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PowerCommand Control3200 Series

Generator Sets

Printed in U.S.A. 960-0521 02-2004

Service Manual

ModelsDFEG, DFEH, DFEJ, DFEK

i

Table of Contents

SECTION TITLE PAGE

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

1 INTRODUCTION

About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test Equipment 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How To Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

General 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sequence of Operation 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Power On/Off Modes 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Panel Assembly 2-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reading Fault Codes 2-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Display and Switches 2-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Menu Units Selection 2-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Menu 2-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Submenus 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator Submenus 2-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Submenu 2-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . History/About Submenus 2-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parallel Data Submenu 2-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transfer Main/Submenus 2-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility (PWR TRAN) Submenus) 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Status (PWR TRAN) Submenus) 2-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transfer Control (PWR TRAN) Submenu) 2-21. . . . . . . . . . . . . . . . . . . . . . . . . . Genset (PWR TRAN) Submenus) 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CONTROL CALIBRATION AND ADJUSTMENTGeneral 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Modifying Setup/Adjust Submenus 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setup Menus 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governing/Volt Reg Submenu 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Customer Faults Submenus 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Submenus 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Isolated Bus/Utility Submenus (Paralleling Application) 3-7. . . . . . . . . . . . . . . Isolated Bus Submenus 3-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Submenus 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

SECTION TITLE PAGE

3 CONTROL CALIBRATION AND ADJUSTMENT (CONT.)Power Transfer Control Main Menus 3-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Utility Sensors Submenus 3-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Genset Sensors Submenus 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Timers Submenu 3-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test/Exercise Submenu 3-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Submenu 3-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Procedure 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Box Wiring 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Run Relays (K11, K12, K13) 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alarm Relay (K16) 3-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magnetic Speed Pickup Unit (MPU) Installation 3-26. . . . . . . . . . . . . . . . . . . . .

4 SERVICING THE GENERATOR

Testing the Generator 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator/PCC Control Isolation Procedure 4-2. . . . . . . . . . . . . . . . . . . . . . . . . Exciter Stator 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exciter Rectifier Bridge (Rotating Rectifier Assembly) 4-4. . . . . . . . . . . . . . . . Exciter Rotor 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Rotor (Generator Field) 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Stator 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test the PMG 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Disassembly 4-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Reassembly 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Generator Mount Pre-Load Adjustment 4-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . Aligning Generator with Engine 4-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPTIONAL ENCLOSURE FUEL TANK SYSTEM

General 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Connections 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Transfer Pump 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Fuel Fill Box 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External Alarm Panel 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rupture Basin Leak Detect Switch Test 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 WIRING DIAGRAMS

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

LS-14Liii

IMPORTANT SAFETY INSTRUCTIONS

SAVE THESE INSTRUCTIONS − This manual containsimportant instructions that should be followed duringinstallation and maintenance of the generator and batter-ies.

Before operating the generator set (genset), read theOperator’s Manual and become familiar with it and theequipment. Safe and efficient operation can beachieved only if the equipment is properly operatedand maintained. Many accidents are caused by failureto follow fundamental rules and precautions.

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

This symbol warns of 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 person-al 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 use zinccoated or copper fuel lines with diesel fuel.

• 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.

• 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 an engine to overspeed andbecome difficult to stop, resulting in possible fire, explo-sion, severe personal injury and death. Do not operate agenset where a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset isequipped with an automatic safety device to block the airintake and stop the engine. The owners and operators ofthe genset are solely responsible for operating the gen-set safely. Contact your authorized Cummins PowerGeneration distributor for more information.

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. Do notwear jewelry. Jewelry can short out electrical con-tacts and cause shock or burning.

• 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 DIRECT-LY TO ANY BUILDING ELECTRICAL SYSTEM.Hazardous voltages can flow from the generator setinto the utility line. This creates a potential for elec-trocution or property damage. Connect onlythrough an approved isolation switch or an ap-proved paralleling device.

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.

• 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.

• Keep multi-class ABC fire extinguishers handy.Class A fires involve ordinary combustible materialssuch as wood and cloth; Class B fires, combustibleand flammable liquid fuels and gaseous fuels; ClassC fires, live electrical equipment. (ref. NFPA No. 10).

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

• Make sure generator set is mounted in a manner toprevent combustible materials from accumulatingunder the unit.

• 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.

• Do not store any flammable liquids, such as fuel,cleaners, oil, etc., near the generator set. A fire orexplosion could result.

• Wear hearing protection when going near an oper-ating generator set.

• To prevent serious burns, avoid contact with hotmetal parts such as radiator, turbo charger and ex-haust system.

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

1-1

1. Introduction

ABOUT THIS MANUAL

This manual provides PowerCommand Control3200 (PCC) calibration and adjustmentprocedures, control operation, alternator test andrepair procedures.Operating and maintenance instructions are in theapplicable Operator’s Manual. Generator settroubleshooting and repair (control and engine)information is provided in the following manuals.

• Troubleshooting and Repair Manual Power-Command Control QSX15, QSK45, QSK60Generator Sets, Bulletin No. 3666394

• Operation and Maintenance Manual QSX15Series Engines (engine repair and service)Bulletin No. 3666423.

Read Safety Precautions and carefully observe allinstructions and precautions in this manual.

TEST EQUIPMENT

To 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.

• Battery Hydrometer

• Jumper Leads

• Tachometer or Frequency Meter

• Wheatstone Bridge or Digital Ohmmeter

• Variac

• Load Test Panel

• Megger or Insulation Resistance Meter

HOW TO OBTAIN SERVICE

Always 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 trained and experienced to per-form electrical and mechanical service. Readand follow Safety Precautions, on pages iii andiv.

Copyright 2004 Cummins Power Generation. All rights reserved.

Cummins and PowerCommand are registered trademarks of Cummins Inc.

1-2

THIS PAGE LEFT INTENTIONALLY BLANK

2-1

2. Control Operation

GENERAL

The following describes the function and operationof the PowerCommand Control 3200 (PCC). All in-dicators, control switches/buttons and graphicaldisplay are located on the face of the control panelas illustrated in Figure 2-1.

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. Setupand calibration procedures are described in Sec-tion 3.

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 controlwill initiate a starter cranking signal and verify thatthe engine is rotating. The control will provide suffi-cient fuel to the engine to accelerate to start discon-nect speed. On reaching that speed, the control willramp the generator set to idle (warm-up) or ratedspeed and voltage.

On reaching rated speed and voltage, the controlchecks the system bus voltage. If no bus voltage is

present, it will wait for a pulse from a remote MasterFirst Start Sensor. On receiving that pulse, the con-trol will signal the paralleling breaker to close.

If bus voltage is present, the control will check forproper phase rotation, adjust the generator set tothe bus voltage and frequency level, and then syn-chronize the generator set to the system bus. Whena synchronous condition is achieved, the control willsend a signal to close the paralleling breaker.

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

CONTROL PANEL POWER ON/OFFMODES

The power on/off modes of the control panel and op-erating software are Power On, Screen Saver andSleep/Awake.

Power On Mode: In this mode, power is continu-ously supplied to the control panel. The control’soperating software and control panel LEDs/graphi-cal display will remain active until the Screen Savermode is activated.

2-2

Screen Saver Mode: Power to the graphical dis-play will be removed after 10 minutes (generator setnot running or running). The 10 minute timer resetsand begins after each control panel action (any but-ton or switch selection) or signal received by the op-erating software. The bottom LEDs of the AnalogAC Metering Panel (bar graphs) may remain on dur-ing Screen Saver mode, indicating that the operat-ing software is active (Awake mode).

When a “Warning” signal is sensed by the PCC (forexample, low coolant temp), the control will displaythe warning message. The control will remain activeuntil the Fault Acknowledge button is pressed toclear the warning message and start the 10 minutetimer.

Sleep/Awake Mode: In the Sleep mode, the con-trol’s operating software is inactive and the LEDsand the graphical display on the control panel are alloff. Sleep mode is a feature that is used to reducebattery power consumption when the control is inthe Auto mode and is not being used.

When all conditions are met (i.e., no unacknowl-edged faults, Screen Saver Mode is active, and O/

Manual/Auto switch is in the Auto position) theSleep mode will be activated.

The operating software is initialized and the controlpanel LEDs and graphical display is turned on in re-sponse to one of the following:

• moving/pressing any control panel switch/but-ton.

• a remote start input signal (generator set inAuto mode), or

• customer fault 2 or 3 only (shutdown or warningindicator is on).

To activate the control and view the menu displaywithout starting the generator set, press any buttonon the control panel.

The InPower service tool is required to enable ordisable the Sleep mode. When shipped from thefactory, the Sleep mode is disabled. When disabled,the operating software will always remain active(Awake mode) when the control is in Auto mode.

InPower service tool is required to selected desiredmode.

2-3

DISPLAY MENUSELECTION BUTTONS

(1 of 6)

0/MANUAL/AUTOSWITCH

REMOTE START,NOT IN AUTO,SHUTDOWN,

WARNINGSTATUS INDICATORS

GRAPHICALDISPLAY

ANALOG ACMETERING

PANEL

OPERATOR PANEL SWITCH PANEL

MANUAL RUN/STOP BUTTON& INDICATOR

EXERCISEBUTTON &INDICATOR

FAULTACKNOWLEDGE

BUTTON

PANEL LAMP/LAMP TEST

BUTTON

EMERGENCYSTOP PUSH

BUTTON

0

FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

2-4

CONTROL PANEL ASSEMBLY

The control panel assembly (Figure 2-1) consist oftwo panels, the Operator Panel and the Switch Pan-el.

Dependent on site requirements, the Operator Pan-el is either mounted on the control panel assembly(full-featured) as shown in Figure 2-1 or containedin a separate enclosure and mounted remotely ofthe control panel assembly.

The function of several buttons on the control panelwill vary dependent on the location of the controlpanel (remote or local of the control panel assem-bly). If the function differs, it is noted as either “re-mote” or “local operator panel” in the button de-scription.

Operator Panel

The operator panel contains the following compo-nents:

Analog AC Metering Panel: This panel simulta-neously displays 3-phase line to line AC volts andcurrent, kW, power factor and frequency.

The meter panel is composed of a series of LEDs,that are configured in bar graphs for each function.The LEDs are color coded, with green indicatingnormal range values, amber for warning levels andred for shutdown conditions.

Scales for each function are in % of nominal values.Resolution is 1% for values close to nominal, and in-creases at values further from nominal.

Graphical Display: The graphical display is capa-ble of displaying up to 9-lines of data with approxi-mately 27 characters per line. The display is used toview the menus of the menu-driven operating sys-tem.

The top three lines of the graphical display containthe following control information in the order de-scribed:

• State Line − modes of operation, such asStopped, Time Delay To Start, Warm Up AtIdle, etc. (see Figure 2-2), and paralleling op-erations, such as Standby, Dead BUS Close,Synchronize, Load Share and Load Govern.

• Action Line − system actions, such as Warning,Derate, Shutdown Cool-down and Shutdown,and fault codes.

• Description Line − Fault code messages.

Display Menu Selection Buttons: Six momentarybuttons—three on each side of the graphical dis-play window—are used to navigate through the sys-tem control menus and to adjust generator set pa-rameters. The button is active when the messageadjacent to the button is highlighted (displayed in in-verse video).

2-5

Switch Panel

The switch panel contains the following compo-nents:

Emergency Stop Button: Push the button in foremergency shutdown of the engine. If the engine isnot running, pushing the button in will prevent thestarting of the engine, regardless of the start signalsource (local or remote).

To reset:1. Pull the button out.2. Move the 0/Manual/Auto switch to 0. 3. Press the front panel Fault Acknowledge

button.4. Select Manual or Auto, as required.

Remote Start Indicator: This green lamp is litwhenever the control is receiving a remote run sig-nal. When flashing, it indicates a load demand stopmode.

Not in Auto Indicator: This red lamp flashes con-tinuously when the 0/Manual/Auto switch is not inthe Auto position. (If in Auto position and lamp isflashing, service is required.)

Shutdown Status Indicator: This red lamp is litwhenever the control detects a shutdown condition.The generator set can not be started when this lampis on. After the condition is corrected, shutdown in-dicators can be reset by turning the 0/Manual/Autoswitch to the 0 position, and pressing the Fault Ac-knowledge button.

Dependent upon the specific fault that occurs, theengine may or may not shut down immediately. Afault that could cause engine damage, causes animmediate engine shutdown (bypasses enginecool-down sequence). All other faults would allowthe engine to run during the cool-down sequencebefore engine shutdown. In this case, the ShutdownStatus Indicator blinks during the cooldown period.

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 Fault Acknowledgebutton. (It is not necessary to stop the generator setif the fault becomes inactive during genset opera-tion.)

Fault Acknowledge: Press this button to acknowl-edge warning and shutdown messages after thefault has been corrected.

To acknowledge a Warning message, the 0/Manu-al/Auto switch can be in any position. (It is not nec-essary to stop the generator set to acknowledge aninactive Warning condition.) To acknowledge ashutdown message with this button, the 0/Manual/Auto switch must be in the 0 (Off) position.

This button is also used to blink a fault code if theShutdown or Warning Status Indicator is lit. (Thisfunction is used when the control does not contain agraphical display.) Refer to Reading Fault Codes inthis section, which describes how to use this buttonfor interpreting fault codes.

Panel Lamp/Lamp Test Button: Press this buttonto turn on or off the panel lamp. Press and holddown this button for three seconds or more to turnall control panel LEDs on to make sure all lamps illu-minate. The illumination will shut off after releasingthe button.

Exercise Button: Press this button to initiate a pre-programmed exercise sequence. To start the exer-cise sequence, press and hold down the Exercisebutton and move the O/Manual/Auto switch fromAuto to Manual and back to Auto or from Manual toAuto.

Manual Run/Stop Button: This button starts andstops the set locally and will bypass Time Delay toStart and Stop sequences. The 0/Manual/Autoswitch must be in the Manual position to enable thisbutton.

0/Manual/Auto Switch: Manual position enablesthe use of the switch panel Manual Run/Stop but-ton.

Auto position enables start/stop control of the en-gine from a remote location. (Disables the use of theswitch panel Manual Run/Stop button.)

0 (Off) position prevents the starting of the set (localor remote). If moved to 0 during set operation, willcause an immediate engine shutdown (bypassescool-down timers). This hot shutdown should beavoided, if possible, to help prolong the life of theengine. Hot shutdowns are logged by the systemsoftware.

