Service Manual

Controller

PowerCommand 1301

English Original Instructions 52012 A031B792 (Issue 2)

Table of Contents

SECTION PAGE

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix
List of Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
2. CIRCUIT BOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Base Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
TB1 Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
DS1 LED Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
S1 Sleep Mode Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3. CONTROL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel Power on/Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Graphical Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Display Text / Symbolic Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Display Menu Selection Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Previous Main Menu Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Off Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Not in Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Shutdown Status Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Warning Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Remote Start Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Auto Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Manual Run Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
System Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

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Communication Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Event Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Fault Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Selecting Auto, Manual Run and Off Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Entering the Mode Change Access Code . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Selecting Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Selecting Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Aborting the Transition to Auto or Manual Run Mode . . . . . . . . . . . . . . . . 3-10
Operator Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Engine Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Alternator Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Alternator Line-to-Line Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Alternator Line-to-Neutral Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Alternator Single Phase Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Alternator Amperage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Status Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Network Status Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
History / About Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
History Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
About Genset Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
About Control Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
About Display Submenu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Screen Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Fault History Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
4. CONTROL ADJUSTMENT AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Circuit Board Removal/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Circuit Board Removal Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Genset Service Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Setup Password Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Genset Service Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Genset Menu, Part 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Genset Menu, Part 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Start/Stop Delay Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Cycle Crank Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
AVR Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Electronic Governor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Genset Number Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Display Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Automatic Voltage Regulator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Volts/Hz Rolloff Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Regulator Gains Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Electronic Governor Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Governor Crank Fuel Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Electronic Governor Regulator Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Electronic Governor Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Electronic Governor Enable Speed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Customer I/O Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Customer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Metering Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Meter Calib Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Freq. Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Metering Voltage Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Metering Current Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Annunciator Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Annunciator Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Annunciator Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Modbus Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Modbus Enable Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

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Modbus Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Genset Setup Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Viewing and Adjusting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Genset Setup Password Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Adjusting Values/Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Genset Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Genset Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Application Rating Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Standby kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Prime kVA Rating Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Battery Select Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Battery Thresholds Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Battery Delay Setup Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Oil Pressure Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Voltage Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
High AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Low AC Voltage Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Overfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Underfrequency Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Current Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
High AC Current Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
High AC Current Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Engine Protection Submenus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Engine Protection Overspeed Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Engine Protection Speed/Frequency Menu . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Low Oil Pressure Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Low Oil Pressure Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
High Coolant Temperature Warning Menu . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
High Coolant Temperature Shutdown Menu . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Engine Protection Low Coolant Temperature and Battery Charger Menus
4-40
TB1 Base Board Customer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
TB1 Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
TB1 Customer Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

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Engine Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Magnetic Speed Pickup Unit (MPU) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Current Transformer (CT) Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
5. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
InPower Service Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Network Applications and Customer Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Reading Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Troubleshooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Voltage/Continuity Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Relay K6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Relay K5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Run Relays K10, K11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Engine Does Not Crank in Manual Mode (No Fault Message) . . . . . . . . . . . . . . . 5-5
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Does Not Crank in Remote Mode (No Fault Message) . . . . . . . . . . . . . . 5-6
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Warning and Shutdown Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
FAULT CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Code 1/202 High or Pre-high Coolant Temperature (Shutdown/Warning) . . . 5-12
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Code 2/215 Low Oil or Pre-low Oil Pressure (Sender) (Warning/Shutdown) . 5-13
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Code 12 High AC Voltage (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Code 13 Low AC Voltage (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

v
SECTION PAGE

CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14

Code 14 Over Frequency (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Code 15 Under Frequency (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Code 31 Overspeed (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Code 45 Speed Signal Lost (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Code 46 High AC Current (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Code 72 Fail to Crank (Shutdown) (Local or Remote) . . . . . . . . . . . . . . . . . . . . 5-18
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Code 73 Fail to Start (Shutdown)
Mechanical Governed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Code 73 Fail to Start (Shutdown)
Electronic Governed Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Code 74 Fail to stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Generator set continues to run after recieving a stop command from the controller
5-22
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Code 75/76 Customer Input (Shutdown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22

vi
SECTION PAGE

Code 202 Pre-high Coolant Temp (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
Code 203 Low Coolant Temperature (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Code 204/205 Customer Input (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Code 212 Coolant Sensor Out of Range (High/Low) (Warning) . . . . . . . . . . . 5-25
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Code 213 Low Battery (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Code 214 High Battery Voltage (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Code 215 Pre-low Oil Pressure (Sender) Warning) . . . . . . . . . . . . . . . . . . . . . . . 5-27
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Code 216 High AC Current (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
Code 217 Oil Pressure Sensor Out of Range (Sender) (High/Low) (Warning) 5-28
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Code 221 Weak Battery (Warning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Code 222/223/224 Annunciator Fault #1 through #3 (Warning) . . . . . . . . . . . . 5-29
POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Code 225 Annunciator Out Configuration Error (Warning) . . . . . . . . . . . . . . . . 5-29

vii
SECTION PAGE

POSSIBLE CAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

CORRECTIVE ACTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
APPENDIX A. SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

viii
Safety Precautions
SAVE THESE INSTRUCTIONS This manual air, and will tend to gather in sumps or low
contains important instructions that should be fol- areas. NFPA code requires all persons han-
lowed during installation and maintenance of the dling propane to be trained and qualified.
generator set and batteries.
Be sure all fuel supplies have a positive shut-
off valve.
Before operating the generator set (genset),
read the Operators Manual and become familiar Be sure battery area has been well-ventilated
with it and the equipment. Safe and efficient op- prior to servicing near it. Lead-acid batteries
eration can be achieved only if the equipment emit a highly explosive hydrogen gas that can
is properly operated and maintained. Many ac- be ignited by arcing, sparking, smoking, etc.
cidents are caused by failure to follow fundamental
rules and precautions. EXHAUST GASES ARE DEADLY
Provide an adequate exhaust system to prop-
The following symbols, found throughout this man- erly expel discharged gases away from en-
ual, alert you to potentially dangerous conditions closed or sheltered areas and areas where in-
to the operator, service personnel, or the equip- dividuals are likely to congregate. Visually
ment. and audibly inspect the exhaust for leaks daily
or per the maintenance schedule. Make sure
DANGER This symbol warns of immediate
that exhaust manifolds are secured and not
hazards which will result in severe personal in- warped. Do not use exhaust gases to heat a
jury or death. compartment.
WARNING This symbol refers to a hazard or The exhaust vent should be high enough to
unsafe practice which can result in severe per- help clear gases, avoid accumulation of snow,
sonal injury or death. and in accordance with local mechanical
codes.
CAUTION This symbol refers to a hazard or Be sure the unit is well ventilated.
unsafe practice which can result in personal
injury or product or property damage. Engine exhaust and some of its constituents
are known to the state of California to cause
FUEL AND FUMES ARE FLAMMABLE cancer, birth defects, and other reproductive
harm.
Fire, explosion, and personal injury or death can
MOVING PARTS CAN CAUSE SEVERE PER-
result from improper practices.
SONAL INJURY OR DEATH
DO NOT fill fuel tanks while engine is running,
Keep your hands, clothing, and jewelry away
unless tanks are outside the engine compart-
from moving parts.
ment. Fuel contact with hot engine or exhaust
is a potential fire hazard. Before starting work on the generator set, dis-
connect battery charger from its AC source,
DO NOT permit any flame, cigarette, pilot
then disconnect starting batteries, negative
light, spark, arcing equipment, or other igni-
() cable first. In lean-burn natural gas
tion source near the generator set or fuel tank.
(LBNG) gensets, also make sure the starters
Fuel lines must be adequately secured and air supply line is disconnected or completely
free of leaks. Fuel connection at the engine vented until the generator set is ready to start.
should be made with an approved flexible line. This will prevent accidental starting.
Do not use zinc coated or copper fuel lines
Make sure that fasteners on the generator set
with diesel fuel.
are secure. Tighten supports and clamps,
Natural gas is lighter than air, and will tend to keep guards in position over fans, drive belts,
gather under hoods. Propane is heavier than etc.

ix
 Do not wear loose clothing or jewelry in the vi- MEDIUM VOLTAGE GENERATOR SETS (601V
cinity of moving parts, or while working on to 15kV)
electrical equipment. Loose clothing and jew- Medium voltage acts differently than low volt-
elry can become caught in moving parts. age. Special equipment and training is re-
If adjustment must be made while the unit is quired to work on or around medium voltage
running, use extreme caution around hot equipment. Operation and maintenance must
manifolds, moving parts, etc. be done only by persons trained and qualified
to work on such devices. Improper use or pro-
DO NOT OPERATE IN FLAMMABLE AND EX- cedures will result in severe personal injury or
PLOSIVE ENVIRONMENTS death.
Do not work on energized equipment. Un-
Flammable vapor can cause an engine to over- authorized personnel must not be permitted
speed and become difficult to stop, resulting in near energized equipment. Due to the nature
possible fire, explosion, severe personal injury of medium voltage electrical equipment, in-
and death. Do not operate a genset where a flam- duced voltage remains even after the equip-
mable vapor environment can be created by fuel ment is disconnected from the power source.
spill, leak, etc., unless the genset is equipped with Plan the time for maintenance with authorized
an automatic safety device to block the air intake personnel so that the equipment can be de-
and stop the engine. The owners and operators of energized and safely grounded.
the genset are solely responsible for operating the
genset safely. Contact your authorized Cummins GENERAL SAFETY PRECAUTIONS
Power Generation distributor for more information. Coolants under pressure have a higher boil-
ing point than water. DO NOT open a radiator
ELECTRICAL SHOCK CAN CAUSE SEVERE or heat exchanger pressure cap while the en-
PERSONAL INJURY OR DEATH gine is running. To prevent severe scalding,
let engine cool down before removing coolant
Remove electric power before removing pro- pressure cap. Turn cap slowly, and do not
tective shields or touching electrical equip- open it fully until the pressure has been re-
ment. Use rubber insulative mats placed on lieved.
dry wood platforms over floors that are metal
or concrete when around electrical equip- Used engine oils have been identified by
ment. Do not wear damp clothing (particularly some state or federal agencies as causing
wet shoes) or allow skin surface to be damp cancer or reproductive toxicity. When check-
when handling electrical equipment. Do not ing or changing engine oil, take care not to in-
wear jewelry. Jewelry can short out electrical gest, breathe the fumes, or contact used oil.
contacts and cause shock or burning. Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus-
Use extreme caution when working on electri-
tible materials such as wood and cloth; Class
cal components. High voltages can cause in-
B fires, combustible and flammable liquid
jury or death. DO NOT tamper with interlocks.
fuels and gaseous fuels; Class C fires, live
Follow all applicable state and local electrical electrical equipment. (ref. NFPA No. 10).
codes. Have all electrical installations per- Make sure that rags or combustible material
formed by a qualified licensed electrician. Tag are not left on or near the generator set.
and lock open switches to avoid accidental
closure. Make sure generator set is mounted in a man-
ner to prevent combustible materials from ac-
DO NOT CONNECT GENERATOR SET DI- cumulating under or near the unit.
RECTLY TO ANY BUILDING ELECTRICAL
SYSTEM. Hazardous voltages can flow from Remove all unnecessary grease and oil from
the generator set into the utility line. This cre- the unit. Accumulated grease and oil can
ates a potential for electrocution or property cause overheating and engine damage which
damage. Connect only through an approved present a potential fire hazard.
isolation switch or an approved paralleling Keep the generator set and the surrounding
device. area clean and free from obstructions. Re-

x
 move any debris from the set and keep the Do not store any flammable liquids, such as
floor clean and dry. fuel, cleaners, oil, etc., near the generator set.
A fire or explosion could result.
Do not work on this equipment when mentally Wear hearing protection when near an oper-
or physically fatigued, or after consuming any ating generator set.
alcohol or drug that makes the operation of
equipment unsafe. To prevent serious burns, avoid contact with
hot metal parts such as radiator system, turbo
charger system and exhaust system.
Substances in exhaust gases have been
identified by some state or federal agencies KEEP THIS MANUAL NEAR THE GENSET FOR
as causing cancer or reproductive toxicity. EASY REFERENCE
Take care not to breath or ingest or come into
contact with exhaust gases. DISPOSE OF THIS UNIT PROPERLY

xi
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xii
List of Acronyms
This list is not exhaustive. For example, it does not LCT Low Coolant Temperature
identify units of measure or acronyms that appear LED Light-emitting Diode
only in parameters, event/fault names, or part/ac-
Mil Std Military Standard
cessory names.
NC Not Connected
ACRONYM DESCRIPTION Normally Closed
AC Alternating Current NFPA National Fire Protection Agency
AMP AMP, Inc., part of Tyco Electronics NO Normally Open
ASTM American Society for Testing and Ma- NWF Network Failure
terials (ASTM International) OEM Original Equipment Manufacturer
ATS Automatic Transfer Switch OOR Out of Range
AVR Automatic Voltage Regulator OORH Out of Range High
AWG American Wire Gauge ORH
CAN Controlled Area Network OORL Out of Range Low
ORL
CB Circuit Breaker
PB Push Button
CE Conformit Europenne
PC Personal Computer
CGT Cummins Generator Technologies
PCC PowerCommand Controller
CT Current Transformer
PGI Power Generation Interface
DC Direct Current
PGN Parameter Group Number
ECM Engine Control Module
PI Proportional/Integral
ECS Engine Control System
PID Proportional/Integral/Derivative
EMI Electromagnetic Interference
PLC Programmable Logic Controller
EN European Standard
PMG Permanent Magnet Generator
EPS Engine Protection System
PT Potential Transformer
E-Stop Emergency Stop
PTC Power Transfer Control
FAE Full Authority Electronic
PWM Pulse-width Modulation
FMI Failure Mode Identifier
RFI Radio Frequency Interference
FSO Fuel Shutoff
RH Relative Humidity
genset Generator Set
RMS Root Mean Square
GCS Genset Control System
RTU Remote Terminal Unit
GND Ground
SAE Society of Automotive Engineers
HMI Human-machine Interface
SPN Suspect Parameter Number
IC Integrated Circuit
SW_B+ Switched B+
ISO International Organization for Stan-
dardization UL Underwriters Laboratories
LBNG Lean-burn Natural Gas
AmpSentry and InPower are trademarks of Cum-
LCD Liquid Crystal Display mins Inc. PowerCommand is a registered trade-
LCL Low Coolant Level mark of Cummins Inc.

xiii
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xiv
Glossary

TERM DEFINITION
Accessory A part comes standard with the product. An accessory is optional and provides additional
Part interfaces or functionality.
Active General terms to describe the states for inputs, signals, or outputs that have only two
Inactive states (like true/false or 1/0). For example, a low coolant level switch is either on (active)
or off (inactive). The Ready to Load output is either on (active) or off (inactive).
For events/faults, this term describes the time the PCC generates the event/fault through
the time the event/fault is cleared.
Active-high Some inputs and outputs use voltage differential to distinguish between active and inac-
Active-low tive. If an input or output is active-high, a high voltage differential means the input or out-
put is active, and a low voltage differential means the input or output is inactive. If an in-
put or output is active-low, a low voltage differential means the input or output is active,
and a high voltage differential means the input or output is inactive.
Configurable analog Both terms refer to inputs that can be assigned one of several functions, depending on
input the genset and the application. For example, the same input might generate a fault in
Configurable input one application but enable Battle Short mode in another application. Configurable input
refers to discrete inputs (for example, open or closed). Configurable analog input refers
to analog inputs (for example, 05 VDC).
Configurable analog Both terms refer to outputs that can be controlled by one of several functions, depending
output on the genset and the application. For example, the same output might be controlled by
Configurable output event 1465 (Ready to Load) in one application and by shutdown fault 1433 (Local Emer-
gency Stop) in another application. Configurable output refers to discrete outputs (for
example, open or closed). Configurable analog input refers to analog outputs (for exam-
ple, 05 VDC).
Connection A connection between two devices. A connection might be as simple as one pin-to-pin
connection, or it might require several pins as well as additional components such as re-
lays, fuses, etc. This term also includes some settings that refer to the physical (for ex-
ample, normally-closed vs. normally-open) or electrical (for example, active-high vs. ac-
tive-low) characteristics of the connection.
Connector This term has no meaning if you do not have access to the PCC base board or the back
panel of the Operator Panel.
One or more pins that are in the same housing. Many times, the pins are related by func-
tion (for example, pins that are connected to the engine) or by electrical characteristics
(for example, relay outputs).
This term also refers to the end of a wire or harness that is plugged into the housing.
Event Used to notify the operator or external devices whether or not certain conditions are true.
Fault Each event or fault has two sets of conditions. When the first set of conditions becomes
true, the event or fault becomes active. This might turn on or turn off a light or LED, dis-
play a warning on the PCC, shut down the genset, or so on. When the second set of
conditions becomes true, the event or fault becomes inactive and can be cleared.
The PCC generates a fault when the conditions indicate a more serious problem; the
PCC generates an event only for information purposes.
Genset Generator set
Low-side driver When this output is active, it provides a path to ground.
Mode A term to describe certain states that affect the PCCs behavior. The PCC is either in a
Mode of operation particular mode or not in a particular mode, and the PCCs behavior changes accordingly.
Sometimes, the PCC is always in one mode out of a set of two or more modes. For ex-
ample, the PCC is always in one of the modes of operation: Off mode, Auto mode, or
Manual mode.
Mounting The physical placement and installation of the PCC or the Operator Panel.

