Manual Ps500

Service Manual

Controller PowerStart® 0500

English Original Instructions

9-2011

A040Y520 (Issue 1)

Table of Contents 1. IMPORTANT SAFETY INSTRUCTIONS ....................................................................................... 1.1 Warning, Caution and Note Styles Used In This Manual ....................................................... 1.2 General Information ................................................................................................................ 1.2.1 General Safety Precautions ........................................................................................ 1.3 Generator Set Safety Code .................................................................................................... 1.3.1 Moving Parts Can Cause Severe Personal Injury Or Death........................................ 1.3.2 Positioning of Generator Set....................................................................................... 1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 1.4.1 AC Supply and Isolation............................................................................................... 1.5 Fuel And Fumes Are Flammable ............................................................................................ 1.5.1 Spillage ....................................................................................................................... 1.5.2 Fluid Containment....................................................................................................... 1.5.3 Do Not Operate in Flammable and Explosive Environments ...................................... 1.6 Exhaust Gases Are Deadly..................................................................................................... 1.6.1 Exhaust Precautions ...................................................................................................

1 1 1 1 2 3 3 3 4 4 5 5 5 5 5

2. SCHEDULE OF ABBREVIATIONS................................................................................................

7

3. GLOSSARY....................................................................................................................................

9

4. INTRODUCTION.......................................................................................................................... 4.1 About this Manual ................................................................................................................. 4.2 System Overview .................................................................................................................. 4.2.1 PowerStart 0500 Components................................................................................... 4.3 Test Equipment..................................................................................................................... 4.4 How To Obtain Service.........................................................................................................

11 11 11 11 11 12

5. CONTROL SYSTEM - POWERSTART 0500 .............................................................................. 5.1 PowerStart 0500 Components.............................................................................................. 5.2 Control Description ............................................................................................................... 5.3 PS0500 Features .................................................................................................................. 5.3.1 Local Status Output ................................................................................................... 5.4 Operating Modes .................................................................................................................. 5.4.1 Off Mode .................................................................................................................... 5.4.2 Manual Mode ............................................................................................................. 5.4.3 Auto Mode.................................................................................................................. 5.4.4 Sleep Mode ................................................................................................................ 5.4.5 Battle Short Mode ...................................................................................................... 5.4.6 Setup Mode................................................................................................................ 5.5 Control Board........................................................................................................................ 5.6 Operator Panel...................................................................................................................... 5.6.1 Alpha Numeric LCD Display ...................................................................................... 5.6.2 LED Indicators and Buttons .......................................................................................

13 13 13 14 14 15 15 15 15 15 16 17 17 18 19 20

A040Y520 (Issue 1)

i

Table of Contents

9-2011

5.7 System Messages................................................................................................................. 5.7.1 Default Settings.......................................................................................................... 5.7.2 Fault Messages.......................................................................................................... 5.7.3 Fault Acknowledgement............................................................................................. 5.8 Selecting Auto, Manual Run, and Off Modes ....................................................................... 5.8.1 Selecting Auto Mode.................................................................................................. 5.8.2 Selecting Manual Mode ............................................................................................. 5.8.3 Selecting Off Mode .................................................................................................... 5.8.4 Configuration Mode.................................................................................................... 5.9 Setup and Calibration ........................................................................................................... 5.9.1 Capture File................................................................................................................ 5.9.2 Entering and Leaving the Setup Mode ...................................................................... 5.9.3 Menu Description ....................................................................................................... 5.9.4 Navigation ..................................................................................................................

20 21 21 21 21 21 22 22 22 23 23 23 23 27

6. CONTROL ADJUSTMENT AND SERVICE ................................................................................. 6.1 General ................................................................................................................................. 6.2 Control Inputs and Outputs................................................................................................... 6.2.1 TB1 Customer Inputs ................................................................................................. 6.2.2 CT Connector............................................................................................................. 6.2.3 Voltage Connector ..................................................................................................... 6.2.4 TB1 Customer Inputs ................................................................................................. 6.2.5 PC Tool Connector .................................................................................................... 6.3 Control Board Removal/Replacement .................................................................................. 6.3.1 Control Board Removal Safety Precautions .............................................................. 6.4 Current Transformer (CT) Installation...................................................................................

29 29 29 29 30 30 30 30 31 31 32

7. TROUBLESHOOTING ................................................................................................................. 7.1 General ................................................................................................................................. 7.2 InPower Service Tool............................................................................................................ 7.3 Network Applications and Customer Inputs.......................................................................... 7.4 Safety Consideration............................................................................................................. 7.5 Troubleshooting Procedure................................................................................................... 7.5.1 Voltage/Continuity Testing ......................................................................................... 7.5.2 Reading Fault Codes .................................................................................................

35 35 35 35 35 36 36 36

8. MANUFACTURING FACILITIES.................................................................................................. 8.1 How to Obtain Service .......................................................................................................... 8.1.1 Locating Your Distributor ...........................................................................................

51 51 51

APPENDIX A. WIRING DIAGRAMS .................................................................................................

53

ii

A040Y520 (Issue 1)

1

Important Safety Instructions SAVE THESE INSTRUCTIONS - This manual contains important instructions that should be followed during installation and maintenance of the generator set and batteries. Before operating the generator set, read the Operator's Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.

1.1

Warning, Caution and Note Styles Used In This Manual The following safety styles and symbols found throughout this manual indicate potentially hazardous conditions to the operator, service personnel or the equipment.

DANGER: Warns of a hazard that will result in severe personal injury or death. WARNING: Warns of a hazard that may result in severe personal injury or death. CAUTION: Warns of a hazard or an unsafe practice that can result in product or property damage. NOTE:

1.2

A short piece of text giving information that augments the current text.

General Information This manual should form part of the documentation package supplied by Cummins Power Generation with specific generator sets. In the event that this manual has been supplied in isolation please contact your authorized distributor. NOTE:

1.2.1

It is in the Operator’s interest to read and understand all Warnings and Cautions contained within the documentation relevant to the generator set, its operation and daily maintenance.

General Safety Precautions WARNING: Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first. To prevent severe scalding, let the engine cool down before removing the coolant pressure cap. Turn the cap slowly, and do not open it fully until the pressure has been relieved. WARNING: 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 contact used oil. NOTE:

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

A040Y520 (Issue 1)

1

1. Important Safety Instructions

9-2011

CAUTION: Make sure that rags are not left on or near the engine. CAUTION: Make sure the generator set is mounted in a manner to prevent combustible materials from accumulating under the unit. CAUTION: Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard. CAUTION: 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. WARNING: 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. WARNING: Substances in exhaust gases have been identified by some state or federal agencies as causing cancer or reproductive toxicity. Take care not to breath, ingest, or come into contact with exhaust gases. WARNING: Do not store any flammable liquids, such as fuel, cleaners, oil, etc., near the generator set. A fire or explosion could result. WARNING: Wear hearing protection when going near an operating generator set. WARNING: To prevent serious burns, avoid contact with hot metal parts such as the radiator, the turbo charger, and the exhaust system. WARNING: Use personal protective equipment when maintaining or installing the generator set. Examples of personal protective equipment include but are not limited to: safety glasses, protective gloves, hard hats, steel-toed boots, and protective clothing. WARNING: Do not use starting fluids that evaporate. They are highly explosive. CAUTION: Do not step on the generator set when entering or leaving the generator room. Parts can bend or break leading to electrical shorts, or to fuel, coolant, or exhaust leaks. CAUTION: To prevent accidental or remote starting while working on the generator set, disconnect the negative (-) battery cable at the battery. WARNING: Ethylene glycol, used as engine coolant, is toxic to humans and animals. Clean up spills and dispose of used engine coolant in accordance with local environmental regulations. WARNING: Moving parts can cause severe personal injury or death. Hot exhaust parts can cause severe burns. Make sure all protective guards are properly in place before starting the generator set.

1.3

Generator Set Safety Code Before operating the generator set, read the manuals and become familiar with them and the equipment. Safe and efficient operation can be achieved only if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions. WARNING: Improper operation and maintenance can lead to severe personal injury or loss of life and property by fire, electrocution, mechanical breakdown, or exhaust gas asphyxiation. Read and follow all Safety Precautions, Warnings and Cautions throughout this manual and the documentation supplied with your generator set.

2

A040Y520 (Issue 1)

9-2011

1. Important Safety Instructions

WARNING: Lifting and repositioning of the generator set must only be carried out using suitable lifting equipment, shackles, and spreader bars, in accordance with local guidelines and legislation, by suitably trained and experienced personnel. Incorrect lifting can result in severe personal injury, death and/or equipment damage. For more information, contact your authorized distributor.

1.3.1

Moving Parts Can Cause Severe Personal Injury Or Death · Keep your hands, clothing, and jewelry away from moving parts. · Before starting work on the generator set, disconnect the battery charger from its AC source, then disconnect the 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 any adjustments must be made while the unit is running, use extreme caution around hot manifolds, moving parts, etc.

1.3.2

Positioning of Generator Set The area for positioning the set should be adequate and level and the area immediately around the set must be free of any flammable material. WARNING: On an enclosed generator set, the canopy doors must be locked before repositioning and they must remain locked during transportation and sitting.

