PCCP3100

Standard PCCP Control Systems
Publication 3535(GB) Issue 02 Feb 2003
FOREWORD
The purpose of this manual is to provide the users with sound, general information. It is for guidance and assistance with recommendations for correct and safe procedures. Cummins Power Generation Limited cannot accept any liability whatsoever for problems arising as a result of following recommendations in this manual. The information contained within the manual is based on information available at the time of going to print. In line with the Cummins Power Generation Limited policy of continual development and improvement, information may change at any time without notice. The users should therefore ensure that before commencing any work, they have the latest information available. Users are respectfully advised that it is their responsibility to employ competent persons to carry out any installation work in the interests of good practice and safety. It is essential that the utmost care is taken with the application, installation and operation of any diesel engine due to their potentially dangerous nature. Careful reference should also be made to other Cummins Power Generation Limited literature, in particular the engine Operation and Maintenance Manual. Should you require further assistance contact: -
Cummins Power Generation Limited
Manston Park
Columbus Avenue Manston Ramsgate Kent CT12 5BF Tel. No.: +44 (0) 1843 255000 Fax. No.: +44 (0) 1843 255902
CONTENTS
Section Title Page
Schedule of Abbreviations ................................................................................................ i 1

1.1 1.2 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5 1.3 1.4 1.5 1.6 1.7 1.7.1 1.8 1.8.1 1.8.2 1.8.3 1.8.4 1.8.5 1.8.6 1.8.7 1.8.8 1.8.9 1.8.10
Safety
.............................................................................................................. 1-1
Warning, Caution and Note Styles Used In This Manual .............................................1-1 Warnings.....................................................................................................................1-1 Electricity...............................................................................................................1-1 High Pressures......................................................................................................1-1 Maintenance .........................................................................................................1-2 Supply Isolation.....................................................................................................1-2 Reinstatement of Supply .......................................................................................1-3 General Information ....................................................................................................1-3 Radio Frequency.........................................................................................................1-4 Standards, Codes & Regulations ................................................................................1-4 Standards ...................................................................................................................1-5 Generator Plant Safety Code ......................................................................................1-6 Genset Warning Labels.........................................................................................1-6 Safety Precautions......................................................................................................1-7 Engine Warning.....................................................................................................1-7 Exhaust Gas Hazards ...........................................................................................1-7 Fire Hazards .........................................................................................................1-8 Moving Part Hazards.............................................................................................1-9 High Temperature Hazards ...................................................................................1-9 Electrical Hazards .................................................................................................1-9 Noise...................................................................................................................1-11 General ...............................................................................................................1-11 Fluids ..................................................................................................................1-12 Disposal of Engine Waste ...................................................................................1-12
2
2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.4
Introduction.......................................................................................................... 2-1
General.......................................................................................................................2-1 Generating Set Identification .......................................................................................2-1 After Sales Services....................................................................................................2-2 Maintenance .........................................................................................................2-2 Warranty ...............................................................................................................2-2 Spares ..................................................................................................................2-2 Overseas...............................................................................................................2-2
3
3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8
System Description ............................................................................................. 3-1

Generator Components...............................................................................................3-1 Engine...................................................................................................................3-2 Alternator ..............................................................................................................3-2 Generator Rating...................................................................................................3-2 Generator Construction .........................................................................................3-2 Fuel System ..........................................................................................................3-2 Cooling System .....................................................................................................3-3 Engine Exhaust (Option) .......................................................................................3-3 DC Electrical System.............................................................................................3-3
Contents
Page i
CONTENTS (continued)
Section 3.2 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 3.2.9 3.2.10 3.2.11 3.3 3.3.1 3.3.2 3.4 3.4.1 3.4.2 3.4.3 3.5 3.5.1 3.5.2 Title Page
Control System ........................................................................................................... 3-4 Control System Components ................................................................................ 3-5 Alarm Module (Option).......................................................................................... 3-6 Starting Control System ........................................................................................ 3-7 Customer Connections ......................................................................................... 3-7 Output Contacts.................................................................................................... 3-8 DC Power ............................................................................................................. 3-8 Paralleling Protection ............................................................................................ 3-8 Commonly Asked Questions About AmpSentry TM Control Systems ..................... 3-9 Communications Network (Option) ..................................................................... 3-14 Remote Start / Stop Scheduling (Option) ............................................................ 3-14 Earth Fault (Option) ............................................................................................ 3-14 Circuit Breakers and Change-over Contactors.......................................................... 3-14 Circuit Breakers (Option) .................................................................................... 3-14 Change-over Panel (Option) ............................................................................... 3-14 Heaters..................................................................................................................... 3-15 Engine Heater (Option) ....................................................................................... 3-15 Alternator Heater (Option)................................................................................... 3-15 Control Panel Heater (Option)............................................................................. 3-16 Mains Powered Battery Charger (Option) ................................................................. 3-16 Operation............................................................................................................ 3-16 Boost Charge (Option) ........................................................................................ 3-16
4
4.1 4.2 4.3 4.3.1 4.4 4.4.1 4.4.2 4.4.3 4.5 4.5.1 4.5.2 4.5.3 4.6 4.6.1 4.6.2 4.7 4.7.1 4.7.2 4.7.3 4.8 4.8.1 4.8.2
Operation ..............................................................................................................4-1
Safety ........................................................................................................................ 4-1 Introduction................................................................................................................. 4-1 Maintenance............................................................................................................... 4-1 Control Mode Definitions....................................................................................... 4-2 Functional Description ................................................................................................ 4-3 Sequence of Operation ......................................................................................... 4-3 Control Panel ........................................................................................................ 4-4 Emergency Stop Controls ................................................................................... 4-20 Start / Run Procedures ............................................................................................. 4-21 Operating Options............................................................................................... 4-21 Lockout ............................................................................................................... 4-22 Manual Start Procedure ...................................................................................... 4-23 Paralleling................................................................................................................. 4-24 Speed and Voltage Matching .............................................................................. 4-24 Operation When in Parallel ................................................................................. 4-24 Shutdown Procedures .............................................................................................. 4-25 Normal Stop........................................................................................................ 4-25 Emergency Stop ................................................................................................. 4-25 Emergency Stop Reset ....................................................................................... 4-26 Locking the Genset Out of Service ........................................................................... 4-27 Introduction......................................................................................................... 4-27 Immobilising the Plant for Safe Working.............................................................. 4-27
Page ii
Contents
Section 4.9 4.9.1 4.9.2 4.9.3 4.10 4.10.1 4.10.2 4.10.3 4.10.4 4.10.5 4.10.6 4.11 4.12 4.12.1 4.12.2 4.12.3 4.13 4.14 4.14.1 4.14.2 4.14.3 4.14.4 Title Page
Fault Alarms & Shutdowns ........................................................................................4-28 Alarm ..................................................................................................................4-28 Controlled Shutdown ...........................................................................................4-28 Immediate Shutdown...........................................................................................4-28 Genset Output Metering............................................................................................4-29 Load Voltage.......................................................................................................4-29 Load Current .......................................................................................................4-29 Load Power .........................................................................................................4-30 Genset Frequency...............................................................................................4-30 Bus Synchronisation............................................................................................4-30 Duty Cycles .........................................................................................................4-30 Engine Metering........................................................................................................4-31 Heaters .....................................................................................................................4-31 Coolant Heater (Option) ......................................................................................4-31 Alternator Heater (Option) ...................................................................................4-31 Control Panel Heater (Option) .............................................................................4-32 Digital Master Control (Option)..................................................................................4-33 Test Runs .................................................................................................................4-34 Pre-start Checks .................................................................................................4-34 Off-load Initial Run ..............................................................................................4-35 On-load Initial Run ..............................................................................................4-37 Maintenance Test Run ........................................................................................4-39
5 6
6.1 6.2 6.3 6.3.1 6.3.2 6.3.3 6.3.4
Maintenance......................................................................................................... 5-1 Troubleshooting .................................................................................................. 6-1

Introduction .................................................................................................................6-1 Safety Considerations .................................................................................................6-1 Fault Finding ...............................................................................................................6-2 Engine Starting Faults ...........................................................................................6-3 Engine Running Faults ..........................................................................................6-4 Electrical Output Faults .........................................................................................6-6 Control System Faults ...........................................................................................6-8
Contents
Page iii
Illustrations
Figure Figure 1-1 Figure 2-1 Figure 3-1 Figure 3-2 Figure 3-3 Figure 3-4 Figure 4-1 Figure 4-2 Figure 4-3 Figure 4-4 Figure 4-5 Figure 4-6 Figure 4-7 Tables Figure Table 4-1 Title Page Radio Frequency Warning ............................................................................. 1-4 Typical Genset Rating Plate........................................................................... 2-1 Typical Genset ............................................................................................... 3-1 International PCCP Panel .............................................................................. 3-5 Alarm Module Front Panel.............................................................................. 3-6 Time-over Current Curve.............................................................................. 3-13 Front Panel .................................................................................................... 4-4 Alphanumeric Display and Switches .............................................................. 4-9 Main Menu ................................................................................................... 4-11 Engine Menu................................................................................................ 4-13 Gen Menu .................................................................................................... 4-15 Adjust Menu ................................................................................................. 4-17 Version Menu............................................................................................... 4-19
Title
Page
Control Mode Definitions ................................................................................ 4-2
Supplementary Publications
The Supplementary Publications appropriate to your system will also be supplied with the system. Where appropriate the corresponding Instruction Manual(s) will also be supplied with any accessory that you order. Title ................................................................................................................. Publication No
Battery Charger ........................................................................................................................ 3393 Lead Acid Battery...................................................................................................................... 3330 NiCad Battery ........................................................................................................................... 3331 COSHH ................................................................................................................................ 3334
Page iv
Contents
Schedule of Abbreviations
AC ACB ACH ATS AVR BHP BMS BST CB CCA CHP COP CT dB(A) DC DIP DMC DMSU EMCU EMF EPU FSS GCP Genset GKWT HV IC I/O kVA kVAR kW kWh LED LTP LV Alternating Current Air Circuit Breaker Anti-Condensation Heaters Automatic Transfer Switch Automatic Voltage Regulator Brake Horsepower Building Management System Busbar Sensing Transformer Circuit Breaker Cold Cranking Amps Combined Heat and Power Continuous Power Rating Current Transformer Unit of noise level Direct Current Dual In-line Package Digital Master Control Demand Load Standby Unit Engine Monitoring and Control Unit Electromotive Force Engine Protection Unit First Start Sensor Generator Control Panel Generator Set Global Kilowatt Transducer High Voltage Integrated Circuit Input / Output Apparent Power Reactive Power Active / Real Power Unit of electrical energy or work Light-Emitting Diode Limited Time Power Rating Low Voltage MCB MCCB MF MFSS MR MST MSU MV NEC PCCP PCL PF PFC PLC PMG PRP PSU PT/CT QCC RFI RMS RPM RTD V VAC VCB VDC VF VT Miniature Circuit Breaker Moulded Case Circuit Breaker Mains Failed Master First Start Sensor Mains Returned Mains Sensing Transformer Mains Sensing Unit Medium Voltage Neutral Earthing Contact PowerCommand Control Paralleling A low cost control system Power Factor Power Factor Controller Programmable Logic Controller Permanent Magnet Generator Prime Power Rating Power Supply Unit Potential Transformer / Current Transformer Quadrature Current Control Radio Frequency Interference Root Mean Square Revolutions Per Minute Resistive Temperature Detector Volts Volts, Alternating Current Vacuum Circuit Breaker Volts, Direct Current Volt-free Voltage Transformer
TM
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Page ii
SECTION 1 PRELIMINARY AND SAFETY 1

1.1
Safety
Warning, Caution and Note Styles Used In This Manual
The following safety styles found throughout this manual indicate potentially hazardous conditions to the operator, service personnel or the equipment. WARNING: WARNS OF A HAZARD THAT MAY RESULT IN SEVERE PERSONAL INJURY OR DEATH. Warns of a hazard or an unsafe practice that can result in product or property damage.
Caution:
Note:
A short piece of text giving information that augments the current text.
1.2
Warnings
WARNING: IT IS IMPORTANT TO READ AND UNDERSTAND ALL SAFETY NOTICES PROVIDED IN THIS MANUAL. IMPROPER OPERATION OR MAINTENANCE COULD RESULT IN A SERIOUS ACCIDENT, OR DAMAGE TO THE EQUIPMENT, CAUSING INJURY OR DEATH.
1.2.1 Electricity
WARNING: ELECTRICITY CAN KILL! LETHAL VOLTAGES MAY BE PRESENT IN MUCH OF THE EQUIPMENT REFERRED TO IN THIS MANUAL.
1.2.2 High Pressures

WARNING: LIQUIDS OR GASES THAT ARE HIGHLY PRESSURISED CAN PASS THROUGH THE SKIN AND INTO THE BODY. THEY CAN ALSO CAUSE DAMAGE TO EQUIPMENT.
Section 1 Preliminary and Safety
Page 1-1
1.2.3 Maintenance
WARNING: ONLY AUTHORISED AND COMPETENT PERSONNEL WHO ARE FAMILIAR WITH THE EQUIPMENT AND ITS OPERATION SHOULD CARRY OUT MAINTENANCE.
WARNING:
DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT MAY OPERATE AUTOMATICALLY AND COULD START WITHOUT WARNING.
1.2.4 Supply Isolation

Caution: If the engine has been running recently, explosive gases (given off during battery charging) may be present in the vicinity of the batteries. Ensure the area is well ventilated before disconnecting batteries. BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO THE GENERATOR AND ANY CONTROL PANELS. RENDER THE GENERATOR INOPERATIVE BY DISCONNECTING THE PLANT BATTERY.
WARNING:
1.
Turn the Mode switch (S12) on the PCCP front panel to OFF. OFF RUN AUTO
2. 3. 4. 5. 6.
Isolate and lock off the supply to the battery charger, where fitted. Disconnect the starting batteries and control system batteries, (if separate). Isolate and lock off the heater control box, where fitted. Isolate the fuel supply to the engine. Fit Warning notices at each of the above points to indicate Maintenance in Progress Plant Immobilised for Safe Working.
Page 1-2
1.2.5 Reinstatement of Supply

WARNING: REINSTATE ALL PROTECTIVE DEVICES REMOVED OR DISCONNECTED DURING MAINTENANCE OR OVERHAUL, BEFORE PUTTING THE UNIT BACK INTO SERVICE.
The procedure for reinstatement is the reverse of the procedure for isolation.
1.3
General Information
Personnel engaged in the installation, commissioning, operation and maintenance of this equipment must be competent and experienced in these fields. They must also comply with all relevant and current statutory requirements and regulations, including the provisions of the Health and Safety at Work Act (1974), and any modification and amendment that may subsequently become a legal requirement. Before operating the genset, read this manual and become familiar with the equipment and its operation (including all controls, manually operated valves and shutdown devices). Correct operation and maintenance is essential for safe and efficient operation of this unit. Read and become familiar with the Safety Precautions listed in this section. Many accidents result from a failure to observe fundamental safety rules and precautions. There are many potential hazards that can occur during the operation of a genset, which cannot always be anticipated. Therefore a warning cannot be included in the manual for every possible circumstance that might involve a potential hazard. Should a procedure be used that has not been specifically recommended, then the personnel involved must be satisfied that it is safe and will not damage the genset.
Page 1-3
1.4
Radio Frequency
The apparatus has been tested according to European Standards EN 50081-2 and BS EN 61000-6-2:1999 (IEC 61000-6-2:1999), specifying the limits of radio frequency immunity and emissions to meet the essential requirements of the EMC directive 89/336/EEC as amended by Directive 92/31/EEC. From these tests the manufacturer has established that as a precaution against undue effects, no radio frequency communications equipment should be operated at a distance of less than three metres from any part of the apparatus when the genset could, or is relied upon to, provide power. The effective separation distance should be increased if the radio frequency communications equipment is found to interfere with the apparatus, the onus lies with the customer to effectively test for adverse effects on the apparatus before usage of the equipment.
NO RADIO FREQUENCY COMMUNICATIONS EQUIPMENT MAY BE OPERATED IN THE VICINITY OF THIS APPARATUS
Figure 1-1 Radio Frequency Warning
1.5
Standards, Codes & Regulations

