Manual de Servicio PS 0500

 

Service Manual Generator  Set X1.3 & X2.5 Engine

with  PowerStart 0500 Control

C8D5 C11D5

C17D5  C17D5 (Spec E)  C22D5  C22D5 (Spec E)  C28D5 C28D5 (Spec E) C12D6  C12D6 (Spec E) C16D6  C16D6 (Spec E) C20D6 C20D6 (Spec E)

English Original Origi nal Instr Instructio uctions ns

08-2017

 A029U889 (Issue 3) (Issue 3)  

 

PowerStart 0500 X1.3 & X2.5 Engine  Engine 

Publication A029U889 Issue 3 - 8-2017

Table Ta ble of Contents   SECTION

TITLE

PAGE

1

IMPORTANT SAFETY INSTRUCT INSTRUCTIONS IONS

5

2

INTRODUCTION

7

2.1

Abou t this Manual

7

2.2

System Overview

7

2.3

Test Equipm ent

7

2.4

How to Obtain Service

7

CONTROL PANEL OPERATION

8

3.1

General

8

3. 3.2 2

Alternator Connections

9

3.3

Contro l Operation

11

3.4

Contro l Panel

12

3.5

Mode of Operation

14

CIRCUIT B OA RD

19

Contro l Input and Output s

21

5

TROUB L ESHOOTING

24

5.1

Safety Safety Consid erations

24

5.2

Troubl eshoot ing Procedur e

24

6

Set u p an d Cal i b r at i o n

34

7

SERVICING THE GENERA TOR

39

7.1

Testing the Generator

39

7.2

Generator Baseboard Isolatio n Procedur e

40

7.3

Excito r Stator

41

7.4

Excito r Rectifier Brid ge

42

7.5

Main Stator

45

7.6

Generator Disassembly

47

8

WITHDRA WING ROTOR

49

8.1

Generator Rea Reassemb ssemb ly

49

3

4 4.1

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PowerStart 0500 X1.3 & X2.5 Engine  Engine 

SECTION

TITLE

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PAGE

9

WIRING DIA GRA MS

53

9.1

General Inform ation

53

9.2

Wiring Diagram

57

9.3

Battery Charger and Coolant Heater Heater

59

9.4

Custom er Connecti ons

62

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 Publication A029U889

PowerStart 0500 X1.3 & X2.5 Engine  Engine 

Issue 3 - 8-2017

SECTION 1 – IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS –  –  This manual contains important instructions that should be followed during installation and maintenance of the generator and batteries. Before operating the generator set (genset), read the Operator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated

highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc. EXHAUST GASES ARE DEADLY •

Provide an adequate exhaust system to properly expel discharged gases away from enclosed or  sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance

and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.

• •

 DANGER

This symbol warns of immediate hazards which will result in severe personal inj ury o r death.

MOVING PARTS CAN CAUSE SEVERE PERSONAL PERSONAL INJURY OR DEATH •

 WARNING

This symbol refers to a hazard or unsafe practice which can result in severe personal inju ry or death. death.  CAUTION

This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage. damage.

•

•

•

FUEL AND FUMES FUMES ARE FLAMMAB LE Fire, explosion, and personal injury or death can result from improper practices. •

•

•

•

•

the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. Be sure the unit is well ventilated. Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

•

Keep your hands, clothing, and jewelry away from moving parts. Before starting work on the generator set, disconnect battery charger from its AC source, then disconnect starting batteries, negative (–) cable first. This will prevent accidental starting. Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. Do not wear loose clothing or jewelry in the vicinity of moving parts, or while working on electrical equipment. Loose clothing and jewelry can become caught in moving parts. If adjustment must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compartment. Fuel contact with hot engine or exhaust is a potential fire hazard. DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. Fuel lines must be adequately secured and free of 

DO NOT OPERATE INFLAMMABLE AND EXPLOSIVE ENVIRONMENTS.

leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use zinc coated or copper fuel lines with diesel fuel Be sure all fuel supplies have a positive shutoff  valve. Be sure battery area has been well-ventilated prior  to servicing near it. Lead-acid batteries emit a

unless the genset is equipped with an automatic safety device to block the air intake and stop the engine. The owners and operators of the genset are solely responsible for operating the genset safely. Contact your authorized Cummins Inc.  distributor for more information.

Flammable vapor can cause an engine to overspeed and become difficult to stop, resulting in possible fire, explosion, severe personal injury and death. Do not operate a genset where a flammable vapor environment can be created by fuel spill, leak, etc.,

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Publication A029U889 Issue 3 - 8-2017

PowerStart 0500 X1.3 & X2.5 Engine  Engine 

ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH •

•

•

Remove electric power before removing protective shields or touching electrical equipment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. Do not wear   jewelry. Jewelry can short out electrical contacts and cause shock or burning. Use extreme caution when working on electrical components. High voltages can cause injury or  death. DO NOT tamper with interlocks. Follow all applicable state and local electrical codes. Have all electrical installations performed

•

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

•

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

•

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

•

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

•

by a qualified licensed electrician. Tag and lock open switches to avoid accidental closure. DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous SYSTEM.  Hazardous voltages can flow from the generator set into the utility line. This creates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling device.

GENERAL SAFETY SA FETY PRECAUTIONS •

•

•

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

•

Do not work on this equipment when mentally or physically fatigued, or after  consuming any alcohol or drug that makes the operation of equipment unsafe. Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity.

•

Coolants sunder pressure have a higher boiling

Take care not breath gases. or ingest or come into contact withtoexhaust

point than water.pressure DO NOTcap open a radiator or  heat ex-changer while the engine is running. To prevent severe scalding, let engine cool down before removing coolant pressure cap. Turn cap slowly, and do not open it fully until the pressure has been relieved. Used engine oils have been identified by some state or federal agencies as causing cancer or  reproductive toxicity. When checking or  changing engine oil, take care not to ingest, breathe the fumes, or con-tact used oil.

•

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

 

•

Wear hearing protection when going near an operating generator set.

•

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

KEEP THIS MANUA L NEA R THE GENSET FOR EASY REFERENCE REFERENCE

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 Publication A029U889 Issue 3 - 8-2017

Power Start 0500 X1.3 & X2.5 Engine  Engine 

SECTION 2 – INTRODUCTION 2.1 ABOUT THIS MANUAL This manual provides troubleshooting and repair information regarding the PowerCommand® 1302Control (PCC) and generators for the generator sets (gensets) listed on the front cover. Engine service instructions are in the applicable engine service manual. Operating and maintenance instructions are in the applicable Operator’s Manual. This manual does not have instructions for servicing printed circuit board assemblies. After determining that a printed circuit board assembly is faulty, replace it, do not repair it. Attempts to repair a printed circuit board can lead to costly damage to the equipment.

display panel. It accepts menu-driven control and set-up input  from the push button switches on the front panel.

2.3 TEST EQUIPMENT To perform the test procedures in this manual, the following test equipment must be available True RMS meter for accurate measurement of small AC and DC voltages. Fluke models 87 or 8060A are good choices.  Grounding wrist strap to prevent circuit board   

This manual contains basic (generic) wiring diagrams and schematics that are included to help in troubleshooting. Service personnel must use the actual wiring diagram and schematic shipped with

   

damage due to electrostatic discharge (ESD). Battery Hydrometer. Jumper Leads. Tachometer or Frequency Meter. Wheatstone Bridge or Digital Ohmmeter. Variac. Load Test Panel. Megger or Insulation Resistance Meter.

each unit. The wiring diagrams and schematics that are maintained with the unit should be updated when modifications are made to the unit. Read Important Safety Safety Instruct ions ions  and carefully observe all instructions and precautions in this manual.

  

InPower™ Service Tool (PC based genset service tool). PCC1302 Interface Kit (Used with InPower  Service Tool)

2.4 HOW TO OBTAIN OBTA IN SERVICE  Always give the complete Model, Specification and

2.2 SYSTEM OVERVIEW The PCC is a microprocessor-based control for Cummins Inc. Inc.   generator sets. All generator set control functions are contained on one circuit board (Base board). The Base board provides fuel control, main alternator voltage output regulation and complete generator set control and monitoring. The operating software provides control of the generator set and its performance characteristics, and displays performance information on a digital

Serial numberwhen of the generator as shownservice on the nameplate seeking set additional information or replacement parts. The nameplate is located on the the front of the control panel.

WARNING

Incorrect

service or replacement of parts can result in severe personal injury or death, and/or equipment damage.. Se damage Service rvice personn el must be trained and experienced to perform electrical and mechanical service. Read and follow Important Safety Safety Instructions on pages iii and i v.

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Publication A029U889 Issue 3 - 8-2017

PowerStart 0500 X1.3 & X2.5 Engine  Engine 

SECTION SECTI ON 3 – OPERATOR PA PANEL NEL OPERATION

FIGURE 3-1. PS0500 - CONTROLL CONTROLL ER  ER 

3.1 GENERAL The PS0500 is a microprocessor-based controller that has these abilities. • Start and stop the genset.

Note: Other devices that can remotely star startt / Stop the genset might be as simple as a switch or a push button or as sophisticated as other controllers or computers. This manual introduces the ways the

• •

• • •

Monitor the status of the genset. Warn the operator when unsafe conditions  are occurring Shut down the genset to prevent damage  Adjust settings that that affect genset behavior. behavior. Provide a way for other devices to remotely start / Stop the genset

Control can interact with other devices, but this manual cannot identify all of the devices that might be used in every application.