2-6

READING FAULT CODES

If the genset contains the optional graphical displayand a fault occurs, the fault code/message will bedisplayed in the display Description Line (Figure2-2). If the control does not contain the graphicaldisplay, the fault code is read from the Warning andShutdown status indicators.

Reading Fault codes Using Warning/ShutdownIndicators: If the Warning or Shutdown status indi-cator is lit, press and hold the Fault Acknowledgebutton and release after one second or more. Afterone second, the Shutdown lamp will begin to blinkthe active fault code(s) as follows.

The Warning lamp is used to indicate the start of anew code. The Warning lamp will remain on for 2seconds, followed by the Shutdown lamp blinkingthe fault code. This sequence occurs three times foreach code. The fourth flash of the Warning lamp in-dicates the beginning of the second fault code.

There are distinct pauses between repetitions of thecode blink transmissions of the Shutdown lamp.

A three digit fault code is indicated by three sets ofblinks separated by a two second pause. The firstset corresponds to the hundreds position, the sec-ond to the tens position and the third to the ones dig-it. Example for Code No. 213:

Shutdown LED:blink-blink-pause-blink-pause-blink-blink-blink

Warning LED:blink (2 seconds)

The light will display the fault codes (active or inac-tive) in succession, starting with the most recent. Upto 32 (unacknowledged) fault codes can be storedin control panel memory.

To return the control to the most recent fault code,press and release the Fault Acknowledge button(less than one second) and repeat procedure.

When the fault code is acknowledged and cor-rected, the recorded fault will be deleted from theLED fault log, but will remain in a data log that main-tains a fault code history. (The InPower service toolis required to view this data log.)

2-7

MENU DISPLAY AND SWITCHES

Figure 2-2 shows the graphical display and themenu selection buttons.

Graphical Display: The graphical display is capa-ble of displaying up to 9-lines of data with approxi-mately 27 characters per line. The display is used toview the menus of the menu-driven operating sys-tem. Refer to the menu trees later in this section.The display is also used to show the following sys-tem information:

• State Line − modes of operation, such asStopped, Time Delay To Start, Warm Up AtIdle, etc., and paralleling operations, such asStandby, Dead BUS Close, Synchronize, etc.

• Action Line − system actions, such as Warning,Derate, Shutdown Cool-down and Shutdown,and fault codes.

• Description Line − Fault code/status mes-sages.

Menu Buttons: Six momentary buttons—three oneach side of the graphical display window—areused to navigate through the system control menusand to adjust generator set parameters. The buttonis active when the message or symbol adjacent tothe switch is highlighted (displayed in inverse vid-eo). The displayed message or symbol indicatesthe function of the button.

In the graphical display, the “ �” symbol indicatesthat selecting the adjacent button causes the operat-ing program to go to the next menu display—asshown in the menu diagrams.

In the graphical display, the “ �” symbol indicatesthat selecting the adjacent button causes the operat-ing program to go back to the previous menu display.

In the graphical display, the “ ” symbol indicatesthat selecting the adjacent button causes the operat-ing program to go back to Main Menu A (Figure 2-4).

STATE LINE

ACTION LINE

MENU DISPLAYAREA

GRAPHICALDISPLAY

MENUBUTTONS

DESCRIPTION LINE

MENUBUTTONS

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-8

MENU UNITS SELECTIONDuring any control panel operation, you can changehow units are displayed by pressing the two lowermenu buttons (one on each side of display). Whenpressing these two buttons simultaneously, theunits submenu will appear (Figure 2-3). After select-ing the desired units, press the ENTER button in thissubmenu to change and save the selections.

Use the + buttons to select the desired option foreach field. Use the arrow ( →) button to move to thenext field. Selected field is highlighted.

Location: This selection must be set to Local whenthe graphical display is mounted on the generatorset front control panel or Remote when mounted re-motely from the generator set.

The Local/Remote selection determines which but-tons in the Control submenu (page 2-13) are active(displayed).

Temp: Used to select °F or °C for temperature read-ings.

Pressure Fluid: Used to select PSI, KPA, BAR orIN for pressure readings.

Pressure Gas: Used to select INHG or MMHG forpressure readings.

Flow Air: Used to select CFM or CMM for air flowreadings.

ENTER

LOCATION LOCALTEMP ° FPRESS FLD PSIPRESS GAS INHGFLOW AIR CFM

+

→

FIGURE 2-3. UNITS SUBMENU

2-9

MAIN MENU

Figure 2-4 shows the main menus (Menu A andMenu B) of the system control. The two main menusare used to divide the system submenus into majorcategories, such as, Engine Data, Alternator Data,Control, etc.

To view system data, simply press the appropriatemenu button to select the category. After pressingthe desired menu button, refer to the page numbershown in Figure 2-4 for detailed information relatedto the selected category.

In the following figures, the boxed/highlighted fieldindicates that the adjacent menu button is active.Also, the submenus are shown in the order in whichthey are displayed when scrolling up � or down �.

Adjust Button

The Adjust submenu is intended for qualified sitepersonnel only. Note that a password may be as-signed to allow only authorized operators to modifythis data. (Password is not required if not assigned.)

Setup Button

The Setup submenu is described in Section 3.

The “Adjust” and “Setup” submenus can be viewed,but not modified without entering the correct pass-words.

_\_ Button (Paralleling Applications Only)

When displayed, indicates that the feature for gen-erator set paralleling applications is installed. Thisbutton is used to open and close the generator setcircuit breaker (CB). The symbol indicates if the CBis opened or closed. Opened _\_, push to close.Closed _−_, push to open.

With the control panel 0/Manual/Auto switch in theAuto position, the opening and closing of the CB iscontrolled by the control system software. The CBsymbol will indicate an open or closed CB, but thebutton will be inactive when the control is in Auto.

In the Manual position, the CB can only be closedby using this button. When manually closed and theCB opens, it must be closed again by using this but-ton. To close the CB, press and hold the button untilthe symbol indicates a closed CB. (CB close will oc-cur only when setup conditions allow − dead bus orgenerator synchronized with bus.)

Power Trans Button (Power TransferControl Applications Only)

When displayed, indicates that the Power TransferControl (PTC) feature is installed. Refer to page2-17 for PTC Data submenu description. The PTCsetup submenu is described in Section 3.

2-10

ENGINE

ALTERNATOR

CONTROL

MORE>>

POWER TRAN or _\_

HISTORY/ABOUT

PAGE2-11

PAGE2-12

PAGE2-13

PAGE2-14

Page2-9

MENUB

GRAPHICALDISPLAY

MENUBUTTONS

MENUBUTTONS

SETUP

ADJUST

PARALLEL DATA

BACK<<

Section3

MENUA

PAGE2-16

Section3

MENU A

MENU B

FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

2-11

ENGINE SUBMENUS

If you press the “ENGINE” button in Menu A, the En-gine submenus will appear (Figure 2-5).

The first submenu displays general information thatapplies to all gensets (coolant temp, oil pressure,etc.) The data in the remaining submenu(s) will varyaccording to the type and number of sensors pro-vided with the engine.

�

COOLANT TEMP 180 ° FOIL PRESSURE 75 PSIENGINE SPEED 1800 RPMBATTERY 29.1 VDC

�

MANF TEMP 75 ° FMANF PRESS ABS 180 INHGRAIL PRESS ABS 180 PSIPUMP PRESS ABS 291 PSIFUEL INLET TEMP 172 ° FCOOLANT PRESSURE 59 PSI

ENGINE

�

BLOWBY FLOW 25 CFMTIMING PRESS 50 PSIAFTERCOOLER TEMP 76 ° FAMBIENT PRESS 88 INHG

�

�

FIGURE 2-5. ENGINE SUBMENUS

2-12

ALTERNATOR SUBMENUS

If you press the “ALTERNATOR” button in Menu A,the Alternator Data submenus will appear (Figure2-6).

Voltage L-L and L-N: Indicates voltage Line-toLine and Line-to-Neutral. Note that the Line-to-Neu-tral column will not be displayed for a 3 phase/3 wiresystem. Accuracy 1%.

The voltage Line-to-Line (L1, L2 and L3) are mea-sured between L1 to L2, L2 to L3 and L3 to L1, re-spectively.

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

AVR DUTY CYCLE: Displays voltage regulator(drive) level in percentage of maximum.

kW, kVA and PF: Displays generator set kW andkVA output (average and individual phase, and di-rection of flow) and power factor with leading/lag-ging indication. Accuracy 5%.

The PF reading will contain an asterisk if the powerfactor is leading (for example, *.30).

�

kW kVA PFL1 350 500 .80L2 350 500 .80L3 350 500 .80TOT 1050 1500 .80

ALTERNATOR

�

V L-L L-N AMPSL1 480 277 1340L2 480 277 1290L3 480 277 1260FREQUENCY 60.0 HZAVR DUTY CYCLE 10.3 %

�

FIGURE 2-6. ALTERNATOR SUBMENUS

2-13

CONTROL SUBMENU

If you press the “CONTROL” button in Menu A, theControl submenu will appear (Figure 2-7).

Local CONTROL Submenu Function

When the operator panel is mounted on the controlpanel assembly, the Run Mode Idle/Rated button isactive (displayed). Note in Figure 2-7 that this but-ton is not displayed in remote applications.

The shaded area in Figure 2-7 displays the se-lected/active mode of operation, either IDLE orRATED.

Remote CONTROL Submenu Functions

When the operator panel (Figure 2-1) is mountedremotely of the control panel assembly, the menubuttons in the Control submenu are used to performthe following remote operations. (To activate thesemenu buttons for remote/local use, refer to page2-8.)

The 0/Manual/Auto switch must be in the Auto posi-tion to activate the Remote Menu Buttons of the Con-trol submenu.

Remote START or STOP Button: This button isused to start and stop the generator set when theoperator panel is mounted in a remote location.

When the generator set is operating, Stop will bedisplayed for this button and Start will be displayedwhen not operating.

Fault Acknowledge Button: Used to reset inactiveWarning messages, not Shutdown messages.

Local/Remote CONTROL SubmenuFunction

Bargraph Test: The function of this button remainsthe same and is not dependent on operator panellocation. This button sequentially lights the LEDs totest the bar graph display.

Enable Sync: Displayed in paralleling applicationsonly. Intended for service personnel to turn off thesynchronizer for troubleshooting/testing purposes.

CONTROL(Remote)

START GENSET

FAULT ACKNOWLEDGE

CONTROL(Local)

+ RUN MODE IDLE �

�

�

BARGRAPH TEST �

�

BARGRAPH TEST �

�

ENABLE SYNC

ENABLE SYNC

FIGURE 2-7. CONTROL SUBMENU

2-14

HISTORY/ABOUT SUBMENUS

If you press the “HISTORY/ABOUT” button in MenuA, the History/About submenus will appear (Figure2-8).

HISTORY: The control maintains a data log of thenumber of engine starts and number of operatinghours for the engine and control, and the megawattand maximum torque hours of the generator set.This information is stored in non-volatile memoryand will not be deleted due to loss of battery power.

ABOUT: The About submenus provide the follow-ing generator set information.

• Genset model and wattage (kW/MW)

• Output voltage and WYE, DELTA or SINGLE

• Frequency 50 or 60 Hz

• Rating: Standby, Prime or Base

• Version level of the controller and panel operat-ing software.

�

STARTS 533ENGINE HOURS 1236CONTROL HOURS 7879KWHRS 890

HISTORY/ABOUT

�

�

HISTORY-HRS@ %MAX TORQUE12345@0-9 23455@50-5912345@10-19 12345@60-6912345@20-29 12345@70-7912345@30-39 12345@80-89

�

�

�

MODEL 1750DQKBVOLTAGE 416 WYEFREQUENCY 60RATING STANDBY

CONTROLLER VERSIONRTOP DN30008.DFABATS APR 23 1999OP PANEL VERSIONRTOP 1.09 AUG 17 1999BATS 1.02 MAY 6 1999

�

�

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS

2-15

HISTORY/ABOUT SUBMENUS (CONT.)

FAULT HISTORY: The control maintains a data logof all fault conditions as they occur, and time stampsthem with the control and engine operating hours.

Up to 32 (unacknowledged) fault codes can bestored in control panel memory. After the fault is ac-knowledged and corrected, the recorded fault willbe deleted from the control panel memory, but willremain in a data log that maintains a fault code his-tory. (The InPower service tool is required to viewthis data log.)

The Fault History display line: 1 of 24 indicates that24 faults are recorded and that the most recent fault(1) detected by the controller is displayed.

The Occurrences display line: In this example, 5 in-dicates that this is the fifth occurrence of this fault.(The InPower service tool is required to review thelast four faults of this code.)

The Occurrences number is incremented for eachnew occurrence of the same fault. The controllermust detect that the original sensed fault is cor-rected before it will increment the occurrence num-ber for that fault.

For example, when a Low Oil Pressure fault is de-tected, the controller will increment the Occurrencesnumber by 1. This fault will remain active until thefault is acknowledged and the controller detects thatthe fault is corrected. An active fault will prevent thecontroller from incrementing the Occurrences num-ber each time the engine is started. When the con-troller detects that the oil pressure is normal the faultwill become inactive, allowing the occurrences num-ber to be incremented for the next detected Low OilPressure fault.

FAULT HISTORY: 1 OF 24CNTL HOURS 459OCCURRENCES 5ENGINE HOURS 334FAULT CODE 1437

(FAULT DESCRIPTION)

HISTORY/ABOUT (CONT.)

�+

FIGURE 2-8. HISTORY/ABOUT SUBMENUS (CONT.)

2-16

PARALLEL DATA SUBMENUIf you press the “PARALLEL DATA” button in MenuB, the Parallel Data submenu will appear (Figure2-9). This menu is displayed in paralleling applica-tions only.

PARALLEL DATA STATUS LINE: The top line ofthe graphical display is used to indicate the follow-ing PARALLEL DATA status:

− STANDBY: Indicates no paralleling activity isoccurring at present.

− DEAD BUS CLOSE: Indicates first genset insystem to close to bus.

− SYNCHRONIZE: Genset is synchronizing tobus.

− LOAD SHARE: Genset has closed to bus andis sharing load with other gensets in system.

− LOAD GOVERN: Genset closed to bus in par-allel with utility (mains).

BUS Voltage L-L: The BUS voltage Line-to-Line(L1, L2 and L3) are measured between L1 to L2, L2to L3 and L3 to L1, respectively.

BUS/GEN HZ: BUS/GEN hertz.

