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Service Manual

Generator Set
with PowerCommandR 1.1 Controller

DSKAA (Spec A−B)


DSKAB (Spec A−B)
DSKBA (Spec A−B)
DSKCA (Spec A−B)

English − Original Instructions 10−2010 961-0516 (Issue 3)


Table of Contents

SECTION TITLE PAGE


IMPORTANT SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IV
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel Power On/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Analog AC Metering Panel (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Selecting Auto, Manual Run and Off Modes . . . . . . . . . . . . . . . . . . . . . . . 2-9
Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
History / About Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
3. CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Base Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . 4-1
Safety Consideration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
PCC Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Table 4-1 Engine does not Crank in Manual Mode
(No Fault Message) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Table 4-2. Engine does not Crank in Remote Mode
(No Fault Message) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Table 4-3. Warning and Shutdown Codes . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Code 121 - Speed Signal Lost (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . 4-12

i
Code 359 − Fail To Start (Shutdown)
Mechanical Governed Engine − DSKCA Only . . . . . . . . . . . . . . . . . . . . . 4-13
Code 359 − Fail To Start (Shutdown)
Electronic Governed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Code 441 - Low Battery voltage (Warning) . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Code 442 - High Battery Voltage (Warning) . . . . . . . . . . . . . . . . . . . . . . . 4-16
Code 1311, 1312 - Customer (Config) Input Warning/Shutdown) . . . . . 4-17
Code 1435 - Low Coolant Temperature (Warning) . . . . . . . . . . . . . . . . 4-17
Code 1438 - Fail to Crank (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Code 1442 - Low Battery (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Code 1446 - High AC Voltage (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . 4-19
Code 1447 - Low AC Voltage (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . 4-20
Code 1448 - Under Frequency (Shutdown) . . . . . . . . . . . . . . . . . . . . . . 4-20
Code 1449 - Over Frequency (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Code 1471 - High AC Current (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Code 1472 - High AC Current (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . 4-21
Code 1992 - Overspeed (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Code 2972 - Field Overload (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
5. CONTROL ADJUSTMENT AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Circuit Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Automatic Voltage Regulator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
Engine Protectin Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
TB1 Base Board Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Auxiliary I/O Module (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Optional Relays (K10, K11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Current Transformer (CT) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-54
6. SERVICING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Generator/Base Board Isolation Procedure . . . . . . . . . . . . . . . . . . . . . . . 6-2

ii
Testing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Generator Disassembly and Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
7. WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
A. 1.1 MENU SYSTEM MAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

! !
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.

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.

iii
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 and batter-  Provide an adequate exhaust system to properly
ies. 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
ator, service personnel, or the equipment. known to the state of California to cause cancer,
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
This symbol refers to a hazard or un-
WARNING
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-
CA This symbol refers to a hazard or un-
UTION 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
iv
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
v
1. Introduction
ABOUT THIS MANUAL play panel. It accepts menu-driven control and set-
up input from the push button switches on the front
This manual provides troubleshooting and repair in- panel.
formation regarding the PowerCommand 1.1 con-
troller (PCC) and generators for the generator sets TEST EQUIPMENT
(gensets) listed on the front cover. Operating and
maintenance instructions for the generator set are To perform the test procedures in this manual, the
in the applicable Operator’s Manual. following test equipment must be available
 True RMS digital multi-meter for accurate mea-
Engine troubleshooting, repair and maintenance in-
surement of resistance, AC voltage (0−1,000
formation is provided in the applicable engine ser-
VAC), and DC voltage
vice manual.
 Grounding wrist strap to prevent circuit board
This manual does not have instructions for servic- damage due to electrostatic discharge (ESD).
ing printed circuit board assemblies. After determin-  Battery hydrometer
ing that a printed circuit board assembly is faulty, re-
 Jumper leads
place it, do not repair it. Attempts to repair a printed
circuit board can lead to costly damage to the equip-  Tachometer or frequency meter
ment.  Wheatstone bridge or digital ohmmeter
 Variac
This manual contains basic (generic) wiring dia-
grams and schematics that are included to help in  Load test panel
troubleshooting. Service personnel must use the  Megger or insulation resistance meter
actual wiring diagram and schematic shipped with  InPower service tool (PC based genset ser-
each unit. The wiring diagrams and schematics that vice tool)
are maintained with the unit should be updated
 PCC1302 interface kit, P/N 0541−1199 (Used
when modifications are made to the unit.
with InPower service tool)
Read Important Safety Instructions and carefully
observe all instructions and precautions in this
HOW TO OBTAIN SERVICE
manual. Always give the complete Model, Specification and
Serial number of the generator set as shown on the
SYSTEM OVERVIEW nameplate when seeking additional service infor-
mation or replacement parts. The nameplate is lo-
The PCC is a microprocessor-based control for cated on the side of the generator housing.
Cummins Power Generation generator sets. All
generator set control functions are contained on WARNING Incorrect service or replacement of
one circuit board (Base board). The Base board parts can result in severe personal injury or
provides fuel control, main alternator voltage output death, and/or equipment damage. Service per-
regulation and complete generator set control and sonnel must be trained and experienced to per-
monitoring. form electrical and mechanical service. Read
and follow Important Safety Instructions on
The operating software provides control of the gen- pages iv and v.
erator set and its performance characteristics, and
displays performance information on a digital dis-