This is the Operator Manual for the PowerStart 0500 control. It is not the Operator Manual for the generator set (“genset”) or any accessories. The third digit is flashed, followed by a half-second pause, and then the fourth digit is flashed, followed by a two-second pause. The PowerStart 0500 is suitable for non-paralleling generator sets (“gensets”) in standby or Prime power applications.

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Publication A029U889 Issue 3 - 8-2017

Power Start 0500 X1.3 & X2.5 Engine  Engine 

3.2 ALTERNATOR A LTERNATOR CONNECTIONS

See Sequences Sequences of Opera Operation tion for more information about the behavior of this output . 

This section introduces the connections between the PS0500 and the alternator .

Genset Connections

Main Ma in A lternator Output

This section introduces the connections betweent he PS0500 and other parts of the genset. Some of these connections are flexible and might be made to many types of devices.

The PS0500 is connected to the main alternator output to measure genset voltage and genset frequency.

Customer Input The PS0500 is also connected to current transformers (CTs) which reduce the genset current by a known ratio for measuring main alternator output current.

The PS0500 has one customer input that can be configured to invoke a shutdown or Warning response   response

Battery Charger Failed Failed Switc h Engine Connections

The PS0500’s Customer Input may be connected to a battery charger’s status output (discrete) to

This section PS0500 and introduces the engine.the   connections between the

monitor the battery charger operation.

Battery Connections

Emergency Eme rgency Stop Butt ons

The battery provides power for the PS0500 and the PS0500 monitors the battery voltage.

The PS0500 may be connected to a push button that shuts the genset down immediately when pressed.

Starter The PS0500 is connected to the starter control relay in order to control the starter. See Sequences of Operation for more information about the behavior of this output.

Fuel Shutoff (FSO) Relay The PS0500 is connected to the fuel shutoff control (FSO) in order to control the fuel shutoff solenoid in the fuel supply line.

FIGURE 3-2. EMERGENCY STOP BUTTON (EXAMPLE)

Customer Output The PS0500 has one customer output that can be configured to become active when either a shutdown or Warning fault occurs.

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 Publication A029U889 Issue 3 - 8-2017

PowerStart 0500 X1.3 & X2.5 Engine  Engine 

PC-based PC -based Servi Servi ce Tools

Certifications

The PS0500 the Operator Paneltool, maysuch be connected to or a PC-based service as InPower.

The PS0500 meets or exceeds the requirements of the following codes and standards. • UL 508 • CSA • C282 compliant • 22.2 compliant • NFPA 99 compliant • MS 202C, Method 101 compliant • IEEE C62.41 compliant • IEEE C37.90 compliant • BS ISO 8528−4:2005 • BS EN 50081−1:1992 • BS EN 61000−6−2:2001 • BS EN 61000−6−3:2001 • BS EN 61000−6−4:2001CE Marking: The control system is suitable for use on generator sets to be CE − marked. • BS EN 61000−6−4:2001CE Marking: The control system is suitable for use on generator sets to be CE − marked.

Note: See the PC-based service tool documentation for more information. The PC-based service tool harness (Figure 3-3) is used to connect the PS0500 to a PC-based service tool.

FIGURE 3-3. PC-BASED SERVICE TOOL HA RNESS RNESS  

Ready Re ady to Lo ad The PS0500 may notify a device when event 1465 (Ready to Load) is active. Typically, the device is a programmable logic controller

Remote Star t   The PS0500 may be connected to a device that can generate a remote start signal. Typically, the device is a transfer switch.

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 Publication A029U889 Issue 3 - 8-2017

Power Start 0500 X1.3 & X2.5 Engine  Engine 

3.3 CONTROL OPERATION In this section, italics are used to identify a specific parameter by name.

Safety Considerations  AC power is present when the genset is running. Do not open the generator output box while the genset is running.

Contacting high -voltage compon ents can cause ele electrocut ctrocut ion, resulting in severe personal injury or death. D Do o not open the generator genera tor out put bo x while the set is r unning . Rea Read d and o bserv e all WARNINGS WARNINGS a and nd CAUT CAUTION IONS S in y our genset manuals.

WARNING 

FIGURE 3-4. CONTROL CONTROL PA PANEL NEL B UTTONS

The PS0500 cabinet must be opened only by technically qualified personnel. TABLE 3-1 CONTROL PANEL BUTTONS

WARNING 

The PS0500 PS0500 cabinet mus t be opened only by qu alified personnel. High-level High-level volt ages (up t o 600 VAC) are present in t he PS0 PS0500 500 cabinet. These These volt age ages s c an cause electrical sh ock, resulting in personal injury or death.

BUTTO BUT TON( N(S) S)

Manual   Manual

CAUTION

Even Eve n with the power removed, improper handling of comp onents can cause electrostatic ele ctrostatic di scharge and damage damage to circuit components.

 Auto    Auto

Stop   Stop

DESC DESCRI RIPT PTIO ION N Puts the control in Manual Mode to Start the genset Manually. You have to push the Start button in less than ten seconds after you push the Manual button.  button.  Puts the control in Auto Mode. The genset starts and stops when it is told by other devices (such as a transfer switch)  switch)  Stops the genset

Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual. When the genset starts and stops, it follows a series of steps, called a sequence of operation that is intended to

Starting and Stopping the Genset The buttons related to changing mode of operation are highlighted in figure 3.4 and described in Table 3.1

maximize the life of the genset. The genset might not start or stop immediately. 

WARNING

The genset might not start or stop i mmediately. mmediately. Do not attempt to service the genset if it do es not appear to respond imm ediate ediately. ly.  Acci  Ac ci den tal st art in ing g o f tthe he gens g ens et dur d ur in g troubleshoo ting can cause seve severe re personal injury or death.

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Power Start 0500 X1.3 & X2.5 Engine  Engine 

3.4 CONTROL PANEL

The control panel (Figure 3-5) is the front panel of the PS0500 control

FIGURE 3-5. CONTROL CONTROL PA NEL (PS0500)  (PS0500)  

Publication A029U889 Issue 3 - 8-2017

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Publication A029U889 Issue 3 - 8-2017

Power Start 0500 X1.3 & X2.5 Engine  Engine 

Conto Panel Description  Al ph a-nu mer ic LCD Dis pl ay

Buttons and LED Indicators Indicators

TABLE 3-3. BUTTONS The 2 line 16 Character, Backlit LCD display is used to indicate various genset parameters in several frames. The frames are normally scrolled one after the other for 3 seconds each at a time. The scrolling can be stopped and parameters on a particular frame can be monitored for longer time by pressing the OK button while the frame of interest is being displayed. Pressing the OK button again causes the frames to start scrolling again. The LCD display is also used to present the setup menus during the setup modes. The set up are described in detail in a separate section in modes this manual.

LED/BU LED /BUTT TTON ON

DESC DESCRI RIPT PTIO ION N

Manual

Press this to put the PS0500 in Manual mode from Stop mode. If you do not press the Start button In ten seconds, the control automatically enters the Stop mode The green LED above this button blinks when the

Start

TABLE 3-2. LED INDICATORS AND BUTTONS  Auto L ED

DESCRIPTION

Genset Running   Running

This green LED is lit when the genset is running at or near rated speed and voltage.

Remote Start  Start 

Shutdown   Shutdown

Warning   Warning

This is not lit while the genset is Stopped.  Stopped.  This green LED is lit when the remote start signal is active. This signal has no effect unless the PS0500 is in Auto mode.  mode.   This red LED is lit when there is any active shutdown fault. Event 1541 (Common Shutdown) is active. This amber LED is lit when there is an active warning fault. Event 1540 (Common Warning) is active.

Stop

Reset   Reset

OK

PS0500 is in Manual mode. In Manual mode, press this to initiate a Manual Start sequence. In other mod modes, es, this button has no effect. Press this to put the PS0500 in Auto mode from Stop mode. The green LED above this button blinks when the PS0500 is in Auto mode. Press this to Stop the running Genset. The Red LED above this button blinks when the PS0500 is in Stop mode. Pressing this button takes the control to STOP mode. This button is used along with the OK button to enter setup mode. Holding these two buttons pressed continuously for 5 Seconds causes the control to enter in setup mode if the control is in STOP mode. This button al also so wakes up the control from Power Down Sleep Mode.   Mode. This button is used mainly in “Setup mode” to select menu items. It is also used to Pause / Resume the scrolling of the parameter frames.

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 Publication A029U889 Issue 3 - 8-2017

Power Start 0500 X1.3 & X2.5 Engine  Engine 

3.5 MODES OF OPERATION The mode of operation determines the ways the Genset can be started and stopped. The PS0500 runs in one of these modes at any given time.Table 2-3 explains how to change the mode of operation.

Stop (Off) Mode Pressing the STOP button will always put the PS0500 in STOP mode and the RED LED above the STOP button will start blinking. In this mode, the PS0500 does not allow the genset to start / Crank. If the genset is running (either in Manual or Auto Mode) when the Stop button is pressed, the PS0500 stops the genset and enters in the STOP mode.  

Setup Se tup Mod e  The Setup mode can be entered only on ly from Stop mode when the genset is not running. This is accomplished by holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led flashes

Pressing the Stop button shall always deactivate the FSO immediately.

Remote Start Signal This signal will start the Genset when these conditions are met. • The PS0500 is in Auto mode • There are no active shutdown faults This signal comes typically from a transfer switch or an external toggle switch.

