconnect the PT/CT module and check the3-ohm resistors (J8-15 to 14, J8-22 to 23,J8-7 to 8). Replace the module if necessary.

*4. Check continuity from A36—through A34—toA33. Repair the connection or replace A34 ifnecessary. Refer to Section 9 for pin reference.

5. Isolate, using the analog input troubleshootingprocedure (Table 4-35a/b). Check the badphase or phases.


4-49

TABLE 4-33. REVERSE POWER (335)



“REVERSEPOWER”shutdown(335)message.


1. If this shutdown condition occurswhen a non-paralleled generatorset is loaded, it indicates that thegenerator set output CT’s or PT’sare incorrectly installed.

1. Verify proper CT orientation, wiring andconnectionson thecontrol system.Refer toCurrent Transformer (CT) Installation inSection 5. Make sure that the no load fre-quency matches the bus frequency. Checkmetering calibration for both generator setand bus.

2. Verify that the generator set is op-erating at the correct frequencyand voltage. The bus voltage andfrequency should be the same asthe no-load generator set frequen-cy and voltage.

2. Make adjustments as required for properoperation.

3. The load sharing line connectionsand orientation must be correctlyaccomplished for proper load shar-ing.

3. Verify that load sharing connections aremade as noted in the drawings and thatthere are no damaged or disconnectedwires.

4. If the alarm occurs when a largeload is added or shed, dissimilartransient response of the genera-tor sets in the system may causethe reverse power condition.

4. Apply various load steps to each generatorset in the system, noting the voltage andfrequency dips/surges and recovery times.The generator sets should be adjusted sothat transient load performance is approxi-mately the same in all machines in the sys-tem.

5. Reverse power alarm can also in-dicate that the generator set is un-able to carry load properly.

5. Verify that the generator set can pick upand carry loads properly, up to the rated ca-pacity of themachine. Inability to carry loadcan be related to engine misadjustments,component failures, or poor fuel quality.Check governing system for binding orsticking. Check fuel filters and fuel lines forcracks, leaks or dents. Check air cleaner(s)for obstructions.

4-50

TABLE 4-34. LOSS OF EXCITATION (337)



“LOSS OFEXCITATION”shutdown(337)message.


1. Improper voltageadjustment of thegenerator set relative to thesystembus.

1. Verify that the no load voltage of the gener-ator set matches the bus voltage. Checkgenerator set metering calibration for bothgenerator set and bus readings. If no prob-lems are found, check the paralleling ad-justments in the PowerCommand control,to see if they match the default settings inthe generator set test report.

2. Load sharing line mis-connectionor damage.

2. Verify load sharing line connections andcondition. Make corrections as required.

4. The generator set may be incapa-ble of carrying full reactive loaddueto component failures.

4. See section 6 of thismanual, “Servicing theGenerator, Exciter Rectifier and ExciterRotor”. See also repair and diagnosis pro-cess for ”Low AC Voltage” in this section.

3. If condition occurswhen thegener-ator set is lightly loaded, leadingpower factor loads may cause thiscondition.

3. Check the load for devices which may ap-ply leading power factor loads to the gener-ator set. These include power factorcorrection capacitors, input filter and somenon-linear load devices with internal volt-age waveform correction provisions.These devices may need to be discon-nected from the bus until other loads areadded to the system.

5. If transient conditions result in thisalarm condition, the PowerCom-mand control internal set pointsmay need adjustment.

5. Consult factory.

4-51

TABLE 4-35a. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG AND DIGITALBOARDS


NOTE: Perform this procedure after you have isolated the problem to either the analogboard (A33) or to the digital board (A32). Youmust have schematics andwiringdiagrams to identify the various inputs and outputs.

*1. Check that the input to the analog board is correct. There are a few signals (e.g.: 3PH Ave, Line Freq,Phase Angle 1 to 3, Lead Lag) that are derived from one or more input signals.

1a. To check the sensor input voltages into the analog board, connect the sender simulator and test thevoltage across the + and -- inputs at A33 J1 using harness tool. (This assumes that you have verifiedthat the harness and the engine interface board is good.)

� If the input voltage to the analog board is correct (refer to Table 4-36), go to step 2.� If the input voltage to the analog board is incorrect, check for 12 VDC at A32 J3-20 and 5 VDC atA32 J3-12. Do this with the analog board connected to the digital (A32).

If the 12 VDC and 5 VDC voltages are OK, replace the analog board.If the 12 VDC and 5 VDC voltages are not OK, disconnect A32 J3 and recheck for 12 VDC atA32 J3-20 and 5 VDC at A32 J3-12.

If the 12 VDC and 5 VDC voltages are now OK, replace the analog board.If the 12 VDC and 5 VDC voltages are still not OK, replace the digital board.

1b. To check the AC inputs into the analog board, drive the PT/CT inputs (voltage or current) and verifythat the input is correct.

� If the input to the analog board is correct, go to step 2.� If the input to the analog board is incorrect, disconnect the ribbon cable at A34 J5 and check the volt-age at A34 J5 again (Customer Interface).

If the voltage is now correct, replace the analog board.If the voltage is still not correct, the problem is not on the analog or digital boards.

2. If the input to the analog board is correct, determine whether the signal is multiplexed (refer to Table4-36). If the signal is not multiplexed, go to step 2a. If the signal is multiplexed, go to step 2b.

2a. This step is for non-multiplexed AC signals. Drive the input to the analog board with an AC source,and test the signal level out of the analog board. You must calculate what the analog output voltageshould be (Table 4-36), assuming the analog board transfer function is linear.

� If the signal level into the digital board is correct, the problem must be on the digital board. Replacethe digital board.

� If the signal level into the digital board is incorrect, remove the ribbon cable connector at A32 J3, andcheck the front panel digital display of the bad analog value.

If the display reads 0, replace the analog board.If the display reads a value other than 0, replace the digital board.


4-52

TABLE 4-35b. TROUBLESHOOTING ANALOG SIGNALS BETWEEN ANALOG ANDDIGITAL BOARDS


NOTE: Perform this procedure after you have isolated the problem to either the analogboard (A33) or to the digital board (A32). Youmust have schematics andwiringdiagrams to identify the various inputs and outputs.

2b. This step is for multiplexed signals. Is more than one multiplexed signal reading bad?� No. If the input to the analog board is correct and only one multiplexed signal is reading bad, replacethe analog board.

� Yes. If more than one multiplexed signal reading is bad, remove the ribbon cable connector atA32 J3 and check the front panel digital display of the bad inputs. It should read 0 for all inputs ex-cept the temperature inputs (which should read less than 32� F or less than 0� C) and power factor(which should read “NA”).

If any values read incorrectly, replace the digital board.If they all read correctly, measure voltages on the multiplexer control lines (with A32-J3 discon-nected, measure from Digital board connector J3). Voltages should be:

A32-J3-23: 3.0 �0.25 VDCA32-J3-24: 2.4 �0.25 VDCA32-J3-27: 1.4 �0.25 VDCA32-J3-33: 3.0 �0.25 VDCA32-J3-34: 3.0 �0.25 VDC

If these control (select) line voltages are not correct, replace the digital board.

If these control (select) line voltages are correct (and the input to the analog board is correct),reconnect the ribbon cable connector (through harness tool) at A32 J3 and check the 5 VDCreference at A32 J3-12 and the 12 VDC supply at A32 J3-20.

If the 5 VDC and the 12 VDC voltages are OK, replace the analog board.

If the 5 VDC and the 12 VDC voltages are not OK, disconnect A32 J3 and check thevoltages again (measured from Digital board side).

If the 5 VDC and the 12 VDC voltages are OK with A32 J3 disconnected, replace theanalog board.

If the 5 VDC and the 12 VDC voltages are not OK with A32 J3 disconnected, replacethe digital board.


4-53

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

Input Name InputConnection

Input SignalRange

Output Name1 OutputConnection2

OutputSignal Range

L1 (0 to nominal) J4-24 to J4-28 0 to 18 VAC L10 (ACH1) J2-4 0 to 3.0 VDC



3PH ave (ACH0) J2-18 0 to 2.9 VDC

Line freq. (HSI.1) J2-21 0-5V sq wave @ L1 Hz

CT21 (0 to full load) J4-33 to J4-34 0 to 1.65 VAC C1 fltrd (ACH4) J2-3 0 to 1.0 VDC



C1 (ACH7) J2-7 0 to 1.0 VDC

C2 (ACH7) J2-7 0 to 1.0 VDC

C3 (ACH7) J2-7 0 to 1.0 VDC

(1 to 0.8 pf) Phase angle 1 (ACH7)3 J2-7 0 to 1.0 VDC



(L1 vs CT21) Lead lag (P2A.1)) 3 J2-29 0 or 5 VDC (digital)

Bus L1 (0 to nominal) 6 J4-15 to J4-18 0 to 18 VAC Bus L1 (ACH7) J2-7 0 to 3.0 VDC



Bus freq (HS1.3) J2-22 0-5V sq wave @ Bus L1 Hz

Phase rot (P2A.0)5 J2-26 0 or 5 VDC (digital)

Bus/gen phase dif (ACH7)5 J2-7 0 to 5.0 VDC

Bus/gen phase (HS1.2)5 J2-19 0-5V 120 Hz 0 to 100% DC

Synch (ACH7)5 J2-7

Battery voltage J1-31 (+) to J1-30(--) 0 to 32 VDC Battery voltage (ACH7) J2-7 0 to 2.9 VDC

Oil press (0 to 100 psi) (See note 4 ) 0.5 to 4.5 VDC Oil press (ACH7) J2-7 0.5 to 4.5 VDC

H2O 1 (6 to 230� F) J1-19/20 to J1-17/18 700 to 1800 � H2O 1 (ACH7) J2-7 1.4 to 3.7 VDC

H2O 2 (6 to 230� F) J1-15/16 to J1-14/15 700 to 1800 � H2O 2 (ACH7) J2-7 1.4 to 3.7 VDC

Oil temp (6 to 230� F) J1-11/12 to J1-9/10 700 to 1800 � Oil temp (ACH7) J2-7 1.4 to 3.7 VDC

Exh temp 1 (32 to 1471� F) J1-7/8 to J1-5/6 100 to 376 � Exh temp 1 (ACH7) J2-7 0.8 to 3.0 VDC

Exh temp 2 (32 to 1471� F) J1-3/4 to J1-1/2 100 to 376 � Exh temp 2 (ACH7) J2-7 0.8 to 3.0 VDC

Notes:1. All output signals on ACH7 are multiplexed.2. All output voltages on A33 J2 are referenced to ground (J2-15 and J2-16).3. Must have L1, L2, L3, CT21, CT22, and CT23 for these phase angle outputs.4. J1-24 (5VDC), J1-23 (signal), J1-18 (return).5. Must have L1, L2, L3, Bus L1, Bus L2, and Bus L3 for these outputs.6. L1, L2, and L3 can be 0 to 180� out of phase with Bus L1, Bus L2, and Bus L3, respectively.

4-54

TABLE 4-37. PCC FUSES

LOCATIONREFERENCEDESIGNATION RATING FUNCTION

Engine Interface A31-F1 5 Amp PCC control B+

Engine Interface A31-F3 5 Amp Auxiliary B+ (for panel lights, run and start relays)

Governor OutputModule

A38-F1 10 Amp Network B+ (to TB1 customer terminal block)


A38-F2 10 Amp Switched B+ (to TB1 customer terminal block)


A38-F3 10 Amp Governor B+ (power for governor output module andactuator)

TB-Bat (EngineHarness Assembly)

F1 20 Amp Customer B+ (to TB1 customer terminal block)

4-55

LOAD SHARING CONTROLSTROUBLESHOOTING PROCEDURE

The generator set load sharing settings in the Pow-erCommand control are factory set and normally donot require adjustment. The controls are designedto cause generator sets in the paralleling system toshare load proportionally, based on the standby rat-ings of the generator sets in the system.

When the system is operating normally, the genera-tor sets in an isolated bus (not utility/mains paral-leled) paralleling system will share both real (kW)and reactive (amps) load equally, within plus or mi-nus 5%. For example, if two 1000 kW generatorsets are paralleled and serving a 1000 kW load, thegenerator sets should each carry between 950 and1050 kW.

In actual practice, load sharing may be much moreprecise than plus or minus 5%, but you should notbe concerned about operational problems unlessthe load sharing is in error by more than 5%. If dis-similar generator sets are used in a system, theremaybe load sharing inequities for a short timewhenloads are applied, but the steady state load sharingshould perform to the plus or minus 5% standard.

If the generator set is paralleled to a utility (mains)gird, the amount of load on the generator set is pro-grammed into the control in the setup mode or setfroma remotedevice. It isNOTa functionof the loadsharing control system. See Section 5 for more in-formationon loadsharing set--up functions, andutil-ity (mains) paralleling set--up.

If the generator set is not sharing load properly, thefollowing procedure can be used to diagnose andsolve the problem:

1. Theno load speedand voltageof the generatorset must be the same as the system bus. Mea-sure the bus voltage and frequency, and thegenerator set voltageand frequencywith a trueRMS digital meter. Calibrate the voltage andcurrent sensing circuits of the control, andmake required adjustments to voltage and fre-quency to match bus conditions. Adjusting thevoltageand frequencyafter thegenerator set isparalleled to the bus will cause load sharing tobe unequal between generator sets.

2. Check to make sure that the load sharing con-trol wiring is properly connected.

3. Check to make sure that each generator set inthe system is capable of carrying its rated load.

4. Fine adjustment to the amount of load carriedby each generator set can be made by adjust-ing the KW BALANCE and KVAR BALANCEsettings under the paralleling setup menu(Section 5).

5. If the generator sets share load approximatelyequally, but there is an oscillating load circulat-ing between the generator sets, the governorgainmay be set too high. Reduce the governorgain (see Setup Menu, Section 5).

6. Consult factory for any other load sharing prob-lems.

5-1

5. Control Service and Calibration

GENERAL

This section contains circuit board removal and re-placement procedures, calibration procedures forthe genset control and test procedures for the gen-erator and engine components. Refer to the figuresincluded with this information and also the WiringDiagrams section when instructed.

Before servicing the PCC, all settings should be re-corded. This will enable correct and complete read-justment of the PCC in the event that all previous en-tries are lost during servicing.

CIRCUIT BOARDREMOVAL/REPLACEMENT

No special tools (other than a groundingwrist strap)are required to remove a circuit board from insidethe control panel or the accessory box.There are several circuit boards that, when re-placed, require you to recalibrate the control panelfunctions. Table 5-1 lists the circuit boards and theappropriate procedure to perform to recalibrate thecontrol panel. The circuit board locations are shownin Figure 5-1.Before you attempt to remove a circuit board, readthe Circuit Board Removal Safety Precautions inthis section.

TABLE 5-1. CONTROL PANEL RECALIBRATION

CIRCUIT BOARD

Analog Board (A33)

ADJUSTMENT PROCEDURE / PAGE

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

Digital Board (A32) Must recalibrate all values, starting withthe Initial Start Setup procedure.

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

5-8).

PT/CT Board (A36) Voltage, Current and PF.

Setup and Calibration Menus (Page 5-8)

Setup and Calibration Menus (Page 5-8)

Bus PT Module (A39) Voltage Setup and Calibration Menus (Page 5-8)

5-2

PT/CT BOARDA36

VOLTAGE REGULATOROUTPUT MODULE

A37


A38


ENGINE INTERFACEA31

ANALOG BOARDA33

DIGITAL BOARDA32

DISPLAY BOARDA35


BUS PT MODULEA39


5-3

Circuit Board Removal Safety Precautions

Toprevent circuit boarddamagedue toelectrostaticdischarge (ESD), a grounding wrist strap must beworn when handling circuit boards or socket-mounted IC’s. (The wrist strap does not provide adirect short to ground, but is typically rated atapproximately 1 megohm to ground.)

Attach the clip to a non -painted surface of the con-trol box andplace the strap around yourwrist beforehandling a circuit board.