1-1
2. Control Operation

GENERAL Sleep Mode: In the Sleep mode, the control’s oper-


ating software is inactive and the LEDs and the
The following describes the function and operation graphical display on the control panel are all off.
of the PowerCommand 1.1 controller. All indica- Sleep mode is a feature used to reduce battery
tors, control buttons and graphical display are lo- power consumption when the control is not being
cated on the face of the control panel as illustrated used and is in either the Off or Auto mode.
in Figure 2-2.
When all conditions are met (i.e., no unacknowl-
edged faults and the control is in the Off or Auto
CONTROL PANEL POWER ON/OFF mode) the Sleep mode is activated after five min-
MODES utes of keypad inactivity.

To activate the control and view the menu display


The power on/off modes of the control panel and op-
without starting the generator set, press any control
erating software are Power On and Sleep.
button.
Power On Mode: In this mode, power is continu- When shipped from the factory, Sleep mode is en-
ously supplied to the control panel. The control’s abled.
operating software and control panel LEDs/graphi-
cal display will remain active until the Sleep mode is TB15 jumper installation: Install jumper between
activated. TB15-1 and TB15-5 to disable sleep mode.

BASE BOARD

ADD JUMPER (TB15-1/TB15-5) TO


DISABLE SLEEP MODE

FIGURE 2-1. SLEEP MODE ACTIVATION SETTINGS

2-1
CONTROL GRAPHICAL
PANEL DISPLAY

LED
INDICATORS

OFF MODE
BUTTON

ANALOG AC METERING DISPLAY MENU PREVIOUS MENU


PANEL (OPTIONAL) SELECTION BUTTONS LEVEL BUTTON

FIGURE 2-2. FRONT PANEL

FRONT PANEL  3-phase line-to-line AC current (A~) (L1, L2


and L3); Single phase line-to-line (L1 and L2)
Figure 2-2 shows the features of the front panel,
which contains a control panel and an optional ana-
log AC metering panel.  KVA

ANALOG AC METERING PANEL  Generator output frequency in hertz (Hz)


(OPTIONAL)
This panel simultaneously displays (in percent of  3-phase line-to-line AC volts (V~) L1, L2 and
genset rated output): L3; Single phase line-to-neutral (L1)

2-2
CONTROL PANEL TABLE 2-1. SYMBOLS
The control panel includes six LED indicators, the SYMBOL DESCRIPTION
graphical display, and six buttons used to navigate
through the menus and adjust parameters. Generator Warning Fault

