Manual Servicio Generator DQCC

Service Manual
Generator Set
QSK23G7 Engine with PowerCommand 3201 Control
DQCA (Spec A−N)

DQCB (Spec A−N)
DQCC (Spec A−N)
English
Original Instructions 7-2016 960−0521 (Issue 18)
California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Table of Contents
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
ABOUT THIS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
AMPSENTRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
SEQUENCE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CONTROL PANEL POWER ON/OFF MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
CONTROL PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
READING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
MENU DISPLAY AND SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
LANGUAGE/UNITS SELECTION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
MAIN MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
ENGINE SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
ALTERNATOR SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONTROL SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
HISTORY/ABOUT SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
HISTORY/ABOUT SUBMENUS (CONT.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
PARALLEL DATA SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
POWER TRANSFER MAIN/SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
UTILITY (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
STATUS (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
TRANSFER CONTROL (PWR TRAN) SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
GENSET (PWR TRAN) SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Copyright  2016 Cummins Inc. i

Table of Contents
3. CONTROL CALIBRATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PARALLELING and NON−PARALLELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SOFTWARE CALIBRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
MODIFYING SETUP/ADJUST SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
SETUP MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
GOVERNING/VOLT REG SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CUSTOMER FAULTS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
CALIBRATION SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
ISOLATED BUS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
UTILITY SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
POWER TRANSFER CONTROL MAIN MENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
UTILITY SENSORS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
GENSET SENSORS SUBMENUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
TIMERS SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
TEST/EXERCISE SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
ADJUST SUBMENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
CALIBRATION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CONTROL BOX WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
RUN RELAYS (K11, K12, K13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
ALARM RELAY (K16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
MAGNETIC SPEED PICKUP UNIT (MPU) INSTALLATION . . . . . . . . . . . . . . . . . . 3-25
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
STATUS INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
READING FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LINE CIRCUIT BREAKER (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
CONTROL AND DIAGNOSTICS VIA NETWORK OR LAPTOP . . . . . . . . . . . . . . . 4-2
FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TABLE 4-2. WARNING AND SHUTDOWN CODES . . . . . . . . . . . . . . . . . . . . . . . . 4-8
ii Copyright  2016 Cummins Inc.

Table of Contents
5. SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
GENERATOR/PCC CONTROL ISOLATION PROCEDURE . . . . . . . . . . . . . . . . . . 5-2
TESTING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
TESTING THE PMG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
BEARING REMOVAL/REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
GENERATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
GENERATOR REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
ALIGNING GENERATOR WITH ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
6. GENERATOR SET LONG TERM STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
REQUIRED MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
ADDITIONAL STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
RETURNING THE GENERATOR SET TO SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 6-2
7. ENCLOSURE FUEL TANK SYSTEM (DFEG-EK) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
EXTERNAL FUEL FILL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
EXTERNAL ALARM PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
RUPTURE BASIN LEAK DETECT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
8. ENCLOSURE FUEL TANK SYSTEM (DQCA-CC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
WIRING CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
FUEL TRANSFER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
EXTERNAL/INTERNAL ALARM PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
RUPTURE BASIN LEAK DETECT SWITCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
9. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Copyright  2016 Cummins Inc. iii

This Page Intentionally Left Blank.
LS-16L
iv Copyright  2016 Cummins Inc.
Important Safety Instructions
SAVE THESE INSTRUCTIONS − This manual contains EXHAUST GASES ARE DEADLY
important instructions that should be followed during
installation and maintenance of the generator set and  Provide an adequate exhaust system to properly
batteries. expel discharged gases away from enclosed or
sheltered areas and areas where individuals are
Before operating the generator set (genset), read the likely to congregate. Visually and audibly inspect
Operator’s Manual and become familiar with it and the the exhaust daily for leaks per the maintenance
equipment. Safe and efficient operation can be schedule. Make sure that exhaust manifolds are se-
achieved only if the equipment is properly operated cured and not warped. Do not use exhaust gases to
and maintained. Many accidents are caused by failure heat a compartment.
to follow fundamental rules and precautions.
 Be sure the unit is well ventilated.
The following symbols, found throughout this manual,
alert you to potentially dangerous conditions to the oper-
 Engine exhaust and some of its constituents are
known to the state of California to cause cancer,
ator, service personnel, or the equipment.
birth defects, and other reproductive harm.
This symbol warns of immediate
MOVING PARTS CAN CAUSE SEVERE
hazards which will result in severe personal in-
jury or death. PERSONAL INJURY OR DEATH
 Keep your hands, clothing, and jewelry away from
WARNING This symbol refers to a hazard or un-
moving parts.
safe practice which can result in severe person-
al injury or death.  Before starting work on the generator set, discon-
nect battery charger from its AC source, then dis-
CAUTION This symbol refers to a hazard or un- connect starting batteries, negative (−) cable first.
safe practice which can result in personal injury This will prevent accidental starting.
or product or property damage.  Make sure that fasteners on the generator set are
secure. Tighten supports and clamps, keep guards
FUEL AND FUMES ARE FLAMMABLE in position over fans, drive belts, etc.
Fire, explosion, and personal injury or death can result  Do not wear loose clothing or jewelry in the vicinity of
from improper practices. moving parts, or while working on electrical equip-
ment. Loose clothing and jewelry can become
 DO NOT fill fuel tanks while engine is running, un- caught in moving parts.
less tanks are outside the engine compartment.
Fuel contact with hot engine or exhaust is a potential  If adjustment must be made while the unit is run-
fire hazard. ning, use extreme caution around hot manifolds,
moving parts, etc.
 DO NOT permit any flame, cigarette, pilot light,
spark, arcing equipment, or other ignition source DO NOT OPERATE IN FLAMMABLE AND
near the generator set or fuel tank.
EXPLOSIVE ENVIRONMENTS
 Fuel lines must be adequately secured and free of
leaks. Fuel connection at the engine should be Flammable vapor can cause an engine to overspeed and
made with an approved flexible line. Do not use zinc become difficult to stop, resulting in possible fire, explo-
coated or copper fuel lines with diesel fuel. sion, severe personal injury and death. Do not operate a
genset where a flammable vapor environment can be
 Be sure all fuel supplies have a positive shutoff created by fuel spill, leak, etc., unless the genset is
valve. equipped with an automatic safety device to block the air
 Be sure battery area has been well-ventilated prior intake and stop the engine. The owners and operators of
to servicing near it. Lead-acid batteries emit a highly the genset are solely responsible for operating the gen-
explosive hydrogen gas that can be ignited by arc- set safely. Contact your authorized Cummins Power
ing, sparking, smoking, etc. Generation distributor for more information.
LS-16L
Copyright  2016 Cummins Inc. iii
ELECTRICAL SHOCK CAN CAUSE  Keep multi-class ABC fire extinguishers handy.
SEVERE PERSONAL INJURY OR DEATH Class A fires involve ordinary combustible materials
such as wood and cloth; Class B fires, combustible
 Remove electric power before removing protective and flammable liquid fuels and gaseous fuels; Class
shields or touching electrical equipment. Use rub- C fires, live electrical equipment. (ref. NFPA No. 10).
ber insulative mats placed on dry wood platforms
over floors that are metal or concrete when around  Make sure that rags or combustible material are not
electrical equipment. Do not wear damp clothing left on or near the generator set.
(particularly wet shoes) or allow skin surface to be
damp when handling electrical equipment. Do not  Make sure generator set is mounted in a manner to
wear jewelry. Jewelry can short out electrical con- prevent combustible materials from accumulating
tacts and cause shock or burning. under or near the unit.
 Use extreme caution when working on electrical
components. High voltages can cause injury or  Remove all unnecessary grease and oil from the
death. DO NOT tamper with interlocks. unit. Accumulated grease and oil can cause over-
heating and engine damage which present a poten-
 Follow all applicable state and local electrical tial fire hazard.
codes. Have all electrical installations performed by
a qualified licensed electrician. Tag and lock open  Keep the generator set and the surrounding area
switches to avoid accidental closure. clean and free from obstructions. Remove any de-
 DO NOT CONNECT GENERATOR SET DIRECT- bris from the set and keep the floor clean and dry.
LY TO ANY BUILDING ELECTRICAL SYSTEM.
Hazardous voltages can flow from the generator set  Do not work on this equipment when mentally or
into the utility line. This creates a potential for elec- physically fatigued, or after consuming any alcohol
trocution or property damage. Connect only or drug that makes the operation of equipment un-
through an approved isolation switch or an ap- safe.
proved paralleling device.
 Substances in exhaust gases have been identified
GENERAL SAFETY PRECAUTIONS by some state or federal agencies as causing can-
 Coolants under pressure have a higher boiling point cer or reproductive toxicity. Take care not to breath
than water. DO NOT open a radiator or heat ex- or ingest or come into contact with exhaust gases.
changer pressure cap while the engine is running.  Do not store any flammable liquids, such as fuel,
To prevent severe scalding, let engine cool down
cleaners, oil, etc., near the generator set. A fire or
before removing coolant pressure cap. Turn cap
explosion could result.
slowly, and do not open it fully until the pressure has
been relieved.  Wear hearing protection when near an operating
 Used engine oils have been identified by some state generator set.
or federal agencies as causing cancer or reproduc-
tive toxicity. When checking or changing engine oil,  To prevent serious burns, avoid contact with hot
take care not to ingest, breathe the fumes, or con- metal parts such as radiator system, turbo charger
tact used oil. system and exhaust system.
KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE
LS-16L
iv Copyright  2016 Cummins Inc.
1. Introduction
ABOUT THIS MANUAL WARNINGIncorrect service or replacement of
parts can result in severe personal injury or
This manual provides PowerCommand Control death, and/or equipment damage. Service per-
3201 (PCC) calibration and adjustment procedures, sonnel must be trained and experienced to per-
control operation, alternator test and repair proce- form electrical and mechanical service. Read
dures. and follow Important Safety Instructions, on
pages iii and iv.
Operating and maintenance instructions are in the
applicable Operator’s Manual. Generator set trou- AMPSENTRY
bleshooting and repair (control and engine) infor-
mation is provided in the following manual.
Breakerless Conductor Connections
 Troubleshooting and Repair Manual PowerCom-
mand Control QSX15, (QSK23), QSK45, QSK60 Overload and Short Circuit Protection of
Generator Sets, Bulletin No. 402-1419 (Not shown
on front cover, but includes QSK23 information.)
Generator
Read Important Safety Instructions and carefully NFPA 70: National Electrical Code compliant gen-
observe all instructions and precautions in this erator sets are required to be protected from an
manual. overload. Cummins Power Generation generator
sets with UL Listed AmpSentry Protective Relay as
TEST EQUIPMENT a standard feature do not require a circuit breaker or
other protective device for NEC compliance or UL
To perform the test procedures in this manual, the
2200 Listing.
following test equipment must be available
 True RMS meter for accurate measurement of small CEC: Each conductor between the generator termi-
AC and DC voltages. nal and the point where load receives supply of gen-
 Battery Hydrometer erator current must be protected by an overcurrent
 Jumper Leads device in accordance with the requirement of CEC
 Tachometer or Frequency Meter 14−100: Overcurrent Protection of Conductor.
 Wheatstone Bridge or Digital Ohmmeter
UL label indicate to the Authority Having Jurisdiction
 Variac
(AHJ) that the generator set incorporates a UL
 Load Test Panel Listed Protective Relay that provides overload and
 Megger or Insulation Resistance Meter short circuit protection for the generator and its
 InPower Service Tool (PC based genset service conductors. The generator set does not require
tool) use of a circuit breaker or other protective device
HOW TO OBTAIN SERVICE for NFPA 70: National Electrical Code compliance
or UL 2200 Listing.
Always give the complete Model, Specification and
Serial number of the generator set as shown on the AmpSentry Labels
nameplate when seeking additional service infor-
mation or replacement parts. The nameplate is lo- These are typical labels for compliant generator
cated on the side of the generator output box. sets produced after January 2012.
Copyright  2016 Cummins Inc. 1-1

FIGURE 1−1. POWER COMMAND 2.2 LABEL
FIGURE 1−2. TYPICAL INFORMATION LABEL
1-2 Copyright  2016 Cummins Inc.

FIGURE 1−3. POWER COMMAND 2.2, 2.3, AND 3.3 tic of the supplied protection. This protection curve
SPACIFIC CHECK LABEL is specifically designed to protect the generator sup-
plied, so adjustments to the operation points for this
AmpSentry Protective Relay Time−Over curve are not allowed.
Current Characteristic Curve
Note: The values shown on the current scale are
shown based on the value of 1.0 being equal to the
The protection provided is shown in the figure nameplate rated current of the generator set for the
below, which shows the time−current characteris- specific operating voltage.

FIGURE 1−4. AMPSENTRY PROTECTIVE RELAY TIME OVER−CURRENT CHARACTERISTIC
CURVE

Coordination of Protective Devices ment R−1053, or it can be found using SKM Power
Tools for Windows library or from your distributor.
Conduct a selective coordination (discrimination)
study on the distribution system that incorporates
the generator set when choosing a generator set. Additional AmpSentry Protective Relay
Visit www.cumminspower.com for a copy of docu- Information
TABLE 1−1. ADDITIONAL AMPSENTRY PROTECTIVE RELAY INFORMATION FOR POWERCOMMAND
2100 CONTROL
Voltage No. of Phases Frequency (Hz) Current (Max) Connection
Battery Supply 8−30V DC 22A TB1 (17−22)
Voltage
g Sense 347/600V
/ 3 50/60
/ 10 mA J8 ((4,, 7,, 12,, 20))
I
Input
Current Sense 3 50/60
/ 5A J7 (11, 12, 15,
I
Input 16,19, 20))
VR Shunt Sup-
p 240V 1 50/60
/ 100mA J8 (21−23)
( )
ply
l
AVR PMG 210V 1 50/60 100mA
AVR Output
p 300V (Peak)
( ) 1 PWM 4A
(C i
(Continuous)
)
AVR Output
p 300V ((Peak)) 1 PWM 6A
(
(Max/10 seconds))
Run Relay 30V DC 8A: 144APilot TB1 (17−22)

Output Duty
Customer Relay 30V DC 5A

Output
Solenoid Driver 250V 1 AC 5A; C300 Pilot Duty‘ 5A; C300 Pilot
Signal Duty
Indicator Supply 5V DC 50Ma J2
Engine Sensor 5V DC 3mA J7 (13, 17, 21,
22, 25, 26,
29−35)
Governor Drive 5−30V DC 100mA J7 (14, 24, 28,
36)
Power Out 8−30V DC 100mA J7 (1−8, 18)
Solenoid Driver- 5−30V DC 100mA J7 (9, 10, 23,
Signal 27)
Switch Input 8−30V DC 1mA J1
Membrane 5V DC 1mA J3
Switch Input
Customer Inputs 8−30V DC 1mA TB1 (1−6)
Power Transfer 5−30V DC 1mA TB2 (5)
Status
Power Transfer 5−30V DC 100mA TB2 (3, 4, 6)
Signal Supply
Interface 5V DC 1mA J50, J51, J4, J6
Communication RS485 TB2 (1, 2)
RS232 J9 (1−5, 9)

CAN (Optional) J10 (1−5)
Trip Current 110% generator nameplate FLA
Voltage No. of Phases Frequency (Hz) Current (Max) Connection
Percentage of 100 300 600
Trip Current
Trip Times 500 seconds 10 seconds 1 second
Temperature 70C Maximum Surrounding Air Ambient

2. Control Operation
GENERAL Power On Mode: In this mode, power is continu-
ously supplied to the control panel. The control’s op-
The following describes the function and operation erating software and control panel LEDs/graphical
of the PowerCommand Control 3200 (PCC). All in- display will remain active until the Screen Saver
dicators, control switches/buttons and graphical mode is activated.
display are located on the face of the control panel
as illustrated in Figure 2-1. Screen Saver Mode: Power to the graphical dis-
play will be removed after 10 minutes (generator set
Normally, generator set configuration options are not running or running). The 10 minute timer resets
set at the factory. When a new control is installed on and begins after each control panel action (any but-
a generator set or when parts are replaced, the con- ton or switch selection) or signal received by the op-
trol must be configured for that generator set. Setup erating software. The bottom LEDs of the Analog
and calibration procedures are described in Sec- AC Metering Panel (bar graphs) may remain on dur-
tion 3. ing Screen Saver mode, indicating that the operat-
ing software is active (Awake mode).
SEQUENCE OF OPERATION When a “Warning” signal is sensed by the PCC (for
example, low coolant temp), the control will display
When the PowerCommand control is in the AUTO the warning message. The control will remain active
mode, it will cause the generator set to start on re- until the Fault Acknowledge button is pressed to
ceiving a signal from a remote device. The control clear the warning message and start the 10 minute
will initiate a starter cranking signal and verify that timer.
the engine is rotating. The control will provide suffi-
cient fuel to the engine to accelerate to start discon- Sleep/Awake Mode: In the Sleep mode, the con-
nect speed. On reaching that speed, the control will trol’s operating software is inactive and the LEDs
ramp the generator set to idle (warm-up) or rated and the graphical display on the control panel are all
speed and voltage. off. Sleep mode is a feature that is used to reduce
battery power consumption when the control is not
On reaching rated speed and voltage, the control being used.
checks the system bus voltage. If no bus voltage is
In Off mode, Sleep mode is activated when there
present, it will wait for a pulse from a remote Master
are no unacknowledged faults and Screen Saver
First Start Sensor. On receiving that pulse, the con-
mode is active.
trol will signal the paralleling breaker to close.
In Auto mode, Sleep mode can be enabled or dis-
If bus voltage is present, the control will check for abled. When shipped from the factory, it is disabled.
proper phase rotation, adjust the generator set to You can enable Sleep mode by making these
the bus voltage and frequency level, and then syn- changes:
chronize the generator set to the system bus. When
a synchronous condition is achieved, the control will  Use InPower service tool to set Auto Sleep Enable
to Sleep in Auto.
send a signal to close the paralleling breaker.
 Set switch S1 on the Genset/Paralleling Card to
When the paralleling breaker is closed, the genera- Sleep/Off. This switch is located next to connector
tor set will assume it’s proportional share of the total J8 and relay K9.
load on the system bus. If these conditions are not met, Sleep mode is dis-
abled in Auto mode.
CONTROL PANEL POWER ON/OFF
Note: The graphical display can enter Screen Saver
MODES mode even if Sleep mode is disabled.
The power on/off modes of the control panel and op- If Sleep mode is enabled in Auto mode, Sleep mode
erating software are Power On, Screen Saver and is activated when there are no unacknowledged
Sleep/Awake. faults and Screen Saver mode is active.

The operating software is initialized and the control  Modem RI latch becoming active.
panel LEDs and graphical display are turned on in
 Digital display waking up.
response to one of the following:
 Lonworks (backplane) wakeup becoming active.
 Moving/pressing any control panel switch/button. (If  Customer fault 2 or 3 only (shutdown or warning in-
Sleep mode is enabled in Auto mode, the control will
dicator is on).
remain asleep if Sleep mode was previously active
in Off mode.)  Dial Out process becoming active.
 Receiving a remote start input signal (generator set To activate the control and view the menu display
in Auto mode) without starting the generator set, press any button
 Receiving an active DCD signal on the RS-232 port. on the control panel.
OPERATOR SWITCH PANEL

PANEL
REMOTE START,
NOT IN AUTO,
ANALOG AC PANEL LAMP/ FAULT SHUTDOWN, EMERGENCY
METERING LAMP TEST ACKNOWLEDGE WARNING STOP PUSH
PANEL BUTTON BUTTON STATUS BUTTON
INDICATORS
GRAPHICAL 0/MANUAL/AUTO
DISPLAY SWITCH
DISPLAY MENU EXERCISE MANUAL
SELECTION BUTTON & RUN/STOP
BUTTONS (1 OF 6) INDICATOR BUTTON &
INDICATOR
FIGURE 2-1. CONTROL PANEL ASSEMBLY (FULL-FEATURED)

CONTROL PANEL ASSEMBLY Scales for each function are in % of nominal values.
Resolution is 1% for values close to nominal, and in-
The control panel assembly (Figure 2-1) consist of creases at values further from nominal.
two panels, the Operator Panel and the Switch Pan-
el. Graphical Display: The graphical display is capa-
ble of displaying up to 9-lines of data with approxi-
Dependent on site requirements, the Operator Pan- mately 27 characters per line. The display is used to
el is either mounted on the control panel assembly view the menus of the menu-driven operating sys-
(full-featured) as shown in Figure 2-1 or contained in tem.
a separate enclosure and mounted remotely of the
control panel assembly.
The top three lines of the graphical display contain
Note: The function of several buttons on the control the following control information in the order de-
panel will vary dependent on the location of the con- scribed:
trol panel (remote or local of the control panel assem-
bly). If the function differs, it is noted as either “re-  State Line − modes of operation, such as Stopped,
mote” or “local operator panel” in the button descrip- Time Delay To Start, Warm Up At Idle, etc. (see Fig-
tion. ure 2-2), and paralleling operations, such as Stand-
by, Dead BUS Close, Synchronize, Load Share and
Operator Panel Load Govern.
 Action Line − system actions, such as Warning, Der-
The operator panel contains the following compo- ate, Shutdown Cool-down and Shutdown, and fault
nents: codes.
Analog AC Metering Panel: This panel simulta-  Description Line − Fault code messages.
neously displays 3-phase line to line AC volts and
current, kW, power factor and frequency. Display Menu Selection Buttons: Six momentary
buttons—three on each side of the graphical display
The meter panel is composed of a series of LEDs, window—are used to navigate through the system
that are configured in bar graphs for each function. control menus and to adjust generator set parame-
The LEDs are color coded, with green indicating ters. The button is active when the message adja-
normal range values, amber for warning levels and cent to the button is highlighted (displayed in in-
red for shutdown conditions. verse video).