BUS/GEN SYNC STATUS: The bottom line of thegraphical display is used to indicate the followingBUS/GEN Sync status:

− NOT SYNCHRONIZING: Genset is in servicemode that does not allow auto sync feature.(Selected via InPower service tool − deactivateto allow synchronization.)

− SYNCHRONIZING: Genset is synchronizing tobus.

− READY TO CLOSE: In manual mode, push cir-cuit breaker close button to close breaker.

_\_ Button: Used to open and close the generatorset circuit breaker (CB). The symbol indicates if theCB is opened or closed. Opened _\_, push to close.Closed _−_, push to open.

With the control panel 0/Manual/Auto switch in theAuto position, the opening and closing of the CB iscontrolled by the control system software. The CBsymbol will indicate an open or closed CB, but thebutton will be inactive when the control is in Auto .

In the Manual position, the CB must be closed bythis button. When manually closed and the CBopens, it must be closed again by using this button.To close the CB, press and hold the button until thesymbol indicates a closed CB. (CB close will occuronly when setup conditions allow − dead bus orgenerator synchronized with bus.)

_\_

�

V BUS GENL1 480 480L2 480 480L3 480 480HZ 60.1 60.1DEG −122 NOT SYNCHRONIZING

PARALLEL DATA

LOAD GOVERN

FIGURE 2-9. BUS DATA SUBMENU

2-17

POWER TRANSFER MAIN/SUBMENUS

If you press the “POWER TRANS” button in MenuA, the Power Transfer main menu will appear (Fig-ure 2-10). The Power Transfer Control (PTC) fea-ture must be installed to display this menu.

The PTC feature enables the PCC to monitor theutility voltage (mains) and frequency for failure andcontrol the opening and closing of the contacts (cir-cuit breakers) for the utility (S1) and the genset(S2).

If utility fails, the control will initiate the genset start-ing sequence, open S1 and close S2 to the load.When utility returns, the load is retransferred to theutility (S1 closes/S2 opens) and the control initiatesthe genset shutdown sequence.

The symbol displayed in the middle of the Pow-er Transfer main menu indicates which breaker(utility or genset) is closed/opened to the load. Thesymbol presently shown indicates that the utilitybreaker is closed and supplying power to the load.

The Power Transfer main menu also indicates if theutility and the generator set are available to acceptload. When the control detects that either source isready to accept load, UTILITY and/or GENSET willbe displayed in inverse video.

The Power Transfer main menu has four submenugroups. Refer to the page numbers shown in Figure2-10 for the Power Transfer submenu descriptions.

2-18

PTC Status Line

The top line of the graphical display is used to indi-cate the following PTC status:

− NOT ENABLED: PTC is not enabled. Controlpanel switch in O (Off) position.

− MANUAL: Control panel switch is in Manualposition. All PTC actions or genset start/stopactions are manually controlled.

− NORMAL UTIL: Load is connected to the util-ity.

− RETRAN: Retransfer of load to utility.− RETRAN OVRD: Immediate retransfer of load

to utility due to genset fault (e.g., warning, der-ate, or shutdown w/cooldown fault). The re-transfer timer is ignored as is the retransfer in-hibit.

− EMERG TEST: Emergency Test sequence ini-tiated through Remote Start switch with emer-gency start sequence enabled (TB8-3 terminalopened). Emergency test mode means that

the genset will continue to run even if a gensetwarning or derate fault occurs. This test can beperformed with or without load (refer to TEST/EXERCISE submenu in Section 3).

− TEST: Test sequence initiated through RemoteStart switch with emergency start sequencedisabled (TB8-3 terminal closed). Test mode isnon-emergency, which means that a retransferto utility will occur if any problems occur withthe genset while testing with load. This test canbe performed with or without load (refer toTEST/EXERCISE submenu in Section 3).

− EXERCISE: Exercise sequence initiatedthrough control panel. This test can be per-formed with or without load (refer to TEST/EX-ERCISE submenu in Section 3). A retransfer toutility will occur if any problems occur with thegenset during the exercise sequence.

− UTILITY FAIL: Utility has failed. (Initiatestransfer of load to genset if O/MANUAL/AUTOswitch is in AUTO.)

� UTILITY

STATUS

TRANSFER CONTROL

GENSET �

PAGE2-19

PAGE2-20

PAGE2-21

MENUA

PAGE2-22

MENUBUTTONS

MENUBUTTONS

DEG −123 SYNCHRONIZING

PTC STATUS LINE

FIGURE 2-10. POWER TRANSFER MAIN MENU

2-19

UTILITY (PWR TRAN) SUBMENUS

If you press the “Utility” button in the Power TransferMain menu, the Utility submenus will appear (Fig-ure 2-11).

Voltage L-L and L-N: Indicates utility voltage Line-to Line and Line-to-Neutral. Note that the Line-to-Neutral column will not be displayed for a 3 phase/3wire system. Accuracy 1%.


Amps: L2 only. Accuracy 1%.

Frequency: Utility frequency.

kW, kVA and PF: Displays (L2 only) utility kW andkVA output (average and direction of flow) and pow-er factor with leading/lagging indication. Accuracy5%.


�

UTILITY:kW kVA PF

L1L2 125 175 .96L3TOT

UTILITY

�

UTILITY:V L-L L-N AMPSL1 480 277L2 480 277 1320L3 480 277FREQUENCY 60.0 HZ

�

FIGURE 2-11. UTILITY SUBMENUS

2-20

STATUS (PWR TRAN) SUBMENUS

If you press the “Status” button in the Power Trans-fer Main menu, the Status submenus will appear(Figure 2-12).

Connected: Indicates which source(s) is con-nected to the load.

Available: Indicates when the correspondingsources have acceptable output voltage and fre-quency. Both can be available simultaneously.

Volt L12: Indicates utility and generator set Line 1 toLine 2 voltage.

HZ: Utility and generator set output frequency.

KW L2: Utility and generator set Phase B (L2) kWoutput.

Transfer Inhibit: This feature is used to controlload transfer to the genset. When activated, loadtransfer to the genset will not take place if the utilityfails.

Transfer inhibit is controlled by connecting a remotecontact between TB3-57 and TB3-58. Closing thecontact enables the feature and opening the con-tact disables it. When enabled, the event is dis-played on the graphical display.

Retransfer Inhibit: This feature is used to preventthe PTC from automatically transferring the loadback to the utility. When activated, load transfer willnot take place unless the genset fails (RetransferInhibit is ignored if the genset fails).

Retransfer inhibit is controlled by connecting a re-mote contact between TB3-64 and TB3-65. Closingthe contact enables the feature and opening thecontact disables it. When enabled, the event is dis-played on the graphical display.

�

TRAN INH OFFRETRAN INH ON

STATUS

�

UTIL GENCONNECTED YES NOAVAILABLE YES NOVOLT L12 480 0HZ 60.0 0.0KW L2 456 0

�

FIGURE 2-12. STATUS SUBMENUS

2-21

TRANSFER CONTROL (PWR TRAN) SUBMENU

If you press the “TRANSFER CONTROL” button inthe Power Transfer Main menu, the Transfer Con-trol submenu will appear (Figure 2-13).

The symbol displayed in the middle of theTRANSFER CONTROL submenu indicates whichbreaker (utility or genset) is closed/opened to theload. The symbol presently shown indicates that theutility breaker is closed and supplying power to theload.

During genset operation in the manual mode, youcan manually transfer/retransfer load between theutility and the genset. To transfer load, press the ap-propriate CB ENABLE button (Utility or Genset).

Example (Figure 2-13)

In the example in Figure 2-13, the CB ENABLE but-ton for “Utility ” was pressed. (If the CB ENABLEbutton for the “Genset ” was pressed, ENABLEGEN CB would be displayed in the second subme-nu, allowing you to open or close the genset circuitbreaker.)

After pressing the “utility” CB ENABLE button, thesecond submenu will be displayed allowing you toeither CANCEL or ENABLE the entered selection.

Pressing the CANCEL button will return the displayto the previous menu.

Pressing the ENABLE button will display the thirdsubmenu. With this submenu displayed you can re-turn to the second submenu without opening theutility circuit breaker (press <<BACK) or you canpress the OPEN UTIL button.

Pressing the OPEN UTIL button will display thefourth submenu, indicating that the utility circuitbreaker is now opened.

Note that the fourth submenu displays CLOSEUTIL. Pressing this button will close the utility circuitbreaker and redisplay the third submenu.

ENABLE UTIL CB

TRANSFER CONTROL

UTILITY GENSET

CB ENABLE CB ENABLE

<< BACK

CANCEL

UTILITY GENSET

OPEN UTIL CB ENABLE

<< BACK

UTILITY GENSET

CLOSE UTIL CB ENABLE

<< BACK

FIGURE 2-13. TRANSFER CONTROL SUBMENUS

2-22

GENSET (PWR TRAN) SUBMENUS

If you press the “Genset” button in the Power Trans-fer Main menu, the Genset submenus will appear(Figure 2-14).

Voltage L-L and L-N: Indicates voltage Line-toLine and Line-to-Neutral. Note that the Line-to-Neu-tral column will not be displayed for a 3 phase/3 wiresystem. Accuracy 1%.


Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

kW, kVA and PF: Displays generator set kW andkVA output (average and individual phase, and di-rection of flow) and power factor with leading/lag-ging indication. Accuracy 5%.


�

GENSET:kW kVA PF

L1 100 150 .97L2 125 175 .96L3 150 200 .95TOT 375 525 .96

GENSET

�

GENSET:V L-L L-N AMPSL1 480 277 1320L2 480 277 1320L3 480 277 1320FREQUENCY 60.0 HZ

�

FIGURE 2-14. GENSET SUBMENUS

3-1

3. Control Calibration and Adjustment

GENERALThis section contains calibration and adjustmentprocedures for the generator set control.

MODIFYING SETUP/ADJUST SUBMENUSThe Setup and Adjust submenus allow you to cali-brate the graphical display meters and to adjustsystem parameters, customer defined faults, gen-erator set voltage/frequency and paralleling ap-plications.

CAUTION Improper calibration or adjustmentof the control can cause equipment malfunctionor damage. Calibration and adjustment must beperformed by technically qualified personnelonly.

The Setup submenus are intended for qualified ser-vice personnel only. The Adjust submenu is in-tended for qualified service and site personnel only.For this reason, a password must be entered beforethis data can be modified. The Setup and Adjustsubmenus can be viewed, but not modified withoutentering the correct password.

Saving Menu Changes

Changes are automatically saved when the menu isexited.

3-2

PASSWORD Menu

To allow the site personnel to modify only the Adjustsubmenu and not the Setup submenus, two pass-words are assigned within the system software. AnApplication password is used for the Setup sub-menus and a User password is used for the Adjustsubmenu.

The two passwords are assigned during the initialinstallation of the generator set (via InPower) andwill vary between sites. The installer must makesure that the passwords are available to the ap-propriate personnel.

When the generator set is first installed, the Applica-tion and User password are both set to GENSET toallow initial modification of the Setup and Adjustsubmenus. Assign new passwords when site instal-lation is complete.

When viewing the Adjust menu, pressing the + or −button will display the User Password menu.

When viewing a Setup menu, pressing the + or −button will always display the Application Passwordmenu.

After entering the correct password, the system willallow you to modify the submenus. To help prevent

unauthorized adjustment, the entered password isvalid for 10 minutes after the last button is pressed(i.e., the password will need to be reentered afterthe ten minute time−out.

Entering Password

To enter the password:

1. Display submenu to modify.

2. Press either the + or − button within the dis-played submenu. The Password menu ap-pears.

3. Press the + and − button to select the first char-acter of the password (A−Z or 0−9). (Enter Ap-plication password for Setup submenus; En-ter User password for Adjust submenu.)

4. Press the → button to select the next characterfield. Selected character field is highlighted.

5. Repeat steps 3 and 4 to enter remaining pass-word characters.

6. Press the Enter button after entering the pass-word. The submenu selected in step 1 will re-appear.

7. After making desired changes to submenu, exitsubmenu to save changes.

+ OR − BUTTON

ENTER

ENTER APPLICATION PASSWORD

+

−

→ XXXXXXXX

+ OR − BUTTON

ENTER

ENTER USER PASSWORD

+

−

→ XXXXXXXX

SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU

FIGURE 3-1. PASSWORD MENUS

3-3

SETUP MENUS

Figure 3-2 shows the main menus (Menu A andMenu B) of the system control and the two Setupmenus.

The Setup procedure is intended for qualified ser-vice personnel only. The APPLICATION passwordmust be entered to modify the Setup submenufields. Refer to PASSWORD Menu in this section toenter password and to save menu changes.

To display the two Setup menus, press the

MORE>> button in Menu A and then the SETUPbutton in Menu B.

To view system data or to adjust system parame-ters, press the appropriate Setup menu button todisplay the desired Setup submenu(s). Refer to thepage number shown in Figure 3-2 for detailed infor-mation related to the selected submenu(s).

CAUTION Improper calibration or adjustmentof the control can cause equipment malfunctionor damage. Calibration and adjustment must beperformed by technically qualified personnelonly.

GOVERNING/VOLT REG

CUSTOMER FAULTS

CALIBRATION

�

�

ISOLATED BUS

UTILITY

ENGINE

ALTERNATOR

CONTROL

MORE>>

POWER TRAN or _\_

HISTORY/ABOUT SETUP

ADJUST

PARALLEL DATA

BACK<<

MENU A MENU B

PAGE3-4

PAGE3-5

PAGE3-6

MENUA

MENUB

NEXTMENU

PAGE3-7

PAGE3-11

MENUA

ABOVEMENU

MENUB

MENUA

�POWER TRANSFER SETUP

SETUP MENU 1

SETUP MENU 2PAGE3-12

FIGURE 3-2. SETUP SUBMENUS

3-4

GOVERNING/VOLT REG SUBMENU

If you press the “GOVERNING/VOLT REG” buttonin the Setup menu, the Governing/Volt Regulatorsubmenu will appear (Figure 3-3).

Use the + and − buttons to increase or decrease thevalues in the following fields. Use the arrow ( →) but-ton to move the cursor within a field or to the nextfield. Exit menu to safe changes.

GOV GAIN: If the gain adjustment is set too high,engine speed will “hunt” or oscillate. If gain is set toolow, the engine will respond too slowly to changes inload and overspeed may result. (Gain should be re-duced to 80% for paralleling installations.)

AVR GAIN: If the gain adjustment is set too high,output voltage will be unstable. If gain is set too low,the output voltage will respond sluggishly tochanges in load and overshoot may result.