xv
TERM DEFINITION
Normally-closed Some inputs and outputs use open circuits and short circuits to distinguish between ac-
Normally-open tive and inactive. If an input or output is normally-closed, an open circuit means the input
or output is active, and a short circuit means the input or output is inactive. If an input or
output is normally-open, a short circuit means the input or output is active, and an open
circuit means the input or output is inactive.
Parameter Refers to monitored values or settings in the PCC or the Operator Panel that can be
looked at and, in some cases, adjusted. Some parameters are protected by passwords.
In this manual, italics are used to identify a specific parameter by name.
Pin A specific point on the PCC or the Operator Panel to which it is acceptable to connect a
specific point on an external device. For example, a B+ pin might be connected to the
positive terminal on the battery. It takes more than one pin to connect an external device
to the PCC. For example, it takes B+ and Ground to connect the battery to the PCC.
Depending on the access you have to the controller, you might see a specific pin on the
PCC base board, the terminal at the end of a harness, a wire that runs between the PCC
and the external device, or nothing at all.
Sensor Refers to a device that measures something and reports one of many (or unlimited) val-
ues. For example, an oil pressure sensor reports the current oil pressure.
Sequence of opera- A term used to describe the steps the PCC follows when it starts the genset or when it
tion stops the genset.
Signal A term used for convenience to talk about two or more connections as a single input.
Usually, all of these connections have the same effect on the PCCs behavior, and it does
not matter which connection is active.
For example, the term remote start signal is used frequently. In Auto mode, the PCC
starts the genset when the remote start signal is active. The remote start signal may
come from any of several connections: a switch connected to the remote start pin, the
Operator Panel, a PLC (programmable logic controller) connected on Modbus, InPower,
etc. It is not important between these connections when explaining the way the remote
start signal affects the PCCs decisions to start and stop the genset. It is only important
whether or not any of them are active.
Switch Refers to a device that measures something and reports one of two states, active or in-
active, about something. For example, a low coolant level switch is active when the cool-
ant level is too low, but the low coolant level switch does not report what the coolant level
really is.
In some cases, this may refer to a physical switch (similar to a light switch) instead.
Trim Refers to the subset of parameters that can be adjusted, as opposed to parameters that
can only be monitored.

xvi
1. Introduction
Read Safety Precautions, and carefully observe True RMS meter for accurate measurement of
all of the instructions in this manual. Keep this small AC and DC voltages. Fluke models 87 or
manual with the other generator set and/or control- 8060A are good choices.
ler manuals. Grounding wrist strap to prevent circuit board
damage due to electrostatic discharge (ESD).
ABOUT THIS MANUAL Battery Hydrometer.
Jumper Leads.
You should have a basic understanding of genera-
tor and power generation before you read this Tachometer or Frequency Meter.
manual. Wheatstone Bridge or Digital Ohmmeter.
Variac.
This is the service manual for the PCC 1301. It is not Load Test Panel.
the service manual for the generator set (genset)
or any accessories. Megger or Insulation Resistance Meter.
InPower Service Tool (PC based genset ser-
SYSTEM OVERVIEW vice tool).
PCC1301 Interface Kit (Used with InPower
The PCC is a microprocessor-based control for Service Tool)
Cummins Power Generation generator sets. All
generator set control functions are contained on HOW TO OBTAIN SERVICE
one circuit board (Base board). The Base board pro-
vides fuel control, main alternator voltage output Always give the complete Model, Specification and
regulation and complete generator set control and Serial number of the generator set as shown on the
nameplate when seeking additional service infor-
monitoring.
mation or replacement parts. The nameplate is lo-
The operating software provides control of the gen- cated on the back of the control box.
erator set and its performance characteristics, and
displays performance information on a digital dis- WARNINGIncorrect service or replacement of
play panel. It accepts menu-driven control and set- parts can result in severe personal injury or
up input from the push button switches on the front death, and/or equipment damage. Service per-
panel. sonnel must be trained and experienced to per-
form electrical and mechanical service. Read
TEST EQUIPMENT and follow Important Safety Instructions on
pages iii and iv.
To perform the test procedures in this manual, the
following test equipment must be available

1-1
THIS PAGE LEFT INTENTIONALLY BLANK

1-2
2. Circuit Board

After determining that a printed circuit board assem- WARNING Stand on a dry wooden platform or
bly is faulty, replace it; do not repair it. Attempts to rubber insulating mat, make sure your clothing
repair a printed circuit board can lead to costly dam- and shoes are dry, remove jewelry and use tools
age to the equipment. with insulated handles.

GENERAL This section describes the function of the Power-

Command 1301 Control (PCC) Base board that is
contained in the control box (Figure 2-1). The block
WARNING WARNING HAZARDOUS VOLT- diagram in Figure 2-2, shows the external connec-
AGE. Touching uninsulated parts inside the tions of the PCC system.
control box can result in severe personal injury
or death. Measurements and adjustments must CAUTION Electrostatic discharge will damage
be done with care to avoid touching hazardous circuit boards. Always wear a grounding wrist
voltage parts. strap when touching or handling circuit boards.

FIGURE 2-1. BASE BOARD LOCATION

2-1
 *CT3
*CT2
*CT1

FIGURE 2-2. BLOCK DIAGRAM

2-2
BASE BOARD TB1. Optional equipment such as sensing devices
used to monitor genset operation, remote start/stop
The Base board (Figure 2-3) contains all of the elec- switches and etc. are attached to this terminal.
tronic circuitry required to operate the generator set.
The Base board provides fuel control, main alterna-
tor voltage output regulation and complete genera- DS1 LED Status Indicator
tor set control and monitoring.

The following paragraphs describe the connectors The status indicator lamp is illuminated when the
(J), terminal board (TB), relays (R) and the LED sta- Base board is in the Power On mode (processor is
tus indicator. Figure 2-3 shows the pin locations for operating).
all Base board connectors.

TB1 Customer Connections S1 Sleep Mode Selection

Display panel B+/data link and customer monitor/

control connections are attached to terminal board Refer to Control Panel On/Off Modes in Section 3.

SLEEP MODE
RS-485 SELECTION CUSTOMER
COMMUNICATIONS CONNECTIONS
S1
TB2 TB1

DS1 STATUS
INDICATOR

J11
J13

VOLTAGE/
FIELD
ENGINE
HARNESS

J12

CTS

FIGURE 2-3. BASE BOARD CONNECTOR/TERMINAL PIN LOCATIONS

2-3
THIS PAGE LEFT INTENTIONALLY BLANK

2-4
3. Control Operation
GENERAL When all conditions are met (i.e., no unacknowl-
edged faults and the control is in the Off or Auto
The following describes the function and operation mode) the Sleep mode is activated after five min-
of the PowerCommand 1301 Control. All indica- utes of keypad inactivity.
tors, control buttons and graphical display are lo-
cated on the face of the control panel as illustrated in To activate the control and view the menu display
Figure 3-2. without starting the generator set, press any control
button.
CONTROL PANEL POWER ON/OFF
MODES When shipped from the factory, Sleep mode is en-
abled for both modes (Off and Auto mode). Internal
The power on/off modes of the control panel and op-
adjustment of the control also allows the Sleep
erating software are Power On and Sleep.
mode to be active only during the Off mode (Base
Power On Mode: In this mode, power is continu- board switch S1) or disabled for both modes (instal-
ously supplied to the control panel. The controls op- lation of jumper). When disabled, the operating soft-
erating software and control panel LEDs/graphical ware will always remain active (Power On mode).
display will remain active until the Sleep mode is ac-
tivated. S1 switch setting:
OFF = Sleep mode is enabled for Auto and Off
Sleep Mode: In the Sleep mode, the controls oper- modes.
ating software is inactive and the LEDs and the ON = Sleep mode is enabled for Off mode only.
graphical display on the control panel are all off.
Sleep mode is a feature used to reduce battery pow- J1/J2 jumper installation: Install jumper between
er consumption when the control is not being used J1-4 and J1-5 to disable sleep mode. (J1 and J2 are
and is in either the Off or Auto mode. identical, either one can be used for jumper.)

3-1
 J1-5

J2

J1

S1 SLEEP
MODE
SELECTION
SWITCH

J1-4 ADD JUMPER TO DISABLE

SLEEP MODE FOR AUTO
AND OFF MODE
BASE BOARD

FIGURE 3-1. SLEEP MODE ACTIVATION SET-

TINGS

GRAPHICAL
DISPLAY LED
INDICATORS

OFF MODE
BUTTON

DISPLAY MENU PREVIOUS MENU

SELECTION BUTTONS LEVEL BUTTON

FIGURE 3-2. FRONT PANEL (WITH DISPLAY)

3-2
 CONTROL PANEL TABLE 3-1. SYMBOLS

Figure 3-2 shows the features of the front panel. It SYMBOL DESCRIPTION
includes six LED indicators, the graphical display,
and six buttons used to navigate through the menus Generator Warning Fault
and adjust parameters.
Generator Shutdown Fault
Graphical Display
This graphical display is used to view menus of the Coolant Temperature
menu-driven operating system. The bottom of the
graphical display indicates the functions that are
Oil Pressure
available by pressing the four selection buttons. Re-
fer to the menu trees later in this section.
Voltage Alternating Current (VAC)
System messages (communication, event, and
fault) are also shown on the graphical display. For
more information, see System Messages later this Voltage Direct Current (VDC)
section.
AC Current
Display Text / Symbolic Versions
This graphical display can be set up to show either Hz Frequency
text or symbolic versions for fault messages, some
Operator menus, and the Mode Change menu. A Battery
description of commonly used symbols used are in-
Out of Range
cluded in Table 3-1. Combinations of symbols are
used to display some fault conditions. Additional High or Pre-High
specialized symbols are also used for some faults.
Low or Pre-Low
When shipped from the factory, symbolic display is
selected. (Refer to the Setup menu to change to text
Annunciator
or symbolic display.)

3-3
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.
When the symbol is displayed, the selec-
The function of the four selection buttons varies with
tion button is used to navigate to an editable
each menu. 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
screen.
When the symbol is displayed, the selec-
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-
ing the button below the symbol decreases
When the up and down triangles ( and ) the value.
are displayed, the selection buttons are used
to navigate between a series of submenus. When SAVE is displayed, the selection button
is used to save changes made in a submenu.
NOTE: When any Operator menu (Figure 3-12 If the Previous Menu button is pressed be-
is displayed, a series of Service menus fore pressing SAVE, the changes are not
can be viewed by simultaneously 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.

3-4
Previous Main Menu Button Off Button

Press the button to switch to the Off mode. The

Press the button to view the previous main Off mode will disable the control Auto or Manual
menu. 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-
der load should be avoided to help prolong the reli-
The button is also used to acknowledge warning ability of the generator set.
and shutdown messages after the fault has been
corrected. Pressing this button clears the fault from The button is also used to acknowledge warning
the front panel display and the previous menu is re- and shutdown messages after the fault has been
displayed. corrected. Pressing this button clears the fault from
the front panel and resets the control.
NOTE: Pressing the or button also clears the
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 a

BUTTON 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.

PREVIOUS MAIN Auto Indicator

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 3-12).

Manual Run Indicator

This green lamp indicates the control is in the Manu-

al Run mode. Manual Run mode can be selected by
FIGURE 3-3. PREVIOUS MAIN MENU AND OFF pressing the selection button from any of the Op-
BUTTONS erator menus (see Figure 3-12).

3-5
 SYSTEM MESSAGES communications between the control panel and the
control logic is lost.
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 button 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 3-4. ESTABLISHING COMMUNICATION
WITH CONTROL
Upon initial power-up, the message Establishing
communication with control is displayed (see Fig-
ure 3-4). This menu also displays the screens soft-
ware number and version.

When the display detects that it is no longer commu-

nicating with the control, the Shutdown, Warning,
and Remote Start LEDs are turned off.

If communications are lost, the message Re-estab-

lishing communication with control is displayed un-
til communications have been re-established (see
Figure 3-5). The LEDs then return to the state deter-
mined by the control.

Note: If either communication message remains dis- FIGURE 3-5. RE-ESTABLISHING COMMUNICATION
played (cannot view other menus), this indicates that WITH CONTROL

3-6
Event Messages after being acknowledged.

When pre-set events (time delay to start or stop) are

activated, Event messages are displayed showing
the time remaining until the event occurs (see Fig- Event = TIME DELAY
TO START, or STOP
ure 3-6).

Fault Messages
A Fault message is an indicator of a Warning or
Shutdown condition. It includes the fault number, a
short description, and when the fault occurred (see
Figure 3-7). Symbolic fault messages include the
fault code number and symbols, indicating the type FIGURE 3-6. EVENT MESSAGE
of fault (see Figure 3-8). 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. Fault = WARNING
or SHUTDOWN
Five of the most recent faults are placed in a fault
history file that can be viewed using the Fault Histo-
ry Menus.

Fault Acknowledgement
Shutdown faults must be acknowledged after the
faults have been corrected. If in Auto or Manual Run
FIGURE 3-7. FAULT MESSAGE
mode, the control must be set to O (off). Also,
faults are acknowledged when in Auto and the Re-
mote Start command is removed. Faults are cleared
from the control panel display by pressing the , EXAMPLE OF
A SYMBOLIC
, or button. WARNING
FAULT
214
Faults are re-announced if they are detected again

EXAMPLE OF
A SYMBOLIC
SHUTDOWN 1
FAULT

FIGURE 3-8. FAULT MESSAGES SYMBOLIC VER-

SION

3-7
 SELECTING AUTO, MANUAL RUN AND 2. Press the arrow selection button to move
OFF MODES to the next numeric character.
3. Press the button below the + or symbols until
Auto, Manual Run, and Off modes can be selected: the value reads 2.
From any of the Operator menus 4. Press the arrow selection button to move
to the next numeric character.
When the message Establishing commu- 5. Press the button below the + or symbols until
nication with control is displayed the value reads 1.
When the message Re-establishing commu- 6. After you have completed entering the pass-
nication with control is displayed word, press the arrow selection button .

Switching to Auto, Manual Run, or Off mode can be NOTE:If an incorrect password is entered, the Op-
restricted to authorized personnel. If a control panel erator menu that was displayed before
is set up with the mode change access code feature Auto, Manual Run, or Off mode was se-
enabled, an access code must first be entered be- lected is redisplayed.
fore the mode can be changed.

Note: The InPower service tool or access to the Gen-

set Service submenu is required to enable/disable
the mode change Access Code feature. Refer to TEXT VERSION
Section 5.

Entering the Mode Change Access Code

If the mode change access code feature is enabled,

an access code must be entered to switch to Auto,
Manual Run, or Off mode. The text and symbolic
versions of the Mode Change menu are shown in SYMBOLIC VERSION
Figure 3-9.

To enter the mode change access code,

1. With the first character highlighted, press the
button below to the + or symbols until the val-
ue reads 1. FIGURE 3-9. MODE CHANGE MENU

3-8
Selecting Auto Mode while in Auto mode.

To switch to Auto mode (see Figure 3-10):

1. Press the button on any of the Operator
menus or the Establishing/Re-establishing
communication with control menus.
2. If the mode change access code feature is en-
abled, the Mode Change Access Code menu is
displayed. Enter the mode change access
code as described above.
3. A menu with alternating arrows is displayed THIS MENU IS
DISPLAYED ONLY IF
above a second symbol. Press the sec- THE MODE CHANGE
ond button. The Operator menu that was ACCESS CODE
FEATURE IS ENABLED
displayed before Auto mode was selected is re-
displayed and the Auto indicator is lit.
4. To disable auto mode, press the button.

NOTE:Manual Run mode can also be selected

ALTERNATING
ARROWS ARE
DISPLAYED

AUTO MODE
SELECTED

FIGURE 3-10. SELECTING AUTO MODE

3-9
Selecting Manual Run Mode fore Auto or Manual Run mode was selected is re-
displayed.
To switch to Manual Run mode (see Figure 3-11):
1. Press the button on any of the Operator me-
nus or if displayed, the Establishing/Re-estab-
lishing communication with control menus.
2. If the mode change access code feature is en-
abled, the Mode Change Access Code menu is
displayed. Enter the mode change access
code as described on the previous page.
3. A menu with alternating arrows is displayed
THIS MENU IS
above a second symbol. Press the second DISPLAYED ONLY IF
button to start the genset. THE MODE CHANGE
ACCESS CODE
The Operator menu that was displayed before FEATURE IS ENABLED
Manual Run mode was selected is redisplayed
and the Manual Run indicator is lit.

To disable Manual Run mode, press the button.

NOTE: Auto mode can also be selected while in

Manual Run mode. Switching to Auto mode ALTERNATING
ARROWS ARE
may result in the generator set shutting DISPLAYED
down.