Manual Mode Pressing the Manual Button while the PS0500 is in the Stop Mode will put the PS0500 in the Manual Mode. In this mode, the genset is controlled manually. Pressing the Start button initiates a Manual Start sequence. Remote start signal has no effect. Note: If you do not press the Start button in ten seconds, the PS0500 changes over to STOP (Off) mode. Pressing the Stop button initiates a stop sequence.

faster (double the normal rate) as long as the control is in setup mode. While in setup mode, pressing Start or Stop button has no effect. Exiting from setup mode will return the control to STOP mode. In the setup mode, a Menu driven setup process is available for making adjustments that are allowed to be made from the control panel. Set up process is described in detail in a separate section later in this manual.

 Au to Mod e Pressing the Auto Button while the PS0500 is in the STOP mode will put the PS0500 in AUTO Mode. Pressing Auto Button while the PS0500 is in Manual Mode (Running or Not Running) has no effect.

WARNING In Auto m ode, the genset can start at any time. NEVER NEVER servi ce the genset in Auto mod e.  Acci  Ac ci den tal st art ing in g o f tthe he gens g ens et dur d ur in g troubleshoo ting can cause seve severe re personal injury or death. Disable Disable the genset before troubleshoo ting.   When the remote start signal becomes active, the PS0500 initiates the start sequence to start the genset. The PS0500 continues to run as long as the signal is active. When the Remote Start signal becomes inactive the PS0500 initiates a normal stop sequence. 

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Publication A029U889

Power Start 0500 X1.3 & X2.5 Engine  Engine 

Power-Down Power-D own Mode

Issue 3 - 8-2017

Sequence Se quence of Operation Operation

The PS0500 can enter power-down or sleep mode, to reduce load on batteries when not being used.

Sequences of operation describe the way the PS0500 starts the genset or stops the genset. This is illustrated in Figure 3-6.

PS0500 Power-down Mode Table 2-4 shows how much current the PS0500 control module consumes in normal operation and in power-down mode. TABLE TAB LE 3-4. PS0500 CURRENT CONSUMPTION CONSUMPTION PS0500 MODE Normal operation Power-down   Power-down

CURRENT 350 mA mA   < 5 mA  mA 

Stopped

Start Sequence

Genset Running

The PS0500 enters power-down mode when these conditions are met. - The genset is not running. - The Power down Mode Time Delay has expired. - There is no active communication on the RS-485 communication link. - There are no active faults - There are no active Wake Up signals present. In power-down mode, the microprocessor in the control stops, thereby reducing the consumption from battery.

Wake Up Up Signals Sign als The PS0500 wakes up from power-down mode when any of these wakeup signals becomes active. − Tool wakeup input (TB15 pin 5) is grounded. − Τhe Reset button on the Control Panel is pressed − Remote Start Signal (Typically, to a transfer switch) is low.

Stop Sequence   FIGURE FIGURE 3-6 3-6.. Sequence of operation

Start Sequences The PS0500 follows different start sequences depending on its setup and conditions. If a start sequence is interrupted for any reason except a shutdown fault (for example, the remote start signal becomes inactive), the PS0500 aborts the start sequence and initiates a Stop sequence.

Remot Re mot e Start Start This sequence begins when these conditions are met. - The PS0500 is in Auto mode. - The remote start signal is active, - There are no active shutdown faults. - This sequence is shown in Figure 3-7.

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Publication A029U889

Power Start 0500 X1.3 & X2.5 Engine  Engine 

Issue 3 - 8-2017

Cycle Cranking

       The The starter turns on for Cycle Crank Engage Time and turns off for Cycle Crank Rest Time.. The starter repeats this process up Time to Crank Attempts times.

The PS0500 turns OFF the Starter Output and keeps it OFF when,

       The The Genset Frequency is >= Starter Disconnect Speed / Frequency Speed gain, gain, (Example: Typically the starter disconnect speed is set to 450 RPM. In case off a four pole alternator the value of the Frequency speed gain is set to 30. So the genset frequency at which the starter disengagement happens would be calculated as 450 / 30 = 15Hz) OR The Battery Charging Alt Voltage >= Voltage >= Start Disconnect threshold If the genset frequency does not reach the start disconnect threshold (15 Hz in above example) before PS0500 finishes the cranking cycle, then it generates shutdown fault 359 (Fail To start). FIGURE FIGU RE 33-7. 7. Remote Start Sequenc e In this sequence, the PS0500 follows these steps to start the engine. 1. The PS0500 PS0500 waits until until Start Time Delay expires. If the trim Glow Plug Enable is set is set to Enabled, the PS0500 turns on the Glow Plug Control output. The PS0500 turns off the Glow Plug Output when  Glow Plug Timeout Period expires. The PS0500 does not proceed to crank until both Start Time Delay expires and the Glow Plug Output is turned off. 2. The PS0500 turns on the fuel shutoff (FSO) (FSO) output and the Starter Output.

The PS0500 waits for the Genset reach the rated frequency and voltage. If that doestonot happen within 10 seconds from the starter disconnect, the PS0500 generates Shutdown Fault 2335 (loss of AC Sensing).

Manual Start

This sequence begins when these conditions are met. • The PS0500 is in Manual mode and the Start   button is pressed. • There are no active shutdown faults. This sequence is shown in Figure 3-8 . There are no active shutdown faults.  .

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Power Start 0500

Issue 3 - 8-2017

X1.3 & X2.5 Engine  Engine 

Meterr Calibration Mete When running in Manual Mode, the control allows meter calibration process to be invoked, when the Genset Running (Ready to Load) state is reached. The Meter Calibration process is invoked by holding the Reset and OK buttons pressed for 5 seconds continuously. The process allows the arrow keys to be used for adjusting the displayed alternator AC Voltage / Current values to actual values (as measured using an independent calibrated instrument) one by one. The Meter Calibration Process is available when running

the genset in Manual Mode only .

Nominal Voltage and Frequency The PS0500 does not have the control con trol of the genset frequency (speed) and the genset voltage. The nominal voltage and the nominal frequency set-up parameters are used only for calculation of the over voltage, under voltage, over frequency and under frequency fault thresholds and determining if the Genset Running (Ready to Load) state has been reached as described above.

Stop Sequences FIGURE FIGU RE 3-8 3-8.. Manual Star t Sequ Sequence ence In this sequence, the PS0500 follows these steps to start the engine. 1. If tthe he trim trim Glow Plug Enable is set is set to Enabled, the PS0500 turns on the Glow Plug Control output. The PS0500 turns off the Glow Plug Output when Glow Plug Timeout Period expires. The PS0500 does not proceed to crank until the Glow Plug Output is turned off. 2. The PS0500 turns ON the fuel shutoff ((FSO) FSO) output and the Starter Output. The cycle cranking process as explained above is followed in Manual Mode also.

Genset Running (Ready (Ready t o Load) The PS0500 enters the Genset Running (Ready to Load) state when the genset frequency and voltage are both >= 90 percent of the nominal frequency and nominal voltage respectively.

The PS0500 follows different stop sequences depending on its setup and conditions.

 Au to Mod e

In Auto mode the stop sequence begins when these conditions are met. − The genset is running at rated speed and voltage − The remote start signal is inactive. The Genset will continue to run for the Stop Delay time and then the FSO Output will be deactivated by the PS0500.

Manual Mode In Manual mode the stop sequence begins when these conditions are met. The genset is running at rated speed and voltage The Stop button has been pressed. − There are no active shutdown faults.  − −

The FSO Output will be deactivated by the PS0500 immediately when the Stop button is pressed.

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Fa Fault ult Shutdown In Manual as well as Auto mode, the FSO Output will be deactivated by the PS0500 immediately when any of the shutdown faults becomes active.

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SECTION 4.  4. CIRC CIRCUIT UIT B BOARD OARD

TB15 – Tool Connecto r  Ar row ro w at Pin 1

J12 – CT con necto r  Ar ro row w at Pin 1

J12 –Pin 4

J16 – Engine Engine con nector  Ar ro row w at Pin 1

J16 –Pin 7 J22 – Voltage connector  Ar row ro w at Pin 1

TB2 – Custo Custo mer TB  Ar row ro w at Pin 1

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The dot designates pin 1 on the connectors.

TB2 – Customer Terminal Block Customer fault input, Customer output, Glow Plug, Remote Start, Remote E-stop.

J22  Alternator Voltage Sense inputs and Field Output

•

•

PS0500 CONTROL CONTR OL B OARD •

J16 Engine Connections Coolant Sensor, Lube Oil Pressure sensor, Run / OFF /  Auto Switch, FSO, FSO, Starter, Battery, Mag Pick Up, Starter Disconnect Feed Back, Battery Charger D+, Chassis GND. Governor PWM

• •

TB15 – Tools Interface Connector

J12 CT Connections

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4.1 CONTROL INPUTS AND OUTPUTS Engine Connector The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). A possible supplier is Molex; their part number is 39299123. The Cummins part number for this connector is 0323-2589. The PCB outline drawing shows where the connector is located as above .Each signal is described as below – Connecto r Pin J16-1 J16-2 J16-3 J16-4 J16-5 J16-6 J16-7 J16-8

Signal Name Coolant temperature sensor Battery charging alternator (WL) Starter Relay Driver (Low Side) Fuel shutoff relay Driver (Low Side) BATChassis GND NC NC

J16-9 J16-10 J16-11 J16-12

Oil Pressure Sensor   Starter Disconnect Input Sensor Common BAT +

CT Connector The CT connector is a 6- pin MATE-N-LOCK connector. connector. The possible manufacturer is Tyco, and the supplier part number for the part is 643749-1. The Cummins part number for this connector is 0323-2154. Connector details are as follows – Connector pin J12-1 J12-2 J12-3 J12-4 J12-5

Signal CT1_input CT2_input CT3_input CT1_COM CT2_COM

J12-6

CT3_COM

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Voltage Connector The voltage connection is via a 4 pin header with alternate spaces between the pins. The possible supplier is Tyco with the supplier part number as 282828-4. The Cummins part number for the same is 0323-2225-03. Connector pin J22-1 J22-2 J22-3 J22-4

Signal Gen_V1 Gen_V2 Gen_V3 Gen_N

Customer Connections TB2 The customer connection TB2 is a 6 pin terminal block. The possible supplier is Magnum: The terminal pins details are as shown belowTerminal Terminal pins TB2-1 TB2-2

Signal Remote start Switch Input Glow Plug Output Relay Driver (Low Side)

TB2-3

Customer Output Relay Driver (Low Side) Customer Input E-Stop NC

TB2-4 TB2-5 TB2-6

 All the inputs are are active GND. And outputs are low side drivers. Rem Remote ote E-Stop switch should have two indepen independent dent potential free contacts. One NC contact for cutting out the Battery supply to the Fuel Solenoid and another NC contact to disconnect controller’s E-Stop input from GND to indicate to the control when the E-Stop is pushed in active state. Battery Positive is not provided on the Customer terminal block (TB2). External provision needs to be made in the harness to provide fused B+ via a 1 amp fuse for wiring up external relays. External Relays of suitable contact ratings must be used for controlling FSO, Starter, Customer Output and Glow plug.