The genset and its control system, are manufactured under a registered quality control system approved to BS EN ISO 9001 (1994). The following regulations are observed where applicable: The Health & Safety at work Act 1974 The Control of Substances Hazardous to Health Regulations 1999 (SI 1999 No. 437) IEE Wiring Regulations for Electrical Installations (16th Edition) The Electricity at Work Regulations 1989 The Environmental Protection Act 1990 The Health & Safety at Work Regulations 1992 The EMC Directive 89/336/EEC as amended by Directive 92/31/EEC The LV Directive 73/23/EEC The Machinery Directive 98/37/EC
Page 1-4
1.6
Standards
The genset and its control system has been designed, constructed and tested generally in accordance with the following Standards where applicable: BS 4999 (IEC 600341) BS 5000 (IEC 600341) BS 5514 (ISO 30462) BS 7671 BS 7698 (ISO 85282) BS EN 50081 (EN 500812) BS EN 61000-6-2:1999 (IEC 61000-6-2:19992) BS EN 60439 (IEC 604392) (EN 604392) BS EN 60947 (IEC 9471) (EN 609472) BS EN 60204-1 KEY:
1. A related, but not equivalent, standard: A BSI publication, the content of which to any extent at all, short of complete identity or technical equivalence, covers subject matters similar to that covered by a corresponding international standard. An identical standard: A BSI publication identical in every detail with a corresponding international standard.
General requirements for rotating electrical machines Rotating electrical machines of particular types or for particular applications Reciprocating internal combustion engines: performance Requirements for electrical installations IEE Wiring Regulations (16th Edition) Reciprocating internal combustion alternating current generating sets engine driven
Electromagnetic compatibility. Generic emission standard Electromagnetic compatibility. Generic immunity standard Specification for low-voltage switchgear and control gear assemblies Specification for low voltage switchgear and control gear
Safety of Machinery Electrical Equipment of Machines
2.
Page 1-5
1.7
Generator Plant Safety Code

Before operating the genset, read the Operation and Maintenance manual and become familiar with it and the equipment. Safe and efficient operation can only be achieved if the equipment is properly operated and maintained. Many accidents are caused by failure to follow fundamental rules and precautions.
1.7.1 Genset Warning Labels

Warning signs are provided on the genset at the point of risk. To avoid injury, always take the necessary precautions - as indicated on the sample signs shown below: Caution / Warning. Indicates a risk of personal injury.
Caution / Warning of Pressure Hazard. Indicates a risk of personal injury from pressurised fluids.
Caution / Warning of Temperature Hazard. Indicates a risk of personal injury from high temperature.
Caution / Warning of Radio Frequency Hazard. Indicates a risk of operating radio frequency communications equipment in the vicinity of the genset. Caution / Warning of High Voltage Hazard. Indicates a risk of personal injury from electric shock. Caution / Warning of High Voltage Hazard. Indicates that earth leads only must be connected at this point.
Page 1-6
1.8
Safety Precautions
Copy and post these suggestions in potentially hazardous areas.
1.8.1 Engine Warning

WARNING: DO NOT OPERATE A DIESEL ENGINE WHERE THERE ARE, OR CAN BE, COMBUSTIBLE VAPOURS. THESE VAPOURS CAN BE SUCKED THROUGH THE AIR INTAKE SYSTEM AND CAUSE ENGINE ACCELERATION AND OVERSPEEDING, WHICH CAN RESULT IN A FIRE, OR AN EXPLOSION. WHERE AN ENGINE, DUE TO ITS APPLICATION, MIGHT OPERATE IN A COMBUSTIBLE ENVIRONMENT, SUITABLE OVERSPEED SHUTDOWN DEVICES MUST BE FITTED. THE EQUIPMENT OWNER AND OPERATOR ARE RESPONSIBLE FOR SAFE OPERATION IN A HOSTILE ENVIRONMENT. CONSULT YOUR INFORMATION. AUTHORISED DEALER FOR FURTHER
1.8.2 Exhaust Gas Hazards

WARNING: RISK FROM TOXIC FUMES
Exhaust fumes are toxic and all necessary measures must be taken to ensure that they do not escape into, or re-circulate within, the plant room or associated buildings. Visually and audibly inspect the exhaust system as detailed in the Maintenance Schedule. Ensure that all exhaust components are secured and true (not warped). Do not use exhaust gases to heat a compartment. Ensure that the genset is kept well ventilated. Thoroughly ventilate the genset plant room to remove all fumes and explosive vapours before disconnecting or connecting battery cables thus reducing the possibility of accidental sparks causing an explosion. Ensure that the exhaust outlet is kept free from obstruction. Should repeated attempts to start the engine fail, unburnt fuel gas may build up in the exhaust system creating a potentially dangerous situation. Allow these gases to disperse before carrying out further attempts to start.
Page 1-7
Benzene and lead, found in some diesel oils, have been identified as causing cancer or reproductive toxicity. When checking, draining or adding diesel, take care not to ingest, breathe the fumes, or contact diesel. Used engine oils have been identified as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil.
1.8.3 Fire Hazards

WARNING: RISK OF FIRE
With the use of fuel, lubricating oils and batteries, there is a fire hazard. Naked flames or sparks should not be allowed near the genset, fuel tank and battery. Explosive fuel and oil vapours are always present in the vicinity of a genset, while a battery on charge can produce inflammable hydrogen gas. An area in the vicinity of the genset should be designated a NO SMOKING area and one that is prohibited to unauthorised persons. Ensure that adequate ventilation is maintained within the plant room at all times. Thoroughly ventilate the genset plant room to remove all fumes and explosive vapours before disconnecting or connecting battery cables thus reducing the possibility of accidental sparks causing an explosion. No loose items of equipment or combustible material should be left on or near any part of the genset. Remove all unnecessary oil and grease from the unit and clean up fuel and oil spills immediately. In the event of a fuel or oil leak, the spillage should be absorbed using a proprietary material (e.g. Fullers Earth granules, or similar). Sawdust should not be used, as this will create a fire hazard. Appropriate fire fighting equipment should be readily available - (CO2 or BCF type fire extinguishers are recommended). Inspect the fuel system before each operation and periodically while running. Do not refill the fuel tank while the genset is running. Keep a fire extinguisher available in or near the plant room and in other areas throughout the site. Use the correct extinguisher for the area.
Page 1-8
1.8.4 Moving Part Hazards

WARNING: RISK OF INJURY
Safety guards and covers must be securely fitted and all cubicle doors, coverplates, etc, should be firmly in place while the genset is in operation. Keep hands and loose clothing away from moving parts. Do not wear jewellery while servicing any part of the genset. Never step on the genset. It can stress and break unit components, possibly resulting in dangerous operating conditions from leaking fuel, leaking exhaust fumes, etc. Before performing any maintenance on the genset, disconnect its batteries to prevent accidental starting. Thoroughly ventilate the genset plant room to remove all fumes and explosive vapours before disconnecting or connecting battery cables thus reducing the possibility of accidental sparks causing an explosion. Avoid contact with any moving part.
1.8.5 High Temperature Hazards

WARNING: RISK OF BURNING AND SCALDING
While the genset is running, and for a period following shutdown, avoid contact with exhaust, radiator and other components that are likely to become hot. At all times, avoid contact with hot oil, hot coolant and hot exhaust gases. Hot coolant is under pressure. DO NOT attempt to remove a radiator or heat exchanger pressure cap while the genset is running. Always allow the genset to cool completely before doing so. DO NOT drain coolant or lubricating oil until the genset has cooled completely.
1.8.6 Electrical Hazards

WARNING: RISK FROM ELECTRIC SHOCK
The genset should be connected only to loads compatible with its electrical characteristics and rated output. Only suitably trained and qualified engineers, who are authorised to do so, should connect the genset load. Connection must also be in compliance with relevant codes and standards.
Page 1-9
The metalwork of the generating plant, bed frame and other exposed parts must be bonded to an effective earth point. Do not touch any electrically energised parts of the genset or cables / conductors with any part of the body or with any non electrically insulated object. Do not operate the genset with any terminal box cover open. Ensure that all connections are insulated. Ensure that all electrical equipment and connections are kept clean and dry. Replace any defective terminal covers and wiring immediately and ensure that all terminations are secure. Reinstate all protective devices removed or disconnected during maintenance or overhaul, before putting the genset back into service. The appropriate neutral earthing requirements must be complied with, or adequate means incorporated to ensure that an isolated neutral system is adequately protected against voltage rises and undetected earth faults. In the situation where the genset is operated in parallel with a network supply, the user must be satisfied that the neutral earthing switch gear (where fitted), is operational and that the associated protection devices are fully functional. Permission must have been obtained from the local electricity supply utility, before parallel operation is considered. Before carrying out any maintenance, isolate all supplies to the genset and any control panels. Render the genset inoperative by disconnecting the plant battery - see also Section 4.8 Locking the Genset Out of Service. To prevent irreparable damage to the battery charging system: Note: Never disconnect the battery whilst the plant is running Never disconnect the charging leads whilst the plant is running Disconnect the battery and charge alternator before electric arc welding on the plant
The charge alternator output lead is live at all times. Follow all applicable electrical safety codes. 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.
Page 1-10
1.8.7 Noise
WARNING: RISK OF DAMAGE TO HEARING
Gensets emit noise. It is recommended that the personnel exposed to noise should wear adequate protection, e.g. ear defenders.
1.8.8 General
WARNING: RISK OF INJURY
On gensets that can be started automatically, or from a remote location, a warning plate should be displayed prominently advising personnel that The Plant may start automatically without warning. Appropriate personal protective equipment should be worn when working on the genset or on any associated equipment. Information on first aid procedures and facilities should be displayed near the plant. The area around the genset should be clear of obstructions and dangerous objects. In addition, the floor should be kept clean, dry and clear of oil deposits. Maintenance work, particularly in confined areas, should be carried out by a minimum of two operators working together. Never lift the genset using the engine or alternator lifting lugs. Refer to the lifting recommendation drawings Lifting Ilus series. Only lifting devices of suitable capacity should be used.
Page 1-11
1.8.9 Fluids
WARNING: RISK OF TOXIC CHEMICALS
There is a health risk associated with exposure to fuel, lubricating oils, coolant additives and battery electrolyte. Avoid contact with these fluids and always wear the appropriate personal protective equipment. Reference should be made to the (Control of Substances Hazardous to Health) COSHH Publication No. 3334, supplied with this manual. Avoid fluid spillage and discard clothing contaminated by fuel oil, coolant, lubricants or battery electrolyte. Ensure that remote fuel storage systems are installed in compliance with relevant codes, standards and local requirements. The user should also contact their supplier of fluids used in the genset for Manufacturers recommendation on Health & Safety.
1.8.10 Disposal of Engine Waste

WARNING: INCORRECT DISPOSAL OF ENGINE WASTE IS ENVIRONMENTALLY HARMFUL AND PRESENTS A HEALTH RISK. SOME ENGINE WASTE IS COMBUSTIBLE AND IS THEREFORE A FIRE RISK. Dispose of unwanted or absorbed substances through an authorised contractor who will transport and correctly dispose of the waste to a licensed site. For further information refer to the COSHH Publication No. 3334, supplied with this manual.
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SECTION 2 - INTRODUCTION 2
2.1
Introduction
General
Before any attempt is made to operate the generator, the user should take time to read this manual and to familiarise him or herself with the Warnings and Operating Procedures.
2.2
Generating Set Identification

Each generating set is provided with a Generating Set Rating Plate as shown below. This provides information unique to the generator.
Figure 2-1
Typical Genset Rating Plate
Section 2 Introduction
Page 2-1
2.3
After Sales Services

We offer a full range of after sales services as follows:
2.3.1 Maintenance
For customers who wish to have their gensets expertly serviced at regular intervals the Customer Service Department offers a complete maintenance contract package. This covers all items subject to routine maintenance and includes a detailed report on the condition of the set. In addition, this can be linked to a 24-hour call-out arrangement, providing assistance 365 days a year if necessary. Specialist engineers are available to maintain optimum performance levels from customers gensets, and it is recommended that maintenance tasks are only undertaken by trained and experienced engineers provided by the Customer Service Department.
2.3.2 Warranty
All gensets have a twelve months warranty from the commissioning date as standard. Extended warranty coverage is also available. In the event of a breakdown prompt assistance can normally be given by factory trained service engineers with facilities to undertake all minor and many major repairs to equipment on site.
2.3.3 Spares
An extensive Spare Parts Department is available for any emergency breakdown and for the engineer who carries out his own routine maintenance. Please quote Plant Nos., Serial Nos., and Part Nos. when ordering spares.
2.3.4 Overseas
Agents and representatives in almost 100 countries throughout the world offer installation and after sales service for the equipment provided. We can provide the name and address of the agent for your specific location. For details on any of the above services contact your distributor.
Page 2-2
Section 2 Introduction
SECTION 3 SYSTEM DESCRIPTION 3

3.1
System Description
Generator Components
The main components of the Generator System are shown below. Refer to the Engine and Alternator Manuals for location of other components, e.g. oil filler, dipstick, etc. Various options are available although they may not be available for all models. Note that the Load Terminal Box, item 9, is mounted optionally on the left or right side and includes the load connection gland plate (with optional entry point location).
Figure 3-1
Typical Genset
KEY: 1. 2. 3. 4. 5. 6. 7. 8. Radiator Exhaust Outlets Air Cleaners Control Housing Load Output Circuit Breaker (LH/RH) Generating Set Rating Plate (LH/RH) Alarm Module (Option) PowerCommand Control Panel 9. 10. 11. 12. 13. 14. 15. Load Terminal Box (LH/RH) Bedframe Alternator Starter Motor Coolant Heater (Option) Engine Oil Filters (RH side)
Section 3 System Description
Page 3-1
3.1.1 Engine
All generators employ a 4-stroke, water-cooled engine and incorporate a governor control and full engine protection system. Refer to the Generating Set Rating Plate for engine type and rating details. For further information refer to the Engine manufacturers Operation and Maintenance Manual supplied with this manual.
3.1.2 Alternator
All generator types use AC alternators of a brushless, rotating field design, which eliminates the maintenance associated with slip rings and brushes. Refer to the Generating Set Rating Plate for alternator type and rating details. For further information refer to the Alternator manufacturers Installation, Service and Maintenance Manual supplied with this manual.
3.1.3 Generator Rating

For details of your generator rating refer to the Generating Set Rating Plate.
3.1.4 Generator Construction

Generators are constructed as a single module with the engine and alternator connected through a coupling chamber with resilient mountings to form one unit. The engine and alternator are mounted on a bedframe on resilient mountings. This results in one unit of immense strength and rigidity, with accurate alignment between the engine and alternator, and effective damping of engine vibration.
3.1.5 Fuel System

A base fuel tank formed from fabricated sheet sections can be provided as an option. The tank is fitted with a large filler cap with in-built coarse filter, and provides a minimum of eight hours operation at a nominal 100% load. Free standing main tanks with stands providing 450, 900 and 1350 litre capacity are available as options.
3.1.5.1 Fuel Transfer Pumps (Option)

Free standing fuel tanks can be filled manually using an optional hand fuel transfer pump. Alternatively, fuel tanks (base tank or free standing) can be filled automatically using an electrical fuel transfer pump. This pump, which is supplied complete with starter, operates under the control of Low and High Fuel Level switches fitted to the tank. On automatically filled systems, the base tank filler cap is replaced with an overflow / breather connection to allow piping to a safe area or return to a bulk tank.
Page 3-2
3.1.5.2 Fuel / Water Separators (Option)

Optional Set-mounted fuel / water separators are available to provide protection for the engine fuel injection system where water-free fuel supplies cannot be guaranteed.
3.1.6 Cooling System

The engine cooling system consists of a radiator and pusher fan, mechanically driven water pump and a thermostat. The fan drives air through the radiator and removes surface heat from the engine and alternator. The alternator has its own internal cooling fan.
3.1.7 Engine Exhaust (Option)

Exhaust systems, which are optional and supplied in loose form, reduce engine noise to acceptable levels and pipe exhaust gases to an area where they will not present a hazard. Industrial and residential types are available as options. Flexible bellows are also available as an option.
3.1.8 DC Electrical System

A 12 or 24 volt battery system (determined by generator type) provides multi-attempt engine starting and DC power for the generator control system.
3.1.8.1 Battery System

Battery type, size and voltage are selected to suit the generator capacity and application on ordering and include lead acid and NiCad types. (All types are options). Lead acid batteries are Set-mounted. NiCad batteries are free standing.
3.1.8.2 Charge Alternator

An engine driven charge alternator is provided as standard to maintain the battery in a charged condition when the engine is running.
3.1.8.3 Mains Powered Battery Charger (Option)