1.4

Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death WARNING: Any work with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or higher poses a significant risk of electrical shock and electrical arc flash. These silent hazards can cause severe injuries or death. Refer to standard NFPA 70E or equivalent safety standards in corresponding regions for details of the dangers involved and for the safety requirements. Guidelines to follow when working on de-energized electrical systems: · Use proper PPE. Do not wear jewelry and ensure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards. · De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is intended to prevent injury due to unexpected start-up of equipment or the release of stored energy. Please refer to the lockout/tagout section for more information. · De-energize and lockout/tagout all circuits and devices before removing any protective shields or making any measurements on electrical equipment. · Follow all applicable regional electrical and safety codes. Guidelines to follow when working on energized electrical systems:

A040Y520 (Issue 1)

3

1. Important Safety Instructions

9-2011

NOTE:

It is the policy of Cummins Inc. to perform all electrical work in a deenergized state. However, employees or suppliers may be permitted to occasionally perform work on energized electrical equipment only when qualified and authorized to do so and when troubleshooting, or if deenergizing the equipment would create a greater risk or make the task impossible and all other alternatives have been exhausted.

NOTE:

Exposed energized electrical work is only allowed as per the relevant procedures and must be undertaken by a Cummins authorized person with any appropriate energized work permit for the work to be performed while using proper PPE, tools and equipment. In summary: · Do not tamper with or bypass interlocks unless you are authorized to do so. · Understand and assess the risks - use proper PPE. Do not wear jewelry and ensure that any conductive items are removed from pockets as these items can fall into equipment and the resulting short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards. · Ensure that an accompanying person who can undertake a rescue is nearby.

1.4.1

AC Supply and Isolation It is the sole responsibility of the customer to provide AC power conductors for connection to load devices and the means to isolate the AC input to the terminal box; these must comply to local electrical codes and regulations. Refer to the wiring diagram supplied with the generator set. NOTE:

Local electrical codes and regulations (for example BS EN 12601:2001) may require the installation of a disconnect means for the generator set, either on the generator set or where the generator set conductors enter a facility.

NOTE:

The AC supply must have the correct over current and earth fault protection according to local electrical codes and regulations. This equipment must be earthed (grounded).

The disconnecting device is not provided as part of the generator set, and Cummins Power Generation accepts no responsibility for providing the means of isolation.

1.5

Fuel And Fumes Are Flammable Fire, explosion, and personal injury or death can result from improper practices. · DO NOT fill fuel tanks while the engine is running, unless the 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 leaks. Fuel connection at the engine should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vibrated or repeatedly bent. · Be sure all fuel supplies have a positive shutoff valve. · Be sure the battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, etc.

4

A040Y520 (Issue 1)

9-2011

1.5.1

1. Important Safety Instructions

Spillage Any spillage that occurs during fueling or during oil top-off or oil change must be cleaned up before starting the generator set.

1.5.2

Fluid Containment If fluid containment is incorporated into the bedframe, it must be inspected at regular intervals. Any liquid present should be drained out and disposed of in line with local health and safety regulations. Failure to perform this action may result in spillage of liquids which could contaminate the surrounding area. Any other fluid containment area must also be checked and emptied, as described above. NOTE:

1.5.3

Where spillage containment is not part of a Cummins supply, it is the responsibility of the installer to provide the necessary containment to prevent contamination of the environment, especially water courses/sources.

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

1.6

Exhaust Gases Are Deadly · Provide an adequate exhaust system to properly expel discharged gases away from enclosed or sheltered areas and areas where individuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Make sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment. · Be sure the unit is well ventilated. WARNING: Engine exhaust and some of its constituents are known to the state of California to cause cancer, birth defects, and other reproductive harm.

1.6.1

Exhaust Precautions WARNING: Exhaust pipes and charge air pipes are very hot and they can cause severe personal injury or death from direct contact or from fire hazard. WARNING: Hot exhaust gas can cause burns resulting in severe personal injury. The exhaust outlet may be sited at the top or bottom of the generator set. Make sure that the exhaust outlet is not obstructed. Personnel using this equipment must be made aware of the exhaust position. Position the exhaust away from flammable materials - in the case of exhaust outlets at the bottom, make sure that vegetation is removed from the vicinity of the exhaust. WARNING: Inhalation of exhaust gases can result in serious personal injury or death. Be sure deadly exhaust gas is piped outside and away from windows, doors, or other inlets to buildings. Do not allow to accumulate in habitable areas.

A040Y520 (Issue 1)

5

1. Important Safety Instructions

9-2011

WARNING: Contaminated insulation is a fire risk which can result in severe personal injury. The exhaust pipes may have some insulating covers fitted. If these covers become contaminated by fuel or oil, they must be replaced before the generator set is run. To minimize the risk of fire, make sure the following steps are observed: · Make sure that the engine is allowed to cool thoroughly before topping off the oil or draining the fuel filters. · Clean the exhaust pipe thoroughly.

6

A040Y520 (Issue 1)

2

Schedule of Abbreviations This list is not exhaustive. For example, it does not identify units of measure or acronyms that appear only in parameters, event/fault names, or part/accessory names. AmpSentry and InPower are trademarks of Cummins Inc. PowerCommand is a registered trademark of Cummins Inc.

ACRONYM AC AMP ASTM

DESCRIPTION Alternating Current

ACRONYM LED

DESCRIPTION Light-emitting Diode

AMP, Inc., part of Tyco Electronics

Mil Std

Military Standard

American Society for Testing and Materials (ASTM International)

MMHG

Millimeters of Mercury

ATS

Automatic Transfer Switch

NC

Not Connected

AVR

Automatic Voltage Regulator

NC

Normally Closed

AWG

American Wire Gauge

CAN

Controlled Area Network

NFPA

National Fire Protection Agency

NO

Normally Open

CB

Circuit Breaker

NWF

Network Failure

CE

Conformité Européenne

OEM

Original Equipment Manufacturer

CFM

Cubic Feet per Minute

OOR

Out of Range

CGT

Cummins Generator Technologies

OORH / ORH

Out of Range High

CMM

Cubic Meters per Minute

OORL / ORL

Out of Range Low

CT

Current Transformer

PSI

Pounds per square inch

DC

Direct Current

PB

Push Button

ECM

Engine Control Module

PC

Personal Computer

ECS

Engine Control System

PCC

PowerCommand® Control

EMI

Electromagnetic interference

PGI

Power Generation Interface

EN

European Standard

PGN

Parameter Group Number

EPS E-Stop

Engine Protection System

PI

Proportional/Integral

Emergency Stop

PID

Proportional/Integral/Derivative

FAE

Full Authority Electronic

PLC

Programmable Logic Controller

FMI

Failure Mode Identifier

PMG

Permanent Magnet Generator

FSO

Fuel Shutoff

Genset

PT

Potential Transformer

Generator Set

PTC

Power Transfer Control

GCP

Generator Control Panel

PWM

Pulse-width Modulation

GND

Ground

RFI

Radio Frequency Interference

HMI

Human-machine Interface

RH

Relative Humidity

IC

Integrated Circuit

RMS

Root Mean Square

INHG

Inches of Mercury

RTU

Remote Terminal Unit

International Organization for Standardization

SAE

Society of Automotive Engineers

ISO

A040Y520 (Issue 1)

7

2. Schedule of Abbreviations

ACRONYM kPA

8

9-2011

DESCRIPTION kilo-Pascal

ACRONYM SPN

LBNG

Lean-burn Natural Gas

SW_B+

LCD

Liquid Crystal Display

UL

LCL

Low Coolant Level

LCT

Low Coolant Temperature

UPS

DESCRIPTION Suspect Parameter Number Switched B+ Underwriters Laboratories Uninterruptible Power Supply

A040Y520 (Issue 1)

3

Glossary

Term

Definition

Accessory Part

A part comes standard with the product. An accessory is optional and provides additional interfaces or functionality.

Active Inactive

General terms to describe the states for inputs, signals, or outputs that have only two states (like true/false or 1/0). For example, a low coolant level switch is either on (active) or off (inactive). The Ready to Load output is either on (active) or off (inactive). Usually, the expected state is inactive. For events/faults, this term describes the time the PCC generates the event/fault through the time the event/fault is cleared.

Active-closed Active-open

Some inputs and outputs use resistance to distinguish between active and inactive. If an input or output is active-closed, the input or output is active if there is no resistance between two pins. If an input or output is active-open, the input or output is active if there is infinite resistance between two pins.

Active-high Active-low

Some inputs and outputs use voltage differential to distinguish between active and inactive. If an input or output is active-high, a high voltage differential means the input or output is active, and a low voltage differential means the input or output is inactive. If an input or output is active-low, a low voltage differential means the input or output is active, and a high voltage differential means the input or output is inactive.

Configurable analog input Configurable input

"Configurable input" refers to discrete inputs (for example, open or closed). "Configurable analog input" refers to analog inputs (for example, 0-5 VDC).

Configurable analog output Configurable output

"Configurable output" refers to discrete outputs (for example, open or closed). "Configurable analog input" refers to analog outputs (for example, 0-5 VDC).

Connection

A connection between two devices. A connection might be as simple as one pin-to-pin connection, or it might require several pins as well as additional components such as relays, fuses, etc. This term also includes some settings that refer to the physical (for example, normally-closed vs. normally-open) or electrical (for example, active-high vs. active-low) characteristics of the connection.