Switch Panel Fault Acknowledge: Press this button to acknowl-
edge warning and shutdown messages after the
The switch panel contains the following compo- fault has been corrected.
nents:
To acknowledge a Warning message, the 0/Manual/
Emergency Stop Button: Push the button in for Auto switch can be in any position. (It is not neces-
emergency shutdown of the engine. If the engine is sary to stop the generator set to acknowledge an in-
not running, pushing the button in will prevent the active Warning condition.) To acknowledge a shut-
starting of the engine, regardless of the start signal down message with this button, the 0/Manual/Auto
source (local or remote). switch must be in the 0 (Off) position.
To reset: This button is also used to blink a fault code if the
1. Pull the button out. Shutdown or Warning Status Indicator is lit. (This
2. Move the 0/Manual/Auto switch to 0. function is used when the control does not contain a
3. Press the front panel Fault Acknowledge graphical display.) Refer to Reading Fault Codes in
button. this section, which describes how to use this button
4. Select Manual or Auto, as required. for interpreting fault codes.
Remote Start Indicator: This green lamp is lit Panel Lamp/Lamp Test Button: Press this button
whenever the control is receiving a remote run sig- to turn on or off the panel lamp. Press and hold down
nal. When flashing, it indicates a load demand stop
this button for three seconds or more to turn all con-
mode. trol panel LEDs on to make sure all lamps illuminate.
Not in Auto Indicator: This red lamp flashes con- The illumination will shut off after releasing the but-
tinuously when the 0/Manual/Auto switch is not in ton.
the Auto position. (If in Auto position and lamp is Exercise Button: Press this button to initiate a pre-
flashing, service is required.) programmed exercise sequence. To start the exer-
cise sequence, press and hold down the Exercise
Shutdown Status Indicator: This red lamp is lit
button and move the O/Manual/Auto switch from
whenever the control detects a shutdown condition.
Auto to Manual and back to Auto or from Manual to
The generator set can not be started when this lamp
Auto.
is on. After the condition is corrected, shutdown indi-
cators can be reset by turning the 0/Manual/Auto Manual Run/Stop Button: This button starts and
switch to the 0 position, and pressing the Fault Ac- stops the set locally and will bypass Time Delay to
knowledge button. Start and Stop sequences. The 0/Manual/Auto
switch must be in the Manual position to enable this
Dependent upon the specific fault that occurs, the
button.
engine may or may not shut down immediately. A
fault that could cause engine damage, causes an 0/Manual/Auto Switch: Manual position enables
immediate engine shutdown (bypasses engine the use of the switch panel Manual Run/Stop button.
cool-down sequence). All other faults would allow
the engine to run during the cool-down sequence Auto position enables start/stop control of the en-
before engine shutdown. In this case, the Shutdown gine from a remote location. (Disables the use of the
Status Indicator blinks during the cooldown period. switch panel Manual Run/Stop button.)
Warning Status Indicator: This yellow lamp is lit 0 (Off) position prevents the starting of the set (local
whenever the control detects a warning condition. or remote). If moved to 0 during set operation, will
After the condition is corrected, warning indicators cause an immediate engine shutdown (bypasses
can be reset by pressing the Fault Acknowledge cool-down timers). This hot shutdown should be
button. (It is not necessary to stop the generator set avoided, if possible, to help prolong the life of the en-
if the fault becomes inactive during genset opera- gine. Hot shutdowns are logged by the system soft-
tion.) ware.

READING FAULT CODES A three digit fault code is indicated by three sets of
blinks separated by a two second pause. The first
If the genset contains the optional graphical display set corresponds to the hundreds position, the sec-
and a fault occurs, the fault code/message will be ond to the tens position and the third to the ones dig-
displayed in the display Description Line (Figure it. Example for Code No. 213:
2-2). If the control does not contain the graphical
display, the fault code is read from the Warning and Shutdown LED:
Shutdown status indicators. blink-blink-pause-blink-pause-blink-blink-blink
Warning LED:
Reading Fault codes Using Warning/Shutdown
blink (2 seconds)
Indicators: If the Warning or Shutdown status indi-
cator is lit, press and hold the Fault Acknowledge The light will display the fault codes (active or inac-
button and release after one second or more. After tive) in succession, starting with the most recent. Up
one second, the Shutdown lamp will begin to blink to 32 (unacknowledged) fault codes can be stored in
the active fault code(s) as follows. control panel memory.
The Warning lamp is used to indicate the start of a To return the control to the most recent fault code,
new code. The Warning lamp will remain on for 2 press and release the Fault Acknowledge button
seconds, followed by the Shutdown lamp blinking (less than one second) and repeat procedure.
the fault code. This sequence occurs three times for
each code. The fourth flash of the Warning lamp in- When the fault code is acknowledged and cor-
dicates the beginning of the second fault code. rected, the recorded fault will be deleted from the
LED fault log, but will remain in a data log that main-
There are distinct pauses between repetitions of the tains a fault code history. (The InPower service tool
code blink transmissions of the Shutdown lamp. is required to view this data log.)

MENU DISPLAY AND SWITCHES Menu Buttons: Six momentary buttons—three on
each side of the graphical display window—are
Figure 2-2 shows the graphical display and the used to navigate through the system control menus
menu selection buttons. and to adjust generator set parameters. The button
is active when the message or symbol adjacent to
Graphical Display: The graphical display is capa- the switch is highlighted (displayed in inverse vid-
ble of displaying up to 9-lines of data with approxi- eo). The displayed message or symbol indicates the
mately 27 characters per line. The display is used to function of the button.
view the menus of the menu-driven operating sys-
tem. Refer to the menu trees later in this section. Note: In the graphical display, the “B” symbol indi-
cates that selecting the adjacent button causes the
The display is also used to show the following sys- operating program to go to the next menu display—
tem information: as shown in the menu diagrams.
 State Line − modes of operation, such as Stopped, Note: In the graphical display, the “Y” symbol indi-
Time Delay To Start, Warm Up At Idle, etc., and par- cates that selecting the adjacent button causes the
alleling operations, such as Standby, Dead BUS operating program to go back to the previous menu
Close, Synchronize, etc. display.
 Action Line − system actions, such as Warning, Der-
ate, Shutdown Cool-down and Shutdown, and fault Note: In the graphical display, the “ ” symbol indi-
codes. cates that selecting the adjacent button causes the
operating program to go back to Main Menu A (Figure
 Description Line − Fault code/status messages. 2-4).
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU DISPLAY
AREA
GRAPHICAL
DISPLAY
MENU MENU
BUTTONS BUTTONS
FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

LANGUAGE/UNITS SELECTION MENU Temp: Used to select F or C for temperature read-
ings.
During any control panel operation, you can select
one of three languages and change how units are Pressure Fluid: Used to select PSI, KPA, BAR or IN
displayed by pressing the two lower menu buttons for pressure readings.
(one on each side of display). When pressing these
two buttons simultaneously, the language/units Pressure Gas: Used to select INHG or MMHG for
menu will appear (Figure 2-3). After making desired pressure readings.
selections, press the ENTER button in this menu to
change and save the selections. Flow Air: Used to select CFM or CMM for air flow
readings.
Note: Use the + buttons to select the desired option
for each field. Use the arrow () button to move to the
next field. Selected field is highlighted.
Language: Used to select desired language (de-

fault = English). LANGUAGE ENGLISH
+ LOCATION LOCAL
Location: This selection must be set to Local when TEMP F ENTER
the graphical display is mounted on the generator PRESS FLD PSI
set front control panel or Remote when mounted re-  PRESS GAS INHG
FLOW AIR CFM
motely from the generator set.
The Local/Remote selection determines which but-

tons in the Control submenu (page 2-13) are active
(displayed). FIGURE 2-3. LANGUAGE/UNITS MENU

MAIN MENU _\_ Button (Paralleling Applications Only)
Figure 2-4 shows the main menus (Menu A and
When displayed, indicates that the feature for gen-
Menu B) of the system control. The two main menus
erator set paralleling applications is installed. This
are used to divide the system submenus into major
button is used to open and close the generator set
categories, such as, Engine Data, Alternator Data,
circuit breaker (CB). The symbol indicates if the CB
Control, etc.
is opened or closed. Opened _\_, push to close.
To view system data, simply press the appropriate Closed _−_, push to open.
menu button to select the category. After pressing
the desired menu button, refer to the page number With the control panel 0/Manual/Auto switch in the
shown in Figure 2-4 for detailed information related Auto position, the opening and closing of the CB is
to the selected category. controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
Note: In the following figures, the boxed/highlighted button will be inactive when the control is in Auto.
field indicates that the adjacent menu button is ac-
tive. Also, the submenus are shown in the order in
which they are displayed when scrolling up Y or In the Manual position, the CB can only be closed
down B. by using this button. When manually closed and the
CB opens, it must be closed again by using this but-
Adjust Button ton. To close the CB, press and hold the button until
the symbol indicates a closed CB. (CB close will oc-
The Adjust submenu is intended for qualified site cur only when setup conditions allow − dead bus or
personnel only. Note that a password may be as- generator synchronized with bus.)
signed to allow only authorized operators to modify
this data. (Password is not required if not assigned.)
Power Trans Button (Power Transfer
Setup Button Control Applications Only)
The Setup submenu is described in Section 3.
When displayed, indicates that the Power Transfer
Note: The “Adjust” and “Setup” submenus can be Control (PTC) feature is installed. Refer to page
viewed, but not modified without entering the correct 2-17 for PTC Data submenu description. The PTC
passwords. setup submenu is described in Section 3.

MENU A
MENU MENU
BUTTONS PAGE MENU BUTTONS
2-10 B
ENGINE MORE>>
PAGE ALTERNATOR POWER TRAN OR _\_ PAGE
2-11 CONTROL HISTORY/ABOUT 2-16
PAGE PAGE
2-12 2-13
MENU B
SECTIO
N3
ADJUST
PARALLEL DATA PAGE
SETUP BACK<< 2-15
GRAPHICAL
SECTIO DISPLAY MENU
N3 A
FIGURE 2-4. SYSTEM CONTROL MAIN MENUS A AND B

ENGINE SUBMENUS
If you press the “ENGINE” button in Menu A, the En-

gine submenus will appear (Figure 2-5). ENGINE
The first submenu displays general information that
applies to all gensets (coolant temp, oil pressure,
etc.) The data in the remaining submenu(s) will vary
according to the type and number of sensors pro- COOLANT TEMP 180 F
vided with the engine. OIL PRESSURE 75 PSI Y
ENGINE SPEED 1800RPM
BATTERY 29.1 VDC B
MANF TEMP 75 F
MANF PRESS ABS 180 INHG Y
RAIL PRESS ABS 180 PSI
PUMP PRESS ABS 291 PSI B
FUEL INLET TEMP 172 F
COOLANT PRESSURE 59 PSI
BLOWBY FLOW 25 CFM

TIMING PRESS 50 PSI Y
AFTERCOOLER TEMP 76  F
AMBIENT PRESS 88 INHG
FIGURE 2-5. ENGINE SUBMENUS

ALTERNATOR SUBMENUS
If you press the “ALTERNATOR” button in Menu A,

the Alternator Data submenus will appear (Figure ALTERNATOR
2-6).
Voltage L-L and L-N: Indicates voltage Line-to Line

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire V L-L L-N AMPS
system. Accuracy 1%. L1 480 277 1340 Y
L2 480 277 1290
L3 480 277 1260 B
The voltage Line-to-Line (L1, L2 and L3) are mea-
FREQUENCY 60.0 HZ
sured between L1 to L2, L2 to L3 and L3 to L1, re- AVR DUTY CYCLE 10.3 %
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.

KW KVA PF
AVR DUTY CYCLE: Displays voltage regulator L1 350 500 .80 Y
(drive) level in percentage of maximum. L2 350 500 .80
L3 350 500 .80
TOT1050 1500 .80
kW, kVA and PF: Displays generator set kW and
kVA output (average and individual phase, and di-
rection of flow) and power factor with leading/lag-
ging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the FIGURE 2-6. ALTERNATOR SUBMENUS
power factor is leading (for example,
*.30).

CONTROL SUBMENU
If you press the “CONTROL” button in Menu A, the location. This button sequentially lights the LEDs to
Control submenu will appear (Figure 2-7). test the bar graph display.
Local CONTROL Submenu Function Enable Sync: Displayed in paralleling applications

only. Intended for service personnel to turn off the
When the operator panel is mounted on the control synchronizer for troubleshooting/testing purposes.
panel assembly, the Run Mode Idle/Rated button is
active (displayed). Note in Figure 2-7 that this button
is not displayed in remote applications. CONTROL
(LOCAL)
The shaded area in Figure 2-7 displays the se-
lected/active mode of operation, either IDLE or
RATED.
Remote CONTROL Submenu Functions

+ RUN MODE IDLE Y
When the operator panel (Figure 2-1) is mounted re- B
motely of the control panel assembly, the menu but- ENABLE SYNC
tons in the Control submenu are used to perform the
following remote operations. (To activate these
menu buttons for remote/local use, refer to page
2-8.)
Note: The 0/Manual/Auto switch must be in the Auto

position to activate the Remote Menu Buttons of the BARGRAPH TEST Y
Control submenu.
Remote START or STOP Button: This button is

used to start and stop the generator set when the
operator panel is mounted in a remote location.
CONTROL
(REMOTE)
When the generator set is operating, Stop will be
displayed for this button and Start will be displayed
when not operating.
When the generator set is operating in the Remote

Start mode, removing the Remote Start command START GENSET Y
does not shut off the engine if the load is 10 per cent, FAULT ACKNOWLEDGE B
the cooldown timer is set to zero, and the control is
ENABLE SYNC
configured for a single unit (not in parallel). The gen-
erator set continues to operate until it runs out of
fuel, the E−stop button is used, or the load is re-
moved.
Fault Acknowledge Button: Used to reset inactive

Warning messages, not Shutdown messages. BARGRAPH TEST Y
Local/Remote CONTROL Submenu

Function
Bargraph Test: The function of this button remains

the same and is not dependent on operator panel FIGURE 2-7. CONTROL SUBMENU

HISTORY/ABOUT SUBMENUS
If you press the “HISTORY/ABOUT” button in Menu

A, the History/About submenus will appear (Figure HISTORY/ABOUT
2-8).
HISTORY: The control maintains a data log of the

number of engine starts and number of operating
hours for the engine and control, and the megawatt STARTS 533
and maximum torque hours of the generator set. ENGINE HOURS 1236 Y
This information is stored in non-volatile memory CONTROL HOURS 7879
KWHRS 890 B
and will not be deleted due to loss of battery power.
ABOUT: The About submenus provide the following

generator set information.
 Genset model and wattage (kW/MW)
 Output voltage and WYE, DELTA or SINGLE
HISTORY-HRS@ %MAX TORQUE
 Frequency 50 or 60 Hz 12345@0-9 23455@50-59 Y
12345@10-19 12345@60-69
 Rating: Standby, Prime or Base 12345@20-29 12345@70-79 B
12345@30-39 12345@80-89
 Version level of the controller and panel operating
software.
MODEL 1750DQKB Y
VOLTAGE 416 WYE
FREQUENCY 60 B
RATING STANDBY
CONTROLLER VERSION
RTOP DN30008.DFA Y
BATS APR 23 1999
OP PANEL VERSION B
RTOP 1.09 AUG 17 1999
BATS 1.02 MAY 6 1999
CONTINUED TO NEXT PAGE
FIGURE 2-8. HISTORY/ABOUT SUBMENUS

HISTORY/ABOUT SUBMENUS (CONT.)
FAULT HISTORY: The control maintains a data log

of all fault conditions as they occur, and time stamps HISTORY/ABOUT (CONT.)
them with the control and engine operating hours.
Up to 32 (unacknowledged) fault codes can be

stored in control panel memory. After the fault is ac-
knowledged and corrected, the recorded fault will FAULT HISTORY: 1 OF 24
be deleted from the control panel memory, but will + CNTL HOURS 459 Y
OCCURRENCES 5
remain in a data log that maintains a fault code his- ENGINE HOURS 334
tory. (The InPower service tool is required to view FAULT CODE 1437
this data log.) (FAULT DESCRIPTION)
The Fault History display line: 1 of 24 indicates that

24 faults are recorded and that the most recent fault
(1) detected by the controller is displayed. FIGURE 2-9. HISTORY/ABOUT SUBMENUS (CONT.)
The Occurrences display line: In this example, 5 in-

dicates that this is the fifth occurrence of this fault.
(The InPower service tool is required to review the
last four faults of this code.)
Note: The Occurrences number is incremented for

each new occurrence of the same fault. The control-
ler must detect that the original sensed fault is cor-
rected before it will increment the occurrence num-
ber for that fault.
Note: For example, when a Low Oil Pressure fault is

detected, the controller will increment the Occur-
rences number by 1. This fault will remain active until
the fault is acknowledged and the controller detects
that the fault is corrected. An active fault will prevent
the controller from incrementing the Occurrences
number each time the engine is started. When the
controller detects that the oil pressure is normal the
fault will become inactive, allowing the occurrences
number to be incremented for the next detected Low
Oil Pressure fault.

PARALLEL DATA SUBMENU
If you press the “PARALLEL DATA” button in Menu _\_ Button: Used to open and close the generator
B, the Parallel Data submenu will appear (Figure set circuit breaker (CB). The symbol indicates if the
2-9). This menu is displayed in paralleling applica- CB is opened or closed. Opened _\_, push to close.
tions only. Closed _−_, push to open.
PARALLEL DATA STATUS LINE: The top line of With the control panel 0/Manual/Auto switch in the
the graphical display is used to indicate the follow- Auto position, the opening and closing of the CB is
ing PARALLEL DATA status: controlled by the control system software. The CB
symbol will indicate an open or closed CB, but the
− STANDBY: Indicates no paralleling activity is occur- button will be inactive when the control is in Auto.
ring at present.
− DEAD BUS CLOSE: Indicates first genset in system In the Manual position, the CB must be closed by
to close to bus. this button. When manually closed and the CB
− SYNCHRONIZE: Genset is synchronizing to bus. opens, it must be closed again by using this button.
− LOAD SHARE: Genset has closed to bus and is To close the CB, press and hold the button until the
sharing load with other gensets in system. symbol indicates a closed CB. (CB close will occur
− LOAD GOVERN: Genset closed to bus in parallel only when setup conditions allow − dead bus or gen-
with utility (mains). erator synchronized with bus.)
BUS Voltage L-L: The BUS voltage Line-to-Line
(L1, L2 and L3) are measured between L1 to L2, L2
PARALLEL DATA
to L3 and L3 to L1, respectively.
BUS/GEN HZ: BUS/GEN hertz.

LOAD GOVERN
BUS/GEN SYNC STATUS: The bottom line of the V BUS GEN
graphical display is used to indicate the following L1 480 480 Y
BUS/GEN Sync status: L2 480 480
L3 480 480 _\_
− NOT SYNCHRONIZING: Genset is in service mode HZ60.1 60.1
that does not allow auto sync feature. (Selected via DEG −122 NOT SYNCHRONIZING
InPower service tool − deactivate to allow synchro-
nization.)
− SYNCHRONIZING: Genset is synchronizing to bus.
− READY TO CLOSE: In manual mode, push circuit
breaker close button to close breaker. FIGURE 2-10. BUS DATA SUBMENU

POWER TRANSFER MAIN/SUBMENUS
If you press the “POWER TRANS” button in Menu The symbol displayed in the middle of the Power
A, the Power Transfer main menu will appear (Fig- Transfer main menu indicates which breaker (utility
ure 2-10). The Power Transfer Control (PTC) fea- or genset) is closed/opened to the load. The symbol
ture must be installed to display this menu. presently shown indicates that the utility breaker is
closed and supplying power to the load.
The PTC feature enables the PCC to monitor the
utility voltage (mains) and frequency for failure and The Power Transfer main menu also indicates if the
control the opening and closing of the contacts (cir- utility and the generator set are available to accept
cuit breakers) for the utility (S1) and the genset (S2). load. When the control detects that either source is
ready to accept load, UTILITY and/or GENSET will
If utility fails, the control will initiate the genset start- be displayed in inverse video.
ing sequence, open S1 and close S2 to the load.
When utility returns, the load is retransferred to the The Power Transfer main menu has four submenu
utility (S1 closes/S2 opens) and the control initiates groups. Refer to the page numbers shown in Figure
the genset shutdown sequence. 2-10 for the Power Transfer submenu descriptions.

PTC Status Line to run even if a genset warning or derate fault oc-
curs. This test can be performed with or without load
The top line of the graphical display is used to indi- (refer to TEST/EXERCISE submenu in Section 3).
cate the following PTC status: − TEST: Test sequence initiated through Remote Start
switch with emergency start sequence disabled
− NOT ENABLED: PTC is not enabled. Control panel
(TB8-3 terminal closed). Test mode is non-emer-
switch in O (Off) position.
gency, which means that a retransfer to utility will oc-
− MANUAL: Control panel switch is in Manual posi- cur if any problems occur with the genset while test-
tion. All PTC actions or genset start/stop actions are ing with load. This test can be performed with or
manually controlled. without load (refer to TEST/EXERCISE submenu in
− NORMAL UTIL: Load is connected to the utility. Section 3).
− RETRAN: Retransfer of load to utility. − EXERCISE: Exercise sequence initiated through
− RETRAN OVRD: Immediate retransfer of load to control panel. This test can be performed with or
utility due to genset fault (e.g., warning, derate, or without load (refer to TEST/EXERCISE submenu in
shutdown w/cooldown fault). The retransfer timer is Section 3). A retransfer to utility will occur if any
ignored as is the retransfer inhibit. problems occur with the genset during the exercise
− EMERG TEST: Emergency Test sequence initiated sequence.
through Remote Start switch with emergency start − UTILITY FAIL: Utility has failed. (Initiates transfer of
sequence enabled (TB8-3 terminal opened). Emer- load to genset if O/MANUAL/AUTO switch is in
gency test mode means that the genset will continue AUTO.)
MENU MENU
BUTTONS PAGE PTC STATUS LINE PAGE BUTTONS
2-18 2-21
B UTILITY GENSET B
PAGE STATUS
2-19 TRANSFER CONTROL
DEG −123 SYNCHRONIZING
PAGE MENU
2-20 A
FIGURE 2-11. POWER TRANSFER MAIN MENU

UTILITY (PWR TRAN) SUBMENUS
If you press the “Utility” button in the Power Transfer Note:

Main menu, the Utility submenus will appear (Figure
2-11). UTILITY
Voltage L-L and L-N: Indicates utility voltage Line-

to Line and Line-to-Neutral. Note that the Line-to-
Neutral column will not be displayed for a 3 phase/3
wire system. Accuracy 1%. UTILITY:
V L-L L-N AMPS Y
L1480 277
L2480 277 1320 B
The voltage Line-to-Line (L1, L2 and L3) are mea-
sured between L1 to L2, L2 to L3 and L3 to L1, re- L3480 277
FREQUENCY 60.0 HZ
spectively.
Amps: L2 only. Accuracy 1%.
Frequency: Utility frequency. UTILITY:

KW KVA PF Y
L1
kW, kVA and PF: Displays (L2 only) utility kW and L2 125 175 .96
kVA output (average and direction of flow) and pow- L3
er factor with leading/lagging indication. Accuracy TOT
5%.
Note: The PF reading will contain an asterisk if the

power factor is leading (for example, *.30). FIGURE 2-12. UTILITY SUBMENUS

STATUS (PWR TRAN) SUBMENUS
If you press the “Status” button in the Power Trans- Retransfer inhibit is controlled by connecting a re-
fer Main menu, the Status submenus will appear mote contact between TB3-64 and TB3-65. Closing
(Figure 2-12). the contact enables the feature and opening the
contact disables it. When enabled, the event is dis-
Connected: Indicates which source(s) is con- played on the graphical display.
nected to the load.
Available: Indicates when the corresponding

sources have acceptable output voltage and fre-
quency. Both can be available simultaneously. STATUS
Volt L12: Indicates utility and generator set Line 1 to

Line 2 voltage.
HZ: Utility and generator set output frequency. UTIL GEN

CONNECTED YES NO Y
KW L2: Utility and generator set Phase B (L2) kW AVAILABLE YES NO
VOLT L12 480 N0 B
output.
HZ 60.0 0.0
KW L2 456 0
Transfer Inhibit: This feature is used to control load
transfer to the genset. When activated, load transfer
to the genset will not take place if the utility fails.
Transfer inhibit is controlled by connecting a remote

contact between TB3-57 and TB3-58. Closing the TRAN INH OFF
contact enables the feature and opening the contact RETRAN INH ON Y
disables it. When enabled, the event is displayed on
the graphical display.
Retransfer Inhibit: This feature is used to prevent

the PTC from automatically transferring the load
back to the utility. When activated, load transfer will
not take place unless the genset fails (Retransfer In-
hibit is ignored if the genset fails). FIGURE 2-13. STATUS SUBMENUS

TRANSFER CONTROL (PWR TRAN) SUBMENU
If you press the “TRANSFER CONTROL” button in

the Power Transfer Main menu, the Transfer Con- TRANSFER CONTROL
trol submenu will appear (Figure 2-13).
The symbol displayed in the middle of the

TRANSFER CONTROL submenu indicates which
breaker (utility or genset) is closed/opened to the UTILITY GENSET
load. The symbol presently shown indicates that the
CB ENABLE CB ENABLE
utility breaker is closed and supplying power to the
load. << BACK
During genset operation in the manual mode, you

can manually transfer/retransfer load between the
utility and the genset. To transfer load, press the ap-
propriate CB ENABLE button (Utility or Genset).
Example (Figure 2-13) ENABLE UTIL CB
In the example in Figure 2-13, the CB ENABLE but-

CANCEL
ton for “Utility” was pressed. (If the CB ENABLE
button for the “Genset” was pressed, ENABLE GEN
CB would be displayed in the second submenu, al-
lowing you to open or close the genset circuit break-
er.)
After pressing the “utility” CB ENABLE button, the UTILITY GENSET

second submenu will be displayed allowing you to
either CANCEL or ENABLE the entered selection. OPEN UTIL CB ENABLE
<< BACK
Pressing the CANCEL button will return the display
to the previous menu.
Pressing the ENABLE button will display the third

submenu. With this submenu displayed you can re-
turn to the second submenu without opening the
UTILITY GENSET
utility circuit breaker (press <<BACK) or you can
press the OPEN UTIL button. CLOSE UTIL CB ENABLE
Pressing the OPEN UTIL button will display the << BACK
fourth submenu, indicating that the utility circuit
breaker is now opened.
Note that the fourth submenu displays CLOSE

UTIL. Pressing this button will close the utility circuit FIGURE 2-14. TRANSFER CONTROL
breaker and redisplay the third submenu. SUBMENUS

GENSET (PWR TRAN) SUBMENUS
If you press the “Genset” button in the Power Trans-

fer Main menu, the Genset submenus will appear GENSET
(Figure 2-14).
Voltage L-L and L-N: Indicates voltage Line-to Line

and Line-to-Neutral. Note that the Line-to-Neutral
column will not be displayed for a 3 phase/3 wire GENSET:
system. Accuracy 1%. VL-L L-N AMPS Y
L1480 277 1320
L2480 277 1320 B
The voltage Line-to-Line (L1, L2 and L3) are mea- L3480 277 1320
sured between L1 to L2, L2 to L3 and L3 to L1, re- FREQUENCY 60.0 HZ
spectively.
Amps: All phases. Accuracy 1%.
Frequency: Generator set output frequency.