CAUTION Electrostaticdischargewill damagecircuit boards. Always wear a grounding wriststrap when handling circuit boards or socket-mounted IC’s.

Turn off or remove AC power from the battery char-ger and then remove the negative (--) battery cablefrom the set starting battery. This is to make surethat the set will not start while working on it and toavoid circuit board damage caused by voltagespikes when removing and replacing circuit boardconnectors.

CAUTION Always disconnect a batterycharger from its AC source before disconnect-ing the battery cables. Otherwise, disconnect-ing the cables can result in voltage spikes highenough todamage theDCcontrol circuits of theset.

WARNING Accidental starting of the generatorset while working on it can cause severe per-sonal injury or death. Prevent accidental start-ingbydisconnecting thestartingbattery cables(negative [- ] first).

Make certain battery area has been well-venti-lated before servicing battery. Arcing can igniteexplosive hydrogen gas given off by batteries,causing severe personal injury. Arcing can oc-cur when cable is removed or re-attached, orwhen negative (- ) battery cable is connectedand a tool used to connect or disconnect posi-tive (+) battery cable touches frame or othergrounded metal part of the set. Always removenegative (- ) cable first, and reconnect it last.Make certain hydrogen from battery, enginefuel, and other explosive fumes are fully dissi-pated. This is especially important if batteryhasbeen connected to battery charger.

GROUND LEAD CLIP

WRIST STRAP

NON-PAINTEDSURFACE

FIGURE 5-2. WRIST STRAP

5-4

INITIAL START SETUP MENU

The facing page shows a block representation ofthe INITIAL START SETUP menu.

CAUTION Selecting this menu resets all oper-ating parameters to the default values for theselected set. All previously selected setup andadjustment settingswill be lost. Therefore, thisprocedure must be performed by technicallyqualified personnel only.

This menu appears on the digital display when thePCC has not been set up for use with a generatorset during factory test, or the digital board was re-placed in the PCC.

When this display is showing, you must go throughthe Initial Start Setup menu to select the operatingparameters for the generator set. These includewhether the set will be used for Prime Power orStandby use, the Model Number of the generatorset, and its operating frequency and output voltage.These choices must be saved into the PCC’s read-only memory before the PCC will accept changesmade to other menus.

If the PCC is already set up to operate with a specificgenerator set, this menuwill not appear when poweris applied. To reset the control and display the InitialStart Setup menu, you can press RESET, MENU, andPHASE SELECT buttons at the same time.

If you choose to do this, the governor/regulator ad-justments and the setup options will be reset to thedefault settings (including the editable customerfault messages). Display calibrations (volts, amps,PF and coolant temperature) are retained (not reset).To ensure correct and complete readjustment of thePCC, it is suggested that all settings be recorded be-fore you perform the reset function.

CAUTION Improper setup, calibration, or ad-justments can cause equipment malfunction ordamage. Setup, calibration, and adjustmentmust be performed by technically qualified per-sonnel only.

STANDBY/PRIMEsubmenu:Use thebuttonsnextto the “��” symbols to toggle the standby/prime op-tion. Press the button next to the “>>” in the displayto move to the model select submenu.

MODEL select submenu: Use the buttons next tothe “�” and “�” symbols to select the correct genera-tor set model number, frequency and power rating.

VOLTAGE SELECT submenu: Use the buttonsnext to the “�” and “�” symbols to select the correctgenerator set nominal line-to-line output voltage.

DELTA / WYE submenu: Use the buttons next tothe “�” and “�” symbols to select the delta or wyeoption.

SAVE submenu: From themodel select submenu,press the button next to the “>>” in the display tomove to the SAVE submenu. Select SAVE to saveyour changes. The MAIN MENU will then be dis-played.

5-5

< >

< >

< >

< >

<

STANDBY/PRIME�� _______ >>

� MODEL� (kw mod# freq) >>

SAVE >> < >< >

INITIAL START SETUP(It can be invoked by simultaneously pressing

the Reset, Menu, and Phase Select keys.)

ENGINE GENADJUST >>

SAVE >> < >STANDBY/PRIME

�� _______ >>

TO LOOP BACK & CHECK:

< >< � VOLTAGE SELECT

� (vac) L-L VAC >>

< >DELTA / WYE

�� _______ >>


5-6

ADJUST MENU

The ADJUST submenus permit adjustment of theoutput voltage and frequency and the start and stopdelay times of the generator set.

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

The facing page shows a block representation ofthe ADJUST menu. If you press the button next tothe word “ADJUST” in the Main menu, the VOLT-AGE ADJUST submenu will appear.

As shown in the diagram, the ADJUST menu hasfive submenus, including a save/exit procedure.

Voltage and frequency can be adjusted only whenthe generator set is running under normal operatingparameters (not in idle mode). For example, if volt-age adjustment is selected when the set is in Idlemode or not running, the digital display will be:

“� VOLTAGE ”“� N/A >>”

VOLTAGE submenu: This is the first submenu.Use the buttons next to the “�” and “�” symbols toadjust output voltage � 5%.

FREQUENCYsubmenu:From theVOLTAGEsub-menu, press the button next to the “>>” in the dis-play to move to the FREQUENCY submenu. Usethe buttons next to the “�” and “�” symbols to adjustoutput frequency � 5%.

START DELAY submenu: This delay applies onlyto remote starting in the Automode. From the FRE-QUENCY submenu, press the button next to the“>>” in the display to move to the START DELAYsubmenu. Use the buttons next to the “�” and “�”symbols to set the start delay. The start delay ad-justment range is 0 to 300 seconds.

STOP DELAY submenu: This delay applies onlyto remote stopping in the Auto mode. From theSTART DELAY submenu, press the button next tothe “>>” in the display to move to the STOP DELAYsubmenu. Use the buttons next to the “�” and “�”symbols to set the stop delay. The stop delay ad-justment range is 0 to 600 seconds.

IDLE SPEED submenu: From the STOP DELAYsubmenu, press the button next to the “>>” in thedisplay tomove to the IDLESPEED submenu. Usethe buttons next to the “�” and “�” symbols to set theidle speed. The idle speed adjustment range is 800RPM �100 RPM. (Default value is 800 RPM.)The idle speed can be adjusted only when the gener-ator set is running in the idle mode.When not in idlemode, N/A is displayed in RPM field.

SAVE/EXIT submenu: From the STOP DELAYsubmenu, press the button next to the “>>” in thedisplay tomove to theSAVE/EXITsubmenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the mainmenu.If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

5-7

< >< >

< >

< >

< >

< ><

<

< >

<

< >

ENGINE GENADJUST >>

< >< >

� VOLTAGE� _______ >>

<

� FREQUENCY� _______ >>

� START DELAY� _______ SEC >>

� STOP DELAY� _______SEC >>

< SAVEEXIT >>

< SAVEEXIT >>

< >< SAVEEXIT >>

< >CHANGES SAVEDEXIT >>

CHANGES SAVEDEXIT >>

< � VOLTAGE� _______ >>

ENGINE GENADJUST >>

< >< >

< >< � VOLTAGE

� _______ >>

ENGINE GENADJUST >>

< >< >

ADJUST


< >< � IDLE SPEED

� _______RPM >>

5-8

SETUP AND CALIBRATION MENUS

The setup and calibration menus allow you to cali-brate the PCC with the reading from a calibratedmeter. There are four setup and calibration menusthat are selectable from the SETUP/CAL menu:

� VERSION AND DISPLAYS

� METERS

� GOVERNOR/REGULATOR

� SETUP

These fourmenus are intended for qualified servicepersonnel only. For this reason, a three-digit accesscode must be entered before you can proceed tothose menus.

ENTER CODE submenu:

The access code for your PCC is: 5 7 4.

To enter the code:1. Press the button next to the “�” to increment the

first digit.

2. Press the button next to the “>>” to select thesecond digit.

3. Press the button next to the “�” to increment thesecond digit.

4. Press the button next to the “>>” to select thethird digit.

5. Press the button next to the “�” to increment thethird digit.

6. Press the button next to the “>>” to proceed tothe DISPLAYS/METERS submenu. (Pro-vided, of course, that you have correctly en-tered the access code.)

The following sub-sections describe how to selectandmake changes to the setup and calibrationme-nus and save the changes made to these menus.

Version Menu

The VERSIONmenu allows you to verify the modelnumber and frequency of the generator set, thedate and version of the operating software and gen-erator set configuration options. From the VER-SION menu you can also review a History file, thatcan contain up to 20 error messages.


The facing page shows a block representation ofthe VERSION submenus. If you press the buttonnext to the “>>” in the Main menu display, the VER-SION/SETUP/CAL menu will appear.

CAUTION Improper calibration or adjustmentof the PowerCommand control can causeequipment malfunction or damage. Calibrationand adjustment must be performed by techni-cally qualified personnel only.

VERSION submenu: If you select VERSION, thedisplay will show the generator set model number,frequency, and kW rating, and the date and versionof the operating software.

To display the generator set configuration options,press thebuttonnext to the “>>” in the submenu thatdisplays themodel number, frequency and etc. Thismenu provides the following information:

� Generator set voltage

� WYE or DELTA

� Standby or Prime

� Parallel or Single

HISTORY: From the VERSION, SETUP/CALmenu, press the button next to the “>>” in the dis-play to move to the HISTORY submenu. Press thebutton next to “HISTORY” to display the last (latest)recorded error message.

The software will record (save) up to 20 error mes-sages. The last error detected will always be dis-played first. As each new error is detected, the old-est error recorded after 20 will be deleted.

To view the generator set runtime at which the erroroccurred and to scroll through the remaining re-corded errors, press the button next to the “>>” inthe error message menu to display the RUNTIME,NEWER/OLDER menu.

The buttons next to NEWER and OLDER are usedto scroll up and down through the error messages.For example, pressing OLDER will display the nextoldest recorded error message. When pressingNEWERand the last (newest) errormessage is dis-played, or OLDERand oldest error is displayed, thedisplay will return to the HISTORY menu.

5-9

< >

< >ENGINE GENADJUST >>

< >

< � ENTER CODE� __ __ __ >>

VERSION MENUS

< >< >VERSION <<SETUP/CAL >>

< >

>>

(kW) (model) (hz) <<__ __ __ V:___.__ >>

BACK

ENGINE GENADJUST >>

< >< >< >VERSION <<SETUP/CAL >>


>>

(kW) (model) (hz) <<__ __ __ V:___.__ >>

_______ V ______<<_______ ______

>BACK


< >HISTORY <<

BACK

< >HISTORY <<>

__________________________________ >>

< >RUNTIME _________NEWER OLDER

REFER TO FOLLOWINGMENUS IN THIS SECTION

DISPLAYS ERRORMESSAGE AND CODE

DISPLAYS VOLTAGE & GENSET CONFIGURATION


5-10

Displays Menu

The DISPLAYS submenus permit calibration of thedigital voltage, current, power factor (PF) and cool-ant temperature displays. Calibration is accom-plishedby using this sectionof themenu software toadjust the display so that it matches the readingtaken on an accurate, recently calibrated meter.


The facing page shows a block representation ofthe DISPLAYS submenus, which is the first of fourSETUP/CAL menus. If you press the button next tothe “>>” in the Main menu display, the VERSION/SETUP/CAL menu will appear.


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

Select SETUP/CAL. The display will show the EN-TER CODE submenu. Enter access code (574) aspreviously described in this section.SelectDISPLAYS toproceed to theDISPLAYSsub-menus. Use the buttons next to the “�” and “�” sym-

bols to calibrate the selected voltage, current, PF orcoolant temperature reading. Press the button nextto the “>>” in the display to move to the next adjust-ment.“VOLTSL12,” “VOLTSL23,” and “VOLTSL31” referto voltages measured from L1 to L2, L2 to L3, andL3 toL1, respectively.Note that the system includesbus voltage reading provisions (“BUS VOLTS L12,”“BUS VOLTS L23,” and “BUS VOLTS L31”), whichmust be calibrated separately from the generatorset voltage settings.“PF1, PF2 and PF3” will display N/A when the gen-erator set is not running.“COOLANTTEMPR”will display “N/A” if the gensethas only one sensor. To calibrate coolant tempera-ture display, a precision resistor (provided in the en-gine sensor tool) must be temporally substituted forthe temperature sender. Refer toCalibrationProce-dure in this section.SAVE/EXIT submenu: From the AMPS L3 sub-menu, press the button next to the “>>” in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

5-11

DISPLAYS MENU

<

<< >

<

<

<< >

< >

< >

< >

� PF3� _______ >>

� COOLANT TEMP R� _______ >>

� COOLANT TEMP L� _______ >>

< >

< >

< >

< >DISPLAYS <<METERS >>

<< >

� VOLTS L12� _______ >>

<< >

� VOLTS L23� _______ >>

<< >

� VOLTS L31� _______ >>

<< >

� AMPS L1� _______ >>

<< >

� AMPS L2� _______ >>

< >< SAVEEXIT >> < >

CHANGES SAVEDEXIT >>

< >< >CHANGES SAVEDEXIT >>

< � VOLTS L12� _______ >>

< SAVEEXIT >> < >

< � VOLTS L12� _______ >>

< SAVEEXIT >> < >


< >< >DISPLAYS <<METERS >>

� PF1� _______ >>

� PF2� _______ >>

<< >

� AMPS L3� _______ >>

< >< � ENTER CODE

� __ __ __ >>


<

<< >

< >� BUS VOLTS L31� _______ >>

� BUS VOLTS L23� _______ >>

<< >

� BUS VOLTS L12� _______ >>


5-12

Meters Menu

The METERS submenus permit calibration of thecontrol’s analogmeters tomatch the calibrated digi-tal values. (Calibrate the digital display before cali-brating the analog meters.) This calibration is ac-complished by using this section of the menu soft-ware to adjust the selected meter reading so that itmatches the reading provided on the digital display.


The facing page shows a block representation ofthe METERS submenus, which is the second offour SETUP/CAL menus. If you press the buttonnext to the “>>” in theMain menu display, the VER-SION/SETUP/CAL submenu will appear.


METERS submenu: The METERS submenus areintended for qualified service personnel only. Forthis reason, a three-digit access code must be en-tered before you can proceed to those menus.

Select SETUP/CAL. The display will show the EN-TER CODE submenu. Enter access code (574) aspreviously described in this section.

Select METERS to proceed to the METERS sub-menus. Use the buttons next to the “�” and “�” sym-bols to calibrate the selected meter to match the“CAL TO:” value provided on the digital display.Press the button next to the “>>” in the display tomove to the next calibration.

“VOLTMETER” and “% AMPERES” calibration ref-erence the phase that is indicated on the phaseselection LED’s.

NOTE: The%AMPERESmeter scale is basedona0.8power factor. (100% of rated current is full load cur-rent at 0.8 PF.)

SAVE/EXIT submenu: From the HERTZ sub-menu, press the button next to the “>>” in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.

If you select SAVE, the adjustments will be retainedafter shutdown, and will be in effect when the set isrestarted. If you select EXIT without saving first, theadjustments will remain in effect until the genset isshut down, but will be reset (and will not be in effect)when the set is restarted.

5-13

< >

< >

< >

< >

< >

<


METERS MENU


<< >

� A---C VOLTS� CAL TO: ___ >>

<< >

� % AMPERES� CAL TO: ___ >>

<< >

� % LOAD� CAL TO: ___ >>

<< >

� HERTZ� CAL TO: ___ >>


CHANGES SAVEDEXIT >> < >



<

< SAVEEXIT >> < >

<

< SAVEEXIT >> < >


< >DISPLAYS <<METERS >> < >

ENTER CODE� __ __ __ >>

� ENTER CODE� __ __ __ >>

� A---C VOLTS� ADJ TO: ___ >>

� A---C VOLTS� ADJ TO: ___ >>


5-14

Governor / Regulator Menu

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

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

Default values are preset by the factory. Due to sitevariables, thedefault valuesmayneed to beadjustedto attain peak performance.