GOVERNING/VOLT REG

�GOV GAIN 80%AVR GAIN 100%

+

−

→

FIGURE 3-3. GOVERNING/VOLT REG SUBMENU

3-5

CUSTOMER FAULTS SUBMENUS

If you press the “CUSTOMER FAULTS” button inthe Setup menu, the Customer Faults submenuswill appear (Figure 3-4).

There are a total of four customer fault inputs.(Faults 3 and 4 paralleling only.) The message dis-played at the bottom of the menu can be modifiedfor each of these faults in addition to selecting thefollowing operating parameters for each fault.

• Enable − On or Off• Active − Closed or Open• Response − Shutdown, Cooldown, Derate or

WarningShutdown : Genset will immediately shutdown. Normally used for engine faults.Cooldown : Cooldown sequence will be initi-ated before shutdown. Should not be used forengine faults.Derate: Used to lower kW output of genset forwarnings such as pre-high coolant tempera-ture, etc. Paralleling application − controller willreduce precentage of kW load sharing on theset. Non-paralleling application − controller willlower percentage of kW load by operating loadshed relay contacts.Warning: Display message, genset continuesto operate.

The Enable and the Active fields apply to the Fault 1and 4 submenus only.

With the Active field selected, pressing the + or −buttons will toggle the selection between CLOSEDand OPEN. Use same operation for remaining fieldselections.

To enter the desired customer fault message, pressthe � or � button to display the submenu that con-tains the customer fault message (1 through 4) to bechanged. Use the → button to scroll down throughthe menu selections to the editable fault message(bottom menu line).

Use the → button to move to each character posi-tion within the fault message line.

With the desired character position selected, use +or − buttons to select the appropriate character.

If these messages are changed, you should notethese changes in the Troubleshooting section of theOperator’s manual for this generator set.

CUSTOMER FAULTS

�

�

CUSTOMER FAULT1:ENABLE ONACTIVE CLOSEDRESPONSE WARNING

***CUSTOMER FAULT1 ******************

+

−

→

CONTINUES THROUGH TWOADDITIONAL MENUS FOR ATOTAL OF FOUR POSSIBLE

CUSTOMER FAULT MESSAGES

�

�

+

−

→

CUSTOMER FAULT2:

RESPONSE WARNING

***CUSTOMER FAULT2 ******************

FIGURE 3-4. CUSTOMER FAULTS SUBMENUS

3-6

CALIBRATION SUBMENUS

If you press the “CALIBRATION” button in the Setupmenu, the Calibration submenus will appear (Fig-ure 3-5).


The Calibration submenus allow you to calibrate thecontrol with the reading from a calibrated meter.Calibration is accomplished by using this section ofthe menu software to adjust the display so that itmatches the reading taken on an accurate, recentlycalibrated meter.

Calibration is normally only required when replac-ing certain circuit cards. Refer to the CalibrationProcedure in this section which contains a list of thecards that require control calibration.

When performing Bus Voltage Calibration from thegraphical display, the genset must be off and the Buslive. If the genset is running, it will synchronize to theBus.

CALIBRATION

VOLTAGE CALIBRATIONL1 480 -X.X%L2 480 -X.X%L3 480 -X.X%

+

−

→

CURRENT CALIBRATIONL1 234 -X.X%L2 123 -X.X%L3 562 -X.X%

+

−

→

BUS VOLTAGE CALIBRATIONL1 480 -X.X%L2 480 -X.X%L3 480 -X.X%

+

−

→

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FIGURE 3-5. CALIBRATION SUBMENUS

3-7

ISOLATED BUS / UTILITY Submenus(Paralleling Application)

The Isolated BUS submenus (Figure 3-6) and theUtility submenus (Figure 3-7) adjust the control pa-rameters for generator set protection, synchroniz-ing and load sharing for both isolated bus and utility(mains) paralleling applications. Utility (mains) par-allel applications may require adjustment of boththe Isolated BUS and Utility submenus.

Always perform ISO BUS calibration before UtilityBUS calibration.

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 are met, the par-alleling breaker is closed automatically by the con-trol (auto mode), or by operation of the breakerclose switch by the operator (manual mode).

The synchronizing function of the control is enabledwhen the control has brought the generator set to90% of rated speed and voltage, and has sensedthat bus voltage is available. The control automati-cally adjusts the generator set speed and voltage tomatch the bus frequency and voltage. The controlcan force the generator set to match bus voltage

and frequency in a range of minus 40% to plus 10%of normal bus conditions. When the parallelingbreaker has closed, the control will bring the gener-ator set back to normal voltage and frequency.

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 based on their standby ratings. If twogenerator sets of different sizes are paralleled, theywill assume the same percentage of the systemload automatically. This can easily be verified on thekW Load LED bar graph on the front of the controlpanel.

When the utility paralleling mode 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 generatorset at 110% of the generator set base load setting.When the load govern signal is between 1 VDC and4.5 VDC the control will operate the generator set ata load level which is determined by a linear relation-ship between the kW reference and the load governsignal.

3-8

ISOLATED BUS SUBMENUS

If you press the “ISOLATED BUS” button in the Set-up menu, the Isolated BUS submenus will appear(Figure 3-6).


SYNC TIME LIMIT: This parameter adjusts the timedelay in seconds before the Fail To Synchronizealarm will operate.

REVERSE PWR LMT: Adjusts the reverse powerset point. For PowerCommand generator sets, atypical set point is 10-15%.

REVERSE PWR TIME: Adjusts the reverse powerfunction time delay. A typical time delay which issuitable for PowerCommand generator sets is 3seconds.

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 sec-onds) for which the generator set must be synchro-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 0.5seconds for isolated bus applications.

ISOLATED BUS

ISOLATED BUS:SYNC TIME LIMIT 120 SECREV PWR LMT 10 %REV PWR TIME 3 SECPERM WIN-PH 20 DEGPERM WIN-TIME .5 SEC

+

−

→

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�


FIGURE 3-6. ISO BUS SUBMENUS

3-9

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.

KW Balance and KVAR Balance changes should beequally shared among all generator sets.

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 the percentage ofthe 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 shared proportionately, the kVAR balance 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.

KW GAIN: 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 the gain adjustment on the gener-ator set. This also allows modification of the rate ofload assumption on transient load change.

ISOLATED BUS (CONT.)

ISOLATED BUS:SYNC GAIN 1.0KW BALANCE 0.3KVAR BALANCE 1.2KW GAIN 1.0KVAR GAIN 1.0

+

−

→

�

�


FIGURE 3-6. ISO BUS SUBMENUS (CONT.)

3-10

1ST FAIL TIME: Time delay in seconds after a sig-nal from the first start master is not sensed by thePCC that a FIRST START FAIL warning is dis-played.

RAMP UNLOAD TIME: When a load demand stopinput 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 UNLOAD LEVEL: The load demand rampunload function will ramp the load down from thepresent level on the set to this level before openingthe set 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.

ISOLATED BUS (CONT.)

ISOLATED BUS:1ST FAIL TIME 12 SECRAMP UNLD 20 SECRAMP UNLD LEVEL 10 %RAMP LOAD TIME 3 SECLOSS FIELD 20 SEC

+

−

→

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FIGURE 3-6. ISO BUS SUBMENUS (CONT.)

3-11

UTILITY SUBMENUS

If you press the “UTILITY” button in the Setupmenu, the Utility submenus will appear (Figure 3-7).


BASE LOAD (%): This controls the maximum kWload level that the generator set will operate at whenparalleled with the utility (mains). The value shownindicates the steady state load on the generator asa percent of the generator set standby rating.

Check generator set ratings for maximum 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.

PF LEVEL: Adjusts the power factor that the gener-ator set will run at when paralleled to the utility(mains). Recommended setting is 1.0.

RAMP LOAD TIME: This is the ramp time frompresent set load to level determined by the load setanalog input. This is active when the control first en-ters the load govern mode.

RAMP UNLOAD TIME: This is the ramp time frompresent set load to 0 kW. This ramp is active whenthe load set analog input is less than 0.5 volts.

MODE − MULTIPLE/SINGLE: This controls wheth-er the set is to operate as part of a multiple set orsingle set (PLTE or PLTF) system. (Refer to “LOADDEMAND SHUTDOWN” and “SINGLE MODE EN-ABLE” function descriptions in wiring diagram,page 5-8.)

KW GOVERN GAIN: This controls the rate that thegenerator set kW load is increased after the genera-tor set has closed to the system bus when utility(mains) paralleled. Decreasing this value will resultin slower loading of the generator set.

KVAR GOVERN GAIN: This controls the rate thatthe generator set kVAR load is increased after thegenerator set has closed to the system bus whenutility (mains) paralleled. Decreasing this value willresult in slower loading of the generator set.

UTILITY

UTILITY:BASE LOAD 80%PF LEVEL 1.00RAMP LOAD 3RAMP UNLD 20MODE MULTIPLE

+

−

→

UTILITY:KW GOVERN GAIN 1.00KVAR GOVERN GAIN 1.00

+

−

→

�

�

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FIGURE 3-7. UTILITY SUBMENUS

3-12

POWER TRANSFER CONTROL MAINMENUS

If you press the “POWER TRANSFER SETUP” but-ton in the Setup menu 2 in Figure 3-2, the two mainmenus of the optional Power Transfer Control(PTC) feature will appear (Figure 3-8).

To adjust PTC system parameters, press the ap-propriate PTC main menu button and refer to thepage number shown in Figure 3-8 for detailed infor-mation related to the submenu selected.

UTILITY SENSORS

GENSET SENSORS

TIMERS

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PAGE3-13

PAGE3-15

PAGE3-17

NEXTMENU

TEST/EXERCISE �PAGE3-18

PTC MAINMENU 1

PTC MAINMENU 2

FIGURE 3-8. PTC SETUP MAIN MENUS

3-13

UTILITY SENSORS SUBMENUS

If you press the “UTILITY SENSORS” button in thePTC Main Menu 1, the Utility Sensors submenuswill appear (Figure 3-9).

The following field descriptions show the valid fieldentries and default value (shown in parenthesis) foreach field.

Use the + and − buttons to increase or decrease thevalues in the following fields. Use the arrow ( →) but-ton to move the cursor within a field or to the nextfield. Exit menu to save changes.

U PT VOLT LL: Enter the value of the utility line-to-line voltage which yields 100% voltage at the termi-nals of the utility (bus) PT module.

Range: 1−15000V, adjustable by standard nominalvoltage values, 100V, 10V and 1V increments (1V).

The 100% voltages for each of the four possible util-ity (bus) PT modules are as follows, based on mod-ule dash number:−01 = 208 volts LL−02 = 416 volts LL−03 = 600 volts LL−04 = 120 volts LL

Example 1: Nominal Utility voltage is 480V. Thismeans that utility (bus) PT module number −02should be used. The voltage which will yield 100%volts at this PT module is 416 per the above table.Thus enter 416V.

Example 2: Nominal Utility voltage is 4160V. A pri-mary stage transformer with a ratio of 4200/240 isused. This means that utility (bus) PT module num-ber −01 should be used. The voltage which will yieldthe 100% volts (208V from above table) is calcu-lated as follows:

208 x (4200/240) = 3640. Thus enter 3640V.

U NOM VOLT LL: Enter the nominal utility line-to-line voltage. For example, 480, 4160, etc.. Range:1−15000 V, adjustable by standard nominal voltagevalues, 100V, 10V and 1V increments (1V).

U CT RATIO: Enter the CT Ratio of the Utility L2 CT.This is the Ratio to 1 Amp. Range: 1−18000 (1A).

CAUTION This CT must be rated for 1 Ampoutput (e.g. NOT 5 Amp). Be sure CT secondarycircuit has burden resistor or a shorting jumperin place before putting power through the CT.Example: CT Ratio = 2650:1. Thus enter 2650.

U SENSOR TYPE: Enter the line-to-line (L-N) for 3phase line-neutral voltage sensing or line-to-line(L-L) for 3 phase line-line voltage sensing. This ap-plies to both the utility undervoltage and overvol-tage sensors. Range: L−L, L−N (L−N).

U <wye> <delta>: Enter utility connection type.Range: Delta, Wye (Wye).

U UNLOADED KW: Enter the kW on utility Line 2 atwhich the utility is considered as unloaded. This isthe L2 kW level at which a closed transition softtransfer will disconnect from the utility.

UTILITY UNDERVOLTAGE: Non-adjustable field,always enabled.

UTILITY OVERVOLTAGE, FREQUENCY: Used toenable or disable menu function. Choose Enabledor Disabled (Enabled).

UV PICKUP: Enter a number between 85 and100% of the nominal voltage (90%).

UV DROP OUT: Enter a number between 75 and98% of the under-voltage pick-up percentage(90%).

UV DELAY: Enter a time between 0.1 and 5.0 sec-onds (0.5 seconds).

UV MIN PHASE: Displays the lowest line voltage ofthe three utility phases.

3-14

OV PICKUP: This adjusts the over-voltage pickupas a percentage of the over-voltage drop-out. Entera number between 95 and 99% (95%).

OV DROP OUT: Enter a percentage between 105and 135% of the nominal voltage (110%).

OV DELAY: Enter a range between 0 and 120 sec-onds (3 seconds).

OV MAX PHASE: Displays the highest line voltageof the three utility phases.

CENTER (FREQ): Enter a frequency between 45and 65 Hz (60 Hz).

PICK UP (FREQ): Enter a percentage between 5and 20% of the nominal frequency (10%).

DROP OUT (FREQ): Enter a percentage between1 and 5% of the nominal frequency (1%).

DELAY (FREQ): Enter a time between 0.1 and 15.0seconds (5.0 seconds).

FREQUENCY: This field displays the sensed utilityline frequency.

UTILITY SENSORS

U PT VOLT LL 416U NOM VOLT LL 480U CT RATIO: 1 1000U SENSOR TYPE L−L

U UNLOADED KW 50 KW

+

−

→

�

UTILITY UV: ENABLED% VLL

PICK UP 95 475DROP OUT 85 465DELAY 0.5 SMIN PHASE 470

+

−

→

�

�

UTILITY OV: DISABLED% VLL

PICK UP 95 487DROP OUT 110 490DELAY 3.0 SMAX PHASE 485

+

−

→

�

�

UTILITY FREQ: DISABLEDCENTER 60 HZPICK UP 10 %DROP OUT 1 %DELAY 1.0 SFREQUENCY 60.5 HZ

+

−

→

�

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FIGURE 3-9. UTILITY SENSORS SUBMENUS

3-15

GENSET SENSORS SUBMENUS

If you press the “GENSET SENSORS” button in thePTC Main Menu 1, the Genset Sensors submenuswill appear (Figure 3-10).