GENSET:
KW KVA PF Y
kW, kVA and PF: Displays generator set kW and L1 100 150 .97
kVA output (average and individual phase, and di- L2 125 175 .96
rection of flow) and power factor with leading/lag- L3 150 200 .95
TOT375 525 .96
ging indication. Accuracy 5%.
Note: The PF reading will contain an asterisk if the

power factor is leading (for example,
*.30). FIGURE 2-15. GENSET SUBMENUS


3. Control Calibration and Adjustment
GENERAL
This section contains calibration and adjustment
procedures for the generator set control. CAUTION If the base card has software as-
sembly A026 F566 v1.0 on the U33 flash memory
PARALLELING AND NON−PARALLELING chip, you must use the latest software calibra-
If the generator set was purchased for a paralling tion for the control, or the board will lock up per-
application but will be used for a non−paralling ap- manently.
plication, entering the checksum data into the Data-
plate Checksum dialog in InPowert is not re-
quired. However, the Adjustments Paralleling − Par- MODIFYING SETUP/ADJUST SUBMENUS
alleling Level must be set to Basic.
SOFTWARE CALIBRATIONS The Setup and Adjust submenus allow you to cali-
brate the graphical display meters and to adjust sys-
If the base card has software assembly A026 F566 tem parameters, customer defined faults, generator
v1.0 on the U33 flash memory chip, you must use
set voltage/frequency and paralleling applications.
the latest software calibration for the control. If you
load an earlier software calibration onto a base card
with software assembly A026 F566 v1.0, the soft- CAUTIONImproper calibration or adjustment
ware calibration will fail, and the board will lock up
of the control can cause equipment malfunction
permanent-
ly. or damage. Calibration and adjustment must be
performed by technically qualified personnel
only.
The Setup submenus are intended for qualified ser-

vice personnel only. The Adjust submenu is in-
tended for qualified service and site personnel only.
For this reason, a password must be entered before
this data can be modified. The Setup and Adjust
submenus can be viewed, but not modified without
entering the correct password.
Saving Menu Changes
Changes are automatically saved when the menu is

FIGURE 3-1. U33 FLASH MEMORY CHIP exited.

PASSWORD Menu After entering the correct password, the system will
allow you to modify the submenus. To help prevent
To allow the site personnel to modify only the Adjust unauthorized adjustment, the entered password is
submenu and not the Setup submenus, two pass- valid for 10 minutes after the last button is pressed
words are assigned within the system software. An (i.e., the password will need to be reentered after
Application password is used for the Setup subme- the ten minute time−out.
nus and a User password is used for the Adjust sub-
menu. Entering Password
The two passwords are assigned during the initial To enter the password:
installation of the generator set (via InPower) and
will vary between sites. The installer must make 1. Display submenu to modify.
sure that the passwords are available to the ap- 2. Press either the + or − button within the displayed
propriate personnel. submenu. The Password menu appears.
3. Press the + and − button to select the first character
Note: When the generator set is first installed, the Ap- of the password (A−Z or 0−9). (Enter Application
plication and User password are both set to GENSET password for Setup submenus; Enter User pass-
to allow initial modification of the Setup and Adjust word for Adjust submenu.)
submenus. Assign new passwords when site instal- 4. Press the  button to select the next character field.
lation is complete. Selected character field is highlighted.
When viewing the Adjust menu, pressing the + or − 5. Repeat steps 3 and 4 to enter remaining password
button will display the User Password menu. characters.
6. Press the Enter button after entering the password.
When viewing a Setup menu, pressing the + or − The submenu selected in step 1 will reappear.
button will always display the Application Password 7. After making desired changes to submenu, exit sub-
menu. menu to save changes.
+ OR − BUTTON + OR − BUTTON
ENTER APPLICATION ENTER USER PASSWORD

PASSWORD
+ ENTER + ENTER
− −
 XXXXXXXX  XXXXXXXX
SETUP SUBMENU PASSWORD MENU ADJUST SUBMENU PASSWORD MENU
FIGURE 3-2. PASSWORD MENUS

SETUP MENUS To view system data or to adjust system parame-
ters, press the appropriate Setup menu button to
display the desired Setup submenu(s). Refer to the
Menu B) of the system control and the two Setup
page number shown in Figure 3-3 for detailed infor-
menus.
mation related to the selected submenu(s).
The Setup procedure is intended for qualified ser-
vice personnel only. The APPLICATION password CAUTION Improper calibration or adjustment
must be entered to modify the Setup submenu of the control can cause equipment malfunction
fields. Refer to PASSWORD Menu in this section to or damage. Calibration and adjustment must be
enter password and to save menu changes. performed by technically qualified personnel
only.
To display the two Setup menus, press the
MORE>> button in Menu A and then the SETUP
button in Menu B.
MENU A MENU B
MENU
ENGINE MORE>> B ADJUST
ALTERNATOR POWER TRAN OR _\_ PARALLEL DATA
MENU
CONTROL HISTORY/ABOUT SETUP BACK<<
A
SETUP MENU 1
PAGE MENU
3-4 B
GOVERNING/VOLT REG Y
PAGE CUSTOMER FAULTS B NEXT
3-5 MENU
CALIBRATION
PAGE MENU
3-6 A
SETUP MENU 2
PAGE ABOVE
3-12 MENU
POWER TRANSFER SETUP Y

PAGE ISOLATED BUS
3-7 UTILITY
PAGE MENU
3-11 A
FIGURE 3-3. SETUP SUBMENUS

GOVERNING/VOLT REG SUBMENU
If you press the “GOVERNING/VOLT REG” button

in the Setup menu, the Governing/Volt Regulator GOVERNING/VOLT REG
submenu will appear (Figure 3-4).
Note: Use the + and − buttons to increase or decrease

the values in the following fields. Use the arrow ()
button to move the cursor within a field or to the next
field. Exit menu to safe changes. + Y
GOV GAIN 80%
− AVR GAIN 100%
GOV GAIN: If the gain adjustment is set too high,
engine speed will “hunt” or oscillate. If gain is set too 
low, the engine will respond too slowly to changes in
load and overspeed may result. (Gain should be re-
duced to 80% for paralleling installations.)
FIGURE 3-4. GOVERNING/VOLT REG SUBMENU
AVR GAIN: If the gain adjustment is set too high,
output voltage will be unstable. If gain is set too low,
the output voltage will respond sluggishly to
changes in load and overshoot may result.

CUSTOMER FAULTS SUBMENUS
If you press the “CUSTOMER FAULTS” button in Use the  button to move to each character position
the Setup menu, the Customer Faults submenus within the fault message line.
will appear (Figure 3-5).
With the desired character position selected, use +
There are a total of four customer fault inputs. or − buttons to select the appropriate character.
(Faults 3 and 4 paralleling only.) The message dis-
played at the bottom of the menu can be modified for Note: If these messages are changed, you should
note these changes in the Troubleshooting section
each of these faults in addition to selecting the fol-
of the Operator’s manual for this generator set.
lowing operating parameters for each fault.
 Enable − On or Off
CUSTOMER FAULTS
 Active − Closed or Open
 Response − Shutdown, Cooldown, Derate or
Warning
Shutdown: Genset will immediately shut down. CUSTOMER FAULT1:
Normally used for engine faults. + ENABLE ON Y
ACTIVE CLOSED
Cooldown: Cooldown sequence will be initiated be- − B
RESPONSE WARNING
fore shutdown. Should not be used for engine faults.

Derate: Used to lower kW output of genset for warn- ***CUSTOMER FAULT1 *******
ings such as pre-high coolant temperature, etc. Par-
alleling application − controller will reduce precen-
tage of kW load sharing on the set. Non-paralleling
application − controller will lower percentage of kW
load by operating load shed relay contacts.
CUSTOMER FAULT2:
Warning: Display message, genset continues to + Y
operate.
− B
RESPONSE WARNING
Note: The Enable and the Active fields apply to the 
Fault 1 and 4 submenus only. ***CUSTOMER FAULT2 ********
With the Active field selected, pressing the + or −

buttons will toggle the selection between CLOSED
CONTINUES THROUGH TWO
and OPEN. Use same operation for remaining field ADDITIONAL MENUS FOR A
selections. TOTAL OF FOUR POSSIBLE
CUSTOMER FAULT
To enter the desired customer fault message, press MESSAGES
the B or Y button to display the submenu that con-
tains the customer fault message (1 through 4) to be FIGURE 3-5. CUSTOMER FAULTS SUBMENUS
changed. Use the  button to scroll down through
the menu selections to the editable fault message
(bottom menu line).

CALIBRATION SUBMENUS
If you press the “CALIBRATION” button in the Setup

menu, the Calibration submenus will appear (Figure CALIBRATION
3-6).
VOLTAGE CALIBRATION
field. Exit menu to safe changes.
+ L1 480-X.X% Y
L2 480-X.X%
The Calibration submenus allow you to calibrate the − L3 480-X.X% B
control with the reading from a calibrated meter. 
Calibration is accomplished by using this section of
the menu software to adjust the display so that it
matches the reading taken on an accurate, recently
calibrated meter.
Calibration is normally only required when replacing CURRENT CALIBRATION

certain circuit cards. Refer to the Calibration Proce- + L1 234-X.X% Y
dure in this section which contains a list of the cards L2 123-X.X%
− L3 562-X.X% B
that require control calibration. 
Note: When performing Bus Voltage Calibration from

the graphical display, the genset must be off and the
Bus live. If the genset is running, it will synchronize
to the Bus.
BUS VOLTAGE CALIBRATION

+ L1 480 -X.X% Y
L2 480 -X.X%
− L3 480 -X.X%

FIGURE 3-6. CALIBRATION SUBMENUS

ISOLATED BUS / UTILITY Submenus can force the generator set to match bus voltage
(Paralleling Application) and frequency in a range of minus 40% to plus 10%
of normal bus conditions. When the paralleling
The Isolated BUS submenus (Figure 3-7) and the breaker has closed, the control will bring the gener-
Utility submenus (Figure 3-8) adjust the control pa- ator set back to normal voltage and frequency.
rameters for generator set protection, synchroniz-
ing and load sharing for both isolated bus and utility When the generator set is paralleled to another gen-
(mains) paralleling applications. Utility (mains) par- erator set, the control provides automatic load shar-
allel applications may require adjustment of both the ing functions for both real (kW) and reactive (kVAR)
Isolated BUS and Utility submenus. loads. Load sharing is proportional between gener-
ator sets based on their standby ratings. If two gen-
Note: Always perform ISO BUS calibration before erator sets of different sizes are paralleled, they will
Utility BUS calibration. assume the same percentage of the system load
automatically. This can easily be verified on the kW
The sync check (permissive) function is operational Load LED bar graph on the front of the control panel.
in both automatic and manual (RUN) modes. The
control will make sure that the generator set is at When the utility paralleling mode is enabled and the
proper voltage, within the defined sync check win- generator set paralleling breaker is closed, the gen-
dow for the defined period of time and that phase erator set will assume load based on external ana-
rotation is correct. When all criteria are met, the par- log input signal. The input signal must be calibrated
alleling breaker is closed automatically by the con- from 0−5 VDC. When the signal is at 0.5 to 1 VDC,
trol (auto mode), or by operation of the breaker the control will operate the generator at no load in
close switch by the operator (manual mode). parallel with the utility (mains) source. At 4.5 VDC
and greater, the control will operate the generator
The synchronizing function of the control is enabled set at 110% of the generator set base load setting.
when the control has brought the generator set to When the load govern signal is between 1 VDC and
90% of rated speed and voltage, and has sensed 4.5 VDC the control will operate the generator set at
that bus voltage is available. The control automati- a load level which is determined by a linear relation-
cally adjusts the generator set speed and voltage to ship between the kW reference and the load govern
match the bus frequency and voltage. The control signal.

ISOLATED BUS SUBMENUS
If you press the “ISOLATED BUS” button in the Set- PERM WIN-TIME: Adjusts the time period (in sec-
up menu, the Isolated BUS submenus will appear onds) for which the generator set must be synchro-
(Figure 3-7). nized with the system bus, before a breaker close
signal is issued by the PowerCommand control.
Note: Use the + and − buttons to increase or decrease Available range is 0.5 to 5 seconds. Recommended
the values in the following fields. Use the arrow () value for PowerCommand generator sets is 0.5 sec-
button to move the cursor within a field or to the next onds for isolated bus applications.
field. Exit menu to safe changes.
SYNC TIME LIMIT: This parameter adjusts the time

ISOLATED BUS
delay in seconds before the Fail To Synchronize
alarm will operate.
REVERSE PWR LMT: Adjusts the reverse power

set point. For PowerCommand generator sets, a ISOLATED BUS:
typical set point is 10-15%. + SYNC TIME LIMIT 120 SEC Y
− REV PWR LMT 10% B
REV PWR TIME 3 SEC
REVERSE PWR TIME: Adjusts the reverse power  PERM WIN-PH 20 DEG
function time delay. A typical time delay which is PERM WIN-TIME 5 SEC
suitable for PowerCommand generator sets is 3
seconds.
CONTINUED TO NEXT PAGE
Note: Lower reverse power set points can result in
nuisance reverse power shutdown faults.
PERM WIN-PHASE: Adjusts the width of the per-

missive (sync-check) acceptance window. The ad- FIGURE 3-7. ISO BUS SUBMENUS
justment range is from five to twenty electrical de-
grees. Recommended set point is 20 degrees for
isolated bus applications, and 15 degrees for utility
(mains) paralleling applications.

Note: Adjusting the control for a smaller sync-check KW GAIN: Adjusts the rate of change of kW load on
window or longer time delay will cause synchroniz- the generator set. With a constant load on the sys-
ing time to be extended. tem, if the generator set load is constantly changing,
reduce the gain adjustment on the generator set.
SYNC GAIN: The sync gain adjustment controls This also allows modification of the rate of load as-
how quickly the governor will respond to try to mini- sumption on transient load change.
mize the bus/generator phase difference. Increas-
ing the gain speeds up the response. If the gain is KVAR GAIN: Adjusts the rate of change of kVAR
too high instability can result. load on the generator set. With a constant load on
the system, if the generator set load is constantly
Note: KW Balance and KVAR Balance changes changing, reduce the gain adjustment on the gener-
should be equally shared among all generator sets. ator set. This also allows modification of the rate of
load assumption on transient load change.
KW BALANCE: This function adjusts the kW load
sharing function of the generator set. Before adjust-
ing this value, all generator set calibrations should ISOLATED BUS (CONT.)
be performed. If the total load on the system is not
shared proportionately, the kW Balance can be
used to adjust the generator set for more precise
load sharing. Increasing the kW Balance value will
cause the generator set to reduce the percentage of ISOLATED BUS:
+ SYNC GAIN 1.0 Y
the total kW load on that set. KW BALANCE 0.3
− KVAR BALANCE 1.2 B
KVAR BALANCE: This function adjusts the kVAR  KW GAIN 1.0
KVAR GAIN 1.0
load sharing function of the generator set. Before
adjusting this value, all generator set calibrations
should be performed. If the total load on the system
is not shared proportionately, the kVAR balance can CONTINUED TO NEXT PAGE
be used to adjust the generator set for more precise
load sharing. Increasing the kVAR balance value
will cause the generator set to reduce the percent-
age of the total kVAR load on that set. FIGURE 3-8. ISO BUS SUBMENUS (CONT.)

1ST FAIL TIME: Time delay in seconds after a sig- LOSS FIELD TIME: Adjusts the loss of field function
nal from the first start master is not sensed by the time delay. A typical delay which is suitable for Pow-
PCC that a FIRST START FAIL warning is dis- erCommand generator sets is 2 seconds.
played.
RAMP UNLOAD TIME: When a load demand stop

input is sensed the load is ramped down from the ISOLATED BUS (CONT.)
present load level on the set to the ramp unload lev-
el in the time specified in seconds.
RAMP UNLOAD LEVEL: The load demand ramp

unload function will ramp the load down from the ISOLATED BUS:
present level on the set to this level before opening + 1ST FAIL TIME 12 SEC Y
RAMP UNLD 20 SEC
the set circuit breaker. Value shown is in % of genset − RAMP UNLD LEVEL 10 %
standby rating.  RAMP LOAD TIME 3 SEC
LOSS FIELD 20 SEC
RAMP LOAD TIME: When the load demand stop
signal is removed the load is ramped from 0kW to
the load share level in the specified time after the cir-
cuit breaker closes. FIGURE 3-9. ISO BUS SUBMENUS (CONT.)

UTILITY SUBMENUS
If you press the “UTILITY” button in the Setup menu, ABLE” function descriptions in wiring diagram, page
the Utility submenus will appear (Figure 3-8). 5-8.)
Note: Use the + and − buttons to increase or decrease KW GOVERN GAIN: This controls the rate that the
the values in the following fields. Use the arrow () generator set kW load is increased after the genera-
button to move the cursor within a field or to the next tor set has closed to the system bus when utility
field. Exit menu to safe changes. (mains) paralleled. Decreasing this value will result
in slower loading of the generator set.
BASE LOAD (%): This controls the maximum kW
load level that the generator set will operate at when KVAR GOVERN GAIN: This controls the rate that
paralleled with the utility (mains). The value shown the generator set kVAR load is increased after the
indicates the steady state load on the generator as a generator set has closed to the system bus when
percent of the generator set standby rating. utility (mains) paralleled. Decreasing this value will
result in slower loading of the generator set.
Check generator set ratings for maximum load level
at which the generator set should operate when par-
alleled with the utility (mains). Extended operation UTILITY
at load levels in excess of the generator set rating
can cause abnormal engine wear or premature en-
gine failure.
UTILITY:
PF LEVEL: Adjusts the power factor that the gener- + BASE LOAD 80% Y
ator set will run at when paralleled to the utility PF LEVEL 1.00
− RAMP LOAD 3 B
(mains). Recommended setting is 1.0.
 RAMP UNLD 20
MODE MULTIPLE
RAMP LOAD TIME: This is the ramp time from
present set load to level determined by the load set
analog input. This is active when the control first en-
ters the load govern mode.
UTILITY:
RAMP UNLOAD TIME: This is the ramp time from + KW GOVERN GAIN 1.00 Y
present set load to 0 kW. This ramp is active when KVAR GOVERN GAIN1.00
−
the load set analog input is less than 0.5 volts. 
MODE − MULTIPLE/SINGLE: This controls wheth-

er the set is to operate as part of a multiple set or
single set (PLTE or PLTF) system. (Refer to “LOAD
DEMAND SHUTDOWN” and “SINGLE MODE EN- FIGURE 3-10. UTILITY SUBMENUS

POWER TRANSFER CONTROL MAIN To adjust PTC system parameters, press the ap-
MENUS propriate PTC main menu button and refer to the
page number shown in Figure 3-9 for detailed infor-
If you press the “POWER TRANSFER SETUP” but- mation related to the submenu selected.
ton in the Setup menu 2 in Figure 3-3, the two main
menus of the optional Power Transfer Control
(PTC) feature will appear (Figure 3-9).
PTC MAIN MENU 1

PAGE
3-13
UTILITY SENSORS Y
PAGE GENSET SENSORS B NEXT
3-15 MENU
TIMERS
PAGE
3-17
PTC MAIN MENU 2
PAGE
TEST/EXERCISE Y
3-18
FIGURE 3-11. PTC SETUP MAIN MENUS

UTILITY SENSORS SUBMENUS
If you press the “UTILITY SENSORS” button in the U CT RATIO: Enter the CT Ratio of the Utility L2 CT.
PTC Main Menu 1, the Utility Sensors submenus This is the Ratio to 1 Amp. Range: 1−18000 (1A).
will appear (Figure 3-10).
CAUTION This CT must be rated for 1 Amp out-
The following field descriptions show the valid field
put (e.g. NOT 5 Amp). Be sure CT secondary cir-
entries and default value (shown in parenthesis) for
cuit has burden resistor or a shorting jumper in
each field.
place before putting power through the CT. Ex-
Note: Use the + and − buttons to increase or decrease ample: CT Ratio = 2650:1. Thus enter 2650.
button to move the cursor within a field or to the next U SENSOR TYPE: Enter the line-to-line (L-N) for 3
field. Exit menu to save changes. phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap-
U PT VOLT LL: Enter the value of the utility line-to-
plies to both the utility undervoltage and overvoltage
line voltage which yields 100% voltage at the termi-
sensors. Range: L−L, L−N (L−N).
nals of the utility (bus) PT module.
Range: 1−15000V, adjustable by standard nominal U <wye> <delta>: Enter utility connection type.
voltage values, 100V, 10V and 1V increments (1V). Range: Delta, Wye (Wye).
The 100% voltages for each of the four possible util- U UNLOADED KW: Enter the kW on utility Line 2 at
ity (bus) PT modules are as follows, based on mod- which the utility is considered as unloaded. This is
ule dash number: the L2 kW level at which a closed transition soft
−01 = 208 volts LL transfer will disconnect from the utility.
−02 = 416 volts LL
−03 = 600 volts LL UTILITY UNDERVOLTAGE: Non-adjustable field,
−04 = 120 volts LL always enabled.
Example 1: Nominal Utility voltage is 480V. This
means that utility (bus) PT module number −02 UTILITY OVERVOLTAGE, FREQUENCY: Used to
should be used. The voltage which will yield 100% enable or disable menu function. Choose Enabled
volts at this PT module is 416 per the above table. or Disabled (Enabled).
Thus enter 416V.
UV PICKUP: Enter a number between 85 and 100%
Example 2: Nominal Utility voltage is 4160V. A pri- of the nominal voltage (90%).
mary stage transformer with a ratio of 4200/240 is
used. This means that utility (bus) PT module num- UV DROP OUT: Enter a number between 75 and
ber −01 should be used. The voltage which will yield 98% of the under-voltage pick-up percentage
the 100% volts (208V from above table) is calcu- (90%).
lated as follows:
208 x (4200/240) = 3640. Thus enter 3640V.
UV DELAY: Enter a time between 0.1 and 5.0 sec-
U NOM VOLT LL: Enter the nominal utility line-to- onds (0.5 seconds).
line voltage. For example, 480, 4160, etc.. Range:
1−15000 V, adjustable by standard nominal voltage UV MIN PHASE: Displays the lowest line voltage of
values, 100V, 10V and 1V increments (1V). the three utility phases.

OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter UTILITY SENSORS
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105

and 135% of the nominal voltage (110%).
U PT VOLT LL 416
OV DELAY: Enter a range between 0 and 120 sec- + U NOM VOLT LL 480 Y
onds (3 seconds). U CT RATIO: 1 1000
− U SENSOR TYPE L−L B
OV MAX PHASE: Displays the highest line voltage 
U UNLOADED KW 50KW
of the three utility phases.
CENTER (FREQ): Enter a frequency between 45

and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5 UTILITY UV: ENABLED

+ % VLL Y
and 20% of the nominal frequency (10%). PICK UP 95 475
− DROP OUT 85 465 B
DROP OUT (FREQ): Enter a percentage between 1  DELAY 0.5 S
and 5% of the nominal frequency (1%). MIN PHASE 470
DELAY (FREQ): Enter a time between 0.1 and 15.0

seconds (5.0 seconds).
FREQUENCY: This field displays the sensed utility

UTILITY OV: DISABLED
line frequency. + % VLL Y
PICK UP 95 487
 DELAY 3.0 S
MAX PHASE 485
UTILITY FREQ: DISABLED

+ CENTER 60 HZ Y
PICK UP 10 %
− DROP OUT 1%
 DELAY 1.0 S
FREQUENCY 60.5 HZ
FIGURE 3-12. UTILITY SENSORS SUBMENUS

GENSET SENSORS SUBMENUS
If you press the “GENSET SENSORS” button in the G RAMP UNLOAD: Enter the ramp time for the
PTC Main Menu 1, the Genset Sensors submenus genset ramp unload rate during a closed transtion
will appear (Figure 3-11). soft load retransfer. Ramp rate is −100%kW divided
by this time setting. Range: 0−900 seconds (20
The following field descriptions show the valid field sec).
entries and default value (shown in parenthesis) for
each field. G UNLOADED KW: Enter the %kW (based on
standby rating) that the genset is considered un-
Note: Use the + and − buttons to increase or decrease loaded. This is the %kW level at which a closed tran-
the values in the following fields. Use the arrow () sition soft retransfer will disconnect from the genset.
button to move the cursor within a field or to the next Range: 0−100% (5%).
field. Exit menu to save changes.
GEN UNDERVOLTAGE: Non-adjustable field, al-
G NOM VOLT LL: Non-adjustable field, displays
ways enabled.
current setting of genset nominal voltage. (See Ad-
just submenu to adjust the output voltage 5%.) GEN OVERVOLTAGE, FREQUENCY: Used to en-
able or disable menu function. Choose Enabled or
G SENSOR TYPE: Enter the line-to-line (L-N) for 3
Disabled (Enabled).
phase line-neutral voltage sensing or line-to-line
(L-L) for 3 phase line-line voltage sensing. This ap- UV PICKUP: Enter a number between 85 and 100%
plies to both the genset undervoltage and overvol- of the nominal voltage (90%).
tage sensors. Range: L−L, L−N (L−N).
UV DROP OUT: Enter a number between 75 and
G BASE LOAD: Enter the maximum load the gen- 98% of the under-voltage pick-up percentage
set will carry during a closed transition. Range: (90%).
0−100% (80%).
UV DELAY: Enter a time between 0.1 and 5.0 sec-
G RAMP LOAD: Enter the ramp time for the genset onds (4 seconds).
ramp load rate during a closed transition soft load
transfer. Ramp rate is +100%kW divided by this time UV MIN PHASE: Displays the lowest line voltage of
setting. Range: 0−900 seconds (20 sec). the three genset phases.

OV PICKUP: This adjusts the over-voltage pickup
as a percentage of the over-voltage drop-out. Enter GENSET SENSORS
a number between 95 and 99% (95%).
OV DROP OUT: Enter a percentage between 105

and 135% of the nominal voltage (110%).
G NOM VOLT LL 480
OV DELAY: Enter a range between 0 and 120 sec- + G SENSOR TYPE L−L Y
onds (3 seconds). G BASE LOAD 80.0%
− G RAMP LOAD 20 S B
OV MAX PHASE: Displays the highest line voltage  G RAMP UNLOAD20 S
G UNLOADED KW5 %
of the three genset phases.
CENTER (FREQ): Enter a frequency between 45

and 65 Hz (60 Hz).
PICK UP (FREQ): Enter a percentage between 5 GEN UV: ENABLED

+ % VLL Y
and 20% of the nominal frequency (10%). PICK UP 95 475
DROP OUT (FREQ): Enter a percentage between 1  DELAY 1.0 S
and 5% of the nominal frequency (1%). MIN PHASE 470
DELAY (FREQ): Enter a time between 0.1 and 15.0

seconds (5.0 seconds).
FREQUENCY: Displays the sensed genset line fre-

GEN OV: DISABLED
quency. + % VLL Y
PICK UP 95 487
 DELAY 8.0 S
MAX PHASE 485
GEN FREQ: DISABLED

+ CENTER 59 HZ Y
PICK UP 12%
− DROP OUT 2%
 DELAY 5.0S
FREQUENCY 60.0HZ
FIGURE 3-13. GENSET SENSORS SUBMENUS

TIMERS SUBMENU
If you press the “TIMERS” button in the PTC Main RETRANSFER: In a Emergency to Normal transfer
Menu 1, the Timers submenu will appear (Figure this function allows the utility to stabilize before the
3-12). load is applied.
Enter a time from 0 to 1800 seconds (600 seconds).

The following field descriptions show the valid field
entries and default value (shown in parenthesis) for PGM TRANSIT: Sets the time delay for Pro-
each field. grammed Transition. A setting of 0.0 disables the
program.
the values in the following fields. Use the arrow () Enter a time from 0 to 60 seconds (0 seconds).
field. Exit menu to save changes. MAX PARALLEL: Sets the maximum time during
closed transition that utility and genset can be paral-
START DELAY: Sets time delay for genset engine leled.
start. Prevents nuisance genset starting during brief
power interruptions. Enter a time from 0 to 1800 seconds (20 seconds).
Enter a range from 0 to 300 seconds (0 seconds).

TIMERS
STOP DELAY: Sets the time delay for engine cool-

down following a re-transfer. This stop delay works
in conjunction with and is activated at the same time
as the normal cooldown timer. (Will extend normal START DELAY 60S
cooldown timer if entered time is greater.) + STOP DELAY 60S Y
TRANSFER 10S
− RETRANSFER 900S
Enter a time from 0 to 600 seconds (0 seconds).  PGM TRANSI 5S
MAX PARALLEL 30S
TRANSFER: In a Normal to Emergency transfer

this function allows the genset to stabilize before the
load is applied. Enter a time from 0 to 120 seconds
(10 seconds). FIGURE 3-14. TIMERS SUBMENU

TEST/EXERCISE SUBMENU
If you press the “TEST/EXERCISE” button in the (TEST) switch, to operate with or without load. De-
PTC Main Menu 2, the Test/Exercise submenu will fault: OFF
appear (Figure 3-13).
EXER WITH LOAD: Feature allows genset Exer-
The following field descriptions show the valid field cise sequence, which is initiated through control
entries and default value (shown in parenthesis) for panel Exercise button to operate with or without
each field. load. Default: OFF

the values in the following fields. Use the arrow () TEST/EXERCISE
field. Exit menu to save changes.
MODE: Indicates the generator set application type

for PTC option.
+ Y
OT-PGM TRAN − Open transition load transfer. −
MODE CT-SOFT
CT-MOMENT − Closed transition load transfer with  TEST WITH LOADOFF
momentary (<100ms) overlap. EXER WITH LOADOFF
CT-SOFT − Closed transition load transfer with load
ramping.
TEST WITH LOAD: Feature allows genset Test se-

quence, which is initiated through the Remote Start FIGURE 3-15. TIMERS SUBMENU

ADJUST SUBMENU disabled to prevent inadvertent misadjustment of
the paralleling load sharing functions.
Menu B) of the system control and the Adjust sub- Note: Use the + and − buttons to increase or decrease
menu. the values in the following fields. Use the arrow ()
To display the Adjust submenu, press the MORE>> field. Exit menu to safe changes.
button in Menu A and then the ADJUST button in
Menu B. START DELAY: This delay applies only to remote
starting in the Auto mode. The Start Delay adjust-
The Adjust submenus are intended for qualified ment range is 0 to 300 seconds.
service personnel and site personnel only and may
require a USER password. If a password is re- STOP DELAY: This delay applies only to remote
quired, the USER password menu will appear when stopping in the Auto mode. The Stop Delay adjust-
you try to modify the Adjust submenus. (Refer to ment range is 0 to 600 seconds.
PASSWORD Menu in this section to enter pass-
word. VOLTAGE: Used to adjust the output voltage 5%.
Changes are automatically saved when you exit this FREQUENCY: Used to adjust the frequency 3 Hz.
menu.
VOLTAGE/SPEED DROOP: These two submenus
If the generator set is operating in parallel with a sys- apply to a genset that has the paralleling option and
tem bus, the voltage and frequency adjustments are is configured to operate in droop mode.
MENU A
ADJUST:
MENU
ENGINE MORE>> + START DELAY 5 SEC Y
B STOP DELAY 11 SEC
ALTERNATOR _\_ − VOLTAGE 208 1.2% B
CONTROL HISTORY/ABOUT  FREQ 60.0 HZ -0.0HZ
MENU B
ADJUST:
+ STANDBY Y
VOLTAGE DROOPOFF
ADJUST − BUS L1 480 B
BUS DATA  POWER FACTOR 0.80
MENU VOLT 4.99 %
SETUP BACK<<
A
ADJUST:
+ STANDBY Y
SPEED DROOPOFF
− BUS FREQ 60.0 HZ
 TOTAL KW 300 KW
FREQ 60.0 0.40 HZ
FIGURE 3-16. ADJUST SUBMENU

CALIBRATION PROCEDURE available and the genset is running. Consequently, it
is not possible to calibrate the genset output voltage
There are several circuit cards/modules that, when display of the genset that is running when the bus is
removed and replaced, require you to recalibrate energized. If it is necessary to adjust the output volt-
age display of the genset that is running, the InPower
the control panel display for genset voltage and cur-
service tool must be used to switch off the synchro-
rent and bus voltage. nizer function of the control.
Note that the type of calibration to perform varies for 1. Display the Voltage Calibration submenu (Page
each card. The letters A, B and C are used to desig- 3-6).
nate which of the following three calibration proce- 2. With the genset OFF, attach a calibrated voltmeter
dures are required for each card/module. to the AC output from L1 to L2. (L1 to Neutral for
single phase alternators.)
 Genset/Parallel board (A, B & C) 3. Start the genset and allow it to reach normal operat-
 PT/CT board (A & B) ing speed.
4. Calibrate voltage reading for L1 so that the reading
 Bus PT (C) on the display agrees with the calibrated voltmeter.
 CT’s (B) 5. Shut the generator set OFF.
WARNING Contacting high voltage compo- 6. Repeat steps 2 through 5 for L2 and L3. (In step 2
nents can cause electrocution, resulting in se- attach meter to the AC output from L2 to L3 to cali-
vere personal injury or death. Calibration and brate L2 and L3 to L1 to calibrate L3.)
adjustment must be performed by technically 7. Exit menu to safe changes.
qualified personnel only. Read and observe all (B) Genset Ammeter Display Calibration
WARNINGS and CAUTIONS in your generator
set manuals. 1. Display the Current Calibration submenu (Page
3-6).
CAUTION Improper calibration or adjustment
2. With the genset OFF, attach a calibrated ammeter to
of the PowerCommand control can cause L1.
equipment malfunction or damage. Calibration 3. Start the genset and allow it to reach normal operat-
and adjustment must be performed by techni- ing speed.
cally qualified personnel only.
4. Load the genset to maximum rated kVA at rated volt-
age.
Use a calibrated RMS multimeter for accurate mea-
surements. 5. Calibrate the reading for L1 current so that the read-
ing on the display agrees with calibrated ammeter.
(A) Genset Voltage Display Calibration 6. Repeat steps 2 through 5 for L2 and L3. (In step 2,
attach meter to L2 to calibrate L2 current and L3 to
Note: The PowerCommand control automatically calibrate L3 current.)
synchronizes to the system bus when bus voltage is 7. Exit menu to safe changes.

(C) Bus Voltage Calibration 2. With all gensets OFF, attach a calibrated voltmeter
to TB1-A (L1) and TB1-B (L2) of the bus PT module
(Figure 3-15).
Note: The PowerCommand control automatically 3. Start another genset and allow it to reach normal
synchronizes to the system bus when bus voltage is operating speed and voltage. Connect operating
available and the genset is running. Consequently, it genset to the bus.
is not possible to calibrate the genset bus voltage
4. Calibrate the voltage reading for Bus Volts L1 so that
display of the genset that is running when the bus is
the reading on the display matches the reading on
energized. If it is necessary to adjust the bus voltage
the calibrated meter.
display of the genset that is running, the InPower ser-
vice tool must be used to switch off the synchronizer 5. Shut the generator set OFF.
function of the control. 6. Repeat steps 2 through 5 for Bus Volts L2 and L3. (In
step 2 attach meter to the AC output from L2 to L3 to
1. Display the Bus Voltage Calibration submenu (Page calibrate L2; L3 to L1 to calibrate L3.)
3-6). 7. Exit menu to safe changes.
CONTROL
BOX DOOR
TB1-A (L1) TB1-C (L3)

TB1-B (L2)
FIGURE 3-17. BUS PT MODULE

CONTROL BOX WIRING Optional equipment such as a remote annunciator
panel, sensing devices used to monitor genset op-
The generator set control box assembly, which can eration, remote start/stop switches, control box
be located on either side of the genset, contains heater, and etc. are also attached to these terminal
connection points for remote control and monitor
blocks. Driver signals for customer supplied relays
options.
are also provided for several alarm and shut down
Customer monitor/control connections are attached conditions. Refer to Customer Connections dia-
to terminal blocks TB3 and TB8 (see Figure 3-16). gram in Section 7.
OPTIONAL OPTIONAL
RUN RELAYS SHUTDOWN
ALARM RELAY K16 CONTROL WIRING
K11, K12 & K13
ACCESS
TB8
CARD CAGE
FIGURE 3-18. CONTROL BOX ASSEMBLY INTERIOR

RUN RELAYS (K11, K12, K13) as fans, pumps and motorized air dampers. The run
relays are energized when the generator set reach-
The optional run relays are rail mounted inside the es operating speed.
control box (Figure 3-16). The rail mount allows you
to easily remove and replace the snap-on relays. The contacts are rated:
The generator set can be equipped with one, two or
three run relays.  10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw run relays (Figure  6 amps at 240 VAC, 80%PF
3-17) are used to control auxiliary equipment such  3 amps at 480/600 VAC, 80%PF
K11, K12, K13
CUSTOMER
K11, K12, K13
CONNECTIONS
K11, K12, K13
K11 K12 K13

RUN RELAY RUN RELAY RUN RELAY
NO NO NO
NC NC NC
COIL TB3-7
TB3-5
(SWITCHED B+) COM (GND)
FIGURE 3-19. OPTIONAL RUN RELAYS (K11, K12, K13)

ALARM RELAY (K16) as audible alarms. Any generator set shutdown will
energize the alarm relay.
The optional alarm relay is rail mounted inside the
control box (Figure 5-2). The rail mount allows you The contacts are rated:
to easily remove and replace the snap-on relay.  10 amps at 28 VDC or 120 VAC, 80%PF
The three-pole, double-throw alarm relay (Figure  6 amps at 240 VAC, 80%PF
5-4) is often used to energize warning devices such  3 amps at 480/600 VAC, 80%PF
K16
CUSTOMER
K16
CONNECTIONS
K16
K16
SHUTDOWN ALARM
NO
NC
COIL TB3-18
TB3-17
(COM ALARM) COM (GND)
FIGURE 3-20. OPTIONAL ALARM RELAY (K16)

MAGNETIC SPEED PICKUP UNIT (MPU)
INSTALLATION
To install the MPU sensor, bar the engine until a
gear tooth on the flywheel lines up in the center of
the mounting hole. Thread the sensor in gently by
hand until it just touches the gear tooth. Back it out
one quarter turn and set the locknut.
CAUTION Do not use fan blade to bar over en-
gine. That can damage blades and cause prop-
erty damage and personal injury.
MAGNETIC
PICKUP
SENSOR
ENGINE
FLYWHEEL
RING GEAR
FIGURE 3-21. MPU SENSOR


4. Troubleshooting
GENERAL Ventilate battery area before working on or near

battery—Wear goggles—Stop genset and dis-
connect charger before disconnecting battery
During genset operation, the PCC control continu- cables—Disconnect negative (−) cable first and
ously monitors engine sensors for abnormal condi- reconnect last.
tions, such as low oil pressure and high coolant tem-
perature. If any of these conditions occur, the con- Disconnect battery charger from AC
CAUTION
trol will light a yellow Warning lamp or a red Shut- source before disconnecting battery cables.
down lamp and display a message on the graphical Otherwise, disconnecting cables can result in
display panel. voltage spikes damaging to DC control circuits
of the generator set.
In the event of an engine shutdown fault (red Shut- WARNING Accidental starting of the generator
down lamp), the control will stop the engine immedi- set can cause severe personal injury or death.
ately; an alternator shutdown fault, the engine will Prevent accidental starting by disconnecting
stop after the cool-down timer has timed out. If the the negative (−) cable from the battery terminal.
generator set is stopped for this reason, the opera-
tor can restart the set after making adjustments or When troubleshooting a set that is shut down, make
corrections. This section lists the warning and shut- certain the generator set cannot be accidentally re-
down codes/messages (Table 4-1), and suggests started as follows:
troubleshooting procedures (Table 4-2).
1. Move the O/Manual/Auto switch on the control
panel to the O (off) position.
Note: Displayed error codes that are not listed in 2. Turn off or remove AC power from the battery
Table 4-2 will require an authorized service represen- charger.
tative to correct the fault. Contact an authorized ser-
vice center for assistance. 3. Remove the negative (−) battery cable from the
generator set starting battery.
SAFETY CONSIDERATIONS STATUS INDICATORS
Not In Auto Indicator: This red lamp flashes con-

WARNING Contacting high voltage compo- tinuously when the 0/Manual/Auto switch is not in
nents can result in severe personal injury or the Auto position (Figure 4-1).
death. Keep the output box covers in place dur-
ing troubleshooting.
Shutdown Status Indicator: This red lamp is lit
whenever the control detects a shutdown condition.
High voltages are present when the set is running. After the condition is corrected, the shutdown indi-
Do not open the generator output box while the set cator can be reset by turning the 0/Manual/Auto
is running. switch to the 0 position, and pressing the Fault Ac-
knowledge button. The generator set can not be
started when this lamp is on.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- Warning Status Indicator: This yellow lamp is lit
ing at battery terminals, light switch or other whenever the control detects a warning condition.
equipment, flame, pilot lights and sparks can ig- After the condition is corrected, the warning indica-
nite battery gas. Do not smoke, or switch trouble tor can be reset by pressing the Fault Acknowledge
light ON or OFF near battery. Discharge static button. (It is not necessary to stop the generator set
electricity from body before touching batteries if the fault becomes inactive during genset opera-
by first touching a grounded metal surface. tion.)

READING FAULT CODES each code. The fourth flash of the Warning lamp in-
dicates the beginning of the second fault code.
If the genset contains the optional graphical display
and a fault occurs, the fault code/message will be There are distinct pauses between repetitions of the
displayed in the display Description Line (Figure code blink transmissions of the Shutdown lamp.
4-1). If the control does not contain the graphical A three digit fault code is indicated by three sets of
display, the fault code is read from the Warning and blinks separated by a two second pause. The first
Shutdown status indicators. set corresponds to the hundreds position, the sec-
ond to the tens position and the third to the ones dig-
After the fault is acknowledged and corrected, the it. Example for Code No. 213:
recorded fault will be deleted from the control panel
memory, but will remain in a data log to maintain a Shutdown LED:
fault code history. The InPower service tool is re- blink-blink-pause-blink-pause-blink-blink-blink
quired to view this data log.
Warning LED:
Reading Fault Codes Using Graphical Display blink (2 seconds)
(Optional): The top three lines of the graphical dis-
The light will display the fault codes (active or inac-
play contain the following control information in the
tive) in succession, starting with the most recent. Up
order described:
to 32 (unacknowledged) fault codes can be stored in
 State Line − modes of operation, such as control panel memory.
Stopped, Time Delay To Start, Warm Up At Idle,
To return the control to the most recent fault code,
etc. (see Figure 3-2), and paralleling opera-
press and release the Fault Acknowledge button
tions, such as Standby, Dead BUS Close, Syn-
(less than one second) and repeat procedure.
chronize, etc.
 Action Line − system actions, such as Warning, When the fault code is acknowledged and the fault
Derate, Shutdown Cool-down and Shutdown, condition is corrected, the fault code will be re-
and fault codes. moved from the LED fault log.
 Description Line − Fault code messages. LINE CIRCUIT BREAKER (OPTIONAL)
Refer to History/About Submenus in Section 3,
Optional line circuit breakers mount in the generator
which describes how to view fault codes using
output box. If the load exceeds the circuit breaker
graphical display.
current rating, the line circuit breaker will open, pre-
venting the generator from being overloaded. If the
Reading Fault Codes Using Warning/Shutdown circuit breaker trips, locate the source of the over-
Indicators: If the Warning or Shutdown status indi- load and correct as necessary. Manually reset the
cator is lit, press and hold the Fault Acknowledge breaker to reconnect the load to the generator.
button and release after ten seconds or more. After
ten seconds, the Shutdown lamp will begin to blink CONTROL AND DIAGNOSTICS VIA
the active fault code(s) as follows. NETWORK OR LAPTOP
The Warning lamp is used to indicate the start of a See your authorized Cummins Power Generation
new code. The Warning lamp will remain on for 2 dealer regarding software, hardware and network
seconds, followed by the Shutdown lamp blinking requirements for control and diagnostics via net-
the fault code. This sequence occurs three times for work or personal computer.