Optional single phase, mains powered battery chargers, which can be panel or wall mounted, are available to maintain the battery in a charged condition when the generator is not running.
Page 3-3
3.2
Control System
The main control panel and its associated equipment are located in the Control Housing, which is mounted on the bedframe at the rear of the genset. A Load Terminal Box will be mounted on either the left or right side of the housing, as required for the site. The PowerCommand Control (Paralleling) system (PCCP) is a microprocessor-based control for gensets providing automatic paralleling. It provides fuel control and engine speed governing, main alternator voltage output regulation, and complete genset control and monitoring. The control also monitors the health of the engine, alternator and auxiliary systems continuously, and will effect an Automatic Shutdown if a serious fault occurs. The PCCP operates in conjunction with an array of sensors and senders located on the engine, alternator and auxiliary systems. Digital data is passed between digital components over a digital data link. An important function of the control system is to continuously monitor the genset for faults. If a fault occurs during engine running, the PCCP will provide an indication for the operator and, if the fault is serious, effect an automatic, fully programmed, Shutdown. One of three fault level signals will be generated by the PCCP. The three fault levels are: 1. 2. 3. Warning, signals an imminent or non-fatal engine fault. The PCCP provides an indication only for this condition. Fault, signals a potentially damaging condition. The PCCP will automatically subject the engine to an off-load, cool-down run, and will then shut it down. Shutdown, signals a potentially fatal fault for the engine. The PCCP will automatically take the engine off-load and shut it down immediately, without a cooldown run.
The control systems operate on 12 or 24VDC battery power. Data backup is taken care of by a small rechargeable battery installed within the PCCP enclosure. Auxiliary equipment operates on LV AC power.
Page 3-4
3.2.1 Control System Components

3.2.1.1 Control Panel
The main control panel for the genset forms the front panel of a PowerCommand Control (Paralleling) enclosure.
Figure 3-2
International PCCP Panel
3.2.1.2 Control Modules

All customer control connections, and the external modules which act as interface modules between the PCCP and the genset are inside the Accessory Box which is mounted on the front face of the control housing. Situated in the Accessory Box are the four modules required for the operation of the PCCP. These modules are: Potential Transformer/Current Transformer (PT / CT) Module (A36) The PT/CT module isolates the PCCP from the load and reduces the voltage from generator output voltage to 18V AC. This module also has a burden resistor for each current transformer. Automatic Voltage Regulator (AVR) Module (A37) The Regulator output module amplifies the low-level PCCP regulator duty cycle signal and sends it to the exciter stator, and uses the PMG voltage as a secondary start disconnect signal Governor Output Module (A38) The Governor Output Module amplifies the low-level PCCP governor duty cycle signal and sends it to the governor actuator, and connects fused B+ and switched B+ to the engine and customer accessories. Bus PT Module (A39) The Bus PT Module converts the bus output voltage (from the load side of the paralleling breaker) to 18V AC and provides this to the analogue board. It also provides a reference signal to the PCCP for synchronising the genset output to a bus system. The Bus PT Module output is used for protection and control of the genset.
Page 3-5
3.2.1.3 Sensors / Senders

Various genset parameters are measured by sensors, senders, RTDs etc and the resulting signals are applied to the PCCP. Engine-mounted sensors are able to monitor the following systems: Fuel Lube Oil Cooling System Charge Air / Exhaust Miscellaneous Areas
Alternator-mounted sensors are able to monitor the following parameter (option) Winding Temps
3.2.2 Alarm Module (Option)

The Alarm Module provides audible warnings. The front panel has a warning horn, two indicator lights and one spring-loaded push-switch. The two indicator lights, Alarm and Horn Silenced, show respectively that the horn has been activated and that the adjacent Push-to-Silence-Horn push-switch has been pressed.
Figure 3-3
Alarm Module Front Panel
Page 3-6
3.2.3 Starting Control System

PCCP uses a multi-function control system, which integrates fuel ramping and field excitation, to minimise frequency and voltage overshoot and to limit black smoke emission on starting. This control system includes the following functions: 1. Fuel Ramping - Upon receiving the Start signal, the digital control system energises the engine fuel system only enough to allow the engine to start. When the control system senses that the engine has reached start disconnect speed, it gradually increases fuel flow to ramp up engine speed, for controlled acceleration up to rated operating conditions. This minimises black smoke emission and frequency overshoot, as well as improving cold starting capability. Fail to Crank - As the Start signal is initiated, the control system checks the speed monitoring pick-up to check that the engine is rotating. If the engine is not rotating, the control system switches off the starter and then makes two further attempts. If the final attempt fails, a Shutdown message is signalled on the alphanumeric display and the genset cannot be started until the fault is cleared. This process helps prevent starter or ring gear damage. Temperature Dynamic Governing - A temperature dynamic adjustment capability enhances cold starting ability, and improves stability when the engine is cold starting, by automatically adjusting governing characteristics based on engine temperature. It also helps limit black smoke emission on cold starting. Digital Excitation Control - The genset voltage regulation system is 3-phase sensing and includes torque matching to provide enhanced load pick-up capability. During starting, the control system ramps output voltage to rated value to minimise voltage overshoot. Cycle Cranking - The PCCP system includes a standard cycle cranking system, which allows the operator to select continuous or cycle cranking mode. The operator can select between three and six cranking cycles, and adjust the crank / rest times between seven and twenty seconds. The standard setting is three cranking cycles, with five seconds crank duration followed by ten seconds rest. Battery Monitoring System - The PCCP system continuously monitors the battery charging system for low and high DC voltage. Functions and messages include: Low DC voltage - battery voltage less than 24VDC (12VDC for 12V battery) High DC voltage - battery voltage greater than 32VDC (16VDC for 12V battery) Weak battery - main battery droop is monitored at start-up and, if the voltage drops below 60% of nominal for more than two seconds, the indication will be given First Start Sensor - provides a positive interlock to prevent multiple gensets from simultaneously closing to a dead system bus. A back-up system is provided to allow normal system operation in the event that the Primary First Start Sensor fails
2.
3.
4.
5.
6.
3.2.4 Customer Connections

All customer connections to the PCCP are made in the control housing, which is mounted on the genset bedframe. Connections are made via large, clearly labelled terminal blocks.
Page 3-7
3.2.5 Output Contacts

The PCCP provides control, alarm and status output signals, which are used to energise / de-energise associated relays. The relays are located within the PCCP panel and contacts are provided for customer use. Signals are provided for the following relays: Common Warning alarm relay - Operates on all Warning conditions. Rated at 2A, 30VDC Common Shutdown alarm relay - Operates on all Shutdown conditions. Rated at 2A, 30VDC Ready to load relay - Operates when the genset reaches 90% of rated voltage and frequency. Rated at 2A, 30VDC Auxiliary Run relays (up to 3 optional) - Each relay is rated at 2A, 30VDC Breaker operation contacts - Provide breaker open and breaker close signals for a paralleling circuit. Rated at 5A, 30VDC Load shed relay - Operates for a specified period of time when an Overload warning occurs. Rated at 6A, 30VDC
3.2.6 DC Power
The PCCP system is powered by the gensets battery system. The control system will function over a voltage range between 8 and 34VDC.
3.2.7 Paralleling Protection

The PCCP system incorporates AmpSentryTM Protection for automatic paralleling operations. This is a comprehensive power monitoring and control system that guards the electrical integrity of the alternator and power system from the following effects: Overcurrent Short circuit Over / under voltage Over / under frequency Overload Reverse power Loss of excitation Alternator phase rotation Paralleling circuit breaker failure to close
Current flow is regulated to 300% for both single phase and 3-phase faults when a short circuit condition is sensed. If the genset is operating for an extended period at a potentially damaging current flow level, an Overcurrent alarm will sound to warn the operator of an impending problem before it causes a system failure. If an Overcurrent condition persists for the time preprogrammed in the time current characteristic for the alternator, the permanent magnet generator (PMG) excitation system is de-energised, avoiding alternator damage. The Overcurrent protection is time delayed in accordance with the alternator thermal capacity.
Page 3-8
This allows current to flow until secondary fuses or circuit breakers operate, isolating the fault and thus achieving selective co-ordination (discrimination). After the fault is cleared, AmpSentryTM Protection softly loads the genset by controlled ramping of output voltage to rated level, allowing the genset to resume normal operation without a potentially damaging voltage overshoot. Fixed over / under voltage and under frequency time delayed set points also provide a degree of protection for load equipment. Over / under voltage conditions trigger a Shutdown message on the alphanumeric display; and under frequency conditions prompt both a Warning and Shutdown message, depending on the length of time and magnitude of variance under rated frequency. AmpSentryTM Protection includes an overload signal that can be used in conjunction with transfer switches or Master Controls to automatically shed load, preventing a potential genset Shutdown. The overload signal is programmable for operation at a specific kW level, on the basis of an under frequency condition. AmpSentryTM Protection for paralleling also includes protection for genset reverse power, loss of excitation, alternator phase rotation and circuit breaker failure to close. It includes permissive (synchronising check) functions for automatic and manual breaker closure operations.
3.2.8 Commonly Asked Questions About AmpSentry TM Control Systems

1. Does the generator FL current monitored change within PCCP for voltage settings? Yes! The control system uses the genset kW rating and voltage to calculate rated current and reset the position of the protection curve within the control system. The control system will use the highest current found on any phase as a basis for the over current actions taken by the control. 2. When the set is selected and entered into PCCP along with the voltage, how is the trip curve changed to accommodate the current which is derived from the kVA and voltage? The actual algorithms and operating system that we use to get to the trip performance shown on R1053 are proprietary. However, you can think of the protection as operating in a similar fashion to that shown on the protection curve. Protection on various units within an alternator family is performed as a function of multiples of the steady state current rating. So, as the current rating changes, the curve automatically shifts to compensate for it. 3. For a given over load current would you expect the alarm position to be given on the R1053 curve or in some place to the left of the curve? The over current pre-alarm point is fixed at 110% and 60 seconds. The Shutdown point is defined by the curve shown on R1053. The genset will Shutdown at the point shown on the curve, with the only deviations to this due to the calibration
Page 3-9
and/or accuracy of the CTs driving the system. Note that the CTs are selected to allow them to not saturate at five times rated current, so that they can provide accurate readings when the system is running in an over current condition. Note also that the algorithms in the control have integrating functions which result in the control reducing the time to trip if you have consecutive faults applied to the system. To completely reset the control you would need to wait for at least six minutes before another fault or test was commenced in order to get an accurate reading of trip time on a specific event. 4. For a 175% and above current would you expect to see the trip point on the curve or to the left of the curve? I assume these levels are closer to the curve. Again, I would expect the unit to trip at the point shown on the curve, not to the right or left of it. 5. Why is the horizontal trip area starting at 4 x FLI when the genset only manages 3 X FLI as a maintained current? The protection curve was drawn based on the thermal capabilities of the alternator, not the ability of the alternator to produce current. We purposely drew the protection curve as close to the damage curve as practical, to minimise the possibility of nuisance tripping, and facilitate discrimination with downstream devices. The curve goes horizontal at the point shown because it is the point of maximum output current for the alternator, and to continue dropping the curve would have no meaning or purpose. 6. Is the 3 x FLI maintained current relative to set output rating or alternator rating? If it is alternator rating, then which alternator frame size is it set for, again, I assume the smallest machine for the genset model? The 3 X current is based on the genset rating, not the alternator rating. Therefore when you have an alternator that is running at lower than rated temperature rise (such as running a class H machine at 105C rise) based on the genset KW rating the protection curve is a bit conservative, but it always works to protect the machine. It is worth noting that another significant difference between PCCP and other control systems is that PCCP measures and regulates fault current. In other systems, the voltage regulator will switch to full field operation on a fault, and the magnitude of fault current that you actually get is determined by the physical capabilities of the machine. Consequently, in non-PCCP machines it is not uncommon for the value of fault current provided to be somewhat more or less than the 300% level which is commonly specified. With PCCP, you will get 300%, because the output of the system is regulated to that level, in a very similar fashion to the way that voltage is regulated on normal operation conditions. 7. For single phase faults, does the time get multiplied up for the extra heating effect such a fault has on the alternator? No! Prototype testing that we did on the system, which included applying bolted faults to machines and measuring temperature rise in the alternators, did not indicate a need to modify the over current algorithms for single phase operation. 8. What happens when the set is de-rated and the output drops? I assume here that protection carries on for the 40C rated product ratings. When you go to de-rate the genset for altitude or temperature, we don't move the protection curve, so the situation is similar to that noted in question number seven
Page 3-10
above - the protection gets more conservative. However, if you actually plot the differences on the curve, you will see that there is not a very significant impact in the location of the damage curve and the protection provided by the control. 9. The customer requires to set the distribution breakers to enable them to discriminate with the genset controller, particularly on faults. I don't see how the AmpSentryTM protection could get into the way of discrimination with downstream devices. The curve is literally hugging the damage curve for the alternator in most cases, so if the downstream device did not co-ordinate with the damage curve, you undoubtedly would be getting to the point where without AmpSentryTM you could damage the machine. Note that most of the problems of discrimination revolve around interference in the instantaneous region of the breaker curves. Since the AmpSentryTM curve goes horizontal at 0.6 seconds, and most breakers have instantaneous set at around 0.05 seconds max, there is a lot of room for discrimination that you can't get in any other way. Even if the downstream breakers have long time ratings as long as 30 cycles, PCCP will allow discrimination between PCCP and the first downstream device(s). If you have a specific situation, which is apparently a problem, I would be happy to look it over and offer suggestions. Perhaps I do not clearly understand the problem that the customer is seeing. 10. We do not show or display anywhere what our settings are. They are not visible on the genset control. We do provide R1053 to describe the performance of the over current protection system, and allow customers and designers to verify system co-ordination. Unlike circuit breaker applications where a single protective device may be applied to many different situations, we have the luxury of only having to protect our machines, so there is no real need for adjustment in the over current protection and a single protective function curve can always be used to describe performance. We have tested the control system with actual short circuits of varying magnitude on real gensets, and also with current injection tests witnessed by third party authorities and proved that the control system functions as shown on our documentation. Since we are talking about processor-based control here, it's practically impossible that the control would fail to function properly, unless the inputs to the control are not performing properly. (In other words, the CTs are not properly calibrated, or are not working right due to improper sizing, etc.) Also, there are some cumulative functions in the control that result in faster tripping under conditions where repeated faults hit the control. 11. Does every customer test the current trips and plot his curve to know where he is? No! The customer is best served by using our curves. 12. Are you saying the curve is reliable and he does not need to test? If you are, then supportive data is needed for each control to present to the customer showing the performance against the output conditions. Yes, the curve is a reliable depiction of actual unit operation. We are proceeding with third party certification of the performance of the control system as part of our effort to get UL2200 listing of the product. At that point testing at your site to verify
Page 3-11
performance should be superfluous. Since the protective functions are adequately described by R1053, I really don't understand what else we could provide that would be more useful for specific situations. 13. Reverse power. How does PCCP calculate rev pwr? For reverse power calculations, the control will add together the power level seen on each phase. So, if you only use one phase, it will logically take three times the expected level of current to get to tripping time. This, of course, assumes that you are also driving appropriate power factor, because the control actually calculates kW, and that requires power factor measurement and calculations. This is one function that is easy to test in the control, because by simply reversing the CT wiring you can make the control think that positive power output is reverse power. So, in the future, when you test for reverse power, I'd suggest that you use that means rather than a current injection test. Standard AmpSentryTM settings
Condition Over Volts Under Volts Over Freq Under Freq Rev Pwr Exciter Loss
Action Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown
Notes At 130% of nominal or 110% for 10 seconds 85% of Nominal for 10 seconds 115% of nominal speed +/- 1% 90% of nominal for 10 seconds, 5 seconds before shutdown a load dump signal is outputted to avoid shutdown if load shed is available 10% of nominal rating. Can be set up via a security code given to service distributors Monitored excitation output is either wrongly set or has failed
Page 3-12
Figure 3-4
Time-over Current Curve
Page 3-13
3.2.9 Communications Network (Option)

The PCCP system includes a Generator Control Module (GCM) which provides for communications over the PCCP Communications Network. The network is suitable for local or remote control and monitoring functions using PCCP Software for WindowsTM.
3.2.10 Remote Start / Stop Scheduling (Option)

PCCP Software for WindowsTM provides for remote monitoring of the genset, or set of gensets, using a laptop PC. The software provides detailed information on the status of the gensets and their associated accessories. A remote access, single-site version of PCCP is provided for each site. Alternatively, one remote access, multi-site version of PCCP can be provided for a host monitoring computer.
3.2.11 Earth Fault (Option)

The Earth Fault option, which employs an earth fault unit, is designed to detect current flow in the neutral earth and provide a Shutdown alarm on the detection of an earth fault. A separate Earth Fault Reset button is provided on the control housing to allow resetting of an earth fault alarm. The resulting Shutdown indication on the control unit must be reset, using the Reset membrane switch on the front panel - see Section 4 System Operation.
3.3
Circuit Breakers and Change-over Contactors
3.3.1 Circuit Breakers (Option)