G NOM VOLT LL: Non-adjustable field, displayscurrent setting of genset nominal voltage. (See Ad-just submenu to adjust the output voltage ±5%.)

G SENSOR TYPE: Enter the line-to-line (L-N) for 3phase line-neutral voltage sensing or line-to-line(L-L) for 3 phase line-line voltage sensing. This ap-plies to both the genset undervoltage and overvol-tage sensors. Range: L−L, L−N (L−N).

G BASE LOAD: Enter the maximum load the gen-set will carry during a closed transition. Range:0−100% (80%).

G RAMP LOAD: Enter the ramp time for the gensetramp load rate during a closed transition soft loadtransfer. Ramp rate is +100%kW divided by thistime setting. Range: 0−900 seconds (20 sec).

G RAMP UNLOAD: Enter the ramp time for thegenset ramp unload rate during a closed transtionsoft load retransfer. Ramp rate is −100%kW dividedby this time setting. Range: 0−900 seconds (20sec).

G UNLOADED KW: Enter the %kW (based onstandby rating) that the genset is considered un-loaded. This is the %kW level at which a closed tran-sition soft retransfer will disconnect from the gen-set. Range: 0−100% (5%).

GEN UNDERVOLTAGE: Non-adjustable field, al-ways enabled.

GEN OVERVOLTAGE, FREQUENCY: Used to en-able or disable menu function. Choose Enabled orDisabled (Enabled).

UV PICKUP: Enter a number between 85 and100% of the nominal voltage (90%).

UV DROP OUT: Enter a number between 75 and98% of the under-voltage pick-up percentage(90%).

UV DELAY: Enter a time between 0.1 and 5.0 sec-onds (4 seconds).

UV MIN PHASE: Displays the lowest line voltage ofthe three genset phases.

3-16

OV PICKUP: This adjusts the over-voltage pickupas a percentage of the over-voltage drop-out. Entera number between 95 and 99% (95%).

OV DROP OUT: Enter a percentage between 105and 135% of the nominal voltage (110%).

OV DELAY: Enter a range between 0 and 120 sec-onds (3 seconds).

OV MAX PHASE: Displays the highest line voltageof the three genset phases.

CENTER (FREQ): Enter a frequency between 45and 65 Hz (60 Hz).

PICK UP (FREQ): Enter a percentage between 5and 20% of the nominal frequency (10%).

DROP OUT (FREQ): Enter a percentage between1 and 5% of the nominal frequency (1%).

DELAY (FREQ): Enter a time between 0.1 and 15.0seconds (5.0 seconds).

FREQUENCY: Displays the sensed genset line fre-quency.

GENSET SENSORS

G NOM VOLT LL 480G SENSOR TYPE L−LG BASE LOAD 80.0%G RAMP LOAD 20 SG RAMP UNLOAD 20 SG UNLOADED KW 5 %

+

−

→

�

GEN UV: ENABLED% VLL

PICK UP 95 475DROP OUT 85 465DELAY 1.0 SMIN PHASE 470

+

−

→

�

�

GEN OV: DISABLED% VLL

PICK UP 95 487DROP OUT 110 490DELAY 8.0 SMAX PHASE 485

+

−

→

�

�

GEN FREQ: DISABLEDCENTER 59 HZPICK UP 12 %DROP OUT 2 %DELAY 5.0 SFREQUENCY 60.0 HZ

+

−

→

�

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FIGURE 3-10. GENSET SENSORS SUBMENUS

3-17

TIMERS SUBMENU

If you press the “TIMERS” button in the PTC MainMenu 1, the Timers submenu will appear (Figure3-11).



START DELAY: Sets time delay for genset enginestart. Prevents nuisance genset starting during briefpower interruptions.

Enter a range from 0 to 300 seconds (0 seconds).

STOP DELAY: Sets the time delay for engine cool-down following a re-transfer. This stop delay worksin conjunction with and is activated at the same timeas the normal cooldown timer. (Will extend normalcooldown timer if entered time is greater.)

Enter a time from 0 to 600 seconds (0 seconds).

TRANSFER: In a Normal to Emergency transferthis function allows the genset to stabilize beforethe load is applied. Enter a time from 0 to 120 sec-onds (10 seconds).

RETRANSFER: In a Emergency to Normal transferthis function allows the utility to stabilize before theload is applied.


PGM TRANSIT: Sets the time delay for Pro-grammed Transition. A setting of 0.0 disables theprogram.


MAX PARALLEL: Sets the maximum time duringclosed transition that utility and genset can be paral-leled.


TIMERS

START DELAY 60 SSTOP DELAY 60 STRANSFER 10 SRETRANSFER 900 SPGM TRANSIT 5 SMAX PARALLEL 30 S

+

−

→

�

FIGURE 3-11. TIMERS SUBMENU

3-18

TEST/EXERCISE SUBMENU

If you press the “TEST/EXERCISE” button in thePTC Main Menu 2, the Test/Exercise submenu willappear (Figure 3-12).



MODE: Indicates the generator set application typefor PTC option.

OT-PGM TRAN − Open transition load transfer.CT-MOMENT − Closed transition load transferwith momentary (<100ms) overlap.CT-SOFT − Closed transition load transfer withload ramping.

TEST WITH LOAD: Feature allows genset Test se-quence, which is initiated through the Remote Start(TEST) switch, to operate with or without load. De-fault: OFFEXER WITH LOAD: Feature allows genset Exer-cise sequence, which is initiated through controlpanel Exercise button to operate with or withoutload. Default: OFF

TEST/EXERCISE

MODE CT-SOFT

TEST WITH LOAD OFFEXER WITH LOAD OFF

+

−

→

�

FIGURE 3-12. TIMERS SUBMENU

3-19

ADJUST SUBMENU

Figure 3-13 shows the main menus (Menu A andMenu B) of the system control and the Adjust sub-menu.

To display the Adjust submenu, press the MORE>>button in Menu A and then the ADJUST button inMenu B.

The Adjust submenus are intended for qualifiedservice personnel and site personnel only and mayrequire a USER password. If a password is re-quired, the USER password menu will appear whenyou try to modify the Adjust submenus. (Refer toPASSWORD Menu in this section to enter pass-word.

Changes are automatically saved when you exitthis menu.

If the generator set is operating in parallel with asystem bus, the voltage and frequency adjustments

are disabled to prevent inadvertent misadjustmentof the paralleling load sharing functions.


START DELAY: This delay applies only to remotestarting in the Auto mode. The Start Delay adjust-ment range is 0 to 300 seconds.

STOP DELAY: This delay applies only to remotestopping in the Auto mode. The Stop Delay adjust-ment range is 0 to 600 seconds.

VOLTAGE: Used to adjust the output voltage ±5%.

FREQUENCY: Used to adjust the frequency ±3 Hz.

VOLTAGE/SPEED DROOP: These two submenusapply to a genset that has the paralleling option andis configured to operate in droop mode.

ENGINE

ALTERNATOR

CONTROL

MORE>>

_\_

HISTORY/ABOUT

SETUP

ADJUST

BUS DATA

BACK<<

MENU A

MENU B

MENUB

MENUA

+

−

→

ADJUST:START DELAY 5 SECSTOP DELAY 11 SECVOLTAGE 208 1.2 %FREQ 60.0 HZ -0.0 HZ

�

�

+

−

→

ADJUST:STANDBYVOLTAGE DROOP OFFBUS L1 480 VPOWER FACTOR 0.80VOLT 4.99 %

�

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+

−

→

ADJUST:STANDBYSPEED DROOP OFFBUS FREQ 60.0 HZ TOTAL KW 300 KWFREQ 60.0 0.40 HZ

�

FIGURE 3-13. ADJUST SUBMENU

3-20

CALIBRATION PROCEDURE

There are several circuit cards/modules that, whenremoved and replaced, require you to recalibratethe control panel display for genset voltage and cur-rent and bus voltage.

Note that the type of calibration to perform varies foreach card. The letters A, B and C are used to desig-nate which of the following three calibration proce-dures are required for each card/module.

• Genset/Parallel board (A, B & C)

• PT/CT board (A & B)

• Bus PT (C)

• CT’s (B)

WARNING 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.

CAUTION Improper calibration or adjustmentof the PowerCommand control can causeequipment malfunction or damage. Calibrationand adjustment must be performed by techni-cally qualified personnel only.

Use a calibrated RMS multimeter for accurate mea-surements. Fluke models 87 or 8060A are goodchoices.

(A) Genset Voltage Display Calibration

The PowerCommand control automatically synchro-nizes to the system bus when bus voltage is avail-able and the genset is running. Consequently, it isnot possible to calibrate the genset output voltage

display of the genset that is running when the bus isenergized. If it is necessary to adjust the output volt-age display of the genset that is running, the InPowerservice tool must be used to switch off the synchro-nizer function of the control.

1. Display the Voltage Calibration submenu(Page 3-6).

2. With the genset OFF, attach a calibrated volt-meter to the AC output from L1 to L2. (L1 toNeutral for single phase alternators.)

3. Start the genset and allow it to reach normaloperating speed.

4. Calibrate voltage reading for L1 so that thereading on the display agrees with the cali-brated voltmeter.

5. Shut the generator set OFF.6. Repeat steps 2 through 5 for L2 and L3. (In step

2 attach meter to the AC output from L2 to L3 tocalibrate L2 and L3 to L1 to calibrate L3.)

7. Exit menu to safe changes.

(B) Genset Ammeter Display Calibration

1. Display the Current Calibration submenu(Page 3-6).

2. With the genset OFF, attach a calibrated am-meter to L1.

3. Start the genset and allow it to reach normaloperating speed.

4. Load the genset to maximum rated kVA atrated voltage.

5. Calibrate the reading for L1 current so that thereading on the display agrees with calibratedammeter.

6. Repeat steps 2 through 5 for L2 and L3. (In step2, attach meter to L2 to calibrate L2 current andL3 to calibrate L3 current.)


3-21

(C) Bus Voltage Calibration

The PowerCommand control automatically synchro-nizes to the system bus when bus voltage is avail-able and the genset is running. Consequently, it isnot possible to calibrate the genset bus voltage dis-play of the genset that is running when the bus is en-ergized. If it is necessary to adjust the bus voltagedisplay of the genset that is running, the InPowerservice tool must be used to switch off the synchro-nizer function of the control.

1. Display the Bus Voltage Calibration submenu(Page 3-6).

2. With all gensets OFF, attach a calibrated volt-

meter to TB1-A (L1) and TB1-B (L2) of the busPT module (Figure 3-14).

3. Start another genset and allow it to reach nor-mal operating speed and voltage. Connect op-erating genset to the bus.

4. Calibrate the voltage reading for Bus Volts L1so that the reading on the display matches thereading on the calibrated meter.

5. Shut the generator set OFF.6. Repeat steps 2 through 5 for Bus Volts L2 and

L3. (In step 2 attach meter to the AC outputfrom L2 to L3 to calibrate L2; L3 to L1 to cali-brate L3.)


TB1-A (L1)

CONTROLBOX DOOR

TB1-B (L2)

TB1-C (L3)

FIGURE 3-14. BUS PT MODULE

3-22

CONTROL BOX WIRING

The generator set control box assembly, which canbe located on either side of the genset, containsconnection points for remote control and monitoroptions.

Customer monitor/control connections are at-tached to terminal blocks TB3 and TB8 (see Figure

3-15). Optional equipment such as a remote annun-ciator panel, sensing devices used to monitor gen-set operation, remote start/stop switches, controlbox heater, and etc. are also attached to these ter-minal blocks. Driver signals for customer suppliedrelays are also provided for several alarm and shutdown conditions. Refer to Customer Connectionsdiagram in Section 5.

3-23

TB8

CARDCAGE

OPTIONALSHUTDOWN

ALARM RELAY K16

OPTIONALRUN RELAYS

K11, K12 & K13

CONTROL WIRINGACCESS

FIGURE 3-15. CONTROL BOX ASSEMBLY INTERIOR

3-24

RUN RELAYS (K11, K12, K13)

The optional run relays are rail mounted inside thecontrol box (Figure 3-15). The rail mount allows youto easily remove and replace the snap-on relays.The generator set can be equipped with one, two orthree run relays.

The three-pole, double-throw run relays (Figure3-16) are used to control auxiliary equipment such

as 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

TB3-7(GND)

TB3-5(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 3-16. OPTIONAL RUN RELAYS (K11, K12, K13)

3-25

ALARM RELAY (K16)

The optional alarm relay is rail mounted inside thecontrol box (Figure 5-2). The rail mount allows youto easily remove and replace the snap-on relay.

The three-pole, double-throw alarm relay (Figure5-4) is often used to energize warning devices such

as audible alarms. Any generator set shutdown willenergize 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

TB3-18(GND)

TB3-17(COM ALARM)

NO

COIL

COM

NC

K16

K16

K16

K16SHUTDOWN ALARM

FIGURE 3-17. OPTIONAL ALARM RELAY (K16)

3-26

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 3-18. MPU SENSOR

4-1

4. Servicing the Generator

TESTING THE GENERATORThese tests can be performed without removing thegenerator. Before starting tests, disconnect thestarting battery negative [-] cable to make sure theengine will not start while performing these tests.

WARNING Arcing at battery terminals, arcingin light switch or other equipment, flame, pilotlights and sparks can ignite battery gas causingsevere personal injury.Ventilate battery area before working on or nearbattery—Wear safety glasses—Do not smoke—Switch trouble light ON or OFF away from bat-tery—Stop genset and disconnect charger be-fore disconnecting battery cables—Disconnectnegative (−) cable first and reconnect last.

CAUTION Disconnect battery charger from ACsource before disconnecting battery cables.Otherwise, disconnecting cables can result involtage spikes damaging to DC control circuitsof the set.

WARNING Accidental starting of the generatorset while working on it can cause severe per-sonal injury or death. Prevent accidental start-ing by disconnecting the negative (−) cable fromthe battery terminal.