Aborting the Transition to Auto or Manual

Run Mode

If the Mode Change Access Code menu or the

menu showing alternating arrows above the or
buttons is displayed, the transition to Auto or
Manual Run mode is aborted when: MANUAL
RUN MODE
SELECTED
Either the , , or button is pressed.

The or button is not pressed within

ten seconds.

If the transition to Auto or Manual Run mode is

aborted, the Operator menu that was displayed be- FIGURE 3-11. SELECTING MANUAL RUN MODE

3-10
 OPERATOR MENUS Alternator Status Menu
Figures 3-12 and 3-13 show block representations This menu displays genset power (in kVA), frequen-
of the following Operator menus. cy, and engine speed (RPM). (In applications with-
out current transformers, the kVA is not shown.)
Engine Status
Alternator Status Alternator Line-to-Line Voltage Menu
Line-to-Line Voltage
Line-to-Neutral Voltage This menu displays L1-L2, L2-L3, and L2-L1 line-to-
line voltages for three phase applications only.
Alternator Amperage
To navigate between the Operator menus, press the Alternator Line-to-Neutral Voltage Menu
buttons next to the and symbols in the graphi-
cal display. This menu displays line-to-neutral voltages for L1,
L2, and L3 for three phase wye configurations only.
The Operator menus can be used to select Auto or (In delta configurations, this menu is not shown.)
Manual Run modes.
Alternator Single Phase Voltage Menu
Note: Appendix A provides a block diagram that illus-
trates the sequence of how the Operator Menus are
This menu displays L1-N, L2-N, and L1-L2 voltages
displayed.
for single phase applications only.
Engine Status Menu
Alternator Amperage Menu
This menu displays the engine starting battery volt-
age, engine coolant temperature, engine oil pres- This menu displays L1, L2, and L3 amperage. (In
sure, and hours of engine operation. (Oil pressure - applications without current transformers, this
only available on some models). menu is not shown.)

3-11
 OPERATOR MENUS TEXT VERSION

THREE PHASE
ONLY SINGLE
PHASE
ONLY

THREE PHASE
WYE ONLY

CURRENT
SENSE ONLY

FIGURE 3-12. OPERATOR MENUS (TEXT VERSION)

3-12
 OPERATOR MENUS SYMBOLIC VERSION

THREE PHASE
ONLY SINGLE
PHASE
ONLY

THREE PHASE
WYE ONLY

CURRENT
SENSE ONLY

FIGURE 3-13. OPERATOR MENUS (SYMBOLIC VERSION)

3-13
 SERVICE MENUS Lamp Test The six LEDs on the control
panel should light as long as the (6) button is
Figure 2-14 shows a block representation of the me- pressed.
nus available from the Service Menus. The third Service Menu can be viewed by pressing
the selection button on the second Service
Note: Appendix A provides a block diagram that illus- Menu. The third Service Menu provides access to
trates the sequence of how the Service Menus are the Network Status menus.
displayed.
Status Menu
The first Service Menu can be viewed from any of
the Operator menus by simultaneously pressing the The Status menu is displayed when the (5) button is
and selection buttons for two seconds. The pressed on the second Service Menu. The Status
first Service Menu provides access to the following menu shows the following:
menus:
Voltage regulator (drive) level, in percentage
Setup Menus Used by Service personnel. of duty cycle
Adjusting the Setup menus is restricted by a Governor regulator (drive) level, in percent-
password. To view the Setup menus only, age of duty cycle. This value is only displayed
press the VIEW button on the Setup pass- if the governor is enabled.
word menu.
Network Status Menus
History / About see page 3-16
The Network Status menus are displayed when the
Screen Adjust see page 3-18 (7) button is pressed on the third Service Menu. Two
menus are used to display the quantity of the follow-
To return to the Operator menu that was displayed ing devices that are connected to the network.
prior to viewing the Service Menu, press the but-
ton. Auto Mains Failure (AMF) modules
Universal Annunciators
The second Service Menu can be viewed by press- Bar graphs
ing the selection button on the first Service Menu. Battery chargers
The second Service Menu provides access to the
Controls
following menus:
I/O modules
Fault History see page 3-19 Operator panels (any type)

Status see below

3-14
 1ST
SERVICE
MENU

SETUP MENUS HISTORY / ABOUT MENUS SCREEN ADJUST MENU

(SECTION 4) SEE PAGE 3-16 SEE PAGE 3-18

2ND 3RD
SERVICE SERVICE
MENU MENU

FAULT HISTORY MENUS

SEE PAGE 3-19

FIGURE 3-14. SERVICE MENUS

3-15
 HISTORY / ABOUT MENUS About Genset Submenu
Figure 3-15 shows a block representation of the His- This submenu displays the generator set model
tory / About menu. The first History / About submenu number and rating.
is displayed when the (2) button is pressed on the
Service Menu. About Control Submenu
Press the buttons next to the and symbols in
the graphical display to navigate between the Histo- This submenu displays the controls part number,
serial number (up to 11 characters), software part
ry / About submenus. Press the button to return
number, and software version.
to the Service Menu.

History Submenu About Display Submenu

This submenu displays the number of engine starts, This submenu displays the optional control panel
hours of operation for the engine, and hours of op- software part number, software version, screen part
eration for the control. number, and screen version of the display.

3-16
 HISTORY / ABOUT MENUS

FIGURE 3-15. HISTORY/ABOUT MENUS

3-17
 SCREEN ADJUST MENU NOTE: If the Previous Menu button is
pressed before pressing the SAVE but-
ton, the changes are not saved.
Figure 3-16 shows a block representation of the
Screen Adjust menu. The Screen Adjust submenu 5. Press the button to return to the Service
is displayed when the (3) button is pressed in the Menu.
first Service Menu. Screen Adjust Menu
This menu allows for adjusting the screens contrast
Adjusting Values/Parameters
and brightness and for selecting the units of mea-
1. Press the ADJUST selection button to select surement (SAE or SI) to be displayed.
the first parameter or value to be changed. Contrast and Brightness: Press the + or
2. Press the + or selection buttons to adjust val- selection buttons to adjust the screens con-
ues or select parameters. trast and brightness. Changing the brightness
3. Press the arrow selection button to navi- setting also affects the brightness of the
gate to the next or previous adjustable value or LEDs on the control panel.
parameter. Units: Press the + or selection buttons to
4. After adjusting values/selecting parameters, select SAE (_F, PSI) or SI (C, kPa) units of
press the SAVE button to save your settings. measurement to be displayed.

SCREEN ADJUST MENU

FIGURE 3-16. SCREEN ADJUST MENU

3-18
 FAULT HISTORY MENU Press the button to return to the Service Menu.

Figure 3-18 shows a block representation of the TIME FAULT

Fault History menu. The first Fault menu is dis- OCCURRED
played when the (4) button is pressed on the second FAULT
Service Menu. If there are any active fault subme- CODE
nus, an Active Fault heading is displayed for the
most recent active fault. All other fault submenus
display a Fault History heading. Five of the most FAULT
recent faults can be viewed. An example of how a DESCRIPTION
fault code is displayed is shown in Figure 3-17.

Press the buttons next to the and symbols in

the graphical display to navigate between menus. FIGURE 3-17. FAULT HISTORY MENU EXAMPLE

3-19
 FAULT HISTORY MENU

Active Fault Fault 1

OR

Fault 2

Oldest Fault
(Maximum of 5)

FIGURE 3-18. FAULT HISTORY MENU

3-20
4. Control Adjustment and Service
GENERAL WARNINGIncorrect service or replacement of
parts can result in severe personal injury or
This section contains circuit board removal and re- death, and/or equipment damage. Service per-
placement procedures and system parameter ad- sonnel must be trained and experienced to per-
justment procedures for the genset control.
form electrical and mechanical service.
This section also describes the function and opera-
tion of engine sensors, genset options, and other WARNINGHAZARDOUS VOLTAGE. The con-
special features of the genset control system, such trol box must be opened only by technically
as customer connection points, magnetic speed qualified personnel. Voltages of up to 600 VAC
pickup unit and current transformers. Installation in- are present in the control box. These voltages
formation is also provided for these items where can cause electrical shock, resulting in person-
necessary. al injury.

4-1
 CIRCUIT BOARD WARNING Ignition of explosive battery gases
REMOVAL/REPLACEMENT can cause severe personal injury or death. Arc-
ing at battery terminals, light switch or other
equipment, flame, pilot lights and sparks can ig-
No special tools (other than a grounding wrist strap
nite battery gas. Do not smoke, or switch trouble
and InPower Service tool) are required to remove a
light ON or OFF near battery. Discharge static
circuit board from inside the control box. The InPow-
electricity from body before touching batteries
er Service tool is required when replacing the Base
by first touching a grounded metal surface.
board.
Ventilate battery area before working on or near
Before replacing the Base board, make sure that a batteryWear gogglesStop genset and dis-
capture file of the gensets parameter values has connect charger before disconnecting battery
been created using InPower. (During genset instal- cablesDisconnect negative () cable first and
lation, it was suggested that a capture file be made reconnect last.
before and after changes were made to the genset CAUTIONDisconnect battery charger from AC
operating parameters.)
source before disconnecting battery cables.
Otherwise, disconnecting cables can result in
After replacing the Base board, use the capture file voltage spikes damaging to DC control circuits
as a template to write the previous settings to the of the genset.
new Base board software.
WARNING Accidental starting of the generator
set can cause severe personal injury or death.
Refer to InPower Users Guide for specifics. Prevent accidental starting by disconnecting
the negative () cable from the battery terminal.
Circuit Board Removal Safety Precautions

Turn off or remove AC power from the battery char-

ger and then remove the negative () battery cable
from the set starting battery. This is to make sure
that the set will not start while working on it and to
avoid circuit board damage, caused by voltage
spikes when removing and replacing circuit board
connectors.

To prevent circuit board damage due to electrostatic

discharge (ESD), a grounding wrist strap must be
worn when handling circuit boards or socket-
mounted ICs. (The wrist strap does not provide a
direct short to ground, but is typically rated at
approximately 1 megohm to ground.)

Attach the clip to the chassis ground screw in the

control box and place the strap around your wrist
before handling a circuit board.

CAUTION Electrostatic discharge will damage

circuit boards. Always wear a grounding wrist
strap when handling circuit boards or socket-
mounted ICs. FIGURE 4-1. WRIST STRAP

4-2
 SETUP MENU (see Figure 4-3). Note that when viewing the Genset
Service menus, the ADJUST button will not be dis-
The Setup Menus menu (Figure 4-2) provides ac- played as shown in Figure 4-3.
cess to genset menus with system parameters that
can be viewed and, if a password is entered, ad- After entering the password from the Setup Pass-
justed. The Setup Password menu is displayed word menu, a second Setup menu is displayed that
when the 1 button is pressed on the Service provides access to the following two categories of
Menu. genset adjust menus.

Pressing the VIEW button in the Setup Password Genset Service menus Go to page 4-4.
menu, will display the 1st Genset Service menu Genset Setup menus Go to page 4-23.

FIGURE 4-2. SETUP MENUS

4-3
 GENSET SERVICE MENUS not be able to go back and correct it. If the
wrong password is entered, you will be able
Note: In the following menu entry descriptions, the to view the Genset Service menus but you
default parameter/value is not shown because the wont be able to change them.
default value is subject to change by model. Always
create and refer to the initial capture file for factory To enter the Genset Service Menus password 574:
default settings of system parameters/values.
1. With the first character highlighted, press the
The Genset Service menus are available by press- button below to the + or symbols until the val-
ing the (1) button in the Setup menu (see Figure ue reads 5.
4-3). 2. Press the arrow selection button to move
to the next numeric character.
This section covers Genset Service menus only. For
information on Genset Setup menus, go to page 3. Press the button below the + or symbols until
4-23. the value reads 7.
4. Press the arrow selection button to move
If a password is entered, the settings in the Genset to the next numeric character.
Service menus can be adjusted. However, if a pass- 5. Press the button below the + or symbols until
word is not entered, these menus can still be the value reads 4.
viewed.
6. After you have completed entering the pass-
Viewing and Adjusting word, press the arrow selection button . The
first main Setup menu is displayed.
Figure 4-3 is a block representation of the two Gen-
set Service menus that are available from the Setup After the correct password is entered, it will be re-
menu after the correct password has been entered. membered until five minutes of button inactivity has
The Genset Service menus provide access to the elapsed. If five minutes of button inactivity has
following categories. elapsed, you will have to re-enter the password to
access and change the Genset Service submenus.
The first Genset Service Menu provides access to
Adjusting Values/Parameters
the following menus:
Genset Once the correct password has been entered after
Genset Service (1) is selected on the Setup Menus
Customer I/O menu, the first Genset Service menu is displayed.
Meter Calibration
1. Press the buttons above the and symbols
The second Genset Service Menu provides access in the digital display to navigate between sub-
to the following menu: menus.
Annunciator 2. Press the ADJUST selection button to select
the first parameter or value to be changed.
Setup Password Menu
3. Press the + or selection buttons to adjust val-
Adjusting the Genset Service submenus is re- ues or select parameters.
stricted to service personnel and a password must 4. Press the arrow selection button to navi-
be entered to modify these menus. gate to the next or previous adjustable value or
When the Password menu is displayed, the first nu- parameter.
meric character (0) is highlighted (see Figure 4-3). 5. After adjusting values/selecting parameters,
press the SAVE button to save your settings.
NOTE: When selected (highlighted), each charac-
ter initially turns to 0 and the remaining NOTE: If the button is pressed before
characters turn to X. pressing the SAVE button, the changes
are not saved.
NOTE: Make sure that each numeric character is
correct before you move to the next charac- 6. Press the button to return to the Service
ter. If a wrong character is entered, you will Menu.

4-4
 GENSET SERVICE MENUS

1ST
GENSET
SERVICE
MENU 2ND
GENSET
SERVICE
MENU

SEE PAGE 4-16 SEE PAGE 4-22

REFER TO I/O MODULE

MANUAL
SEE PAGE 4-7 SEE PAGE 4-18 SEE PAGE 4-20

FIGURE 4-3. GENSET SERVICE MENUS

4-5
 GENSET SERVICE SUBMENUS The average engine speed (if a mag-
netic pickup unit is installed)
The Genset Service submenus are available by
pressing the (1) button on the first Genset Service The average frequency
menu (see Figure 4-3). The charging alternator voltage (if the
Charging Alt feature is enabled)
Note: Appendix A provides a block diagram that illus-
trates the sequence of how the Genset Service Sub- The Charging Alt. Enable menu is used to en-
menus are displayed.
able or disable the Charging Alt feature. This
menu provides a means to disable the controls
The Genset Service submenus consist of ten basic
charging alternator logic if it is not supported by
menus.
the alternator. If the alternator does not support
Genset, Part 1 this functionality, the Charger Failure warning
(fault code 219) will constantly be displayed un-
Genset, Part 2
less this setting is changed to No. When dis-
Fuel System abled (set to No), the start disconnect signal is
based only on the average engine speed or fre-
Start/Stop Time Delays
quency and the Charger Failure warning is dis-
Cycle Crank abled.
Battle Short
Fuel System
Automatic Voltage Regulator Setup*
The Fuel System menu allows for selecting fuel type
Electronic Governor*
and, depending on the type selected, enabling/dis-
Genset Model and Serial Number abling glow plugs or setting a fuel burn time delay.
Display Setup Fuel System: Allows for selecting the fuel type
(Diesel or Gas).
Genset Menu, Part 1
If Fuel System is set to Diesel
The first genset menu displays the preset AC Volt-
age, genset frequency, number of phases, and Glow Plug Enable: Allows control of Glow
phase type. Plugs for a particular genset (Yes or No).

Volts AC: Displays the AC voltage (190, 200, If Fuel System is set to Gas
208, 220, 230, 240, 380, 400, 416, 440, 460, or
480 VAC). Fuel Burn Delay: After the genset receives a
stop signal, this feature allows for setting a fuel
Hertz: Displays the genset frequency (50 or 60 time delay from 0 to 10 seconds in which the
Hz). The control selects limits, gains, and fre- ignition remains on so that any fuel down
quency values based upon this selection. stream of the intake manifold is burned.
No. of Phases: Displays the number of phases
(1 or 3). Start/Stop Delay Menu
Phase: Displays the phase type (Delta or Wye). The time delay after receiving a valid start signal,
until the genset starts, can be adjusted. The time
Genset Menu, Part 2 delay that the genset is allowed to run at rated
speed after receiving a stop signal, until the genset
The second genset menu allows for enabling or dis- stops, can also be adjusted. These time delays do
abling charging alternators. not apply to manual start/runs.
Charging Alt. Enable: Start: The genset start time delay can be ad-
justed from 0 to 300 seconds.
A starter disconnect will occur whenever any
one of the following three possible signals Stop: The genset stop time delay can be ad-
reaches its disconnect setpoint. justed from 0 to 600 seconds.