Connector

This term has no meaning if you do not have access to the PCC control board or the back panel of the Operator Panel. One or more pins that are in the same housing. Many times, the pins are related by function (for example, pins that are connected to the engine) or by electrical characteristics (for example, relay outputs). This term also refers to the end of a wire or harness that is plugged into the housing.

Event Fault

Used to notify the operator or external devices whether or not certain conditions are true. Each event or fault has two sets of conditions. When the first set of conditions becomes true, the event or fault becomes active. This might turn on or turn off a light or LED, display a warning on the PCC, shut down the genset, or so on. When the second set of conditions becomes true, the event or fault becomes inactive and can be cleared. The PCC generates a fault when the conditions indicate a more serious problem; the PCC generates an event only for information purposes.

Low-side driver

When this output is active, it provides a path to ground. When this output is inactive, it blocks the path to ground.

Mode Mode of operation

A term to describe certain states that affect the PCC's behavior. The PCC is either in a particular mode or not in a particular mode, and the PCC's behavior changes accordingly. Sometimes, the PCC is always in one mode out of a set of two or more modes. For example, the PCC is always in one of the modes of operation: Off mode, Auto mode, or Manual mode.

Mounting

The physical placement and installation of the PCC or the Operator Panel.

A040Y520 (Issue 1)

9

3. Glossary

9-2011

Term

Definition

Normally-closed Normally-open

Some inputs and outputs use open circuits and short circuits to distinguish between active and inactive. If an input or output is normally-closed, an open circuit means the input or output is active, and a short circuit means the input or output is inactive. If an input or output is normally-open, a short circuit means the input or output is active, and an open circuit means the input or output is inactive.

Parameter

Refers to monitored values or settings in the PCC or the Operator Panel that can be looked at and, in some cases, adjusted. Some parameters are protected by passwords. In this manual, italics are used to identify a specific parameter by name.

Pin

A specific point on the PCC or the Operator Panel to which it is acceptable to connect a specific point on an external device. For example, a B+ pin might be connected to the positive terminal on the battery. It takes more than one pin to connect an external device to the PCC. For example, it takes B+ and Ground to connect the battery to the PCC. Depending on the access you have to the controller, you might see a specific pin on the PCC control board, the terminal at the end of a harness, a wire that runs between the PCC and the external device, or nothing at all.

Sensor

Refers to a device that measures something and reports one of many (or unlimited) values. For example, a coolant level sensor reports the current level of coolant.

Sequence of operation

A term used to describe the steps the PCC follows when it starts the genset or when it stops the genset.

Signal

A term used for convenience to talk about two or more connections as a single input. Usually, all of these connections have the same effect on the PCC's behavior, and it does not matter which connection is active. For example, the term remote start signal" is used frequently. In Auto mode, the PCC starts the genset when the remote start signal is active. The remote start signal may come from any of several connections: a switch connected to the remote start pin, the Operator Panel, a PLC (programmable logic controller) connected on Modbus, InPower, etc. It is not important between these connections when explaining the way the remote start signal affects the PCC's decisions to start and stop the genset. It is only important whether or not any of them are active.

Switch

Refers to a device that measures something and reports one of two states, active or inactive, about something. For example, a low coolant level switch is active when the coolant level is too low, but the low coolant level switch does not report what the coolant level really is. In some cases, this may refer to a physical switch (similar to a light switch) instead.

Trim

Refers to the subset of parameters that can be adjusted, as opposed to parameters that can only be monitored.

10

A040Y520 (Issue 1)

4

Introduction Read Chapter 1 and carefully observe all instructions and precautions in this manual. Keep this manual with the other generator set and/or controller manuals.

4.1

About this Manual This is the Service Manual for the PowerStart® 0500 Controller. It is not the Service Manual for the generator set or any accessories.

4.2

System Overview The PowerStart 0500® (PS0500) is a microprocessor-based control for Cummins Power Generation generator sets. All generator set control functions are contained on one control board. The operating software provides control of the generator set and its performance characteristics, and displays performance information on a digital display panel. It accepts menu-driven control and set-up input from the push button switches on the front panel.

4.2.1

PowerStart 0500 Components The PowerStart 0500 System consists of the following: · A PS 0500 Integral Control Board

4.3

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 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 · InPower™ Service Tool (PC based generator set service tool) · PS0500 Interface Kit (Used with InPower Service Tool)

A040Y520 (Issue 1)

11

4. Introduction

4.4

9-2011

How To Obtain Service When the control requires servicing, contact your nearest Cummins Power Generation distributor. To contact your local Cummins Power Generation distributor refer to the Manufacturing Facilities section contained within this document. When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the nameplate. WARNING: Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. Read and follow Important Safety Instructions.

12

A040Y520 (Issue 1)

5

Control System - PowerStart 0500

5.1

PowerStart 0500 Components The PowerStart 0500 System consists of the following: · A PS 0500 Integral Control Board

5.2

Control Description The control is used to start and stop the generator set, and provides full generator set monitoring capability and protection in a stand-alone situation (non paralleling) from the display screen. It monitors the engine for temperature, oil pressure and speed, and provides voltage and current metering. In the event of a fault, the unit indicates the fault type and on critical faults automatically shuts down the generator set. All indicators, control buttons, and the display screen are on the face of the operator panel. There are two fault level signals generated by the control: · Warning: signals an imminent or non-critical fault for the engine. The control provides an indication only for this condition. · Shutdown: signals a potentially critical fault for the engine. The control immediately takes the engine off-load and automatically shuts down. The standard control system operates on 12 VDC battery power. The auxiliary equipment operates on LV AC power. The history data is stored in non-volatile memory and is not deleted if battery power is lost.

A040Y520 (Issue 1)

13

5. Control System - PowerStart 0500

9-2011

No. 1

Display Module

2

Emergency Stop Button

FIGURE 1.

5.3

Description

TYPICAL CONTROL SYSTEM PANEL

PS0500 Features The PS0500 includes: · Single-phase or three-phase (delta or wye) 600 volt voltage sensing and 5 amp CT current sensing · 50 or 60 Hertz frequency · Service Tool / ModBus communications connector (TB15) · Start/stop functionality through control board · Control board status LED · Common connector scheme support · Programmable wake-in-auto function

5.3.1

Local Status Output A status indicator lamp can be used to flash generator set status and shutdown fault codes. The Manual Run/Off/Auto switch may include a status indicator lamp. · Constant On = The generator set is running.

14

A040Y520 (Issue 1)

9-2011

5. Control System - PowerStart 0500

· Shutdown, warning and remote start LED indicators are available on front display. NOTE:

5.4

Only the last shutdown fault is flashed.

Operating Modes The PS0500 control is operated by the Manual/Start/Stop/Auto buttons on the display module face.

5.4.1

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. When in Off mode, the control does not allow the generator set to start. If the generator set is already running, in either Manual Run or Auto mode, and the Stop button is pressed, a normal shutdown sequence will be initiated. In Off Mode the red LED above the Stop button will be lit.

5.4.2

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 generator set is controlled manually. Pressing the Start button initiates a Manual Start sequence. Remote start signal has no effect. NOTE:

5.4.3

If the Start button is not pressed in ten seconds, the PS0500 changes over to Stop (Off) mode.

Auto Mode 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 mode, the generator set can start at any time. Never service the generator set in Auto mode. Accidental starting of the generator set during troubleshooting can cause severe personal injury or death. Disable the generator set before troubleshooting. When the remote start signal becomes active, the PS0500 initiates the start sequence to start the generator set. 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. Pressing the Stop button shall always deactivate the FSO immediately.

5.4.4

Sleep Mode The PS0500 control enters a low power (sleep) mode of operation where the current draw is less than 60 milliamps (DC) at normal battery voltage levels. Sleep mode is automatically enabled and the display module will turn itself off after five minutes of keypad inactivity when in Off mode.

A040Y520 (Issue 1)

15

5. Control System - PowerStart 0500

9-2011

When in Auto mode, the Sleep mode is enabled only when the trim "Wake in Auto Enabled" is enabled. If the trim is disabled (which is the default value), the Sleep mode will never be enabled when in Auto mode. It awakes from the Sleep mode if the reset button is pressed or if there is a Tool wakeup input or a Remote Start signal is received or an E-stop signal is received both in Stop as well as Auto mode. The control will not enter the Sleep mode if the there are any active, unacknowledged, shutdown faults or if the control is in the Manual Run mode. NOTE:

5.4.5

To enable the Sleep mode when the control is in Auto mode, contact your authorized distributor.

Battle Short Mode The purpose of Battle Short is to satisfy local code requirements, where necessary. NOTE:

The PS0500 control does not support a customer selectable Battle Short Mode. However, Cummins Service Technicians can invoke the mode of operation using a service tool for troubleshooting purpose if required.