All generators can be equipped with optional mechanically operated 3 or 4-pole circuit breakers (MCCBs), mounted in the Load Terminal Box. The circuit breaker is used to isolate the generator output from the load. Up to 1250A generator rating circuit breakers are installed in a Set-mounted load box which is close coupled to the alternator output terminal box. Customer cables are fed to the circuit breaker via a bottom or side exit gland plate. Above 1250A generator rating circuit breakers are installed in a free-standing enclosure. With this arrangement the control panel remains Set-mounted using resilient mountings to reduce vibration.
3.3.2 Change-over Panel (Option)

Change-over panels, fitted with either 3 or 4-pole contactors, are available as options. Up to 1250A generator rating change-over panels are wall mounted. Above 1250A generator rating change-over panels are free standing.
Page 3-14
3.4
Heaters
Caution: Heater(s) must not be energised if the coolant system has been drained.
3.4.1 Engine Heater (Option)

The engine heater is designed to keep the engine coolant warm when the engine is shut down. It heats and circulates the coolant within the engine, reducing start-up time and engine wear caused by cold starts. The heater is controlled by an associated thermostat, but is locked out by the PCCP at engine start. The engine heater is supplied with 230V AC via the engine heater supply, the associated thermostat and an isolator relay. The relay is controlled by the PCCP. The engine mounted Engine Heater Isolator switch should normally be left in the On position. When the engine is running, heater operation is controlled automatically by a relay and thermostat. WARNING: ALWAYS ISOLATE THE SUPPLY TO THE ENGINE HEATER / THERMOSTAT BEFORE CARRYING OUT ANY MAINTENANCE ON THE ENGINE. ALWAYS ISOLATE THE GENSET PRIOR TO ANY MAINTENANCE. The engine heater is in no way intended to protect the engine and cooling system from freezing in sub zero conditions. If there is any danger from freezing, then a suitable antifreeze agent must be added to the cooling system.
Caution:
3.4.2 Alternator Heater (Option)

The alternator heater is designed to keep the alternator free of condensation when the genset is not running. During cool and humid conditions, condensation can form within the alternator, which can create flashing and a shock hazard. The heater is locked out by the PCCP at engine start. The alternator heater is supplied with power via the Engine Heater Isolator switch, which should normally be left in the On position as heater operation is controlled automatically by a relay and thermostat. The relay is controlled by the PCCP. WARNING: ALWAYS ISOLATE THE ALTERNATOR HEATER FROM THE AC SUPPLY BEFORE WORKING ON THE ALTERNATOR OR HEATER.
Page 3-15
3.4.3 Control Panel Heater (Option)

The control panel heater provides a means of humidity / temperature control within the control box interior. It protects the components and ensures their effectiveness when the genset is subjected to varying ambient air conditions during extended periods of non-use. The heater is locked out by the PCCP at engine start. The alternator heater is supplied with power via the Engine Heater Isolator switch, which should normally be left in the On position as heater operation is controlled automatically by a relay and thermostat. The relay is controlled by the PCCP. WARNING: ALWAYS ISOLATE THE CONTROL PANEL HEATER FROM THE AC SUPPLY BEFORE WORKING ON THE CONTROL PANEL OR HEATER.
3.5
Mains Powered Battery Charger (Option)

This unit maintains the lead-acid or NiCad battery in a fully charged condition without over-charging. The unit also provides rapid charging, when necessary, at a current up to the rated output. The chargers electronic control circuit allows the charger to be left in circuit during engine cranking and to operate in parallel with the charge alternator. The charger will supply current to the battery system when the battery terminal voltage is equal to the set float voltage, at which point only a trickle charge current is present. When the battery becomes discharged due to a load being present and the terminal voltage falls, the charger will again supply current to restore the voltage of the battery to the float voltage. Should a charge fail condition occur for longer than ten seconds then the charge fail relay will energise, and its contact close. Charger operation is indicated by a red LED. Note: The LED will light even if the charger output fuse is blown.
3.5.1 Operation
3.5.2 Boost Charge (Option)

During trickle charging, not all cells in the battery receive the same charge and over a period of several months this may affect battery performance. It is therefore normal to give batteries a regular charge at their full rate to return all cells to full capacity. This is referred to as Boost Charging (also known as equalise charging). If the charger is fitted with a Boost Charge switch, the Boost position should be selected at intervals detailed by the battery manufacturer (normally around every six months). Caution: Batteries should not be left on Boost Charge for extended periods as this will result in excessive water consumption, gassing and may impair battery performance.
Page 3-16
SECTION 4 SYSTEM OPERATION 4

4.1
Operation
Safety
Only suitably qualified and experienced personnel should carry out genset operations. Before operating the system, the operator should become familiar with Section 1 of this manual Preliminary and Safety instructions. Observe the following WARNINGS and CAUTIONS at all times. WARNING: BEFORE OPERATING THE PLANT BECOME FAMILIAR WITH THE EQUIPMENT AND HOW IT IS OPERATED (INCLUDING ALL CONTROLS, MANUALLY OPERATED VALVES AND ALARM DEVICES). SAFE AND EFFICIENT OPERATION CAN ONLY BE ACHIEVED IF THE PLANT IS OPERATED CORRECTLY.
WARNING:
CONTACTING HIGH VOLTAGE COMPONENTS CAN CAUSE ELECTROCUTION, RESULTING IN SEVERE PERSONAL INJURY OR DEATH. DO NOT OPEN THE GENERATOR OUTPUT BOX WHILE THE GENSET IS RUNNING. READ AND OBSERVE ALL WARNINGS AND CAUTIONS IN YOUR GENSET MANUALS.
Caution:
Only technically qualified personnel should open the PCCP front panel. Lower level voltages (18VAC to 24VAC) are present in the PCCP, which can cause electrical shock, resulting in personal injury. Even with power removed, improper handling of components can cause electrostatic discharge and damage circuit board components.
4.2
Introduction
This section describes the control settings required for operation of the genset, and the sequences that occur during generator Start-up and Running. Normal and Emergency Stop procedures are described, together with Alarm and Shutdown procedures, and controls. The text should be read in conjunction with the System Description, and the Engine and Alternator Operating Manuals.
4.3
Maintenance
To secure maximum performance and reliability from your genset it is essential that certain components are inspected periodically and, where necessary, maintenance procedures carried out as detailed in Section 5 - Maintenance.
Section 4 System Operation
Page 4-1
4.3.1 Control Mode Definitions

The following Control Mode Definitions are used in this manual:
Control Mode Normal Stop Definition A stop initiated manually during normal genset running. Alarm condition with alarm indication / horn / beacon. Alarm condition with alarm indication / horn / beacon. Critical alarm condition with immediate engine stop alarm indication / horn / beacon. Engine inhibited from starting with alarm indication / horn / beacon.
Table 4-1
Initiating Condition / Reset Stop with PCCP STOP switch. Manually reset any alarm at PCCP before restart. Non critical alarm condition. Alarm reset at PCCP. Alarm requiring controlled engine stop. Switch off & manually reset at PCCP before restart. Critical alarm condition. Switch off & manually reset at PCCP before restart.
Generator Load Auto ramping down of load before stopping.
Alarm
Loading maintained.
Controlled Shutdown
Auto ramping down of load.
Immediate Shutdown
All of load dumped with immediate engine shutdown.
Lockout
Start inhibit due to critical fault condition. Reset at PCCP when alarm condition is clear.
Control Mode Definitions
Load previously removed. Engine stopped.
Page 4-2
4.4
Functional Description
4.4.1 Sequence of Operation

The genset is run Automatically, using a Remote Start signal, or Manually, by using the genset controls. Genset indications are provided on the PCCP. If a fault is sensed at Start-up, the engine is locked out and will not start. When the PCCP is put in the Run mode, the genset performs an automatically sequenced manual start. When the PCCP is put in the Auto mode, the genset performs an automatically sequenced start when initiated by a start signal from a remote device. First, the PCCP initiates a starter cranking signal and verifies that the engine is rotating. Then it provides sufficient fuel to the engine to accelerate to start-disconnect speed. After the initial start procedure, the control system ramps the genset to rated speed and voltage. On reaching rated speed and voltage, the PCCP checks the system bus voltage. If the genset is working in a multiple (paralleling) genset installation and no bus voltage is present, it waits for a pulse from a remote Master First Start Sensor (MFSS). On receiving that pulse, the control will signal the paralleling breaker to close. If bus voltage is present, the PCCP checks for proper phase rotation, adjusts the genset to the bus voltage and frequency level, and then synchronises the genset to the system bus automatically. When a synchronised condition is achieved, PCCP will send a signal to close the paralleling breaker and the genset will assume its proportional share of the total load on the system bus.
Page 4-3
4.4.2 Control Panel

4.4.2.1 Front Panel
5 16 6
15 14
13
8 9
12
11
10
Figure 4-1
Front Panel
1. 2. 3. 4. 5. 6. 7. 8.
% Kilowatt Meter Frequency Meter AC Voltmeter % AC Ammeter System Control Selection Switches Voltage Meter Scale Indicator Lamp Phase Selector Switch + Indicators Emergency Stop Switch
9. 10. 11. 12. 13. 14. 15. 16.
Menu Home Switch Panel Lights Switch Self-test Switch Run / Off / Auto Switch (Mode switch) Breaker Control Push- buttons Reset Switches Status Indicators Digital Display & Status Panel
Page 4-4
Control Panel Switches and Indicators.

1) Kilowatt Meter: Indicates 3-phase AC power output as % of rated load.
2) Frequency Meter: Indicates generator output frequency in Hz.
3) AC Voltmeter: Dual scale instrument, which indicates AC voltage. Measurement scale is shown on scale indicator lamp.
4) AC Ammeter: Indicates current output in % of maximum rated output (percent current is based on 0.8 Power Factor).
5) System Control Selection Switches: Four membrane switches - two on each side of the alphanumeric display window are used to step through the various menu options and to adjust genset parameters. The green arrow on the alphanumeric display adjacent to the switch is lit when the switch can be used (switch is active). 6) Voltage Meter Scale Indicator Lamps: Indicate AC Voltmeter scale selected.
ENGINE
GEN
ADJUST
>>
7) Phase Selector Switch and Indicators: Press this momentary switch to select phases of generator output to be measured by the analogue AC Voltmeter and Ammeter. LEDs indicate the selected phase.
Phase Selector
Page 4-5
8) Emergency Stop Push-switch: Push the switch for an emergency shutdown of the engine. To reset at the PCCP: a) b) c) d) Pull the Emergency Stop to unlatch it Move the Mode switch to Off Press the Reset membrane switch Select Run or Auto, as required
9) Menu Home Switch: At any time, press this membrane switch to return the alphanumeric display to the Main Menu. Refer to the menu trees later in this section. 10) Panel Lights Switch: Press this membrane switch to turn control panel illumination on and off. The illumination will shut off automatically after approximately eight minutes to save battery power. 11) Self-test Switch: Press and hold this membrane switch to light all front panel LEDs and cycle through all shutdown and warning messages. . In the Standby (sleep) mode, the control's operating software is inactive and the LEDs and displays on the front panel are all deactivated. . To activate and view the menu displays without starting the genset, press and hold the Self-Test switch until the front panel LEDs are lit. The PCCP will initialise the operating software and reactivate the menu display panel. If no menu selections are made, a software timer will shut down the display after 30 seconds.
Page 4-6
12) Run l Off l Auto Switch (Mode Switch): This switch starts and stops the genset locally, or enables start / stop control of the engine from a remote location. (Ground to start.) Off - de-energises all primary DC circuits, preventing genset operation. When the switch is in this position, a Non-Automatic indicator LED will flash continuously. Run - energises the control system and initiates genset starting and operation. The breaker control switches are enabled only in the Run position. The Non-Automatic indicator will flash when the switch is in the Run position, indicating that the paralleling breaker will not automatically close. Auto - enables the control system to receive a start signal from a remote location. This will energise the control system, initiating the genset starting and operation sequences. 13) Breaker Control Push buttons: These push button controls are used to manually control the opening and closing of the generator paralleling breaker when in the Run mode. The breaker close operation is operated through a permissive function (with dead bus logic) to prevent accidental out of phase paralleling of the genset to the system bus. 14) Reset Switch: Press this membrane switch to reset Warning and Shutdown messages after the condition has been corrected. To reset a Shutdown message with the Reset switch, the Mode switch must be in the Off position. With the Mode switch in the Auto mode, shutdown faults can be reset by removing the start input and then cycling the remote reset input.
OFF RUN AUTO
CLOSED
OPEN
Page 4-7
15) Status Indicators:
Non-Automatic Indicator flashes continuously when the Mode switch is in the Off or Run position. Warning Indicator is illuminated to indicate that a condition outside the desired parameters has occurred. The reset switch is used to clear this message when the Warning condition has been corrected. Shutdown Indicator illuminates when a Shutdown condition has occurred. The reset switch is used to clear this message when the Shutdown condition has been corrected. 16) Alphanumeric Display and Status Panel: This two-line 16-character per line digital display is used in the menudriven operating system, in conjunction with the Menu Selection switches and the Menu switch. Refer to the menu trees later in this manual. The display is also used to show Warning and Shutdown messages.
Non-Automatic Warning Shutdown
ENGINE
GEN
ADJUST
>>
Page 4-8
4.4.2.2 Alphanumeric Display and Switches

The illustration shows the PCCPs alphanumeric display and the menu selection membrane switches. Refer to section 4.4.2.1 Front Panel, which describes the display and all the switches.
ENGINE
GEN
ADJUST
>>
MENU
RESET
Figure 4-2
Alphanumeric Display and Switches
In the Standby (sleep) Mode, to activate and view the menu displays without starting the genset, press and release the Self-Test membrane switch (see Front Panel illustration). This will initialise the PCCP operating software and permit operation of the menu display panel. If no menu selections are made, a software timer will shutdown the display after 30 seconds. In the Power On (awake) Mode, power is continuously supplied to the control panel and the alphanumeric display will remain on. Note: In the alphanumeric display, the >> symbol indicates that selecting the adjacent membrane switch causes the operating program to branch to the next menu display as shown in the menu diagrams. The << symbol indicates that selecting the adjacent membrane switch causes the operating program to return to the previous menu displayed.
Note:
Page 4-9
4.4.2.3 Main Menu

The facing page shows the Main Menu and a block representation of the menu tree, including all available sub-menus. Initially the alphanumeric display shows the titles in the central block (i.e. Engine, Gen, Adjust, >>). Pressing a membrane switch next to a title displays the next indication in the tree. As shown in the diagram, the Main Menu can branch into one of four directions: 1. Engine: To display engine parameters, such as oil pressure and temperature, water temperature, engine speed (RPM), and exhaust temperature, press the membrane switch next to the word Engine in the display. Refer to Engine menu. Gen: To display generator parameters, such as volts, amps, power (kW), and frequency, press the membrane switch next to the word Gen in the display. Bus voltage, frequency and a digital synchroscope can also be viewed from this menu branch. Refer to Gen menu. Adjust: To adjust output voltage and frequency, or start and stop delays, press the membrane switch next to the word Adjust in the display. Refer to Adjust menu.
2.
3. 4.
>>
(version): To display the selected genset model and the resident version software, press the membrane switch next to the >> in the display. From this selection, you can also review a History file that can record and save up to twenty error messages. Refer to Version menu.
Page 4-10
Figure 4-3
Main Menu
Page 4-11
4.4.2.4 Engine Menu

The facing page shows a block representation of the Engine menu tree, including all available sub-menus. Pressing the membrane switch next to the word Engine in the display introduces the first Engine sub-menu. As shown in the diagram, the Engine menu has three sub-menus: 1. Oil / Coolant sub-menu: This is the first sub-menu. Select Oil for a display of oil pressure and oil temperature. Select Coolant for a display of coolant temperature. When oil or coolant parameters are displayed, pressing the membrane switch next to the << will return the display (Back) to the Oil Coolant sub-menu. Battery / Hours sub-menu: From the Oil Coolant sub-menu, press the membrane switch next to the >> in the display to move to the Battery / Hours sub-menu. Select Battery for a display of battery voltage. Select Hours for a display of the number of starts and the running hours. When battery or hours parameters are displayed, pressing the membrane switch next to the << will return the display (Back) to the Battery / Hours sub-menu. RPM / Exhaust sub-menu: From the Battery / Hours sub-menu, press the membrane switch next to the >> in the display to move to the RPM / Exhaust submenu. Select RPM for a display of engine RPM. Select Exhaust for a display of the (optional) exhaust temperature. When RPM or exhaust parameters are displayed, pressing the membrane switch next to the << will return the display (Back) to the RPM / Exhaust sub-menu.
2.
3.
Page 4-12
Figure 4-4
Engine Menu
Page 4-13
4.4.2.5 Gen Menu