4-6
 GENSET SERVICE SUBMENUS

PART 1

PART 2

WHEN FUEL SYSTEM IS

SET TO DIESEL, THE B
GLOW PLUG ENABLE
SUBJECT IS DISPLAYED.
WHEN FUEL SYSTEM IS
SET TO GAS, THE FUEL
BURN DELAY SUBJECT
IS DISPLAYED.

CONTINUED ON
PAGE 4-8

FIGURE 4-4. GENSET SERVICE SUBMENUS (SHEET 1 OF 3)

4-7
Cycle Crank Menu Attempts: The maximum number of times the
starter can be engaged when attempting to
The Cycle Crank menu allows for configuring the start the engine with cycle cranking can be set
generator for all starting modes (manual and re- from 1 to 7 attempts.
mote), as follows:
AVR Setup Menu
Crank: The cranking period can be set from 3
to 30 seconds. This time limit is used to deter-
The AVR Setup menu is used to enable or disable
mine a Fail to Start status.
the automatic voltage regulator. If enabled, two
Rest: The minimum amount of time between additional menus are displayed that can be used to
crank attempts can be set from 0 to 60 seconds. adjust the AVR settings (see page 4-11).

GENSET SERVICE SUBMENUS (CONTINUED)

A RETURN TO
PAGE 4-7
B

YES NO
K
OR

C E
GO TO AVR CONTINUED
SETUP MENUS ON PAGE 4-10
ON PAGE 4-12

FIGURE 4-5. GENSET SERVICE SUBMENUS (SHEET 2 OF 3)

4-8
Electronic Governor Menu Display Setup Menu
The Display Setup menu is used to set the display
The engine Electronic Governor Enable menu is for Local (Auto/Off/Manual Run switch functions on
used to enable or disable the electronic governor on the operator panel are turned on) or Remote (Auto/
gensets with electronic governors and magnetic Off/Manual Run switch functions on the operator
pickup sensors. If enabled (set to Yes), four addi- panel are turned off).
tional menus are displayed that can be used to ad- Connection: A display can be set up to be Local
just governor settings (see page 4-13). or Remote.
Access Code: A display can be set up to require
Genset Number Menu or not require entering the mode change ac-
cess code. If enabled, an access code must be
entered to change genset mode of operation
The Genset Number menu is used to enter the gen- (Auto, Manual Run or Off).
sets model and serial numbers. Each allow up to 16 Symbols: A display can be set up to display in-
characters to be entered. ternational symbols on the Operator menus.

4-9
 GENSET SERVICE SUBMENUS (CONTINUED)

RETURN TO
E PAGE 4-8
F

IF AVR IS NOT
ENABLED
OR
YES NO
IF AVR IS
OR ENABLED

D H

GO TO GO TO
GOVERNOR PAGE 4-12
SETUP MENUS
ON PAGE 4-14

FIGURE 4-6. GENSET SERVICE SUBMENUS (SHEET 3 OF 3)

4-10
 AUTOMATIC VOLTAGE REGULATOR duced 5%. If the frequency drops to 53 Hz, the volt-
SUBMENUS age set point is reduced 10%, etc.

NOMINAL
The Automatic Voltage Regulator (AVR) submenus
are available only if the AVR is enabled (see page
4-8). KNEE FREQUENCY
NOMINAL
(100%)
SLOPE VOLTAGE SET-
Two Automatic Voltage Regulator (AVR) submenus VOLTAGE POINT CURVE
(see Figure 4-8) can be used to adjust Volts/Hz Rol- FREQUENCY
loff and Regulator Gains settings.
FIGURE 4-7. KNEE FREQUENCY AND SLOPE
Volts/Hz Rolloff Menu
V/Hz Knee: The Knee Frequency can be ad-
justed from 0.0 to 10.0 Hertz in 0.1 Hz incre-
The Volts/Hz Rolloff function helps optimize the ments. When generator set speed decreases by
gensets response to added load. If the engine more than the value of the knee frequency, the
speed drops below nominal frequency, the control generator set voltage decreases by the %/Hz
automatically drops the voltage until the engine value.
speed starts to recover.
V/Hz Rolloff: The Rolloff setting can be adjusted
from 0.0 to 5.0 percent of rated voltage, in 0.1%
This menu allows for adjusting the knee frequency increments.
and voltage setpoint slope parameters. The knee
frequency is the value below nominal frequency at Regulator Gains Menu
which the rolloff function begins. For example, if the
knee frequency is set to 5 Hz on a 60 Hz genset, this The Regulator menu allows for setting proportional
function begins when the frequency drops below 55 Gain, Integral Gain, and Damping values.
Hz.
Gain: The proportional Gain (K1) multiplier can
be set from 5 to 1000%. This allows for a scale
Slope refers to how fast the voltage is rolled off be- factor of 0.05 to 10.0.
low the knee frequency. The voltage is rolled off the
slope percent setting for every 1 Hz below the knee. Int: The Integral Gain (K2) multiplier can be set
For example, on a 60 Hz genset, if the slope is set to from 5 to 1000%.
5% and the knee frequency is set to 5 Hz, then if the D: The Damping adjustment can be set from 95
frequency drops to 54 Hz, the voltage set point is re- to 105%.

4-11
 AUTOMATIC VOLTAGE REGULATOR SUBMENUS

NOTE: These menus are only available if RETURN TO

the Automatic Voltage Regulator PAGE 4-8
(AVR) is enabled (see page 4-8). C F

RETURN TO
PAGE 4-8

FIGURE 4-8. AUTOMATIC VOLTAGE REGAULATOR SUBMENUS

4-12
 ELECTRONIC GOVERNOR SUBMENUS Int: The integral governor gain (K2) multiplier
can be set from 5 to 1000%.
The Electronic Governor submenus are available
only if the governor is enabled (see page 4-9). D: The governor Damping adjustment can be
set from 95 to 105%.
Four Electronic Governor submenus (see Figure
4-9) can be used to adjust governor settings. Electronic Governor Menu

Governor Crank Fuel Menu The Electronic Governor menu allows for setting
Crank Exit Fuel DC, Dither Factor, and Damping
The Governor Crank Fuel menu allows for setting values. This menu is displayed only if the governor
the Initial Crank Fuel Duty Cycle, the Initial Crank has been enabled with the Engine Electronic Gover-
Fueling Period, the Crank Fuel Ramp Rate, and the nor Enable menu.
Maximum Crank Fuel Duty Cycle.
Crank Exit Fuel DC: The Crank Exit Fuel Duty
Initial DC: The Initial Crank Fuel Duty Cycle is Cycle is the value at which the governor duty
the initial value assigned to the Governor Duty cycle is held after disengaging the starter until
Cycle parameter when cranking begins. This the governor is enabled. This value can be set
value can be set from 0 to 50 percent. from 0 to 100%.
Initial Time: The Initial Crank Fueling Period is Dither Factor: Dither is a signal that is superim-
the amount of time for which the value of Initial posed on the PWM (pulse width modulation)
Crank Fuel Duty Cycle is assigned to the gover- duty cycle to prevent the actuator valve from
nor duty cycle after cranking begins. This value sticking. The Dither Factor is the dither percent
can be set from 0 to 10 seconds. added to the current duty cycle. The Dither Fac-
Ramp Rate: The Crank Fuel Ramp Rate is the tor can be set from 0 to 30%. The dither function
rate at which the value of the Governor Duty is disabled when the dither factor is set to 0%.
Cycle is ramped up by during the Crank State,
Ramp Time: This feature is used to set the mini-
after expiration of the Initial Crank Fueling Peri-
mum governor speed reference ramp rate. The
od. This value can be set from 5 to 100.
governor Ramp Time can be set from 0.00 to
Max DC: The Maximum Crank Fuel Duty Cycle 30.0 seconds, in 0.01 second increments.
is the maximum level to which the Governor
Duty Cycle should be limited to during a crank Electronic Governor Enable Speed Menu
state. This value can be set from 50 to 100%.
The Electronic Governor Enable Speed menu al-
Electronic Governor Regulator Menu lows for setting the minimum and maximum gover-
nor duty cycle.
The Electronic Governor Regulator menu allows for
setting proportional Gain, Integral Gain, and Damp- Min. Gov DC: The Minimum Governor Duty
ing values. Cycle can be set from 0 to 100%.
Gain: The proportional governor gain (K1) mul- Max. Gov DC: The Maximum Governor Duty
tiplier can be set from 5 to 1000%. This allows Cycle (with dithered value) can be set from 0 to
for a scale factor of 0.05 to 10.0. 100%).

4-13
 ELECTRONIC GOVERNOR SUBMENUS

NOTE: These menus are only available D RETURN TO

PAGE 4-8
if the governor is enabled (see
page 4-9). F

RETURN TO
PAGE 4-10

FIGURE 4-9. ELECTRONIC GOVERNOR SUBMENUS

4-14
 CUSTOMER I/O SUBMENUS Map menus allow for entering a fault number and
fault name to be displayed for the two configurable
The Customer I/O submenus are available by customer outputs.
pressing the (2) button on the first Genset Service
menu (see Figure 4-3). Number: Enter a code number 0 to 255 for the
event. Table 5-3 provides a list of all warning
Four Customer I/O submenus (see Figure 4-10) can and shutdown codes. Table 4-1 contains event
be used to define customer input messages and codes that are not shown in that table.
output maps. A brief description of the event is automatically
displayed.
Customer Inputs
TABLE 4-1. EVENT CODES
The Customer Input Text message menus are used
to enter an event type and description for two CODE DESCRIPTION
events.
150 READY TO LOAD
Type: Enter the event type (Warning, Shutdown 151 UTILITY CONNECTIONS
or Event. 152 GENSET CONNECTED
153 NOT IN AUTO
Enter a brief description of the event (up to 32 155 COMMON ALARM
characters). Example inputs: Low Coolant Lev- 156 COMMON WARNING
el, Low Fuel Pressure, Ground Fault, etc. 157 COMMON SHUTDOWN
158 CUSTOMER FAULT INPUT 1
Customer Outputs 159 CUSTOMER FAULT INPUT 2
160 ANNUNCIATOR FAULT 1
Two Customer Outputs are configurable to display 161 ANNUNCIATOR FAULT 2
common warning alarms. The two Customer Output 162 ANNUNCIATOR FAULT 3

4-15
 CUSTOMER I/O SUBMENUS

FIGURE 4-10. CUSTOMER I/O SUBMENUS

4-16
 METERING SUBMENUS 4. Calibrate voltage reading for L1 so that the
reading on the display agrees with the cali-
The Metering submenus are available by pressing brated voltmeter.
the (3) button on the first Genset Service menu (see
5. After adjusting, press the SAVE button to save
Figure 4-3).
the setting.
Four Metering submenus (see Figure 4-11) can be 6. Shut the generator set OFF.
used to adjust regulated voltage, frequency, line-to-
7. Repeat steps 1 through 6 for L2 and L3. (In step
neutral voltage, and line current settings.
1, attach meter to the AC output from L2 to L3
Meter Calib Menu to calibrate L2, and L3 to L1 to calibrate L3.)

The Meter Calib menu allows for adjusting the actu- Metering Current Adjust Menu
al output voltage of the genset. The percentage can
The Metering Current Adjust menu allows for ad-
be set from 90 to 110%. The alternator voltage is
justing metered amps.
also shown on this menu.
1. With the genset OFF, attach a calibrated am-
Freq. Adjust Menu meter to L1.
2. Start the genset and allow it to reach normal op-
The Frequency Adjust menu allows for adjusting the
erating speed.
genset frequency. The frequency can be adjust from
6.0 to +6.0 Hz. The actual frequency is also shown 3. Display the Metering Current Adjust menu.
on this menu. 4. Load the genset to maximum rated kVA at rated
voltage.
Metering Voltage Adjust Menu
5. Calibrate the reading for L1 current so that the
The Metering Voltage Adjust menu allows for ad- reading on the display agrees with calibrated
justing metered genset line voltage. ammeter.
1. With the genset OFF, attach a calibrated volt- 6. After adjusting, press the SAVE button to save
meter to the AC output from L1 to L2. (L1 to the setting.
Neutral for single phase alternators.) 7. Shut the generator set OFF.
2. Start the genset and allow it to reach normal op- 8. Repeat steps 1 through 7 for L2 and L3. (In step
erating speed. 1, attach meter to L2 to calibrate L2 current, and
3. Display the Metering Voltage Adjust menu. L3 to calibrate L3 current.)

4-17
 METERING SUBMENUS

FIGURE 4-11. METERING SUBMENUS

4-18
 ANNUNCIATOR SUBMENUS Annunciator Outputs
The Annunciator submenus are available by press-
ing the (4) button on the second Genset Service An annunciator has four custom (N.O.) relays that
menu (see Figure 4-3). can be controlled. When a specified event becomes
active, a message can be sent to the annunciator to
Seven annunciator submenus (see Figure 4-12) turn the relay on or off. Only one event per relay is
can be used to define three Annunciator Fault Text allowed.
messages and four Annunciator Output Maps.
The four annunciator outputs are configurable to
Annunciator Inputs display common warning alarms. The four Annun-
ciator Output Map menus allow for entering a fault
The annunciator has three possible customer-de- number and fault name to be displayed for the confi-
fined fault conditions that can be shown on the dis- gurable annunciator outputs.
play. The Annunciator Fault Text message menus
are used to enter an event type and description for Number: Enter a code number 0 to 255 for the
those three customer-defined annunciator faults. event. Table 5-3 provides a list of all warning
Type: Enter the event type (Warning, Shutdown and shutdown codes. Table 4-1 contains event
or Event. codes that are not shown in that table.
Enter a brief description of the event (up to 32 Description: A brief description of the event is
characters). automatically displayed.

4-19
 ANNUNCIATOR SUBMENUS

CONTINUED ON
PAGE 4-21

FIGURE 4-12. ANNUNCIATOR SUBMENUS (SHEET 1 OF 2)

4-20
ANNUNCIATOR SUBMENUS (Continued)
A B RETURN TO PAGE 4-20

FIGURE 4-13. ANNUNCIATOR SUBMENUS (SHEET 2 OF 2)

4-21
 MODBUS SUBMENUS Modbus Setup Menu
The Modbus submenus are available by pressing
The Modbus Setup menu allows for setting a nu-
the (5) button on the second Genset Service menu
meric address and a baud rate. The parity value is
(see Figure 4-3).
automatically displayed.
Modbus Enable Menu Address: Enter a numerical value (up to three
digits) for the address.
The Modbus Enable menu allows for enabling or
disabling the Modbus feature. Baud Rate: Select one of the four available
baud rates (2400, 4800, 9600, or 19200).
If set to Yes, the Modbus Setup menu is made
available. Parity: This value is automatically displayed.

MODBUS SUBMENUS

FIGURE 4-14. MODBUS SUBMENUS

4-22
 GENSET SETUP SUBMENUS menu go to page 4-24 or press the View only
button.

Note: In the following menu entry descriptions, the

default parameter/value is not shown because the
default value is subject to change by model. Always SETUP
PASSWORD
create and refer to the initial capture file for factory MENU
default settings of system parameters/values.

The first Setup Password menu is displayed when

the (1) button is pressed on the Service Menu. From
the Setup Password menu, a Setup Menus menu is
displayed that provides access to the following two
categories of genset adjust menus. SETUP
MENUS
MENU
Genset Service menus Go to page 4-4

Genset Setup menus

This section covers Genset Setup menus only. To

access the Genset Setup menus:
GENSET SETUP
PASSWORD
1. Enter the password into the Setup Password MENU
Menu. Refer to page 5-4 to enter password.

2. Press the 2 button in the Setup Menus to dis-

play the Genset Setup Password Menu.

3. Enter the password into the Genset Setup FIGURE 4-15. SETUP PASSWORD MENUS

4-23
Viewing and Adjusting 3. Press the button below the + or symbols until
the value reads 2.
Figure 4-16 is a block representation of the two 4. Press the arrow selection button to move
Genset Setup menus that are available after the to the next numeric character.
correct password has been entered or the View but-
ton is pressed in the Genset Setup Password menu. 5. Press the button below the + or symbols until
The Genset Setup menus provide access to the fol- the value reads 0.
lowing categories. 6. Press the arrow selection button to move
to the next numeric character.
The first Genset Setup Menu provides access to the
following menus: 7. Press the button below the + or symbols until
the value reads 9.
Genset
8. After you have completed entering the pass-
Voltage Protection word, press the arrow selection button . The
Current Protection first main Setup menu is displayed.

The second Genset Setup Menu provides access to After the correct password is entered, it will be re-
the following menu: membered until five minutes of button inactivity has
elapsed. If five minutes of button inactivity has
Engine Protection elapsed, you will have to re-enter the password to
access and change Genset Setup menus.
Genset Setup Password Menu
Adjusting Values/Parameters
Adjusting the Genset Setup menus is restricted to
service personnel and a password must be entered Once the correct password has been entered on the
to modify these menus. Genset Setup Password menu, the first Genset Set-
up submenu is displayed.
Once the Genset Setup button (2) is selected on the
Setup Menus menu (see Figure 4-15), the Genset 1. Press the buttons above the and symbols
Setup Password menu is displayed. in the digital display to navigate between sub-
menus.
When the Genset Setup Password menu is dis-
played, the first numeric character (0) is highlighted 2. Press the ADJUST selection button to select
(see Figure 4-16). the first parameter or value to be changed.