PC Tool Connecto r The PC tool connector is a dedicated 5 pin connector header block. The possible supplier is Tyco, with the supplier part numbers are 796643-5. The Cummins part number for the same is 0323-2191-04. Terminal Terminal pins TB15-1 TB15-2

Signal GND NC

TB15 3 TB15-4 TB15-5

RS485_DATA_A RS485_DATA_B TOOL_WAKEUP

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Connector Part Numbers Quantity

Name

Description

Manufacturer

Manufacturer’s part number

Cummins part no

1

J22

 Alt Voltage Connector

TYCO

282828-4

0323-2225-03

1

J12

CT Connector

TYCO

643749-1

0323-2154

1

J16

Engine Connector

MOLEX

39299123

0323-2589

1

TB2

Customer TB

MAGNUM

EM257506VC

0323-1677-05

1

TB15

Tool Connector

TYCO

796643-5

0323-2191-04

1

J22

 Alt Voltage Connector

TYCO

282809-4

0323-2226-03

1-480704-0

0323-1932

350551-1

0323-1200

39012120

0323-2602

39000038

0323-2603

EM256506H

0323-1678-05

CT Connector 1

1

J12

J16

Crimp Terminals Engine Connector Crimp terminals

TYCO

Remarks

 Al l tthes hes e connectors are PCB mounted connectors

MOLEX

1

TB2

Customer TB

MAGNUM

1

TB15

Tool Connector

TYCO

Communication cable Kit 0541-1199 is used for the tool interface

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SECTION 5 - TROUBLESHOOTING General

ON or OFF near battery. Discharge static electricity from body before touching batteries by first touchi ng a grounded metal surface.

The PS0500 control continuously monitors engine sensors for abnormal conditions, such as low oil pressure and high coolant temperature. If any of these

Ventilate Ventilate battery area before working on o r n ea earr battery—Wear goggles—Stop genset and

conditions occur, the control will light a yellow warning lamp or a red shutdown lamp and display a message on the LCD display.

discon nect charger be before fore disconn ecting battery cables—Disconnect negative (-) cable first and reconnect last.

PC Based Servic Servic e Tool The PC based service tool can be used in troubleshooting to perform tests, verify control inputs and outputs, and test protective functions. When used improperly, a PC based service tool can cause symptoms like warnings and shutdowns that appear to be a defective control. When these problems occur, always verify that a self-test s elf-test or fault simulation (override) have not been left enabled with the tool. If you do not have a PC based service tool, or the enabled fault simulation(s) can not be found using the tool, disconnect battery power to disable the test or override condition. Make sure that parameter adjustments and time delays, related to the fault condition, have been appropriately set for the application. It may be necessary to write the initial capture file to the device or update the calibration file. Updating a calibration file requires a Pro version of many of PC based service tools. Confirm that the installed calibration part number matches the serial plate information.

 CAUTION

Using the wrong capture file can result in equipment damage. damage. Do Do not swap Controls from another genset model and only u se the calibration file show n on the namepla nameplate. te.

5.1 SAFETY CONSIDERATIONS WARNING

Contacting high voltage compon ents can cause ele electrocut ctrocut ion, resulting in severe personal injury or death. Kee Keep p the output box covers in place during Trouble shooting.

 WARNING

Ignition of explosive battery gases can cause severe personal injury or death.  Ar ci ng at bat ter y ter mi nal s, li gh t sw it itch ch or ot her equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light

CAUTION

Disconnect battery charger from  AC sou s ou rce rc e bef or e di sc on nec ti ng bat ter y cabl c abl es.  es.  

Reading Rea ding Fault Codes The fault code and message can be viewed on the display. After the fault is acknowledged and corrected, the recorded fault will be deleted from the control panel memory, but will remain in a data log to maintain a fault code history. A PC based service tool is required to view this data log.

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

Voltage/Continuity Testing Voltage and continuity tests are required in the following tables. In some cases, it is necessary to remove a plug to complete the test. Where required, the corrective action will mention when it is necessary to remove a plug for testing. In other cases, the plug cannot be removed for testing. When plug removal is not mentioned, testing must be performed by inserting a narrow meter probe into the back of the plug.

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TABLE 20-1. ENGINE DOES NOT CRANK IN MANUAL MODE Reason: This indicates that the control has not received or recognized a manual start signal. Effect: Engine will not start. POSSIBLE CORRECTIVE ACTION CAUSE   CAUSE 1. No po powe wer  r  Check if the control is in Manual supplied to mode and when the Start button is control pressed, and that there are no shutdown faults present. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. Check for blown fuses.

2. Contro Controll not properly calibrated or corrupt calibration. 3. Th The e Emergency Stop switch or wiring is defective.

Issue 3 - 8-2017

TABLE 20-2. ENGINE DOES NOT CRANK IN REMOTE MODE Reason: This indicates that the PS0500 control has not received or recognized a remote start signal. Effect: Engine will not start in remote mode, but starts in manual mode. POSSIBLE CORRECTIVE CORRECTI VE A CTION CTION   CAUSE   CAUSE 1. The remo remote te Check if the control is in Auto mode start switch or and there are no shutdown faults wiring is faulty. present. Attempt to start, and check for ground at TB2-1. If ground level is not present, isolate to the remote switch or wiring. Repair as necessary. If ground level is present then the control is bad. Replace the control

Remove connector P16 and check for B+ at P16-12 and GND at P16-5. If B+ or ground missing, check the harness. If B+ and ground check OK, cycle power to control by reconnecting P16. Press Reset Button to wake the control up. And retry operation. Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary. With Emergency Stop push button not activated (switch closed), remove leads from TB2-5 and B- and check for continuity between these two leads. If circuit is open, isolate to Emergency Stop switch and wiring. If there is continuity, go to next step.

5. Oil Press Pressure ure switch or wiring

Remove P16 connection and check wiring between P16-9 and P16-11 to

is defective

the switch. Verify control is configured for the type of sensor installed. Verify proper operation of the switch Remove P16 connection and check wiring between P16-9, P16-11 to the sender. Verify control is configured for the type of sender. Verify operation of the sender

6. Oil Press Pressure ure sender, setup on wiring is defective.

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TABLE 20-3. WARNING AND SHUTDOWN CODES FAULT CODE  CODE  CORRECTIVE ACTION  ACTION  151 Indicates engine has overheated HIGH COOLANT (coolant temperature has risen above the shutdown trip point). TEMP Lamp: Shutdown  Allow engine to cool down completely before proceeding with the following checks: a. Ch Chec eck k cool coolan antt le leve vell and and replenish if low. Look for 

415 LOW OIL PRESSURE Lamp: Shutdown  Shutdown 

1446 HIGH AC VOLTAGE Lamp: Shutdown  Shutdown 

1447 LOW AC VOLTAGE Lamp: Shutdown 1449 OVER FREQUENCY Lamp: Shutdown 1448 UNDER FREQUENCY Lamp: Shutdown 1434 EMERGENCY STOP Lamp: Shutdown  Shutdown 

possible coolant points and repairleakage if  necessary. b. Ch Chec eck k for for ob obst stru ruct ctio ions ns to cooling airflow and correct as necessary. c. Ch Chec eck k fan fan bel belt and and repa repair ir or  tighten if necessary. d. Ch Chec eck k bl blow ower er fan fan and and circulation pumps on remote radiator installations. e. Re Rese sett cont contro roll an and d rest restar artt af afte ter  r  locating and correcting problem. Indicates engine oil pressure has dropped below the shutdown trip point. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Reset control and restart. If oil switch is used, check switch performance. Indicates that one or more of the phase voltages has exceeded 130% of nominal for 0 second, or has exceeded high ac voltage threshold for High AC Voltage time delay seconds. Indicates that one or more of the phase voltages has dropped below low ac voltage threshold for low ac voltage time delay seconds. Indicates frequency is 10% above base frequency for approximately 10 seconds. Indicates that Frequency had dropped below 90% of nominal for approximately 10 seconds. Check fuel supply, intake air supply and load. Indicates remote Emergency Stop. To reset the remote Emergency Stop button: 1. Ope Open n ((dis disabl able) e) rremo emote te

emergency stop button. Pre ress ss the OFF but button. ton. Select the desired operating mode (manual or auto). Indicates possible fuel system or air induction problem. (Engine cranks but fails to start) a. Check ffo or em empty ffu uel tta ank, fuel leaks, or plugged fuel lines and correct as

2.