The facing page shows a block representation of the Gen (generator) menu tree, including all available sub-menus. Pressing the membrane switch next to the word Gen in the display introduces the first Gen sub-menu. As shown in the diagram, the Gen menu has three sub-menus: 1. Volts / Amps sub-menu: This is the first sub-menu. Select Volts for a display of a line-to-line or line-to-neutral selection, or for viewing of the system bus line-to-line voltage. Select line-line or line-neutral for the desired voltage display. Select Amps for a display of Ll, L2, and L3 current in amps. When voltage or current parameters are displayed, pressing the membrane switch next to the << will return the display (Back) to the L-L / L-N sub-menu. If Delta is selected in the Initial Start Set-up sub-menu when selecting Volts, the line-line or line-neutral sub-menus will not be displayed. Only the Ll2, L23, L31 sub-menu will be displayed.
Note:
2.
Power / kW Hours sub-menu: From the Volts / Amps sub-menu, press the membrane switch next to the >> in the display to move to the Power / kW Hours submenu. Select Power for a display of power output in kilowatts and a power factor value. Select kW Hours for a display of kilowatt-hours. When Power or kW Hours parameters are displayed, pressing the membrane switch next to the << will return the display (Back) to the Power / kW Hours sub-menu. The PF reading will contain an asterisk if the power factor is leading (for example, *.3PF). Beginning at PCC Version 1.06, N/A is displayed in the PF field when the genset is not running.
Note: Note: 3.
% Gov / Reg / Frequency sub-menu: From the Power/ kW Hours sub-menu, press the membrane switch next to the >> in the display to move to the % Gov / Reg / Frequency sub-menu. Select % Gov / Reg for a display of voltage regulator and governor duty cycle (drive) levels in percentage of maximum. Select Frequency for a display of the generator output frequency, the bus frequency, or the digital synchroscope. When voltage regulator and governor or frequency parameters are displayed, pressing the membrane switch next to the << will return the display (Back) to the % Gov / Reg / Frequency sub-menu. Bus Frequency (Digital Synchroscope) sub-menu: When the bus frequency (digital synchroscope) information is displayed, the operator can observe the genset synchronising with the system bus. The display indicates bus frequency and number of degrees from synchronous condition (+ indicates faster, - indicates slower). When the genset is operating within the sync-check window, an asterisk will indicate that the paralleling breaker can be closed. When is displayed, the synchroniser is not active.
Page 4-14
Figure 4-5
Gen Menu
Page 4-15
4.4.2.6 Adjust Menu

The facing page shows a block representation of the Adjust menu. If you press the button next to the word Adjust in the display, the Voltage Adjust sub-menu will appear. As shown in the diagram, the Adjust menu has six sub-menus, including a save / exit procedure. Voltage and frequency can be adjusted only when the genset is running under normal operating parameters (not in idle mode). For example, if voltage adjustment is selected when the set is in Idle mode or not running, the alphanumeric display will be:

1. 2.
VOLTAGE N/A >>
Voltage sub-menu: This is the first sub-menu. Use the buttons next to the and symbols to adjust output voltage 5%. Frequency sub-menu: From the Voltage sub-menu, press the button next to the >> in the display to move to the Frequency sub-menu. Use the buttons next to the and symbols to adjust output frequency 5%. Start Delay sub-menu: This delay applies only to remote starting in the Auto mode. From the Frequency sub-menu, press the button next to the >> in the display to move to the Start Delay sub-menu. Use the buttons next to the and symbols to set the start delay. The start delay adjustment range is 0 to 300 seconds. Stop Delay sub-menu: This delay applies only to remote stopping in the Auto mode. From the Start Delay sub-menu, press the button next to the >> in the display to move to the Stop Delay sub-menu. Use the buttons next to the and symbols to set the stop delay. The stop delay adjustment range is 0 to 600 seconds. Idle Speed sub-menu: From the Stop Delay sub-menu, press the button next to the >> in the display to move to the Idle Speed sub-menu. Use the buttons next to the and symbols to set the idle speed. The idle speed adjustment range is 800 RPM 100 RPM (Default value is 800 RPM). The idle speed can be adjusted only when the genset is running in the Idle mode. When not in Idle mode, N/A is displayed in the RPM field. The Idle Speed sub-menu will not be used for gensets that do not require their speed to be reduced to idle before shutting down. Under this circumstance only the Stop Delay sub menu is used to initiate a cooling run before shutting down the genset.
3.
4.
5.
Note:
6.
Save/Exit sub-menu: From the Stop Delay sub-menu, press the button next to the >> in the display to move to the Save/Exit sub-menu. Select Save to save your changes. At the Changes Saved sub-menu, select Exit to return to the main menu. If you select Save, the adjustments will be retained after shutdown, and will be in effect when the set is restarted. If you select Exit without saving first, the adjustments will remain in effect until the genset is shut down, but will be reset (and will not be in effect) when the set is restarted.
Page 4-16
Figure 4-6
Adjust Menu
Page 4-17
4.4.2.7 Version Menu

The facing page shows a block representation of the Version sub-menus. If you press the button next to the >> in the Main menu display, the Version/Set-Up/Cal menu will appear. Version sub-menu: If you select Version, the display will show the genset model number, frequency and kW rating, and the date and version of the operating software. To display the genset configuration options, press the button next to the >> in the submenu that displays the model number, frequency, etc. This menu provides the following information: Genset voltage Wye (i.e., Star) or Delta and Full or Standard Standby or Prime 1 or 3-phase
To modify any of these entries, you must return to the Initial Start Set-up sub-menus described in the Service manual. History: From the Version menu, press the button next to the >> in the display to move to the History sub-menu. Press the button next to History to display the last (latest) recorded error message. The software will record (i.e. save) up to twenty error messages. The last error detected will always be displayed first. As each new error is detected, the oldest error recorded after twenty will be deleted. To view the genset runtime at which the error occurred and to scroll through the remaining recorded errors, press the button next to the >> in the error message menu to display the Runtime, Newer/Older menu. The buttons next to Newer and Older are used to scroll up and down through the error messages. For example, pressing Older will display the next oldest recorded error message. When pressing Newer the last (newest) error message will be displayed, the display will return to the History menu.
Page 4-18
Figure 4-7
Version Menu
Page 4-19
4.4.3 Emergency Stop Controls

Caution: The Emergency Stop push-switch must not be used for a normal shutdown, as this will prevent a cooling down run in which the lubricating oil and engine coolant carry heat away from the engine combustion chamber and bearings in a safe manner.
4.4.3.1 Emergency Stop Switches

PCCP Switch The Emergency Stop push-switch, located in the lower right hand corner of PCCP front panel, is a mechanically latched switch that will unconditionally stop engine when pressed. When the switch is pressed the PCCP panel will display Shutdown condition by illuminating the red Shutdown status LED and displaying following message on the alphanumeric display: EMERGENCY STOP 102 - SHUTDOWN The Emergency Stop push-switch must not be used for a normal shutdown, as this will prevent a cooling run in which the lubricating oil and engine coolant carry heat away from the engine combustion chamber and bearings in a safe manner. Plant Room Switches (Optional) The remote Emergency Stop push-switches located in the Plant Room are mechanically latched switches that will unconditionally stop the engine when pressed. When a switch is pressed, the PCCP panel will display the Shutdown condition by illuminating the red Shutdown status LED and displaying the following message on the alphanumeric display: EMERGENCY STOP 102 - SHUTDOWN A remote Emergency Stop push-switch must not be used for a normal Shutdown, as this will prevent a cooling run in which the lubricating oil and engine coolant carry heat away from the engine combustion chamber and bearings in a safe manner. the the the the
Page 4-20
4.5
Start / Run Procedures

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENERATOR UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT THE SET IS ABOUT TO START. Avoid off-load running for other than short periods. A minimum loading of 30% is recommended. This loading will help to prevent the build up of carbon deposits in the injectors, due to unburnt fuel, and reduce the risk of fuel dilution of the engine lubricating oil. The engine must be shutdown as soon as possible after the appropriate functions have been checked.
Caution:
4.5.1 Operating Options

The genset is normally operated remotely, using a Remote Start signal. However, manual operation of each genset is also possible by using the PCCP systems on their own. An additional option in the control system is that the PCCP can be set to run with its indicators blanked, to save battery power, or with the indicators showing all the time if the optional battery charger is used. Either way, the PCCP is still functioning in the background. In the Standby (sleep) Mode, selector switch S5, located on a printed circuit board inside the PCC, is set to the right. If no menu selections are made, the power to the control panel will shut down after 30 seconds. The PCCPs operating software is inactive and the LEDs and displays on the front panel are all de-activated. The panel appears to be dead. In the Power On (awake) Mode, selector switch S5 is set to the left. The PCCP initialises the operating software and activates the menu display panel continuously. It is recommended that switch S5 be left in the Power On Mode, unless battery charging is not available. Caution: Electrostatic discharge will damage circuit boards. To prevent this damage, always wear a grounding wrist strap when touching or handling either circuit boards or socket-mounted lCs, and also when disconnecting or connecting harness connectors.
4.5.1.1 Wake Up Signals

If the PCCP is set to Standby Mode, the operating software is initialised and the front panel automatically reactivated in response to a run signal or any one of eight wake up signals from remote sensing switches. The wake up signals are: Emergency Stop Low Coolant Level Low Coolant Temperature Low Fuel Customer Fault Inputs 2 and 3
Page 4-21
Run Selected on Mode Switch Remote Start Signal in Auto Mode Self-test membrane switch operation
4.5.1.2 Automatic Operation

Automatic control of the genset is provided by positioning the three position Mode switch to the Auto position.
Note:
A red Non-automatic Status Indicator lamp on the PCCP will flash continuously if the Mode switch is not in the Auto position.
4.5.1.3 Manual Operation

Manual control of the genset is provided by positioning the three position Mode switch to the Run position.
Note:
The red Non-automatic Status indicator lamp on the PCC will flash continuously if the Mode switch is not in the Auto position.
4.5.2 Lockout
The engine will be inhibited from starting if a critical fault condition exists when an attempt is made to start the genset. An indication is initiated and a horn and beacon are activated. Additionally, a number of non-critical circumstances arise where starting is prevented such as: Low battery voltage HV Switchgear protection (option)
Page 4-22
4.5.3 Manual Start Procedure

4.5.3.1 Start Sequence
The following description applies to Automatic or Manual operation. In an Automatic sequence, with the Mode switch set to the Auto position, a Remote Start signal is applied to the PCCP. The Manual sequence is initiated directly by setting the Mode switch to the Run position. The installed generators start independently of each other, controlled by their respective PCCPs. During starting, automatic checks are carried out for the integrity of various protection systems, such as the speed probe and the critical temperature sensors. The PCCP will not allow the genset to continue the starting sequence if the integrity of a sensor is considered to be in doubt by the PCCP checking system. The starting sequence consists of three cranking intervals of approximately five seconds, each followed by a rest period of fifteen seconds. If, at any time during the sequence, the engine is sensed to have achieved firing speed (a speed calculated to be beyond the starter motor capability), the remainder of the sequence is aborted. If, at the end of the third crank period, firing speed has not been detected, the PCCP ends the start sequence and a fail to start situation is indicated as an Overcrank.
4.5.3.2 Run-up to Speed

When the engine is called to start, and firing speed is attained, the starter motor function ceases and is then locked out. The run-up sequence is closely controlled by the PCCP software to reduce smoke emission.
4.5.3.3 Generator Running

Upon attaining correct speed (frequency), and correct output voltage, the generator is deemed to be running by the PCCP. During running, all systems associated with the engine and its auxiliary systems will be monitored by the PCCP to control the generator and to detect any abnormal conditions. If in Auto mode, the genset will continue to run off-load until signalled by the PCCP to close the genset breaker. In Manual (Run) mode, it will continue to run off-load, if the circuit breaker is open, until the Mode switch is changed to Off (which will initiate the stop sequence), or Auto (which will initiate a load transfer, if required). Automatic synchronisation is provided for manual paralleling. Caution: The engine should not be allowed to run off-load for extended periods, except as absolutely necessary during maintenance or cooling cycles.
Page 4-23
4.6
Paralleling
4.6.1 Speed and Voltage Matching

Once the generator has achieved nominal voltage and frequency, the genset is ready to be paralleled with the busbar supply. Each genset is paralleled completely independently of the others. The PCCP monitors both the incoming supply and the busbar voltage and frequency and adjusts the incoming supply to match the busbar supply over a wide span of busbar parameters. Synchronisation is achieved under full control, and at the correct phase coincidence. In Automatic mode, the PCCP receives a breaker close signal when synchronisation has been achieved and signals the main breaker to close. In Run mode, the main breaker is closed to connect the genset to the busbars, by using the breaker Open / Close pushbuttons.
4.6.2 Operation When in Parallel

When in parallel with the busbar supply, the genset voltage and frequency are dependent upon the busbar parameters, and control is changed to kW and kVAR load management. Each genset is individually controlled by separate PCCPs. Apart from the protection systems, there is no common coupling between gensets. This allows for any genset, or its relevant controls, to be under maintenance without affecting the others. When the control system detects that the generator is up to speed and voltage, the load is then ramped from the mains to the generator, the engine governor control system keeping the electrical output within the correct parameters.
Page 4-24
4.7
Shutdown Procedures
Specific procedures must be followed to shutdown the power plant, in normal use, or in an emergency situation. Additional reset procedures must also be followed in order to put the power plant back to work.
4.7.1 Normal Stop

A Normal Stop is initiated by the removal of the remote start signal, or by turning the Mode switch on the PCCP to Off.
In the event of a Normal Stop, load will be ramped down before the generator circuit breaker is opened, and the engine enters a cooling run under the control of the PCCP before stopping. The cooling run allows for the safe dissipation of excess engine heat, before the engine stops and the cooling system is de-energised.
4.7.2 Emergency Stop

Press the Emergency Stop push switch located in the lower right hand corner of the PCCPs front panel
OR Press one of the Remote Emergency Stop push switches located in the Plant Room (if separate switches are provided). Note: When an emergency stop is initiated all generator load is dumped immediately and the engine is stopped without a cooling run. Do not use an emergency stop control for a normal stop.
Caution:
Page 4-25
4.7.3 Emergency Stop Reset

After an emergency stop, the following reset procedure must be carried out to return the genset to an operating condition:
4.7.3.1 Push switch Reset

To carry out a reset from an emergency stop condition initiated by an Emergency Stop push switch: 1. 2. 3. 4. Pull the activated Emergency Stop push switch to unlatch it. Move the Mode switch on the PCCP panel to Off. Press the PCCP panel Reset button. Select Run or Auto as required on the PCCP panel. Ensure that the cause of the emergency is fully investigated and remedied before an emergency stop Reset, and genset Start are attempted.
Caution:
Page 4-26
4.8
Locking the Genset Out of Service
4.8.1 Introduction
Before any work is carried out for maintenance, etc, the plant must be immobilised. Even if the plant is put out of service using the Mode switch Off position on the PCCP panel, the plant cannot be considered safe to work on until the engine is properly immobilised as detailed in the following procedures. WARNING: BEFORE CARRYING OUT ANY MAINTENANCE, ISOLATE ALL SUPPLIES TO THE GENERATOR AND ANY CONTROL PANELS. RENDER THE GENERATOR INOPERATIVE BY DISCONNECTING THE PLANT BATTERY. If the engine has been running recently, explosive gases (given off during battery charging) may be present in the vicinity of the batteries. Ensure the area is well ventilated before disconnecting batteries.
Caution:
4.8.2 Immobilising the Plant for Safe Working

Note: Shutdown the engine first, as described under Normal Stop.
To immobilise the engine: 1. Turn the Mode switch on the PCCP panel to the Off position.
2. 3. 4. 5. 6. 7.
Isolate and lock off the supply to the battery charger, where fitted. As an additional precaution, disconnect the starting batteries and control system batteries (if separate). Isolate and lock off the heater control box, where fitted. Isolate the fuel supply to the engine. As an additional precaution, disconnect the starter / control system batteries. Fit warning notices at each of the above points to indicate Maintenance in Progress Plant Immobilised for Safe Working.
Page 4-27
4.9
Fault Alarms & Shutdowns