Graphical Display
Generator Shutdown Fault
This graphical display is used to view menus of the
menu-driven operating system. The bottom of the Coolant Temperature
graphical display indicates the functions that are
available by pressing the four selection buttons. Re-
Oil Pressure
fer to the menu trees later in this section.
System messages (communication, event, status Voltage Alternating Current (VAC)
and fault) are also shown on the graphical display.
For more information, see System Messages later
this section. Voltage Direct Current (VDC)

Display Text / Symbolic Versions


AC Current
This graphical display can be set up to show either
text or symbolic versions for fault messages, some
Operator menus, and the Mode Change menu. A
Hz Frequency

description of commonly used symbols used are in- Battery


cluded in Table 2-1. Combinations of symbols are
used to display some fault conditions. Additional Out of Range
specialized symbols are also used for some faults High or Pre-High
(see Section 4).
Low or Pre-Low
When shipped from the factory, symbolic display is
selected. (Refer to Setup menu in Section 5 to
Annunciator
change to text or symbolic display.)

2-3
Display Menu Selection Buttons menu that was displayed before the Auto or
Manual Run mode was selected.
Four momentary soft-key buttons are used to step
through the various menus and to adjust parame-  When ADJUST is displayed, the selection
ters. These selection buttons are “active” when a button is used to display an adjustable menu.
word or symbol in the graphical display is shown When the ADJUST button is pressed, the
above the button. Some submenus do not include first adjustable parameter or value in the sub-
any active buttons. menu is highlighted.

The function of the four selection buttons varies with  When the symbol is displayed, the selec-
each menu. tion button is used to navigate to an editable
field within a menu.
 When the symbol is displayed, the  When the + and − symbols are displayed, the
selection button can be used to switch to selection buttons are used to increase or de-
Auto mode. crease a parameter or value shown on the
 When the symbol is displayed, the selec- screen.
tion button can be used to switch to Manual When changing values, pressing the button be-
Run mode. low the + symbol increase the value and press-
 When the up and down triangles ( and ) ing the button below the − symbol decreases
are displayed, the selection buttons are used the value.
to navigate between a series of submenus.  When SAVE is displayed, the selection but-
ton is used to save changes made in a sub-
NOTE: When any Operator menu (Figure 2-13
menu. If the Previous Menu button is
is displayed, a series of Service menus
pressed before pressing SAVE, the
can be viewed by simultaneously
changes are not saved.
pressing the and selection but-
tons for two seconds.  Some menus include a list of numbered sub-
jects. These menus include numbers in pa-
NOTE: When a fault is displayed, it can be renthesis (for example, (1)) displayed above
cleared from the front panel by press- the selection buttons. The selection buttons
ing the or button. are then used to display submenus of the
subjects included in the list.
 When a symbol is displayed, the selection
button can be used to abort the Auto or  When a black box is displayed, the
Manual Run mode and return to the Operator selection button has no function.

2-4
Previous Main Menu Button Off Button

Press the button to view the previous main Press the button to switch to the Off mode. The
menu. Off mode will disable the control Auto or Manual
modes.
NOTE: In the Screen Adjust menu, settings are not
If the button is pressed during generator set op-
saved when the button is pressed. eration (manual or remote start), the engine will im-
mediately shut down. If possible, hot shutdown un-
The button is also used to acknowledge warn- der load should be avoided to help prolong the reli-
ing and shutdown messages after the fault has ability of the generator set.
been corrected. Pressing this button clears the fault
from the front panel display and the previous menu The button is also used to acknowledge warn-
is redisplayed. ing and shutdown messages after the fault has
been corrected. Pressing this button clears the fault
NOTE: Pressing the or button also clears the from the front panel and resets the control.
fault from the front panel display. Not in Auto Indicator
This red lamp is lit when the control is not in the Auto
mode.
Shutdown Status Indicator
This red lamp is lit when the control detects a Shut-
down condition. The generator set cannot be
started when this lamp is on. After the condition is
corrected, the lamp can be reset by pressing the
(off) button.