Battle Short mode is a generator set mode of operation that prevents the generator set from being shutdown by all but a few select, critical shutdown faults. CAUTION: All shutdown faults, including those overridden by Battle Short, must be acted upon immediately to ensure the safety and well being of the operator and the generator set. WARNING: Use of the Battle Short mode feature can cause a fire or electrical hazard, resulting in severe personal injury or death and/or property and equipment damage. Operation of the generator set must be supervised during battle short operation. This feature must only be used during supervised, temporary operation of the generator set. The faults that are overridden in Battle Short mode can affect generator set performance, or can cause permanent engine, alternator or connected equipment damage. Battle Short mode prevents the generator set from being shutdown by all but a select few critical shutdown faults. All shutdown faults, including those overridden by Battle Short, must be acted upon immediately to ensure the safety and well being of the operator and the genset. Only trained and experienced service personnel should enable this feature. When shipped from the factory, this feature is disabled. CAUTION: If this mode of operation is selected, the protection of load devices will be disabled. Cummins Power Generation Limited will not be responsible for any claim resulting from the use of this mode. NOTE:

The Battle Short feature must be enabled or disabled using the PC Service tool.

When Battle Short mode is enabled and an overridden shutdown fault occurs, the shutdown lamp remains lit even though the generator set continues to run. Fault code 1416 - Fail to Shut Down is displayed. If the OK button is pressed to acknowledge the fault, the fault message is cleared from the display but remains in one of the scrolling screens displaying the fault code and its description to indicate that it is an active fault as long as Battle Short mode is enabled.

16

A040Y520 (Issue 1)

9-2011

5. Control System - PowerStart 0500

Battle Short is suspended and a shutdown occurs immediately if: · Any of the following shutdown faults occurs. · Overspeed - Fault code 234 · Speed Signal Lost (Loss of Speed Sense) - Fault code 121 · Excitation Fault (Loss of Voltage Sense) - Fault code 2335 · Local Emergency Stop - Fault Code 1433 Fault code 1123 - Shutdown After Battle Short is then displayed.

5.4.6

Setup Mode The Setup mode can be entered only from Stop mode when the generator set 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. While in Setup mode, pressing Start or Stop button has no effect. Exiting from setup mode will return the control to Stop mode.

5.5

Control Board WARNING: HAZARDOUS VOLTAGE. Touching uninsulated parts in the controller can result in severe personal injury or death. Measurements and adjustments must be done with care to avoid touching hazardous voltage parts. WARNING: Stand on a dry wooden platform or rubber insulating mat, make sure your clothing and shoes are dry, remove jewelry and use tools with insulated handles. CAUTION:

Electrostatic discharge will damage circuit boards. Always wear a grounding wrist strap when touching or handling circuit boards.

The control board contains all of the electronic circuitry required to operate the generator set. The control board provides main alternator voltage output regulation and complete generator set control and monitoring. Refer to Block diagram in Appendix A for each terminal board connection and connector pin input/output signal. The block diagram that follows shows the external connections of the PCC system. After determining that a control board assembly is faulty, replace it; do not repair it. Attempts to repair a control board can lead to costly damage to the equipment.

A040Y520 (Issue 1)

17

5. Control System - PowerStart 0500

FIGURE 2.

5.6

9-2011

CONTROL BOARD CONNECTOR/TERMINAL PIN LOCATIONS

Operator Panel Figure 3 on page 19 shows the features of the front panel. It includes four LED indicators, the graphical display, and six buttons used to navigate through the menus and adjust parameters.

18

A040Y520 (Issue 1)

9-2011

5. Control System - PowerStart 0500

1

LED Indicator – Genset Running

7

Auto Mode Button

2

LED Indicator – Remote Start

8

Reset Button

3

LED Indicator – Shutdown

9

Stop Button

4

LED Indicator – Warning

10 OK Button

5

Manual Mode Button

11 Alpha numeric LCD Display

6

Start Button

FIGURE 3.

5.6.1

OPERATOR PANEL

Alpha Numeric LCD Display The two line sixteen character, backlit LCD display is used to indicate various generator set parameters in several frames. The frames scroll sequentially and display for two seconds. The scrolling can be stopped and parameters on a particular frame can be monitored for longer by pressing the OK button. Pressing the OK button again causes the frames to start scrolling again. The display is also used to present the setup menus in the configuration mode.

FIGURE 4.

A040Y520 (Issue 1)

SCROLLING DISPLAY MESSAGES

19

5. Control System - PowerStart 0500

5.6.2

9-2011

LED Indicators and Buttons TABLE 1.

LED INDICATORS FOR PS0500

LED

Description

Genset Running

This green LED is lit when the generator set is running at or near rated speed and voltage. This is not lit while the generator set is stopped.

Remote Start

This green LED is lit when the remote start signal is active. This signal has no effect unless the PS0500 is in Auto mode.

Shutdown

This red LED is lit when there is any active shutdown fault. Event 1541 (Common Shutdown) is active.

Warning

This amber LED is lit when there is an active warning fault. Event 1540 (Common Warning) is active.

TABLE 2.

OPERATOR PANEL BUTTONS

LED/Button

Description

Manual

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

Start

In Manual mode, press this to initiate a Manual Start sequence. In other modes, this button has no effect.

Auto

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.

Stop

Press this to Stop the running generator set. The red LED above this button blinks when the PS0500 is in Stop mode. Pressing this button takes the control to Stop mode.

Reset

This button is used along with the OK button to enter the setup mode. Holding these two buttons pressed continuously for five seconds causes the control to enter in setup mode if the control is in Stop mode. This button also wakes up the control from Power Down Sleep mode.

OK

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.

5.7

System Messages A system pop-up message is displayed when the event it is displaying becomes active. These pop-up messages remain displayed until pre-empted by another pop-up message.

20

A040Y520 (Issue 1)

9-2011

5.7.1

5. Control System - PowerStart 0500

Default Settings The Operator Panel can display SAE or Metric units of measurement and should be set during the initial setup of the generator set. Only trained and experienced personnel are allowed to change the default setting. Contact your authorized distributor.

5.7.2

Fault Messages A Fault message is an indicator of a Warning or Shutdown condition that is also announced with a lamp indicator. Fault Messages include the fault code number and a short description.

5.7.3

Fault Acknowledgement Shutdown faults are reset after a shutdown fault is cleared when the engine comes to a standstill and all start commands are removed. In Manual mode, the start command is removed when the Stop button, on the front panel, is pressed. In Auto mode, the start command is removed when the Remote Start signal is removed. Faults are removed from the display when they are cleared. NOTE:

5.8

Faults are re-announced if they are detected again after being acknowledged.

Selecting Auto, Manual Run, and Off Modes Auto, Manual Run, and Off modes can be selected: · From any of the Operator menus · When the message "Establishing communication with control" is displayed · When the message "Re-establishing communication with control" is displayed WARNING: When changing modes, the generator set may start or stop without warning. Ensure there is no danger to personnel or equipment should the generator set start or stop when changing modes.

5.8.1

Selecting Auto Mode WARNING: When changing modes, the generator set may start or stop without warning. Ensure there is no danger to personnel or equipment should the generator set start or stop when changing modes. To switch to Auto mode: 1. Ensure that it is safe to do so before proceeding to change the mode. 2. Press the Stop button to ensure that the control is in the Off mode. 3. Press the Auto button while in the Off mode. The green LED above this button is lit when the control is in Auto mode. To disable Auto mode, press the Stop button. The generator set is now ready to receive a remote signal that will initiate the Auto run mode.

A040Y520 (Issue 1)

21

5. Control System - PowerStart 0500

9-2011

WARNING: Should a remote start signal be received, the generator set will start automatically. Ensure there is no danger to personnel or equipment should the generator set start without warning. WARNING: Manual run mode cannot be selected from Auto mode. The control has to be in Stop mode before changing the mode. Switching to Stop mode will result in the generator set shutting down.

5.8.2

Selecting Manual Mode WARNING: When changing modes, the generator set may start or stop without warning. Ensure there is no danger to personnel or equipment should the generator set start or stop when changing modes. To switch to Manual mode: 1. Ensure that it is safe to do so before proceeding to change the mode. 2. Press the Stop button to ensure that the control is in the Off mode. 3. Press the Manual button on the front panel while in the Off mode. The green LED above this button is lit when the control is in Manual mode. To disable Manual mode, press the Stop button. CAUTION: Ensure that there is no danger to personnel or equipment when the generator set is started. NOTE:

5.8.3

Auto mode cannot be selected while in Manual mode. The control has to be in Off mode before changing the mode. Switching to Off mode will result in the generator set shutting down.

Selecting Off Mode WARNING: When changing modes, the generator set may start or stop without warning. Ensure there is no danger to personnel or equipment should the generator set start or stop when changing modes. To switch to Off mode: 1. Ensure that it is safe to do so before proceeding to stop the set. 2. Press the Stop button on the front panel. The red LED above the Stop button is lit when the control is in the Off mode. CAUTION: Ensure that there is no danger to personnel or equipment if the generator set is stopped.

5.8.4

Configuration Mode WARNING: Adjusting the settings in the Configuration mode must only be done by technically trained and experienced service personnel. The frequency settings must only be adjusted to correspond to the parameters of the installed input power supply. Saving settings that do not correspond to the power supply can cause severe personal injury and equipment or property damage. The Configuration mode is used to adjust the parameters of the generator set and must only be done by technically trained and experienced service personnel.

22

A040Y520 (Issue 1)

9-2011

5. Control System - PowerStart 0500

In Configuration mode the PS0500 control has the following menus: · Alt Setup: Select alternator set-up parameters (Single/Three phase, 50/60 Hz operation, Star/Delta, Voltage etc.) · Units: Select SAE or metric units of measure for coolant temperature and oil pressure. · Oil Pr Input: Select the oil pressure sensor type. · Customer I/O: Configure the response to Customer Input and use of the Customer Output. · Flt History: Displays the last five faults. · Lamp/LED Test: Tests all the LEDs on the PS0500 display module. · Load Defaults: Resets to the default values.