359 FAIL TO START Lamp: Shutdown

required. C heck heck for for di dirt rty y fuel uel fi filt lter er and and replace if necessary. c. Check for dirty or plugged air filter and replace if  necessary. d. Reset th the co control a an nd restart after correcting the problem. Genset continues to run after receiving shutdown command from the controller. Check the FSO Relay and related wiring. Check that the FSO is not mechanically stuck  A shutdown fault occurred while b.

2677 FAIL TO STOP Lamp: Shutdown

1123 SHUTDOWN  AFTER BS Lamp: Shutdown 146 HIGH COOL TEMP. Lamp: Warning

1435 LOW COOLANT TEMP Lamp: Warning Set is not operating. Warning occurs when engine coolant temperature is       C) 70F (21 C) or lower. NOTE NOTE:: In applications   applications where the ambient   ambient temperature tempera ture falls below belo w 40F (4C),

the Battle Short mode was enabled. Check fault history for faults that may have been bypassed. Indicates engine is operating near cooling system capacity. Increase in load or higher ambient temperature may cause High Coolant Temp (151 (151)) shutdown. Review code 151 correction list for other possible causes. Indicates engine coolant heater is not operating or is not circulating coolant. Check for the following conditions: a. Cool oolant ant heat heater er not not connected to power supply. Check for blown fuse or  disconnected heater cord and correct as required. b. Chec Check k ffor or lo low w coo coola lant nt le leve vell c. and and rrep eple leni nish sh if requ requir ired ed.. Look for possible coolant leakage points and repair as required. Open heater element. Check current draw of heater.

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Low Coolant Temp  may be Temp

Publication A029U889   A029U889 Issue 3 - 8-2017

Coolant temperature must be below 70F (default setting) for one

seconds). Refer to engine service manual if this fault occurs. If not

minute to activate warning and be above 70F for five minutes before the warning can be cleared.

indicated eve even n  though the coolant heaters heaters   are operating.  operating.  1312 CUSOMER INPUT FAULT Lamp: Warning Or Shutdown Depending on the setup

Indicates the Customer Input is active. Example inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.

1416 FAIL TO SHUTDOWN Lamp: Warning  Warning 

1442 WEAK BATTERY Lamp: Warning  Warning 

If multiple of these are connected in parallel, check if any one of them is active. 144 COOL SENSOR OOR Lamp: Warning

Indicates that the control has sensed that the engine coolant temperature sensor output is out of range (high or low). Check sender/connectors/wires. This fault will only occur if water temperature sensor is equipped on the genset. Indicates battery voltage supply to the control is approaching a low level at which unpredictable

441 LOW B ATTERY Lamp: Warning

operation will occur. a. Di Disc scha harg rged ed or de defe fect ctiv ive e battery.Check the battery charger fuse.Recharge or  replace the battery. b. Poor oor bat batte tery ry ca cabl ble e connections. Clean the battery cable terminals and tighten all connections. c. Check battery wiring/calibration. Check engine DC alternator. Replace engine DC alternator  if normal battery charging voltage is not obtained. e. Ch Chec eck k batt batter ery y ch char arge ge v vol olta tage ge float level if applicable (raise

CODE 151/146 - HIGH OR PRE-HIGH COOLANT COOLA NT TEMPERATURE (SHUTDOWN/SHUTDOWN) Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant temperature. Effect: 146 – . Warning Lamp lights , Faul code pops up. 151.151 .- Engine will will shut down 1. Faul Faultt simulation was enabled with a PC based service tool.

2. Engine Engine or  sensor circuitry problem.

3. The sens sensor  or  could be bad.

Indicates that the control is in Battle Short mode - used to bypass several fault shutdowns for genset operation during emergencies. Indicates the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120

1. With a PC based based servi service ce tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. Check the sensor accuracy with a thermocouple or similar temperature probe. • If the coolant temperature reading is accurate, the engine may be overheating. Refer to the engine service manual. • If the coolant temperature reading is not accurate, go to next step. Disconnect the sensor and connect a coolant temperature sensor simulator to the harness. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step.

float level). 1131 BATTLE SHORT ACTIVE Lamp: Warning  Warning  2678 CHARGER FAILURE Lamp: Warning

failed, check wiring. Genset continues to run after receiving shutdown command from the controller. Battle Short feature enabled - used to bypass several critical fault shutdowns for genset operation during emergencies. Indicates that during cranking, the battery voltage is at or below the weak battery warning trip point for a time greater than or equal to the weak battery set time. See code 441 for corrective action.

4. The harne harness ss or Control could be bad.

4. Measure Measure the resis resistance tance of the coolant sensor and reconnect harness to sensor. Remove connector P16 from Control and check resistance between pins P161 and P16-11.

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• •

If resistance is not the same, harness is bad. If resistance is the same, Control is bad.

CODE 143/ 415 - LOW L OW OIL OR PRE-L PRE-LOW OW PRESSURE (WARNING/SHUTDOWN) Reason: Engine oil pressure has dropped below the

5. Low Oi Oill Pressure fault set points could

P16-11 (Sensor COMM). If the resistance signal (100 to 33 Ohm) does not get to P16, isolate to the harness. If the resistance does go to P16, the Control is bad. Verify set points against the normal operating pressures of the engine. Refer to engine manual.

warning/shutdown threshold for low/high oil pressure. Effect: 143. 143. – Warning Lamp lights, Engine will shut down for code 415 415.. – Engine shuts down POSSIBLE CAUSE   CAUSE 1. Faul Faultt simulation was enabled with a PC based service tool.

2. Low oil oil level. level. Clogged lines or filters. 3. Sensor Sensor o orr oil pump could be bad. Or the generator set may be shutting down onfault. another

4. Harnes Harness s or  Control could be bad.

CORRECTIVE ACTION  ACTION  With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. Check oil level, lines and filters. If oil system is OK but oil level is low, replenish. Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. a. If the control control res responds ponds to th the e simulator, thewire sensor, disconnectreconnect the + signal at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. • If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The genset may be shutting down on another fault (out of fuel, intermittent connector). Restart the genset and monitor the display panel for other faults. • If the display does not show an acceptable oil pressure, replace the sensor. If the Control still doesn’t display an oil pressure while cranking, the oil pump may be bad. Refer to the engine service manual. b. If the control control does not rrespon espond d to the simulator, go to next step. If the control does not respond to the simulator, the Control or the harness is bad. Check the resistance in P16-9 and

be incorrect. CODE 1446 - HIGH AC VOLTAGE VOL TAGE (SHUTDOWN) Reason: One or more of the phase voltages has exceeded 130% of nominal for 1 seconds, or has exceeded the High AC Voltage Threshold for the High  AC Voltage Delay seconds. Effect: Engine will shut down. POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE based service service tool, 1. Fault simulation simulation 1. With a PC based verify that the related fault was enabled with simulation is not enabled. a PC based If you do not have a PC based service tool. service tool, remove battery power from the control to disable fault simulation overrides. 2. Single Single step step 2. Clear Clear fault and restart genset. genset. large block load removal. 3. Fault threshold threshold 3. Reset the the threshold threshold to the is not set correctly highest allowable setting. with Determine the required operating InPower. range before adjusting the threshold. 4. AVR AVR o or  r  4. Refer to Generator AVR AVR Board generator is bad. Isolation Procedure in Alternator manual to determine if the AVR board is causing the high AC voltage shutdown fault. 5. Voltage Voltage sense See Section 17 for proper corrective actions. connections/set up could be incorrect.

CODE 1447 - LOW AC VOLTAGE (SHUTDOWN) Reason: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low  AC Voltage Delay seconds. Effect: Engine will shut down. POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE 1. With a PC based based servi service ce tool, 1. Fault simulation simulation was enabled with a verify that the related fault PC based service simulation is not enabled. tool. If you do not have a PC based

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Power Start 0500 X1.3 & X2.5 Engine  Engine 

2. Fault thresho threshold ld is not set correctly with a PC based service tool. 3. Overload.

4. Improp Improper  er  connections have been made at the

Publication A029U889   A029U889 Issue 3 - 8-2017

service tool, remove battery power from the control to disable fault simulation overrides. 2. Reset the the threshold threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. 3. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. 4. Reconnect Reconnect acco according rding to the appropriate reconnection diagram. See Section 17.

CODE 1448 - UNDER FREQUENCY (SHUTDOWN) Reason: Generator AC output frequency is low. Effect: Generator set will shut down. POSSIBLE CORRECTIVE CORRECTI VE A CTION CTION   CAUSE   CAUSE 1. Faul Faultt 2. Reset the threshold to the lowest threshold is not allowable setting. Determine the set correctly required operating range before with adjusting the threshold. PC based service tool. 2. Overload. 3. Check tth he llo oad a an nd c co orrect an any overload. Check operation by disconnecting load and restarting generator set.

generator output terminals. 5. Voltage Voltage se sense nse o or  r  setup wiring connection could be incorrect. 6. The rotati rotating ng rectifier assembly (diodes CR1 through CR6) is faulty. 7. Loose conne connector  ctor  or Control is bad. 8. AVR AVR o or  r   Alternator is bad.