RECONNECTIONTERMINALS

STATOR

BLOWER

COUPLING

DRIVEDISCS

ROTORSHAFT

AIR DISCHARGECOVERS

FRAME

ROTATINGRECTIFIERASSEMBLY

PMGSTATOR

EXCITERROTOR

END BRACKET

PMGROTOR

EXCITERSTATOR

END BRACKET/ENGINEADAPTOR

ROTOR

ENDBEARING

PRESSUREPLATE

FIGURE 4-1. TYPICAL GENERATOR

4-2

GENERATOR/PCC CONTROL ISOLATIONPROCEDURE

The following procedure is used to determine if thegenerator or the PCC control circuitry is causing ahigh AC voltage shutdown fault.

1. Throw the line circuit breaker OFF and shutdown the set.

CAUTION This test involves unregulatedexcitation of the generator. To prevent dam-age to the generator due to overcurrent,make sure that all loads have been discon-nected and that all faults have been clearedfrom the power output terminals of the gen-erator.

2. Open the door of the control box assembly andremove plug 10 from connector 10 of the volt-age regulator output module (A37). See Figure3-11.

3. Prepare to measure output voltage across thegenerator terminals while the set is running.

4. Bring two jumpers from a 12 volt battery forconnection to the X (Field +) and XX (Field −)pins of plug 10.X = Red wire of connector 10-6XX = Brown wire of connector 10-3Connect the jumper from the positive (+) postof the battery to the X pin (red wire) of 10-6. Beprepared to connect the jumper from the nega-tive (−) post of the battery to the XX pin (brownwire) of 10-3. If one of the 12 volt cranking bat-teries is used, bring the jumpers from the bat-

tery connected on the grounded side of the sys-tem to avoid inadvertently imposing 24 volts onthe system.

5. Check polarity again. Polarity must be corrector this test will be inconclusive because the in-duced and residual magnetic polarities in theexciter stator will be opposed.

WARNING HAZARDOUS VOLTAGE.Touching uninsulated parts inside the con-trol housing and power output boxes canresult in severe personal injury or death.Measurements and adjustments must bedone with care to avoid touching hazard-ous voltage parts.

Stand on a dry wooden platform or rubberinsulating mat, make sure your clothingand shoes are dry, remove jewelry and usetools with insulated handles.

6. Start the set and connect the jumper from thebattery negative (−) terminal to the XX lead.

7. The generator circuitry is probably okay if ratedoutput voltage or higher is obtained and thevoltages for all phases are balanced when theexciter is powered by a 12 volt battery. Refer toSection 4 to troubleshoot the PCC control cir-cuitry. (Normal excitation voltage ranges fromapproximately 10 VDC at no-load to approxi-mately 40 VDC at full−load.)

8. If the voltages are unbalanced, troubleshootthe main stator first. If the voltages are uniform-ly low, troubleshoot the exciter and field circuitsfirst.

4-3

EXCITER STATOR

Testing Winding Resistance: Measure windingresistance with a Wheatstone bridge or digital ohm-meter. Replace the stator if winding resistance isnot as specified by Table 4-2.

Testing Winding Insulation Resistance: Discon-nect exciter stator leads F1 and F2 from their con-nectors in the AC generator wiring harness and iso-late them from ground.

Connect the megger between one of the leads andground and conduct the test. Refer to Table 4-1 formegger voltage selection and required resistancevalues.

MEASURE WINDING INSULATIONRESISTANCE BETWEEN EITHER

LEAD AND THE STATORLAMINATIONS

MEASURE WINDING RESISTANCEBETWEEN THE TWO STATOR

LEADS, F1 (X) AND F2 (XX)

FIGURE 4-2. TESTING THE EXCITER STATOR

4-4

EXCITER RECTIFIER BRIDGE (ROTATINGRECTIFIER ASSEMBLY)

The exciter rectifier bridge is mounted on the exciterrotor, inboard, facing the main rotor. It consists of apositive plate and a negative plate, split diametrical-ly. Each carries three diodes, three terminal postsfor connecting exciter rotor leads to the diode pig-tails 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.

Testing Diodes: Disconnect the diode pigtails fromthe terminal posts. Using an ohmmeter, measureelectrical resistance between each diode pigtail andthe plate on which the diode is mounted. Reversethe meter test probes and repeat the tests. Theelectrical resistance across each diode should behigh in one direction and low in the other. If the re-sistance is high or low in both directions, replace thediode.

Replacing Diodes: Make sure the replacementdiode is of the correct polarity. Disconnect the pigtailfrom the terminal post and unscrew the old diode.Apply heat-sink compound under the head of thediode. Make sure the compound does not get on thethreads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8N-m) and the pigtail terminals to 24 in-lbs (2.7 N-m)when reassembling.

Surge Suppresser Testing and Replacement:Remove the suppresser. Replace the suppresser 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 N-m) 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 PIG-

TAIL FROM THE TERMINALAND MEASURE ELECTRICALRESISTANCE BETWEEN THE

PIGTAIL AND THE METALPLATE UNDER THE DIODE

SURGE SUPPRESSERREMOVE TO TEST

DIODE PLATES(TWO)

FIGURE 4-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

4-5

EXCITER ROTORTesting Winding Resistance: Disconnect the sixrotor winding leads from the terminal posts on therectifier assembly. With a Wheatstone bridge, mea-sure electrical resistance across each pair of rotorwindings: U (CR1 or CR4) and V (CR2 or CR5), V(CR2 or CR5) and W (CR3 or CR6), W (CR3 orCR6) and U (CR1 or CR4). See the winding sche-matic. Replace the whole rotor shaft assembly if theresistance of any winding is not as specified in Table4-2.

Testing Winding Insulation Resistance: Discon-nect all six exciter rotor leads from diode terminalsCR1 through CR6 and isolate them from ground.

Connect the megger between one of the leads andground and conduct the test. Refer to Table 4-1 formegger voltage selection and required resistancevalues.

WINDING SCHEMATIC

MEASURE WINDING INSULATIONRESISTANCE BETWEEN ANY LEADOR THE TERMINAL TO WHICH IT IS

CONNECTED AND THE ROTORLAMINATIONS

DISCONNECT THE SIX ROTOR WINDINGLEADS FROM THEIR TERMINALS ANDMEASURE ELECTRICAL RESISTANCE

ACROSS EACH PAIR OF WINDINGS: U-V,V-W, W-U

MAIN ROTORLEADS

FIGURE 4-4. TESTING THE EXCITER ROTOR

4-6

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 4-5. Measureelectrical resistance between the two leads with aWheatstone bridge or digital ohmmeter. Replacethe rotor if the resistance is not as specified in Table4-2. Connect the rotor leads and torque the termi-nals to 23 in-lbs (3.3 N-m) when reassembling.

Insulation Resistance and PI Test: Disconnectthe main rotor and voltage suppressor leads fromterminals F1+ and F2− on the rotating rectifier as-semblies and isolate them from ground. Tag andmark each lead with its terminal number (F1+ orF2−).

Connect the megger between one of the rotor leadsand ground and conduct the test. Refer to Table 4-1for megger voltage selection and required resist-ance values.

DISCONNECT THE MAIN ROTOR LEADSFROM THE ROTATING RECTIFIER ASSEMBLYAND MEASURE THE WINDING RESISTANCE

BETWEEN THEM

MEASURE WINDING INSULATION RE-SISTANCE BETWEEN EITHER ROTOR LEAD

AND THE ROTOR LAMMINATIONS

FIGURE 4-5. TESTING THE MAIN ROTOR

4-7

MAIN STATOR

Testing Main Stator Winding Resistance: Dis-connect all stator leads from the terminals to whichthey are connected. Using a Wheatstone bridgehaving at least 0.001 ohm precision, measure elec-trical resistance across each pair of stator leads:U1-U2, V1-V2, W1-W2, U5-U6, V5-V6 and W5-W6.Replace the stator if the resistance of any winding isnot as specified in Table 4-2.

Insulation Resistance and PI Test: Remove andseparate all leads of the generator from the genera-tor load terminal block. Number of neutral leads(three or six) to remove will vary between low andmedium voltage generators.

Connect the megger between one phase of the sta-tor and ground while grounding the other twophases and conduct the test. Refer to Table 4-1 formegger voltage selection and required resistancevalues.

Repeat this step in turn for the other two phases.

WHEATSTONEBRIDGE

FIGURE 4-6. TESTING THE GENERATOR STATOR

4-8

TABLE 4-2. WINDING RESISTANCE VALUES*

FRAME EXCITER EXCITER MAINMAIN STATOR

FRAMESIZE

EXCITERSTATOR

EXCITERROTOR

MAINROTOR WINDING

11WINDING

12WINDING

17WINDING

07

5C 17 0.174 1.55 0.0068 N/A 0.0105 N/A

5D 17 0.174 1.77 0.0057 N/A 0.0079 N/A

5E 17 0.174 1.96 0.0043 N/A 0.0068 N/A

5F 17 0.174 2.16 0.0037 N/A 0.0049 N/A

* Resistance figures are approximates, at 68° F (20° C) + 10%.

TESTING THE PMG

WARNING HAZARDOUS VOLTAGE.Touching uninsulated parts inside the con-trol housing and power output boxes canresult in severe personal injury or death.Measurements and adjustments must bedone with care to avoid touching hazard-ous voltage parts.

Stand on a dry wooden platform or rubberinsulating mat, make sure your clothingand shoes are dry, remove jewelry and usetools with insulated handles.

1. Disconnect plug J10 from the voltage regulatoroutput stage module.

2. Start the engine at the set and let the speed sta-bilize.

3. Measure voltage across lead pairs J10-1 &J10-4, J10-4 & J10-5, and J10-5 & J10-1. Volt-age should be at least 150 VAC for 50 Hz setsand at least 180 VAC for 60 Hz sets, and shouldbe approximately the same for each set ofleads. If the voltages are low or uneven, checkall the leads and connections between the volt-age regulator output stage module and thePMG and repair as necessary before disas-sembling the PMG.

4. Stop the set and measure electrical resistanceacross lead pairs J10-1 & J10-4, J10-4 &J10-5, and J10-5 & J10-1 with a Wheatstonebridge or digital ohmmeter. Each windingshould have a resistance of approximately 2.6ohms.

4-9

GENERATOR DISASSEMBLYThe following procedures provide information forremoval and reassembly of the PMG, exciter, con-trol housing, and stator/rotor assemblies. Be sure toread through this section first, before performingprocedures listed, to determine the steps most ap-propriate for the service attention required.

Permanent Magnet Generator (PMG)Removal

1. Turn off and disconnect battery charger (ifequipped).

2. Disconnect the negative (−) battery cable toprevent accidental starting of the generator setwhile servicing.

WARNING Arcing at battery terminals, arc-ing in light switch or other equipment,flame, pilot lights and sparks can ignite bat-tery gas causing severe personal injury.

Ventilate battery area before working on ornear battery—Wear safety glasses—Do notsmoke—Switch trouble light ON or OFFaway from battery—Stop genset and dis-connect charger before disconnecting bat-tery cables—Disconnect negative (−) cablefirst and reconnect last.

CAUTION Disconnect battery chargerfrom AC source before disconnecting bat-tery cables. Otherwise, disconnectingcables can result in voltage spikes damag-ing to DC control circuits of the set.

WARNING Accidental starting of the gen-erator set while working on it can cause se-vere personal injury or death. Prevent acci-dental starting by disconnecting the nega-tive (−) cable from the battery terminal.

3. Remove the lower back panel of the controlhousing (see Figure 4-7).

4. Remove the three M5X12mm capscrews andlockwashers from the PMG cover, and removecover.

5. Disconnect the PMG wiring harness connector.

6. Remove the four bolts and clamps retaining theexciter stator housing to the endbracket.

7. Tap the stator housing out of its spigot, andcarefully remove from generator endbracket.

The highly magnetic rotor will attract the statorcore; care must be taken to avoid any contactwhich may damage the windings.

8. Remove the hex head through-bolt from the ro-tor shaft and firmly pull the complete rotor as-sembly from its location. Keep the rotor cleanby avoiding contact with metal dust or particles.

CAUTION The rotor assembly must not bedismantled, or the magnetic properties willbe destroyed.

4-10

Main Stator and Rotor Removal

1. Remove the PMG, refer to Permanent MagnetGenerator Removal, earlier this section.

2. Remove the lower back panel, the two lowerfront panels and the upper access panels of thecontrol housing assembly (see Figure 4-7).

3. Remove the air inlet and discharge panels ofthe generator.

CAUTION Do not use fan blade to bar overengine. That can damage blades and causeproperty damage and personal injury.

4. Crank or bar the engine/generator to positionthe rotor such that a full pole face is at the bot-tom of the main stator core. Proper positioningcan be viewed through the generator access

openings. Refer to engine service manual forproper cranking or barring procedure.

5. Disconnect all load wires from the reconnec-tion terminal block assembly. If equipped withthe circuit breaker option, disconnect loadwires from circuit breaker. Check that all leadsare labeled to ease reassembly.

6. Disconnect the remote control wiring and con-duit from the control housing. For reconnec-tions later, make sure each wire is clearlymarked to indicate the correct terminal.

7. Disconnect the engine harness connectors(INLINE A, B, and C) and the DC power con-nector for the engine block heaters (INLINE F)and place harness on top of control housing.

8. Mark and disconnect the wires to the CT’s.

LOWER FRONTPANELS

UPPER FRONTPANEL

LOWER BACKPANEL

SIDEPANEL

UPPER ACCESSPANEL LOCATION

(BOTH SIDES)

FIGURE 4-7. CONTROL HOUSING ASSEMBLY

4-11

9. Use a hoist or similar lifting device to supportthe control housing assembly.

WARNING To prevent personal injury, useadequate lifting devices to support heavycomponents. Keep hands and feet clearwhile lifting.

10. Loosen the fasteners that secure the controlhousing side and bottom panels to generator.Make sure that hoisting device is controllingweight of control housing assembly.

11. Remove control housing fasteners, and re-move the control housing assembly from thegenerator.

To remove the stator and rotor at the same time,skip to step 27. To remove the stator and rotorindividually, continue with step 12.

12. Remove the four bolts retaining the bearingcartridge housing in the endbracket (outer fourbolts).

13. Remove the eight bolts holding the endbracketto the generator housing.

14. Insert two bolts (M10) in the two holes providedfor “jacking” purposes, on the endbracket cen-ter line. Screw bolts in until endbracket spigotis clear of locating recess.

15. Carefully tap the whole assembly off the bear-ing cartridge housing, ensuring the endbracketis supported to prevent the exciter stator fromdamaging the windings on the exciter rotor.