NOTE: When selected (highlighted), each charac- 3. Press the + or selection buttons to adjust val-
ter initially turns to 0 and the remaining ues or select parameters.
characters turn to X.
4. Press the arrow selection button to navi-
NOTE: Make sure that each numeric character is gate to the next or previous adjustable value or
correct before you move to the next charac- parameter.
ter. If a wrong character is entered, you will
not be able to go back and correct it. If the 5. After adjusting values/selecting parameters,
wrong password is entered, you will be able press the SAVE button to save your settings.
to view the Genset Setup menus but you
wont be able to change them. NOTE: If the button is pressed before
pressing the SAVE button, the changes
To enter the Genset Setup password 1209: are not saved.

1. With the first character highlighted, press the 6. Press the button to return to the genset Set-
button below to the + or symbols until the val- up Menus menu.
ue reads 1.
2. Press the arrow selection button to move 7. To return to the Service Menu from the genset
to the next numeric character. Setup Menus menu, press the button.

4-24
 GENSET SETUP MENUS

1ST
GENSET
SETUP
MENU

2ND
GENSET
SETUP
MENU

SEE PAGE 4-33

SEE PAGE 4-27 SEE PAGE 4-35 SEE PAGE 4-37

FIGURE 4-16. GENSET SETUP MENUS

4-25
 GENSET SUBMENUS Standby kVA Rating Menu

The Genset submenus are available by pressing The kVA Rating menu displays the kVA rating of
the (1) button on the first Genset Setup menu (see single-phase or three-phase, 50 or 60 hertz standby
Figure 4-16). genset systems. These value are used by the con-
trol to determine what is 100% load. The values
Note: Appendix A provides a block diagram that illus- must match the kVA rating of the genset application
trates the sequence of how the Genset Setup Subme- and cannot be more than 2000 kVA.
nus are displayed.
3Ph/50Hz: The three phase, 50 Hertz rating
can be set from 0 to 2000 kVA.
Figure 4-17 through Figure 4-19 is a block represen-
tation of the Genset Submenus. 3Ph/60Hz: The three phase, 60 Hertz rating
can be set from 0 to 2000 kVA.
Genset Menu 1Ph/50Hz: The single phase, 50 Hertz rating
can be set from 0 to 2000 kVA.
The Genset menu is used to set the CT Ratio, en-
able the Magnetic Pickup Unit (MPU), set the num- 1Ph/60Hz: The single phase, 60 Hertz rating
ber of teeth pulses per revolution on the Flywheel, can be set from 0 to 2000 kVA.
and set the Speed/Frequency Ratio.
Prime kVA Rating Menu
CT Ratio: The CT Ratio value must be set to
match the CT Ratio of the current transformers The kVA Rating menu displays the kVA rating of
on the genset. single-phase or three-phase, 50 or 60 hertz prime
genset systems. These value are used by the con-
MPU Enable: Displays whether or not the Mag- trol to determine what is 100% load. The values
netic Pickup Unit is installed (Yes or No). must match the kVA rating of the genset application
Fly. Teeth: The total number of teeth pulses per and cannot be more than 2000 kVA.
revolution on the flywheel (used for electronic 3Ph/50Hz: The three phase, 50 Hertz rating
governed systems) can be set from 0 to 256. can be set from 0 to 2000 kVA.
RPM/Hz Ratio: Allows for setting the Speed/ 3Ph/60Hz: The three phase, 60 Hertz rating
Frequency Ratio to 20, 30, or 60 RPM/Hz. can be set from 0 to 2000 kVA.

Application Rating Select Menu 1Ph/50Hz: The single phase, 50 Hertz rating
can be set from 0 to 2000 kVA.
The genset application rating can be set to either 1Ph/60Hz: The single phase, 60 Hertz rating
Standby or Prime. can be set from 0 to 2000 kVA.

4-26
 GENSET SUBMENUS

CONTINUED ON
PAGE 4-29

FIGURE 4-17. GENSET SETUP SUBMENUS (SHEET 1 OF 3)

4-27
Battery Select Menu teries and from 28.0 to 34.0 VDC for 24 volt bat-
teries, in 0.1 VDC increments.
The Battery Select menu is used to set the nominal
battery voltage. Weak Batt: The weak battery voltage threshold
can be set from 6.0 to 10.0 VDC for 12 volt bat-
Nominal Battery Voltage: Allows for setting the teries and from 12.0 to 16.0 VDC for 24 volt bat-
nominal battery voltage (12 or 24V). teries, in 0.1 VDC increments.
Battery Thresholds Menus
Battery Delay Setup Menu
The Battery Thresholds menu is used to set the low
and high voltage values to determine when the bat- This menu is used to determine when, after deter-
tery voltage is out of the set range during normal op- mining that the battery condition is out of the preset
eration. This menu is also used to determine when operating range, a warning message is announced.
the battery voltage is below weak battery thresholds
during cranking. The Battery Thresholds menu that L. Batt TD: A time delay from 2 to 60 seconds
is displayed is dependent upon the battery voltage can be set before the Low Battery warning mes-
entered in the Battery Select menu. sage (fault code 213) is announced.

Low Batt: The low battery voltage threshold can H. Batt TD: A time delay from 2 to 60 seconds
be set from 11.0 to 13.0 VDC for 12 volt batter- can be set before the High Battery warning
ies and from 22.0 to 27.0 VDC for 24 volt batter- message (fault code 214) is announced.
ies, in 0.1 VDC increments. Wk Batt TD: A time delay from 1 to 5 seconds
High Batt: The high battery voltage threshold can be set before the Weak Battery warning
can be set from 14.0 to 17.0 VDC for 12 volt bat- message (fault code 221) is announced.

4-28
 GENSET SUBMENUS (CONTINUED)

RETURN TO PAGE 4-27

A B

12V 24V

OR

OR

C
CONTINUED ON
PAGE 4-31

FIGURE 4-18. GENSET SETUP SUBMENUS (SHEET 2 OF 3)

4-29
Oil Pressure Setup Menus Sender Type: This menu is displayed only if the
sensor type is set to Sender. The sender type
A menu is available to set the sensor type. If the sen- can be set to either 2 Wire or 3 Wire.
sor type is Switch, then another menu is available to OOR Startup Delay: This menu is displayed
set the sensor polarity. If the sensor type is Sender, only if the sensor type is set to Sender. This
then another menu is available to set the sender menu allows for setting a time delay (0 to 400
type. seconds, default = 0 seconds) that prevents the
Sensor Type: The sensor type can be set for ei- oil pressure out-of-range fault warning (fault
ther Switch or Sender. code 217) from being displayed for the speci-
fied time period when the genset is starting.
Sensor Polarity: This menu is displayed only if Setting this time delay is useful with gensets
the sensor type is set to Switch. Sensor polarity that build up more than 100 psi oil pressure dur-
can be set to either Active Low or Active High. ing start-up and warm-up.

4-30
 GENSET SUBMENUS (CONTINUED)

RETURN TO PAGE 4-29

C
D

SWITCH SENDER

OR

FIGURE 4-19. GENSET SETUP SUBMENUS (SHEET 3 OF 3)

4-31
 VOLTAGE PROTECTION SUBMENUS down and the Low AC Voltage shutdown mes-
sage (fault code 13) is announced.
The Voltage Protection submenus are available by
pressing the (2) button on the first Genset Setup Overfrequency Menu
menu (see Figure 4-16).
This menu is used to determine when an overfre-
Figure 4-20 is a block representation of the four Volt- quency fault condition exists and for how long the
age Protection submenus that are available. fault condition should be present before the engine
is shut down.
High AC Voltage Menu Overfrequency Threshold: This threshold is
used to set the amount of Hertz that the alterna-
This menu is used to determine when a high AC tor line frequency can be over to activate an
voltage fault condition exists and for how long the Overfrequency fault condition. This value can
fault condition should be present before the engine be set from 2 to 10 Hz.
is shut down.
Overfrequency Delay: A time delay of 100 to
High AC Voltage Threshold: This threshold is 2000 half cycles must expire before the engine
used to set the percentage of desired voltage shuts down because of an overfrequency fault
necessary to activate a High AC Voltage fault condition. If the fault condition is active for the
condition. This value can be set from 105 to duration of this time delay, the engine shuts
125%. down and the Overfrequency shutdown mes-
High AC Voltage Time Delay: A time delay of 1 sage (fault code 14) is announced.
to 10 seconds must expire before the engine
shuts down because of a high AC voltage fault Underfrequency Menu
condition. If the fault condition is active for the
This menu is used to determine when an underfre-
duration of this time delay, the engine shuts quency fault condition exists and for how long the
down and the High AC Voltage shutdown mes- fault condition should be present before the engine
sage (fault code 12) is announced. is shut down.
Low AC Voltage Menu Underfrequency Threshold: This threshold is
used to set the Hertz number that the alternator
This menu is used to determine when a low AC volt- line frequency can be under to activate an Un-
age fault condition exists and for how long the fault derfrequency fault condition. This value can be
condition should be present before the engine is set from 2 to 10 Hz.
shut down. Underfrequency Time Delay: A time delay of
Low AC Voltage Threshold: This threshold is 500 and 2000 half cycles must expire before
used to set the percentage of desired voltage the engine shuts down because of an underfre-
necessary to activate a Low AC Voltage fault quency fault condition. If the fault condition is
condition. This value can be set from 50 to 95%. active for the duration of this time delay, the en-
gine shuts down and the Underfrequency shut-
Low AC Voltage Time Delay:A time delay of 2 down message (fault code 15) is announced.
to 20 seconds must expire before the engine
shuts down because of a low AC voltage fault
condition. If the fault condition is active for the
duration of this time delay, the engine shuts

4-32
 VOLTAGE PROTECTION SUBMENUS

FIGURE 4-20. VOLTAGE PROTECTION SUBMENUS

4-33
 CURRENT PROTECTION SUBMENUS active for the duration of this time delay, the
High AC Current warning message (fault code
The Current Protection submenus are available by 216) is announced.
pressing the (3) button on the first Genset Setup
menu (see Figure 4-16). High AC Current Shutdown Menu
Figure 4-21 is a block representation of the two Cur-
This menu is used to determine when a high AC cur-
rent Protection submenus.
rent shutdown fault condition exists and for how
High AC Current Warning Menu long the fault condition should be present before the
engine is shut down.
This menu is used to determine when a high AC cur- H. Curr Shutdown Threshold: This threshold is
rent warning fault condition exists and for how long used to set the percentage of rated AC current
the fault condition should be present before the High at which the High AC Current shutdown fault
AC Current warning message is announced. condition becomes active. This value can be
H. Curr Warning Threshold: This threshold is set from 130 to 190%.
used to set the percentage of rated AC current H. Curr Shutdown Time Delay: A time delay of
at which the High AC Current warning fault con- 2 to 60 seconds must expire before the engine
dition becomes active. This value can be set shuts down because of a high AC current fault
from 110 to 130%. condition. If the fault condition is active for the
H. Curr Warning Time Delay: A time delay of 10 duration of this time delay, the engine shuts
to 60 seconds must expire before a warning down and the High AC Current shutdown mes-
message is announced. If the fault condition is sage (fault code 46) is announced.

4-34
 CURRENT PROTECTION SUBMENUS

FIGURE 4-21. CURRENT PROTECTION SUBMENUS

4-35
 ENGINE PROTECTION SUBMENUS for how long the fault condition should be present
before the engine is shut down.
The Engine Protection submenus are available by
pressing the (4) button on the second Genset Setup Speed/Freq Fault Threshold: This threshold is
menu (see Figure 4-16). used to set the value necessary to activate the
speed/frequency conflict shutdown fault condi-
The Engine Protection submenus (see Figure 4-22 tion. This value can be set from 0.1 to 20.0 Hz.
and Figure 4-23) are used to set thresholds to deter-
Speed/Freq Fault Time Delay: A time delay of
mine when engine fault conditions exist and time
0.2 to 10.0 seconds must expire before the
delays to determine how long a fault condition is
warning message is announced because of a
present before the fault message is announced and,
speed/frequency conflict shutdown fault condi-
if necessary, shut down the engine.
tion. If the fault condition is active for the dura-
Engine Protection Overspeed Menu tion of this time delay, the genset is shut down
and the Speed Hz Match shutdown message
This menu is used to set the value necessary to shut (fault code 71) is announced.
down the genset and activate an Overspeed shut-
down message (fault code 31) on 50 and 60 Hz gen- Low Oil Pressure Warning Menu
sets, indicating that the engine has exceeded nor-
mal operating speed. This menu is used to determine when a low oil pres-
Overspeed (50Hz) Threshold: This threshold is sure warning fault condition exists and for how long
used to set the overspeed value necessary to the fault condition must be present before the warn-
activate an Overspeed shutdown fault condi- ing message is announced.
tion on 50 Hz gensets. This value can be set
LOP Warning Threshold: This threshold is used
from 0 to 8192 RPM, in 25 RPM increments.
to set the oil pressure value necessary to acti-
Overspeed (60Hz) Threshold: This threshold is vate a Pre-Low Oil Pressure warning fault con-
used to set the overspeed value necessary to dition. This value can be set from 0 to 100 psi.
activate an Overspeed shutdown fault condi-
tion on 60 Hz gensets. This value can be set LOP Warning Time Delay: A time delay of 2 to
from 0 to 24,096 RPM, in 25 RPM increments. 15 seconds must expire before the warning
message is announced because of a low oil
Engine Protection Speed/Frequency Menu pressure warning fault condition. If the fault
condition is active for the duration of this time
This menu is used to determine when a speed/fre- delay, the Pre-Low Oil Pressure warning mes-
quency conflict shutdown fault condition exists and sage (fault code 215) is announced.

4-36
 ENGINE PROTECTION SUBMENUS

CONTINUED ON
PAGE 4-39

FIGURE 4-22. ENGINE PROTECTION SUBMENUS (SHEET 1 OF 3)

4-37
Low Oil Pressure Shutdown Menu HCT Warning Time Delay: A time delay of 2 to
10 seconds must expire before the warning
This menu is used to determine when a low oil pres- message is announced. If the fault condition is
sure shutdown fault condition exists and for how active for the duration of this time delay, the
long the fault condition should be present before the High Coolant Temperature warning message
engine is shut down. (fault code 202) is announced.
LOP Shutdown Threshold: This threshold is
used to set the oil pressure value necessary to
activate a Low Oil Pressure Shutdown fault High Coolant Temperature Shutdown
condition. This value can be set from 0 to 100 Menu
psi.
LOP Shutdown Time Delay: A time delay of 2 This menu is used to determine when a high coolant
to 15 seconds must expire before the engine temperature shutdown fault condition exists and for
shuts down because of a low oil pressure fault how long the fault condition should be present be-
condition. If the fault condition is active for the fore the engine is shut down.
duration of this time delay, the engine shuts
down and the Low Oil Pressure shutdown mes- HCT Shutdown Threshold: This threshold is
sage (fault code 2) is announced. used to set the temperature value necessary to
activate a High Coolant Temperature Shut-
High Coolant Temperature Warning Menu down fault condition. This value can be set from
200 to 230 degrees F.
This menu is used to determine when a high coolant
temperature warning fault condition exists and for HCT Shutdown Time Delay: A time delay of 2
how long the fault condition should be present be- to 10 seconds must expire before the engine
fore the warning message is announced. shuts down because of a high coolant tempera-
HCT Warning Threshold: This threshold is ture fault condition. If the fault condition is ac-
used to set the temperature value necessary to tive for the duration of this time delay, the en-
activate a High Coolant Temperature Warning gine shuts down and the High Coolant Temper-
fault condition. This value can be set from 180 ature shutdown message (fault code 1) is an-
to 220 degrees F. nounced.

4-38
 ENGINE PROTECTION SUBMENUS (CONTINUED)

RETURN TO PAGE 4-37

A B

CONTINUED ON
PAGE 4-41

FIGURE 4-23. ENGINE PROTECTION SUBMENUS (SHEET 2 OF 3)

4-39
Engine Protection Low Coolant Charger Failed H Threshold: This threshold is
Temperature and Battery Charger Menus used to set the high charging alternator voltage
value. This value can be set from 13.0 to 20.0
The low coolant temperature menu is used to deter- VDC for 12V units and from 25.0 to 40.0 VDC
mine when the gensets coolant temperature is too for 24V units.
low and a Low Coolant Temperature warning mes-
sage (fault code 203) is announced. This warning Charger Failed L Threshold: This threshold is
message is not announced unless the coolant tem- used to set the low charging alternator voltage
perature has been determined to be low for one min- value. This value can be set from 2.0 to 13.0
ute. VDC for 12V units and from 2.0 to 25.0 VDC for
LCT Warning Threshold: This threshold is used 24V units.
to set the temperature value necessary to acti- Charger Failed Time Delay: A time delay of 2
vate a Low Coolant Temperature Warning fault to 300 seconds must expire before the warning
condition. This value can be set from 32 to 100 message is announced. If the fault condition is
degrees F. active for the duration of this time delay, the
The battery charger menu is used to determine Charger Failure warning message (fault code
when the alternator charger failure condition exists 219) is announced.
and when the warning message should be an-
nounced. The fault condition exists when either the
low or high threshold is reached.