The facing page shows a block representation ofthe GOV/REG submenus, which is the third of fourSETUP/CALmenus. If you press the button next tothe “>>” in the Main menu display, the VERSION/SETUP/CAL submenu will appear.


GOV/REG submenu: The GOV/REG submenusare intended for qualified service personnel only.For this reason, a three-digit access code must beentered before you can proceed to those menus.

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

From theDISPLAYS/METERSsubmenu, press thebutton next to the “>>” in the display to move to theGOV/REG/SETUP submenu. Select GOV/REG toproceed to the GOV/REG submenus.

Use the buttons next to the “�” and “�” symbols toadjust the selected governor and regulator parame-ters. Press the button next to the “>>” in the displayto move to the next adjustment.

GOV GAIN: If the gain adjustment is set too high,enginespeedwill “hunt” or oscillate. If gain is set toolow, the enginewill respond too slowly to changes inload—overspeed may result.

Forparalleling applications the default value for gov-ernor gain is 70.

GOV INTEGRAL: If this adjustment is set too low,the engine will respond too slowly to changes inload. If it is set too high, engine responsewill be un-stable.

GOV RAMP: This adjustment sets the time for theengine to ramp to full operating speed. This adjust-ment applies only to set start up and does not affectthe transient response. (Adjustable range: 0through 10 seconds.)

REG GAIN: If the gain adjustment is set too high,output voltagewill be unstable. If gain is set too low,the output voltage will respond sluggishly tochanges in load—overshoot may result.

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

REG VHZ: This underfrequency roll-off adjustmentcontrols how much excitation is reduced in re-sponse to underfrequency. If the value is set toolow, excitation will be cut too fast, and the voltagewill drop toomuch. If set too high, the generator setmay not be able to pick up rated load in one step.(Adjustable range: 1 through 50; normal range 7through 21.)

SAVE/EXIT submenu: From the REG VHZ sub-menu, press the button next to the “>>” in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.


5-15

< >< >

>

< >

< >

< >


GOVERNOR/REGULATOR MENU

< >GOV / REG <<SETUP

<< >

� GOV GAIN� _______% >>

<< >

� GOV INTEGRAL� _______% >>

<< >

� GOV RAMP� _______ >>





<

< SAVEEXIT >> < >

<

< SAVEEXIT >> < >


<< >

� REG GAIN� _______% >>

<< >

� REG INTEGRAL� _______% >>

<< >

� REG VHZ� _______ >>

� GOV GAIN� _______% >>

� GOV GAIN� _______% >>

>GOV / REG <<PARALLEL SETUP


< ><


� ENTER CODE� __ __ __ >>


5-16

Setup Menu

The SETUP submenus permit selection of severalconfiguration and operation options. Setup optiondefaults are listed in Table 5-2.

TABLE 5-2. SETUP DEFAULTS

SELECTION DEFAULT

CYCLE CRANK ONSYSTEM OF UNITS IMPERIAL*CUSTOMER FAULT 1 WARN*GRND FAULT WARN*DAY TANK WARN*HIGH GEN TEMP WARNEGT L NOEGT R NOLOW COOLANT SHTDLANGUAGE ENGLISH

* Default display messages for customer faults 1through 4. To change the customer fault mes-sage(s), to display the desired fault condition, referto heading Edit Customer Fault Messages.

The facing page shows a block representation ofthe SETUP submenus, which is the fourth of fourSETUP/CALmenus. If you press the button next tothe “>>” in the Main menu display, the VERSION/SETUP/CAL submenu will appear.


SETUP submenu: The SETUP submenus are in-tended for qualified service personnel only. For thisreason, a three-digit access code must be enteredbefore you can proceed to those menus.

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

From theDISPLAYS/METERSsubmenu, press thebutton next to the “>>” in the display to move to theGOV/REG/SETUP submenu. Select SETUP toproceed to the SETUP submenus.

Use the buttons next to the “��” symbols to togglethe setup options. Press the button next to the “>>”in the display to move to the next adjustment.

If the cycle crankingoption is selected, themenuwillprompt for the selection of cycle number (3, 4, or 5)and crank and rest times (7 to 20 seconds).

An in-line engine that has the EGT (exhaust gastemp.) option, select “YES” for EGT L and ’NO” forEGT R.

Edit Customer Fault Message(s): The four cus-tomer fault messages shown in Table 2-1 are edit-able. To enter the desired customer fault message,press the button next to the “>>” in the display todis-play the customer fault message to be changed.

Press the upper-left button by the display to selectthe desired character. Press the upper-right buttonto move the cursor to the next character to bechanged. (Holding this button down will return thecursor to the first position.) Themessage can be upto 16 characters. The fault code number will remainthe same, this code cannot be edited.

If these messages are changed, you should notethese changes in the Troubleshooting section of theOperator’s manual for this generator set.

SAVE/EXIT submenu: From the LANGUAGE sub-menu, press the button next to the “>>” in the dis-play to move to the SAVE/EXIT submenu. SelectSAVE to save your changes. At the CHANGESSAVED submenu, select EXIT to return to the DIS-PLAYS/METERS submenu.


5-17

< >

< >

< >

< >

< >< >

< ><

< � REST TIME --- SEC� (7 to 20) >>

<

<

DISPLAYS <<METERS >>

< � ENTER CODE� __ __ __ >>

� LANGUAGE� _______________>>

< >

< >

< >

< >

SETUP MENU

< >GOV / REG <<PARALLEL SETUP

< >CYCLE CRANK

�� ON / OFF >>

< >SYSTEM OF UNITS

�� MET/ IMP >>





< SAVEEXIT >> < >

< SAVEEXIT >> < >


< >LOW COOLANT

�� SHTD / WARN >>

< >CUSTOMER FAULT1�� SHTD / WARN >>

< >

< >EGT L

�� YES / NO >>

< >EGT R

�� YES / NO >>

CYCLE CRANK�� ON / OFF >>

CYCLE CRANK�� ON / OFF >>

< >


< >� # OF CYCLE S� (3, 4, or 6) >>

RESET MENU >

< >CYCLE CRANK

�� ON / OFF >>

RESET MENU >

< >� CRANK TIME --- SEC� (7 to 20) >>

RESET MENU >

IF CYCLE CRANK ON :

RESET MENU >RESET MENU >

< >

< >DAY TANK

�� SHTD / WARN >>

< >HIGH GEN TEMP�� SHTD / WARN >>

GRND FAULT�� SHTD / WARN >>


5-18

Paralleling Setup Menu

The PARALLELING SETUP submenus adjust thecontrol parameters for generator set protection,synchronizing and load sharing for both isolatedbus and utility (mains) paralleling applications. Util-ity (mains) parallel applications may require adjust-ment of both the “isolated bus” and “utility” branchsubmenus.

The sync check (permissive) function is operationalin both automatic and manual (RUN) modes. Thecontrol will make sure that the generator set is atproper voltage, within the defined sync check win-dow for the defined period of time and that phaserotation is correct.When all criteria aremet, the par-alleling breaker is closed automatically by the con-trol (auto mode), or by operation of the breakerclose switch by the operator (run mode).

The synchronizing function of the PowerCommandcontrol is enabled when the control has brought thegenerator set to rated speed and voltage, and hassensed that bus voltage is available. The control au-tomatically adjusts the generator set speed andvoltage to match the bus frequency and voltage.The control can force the generator set to match abus voltage and frequency in a range of minus 40%to plus 10% of normal bus conditions. When theparalleling breaker has closed, the control will bringthe generator set back to normal voltage and fre-quency.

When the generator set is paralleled to anothergenerator set, the control provides automatic loadsharing functions for both real (kW) and reactive(kVAR) loads. Load sharing is proportional betweengenerator sets basedon their standby ratings. If twogenerator sets of different sizes are paralleled, theywill assume the same percentage of the systemloadautomatically. This caneasily be verified on theanalog % Load meters on the front of the Power-Command control panel.

When the utility parallelingmode is enabled and thegenerator set paralleling breaker is closed, the gen-erator set will assume load based on external ana-log input signal. The input signal must be calibratedfrom 0--5 VDC. When the signal is at 0.5 to 1 VDC,the control will operate the generator at no load inparallel with the utility (mains) source. At 4.5 VDCand greater, the control will operate the generator

set at 110% of the generator set base load setting.When the load govern signal is between 1 VDCand4.5VDC (seeFigure 5-4) the controlwill operate thegenerator set at a load level which is determined bya linear relationship between the kW reference andthe load govern signal.

ISOLATED BUS ADJUSTMENTS

SYNCTIMELIMIT:This parameter adjusts the timedelay in seconds before the Fail To Synchronizealarm will operate.

- PWR LIMIT (%): Adjusts the reverse power setpoint. ForPowerCommandgenerator sets, a typicalset point is 10-15%.

- PWR LIMIT (TIME): Adjusts the reverse powerfunction time delay. A typical time delay which issuitable for PowerCommand generator sets is 3 se-conds.

Lower reverse power set points can result in nui-sance reverse power shutdown faults.

PERM WIN-PHASE: Adjusts the width of the per-missive (sync-check) acceptance window. The ad-justment range is from five to twenty electrical de-grees. Recommended set point is 20 degrees forisolated bus applications, and 15 degrees for utility(mains) paralleling applications.

PERM WIN-TIME: Adjusts the time period (in se-conds) forwhich thegenerator setmust besynchro-nized with the system bus, before a breaker closesignal is issued by the PowerCommand control.Available range is 0.5 to 5 seconds. Recommendedvalue for PowerCommand generator sets is 0.5 se-conds for isolated bus applications.

Adjusting the control for a smaller sync-check win-dow or longer time delay will cause synchronizingtime to be extended.

SYNC GAIN: The sync gain adjustment controlshow quickly the governor will respond to try to mini-mize the bus/generator phase difference. Increas-ing the gain speeds up the response. If the gain istoo high instability can result.

SYNC INTEGRAL: The sync integral adjustmentcontrols the rate at which the governor will be ad-justed to try to minimize the bus/generator phasedifference. The lower the number the slower the re-sponse.

5-19

< >


< � ENTER CODE� __ __ __ >>

< >

< >

PARALLELING SETUP MENU

< >GOV / REG <<PARALLEL SETUP

<ISO BUS <<UTILITY


< >

<ISO BUS <<UTILITY

< >

< � SYNC TIME LMT� 120 >>< >

< � -PWR LMT (%)� 10 >>< >

< � -PWR LMT (TIME)� 3 >>< >

< � PERM WIN-PHASE� 20 >>< >

< � PERM WIN-TIME� .5 >>< >

< � SYNC GAIN� 95 >>< >

B (CONTINUED)

< � SYNC INTEGRAL� 12 >>< >

A (CONTINUED)


5-20

ISOLATED BUS ADJUSTMENTS (Cont.) (A)

KW BALANCE: This function adjusts the kW loadsharing function of the generator set. Before adjust-ing this value, all generator set calibrations shouldbe performed. If the total load on the system is notshared proportionately, the kW Balance can beused to adjust the generator set for more preciseload sharing. Increasing the kW Balance value willcause the generator set to reduce thepercentageofthe total kW load on that set.

KVAR BALANCE: This function adjusts the kVARload sharing function of the generator set. Beforeadjusting this value, all generator set calibrationsshould be performed. If the total load on the systemis not sharedproportionately, the kVARbalance canbe used to adjust the generator set for more preciseload sharing. Increasing the kVAR balance valuewill cause the generator set to reduce the percent-age of the total kVAR load on that set.

KWGAIN:Adjusts the rate of change of kW load onthe generator set. With a constant load on the sys-tem, if the generator set load is constantly chang-ing, reduce the gain adjustment on the generatorset. This also allows modification of the rate of loadassumption on transient load change.

KVAR GAIN: Adjusts the rate of change of kVARload on the generator set. With a constant load onthe system, if the generator set load is constantlychanging, reduce thegain adjustment on the gener-ator set. This also allows modification of the rate ofload assumption on transient load change.1ST START FAIL: Time delay in seconds after asignal from the first start master is not sensed by thePCC that a FIRST START FAIL warning is dis-played.RAMP UNLD TIME:When a load demand stop in-put is sensed the load is ramped down from thepresent load level on the set to the ramp unload lev-el in the time specified in seconds.RAMP UNLD LEVEL: The load demand ramp un-load function will ramp the load down from the pres-ent level on the set to this level before opening theset circuit breaker. Value shown is in % of gensetstandby rating.RAMP LOAD TIME: When the load demand stopsignal is removed the load is ramped from 0kW tothe load share level in the specified time after thecircuit breaker closes.LOSS FIELD TIME: Adjusts the loss of field func-tion time delay. A typical delay which is suitable forPowerCommand generator sets is 2 seconds. (Ver-sion 1.06, beginning 9-26-96 only.)

5-21

< >

< >

PARALLELING SETUP MENU (Cont.)

< SAVEEXIT >>

< SAVEEXIT >> < >


< � KW BALANCE� 165 >>< >

< � KVAR BALANCE� 0 >>< >

< � KW GAIN� 6 >>< >

< � KVAR GAIN� 300 >>< >

<ISO BUS <<UTILITY

< >

A (CONTINUED)

< � 1ST START FAIL� 10 >>< >

< � RAMP UNLD TIME� 10 >>< >

< � RAMP UNLD LEVEL� 20 >>< >

< � RAMP LOAD TIME� 10 >>< >


< � LOSS FIELD TIME� 2 >>< >

5-22

UTILITY (MAINS) ADJUSTMENTS (B)BASE LOAD (%): Controls the maximum kW loadlevel that the generator set will operate at when par-alleledwith the utility (mains). The value shown indi-cates the steady state load on the generator as apercent of the generator set standby rating.Check generator set ratings formaximum load levelat which the generator set should operate whenparalleled with the utility (mains). Extended opera-tion at load levels in excess of the generator set rat-ing can cause abnormal engine wear or prematureengine failure.PFLEVEL:Adjusts the power factor that the gener-ator set will run at when paralleled to the utility(mains). Recommended setting is 1.0.KWGOVERNGAIN:Controls the rate that the gen-erator set kW load is increased after the generatorset has closed to the system bus when utility(mains) paralleled. Decreasing this value will resultin slower loading of the generator set.KW INTEGRAL: The kW integral adjustment isused to control the response of the generator set tolarge load changes when utility (mains) paralleled.Use of a higher integral valuewill result in slower re-sponse, and reduced kW overshoot on load as-sumption or rejection, especially on large systemload changes. Decreased integral values will alsoresult in slower load acquisition and rejection.

KVAR GOVERN GAIN: Controls the rate that thegenerator set kVAR load is increased after the gen-erator set has closed to the system bus when utility(mains) paralleled. Decreasing this value will resultin slower loading of the generator set.KVAR INTEGRAL: The kVAR integral adjustmentis used to control the response of the generator setto large load changes when utility (mains) paral-leled. Use of a higher integral value will result inslower response and reduced kVAR overshoot onload assumption or rejection, especially on largesystem load changes. Decreased integral valueswill also result in slower load acquisition and rejec-tion.RAMP LOAD TIME: This is the ramp time frompresent set load to level determined by the load setanalog input. This is activewhen the control first en-ters the load govern mode.RAMP UNLD TIME: This is the ramp time frompresent set load to the 0 kW. This ramp is activewhen the load set analog input is less than 0.5 volts.MULTIPLE/SINGLE: This controls whether the setis to operate as part of a multiple set or single set(PLTE of PLTF) system. (Refer to “LOAD DE-MAND” and “UTILITY SINGLE VERIFY” functiondescriptions in Table 5-3 for additional informationregarding Multiple/Single menu selection.)

5-23

< >

PARALLELING SETUP MENU (Cont.)