16. The exciter stator is now accessible for inspec-tion and removal from endbracket/engineadaptor.

17. The end bearing can now be removed if re-quired. Refer to Bearing Removal.

18. Remove the M20 fastener from the two genera-tor mounting feet brackets (Figure 4-10).

WARNING Generator weight can cause se-vere personal injury or death. Use extremecaution when lifting, hoisting, or movingthe generator. Make certain to use a hoist orother lifting device whose capacity is ratedwell above the weight of the generator. Thegenerator (dependent on model type) canweigh up to 3,745 pounds (1685 kgs). Makecertain that the maximum lifting capacity ofthe hoist exceeds the weight of the genera-tor by a large margin. Follow the manufac-turer’s instructions carefully regarding theweight capacity of the hoist and the recom-mended hoisting procedure.

19. Using an adequate lifting device, lift the gener-ator (at lifting eyes provided) so that the gener-ator is completely supported by the lifting de-vice. (Note that the engine is still supported byfour mounting feet. Do not lift generator anyhigher than necessary to support weight ofgenerator with lifting device, or binding will oc-cur between top of generator and engine.)

4-12

STATORASSEMBLY

LIFT

ROTORASSEMBLY

LIFT

STATORASSEMBLY ROTOR

ASSEMBLY

USE FORKLIFT OROTHER ADEQUATELIFTING DEVICE TO

SLIGHTLY LIFT ROTORSHAFT UNTIL ROTORCAN BE SUPPORTED

BY HOIST/SLING.

MOUNTING FEETBRACKETS

FIGURE 4-8. REMOVING STATOR ASSEMBLY

4-13

20. Using a forklift, position a lifting bar of the forklift(inside and in-line with the generator) under therotor shaft. Lift the rotor shaft slightly so that ro-tor is not resting on inside of stator assembly.See Figure 4-8. (Use V-block secured to liftingbar or straps to secure rotor shaft to forklift bar.)

21. Verify that the stator is adequately supportedand then carefully remove the capscrews fromthe stator attachment ring.


CAUTION Improper stator assembly rig-ging and handling can result in damage tostator and rotor assemblies. Lifting eyesmay not be at center-of-gravity position ofstator assembly. Therefore, lifting and mov-ing the stator assembly alone, by hoistingat lifting eyes only, presents the hazard ofload imbalance; allowing one end to dropand other end to rise. Make sure the statoris adequately hooked/strapped to maintainlevel control of stator assembly while liftingand moving.

22. Being careful not to drag the windings on therotor, move the stator assembly sufficientlyaway from engine to sling and support the rotorassembly. Do not allow rotor assembly to hangon engine flywheel.

CAUTION Drive disc damage can becaused by allowing the rotor assembly tohang on flywheel. Use adequate hoist andsling to support the rotor assembly.

23. Reposition or add hoist and sling support forthe main rotor, and remove the forklift. See Fig-ure 4-9, Rotor Lift detail.


24. Remove the stator assembly, being careful notto drag the windings on the rotor. Place statorassembly away from the chassis in the horizon-tal position.

25. Using the hoist and sling to support the rotor,carefully remove the capscrews and flat wash-ers that secure the drive discs to the engine fly-wheel.


26. Remove the rotor assembly and place it onwood blocks in the horizontal position. To avoidpossible distortion, do not allow the drive discsand fan to rest on anything.

ROTOR LIFT(EXAMPLE)

STATOR LIFT(EXAMPLE)

FIGURE 4-9. STATOR/ROTOR LIFT EXAMPLE

4-14

Generator Assembly Removal

27. Remove the M20 fastener from the two genera-tor mounting feet brackets (Figure 4-10).

WARNING Generator weight can cause se-vere personal injury or death. Use extremecaution when lifting, hoisting, or movingthe generator. Make certain to use a hoist orother lifting device whose capacity is ratedwell above the weight of the generator. Thegenerator (dependent on model type) canweigh up to 3,745 pounds (1685 kgs). Makecertain that the maximum lifting capacity ofthe hoist exceeds the weight of the genera-tor by a large margin. Follow the manufac-turer’s instructions carefully regarding theweight capacity of the hoist and the recom-mended hoisting procedure.

28. Using an adequate lifting device, lift the gener-ator (at lifting eyes provided) so that the gener-ator is completely supported by the lifting de-vice. (Note that the engine is still supported byfour mounting feet. Do not lift generator anyhigher than necessary to support weight ofgenerator with lifting device, or binding will oc-cur between top of generator and engine.)

29. Carefully remove the capscrews and flat wash-ers that secure the drive discs to the engine fly-wheel.

30. Verify that the generator assembly is ade-quately supported. Carefully remove the caps-crews securing the engine adaptor endbracketto the engine flywheel housing.

CAUTION Improper generator assemblyrigging and handling can result in damageto stator and rotor assemblies. Lifting eyesmay not be at center-of-gravity position ofstator assembly. Therefore, lifting and mov-ing the generator by hoisting at lifting eyesonly, presents the hazard of load imbal-ance; allowing one end to drop and otherend to rise. Make sure the generator is ade-quately hooked/strapped to maintain levelcontrol of assembly while lifting and mov-ing.

31. Remove the generator assembly away fromengine. Place generator assembly on floor witha piece of wood beneath the stator housing (to-ward PMG end) to allow for endbracket remov-al, if desired.

4-15

Bearing Removal

The sealed end bearing is enclosed in a cartridgehousing and must only be dismantled as necessaryfor replacement, or when a major overhaul is car-ried out on the generator set.

Removal of the bearing can only be accomplishedafter removal of the endbracket, as follows:

1. Remove the four screws holding bearing cap.2. Remove cap.3. Remove circlip.4. Remove bearing cartridge housing complete

with bearing.

When replacing bearing onto rotor shaft, be sure toapply pressing force to the inner face of the bearingonly.

4-16

GENERATOR REASSEMBLY

Generator reassembly is the reverse of disassem-bly procedure.

To assemble the stator and rotor at the same time,continue with step 1. To assemble the stator and ro-tor individually, skip to step 16.

1. Using an adequate lifting device, locate thegenerator assembly into position near the en-gine flywheel housing.


CAUTION Improper generator assemblyrigging and handling can result in damageto stator and rotor assemblies. Lifting eyesmay not be at center-of-gravity position ofstator assembly. Therefore, lifting and mov-ing the generator by hoisting at lifting eyesonly, presents the hazard of load imbal-ance; allowing one end to drop and otherend to rise. Make sure the generator is ade-quately hooked/strapped to maintain levelcontrol of assembly while lifting and mov-ing.

2. Align the holes of the engine adaptor endbrack-et with the holes in the flywheel housing andinstall the capscrews and lock washers. Tight-en fasteners to 65-70 ft-lbs. (88-95 N-m)torque.

3. Using a wood pry bar inserted between the en-gine adaptor and blower, carefully lift end of ro-tor assembly to allow drive discs to snap intoflywheel. Align the holes of the rotor drive discswith the holes of the engine flywheel. Install thecapscrews and flat washers that secure thedrive discs to the engine flywheel.

4. Secure the rotor assembly to the flywheel.Tighten fasteners to 75-85 ft-lbs. (102-115N-m) torque.

5. Review the Generator Mount Pre-load Adjust-ment, later this section, to determine if this ad-justment is required at this time. (Skip step 6 ifthis procedure is performed.)

6. Secure the generator foot brackets to the vibra-tion isolators. Apply Loctite 271 to the M20screw and tighten the fastener to 270-330 ft-lbs. (365-447 N-m) torque.

If endbracket has been removed, continue withstep 7, otherwise skip to step 15.

7. Lift slightly on end of rotor shaft and installwooden shims to hold rotor on center with sta-tor.

8. Press bearing onto rotor shaft, applying forceto the inner face of the bearing. Install twothreaded studs into end bearing cartridge to aidsubsequent procedures. Position the endbearing cartridge assembly close to properposition for hole alignment with endbracket.

9. Assemble exciter stator, if removed, to inside ofendbracket. Tighten fasteners to 4.5 ft-lbs. (6N-m) torque.

10. Install endbracket to the stator frame using theproper capscrews and lock washers, but do nottighten securely as yet.

11. Insert and start the threads of the bearing car-tridge fasteners, and remove threaded align-ment studs, through the endbracket into thecartridge housing.

12. Lift slightly on endbracket and remove woodenshims holding rotor on center with stator.

13. Securely tighten the endbracket fasteners.

14. Tighten the bearing cartridge fasteners to 4.5ft-lbs. (6 N-m) torque.

4-17

15. Install the PMG assembly, if removed. Refer toPermanent Magnet Generator (PMG) Installa-tion, later this section.

To assemble the control housing, skip to step33.

To assemble the stator and rotor individually be-gin here.

16. If removed, replace exciter rotor and rotatingrectifier assembly to main rotor shaft. Recon-nect main rotor wire leads to positive and nega-tive terminals of rectifier assembly.

17. If removed, install the drive disc spacer, drivedisc and pressure plate on the rotor shaft.Install the cap screws and flat washers andtighten to 352 ft-lbs. (476 N-m) torque.

18. Using a hoist and sling to support the rotor,align the holes in the drive disc with the corre-sponding holes in the flywheel.


19. Secure the rotor assembly drive disc to the fly-wheel using appropriate capscrews and flatwashers. Tighten fasteners to 75-85 ft-lbs.(88-95 N-m) torque. Do not allow rotor assem-bly to hang on engine flywheel. (Refer to Figure4-8)

CAUTION Drive disc damage can becaused by allowing the rotor assembly tohang on flywheel. Use adequate hoist andsling to support the rotor assembly.

20. Reassemble engine adaptor endbracket tostator frame if removed. Using an adequate lift-ing device, carefully move the stator into posi-tion over the rotor assembly, being careful notto drag the windings on the rotor.


CAUTION Improper stator assembly rig-ging and handling can result in damage tostator and rotor assemblies. Lifting eyesmay not be at center-of-gravity position ofstator assembly. Therefore, lifting and mov-ing the stator assembly alone, by hoistingat lifting eyes only, presents the hazard ofload imbalance; allowing one end to dropand other end to rise. Make sure the statoris adequately hooked/strapped to maintainlevel control of stator assembly while liftingand moving.

21. Using a forklift, position a lifting bar of the forklift(inside and in-line with the generator) under therotor shaft. Lift the rotor shaft slightly so that ro-tor is not resting on inside of stator assembly.See Figure 4-8.

22. Remove the hoist/sling support of the rotor as-sembly. Align the holes of the engine adaptorendbracket with the holes in the flywheel hous-ing and install the capscrews and lock wash-ers. Tighten fasteners to 65-70 ft-lbs. (88-95N-m) torque.

23. Review the Generator Mount Pre-load Adjust-ment, later this section, to determine if this ad-justment is required at this time. (Skip step 24if this procedure is performed.)

24. Secure the generator foot brackets to the vibra-tion isolators. Apply Loctite 271 to the M20screw and tighten the fastener to 270-330 ft-lbs. (365-447 N-m) torque.

25. Reassemble the covers over the generator airdischarge openings and fasten securely.

4-18

26. Press bearing onto rotor shaft, applying forceto the inner face of the bearing. Install twothreaded studs into end bearing cartridge to aidsubsequent procedures. Position the endbearing cartridge assembly close to properposition for hole alignment with endbracket.

27. Assemble exciter stator, if removed, to inside ofendbracket. Tighten fasteners to 4.5 ft-lbs. (6N-m) torque.

28. Install endbracket to the stator frame using theproper capscrews and lock washers, but do nottighten securely as yet.

29. Insert and start the threads of the bearing car-tridge fasteners, and remove threaded align-ment studs, through the endbracket into thecartridge housing.

30. Lift slightly on endbracket and remove woodenshims holding rotor on center with stator.

31. Securely tighten the endbracket fasteners.

32. Tighten the bearing cartridge fasteners to 4.5ft-lbs. (6 N-m) torque.

33. Use an adequate lifting device to lift the controlhousing in position for mounting to the skid. Re-place the capscrews and lock washers andtighten to 18 ft-lbs. (24 N-m) torque.


34. Reassemble any engine air intake compo-nents removed during generator disassembly.

35. Connect all control wires and generator leadsusing the proper generator set AC and DC wir-ing diagram/schematic.

36. Refer to Permanent Magnet Installation.

37. If equipped with the circuit breaker option, re-connect load wires to circuit breaker. Recon-nect all lead wires to the terminal block assem-bly using proper reconnection diagram in Sec-tion 5.

38. Verify that all connections are proper and se-cure and then install all control housing panels(see Figure 4-7).

39. Connect the negative (-) battery cable.

40. Connect the battery charger (if applicable) andtest the generator set for operation. If objec-tionable vibration is present, refer to AligningGenerator with Engine procedure later thissection.

Permanent Magnet Generator (PMG)Installation

1. Install the complete rotor assembly to the endof the main rotor shaft using the hex headthrough-bolt. Keep the rotor clean by avoidingcontact with metal dust or particles.

2. Carefully locate the stator housing to positionon the generator endbracket. Fasten in placeusing the 4 bolts and clamps, and tighten se-curely.

The highly magnetic rotor will attract the statorcore, care must be taken to avoid any contactwhich may damage the windings.

3. Connect the PMG wiring harness connector.4. Install the PMG assembly cover using the three

M5x12mm capscrews and lockwashers, andtighten securely.

4-19

GENERATOR MOUNT PRE-LOADADJUSTMENT

This procedure must be performed if one or more ofthe following conditions have occurred.

• Installation of new stator

• Loosening of hardware that secures enginemount bracket(s) to flywheel housing (see Fig-ure 4-10).

• Installation of new engine or generator vibra-tion isolator(s).

Special tools − This procedure requires two1 3/4“T x 2”W x 6”L steel spacers.

WARNING Accidental starting of the generatorset during this procedure presents the hazardof severe personal injury or death. Make sure todisconnect the negative (−) battery cable(s) be-fore beginning.

1. Turn off and disconnect battery charger (ifequipped).

2. Disconnect the negative (−) battery cable(s) toprevent accidental starting of the generator setwhile servicing.

3. Unscrew bolt (Item 2 in Figure 4-10) from skidbut do not remove the bolt from either rear en-gine vibration isolator.

4. Loosen the three screws that secure the en-gine mount brackets to the engine to allow thebrackets to move up and down.

5. Loosen but do not remove the hex nut (Item 1)from the M20 screw of the generator vibrationisolators.

6. Using an adequate lifting device, lift the gener-ator (at lifting eyes provided) until the mountingfeet brackets are high enough to insert a 1 3/4inch steel spacer under both stator foot brack-ets.