If a Fault condition is sensed by the PCCP, one of the following three events will be initiated depending on the seriousness of the Fault. Refer to Section 3.2, Control System, for further information.
4.9.1 Alarm
In the event of the PCCP detecting a non-critical condition, an alarm indication will be initiated and a beacon will be activated. If the genset is loaded, that loading will be maintained and the generator will continue to run at regulated speed.
4.9.2 Controlled Shutdown

In the event of a Fault condition that is serious, but not considered fatal to the engine, a controlled Shutdown will be automatically initiated by the PCCP. First an indication is initiated and a beacon is activated. Then the genset load is ramped down before the generator circuit breaker is opened, and the engine enters a cooling run under the control of the PCCP before stopping.
4.9.3 Immediate Shutdown

In the event of a Fault condition that may be fatal to the engine, an immediate Shutdown is initiated. Again an indication is initiated and a beacon is activated. This time the generator circuit breaker is opened without ramping down the load and the engine is stopped immediately, without a cooling run.
Page 4-28
4.10 Genset Output Metering

Two types of metering are provided on the PCCP, analogue and digital. Four analogue meters provide indications of voltage, current, frequency and power for walkby observations. Additional indications, which allow for better interpretation of the genset power situation, are provided on the Gen menu of the digital alphanumeric display. Details of how to access the menu and its sub-menus are given in Section 4.4.2 Control Panel.
4.10.1 Load Voltage

The analogue, dual scale, AC voltmeter, on the PCCP, displays the outgoing load voltage of the generator. By using the Phase Select switch, the operator can choose which phase is displayed. Indication of the phase selected is given by illumination of the appropriate phase selector indicator light. The upper or lower scale of the voltmeter is selected automatically and identified by illumination of the upper or lower scale indicator light. Additional indications can be shown on the alphanumeric display. The indications are genset output voltage (3-phase, line-to-line or line-to-neutral) and parallel bus voltage (3phase, line-to-line). The generator output voltage is given on the Generator Set Rating Plate WARNING: UNDER NO CIRCUMSTANCES MUST THE SET BE OPERATED AT A GREATER VOLTAGE THAN THE RATED VOLTAGE STAMPED ON THE GENERATOR SET RATING PLATE. SERIOUS DAMAGE OR INJURY MAY RESULT IF THIS CONDITION IS ALLOWED TO OCCUR.
4.10.2 Load Current

An analogue AC ammeter is provided to indicate the outgoing load current in each phase of the generator output. By using the Phase Select switch, the operator can choose which phase is displayed. Indication of the phase selected is given by illumination of the appropriate phase selector indicator light. Additional indications of genset output current can be accessed by selecting the Gen menu on the alphanumeric display. The generator output current is given on the Generator Set Rating Plate. WARNING: UNDER NO CIRCUMSTANCES SHOULD THE LOAD CURRENT BE ALLOWED TO RISE ABOVE THE RATED OUTPUT CURRENT, ALLOWING FOR ANY OVERLOAD RATING GIVEN. IF HIGH CURRENT READINGS ARE ENCOUNTERED, THE POWER FACTOR OF THE LOAD SHOULD BE CHECKED.
Page 4-29
4.10.3 Load Power

The analogue kilowatt meter displays 3-phase AC power output as a percentage of rated load. This is a true indication of total kW load, regardless of the power factor. Additional indications of power can be shown on the alphanumeric display. The indications are AC kilowatt load and AC kilowatt hours. Power Factor (PF) is also shown, with a display of 0 - 1, leading or lagging. An asterisk is included for leading power factors.
4.10.4 Genset Frequency

The analogue frequency meter displays the output frequency of the genset in Hz. Additional indications are provided on the alphanumeric display. The indications are genset output frequency and parallel bus frequency. Frequency is directly related to engine speed and, for a nominal engine speed of 1500 RPM (or 1800 RPM), the relationship between engine speed and frequency is given by the following formula: Hz = RPM / 30 (for a 4-pole machine) Where Hz represents the output frequency of the alternator and RPM is the engine speed The generator output frequency is given on the Plant Rating Plate on the generator. Caution: Under no circumstances must the Set be operated outside the rated frequency range stamped on the Generator Set Rating Plate. Serious damage or injury may result if this condition is allowed to occur.
4.10.5 Bus Synchronisation

A synchroscope can be shown on the alphanumeric display, and this provides a visual display of the genset synchronising with the system bus under full control of the PCCP. Bus frequency is shown, along with degrees difference (plus or minus). An asterisk is included on the display when genset frequency is within a sync-check window, signalling that the operator can effect closure of the paralleling breaker. Note: The PCCP inhibits closure of the paralleling breaker outside the sync-check window. Therefore the breaker close control can be operated even before synchronisation, although the breaker will not close until a signal is sent from the PCCP to allow it.
4.10.6 Duty Cycles

To complete the observations of genset power status provided by the PCCP, the Gen menu of the alphanumeric display can be set to show percentages of generator exciter duty and governor duty.
Page 4-30
4.11 Engine Metering

Engine and auxiliary system parameters are constantly monitored by the PCCP. No action is required by the operator, except for maintenance as described in Section 5. Indications for the following critical parameters can be displayed on the alphanumeric display, by using the Engine menu as detailed in Section 4.4.2 Control Panel: Oil temperature Coolant temperature Exhaust gas temperature (option) Oil pressure Engine speed Battery voltage Engine operating hours Number of starts
4.12 Heaters
Caution: Heater(s) must not be energised if coolant system has been drained.
4.12.1 Coolant Heater (Option)

The coolant heater is controlled by its associated thermostat to maintain a reasonable engine temperature. The heater is locked out by the PCCP at engine start. WARNING: ALWAYS ISOLATE THE SUPPLY TO THE ENGINE HEATER / THERMOSTAT BEFORE CARRYING OUT ANY MAINTENANCE ON THE ENGINE. ALWAYS ISOLATE THE GENSET PRIOR TO ANY MAINTENANCE. The coolant heater is in no way intended to protect the engine and cooling system from freezing in sub zero conditions. If there is any danger of freezing then a suitable antifreeze agent must be added to the cooling system.
Caution:
4.12.2 Alternator Heater (Option)

The alternator heater is controlled by its associated thermostat. The heater is locked out by the PCCP at engine start. WARNING: ALWAYS ISOLATE THE SUPPLY TO THE ALTERNATOR AND THE THERMOSTAT BEFORE CARRYING OUT MAINTENANCE ON THE ALTERNATOR.
Page 4-31
4.12.3 Control Panel Heater (Option)

The control panel heater is controlled by its associated thermostat. The heater is locked out by the PCCP at engine start. WARNING: ALWAYS ISOLATE THE CONTROL PANEL HEATER FROM THE AC SUPPLY BEFORE WORKING ON THE CONTROL PANEL OR HEATER.
Page 4-32
4.13 Digital Master Control (Option)

The Digital Master Control (DMC) is a stand-alone system that controls multiple genset installations and utility supply switching. The control equipment includes a touchscreen, digital meters and annunciators, all mounted in a single enclosure. Refer to separate manual for DMC configurations and availability.
Page 4-33
4.14 Test Runs

4.14.1 Pre-start Checks
Before starting the plant Manually, or selecting Auto operation, be sure competent personnel have made the following checks to ensure that the unit is ready for operation: Lubrication - Check the engine lubricating oil level and ensure that the level is always maintained as detailed in the engine Operation and Maintenance manual Coolant - Check the engine coolant level and ensure that the level is always maintained at the coolant expansion tank. Fill the cooling system to the bottom of the fill neck in the radiator fill or expansion tank. Do not check while the engine is hot Note: Some radiators have two fill necks, both of which must be filled when the cooling system has been drained. Do not attempt to remove a radiator pressure cap while the generator is running, or is stationary but hot. Always allow it to cool before removing the cap.
Caution:
Cooling Air Inlet / Outlets - Ensure that the cooling air inlets / outlets are unobstructed Exhaust Outlet - Ensure that exhaust components are secured and not warped, and that the exhaust outlet is unobstructed; that no combustible materials are near the system, and gases are discharged away from building openings. Ensure that there are no leaks and that all fittings are tight Fuel Supply - Ensure that the fuel tank is filled to the normal level and that the fuel system is primed and all the valves required for operation are open. Ensure that there are no leaks and that all fittings are tight Batteries Ensure that the batteries are charged, that the electrolyte is at the correct level and that all connections are correct Auxiliary AC Supplies - Ensure that all auxiliary equipment is receiving power from the Load Terminal Box Emergency Stop / Fire Detection Equipment - Ensure that all related equipment is fully operational
Page 4-34
4.14.2 Off-load Initial Run

WARNING: ENSURE THAT ALL PRE-START CHECKS ARE CARRIED OUT BEFORE STARTING THE GENSET. DO NOT ATTEMPT TO START THE GENERATOR UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT THE SET IS ABOUT TO START. One operator should be in complete charge, or working under the direction of someone who is. Remember that, upon starting the engine, cables and switchgear will become energised, possibly for the first time. Furthermore, equipment that does not form part of the generator installation may become electrically charged. Only authorised and competent personnel should carry out this work. Do not use an Emergency Stop switch to shut down an engine unless a serious fault develops. The Emergency Stop push-switch must not be used for a normal shut-down, as this will prevent a cooling down run in which the lubricating oil and engine coolant carry heat away from the engine combustion chamber and bearings in a safe manner. Avoid off-load running for other than short periods. A minimum loading of 30% is recommended. This loading will help to prevent the build up of carbon deposits in the injectors, due to unburnt fuel, and reduce the risk of fuel dilution of the engine lubricating oil. The engine must be shutdown as soon as possible after the appropriate functions have been checked.
Caution:
Caution:
Caution:
The PCCP will automatically make up to three start attempts, and lock the engine out of service if the third attempt fails. If the PCCP senses an operating fault, either a Warning will be indicated on the PCCP or the engine will be shut down automatically. Automatic shutdowns require no operator action other than to observe the detail. Note: The Non-Automatic LED on the PCCP will be illuminated whenever the Mode switch is not set to Auto. Also, if the PCCP is set to operate with the Standby (Sleep) Mode active, the PCCP indications may de-activate and need to be reactivated (press the Self-Test membrane switch to reactivate).
1.
As a precautionary measure, for the initial runs only, place suitable fire extinguishers at strategic locations around the genset. Also ensure that all test personnel are fully aware of the positions of all emergency shutdown switches and fire break glass units (if fitted). If the ambient temperature is low, it is preferable to have had the engine / alternator / panel heaters on for some time beforehand to improve starting and to eliminate any condensation. On the PCCP, set the Mode switch to Run and check that the engine starts and runs automatically. The PCCP may make up to three start attempts before it terminates the automatic start-up function. If all three start attempts fail, the fault must be investigated before the system is reset and another start-up is initiated.
2.
3.
Page 4-35
4.
During start-up and the initial run, observe the PCCP and check for unusual indications that may highlight a problem; observe the associated power systems for signs of flashovers, burning, etc. Should any items require urgent attention, shut down the genset immediately and rectify the fault, using skilled assistance if required. Activate the PCCPs Engine menu and check the engine lubrication oil pressure (consult the engine Operation and Maintenance Manual for correct value). Check the engine speed and ensure that the engine is running near to nominal speed. The speed governing should be stable with no tendency to hunt. Make careful observations of any sign of a malfunction of the engine, alternator and auxiliary systems. Engine operating speed is adjusted at the factory to 1500 RPM at full load (50 Hz Sets) and 1800 RPM at full load (60 Hz Sets). The no-load operating speed is within 2 to 2.5 Hz higher than the full load operating speed. Activate the PCCPs GEN menu and check the alternator output voltage and frequency. Refer to the alternator Installation, Service and Maintenance Manual. Check the engine / associated pipe-work, including the exhaust system, for leaks. In the event of a fuel or exhaust leak, shut down the genset immediately. Take extreme care when working on a hot exhaust system. In case of a fuel or lubricating oil leak, the spilled fluid should be absorbed using a proprietary material (Fullers Earth granules or similar). Sawdust should not be used, as this will create a fire hazard.
5.
6. 7.
Caution:
8.
After a short period of running off-load (between five and fifteen minutes), shut down the Genset by turning the Mode switch to the Off position. A controlled shutdown is effected by the PCCP, and this may include a short cooling down run.
Page 4-36
4.14.3 On-load Initial Run

WARNING: DO NOT ATTEMPT TO START THE GENERATOR UNTIL IT IS SAFE TO DO SO. WARN ALL OTHERS IN THE VICINITY THAT THE SET IS AVAILABLE AND ABOUT TO START. Ensure Pre-start Checks have been carried out.
Caution:
If the genset is in order on the off-load initial run, arrange for an on-load (mains failure) test run. This should be performed during a non-critical period, as it may be necessary to stop the genset during the test. Caution: One operator should be in complete charge, or working under the direction of someone who is. Remember that, upon starting the engine, cables and switchgear will become energised, possibly for the first time. Furthermore, equipment that does not form part of the generator installation may become electrically charged. Only authorised and competent personnel should carry out this work. Do not use an Emergency Stop switch to shutdown an engine, unless a serious fault develops.
Caution:
1.
Initiate an engine start as follows: a) Manual Start Gensets at the PCCP, set the Mode switch to Run. The engine starts and runs up to speed b) Automatic / Remote Start Gensets at the PCCP, set the Mode switch to Auto and initiate a genset start from the remote location. The engine should start and run up to speed Automatic Mains Fail Gensets at the PCCP, set the Mode switch to Auto and initiate a manual start from the remote location. The engine will start and run up to speed
c)
2.
On Manual Start Gensets, the circuit breaker will have to be closed once the generator has attained its operating speed and voltage. The PCCPs automatic synchroniser will prevent closure of the breaker until full synchronisation is effected. If required, the PCCPs Gen menu can be checked for sync indications. Observe the genset and power system performance closely. In the unlikely event of an engine fire, activate a Fire Break Glass unit (if fitted). This will result in an immediate shutdown and fire alarm indications. PERSONAL SAFETY MUST COME BEFORE ENGINE SAFETY. THE ABOVE PROCEDURE IS TO BE CARRIED OUT ONLY IF THE SITUATION ALLOWS IT. ALWAYS OBEY INSTRUCTIONS GIVEN BY EMERGENCY SERVICE PERSONNEL, AND OBSERVE LOCAL FIRE REGULATIONS AT ALL TIMES.
3.
WARNING:
Page 4-37
4.
Allow the genset to run for fifteen minutes on-load to check initial readings and functions of the engine. Engine parameters can be checked on the PCCPs Engine menu and power parameters on the analogue meters and the Gen menu. Oil pressure should be maintained after an initial drop and should stabilise as the engine temperature stabilises. The pressure should always be within the manufacturer's specification. Engine temperature should rise rapidly and then stabilise after a few minutes. The normal running temperature should be within the range 176F to 203F (80OC to 95OC). Voltage should be maintained within 2% for stable load conditions. Frequency should be maintained within 2 Hz for all stable loads between zero and full-load. Check all engine systems for leaks. If any leaks are detected, the genset should be shut down by setting Mode switch to Off, and the leaks rectified. If the leak is serious or may cause immediate danger, use an Emergency Stop switch to shut down the engine.
5.
6.
7. 8. 9.
10. On satisfactory completion of the test the generator can be signalled to stop (set the Mode switch to Off) and the mains supply can be returned. The genset will open the circuit breaker and automatically be put into a cooling run off-load before performing a controlled shutdown. 11. Complete a Commissioning Form, if required.
Page 4-38
4.14.4 Maintenance Test Run