5.9

Setup and Calibration Read Safety Precautions, and carefully observe all of the instructions and precautions in this manual. CAUTION: Only qualified technicians should adjust the parameters described in this section. Failure to follow this may affect generator set operation and may cause damage to the generator set or to equipment connected to it.

5.9.1

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.

5.9.2

Entering and Leaving the Setup Mode The Setup mode can be entered only from Stop mode when the generator set 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 ← while in Main Menu exits the Setup mode. Navigation through the setup menus is described further in a later section.

5.9.3

Menu Description The tables below show a summary of the menus offered on the control panel of the PS0500. TABLE 3. Menu

Alt Setup

A040Y520 (Issue 1)

MAIN MENU DESCRIPTION Description Use this menu to select alternator setup parameters like Single/Three phase, 50/60 Hz operation, Wye/Delta, Voltage etc.

23

5. Control System - PowerStart 0500

9-2011

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.

Customer I/O

Use this menu to configure the response to Customer input and to configure usage of the 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.

Lamp/LED Test Menu

Use this menu to test all the LEDs on the PS0500 display module.

TABLE 4.

ALT SETUP MENU

Sub Menu

Description

Phase type

Select this submenu to choose between single/three phase operation.

CT Ratio

Select this submenu to choose the CT Ratio.

Connect Type

Select this submenu to choose between Wye/Delta connection of alternator windings.

Nom LL Voltage

Select this submenu to choose the alternator nominal voltage.

Frequency

Select this submenu to choose the frequency of operation.

TABLE 5.

FREQUENCY SUB MENU Menu Items

50 Hz 60 Hz

TABLE 6.

CT RATIO SUB MENU Menu Items

50:5 75:5 100:5 150:5 200:5 250:5 300:5

TABLE 7.

NOMINAL LL VOLTAGE SUB MENU Menu Items

24

A040Y520 (Issue 1)

9-2011

5. Control System - PowerStart 0500

190 200 208 220 230 240 380 400 416 440 460 480 600

TABLE 8.

CONNECT TYPE SUB MENU Menu Items

Single 3 Wire 3 Phase Single 2 Wire

TABLE 9.

CONNECT TYPE SUB MENU Menu Items

Start Connect Delta Connect

TABLE 10. UNITS MENU Menu Item

Description

Metric

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

US

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

TABLE 11. OIL PR INPUT SubMenu

Description

Sensor

Select this if using a Sender.

Switch

Select this if using a Switch.

A040Y520 (Issue 1)

25

5. Control System - PowerStart 0500

9-2011

TABLE 12. OIL PRESSURE SENSOR SUB MENU Menu Items CPGF CIL

TABLE 13. CUSTOMER I/O MENU SubMenu

Description

Cust I/P Flt

Choose the response to the input when active.

Customer O/P1

Choose the function of this output.

Customer O/P2

Choose the function of this output.

TABLE 14. CUST I/P FLT SUB MENU Menu Items ShutDown Warning

TABLE 15. CUSTOMER O/P1 MENU Menu Items Glow Plug Warning Shutdown

TABLE 16. CUSTOMER O/P2 MENU Menu Items ShutDown Warning Genset Running

TABLE 17. FLT HISTORY MENU Menu Items Fault 1 - Fault 5

Description View the last 5 faults stored in the control.

TABLE 18. LOAD DEFAULT Menu Items Confirmation Screen

26

Description To confirm the action press OK.

A040Y520 (Issue 1)

9-2011

5.9.4

5. Control System - PowerStart 0500

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 keys. The red Stop lamp flashes twice the normal rate as long as the setup mode is not exited and the control is not returned to Stop mode. For example, if you need to set the nominal LL voltage to 440 you will see the Setup Main 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

· →

Select the item shown on line 2

FIGURE 5.

EXAMPLE NAVIGATION SCREEN

When a menu or submenu containing more choices is selected, the Name of the Menu or Submenu moves to line 1 and the choices in the menu are displayed on line 2. / / (↓) button can be used to scroll through the 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. In the current example, pressing → will take you to the Alt Setup menu. The name of the chosen menu (Alt Setup) will move into line 1 and the first choice within that menu (phase type) will be shown on line 2.

FIGURE 6.

EXAMPLE ALT SETUP MENU

Pressing / / (↓) until Nom LL Voltage submenu is displayed in line 2 brings up the menu shown below.

FIGURE 7.

EXAMPLE NOM LL VOLTAGE SCREEN

Pressing → will bring up choices available for nominal line to line voltages. Pressing ← will bring up the main menu and pressing / / (↓) will bring up the next item within Alt Setup Menu.

A040Y520 (Issue 1)

27

5. Control System - PowerStart 0500

9-2011

If → was pressed, the display will show as shown below.

FIGURE 8.

EXAMPLE NOM LL VOLTAGE SELECT SCREEN

Pressing / / (↓) will show all the choices available for Nominal LL Voltage one by one. Press / / (↓) until 440 is displayed.

FIGURE 9.

EXAMPLE NOM LL VOLTAGE 440 SCREEN

Pressing → will select 440 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 ←.

FIGURE 10. EXAMPLE NOM LL VOLTAGE 440 SELECTED SCREEEN Pressing ← will move one level up in the menu tree at a time. Press ← several times to reach the main menu. Pressing ← while at the main menu will exit the setup mode. The figure shown below will show before leaving the setup mode.

FIGURE 11. EXAMPLE CONFIRMATION SCREEN FOR EXITING SETUP MODE Press ← to leave the Setup mode and resume normal operation. The red Stop LED will resume flashing with normal rate (1Hz).

28

A040Y520 (Issue 1)

6

Control Adjustment and Service

6.1

General This section contains circuit board removal and replacement procedures and adjustment procedures for the generator set control. This section also describes the function and operation of engine sensors, generator set options, and other special features of the generator set control system, such as, customer connection points, optional run relays, etc. Installation information is also provided for these items where necessary. WARNING: Incorrect service or replacement of parts can result in severe personal injury or death, and/or equipment damage. Service personnel must be trained and experienced to perform electrical and mechanical service. WARNING: HAZARDOUS VOLTAGE. The PS0500 control must be opened only by technically qualified personnel. Site power for optional equipment and generator set voltages of up to 600 VAC are present on the control board. These voltages can cause electrical shock, resulting in personal injury.

6.2

Control Inputs and Outputs

6.2.1

TB1 Customer Inputs The engine connector (J16) is a 12 pin connector-plug (12 MINI M-N-L). Each signal is described below. TABLE 19. ENGINE CONNECTOR (J16) Connector Pin

Signal Name

J16-1

Coolant temperature sensor

J16-2

Battery charging alternator (WL)

J16-3

Starter relay driver (Low Side)

J16-4

Fuel Shutoff relay driver (Low Side)

J16-5

BAT-

J16-6

Chassis GND

J16-7

NC

J16-8

NC

J16-9

Oil pressure sensor

J16-10

Starter disconnect input

J16-11

Sensor Common

J16-12

BAT+

A040Y520 (Issue 1)

29

6. Control Adjustment and Service

6.2.2

9-2011

CT Connector The CT connector is a 6-pin MATE-N-LOCK connector. Connector details are as described below. Connector Pin

Signal

J12-1

CT1_input

J12-2

CT2_input

J12-3

CT3_input

J12-4

CT1_COM

J12-5

CT2_COM

J12-6

CT3_COM

6.2.3

Voltage Connector The voltage connection is via a 4-pin header with alternate spaces between the pins. Connector details are described below. Connector Pin

Signal

J22-1

Gen_V1

J22-2

Gen_V2

J22-3

Gen_V3

J22-4

Gen_N

6.2.4

TB1 Customer Inputs The customer connection TB2 is a 6-pin terminal block. The terminal details are shown below. Terminal Pins

Signal

TB2-1

Remote Start Switch Input

TB2-2

Glow Plug Output Relay Driver (Low Side)

TB2-3

Customer Output Relay Diver (Low Side)

TB2-4

Customer Input

TB2-5

E-Stop

TB2-6

NC

6.2.5

PC Tool Connector The PC tool connector is a dedicated 5-pin connector header block. Connector details are shown below. Terminal Pins

Signal

TB15-1

GND

TB15-2

NC

TB15-3

RS485_DATA_A

30

A040Y520 (Issue 1)

9-2011

6. Control Adjustment and Service

TB15-4

RS485_DATA_B

TB15-5

TOOL_WAKEUP

6.3

Control Board Removal/Replacement No special tools (other than a grounding wrist strap and InPower Service tool) are required to remove a control board. The InPower Service tool is required when replacing the control board. Before replacing the control board, make sure that a capture file of the generator set parameter values has been created using InPower. (During generator set installation, it was suggested that a capture file be made before and after changes were made to the generator set operating parameters.) After replacing the control board, use the capture file as a template to write the previous settings to the new control board software. Refer to InPower User's Guide for specifics.