7. Insert spacers and lower the generator so thefull weight is resting on the generator mountingfoot brackets.

8. Make sure that no gap is present between theskid and the lower mount of the rear enginevibration isolators (see Figure 4-10). Whilepushing down on the engine mount bracket,tighten the three screws to secure the bracketto the engine. Tighten the three screws to190-200 ft-lbs. (260-270 N-m) torque.

9. Lift the generator until the mounting feet brack-ets are high enough to remove the two 1 3/4inch steel spacers.

10. Before lowering the generator, start thethreads of the rear engine vibration isolatorbolts (Item 2).

11. Lower the generator and tighten the two rearengine vibration isolator bolts to 270-330 ft-lbs.(365-447 N-m) torque.

12. Secure the generator foot brackets to the vibra-tion isolators. Tighten the fastener to 270-330ft-lbs. (365-447 N-m) torque.

4-20

ÈÈÈÈÈÈ

SECTION A(REAR ENGINE

VIBRATION ISOLATOR)

SECTION B(GENERATOR VIBRATION

ISOLATOR)

A

A

B

B

ENGINE MOUNTBRACKET

ITEM 1(HEX NUT)

FLYWHEELHOUSING

ENGINE MOUNTBRACKET

SCREW X 3STATOR FOOT

BRACKET

1 3/4 INCH THICKSTEEL SPACER

SKID

LOWERMOUNT

REMOVEGAP

(STEP 8)

ITEM 2M20

SCREW

SNUBBERWASHER

WASHER

MOUNTINGPLATE

FIGURE 4-10. GENERATOR MOUNT PRE-LOAD ADJUSTMENT

4-21

ALIGNING GENERATOR WITH ENGINE

Proper alignment of the generator and engine as-semblies is necessary to avoid premature wear andimproper operation of the genset.Axial Misalignment: Is the result of the generatorshaft axis not aligning with engine crankshaft axis.The tolerances in the bolted flywheel and drive discconnection may add up to displace the generatoraxially relative to the crankshaft axis.

Axial misalignment needs to be checked only whenan objectionable vibration is present.

Axial Alignment Procedure

Axial misalignment needs to be checked only whenan objectionable vibration is present.

Fasten dial indicator holding device to skid base,engine block, or generator shell with a magneticbase or clamp and position so the sensor point of in-dicator rests on the generator shaft hub, see Figure4-11. Bar the engine over in a clockwise rotation asviewed from engine flywheel, through a couple ofrotations. Record indicator readings in eight equallyspaced points around the shaft diameter. This willprovide a T.I.R. for Axial shaft misalignment.The maximum allowable T.I.R. runout is subjective,the optimal T.I.R. for runout would be .000”, howev-

er, that may not be attainable. The recommendationof this procedure will be to reduce the measuredT.I.R. runout by one half. Specific out-of-tolerancerunout levels are difficult to establish due to thevarying surface quality of the generator shaft’s drivedisc mountain hub.

The goal of the Axial realignment is to reduce thevibration level of the genset while it is operating. Asmall improvement in the T.I.R. runout may havedramatic effects in the mechanically measured orphysically observed vibration levels.

To correct for an out of tolerance T.I.R. indication,remove the capscrews connecting drive discs andflywheel. Mark the drive discs and flywheel with re-spect to each other. Rotate either the engine or gen-erator so that drive discs holes are repositioned180 degrees from their original location. Put thedrive discs capscrews back in and retorque. Re-check shaft alignment as before. If shaft T.I.R.runout remains unchanged then the discs should berotated to either 30, 60, or 90 degrees from originallocation to correct the out of tolerance condition. Ifthe T.I.R. does not improve after repositioning, acloser inspection of the flywheel pilot and drive discrunouts is required. This will help determine thecause of the Axial misalignment.

GENERATORAND ENGINECRANKSHAFTCENTERLINE FAN HOUSING

CLAMP

GENERATORSHAFT HUB

DIALINDICATOR

FIGURE 4-11. AXIAL ALIGNMENT MEASUREMENT

4-22

THIS PAGE LEFT INTENTIONALLY BLANK

5-1

5. Optional Enclosure Fuel Tank System

GENERAL

This section describes the operation and testing ofthe optional components of the fuel tank systemshown in Figure 5-1.

When a sub-base fuel tank is provided, a fuel trans-fer pump with control, an external fuel alarm paneland external fuel fill box are available as an option.

WIRING CONNECTIONS

Fuel Transfer Control Customer Outputs

See Fuel Tank Wiring diagram in Section 6 for cus-tomer connections to remote annunciators.

PCC Customer Inputs

PCC Customer Inputs 3 (Low Fuel) and 4 (RuptureBasin) are prewired to the sub-base fuel tank whenshipped from the factory.

The “Low Fuel” warning message, when displayedby the PCC, indicates that the fuel level hasdropped below the low fuel level (approximately62%).

The “Rupture Basin” warning message is used to in-dicate that fuel is detected in the fuel tank basin.

FUEL ALARMPANEL

EXTERNALFUEL FILL BOX

FUEL FILL(INTERNAL)

FUEL TRANSFERCONTROL

FIGURE 5-1. FUEL TANK SYSTEM OPTIONAL COMPONENTS

5-2

FUEL TRANSFER PUMP

The fuel transfer pump and control are available asan option when a sub-base fuel tank is provided.The automatic control operates the fuel pump tomaintain a reservoir of fuel in the sub-base tank.

This section explains functions of the control panellamps, components and operation/testing of theday tank fuel control system. All red color lamps in-dicate a fault condition.

Control Panel Switches and IndicatorsThe following paragraphs describe the operation ofthe control switches and indicators.

Indicators:• FUEL LEVEL (green): indicates in percent the

amount of fuel that is contained in the sub-basetank.

• HIGH FUEL (red): indicates that the fuel hasreached an abnormally high level. It indicates apossible failure of the ”pump-off” float gauge inthe sub-base tank. The lamp will turn off whenthe fuel level drops to normal.

FIGURE 5-2. TRANSFER PUMP CONTROL FRONT PANEL

5-3

• LOW FUEL (red): indicates that the fuel levelhas dropped below the low fuel level. Thiswarning enables the operator time to react to apotential problem before low fuel shutdown oc-curs. It indicates a possible empty main fueltank, fuel line restriction, pump failure, or failureof the float gauge.

• CRITICAL LOW FUEL (red): indicates that thefuel level has dropped to tank bottom. Thiswarning enables the operator time to shutdown generator set before fuel runs out, pre-venting loss of prime or engine damage. It indi-cates a possible empty main fuel tank, fuel linerestriction, pump failure, or failure of the floatgauge.

The control should be wired to shut down thegenset (optional) as continued operation will al-low air to enter the engine injection pump ne-cessitating bleeding to restart the engine. Thecontrol will reset after restoring the tank fuellevel. This will also restore engine operation ifthe tank control has been connected to shutdown the engine.

CAUTION Continued operation with aCRITICAL LOW FUEL fault can lead to a lowfuel shutdown if the fuel level float switchfails.

• FUEL IN RUPTURE BASIN (red): indicatesthat the fuel has flooded the safety basin sur-rounding the fuel tank. The basin float switchturns off the fuel pump. The pump cannot func-tion again until the basin is drained of fuel. Pos-sible cause, leak in fuel tank.

• PUMP (green): indicates that the fuel pump isrunning. It will come on and go off as fuel ispumped to maintain the fuel tank level.

• ECM FUNCTIONAL (green): indicates nofaults are detected within the control circuitry(including float gauge). If a fault occurs, thelamp will go out and de-energize the controlrelay. It is suggested that the customer wire to

the normally closed contact to provide a signalif a fault does occur.

• POWER ON (green): indicates that AC poweris available to the control.

Switches:

• ON: This pushbutton activates the control afterthe OFF pushbutton has been pressed.

• OFF: This pushbutton disables the control forroutine maintenance to the tank system withoutdisrupting the control. NOTE: This also de-ener-gizes the ECM FUNCTIONAL relay which will ac-tivate a customer alarm wired to this relay.

• TEST: This pushbutton will test all front panellamps for three seconds and activate pump/motor for as long as the button is pressed. Allalarm relays will not activate but will maintaintheir original state.

Operation

The following steps describe how to operate the daytank controller.

NOTE: When power is applied to the control or is re-stored after a power interruption, the control will au-tomatically go to the power on mode (functions thesame as pressing the ON switch). The pump will startif the control detects low fuel in tank.

1. Press the control ON switch for automatic op-eration. The green PUMP light will come onand the pump will fill the tank. The level of fuel inthe tank will be automatically kept between aset of pump-on and pump-off float gauge.

When filling an empty tank, the red CRITICALLOW FUEL and LOW FUEL lights will come onwhen the control switch is pushed to the ONposition. This is normal. The red lights will turnoff as the tank is filled.

2. The green PUMP light indicates when thepump is running. It will come on and off as fuelis pumped to maintain the proper level in thetank.

5-4

EXTERNAL FUEL FILL BOX

The external fuel fill box plumping may contain theoptional overflow preventive valve (OFPV), which isused to prevent the overfilling of the fuel tank. Thevalve will energize (close) when a Critical High fuelcondition (95% full) is detected/displayed by the Ex-ternal Alarm panel.

If the valve remains closed after correcting the criti-cal high fuel condition, check the following possiblecauses before replacing the valve.

• Defective Critical High switch mounted on fueltank. (Critical High switch remains closed withfuel gauge indicating less than 95% full.)

• Defective External Alarm panel (refer to AlarmPanel Wiring in Section 6).

EXTERNALFUEL FILL BOX

OVERFLOWPREVENTIVEVALVE (OFPV)(OPTIONAL)

FIGURE 5-3. OPTIONAL FUEL (SPILL) FILL BOX

5-5

EXTERNAL ALARM PANEL

The following paragraphs describe the operation ofthe external alarm panel components.

Overfill Indicator/Horn/Mute Button

The overfill alarm Indicates that the fuel hasreached an abnormally high level (95%). Immedi-ately stop adding fuel. It also indicates a possiblefailure of the “pump-off” float gauge for fuel systemsthat contain the fuel transfer pump.

The horn can be turned off by pressing the mute but-ton. The indicator will turn off when the fuel leveldrops to normal.

Fuel Gauge

Indicates the amount of fuel that is contained in thesub-base tank.

Solenoid Override Button

The Solenoid Override Button is only provided onthe Alarm Panel when the optional overflow preven-tive valve (Figure 5-3) is provided with the externalfill box feature.

This switch is used to release the delivery hosepressure caused by the closing of the overflow pre-ventive valve. This valve automatically closes dur-ing an overfill alarm, stopping the filling of the tankand creating pressure between the valve and thedelivery hose. Before disconnecting the deliveryhose, always press this button after an overfill warn-ing to release fuel back pressure into the sub-basetank.

Test Button

Press the TEST switch to test the indicator light andthe horn. The test will remain active for as long asthe button is pressed.

TEST BUTTON MUTE BUTTON

OVERFILLINDICATOR

HORN

FUELGAUGE

SOLENOID OVERRIDEBUTTON (OPTIONAL)

FIGURE 5-4. EXTERNAL ALARM PANEL

5-6

RUPTURE BASIN LEAK DETECT SWITCHTEST

The rupture basin leak detect switch (Figure 5-5) isprovided with sub-base fuel tanks used with the op-tional enclosure. This switch should be checkedonce a year to make sure switch is properly operat-ing. In some areas, weekly inspections may be re-quired by safety code regulations.

To test the leak detect switch:

1. Remove the pipe fitting/switch assembly fromthe rupture basin tank.

2. Move the O/Manual/Auto switch to the MANU-AL position.

3. Activate leak detect switch (move float up-ward).

4. Check control display for Rupture Basin faultmessage. If no indication of fault, repair defec-tive circuit. Refer to Fuel Tank Wiring diagramin Section 6.

5. Apply thread sealant to pipe fitting and installswitch assembly.

LEAK DETECTSWITCH ASSEMBLY

ENCLOSURESUB-BASEFUEL TANK

FIGURE 5-5. RUPTURE BASIN LEAK DETECT SWITCH

6-1

6. Wiring Diagrams

GENERALThis section consists of the schematic and connec-tion wiring diagrams referenced in the text. The fol-lowing drawings are included.

• Page 6-2, DC Power and Starter Wiring• Page 6-3, Engine Sensors• Page 6-4, Control Wiring• Page 6-5, Generator / Bus Connections• Page 6-6, Customer Connections• Page 6-7, Customer Connections• Page 6-8, TB3 Terminal Descriptions• Page 6-9, Customer Connections Terminal Strip• Page 6-10, Enclosure Options Wiring• Page 6-11, Fuel Tank Wiring• Page 6-12, Customer Connections (Enclosure

Option)• Page 6-13, Alarm Panel Wiring

6-2

No. 630-2592 sh 1 of 11Rev. EModified 12-03

THIS IS A REPRESENTATIVE (GENERIC) SCHEMATIC/WIRING DIAGRAM. FORTROUBLESHOOTING, REFER TO THEWIRING DIAGRAM PACKAGE THAT WASINCLUDED WITH YOUR GENSET.

DC POWER AND STARTER WIRING

6-3



ENGINE SENSORS

6-4



CONTROL WIRING

6-5



GENERATOR / BUS CONNECTIONS

6-6



CUSTOMER CONNECTIONS

6-7



CUSTOMER CONNECTIONS

6-8



TB3 TERMINAL DESCRIPTIONS

6-9



CUSTOMER CONNECTIONS TERMINAL STRIP

6-10



ENCLOSURE OPTIONS WIRING

6-11

No. 630-2592sh 10 of 11Rev. EModified 12-03


FUEL TANK WIRING

6-12

No. 630-2592sh 11 of 11Rev. EModified 12-03


CUSTOMER CONNECTIONS (ENCLOSURE OPTION)

6-13

No. 541-1066 sh 2/3 of 3Rev. BModified 12-03


ALARM PANEL WIRING WITH TRANSFER PUMP CONTROL

ALARM PANEL WIRING WITHOUT TRANSFER PUMP CONTROL

CRITICALHIGH

FUELGAUAGE

FUELGAUAGE

HIGHFUEL

HIGHFUEL

OVERFILL VALVE(USED WITH

SPILL FILL BOX)

ALARM PANEL WIRING

Cummins Power Generation1400 73rd Avenue N.E.Minneapolis, MN 554321-800-888-6626763-574-5000 International UseFax: 763-528-7229

Cummins is a registered trademark of Cummins Inc.

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