< SAVEEXIT >>

< >< >DISPLAYS <<METERS >>

< � BASE LOAD %� 80 >>< >

< � PF LEVEL� 1.00 >>< >

< � KW GOVERN GAIN� 100 >>< >

< � KW INTEGRAL� 4 >>< >

< � KVAR GOVERN GAIN� 300 >>< >

< � KVAR INTEGRAL� 200 >>< >

<ISO BUS <<UTILITY

< >

B (CONTINUED)

< � RAMP LOAD TIME� 10 >>< >

< � RAMP UNLD TIME� 10 >>< >

< � MULTIPLE/SINGLE� SINGLE>>< >


< >< SAVEEXIT >>

5-24

CALIBRATION PROCEDUREWARNING Contacting high voltage compo-

nents can cause electrocution, resulting in se-vere personal injury or death. Calibration andadjustment must be performed by technicallyqualified personnel only. Read and observe allWARNINGS and CAUTIONS in your generatorset manuals.


The calibration procedure is divided into 7 subsec-tions, with the subsections arranged in a specifiedorder. If twoormoreof the following subsectionsarerequired to calibrate the PCC, they must be com-pleted in the order shown.

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

Use a calibrated RMS multimeter for accuratemeasurements. Fluke models 87 or 8060A aregood choices.

Initial Start Setup1. 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 aspecific generator set, refer to the VERSIONmenu (Page 5-9). Thismenuwill show the gen-erator set model number, frequency, and kWrating. If any of these values are incorrect, youmust perform the Initial Start Setup procedure.

Voltage and Frequency Adjustment2. With the generator set OFF, attach a calibrated

frequency/voltmeter to the AC output from L1to L2.

3. SelectADJUST from theMainMenu (page5-7)to display the VOLTAGE adjust menu.

4. Start the genset by moving the Run-Stop-Re-mote switch to the RUN position and allow thegenset to reach normal operating speed.

5. Adjust VOLTAGE (genset output voltage) sothat the calibrated voltmeter reads the desiredvoltage. (Use a calibrated voltmeter becausethe value displayed on the PCC digital displaymay not be calibrated at this time; therefore, itsaccuracy is unknown.)

6 Select the Frequency adjust menu.7. Verify that the frequency displayed on the cali-

brated meter is the desired frequency. If not,adjust to the desired frequency. (Note: If thefrequency reading on the digital display is notthe same as frequency shown on calibratedmeter, there is an equipment malfunction.)

8. If no frequency or voltage adjustment wasmade, select EXIT. If anadjustmentwasmade,SAVE, then EXIT.

Digital Voltage Display Calibration

The paralleling bus must be de-energized whilevoltage calibrations are performed. If this is notpossible, disconnect and isolate bus voltage in-puts to the Bus PTModule (A39) before attempt-ing voltage calibration.

9. Select “>>” from the Main Menu (Page 5-9).From this menu proceed to the VOLTS L12menu (Page 5-11).

10. With the genset OFF, attach a calibrated fre-quency/voltmeter to the AC output from L1 toL2.

11. Start the genset and allow it to reach normaloperating speed.

12. Calibrate voltage reading for VOLTS L12 sothat the reading on the digital display agreeswith the calibrated voltmeter.

13. Shut the generator set OFF.14. Repeat steps 10 through 13 for L23 and L31.

(In step 10 attach meter to the AC output fromL2 to L3 to calibrateVOLTS L23 and L3 to L1 tocalibrate VOLTS L31.)

15. If no calibration was made, select EXIT. If acalibration was made, SAVE, then EXIT.

5-25

Digital Ammeter Display Calibration16. Select “>>” from the Main Menu (Page 5-9).

From thismenu proceed to theAMPSL1menu(Page 5-11).

17. With the genset OFF, attach a calibratedammeter to L1.


19. Load the genset to maximum rated kVA atrated voltage.

20. Calibrate the reading for AMPS L1 so that thereading on the digital display agrees with cali-brated ammeter.

21. Repeat steps 17 through 20 for L2 and L3. (Instep 17, attach meter to L2 to calibrate AMPSL2 and L3 to calibrate AMPS L3.)


Digital Power Factor Display Calibration

Power factor calibration is not requiredexcept in ap-plications requiring a higher accuracy than �5%. Ifthe �5%accuracy is not acceptable, further calibra-tion will require reactive load sufficient to reach 0.8PF at rated load, and calibrated instruments with�1% accuracy or better. Typical load rack instru-ments are not accurate enough to perform this pro-cedure.

23. Select “>>” from the Main Menu (Page 5-9).From this menu proceed to the PF1 menu(Page 5-11).

24. With the genset OFF, attach the power factormeter to L1.


26. Load the genset to maximum rated kVA atrated voltage.

27. Calibrate the reading for PF1 so that the read-ing on the digital display agrees with powerfactor meter.

28. Repeat steps 24 through 27 for L2 and L3. (Instep 24, attachmeter to L2 to calibratePF2andL3 to calibrate PF3.)

29. If no calibrationwasmade, select EXIT. If a cal-ibration was made, SAVE, then EXIT.

Digital Bus Voltage Calibration

30. Select “>>” from the Main Menu (Page 5-9).From this menu proceed to the Bus Volts L12menu (Page 5-11).

31. With the genset OFF, attach a calibrated fre-quency/voltmeter to the alternator AC outputfrom L1 to L2.

The paralleling bus must be de-energized whilevoltage calibrations are performed. If this is notpossible, disconnect and isolate bus voltage in-puts to the Bus PTModule (A39) before attempt-ing voltage calibration.

32. Start the genset and allow it to reach normaloperating speed and voltage.

33. Push the breaker close switch on the front ofthe PowerCommand control and verify that theparallelingbreaker has closedby observing theclosed lamp on the control panel and physicalcheck of the breaker.

34. Calibrate the voltage reading for Bus Volts L12so that the reading on the digital displaymatches the reading on the calibrated meter.

35. Shut the generator set OFF.

36. Repeat steps 31 through 35 for Bus Volts L23and Bus Volts L31.

37. If no calibrationwasmade, select EXIT. If a cal-ibration was made, SAVE, then EXIT.

5-26

Digital Coolant Temperature DisplayCalibration

A engine sensor calibration tool is required to per-form this procedure.

30. With the genset OFF, replace the coolanttemperature sender with the precision resistorprovided in the calibration tool.

31. Select “>>” from the Main Menu (Page 5-9).From this menu proceed to the COOLANTTEMP L menu (5-11).

32. Calibrate the temperature reading tomatch thetemperature indicated on the calibration tool.

33. Repeat step 32 for COOLANT TEMP R if theengine uses two sensors.


Analog meter calibration

35. Select “>>” from the Main Menu (Page 5-9).From this menu proceed to the A--C VOLTSCAL TO: menu (Page 5-13).

36. Start the genset and allow the genset to reachnormal operating speed.

37. Calibrate the analog Voltmeter to the digitallydisplayed value.

38. Calibrate the analog% Ampsmeter to the digi-tally displayed value.

39. Calibrate the analog % Load meter to the digi-tally displayed value.

40. Calibrate the analog Frequency meter to thedigitally displayed value.

41. SAVE, then EXIT.

5-27

ACCESSORY BOX CONTROLCOMPONENTS

Thegenerator set accessory box (Figure 5-3)whichis located on the backside of the control housing,

contains components that provide connectionpoints for remote control and monitor options. Theset can be equipped with one or more of the follow-ing components (customer terminal block TB1 isstandard).

OPTIONAL COMMONALARM RELAY K14

OPTIONAL RUN RELAYSK11, K12 & K13

CUSTOMER TERMINALBLOCK (TB1)

FIGURE 5-3. ACCESSORY BOX COMPONENTS

5-28

TB1 Customer Inputs

Refer to Page 9-9 for typical connections to TB1.

1, 2, 3, 4

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS

A39/A40 TB1TERMINAL # FUNCTION DESCRIPTION

Bus PT Input (OnBus PT Module)

Phase to Neutral input voltages from system bus (load side of parallelingbreaker.

5 Remote Start Close to ground to start generator set. (RUN/OFF AUTO switch must bein AUTO position.)

41, 42 Common AlarmWarning

Form C output contact for remote indication of warning condition ongenerator set.

50 Master FirstStart/SynchronizerEnable

For isolated bus or multiple generator set utility (mains) applications, aB+ signal from a remote Master First Start Sensor is applied on thisterminal. For single generator set utility (mains) parallel applications,apply 24VDC to this terminal to enable synchronizer function in control.

16 -- 19 Customer Fault Grounding these terminals initiates an alarm or shutdown condition inthe control.

20 Fault Reset Applying a momentary ground signal to this terminal clears warning orshutdown faults in the control. (Except Emergency Stop.)

21 Engine Idle Grounding this input activates the Low Fuel warning.

35 Rupture BasinAlarm

Applying a ground signal to this point will cause the generator set toannunciate a Rupture Basin Alarm.

46 Utility ParallelSignal

Apply a 24VDC signal to terminal 46 to indicate to the control that it isoperating in parallel with a utility (mains) service.

47 Utility ParallelSignal

Apply a ground signal to terminal 47 to indicate to the control that it isoperating in parallel with a utility (mains) service.

A39

A40

CONTINUED

6 RemoteEmergency Stop

Grounding this input causes an immediate shutdown.

22 Low Fuel Applying a ground signal at this terminal will cause engine to run atrecommended idle speed. Voltage will be disabled.

5-29

TABLE 5-3. A39/A40 TB1 CUSTOMER INPUTS (Cont.)

A39/A40 TB1TERMINAL # FUNCTION DESCRIPTION

51 Load Demand Close to ground to initiate load demand mode in PowerCommandcontrol. (Select “Multiple” in Paralleling Setup Menu to enable loaddemand mode.)

52 Breaker Open /Inhibit

Close to ground to manually open the paralleling breaker or inhibitbreaker closure.

53 Breaker Position Close to ground to indicate breaker closed.

54, 55 kVAR LoadShare

Load Sharing Lines. Connect to load sharing lines in other generatorsets in the system.

56, 57 kW Load Share Load Sharing Lines. Connect to load sharing lines in other generatorsets in the system.

59, 60 External LoadSet

Analog 0 -- 5 VDC input to control kW load level on generator set whenthe generator set is paralleled to utility.

51 Utility SingleVerify

For single generator set utility (mains) applications (“SINGLE” selectedin the Paralleling Setup Menu), this terminal must be connected[strapped] to ground to enable breaker closure. (Version 1.06, beginning9-26-96 only.)

A40

Remote Start:When the Run/Off/Auto switch is inthe Auto position, grounding this input initiates theengine cranking and start sequence. This circuitmust beopened topermit resettinga shutdowncon-dition with the Reset input.

Low Fuel: Grounding this input actuates the LowFuelwarning. This input canbe connected to a localday tank or to amain fuel tank that is located on site.When the switch grounds this designated input, theinput will “wake up” the control, if it is not operating,and then initiate the fault.

Customer Fault Inputs 1 through 4: Groundingany one of these inputs activates the correspondingwarning or shutdown sequence. Warning or shut-down status is selected in the setup menu.

External sensing equipment must be connected tothe designated digital input.

The four customer faultmessagescanbeseparate-ly edited in the setup menu to display any desired

message. This allows each customer “default” faultmessage to be customized to represent the type ofdevice that is attached the the fault input.

The “default” message that is displayed, whenground is applied to the input, is as follows:

Fault 1 = CUSTOMER FAULT1Fault 2 = GRND FAULTFault 3 = DAY TANKFault 4 = HIGH GEN TEMP

If Fault 2 or 3 input is grounded, the control will“wake up” if it is not operating, and then initiate thefault.

Fault Reset: When the Run/Off/Auto switch is inthe Auto position and the remote start switch isopen, grounding this input resets any warning andlatched shutdown fault (except Emergency Stop,which must be reset at the front panel.)

5-30

Engine Idle:When the set is operating in the RUNmode, grounding this input causes generator buildup to be inhibited and the engine to be governed at800RPM. When ground is removed from this input,the set returns to normal speed and voltage.Engine idle operation is applicable only in the RUNmode. The PCC operating program does not permitengine idle operation when the set is operating inAUTO mode.

When the engine idle function is enabled, the con-trol automatically sets lower oil pressure warningand shutdown trip points to reflect the lower operat-ing speed. When the engine idle function is re-moved and the set reverts to normal operatingspeed, the control automatically resets oil pressurewarning and shutdown trip points to the normal set-tings.

Remote Emergency Stop: Grounding this inputcauses an immediate shutdown. Emergency stopmust be reset at the front panel.

Master First Start/Synchronizer Enable: This in-put is received from a Master First Start Sensor,which is mounted remotely from the PowerCom-mand control. The input is a pulsed signal which isused by the PowerCommand control to enable safeclosing of the paralleling breaker when the systembus is de-energized. the control will receive a pulsefrom the Master First Start Sensor approximatelyonce per second. If the PowerCommand controldoes not receive a pulse within the programmabletime delay (default is 10 seconds), the FIRSTSTART warning is displayed by the control and abackup system is enabled by the control.

When the system is set up for paralleling a singlegenerator set with a utility (mains) bus, this input is

used to enable the synchronizer in the PowerCom-mand control. (See Paralleling Setup Menu, pathB.) A 24VDC signal applied to the terminal willcause the generator set to synchronize with thevoltage reference signal applied to the bus PTmod-ule (A39).

All PCC’s in a systemshould be programmed to adif-ferent first start fail time. Thiswill help prevent simul-taneous closure of breakers in the event of a failureof the master first start module

Load Demand: On receipt of a signal on the LoadDemand terminals (normally open, close toground), the generator set will ramp down to amini-mum load level and the paralleling breaker willopen. The generator set will run for a cool-down pe-riod and shut down. LOAD DEMANDSHUTDOWNwill be displayed on the PowerCommand panel.

When the Load Demand input is removed, the gen-erator set will start, synchronize and close to thesystem bus and accept it’s proportional share of thetotal load on the bus.

The Load Demand function of the PowerCommandcontrol is only active when the RUN/OFF/AUTOswitch is in the AUTO position and “PARALLEL” isselected in the Paralleling Setup Menu.

Utility SingleVerify:For single generator set utility(mains) applications, this input must be strapped toground before the generator set breaker will closewhen the utility breaker is opened.

The Load Demand function of the PowerCommandcontrol is only active when the RUN/OFF/AUTOswitch is in the AUTO position and “SINGLE” is se-lected in the Paralleling Setup Menu.

5-31

Utility (Mains) Parallel Input:Closure of a normal-ly open contact to ground on terminal 47 and apply-ing a 24VDC signal to terminal 46 will cause thePowerCommand control to begin operation in a util-ity (mains) paralleling mode. The ground signal isusually applied by operation of auxiliary contacts inthe utility paralleling breaker. In this operationmode, the control will ignore inputs from the loadsharing lines and operate at the load level which isdetermined by the magnitude of the Load Governsignal and the base load adjustment in the controlsetup.

Load Govern: This input is enabled when the con-trol has receivedaUtility (Mains) Parallel indication.A 0--5 VDC signal applied to these terminals will di-rect the control to operate at a specific load level,rather than being controlled by the load sharinglines (Figure 5-4). Operating load level is deter-mined by the following parameters:

0 -- 0.5 VDC: Ramp from present load tono load

0.5 -- 1.0 VDC: No load1.0 -- 4.5 VDC: 0 -- 100%of base loadsetting4.5 -- 5.0 VDC: 110% of base load setting

Rate of load ramp and base load setting are con-trolled by adjustments in the Paralleling Setupmenu of the control.

When the PCC first senses a utility breaker closurethe control will ramp up to the load govern input lev-el.

Parallel Breaker Open/Close Inhibit: This func-tion is operational only when the RUN/OFF/AUTOswitch is in the AUTO position. Closing a normallyopen contact to ground on this contact will causethe paralleling breaker to open if it is closed, or pre-vent it from closing if it is open. Removing theground signal will cause the PowerCommand con-trol to return to normal operation.