6.3.1

Control Board Removal Safety Precautions CAUTION: Before disconnecting battery cable(s), press the Emergency Stop button and wait at least 30 seconds. Fault Code 1117 may display and engine performance may be affected (e.g., engine dying or hard starting) if battery cable(s) is removed during the 30 second waiting period. See Fault code 1117 to reset ECM. WARNING: 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 generator set and disconnect charger before disconnecting battery cablesDisconnect negative (-) cable first and reconnect last. CAUTION: Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the set. WARNING: Accidental starting of the generator set can cause severe personal injury or death. Prevent accidental starting by disconnecting the negative (-) cable from the battery terminal. CAUTION: Electrostatic discharge will damage circuit boards. Always wear a grounding wrist strap when handling circuit boards or socket-mounted ICs. Before starting procedure, disconnect the negative (-) cable from the battery. This is to make sure the set will not start while working on it and to avoid circuit board damage, caused by voltage spikes when removing and replacing circuit board connectors. 1. Press the STOP button to switch to the Off mode. 2. Turn off or remove AC power from the battery charger. 3. Press the Emergency Stop button and wait at least 30 seconds before completing Step 4. 4. Remove the negative (-) battery cable from the generator set starting battery.

A040Y520 (Issue 1)

31

6. Control Adjustment and Service

9-2011

5. To prevent circuit board damage due to electrostatic discharge (ESD), a grounding wrist strap must be worn when handling circuit boards or socket-mounted IC's. (The wrist strap does not provide a direct short to ground, but is typically rated at approximately 1 megohm to ground.) 6. Attach the clip to the chassis ground screw in the mounting area of the control board and place the strap around your wrist before handling a circuit board.

FIGURE 12. WRIST STRAP

6.4

Current Transformer (CT) Installation The current transformers (CT's) are used to display generator set load in kVA and alternator amperage. The CT's must be installed as noted in the following CT Installation Requirements. Refer to Appendix A to identify the generator output leads/phase that must be routed through each CT, and also appropriate transformer post selection for control sensing leads. The transformers are labeled CT1, CT2 and CT3 on the reconnection wiring diagram. (The Reconnection Diagram is located on the hardware on which the CT is installed.) CT Installation Requirements: 1. The CT has a dot on one side. This dot must be facing toward the generator reconnection terminal block. A dot is also used to indicate pin 1 of the CT. 2. Route the load lead (U, V, or W; or A, B, or C) through the appropriate CT (refer to Appendix A). 3. The CT's have dual secondaries (3 pins marked X1, X2 & X3). (Refer to Appendix A). X1 & X2 for above 300 volts L-L

32

A040Y520 (Issue 1)

9-2011

6. Control Adjustment and Service

X1 & X3 for below 300 volts L-L

A040Y520 (Issue 1)

33

6. Control Adjustment and Service

9-2011

This page is intentionally blank.

34

A040Y520 (Issue 1)

7

Troubleshooting

7.1

General The PowerStart0500 (PS0500) continuously monitors the generator set for abnormal conditions, such as high oil pressure and high coolant temperature. If any of these conditions occur, the control will light an amber Warning lamp or a red Shutdown lamp and display a message on the LCD display.

7.2

InPower Service 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 or fault simulation (override) have not been left enabled with the 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. Do not swap Controls from another generator set model and only use the calibration file shown on the nameplate.

7.3

Network Applications and Customer Inputs In applications with networks and remote customer inputs, the generator set may start unexpectedly or fail to crank as a result of these inputs. These symptoms may appear to be caused by the base board. Verify that the remote input is not causing the symptom or isolate the control from these inputs before troubleshooting the control.

7.4

Safety Consideration WARNING: Contacting high voltage components can cause electrocution, resulting in severe personal injury or death. Keep the output box covers in place during troubleshooting. WARNING: Ignition of explosive battery gases can cause severe personal injury or death. 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.

A040Y520 (Issue 1)

35

7. Troubleshooting

9-2011

Ventilate battery area before working on or near battery-Wear goggles-Stop generator set and disconnect charger before disconnecting battery cablesDisconnect negative (-) cable first and reconnect last. CAUTION: Disconnect battery charger from AC source before disconnecting battery cables. Otherwise, disconnecting cables can result in voltage spikes damaging to DC control circuits of the generator set .

7.5

Troubleshooting Procedure Fault codes information together with Warning and Shutdown information is provided in this section to assist in locating and identifying the possible causes of faults. The following procedures are a guide to help you evaluate problems with the control. NOTE:

Each fault code "warning" can be changed to "shutdown" using InPower. Default settings are used in this manual. It is recommended that all changes to settings be recorded at each site to aid in the troubleshooting of the generator set.

CAUTION: Always make sure that the PCC is in the OFF mode before disconnecting or connecting harness connectors. Otherwise, disconnecting the harness connectors can result in voltage spikes high enough to damage the DC control circuits of the set. CAUTION: Electrostatic discharge will damage circuit boards. Always wear a wrist strap when handling circuit boards or when disconnecting or connecting harness connectors. See Circuit Board Removal/Replacement in Chapter 6 on page 29.

7.5.1

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. The following corrective actions will mention when it is necessary to remove a plug for testing. In other cases, the plug must not 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.

7.5.2

Reading 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.

7.5.2.1 Fault Codes 7.5.2.1.1 Engine Does Not Crank in Manual Mode Logic: This indicates that the control has not received or recognized a manual start signal. Possible Causes: · No power supplied to the control. · Control not properly calibrated or corrupt calibration. · The Emergency Stop switch or wiring is defective. 36

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

· Oil pressure switch or wiring is defective. · Oil pressure sender, setup on wiring is defective. Diagnosis and Repair: 1. No power supplied to the control. a. Check if the control is in Manual mode and when the Start button is pressed, and that there are no shutdown faults present. b. Poor battery cable connections. Clean the battery cable terminals and tighten all connections. c. Check for brown fuses. d. Remove connector P16 and check for B+ at P16-2 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. 2. Control not properly calibrated or corrupt calibration. a. Confirm that the installed calibration part number matches the serial plate information. Re-enter calibration file if necessary. 3. The Emergency Stop switch or wiring is defective. a. 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. 4. Oil pressure switch or wiring is defective. a. Remove P16 connection and check wiring between P16-9 and P16-11 to the switch. b. Verify control is configured for the type of sensor installed. c. Verify proper operation of the switch. 5. Oil pressure sender, setup on wiring is defective. a. 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.

7.5.2.1.2 Engine Does Not Crank in Remote Mode Logic: This indicates that the PS0500 control has not received or recognized a remote start signal. Possible Causes: 1. The remote start switch or wiring is faulty. Diagnosis and Repair: 1. The remote start switch or wiring is faulty. a. Check if the control is in Auto mode and there are no shutdown faults 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.

A040Y520 (Issue 1)

37

7. Troubleshooting

9-2011

7.5.2.1.3 Code 141 - Oil Pressure Sensor OOR - (High/Low) (Warning) Logic: Engine oil pressure sensor is out of range – shorted high or low. Possible Causes: 1. The sensor connections could be bad. 2. The sensor could be bad. 3. The harness could be bad. 4. The control could be bad. Diagnosis and Repair: 1. The sensor connections could be bad. a. Inspect the sensor and engine harness connector pins. Repair or replace as necessary. 2. The sensor could be bad. a. Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. 3. The harness could be bad. a. Remove connector P7 from Control and connector from sensor. · Check for a short circuit from pin to pin (more than 200k Ohms Ok). · Check for an open circuit (10 Ohms or less Ok). 4. The control could be bad. a. Check pressure signal (.500 to .033 VDC) at P16-9 and P16-11 (sensor common). If in range, replace control.

7.5.2.1.4 Code 143/415 - Low or Pre-Low Engine Oil Pressure (Warning/Shutdown) Logic: Engine oil pressure is below the low/pre-low oil pressure warning threshold. Possible Cause: 1. Fault simulation was enabled with a PC based service tool. 2. Low oil level. Clogged lines or filters. 3. Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault. 4. Harness or control could be bad. 5. Low oil pressure fault set points could be incorrect. Diagnosis and Repair: 1. Fault simulation was enabled with a PC based service tool. a. With a PC based service tool, verify that the fault simulation is not enabled for the oil pressure sensor.

38

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

b. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. 2. Low oil level. Clogged lines or filters. a. Check oil level, lines and filters. b. If oil system is Ok but oil level is low, replenish. 3. Sensor or oil pump could be bad. Or the generator set may be shutting down on another fault. a. Disconnect the oil pressure sensor leads, and connect an oil pressure sensor simulator to the harness. · If the control responds to the simulator, reconnect the sensor, disconnect the + signal wire at the fuel solenoid, and crank the engine. Check the oil pressure reading on the digital display. · If the display shows an acceptable oil pressure, the problem may not be in the oil or oil sensing system. The generator set may be shutting down on another fault (out of fuel, intermittent connector). Restart the generator set 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. · If the control does not respond to the simulator, go to the next step. 4. Harness or control could be bad. a. If the control does not respond to the simulator, the control or the harness is bad. · Check the resistance in P16-9 and 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 not go to P16, the control is bad. 5. Low oil pressure fault set points could be incorrect. a. Verify set points against the normal operating pressures of the engine. Refer to the engine service manual.