9. Voltage Voltage sense connections/setup could be incorrect

5. Check that that Volt Voltage age sense senses s inputs P22-1 to 4 are connected to the correct voltage sensing point at alternator. 6. Check each each diode. S See ee genset service manual

8. Repair Repair connections connections (P2 (P22) 2) or  replace the Control if necessary. 4. Refer to Alternator / AVR Board Isolation Procedure in Alternator manual to determine if the AVR board is causing the Low AC voltage shutdown fault. See section 17 for proper connections

CODE 1449 - OVER FREQUENCY (SHUTDOWN) Reason: Generator AC output frequency is high. Effect: Generator set will shut down. POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE 1. Faul Faultt 2. Reset the thresho threshold ld to the highest threshold is not allowable setting. Determine the set correctly required operating range before with adjusting the threshold. PC based service tool. 2. Fuel or ai air  r  delivery problem. 3. Lo Loos ose e connector or Control is bad.

3. Fuel Fuel or air  air  delivery problem. 4. Govern Governor  or  fault. 5. Lo Loos ose e connector or Control is bad.

4. Refer to the engine service manual. manual.

5. Check fuel fuel shutoff solenoid solenoid adjustment (refer to Section 8). 6. Repair Repair connections connections (P22 (P22 – 1 to 4) or replace the Control if necessary.

CODE 234 - OVERSPEED (SHUTDOWN) Reason: Engine speed signal indicates an engine speed greater than shutdown threshold. Effect: Engine will shut down. POSSIBLE CORRECTIVE CORRECTI VE A CTION CTION   CAUSE   CAUSE 1. Cold Cold engine engine 1. Overspeed Overspeed can occur when starting starting (no coolant a very cold engine. Clear fault and heaters) restart genset. 2. Single Single step step large block load removal. 3. Faul Faultt simulation was enabled with a PC based service tool.

4. Faul Faultt threshold is not set correctly

2. Clear fault fault and restart restart genset.

3. With PC based service ttool, ool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have PC based service tool, remove battery power from the control to disable fault simulation overrides. 4. Reset the threshol threshold d to the highest allowable setting. Determine the required operating range before adjusting the threshold.

3. Refer to the engine service manual. manual.

withbased PC service tool.

4. Repair Repair connections connections (P (P22 22 – 1 to 4) or replace the Control if necessary.

5. Monito Monitorr the engine rpm using InPower.

5. If the RPM RPM is not correct, refer to fault code 1449 for corrective action.

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Power Start 0500 X1.3 & X2.5 Engine  Engine 

6. Govern Governor  or  fault.

7. Mechan Mechanica icall Fuel system setup could be incorrect.

Issue 3 - 8-2017

6a. Check fuel shutoff solenoid adjustment (refer to Section 8). 6b. Replace defective injection pump unit. Verify fuel stop settings for the application.

CODE 359 - FAIL TO START (SHUTDOWN) MECHANICAL GOVERNED ENGINE ENGINE Reason: This indicates that the engine failed to start after expiration of last crank time. Effect: Engine will not start. POSSIBLE CORRECTIVE CORRECTI VE A CTION  CTION  CAUSE   CAUSE 1a. Add fuel if low. Prime the fuel 1. Restricted Restricted fuel system. supply due to: 1b. Open any closed shutoff valve a. Fuel level below in the fuel line supplying the engine. pickup tube 1c. Refer to engine service manual.

3. Fuel solen solenoid oid on the injection pump not energized due to: a. Fuse may be open. b. Fuel solenoid is bad. c. Control/K7 Fuel Relay is bad.

2 should be at GND potential. potential. If the TB2-2 is at GND and K2 relay is not working check relay coil. • If TB2-2 is not at GND potential replace the Control. • If B+ is present, check for open circuit between glow plug relay contact and glow plugs. Isolate to fuse, K7 relay, fuel solenoid or Control. 3a. Remove fuse (if installed) and check continuity. If open, replace the fuse with one of the same type and amp rating. If fuse reopens, check wiring continuity of fuel solenoid circuit/test fuel solenoid. Binding in the solenoid linkage can prevent activation of the hold

b.

c.

d.

in tank. Closed shutoff valve in supply line. Fuel injectors clogged. Air in fuel system.

2. plugs are notGlow heating due to: a. Glow pl plug(s) iis s bad. b. Control is is ba bad. c. Glow Plug Relay is bad.

coil circuitry in the solenoid. Make sure solenoid shaft moves completely in and out freely. (Applies to solenoids with both Pull and Hold coils.)

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

3b. Attempt to start and check for B+ at the fuel solenoid coil. • If B+ is present, fuel solenoid is bad. • If B+ is not present, go to The Control determines atof what temperature and duration time that the glow plugs will be energized. Using sensed coolant temperature, the glow plugs are energized at 77        F (25        C) C) and colder. The glow plugs are energized for up to 15 seconds when the coolant temperature is             C) 5  F (-20.5 C) or colder. Time duration (15-0 seconds) is linear        F. between -5F and 77 F.

step c.wiring continuity/test 3c. Check K7 relay or fuel pilot: Remove lead from K7-COM (fuel pilot). Attempt to start and check for GND at lead COM. • If there is no GND, check for  open circuit between K7 COM and Base card. • If GND is present, reconnect lead COM to relay. Remove lead from N/O connection.  Attempt to start and check for  B+ at terminal N/O connection. • If B+ is present, check for  open circuit between N/O

With coolant temperature colder than 77F (25C): 2a. Each glow plug should be warm to the touch if the engine has just been cranking. First clean and tighten the terminal of any cold glow plug and then replace it if necessary. 2b. Attempt to start and check for if Glow plug relay energizes. TB2-

5. The engine engine fuel system is worn or

connection and fuel solenoid(+). • If B+ is not present, check for  relay contacts. 4. Service Service accord according ing to the engine service manual.

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malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing). 6. The engin engine e is 5. Service according according to to the engine service manual. worn or malfunctioning mechanically. CODE 1312 - CONFIGURABL E INPUT (SHUTDOWN) (SHUTDOWN) Reason: The nature of the fault is an optional configurable selection. Effect: Shutdown. POSSIBLE CAUSE  CAUSE  CORRECTIVE ACTION  ACTION  If there is no actual Disconnect the signal lead from fault, the problem TB2 and reset the control. Check may be an external the following two points. wiring problem.

•

Customer Input – TB2-4 If the message drops out, the external wiring has a short circuit. Grounding of the input activates fault.

CODE 146 - HIGH COOLANT TEMP (WARNING) Reason:

could be bad. (Radiant heat should be felt with hand held close to outlet hose.)

4. The sens sensor  or  connections could be bad. 5. The sens sensor  or  could be bad.

Coolant heater not connected to power. Check for blown fuse, or  disconnected heater cord and correct as required. • Low coolant level. Look for possible coolant leakage points and repair  as required. • Defective heater  element/thermostat. With coolant heater removed from engine and power disconnected, flush with cold tap water for two minutes to close internal heater thermostat (opens  and closes at 80˜   F).  ). at 100˜   F F Check resistance across input power leads: a. Open - re replace place coolant coolant h heater eater.. •

b. resistance Closed Closed - coolant coofolant heater heate r OK (coil 10 to 60 ohms) 4. Inspect Inspect the sensor sensor and engine harness connector pins. Repair or replace as necessary. 5. Disconnect Disconnect the sensor, sensor, and plug in a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If

Effect: POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE 1. Refer Refer to 1. Refer Refer to code 151 151.. code 151 151.. CODE 1435 - LOW COOLANT TEMPERATURE (WARNING) Reason: Engine coolant temperature has dropped below the warning threshold for low coolant temperature. Effect: No action is taken by the control. Engine may not start due to slow cranking speed. CORRECTIVE ACTION  ACTION  POSSIBLE   CAUSE  CAUSE 1. Faul Faultt 1. With PC based service ttool, ool, verify simulation was that the fault simulation is not enabled enabled with for the coolant sensor. PC based If you do not have a based service tool, remove battery power from the service. control to disable fault simulation overrides. 2. Faul Faultt 2. Reset the the threshold threshold to the lowest threshold is not allowable setting. Determine the set correctly required operating range before

control does not respond, harness or Control are bad. 6. The harne harness ss 6. Measure Measure the resist resistance ance of the or Control could coolant temperature sensor and be reconnect harness to sensor. Remove bad. connector P16 from Control and check resistance between pins P16-1 and P16-11 (Sensor Common). • If resistance is not the same, harness is bad. • If resistance is the same, Control is bad. CODE 1312 - CONFIGURABLE INPUT (WARNING) Reason: The nature of the fault is an optional configurable selection. Effect: Warning. CORRECTIVE CORRECTI VE A CTION CTION   POSSIBLE CAUSE   CAUSE Disconnect the signal lead from TB2 If there is no actual fault, the and reset the control. Check the following pins .Customer Input – problem may be an external TB2-4 If the message drops out, the

with a PC based service tool. 3. The engi engine ne coolant heater

wiring problem.

adjusting the threshold.

external wiring has a short circuit.fault. Grounding of the input activates

3. Coolant Coolant heater not operating operating due to:

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CODE 144 - COOLANT COOLA NT SENSOR OOR (HIGH/LOW) (HIGH/LOW) (WARNING)

3. Batter Battery y connections

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

Reason: This indicates that the coolant temperature sensor signal is out of range - shorted high or low. Effect: No engine protection for coolant temperature during genset operation. Possible white smoke. POSSIBLE CORRECTIVE CORRECT IVE A CTION  CTION  CAUSE   CAUSE 1. The sensor  sensor  2. Inspect Inspect the sensor sensor and engine connections harness connector pins. Repair or could be bad. replace as necessary. 2. The sensor  sensor  3. Disconnect Disconnect the sensor, sensor, and plug in could be bad. a resistive sensor simulator to isolate the fault. If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. 3. The harn harness ess 4a. Remove connector P16 from or Control could Control and disconnect sensor. be bad. Check pins P16-1 and P16-11 (Sensor common) for short circuit as follows: • Check for a short circuit to the engine block ground (more than 200k ohms OK). Check for a short circuit from pin to pin (more than 200k ohms OK).Repair or replace as necessary. 4b. Measure the resistance of the coolant sensor and reconnect harness to sensor. Remove connector P16 from Control and

loose or dirty. 4. Insuffici Insufficient ent battery charging voltage. 5. Engine Engine DC alternator could be bad.

at the battery and the set. 4. Adjust charge rate of A AC C powered battery charging circuit, according to manufactures instructions. 5. Replace Replace engine DC alternator alternator if  normal battery charging voltage (12 to 14 VDC) is not obtained.