70

60

50

100

90

80

30

20

10

0

40

10 2 3 4 5

LOAD GOVERN SIGNAL (VDC)

LOAD LEVEL % OFBASE LOAD

.5 4.5

110

FIGURE 5-4. LOAD GOVERN SIGNAL VERSUS LOAD LEVEL

5-32

Operating PowerCommand in Droop Mode

ThePowerCommandcontrol is designed tooperateisochronously (with no intended droop) so thatvoltage and frequency are as constant as possiblewhen the generator set is paralleled to otherPowerCommand generator sets. In certainsituations, however, such as paralleling with othergenerators that are operating in droopmode, it maybenecessary tooperate thecontrol in a droopmodefor frequency, voltage, or both.

Note that when the generator set is paralleled to autility (mains) service it is recommended that thecontrol be operated in its utility parallelmode, ratherthan in droop, even if other generator sets in thesystemoperate in droop for that function. Thedroopmode inPowerCommandwill onlyworkwhenall theother generator sets in the system are operating indroop and the system bus voltage and frequencychange with load.

PowerCommand controls that are set up to operatein droop mode must include the paralleling option(H532). The generator set should be set up formultiple unit paralleling, but load sharinginterconnecting wiring is not used. Connect a 5Kresistor across terminal A40-TB1-54 and 55(KVAR) to cause voltage to droop. A 5K resistoracross terminal A40-TB1-56and57 (KW)will causefrequency to droop. Resistors can be used on oneor both of the load sharing terminal connections,depending on the needs of the application.

Complete all start up procedures as described inSection 8 of this manual up to the point that you areready to make load sharing adjustments. To set the

governor and voltage regulation system drooplevel:

1. Set the no load speed and voltage at thedesired level. Bus must be de-energized whenthis setting is made, or disconnect Bus PTmodule.

2. Apply 100% load to the generator set, andadjust the KW load sharing gain to obtain thedesired full load operating frequency. Adjustthe KVAR load sharing gain to obtain thedesired full load operating voltage. Refer toFigure 5-5 for typical gain settings for specificdroop levels.

3. Repeat the process for other generator sets inthe system.

4. When initial settings have been made, test thesystem with all available load, and verify thatthe generator sets share load approximatelyequally at no load and maximum availableload.

Proper adjustment of load sharing in droopoperation requires use of both real and reactive loadbanks. It is possible that precise load sharingwill notbepossiblewith all generator sets in thesystemat allload levels, due to the non-linearity of the droopcharacteristic of some generator sets. In that case, itis generally best to set up the system so thatavailable load is equally shared at themaximum loadlevel expected on the system. Note also that thesynchronizer is active and functional inPowerCommand even when the system is set up fordroop load sharing. Manual paralleling and systemsynchronizing should be performed by thePowerCommand control. It is recommended thatparalleling breakers be electrically operated by thePowerCommand control.

5-33

9.00

8.00

7.00

6.00

5.00

3.00

2.00

1.00

0.00

4.00

1 2 3 4 5

LOAD SHARE GAIN

% DROOP

% DROOP @1800 RPM% DROOP @1500 RPM

76 8 9 10 11 12 13 14 15 16 17 18 19

FIGURE 5-5. PERCENT SPEED DROOP VERSUS KW LOAD SHARE GAIN

5-34

TB1 Customer Outputs

Refer to Page 9-9 for typical connections to TB1.

1

TABLE 5-4. TB1 CUSTOMER OUTPUTS

TB1TERMINAL # FUNCTION DESCRIPTION

B+ Auxiliary Power 24 VDC control power supply, fused at 20 amps.

2 Switched B+Auxiliary Power

24 VDC control power available when genset is running, fused at 10amps.

3, 4 Ground

7, 8, 9 Common Alarm Form C contact set to indicate to a remote device that a generator setshutdown fault has occurred.

10, 11 Parallel BreakerClose Signal

Normally open contact which closes to close a remote parallelingbreaker.

14, 15 Network Data Terminations for network data twisted pair, operational when generatorset is equipped with generator communications module (GCM).

38, 40 Ready to Load Indicates that the generator set is at rated frequency and voltage and isready to accept load. Normally open contact between 38 and 40, whichis common.

39, 40 Load Dump Normally open contact which closes to indicate that the generator set isoverloaded.

41, 42 Common Warning Normally open contact that closes to indicate a warning condition on thegenerator set.

43, 44 Common Warning Normally closed contact that opens to indicate a warning condition onthe generator set

48, 49 Parallel BreakerOpen Signal

Normally closed contact which opens to open the paralleling breaker.

23--32, 33 NFPA FaultContacts

Normally open contact which closes to indicate that a specific fault hasoccurred in the generator set. Common is terminal 33.

5-35

Paralleling Breaker Control: Contacts are pro-vided to allow the PowerCommand control to oper-ate a remote paralleling circuit breaker. A normallyopen contact will close to signal the parallelingbreaker to close. A normally closed contact willopen to open the paralleling breaker.

When the RUN/OFF/AUTO switch is in the RUNposition the breaker signals will be initiated on op-eration of the paralleling breaker control switcheson the front panel of the PowerCommand control.The breaker control switches on the front panel ofthe control are not operational in other control op-eration modes.

When the RUN/OFF/AUTO switch is in the AUTOposition, the PowerCommand control will automati-cally close the paralleling breaker if the system busis de-energized and the master first start sensorpulse is received, or if synchronous condition withthe bus is achieved.

Warning Alarm: One set of normally open (NO)and one set of normally closed (NC), rated for 2amps at 30 VDC. Any warning causes the warningalarm relay (labeled Spare Relay on Customer In-terface board) to be energized. This output is oftenused to energize an audible alarm.

CommonAlarm:Oneset of form-C contacts, ratedfor 2 amps at 30 VDC. Any shutdown causes thecommonalarm relay to be energized. This output isoften used to energize an audible alarm.

Load Dump: One set of normally open (NO) con-tacts, rated for 2 amps at 30VDC. If an overload oc-curs which causes generator set frequency to dropmore than3hertz belownominal formore than3 se-conds, or a load of more than 105% of the standbyrating is applied to the generator set for more than60 seconds, the normally open load dump contactsare closed. This relay is energized before shutdown(for overload or underfrequency) occurs.

Ready To Load: One set of normally open (NO)contacts, rated for 2ampsat 30VDC. This output isactivated whenever AC voltage and frequency ex-ceed 90% of nominal.

Switched B+: This is a fused 10 amp, 24 voltswitched output. This output is activated by the runpilot signal, at the governor output module. (Fuse islocated on Governor Output Module.)

B+: This is a fused 20 amp, 24 volt output. (Fuse islocated onTB-BAT terminal block of the engine har-ness.)

5-36

Run Relays (K11, K12, 13)

The optional run relays are rail mounted inside theaccessory box (Figure 5-3). The rail mount allowsyou to easily remove and replace the snap-on re-lays. The generator set can be equipped with one,two or three run relays.

The three-pole, double-throw run relays (Figure5-6) are used to control auxiliary equipment suchas

fans, pumps and motorized air dampers. The runrelays are energized when the generator set reach-es operating speed.

The contacts are rated:

� 10 amps at 28 VDC or 120 VAC, 80%PF

� 6 amps at 240 VAC, 80%PF

� 3 amps at 480/600 VAC, 80%PF

CUSTOMERCONNECTIONS

A40-TB1-4(B-)

A40-TB1-2(SWITCHED B+)

NO

COIL

COM

NC

K11, K12, K13

K11RUN RELAY

K11, K12, K13

K11, K12, K13

K12RUN RELAY

K13RUN RELAY

NO

NC

NO

NC

FIGURE 5-6. OPTIONAL RUN RELAYS (K11, K12, K13)

5-37

Alarm Relay (K14)

The optional alarm relay is rail mounted inside theaccessory box (Figure 5-3). The rail mount allowsyou to easily remove and replace the snap-on relay.

The three-pole, double-throw alarm relay (Figure5-7) is often used to energize warning devices such

as audible alarms. Any generator set warning orshutdown will energize the alarm relay.

The contacts are rated:

� 10 amps at 28 VDC or 120 VAC, 80%PF� 6 amps at 240 VAC, 80%PF� 3 amps at 480/600 VAC, 80%PF

CUSTOMERCONNECTIONS

A40-TB1-4(B-)

A40-TB1-8(COM ALARM)

NO

COIL

COM

NC

K14

K14

K14

K14COMMON ALARM

FIGURE 5-7. OPTIONAL ALARM RELAY (K14)

5-38

ENGINE SENSORS

Figures 5-8 and5-5 show the locations of the oil andcoolant temperature and oil pressure senders towhich the PCC responds. The switches function by

closing the fault or warning circuit to the enginechassis ground (battery negative [--]). The low cool-ant level switch has its own ground wire. The lowcoolant level switch is not shown in Figure 5-8; thisswitch is located near the top of the radiator.

COOLANT TEMPERATURESENDER (S2)

OIL TEMPERATURESENDER (E4)

(4 CYL ENGINE)

OIL PRESSURESENDER (E1)

OIL TEMPERATURESENDER (E4)

(6 CYL ENGINE)

LOW ENGINE TEMPERATURESENDER (S4)

FIGURE 5-8. ENGINE SENSOR LOCATIONS (4B/6B SERIES ENGINES)

5-39

COOLANT TEMPERATURESENDER (S2) OIL TEMPERATURE

SENDER (E4)

OIL PRESSURESENDER (E1)LOW ENGINE TEMPERATURE

SENDER (S4)

FIGURE 5-9. ENGINE SENSOR LOCATIONS (6C SERIES ENGINES)

5-40

MAGNETIC SPEED PICKUP UNIT (MPU)INSTALLATION

To install the MPU sensor, bar the engine until agear tooth on the flywheel lines up in the center ofthe mounting hole. Thread the sensor in gently byhand until it just touches the gear tooth. Back it outone quarter turn and set the locknut.

CAUTION Do not use fan blade to bar over en-gine. That can damage blades and cause prop-erty damage and personal injury.

MAGNETICPICKUPSENSOR

ENGINEFLYWHEELRING GEAR

FIGURE 5-10. MPU SENSOR

5-41

CURRENT TRANSFORMER (CT)INSTALLATION

Current transformers (CT’s) are required on gen-sets that contain AC meters. The CT’s must beinstalled as noted in the following CT InstallationRequirements. Improper installation of CT’s willcause a “335 Reverse Power” shutdown error.

Refer to the Reconnection Diagram to identify theoutput leads/phase that must be routed througheach CT, and also appropriate transformer postselection formeter sensing leads. The transformersare labeled CT21, CT22 and CT23 on the recon-nection wiring diagram. (The Reconnection Dia-gram is located on the upper side cover of the con-trol housing.)

CT Installation Requirements

A. TheCT has a dot on one side. This dot must befacing toward the generator (conventional cur-rent flowing into the dot). A dot is also used toindicate pin 1 of the CT.

B. CT21 -- U load leads (A phase)CT22 -- V load leads (B phase)CT23 -- W load leads (C phase)

C. Route the appropriate leads through each CT.� 6 lead generator sets -- generator outputleads are routed through the CT’s.

� 12 lead generator sets -- load wires arerouted through the CT’s.

D. Reconnectable gensets (12 leads) have dualsecondary CT’s (3 pins). The CT secondarywire marked 1 is connected to pin 1 of the CT.CT secondary wire marked 2/3 is connected topin 2 for high voltage gensets or to pin 3 for lowvoltage gensets. (Refer to Reconnection Dia-gram.)Non-reconnectable gensets (6 leads) havesingle secondary CT’s (2 pins).� The lead from CT terminal #1 connects tothe metering circuitry.

� The lead from CT terminal #2/3 connectsto ground.

6-1

6. Servicing the Generator

TESTING THE GENERATORThese tests canbeperformedwithout removing thegenerator. Before starting tests, disconnect thestarting battery cables (negative [-] first) to makesure the engine will not start while performing thesetests.

CAUTION Always disconnect a batterycharger from its AC source before disconnect-ing the battery cables. Otherwise, disconnect-ing the cables can result in voltage spikes highenough todamage theDCcontrol circuits of theset.

WARNING Accidental starting of the generatorset while working on it can cause severe per-sonal injury or death. Prevent accidental start-ingbydisconnecting thestartingbattery cables(negative [- ] first).

Make certain battery area has been well-venti-lated before servicing battery. Arcing can igniteexplosive hydrogen gas given off by batteries,causing severe personal injury. Arcing can oc-cur when cable is removed or re-attached, orwhen negative (- ) battery cable is connectedand a tool used to connect or disconnect posi-tive (+) battery cable touches frame or othergrounded metal part of the set. Always removenegative (- ) cable first, and reconnect it last.Make certain hydrogen from battery, enginefuel, and other explosive fumes are fully dissi-pated. This is especially important if batteryhasbeen connected to battery charger.

OUTPUTTERMINALS

ENDPLATE

EXCITERSTATOR

DRIVEDISCS

MAIN ROTOR(GENERATOR FIELD)

ROTATINGRECTIFIERASSEMBLY

EXCITERROTOR

ROTORSHAFTBEARING

COOLINGBLOWER

PMGASSEMBLY

STATORLEADS

GENERATORADAPTORCASTING

MAINSTATOR

FIGURE 6-1. GENERATOR

6-2

Exciter Stator

Testing Winding Resistance: Measure windingresistancewith aWheatstone bridge or digital ohm-meter. Replace the stator if winding resistance isnot as specified by Table 6-1.

Testing Winding Insulation Resistance: Discon-nect the exciter stator leads from terminals X andXX on the auxiliary terminal board in the generatoroutput box. Using an ohmmeter, measure resis-tance between either lead and the stator lamina-tions. Replace the stator if insulation resistance isless than 1 megohm (1,000,000 ohms)

Flashing the Field (Self-Excited GeneratorsOnly): If necessary, flash the exciter field before orafter installation. Apply 110 to 220 VAC for one totwoseconds to theXandXX leads of the exciter sta-tor. The generator must be shut down, the AVRdisconnected, a diode used to establish correctpolarity anda3amp fuse topreventover-excita-tion. See the diagram.

Alternatively, while the set is running and discon-nected from all loads, apply a 12 VDC battery forone to two seconds as shown in the diagram.Polar-ity must be correct: + to X, -- to XX.

MEASURE WINDINGINSULATION RESISTANCEBETWEEN EITHER LEAD

AND THE STATORLAMINATIONS

MEASURE WINDINGRESISTANCE BETWEEN

THE TWO STATORLEADS, X AND XX

X

XX

110 to 220VAC

DIODE

EXCITERSTATOR

APPLY 110 TO 220 VAC TO THE EXCITERSTATOR FOR 1 TO 2 SECONDS WITH THEAVR DISCONNECTED AND THE SET NOT

RUNNING

3 AMPFUSE

X

XX

12 VDCBATTERY

DIODE

EXCITERSTATOR

ALTERNATIVELY, APPLY 12 VDC FROM ABATTERY TO THE EXCITER STATOR FOR 1TO 2 SECONDS WITH THE AVR CONNECTEDAND THE SET RUNNING WITHOUT LOAD

+

--

AVR

— FLASHING THE FIELD (SELF-EXCITED GENERATORS ONLY) —

FIGURE 6-2. TESTING AND FLASHING THE EXCITER STATOR

6-3

Exciter Rectifier Bridge (Rotating RectifierAssembly)

Theexciter rectifier bridge ismountedon theexciterrotor, inboard, facing the main rotor. It consists of apositive plate and a negative plate, split diametri-cally. Each carries three diodes, three terminalposts for connecting exciter rotor leads to the diodepigtails and a terminal for the main rotor (generatorfield) lead. A surge suppresser is connected acrossthe two plates to prevent transient voltages thatcould damage the diodes.

TestingDiodes:Disconnect the diode pigtails fromthe terminal posts. Using an ohmmeter, measureelectrical resistancebetweeneachdiodepigtail andthe plate on which the diode is mounted. Reversethe meter test probes and repeat the tests. Theelectrical resistance across each diode should behigh in onedirection and low in the other. If the resis-

tance is high or low in both directions, replace thediode.