7.5.2.1.5 Code 144 − Coolant Sensor OOR (High/Low) (Warning) Logic: This indicates that the coolant temperature sensor signal is out of range - shorted high or low. Possible Causes: 1. The sensor connections could be bad. 2. The sensor could be bad. 3. The harness or control could be bad. Diagnosis and Repair: 1. The sensor connections could be bad. a. Inspect the sensor and engine harness connector pins. Repair or replace as necessary.

A040Y520 (Issue 1)

39

7. Troubleshooting

9-2011

2. The sensor could be bad. a. Disconnect the sensor, and plug in a resistive sensor simulator to isolate the fault. · If the control responds to the simulator, replace the sensor. · If the control does not respond to the simulator, go to the next step. 3. The harness or control could be bad. a. Remove connector P16 from control and disconnect the sensor. b. Check pins P16-1 and P16-11 (Sensor Common) for short circuit. · Check for a short circuit to the engine block ground (more than 200k Ohms okay). · Check for a short circuit from pin to pin (more than 200k Ohms okay). Repair or replace as necessary. c. Measure the resistance of the coolant sensor and reconnect the harness to sensor. Remove 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, the control is bad.

7.5.2.1.6 Code 151/146 - High or Pre-High Coolant Temperature (Shutdown) Logic: Engine coolant temperature has exceeded 22the warning threshold for pre-high/high coolant temperature. Possible Cause: 1. Fault Simulation was enabled with a PC based service tool. 2. Engine or sensor circuitry problem. 3. The sensor could be bad. 4. The harness or control could be bad. Diagnosis and Repair: 1. Fault Simulation was enabled with a PC based service tool. a. With a PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. 2. Engine or sensor circuitry problem. a. 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 the next step. 3. The sensor could be bad. a. Disconnect the sensor and connect a coolant temperature sensor simulator to the harness.

40

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

b. If the control responds to the simulator, replace the sensor. If the control does not respond, go to the next step. 4. The harness or control could be bad. a. Measure the resistance of the coolant sensor and reconnect the harness to the sensor. Remove connector P16 from Control and check resistance between pins P161 and P16-11. · If resistance is not the same, harness is bad. · If resistance is the same, control is bad.

7.5.2.1.7 Code 234 – Overspeed (Shutdown) Logic: Engine speed signals indicate an engine speed greater than shutdown threshold. Possible Causes: 1. Cold Engine (no coolant heaters). 2. Single step large block load removal. 3. Fault simulation was enabled with a PC based service tool. 4. Fault threshold is not set correctly with PC based service tool. 5. Monitor the engine RPM using InPower. 6. Mechanical fuel system setup could be incorrect. Diagnosis and Repair: 1. Cold engine (no coolant heaters) a. Overspeed can occur when starting a very cold engine. Clear fault and restart generator set. 2. Single step large block load removal. a. Clear fault and restart generator set. 3. Fault simulation was enabled with a PC based service tool. a. With PC based service tool, verify that the fault simulation is not enabled for the coolant sensor. b. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. 4. Fault threshold is not set correctly with PC based service tool. a. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. 5. Monitor the engine RPM using InPower. a. If the RPM is not correct, refer to fault code 1449 for corrective action. 6. Mechanical fuel system setup could be incorrect. a. Verify fuel stop settings for the application.

A040Y520 (Issue 1)

41

7. Troubleshooting

9-2011

7.5.2.1.8 Code 359 - Fail to Start - Mechanical Governed Engine (Shutdown) Logic: This indicates that the engine failed to start after expiration of last crank time. Possible Causes: 1. Restricted fuel supply. 2. Glow plugs are not heating. 3. Fuel Solenoid on the injection pump not energized. 4. The engine fuel system is worn or malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing). 5. The engine is worn or malfunctioning mechanically. Diagnosis and Repair: 1. Restricted fule supply due to: · Fuel level below pickup tube in tank. · Add fuel if low. Prime the fuel system. · Closed shutoff valve in supply line. · Open any closed shutoff valve in the fuel line supplying the engine. · Fuel injectors clogged. · Refer to the engine service manual. · Air in fuel system. · Bleed air from the fuel system. Refer to the engine service manual. 2. Glow plugs are not heating due to: · Glow plug(s) is bad. · 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. · Control is bad. · Attempt to start and check if glow plug relay energizes. TB2-2 should be at GND 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. · Glow plug relay is bad. 3. Fuel solenoid on the injection pump not energized due to: · Fuse may be open. · 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.

42

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

· Binding in the solenoid linkage can prevent activation of the hold coil circuitry in the solenoid. Make sure solenoid in shaft moves completely in and out freely. (Applies to solenoids with both pull and hold coils). · Fuel solenoid is bad. · 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 next step. · Control/K7 Fuel Relay is bad. · Check wiring continuity/test 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 connection and fuel solenoid (+). · If B+ is not present, check for relay contacts. · The engine fuel system is worn or malfunctioning or has lost prime (fuel lift pump, injection pump, injectors, timing). · Service according to the engine service manual. · The engine is worn or malfunctioning mechanically. · Service according to the engine service manual. 4. Improper connections have been made at the generator output terminals. a. Reconnect according to the appropriate reconnection diagram. 5. The voltage sense or setup wiring connection could be incorrect. a. Check that voltage senses inputs P22-1 to 4 are connected to the correct voltage sensing point at alternator. 6. The rotating rectifier assembly (diodes CR1 through CR6) is faulty. a. Check each diode. See the generator set service manual. 7. Loose connector or control is bad. a. Repair connections (P22) or replace the control if necessary. 8. AVR or alternator is bad. a. Refer to Alternator/AVR Board Isolation Procedure in Alternator service manual to determine if the AVR board is causing the low AC voltage shutdown fault. 9. Voltage sense connections/setup could be incorrect. a. See wiring diagrams for proper connections.

7.5.2.1.9 Code 441 - Battery Voltage Low (Warning) Logic: Low voltage has been detected for the battery.

A040Y520 (Issue 1)

43

7. Troubleshooting

9-2011

Possible Causes: 1. Weak or discharged battery. 2. Low electrolyte level in battery. 3. Battery connections loose or dirty. 4. Insufficient battery charging voltage. 5. Engine DC alternator could be bad. 6. If the batteries are okay, the problem may be the harness or the control. 7. Fault threshold could be bad. Diagnosis and Repair: 1. Weak or discharged battery. a. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80°F (27°C). 2. Low electrolyte level in battery. a. Replenish electrolyte and recharge battery. 3. Battery connections loose or dirty. a. Clean and tighten to replace the battery cable connectors and cables at the battery and the generator set. 4. Insufficient battery charging voltage. a. Adjust charge rate of AC powered battery charging circuit, according to manufacture's instructions. 5. Engine DC alternator could be bad. a. Replace engine DC alternator if normal battery charging voltage (12 to 14 VDC) is not obtained. 6. If the batteries are okay, the problem may be the harness or the control. a. Remove connector P16 from control and check battery voltage at P16-2 (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 okay, the control is bad. 7. Fault threshold could be bad. a. Check fault threshold against requirement of the application.

7.5.2.1.10 Code 442 - Battery Voltage High (Warning) Logic: High voltage has been detected for the battery. Possible Causes: 1. Excessive battery charging voltage. 2. Engine DC alternator could be bad. 3. Fault threshold could be bad.

44

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

Diagnosis and Repair: 1. Excessive battery charging voltage. a. Adjust charge rate of AC powered battery charging circuit according to the manufacturer's instructions. 2. Engine DC alternator could be bad. a. Replace engine DC alternator if normal battery charging voltage (12 to 24 VDC) is not obtained. 3. Fault threshold could be bad. a. Check fault threshold against requirement of the application.

7.5.2.1.11 Code 1123 - Shutdown After Battle Short (Shutdown) Logic: A shutdown fault occurred while the Battle Short mode was enabled. Check fault history for faults that may have been bypassed.

7.5.2.1.12 Code 1131 − Battle Short Active(Warning) Logic: Indicates that the control is in Battle Short mode - used to bypass several fault shutdowns for generator set operation during emergencies.

7.5.2.1.13 Code 1312 − Configurable Input (Warning) Logic: The nature of the fault is an optional configurable selection. Possible Cause: If there is no actual fault, the problem may be an external wiring problem. Diagnosis and Repair: 1. External wiring problem. a. Disconnect the signal lead from TB2 and reset the control. b. Check the Customer input pin TB2-4. If the message drops out, the external wiring has a short circuit. Grounding of the input activates the fault.

7.5.2.1.14 Code 1416 − Fail to Shutdown (Warning) Logic: Generator set continues to run after receiving shutdown command from the controller. Battle short feature enabled - used to bypass several critical fault shutdowns for generator set operation during emergencies.

7.5.2.1.15 Code 1434 − Remote E−Stop Logic: The Remote Emergency Stop has been activated. Possible Causes: 1. The Remote Emergency stop button has been activated A040Y520 (Issue 1)

45

7. Troubleshooting

9-2011

Diagnosis and Repair: 1. The Remote Emergency stop button has been activated a. Reset the Remote Emergency Stop: a. Open (disable) remote emergency stop button. b. Press the OFF button. c. Select the desired operating mode (Manual or Auto).