4-40
 ENGINE PROTECTION SUBMENUS (CONTINUED)

RETURN TO PAGE 4-39

C
D

FIGURE 4-24. ENGINE PROTECTION SUBMENUS (SHEET 3 OF 3)

4-41
 TB1 BASE BOARD CUSTOMER Enter a brief description of the event (up to 32
CONNECTIONS characters).

The Base board (Figure 4-25) provides connection Note: The InPower service tool or access to the Gen-
set Service Menus is required to modify the customer
points (TB1) for remote control and monitor options.
fault inputs.
TB1 Customer Inputs
TB1 Customer Outputs
Note: Available options will vary between control
models (control with or without display). Note: Available options will vary between control
models (control with or without display).
Remote Start: When the control is in Auto/Remote
mode, grounding this input initiates the engine
Customer Outputs 1 and 2: One set of normally
cranking and start sequence. This circuit must be
open (NO) contacts, rated for 2 amps at 30 VDC for
opened to permit resetting a shutdown condition
each of the two output signals. The relays can be
with the Reset input. (The remote stop is actually the
used to control small devices and indicator lamps.
removal of the remote start signal to the control.)

Local/Remote Emergency Stop: Grounding this The nature of the customer output signal (contacts
input causes an immediate shutdown. Emergency closed) is an optional customer selection. Example
stop must be reset at the front panel. outputs: Genset running (event), common warning,
common shutdown, etc. (Refer to Table 5-3 for the
Customer Fault Inputs 1 and 2: Grounding any warning and shutdown code listing and Table 4-1 for
one of these inputs activates the corresponding the event code listing.)
warning or shutdown sequence.
Each relay can be independently programmed to
External sensing equipment must be connected to energize by entering the a code number (0 through
the designated digital input. 255, default = 0) for the desired event.
The nature of the fault is an optional customer selec-
Note: The InPower service tool or access to the Gen-
tion. Example inputs: Low Coolant Level, Low Fuel set Service Menus is required to modify the customer
Pressure, Ground Fault, etc. outputs.

Each of the two fault functions can be programmed

as follows: Ready To Load: Operates when the generator set
has reached 90% of rated speed and voltage and
Status, Warning or Shutdown. Default = Warn- latches until generator set is switched to off mode
ing. (B+ signal output).

FIGURE 4-25. CONTROL BOX

4-42
 ENGINE SENSORS The oil pressure sender functions by converting the
sensed oil pressure to voltage which varies the sup-
Figure 4-26 shows the locations of the coolant tem- plied 5 VDC to the sender. The output signal of the
perature and oil pressure sender to which the con- sender is approximately 0.5 VDC at 0 psi and 4.5
trol responds. VDC at 100 psi.
The coolant temperature sender functions by vary-
ing the resistance with the coolant and oil tempera-
ture. With 5 VDC supplied to the sensor, the output The low coolant level switch functions by closing the
signal (which varies with temperature) is supplied to circuit to the engine chassis ground (battery nega-
the Base board. The coolant sender enables the tive []). The low coolant level switch is not shown in
Base board to detect low, pre-high and high coolant Figure 4-26; this switch is located near the top of the
temperatures. radiator.

COOLANT
TEMPERATURE
SENDER E2

OIL
PRESSURE
SENDER E1

FIGURE 4-26. ENGINE SENSOR LOCATIONS

4-43
 MAGNETIC SPEED PICKUP UNIT (MPU) CURRENT TRANSFORMER (CT)
INSTALLATION INSTALLATION
To install the MPU sensor, bar the engine until a
gear tooth on the flywheel lines up in the center of The optional current transformers (CTs) are used to
the mounting hole. Thread the sensor in gently by display genset load in kVA and alternator amper-
hand until it just touches the gear tooth. Back it out age. The CTs must be installed as noted in the fol-
one quarter turn and set the locknut. lowing CT Installation Requirements.
To troubleshoot the MPU, refer to fault code 45.
CAUTION Do not use fan blade to bar over en- Refer to the Reconnection Diagram to identify the
gine. That can damage blades and cause prop- generator output leads/phase that must be routed
erty damage and personal injury. through each CT, and also appropriate transformer
post selection for control sensing leads. The trans-
formers are labeled CT1, CT2 and CT3 on the re-
connection wiring diagram. (The Reconnection Dia-
gram is located on the control box cover.)
MPU
SENSOR
CT Installation Requirements:

A. The CT has a dot on one side. This dot must be

facing toward the generator reconnection ter-
minal block. A dot is also used to indicate pin 1
of the CT.
B. Route the load lead (U, V or W) through the ap-
propriate CT (refer to Reconnection Diagram).
C. The CTs have dual secondaries (3 pins
marked X1, X2 & X3). (Refer to Reconnection
Diagram.)
ENGINE X1 & X2 for above 300 volts LL
FLYWHEEL
RING GEAR X1 & X3 for below 300 volts LL

FIGURE 4-27. MPU SENSOR

4-44
5. Troubleshooting
GENERAL Make sure that parameter adjustments and time de-
lays, related to the fault condition, have been appro-
The PowerCommand 1301 Control (PCC) contin- priately set for the application. It may be necessary
uously monitors engine sensors for abnormal condi- to write the initial capture file to the device or update
tions when genset is operating, such as low oil pres- the calibration file.
sure and high coolant temperature. If any of these
conditions occur, the control (with graphical display) Updating a calibration file requires the InPower Pro
will light a yellow Warning lamp or a red Shutdown version. Confirm that the installed calibration part
lamp and display a message on the graphical dis- number matches the serial plate information.
play. A control without the graphical display indi-
CAUTION Using the wrong calibration file can
cates a shutdown condition by intermittent flashing
result in equipment damage. Do not swap Base
of the status indicator.
boards from another genset model and only use
the calibration file shown on the nameplate.
INPOWER SERVICE TOOL
Some features are not available until the hardware
The InPower service tool with PCC3101 Interface for that feature is installed and InPower Pro is used
Kit can be used in troubleshooting to perform tests, to update (enable) that feature. Confirm that the fea-
verify control inputs and outputs, and test protective ture is installed and enabled prior to troubleshooting
functions. Refer to the InPower Users Guide, pro- the base board for symptoms related to a feature.
vided with the InPower software for test procedures.
NETWORK APPLICATIONS AND
InPower, when used improperly, can cause symp- CUSTOMER INPUTS
toms like warnings and shutdowns that appear to be
a defective base board. When these problems oc- In applications with networks and remote customer
cur, always verify that a self-test or fault simulation inputs, the genset may start unexpectedly or fail to
(override) have not been left enabled with InPower. crank as a result of these inputs. These symptoms
If you do not have InPower, or the enabled fault sim- may appear to be caused by the base board. Verify
ulation(s) can not be found using InPower, discon- that the remote input is not causing the symptom or
nect battery power to disable the test or override isolate the control from these inputs before trouble-
condition. shooting the control.

5-1
 SAFETY CONSIDERATIONS WARNINGAccidental starting of the generator
set can cause severe personal injury or death.
WARNING Contacting high voltage compo- Prevent accidental starting by disconnecting
nents can cause electrocution, resulting in se- the negative () cable from the battery terminal.
vere personal injury or death. Keep the output
box covers in place during troubleshooting. When troubleshooting a generator set that is shut
down, make certain the generator set cannot be ac-
High voltages are present when the genset is run- cidentally restarted as follows:
ning. Do not open the generator output box while the
genset is running. 1. Press the button to switch to the Off mode.
WARNING Ignition of explosive battery gases 2. Turn off or remove AC power from the battery
can cause severe personal injury or death. Arc- charger.
ing at battery terminals, light switch or other
3. Remove the negative () battery cable from the
equipment, flame, pilot lights and sparks can ig-
generator set starting battery.
nite battery gas. Do not smoke, or switch trouble
light ON or OFF near battery. Discharge static
electricity from body before touching batteries READING FAULT CODES
by first touching a grounded metal surface.
When a fault occurs, the graphical display will dis-
Ventilate battery area before working on or near play the fault code/message.
batteryWear gogglesStop genset and dis-
connect charger before disconnecting battery
After the fault is acknowledged and corrected, the
cablesDisconnect negative () cable first and
recorded fault will be deleted from the control panel
reconnect last.
memory, but will remain in a data log to maintain a
CAUTION Disconnect battery charger from AC fault code history. The InPower service tool is re-
source before disconnecting battery cables. quired to view this data log.
Otherwise, disconnecting cables can result in
voltage spikes damaging to DC control circuits Refer to Fault History Menu, which describes how to
of the genset. view fault codes.

5-2
 TROUBLESHOOTING PROCEDURE Figure 5-1 shows the location of the components
within the control panel that are referenced in the
The following tables are a guide to help you evalu- following troubleshooting procedures.
ate problems with the generator set. You can save
time if you read through the manual ahead of time CAUTIONAlways make sure that the PCC is in
and understand the system. the OFF mode before disconnecting or connect-
ing harness connectors. Otherwise, discon-
Try to think through the problem. Go over what was necting the harness connectors can result in
done during the last service call. The problem could voltage spikes high enough to damage the DC
be as simple as a loose wire, an opened fuse or a control circuits of the set.
tripped circuit breaker.
CAUTION Electrostatic discharge will damage
Note: NOTE: Each fault code warning can be circuit boards. Always wear a wrist strap when
changed to shutdown using InPower. Default set-
handling circuit boards or when disconnecting
tings are used in this manual. It is recommended that
all changes to settings be recorded at each site to aid or connecting harness connectors. See Circuit
in the troubleshooting of the genset. Board Removal/Replacement in Section 5.

This section contains the following information: Voltage/Continuity Testing

Table 5-1 and 5-2: Describes how to trouble- Voltage and continuity tests are required in the fol-
shoot a local/remote fail to crank problem when lowing tables. In some cases, it is necessary to re-
control panel does not indicate fault condition. move a plug to complete the test.
Table 5-3: Describes how to troubleshoot en-
gine problems that are not within the detectable The following corrective actions will mention when it
range of the PCC control. is necessary to remove a plug for testing. In other
Fault Code Tables: Provide detailed trouble- cases, the plug must not be removed for testing.
shooting procedures. In the following tables, When plug removal is not mentioned, testing must
the fault codes are used as the table reference be performed by inserting a narrow meter probe into
number and are arranged in numeric order. the back of the plug.

5-3
 FIGURE 5-1. PCC 1301 COMPONENTS
Relay K6 control battery B+ to the fuel solenoid(s). K12 is part
of the engine harness assembly.
The Starter Control relay is used by the Base board
to energize the starter solenoid. K4 is part of the en- Run Relays K10, K11
gine harness assembly.
The optional Run relays are used to control auxiliary
Relay K5 equipment such as fans, pumps and motorized air
dampers. The relays are energized when the con-
The Fuel Control relay is used by the Base board to trol receives a run command.

5-4
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.
TABLE 5-1. ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE)

ENGINE DOES NOT CRANK IN MANUAL MODE (NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a manual start signal.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. No power supplied to control. a. Poor battery cable connections. Clean the battery cable termi-
nals and tighten all connections.
b. Remove connector P11 and check for B+ at P11-3 & 15 and
GND at P11-9 & 10. If B+ or ground missing, isolate to harness
and TB BAT terminal mounted on engine block.
If B+ and ground check OK, cycle power to Base board by re-
connecting P11 and retry operation.
2. No power supplied to front membrane Check for B+ at TB1-1 and GND at TB1-4. If B+ or ground miss-
panel. ing, the Base board is bad.
If B+ and ground check OK, remove P1 from back of front mem-
brane panel. Check for B+ at P1-3 and ground at P1-5. If B+ or
ground missing, repair harness.
3. Base board not properly calibrated or Confirm that the installed calibration part number matches the
corrupt calibration. serial plate information. Re-enter calibration file if necessary.
4. The Emergency Stop switch or wiring is With Emergency Stop push button not activated (switch closed),
defective. remove customer leads from TB1-15 and TB1-16 and check for
continuity between these two leads. If circuit is open, isolate to
Emergency Stop switch and wiring. If there is continuity, go to
next step.
5. Base board not properly calibrated or Confirm that the installed calibration part number matches the
corrupt calibration. serial plate information. Re-enter calibration file if necessary.
6. The menu display manual Run button, Check for continuity between P11-4 (RUN) to TB1-4 (GND). If
harness or the Base board is bad. no continuity when pressing the manual Run button, isolate to
front membrane panel and wiring.
If there is continuity, the Base board is bad.
7. Oil pressure sender, setup or wiring is a. Remove P11 connection and check wiring between P11-5,
defective. P11-6 and P11-17 (for three wire sender) to the sender.
b. Verify control is configured for the type of sender.
c. Verify operation of the sender.

5-5
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.
TABLE 5-2. ENGINE DOES NOT CRANK IN REMOTE MODE (NO FAULT MESSAGE)

ENGINE DOES NOT CRANK IN REMOTE MODE (NO FAULT MESSAGE)

Reason: This indicates that the PCC has not received or recognized a remote start signal.
Effect: Engine will not start in remote mode, but starts in manual mode.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The remote start switch or customer wir- Reset the control. Attempt to start, and check for ground at
ing is faulty. TB1-11. If ground level is not present, isolate to the remote
switch or customer wiring. Repair as necessary.
If ground is present, go to next step.
2. The menu display Auto button, harness Check for continuity between P11-16 (AUTO) to TB1-4 (GND). If
or the Base board is bad. no continuity when pressing the menu display Auto button, iso-
late to front membrane panel or wiring harness.
If there is continuity, the Base board is bad.

5-6
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

TABLE 5-3. WARNING AND SHUTDOWN CODES

WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

1 Indicates engine has overheated (coolant temperature has risen above the
HIGH COOLANT TEMP shutdown trip point).
Lamp: Shutdown Allow engine to cool down completely before proceeding with the following
checks:
a. Check coolant level and replenish if low. Look for possible coolant leakage
points and repair if necessary.
b. Check for obstructions to cooling airflow and correct as necessary.
c. Check fan belt and repair or tighten if necessary.
d. Check blower fan and circulation pumps on remote radiator installations.
e. Reset control and restart after locating and correcting problem.
2 Indicates engine oil pressure has dropped below the shutdown trip point. Check
LOW OIL PRESSURE oil level. If oil level is low, replenish. Reset control and restart.
Lamp: Shutdown
12 Indicates that one or more of the phase voltages has exceeded 130% of nomi-
HIGH AC VOLTAGE nal for 1.0 second, or has exceeded 110% of nominal for 10 seconds.
Lamp: Shutdown
13 Indicates that one or more of the phase voltages has dropped below 85% of
LOW AC VOLTAGE nominal for 10 seconds.
Lamp: Shutdown
14 Indicates frequency is 10% above base frequency for 10 seconds.
OVER FREQUENCY
Lamp: Shutdown
15 Indicates that engine speed has dropped below 90% of nominal for 10 seconds.
UNDER FREQUENCY Check fuel supply, intake air supply and load.
Lamp: Shutdown
27 Indicates a loss of all three voltage sense leads or failure in excitation circuit.
EXCITATION FAULT Check field wiring (X1 and X2) for shorts or opens. (Refer to Section 6.)
Lamp: Shutdown
31 Indicates engine has exceeded normal operating speed. The threshold is 1725
OVERSPEED RPM (50 Hz) or 2075 RPM (60 Hz).
Lamp: Shutdown Possible causes are single step large block load removal or flammable vapors
drawn into the intake air passage. Reset control and restart after locating and
correcting problem.
38 Indicates that the Field AVR Duty Cycle has been at the maximum for at least
FIELD OVERLOAD 15 seconds.
Lamp: Shutdown
45 Indicates that no magnetic pickup pulses are sensed for a Loss of Speed delay.
SPEED SIGNAL LOST (If a magnetic pickup is not installed, then speed sensing is performed by moni-
Lamp: Shutdown toring AC line frequency and this fault cannot occur.)