Warning Indicator

OFF
This yellow lamp is lit whenever the control detects
BUTTON a warning condition. This lamp is automatically shut
off when the warning condition no longer exists.
Remote Start Indicator
This green lamp indicates the control is receiving a
remote run signal.
Auto Indicator
PREVIOUS MAIN
MENU BUTTON This green lamp indicates the control is in Auto
mode. Auto mode can be selected by pressing the
selection button from any of the Operator me-
nus (see Figure 2-13).
Manual Run Indicator
This green lamp indicates the control is in the Manu-
al Run mode. Manual Run mode can be selected by
FIGURE 2-3. PREVIOUS MAIN MENU AND OFF pressing the selection button from any of the Op-
BUTTONS erator menus (see Figure 2-13).

2-5
SYSTEM MESSAGES
A system pop-up message is displayed when the
event it is displaying becomes active. These pop-up
messages remain displayed until pre-empted by
another pop-up message or until the or the
display buttons is pressed. Once the or the
button is pressed, the previous screen is redis-
played.
Communication Messages
System messages are displayed for initial power-up
or when there is a subsequent loss of communica-
tions. Note that the Auto and Manual Run modes
can be selected when communication messages
are displayed. FIGURE 2-4. ESTABLISHING COMMUNICATION
WITH CONTROL
Upon initial power-up, the message “Establishing
communication with control” is displayed (see Fig-
ure 2-4). This menu also displays the screen’s soft-
ware number and version.
When the display detects that it is no longer com-
municating with the control, the Shutdown, Warn-
ing, and Remote Start LEDs are turned off.
If communications are lost, the message “Re-es-
tablishing communication with control” is displayed
until communications have been re-established
(see Figure 2-5). The LEDs then return to the state
determined by the control.
If either communication message remains displayed
(cannot view other menus), contact an authorized
service center for service. This indicates that com-
munications between the control panel and the con- FIGURE 2-5. RE-ESTABLISHING COMMUNICATION
trol logic is lost. WITH CONTROL

2-6
Event Messages

Event = TIME DELAY


When pre-set events (time delay to start or stop) are TO START, or STOP
activated, Event messages are displayed showing
the time remaining until the event occurs (see Fig-
ure 2-6).

Status Messages

Status messages for some events are displayed on FIGURE 2-6. EVENT MESSAGE
the control panel with a code number but are not an-
nounced with a lamp indicator. Text status mes-
sages include the event code, a short description,
and the time the event occurred. Symbolic status
messages include the event code and symbols to
indicate the type of event that occurred.

On Full Authority Electronic engines, the engine


controller saves data after each run. During this
time, the display displays the message shown in
Figure 2-7. The generator can still be started while
the ECM Datasave is in progress. FIGURE 2-7. DATASAVE STATUS MESSAGE

2-7
Fault Messages

A Fault message is an indicator of a Warning or Fault = WARNING


Shutdown condition. It includes the fault number, a or SHUTDOWN
short description, and when the fault occurred (see
Figure 2-8). Symbolic fault messages include the
fault code number and symbols, indicating the type
of fault (see Figure 2-9). With the symbolic versions
of fault messages, the and symbols flash.
Section 4 provides a list of fault codes, fault types,
messages displayed, and descriptions of the faults. FIGURE 2-8. FAULT MESSAGE - TEXT VERSION

Five of the most recent faults are placed in a fault


history file that can be viewed using the Fault Histo- EXAMPLE OF
ry Menus (see Figure 2-19). A SYMBOLIC
WARNING
FAULT
214
Fault Acknowledgement

Shutdown faults must be acknowledged after the


faults have been corrected. If in Auto or Manual Run
mode, the control must be set to “O” (off). Also, EXAMPLE OF
faults are acknowledged when in Auto and the Re-
mote Start command is removed. Faults are
A SYMBOLIC
SHUTDOWN 1
FAULT
cleared from the control panel display by pressing
the , , or button.

Faults are re-announced if they are detected again FIGURE 2-9. FAULT MESSAGES − SYMBOLIC
after being acknowledged. VERSION

2-8
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