SHUTDOWN,
WARNING
STATUS
INDICATORS
FAULT
ACKNOWLEDGE
BUTTON
STATE LINE
ACTION LINE
DESCRIPTION LINE
MENU
DISPLAY AREA
OPERATOR SWITCH
GRAPHICAL
PANEL PANEL
DISPLAY
FIGURE 4-1. FRONT CONTROL PANEL (FULL-FEATURED)

FAULT CODES cannot be shut down. Requires repair by qualified
service personnel.
The fault codes have been divided into five catego-
ries to help you determine what corrective action to Category C Fault Codes: Consist of faults that do
take for safe operation of the generator set. Use not affect generator set performance but require
Table 4-1 to find the category (CTG) and fault de- qualified service personnel to repair. These code in-
scription for all codes. Gaps in the code numbers dicate a defective harness or wiring problem.
are for codes that do not apply to this genset
These codes can also indicate a defective engine
model. Also, some of the codes listed are fea-
sensor, leaving no engine protection. (Engine dam-
ture dependent, and will not be displayed by this
age can occur without detection.) Continued op-
genset control.
eration may void generator set warranty if dam-
age occurs that relates to fault condition.
Category A Fault Codes: Pertain to engine or al-
ternator shutdown faults that require immediate re- Category D Fault Codes: Consist of faults that are
pair by qualified service personnel (generator set repairable by site personnel. Service will be re-
non-operational). The control prevents the genera- quired by qualified service personnel if site person-
tor set from being restarted if the shutdown fault is nel cannot resolve the problem after taking the cor-
not corrected. rective actions suggested in Table 4-2.
Category B Fault Codes: Consist of faults that can Category E Fault Codes: Indicates non-critical op-
affect genset performance or cause engine, alter- erational status of generator set, external faults, or
nator, or connected equipment damage. Oper- customer fault inputs. May require repair by quali-
ate genset only when it is powering critical loads and fied service personnel.

TABLE 4-1. FAULT CODES
CTG CODE LAMP DISPLAYED MESSAGE CTG CODE LAMP DISPLAYED MESSAGE
A 111 Shtdn Internal ECM error A 254 Shtdn Fuel shutoff valve
A 112 Shtdn Actuator not responding C 259 Wrng Fuel shutoff valve
B 113 Wrng Actuator sensor fault C 261 Wrng Fuel temperature sensor
A 115 Shtdn No speed signal C 263 Wrng Fuel temperature sensor
A 116 Shtdn Time press sensor high C 265 Wrng Fuel temperature sensor
A 117 Shtdn Time press sensor low A 266 Shtdn Fuel temperature
B 118 Wrng Pump press sensor high B 316 Wrng Fuel supply pump
B 119 Wrng Pump press sensor low B 318 Wrng Fuel supply pump
C 121 Wrng No engine speed signal D 326 Wrng Oil level warning
B 122 Wrng Manifold air press sensor B 343 Wrng Internal ECM error
B 123 Wrng Manifold air press sensor D 359 Wrng Engine failed to start
C 135 Wrng Oil pressure sensor A 378 Wrng Fueling actuator #1
C 141 Wrng Oil pressure sensor A 379 Wrng Fueling actuator #1
B 143 Wrng Low oil pressure A 394 Wrng Fueling actuator #1
C 144 Wrng Coolant temperature sensor A 395 Wrng Fueling actuator #1
C 145 Wrng Coolant temperature sensor A 396 Wrng Fueling actuator #2
D 146 Wrng High coolant temp warning A 397 Wrng Fueling actuator #2
C 151 Shtdn High coolant temp alarm A 398 Wrng Fueling actuator #2
D 152 Wrng Low coolant temp A 399 Wrng Fueling actuator #2
C 153 Wrng Manifold air temp sensor B 415 Shtdn Low oil pressure alarm
C 154 Wrng Manifold air temp sensor B 421 Wrng High oil temperature
A 155 Shtdn Manifold air temp alarm B 423 Wrng Fuel timing
D 197 Wrng Coolant level warning D 441 Wrng Low battery voltage
C 212 Wrng Oil temperature sensor D 442 Wrng High battery voltage
C 213 Wrng Oil temperature sensor B 449 Wrng High fuel supply pressure
A 214 Shtdn High oil temperature B 451 Wrng Fuel rail pressure sensor
C 221 Wrng Air pressure sensor B 452 Wrng Fuel rail pressure sensor
C 222 Wrng Air pressure sensor A 455 Shtdn Fuel control valve sensor
A 228 Shtdn Low coolant pressure B 467 Wrng Timing rail act sensor
C 231 Wrng Coolant pressure sensor B 468 Wrng Fuel rail actuator sensor
C 232 Wrng Coolant pressure sensor D 471 Wrng Low oil level
A 233 Wrng Coolant pressure warning B 482 Wrng High fuel supply pressure
A 234 Shtdn Overspeed B 488 Wrng High intake manifold temp
D 235 Shtdn Coolant level alarm C 498 Wrng Oil level sensor
A 236 Shtdn Position sensor C 499 Wrng Oil level sensor
D 253 Shtdn Oil level alarm A 514 Shtdn Fuel control valve

TABLE 4-1. FAULT CODES (CONT.)
B 546 Wrng Fuel pressure sensor E 1318 Shtdn/ Customer input #4
B 547 Wrng Fuel pressure sensor Wrng
B 554 Wrng Fuel rail pressure sensor B 1319 Wrng High alternator temp
B 555 Wrng Blowby pressure C 1321 Wrng Common warning driver
A 556 Shtdn Blowby pressure A 1322 Shtdn Load gov kW setpoint oor hi
A 586 Shtdn Run/Stop switch A 1323 Shtdn Load gov kW setpoint oor lo
A 587 Shtdn Run/Stop switch B 1324 Wrng Load gov kVAR oor hi
D 611 Wrng Engine hot B 1325 Wrng Load gov kVAR oor lo
D 688 Shtdn High oil level alarm B 1326 Wrng Backup starter disconnect
B 689 Wrng Crank shaft sensor A 1327 Shtdn Load gov kW analog oor
B 719 Wrng Blowby pressure sensor D 1328 Wrng Genset CB tripped
B 729 Wrng Blowby pressure sensor B 1329 Wrng AVR DC power failure
B 731 Wrng Cam/Crank misalignment A 1331 Shtdn AVR driver shorted
B 778 Wrng Camshaft sensor A 1332 Shtdn Manual switch oor lo
C 1118 Wrng Prelube relay driver A 1333 Shtdn Manual switch oor hi
B 1121 Wrng Failed to Disconnect A 1334 Shtdn Critical scaler oor
C 1219 Wrng Utility CB tripped
B 1335 Wrng Non critical scaler oor
C 1222 Wrng Power transfer not in auto
E 1336 Cooldown complete
C 1223 Wrng Utility frequency sensor
E 1337 None Network wink
C 1224 Wrng Gen over voltage sensor
E 1341 Shtdn Load demand stop
C 1225 Wrng Gen under voltage sensor
A 1342 Shtdn Slot 0 card
C 1226 Wrng Genset frequency sensor
A 1343 Shtdn Slot 1 card
E 1311 Shtdn/ Customer input #1
Wrng A 1345 Shtdn Slot 3 card
E 1312 Shtdn/ Customer input #2 A 1346 Shtdn Slot 4 incorrect
Wrng C 1351 Wrng Slot 4 / network enabled
E 1313 Shtdn/ Network Fault 1 C 1414 Wrng Run relay contact
Wrng
C 1415 Wrng Run relay driver
E 1314 Shtdn/ Network Fault 2
Wrng D 1416 Wrng Fail to shutdown
E 1315 Shtdn/ Network Fault 3 D 1417 Wrng Power down error
Wrng
B 1419 Wrng Fuel rail driver
E 1316 Shtdn/ Network Fault 4
B 1421 Wrng Timing rail driver #1
Wrng
B 1422 Wrng Timing rail driver #2
E 1317 Shtdn/ Customer input #3
Wrng C 1424 Wrng High side driver

TABLE 4-1. FAULT CODES (CONT.)
C 1427 Wrng Overspeed relay driver C 1468 Wrng Network error
C 1428 Wrng LOP shutdown relay driver B 1471 Wrng High current
D 1433 Shtdn Emergency stop − local A 1472 Shtdn Overcurrent
D 1434 Shtdn Emergency stop − remote A 1473 Shtdn Watchdog failure
D 1435 Wrng Engine cold A 1474 Shtdn Software version mismatch
B 1436 Wrng PT fuel system drivers C 1475 Wrng First start backup
A 1437 Shtdn E-stop path fuse blown C 1476 Wrng LonWorks card
D 1438 Wrng Fail to crank C 1477 Wrng Crank relay contact
D 1439 Wrng Fuel level low in day C 1478 Wrng Crank relay driver
D 1441 Wrng Fuel level low in main A 1481 Shtdn AVR driver open
D 1442 Wrng Battery is weak
E 1483 None Common alarm status
D 1443 Wrng Battery is dead
A 1485 Shtdn EFC driver shorted
B 1444 Wrng kW overload
A 1486 Shtdn EFC driver open
A 1445 Shtdn Alternator short circuit
C 1487 Wrng Auto acknowledge driver
A 1446 Shtdn AC output voltage is high
C 1488 Wrng Warning LED driver
A 1447 Shtdn AC output voltage is low
C 1489 Wrng Shutdown LED driver
A 1448 Shtdn AC output frequency low
C 1491 Wrng Ready to load relay driver
A 1449 Wrng AC output frequency high
C 1492 Wrng Load dump relay driver
B 1451 Wrng Gen/Bus voltage differ
C 1493 Wrng Display control driver
A 1452 Shtdn Gen CB failed to close
C 1494 Wrng Modem power relay driver
A 1453 Shtdn Gen CB failed to open
C 1495 Wrng Common shutdown2 driver
C 1454 Wrng Gen CB position contact
C 1496 Wrng Auto mode relay driver
A 1455 Wrng Util CB contact
E 1456 Wrng Bus out of range C 1497 Wrng Manual run LED driver
E 1457 Wrng Fail to synchronize C 1498 Wrng Exercise run LED driver
E 1458 Wrng Phase rotation C 1499 Wrng Remote start LED driver
A 1459 Shtdn Reverse kW C 2111 Wrng Aftercooler temp sensor

A 1461 Shtdn Loss of field C 2112 Wrng Aftercooler temp sensor
B 1462 Wrng High ground current B 2113 Wrng High aftercooler temp
E 1463 None Not in Auto A 2114 Shtdn High aftercooler temp
E 1464 None Load dump C 2331 Wrng Utility under volt sensor
E 1465 None Ready to load C 2358 Wrng Utility over volt sensor
C 1466 Wrng Modem failure C 2396 Wrng Utility CB failed to close
C 1467 Wrng Unable to connect modem C 2397 Wrng Utility CB failed to open

CODE: 152 Indicates engine coolant heat-
TABLE 4-2. WARNING AND SHUTDOWN
LAMP: er is not operating or is not cir-
CODES Warning culating coolant. Set is in
MESSAGE: standby mode but is not oper-
LOW COOL- ating. Warning occurs when
WARNING Many troubleshooting proce-
ANT TEMP engine jacket water coolant
dures present hazards which can result in
temperature is 70 F (21 C) or
severe personal injury or death. Only quali- lower.
fied service personnel with knowledge of
fuels, electricity, and mechanical hazards NOTE: In applications where
should perform service procedures. Review the ambient temperature
safety precautions. falls below 40 F (4 C), Low
Coolant Temp may be indi-
cated even though the cool-
SYMPTOM CORRECTIVE ACTION ant heaters are operating.
CODE: 146 Indicates engine is operating Check for the following condi-
LAMP: near cooling system capacity. tions:
Warning Increase in load or higher am- a. Make sure both ball
MESSAGE: bient temperature may cause valves in heater coolant
HIGH COOL- High Coolant Temp (151) shut- lines are open.
ANT TEMP down. Review 151 correction b. Coolant heater not con-
WARNING list for other possible causes. nected to power supply.
Check for blown fuse or
CODE: 151 Indicates engine has over- disconnected heater cord
LAMP: heated (coolant temperature and correct as required.
Shutdown has risen above the shutdown c. Check for low jacket wa-
MESSAGE: trip point). Allow engine to cool ter coolant level and re-
HIGH COOL- down completely before pro- plenish if required. Look
ANT TEMP ceeding with the following for possible coolant leaks
ALARM checks: and repair as required.
a. Check coolant level and
replenish if low. Look for CODE: 197 Indicates engine coolant level
coolant leaks and repair if LAMP: has fallen to an unacceptable
necessary. Warning level. If generator is powering
b. Check for obstructions to MESSAGE: critical loads and cannot be
cooling airflow and cor- COOLANT shut down, wait until next shut-
rect as necessary. LEVEL down period, then follow 235
c. Check fan belt and repair WARNING Coolant Level Alarm proce-
or tighten if necessary. dure. If engine can be stopped,
follow 235 procedure.
d. Check blower fan and cir-
culation pumps on re-
mote radiator installa-
tions.
e. Reset control and restart
after locating and correct-
ing problem.

CODE: 235 Indicates engine coolant level CODE: 442 Indicates battery voltage ex-
LAMP: has fallen below the alarm trip LAMP: ceeds 32 VDC.
Shutdown point. Allow engine to cool Warning
MESSAGE: down completely before pro- MESSAGE: Check float level on battery
COOLANT ceeding. HIGH BAT- charger if applicable (lower
LEVEL TERY VOLT- float level).
a. Check jacket water cool-
ALARM AGE
ant level and replenish if Check engine DC alternator.
low. Look for possible Replace engine DC alternator
coolant leakage points if normal battery charging volt-
and repair if necessary. age (24 to 26 VDC) is not ob-
b. Reset control and restart tained.
after locating and correct-
ing problem.
CODE: 611 Indicates that an engine hot
LAMP: shut down has occurred (cool-
CODE: 359 Indicates possible fault with Warning down timers were bypassed).
LAMP: control or starting system. MESSAGE: This condition will occur when
Warning Check for the following condi- ENGINE HOT the operator presses the
MESSAGE: tions: Emergency Switch or moves
ENGINE the 0/Manual/Auto switch to
a. Poor battery cable con-
FAILED TO the 0 (Off) position before the
nections. Clean the bat-
START genset completes the cool-
tery cable terminals and
tighten all connections. down operation. (Genset
b. Discharged or defective should run at 10% or less load
battery. Recharge or re- for 3 minutes before engine
place the battery. shutdown.) This type of shut-
down should be avoided. Can
cause possible loss of perfor-
CODE: 441 Indicates battery voltage is be- mance and engine damage.
LAMP: low 24 VDC.
Warning
a. Discharged or defective CODE: 1311 When any one of these cus-
MESSAGE:
battery. Check the battery through 1318 tomer defined inputs is de-
LOW BAT-
charger fuse. LAMP: tected by the control, the corre-
TERY VOLT-
Recharge or replace the Shutdown/ sponding fault message is dis-
AGE
battery. Warning played. The nature of the fault
b. Poor battery cable con- MESSAGE: is an optional customer selec-
nections. Clean the bat- Customer De- tion. These fault functions can
tery cable terminals and fined Fault be programmed to initiate a
tighten all connections. shutdown or warning as indi-
c. Check engine DC alter- cated by the Warning or Shut-
nator. Replace engine DC down lamp.
alternator if normal bat-
tery charging voltage (24 Note: Customer fault mes-
to 26 VDC) is not ob- sages are editable. The mes-
tained. sage displayed for the code
d. Check float level if appli- shown (1311 through 1318) is
cable (raise float level). determined by the customer.

CODE: 1416 Status − indicates that the CODE: 1439 Indicates fuel supply is running
LAMP: “Fault Bypass” mode is en- LAMP: low. Check fuel supply and re-
Warning abled and that a critical shut- Warning plenish as required.
MESSAGE: down fault has occurred. In this MESSAGE:
FAIL TO mode the generator set ig- FUEL LEVEL
SHUTDOWN nores the majority of system LOW IN DAY
shutdown faults. The purpose
of this mode is to satisfy local
code requirements where nec- CODE: 1441 Indicates fuel supply is running
essary. The InPower service LAMP: low. Check fuel supply and re-
tool is required to enable/dis- Warning plenish as required.
able the Fault Bypass mode. MESSAGE:
FUEL LEVEL
LOW IN MAIN
CODE: 1417 Indicates that the control can
LAMP: not power down due to some
Warning unknown condition. Possible CODE: 1442 Indicates battery voltage drops
MESSAGE: drain on battery. Contact an LAMP: below 14.4 volts for two sec-
POWER authorized service center for Warning onds during starting.
DOWN ER- service. MESSAGE: Discharged or defective bat-
ROR BATTERY IS tery.
WEAK See Warning message 441
Low Battery Voltage.
CODE: 1433 / Indicates local or remote
1434 Emergency Stop. Emergency
LAMP: Stop shutdown status can be CODE: 1443 Indicates battery has dropped
Shutdown reset only at the local control LAMP: below genset operating range
MESSAGE: panel. Warning (3.5 volts when cranking) to
EMERGENCY To reset the local/remote MESSAGE: power the starter and the con-
STOP − LO- Emergency Stop button: BATTERY IS trol circuitry.
CAL / Pull the button out. DEAD See Warning message 441
EMERGENCY Move the O/Manual/Auto Low Battery Voltage.
STOP − RE- switch to O (Off).
MOTE Press the front panel Fault Ac-
knowledge button. CODE: 1472 Indicates that generator output
Return O/Manual/Auto switch current has exceeded 110% of
LAMP: rated, and that a control time/cur-
to desired position.
SHUTDOWN rent calculation has initiated an
CODE: 1438 Indicates possible fault with overcurrent shutdown. This fault
MESSAGE:
LAMP: control or starting system. remains active and cannot be re-
Warning Check for the following condi- OVER CURRENT set until the Alternator Overheat
MESSAGE: tions: Integral time
FAIL TO has expired (which takes up to five
a. Poor battery cable con-
CRANK minutes). The Alternator Over-
nections. Clean the bat-
tery cable terminals and heat Integral time allows the alter-
tighten all connections. nator to cool down before allowing
b. Discharged or defective a restart.Check load and load lead
battery. Recharge or re- connections. (Fault may not reset
place the battery. for several minutes.)

5. Servicing the Generator
GENERAL WARNINGIncorrect service or replacement of
parts can result in severe personal injury or
This section describes how to isolate a voltage fault death, and/or equipment damage. Service per-
to the PCC control circuitry or generator, and the sonnel must be trained and experienced to per-
procedures to test, disassemble and reassemble form electrical and mechanical service.
the generator (Figure 4-1). WARNING HAZARDOUS VOLTAGE. The
PCC1301 control box must be opened only by
technically qualified personnel. Voltages of up
to 600 VAC are present in the PCC box. These
voltages can cause electrical shock, resulting in
personal injury.
EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET
PMG
STATOR
END
STATOR BEARING
BLOWER PMG
ROTOR
COUPLING
EXCITER
ROTOR
ROTATING
RECTIFIER
ASSEMBLY
DRIVE ROTOR
DISCS
FRAME
END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
FIGURE 5-1. TYPICAL GENERATOR

GENERATOR/PCC CONTROL ISOLATION 3. Prepare to measure output voltage across the gen-
PROCEDURE erator terminals while the set is running.
4. Bring two jumpers from a 12 volt battery for connec-
The following procedure is used to determine if the tion to the X (Field +) and XX (Field −) pins of plug 10.
generator or the PCC control circuitry is causing a X = Red wire of connector 10-6
high/low AC voltage shutdown fault. XX = Brown wire of connector 10-3
Connect the jumper from the positive (+) post of the
1. Throw the line circuit breaker OFF and shut down battery to the X pin (red wire) of 10-6. Be prepared to
the set. connect the jumper from the negative (−) post of the
CAUTION This test involves unregulated battery to the XX pin (brown wire) of 10-3. If one of
excitation of the generator. To prevent dam- the 12 volt cranking batteries is used, bring the
jumpers from the battery connected on the
age to the generator due to overcurrent,
grounded side of the system to avoid inadvertently
make sure that all loads have been discon- imposing 24 volts on the system.
nected and that all faults have been cleared
5. Check polarity again. Polarity must be correct or this
from the power output terminals of the gen-
test will be inconclusive because the induced and
erator. residual magnetic polarities in the exciter stator will
be opposed.
WARNING HAZARDOUS VOLTAGE.
Touching uninsulated parts inside the con- 6. Start the set and connect the jumper from the battery
negative (−) terminal to the XX lead.
trol housing and power output boxes can
result in severe personal injury or death. 7. The generator circuitry is probably okay if rated out-
Measurements and adjustments must be put voltage or higher is obtained and the voltages for
all phases are balanced when the exciter is powered
done with care to avoid touching hazardous
by a 12 volt battery. Refer to Troubleshooting and
voltage parts. Repair Manual PowerCommand Control to trouble-
Stand on a dry wooden platform or rubber shoot the PCC control circuitry. (Normal excitation
voltage ranges from approximately 10 VDC at no-
insulating mat, make sure your clothing and
load to approximately 40 VDC at full−load.)
shoes are dry, remove jewelry and use tools
8. If the voltages are unbalanced, troubleshoot the
with insulated handles.
main stator first. If the voltages are uniformly low,
2. Open the door of the control box assembly and re- troubleshoot the exciter and field circuits first. Per-
move plug 10 from connector 10 of the voltage regu- form the Winding Resistance Test procedure for the
lator output module. desired windings as noted in this section.