7.5.2.1.16 Code 1435 − Low Coolant Temperature (Warning) Logic: Indicates engine coolant heater is not operating or is not circulating coolant. Warming occurs when engine coolant temperature is 70°F (21°C) or lower. NOTE:

In applications where the ambient temperature falls below 40°F (4°C), low coolant temperature may be indicated even though the coolant heaters are operating.

Check the following conditions: · Coolant heater not connected to power supply. Check for brown fuse or disconnected heater cord and correct as required. · Check for low coolant level and replenish if required. · Look for possible coolant leakage points and repair as required. · Open heater element. Check current draw of heater. Coolant temperature must be below 70°F (default setting) for one minute to activate warning and be above 70°F for five minutes before the warming can be cleared.

7.5.2.1.17 Code 1442 − Weak Battery (Warning) Logic: 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 Fault code 441 for corrective action.

7.5.2.1.18 Code 1446 − High AC Voltage (Shutdown) Logic: One or more of the phase voltages has exceeded 130% of nominal for 1 second, or has exceeded the High AC Voltage Threshold for the High AC Voltage Delay seconds. Possible Causes: 1. Fault simulation feature was enabled with a PC based service tool. 2. Single step large block load removal. 3. Fault threshold is not set correctly with a PC based service tool. 4. AVR or generator is bad. 5. Voltage sense connections/setup could be incorrect.

46

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

Diagnosis and Repair: 1. Fault simulation feature is enabled with a PC based service tool. a. With a PC based service tool, verify that the related fault simulation is not enabled. b. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. 2. Single step large block load removal. · Clear fault and restart generator set. 3. Fault threshold is not set correctly with a PC based service tool. a. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. 4. AVR or generator is bad. a. Refer to generator AVR board isolation procedure in alternator service manual to determine if the AVR board is causing the high AC voltage shutdown fault. 5. Voltage sense connections/setup could be incorrect. a. See engine service manual.

7.5.2.1.19 Code 1447 − Low AC Voltage (Shutdown) Logic: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage Delay seconds. Possible Causes: 1. Fault simulation feature was enabled with a PC based service tool. 2. Fault threshold is not set correctly with a PC based service tool. 3. Overload. 4. Improper connections have been made at the generator output terminals. 5. The voltage sense or setup wiring connection could be incorrect. 6. The rotating rectifier assembly (diodes CR1 through CR6) is faulty. 7. Loose connector or control is bad. 8. AVR or alternator is bad. 9. Voltage sense connections/setup could be incorrect. Diagnosis and Repair: 1. Fault simulation feature is enabled with a PC based service tool. a. With a PC based service tool, verify that the related fault simulation is not enabled. b. If you do not have a PC based service tool, remove battery power from the control to disable fault simulation overrides. 2. Fault threshold is not set correctly with a PC based service tool. a. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold.

A040Y520 (Issue 1)

47

7. Troubleshooting

9-2011

3. Overload. a. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. 4. Improper connections have been made at the generator output terminals. a. Reconnect according to the appropriate reconnection diagram. 5. The voltage sense or setup wiring connection could be incorrect. a. Check that voltage senses inputs P22-1 to 4 are connected to the correct voltage sensing point at alternator. 6. The rotating rectifier assembly (diodes CR1 through CR6) is faulty. a. Check each diode. See the generator set service manual. 7. Loose connector or control is bad. a. Repair connections (P22) or replace the control if necessary. 8. AVR or alternator is bad. a. Refer to Alternator/AVR Board Isolation Procedure in Alternator service manual to determine if the AVR board is causing the low AC voltage shutdown fault. 9. Voltage sense connections/setup could be incorrect. a. See wiring diagrams for proper connections.

7.5.2.1.20 Code 1448 − Underfrequency (Shutdown) Logic: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage Delay seconds. Possible Causes: 1. Fault threshold is not set correctly with a PC based service tool. 2. Overload. 3. Fuel or air delivery problem. 4. Governor fault. 5. Loose connector or control is bad. Diagnosis and Repair: 1. Fault threshold is not set correctly with a PC based service tool. a. Reset the threshold to the lowest allowable setting. Determine the required operating range before adjusting the threshold. 2. Overload. a. Check the load and correct any overload. Check operation by disconnecting load and restarting generator set. 3. Fuel or air delivery problem. a. Refer to the engine service manual.

48

A040Y520 (Issue 1)

9-2011

7. Troubleshooting

4. Governor fault. a. Check fuel shutoff solenoid adjustment. 5. Loose connector or control is bad. a. Repair connections (P22-1 to 4) or replace the control if necessary.

7.5.2.1.21 Code 1449 − Overfrequency (Shutdown) Logic: One or more of the phase voltages has dropped below the Low AC Voltage Threshold for Low AC Voltage Delay seconds. Possible Causes: 1. Fault threshold is not set correctly with a PC based service tool. 2. Fuel or air delivery problem. 3. Loose connector or control is bad. Diagnosis and Repair: 1. Fault threshold is not set correctly with a PC based service tool. a. Reset the threshold to the highest allowable setting. Determine the required operating range before adjusting the threshold. 2. Fuel or air delivery problem. a. Refer to the engine service manual. 3. Loose connector or control is bad. · Repair connection (P22-1 to 4) or replace the control if necessary.

7.5.2.1.22 Code 2677 - Fail to Stop (Shutdown) Logic: Generator set 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.

7.5.2.1.23 Code 2678 - Charger Failure (Warning) Logic: Indicates that the battery charging alternator has not reached an acceptable voltage range within the selected period (default = 120 seconds). Refer to engine service manual if this fault occurs. If not failed, check wiring.

A040Y520 (Issue 1)

49

7. Troubleshooting

9-2011

This page is intentionally blank.

50

A040Y520 (Issue 1)

8

Manufacturing Facilities

NORTH AMERICA

EMEA, CIS

ASIA PACIFIC

Cummins Power Generation Limited 1400 73rd Ave. NE Minneapolis, MN 55432 USA

Cummins Power Generation Limited Columbus Avenue Manston Park Manston, Ramsgate Kent CT12 5BF United Kingdom

Cummins Power Generation Limited 10 Toh Guan Road #07-01 TT International Tradepark Singapore 608838

Phone +1 763 574 5000 Toll Free +1 800 888 6626 Fax +1 763 574 5298

Phone +44 1843 255000 Fax +44 1843 255902

Phone +65 6417 2388 Fax +65 6417 2399

BRAZIL

CHINA

INDIA

Rua Jati, 310, Cumbica Guarulhos, SP 07180-900 Brazil

Cummins Power Generation 2 Rongchang East Street, Beijing Economic – Technological Development Area Beijing 100176, P.R.China

35A/1/2, Erandawana Pune 411 038 India

Phone +55 11 2186 4195 Fax +55 11 2186 4729

Phone +86 10 5902 3000 Fax +86 10 5902 3199

Phone +91 020 6602 7525 Fax +91 020 6602 8090

LATIN AMERICA

MEXICO

3350 Southwest 148th Ave. Suite 205 Miramar, FL 33027 USA

Eje 122 No. 200 Zona Industrial San Luis Potosi, S.L.P. 78395 Mexico

Phone +1 954 431 551 Fax +1 954 433 5797

Phone +52 444 870 6700 Fax +52 444 824 0082

8.1

How to Obtain Service When a product requires servicing, contact your nearest Cummins Power Generation distributor. To locate your local Cummins Power Generation distributor, refer to www.cumminspower.com and select Distributor Locator. When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the nameplate.

8.1.1

Locating Your Distributor In North America Telephone +1-800-888-6626 (this is an automated service for touch-tone phones only) to contact the nearest Cummins Power Generation distributor in the United States or Canada. By selecting Option 1 (press 1), you will be automatically connected to the distributor nearest you. If you are unable to contact a distributor using the automated service, consult the Yellow Pages. Typically, our distributors are listed under: GENERATORS – ELECTRIC or

A040Y520 (Issue 1)

51

8. Manufacturing Facilities

9-2011

ENGINES – GASOLINE OR DIESEL If you have difficulty arranging service or resolving an issue, please contact the Service Manager at the nearest Cummins Power Generation distributor for assistance. When contacting your distributor, always supply the complete Model, Specification, and Serial Number as shown on the product nameplate. Outside North America If you are outside North America, telephone Cummins Power Generation at +1-763-574-5000 from 7:30 am to 4:00 pm, Central Standard Time, Monday through Friday, or fax +1-763-5287229.

52

A040Y520 (Issue 1)

Appendix A. Wiring Diagrams Table of Contents Figure 13. PS0500 Wiring Digaram ............................................................................................................ 55

A040Y520 (Issue 1)

53

Appendix A.

Wiring Diagrams

9-2011

Note: This section contains basic (generic) wiring diagrams and schematics to help in troubleshooting. Service personnel must use the wiring diagrams and schematics shipped with the unit. These wiring diagrams and schematics should be updated when modifications are made to the unit.

54

A040Y520 (Issue 1)

9-2011

Appendix A.

Wiring Diagrams

FIGURE 13. PS0500 WIRING DIGARAM

A040Y520 (Issue 1)

55

Appendix A.

Wiring Diagrams

9-2011

This page is intentionally blank.

56

A040Y520 (Issue 1)

www.cumminspower.com Cummins, the "C" logo, and "Our energy working for you." are trademarks of Cummins Inc. Copyright © 2011 Cummins Power Generation, Inc. All rights reserved.