Replacing Diodes:Make sure the replacement di-ode is of the correct polarity. Disconnect the pigtailfrom the terminal post and unscrew the old diode.Apply heat-sink compound under the headof the di-ode. Make sure the compound does not get on thethreads. Torque thediodes to36 to42 in-lbs (4 to4.8Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm)when reassembling.

Surge Suppresser Testing and Replacement:Remove the suppresser. Replace the suppresser ifit appears to have overheated or if ohmmeter read-ings indicate less than infinite resistance (end ofscale) in both directions. Torque the terminals to 24in-lbs (2.7 Nm) when reassembling.

CAUTION Layers of dust can cause diodes tooverheat and fail. Brush dust off regularly.

TERMINAL(ONE OF SIX)

DIODE (ONE OF SIX)DISCONNECT THE

DIODE PIGTAIL FROMTHE TERMINAL AND

MEASURE ELECTRICALRESISTANCE BETWEENTHE PIGTAIL AND THEMETAL PLATE UNDER

THE DIODE

SURGE SUPPRESSERREMOVE TO TEST

DIODE PLATES(TWO)

FIGURE 6-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

6-4

Exciter Rotor

Testing Winding Resistance: Disconnect the sixrotor winding leads from the terminal posts on therectifier assembly. With a Wheatstone bridge,measure electrical resistance across each pair ofrotor windings: U (CR1 or CR4) and V (CR2 orCR5), V (CR2 or CR5) and W (CR3 or CR6), W(CR3 or CR6) andU (CR1 or CR4). See thewinding

schematic. Replace the whole rotor shaft assemblyif the resistance of any winding is not as specified inTable 6-1.

Testing Winding Insulation Resistance: Usingan ohmmeter,measure the resistance betweenanyrotor winding lead or the terminal to which it isconnected and the rotor laminations. Replace thewhole rotor shaft assembly if insulation resistanceis less than 1 megohm.

WINDING SCHEMATIC

MEASURE WINDINGINSULATION RESISTANCEBETWEEN ANY LEAD ORTHE TERMINAL TO WHICHIT IS CONNECTED AND

THE ROTOR LAMINATIONS

DISCONNECT THE SIXROTOR WINDING LEADSFROM THEIR TERMINALS

AND MEASUREELECTRICAL RESISTANCEACROSS EACH PAIR OFWINDINGS: U-V, V-W,W-U

MAIN ROTORLEADS

FIGURE 6-4. TESTING THE EXCITER ROTOR

6-5

Main Rotor (Generator Field)

Testing Winding Resistance: Disconnect the twoleads of the main rotor from the terminals on the ro-tating rectifier assembly. See Figure 6-4. Measureelectrical resistance between the two leads with aWheatstone bridge or digital ohmmeter. Replacethe rotor if the resistance is not as specified in Table

6-1. Connect the rotor leads and torque the termi-nals to 24 in-lbs (2.7 Nm) when reassembling.

Testing Winding Insulation Resistance: Usingan ohmmeter, measure the resistance betweeneither lead of the main rotor windings, or the termi-nal to which it is connected, and themain rotor lami-nations. Replace the rotor if insulation resistance isless than 1 megohm.

DISCONNECT THE MAIN ROTOR LEADSFROM THE ROTATING RECTIFIERASSEMBLY AND MEASURE THE

WINDING RESISTANCE BETWEEN THEM

MEASURE WINDING INSULATIONRESISTANCE BETWEEN EITHERROTOR LEAD AND THE ROTOR

LAMMINATIONS

FIGURE 6-5. TESTING THE MAIN ROTOR

6-6

Main Stator

Testing Winding Resistance: Measure electricalresistance across each pair of stator leads (U1-U2,U5-U6, VI-V2, V5-V6, W1-W2 and W5-W6) with aWheatstone bridge or ohmmeter having at least0.001 ohm precision. Replace the stator if the resis-tance of any winding is not as specified in Table 6-1.

Alternatively, winding resistance can be measuredline-to-line at the generator terminals (U-V, V-W,W-U) on “star” connected generators. On a 600 voltgenerator, line-to-line resistance should be twicethe table value (twowinding elements in series). Ona “series star” connected generator, line-to-line re-

sistance should be four times the table value (fourwinding elements in series). On a “parallel star”connected generator, line-to-line resistance shouldbe the same as the table value (two sets of twowinding elements in series). Single phase onlywindings can be measured at W-V and should betwice the table value.

Testing Winding Insulation Resistance: Discon-nect all stator leads and winding taps from their re-spective terminals and make sure the ends do nottouch the generator frame. Using an ohmmeter,measure electrical resistance between any statorleadand the stator laminations. Replace the stator ifinsulation resistance is less than 1 megohm.

THE LAST SIX DIGITS OF THE STATORPART NUMBER ARE STAMPED HERE

WHEATSTONEBRIDGE

FIGURE 6-6. TESTING THE GENERATOR STATOR

6-7

TABLE 6-1. GENERATOR WINDING RESISTANCES

* - These values are approximate, plus or minus 10 percent at 68� F (20� C).** - These values are approximate, plus or minus 10 percent at 77� F (25� C).*** - See Figure 7-6 for the location of the stator part number.

220-4447-06220-4447-07220-4447-08220-4447-09220-4447-10220-4447-11220-4447-12220-4447-13220-4447-14220-4447-15220-4447-16220-4447-17220-4447-18220-4447-19220-4447-20

220-4447-26220-4447-27220-4447-28220-4447-29220-4447-30

220-4448-07220-4448-08220-4448-09220-4448-10220-4448-11220-4448-12220-4448-13220-4448-14220-4448-15220-4448-16220-4448-17220-4448-18220-4448-19220-4448-20220-4448-21220-4448-22220-4448-23220-4448-24(CONT.)

0.0561--0.06200.0466--0.05150.0371--0.04100.0228--0.02520.0181--0.02000.0860--0.09500.0613--0.06770.0480--0.05300.0309--0.03410.0261--0.02890.0561--0.06200.0428--0.04730.0333--0.03680.0228--0.02520.0171--0.0189

0.1354--0.14960.0960--0.10500.0713--0.07880.0485--0.05360.0404--0.0446

0.0209--0.02310.0162--0.01790.0143--0.01580.0095--0.01050.0076--0.00840.0066--0.00720.0260--0.03100.0214--0.02360.0147--0.01630.0114--0.01260.0100--0.01100.0071--0.00790.0204--0.02260.0152--0.01680.0105--0.01160.0090--0.01000.0076--0.00840.0062--0.0068

0.570.640.670.800.930.570.640.670.800.930.570.640.670.800.93

0.570.640.670.800.93

1.111.201.311.501.661.801.111.201.311.501.661.801.111.201.311.501.661.80

20.320.319.519.519.520.320.319.519.519.520.320.319.519.519.5

20.320.319.519.519.5

19.519.519.519.519.519.519.519.519.519.519.519.519.519.519.519.519.519.5

0.1670.1670.1800.1800.1800.1670.1670.1800.1800.1800.1670.1670.1800.1800.180

0.1670.1670.1800.1800.180

0.1800.1800.2100.2100.2100.2100.1800.1800.2100.2100.2100.2100.1800.1800.2100.2100.2100.210

MAIN STATORPART

NUMBER***

MAINSTATOR(OHMS*)

MAINROTOR(OHMS**)

EXCITERSTATOR(OHMS**)

EXCITERROTOR(OHMS*)

6-8

TABLE 6-1. GENERATOR WINDING RESISTANCES (CONT.)

* - These values are approximate, plus or minus 10 percent at 68� F (20� C).** - These values are approximate, plus or minus 10 percent at 77� F (25� C).*** - See Figure 7-6 for the location of the stator part number.

220-4448-31220-4448-32220-4448-33220-4448-34220-4448-35220-4448-36

220-4448-37220-4448-38220-4448-39220-4448-40220-4448-41220-4448-42

0.0413--0.04570.0229--0.03310.0238--0.02630.0181--0.02000.0124--0.01370.0133--0.0147

0.0085--0.00950.0095--0.01050.0074--0.00820.0066--0.00740.0065--0.00730.0131--0.0145

1.111.201.311.501.661.80

2.052.052.052.052.052.05

19.519.519.519.519.519.5

19.519.519.519.519.519.5

0.1800.1800.2100.2100.2100.210

0.2100.2100.2100.2100.2100.210

MAIN STATORPART

NUMBER***

MAINSTATOR(OHMS*)

MAINROTOR(OHMS**)

EXCITERSTATOR(OHMS**)

EXCITERROTOR(OHMS*)

6-9

GENERATOR DISASSEMBLY

The generator is heavy. You will need an assistantand a hoist of sufficient capacity to remove andservice the generator.

WARNING Accidentally dropping the genera-tor can damage it and cause severe personal in-jury and death. The hoist, straps and chainsmust have sufficient capacity and be attachedproperly so that the load cannot shift.

Before starting, disconnect the starting battery ca-bles (negative (-) first) to make sure the set will notstart while working on it.

WARNING Accidental starting of the generatorset while working on it can cause severe injuryor death. Prevent accidental starting by discon-necting the starting battery cables (negative (-)first).

Always remove the negative (-) cable first, andreconnect it last, to prevent arcing if a tool acci-dentally touches the frame or other groundedmetal part while removing the positive (+) bat-tery cable. Arcing can ignite the explosive hy-drogen gas given off by the batteries, causingsevere injury.

Removing The Generator Output Box1. Disconnect the line cables and conduit. For

reconnections later, make sure each cable isclearly marked to indicate the correct terminal.

2. Disconnect the remote control wiring and con-duit. For reconnections later, make sure eachwire is clearly marked to indicate the correctterminal.

3. Disconnect all engine wiring harness connec-tions in the generator control and output boxes.For reconnections later,make sure eachwire isclearly marked to indicate the correct terminal.

4. Disconnect all generator control leads (windingtaps) from connections in the output box. Forreconnections later, make sure each wire isclearly marked to indicate the correct terminal.

5. If the set hasamounted line circuit breaker, dis-connect the cables to the circuit breaker. Forreconnections later, make sure each cable isclearly marked to indicate the correct terminal.

6. Attach a hoist to the generator output box,loosen the mounting bolts on the sides of thegenerator and remove the box.

Withdrawing The Generator From The Set

CAUTION Donot use fan blade to bar overengine. That can damage blades and causeproperty damage and personal injury.

1. The rotor will be carried inside the stator whenthe generator is withdrawn from the engine.Bar the engine until one of the four poles of therotor points straight down so that the rotor willrest on the face of the pole when the generatoris withdrawn.

CAUTION The rotor can be damaged if itrests on the edges of the winding slot be-tween two poles.

2. Attach lifting eyes and a hoist of sufficient ca-pacity (Figure 6-7).

3. Take up hoist slack and remove the twothroughbolts securing the generator to the rub-ber isolation mounts.

4. Raise the generator end approximately oneinch (12mm) and securely block the engine un-der the flywheel housing. Lower the generatorslightly so that the blocks carry most of theweight.

5. Remove the bolts securing the generator drivediscs to the flywheel.

6. Loosen all the bolts securing the generatoradapter casting to the flywheel housing. Adjustthe hoist to carry the full weight of the genera-tor, remove the bolts and pull the generatoraway.

CAUTION Never withdraw the generatorleaving the rotor to hang by the drive discs.The weight of the rotor will damage thedrive discs.

6-10

MAINROTOR ROTATING

DIODEASSEMBLY

EXCITERROTOR

MAINROTORBEARING

STATOR

EXCITERSTATOR

ENDPLATE

COOLINGBLOWER

GENERATORLIFT POINTS

STATORLEADS

CINCHSTRAPAROUND

THE MIDDLEOF THEROTORCORE TO

LIFT

DRIVEDISCS

FIGURE 6-7. GENERATOR ASSEMBLY

6-11

Withdrawing the Rotor From theGenerator1. Remove the generator adaptor casting on the

drive disc end and the end plate on the bearingend.

2. Using a hoist of sufficient capacity, cinch a lift-ing strap on the drive end of the rotor. Lift thebearing end of the rotor by hand and push it to-wards the drive end of the generator until halfthe width of the rotor core protrudes from thestator. Release the weight of the rotor and re-cinch the lifting strap around the middle of therotor core. Withdraw the rotor until it is free ofthe stator, guiding it by hand on both ends toprevent contact with the stator windings

3. Rest the rotor in a cradle, solidly supporting iton two pole faces—not on the drive discs,blower or exciter.

4. Remove the retaining clip if the rotor shaft bear-ing is to be removed.

GENERATOR REASSEMBLY

Reassembling is the reverse of disassembling.Note the following.

1. Apply force to the inner raceof the rotor bearingwhenpressing it onto the shaft, otherwise, it willbe damaged. Be sure to secure the retainingclip.

2. The drive disc-to-rotor bolts should be torquedto 190 ft-lbs (257 Nm).

3. The drive disc-to-flywheel bolts should betorqued to 50 ft-lbs (67 Nm).

4. The exciter stator mounting screws should betorqued to 7 ft-lbs (10 Nm).

5. The generator end platemounting bolts shouldbe torqued to 25 ft-lbs (34 Nm).

6. Make sure the rubber O-ring is in place in thebearing bore in the generator endplate.

7. The generator mounting bracket bolts shouldbe torqued to 65 ft-lbs (88 Nm) if M12 or 35 ft-lbs (47 Nm) if M10.

8. The generator-to-adaptor bolts should betorqued to 40 ft-lbs (55 Nm).

9. The adaptor-to-engine bolts should be torquedto 35 ft-lbs (48 Nm).

10. Reconnect the generator as required. SeePage 10-3 or 10-4.

SERVICING THE PMG

The following is applicable if the generator isequipped with a PMG (permanent magnet) exciter.

Testing

1. Disconnect leads P2, P3 and P4 from the volt-age regulator.

2. Start theengineat the set and let the speedsta-bilize.

WARNING HAZARDOUS VOLTAGE.Touchinguninsulatedhighvoltageparts in-side the control and power output boxescan result in severe personal injury ordeath. Measurements and adjustmentsmust be done with care to avoid touchinghigh voltage parts.

For your protection, stand on a drywoodenplatform or rubber insulating mat, makesure your clothing and shoes are dry, re-move jewelry and use tools with insulatedhandles.

3. Measure voltage across lead pairs P2-P3,P3-P4 and P4-P2. Voltage should be at least150VAC for 50Hzsets andat least 180VAC for60 Hz sets, and should be approximately thesame for each set of leads. If the voltages arelow or uneven, check all the leads and connec-tions between the voltage regulator and thePMG and repair as necessary before disas-sembling thePMG.Note theconnections at theauxiliary terminal board in the power outputbox. See Figure 2-3.

4. Stop the set and measure electrical resistanceacross leadpairsP2-P3,P3-P4andP4-P2withaWheatstonebridgeor digital ohmmeter. Eachwinding should have a resistance of approxi-mately 4.4 ohms.

6-12

Disassembling the PMG

1. Disconnect the starting battery cables (nega-tive (-) first) to make sure the set will not startwhile working on it.

WARNING Accidental starting of the gen-erator set while working on it can cause se-vere injury or death. Prevent accidentalstarting by disconnecting the starting bat-tery cables (negative (-) first).

Always remove the negative (-) cable first,and reconnect it last, to prevent arcing if atool accidentally touches the frameorothergrounded metal part while removing thepositive (+) battery cable. Arcing can ignitethe explosive hydrogen gas givenoff by thebatteries, causing severe injury.

CAUTION Always disconnect a batterycharger from its AC source before discon-necting the battery cables. Otherwise, dis-connecting the cables can result in voltagespikes high enough to damage the DC con-trol circuits of the set.

2. Remove the PMG cover and disconnect theleads at the connector.

3. Remove the bolts and clamps that secure thePMG stator to the generator frame and care-fully pull away the stator.

The rotor is magnetic and will attract the stator.Hold the stator firmly so that the windings arenot damagedbystriking the stator support lugs.