On completion of all maintenance, and only when it is safe to run the generator, a Test Run should be carried out. This test should be performed at least weekly on engines that have not been run. Note: The control system (i.e. the PCCP) will make up to three start attempts automatically, and will indicate a Shutdown if the third attempt fails. If a fault condition arises, running faults will be displayed on the PCCP. The indications should be noted down to assist in fault finding, as detailed in Section 6.
To carry out a test run, perform the following: 1. 2. 3. 4. Re-connect all supplies to the generator. Re-connect the plant battery. Check the output of the battery charger (if fitted). Perform a self test on the PCCP by pressing and holding the Self Test membrane switch. Ensure that the PCCP illuminates all LEDs and cycles through all Warning and Shutdown messages. Release the switch at end of test cycle. DO NOT ATTEMPT TO START THE GENERATOR UNTIL IT IS SAFE TO DO SO.
WARNING:
5.
Start the genset as follows: a) b) c) Set the fuel shut-off lever to the Work position (open) On Manual Start gensets, turn the Mode switch to the Run position and the engine should start automatically On Automatic / Remote Start gensets ensure that the Mode switch is set to the Auto position. Initiate a genset start by providing a remote start signal If the genset fails to start after three attempts, and the PCCP indicates a Shutdown, the fault must be cleared before any further start attempts are made. Refer to Section 6 for fault finding.
Caution:
6.
If the genset fails to start, as detailed above, reset the control system as follows: a) b) c) d) Return the Mode switch to the Off position Identify and clear the fault before any further start attempts are made Press the Reset button Select Run or Auto, as required, and repeat the above starting procedure
7.
With the genset running, activate the Engine menu on the PCCP and check the following engine parameters: a) b) Oil pressure should be maintained after an initial drop. The pressure should always be within the manufacturer's specification Engine temperature should rise rapidly and then stabilise after a few minutes. The normal running temperature should be within the range 176F to 203F (800C to 950C)
8.
Load the genset to at least 30% rated kilowatt output and observe the performance closely. Avoid off-load running for extended periods.
Page 4-39
9.
Check the engine and associated pipework, including the exhaust system, for leaks. In the event of an exhaust leak, the genset should be shut down immediately and measures taken to ensure personal safety. Observe the Exhaust Gas Hazards safety requirements listed in Section 1. RISK OF TOXIC FUMES Take extreme care when working on a hot exhaust system. In case of a fuel or lubricating oil leak, the spilled fluid should be absorbed using a proprietary material (Fullers Earth granules or similar). Sawdust should not be used, as this will create a fire hazard
WARNING: Caution:
10. Activate the Gen menu on the PCCP and check the generator output by observing the analogue meters and the more detailed information on the digital display: a) b) Note: Voltage should be maintained within 2% for stable load conditions Frequency should be maintained within 2 Hz for all stable loads between zero and full-load If required, the Phase Select switch can be used to select alternative phase data on the analogue voltmeter and ammeter.
11. On satisfactory completion of the test, open the genset circuit breaker to return the load to the mains supply. 12. This operation applies to the initial start-up only. Confirm correct operation of the Emergency Stop facility as follows: a) b) c) d) Press the Emergency Stop push-button on the PCCP and ensure that the engine shuts down immediately, without a cooling down run When the engine has stopped rotating, pull the Emergency Stop push switch to unlatch the switch Return the Mode switch to Off Press the Reset membrane switch
13. As soon as possible after the Emergency Stop, set the Mode switch on the PCCP to Run or Auto as required for a restart. Ensure that the genset starts and runs and that the engine temperature stabilises. Avoid off-load running for extended periods. 14. If plant room Emergency Stop push switches are provided, repeat the above two paragraphs for each of the push buttons provided, always allowing time for the engine temperature to stabilise. Bear in mind that shutting the engine down without a cooling down run can cause overheating, so space the checks accordingly. Note: The requirement for further checks on the Emergency Shutdown system will depend on generator usage. Contact an authorised Service Department for a site-specific recommendation.
15. Perform the following procedure to shut down the genset, and ensure that the engine completes a short cooling run before shutting down: a) b) On Manual Start Gensets, turn the Mode switch to the Off position On Automatic/Remote Start Gensets remove the Remote Start signal
16. Return the genset to its normal operating mode as required. 17. Keep a record of all maintenance work carried out.
Page 4-40
SECTION 5 MAINTENANCE 5 Maintenance

Maintenance work, particularly in confined areas, should be carried out by two engineers working together. Ensure that adequate lighting and staging (where required) are installed. Caution: Only authorised and qualified maintenance engineers who are familiar with the equipment and its operation should carry out maintenance.
WARNING:
DEPENDENT UPON THE CONTROL SYSTEM FITTED, THIS UNIT MAY OPERATE AUTOMATICALLY AND COULD START WITHOUT WARNING.
Caution:
Before carrying out any maintenance work, become familiar with the Generator Plant Safety Code given in Section 1 of this manual.
WARNING:
BEFORE CARRYING OUT ANY MAINTENANCE WORK LOCK OFF FOR SAFE WORKING: 1. SELECT THE MODE SWITCH ON THE SET CONTROL PANEL TO OFF. 2. ISOLATE ALL SUPPLIES TO THE GENERATOR. 3. ISOLATE THE BATTERY CHARGER. 4. DISCONNECT THE BATTERY. 5. REMOVE THE STARTER CONTROL WIRES. 6. A SUITABLE WARNING PLATE STATING MAINTENANCE IN PROGRESS SHOULD BE DISPLAYED PROMINENTLY.
Section 5 Maintenance
Page 5-1
Suggested Maintenance Schedule ITEM

Engine
TASK
Check all exhaust components / connections Check lubrication oil level Change lubrication oil and filter Check fuel tank level Check coolant level Drain water from fuel pre-filter (where fitted) Change coolant filter (where fitted) Change fuel pre-filter (where fitted) Clean charger air cooler (where fitted). Check fuel injector settings Check valve clearances Check anti-freeze / inhibitor content Check vee belt tension Clean air filter or check oil bath Check all pipework for leaks Drain sediment from fuel tank Check and clean radiator matrix Perform any maintenance tasks specified in the Engine Manufacturers Manual Periodically clean the engine Check electrolyte level in battery Check state of charge
Weekly / 10 hours
l l
Monthly / Yearly / 100 hours 200 hours
l l l l l l 800 hours See Engine Manual See Engine Manual Change every two years l l l l As directed l l l l l l l l See manufacturers data l As directed l l l l l l l l l l l l l
Set Electrics
Clean battery terminals and regrease Check fuel solenoid and linkage Check all electrical connections Clean all apertures (with vacuum cleaner) Grease bearings if required Check all ventilation points Perform any maintenance tasks specified in the Alternator Manufacturers Manual Clean the alternator Check circuit breaker contacts Carry out a Lamp Test Check all fuses and tripping devices Clean the control panel Check security of all fixings as required Check plant room for cleanliness Have set / panel inspected by manufacturer Check air inlets / outlets for freedom from obstruction Run the set on-load at least 50% load Check anti-vibration mounts Check all systems functioning Check operation of Emergency Stop
Alternator
Control Panel
General
Test Run
Page 5-2
Section 5 Maintenance
SECTION 6 TROUBLESHOOTING 6
6.1
Troubleshooting
Introduction
Fault diagnosis charts are provided in this section to assist in locating and identifying the possible causes of faults in the genset system. The PCCP displays faults and warnings by illuminating its lamps, and also displays numbered fault messages on its digital display. These are detailed in the PCCP Fault Finding Charts. If an operating fault occurs, first check the PCCP indications against these charts. If the problem cannot be resolved, continue with the General Fault Finding Charts that contain basic troubleshooting procedures. The engine Operation and Maintenance Manual contains its own fault finding charts and covers many possible engine faults. Similarly, the alternator Installation, Service and Maintenance Manual contains its own fault finding details. Many common faults are highlighted in this section.
6.2
Safety Considerations
Fault finding work, particularly in confined areas, should be carried out by two engineers working together. Refer to Section 4.8 - Locking the Genset Out of Service. High voltages are present within the genset output box when the generator is running. WARNING: DURING TESTING IT MAY BE NECESSARY TO REMOVE COVERS TO ADJUST CONTROLS EXPOSING LIVE TERMINALS OR COMPONENTS. ONLY PERSONNEL QUALIFIED TO PERFORM ELECTRICAL SERVICING SHOULD CARRY OUT TESTING AND/OR ADJUSTMENTS. REFIT ALL ACCESS COVERS AFTER ADJUSTMENTS HAVE BEEN COMPLETED.
The installation of a genset can be designed for remote starting. When troubleshooting a genset that is shutdown ensure that the set cannot be accidentally re-started. To prevent accidental starting always remove the negative (-) battery lead from the set starting battery. Caution: Always disconnect a battery charger from its AC source before disconnecting the battery leads. Failure to do so can result in voltage spikes high enough to damage the DC control circuits of the genset.
Section 6 Troubleshooting
Page 6-1
WARNING:
ACCIDENTAL STARTING OF THE GENSET WHILE WORKING ON IT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. PREVENT ACCIDENTAL STARTING BY DISCONNECTING THE STARTING BATTERY LEADS (NEGATIVE [-] FIRST). ENSURE BATTERY AREA HAS BEEN WELL-VENTILATED BEFORE SERVICING THE BATTERY. ARCING CAN IGNITE EXPLOSIVE HYDROGEN GAS GIVEN OFF BY BATTERIES, CAUSING SEVERE PERSONAL INJURY. ARCING CAN OCCUR WHEN LEADS ARE REMOVED OR REPLACED, OR WHEN THE NEGATIVE (-) BATTERY LEAD IS CONNECTED AND A TOOL USED TO CONNECT OR DISCONNECT THE POSITIVE (+) BATTERY LEAD TOUCHES THE FRAME OR OTHER GROUNDED METAL PART OF THE GENSET. ALWAYS REMOVE THE NEGATIVE (-) LEAD FIRST AND RECONNECT LAST. MAKE CERTAIN HYDROGEN FROM THE BATTERY, ENGINE FUEL AND OTHER EXPLOSIVE FUMES ARE FULLY DISSIPATED. THIS IS ESPECIALLY IMPORTANT IF THE BATTERY HAS BEEN CONNECTED TO A BATTERY CHARGER.
6.3
Fault Finding
Should a fault condition occur during operation, follow the procedures in the following tables to locate and correct the problem. For any symptom not listed, contact an Authorised Service Centre for assistance. Before starting any fault finding, ensure that the following basic checks are carried out: All switches and controls are in their correct positions The fuel oil level is correct The lubricating oil level is correct The coolant level is correct The radiator matrix is free from obstruction The battery charge condition is satisfactory and the connections are secure The genset electrics and alternator connections are secure The panel connections are secure The protection circuits have been reset Blown fuses have been replaced Tripped contactors or circuit breakers have been reset WARNING: MANY TROUBLESHOOTING PROCEDURES PRESENT HAZARDS THAT CAN RESULT IN SEVERE PERSONAL INJURY OR DEATH. ONLY QUALIFIED SERVICE PERSONNEL WITH KNOWLEDGE OF FUELS, ELECTRICITY, AND MACHINERY HAZARDS SHOULD PERFORM SERVICE PROCEDURES. REVIEW SAFETY PRECAUTIONS LISTED WITHIN SECTION 1 PRELIMINARY AND SAFETY SECTION - OF THIS MANUAL.
Page 6-2
6.3.1 Engine Starting Faults

Symptom Engine does not crank with Mode switch set to correct position. Possible Cause Shutdown alarm condition active AIR START Low starting air pressure ELECTRIC START Starting batteries discharged or battery life span exceeded Air start or electric starter motor pinion locked or not engaging (if applicable) Damaged teeth on motor pinion or flywheel starter ring Coolant in one or more cylinders Incorrect grade of oil Fuel tank empty Fuel solenoid faulty Waxed fuel / blocked filters Engine too cold No fuel at pump / injector unit(s) Remedy a) Reset shutdown alarm after clearing fault a) Check compressor, reducing valve and start solenoid a) Check electrolyte for correct specific gravity and level b) Check charger function c) Test, and renew batteries if required a) Turn flywheel with barring gear to release pinion and / or remove motor b) Clean and grease pinion a) Repair or renew start motor b) Seek qualified technical advice a) Refer to Engine Manual a) Refill with correct viscosity a) Fill to required level a) If jammed, free up b) Renew coil or entire solenoid valve a) Change filters and switch heaters on a) If heaters are fitted, ensure they are operative. a) Check fuel supply pump b) Ensure all bleed screws are closed c) Pressurise the fuel system d) Bleed off any air a) Remove & clean / renew a) Renew probe a) Install new actuator a) Check fuses/relays a) Find cause and rectify b) Reset trip a) Bleed air from fuel system a) Fill to required level a) Ensure all valves are open a) Renew filters a) Clean / renew air cleaner a) Check for obstruction such as collapsed silencer or trunking a) Seek qualified technical help a) Reduce load steps a) Reduce load level
Engine cranks but fails to start (after a predetermined number of start attempts), OR engine cranks and starts but fails to continue to run.
Air filter clogged Speed probe faulty Actuator malfunctioning No fuel control output from panel Over-speed trip operated Engine starts but fails to run up to speed, OR engine loses speed when on load. Air in fuel Fuel tank level low Obstruction in spill return line Fuel filters choked Air cleaner blocked High exhaust gas back-pressure Turbocharger faulty Load step excessive Engine overloaded
Page 6-3
6.3.2 Engine Running Faults

Symptom Excessive black smoke Possible Cause Engine overloaded Blocked air cleaner High exhaust gas back pressure Injectors / pumps require servicing Turbocharger requires servicing Excessive light load running Overheating Incorrect inlet and or exhaust valve clearances Damaged valves / seats Faulty pump / injectors Excessive light load running Turbocharger turbine seal faulty Contaminated fuel Remedy a) Reduce load level a) Clean / renew air cleaner a) Check for obstruction such as collapsed silencer or trunking a) Refer to Engine Manual a) Refer to Engine Manual a) Ensure correct loading a) See Engine Overheats a) Refer to Engine Manual a) Refer to Engine Manual a) Refer to Engine Manual a) Ensure correct loading a) Refer to Engine Manual a) Check fuel system for contaminates b) Discard fuel and renew if necessary a) Refer to Engine Manual a) Ensure correct loading a) Refer to Engine Manual a) Reduce to correct level a) Check fuel system for contaminates b) Discard fuel and renew if necessary a) Clean radiator air matrix a) Test circuitry - renew motor if necessary b) Check fan belt and renew if necessary a) Top-up to required level b) Ascertain reason for loss and rectify a) Refer to Engine Manual a) Open louvres a) Refer to Engine Manual a) Check for obstruction b) Ensure that all valves are open a) If faulty, renew coil or renew whole unit a) Overhaul - renew injectors a) Renew seals / renew actuator
Excessive white smoke with engine misfiring
Excessive blue smoke
Worn pistons / piston rings - liners / valve stems or valve guides Excessive light load running Turbocharger compressor seal faulty High engine oil level Contaminated fuel
Engine overheats
Radiator air matrix choked Radiator fan not turning
Loss of coolant Cooling pumps faulty Ventilation louvres not open Engine Overspeeds Actuator faulty Restricted fuel spill return line
Engine will not stop / stops very slowly
Fuel drain-off solenoid valve faulty Worn injector valves Actuator / drain off seals faulty
Page 6-4
Symptom Engine speed unstable
Possible Cause Actuator faulty Restriction in spill return line Restricted exhaust system Disrupted screen connection from probe a) a) b) a)
Remedy Overhaul or renew Check for obstruction Ensure all valves are open Check for obstruction such as collapsed silencer or trunking a) Carry out a continuity test to locate the fault a) Refer to Engine Manual a) Lubricate with half-and-half mixture of fuel oil and lubricating oil a) Refer to Engine Manual a) Refer to Engine Manual a) Contact your Authorised Dealer a) Renew coupling b) Contact your Authorised Dealer a) Contact your Authorised Dealer a) Renew control unit b) Contact your Authorised Dealer a) Check and test connections a) Top up oil to correct level b) Call your distributor to service the engine lubrication system a) Change filter / clean cooler a) Determine by inspection and rectify a) Overhaul or adjust a) Remove, inspect b) Overhaul or renew c) Contact your Authorised Dealer a) Top up coolant b) Check for leaks a) Clean radiator matrix a) Test circuitry b) Renew motor if necessary a) Check pump drives and impellers for wear b) Overhaul or renew a) Rectify fault or renew charge alternator /battery charger a) Check the fuel system for any of these faults
Excessive vibration due to engine misfire
Pump injector unit(s) faulty Inlet or exhaust valves sticking Badly worn valve stems and / or guides Burned valve seats / valves
Rotary vibration
Alternator / engine misaligned Coupling faulty Alternator shaft distorted
No speed control - trim
Speed control faulty Disrupted connections
Engine stops due to low oil pressure
Low oil level Choked filter or dirty oil cooler Internal or external oil leakage Oil pressure relief valve faulty or requiring adjustment Oil pump faulty Worn engine bearings
Engine stops due to high temperature.
Low coolant level Radiator matrix choked Radiator fan motor faulty Cooling pumps faulty
Discharged battery Engine stops due to fuel starvation
Faulty charge alternator or battery charger Low fuel level, fuel system leakage or fuel pipe blockage
Page 6-5
6.3.3 Electrical Output Faults