TESTING THE GENERATOR Insulation Resistance Testing
These tests can be performed without removing the The insulation resistance test should be performed
generator. Before starting tests, disconnect the neg- before the initial start-up of the generator set or
ative (−) cable from the battery to make sure the en- when low winding insulation is suspected, e.g.
gine will not start while performing these tests. damp or wet windings.
A 500 VAC megger is recommended for insulation
WARNING Ignition of explosive battery gases testing. A test consists of applying the test potential
can cause severe personal injury or death. Arc- between the winding and ground (winding lamina-
ing at battery terminals, light switch or other tions).
equipment, flame, pilot lights and sparks can ig-
nite battery gas. Do not smoke, or switch trouble Resistance values of at least 5.0 megohms should
light ON or OFF near battery. Discharge static be obtained for a new generator with dry windings.
electricity from body before touching batteries For a set that has been in service, the resistance
by first touching a grounded metal surface. reading should not be less than 1 megohm.
If low readings are obtained, the cause should be in-
Ventilate battery area before working on or near vestigated and corrected before the generator set is
battery—Wear goggles—Stop genset and dis- returned to service.
connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and If moisture is determined to be the cause of low test
reconnect last. readings, a winding drying process will be required.
Megger Testing:
CAUTION Disconnect battery charger from AC
source before disconnecting battery cables. 1. Open the control box door and remove connec-
Otherwise, disconnecting cables can result in tor 10 from the AVR module.
voltage spikes damaging to DC control circuits 2. Disconnect the AC voltage sense leads from
of the set. the generator output terminals. The AC voltage
sense leads are marked 5, 6, 7 and 8. Refer to
WARNING Accidental starting of the generator the appropriate Reconnection Diagram in Sec-
set can cause severe personal injury or death. tion 7.
Prevent accidental starting by disconnecting
3. If the RTD (resistive thermal device) option is
the negative (−) cable from the battery terminal. installed, ground all six RTD temperature
leads. Each RTD has three leads, one red and
two white leads. Total of 18 leads must be
grounded.
4. Perform the Insulation Resistance Test proce-
dure for the desired windings as noted in this
section.
Drying the Windings: If low readings are obtained
or the set has been in standby for a long time in high
humidity conditions, the windings should be dried
out and the test repeated. Use the generator heat-
ers (if so equipped) or blow warm air through the
generator from front to back with a fan.

Exciter Stator Testing Winding Insulation Resistance: Discon-
nect exciter stator leads F1 and F2 from their con-
Testing Winding Resistance: Measure winding nectors in the AC wiring harness and isolate them
resistance with a Wheatstone bridge or digital ohm- from ground. Connect either one to the megger and
meter. Replace the stator if winding resistance is not conduct the test as instructed under Insulation Re-
as specified by Table 4-1. sistance Testing.
MEASURE WINDING MEASURE WINDING RESISTANCE

INSULATION RESISTANCE BETWEEN THE TWO STATOR
BETWEEN EITHER LEAD LEADS, F1 (X) AND F2 (XX)
AND THE STATOR
LAMINATIONS
FIGURE 5-2. TESTING THE EXCITER STATOR

Exciter Rectifier Bridge (Rotating Rectifier sistance is high or low in both directions, replace the
Assembly) diode.
Replacing Diodes: Make sure the replacement

The exciter rectifier bridge is mounted on the exciter
diode is of the correct polarity. Disconnect the pigtail
rotor, inboard, facing the main rotor. It consists of a
from the terminal post and unscrew the old diode.
positive plate and a negative plate, split diametrical-
Apply heat-sink compound under the head of the
ly. Each carries three diodes, three terminal posts
diode. Make sure the compound does not get on the
for connecting exciter rotor leads to the diode pig-
threads. Torque the diodes to 36 to 42 in-lbs (4 to 4.8
tails and a terminal for the main rotor (generator
Nm) and the pigtail terminals to 24 in-lbs (2.7 Nm)
field) lead. A surge suppresser is connected across
when reassembling.
the two plates to prevent transient voltages that
could damage the diodes. Surge Suppresser Testing and Replacement:
Remove the suppresser. Replace the suppresser if
Testing Diodes: Disconnect the diode pigtails from it appears to have overheated or if ohmmeter read-
the terminal posts. Using an ohmmeter, measure ings indicate less than infinite resistance (end of
electrical resistance between each diode pigtail and scale) in both directions. Torque the terminals to 24
the plate on which the diode is mounted. Reverse in-lbs (2.7 Nm) when reassembling.
the meter test probes and repeat the tests. The
electrical resistance across each diode should be CAUTION Layers of dust can cause diodes to
high in one direction and low in the other. If the re- overheat and fail. Brush dust off regularly.
DIODE (ONE OF SIX) TERMINAL

DISCONNECT THE DIODE (ONE OF SIX)
PIGTAIL FROM THE TERMINAL
AND MEASURE ELECTRICAL
RESISTANCE BETWEEN THE
DIODE PLATES
PIGTAIL AND THE METAL
(TWO)
PLATE UNDER THE DIODE
SURGE SUPPRESSER
REMOVE TO TEST
FIGURE 5-3. TESTING THE ROTATING RECTIFIER ASSEMBLY

Exciter Rotor Testing Winding Insulation Resistance: Connect
any lead to the megger and conduct the test as
Testing Winding Resistance: Disconnect the six
instructed under Insulation Resistance Testing.
rotor winding leads from the terminal posts on the
rectifier assembly. With a Wheatstone bridge, mea-
sure electrical resistance across each pair of rotor
windings: U (CR1 or CR4) and V (CR2 or CR5), V
(CR2 or CR5) and W (CR3 or CR6), W (CR3 or CR6)
and U (CR1 or CR4). See the winding schematic.
Replace the whole rotor shaft assembly if the resist-
ance of any winding is not approximately 0.136
ohms.
MEASURE WINDING INSULATION

RESISTANCE BETWEEN ANY LEAD
OR THE TERMINAL TO WHICH IT IS
CONNECTED AND THE ROTOR
LAMINATIONS MAIN ROTOR
LEADS
WINDING SCHEMATIC
DISCONNECT THE SIX ROTOR WINDING

LEADS FROM THEIR TERMINALS AND
MEASURE ELECTRICAL RESISTANCE
ACROSS EACH PAIR OF WINDINGS: U-V,
V-W, W-U
FIGURE 5-4. TESTING THE EXCITER ROTOR

Main Rotor (Generator Field) Testing Winding Insulation Resistance: Connect
either lead to the megger and conduct the test as
Testing Winding Resistance: Disconnect the two
instructed under Insulation Resistance Testing.
leads of the main rotor from the terminals on the ro-
tating rectifier assembly. See Figure 4-4. Measure
electrical resistance between the two leads with a
Wheatstone bridge or digital ohmmeter. Replace
the rotor if the resistance is not as specified in Table
4-1. Connect the rotor leads and torque the termi-
nals to 24 in-lbs (2.7 Nm) when reassembling.
MEASURE WINDING INSULATION

RESISTANCE BETWEEN EITHER ROTOR
LEAD AND THE ROTOR LAMINATIONS
DISCONNECT THE MAIN ROTOR LEADS

FROM THE ROTATING RECTIFIER ASSEMBLY
AND MEASURE THE WINDING RESISTANCE
BETWEEN THEM
FIGURE 5-5. TESTING THE MAIN ROTOR

Main Stator Winding Resistance: Disconnect all main stator
leads from the terminals to which they are con-
Winding Insulation Resistance: Test each wind-
nected. Using a Wheatstone bridge having at least
ing separately. Disconnect the winding lead from its
0.001 ohm precision, measure electrical resistance
grounded neutral connection and isolate it (see re-
across each pair of stator leads (see reconnection
connection drawing). Leave the other windings
drawing). Replace the stator if the resistance of any
grounded. Connect either or both winding leads to
winding is not as specified in Table 4-1.
the megger and conduct the test as instructed under
Insulation Resistance Testing.
WHEATSTONE
BRIDGE
FIGURE 5-6. TESTING THE GENERATOR STATOR

TABLE 5-1. WINDING RESISTANCE VALUES*
MAIN STATOR
FRAME EXCITER EXCITER MAIN
MODEL WINDING WINDING WINDING WINDING
SIZE STATOR ROTOR ROTOR
11 12 17 07
5C 17 0.174 1.55 0.0068 N/A 0.0105 N/A
DFEG 5D 17 0.174 1.77 0.0057 N/A 0.0079 N/A
thru
DFEK 5E 17 0.174 1.96 0.0043 N/A 0.0068 N/A
5F 17 0.174 2.16 0.0037 N/A 0.0049 N/A
6G 17 0.158 1.44 0.0037 0.0148 N/A 0.011
DQCA 6H 17 0.158 1.54 0.0027 0.0108 N/A 0.0072
thru
DQCC 6J 17 0.158 1.73 0.0024 0.0096 N/A 0.006
6K 17 0.158 1.95 0.0019 0.0076 N/A 0.0052
* Resistance figures are approximate, at 68 F (20 C) + 10%.
TESTING THE PMG 2. Start the engine at the set and let the speed stabi-
lize.
WARNING HAZARDOUS VOLTAGE.
3. Measure voltage across lead pairs J10-1 & J10-4,
Touching uninsulated parts inside the con- J10-4 & J10-5, and J10-5 & J10-1. Voltage should
trol housing and power output boxes can be at least 150 VAC for 50 Hz sets and at least 180
result in severe personal injury or death. VAC for 60 Hz sets, and should be approximately the
Measurements and adjustments must be same for each set of leads. If the voltages are low or
done with care to avoid touching hazardous uneven, check all the leads and connections be-
voltage parts. tween the voltage regulator output stage module
and the PMG and repair as necessary before disas-
Stand on a dry wooden platform or rubber sembling the PMG.
insulating mat, make sure your clothing and
shoes are dry, remove jewelry and use tools 4. Stop the set and measure electrical resistance
across lead pairs J10-1 & J10-4, J10-4 & J10-5, and
with insulated handles. J10-5 & J10-1 with a Wheatstone bridge or digital
1. Disconnect plug J10 from the voltage regulator out- ohmmeter. Each winding should have a resistance
put stage module. of approximately 2.6 ohms.

BEARING REMOVAL/REPLACEMENT Bearing Lubrication
Bearing Removal
When re-lubricating or replacing the bearing, review
The end bearing is enclosed in a pre-packed car- the following.
tridge housing and must only be dismantled as nec-
essary for relubrication, replacement, or when a
 Recommended Lubricant: Lithium based grease,
major overhaul is carried out on the generator set. Mobilux No. 2 or Shell Alvania R3.
Removal of the bearing can only be accomplished  Temperature Range: -22F to +248F (-30C to
after removal of the endbracket, as follows: +120C).
1. Remove the four screws holding bearing cap.  Quantity: 2.74 oz. (81 ml). The grease should be
2. Remove cap. equally divided between the bearing, the bearing
cap cavity, and the bearing cartridge cavity.
3. Remove circlip.
4. Remove bearing cartridge housing complete with  Inspect all sealed bearings every 4000 to 4500
bearing. hours.
Bearing Replacement  Replace all bearings (sealed or regreasable) every

30000 hours / 5 years (or if necessary after 10000
When replacing bearing onto rotor shaft, be sure to hours / 2 years).
apply pressing force to the inner face of the bearing  Regrease all bearings every 4000 to 4500 hours / 6
only. Install the bearing in reverse order of removal. months.

GENERATOR DISASSEMBLY 3. Remove the lower back panel of the control
housing (see Figure 4-7).
The following procedures provide information for re- 4. Remove the three M5X12mm capscrews and
moval and reassembly of the PMG, exciter, control lockwashers from the PMG cover, and remove
housing, and stator/rotor assemblies. Be sure to cover.
read through this section first, before performing
5. Disconnect the PMG wiring harness connector.
procedures listed, to determine the steps most ap-
propriate for the service attention required. 6. Remove the four bolts and clamps retaining the
exciter stator housing to the endbracket.
Permanent Magnet (PMG) Removal 7. Tap the stator housing out of its spigot, and
carefully remove from generator endbracket.
WARNING Ignition of explosive battery gases
can cause severe personal injury or death. Arc- The highly magnetic rotor will attract the stator
ing at battery terminals, light switch or other core; care must be taken to avoid any contact
equipment, flame, pilot lights and sparks can ig- which may damage the windings.
nite battery gas. Do not smoke, or switch trouble 8. Remove the hex head through-bolt from the ro-
light ON or OFF near battery. Discharge static tor shaft and firmly pull the complete rotor as-
electricity from body before touching batteries sembly from its location. Keep the rotor clean
by first touching a grounded metal surface. by avoiding contact with metal dust or particles.
Ventilate battery area before working on or near CAUTION The rotor assembly must not be
battery—Wear goggles—Stop genset and dis- dismantled, or the magnetic properties will
connect charger before disconnecting battery be destroyed.
cables—Disconnect negative (−) cable first and
reconnect last. Permanent Magnet (PMG) Installation
1. Install the complete rotor assembly to the end
CAUTION Disconnect battery charger from AC of the main rotor shaft using the hex head
source before disconnecting battery cables. through-bolt. Keep the rotor clean by avoiding
Otherwise, disconnecting cables can result in contact with metal dust or particles.
voltage spikes damaging to DC control circuits
of the set. 2. Carefully locate the stator housing to position
on the generator endbracket. Fasten in place
WARNING Accidental starting of the generator using the 4 bolts and clamps, and tighten se-
set can cause severe personal injury or death. curely.
Prevent accidental starting by disconnecting The highly magnetic rotor will attract the stator
the negative (−) cable from the battery terminal. core, care must be taken to avoid any contact
1. Turn off and disconnect battery charger (if which may damage the windings.
equipped). 3. Connect the PMG wiring harness connector.
2. Disconnect the negative (-) battery cable to 4. Install the PMG assembly cover using the three
prevent accidental starting of the generator set M5x12mm capscrews and lockwashers, and
while servicing. tighten securely.

UPPER ACCESS
PANEL LOCATION
(BOTH SIDES)
UPPER FRONT
PANEL
LOWER BACK
PANEL
LOWER FRONT SIDE
PANELS PANEL
DFEG−DFEK CONTROL HOUSING
CONTROL HOUSING
CONTROL HOUSING
ACCESS COVERS
(BOTH SIDES)
GENERATOR AIR INLET

GENERATOR
COVER (ROTATING
AIR
RECTIFIER ACCESS)
DISCHARGE
COVERS
DQCA−DQCC CONTROL HOUSING
FIGURE 5-7. CONTROL HOUSING ASSEMBLIES

Main Stator and Rotor Removal generator. Make sure that hoisting device
is controlling weight of control housing as-
1. Remove the PMG, refer to Permanent Magnet
sembly.
Generator Removal, earlier this section.
b. Remove control housing fasteners, and re-
2. DFEG−DFEK: Remove the lower back panel, move the control housing assembly from
the two lower front panels and the upper access the generator.
panels of the control housing assembly (see
12. DQCA−DQCC Control Housing Removal
Figure 4-7).
3. DQCA−DQCC: Remove the upper access a. Loosen the fasteners that secure the con-
panels of the control housing assembly. trol housing side panels to generator.
Make sure that hoisting device is control-
4. Remove the air inlet and discharge panels of ling weight of control housing assembly.
the generator.
b. Remove control housing fasteners, and re-
CAUTION Do not use fan blade to bar over move the control housing assembly from
engine. That can damage blades and cause the generator. Replace panel fasteners to
property damage and personal injury. their respectable positions for safe keep-
ing, and tighten finger-tight.
5. Crank or bar the engine/generator to position
the rotor such that a full pole face is at the bot- To remove the stator and rotor at the same time,
tom of the main stator core. Proper positioning skip to step 30. To remove the stator and rotor in-
can be viewed through the generator access dividually, continue with step 13.
openings. Refer to engine service manual for 13. Remove the four bolts retaining the bearing
proper cranking or barring procedure. cartridge housing in the endbracket (outer four
6. Disconnect all load wires from the reconnection bolts).
terminal block assembly. If equipped with the 14. Remove the eight bolts holding the endbracket
circuit breaker option, disconnect load wires to the generator housing.
from circuit breaker. Check that all leads are la-
beled to ease reassembly. 15. Insert two bolts (M10) in the two holes provided
for “jacking” purposes, on the endbracket cen-
7. Disconnect the remote control wiring and con- ter line. Screw bolts in until endbracket spigot
duit from the control housing. For reconnec- is clear of locating recess.
tions later, make sure each wire is clearly
marked to indicate the correct terminal. 16. Carefully tap the whole assembly off the bear-
ing cartridge housing, ensuring the endbracket
8. Disconnect the engine harness connectors (IN- is supported to prevent the exciter stator from
LINE A, B, and C) and the DC power connector damaging the windings on the exciter rotor.
for the engine block heaters (INLINE F) and
place harness on top of control housing. WARNING To prevent personal injury, use
9. Mark and disconnect the wires to the CT’s. adequate lifting devices to support heavy
components. Keep hands and feet clear
10. Use a hoist or similar lifting device to support while lifting.
the control housing assembly.
17. The exciter stator is now accessible for inspec-
WARNING To prevent personal injury, use tion and removal from endbracket/engine
adequate lifting devices to support heavy adaptor.
components. Keep hands and feet clear 18. The end bearing can now be removed if re-
while lifting. quired. Refer to Bearing Removal in this sec-
11. DFEG−DFEK Control Housing Removal tion.
a. Loosen the fasteners that secure the con- 19. Remove the fasteners from the two generator
trol housing side and bottom panels to mounting feet brackets.

20. Using an adequate lifting device, lift the genera- place by supporting the flywheel housing. A
tor (at lifting eyes provided, and main stator length of steel channel and wooden blocking is
housing) until the mounting feet brackets are required to support the rear of the engine. Place
clear of the frame member (see Figure 4-8). the channel and blocking under the flywheel
housing. Lower the generator until most of the
21. If the engine does not have chassis mounts at genset weight is supported by the blocking (see
generator end, block the rear of the engine in Figure 4-8).
STATOR ROTOR
ASSEMBLY ASSEMBLY
LIFT LIFT
USE FORKLIFT OR
OTHER ADEQUATE
LIFTING DEVICE TO
SLIGHTLY LIFT
ROTOR SHAFT UNTIL
ROTOR CAN BE
SUPPORTED BY
HOIST/SLING.
BLOCKING UNDER
STATOR MOUNTING FEET ROTOR ENGINE FLYWHEEL
ASSEMBLY BRACKETS ASSEMBLY HOUSING
FIGURE 5-8. REMOVING STATOR ASSEMBLY

22. Disconnect the grounding strap from the fly- sembly. Do not allow rotor assembly to hang on
wheel housing. engine flywheel.
23. Using a forklift, position a lifting bar of the forklift CAUTION Drive disc damage can be
(inside and inline with the generator) under the caused by allowing the rotor assembly to
rotor shaft. Lift the rotor shaft slightly so that ro- hang on flywheel. Use adequate hoist and
tor is not resting on inside of stator assembly. sling to support the rotor assembly.
See Figure 4-9.
26. Reposition or add hoist and sling support for the
24. Verify that the stator is adequately supported main rotor, and remove the forklift. See Figure
and then carefully remove the capscrews from 4-9, Rotor Lift detail.
the stator attachment ring.
WARNING To prevent personal injury, use
WARNING To prevent personal injury, use adequate lifting devices to support heavy
adequate lifting devices to support heavy components. Keep hands and feet clear
components. Keep hands and feet clear while lifting.
while lifting. 27. Remove the stator assembly, being careful not
to drag the windings on the rotor. Place stator
CAUTION Improper stator assembly rig- assembly away from the chassis in the horizon-
ging and handling can result in damage to tal position.
stator and rotor assemblies. Lifting eyes 28. Using the hoist and sling to support the rotor,
may not be at center-of-gravity position of carefully remove the capscrews and flat wash-
stator assembly. Therefore, lifting and mov- ers that secure the drive discs to the engine fly-
ing the stator assembly alone, by hoisting wheel.
at lifting eyes only, presents the hazard of
load imbalance; allowing one end to drop WARNING To prevent personal injury, use
and other end to rise. Make sure the stator is adequate lifting devices to support heavy
adequately hooked/strapped to maintain components. Keep hands and feet clear
level control of stator assembly while lifting while lifting.
and moving. 29. Remove the rotor assembly and place it on
25. Being careful not to drag the windings on the ro- wood blocks in the horizontal position. To avoid
tor, move the stator assembly sufficiently away possible distortion, do not allow the drive discs
from engine to sling and support the rotor as- and fan to rest on anything.

EXCITER
RECONNECTION
STATOR
TERMINALS
END BRACKET
PMG
STATOR
END
STATOR BEARING
BLOWER PMG
ROTOR
COUPLING
EXCITER
ROTOR
ROTATING
RECTIFIER
ASSEMBLY
DRIVE ROTOR
DISCS
FRAME
END BRACKET/ENGINE
ADAPTOR
AIR DISCHARGE
PRESSURE COVERS
ROTOR
PLATE
SHAFT
STATOR LIFT
(EXAMPLE)
ROTOR LIFT
(EXAMPLE)
FIGURE 5-9. TYPICAL GENERATOR ASSEMBLY

Generator Assembly Removal
GENERATOR
30. Remove the fasteners from the two generator LIFTING
mounting feet brackets. POSITIONS
31. Using an adequate lifting device, lift the genera-

tor (at lifting eyes provided, and main stator
housing) until the mounting feet brackets are
clear of the frame member (see Figure 4-10).
32. f the engine does not have chassis mounts at

generator end, block the rear of the engine in
place by supporting the flywheel housing. A
length of steel channel and wooden blocking is
required to support the rear of the engine. Place
the channel and blocking under the flywheel
housing. Lower the generator until most of the
set weight is supported by the blocking (see
Figure 4-10).
MOUNTING FEET BLOCKING UNDER
BRACKETS ENGINE FLYWHEEL
33. Disconnect the grounding strap from the fly-
HOUSING
wheel housing.
34. Carefully remove the capscrews and flat wash- FIGURE 5-10. GENERATOR LIFTING POSITIONS
ers that secure the drive discs to the engine fly-
wheel.
35. Verify that the generator assembly is adequate-

ly supported. Carefully remove the capscrews
securing the engine adaptor endbracket to the
engine flywheel housing.

adequate lifting devices to support heavy
while lifting.
CAUTION Improper generator assembly

rigging and handling can result in damage
to stator and rotor assemblies. Lifting eyes
may not be at center-of-gravity position of
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes
only, presents the hazard of load imbal-
ance; allowing one end to drop and other
end to rise. Make sure the generator is ade-
quately hooked/strapped to maintain level
control of assembly while lifting and mov-
ing.
36. Remove the generator assembly away from
engine. Place generator assembly on floor with
a piece of wood beneath the stator housing (to-
ward PMG end) to allow for endbracket remov-
al, if desired.