4. Remove the rotor center bolt and pull away therotor. The rotor is magnetic and will attract ironfilings. Put it in a clean plastic bag until it is re-mounted. Do not take it apart or it will lose itsmagnetism. Also, if the dowel pin in the end ofthe shaft is loose, stow it in a safe placeuntil it istime to reassemble the PMG.

Reassembling the PMG

Reassembling is the reverse of disassembling.Torque the rotor center bolt to 40 ft-lbs (54Nm). Thestator leads must be at 12 o’clock.

DOWELPIN

PMGROTOR

PMG STATORCLAMP

SPACERBOLT

COVER

PMGROTOR

THROUGHBOLT

PMGSTATOR

FIGURE 6-8. PMG ASSEMBLY

7-1

7. Day Tank Fuel Transfer Pump and Control

A fuel transfer pump and control are available whena sub-base or in-skid day tank are provided. Theautomatic control operates the fuel pump to main-tain a reservoir of fuel in the day tank.

WARNING Diesel fuel is highly combustible.Improper installation of this kit can lead to spill-

ageof largequantitiesof fuel and lossof life andproperty if the fuel isaccidentally ignited. Instal-lation and service must be performed by quali-fied persons in accordance with the applicablecodes, including environmental regulations.

Donot smoke near fuel and keep flames, sparksand other sources of ignition well away.

539--1189

CONTROL

FUELGAUGE

FLEXIBLE FUELSUPPLY LINE

FLEXIBLE FUELRETURN LINE

DAYTANK

FLOAT SWITCHASSEMBLY

FUEL FILLCAP

FUEL PUMPAND MOTOR

FIGURE 7-1. TYPICAL IN-SKID DAY TANK INSTALLATION

7-2

OPERATION

1. Push the control switch to the ON position forautomatic operation. The green SYSTEMREADY light will come on and the pump will fillthe tank if AC power is available for pumpingand DC power is available for the internal logiccircuits. The level of fuel in the tankwill be auto-matically kept between a set of pump-on andpump-off float switches.

When filling an empty tank, the red LO SHUT-DOWN and LO FUEL lights will come on whenthe control switch is pushed to the ON position.This is normal. Push the panel RESET switch toturn off the red lights after the tank has beenfilled.

If the SYSTEM READY light does not come on,check for correct AC and DC power connec-tions. See Wiring Connections and Fuel PumpMotor Connections below.

2. The green PUMP ON light indicates when thepump is running. It will come on and go off asfuel is pumped to maintain the proper level inthe tank.

3. Push the control switch to the EMERGENCYRUN position (momentary contact) to pump

fuel into the tank if the control fails to operatethe pump automatically.

The green PUMP ON light does not come onwhen the switch is in the EMERGENCY RUN po-sition.

4. The red lights indicate fault conditions and theneed for service. The control panel includes thefollowing lights:

A. HI FUEL: The fuel in the tank has reachedan abnormally high level, indicating possi-ble failure of the pump-off float switch. Thehigh-fuel float switch takes over as theautomatic pump-off switch. The HI FUELlight stayson. The light canbeRESETwiththe panel switch when the fuel level dropsto normal, but will comeback on again dur-ing the next pumping cycle if the fault re-mains.

WARNING Continued operation with aHI FUEL fault present can lead to spill-age of large quantities of fuel if thehigh-fuel float switch fails. Spilled fuelcan cause loss of life and property if itis accidentally ignited, or environmen-tal damage.

HI FUEL (RED)

LO FUEL (RED)

LO SHUTDOWN (RED)

BASIN (RED)

BLANK (RED)

SYSTEM READY (GREEN)

PUMP ON (GREEN)

FIGURE 7-2. FUEL PUMP CONTROL PANEL

7-3

B. LO FUEL: The fuel in the tank hasdropped to an abnormally low level, indi-cating possible failure of the pump-on floatswitch. The lo-fuel float switch takes overas the automatic pump-on switch. The LOFUEL light stays on. The light can be RE-SET with the panel switch when the fuellevel rises to normal, but will come back onagain during the next pumping cycle if thefault remains.

C. LOSHUTDOWN: The fuel has dropped toa level near the bottom of the tank, indicat-ing an empty main fuel tank, pump failureor possible failure of both the pump-onandlow-fuel level float switches. Further op-erationwill allowair to enter the engine fuelunit, causing shutdown and the necessityto bleed the fuel unit to start up the engineagain. Connections should have beenmade to Terminals TB1-14 and TB1-15 toshut down the engine automatically (toground one of four customer fault inputson terminalsA40-TB1-16, 17, 18, or 19). Ifthe light comes on, check the fuel level inthemain fuel tank and fill it if necessary. As

the day tank is refilling, RESET the lightwith the panel switch.

To restore engine operation following thisfault, both the pump control and the PCChave to be RESET.

D. BASIN: Fuel has overflowed into the rup-ture basin (if provided), indicating possiblefailure of both the pump-off and hi-fuellevel float switches, or a leak in the daytank. RESET the control after the fuel inthe basin has been safely disposed of andthe cause of the overflow corrected.

E. BLANK: For customer use.

The control fault circuits will trip and latch,requiring RESET, even if AC power is lost.

5. Press the TEST switch to test the indicatorlights and pump operating circuits. Replaceany light that does not come on. The pump willstop automatically after it has filled the tank tothe normal pump-off fuel level.

6. Press the reset button of the AC or DC circuitbreaker if either has tripped.

7-4

WIRING CONNECTIONS

SeeDayTankPumpControlWiringdiagram inSec-tion 8 when making connections at the control boxterminal board. The following should be noted.

1. The control can be powered by 120VACor 240VAC. The control is set up at the factory for con-nection to 240 VAC.

To convert the day tank controller from 240VAC to 120 VAC, perform the following steps.

A. Remove the two jumpers between termi-nals TB1-6 and TB1-7 in the control boxand connect one between terminalsTB1-5 and TB1-6 and the other betweenterminals TB1-7 and TB1-8.

B. Move selector switch S103 on the controlPCB to the up position for 120V.

C. If the control is equipped with a trans-former, remove the two jumpers betweenterminals H2 and H3 and connect one be-tween H1 and H3 and the other betweenH2 and H4.

To convert the day tank controller from 120VAC to 240 VAC, perform the following steps.A. Remove the jumpers between terminals

TB1-5 and TB1-6, and TB1-7 and TB1-8in the control box and connect the twojumpers between terminals TB1-6 andTB1-7.

B. Move selector switch S103 on the controlPCB to the down position for 240 VAC.

C. If the control is equipped with a transform-er, remove the jumpers between terminalsH1 and H3, and H2 and H4 and connectthe two jumpers between H2 and H3.

2. Attach a tag to the control box indicating thesupply voltage.

3. If a two lead wiring harness is provided, thecontrol does not include a power transformer.To provide 24 VDC for the control circuit, con-nect terminal TB1-19 to the positive (+) termi-nal of the 24 V starter motor solenoid andterminal TB-20 to the negative (-) terminal.

4. To immediately shut down the engine when theLO SHUTDOWN light comes on, connect ter-minal TB1-14 to a good grounding point on theengine block and terminal TB1-15 to terminalA40-TB2-16, 17, 18, or 19 (Customer Fault in-puts). The customer fault input selected, mustbe set for a shutdown operation (refer to SET-UP MENU in Section 5).

5. TerminalsTB1-10 throughTB1-17andTB2-23through TB2-27 are available for connectionsto remote annunciators or to any oneof the fourcustomer fault inputs of the PCC.

6. Terminal TB2-22 is available for connection ofa grounding signal to activate the blank redlight.

7. Terminals TB1-8 and TB1-5 are available forconnection of a 120 or 240 VAC electric fuelshutoff valve rated not more than 0.5 amps.The voltage rating of the valve must corre-spond with the voltage utilized for the pump.See Item 2 above.

7-5

GNDTO A40-TB1-22 (LOW FUEL)TO A40-TB1-16,17,18, or 19 (RUPTURE BASIN)

USE WITH PCC,SEE DETAIL A

DETAIL A

FIGURE 7-3. FUEL PUMP CONTROL TERMINAL BOARD

7-6

FUEL TRANSFER PUMP MOTORCONNECTIONS

Connect a replacement fuel transfer pumpmotor asfollows.

1. Remove the end bell cover for access to themotor wiring terminals.

2. Disconnect the brown lead frommotor terminalP103-3 and connect it to terminalP103-6. (Ter-minal P103-6 is an insulated receptacle for se-curing theendof the leadso that it cannotmoveand touch the motor frame or a live terminaland cause a short circuit.)

3. Disconnect the red lead from motor terminalP103-2. It will be connected to the piggy-back

terminal on the lead connected at motorterminal P103-3.

4. Cut the white lead from its ring connector atmotor terminal P103-4. Strip 1/2 inch (12 mm)of insulation from the end of the white motorlead for splicing to the wire harness leadmarked P103-WHITE.

5. Connect each lead of the five-lead wiring har-ness to themotor terminal or leadmarked on it.

6. Connect the red motor lead to the piggy-backterminal at motor terminal P103-3.

7. Secure the end bell cover.

FIGURE 7-4. FUEL TRANSFER PUMP MOTOR CONNECTIONS

7-7

TESTING THE FLOAT SWITCH ASSEMBLY

The float switch assembly consists of 5 switches.Each switch has a pair of color coded leads con-nected to a common jack.

To test the float switches, remove the fuel pumpcontrol cover, disconnect the wiring jack and un-screw the assembly from the top of the day tank.Test as follows:

1. With an ohmmeter, test for electrical continuity(switch closed) between each pair of coloredleads, while holding the assembly vertical. Re-place the assembly if any switch is open (all thereadings should be zero).

2. Lift each float, in turn, to 1/8 inch (3 mm) belowthe C-clip stop above it (use a feeler gauge)and test for electrical continuity. Replace theassembly if any switch does not open (all thereadings should be infinity).

3. Use pipe thread sealant when replacing the as-sembly.

SWITCH 1 -- SHUTDOWN

SWITCH 2 -- LOW FUEL

SWITCH 3 -- PUMP ON

SWITCH 4 -- PUMP OFF

SWITCH 5 -- HI FUEL

SWITCH 5

SWITCH 4

SWITCH 3

SWITCH 1

SWITCH 2

J5

J5

FIGURE 7-5. FLOAT SWITCH ASSEMBLY

8-1

8. Initial System Startup

GENERAL

Do not perform any procedure inthis section on medimum voltage (601 through15,00 volts) generator sets. Special equipmentand training is required to work on or aroundmedium voltage equipment. Operation andmaintenance must be done only by personstrained and qualified to work on such devices.Improper useor procedureswill result in severepersonal injury or death.

This section describes aprocesswhichcanbeusedin the initial startup and test of generator sets whichare paralleled using PowerCommand Digital Paral-leling controls. PowerCommand Digital Parallelingsystemshavemany functionswhich are common totraditional paralleling systems, but they are com-pletely different in the way that these functions aresupplied in the system. The intent of this section isto provide you with guidance in the initial running ofthe equipment, so that you canperform this functionwith as safe and efficient procedures as possible.

The accessory box of the Power-CommandControl containshighvoltageswhenthe generator set is running. It can be energizedfrom the system bus and contain high voltageseven when the generator set is not running.Contacting these high voltage components willcause severe injury or death. Do not attempt toservice, operate or adjust the control unlessyou have been trained in proper service tech-niques.

THE STARTUP PROCESS

The startup process described in this section is typi-cal for paralleling systemswhich utilize PowerCom-mand Digital Paralleling equipment. Every parallel-ing system is different in its design and application,so portions of the recommended procedures maybe inappropriate for your application, or some pro-

cedures may be needed which are not described inthis section. Use your experience as the best guidefor enhancing these general guidelines to providethe best process for the specific site which you areservicing.

In general, the startup process contains these ma-jor steps:

� Installation design review, including mechani-cal and electrical support systems for the gen-erator sets and paralleling equipment.

� Individual generator set preparation, operationand performance review.

� Manual system operation.� Automatic system operation and adjustments.� Black start testing of system.� Customer acceptance testing.� Customer training.� Issuing an installation report showing the workdone, system performance and customer ac-ceptance.

EQUIPMENT APPLICATION REVIEW

The purpose of the equipment application review isto visually inspect the installation to confirm that theequipment has been installed within specified pa-rameters and that the equipment can be started asspecified. Onan technical application manualsT-030 Liquid-Cooled Generator Sets and T-016Paralleling and Paralleling Switchgear provideguidance in evaluating installation requirements. Itis recommended that you use an installation reviewreport form, included at the end of this section, toavoidmissing anymajor points in the equipment re-view and simplify reporting of problem areas to theinstaller or customer.

The system startup process should not proceed un-til the inspection and review are complete and all is-sues resolved.

8-2

INDIVIDUAL GENERATOR SET STARTUP

The generator set should be properly serviced, withproper levels of coolant and lubricants in the sys-tem. Care should be taken to remove all shippingblocks and braces from the equipment. Completeall pre-start service and checks as for a standardnon-paralleled generator set.

Equipment needed to perform the startup:

� Two properly calibrated hand-held digital me-ters.

Be certain that the meters are rated for use on acircuit operating at proper voltage.

� Phase rotation meter.

� PowerCommand service tool kit.

� Individual generator set and system drawings,specific to the project being installed. Opera-tor’s manual, including PC program documen-tation, if available.

A two channel strip chart recorder with voltage andfrequency modules is helpful, but not required forthe startup.

Operate the generator set RUN/OFF/AUTO switchto the OFF position. Connect the generator setstarting and control batteries at their proper loca-tions and verify that no fuses are blown (indicatingimproper connections in the system). Verify that thestationary battery chargers are properly installedand wired and turn them on.

If the system includes amaster control panel, verifythat control power is present in the master controland operate the system mode select switch to themanual operation position, so that the system doesnot inadvertently receive a start signal. If the systemincludes a touchscreen, PLC bridge/MUX or net-work interconnections, verify that these are all func-tional.

Check the settings of the paralleling control func-tions. Typical values for these functions are shownin Table 8-1. If the generator set was tested in paral-lel at the factory, do notmodify these adjustments atthis time. Check the factory test report to verify thatthe settings of the control match the test report.

For paralleling applications, the default value of thegovernor gain should be set to 70. See Section 5 -Governor/Regulator menu for more information.Generator sets that are shipped from the factorywithout Onan parallel gear are set up as single units.For multiple unit paralleling applications you mustreconfigure the control. See Section 5 - ParallelingSetup menu.

TABLE 8-1. TYPICAL PARALLEL SET-UPPARAMETERS

FUNCTION TYPICAL SETTING

ISOLATED BUS PARAMETERSSYNC TIME LIMIT 120 seconds-- PWR LIMIT 10 percent-- PWR LIMIT (TIME) 3 secondsPERM WIN-PHASE � 20 degrees (ISO bus)

� 15 degrees (utility)

PERM WIN-TIME 0.5 seconds

SYNC GAIN 95SYNC INTEGRAL 12KW BALANCE 165KVAR BALANCE 0KW GAIN 6KVAR GAIN 3001ST START FAIL 10 secondsRAMP UNLD TIME 30 secondsRAMP UNLD LEVEL 5 percentRAMP LOAD TIME 30 secondsLOSS FIELD TIME 2 seconds

UTILITY PARAMETERSBASE LOAD % 80 percentPF LEVEL 1.00KW GOVERN GAIN 100KW INTEGRAL 4KVAR GOVERN GAIN 300KVAR INTEGRAL 200RAMP LOAD TIME 10 secondsRAMP UNLD TIME 10 seconds

8-3

Connect a jumper to the idle terminals of the gener-ator set in the accessory box, so that it will start andrun initially at idle speed.

Verify that starting the generator set and energizingthe system bus will not cause hazards to other per-sons working in the vicinity of the equipment, or di-rectly on the equipment or anything electrically con-nected to the equipment. Notify responsible per-sons in the building that the equipment may be en-ergized and operating at any time.