6. If the the batteries are OK, the problem may be the harness or the Control.

6. Remove Remove connect connector or P16 from Control and check battery voltage at P16-12 (B+) to P16-5 (GND). • If the voltage at P16 is not the same as the battery voltage, the harness is bad. If the voltage at P16 is OK, the Control is bad. 7. Check fault fault threshold threshold against requirement of the application.

7. Faul Faultt threshold could be bad.

CODE 442 - HIGH BATTERY VOLTAGE (WARNING) Reason: High voltage has been detected for battery. Effect: Control damage will occur. POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE 1. Excess Excessive ive 1. Adjust charge rate of A AC C powered battery charging battery charging circuit according to voltage. manufacturers instructions. 2. Engine Engine DC 2. Replace Replace engine DC alternator alternator if  alternator could normal battery charging voltage

check resistance between pins P16-1 and P16-11 (Sensor Common). • If resistance is not the same, harness is bad. • If resistance is the same, Control is bad.

CODE 441 - LOW BATTERY (WARNING) Reason: Low voltage has been detected for battery. Effect: The control’s voltage supply approaching level at which unpredictable operation may occur. POSSIBLE CORRECTIVE CORRECT IVE A CTION  CTION  CAUSE   CAUSE 1. Weak Weak o or  r  1. Recharge Recharge or replace the batte battery. ry. discharged Specific gravity for a fully charged        F battery. battery is approximately 1.260 at 80 (27       C C). ). 2. Low Low 2. Replenish electrolyte and recha recharge rge electrolyte level battery. in battery.

be bad. 3. Faul Faultt

(12 to 14 VDC) is not obtained. 3. Check fault fault threshold threshold against

threshold could requirement of the application. be bad. CODE 143 - LOW OIL PRESSURE (WARNING) Reason: Effect: POSSIBLE CAUSE  CAUSE  CORRECTIVE CORRECT IVE A CTION CTION   1. Refer to c code ode 415 415.. 1. R Re efer to code 415 415.. CODE 141 - OIL PRESSURE PRESSURE SENSOR OOR (HIGH/LOW) (WARNING) Reason: This indicates that the engine oil pressure sensor signal is out of range - shorted high or low. Effect: No engine protection for oil pressure during genset operation. POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE 1. The sens sensor  or  2. Inspect Inspect the senso sensorr and engine connections could be bad.

harness connector pins. Repair or replace as necessary.

2. The The s se ensor nsor

3. Di Disc scon onne nect ct the the oil oil pres pressu surre s sen enso sor  r 

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could be bad.

Issue 3 - 8-2017

leads, and connect an oil pressure sensor simulator to the harness. “ OIL PRESS PRESSURE URE SEN SENSOR SOR OOR OOR”” warning is d isplayed after after the fault condit ion is sensed for 10 seconds.

3. The harn harness ess could be bad.

4. Th The e Con Contr trol ol

If the control responds to the simulator, replace the sensor. If control does not respond, go to next step. 4. Remove connector connector P7 from Contr Control ol and connector from sensor. Check P16-9 and P16-11 as follows: • Check for a short circuit from pin to pin (more than 200k ohms OK). • Check for an open circuit (10 ohms or less OK). Repair or replace as necessary. 5. With With al alll con conne nect ctor ors sa att ttac ache hed, d,

could be bad.

check pressure signal (.500 to .033 VDC) at P16-9 and P16-11 (Sensor Common). If in range, replace Control. CODE 1442 - WEAK BATTERY (WARNING) Reason: Effect: POSSIBLE CORRECTIVE ACTION  ACTION  CAUSE   CAUSE 1. Refer to c code ode 1. Refer to c code ode 441 441.. 441   441

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SECTION SECTIO N 6 – SETU SETUP P AND CAL CALIBRA IBRATION TION   Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual.

CAUTION 

Only qualified technicians sho uld adjust the parame parameters ters described in t his section. Failure to follow this may affect genset opera operation tion and may cause dama damage ge to the genset or to equipment conn ected to the genset. In this section, italics are used to identify a specific parameter by name .

Parameters See Section 4 for more information about parameters that you can adjust in the Operator Panel. 

Capture File Use InPower to save the current settings in a capture file on a PC or network. You can use the capture file to look at the current settings while you are away from the PS0500 or to restore settings if you have to reset the PS0500 for any reason. See the InPower User Guide for more information. While InPower can be used with the PS0500 for facilitating the setup, it is not essential for carrying out the basic setup operations. The basic setup can be performed directly from the control panel of PS0500. Following paragraphs Describe the process of carrying out basic setup from the control panel .

Entering and leaving t he Se Setup tup Mod e The Setup mode can be entered only from Stop mode when the genset is not running. This is accomplished by holding the Reset and the OK buttons pressed for 5 seconds continuously while in stop mode. The RED Stop Led flashes faster (double the normal rate) as long as the control is in setup mode. Pressing ← button while in Main Menu exits the setup mode. Navigation through the setup menus is described further in a separate section later.

MENU MEN U Descr Descr ipti on Tables 6.1 to 6.18 show a summary of the menus offered on the control panel of the PS0500. Table 6.1 6.1 Main Main Menu Descri ptio n  

Men u

Des c r i p t i o n

 Alt Setup

Use this menu tto o select alternator setup parameters like Single / Three phase, 50 / 60 Hz operation, Wye / Delta , Voltage etc.

Units

Use this menu to select Metric or US units for Coolant Temperature and Oil Pressure

Oil Pr Input

Use this menu to select the sensor types used with oil pressure Use this Menu to configure the response to Customer input and to configure usage of the

Customer I/O

customer output Flt History

Use this menu to view last five faults that are stored in the control

Load Defaults

Use this menu to set the default values.

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Table 6.5 6.5 Nom LL Voltage Sub Menu  

Table 6.2 Alt Setup Menu Su b Men u Phase Type

Des c r i p t i o n Select this submenu to choose between single / three phase operation

Menu Items 190 200

CT Ratio

Connect Type

Nom LL Voltage

Frequency

Select choosethis thesubmenu CT Ratio to Select this submenu to choose between Wye / Delta connection of alternator windings Select this submenu to choose the alternator nominal voltage Select this submenu to choose the frequency of operation

208 220 230 240 380 400 416 440 460

Table 6.3 Frequency Sub Menu Menu Items 50 Hz

480 600

Table 6.6 6.6 Connect Typ e Sub Menu Menu  

60 Hz Menu Items Single 3 Wire

Table 6.4 CT CT Ratio Sub Menu

3 Phase Single 2 wire

Menu Items 50:5 75:5

Table 6.7 6.7 Connect Typ e Sub Menu Menu  

100:5

Menu Items

150:5

Star Connect

200:5 250:5

Delta Connect

300:5

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Table 6.8 Units Menu Table 6.13 6.13 Custo mer O/P1 menu Menu Item

Description Select this item to choose Metric Metric Units for the display of Coolant

Metric

Temperature and Oil Pressure

US

Select this item to choose US Units for the display of Coolant Temperature and Oil Pressure

Table 6.9 Oil Pr Inp ut SubMenu Sensor Switch

Description Select this if using a Sender  Select this if using a Switch

Menu Items Glow Plug Warning Shutdown Table 6.14 Customer O/P2 menu Menu Items ShutDown Warning Genset Running Table 6.15 6.15 Flt Flt Hist ory Menu

Menu Me nu Items

Descripti on

Fault 1 – Fault 5

View the last 5 faults stored in the control

Table 6.10 Oil Pressure Sensor Sub Menu

Table 6.16 6.16 Load Default

MenuItems ONAN CIL

Menu Me nu Ite Items ms Confirmation Screen

Table 6.11 6.11 Custo mer I/O Menu S u b M en u

Cust I/P Flt

Customer O/P1

Customer O/P2

Des c r i p t i o n Choose the response to the input when active Choose the function of this output Choose the function of this output

Table 6.12 Cust I/P Flt Submenu MenuItems ShutDown Warning

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De Descriptio scriptio n To confirm the action press OK

 

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Navigation The manual (↑), Reset (↓ //), OK (→) and Auto (←) buttons are used for navigation during the setup. As long as setup mode is not exited these buttons will only act as arrow a rrow keys. The RED Stop lamp flashes at twice the normal rate as long as the setup mode is not exited and the control is not returned to STOP mode.

Navigation Example

(Set the nominal LL voltage to 440)

← Main Menu

//

 Alt Setup Setup

→

The Fig above shows the basic elements of a Setup Menu. Line 1 always bears the Menu Name and Line 2 shows items in the Menu. The symbols ←, / /, → indicate that the buttons bearing those symbols are active and can be used as follows ← 

// → 

Back Button (↓) Scroll Down to the next item  item  Select  the item shown on line 2  Select 2 

When a menu or submenu choices is selected, Name the be Menu or to Submenu movesthe to line 1 and the choices in thecontaining menu aremore displayed on line 2. / / (↓) the button canofthen used scroll through choices available in the Menu, and → (OK) button can be used to choose the item shown on line 2. The ← button can be used to go back one level up in the menu. Here in the current example, pressing → will take you to the Alt Setup menu. The Name of the chosen Menu (Alt Setup) will move into the line 1 and the first choice within that menu (phase type) will be shown on line 2.