5-7
 WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

46 Indicates that an individual phase of alternator output current has exceeded
HIGH AC CURRENT 150% of the rated output current continuously for more than 10 seconds.
Lamp: Shutdown Check load and load lead connections.
61 Indicates remote Emergency Stop. To reset the remote Emergency Stop button:
EMERGENCY STOP 1. Open (disable) remote emergency stop button.
Lamp: Shutdown
2. Move the rocker switch to the OFF position or press the OFF button.
3. Select the desired operating mode (manual or remote).
71 Indicates that measured speed and measured AC output frequency do not
SPEED HZ MATCH agree. Check genset setup for number of flywheel teeth.
Lamp: Shutdown
72 The genset has failed to sense rotation for two start attempts. Indicates pos-
FAIL TO CRANK sible fault with control, speed sensing or starting system.
Lamp: Shutdown
73 Indicates possible fuel system or air induction problem. (Engine cranks but fails
FAIL TO START to start)
Lamp: Shutdown a. Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as re-
quired.
b. Check for dirty fuel filter and replace if necessary.
c. Check for dirty or plugged air filter and replace if necessary.
d. Reset the control and restart after correcting the problem.
75, 76 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1 & #2 Fuel Day Tank, Water In Fuel, Ground Fault, etc.
Lamp: Shutdown Each of the fault functions can be programmed (using service tool), as follows:
Warning or Shutdown (Default: Warning) (See fault code 204/205 for Warn-
ing)
Change display name using up to 32 characters.
81, 82, 83 The nature of the annunciator fault is an optional customer selection.
ANNUNCIATOR FAULT
1, 2, 3
Lamp: Shutdown
84 91 The nature of the Base I/O Module fault is an optional customer selection. Ex-
BASE I/O MODULE INPUT ample inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
18 Each of the fault functions can be programmed (using InPower service tool or
Lamp: Shutdown access to Setup menu), as follows:
Warning, Shutdown or Event (Default = Warning) (See fault code 226233 for
Warning and code 163170 for Event)
Change display name using up to 32 characters.
92 95 The nature of the Aux I/O Module fault is an optional customer selection. Exam-
AUX i/O MODULE INPUT ple inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
9 12 Each of the fault functions can be programmed (using InPower service tool or
Lamp: Shutdown access to Setup menu), as follows:
Warning, Shutdown or Event (Default = Warning) (See fault code 234237 for
Warning and code 171174 for Event)
Change display name using up to 32 characters.

5-8
 WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

96 Indicates that the engine oil temperature is above normal and has reached the
OIL TEMP HIGH shutdown trip point. (I/O Module option.)
Lamp: Shutdown
98 Indicates ambient temperature is above normal and has reached the shutdown
AMBIENT TEMP HIGH trip point. (I/O Module option.)
Lamp: Shutdown
99 Indicates that fuel level has reached the shutdown trip point. (I/O Module op-
FUEL LEVEL LOW tion.)
Lamp: Shutdown
102 Indicates the voltage bias circuit output is out of range (OOR), high or low. (I/O
VOLTAGE BIAS OOR Module option.)
Lamp: Shutdown
103 Indicates the speed bias circuit output is out of range (OOR), high or low. (I/O
SPEED BIAS OOR Module option.)
Lamp: Shutdown
106 Indicates the data link between the I/O module and the Base board is lost.
I/O MODULE LOST
Lamp: Shutdown
163 170 The nature of the Base I/O Module event is an optional customer selection.
BASE I/O MODULE INPUT Each event function can be programmed (using InPower service tool or access
18 to Setup menu), as follows:
Lamp: None
Change display name using up to 32 characters.
Select active low or high input.
171 174 The nature of the Aux I/O Module event is an optional customer selection.
AUX I/O MODULE INPUT Each event function can be programmed (using InPower service tool or access
9 12 to Setup menu), as follows:
Lamp: None
Change display name using up to 32 characters.
Select active low or high input.
202 Indicates engine is operating near cooling system capacity (monitor condition).
PRE-HIGH COOL TMP Increase in load or higher ambient temperature may cause High Coolant Temp
Lamp: Warning (1) shutdown. Review code 1 correction list for other possible causes.
203 Indicates engine coolant heater is not operating or is not circulating coolant.
LOW COOLANT TEMP Check for the following conditions:
Lamp: Warning a. Coolant heater not connected to power supply. Check for blown fuse or dis-
Set is not operating. Warning connected heater cord and correct as required.
occurs when engine coolant b. Check for low coolant level and replenish if required. Look for possible coolant
temperature is 70 F (21 C) leakage points and repair as required.
or lower. NOTE: In applica-
tions where the ambient c. Open heater element. Check current draw of heater.
temperature falls below 40 Coolant temperature must be below 70 F (default setting) for one minute to
F (4 C), Low Coolant Temp activate warning and be above 70 F for five minutes before the warning can be
may be indicated even cleared.
though the coolant heaters
are operating.

5-9
 WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

204, 205 The nature of the fault is an optional customer selection. Example inputs: Low
CUSTOMER INPUT #1, #2 Fuel Day Tank, Water In Fuel, Ground Fault, etc.
Lamp: Warning Each of the fault functions can be programmed (using service tool), as follows:
Warning or Shutdown (Default: Warning) (See fault code 75/76 for Shutdown)
Change display name using up to 32 characters.
212 Indicates that the control has sensed that the engine coolant temperature sen-
COOL SENSOR OUT OF sor output is out of range (high or low). Check sender/connectors/wires.
RANGE
Lamp: Warning
213 Indicates battery voltage supply to the control is approaching a low level at
LOW BATTERY which unpredictable operation will occur.
Lamp: Warning a. Discharged or defective battery.
Check the battery charger fuse.
Recharge or replace the battery.
b. Poor battery cable connections. Clean the battery cable terminals and tighten
all connections.
c. Check battery wiring/calibration.
d. Check engine DC alternator. Replace engine DC alternator if normal battery
charging voltage is not obtained.
e. Check battery charge voltage float level if applicable (raise float level).
214 Indicates battery voltage supply to the control is approaching a high level at
HIGH BATTERY which damage to the control can occur. Check float level on battery charger if
Lamp: Warning applicable (lower float level). Check battery wiring/calibration.
215 Indicates engine oil pressure has dropped below the warning trip point. If gen-
PRE-LOW OIL PRESSURE erator is powering critical loads and cannot be shut down, wait until next shut-
Lamp: Warning down period and then follow code 2 procedure.
216 Indicates that one or more of the phase currents has exceeded 110% of nomi-
HIGH AC CURRENT nal for 60 seconds.
Lamp: Warning Check load and load lead connections.
217 Indicates that the control has sensed that the engine oil pressure sensor output
OIL PRESS SENSOR OUT is out of range (high or low). Check sender/connectors/wires.
OF RANGE
Lamp: Warning
219 Indicates the battery charging alternator has not reached an acceptable voltage
CHARGER FAILURE range within the selected period (default = 120 seconds). Refer to engine ser-
Lamp: Warning vice manual.
221 Indicates that during cranking, the battery voltage is at or below the weak bat-
WEAK BATTERY tery warning trip point for a time greater than or equal to the weak battery set
Lamp: Warning time. See code 213 for corrective action.
222, 223, 224 The nature of the annunciator fault is an optional customer selection.
ANNUNCIATOR FAULT
1, 2, 3
Lamp: Warning
225 Indicates a mismatch in the configuration of one of the annunciator relay out-
ANNUNCIATOR OUTPUT puts.
CONFIGURATION ERROR
Lamp: Warning

5-10
 WARNING AND SHUTDOWN CODES

FAULT CODE CORRECTIVE ACTION

226 233 The nature of the Base I/O Module fault is an optional customer selection. Ex-
BASE I/O MODULE INPUT ample inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
18 Each of the fault functions can be programmed (using InPower service tool or
Lamp: Warning access to Setup menu), as follows:
Warning, Shutdown or Event (Default = Warning) (See fault code 8491 for
Shutdown and code 163170 for Event)
Change display name using up to 32 characters.
234 237 The nature of the Aux I/O Module fault is an optional customer selection. Exam-
AUX I/O MODULE INPUT ple inputs: Low Fuel Day Tank, Water In Fuel, Ground Fault, etc.
9 12 Each of the fault functions can be programmed (using InPower service tool or
Lamp: Warning access to Setup menu), as follows:
Warning, Shutdown or Event (Default = Warning) (See fault code 9295 for
Shutdown and code 171174 for Event)
Change display name using up to 32 characters.
238 Indicates engine has begun to overheat (oil temperature has risen to an unac-
OIL TEMP HIGH ceptable level). Increase in load or higher ambient temperature may cause High
Lamp: Warning Oil Temp (code 96) shutdown. (I/O Module option.)
239 Indicates the oil temperature sensor output is out of range (OOR), high or low.
OIL TEMP OOR (I/O Module option.)
Lamp: Warning
242 Indicates the ambient temperature has exceeded the warning threshold for gen-
AMBIENT TEMP HIGH set room temperature. Increase in load may cause Ambient Temp High (code
Lamp: Warning 98) shutdown. (I/O Module option.)
243 Indicates the ambient temperature sensor output is out of range (OOR), high or
AMBIENT TEMP OOR low. (I/O Module option.)
Lamp: Warning
244 Indicates that the fuel level has dropped below the low fuel level trip point. Al-
FUEL LEVEL LOW lows time to refill before Fuel Level Low (code 99) shutdown occurs. (I/O Mod-
Lamp: Warning ule option.)
245 Indicates the fuel level sensor output is out of range (OOR), high or low. (I/O
FUEL LEVEL OOR Module option.)
Lamp: Warning
252 Indicates an intermittent data link between the I/O module and the Base board.
I/O MODULE LOST
Lamp: Warning

5-11
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 1/202 HIGH OR PRE-HIGH COOLANT TEMPERATURE (SHUTDOWN/WARNING)

Reason: Engine coolant temperature has exceeded the warning threshold for pre-high/high coolant tempera-
ture.
Effect: Calibration-dependent. No action is taken by the PCC for code 202. Engine will shut down for code 1.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with In- 1. With InPower, verify that the fault simulation is not enabled for
Power. the coolant sensor.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
2. Engine or sensor circuitry problem. 2. Check the sensor accuracy with a thermocouple or similar tem-
perature probe.
If the PCC coolant temperature reading is accurate, the en-
gine may be overheating. Refer to the engine service
manual.
If the PCC coolant temperature reading is not accurate, go
to next step.
3. The sensor could be bad. 3. Disconnect the sensor and connect a coolant temperature sen-
sor simulator to the harness.
If the control responds to the simulator, replace the sensor. If
control does not respond, go to next step.
4. The harness or Base board could be 4. Measure the resistance of the coolant sensor and reconnect
bad. harness to sensor. Remove connector P11 from Base board
and check resistance between pins P11-18 (H20) and P11-6
(COM).
If resistance is not the same, harness is bad.
If resistance is the same, Base board is bad.

5-12
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 2/215 LOW OIL OR PRE-LOW OIL PRESSURE (SENDER)

(WARNING/SHUTDOWN)
Reason: Engine oil pressure has dropped below the warning/shutdown threshold for low/high oil pressure.
Effect: Calibration-dependent. No action is taken by the PCC for code 215. Engine will shut down for code 2.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with In- 1. With InPower, verify that the fault simulation is not enabled for
Power. the oil pressure sensor.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
2. Low oil level. Clogged lines or filters. 2. Check oil level, lines and filters. If oil system is OK but oil level is
low, replenish.
3. Sensor or oil pump could be bad. Or the 3. Disconnect the oil pressure sensor leads, and connect an oil
generator set may be shutting down on pressure sensor simulator to the harness.
another fault. a. If the control responds to the simulator, reconnect the sensor,
disconnect the + signal wire at the fuel solenoid, and crank the
engine. Check the oil pressure reading on the digital display.
If the display shows an acceptable oil pressure, the prob-
lem may not be in the oil or oil sensing system. The genset
may be shutting down on another fault (out of fuel, intermit-
tent connector). Restart the genset and monitor the PCC
display panel for other faults.
If the display does not show an acceptable oil pressure, re-
place the sensor. If the PCC still doesnt display an oil pres-
sure while cranking, the oil pump may be bad. Refer to the
engine service manual.
b. If the control does not respond to the simulator, go to next step.
4. Harness or Base board could be bad. 4. If the control does not respond to the simulator, the Base board
or the harness is bad.
Check for +5 VDC at the sensor (lead marked S1). If there is no 5
VDC at the sensor:
Check for 5 VDC at P11-5.
If yes, harness is bad. If no, Base board is bad.
If there is 5 VDC at the sensor, use the sensor simulator to gen-
erate a signal to P11-17 (SIGNAL) and P11-6 (COMM). If the
pressure signal (.5 to 4.5 VDC) does not get to P11, isolate to the
harness. If the pressure signal does go to P11, the Base board is
bad.

5-13
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 12 HIGH AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has exceeded 130% of nominal for 1.0 second, or has exceeded
110% of nominal for 10 seconds.
Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with In- 1. With InPower, verify that the related fault simulation is not en-
Power. abled.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
2. Single step large block load removal. 2. Clear fault and restart genset.
3. Fault threshold is not set correctly with 3. Reset the threshold to the highest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
4. Base board or generator is bad. 4. Refer to the generator base board isolation procedure to deter-
mine if the generator or the Base board is causing the high AC
voltage shutdown fault.

CODE 13 LOW AC VOLTAGE (SHUTDOWN)

Reason: One or more of the phase voltages has dropped below 85% of nominal for 10 seconds.
Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with In- 1. With InPower, verify that the related fault simulation is not en-
Power. abled.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
2. Fault threshold is not set correctly with 2. Reset the threshold to the lowest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
3. Overload. 3. Check the load and correct any overload. Check operation by
disconnecting load and restarting generator set.
4. Improper connections have been made 4. Reconnect according to the appropriate reconnection diagram.
at the generator output terminals. See Section 8.
5. Voltage sense wiring connection could 5. Check that Sense leads P131 through P13-4 If misconnected
be incorrect. to a high voltage, the AVR fault will shut down excitation and
cause Low AC Voltage condition.
6. The rotating rectifier assembly (diodes 6. Check each diode.
CR1 through CR6) is faulty.
7. Loose connector or Base board is bad. 7. Repair connections (P13) or replace the Base board if neces-
sary.

5-14
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 14 OVER FREQUENCY (SHUTDOWN)

Reason: Generator AC output frequency is high.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault threshold is not set correctly with 1. Reset the threshold to the highest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
2. Fuel or air delivery problem. 2. Refer to the engine service manual.
3. Governor fault. 3. Check governor frequency adjustment.
4. Loose connector or Base board is bad. 4. Repair connections (P13) or replace the Base board if neces-
sary.

CODE 15 UNDER FREQUENCY (SHUTDOWN)

Reason: Generator AC output frequency is low.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with In- 1. With InPower, verify that the related fault simulation is not en-
Power. abled.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
2. Fault threshold is not set correctly with 2. Reset the threshold to the lowest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
3. Overload. 3. Check the load and correct any overload. Check operation by
disconnecting load and restarting generator set.
4. Fuel or air delivery problem. 4. Refer to the engine service manual.
5. Governor fault. 5. Check fuel shutoff solenoid adjustment.
6. Loose connector or Base board is bad. 6. Repair connections (P13) or replace the Base board if neces-
sary.

5-15
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 31 OVERSPEED (SHUTDOWN)

Reason: Engine speed signal indicates an engine speed greater than shutdown threshold.
Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Cold engine (no coolant heaters) 1. Overspeed can occur when starting a very cold engine. Clear
fault and restart genset.
2. Single step large block load removal. 2. Clear fault and restart genset.
3. Fault simulation was enabled with In- 3. With InPower, verify that the fault simulation is not enabled for
Power. the coolant sensor.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
4. Fault threshold is not set correctly with 4. Reset the threshold to the highest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
5. Monitor the engine rpm using InPower. 5. If the RPM is not correct, refer to fault code 45 for corrective ac-
tion.
6. Governor fault. 6a. Check fuel shutoff solenoid adjustment.
6b. Check governor frequency adjustment.
6c. Replace defective injection pump unit.

CODE 45 SPEED SIGNAL LOST (SHUTDOWN)

Reason: This indicates that the PCC is not sensing the magnetic pickup signal.
Effect: Engine will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Loose or damaged magnetic pickup 1. Inspect the wires/connector pins, and repair or replace as nec-
(MPU) wires/connector pins. essary.
2. The magnetic pickup, harness or Base 2. To isolate the problem, reset the control and attempt to start the
board could be bad. set.
If 72 (Fail To Crank) is displayed, or if the engine starts, but then
shuts down on 45 (Speed Signal Lost), the MPU sender could
be bad. Remove the MPU connectors and check for 3.5 to 15
VAC at the MPU while cranking.
If no output, check for damage or debris. Also check for im-
proper adjustment of the MPU. If there is still no output, re-
place the MPU sender.
If the MPU output is OK, check for MPU voltage at P1112
(MAG PICK+) to P11-24 (MAG PICK) while cranking. If
OK, replace the Base board. If not OK, use continuity
checks to isolate connectors/harness.