GENERATOR REASSEMBLY 6. Install the mounting feet bracket fasteners; and
tighten securely.
Generator reassembly is the reverse of disassem-
bly procedure. If endbracket has been removed, continue with
step 7, otherwise skip to step 16.
Note: To assemble the stator and rotor at the same
time, continue with step 1. To assemble the stator 7. Lift slightly on end of rotor shaft and install
and rotor individually, skip to step 17. wooden shims to hold rotor on center with sta-
1. Using an adequate lifting device, locate the tor.
generator assembly into position near the en- 8. If removed, refer to Bearing Removal/Replace-
gine flywheel housing. Align the holes of the ro- ment procedure in this section to install end
tor drive discs with the holes of the engine fly- bearing.
wheel. Install the capscrews and flat washers
that secure the drive discs to the engine fly- 9. Install two threaded studs into end bearing car-
wheel, hand tighten. tridge to aid subsequent procedures. Position
the end bearing cartridge assembly close to
WARNING To prevent personal injury, use proper position for hole alignment with end-
adequate lifting devices to support heavy bracket.
10. Assemble exciter stator, if removed, to inside of
while lifting.
endbracket. Tighten fasteners to 4.5 ft-lbs. (6
CAUTION Improper generator assembly Nm) torque.
rigging and handling can result in damage 11. Install endbracket to the stator frame using the
to stator and rotor assemblies. Lifting eyes proper capscrews and lock washers, but do not
may not be at center-of-gravity position of tighten securely as yet.
stator assembly. Therefore, lifting and mov-
ing the generator by hoisting at lifting eyes 12. Insert and start the threads of the bearing car-
only, presents the hazard of load imbal- tridge fasteners, and remove threaded align-
ance; allowing one end to drop and other ment studs, through the endbracket into the
end to rise. Make sure the generator is ade- cartridge housing.
quately hooked/strapped to maintain level 13. Lift slightly on endbracket and remove wooden
control of assembly while lifting and mov- shims holding rotor on center with stator.
ing.
2. Align the holes of the engine adaptor endbrack- 14. Securely tighten the endbracket fasteners.
et with the holes in the flywheel housing and 15. Tighten the bearing cartridge fasteners to 4.5 ft-
install the capscrews and lock washers. Refer lbs. (6 Nm) torque.
to Table 4-2 for torque specifications.
3. Secure the rotor assembly to the flywheel. Re- TABLE 4-2. GENERATOR MOUNTING TORQUE
fer to Table 4-2 for torque specifications. FLYWHEEL HSG.
ROTOR ASSEM.
4. Lift the generator slightly and remove any MODEL ENDBRACKET TO
TO FLYWHEEL
blocking from under the flywheel housing. Low- ENGINE ADAPTER
er the generator (see Figure 4-10). DFEG− 75−85 ft-lbs. 65−70 ft-lbs.
DFEK (102−115 Nm) (88−95 Nm)
5. Connect the grounding strap to the flywheel
housing using a capscrew and EIT locking DQCA− 125−145 ft-lbs. 56−64 ft-lbs.
washer; and tighten securely. DQCC (165−195 Nm) (75−85 Nm)

16. Install the PMG assembly, if removed. Refer to 21. Reassemble engine adaptor endbracket to sta-
Permanent Magnet (PMG) Installation. tor frame if removed. Using an adequate lifting
device, carefully move the stator into position
Perform the ‘Aligning Generator with Engine’ over the rotor assembly, being careful not to
procedures, later in this section, then return to drag the windings on the rotor.
the following steps.
To assemble the control housing, skip to step adequate lifting devices to support heavy
37. components. Keep hands and feet clear
while lifting.
To assemble the stator and rotor individually be-
gin here. CAUTION Improper stator assembly rig-
17. If removed, replace exciter rotor and rotating ging and handling can result in damage to
rectifier assembly to main rotor shaft. Recon- stator and rotor assemblies. Lifting eyes
nect main rotor wire leads to positive and nega- may not be at center-of-gravity position of
tive terminals of rectifier assembly. stator assembly. Therefore, lifting and mov-
ing the stator assembly alone, by hoisting
18. If removed, install the drive disk spacer, drive
at lifting eyes only, presents the hazard of
disc and pressure plate on the rotor shaft.
load imbalance; allowing one end to drop
Install the cap screws and flat washers and
and other end to rise. Make sure the stator is
tighten to 352 ft-lbs. (476 Nm).
adequately hooked/strapped to maintain
19. Using a hoist and sling to support the rotor, level control of stator assembly while lifting
align the holes in the drive disc with the corre- and moving.
sponding holes in the flywheel. 22. Using a forklift, position a lifting bar of the forklift
(inside and inline with the generator) under the
rotor shaft. Lift the rotor shaft slightly so that ro-
adequate lifting devices to support heavy tor is not resting on inside of stator assembly.
while lifting. 23. Remove the hoist/sling support of the rotor as-
sembly. Align the holes of the engine adaptor
20. Secure the rotor assembly drive disc to the fly-
endbracket with the holes in the flywheel hous-
wheel using appropriate capscrews and flat
ing and install the capscrews and lock washers.
washers. Refer to Table 4-2 for torque specifi-
Refer to Table 4-2 for torque specifications.
cations. Do not allow rotor assembly to hang on
engine flywheel. 24. Using an adequate lifting device, slightly raise
the generator so that the wooden blocking and
CAUTION Drive disc damage can be steel channel can be removed from under the
caused by allowing the rotor assembly to flywheel housing; then lower the generator so
hang on flywheel. Use adequate hoist and the full weight is resting on the generator
sling to support the rotor assembly. mounting feet brackets.

25. Connect the grounding strap to the flywheel 35. Tighten the bearing cartridge fasteners to 4.5 ft-
housing using a capscrew and EIT locking lbs. (6 Nm) torque.
washer; and tighten securely. 36. Install the PMG assembly, if removed. Refer to
26. Install the mounting feet bracket fasteners; and Permanent Magnet (PMG) Installation.
tighten securely.
27. Lift slightly on end of rotor shaft and install adequate lifting devices to support heavy
wooden shims to hold rotor on center with sta- components. Keep hands and feet clear
tor. while lifting.
37. Use an adequate lifting device to lift the control
28. If removed, refer to Bearing Removal/Replace-
housing in position for mounting. Replace the
ment procedure in this section to install end
capscrews and lock washers and tighten to 18
bearing.
ft-lbs. (24 Nm) torque.
29. Install two threaded studs into end bearing car- 38. Connect all control wires and generator leads
tridge to aid subsequent procedures. Position using the proper generator set AC and DC wir-
the end bearing cartridge assembly close to ing diagram/schematic.
proper position for hole alignment with end-
bracket. 39. Reassemble any engine air intake components
removed during generator disassembly.
30. Assemble exciter stator, if removed, to inside of 40. Reassemble the covers over the generator air
endbracket. Tighten fasteners to 4.5 ft-lbs. (6 discharge openings and fasten securely.
Nm) torque.
41. If equipped with the circuit breaker option, re-
31. Install endbracket to the stator frame using the connect load wires to circuit breaker. Recon-
proper capscrews and lock washers, but do not nect all lead wires to the terminal block assem-
tighten securely as yet. bly using proper reconnection diagram in Sec-
tion 7.
32. Insert and start the threads of the bearing car-
tridge fasteners, and remove threaded align- 42. Verify that all connections are proper and se-
ment studs, through the endbracket into the cure and then install the air inlet panel and ac-
cartridge housing. cess covers to control housing.
33. Lift slightly on endbracket and remove wooden 43. Connect the negative (-) battery cable and test
shims holding rotor on center with stator. the generator set for operation. If objectionable
vibration is present, refer to Aligning Generator
34. Securely tighten the endbracket fasteners. with Engine procedure later this section.

ALIGNING GENERATOR WITH ENGINE Misalignment Symptoms: If the assembly is al-
lowed to run under these conditions, the discs must
flex in alternate directions twice for each engine rev-
Proper alignment of the generator and engine as- olution. It is important to minimize the amount of disc
semblies is necessary to avoid premature wear and flexing since, if it is excessive, the drive disc will
improper operation of the genset. Review the fol- crack. Although perfect bearing alignment is desir-
lowing alignment conditions and procedures for able, it is more important to keep disc deflection to
aligning the generator assembly to engine flywheel the minimum possible. This procedure assumes
housing. that the pilot bore of the drive discs are in the exact
center and the flywheel counterbore (pilot) has no
Angular Misalignment: Is the result of the genera- practical runout. Under these conditions, perfect
tor bearing center axis not aligning with axis of the Angular alignment will be attained when no deflec-
engine crankshaft. This condition creates an angle tion of the disks is measured.
between the generator shaft axis and the crankshaft
axis. The cause of this type of misalignment is usu- Excessive Axial misalignment will cause more gen-
ally shimming error. erator vibration than Angular misalignment.
Either type of misalignment may be present in a

Axial Misalignment: Is the result of the generator generator set assembly, with angular misalignment
shaft axis not aligning with engine crankshaft axis. being the most common problem. Angular align-
The tolerances in the bolted flywheel and drive disc ment may also be effected by set installation condi-
connection may add up to displace the generator tions and/or mishandling during shipping of the gen-
axially relative to the crankshaft axis. set.

Angular Alignment Procedure disc at the bolt circle diameter, see Figure 4-11. Bar
the engine over in a clockwise rotation as viewed
WARNING Accidental starting of the generator from engine flywheel. Do not allow it to roll back on
set during this procedure presents the hazard of compression at the end of the travel of each read-
severe personal injury or death. Make sure to ing. It is unnecessary to zero the indicator since the
disconnect the negative (-) battery cable(s) be- total indicator reading (T.I.R.) of the deflection mea-
fore beginning.
surement to the bolt heads is what is required. T.I.R.
Fasten a dial indicator to either the generator shaft will be the sum of the maximum positive and nega-
or the cooling fan with the sensing point resting on tive dial indicator readings as the engine completes
the capscrew head or the flat surface of the drive one revolution.
SEE DETAIL A
CLAMP DIAL
INDICATOR
FLEX
DISCS
GENERATOR
MOUNTING BOLT
AND ENGINE AXIAL
TO DISC
CRANKSHAFT ALIGNMENT, SEE
MEASUREMENT
CENTERLINE FIGURE 4-13
DETAIL A
SHIMS
FIGURE 5-11. ANGULAR ALIGNMENT MEASUREMENT

Sample Generator Runout Readings 2. Measure the distance from the generator side of the
flex discs to the center of the generator mounting
When taking the deflection readings described, bolt, refer to Figure 4-11. (For example; a HC6
make a diagram similar to the example shown in Frame’s distance is 28.4”.)
Figure 4-12, where a total indicator reading of .025”. 3. Compare the distance measured in steps 1 and 2.
(The highest positive value of +.010 and the largest (28.4” vs 10.7” or a 2.65 to 1 ratio.) Multiply this ratio
negative value of -.015”.) The indicator is closer to times one half the T.I.R. (In our example, .025” divid-
the top and further away at the bottom. This exam- ed by 2 is .0125”. This, times 2.65 equals .033”.
ple indicates that the generator bearing is high. Therefore, remove .033” of shims from under both
Since the side readings are equal, the generator is mounting feet.)
centered side to side. To lower the generator, re-
move equal shims from under both generator In general, the T.I.R. should not be more than .001”
mounting feet. To approximate the amount of shims for each inch of radius (center of shaft to indicator
to remove or add: axis). If we use our example of 10.7”, then the maxi-
1. Measure the distance between the center of the mum T.I.R. would be .011”. This would only require a
generator shaft to the point the indicator is measur- correction of .014” from the T.I.R. of .025”. (A read-
ing at. (For example; a SAE 18 Disc coupling dis- ing of +.002 at the top and -.009 at the bottom would
tance is 10.7”). fall within the satisfactory range.)
+.010 +.010
MEASURED AT
BOLT CIRCLE
DIAMETER
-.002
-.004
10.7
IN.
-.010
-.010
-.015 -.015
FIGURE 5-12. ANGULAR ALIGNMENT MEASUREMENT READINGS (Example)

Axial Alignment Procedure varying surface quality of the generator shaft’s drive
disc mounting hub.
Note: Axial misalignment needs to be checked only
when an objectionable vibration is present. The goal of the Axial realignment is to reduce the
vibration level of the genset while it is operating. A
If excessive vibration remains after the angular small improvement in the T.I.R. runout may have
alignment, check for concentric alignment of the dramatic effects in the mechanically measured or
generator shaft/engine crankshaft axes. physically observed vibration levels.
To correct for an out of tolerance T.I.R. indication, re-

Fasten dial indicator holding device to skid base, move the capscrews connecting drive discs and fly-
engine block, or generator shell with a magnetic wheel. Mark the drive discs and flywheel with re-
base or clamp and position so the sensor point of inspect to each other. Rotate either the engine or gen-
dicator rests on the generator shaft hub, see Figure erator so that drive discs holes are repositioned 180
4-13. Bar the engine over in a clockwise rotation as degrees from their original location. Put the drive
viewed from engine flywheel, through a couple of discs capscrews back in and retorque. Recheck
rotations. Record indicator readings in eight equally shaft alignment as before. If shaft T.I.R. runout re-
spaced points around the shaft diameter. This will mains unchanged then the discs should be rotated
provide a T.I.R. for Axial shaft misalignment. to either 30, 60, or 90 degrees from original location
to correct the out of tolerance condition. If the T.I.R.
The maximum allowable T.I.R. runout is subjective, does not improve after repositioning, a closer in-
the optimal T.I.R. for runout would be .000”, howev- spection of the flywheel pilot and drive disc runouts
er, that may not be attainable. The recommendation is required. This will help determine the cause of the
of this procedure will be to reduce the measured Axial misalignment.
T.I.R. runout by one half. Specific out-of-tolerance
runout levels are difficult to establish due to the
ANGULAR ALIGNMENT,
SEE FIGURE 4-11
GENERATOR
SHAFT HUB
DIAL
INDICATOR
GENERATOR AND
ENGINE CLAMP
CRANKSHAFT SEE DETAIL A FAN HOUSING
CENTERLINE
DETAIL A
FIGURE 5-13. AXIAL ALIGNMENT MEASUREMENT

6. Generator Set Long Term Storage
Following are the necessary steps that need to be  Tectylt 511−M or equivalent rust preventative
taken any time that a Cummins powered diesel gen- compound that meets military specification
erator set with the HPI Fuel system will either be in MIL−C−16173C, type P−2, Grade 1 or 2
storage, or inactive without exercise, for a period of  Daubert Chemical NoxRust No. 518 or equiva-
6 to 24 months. lent preservative oil that meets military specifi-
cation MIL−L−644, type P−9
Note: Failure to follow these instructions may invali-
date the warranty and may result in reduced reliabil-  Moisture indicating silica desiccant gel packs
ity. Please contact your local factory representative  Heavy paper or plastic and tape
for more details.
 Corrosion inhibiting plastic such as Zerust
Note: This procedure must be repeated every 24 Note: Do not leave Bio−Free diesel fuel in the fuel
months for HPI fuel system equipped engines. system longer than 6 months.
WARNING Hot Pressurized Liquid Note: Do not leave diesel fuel containing bio compo-
Contact with hot liquid can cause severe burns. nents in the fuel system during storage. Fuel proper-
Do not open the pressure cap while the engine is run- ties degradation may cause damages and lead to pre-
mature failure of the fuel system components.
ning. Let the engine cool down before removing the
cap. Turn the cap slowly and do not open it fully until PROCEDURE
the pressure has been relieved. Follow the proper starting procedure to start the
generator set.
WARNING Moving Parts Bring the generator set to rated speed with no
Moving parts can cause severe personal injury. load.
Use extreme caution around moving parts. All Operate the generator set until the coolant tem-
guards must be properly fastened to prevent unin- perature reaches 160_F (70_C).
tended contact. Follow the proper procedure to turn off the gener-
ator set.
WARNING High Noise Level Follow the necessary lock−out−tag−out proce-
Generator sets in operation emit noise, which can dures to ensure the generator does not start.
cause hearing damage. Drain the engine oil from the oil sump.
Wear appropriate ear protection at all times. Install the drain plug and fill the engine to the high
mark with the Tectylt 915W40, or equiva-
WARNING Hot Surfaces lent engine preservative oil.
Contact with hot surfaces can cause severe- Disconnect the inlet fuel line to the engine fuel fil-
burns. Wear appropriate PPE when working on ter.
hot equipment and avoid physical contact with Disconnect the injector fuel return line.
hot surfaces. Put both fuel lines in the container of bio−free die-
sel fuel.
Keep multi−class ABC fire extinguishers handy. Follow the proper starting procedure to start the
Class A fires involve ordinary combustible ma- generator set.
terials such as wood and cloth. Class B fires in- Once the engine is operating smoothly, transfer
volve combustible and flammable liquid fuels the fuel supply line to the container of the
and gaseous fuels. Class C fires involve live Daubert Chemical NoxRust No. 518 or
electrical equipment. (Refer to NFPA No. 10 in equivalent preservative oil outlined in the
applicable region.) Required Materials section.
Operate the generator set at idle for 25 minutes
REQUIRED MATERIALS
to ensure the engine preservative oil and the
 Tectylt 915W40 or equivalent engine preser- fuel system preservative is fully distributed.
vative oil that meets military specification MIL− Follow the proper procedure to turn off the gener-
PRF−21260, type P−10, Grade 2, SAE 30 ator set.

Follow the necessary lock−out−tag−out proce- Place a warning tag on the generator set stating
dures to ensure the generator set does not “Engine Does Not Contain Oil” and “Do
start. not Operate.”
Re−connect both fuel lines. Store the generator set in a clean, dry, vibration
Drain the preservative oil from the engine oil pan free and climate controlled area.
sump, oil filter and fuel filters. ADDITIONAL STEPS
Install the drain plug in the oil sump. The sump
can remain empty until the engine is ready Note: For two bearing alternators, decouple the alter-
to put in a service application. nator from the engine. For single bearing machines,
do not decouple.
Remove the intake and exhaust manifolds
Spray Tectylt 511−M or equivalent into the in- Note: Do not rotate the engine during long term stor-
take and exhaust ports in the cylinder heads age.
and in the manifolds. Note: If the two bearing alternator is decoupled, ro-
Note: Do not spray Tectylt 511−M or equivalent pre- tate only the alternator 6 complete revolutions every
servative oil on the intake manifold or any fuel sys- 4 weeks. For single bearing machines, do not rotate.
tem components as this may permanently damage  Leave the alternator anti−condensation heat-
sensors or valves. ers in operation. If power to the heaters is un-
available, then place multiple silica desiccant
Brush or spray Tectylt 511−M or equivalent on
gel packs in the core of the alternator at both
all the exposed surfaces that are not
ends of the rotor and in the terminal box.
painted. Preservative oil should not be ap-
plied to any plastic, rubber or similar sur-  Place multiple silica desiccant gel packs on the
faces. Make sure to coat the flywheel, fly- outside of the generator at, or near the following
wheel housing and all other unpainted ma- areas:
chined surfaces with this preservative oil. Intake/exhaust manifolds
Remove the rocker lever covers. Generator set control panel
Spray Tectylt 511−M or equivalent onto the ECM’s
rocker levers, valve stems, springs, valve Alternator Entrance box
guides, crossheads and push rods. Note: The amount of silica desiccant gel packs re-
Install the covers. quired and the replacement interval for the silica gel
Remove camshaft inspection covers. packs will vary based on manufacturer and the envi-
Spray Tectylt 511−M or equivalent onto the ronment the generator is exposed to. Follow
camshaft. manufacturer guidelines for replacement intervals
and to determine the amount needed. Moisture indi-
Install the covers.
cating gel packs will better determine when the re-
For components containing exposed bearings placements need to occur. Inspect the silica gel
that are not easily accessible (e.g. fan packs once a month.
hubs), remove the component to aid access.
 If necessary, disconnect the generator set bat-
Brush or spray Tectylt 511−M or equivalent
teries. Follow the manufacturer’s storage pro-
on all surfaces that are not painted and refit
cedures to store the batteries.
the component.
Remove any external drive belts to prevent local-  Cover all openings with heavy paper or plastic
ized stretching and deformation. and tape to prevent dirt and moisture from en-
If the generator set will remain in storage for 24 tering the engine/alternator.
months or more, the cooling system must be  Place a warning tag on the generator set stating
drained. there are silica desiccant gel packs at the loca-
tions placed.
Note: If the storage period will be less than 24
months, and if it meets Cummins coolant specifica-  Wrap the generator set in a corrosion inhibiting
tions for anti−freeze with anti−corrosion inhibitor, plastic such as Zerust.
then it is not necessary to drain the coolant.
RETURNING THE GENERATOR SET TO
SERVICE
Note: The engine cooling system must be drained
and flushed with suitable solvent or a hot, light- Remove the protective paper and plastic cover-
weight mineral oil after each 24−month period. ings.

Remove all silica desiccant gel packs. Flush the engine preservative oil out of the en-
For alternators with re−greasable bearings: gine by removing the plug from the main en-
If the alternator has been rotated during the gine oil rifle and pumping a hot, lightweight
storage period and has been in storage mineral oil through it. Make sure that the en-
between 6 and 24 months, re−grease gine crankshaft is barred at least 3 to 4 revo-
the bearings during the first run. Follow lutions during this flushing procedure.
the recommended re−greasing proce- Drain all the mineral oil that was used to flush the
dure found in the specific alternator ser- engine clean and the engine preservative
vice manual. oil.
If the alternator has not been rotated during Install the drain plugs.
the storage period and has been in stor- If necessary fill or flush/fill the cooling system:
age for a period longer than 12 months, If the generator set has been in storage for
replace the bearings. Follow the recom- less than 24 months and if the cooling
mended replacement procedure found system was drained, fill the cooling sys-
in the specific alternator service manu- tem with new coolant.
al. If the generator set has been in storage for
For alternators with sealed for life bearings: 24 months or more, the cooling system
If the alternator has been rotated during the must be drained and flushed with a suit-
storage period and has been in storage able solvent or a hot, lightweight miner-
for a period longer than 24 months, real oil.
place the bearings. Follow the recom- If the generator set has been in storage for
mended replacement procedure found less than 24 months and the cooling
in the specific alternator service manu- system has an extended life coolant
al. with a rust inhibitor, then drain and fill
If the alternator has not been rotated during the new cooling system with new cool-
the storage period and has been in stor- ant.
age for a period longer than 12 months, Fill and install new oil, fuel and coolant filters
replace the bearings. Follow the recom- Fill the oil pan sump.
mended replacement procedure found
If necessary, re−connect the generator set bat-
in the specific alternator service manu-
teries.
al.
Prime the lubricating system using the main oil
For two bearing machines, recouple the alterna-
rifles of the engine.
tor to the engine if necessary.
Reinstall any belts that were removed.
For the alternator, carry out the “pre−running”
checks as detailed in the specific alternator Note: The engine may run unstable until the fuel sys-
model service manual to determine the con- tem is completely primed, or until the preservative
dition of the windings. fluid is completely flushed out of the fuel system.