Symptom Earth fault trip Possible Cause Insulation in terminal box or cables faulty Earth fault in alternator stator windings Current transformer(s) faulty Earth Fault relay malfunction Multiple neutral earths Voltage does not build up to rated value Low residual or incorrect polarity between exciter output and generator field Exciter defective Short-circuited rotating diodes Open circuit connection to main field Prime mover not up to required speed Poor regulation Poor voltage stability Voltage recovery slow with load change Paralleled generators do not share real kW load equally Output voltage falls off as load increases Output voltage rises as load increases System does not start on mains failure Remedy a) Test all cables for earth fault b) Locate faulty section c) Renew or repair section of cable a) Contact your Authorised Dealer a) Test transformers for continuity and earth fault b) Replace if faulty a) Replace relay a) Contact your Authorised Dealer a) Field flashing is required. Refer to Alternator Manual for these instructions a) Test Exciter output and refer to Alternator Manual a) Test and renew defective diodes b) Refer to Alternator Manual a) Test for and locate fault in field b) Make good or contact your Authorised Dealer a) Check fuel filters
Contact your Authorised Dealer Contact your Authorised Dealer Contact your Authorised Dealer Contact your Authorised Dealer Contact your Authorised Dealer Contact your Authorised Dealer Mode switch on Mains Failure Unit not in Auto Global Emergency Stop button on Common Control Unit depressed No sets available a) Set Mode switch to Auto a) Release Emergency button a) Check set status Stop
Page 6-6
Symptom Set does not supply load
Possible Cause Defective circuit breaker or coil Alternator voltage low / high Faulty synchronisation Fault at Common Control Unit Set switched to LOCAL on Set Management Controller
Remedy a) Renew coil or entire breaker a) Ascertain reason for wrong voltage and take the required action a) Retry b) Contact your Authorised Dealer a) Contact your Authorised Dealer a) Check switch setting a) Contact your Authorised Dealer a) Reset or Contact your Authorised Dealer a) Contact your Authorised Dealer a) Set Mode switch to Auto Mains Return position
System does not supply load
Defective circuit breaker interlocks Circuit breaker trip unit requires resetting Fault at Mains Failure Unit
Mains does not return automatically
Mode switch on MFU in Manual Mains Return or Test on Load. Mains supply not achieving MFU setting
Page 6-7
6.3.4 Control System Faults

SYMPTOM Control does not power-up when the Mode switch is set to Run or the Self-test switch is pressed POSSIBLE CAUSE There is no DC power to the control a) b) c) d) Warning, Shutdown, and NonAutomatic lamps are not lit. Digital display shows main menu or selected menu Non-Automatic lamp flashes None CORRECTIVE ACTION Check the battery electrolyte level and specific gravity Check terminals are clean and tight Check Fuse 1 on the engine interface board Contact an Authorised Service Centre Indicates all engine systems are normal No corrective action required Move the Mode switch to the Auto position for automatic operation None Automatic lamp stops flashing
a) b)
Mode switch is not in the Auto position. This will prevent automatic starting PCCP idles the engine at start up if jacket temperature is below 140F o (40 C), and continues to do so until this temperature is reached. PCCP idles the engine during cooling run before shutting down. The above conditions only apply to engines requiring these procedures to be set up
a) b)
MESSAGE: IDLE MODE 101 INDICATION ONLY Engine continues to operate at reduced RPM
Shutdown lamp lights MESSAGE: EMERGENCY STOP 102 SHUTDOWN Engine shuts down and will not crank Warning lamp lights MESSAGE: LOW OIL PRESSURE 200 WARNING Engine continues to operate
Local or remote Emergency Stop Operated
Indicates that the engine is operating in Idle mode. a) When the genset is operating in the Run mode, grounding the engine idle input causes generator build-up to be inhibited and the engine to be governed at idling speed b) When ground is removed from this input, the genset returns to normal speed and voltage c) When the engine idle function is enabled, the control automatically sets lower oil pressure warning and shutdown trip points to reflect the lower operating speed d) When the engine idle function is removed and the genset reverts to normal operating speed, the control automatically resets the oil pressure warning and shutdown trip points to the normal settings To Reset: a) Pull the switch and allow it to un-latch b) Turn the Mode switch to Off c) Press the Reset switch d) Select Run or Auto as required a) The engine must be stopped as soon as possible to prevent serious damage. If the engine can be stopped, do so If the generator is powering critical loads and cannot be shut down, wait until the next shutdown period then follow the next procedure, - Low Oil Pressure. Shutdown Check all possible causes as in 200 warning Rectify the problem Reset the control system and re-start Check engine running conditions under no load Contact an Authorised Service Centre if the problem persists
Indicates that the engine oil pressure has dropped to an unacceptable level. Possibly due to high oil temperature, low oil level, dirty filters, dirty cooler, relief valve failure, potential oil pump failure, excessively worn engine bearings eventual bearing failure Indicates that the engine oil pressure has dropped below the shutdown trip point. The reason for this shutdown must be determined before restarting the engine. Check possible causes as in 200 warning
b)
Shutdown lamp lights MESSAGE: LOW OIL PRESSURE 201 SHUTDOWN Engine shuts down
a) b) c) d) e)
Page 6-8
SYMPTOM Warning lamp lights MESSAGE: OIL PRES SENDER 204 WARNING Warning lamp lights MESSAGE: LOW COOLANT TEMP 210 WARNING The genset is in standby mode but is not operating. Warning occurs when the engine coolant temperature is 21C (70F) or lower. Note: In applications where the ambient temperature falls below 4C (40F), Low Engine Temp may be indicated even though the coolant heaters are operating Warning lamp lights MESSAGE: HIGH COOLANT TEMP 211 WARNING Engine continues to operate
POSSIBLE CAUSE Indicates that the engine oil pressure sender is not functioning correctly Indicates that the engine coolant heater is not operating or is not circulating coolant a) b)
CORRECTIVE ACTION Check that the engine oil pressure sender is properly connected Contact an Authorised Service Centre if problem persists
Check for the following conditions: a) Coolant heater not connected to the power supply b) Check for blown fuse or disconnected heater cord and correct as required c) Check for low coolant level and replenish if required d) Look for possible coolant leakage points and repair as required e) Contact an Authorised Service Centre if none of above Note: This signal wakes-up the PCCP from the Standby condition If the engine can be stopped. a) Allow the engine to cool before checking the coolant level and replenish if required b) Determine reason for coolant loss and rectify c) Check coolant pump & pump drive d) Check radiator matrix for air-born debris and clean if required or if heat exchanger is employed check raw water pump and raw water supply e) Check fan belt and / or fan motor circuitry f) Access the Coolant Temp menu prior to clearing the fault g) Run engine on no load test after rectifying the fault Allow the engine to cool down completely before proceeding with the following checks: a) Check the coolant level and replenish if low b) Look for coolant leakage and repair if necessary c) Check for obstructions to cooling airflow and correct as necessary d) Carry out all checks as in 211 warning e) Run engine on no load test after rectifying the fault a) Check the sender. Resistance should be 500 to 2k ohm b) If faulty fit new sender
Indicates that the engine has begun to overheat and the coolant temperature has risen to an unacceptable level: 101C (215F) Standby / 97C (207F) Primary. If the generator is powering noncritical and critical loads and cannot be shutdown reduce the load if possible by turning off noncritical loads. Check air inlets and outlets and remove any obstructions to airflow
Shutdown lamp lights MESSAGE: HIGH COOLANT TEMP 212 SHUTDOWN Engine shuts down
Indicates that the engine has overheated (coolant temperature has risen above the shutdown trip point: 101C (215F) Standby / 97C (207F) Primary
Warning lamp lights MESSAGE: ENG COOLANT SENDER 213 WARNING
Indicates that the resistance of the coolant temperature sender is out of range
Page 6-9
SYMPTOM Shutdown lamp lights MESSAGE: LOW COOLANT LVL 214 WARNING Engine shuts down OR LOW COOLANT LVL 215 SHUTDOWN Shutdown lamp lights MESSAGE: MAG PICKUP 220 SHUTDOWN Engine shuts down
POSSIBLE CAUSE Indicates that the engine coolant level has fallen below the trip point. Allow the engine to cool down completely before proceeding. Note: This signal wakes up the PCCP. (Low Coolant Warning only) a)
CORRECTIVE ACTION Check the coolant level and replenish if low b) Look for possible coolant leakage points and repair if necessary c) Reset the control system and restart after locating and correcting the problem d) Contact Authorised Service Centre if problem persists e) LOW COOLANT LVL Shutdown will not occur if genset is in Idle mode a) Check that the pickup sensing head is clean b) Check cable for continuity and good screening c) Restart and check RPM on the digital display d) Contact an Authorised Service Centre if the problem persists Check for the following conditions: a) Check fuse F3 on the Engine Interface Board b) Recharge or replace the battery c) Clean the battery cable terminals and tighten all connections including starter motor d) Contact an Authorised Service Centre for service of starter and starting system a) Replenish fuel supply tank b) Renew fuel filters c) Ensure engine heaters are operating d) Clean/renew induction filters e) Reset air shut-off valves f) Reset the control system and restart after correcting the problem g) Contact an Authorised Service Centre if none of the above a) Contact an Authorised Service Centre
Indicates that the magnetic pick-up speed indication is not being sensed or does not match the genset output frequency
Engine will not crank Shutdown lamp lights MESSAGE: FAIL TO CRANK 221 SHUTDOWN
Indicates a possible fault with the control or starting system. Discharged or defective battery. Poor battery cable connections. Locked starter motor or damaged flywheel starter ring
Shutdown lamp lights Engine Stops Cranking MESSAGE: OVERCRANK 222 SHUTDOWN
Indicates a possible fuel problem or air induction problem: Fuel supply tank low level or contaminated fuel. Fuel filters choked. Waxed fuel. Air induction filters choked. Air shut-off valves operated Indicates that the engine has exceeded its normal operating speed trip point.
Engine runs and then shuts down Shutdown lamp lights MESSAGE: OVERSPEED 223 SHUTDOWN Warning lamp lights MESSAGE: LOW DC VOLTAGE 230 WARNING
Indicates that the battery voltage is below 24V DC. (12V DC for 12V battery) Discharged or defective battery. Battery charger fault/fuse
a) Check the battery electrolyte level b) c) d) e)

f) and specific gravity Repair battery charger Recharge or replace the battery Poor battery cable connections Clean the battery cable terminals and tighten all connections Contact an Authorised Service Centre if none of the above Contact an Authorised Service Centre
Warning lamp lights. MESSAGE: HIGH DC VOLTAGE 231 WARNING
Indicates that the battery voltage exceeds 32V DC (16V DC for 12V battery)
a)
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SYMPTOM Warning lamp lights MESSAGE: WEAK BATTERY 232 WARNING Engine continues to run Warning lamp lights MESSAGE: LOW FUEL DAY 240 WARNING Warning lamp lights. MESSAGE: LOW FUEL 241 WARNING Shutdown lamp lights. MESSAGE: EEPROM ERROR 250 SHUTDOWN Warning lamp lights. MESSAGE: EEPROM ERROR 251 WARNING or 252 WARNING Engine continues to run Shutdown lamp lights. MESSAGE: RACK POSITION 260 WARNING Shutdown lamp lights. MESSAGE: CUSTOMER FAULT 1 260 SHUTDOWN
(not applicable for QST30 series)
POSSIBLE CAUSE Indicates the battery voltage dropping below 60% of nominal for two seconds, during starting. Discharged or defective battery Indicates that the day tank fuel supply is running low
CORRECTIVE ACTION
a) See Warning Message 230 LOW DC

VOLTAGE
a)
Check the fuel supply and replenish as required Note: This signal wakes up the PCCP Check the fuel supply and replenish as required
Indicates that the fuel supply is running low
a)
Indicates PCCP memory error. Data corruption of critical operating parameters Indicates PCCP memory error. Data corruption of non-critical operating parameters
a) Contact an Authorised Service Centre
a)
Contact an Authorised Service Centre
QST30 SERIES ONLY. Indicates that one, or both, of the fuel racks is not at the commanded position. When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a Shutdown or a Warning. Customer fault 261 or 262 input can wake-up the control if it is not operating. As indicated by the Shutdown lamp, a shutdown response has been pre-selected. Note: Customer fault messages are editable. The message displayed for the code shown (260 to 263) may have been edited and will not appear as shown in this table. Note: for QST30 series the code 260 is reserved for the RACK POSITION fault and is not available as Customer Fault 1.
a) b) c) a)
Check fuel pump connections Check left and right actuator fuses (A38-F1 & F2) on the Governor Output Module Contact an Authorised Service Centre Contact an Authorised Service Centre
or GROUND FAULT 261 SHUTDOWN or RUPTURE BASIN 262 SHUTDOWN or HIGH GEN TEMP 263 SHUTDOWN Engine shuts down
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SYMPTOM Warning lamp lights. MESSAGE: CUSTOMER FAULT 1 260 WARNING

(not applicable for QST30 series)
POSSIBLE CAUSE When any one of these customer defined inputs is closed to ground, the corresponding fault message is displayed. The nature of the fault is an optional customer selection. These fault functions can be programmed to initiate a Shutdown or a Warning. Customer fault 261 or 262 input can wake-up the control if it is not operating. As indicated by the Warning lamp, a shutdown response has been pre-selected. Note: Customer fault messages are editable. The message displayed for the code shown (260 to 263) may have been edited and will not appear as shown in this table. Note: for QST30 series the code 260 is reserved for the RACK POSITION fault and is not available as Customer Fault 1. Indicates that one of the phase voltages has exceeded 130% of nominal, or has exceeded 110% of nominal for 10 seconds Indicates that one of the phase voltages has dropped below 85% of nominal for 10 seconds a)
CORRECTIVE ACTION Contact an Authorised Service Centre
or GROUND FAULT 261 WARNING or RUPTURE BASIN 262 WARNING or HIGH GEN TEMP 263 WARNING
Shutdown lamp lights. MESSAGE: HIGH AC VOLTAGE 301 SHUTDOWN Engine shuts down Shutdown lamp lights. MESSAGE: LOW AC VOLTAGE 303 SHUTDOWN Engine shuts down Shutdown lamp lights. MESSAGE: UNDER FREQUENCY 313 SHUTDOWN Engine shuts down Warning lamp lights. MESSAGE: OVERCURRENT 320 WARNING Engine continues to run Shutdown lamp lights. MESSAGE: OVERCURRENT 321 SHUTDOWN Engine shuts down Shutdown lamp lights. MESSAGE: SHORT CIRCUIT 322 SHUTDOWN Engine shuts down
a)
Indicates that engine speed has dropped below 90% of nominal for 10 seconds Note: Five seconds before Shutdown, a Load Dump signal is initiated Indicates that the generator output current has exceeded 110% of rated value for 60 seconds
a)
a)
Indicates that the generator output current has exceeded 110% of rated value and that a PCCP time/current calculation has initiated an overcurrent Shutdown Indicates that the generator output current has exceeded 175% of rated value
a)
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SYMPTOM Warning lamp lights. MESSAGE: OVERLOAD 330 WARNING Engine continues to run Shutdown lamp lights. MESSAGE: REVERSE POWER 335 SHUTDOWN Engine starts from the generator control panel but will not start automatically or from a remote panel. Note: The Mode switch must be in the Auto position for automatic or remote starting No AC output voltage
POSSIBLE CAUSE Indicates that the 3-phase power exceeds 105% of Standby (or 115% of Prime) rating. After 5 seconds the Load Dump output is activated. After 60 seconds the Overload warning is activated Indicates improper CT or PT phasing (Non-paralleling units only) Check the control wiring between the remote switch and the PCCP a)
CORRECTIVE ACTION Contact an Authorised Service Centre
a)
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Page 6-14

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Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

Cummins Power Generation Limited

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

Schedule of Abbreviations ................................................................................................ i 1

System Description ............................................................................................. 3-1

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

Maintenance......................................................................................................... 5-1 Troubleshooting .................................................................................................. 6-1

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

Control Mode Definitions ................................................................................ 4-2

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

SECTION 1 PRELIMINARY AND SAFETY 1

1.2.2 High Pressures

Section 1 Preliminary and Safety

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

1.2.4 Supply Isolation

Section 1 Preliminary and Safety

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

1.2.5 Reinstatement of Supply

Section 1 Preliminary and Safety

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

Standards, Codes & Regulations

Section 1 Preliminary and Safety

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

Safety of Machinery Electrical Equipment of Machines

Section 1 Preliminary and Safety

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

Generator Plant Safety Code

1.7.1 Genset Warning Labels

Section 1 Preliminary and Safety

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

1.8.1 Engine Warning

1.8.2 Exhaust Gas Hazards

Section 1 Preliminary and Safety

Publication 3535(GB) Issue 02 Feb 2003

Standard PCCP Control Systems

1.8.3 Fire Hazards

Section 1 Preliminary and Safety

Standard PCCP Control Systems

Publication 3535(GB) Issue 02 Feb 2003

1.8.4 Moving Part Hazards

1.8.5 High Temperature Hazards