5-16
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 46 HIGH AC CURRENT (SHUTDOWN)

Reason: Indicates that an individual phase of alternator output current has exceeded 150% of the rated output
current continuously for more than 10 seconds.
Effect: Generator set will shut down.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault threshold is not set correctly with 1. Reset the threshold to the highest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
2. Short or overload. 2. Check the load and load cables. Repair if necessary. Check op-
eration by disconnecting load and restarting generator set.
3. Incorrect CTs or CT connections. 3. Check CTs and CT connections. Correct if necessary. Refer to
Current Transformer Installation.
4. The problem may be the Base board or 4. Remove connector P12 from the Base board. Check continuity
harness connections. from P12 to CTs.
P12-1 (CT1) to P12-4 (CT1-COM)
P12-2 (CT2) to P12-5 (CT2-COM)
P12-3 (CT3) to P12-6 (CT3-COM)

5-17
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 72 FAIL TO CRANK (SHUTDOWN) (LOCAL OR REMOTE)

Reason: This indicates that the engine failed to crank after the PCC received a start signal.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Starter is bad. 1. Reset the control. Attempt to start, and test for B+ at the starter.
If there is B+ at the starter, the starter could be bad. Test starter
(see engine service manual). Replace the starter.
If B+ is not present at the starter, go to next step.
2. Starter not energized due to: 2a. Isolate to defective K4 relay/wiring.
a. Starter Output Relay K7 is bad. 2b. Remove lead from K4-5. Attempt to start and check for ground
b. Base board is bad. at K7-85 lead. If circuit remains open, Base board is bad.
3. The Emergency Stop switch or wiring is 3. With Emergency Stop push button not activated, remove cus-
defective. tomer leads from TB1-15 and TB1-16 and check for continuity
between these two leads. If circuit is open, isolate to Emergency
Stop switch and wiring.
If there is continuity, go to next step.
4. MPU/circuit or Base board is bad. 4. Refer to Code 45 instructions.

5-18
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 73 FAIL TO START (SHUTDOWN)

MECHANICAL GOVERNED ENGINE
Reason: This indicates that the engine failed to start after expiration of last crank time.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Restricted fuel supply due to:
a. Fuel level below pickup tube in 1a. Add fuel if low. Prime the fuel system.
tank. 1b. Open any closed shutoff valve in the fuel line supplying the en-
b. Closed shutoff valve in supply line. gine.
c. Engine fuel system not primed. 1c. Refer to engine service manual.
d. Fuel injectors clogged. 1d. Refer to engine service manual.
e. Air in fuel system. 1e. Bleed air from fuel system. Refer to engine service manual.
2. Fuel solenoid (K1) on the injection pump Isolate to K1 solenoid, K8 relay, or Base board.
not energized due to: 2a. Attempt to start and check for B+ at the fuel solenoid coil K1.
a. Fuel solenoid (K1) is bad. If B+ is present, fuel solenoid is bad.
b. K12 Fuel Shutoff Relay is bad.
If B+ is not present, go to step b.
c. Base board is bad.
2b. Isolate to defective K12 relay/wiring.
2c. Remove lead from K12-5. While cranking, check for ground at
K8-6 lead. If circuit remains open, Base board is bad.
3. The engine fuel system is worn or mal- 3. Service according to the engine service manual.
functioning or has lost prime (fuel lift
pump, injection pump, injectors, timing).
4. The engine is worn or malfunctioning 4. Service according to the engine service manual.
mechanically.

5-19
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

CODE 73 FAIL TO START (SHUTDOWN)

ELECTRONIC GOVERNED ENGINE
Reason: This indicates that the engine failed to start after expiration of last crank time.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Restricted fuel supply due to:
a. Fuel level below pickup tube in 1a. Add fuel if low. Prime the fuel system.
tank. 1b. Open any closed shutoff valve in the fuel line supplying the en-
b. Closed shutoff valve in supply line. gine.
c. Engine fuel system not primed. 1c. Refer to engine service manual.
d. Fuel injectors clogged. 1d. Refer to engine service manual.
e. Air in fuel system. 1e. Bleed air from fuel system. Refer to engine service manual.
2. The governor linkage needs adjust- 2. Repair and adjust the linkage as necessary.
ment.

5-20
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

CODE 73 FAIL TO START (SHUTDOWN)

ELECTRONIC GOVERNED ENGINE
Reason: This indicates that the engine failed to start after expiration of last crank time.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

3. Injection pump actuator not energized Isolate to harness, governor actuator or Base board.
due to: the harness, Electronic Gover- 3a. Display Governor Duty Cycle menu. Attempt to start and
nor Power module, governor actuator or check for duty cycle (44% is about average). If percentage of
the Base board is bad. duty cycle is displayed. (Duty cycle displayed indicates proces-
a. Base board is bad. sor is functioning, but output circuitry of Base board could still be
b. Wiring harness is bad. defective, continue with this procedure.) If the duty cycle is not
displayed, the Base board is bad.
c. Governor actuator is bad.
3b. Check wiring continuity of actuator circuit. Repair as necessary.
d. K8 Fuel Shutoff Relay is bad.
If continuity is OK, go to step c.
e. Electronic Governor Power Mod-
3c. Disconnect the actuator leads and attach jumper leads to the
ule/wiring is bad.
actuator terminals. Connect the ACT+ lead to the BAT terminal
on the starter solenoid and touch the ACT lead to a good
ground on the block. Replace the actuator unit if it does not drive
the linkage through its full travel when power is connected or re-
turn it when power is disconnected. If actuator is OK, reconnect
actuator leads and go to step d.
3d. Attempt to start and check for CNTL B+ at terminal lead ACT + of
governor actuator (use engine block for meter ground). If not
present:
Isolate to defective K12 relay/wiring.
Isolate to defective Base board. Remove lead from K12-5.
While cranking, check for ground at K12-5 lead. If circuit re-
mains open, Base board is bad.
If CNTL B+ is present, attempt to start and check for GOV PWM
(pulse width modulated) signal. Measure across terminals of ac-
tuator using a high impedance analog voltmeter. If not present,
Base board or Electronic governor Power Module is bad. Go to
step e.
3e. Disconnect P1 from the Electronic Governor Power Module.
Check for continuity between P1-3 to T-26 and P1-5 to control
ground. If circuit is open, repair wiring.
If there is continuity, attempt to start and check for GOV PWM
signal at J11-7 (GOV DR +) and J11-14 (GOV DR ).
If there is no GOV PWM signal, replace the Base board.
If the GOV PWM signal is present, replace the Electronic
Governor Power Module.

5-21
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electric-
ity, and machinery hazards should perform service procedures. Read Safety Precautions page
and observe all instructions and precautions in this manual.

CODE 73 FAIL TO START (SHUTDOWN)

ELECTRONIC GOVERNED ENGINE
Reason: This indicates that the engine failed to start after expiration of last crank time.
Effect: Engine will not start.

POSSIBLE CAUSE CORRECTIVE ACTION

4. The engine fuel system is worn or mal- 4. Service according to the engine service manual.
functioning or has lost prime (fuel lift
pump, injection pump, injectors, timing).
5. The engine is worn or malfunctioning 5. Service according to the engine service manual.
mechanically.

CODE 74 FAIL TO STOP

GENERATOR SET CONTINUES TO RUN AFTER RECIEVING A STOP COMMAND FROM
THE CONTROLLER
Reason: The PCC1301 uses the key switch to tell the engine controller to stop.
Effect: The generator set remains running.

POSSIBLE CAUSE CORRECTIVE ACTION

The key switch relay is stuck closed. 1. Activate the emergency stop switch.

2. If the key switch fails to open, refer to the generator set service
manual for other possible causes and solutions.

CODE 75/76 CUSTOMER INPUT (SHUTDOWN)

Reason: The nature of the fault is an optional customer selection.
Effect: Shutdown.

POSSIBLE CAUSE CORRECTIVE ACTION

If there is no actual fault, the problem may be Disconnect the signal lead from TB1 and reset the control.
an external wiring problem.
CUST_IN1 TB1-14
CUST_IN2 TB1-12
If the message drops out, the external wiring has a short circuit.
Grounding of either input activates fault.

5-22
 CODE 202 PRE-HIGH COOLANT TEMP (WARNING)
Reason:
Effect:

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 1. 1. Refer to code 1.

5-23
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 203 LOW COOLANT TEMPERATURE (WARNING)

Reason: Engine coolant temperature has dropped below the warning threshold for low coolant temperature.
Effect: No action is taken by the PCC. Engine may not start due to slow cranking speed.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Fault simulation was enabled with In- 1. With InPower, verify that the fault simulation is not enabled for
Power. the coolant sensor.
If you do not have InPower, remove battery power from the con-
trol to disable fault simulation overrides.
2. Fault threshold is not set correctly with 2. Reset the threshold to the lowest allowable setting. Determine
InPower. the required operating range before adjusting the threshold.
3. The engine coolant heater could be bad. 3. Coolant heater not operating due to:
(Radiant heat should be felt with hand Coolant heater not connected to power. Check for blown
held close to outlet hose.) fuse, or disconnected heater cord and correct as required.
Low coolant level. Look for possible coolant leakage points
and repair as required.
Defective heater element/thermostat. With coolant heater
removed from engine and power disconnected, flush with
cold tap water for two minutes to close internal heater ther-
mostat (opens at 100 F and closes at 80 F). Check re-
sistance across input power leads:
a. Open replace coolant heater.
b. Closed coolant heater OK (coil resistance of 10 to 60
ohms)
4. The sensor connections could be bad. 4. Inspect the sensor and engine harness connector pins. Repair
or replace as necessary.
5. The sensor could be bad. 5. Disconnect the sensor, and plug in a resistive sensor simulator
to isolate the fault.
If the control responds to the simulator, replace the sensor. If
control does not respond, harness or Base board is bad.
6. The harness or Base board could be 6. Measure the resistance of the coolant temperature sensor and
bad. reconnect harness to sensor. Remove connector P11 from
Base board and check resistance between pins P11-18 (H20)
and P11-6 (H20 COM).
If resistance is not the same, harness is bad.
If resistance is the same, Base board is bad.

5-24
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 204/205 CUSTOMER INPUT (WARNING)

Reason: The nature of the fault is an optional customer selection.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION

If there is no actual fault, the problem may be Disconnect the signal lead from TB1 and reset the control.
an external wiring problem.
CUST_IN1 TB1-14
CUST_IN2 TB1-12
If the message drops out, the external wiring has a short circuit.
Grounding of either input activates fault.

CODE 212 COOLANT SENSOR OUT OF RANGE (HIGH/LOW) (WARNING)

Reason: This indicates that the coolant temperature sensor signal is out of range shorted high or low.
Effect: No engine protection for coolant temperature during genset operation. Possible white smoke.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The sensor connections could be bad. 1. Inspect the sensor and engine harness connector pins. Repair
or replace as necessary.
2. The sensor could be bad. 2. Disconnect the sensor, and plug in a resistive sensor simulator
to isolate the fault.
If the control responds to the simulator, replace the sensor. If
control does not respond, go to next step.
3. The harness or Base board could be 3a. Remove connector P11 from Base board and disconnect sen-
bad. sor. Check pins P11-18 (H20) and P11-6 (H20 COM) for short
circuit as follows:
Check for a short circuit to the engine block ground (more
than 200k ohms OK).
Check for a short circuit from pin to pin (more than 200k
ohms OK).
Repair or replace as necessary.
3b. Measure the resistance of the coolant sensor and reconnect
harness to sensor. Remove connector P11 from Base board
and check resistance between pins P11-18 (H20) and P11-6
(H20 COM).
If resistance is not the same, harness is bad.
If resistance is the same, Base board is bad.

5-25
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 213 LOW BATTERY (WARNING)

Reason: Low voltage has been detected for battery.
Effect: PCC voltage supply approaching level at which unpredictable operation may occur.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Weak or discharged battery. 1. Recharge or replace the battery. Specific gravity for a fully
charged battery is approximately 1.260 at 80 F (27 C).
2. Low electrolyte level in battery. 2. Replenish electrolyte and recharge battery.
3. Battery connections loose or dirty. 3. Clean and tighten or replace the battery cable connectors and
cables at the battery and the set.
4. Insufficient battery charging voltage. 4. Adjust charge rate of AC powered battery charging circuit, ac-
cording to manufactures instructions.
5. Engine DC alternator could be bad. 5. Replace engine DC alternator if normal battery charging voltage
(12 to 14 VDC) is not obtained.
6. If the batteries are OK, the problem may 6. Remove connector P11 from Base board and check battery volt-
be the harness or the Base board. age at P113 & 15 (B+) to P11-9 & 10 (GND).
If the voltage at P11 is not the same as the battery voltage,
the harness is bad.
If the voltage at P11 is OK, the Base board is bad.
7. Fault threshold setting incorrect. 7. Check fault threshold against requirement of the application.

CODE 214 HIGH BATTERY VOLTAGE (WARNING)

Reason: High voltage has been detected for battery.
Effect: PCC damage will occur.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Excessive battery charging voltage. 1. Adjust charge rate of AC powered battery charging circuit ac-
cording to manufacturers instructions.
2. Engine DC alternator could be bad. 2. Replace engine DC alternator if normal battery charging voltage
(12 to 14 VDC) is not obtained.
3. Fault threshold setting incorrect. 3. Check fault threshold against requirement of the application.

5-26
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 215 PRE-LOW OIL PRESSURE (SENDER) WARNING)

Reason: This indicates engine oil pressure has dropped below the warning trip point.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 2 for Oil Pressure Sender. 1. Refer to code 2 for Oil Pressure Sender.

CODE 216 HIGH AC CURRENT (WARNING)

Reason: This indicates that one or more of the phase currents has exceeded 110% of nominal for 60 seconds.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 46. 1. Refer to code 46.

5-27
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 217 OIL PRESSURE SENSOR OUT OF RANGE (SENDER) (HIGH/LOW)

(WARNING)
Reason: This indicates that the engine oil pressure sensor signal is out of range shorted high or low.
Effect: No engine protection for oil pressure during genset operation.

POSSIBLE CAUSE CORRECTIVE ACTION

1. The sensor connections could be bad. 1. Inspect the sensor and engine harness connector pins. Repair
or replace as necessary.
2. The sensor could be bad. 2. Disconnect the oil pressure sensor leads, and connect an oil
pressure sensor simulator to the harness.
OIL PRESSURE SENSOR OOR warning is displayed after
the fault condition is sensed for 10 seconds.
If the control responds to the simulator, replace the sensor. If
control does not respond, go to next step.
3. The harness could be bad. 3. Remove connector P11 from Base board and connector from
sensor. Check P11-5, 6 & 17 as follows:
Check for a short circuit from pin to pin (more than 200k
ohms OK).
Check for an open circuit (10 ohms or less OK).
Repair or replace as necessary.
4. The Base board could be bad. 4. With all connectors attached, check pressure signal (.5 to 4.5
VDC) at P1-17 (OP OUT) and P11-6 (OP COM). If in range, re-
place Base board.

5-28
 WARNING Hazards present in troubleshooting can cause equipment damage, severe personal in-
jury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform service procedures. Read Safety Precautions page and ob-
serve all instructions and precautions in this manual.

CODE 221 WEAK BATTERY (WARNING)

Reason:
Effect:

POSSIBLE CAUSE CORRECTIVE ACTION

1. Refer to code 213. 1. Refer to code 213.

CODE 222/223/224 ANNUNCIATOR FAULT #1 THROUGH #3 (WARNING)

Reason: The nature of the fault is an optional customer selection.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION

1. If there is no actual fault, the problem 1. Disconnect the signal lead from TB1 and reset the control.
may be an external wiring problem. Check the following pins. These connections are on the Univer-
sal Annunciator.
CUST_FAULT #1 TB1-1
CUST_FAULT #2 TB1-2
CUST_FAULT #3 TB1-3
If the message drops out, the external wiring has a short circuit.
Grounding of either input activates fault.

CODE 225 ANNUNCIATOR OUT CONFIGURATION ERROR (WARNING)

Reason: Indicates that more then one network device is configured to activate one of the annunciator output
relays.
Effect: Warning.

POSSIBLE CAUSE CORRECTIVE ACTION

1. Network configuration is bad. 1. Check setup of devices on the network against duplicate use of
the same annunciator relay output.
2. Bad device on network. 2. Troubleshoot network for malfunctioning devices.

5-29
Appendix A. Schematics
Note: This section contains basic (generic) wiring and schematics shipped with the unit. These wiring
diagrams and schematics to help in troubleshoot- diagrams and schematics should be updated when
ing. Service personnel must use the wiring diagrams modifications are made to the unit.

DRAWING PAGE

PCC 1301 WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

MENU SYSTEM MAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

A-1
THIS PAGE LEFT INTENTIONALLY BLANK

A-2
PCC 1301 WIRING DIAGRAM

06302926_G_200609

A-3
THIS PAGE LEFT INTENTIONALLY BLANK

A-4
 GENSET SERVICE MENUS

VIEWING AND
VIEWING ONLY ADJUSTING

GO TO
GENSET

OR
SETUP AND
MENU SYSTEM MAPS

SERVICE
MENUS

OR
SEE
A030K737
IF AVR IS
OR

NO

YES
ENABLEDENABLED
NOTIF AVR IS

NO

YES
OR

OR

A-5
 GENSET SETUP AND SERVICE MENUS

OR
OR

GO TO GENSET
SERVICE MENUS

VIEWING AND
VIEWING ONLY ADJUSTING

OR
24V

12V
OR
OR
SWITCH
SENDER

OR

A-6
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