THIS PAGE LEFT INTENTIONALLY BLANK

7. Enclosure Fuel Tank System (DFEG-EK)
GENERAL PCC Customer Inputs
This section describes the operation and testing of
the components of the optional fuel tank system
shown in Figure 7-1. PCC Customer Switch 1 (Rupture Basin) and Local
Low Fuel Switch Input are prewired to the sub-base
When a sub-base fuel tank is provided, a fuel trans-
fuel tank when shipped from the factory.
fer pump with control, an external fuel alarm panel
and external fuel fill box are available as an option.
WIRING CONNECTIONS The “Low Fuel” warning message, when displayed
Fuel Transfer Control Customer Outputs by the PCC, indicates that the fuel level has dropped
below the low fuel level (approximately 62%).
Refer to Enclosure/Options Wiring (DFEG−DFEK)
diagram in Section 7 for customer connections to re-
mote annunciators. The “Rupture Basin” warning message is used to in-
dicate that fuel is detected in the fuel tank basin.
FUEL TRANSFER
CONTROL
FUEL ALARM
PANEL
EXTERNAL
FUEL FILL BOX
FUEL FILL
(INTERNAL)
FIGURE 7-1. FUEL TANK SYSTEM OPTIONAL

COMPONENTS

FUEL TRANSFER PUMP Control Panel Switches and Indicators
The following paragraphs describe the operation of
The fuel transfer pump and control are available as the control switches and indicators.
an option when a sub-base fuel tank is provided. Indicators:
The automatic control operates the fuel pump to
maintain a reservoir of fuel in the sub-base tank.  FUEL LEVEL (green): indicates in percent the
amount of fuel that is contained in the sub-base
tank.
This section explains functions of the control panel  HIGH FUEL (red): indicates that the fuel has
reached an abnormally high level. It indicates a pos-
lamps, components and operation/testing of the day sible failure of the ”pump-off” float gauge in the sub-
tank fuel control system. All red color lamps indicate base tank. The lamp will turn off when the fuel level
a fault condition. drops to normal.
FIGURE 7-2. TRANSFER PUMP CONTROL FRONT

PANEL

 LOW FUEL (red): indicates that the fuel level has  POWER ON (green): indicates that AC power is
dropped below the low fuel level. This warning en- available to the control.
ables the operator time to react to a potential prob-
lem before low fuel shutdown occurs. It indicates a Switches:
possible empty main fuel tank, fuel line restriction,
pump failure, or failure of the float gauge.
 ON: This pushbutton activates the control after the
OFF pushbutton has been pressed.
 CRITICAL LOW FUEL (red): indicates that the fuel
level has dropped to tank bottom. This warning en-  OFF: This pushbutton disables the control for rou-
ables the operator time to shut down generator set tine maintenance to the tank system without disrupt-
before fuel runs out, preventing loss of prime or en- ing the control. NOTE: This also de-energizes the
gine damage. It indicates a possible empty main fuel ECM FUNCTIONAL relay which will activate a
tank, fuel line restriction, pump failure, or failure of customer alarm wired to this relay.
the float gauge.  TEST: This pushbutton will test all front panel lamps
The control should be wired to shut down the genset for three seconds and activate pump/motor for as
(optional) as continued operation will allow air to en- long as the button is pressed. All alarm relays will not
ter the engine injection pump necessitating bleeding activate but will maintain their original state.
to restart the engine. The control will reset after re- Operation
storing the tank fuel level. This will also restore en-
gine operation if the tank control has been con-
The following steps describe how to operate the day
nected to shut down the engine.
tank controller.
CAUTION Continued operation with a
CRITICAL LOW FUEL fault can lead to a low Note: NOTE: When power is applied to the control or
fuel shutdown if the fuel level float switch is restored after a power interruption, the control will
fails. automatically go to the power on mode (functions
the same as pressing the ON switch). The pump will
 FUEL IN RUPTURE BASIN (red): indicates that the start if the control detects low fuel in tank.
fuel has flooded the safety basin surrounding the
fuel tank. The basin float switch turns off the fuel 1. Press the control ON switch for automatic operation.
pump. The pump cannot function again until the ba- The green PUMP light will come on and the pump
sin is drained of fuel. Possible cause, leak in fuel will fill the tank. The level of fuel in the tank will be
tank. automatically kept between a set of pump-on and
pump-off float gauge.
 PUMP (green): indicates that the fuel pump is run-
ning. It will come on and go off as fuel is pumped to When filling an empty tank, the red CRITICAL
maintain the fuel tank level. LOW FUEL and LOW FUEL lights will come on
when the control switch is pushed to the ON
 ECM FUNCTIONAL (green): indicates no faults are position. This is normal. The red lights will turn
detected within the control circuitry (including float off as the tank is filled.
gauge). If a fault occurs, the lamp will go out and de-
energize the control relay. It is suggested that the 2. The green PUMP light indicates when the pump is
customer wire to the normally closed contact to pro- running. It will come on and off as fuel is pumped to
vide a signal if a fault does occur. maintain the proper level in the tank.

EXTERNAL FUEL FILL BOX If the valve remains closed after correcting the criti-
cal high fuel condition, check the following possible
causes before replacing the valve.
The external fuel fill box plumping may contain the  Defective Critical High switch mounted on fuel tank.
optional overflow preventive valve (OFPV), which is (Critical High switch remains closed with fuel gauge
used to prevent the overfilling of the fuel tank. The indicating less than 95% full.)
valve will energize (close) when a Critical High fuel  Defective External Alarm panel. Refer to Enclosure/
condition (95% full) is detected/displayed by the Ex- Options Wiring (DQCA−DQCC) diagram in Section
ternal Alarm panel. 7.
OVERFLOW
PREVENTIVE
VALVE (OFPV)
(OPTIONAL)
EXTERNAL
FUEL FILL BOX
FIGURE 7-3. OPTIONAL FUEL (SPILL) FILL BOX

EXTERNAL ALARM PANEL Solenoid Override Button
The following paragraphs describe the operation of The Solenoid Override Button is only provided on
the external alarm panel components. the Alarm Panel when the optional overflow preven-
tive valve (Figure 7-3) is provided with the external
Overfill Indicator/Horn/Mute Button fill box feature.
This switch is used to release the delivery hose

The overfill alarm Indicates that the fuel has
pressure caused by the closing of the overflow pre-
reached an abnormally high level (95%). Immedi-
ventive valve. This valve automatically closes dur-
ately stop adding fuel. It also indicates a possible
ing an overfill alarm, stopping the filling of the tank
failure of the “pump-off” float gauge for fuel systems
and creating pressure between the valve and the
that contain the fuel transfer pump.
delivery hose. Before disconnecting the delivery
hose, always press this button after an overfill warn-
The horn can be turned off by pressing the mute but- ing to release fuel back pressure into the sub-base
ton. The indicator will turn off when the fuel level tank.
drops to normal.
Test Button
Fuel Gauge
Press the TEST switch to test the indicator light and
Indicates the amount of fuel that is contained in the the horn. The test will remain active for as long as
sub-base tank. the button is pressed.
FUEL
GAUGE
OVERFILL
INDICATOR
SOLENOID OVERRIDE
BUTTON (OPTIONAL) HORN
TEST BUTTON MUTE BUTTON
FIGURE 7-4. EXTERNAL ALARM PANEL

RUPTURE BASIN LEAK DETECT SWITCH 2. Move the O/Manual/Auto switch to the MANU-
TEST AL position.
The rupture basin leak detect switch (Figure 7-5) is 3. Activate leak detect switch (move float up-
provided with sub-base fuel tanks used with the op- ward).
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat- 4. Check control display for Rupture Basin fault
ing. In some areas, weekly inspections may be re- message. If no indication of fault, repair defec-
quired by safety code regulations. tive circuit. Refer to Enclosure/Options Wiring
(DQCA−DQCC) diagram in Section 7.
To test the leak detect switch:
1. Remove the pipe fitting/switch assembly from 5. Apply thread sealant to pipe fitting and install
the rupture basin tank. switch assembly.
LEAK DETECT ENCLOSURE

SWITCH ASSEMBLY SUB-BASE
FUEL TANK
FIGURE 7-5. RUPTURE BASIN LEAK DETECT SWITCH

8. Enclosure Fuel Tank System (DQCA-CC)
GENERAL PCC Customer Inputs

This section describes the operation and testing of
the components of the optional fuel tank system PCC Customer Fault Inputs 3 (Low Fuel) and 4
shown in Figure 6-1.
(Rupture Basin) are prewired to the sub-base fuel
When a sub-base fuel tank is provided, a fuel trans- tank when shipped from the factory.
fer pump with control and external or internal fuel
alarm panel are available as options.
The “Low Fuel” warning message, when displayed
WIRING CONNECTIONS by the PCC, indicates that the fuel level has dropped
below the low fuel level (approximately 62%).
Fuel Transfer Control Customer Outputs
See Enclosure/Options Wiring (DQCA−DQCC) dia-
gram in Section 7 for customer connections to re- The “Rupture Basin” warning message is used to in-
mote annunciators. dicate that fuel is detected in the fuel tank basin.
FUEL TRANSFER EXTERNAL

PUMP AND CONTROL FUEL ALARM
PANEL
INTERNAL FUEL
ALARM PANEL
FIGURE 7-1. FUEL TANK SYSTEM OPTIONAL COMPONENTS

FUEL TRANSFER PUMP  SYSTEM TEST: This switch will test all front panel
lamps and activate pump/motor for as long as the
switch is in the System Test position. All alarm relays
The fuel transfer pump and control are available as will not activate but will maintain their original state.
an option when a sub-base fuel tank is provided.
The automatic control operates the fuel pump to  RESET: This switch will reset the control system af-
ter a latched alarm event.
maintain a reservoir of fuel in the sub-base tank.
Operation
This section explains functions of the control panel
lamps, components and operation/testing of the day The following steps describe how to operate the day
tank fuel control system. tank controller.
1. Activate the control ON switch for automatic opera-
Control Panel Switches and Indicators tion. The PUMP light will come on and the pump will
fill the tank. The level of fuel in the tank will be auto-
matically kept between a set of pump-on and pump-
The following paragraphs describe the operation of off float gauge switches.
the control switches and indicators. 2. The PUMP light indicates when the pump is running.
It will go on and off as fuel is pumped to maintain the
proper level in the tank.
Indicators:
 POWER: indicates that AC power is available to the

control.
 PUMP: indicates that the fuel pump is running. It will
go on and off as fuel is pumped to maintain the fuel
tank level.
 CRITICAL HIGH: indicates that the fuel has
reached an abnormally high level. It indicates a pos-
sible failure of the ”pump-off” float gauge in the sub-
base tank. The lamp will turn off when the fuel level
drops to normal.
 LOW FUEL SUPPLY TANK: indicates that the fuel
level in the main fuel tank has dropped below the
customer set low fuel level. This signal is used by the
fuel system control to stop the operation of the fuel
transfer pump to prevent pump damage. The control
will enable the fuel transfer pump operation after
tank fuel level is restored.
 RUPTURE BASIN: indicates that the fuel has
flooded the safety basin surrounding the fuel tank.
The basin float switch turns off the fuel pump. The
pump cannot function again until the basin is
drained of fuel. Possible cause, leak in fuel tank.
FIGURE 7-2. TRANSFER PUMP CONTROL FRONT
Switches: PANEL
 ON: This switch activates the control.

 OFF: This switch disables the control for routine
maintenance to the tank system without disrupting
the control.
 TEST: This switch will activate the pump for as long
as the switch is in the Test position. All alarm func-
tions will operate accordingly. Pump-on and pump-
off float switches will remain de-energized.

EXTERNAL/INTERNAL ALARM PANELS The horn can be turned off by pressing the mute but-
ton. The indicator will turn off when the fuel level
drops to normal.
The following paragraphs describe the operation of
the external/internal alarm panel components. Fuel Gauge
Overfill Indicator/Horn/Silence Button Indicates the amount of fuel that is contained in the
sub-base tank.
The overfill alarm Indicates that the fuel has Test Button
reached an abnormally high level (95%). Immedi-
ately stop adding fuel. It also indicates a possible Press the TEST switch to test the indicator light and
failure of the “pump-off” float gauge for fuel systems the horn. The test will remain active for as long as
that contain the fuel transfer pump. the button is pressed.
OVERFILL
INDICATOR/ FUEL
TEST BUTTON GAUGE
HORN
HORN
SILENCE
BUTTON
HORN SILENCE/
TEST BUTTON
INTERNAL ALARM PANEL

HORN
EXTERNAL ALARM PANEL
FIGURE 7-3. EXTERNAL AND INTERNAL ALARM

PANELS

RUPTURE BASIN LEAK DETECT SWITCH 2. Move the O/Manual/Auto switch to the MANU-
TEST AL position.
The rupture basin leak detect switch (Figure 6-4) is 3. Activate leak detect switch (move float up-
provided with sub-base fuel tanks used with the op- ward).
tional enclosure. This switch should be checked
once a year to make sure switch is properly operat- 4. Check control display for Rupture Basin fault
ing. In some areas, weekly inspections may be re- message. If no indication of fault, repair defec-
quired by safety code regulations. tive circuit. Refer to Enclosure/Options Wiring
(DQCA−DQCC) diagram in Section 7.
To test the leak detect switch:
1. Remove the pipe fitting/switch assembly from 5. Apply thread sealant to pipe fitting and install
the rupture basin tank. switch assembly.
ENCLOSURE
SUB-BASE
LEAK DETECT FUEL TANK
SWITCH ASSEMBLY
FIGURE 7-4. RUPTURE BASIN LEAK DETECT SWITCH

9. Wiring Diagrams
GENERAL
This section consists of the schematic and connection wiring diagrams referenced in the text. The following
drawings are included.
 Page 9−3 through 9−4, AC RECONNECT WIRING DIAGRAM
 Page 9−5 through 9−15 DC POWER AND STARTER WIRING (DFEG−DFEK)
 Page 9−16 through 9−18 ALARM PANEL WIRING, WITH FUEL PUMP CONTROL (DFEG−DFEK)
 Page 9−19 through 9−25 DC POWER AND STARTER WIRING (DQCA−DQCC)
 Page 9−26 through 9−27 ENCLOSURE/OPTIONS WIRING (DQCA−DQCC)
 Page 9−28 through 9−29 NEC ENTRANCE BOX OPTION INSTALLATION DRAWING
 Page 9−30 through 9−43 GENSET INSTALLATION DRAWINGS
 Page 9−36 through 9−48 PC 3201 WIRING

THIS PAGE LEFT INTENTIONALLY BLANK
9-2
THIS IS A REPRESENTATIVE DRAWING.
FOR SERVICE, USE DRAWING SUPPLIED
WITH GENSET, IF AVAILABLE.
No. 625-3100 sh 1 of 2
Rev. H
Modified 2/22/2011
AC RECONNECT WIRING DIAGRAM (Sh 1 of 2)
Copyright  2016 Cummins Inc. 9−3

No. 625-3100 sh 2 of 2
Rev H
Modified 2/22/2011
AC RECONNECT WIRING DIAGRAM (Sh 2 of 2)
9−4 Copyright  2016 Cummins Inc.

THIS IS A REPRESENTATIVE (GENERIC)
SCHEMATIC/WIRING DIAGRAM. FOR
TROUBLESHOOTING, REFER TO THE
WIRING DIAGRAM PACKAGE THAT WAS
INCLUDED WITH YOUR GENSET.
No. 630-2592 sh 1 of 11
Rev. F
Modified 7/05
DC POWER AND STARTER WIRING (DFEG−DFEK)

No. 630-2592 sh 2 of 11
Rev. F
Modified 7/05
ALARM PANEL WIRING (DFEG−DFEK)

No. 630-2592 sh 3 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS TERMINAL STRIP (DFEG−DFEK)

No. 630-2592 sh 4 of 11
Rev. F
Modified 7/05
ENGINE SENSORS (DFEG−DFEK)

No. 630-2592 sh 5 of 11
Rev. F
Modified 7/05
CONTROL WIRING (DFEG−DFEK)

No. 630-2592 sh 6 of 11
Rev. F
Modified 7/05
GENERATOR/BUS CONNECTIONS (DFEG−DFEK)

No. 630-2592 sh 7 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS (DFEG−DFEK)

No. 630-2592 sh 8 of 11
Rev. F
Modified 7/05

No. 630-2592 sh 9 of 11
Rev. F
Modified 7/05

No. 630-2592sh 10 of 11
Rev. F
Modified 7/05
CUSTOMER CONNECTIONS TERMINAL STRIP (DFEG−DFEK)

No. 630-2592sh 11 of 11
Rev. f
Modified 7/05
FUEL TANK WIRING, ENCLOSURE

No. 541-1066 sh 2 of 4
Rev. C
Modified 9/04
ALARM PANEL WIRING, WITH FUEL PUMP CONTROL (DFEG−DFEK)

No. 541-1066 sh 3 of 4
Rev. C
Modified 9/04
ALARM PANEL WIRING, WITHOUT FUEL PUMP CONTROL (DFEG−DFEK)

No. 541-1066 sh 4 of 4
Rev. C
Modified 9/04
ALARM PANEL WIRING, REVISED WITH FUEL PUMP CONTROL (DFEG−DFEK)

No. 630-2878 sh 1 of 7
Rev. D
Modified 5/27/2011
DC POWER AND STARTER WIRING (DQCA−DQCC)

No. 630-2878 sh 2 of 7
Rev. D
Modified 5\27\2011
ENGINE SENSORS (DQCA−DQCC)

No. 630-2878 sh 3 of 7
Rev. D
Modified 5/27/2011
CONTROL WIRING (DQCA−DQCC)

No. 630-2878 sh 4 of 7
Rev. D
Modified 5/27/2011
GENERATOR/BUS CONNECTIONS (DQCA−DQCC)

No. 630-2878 sh 5 of 7
Rev. D
Modified 5/27/2011
CUSTOMER CONNECTIONS (DQCA−DQCC)

No. 630-2878 sh 6 of 7
Rev. D
Modified 5/27/2011

No. 630-2878 sh 7 of 7
Rev. D
Modified 5/27/2011

ENCLOSURE/OPTIONS WIRING (SHEET 1 OF 2)

ENCLOSURE/OPTIONS WIRING (SHEET 2 OF 2)

NEC ENTRANCE BOX OPTION INSTALLATION DRAWING (SHEET 1 OF 2)

NEC ENTRANCE BOX OPTION INSTALLATION DRAWING (SHEET 2 OF 2)

GENERATOR SET ENCLOSURE SHEET 1 OF 7














No. A034P810 sh 1 of 13
Rev F
Modified 5/04/2015
ENGINE TO GENERATOR SET HARNESS CONNECTIONS (Sh 1 of 13)

No. A034P810 sh 2 of 13
Rev. F
Modified 5/04/2015
OPERATOR PANEL TO CONTROL BOARD CONNECTIONS (Sh 2 of 13)

No. A034P810 sh 3 of 13
Rev F
Modified 5/04/2015
ENGINE HARNESS AND ECM CONNECTIONS (Sh 3 of 13)

No. A034P810 sh 4 of 13
Rev. F
Modified 5/04/2015
ENGINE HARNESS AND ECM (Sh 4 of 13)

No. A034P810 sh 5 of 13
Rev F
Modified 5/04/2015
LOW VOLTAGE P80 ALTERNATOR CONNECTIONS (Sh 5 of 13)

No. A034P810 sh 6 of 13
Rev. F
Modified 5/04/2015
MEDIUM/HIGH VOLTAGE P80ALTERNATOR CONNECTIONS (Sh 6 of 13)

No. A034P810 sh 7 of 13
Rev F
Modified 5/04/2015
MEDIUM/HIGH VOLTAGE P80 ALTERNATOR CONNECTIONS (Sh 7 of 13)

No. A034P810 sh 8 of 13
Rev. F
Modified 5/04/2015
GENERATOR AND CUSTOMER HARNESS (Sh 8 of 13)

No. A034P810 sh 9 of 13
Rev F
Modified 5/04/2015
CUSTOMER HARNESS CONNECTIONS (Sh 9 of 13)

No. A034P810 sh 10 of 13
Rev. F
Modified 5/04/2015
GENERATOR SET UTILITY BUS VOLTAGE AND CURRENT SENSING (Sh 10 of 13)

No. A034P810 sh 11 of
13
Rev F
Modified 5/04/2015
GROUND FAULT RELAY, AUDIBLE ALARM (Sh 11 of 13)

No. A034P810 sh 12 of
13
Rev. F
Modified 5/04/2015
CONGFIGURABLE AND CIRCUIT BREAKER RELAYS (Sh 12 of 13)

No. A034P810 sh 13 of
13
Rev F
Modified 5/04/2015
CONTROL BOX WIRING DIAGRAM (Sh 13 of 13)

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Copyright E 2016 Cummins Inc. All rights reserved.
Cummins Power Generation, the “C” logo, and Cummins are trademarks of Cummins Inc.
PowerCommand, AmpSentry, InPower and “Our energy working for you.” are trademarks of Cummins Power Generation Inc.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.

Manual Servicio Generator DQCC

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What is the purpose of this manual?

What is the purpose of this manual?

What are some of the main features of the control system described in the manual?

What are some of the main features of the control system described in the manual?

Service Manual

DQCA (Spec A−N)

Copyright  2016 Cummins Inc. i

3. CONTROL CALIBRATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

ii Copyright  2016 Cummins Inc.

5. SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Copyright  2016 Cummins Inc. iii

KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE

Copyright  2016 Cummins Inc. 1-1

FIGURE 1−2. TYPICAL INFORMATION LABEL

1-2 Copyright  2016 Cummins Inc.

Copyright  2016 Cummins Inc. 1-3

1-4 Copyright  2016 Cummins Inc.

Run Relay 30V DC 8A: 144APilot TB1 (17−22)

Customer Relay 30V DC 5A

Copyright  2016 Cummins Inc. 1-5

1-6 Copyright  2016 Cummins Inc.

Copyright  2016 Cummins Inc. 2-1

OPERATOR SWITCH PANEL

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

2-2 Copyright  2016 Cummins Inc.

Copyright  2016 Cummins Inc. 2-3

2-4 Copyright  2016 Cummins Inc.

Copyright  2016 Cummins Inc. 2-5

FIGURE 2-2. GRAPHICAL DISPLAY AND MENU SELECTION BUTTONS

2-6 Copyright  2016 Cummins Inc.

Language: Used to select desired language (de-

The Local/Remote selection determines which but-

Copyright  2016 Cummins Inc. 2-7

2-8 Copyright  2016 Cummins Inc.

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

Copyright  2016 Cummins Inc. 2-9

If you press the “ENGINE” button in Menu A, the En-

BLOWBY FLOW 25 CFM

FIGURE 2-5. ENGINE SUBMENUS

2-10 Copyright  2016 Cummins Inc.

If you press the “ALTERNATOR” button in Menu A,

Voltage L-L and L-N: Indicates voltage Line-to Line

Amps: All phases. Accuracy 1%.

Frequency: Generator set output frequency.

Copyright  2016 Cummins Inc. 2-11

Local CONTROL Submenu Function Enable Sync: Displayed in paralleling applications

Remote CONTROL Submenu Functions

Note: The 0/Manual/Auto switch must be in the Auto

Remote START or STOP Button: This button is

When the generator set is operating in the Remote

Fault Acknowledge Button: Used to reset inactive

Local/Remote CONTROL Submenu

Bargraph Test: The function of this button remains

2-12 Copyright  2016 Cummins Inc.

If you press the “HISTORY/ABOUT” button in Menu

HISTORY: The control maintains a data log of the

ABOUT: The About submenus provide the following

CONTINUED TO NEXT PAGE

FIGURE 2-8. HISTORY/ABOUT SUBMENUS