← Alt Setup Phase Type

// →

You can now press / / (↓) button to scroll through the choices available in the Alt Setup Menu one by one. When the choice that you want appears on line 2, pressing p ressing → will take you into that submenu. Here in our example, let us say, you pressed / / (↓) until “Nom LL Voltage” submenu was displayed in line 2.

← Alt Setup Nom LL Voltage

// →

Pressing → will take you into the choices available for nominal line to line voltages. Pressing ← will take you to the main menu and pressing / / (↓) will take you to the next item within Alt Setup Menu. Let us say you pressed →. The display will now look like this.

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← Nom LL Voltage 190

// →

Pressing / / (↓) will show all the choices available for nominal LL voltage one by one. Let us say you pressed / / (↓) until 440 was displayed.

← Nom LL Voltage

//

440

→

Pressing → will select that as the Nominal LL Voltage. An asterisk (*) will appear in line 2 indicating that to be the current selection. The → at the end of line 2 will change to ← indicating that the only active buttons now are / / (↓) and ←.

← Nom LL Voltage

//

* 440

←

Pressing ← button will take you to one level up in the menu tree at a time. You have to press ←  ← several times to reach the main menu. Pressing ← button while at the main menu shall exit the setup mode. Following message shall be displayed before leaving the setup mode.

Current Config Saved

←

Press ← to leave setup mode and resume normal operation. The red Stop LED will resume flashing with normal rate (1 Hz).

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Power Start 0500 X1.3 & X2.5 Engine  Engine 

SECTION 7 - SERVICING THE GENERATOR

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7.1 TESTING THE GENERATOR These tests can be performed without removing the generator. Before starting tests, disconnect the negative ( –)  –) cable from the battery to make sure the engine will not start while performing these tests.

Ignition of explosive battery gases can cause severe personal injury or death. Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can ignite battery gas. Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from body before touching batteries by first touching a grounded metal surface. Ventilate battery area before working on or near battery—Wear goggles—Stop genset and disconnect charger before disconnecting battery cables— Disconnect negative (–) cable first and reconnect last

CAUTION

Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, Otherwise, disconnecting cables can result in voltage spikes damaging to DC control ci rcuits of the set.

 Ac ci den tal st art in ing g of th e generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (–) cable from the battery t erminal.

FIGURE 7.1 Po P1 Appropriate frame and type of connection is used to meet the application requi rements in term s of sin gle phase three phase, 50 Hz, 60 Hz temperatur e rise a and nd the KVA rating

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7.2 GENERATOR/BASE BOARD ISOLATION PROCEDURE PROCEDURE The following procedure is used to determine if the generator or the control Base board is causing a high  AC voltage shutdown shutdown fault. 1. Thr Throw ow the line line c circ ircuit uit bre breake akerr OFF and shutdown the set.

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4. Bri Bring ng tw two o jumper jumpers s from from a 12 volt volt b batt attery ery for  for  connection to the exciter stator X (Field +) and XX (Field –) leads. Connect the jumper from the positive (+ (+) post of the battery to the X lead. Be prepared to connect the  jumper from the negative ( –)  –) post oft he battery to the XX leads. If one of the 12 volt cranking batteries is

CAUTION  

This

test

involves

unregulated excitation of generator the generator. Tto o prevent dam-age to the due To over curr ent, make sure that all loads have been disconnected and that all faults have been cleared from the power output terminals of the generator.

WARNING

HAZARDOUS VOLTAGE. Touching Un-insulated parts inside the control housing and power output boxes can result in severe personal injury or death. Measurements and adjustments must be done with care to avoid touching hazardous haza rdous voltage parts.

Stand on mat, a dry insulating makewooden sure yourplatform clothing or and rubber shoes are dry, remove jewelry and use tools with insulated h andles. 2. Rem Remove ove tthe he side side ac acces cess s cov cover er of tthe he co contr ntrol ol housing to access the exciter stator leads (X (X and XX XX). ). Disconnect the X and XX leads from the AC harness (quick connect type connectors). 3. Pre Prepar pare e to measu measure re ou outpu tputt vol voltag tage e across across tthe he generator terminals while the set is running.

used, bring the jumpers from the battery connected on the grounded side of the system to avoid inadvertently imposing 24 volts on the system. 5. Che Check ck polar polarity ity a agai gain. n. P Pola olarit rity y must must be corrector this test will be inconclusive because the induced and residual magnetic polarities in the exciter stator will be opposed. Genset may shut down on a fault condition with in 5 to15 seconds du e to the exciter stator leads being disconnected from the Base board. Clear fault and start genset to check next phase. 6. Start the set and connect connect tthe he jumper jumper fr from om the battery negative ( –)  –) terminal to the XX lead. 7. The gen generato eratorr cir circuitr cuitry y is probabl probably y okay iif  f  rated output voltage or higher is obtained and the all phases balanced when the voltages exciter isforpowered by are a 12 volt battery. Refer to Section 4to 4to troubleshoot the PCC control circuitry. (Normal excitation voltage ranges from approximately 10 VDC at no-load to approximately 40 VDC at full–load.)

8. If th the e voltages voltages are unbal unbalanced, anced, trouble trouble shoot shoot the main stator first. If the voltages are uniformly low, troubleshoot the exciter and field circuits first.

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7.3 EXCITER STATOR Testing Winding Resistance: Measure winding resistance with a stone bridge or digital ohm-meter. Replace the stator if winding resistance is not as specified by Table 7-2.

Te Testing sting Winding Insulation Resistance: Resistance: Disconnect the exciter stator leads X and XX from their connectors in the AC harness and isolate them from ground. Using an ohmmeter, measure resistance between either lead and the stator laminations. Re-place

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Flashing the Field (Self-Excited Generators Only): If necessary, flash the exciter field before or after installation. Apply 110 to 220 VAC for one to two seconds to the X and XX leads of the exciter stator. The generator must be shut down, the Baseboard disconnected, a diode used to establish correct polarity and a 3 amp fuse to prevent over-excitation. See the diagram.  Alternatively, while the set is running and disconnected from all loads, apply a 12 VDC battery for one to two seconds as shown in the diagram. Polarity must b e correct: + to X, – to XX XX..

the stator if insulation resistance is less than 1megohm (1,000,000 ohms)

FIGURE 7-2. TESTING AND FLA SHING THE EXCIT EXCITER ER STATOR STATOR  

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  Power Start 0500 X1.3 & X2.5 Engine  Engine 

7.4 EXCITER RECTIFIER BRIDGE (R (Rotating otating Rectif Rectif ier Assembl y) The exciter rectifier bridge is mounted on the exciter rotor, inboard, facing the main rotor. It consists of a positive plate and a negative plate, split diametrically. Each carries three diodes, three terminal posts for connecting exciter rotor leads to the diode pig-tails and a terminal for the main rotor (generator field) lead. A surge suppresser is connected across the two plates to prevent transient voltages that could damage the diodes. Testing Diodes:  Diodes:  Disconnect the diode pigtails from the terminal posts. Using an ohmmeter, measure electrical resistance each diodeReverse pigtail and platetest on which the between diode is mounted. thethe meter probes and repeat the tests. The electrical resistance across each diode should be high in one direction and low in the other. If the resistance is high or low in both directions, replace the diode.

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Replacing Diodes: Make sure the replacement diode Replacing is of the correct polarity. Disconnect the pig tail from the terminal post and unscrew the old diode. Apply heat-sink compound under the head of the diode. Make sure the compound does not get on the threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm) when reassembling. Surge Suppresser Testing and Replacement: Remove the suppresser. Replace the suppresser if it appears to have overheated or if ohmmeter readings indicate less than infinite resistance (end of scale) in both directions. Torque the terminals to 24in-lbs (2.7 Nm) when reassembling.

CAUTION

Layers of dust can cause diodes to o verhea verheatt and fail. Brush dust o ff regularly.   regularly.

FIGURE 7–3. TESTING TESTING THE ROTATING RECTIFIER ASSEMBL Y

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Exciter Rotor

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assembly if the resistance of any winding is not as specified in Figure 7-4.

Testing Winding Resistance: Disconnect the six rotor winding leads from the terminal posts on the rectifier assembly. With a Wheatstone bridge, mea-sure electrical resistance across each pair of rotor windings: 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 schematic. Replace the whole rotor shaft

Te Testing sting Winding Insulation Resistance: Resistance: Using an ohmmeter, measure the resistance between any rotor winding lead or the terminal to which it is connected and the rotor laminations. Replace the whole rotor shaft assembly if insulation resistance is less than 1 megohm. 

FIGURE 7–4. TESTING THE EXCITER ROTOR

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Main Rotor (Generator Field)

Te Testing sting Winding Insulation Resistance

Testing Winding Resistance:

Using an ohmmeter, measure the resistance either lead of the main rotor windings, or the between terminal to which it is connected, and the main rotor laminations. Replace the rotor if insulation resistance is less than 1 mega ohm.

Disconnect the two leads of the main rotor from the terminals on the rotating rectifier assembly. See Figure 7-5. Measure electrical resistance between the two leads with a Wheatstone bridge or digital ohmmeter. Replace the rotor if the resistance is not as specified in Table 6-1. Connect the rotor leads and torque the terminals to 24 in-lbs (2.7 Nm) when reassembling.

NOTE : Incorrect resistances indicate faulty windings and component replacement  is necessary.