Start the generator set by operating the RUN/OFF/AUTO switch to the RUN position. The generatorset should start andaccelerate to idle speed. An idlemodealarmshould appear on thegenerator set dig-ital display panel. Allow the generator set to run atidle, taking care to note unusual noises or vibrationfrom the engine or alternator, leaking fluids or ex-haust connections. Run thegenerator set at idle un-til the coolant temperature is greater than 100 de-grees F (40 degrees C) Make any corrections nec-essary prior to continuing with the startup process.

Stop the generator set and remove the idle speedjumper from the accessory box interconnection ter-minal block. Start the generator set by operating theRUN/OFF/AUTO switch to the RUN position andobserve it accelerating to rated frequency and volt-age. Calibrate and adjust all generator set metering(if necessary) using the hand-held digital meter andtheprocedure inSection 5of thismanual. Adjust thegenerator set to proper voltage and frequency. Re-cord the values of voltage and frequency so that allunits can be adjusted to the same values. Remem-ber to save all changes and adjustments prior toswitching off the generator set.

Make sure that the paralleling breaker is chargedand ready to close (power circuit breakers only) andthat theparalleling bus is de-energized. If thebreak-er is not charged, manually charge the breaker.Manually close the paralleling breaker for the gen-erator set. Most paralleling breakers will automati-cally re-charge on closing (power circuit breakersonly). When the charging cycle is complete, electri-cally open the breaker using the breaker open con-trol switch on the front of the PowerCommand con-trol. Close the breaker using the breaker close

switch on the front of the PowerCommand control.Verify proper functioning of the breaker open andclose lamps on the PowerCommand Control andproper operation of the manual breaker controlswitches on the PowerCommand control.

Use extreme cautionwhen perform-ing phase relationship testing. The system isenergized and dangerous voltages are presentinmany locations. Contactwith energizedpartswill cause serious injury or death. Do not at-tempt these tests unless you have properequipment for testing and are trained in its safeuse.

Verify that the phase rotation of the generator setmatches the phase rotation of the utility service ateach transfer switch or breaker power transfer pair.Correct generator set phase rotation tomatch utilitycondition, if required, by reversing the phase L1 (Aor U) and L2 (C orW) connections on the generatorset output.

Note: The purpose of this procedure is to make surethat the generator set output matches the bus phaserelationship. Later in the startup process the wiringand interconnection of the bus and generator set PTmodules will be verified. Note that the PT/CTmodulephases must be matched to the generator set phasechanges, or a FAIL TO SYNCHRONIZE alarm will oc-cur.

If a master control is used in the system, make surethat the main bus metering is functioning and prop-erly calibrated.

Using the loadbank or available loadon thesystem,check the generator set load carrying ability and thetransient performance of the generator set. Adjustas necessary for proper generator set operation.Disconnect the load from the system.

Make sure that all alarm and shutdown circuits inthe generator set are functioning properly. Shutdown the generator set by switching the RUN/OFF/AUTO switch to OFF.

Repeat the process described in this section foreach generator set in the system before moving onto the next step of the startup process.

8-4

MANUAL SYSTEM OPERATION

Once all generator sets in the system have beensuccessfully run individually, the generator sets areready for verification of manual paralleling capabili-ty.

Make sure that all generator set RUN/OFF/AUTOcontrol switches are placed in the OFF position andthat the master control switch (if used) is also in themanual mode position.

Operate the control switch of one generator set tothe RUN position and allow the generator set tostart and accelerate to rated speed and voltage.Manually close the paralleling breaker on this gen-erator set by pushing the breaker close pushbuttonon the front face of the PowerCommand control. Al-low the generator set to run at no load for the firstphase of the manual paralleling test.

Use extreme cautionwhen perform-ing phase relationship testing. The system isenergized and dangerous voltages are presentinmany locations. Contactwith energizedpartswill cause serious injury or death. Do not at-tempt these tests unless you have properequipment for testing and are trained in its safeuse.

Check the phase relationship of the generator setoutput to its Bus PTmodule. The voltage differencebetween the L1 phase on the input to the Bus PTboard and the generator set PT/CTboard should bezero. Repeat this process for each generator set inthe system.

Make sure that all generator set RUN/OFF/AUTOcontrol switches are placed in the OFF position andthat the master control switch (if used) is also in themanual mode position.

Operate the control switch of one generator set tothe RUN position and allow the generator set tostart and accelerate to rated speed and voltage.Manually close the paralleling breaker on this gen-

erator set by pushing the breaker close pushbuttonon the front face of the PowerCommand control.Check the phase relationship of the generator setwhich is closed to the bus, with each individual gen-erator set. This can be accomplished by starting thesecondgenerator set in the systembyoperating theRUN/OFF/AUTOcontrol switch to theRUNpositionand allow the generator set to start and accelerateto rated speed and voltage.Whengenerator set fre-quency and voltage have stabilized, operate thedisplay screenof thePowerCommandcontrol to thevoltage and frequency screens and use the digitaldisplay to verify that the generator set voltage andfrequency matches the bus voltage and frequency.

Switch the display screen to the digital synchro-scope (bus frequency) screen andobserve the con-trol phase relationship between the generator setand the bus.When the phase relationship of the on-coming generator set is within the acceptance pa-rameters programmed into the control, an asterisk(*) will be displayed on the screen next to the phasedifference display.

When the asterisk is displayed on the control panel,check the phase relationship between the genera-tor set and the bus. With the hand-held digital volt-meter, check the voltage from the line side to theload side for each phase of the open parallelingbreaker on twophases simultaneously (Figure 8-1).If the phase relationship is proper, the voltageacross the breaker (with the breaker open) shouldbe zero, or nearly zero on both phases when the”synchronized” indicator lamp is on. The voltage ofthe twometers should rise and fall at approximatelythe same time.

Note: If the generator set output phase rotationmatches the bus and a PHASE ROTATION warningappears when you attempt to close the parallelingbreaker, you should check the generator set andBusPT boards for proper wiring and interconnection.Both the primary and secondarywiring in the BusPTboard should be checked. See Table 4-27.

8-5

Power Command Control

Accessory Box

Bus PTBoard (A39)

PT/CTBoard (A36)

VM2

VM1

CB

(Open)

To Load Bus

FIGURE 8-1. CHECKING PHASE RELATIONSHIP BETWEEN GENERATOR SET AND SYSTEM BUS

Note: For applications where a wye connected gen-erator set is paralleled to a delta connected bus, thegenerator neutral bus must be floating and the neu-tral connection to the bus PT module must not beused.

8-6

Make sure that the “charged” flag is present on theparalleling breaker and push the breaker closepushbutton on the PowerCommand Control tomanually close the oncoming set paralleling break-er and paralleling the generator set to the systembus.

Note: The breaker close function operates through apermissive relay function in the PowerCommandControl, so the paralleling breaker will not close un-less the generator set is properly synchronized withthe system bus.

Perform the phase rotation verification on eachgenerator set in the system, prior to attempting toclose it to the live parallel bus for the first time.

When all generator sets have been closed to thebus, observe the voltage, frequency, amp load andkilowatt load on each generator set metering set.The metering should indicate identical voltage andfrequency readings on all generator sets in the sys-tem. Amp and kilowatt readings should all be zero.With no load on the system, a positive amp loadreading on generator sets indicates a voltage differ-ence between the generator sets in the system. A

positive kilowatt reading on any generator set indi-cates a frequency misadjustment on at least onegenerator set. Perform adjustments necessary toeliminate circulating currents and kilowatt loads.Save the generator set adjustments made prior toswitching off the generator set.

With all generator sets running in parallel in manual(RUN) mode, apply available load to the system.Observe load sharing levels on the generator sets.The units should share load proportionally. (The%load and%amps meters on the PowerCommandcontrol should all read within plus or minus 5% ofeach other.)

Adjust load sharing parameters within control sys-tem to achieve proper load sharing. Save allchanges.

If possible, operate the system at various load lev-els and verify proper operation at each level.

Remove all load from the system and return thegenerator sets to their normal automatic mode byplacing the RUN/OFF/AUTO switch in the AUTOposition.

8-7

AUTOMATIC SYSTEM OPERATION

If the system includes amaster control panel, movethe mode selection switch on that panel to the fullautomatic position.Operate the test switch to causethe system to automatically start and parallel allgenerator sets.

The generator sets should automatically start, ac-celerate to rated speed and voltage, synchronizeand parallel on the system bus. As the generatorsets synchronize and close to the system bus, ob-serve the operation of the loadadding (priority) con-trol relays in the master control. (If load add controlrelays are provided.) Observe and record the timeto synchronize for each generator set.

With all the generator sets running and closed to thesystem bus, apply load to the running generatorsets, but at a low enough level that all the generatorsets need not be running in order to carry the busload. On one generator set, ground the Load De-mand contact in the accessory box. The followingsequence should then occur:

� The ”LOAD DEMAND” shutdown messageshould be displayed on the PowerCommanddigital display panel.

� The load should ramp down on the generatorset to its minimum set point level.

� The generator set paralleling breaker shouldopen.

� The generator should run for its normal cool-down period and then shut down.

When the unit has shut down, remove the groundsignal on the Load Demand termination point. Thegenerator set should start, build up to rated frequen-cy and voltage, synchronize and parallel to the sys-tem bus. When it has closed to the bus, it shouldramp up to its proportional share of the total busload.

Repeat the load demand test for each of the gener-ator sets in the system.

Switch off the test switch in the master control. Allthe paralleling breakers should simultaneouslyopen and the generator sets should run for a cool-down period and shut down.

Simulate a remote start in the master control. Thegenerator sets should automatically start, acceler-ate to rated speed and voltage, synchronize andparallel on the system bus. Remove the remotestart jumper on the master control. The generatorset paralleling breakers should all open and thegenerator sets should run for a cooldown periodand shut down.

At this point the various control functions of themaster control can be tested and verified. Consultthe project drawings and specifications or approvedsubmittal documents for details on master controlfunctions and requirements.

8-8

BLACK START TESTING

The black start testing process is designed to dem-onstrate that the entire on-site power system isinstalled correctly and that system support equip-ment, such as day tanks, fuel pumps, or supple-mental ventilation equipment, is designed andinstalled correctly. It is primarily used in applicationswhere the paralleling system is intended to provideemergency power in the event of a normal utility(mains) power failure. The black start testing pro-cess is performedafter the entire on-site power sys-tem is installed. This testing process is often per-formed in conjunction with the customer approvaltesting, since itmay bedisruptive to the operation ofthe facility and demand special arrangements toavoid potentially dangerous or costly power failuresin the facility.

The specific details of this testing process are verydependent on the design of the electrical and me-chanical systems of the facility. In general the stepsin this process are as follows:

� A power failure is simulated in the facility byopening the main power feeder in the building.It is desirable to do this to be certain that criticalloads such as fuel pumps are fed from both thegenerator and utility (mains) bus.

� The generator sets start and parallel. The timerequired for the generator sets to start and par-allel should be recorded and noted on the finaltest report for the system.

� Observe operation of all power transfer de-vices, noting the time required to transfer.

� The generator sets should be run in parallelwith all available load in the building, at a mini-mum of approximately 30% of their standbyKW rating. The duration of the test should besufficient for the generator sets to reach theirnormal operating temperatures. The load de-mand system (if provided in the systemmastercontrol) should be shut down until all generatorsets in the systemhave reached normal opera-tion temperatures and their operation tempera-

tures have stabilized. During this process, datashould be gathered to demonstrate the loadapplied and the operational performance of thesystem. It is customary to document the gener-ator set performance during this period, by re-cording all values on all meters and enginemonitors every 15 minutes.

� When all required customer testing and verifi-cations have been performed, return the sys-tem to normal power by restoring utility (mains)power at the point where it was disconnected.

� Verify that the generator sets and power trans-fer devices all return to their normal ready-to-start states.

TEST REPORTS AND ACCEPTANCE

The technician performing the system startupshould issue a start up and test report to documentthe work performed and demonstrate that the sys-tem is functional and operational. The exact re-quirements of this report will vary depending oncustomer requirements, but should include, as aminimum:

� The application and review and evaluation. Acopy of the site review checklist performed atthe start of the testing process might be in-cluded to document this step of the process.

� A copy of the startup check list (a typical checklist is included at the end of this section), docu-menting the functions tested and that eachfunction performed properly.

� Test data sheets documenting results of loadtesting.

� List of all the settings of each generator setcontrol.

� Black start test results.� Certification that the system is operational andready to run.

� It is customary for an owner’s representative toreview and sign all test documents, indicatingacceptance of the test data and system perfor-mance.

8-9

ON SITE POWER SYSTEM APPLICATION REVIEW (DIESEL/600VAC AND LOWER)

Date: ___________ Location: __________________________________________________________

Owner/Operator: ______________________________________________________________________

Generator Set Model: ____________________ Serial Number: ____________________

Transfer Switch Model: ____________________ Serial Number: ____________________

Project/Order Number: ________________________________________

Review Performed By: _____________________________

Mounting/Noise/Isolation

[ ] Flexible power output conduit, supported by bldg.[ ] Isolators/pad (integral to set)[ ] Isolators/pad (external to set)[ ] Isolators/spring-pad, adjusted correctly[ ] Flexible stainless steel exhaust connection[ ] Flexible fuel lines (supply& return), secured[ ] Flexible power output conduit, supported by bldg.[ ] Flexible auxiliary power connections[ ] Flexible control connections[ ] Flexible exhaust air duct[ ] Seismic restraints (where required)[ ] Provisions for draining oil/coolant[ ] Clearance around genset (3ft/1 meter min.)[ ] Fire alarm provisions[ ] System covers/shields all in place

Exhaust

[ ] Silencer close to genset[ ] Exhaust connections sealed[ ] Exhaust insulated[ ] Proper personnel protection provided[ ] Exhaust run slopes away from genset[ ] Condensate trap with valve on exhaust silencer[ ] Provisions for thermal expansion[ ] Raincap/birdscreen on exterior of building[ ] Exhaust thimble[ ] Correct pipe size, supported by building[ ] Facility vent air intake, windows, doors not close to

exhaust outlet[ ] No combustible materials, or fire system

components near uninsulated pipe

Cooling System

[ ] Filled with soft water/E.G./DCA mixture[ ] Jacket water heater provided[ ] Valves to isolate jacket water heater[ ] Power supply to heater from normal power

Ventilation System

[ ] Inlet air duct properly sized (approx. 1.5x radiator)[ ] Exhaust air duct properly sized (effective open area

not less than radiator area)

[ ] Heat sources in room insulated[ ] Recirculation of radiator exhaust air unlikely[ ] Access door to room opens in (or vented)[ ] Vent dampers powered from emergency power

supply[ ] Direction of prevailing winds

Fuel System

[ ] Piping is not galvanized or copper[ ] Manual shut-off valve[ ] Solenoid valve on fuel supply, power from set[ ] Fuel returns to main tank[ ] Fuel line size adequate[ ] Fuel line high loops[ ] Day tank/vent at highest point[ ] Day tank/location below return lines[ ] Day tank/strainer-filter[ ] Day tank/level alarms[ ] Main fuel tank below set[ ] Fuel transfer pump/power from genset[ ] Main fuel tank above set[ ] Solenoid valve[ ] Sub-base tank[ ] Level gage[ ] Vent

Electrical System

[ ] Control connections isolated from power[ ] Control connections use stranded wire[ ] Conductor size OK (power & control)[ ] Proper battery size/filled with electrolyte[ ] Battery rack isolated from floor[ ] Battery charger/power from utility[ ] Start signal wired to ATS[ ] Generator frame grounded (bonded)[ ] Neutral connection (where/how)[ ] Power/control conductors torqued[ ] Wiring accuracy/matches drawings

Other

[ ] Oil installed in engine[ ] Posted operating instructions[ ] Generator/ATS manuals, drawings provided[ ] Generator room/control boxes cleaned

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